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Iveco Aifo 8001 User guide

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8001
3·4
cylinders
INDUSTRIAL
ENGINES
l
Use
and
maintenance _Usa emanutenzione -Emploi
et
entretien
_Betriebsanleitung
Ii
Usa ymanutenci6n IVECO aito
Thank you for deciding on Iveco Aifo and at the same time,
we
would like
ta
congratulate you on your choice.
We request that you read the operating and maintenance instructions regar-
ding your new engine.
If you follow these instructions, you can ensure that your englne will operate
pertectlyand have along service life.
We would Iike
ta
remind you thatthe Iveco Aifo Servlce Organization is always
at yaur disposal whereever yau
may
be,
ta
pravide yau with ahigh degree af
efficiency and professional advice.
Warranty
To ensure best possible engine efficiency and take avail
of
warranty benefits
you
must
foHow
scrupulous!y all the instructions provided herein.
Rememberthat
failure
ta
complywith
or
incorrect pertormance
af
recommen-
ded
service operationswill invalidate the warranty.
Spares
The exclusive use
of
Iveco Original Parts is aprerequisite for excel1ent mainte-
nance
of
the engine.
Orders should specify:
-engine technical code and serlal
number
-part number ofthe component
(see
Spare Parts Catalog).
ENGLlSH
Responsibilily
The information contained in this manual is correet at the publication date.
The manufacturer reserves the right to make any modification without notice,
at anytime, for technical or commercial reasons
ar
ta
comply
withthe laws of
the different countries and disclaims all responsibility for
any
errors
ar
amis-
sions.
SAFETY REQUIREMENTS
Basic rules
The
tollowing
recommendations indicate
how
to reduce the risk
af
damages
ta
persons
ar
goods
when the system is either in/ar
out
of
service.
-The
engines
must
never be used
tor
any
purpose otMer than
that
agreed
by
written
with
the manufacturer.
ArJy
other applications
must
be
subjectto
aspe-
cial
agreement
with
the manufacturer and
must
include safetyspeciflcations.
-Anyform
oftampering,
modification
orthe
useofnon-genuinepartsmaycom-
promise
safetystandards.
-The present recommendations have to be applied considering the pertinent
regulations
af
the various Countries.
Maintenance
-
VVhen
working
nearthe
engine arany
moving
parts,
do
notwearbaggyor
100-
se-fitting clothes, rings ar necklaces.
-PJways wear protective gloves and g0991es :
·when
topping
up
the battery acid;
·when
topping
up the inhibitoragent or anti-freeze fluid;
;when either changing or
tapping
up
oil (hot
motor
oil can cause burns, leave
it
to cool to atemperature
of
less than 60° Cbefore draining
);
·when using compressed air (the
maximum
air pressure which
may
be used
forcleaning
parts
must
be
below
2atm. or 30 psi, 2
kg/cm
2
j.
~
Nways
wear
aprotective steel-cap wheneverworking in areaswhere there are
overhanging loads orwhere the machinery is
at
head height.
-ftJways wear safety boots
and
overalls.
-Use protective creams
tor
the hands.
~
Immediately replace wet overalls.
2
-When
working
on
components
which
may
be carrying an electrical charge,
always ensure that both
the
hands
and
teet
are completely dry. When
neces~
sary,
perform
the
work
using anon-conducting
work
platform.
In
anycase,
it
is
mandatory
that
the person performing
any
of
its kind
af
works
is
both experien-
ced and qualified.
~
No person should
attempt
to
pertorm
any
maintenance operation
nor
adju-
stmentsiftheyare
notfamiliarwith
theprocedure. The instructions
mustalways
be
closely followed and, in their absense, the
supplier
or qualified personnel
should
be
contacted. f
-Always keep
the
engine clean
by
removing all oil, diesel
and/ar
coo!antwhich
may
be
splashed on it.
~
Dispose
of
oil rags in fire
proof
containers.
-Never leave rags on
the
engine.
-Use containers
of
suitable size and safetyfor the disposal
of
old engine oil.
-When starting on engine after having carried
out
repairs,
always
take stepsto
stop
air intake in case their should be atrouble-shutting
during
start-up.
