Iveco S30 Ent M23 Users Manual

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SOFIM

S30 ENT M23

4 CYLINDERS IN LINE

DIESEL CYCLE

FOR MARINE APPLICATIONS

INSTALLATION DIRECTIVE

MAY 2006 EDITION

TECHNOLOGICAL EXCELLENC E

INSTALLATION DIRECTIVE

2MAY 2006

S30 ENT M23

FOREWORD

We strongly recommend that you carefully read the indica-

tions contained in this document: compliance with them

protects the engine against irregular operation and assures

its reliability, safeguarding sea-going and maintenance person-

nel 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 condi-

tion 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 characteris-

tics that are current as of the publication date.

IVECO MOTORS reserves the right to make modifications

at any time and without advance notice, to meet technical or

commercial requirements or to comply with local legal and

regulatory requirements.

We refuse all liability

for any errors

and omissions.

The reader is reminded that the IVECO MOTORS Technical

Assistance Network is always at the Customer’s side with its

competence and professionalism.

Publication IVECO MOTORS edited by:

IVECO PowerTrain

Advertising & Promotion

Pregnana Milanese (MI)

www.ivecomotors.com

Printed P3D64S001 E - May 2006 Edition

INSTALLATION DIRECTIVE 3
MAY 2006 S30 ENT M23
CONTENTS
  Page
 WARNINGS AND CAUTIONS  4
 ENGINE PARTS AND COMPONENTS  6
 INSTALLATION OVERVIEW  8
 GENERAL INSTALLATION CRITERIA  9
 TECHNICAL DATA FOR INSTALLATION  10
 IDENTIFICATION DATA  12
 COMPONENTS SUPPLIED WITH THE ENGINE  13
 FUEL LINE  14
 ELECTRICAL EQUIPMENT  17
MAIN ANALOG INSTRUMENT PANEL  26
SECONDARY ANALOG INSTRUMENT PANEL  30
DRILLING PLANS FOR ANALOG PANELS  31
CUSTOMIZED INSTRUMENT PANEL  32
SENSORS FOR DETECTION   
AND PANEL SIGNALING  34
PREPARING THE ENGINE   
FOR FIRST START-UP  36
 TESTS BEFORE THE FIRST START-UP  36
 FIRST ENGINE START  37
EDC ANOMALIES INDICATION  38
 BLINK CODE TABLE  39
 UNDERWAY CHECKS  41
PREPARING THE ENGINE   
FOR LONG IDLE PERIODS  42
WIRING DIAGRAMS  43

INSTALLATION DIRECTIVE

4MAY 2006

S30 ENT M23

To obtain the best engine performance, it is essential not to

deviate from the mission profile for which it was produced

and set up. The engine must not be used for purposes other

than those stated by the manufacturer. IVECO MOTORS

is willing to examine any need for particular installations

beforehand. Use of an electronically controlled injection

system, in providing the engine with performance benefits,

requires that the installer and maintenance specialist comply

with some fundamental rules, which will become more and

more commonplace as use of such equipment becomes

progressively more widespread. Boat outfitters and mainte-

nance specialists are invited to closely follow the instructions

contained herein. No modifications to the engine, its acces-

sories and components, are allowed.

Failure to comply with the instructions that follow shall

void the warranty and relieve IVECO MOTORS of all

liabilities.

For personnel safety

Specialists and installers are cautioned to comply with

workplace safety rules and to adopt prescribed individual

protection devices when working.

o Drain the cooling, lubrication and fuel lines only after

the fluids have duly cooled. The pressurized cap of the

water line may be opened only after the engine has duly

cooled.

o Batteries contain a highly corrosive sulfuric acid solution:

must never be upset and must be handled with the

utmost caution to prevent spillage. Ensure that the bat-

tery compartment is adequately ventilated.

Handling

The engine must be handled by experienced personnel,

using the prescribed tool or a rocker arm that keeps the

lifting lines parallel and with adequate equipment in terms

of capacity and size. The two eyebolts provided for lifting the

engine alone must always be used simultaneously.

Installation

o Knife switches or battery breakers may be used on the

power supply line of the engine electronic unit, provided

they are not used to shut the engine off.

o Do not modify the wiring harnesses; their length may

not be modified: use only available extensions.

o Do not use electronic device wiring harnesses not com-

pliant with the IVECO MOTORS directive, in terms of

length, type of conductor, location, clamping, connection

of the shielding and earth braids.

o To avoid any interference, the wiring harnesses of the

different on-board electronic devices must follow differ-

ent paths from those of the engine electronic systems.

o Do not connect any extraneous user device to the

engine electrical equipment.

o Do not place voltage across the boat’s on-board electri-

cal system without first verifying that there are no short

circuits.

o Do not branch pipes off to draw fuel from the engine

supply lines.

o Do not make any change to the engine’s hydraulic cir-

cuits and components.

o Do not execute arc welding operations before removing

the electronic units from their seating, placing them at an

adequate safety distance.

o Do not subject electronic units to temperatures exceed-

ing 80 °C.

o Do not paint electrical components and their connec-

tions.

o Do not alter the data contained in the engine control

electronic unit.

o Comply with prescribed procedures and torque values

when tightening threaded elements.

Start-up

o Ready the engine following the procedure set out in

Chapter 15.

o When starting the engine the first time, have suitable

means available to cut off air intake in case of a runaway

condition.

o Start the engine after ensuring that it is complete with

every part specified by the manufacturer and required

by the installation, without attempting to 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-elec-

tronic equipment of the engine and the other electronic

equipment present on the boat.

Tests and tuning up

o Never disconnect the batteries when the engine is

running.

o Remove the electrical connections from the batteries

before any operation on the electrical system.

o Ensure that the battery terminals comply with the exact

polarity, are properly tightened and protected against

accidental short circuits and corrosion phenomena.

o Do not connect or disconnect electrical connections

when electrical power supply is present.

1. WARNINGS AND CAUTIONS

INSTALLATION DIRECTIVE 5

MAY 2006 S30 ENT M23

o Do not cause sparks in the attempt to verify the pres-

ence of electrical voltage.

o Do not draw fuel through unfiltered lines.

o Do not clean the engine and its parts with corrosive or

abrasive detergent substances, to avoid compromising

the integrity of electrical connections.

o The engine fluids and air, water, and oil filters discarded

after use must be properly stored and delivered to

appropriate collection centers.

Long engine inactivity periods

Before long periods of inactivity, ready the engine following

the procedure set out in Chapter 21.

