Iveco Aifo 8001 User guide

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

ENGlNE SPECIFICATIONS
Duplex replaceable cartridge fuel filte.
Fuel
supply by double diaphragm pump.
Injection pump type : CAV.· DPSwith rotating piston distributor, all-speed go-
vernor
and variator advance incorporated.
Hx.ed injection pump deliverystart advance ,O0±10
Fuel injectors setting 230 +8 kg/cm 2
Rring order , , , , ,1"3-4-2
FUELSYSTEM
Clearance between valve and rockers for timimg checks, 0.45 mm
Operating clearance between valves and rockers, cold englne:
•intake " ., , " 0.30 mm
.. 8041i05
.........4, in line
..1Q4x 115mm
.. 3.91
.. 17 : 1
... 59 kW (80 CV)
. 2500 rpm
Engine rotation:
(see
from flywheel) .. CCW
Dry weight..... - 415 kg
(')ISO Fuel Stop Power
~Ambient reference conditions:
ISO
3046/1; 2ff C; 100 kPa; 30% relative humidity
Engine type , .
4 -stroke Diesel with direet injection
CyHnders, number and arrangement .
Sore xstroke ..
Displacement .
Compression
ratia.
Maximum rating(*): " .
At .
LUBRICATION
........................................................2.5 kg/cm'
..................................................... 0.7 kg/cm'
TIMING
Overhead valves controlled by pushrodsand rockers with camshaftin crankca·
se.
Gear-driven camshaft.
Valv8 timing:
-Intake
open: before T.D.C , ., ,3 0
closes: after B.D.C. ,... . 23°
-Exhaust
opens: before B.D.C..,,,.....
.. 48 030'
closes: after TD.C....
.. ..... ff'
Forced-feed lubrication by gear-pump driven by crankshaft.
Pressure relief valve secured
ta the oil pump.
Tatal and continuous oil filtering bya replaceable cartridge filter.
Minimum oil pressure:
- at full throttle .
- when idling .. , .
11

COOLlNG SYSTEM
Forced water circutation controlled by centrifugal pump.
Water temperature controlled bythermostat.
Radiator cooling fan driven by V~belt.
STARTING
Bystarter mator.
ELECTRICAL SYSTEM
"Voltage.""""" """""" .. "" "",, .. ,,",, ""."",,.,," """""",, 12V
~ Self-regulated alternator 14V, 45 A
~ Starting mator power . , 3 kW
-Battery (optiona!) "" """"""""". """"""""""""""""""""""""""".176Ah
12

Fuel filtration by replaceable cartridge filter.
Fuel supply by double diaphragm pump.
Injection pumptype :C.A.V," OPS with rotating piston distributor, all-speed go-
vernorand variator advance incorporated.
Boostcontrol (LOA) on injection pump .
Fixedinjectionpumpdeliverystartadvance... . 0 0±10
Fuel injectorssetting .. "... .. ,230 +8 kg/cm 2
Firing order ,... . " 1-3-4-2
Clearance between valve and rockers for timimg checks 0.45 mm
Cperating clearance between valves and rockers, cold engine:
-intake and exhaust 0.30 mm
TURBOCHARGER
FUELSYSTEM
.. 8041 Si 25
......................................... CCW
- 400 k9
.... .4, in line
. " 1Q4x 115mm
................................................3.91
........................ 16.5: 1
85 kW (115 CV)
.... 2500 rpm
ENGINE SPECIFICATIONS
Engine type .
4 - stroke Diesel with direct injection
Cylinders, number and arrangement ....
Sore xstroke " .
Displacement .
Compression ratia
Maximum rating{*): ..
At ..
Engine rotation:
(see from flywheel) .
Dryweight .
(*) ISO Fuel Stap Power
-Ambient reference conditions:
ISO 3046/1 ; 25' C; 100kPa ; 30% relative humidity.
TIMING
The engine is supercharged by turbocharger driven by the exhaust gases.
The turbocharger is lubricated with the engine oil under pressure.
Forced-feed lubrication by gear-pump driven by crankshaft.
Pressure reUef valve secured ta the oil pump.
Tota! and continuous oi! filtering bya rep!aceable cartridge filter.
Oil cooling with oil-water heat exchanger.
Minimum oi! pressure:
"at ful! thrott!e ..2.5 kg/cm
2
-when idling .0.7 kg/cm
2
LUBRICATION
........................................... 30
........ 230
Overhead valves controlled bypushrods and rockers with camshaft in Cfankca~
se.
Gear-driven camshaft.
Valve tirning:
-Intake
open: before r.D.C.
closes: after B.D.C. '" .
-Exhaust
opens: before 8.0.C "48 030'
closes: after T.D.C....... . ff>
13

