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C78 ENS M20


C78 ENT M30-M50-M55
6 CYLINDER IN LINE
DIESEL CYCLE
FOR MARINE APPLICATIONS

INSTALLATION DIRECTIVE
MAY 2006 EDITION
E X C E L L E N C E
T E C H N O L O G I C A L
C78 ENS M20
 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

FOREWORD

We strongly recommend that you carefully read the indica-


tions contained in this document: compliance with them
protects the engine against irregular operation and assures
its reliability, safeguarding sea-going and maintenance person-
nel against accident hazards.
The indications contained in this directive pertain to the C78
ENS M20, C78 ENT M30, C78 ENT M50 and C78 ENT M55
engines and complement the IVECO MOTORS publication
“Guide to the Installation of Marine Engines”, the reader
should refer to for anything that is not explained herein.
For more complete information about the engine, please
refer to the appropriate technical brochure.
Use of fuels and oils with different characteristics from
those set out in the operation and maintenance manual may
compromise the regular operation of the engine, limiting its
performance, reliability and working life.

Exclusive use of IVECO Original Parts is a necessary condi-


tion to maintain the engine in its original integrity.

Tampering, making modifications and using non original parts


can jeopardize the safety of boat engineers and users.

To obtain spare parts, you must indicate:


- Commercial code, serial number and indications shown
on the engine tag;
- Part number of the spare as per spare part catalog.

The information provided below refer to engine charac-


teristics that are current as of the publication date. IVECO
MOTORS reserves the right to make modifications at any
time and without advance notice, to meet technical or
commercial requirements or to comply with local legal and
regulatory requirements.

We refuse all liability for any errors and omissions.

The reader is reminded that the IVECO MOTORS Technical


Assistance Network is always at the Customer’s side with its
competence and professionalism.

Publication IVECO MOTORS edited by:


IVECO PowerTrain
Advertising & Promotion
Pregnana Milanese (MI)
www.ivecomotors.com

Printed P3D64C001 E - May 2006 Edition


C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 

CONTENTS

Page

1. WARNINGS AND CAUTIONS 4

2. ENGINE PARTS AND COMPONENTS 6

3. INSTALLATION OVERVIEW 8

4. GENERAL INSTALLATION CRITERIA 9

5. TECHNICAL DATA FOR INSTALLATION 10

6. IDENTIFICATION DATA 12

7. FUEL LINE 13

8. ELECTRICAL EQUIPMENT 15

9. MAIN ANALOG INSTRUMENT PANEL 22

10. SECONDARY ANALOG INSTRUMENT PANEL 26

11. DRILLING PLANS FOR ANALOG PANELS 27

12. MAIN DIGITAL INSTRUMENT PANEL 28

13. SECONDARY DIGITAL INSTRUMENT PANEL 34

14. DRILLING Plan FOR DIGITAL PANELS 35

15. CUSTOMIZED INSTRUMENT PANEL 36

16. SENSORS FOR DETECTION


AND PANEL SIGNALING 38

17. PREPARING THE ENGINE FOR FIRST START-UP 41

18. TESTS BEFORE THE FIRST START-UP 41

19. FIRST ENGINE START 42

20. EDC ANOMALIES INDICATION 44

21. BLINK CODE TABLE 45

22. UNDERWAY CHECKS 46

23. PREPARING THE ENGINE


FOR LONG IDLE PERIODS 47

24. ELECTRIC DIAGRAMS 48

25. C78 ENS M20 ENGINE 59

26. APPENDIX 63

Indications for consultation


The different versions of the motors are generally hown
using the same pictures and descriptions, however important
differences are shown separately.
The specific characteristics of the C78 ENS M20 engine
electric system are described in Chapter 25.
C78 ENS M20
 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

1. WARNINGS AND CAUTIONS

To obtain the best engine performance, it is essential not to o Do not connect any extraneous user device to the
deviate from the mission profile for which it was produced engine electrical equipment.
and set up. The engine must not be used for purposes other
than those stated by the manufacturer. IVECO MOTORS o Do not place voltage across the boat’s on-board electri-
is willing to examine any need for particular installations cal system without first verifying that there are no short
beforehand. Use of an electronically controlled injection circuits.
system, in providing the engine with performance benefits, o Do not branch pipes off to draw fuel from the engine
requires that the installer and maintenance specialist comply supply lines.
with some fundamental rules, which will become more and
more commonplace as use of such equipment becomes o Do not make any change to the engine’s hydraulic cir-
progressively more widespread. Boat outfitters and mainte- cuits and components.
nance specialists are invited to closely follow the instructions o Do not execute arc welding operations before removing
contained herein. No modifications to the engine, its acces- the electronic units from their seating, placing them at an
sories and components, are allowed. adequate safety distance.

Failure to comply with the instructions that follow shall o Do not subject electronic units to temperatures exceed-
void the warranty and relieve IVECO MOTORS of all ing 80°C.
liabilities. o Do not paint electrical components and their connec-
tions.
For personnel safety o Do not alter the data contained in the engine control
electronic unit.
Specialists and installers are cautioned to comply with
o Comply with prescribed procedures and torque values
workplace safety rules and to adopt prescribed individual
when tightening threaded elements.
protection devices when working.

o Drain the cooling, lubrication and fuel lines only after


Start-up
the fluids have duly cooled. The pressurized cap of the
coolant line may be opened only after the engine has o Ready the engine following the procedure set out in
duly cooled. Chapter 17.
o Batteries contain a highly corrosive sulfuric acid solution: o When starting the engine the first time, have suitable
must never be upset and must be handled with the means available to cut off air intake in case of a runaway
utmost caution to prevent spillage. Ensure that the bat- condition.
tery compartment is adequately ventilated. o Start the engine after ensuring that it is complete with
every part specified by the manufacturer and required
by the installation, without attempting to start it with
Handling caps and occlusions to the lubrication, cooling and fuel
The engine must be handled by experienced personnel, feed lines.
using the prescribed tool or a rocker arm that keeps the o Check that the fluid lines are perfectly sealed, especially
lifting lines parallel and with adequate equipment in terms lines for fuels and lubricants, which may cause fires and
of capacity and size. The two eyebolts provided for lifting the consequent harm to persons and equipment.
engine alone must always be used simultaneously.
o Make sure that the various pipelines are not in contact
with warm surfaces or moving parts.
Installation o The installing yard is required to carry out tests to verify
o Knife switches or battery breakers may be used on the the functional compatibility between the electrical-elec-
power supply line of the engine electronic unit, provided tronic equipment of the engine and the other electronic
they are not used to shut the engine off. equipment present on the boat.
o Do not modify the wiring harnesses; their length may
not be modified: use only available extensions.
Tests and tuning up
o Do not use electronic device wiring harnesses not com-
pliant with the IVECO MOTORS directive, in terms of o Never disconnect the batteries when the engine is run-
length, type of conductor, location, clamping, connection ning.
of the shielding and earth braids. o Remove the electrical connections from the batteries
o To avoid any interference, the wiring harnesses of the before any operation on the electrical system.
different on-board electronic devices must follow differ- o Ensure that the battery terminals comply with the exact
ent paths from those of the engine electronic systems. polarity, are properly tightened and protected against
accidental short circuits and corrosion phenomena.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 

o Do not connect or disconnect electrical connections


when electrical power supply is present.
o Do not cause sparks in the attempt to verify the pres-
ence of electrical voltage.
o Do not draw fuel through unfiltered lines.
o Do not clean the engine and its parts with corrosive or
abrasive detergent substances, to avoid compromising
the integrity of electrical connections.
o The engine fluids and air, coolant, and oil filters discarded
after use must be properly stored and delivered to
appropriate collection centers.

Long engine inactivity periods


Before long periods of inactivity, ready the engine following
the procedure set out in Chapter 23.
C78 ENS M20
 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

2. ENGINE PARTS AND COMPONENTS

Figure 1

3 4
2 5
1
6

9
25

24

23

22
10

21

11
20

19
12

18
13
17 16 15
14
80819

1. Intake air filter - 2. Location of intake air pressure and temperature sensors - 3. Lubricating oil refill cap - 4. Lifting padeyes -
5. Coolant level sensor - 6. Engine coolant tank - 7. Coolant refill cap - 8. Injector solenoid valve connector - 9. Location of
thermostatic valve - 10. Cap for engine coolant outlet to sanitary water heating system - 11. Alternator location - 12. Coolant/sea
water tube bundle heat exchanger - 13. Auxiliary pulley - 14. Oil drain sump plug - 15. Sacrificial anodes - 16. Sea water intake -
17. Sea water drain plug - 18. Air/sea water heat exchanger (not present on the C78 ENS M20 engine) - 19. Sea water pump -
20. Electrical starter motor - 21. Sea water pump gear - 22. Fuel transfer pump - 23. Fuel filter - 24. Filter clogging sensor -
25. Fuel temperature sensor.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 

Figure 2

3 4 5 6 7 8 9

1
10

11

12

20

13

14

19 18 17 16 15 04_001_C

1. Coolant feed to exhaust manifold - 2. Lubricating oil filters - 3. Lubricating oil dipstick - 4. Insulated support - 5. Electronic Central
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 outlet flange - 13. Phase and
engine shaft rotation sensor location - 14. Waste-gate actuator - 15.Timing phase inspection port - 16.Throttle position sensor
potentiometer - 17. Electrical equipement wiring connectors - 18. Oil fill-in fill-out / pre-lubrication electrical pump (optional) -
19. Oil fill-in fill-out / pre-lubrication electrical pump solenoid valve (optional) - 20. Cap for engine coolant discharge and
recyrculation from sanitary water heating system
C78 ENS M20
 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

3. INSTALLATION OVERVIEW

Figure 3
1 2
12
11 3

10

04_016_C 6
7

1. Exhaust gas and sea water discharge - 2. Electrical system cabinet - 3. Secondary instrument panell - 4. Fuel tank with suction/
return assembly - 5. Fuel suction pipe - 6. Fuel return pipe to tank - 7. Pre-filter - 8. Fuel feed pipe to the fuel transfer pump -
9. Sea water decanter filter - 10. To the filtered sea water intake - 11. Main instrument panel - 12. Throttle actuator.

The figure shows the set of components of an installation,


including those supplied with the engine equipment, standard
or optional, and those supplied or produced by the yard.
It provides a comprehensive picture of the operations
required to install the engine.
Components arrangement and illustrations are not binding
but merely indicative, subject to the choices made by yard
engineers according to their skills, available spaces and the
prescriptions set out herein.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 

4. GENERAL INSTALLATION CRITERIA

Accessibility Exhaust gas discharge


The engine must be located in such a way as to allow filling The exhaust gas discharge conduit shall be compliant with
and draining engine liquids when doing servicing operations. the guidelines contained in the IVECO MOTORS publication
Moreover, the relay box and the diagnostic push-button “Guide to the installation of marine engines”; it also provides
present on it must be accessible, also when underway. indications to compute the dimensions of the exhaust pipe-
lines, which is the Yard’s responsibility.
Anchoring
Engine installations to which the inverter has been directly Electric - electronic equipment
coupled, must be carried out in compliance with the number Provide a suitable arrangement of the relay box, and of the
of supports, as specified here below: optional electronic unit referring to the dimensions and posi-
tion of the wire harnesses and the relative connectors.
o C78 ENS M20 for commercial or heavy duty supports:
Both units must be anchored in such a way as to dampen the
6 supports: 4 for the engine - 2 for the inverter;
vibrations and stresses undergone by the hull while under-
NOTE: with the inverter weighting < 200 kg and gear-
way and/or induced by the engine’s operation.
ing-down ratio < 3, please contact IVECO MOTORS in
order to assess the installation of the 4 engine supports
NOTE: Information about optional equipment are described
alone.
in the Chapter 26.
o C78 ENT M30 for commercial or heavy duty supports:
6 supports: 4 for the engine - 2 for the inverter. (1) The EDC engine electronic control is programmed to
reduce maximum deliverable power if the operating
o C78 ENT M50/M55 for commercial use 6 suppor ts: parameters measured by the sensors show that criti-
4 for the engine - 2 for the inver ter. cal conditions have been reached, and if exceeded the
o C78 ENT M50/M55 for recreational use 4 supports for engine could be damaged.
the engine.
In case spring inserts are used, they have to be capable of
supporting the engine mass, the dynamic force, the force
resulting from the torque reaction generated by the trans-
mission and the longitudinal thurst performed by the propel-
ler axis during navigation.
If rigid mounting is adopted, particular care must be given to
support alignment and co-planarity.
Information on dimensions and fastening values are provided
in the “Installation Diagram”.
Combustion and ventilation air
Compliance with prescriptions on the quantity of air
required for combustion and ventilation assures a regular
operation of the engine even in adverse conditions and it
enables to deliver its maximum design power (1).
Sea water line
It must be provided with an intake capable of preventing
the entry of foreign bodies into the suction pipes. Between
the intake and the pump, it is best to interpose a gate to be
closed in emergencies or for extended idle periods and a
filter to stop the smaller impurities; it is also recommended
to install a suitably dimensioned and easily replaced zinc
anode.
The engine sea water line was provided by the manufacturer
with protection anodes to be replaced periodically.
The rubber hoses positioned along the pipeline shall be suffi-
ciently rigid not to create choked areas caused by crushing (1).
Engine pre-heating
If the engine usage profile requires immediate delivery of
power at the highest rpm’s, it is recommended to install an
auxiliary pre-heater on the closed cooling loop.
C78 ENS M20
10 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

5. TECHNICAL DATA FOR INSTALLATION

C78 C78 C78 C78


ENS ENT ENT ENT
M20 M30 M50 M55
Engine intake and ventilation air when underway
kPa ≤ 3,5 ≤ 3,5 ≤ 3,5 ≤ 3,5
Static vacuum allowed downstream of the air filter
mm H2O ≤ 350 ≤ 350 ≤ 350 ≤ 350
Engine air intake flow rate m3/h ≥ 870 ≥ 1000 ≥ 1560 ≥ 1800
Engine room ventilation air flow rate (excluding engine air intake) m /h
3
≥ 3100 ≥ 3600 ≥ 6000 ≥ 6600
kPa ≤ 0,1 ≤ 0,1 ≤ 0,1 ≤ 0,1
Static vacuum allowed in the engine room
mm H2O ≤ 10 ≤ 10 ≤ 10 ≤ 10
Temperature allowed in the engine room °C ≤ 50 ≤ 50 ≤ 50 ≤ 45
Maximum engine room temperature exceed outside temperature °C ≤ 15 ≤ 15 ≤ 15 ≤ 15

Exhaust gas discharge


kPa ≤ 10 ≤ 10 ≤ 10 ≤ 10
Allowed static back pressure
mm H2O ≤ 1000 ≤ 1000 ≤ 1000 ≤ 1000
540 560 680 690
Temperature at maximum power (turbocharger inlet) °C ± 25 ± 25 ± 25 ± 25
Flow rate at maximum power kg/h 950 1160 1980 2320
mm 153 153 153 153
Riser outer diameter
inches 6 6 6 6
mm 114 114 114 114
Dry exhaust outer diameter
inches 4,5 4,5 4,5 4,5
mm 150 150 150 150
Diameter of circumference of distance between 6 locking holes
inches 5,9 5,9 5,9 5,9

Fuel supply
Transfer pump delivery at maximum rpm l/h 160 160 160 160
Fuel temperature to allow maximum power °C ≤ 50 ≤ 50 ≤ 50 ≤ 50
Inner diameter, intake pipe mm ≥8 ≥8 ≥8 ≥8
Inner diameter, return pipe mm ≥8 ≥8 ≥8 ≥8
Thread on pre-filter junctions M 14 x 14 x 1,5 14 x 1,5 14 x 1,5
1,5
Thread on engine junctions inches UIC 1/2 1/2 1/2 1/2
kPa ≤ 20 ≤ 20 ≤ 20 ≤ 20
Allowed intake vacuum
mm H2O ≤ 2000 ≤ 2000 ≤ 2000 ≤ 2000

