Iveco S30 ENT M23 User Manual
SOFIM
S30 ENT M23
4 CYLINDERS IN LINE
DIESEL CYCLE
FOR MARINE APPLICATIONS
INSTALLATION DIRECTIVE
MAY 2006 EDITION
T E C H N O L O G I C A L E X C E L L E N C E
INSTALLATION DIRECTIVE
2
MAY 2006
S30 ENT M23
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 S30
ENT M23 engines and complement the IVECO MOTORS
publication “Guide to the Installation of Marine Engines” the
reader should refer to, for anything that is not explained
herein.
For more complete information about the engine, please
refer to the appropriate technical brochure.
Use of fuels and oils with different characteristics from
those set out in the operation and maintenance manual may
compromise the regular operation of the engine, limiting its
performance, reliability and working life.
Exclusive use of IVECO Original Par ts is a necessary 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 parts, you must indicate:
- Commercial code, serial number and indications shown
on the engine tag;
- Part number of the spare as per spare part catalog.
The information provided below refer to engine 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 P3D64S001 E - May 2006 Edition
INSTALLATION DIRECTIVE
3
MAY 2006
S30 ENT M23
CONTENTS
Page
1. WARNINGS AND CAUTIONS 4
2. ENGINE PARTS AND COMPONENTS
6
3. INSTALLATION OVERVIEW
8
4. GENERAL INSTALLATION CRITERIA
9
5. TECHNIC AL DATA FOR INSTALLATION 1
0
6. IDENTIFICATION DATA 1
2
7. COMPONENTS SUPPLIED WITH THE ENGINE 1
3
8. FUEL LINE 1
4
9. ELECTRICAL EQUIPMENT 1
7
10. MAIN ANALOG INSTRUMENT PANEL 2
6
11. SECONDARY ANALOG INSTRUMENT PANEL 3
0
12. DRILLING PLANS FOR ANALOG PANELS 3
1
13. CUSTOMIZED INSTRUMENT PANEL 3
2
14. SENSORS FOR DETECTION
AND PANEL SIGNALING 3
4
15. PREPARING THE ENGINE
FOR FIRST START-UP 3
6
16. TESTS BEFORE THE FIRST START-UP 3
6
17. FIRST ENGINE START 3
7
18. EDC ANOMALIES INDIC ATION 3
8
19. BLINK CODE TABLE 3
9
20. UNDERWAY CHECKS 4
1
21. PREPARING THE ENGINE
FOR LONG IDLE PERIODS 4
2
22. WIRING DIAGRAMS 4
3
INSTALLATION DIRECTIVE
4
MAY 2006
S30 ENT M23
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 particular 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.
o 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.
o 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
o 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.
o Do not modify the wiring harnesses; their length may
not be modified: use only available extensions.
o 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 ear th braids.
o 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.
o Do not connect any extraneous user device to the
engine electrical equipment.
o Do not place voltage across the boat’s on-board electri-
cal system without first verifying that there are no short
circuits.
o Do not branch pipes off to draw fuel from the engine
supply lines.
o Do not make any change to the engine’s hydraulic cir-
cuits and components.
o Do not execute arc welding operations before removing
the electronic units from their seating, placing them at an
adequate safety distance.
o Do not subject electronic units to temperatures exceed-
ing 80 °C.
o Do not paint electrical components and their connec-
tions.
o Do not alter the data contained in the engine control
electronic unit.
o Comply with prescribed procedures and torque values
when tightening threaded elements.
Start-up
o Ready the engine following the procedure set out in
Chapter 15.
o When starting the engine the first time, have suitable
means available to cut off air intake in case of a runaway
condition.
o Start the engine after ensuring that it is complete with
every part specified by the manufacturer and required
by the installation, without attempting to star t it with
caps and occlusions to the lubrication, cooling and fuel
feed lines.
o 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.
o Make sure that the various pipelines are not in contact
with warm surfaces or moving parts.
o The installing yard is required to carry out tests to verify
the functional compatibility between the electrical-electronic equipment of the engine and the other electronic
equipment present on the boat.
Tests and tuning up
o Never disconnect the batteries when the engine is
running.
o Remove the electrical connections from the batteries
before any operation on the electrical system.
o Ensure that the battery terminals comply with the exact
polarity, are properly tightened and protected against
accidental short circuits and corrosion phenomena.
o Do not connect or disconnect electrical connections
when electrical power supply is present.
1. WARNINGS AND CAUTIONS
INSTALLATION DIRECTIVE
5
MAY 2006
S30 ENT M23
o Do not cause sparks in the attempt to verify the pres-
ence of electrical voltage.
o Do not draw fuel through unfiltered lines.
o Do not clean the engine and its par ts with corrosive or
abrasive detergent substances, to avoid compromising
the integrity of electrical connections.
o 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 21.
