Iveco Marine Diesel Engines Installation Handbook
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Iveco Marine Diesel Engines Installation Handbook

Iveco Marine Diesel Engines Installation Handbook

Marine diesel engines
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ARINE
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E
IESEL
NGINES
I
NSTALLATION
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ANDBOOK

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  • Page 1 ARINE IESEL NGINES NSTALLATION ANDBOOK...
  • Page 2 MARCH 2004 MARINE ENGINES INSTALLATION Publication IVECO MOTORS edited by: IVECO PowerTrain Advertising & Promotion Pregnana Milanese (MI) www.ivecomotors.com Printed P3D63Z001 E – March 2004 Edition...

  • Page 3: Table Of Contents

    MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 CONTENTS Page Page CONTENTS PREMISE FUEL SUPPLY 6.1 FUEL CHARACTERISTICS INTRODUCTION 6.2 HYDRAULIC CIRCUIT 1.1 ENGINE 6.3 RESERVOIR 1.2 BOAT 6.4 ENGINE-RESERVOIR PIPES ENGINE/BOAT CHOICE FACTORS 6.5 FUEL FILTERING 2.1 GENERAL INFORMATION LUBRICATION 2.2 USE OF THE BOAT - ENGINE SETTING 25 7.1 LUBRICANT CHARACTERISTICS 2.3 ENGINE PERFORMANCE 7.2 OIL FILTERS...
  • Page 4 MARCH 2004 MARINE ENGINES INSTALLATION Page AUXILIARY SERVICES 10.1 OVERVIEW 10.2 POWER TAKE-OFF ON THE FLY WHEEL 101 10.3 FRONT PULLEY POWER TAKE-OFF 10.4 BUILT-IN POWER TAKE-OFF ON TIMING OR FLYWHEEL HOUSING CONTROLS 11.1 OVERVIEW 11.2 FUNCTIONS ELECTRICAL INSTALLATION 12.1 OVERVIEW 12.2 POWER CIRCUIT 12.3 WIRING 12.4 STORAGE BATTERIES...

  • Page 5: Premisev

    Every information included in this Installation Handbook is correct at the time of approval for printing. IVECO reserves the right to make changes without prior notice, at any time, for technical or commer- cial reasons or possible adaptations to the laws of the different Countries and declines any responsibil- ity for possible errors or omissions.
  • Page 6 Safety precautions We remind you that IVECO marine engines are designed for professional and sailing applications, and not for sports or competitive purposes for which the warranty decays and the supplier’s responsibility is excluded.

  • Page 7: Introduction

    MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 SECTION 1 INTRODUCTION Page 1.1 ENGINE Piston displacement Real average pressure Driving torque Power Brake real power Correct power Engine total efficiency Fuel consumption Load factor Engine duration 1.2 BOAT Types of hull Displacement Relative speed (Taylor ratio) Power definitions for boat propulsion Protection against galvanic corrosion...
  • Page 8 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION...

  • Page 9: Engine

    MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 ENGINE Before analysing the main characteristics of the engine relevant for its choice and suitability for the boat and the connection to the engine elements, we believe it is useful to identify the names of the engine components.

  • Page 10: Piston Displacement

    1.10 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION Piston displacement The element which best distinguishes the engine is the “overall piston displacement” which represents the total volume of air moved by the pistons during one complete turn of the drive shaft. It represents also the theoretical quantity of air sucked by the cylinders during 2 revolutions of the drive shaft.

  • Page 11: Power

    1.11 MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 The driving torque M depends on the power according to: where: • M : driving torque [Nm] • n : rotation rpm [rad/sec] (1 rev per min = π/30 rad/sec) • N : power [kW] The formula shows that with equal power it is possible to install engines with high torque and low rota- tion speeds or vice versa, low torque and high rotation speeds.

  • Page 12: Brake Real Power

    1.12 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION Figure 3 d. bore - c. travel - w. angle speed - F. force generated by the real average pressure. - c/2. crank arm. Brake real power It is the power measured with the dynamometric brake at the drive shaft (flywheel) during the bench tests.

  • Page 13: Engine Total Efficiency

    In addition, IVECO provides the customers with the technical and commercial documentation concern- ing IVECO engines including the reference to the rules required for the correct choice of the engine. Figure 4 illustrates the power curves of an IVECO engine.

  • Page 14: Load Factor

    1.14 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION The “specific consumption” represents the quantity of fuel used to obtain a unit of mechanical energy; it is expressed in g/kWh and derives from the formula: Where L is the volume in cm of the fuel having specific gravity y (in g./ cm ), consumed by the engine in time t expressed in seconds, while power N (in kW) is supplied at given rpm.
  • Page 15 1.15 MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 Since there are no established rules for the calculation of the heavy duty rate according to the load fac- tor, it is possible to consider the following elements: I Light work load factor below 50% I Medium work load factor from 50 to 70% I Heavy work...

  • Page 16: Engine Duration

    1.16 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION Engine duration The engine duration is identified by the relevant BE10 and is related to a given Load Factor (L.F.). Example: BE10 (L.F. - 0.7) = 10.000 h It shows that 90% of the engines working with a medium load factor of 70% exceed the operation duration of 10,000 h, without actions needed for the removal of their main components.