COOLlNG SYSTEM
Forced water circu!ation controHed by centrifugal pump.
Water temperature controlled bythermostat
Radiator cooling fan driven byV·belt.
STARTING
By starter mator.
ELECTRICAL SYSTEM
·Voltage........................................ . , 12V
-Self-regulated a1temator 14V,
65 A
·Starting motorpower , 3 kW
• Battery (optionai) 143 Ah
14

FILLUP DATA
Item
Water circuit 8031 i 05
- 8041 I 05-S1 25
Quantity
I kg
-5
-6,7
Product
Water
(1)
1) Use waterwith 30% of FIAT PARAFLU 11 antj~freeze; use the same amount
of antl-freeze
even during the summer months to prevent corrosion.
/J.$an option, productshaving similar-characteristicscan be used, providedthey
complywith international standards
SAE J 1034
2) This quantity re!ates to periodical 011 changes.
Engine sump and filters
(totai capaclty)
8031 1 05 7,7 7
-8041105
11,5 10,5
- 8041 SI25 10.5 9.5
Oli (31
Engine sump only:
~ Mln.level 8031 i 05
4,4 4
-8041105 7,2 6,5
- 8041 Si25 6.4 5.8
-
Max. level (2) 8031 i 05
6,6
6
-8041i05 10,5 9,5
-8041
SI25
9
8.2
Fuel tank -Automotive
Diesel oli (4)
15
3) Recommended oil: Rat Oil Urania Turbo LD (M1L.L-2104E) af 9CMCD5.
Qualrtity of
oil requires in relation to outdoortemperature, see table.
4) For filling fuel tank use funnel with avery fina meta] strainer to prevent filter
clogging caused
by impurities in the fue!.

.-
"-
/\
-
3S
95
0.
0
..-
UJ
<l:
0
V)
:t
0
?;
'"
UJ
'"
<l:
-
V>
UJ
<l:
.,
Vl
50
10
~
•
L,.
0
N
32
0LU
/';,.
~
14
10
~
-
1" l,
LU
f--
<l:
5
-15
Vl
-
'" '7
-Il
25
'F
'c
16
USE OF ENGINE OIL
URAN IA
Far efficient engine operation SAE viscosity should be as indicated in relation
to outdoortemperature.

on
RUNNING-IN (50 hours)
_After starting, slowlywarm up the engine when running, without reaching full
throttle.
_ 00 not run engine for a long period at tuli throttle.
•Check
oillevel frequently.
The following operation are
needed after running-in:
- Eng ine oil change
~ Cartridge oil fi!ter replacements
BEFORE STARTING
When the engine has been out of action for long periods:
-check
the level of the lubricants
•bleed the air from the tuel circuit.
Only
for supercharaed engines:
-keeping
the accelerator lever at minimum tum engine bymeans of starter me-
torfor apprax. 20-30 secs. This is necessaryto ensure iostant lubrication of the
intemal gear of the turbocharger on engine starting.
Eva[\{ day:
-check the leve! of the tue!, engine oil and fresh cooling water
-check to ensure thatthe airfilter on the intake pipe is not clogged.
17
PRECAUTION IN THE USE OFTURBOCHARGED ENGINES
The turboeharger is an integral part of the engine.
Very often faults are attribuited ta the turbocharger when the real trouble !ies
with the
engine Dr with one af the flttings.
Ta avold pointless downtimes and ta extend turbocharger life and efficiency,
some basicaHy important instructions are given below.
1- Possible causes
af turbocharger trouble are essentiaHythree:
a) Laek af lubricant: causes bearing failure with consequent seizure af rotary
components.
b) introduction offoreign matter: poor setvicing of aircleaner will involve the in-
troduction of solid particles which will damage the compressor-impeller bla·
des:
fragments would then be carried to the cytinders.
c) Lubricant contamination: thiscausesscoring of journalsand bearings, clogs
oil passages, wears the seals, with consequent leakages and seizures.
Important:
It istherefore recommended thatyou take utmast care in cleaning
the air c1eaner and air ductings: also, renewengine oil supply and filters at the
specified setvicing intetvals.
2-
Turbocharger construction simplicity is only apparent: in faet many af its
parts are
maehined to 1/1000mm tolerances.1t is therefore reeommended that
you entrust any setvicing to skiUed personnel having availability of special
equipment provided by the setvice network.
3- Preventive maintenance will extend the life and efficiency af the turbocher-
ge3.
Should you notibe los3 of lubricant, vibrations ar abnormal noises, stop
engine immediately. Timelyservicing will avoid costly and unexpected repairs,
4- Turbocharged engines impose simple though essential precautlons durlng
engine starts and shutdowns.

