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Make/Model Information:

  • Brand:   Iveco
  • Models included:
    • Iveco C78 ENS M20.10
    • Iveco C78 ENT M30.10
    • Iveco C78 ENT M50.11
    • Iveco C78 ENT M55.10

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English (EN)
  • Number of pages:   255
  • File size:  ∼ 10.15 MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   ENIV-0003

NOTE:  This list was created by program script and may not accurately represent the text from the source pages.   For full preview please click on 'Download sample':

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04_004_C
CURSOR SERIES
C78 ENS M20.10
C78 ENT M30.10
C78 ENT M50 .11
C78 ENT M55.10
C78 ENS M20.10
C78 ENT M30.10
C78 ENT M50.11
C78 ENT M55.10
TEChNiCal aNd REpaiR
MaNual
JUNE 2007 EDITION
T E C H N O L O G I C A L E X C E L L E N C E
1. JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
Indications for consultation
The several engine versions are usually explained with
common images and descriptions. In cases of considerable
differences, they are explained separately.
The specific characteristics of the C78 ENS M20 engine
electric system are described in Section 9.
Sections 1-2-3 are intended for sales personnel, to provide
them with an exact knowledge of the product’s character-
istics and enable them to accurately meet the Customer’s
requirements.
The remaining sections are intended for the personnel that
has the task of performing both ordinary and extraordinary
maintenance; by referring carefully to the chapter devoted to
diagnosis, they too will be able to provide an effective service
of technical assistance.
This manual keeps the original contents unchanged over
time. In section 11 there is a chronological list of the modifi-
cations and updating which characterizes the normal evolu-
tion of the products.
SECTION CONTENTS
Section Page
1. OVERVIEW 5
2. TECHNICAL DATA 35
9. ELECTRICAL EQUIPMENT 41
4. DIAGNOSTICS 67
5. MAINTENANCE 89
6. SERVICING OPERATIONS
ON INSTALLED ENGINE 95
7. TOOLS 113
8. OVERHAUL 125
9. C78 ENS M20 ENGINE 199
10. SAFETY SYSTEM FOR
HOMOLOGATED INSTALLATIONS 211
11. UPDATING 237
12. SAFETY REGULATIONS 249
OVERVIEW 1. JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 1
IDENTIFICATION DATA 7
Identification Tag 7
COMMERCIAL CODE 8
PRODUCT MODEL NUMBER 9
ENGINE PARTS AND COMPONENTS 10
ENGINE ARCHITECTURE 12
COMBUSTION AIR INTAKE
AND EXHAUST SYSTEM 14
Air/sea water heat exchanger 15
Combustion air pre-heating 15
Intake and exhaust assembly 15
COOLING FRESH WATER CLOSED LOOP 16
Tube bundle water/water heat exchanger 17
Bypass junction for thermostatic valve 17
SEA WATER OPEN COOLING LOOP 18
Sea water pump 19
ENGINE OIL - LUBRICATION LOOP 20
Gear pump 21
Oil vapor filter 21
Pre-lubrication system (on request) 21
Commutable filters (on request) 21
FUEL LINES 22
Hydraulic schematic diagram 23
INJECTION SYSTEM - EDC 24
EUI electrically controlled pumping injector 25
Electrical and electronic components 28
System functions 30
Reference signals 32
OVERVIEW
OVERVIEW 1.7 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
figure 2
The engine identification data are stenciled on a tag positioned over the engine coolant tank.
figure 1
Identification Tag
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE
ENGINE DWG
ENGINE S/N
COMMERC. TYPE / VERSION
POWER SET CODE
HOMOLOGA TION N
ENGINE F AMIL Y
POWER (KW ) AND SPEED (RPM )
YEAR OF BUILD
S. p. A.
04_002_N
IDENTIFICATION DATA
OVERVIEW 1. JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the
engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for technical
purposes and to identify the engine’s components, this is the purpose of the “ENGINE S/N”.
COMMERCIAL CODE
C 78 E N T M 50 . 1 1
ENGINE FAMILY IDENTIFIER: C = CURSOR
DISPLACEMENT: 78 = 7800 cc NOMINAL
FUEL SUPPLY: E = ELECTRONIC INJECTION
BLOCK: N = NON STRUCTURAL
AIR INTAKE: T = INTERCOOLED SUPERCHARGED
APPLICATION: M = MARINE
MAXIMUM PERFORMANCE LEVEL ACHIEVABLE
50 = 500 HP
VERSION:
TURBOCOMPRESSOR:
1 = COOLED
2 = NOT COOLED
VERSION
OVERVIEW 1. JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
PRODUCT MODEL NUMBER
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to character-
ize its application and power output level. It is stamped on the side of the crank-case.
F 2 B E 0 6 8 6 A
ENGINE FAMILY IDENTIFIER
DESIGN ITERATION
ENGINE
NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL)
NO. OF CYLINDERS
FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION)
INTENDED USE (6 = MARINE)
POWER RANGE
A = 500 HP not certified
B = 400 HP certified
C = 330 HP not certified
D = 300 HP certified
ACTUAL POWER OUTPUT
A = 500 HP
B = 400 HP
C = 350 HP
D = 300 HP
E = 220 HP
F = 190 HP
VARIANTS TO
BASIC ENGINE
} duty
pleasure
TECHNICAL DATA 2. JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 2
TECHNICAL DATA
Page
SPECIFICATIONS 37
Dimensions 39
ELECTRICAL EQUIPMENT .1 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
ELECTRICAL EQUIPMENT
Page
OVERVIEW 43
SYNOPSIS 44
WIRE HARNESS 45
LOCATION OF ELECTRICAL
COMPONENTS ON ENGINE 46
POWER SUPPLY LINE 48
ALTERNATOR 49
ELECTRICAL STARTER MOTOR 50
RELAY BOX 51
Relays contained in the relay box 51
RPM control 51
Diagnosis connector J1 51
RELAY BOX CONNECTORS 52
CONNECTIONS OF THE CENTRAL
ELECTRONIC UNIT (ECU) 52
ECU connector removal and insertion 52
Identification of terminal functions 53
EUI SOLENOID VALVE CONNECTOR 54
Through-bulkhead E connector 54
OPTIONAL EQUIPMENT 55
Lubricating oil transfer module 55
Pre-lubrication and oil transfer module 55
Pre-lubrication system 55
Low temperature starting aid 55
EQUIPOTENTIAL CONNECTIONS
TO ENGINE GROUND 56
(cont.)
DIAGNOSTICS .7 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
DIAGNOSTICS
Page
FOREWORD 69
ECU BEHAVIOUR 70
Anomalies indicator light 70
Blink code 70
Error deletion procedure 70
Recovery 70
BLINK CODE TABLE 71
DIAGNOSIS WITH THE PT-01 INSTRUMENT 72
Functions of the Instrument 72
Identifier 72
Fault Memory 73
Parameter reading 73
Active diagnostics 73
MAJOR DIAGNOSTIC ACTIONS 74
Checking pressure in fuel supply line 74
Venting the fuel loop 74
Checking the keying of timing phonic wheel 74
Checking the timing phase 74
Checking component resistance value 75
Checking line insulation 75
REFERENCE VALUES 76
For non hardwired sensors 76
Throttle position sensor 76
Sensors wired with shielded wires 76
For wired sensors powered by the ECU 77
GUIDE TO BLINK CODE DIAGNOSIS 78
GUIDE TO SYMPTOM DIAGNOSIS 84
MAINTENANCE . JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
MAINTENANCE
Page
PERIODICITY OF CHECKS
AND MAINTENANCE OPERATIONS 91
PREPARING THE ENGINE
FOR LONG IDLE PERIODS 93
ENGINE’S FIRST START/RESTORING
NORMAL OPERATING CONDITIONS 93
SERVICING OPERATIONS ON INSTALLED ENGINE . JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
SERVICING OPERATIONS ON INSTALLED ENGINE
Page
FOREWORD 97
PRESCRIPTIONS FOR WORK ON THE
INJECTION SYSTEM AND ITS COMPONENTS 98
REPLACING BELT 99
REPLACING EUI PUMPING UNITS 99
EUI Disassembly 99
EUI Assembly 100
Rocker arm shaft assembly 100
VENTING THE AIR FROM THE FUEL FEED LOOP 101
CLEANING THE ENGINE COOLANT/SEA
WATER HEAT EXCHANGER 102
CLEANING THE AIR/SEA
WATER HEAT EXCHANGER 103
ADJUSTMENTS 104
Adjusting camshaft phase 104
Checking the timing phase 106
Timing shaft phonic wheel keying 106
Flywheel sensor seat position 107
Adjusting valve clearance and EUI pump position 108
UNCOUPLING MARINE PARTS 110
Intake side 110
Exhaust side 111
INSTRUCTIONS FOR DISEMBARKING THE ENGINE 112
Handling 112
TOOLS 7.11 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 7
Page
TOOLS 115
OVERHAUL .12 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
OVERHAUL
Page
Graph and symbols 127
GENERAL CHARACTERISTICS 128
ASSEMBLY CLEARANCE DATA 129
TIGHTENING TORQUES 135
TIGHTENING ORDERS 138
ENGINE DISASSEMBLY AT THE BENCH 142
CYLINDER BLOCK 147
Checks and measurements 147
CYLINDER LINERS 148
Replacing cylinder liners - Removal 149
Fitting and checking protrusion 149
CRANKSHAFT 150
Measuring main journals and crankpins 151
