NEF SERIES INTRODUCTION

We would like to thank you for buying an IVECO MOTORS product,

and compliment you on your choice of engine.
MECHANICAL INJECTION Before you carry out any operation involving the engine or its fittings,
SYSTEM please read the contents of this manual carefully; compliance with the
instructions provided in the manual is the best way to guarantee
trouble-free, long term operation of the engine.
N45 MNA M10.00

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N67 MNA M15.00 The contents of this manual refer to the standard configuration of the
engine, and the illustrations are purely indicative. Some instructions are
N67 MNT M28.10 provided by giving the sequence of operations to be carried out in
order to allow the engine and/or its fittings to perform in a certain way.
In some cases they will be dependent on the configuration of the
commands and the set-up of the vessel on which the engine is
YEAR 2005 installed; for any points that differ from the contents of this manual,
please consult the instructions provided by the Boatbuilder or a
specific manual.
USE AND MAINTENANCE The information provided below was current at the date of
publication.
The Manufacturer reserves the right to make modifications at any time
without prior notice, for technical or commercial reasons or to update
the engines to comply with legal requirements in the various
Countries.
The Manufacturer declines all liability for any errors or omissions.

Please remember that the IVECO MOTORS Technical Service

Network is available to offer you its experience and professional skills,
wherever you may be.

1
CONTENTS Page Page
„ GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 „ IN APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Oil viscosity level according to surrounding temperatures . . . . . . .
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Engine technical data N45 MNA M10 . . . . . . . . . . . . . . . . . . . . . . .4
Engine technical data N67 MNA M15 . . . . . . . . . . . . . . . . . . . . . . .6
Engine technical data N67 MNT M28 . . . . . . . . . . . . . . . . . . . . . . .8
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
„ USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Starting and stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Starting and stopping the engine from the analogue control panel . . 12
Recognising alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
„ CONTROLS AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . .19
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
How to proceed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
„ LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . .31
Preparing the engine for a long period of inactivity . . . . . . . . . . .31
Restarting the engine after a long period of inactivity . . . . . . . . .32
„ EMERGENCIES ON BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2
„ GENERAL INFORMATION SAFETY
The following information is intended to encourage caution when
using the engine, so as to avoid damage to persons or property as a
GUARANTEE result of improper or incorrect behaviour.
In order to ensure that your engine gives the best possible
performance and to take advantage of the IVECO MOTORS ‰ The engines must only be used for the purposes indicated by the
guarantee, you must follow the indications provided in this publication Manufacturer.
with great care; failure to do so may result in invalidation of the ‰ Any tampering, modification and use of non-original spare parts

ENGLISH
guarantee. may compromise proper operation of the engine and safe
navigation; never, under any circumstances make
modifications to the wiring and to the units equipping the engine,
SPARE PARTS or connect them to other power systems.
Always use Original IVECO MOTORS Spare parts. This is essential to ‰ The engine has moving parts, parts operating at high temperatures
keep the engine in original running order. and other parts containing pressurised fluids; its electrical
The use of non-original spare parts will not only invalidate the equipment houses electrical currents and voltage.
guarantee, but will mean that IVECO MOTORS will not be considered
‰ The exhaust fumes produced by the engine are bad for your health.
liable in any way during the whole working life of the engine.
‰ The engine must only be moved using suitable lifting tackle, making
use of the U-bolts provided on the engine for that purpose.
LIABILITY ‰ The engine must not be started up and used until the vessel in
The Manufacturer will only be considered liable subject to which it installed has satisfied all necessary safety requirements, or
performance of the control and maintenance operations indicated and until the vessel has been guaranteed to comply with local laws and
described in this manual; to this effect, proof that these operations regulations.
have been performed must be provided. Any special maintenance
‰ The operations required to guarantee the best possible use and
operations that may be necessary must be carried out by qualified
preservation of the engine must only be carried out by persons of
technicians from authorised Workshops in the IVECO MOTORS
proven experience, equipment with tools considered suitable by
Network, using the instruments and equipment provided for the
IVECO MOTORS.
purpose.
For the purpose of safety, further recommendations are given in the
chapter CONTROLS AND MAINTENANCE.

3
ENGINE TECHNICAL DATA N45 MNA M10
The technical code and serial number are indicated on the rating plate, Available settings (*) N45 MNA M10
which is located on different parts of the engine, according to the A1 74 kW (100 CV) @ 2800 rpm
model: flywheel casing, tappet cover, coolant tank.
B 66.5 kW (90 CV) @ 2800 rpm
Commercial code N45 MNA M10 C 63 kW ( 85 CV) @ 2800 rpm
Engine family F4 D 63 kW ( 85 CV) @ 2800 rpm
Cycle 4-stroke diesel
Number and arrangement (*)Maximum net power to the flywheel in compliance with ISO 3046-1.
of cylinders 4, in line Test conditions: T 25 °C; atmospheric pressure 100 kPa; relative
humidity 30%.
Bore x stroke 104 x 132 mm
Total displacement 4,480 cm3 WARNING
Air system Natural aspiration (NA)
Any alteration of the above mentioned characteristics, in particular
Injection type Direct with VE rotating pump modification of the calibration of the injection system or the
Engine direction of Anticlockwise characteristics of the engine and its fittings, is strictly prohibited,
rotation (seen from flywheel side) penalty invalidation of the guarantee and absence of all liability on the
part of IVECO MOTORS.
Dry weight 495 kg

Electrical system 12 V (24 V on request)

Accumulator/s
- capacity 180 Ah or above
- discharge current 800 A or above

4
               

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04_365_N 04_366_N

             

Engine N45 MNA M10 Engine N40 ENT M10

1. Exhaust gas discharge - 2. Lifting U-bolt - 3. Exhaust manifold - 1. Coolant tank pressurisation cap - 2. Oil dipstick - 3. Water-heater
4. Oil filler cap - 5. Lifting U-bolt - 6. Coolant tank- 7. Thermostat system manifold - 4. Air filter - 5. Oil vapour recirculation - 6. Fuel
valve location - 8. Alternator - 9. Water-heater system tap or coolant outlet towards the tank - 7. Injection pump - 8. Oil extraction pump -
drainage plug - 10. Oil filter - 11. Engine coolant-sea water heat 9. Cold injection timing regulator (KSB) - 10. Sea water pump - 11. Sea
exchanger - 12. Starter motor - 13. Removable anode. 14. Sea-water water pump inlet - 12. Fuel inlet from tank - 13. Fuel transfer pump -
outlet manifold. 14. Fuel filter - 15. Auxiliary member drive belt.

