Iveco Motors 8065E00 Operating instructions

USE AND MAINTENANCE
USO E MANUTENZIONE
EMPLOI ET ENTRETIEN
BETRIEBSANLEITUNG
USO Y MANUTENCIÓN
INDUSTRIAL ENGINES
Iveco SpA
PowerTrain
Publication edited by
Marketing - Adv. & Promotion
Print L31022019 - 01/05
8060
SERIES
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

1
GB
Thank you for preferring Iveco Motors and may we compliment you
on the choice you have made.
Before carrying out any work on the engine, read through the pro-
cedures set out in this manual carefully.
If you follow these instructions your engine will be guaranteed trou-
ble-free operation and a long life.
Remember that, wherever you are, the Iveco Motors Service
Network will be at your side to offer you highest levels of skill and
professionalism.
Guarantee
In order to get the best performance from your engine and benefit
from the guarantee you must comply with the instructions contained
in this publication.
Failure to carry out these operations correctly or not at all may inva-
lidate the guarantee.
Spare parts
It is essential to use only Original Iveco Motors Spare Parts if the en-
gine is to be kept in its original sound condition.
The use of non-original spare parts will invalidate the guarantee and
release Iveco Motors from any long-term liability.
Liability
The manufacturer's liability is dependent on the execution of the
"Checks and Maintenance" operations mentioned in this manual.
For this purpose, a record must be kept of the maintenance opera-
tions carried out, which, as far as extraordinary maintenance is con-
cerned, must be performed by authorised workshops.
Warning
The contents of this manual refer to the engine only; in particular, il-
lustrations are approximate and some instructions are described in
a purely functional manner, to permit the operations to be carried
out on the engine.
The ways of executing the above instructions depend on the confi-
guration of the controls and/or accessories of the machine on which
the engine is installed and reference is made to the machine manual.
The information contained in this manual is correct at the time of pu-
blication.
The Manufacturer reserves the right to make amendments without
prior notice at any time for reasons of a technical or commercial na-
ture as well as to comply with legal requirements in different coun-
tries. It declines any liability for any errors or omissions.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

2
LIST OF CONTENTS
Page
General information ........................................................................ 1
Safety requirements ........................................................................ 3
Warning labels ................................................................................. 4
Maintenance operations .................................................................. 5
Engine identification data................................................................. 5
Industrial engines
Engine views.................................................................................... 6
Engine data ...................................................................................... 9
Before starting................................................................................. 9
Starting the engine......................................................................... 10
Stopping the engine....................................................................... 11
Water pre-heating ......................................................................... 11
Precautions for normal engine operation...................................... 12
Running in...................................................................................... 13
Checks and maintenance............................................................... 14
Routine checks .............................................................................. 16
Routine maintenance..................................................................... 20
Engines for generating units
Engine views.................................................................................. 21
Engine data .................................................................................... 24
General.......................................................................................... 25
Starting with mechanical governor................................................ 26
Starting with electronic governor.................................................. 26
Stopping the engine ....................................................................... 26
Precautions for normal engine operation ...................................... 27
Checks and maintenance...............................................................27
Engines for fire pumps
Engine views .................................................................................. 28
Engine data .................................................................................... 28
General .......................................................................................... 29
Before starting ............................................................................... 29
Starting the engine ......................................................................... 29
Stopping the engine ....................................................................... 30
Engine fault diagnosis..................................................................... 31
Maintenance when engine is out of commission
for long periods ............................................................................. 34
Main regulation and repair data ..................................................... 35
Capacities ...................................................................................... 36
Engine handling .............................................................................. 38
Disposal of used parts.................................................................... 38
What to do in an emergency ......................................................... 39
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

3
SAFETY REQUIREMENTS
Basic rules
The following recommendations are given so as to reduce the risk to
persons and property when an engine is in service or out of service.
Engines must not be used for applications other than those declared
by the manufacturer.
Incorrect handling, modifications and use of non-original parts may
affect safety.
When handling the engine, take care to use suitable equipment to be
applied to the points specially provided on the engine (see paragraph
"Handling engine").
This publication refers to the engine component; the machine on
which it is installed must meet the specific safety requirements.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