PRELIMINARY MEASUREMENT OF MAIN AND
BIG END BEARING SHELL SELECTION DATA 152
Selecting the main and big end bearing shells 153
Replacing the timing control
gear and the oil pump 159
Checking main journal installation clearance 159
Checking crankshaft end float 160
PISTON CONNECTING ROD ASSEMBLY 161
Removal 161
Measuring the diameter of the pistons 162
Conditions for correct
gudgeon pin-piston coupling 162
Piston C78 ENS M20 - C78 ENT M30 163
Piston C78 ENT M50-M55 164
Piston rings 165
(cont.)
OVERHAUL .12 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
CONNECTING ROD 166
Checking connecting rod alignment 167
Mounting the connecting rod-piston assembly 167
Mounting the piston rings 167
Fitting the connecting rod-piston
assembly into the piston liners 168
Piston protrusion check 168
CYLINDER HEAD 169
Valve removal 169
Checking the planarity of the
head on the cylinder block 169
VALVES 170
Valve guides 170
REPLACING INJECTOR HOLDER CASES 171
Removal 171
Mounting 172
Checking protrusion of injectors 173
TIMING GEAR 174
Camshaft drive 174
Intermediate gear pin 174
Idler gear 174
Twin idler gear 174
Replacing the bushings 174
Checking cam lift and pin alignment 175
Camshaft 176
BUSHES 177
Removal 178
Assembly 178
VALVE SPRINGS 180
Fitting the valves and oil seal ring 180
ROCKER SHAFT 181
Shaft 181
Rockers 181
LUBRICATION SYSTEM COMPONENTS 182
Oil pump 182
Overpressure valve 182
Oil pressure control valve 182
Heat exchanger 183
Filter by-pass valve 184
Thermostatic valve 184
Oil filter 184
COOLING SYSTEM COMPONENTS 185
Water pump 185
Thermostatic valve 185
FUEL FEED COMPONENTS 186
Fuel feed 186
Injector-pump 186
ASSEMBLING THE ENGINE ON THE BENCH 187
Diagram showing the underblock
fixing screws tightening order 189
Fitting the connecting rod-piston
assembly into the cylinder liners 190
Piston protrusion check 190
ENGINE FLYWHEEL 193
FITTING CAMSHAFT 194
EUI Assembly 195
Rocker arm shaft assembly 195
Adjusting camshaft phase 196
Checking the timing phase 196
Timing shaft phonic wheel keying 196
Adjusting valve clearance and EUI pump position 196
ENGINE COMPLETION 197
C7 ENS M20 ENGINE .1 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 
C7 ENS M20 ENGINE
Page
SPECIFICATIONS 201
Dimensions 203
INJECTION SYSTEM - EDC 204
WIRE HARNESS 205
LOCATION OF ELECTRICAL
COMPONENTS ON ENGINE 206
SENSORI EDC 207
Combustion air pressure/temperature sensor 207
Intake air sensor 207
Electrical equipment component code 208
Wiring diagram EDC connector A 210
10.211 JUNE 2007 SAfETy SySTEM fOR HOMOLOGATED INSTALLATIONS C78 ENS M20
C78 ENT M30-M50-M55
SAfETy SySTEM fOR HOMOLOGATED
INSTALLATIONS
Page
(cont.)
SAFETY SYSTEM FOR
HOMOLOGATED INSTALLATIONS 213
Unit installed 213
Electronic monitoring unit 214
Sensors 214
Wiring 215
Insulated pole power network (optional) 215
Electrical starting motor 216
Alternator 216
Auxiliary EDC electronic unit 217
Synoptic 218
Wiring 219
Monitoring unit 220
Function of JS connection terminals 221
Position of the safety system sensors 222
Drive shaft rev. speed sensor (BA) 224
Exhaust gas temperature sensor (O) 224
Coolant high temperature sensor (IA) 224
Engine oil low pressure sensor (WA) 225
Engine oil pressure sensor (VA) 225
Coolant oil temperature sensor (S) 225
Refrigerating liquid pressure
and low pressure sensor (WVA) 226
Fuel pressure sensor (VCA) 226
Line balancing components 227
Engine cut-out control buttons (JEM) 227
SECTION 10
UPDATING 11.27 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 11
UPDATING
Page
TURBOCOMPRESSOR 239
INJECTION SYSTEM - EDC 240
Wire harness 241
Location of electrical components on engine 242
Electrical equipment component code 244
Wiring diagram EDC connector A 246
Guide to blink code diagnosis 247
SAfETy REGULATIONS 12.2 JUNE 2007 C78 ENS M20
C78 ENT M30-M50-M55
SECTION 12
SAfETy REGULATIONS
Page
SAFETY REGULATIONS 251
Standard safety regulations 251
Accident prevention 251
During maintenance 251
Respecting the Environment 252


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