C13 ENS M33 C13 ENT M50

Transcription

1 CURSOR C3 ENT M50 6 CYLINDER IN LINE DIESEL CYCLE FOR MARINE APPLICATIONS INSTALLATION DIRECTIVE MAY 006 EDITION T E C H N O L O G I C A L E X C E L L E N C E

2 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 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 C3 ENS M33 and C3 ENT M50 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) Printed P3D64C00 E - May 006 Edition

3 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 CONTENTS Page. WARNINGS AND CAUTIONS 4. ENGINE PARTS AND COMPONENTS 6 3. INSTALLATION OVERVIEW 8 4. GENERAL INSTALLATION CRITERIA 9 5. TECHNICAL DATA FOR INSTALLATION 0 6. IDENTIFICATION DATA 7. FUEL LINE 3 8. ELECTRICAL EQUIPMENT 5 9. MAIN ANALOG INSTRUMENT PANEL 0. SECONDARY ANALOG INSTRUMENT PANEL 6. DRILLING PlanS FOR ANALOG PANELS 7. MAIN DIGITAL INSTRUMENT PANEL 8 3. SECONDARY DIGITAL INSTRUMENT PANEL DRILLING PLAN FOR DIGITAL PANELS CUSTOMIZED INSTRUMENT PANEL SENSORS FOR DETECTION AND PANEL SIGNALING PREPARING THE ENGINE FOR FIRST START-UP 4 8. TESTS BEFORE THE FIRST START-UP 4 9. FIRST ENGINE START 4 0. EDC ANOMALIES INDICATION 44. BLINK CODE TABLE 45. UNDERWAY CHECKS PREPARING THE ENGINE FOR LONG IDLE PERIODS ELECTRIC DIAGRAMS ENGINE APPENDIX 63 Indications for consultation The different versions of the motors are generally hown using the same pictures and descriptions, however important differences are shown separately. The specific characteristics of the engine electric system are described in Chapter 5.

4 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006. WARNINGS AND CAUTIONS To obtain the best engine performance, it is essential not to deviate from the mission profile for which it was produced and set up. The engine must not be used for purposes other than those stated by the manufacturer. IVECO MOTORS is willing to examine any need for particular installations beforehand. Use of an electronically controlled injection system, in providing the engine with performance benefits, requires that the installer and maintenance specialist comply with some fundamental rules, which will become more and more commonplace as use of such equipment becomes progressively more widespread. Boat outfitters and maintenance specialists are invited to closely follow the instructions contained herein. No modifications to the engine, its accessories and components, are allowed. Failure to comply with the instructions that follow shall void the warranty and relieve IVECO MOTORS of all liabilities. For personnel safety Specialists and installers are cautioned to comply with workplace safety rules and to adopt prescribed individual protection devices when working. 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. o Batteries contain a highly corrosive sulfuric acid solution: must never be upset and must be handled with the utmost caution to prevent spillage. Ensure that the battery compartment is adequately ventilated. Handling The engine must be handled by experienced personnel, using the prescribed tool or a rocker arm that keeps the lifting lines parallel and with adequate equipment in terms of capacity and size. The two eyebolts provided for lifting the engine alone must always be used simultaneously. Installation o Knife switches or battery breakers may be used on the power supply line of the engine electronic unit, provided they are not used to shut the engine off. o Do not modify the wiring harnesses; their length may not be modified: use only available extensions. o Do not use electronic device wiring harnesses not 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 Do not connect any extraneous user device to the engine electrical equipment. o Do not place voltage across the boat s on-board electrical 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 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 subject electronic units to temperatures exceeding 80 C. o Do not paint electrical components and their connections. 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 7. 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-electronic equipment of the engine and the other electronic equipment present on the boat. Tests and tuning up o Never disconnect the batteries when the engine is running. o Remove the electrical connections from the batteries before any operation on the electrical system. o Ensure that the battery terminals comply with the exact polarity, are properly tightened and protected against accidental short circuits and corrosion phenomena.

5 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 o Do not connect or disconnect electrical connections when electrical power supply is present. 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 centers. Long engine inactivity periods Before long periods of inactivity, ready the engine following the procedure set out in Chapter 3.

6 6 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006. ENGINE PARTS AND COMPONENTS Figure _7_C. Intake air filter -. Location of intake air pressure and temperature sensor - 3. Lubricating oil refill cap - 4. Lifting padeyes - 5. Coolant level sensor - 6. Engine coolant tank - 7. Coolant refill cap - 8. Injector solenoid valve connector - 9. Location of thermostatic valve 0. Cap for engine coolant outlet to sanitary water heating system. Alternator location -. Coolant-sea water tube bundle heat exchanger - 3. Auxiliary pulley - 4. Oil drain sump plug - 5. Sacrificial anodes - 6. Sea water intake - 7. Sea water drain plug - 8. Air-sea water heat exchanger (not present on the engine) - 9. Sea water pump - 0 Electrical starter motor -. Fuel transfer pump -. Fuel filter - 3. Filter clogging sensor - 4. Fuel temperature sensor.

7 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 Figure _8_C. Coolant feed to exhaust manifold -. Lubricating oil filters - 3. Lubricating oil dipstick Insulated support - 5. Electronic Central Unit - 6. Cooled exhaust manifold - 7.Turbocharger inlet pipe-fitting - 8.Timing mechanism and oil vapor filter cover - 9. Location of timing phase sensor - 0. Oil filter clogging indicator -. Cooled turbo-charger -. Exhaust gas outlet flange - 3. Waste-gate actuator - 4. Phase and engine shaft rotation sensor location - 5.Timing phase inspection port - 6.Throttle position sensor potentiometer - 7. Electrical equipement wiring connectors - 8. Oil fill-in fill-out / pre-lubrication electrical pump (optional) - 9. Oil fill-in fill-out / pre-lubrication electrical pump solenoid valve (optional) - 0. Cap for engine coolant discharge and recyrculation from sanitary water heating system.

8 C3 ENT M50 INSTALLATION DIRECTIVE MAY INSTALLATION OVERVIEW Figure _9_C. Exhaust gas and sea water discharge -. Electrical system cabinet - 3. Secondary instrument panell - 4. Fuel tank with suction/ return assembly - 5. Fuel suction pipe - 6. Fuel return pipe to tank - 7. Pre-filter - 8. Fuel feed pipe to the fuel transfer pump - 9. Sea water decanter filter - 0. To the filtered sea water intake -. Main instrument panel -. Throttle actuator 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.

9 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 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 Engine installations to which the inverter is directly coupled to, must be performed in compliance with the number of supports, as specified here below: o for heavy duty 6 supports: 4 for the engine - for the inverter. NOTE: with the inverter weighting < 00kg and gearing-down ratio < 3, please contact IVECO MOTORS in order to assess the installation of the 4 engine supports alone. o C3 ENT M50 for commercial or heavy duty use 6 supports: 4 for the engine - for the inverter. In case spring inserts are used, they have to be capable of supporting the engine mass, the dynamic force, the force resulting from the torque reaction generated by the transmission and the longitudinal thurst performed by the propeller axis during navigation. 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 (). 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 (). Engine pre-heating If the engine usage profile requires immediate delivery of power at the highest rpm s, it is recommended to install an auxiliary pre-heater on the closed cooling loop. Exhaust gas discharge The exhaust gas discharge conduit shall be compliant with the guidelines contained in the IVECO MOTORS publication Guide to the installation of marine engines ; it also provides indications to compute the dimensions of the exhaust pipelines, which is the Yard s responsibility. Electric - electronic equipment Provide a suitable arrangement of the 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 6. () The EDC engine electronic control is programmed to reduce maximum deliverable power if the operating parameters measured by the sensors show that critical conditions have been reached, and if exceeded the engine could be damaged.

10 0 C3 ENT M50 INSTALLATION DIRECTIVE MAY TECHNICAL DATA FOR INSTALLATION Engine intake and ventilation air when underway Static vacuum allowed downstream of the air filter kpa mm H O C3 ENS M C3 ENT M Engine air intake flow rate m 3 /h Engine room ventilation air flow rate (excluding engine air intake) m 3 /h Static vacuum allowed in the engine room kpa mm H O Temperature allowed in the engine room C Maximum engine room temperature exceed outside temperature C Exhaust gas discharge Allowed static back pressure kpa mm H O Temperature at maximum power (turbocharger inlet) C 50 ± 5 50 ± 5 Flow rate at maximum power Kg/h Riser outer diameter Dry exhaust outer diameter Diameter of circumference of distance between 6 locking holes Fuel supply mm Inches mm Inches mm Inches Transfer pump delivery at maximum rpm l/h Fuel temperature to allow maximum power C Inner diameter. intake pipe mm 8 8 Inner diameter. return pipe mm 8 8 Thread on pre-filter junctions M 4 x.5 4 x.5 Thread on engine junctions inches UIC ½ ½ Allowed intake vacuum Open sea water cooling line Intake pipeline diameter kpa mm H O mm Inches Pump delivery at maximum rpm l/h Allowed intake vacuum Discharge pipeline diameter Gear box oil heat exchanger kpa mm H O mm Inches ¾ ¾ Thread on engine junctions inches UIC ½ or ¾ ½ or ¾

11 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 Allowed engine inclination angles C3 ENS M33 C3 ENT M50 Maximum longitudinal in continuous operation (static + dynamic) degrees/ Maximum transvers in continuous operation(static + dynamic) degrees/360 ±.5 ±.5 Longitudinal for oil level check with standard dipstick degrees/360 0 to 0 0 to 0 Power takeoffs (optional) -race front pulley for V belts Reference diameter mm Race dimension mm.7.7 Power available per belt at 650 rpm Power available per belt at 300 rpm -race front pulley + elastic joint for flange (GIUBO) Torque available in engine axis -race front pulley + elastic joint for crankshaft (CENTA) Torque available in engine axis Radial force resulting from belt tension (*) N (*) For direction of the resulting radial force between 60 and 300 with reference to the cylinder axis (piston at top dead center = 0 ) Moment of inertia of rigidly added masses kgm kw HP kw HP Nm Kgm Nm Kgm Dimensions Figure (40,94) 870 (73,6) 99 (439,05) 05_38_C Measurements in: millimeters (inches)

