66 ENGINE TURBODAILY INTERCOOLER

FUEL SYSTEM

FIGURE 235
)

2
, 4
5

3 9
I 8:--ttIHI

2~866

FUEL SYSTEM DIAGRAM

I. Solenoid Valve for Thermo-starter - 2. Thermo-starter - 3. Fuel Filter - 4. Transfer Pump - 5. Injection Pump. 6. Thermo-starter Circuit Valve - 7. Injectors • 8.
Fuel Tank - 9. Fuel Pump.

The fuel system comprises: When the pressure of the excess fuel is greater than
o dry air filter; the calibrated pressure (OJ bar) of the single-acting
o fuel filter; valve (6), it is sent back to the tank. When starting the
o fuel tank; engine in ambient temperature conditions below
o pipes; 2° ± 2°C, the thermostarter control device enrgizes the
o fuel lift pump; solenoid valve (I) which enables the supply of fuel to
oVER 293 injection pump with rotating distributor. the thermostarter (2). The pressure drop in the
speed governor, advance unit. excess-fuel injection thermostarter fuel supply pipe activates the single-
and LDA device; acting valve that stops the fuel from returning to the
o injectors; tank and supplies constantly fuel to the thermostarter.
o device to start engine at temperatures below 2°C With the engine running, after the post-heating stage.
(Thermo-starter). the solenoid valve (I) is de-energized; this interrupts
,
the supply of fuel to the thermostarter and causes an
DESCRIPTION increase in pressure which causes the single-acting valve
to open, thus enabling the return of excess fuel to the
Fuel is drawn from fuel tank (I) by injection pump (5) tank.
and through the filters it reaches the inlet which leads
into the intake chamber of transfer pump (4).
The transfer vane pump serves to increase the fuel
pressure to cater for increased engine speed.
The fuel' then reaches the valve which regulates its
pressure inside the injection pump.
The distriQutor plunger further increases this pressure
and pushes the fuel through the delivery outlet and into
the injectors.
Fuel that leaks from the injectors is recovered by the
backflow valve and returned to the tank.
Excess fuel which returns from the injectors and from
the injection pump will feed. when necessary, the
thermostarter (2) through the solenoid valve (I).
TURBODAILY INTERCOOLER ENGINE 67

AIR FILTER FUEL FILTER

FIGURE 239

33126

The air filter cartridge is replaced by operating from

underneath the vehicle as follows:
o unscrew bayonet wing nuts (I) and remove protec-
tive cover;
24868

If the pilot light ( I), indicating the presence of water in

FIGURE 237 the fuel filter, on the dashboard lights up, drain the
water from the fuel filter (2) by turning tap (3). Perform
bleed operations every time the filter is replaced,

PIPES

Check that fuel pipes are in good conditions and that

their connections are always well fastened, The copper
gaskets of the connections must always be replaced
when dismantling,

NOTE: When one or more fuel pipes are replaced or

simply disassembled from the injection pump or the
injectors, all pipe clamps involved must be replaced
complete with their rubber block, screw and bracket
o unscrew knob (I) and remove protective cover;

FUEL LIFT PUMP

......
", -FIGURE 240'\, ;-
, .-.-...................

19184
33128

o unscreW wing nut (I), pull out the cartridge and Check that fuel pump is working efficiently_ The self-
, replace it with a new one after having cleaned its regulating pressure should be 2.5 to 0.5 bar, if not.
seat in its housing, before replacing pump 'check that push rod stroke is
2.5 to 2.6 mm.
00 ENGINE
INJECTORS
DISMANTLING
FIGURE 241
00000
INJECTOR COMPONENTS
I. Injector body - 2. Injection Pressure Adjustment Shim - 3. Spring - 4. Plate
- 5. Spacer - 6. Nozzle Body - 7. Nozzle Retaining Nut.
Block the injector in a vice, unscrew nozzle retaining nut
(7). Remove nozzle body (6), spacer (5) with pressure
pin and spring support plate (4), spring (3) and collect
injection pressure adjustment shim from injector body.
Check that component parts do not show any trace of
wear or breakage, if necessary, replace damaged parts.
Invert dismantling operations to reassemble.
FIGURE 242
19165
NOTE: The variable pitch spring (I) is fitted correctly
when it is positioned with its larger pitch turns (2)
against the spring support plate (3).
I UKBUDAILY IN I ~KCOUL~K
CALIBRATION
FIGURE 243 )
[IJ-------'f
[IJ-------
16689
,
Injectors (I) are checked and calibrated with special
tool 9930 I I 16 (2); the calibration value must be 240-8
bar. if it is not, replace injection pressure adjustment
shim.
Also check that the liquid comes out in a uniform way
from the four holes on the nozzle; then check that no
leakage occurs when the pressure is slightly lower than
the set pressure.
.
STARTING THE ENGINE AT LOW
TEMPERATURES
FIGURE 24-4
33~3S
Insert key in the commutator and turn it to position I
(MAR). The thermostarter is automatically activated
when the temperature is below 2° ± 2°e. If the
temperature is above this value. the pilot lamp (3) will
flash only once. If the temperature is below 2°C the
thermostarter is activated and the pilot lamp will light
up with out flashing for around 35 to 40 seconds. After
this time the pilot lamp (3) will begin flashing for around
6 to I0 seconds.
Proceed to start the engine during this stage (flashing),
by turning the key to position 2 (AW).
If the flashing stage is overshot before starting the
engine. it is necessary to repeat the preheating opera-
tion.
During the engine starting stage the pilot lamp returns
to a steady light. When the engine is running the pilot
lamp will flash again for around 30 to 40 seconds.
during this time the thermostarter is in the postheating
stage.
INJECTION PUMP VER 293

FIGURE 245

-----+~;d-----15

2 ------+--¥~1£.41.,.1
-----14

5--------t7..1-~~~

,..---12

9--------:::~--__1Hf. tI1

LONGITUDINAL SECTION OF INJECTION PUMP

I. Diaphragm - 2. Adjustment Ring Nut - 3. Feeler Pin - 4. Control lever - S. Speed Governor - 6. Transfer Pump - 7. Drive Shaft - B. Cam disc - 9. Advance Unit-
10. Distributor Plunger - 1I. Delivery Connection - 12. Hydraulic Head - 13. Control plate - 14. Adjustment Pin - 1S. Counteracting Spring.
DESCRIPTION OF OPERATION
SUPPLY STAGE
NOTE: The parts mentioned in the following text refer
to Figure 247.
Due to rotation of the cam disc, distributor plunger (5)
....· 1 1 - - - - 2
rises to TDC and at the same time rotates on its own
axis. The combination of these two movements closes
fuel inlet ( I) and at the same time compresses the fuel
in chamber (2). The internal passage (5) in the
distributor plunger now connects with passage (4)
enabling delivery to injectors (6).
&

7 9

END OF DELIVERY STAGE

-
B 5 FIGURE 2-48
19198
I. Fuel Inlet - 2. Solenoid Valve - 3. Axial Groove - 4. Compression
Chamber - 5. Fuel Passage between Pumping Element and Injectors - 6.
Distributor Plunger - 7. End-Of-Delivery Hole - 8. Slider - 9. Injector.

Distributor plunger (6) is at BDC and slider (8) closes

end-of-delivery hole (7).
Fuel is sent to compression chamber (4) via fuel inlet
2
( I). held open by solenoid valve (2).

DELIVERY STAGE

.FIGURE 2-47

& 5 4 3
19200

I. Fuel Inlet - 2. Compression Chamber - 3. Delivery Passage - 4. End-Of- -J )

Delivery Passage - 5. Slider - 6. Distributor Plunger.

As it moves towards TDe. distributor plunger (6)

connects with the high-pressure internal chamber
2 through inlet (I), thus establishing a pressure balance
between internal chamber of distributor plunger, deli-
very pipe to injectors and inside of pump body.
&---+-- . Since this pressure is too low to operate the injector.
delivery ends.

5 3 4

19199

. I. Fuel Inlet - 2. Compression Chamber - 3. Internal Passage of Distributor

Plunger - 4. Fuel Passage between Pumping Element and Injectors - 5.
Distributor Plunger - 6. Injector.
STOPPING THE ENGINE

"- -
FIGURE 2-49 .-
~.
FIGURE 251 "

•.....- J - - - - 4
""".J+j~---3

'- I --tlt---t--- 2

'Z-_---5

19201

I. Fuel Inlet - 2. Mobile Plug - 3. Spring - 4. Solenoid Valve - 5. Compression

Chamber.

The engine is stopped by cutting out the starter

contact 6726
The electric current that operates solenoid valve (4) is 2 3 6 1
cut off. Spring (3) causes the solenoid valve to push
mobile plug (2) to the end of its stroke which blocks I. Plunger - 2. Spring - 3. Connecting Pin - 4. Roller Ring - 5. Locking Pin - 6.
Connecting Pin.
fuel inlet (I).
The automatic injection advance unit is embodied in the
injection pump.
This device is operated by the pressure of the fuel from
the transfer pump and controlled by the regulating
valve.
The fuel pressure activates plunger (I), resisted by
spring (2) and connected to pin (6) and roller ring (4).
by pin (3), so as to convert the reciprocating movement
of plunger (I) into the rotary movement of roller ring
(4).
As the engine speed increases, so the supply pressure
increases which moves plunger (I) of the unit in the
AUTOMATIC ADVANCE UNIT opposite direction to the force exerted by spring (2);
the spring normally holds the plunger in the retard .
FIGURE 250 position.

