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S 07 MAINTENANCE

GENSET MAINTENANCE

About this manual

Generalities 54
Maintenance intervals

Engine oil level check

Oil Level Engine.

Engine coolant level check

Engine oil replacement

Oil filling

Oil filter replacement

Check fuel hoses and clamp bands

Air filter box control & clean

Alternator belt

Belt tension

Belt damage and wear

Belt replacement

Fuel filter cartridge replacement

Bleeding the fuel system

Engine flexible mounts

Exhaust elbows inspections

Aluminum wet exhaust elbow:

Stainless steel dry exhaust elbow:

Raw water and coolant screws, clamps, and hoses tightening

Raw water impeller pump replacement

Coolant fluid replacement

Coolant drain

Coolant filling

Anti-freeze 65

Hoses & clamps replacement

Coolant & Sea water circuit

Fuel circuit

Thermostat replacement

Thermostat removal:

Thermostat installation:

Thermostat Valve Opening Temperature

Pressurized filling cap replacement

Heat exchanger maintenance

Coolant draining.

Coolant hoses removal

Raw water hoses removal

Heat Exchanger removal

Heat Exchanger Dismantling

Heat Exchanger Core Cleaning.

Heat exchanger reassembly

Heat exchanger Installation

Coolant hoses installation

Raw water hoses installation

Coolant circuit filling.

Raw water pump impeller replacement

S 07

MAINTENANCE

Содержание Q2400 Series

Страница 1: ...NANNI GENERATOR SET USER MANUAL DGBXXT090041 Q2400 Series...

Страница 2: ......

Страница 3: ...HANGES TRACKED CHANGES CODE INDEX DATE INITIALS NATURE OF TRANSLATIONS PAGES DGBXXT09041 02 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: ...N 1 of 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 SC...

Страница 7: ...ng operations 94 Cleaning and lubrication 95 Maintenance 95 Routine maintenance 96 Extraordinary maintenance 98 Tightening torque table 98 TROUBLE SHOOTING 99 S10 STORAGE 101 STORAGE PROCEDURE 102 Lon...

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 GENERATOR SET 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 COMPONENTS...

Страница 39: ...belt 3 Starter motor 4 Control panel connector 5 Air filter 6 Fuel filter 7 Coolant drain plug 8 Fuel injection pump 9 Heat exchanger 10 Coolant fill plug 11 Coolant pump 12 Starter solenoid 13 Cooled...

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

Страница 41: ...33 S05 COMPONENTS 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: ...r and coolant screws clamps and hoses tightening 63 Raw water impeller pump replacement 63 Coolant fluid replacement 64 Coolant drain 64 Coolant filling 65 Anti freeze 65 Hoses clamps replacement 66 C...

Страница 52: ...replacement 72 Sea Water Pump Removal 72 Sea Water Pump overview 72 Sea Water Pump Installation 73 Batteries 74 Battery Voltage 74 Battery Specific Gravity 74 ELECTRIC DIAGRAM 50Hz SINGLE PHASE 76 ELE...

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

Страница 54: ...ot trained in marine techniques are prohibited for obvious safety reasons Operations related to the timing and in jection system are the exclusive responsibility of Nanni s trained representatives The...

Страница 55: ...elbow 1 Electricity Battery electrolyte level Harness connectors check Alternator belt tension check Replacement 1 Command panel Indicators Alarms lights Engine Generalities Engine flrxible mounts Re...

Страница 56: ...NT LEVEL CHECK Remove the expansion bowl cap 1 and check to see that the coolant level between the low and maxi level marks If coolant level is too low check the reason for decreasing coolant level IM...

Страница 57: ...ary IMPORTANT When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two dif ferent types of oil Use the proper SAE Engine Oil accord ing to ambien...

Страница 58: ...e Thus see that the engine oil does not leak through the seal and be sure to read the oil level on the dipstick Then replenish the engine oil up to the specified level IMPORTANT To prevent serious dam...

Страница 59: ...element ALTERNATOR BELT Belt tension WARNING Stop the engine before work on alternator belt Measure the deflection A depressing the belt halfway between the crankshaft pulley and alternator pulley at...