INSTALLATION DIRECTIVE
6
MAY 2006
S30 ENT M23
2. ENGINE PARTS AND COMPONENTS
Figure 1
1. Engine coolant discharge cap - 2. Electric star ter motor - 3. Tube bundle engine coolant/sea water heat exchanger - 4. Exhaust gas
and sea water discharge pipeline - 5. Engine coolant tank - 6. Coolant refill cap - 7. Lifting eyebolts - 8. Oil refill cap - 9. Sea water
pump actuation pulley - 10. Auxiliary belt automatic tensioner - 11. Alternator - 12. Location of sacrificial anode.
12
11
2
3
4
7 8 7
9
05_003_S
65
10
1
INSTALLATION DIRECTIVE
7
MAY 2006
S30 ENT M23
Figure 2
1. Engine coolant discharge cap location - 2. Combustion air filter - 3. Sacrificial anode - 4. Throttle potentiometer - 5. Combustion
air-sea water heat exchanger - 6. Oil dipstick - 7. Location of common rail high pressure injection pump - 8. Sea water pump - 9. Sea
water inlet - 10. Manual lubricating oil extraction pump - 11. Oil vapor separator - 12. Lubricating oil filters -
13. Common rail distributor - 14. Waste-gate actuator - 15. Cooled turbocharger - 16. Sea water junction pipe from after-cooler to
engine coolant/sea water heat exchanger.
6
12 13
17
05_002_S
23
16
17
15
4
8
7
9
11
5
10
1
14
INSTALLATION DIRECTIVE
8
MAY 2006
S30 ENT M23
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 electric pump - 8. Fuel pre-
filter - 9. Fuel filter - 10. Fuel priming pipe - 11. Fuel return pipe to the tank - 12. Accelerator Bowden cable - 13. Accelerator lever.
Figure 3
1 2
45678
3
12
06_005_S
11
10
13
9
10
INSTALLATION DIRECTIVE
9
MAY 2006
S30 ENT M23
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.
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 entr y 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.
INSTALLATION DIRECTIVE
10
MAY 2006
S30 ENT M23
5. TECHNICAL DATA FOR INSTALLATION
Combustion and ventilation air when underway
Static vacuum allowed downstream of the air filter
kPa
mm H2O
≤ 3,5
≤ 350
Combustion air flow rate m3/h
≥ 710
Engine room ventilation air flow rate (excluding combustion air) m3/h
≥ 3590
Static vacuum allowed in the engine room
kPa
mm H2O
≤ 0,1
≤ 10
Temperature allowed in the engine room °C
≤ 45
Temperature increase in the engine room to ext. temperature °C
≤ 15
Exhaust gas discharge
Allowed static back pressure
kPa
mm H2O
≤ 10
≤ 1000
Exhaust gas temperature at maximum power (turbocharger inlet) °C 700
Flow rate at maximum power kg/h 875
Outer diameter of exhaust mixed with sea water
mm
inches
100
4
Fuel supply
Transfer pump delivery at maximum rpm l/h
≤ 190
Flow rate return to tank l/h
≤ 185
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
Electric pump approved intake vacuum
kPa
mmH2O
≤ 15
≤ 1500
Approved intake pressure at the low pressure mechanical pump
kPa
mmH2O
20 to 120
2000 to 12000
Allowed on tank return pipe back pressure
kPa
mm H2O
≤ 40
≤ 4000
Open sea water cooling line
Intake pipeline diameter
mm
inches
32
1,26
Pump delivery at maximum rpm l/h 9000
Sea water pump height above sea level m
≤ 2
Allowed intake vacuum
kPa
mm H2O
≤ 20
≤ 2000
Dry exhaust outer diameter
mm
inches
Not foreseen
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360 +20
Maximum transverse in continuous operation (static + dynamic) degrees/360 ± 22º30'
Longitudinal for oil level check with standard dipstick degrees/360 0 to +6
INSTALLATION DIRECTIVE
11
MAY 2006
S30 ENT M23
Figure 4
Dimensions
Measurements in: millimeters (inches).
Power takeoffs (optional)
1-race front pulley for “V” belts
Reference diameter mm 83
Race dimension mm 10
Power available at 1000 rpm (*) kW
≤ 1
Power available at 2000 rpm (*) kW
≤ 2
Radial force resulting from belt tension (*) N
≤ 400
(*) These values are valid for driving to the side opposite to that of the sea water pump
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06_001_S
INSTALLATION DIRECTIVE
12
MAY 2006
S30 ENT M23
6. IDENTIFICATION DATA
Figure 6
Figure 5
06_004_S
05_003_S
The engine identification data are stenciled on a tag positioned over the engine coolant tank
INSTALLATION DIRECTIVE
13
MAY 2006
S30 ENT M23
7. COMPONENTS SUPPLIED WITH THE ENGINE
Figure 7
06_019_S
*&# 0& ! -:
6 75
4
1. Connectors to be assembled - 2. Conductor terminals - 3. Gaskets to be fitted on individual wires - 4. PF connector rear cover -
5. Fuel electric pump - 6. Fuel pre-filter - 7. Fuel filter - 8. Components to replace fittings mounted on the fuel filter.