INSTALLATION DIRECTIVE

6MAY 2006

S30 ENT M23

2. ENGINE PARTS AND COMPONENTS

Figure 1

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.

7 8 7

05_003_S

INSTALLATION DIRECTIVE 7

MAY 2006 S30 ENT M23

Figure 2

1. Engine coolant discharge cap location - 2. Combustion air filter - 3. Sacrificial anode - 4. Throttle potentiometer - 5. Combustion

air-sea water heat exchanger - 6. Oil dipstick - 7. Location of common rail high pressure injection pump - 8. Sea water pump - 9. Sea

water inlet - 10. Manual lubricating oil extraction pump - 11. Oil vapor separator - 12. Lubricating oil filters -

13. Common rail distributor - 14. Waste-gate actuator - 15. Cooled turbocharger - 16. Sea water junction pipe from after-cooler to

engine coolant/sea water heat exchanger.

12 13

05_002_S

INSTALLATION DIRECTIVE

8MAY 2006

S30 ENT M23

The figure shows the set of components of an installation,

including those supplied with the engine equipment, standard

or optional, and those supplied or produced by the yard.

It provides a comprehensive picture of the operations

required to install the engine.

Components arrangement and illustrations are not binding

but merely indicative, subject to the choices made by yard

engineers according to their skills, available spaces and the

prescriptions set out herein.

3. INSTALLATION OVERVIEW

1. Indicator and control panel - 2. Electrical panel with relay box and EDC electronic unit - 3. Exhaust gas and sea water discharge -

4. Filtered sea water intake - 5. Decanter filter - 6. Fuel feed pipe to the high pressure pump - 7. Fuel electric pump - 8. Fuel pre-

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

Figure 3

1 2

45678

06_005_S

INSTALLATION DIRECTIVE 9

MAY 2006 S30 ENT M23

4. GENERAL INSTALLATION CRITERIA

Accessibility

The engine must be located in such a way as to allow filling

and draining engine liquids when doing servicing operations.

Anchoring

If anchoring is accomplished by interposing shock mounts,

they must be able to support the engine’s mass and the lon-

gitudinal 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 suffi-

ciently 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 pipe-

lines, which is the Yard’s responsibility.

Electric - electronic equipment

Provide a suitable arrangement of the engine control elec-

tronic 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 under-

way 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 criti-

cal conditions have been reached, and if exceeded the

engine could be damaged.

INSTALLATION DIRECTIVE

10 MAY 2006

S30 ENT M23

5. TECHNICAL DATA FOR INSTALLATION

Combustion and ventilation air when underway

Static vacuum allowed downstream of the air filter kPa

mm H2O

≤ 3,5

≤ 350

Combustion air flow rate m3/h ≥ 710

Engine room ventilation air flow rate (excluding combustion air) m3/h ≥ 3590

Static vacuum allowed in the engine room kPa

mm H2O

≤ 0,1

≤ 10

Temperature allowed in the engine room °C ≤ 45

Temperature increase in the engine room to ext. temperature °C ≤ 15

Exhaust gas discharge

Allowed static back pressure kPa

mm H2O

≤ 10

≤ 1000

Exhaust gas temperature at maximum power (turbocharger inlet) °C 700

Flow rate at maximum power kg/h 875

Outer diameter of exhaust mixed with sea water mm

inches

100

Fuel supply

Transfer pump delivery at maximum rpm l/h ≤ 190

Flow rate return to tank l/h ≤ 185

Fuel temperature to allow maximum power °C ≤ 70

Inner diameter, intake pipe mm ≥ 8

Inner diameter, return pipe mm ≥ 8

Thread on pre-filter junctions M 14 x 1,5

Electric pump approved intake vacuum kPa

mmH2O

≤ 15

≤ 1500

Approved intake pressure at the low pressure mechanical pump kPa

mmH2O

20 to 120

2000 to 12000

Allowed on tank return pipe back pressure kPa

mm H2O

≤ 40

≤ 4000

Open sea water cooling line

Intake pipeline diameter mm

inches

1,26

Pump delivery at maximum rpm l/h 9000

Sea water pump height above sea level m ≤ 2

Allowed intake vacuum kPa

mm H2O

≤ 20

≤ 2000

Dry exhaust outer diameter mm

inches Not foreseen

Allowed engine inclination angles

Maximum longitudinal in continuous operation (static + dynamic) degrees/360 +20

Maximum transverse in continuous operation (static + dynamic) degrees/360 ± 22º30'

Longitudinal for oil level check with standard dipstick degrees/360 0 to +6

INSTALLATION DIRECTIVE 11

MAY 2006 S30 ENT M23

Figure 4

Dimensions

Measurements in: millimeters (inches).

Power takeoffs (optional)

1-race front pulley for “V” belts

Reference diameter mm 83

Race dimension mm 10

Power available at 1000 rpm (*) kW ≤ 1

Power available at 2000 rpm (*) kW ≤ 2

Radial force resulting from belt tension (*) N ≤ 400

(*) These values are valid for driving to the side opposite to that of the sea water pump

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06_001_S

INSTALLATION DIRECTIVE

12 MAY 2006

S30 ENT M23

6. IDENTIFICATION DATA

Figure 6

Figure 5

06_004_S

05_003_S

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

INSTALLATION DIRECTIVE 13

MAY 2006 S30 ENT M23

7. COMPONENTS SUPPLIED WITH THE ENGINE

Figure 7

06_019_S

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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 see-

through bags, together with small parts required to com-

plete them. In order to avoid connection errors, connectors

are different from one another; each one of them must be

exclusively mounted by using the small parts contained in the

relevant plastic bag

Connection function

o A. Fuel temperature sensor for EDC

o M. Sensor designed to detect the presence of water in

the fuel pre-filter

o Z. Fuel filter clog sensor

o PF. Heating element on the fuel filter

o JFC. Connection to the JFC connector on the engine

harness

Chapter 9 shows the instructions to be followed to perform

connections.

Mechanical components

As shown in picture 8, they must be used to replace the fit-

tings 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 compo-

nents must be used to set up the fuel feeding system.

Chapter 8 shows the instructions to be followed in order to

perform connections.

INSTALLATION DIRECTIVE

14 MAY 2006

S30 ENT M23

8. FUEL LINE

For the installation, the following connections are required:

- from the tank to the pre-filter

- from the pre-filter to the pump inlet

- from the electric pump to the filter inlet

- from the filter outlet to the low pressure mechanical

feeding pump

- from the fuel discharge outlet to the tank.

