Iveco C78 ENT M50 Service Manual

C78 ENT M50

MARINE ENGINE

INSTALLATION INSTRUCTION

C78 ENT M50

II

FEBRUARY 2003 EDITION

Please read carefully the indications provided in this docu­ment: compliance with them will ensure the engine will con­tinue to run smoothly and reliably, protecting users and ser­vice personnel against the risk of mishaps.

The instructions contained in this document per tain specif­ically to the C78 ENT M50 engine and complement the
IVECO Aifo publication “Marine Engine Installation Manual”,
which should be referred to for all matters not covered
herein.

Any installation not in compliance with the contents of
these instructions, or modifications to the engine and its fit­tings are not admitted.The installing Yard is required to con­duct tests to verify the functional compatibility between the
engine’s electrical-electronic equipment and the other elec­tronic devices present on the boat.

Engineers and installation personnel are reminded of their
obligation to comply with workplace safety rules.

To ready the engine for starting, follow the procedure set
out at the end of Section 2 of this document.

To get the best possible performance out of the engine, it
is mandatory to conform with its intended mission profile.
The engine must not be used for purposes other than those
stated by the manufacturer. IVECO Aifo is willing to exam­ine 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, it is

absolutely mandatory to use only Original IVECO
Parts.

❏ Any tampering, modifications, or use of non-original

parts may jeopardize the safety of service personnel
and boat users.

Spares may be supplied only if the following are indicated:

- Commercial code and serial number of the engine;

- Part number as per spares catalog.

The information provided below refers to engine features
as of the date of publication.The manufacturer 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.

The manufacturer

is not liable for any errors

or omissions.

The IVECO competence and professionalism of the
Customer Service Network is always available to our cus­tomers.

FOREWORD

Publication Edited by:
IVECO Engine Business Unit
C.O. Mkt. Adver tising & Promotion
IVECO Aifo – Pregnana Milanese

Printed L 320.34.011 - Ed. 02/03

C78 ENT M50

III

FEBRUARY 2003 EDITION

SECTION CONTENTS

OVERVIEW 1

INSTALLATION INSTRUCTIONS 2

DIAGNOSTICS 3

C78 ENT M50

IV

FEBRUARY 2003 EDITION

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

C78 ENT M50OVERVIEW

2

FEBRUARY 2003 EDITION

C78 ENT M50 OVERVIEW

3

FEBRUARY 2003 EDITION

IDENTIFYING 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

Istversion tag

II

nd

version tag

1

2

2

3

3

4

4

C78 ENT M50OVERVIEW

4

FEBRUARY 2003 EDITION

The model number is assigned by the manufacturer: it is used to identify the main characteristics of the engine, and to char­acterize its application and power output level.This number is stenciled on 1stversion tag and always stamped on a 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 = 350 HP
D = 300 HP
E = 220 HP
F = 190 HP

VARIANTS TO
BASIC ENGINE
OR CUSTOMER

}
}

duty

pleasure

C78 ENT M50 OVERVIEW

5

FEBRUARY 2003 EDITION

The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the
engines according to their family, origins and intended application.The commercial code, therefore, cannot be used for techni­cal purposes to recognize the engine’s components: this purpose is ser ved 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

VERSION:

TURBO-CHARGER:

1 = COOLED
2 = NOT COOLED

VERSION: Restyling

C78 ENT M50OVERVIEW

6

FEBRUARY 2003 EDITION

Figure 3

C78 ENT M50 ENGINE COMPONENTS

1. Intake air filter - 2. Intake air pressure and temperature sensor - 3. Lubricating oil refill cap - 4. Lifting padeyes - 5. Coolant
level sensor - 6. Coolant tank - 7. Coolant refill cap - 8. Injector solenoid valve connector - 9. Coolant thermostatic valve

10. Alternator location - 11. Coolant-sea water tube bundle heat exchanger - 12. Auxiliary pulley - 13. Sacrificial anodes

14. Sea water intake - 15. Sea water drain plug - 16. Air-sea water heat exchanger - 17. Sea water pump - 18. Electrical starter
motor - 19. Sea water pump gear - 20. Fuel transfer pump - 21. Fuel filter - 22. Filter clogging sensor -

23. Fuel temperature sensor.

23

22

2

5 7

4

4

8

9

10

11

13

17

18

19

20

1416

15

12

21

1

3

6

C78 ENT M50 OVERVIEW

7

FEBRUARY 2003 EDITION

Figure 4

C78 ENT M50 ENGINE COMPONENTS

1. Coolant feed to exhaust manifold - 2. Lubricating oil filters - 3. Lubricating oil dipstick. - 4. Electronic Management Box

5. Lubricating oil intake-exhaust control unit - 6. Cooled exhaust manifold - 7. Turbocharger inlet pipe-fitting - 8.Timing
mechanism and oil vapor filter cover - 9. Location of timing phase sensor - 10. Oil filter clogging indicator - 11. Cooled

turbo-charger - 12. Exhaust gas manifold - 13. Phase and engine shaft rotation sensor location - 14. Waste-gate actuator

15.Timing phase inspection port - 16.Throttle position sensor potentiometer - 17. Oil drain sump plug - 18. Instrument panel,
diagnostics and EMB power supply wiring connectors - 19. Location of electrical pump and oil and pre-lubrication

intake/exhaust solenoid valve - 20. Location of lubricating oil temperature and pressure sensors - 21. Coolant drain plug.