18588

AUTOMATIC ADVANCE UNIT COMPONENTS

I. Plunger - 2. Connecting Pin - 3. Fixed Shim - 4. Adjustment Shim - 5.
Spring.
 I UI\DVU/'\IL I II'! 1l:I\\..VVLl:1\

STARTER

FIGURE 252.

6723

I. Starter Lever - 2. Leaf Spring - 4. Slider - 5. Adjustment Sleeve - 6. Solenoid Valve - 7. Compression Chamber.

When solenoid valve (6) is supplied with power, fuel Thus the full stroke of the pumping element is utilised
flows into compression chamber (7): in this condition for the effective delivery to the injectors.
the counterweights of governor sleeve (5) are closed;
leaf spring (2) then pushes lever (I) and slider (4) into
the excess-fuel position.

STARTER CUT OFF

FIGURE 253 -

JI

7148

I. Starter Lever - 2. Leaf Spring - 3. Tension Lever - 4. Slider - 5. Adjustment Sleeve - 6. Solenoid Valve - 7. Counterweights - 8. Correction Lever.

Once the engine has started, the effect of centrifugal In this condition slider (4) moves across and causes
force due counterweights (7) opening causes adjust- minimum delivery.
ment sleeve (5) to move axially. pushing starter lever
(I) into contact with tension lever (3) and thus
compressing leaf spring (2).
START OF DELIVERY TO MATCH LOAD (LFB)

FIGURE 25-4

---------3

1+--->c:t------4

+------5

30434

STRUCTURE OF GOVERNOR ASSEMBLY WITH CORRECTION OF START OF DELIVERY TO MATCH LOAD

I. Adjustment Spring - 2. Governor Sleeve· 3. Tension Lever· 4. Starter Lever· 5. Adjustment Sleeve - 6. Distributor Plunger. 7. Governor Spindle - 8.
Centrifugal Counterweights.

DESCRIPTION

The device for correcting start of delivery to match
load (LFB) governs the transfer pressure that controls
the advance unit of the injection pump.
This allows the device to adjust the injection advance
according to the delivery of fuel when engine speed
increases or decreases. By doing so it reduces engine
noise (smoother running).
OPERATION
As the r.p.m. of the injection pump increase. regardless
of the position of the external acceleration lever, the
governor counterweights, due to centrifugal force,
move governor sleeve (4, Fig. 255) along the governor
spindle (2), thus aligning hole (3) with groove (6) and
hole (7). Part of the fuel is discharged through passages
( I and 5) into the supply chamber, thus causing a
reduction in the transfer pressure inside the pump and
therefore a reduction in the injection advance.

.
FIGURE 255
.
., ~ ~
If, on the contrary, the r.p.rl). of the injection pump
decrease, the movement of sleeve (4) will not align hole
(3) with groove (6) and hole (7). thus. since there is no
fuel discharge. the pressure inside the pump will
increase the injection advance.

NOTE: The LFB device can be adjusted only on the test

bench.

a. Sleeve at Rest· b. Sleeve in Motion· c. Sleeve in Correcting Position. drop

in internal pressure· I. Longitudinal Hole in Governor Support Spindle· 2.
Governor Spindle - 3. Transverse Hole in Governor Sleeve· 4. Governor
Sleeve • 5. Transverse Hole in Governor Spindle • 6. Groove through
Governor Axis - 7. Transverse Hole in Governor Spindle.
LDA DEVICE (ADJUSTMENT OF FLOW RELATIVE
TO LOAD)
FIGURE 258

2---+-+==:::::::
3--------'.cAftt€E~

4----~~~-

5----fF~~~~f
6~r-ttm~iiiPfQ~
3~53

Unhook return spring (2) from plate (I).

19202
FIGURE 259

OPERATION

The purpose of the LDA device is to vary the flow of

fuel in relation to the air pressure in the induction
manifold.
This air pressure acts on diaphragm (I) which forms (I)~~~~~
one part with adjustment pin (4). The bottom of
adjustment pin (4) has a tapered seat on which a feeler 0-~-
pin (6) slides.
The axial movement of adjustment pin (4) causes feeler
pin (6) to move which in turn pushes stop lever (7). The
stop lever rotates on its spindle (8) and works the 2040
control plate so as to match the flow of fuel to the·
Note position of reference marks between spindle (2)
amount of air allowed into the cylinders.
and lever (4).
Unscrew nut (3) and remove spindle (2), lever (4)
DISMANTLING THE INJECTION PUMP
complete with plate (5) and control lever (I).

FIGURE 257

m-------==~
m---I'!,~~~==~~

19203

Remove: cup (2), spring (3) and cup (4). Remove fixing
Fix injection pump (I) to plate (2) of Adjustable bolts and take off LDA cover (I).
Support 99365014.
I UI\DUUI\IL I "'I I t:1\~UULt:1\

.. FIGURE 261 FIGURE 2604

19209

Mark fitting position (see arrow) of diaphragm (I) in Unscrew spring load adjustment ring nut (I).
relation to cover (2).Take off lead seal (3) and remove
stop pins (5) and turbocharge maximum flow screw (4).
Remove plug (6).
FIGURE 265
FIGURE 262

2r-------l

19207
Remove seal plug (2). remove bleed screw ( I ), unscrew
Turn diaphragm (I) complete with adjustment pin (2) bolts (3) fixing cover to pump body.
and remove from housing.

FIGURE 263 .'" ~

19211

Remove cover (I) and pullout drive spindle (2) by

Remove diaphragm reaction spring ( I) and spacer bush pressing downwards (in direction of arrow).
(2). Remove seal from cover.
 I U~DVLJI'\IL I 11'\1 I CI"\.\",.VVLCI'\.

FIGURE 267

19212

Push out guide pin using a punch and pull out shut-off
lever (I). Measure distance between top of bush (I) and surface
of cover and note it down.
Unscrew nut (3), remove spring clip (2) and unscrew
guide bush (I) for adjustment pin.
FIGURE 268
FIGURE 271

19213

Pull out feeler pin (I) using pliers.

FIGURE 269

FIGURE 272

Unscrew ring nut (I) from cover (5), then using an

extractor, take out sealing ring (2), guide bush (3) and
seal (4).

Using Spanner 99352139 ( I) remove transfer pressure

adjustment valve.
 FIGURE 273 FIGURE 276

[IJ-----------.

Remove lock nut and washer; using an allen key

unscrew governor spindle (I). Remove solenoid valve ( I) and valve (2) complete with
internal spring.

\
FIGURE 27-4 FIGURE 277

19221

Take out speed governor assembly (I) and retain Turn the pump and using wrench 99352140 (I)
thrust washer and adjusting plate (2). unscrew the hydraulic head closing plug. Unscrew the 4
delivery connections (2).

..... FIGURE 278,' "'"

•

OJ------------:IIl'...,c""'IIII~

[I)-----------iIl~

o ~
m~ 3O~1

The speed governor assembly (I) consists of an

adjustment sleeve (3) with adjusting plug with spring 26~8
clip, shim (4) and 4 centrifugal counterweights (2).
DELIVERY CONNECTION COMPONENTS
I. Connection - 2. Spring Support - 3. Shims - 4. Spring - S. Valve Seat - 6.
Ball - 7. Spring Support with Calibrated Hole - 8. Spring? 9. Valve Body.
, U CI'4UII'4C I UI'\DVU1'\IL I 11'4 I CI'\'-VVLCf\

FIGURE 282

-OJ-~-------r OJ -,:.---=-----"-.:...:.....-----,,+-
~~
/ ml---'1L--if.SS~'f=::~~·
/
m---=-:::::;;==,:~ m--~~-i?=2T-

0--4~~

Using wrench (I) undo screws (2) fixing hydraulic head.
FIGURE 280
19226
Remove distributor plunger (I) complete with return
springs (2), slider (3) and spring support plate (4), and
levelling and adjusting shims from pump body.

FIGURE 283

19224

Pushing against distributor plunger (3) remove hydraulic

head (I), ensuring that control plate guide pins (4) and
reaction springs (2) remain in the head.
Using wrench 99352141 (I) undo screws holding
control plate (2) and remove plate.

. FIGURE 281
FIGURE 284
,J

OJ--~

0 - -A
m---+~~~=~ji'lJ

m---;-r~~~~

Remove pumping element return spring washers (2),

shims, guide pins (I). reaction springs (3) and sealing
Using round nose pliers, take out cam disc (2) with start
ring (4) from bottom of hydraulic head.
delivery adjustment pad (I).
 FIGURE 285 FIGURE 288

O]_....J

18609

19229 Take out roller ring (I), without .changing position of

rollers in their seats.
Again using round nose pliers remove cross (I).

FIGURE 286 .. FIGURE 289

OJ-;;-;;..;n.~~~~
[IJ-+f-\\--W~---;":'~fnlr('
rn---ij~~~Ul--1Y-

18623 19230

Remove spring clip (I) and locking pin (2). Using socket wrench (2) undo fixing screw (I) and
remove both covers of advance unit.

FIGURE 287

18608

Move advance unit control pin (2) towards inside of Take out complete advance unit (I).
roller ring (3).
 I Ul'\DVUI'\IL I II'" I CI'\\..VVLCI'\

- -
FIGURE 291 FIGURE 294

Refit drive shaft, turn injection pump and remove

transfer pump components (2) together with drive
Unscrew nut (I) fixing connection (3) on pump drive
shaft (I).
shaft; to do so, stop connection from turning by using
wrench 99365147 (2).