Open sea water cooling line


mm 60 60 60 60
Intake pipeline diameter
inches 2,36 2,36 2,36 2,36
Pump delivery at maximum rpm l/h 16500 16500 17500 20000
kPa ≤ 20 ≤ 20 ≤ 20 ≤ 20
Allowed intake vacuum
mm H2O ≤ 2000 ≤ 2000 ≤ 2000 ≤ 2000
mm 50 50 50 50
Discharge pipeline diameter
inches 2 2 2 2

Gear box oil heat exchanger


Thread on engine junctions inches UIC 1/2 1/2 1/2 1/2
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 11

C78 C78 C78 C78


ENS ENT ENT ENT
M20 M30 M50 M55
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360 +20° +20° +20° +20°
Maximum transvers in continuous operation(static + dynamic) degrees/360 ± 22°30’ ± 22°30’ ± 22°30’ ± 22°30’
Longitudinal for oil level check with standard dipstick degrees/360 0 ÷ 10° 0 ÷ 10° 0 ÷ 10° 0 ÷ 10°

Power takeoffs (optional)


2-race front pulley for “V” belts
Reference diameter mm 207 207 207 207
Race dimension mm 12.7 12.7 12.7 12.7
kW ≤ 3,7 ≤ 3,7 ≤ 3,7 ≤ 3,7
Power available per belt at 650 rpm CV ≤5 ≤5 ≤5 ≤5
kW ≤ 7,4 ≤ 7,4 ≤ 7,4 ≤ 7,4
Power available per belt at 1300 rpm CV ≤ 10 ≤ 10 ≤ 10 ≤ 10
2-race front pulley + elastic joint for flange
Nm ≤ 400 ≤ 400 ≤ 400 ≤ 400
Torque available in engine axis kgm ≤ 41 ≤ 41 ≤ 41 ≤ 41
2-race front pulley + elastic joint for crankshaft
Nm ≤ 400 ≤ 400 ≤ 400 ≤ 400
Torque available in engine axis kgm ≤ 41 ≤ 41 ≤ 41 ≤ 41
Radial force resulting from belt tension (*) N ≤ 1600 ≤ 1600 ≤ 1600 ≤ 1600
(*) For direction of the resulting radial force between 60° and 300° with reference to the cylinder axis (piston at top dead
center = 0°)
Moment of inertia of rigidly added masses (*) kgm2 ≤ 0,015 ≤ 0,015 ≤ 0,015 ≤ 0,015

Dimensions

Figure 4

¬  ¬ 
¬ 

¬ 
¬ 

¬ 


¬    ¬  ¬ 
¬  ¬ 
¬  ¬ 

Centre of gravity MM¬INCHES 04_017_C


C78 ENS M20
12 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

6. IDENTIFICATION DATA

Figure 5

S. p. A.
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE

ENGINE FAMILY ENGINE DWG


POWER (KW)
AND SPEED (RPM) POWER SET CODE

ENGINE S/N YEAR OF BUILD

HOMOLOGATION N°

COMMERC. TYPE / VERSION

04_039_C

Figure 6

80818

The engine identification data are stenciled on a tag positioned over the engine coolant tank
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 13

7. FUEL LINE

Figure 7
5 6 7 8

4
10

80839

Fuel inlet Fuel return

1. Return and suction flows from the tank - 2. Pre-filter - 3. Low pressure supply pump - 4. Return loop pressurization valve -
5. Inlet and outlet fittings from cylinder head - 6. Fuel filter - 7. Injector pump - 8. Fuel return line - 9. Cylinder head channel
venting point - 10. Low pression injector feeding line

For the installation, the following connections are required: Tanks must be provided with vents to avoid exceeding an
internal pressure of ± 5kPa (± 0.5 m of H2O column); their
- from the tank to the pre-filter shape and the suction assembly must be such as to assure a
- from the pre-filter to the pump inlet suction at the maximum longitudinal and transverse inclina-
- from the fuel discharge outlet to the tank tion allowed for the boat, with a residual quantity of fuel oil
considered “reserve”.
Pre-filter The suction inlet should be positioned in such a way as to
The pre-filter with priming pump, supplied separately from avoid taking in sludge. The return flow must be in such a way
the engine, must be fastened near the tank, in a relatively low as to facilitate the mixing of the returning fuel with the fuel
point of the line to allow for easy replacement the filtering in the tank. If the tank is lower than the filter, then the return
cartridge and/or the operation of the hand pump. Avoid the pipe must always be submerged. The pipes and union fittings
use of additional mesh or paper filters along the feed lines of the fuel line must withstand a fuel oil flow rate of 160
between pre-filter and engine. To avoid introducing impuri- l/h at a temperature of 90°C and a pressure of 3 bar (300
ties in the feeding lines inside the engine, do not place filter kPa) without noticeable deformation, wear or release of
cartridges pre-filled with fuel in the system. material. Metal tubes, preferably made of iron alloys, are rec-
ommended, taking care to connect each individual segment
Materials Characteristics to engine ground to avoid the accumulation of electrostatic
The fuel tank and the suction and return assembly must charges and inserting a vibration damper elastic joint on each
withstand the continuous abrasion caused by a flow of fuel segment. The pipes used must be certified according to the
oil of 160 l/h at a temperature of 90°C without noticeable relevant Countries’ rules or to the standards issued by clas-
deformation or wear or release of material. Use of metal sification Bodies.
tanks, preferably made of iron alloys, is allowed, provided
they are connected to the negative terminal of the battery
to prevent the accumulation of electrostatic charges.
C78 ENS M20
14 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Fuel supply system scheme

Figure 8 3 4 5
6

1
7
22
21
8 9 10 11 12

20

19 18 17 16 15 14 13
80840

1. EUI injector - 2. EUI pumper - 3. Rocker arm - 4. Actuating cam - 5. EUI solenoid valve - 6. Vent fitting on cylinder head -
7. Calibrated hole - 8 Vent fitting on pre-filter - 9. One-way valve - 10. Hand pump - 11. Fuel pre-filter - 12. One-way valve -
13. Fuel tank - 14. Gear pump assembly - 15. Fuel supply gear pump - 16. Pressure limiter valve (initial opening pressure 5 bar) -
17. One-way valve - 18. One-way valve - 19. Calibrated hole - 20. Pressure regulating valve (initial opening pressure 3.5 bar) -
21. Fuel filter - 22. Vent fitting on fuel filter support.
Hydraulic connections
Figure 9
1

10
3

9 4

8 6

7
04_019_C

1. Outlet fitting from cylinder head - 2. Inlet fitting to cylinder head - 3. Pressure regolating valves location -
4. Outlet fitting for fuel outflow to the tank - 5. Inlet fitting from pre-filter - 6. Pre-filter - 7. Inlet pipe from the tank -
8. Outlet pipe to the tank - 9. Low pressure feed pump - 10. Fuel filter.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 15

8. ELECTRICAL EQUIPMENT

Figure 10

1 2
3

15

14
5

13

12 6

7
11

10 8
04_004_C
9

1. Indicator and control panel - 2. Engine wiring - 3. Electronic Central Unit - 4. M Connector - 5. Relay box -
6. JF and JF1 connectors - 7. Sedimenting pre-filter - 8. Sensor for the presence of water in the fuel -
9.Wiring harness to be manufactured by the yard -10. Power supply and interface wire harness - 11. JG Connector -
12. JE Connector - 13. JA Connection - 14. JB Connection - 15. Power line for electric starter motor and alternator.

The electrical equipment of the engine comprises a series of Along with the coupling of all connectors provided in the
components provided separately from the engine to enable wire harnesses, completing the installation also requires the
an easy and diversified installation, according to the Yard’s connecting wire harness (9) for the sensor for the presence
design choices.The need to make accessible, at sea or under- of water in the fuel (8), to complete the power line and to
way, the controls to the electrical components and to the connect the accumulator to the engine wire harness.
connector for diagnostics contained in the relay box may be
met through different installation arrangements.
C78 ENS M20
16 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Synoptic

Figure 11
GEAR BOX

INDICATIONS AND
ALARMS SENSORS

INDICATIONS AND
ALARMS SENSORS

THROTTLE POSITION
SENSOR

EDC COMPONENTS

EUI SOLENOID
VALVES

!
ALTERNATOR
EDC

"
ELECTRIC STARTER
MOTOR

*' *%
#¬%.3¬-
#¬%.4¬-  
*" *!

*& *&

RELAY
BATTERY
BOX
1 2 3 4 5 6 04_005_C

1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Connector for pre-lubricating system -
4. Connector for certified installations by classification Bodies - 5. Interface wire harness - 6. Power line.

The wire harnesses provided with the engine include the connectors for all optional components which may ordered and their
connections to the JB connector for the indication and control panel.

F
JF1 JF

05_116_C
MAY 2006

JG I H
Figure 12
Wire harness

E
JE J GH
T

*
+ BATT W T

Engine wire harness


W
VI
V S
VI
V S SI K
– BATT O
SI K GG
WI
JA X A
C
U WI
JA X GG


Z
B MM

Interface wire harness


JB
INSTALLATION DIRECTIVE

B EDC M
PO
A EDC PA EC
A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E.
EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure/
temperature sensor for EDC - I. High coolant temperature - J. Low coolant level sensor (for alarm) - K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the
presence of water in the fuel pre-filter (for alarm) - O. Exhaust gas temperature sensor (for gauge) - S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for
gauge) - U. Clogged oil filter sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged blow-by filter sensor (for alarm) - Z.
Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection
C78 ENT M30-M50-M55
C78 ENS M20

wire harness - JE. Alarms control unit (for Certification Bodies) - JF,JF1. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor
- PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure sensor (25 bar) - WI. Low gear box oil pressure sensor (7 bar) - *
Sensor H wiring harness.
17
C78 ENS M20
18 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Power supply line Supplementary services battery


To assure that the engine can be started with a sufficient
Figure 13
quantity of energy, it is advisable to provide for the instal-
2 lation of a supplementary battery, dedicated to supplying
power to the on-board electrical services. The power line to
Equipment power supply recharge it may be constructed according to the indications
provided in Chapter 20.

If one engine is installed


30 50 +B S L IG The battery used for services may be recharged interposing
on the power supply line a relay actuated by the recharge
signal of the alternator’s electronic regulator (L).
M If two engines are installed
The presence of two generators allows to keep the recharg-
ing functions separated: the generator (G1) recharges the
battery (AC1) dedicated to starting both engines and pow-
ering both electrical/electronic control circuits, whilst the
generator (G2) recharges the battery (AC2) used to power
the services.
1 4 3
05_040_C
In two-engine applications, it is essential to connect the
engine grounds to a common potential; the solution pro-
1. Electric starter motor - 2. Engine wire harness - posed in Chapter 20 fully complies with this need, assuring
3. Batteries - 4. Alternator. the full functionality and independence of the two circuits.
The connection of the +B terminal of the alternator to the
positive +30 terminal of the electric starter motor must be
achieved with a conductor having a cross section of at least
40 mm2. The connection of the positive +30 terminal of the
electric starter motor to the positive pole of the battery,
achieved with a conductor having a cross section of at least
95 mm2, allows to obtain, as shown in the figure, the simulta-
neous connection of the alternator to the battery. The con-
nection between the engine ground and the negative pole
of the battery must be achieved according to the guidelines
provided in the Engine electrical ground paragraph.

caution
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 19

Engine electrical ground Battery recharging


Figure 14 Figure 15A
B+
Connect to positive
pole terminal of the
starter motor

S
L IG 05_038_C

1 04_038_C
This is accomplished through the power supply line of
1. Point of connection of the engine electrical ground. the electric starter motor and connection to the +B of
the alternator. The electronic regulator of the alternator
The connection of the engine electrical ground is achieved that equips the engine allows an effective control over the
by connecting with a cable of at least 95 mm2 cross section battery recharging operation.
to the negative pole of the battery to the tightening point of If, due to installation requirements, the batteries need to be
the electric starter motor as shown in Figure 14. positioned at a distance from the engine, we recommend
To anchor the grounding terminal to the engine, proceed as increasing the cross section of the power line conductors
follows: and verifying recharging effectiveness by measuring voltage
across the battery poles.
o completely remove the paint from both parts constitut-
ing the connection, using mechanical means or suitable For the best control of the battery recharge cabling the line
chemical product;if the anchoring operation is to take relating to the S terminal of the alternator directly to the
place on superficially treated parts, completely remove positive pole terminal of the battery (see figure 15B).
the anaphoretic paint with mechanical means, obtaining
a smooth support surface; Figure 15B
o apply a uniform layer of BH44D paint (IVECO standard
18-1705) with a brush or spray gun;
o join the parts constituting the grounding note within 5
minutes from the time the paint was applied. +B S L IG

05_039_C

B+
Connect to positive
pole terminal of the
starter motor

Connect to positive
pole terminal of the
S
batteries
L
81790 IG
C78 ENS M20
20 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Connections of the central electronic unit Relay Box


(ECU) EDC MS 6.2
Figure 17
Figure 16

ENGINE ENGINE PTO


ROOM STOP PTO – ON

BRIDGE ENGINE PTO + PTO CHECK


START OFF
04_002_C

1 2 3 4 5 6 7

A B 80852
1. Bridge or engine room engine control selector - 2. Start and
stop push button - 3. Manual accelerator throttle control in
A. Engine component wiring connector engine room - 4. PTO ON / PTO OFF selector - 5. EDC fault
B.Vessel side wiring connector indicator and blink code LED - 6. Blink code emission request
push-button - 7. Connector for external diagnostic tool.
The connection of the central electronic unit, ECU, to the
EDC system, takes place by means of two 35 way connectors This shall be installed and anchored in such a way as to
mechanically polarized in the latching system to prevent dampen the vibrations and stresses occurring when under-
switching. The presence of the two connectors provides for way, and they shall be accessible during servicing operations
a subdivision of the wiring harnesses to distribute the large and when underway. The electrical commands positioned on
quantity of conductors and at the same favor a more rapid the panel allow to control engine starting and stopping (2)
identification of the lines during testing operations conducted directly from the engine room, while excluding any possibil-
by technical assistance personnel. ity that anyone may involuntarily start the engine from the
bridge (1), during servicing operations. Engine rpm control
could be obtained directly from engine room by the push-
button (3) after positioning the switch (4) ON.
Among the controls present on the panel are also the push-
button (6) and the “blink code” light indicator (5), useful
to obtain, also while underway, indications that will lead to
identify failures or improper engine operating conditions (see
Chapter 20).
On the relay box is located the multipolar connector (7),
protected by a screw-on lid, for connection with the com-
puterized diagnostic tools prescribed by IVECO MOTORS
(see Chapter 20).
Inside the box, anchored to a printed circuit board, are
present the power management relays of some components
and the elements that protect the electrical lines against
short circuits or excessive current absorption. These com-
ponents perform a similar function to that of fuses, almost
totally avoiding the need to restore the electrical continuity
of circuits subjected to an anomaly condition. These compo-
nents are able to limit and eliminate short circuit currents
without melting, restoring their own and the circuit’s electri-
cal continuity, once the cause of the anomaly is removed.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 21

Throttle lever position sensor Water presence in the pre-filter sensor


Figure 17A Figure 17B

05_078_C
1
After testing the working condition of the linkage, adjust the
run of the servo components (see Chapter 18).
o With the throttle at idle setting, the potentiometer rod 05_018_V
3
has to be in the resting position;
o With the throttle at the stop, the potentiometer rod has
to be in the position of maximum run out. 1. Pre - filter - 2. Conductor to be connected
with the negative battery terminal -
3. Sensor to detect water in the fuel.