1

21

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

2

C78 ENT M50OVERVIEW

8

FEBRUARY 2003 EDITION

Brake horsepower values in accordance with ISO 3046-1, attainable after about 50 hours of operation under reference envi­ronmental conditions characterized by 750 mmHg, 25°C, 30% relative humidity.Values fall within a tolerance of 5%.

Short range pleasure service (A1)

Type of boat

Pleasure and military boats with planing hull for high speed or semi-planing and displacing pleasure hulls that use maximum
power for short periods alternating with prolonged periods at lower than maximum speed.

Engine utilization

Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 300 hours/year. Definition of calibrations and operating limits for military and government agencies according to contrac­tual specifications.

Nominal maximum power kW (HP) @ rpm 368 (500) @ 2600

Nominal maximum torque Nm (kgm) @ rpm 1500 (153) @ 1600÷2200

Long range pleasure service (A2)

Type of boat

Pleasure and military boats with planing hull for high speed or semi-planing and displacing pleasure hulls that use maximum
power for short periods alternating with prolonged periods at lower than maximum speed.

Engine utilization

Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1000 hours/year. Definition of calibrations and operating limits for military and government agencies according to con­tractual 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 passen­ger boats, high speed patrol boats for police, emergency, rescue, and special operations uses.

Engine utilization

Use of maximum power limited to 10% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1,000 hours/year. Definition of calibrations and operating limits for militar y and government agencies according to con­tractual specifications.

Nominal maximum power kW (HP) @ rpm 294 (400) @ 2600

Nominal maximum torque Nm (kgm) @ rpm 1400 (143) @ 1600÷1800

Intermediate service (C)

Type of boat

Light boats for commercial, military, work and light fishing uses with variable speed. E.g.: patrol boats, pilot boats, light fishing ves­sels, water taxies, medium range seasonal passenger transport, fire-fighting.

Engine utilization

Use of maximum power limited to 25% of the time. Cruising speed at engine rpm < 90% of nominal calibration rpm. Operating
limit: 1,000 ÷ 3,000 hours/year. Definition of calibrations and operating limits for military and government agencies according
to contractual specifications.

Nominal maximum power kW (HP) @ rpm 258 (350) @2600

Nominal maximum torque Nm (kgm) @ rpm 1180 (120) @1600÷2200

PERFORMANCE

C78 ENT M50 OVERVIEW

9

FEBRUARY 2003 EDITION

Fuel economy – Pleasure use (A1)

Specific fuel consumption at maximum power g/kWh (g/HPh) @ rpm ≤ 218 (≤ 160) @ 2600

Specific fuel consumption at maximum torque g/kWh (g/HPh) @ rpm ≤ 200 (≤ 147) @ 1800

Lubricating oil consumption at maximum power g/h @ rpm ≤ 240 @ 2600

Gas Emissions

Compliance with Standard IMO MARPOL 73/78

ADDENDUM DIR. 94/25/EC

Sound Emissions

Maximum value of average level
for engines in basic configuration dB@A (measurement standard) 95 (ISO 3744)

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 (kgm) ≤ 500 (≤ 51)

3-throated Front Pulley + Elastic Joint for Shaft Coupling

Available torque Nm (kgm) ≤ 400 (≤ 40,8)

C78 ENT M50OVERVIEW

10

FEBRUARY 2003 EDITION

Model C 78 ENT M50

Cycle 4-Stroke Diesel
Charge Supercharged and intercooled
Injection Direct

Number of cylinders 6 in line

Bore mm 115

Stroke mm 125

Total displacement cm

3

7790

Compression ratio 16 ± 0,8 : 1

Direction of rotation, flywheel side counterclockwise

Minimum idling rpm rpm 600 ± 25

Maximum engine rpm, no load rpm 2800 ± 25

Engine inclination in continuous operation

Maximum longitudinal angle (static) min / max degrees/360 + 4 / + 10

Maximum longitudinal angle (static + dynamic) degrees/360 + 20

Maximum transverse angle (static + dynamic) degrees/360 ± 22,5

Oil dipstick valid for static inclination degrees/360 ± 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 level liters (kg) 25 (22,7)

Oil pressure, warm engine, minimum idling rpm bar ≥ 1,5

Oil pressure, warm engine, maximum rpm bar ≥ 5

Maximum allowed temperature °C 105

Oil dipstick valid for static inclination degrees/360 ± 10

Fuel supply

Fuel oil compliant with standard EN 590

Low pressure transfer pump gear pump

Flow rate at maximum rpm kg/h 88

Fuel return flow rate to tank kg/h ≤ 12

Filtering: pre filter µm 36,5

Filtering: filter µm 5

GENERAL SPECIFICATIONS

C78 ENT M50 OVERVIEW

11

FEBRUARY 2003 EDITION

Injection system

Type pump - injectors (PDE)

System Bosch EDC MS 6.2

Maximum injection pressure bar 1600

Low temperature starting

Allowed, without external aids, down to °C -15

With electrical heating of intake air (optional), down to °C -25

With additional external heater, down to °C -30

Cooling

Closed coolant loop with sea water heat exchanger 50% mixture of water/Paraflu II or equiv.