4
WARNING LABELS
Warning labels are applied to the engine by the machine’s builder.
Their meanings are given below.
N. B. Labels which show an exclamation mark indicate that there is
a possibility of danger.
Lift point for engine only.
Fuel filler indication on tank
(where present).
Lubricating oil filler indication.
Oil dipstick indication.
Danger of burns:
Expulsion of pressurised hot water.
Danger of burns:
Hot parts indication.
Risk of fire:
Due to presence of fuel.
Risk of entangling and cutting:
Indication of rotating parts
(pulleys, belts, fan).
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

5
MAINTENANCE OPERATIONS
For the purposes of safety it is important that the maintenance ope-
rations indicated in this manual are carried out according to the fol-
lowing guidelines:
- checks, can be carried out both by the workshop and the machi-
ne user;
-routine maintenance checks, marked by the spanner sym-
bol (see diagram below), must be carried out by qualified persons
using the appropriate equipment and protections;
-non-routine maintenance operations, given their parti-
cular nature, must be carried out by authorised workshops which
are equipped with the appropriate tools and are in possession of the
proper technical information.
"Authorised workshops" are those workshops belonging to the Iveco
Motors service organisation and those belonging to the machine ma-
nufacturer's service organisation if authorised by lveco Motors.
ENGINE IDENTIFICATION DATA
The technical code and the serial number are stamped on a label po-
sitioned, depending on the model, on the flywheel housing or tappet
cover.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

6
INDUSTRIAL ENGINES
Engine 8065E00: right side view
1. Starter motor - 2. Fuel filters - 3. Intake manifold - 4. Thermostat
housing - 5. Fuel pump - 6. Injection pump - 7. Oil filler cap/dipstick.
Engine 8065E00: left side view
1. Alternator - 2. Water pump-alternator drive belts - 3. Engine lift
eyes - 4. Oil vapour breather - 5. Exhaust manifold - 6. Oil filters - 7.
Oil-water heat exchanger - 8. Oil drain plug.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

7
Engine 8065SE00: right side view
1. Starter motor - 2. Fuel filters - 3. Intake manifold - 4. Thermostat
housing - 5. Fuel pump - 6. Injection pump - 7. Oil filler cap/dipstick.
Engine 8065SE00: left side view
1. Alternator - 2. Water pump-alternator drive belts - 3. Engine lift
eyes - 4. Oil vapour breather - 5. Turbocharger - 6. Exhaust manifold
- 7. Oil filters - 8. Oil-water heat exchanger - 9. Oil drain plug.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

8
Engine 8065SRE10: right side view
1. Starter motor - 2. Fuel filters - 3. Intake manifold/intercooler - 4.
Fuel pump - 5. Injection pump - 6. Oil filler cap/dipstick.
Engine 8065SRE10: left side view
1. Alternator - 2. Drive belts - 3. Thermostat housing - 4. Engine bre-
ather - 5. Turbocharger - 6. Exhaust manifold - 7. Engine lift eye - 8.
Oil filters - 9. Oil-water heat exchanger - 10. Oil drain plug.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

9
GENERAL ENGINE DATA
- Diesel cycle, 4-stroke, injection .............................................direct
- Cylinders, number and layout ............................................6, in line
- Bore and stroke ........................................................104 x 115mm
- Total capacity ........................................................................... 5.9 l
- Direction of rotation (seen from flywheel side)....... anti-clockwise
SPECIFIC INDUSTRIAL ENGINE DATA
Description 8065 8065 8065
E00 SE00 SRE10
- Injection pump type Distrib. Distrib. Distrib.
- Intake NA TC TCA
- Maximum output (*)
kW (CV) 81 (110) 125 (170) 147 (200)
- At speed of rpm 2500 2400 2400
- Dry weight kg 490 500 540
(*)ISO Fuel Stop Power: reference ambient conditions: ISO 3046/1;
25°C, 100 kPa; 30% relative humidity
WARNING
It is absolutely forbidden, at risk of invalidating the gua-
rantee and the liability of Iveco Motors, to change the
above characteristics, and in particular to change the adjustment of
the injection pump and, where fitted, the waste-gate valve.
BEFORE STARTING
Every day, before starting the engine:
- check the fluid levels (fuel, engine oil and coolant).
- check that the air intake cleaner is not clogged, checking that the
mechanical indicator on the cleaner is not showing "red”.
If the cleaner is clogged, clean it following the instructions set out in
the paragraph "Routine Checks and Maintenance”.
N.B. When an electric indicator is fitted (optional) a warning light on
the control panel will light up immediately; in this case the cleaner
must be cleaned straightaway.
Attention!
Before starting the engine, check that the environment in
which you are to work is suitable for the mixture of har-
mful exhaust gases. Also check that combustible fuel gases such as
hydrocarbons are not present in the ambient air.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

