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VECTOR V08 ENT M75 V08 ENT M11 V08 ENT M12 V 8 MODEL DIESEL CYCLE FOR MARINE APPLICATIONS INSTALLATION DIRECTIVE T E C H N O L O G I C A L E X C E L L E N C E MAY 2006 EDITION V08 ent m75 - M11 - M12 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 V08 ent m75 - M11 - M12 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 P3D64V001 E - May 2006 Edition MAY 2006 MAY 2006 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 CONTENTS Page 1. WARNINGS AND CAUTIONS 4 2. ENGINE PARTS AND COMPONENTS 6 3. INSTALLATION OVERVIEW 10 4. GENERAL INSTALLATION CRITERIA 11 5. TECHNICAL DATA FOR INSTALLATION 12 6. IDENTIFICATION DATA 14 7. FUEL LINE 15 8. ELECTRICAL EQUIPMENT 17 9. MAIN ANALOG INSTRUMENT PANEL 26 10. SECONDARY ANALOG INSTRUMENT PANEL 30 11. DRILLING PLANS FOR ANALOG PANELS 31 12. CUSTOMIZED INSTRUMENT PANEL 32 13. SENSORS FOR DETECTION AND INSTRUMENT PANEL SIGNALLING 34 14. PREPARING THE ENGINE FOR FIRST START-UP 37 15. TESTS BEFORE THE FIRST START-UP 37 16. FIRST ENGINE START 38 17. EDC ECU INDICATION LIGHTS 40 18. UNDERWAY CHECKS 43 19. PREPARING THE ENGINE FOR LONG IDLE PERIODS 44 20. ELECTRIC DIAGRAMS 46 21. APPENDIX 53 Indications for consultation The different versions of the motors are generally shown using the same pictures and descriptions, however important differences are shown separately. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE 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. o Do not connect any extraneous user device to the engine electrical equipment. Failure to comply with the instructions that follow shall void the warranty and relieve IVECO MOTORS of all liabilities. o Do not subject electronic units to temperatures exceeding 80°C. For personnel safety o Do not alter the data contained in the engine control electronic unit. Specialists and installers are cautioned to comply with workplace safety rules and to adopt prescribed individual protection devices when working. o Comply with prescribed procedures and torque values when tightening threaded elements. o Do not energize the on-board electrical system of the boat 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 circuits 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 paint electrical components and their connections. o Drain the cooling, lubrication and fuel lines only after the fluids have duly cooled. The pressurized cap of the coolant line may be opened only after the engine has duly cooled. Start-up o Batteries contain a highly corrosive sulphuric 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. o When starting the engine the first time, have suitable means available to cut off air intake in case of a runaway condition. 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 off the engine. 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 compliant with the IVECO MOTORS directive, in terms of length, type of conductor, location, clamping, connection of the shielding and earth 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 Ready the engine following the procedure set out in Chapter 14. 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 start 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 oNever 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. MAY 2006 INSTALLATION DIRECTIVE o Do not connect or disconnect electrical connections when electrical power supply is on. o Do not cause sparks in the attempt to verify the presence of electrical voltage. o Do not draw fuel through unfiltered lines. o Do not clean the engine and its parts with corrosive or abrasive detergent substances, to avoid compromising the integrity of electrical connections. o The engine fluids and air, coolant, and oil filters discarded after use must be properly stored and delivered to appropriate collection centres. Long engine inactivity periods Before long periods of inactivity, ready the engine following the procedure set out in Chapter 19. V08 ent m75 - M11 - M12 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 2. ENGINE PARTS AND COMPONENTS Figure 1A 1 2 1 3 4 5 6 7 9 8 18 17 16 15 14 05_001_V 13 10 12 11 1. Intake air filter - 2. EDC Electronic Central Unit - 3. Common rail high pressure injection pump - 4. Cooled turbo-charger 5. Exhaust gas outlet - 6. Lever for switching fuel filters - 7. Engine coolant level sensor - 8. Water/water heat exchanger 9. Pressurization cap for coolant tank - 10. Sea water pump - 11. Engine coolant pump - 12. Fuel filters - 13. Lifting padeyes 14. Cylinder 1 electro-injector - 15. Cooled exhaust manifold - 16. Cylinder 4 electro-injector - 17. Lifting padeyes 18. Air-sea water heat exchanger. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Figure 1B 1 4 3 2 5 7 7 6 9 8 10 12 24 15 23 14 11 13 05_008_V 22 16 21 17 20 19 18 1. Engine coolant tank - 2. Pressurization cap for coolant tank - 3. Exhaust gas outlet - 4. Cooled turbo-charger - 5. Common rail high pressure injection pump - 6. EDC Electronic Central Unit - 7. Intake air filter - 8. Air-sea water heat exchanger - 9. Lifting padeyes 10. Cylinder 8 electro-injector - 11. Lubricating oil dipstick - 12. Lubricating oil refill cap - 13. Cylinder 5 electro-injector - 14. Cooled exhaust manifold - 15. Lifting padeyes - 16. Location of the low pressure fuel transfer pump - 17. Tap and fitting for lubricating oil transfer - 18. Sacrificial anode - 19. Lubrication oil transfer electrical pump - 20. Sea water intake - 21. Alternator - 22. Lubricating oil filters - 23. Engine coolant pump - 24. Electrical equipment wiring connectors. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Figure 2A 1 16 15 2 14 13 3 4 5 12 11 10 9 05_002_V 8 7 6 1. Lubricating oil filters - 2. Location of thermostatic valves - 3. Air-sea water heat exchanger - 4. EDC Electronic Central Unit 5. Exhaust gas outlet - 6. Fuel inlet and outlet fittings - 7. Crankshaft sensor - 8. Cooled turbo-charger - 9. Lifting padeyes 10. Cooled exhaust manifold - 11. Cylinder 8 electro-injector - 12. Lubricating oil dipstick - 13. Lubricating oil refill cap 14. Cylinder 5 electro-injector - 15. Lifting padeyes - 16. Sea water intake. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Figure 2B 1 2 4 3 5 6 7 8 9 10 05_009_V 11 12 1. Exhaust gas outlet - 2. EDC Electronic Central Unit - 3. Air-sea water heat exchanger - 4. Location of thermostatic valves 5. Fuel filters - 6. Lifting padeyes - 7. Cylinder 1 electro-injector - 8. Cooled exhaust manifold - 9. Cylinder 4 electro-injector 10. Lifting padeyes - 11. Cooled turbo-charger - 12. Sacrificial anode (placed on the air/water heat exchanger). 10 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 3. INSTALLATION OVERVIEW Figure 3 1 2 3 3 4 5 6 7 8 9 11 05_003_V 10 1. Main instrument panel - 2. Throttle actuator - 3. Exhaust gas outlet - 4. Fuel return pipe to tank - 5. Fuel suction pipe 6. Prefilter with priming pump - 7. Sea water outlet from air/water heat exchanger - 8. To the filtered sea water intake 9. Sea water decanter filter - 10. Sea water outlet from water/water heat exchanger - 11. Electrical system cabinet. 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 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 11 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. 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 rated 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 outlet The exhaust gas outlet conduits 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 relay box, and of the optional electronic unit referring to the dimensions and position of the wire harnesses and the relative 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. NOTE: Information about optional equipment are described in the Chapter 21. (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. 12 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 5. TECHNICAL DATA FOR INSTALLATION V08 ENT M75 V08 ENT M11 V08 ENT M12 Engine intake and ventilation air when underway Static vacuum allowed downstream of the air filter kPa mmH2O ≤ 3.5 ≤ 350 ≤ 3.5 ≤ 350 ≤ 3.5 ≤ 350 Engine air intake flow rate m3/h ≥ 3050 ≥- ≥ 4000 Engine room ventilation air flow rate (excluding engine air intake) m3/h ≥ 7950 ≥- ≥ 6600 Static vacuum allowed in the engine room kPa mmH2O ≤ 0.1 ≤ 10 ≤ 0.1 ≤ 10 ≤ 0.1 ≤ 10 Temperature allowed in the engine room °C ≤ 45 ≤- ≤ 40 Maximum engine room temperature exceed outside temperature °C ≤ 15 ≤ 15 ≤ 15 ≤ 10 ≤ 1000 ≤ 10 ≤ 1000 ≤ 10 ≤ 1000 510 ± 25 - 660 ± 25 3550 - 4800 - - - 105 4 105 4 105 4 127 5 127 5 127 5 Exhaust gas outlet Allowed static back pressure Temperature at maximum power (turbocharger inlet) Flow rate at maximum power Riser outer diameter Dry exhaust outer diameter Diameter of circumference of distance between 6 locking holes kPa mmH2O °C kg/h mm inches mm inches mm inches Fuel supply Low pressure pump delivery at maximum rpm Fuel temperature to allow maximum power l/h °C 400 400 400 ≤ 70 ≤ 70 ≤ 70 Inner diameter, intake pipe mm ≥ 14 ≥ 14 ≥ 14 Inner diameter, return pipe mm Thread on prefilter fittings M inches UIC kPa mmH2O kPa mmH2O Thread on engine fittings Allowed intake vacuum Allowed intake pressure ≥8 ≥8 ≥8 14 x 1.5 14 x 1.5 14 x 1.5 1/2 1/2 1/2 ≤ 50 ≤ 5000 ≤ 50 ≤ 5000 ≤ 50 ≤ 5000 ≤ 20 ≤ 2000 ≤ 20 ≤ 2000 ≤ 20 ≤ 2000 101 4 101 4 101 4 61000 - 78000 ≤ 20 ≤ 2000 ≤ 20 ≤ 2000 ≤ 20 ≤ 2000 51 2 51 2 51 2 89 3½ 89 3½ 89 3½ Open sea water cooling line Intake