Compliant with SAE J 1034 specification

Total coolant quantity liters ~ 40

Engine-only capacity liters ~ 15,5

Expansion tank standard

Forced circulation centrifugal pump

Flow rate at maximum rpm l/h 25200

Temperature regulation with thermostatic valve

Initial opening °C 68 ± 2

Maximum opening °C 78 ± 2

Sea water line forced circulation

Self-priming pump with neoprene impeller

Sea water pump height above sea level m ≤ 2

Max. pump capacity l/h 17500

Exhaust gas expulsion

Optional stack

Optional riser

Electrical system

Nominal voltage V dc 24

Self-regulated alternator:
voltage V dc 29
maximum current intensity A 90

Electrical starter motor:
nominal voltage V dc 24
absorbed electrical power W 4500

Recommended batteries capacity Ah ≥ 120

Current discharge at - 18 °C (SAE J 537) A ≥ 900

Drive train coupling

Flywheel diameter mm (inches) 355 (14)

Flywheel case type SAE 1

Weights

Dry without inver ter Kg 900

C78 ENT M50OVERVIEW

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

C78 ENT M50 INSTALLATION INSTRUCTIONS

1

FEBRUARY 2003 EDITION

SECTION 2

Installation Instructions

Page

INSTALLATION OVERVIEW 3

CAUTIONS 4

❏ Handling cautions 4

❏ Installation cautions 4

❏ Engine’s first start 4

❏ Use and servicing cautions 4

❏ Prolonged engine inactivity 4

DESIGN STANDARDS 5

❏ Accessibility 5

❏ Securing 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 TESTS 12

❏ Lubricating oil fill 12

❏ Fuel tank suction 12

❏ Throttle position sensor 12

❏ Pre-lubrication 12

C78 ENT M50INSTALLATION INSTRUCTIONS

2

FEBRUARY 2003 EDITION

Page

❏ First star t 13

❏ Fuel pressure in fuel supply line 14

❏ Indication and control 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

C78 ENT M50 INSTALLATION INSTRUCTIONS

3

FEBRUARY 2003 EDITION

INSTALLATION OVERVIEW

1. Fuel tank with suction/return assembly. - 2. Electrical system cabinet - 3. Servo-throttle - 4. Instrument panel - 5.Throttle
lever - 6. Engine and ventilation air intake - 7. Batteries - 8. Electronic Management Box (EMB) - 9.Ventilation air exhaust -

10. Sea water suction and decanting filter - 11. Exhaust gas and sea water drain pipe - 12. EMB power supply wiring -

13. Indication and control panel wiring - 14. Linkage for throttle potentiometer operation - 15. Power grid wiring from
battery to generator/electrical star ter 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. Component positions and illustrations are not binding, but merely provided by way of indica­tion, and they depend on the choices made by yard engineers according to their competence, to the spaces and the prescrip­tions set out in the chapter that follows.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Figure 1

81421

C78 ENT M50INSTALLATION INSTRUCTIONS

4

FEBRUARY 2003 EDITION

CAUTIONS

Use and servicing

- When starting the engine the first time, have available
appropriate means to shut off engine air intake in case
of runaway speed rate.

- Never disconnect the batteries electrically when the
engine is running.

- Remove the batteries’ electrical connections before any
operation on the electrical system.

- Ensure that battery terminals comply with the correct
polarity, that they are properly tightened and protected
against any short circuits and corrosion phenomena.

- Do not connect or disconnect electrical connections
on supplied circuits.

- Do not cause any sparks in the attempt to verify the
presence of electrical voltage.

- Do not draw fuel from tanks made of copper alloys
and/or with pipes lacking filtering systems.

- Do not wash the engine and its components with cor­rosive or abrasive detergents, to avoid jeopardizing the
operating condition of the electrical connections.

Prolonged engine inactivity

The end of this section contains a list of the steps for
preparing the engine before long inactivity periods, and for
restoring it to its operating condition.

While an electronically controlled injection system provides
for better engine performance, it also makes it mandatory
for installing and servicing personnel to comply with some
fundamental rules that will surely become the norm as elec­tronic engine control equipment becomes ever more wide­spread.
Boat fitters and servicing personnel are invited to familiar­ize themselves with the notes that follow and to contact
IVECO Aifo personnel whenever compliance 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 the engine alone shall
always be used simultaneously.

Installation

- Use of switches or battery disconnects on the EMB
power supply line is not allowed.

- Do not modify wiring; wire length cannot be changed.

- Use only electronic device wiring compliant with the
IVECO standard, in terms of length, conductor type,
location, clamping, shielding and grounding braids con­nection.

- To avoid any interference, the wiring for devices other
than engine electronic systems must follow different
paths.

- Do not connect any extraneous device to the engine
electrical equipment.

- Do not provide electrical voltage to the boat’s system
before first verifying that there are no short circuits.

- Do not insert pipes for drawing fuel from the engine
fuel supply pipelines.

- Do not make any modification to the engine’s
hydraulic circuits and components.

- Do not perform any electric arc welding operations
without first removing the electronic units from the
seat, placing them at a suitable distance for safety.

- Do not subject electronic units to temperatures
exceeding 80 °C.

- Do not paint electrical components and connections.

- Do not alter the data contained in the engine control
unit.

- Tighten threaded elements according to the prescri­bed procedures and torque values.