FIGURE 295
FIGURE 292

ITJI--~';:'

Remove connection from pump drive shaft uSing

19233

Remove drive gear (3), speed governor and spnng

. pads (2) from drive shaft (I).
18618
-
Extractor 99342138 (I).

FIGURE 293

CHECKS

Thoroughly wash pump body and dismantled parts

18611
Temporarily pullout drive shaft and undo retaining
screws of transfer pump plate (I).
with petrol.
Check each part for signs of wear or cracks; carefully
check all working surfaces for signs of seizure. Ensure
that springs are not distorted or broken.
Replace parts found to be damaged or in any way faulty
with new parts.
 REFITTING

FIGURE 296 NOTE - To ensure that the eccentric ring (I Fig. 298) is
fitted correctly. position it so that transfer pressure
hole (3 Fig 298) is facing the cover. and that hole (2 Fig.
298). which is furthest away from the internal diameter
of the ring. is facing the pump identification plate.

Place pump body on plate 99365014 (I).

FIGURE 297 FIGURE 299

OJ---------i=-

Fit seal (2) onto pump body using standard drift (I). TRANSFER PUMP COMPONENTS
I. Drive Shaft - 2. Spring Pads - 3. Governor Drive Gear - 4. Shim - S.
. Retaining Plate - 6. Vane Transfer Pump - 7. Eccentric Ring.

NOTE - To avoid knocking the eccentric ring during

assembly, it is recommended that the following parts
be fitted temporarily: drive shaft (I). governor drive
gear (3), spring pads (2), shim (4). retaining plate (5),
vane transfer pump (6) and eccentric ring (7).

Fit eccentric ring ( I) into pump body together with its

.' vane transfer pump (4).
 ~

FIGURE 300 FIGURE 303

Remove drive shaft again and secure retaining plate ( I )

with its screws.
Fit key on drive shaft and place assembly inside pump Insert bushing (I) into the piston (2) and fit it into the
body so that the key enters its seat in the vane impeller. pump body.

NOTE: The spring input side of the plunger must line

up with the anti-syphon hole in the pump body.

FIGURE 301 FIGURE 304

18620 18608

Place advance unit drive pin (2) in its seat in roller ring Push drive pin (2) into unit plunger connecting pin (I fig. -....-/1
( I). 303). Arrange the final section of the drive shaft as
shown in the figure.

-~-~
FIGURE 302 FIGURE 305

OJ-ii'ii"m~~"'i'::=:\"t:\-1
rn----l~~~=::rv/T11T(
0----lt~~~t~

18623
18621

Fit roller ring (I) into pump body. Insert lock pin (2) into connecting pin (3) together with
its spring clip (I).
 ADJUSTING PRELOAD ON DISTRIBUTOR
PLUNGER RETURN SPRINGS ("KF Dimension")
FIGURE 309 .
. ~ ~ "

Fit sealing rings (2) and flat cover (5). Fit a I mm shim in
spring seat, fit spring (3). Fit a shim (4) in cover recess
(I) and fit cover.

NOTE: The exact number of shims must be determi- Place a dial gauge in tool 99365 150 (2), then set it to
ned on the test bench (see SVS measurement). zero on surface plate (I) with a pre-load of 6 mm.

FIGURE 310
FIGURE 307 •
1~---- .....
2

19858

Fit cross (I) into its seat. Fit spring guide pins (5), shims (4), spring support
washers (2) and springs (3) into hydraulic head (I).

FIGURE 311
---~

CD 19859
/8629
Fit distributor plunger ( I) into hydraulic head complete
Fit cam disc (I). taking care to position it with the with spring support plate (4) and two shims (2 and 3).
pumping element stop (2) facing the keyway in the
drive shaft. Fit delivery start pad (3).
 FIGURE 312 CONTROL PLATE WITH NEGATIVE
ADJUSTMENT
FIGURE 314

Position tool 99365150 as shown and carry out check. The control plate with negative adjustment increases
the delivery of fuel as the engine speed increases.

FIGURE 313 FIGURE 315

KF

Fit distributor plunger (I) into pump body so that slot

on base of plunger keys onto drive dowel (2) on cam
disc.

FIGURE 316 ~
6729

Without compressing the springs, check that Measure-

ment KF is 5.31 mm, if not, replace adjusting washers.

m--r-~~~~~
NOTE - Only one adjusting washer of the same size f21
should be fitted on each guide pin. ~---i--J

Continue assembly, fitting slider on distributor plunger

and ensuring that lubrication hole is turned towards
base of plunger.
I
19239

Fit control plate (3) placing drive pin (2) in .seat (I) in
slider. ]
 FIGURE 317 . ~.~
After plaCing springs (3) in spring plate and thrust
springs (2) in their seats, center hydraulic head (I) on
pumping element and insert it into pump body,
securing it in place with the four retaining screws
tightened to a torque of I I to 13 Nm.
ADJUSTING POSITION OF DISTRIBUTOR
PLUNGER (MEASUREMENT UK")
FIGURE 318
Fit dial gauge into tool 99365150 (2) and zero it on
surface plate (I) with a pre-load of 6 mm.
FIGURE 319
OJ------+-
(lJ------f-
26353
Place tool with dial gauge (I) on hydraulic head (2).
FIGURE 320 ,"';..
2635~
Check that Measurement uK" is 3.3 mm.
NOTE - Measurement UK" is the distance between
sealing surface of head (2) and surface of distributor
plunger (I).
FIGURE 321
If Measurement uK" is not to specification, replace
adjustment pad (2) under base of distributor plunger
(I ).
Fit plug (3) together with bleed screw and tighten it to a
torque of 60 to 80 Nm: fit delivery valves and pressure
connections (2), tightening them to a torque of 35 to 45
Nm. Fit solenoid valve (I).
 ADJUSTING GOVERNOR SPINDLE (LFB)

FIGURE 326 ~)

26356

Fit spring clip (2) on plug (I) and insert them into
adjustment sleeve (3).

NOTE - The exact thickness of the plug must be

defined when next measuring the "MS" Measurement.
,
Using ruler (2), check that end of governor spindle ( I) is
3.0 mm from flange of pump body.

FIGURE 324 FIGURE 327

~~ffi
~-----[IJffi
)003

GOVERNOR COMPONENTS
I. Governor Spindle Lock Nut - 2. Washer - 3. Governor Spindle· 4. Shim
Plate - 5. Shim Washer - 6. Governor Body· 7. Counterweights - 8. Spacer
Washer - 9. Adjustment Sleeve.
GOVERNOR SPINDLE SETTING
A+ -3
Place counterweights (7), washers (5 and 8) and
adjustment sleeve (9) in governor body (6). Exact adjustment is carried out later on test bench.

FIGURE 325

CD--------

... ~\\

c~
rf 1'1:: s
Using feeler gauge (I), check axial clearance of gover-
nor (3). This clearance should be 0.25 to 0.45 mm
between pin (2) and governor (3); if not, replace
Place shim plate (4 Fig. 324) and governor in pump adjustment shim.
body. Screw in spindle (I).
CHECKING TRANSFER PRESSURE REGULATING
VALVE
FIGURE 329

OJ-------o---
L -- -.-.-/
--......_ ..
Using tool 99342141 (I), pull off spring clip (I Fig. 330),
then pull out plunger (2 Fig. 330) and spring (3 Fig. 330)
Temporarily fit cover (3) onto pump body, screw in
of valve body (5 Fig 330).
bush ( I) so that distance between its end and the cover
surface is the same as when dismantling, with hole (2)
facing downwards pointing towards seat of feeler pin
FIGURE 330 (4).

FIGURE 333

26359

PRESSURE REGULATING VALVE

I. Spring Clip - 2. Plunger - 3. Spring - 4. Sealing Ring· 5. Valve Body - 6.
Sealing Ring.

Check that regulating valve components are not worn;

if so, renew them.

Insert spring clip (I).

FIGURE 331

Using a punch. bring adjustment plunger level with

valve body. Reassemble transfer pressure regulating
valve and screw it onto pump body.
Screw up lock nut and tighten with torque wrench to
25 to 30 Nm.
PRESETTING ADJUSTMENT RING NUT

FIGURE 335

19246
192+4

Place dial gauge (I) in tool 99365150 (2) and zero it

Screw adjustment ring nut (I) fully onto bush. with a pre-load of I0 mm.

FIGURE 336 .FIGURE 338

19247
1924S

Rest dial gauge (I) on diaphragm (2); read and note

Using gauge (I), measure distance between ring nut ( I
down Measurement « C ».
Fig. 335) and top of cover then unscrew ring nut (I Fig.
335) until distance previously measured is reduced by 3
mm.
.. FIGURE 33~ • ,
NOTE - Exact adjustment is carried out later on test
bench.

PRESETTING LOA ADJUSTMENT SCREW DURING

SUCTION PERIOD

This is done to prevent the diaphragm retaining disc

from coming into contact with the cover of the LOA.

