Iveco N60 ENT M37 Service Manual

TECHNOLOGICAL EXCELLENCE
NEF
N60 ENT M37
6 CYLINDERS IN LINE
DIESEL CYCLE
FOR MARINE APPLICATIONS
INSTALLATION DIRECTIVE
FOREWORD
We strongly recommend that you carefully read the indica­tions contained in this document: compliance with them pro­tects the engine against irregular operation and assures its reliability, safeguarding sea-going and maintenance personnel against accident hazards. The indications contained in this directive pertain to the N60 ENT M37 engine 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 necessar y condi­tion 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 par ts, you must indicate:
- Commercial code, serial number and indications shown on the engine tag;
- Part number of the spare as per spare par t catalog.
The information provided below refer to engine characteris­tics 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 P3D64N001 E - March 2004 Edition
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
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 20
10. SECONDARY ANALOG INSTRUMENT PANEL 24
11. DRILLING PLANS FOR ANALOG PANELS 25
12. MAIN DIGITAL INSTRUMENT PANEL 26
13. SECONDARY DIGITAL INSTRUMENT PANEL 32
14. DRILLING PLAN FOR DIGITAL PANELS 33
15. CUSTOMIZED INSTRUMENT PANEL 34
16. SENSORS FOR DETECTION AND PANEL SIGNALING 36
17. PREPARING THE ENGINE FOR FIRST START-UP 38
18. TESTS BEFORE THE FIRST START-UP 38
19. FIRST ENGINE START 39
20. EDC ANOMALIES INDICATION 40
21. BLINK CODE TABLE 41
22. UNDERWAY CHECKS 43
23. PREPARING THE ENGINE FOR LONG IDLE PERIODS 44
24. WIRING DIAGRAMS 45
N60 ENT M37INSTALLATION DIRECTIVE
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MARCH 2004
To obtain the best engine performance, it is essential not to deviate from the mission profile for which it was produced and set up.The engine must not be used for purposes other than those stated by the manufacturer. IVECO MOTORS is willing to examine any need for par ticular installations beforehand. Use of an electronically controlled injection sys­tem, in providing the engine with performance benefits, requires that the installer and maintenance specialist comply with some fundamental rules, which will become more and more commonplace as use of such equipment becomes progressively more widespread. Boat outfitters and mainte­nance specialists are invited to closely follow the instructions contained herein. No modifications to the engine, its acces­sories and components, are allowed.
Failure to comply with the instructions that follow shall void the warranty and relieve IVECO MOTORS of all lia­bilities.
For personnel safety
Specialists and installers are cautioned to comply with workplace safety rules and to adopt prescribed individual protection devices when working.
Drain the cooling, lubrication and fuel lines only after the
fluids have duly cooled.The pressurized cap of the water line may be opened only after the engine has duly cooled.
Batteries contain a highly corrosive sulfuric acid solution:
must never be upset and must be handled with the utmost caution to prevent spillage. Ensure that the bat­tery compartment is adequately ventilated.
Handling
The engine must be handled by experienced personnel, using the prescribed tool or a rocker arm that keeps the lift­ing lines parallel and with adequate equipment in terms of capacity and size. The two eyebolts provided for lifting the engine alone must always be used simultaneously.
Installation
Knife switches or battery breakers may be used on the
power supply line of the engine electronic unit, provided they are not used to shut the engine off.
Do not modify the wiring harnesses; their length may
not be modified: use only available extensions.
Do not use electronic device wiring harnesses not com-
pliant with the IVECO MOTORS directive, in terms of length, type of conductor, location, clamping, connection of the shielding and earth braids.
To avoid any interference, the wiring harnesses of the
different on-board electronic devices must follow differ­ent paths from those of the engine electronic systems.
Do not connect any extraneous user device to the
engine electrical equipment.
Do not place voltage across the boat’s on-board electri-
cal system without first verifying that there are no short circuits.
Do not branch pipes off to draw fuel from the engine
supply lines.
Do not make any change to the engine’s hydraulic cir-
cuits and components.
Do not execute arc welding operations before remov-
ing the electronic units from their seating, placing them at an adequate safety distance.