Engine’s first start

Follow the procedure set out in the paragraph entitled
"Engine’s first start / Restoring normal operating conditions"
at the end of this section.

C78 ENT M50 INSTALLATION INSTRUCTIONS

5

FEBRUARY 2003 EDITION

DESIGN STANDARDS

Starting aid

When the engine is to be used at temperatures lower than

-15 °C, an electrical grid heater is installed. 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 and
connection to the power supply grid.
For use at temperatures lower than -25 °C, adoption of an
auxiliary preheating system is recommended.

1. Specific junction pipe

2. Electrical grid heater

3. Power relay

(1) The EDC electronic engine control is programmed to
reduce maximum power output whenever the operating
parameters measured by the sensors indicate that critical
conditions have been reached which, if exceeded, would
lead to the risk of damaging the engine.

Accessibility

The engine shall be located in such a way as to allow to refill
and drain engine fluids as required by servicing ope-rations
and to provide, even when underway, for easy access to
electrical fuses and to the diagnostics push-buttons within
the EMB.
Note that the lower part of the flywheel case has an inspec­tion port, useful when phasing the engine references of the
injection systems, and a window flanked with threaded
holes, needed for fastening the “flywheel rotator” tool. If
raised limber boards are installed in the engine room, these
provisions may no longer be accessible to servicing person­nel. In this case, the 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 in motion.
Dimension and fastening information is provided in the
“Installation Diagram”.

Engine intake and ventilation Air

Compliance with prescriptions on the quantity of air neces­sary for combustion and ventilation assures regular engine
operation even under adverse conditions and allows the
engine to reach its maximum design power output. (1)

Sea water pipeline

It shall be provided with an inlet suitable for preventing
extraneous bodies from entering the intake pipe. Between
the inlet and the pump it is advisable to place a gate, to be
closed in case of emergency or for extended stops, and a
filter to hold the smaller impurities; it is also advisable to
install a suitably sized, easily replaced zinc anode.
The engine sea water pipeline is fitted by the manufacturer
with protective anodes to be replaced periodically (see
“OVERVIEW” section).
The rubber hoses positioned along the pipeline shall be suf­ficiently rigid to avoid creating choke points due to pinching.
(1)

Engine pre-heating

In case of usage requiring maximum power output immedi­ately, installation of an auxiliary pre-heater on the closed
cooling loop is recommended.

Exhaust gas

The exhaust fume discharge pipeline shall be positioned in
compliance with the indications contained in the IVECO
Aifo Publication “Marine Engine Installation Manual”, which
also provides indications to design the exhaust pipeline.

Figure 2

1

2

3

➩

80829

C78 ENT M50INSTALLATION INSTRUCTIONS

6

FEBRUARY 2003 EDITION

TECHNICAL DATA FOR INSTALLATION

Engine intake and ventilation air when underway

Static vacuum allowed downstream of the air filter kPa ≤ 3

mmH2O ≤ 300

Engine air intake flow rate m3/h ≥ 1785

Engine room ventilation air flow rate m3/h ≥ 9000

Static vacuum allowed in the engine room kPa ≤ 0,1

mmH

2

O ≤ 10

Temperature allowed in the engine room °C ≤ 50

Exhaust gas discharge

Optimum static back pressure kPa ≤ 7

mmH2O ≤ 700

Allowed static back pressure kPa ≤ 10

mmH2O ≤ 1000

Temperature at maximum power °C 480

Flow rate at maximum power Kg/h 1900

Riser outer diameter mm (inches) 153 (6)

Dry exhaust outer diameter mm (inches) 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 line

Intake pipeline diameter mm (inches) 60 (2,36)

Pump delivery at maximum rpm l/h 17500

Sea water pump height above sea level m ≤ 2

Allowed intake vacuum kPa 20

mmH

2

O 2000

Discharge pipeline diameter mm (inches) 50 (2)

Inverter oil heat exchanger

thread on engine junctions inches UIC 1/2

Angle of inclination of the engine under continuous operation conditions

Longitudinal (static + dynamic) degrees/360 ≤ 25

Starboard side or port side (static + dynamic) degrees/360 ≤ 22,5

C78 ENT M50 INSTALLATION INSTRUCTIONS

7

FEBRUARY 2003 EDITION

FUEL LINE

charges. The tank shall be provided with a vent to prevent
internal pressure from exceeding ± 5kPa (± 0.5 mmH2O).
Fuel tank and suction assembly shall be so shaped as to
assure suction even at the maximum longitudinal and trans­verse inclination allowed for the boat, with a residual quan­tity of fuel oil considered “reser ves”.
It is recommended to obtain a residual capacity on the bot­tom of the tank, where the intake inlet should be posi­tioned, and to use a Venturi inlet cup to prevent the entry
of sludge.The return flow must take place in such a way as
to favor the mixing of returning fuel oil with the fuel oil in
the tank.
Use of metallic pipes, except those made of copper or its
alloys, shall entail connecting each individual segment to the
engine ground or battery negative terminal to prevent the
accumulation of electrostatic discharges, and inserting a
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 filtering car­tridges previously filled with fuel in the system.