Components

Pre-filter, electric pump and filter, supplied with the engine,

must be fitted in proximity of the tank, in a relatively low

point of the system. The filter must be prepared as indicated

here below and fastened in such a way to allow easy replace-

ment 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

1. Low pressure mechanical feeding pump and high pressure common rail injection pump - 2. Electro-injector - 3. Common rail -

4. Pre-filter - 5. Fuel electric pump - 6. Filter.

Figure 8

High pressure

Low pressure

06_006_S

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 inclina-

tion 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 rec-

ommended, 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 clas-

sification Bodies.

INSTALLATION DIRECTIVE 15

MAY 2006 S30 ENT M23

Fuel supply system scheme

1. Low pressure limiter valve - 2. Pressure regulating electric valve - 3. High pressure radial pump - 4. Pressure sensor - 5. Common

rail - 6. Electro-injector - 7. Fuel tank - 8. Pre-filter - 9. Fuel electric pump - 10. Filter - 11. Vent fitting - 12. Low pressure mechanical

feed pump.

Figure 9

06_007_S

11 7

5 6

10 8

Hydraulic connections

Figure 10

06_020_S

1. Rubber holder fitting for fuel inflow into the low pressure mechanical feeding pump -

2. Rubber holder fitting to allow fuel outflow towards the tank.

INSTALLATION DIRECTIVE

16 MAY 2006

S30 ENT M23

Preparation of the fuel filter support

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

The filter 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.

Figure 11

06_010_S

1 2 23

INSTALLATION DIRECTIVE 17

MAY 2006 S30 ENT M23

Figure 12

06_012_S

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 accumula-

tor, while the terminal identified as +BATT/CC must be

connected to the +30 pole of the starter motor.

9. ELECTRICAL EQUIPMENT

1. Engine wiring - 2. +BATT/CC terminal - 3. Power line for electric starter motor and alternator - 4. Indicator and control panel - 5.

Extension harness - 6. Engine pre-heating glow plugs electronic control unit - 7. Fuse holder for the engine pre-heating glow plugs

electronic control unit - 8. ECU EDC connectors - 9. Relay box - 10. Diagnostic tool connector - 11. Harnessing to be made by

construction site personnel - 12. Fuel filter support - 13. Fuel electric pump

INSTALLATION DIRECTIVE

18 MAY 2006

S30 ENT M23

Synoptic

Figure 13

1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Connector for fuel filter wiring - 4. Power line.

Wires supplied with the engine include connectors for all

concerned components, connector JB to ensure connection

to the warning and control panel, and the JFC connector

to allow the connection to the components located on the

fuel filter.

06_030_S

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BATTERIA

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INDICATIONS AND

ALARMS SENSORS

ELECTRO-INJECTORS

EDC COMPONENTS

ALTERNATOR

ELECTRIC STARTER

MOTOR

THROTTLE POSITION

SENSOR

INSTALLATION DIRECTIVE 19

MAY 2006 S30 ENT M23

Wire harness

Engine wire harness Fuel filter interface wire harness

Figure 14

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A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - F. Engine coolant temperature sensor for EDC - ECF. Connector for the engine

stopping functions if stressed - ECM. Connector for the engine stopping function if stressed - H. Combustion air pressure/temperature sensor for EDC - K. Air filter clogging sensor

(for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter (for alarm) - O. Exhaust gas temperature sensor (for gauge) - T. Coolant temperature sensor (for

gauge) - V. Oil pressure sensor (for gauge) - E1. Cylinders 1 and 2 electro-injectors - E2.-Cylinders 3 and 4 electro-injectors - E3. Cylinders 5 and 6 electro-injectors -

GG. Alternator - JB. Instrument panel connection wire harness - JF1,JF2. Relay box - MM.-Electric starter motor - PA.-Throttle position sensor - PF. Heating element on fuel filter

- PR. Rail pressure sensor - SI. Gear box oil temperature sensor - VE. Engine oil pressure/temperature sensor for EDC - VI. High gear box oil pressure sensor (25 bar) -

WI. Low gear box oil pressure sensor (7 bar) - ZH. Pressure control solenoid valve.

INSTALLATION DIRECTIVE

20 MAY 2006

S30 ENT M23

Power supply line

1.Alternator - 2. Electric starter motor - 3. Battery -

4. Engine wire harness.

The connection of terminal +B of the alternator to the

positive terminal +30 of the electric starter motor consists

of a 25 mm2 diameter conductor or bigger. The connection

of the positive +30 terminal of the electric starter motor to

the positive pole of the battery, achieved with a conductor

having a cross section of at least 70 mm2, allows to obtain,

as shown in the figure, the simultaneous connection of the

alternator to the battery. The simultaneous connection of the

alternator to the accumulator; on the same terminal, one will

have to connect the cable terminal to an eyelet marked as

+BATT/CC of the engine harness. The connection between

the engine ground and the negative pole of the battery must

be achieved according to the guidelines provided in the

Engine electrical ground paragraph.

CAUTION

If magneto-thermal protecting breakers are inserted, they

must not be used to stop the engine and in any case they

must be activated only a few seconds after shut-down.

Figure 15

50 D++B30

+BATT/CC

06_043_S

Equipment power supply

Supplementary services battery

To assure that the engine can be started with a sufficient

quantity of energy, it is advisable to provide for the instal-

lation 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 22.

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 (D+).

If two engines are installed

The presence of two generators allows to keep the recharg-

ing functions separated: the generator (G1) recharges the

battery (AC1) dedicated to starting both engines and pow-

ering 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 con-

nect the engine grounds to a common potential; the solution

proposed in Chapter 22 fully complies with this need, assuring

the full functionality and independence of the two circuits.

INSTALLATION DIRECTIVE 21

MAY 2006 S30 ENT M23

Battery recharging

B+. Connected to the +30 of the electric starter motor - D+.

Excitation - N. Not connected.

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 bat-

tery 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.

Engine electrical ground

The connection of the engine electrical ground is achieved

by connecting with a cable of at least 70 mm2 cross section

to the negative pole of the battery to the tightening point of

the electric starter motor as shown in the following figure.