5
ENGINE TECHNICAL DATA N67 MNA M15
The technical code and serial number are indicated on the rating plate,
which is located on different parts of the engine, according to the
model: flywheel casing, tappet cover, coolant tank. Available settings (*) N67 MNA M15
A1 110 kW (150 CV) @ 2800 rpm
Commercial code N67 MNA M15
B 99.5 kW (135 CV)@ 2800 rpm
Engine family F4
C 92 kW (125 CV)@ 2800 rpm
Cycle 4-stroke diesel
D 92 kW (125 CV)@ 2800 rpm
Number and arrange-
ment 6, in line
of cylinders (*)Maximum net power to the flywheel in compliance with ISO 3046-1.
Test conditions: T 25 °C; atmospheric pressure 100 kPa; relative
Bore x stroke 104 x 132 mm humidity 30%.
Total displacement 6,700 cm3
Air system Natural aspiration (NA) WARNING

Injection type Direct with VE rotating pump Any alteration of the above mentioned characteristics, in particular
modification of the calibration of the injection system or the
Engine direction of rota- Anticlockwise (seen from flywheel side)
characteristics of the engine and its fittings, is strictly prohibited,
tion
penalty invalidation of the guarantee and absence of all liability on the
Dry weight 600 kg part of IVECO MOTORS.

Electrical system 12 V (24 V on request)

Accumulator/s
- capacity 180 Ah or above
- discharge current 800 A or above

6
               

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04_367_N 04_368_N

            

Engine N67 MNA M15 Engine N67 MNA M15

1. Exhaust gas manifold - 2. Lifting U-bolt - 3. Oil vapour recirculation - 1. Coolant tank pressurisation cap - 2. Water-heater system manifold -
4. Oil filter - 5. Oil filler cap - 6. Lifting U-bolt - 7. Thermostat valve 3. Air filter - 4. Fuel outlet towards the tank - 5. Lifting U-bolt - 6. Oil
location - 8. Alternator - 9. Water-heater system tap or coolant dipstick - 7. Injection pump - 8. Oil extraction pump - 9. Sea water pump
drainage plug - 10. Engine coolant-sea water heat exchanger - - 10. Sea water pump inlet - 11. Cold injection timing regulator (KSB) -
11. Removable anode - 12. Sea-water outlet manifold - 13. Starter 12. Fuel inlet from tank - 13. Fuel transfer pump - 14. Fuel filter -
motor. 15. Auxiliary member drive belt.

7
ENGINE TECHNICAL DATA N67 MNT M28
The technical code and serial number are indicated on the rating plate, Available settings (*) N67 MNT M28
which is located on different parts of the engine, according to the A1 206 kW (280 CV) @ 2800 rpm
model: flywheel casing, tappet cover, coolant tank.
B 191 kW (260 CV) @ 2800 rpm
Commercial code N67 MNT M28 C 169 kW (230 CV)@ 2800 rpm
Engine family F4 D 132 kW (180 CP)@ 2500 rpm
Cycle 4-stroke diesel
Number and arrangement (*)Maximum net power to the flywheel in compliance with ISO 3046-1.
of cylinders 6, in line Test conditions: T 25 °C; atmospheric pressure 100 kPa; relative
humidity 30%.
Bore x stroke 104 x 132 mm
Total displacement 6,700 cm3 WARNING
Air system Supercharged and aftercooled
Any alteration of the above mentioned characteristics, in particular
Injection type Direct with VE rotating pump modification of the calibration of the injection system or the
Engine direction of Anticlockwise characteristics of the engine and its fittings, is strictly prohibited,
rotation (seen from flywheel side) penalty invalidation of the guarantee and absence of all liability on the
part of IVECO MOTORS.
Dry weight 600 kg

Electrical system 12 V (24 V on request)

Accumulator/s
- capacity 180 Ah or above
- discharge current 800 A or above

8
               
    

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04_336_N 04_337_N

             

Engine N67 MNT M28 Engine N67 MNT M28

1. Exhaust gas discharge - 2. Turbocharger - 3. Engine coolant-sea 1. Fuel filter - 2. Fuel inlet from tank - 3. Coolant tank - 4. Location of
water heat exchanger - 4. Coolant outlet manifold from engine - water-heater system manifold or plug - 5. Oil filler cap - 6. Oil dipstick -
5. Oil filter - 6. Lifting U-bolt - 7. Coolant filler cap - 8. Location of 7. Fuel outlet towards the tank - 8. Lifting U-bolt - 9. Oil vapour filter -
thermostat valve - 9. Alternator - 10. Manifold connecting to coolant 10. Air filter - 11. Sea water connector pipe - 12. Injection pump -
tank - 11. Coolant infeed to engine - 12. Water-heater system tap or 13. Sea water pump inlet - 14. Removable anode - 15. Auxiliary member
plug - 13.Coolant drainage plug - 14. Connection to battery positive pulley casing - 16. Oil extraction pump.
terminal - 15. Electrical starter motor - 16. Removable anode -
17. Sea-water outlet manifold.