pipe outer diameter Pump delivery at maximum rpm Allowed intake vacuum Discharge pipeline outer diameter from air/water heat exchanger Discharge pipeline diameter outer from water/water heat exchanger mm inches l/h kPa mmH2O mm inches mm inches INSTALLATION DIRECTIVE MAY 2006 13 V08 ent m75 - M11 - M12 V08 ENT M75 V08 ENT M11 V08 ENT M12 inches UIC - - - Maximum longitudinal in continuous operation (static + dynamic) degrees/360 +20° +20° +20° Maximum transversal in continuous operation(static + dynamic) degrees/360 ± 22°30’ ± 22°30’ ± 22°30’ Longitudinal for lubricating oil level check with standard dipstick degrees/360 0 ÷ 10° 0 ÷ 10° 0 ÷ 10° Gear box oil heat exchanger Thread on the intermediate engine fittings Allowed engine inclination angles Power takeoffs (optional) 2-race front pulley for “V” belts Reference diameter mm - - - Race dimension mm - - - kW CV kW CV - - - Nm kgm - - - Nm kgm N - - - - - Power available per belt at 650 rpm Power available per belt at 1300 rpm 2-race front pulley + elastic joint for flange Torque available in engine axis 2-race front pulley + elastic joint for crankshaft Torque available in engine axis Radial force resulting from belt tension (*) (*) For direction of the resulting radial force between 60° and 300° with reference to vertical axis Moment of inertia of rigidly added masses (*) Dimensions kgm2 - 1182 (46.5) Figure 4 2120 (83.4) 1220 (48) Dimension in millimetres (inches) 05_004_V 14 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 6. IDENTIFICATION DATA Figure 5 S. p. A. Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY ENGINE TYPE ENGINE FAMILY ENGINE DWG POWER (KW) AND SPEED (RPM) POWER SET CODE ENGINE S/N YEAR OF BUILD HOMOLOGATION No COMMERC. TYPE / VERSION 04_039_C Figure 6 05_002_V The engine identification data are stenciled on a tag positioned over the engine coolant tank INSTALLATION DIRECTIVE MAY 2006 15 V08 ent m75 - M11 - M12 7. FUEL LINE Figure 7 6 8 7 1 5 2 3 4 05_012_V 1. Return and suction flows from the tank - 2. Prefilter - 3. Fuel fitting support - 4. Low pressure supply pump 5. Fuel filters - 6. Lever for switching fuel filters - 7. Common rail high pressure injection pump - 8. Rail overpressure valve. For the installation, the following connections are required: - - - from the tank to the prefilter from the prefilter to fitting to engine inlet from engine outlet fitting to the tank recirculation Prefilter The prefilter 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 the filtering cartridge and/or the operation of the hand pump. Avoid the use of additional mesh or paper filters along the feed lines between prefilter 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 90°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 250 l/h at a temperature of 90°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. 16 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Fuel supply system scheme Figure 8 1 2 3 4 6 5 21 7 8 20 9 19 21 3 4 10 11 18 17 16 15 14 12 13 05_014_V 1. Vent fitting - 2. Compensation duct between two rails - 3. Common rail - 4. Electro-injector - 5. Low pressure limiter valve 6. Vent fitting - 7. Twin-cylinder high pressure pump - 8. Pressure control solenoid valve - 9. Pressure sensor - 10. Common rail overpressure valve - 11. Low pressure recirculation duct - 12. Fuel tank - 13. Prefilter - 14. Manual priming pump - 15. Vent fitting 16. Recirculation valve for low pressure pump - 17. Low pressure mechanical feed pump - 18. By-pass valve for low pressure pump 19. Lever for switching filters - 20. Fuel filters - 21. Filter exclusion valves. Hydraulic connections Figure 9 5 4 1 2 3 05_015_V 1. Fitting for fuel outflow to the tank - 2. Fitting for for fuel inflow from prefilter - 3. Prefilter 4. Fuel inlet pipe from the tank - 5. Fuel return pipe to the tank. 17 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 8. ELECTRICAL EQUIPMENT Figure 10 1 2 18 3 17 16 15 14 13 4 12 5 11 6 10 9 8 7 05_013_V 1. Indicator and control panel - 2. Electronic Central Unit - 3. Power line for electric starter motor and alternator - 4. Sedimenting prefilter - 5. Sensor to detect the presence of water in the fuel - 6. Control unit of the lubrication oil transfer electrical pump 7. JG Connector - 8. JG1 Connector for control unit of the lubrication oil electrical pump - 9. JC Connector - 10. JF1 and JF2 connectors - 11. Relay box - 12. Wiring harness to be manufactured by the yard - 13. M Connector - 14. J4 Connector for the electrical pre-lubrication pump - 15. J3 Connector for the electrical lubricating oil pump - 16. JA Connection - 17. JB Connection 18. Instrument panel wire harness. 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 to detect the presence of water in fuel (5), to complete the power line and to connect the accumulator to the engine wire harness. The connection of the J3 connector enables the electric connection of the control module to the lubricating oil pouring pump. The JC connector is set for the connection to the emergency stop button. 18 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Synoptic Figure 11 GEAR BOX INDICATIONS AND ALARMS SENSORS INDICATIONS AND ALARMS SENSORS THROTTLE POSITION SENSOR EDC COMPONENTS ELECTRO-INJECTORS J2 J1 EDC ELECTRONIC CENTRAL UNIT ALTERNATOR ELECTRIC STARTER MOTOR V08 ENT M JB JA JF1 JF2 JG 1 2 JG1 3 4 RELAY BOX BATTERY 05_006_V 5 6 1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Connector for control unit of the lubrication oil transfer electrical pump - 4. Connector for control unit of the electrical pre-lubrication oil 5. Interface wire harness - 6. Power line. The wire harnesses provided with the engine include the connectors for all optional components which may be ordered and their connections to the JB connector for the indication and control panel. # ¬ %$#¬* ¬ %$#¬* *& *& *' *' / + !0 ( 0 / "!44 n"!44 *# " 0& + 3) 7) 6) '. % % : - * 4'# '( 8 % % * * *! 6 3 & *" 5 6 4 % ! 02 % 0/ 0/0 % % 0! 3 " ¬ '' -- INSTALLATION DIRECTIVE Figure 12 A. Fuel temperature sensor - AP. Atmospheric pressure sensor - B. Crankshaft sensor for EDC - C. Camshaft sensor - E1/E8. Electro-injectors - F. Engine coolant temperature sensor for EDC - GG. Alternator - GH. Grid heater power relay - GN. Neutral gear sensor (in installation with no sensor, do not remove the cap of the GN connector to avoid compromising start engine function) - H. Combustion air pressure sensor for EDC - J. Low coolant level sensor (for alarm) - JB. Instrument panel connection wire harness JC. Emergency shut-off push-button (optional, installer’s responsibility) - J3. Connector for lubrication oil transfer electrical pump - J4. Connector for pre-lubrication electrical pump - JF1, JF2. Relay box - JG. Lubrication oil transfer electrical pump control unit - JG1. Pre-lubrication electrical pump control unit - K,K1. Clogged air filter sensors (for alarm) M. Sensor to detect water in the fuel prefilter (for alarm) - MM. Electric starter motor - O,O1. Exhaust gas temperature sensors (for gauge) - P. Combustion air temperature sensor for EDC - PA. Throttle position sensor - PF. Rail pressure control solenoid valve - PO. Lubrication oil transfer electrical pump - POP. Pre-lubrication electrical pump PR. Rail pressure sensor - S. Oil temperature sensor for EDC - S1. Engine oil temperature sensor (for gauge) - SI. Gear oil temperature sensor - T. Coolant temperature sensor (for gauge) - TGC. Power relay for electric starter motor insulation (provision) - U. Clogged oil filter sensor (for alarm) - V. Engine oil pressure sensor for EDC - V1. Engine oil pressure sensor (for gauge) - VI. Gear oil pressure sensor - WI. Low gear oil pressure sensor - X. Clogged blow-by filter sensor - Z. Clogged fuel filter sensor (for alarm). 05_005_V MAY 2006 V08 ent m75 - M11 - M12 19 Wire harness 20 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Power supply line The power network must be carried out in order to avoid using both the structure of engine and the structure of the hull (if this is metallic). For this purpose the electrical starter motor and the alternator required for this equipment are characterized by the presence of the terminals for electrical connections both with the positive and with the negative pole of the battery. Figure 13 C 4 B Equipment power supply 2 " 3 , )' 05_113_C n" A D 1 3 1. Alternator - 2. Electrical starter motor - 3. Battery 4. Engine wire harness. The power supply line, to be built by the yard, comprises: o A. Connection between the negative pole of the battery and the terminal “–B” of the electric starter motor realized with a conductor having a cross section of at least 95 mm2; o B. Connection between the positive pole of the battery and the terminal “30” of the electrical starter motor realized with a conductor having a cross section of at least 50 mm2; o C. Connection between the “30” terminal of the alternator to the positive “+B” terminal of the electric starter motor, to close the power supply and recharge circuit of the battery realized with a conductor having a cross section of at least 50 mm2. o D. Connection between the “−B” terminal of the alternator to the positive “−B” terminal of the electric starter motor, to close the power supply and recharge circuit of the battery realized with a conductor having a cross section of at least 50 mm2. The connection of the electric equipment of the engine to the battery has