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S 07

MAINTENANCE

HEAT EXCHANGER MAINTENANCE

DANGER!

Do not remove the heat exchanger cap (1) when the en-

gine is hot. Then loosen the cap slightly to release excess

pressure before removing it completely.

Coolant drain.

•

See coolant replacement section.

Coolant hoses removal

•

See chapter on replacing hoses and clamps

Raw water hoses removal

•

See chapter on replacing hoses and clamps

Heat exchanger removal

• Unscrew and remove the 2 nuts (1) and remove

the heat exchanger (2) with the two RSGU collars.

DANGER!

Do not start the engine without coolant or without the

seawater system isolated.

Cleaning the heat exchanger core.

Clean the cooler core on the coolant side with a par

affin-based engine detergent.

2. Remove any internal deposits on the raw water side

with a round brush.

3. Replace cooler core if damaged.

CAUTION!

Do not use caustic soda as it may damage the core.

Heat exchanger installation

Check the condition of the two RSGU clamps (replace

them if necessary). Install them before mounting the

heat exchanger.

Install the heat exchanger (2) on the two RSGU collars

using the 2 nuts (1) with their 2 GROWER washers.

3. Tighten the nuts.

Coolant Hose Installation

•

See chapter on replacing hoses and clamps

Installation of raw water hoses

•

See chapter on replacing hoses and clamps

Filling the coolant system.

Содержание Q1500 Series

Страница 1: ...NANNI GENERATOR SET USER MANUAL DGBXXT090049 Q1500 Series...

Страница 2: ......

Страница 3: ...HANGES TRACKED CHANGES CODE INDEX DATE INITIALS NATURE OF TRANSLATIONS PAGES DGBXXT09049 03 2023 PJ Creation Please note all changes and pages associated For further clarity please add a line in front...

Страница 4: ...4 Q00 TRACKED CHANGES...

Страница 5: ...Rotating Drive Lines 15 Paint Removal Before Heating 15 High Pressure Fuel System Opening Risk 15 Avoid High Pressure Fluids 15 Safe Cooling System Service 16 Avoid Heat Near Pressurized Fluid Lines...

Страница 6: ...f the generator set 32 View N 2 of the generator set 33 View N 3 of the generator set 34 S06 STARTING RUNNING 43 COMMAND PANEL Si 2 44 Description of the generator set control panel 44 DISPLAY SCREENS...

Страница 7: ...BLE SHOOTING 87 S10 STORAGE 89 STORAGE PROCEDURE 90 Long term storage 90 Long term storage procedure 90 Batteries 92 S11 TROUBLE SHOOTING 93 TROUBLE SHOOTING 93 The engine is difficult to start 93 Low...

Страница 8: ...8 S00 SUMMARY...

Страница 9: ...tact an authorized NAN NI INDUSTRIES S A S dealer for maintenance of your engine A list of dealers is available on our website www nannienergy com Read this manual carefully to learn how to properly o...

Страница 10: ...vice manu al workshop manual On the following pages the reader will find numerous descriptions of the generator set its operation and maintenance as well as tips and guidelines for troubleshooting Spe...

Страница 11: ...ise Protection 15 Genset Output Generated Power 15 Guards Requirements 15 Staying Clear Of Rotating Drive Lines 15 Paint Removal Before Heating 15 High Pressure Fuel System Opening Risk 15 Avoid High...

Страница 12: ...tion contained on parts and components sourced from suppliers that is not reproduced in this Operator Manual Read Safety Instruction Carefully read all safety messages in this manual and on your gense...

Страница 13: ...haust gases and components Exhaust parts and streams become very hot during operation Exhaust gases and components reach temperatures hot enough to burn people ignite or melt common materials WORK IN...

Страница 14: ...s PROPER USE OF TOOLS Use tools appropriate to the work Makeshift tools and unfollowed procedures can create safety hazards Do not use U S mechanical tools on metric fasteners i e a 1 2 inch wrench on...

Страница 15: ...int a minimum of 100 mm 4 in from area to be affected by heating If paint cannot be removed wear an approved respirator mask before heating or welding If you sand or grind paint avoid breathing the du...

Страница 16: ...ng point and away from control units 6 After welding reverse Steps 1 5 STATIC ELECTRICITY RISK The removal of sulphur and other compounds in Ultra Low Sulphur Diesel ULSD fuel decreases its conductivi...

Страница 17: ...ell ventilated area Wearing eye protection and rubber gloves Avoiding use of air pressure to clean batteries Avoiding breathing fumes when electrolyte is Avoiding spilling or dripping electrolyte Usin...

Страница 18: ...turning engine to customer make sure engine is functioning properly especially the safety systems Make sure that all guards and shields are in place PREVENT ACCIDENTS When engine is OFF always set the...