9
SIGNS
Certain warning signs are affixed to the engine by the boatbuilders, and
their meanings are indicated below.
NOTE: The signs with an exclamation mark on them underline a
potential danger.

Lifting point (engine only). Danger of burning:

Expulsion of hot water under pressure.

Fuel Cap Danger of burning:

(on the fuel tank, if there is one). Presence of high temperature parts.

Oil Cap. Danger of fire:

Fuel present.

Danger of impact or catching

Oil dipstick. on moving parts:
Presence of fans, pulleys, belts or the like.

10
„ USE STARTING AND STOPPING THE ENGINE
For vessels equipped with instrument panels that
PRELIMINARY CHECKS are not manufactured by IVECO MOTORS
Before starting the engine each time: The start-up and shut-down operations described below apply to an
‰ Make sure that the sea-water inlet valve is open. Operation of the on-board control panel manufactured by IVECO MOTORS; if the
sea water pump without water would cause irreparable damage to vessel is fitted with an instrument panel that has been customised by
the internal rotor within a very few seconds. the Boatbuilder or Fitter, these operations may vary according to the

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various choices made during construction. In these cases, follow the
‰ Check the level of technical fluids (fuel, engine oil and coolant). start-up/shut-down sequence and use the instrument panel
description provided by the Boatbuilder on specific documentation.
CAUTION!

Before starting the engine, make sure that no combustible

vapours or gasses are present in the engineroom.

11
STARTING AND STOPPING THE ENGINE
FROM THE ANALOGUE CONTROL PANEL
2 5
Procedure for start-up from the main IVECO 4
MOTORS control panel (supplied on demand)
1. Lift the protective cover over the key switch (8), insert the key and
turn it to the right to position 8B. 3
2. Make sure that the analogue instruments are showing values that
conform with the relevant physical parameters (temperature,
battery voltage and oil pressure). 1 10 7 6
3. Wait for the beeper to stop sounding and for the alarm indicator
lights on the indicator module (5) to switch off, with the exception
of the “alternator malfunction” and “low oil pressure” indicators. At
the same time, check that the indicator test has been performed 9 8
successfully (information on how to interpret this test and
indications on the module are given in the relevant paragraph).
4. Turn the key to position 8C; once the engine has started, release 04_354_N

the key quickly and do not accelerate. 1. Coolant temperature indicator - 2. Rev counter and hour counter -
5. Make sure that the analogue instruments are showing values that 3. Voltmeter - 4. Beeper - 5. Indicator and alarm module - 6. Engine
conform with the relevant physical parameters (temperature, oil pressure indicator - 7. Control panel instrument light switch - 8. Key
battery voltage and oil pressure). switch to start/stop the engine - 9. Button to stop the engine -
6. If the engine does not start, after releasing the key it will only be 10. Button to disable the beeper.
possible to turn it back to the start position after first returning the
switch to the rest position 8A. Detail of the key switch 8A 8B

8C
04_356_N

12
Procedure for start-up from IVECO MOTORS
secondary or fly-bridge control panel (supplied on 2
demand) 1 3
1 Enable the secondary control panel, by turning the key
switch on the main panel to position 8B.
2. Wait for the beeper to stop sounding and for the alarm indicators
on the indicator module (5) to switch off, with the exception of the

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“alternator recharge” and “low oil pressure” indicators. At the same
time, check that the indicator test has been performed successfully
(information on how to interpret this test and indications on the 4
module are given in the relevant paragraph).
5 6
3. Press the green button (5) and release it when the engine has
started.
04_355_N
4. Check that the rev indicator shows a plausible value.
1. Rev counter and hour counter - 2. Beeper - 3. Indicator and alarm
module - 4. Button to disable the beeper - 5. Engine start button -
6. Engine stop button.

13
Stopping the engine
Before stopping the engine it is recommended you run it for a few
minutes at minimum speed with no load; this will allow the
temperature to drop evenly and will avoid harmful thermal shocks.
A. The engine is normally stopped from the main IVECO MOTORS
control panel by turning the key switch to the rest position 8A or
by turning a similar command on the customised control panel.
B. The IVECO MOTORS secondary control panel is stopped by
pressing the red button (6) on the control panel.

The main IVECO MOTORS control panel for engines equipped with
an “excited” device (on request or as prescribed by the Certification
Body), is stopped by pressing the red button (9).

To re-start the engine from the main control panel:

1. Return the key switch to the rest position 8A to reset all the on-
board control panel functions.
2. Proceed as described.

To re-start the engine from the secondary control panel:

1. Make sure that the panel has been enabled (key switch on the main
control panel turned to position 8B).
2. Press the green button (5) and release it when the engine has
started, making sure that the rev indicator is showing a plausible
reading.

14
RECOGNISING ALARMS
IVECO MOTORS on-board control panels with analogue instruments
are fitted with an electronic module that includes the indicator lights
and the interface, timer and alarm storage circuits. 7
The figure illustrates the dial and the key indicates the meaning of the
alarm signals sent by all the indicator lights; some types of engine and
relevant equipment only make some of the above mentioned 5 6 8 9
functions available.