12 C3 ENT M50 INSTALLATION DIRECTIVE MAY IDENTIFICATION DATA Figure 5 Viale dell'industria, 5/7-000 Pregnana Mil.se MI - ITALY ENGINE TYPE S. p. A. ENGINE FAMILY POWER (KW) AND SPEED (RPM) ENGINE S/N ENGINE DWG POWER SET CODE YEAR OF BUILD HOMOLOGATION N COMMERC. TYPE / VERSION 04_039_C Figure The engine identification data are stenciled on a tag positioned over the engine coolant tank

13 MAY 006 INSTALLATION DIRECTIVE C3 ENT M FUEL LINE Figure _00_C Fuel inlet Fuel return. Return and suction flows from the tank -. Pre-filter - 3. Low pressure supply pump - 4. Return loop pressurization valve - 5. Inlet and outlet fittings from cylinder head - 6. Fuel filter - 7. Injector pump - 8. Fuel return line - 9. Cylinder head channel venting point - 0. Low pression injector feeding 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 fuel discharge outlet to the tank Pre-filter The pre-filter with priming pump, supplied separately from the engine, must be fastened near the tank, in a relatively low point of the line to allow for easy replacement 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 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 60 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 H O column); their shape and the suction assembly must be such as to assure a suction at the maximum longitudinal and transverse inclination allowed for the boat, with a residual quantity of fuel oil considered reserve. The suction inlet should be positioned in such a way as to avoid taking in sludge. The return flow must be in such a way as to facilitate the mixing of the returning fuel with the fuel in the tank. If the tank is lower than the filter, then the return pipe must always be submerged. The pipes and union fittings of the fuel line must withstand a fuel oil flow rate of 60 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.

14 4 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Fuel supply system scheme Figure EUI injector -. EUI pumper - 3. Rocker arm - 4. Actuating cam - 5. EUI solenoid valve - 6. Vent fitting on cylinder head - 7. Calibrated hole - 8 Vent fitting on pre-filter - 9. One-way valve - 0. Hand pump -. Fuel pre-filter -. One-way valve - 3. Fuel tank - 4. Gear pump assembly - 5. Fuel supply gear pump - 6. Pressure limiter valve (initial opening pressure 5 bar) - 7. One-way valve - 8. One-way valve - 9. Calibrated hole - 0. Pressure regulating valve (initial opening pressure 3.5 bar) -. Fuel filter -. Vent fitting on fuel filter support Hydraulic connections Figure _09_C. Outlet fitting from cylinder head -. Inlet fitting to cylinder head - 3. Pressure regolating valves location - 4. Outlet fitting for fuel outflow to the tank - 5. Inlet fitting from pre-filter - 6. Pre-filter - 7. Inlet pipe from the tank - 8. Outlet pipe to the tank - 9. Low pressure feed pump - 0. Fuel filter.

15 MAY 006 INSTALLATION DIRECTIVE C3 ENT M ELECTRICAL EQUIPMENT Figure _0_C Indicator and control panel -. Engine wiring - 3. Electronic Central Unit - 4. M Connector - 5. Relay box - 6. JF and JF connectors - 7. Sedimenting pre-filter - 8. Sensor for the presence of water in the fuel - 9.Wiring harness to be manufactured by the yard -0. Power supply and interface wire harness -. JG Connector -. JE Connector - 3. JA Connection - 4. JB Connection - 5. Power line for electric starter motor and alternator. 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 (9) for the sensor for the presence of water in the fuel (8), to complete the power line and to connect the accumulator to the engine wire harness.

16 6 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Synoptic Figure GEAR BOX INDICATIONS AND ALARMS SENSORS INDICATIONS AND ALARMS SENSORS THROTTLE POSITION SENSOR EDC COMPONENTS EUI SOLENOID VALVES EDC ALTERNATOR ELECTRIC STARTER MOTOR RELAY BATTERY BOX _008_C. Connector for instrument panel connection wire harness -. Engine wire harness - 3. Connector for pre-lubricating system - 4. Connector for certified installations by classification Bodies - 5. Interface wire harness - 6. Power line. The wire harnesses provided with the engine include the connectors for all optional components which may ordered and their connections to the JB connector for the indication and control panel.

17 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 7 Wire harness Figure F JF JF 05_6_C GH GG GG H J C * I T T VI VI SI K SI O K X A X Z JG E W W V S V S WI JA U WI JA JE + BATT BATT B MM JB Engine wire harness Interface wire harness M B EDC PO PA EC A EDC A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E. EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure/ temperature sensor for EDC - I. High coolant temperature - J. Low coolant level sensor (for alarm) - 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) - S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for gauge) - U. Clogged oil filter sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged blow-by filter sensor (for alarm) - Z. Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection wire harness - JE. Alarms control unit (for Certification Bodies) - JF,JF. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor - PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure sensor (5 bar) - WI. Low gear box oil pressure sensor (7 bar) - * Sensor H wiring harness.

18 8 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Power supply line Figure 3 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 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 B S L IG 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). M 05_040_C. Electric starter motor -. Engine wire harness - 3. Batteries - 4. Alternator. 4 3 If two engines are installed The presence of two generators allows to keep the recharging functions separated: the generator (G) recharges the battery (AC) dedicated to starting both engines and powering both electrical/electronic control circuits, whilst the generator (G) recharges the battery (AC) 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 0 fully complies with this need, assuring the full functionality and independence of the two circuits. The connection of the +B terminal of the alternator to the positive +30 terminal of the electric starter motor must be achieved with a conductor having a cross section of at least 40 mm. 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 95 mm, allows to obtain, as shown in the figure, the simultaneous connection of the alternator to the battery. The connection between the engine ground and the negative pole of the battery must be achieved according to the guidelines provided in the Engine electrical ground paragraph. caution If magneto-thermal protecting breakers are inserted, they must not be used to stop the engine and in any case they must be activated only a few seconds after shut-down.

19 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 9 Engine electrical ground Figure 4 Battery recharging Figure 5A Connect to positive pole terminal of the starter motor B+ S L IG 05_038_C 04_038_C. Point of connection of the engine electrical ground. The connection of the engine electrical ground is achieved by connecting with a cable of at least 95 mm cross section to the negative pole of the battery to the tightening point of the electric starter motor as shown in Figure 4. To anchor the grounding terminal to the engine, proceed as follows: o completely remove the 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 mechanical means, obtaining a smooth support surface; o apply a uniform layer of BH44D paint (IVECO standard 8-705) with a brush or spray gun; o join the parts constituting the grounding note within 5 minutes from the time the paint was applied. 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. 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 5B). Figure 5B +B S L IG 05_039_C Connect to positive pole terminal of the starter motor B S L IG Connect to positive pole terminal of the batteries

20 0 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Connections of the central electronic unit (ECU) EDC MS 6. Figure 6 Relay Box Figure 7 ENGINE ROOM ENGINE STOP PTO PTO ON BRIDGE ENGINE START PTO + PTO OFF CHECK 04_00_C A B 8085 A. Engine component wiring connector B.Vessel side wiring connector The connection of the central electronic unit, ECU, to the EDC system, takes place by means of two 35 way connectors mechanically polarized in the latching system to prevent switching. The presence of the two connectors provides for a subdivision of the wiring harnesses to distribute the large quantity of conductors and at the same favor a more rapid identification of the lines during testing operations conducted by technical assistance personnel.. Bridge or engine room engine control selector -. Start and stop push button - 3. Manual accelerator throttle control in engine room - 4. PTO ON / PTO OFF selector - 5. EDC fault indicator and blink code LED - 6. Blink code emission request push-button - 7. Connector for external diagnostic tool. 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 to control 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. Engine rpm control could be obtained directly from engine room by the pushbutton (3) after positioning the switch (4) ON. Among the controls present on the panel are also the pushbutton (6) and the blink code light indicator (5), useful to obtain, also while underway, indications that will lead to identify failures or improper engine operating conditions (see Chapter 0). On the relay box is located the multipolar connector (7), protected by a screw-on lid, for connection with the computerized diagnostic tools prescribed by IVECO MOTORS (see Chapter 0). 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.

21 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 Throttle lever position sensor Figure 7A Water presence in the pre-filter sensor Figure 7B 05_078_C After testing the working condition of the linkage, adjust the run of the servo components (see Chapter 8). 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. 3. Pre - filter -. Conductor to be connected with the negative battery terminal - 3. Sensor to detect water in the fuel. 05_08_V CAUTION In order to enable the proper working of the sensor to detect water in the fuel, it is necessary that the pre-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 pre-filter support from the boat mass and then connect the support with the negative battery terminal.

22 C3 ENT M50 INSTALLATION DIRECTIVE MAY MAIN ANALOG INSTRUMENT PANEL Figure electronic RPMx00 HOURS V C F bar _00_C. Coolant temperature gauge (TA) -. 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) -0. Engine stop push-button (usable only with electric harness versions with excitation engine stop) -. Sound alarm inhibition push-button (P) -. SIFC Alarm abilitation connector - 3. Connector for main panel wiring (JC) - 4. 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 meter-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 with no secondary panel, do not remove the cap of the JE connector to avoid compromising the electrical continuity of the systems power supply circuit. To allow the work of the fuel filter clogging alarm, in the indication alarm module, it has to disconnect the connector () fitted close to JC.

23 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 3 Synoptic of the connections of the analog panels Figure 9 MAIN INSTRUMENT PANEL JE JE JH JH SECONDARY INSTRUMENT PANEL JC JC A ENGINE EQUIPMENT EDC B JB JA JF JF BATTERY 04_0_C. JB-JC Extension wire harness -. JE-JH Extension wire harness. Figure JC JB 04_50_N 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 4.