Страница 19: ...oper Coolant Concentration 24 Biodiesel 24 Winter fronts 24 DIESEL ENGINE COOLANTS 25 RECOMMENDED COOLANTS 25 WATER QUALITY 25 COOLANT DRAIN INTERVALS 25 OPERATING IN WARM TEMPERATURE CLIMATES 25 WATE...

Страница 20: ...ptable for use at all percentage mixture levels Required Fuel Properties In all cases the fuel shall meet the following properties Cetane number of 40 minimum Cetane number greater than 47 is preferre...

Страница 21: ...l and filter change interval IMPORTANT Do not mix used diesel engine oil or any other type of lu bricating oil with diesel fuel Improper fuel additive usage may cause damage on fuel injection equipmen...

Страница 22: ...nce dose of a biocide will prevent microbial growth Contact your fuel supplier or NANNI dealer for recommendations RECOMMENDED FUEL Approved fuel Diesel approved by NANNI Industries on the engines of...

Страница 23: ...ng biofuels IMPORTANT Biodiesel is not recommended by NANNI Raw pressed vegetable oils are NOT acceptable for use as fuel in any concentration in NANNI engines Their use could cause engine failure TES...

Страница 24: ...ome engines to aid cold weather starting Ether An ether port on the intake is available to aid cold weather starting CAUTION Ether is highly flammable and not recommended by NAN NI Do not use ether wh...

Страница 25: ...lloys such as brass from corrosion WATER QUALITY Water quality is important to the performance of the cooling system Deionized or demineralized water is recommended for mixing with ethylene glycol and...

Страница 26: ...0 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze Protection Limit 40 21 C 6 F 50 33 C 27 F 60 49 C 56 F DO NOT use a coolant water mixture greater than 60 ethylene glycol or 60 propylene...

Страница 27: ...1000 2000 ppm REDUCES the oil and filter ser vice interval BEFORE using diesel fuel with sulfur content great er than 2000 mg kg 2000 ppm contact your NANNI dealer or qualified service provider DO NO...

Страница 28: ...sity diesel engine oils are preferred Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates Oil Viscosities for Air...

Страница 29: ...from debris and water always change engine fuel filters as specified in this manual ALTERNATIVE AND SYNTHETIC LUBRI CANTS Conditions in certain geographical areas may require lu bricant recommendation...

Страница 30: ...n that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lu bricant they may contain MIXING OF LUBRICANTS In general avoid mixing di...

Страница 31: ...king from them Wear gloves and eye protection glasses Follow all safety rules Wait for engine to cool down Do not let waste to drip on the ground down a city drain or into any water source Improperly...

Страница 32: ...32 S03 FLUIDS...

Страница 33: ...be quoted when ordering ser vice and replacement parts Depending of type of engine identification plate are as follows Or TYP Indicates the commercial designation of the engine NR Indicates the engin...

Страница 34: ...operation instructions stated in the relevant manuals should be follow by the user Nanni s responsibility for the engine specification being in accordance with the certification will be void if one or...

Страница 35: ...being carried out by an authorized Nanni representative NOTE Late or improper maintenance or use of spare parts other than NANNI original spare parts will invalidate NANNI s responsibility for the en...

Страница 36: ...is listed on the Emissions Label When installed in accordance with the manufacturer s instructions Nanni Industries Marine Diesel Propulsion Engines without integral exhaust certified under Direc tive...

Страница 37: ...29 S05 COMPONENTS 37 GENSET MAIN COMPONENTS 39 List of components 39 View N 1 of the generator set 40 View N 2 of the generator set 41 View N 3 of the generator set 42 S05 COMPONENTS...

Страница 38: ...30 S05 COMPOSANTS...

Страница 39: ...ernator belt 3 Starter motor 4 Control panel connector 5 Air filter 6 Fuel filter 7 Coolant drain valve 8 Fuel injection pump 9 Heat exchanger 10 Coolant filler cap 11 Coolant pump 12 Starter solenoid...

Страница 40: ...32 S05 COMPOSANTS VIEW N 1 OF THE GENERATOR SET...

Страница 41: ...33 S05 COMPOSANTS VIEW N 2 OF THE GENERATOR SET...

Страница 42: ...the generating set in using the lifting eyelets Adjust the lifting slings to lift the unit horizontally For safety and operational reasons never insert any objects or block the vents of the generator...

Страница 43: ...g and stop buttons 45 BEFORE STARTING 46 Fuel system 46 Raw water 46 Electric system 47 PRELIMINARY CHECKS 47 STARTING THE GENSET 48 Cold climate start up 48 Starting with back up batteries 48 RUNNING...

Страница 44: ...ET button Use this button to deac tivate the horn output without acknowledging the alarms 4 FAULT RESET button Use this button to ac knowledge alarms and deactivate the horn output Inactive alarms wil...

