Iveco C78 ENT M50 PDF Installation Instruction
Iveco C78 ENT M50 PDF Installation Instruction
Iveco C78 ENT M50 PDF Installation Instruction
FOREWORD
In particular
❏ Use of unsuitable fuels and oils may compromise the
engine’s regular operation, reducing its performance,
reliability and working life.
❏ For the engine to maintain its original condition, it is
absolutely mandatory to use only Original IVECO
Parts.
❏ Any tampering, modifications, or use of non-original
parts may jeopardize the safety of service personnel
and boat users.
The manufacturer
is not liable for any errors
or omissions.
Publication Edited by:
The IVECO competence and professionalism of the
IVECO Engine Business Unit
Customer Service Network is always available to our cus-
C.O. Mkt. Advertising & Promotion
tomers.
IVECO Aifo – Pregnana Milanese
SECTION CONTENTS
OVERVIEW 1
INSTALLATION INSTRUCTIONS 2
DIAGNOSTICS 3
SECTION 1
Overview
Pagina
IDENTIFYING DATA 3
❏ Commercial code 5
ENGINE COMPONENTS 6
PERFORMANCE 8
GENERAL SPECIFICATIONS 10
IDENTIFYING DATA
Figure 1/1
Ist version tag
Figure 1/2
IInd version tag
3 2
Figure 2
The engine’s Model Number and identifying data are stenciled on a tag located on the engine coolant tank.
The model number is assigned by the manufacturer: it is used to identify the main characteristics of the engine, and to char-
acterize its application and power output level. This number is stenciled on 1st version tag and always stamped on a side of
crank-case.
F 2 B E 0 6 8 6 A * A
B B
C C
D D
VARIANTS TO
BASIC ENGINE
OR CUSTOMER
POWER RANGE
A ≤ 500 HP not certified
B = 400 HP certified } pleasure
C ≤ 330 HP not certified
D ≤ 300 HP certified } duty
INTENDED USE (6 = MARINE)
NO. OF CYLINDER
ENGINE
DESIGN ITERATION
COMMERCIAL CODE
The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the
engines according to their family, origins and intended application.The commercial code, therefore, cannot be used for techni-
cal purposes to recognize the engine’s components: this purpose is served by the model number.
C 78 E N T M 50 . 1 0
VERSION: Restyling
VERSION:
TURBO-CHARGER:
1 = COOLED
2 = NOT COOLED
APPLICATION: M = MARINE
Figure 3
1 2 5 6 7 4
23 3
8
22
21
10
20
19
18
11
17
12
16 14 13
15
1. Intake air filter - 2. Intake air pressure and temperature sensor - 3. Lubricating oil refill cap - 4. Lifting padeyes - 5. Coolant
level sensor - 6. Coolant tank - 7. Coolant refill cap - 8. Injector solenoid valve connector - 9. Coolant thermostatic valve
10. Alternator location - 11. Coolant-sea water tube bundle heat exchanger - 12. Auxiliary pulley - 13. Sacrificial anodes
14. Sea water intake - 15. Sea water drain plug - 16. Air-sea water heat exchanger - 17. Sea water pump - 18. Electrical starter
motor - 19. Sea water pump gear - 20. Fuel transfer pump - 21. Fuel filter - 22. Filter clogging sensor -
23. Fuel temperature sensor.
Figure 4
4
5
3 6
7 9
1 8
2
21
10
11
20
12
19
18
14 13
17
15
16
1. Coolant feed to exhaust manifold - 2. Lubricating oil filters - 3. Lubricating oil dipstick. - 4. Electronic Management Box
5. Lubricating oil intake-exhaust control unit - 6. Cooled exhaust manifold - 7.Turbocharger inlet pipe-fitting - 8.Timing
mechanism and oil vapor filter cover - 9. Location of timing phase sensor - 10. Oil filter clogging indicator - 11. Cooled
turbo-charger - 12. Exhaust gas manifold - 13. Phase and engine shaft rotation sensor location - 14. Waste-gate actuator
15.Timing phase inspection port - 16.Throttle position sensor potentiometer - 17. Oil drain sump plug - 18. Instrument panel,
diagnostics and EMB power supply wiring connectors - 19. Location of electrical pump and oil and pre-lubrication
intake/exhaust solenoid valve - 20. Location of lubricating oil temperature and pressure sensors - 21. Coolant drain plug.
PERFORMANCE
Brake horsepower values in accordance with ISO 3046-1, attainable after about 50 hours of operation under reference envi-
ronmental conditions characterized by 750 mmHg, 25°C, 30% relative humidity.Values fall within a tolerance of 5%.