  • Page 17: Boat

    1.17 MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 BOAT The choice of a boat engine and its performance in terms of power needed for reaching a pre-estab- lished speed depend on the marine engineer. The following data are given just for your information and therefore must be interpreted as such. Figure 7 illustrates the main geometrical data of a boat.

  • Page 18: Types Of Hull

    1.18 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION Types of hull Displacing hulls This type of hull is usually characterised by a round bottom and narrow stern. Figure 9 During sailing this type of boat maintains the same static trim and does not reduce its draught also when the speed increases.

  • Page 19: Displacement

    1.19 MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 Gliding hulls These hulls, due to the shape of their bottom and the power installed, can reach a gliding trim by exploiting the hydro-dynamic phenomena, starting from an initial displacing condition. Figure 11 The gliding hulls move the water only when stationary or at low speeds;...

  • Page 20: Relative Speed (Taylor Ratio)

    1.20 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION The block coefficients are included in the following table: Type of boat Coefficient C Speedboat hulls with V bottom, gliding 0,30 Hulls for sports fishing with length up to 12 m (40 ft),V bottom 0,35 Pilot boats with length below a 12 m (40 ft) 0,35...

  • Page 21: Power Definitions For Boat Propulsion

    1.21 MARINE ENGINES INSTALLATION INTRODUCTION MARCH 2004 For example, if the above mentioned calculation is applied to a hull having floating length L = 25 feet, it results in: I Displacing hull, limit value knots I Semi-gliding hull, limit speed knots Values above 3 are for gliding hulls.

  • Page 22: Protection Against Galvanic Corrosion

    1.22 MARCH 2004 INTRODUCTION MARINE ENGINES INSTALLATION Protection against galvanic corrosion The hulls made up of metal are subject to corrosion due to galvanic currents. Therefore, if two different metals come into contact, you are recommended to insulate electrically one of the components.

  • Page 23: Engine/Boat Choice Factors

    2.23 MARINE ENGINES INSTALLATION ENGINE/BOAT CHOICE FACTORS MARCH 2004 SECTION 2 ENGINE/BOAT CHOICE FACTORS Page 2.1 GENERAL INFORMATION 2.2 USE OF THE BOAT - ENGINE SETTING 25 Fast short-range yachts Long-range yachts/commercial boats Light service Medium service Continuous service 2.3 ENGINE PERFORMANCE 2.4 ENVIRONMENTAL CONDITIONS AND “DERATING”...
  • Page 24 2.24 MARCH 2004 ENGINE/BOAT CHOICE FACTORS MARINE ENGINES INSTALLATION...

  • Page 25: General Information

    The engine setting is established for each type of engine after exhaustive duration tests carried out at IVECO testing bodies and after practical use on the boats. As a result, the engine power and rotation maximum rates admitted for an application are identified.The engine performance can be derived from the typical curves of the engine which usually include five different types of use.

  • Page 26: Engine Performance

    2.26 MARCH 2004 ENGINE/BOAT CHOICE FACTORS MARINE ENGINES INSTALLATION Light service Boat Light boats for tourist, professional or military use subject to frequent speed variations. For example, yachts, charters, light passenger boats, fast patrol boats, police boats, civil protection boats, rescue boats, special squads.
  • Page 27 The curve linking the maximum power value to the null power at the maximum speed is called gap curve.The gap in IVECO marine engines usually amounts to 10%. I Maximum torque speed (n ): it is the speed, or speed interval, at which the engine reaches the maximum torque.
  • Page 28 2.28 MARCH 2004 ENGINE/BOAT CHOICE FACTORS MARINE ENGINES INSTALLATION In addition, it is important to make the right choice to prevent: I Requesting a power above the rated one I Requesting a power needed for gliding incompatible with the power which can be supplied by the engine The wrong design of the propeller substantially reduces the boat performance: in the first case the max- imum speed reached by the engine will be below the rated value and equal to the balance between...

  • Page 29: Environmental Conditions And "Derating

    2.29 MARINE ENGINES INSTALLATION ENGINE/BOAT CHOICE FACTORS MARCH 2004 Gliding boats Figure 3 1.Torque limit curve/real average pressure/input, for the engine - 2. Absorption curve of a propeller too big for the application - 3. Absorption curve of a propeller with the right size (pattern between the cube and square one, except for the gliding phase when the square pattern is exceeded) - 4.

  • Page 30: Ambient Temperature

    I 0,5% for ambient temperature of 30 °C I 1% for ambient temperature of 40 °C I 1.5% for ambient temperature of 50 °C The “derating” is managed by IVECO during the contractual negotiations according to the operating conditions of the boat supplied by the Customer.

  • Page 31: Mechanical And Auxiliary Components

    2.31 MARINE ENGINES INSTALLATION ENGINE/BOAT CHOICE FACTORS MARCH 2004 MECHANICAL AND AUXILIARY COMPONENTS For the evaluation of the engine installed it is necessary to consider the presence of each component producing power absorption and to know exactly the absorbed powers, as the power taken by auxil- iary components is no longer available for the flywheel.
  • Page 32 2.32 MARCH 2004 ENGINE/BOAT CHOICE FACTORS MARINE ENGINES INSTALLATION Gliding hulls The speed of gliding hulls can be obtained through the Equadro formula: where : • V : Hull speed • SHP :Total installed power (HP) • D : Displacement with hull fully laden (long tons) •...