Страница 45: ...at the last record is displayed first STARTING USE STARTING AND STOP BUTTONS These buttons are used to start and stop the engine START button Works in MAN mode only Press this button to initiate the s...

Страница 46: ...fuel filter It should never be installed on top of the engine because vibration affects the fuel water separation pro cess If the fuel tank is located under the engine fuel injection pump an additiona...

Страница 47: ...eller will be damaged if it runs dry even for a few seconds and may cause the engine to overheat Perform the following before starting the engine 1 Open the sea cock Prime if required 2 Start the comp...

Страница 48: ...lant heater for at least 2 hours be fore starting the engine Additional information on cold weather operation is available from your Nanni engine distributor or authorized dealer Synthetic oils improv...

Страница 49: ...or during navigation or to repair it try to reduce the load delivered by the gen erator and check the whole system once back in port If necessary consult your local Nanni representative AFTER RUNNING...

Страница 50: ...ION Do not forget to open the sea cock before restarting the group COLD CLIMATE PRECAUTIONS See maintenance chapter fore more details CAUTION Keep the battery fully charged An improperly charged batte...

Страница 51: ...rsion 62 Tightening of screws clamps and raw water and coolant hoses 63 Raw water pump impeller replacement 63 COOLANT REPLACEMENT 64 Coolant draining 64 Coolant filling 65 Anti gel 65 Hose and clamp...

Страница 52: ...52 S 07 MAINTENANCE Battery voltage 72 Battery specific gravity 72...

Страница 53: ...53 S 07 MAINTENANCE...

Страница 54: ...echnicians not trained in marine techniques are prohibited for obvious safety reasons Operations related to the timing and injection system are the ex clusive responsibility of Nanni s trained represe...

Страница 55: ...attery electrolyte level Checking the connectors of the harness Checking the alternator belt tension Replacement 1 Control panel Indicator lights and alarms Engine generalities Flexible motor supports...

Страница 56: ...CHECKING THE ENGINE COOLANT LEVEL Remove the expansion tank cap 1 and check that the coolant level is between the low and high marks If the coolant level is too low check the reason for the low coolan...

Страница 57: ...check the level again Adjust the oil level if necessary IMPORTANT When using a different brand or viscosity of oil remove all the old oil Never mix two different types of oil Use the proper SAE engine...

Страница 58: ...s a little Therefore make sure that the engine oil does not leak from the seal and read the oil level on the dipstick Then fill up the engine oil to the specified level IMPORTANT To prevent serious da...

Страница 59: ...ement ALTERNATOR BELT Belt tensioning DANGER Stop the engine before working on the alternator belt Measure the deflection A by pushing the belt halfway between the crankshaft pulley and the alternator...

Страница 60: ...dust from the tank and circuit are collected in this cartridge It should therefore be replaced at the first service visit and every 250 hours of operation or annually whichever comes first ENVIRONMEN...

Страница 61: ...no longer rise Close the bleed valve 2 on top of the fuel injec tion pump NOTE Always keep the air bleed valve on the injection pump closed unless you are releasing air Otherwise it may cause the eng...

Страница 62: ...ORTANT On this type of elbow there is no anode so there is no need to check or replace the zinc anodes Stainless steel dry exhaust elbow optional for the non soundproof version Disassembly Unscrew and...

Страница 63: ...ge to the motor prevent dust and foreign objects from entering the pipes RAW WATER PUMP IMPELLER REPLACEMENT CAUTION Before replacing the seawater pump impeller make sure that the seawater valves are...

Страница 64: ...cause motor failure or fire COOLANT REPLACEMENT DANGER Do not remove the pressure cap from the heat exchanger when the engine is hot Then loosen the cap slightly to release excess pressure before rem...

Страница 65: ...e adding antifreeze for the first time clean the inside of the heat exchanger by pouring fresh cool water and draining it several times The procedure for mixing water and antifreeze differs de pending...

Страница 66: ...e coolant 2 Unscrew all clamps 1 3 Remove seawater 2 and 3 4 Remove the coolant hoses 4 5 6 7 8 and 9 5 Remove the hose 9 under the seawater pump after loosening the two clamps 1 6 Inspect and replace...

Страница 67: ...STAT REPLACEMENT DANGER Stop the engine before replacing the thermostat Do not remove the thermostat from the heat exchanger until the coolant temperature is too high The thermostat should be replaced...

Страница 68: ...approximately 6 mm 0 2 in Specifications Thermostat valve opening temperature 69 5 72 5 C 157 1 162 5 F Temperature at which the thermostat opens fully 85 C 185 F CAUTION If the measurement is not ac...

Страница 69: ...t the seawater system isolated Cleaning the heat exchanger core 1 Clean the cooler core on the coolant side with a par affin based engine detergent 2 Remove any internal deposits on the raw water side...