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If the Boatyard uses different technical options there may also be
changes to the above. 4 3 13 10 11

Operation
When the key switch is turned to position 8B the signals and alarms 2 1 12
module will perform an efficiency test on all the indicator lights, lasting
5 seconds, with the exception of the “Pre-lubrication”, “Pre-post
heating”, “EDG system malfunction” indicators, and simultaneously the
beeper sounds.
It is possible to stop the beeper before the end of the test, by pressing
the relevant button. 04_234_N
During start-up and for the following 15 seconds, all alarm functions
are disabled; after this period, each alarm detected by the sensors 1. Maximum allowed rotation speed exceeded (on request) - 2.
provided on the engine will result in the relevant indicator flashing and Water in the fuel pre-filter - * 3. Engine coolant level low - 4.
a simultaneous warning sound from the beeper. If the beeper is Alternator malfunction - *5. Oil filter blocked - *6. Oil vapour filter
disabled by pressing the relevant button, the indicator light will turn on blocked - *7. Pre-lubrication in progress - 8. Air filter blocked -
without flashing and the alarm will be stored until the engine is next *9. Fuel filter blocked - 10. Coolant temperature high - 11. Oil
stopped. pressure low - *12. Pre-post heating - *13. Malfunction in EDC
electronic injection system.

*Alarm functions not available with standard setup.

15
FOR PROPER USE OF THE ENGINE SPECIAL WARNINGS
‰ Do not continue to press the starter, when the engine has started. Coolant temperature high
‰ Do not remain in dock while waiting for the engine to warm up, If the temperature indicated on the instrument is considered too high,
but after starting, commence navigation at low speed; the working or if the alarm is displayed, reduce speed and return to port to check
temperature will be reached properly with the engine running at the state of the sea water intake and cooling system circuits; also check
medium speeds. and have checked:
‰ Do not operate the engine at minimum speed for long periods, as • tension of the water pump and alternator command belts.
this encourages the production of harmful exhaust and does not
guarantee optimum performance. • operation of the thermostat valve.
‰ The engine speed must be increased and decreased gradually, to • whether or not the heat exchangers are clean.
allow regular combustion and proper operation of all engine
components; sudden acceleration may result in very smokey CAUTION!
exhaust.
‰ The maximum cruising speed must not be more than 90% of the When the engine is warm, a pressure liable to cause hot
speed corresponding to maximum power (see ENGINE liquid to be expelled with extreme violence is created
TECHNICAL DATA). within the cooling circuits. This results in a danger of
burning. Only open the coolant tank cap if strictly
‰ During navigation, check that: necessary, and only when the engine is cold.
• The engine coolant temperature does not reach the alarm
threshold.
• The oil pressure remains within normal values.
Low lubricant pressure
If the pressure indicated by the instrument is considered insufficient, or
if the “low oil pressure” indicator lights up, stop the engine and check
the oil level. Top up if necessary (see CONTROL AND
MAINTENANCE section).
If the condition persists, return to port at low speed and contact an
Authorised Service Centre.

16
Water in the fuel pre-filter Alternator malfunction
It is a good rule to drain the water from the filters, before the relevant Check it or have it checked periodically for cleanliness, wear and
indicator comes on. proper tensioning of the drive belt.
Avoid using the engine with the fuel tank only a small reserve of fuel;
this encourages the formation of condensation and makes it more CAUTION!
likely you will suck up dirt or air, resulting in engine stoppage.
The drive members are located under protective casings.
These must only be removed when the engine is not

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CAUTION!
turning.
When refuelling, always pay great care to ensure that no
solid or liquid pollutants enter the fuel tank; you must also
remember that smoking and live flames are prohibited Irregularities in the electrical system
when refuelling. Periodically check, particularly during the winter, to ensure that the
batteries are clean and in full working order, checking and topping up
as indicated in the section CONTROLS AND MAINTENANCE;
Air filter blocked and exhaust circuit inefficient always comply with the WARNINGS provided. Should it be necessary
Inspect the cleanliness of the air intakes and discharge pipes on a to replace the batteries, always comply with the characteristics indicated
regular basis. The maintenance intervals indicated in this manual only in the section ENGINE TECHNICAL DATA.
take into account the performance of engine components, and not any
additional fittings installed by the Boatbuilder and any external events.
RUNNING IN
CAUTION! Thanks to modern engine construction technology, no particular
running in procedure is required. However, it is recommended that,
Visually check that the exhaust circuit is not blocked or for the first 50 hours, you do not use the engine at high power for long
damaged, so as to prevent dangerous fumes within the periods.
vessel.

17
REFUELLING (3) The amounts indicated refer to initial refuelling, and include filling
the engine, sump and filter.
Parts to be supplied N45 MNA M1O N67 MNA M15 N67 MNT M28
litres (kg) litres (kg) litres (kg) (4) Only use normal commercial diesel fuel (EN590 standards). Do
not use additives. Do not use fuels derived from the synthesis of
Cooling organic substances and vegetable oils (Biodiesel).
circuit(1) 21 22.5 24.5
WARNING
Lubrication circuit (2)
total capacity (3) 11.5 (10.5) 16.5 (15) 16.5 (15) Refuelling from drums or tanks may result in pollution of the diesel
fuel, with the risk of damage to the injection system; if necessary, filter
Periodic changing: the fuel in a suitable manner or allow sedimentation of the impurities
oil sump at minimum level 7.7 (7) 9 (8) 9 (8) before refuelling.
oil sump at maximum lev- 9.9 (9) 14.5 (13) 14.5 (13)
el
Low temperature diesel
Fuel EN590 specifications distinguish different classes of diesel fuel,
tank(4) - - - identifying the characteristics of those best suited to low temperatures.
It is entirely up to the Oil companies to comply with these regulations,
which foresee that fuels suited to the climactic and geographic
(I) Use a mixture of water and 50% PARAFLU 11 even during the conditions of the various Countries be distributed.
summer months. As an alternative to PARAFLU 11, you can use
another product that complies with international specifications SAE Filling up with marine gear oil
J 1034. For the amount and types of oil to be used in the marine gear, please
see the manual provided by the Manufacturer.
(2) Use lubricants that comply with international specifications ACEA E3
- E5 (high power engines), API CF - CH4 (associated with fuels with
a percentage sulphur < 0.5%), MIL - L - 2104 F.
Oil consumption is considered acceptable when it reaches a
maximum of 0.5% of fuel consumption.