Material Characteristics

The fuel tank, the suction and return assembly and the feed
pipes shall withstand the continuous abrasion caused by a
90 l/h flow of fuel oil at a temperature of 80 °C without
noticeable warping, wear, or release of material.
Use of metallic materials, though not copper alloys, is
allowed provided they are connected to the battery’s neg­ative terminal to avoid the accumulation of electrostatic dis-

1. From the tank - 2. Sensor for detecting the presence of water in the filter - 3. Decanting filter - 4.Priming pump -

5. Fuel inlet junction - 6. Fuel return junction to tank - 7. Gear pump - 8. Junctions for inverter oil heat exchanger.

Figure 3

3

1

8

7

2

6

5

4

81795

C78 ENT M50INSTALLATION INSTRUCTIONS

8

FEBRUARY 2003 EDITION

ELECTRICAL CIRCUIT

Electrically insulate the container, if secured to a metal bulk­head, to avoid the onset of parasite currents, and connect it
to the negative terminal of the battery. The position must
allow for easy access to the fuses and the diagnosing push­buttons contained in it, even when underway. No modifica­tion is allowed to the wiring.

EMB (Electronic Management Box)

This is the housing for the electrical and electronic units
managing and controlling the engine’s operation. It is sup­plied fastened to the engine in such a position as to allow
for an easy access to the electrical components. If it is nec­essary to position it differently, fasten it in the vertical posi­tion with the wire bundles to the engine projecting down­wards and at such a distance that no modifications to the
engine wiring are required.

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

locking elements.

1. EDC system electronic control unit - 2. ECU B connector - 3. Pre-lubrication control unit - 4. Electrical pre-lubrication
pump intake/exhaust enabling control - 5. Pre-lubrication/engine oil replacement solenoid valve enabling control -

6. G connector for instrument panel wiring - 7. Fitting for negative polarity – electrical ground connections - 8. Q connector
for diagnostic instrument connection - 9. H connector for power supply grid wiring - 10. Grid heater relay - 11. Alternator

excitation resistor - 12. Engine electrical wiring and throttle potentiometer - 13. Location of blink-code push-button and

indicator light - 14. Relay and fuse box - 15. ECU A connector.

Figure 4

1 2

3 4

5

6

7

8

9

10

11

12

13

14

15

81422

C78 ENT M50 INSTALLATION INSTRUCTIONS

9

FEBRUARY 2003 EDITION

Fuses

F1 EDC power supply
F2 alternator recharge indication circuit
F3 not used
F4 not used
F5 intercooler bypass
F6 not used
F7 master power supply
F8 electrical oil pump
F9 not used

Relays

K1 EDC main
K2 not used
K3 not used
K4 not used
K5 intercooler bypass control
K6 key switch discharge
K7 engine shut down
K8 starter control
K9 pre-lubricating oil pump control

E

D

C

M

Z

Y

K9

K7

K6

K5

K8

K1

F7

F5

F2

F1

F8

T

F

VKP

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 relay and fuse board

81423

CAUTION

If magneto-thermal protection and intervention devices are interposed, they must not be used to shut the engine down or
otherwise used just a few seconds after shutting the engine down.

C78 ENT M50INSTALLATION INSTRUCTIONS

10

FEBRUARY 2003 EDITION

Power grid

This provides electrical power to the EMB and the electri­cal starter motor and allows the alternator to recharge the
batteries. The EMB is connected to the batteries by means
of a wire bundle led to the H connector. The yard shall use
conductors with a cross section of at least 6 mm2 taking
care to connect both conductors set to positive polarity to
the + terminal of the battery.
Connection of the positive +30 of the electrical starter
motor to the positive terminal of the battery allows to
obtain, as shown in the figure, the simultaneous connection
of the alternator.
To have a sufficient quantity of energy available when start­ing the engine, we recommend installing two series of ded­icated batteries separately, the first for starting the engine
and powering the injection system, the second one for on­board electrical machinery. The batter y used to power the
machinery may be recharged by interposing on the power
supply line a relay commanded by the voltage of the alter­nator’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 proceed­ing as follows:

❏ Completely remove the conducting paint or the old

conducting paint from both parts constituting the con­nection, either with mechanical means or with a suit­able chemical product; if par ts whose surface has been
treated need to be used for the securing operation, first

completely remove the anaphoretic paint by
mechanical means, obtaining a smooth support
plane;

❏ Apply a uniform layer of the BH44D product (IVECO

Standard 18-1705) with a brush or spray gun;

❏ Join the parts constituting the ground node within 5

minutes after applying the product.

Figure 8

POWER GRID DIAGRAM

1. H Connector.

ENGINE ELECTRICAL GROUND

CONNECTION POINT

70 mm

2

10 mm

2

6 mm

2

6 mm

2

6 mm

2

70 mm

2

H CONNECTOR

1. EMB Power supply (positive) - 2. Grid heater power
supply (positive) - 3. EMB power supply (negative).

3

1

2

81424

81425

81789

Figure 6

Figure 7

1

C78 ENT M50 INSTALLATION INSTRUCTIONS

11

FEBRUARY 2003 EDITION

Battery recharge

The electronic regulator of the alternator supplied with the
engine can effectively control battery recharge through the S
terminal of the three-pole connector.
For reasons related to the test bench testing phase, this ter­minal’s line is connected to the positive polarity of the elec­trical system, meeting the need to control the recharge of
batteries located near the engine.
If different installation needs require to connect the batteries
far from the engine, we recommend changing this connec­tion, cabling the line relating to the S terminal of the alterna­tor directly to the positive terminal of the battery.