  • Page 33: Drive

    3.33 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 SECTION 3 DRIVE Page 3.1 PROPULSION SYSTEMS Axis line propulsion systems Drive with universal joint shaft Angle drive - V drive Inboard-outboard unit with astern foot “S” drive (sailing boats) Water jet propeller 3.2 PROPELLERS Propeller technical characteristics Dimensioning...
  • Page 34 3.34 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION...

  • Page 35: Propulsion Systems

    3.35 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 PROPULSION SYSTEMS The drive in most boats is given by means of an engine consisting of: inverter-reducer, propeller sup- port axis and propeller, sometimes ducted, or in alternative a water jet propeller. The size and position of the compartments available for the engine location lead to a different layouts of the engine.The possible solutions are the following: Figure 1 AXIS LINE DRIVE...

  • Page 36: Axis Line Propulsion Systems

    3.36 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION Axis line propulsion systems On inboard applications, the propulsion system consists of an engine, an inverter-reducer, an axis line and a propeller, as in the diagram illustrated in figure 2 Figure 2 The advantages of this system can be summarised as follows: I Simplicity and reliability I Availability of a wide range of components I Compliance with the needs of distributing weights on the boat.

  • Page 37: Drive With Universal Joint Shaft

    3.37 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 Drive with universal joint shaft Some installations may need an angle drive or offset drive; the right solution is provided by the univer- sal joint shafts: I W layout, angle drive I Z layout, offset drive In the applications with universal joint shafts it is necessary to strictly observe the use and installation instructions provided by the manufacturers to prevent any faults due to the drive supplied with uneven speeds.

  • Page 38: Angle Drive - V Drive

    3.38 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION Angle drive - V drive Due to the size, the weight distribution and the hull structure it could be necessary to install an angle drive. On this type of drive it is important that the supporting plane of the engine on the inverter side is close to the connecting plane between the unit output and the propeller axis support.

  • Page 39: S" Drive (Sailing Boats)

    3.39 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 The advantages offered by this solution are: I More habitable space inside the hull I Better power efficiency, despite the lower mechanical efficiency, since the propeller axis is parallel to the travelling speed I Good manoeuvrability at high speeds, enabled by the simultaneous rotation of the foot-rudder and the propeller I Possibility of correcting the boat trim as a result of the adjustment of the whole astern foot slant...

  • Page 40: Water Jet Propeller

    3.40 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION The advantages are: I Low level of noise and vibrations I Facility of installation for the unit limited size I Flexibility in the choice of the position onboard I Low resistance to the sailing progress The drawbacks are: I Impossibility of use on boats with deep keel I Limited choice of drive and propeller ratios.

  • Page 41: Propellers

    3.41 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 PROPELLERS In the project of an engine for marine applications the propeller plays an essential role, comparable to that of the engine. The propeller receives the energy transmitted by the engine, deducted from the drive mechanical losses, and it shall be able to translate this energy into speed for the boat progress.

  • Page 42: Propeller Technical Characteristics

    3.42 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION Propeller technical characteristics The characteristics defining the efficiency of a propeller are the diameter and the pitch. As to the boat performance, another important characteristic is the slip, defined as the difference between the theo- retical pitch and the real pitch.
  • Page 43 3.43 MARINE ENGINES INSTALLATION DRIVE MARCH 2004 Another important value is the blade area-disc area ratio (As/Ad), i.e. the ratio between the total area developed by the blades and the area corresponding to the circle formed by the propeller rated diam- eter.
  • Page 44 3.44 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION The propeller power is proportional to the value of its cubed rotation speed. We call this relation as the “propeller cube rule”. This relation complies with the resistance progress of displacing hulls. On gliding hulls the pattern of the absorbed power is illustrated in figure 11 which highlights the “hump”...

  • Page 45: Rotation Direction

    I Left-hand (left-handed, anticlockwise/counter-clockwise) if contrary to the above mentioned movement. IVECO marine engines are left-handed, therefore this shall be taken into consideration for the choice of the inverter. The rotation direction of the inverter output shaft depends on the type of structure and therefore there is a difference between the models with the same rotation direction of the engine and those contrary to it;...

  • Page 46: Engine With Reversible Blades

    3.46 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION Engine with reversible blades In this system the propeller blades hinge on the hub; the blade rotation on their axis is obtained by means of the suitable mechanism in the hub actuated through the propeller hollow supporting shaft (figure 13).The blade rotation is such to reverse the movement forward/backward and to keep at the same time the same engine rotation direction.

  • Page 47: Inverter-Reducer

    NOTE Inverters different from those proposed by IVECO shall receive prior approval. It is extremely important to insert the damper snap joint in the connection between the engine fly- wheel and the inverter input shaft, in order to prevent twisting and overloading the engine shaft end.