1. Point of connection of the engine electrical ground.

To anchor the grounding terminal to the engine, proceed as

follows:

o Completely remove the conducting paint from both

parts constituting the connection, using mechanical

means or suitable chemical product; if the anchoring

operation is to take place on superficially treated parts,

completely remove the anaphoretic paint with mechani-

cal means, obtaining a smooth support surface.

o Apply a uniform layer of BH44D paint (IVECO standard

18-1705) with a brush or spray gun.

o Join the parts constituting the grounding note within 5

minutes from the time the paint was applied.

Figure 16

04_078_N

Figure 17

06_020_N

INSTALLATION DIRECTIVE

22 MAY 2006

S30 ENT M23

Figure 18

Wiring to the JFC connector

By stabilizing the fuel filter assembly position, it will be possi-

ble to set up the wiring to connect the components located

on the fuel filter.

The diagram in the picture shows the connections to be

performed on connectors.

Connection function

o A. Fuel temperature sensor for EDC

o M. Sensor designed to detect the presence of water in

the fuel pre-filter

o Z. Fuel filter clog sensor

o PF. Heating element on the fuel filter

o JFC. Connection to the JFC connector on the engine

harness

NOTE

Comply with conductors’ minimum diameters indicated in

the diagram in order to avoid voltage drops which would

endanger the system operation.

0.5 J

1.5 C

1.5

F0.5

E0.5

H0.5

G0.5

1.5 A

1.5 B

JFC

2.5A

2.5B

2 0.5

0.53

1 0.5

B 0.5

A 0.5

2 0.5

0.51

06_041_S

Minimum cable

cross section in mm2

Connector code

Component

terminal

Minimum cable

cross section in mm2

Connector code

Component

terminal

INSTALLATION DIRECTIVE 23

MAY 2006 S30 ENT M23

*&#







06_031_S

Figure 19

1. Fuel filter

The picture shows 5 connectors and the position that con-

ductors must have in order to ensure correct connections.

Wiring must be performed to ensure minimum diameters of

conductors, as indicated in the electric diagram.

CAUTION

Wrong connections of conductors can generate malfunc-

tions and damage electric components.

The wiring must be made with the JFC connector, not

connected to the engine harness. Coupling of the two JFC

connectors will have to be done with the power supply

switched off.

INSTALLATION DIRECTIVE

24 MAY 2006

S30 ENT M23

Relay box

It represents the main interconnection point and it performs

multiple interfacing functions between the various system

components.

It is the seat of remote control switches and fuses; compo-

nents are mounted on a base and thus it is possible to extract

them to set up verification or replacement operations.

Remote control switches (relays) depend upon the following

components:

K1 key switch electric discharge

K2 emergency engine shut-down provision

K3 EDC main (power supply

K4 power supply to terminal 50 of the electric

starter motor

K5 Electric fuel pump power supply

K6 fuel filter heater element power supply

The components to which fuses depend upon are as follows:

F1 electric fuel pump

F2 heating element on fuel filter

F3 power supply to the heater plug control unit (15 A)

F4 EDC (10 A)

F5 EDC (25 A)

Figure 23

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&¬

&¬

&¬

&¬

+

+

+

+

+

+

06_024_S

Connections of the central electronic unit

(ECU) EDC 16C8

A. 60 pole connector - B. 94 pole connector.

The connection of the central electronic unit, ECU, to the

components of the EDC system is achieved by means of

three connectors to subdivide the wiring harnesses, thereby

favoring a quicker identification of the lines during testing

operations.

o B for engine mounted components

o A for boat side connections

The different connectors are polarized and provided with

levers to favor the connection and disconnection operations

and assure proper coupling.

The sequence of operations allowing the removal of connec-

tors from their housing is as follows:

A) Extract the extraction lever retaining device;

B) Lift the extraction lever, make sure the anchoring slide is

extracted from its housing;

C) Lift the connector without causing any fluctuation which

would jeopardize the integrity of electric terminals.

Figure 20

Figure 21

Figure 22

06_029_S

06_060_S

06_061_S

INSTALLATION DIRECTIVE 25

MAY 2006 S30 ENT M23

Water presence in the filter sensor

1. filter - 2. Conductor to be connected

with the negative battery terminal.

CAUTION

In order to enable the proper working of the sensor to

detect water in the fuel, it is necessary that the filter

support is connected electrically to the negative battery

terminal.

In the engine models which use parts with insulated poles it

is necessary to electrically insulate the filter support from the

boat mass and then connect the support with the negative

battery terminal.

Figure 27

Heater plug fuse

A maxi 60 A fuse is located in serial connection with the

electric network of heater plugs.

Diagnostic connector

A multipolar plug is located in proximity of the relay box,

to which an IVECO MOTORS diagnostic tool can be con-

nected to.

The diagnostic tool allows the processing of data recorded

during the engine operation phase and memorized in the

ECU; data interpretation will provide useful indications to

better schedule maintenance interventions.

Throttle lever position sensor

After testing the working condition of the linkage, adjust the

run of the servo components (see Chapter 18).

o With the throttle at idle setting, the potentiometer rod

has to be in the resting position.

o With the throttle at the stop, the potentiometer rod has

to be in the position of maximum run out.

06_050_S

06_048_S

Figure 24

Figure 25

Figure 26

06_040_S

80856

INSTALLATION DIRECTIVE

26 MAY 2006

S30 ENT M23

10. MAIN ANALOG INSTRUMENT PANEL

Installation of the IVECO MOTORS onboard panel with

analog indicators entails connecting the panel’s JC connec-

tor to the JB connector on engine wire harness, interposing

the appropriate extension wire harness available in 3, 5 and

7 meter-long versions. The JC-JB wire harness comprises 47

lines, each connected to the terminal identified on both con-

nectors by the same number.

To the main panel is connected the JE connector, provided

for connection to the secondary panel; in installations with

no secondary panel, do not remove the cap of the JE con-

nector to avoid compromising the electrical continuity of the

systems’ power supply circuit.

To allow the work of the fuel filter clogging alarm (SIFC), in

the indication alarm module, it has to disconnect the connec-

tor (12) fitted close to JC.

Figure 28

1. Coolant temperature gauge (TA) - 2. Revolution counter and hour counter (CG) - 3.Voltmeter (V) - 4. Buzzer (SA) - 5. Indication

and alarm 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 with electric harness

versions with excitation engine stop) - 11. Sound alarm inhibition push-button (P1) -12. SIFC Alarm abilitation connector -

13. Connector for main panel wiring (JC) - 14. Cap with electrical continuity connection.



bar







 





 







06_002_S

3 4 5

11 10 98

INSTALLATION DIRECTIVE 27

MAY 2006 S30 ENT M23

CONNECTORS OF THE JB - JC EXTENSION WIRE HARNESS, SEEN FROM THE COUPLING SIDE

To identify the functions served by the individual lines, refer to the electrical diagrams in Chapter 22.