Do not subject electronic units to temperatures exceed-
ing 80 °C.
Do not paint electrical components and their connec-
tions.
Do not alter the data contained in the engine control
electronic unit.
Comply with prescribed procedures and torque values
when tightening threaded elements.
Start-up
Ready the engine following the procedure set out in
Chapter 17.
When star ting the engine the first time, have suitable
means available to cut off air intake in case of a runaway condition.
Start the engine after ensuring that it is complete with
every par t specified by the manufacturer and required by the installation, without attempting to start it with caps and occlusions to the lubrication, cooling and fuel feed lines.
Check that the fluid lines are perfectly sealed, especially
lines for fuels and lubricants, which may cause fires and consequent harm to persons and equipment.
Make sure that the various pipelines are not in contact
with warm surfaces or moving par ts.
The installing yard is required to carr y out tests to veri-
fy the functional compatibility between the electrical­electronic equipment of the engine and the other elec­tronic equipment present on the boat.
Tests and tuning up
Never disconnect the batteries when the engine is
running.
Remove the electrical connections from the batteries
before any operation on the electrical system.
Ensure that the battery terminals comply with the exact
polarity, are properly tightened and protected against accidental short circuits and corrosion phenomena.
Do not connect or disconnect electrical connections
when electrical power supply is present.
Do not cause sparks in the attempt to verify the pres-
ence of electrical voltage.
Do not draw fuel through unfiltered lines.
Do not clean the engine and its parts with corrosive or
abrasive detergent substances, to avoid compromising the integrity of electrical connections.
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
1. WARNINGS AND CAUTIONS
The engine fluids and air, water, 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.
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MARCH 2004
2. ENGINE PARTS AND COMPONENTS
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MARCH 2004
Figure 1
1. Engine coolant discharge cap - 2. Electric starter motor - 3. Tube bundle engine coolant/sea water heat exchanger -
4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea water discharge pipeline -
7. Cap for engine coolant outlet to sanitary water heating system - 8. Lifting eyebolts - 9. Rocker arm cover - 10. Oil refill cap
- 11. Coolant refill cap - 12. Location of thermostatic valve - 13. Engine coolant tank - 14. Auxiliar y belt automatic tensioner -
15. Alternator - 16. Cap for engine coolant discharge and recirculation from sanitary water heating system - 17. Oil filter.
17
16
2
3
4
5
6
9 10 11
8
12
13
15 14
1
04_006_N
7
N60 ENT M37INSTALLATION DIRECTIVE
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Figure 2
1. Combustion air filter - 2. Common rail high pressure injection pump -3. Fuel filter - 4. Sea water pump - 5. Sea water inlet -
6.Throttle potentiometer - 7. Sacrificial anode - 8. Oil vapor separator - 9. Combustion air-sea water heat exchanger -
10. Location of sea water discharge cap - 11. Manual lubricating oil extraction pump - 12. Combustion air pressure and
temperature sensor - 13. Oil dipstick - 14. Common rail distributor - 15. Air filter clogging sensor - 16. Cooled turbocharger -
17. Sea water junction pipe from after-cooler to engine coolant/sea water heat exchanger.
1234
9
10
11
12 14 15 16
7
8
13
17
5
6
04_007_N
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
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.
3. INSTALLATION OVERVIEW
1. Indicator and control panel - 2. Electrical panel with relay box and EDC electronic unit - 3. Exhaust gas and sea water
discharge - 4. Filtered sea water intake - 5. Decanter filter - 6. Fuel feed pipe to the high pressure pump - 7. Fuel return pipe
to tank - 8. Fuel suction pipe - 9. Tank - 10.Throttle Bowden rod - 11.Throttle lever.
Figure 3
11
1 2
456789
3
10
04_071_N
4. GENERAL INSTALLATION CRITERIA
Accessibility
The engine must be located in such a way as to allow filling and draining engine liquids when doing ser vicing operations. Moreover, the relay box and the diagnostic push-button pre­sent on it must be accessible, also when underway.
Anchoring
If anchoring is accomplished by interposing shock mounts, they must be able to support the engine’s mass and the lon­gitudinal thrust exerted by the propeller shaft in motion. 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 suffi­ciently 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.