to be carried out via the two eyed terminals, “+B” and “–B”, present on the wiring harness. MAY 2006 CAUTION If magneto-thermal protecting breakers are installed on the wiring lines of the engine control system, they must not be used to stop the engine and in any case they must be activated only a few seconds after shut-off. Alternator 21 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Electrical starting motor Figure 15 Figure 14 1 2 +B 3 2 1 -B 3 S 05_112_C IG L 05_076_V Technical data: 1. Excitation coil command (50) - 2. Positive power pole (+B) - 3. Negative supply pole (−B). -Nominal voltage 24 V -Nominal current 90 A - Terminal connection “+B” M8 x 1.25 tightening torque 12.5 Nm ± 20% Technical characteristics: - Terminal connection “–B” M6 x 1 tightening torque 6.0 Nm ± 20% - Absorbed power 8.5 kW - Terminal connection “50” tightening torque 2 to 3 Nm - Terminal connection “+B” tightening torque 20 to 30 Nm - Terminal connection “–BATT” tightening torque 20 to 30 Nm +B. (24 V) Power supply output terminal –B. (0 V) Power supply output terminal S. (Sense) Reference voltage of battery charge status (connected to “+B” terminal or to be connected to the positive pole of the battery in case of remote installation of the battery); IG. (Ignition) Regulator enabling signal (connected to voltage “+ 15”, driven by key switch); L. (Lamp) Power supply voltage of recharge/alarm indicator light located on the panel. -Nominal supply voltage 24 V 22 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Battery recharging Figure 17 Figure 16 Connect to positive pole terminal of the starter motor S L IG MAY 2006 Connect to positive pole terminal of the battery B+ +B S L IG 05_074_V B− Connect to negative pole terminal of the starter motor 05_073_V Connect to positive pole terminal of the starter motor This is accomplished through the power supply line of the electric starter motor and connection to the +B of the alternator. The electronic regulator of the alternator that equips the engine allows an effective control over the battery recharging operation. If, due to installation requirements, the batteries need to be positioned at a distance from the engine, we recommend increasing the cross section of the power line conductors and verifying recharging effectiveness by measuring voltage across the battery poles. S For the best control of the battery recharge cabling the line relating to the S terminal of the alternator directly to the positive pole terminal of the battery (see figure 17). 05_075_V L IG B+ B− Connect to negative pole terminal of the starter motor Connect to positive pole terminal of the battery MAY 2006 Supplementary services battery To assure that the engine can be started with a sufficient quantity of energy, it is advisable to provide for the installation of a supplementary battery, 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 20. If one engine is installed The battery used for services may be recharged interposing on the power supply line a relay actuated by the recharge signal of the alternator’s electronic regulator (L). If two engines are installed The presence of two generators allows keeping 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 20 fully complies with this need, assuring the full functionality and independence of the two circuits. 23 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Relay Box Figure 18 9 8 7 #(%#+ %.').% 2//- 20- "2)$'% )'.)4)/. 1 2 34!24 3 20- 4 5 6 05_007_V 1. Control selector from bridge or engine room - 2. Power supply switch of the engine electric circuits - 3. Start button from engine room - 4. Reset button of the “maintenance alarm” 5. Button for managing acceleration and deceleration - 6. Connector for diagnostic instrument 7. Blink code emission LED (EDC) - 8. Signalling LED of maintenance interval expiration - 9. Signalling LED for fault engine operating parameters (WARNING). This shall be installed and anchored in such a way as to dampen the vibrations and stresses occurring when underway, and they shall be accessible during servicing operations and when underway. The electrical commands positioned on the panel allow controlling engine starting and stopping directly from the engine room, while excluding any possibility that anyone may involuntarily start the engine from the bridge, during servicing operations. On the relay box is located the multipolar connector (6), protected by a screw-on lid, for connection with the computerized diagnostic tools prescribed by IVECO MOTORS. Inside the box, anchored to a printed circuit board, are present the power management relays of some components and the elements that protect the electrical lines against short circuits or excessive current absorption. These components perform a similar function to that of fuses, almost totally avoiding the need to restore the electrical continuity of circuits subjected to an anomaly condition. These components are able to limit and eliminate short circuit currents without melting, restoring their own and the circuit’s electrical continuity, once the cause of the anomaly is removed. 24 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Connections of the central electronic unit (ECU) ADEM III MAY 2006 Modality for inserting and disconnecting ECU connectors Figure 20 Figure 19 05_048_V J1 J2 A 05_010_V J1. Vessel side wiring connector - J2. Engine component wiring connector - A. Ground connection of the ECU. The connection of the central electronic unit, ECU, to the EDC system, takes place by means of two 70-way connectors. The presence of the two connectors provides for a subdivision of the wire harnesses to distribute the large quantity of conductors and at the same time favour a quicker identification of the lines during the service check operations carried out by technical assistance personnel. The connectors are polarized and equipped with fixing screws to facilitate the insertion and disconnection operations and guarantee the link. Both connectors are fastened to the ECU by means of 4 mm socket head screws. For the disconnection: loose the screw until the connector is completely free. For the insertion: fit the connector into the seat, fit the screw and tighten it firmly. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Throttle lever position sensor Figure 21 25 Sensor to detect water in fuel Figure 22 2 05_019_V After testing the working condition of the linkage, adjust the run of the servo components (see Chapter 15). o With the throttle at idle setting, the potentiometer rod has to be in the resting position; 1 o With the throttle at the stop, the potentiometer rod has to be in the position of maximum run out. Neutral gear sensor CAUTION When neutral gear sensor is installed remember to connect it to GN connector. In installation with no sensor, do not remove the cap of the GN connector to avoid compromising start engine function. 05_018_V 3 1. Prefilter - 2. Conductor to be connected with the negative battery terminal 3. Sensor to detect water in fuel. CAUTION In order to enable the proper working of the sensor to detect water in fuel, the prefilter support needs to be electrically connected to the negative battery terminal. In the engine models which use parts with insulated poles it is necessary to electrically insulate the prefilter support from the boat mass and then connect the support with the negative battery terminal. 26 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 9. MAIN ANALOG INSTRUMENT PANEL Figure 23 3 4 5 electronic RPMx100 2 HOURS V oC 1 bar oF 11 10 9 6 8 7 12 13 04_233_N 1. Coolant temperature gauge (TA) - 2. Revolution counter and hour counter (CG) - 3.Voltmeter (V) - 4. Buzzer (SA) 5. Indications and alarms module (MS) - 6. Engine oil pressure gauge (MO) - 7. Connector for secondary instrument panel (JE) 8. On board panel instrument light switch (L) - 9. Engine start/stop key switch (CA) - 10. Engine stop push-button (usable only on versions with excitation engine stop) - 11. Sound alarm inhibition push-button (P1) - 12. Connector for main panel wiring (JC) 13. Cap with electrical continuity connection. Installation of the IVECO MOTORS onboard panel with analog indicators entails connecting the panel’s JC connector to the JB connector on engine wire harness, interposing the appropriate extension wire harness available in 3, 5 and 7 metre-long versions. The JC-JB wire harness comprises 47 lines, each connected to the terminal identified on both connectors by the same number. To the main panel is connected the JE connector, provided for connection to the secondary panel; in installations without secondary panel, do not remove the cap of the JE connector to avoid compromising the electrical continuity of the systems’ power supply circuit. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 27 Synoptic of the connections of the analog panels Figure 24 2 MAIN INSTRUMENT PANEL JE JH JE SECONDARY INSTRUMENT PANEL JH JC JC ENGINE EQUIPMENT 1 J2 EDC J1 JA JB JF2 JF1 RELAY BOX BATTERY 06_131_V 1. JB-JC Extension wire harness - 2. JE-JH Extension wire harness. Figure 25 46 34 47 32 45 29 16 43 28 42 7 1 6 5 37 24 4 27 26 37 11 4 38 39 39 40 41 46 32 19 31 18 30 7 1 17 45 6 24 38 12 25 9 3 2 10 47 33 8 22 23 23 11 15 14 13 20 21 22 10 3 17 44 9 2 18 34 35 36 36 21 8 19 31 30 35 20 33 5 12 13 14 25 40 29 15 26 16 28 27 44 43 42 41 04_250_N JC JB Connectors of the extension wire harness JB - JC, seen from the coupling side The JC-JB wire harness comprises 47 lines, each connected to the terminal identified on both connectors by the same number. To identify the functions served by the individual lines, refer to the electrical diagrams in Chapter 20. 