24 4 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Installation In order to drill holes on the area where the panel is to be mounted, refer to the dimensions indicated in Chapter. Operation of the panel After completing the electrical connections and engine preparation, perform the tests required for the first start, as described in Chapter 8. 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 according to the procedures set out below. 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 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 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. Indications and Alarms Module Figure. Engine overspeed (SSV) -. Presence of water in the fuel pre-filter (SAC) - 3. Low 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)- 0. High coolant temperature (SATA) -. Low oil pressure (SBPO) -. Pre/ post heating (SCP) - 3. 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 5 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 _34_N The standard set-up of the C3 ENT M50 provides for use of the indicators: SBLA, SIFA, SIFC, SIFO, EDC, SS.

25 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 5 Revolution-counter calibration Figure A Revolution-counter calibration Figure B 04_55_N 06_3_V. Adjustment screw -. Panel lighting lamp. 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 (), located in the rear part of the revolution counter, 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 A).. Calibration increasing button -.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, press the button and 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.

26 6 C3 ENT M50 INSTALLATION DIRECTIVE MAY SECONDARY ANALOG INSTRUMENT PANEL Figure 3 electronic RPMx00 04_40_N.Connector for secondary panel wire harness (JH) -. 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 (P). 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 meter-long versions (see Fig. 9). The JE-JH wire harness comprises lines, each connected to the terminal identified on both connectors by the same number (see fig. 4). Figure _5_N 7 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. 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 8), 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 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.

27 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 7. DRILLING PlanS FOR ANALOG PANELS Figure 5 Ø4 Ø4 Main panel Ø4 Ø4 4 6 = = = = _0_C Dimension in millimeters. Figure 6 8 = = 8 Ø4 Ø4 Secondary Panel Ø4 Ø4 8 = = _03_C

28 8 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006. MAIN DIGITAL INSTRUMENT PANEL Figure BAR BAR RPM X00 35 MIN MAX C RPM + V 6 h PROG _56_N. Engine coolant temperature indicator -. Lubrication loop pressure indicator - 3. Service and alarm indicators - 4. Revolution counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Engine start/stop key switch - 8. JE connector for secondary panel - 9. Cap with electrical continuity connection - 0. Accessory function programming push-button -. Push-button for selecting accessory information -. Digital display - 3. Push-button for zeroing the programmed maintenance indication - 4. Sound alarm inhibition push-botton - 5. JH connector for panel wiring - 6. Buzzer. Installing the panel provided with digital displays requires connecting the JH-D connector of the panel to the JE connector of the interface wire harness, itself connected to the Converter Module, interposing the JE extension wire harness, available in 3, 5 and 7 meter-long versions (Figure 4). To the main panel is connected the JE connector, set for connection to the secondary panel; in installations lacking the secondary panel, do not remove the cap of the JE connector in order not to compromise the electrical continuity of the system power supply circuit.

29 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 9 Synoptic of digital panel connections Figure 8 SECONDARY INSTRUMENT PANEL MAIN INSTRUMENT PANEL JE JE JH JA JH JH JE JE JE JD JO CAN - BUS CONVERTER MODULE ENGINE EQUIPMENT A EDC B JB JA JF JF 04_04_C RELAY BOX BATTERY. Interface wire harness for converter module -. JE-JH extension wire harness. The JE connector provides connection to a second main onboard panel. Its installation is subject to IVECO MOTORS approval.

30 30 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Can-bus converter module Figure 9 REAR VIEW OF THE MODULE WITH JO CONNECTOR The presence of the Converter Module is necessary to translate the information of some sensor, provided in analog form, into information suited to be decoded by the digital converters of the panel. The interface wire harness is set up to connect the main panel (JE) from which the secondary panel is to be branched off, and it is provided with a branch (JD) for connecting an electronic engine rpm managing system or an electronic throttle. The JE connector is branched from the interface cable. The connector provides connection to an optional second main onboard panel. Its installation is subject to IVECO MOTORS approval (see figure 8). Figure 30 04_8_N JO CONNECTOR VIEW OF THE WIRE HARNESS TERMINAL, COUPLING SIDE 04_59_N Functions of the JO terminals Gear box oil pressure signal CAN L 3 CAN H 4 Power supply positive (+ B) 5 Power supply positive (+ B) 6 Battery positive with key in ON position 7 Battery positive with key in ON position 8 Power supply negative (ground) 9 Optional output 0 Engine rpm signal Pre-lubrication signal Not connected 3 Exhaust gas temperature signal (-) 4 Exhaust gas temperature signal (+) 5 Gear box oil temperature signal 6 Engine oil temperature signal 7 Engine oil pressure signal 8 Air filter clogging signal 9 Power supply negative (ground) 0 Not connected Alternator anomaly signal Pre-heating signal 3 EDC failure signal 4 Low coolant level signal 5 Exhaust gas temperature signal (-) 6 Exhaust gas temperature signal (+) 7 External throttle input signal 8 Coolant temperature signal 9 Air filter clogging signal 30 Not connected 3 Power supply negative (ground) 3 Not connected 33 Runaway engine signal 34 Water in fuel signal 35 Oil filter clogging signal 36 Fuel filter clogging signal

31 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 3 Connector JD Figure 3 PIN PIN 4 04_63_N The JD connector enables to use an electronic engine rpm management instead of the system provided on the engine. If this solution is used, the throttle position sensor, situated on the engine, will remain electrically connected but not used and the EDC Central Unit will manage engine rpm according to the voltage signal applied to the terminals of the JD connector. In case of a fault in the electronic throttling system, the engine rpm may be managed in emergency condition, mechanically operating the sensor lever positioned on the engine. The connection requires a METRI PACK 50 four-way connector with male terminals. PIN Wire code (U) Voltage Interpreted function I max 773 +B with key in ON position Electronic throttle enabling 0,5 A V - (Ground) Common reference terminal - 0 to 0, V Poor value. EDC recognises a fault - 0, to 0,5 V Accelerator at minimum level ,5 to 4,5 V Accelerator min. to max., U function - 4,5 to 4,8 V Accelerator at maximum level - 4,8 to 5 V Excessive value. EDC recognises a fault Ground, with engine in overspeed Overspeed engine indication 0, A NOTE: The voltage values for the rotation of the motor must be between 0. and 4.8 V. Values below 0. V or above 4.8 V generate the recognition of a fault and consequent deactivation of the function.

32 3 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Installation In order to drill holes on the area where the panel is to be mounted, refer to the dimensions indicated in Chapter 4. Operation of the panel After completing the electrical connections and engine preparation, perform the tests required for the first start, as described in Chapter 8. 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. During this phase, all indicator lights must be lighted, with the exception of those for pre-lubrication, prepost heating and EDC failure. A sound signal must be emitted by the buzzer; it may be silenced before the end of the test, pressing the push-button on the panel. o Once the test is complete, only the indications prescribed for the engine stopped must remain lighted: e.g. alternator charge and low oil pressure ; the analog instruments must provide values consistent with the respective 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 above. Using appropriate measuring instruments, verify the consistency of the indications provided by the analog instruments. 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. Programming accessory functions The following programming operations are required when the panel is first operated: o The hours of the maintenance interval relevant to the characteristics of the engine in use. o The maximum quantity of introduction, necessary to compute fuel consumption. With reference to Figure 7, proceed as follows: o Holding down the Programming (0) and Slide-down selection () push-buttons, positioned on the panel, turn the key switch to the first position and wait for the display to show the value of the maintenance interval set previously (e.g., 00 hours). o Release the push-buttons and set the hours of the time interval, indicated for oil replacement, provided on the operation and maintenance manual; the operation is completed by repeatedly pressing the Slide-down Selection push-button () until the number that is selected and highlighted by flashing is correctly set, then operating the Programming push-button (0) to select the number to set. o Press and hold the Programming push-button (0) until the display shows the maximum introduction value, set by default to the value 0 mg/strk, then release it. o Set the number for engine calibration, obtaining it from the table that follows, proceeding as described in item. o Press and hold the Programming push-button (0) until the display shows the engine rpm indication. If programming operations were not performed correctly, the display will show the indication Err.P ; check whether the electrical connections of the main panel and of the converter module were performed correctly, then repeat the procedure. Maximum power calibration [HP] Fuel introduction [mg/strk] C3 ENT M50 Maximum power calibration [HP] Fuel introduction [mg/strk]

33 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 33 Symbology key Clogged air filter Expired programmed maintenance interval Clogged oil filter Pre-lubrication in progress Pre-post heating Clogged fuel filter Presence of water in the fuel filter Clogged blow-by filter Alternator fault Low oil pressure High coolant temperature Runaway engine Low engine coolant leve EDC fault 04_64_N

34 34 C3 ENT M50 INSTALLATION DIRECTIVE MAY SECONDARY DIGITAL INSTRUMENT PANEL Figure BAR 0 30 BAR C 0 5 RPM X00 RPM 35 MIN + V MAX 6 h START STOP _57_N. Engine coolant temperature indicator -. Lubrication loop pressure indicator - 3. Service and alarm indicators - 4. Revolution counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Push-button for selecting accessory information - 8. Engine stop push-button - 9. Digital display - 0. JA connector for panel wire harness -. Engine start push-button.. Sound alarm inhibition push button. The secondary panel is branched to the main panel. Remove the cap from the main panel JE connector and connect the JE connector to the JA connector on the secondary panel, placing the special extension JE-JH cable, available 3.5 and 7 meters long (see figure 4). IVECO MOTORS standard supply is provided for the installation of the main and secondary board and their simultaneous use with no operation limitations. Installation In order to drill holes on the area where the panel is to be mounted, refer to the dimensions indicated in Chapter 4. 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 8), 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 the main and secondary 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 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.

