Iveco C78 ENT M50, Installation Instruction

Page 1: ...C78 ENT M50 MARINE ENGINE INSTALLATION INSTRUCTION ...

Page 2: ...ts intended mission profile The engine must not be used for purposes other than those stated by the manufacturer IVECO Aifo is willing to exam ine beforehand any requirements for particular installations In particular Use of unsuitable fuels and oils may compromise the engine s regular operation reducing its performance reliability and working life For the engine to maintain its original condition...

Page 3: ...C78 ENT M50 III FEBRUARY 2003 EDITION SECTION CONTENTS OVERVIEW 1 INSTALLATION INSTRUCTIONS 2 DIAGNOSTICS 3 ...

Page 4: ...C78 ENT M50 IV FEBRUARY 2003 EDITION ...

Page 5: ...C78 ENT M50 OVERVIEW 1 FEBRUARY 2003 EDITION Overview Pagina IDENTIFYING DATA 3 Product model number 4 Commercial code 5 ENGINE COMPONENTS 6 PERFORMANCE 8 GENERAL SPECIFICATIONS 10 SECTION 1 ...

Page 6: ...C78 ENT M50 OVERVIEW 2 FEBRUARY 2003 EDITION ...

Page 7: ...NG DATA Figure 2 The engine s Model Number and identifying data are stenciled on a tag located on the engine coolant tank 1 Model number 2 Drawing number 3 Serial number 4 Commercial code Figure 1 1 Figure 1 2 Ist version tag IInd version tag 1 2 2 3 3 4 4 ...

Page 8: ...side of crank case PRODUCT MODEL NUMBER F 2 B E 0 6 8 6 A B C D A B C D E ENGINE FAMILY IDENTIFIER DESIGN ITERATION ENGINE NO OF STROKES AND CYLINDER DISPOSITION 0 4 STROKES VERTICAL NO OF CYLINDER FUEL INJECTION 8 DIESEL TCA DIRECT INJECTION INTENDED USE 6 MARINE POWER RANGE A 500 HP not certified B 400 HP certified C 330 HP not certified D 300 HP certified ACTUAL POWER OUTPUT A 500 HP B 400 HP C...

Page 9: ...therefore cannot be used for techni cal purposes to recognize the engine s components this purpose is served by the model number COMMERCIAL CODE C 78 E N T M 50 1 0 ENGINE FAMILY IDENTIFIER C CURSOR DISPLACEMENT 78 7800 cc NOMINAL FUEL SUPPLY E ELECTRONIC INJECTION BLOCK N NON STRUCTURAL AIR INTAKE T INTERCOOLED SUPERCHARGED APPLICATION M MARINE MAXIMUM PERFORMANCE LEVEL ACHIEVABLE 50 500 HP VERSI...

Page 10: ...r solenoid valve connector 9 Coolant thermostatic valve 10 Alternator location 11 Coolant sea water tube bundle heat exchanger 12 Auxiliary pulley 13 Sacrificial anodes 14 Sea water intake 15 Sea water drain plug 16 Air sea water heat exchanger 17 Sea water pump 18 Electrical starter motor 19 Sea water pump gear 20 Fuel transfer pump 21 Fuel filter 22 Filter clogging sensor 23 Fuel temperature sen...

Page 11: ...ming phase sensor 10 Oil filter clogging indicator 11 Cooled turbo charger 12 Exhaust gas manifold 13 Phase and engine shaft rotation sensor location 14 Waste gate actuator 15 Timing phase inspection port 16 Throttle position sensor potentiometer 17 Oil drain sump plug 18 Instrument panel diagnostics and EMB power supply wiring connectors 19 Location of electrical pump and oil and pre lubrication ...

Page 12: ...ting limit 1000 hours year Definition of calibrations and operating limits for military and government agencies according to con tractual specifications Nominal maximum power kW HP rpm 330 450 2600 Nominal maximum torque Nm kgm rpm Light service B Type of boat Light boats for tourism professional or military use with frequent speed changes E g pleasure boats chartering light passen ger boats high ...

Page 13: ...liance with Standard IMO MARPOL 73 78 ADDENDUM DIR 94 25 EC Sound Emissions Maximum value of average level for engines in basic configuration dB A measurement standard 95 ISO 3744 Power Takeoffs Optional 3 throated Front Pulley for V belts Basic diameter mm 202 Throat size mm 10 Power available to each belt kW HP 7 4 10 3 throated Front Pulley Elastic Joint for Flange Coupling Available torque Nm ...

