Nanni Z4.205, Operator'S Manual

Page 1: ...NANNI MARINE ENGINE OPERATOR MANUAL DGBXXT09009A ENGINE T4 205 T4 230 T4 270 Z4 205 Z4 230 Z4 270...

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Page 3: ...S CODE INDEX DATE INITIALS NATURE OF TRANSLATIONS PAGES DGBXXT09009 12 2018 MC Create Please note all changes and pages associated For further clarity please add a line in front of each change DGBXXT0...

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Page 5: ...N WINTERIZATION 16 LIVE WITH SAFETY 16 PREVENT ACCIDENTS 16 S03 FLUIDS 17 SUMMARY 17 FUELS 18 DIESEL FUEL 18 SULPHUR CONTENT 18 WINTER DIESEL 18 WATER IN FUEL 18 MICRO ORGANISMS IN FUEL 18 INERT IMPUR...

Page 6: ...51 ANCHORING 52 COLD WEATHER PRECAUTIONS 52 S08 MAINTENANCE 53 SUMMARY 53 ABOUT 54 GENERALITIES 56 CONTROL CABLES 56 EXHAUST SYSTEM 57 AIR INTAKE 57 CHECK THE AIR FILTER BOX 57 FUEL SYSTEM 58 DRAIN W...

Page 7: ...perating procedures Contact a NANNI INDUSTRIES S A S authorized dealer for the servicing of your engine A list of dealers is available on our website www nannienergy com Read this Manual carefully to...

Page 8: ...the engine i e anyone renting borrowing or buying the engine from you CONTENT UPDATES All the informations and specifications in this Manual are based on the technical data applicable at the time of i...

Page 9: ...3 SAFE ILLUMINATED WORK AREA 13 PROPER LIFTING EQUIPMENT 13 NOISE PROTECTION 13 GENSET OUTPUT GENERATED POWER 13 GUARDS REQUIREMENTS 13 STAYING CLEAR OF ROTATING DRIVE LINES 14 PAINT REMOVAL BEFORE HE...

Page 10: ...tion contained on parts and components sourced from suppliers that is not reproduced in this Operator Manual READ SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your gens...

Page 11: ...efers to important informations and instructions to follow before handling the engine Indicates possible electrical hazards Indicates hot parts entailing substantial risks of burns Indicates an area c...

Page 12: ...tal or recycling center or your dealer for information on the proper way to recycle or dispose of waste UNWANTED ENGINE START Avoid possible injury or death from engine runaway Do not start engine by...

Page 13: ...ures in this manual SAFE ILLUMINATED WORK AREA Illuminate your work area adequately and safely Use a portable safety light for working inside the engine room Make sure the bulb is enclosed by a wire c...

Page 14: ...sors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform r...

Page 15: ...to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices HANDLE FUEL SAFELY AVOID FIRE Handle fuel with care it is highly flammable Do not...

Page 16: ...EVENT BATTERY EXPLOSIONS Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a vol...

Page 17: ...COMMENDED OR AUTHORIZED 19 GENERALITIES 19 OILS VISCOSITY 20 CORRESPONDENCE BETWEEN API AND ACEA OILS 20 DIESEL SULPHUR CONTENT 20 COOLANTS 21 COOLANT DRAIN INTERVALS 21 WATER PROPERTIES 21 WATER PROP...

Page 18: ...geographically available Generally speaking summer diesel fuel complying with EN 590 is usable down to a temperature of 0 C 32 F and the winter formulated fuel down to a temperature of 20 C 4 F type...

Page 19: ...of impurities into the engine during filling or topping up be sure to thoroughly clean the filler inlet hole first and use a container free of any contamination OILS RECOMMENDED OR AUTHORIZED It is n...

Page 20: ...ce towards oxidation and fuel economy Refer to the expertise of the local Nanni rep resentative regarding the oil that best suits your engine CORRESPONDENCE BETWEEN API AND ACEA OILS API ACEA JAMA CG...