18
„ CONTROLS AND MAINTENANCE • filling up batteries with acid solution
• refuelling with inhibitors or antifreeze
• replacing or topping up lubricant (hot engine oil may cause burns and
MAINTENANCE PERSONNEL scalds. Only carry out these operations when the oil has dropped to
The engine control and maintenance operations described in the a temperature of below 50°C).
following chapter require training, experience and compliance with ‰ When working in the engine compartment, pay particular attention
current safety regulations; for this reason they must be carried out by to how you move, to avoid contact with moving parts or high
special technicians, as indicated below.

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temperature components.
‰ Controls: by workshop technicians or the vessel user if necessary. ‰ Wear goggles and use high pressure air jets (maximum air pressure
‰ Periodic maintenance: by qualified personnel used to clean is 200 kPa (2 bar, 30 psi, 2 kg/cm2).
equipped with suitable equipment and adequate means ‰ Wear a protective helmet when working in an area were there are
of protection. Operations marked by the key symbol suspended loads or systems installed at head-height.
(see illustration).
‰ Use protective hand cremes.
‰ Special maintenance: by qualified Authorised
Service Centre staff with specific technical information ‰ Immediately replace wet overalls.
and equipment. Operations marked by the key symbol ‰ Always keep the engine clean, removing oil, grease and coolant
(see illustration). stains.
‰ Store cloths in flame-proof containers.
The Authorised Service Centres are the ones in the IVECO MOTORS
‰ Do not leave foreign bodies on the engine.
Technical Service Network.
‰ Use suitable, safe containers for used oil.
‰ When completing a repair, make suitable provisions to stop the
ACCIDENT PREVENTION engine taking in air if, after start-up, an uncontrolled increase in engine
‰ Always wear heavy-duty footwear and overalls. speed were to occur.
‰ Never wear loose, flapping garments, rings, bracelets and/or
necklaces in the vicinity of engines or moving parts.
‰ Always wear protective gloves and goggles when:

19
 CAUTION!
Planned maintenance Frequency
Do not carry out maintenance operations when the
electric power supply is turned on: always check to ensure Clean air filter/s 300 hours (2) (7)
that the appliances are properly earthed. During diagnosis
and maintenance operations, make sure that your hands Check corrosion of zinc anodes 300 hours (4) (7)
and feet are dry, and whenever possible use insulating Check state of oil vapour filter 300 hours (7)
stands. (for engine N67 MNT M28)
Drain/suck condensation from fuel tank/s 300 hours (1) (7)
FREQUENCY
Replace engine oil 600 hours (5) (7)

Controls Frequency Change oil filter/s 600 hours (5) (7) (8)

Check oil level in engine Daily Change fuel filter/s 600 hours (1) (7) (8)

Check oil level in marine gear Daily Change fuel pre-filter 600 hours (1) (7)

Check engine coolant level Daily Change oil in the marine gear see relevant details

Check exhaust pipe/s for damage Daily Inspect sea chest yearly

Drain water from the fuel filter or 150 hours (1) Check tension and state of belt yearly (3)
pre-filter Change coolant 1200 hours or 2 years
Check/top up electrolyte level in batteries and Change air filter 2 years
clean terminals Half-yearly
Change oil vapour filter 2 years (5)
(for engine N67 MNT M28)
The maintenance intervals indicated below take into account the
typical working factors for various types of engine use; the most
suitable interval for maintenance operations for the various
applications will be indicated by the maintenance staff, according to the
way and working conditions in which the engine is used.

20
 5) Replace lubricants according to the frequency indicated in the
REFUELLING table.
Special maintenance Frequency 6) Sea water/combustion air heat exchanger: clean both the air and
water sections; engine coolant/sea water heat exchanger: clean the
Check wear in sea water pump rotor 900 hours sea water section; optional sea water/marine gear oil heat
exchanger: clean the sea water section.
Change auxiliary member belt 1200 hours or 2
years 7) Must be performed annually, even if the required number of
working hours are not reached.

ENGLISH
Clean heat exchangers 2 years (6) 8) Only use filters with the following characteristics:
Clean the turbocharger 2 years (5) - filtration level < 12 µm
Injector calibration 1800 hours - filtering efficiency ß > 200.
Overhaul injection pump 3000 hours
Adjust play in valves-rocker arms 3000 hours WARNING

When using fuel with a percentage sulphur exceeding 0.5%, or when

I) Maximum period when using good quality fuel, (EN 590 standard); using oils that do not comply with the specifications provided in the
this is reduced if the fuel is contaminated and alarms are triggered refuelling table, the times at which the engine oil, engine oil filter and
due to blockage of the filters and presence of water in the pre-filter. oil vapour filter must be changed will vary according to the use and
When blockage of the filter is indicated, it must be replaced. If the working conditions of the engine itself; for further information, please
water in pre-filter indicator does not go out after drainage, the pre- consult the technicians responsible for maintenance.
filter must be replaced
2) The frequency with which operations are carried out will depend
on the working conditions and efficiency/wear of the product. If the
engine is not used for long periods of time, check it before you start
it.
3) Refers to engines with traditional and automatic tensioning devices.
4) The anode must be replaced if corrosion has exceeded 50% of the
volume of zinc.