28 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Installation MAY 2006 Indications and Alarms Module In order to drill holes on the area where the panel is to be mounted, refer to the dimensions indicated in Chapter 11. Figure 26 Operation of the panel 7 After completing the electrical connections and engine preparation, perform the tests required for the first start, as described in Chapter 18. Verify the proper operation of the panel, proceeding as follows: 6 8 5 9 o Make sure that the “ENGINE ROOM / BRIDGE” switch of the Relay Box is in the “BRIDGE” position, then turn the key switch to the first position and verify that the instruments are powered and the Indications and Alarms Module runs the alarm test for about 5 seconds according to the procedures set out below. 4 o Once the test is complete, only the indications prescribed for the engine not running must remain lighted: e.g. “alternator charge” and “low oil pressure”; the analog instruments must provide values consistent with the relevant physical parameters. Testing the engine start function Turn the key switch in the second position and release it quickly; the start function is fully controlled by the ECU and begins when the key is released. Checking indications After starting the engine, verify whether the operating modes of the Indications and Alarms Module are similar to those set out below. Using appropriate measuring instruments, verify the consistency of the indications provided by the analog instruments. Verify the indication of the panel revolution counter, comparing it with the one measured by a reference instrument; if the indication is different, proceed as described below. Testing the engine stop function The engine is stopped and the panel is disabled by returning the key switch to the resting or zero position. The panel has an engine stop push-button whose function is only enabled in versions where the engine stops as a result of the excitation of an actuator, i.e. engine versions requiring certification by Certification Bodies. 3 10 11 12 2 1 13 04_234_N 1. Engine overspeed (SSV) - 2. Presence of water in the fuel prefilter (SAC) - 3. Low engine coolant level (SBLA) 4. Alternator anomaly (SS) - 5. Clogged oil filter (SIFO)6. Clogged blow-by filter (SIFB) - 7. Pre-lubrication in progress (SP) - 8. Clogged air filter (SIFA) - 9. Clogged fuel filter (SIFC) 10. High coolant temperature (SATA) - 11. Low oil pressure (SBPO) - 12. Pre/post heating (SCP) - 13. EDC Malfunction (EDC). The Indications and Alarm Module comprises the indicator lights and the electronic alarm interface, timing and storage circuit. It is programmed in such a way that when it is powered, all indicator lights are lighted, with the exception of those for “pre-lubrication”, “pre-post heating” and “EDC” failure and a sound signal is emitted by the buzzer. The buzzer may be silenced before the end of the test, acting on the appropriate control. During the starting phase and for the subsequent 15 seconds, needed to stabilize the low oil pressure signal, all the module’s functions are inhibited; once this time interval has elapsed, every alarm state detected by the sensors will cause the associated indicator to be lighted and the buzzer to be powered; the exceptions are the “pre-lubrication” and “prepost heating” indicators, given only visually. When a new alarm state is detected, the indicator light will flash to highlight the occurrence with respect to any others which may be ongoing at the time. When the sound alarm is shut off, the light indicator will remain lighted and the alarm will be stored until the engine is stopped. The standard set-up of the V08 ENT M75, V08 ENT M11 and V08 ENT M12 provides for use of the indicators: SBLA, SIFA, SIFC, SIFO, EDC, SS. V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Revolution-counter calibration 29 Revolution-counter calibration Figure 27A Figure 27B 2 1 2 1 06_113_V 04_255_N 1. Adjustment screw - 2. Panel lighting lamp. 1. Calibration increasing button 2.Calibration decreasing button. Verify the indication of the panel revolution counter by comparing it with the one measured with a reference instrument; if it differs, operate the adjustment screw (1), located in the rear part of the revolution counter, until consistency is achieved; repeat the operation for different engine rpms. Verify the indication of the panel revolution counter by comparing it with the one measured with a reference instrument; if it differs, press the button 1 and 2 situated on the rear of the tachometer, until consistency is achieved; repeat the operation for different engine rpms. Maintenance Maintenance Should it become necessary to replace a panel light, remove the lamp holder from the rear part of the instrument (see Figure 27A). The board is illuminated by not-replaceable internal LEDs. 30 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 10.SECONDARY ANALOG INSTRUMENT PANEL Figure 28 electronic RPMx100 04_240_N 1.Connector for secondary panel wire harness (JH) - 2. Engine start push-button (CS) - 3. Revolution-counter (CG) 4. Buzzer (SA) - 5. Indications and alarms module (MS) - 6. Engine stop push-button (AS) 7. Sound alarm inhibition push-button (P1). The connection is achieved by removing the cap on the JE connector of the main panel, and connecting the JE connector to the JH connector on the secondary panel, interposing the extension wire harness, available in 3, 5 and 7 metre-long versions (see Fig. 19). The JE-JH wire harness comprises 12 lines, each connected to the terminal identified on both connectors by the same number (see fig. 24). Figure 29 1 6 6 1 Operation of the secondary panel After completing the electrical connection to the main panel and engine preparation, and performing the tests required for the first start (as described in Chapter 18), verify the proper operation of the panel, proceeding as follows: o Make sure that the “ENGINE ROOM / BRIDGE” switch of the Relay Box is in the “BRIDGE” position, then turn the key switch to the first position, thus enabling the operation of both panels. o Carry out the same tests for the secondary panel as were carried out for the main panel. o Disable the secondary panel by bringing the key switch on the main panel to the resting or zero position. Testing the engine start and stop function. 04_251_N 7 *% 12 12 *( 7 CONNECTORS OF THE JE-JH EXTENSION WIRE HARNESS, SEEN FROM THE COUPLING SIDE Installation In order to drill holes on the area where the panel is to be mounted, refer to the dimensions indicated in Chapter 11. With the panel enabled, press the green push-button until the engine starts, then release it; wait for engine rpm to stabilize before stopping it by pressing the red push-button. The starting and stopping operations can be performed several times and consecutively from the secondary panel Checking indications Proceed in the same way as for the main panel. 31 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 11.DRILLING PLANS FOR ANALOG PANELS Ø Ø 4 26 4 Figure 30 4 = 200 140 = Main panel Ø4 Ø 4 26 4 4 26 = = 26 4 225 285 04_022_C Dimension in millimetres. 28 2 Figure 31 Ø Ø 4 4 140 = 80 = Secondary Panel 4 2 28 = = 28 2 28 4 Ø Ø 180 240 04_023_C 32 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 12.CUSTOMIZED INSTRUMENT PANEL Using only the components of the panel that are not wired to allow the panel customization, they will have to be wired using the 10 metre long wire harness, set up at one end for coupling to the JB connector and at the opposite end with conductors with free terminals with identifying numbering on each wire. The conductors will have to be connected to the individual components as indicated in the electrical and wiring diagrams in Chapter 20. Figure 35 1 2 3 5 6 7 9 4 8 10 11 12 13 14 15 16 caution 17 18 19 20 To assure the functionality of the safeties pertaining to the engine start/stop commands from the instrument panel or engine room, it is mandatory to wire the key switch strictly as shown in the electrical diagrams in Chapter 20. The wiring details of the indications and alarms module alone are provided below; indications for IVECO MOTORS indicator instruments are shown in the related wiring diagrams in Chapter 20. JD Connector for indications and alarms module 21 22 23 24 04_241_N VIEW FROM THE TERMINAL SIDE OF THE COUPLING SIDE WIRING connector TRIDENT / ITT CANNON part TST 24PA00 terminal female part 192990-0050 lid rear part TST24AH0 Figure 34 JD connects the indications and alarms module to the electrical system of the engine (sensors, power supply, etc.). The terminal part of the wire harness, supplied with the module, must be completed using female terminals, as described in the electrical diagram of Chapter 20. For standard-equipped engines, to have the essential indications available, the following ways must be wired: 1, 3, 7, 8, 9, 10, 11, 13, 14, 15, 16, 17, 18, 19 with the female terminals supplied as standard equipment. 