The engine is supplied with a box containing the parts
showed in the pictures, as well as spring suppor ts to allow
keelson anchoring.
Electric connectors
As shown in pictures 1, 2, 3, 4, they must be used to set up
the cabling connecting them to the components located on
the fuel filter.
Individual electric connectors are each one sealed in seethrough bags, together with small par ts required to complete them. In order to avoid connection errors, connectors
are different from one another; each one of them must be
exclusively mounted by using the small parts contained in the
relevant plastic bag
Connection function
o A. Fuel temperature sensor for EDC
o M. Sensor designed to detect the presence of water in
the fuel pre-filter
o Z. Fuel filter clog sensor
o PF. Heating element on the fuel filter
o JFC. Connection to the JFC connector on the engine
harness
Chapter 9 shows the instructions to be followed to perform
connections.
Mechanical components
As shown in picture 8, they must be used to replace the fittings mounted on the fuel filter support.
Chapter 8 shows the instructions to be followed in order to
carry out assembly operations.
Hydraulic components
Identified in the picture by numbers 5, 6, 7, hydraulic components must be used to set up the fuel feeding system.
Chapter 8 shows the instructions to be followed in order to
perform connections.
INSTALLATION DIRECTIVE
14
MAY 2006
S30 ENT M23
8. FUEL LINE
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 electric pump to the filter inlet
- from the filter outlet to the low pressure mechanical
feeding pump
- from the fuel discharge outlet to the tank.
Components
Pre-filter, electric pump and filter, supplied with the engine,
must be fitted in proximity of the tank, in a relatively low
point of the system. The filter must be prepared as indicated
here below and fastened in such a way to allow easy replacement of the filtering car tridge.
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 200 l/h at a temperature of 120 °C without noticeable
1. Low pressure mechanical feeding pump and high pressure common rail injection pump - 2. Electro-injector - 3. Common rail -
4. Pre-filter - 5. Fuel electric pump - 6. Filter.
Figure 8
High pressure
Low pressure
1
4
06_006_S
2
3
6
5
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 H2O 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 200 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.
INSTALLATION DIRECTIVE
15
MAY 2006
S30 ENT M23
Fuel supply system scheme
1. Low pressure limiter valve - 2. Pressure regulating electric valve - 3. High pressure radial pump - 4. Pressure sensor - 5. Common
rail - 6. Electro-injector - 7. Fuel tank - 8. Pre-filter - 9. Fuel electric pump - 10. Filter - 11. Vent fitting - 12. Low pressure mechanical
feed pump.
Figure 9
06_007_S
M
3
1
11
7
5 6
2
4
10
8
9
12
Hydraulic connections
Figure 10
1
2
06_020_S
1. Rubber holder fitting for fuel inflow into the low pressure mechanical feeding pump -
2. Rubber holder fitting to allow fuel outflow towards the tank.
INSTALLATION DIRECTIVE
16
MAY 2006
S30 ENT M23
Preparation of the fuel filter support
1. Screw - 2. Seal washers - 3. Rubber holder fitting.
The filter suppor t must be prepared by replacing fuel inlet
and outlet fittings with the supplied ones.
Following the removal of the fittings on the suppor t, Rubber
holder fitting must be mounted on the screws by fitting seal
washers as shown in the picture. Tighten the screws.
Figure 11
06_010_S
1 2 23
INSTALLATION DIRECTIVE
17
MAY 2006
S30 ENT M23
Figure 12
1
4
5
9
06_012_S
12
32
13
6
7
10
8
11
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 to the connector JFC (11) for the
fuel filter, to complete the power line and to connect the
accumulator to the engine wire harness.
NOTE
The two general power supply terminals identified as
+BATT and −BATT must be connected to the accumulator, while the terminal identified as +BATT/CC must be
connected to the +30 pole of the starter motor.
9. ELECTRICAL EQUIPMENT
1. Engine wiring - 2. +BATT/CC terminal - 3. Power line for electric starter motor and alternator - 4. Indicator and control panel - 5.
Extension harness - 6. Engine pre-heating glow plugs electronic control unit - 7. Fuse holder for the engine pre-heating glow plugs
electronic control unit - 8. ECU EDC connectors - 9. Relay box - 10. Diagnostic tool connector - 11. Harnessing to be made by
construction site personnel - 12. Fuel filter support - 13. Fuel electric pump
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