10
STARTING INDUSTRIAL ENGINES
Engines type 8065E, 8065SE, 8065SRE - with distributor injec-
tion pump - fitted with Iveco Motors instrument panel (optional)
WITH COLD ENGINE
1) Bring the accelerator lever to 1/2 of its maximum travel
2) Turn the key from position "A" to position "B". The alarm indica-
tors and buzzer are activated for about 2 seconds
If an air pre-heating system is fitted (for 8065E/SE only):
3) Turn the key from position "B" to position "C", keeping it there for
about 20 seconds
4) Press the key right in and turn to position "D", until the engine star-
ts. If the engine does not start reset the key to position "A" and re-
peat the operation from point 3;
5) Once the engine has started, operate the accelerator strai-
ghtaway, bringing the lever to a position where engine speed is just
above minimum.
WITH WARM ENGINE
1) Hold the accelerator lever at minimum
2) Turn the key from position "B" to position "D" and release it as
soon as the engine starts.
ATTENTION: Indicator "7D" showing pre-heating completed is
not connected.
1. Buzzer
2. Oil gauge
3. Water temperature gauge
4. Voltmeter
5. Rev counter/hourmeter
6. Engine stop button
7. Starter/stop switch
8. Alarm indicators
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

11
ENGINES WITHOUT IVECO MOTORS
INSTRUMENT PANEL
If the engines are not fitted with an Iveco Motors instrument panel,
the starting instructions given previously may vary according to the
type of control panel fitted to the machine on which the engine is in-
stalled (see the instructions supplied by the machine's manufactu-
rer).
GENERAL GUIDELINES FOR STARTING
(valid for all engines)
Release the starter control as soon as the engine starts so as not to
damage the engine and starter motor.
Remember that it is not efficient, in terms of reaching the operating
temperatures, to keep the engine idling.
After about 1 minute start to use the engine but avoid using it at high
output.
STOPPING THE ENGINE
1. Before stopping the engine, let it idle for a few minutes with no
load; this allows a uniform reduction in the water and oil temperatu-
re, avoiding serious damage to the engine caused by thermal shock.
2. The engine is stopped as follows:
- de-energise the stop solenoid incorporated in the pump.
- for engines 8065SE and 8065SRE it is also possible to operate the
stop lever (mechanically or electrically).
If the engines are fitted with Iveco Motors instrument panels (optio-
nal), the engine is stopped by pressing the stop button (6) or by tur-
ning the starter key to "A".
WATER PRE-HEATING
(electric 220 V, single-phase - optional)
This device, supplied on request, is provided to aid starting at low
temperatures or in circumstances where an immediate supply of
power is required. It incorporates a thermostat which cuts off the
supply when the set temperature is reached.
WARNING!
Always check that the equipment is properly earthed.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

12
PRECAUTION FOR NORMAL OPERATION OF
THE ENGINE
- Increasing engine speed from idling to full speed and viceversa
must be achieved gradually in order to ensure perfect combustion
and trouble-free operation of all the engine components.
- The speed/power values in engine use must conform to the speci-
fications given in the technical/commercial documentation.
- During engine operation, monitor the following points:
Engine cooling system - Check that the water temperature is
kept within the maximum permitted values as specified in the table
"Main regulation and repair data". If the water temperature is exces-
sive, check the cause consulting the table "Engine fault diagnosis".
When topping up the engine coolant, follow the instructions given in
the paragraph "Checks and maintenance".
Attention!
Never open the water filler plug when the engine is hot.
The cooling system is pressurised and the hot liquid will
be expelled violently if the pressure is released too violently, causing
burns.
Lubrication system - Check that the oil pressure, with the en-
gine hot and operating at normal speed, falls within the limits indica-
ted in the table "Main regulation and repair data". If the oil pressure
does not correspond to the values indicated check the cause for this
by consulting the table "Engine fault diagnosis". When topping up the
oil in the lubrication system, follow the instructions given in the pa-
ragraph "Checks and maintenance".
Fuel system - Avoid working with the fuel tank at minimum re-
serve levels so as to prevent the formation of condensation and fai-
lure of the system due to intake of air, which causes the engine to
stop
Attention!
When filling up with fuel be particularly careful that the
solid or liquid pollutants do not enter the tank with the
fuel. Do not smoke or use naked flames.
Intake and exhaust system - Check regularly that the air in-
take system is clean. The maintenance intervals change according to
the working conditions. In particularly dusty environments more re-
gular cleaning is required; follow the instructions set out in the para-
graph "Checks and maintenance".
Attention!
Visually inspect that the exhaust system is not blocked or
damaged so as to prevent dangerous fumes.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