Page 21: ...ethylene glycol and propylene glycol base coolants together Do not mix coolants of various brands and makes together Do not use coolants containing nitrites WATER PROPERTIES TO MIX WITH COOL ANT CONC...

Page 22: ...lycol or 60 propylene glycol Refer to the ta ble below Ethylene Glycol Freeze protection limit 40 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze protection limit 40 24 C 12 F 50 37 C 34 F...

Page 23: ...hem 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 disposing o...

Page 24: ...glycol dm3 litre 9 11 12 14 15 30 12 14 16 18 20 40 15 18 20 23 25 50 18 21 24 27 30 60 21 25 28 32 35 70 24 28 32 36 40 80 27 32 36 41 45 90 30 35 40 45 50 100 33 39 44 50 55 110 36 42 48 54 60 120...

Page 25: ...e can be exhaust emission certified It means that Nanni guarantees that all engines of the same type that are manufactured are approved and certified by the authorities in accordance with different ex...

Page 26: ...o comply with the warranty conditions will void the Warranty The validity of the Warranty is also dependent on proper installation and maintenance operation being carried out by an authorized Nanni re...

Page 27: ...S The U S EPA and CARB prohibit the removal or render ing inoperative of any device or element of design in stalled on or in engines equipment in compliance with applicable emission regulations prior...

Page 28: ...0 BATTERY CHARGE 30 PREHEATING 31 ENGINE OIL PRESSURE 31 WATER IN THE FUEL FILTER 31 C5 PANEL 32 C5 STANDARD LOOSE INSTRUMENTS 32 C5 OPTIONAL LOOSE INSTRUMENTS 32 C5 TACHOMETER LCD DISPLAY 32 ALTERNAT...

Page 29: ...n the Flying Bridge deck As a proper practice code the main panel is fitted with a key switch located in the wheelhouse and used to prevent unauthorized starting from the secondary panel To start the...

Page 30: ...R Never open the coolant filler cap or any plug of the cooling system when the engine is warm Steam or hot fluid can spray out CAUTION If this alarm comes ON while operating the engine stop the engine...

Page 31: ...me emergencies and check the engine oil level and the oil filter condition To operate an engine when oil pressure is too lowcan lead to a severe engine damage Do not operate the engine if the problem...

Page 32: ...nts manual C5 TACHOMETER LCD DISPLAY The analog tachometer displays the engine speed Multiply the value by 1000 to get the revolutions per minute of the engine See the example below ALTERNATOR CHARGE...

Page 33: ...is alarm comes ON while operating the engine stop the engine exept in extreme emergencies Wait for the engine to cool down Check the coolant level the belt condition the raw water filter and if the se...

Page 34: ...n towing the boat Never start nor run the engine when the drive is in the lift range RUDDER INDICATOR This indicator displays the rudder angle of the vessel Depending of the country this may be a lega...

Page 35: ...12 V X X X X X X X X X C4 C4 12 V X X X S S S S S C4 12 V C4 24 V X X X C4 loose instr X X X X X X X X C4 loose instr C4 w o key X X X X X X X X C5 Pleasure CAN 10B C5 Pleasure CAN 5B C5 Pro CAN 10B C...

Page 36: ...4 24 V C4 loose instr C4 loose instr X X X C4 w o key C5 Pleasure CAN 10B X X C5 Pleasure CAN 5B X X C5 Pro CAN 10B C5 Pro CAN 5B X X C5 Fly loose instr X X X C5 loose instr S S S C5 loose instr indic...

Page 37: ...37 S06 COMPONENTS SUMMARY Table des mati res S06 COMPONENTS 37 SUMMARY 37 MAIN ENGINE COMPONENTS 38 ENGINE VIEWS T4 205 T4 230 T4 270 39 ENGINE VIEWS Z4 205 Z4 230 Z4 270 40...

Page 38: ...MPONENTS 1 Alternator 2 Alternator Belt 3 Starter 4 Fuses box 5 Air filter 6 Fuel filter 7 Fuel feed pump 8 High pressure fuel injection pump 9 Heat exchanger 10 heat exchanger coolant filler plug 11...