21--------...,

Using dial gauge (I) read Measurement «F» on cover

(2); it should be «C-I mm ».
 I UK.ISUUAIL T IN I tK.\..UULt/\
'.
FIGURE 340
If Measurement « F» is not to specification, correct by
turning adjustment screw (I) with allen key (2).
ADJUSTING LDA LIFT
FIGURE 341
19250
Fit spring (2) and diaphragm (I) complete with adjust-
ment pin.
FIGURE 342
Fit cut-away cover (2) without adjustment screw, rest
spindle of dial gauge ( I) on diaphragm disc (3), preload
and zero it. Pushing diaphragm adjustment pin down-
wards, check its maximum travel (LOA lift). Subtract
measurement read in Setting Table (LOA lift) from
measurement just taken. Make up the difference with
an adjustment shim.
19252
Remove cut-away cover and complete diaphragm,
then fil adjustment shim (2) and spring (I).
FIGURE 344
Fit diaphragm complete with adjustment pin so that
marks (I and 2), made when dismantling, match up.
NOTE - If replacing diaphragm or cover, determine
position of diaphragm as described below.
30670
Place tool from kit 99395622 (3) on cover (I) with
curved part in contact with lever (2). The exact fitting
position of diaphragm is found when, on turning the
diaphragm, resistance is encountered due to tapered
part of spindle coming into contact with feeler pin.
 FIGURE 346 .
/)

19253

Fit cover (I) and secure it with its own screws. Screw in plug (I) with allen key (2).

FIGURE 347 FIGURE 350

19257

Fit ring nut (2) and guide bush ( I), complete with sealing Remove cover ( I) from pump, fit stop lever (3) and fix
ring and copper washer. onto special tool and place in it to cover with guide pin (2).
housing on pump body.

.~ -
FIGURE 348 l FIGURE 3_5I...............

Tighten side screws (I) with their seals. using a

Fit feeler pin (I) with point facing inwards. screwdriver.
TURBODAILY IN I ~KLUUL~K

SETTING STARTER MEASUREMENT «MS»

..
FIGURE 352 FIGURE 35<4

Position tool from kit 99395622 on cover (3). Bring
movable part (2) of tool into contact with turbocharge
adjustment screw (4) and fix it in that position by means
of screw (5).
Using a gauge, measure the distance between slot on
tool (I) and inner side of movable part (2): Measure-
ment « A », e.g. 11.5 mm.
Fit tool from kit 99395622 (2) onto pump body (3) and
secure it with bolts (I). .
Keeping control plate (4) in contact with pin (6), insert
feeler gauge (5) as shown in Figure and check that
Measurement « MS» is 0.8 to I mm.
FIGURE 355

FIGURE 353

26356

If value is different, remove governor from pump body,

take plug ( I) out of adjustment sleeve (3) and replace
plug with another of suitable thickness.
Refit governor in pump body.

FIGURE 356

Arrange screw (2) of tool from kit 99395622 (I) so that

the protrusion of screw (2) in relation to inner side of
tool ( I): Measurement C. is given by C = A - B, where
A is the measurement made previously (11.5 mm), B is
the distance between the axes of screws (3) and inner
side of tool (I) and is 9 mm to manufacturer's
specifications, therefore:
C= 11.5-9=2.5 mm.

Fit guide pin (3), idling spring (5) and spring support disc
(4) on control plate: hook on expansion spring (2) and
drive spindle (.I), complete with ring and shim washer.
 I UI\DVUAIL T IN I t:1\~VULt:1\

FIGURE 357 FIGURE360 "'

)

rIJ--1;;:::£;~~~
rn-~"'

Then fit lever (4) complete with plate (5) and control
Fit gasket (I) in housing on cover. lever (I). positioning it so that the reference mark
coincides with the one made when spindle (2) was
removed and secure lever with nut (3).

FIGURE 358
FIGURE 361.

Fit cover (4). relief valve (I). idling and maximum

adjustment screw (2) and maximum flow adjustment
screw (3). Position key. fit drive connection (2) and washer and
using torque wrench (3) and tool 99365147 (I). tighten
nut to 59 Nm.

FIGURE 359

16341

Position bottom cup (4). spring (3) and top cup (2) on
drive spindle.
7
 INJECTION PUMP TESTING DATA

INJECTION PUMP: VER 393 IVECO REF.: 48330159

GOVERNOR: ALL SPEEiS SUPPLIER'S REF.: 460414078
SUPPLIER: Bosch

ENGINE: 8140.47.2700

PRESSURE PIPES (ENGINE): DIAM. 6 X 2 X 430 mm

CYL. 1-2-3-4

INJECTOR SETIING (ENGINE): 210 + 8 bar

IDLING SPEED OF ENGINE: 750. ± 25 r.p.m.
FITIING 5 ± 0.5 DEGREES BEFORE TDC WITH INJECTION PUMP PLUNGER IN DELIVERY STAGE I mm FROM BDC
AND DISTRIBUTOR DELIVERY PORT CORRESPONDING TO OUTLET "A ...

STATIC AND DYNAMIC SPECIFICATIONS OF TEST BENCH COMPLY WITH ISO STANDARDS 400811 AND 400812.
PIPES I 680750073 (6 x 2 x 450 mm)
INJECTORS I 688 90 I 027
INJECTOR SETIING: 250 + 3 bar
CALIBRATED HOLE IN PAD: DIAM. 0.5 mm
TEST FLUID COMPLIES WITH ISO STANDARD 41 13
SUPPLY PRESSURE: 0.30 ± 0.05 bar
BURETIE EMPTYING TIME: 30 seconds
TEST OIL TEMPERATURE: WITH THERMOMETER = 38 to 42°C
: ELECTRONIC = .......oC

«INJECTION PUMP SETTINGS»

«NUMBERS GIVEN IN BRACKETS MUST BE USED ONLY AS CONTROL VALUES»

I • START OF DELIVERY 4 • FLOW AT FULL LOAD WITH SUPERCHARGE PRESSURE

.1 Prelift (from BDC): mm :0±0.02 Speed r.p.m.: 1800
:(±0.04) Pressure on LDA hPa: 1000
.2 Rotation Clockwise Average Flow
.3 Pump Injection Order :A-B-C-D per 1000 Deliveries cm) : 58.5 - 59.5
.4 Engine Firing Order . : 1-4-3-2 Max Imbalance cm) :(3.0)

2 • ADVANCE UNIT STROKE 5 • FLOW AT FULL LOAD WITHOUT

Speed r.p.m.: I 100 SUPERCHARGE PRESSURE
Pressure on LDA hPa: 1000 Speed r.p.m.: 550
Settings mm: 1.2- 1.6 Average Flow
per 1000 Deliveries cm): 24.0 - 25.0

3 • FUEL PUMP PRESSURE 6 • DEVIATION CURVE WITH GOVER·

Speed r.p.m.: I 100 NOR AT IDLING
Pressure on LDA hPa: 1000 Speed r.p.m.: 375
Settings bar: 5.0 - 5.6 Average Flow
per 1000 Deliveries cm): 9.8 - 10.2
Max Imbalance cm):(3.0)

7 • RESIDUAL FLOW SETIINGS:

Speed r.p.m.
Average Flow
per 1000 Deliveries cm)

DATE: 01.12.90
 8 - DEVIATION CURVE WITH GOVER- 12 - SETTING AND CHECKING "LFB"
NOR AT MAXIMUM DELIVERY Speed r.p.m. : I 100
Speed r.p.m.: 2100 Pressure on LDA hPa: 1000
Pressure on LDA hPa: 1000 Setting:
Average Flow .1 Average Flow
per 1000 Deliveries cm 3 : 49.5-57.5 per 1000 Deliveries cm 3: minus 20 ± 1.0
Transfer Pressure bar: minus 0.2 ± 0.1
.2 Average Flow
9 - STARTING per 1000 Deliveries cm 3 : minus 25 ± 4.0
Speed r.p.m.: 100 Advance Stroke mm: minus 0.8 ± 0.1
Average Flow Control:
per I 000 Deliveries cm 3: 40-70 .1 Average Flow
per I 000 Deliveries cm 3: 5.0 ± 3.0
Advance Stroke mm:0.6±OJ
10 - DEVELOPMENT OF TRANSFERT .2 Average Flow
PRESSURE per 1000 Deliveries
hPa: 1000 Advance Stroke
Pressure on LDA
.1 Speed r.p.m. : I 100
13 - FLOW ON BACKFLOW
Transfer Pump
VALVE
Pressure bar: 4.7-5J
.2 Speed r.p.m. : I sao Speed r.p.m.: 550
Trasfer Pump Pressure on LDA hPa:O
Pressure bar: 6.2-6.8 Backflow :41-83
J Speed r.p.m. : 1900 Flow cm 3: (26-98)
Trasfer Pump .1 Speed r.p.m.: 1900
Pressure bar: 7J-7.9 Pressure on LDA hPa: 1000
.4 Speed r.p.m.: Backflow : 55-138
Transfer Pump Flow cm 3: (40-153)
Pressure bar:

II - DEVELOPMENT OF INJECTION
ADVANCE
Pressure on LDA hPa: iooo
.1 Speed r.p.m. : I 100
Advance Stroke mm: 1.2- i.6
:(1.0-1.8)
.2 Speed r.p.m. : I sao -.....-II
Advance Stroke mm: 3J-4.1
:(3.0-4.4)
J Speed r.p.m. : 1900
Advance Stroke mm: 5.2-6.0
:(4.9-6J)
.4 Speed r.p.m.:
Advance Stroke mm:

DATE: 01.12.90
 14 - DEVELOPMENT OF FLOW RATES 15 - ZERO FLOW (STOP)
.1 Speed r.p.m. :700 .1 Mechanical:
Speed r.p.m.:
Setting Point
Pressure on LDA hPa:(*) 400 Average Flow
Average Flow per 1000 Deliveries
per 1000 Deliveries em 3 : 47.5-48.5 .2 Electrical:
r.p.m.: 500 Speed r.p.m.:
.2 Speed
Pressure on LDA hPa: 1000 Voltage volt:
Average Flow Average Flow
per I000 Deliveries em 3: 56.5-60.3 per 1000 Deliveries
.3 Speed r.p.m.: 800
Pressure on LDA hPa: O 16 - FLOW AT IDLING
Average Flow .1 Speed rp·m.:500
per 1000 Deliveries em 3: 32.0-36.0 Average Flow
.4 Speed r.p.m.: 500 per 1000 Deliveries em 3: 0.0-2.0
Pressure on LDA hPa: O .2 Speed r.p.m.: 375
Average Flow Average Flow
per 1000 Deliveries em 3: 24.0-25.0 per 1000 Deliveries em 3: 13.0-14.0
.5 Speed r.p.m.: 1500 .3 Speed r.p.m.: 300
Pressure on LDA hPa: 1000 Average Flow
Average Flow per 1000 Deliveries em 3: 41.0-51.0
per 1000 Deliveries em 3: 55.5-60.5 Radial Flow:
.6 Speed r.p.m.: 1800 .4 Speed r.p.m.:
Pressure on LDA hPa: 1000 Average Flow
Average Flow per 1000 Deliveries
per 1000 Deliveries em 3: 58.5-59.5
.7 Speed r.p.m.: 1900 17 - EXTRA FLOW AUTOMATIC
Pressure on LDA hPa: 1000 STARTER
Average Flow .1 Speed r.p.m.:
per 1000 Deliveries em 3 : 55.8-59.8 Average Flow
.8 Speed r.p.m.: 2000 per 1000 Deliveries
Pressure on LDA hPa: 1000 .2 Speed
Average Flow Average Flow
per 1000 Deliveries em 3: 53.0-59.0 per 1000 Deliveries
.9 Speed r.p.m.: 2100
Pressure on LDA hPa: 1000
Average Flow
per 1000 Deliveries em 3: 49.5-57.5
.10 Speed r.p.m.: 2300
Pressure on LDA hPa: 1000
Average Flow
per I000 Deliveries em 34.5-9.5
.11 Speed r.p.m.:
Pressure on LDA hPa:
Average Flow
per I000 Deliveries

DATE: 01.12.90
18 - SETTING AND CHECKING THE NOTES:
POTENTIOMETER I) ENTRIES WITH NO ALPHANUMERIC VALUES
Supply volts: REFER TO OTHER TYPES OF INJECTION
Setting: PUMPS.
Speed r.p.m.: 3) MEASUREMENTS MADE ON INJECTION
Average Flow PUMPS FITTED WITH "KSB" MUST BE TAKEN
per 1000 Deliveries em 3: WITH THE KSB OFF.
Potentiometer Output 4) (*) TURN LDA SPRING PRELOAD ADjUST-
Voltage volts: MENT RING NUT (BOSCH REFERENCE N° 46).
Control:
Speed r.p.m.:
Average Flow
per 1000 Deliveries em 3:
Potentiometer Output
Voltage volts:

19 - STOP ELECTROMAGNET
Minimum Working
Voltage volts:
Rated Voltage volts:

20 - FITTING AND SETTING MEASUREMENTS

Deseripeion:
K mm: 3.3
KF mm:5.31
MS mm: 1.00
SVS mm:max.
XK mm:
XL mm
LDASTROKE mm:6.0+ 1.0
DAILY - TURBODAILY - TURBODAJLY 4X4 FEEDING 93

INJECTION PUMP TEST VALUES.

IVECO ENGINEERING No. 99478071 Edit 2

INJECTION ROTARY PUMP TEST VALUES

Injection pump: VE411 OF21 OOR675 IVECO PART N. 98492219

Speed governor: MIN/MAX BOSCH PART N. 0460 404 08S

Engine 8140.67F.3700 For: IVECO

Timing:
- Injection pump static advance (Output reference "A") 0 ± 05
degrees before II after II ID.C With I.P pumping in phase of delivery at I mm from BDC
- Or with piston at IDC and injection pump pumping in phase of delivery at I ± 0.04 mm from BDC
- Engine idling speed without load: 77S ± 2S rpm

TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS

CONFORMING TO STANDARDS ISO 400811 -/2

- Rotation direction: Right

Left
IXI -
-
Supply pressure:
Burette evacuation time:
O.3S ± 0.05 bar
30"
- Pipes: 0 6 x 0 2 x 450 mm - Test fiuid conforming to standard: ISO 4113
-
-
Injectors: 1688 90 I 022
Calibrated hole pad: 0 = mm
- Temperature Infiux
Defiuxion
IXI
- Injector setting: I 30 + 3 bar - Thermometer : 45 ± I °C
- Bacldlow chock 0 =055 mm - Electronic ± 4 °C

"INJECTION PUMP ADJUSTMENT VALUES"

"THE NUMBERS GIVEN IN BRACKETS SHOULD
BE USED ONLY AS CONTROL VALUES"

Date: 04--{)4-1996 Sheet 1/4

94 fEEDING DAlLY - TURBODAILY - TURBODAlLY 4X4

IVECO ENGINEERING No. 99478071 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

9- START 14 - DELIVERY RUN AND ADJUSTMENT

Speed rpm: 100 I Speed rpm: (0)

Delivery per 1000 shots cm 3: 80.0 ± 20 Overcharging pressure hPa:
Minimum delivery em 3: 60.0 Delivery per I000 shots em 3;
em 3;
10 - "LFB" SETTING
2 Speed rpm: 2600
1250 Overchargng pressure hPa:
Speed rpm: Delivery per 1000 shots em 3; 1.5± 1.5
Overcharging pressure hPa: em 3;
I. Delivery difference
(± 1.5)
per I000 shots em 3; -10±1.0 3 Speed rpm: 2300
2. Transfer pump pressure Overcharging pressure hPa:
Delivery per I000 shots em 3; 32 ± 2.0
difference bar: 0.2 ±O.I em 3; (± 6.0)
I I -INJECTION ADVANCE RUN 4 Speed rpm: 2100
Overcharging pressure hPa:
Overcharging pressure hPa: Delivery per 1000 shots em 3; 44.0 ± 1.5
I Speed rpm: 1250 em 3; (± 2.5)
Advance travel mm: V±O.I S Speed rpm: 1500
mm: (± 0.6) Overcharging pressure hPa:
2 Speed rpm: 2000 Delivery per 1000 shots cm3: 43.5 ± 0.5
Advance travel mm: 7.4 ±OJ cm 3: (2.0)
mm: (± 0.7) 6 Speed rpm: 1000
3 Speed rpm: 1000 Overcharging pressure hPa:
Advance travel mm: 0.9 ±OJ Delivery per 1000 shots em 3; 41.0± 1.5
mm; (± 0.7) em 3: (± 2.5)
4 Speed rpm: 7 Speed rpm: 600
Advance travel mm: Overcharging pressure hPa
mm: Delivery per 1000 shots em); 36.5 ± 1.5
em 3; (± 3.0)
12 - TRANSFER PRESSURE RUN
8 Speed rpm:
OverCharging pressure . hPa:
Overcharging pressure hPa: em 3;
Delivery per 1000 shots
I Speed rpm: 1250
cm l
Transfer pump pressure bar: 5.8 ± OJ 9 Speed rpm:
2 Speed rpm: 2000 Overcharging pressure hPa:
Transfer pump pressure bar: 82 ± 0.3 Delivery per 1000 shots em 3:
3 Speed rpm: 600 em 3:
Transfer pump pressure bar: 3J ± OJ 10 Speed rpm:
4 Speed rpm: Overcharging pressure hPa:
Transfer pump pressure bar: Delivery per I000 shots em 3:
13 - BACKFLOW VOLUME ON VALVE em);

I Speed rpm: 600

Overcharging pressure hPa:
Bacldlow volume c.cl lOs: 41.4"' 85.5
c.cl lOs: (26.4", 100.5)
2 Speed . rpm: 2100
Overcharging pressure hPa:
Backflow volume c.c./ lOs: 55.2"' 138.0
c.c./IOs: (40.2", 153)

Date: 04-04-1997 Sheet 2/4

DAILY - TURBODAILY - TURBODAILY 4X4 FEEDING 95

IVECO ENGINEERING No. 99478071 Edit 2

Date: 04-04--1997 Sheet 3/4

96 FEEDING DAILY - TURBODAlLY - TURBODAILY 4X4

IVECO ENGINEERING No. 478071 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

REMARKS:
I) References for which no letters or numbers are given are reserved for other injection pump
designs.

2) For a conrect adjustment of injecton pumps on the electric bench, conform to the manual
IVECO Technical Publications and Training No. XXXXXXXXX

3) Measurements taken on injection pumps equipped with "KSB" must be performed with the
same at rest.

4) (") LOA adjusting point: act on spring pre-loading ring.

5) After every variation of LOA pressure, act on the control lever

6) For adjusting the starting point (ARF valve) add a 12.0 mm spacer to the third delivery stop.