1. JB-JC extension wire harness - 2. JE-JH extension wire harness.

Figure 30

Synoptic of the connections of the analog panels

JB JA

JF1 JF2

JHJH

JE JE

04_254_N

MAIN

INSTRUMENT

PANEL

RELAY

BOX

EDC

SECONDARY

INSTRUMENT

PANEL

BATTERY

ENGINE

EQUIPMENT

JC JB

45 17

44 16

711

2627

25 39

11 4

10 2

832

34 47

04_250_N

Figure 29

INSTALLATION DIRECTIVE

28 MAY 2006

S30 ENT M23

Indications and alarms module

1. Runaway engine (SSV) - 2. Presence of water in fuel pre-

filter (SAC) - *3. Low coolant level (SBLA) - 4. Alternator fault

(SS) - *5. Clogged oil filter (SIFO) - *6. Clogged oil vapor filter

(SIFB) - *7. Pre-lubrication (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).

* Unavailable functions on S30 ENT M23 engines.

The indications and alarms module comprises the indicator

lights and the electronic alarm interface, timing and stor-

age 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 sound alarm may be silenced before the end of the test,

acting on the appropriate control.

During the starting phase and for the subsequent 15 sec-

onds, 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 “pre-

post 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 S30 ENT M23 provides for use

of the indicators SAC, SS, SIFA, SATA, SBPO, EDC.

Installation

In order to drill holes on the area where the panel is to be

mounted, refer to the dimensions indicated in Chapter 12.

Operation of the panel

After completing the electrical connections and engine

preparation, perform the tests required for the first start, as

described in Chapter 17.

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 and verify that the

instruments are powered and the indications and alarms

module runs the alarm test for about 5 seconds accord-

ing to the procedures set out below.

o Once the test is complete, only the indications pre-

scribed 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 to the second position and keep it in it

until the engine has started, then release the switch, which

will stably return to the first position; after releasing the key,

the switch may be brought back to the starting position only

after the switch is returned to the resting or zero position.

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 consist-

ency of the indications provided by the analog instruments.

Verify the indication of the panel revolution counter, compar-

ing 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.

If the engine stopping function if stressed is present, press the

stopping button situated on the board.

Figure 31

04_234_N

INSTALLATION DIRECTIVE 29

MAY 2006 S30 ENT M23

Revolution-counter calibration

1. Adjustment screw -

2. Panel lighting lamp.

Verify the indication of the panel revolution counter by com-

paring it with the one measured with a reference instrument;

if it differs, operate the adjustment screw (1), located in the

rear part of the instrument, until consistency is achieved;

repeat the operation for different engine rpms.

Maintenance

Should it become necessary to replace a panel light, remove

the lamp holder from the rear part of the instrument (see

Figure 32A).





04_255_N

Revolution-counter calibration

1. Calibration increasing button -

2.Calibration decreasing button.

Verify the indication of the panel revolution counter by com-

paring 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

The board is illuminated by not-replaceable internal LEDs.

Figure 32B





06_113_V

1 2

Figure 32A

INSTALLATION DIRECTIVE

30 MAY 2006

S30 ENT M23

11. SECONDARY ANALOG INSTRUMENT PANEL

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).

Figure 33

The connection is achieved by removing the cap on the JE

connector of the main panel, and connecting the JE connec-

tor to the JH connector on the secondary panel, interposing

the extension wire harness, available in 3, 5 and 7 meter-long

versions (see Figure 29). The JE-JH wire harness comprises

12 lines, each connected to the terminal identified on both

connectors by the same number (see Figure 34).

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 12.

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 17), 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.

With the panel enabled, press the green push-button until

the engine starts, then release it; wait for engine rpm to sta-

bilize before stopping it by pressing the red push-button.

The starting and stopping operations can be performed sev-

eral times and consecutively from the secondary panel

Checking indications

Proceed in the same way as for the main panel.

Figure 34

*% *(

1 6 6 1

7 12 12 7

04_251_N

INSTALLATION DIRECTIVE 31

MAY 2006 S30 ENT M23

12. DRILLING PLANS FOR ANALOG PANELS

Measurements in: millimeters.

= =

225

285

264

Ø4

140

200

26264 4

26 4

MAIN PANEL

= =

180

240

282

140

2828

Ø4

SECONDARY PANEL

Figure 35

Figure 36

INSTALLATION DIRECTIVE

32 MAY 2006

S30 ENT M23

13. CUSTOMIZED INSTRUMENT PANEL

Using only the components of the panel that are not wired

to allow for panel customization, they will have to be wired

using the 10 meter 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 22.

CAUTION

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 22.

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 dia-

grams in Chapter 22.

JD Connector for indications and alarms module

VIEW FROM THE INTEGRATED SIDE

IN THE REAR PART OF THE MODULE

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 # TST24AH00

JD connects the indications and alarms module to the elec-

trical 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 24.

For standard-equipped engines, to have the essential indica-

tions available, the following ways must be wired: 1, 2, 3, 7, 8,

9, 10, 13, 14, 15, 17, 18, 19 with the female terminals supplied

as standard equipment.

Figure 37

Figure 38

14 15 16

10 11 12

7 8

21 22 23 24

17 18 19 20

04_241_N

123

568 7

10 912 11

1314

16 15

171820 19

212224 23

05_034_C

INSTALLATION DIRECTIVE 33

MAY 2006 S30 ENT M23

CAUTION

To assure the utmost reliability and safety while underway, all installations must be provided with the following alarm indica-

tions:

(EDC) EDC failure

(SATA) high coolant temperature

(SBPO) low oil pressure

It is also recommended that the following indications be present:

(SAC) presence of water in the fuel pre-filter

(SIFA) clogged air filter

(SIFC) fuel filter indication

(SS) alternator fault

Functions of the JD terminals

PIN Description Electric level

OFF Indication ON Indication

1 Module power supply Positive (+B)

2 Not connected -

3 EDC Fault indication High (+B) Low (ground)

4 Not connected -

5 Pre-heating indication High (+B) Low (ground)

6 Pre-lubrication indication Open circuit High (+B)

7 Engine start Power supply positive (+B) while starting

8 Sound alarm inhibition Negative (ground) during the request

9 Module power supply Negative (ground)

10 Buzzer power supply Negative (ground) during the emission of sound

11 Clogged oil filter indication Open circuit Low (ground)

12 Clogged oil vapor filter indication 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)

21 Not connected -

22 Not connected -

23 Reception of data from main panel NMEA communication protocol (0 to 5 V)

24 Transmission of data to secondary panel NMEA communication protocol (0 to 5 V)

INSTALLATION DIRECTIVE

34 MAY 2006

S30 ENT M23

14. SENSORS FOR DETECTION AND PANEL SIGNALING

Coolant temperature sensor

Resistor with negative temperature coefficient, providing the

signal for analog temperature indication.