35 MAY 006 INSTALLATION DIRECTIVE C3 ENT M DRILLING PLAN FOR DIGITAL PANELS Figure 33 = 6 Ø7 Ø7 Main panel and secondary panel = 59 9 Ø7 Ø7 6 = = _05_C Dimensions in millimeters

36 36 C3 ENT M50 INSTALLATION DIRECTIVE MAY 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 0 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 4. Figure 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 _4_N 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 4. JD Connector for indications and alarms module Figure 34 VIEW FROM THE TERMINAL SIDE OF THE COUPLING SIDE WIRING connector TRIDENT / ITT CANNON part TST 4PA00 terminal female part lid rear part TST4AH0 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 4. For standard-equipped engines, to have the essential indications available, the following ways must be wired:,, 3, 7, 8, 9, 0,, 3, 4, 5, 6 with the female terminals supplied as standard equipment _034_C VIEW FROM THE INTEGRATED SIDE IN THE REAR PART OF THE MODULE

37 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 37 Functions of the JD terminals PIN Description Electric level OFF Indication ON Indication Module power supply Positive (+B) EDC lamp power supply Power supply positive (+B) 3 EDC Fault indication High (+B) Low (ground) 4 Pre-heating light power supply Power supply positive (+B) 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 Buzzer inhibition Negative (ground) during the request 9 Module power supply Negative (ground) 0 Sound alarm power supply Negative (ground) during the emission of sound Clogged oil filter indication Open circuit Low (ground) Clogged oil vapor filter indication Open circuit Low (ground) 3 Clogged air filter indication Open circuit Low (ground) 4 Clogged fuel filter indication Low (ground) Open circuit 5 Alternator fault indication High (+B) Low ( to 3 V) 6 Low engine coolant level indication Open circuit Low (ground) 7 High coolant temperature indication Open circuit Low (ground) 8 Low engine oil pressure indication Open circuit Low (ground) 9 Presence of water in fuel indication Open circuit Low (ground) 0 Overloaded or runaway engine indication Open circuit High (+B) Not connected - Not connected - 3 Reception of data from main panel NMEA communication protocol (0 to 5 V) 4 Transmission of data to secondary panel NMEA 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 be present: (SAC) presence of water in the fuel pre-filter (SIFA) clogged air filter (SS) alternator fault

38 38 C3 ENT M50 INSTALLATION DIRECTIVE MAY SENSORS FOR DETECTION AND PANEL SIGNALING Coolant temperature sensor Figure 36 Oil pressure sensor Figure 38 04_06_C Resistor with negative temperature coefficient, providing the signal for analog temperature indication. Operating voltage from 6V to 4 V Calibration range from 0 C to 0 C Resistance value at 90 C 5. ± 4.3 Ω Poles isolated High coolant temperature sensor Figure 37 04_37_N Rheostat component providing the signal for the analog indication of pressure. Operating voltage from 6V to 4 V Calibration range from 0 bar to 0 bar Resistance value at 0 bar 0 Ω +3/-5 Ω Resistance value at bar 5 ± 4 Ω Resistance value at 4 bar 88 ± 4 Ω Resistance value at 6 bar 4 ± 5 Ω Maximum value of resistance 84 Ω Operating temperature from - 5 C to 00 C Poles isolated 04_07_C Switching coolant temperature sensor, providing the signal for the related indicator. Low oil pressure sensor Figure 39 Operating voltage: from 6 to 4 V Condition at ambient temperature normally open Closing temperature: 00 ± 3 C Electrical poles isolated 04_08_C Pressure switch, providing the signal for the related indicator. Operating voltage: Condition at ambient pressure Calibration range Closing pressure: Opening pressure: Maximum current Electrical poles from 6 to 4 V normally closed bar 0.5 bar 0.8 bar 5 A (not inductive) isolated

39 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 39 Air filter clogging sensor Figure 40 Fuel filter clogging sensor Figure 4 04_030_C Vacuum switch, providing the signal for the clogged air filter alarm indicator. Operating voltage: Condition at ambient pressure Closing vacuum: from 6 to 4 V normally open -5 mbar Operating temperature: -0 / +80 C Maximum current Electrical poles Oil filter clogging sensor 0. A (not inductive) isolated 04_38_N Pressure switch, providing the signal for the related indicator. Operating voltage: Condition at ambient pressure Opening pressure: Maximum current Electrical poles from 6 to 4 V normally closed.5 ± 0. bar 0, A (not inductive) isolated Exhaust gas temperature sensor Figure 43 Figure 4 04_60_N NiCr-Ni thermocouple sensor with insulated poles, providing the signal for the analog indication of exhaust gas temperature. Differential pressure switch, providing the signal for the related indicator when pressure difference between inlet / outlet oil filter is more then a limit value. Operating voltage: Condition at ambient pressure Closing pressure: Opening pressure: Maximum current Electrical poles from 6 to 4 V normally open.4 ± 0.3 bar.8 ± 0.3 bar 3 A (not inductive) isolated 04_09_C Temperature Voltage C mv

40 40 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Sensor to detect the presence of water in fuel Figure 44 CAUTION In order to enable the proper working of the sensor to detect water in the fuel, it is necessary that the pre-filter support is connected electrically to the negative battery terminal. Fuel resistivity sensor, integrated with the control and amplification electronic circuit, providing the signal for the indicatorof the presence of water in the fuel. Operating voltage from V to 4 V Condition in the absence of water open circuit Closed condition resistance of the liquid MΩ Operating temperature from -0 C to +80 C Connections of the sensor detecting the presence of water in fuel Figure 45 04_03_C In the engine models which use parts with insulated poles it is necessary to electrically insulate the pre-filter support from the boat mass and then connect the support with the negative battery terminal. Low level coolant sensor Figure 46 The sensor detect the presence of coolant and is provided with the control and amplification electronic circuit; it providing the signal for the alarm for low level coolant. Operating voltage Condition for high level Maximum current from to 4 V open 0. A not inductive 04_033_C 3 04_03_C. M Connector of the engine wire harness -. 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 pre-filter in the boat. Connection to the engine wire harness requires a METRI- PACK50 three-pole connector with three male terminals; connection to the sensor requires a JUNIOR TIMER threepole connector with three female terminals

41 MAY 006 INSTALLATION DIRECTIVE C3 ENT M PREPARING THE ENGINE FOR FIRST START-UP. Drain the residual 30/M protective oil from the sump.. 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 3 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 3 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. In order to enable the see water pump priming it is necessary to input water into the forcing circuit. Remove the sacrifical anode ( of figure 47), introduce.5 litres of water into the hole; reassemble the anode and tighten it as required. WARNING If the engine is activated after a long time, it is necessary to repeat the operations mentioned in item Remove from the engine the labels with the inscription ENGINE WITHOUT OIL. 8. 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 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 indicator light to be permanently lighted. Throttle lever position sensor Figure 48 Figure 47 04_080.N 8089 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: o that in the resting position the safety switch inside it is electrically open. Carry out the test with an ohmmeter between the points D and E of the potentiometer connector. - Value read Ω = optimal adjustment; - Value read kω = a better mechanical adjustment of the resting position is required, to bring the value back to Ω. o In the position of maximum acceleration, the rod of the sensor has reached the mechanical end stop. Instruments and control panel Verify the efficiency of all light indicators, as described in the related Chapters.

42 4 C3 ENT M50 INSTALLATION DIRECTIVE MAY 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 pre-filter or with the aid of a dedicated electrical pump. The venting air points are fitted on the pre-filter supplied from IVECO MOTORS, after the main filter, on the cylinder head near the injectors solenoid valves connector. (see Figure 49). Loosen the vent fitting on the pre-filter and operate the pump until only fuel without air flows out. Tighten the vent fitting and complete the purge operation on the vent fitting placed on the cylinder head during the initial start-up phases. Figure 49 Start-up procedures Figure 50 ENGINE ROOM BRIDGE ENGINE STOP ENGINE START PTO- PTO+ 3 4 PTO ON PTO OFF CHECK 04_035_C The electrical equipment of this engine allows to start 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. PURGE FITTING ON CYLINDER HEAD 04_034_C CAUTION Make sure that the fuel that flows out of the fitting dont coming in conctact with the auxiliaries drive belt and is not dispersed in the environment. Starting the engine from the bridge This is allowed only if the Relay box switch () is in the BRIDGE position. Start the engine and let it run until the idling rpm has fully stabilized (see also the Chapters on the instrument panels) Starting the engine from the engine room Moving the Relay box switch () to the ENGINE ROOM position (which must absolutely not be done when the engine is running), regardless of the position of the key switch on the indicator and control panel, enables the use of the adjacent STOP - START push-button (). It will thereby be possible to start and stop the engine with complete independence from the bridge controls. Moving the switch () back to the BRIDGE position, inhibits use of the START-STOP push-button positioned on the Box, allowing the engine to be started only from bridge controls. RPM control To allow easily to control engine RPM from the engine room, a simultaneous acceleration/deceleration function (PTO+/PTO-), active only when the switch () is in the ENGINE ROOM position, and the switch (4) is in PTO ON position. Acceleration (PTO +) If, the engine is running, and PTO+ / PTO- push-button is held down in the PTO+ position, then engine rpm are progressively increased (50 rpm per second). The increase ends when the push-button is released, allowing the engine to run at the desired rpm. Deceleration (PTO -) If the engine is running, and PTO+ / PTO- push-button is held down in the PTO- position, a progressive reduction in rpm is obtained (50 rpm per second). The reduction ends

43 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 43 when the push-button is released, allowing the engine to run at the desired rpm. The rpm reached at that point is maintained until the engine is stopped. (function takes priority and always stops the engine) or switching the PTO ON / PTO OFF push-button in the OFF position. CAUTION Never operate the BRIDGE - ENGINE ROOM switch when the engine is running. 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 5 05_00_C keep the engine at minimum rotation speed, slowly loosen screw () positioned on the coolant tank near the cap and the two screws () situated on the exhaust induction in order to facilitate the exit of possible air bubbles. When this operation is finished, tighten the screws as required, stop the engine and verify the level of the coolant liquid. Fill it up if necessary. Take care not to disperse the exiting liquid 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 5 minutes with the engine running, is no less than about 6 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 0.