CAUTION
In order to enable the proper working of the sensor to
detect water in the fuel, it is necessary that the pre-filter
support is connected electrically to the negative battery
terminal.

In the engine models which use parts with insulated poles


it is necessary to electrically insulate the pre-filter support
from the boat mass and then connect the support with the
negative battery terminal.
C78 ENS M20
22 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

9. MAIN ANALOG INSTRUMENT PANEL

Figure 18
3 4 5

electronic
RPMx100

2
HOURS

oC

bar
oF
1 6

12

11 10 9 8
7
13

14
04_020_C

1. Coolant temperature gauge (TA) - 2. Revolution counter and hour counter (CG) - 3.Voltmeter (V) - 4. Buzzer (SA) - 5. Indication
and alarm module (MS) - 6. Engine oil pressure gauge (MO) - 7. Connector for secondary instrument panel (JE)- 8. On board panel
instrument light switch (L) - 9. Engine start/stop key switch (CA) -10. Engine stop push-button (usable only with electric harness
versions with excitation engine stop) - 11. Sound alarm inhibition push-button (P1) -12. SIFC Alarm abilitation connector -
13. Connector for main panel wiring (JC) - 14. Cap with electrical continuity connection.

Installation of the IVECO MOTORS onboard panel with To the main panel is connected the JE connector, provided
analog indicators entails connecting the panel’s JC connec- for connection to the secondary panel; in installations with
tor to the JB connector on engine wire harness, interposing no secondary panel, do not remove the cap of the JE con-
the appropriate extension wire harness available in 3, 5 and nector to avoid compromising the electrical continuity of the
7 meter-long versions. The JC-JB wire harness comprises 47 systems’ power supply circuit.
lines, each connected to the terminal identified on both con- To allow the work of the fuel filter clogging alarm (SIFC), in
nectors by the same number. the indication alarm module, it has to disconnect the connec-
tor (12) fitted close to JC.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 23

Synoptic of the connections of the analog panels


Figure 19
2

MAIN SECONDARY
INSTRUMENT INSTRUMENT
PANEL JE JE JH JH PANEL

JC

JC
ENGINE
EQUIPMENT

1
A

EDC

JB JA

JF JF1

RELAY BATTERY
BOX
04_021_C

1. JB-JC Extension wire harness - 2. JE-JH Extension wire harness.

Figure 20

34 34
47 35 35 47
46 33 20 36 36 20 33 46
32 8 21 21 8 32
31 19 9 22 9 19 31
22
18 2 10 10 3 2 18 30
30 23 23
3 37 7
45 7 1 37 11 4 1 17
17 11 45
29 6 4 24 38 24 6 29
44 5 38 5 15
16 12 12 13 16 44
39 14
15 14 13 25 43
43 28 25 39 28
40 42
27 26 26 27
42 40
41
41

04_250_N

JC JB

Connectors of the extension wire harness JB - JC, seen from the coupling side

The JC-JB wire harness comprises 47 lines, each connected To identify the functions served by the individual lines, refer
to the terminal identified on both connectors by the same to the electrical diagrams in Chapter 24.
number.
C78 ENS M20
24 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Installation Indications and Alarms Module


In order to drill holes on the area where the panel is to be Figure 21
mounted, refer to the dimensions indicated in Chapter 11.
Operation of the panel 7
After completing the electrical connections and engine 6 8
preparation, perform the tests required for the first start, as
described in Chapter 18.
Verify the proper operation of the panel, proceeding as fol- 5 9
lows:
10
o Make sure that the “ENGINE ROOM / BRIDGE” switch 4
of the Relay Box is in the “BRIDGE” position, then 11
turn the key switch to the first position and verify that
the instruments are powered and the Indications and 3 12
Alarms Module runs the alarm test for about 5 seconds
according to the procedures set out below. 2
o Once the test is complete, only the indications prescribed 13
for the engine not running must remain lighted: e.g. 1
“alternator charge” and “low oil pressure”; the analog 04_234_N
instruments must provide values consistent with the
relevant physical parameters.
1. Engine overspeed (SSV) - 2. Presence of water in the fuel
Testing the engine start function pre-filter (SAC) - 3. Low coolant level (SBLA) - 4. Alternator
anomaly (SS) - 5. Clogged oil filter (SIFO)- 6. Clogged blow-by
Turn the key switch to the second position and keep it in it filter (SIFB) - 7. Pre-lubrication in progress (SP) - 8. Clogged
until the engine has started, then release the switch, which air filter (SIFA) - 9. Clogged fuel filter (SIFC)- 10. High coolant
will stably return to the first position; after releasing the key, temperature (SATA) - 11. Low oil pressure (SBPO) - 12. Pre/
the switch may be brought back to the starting position only post heating (SCP) - 13. EDC Malfunction (EDC).
after the switch is returned to the resting or zero position.
Checking indications
The Indications and Alarm Module comprises the indicator
After starting the engine, verify whether the operating lights and the electronic alarm interface, timing and stor-
modes of the Indications and Alarms Module are similar to age circuit. It is programmed in such a way that when it is
those set out below. powered, all indicator lights are lighted, with the exception
Using appropriate measuring instruments, verify the consist- of those for “pre-lubrication”, “pre-post heating” and “EDC”
ency of the indications provided by the analog instruments. failure and a sound signal is emitted by the buzzer.
Verify the indication of the panel revolution counter, compar- The buzzer may be silenced before the end of the test, acting
ing it with the one measured by a reference instrument; if the on the appropriate control.
indication is different, proceed as described below. During the starting phase and for the subsequent 15 sec-
onds, needed to stabilize the low oil pressure signal, all the
Testing the engine stop function
module’s functions are inhibited; once this time interval has
The engine is stopped and the panel is disabled by returning elapsed, every alarm state detected by the sensors will cause
the key switch to the resting or zero position. the associated indicator to be lighted and the buzzer to be
The panel has an engine stop push-button whose function is powered; the exceptions are the “pre-lubrication” and “pre-
only enabled in versions where the engine stops as a result post heating” indicators, given only visually.
of the excitation of an actuator, i.e. engine versions requiring When a new alarm state is detected, the indicator light will
certification by Certification Bodies. flash to highlight the occurrence with respect to any others
which may be ongoing at the time. When the sound alarm is
shut off, the light indicator will remain lighted and the alarm
will be stored until the engine is stopped.

The standard set-up of the C78 ENS M20, C78 ENT M30,
C78 ENT M50 and C78 ENT M55 provides for use of the
indicators: SBLA, SIFA, SIFC, SIFO, EDC, SS.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 25

Revolution-counter calibration Revolution-counter calibration


Figure 22A Figure 22B

       

1 2
1

04_255_N 06_113_V

1. Adjustment screw - 2. Panel lighting lamp. 1. Calibration increasing button -


2.Calibration decreasing button.
Verify the indication of the panel revolution counter by
comparing it with the one measured with a reference Verify the indication of the panel revolution counter by com-
instrument; if it differs, operate the adjustment screw (1), paring it with the one measured with a reference instrument;
located in the rear part of the revolution counter, until if it differs, press the button 1 and 2 situated on the rear
consistency is achieved; repeat the operation for different of the tachometer, until consistency is achieved; repeat the
engine rpms. operation for different engine rpms.

Maintenance Maintenance
Should it become necessary to replace a panel light, remove The board is illuminated by not-replaceable internal LEDs.
the lamp holder from the rear part of the instrument (see
Figure 22A).
C78 ENS M20
26 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

10. SECONDARY ANALOG INSTRUMENT PANEL

Figure 23

5
electronic
RPMx100

2
6

1 7
04_240_N

1.Connector for secondary panel wire harness (JH) - 2. Engine start push-button (CS) - 3. Revolution-counter (CG) -
4. Buzzer (SA) - 5. Indications and alarms module (MS) - 6. Engine stop push-button (AS) -
7. Sound alarm inhibition push-button (P1).

The connection is achieved by removing the cap on the JE Operation of the secondary panel
connector of the main panel, and connecting the JE connec- After completing the electrical connection to the main panel
tor to the JH connector on the secondary panel, interposing and engine preparation, and performing the tests required
the extension wire harness, available in 3, 5 and 7 meter-long for the first start (as described in Chapter 18), verify the
versions (see Fig. 19). The JE-JH wire harness comprises 12 proper operation of the panel, proceeding as follows:
lines, each connected to the terminal identified on both con-
nectors by the same number (see fig. 24). o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then turn
Figure 24 the key switch to the first position, thus enabling the
operation of both panels.
1 6 6 1 o Carry out the same tests for the secondary panel as
were carried out for the main panel.
o Disable the secondary panel by bringing the key switch
on the main panel to the resting or zero position.

Testing the engine start and stop function.


04_251_N With the panel enabled, press the green push-button until
the engine starts, then release it; wait for engine rpm to sta-
7
*% 12 12
*( 7 bilize before stopping it by pressing the red push-button.
The starting and stopping operations can be performed sev-
CONNECTORS OF THE JE-JH EXTENSION WIRE eral times and consecutively from the secondary panel
HARNESS, SEEN FROM THE COUPLING SIDE
Checking indications
Installation Proceed in the same way as for the main panel.
In order to drill holes on the area where the panel is to be
mounted, refer to the dimensions indicated in Chapter 11.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 27

11. DRILLING PLANS FOR ANALOG PANELS

Figure 25

4
26
4
Ø

Ø
4

Main panel

140

200
=
Ø
Ø4

26
4
4 26 = = 26 4

225

285 04_022_C

Dimension in millimeters.

Figure 26
2
28

Ø
4
4
Ø

Secondary Panel
=

140
80
=

4
Ø
Ø
4

28
2

2 28 = = 28

180

240 04_023_C
C78 ENS M20
28 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

12. MAIN DIGITAL INSTRUMENT PANEL

Figure 27

3 4 3

– +
20
15 25
2 8 1 2

0 10 0 3

2 10 30 5
BAR BAR

50 90

RPM MIN MAX


40 120
5 X100 35

1 RPM 6
C – +
V
h

PROG.

16 7

15 14 13 12 11 10
8

04_256_N

1. Engine coolant temperature indicator - 2. Lubrication loop pressure indicator - 3. Service and alarm indicators - 4. Revolution
counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Engine start/stop key switch - 8. JE connector for secondary
panel - 9. Cap with electrical continuity connection - 10. Accessory function programming push-button - 11. Push-button for
selecting accessory information - 12. Digital display - 13. Push-button for zeroing the “programmed maintenance” indication -
14. Sound alarm inhibition push-botton - 15. JH connector for panel wiring - 16. Buzzer.

Installing the panel provided with digital displays requires To the main panel is connected the JE connector, set for
connecting the JH-D connector of the panel to the JE con- connection to the secondary panel; in installations lacking the
nector of the interface wire harness, itself connected to the secondary panel, do not remove the cap of the JE connector
“Converter Module”, interposing the JE extension wire har- in order not to compromise the electrical continuity of the
ness, available in 3, 5 and 7 meter-long versions (Figure 24). system power supply circuit.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 29

Synoptic of digital panel connections


Figure 28
SECONDARY
INSTRUMENT
PANEL

MAIN
INSTRUMENT
PANEL JE JE JH JA

JH

JH
2

JE

JE JE1

CAN - BUS
JD CONVERTER
MODULE
JO

ENGINE
EQUIPMENT

1
A

EDC

JB JA

JF JF1
RELAY BATTERY
BOX
04_024_C

1. Interface wire harness for converter module - 2. JE-JH extension wire harness.

The JE1 connector provides connection to a second main


onboard panel. Its installation is subject to IVECO MOTORS
approval.
C78 ENS M20
30 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

CAN-BUS CONVERTER MODULE Functions of the JO terminals

Figure 29
1 Gear box oil pressure signal
2 CAN L
3 CAN H
4 Power supply positive (+ B)
5 Power supply positive (+ B)
04_259_N 6 Battery positive with key in ON position
Rear view of the module with JO connector 7 Battery positive with key in ON position
8 Power supply negative (ground)
The presence of the “Converter Module” is necessary to
translate the information of some sensor, provided in analog 9 Optional output
form, into information suited to be decoded by the digital 10 Engine rpm signal
converters of the panel.
The interface wire harness is set up to connect the main 11 Pre-lubrication signal
panel (JE) from which the secondary panel is to be branched 12 Not connected
off, and it is provided with a branch (JD) for connecting an
electronic engine rpm managing system or an electronic 13 Exhaust gas temperature signal (-)
throttle. 14 Exhaust gas temperature signal (+)
The JE1 connector is branched from the interface cable. The 15 Gear box oil temperature signal
connector provides connection to an optional second main 16 Engine oil temperature signal
onboard panel. Its installation is subject to IVECO MOTORS
approval (see figure 28). 17 Engine oil pressure signal
18 Air filter clogging signal 2
Figure 30 19 Power supply negative (ground)
20 Not connected
21 Alternator anomaly signal
22 Pre-heating signal
23 EDC failure signal
24 Low coolant level signal
25 Exhaust gas temperature signal (-)
26 Exhaust gas temperature signal (+)
27 External throttle input signal
04_218_N
28 Coolant temperature signal
JO CONNECTOR 29 Air filter clogging signal 1

VIEW OF THE WIRE HARNESS TERMINAL,


30 Not connected
COUPLING SIDE 31 Power supply negative (ground)
32 Not connected
33 Runaway engine signal
34 Water in fuel signal
35 Oil filter clogging signal
36 Fuel filter clogging signal
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 31

Connector JD

Figure 31

04_263_N

PIN 1 PIN 4

The JD connector enables to use an electronic engine rpm


management instead of the system provided on the engine.
If this solution is used, the throttle position sensor, situated
on the engine, will remain electrically connected but not
used and the EDC Central Unit will manage engine rpm
according to the voltage signal applied to the terminals of
the JD connector.
In case of a fault in the electronic throttling system, the engine
rpm may be managed in emergency condition, mechanically
operating the sensor lever positioned on the engine.
The connection requires a METRI PACK 150 four-way con-
nector with male terminals.

PIN Wire code (U) Voltage Interpreted function Imax


1 7731 +B with key in ON position Electronic throttle enabling 0,5 A
2 0000 0 V - (Ground) Common reference terminal -
0 to 0,2 V Poor value. EDC recognises a fault -
0,2 to 0,5 V Accelerator at minimum level
3 5584 0,5 to 4,5 V Accelerator min. to max., U function -
4,5 to 4,8 V Accelerator at maximum level -
4,8 to 5 V Excessive value. EDC recognises a fault
4 5551 Ground, with engine in overspeed Overspeed engine indication 0,1 A

NOTE: The voltage values for the rotation of the motor must be between 0.2 and 4.8 V. Values below 0.2 V or above 4.8 V
generate the recognition of a fault and consequent deactivation of the function.
C78 ENS M20
32 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Installation Programming accessory functions


In order to drill holes on the area where the panel is to be The following programming operations are required when
mounted, refer to the dimensions indicated in Chapter 14. the panel is first operated:
Operation of the panel o The hours of the maintenance interval relevant to the
characteristics of the engine in use.
After completing the electrical connections and engine
preparation, perform the tests required for the first start, as o The maximum quantity of introduction, necessary to
described in Chapter 18. compute fuel consumption.
Verify the proper operation of the panel, proceeding as fol-
lows:
With reference to Figure 27, proceed as follows:
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then o Holding down the “Programming” (10) and “Slide-down
turn the key switch to the first position and verify that selection” (11) push-buttons, positioned on the panel,
the instruments are powered and the Indications and turn the key switch to the first position and wait for the
Alarms Module runs the alarm test for about 5 seconds. display to show the value of the maintenance interval
During this phase, all indicator lights must be lighted, set previously (e.g., 200 hours).
with the exception of those for “pre-lubrication”, “pre-
o Release the push-buttons and set the hours of the
post heating” and “EDC failure”. A sound signal must be
time interval, indicated for oil replacement, provided on
emitted by the buzzer; it may be silenced before the end
the operation and maintenance manual; the operation
of the test, pressing the push-button on the panel.
is completed by repeatedly pressing the “Slide-down
o Once the test is complete, only the indications pre- Selection” push-button (11) until the number that is
scribed for the engine stopped must remain lighted: e.g. selected and highlighted by flashing is correctly set, then
“alternator charge” and “low oil pressure”; the analog operating the “Programming” push-button (10) to select
instruments must provide values consistent with the the number to set.
respective physical parameters.
o Press and hold the “Programming” push-button (10)
until the display shows the maximum introduction value,
Testing the engine start function set by default to the value 10 mg/strk, then release it.
Turn the key switch to the second position and keep it in it
o Set the number for engine calibration, obtaining it from
until the engine has started, then release the switch, which
the table that follows, proceeding as described in item 2.
will stably return to the first position; after releasing the key,
the switch may be brought back to the starting position only o Press and hold the “Programming” push-button (10)
after the switch is returned to the resting or zero position. until the display shows the engine rpm indication.
Checking indications If programming operations were not performed correctly,
the display will show the indication “Err.P”; check whether
After starting the engine, verify whether the operating
the electrical connections of the main panel and of the
modes of the Indications and Alarms Module are similar to
converter module were performed correctly, then repeat
those set out above.
the procedure.
Using appropriate measuring instruments, verify the consist-
ency of the indications provided by the analog instruments.
C78 ENS M20
Testing the engine stop function
Maximum power calibration Fuel introduction
The engine is stopped and the panel is disabled by returning [HP] [mg/strk]
the key switch to the resting or zero position.
The panel has an engine stop push-button whose function is 230 118,5
only enabled in versions where the engine stops as a result 200 118,5
of the excitation of an actuator, i.e. engine versions requiring
certification by Certification Bodies.