13
Electrical starter system - Check the battery state of charge
regularly, particularly during the winter months.
When topping up the electrolyte level in the batteries, follow the in-
structions set out in the paragraph "Checks and maintenance".
Attention!
Do not smoke or bring naked flames in the vicinity of the
batteries to avoid explosions.
RUNNING IN (50 Hours)
Avoid using the engine for long periods, at high output.
After the running-in period remember to carry out the operations
indicated in the paragraph "Checks and Maintenance".
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

14
CHECKS AND MAINTENANCE
INTRODUCTION
The checks indicated in this section can be carried out either by
the workshop or by the machine user.
The routine maintenance operations, identified by the key
symbol, must be carried out by qualified personnel who have the ap-
propriate equipment and protections.
The non-routine maintenance operations identified by
the spanner symbol, given their particular nature, must be carried
out by authorised workshops equipped with appropriate equipment
and with the proper technical information.
DURING MAINTENANCE
- Never wear loose clothing, rings, bracelets and/or chains when
working next to engines or moving parts.
- Use protective gloves and goggles:
. when topping up batteries with acid
. when topping up with inhibitors or anti-freeze
. when changing or topping up the lubricating oil (hot engine oil can
cause burns when it is drained. Let it cool down to under 50°C).
Use goggles if compressed air is used (in this case the maximum
pressure of the air, used for cleaning, must be under 2 Atm (30 psi,
2 kg/cm2).
- Use the protective helmet if working in an area with suspended
loads or with installations at head height.
- Always wear safety shoes and overalls.
- Use protective cream for the hands.
- Always change out of wet overalls.
Attention!
Avoid carrying out maintenance when there is live voltage;
always check that the equipment is properly earthed.
During regulation operations make sure that you have dry hands
and feet and use insulating platforms.
- Never carry out repairs with which you are unfamiliar. Always fol-
low the instructions and, if these are not available, contact the sup-
plier or qualified personnel as described above.
- Always keep the engine clean, eliminating oil, diesel and/or coolant
stains.
- Place dirty rags inside flameproof containers.
- Do not leave rags on the engine.
- Use suitable secure containers for used oil.
- When you start an engine after a repair, take steps to stop the in-
take of air in case of over-rewing on starting.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

15
CHECKS
Regularity
Check oil level in sump ..............................................................daily
Check water level in radiator (1)................................................ daily
Check air cleaner for clogging (1)............................................... daily
Check radiator/intercooler for restriction (1) ............................daily
Check electrolyte level in batteries (1) (2).............. every 300 hours
ROUTINE MAINTENANCE
Regularity
Change engine oil (2)(4)(5) ________________________300 hours
Change oil filters (2)(4) __________________________300 hours
Change fuel filter (2) __________________________ 300 hours (3)
Clean fuel pump filter (2) ______________________ 300 hours (3)
Adjust drive belt tension (2) _______________________300 hours
Adjust valve clearance ____________________________900 hours
Calibrate injectors and possible nozzles replacement
(as service items)________________________________900 hours
NON-ROUTINE MAINTENANCE
During its life the engine will also require certain specialist opera-
tions to be carried out, such as: valve seat dressing, turbocharger and
heat exchanger cleaning, injection pump, water pump and electrical
system overhaul.
Consult the Iveco Motors Service Network which is available to give
you advice and carry out the above operations promptly using fully
trained and professional personnel to ensure that the engine has a
long and efficient life.
Replace crankshaft damper (1):
- engines 8065E00 __________________________ 9000 hours (6)
- engines 8065SE00, 8065SRE10 _______________ 6000 hours (6)
(1)The regularity of these operations can vary depending on engine use
and the ambient conditions in which it operates.
(2)These operations must be carried out annually even when the speci-
fied operating hours have not been reached.
(3)Maximum period, with high-quality fuel; it may vary depending on fuel
contamination.
(4)Change after the first 50 hours of service (running-in).
(5)If fuel with a sulphur content of more than 0.5% is used, the engine
oil change intervals must be halved.
(6)Whenever the engine is subject to a general overhaul.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