Exhaust gas discharge
The exhaust gas discharge conduit shall be compliant with the guidelines contained in the IVECO MOTORS publication “Guide to the installation of marine engines”; it also provides indications to compute the dimensions of the exhaust pipelines, which is the Yard’s responsibility.
Electric - electronic equipment
Provide a suitable arrangement of the engine control elec­tronic unit, of the relay box and of the possible optional elec­tronic units, referring to the dimensions and position of the wire harnesses and their connectors. Both units must be anchored in such a way as to dampen the vibrations and stresses undergone by the hull while under­way and/or induced by the engine’s operation.
(1) The EDC engine electronic control is programmed to
reduce maximum deliverable power if the operating parameters measured by the sensors show that critical conditions have been reached, and if exceeded the engine could be damaged.
N60 ENT M37INSTALLATION DIRECTIVE
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MARCH 2004
5. TECHNICAL DATA FOR INSTALLATION
Combustion and ventilation air when underway
Static vacuum allowed downstream of the air filter kPa 3,5
mmH2O 350
Combustion air flow rate m3/h 1050
Engine room ventilation air flow rate (excluding combustion air) m3/h 4700
Static vacuum allowed in the engine room kPa 0,1
mmH2O 10
Temperature allowed in the engine room °C 50
Temperature increase in the engine room to ext. temperature °C 15
Exhaust gas discharge
Allowed static back pressure kPa 10
mmH2O 1000
Exhaust gas temperature at maximum power (turbocharger inlet) °C 640 ± 25
Flow rate at maximum power kg/h 1560
Outer diameter of exhaust mixed with sea water mm 127
inches 5
Fuel supply
Transfer pump delivery at maximum rpm litres/h ≤ 250
Flow rate return to tank litres/h 240
Fuel temperature to allow maximum power °C 70
Inner diameter, intake pipe mm 8
Inner diameter, return pipe mm 8
Thread on pre-filter junctions M 14 x 1,5
Free height below filter to replace filter mm 30
Open sea water cooling line
Intake pipeline diameter mm 45
inches 1,77
Pump delivery at maximum rpm litres/h 12000
Sea water pump height above sea level m ≤ 2
Allowed intake vacuum kPa 20
mmH2O 2000
Discharge pipeline diameter (only if unmixed gas exhaust) mm 45
inches 1,77
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360 + 18
Maximum transverse in continuous operation (static + dynamic) degrees/360 ± 23
Longitudinal for oil level check with standard dipstick degrees/360 0 to +6
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
Power takeoffs (optional)
2-race front pulley for “V” belts
Reference diameter mm 187
Race dimension mm 12.7
Power available at 900 rpm kW (HP) 6 (8,1)
Power available at 1800 rpm kW (HP) 12 (16,3)
Radial force resulting from belt tension (*) N 1340
(*) For direction of the resulting radial force between 60° and 300° with reference to the cylinder axis (piston at top dead center = 0°)
3-race front pulley + elastic joint
Torque available in engine axis Nm (kgm) 150 (15)
Moment of iner tia of rigidly added masses kgm
2
0,015
N60 ENT M37INSTALLATION DIRECTIVE
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MARCH 2004
177
(6.96) 840 (33.07)
1350 (53.15)
243 (9.57)
610 (24.01)
850 (33.46)
==
780 (30.70)
45 (1.77)
Figure 4
Dimensions
Measurements in: millimeters (inches).
04_070_N
6. IDENTIFICATION DATA
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
Figure 6
Figure 5
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE
ENGINE DWG
ENGINE S/N
COMMERC. TYPE / VERSION
POWER SET CODE
HOMOLOGATION
N°
ENGINE FAMILY
POWER (KW) AND SPEED (RPM)
YEAR OF BUILD
S. p. A.
04_002_N
04_007_N
The engine identification data are stenciled on a tag positioned over the flywheel case.