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21 05_034_C VIEW FROM THE SIDE INTEGRATED IN THE REAR PART OF THE MODULE MAY 2006 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 33 Functions of the JD terminals PIN Description Electric level OFF Indication ON Indication 1 Module power supply Positive (+B) 2Not connected 3 - EDC Fault indication High (+B) 4Not connected 5 Pre-heating indication 6 Low (ground) High (+B) Low (ground) Pre-lubrication indication Open circuit High (+B) 7 Engine start Power supply positive (+B) while starting 8 Buzzer inhibitionNegative (ground) during the request 9 Module power supplyNegative (ground) 10 Sound alarm power supplyNegative (ground) during the emission of sound 11 Clogged oil filter indication Open circuit Low (ground) 12 Clogged oil vapour filter indication (not applicable) Open circuit Low (ground) 13 Clogged air filter indication Open circuit Low (ground) 14 Clogged fuel filter indication Low (ground) Open circuit 15 Alternator fault indication High (+B) Low (1 to 3 V) 16 Low engine coolant level indication Open circuit Low (ground) 17 High coolant temperature indication Open circuit Low (ground) 18 Low engine oil pressure indication Open circuit Low (ground) 19 Presence of water in fuel indication Open circuit Low (ground) 20 Overloaded or runaway engine indication Open circuit High (+B) 21Not connected - 22Not connected - 23 Reception of data from main panel NMEA communication protocol (0 to 5 V) 24 Transmission of data to secondary panelNMEA communication protocol (0 to 5 V) caution To assure the utmost reliability and safety while underway, all installations must be provided with the following alarm indications: (EDC) EDC failure (SATA) high coolant temperature (SBPO) low oil pressure It is also recommended that the following indications are present: (SAC) presence of water in the fuel prefilter (SIFA) clogged air filter (SS) alternator fault 34 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 13.SENSORS FOR DETECTION AND INSTRUMENT PANEL SIGNALLING Oil pressure sensor Coolant temperature sensor Figure 38 Figure 36 05_114_C Resistor with negative temperature coefficient, providing the signal for analog temperature indication. 04_237_N Operating voltage from 6 to 24 V Calibration range from 0° to 120 °C Resistance value at 90°C 51.2 ± 4.3 Ω Electrical poles isolated Low level coolant sensor Figure 37 05_011_V Microswitch sensor controlled by the float of the coolant tank. Operating voltage: from 6 to 24 V Condition for high level open Maximum current 2 A not inductive Electrical poles isolated Rheostat component providing the signal for the analog indication of pressure. Operating voltage from 6 to 24 V Calibration range from 0 to 10 bar Resistance value at 0 bar 10 Ω +3/-5 Ω Resistance value at 2 bar 52 ± 4 Ω Resistance value at 4 bar 88 ± 4 Ω Resistance value at 6 bar 124 ± 5 Ω Maximum value of resistance 184 Ω Operating temperature from - 25 to 100 °C Electrical poles isolated Clogged air filter sensor 35 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Clogged fuel filter sensor Figure 40 Figure 42 04_030_C 04_238_N Vacuum switch, providing the signal for the clogged air filter alarm indicator. Operating voltage: from 6 to 24 V Condition at ambient pressure normally open Closing vacuum: ≥ -52 mbar Operating temperature: -20 / +80 °C Maximum current 0.1 A (not inductive) Electrical poles isolated Pressure switch, providing the signal for the related indicator, when the pressure at the fuel filter inlet is too high. Operating voltage: from 6 to 24 V Condition at ambient pressure normally closed Opening pressure: 1.5 ± 0.1 bar Maximum current 0.1 A (not inductive) Electrical poles isolated Exhaust gas temperature sensor Clogged oil filter sensor Figure 43 Figure 41 04_260_N NiCr-Ni thermocouple sensor with insulated poles, providing the signal for the analog indication of exhaust gas temperature. 04_029_C Differential pressure switch, providing the signal for the related indicator when pressure difference between inlet / outlet oil filter is more then a limit value. Temperature Voltage °C mV 100 4.10 200 8.13 Operating voltage: from 6 to 24 V 300 12.21 Condition at ambient pressure normally open 400 16.40 Closing pressure: 2.4 ± 0.3 bar 500 20.65 Opening pressure: 1.8 ± 0.3 bar 600 24.91 Maximum current 3 A (not inductive) 700 29.14 Electrical poles isolated 800 33.30 900 37.36 36 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE Sensor to detect water in fuel MAY 2006 CAUTION In order to enable the proper working of the sensor to detect water in fuel, the pre-filter support needs to be electrically connected to the negative battery terminal. Figure 44 04_031_C Fuel resistivity sensor, integrated with the control and amplification electronic circuit, providing the signal for the indicatorof the presence of water in the fuel. In the engine models which use parts with insulated poles it is necessary to electrically insulate the prefilter support from the boat mass and then connect the support with the negative battery terminal. Neutral gear sensor CAUTION Operating voltage from 12 to 24 V Condition in the absence of water open circuit Closed condition resistance of the liquid ≤ 1 MΩ Operating temperature from -20 to +80 °C Connections of the sensor detecting the presence of water in fuel Figure 45 2 1 1 2 3 1 2 3 3 1 2 3 1 2 3 05_017_V 1. M Connector of the engine wire harness 2. Sensor detecting the presence of water in the fuel 3.Wiring harness (outfitter’s responsibility). The three pole connection between the sensor for detecting the presence of water in the fuel and the engine wire harness must be produced by the outfitter according to the position of the fuel prefilter in the boat. Connection to the engine wire harness requires a METRIPACK150 three-pole connector with three male terminals; connection to the sensor requires a JUNIOR TIMER threepole connector with three female terminals. When neutral gear sensor is installed remember to connect it to GN connector. In installation without sensor, do not remove the cap of the GN connector to avoid compromising start engine function. MAY 2006 INSTALLATION DIRECTIVE 14.PREPARING THE ENGINE FOR FIRST START-UP 1. Drain the residual 30/M protective oil from the sump. 2. Pour into the lubricating loop only lubricating oil of the type and in the quantities set out in the Refilling Table. 3. Drain the CFB protective liquid from the fuel loop, completing the operations as indicated under item 3. of Chapter 19. 4. Remove the caps and/or seals from the engine intake, exhaust, aeration and venting ports, restoring normal conditions of use. Connect the inlet of the turbocharger to the air filter. 5. Connect the fuel loops to the boat tank, completing the operations set out in item 4. of Chapter 19. During filling operations, connect the pipe returning fuel to the tank to a collecting container, to prevent residues of CFB protective liquid from ending up into the boat tank. V08 ent m75 - M11 - M12 37 15.TESTS BEFORE THE FIRST START-UP Although they are extremely important, “common sense” checks such as the exposure of sensitive parts (plastics, wire harness, electronic units, etc. ...) to heat, and those that for years have characterized the quality of the work performed in the yard, are not mentioned herein. Tests of the proper operation of the engine and the components of the electronic control system may be performed rapidly and with the utmost reliability using specific diagnostic tools, available from IVECO MOTORS Technical Assistance Centres. Fuel tank suction Verify the fuel suction at the maximum allowed longitudinal and transverse inclination, with the residual quantity of fuel considered “RESERVE”, such as to cause the reserve indicator light to be permanently lighted. 6. Verify and refill engine coolant as prescribed. 7. Remove from the engine the labels with the inscription “ENGINE WITHOUT OIL”. Throttle lever position sensor In the positions of minimum and maximum travel, verify the correlation between the position of the throttle control valve on the bridge and the position of the sensor rod. Instruments and control panel Verify the efficiency of all light indicators, as described in the related Chapters. 38 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 16.FIRST ENGINE START Before starting the engine, please make sure the sea water gate valve is open, check the levels of the lubricating oil and of the engine coolant, and complete venting the air from the fuel feed loop, acting on the hand pump of the prefilter or with the aid of a dedicated electrical pump. Loosen the vent fitting on the prefilter and operate the pump until only fuel without air flows out. Start-up procedures Figure 44 Venting fuel supply line Figure 43 1 2 #(%#+ %.').% 2//- 3 20- "2)$'% )'.)4)/. 1 2 34!24 20- 3 4 05_007_V 1. Control selector from bridge or engine room 2. Power supply switch of the engine electric circuits 3. Start button from engine room 4. Button for managing acceleration and deceleration. 