Operating voltage: from 6V to 24 V

Calibration range from 0 °C to 120 °C

Resistance value at 90 °C 51,2 ± 4,3 Ω

Electrical poles isolated

High coolant temperature sensor

Switching coolant temperature sensor, providing the signal

for the related indicator.

Operating voltage: from 6 to 24 V

Condition at ambient temperature normally open

Closing temperature: 100 ± 3 °C

Electrical poles isolated

Oil pressure sensor

Rheostat component providing the signal for the analog

indication of pressure.

Operating voltage from 6V to 24 V

Calibration range from 0 bar 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°C to 100°C

Electrical poles isolated

Figure 39

Figure 40

Figure 41

04_027_C

04_237_N

04_236_N

INSTALLATION DIRECTIVE 35

MAY 2006 S30 ENT M23

Figure 42

Low oil pressure sensor

Pressure switch, providing the signal for the related indicator.

Operating voltage: from 6 to 24 V

Condition at ambient pressure normally closed

Calibration range 0.5 - 0.8 bar

Closing pressure: 0.5 bar

Opening pressure: 0.8 bar

Maximum current 15 A (not inductive)

Electrical poles isolated

Air filter clogging sensor

Vacuum switch, providing the signal for the clogged air filter

alarm indicator.

Operating voltage from 6V to 24 V

Condition at ambient pressure normally open

Closing vacuum ≥ 52 mbar

Operating temperature from -20 °C to +80 °C

Maximum current 0,1 A (not inductive)

Electrical poles isolated

Figure 43

04_028_C

04_238_N

Fuel filter clogging sensor

Figure 44

Pressure switch, providing the signal for the related indica-

tor.

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

NiCr-Ni thermocouple sensor with insulated poles, pro-

viding the signal for the analog indication of exhaust gas

temperature.

Temperature Voltage

°C mV

100 4.10

200 8.13

300 12.21

400 16.40

500 20.65

600 24.91

700 29.14

800 33.30

900 37.36

Figure 45

04_030_C

04_260_N

INSTALLATION DIRECTIVE

36 MAY 2006

S30 ENT M23

15. 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 21.

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 21. 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.

6. Verify and refill engine coolant as prescribed.

7. Remove from the engine the labels with the inscription

“ENGINE WITHOUT OIL”.

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 com-

ponents of the electronic control system may be performed

rapidly and with the utmost reliability using specific diagnostic

tools, available from IVECO MOTORS Technical Assistance

Centers.

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 indica-

tor light to be permanently lighted.

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, checking:

Instrument panel

Verify the efficiency of all light indicators, as described in the

related Chapters.

16. TESTS BEFORE

THE FIRST START-UP

INSTALLATION DIRECTIVE 37

MAY 2006 S30 ENT M23

17. 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:

o Turn the key on “ON”; so that the ECU EDC feeds the

fuel electric pump for a few seconds, thus pressurizing

the low pressure feeding circuit.

o Loosen the vent fitting on the pre-filter.

o Newly turn the key on “ON” to feed the electric pump

until air-free fuel flows out of it.

o Tighten the vent fitting.

Make sure that the fuel that flows out of the fitting is not

dispersed in the environment.

CAUTION

Never attempt to vent the high pressure system, as this is

useless and extremely dangerous.

NOTE

A few moments after engine start, make sure sea water is

correctly expelled out of the system.

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 into the hull.

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 13 V.

o Stop the engine and delete any “errors” which may have

been stored in the injection system ECU during the

stabilization phases. For the deletion procedure, refer to

Chapter 20.

INSTALLATION DIRECTIVE

38 MAY 2006

S30 ENT M23

18. EDC ANOMALIES INDICATION

Anomalies indicator light

The ECU continuously monitors, with complex self-testing

routines, its own operating conditions as well as those of the

components connected to it and of the engine.

When anomalies are detected, the alarm indicator light on

the indicator and control panel is lighted in manners that

provide a first indication on the severity of the problem.

Light off: no anomaly detected or slight anomaly

that does not compromise operating

safety

Light on: significant anomaly, allowing to proceed to

a service center

Blinking light: severe anomaly requiring immediate

repairs. If possible, shut the engine down.

Recovery

The recognition of significant or severe anomalies causes

the adoption of strategies that allow to use the engine with

complete safety, guaranteed by limiting performance within

pre-set thresholds according to the severity of the case.

These strategies cause the reduction of the maximum values

of torque and power delivered by the engine.

In the case of intermittent anomalies, i.e. recognized by the

ECU and subsequently no longer present, performance

reduction will continue until the engine is shut down.

Normal operation will be restored only the next time the

engine is started, while the anomaly data will be “saved” in

the failure memory.

NOTE

Identification of severe anomalies of the accelerator posi-

tion sensor, causes the ECU to increase the engine rpm

from about 800 rpm to about 1050 rpm, in order to

achieve a minimum engine thrust and allow manoeuvers.

Error deletion procedure

It will be possible through the IVECO PT01 device con-

nected to the dedicated J1 diagnostic connector.

CAUTION

The mistake deleting procedure is intended to eliminate

the information relating to the mistakes from the ECU

memory, which happened during previous working periods.

The mistakes will not be deleted unless the relating cause

has been removed. Please remember that some anomalies

can be detected by the ECU self-diagnosis only during a

complete engine working cycle.