C78 ENT M30


Maximum power calibration Fuel introduction
[HP] [mg/strk]
330 153
300 153
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 33

C78 ENT M50 Symbology key


Maximum power calibration Fuel introduction
[HP] [mg/strk]
500 195
Clogged air filter
450 179
400 170 Expired programmed main-
350 144 tenance interval
330 153
300 153 Clogged oil filter
280 144
260 137
Pre-lubrication in progress
240 129
220 119
190 106 Pre-post heating

C78 ENT M55 Clogged fuel filter


Maximum power calibration Fuel introduction
[HP] [mg/strk] Presence of water in the
550 218 fuel filter

500 218
450 218 Clogged blow-by filter
400 210

Alternator fault

Low oil pressure

High coolant temperature

Runaway engine

Low engine coolant leve

EDC fault

04_264_N
C78 ENS M20
34 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

13. SECONDARY DIGITAL INSTRUMENT PANEL

Figure 32
3 4 3

– +
20
15 25
2 8 1 2

0 10 0 3

2 10 30 5
BAR BAR

50 90

RPM MIN MAX


40 120
5 X100 35

1 RPM 6
C – +
V
h

12 7
START STOP

11 8

10 9 04_257_N

1. Engine coolant temperature indicator - 2. Lubrication loop pressure indicator - 3. Service and alarm indicators -
4. Revolution counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Push-button for selecting accessory information -
8. Engine stop push-button - 9. Digital display - 10. JA connector for panel wire harness - 11. Engine start push-button.
12. Sound alarm inhibition push button.

The secondary panel is branched to the main panel. Remove o Carry out the same tests for the secondary panel as
the cap from the main panel JE connector and connect the were carried out for the main panel.
JE connector to the JA connector on the secondary panel,
placing the special extension JE-JH cable, available 3.5 and o Disable the secondary panel by bringing the key switch
7 meters long (see figure 24). IVECO MOTORS standard on the main panel to the resting or zero position.
supply is provided for the installation of the main and sec-
ondary board and their simultaneous use with no operation Testing the engine start and stop function.
limitations. With the panel enabled, press the green push-button until
the engine starts, then release it; wait for engine rpm to sta-
Installation bilize before stopping it by pressing the red push-button.
In order to drill holes on the area where the panel is to be The starting and stopping operations can be performed sev-
mounted, refer to the dimensions indicated in Chapter 14. eral times and consecutively from the secondary panel.
Operation of the secondary panel Checking indications
After completing the electrical connection to the main panel Proceed in the same way as for the main panel.
and engine preparation, and performing the tests required
for the first start (as described in Chapter 18), verify the
proper operation of the panel, proceeding as follows:
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then turn
the key switch to the first position, thus enabling the
operation of the main and secondary panels.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 35

14. DRILLING Plan FOR DIGITAL PANELS

Figure 33

16
7
Ø
Ø
7

Main panel
and

=
secondary panel

159

191
=
7 Ø
Ø 7

16 = =

244

276 04_025_C

Dimensions in millimeters
C78 ENS M20
36 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

15. CUSTOMIZED INSTRUMENT PANEL

Using only the components of the panel that are not wired Figure 35
to allow for panel customization, they will have to be wired
using the 10 meter long wire harness, set up at one end for
coupling to the JB connector and at the opposite end with
conductors with free terminals with identifying numbering
1 2 3
on each wire. The conductors will have to be connected to 4
the individual components as indicated in the electrical and 5 6 7 8
wiring diagrams in Chapter 24. 9 10 11 12

caution 13 14 15 16
17 18 19 20
To assure the functionality of the safeties pertaining to the
engine start/stop commands from the instrument panel or 21 22 23 24
engine room, it is mandatory to wire the key switch strictly
as shown in the electrical diagrams in Chapter 24.
04_241_N

The wiring details of the indications and alarms module VIEW FROM THE TERMINAL SIDE
alone are provided below; indications for IVECO MOTORS OF THE COUPLING SIDE WIRING
indicator instruments, are shown in the related wiring dia-
grams in Chapter 24.
connector TRIDENT / ITT CANNON part TST 24PA00
JD Connector for indications and alarms terminal female part 192990-0050
module lid rear part TST24AH0
Figure 34

JD connects the indications and alarms module to the elec-


trical system of the engine (sensors, power supply, etc.).
The terminal part of the wire harness, supplied with the
module, must be completed using female terminals, as
described in the electrical diagram of Chapter 24.
For standard-equipped engines, to have the essential indica-
tions available, the following ways must be wired: 1, 2, 3, 7, 8,
9, 10, 11, 13, 14, 15, 16 with the female terminals supplied as
standard equipment.

4 3 2 1
8 7 6 5
12 11 10 9

16 15 14 13
20 19 18 17
24 23 22 21

05_034_C

VIEW FROM THE INTEGRATED SIDE


IN THE REAR PART OF THE MODULE
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 37

Functions of the JD terminals

PIN Description Electric level


OFF Indication ON Indication
1 Module power supply Positive (+B)
2 EDC lamp power supply Power supply positive (+B)
3 EDC Fault indication High (+B) Low (ground)
4 Pre-heating light power supply Power supply positive (+B)
5 Pre-heating indication High (+B) Low (ground)
6 Pre-lubrication indication Open circuit High (+B)
7 Engine start Power supply positive (+B) while starting
8 Buzzer inhibition Negative (ground) during the request
9 Module power supply Negative (ground)
10 Sound alarm power supply Negative (ground) during the emission of sound
11 Clogged oil filter indication Open circuit Low (ground)
12 Clogged oil vapor filter indication Open circuit Low (ground)
13 Clogged air filter indication Open circuit Low (ground)
14 Clogged fuel filter indication Low (ground) Open circuit
15 Alternator fault indication High (+B) Low (1 ÷ 3 V)
16 Low engine coolant level indication Open circuit Low (ground)
17 High coolant temperature indication Open circuit Low (ground)
18 Low engine oil pressure indication Open circuit Low (ground)
19 Presence of water in fuel indication Open circuit Low (ground)
20 Overloaded or runaway engine indication Open circuit High (+B)
21 Not connected -
22 Not connected -
23 Reception of data from main panel NMEA communication protocol (0 ÷ 5 V)
24 Transmission of data to secondary panel NMEA communication protocol (0 ÷ 5 V)

caution
To assure the utmost reliability and safety while underway, all installations must be provided with the following alarm indications:
(EDC) EDC failure
(SATA) high coolant temperature
(SBPO) low oil pressure
It is also recommended that the following indications be present:
(SAC) presence of water in the fuel pre-filter
(SIFA) clogged air filter
(SS) alternator fault
C78 ENS M20
38 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

16. SENSORS FOR DETECTION AND PANEL SIGNALING

Coolant temperature sensor Oil pressure sensor


Figure 36 Figure 38

04_026_C

Resistor with negative temperature coefficient, providing the


signal for analog temperature indication.
04_237_N

Operating voltage from 6V to 24 V Rheostat component providing the signal for the analog
indication of pressure.
Calibration range from 0°C to 120°C
Resistance value at 90°C 51.2 ± 4.3 Ω Operating voltage from 6V to 24 V
Electrical poles isolated Calibration range from 0 bar to 10 bar
Resistance value at 0 bar 10 Ω +3/-5 Ω
High coolant temperature sensor Resistance value at 2 bar 52 ± 4 Ω
Figure 37 Resistance value at 4 bar 88 ± 4 Ω
Resistance value at 6 bar 124 ± 5 Ω
Maximum value of resistance 184 Ω
Operating temperature from - 25°C to 100°C
Electrical poles isolated

04_027_C
Low oil pressure sensor
Switching coolant temperature sensor, providing the signal Figure 39
for the related indicator.

Operating voltage: from 6 to 24 V


Condition at ambient temperature normally open
Closing temperature: 100 ± 3 °C
Electrical poles isolated 04_028_C

Pressure switch, providing the signal for the related indicator.

Operating voltage: from 6 to 24 V


Condition at ambient pressure normally closed
Calibration range 0.5 - 0.8 bar
Closing pressure: 0.5 bar
Opening pressure: 0.8 bar
Maximum current 15 A (not inductive)
Electrical poles isolated
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 39

Air filter clogging sensor Fuel filter clogging sensor


Figure 40 Figure 42

04_030_C

04_238_N
Pressure switch, providing the signal for the related indica-
Vacuum switch, providing the signal for the clogged air filter tor.
alarm indicator.
Operating voltage: from 6 to 24 V
Operating voltage: from 6 to 24 V Condition at ambient pressure normally closed
Condition at ambient pressure normally open Opening pressure: 1.5 ± 0.1 bar
Closing vacuum: ≥ -52 mbar Maximum current 0,1 A (not inductive)
Operating temperature: -20 / +80 °C Electrical poles isolated
Maximum current 0.1 A (not inductive)
Electrical poles isolated
Exhaust gas temperature sensor
Figure 43
Oil filter clogging sensor
Figure 41

04_260_N

NiCr-Ni thermocouple sensor with insulated poles, pro-


viding the signal for the analog indication of exhaust gas
temperature.
04_029_C

Differential pressure switch, providing the signal for the Temperature Voltage
related indicator when pressure difference between inlet / °C mV
outlet oil filter is more then a limit value.
100 4.10
200 8.13
Operating voltage: from 6 to 24 V
300 12.21
Condition at ambient pressure normally open
400 16.40
Closing pressure: 2.4 ± 0.3 bar
500 20.65
Opening pressure: 1.8 ± 0.3 bar
600 24.91
Maximum current 3 A (not inductive)
700 29.14
Electrical poles isolated
800 33.30
900 37.36
C78 ENS M20
40 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Sensor to detect the presence of water in fuel CAUTION

Figure 44 In order to enable the proper working of the sensor to


detect water in the fuel, it is necessary that the pre-filter
support is connected electrically to the negative battery
terminal.

In the engine models which use parts with insulated poles


it is necessary to electrically insulate the pre-filter support
04_031_C
from the boat mass and then connect the support with the
negative battery terminal.

Fuel resistivity sensor, integrated with the control and ampli- Low level coolant sensor
fication electronic circuit, providing the signal for the indica-
Figure 46
torof the presence of water in the fuel.

Operating voltage from 12V to 24 V


Condition in the absence of water open circuit
Closed condition resistance of the liquid
≤ 1 MΩ
04_033_C
Operating temperature from -20 °C to +80 °C
The sensor detect the presence of coolant and is provided
Connections of the sensor detecting the presence of water with the control and amplification electronic circuit; it provid-
in fuel ing the signal for the alarm for low level coolant.

Figure 45
Operating voltage from 12 to 24 V
1 2
Condition for high level open
Maximum current 0.1 A not inductive

  
! " #

  
! " #

3 04_032_C

1. M Connector of the engine wire harness -


2. Sensor detecting the presence of water in the fuel -
3.Wiring harness (outfitter’s responsibility).

The three pole connection between the sensor for detect-


ing the presence of water in the fuel and the engine wire
harness must be produced by the outfitter according to the
position of the fuel pre-filter in the boat.
Connection to the engine wire harness requires a METRI-
PACK150 three-pole connector with three male terminals;
connection to the sensor requires a JUNIOR TIMER threep-
ole connector with three female terminals
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 41

17. PREPARING THE ENGINE FOR FIRST 18. TESTS BEFORE THE FIRST START-UP
START-UP
1. Drain the residual 30/M protective oil from the sump. Although they are extremely important, “common sense”
checks such as the exposure of sensitive parts (plastics, wire
2. Pour into the lubricating loop only lubricating oil of the
harness, electronic units, etc. ...) to heat, and those that for
type and in the quantities set out in the Refilling Table.
years have characterized the quality of the work performed
3. Drain the CFB protective liquid from the fuel loop, in the yard, are not mentioned herein.
completing the operations as indicated under item 3. of Tests of the proper operation of the engine and the com-
Chapter 23 ponents of the electronic control system may be performed
rapidly and with the utmost reliability using specific diagnostic
4. Remove the caps and/or seals from the engine intake, tools, available from IVECO MOTORS Technical Assistance
exhaust, aeration and venting ports, restoring normal Centers.
conditions of use. Connect the inlet of the turbocharger
to the air filter. Fuel tank suction
5. Connect the fuel loops to the boat tank, completing Verify the fuel suction at the maximum allowed longitudinal
the operations set out in item 4. of Chapter 23 During and transverse inclination, with the residual quantity of fuel
filling operations, connect the pipe returning fuel to the considered “RESERVE”, such as to cause the reserve indica-
tank to a collecting container, to prevent residues of CFB tor light to be permanently lighted.
protective liquid from ending up into the boat tank.
Throttle lever position sensor
6. Verify and refill engine coolant as prescribed.
7. Engine C78 ENT M55: in order to enable the see Figure 48
water pump priming it is necessary to input water into
the forcing circuit.
Remove the sacrifical anode (1 of figure 47), intro-
duce 1.5 litres of water into the hole; reassemble the
anode and tighten it as required.
WARNING
If the engine is activated after a long time, it is necessary
to repeat the operations mentioned in item 7.
8. Remove from the engine the labels with the inscription
“ENGINE WITHOUT OIL”.

Figure 47

04_080.N

In the positions of minimum and maximum travel, verify the


correlation between the position of the throttle control valve
on the bridge and the position of the sensor rod, checking:
o that in the resting position the safety switch inside it is
electrically open. Carry out the test with an ohmmeter
between the points D and E of the potentiometer con-
nector.
1 - Value read ∞ Ω = optimal adjustment;
80819 - Value read 1 kΩ = a better mechanical adjustment
of the resting position is required, to bring the
value back to ∞ Ω.
o In the position of maximum acceleration, the rod of the
sensor has reached the mechanical end stop.