Engine utilization
Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 300 hours/year. Definition of calibrations and operating limits for military and government agencies according to contrac-
tual specifications.
Engine utilization
Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1000 hours/year. Definition of calibrations and operating limits for military and government agencies according to con-
tractual specifications.
Engine utilization
Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1,000 hours/year. Definition of calibrations and operating limits for military and government agencies according to con-
tractual specifications.
Engine utilization
Use of maximum power limited to 25% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1,000 ÷ 3,000 hours/year. Definition of calibrations and operating limits for military and government agencies according
to contractual specifications.
Gas Emissions
Compliance with Standard IMO MARPOL 73/78
ADDENDUM DIR. 94/25/EC
Sound Emissions
Maximum value of average level
for engines in basic configuration dB@A (measurement standard) 95 (ISO 3744)
GENERAL SPECIFICATIONS
Supercharge
Turbo-charger with water-cooled body KKK K31
Pressure regulation with waste-gate
Waste-gate maximum opening pressure bar 2,5 ± 0,1
Lubrication
Oil type SAE 15 W40/E 3
Oil compliant with specifications ACEA E3 / API CF4 / MIL L2104E/F
Total oil capacity on first filling liters (kg) 31 (28)
Total oil capacity with sump at minimum level liters (kg) 18 (16,3)
Total oil capacity with sump at top level liters (kg) 25 (22,7)
Oil pressure, warm engine, minimum idling rpm bar ≥ 1,5
Oil pressure, warm engine, maximum rpm bar ≥5
Maximum allowed temperature °C 105
Oil dipstick valid for static inclination degrees/360 ± 10
Fuel supply
Fuel oil compliant with standard EN 590
Low pressure transfer pump gear pump
Flow rate at maximum rpm kg/h 88
Fuel return flow rate to tank kg/h ≤ 12
Filtering: pre filter µm 36,5
Filtering: filter µm 5
Injection system
Type pump - injectors (PDE)
System Bosch EDC MS 6.2
Maximum injection pressure bar 1600
Cooling
Closed coolant loop with sea water heat exchanger 50% mixture of water/Paraflu II or equiv.
Compliant with SAE J 1034 specification
Total coolant quantity liters ~ 40
Engine-only capacity liters ~ 15,5
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm l/h 25200
Temperature regulation with thermostatic valve
Initial opening °C 68 ± 2
Maximum opening °C 78 ± 2
Sea water line forced circulation
Self-priming pump with neoprene impeller
Sea water pump height above sea level m ≤2
Max. pump capacity l/h 17500
Electrical system
Nominal voltage V dc 24
Self-regulated alternator:
voltage V dc 29
maximum current intensity A 90
Electrical starter motor:
nominal voltage V dc 24
absorbed electrical power W 4500
Recommended batteries capacity Ah ≥ 120
Current discharge at - 18 °C (SAE J 537) A ≥ 900
Weights
Dry without inverter Kg 900
Figure 5
187 (7,36)
943(37,12)
328(12,91)
13 (0,51)
273
903 (35,55) (10,75) 380 (14,96) 380 (14,96)
1671 (65,79) 856 (33,70)
1774 (69,84) 956 (37,64)
SECTION 2
Installation Instructions
Page
INSTALLATION OVERVIEW 3
CAUTIONS 4
❏ Handling cautions 4
❏ Installation cautions 4
DESIGN STANDARDS 5
❏ Accessibility 5
❏ Securing 5
❏ Engine pre-heating 5
❏ Exhaust gas 5
❏ Starting aid 5
FUEL LINE 7
❏ Prefilter 7
❏ Material characteristics 7
ELECTRICAL CIRCUIT 8
❏ EMB 8
❏ Power grid 10
❏ Battery recharge 11
INSTALLATION TESTS 12
❏ Pre-lubrication 12
Page
❏ First start 13
❏ ECU temperature 14
❏ Fuel temperature 14
❏ Exhaust back-pressure 14
❏ Exhaust temperature 14
PANEL WIRING 15
INSTALLATION OVERVIEW
The figure shows the set of components of an installation including those supplied, as standard or optional items, with the
engine equipment, and those supplied or built by the yard.The figure is meant to provide an overall picture of the operations
required for engine installation. Component positions and illustrations are not binding, but merely provided by way of indica-
tion, and they depend on the choices made by yard engineers according to their competence, to the spaces and the prescrip-
tions set out in the chapter that follows.