Figure 46

06_048_S

INSTALLATION DIRECTIVE 39

MAY 2006 S30 ENT M23

19. BLINK CODE TABLE (software version P315 V4.B)

Blinking

code

EDC indicator

light

Indicated fault Max power

reduction

DTC code

Control area

11 (on) not significant in marine applications -117 - 119

13 (off) not significant in marine applications -78

14 blinking throttle position sensor (line 1 o line 2) x8 - 9

17 off not plausible accelerator position sensor signals -11

18 off EDC anomalies warning light control -108

Engine Area 1

21 blinking water temperature sensor x20 - 21

22 off air temperature sensor -57

23 on fuel temperature sensor -40

24 blinking supercharge air pressure sensor x17 - 131

25 off ambient pressure sensor (inside the unit) -10

27 on electric fuel pump control relay exication circuit -94

28 off coil relay fuel heater -42

Engine Area 2

35 off battery voltage value -18

36 off pre-heating warning light control circuit -48

37 off engine heater plugs feeding relay -47

38 off not plausible signal "15", power supply from key -109

39 off engine heater plugs control unit -49

Injectors

51 blinking cylinder 1 electro-injector x66 - 67

52 blinking cylinder 2 electro-injector x68 - 69

53 blinking cylinder 3 electro-injector x70 - 71

54 blinking cylinder 4 electro-injector x72 - 73

57 blinking electro-injector cylinder 1-2-3 power driver 1-4 x60 - 61

58 blinking electro-injector cylinder 4-5-6 power driver 1-4 x62 - 63

59 blinking cylinder electroinjector unit power stage (A o B chip internal

error) x64 - 65

Engine RPM sensor

61 blinking driving shaft sensor signal x37

62 blinking timing shaft sensor signal x36

63 blinking not plausible driving and timing shifts sensors signals x38

(continue to next page)

INSTALLATION DIRECTIVE

40 MAY 2006

S30 ENT M23

Blinking

code

EDC indicator light Indicated fault Max power

reduction

Code DTC

Interface

72 on CAN lines error -87 - 88- 45

73 on CAN lines error -43 - 44 - 46

74 off CAN lines error -29 - 126 - 128

129 - 130

75 off CAN lines error -125 - 127

Fuel pressure

81 blinking fuel pressure control deviation STOP 98 - 99

81 blinking rail pressure too low value STOP 100

81 blinking rail pressure too high value STOP 101

81 blinking fuel pressure control management - 102 - 103

82 blinking fuel pressure sensor signal STOP 95

82 on fuel pressure sensor signal deviation x96

83 blinking pressure adjustment solenoid valve STOP 82 - 83 - 84

Electronic unit

91 blinking internal errors -50 - 52 - 54 - 55

56 - 86 - 121

92 blinking EEPROM memory error -51

93 (on) not relevant for marine applications -58

94 on main relay -80

96 blinking initialization error (inside control unit) x104

97 blinking analogical-digital converter -3

97 blinking control unit/sensors feeding x105

97 blinking control unit/sensors feeding STOP 106

98 blinking internal errors -90 - 91

99 on internal errors -110

INSTALLATION DIRECTIVE 41

MAY 2006 S30 ENT M23

20. 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 min-

utes underway at full engine power, does not exceed 45 °C

and, in any case, does not exceed the value of external tem-

perature 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 absorp-

tion curve, it will also be possible to obtain the fuel injec-

tion values from the ECU parameters 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 ten-

dency 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 reli-

ability of the components of the fuel supply and injection

system, you need to verify that:

o Diesel feeding pipe pressure to low pressure mechanical

pump should range between 0.2 and 1.2 bar (2000 to

12000 mm H2O);

o pressure in the fuel oil return line to the tank is less than

0.4 bar relative (4000 mm H2O).

Measures are carried out inserting a “T” junction near the

fuel inlet and outlet, taking care to avoid any air suction. Val-

ues 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.

INSTALLATION DIRECTIVE

42 MAY 2006

S30 ENT M23

21. 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-months 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

with 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 filter,

taking care to avoid letting the fuel come in contact with

the auxiliaries belt.

4. Connect the fuel line to a tank containing CFB protec-

tive 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 12 V, using a conduc-

tor prepared for the occasion.

5. Nebulize 30/M protective oil at the rate of about 70 g

(30 g per liter of displacement) into the turbocharger

intake, 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 opera-

tions.

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 anti-

freeze 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, con-

nector cables and electrical equipment.

INSTALLATION DIRECTIVE 43

MAY 2006 S30 ENT M23

Wiring diagram key

Figure 47

General conditions for the preparation and interpretation of wiring diagrams

o Key switch open

o Engine not running

o Liquids at efficient levels and pressures

22. WIRING DIAGRAMS

B62 4

85150

28 72 5 1 68 61 62 25 48 52 93 71 92

BAT

–

B+

5030

50 15

EJFC

5JB

R1 SS EDC SCP

18 12 17

T C D B E

87 30

85 86

30 87

86 85

87a

86 85

K2 JC

F3F4

87 30

85 86

30 87

86 85

30 87

86 85

F1 F6

MPO

91 31 30 45

6 3 2

46 8 9

1 5 4

18 12 17

ST30 86 D G4 31G1 G2 G3

G4G1 G2 G3

JFC

A B

JFC C D

Terminal

connections

Minimum cable

cross section in mm2

Component code

or connector code

Component

terminal

Connection

JC: connector

8: terminal

Component

code

Fuse code

Sk Connett_B S30

INSTALLATION DIRECTIVE

44 MAY 2006

S30 ENT M23

Electrical equipment component code

A fuel temperature sensor for EDC

B drive shaft sensor

C camshaft sensor

F engine coolant temperature sensor for EDC

H combustion air pressure/temperature sensor for

EDC

I coolant high temperature sensor

K air filter clogging sensor (for alarm)

L instrument panel light switch

M sensor for detecting the presence of water in

the fuel pre-filter (for alarm)

O exhaust gas temperature sensor

T coolant temperature sensor (for gauge)

V oil pressure sensor (for gauge)

W engine oil low pressure sensor

Z fuel filter clogging sensor

P1 sound alarm inhibition push-button

R1 120 Ω resistor for CAN line balancing

R2 alternator pre-excitation resistor

AC battery

AQ engine shut-off push-button on main panel

AS engine shut-off push-button on secondary panel

CA key switch

CC engine pre-heating glow plugs electronic control

unit

CS engine start push-button on secondary panel

E1, E2, E3, E4

electro-injector

G1, G2, G3, G4

engine pre-heating glow plugs

GG alternator

MM electric starter motor

MS IVECO MOTORS indications and alarms module

PA throttle position sensor

PE fuel electric pump

PF heating element on fuel filter

PR rail pressure sensor

QP main analog instrument panel

QS secondary analog instrument panel

SA buzzer

WI low gear box oil pressure sensor (7 bar)