05_016_V 1. Prefilter vent fitting - 2. Vent fitting on the filter support 3. Vent fitting on the high pressure pump. o Loose the vent fitting on the prefilter (1) and operate the pump until only fuel without air flows out. Tighten the vent fitting. The electrical equipment of this engine allows starting it from the “engine room” and from the “bridge”. NOTE A few moments after start-up, make sure sea water is correctly drained from the relevant circuit. o Loosen the vent fitting (2) on the filter support and operate the pump until only fuel without air flows out. o Tighten the vent fitting (2) and continue pumping during the initial start-up phases. Make sure that the fuel that flows out of the fitting is not dispersed in the environment. Only if the engine starting is very difficult, stop the engine, insert a hose on the vent fitting of the high pressure pump (3), loose the junction and start the engine for a few seconds. Stop the engine, remove the hose and tight the junction to the prescribed torque value. Make sure that the fuel that flows out of the fitting is not dispersed in the environment. Start the engine. Starting the engine from the bridge This is allowed only if the Relay box switch (1) is in the “BRIDGE” position. Procedures and warnings are provided in the operation and maintenance manual. Starting engine from the “bridge” - Switch over the switch (1) of the relay box in the position “ENGINE ROOM”. This operation excludes all the bridge controls and must be absolutely avoided when the engine has been started. - Switch over the switch IGNITION (2) to power the electric circuits of the system and enable the controls available on the panel. - Press the button START (3) to start the engine. Caution Never attempt to vent the high pressure system as this is useless and extremely dangerous. Warning caution Avoid accurately that fuel comes into contact with the alternator belt. The engine start is fully controlled by the ECU; the start-up phase begins when the button START is released. Engine shut-off from “bridge” The engine shut-off occurs switching over the switch IGNITION (2). Bringing again the switch (1) in position “BRIDGE”, the use of the controls will be disabled on the Box, enabling the startup only the bridge controls. INSTALLATION DIRECTIVE MAY 2006 RPM control To allow easily to control engine RPM from the “engine room”, a simultaneous acceleration/deceleration function (RPM+/RPM-), active only when the switch (1) is in the “ENGINE ROOM” position, and the switch (2) is in IGNITION position. Acceleration (RPM +) If, the engine is running, and RPM+ / RPM- push-button (4) is held down in the “RPM+ position, then engine rpm are progressively increased. The increase ends when the pushbutton is released, allowing the engine to run at the desired rpm. V08 ent m75 - M11 - M12 39 Once the first start-up phase is complete, verify that: o There are no liquid leaks from the coolant loop pipeline junction hoses. o There are no exhaust gas leaks in the hull. o In order to carry out the cooling system degassing, do as follows: Figure 45 1 05_009_V Deceleration (RPM −) If the engine is running, and RPM+ / RPM- push-button is held down in the “RPM-” position, a progressive reduction in rpm is obtained.The reduction ends when the push-button is released, allowing the engine to run at the desired rpm. The set out engine speed will be kept until the next engine shut-off. The engine shut-off resets every previous configuration. NOTE The effect of the RPM + e RPM – controls varies according to the duration of the operation: it is achieved a very slow variation during the first 3 seconds; continuing the operation, the regulation becomes much more effective and enables to complete the full range of the engine speed in a overall time of about 20 seconds. caution Never operate the “BRIDGE - ENGINE ROOM” switch when the engine is running. 1. Venting screw. Stop the engine, then loose the venting screw (1) carefully to degas the expansion tank. When the operation is completed, tighten the screw to the prescribed torque, start the engine and keep it up for a few minutes. Stop the engine and verify the coolant level again, fill it up, if necessary. Make sure that the coolant that flows out is not dispersed in the environment. o Complete the instrument panel operation tests as described in the related Chapters. o Verify that the power supply voltage across the battery, after about 15 minutes with the engine running, is no less than about 26 V. o Stop the engine and delete any “errors” which may have been stored in the injection system ECU during the stabilization phases. The error deletion can be carried out by the diagnostic instrument IVECO SERVICE TOOL. 40 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 17.EDC ECU INDICATION LIGHTS identification is taken “reading” the blink code of the CHECK indication light. (Indications for decoding codes are in the following chapter). The code emission happens automatically and sequentially when the anomalies are detected; the sum of the current anomaly code is designated “list”. CHECK Indication light Figure 45 9 8 7 Each single code is organized in 3-digit numerical blocks with a fixed lighting duration equal to 0.6 s. #(%#+ %.').% 2//- The pauses (switch-off time) have a different duration to distinguish the given type of information: pause between blinking of the same digit 0.36 s pause between different digits of the same code 1.5 s pause between different codes of the same list 3s pause between consecutive lists 6s 20- "2)$'% )'.)4)/. 34!24 20- 05_007_V 4 The emission is continuative, i.e. the code list is repeated consecutively with the same order; a 6-second pause separates the list repetitions. 4. Reset button of the “maintenance alarm” 7. Blink code emission LED (EDC) - 8. Signalling LED of maintenance interval expiration - 9. Signalling LED for fault engine operating parameters (WARNING). NOTE Only the codes of the current anomalies are returned; a temporary anomaly causes the emission of the associated code for the whole period the anomaly is present. The emission code stops when the operating conditions are restored, while the data concerning the anomaly are stored in the failure memory of the ECU. The ECU continuously monitors its own operating conditions, as well as of the engine and of components connected to it with complex auto-diagnosis routines. The identification of anomalies causes: - the anomaly data storage in the ECU. - the blinking lighting of the fault indication light EDC on the instrument panel. - the lighting of the green indication light CHECK (7) on the relay box. The stored information are able to be decoded and erasable by the IVECO SERVICE TOOL. The blinking lighting of the EDC fault indication light has the purpose to inform about a detected anomaly, whose Example of emission of the anomaly codes: Figure 45 /&& ¬S ¬S ¬S ¬S ¬S ¬S ¬S ¬S ¬S ¬S ¬S EMISSION CODE 142 /&& ¬S ¬S ¬S EMISSION CODES 142 AND 511 ¬S ¬S ¬S ¬S ¬S ¬S ¬S ¬S 05_090_V MAY 2006 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 41 WARNING Indication light Signalling maintenance interval expiration The ECU carries out a control activity on the operating conditions through the analysis of the detected operating parameters; it evaluates the behaviour of the single signals emitted by the sensors and classifies the situation, according to predetermined threshold, activating the red indication light (9 figure 45). The lighting of the indication lights MAINTENANCE (8 figure 45), caused by the ECU, indicates the need to perform the periodical lubricating oil replacement. When the operation is performed, it is necessary to press the button (4 figure 45) to restore the counter and begin a new operating cycle. The signalling is available on the relay box only, and does not involve any other signalling on the instrument panel. Blinking indication light - warning level: Lighting cycle of 0.6 s and pause of 0.24 s. It indicates that the value is slightly above the normal threshold; the user of the vessel does not notice any difference in the engine behaviour. Indication light constantly On - derating level: It indicates that the value is significantly above the normal threshold; the maximum power of the engine is reduced to protect its intactness. The user of the vessel can notice the reduction of the power of the engine. NOTES Only the current anomalies enable the behaviour specified above; a temporary anomaly causes the lighting of the indication light, according to the modalities illustrated, for the whole period the anomaly is present. The emission code stops when the operating conditions are restored, while the data concerning the anomaly are stored in the failure memory of the ECU. The signalling is available on the relay box only, and does not involve any other indications on the instrument panel. The stored information are able to be decoded and erasable by the IVECO SERVICE TOOL. SHUTDOWN (preliminary) When the most critical thresholds exceed their normal values, it can be enabled the forced engine shutdown. The next time the engine is started, if the normal operation are restored, there will not be any lighting signalling, while the data concerning the anomaly are stored in the failure memory of the ECU. Parameter list that can cause warning, derating or shutdown conditions: Engine coolant high temperature Intake air high temperature Engine oil low pressure Engine overspeed Fuel high temperature Engine oil low temperature Engine oil high temperature Rail low pressure Rail high pressure Loss on the high pressure fuel line Intake air high pressure Intake air low pressure Power supply voltage 42 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Blink code table (temporary list) Component Anomaly Code Cylinder 1 electro-injector open circuit/short circuit 111 Cylinder 2 electro-injector open circuit/short