7. FUEL LINE
N60 ENT M37INSTALLATION DIRECTIVE
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For the installation, the following connections are required:
- from the tank to the pre-filter
- from the pre-filter to the pump inlet
- from the fuel discharge outlet to the tank
Pre-filter
The pre-filter with priming pump, supplied separately from the engine, must be fastened near the tank, in a relatively low point of the line to allow for easy replacement of the filter­ing car tridge and/or the operation of the hand pump. Avoid the use of additional mesh or paper filters along the feed lines between pre-filter and engine. To avoid introducing impurities in the feeding lines inside the engine, do not place filter cartridges pre-filled with fuel in the system.
Materials’ Characteristics
The fuel tank and the suction and return assembly must withstand the continuous abrasion caused by a flow of fuel oil of 250 l/h at a temperature of 120 °C without noticeable deformation or wear or release of material. Use of metal 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.
Tanks must be provided with vents to avoid exceeding an internal pressure of ± 5kPa (± 0.5 m of H
2
O column); their shape and the suction assembly must be such as to assure a suction at the maximum longitudinal and transverse inclina­tion allowed for the boat, with a residual quantity of fuel oil considered “reserve”. The suction inlet should be positioned in such a way as to avoid taking in sludge.The return flow must be in such a way as to facilitate the mixing of the returning fuel with the fuel in the tank. If the tank is lower than the filter, then the return pipe must always be submerged.The pipes and union fittings of the fuel line must withstand a fuel oil flow rate of 250 l/h at a temperature of 120 °C and a pressure of 3 bar (300 kPa) without noticeable deformation, wear or release of material. Metal tubes, preferably made of iron alloys, are rec­ommended, taking care to connect each individual segment to engine ground to avoid the accumulation of electrostatic charges and inserting a vibration damper elastic joint on each segment. The pipes used must be certified according to the relevant Countries’ rules or to the standards issued by clas­sification Bodies.
1. Fuel filter - 2. Common rail - 3. Electro-injector - 4. Electro-injector return loop pressurization valve - 5. Rail overpressure valve - 6. High and low pressure pump - 7. Priming pump - 8. Settling pre-filter.
High pressure Low pressure
Figure 7
1
2
3
5
4
8
6
04_072_N
7
Fuel supply system scheme
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
1. High pressure radial pump - 2. Fuel temperature sensor - 3. Fuel filter - 4. Electro-injector - 5. Pressure sensor - 6. Common rail - 7. Common rail overpressure valve - 8. Electro-injector return loop pressurization valve, 1.3 to 2 bar - 9. Fuel tank -
10. Recirculation manifold - 11. Manual priming pump - 12. Pre-filter - 13. Low pressure pump recirculation valve - 14. High and low pressure pump - 15. Low pressure mechanical feed pump - 16. Low pressure pump by-pass valve - 17. Fuel filter
support - 18. Low pressure limiter valve - 19. Pressure regulating electrical valve.
04_040_N
1
17
19
16
18
15
1314 12 11
10 9
2 3 5 6 74 8
Figure 8
04_244_N
Figure 9
5
2
3
4
Hydraulic connections
B
A
1
A.To rail supply - B. Return flow from rail - 1. Low pressure fuel feed pump - 2. High pressure pump - 3. Rubber holder
junction for fuel inflow from pre-filter - 4. Rubber holder junction for fuel outflow to the tank - 5. Fuel filter.
8. ELECTRICAL EQUIPMENT
N60 ENT M37INSTALLATION DIRECTIVE
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MARCH 2004
Figure 10
The electrical equipment of the engine comprises a series of components provided separately from the engine to enable an easy and diversified installation, according to the Yard’s design choices.The need to make accessible, at sea or under­way, the controls to the electrical components and to the connector for diagnostics contained in the relay box may be met through different installation arrangements. Along with the coupling of all connectors provided in the wire harnesses, completing the installation also requires the connecting wire harness (12) for the sensor for the presence of water in the fuel (13), to complete the power line and to connect the accumulator to the engine wire harness.
1
2
4
3
6
7 8
5
10
9
15
04_073_N
1. Engine wiring - 2. Indicator and control panel - 3. Provided wire harness - 4. JB Connection - 5. Relay box -
6. JA Connection - 7. Power supply and interface wire harness - 8. JF1 and JF2 connectors - 9. A2 connector of the ECU -
10. A and A1 connectors of the ECU - 11. M Connector - 12.Wiring harness to be manufactured by the yard -
13. Sensor for the presence of water in the fuel - 14. Sedimenting pre-filter -
15. Power line for electric starter motor and alternator.
11
12
13
14
Synoptic
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
JB JA
JF1 JF2
A2
A1
A
04_235_N
Figure 11
1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Interface wire harness - 4. Power line.