Страница 70: ...d the motor may overheat Do not use antifreeze and scale inhibitor at the same time Never mix different types or brands of coolants or anti freeze See coolant replacement section RAW WATER PUMP REPLAC...

Страница 71: ...O ring 7 Gasket 15 Ball bearing 8 Cam 16 Stop ring Raw water pump installation 1 Check the condition of the spacer contact surface be fore mounting the seal and the pump 2 Replace the gasket 2 and aft...

Страница 72: ...g the voltage with a circuit tester across the battery terminals 1 Positive Terminal 2 Negative Terminal IMPORTANT If the battery voltage is below factory specifications check the density and recharge...

Страница 73: ...refore using 20 C 68 F as a reference the specific gravity reading must be corrected by the following for mula Specific gravity at 20 C Measured value 0 0007 electrolyte temperature 20 C Specific grav...

Страница 74: ...74 S 07 MAINTENANCE...

Страница 75: ...Electrical connection 86 Rotation and sequence of phases 86 Winding connection methods 86 Starting and stopping operations 87 Cleaning and lubrication 87 Maintenance 88 Routine maintenance 88 Evaluati...

Страница 76: ...76 S08 AL TERNATOR...

Страница 77: ...ass 9 Power factor 10 Nominal power as a function of temperature 11 Maximum ambient temperature 12 Rated voltage 13 Rated current 14 Rated frequency N Identification 15 Class of nominal characteristic...

Страница 78: ...with keyed fan The protection grade is IP21 on request it is possible to realize a higher protection grade Insulation is class H the impregnations in epoxy varnish for the rotating parts and the part...

Страница 79: ...vices The safety features of the alternator are 1 Protective screen on the front shield 2 Terminal box cover 3 Rear cover DANGER During operation these guards must be in place Safety labels CAUTION Do...

Страница 80: ...cordance with safety standards HANDLER This symbol identifies the type of operator responsible for the operation described This qualification requires a complete knowledge and understanding of the inf...

Страница 81: ...rature Maximum ambient temperature to guarantee the rated power 40 C Maximum operating altitude to ensure power rating Less than 1000 m Install the alternator in a well ventilated area Insufficient ve...

Страница 82: ...phases is L3 L2 L1 the order is reversed Winding connection methods The alternators are manufactured with 12 standard output cables to allow different output voltages for example at 50 Hz 115 V 200 V...

Страница 83: ...d be done at reduced speed the operator should check that no abnormal noise can be detected If an abnormal noise is detected stop the system immediately and improve the mechanical coupling CLEANING AN...

Страница 84: ...ct operation absence of abnormal noises or vibrations 3 Mechanical checks of all fastening bolts and in particular of the electrical connections 4 External cleaning of the generator The extraordinary...

Страница 85: ...absence of abnormal noise or vibration Intervention type Operator PPE to wear Periodicity Every 2500 hours of use Materials and equipment Outils d atelier At regular intervals we recommend checking th...

Страница 86: ...e used for external cleaning of the generator The use of hydro cleaners and detergent liquids is strictly forbidden The standard degree of protection of the generator is IP23 therefore the use of flui...

Страница 87: ...n cables according to the attached drawings Low voltage at no load Reset the voltage potentiom eter Check the speed Check the windings High no load voltage Reset the voltage potentiom eter to zero Rep...

Страница 88: ......

Страница 89: ...89 S10 STORAGE 89 STORAGE PROCEDURE 90 Long term storage 90 Long term storage procedure 90 Batteries 92 S10 STORAGE...

Страница 90: ...rocedure Shutdown of the generator set 1 Drain and change the engine oil 2 Replace the engine oil filter 3 Replace fuel filter and pre filter 4 Bring the engine to operating temperature 5 Stop the eng...

Страница 91: ...less than 1 M EN60204 1 you will need to dry the alternator by blowing pressurized air at 50 60 C into the alternator air inlets and outlets 1 Clean the engine and check its condition 2 Drain and rep...

Страница 92: ...y as often as possible to extend its life WARNING Do not leave the battery unattended for a long time it will be deeply discharged about 7 to 8 volts In such a situa tion the battery will not recover...

Страница 93: ...ype of oil according to weather conditions Compression too low Valve piston cylinder and ring wear Flat battery Charge the battery In winter store the battery in a frost free place Recharge it peri od...

Страница 94: ...Check the lubrication Replace the oil filter every second oil change Check bearing clearance EXHAUST SMOKE TOO BLACK Defect Solutions Fuel control defective Contact NANNI dealer Wrong fuel The fuel m...

Страница 95: ...belt or adjust the tension Coolant level too low Check the system and top up with recommended fluid identical to that in the engine Too much antifreeze Add water and check the antifreeze concentration...

Страница 96: ...96 S11 TROUBLE SHOOTING...

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