  • Page 48: Lubrication

    3.48 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION Lubrication On small mechanically-operated inverters the lubrication of gears, bearings and connected parts is car- ried out by means of shaking due to the partial soaking of the toothed wheels in the oil contained in the unit box.

  • Page 49: Torsional Vibrations

    Additional power takeoffs can compromise the torsional balance of the involved parts. The analyses of the torsional vibrations of the whole application shall be carried out by the builder fitter-out. IVECO Technical Bodies can make suggestions about the engine data which are needed for the cal- culation.
  • Page 50 3.50 MARCH 2004 DRIVE MARINE ENGINES INSTALLATION...

  • Page 51: Engine Installation

    4.51 MARINE ENGINES INSTALLATION ENGINE INSTALLATION MARCH 2004 SECTION 4 ENGINE INSTALLATION Page 4.1 TRANSPORTATION 4.2 INSTALLATION ON THE HULL 4.3 SUSPENSION Rigid suspension Flexible suspension 4.4 TILTING 4.5 AXIS LINE ALIGNMENT Check of concentricity Check of parallelism...
  • Page 52 4.52 MARCH 2004 ENGINE INSTALLATION MARINE ENGINES INSTALLATION...

  • Page 53: Transportation

    4.53 MARINE ENGINES INSTALLATION ENGINE INSTALLATION MARCH 2004 TRANSPORTATION The transportation of the engine or the whole engine/inverter unit shall be carried out with the suit- able lifting systems by means of grommets (eyebolts) made for this purpose and in a safe way to pre- vent any injuries to the operator and irregular stresses on the unit components.

  • Page 54: Rigid Suspension

    Figure 2 illustrates an example of the flexible support adjustable in height, supplied upon request by IVECO for some applications and figure 3 shows an example of installation. The height adjustment shall be carried out according to the specific instructions provided by each sup- port supplier.
  • Page 55 4.55 MARINE ENGINES INSTALLATION ENGINE INSTALLATION MARCH 2004 You can implement the following procedure: I First adjust value X from 5 to 7 mm by operating nuts “B” and “C”. I Fasten the supports on the engine brackets by tightening nut “A “. I Place the engine on the keelson and check if there is clearance below the flexible support.

  • Page 56: Tilting

    4.56 MARCH 2004 ENGINE INSTALLATION MARINE ENGINES INSTALLATION TILTING The maximum tilting angles are a typical characteristic of each engine family and basically depend on the type of oil sump, the characteristics of the lubrication circuits and the technology of some systems, such as the oil supply to the hydraulic tappet.

  • Page 57: Axis Line Alignment

    4.57 MARINE ENGINES INSTALLATION ENGINE INSTALLATION MARCH 2004 Figure 5 In the applications with V-drive or in other special applications it is important not to tilt the engine with the front side down, not to compromise the regular operation of the cooling system, suitably designed for the tilted operation with the engine front part up;...

  • Page 58: Check Of Concentricity

    NOTE For particular installations (e.g. the astern foot, etc.) follow the indications of the specific publications of the manufacturer. You are reminded that the shipyard has the whole responsibility for the alignment operations; any IVECO responsibility is excluded.

  • Page 59: Air Supply

    5.59 MARINE ENGINES INSTALLATION AIR SUPPLY MARCH 2004 SECTION 5 AIR SUPPLY Page 5.1 SUPPLY AND VENTILATION 5.2 ENGINE ROOM VENTILATION 5.3 AIR FILTERS...
  • Page 60 5.60 MARCH 2004 AIR SUPPLY MARINE ENGINES INSTALLATION...

  • Page 61: Supply And Ventilation

    5.61 MARINE ENGINES INSTALLATION AIR SUPPLY MARCH 2004 SUPPLY AND VENTILATION The temperature and pressure of the air sucked by the engine influence, as seen before, the engine per- formance and operation. As a result, for the engine correct operation and duration, the designer of the engine room shall: I Ensure the correct air flow in the quantity required for the engine combustion.

  • Page 62: Air Filters

    The environment where the marine engine operates does not usually have a high level of dust (< 2 mg/m In most cases simplified filters usually fitted on IVECO engines are sufficient. In particular cases where the environment can be dusty, as on work boats for the transport of dusty materials, it is necessary to apply, separated from the engine, more efficient air filters usually adopted on industrial applications.
  • Page 63 5.63 MARINE ENGINES INSTALLATION AIR SUPPLY MARCH 2004 Figure 1 AIR FILTER FOR DUSTY ENVIRONMENTS The purpose of an industrial air filter use is to ensure a more silent suction. Figure 2 illustrates a system with filter-silencer and external air outlet, fitted with the separator against the water inlet, to be set at the shipyard.
  • Page 64 5.64 MARCH 2004 AIR SUPPLY MARINE ENGINES INSTALLATION...

  • Page 65: Fuel Supply

    6.65 MARINE ENGINES INSTALLATION FUEL SUPPLY MARCH 2004 SECTION 6 FUEL SUPPLY Page 6.1 FUEL CHARACTERISTICS 6.2 HYDRAULIC CIRCUIT 6.3 RESERVOIR 6.4 ENGINE-RESERVOIR PIPES 6.5 FUEL FILTERING...
  • Page 66 6.66 MARCH 2004 FUEL SUPPLY MARINE ENGINES INSTALLATION...

