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

	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

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 Parts 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

MAY 2006 INSTALLATIONDIRECTIVE 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.	TECHNICAL DATA FOR INSTALLATION	10
6.	IDENTIFICATION DATA	12
7.	COMPONENTS SUPPLIED WITH THE ENGINE	13
8.	FUEL LINE	14
9.	ELECTRICAL EQUIPMENT	17
10.	MAIN ANALOG INSTRUMENT PANEL	26
11.	SECONDARY ANALOG INSTRUMENT PANEL	30
12.	DRILLING PLANS FOR ANALOG PANELS	31
13.	CUSTOMIZED INSTRUMENT PANEL	32
14.	SENSORS FOR DETECTION
	AND PANEL SIGNALING	34
15.	PREPARING THE ENGINE
	FOR FIRST START-UP	36
16.	TESTS BEFORE THE FIRST START-UP	36
17.	FIRST ENGINE START	37
18.	EDC ANOMALIES INDICATION	38
19.	BLINK CODE TABLE	39
20.	UNDERWAY CHECKS	41
21.	PREPARING THE ENGINE
	FOR LONG IDLE PERIODS	42
22.	WIRING DIAGRAMS	43

	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

1. WARNINGS AND CAUTIONS

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.

oDrain 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.

oBatteries 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

oKnife 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.

oDo not modify the wiring harnesses; their length may not be modified: use only available extensions.

oDo not use electronic device wiring harnesses not compliant with the IVECO MOTORS directive, in terms of length, type of conductor, location, clamping, connection of the shielding and earth braids.

oTo avoid any interference, the wiring harnesses of the different on-board electronic devices must follow different paths from those of the engine electronic systems.

oDo not connect any extraneous user device to the engine electrical equipment.

oDo not place voltage across the boat’s on-board electrical system without first verifying that there are no short circuits.

oDo not branch pipes off to draw fuel from the engine supply lines.

oDo not make any change to the engine’s hydraulic circuits and components.

oDo not execute arc welding operations before removing the electronic units from their seating, placing them at an adequate safety distance.

oDo not subject electronic units to temperatures exceeding 80 °C.

oDo not paint electrical components and their connections.

oDo not alter the data contained in the engine control electronic unit.

oComply with prescribed procedures and torque values when tightening threaded elements.

Start-up

oReady the engine following the procedure set out in Chapter 15.

oWhen starting the engine the first time, have suitable means available to cut off air intake in case of a runaway condition.

oStart the engine after ensuring that it is complete with every part specified by the manufacturer and required by the installation, without attempting to start it with caps and occlusions to the lubrication, cooling and fuel feed lines.

oCheck that the fluid lines are perfectly sealed, especially lines for fuels and lubricants, which may cause fires and consequent harm to persons and equipment.

oMake sure that the various pipelines are not in contact with warm surfaces or moving parts.

oThe installing yard is required to carry out tests to verify the functional compatibility between the electrical-elec- tronic equipment of the engine and the other electronic equipment present on the boat.

Tests and tuning up

oNever disconnect the batteries when the engine is running.

oRemove the electrical connections from the batteries before any operation on the electrical system.

oEnsure that the battery terminals comply with the exact polarity, are properly tightened and protected against accidental short circuits and corrosion phenomena.

oDo not connect or disconnect electrical connections when electrical power supply is present.

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23

oDo not cause sparks in the attempt to verify the presence of electrical voltage.

oDo not draw fuel through unfiltered lines.

oDo not clean the engine and its parts with corrosive or abrasive detergent substances, to avoid compromising the integrity of electrical connections.

oThe 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.

	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

2. ENGINE PARTS AND COMPONENTS

Figure 1

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05_003_S

10

1. Engine coolant discharge cap - 2. Electric starter 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.

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23

Figure 2

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05_002_S

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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.

	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

3. INSTALLATION OVERVIEW

Figure 3

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06_005_S

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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 prefilter - 9. Fuel filter - 10. Fuel priming pipe - 11. Fuel return pipe to the tank - 12. Accelerator Bowden cable - 13. Accelerator lever.

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.

MAY 2006	INSTALLATIONDIRECTIVE	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 servicing 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 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.

	10		S30 ENT M23	INSTALLATIONDIRECTIVE		MAY 2006
5. TECHNICAL DATA FOR INSTALLATION
		Combustion and ventilation air when underway
		Static vacuum allowed downstream of the air filter			kPa	≤ 3,5
					mm H2O	≤ 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	≤ 0,1
					mm H2O	≤ 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	≤ 10
					mm H2O	≤ 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	100
					inches	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	≤ 15
					mmH2O	≤ 1500
		Approved intake pressure at the low pressure mechanical pump			kPa	20 to 120
					mmH2O	2000 to 12000
		Allowed on tank return pipe back pressure			kPa	≤ 40
					mm H2O	≤ 4000
		Open sea water cooling line
		Intake pipeline diameter			mm	32
					inches	1,26
		Pump delivery at maximum rpm			l/h	9000
		Sea water pump height above sea level			m	≤ 2
		Allowed intake vacuum			kPa	≤ 20
					mm H2O	≤ 2000
		Dry exhaust outer diameter			mm	Not foreseen
					inches
		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

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23	11

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

Dimensions

Figure 4

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¬

-!8¬ ¬ -).¬ ¬

¬	¬
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¬
	06_001_S

Measurements in: millimeters (inches).

12	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

6. IDENTIFICATION DATA

Figure 5

06_004_S

Figure 6

05_003_S

The engine identification data are stenciled on a tag positioned over the engine coolant tank

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23	13

7. COMPONENTS SUPPLIED WITH THE ENGINE

Figure 7

5			6	7
*	0&	!	:	-

06_019_S

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 supports 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 parts 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

oA. Fuel temperature sensor for EDC

oM. Sensor designed to detect the presence of water in the fuel pre-filter

oZ. Fuel filter clog sensor

oPF. Heating element on the fuel filter

oJFC. 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.

14	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

8. FUEL LINE

Figure 8

3

2

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High pressure
Low pressure	6	06_006_S

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.

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 cartridge.

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

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.

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23	15

Fuel supply system scheme

Figure 9

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06_007_S

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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.

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.

16	S30 ENT M23	INSTALLATIONDIRECTIVE	MAY 2006

Preparation of the fuel filter support

Figure 11

1 2 3 2

06_010_S

1. Screw - 2. Seal washers - 3. Rubber holder fitting.

The filter support must be prepared by replacing fuel inlet and outlet fittings with the supplied ones.

Following the removal of the fittings on the support, Rubber holder fitting must be mounted on the screws by fitting seal washers as shown in the picture.Tighten the screws.

MAY 2006	INSTALLATIONDIRECTIVE	S30 ENT M23	17

9. ELECTRICAL EQUIPMENT

Figure 12

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06_012_S

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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

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.