16
ROUTINE CHECKS
ENGINE OIL LEVEL CHECK
Carry out the check with the engine off, cold and with the machine
on the level.
Check that the oil level falls between the "Min" and "Max" limits
etched on the dipstick. If necessary, top up through the oil filler, after
turning the cap anti-clockwise.
WARNING
The level must never exceed the "Max" mark etched on
the dipstick. After the check, reposition the dipstick cor-
rectly and fully tighten the filler cap, turning it clockwise as far as it
will go.
RADIATOR WATER LEVEL CHECK
Carry out the check with the engine off and cold.
Remove the radiator water filler cap by turning it anti-clockwise and
inspect the water level.
The level must never exceed two thirds of the height of the reservoir
to allow for an increase in volume when the engine is hot.
If necessary, top up bearing in mind that overfilling may, during engi-
ne operation, result in excess water being expelled from the drain
pipe or pressure relief valve.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

17
To top up, use a mix of clean water and anti-freeze/corrosion inhibi-
tor of the type described in the "Capacities" table.
During the winter months, check that there is the correct percenta-
ge of anti-freeze to prevent the engine being damaged by ice.
Different water level check procedures may be required depending
on the various cooling system configurations of the machine on whi-
ch the engine is installed.
Attention!
Never open the water filler cap when the engine is hot.
The cooling system is pressurised and the hot fluid will
spurt out if the pressure is released too quickly, causing burns.
AIR CLEANER CONDITION CHECK
As previously indicated in the paragraph "Before starting", if the air
cleaner requires cleaning, proceed as follows:
- stop the engine and leave to cool
- lift the cleaner cover A turning the wing nut B anti-clockwise
- turn the retaining nut D anti-clockwise and take out the external
cartridge C, making sure that no dust gets into the hose.
Pay attention to the following advice when working on the cartridge:
- never strike the cartridge with tools
- clean the cartridge with dry compressed air working from the in-
side outwards from the inside (the pressure must not exceed 2 bar
so as not to damage the cartridge);
- check the condition of the cartridge before removing it, using a
lamp to light up the inside;
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

18
Change the cartridge if it has any tears or holes;
- check that the seal on the base of the cartridge is in good condi-
tion.
Some air cleaners are fitted with a safety cartridge (optional); this
cartridge (E) must never be cleaned but changed every 3 changes of
the external cartridge.
To refit, reverse the dismantling operations, checking that the cartri-
dge is housed correctly in its seat.
WARNING
If the cartridge is not properly fitted, unfiltered air could
enter the engine and cause serious damage. Where possi-
ble, have the above operations carried out by qualified personnel.
After the work on the cartridge has been completed, the mechanical
clogging indicator (see figure opposite) must be put back into ser-
vice by pressing the special button located at the top of the indica-
tor.
The electrical indicator does not require this operation.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/

19
RADIATOR/INTERCOOLER RESTRICTION CHECK
(AIR/AIR for SRi 26/27)
Check that the air input surfaces in the radiators are free of dirt
(dust, mud, straw etc.) and clean them straightaway using compres-
sed air/steam.
The use of these cleaning methods means that suitable protection
must be worn on the hands, face and eyes.
BATTERY ELECTROLYTE LEVEL CHECK
With the batteries out of service and cold, check that the electrolyte
level falls between the "Max" and "Min" limits; if the level is below the
minimum, top up with distilled water.
During the summer months, check the level more frequently.
If the engine is unused, check the electrolyte monthly and, if the bat-
tery needs to be recharged, consult a specialist workshop.
Also check that the terminals and clamps are clean, tightened and
protected with vaseline.
Attention!
The batteries contain highly corrosive sulphuric acid;
when topping up with distilled water wear protective glo-
ves and goggles. Where possible, have the above operations carried
out by qualified personnel.
Do not smoke or bring naked flames within the vicinity of the batte-
ries to avoid explosions.
BDC for engine manuals and specs
https://barringtondieselclub.co.za/