Page 39: ...39 S06 COMPONENTS ENGINE VIEWS T4 205 T4 230 T4 270...

Page 40: ...40 S06 COMPONENTS ENGINE VIEWS Z4 205 Z4 230 Z4 270...

Page 41: ...R OPERATION 43 ENGINE START 44 ENGINE STARTED 46 STARTING WITH BOOSTER BATTERIES 46 ENGINE RELUCTANT TO START 46 IDLING ENGINE 46 NORMAL ENGINE OPERATION 47 BREAK IN 47 POWER TAKE OFF 47 REMOTE CONTRO...

Page 42: ...feed pump should be installed between the prefilter and the feed pump of the engine RAW WATER SYSTEM The raw water system allows to cool the engine coolant and the exhaust gas Raw water is drawn into...

Page 43: ...that nobody is in the water near the propeller before starting Never use a start spray or any other equivalent product These products are highly flammable CAUTION Always preheat the engine Never race...

Page 44: ...perature to preheat the engine POSITION 1 POSITION 1 2 preheating POSITION 2 5 Press fully to start the engine position 2 Once the engine has started release the button all lamps go out POSITION 1 POS...

Page 45: ...w water flows from the exhaust outlet at the hull If the water does not flow stop the engine and check the raw water level Electronic type 5 Turn the ignition key to the ON position It is not required...

Page 46: ...for few minutes to charge the battery 4 Stop the engine and remove the cables in the exact reverse order from installation ENGINE RELUCTANT TO START If a water lift water lock muffler is installed on...

Page 47: ...sual noise or vibration Sudden loss of power Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks BREAK IN Operate the engine with care for the first 50 hours of op...

Page 48: ...void violent manoeuvres or unexpected speed changes while sailing People can fall over or overboard Keep also in mind that the weight distribution passengers equipments etc inside the boat has an impa...

Page 49: ...ating temperature regularly Run the engine at full throttle regularly in order to burn off any possible deposits in the fuel system S07 STARTING RUNNING MANOEUVRING WARNING Shifting at high speed can...

Page 50: ...and with the lever in neutral must not exceed 6 hours in a row The propeller can drive the rotation of the shaft and damage the transmission Run the engine for 15 minutes to lubricate the transmissio...

Page 51: ...The engine stops Turn the key of the main panel counter clockwise All indicators will turn off AFTER STOPPING THE ENGINE CAUTION Even after the engine has stopped some components and fluids will remai...

Page 52: ...d before the next time the boat is used Vegetation and fouling can also obstruct the raw water system and result in damage to the engine by overheating Inspect and clean the boat and the raw water sys...

Page 53: ...STED STEERING OIL LEVEL 65 STERN DRIVE GEAR LUBE Z SERIES 65 COOLING SYSTEM 66 OVERVIEW 66 COOLANT 67 COOLANT LEVEL 67 COOLANT FILLING 68 RAW WATER SYSTEM 69 ZINC SACRIFICIAL ANODE CHECK 69 SIPHON BRE...

Page 54: ...r if there is no repair workshop nearby We recommend to have all your works checked by a Nanni authorized workshop Repairs and or adjustment works on the engine by unseasoned marine trained technician...

Page 55: ...spection 2 Electrical Battery electrolyte level Electrical Harness Connectors Inspection Alternator Belt Tension 2 Panel Command Indicators Warning Lamps Read Record Defect Trouble Codes 4 Whole Engin...

Page 56: ...any maintenance Watch for any oil or fluid drop as it is an evidence of a leak somewhere CAUTION Do not let oil fuel or grease deposits build up around the engine as they may increase the risk of fire...

Page 57: ...es for as long as possible some basic rules must be followed Changing or cleaning the air filter on a regular basis is a good way to keep debris from causing problems with the intake side of turbochar...

Page 58: ...r or routed to a place which will not interfere with the operator by exhaust pipe The most important point in all cases is to reduce back pressure to a minimum Inspect the exhaust system at whole hose...