Instrument and control panel

Supplied on request by IVECO Aifo, this is connected to the
EMB with three different lengths of wiring as indicated in the
item that follows.
Technical information and data for the manufacture of pan­els by 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 differ­ent 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 so that:

❏ With the throttle at idle, the potentiometer rod is in the

resting position and the safety switch inside is electrical­ly open.
The test must be conducted with an ohmmeter
between the points D and E of the potentiometer con­nector.
With readings of:
∞Ω= optimal adjustment
1 KΩ = the resting position requires better mechanical
adjustment, to bring the value back to ∞Ω

❏ With the throttle at the maximum rpm stop, the rod of

the potentiometer is in the maximum travel position.

Technical notes for Yard wiring are provided at the end of
this section.

Figure 9

CONNECTIONS TO THE REGULATOR

EMB TO PANEL CONNECTING CABLE

TESTING POTENTIOMETER

ROD TRAVEL

Connect to positive
terminal of the battery

Figure 10

Figure 11

81790

81792

81791B

C78 ENT M50INSTALLATION INSTRUCTIONS

12

FEBRUARY 2003 EDITION

“Common sense” tests, such as exposing heat-sensitive parts
to heat (plastic, wiring, electronic units, etc.….), and those
that for years have characterized the quality of the work per­formed in yards, are not mentioned herein, although they are
of the utmost importance.

Tests to verify the engine’s and the electronic control system
components’ operating condition can be performed quickly
and with top reliability using specific diagnostic tools, available
to the IVECO Aifo Technical Assistance Centers.

Lubricating oil fill

Lubricating oil transfer operations are simplified by the pres­ence of an electrical control system. Manual controls for
transfer and pre-lubrication operations are positioned on the
unit above the EMB. For safety reasons, controls are enabled
only with the key switch in the “OFF” position

Sequence

1. Place the stable switch in the “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 intake/exhaust push-button to complete the
desired operation.

3. Place the stable switch back to the “OFF” position.

Fuel tank suction

Check assembly suction at the maximum allowed longitudi­nal 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 idling and maximum rpm positions, the correla­tion between the throttle on the bridge and the sensor rod,
noting:

❏ Whether, with the lever in the idle position, the switch in

the sensor is electrically open.

❏ Whether in the maximum rpm position the sensor rod

reaches the mechanical end stop.

Pre-lubrication

The task of pre-lubricating the engine’s internal components
is managed and controlled by an electronic circuit of the
EMB; the operation can also be conducted by acting manu­ally, with the key switch in the “OFF” position, only on the oil
intake/exhaust push-button positioned on the related unit. If
the push-button is placed for a few seconds in the
“EXHAUST” position, the filters and the internal engine
ducts will be filled.

INSTALLATION TESTS

1

2

ELECTRICAL LUBRICATING PUMP CONTROLS

1. Oil intake/exhaust control.

2. Switching solenoid valve control.

PRE-LUBRICATION SYSTEM

1. One way valve - 2. Switching solenoid valve

3. Electrical pump.

Figure 13

2

3

Figure 12

81422

80836

1

C78 ENT M50 INSTALLATION INSTRUCTIONS

13

FEBRUARY 2003 EDITION

Depending on the manufacturing date, the operating logic
for the electronic control may be of two different kinds:

The version manufactured until March 2002 depends on a
pressure contact inserted in the lubrication circuit at the out­let of the oil filter assembly, identified in the engine wiring by
the J30 connector.
When the key switch is placed and kept in the “START” posi­tion, the electrical pre-lubricating pump is powered until the
pressure measured reaches about 0.5 bar or for a time inter­val of up to 10 seconds, during which engine star ting is inhib­ited. Once these phases are completed, the electrical pump
is disabled and engine starting is enabled.

Pressure contact specifications

- R at ambient pressure (0 bar) = 0 Ω

- R at tripping pressure (≥ 0,3 ± 0,15 bar) = ∞Ω

In the version manufactured starting in April 2002, the pres­sure switch is replaced by a thermal switch placed to mea­sure the temperature of the liquid in the closed cooling loop
identified in the wiring from the same connector J30. If the
key switch is placed and held in the “START” position, when
the temperature measured by the sensor is ≥ 60°C, the
engine starts immediately. For lower temperatures, the elec­trical 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 engine as set out in the paragraph
entitled “Engine’s first star t / Restoring normal operating con­ditions” at the end of this section.
Before starting the engine the first time, it is necessary to
completely purge the air from the fuel supply line, acting on
the hand pump of the pre-filter or with the aid of a dedicat­ed electrical pump. Purge valves are provided on the pre-fil­ter supplied by IVECO Aifo, downstream of the main filter
and on the cylinder head near the injectors’ electrical con­nector.
During the first steps of the engine star t, complete the oper­ation from the fitting on the cylinder head.

CAUTION

Carefully prevent the fuel from coming in contact with the
auxiliaries drive belt.

Also check that:
❏ There are no water leaks from the connecting hoses

of the cooling loop pipes.

❏ There are no exhaust gas leaks inside the hull.