Страница 60: ...ined in the tank and circuit are col lected in this cartridge Therefore it must be replaced during the first maintenance visit and every 250 hours of operation or year whichever come first ENVIRONMENT...

Страница 61: ...the air vent cock 2 on top of the fuel injection pump NOTE Always keep the air vent cock on the fuel injection pump closed unless when you release the air If not it can cause the engine to stop ENGINE...

Страница 62: ...the 4 bolts IMPORTANT On this type of elbow there is no anode so no control or replacement to perform of the zinc anodes Stainless steel dry exhaust elbow Removal Unscrew and remove the 4 nuts 1 Remo...

Страница 63: ...n object from getting inside hoses RAW WATER IMPELLER PUMP REPLACEMENT CAUTION Before replacing the seawater pump impeller make sure that the sea water valves are all closed and the engine is stopped...

Страница 64: ...REPLACEMENT WARNING Do not remove the heat exchanger pressurized cap when the engine is hot Then loosen the cap slightly to release the excess pressure before removing it completely ENVIRONMENT Use a...

Страница 65: ...Before adding anti freeze for the first time clean the heat exchanger interior by pouring fresh soft water and drain ing it a few times The procedure for mixing water and anti freeze differs accordin...

Страница 66: ...before removing cap completely 1 Drain the coolant 2 Unscrew all the clamp bands 3 Remove the 2 RSGU clamps 2 4 Remove the sea water hose 3 5 Remove the coolant hose 4 5 6 7 8 9 6 Inspect and replace...

Страница 67: ...the thermostat from the heat exchanger until the coolant temperature is too high The thermostat replace ment must be done every 2 years or 400 hours whichever comes first Thermostat removal 1 Drain th...

Страница 68: ...ifications Thermostat s valve open ing temperature 69 5 to 72 5 C 157 1 to 162 5 F Temperature at which thermostat completely opens 85 C 185 F CAUTION If the measurement is not acceptable replace the...

Страница 69: ...xchanger removal Unscrew and remove the 3 bolts 1 and remove the heat exchanger with its support WARNING Do not start the engine without coolant or the isolated seawater circuit Heat Exchanger Dismant...

Страница 70: ...ant hoses installation See chapter hoses clamps replacement Raw water hoses installation See chapter hoses clamps replacement Coolant circuit filling WARNING Do not start the engine without coolant Us...

Страница 71: ...onents if neces sary 5 Replace the impeller shaft seal if necessary 6 Lubricate the lip seal with glycerine do not lubricate the mechanical seal 7 Lubricate the inside of the pump with the glycerine i...

Страница 72: ...ove the pump with the spacer 4 with it gasket 5 3 Unscrew and remove the 4 bolts 6 when remove the sea pump 7 with the gasket 8 Sea Water Pump overview 1 Bolts 5 Pump flange 2 Sea water pump 6 Gasket...

Страница 73: ...the fluted hub so that the seawater pump is turned 45 downwards 2 Replace the gasket 8 and after greasing install the sea water pump 7 using 4 bolts 6 with their corru gated washers 3 Install the pum...

Страница 74: ...easure the voltage with a circuit tester between the battery terminals 1 Positive Terminal 2 Negative Terminal IMPORTANT If the battery voltage is less than the factory specifica tion check the batter...

Страница 75: ...ith a decrease of 1 F Therefore 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 tempe...

Страница 76: ...76 S 07 MAINTENANCE ELECTRIC DIAGRAM 50Hz SINGLE PHASE...

Страница 77: ...77 S 07 MAINTENANCE ELECTRIC DIAGRAM 60Hz SINGLE PHASE...

Страница 78: ...78 S 07 MAINTENANCE...

Страница 79: ...perations 78 Ordinary Maintenance 79 Air filter cleaning if present 79 Visual Inspection 79 Verification of winding state 79 Verification of correct alternator operation 80 Tightening torque check 80...

Страница 80: ...80 S08 AL TERNATOR...

Страница 81: ...l wire earthed N Identification 1 Serial number 2 Model 3 Update Index 4 Nomber of phases 5 Service Type 6 Mfg Date mm yyyy 7 Rated rotating speed 8 Insulation class 9 Power factor 10 Rated power vs t...