44 44 C3 ENT M50 INSTALLATION DIRECTIVE MAY 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: Light on: Blinking light: no anomaly detected or slight anomaly that does not compromise operating safety significant anomaly, allowing to proceed to a service center severe anomaly requiring immediate repairs. If possible, shut the engine down. Blink code The emission of the anomaly codes detected during self-testing and stored in the ECU starts after pressing and releasing the CHECK push-button on the relay box panel, when the BRIDGE - ENGINE ROOM switch is in the ENGINE ROOM position The LED located at the side of the push-button and the EDC indicator light on the indicator and control panel will simultaneously signal, with two series of emissions at different frequencies, the blink codes that indicate the anomaly with decimal numbering. Slow blinks identify the area of the anomaly (engine, injectors,...), fast blinks identify a specific anomaly. Every time the push-button is pressed and released, only one of the stored codes is emitted; therefore, the procedure must be repeated until an error indication identical to the first one is obtained, which means the entire error memory has been analyzed. If no anomalies are stored, the light comes on when the push-button is pressed and comes off about second after its release, without any subsequent blinking. Recovery The recognition of significant or sever 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. Error deletion procedure Figure 5 ENGINE ROOM BRIDGE ENGINE STOP ENGINE START PTO- PTO+ PTO ON PTO OFF CHECK 3 04_035_C A. Shut the engine down and keep the key switch in the OFF position for 5 seconds (after run). B. Approach the relay box. Keeping the CHECK diagnostic push-button (3), move the adjacent BRIDGE - ENGINE ROOM switch () to the ENGINE ROOM, wait for the luminous indicator (4) to switch off position, while keeping the diagnostic push-button pressed for 8 more seconds. C. Release the push-button and move the ENGINE ROOM switch to the BRIDGE position 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. At the end of this procedure, the codes of any anomalies detected during the engine installation and first start-up operations will be deleted in the ECU. To make sure that no anomaly data remain stored in it, or that there are no other errors in the system, set the BRIDGE - ENGINE ROOM switch to the ENGINE ROOM position and verify that, when the diagnostic push-button is pressed, the blink code light () does not emit any code. At the end of these operations, return the switch to the BRIDGE position If the ECU signals the presence of errors or operating anomalies, the installation will have to be reviewed to remove the cause of the error or anomaly. Indications for decoding the codes are provided in Chapter. NOTE: The blink code diagnostic procedure provides indications about current anomalies as well as past anomalies that are no longer present when the diagnosis is carried out; therefore, it is absolutely mandatory, at the end of every repair operation, to erase the error memory to prevent anomalies whose cause has already been removed from being signaled in the future.

45 MAY 006 INSTALLATION DIRECTIVE C3 ENT M BLINK CODE TABLE Blinking Code EDC Indicator light Indicated Fault Control area. (on) not significant in marine applications. (on) not significant in marine applications.3 (off) not significant in marine applications.4 on throttle position sensor.5 (off) not significant in marine applications.6 (on) not significant in marine applications.7 (off) not significant in marine applications Engine area. off coolant temperature sensor. off intake air temperature sensor.3 off fuel temperature sensor.4 on supercharge air pressure sensor.5 off ambient pressure sensor (inside the unit).6 (on) not significant in marine applications 3.5 off battery voltage Injectors 5. on cylinder injector fault 5. on cylinder injector fault 5.3 on cylinder 3 injector fault 5.4 on cylinder 4 injector fault 5.5 on cylinder 5 injector fault 5.6 on cylinder 6 injector fault Engine rpm sensor 6. on flywheel sensor 6. on timing system sensor 6.4 blinking runaway engine Electronic unit 9. blinking defective unit 9. on incorrect EEPROM data 9.3 (blinking) not significant in marine applications 9.4 on main relay 9.5 on erroneous engine shut-down procedure 9.6 on unit data storage operation not completed

46 46 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006. 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 50 C and, in any case, does not exceed the value of external temperature by more than 5 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 50 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. bar relative (000 mm H O); o pressure in the fuel oil return line to the tank is less than 0. bar relative (000 mm H O). 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 00 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.

47 MAY 006 INSTALLATION DIRECTIVE C3 ENT M 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:. Drain the lubricating oil from the sump, after heating the engine.. Pour 30/M protective oil (alternatively, oil conforming with MIL 60B Type 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..to do so, loosen the drain cap in the front part of the cylinder head and the fuel inlet junction with the cylinder head, taking care to prevent the fuel from coming in contact with the auxiliaries belt. 4. Connect the fuel line to a tank containing CFB protective liquid (ISO 43) and assist the inflow of the liquid by pressurizing the line and turning the engine over for about 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 4 V, using a conductor prepared for the occasion. 5. Nebulize 30/M protective oil at the rate of about 30 g (0 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 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 9 AR onto unpainted metal parts, such as flywheel, pulleys and others; avoid spraying belts, connector cables and electrical equipment.

48 48 C3 ENT M50 INSTALLATION DIRECTIVE MAY 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 5 Component terminal Connection JC: connector 8: terminal Fuse code Component code Minimum cable cross section in mm Component code or connector code Terminal connection Schema_Connettore_B

49 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 49 Electrical equipment component code A AC AQ AS B C CA CS DL EC F GG GH H I IN J K L M MC MM MP MS O P PA PE PH PO QP QS R R R3 S SA fuel temperature sensor for EDC battery engine shut-off push-button on main panel engine shut-off push-button on secondary panel drive shaft sensor for EDC camshaft sensor key switch engine start push-button on secondary panel EDC fault indicator and blink code LED switching solenoid valve for oil charge/discharge engine coolant temperature sensor for EDC alternator grid heater power relay combustion air pressure/temperature sensor for EDC high coolant temperature sensor (for alarm) injectors solenoid valve low coolant level sensor (for alarm) air filter clogging sensor (for alarm) instrument panel light switch sensor for detecting the presence of water in the fuel pre-filter (for alarm) CAN - BUS converter module for digital panel electric starter motor pre-lubrication and oil transfer module IVECO MOTORS indications and alarms module exhaust gas temperature sensor (for gauge) sound alarm inhibition push-button throttle position sensor emergency shut-down push-button (optional, installer s responsibility) grid heater pre-lubrication electrical pump main analog instrument panel secondary analog instrument panel 3.3 kω resistor to inhibit speed input DL resistor alternator pre-excitation resistor oil temperature sensor (for gauge) buzzer SI SW SW gear box oil temperature sensor bridge or engine room engine control selector (on relay box panel) start and stop push button (on relay box panel) SW3 manual accelerator throttle control in engine room (on relay box panel) SW4 SW5 T U V VI W WI X Z PTO ON / PTO OFF selector (on relay box panel) blink code emission request push-button (on relay box panel) coolant temperature sensor (for gauge) clogged oil filter sensor (for alarm) oil pressure sensor (for gauge) high gear box oil pressure sensor (5 bar) low oil pressure sensor (for alarm) low gear box oil pressure sensor (7 bar) clogged blow-by filter sensor (for alarm) clogged fuel filter sensor (for alarm) 8550 ECU of the EDC system (continues on next page)

50 50 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Connectors A B E J JA 35 pole EDC - boat components connection 35 pole EDC - engine components connection EUI injectors solenoid valve on the relay box panel for external diagnostic tool connection between engine wiring and interface wire harness JA ON SECONDARY DIGITAL INSTRUMENT PANEL set for connection to the main digital instrument 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 JD set for connection to the engine wire harness IVECO MOTORS indications and alarms module JD ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE external throttle control JE ON MAIN ANALOG INSTRUMENT PANEL set for connection to the secondar y analog instr ument panel JE ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE set for connection to the main digital instrument panel JE ON MAIN DIGITAL INSTRUMENT PANEL set for connection to the secondary digital instrument panel JE ON MAIN INTERFACE WIRE HARNESSE set for connection to the alarms control unit (for Certification Bodies) JE ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE JF JF JG set for connection to the main digital instrument panel relay box relay box pre-lubrication control unit JH ON SECONDARY ANALOG INSTRUMENT PANEL set for connection to the main analog instrument panel Indicator lights EDC SAC SATA SBLA SBPO SCP SIFA SIFB SIFC SIFO SIM SP SS SSV Gauges CG MI MO TA TI TS V EDC malfunction presence of water in fuel pre-filter coolant high temperature low coolant level low oil pressure pre-post heating clogged air filter clogged oil vapor filter clogged fuel filter clogged oil filter expired programmed maintenance interval pre-lubrication alternator fault engine overspeed revolution-counter gear box oil pressure engine oil pressure engine temperature gear box oil temperature exhaust gas temperature voltmeter Relays contained in the relay box K K K3 K4 K5 K6 EDC main (power supply key switch electric discharge emergency engine shut-down provision enabling start engine from engine room power supply to terminal 50 of the electric starter motor cranking exclusion when engine is running Fuses contained in the relay box F- F self restoring (not replaceables) JH ON MAIN DIGITAL INSTRUMENT PANEL JO set for connection to the interface wire harness for converter module converter for digital panels

51 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 5 EDC connector B Schema_Connettore_B

52 5 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 EDC connector A P U R t Schema_Connettore_A

53 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 53 Main analog instrument panel C78_Quadro Di Bordo C78

54 54 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Secondary analog instrument panel C78_Elettrico_Quadro_fly * See main indicator and control panel wiring diagram

55 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 55 CAN - BUS converter module interface wiring JE JD JB JE JO Connector key: JB instrument panel (engine side) JD external throttle control JE main digital instrument panel (see Installation directive document.) JE main digital instrument panel (engine side) JO converter for digital panel Sk_Cablag_Convert_C78

56 56 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Wiring of a specific personalised instrument board 8 4 JB min X C F 50 G meter long wire harness bar psi 4 VOLT G 8 7 Connections Identifying numbering on each wire JD connector integrated in the rear part of the indications and alarms module Sk Strumenti Quadri VDO C78

57 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 57 Wiring of the double personalised instrument board (main and secondary board) C bar min X F psi VOLT 3 G G MAIN PANEL OFF ON START JB JB C bar min X F psi VOLT 3 SECONDARY PANEL G G Sk Strumenti Quadri VDO + C78

58 58 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Supplementary services battery recharge BAT + + BAT MM MM 8 JB AC GG M M GG BAT BAT AC M IE IE JB 8 + B+ B BAT AC BAT MM B+ GG 8 JB RL AC Single engine installation Two-engines installation * Key: * - AC: Main Battery - AC: Battery for auxiliary services - IE: Engine electrical system - IE: Engine electrical system - RL: Relay 50A max. *: Electrical power supply for services Sk Accum_Servizi S

59 MAY 006 INSTALLATION DIRECTIVE C3 ENT M ENGINE Due to the light supercharge pressure required, the C3 ENS M33 engine does not require the presence of the air/air heat exchanger. The electric system is common also to other engines of the same family, but the C78 ENS M0 engine is differentiated by the use of specific sensors for temperature and combusting air pressure. To connect these sensors to the engine wiring system it is necessary to use an extension cable connected to the H connector. The following pages show the global wiring scheme and the electric scheme of the connections between the EDC and the A connector, where it is possible to identify the H and H sensors and the relating H extension cable necessary for the connection.