21
REQUIREMENTS HOW TO PROCEED
1. Do not disconnect the batteries with the engine running. Check oil level in engine
2. Do not carry out arc welding operations in the vicinity of the engine Only proceed with the engine stopped and at a low temperature, so
without first removing electrical cables. as to avoid the risk of burning.
3. After each maintenance operation involving disconnection of the ‰ Using the dipstick (1), check that the oil level is between the "Min"
battery/batteries, make sure that the terminals have been properly and "Max" levels.
locked onto the poles.
‰ If the level is too low, top up through the inlet on the cylinder head,
4. Do not use battery chargers to start the engine. after first removing the relevant cap (2).
5. Disconnect the on-board network battery/batteries when
recharging. 04_304_N
2
6. Do not paint the appliances, components and electrical connectors 3
equipping the engine.
7. Disconnect the battery/batteries before any electrical operations. 1
8. Contact the Boatyard before installing electronic equipment on
board (two-way radios, echo-sounding equipment, etc.).

WARNING

‰ After topping up, make sure that the oil level does not exceed the
"Max" limit marked on the dipstick.
‰ Make sure that the dipstick is inserted properly and the filler cap
is turned in a clockwise direction until it stops turning completely.

22
Check oil level in marine gear Draining water from the fuel filter of pre-filter
Check the oil level in the marine gear following the indications The high risk of refuelling with fuel that is polluted by foreign bodies
provided in the marine gear Manufacturer's manual. and water means that it is necessary to perform this control even if no
alarm is shown on the on-board control panel.
Proceed with the engine stopped.
Check coolant level
‰ Place a container under the filter or
Only proceed with the engine stopped and at a low temperature, so pre-filter to collect the fluid.
as to avoid the risk of burning.
‰ Unscrew the tap plug (1) in the

ENGLISH
‰ Remove the loading tank pressurisation cap (3 - previous page). bottom part of the filter or pre-filter;
‰ Visually check the coolant level. in some lay-outs the plug includes a
sensor to detect the presence of
‰ Top up the tank if necessary, using a mixture of 50% clean water water in the diesel.
(not distilled) and Paraflù 11 (see REFUELLING table).
‰ Drain off liquid until only “diesel” can
be seen”.
CAUTION! ‰ Close the plug again, tightening it
completely by hand.
Only open the coolant tank cap when the engine is cold. ‰ Dispose of the drained fluids
according to current requirements.
1 04_361_N

Check exhaust pipe/s for damage Checking the level of electrolyte solution in
Visually check that the exhaust system is not blocked or damaged. the batteries
‰ Make sure that there is no risk of dangerous fumes within the Place the batteries on a level surface, then proceed as follows.
vessel. Contact the Boatyard if necessary. ‰ Visually check that the fluid level is between the "Min" and "Max"
limits; in the absence of references, check that the fluid covers the
Lead plates inside the elements by approximately 5 mm.
‰ If necessary, top up with distilled water only those elements in
which the level is below minimum.
‰ Contact specialised technical staff if the battery needs recharging.

23
‰ Have the efficiency of the battery recharging system tested if a Cleaning the air filter
voltage of less than 11 V (for 12 V rated systems) or 22 V (for ‰ Remove the filter by loosening the screws (4) indicated in the
24 V rated systems) is detected with the engine running.
figure.
‰ On this occasion, make sure that the terminals and clamps are ‰ Blow dehumidified compressed air through the filter element,
clean, properly locked and protected by vaseline. from the inside outward (maximum pressure 200 kPa), or wash
with water only, avoiding the use of detergents; do not use die-
CAUTION! sel.
‰ Replace the filter if any breakages are found.
‰ The batteries contain sulphuric acid, which is extremely ‰ Replace the filter once every 2 years.
caustic and corrosive; always wear protective gloves and ‰ Restore normal operating conditions after positioning the filter in
goggles when topping them up. Whenever possible it is its housing.
recommended that this control be carried out by specialised
personnel. 3
2 4
‰ Do not smoke or use live flames near the batteries during
controls, and make sure that the room you are working in is
adequately ventilated.

Some types of battery have

a single cover for all the
inspection plugs. To access
the elements, use a lever as
shown in the figure.

1
04_362_N

04_304_N 5

24
Check corrosion of zinc anodes Changing engine oil (figure on page 24)
Only proceed with the engine stopped and at a low temperature: Only proceed with the engine stopped and at a low temperature, so
‰ Provide suitable containers to ensure that no water is dispersed as to avoid the risk of burning.
inside the vessel during removal of the anodes. ‰ Place a container under the hand pump (1) outlet pipe (2), to
‰ Remove the anodes, unscrewing them from their housings (see collect the used oil.
location in the section ENGINE TECHNICAL DATA). ‰ Unscrew the filler cap, turn the hand pump provided (2), which is
‰ Make sure that corrosion has not exceeded 50% of the volume of set up to extract the oil only, until the oil sump is completely empty.

ENGLISH
zinc. If this is the case, change them. ‰ Fill up with fresh oil through the feeder hole (3) on the timer cover,
‰ Replace the anodes in their housings, locking them to the using the types and amounts of oil indicated in the table
prescribed torque. REFUELLING.
‰ Using the dipstick, check that the oil level is between the "Min" and
"Max" levels.
Check state of oil vapour filter (figure on page 24)
‰ Dispose of used oil according to current requirements.
Required for engine N67 MNT M28
Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning:
‰ Unfasten the screws and remove the cover (5) to the filter
compartment.
‰ Remove the two filters and check them for deposits; if any deposits
are found, replace them.
‰ Replace the cover in its housing.

25
Changing the engine oil filter Changing the fuel filter
Only proceed with the engine stopped and at a low temperature, so Only proceed with the engine stopped and at a low temperature.
as to avoid the risk of burning. Only use filters with a filtration level equivalent to the ones you are
Only use filters with a filtration level equivalent to the ones you are replacing (see section FREQUENCY).
replacing (see section FREQUENCY). ‰ Remove the filter by unscrewing it. 1
‰ Place a container under the filter support (1), to collect the used oil. ‰ Check that the new filter has
‰ Unscrew the filter and remove it. performance levels that satisfy the
‰ Carefully clean the surfaces of the support that are in contact with needs of the engine (e.g. by
the filter seal. comparing them with the old one).
‰ Damp the new filter seal with a thin layer of oil. ‰ Damp the new filter seal with diesel
or engine oil.
‰ Hand screw the new filter into place until the seal gasket touches
the support, then lock by a further 3/4 of a turn. ‰ Hand screw the new filter into
place until the seal gasket touches
‰ Dispose of the old filter according to current requirements.
the support, then lock by a further
3/4 of a turn.
05_369_N

WARNING

Do not fill up the new filter before fitting it to the support, to avoid
introducing harmful impurities into the injection system and circuit.