Page 59: ...NER SPRAY 970317078 Kit Air filter cleaner FR IT DEU Long life NANNI air filters require periodic cleaning Maintenance of these air filters is very simple Please follow the 4 steps below Cleaning Spra...

Page 60: ...check for leaks FUEL SYSTEM DANGER Stop the engine and let it cool down before refuelling or carrying out any operation on the fuel system CAUTION Fuel is flammable and can be dangerous Fuel spilled o...

Page 61: ...matting surface Thight up a further half turn 7 To bleed the air in the fuel system see next paragraph for complete explanations S08 MAINTENANCE AIR BLEEDING Bleeding the air in the fuel system might...

Page 62: ...nting screw 3 Start the engine for 5 to 10 seconds to let the electric fuel feed pump bring fuel up to the injection pump 4 Pump the fuel using the lever until fuel free of air bubbles flows from the...

Page 63: ...engine and transmission oil level before starting the engine The oil level should be within the range indicated on the dipstick between the Mini and Maxi level TO CHECK THE OIL LEVEL 1 Pull off and w...

Page 64: ...oil check dipstick duct CHANGING THE OIL FILTER Replace the oil filter every time the engine oil is drained 1 Remove the oil filter with a filter wrench tool Turn the filter counter clockwise CCW Rem...

Page 65: ...fluid Replace the fill cap and dipstick STERN DRIVE GEAR LUBE Z SERIES CAUTION Damage to the Stern Drive unit may occur due to lack of lubrication If any water is visible at the bottom of the gear lub...

Page 66: ...the heat exchanger when the en gine reach the appropriate temperature of the engine Principle of operation of water cooling with heat exchanger on an engine CAUTION Engines designed with an heat excha...

Page 67: ...y fill the coolant system COOLANT EXPANSION When the engine is running the internal temperature is high as a result the coolant liquid expands its volume The heat exchanger is designed to accomodate t...

Page 68: ...anger For Keel Cooling system or when using a water boiler the coolant capacity must be adapted according to the pipes length and the tank capacity TO FILL THE COOLANT SYSTEM 1 Check that the drain pl...

Page 69: ...cture below Zinc anodes SIPHON BREAKER DANGER Close the sea cock before any operation on the siphon breaker NOTE Siphon breaker itself is not part of maintenance sheddule but check regularly that the...

Page 70: ...in order to installitinthecorrectpositionincaseofreinstallation 5 Gently pull off the impeller in using an extractor 6 Closely inspect the impeller Check for damaged cracked broken missing or flattene...

Page 71: ...nd check for leaks 5 Notice When the boat is out of water check that the through hull is not clogged by mud or algae S08 MAINTENANCE RAW WATER SYSTEM DRAINING WARNING It is highly recommended to carry...

Page 72: ...e still present consult your Nanni representative Do not add up cleaners additives of your own taste as metal parts are prone to fast corrosion if harshly cleaned 8 Clearly identify all closed valves...

Page 73: ...R CABLES 1 Disconnect the negative cable first 2 Then remove the positive cable If the battery is replaced make sure that the previous one was the correct model Check against the table below Engine No...

Page 74: ...th a hydrometer Follow these indications Unscrew completely the vent plugs and check level with a flashlight in each and every orifice Use a syringe filled with distilled water to top up the compartme...

Page 75: ...of alternator charge A too tighten belt can damage the bearings of the water pump and of the alternator VISUAL CHECK OF THE ALTERNATOR BELT If belt internal wires become visible and frayed replace it...

Page 76: ...simple incident If you are still at shore do not start the engine and check first on your on in taking all usual precautions If the fault is not resolved quickly contact your nearest Nanni representa...

Page 77: ...s ordered through a belt cased inside the grey cover shown below The timing Belt must be replaced in accordance with the Nanni service maintenance chart even with no visual defect and must be performe...