PRE-LUBRICATION SYSTEM SENSORS

1. Pressure switch - 2. Thermal switch location.

PURGE FITTING ON CYLINDER HEAD

1

2

Figure 14

Figure 15

81793

81419

C78 ENT M50INSTALLATION INSTRUCTIONS

14

FEBRUARY 2003 EDITION

EMB electrical power

Verify whether the power supply voltage to the H connec­tor, with the engine idling, is no more than 0.4 V smaller than
the battery voltage measured during the test.
Shut the engine down, placing the key in the OFF position,
and test whether the relay K 1 that powers the electronic
engine control unit is de-energized after 2 ÷ 7 seconds

ECU temperature

Check whether the temperature of the surface of the ele­ctronic engine control unit, after 30 minutes with the engine
at maximum power output, is less than +80 °C.

Engine compartment vacuum

Verify that ambient pressure in the engine room, with the
engine at full load and maximum power output, complies
with the technical data set out herein.

Engine compartment air temperature

Verify that temperature in the engine room, after 30 minutes
underway with the engine at maximum power output, does
not exceed 50°C, or +15°C over outside temperature.

Fuel temperature

Verify that temperature of the fuel in the transfer line, while
underway at maximum power output and with a stable
quantity of fuel in reserve does not exceed 80°C. A higher
value would lead to a reduction in engine performance due
to the safety strategies built in the electronic control unit. If
the fuel tends to reach the maximum allowed temperature,
install a heat exchanger for the fuel.

Exhaust back-pressure

Verify that the back pressure at the inlet of the exhaust gas
duct, with the engine at full load and maximum power out­put, complies with the technical data set out herein.

Exhaust temperature

Verify that the temperature of the exhaust gas under
maximum power conditions is close to the prescribed value.

Fuel pressure in fuel supply line

The value of fuel pressure in the transfer loop must be mea­sured from the purge fitting on the cylinder head. We rec­ommend 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 the sensors connected to them. To reset any
errors that may be stored in the engine electronic control
unit, proceed as follows:

1. Shut the engine down, rotating the key switch to the
“OFF” position.

2. While holding down the diagnosing push-button in the
EMB, rotate the key switch to the “ON” position and
keep the diagnosing push-button down for at least 5
seconds

3. Release the push-button and rotate the key switch back
to the “OFF” position.

At the end of this procedure, the codes of any faults detect­ed during engine installation operations will be dele-ted from
the ECU.To make sure that no fault data remains stored in
it, and also that there are no additional faults in the system,
proceed as follows:

1. Rotate the key switch to the “ON” position.

2. Press the diagnosing push-button making sure that, after
it briefly lights up as a test, the flashing code indicator
light remains off.

If the ECU detects the presence of errors or operating
anomalies, the indicator light will emit the code of the first
stored error with two series of flashes of different frequen­cy; after a few seconds have elapsed from the end of the
emission, the codes of any subsequent errors will be emitted
if the push-button is pressed again.The repetition of the first
of the emitted code will indicate that all information con­tained in the memory have been emitted.
Such an event will require a review of the installation, in
order to remove the cause of the error or of the anomaly.
The table containing the explanation of each code is
provided in the “DIAGNOSTICS” section.

C78 ENT M50 INSTALLATION INSTRUCTIONS

15

FEBRUARY 2003 EDITION

ON-BOARD PANEL WIRING COMPONENTS

Function AMP Code

®

CPC removable wiring connector EMB side – Component code 182923/1

Female terminal for G 1 terminal type III + 163082/1

CPC panel connector mounted on EMB – component code G 182918/1

Male terminal for G type III + connector 163084/1

Cable holder for G 1 connector 182652/1

Removable through-bulkhead connector for panel side wiring – component code S 1 20515

Female connector for S I connector

SICMA 1,5 for 0,35 ÷ 0,75 mm

2

section cable 20410

SICMA 1,5 for 1,00 ÷ 1,50 mm

2

section cable 20380
SICMA 2,8 for 0,35 ÷ 0,75 mm2section cable 20415
SICMA 2,8 for 1,00 ÷ 2,50 mm

2

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 mm

2

section cable 20420
SICMA 1,5 for 1,00 ÷ 1,50 mm

2

section cable 20425
SICMA 2,8 for 0,35 ÷ 0,75 mm2section cable 20430
SICMA 2,8 for 1,00 ÷ 2,50 mm2section cable 20435

Extractor for G – G1 terminals 150807

Figure 16

81794B

81794A

C78 ENT M50INSTALLATION INSTRUCTIONS

16

FEBRUARY 2003 EDITION

PREVENTIVE MAINTENANCE IN CASE
OF PROLONGED ENGINE INACTIVITY

ENGINE’S FIRST START / RESTORING
NORMAL OPERATING CONDITIONS

To prevent oxidation to the inner parts of the engine and
some components of the injection system, if periods of inac­tivity exceeding two months are expected, the engine must
be prepared every six months by proceeding as follows:

1. Drain the lubricating oil from the sump, after heating the
engine.

2. Fill the engine with protective oil type 30/M (or MIL
2160B type 2) up to the “minimum” level indicated on
the dipstick.
Start the engine and let it run for about 5 minutes.

3. Drain the fuel from the injection line, from the filter and
from the ducts in the cylinder heads.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. See “First star t” paragraph at page 13 in this
section.

4. Connect the fuel line with a tank containing CFB pro­tective liquid (ISO 4113) and let the liquid enter the by
pressurizing the line and turning the engine over for
about 2 minutes, after excluding the operation of the
injection system. The required operation can be com­pleted by directly polarizing the terminal 50 of the elec­tric starter motor with 24V positive voltage, by means of
a conductor prepared for the occasion.