Bleeding procedure:
‰ Loosen the fuel outlet manifold, located on the upper part of the
filter (1).
1
‰ Make sure that any diesel coming out will not dirty the auxiliary
04_006_N
member drive belt or be dispersed into the environment.
‰ Use the pre-filter hand pump until the diesel coming out is free
from any residual air.

26
‰ Lock the manifold loosened as above to the required torque. Changing the fuel pre-filter
‰ Dispose of any diesel expelled during the above operation. Only proceed with the engine stopped and at a low temperature.
‰ Start the engine and run it at minimum speed for a few minutes to ‰ Remove the pre-filter by 1
eliminate any residual air. unscrewing it.
‰ Check that the new filter has
NOTE: should it be necessary to accelerate the bleeding phase, the performance levels that satisfy the
hand pump can be used during start-up. needs of the engine (e.g. by

ENGLISH
comparing them with the old
one).
‰ Damp the new filter seal with
diesel or engine oil. 2
‰ Hand screw the new filter into
place until the seal gasket touches
the support, then lock by a further
3/4 of a turn.
‰ Bleed the system using the hand
pump (1) as indicated when
changing the filter, and also turning 04_361_N
the bleeder screw on the pre-filter
(2).
‰ Start the engine and run it at minimum speed for a few minutes to
eliminate any residual air.

27
Check tension and state of the auxiliary member Replace coolant
drive belt Only proceed with the engine stopped and at a low temperature, so
Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.
as to avoid the risk of burning. ‰ Provide suitable containers to ensure that no coolant is dispersed
‰ Remove the casing protecting the pulleys. into the environment.
‰ Check that the pulleys are not torn or worn, and that there are no ‰ Remove the plugs on the circuit components and wait until the
lubricants or fuel on them. If this is not the case, replace them. circuit has drained completely (the location of plugs is given in the
‰ At the same time, make sure that the tensioning device is working section ENGINE TECHNICAL DATA). After emptying, replace the
properly, proceeding as indicated in the figure. plugs in their housings, making sure that the seal rings are all
‰ Replace the guard casing in its housing, and lock all the seal undamaged.
elements. ‰ Fill up the circuit as indicated in the table REFUELLING.
‰ Bleed the circuit and top-up if necessary.

Change oil vapour filter (figure on page 24)

Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning.
‰ Unfasten the screws and remove the cover (5) to the filter
compartment.
‰ Remove the two filters, and dispose of them according to current
requirements.
‰ Insert the new filters and replace the cover.
74178

28
 MOVING THE ENGINE
The operations necessary to embark and disembark the engine must
only be carried out by technicians from Authorised Service Centres.
WARNING
When lifting the engine only, use the U-bolts indicated in this manual
in the section ENGINE TECHNICAL DATA and marked on the
The operations listed below must only be carried out by qualified staff engine with special stickers.
from the IVECO MOTORS Service Centres or by staff from the Lifting must be carried out using a rocker arm that keeps the metal
Boatbuilders. cables supporting the engine parallel, using all the U-bolts provided

ENGLISH
The methods used to perform them are described in the Technical simultaneously; the use of a single U-bolt only is not allowed.
and Repair Manuals. The engine lifting system must have a capacity and size suited to the
weight and dimensions of the engine; check that there is no
interference between the lifting system and the engine components.
Drain/suck water and condensation from tanks Do not lift the engine before removing the transmission members that
Inspect sea chest are coupled to it.
Check wear in sea water pump rotor
Clean heat exchangers
Clean the turbocharger
Injector calibration
Overhaul injection pump
Adjust play in valves-rocker arms

The method used to change the oil in the marine gear is indicated in the
relevant documentation supplied by the Manufacturer of the marine
gear itself.

29
DISPOSAL OF WASTE
The engine is made up of parts and elements that, if discarded, may
cause damage to the environment.
The materials listed below must be handed over to specialised
Collection Centres; the laws in force in the various Countries foresee
severe penalties for transgressors:
‰ Starter batteries.
‰ Used lubricants.
‰ Mixtures of water and antifreeze.
‰ Filters.
‰ Additional cleaning materials (e.g. greasy or fuel-soaked cloths).

30
„ LONG PERIODS OF INACTIVITY 7. Drain the residual 30/M protective oil from the sump. This oil can
be used again for a further 2 preparation operations.
8. Fit signs reading ENGINE WITHOUT OIL to the engine and to the
PREPARING THE ENGINE FOR A LONG on-board control panel.
PERIOD OF INACTIVITY
9. Drain the coolant, if it has not been mixed with suitable antifreeze
In order to prevent oxidation of the internal parts of the engine and and corrosion inhibitors, and affix a sign to indicate the fact.
of certain components in the injection system, when the engine is
expected to be inoperative for periods of more than two months, the