Instruments and control panel


Verify the efficiency of all light indicators, as described in the
related Chapters.
C78 ENS M20
42 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

19. FIRST ENGINE START

Before starting the engine, please make sure the sea water Start-up procedures
gate valve is open, check the levels of the lubricating oil and
of the engine coolant, and complete venting the air from the Figure 50
fuel feed loop, acting on the hand pump of the pre-filter or
with the aid of a dedicated electrical pump.
The venting air points are fitted on the pre-filter supplied
from IVECO MOTORS, after the main filter, on the cylinder ENGINE
ROOM
ENGINE
STOP PTO-
PTO
ON
head near the injectors solenoid valves connector. (see Fig-
ure 49).
Loosen the vent fitting on the pre-filter and operate the BRIDGE ENGINE
START
PTO+ PTO
OFF
CHECK

pump until only fuel without air flows out.


Tighten the vent fitting and complete the purge operation 1 2 3 4 04_035_C
on the vent fitting placed on the cylinder head during the
initial start-up phases.
The electrical equipment of this engine allows to start it from
Figure 49 the “engine room” and from the “bridge”.

NOTE
A few moments after start-up, make sure sea water is cor-
rectly drained from the relevant circuit.

 04_034_C
Starting the engine from the bridge
This is allowed only if the Relay box switch (1) is in the
“BRIDGE” position.
Start the engine and let it run until the idling rpm has fully
stabilized (see also the Chapters on the instrument panels)
Starting the engine from the “engine room”
Moving the Relay box switch (1) to the “ENGINE ROOM”
position (which must absolutely not be done when the
Purge fitting on cylinder head
engine is running), regardless of the position of the key
switch on the indicator and control panel, enables the use of
the adjacent STOP - START push-button (2).
caution It will thereby be possible to start and stop the engine with
Make sure that the fuel that flows out of the fitting dont complete independence from the bridge controls.
coming in conctact with the auxiliaries drive belt and is Moving the switch (1) back to the “BRIDGE” position, inhibits
not dispersed in the environment. use of the “START-STOP” push-button positioned on the
Box, allowing the engine to be started only from bridge
controls.
RPM control
To allow easily to control engine RPM from the “engine
room”, a simultaneous acceleration/deceleration function
(PTO+/PTO-), active only when the switch (1) is in the
“ENGINE ROOM” position, and the switch (4) is in PTO
ON position.
Acceleration (PTO +)
If, the engine is running, and PTO+ / PTO- push-button is
held down in the “PTO+ position, then engine rpm are pro-
gressively increased (50 rpm per second). The increase ends
when the push-button is released, allowing the engine to run
at the desired rpm.
Deceleration (PTO -)
If the engine is running, and PTO+ / PTO- push-button is
held down in the “PTO-” position, a progressive reduction in
rpm is obtained (50 rpm per second). The reduction ends
when the push-button is released, allowing the engine to run
at the desired rpm.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 43

The rpm reached at that point is maintained until the ”


engine is stopped. (function takes priority and always stops
the engine) or switching the PTO ON / PTO OFF push-but-
ton in the OFF position.

caution
Never operate the “BRIDGE - ENGINE ROOM” switch
when the engine is running.

Once the first start-up phase is complete, verify that:


o There are no liquid leaks from the coolant loop pipeline
junction hoses.
o There are no exhaust gas leaks in the hull.
o In order to carry out the cooling system degassing, do as
follows:
Figure 51

1 2

05_001_C

o keep the engine at minimum rotation speed, slowly


loosen screw (1) positioned on the coolant tank near
the cap and the two screws (2) situated on the exhaust
induction in order to facilitate the exit of possible air
bubbles. When this operation is finished, tighten the
screws as required, stop the engine and verify the level
of the coolant liquid. Fill it up if necessary.
Take care not to disperse the exiting liquid in the envi-
ronment.
o Complete the instrument panel operation tests as
described in the related Chapters.
o Verify that the power supply voltage across the battery,
after about 15 minutes with the engine running, is no
less than about 26 V.
o Stop the engine and delete any “errors” which may have
been stored in the injection system ECU during the
stabilization phases. For the deletion procedure, refer to
Chapter 20.
C78 ENS M20
44 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

20. EDC ANOMALIES INDICATION

Anomalies indicator light Error deletion procedure


Figure 52
The ECU continuously monitors, with complex self-testing
routines, its own operating conditions as well as those of the
components connected to it and of the engine.
When anomalies are detected, the alarm indicator light on ENGINE ENGINE PTO
the indicator and control panel is lighted in manners that ROOM STOP PTO- ON

provide a first indication on the severity of the problem.


BRIDGE ENGINE PTO+ PTO CHECK

Light off: no anomaly detected or slight anomaly START OFF

that does not compromise operating safe-


1 2 3 04_035_C
ty
Light on: significant anomaly, allowing to proceed to A. Shut the engine down and keep the key switch in the
a service center “OFF” position for 15 seconds (after run).

Blinking light: severe anomaly requiring immediate B. Approach the relay box. Keeping the “CHECK” diag-
repairs. If possible, shut the engine down. nostic push-button (3), move the adjacent “BRIDGE
- ENGINE ROOM” switch (1) to the “ENGINE ROOM”,
wait for the luminous indicator (4) to switch off position,
Blink code while keeping the diagnostic push-button pressed for 8
The emission of the anomaly codes detected during self-test- more seconds.
ing and stored in the ECU starts after pressing and releasing
C. Release the push-button and move the “ENGINE
the “CHECK” push-button on the relay box panel, when
ROOM” switch to the “BRIDGE” position
the “BRIDGE - ENGINE ROOM” switch is in the “ENGINE
ROOM” position
The LED located at the side of the push-button and the caution
EDC indicator light on the indicator and control panel will
The mistake deleting procedure is intended to eliminate
simultaneously signal, with two series of emissions at different
the information relating to the mistakes from the ECU
frequencies, the blink codes that indicate the anomaly with
memory, which happened during previous working periods.
decimal numbering.
The mistakes will not be deleted unless the relating cause
has been removed. Please remember that some anomalies
Slow blinks identify the area of the anomaly (engine, injectors,
can be detected by the ECU self-diagnosis only during a
...), fast blinks identify a specific anomaly.
complete engine working cycle.
Every time the push-button is pressed and released, only
one of the stored codes is emitted; therefore, the procedure At the end of this procedure, the codes of any anomalies
must be repeated until an error indication identical to the detected during the engine installation and first start-up
first one is obtained, which means the entire error memory operations will be deleted in the ECU. To make sure that no
has been analyzed. anomaly data remain stored in it, or that there are no other
errors in the system, set the “BRIDGE - ENGINE ROOM”
If no anomalies are stored, the light comes on when the switch to the “ENGINE ROOM” position and verify that,
push-button is pressed and comes off about 1 second after when the diagnostic push-button is pressed, the blink code
its release, without any subsequent blinking. light (2) does not emit any code.

Recovery At the end of these operations, return the switch to the


“BRIDGE” position
The recognition of significant or sever anomalies causes the
adoption of strategies that allow to use the engine with If the ECU signals the presence of errors or operating anom-
complete safety, guaranteed by limiting performance within alies, the installation will have to be reviewed to remove the
pre-set thresholds according to the severity of the case. cause of the error or anomaly.
Indications for decoding the codes are provided in Chapter 21.
These strategies cause the reduction of the maximum values
of torque and power delivered by the engine. NOTE: The blink code diagnostic procedure provides indica-
In the case of intermittent anomalies, i.e. recognized by the tions about current anomalies as well as past anomalies that
ECU and subsequently no longer present, performance are no longer present when the diagnosis is carried out;
reduction will continue until the engine is shut down. therefore, it is absolutely mandatory, at the end of every
repair operation, to erase the error memory to prevent
Normal operation will be restored only the next time the anomalies whose cause has already been removed from
engine is started, while the anomaly data will be “saved” in being signaled in the future.
the failure memory.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 45

21. BLINK CODE TABLE

Blinking Code EDC Indicator light Indicated Fault


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
Engine rpm sensor
6.1 on flywheel sensor
6.2 on timing system sensor
6.4 blinking runaway engine
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
C78 ENS M20
46 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

22. UNDERWAY CHECKS

ECU Temperature
Verify that the temperature of the surface of the electronic
engine control unit, after 30 minutes underway at full engine
power, is less than +70°C.
Engine compartment vacuum
Verify that value of ambient air pressure in the engine room
with the engine(s) at full load and maximum power output
complies with the value specified herein.
Combustion air temperature
Verify that the temperature in the engine room, after 30 min-
utes underway at full engine power, does not exceed 50°C
(C78 ENS M20, C78 ENT M30 and C78 ENT M50) or 45°C
(C78 ENT M55) and, in any case, does not exceed the value
of external temperature by more than 15°C.
Exhaust back-pressure
Verify that the value of back-pressure present at the inlet of
the exhaust gas conduit, with the engine(s) at full load and
maximum power output, complies with the value specified
herein.
Exhaust temperature
Verify that the temperature of the exhaust gases under
maximum engine power output conditions is close to the
prescribed value; to determine the propeller power absorp-
tion curve, it will also be possible to obtain from the ECU
parameters the fuel injection values by using the IVECO
MOTORS tool.
Fuel temperature
Verify that the temperature of the fuel in the low pressure
line, while underway at full power and with a stable quantity
of fuel in reserve, does not exceed 50°C. A higher value
would entail a reduction in engine performance. If the ten-
dency to reach the maximum allowed temperature is noted,
install a heat exchanger for the fuel.
Pressure in the fuel supply line
To assure the regular operation of the engine and the reli-
ability of the components of the fuel supply and injection
system, you need to verify that:
o vacuum in the fuel oil supply line to the low pressure
pump is less than 0.2 bar relative (2000 mm H2O);
o pressure in the fuel oil return line to the tank is less than
0.2 bar relative (2000 mm H2O).
Measures are carried out inserting a “T” junction near the
fuel inlet and outlet, taking care to avoid any air suction. Val-
ues are read at variable rpm, from idle to maximum, at 200
rpm intervals.
If there are any symptoms indicating the possible presence of
air in the fuel supply line, a check may be made by inserting
a clear tube, arranged as an inverted U, before the engine
inlet junction.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 47

23. PREPARING THE ENGINE FOR LONG IDLE PERIODS

To prevent oxidation to the internal parts of the engine and


to some components of the injection system, if idle periods
exceeding two months are expected, the engine needs to
be prepared with six-months periodicity, proceeding as
follows:

1. Drain the lubricating oil from the sump, after heating the
engine.
2. Pour 30/M protective oil (alternatively, oil conforming
with MIL 2160B Type 2 specifications) into the engine to
the “minimum” level marked on the dipstick.
Start the engine and let it run for about 5 minutes.
3. Drain the fuel from the injection line and from the filter,
taking care to avoid letting the fuel come in contact with
the auxiliaries belt. .To do so, loosen the drain cap in the
front part of the cylinder head and the fuel inlet junction
with the cylinder head, taking care to prevent the fuel
from coming in contact with the auxiliaries belt.
4. Connect the fuel line to a tank containing CFB protec-
tive liquid (ISO 4113) and assist the inflow of the liquid
by pressurizing the line and turning the engine over for
about 2 minutes, after excluding the operation of the
injection system. The required operation may be carried
out by directly polarizing the terminal 50 of the electric
starter motor with positive voltage 24 V, using a conduc-
tor prepared for the occasion.
5. Nebulize 30/M protective oil at the rate of about 80 g
(10 g per liter of displacement) into the turbocharger
intake, while the engine is turning over as described
above.
6. Close with suitable stoppers or seal with adhesive tape
all engine intake, exhaust, aeration and venting ports.
7. Drain the residual 30/M protective oil from the sump; it
may be re-used for 2 more engine preparation opera-
tions.
8. Apply tags with the inscription “ENGINE WITHOUT
OIL” on the engine and onboard panel.
9. Drain the coolant, if it has not been mixed with anti-
freeze and corrosion inhibiting agents, affixing tags to
indicate that the operation has been carried out.
If external parts of the engine are to be protected, spray
protective liquid OVER 19 AR onto unpainted metal parts,
such as flywheel, pulleys and others; avoid spraying belts, con-
nector cables and electrical equipment.
C78 ENS M20
48 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

24. ELECTRIC DIAGRAMS

Wiring diagram key


General condition for the preparation and interpretation of wiring diagrams
o Key switch open
o Engine not running
o Liquids at efficient levels and pressures
Figure 53

Component Connection Component


JC: connector Fuse code
terminal 8: terminal code


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Minimum cable cross Component code or Terminal


section in mm2 connector code connection Schema_Connettore_B
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 49

Electrical equipment component code

A fuel temperature sensor for EDC SI gear box oil temperature sensor
AC battery SW1 bridge or engine room engine control selector
(on relay box panel)
AQ engine shut-off push-button on main panel
SW2 start and stop push button (on relay box panel)
AS engine shut-off push-button on secondary panel
SW3 manual accelerator throttle control in engine
B drive shaft sensor for EDC room (on relay box panel)
C camshaft sensor SW4 PTO ON / PTO OFF selector
(on relay box panel)
CA key switch
SW5 blink code emission request push-button
CS engine start push-button on secondary panel (on relay box panel)
DL1 EDC fault indicator and blink code LED T coolant temperature sensor (for gauge)
EC switching solenoid valve for oil charge/discharge U clogged oil filter sensor (for alarm)
F engine coolant temperature sensor for EDC V oil pressure sensor (for gauge)
GG alternator VI high gear box oil pressure sensor (25 bar)
GH grid heater power relay W low oil pressure sensor (for alarm)
H combustion air pressure/temperature sensor for WI low gear box oil pressure sensor (7 bar)
EDC
X clogged blow-by filter sensor (for alarm)
I high coolant temperature sensor (for alarm)
Z clogged fuel filter sensor (for alarm)
IN injectors solenoid valve
85150 ECU of the EDC system
J low coolant level sensor (for alarm)
K air filter clogging sensor (for alarm)
L instrument panel light switch
M sensor for detecting the presence of water in the
fuel pre-filter (for alarm)
MC CAN - BUS converter module for digital panel
MM electric starter motor
MP pre-lubrication and oil transfer module
MS IVECO MOTORS indications and alarms module
O exhaust gas temperature sensor (for gauge)
P1 sound alarm inhibition push-button
PA throttle position sensor
PE emergency shut-down push-button
(optional, installer’s responsibility)
PH grid heater
PO pre-lubrication electrical pump
QP main analog instrument panel
QS secondary analog instrument panel
R1 3.3 kΩ resistor to inhibit speed input
R2 DL1 resistor
R3 alternator pre-excitation resistor
S oil temperature sensor (for gauge)
SA buzzer

(continues on next page)


C78 ENS M20
50 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Connectors Indicator lights


A 35 pole EDC - boat components connection EDC EDC malfunction
B 35 pole EDC - engine components connection SAC presence of water in fuel pre-filter
E EUI injectors solenoid valve SATA coolant high temperature
J1 on the relay box panel for external diagnostic SBLA low coolant level
tool
SBPO low oil pressure
JA connection between engine wiring and interface
wire harness SCP pre-post heating
JA ON SECONDARY DIGITAL INSTRUMENT PANEL SIFA clogged air filter
set for connection to the main digital instrument SIFB clogged oil vapor filter
panel
SIFC clogged fuel filter
JB ON ENGINE WIRE HARNESS
SIFO clogged oil filter
set for connection to the main analog
instrument panel or to the interface wire SIM expired programmed maintenance interval
harness for converter module SP pre-lubrication
JC ON MAIN ANALOG INSTRUMENT PANEL
SS alternator fault
set for connection to the engine wire harness
SSV engine overspeed
JD IVECO MOTORS indications and alarms module
JD ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE
Gauges
external throttle control
CG revolution-counter
JE ON MAIN ANALOG INSTRUMENT PANEL
MI gear box oil pressure
set for connection to the secondar y
analog instr ument panel MO engine oil pressure
JE ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE TA engine temperature
set for connection to the main digital instrument TI gear box oil temperature
panel
TS exhaust gas temperature
JE ON MAIN DIGITAL INSTRUMENT PANEL
V voltmeter
set for connection to the secondary digital
instrument panel
JE ON MAIN INTERFACE WIRE HARNESSE Relays contained in the relay box
set for connection to the alarms control unit K1 EDC main (power supply
(for Certification Bodies) K2 key switch electric discharge
JE1 ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE
K3 emergency engine shut-down provision
set for connection to the 2° main digital
K4 enabling start engine from engine room
instrument panel
JF relay box K5 power supply to terminal 50 of the electric
starter motor
JF1 relay box
K6 cranking exclusion when engine is running
JG pre-lubrication control unit
JH ON SECONDARY ANALOG INSTRUMENT PANEL
Fuses contained in the relay box
set for connection to the main analog
instrument panel F1- F2 self restoring (not replaceables)
JH ON MAIN DIGITAL INSTRUMENT PANEL

set for connection to the interface wire harness


for converter module
JO converter for digital panels
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C78 ENS M20