  • Page 67: Fuel Characteristics

    The design and implementation of the whole system are part of the expertise and responsibility of the shipyard. The fuel circuits required for IVECO engines are characterised by the use of different injection systems, as illustrated in the following figures:...
  • Page 68 6.68 MARCH 2004 FUEL SUPPLY MARINE ENGINES INSTALLATION Figure 2 CIRCUIT FOR COMMON RAIL SYSTEM (CP1) Figure 3 CIRCUIT FOR COMMON RAIL SYSTEM (CP3)

  • Page 69: Reservoir

    6.69 MARINE ENGINES INSTALLATION FUEL SUPPLY MARCH 2004 Figure 4 CIRCUIT FOR PUMP INJECTOR SYSTEM (EUI) Because of the different performances of the injections system, the fuel pressures, temperatures and capacities have specific values; therefore, you are suggested to see the installation diagrams of each engine for the prescriptions concerning each different system.
  • Page 70 6.70 MARCH 2004 FUEL SUPPLY MARINE ENGINES INSTALLATION I It shall be made with materials able to resist chemical agents and hot fuel for the whole boat life. Metal reservoirs protected through zinc-coating or copper-coating galvanic treatments are not suit- able to contain “diesel fuel”...

  • Page 71: Engine-Reservoir Pipes

    6.71 MARINE ENGINES INSTALLATION FUEL SUPPLY MARCH 2004 NOTE In particular, the fuel reservoir, the pipes and the relevant pipe unions shall observe the specifications and rules of the country where the boat is to be used, especially in relation to fire safety rules. ENGINE-RESERVOIR PIPES The engine and the reservoir are mutually connected by fuel supply and return pipes.

  • Page 72: Fuel Filtering

    (see figure 7). IVECO supplies a decanting pre-filter with the engine which, if installed at the shipyard along the pipe supplying the fuel to the engine, protects the feed pump against the wear caused by the impurities and the water present in the fuel.
  • Page 73 6.73 MARINE ENGINES INSTALLATION FUEL SUPPLY MARCH 2004 Figure 7 FUEL FILTERS 1. Individual cartridge fuel filter - 2. Dual cartridge fuel filter with possibility of substitution with running engine - 3. Exclusion lever. NOTE The design and realisation of the whole fuel system (reservoirs included) are part of the expertise and respon- sibility of the shipyard.
  • Page 74 6.74 MARCH 2004 FUEL SUPPLY MARINE ENGINES INSTALLATION...

  • Page 75: Lubrication

    7.75 MARINE ENGINES INSTALLATION LUBRICATION MARCH 2004 SECTION 7 LUBRICATION Page 7.1 LUBRICANT CHARACTERISTICS 7.2 OIL FILTERS 7.3 OIL QUANTITY AND LEVEL DIPSTICK 7.4 LOW PRESSURE SIGNALLING 7.5 PERIODIC CHANGE 7.6 ENGINE VENT...
  • Page 76 7.76 MARCH 2004 LUBRICATION MARINE ENGINES INSTALLATION...

  • Page 77: Lubricant Characteristics

    OIL FILTERS IVECO engines take full flow; easy-change filters, or filter cartridges that filter the total flow of oil in the engine. The filtering material of the cartridge is a special kind of paper, which has a filtering level suitable to the engine type of use.

  • Page 78: Oil Quantity And Level Dipstick

    To substitute the oil easily, IVECO engines are fitted with a special pump, shown in fig. 2, which is con- nected to the bottom of the oil sump through a pipe that leads to the oil drain plug.

  • Page 79: Engine Vent

    This gas mixture, generally called blow-by, is exhausted out of the engine because of the engine overpressure. In the IVECO marine engines, the blow-by gases are concentrated in calibrated channels before they reach the air filter, to be suctioned again and taken into combustion. Every model has a device that reg- ulates the flow of re-suctioned blow-by, separates the liquid components through appropriate filters and leads them to the oil sump.
  • Page 80 7.80 MARCH 2004 LUBRICATION MARINE ENGINES INSTALLATION...

  • Page 81: Cooling

    8.81 MARINE ENGINES INSTALLATION COOLING MARCH 2004 SECTION 8 COOLING Page 8.1 INSTALLATION 8.2 PRIMARY CIRCUIT Filling Coolant tank Heater 8.3 SECONDARY CIRCUIT Water seacock fitting Water filter Pipes and connexions Water pump Heat exchangers 8.4 KEEL COOLING 8.5 GALVANIC CORROSION PROTECTION...
  • Page 82 8.82 MARCH 2004 COOLING MARINE ENGINES INSTALLATION...

  • Page 83: Installation

    8.83 MARINE ENGINES INSTALLATION COOLING MARCH 2004 INSTALLATION The aim of the cooling system is to keep the engine at a constant temperature to ensure proper func- tioning and guarantee the expected nominal performance. Marine engines are generally provided with a cooling system made up of two circuits: I A closed and pressurised primary circuit through which coolant circulates (water 50% and Paraflu 11 or its equivalent, complying with SAE J 1034).