ENGLISH
In the event of prolonged inactivity, the operations described must be
following operations must be carried out in preparation for this:
repeated every 6 months, following the procedure given below:
1. Drain the lubricant from the sump, after first warming up the
A) drain the 30/M protective oil from the sump;
engine.
B) repeat the operations described from point 2 to point 7.
2. Fill the engine with protective oil type 30/M (or alternatively oil that
complies with MIL 2160B type 2 specifications), up to the
Should you intend to protect external parts of the engine, proceed by
"minimum" level indicated on the dipstick. Start the engine and keep
spraying OVER 19 AR protective liquid on unpainted metal parts, such
it running for approximately 5 minutes.
as the flywheel, pulleys and the like, avoiding belts, connector cables
3. Drain the fuel from the injection circuit, from the filter and from the and electrical equipment.
injection pump pipes.
4. Connect the fuel circuit to a tank containing CFB (ISO 4113)
protective fluid, and feed in the fluid by putting the circuit under
pressure and running the engine for approximately 2 minutes, after
first disabling the injection system. This operation can be performed
by polarising terminal 50 of the starter motor with a positive
voltage equivalent to the rated voltage of the system, using a
conductor provided for that purpose.
5. Nebulise approximately 60 g of 30/M protective oil (10 g per litre
displacement) into the turbocompressor suction inlet, during the
pressurised filling operation described in the previous point.
6. Close all the suction, delivery, ventilation and bleeder openings in
the engine with suitable plugs, or seal them with adhesive tape.

31
RESTARTING THE ENGINE AFTER A LONG
PERIOD OF INACTIVITY
1. Drain the residual 30/M protective oil from the sump.
2. Fill the engine, as prescribed, with lubricant of the type and amount
indicated in the table REFUELLING.
3. Drain the CFB protective fluid from the fuel circuit, carrying out this
operation as indicated under point 3. of PREPARING THE
ENGINE FOR A LONG PERIOD OF INACTIVITY.
4. Remove the plugs and/or seals from the suction, delivery,
ventilation and bleeder openings in the engine, restoring it to a
normal state of use. Connect the turbocharger suction inlet to the
air filter.
5. Connect the fuel circuits to the vessel’s fuel tank, completing the
operations as indicated in point 4. of PREPARING THE ENGINE
FOR A LONG PERIOD OF INACTIVITY. During filling operations,
connect the fuel return pipe to a collection tank, so as to prevent
any residual CFB protective fluid from flowing into the vessel’s fuel
tank.
6. Check the engine and fill it up with coolant as prescribed.
7. Start the engine and keep it running until the idling speed rate has
stabilised completely.
8. Check that the instruments on the on-board control panel/s are
showing plausible values, and that no alarms are shown.
9. Stop the engine.
10.Remove the ENGINE WITHOUT OIL signs from the engine and
from the on-board control panel.

32
„ EMERGENCIES ON BOARD Burns and scalds
1. Extinguish any flames on the burned person's clothing, by:
The user of a vessel that has been constructed according to safety • throwing water over them;
regulations, when following the instructions provided in this manual
and the indications given on the engine labels, will be working in safe • using a powder fire-extinguisher, without directing the jet at the
conditions. person's face;
Should improper conduct result in accidents, always request the • covering with blankets or rolling the victim on the ground.
intervention of trained first aid specialists immediately. 2. Do not attempt to remove pieces of clothing that may have stuck

ENGLISH
In an emergency and while awaiting the arrival of first aid specialists, to the skin;
follow the instructions given below.
3. In the case of scalding, immediately but carefully remove any
clothing that may be soaked in the hot liquid;
Engine malfunctions 4. Cover the burn with a special burn dressing or sterile bandage.
When navigating with a malfunctioning engine, take the greatest
possible care when manouevering and make sure that all those aboard
Carbon monoxide intoxication (CO)
are holding firmly to safe hand-holds (see section on ENGINE
MALFUNCTIONS). Carbon monoxide from the engine exhaust is without smell, and is
dangerous both because it causes intoxication, and because when
combined with air it forms an explosive mixture.
In case of fire In closed rooms, carbon monoxide is extremely dangerous, as it can
Extinguish the fire using the fire-fighting equipment provided aboard, reach critical concentrations within a very short time.
and in the manner indicated by Fire prevention authorities (the fire- When assisting an intoxicated person in a closed room:
fighting equipment required on board is compulsory under current 1. Ventilate the room immediately, to reduce the concentration of
safety legislation). gas.
2. When entering the room, hold your breath, do not light flames,
lights or ring electric doorbells or phones, to avoid the risk of
explosion.
3. Carry the intoxicated person out into the fresh air or into a well
ventilated room, resting him on one side if he is unconscious.

33
Electrocution Caustic burns
The engine's electrical 12 V or 24 V electrical system does not involve Caustic skin burns are caused by contact with extremely acid or
the risk of electrocution, however, in the event of a short-circuit alkaline substances.
caused, for example, by a metal tool, there is a risk of burning due to For electric maintenance technicians these are typically caused by acid
overheating of the object through which the electrical current runs. In from batteries; in these circumstances, proceed as follows:
these circumstances: 1. Remove any clothing soaked in the caustic substance.
1. Remove the object that caused the short-circuit, using means that 2. Wash the area with lots of running water, avoiding parts that have
provide sufficient heat insulation. not been burned.
2. Switch off the power at the main switch, if there is one.
If either battery acid, lubricants or diesel come into contact with the
eyes: wash the eyes with water for at least 20 minutes, keeping the
Injuries and fractures eyelids open so that the water flows over the eyeball (move the eye
The vast number of possible circumstances and the specific nature of in all directions to wash more thoroughly).
operations required means that the intervention of a medical team is
necessary.
1. In the event of bleeding, keep the edges of the wound pressed
together until help arrives.
2. If there is any suspicion of a fracture, do not move the injured part
and only move the patient if absolutely necessary.

34
                  ƒ&

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ENGLISH
6$(:
6$(
6$(
6$(:
6$(:
6$(:
6$(:PLQHUDOEDVH
6$(:VHPLV\QWKHWLFEDVH
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                  ƒ)

35