circuit 112 Cylinder 3 electro-injector open circuit/short circuit 113 Cylinder 4 electro-injector open circuit/short circuit 114 Cylinder 5 electro-injector open circuit/short circuit 115 Cylinder 6 electro-injector open circuit/short circuit 116 Cylinder 7 electro-injector open circuit/short circuit 117 Cylinder 8 electro-injector open circuit/short circuit 118 Air intake temperature sensor open circuit/short circuit to +B or to ground 133 Air intake pressure sensor open circuit/short circuit to +B or to ground 135 Flywheel sensor anomalous or missing signal 141 Timing system sensor anomalous or missing signal 142 Timing system sensor irregular mechanical behaviour 142 Relay for engine start open circuit/short circuit 145 Atmospheric pressure sensor open circuit/short circuit to +B or to ground 152 Throttle position sensor anomalous or missing signal 154 Engine oil temperature sensor open circuit/short circuit to +B or to ground 156 Engine oil pressure sensor open circuit/short circuit to +B or to ground 157 Rail pressure sensor open circuit/short circuit to +B or to ground 159 Pressure limiter valve open circuit/short circuit 162 Pressure limiter valve irregular mechanic behaviour 162 Fuel temperature sensor open circuit/short circuit to +B or to ground 165 Engine temperature sensor open circuit/short circuit to +B or to ground 168 Relay for pre-post heating resistor open circuit/short circuit 178 Engine high temperature indication light open circuit/short circuit 191 Engine oil low pressure indication light open circuit/short circuit 192 Throttle control from relay box anomalous or missing signal 195 Battery voltage insufficient or excessive value 511 Power supply voltage 5 V connector J2 insufficient or excessive value 516 Power supply voltage 8 V insufficient or excessive value 517 Indication light Warning open circuit/short circuit 525 Indication light Maintenance open circuit/short circuit 526 Power supply voltage 5 V connector J1 insufficient or excessive value 599 MAY 2006 INSTALLATION DIRECTIVE 18.UNDERWAY CHECKS ECU Temperature Verify that the temperature of the surface of the electronic engine control unit, after 30 minutes underway at full engine power, is less than +70°C. Engine compartment vacuum Verify that value of ambient air pressure in the engine room with the engine(s) at full load and maximum power output complies with the value specified herein. Combustion air temperature Verify that the temperature in the engine room, after 30 minutes underway at full engine power, does not exceed 45°C (V08 ENT M75) or 50°C (V08 ENT M11 e V08 ENT M12) and, in any case, does not exceed the value of external temperature by more than 15°C. Exhaust back-pressure Verify that the value of back-pressure present at the inlet of the exhaust gas conduit, with the engine(s) at full load and maximum power output, complies with the value specified herein. Exhaust temperature Verify that the temperature of the exhaust gases under maximum engine power output conditions is close to the prescribed value; to determine the propeller power absorption curve, it will also be possible to obtain from the ECU parameters the fuel injection values by using the IVECO MOTORS tool. Fuel temperature Verify that the temperature of the fuel in the low pressure line, while underway at full power and with a stable quantity of fuel in reserve, does not exceed 70°C. A higher value would entail a reduction in engine performance. If the tendency to reach the maximum allowed temperature is noted, install a heat exchanger for the fuel. Pressure in the fuel supply line To assure the regular operation of the engine and the reliability of the components of the fuel supply and injection system, you need to verify that: o vacuum in the fuel oil supply line to the low pressure pump is less than 0.5 bar relative (5000 mmH2O); pressure in the fuel oil supply line to the low pressure pump is less than 0.5 bar relative (5000 mmH2O); o pressure in the fuel oil return line to the tank is less than 0.2 bar relative (2000 mmH2O). Measures are carried out inserting a “T” junction near the fuel inlet and outlet, taking care to avoid any air suction. Values are read at variable rpm, from idle to maximum, at 200 rpm intervals. If there are any symptoms indicating the possible presence of air in the fuel supply line, a check may be made by inserting a clear tube, arranged as an inverted U, before the engine inlet junction. V08 ent m75 - M11 - M12 43 44 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE 19.PREPARING THE ENGINE FOR LONG IDLE PERIODS To prevent oxidation to the internal parts of the engine and to some components of the injection system, if idle periods exceeding two months are expected, the engine needs to be prepared with six-month periodicity, proceeding as follows: 1. Drain the lubricating oil from the sump, after heating the engine. 2. Pour 30/M protective oil (alternatively, oil conforming to MIL 2160B Type 2 specifications) into the engine to the “minimum” level marked on the dipstick. Start the engine and let it run for about 5 minutes. 3. Drain the fuel from the injection line and from the filters, taking care to prevent the fuel from coming in contact with the alternator’s belt. 4. Connect the fuel line to a tank containing CFB protective liquid (ISO 4113) and assist the inflow of the liquid by pressurizing the line and turning the engine over for about 2 minutes, after excluding the operation of the injection system. The required operation may be carried out by directly polarizing the terminal 50 of the electric starter motor with positive voltage 24 V, using a conductor prepared for the occasion. 5.Nebulize 30/M protective oil at the rate of about 100 g (10 g per litre of displacement) in both turbochargers, while the engine is turning over as described above. 6. Close with suitable stoppers or seal with adhesive tape all engine intake, exhaust, aeration and venting ports. 7. Drain the residual 30/M protective oil from the sump; it may be re-used for 2 more engine preparation operations. 8. Apply tags with the inscription “ENGINE WITHOUT OIL” on the engine and onboard panel. 9. Drain the coolant, if it has not been mixed with antifreeze and corrosion inhibiting agents, affixing tags to indicate that the operation has been carried out. If external parts of the engine are to be protected, spray protective liquid OVER 19 AR onto unpainted metal parts, such as flywheel, pulleys and others; avoid spraying belts, connector cables and electrical equipment. MAY 2006 MAY 2006 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 45 46 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 20.ELECTRIC DIAGRAMS Wiring diagram key General condition for the preparation and interpretation of wiring diagrams o Key switch open o Engine not running o Liquids at efficient levels and pressures Figure 48 Connection JC: connector 8: terminal Component code 1 7 JF1 14 22 JA JF2 2 JB 2 JC 11 JA 17 15 DK5 K1 POP MS 2 SW2 CA JC 37 12 18 35 31 JC JB 37 12 18 35 31 JB JA 13 7 K2 A M B J4 C B J4 A 1 12 6 7 8 9 10 2 3 11 4 JG1 JF1 15 J1 U T V 50 1 TGC IGNITION 30 5 K5 a SBPO 13 ENGINE ROOM SS b 8 JF2 SW1 BRIDGE SATA F1 7 EDC 2 SP Component terminal D C B A 15 7 JC 8 JC 7 JB 8 JB 21 JA 20 JA 10 JF1 5 JF1 15 9 DK2 DK1 3 JF2 R2 120? JF1 31 32 33 34 35 L3 K4 JF1 4 2 3 1 L2 L1 PA F2 SW3 DK4 START K3 1 4 2 JF1 25 26 27 28 29 30 KR DK3 4 JA 3 JF2 JA 11 JF1 20 JA 9 JF1 18 JA 10 JF1 19 R R 1 JA DR JB JF1 13 14 JF1 17 JC AC - M JF1 21 6 9 JF1 8 11 16 JA 12 6 JA 27 16 J1 95 - BAT 50 30 JA 23 24 26 25 JA 13 14 JA 18 SW4 MM 50 50 35 + 8 70 10 62 5 44 19 23 JA 17 JF1 JA 48 52 53 64 JB JB 10 44 JB JB JB 9 11 43 34 50 9 8 21 28 SLOW VESSEL MODE + BAT TROLLING MODE 6 4 10 16 6 4 CG 41 59 2 GH 1 2 GN GN 13 JB JB JB 29 1 GH 30 31 38 4 66 5 68 12 46 61 63 65 PH 50 6 12 85150 35 6 JF2 18 JA 1 JA 2 Minimum cable cross section in mm2 Component code or connector code Terminal connection Sk EDC J1 V08pi V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 47 Electrical equipment component code A fuel temperature sensor for EDC PR rail pressure sensor AC battery QP main analog instrument panel AP atmospheric pressure sensor QS secondary analog instrument panel AQ engine shut-off push-button on main panel S oil temperature sensor for EDC AS engine shut-off push-button on secondary panel SA buzzer B crankshaft sensor for EDC SI gear oil temperature sensor C camshaft sensor S1 engine oil temperature sensor (for gauge) CA key switch SW1 CS engine start push-button on secondary panel E1/E8 electro-injectors F engine coolant temperature sensor for EDC GG alternator GH grid heater power relay GN neutral gear sensor H combustion air pressure sensor for EDC J low coolant level sensor (for alarm) engine control selector from bridge or engine room (on relay box panel) power supply switch of the engine electric circuits (on relay box panel) start button from engine room (on relay box panel) reset button of the “maintenance alarm” (on relay box panel) manual throttle control in engine room (on relay box panel) coolant temperature sensor (for gauge) JC emergency shut-off push-button installer’s responsibility) JF1, JF2 relay box SW5 (optional, lubrication oil transfer electrical pump control unit JG1 pre-lubrication electrical pump control unit K,K1 clogged air filter sensors (for alarm) L instrument panel light switch L1 MM EDC