  • Page 84: Primary Circuit

    8.84 MARCH 2004 COOLING MARINE ENGINES INSTALLATION PRIMARY CIRCUIT This circuit cools down the engine, the lubricant oil, and often the exhaust manifold, as well. The pri- mary circuit is enclosed and pressurised, and except for the keel-cooling system, it does not require installation procedures.

  • Page 85: Water Seacock Fitting

    8.85 MARINE ENGINES INSTALLATION COOLING MARCH 2004 Water seacock fitting It draws sea water overboard for the secondary cooling circuit. It must be properly fitted to filter out debris before it gets into the suction pipe and to resist seawater aggressions. Its position in the hull must be carefully chosen to guarantee correct water suction in any navigation condition.

  • Page 86: Pipes And Connexions

    8.86 MARCH 2004 COOLING MARINE ENGINES INSTALLATION Pipes and connexions The secondary circuit water pipes should not cause excessive pressure drop, which may be incompat- ible with proper pump functioning and regular engine refrigeration. Suction vacuum at the engine maximum power rate, including the suction lift and all the connected ele- ments lift should not be over 0.2 bar.

  • Page 87: Keel Cooling

    8.87 MARINE ENGINES INSTALLATION COOLING MARCH 2004 Water pump As a rule, the water pump is mounted in and activated by the engine.The rubber or neoprene impeller is subjected to wear and tear and it needs to be periodically changed, as indicated in the use and main- tenance manuals.
  • Page 88 8.88 MARCH 2004 COOLING MARINE ENGINES INSTALLATION An example of circuit for a supercharged engine: Figure 5 1. Water charge tank - 2. Inverter water/oil exchanger - 3. Water/air exchanger - 4. Keel cooling - 5. Water intake - 6. Water outlet - 7. Freshwater pump - 8. Refrigerated turbine - 9. Refrigerated exhaust manifold - 10.

  • Page 89: Galvanic Corrosion Protection

    It is advisable to refer to the electrical equipment section for more details. All IVECO engines are supplied with protection zinc anodes all along the secondary cooling circuit.The dockyard personnel must pay attention to the instructions about protection against eddy currents cor- rosion by using the suitable protective anodes in the complementary installation components and relat- ed parts.
  • Page 90 8.90 MARCH 2004 COOLING MARINE ENGINES INSTALLATION Figure 7 PLUG WITH ANODE PROTECTION EFFECT...

  • Page 91: Discharge

    9.91 MARINE ENGINES INSTALLATION DISCHARGE MARCH 2004 SECTION 9 DISCHARGE Page 9.1 OVERVIEW 9.2 DRY DISCHARGE 9.3 MIXED DISCHARGE Engine with exhaustion gas outlet flange above the water line Engine with exhaustion gas outlet flange below the water line 9.4 SILENCERS 9.5 COUNTERPRESSURE...
  • Page 92 9.92 MARCH 2004 DISCHARGE MARINE ENGINES INSTALLATION...

  • Page 93: Overview

    9.93 MARINE ENGINES INSTALLATION DISCHARGE MARCH 2004 OVERVIEW The discharge system of marine engine exhaust gases can be divided in two categories: I Dry discharge I Mixed discharge The choice of the type of discharge is the staff ’s decision and it depends on the vessel structure and on the desired comfort.

  • Page 94: Mixed Discharge

    The pipes placed after the mixer must be resistant to exhaust gases and certified by vessel certifying Entities. IVECO mixer configuration may not be suitable for all kinds of vessels. The dockyard personnel have to devise an exhaust system in such a way to avoid the return of water to the exhaust manifold or to the engine turbine under any working conditions.They should also install...
  • Page 95 9.95 MARINE ENGINES INSTALLATION DISCHARGE MARCH 2004 The overboard discharge pipe is also an inverted U-shaped tube that hinders direct outside water flow- ing; its height depends on the kind of vessel. The silencer capacity must be superior to the water volume discharged when stopping the engine. Materials used must be resistant to exhaust gases and seawater aggression.

  • Page 96: Silencers

    To size the pipes for gas mixed with water increase the diameter by 10% taking as a reference value the dry discharge pipe diameter. In engines equipped with IVECO standard mixers, the pipe diameter shall never be smaller than the mixer outlet diameter. In each case, it is advisable to check the counterpressure originated by the dis- charge pipe and the silencer, if present.
  • Page 97 9.97 MARINE ENGINES INSTALLATION DISCHARGE MARCH 2004 Figure 3 Pipe diameter in mm Counterpressure inside pipe in mm H O (silencer excluded) Insulated Not insulated Elbows number at 90° - R=2.5 D Elbows number at 90° - R=2.5 D...
  • Page 98 9.98 MARCH 2004 DISCHARGE MARINE ENGINES INSTALLATION...