Page 14: ...60 10 Supercharge Turbo charger with water cooled body KKK K31 Pressure regulation with waste gate Waste gate maximum opening pressure bar 2 5 0 1 Lubrication Oil type SAE 15 W40 E 3 Oil compliant with specifications ACEA E3 API CF4 MIL L2104E F Total oil capacity on first filling liters kg 31 28 Total oil capacity with sump at minimum level liters kg 18 16 3 Total oil capacity with sump at top le...

Page 15: ...rced circulation centrifugal pump Flow rate at maximum rpm l h 25200 Temperature regulation with thermostatic valve Initial opening C 68 2 Maximum opening C 78 2 Sea water line forced circulation Self priming pump with neoprene impeller Sea water pump height above sea level m 2 Max pump capacity l h 17500 Exhaust gas expulsion Optional stack Optional riser Electrical system Nominal voltage V dc 24...

Page 16: ...50 OVERVIEW 12 FEBRUARY 2003 EDITION Figure 5 380 14 96 856 33 70 956 37 64 328 12 91 943 37 12 1774 69 84 1671 65 79 903 35 55 273 10 75 380 14 96 13 0 51 187 7 36 454 18 87 30 1 18 mm inches Centre of gravity ...

Page 17: ...ecuring 5 Engine intake and ventilation air 5 Sea water pipeline 5 Engine pre heating 5 Exhaust gas 5 Starting aid 5 TECHNICAL DATA FOR INSTALLATION 6 FUEL LINE 7 Prefilter 7 Material characteristics 7 ELECTRICAL CIRCUIT 8 EMB 8 Power grid 10 Engine electrical ground 10 Battery recharge 11 Instrument and control panel 11 Instrument panel connection cable 11 Throttle position sensor 11 INSTALLATION...

Page 18: ...rol panel 14 EMB Electrical power supply 14 ECU temperature 14 Engine compartment vacuum 14 Engine compartment air temperature 14 Fuel temperature 14 Exhaust back pressure 14 Exhaust temperature 14 PANEL WIRING 15 PREVENTIVE MAINTENANCE IN CASE OF PROLONGED ENGINE INACTIVITY 16 ENGINE S FIRST START RESTORING NORMAL OPERATING CONDITIONS 16 ...

Page 19: ...peration 15 Power grid wiring from battery to generator electrical starter motor 16 Fuel tank feed and return pipe The figure shows the set of components of an installation including those supplied as standard or optional items with the engine equipment and those supplied or built by the yard The figure is meant to provide an overall picture of the operations required for engine installation Compo...

Page 20: ...iance should prove impossible Failure to comply with the rules set out below shall void the warranty and exonerate IVECO Aifo from all liabilities Handling The engine shall be handled by experienced personnel using the prescribed tool or an equalizer that will keep the lifting lines parallel and with suitable equipment in terms of load bearing capacity and size The two padeyes provided for lifting...

Page 21: ...phasing operation can be carried out using a procedure that is typical of the marine application and described in the OVERHAUL section of the Technical and Repair Manual use of the tool to rotate the flywheel however will be impossible Securing Securing shall be accomplished by means of elastic blocks able to support the engine s mass and the longitudinal thrust exerted by the propeller shaft when...

Page 22: ...es 114 4 5 Diameter of circumference of distance between 6 locking holes mm inches 150 5 9 Fuel supply Transfer pump delivery at maximum rpm Kg h 88 Flow rate return to tank kg h 12 Fuel temperature to allow maximum power C 78 Inner diameter intake pipe mm 8 Inner diameter return pipe mm 8 Thread on pre filter junctions M 14 x 1 5 Thread on engine junctions inches UIC 1 2 Open sea water cooling li...

Page 23: ... vibration damping elastic junction on each segment Installed pipes shall be CE certified Pre filter The pre filter with priming pump supplied separate from the engine must be adequately fastened in such a way as to enable easily to replace the filtering cartridge and or to operate the pump To avoid introducing impurities in the feeding pipelines inside the engine we recommend not installing filte...

Page 24: ...DO NOT USE wiring belonging to the engine s electrical equipment to supply power to other devices in the boat PLACE engine electrical wiring independently from the other wiring installed on the boat USE of switches or battery disconnects on the EMB power supply line is not allowed EXTREME CARE SHOULD BE PLACED in the polarization of the electrical connections and in the correct coupling of their l...