3 41 2
INDICATIONS AND
ALARMS SENSORS
INDICATIONS AND
ALARMS SENSORS
ELECTRO-INJECTORS
EDC COMPONENTS
ALTERNATOR
BATTERY
EDC
RELAY
BOX
ELECTRIC STARTER
MOTO R
NEF ENT M37
GEAR BOX
THROTTLE POSITION
SENSOR
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 indicator and control panel.
Wire harness
N60 ENT M37INSTALLATION DIRECTIVE
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MARCH 2004
T
T
O
E2F
VE
WI
WI
SI
SI
VI
MM
A2 EDC
JB
M
JA
GG
B
PA
+ BATT
A EDC
A1 EDC
PF
A
ZH
V
C
K
K
E3
E2
PR
H
E1
V
- BATT
JF2 JF1
VI
Engine wire harness Interface wire harness
04_221_N
Figure 12
A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - F. Engine coolant temperature sensor for EDC - H. Combustion air
pressure/temperature sensor for EDC - 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) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - E1. Cylinders 1 and 2 electro-injectors - E2. Cylinders 3 and 4
electro-injectors - E3. Cylinders 5 and 6 electro-injectors - GG. Alternator - JB. Instrument panel connection wire harness - JF1,JF2. Relay box - MM. Electric starter motor -
PA. Throttle position sensor - PF. Heating element on fuel filter - PR. Rail pressure sensor - SI. Gear box oil temperature sensor - VE. Engine oil pressure/temperature sensor for
EDC - VI. High gear box oil pressure sensor (25 bar) - WI. Low gear box oil pressure sensor (7 bar) - ZH. Pressure control solenoid valve.
Power supply line
1.Alternator - 2. Electric star ter motor - 3. Battery - 4. Engine wire harness.
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 10 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 70 mm2, allows to obtain, as shown in the figure, the simulta­neous connection of the alternator to the battery. The con­nection 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.
Supplementary services battery
To assure that the engine can be star ted with a sufficient quantity of energy, it is advisable to provide for the installa­tion of a supplementar y batter y, dedicated to supplying power to the on-board electrical services.The power line to recharge it may be constructed according to the indications provided in Chapter 24.
If one engine is installed
The batter y used for ser vices may be recharged interpos­ing on the power supply line a relay actuated by the recharge signal of the alternator’s electronic regulator (D+).
If two engines are installed
The presence of two generators allows to keep the recharg­ing functions separated: the generator (G1) recharges the battery (AC1) dedicated to starting both engines and pow­ering both electrical/electronic control circuits, whilst the gen­erator (G2) recharges the battery (AC2) used to power the
services. In two-engine applications, it is essential to connect the engine grounds to a common potential; the solution pro­posed in Chapter 24 fully complies with this need, assuring the full functionality and independence of the two circuits.
Engine electrical ground
The connection of the engine electrical ground is achieved by connecting with a cable of at least 70 mm2cross section to the negative pole of the battery to the tightening point of the electric starter motor as shown in Figure 14.
1. Point of connection of the engine electrical ground.
To anchor the grounding terminal to the engine, proceed as follows: Completely remove the conducting paint from both parts constituting the connection, using mechanical means or suit­able chemical product; if the anchoring operation is to take place on superficially treated par ts, completely remove the anaphoretic paint with mechanical means, obtaining a smooth support surface. Apply a uniform layer of BH44D paint (IVECO standard 18-
1705) with a brush or spray gun. Join the parts constituting the grounding note within 5 min­utes from the time the paint was applied.
Battery recharging
B+. Connected to the +30 of the electric star ter motor -
D+. Excitation - N. Not connected.
N60 ENT M37 INSTALLATION DIRECTIVE
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MARCH 2004
EDC power supply
04_076_N
4
1
2
3
Figure 14
1
04_077_N
04_078_N
Figure 15
Figure 13
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