  • Page 99: Auxiliary Services

    10.99 MARINE ENGINES INSTALLATION AUXILIARY SERVICES MARCH 2004 SECTION 10 AUXILIARY SERVICES Page 10.1 OVERVIEW 10.2 POWER TAKE-OFF ON THE FLY WHEEL 101 On the engine shafts Lateral with belt transmission 10.3 FRONT PULLEY POWER TAKE-OFF On the engine shafts Lateral with belt transmission 10.4 BUILT-IN POWER TAKE-OFF ON TIMING OR FLYWHEEL HOUSING...
  • Page 100 10.100 MARCH 2004 AUXILIARY SERVICES MARINE ENGINES INSTALLATION...

  • Page 101: Overview

    MARCH 2004 10.1 OVERVIEW IVECO engines are fitted to drive all the necessary equipments for onboard services, such as pumps and electric generators. Depending on the power required and on the features of the element to be powered, the movement can be obtained by: I Engine flywheel, the engine is not used for propelling but as an auxiliary device.

  • Page 102: Front Pulley Power Take-Off

    The limit values are indicated in each engine technical information chart. When an IVECO joint is not being used, the dockyard technical staff will be in charge of finding an appropriate solution in terms of the driving torque, flexibility, rotational speed and the allowable vibra-...

  • Page 103: Built-In Power Take-Off On Timing Or Flywheel Housing

    IVECO engines for professional applications can be supplied with front pulleys with supplementary throats for belt transmission. Supplementary pulleys other than the ones supplied by IVECO can be used as long as balance, cen- tring, alignment, and maximum inertial limits are ensured.Thus, the dockyard personnel will be in charge of mounting the application correctly.
  • Page 104 10.104 MARCH 2004 AUXILIARY SERVICES MARINE ENGINES INSTALLATION...

  • Page 105: Controls

    11.105 MARINE ENGINES INSTALLATION CONTROLS MARCH 2004 SECTION 11 CONTROLS Page 11.1 OVERVIEW 11.2 FUNCTIONS Engine startup Accelerator lever drive Reverser selector lever drive Engine stop...
  • Page 106 11.106 MARCH 2004 CONTROLS MARINE ENGINES INSTALLATION...

  • Page 107: Overview

    Except for the compressed air system, the engine is set to rotate with an electric motor powered by a storage battery.The engine is powered by a key or a push-button located on the board. IVECO plans for its own engines fitted with an electronic injection system, the possibility of a remote control at the engine room to be used during testing and maintenance procedures.
  • Page 108 The engine cannot be stopped with a battery circuit breaker to guarantee the engine control method operating conditions. IVECO engines, fitted with an electronic injection system, have been designed with the possibility of using a remote control at the engine room to carry out tests and maintenance operations.

  • Page 109: Electrical Installation

    12.109 MARINE ENGINES INSTALLATION ELECTRICAL INSTALLATION MARCH 2004 SECTION 12 ELECTRICAL INSTALLATION Page 12.1 OVERVIEW 12.2 POWER CIRCUIT 12.3 WIRING Ground connexion Positive Other connexions 12.4 STORAGE BATTERIES Storage batteries recharge 12.5 ENGINE ELECTRICAL CIRCUIT Wiring Sensors Relays and short-circuits protection ECU Electronic central unit 12.6 CAN LINE 12.7 INSTRUMENT PANEL...
  • Page 110 12.110 MARCH 2004 ELECTRICAL INSTALLATION MARINE ENGINES INSTALLATION...

  • Page 111: Overview

    Therefore, installations shall be carried out following strictly the instructions supplied by IVECO and the companies that supply the equipment and system components.
  • Page 112 12.112 MARCH 2004 ELECTRICAL INSTALLATION MARINE ENGINES INSTALLATION Figure 1 INSTALLATION CARRIED OUT WITH NEGATIVE POLE COMPONENTS CONNECTED TO METALLIC GROUND CONNEXION ENGINE INSTALLATION CARRIED OUT WITH COMPONENTS THAT HAVE BOTH POLES INSULATED FROM THE METALLIC GROUND CONNEXION Reference chart for the conductor’s choice according to their current intensity. Section I max.

  • Page 113: Wiring

    I In case any element should be fastened onto treated surfaces, remove anaphoresis coating to get a smooth supporting base. I Apply a uniform paint coat BH44D (IVECO Standard 18-1705) with a brush or an aerosol can. I Join the ground connexion knot within 5 minutes following painting.

  • Page 114: Other Connexions

    12.114 MARCH 2004 ELECTRICAL INSTALLATION MARINE ENGINES INSTALLATION Other connexions All electrical cables and cords must have appropriate tinned sulphurous copper terminals; wires with- out terminals must not be connected by means of screwed terminals.To prepare the terminal, remove a portion of plastic sheath without cutting copper threads; then, press carefully the copper conductor. Finally, press the copper again to ensure mechanical retention of the protective sheath.

  • Page 115: Storage Batteries

    12.115 MARINE ENGINES INSTALLATION ELECTRICAL INSTALLATION MARCH 2004 12.4 STORAGE BATTERIES The storage batteries must be properly sized to provide the appropriate current intensity to the elec- tric engine startup and to the other engine electric uses. Should the vessel have electrical equipment with non-rotating motor, two different storage batteries assemblies should be installed, each one for the engine and the auxiliary services.
  • Page 116 12.116 MARCH 2004 ELECTRICAL INSTALLATION MARINE ENGINES INSTALLATION Figure 7 LAYOUT FOR THE INSTALLATION OF SUPPLEMENTARY STORAGE BATTERY FOR SERVICES...