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control panel wiring diagram
MAY 2006
JO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Connector key:

1.0
0.5
0.5
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
MAY 2006

JB
1
2.5
2
JB instrument panel (engine side)
1.0
3 JD external throttle control
4 JE1 2° main digital instrument panel
5 (see “Installation directive” document.)
1.0
6
JE main digital instrument panel (engine
7
1.0 side)
8
1.0
9
JO converter for digital panel
10
0.5
11
0.5
12
1.0
13

14
JD
15
1.0
16 1
17 1.0
1.0 2
1.0
18 3
1.0
1.0
19 4
1.0
20
1.0
CAN - BUS converter module interface wiring

21
1.0
22

23
1.0
24
1.0
25
1.0
26
1.0
27
1.0
INSTALLATION DIRECTIVE

28
1.0
29
1.0
30
1.0
31

32
1.0
33
1.0
34
2.5
35

36

37
1.0
38

39

40

41

42

43

44

0.5
0.5
1.0
1.0
1.0
1.0
1.0
1.0
0.5
0.5
1.0
1.0
1.0
1.0
1.0
1.0
C78 ENT M30-M50-M55
C78 ENS M20

45

46

47 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
JE JE1

Sk_Cablag_Convert_C78
55
56

°C bar
80 100 2 4 6 12 14
8
40 120 0 10 8 16
175 210 58 87
29 116
105 °F 250 0 psi 145 VOLT
min
X100
C78 ENS M20
C78 ENT M30-M50-M55

G G

8 7 6 5 4 3 2 1
4 3 2 1
8 7 6 5
Wiring of a specific personalised instrument board

12 11 10 9

16 15 14 13
INSTALLATION DIRECTIVE

20 19 18 17

24 23 22 21

JB 13 5 33 34 32 2 8 7 24 20 28 19 18 31 29 35 30 17 38 12 3

10 meter long Connections Identifying numbering JD connector integrated in the rear part
wire harness on each wire of the indications and alarms module

Sk Strumenti Quadri VDO C78


MAY 2006
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 57

Wiring of the double personalised instrument board (main and secondary board)

°C bar
80 100 2 4 6 24 28
8
40 120 0 10 16 32
175 210 58 87
29 116
105 °F 250 0 psi 145 VOLT
min
X100

G G
MAIN PANEL

8 7 6 5
4 3 2 1
4 3 2 1
OFF ON
8 7 6 5
START

12 11 10 9

16 15 14 13

20 19 18 17

24 23 22 21

JB JB 13 5 33 34 32 2 7 37 24 28 20 19 18 31 29 35 30 17 38 12 3

°C bar
80 100 24 6 24 28
8
40 120 0 10 16 32
175 210 58 87
29 116
105 °F 250 0 psi 145 VOLT
min
X100
SECONDARY PANEL

G G

4 3 2 1
8 7 6 5

4 3 2 1
8 7 6 5

12 11 10 9

16 15 14 13

20 19 18 17

24 23 22 21

Sk Strumenti Quadri VDO 1°+2° C78


58

4
18 JB
+ BAT
Key:

Sk Accum_Servizi S2
RL
+
30 87 - AC1: Main Battery

70
10
MM 86 85 - AC2: Battery for auxiliary services
AC1

10
10
C78 ENS M20

- IE1: Engine 1 electrical system


30 50 +
– - IE2: Engine 2 electrical system
B+ - RL: Relay 50A max.
– AC2
Single engine M GG
C78 ENT M30-M50-M55

BAT 1 * *: Electrical power supply for services


installation

4
70

10
Supplementary services battery recharge

IE1 IE2

4
Two-engines
installation BAT + + BAT
INSTALLATION DIRECTIVE

+
10

70

70
JB 18 MM MM 18 JB
AC1

50 30 30 50

10
B+ – B+
+ GG2 M M GG1
1 1

70
70

AC2
*

BAT – – BAT

10
4

4
MAY 2006
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 59

25. C78 ENS M20 ENGINE

Due to the light supercharge pressure required, the C78


ENS M20 engine does not require the presence of the air/air
heat exchanger. The electric system is common also to other
engines of the same family, but the C78 ENS M20 engine is
differentiated by the use of specific sensors for temperature
and combusting air pressure. To connect these sensors to
the engine wiring system it is necessary to use an extension
cable connected to the H connector.
The following pages show the global wiring scheme and the
electric scheme of the connections between the EDC and
the A connector, where it is possible to identify the H1 and
H2 sensors and the relating H extension cable necessary for
the connection.

60
F H1 H2
JF

06_002_C
JF1
JG
Figure 54
I
E
JE
C78 ENS M20

*
J GH
+ BATT W T
C78 ENT M30-M50-M55

Engine wire harness


W VI H

V S VI
V S SI K
– BATT
SI O
WIRE HARNESS C78 ENS M20 ENGINE

K GG
A
WI
X
C
U WI
JA
X Z +B

Interface wire harness


INSTALLATION DIRECTIVE

JB B MM

A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor -
M
B EDC E. EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H2. Combustion air pressure
PA PO sensor for EDC - I. High coolant temperature sensor (for alarm) - J. Low coolant level sensor (for alarm)
- K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter
A EDC EC (for alarm) - O. Exhaust gas temperature sensor (for gauge) - H1. Intake air temperature sensor for EDC
- S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for gauge) - U. Clogged oil filter
sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged
blow-by filter sensor (for alarm) - Z. Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for
oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection wire harness - JE. Alarms control unit (for Certification Bodies) - JF, JF1. Relay
box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor - PO. Pre-lubrication electrical pump - SI. Gearbox oil temperature sensor -
VI. High gearbox oil pressure sensor (25 bar) - WI. Low gearbox oil pressure sensor (7 bar) - * Sensor H1/H2 wiring harness.
MAY 2006
MAY 2006



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C78 ENS M20 ENGINE Wiring diagram EDC connector A
INSTALLATION DIRECTIVE


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C78 ENT M30-M50-M55
C78 ENS M20
61

Schema_Connettore_A2° ENS
C78 ENS M20
62 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 63

26. APPENDIX

Page

���������������������������������
LUBRICATING OIL TRANSFER MODULE 64

PRE-LUBRICATION
AND OIL TRANSFER MODULE 64

STARTING AID 65

ELECTRONIC CONTROL
GOVERNING LEVERS 66

SAFETY SYSTEM FOR


HOMOLOGATED INSTALLATIONS 68

ELECTRICAL DIAGRAMS
FROM THE SAFETY SYSTEM 82

METHOD OF USE OF THE


SAFETY SYSTEM INTERFACE 85
C78 ENS M20
64 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

LUBRICATING OIL TRANSFER MODULE PRE-LUBRICATION AND OIL


TRANSFER MODULE
Figure 1 Figure 2

%6
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$)3#(!2'% %6
$)3#(!2'%
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1 1 2 04_037_C
04_036_C

1. Oil intake/exhaust control. -


1. Oil intake/exhaust control. 2. Switching solenoid valve control.

Lubricating oil transfer operations are simplified by the The module is connected to the JG connector of the
presence of an electrical control system connected to the JG interface wiring harness.
connector of the interface wiring harness. Manual control for The task of pre-lubricating the engine’s internal components
transfer operations is positioned on the front panel unit. For is managed and controlled by the electronic circuit of the
safety reasons, control is enabled only with the key switch in module when the key switch is placed in “ON” position. The
the “OFF” position operation can also be conducted by acting manually, with the
key switch in the “OFF” position, only on the oil intake/exhaust
push-button positioned on the unit. If the push-button is
placed for a few seconds in the “DISCHARGE” position, the
filters and the internal engine ducts will be filled.

Lubricating oil transfer sequence:


1. Place the “EV-OFF/ EV-ON” (2) switch in the “EV-ON”
position, thus energizing the switching solenoid valve
to place the emptying/filling junction in communication
with the electrical pump and with the oil sump.
2. Use the “CHARGE/DISCHARGE” (1) push-button to
complete the desired operation.
3. Place the “EV-OFF/ EV-ON” switch back to the “EV-OFF”.

Figure 3
1 2

3 80836

1. One way valve - 2. Switching solenoid valve (EC) -


3. Electrical pump (PO).
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 65

STARTING AID

Figure 4

1 3

05_061_C

1. Specific junction pipe - 2. Electrical grid heater -


3. Power relay.

When the engine is to be used at temperatures lower than -


15 °C, an electrical grid heater is installed, (PH). Its operation
is controlled by the electronic unit of the injection system.
The element will be placed between the turbocharger and
the air-water heater exchanger (after-cooler), replacing the
terminal part of the intake duct. Connection to the electrical
wiring provided is achieved interposing a specific relay (GH)
and connection to the power supply grid, (see Chapter 24)
For use at temperatures lower than -25 °C, adoption of an
auxiliary preheating system is recommended.
C78 ENS M20
66 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

ELECTRONIC CONTROL GOVERNING LEVERS

For version with analogue instruments


Figure 5

MAIN SECONDARY
INSTRUMENT INSTRUMENT
JC JC PANEL JE JE JH JH PANEL

MAIN SECONDARY
CUSTOMIZED CUSTOMIZED
INSTRUMENT INSTRUMENT
PANEL PANEL
JB JB

4 JB1
ENGINE
EQUIPMENT

CONVERTER
3 MODULE A
JD JO
EDC
2
JB B
JB
JA

JF JF1

RELAY BATTERY
BOX
05_041_C 1

1. Engine wiring connector for connection of the control panels - 2. Interface wiring for the installation of electronic control levers -
3. Connector for the connection of the exterior governor - 4. Conversion module for codifying the signals of the exterior governor.

This option offers the chance, in alternative to that prepared If this solution is used the accelerator position sensor
for the engine, electronic management of the engine rev. installed on the engine will remain electrically connected but
speed. unused and the EDC central unit will manage the engine
Installation must take place inserting the interface wiring (2) speed according to the power signal applied to the JD con-
between the engine and the wiring of the control panels nector terminals (3).
to which the exterior governor will be connected and the If the electronic acceleration system fails, it will be possible
electronic module for converting the electric signals from the to manage the engine rev speed in an emergency, by discon-
lever into electronic information recognisable by the EDC necting the JD connector and mechanically activating the
central unit. lever of the sensor installed on the engine.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 67

Interface wiring
Figure 6
3 4

1 2 05_043_C

1. Connector JB1 - 2. Connector JD - 3. Connector JO - 4. Connector JB.

The JB connector will be coupled to the JB connector of the The converter module will be connected to the JO
engine wiring, while the JB1 connector will be coupled to the connector while the JD connector will be available to make
JB connector of the wiring connecting the control panel. the connections to the electronic governance system unit.

Connector JD
Figure 7

05_042_C
PIN 1 PIN 3

The connection requires a METRI-PACK 150 three-way con-


nector with male terminals.

PIN Wire code (U) Voltage Interpreted function Imax


1 7731 +B with key in ON position Electronic throttle enabling 0,5 A
2 0000 0 V - (Ground) Common reference terminal -
0 to 0,2 V Poor value. EDC recognises a fault -
0,2 to 0,5 V Accelerator at minimum level
3 5584 0,5 to 4,5 V Accelerator min. to max., U function -
4,5 to 4,8 V Accelerator at maximum level -
4,8 to 5 V Excessive value. EDC recognises a fault

NOTE: The voltage values for the rotation of the motor must be between 0.2 and 4.8 V. Values below 0.2 V or above 4.8 V
generate the recognition of a fault and consequent deactivation of the function.
C78 ENS M20
68 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS

Unit installed
Figure 8
electronic
RPMx100

HOURS

oC

bar
oF

1 2 3 4 5 6

electronic
RPMx100

HOURS

oC

bar
oF

10

11

12
05_045_C

1. Fuel filters which can be replaced when the engine is rotating - 2. EDC electronic unit - 3. EDC auxiliary unit - 4. Acoustic alarm -
5. Warning light - 6. Control panel - 7. Electronic monitoring and alarm management unit - 8. Connector JC - 9. Connector JS -
10. Emergency engine cutout button - 11. Oil filters which can be replaced when the engine is rotating -
12 . JB, JC wiring, specific for homologated systems.

The electric and electronic equipment of engines requiring ted by acoustic and optic alarms installed by the Yard or by
a conformity declaration issued by the Certifying bodies the Fitter. For boats equipped with only one engine, to offer
comprises, in addition to that provided for the standard a higher level of safety during navigation, it is necessary to
configuration, a series of components for the measurement, install a second auxiliary EDC unit alongside the EDC engine
processing and recording of engine operating parameters. controlling electronic unit to enable rapid replacement in the
The aim of the system is to emit acoustic and optic alarms event of a failure.
indicating that set limits have been exceeded.These limits will
be programmed in accordance with different homologation
requirements and may, when necessary, cut-out the engine
in an emergency.
The system is made up of an electronic unit for the acquisi-
tion, display and recording of events occurring while the
engine is running, using a series of sensors for this specific
purpose; the alarm signals produced by the Unit will be emit-
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 69

Electronic monitoring unit Sensors


Some sensors produce electric signals with a value propor-
Figure 9
tionate to their physical entity
(temperature, pressure or rev. speed), allowing the electronic
unit to monitor the engine operation to measure tendencies
to approach the critical values; others indicate, with com-
mutation by an electric switch, that a set pressure or tem-
perature limit has been exceeded, generating an immediate
“alarm” signal.
Given the high level of safety required, many of the moni-
toring system sensors are connected exclusively to this
system; this means that the engine equipment comprises
several components to measure the same physical entity but
dedicated to different systems. In order to obtain an effec-
tive control of the integrity of the wiring, there are several
resistors, connected in series with or parallel to the connec-
tion lines of the main sensors, which are used to recognise
the conditions of cut-out or short-circuit of the connectors.
After installation it is best to check that these components
05_046_C
are correctly connected to the wiring (Figure 10).
This unit monitors the operation of the specific safety system. Figure 10
With its computerised logic it acquires the electric signals
issued by the sensors linked up to it, converting them into
physical parameters of temperature, pressures and revs. This
data is displayed on the liquid crystal display and processed
according to the set parameters to draw attention to any
approach towards the critical limits programmed and alarms
should these limits be exceeded. Equipped with a built-in
clock/calendar function, it is able to record and memorise the 05_047_C
last 1000 alarms issued and the values of about 1000 sam-
ples of signals from sensors. It also issues electric signals to - Line balancing element -
activate the acoustic and luminous alarm signals as requested
by the homologation standards. In observance of the provisions of the certifying bodies, the
system equipment includes the presence of solutions which
make it possible to check the efficiency of the monitoring
functions and measure the relative parameters. By way of
example, there is a valve which cuts off the oil in the connec-
tion of the “Low oil pressure” (WA) sensor, in order to test
the efficiency of the related function and an unused exten-
sion cable (BA1 – BA1U).
C78 ENS M20
70 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Wiring Electrical starting motor