NOTES: "PROVISIONAL:' TEST VALUES CID. DATE

APPROVAL PROTOCOL N. 200-2195 OF 20.10.1995 04-04-97

Sheet 4/4
DAJLY - TURBODAJLY - TURBODAILY 4X4 FEEDING 97

IVECO ENGINEERING No, 99464658 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

Injection pump: VE4/ 12F 1800R657 IVECO PART N,994778S9

Speed governor: All speeds BOSCH PART N, 0460 424 124

Engine 8140,233700 For: IVECO

8140233800
Timing:
- °
Injection pump static advance (Output reference "A") ± 0.5
degrees before IXI after I I TOC w~h I.P pumping in phase of delivery at I mm from BDC
- Or with piston at TD,C and injection pump pumping In phase of delivery
at 0,78 ± 0,04 mm from BDC
- Engine idling speed w~hout load: 750 ± 25 rpm

TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS

CONFORMING TO STANDARDS ISO 4008/1 -/2

- Rotation direction: Right

Left
IXI -
-
Supply pressure:
Burette evacuation time:
0.35 ± O,OS bar
KMM
- Pipes: 121 6 x 121 2 x 840 mm - Test fluid conforming to standard: ISO 41 13
- -
-
-
Injectors: 1688 90 I 027
=
Calibrated hole pad: O,S mm
Injector setting: 2S0 + 3 bar -
Temperature

Thermometer
Influx
Defluxion
: S5 ± I °C
Ixi
- =
Backflow chock: 121 0,60 mm - Electronic ±4°C

"INJECTION PUMP ADJUSTMENT VALUES"

"THE NUMBERS GIVEN IN BRACKETS SHOULD
BE USED ONLY AS CONTROL VALUES"

Date: 03 -06-1996 Sheet 1/4

98 FEEDING DAILY - TURBODAILY - TURBODAILY 4X4

IVECO ENGINEERING No. 99464658 Edit. 2

INJECTION ROTARY PU M P TEST VALUES

9- START 14 - DELIVERY RUN AND ADJUSTMENT

Speed rpm: 100 I Speed rpm: 800 (0)

Delivery per I000 shots em 3: 8S.0 ± 2S Overcharging pressure hPa: SOO
Minimum delivery em 3; 60.0 Delivery per 1000 shots em 3: S1.0 ± 0.5
10 - "LFB" SETIING cm J (± 3.5)
2 Speed rpm: 2200
Overcharging pressure hPa: 1200
Speed rpm:
Delivery per 1000 shots em 3: 2.0 ± 2.0
Overcharging pressure hPa:
em 3: (± 2.0)
I. Delivery difference
3 Speed rpm: 2100
per I000 shots em 3:
Overcharging pressure hPa: 1200
2. Transfer pump pressure
difference bar:
Delivery per 1000 shots cm J 20.0 ± 6.0
em 3; (± 9.0)
I I -INJECTION ADVANCE RUN 4 Speed rpm: 2200
Overcharging pressure hPa: 1200
Overcharging pressure hPa: 1200 Delivery per 1000 shots em 3: 430 ± 30
I Speed rpm: 1200 em 3: (± 45)
Advance travel mm: 1.1 ±O.I 5 Speed rpm: 1800
mm: (± 0.7) Overcharging pressure hPa: 1200
2 Speed rpm: ISOO Delivery per 1000 shots cm J 615±2.0
Advance travel mm: 32 ± 05 em 3: (±3.5)
mm: (± 0.7) 6 Speed rpm: 1100
3 Speed rpm: 1800 Overcharging pressure hPa: 1200
Advance travel mm: 4.9 ± OJ Delivery per 1000 shots em 3: 58.5 ± 05
mm: (± 0.5) em 3: (± 35)
4 Speed rpm: 7 Speed rpm: 9S0
Advance travel mm: Overcharging pressure hPa: 1200
mm: Delivery per 1000 shots em 3: 58.0 ± 3.0
em 3: (± 5.0)
12 - TRANSFER PRESSURE RUN
8 Speed rpm: 600
Overcharging pressure hPa: 1200
Overcharging pressure hPa: 1200
I Speed Delivery per 1000 shots cm 3: 625 ± 3.5
rpm: 1200
Transfer pump pressure bar: 7.2 ± 0.3 em 3: (± 6.0)
9 Speed rpm: SSO
2 Speed rpm: 1800
Transfer pump pressure bar: 9J ± OJ
Overcharging pressure hPa: a
Delivery per I000 shots em 3: 305 ± 05
3 Speed rpm: 600
Transfer pump pressure bar: 4.7 ± 0.3 em 3: (± 3.S)
10 Speed rpm:
4 Speed rpm:
Transfer pump pressure Overcharging pressure hPa:
bar:
Delivery per 1000 shots em 3:
13 - BACKFLOW VOLUME ON VALVE em 3:

I Speed rpm: 600

Overcharging pressure hPa: 1200
Backflow volume c.c.lIOs: 1104 + 132,5
c.c./IOs: (954 + 1465)
2 Speed rpm: 1800
Overcharging pressure hPa: 1200
Backflow volume c.c.lIOs: IS2.0 + 207.0
c.c.lIOs: (137 + 222)

Date: 03-D6-1997 Sheet 2/4

DAILY - TURBODAILY - TURBODAILY 4X4 FEEDING 99

IVECO ENGINEERING No. 99464658 Edit 2

INJECTION ROTARY PUMP TE5T VALUES

Date: 19--D2-1996 Sheet 3/4

100 FEEDING DAILY - TURBODAILY - TURBODAILY 4X4

IVECO ENGINEERING No. 99464658 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

REMARKS:
I) References for which no letters or numbers are given are reserved for other injection pump
designs.

2) For a correct adjustment of injection pumps on the electric bench, conform to the manual
IVECO Technical Publications and Training No. XXXXXXXXX

3) Measurements taken on injection pumps equipped with "KSB" must be performed with the
same at rest.

./'.

4) ('O) LDA adjusting point: act on spring pre-loading ring.

5) After every variation of LDA pressure, act on the control lever

6) For adjusting the starting point (ARF valve) add a 12.0 mm spacer to the third delivery stop.

NOTES: "PROVISIONAL:' TEST VALUES C.I.D. DATE

TABEL BOSCH OF 02.04.1996 77-9503-0501-085 03-06-1996

Sheet 4/4
 DAILY - TURBODAJLY - TURBODAILY 4X4 FEEDING 101

IVECO ENGINEERING No. 99464659 Edit 2

I N J E C T ION ROT A R Y P U M p. T EST V A L U E S

Injection pump VE4/12F 1800R660 IVECO PART N.99477860

Speed governor ALL SPEEDS BOSCH PART N. 0460 .

Engine: 8140.433700 For:IVECO

Timing:
- Injection pump static advance (Output reference "A") 15 ± 05 degrees
before IXI after II TDC with I.P pumping in phase of delivery at I mm from BD.C
- Or with piston at TDC and injection pump pumping in phase of delivery
at 1.1 S ± 0.04 mm from BD.C
- Engine idling speed without load: 7S0 ± 2S rpm

TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS

CONFORMING TO STANDARDS ISO 4008/ I -/2

- Rotation direction: Right - Supply pressure: 0.35 ± 0.05 bar

Left - Burette evacuation time: KMM
Pipes: 0 6 x 0 2 x 450 mm - Test fluid conforming to standard: ISO 41 I 3
Injectors: 1688 90 I 027
Calibrated hole pad: 0 = 05 mm
- Temperature at Influx
Defluxion
II
X
Injector settng : 250 + 3 bar Thermometer: 55 ± I °C
Backflow chock 0 = 0.7S mm Electronic ±4°C

"INJECTION PUMP ADJUSTMENT VALUES"

"THE NUMBERS GIVEN IN BRACKETS SHOULD
BE USED ONLY AS CONTROL VALUES"

1- START OF DELIVERY S- DELIVERY AT FULL LOAD WITHOUT

OVERCHARGING
r-- Pre-lift (from BD.C) mm: o± 0.Q2
Speed rpm: SSO
2- ADVANCE CHANGER TRAVEL
Delivery per 1000 shots cm 1 34.0± 05
Max difference em 3:
Speed rpm: 1100
Overcharging pressure hPa: 1200 6- IDLE SPEED ADJUSTMENT
Adjustment values mm: 1.6 ± 0.1
Speed rpm: 375
3- TRANSFER PUMP PRESSURE
Delivery per 1000 shots em 3: 7.0 ± 2.0
Max difference em3: 60 (65)
Speed rpm: 1100
Overcharging pressure hP.: 1200 7- ADJUSTING THE RESIDUAL DELIVERY
Adjustment values bar: 7.4 ± 0.3
Speed rpm:
4- DELIVERY AT FULL LOAD WITH OVERCHARGING
Delivery per 1000 shots em 3:
Speed rpm: 1750 8- MAXIMUM SPEED ADJUSTMENT
Overcharging pressure hPa: 1200
Delivery per 1000 shots em 3: 63.0 ± 05 Speed rpm: 2100
Max difference em 3: 4.0 (45) Overcharging pressure hPa: 1200
Delivery per 1000 shots em 3: 20± 5

Date: 03-06-1996 Sheet 1/4

102 FEEDING DAlLY - TURBODAlLY - TURBODAlLY 4X4

IVECO ENGINEERING No. 99464659 Edit. 2

INJECTION ROTARY P U M P T EST VALUES

9- START 14 - DELIVERY RUN AND ADJUSTMENT

Speed rpm: 100 I Speed rpm: 800(')