  • Page 117: Engine Electrical Circuit

    Wiring IVECO units are normally fitted with complete wiring for electrical and electronic connexions and the engine wiring is supplied with standard connexions, and prepared to admit optional connecting com- ponents.

  • Page 118: Instrument Panel

    MARINE ENGINES INSTALLATION 12.7 INSTRUMENT PANEL IVECO manufactures, for its own engines, some types of on-board signal and controls panel.Their con- nexion to the electrical equipment is done through the engine wiring. Systems for the main deck and upper deck (fly bridge) have been provided for better control and manoeuvre conditions.

  • Page 119: Galvanic Corrosion Protection

    13.119 MARINE ENGINES INSTALLATION GALVANIC CORROSION PROTECTION MARCH 2004 SECTION 13 GALVANIC CORROSION PROTECTION Page 13.1 OVERVIEW 13.2 GROUND CONNEXION 13.3 DISPOSABLE ANODES PROTECTION 13.4 ISOLATED POLES INSTALLATION...
  • Page 120 13.120 MARCH 2004 GALVANIC CORROSION PROTECTION MARINE ENGINES INSTALLATION...

  • Page 121: Overview

    13.121 MARINE ENGINES INSTALLATION GALVANIC CORROSION PROTECTION MARCH 2004 13.1 OVERVIEW Joining different materials or metallic alloys in an electrolyte, for instance, a good electric conductor such as water, causes an exchange of electrons or an electric current.This electric current, although small, will take a real direction out of the more active metal or anode, causing particles carry with visible corro- sion effects that will become more evident with time.

  • Page 122: Ground Connexion

    13.122 MARCH 2004 GALVANIC CORROSION PROTECTION MARINE ENGINES INSTALLATION Other factors favouring corrosion are: I Important relation difference between the cathode surface and the anodic one. I High saline concentration in sea water. I High water speed on surfaces I Temperature and sea water ventilation rise. Since eddy or galvanic currents are reduced in intensity, they may leak to the important vessel compo- nents risking corrosions on the engine elements or on the keel.

  • Page 123: Isolated Poles Installation

    13.123 MARINE ENGINES INSTALLATION GALVANIC CORROSION PROTECTION MARCH 2004 Assessment of progressive wear and tear indicates the importance of this phenomenon. The anodes that wear down faster must be replaced by larger ones. Long-lasting efficacious protection is guaranteed only by periodical zinc anode control and replacement of the markedly corroded ones.
  • Page 124 13.124 MARCH 2004 GALVANIC CORROSION PROTECTION MARINE ENGINES INSTALLATION Figure 2 Ground connexion rod Electrical accessories Electrical accessories Syntherized brass ground plate Other metallic parts Power supply Battery Reservoir Engine Engine Ground Disposable connexions aft anodes for boxes GROUND CONNEXION IN METALLIC HULLS...

  • Page 125: Control Test Procedures

    14.125 MARINE ENGINES INSTALLATION CONTROL TEST PROCEDURES MARCH 2004 SECTION 14 CONTROL TEST PROCEDURES Page 14.1 OVERVIEW 14.2 STATIC TEST 14.3 OPEN SEA TESTS Power absorption curve Testing the cooling and venting systems installation Suction vacuum and exhaust back-pressure tests 14.4 RECOMMENDED GAUGES...
  • Page 126 14.126 MARCH 2004 CONTROL TEST PROCEDURES MARINE ENGINES INSTALLATION...

  • Page 127: Overview

    IVECO shall not be liable for failures in manufacturing.The vessel manufacturer shall be responsible for observ- ing all aspects to prevent personal injury and property damage.»...

  • Page 128: Open Sea Tests

    In the case of engines supplied with electronic control injection system, it is possible to assess the main burning air pressure and temperature, the coolant temperature and the amount of injected fuel using the diagnosis instrument that can be found on the technical / commercial IVECO network. Testing the cooling and venting systems installation The test is not generally carried out in the case of engines with standard cooling system installation (water/water heat exchanger and secondary seawater heat exchanger).

  • Page 129: Suction Vacuum And Exhaust Back-Pressure Tests

    In the case of a non-standard cooling system, for example keel cooling or heat exchanger systems that have not been supplied by IVECO, the test should be carried out as follows: I Open and lock the engine coolant thermostat valve.

  • Page 130: Recommended Gauges

    I Doppler effect tachometer to measure the vessel speed or a GPS to take measurements indirect- ly in combination with other navigation data. If engines fitted with EDC system are to be tested, the use of diagnosis instruments supplied by IVECO is highly recommended. These instruments are able to measure temperature, rotation rate and fuel injection values as well as many other values by analysing the data processed by the Electronic Unit and gathered by means of sensors and transducers fitted in the installation.
  • Page 132 Iveco S.p.A. PowerTrain Viale Dell’Industria, 15/17 20010 Pregnana Milanese - MI - (Italy) Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29 www.ivecomotors.com...

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