The presence of the Safety system in question in the electrics
Figure 12
of the boat requires the use of specific
wiring unlike standard wiring.
The connection of the monitoring unit and the components 1 2
connected to it are made on the JB-JC wiring used for the
connection of the main control panel to the engine wiring. 3
The electric connection of the system devices is made using
connectors. Every multipolar connector is polarised to pre-
vent inversion and is dedicated to a particular function.
The electric diagrams, referred to the identification of the
inputs/outputs of the connectors of the
monitoring unit may vary following the programming of par-
ticular features of the application.

caution
To obtain the engine cut-out function by the JS monitoring
unit it is necessary to unite the two JE connectors on the
JB-JC wiring and the engine wiring. 1 2

Insulated pole power network (optional)


Figure 11

Equipment power supply

  " 3 , )'
05_109_C

- 1. Excitation coil command (50) - 2. Positive power


pole (+B) - 3. Negative supply pole (-BATT).

 n" Technical characteristics:


- Supply nominal voltage 24 V
- Absorbed power 5 kW
05_113_C
- Terminal connection “50” M5 x 0,8
tightening couple 2-2,5 Nm
The power network may be carried out in order to avoid
using both the structure of engine and the structure of the - Terminal connection “+B” M10 x 1,5
hull (if this is metallic). For this purpose the electrical starting tightening couple 14,7-17, 7 Nm
motor and the alternator required for this equipment are
characterized by the presence of the terminals for electrical - Terminal connection “-BATT” M8 x 1,25
connections both with the positive and with the negative tightening couple 9,8-11,8 Nm
pole of the battery.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 71

Alternator Auxiliary EDC electronic unit


This is fastened to the side of the unit in use to enable rapid
Figure 13
replacement in the event of a failure.
Should it be necessary to replace it, proceed as follows:
o stop the engine;
o wait 10 seconds, then disconnect the terminal clamps
from the battery;
o roceed as follows to extract and reinsert the connec-
tors.
Figure 14

+B

80802A

-B REMOVING ECU CONNECTORS

05_112_C S IG L

Technical characteristics:
- Nominal voltage 24 V
- Nominal voltage 90 A
- Terminal connection “+B” M8 x 1,25
80802B
tightening couple 12,5 Nm ± 20%
- Terminal connection “-B” M6 x 1 INSERTING ECU CONNECTORS
tightening couple 6,0 Nm ± 20%
+B. (24 V) Power supply output terminal
At the end of the operation:
-B. (0 V) Power supply output terminal
o reconnect the battery terminal clamps;
S. (Sense) Reference voltage of battery charge status
(connected to +B terminal or to be con- o start up the engine to run an efficiency test.
nected to the positive pole of the battery in
case of remote installation of the battery);
IG. (Ignition) Regulator enabling signal (connected to volt-
age +, driven by key switch);
L. (Lamp) Power supply voltage of recharge/alarm indi-
cator light located on the panel.
C78 ENS M20
72 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Synoptic

Figure 15
BA BA1 BA1U

IA IR
JSA
WA IR1
JSB
WVA BAR
MONITORING
JSC
UNIT JS
VA BAD
JSD
VCA WR
JSE
JEM WR1
JSF
FA

MAIN SECONDARY
INSTRUMENT INSTRUMENT
JC JC PANEL JE JE JH JH PANEL

ENGINE
EQUIPMENT

A
EDC EDC
ELECTRONIC ELECTRONIC
AUXILIARY
UNIT UNIT
B
JB JB

JA JA
1 2 3 JF JF1 4

JE JE RELAY batterY
JG box
05_032_C

1. Specific wiring unit for installation of instrument panel and monitoring unit - 2. Engine wiring -
3. Interface wiring - 4. Power network.

DESTINATION OF CONNECTORS OF THE SAFETY SYSTEM (excluding standard supply connectors)


BA. Drive shaft sensor - BAD. Diode for BA - BAR. Resistor for BA - BA1, BA1U. Connectors of the extension cable for engine rev.
speed - FA. Acoustic and luminous alarms - IA. Coolant temperature sensor - IR. Parallel resistor for IA - IR1. Series resistor for IA -
JE. Connector for cutting out agitated engine - JEM. Connector for cutout switches in the case of an emergency and motor cutout
from the engine room - JS. Electronic monitoring unit - JSA, JSB, JSC, JSD, JSE, JSF. Connectors for monitoring unit - VA: Engine oil
pressure sensor - VCA. Fuel pressure sensor - WA. Engine oil low pressure sensor - WR. Parallel resistor for WA -
WR1. Series resistor for WA - WVA. Coolant pressure and low pressure sensor.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 73

Wiring

Figure 16
F J

GH
E
JF1 JF I

P
W
JG T T
H
W
+ BATT VI
S
V VI
V S A
SI
SI GG
C
U Z
– BATT WI K
K


JA M WI
PA X O
JA PO +B

B X MM
EC

EJ

JE JE
JSA
BA1U
A B

 JSB
B EDC

MONITORING UNIT
JSC
JB JB
IR IR1
JEM
JSD
WA VA
A EDC


JC WR WR1
IA
VA JSE
JC
BAR BAD
WVAG QP
WVA WVAA JSF
WVAS
electronic
RPMx100

HOURS
FA1
VCA
V

FA2
BA1 oC

oF
bar

FA3
05_033_C
VCA BA
FA4

DESTINATION OF CONNECTORS OF THE STANDARD ENGINE (excluding safety system connectors)


A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E. EUI solenoid valves -
F. Engine coolant temperature sensor for EDC - H. Combustion air pressure sensor for EDC - I. High coolant temperature -
J. Low coolant level sensor - K. Air filter clogging sensor - M. Sensor for detecting the presence of water in the fuel pre-filter -
O. Exhaust gas temperature sensor - P. Intake air temperature sensor for EDC - S. Oil temperature sensor - T. Coolant
temperature sensor - U. Clogged oil filter sensor - V. Oil pressure sensor - W. Low oil pressure sensor - X. Clogged blow-by
filter sensor - Z. Clogged fuel filter sensor - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator -
GH. Pre-heating power relay - JA. Interface wiring - JB. Instrument panel connection wire harness - JE. Alarms control
unit (for Certification Bodies) - JF,JF1. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle
position sensor - PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure
sensor (25 bar) - WI. Low gear box oil pressure sensor (7 bar).
C78 ENS M20
74 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Monitoring unit
Figure 17

200 131

134
150

(The picture shown is purely indicative)

JSA JSB JSC


1 1 1 Dimensions in mm

11 11 11

Drilling template 183 mm x 135 mm


134

JSD JSE JSF


1 1 1

11 11 11

182 05_031_C

The total integration of the system with the engine equip- which can be fitted outside, as well as the preparation of the
ment means that the installation procedures already listed alarm management components pursuant to the homologa-
for the standard version are joined by the placement of the tion standard: acoustic and luminous signals, cut-out buttons.
electronic monitoring unit inside a console or dashboard,

GENERAL FEATURES AND REFERENCE STANDARDS


Power supply 12/24 V d.c.
Current absorption 500 mA (approx.)
R.I.N.A. “Regulation for automation systems” - Section E
Performances in compliance with *
Functional, climatic, vibration and EMC tests in accordance with * IEC 945 “Maritime navigation and radio-communication
equipment and system - General requirements - Methods of
testing and required test results”

* The test reports are supplied by request


C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 75

Function of JS connection terminals

pin JSA JSB JSC


Thermocouples Supply CAN network

1 Exhaust fumes temperature Supply 12/24 V (+) CAN (H)


2 - Supply 12/24 V (+) CAN (L)
3 - Mass (-) -
4 - Mass (-) -
5 Exhaust fumes temperature - GPS - NMEA 0183(2) protocol
6 - N.C. relay 1 - Acoustic signaling(2) Echo sounder - NMEA 0183(2) protocol
7 - Mass (-) -
8 - N.O. relay 1 - Acoustic signaling -
9 - N.C. relay 2 - light signal(2) GPS/Eco sounder(2) Mass (-)
10 - Mass (-) -
11 - N.O. relay 2 - light signal -
NOTE: one of the terminals of the following components is connected to the electric mass: VCA, WVA(G), VA, WA, BAD, IA, JE.

pin JSD JSE JSF


Sensors Signals Signals and alarms

1 Gear box oil pressure(2) Engine revs (EDC)(1) N.C. Cut-out relay 3(2)
2 Coolant pressure (WVAS)(1) Engine revs (BA)(1) -
3 Engine oil pressure (VA)(1) Low coolant level (J)(1) 12/24 V (+) common relay 3 stoppage
4 Sea water circuit pressure(2) Low gear box oil pressure(2) N.O. Cut-out relay 3 (JE)(1)
5 Engine oil temperature (S)(1) Air filter blockage (K)(1) Alternator recharge (L)(1)
6 Low engine oil pressure (WA)(1) Low coolant pressure (WVAA)(1) Pre-lubrication (opt.)
7 Water in the pre-filter (M)(1) Fuel filter blockage (Z)(1) Imp. Voltage signal 12/24 V (+)
Engine stopping circuit damaged
8 Fuel pressure (VCA)(1) Engine revs (BAR - BA)(1)
(JEM - JE)(1)
9 EDC (failure signal)(1) - -
10 High coolant temperature (IA)(1) Oil filter blockage (U)(1) -
11 Mass (-) Engine cut-out (pin 4 JSF) -
1) Code of the component or sensor to which the terminal is connected
2) The terminal is prepared but not connected with the wiring.

3 2 1
6 5 4
9 8 7
11 10
05_051_C

CONNECTORS JS SEEN FROM WIRING SIDE


C78 ENS M20
76 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Position of the safety system sensors

Figure 18

3
4
05_048_C
5
2 6

1. Engine rotation speed and EDC system damaged signal - 2. Oil temperature analogical sensor - 3. Low oil pressure sensor (WA) -
4. Oil filters congestion sensor - 5. WA efficiency test tap - 6. Oil pressure analogical sensor (VA) - 7. Cooling liquid pressure and low
pressure analogical sensor (WVA) - 8. Cooling liquid high temperature sensor (IA).
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 77

Figure 19

1 2
8

3
7
4

6
5
05_049_C

1. Fuel pressure analogical sensor (VCA) - 2. Engine cooling liquid level sensor - 3. Battery recharge signal - 4. Fuel filter congestion
sensor - 5. Presence of water in the fuel sensor - 6. Engine rotation speed sensor (BA) - 7. EDC engine rotation speed sensor -
8. Air filter congested signal - 9. Exhaust gas or thermocouple temperature analogical sensor (O).
C78 ENS M20
78 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Drive shaft rev. speed sensor (BA) Coolant high temperature sensor (IA)
Figure 20 Figure 22

05_052_C

This is of the inductive type and when the engine is running


it produces a sinusoidal alternate signal the value of which
increases in proportion to the engine rev. speed. The sensor
BA enables the measurement of the engine rev- speed using
the passage of the holes positioned in a radial arrangement
on the outer circumference of the flywheel. The presence of
the resistor BAR and the diode BAD can alter the value of
the sensor resistance if measured on the JSE connector of
the monitoring unit.

Resistance value at 20°C 220 ± 20 Ω


Poles Isolated

Exhaust gas temperature sensor (O) 05_053_C

Figure 21
Thermometric switch which supplies the information for the
engine high temperature alarm.

04_260_N Operating power from 6 V to 24V


NiCr-Ni thermocouple sensor with insulated poles, pro- Condition at ambient
normally open
viding the signal for the analog indication of exhaust gas temperature
temperature. Commutation temperature: °C
Poles Isolated
Temperature Voltage
°C mV Electric diagram:
100 4,10 05_054_C

200 8,13
300 12,21
  
400 16,40 

500 20,65

600 24,91 

700 29,14
800 33,30
900 37,36
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 79

Engine oil low pressure sensor (WA) Engine oil pressure sensor (VA)
Figure 23 Figure 24

04_237_N
05_055_C

Component which supplies a rheostatic signal for the ana-


Switch activated by the fluid pressure, which supplies the logical indication of the fluid pressure.
information for the engine lubricant low pressure alarm.
Operating power from 6 V to 24 V
Operating power from 6 V to 24V Setting field from 0 bar to 10 bar
Condition at ambient pressure normally closed Resistance value at 0 bar 10 Ω +3/-5 Ω
Commutation pressure: 0,4 / 0,8 / 1,2 bar Resistance value at 2 bar 52 ± 4 Ω
Poles Isolated Resistance value at 4 bar 88 ± 4 Ω
Resistance value at 6 bar 124 ± 5 Ω
Electric diagram: Maximum value of resistance 184 Ω
05_054_C
Operating temperature from - 25°C to +100°C
Poles Isolated

  


Coolant oil temperature sensor (S)

 Figure 25

05_114_C

Resistor with negative temperature coefficient, providing the


signal for analog temperature indication.

Operating voltage 6 V to 24 V
Calibration range 0°C to 120 °C
Resistance value at 90°C 51,2 ± 4,3 Ω
Poles isolated
C78 ENS M20
80 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Refrigerating liquid pressure and low Fuel pressure sensor (VCA)


pressure sensor (WVA)
Figure 27
Figure 26

04_237_N
05_056_C

Component which supplies the rheostatic signal for the ana-


This integrates a component which supplies the rheostatic logical indication of the fluid pressure.
signal for the analogical indication of the pressure and a
switch activated by the pressure which supplies the informa-
tion for the engine coolant low pressure alarm. Operating power 12 / 24 V
Field of intervention from 0 bar to 10 bar
Operating power 12 / 24 V Poles Isolated

Rheostat
Field of intervention from 0 to 5 bar
Stamping of the terminals M-G
Wiring terminals WVAG - WVAS

Switch
Condition at ambient pressure normally open
Closing pressure ≥ 0,25 bar
Stamping of the terminals M - WK
Wiring terminals WVAG - WVAA
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 81

Line balancing components Engine cut-out control buttons (JEM)


Figure 28
Electric diagram:
Figure 29
EMERGENCY


05_047_C 2


Electric diagram:






05_058_C

05_060_C STOPPAGE DURING EXCITATION


Code Resistor features
IR 1,5 kΩ 1W The balancing resistor R has a value of 10 kΩ.