60 60 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 WIRE HARNESS ENGINE Figure 54 JF F H H JF 06_00_C J GH * JG I E T W T JE + BATT Engine wire harness H GG A C +B VI S VI S SI K SI K O WI X WI X Z W V V BATT U JA Interface wire harness B JB MM A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E. EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure sensor for EDC - I. High coolant temperature sensor (for alarm) - J. Low coolant level sensor (for alarm) - 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) - H. Intake air temperature sensor for EDC - S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for gauge) - U. Clogged oil filter sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged blow-by filter sensor (for alarm) - Z. Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for M B EDC PO PA EC A EDC oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection wire harness - JE. Alarms control unit (for Certification Bodies) - JF, JF. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor - PO. Pre-lubrication electrical pump - SI. Gearbox oil temperature sensor - VI. High gearbox oil pressure sensor (5 bar) - WI. Low gearbox oil pressure sensor (7 bar) - * Sensor H/H wiring harness.

61 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 6 ENGINE Wiring diagram EDC connector A P U Schema_Connettore_A ENS

62 6 INSTALLATION DIRECTIVE C3 ENT M50 MAY 006

63 MAY 006 INSTALLATION DIRECTIVE C3 ENT M APPENDIX Page LUBRICATING OIL TRANSFER MODULE 64 PRE-LUBRICATION AND OIL TRANSFER MODULE 64 STARTING AID 65 ELECTRONIC CONTROL GOVERNING LEVERS 66 SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS 68 ELECTRICAL DIAGRAMS FROM THE SAFETY SYSTEM 8 METHOD OF USE OF THE SAFETY SYSTEM INTERFACE 85

64 64 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 LUBRICATING OIL TRANSFER MODULE Figure Figure PRE-LUBRICATION AND OIL TRANSFER MODULE. Oil intake/exhaust control. 04_036_C 04_037_C. Oil intake/exhaust control. -. Switching solenoid valve control. Lubricating oil transfer operations are simplified by the presence of an electrical control system connected to the JG connector of the interface wiring harness. Manual control for transfer 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 is connected to the JG 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. The operation can also be conducted by acting manually, with the key switch in the OFF position, only on the oil intake/ exhaust push-button positioned on the unit. If the pushbutton is placed for a few seconds in the DISCHARGE position, the filters and the internal engine ducts will be filled. Lubricating oil transfer sequence:. Place the EV-OFF/ EV-ON () switch in the EV-ON position, thus energizing the switching solenoid valve to place the emptying/filling junction in communication with the electrical pump and with the oil sump.. Use the CHARGE/DISCHARGE () push-button to complete the desired operation. 3. Place the EV-OFF/ EV-ON switch back to the EV-OFF Figure One way valve -. Switching solenoid valve (EC) - 3. Electrical pump (PO).

65 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 65 STARTING AID (not available at the moment) Figure _06_C. Specific junction pipe -. Electrical grid heater - 3. Power relay. When the engine is to be used at temperatures lower than - 5 C, an electrical grid heater is installed, (PH). Its operation is controlled by the electronic unit of the injection system. The element will be placed between the turbocharger and the air-water heater exchanger (after-cooler), replacing the terminal part of the intake duct. Connection to the electrical wiring provided is achieved interposing a specific relay (GH) and connection to the power supply grid, (see Chapter 4) For use at temperatures lower than -5 C, adoption of an auxiliary preheating system is recommended.

66 66 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 ELECTRONIC CONTROL GOVERNING LEVERS For version with analogue instruments Figure 5 JC JC MAIN INSTRUMENT PANEL JE JE JH JH SECONDARY INSTRUMENT PANEL MAIN CUSTOMIZED INSTRUMENT PANEL SECONDARY CUSTOMIZED INSTRUMENT PANEL JB JB 4 JB ENGINE EQUIPMENT 3 JD JB JB JO CONVERTER MODULE A B JA EDC JF JF 05_04_C RELAY BOX BATTERY. Engine wiring connector for connection of the control panels -. Interface wiring for the installation of electronic control levers - 3. Connector for the connection of the exterior governor - 4. Conversion module for codifying the signals of the exterior governor. This option offers the chance, in alternative to that prepared for the engine, electronic management of the engine rev. speed. Installation must take place inserting the interface wiring () between the engine and the wiring of the control panels to which the exterior governor will be connected and the electronic module for converting the electric signals from the lever into electronic information recognisable by the EDC central unit. If this solution is used the accelerator position sensor installed on the engine will remain electrically connected but unused and the EDC central unit will manage the engine speed according to the power signal applied to the JD connector terminals (3). If the electronic acceleration system fails, it will be possible to manage the engine rev speed in an emergency, by disconnecting the JD connector and mechanically activating the lever of the sensor installed on the engine.

67 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 67 Interface wiring Figure _043_C. Connector JB -. Connector JD - 3. Connector JO - 4. Connector JB. The JB connector will be coupled to the JB connector of the engine wiring, while the JB connector will be coupled to the JB connector of the wiring connecting the control panel. The converter module will be connected to the JO connector while the JD connector will be available to make the connections to the electronic governance system unit. Connector JD Figure 7 PIN PIN 3 05_04_C The connection requires a METRI-PACK 50 three-way connector with male terminals. PIN Wire code (U) Voltage Interpreted function I max 773 +B with key in ON position Electronic throttle enabling 0,5 A V - (Ground) Common reference terminal - 0 to 0, V Poor value. EDC recognises a fault - 0, to 0,5 V Accelerator at minimum level ,5 to 4,5 V Accelerator min. to max., U function - 4,5 to 4,8 V Accelerator at maximum level - 4,8 to 5 V Excessive value. EDC recognises a fault NOTE: The voltage values for the rotation of the motor must be between 0. and 4.8 V. Values below 0. V or above 4.8 V generate the recognition of a fault and consequent deactivation of the function.

68 C F electronic RPMx00 HOURS V bar C F electronic RPMx00 HOURS V bar 68 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS Unit installed Figure _045_C. Fuel filters which can be replaced when the engine is rotating -. EDC electronic unit - 3. EDC auxiliary unit - 4. Acoustic alarm - 5. Warning light - 6. Control panel - 7. Electronic monitoring and alarm management unit - 8. Connector JC - 9. Connector JS - 0. Emergency engine cutout button -. Oil filters which can be replaced when the engine is rotating -. JB, JC wiring, specific for homologated systems. The electric and electronic equipment of engines requiring a conformity declaration issued by the Certifying bodies comprises, in addition to that provided for the standard configuration, a series of components for the measurement, processing and recording of engine operating parameters. The aim of the system is to emit acoustic and optic alarms indicating that set limits have been exceeded. These limits will be programmed in accordance with different homologation requirements and may, when necessary, cut-out the engine in an emergency. The system is made up of an electronic unit for the acquisition, display and recording of events occurring while the engine is running, using a series of sensors for this specific purpose; the alarm signals produced by the Unit will be emitted by acoustic and optic alarms installed by the Yard or by the Fitter. For boats equipped with only one engine, to offer a higher level of safety during navigation, it is necessary to install a second auxiliary EDC unit alongside the EDC engine controlling electronic unit to enable rapid replacement in the event of a failure.

69 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 69 Electronic monitoring unit Figure 9 05_046_C This unit monitors the operation of the specific safety system. With its computerised logic it acquires the electric signals issued by the sensors linked up to it, converting them into physical parameters of temperature, pressures and revs. This data is displayed on the liquid crystal display and processed according to the set parameters to draw attention to any approach towards the critical limits programmed and alarms should these limits be exceeded. Equipped with a built-in clock/calendar function, it is able to record and memorise the last 000 alarms issued and the values of about 000 samples of signals from sensors. It also issues electric signals to activate the acoustic and luminous alarm signals as requested by the homologation standards. Sensors Some sensors produce electric signals with a value proportionate to their physical entity (temperature, pressure or rev. speed), allowing the electronic unit to monitor the engine operation to measure tendencies to approach the critical values; others indicate, with commutation by an electric switch, that a set pressure or temperature limit has been exceeded, generating an immediate alarm signal. Given the high level of safety required, many of the monitoring system sensors are connected exclusively to this system; this means that the engine equipment comprises several components to measure the same physical entity but dedicated to different systems. In order to obtain an effective control of the integrity of the wiring, there are several resistors, connected in series with or parallel to the connection lines of the main sensors, which are used to recognise the conditions of cut-out or short-circuit of the connectors. After installation it is best to check that these components are correctly connected to the wiring (Figure 0). Figure 0 - Line balancing element - 05_047_C In observance of the provisions of the certifying bodies, the system equipment includes the presence of solutions which make it possible to check the efficiency of the monitoring functions and measure the relative parameters. By way of example, there is a valve which cuts off the oil in the connection of the Low oil pressure (WA) sensor, in order to test the efficiency of the related function and an unused extension cable (BA BAU).