Figure 1
1 2 3
4 5
6
81421
10
16 15 14 11
13 12
1. Fuel tank with suction/return assembly. - 2. Electrical system cabinet - 3. Servo-throttle - 4. Instrument panel - 5.Throttle
lever - 6. Engine and ventilation air intake - 7. Batteries - 8. Electronic Management Box (EMB) - 9.Ventilation air exhaust -
10. Sea water suction and decanting filter - 11. Exhaust gas and sea water drain pipe - 12. EMB power supply wiring -
13. Indication and control panel wiring - 14. Linkage for throttle potentiometer operation - 15. Power grid wiring from
battery to generator/electrical starter motor - 16. Fuel tank feed and return pipe.
CAUTIONS
DESIGN STANDARDS
Securing
Securing shall be accomplished by means of elastic blocks
able to support the engine’s mass and the longitudinal
thrust exerted by the propeller shaft when in motion.
Dimension and fastening information is provided in the
“Installation Diagram”.
Fuel supply
Transfer pump delivery at maximum rpm Kg/h ≤ 88
Flow rate return to tank kg/h ≤ 12
Fuel temperature to allow maximum power °C ≤ 78
Inner diameter, intake pipe mm 8
Inner diameter, return pipe mm 8
Thread on pre-filter junctions M 14 x 1,5
Thread on engine junctions inches UIC 1/2
FUEL LINE
Figure 3
6
5
4
3
81795
1. From the tank - 2. Sensor for detecting the presence of water in the filter - 3. Decanting filter - 4.Priming pump -
5. Fuel inlet junction - 6. Fuel return junction to tank - 7. Gear pump - 8. Junctions for inverter oil heat exchanger.
ELECTRICAL CIRCUIT
GENERAL NOTES
DO NOT USE wiring belonging to the engine’s electrical equipment to supply power to other devices in the boat.
PLACE engine electrical wiring independently from the other wiring installed on the boat.
USE of switches or battery disconnects on the EMB power supply line is not allowed.
EXTREME CARE SHOULD BE PLACED in the polarization of the electrical connections and in the correct coupling of their
locking elements.
Figure 4
3 4 5
1 2
15 14
13 9
11
12
10
81422
1. EDC system electronic control unit - 2. ECU B connector - 3. Pre-lubrication control unit - 4. Electrical pre-lubrication
pump intake/exhaust enabling control - 5. Pre-lubrication/engine oil replacement solenoid valve enabling control -
6. G connector for instrument panel wiring - 7. Fitting for negative polarity – electrical ground connections - 8. Q connector
for diagnostic instrument connection - 9. H connector for power supply grid wiring - 10. Grid heater relay - 11. Alternator
excitation resistor - 12. Engine electrical wiring and throttle potentiometer - 13. Location of blink-code push-button and
indicator light - 14. Relay and fuse box - 15. ECU A connector.
Figure 5
S2
F8
E Y K9
LD1
D
T F1
K1
K7
C F2
K6
F7
K8
K5
F
F5
M CNB1
P K V CNA1
Z
81423
Relays Fuses
K1 EDC main F1 EDC power supply
K2 not used F2 alternator recharge indication circuit
K3 not used F3 not used
K4 not used F4 not used
K5 intercooler bypass control F5 intercooler bypass
K6 key switch discharge F6 not used
K7 engine shut down F7 master power supply
K8 starter control F8 electrical oil pump
K9 pre-lubricating oil pump control F9 not used
CAUTION
If magneto-thermal protection and intervention devices are interposed, they must not be used to shut the engine down or
otherwise used just a few seconds after shutting the engine down.
6 mm2
of the battery to the fastening point of the electrical starter
motor as shown in Figure 8. 6 mm2
The grounding terminal is secured to the motor proceed-
ing as follows:
70 mm2
❏ Completely remove the conducting paint or the old
conducting paint from both parts constituting the con-
nection, either with mechanical means or with a suit- 10 mm2
able chemical product; if parts whose surface has been
treated need to be used for the securing operation, first
completely remove the anaphoretic paint by
mechanical means, obtaining a smooth support
plane;
❏ Apply a uniform layer of the BH44D product (IVECO
Standard 18-1705) with a brush or spray gun;