Engine cooling system
-Never
add
cootantto an overheated engine-always wait for normal
water
de-
grees.
-Regu!arly
check
the coolant leve!
and
top
up when necessary using
only
the
recommended
Iiquid.
The water used jn the engine cooling system
must
be
e1ean
and
as
free
as
pos-
sible
from
corrosive chemical and materials.
Artlficially softened water
must
never be used in the coolin9 system; it
is
pos-
sible to prevent the formation
of
rust
and
corrosion
byadding
rust inhibitor
agents
to
the
water as
recommended
by
the manufacturer.
~
During the colder
months
regularly measure the speclfic gravity
of
the
anti-
freeze
mixture
to
ensure the
adequate
protection
of
the engine.
-
Always remove the radiator cap slowly.
The
cooling system
is
general1y under
pressure and, when hot, thecoolant
mayviolently
blow-Qut
ifthe
pressure
is
re-
leased too rapidly.
•Regularly check the drive belts for correct tension and usage limits.
Lubrication system
Regularly check the level
of
the sump oil,
topping
up when necessary.
-
Orain
and refill the oil at the indicated intervals
by
the manufacturer using
an
oil of the recommended characteristics and viscosity as indicated in this pub-
licatlon.
Fuelsystem
•
Tryto
keep the fuel tank
as
full
as
possible, in this
way
itis possible to reduce
the condensation into the tank.
-Periodicallydrain the fuel tank
to
remove water and sediments.
•Renew the fuel filter periodically, mainly if there isa
drop
in the engine'spres-
sure of performance.
-Never smoke nor lightduring refuelling.
Inlet and exhaust system
•Regularly check the condition of the air filter. The maintenance intervals will
varyaceording
to
the weather and operating conditions.ln particularlydusty
10-
cations it will be necessary
to
perform maintenance
to
the element more fre-
quently.
-Visually check the exhaust system for the presence
of
oil, which
may
indica-
te oi! ieak, and immediatelyrepair any malfunctions if detected
to
avoidtherisk
offire.
3
Ignition system
•Periodically check the battery eleetrolyte level and top
up
when necessary
using distilled water only.
-Keep the battery
e1ean.
_T0avoid risk of not necessary staft-up, disconneet the batteryearth terminai
beforeworking onthe engine. Ensure that
an
eventualengine'sautomaticigni-
tion system is not activated while work
is
on duty.
_PJways disconnect one
of
the starter moter terminals when working on
an
eventual generating set alternator.
•Ensure
that
all connections are correct and tightand that the insulation on
all
electrical wires
are
in asatisfaetorycondition.
_During recharging, the batterygivesoff acertain arnount
offlammable
gas, it
is therefore
mandatorythat
the area mustbe well ventilated, that
no
personnel
smoke,
and
that there are
no
naked flames near
the
battery.
_To reduce the likelihood of arcing,
it
is
good practiceto always reconnectthe
battery's positive terminaI first and then the negative (generallythe earth).
-Periodica!lycheckthe alternator drive belts for correct tension.
TABLE OF CONTENTS
Page
Engine identification data
,.,
.4
_Englne description 8031 i05............
..
5
Engine description
8041
i05 ,...... . 6
Engine description
8041
Si
25..... . 7
Engine
specifica.tions
8031
j05....................
..
,", , , ,,9
Engine specifications
8041
i05.................. .
11
Engine specifications
8041
Si
25., ,
..
,."
,,',
..
,13
Fillup data ""."",,............ .
15
Routine maintenance .
21
Special maintenance
.,
".,
,27
Long inactivity instructions ,
..
"
31
Supplementtorgenset engines:
-8031
i05A500-8041
i05A500
33
ENGINE IDENTIFICATION
DATA
Engine technical code and serial
number
are punched on aplate located on
the tlywheel cover.
Note:
Nways
specifyengine technical code and serial
number
when ordering
replacement parts and tor after sales services,
4
----
---------------------
45
8,
2
6
36
2
3
7
Engine
8031
i
05
-Right hand view
1-lntakemanifold -
2.
Fuel
filters-
3.
Starting motof-4.lnjection
pump
-
5.
Ther-
mostat
socket·
6. Gil tiller cap -
7.
Fuel
pump
-
8.
QiI
drain plug.