blink code emission green LED (on relay box panel) signalling red LED for fault engine operating parameters (WARNING) (on relay box panel) signalling yellow LED of maintenance interval expiration (on relay box panel) sensor for detecting the presence of water in the fuel prefilter (for alarm) electric starter motor MS IVECO MOTORS indications and alarms module O,O1 exhaust gas temperature sensors (for gauge) P combustion air temperature sensor for EDC P1 sound alarm inhibition push-button PA throttle position sensor PF rail pressure control solenoid valve PH grid heater PO lubrication oil transfer electrical pump POP pre-lubrication electrical pump L3 M SW3 SW4 JG L2 SW2 T TGC U power relay for electric starter motor insulation (provision) clogged oil filter sensor (for alarm) V engine oil pressure sensor for EDC VI gear oil pressure sensor V1 engine oil pressure sensor (for gauge) WI low gear oil pressure sensor X clogged blow-by filter sensor (for alarm) Z clogged fuel filter sensor (for alarm) 85150 ECU of the EDC system (continues on next page) 48 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Connectors Gauges J1 CG revolution-counter MI gear box oil pressure MO engine oil pressure TA engine temperature TI gear box oil temperature TS exhaust gas temperature V voltmeter J1 on the relay box panel for external diagnostic tool 70-pole EDC - boat components connections J2 70-pole EDC - engine components connections J3 lubrication oil transfer electrical pump J4 pre-lubrication electrical pump JA connection between engine wiring and interface wire harness JB ON ENGINE WIRE HARNESS ready for connection to the main analog instrument panel JC ON MAIN ANALOG INSTRUMENT PANEL ready for connection to the engine wire harness IVECO MOTORS indications and alarms module JD JE ON MAIN ANALOG INSTRUMENT PANEL JF1,JF2 JH ready for connection to the secondar y analog instr ument panel relay box Relays contained in the relay box K1 key switch electric discharge K2 IGNITION switch electric discharge K3 K5 power supply to terminal 50 of the electric starter motor start request signal, from key switch to EDC electronic unit TGC control ready KR EDC blink code emission LED control K4 ON SECONDARY ANALOG INSTRUMENT PANEL ready for connection to the main analog instrument panel Indicator lights EDC EDC malfunction SAC presence of water in fuel prefilter SATA coolant high temperature SBLA low coolant level SBPO low oil pressure SCP pre-post heating SIFA clogged air filter SIFB clogged oil vapour filter SIFC clogged fuel filter SIFO clogged oil filter SIM expired programmed maintenance interval SP pre-lubrication SS alternator fault SSV engine overspeed Fuses contained in the relay box F1- F2 self restoring (not replaceable) 8 7 14 JF2 18 12 6 JF2 95 JA 1 JA 2 - BAT - AC + 1 M 50 JB 7 K4 JF1 DK3 K3 DK4 10 30 50 15 JC 2 JC JB 2 7 JA 22 21 JA 30 JF1 7 50 50 35 2 JB JC F1 4 4 5 MM JA 10 16 DK1 K1 JF2 SW3 START JF1 20 JA 8 8 CA 50 13 + BAT 6 6 b 70 10 12 JA 8 J1 6 62 6 9 DK2 K2 SW2 SW1 JF1 21 IGNITION BRIDGE 44 JA 5 JF1 8 a 19 27 11 ENGINE ROOM F2 16 JA JF1 SW4 1 JA 17 JC JB 48 52 53 64 JA 3 C 3 B 2 A 1 L2 L1 9 8 21 28 11 9 34 50 JB JB 43 44 10 JB JB 29 KR 59 JB JB 4 18 18 6 SS 41 DR JF1 13 14 JF1 17 L3 7 JF1 15 12 JB 37 12 JA 13 JC 37 EDC JA 23 24 26 25 JA 13 14 JA 18 JF1 4 R2 120? D 2 TGC 1 SP JB JF1 25 26 27 28 29 30 16 23 15 J1 U T V JA 17 5 11 JF1 31 32 33 34 35 DK5 K5 JF2 31 31 35 30 31 SBPO 35 38 JB 13 CG JB JC 1 12 66 5 2 GN 1 GN 2 11 GH JF1 19 JA 10 3 1 JF1 18 JA 9 2 GH JF1 20 JA 11 JF2 3 9 15 9 10 85150 68 12 46 61 63 65 PA 7 J4 A J4 C B 6 M B 8 POP A 1 4 2 4 MS 4 JG1 PH RPM - RPM + 4 SW5 1 M 5 JB 1 12 8 3 2 GG S IG L 1 2 GG 9 10 J3 A M B PO JA 28 7 B A 11 19 JA 12 24 36 100? D1 3 JF1 JG INSTALLATION DIRECTIVE 35 SATA TROLLING MODE Sk EDC J1 V08pi SLOW VESSEL MODE MAY 2006 V08 ent m75 - M11 - M12 49 EDC connector J1 BAT – AC BAT + 6 1 JF2 14 13 8 7 2 J2 J1 1 18 12 6 JF2 50 JA JF1 20 5 PF 2 1 61 61 63 65 JB 8 JC 8 JB 7 15 CA JC JC 2 7 62 30 JB JA 22 2 JF1 7 F1 A 1 U AP P B C 18 14 DK1 K1 b 1 3 U PR P 2 24 70 3 A P H U B C 40 44 JA 5 JA 8 a ENGINE ROOM JF1 8 41 DK2 K2 SW2 SW1 JF1 21 2 IGNITION BRIDGE A P V U B C 42 25 P 2 1 35 F 2 1 33 A 2 1 34 S 2 1 32 B 2 1 48 49 48 52 53 JA 3 JF1 25 26 27 28 29 30 F2 JF1 31 32 33 34 35 C 2 1 58 59 E1 1 2 36 44 E2 1 2 20 E3 1 2 37 45 E4 1 2 21 85150 E5 1 2 38 46 E6 1 2 28 E7 1 2 39 47 E8 1 2 29 V08 ent m75 - M11 - M12 6 50 INSTALLATION DIRECTIVE MAY 2006 EDC connector J2 Sk EDC J2 V08 - + F1 BATT - AC + DK1 6 12 18 K1 JF2 JA L3 L1 L2 b SW1 3 ENGINE ROOM JA 25 26 27 28 29 30 BATT 1 2 7 8 13 14 JF2 JF1 JF1 QP 1 1 2 KR 1 JA BRIDGE JB JC 8 J1 K4 7 36 36 61 63 65 JF1 JA 13 spia MAINT. 14 13 6 6 0 20 4 21 28 41 59 40 15 43 44 JF1 JA 14 10 spia WARNING. 40 15 43 44 JF1 JA 22 21 29 7 7 L AQ 50 JF1 10 DK4 5 JA 16 16 JE 10 8 JH 10 22 20 2 2 JH 4 AS JE 4 15 CA TROLLING MODE 30 4 4 13 10 11 13 10 11 1 2 50 30 40 85150 JC 17 28 3 9 9 JA JA JB JC 9 15 JF2 38 50 34 30 31 64 3 0 0 0 1 X100 CAN_BUS (L) F2 31 32 33 34 35 6 CAN_BUS (H) Sk Quadro princ V08pi SLOW VES. MODE CG 33 33 C TA T 5 5 1 34 34 V1 JA JB JC 32 32 C MO – + 9 SA JD 1 – 7 + 8 S1 O M 3 M 2 1 1 1 2 VI 2 3 WI 3 1 2 GG SS SIFA 1 2 3 17 18 EDC SATA SBPO K1 2 1 K 2 1 19 18 30 38 12 35 31 19 18 30 38 12 35 31 10 19 15 13 SAC O1 S IG L B+ GG B+ SI 2 14 27 46 26 25 21 47 22 39 23 45 42 41 14 27 46 26 25 21 47 22 39 23 45 42 41 P1 V MS SCP SBLA 5 SP SIFC SIFO SIFB 16 12 11 14 6 SSV J 3 2 1 X U 6 1 2 C 3 17 20 24 28 29 37 3 17 20 24 28 29 37 4 Z JG1 J4 JB JC 20 B A JD INSTALLATION DIRECTIVE 6 MAY 2006 V08 ent m75 - M11 - M12 51 Main analog instrument panel F2 – BAT – AC + + BAT 1 2 13 8 7 14 JF2 1 JA F1 50 L AQ P1 10 0 0 0 0 1 X100 DK4 K4 DK1 BRIDGE 10 JF1 5 29 JA 22 JF1 21 JA 7 28 JA 3 JF2 9 15 J1 EDC 38 JB 1 2 8 4 7 6 14 15 36 16 27 9 39 13 22 20 50 30 4 3 2 1 20 * See main indicator and control panel wiring diagram JF2 6 12 18 15 30 CA CG JC 1 2 8 4 7 6 14 15 36 16 27 9 39 13 K1 b SW1 ENGINE ROOM JA 3 JF1 25 26 27 28 29 30 31 32 33 34 35 JF1 6 SA 5 34 JB 5 34 JC 40 JE 1 2 3 * C TA 4 5 6 7 8 9 10 11 12 * C MO V AS CS 10 0 4 20 3 2 X100 CG 40 JD 9 1 7 QP P1 8 10 19 15 13 JH 12 11 10 9 8 7 6 5 4 3 2 1 1 50 30 MS JD 9 1 7 8 10 19 15 13 2 3 17 18 4 5 16 12 11 14 6 24 MS 2 SA 3 17 18 4 QS 5 16 12 11 14 6 23 V08 ent m75 - M11 - M12 6 52 INSTALLATION DIRECTIVE MAY 2006 Secondary analog instrument panel Sk Quadro secon V08pi 3 4 JB 2 6 1 5 13 33 34 °F 10 meter long wire harness 5 105 175 °C 210 G 250 100 120 2 Connections 32 OFF 0 0 7 16 VOLT 24 Identifying numbering on each wire 8 START G 6 8 10 58 87 116 psi 145 bar 4 ON 29 2 28 32 23 24 18 22 18 14 10 6 2 31 29 21 17 13 9 5 1 35 30 12 JD connector integrated in the rear part of the indications and alarms module 19 19 20 20 15 16 37 24 28 11 7 3 12 8 4 INSTALLATION DIRECTIVE JB 7 8 min X100 40 80 MAY 2006 V08 ent m75 - M11 - M12 53 Wiring of a specific personalised instrument board Sk Strumenti Quadri VDO V08 54 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 Wiring of the double personalised instrument board (main and secondary board) °C 80 40 min X100 100 175 210 105 250 °F 2 120 0 0 29 bar 4 MAIN PANEL G 8 7 6 5 4 3 2 1 24 6 8 10 58 87 116 psi 145 28 16 32 VOLT G 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21 OFF ON START JB JB 13 5 33 34 32 2 7 37 24 28 20 19 18 31 29 35 30 17 38 12 8 bar °C 80 40 SECONDARY PANEL min X100 100 175 210 105 250 °F G 8 7 6 5 4 3 2 1 4 6 8 10 58 87 29 116 psi 0 145 24 2 120 0 16 28 32 VOLT G 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21 Sk Strumenti Quadri VDO 1°+2° V08 3 * – + AC2 Two-engines installation IE1 M 50 30 50 JA 50 19 MM 1 10 GG2 B+ 50 MM B+ GG 1 30 50 M 85 86 BAT + 87 RL 30 BAT – – AC2 + – + AC1 * - - - - - + BAT – BAT M 50 30 MM 1 B+ GG1 19 AC1: Main Battery AC2: Battery for auxiliary services IE1: Engine 1 electrical system IE2: Engine 2 electrical system RL: Relay 50A max. *: Electrical power supply for services Key: 4 4 – BAT – 4 AC1 95 + 10 Single engine installation 10 10 19 JA 95 4 JA 95 + BAT 50 50 4 4 50 Sk Accum_Servizi V 4 JA IE2 INSTALLATION DIRECTIVE 50 MAY 2006 V08 ent m75 - M11 - M12 Supplementary services battery recharge 55 10 56 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE MAY 2006 MAY 2006 INSTALLATION DIRECTIVE V08 ent m75 - M11 - M12 57 21.APPENDIX Page ��������������������������������� LUBRICATING OIL TRANSFER MODULE 54 PRE-LUBRICATION MODULE 54 58 V08 ent m75 - M11 - M12 INSTALLATION DIRECTIVE LUBRICATING OIL TRANSFER MODULE MAY 2006 PRE-LUBRICATION MODULE Figure 1 Figure 2 #(!2'% #(!2'% $)3#(!2'% $)3#(!2'% 1 04_036_C 1 %6 /&& %6 /. 2 04_037_C 1. Oil discharge control. 1. Not used - 2. Not used. Lubricating oil exhaust operations are simplified by the presence of an electrical control system connected to the JG connector of the interface wiring harness. Manual control for exhaust operations is positioned on the front panel unit. For safety reasons, control is enabled only with the key switch in the “OFF” position. The module (on request) is connected to the JG1 connector of the interface wiring harness. The task of pre-lubricating the engine’s internal components is managed and controlled by the electronic circuit of the module when the key switch is placed in “ON” position. IVECO S.p.A. PowerTrain Viale Dell’Industria, 15/17 20010 Pregnana Milanese - MI - (Italy) Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29 www.ivecomotors.com