ZH pressure control solenoid valve

85150 ECU of the EDC system

(continues on next page)

INSTALLATION DIRECTIVE 45

MAY 2006 S30 ENT M23

Electrical equipment component code (follows)

Connectors

A 60 pole EDC engine components

B 94 pole EDC electro-injectors

J1 external diagnostic tool (on the relay box panel)

JB on engine wire harness

set for connection to the main analog

instrument-panel or to the interface wire

harness for converter module

JC on main analog instrument panel

set for connection to the engine wire harness

JD IVECO MOTORS indications and alarms module

Je on main analog instrument panel

set for connection to the secondary analog

instrument panel

Jh on seCondary analog instrument panel

set for connection to the main analog

instrument-panel

vIndicator lights

EDC EDC malfunction

SAC presence of water in fuel pre-filter

SATA high coolant temperature

SBLA low coolant level

SBPO low oil pressure

SCP pre-post heating

SIFA clogged air filter

SIFB clogged oil vapor filter

SIFC clogged fuel filter

SIFO clogged oil filter

SP pre-lubrication

SS alternator fault

SSV runaway engine

Gauges

CG revolution-counter

MI gear box oil pressure gauge

MO engine oil pressure gauge

TA engine temperature

TI gear box oil temperature

TS exhaust gas temperature

V voltmeter

Remote control switches mounted on the relay box

K1 key switch electric discharge

K2 emergency engine shut-down provision

K3 EDC main (power supply

K4 power supply to terminal 50 of the electric

starter motor

K5 fuel electric pump power supply

K6 fuel filter heater element power supply

Fuses mounted on the relay box

F1 fuel electric pump

F2 heating element on fuel filter

F3 power supply to the heater plug control unit (15 A)

F4 EDC (10 A)

F5 EDC (25 A)

Maxi fuse

F6 heater plug power circuit

INSTALLATION DIRECTIVE

46 MAY 2006

S30 ENT M23

EDC connector B

B62 4

85150

28 72 5 1 68 61 62 25 48 52 93 71 92

BAT

–

B+

5030

50 15

EJFC

5JB

R1 SS EDC SCP

18 12 17

T C D B E

87 30

85 86

30 87

86 85

87a

86 85

K2 JC

F3F4

87 30

85 86

30 87

86 85

30 87

86 85

F1 F6

MPO

91 31 30 45

6 3 2

46 8 9

1 5 4

18 12 17

ST30 86 D G4 31G1 G2 G3

G4G1 G2 G3

JFC

A B

JFC C D

Sk Connett_B S30

INSTALLATION DIRECTIVE 47

MAY 2006 S30 ENT M23

EDC connector A

123

43 28

50 11 20

2 1 3

F3F4

BAT

–

19 23

1342

13 40 53 52 58 41 51 12 27

B C

47 16 33 17

46 311

85150

A F

2 1 3

4 72642

K5 85

K6 85

CC 86

3087

8685

JFC H

JFC I

Sk Connett_A S30

INSTALLATION DIRECTIVE

48 MAY 2006

S30 ENT M23

Main analog instrument panel

C C

TA MO V

JB 41

JB 32

34 40

85150

K I

48642 7128

422526 21 4322 23 19194746 3018 1238

92 726162 15

3135 17 20 2928 JB

1037 11

JC 41

82 7146 15 39271636 13 5

4 3 2 1

JC 32

34 40

1245422526 21 4322 23

199

194746 3018 38

1987 10 1315 2 3

3135 173 24

3 24

20 2928

17 18 54 1216 1411

1037 11

6 20

SAC

SI FA

EDC

S ATA

SBPO

1 32

4JE

4JH

10 JH

10 JE

SCP

SBLA

SIFB

SIFO

SIFC

SSV

1 82 7146 15 39271636 13 5

BAT

–

B+

5030

87 30

85 86

30 87

86 85

87a

86 85

87 30

85 86

500

20 30

JFC

C D

JFC

Sk Quadro principale S30

INSTALLATION DIRECTIVE 49

MAY 2006 S30 ENT M23

Secondary analog instrument panel

4 1

9 198

710 13

15 2317 18 5

412

16 1411 623

346

7109 11 12

12 11 10 9 7

500

20 30

C C

TA MO V

82 7146 15 39271636 13 5

4 3 2 1

SAC

SI FA

EDC

S ATA

SBPO

SCP

SBLA

SIFB

SIFO

SIFC

SSV

1 82 7146 15 39271636 13 5

BAT

–

B+

5030

87 30

85 86

30 87

86 85

87 30

85 86

500

20 30

* * 72 5 1 B EDC

99 198

710 13

15 2317 18 5

412

16 1411 624

Sk Quadro secondario S30

* See main instrument panel

wiring diagram

INSTALLATION DIRECTIVE

50 MAY 2006

S30 ENT M23

Wiring of a specific personalised instrument board

123

10 912 11

1314

16 15

171820 19

212224 23

1234

5678

bar

psi

246810

29 58 87

116

145

250

210175

105

120

100

VOLT

12 14

35 29 30 17 1278232335 3413 19 18 31

OFF ON

START 7









 

min

X100

Connections

to be carried out

Identifying numbering

on each wire

10 meter long

wire harness

JD Connector integrated in the rear part

of the indications and alarms module

Sk Quadri VDO S30

INSTALLATION DIRECTIVE 51

MAY 2006 S30 ENT M23

Wiring of the double personalised instrument board (main and secondary board)

MAIN PANEL SECONDARY PANEL

123

10 912 11

1314

16 15

171820 19

212224 23

JBJB

1234

5678

bar

psi

246810

29 58 87

116

145

250

210175

105

120

100

VOLT

19 18 317232335 3413

123

10 912 11

1314

16 15

171820 19

212224 23

1234

5678

bar

psi

246810

29 58 87

116

145

250

210175

105

120

100

VOLT

OFF ON

START

12 14







 

min

X100







 

min

X100

35 29 30 17 12

Sk Quadri VDO 1°+2° S30

INSTALLATION DIRECTIVE

52 MAY 2006

S30 ENT M23



 







!#



"!4 "!4

"!4 nn "!4



''

"

!#





''

"



-- *!



)% )%



 





"!4



!# --

"!4



"















!#

























& &

Sk Accum_Servizi S30

Supplementary services battery recharge

Single engine

installation

Two-engines

installation

Key:

- 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

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

Iveco S30 Ent M23 Users Manual

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