Страница 82: ...d inspections of the various components The case is made of steel the shields are made of aluminum cast iron the shaft is made of C45 steel with a fan splined onto the shaft The protection rating is I...

Страница 83: ...case of faults it flashes differently TECHNICAL DATA IP Protection Rating The alternator is built with an IP23 protection rating Radial Loads Maximum allowable radial loads applied to shaft projection...

Страница 84: ...TY IMPORTANT See Safety chapter for more information about genset safety Alternator Safety devices The safety devices of the alternator are 1 Protection screen on the front shield 2 Cover of terminal...

Страница 85: ...ouching the alternator wait for it to cool off CAUTION Risk of crushing while lifting Do not stand under the suspended load do not come close to it use adequate PPE Conventional symbols and symbols de...

Страница 86: ...ustment maintenance cleaning and or repair operations ELECTRICAL SERVICE MAN This symbol identifies the type of operator in charge of the operation described This qualification requires a complete kno...

Страница 87: ...ng side the order of the outgoing phases is L3 L2 L1 the order is reversed Winding connection modalities The alternators are manufactured with 12 standard outgoing cables in order to allow different v...

Страница 88: ...The ECP series alternators are built to operate without maintenance for a long time The maintenance interventions on the alternator are divided into ordinary and extraordinary Maintenance summary tabl...

Страница 89: ...llow you to determine if you should intervene 1 Remove the grid 1 2 Remove the filter elements 2 and clean 3 Reassemble everything according to the initial configuration Visual Inspection Type of inte...

Страница 90: ...tential presence of stresses in the heat engine The potential presence of stresses in the anti vibration supports The functional data see the nameplate of the alternator Tightening torque check Type o...

Страница 91: ...ENANCE DANGER This type of maintenance must be done by a NANNI dealer CAUTION Carry out extraordinary maintenance with accuracy and as often as specified by the manufacturer WARNING All the maintenanc...

Страница 92: ...M6 X 10 CL 8 8 9 Terminal box cover fixing M6 X 16 CL 8 8 9 Ground terminal on the frame M6 X 16 CL 8 8 9 Ground terminal on the foot M6 X 25 CL 8 8 9 Clamp for fan fastening M8 X 30 CL 8 8 12 5 Regu...

Страница 93: ...with inclined grooves N Identification 1 Serial number 2 Model 3 Update Index 4 Nomber of phases 5 Service Type 6 Mfg Date mm yyyy 7 Rated rotating speed 8 Insulation class 9 Power factor 10 Rated po...

Страница 94: ...pecific meaning as illustrated on the chapter Alternator safety earlier in this section STARTING AND STOPPING OPERATIONS All the instrumentation for starting running and stopping the system shall be p...

Страница 95: ...achine is turned off and insulated from the electric installation or from the power mains High qualified mechanical or electrical technicians must carry out maintenance operations and any fault search...

Страница 96: ...ect the voltage regulator fig a the rotating diode bridge fig b and the radio interference filter fig c as well as any other device connected to the windings to be checked before carrying out the meas...

Страница 97: ...data which must comply with the data on the generator s plate Mechanical checks of fastening bolts and in particular of electric connections Type of intervention Operator PPE to wear Periodicity Every...

Страница 98: ...s often as specified by the manufacturer WARNING All the maintenance intervals described below refer to a normal use of the alternator In case it is used in more severe conditions high humidity temper...

Страница 99: ...potentiometer Check speed Check windings High voltage at no load Reset voltage potentiometer Substitute regulator At load conditions voltage lower than rated value Reset voltage potentiometer Current...

Страница 100: ...100 S08 AL TERNATOR...

Страница 101: ...101 S10 STORAGE 101 STORAGE PROCEDURE 102 Long term storage 102 Long term storage procedure 102 Batteries 104 S10 STORAGE...

Страница 102: ...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 103: ...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 104: ...ry 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 105: ...type 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 o...

Страница 106: ...l 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...

Страница 107: ...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 108: ...108 S11 TROUBLE SHOOTING...

Страница 109: ......

Страница 110: ......

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