5. Nebulize about 80 g (10 g per liter of displacement) of
protective oil type 30/M into the intake mouth of the
turbocharger, while turning the engine over as described
in the previous paragraph.

6. Close all the engine’s intake, exhaust, aeration and vent
ports with appropriate caps 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 anticorro­sive substances.

If exterior parts of the engines are to be protected as well,
spray OVER 19 AR protective liquid on unpainted metal
parts, such as flywheel, pulleys and others, taking care not to
spray it on belts, connecting cables and electrical equipment.

1. Drain the residual protective oil type 30/M from the
sump.

2. Pour lubricating oil into the engine, as provided by the
specifications and in the quantities set out in the Table of
Refills.

3. Drain the CFB protective liquid from the fuel line, com­pleting the operations set out in item 3 of “PREVENTIVE
MAINTENANCE IN CASE OF PROLONGED
ENGINE INACTIVITY”.

4. Remove the caps and/or the seals from the engine’s
intake, exhaust, aeration and vent ports, restoring nor­mal operating conditions. Connect the turbocharger
intake to the air filter.

5. Attach the fuel lines to the vessel’s fuel tank, completing
the operations set out in item 4 of “PREVENTIVE
MAINTENANCE IN CASE OF PROLONGED
ENGINE INACTIVITY”. During the filling operations,
attach the fuel tank return pipe to a collecting container
to prevent residues of CFB protective liquid from flow­ing into the vessel’s fuel tank.

6. Verifiy the quantity of cooling liquid and refill as provid­ed by the specifications.

7. Start the engine and keep it running until idling speed
has completely stabilized.

8. Shut the engine down and delete the “errors” which
may have been stored in the injection system ECU dur­ing the operation stabilization phases. For reset opera­tion, see “Blink code” paragraph at page 3 in the next
section.

9. Remove the tags with the inscription “ENGINE WITH­OUT LUBE OIL” from the engine and from the panel.

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

C78 ENT M50DIAGNOSTICS

2

FEBRUARY 2003 EDITION

C78 ENT M50 DIAGNOSTICS

3

FEBRUARY 2003 EDITION

Recovery

Associated to the detection of significant or severe faults,
the ECU adopts strategies that, to allow safe use of the
engine, limit some injection parameters within pre-set
thresholds according to the severity of the situation.

As a result of these strategies, the engine’s maximum power
output is reduced. In case of intermittent faults, i.e. faults
that are detected by the ECU and subsequently are no
longer present, performance reduction will be active until
the engine is shut down.

Normal operation will be restored only at the subsequent
start-up, while the fault data will be “saved” in the fault
memory.

Fault Indicator Light

The ECU continuously monitors its own operating condi­tions as well as those of the components connected to it
and of the engine itself, with complex self-diagnostics rou­tines. If faults are detected, the fault indicator light on the
indications and control panel is lit in ways that provide an
initial indication of the severity of the problem.

Light off: no fault detected or minor fault that does

not compromise operating safety.

Light on: significant fault, allowing to proceed to a diag-

nostics center.

Blinking light: severe fault, requiring immediate servicing.

If circumstances allow shutting the engine
down.

Blink code

The emission of the fault codes detected by the self-diag­nostics routines and stored in the ECU starts after the
push-button located on the relay and fuse board is pressed
and released. The LED to the side of the push-button and
the EDC indicator light on the indications and control panel
will simultaneously signal the codes by blinking two series of
emissions at different frequency, reproducing the digits indi­cating the fault with decimal numbering.

Slow blinking indicates the area of the fault (engine, injec­tors, …), fast blinking indicates a specific fault.

Every time the push-button is pressed and released, only
one of the stored codes is emitted; therefore, the proce­dure needs to be repeated until the system emits the same
error data as the first one: this will mean that the entire fault
memory has been analyzed.

If no anomalies are stored, the light comes on when the
push-button is pressed and comes off about 1 second after
it is released, without blinking.

Note:The blink code diagnostic procedure provides indica­tions about faults that are currently present but also about
other faults, which arose in the past and are no longer pre­sent at the time of the diagnostic procedure.Therefore, it is
absolutely necessary, at the end of each ser vicing operation,
to reset the error memory to prevent the system from sig­naling faults, in the future, whose cause has already been
removed.

Fault memory reset

In current applications, the reset operation is carried out
keeping the blink code push-button pressed down with the
key switch in the OFF position and keeping it pressed for 5
more seconds are setting the switch to ON. Confirmation
of the reset will be obtained by turning the key switch from
OFF to ON and requesting blink codes again: at that point,
no codes should be produced.

ECU BEHAVIOR

C78 ENT M50DIAGNOSTICS

4

FEBRUARY 2003 EDITION

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

BLINK CODE TABLE

C78 ENT M50

5

FEBRUARY 2003 EDITION

NOTES

C78 ENT M50

6

FEBRUARY 2003 EDITION

NOTES

C78 ENT M50

7

FEBRUARY 2003 EDITION

Iveco Aifo S.p.A.
Viale Dell’Industria, 15/17

20010 Pregnana Milanese - MI - (Italy)
Tel. [phone] - Fax [phone]

www.iveco.com