Page 78: ...78 S09 STORAGE SUMMARY Table des mati res S09 STORAGE 78 SUMMARY 78 LONG TERM STORAGE 79 LONG TERM STORAGE PROCEDURE 79 RESTARTING THE ENGINE 80 BATTERY 80...

Page 79: ...ge the fuel filter and prefilter 4 Run the engine to normal operating temperature 5 Stop the engine and take the boat out of water 6 Drain and clean all components of the seawater system Protect the c...

Page 80: ...sary 10 Connect fully charged batteries 11 Check the anodes 12 Install the propeller 13 Check the operation of the control cables and their condition 14 Check belts Adjust the tension 15 Bleed the fue...

Page 81: ...slowly 8 9 The starter motor turns but the engine does not start 1 2 3 4 5 6 7 The engine does not reach its rated speed at wide open throttle 2 3 4 5 6 7 12 14 15 16 17 26 28 The engine operate uneve...

Page 82: ...top control pulled out 14 Too much load on board 15 Fouling on underwater hull drive or propeller 16 Defective incorrect propeller 17 Faulty operation of control lever control cables 18 Loosen or dama...

Page 83: ...Commune Control e lectroniquement Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational direction view flywhee...

Page 84: ...Fuel consumption propeller load exp 3 l h 1 9 4 3 6 9 10 9 16 9 24 5 34 5 40 5 gal US h 0 5 1 1 1 8 2 9 4 4 6 5 9 1 10 7 Consommation de carburant pleine charge Fuel consumption at full load l h 6 5...

Page 85: ...axi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 3 inH O 120 4 Temp rature d chappement maxi Maximum exhaust temperature C 580 F 1076 SYSTEME D ADMISSION A...

Page 86: ...0 150 100 to 150 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 350 lbs 771 6 Poids sec avec TTM40A Dry weight with TTM40A kg 390 lbs 859 8 CONSEILS D INSTALLATION INSTA...

Page 87: ...Commune Control e lectroniquement Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational direction view flywhee...

Page 88: ...xp 3 Fuel consumption propeller load exp 3 l h 2 1 4 9 8 12 5 19 4 28 2 39 6 46 5 gal US h 0 6 1 3 2 1 3 3 5 1 7 4 10 5 12 3 Consommation de carburant pleine charge Fuel consumption at full load l h 7...

Page 89: ...axi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 3 inH O 120 4 Temp rature d chappement maxi Maximum exhaust temperature C 580 F 1076 SYSTEME D ADMISSION A...

Page 90: ...0 150 100 to 150 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 350 lbs 771 6 Poids sec avec TTM40A Dry weight with TTM40A kg 390 lbs 859 8 CONSEILS D INSTALLATION INSTA...

Page 91: ...Commune Control e lectroniquement Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational direction view flywhee...

Page 92: ...Fuel consumption propeller load exp 3 l h 2 5 5 7 9 2 14 4 22 3 32 5 45 7 53 6 gal US h 0 7 1 5 2 4 3 8 5 9 8 6 12 1 14 2 Consommation de carburant pleine charge Fuel consumption at full load l h 8 7...

Page 93: ...axi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 3 inH O 120 4 Temp rature d chappement maxi Maximum exhaust temperature C 580 F 1076 SYSTEME D ADMISSION A...

Page 94: ...00 150 100 to 150 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 350 lbs 771 6 Poids sec avec ZF63A Dry weight with ZF63A kg 360 lbs 793 7 CONSEILS D INSTALLATION INSTAL...

Page 95: ...n label affixed to the engine and sold as stated above in the geographic areas When applied onto engine Emission Control label must never be removed from engine block neither covered with a layer of p...

Page 96: ...lad to inform you and to guide you for the correct care and operating procedures to follow on your en gine Should you be in need of additional assistance please contact NANNI INDUSTRIES S A S 11 Avenu...

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Page 98: ...Nanni Industries S A S 11 Avenue Mariotte 33260 La Teste France Tel 33 0 5 56 22 30 60 Fax 33 0 5 56 22 30 79 www nannienergy com...