70 70 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Wiring The presence of the Safety system in question in the electrics of the boat requires the use of specific wiring unlike standard wiring. The connection of the monitoring unit and the components connected to it are made on the JB-JC wiring used for the connection of the main control panel to the engine wiring. The electric connection of the system devices is made using connectors. Every multipolar connector is polarised to prevent inversion and is dedicated to a particular function. The electric diagrams, referred to the identification of the inputs/outputs of the connectors of the monitoring unit may vary following the programming of particular features of the application. caution To obtain the engine cut-out function by the JS monitoring unit it is necessary to unite the two JE connectors on the JB-JC wiring and the engine wiring. Electrical starting motor Figure 3 Insulated pole power network (optional) Figure Equipment power supply 3 05_09_C 05_3_C The power network may 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 starting 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.. Excitation coil command (50) -. Positive power pole (+B) - 3. Negative supply pole (-BATT). Technical characteristics: - Supply nominal voltage 4 V - Absorbed power 5 kw - Terminal connection 50 M5 x 0,8 tightening couple -,5 Nm - Terminal connection +B M0 x,5 tightening couple 4,7-7, 7 Nm - Terminal connection -BATT M8 x,5 tightening couple 9,8-,8 Nm

71 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 7 Alternator Figure 3 Auxiliary EDC electronic unit This is fastened to the side of the unit in use to enable rapid replacement in the event of a failure. Should it be necessary to replace it, proceed as follows: o stop the engine; o wait 0 seconds, then disconnect the terminal clamps from the battery; o roceed as follows to extract and reinsert the connectors. Figure 4 + B 8080A - B REMOVING ECU CONNECTORS 05 C S IG L Technical characteristics: - Nominal voltage 4 V - Nominal voltage 90 A - Terminal connection +B M8 x,5 tightening couple,5 Nm ± 0% - Terminal connection -B M6 x tightening couple 6,0 Nm ± 0% +B. (4 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 +, driven by key switch); L. (Lamp) Power supply voltage of recharge/alarm indicator light located on the panel. 8080B INSERTING ECU CONNECTORS At the end of the operation: o reconnect the battery terminal clamps; o start up the engine to run an efficiency test.

72 7 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Synoptic Figure 5 BA BA BAU JSA IA IR JSB WA IR JSC JSD MONITORING UNIT JS WVA VA BAR BAD JSE VCA WR JSF JEM WR FA JC JC MAIN INSTRUMENT PANEL JE JE JH JH SECONDARY INSTRUMENT PANEL ENGINE EQUIPMENT JB JB A B EDC ELECTRONIC UNIT EDC ELECTRONIC AUXILIARY UNIT JA JA 3 JF JF 4 JE JE JG RELAY box battery 05_03_C. Specific wiring unit for installation of instrument panel and monitoring unit -. Engine wiring - 3. Interface wiring - 4. Power network. DESTINATION OF CONNECTORS OF THE SAFETY SYSTEM (excluding standard supply connectors) BA. Drive shaft sensor - BAD. Diode for BA - BAR. Resistor for BA - BA, BAU. Connectors of the extension cable for engine rev. speed - FA. Acoustic and luminous alarms - IA. Coolant temperature sensor - IR. Parallel resistor for IA - IR. Series resistor for IA - JE. Connector for cutting out agitated engine - JEM. Connector for cutout switches in the case of an emergency and motor cutout from the engine room - JS. Electronic monitoring unit - JSA, JSB, JSC, JSD, JSE, JSF. Connectors for monitoring unit - VA: Engine oil pressure sensor - VCA. Fuel pressure sensor - WA. Engine oil low pressure sensor - WR. Parallel resistor for WA - WR. Series resistor for WA - WVA. Coolant pressure and low pressure sensor.

73 C F electronic RPMx00 HOURS V B A bar MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 73 Wiring Figure 6 F J JF JF E I GH JG +BATT BATT JA JA V PA U V W W S M PO S VI SI WI WI SI T VI X T K K P A Z O H C GG +B EC B X MM JE BEDC WVA AEDC WVAG WVAA JB IA JB WA JE JE VA VA JC JC BAU JEM QP IR WR BAR IR WR BAD JSA JSB JSC JSD JSE JSF MONITORING UNIT 05_033_C WVAS VCA VCA BA BA FA FA FA3 FA4 DESTINATION OF CONNECTORS OF THE STANDARD ENGINE (excluding safety system connectors) A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E. EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure sensor for EDC - I. High coolant temperature - J. Low coolant level sensor - K. Air filter clogging sensor - M. Sensor for detecting the presence of water in the fuel pre-filter - O. Exhaust gas temperature sensor - P. Intake air temperature sensor for EDC - S. Oil temperature sensor - T. Coolant temperature sensor - U. Clogged oil filter sensor - V. Oil pressure sensor - W. Low oil pressure sensor - X. Clogged blow-by filter sensor - Z. Clogged fuel filter sensor - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JA. Interface wiring - JB. Instrument panel connection wire harness - JE. Alarms control unit (for Certification Bodies) - JF,JF. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor - PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure sensor (5 bar) - WI. Low gear box oil pressure sensor (7 bar).

74 74 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Monitoring unit Figure (The picture shown is purely indicative) JSA JSB JSC Dimensions in mm 34 JSD JSE JSF Drilling template 83 mm x 35 mm 8 05_03_C The total integration of the system with the engine equipment means that the installation procedures already listed for the standard version are joined by the placement of the electronic monitoring unit inside a console or dashboard, which can be fitted outside, as well as the preparation of the alarm management components pursuant to the homologation standard: acoustic and luminous signals, cut-out buttons. GENERAL FEATURES AND REFERENCE STANDARDS Power supply Current absorption Performances in compliance with * Functional, climatic, vibration and EMC tests in accordance with * * The test reports are supplied by request /4 V d.c. 500 ma (approx.) R.I.N.A. Regulation for automation systems - Section E IEC 945 Maritime navigation and radio-communication equipment and system - General requirements - Methods of testing and required test results

75 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 75 Function of JS connection terminals pin JSA Thermocouples JSB Supply JSC CAN network Exhaust fumes temperature Supply /4 V (+) CAN (H) - Supply /4 V (+) CAN (L) 3 - Mass (-) Mass (-) - 5 Exhaust fumes temperature - GPS - NMEA 083 () protocol 6 - N.C. relay - Acoustic signaling () Echo sounder - NMEA 083 () protocol 7 - Mass (-) N.O. relay - Acoustic signaling N.C. relay - light signal () GPS/Eco sounder () Mass (-) 0 - Mass (-) - - N.O. relay - light signal - NOTE: one of the terminals of the following components is connected to the electric mass: VCA, WVA(G), VA, WA, BAD, IA, JE. pin JSD Sensors JSE Signals JSF Signals and alarms Gear box oil pressure () Engine revs (EDC) () N.C. Cut-out relay 3 () Coolant pressure (WVAS) () Engine revs (BA) () - 3 Engine oil pressure (VA) () Low coolant level (J) () /4 V (+) common relay 3 stoppage 4 Sea water circuit pressure () Low gear box oil pressure () N.O. Cut-out relay 3 (JE) () 5 Engine oil temperature (S) () Air filter blockage (K) () Alternator recharge (L) () 6 Low engine oil pressure (WA) () Low coolant pressure (WVAA) () Pre-lubrication (opt.) 7 Water in the pre-filter (M) () Fuel filter blockage (Z) () Imp. Voltage signal /4 V (+) 8 Fuel pressure (VCA) () Engine revs (BAR - BA) () Engine stopping circuit damaged (JEM - JE) () 9 EDC (failure signal) () High coolant temperature (IA) () Oil filter blockage (U) () - Mass (-) Engine cut-out (pin 4 JSF) - ) Code of the component or sensor to which the terminal is connected ) The terminal is prepared but not connected with the wiring _05_C CONNECTORS JS SEEN FROM WIRING SIDE

76 76 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Position of the safety system sensors Figure _048_C. Engine rotation speed and EDC system damaged signal -. Oil temperature analogical sensor - 3. Low oil pressure sensor (WA) - 4. Oil filters congestion sensor - 5. WA efficiency test tap - 6. Oil pressure analogical sensor (VA) - 7. Cooling liquid pressure and low pressure analogical sensor (WVA) - 8. Cooling liquid high temperature sensor (IA).

77 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 77 Figure _049_C 6 5. Fuel pressure analogical sensor (VCA) -. Engine cooling liquid level sensor - 3. Battery recharge signal - 4. Fuel filter congestion sensor - 5. Presence of water in the fuel sensor - 6. Engine rotation speed sensor (BA) - 7. EDC engine rotation speed sensor - 8. Air filter congested signal - 9. Exhaust gas or thermocouple temperature analogical sensor (O).