70 mm2
❏ Join the parts constituting the ground node within 5 81425
Figure 8
81789
81792
INSTALLATION TESTS
Pre-lubrication
The task of pre-lubricating the engine’s internal components
is managed and controlled by an electronic circuit of the
EMB; the operation can also be conducted by acting manu-
ally, with the key switch in the “OFF” position, only on the oil
intake/exhaust push-button positioned on the related unit. If
the push-button is placed for a few seconds in the
“EXHAUST” position, the filters and the internal engine
ducts will be filled. 80836
PRE-LUBRICATION SYSTEM
1. One way valve - 2. Switching solenoid valve
3. Electrical pump.
CAUTION
Carefully prevent the fuel from coming in contact with the
auxiliaries drive belt. 81419
Fuel temperature
At the end of this procedure, the codes of any faults detect-
ed during engine installation operations will be dele-ted from Verify that temperature of the fuel in the transfer line, while
the ECU. To make sure that no fault data remains stored in underway at maximum power output and with a stable
it, and also that there are no additional faults in the system, quantity of fuel in reserve does not exceed 80°C. A higher
proceed as follows: value would lead to a reduction in engine performance due
to the safety strategies built in the electronic control unit. If
1. Rotate the key switch to the “ON” position. the fuel tends to reach the maximum allowed temperature,
2. Press the diagnosing push-button making sure that, after install a heat exchanger for the fuel.
it briefly lights up as a test, the flashing code indicator
light remains off. Exhaust back-pressure
Verify that the back pressure at the inlet of the exhaust gas
duct, with the engine at full load and maximum power out-
If the ECU detects the presence of errors or operating put, complies with the technical data set out herein.
anomalies, the indicator light will emit the code of the first
stored error with two series of flashes of different frequen- Exhaust temperature
cy; after a few seconds have elapsed from the end of the
emission, the codes of any subsequent errors will be emitted Verify that the temperature of the exhaust gas under
if the push-button is pressed again.The repetition of the first maximum power conditions is close to the prescribed value.
of the emitted code will indicate that all information con-
tained in the memory have been emitted.
Such an event will require a review of the installation, in
order to remove the cause of the error or of the anomaly.
The table containing the explanation of each code is
provided in the “DIAGNOSTICS” section.
Figure 16
81794A
81794B
5. Nebulize about 80 g (10 g per liter of displacement) of 8. Shut the engine down and delete the “errors” which
protective oil type 30/M into the intake mouth of the may have been stored in the injection system ECU dur-
turbocharger, while turning the engine over as described ing the operation stabilization phases. For reset opera-
in the previous paragraph. tion, see “Blink code” paragraph at page 3 in the next
section.
6. Close all the engine’s intake, exhaust, aeration and vent
ports with appropriate caps or seal with adhesive tape. 9. Remove the tags with the inscription “ENGINE WITH-
OUT LUBE OIL” from the engine and from the panel.
7. Drain from the oil sump the residual protective oil type
30/M, which may be reused for 2 more engine lay-ups.
8. Apply tags bearing the inscription “ENGINE WITHOUT
LUBE OIL” on the engine and on the panel.
9. Drain the cooling liquid if it is not mixed with anticorro-
sive substances.
SECTION 3
Diagnostics
Pagina
ECU BEHAVIOR 3
❏ Blink code 3
❏ Recovery 3
ECU BEHAVIOR
Blink code
The emission of the fault codes detected by the self-diag-
nostics routines and stored in the ECU starts after the
push-button located on the relay and fuse board is pressed
and released. The LED to the side of the push-button and
the EDC indicator light on the indications and control panel
will simultaneously signal the codes by blinking two series of
emissions at different frequency, reproducing the digits indi-
cating the fault with decimal numbering.
Control area
1.1 (on) not significant in marine applications
1.2 (on) not significant in marine applications
1.3 (off) not significant in marine applications
1.4 on throttle position sensor
1.5 (off) not significant in marine applications
1.6 (on) not significant in marine applications
1.7 (off) not significant in marine applications
Engine area
2.1 off coolant temperature sensor
2.2 off intake air temperature sensor
2.3 off fuel temperature sensor
2.4 on supercharge air pressure sensor
2.5 off ambient pressure sensor (inside the unit)
2.6 (on) not significant in marine applications
3.5 off battery voltage
Injectors
5.1 on cylinder 1 injector fault
5.2 on cylinder 2 injector fault
5.3 on cylinder 3 injector fault
5.4 on cylinder 4 injector fault
5.5 on cylinder 5 injector fault
5.6 on cylinder 6 injector fault
Electronic unit
9.1 blinking defective unit
9.2 on incorrect EEPROM data
9.3 (blinking) not significant in marine applications
9.4 on main relay
9.5 on erroneous engine shut-down procedure
9.6 on unit data storage operation not completed
NOTES
NOTES