ATIENTION !For the best lubrication af the turbocharger we advise ta let the
engine run without loact foratleast 30 seconcts when starting and at least3mi-
nuteswhen stopping Qonger periods could be necessary accorcting ta the ser·
vice).
STARTING UP
-Push accelerator lever ta travel end.
-Insert lock switch key and push contral Jever ta the stop.
- 00 not release lever untH engine has asufficientimpuJse. Dnce engine isstar-
ted properly, act on the acceJerator without running immediately at high spe--
ed.
STOPPING THE ENGINE
Position the accelerator lever to zero, and after allowing the engine ta lelle at
low speed for afew mlnutes, bring back the starting switch keyto zero.
18
PRECAUTIONS FOR PROPER ENGINE FUNCTIONING
Run engine from ielle to full throttle anel vice versa graeluallyto ensure satisfac~
tory combustlon and properfunctioning of ali components.
Ävoid running the engine at full throttle ior long periocls of tlme.
VVhen the engine is running make sure that:
~ Fresh oooling water temperature are maintained normal, Le, green zone on
temperature gauge,
~ temperature is excessive, check:
a)vee~belt tension on water pump-alternator
b) properfunctioning of thermostat,
c) heat exchanger, deaning condltion,
-Engine oi! pressure when hot and at normal engine speed must be in green
zone of pressure gauge.
COLD CLlMATE PRECAUTIONS
VV'hen temperatures approximate 0° C, make sure water is mixed with proper
amount of FIAT Paraflu 11 which prevents oxidation, corrosion, foaming, fou-
ling and freezing down ta -20 0Cwith Paraflu 11 admixed to 30%.
Do not remove the f!uid jn the other seasons but renew it every 2years.
r

BLEEDING OF THE WATER COOLlNG SYSTEM (AT EACH
NEW REFILLlNG)
Loosen completelythe bleed plug Aof the cooHng circuit.
Fill slowly the cooling liquid through the tiller cap ot the radiator, to the top.
~er Verify on the cylinder head; where the bleed plug Ais located, that the water
IU· tjows withoutair bubbles, then tighten the plug. RII completelythe cooling cir-
cuit through the fi!lercap
af the radiator.
.0-
'n
BLEEDING OF THE FUEL SYSTEM
(C.A.V. DPS INJECTION PUMP)
Loosen thebleed plugs 1 Qow pressure circuit) ofthe tuel filter and ofthe injeo-
tion pump, then operate repeatedlythe !everAot
thefuel pump: when the tuel
flows without air bubbles, tighten p!ugs
1.
Then ble~dthe injection pump, looseningthe plug B(high pressure circuit) and
turn the engine
by means ot the starting motor and, in the sametime, actuate
on the accelerator lever,
so thatthe possible tuel pump air comes out.
When
th~ tuel flows witholit air bubbles, tighten plug B.
19

F
ROUTINE MAINTENANCE
Operations Daily Every Every Every Every Every Every
100h
200 h
400h 800 h1000h year
Checking sump oil level •
Checking radiator water level •
Draining the condensate from the tuel tilter •
Checking battery electrolyte level and charge •
Changing engine sump oi! •Y
Checking drive belttension and conditions •Y
Changlng oil filter cartfidges •Y
Changing tuel tilter cartrldges MY
Cleaning tuel pump tilter •y
Checklng valve clearance tirst check •
Checking tue! injeetor setting •Y
M=Maximum operating time with high qualitytue!.
Y=Qperations ta be aceomplished at least every year regardless ot operating hours.
21