Page 25: ... pump control E D C M Z Y K9 K7 K6 K5 K8 K1 F7 F5 F2 F1 F8 T F V K P S2 LD1 CNB1 Figure 5 CNA1 E D C M Z P K V F T Y wire board electrical wiring connectors CNAI connection to battery s positive pole CNBI connection to terminal 50 of the electrical starter engine PI push button for emission of EDC error codes LDI indicator light signaling the emission of EDC error codes Location of components on r...

Page 26: ...elay commanded by the voltage of the alter nator s electronic regulator recharge signal Engine electrical ground The engine electrical connection is achieved by connecting with a cable of suitable cross section the negative terminal of the battery to the fastening point of the electrical starter motor as shown in Figure 8 The grounding terminal is secured to the motor proceed ing as follows Comple...

Page 27: ...the Yard must be requested from the IVECO Aifo technical assistance service Connecting cable between the indication panel and the EMB Supplied by IVECO Aifo on request it is available in 3 differ ent lengths 3 meters Drawing 8031150 5 meters Drawing 8031151 7 meters Drawing 8031152 Throttle position sensor After testing the operating condition of the linkage adjust the stroke of servo components s...

Page 28: ...ack to the OFF position Fuel tank suction Check assembly suction at the maximum allowed longitudi nal and transverse inclinations with such a residual quantity in the tank as to cause the reserve indicator light to stay on permanently Verify the absence of air in the fuel feed pipeline using a clear pipe placed in inverted U fashion before the engine inlet Throttle position sensor Verify in the id...

Page 29: ...he engine starts immediately For lower temperatures the elec trical pre lubrication pump is powered for about 10 seconds during which starting is inhibited Once the pre lubrication phase is complete power to the electrical pump is cut off and starting is enabled Thermal switch specifications R at ambient temperature Ω R at tripping temperature 60 C 3 C 0 Ω First start Prepare to re start the engin...

Page 30: ...ue of fuel pressure in the transfer loop must be mea sured from the purge fitting on the cylinder head We rec ommend using a manometer with oil damped needle and end of scale at 5 bar The pressure measured with the engine idling must be about 3 5 bar and tend to rise slightly as engine rpm increases Instrument and control panel Check the operation of all indicator lights simulating the behavior of...

Page 31: ...panel side wiring component code S 1 20515 Female connector for S I connector SICMA 1 5 for 0 35 0 75 mm2 section cable 20410 SICMA 1 5 for 1 00 1 50 mm2 section cable 20380 SICMA 2 8 for 0 35 0 75 mm2 section cable 20415 SICMA 2 8 for 1 00 2 50 mm2 section cable 20415 Through bulkhead panel connector panel mounted component code S 20520 Male terminal for S connector SICMA 1 5 for 0 35 0 75 mm2 se...

Page 32: ...aps or seal with adhesive tape 7 Drain from the oil sump the residual protective oil type 30 M which may be reused for 2 more engine lay ups 8 Apply tags bearing the inscription ENGINE WITHOUT LUBE OIL on the engine and on the panel 9 Drain the cooling liquid if it is not mixed with anticorro sive substances If exterior parts of the engines are to be protected as well spray OVER 19 AR protective l...

Page 33: ...C78 ENT M50 DIAGNOSTICS 1 FEBRUARY 2003 EDITION Diagnostics Pagina ECU BEHAVIOR 3 Fault indicator light 3 Blink code 3 Fault memory reset 3 Recovery 3 BLINK CODE TABLE 4 SECTION 3 ...

Page 34: ...C78 ENT M50 DIAGNOSTICS 2 FEBRUARY 2003 EDITION ...

Page 35: ...and fuse board is pressed and released The LED to the side of the push button and the EDC indicator light on the indications and control panel will simultaneously signal the codes by blinking two series of emissions at different frequency reproducing the digits indi cating the fault with decimal numbering Slow blinking indicates the area of the fault engine injec tors fast blinking indicates a spe...

Page 36: ...ature 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 ...

Page 37: ...C78 ENT M50 5 FEBRUARY 2003 EDITION NOTES ...

Page 38: ...C78 ENT M50 6 FEBRUARY 2003 EDITION NOTES ...

Page 39: ...C78 ENT M50 7 FEBRUARY 2003 EDITION ...

Page 40: ...Iveco Aifo S p A Viale Dell Industria 15 17 20010 Pregnana Milanese MI Italy Tel 39 02 93 51 01 Fax 39 02 93 59 00 29 www iveco com ...