Delivery per 1000 shots em 3: 85.0 ± 25 Overcharging pressure hPa: 500
Minimum delivery em 3: 60.0 Delivery per 1000 shots em 3: 54.0 ± 0.5
cm 1 (± 3.5)
10 - "LFB" SETTING
2 Speed rpm: 2200
Overcharging pressure hPa: 1200
Speed rpm:
Delivery per 1000 shots em 3: 2.0 ± 2.0
hPa:
em 3: (± 2.0)
I. Delivery difference
3 Speed rpm: 2100
per 1000 shots
Overcharging pressure hPa: 1200
em 3:
Delivery per 1000 shots em 3: 2.0 ± 5.0
2. Transfer pump pressure
cm 1
difference
I I -INJECTION ADVANCE RUN
bar:
4 Speed
Overcharging pressure
rpm:
hPa:
(± 7.0)
2200
1200
."
Delivery per 1000 shots em 3: 43.0 ± 3
Overcharging pressure hPa: 1200 em 3: (± 4.5)
I Speed rpm: 1100 5 Speed rpm: 1800
Advance travel mm: 1.6 ± 0.1 Overcharging pressure hPa: 1200
mm: (± 0.7) Delivery per 1000 shots em 3: 63.0 ± 2.0
2 Speed rpm: 1600 em 3: (± 3.S)
Advance travel mm: 4 ± 0.3 6 Speed rpm: 1750
mm: (± 0.7) Overcharging pressure hPa: 1200
3 Speed rpm: 1400 Delivery per 1000 shots em 3: 3.0 ± 0.5
Advance travel mm: 2.B ± 0.3 em 3: (± 3.5)
mm: (± 0.7) 7 Speed rpm: 1400
4 Speed rpm: 1800 Overchar~ng pressure hPa: 1200
Advance travel mm: S.I ±Ol Delivery per I000 shots cm 1 61.0±2.5
mm: em 3; (± 5.0)
8 Speed rpm: 900
12 - TRANSFER PRESSURE RUN Overcharging pressure hPa: 1200
Delivery per 1000 shots cm 1 58.0 ± 2.5
Overcharging pressure hPa: 1200
rpm: 110 cm 1 ± 5.0)
I Speed 9 Speed rpm:
Transfer pump pressure bar: 6.B ± 0.3 600
Overcharging pressure hPa: 1200
2 Speed rpm: 1800
Delivery per 1000 shots em 3: 64.0 ± 2.0
Transfer pump pressure bar: B.8 ± 0.3
em 3; (± 6.0)
3 Speed rpm: 600
bar: 52 ± 0.3 10 Speed rpm: 550
Transfer pump presSUre
Overcharging pressure hPa: 0
4 Speed rpm: em 3;
Delivery per 1000 shots 34.0 ± 0.5
Transfer pump pressure bar:
em 3: (± 3.5)
13 - BACKFLOW VOLUME ON VALVE

I Speed rpm: 600

Overcharging pressure hPa: 1200
Backflow volume eel lOs: 75.0.;- 18.7
eel lOs: (60.5.;- 133.7)
2 Speed rpm: 1800
Overcharging pressure hPa: 1200
Backflow volume eell Os: 96.6.;- 179.4
ec.! lOs: (82.3.;- 195.7)

Date: 03--D6-1996 Sheet 214

DAilY - TURBODAllY - TURBODAllY 4X4 FEEDING 103

IVECO ENGINEERING No. 99464659 Edrt:.2

INJECTION ROTARY PUMP TE5T VALUES

Date: 03-06-1996 Sheet 3/4

104 fEEDING DAILY - TURBODAILY - TURBODAILY 4X4

IVECO ENGINEERING No. 99464659 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

REMARKS:
I) References for which no letters or numbers are given are reserved for other injection pump
designs.

2) For a correct adjustment of injection pumps on the electric bench, conform to the manual
IVECO Technical Publications and Training No. XXXXXXXXX

3) Measurements taken on injection pumps equipped with "KSB" must be performed with the
same at rest.

4) (*) LDA adjusting point act on spring pre-loading ring.

5) After every variation of LDA pressure, act on the control lever

6) For adjusting the starting point (ARF valve) add a 12.0 mm spacer to the third delivery stop.

NOTES: "PROVISIONAL:' TEST VALUES C.I.D. DATE

TABLE BOSCH OF 9.2.1996 77-9503-0501-085 03-06-96

Sheet 4/4
 DAlLY - TURBODAILY - TURBODAlLY 4X4 FEEDING 105

IVECO ENGINEERING No. 98496232 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

Injection pump: VE4/ I IE 1900R565 IVECO PART N.98475855

Speed governor: ELECTRONIC BOSCH PART N. 0460 414 996

Engine: 8140.47R.2790 FROM 8140.47B.3790 For: IVECO

8140.47R.2280
Timing:
- Injection pump static advance (Output reference "A") 4.5 ± 0.5 degrees
before [I after IXI TD.C. with I.P pumping in phase of delivery at I mm from B.D.C.
- Or with piston at TD.C. and injection pump pumping in phase of delivery
at 0.53 ± 0.04 mm from B.D.C.
- Engine idling speed without load: 775 ± 25 rpm

TEST BENCH WITH STATIC AND DYNAMIC CHARACTERISTICS

CONFORMING TO STANDARDS ISO 400811 -/2

- Pipes: I 680 750 073 (6X2X450) Bench test control box: EPS 865
- Injectors: 1688 90 I I 16 Signal converter: EPS 9 10
- Calibrated hole pad: d='" mm - Supply pressure bar 0.35 ± 0.05
- Injector setting: 207 + 3 bar - Burette emptyng time 30"
- Backfiow chock: '" = 0.75 mm - Test fluid ISO 4113
- Test cables: Temperature at:
I) Delivery actuator: KDEP 1865/5 • Defluxion: Electronic 45°C
2) Injection start electromagnetic valve: KDEP 1865/6 • Influx: Thermometer 35 + 40°C
• Wa~ing state 1100
• Recovery signaling voltage 2500 mv

INJECTION ROTARY PUMP TEST VALUES

1- ACTUATOR 3- FUEL TEMPERATURE DETECTOR

I Connections 5 and 6
IConnections 4 and 7 Test temperature:
r--- Test temperature: 15 + 30°C kOhm: 1.2 - 4.0
15 + 30°C Ohm: 0.40 - 1.0 50 + 70°C kOhm: 0.3 - 1.2
50 + 70°C Ohm: 0.45-1.1 2 Connection 5 and earth MOhm: 1.0
2 Connection 4 and earth MOhm: 1.0 min. 3 Connection 6 and earth MOhm: 1.0
3 Connection 7 and earth MOhm: 1.0 min.
4- INJECTION START ELECTROMAGNETIC VALVE
4 Connections 2 and 7 MOhm: 1.0min.
5 Connections 4 and 6 MOhm: 1.0 min.
Connections I and 2
2- HDK TRANSDUCER Test temperature:
15 + 30'C Ohm: 14.3- 17.3
Transducer coils 50 + 70°C Ohm: 15.5 - 21.0
Test temperature 15 + 70°C 5- STANDSTILL START mV: 4120 - 4650
I Connections 2 and 3 Ohm: 4.9 - 6.5
2 Connections I and 2 Ohm: 9.8 - 13.0 I STANDSTILL STOP mV: 650 - 850
3 Connections I and 3 Ohm: 4.9 - 6.5
4 Connection I and earth MOhm: 1.0 min.
5 Connection 2 and earth MOhm: 1.0 min.
6 Connection 3 and earth MOhm: 1.0min.

Date: 17-03-1995 Sheet 1/4

106 FEEDING DAILY - TURBODAILY - TURBODAILY 4X4

IVECO ENGINEERING No. 98496232 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

INJECTION ROTARY PUMP TEST VALUES
"INJECTION PUMP ADJUSTMENT VALUES"
"THE NUMBERS GIVEN IN BRACKETS SHOULD BE USED ONLY AS CONTROL VALUES"

6- START OF DELIVERY 4 Speed: rpm:

Recovery signaling voltage mV:
Pre-lif\ (from B.D.C) mm: 0 Feed pump pressure bar:
Injection start
7- TRANSFER PUMP PRESSURE
electro--magnetic valve volt
Speed rpm: 500 I I -INJECTION ADVANCE CALIBRATOR RUN
Recovery signaling voltage mV: 1950
Adjustment value bar: 6.9 ± 004 I Speed: rpm: 1900
Injection start Recovery signaling voltage mV: 3S00
electromagnetic valve vo~: 0 Injection advance calibrator
travel mm: 1104 ± 0.6
8- INJECTION ADVANCE CALIBRATOR TRAVEL Injection start
electromagnetic valve volt: 0
Speed rpm: SOO
2 Speed: rpm: 750
Recovery signaling voltage mV: 1950
Recovery signaling voltage mY: 2050
Injection advance calibrator travel mm: 9A± 1.0
Injection advance
Injection start
calibrator travel mm: 10A± 1.5
electromagnetic valve volt: 0
Injection start
9- DELIVERY AT FULL LOAD electromagnetic valve volt: 0
3 Speed: rpm: 1300
Speed rpm: 750 Recovery signaling voltage mY: 1420
Recovery signaling voltage mY: 2050 Injection advance
Delivery per 1000 shots em 3: 39.7± 1.5 calibrator travel mm: 1.5 max.
Injection start Injection start
electromagnetic valve volt 0 electromagnetic valve volt: 12
Leakage per I000 shots 2.5 4 Speed: rpm:
Recovery signaling vo~age mY:
10 - TRANSFER PUMP PRESSURE RUN Injection advance
calibrator travel mm:
I Speed: rpm: 100 Injection start
Recovery signaling voltage mY: 2870
electromagnetic valve volt
Feed pump pressure bar: 1.9 ± 0.3 rpm:
5 Speed:
Injection start electromagnetic Recovery signaling voltage mV:
valve volt 0 Injection advance
2 Speed: rpm: 500 calibrator travel mm:
Recovery signaling voltage mY: 1950 Injection start
Feed pump pressure bar: 6.9 ± 004 electromagnetic valve volt:
Injection start
electromagnetic valve volt 0
3 Speed: rpm: 1900
Recovery signaling voltage mV: 350
Feed pump pressure bar: 8.8 ± 004
Injection start
electromagnetic valve volt: 0