Engine
8031
i
05
-Left hand view
1.
A1ternator·
2.
Alternatof-water
pump
drive belt -
3.011
dipstick -
4.
Exhaust
manifold -5. Gil filter -
6.
Engine breather-
7.
Qil drain plug -
8.
Fan
(option).
5
6
Engine
8041
i
05
-Right -hand view
1.
Intake manifold
~
2.
Fuel filters -
3.
Starting mater •
4.
Thermostat socket -
5.
Oil
fitJer
cap -
6.
lnjection
pump
-
7.
Fuel
pump
-
8.
Fan (option).
6
Engine
8041
i
05
-Left-hand view
1.
A1ternator -
2.
Alternator-water
pump
drive belt -
3.
Gil
dipstick-
4.
Exhaust
manifold -5. Oil filter -
6.
Engine breather -
7.
Qil drain plug.
6
•
•
Engine
8041
Si
25
-Right hand view
1.
Intake manifold •
2.
Fuel
filter·
3.
Starting
mator
-
4.
Gil drain plug -
5.
OH
fil-
ter
cap
-6. lnjeetion
pump
-7. Fuel
pump
-
8.
Thermostat socket -
9.
Oil dip-
stick.
7
Engine
8041
Si
25
-Lefl-hand view
1.
Engine breather -
2.
Gil filter -
3.
Oil water heat exchanger -4. Oil
drain
plug
-
5.
Alternator-water
pump
drive
belts·
6.
Fan
-
7.
A1ternator -
8.
Exhaust mani-
fold -9. Turbocharger.
Fuel filtration
by
replaceab!e cartridge filter.
Fuel
supply
by
dauble
diaphragm
pump.
lnjection
pump
type: C.A.V. -DPS with rotating piston distributor,all-speed
go~
vernor
and
variator advance incorporated.
Rxed injection
pump
deliverystart advance 00±10
Fue! injectarssetting
",
230 +8
kg/cm
2
Rring order
".,
1-2-3
FUELSYSTEM
Clearance between valve and rockers for
timimg
checks
...
..
.... 0,45
mm
Operating clearance between valves
and
rockers, cold engine:
~
intake
and
exhaust " ·
..
·0.30
mm
..
,
eew
335
kg
ENGINE SPECIFICATIONS
Engine
type "................... .
8031
i
05
4 - stroke Diesel with direet injeetion
Cylinders,
number
and arrangement. .....
3,
in line
Sore xstroke.....................
..
104 x115
mm
Displacement.
..
,2,9 I
Compression ratia .
17:
1
Maxlmum
ratlng(*):
..
44
kW
(60
eI/)
At
..
2500
rpm
Engine rotation:
(see
from flywheel)
..
'......
Dryweight. .
1*)
ISO
Fuel
Stop Power
-Ambient reference conditions:
ISO 3046/1 ;
25
0
C;
100
kPa;
30% relative humidity.
TIMING
..
..........
48
030'
.. ..
60
. 3 0
..
23 0
..
2,5 kg/cm'
..
0.7
kg/cm'
Overhead varves controlled
by
pushrodsand rockerswith camshaft in crankca-
se.
Gear-driven
camshaft.
Valve
timing:
-Intake
open: before T,O,C.
c1oses:
after B.D.C.
~
Exhaust
opens: before B.D.C.
closes: after T.D.C.
LUBRICATION
Forced-feed lubrication
by
gear-pump
driven
by
crankshaft.
Pressure relief valve secured ta the oil
pump.
Tota! and continuous oil flltering
by
areplaceable cartridge filter.
Gil cooling with oil-fresh water heat exchanger.
Minimum
oi! pressure:
-
at
tuli
throttle....
..
.
-when
idling
.,
..
9
rCOOLlNG SYSTEM
Forced water circulatlon controlled
by
centrifugal
pump.
Watertemperature contfolled
by
thermostat.
Radiator cooling fan drive
by
V-belt.
STARTING
By
starter mator.
ELECTRICAL SYSTEM
-Voltage
..
~
Self-regulated
altern,ator
-Power
af
starter
mator
" .
-8attery (optionai)
............... .12V
..............................14V,45A
.........................................
3kW
......................176Ah
10