78 78 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Drive shaft rev. speed sensor (BA) Coolant high temperature sensor (IA) Figure 0 Figure 05_05_C This is of the inductive type and when the engine is running it produces a sinusoidal alternate signal the value of which increases in proportion to the engine rev. speed. The sensor BA enables the measurement of the engine rev- speed using the passage of the holes positioned in a radial arrangement on the outer circumference of the flywheel. The presence of the resistor BAR and the diode BAD can alter the value of the sensor resistance if measured on the JSE connector of the monitoring unit. Resistance value at 0 C Poles 0 ± 0 Ω Isolated Exhaust gas temperature sensor (O) Figure 05_053_C Thermometric switch which supplies the information for the engine high temperature alarm. NiCr-Ni thermocouple sensor with insulated poles, providing the signal for the analog indication of exhaust gas temperature. Temperature Voltage C mv 00 4,0 00 8,3 300, 400 6, , , , , ,36 04_60_N Operating power Condition at ambient temperature from 6 V to 4V normally open Commutation temperature: C Poles Electric diagram: 05_054_C Isolated

79 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 79 Engine oil low pressure sensor (WA) Figure 3 Figure 4 Engine oil pressure sensor (VA) Switch activated by the fluid pressure, which supplies the information for the engine lubricant low pressure alarm. Operating power from 6 V to 4V Condition at ambient pressure normally closed Commutation pressure: Poles Electric diagram: 05_054_C 0,4 / 0,8 /, bar Isolated 05_055_C Component which supplies a rheostatic signal for the analogical indication of the fluid pressure. Operating power Setting field from Resistance value at 0 bar Resistance value at bar Resistance value at 4 bar Resistance value at 6 bar Maximum value of resistance Operating temperature Poles from 6 V to 4 V 0 bar to 0 bar 0 Ω +3/-5 Ω 5 ± 4 Ω 88 ± 4 Ω 4 ± 5 Ω 84 Ω from - 5 C to +00 C Isolated 04_37_N Coolant oil temperature sensor (S) Figure 5 05_4_C Resistor with negative temperature coefficient, providing the signal for analog temperature indication. Operating voltage 6 V to 4 V Calibration range 0 C to 0 C Resistance value at 90 C 5, ± 4,3 Ω Poles isolated

80 80 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 Refrigerating liquid pressure and low pressure sensor (WVA) Figure 6 Fuel pressure sensor (VCA) Figure 7 This integrates a component which supplies the rheostatic signal for the analogical indication of the pressure and a switch activated by the pressure which supplies the information for the engine coolant low pressure alarm. Operating power / 4 V 05_056_C Component which supplies the rheostatic signal for the analogical indication of the fluid pressure. Operating power Field of intervention Poles 04_37_N / 4 V from 0 bar to 0 bar Isolated Rheostat Field of intervention Stamping of the terminals Wiring terminals from 0 to 5 bar M - G WVAG - WVAS Switch Condition at ambient pressure Closing pressure Stamping of the terminals Wiring terminals normally open 0,5 bar M - WK WVAG - WVAA

81 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 8 Line balancing components Figure 8 Engine cut-out control buttons (JEM) Electric diagram: Figure 9 EMERGENCY Electric diagram: 05_047_C 05_058_C Code Resistor features IR,5 kω W IR 470 kω W WR,5 kω W WR 470 kω W BAR 4,7 kω W 05_060_C STOPPAGE DURING EXCITATION The balancing resistor R has a value of 0 kω. Electric diagram: 05_059_C Code Diode code BAD N 4007

82 8 C3 ENT M50 INSTALLATION DIRECTIVE MAY 006 ELECTRICAL DIAGRAMS FROM THE SAFETY SYSTEM Code of components of the standard version Code of components of the safety system A B C E F H I J K M O P S T U V W X Z EC Fuel temperature sensor for EDC Drive shaft sensor for EDC Camshaft sensor EUI solenoid valves Engine coolant temperature sensor for EDC Combustion air pressure sensor for EDC High coolant temperature Low coolant level sensor Air filter clogging sensor Sensor for detecting the presence of water in the fuel pre-filter Exhaust gas temperature sensor Intake air temperature sensor for EDC Oil temperature sensor Coolant temperature sensor Clogged oil filter sensor Oil pressure sensor Low oil pressure sensor Clogged blow-by filter sensor Clogged fuel filter sensor Switching solenoid valve for oil charge/discharge GG Alternator GH Pre-heating power relay JB JE Instrument panel connection wire harness Alarms control unit (for Certification Bodies) JF, JF Relay box JG Pre-lubrication control unit MM Electric starter motor PA PO SI VI WI Throttle position sensor Pre-lubrication electrical pump Gear box oil temperature sensor High gear box oil pressure sensor (5 bar) Low gear box oil pressure sensor (7 bar) BA Drive shaft sensor BAD Diode for BA BAR Resistor for BA BA, BAU Connectors of the extension cable for engine rev. speed FA IA IR IR JE Acoustic and luminous alarms Coolant temperature sensor Parallel resistor for IA Series resistor for IA Connector for cutting out agitated engine JEM Connector for cutout switches in the case of an emergency and motor cutout from the engine room JS Electronic monitoring unit JSA, JSB, JSC, JSD, JSE, JSF Connectors for monitoring unit VA Engine oil pressure sensor VCA Fuel pressure sensor WA Engine oil low pressure sensor WR Parallel resistor for WA WR Series resistor for WA WVA Coolant pressure and low pressure sensor

83 6 6 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 83 Wiring unit JB - JC CG MS QP 30 CA 0 30 X00 TA MO V 5 4 JE C C SAC SS SIFA EDC SATA SBPO SCP SBLA SIFB SIFO SIFC SP SSV 4 JH AS L L- L+ 3 JD JD JH 0 JE AQ P SA JC JC JC JEM JEM JEM 3 JEM 4 JS BA A BA B 5 JSA P BAU B BAU A VCA VCA FA FA FA 3 FA 4 WVAA WVAG WVAS 3 4 JSB JSC 470 Ω,5 kω P 4,7 kω 470 Ω,5 kω VA VA WR WR WR WR WA WA WA 3 WA 4 BA A BA B BAD A BAD K BAR BAR IR IR IR IR JSD JSE JSF T IA IA IA 3 IA 4 JE JE JE 4 JB JB A JB F ENGINE NORMAL ROOM B SW 8 JA 30 JF D JA O B VI WI SI JA 6 JF 3 JA 6 JG K 8 JF 4 K3 SW "A" 3 7 D9 D K5 D0 SW "STOP" + BATT + AC - - BATT JF 5 6 D 3 JF 9 0 JA T V S M A B 3 C M B+ 3 GG S IG L GG K B+ A 3 A W J U I X Z JA 8550 B B C78 unità monitor omolog

84 84 C3 ENT M50 INSTALLATION DIRECTIVE MAY JF JC NORMAL JF JF BAT + AC - 30 JF 8 JA JF JF 5 6 ENGINE ROOM JF SW 9 0 JA STOP START JB T U C D A B F E V J K 8 JF JF GH 4 JA 37 JC JA 3 S IG L BAT JA F JB JC CA JB JA K5 D MM M JF K K3 D9 D0 JF 6 JA JB B A + - SW3 SW4 F D8 DL JA JF JB JC JA SW5 JA JF JA R JB JB JB JF JA JD SCP JD JC JB EDC 9 JF 7 JA E PA C A B D JG PO M JB JA D3 K6 D8 R3 GG PH GG MP JF JA A EC B EDC system connector B C78 Conn_B omolog

85 MAY 006 INSTALLATION DIRECTIVE C3 ENT M50 85 METHOD OF USE OF THE SAFETY SYSTEM INTERFACE The following information relates to the method of use of the system in the configuration which is considered to be the IVECO MOTORS standard. Information concerning functions which require connection to external systems such as echo sounders and GPS, which are outside the safety system, are voluntarily explained briefly. The programming method which must be carried out by the Supplier or by the Assistance Service technician is not explained. For all the information which are not contained in this document, please refer to the manuals issued by the Supplier. caution The system is supplied programmed to suit the homologation instructions arranged; every need linked to different programming of the operating characteristics will be met by the information presented by the Constructor with specific documentation. Please remember that the settings, allowed to adapt the system to different installations, will only be possible after the system password has been entered. Monitoring The monitoring interface enables a constant verification of the mechanic parameters required by the homologation norms so that it is possible to quickly identify the arousal of an anomalous condition. The information contained in the unit memory also enables the analysis of the events relating to the period preceding the survey. If there is an alarm status, an acoustic signal is emitted and the box containing the anomalous parameter data is visually highlighted through a flashing border. The function of the keys changes depending on the different displays. 6 Figure Analogue indicators in the form of bars or circles with reference to the parameter, value and unit of measurement -. Recognition of the pre-set alarm limits - 3. Page number - 4. Membrane keys - 5. luminous indicators - 6. Key functions. 3 05_035_C Basic operations o Press the keys << and >> to display the sequence of the pages containing the information relating to all the monitored parameters, including maintenance rates and optional information (see the relating figures). The IVECO MOTORS standard configuration requires the detection of the following data: o Pressure of engine cooling liquid (FRESHWATER PRESS) o Low lever of engine cooling liquid (LOW WATER LEVEL) o Low pressure of engine cooling liquid (FRESHWATER LOW P) o Excessive temperature of engine cooling liquid (HIGH WATER TEMP) o Pressure of engine lubricating oil (OIL PRESS) o Absence of engine lubricating oil pressure (LOW OIL PRESS) o Temperature of engine lubricating oil (OIL TEMP) o Oil filter blocked (OIL FILTER CLOG) o Presence of water in fuel (WATER IN FUEL) o Fuel pressure (FUEL PRESS) o Fuel filter blocked (FUEL FILTER CLOG) o Injection system failure (INJECT WARNING) o The battery is not recharging (BATTERY WARNING) o On going pre-lubrication (PRELUBRICATING)* o Power System Tension (VOLTMETER) o Exhaust gas temperature (EX GAS TEMP) o Engine rotation speed from EDC system (ENGINE E) o Engine rotation speed from sensor (ENGINE S) o Engine rotation speed sensor damaged (PICK-UP L FAULT) o Engine stopping circuit damaged (MAN STOP L FAULT) o Automatic engine stopping circuit damaged (AUTOSTOP L FAULT) o Air filter blocked (AIR FILTER CLOG) o Gear oil pressure (GEAR OIL PRESS)* o Absence of pressure in the gear oil (LOW GEAR OIL P)* o Sea water pressure (SEA WATER PRESS) * *) Information given only in the presence of the relating parts. The setting of the alarm threshold must be carried out by the Technical Assistance Service personnel and requires the inputting of a password.