Date: 17-03-1995 Sheet 214

DAILY - TURBODAJLY - TURBODAILY 4X4 FEEDING 107

IVECO ENGINEERING No. 98496232 Edit. 2

INJECTION ROTARY PU M P T EST VALUES

12 - OVERFLOW DELIVERY ON BACKFLOW VALVE 5 Speed: rpm: 500

Recovery signaling voltage mV: 1360
ISpeed: rpm: 1900 Injection start
Recovery signaling voltage mV: 3S00 electromagnetic valve volt: 12
Injection start Delivery per 1000 shots cm 1 I 1.5
electromagnetic valve volt: 0 cm 1 (± 3.5)
Delivery cm 3/1 Os: 96.6 - 179.4 Leakage per I000 shots em 3: (4.0)
2 Speed: rpm: 6 Speed: rpm:
Recovery signaling vo~age mV: Recovery signaling vo~age mV:
Injection start Injection start
electromagnetic valve volt: electromag~etic valve volt:
Delivery cm 3/IOs: Delivery per I000 shots em 3:
em 3:
13 - DELIVERY RUN
Leakage per I000 shots em 3:
7 Speed: rpm:
I Speed: rpm: 1900
Recovery signaling voltage mV:
Recovery signaling voltage mV: 3S00
Inject:on start
Injection start
electromagnetic valve vo~:
electromagnetic valve vo~: 0
Delivery per 1000 shots em 3:
Delivery per 1000 shots em 3: 66.7
em 3:
em 3: (± 2.3)
Leakage per I000 shots em 3:
Leakage per I000 shots cm 1 (30)
8 Speed: rpm:
2 Speed: rpm: 1185
Recovery signaling vo~age mV:
Recovery signaling voltage mV: 2170
Injection start
Injection start
electromagnetic valve volt
electromagnetic valve volt: 0
Delivery per I000 shots cm 1
Delivery per I000 shots em 3: 36.5
em 3:
em 3: (± 2.3)
Leakage per I000 shots em 3:
Leakage per 1000 shots em 3: (2.5)
9 Speed: rpm:
3 Speed: rpm: 900
Recovery signaling voltage mV:
Recovery signaling voltage mV: 2900
Injection start
Injection start
electromagnetic valve vo~:
electromagnetic valve volt: 0
Delivery per 1000 shots em 3:
Delivery per 1000 shots em 3: 70.2
em 3:
em 3: (± 2.0)
Leakage per 1000 shots em 3:
Leakage per I000 shots em 3: (30)
4 Speed: rpm: 500
Recovery signaling vo~age mV: 1950
Injection start
electromagnetic valve volt: 0
Delivery per I000 shots em 3: 41.5
em 3: (± 2.5)
Leakage per 1000 shots em 3: (2.5

Date: I7--D3-1 995 Sheet 3/4

108 FEEDING DAILY - TURBODAILY - TURBODAILY 4X4

IVECO ENGINEERING No. 98496232 Edit. 2

INJECTION ROTARY PUMP TEST VALUES

14 -STARTING IS - STOP CHECK

I Speed: rpm: 100
Recovery signaling voltage mV: 2870 Speed: rpm:
Delivery per 1000 shots cm J 82.0 ± 15 Recovery signaling voltage mV:
Injection start LEAB vo~
electromagnetic valve volt 12 Delivery per I000 shots cm J
Leakage per I000 shots cm 3:
I 6 - ELECTROMAGNET FOR STOP
2 Speed: rpm:
Recovery signaling voltage mV:
Operating minimum voltage volt 10
Delivery per 1000 shots cm 3:
Rated voltage vo~ 12
Injection start
electromagnetic valve volt 17 - ASSEMBLY AND ADJUSTMENT DIMENSIONS

Denomination:
K mm: 3.74
KF mm: K-oT
SVS max mm:
FH mm:

REMARKS:
I) References for which no letters or numbers are given, are reserved for other injection
pump designs.
2) Checking HDK transducer in only allowed with EPS 910 signal converter.
3) Concerning the bench test of injection pump, conform to the manual IVECO Technical
Publications and Training No. XXXXXXXX

NOTE: (BOSCH CARD RBIT/CRV4 OF 24/02l199S C.I.D. DATE

77 9S33 0003 085 21/0211994
77 9533 0004 085 17/0311995

Date: 17-03-1995 Sheet 4/4

DAILY - TURBODAILY - TURBODAILY 4X4 fEEDING 109

COLD INJECTION ADVANCE AUTOMATIC DEVICE (KSB) [KALT START

I
BETRIEBSEINRICHTUNG]
figu.e I C-c
1
a b 3
I-C

! ~ \
-l~yA
I-c I42032A I
I. Wax thermal bulb - 2. Control lever - 3. Flexible connecting cable - 4. Eccentric pin -
5. Rolkarrier ring - 6. Advance changer piston - a. Lever position (2) in cold start condition - .
b. Lever position (2) in normal operating condition
Description
Rotary injection pumps, With mechanical speed governoc that
are frtted on the engines we dealt with in this publication. are
equipped with a cold injection advance automatic device
(K5B). This tool has the purpose to set the injection advance,
below a given temperature, to a greater value than that static
of pump fitting to the engine, and to reset it by degrees to the
value of this latter; as temperature rises.

Operation
KSB cold injection advance automatic device is a mechanical
type electric drive tool that mainly consists of a wax thermal
bulb (I) that acts on the advance changer control lever (2),
through a pushing rod and a connecting cable (3). When
starting a cold engine, the thermal bulb (I) pushing rod, that
operates on the connecting cable (3), is placed at back
position: consequently the lever (2) is kept in position "a". In
this condition the eccentric pin (4) (which is operated by the
lever (2»), changes the position of roll carrier nng (5) with
respect to its normal position and, in its turn. it causes piston
'''''I/'~~_::::::r4+1\.7)
1420341
(6) to move, thus producing an increase of advance with
Remove the cover of advance changer piston. fit tool
respect to the value of fitting static advance. At engine start 99365143 (7) and set it to zero.
the resistance existing in the thermal bulb (I) is fed by 5upplya 12V voltage to the thermal bulb (I) ofKSB to cut out
alternator 0+. The heat generated by the flow of current, this lattec
heats the wax that expands and causes pushing rod to come --'-- ..........--
out, resetting the lever (2) to position "b" by degrees.
~.I KSB device is cut out when the lever (2) is released.
In this way the extra advance is cancelled, since the parts of
advance changer come back to their normal operating position. ........
The full cut-out of KSB device is achieved after about 3-4 Shift the lever (2) leftward, so as to put the pin (4, Fig. 246) in
minutes of operation. contact with roll canner ring (5, Fig. 246). In this cond~ion, check
with thickness gauge (4) that a distance, according to the
prescribed value, existS between the lever (2) and the stop (3).
Otherwise, loosen the screws (0=» and position in the proper
way the stop (3), then tighten the screws (0=»: disconnect the
Check and adjustment thermal bulb. Set the lever (2) so as to read, on tool 99365 14 3,
a piston (4, Fig. 246) travel of the advance changec equal to
The check and adjustment, if required, of K5B tool is the prescribed value, otherwise loosen the clamp (6) and
carried out with the injection pump placed on a test tighten it again after placing it conveniently on the cable (5). Fit
bench. then thermal bulb (I).
110 FEEDING DAILY - TURBODAILY - TURBODAILY 4X4

FEED PUMP
I INJECTORS
The check and setting of injectors IS carried out by means of
tool 99305017: the setting value must be the same aIS that
indicated in the following table:

(
~--
SmlNG
ENGINE
--~ ' - '
PRESSURE I
I 814067F 120+8
-- ~---

8140.23/43 240+ 12-

8140.47R 240+ 8-

• When checking, for values of less than 200 bars,

set the injectors to 230 bars.
If a different value is found. decompose the injector and
replace adjusting spacers.
Also check that nebulized fluid comes out non-nebulized and
unifomnly from all of sprayer holes; then check that the
injectors does not drip at a pressure a little lower than the
setting pressure.
Check that feed pump operation is correct.
Check the automatic adjustment pressure: it must be 2.5 +
0.5 bar. Ifthe value is different before replacing the feed pump
(I). disconnect ~ from ~ support (2) and. relative to the plane
ofthe support check the start and end oftravel ofthe control
cap.

x = 2.6 mm push rod stroke

=
XI 15.4 mm push rod end-of-stroke
=
,X2 18 ± 0.1 mm push rod beginning of stroke