IR1 470 kΩ 1W
WR 1,5 kΩ 1W
WR1 470 kΩ 1W
BAR 4,7 kΩ 1W

Electric diagram:



05_059_C

Code Diode code


BAD 1N 4007
C78 ENS M20
82 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

ELECTRICAL DIAGRAMS FROM THE SAFETY SYSTEM

Code of components of the standard version Code of components of the safety system

A Fuel temperature sensor for EDC BA Drive shaft sensor


B Drive shaft sensor for EDC BAD Diode for BA
C Camshaft sensor BAR Resistor for BA
E EUI solenoid valves BA1, BA1U Connectors of the extension cable for engine
rev. speed
F Engine coolant temperature sensor for EDC
FA Acoustic and luminous alarms
H Combustion air pressure sensor for EDC
IA Coolant temperature sensor
I High coolant temperature
IR Parallel resistor for IA
J Low coolant level sensor
IR1 Series resistor for IA
K Air filter clogging sensor
JE Connector for cutting out agitated engine
M Sensor for detecting the presence of water in the
fuel pre-filter JEM Connector for cutout switches in the case of an
emergency and motor cutout from the engine room
O Exhaust gas temperature sensor
JS Electronic monitoring unit
P Intake air temperature sensor for EDC
JSA, JSB, JSC, JSD, JSE, JSF
S Oil temperature sensor
Connectors for monitoring unit
T Coolant temperature sensor
VA Engine oil pressure sensor
U Clogged oil filter sensor
VCA Fuel pressure sensor
V Oil pressure sensor
WA Engine oil low pressure sensor
W Low oil pressure sensor
WR Parallel resistor for WA
X Clogged blow-by filter sensor
WR1 Series resistor for WA
Z Clogged fuel filter sensor
WVA Coolant pressure and low pressure sensor
EC Switching solenoid valve for oil charge/discharge
GG Alternator
GH Pre-heating power relay
JB Instrument panel connection wire harness
JE Alarms control unit (for Certification Bodies)
JF, JF1 Relay box
JG Pre-lubrication control unit
MM Electric starter motor
PA Throttle position sensor
PO Pre-lubrication electrical pump
SI Gear box oil temperature sensor
VI High gear box oil pressure sensor (25 bar)
WI Low gear box oil pressure sensor (7 bar)
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 83

Wiring unit JB - JC

CG MS

TA MO V
QP
20 30
30 CA
X100

10 40

SBPO

SBLA
SATA
EDC

SIFO
SIFC
SIFA
SAC

SIFB
SCP

SSV
SS

SP
C C
15 50
0 0 0 0 1 50
4 JE

4 JH L
L- L+ 3 2 1
JD 9 1 7 8 10 19 15 13 2 3 17 18 4 5 16 12 11 14 6 20 JD
AS

10 JH

10 JE

SA
AQ P1

JC 1 2 8 4 7 6 9 40 36 39 14 15 16 13 5 10 11 JC 33 34 32 44 27 41 26 25 21 42 22 43 23 45 46 47 19 18 30 38 12 35 31 3 17 20 24 28 29 37 JC

JEM 1
JEM 2
JEM 3
JEM 4
JS
BA1 A 1
JSA
BA1 B 5

BA1U B
BA1U A 1
2
VCA 3
VCA 4
JSB
7
FA 2 8
FA 1
FA 3 10
FA 4 11

P
WVAA 1
JSC
WVAG 2
WVAS

VA 2
VA 3
5
WR1 1 6
470 Ω
WR1 2 7 JSD
8
WR 2 9
1,5 kΩ
WR 1 10
11
WA 1
WA 2
P WA 3 1
WA 4 2
3
BA A 5
BA B 6 JSE
7
BAD A 8
BAD K 10
11
BAR 1
4,7 kΩ
BAR 2
3

470 Ω
IR1 1 4
IR1 2 5
JSF
6
IR 2 7
1,5 kΩ
IR 1 8

IA 1
IA 2
T IA 3 JE 1
IA 4 JE 2
JE 4

JB
JB 1 2 8 4 7 6 9 40 36 39 14 15 16 13 5 10 11 JB 33 34 32 44 27 41 26 25 21 42 22 43 23 45 46 47 19 18 30 38 12 35 31 3 17 20 24 28 29 37
A

28 22 JA 1 JA 13 JA
O VI WI SI
ENGINE NORMAL
ROOM
30 11 JF B JA 6 JG
F2 B
26
SW1 D1
JF
28
K2
JF1 SW1
14 K3 "A"
13
7 D9
2 D10
1 D2
K5
SW2
"STOP"
6

JF1
+ BATT JF2
15
9 10 21
+ 16 B+
D12 3 JA
AC M A B C
3 2 1
A 1 3 1 A
1 2 3 4 15 32 33 34 5 12 11 6 18 3 1 2
GG S IG L
-
T V S GG K I W J X U Z
BATT M B+
-
B 2 2 B
JA
6

85150
1

C78 unità monitor omolog


84
*! *" *# *3&
   
1 *& *%- *%- 30 33
37   
2 ENGINE
F2 & NORMAL ROOM

*3%
7 *%-¬  10

*%

C78 Conn_B omolog


13 B A
*&  *3&
14 30 JF 37 JC 18
 
F1 $ PO
JF1 28 JA *& *! *" *# *# *" 37 JB 18
SW4       M
C78 ENS M20

2 JB + - $ 13 JA
$ SW3 !1 4 JA 2
2 JC
30
13 25 35 JF SW2 JG 4 1 12 7 8 9 10 6 2 3 11 5
K2 K3
CA $
C78 ENT M30-M50-M55

11 9 10 JA $ STOP START


MP
EDC system – connector B

50 15 $ $ $
16 14 15 JB
7 JC 8 $
7 JB 8
D9 D10 $
25 JA 22 $
JF1
26 JF JF 11
 D3

5
6 T U C D A B F E V J1 K1
K6
8 K5 D18 R3
9

D8 2

D12
+ DL1
28 JF JF 3 4 15 16    JF
26 JA
JF1     
 JB 38 JA 3
9 10 21 JF
INSTALLATION DIRECTIVE

SW5
$ 3 JC 38

4
1 17 JA JA 14
JB 10 4 JD 2
+ BAT  JA GH
SCP EDC PA
2
JF    29 JF
R

50
10
10
+ MM JB 11
1 7
5 JD 3 JA
AC 30 50 16 JA JF 23 36 32 22 20 12 27 17 JC 12
JF 18 31
E C A B D
JA 23 24 29 27 18 6 20 17 JB 12
- JA 5 12
M JB 13

70
! - 3 2 1 GG
- BAT A
15 25 29 34 32 33 11 12 24 13 9 5 27 18 6 3 4 10 17 35 23 16 1 2 10
 * PH S IG L

4
EC
GG
JF1 B
*%  JB
 15
85150
16
JA 1
MAY 2006
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 85

METHOD OF USE OF THE SAFETY SYSTEM INTERFACE

The following information relates to the method of use of Basic operations


the system in the configuration which is considered to be the o Press the keys “<<” and “>>” to display the sequence of
IVECO MOTORS standard. Information concerning func- the pages containing the information relating to all the
tions which require connection to external systems such as monitored parameters, including maintenance rates and
echo sounders and GPS, which are outside the safety system, optional information (see the relating figures).
are voluntarily explained briefly. The programming method
which must be carried out by the Supplier or by the Assist- The IVECO MOTORS standard configuration requires the
ance Service technician is not explained. For all the informa- detection of the following data:
tion which are not contained in this document, please refer o Pressure of engine cooling liquid
to the manuals issued by the Supplier. (FRESHWATER PRESS)
caution o Low lever of engine cooling liquid
(LOW WATER LEVEL)
The system is supplied programmed to suit the homologa-
tion instructions arranged; every need linked to different o Low pressure of engine cooling liquid
programming of the operating characteristics will be met (FRESHWATER LOW P)
by the information presented by the Constructor with o Excessive temperature of engine cooling liquid
specific documentation. Please remember that the set- (HIGH WATER TEMP)
tings, allowed to adapt the system to different installations,
will only be possible after the system password has been o Pressure of engine lubricating oil (OIL PRESS)
entered. o Absence of engine lubricating oil pressure
(LOW OIL PRESS)
Monitoring o Temperature of engine lubricating oil (OIL TEMP)
The monitoring interface enables a constant verification of
o Oil filter blocked (OIL FILTER CLOG)
the mechanic parameters required by the homologation
norms so that it is possible to quickly identify the arousal of o Presence of water in fuel (WATER IN FUEL)
an anomalous condition. The information contained in the
o Fuel pressure (FUEL PRESS)
unit memory also enables the analysis of the events relat-
ing to the period preceding the survey. If there is an alarm o Fuel filter blocked (FUEL FILTER CLOG)
status, an acoustic signal is emitted and the box containing
the anomalous parameter data is visually highlighted through o Injection system failure (INJECT WARNING)
a flashing border. o The battery is not recharging (BATTERY WARNING)
The function of the keys changes depending on the different
displays. o On going pre-lubrication (PRELUBRICATING)*
o Power System Tension (VOLTMETER)
Figure 30
o Exhaust gas temperature (EX GAS TEMP)
o Engine rotation speed from EDC system (ENGINE E)
o Engine rotation speed from sensor (ENGINE S)
o Engine rotation speed sensor damaged
(PICK-UP L FAULT)
1 o Engine stopping circuit damaged
(MAN STOP L FAULT)
o Automatic engine stopping circuit damaged
2
(AUTOSTOP L FAULT)
o Air filter blocked (AIR FILTER CLOG)
6 3
o Gear oil pressure (GEAR OIL PRESS)*
o Absence of pressure in the gear oil
(LOW GEAR OIL P)*
05_035_C o Sea water pressure (SEA WATER PRESS) *
5 4
*) Information given only in the presence of the relating
1. Analogue indicators in the form of bars or circles with parts.
reference to the parameter, value and unit of measurement - The setting of the alarm threshold must be carried out by
2. Recognition of the pre-set alarm limits - 3. Page number - the Technical Assistance Service personnel and requires the
4. Membrane keys - 5. luminous indicators - 6. Key functions. inputting of a password.
C78 ENS M20
86 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Video mode setting Figure 32


The interface performances enable the modification of the
brightness, the contrast and the image presentation mode, 1 2
which is characterized by the inversion of the day/night.
o Press the “MENÚ” key to display the fast choice win-
dow.
o Press the keys “<<” and “>>” to highlight the display
mode to be regulated: “BRIGHTNESS”, “CONTRAST”,
DAY/NIGHT”.
o Press the “OK” key to confirm your choice.
o Modify the parameter setting using the “<<” and “>>”
keys 4
o Press the “OK” key again to confirm.
o Press the “CLR” key to exit the “MENU”.

Advanced operations 3 05_126_C

Figure 31 1. Parameter displayed - 2. Outside the stairs and measurement


unit - 3. Period selection key (last 15 minutes, 1 hour, 6 hours,
24 hours) - 4. Displayed duration period.

o “SAVE”: this enables the recording of the values of the


parameters detected by the system in specific moments
of the system working. Recording is carried out when
the “OK” is pressed. The following pressures cause other
data acquisitions. The recorded values can be shown in
all the set modes.
05_124_C o “AUTO REC.”: this choice enables the modification of
the data recording mode. It is not possible to carry out
modifications.
The values of the monitored parameters can be shown in
different ways, including a diagram showing their evolution o “HOURCOUNTER”: this enables the management of
over a period of time. the effective propeller/s movement hours; the data is
displayed, as hours (ENGINE) or statistics (STATISTIC)
To chose the display mode, do as follows: only after inputting the correct password. This data can
o Press the “MENÚ” key and display the fast choice window. be used by the Assistance Centres Personnel to add just
the programming of the maintenance intervals. From
o Use the “<<” and “>>” keys to select the “DATALOG- this mode it is possible to select the option “SERVICE
GER” option inside the window. RESET”, which is explained in the paragraph: “Mainte-
o Press the “OK” key to confirm and display a second nance rates monitoring”.
window containing the options which can be chosen. o “FUELCOUNTER”: (not programmed).
o To select the required display mode use the “<<” and o “SERVICE ONLY”: this is used only for the programming
“>>” keys. which must be carried out by the personnel of the Tech-
o Press “OK” to confirm. nical Assistance Service and requires the inputting of a
password.
Modalità di visualizzazione
o “GRAPHICS”: this displays the evolution of the param-
eters value over time; the “ZOOM” key enables the
modification of the time period shown on the display.
o Press the “<<” and “>>” keys to display the diagrams
relating to the different parameters.
o Press the “CLR” key to exit form this mode.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 87

Maintenance rates monitoring Maintenance intervals resetting


This unit is programmed to enable the monitoring of the If one of the listed maintenance interventions has been car-
hours during which the engine works before set mainte- ried out, to reset the counting data referring to the number
nance interventions. Only the Technical Assistance Service of hours after which interventions is required again, do as
Personnel can modify the data relating to the hours of the follows:
different intervals.
o Press the “MENU” key to display the fast choice win-
The unit hour counter decreases the data according to
dows.
the effective working hours and, until negative values are
reached, it enables the identification of interventions consid- o Use the “<<” and “>>” keys to select the “DATALOG-
erably before the need. GER” option inside the window.
After each maintenance intervention, it is the boat user, or
the personnel in charge, that must reset the display of initial o Press the “OK” key to confirm and display a second
data used for the counting. window containing the choice options.
The list of the number of working hours of the engine/s o Select the “HOURCOUNTER” mode by pressing the
allowed before maintenance interventions can be displayed “<<” and “>> keys.
using the basic operations described in the sequence of
pages which can be opened using the “<<” and “>>” keys. o Press the “OK” key to confirm.

Figure 34
Figure 33
05_125_C

2
05_127_C

o Use the “<<” and “>>” keys to select the option “SERV-
ICE RESET”, inside the new window.
o Press the “OK” key to confirm and display the pro-
grammed interventions list together with the number of
1. Engine working hours indicator - 2. Indicator of the remaining
hours before intervention is required. working hours still allowed before the next intervention
is required or, if there is a minus sign (-) the hours of
delay from the intervention request.
o Use the “<<” and “>>” keys to highlight the option
relating to the intervention which has been finished
o Press the “OK” key twice consecutively to confirm.
o Verify that the number of hours shown as a maximum
period is displayed. If this is not the case, repeat the last
operations of the procedure.
C78 ENS M20
88 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Alarms management Navigation monitoring


The electronic system carries out in a sequence the verifica- If the interface has been connected with a GPS or self-pilot-
tion of all the parameters which must be checked, irrespec- ing system (refer to the “JS connectors terminal working”
tive of the page shown on the display. Two lower and two section) which is able to supply navigation data according
higher thresholds are set for each parameter, which respec- to the NMEA 0183 protocol, a pointing diagram useful to
tively refers to the pre-alarm and to the alarm and which navigate will be shown among the monitoring pages.
sometimes coincide. The programmed thresholds are shown Abbreviations list:
on the bar analogical indicator which relates to the param- RNG – Distance from the next waypoint
eter (see the figure). Only the Technical Assistance Service BRG – Direction of the next waypoint
personnel can modify these settings. VMG – Real speed at waypoint
ETE – Expected arrival time
Figure 35 TRN – Course direction for waypoint
XTE – Off course mistake
Figure 36
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1

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If a parameter value is higher than the set threshold, the


acoustic signal is activated and the box representing the
indicator is highlighted through a dark flashing border (clear
border in the “NIGHT” mode) 3 2
Press the “CLR” key to stop the acoustic signal and the
border flashing. The border is still displayed. The alarm condi-
tion is visually shown until the normal status is reset and the 1. Destination (Waypoint) - 2. Course and speed -
“ACK” key is pressed. 3. Position of the moment.

CAUTION
When an alarm signaling occurs, in order to verify that a
damage really exists, it might be useful to press the “ACK”
key. If the limit has only temporarily been passed, the alarm
signaling stops immediately. If the alarm continues it is nec-
essary to carry out the diagnosis of the cause. Once the
cause is definitively removed, in order to reset the normal
display status, press the “ACK” key.
C78 ENS M20
MAY 2006 INSTALLATION DIRECTIVE C78 ENT M30-M50-M55 89

Depth monitoring (Echo sounder) Safety behaviour


If the interface has been connected with an echo sounder In order to guarantee the integrity of the engine and avoid
(refer to the “JS connectors terminal working” section) which major risks for the crew, The Monitoring Electronic Unit is
is able to supply water depth data according to the NMEA programmed to cause the automatic stopping of the engine
0183 protocol, a diagram showing the depth evolution and (this operation is carried out through the relay 3 and after
the relating numeric value, including possible temperature, connecting the JE connectors).
will be shown among the monitoring pages. The following conditions are at the base of the engine auto-
matic stopping:
Figure 37
- Lubrication low oil pressure
1 2 (LOW OIL PRESS, WA sensor)
- Cooling high water temperature
(HIGH WATER TEMP, IA sensor)
3 - Engine excessive rotation speed
(ENGINE S, BA sensor).

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1.Water temperature - 2. Depth of the moment -


3. Graphic representation of the sea floor altimetry.
C78 ENS M20
90 C78 ENT M30-M50-M55 INSTALLATION DIRECTIVE MAY 2006

Update notes
IVECO S.p.A.
PowerTrain
Viale Dell’Industria, 15/17
20010 Pregnana Milanese - MI - (Italy)
Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29
www.ivecomotors.com