Turbo Daily Fuel System

66
TURBODAILY INTERCOOLER
ENGINE
FUEL SYSTEM
FIGURE 235
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:

o dry air filter;
o fuel filter;
o fuel tank;
o pipes;
o fuel lift pump;
oVER 293 injection pump with rotating distributor.
speed governor, advance unit. excess-fuel injection
and LDA device;
o injectors;
o device to start engine at temperatures below 2C
(Thermo-starter).
,
DESCRIPTION
Fuel is drawn from fuel tank (I) by injection pump (5)
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).
When the pressure of the excess fuel is greater than

the calibrated pressure (OJ bar) of the single-acting
valve (6), it is sent back to the tank. When starting the
engine in ambient temperature conditions below
2 2C, the thermostarter control device enrgizes the
solenoid valve (I) which enables the supply of fuel to
the thermostarter (2). The pressure drop in the
thermostarter fuel supply pipe activates the singleacting valve that stops the fuel from returning to the
tank and supplies constantly fuel to the thermostarter.
With the engine running, after the post-heating stage.
the solenoid valve (I) is de-energized; this interrupts
the supply of fuel to the thermostarter and causes an
increase in pressure which causes the single-acting valve
to open, thus enabling the return of excess fuel to the
tank.
TURBODAILY INTERCOOLER
ENGINE
AIR FILTER
67
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 protective cover;
24868
If the pilot light ( I), indicating the presence of water in

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,
FIGURE 237
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,
o unscrew knob (I) and remove protective cover;
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
FUEL LIFT PUMP
240'\, ;", -FIGURE

, .-.-...................
......
19184
33128
o unscreW wing nut (I), pull out the cartridge and

, replace it with a new one after having cleaned its
seat in its housing,
Check that fuel pump is working efficiently_ The selfregulating pressure should be 2.5 to 0.5 bar, if not.
before replacing pump 'check that push rod stroke is
2.5 to 2.6 mm.
00
I UKBUDAILY IN I ~KCOUL~K
ENGINE
CALIBRATION
INJECTORS
DISMANTLING
FIGURE 243
FIGURE 241
[IJ-------'f
[IJ------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.
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
FIGURE 242
33~3S
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).
Insert key in the commutator and turn it to position I

(MAR). The thermostarter is automatically activated
when the temperature is below 2 2e. If the
temperature is above this value. the pilot lamp (3) will
flash only once. If the temperature is below 2C 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 operation.
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 Unit10. 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)
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).
.... 1 1 - - - - 2
&
END OF DELIVERY STAGE

-
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
( I). held open by solenoid valve (2).
DELIVERY STAGE
.FIGURE 2-47
&
3
19200
I. Fuel Inlet - 2. Compression Chamber - 3. Delivery Passage - 4. End-OfDelivery Passage - 5. Slider - 6. Distributor Plunger.
As it moves towards TDe. distributor plunger (6)

connects with the high-pressure internal chamber
through inlet (I), thus establishing a pressure balance
between internal chamber of distributor plunger, delivery pipe to injectors and inside of pump body.
. Since this pressure is too low to operate the injector.
delivery ends.
&---+--
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.
-J )
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
The electric current that operates solenoid valve (4) is
cut off. Spring (3) causes the solenoid valve to push
mobile plug (2) to the end of its stroke which blocks
fuel inlet (I).
6726
I. Plunger - 2. Spring - 3. Connecting Pin - 4. Roller Ring - 5. Locking Pin - 6.

Connecting Pin.
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
opposite direction to the force exerted by spring (2);
the spring normally holds the plunger in the retard .
position.
AUTOMATIC ADVANCE UNIT

FIGURE 250
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

flows into compression chamber (7): in this condition
the counterweights of governor sleeve (5) are closed;
leaf spring (2) then pushes lever (I) and slider (4) into
the excess-fuel position.
Thus the full stroke of the pumping element is utilised

for the effective delivery to the injectors.
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

force due counterweights (7) opening causes adjustment sleeve (5) to move axially. pushing starter lever
(I) into contact with tension lever (3) and thus
compressing leaf spring (2).
In this condition slider (4) moves across and causes

minimum delivery.
START OF DELIVERY TO MATCH LOAD (LFB)

FIGURE 25-4
---------3
1+--->c:t------4
+------5
6
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
FIGURE 255
.,
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.
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--------'.cAfttE~
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
one part with adjustment pin (4). The bottom of
adjustment pin (4) has a tapered seat on which a feeler
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
control plate so as to match the flow of fuel to the
amount of air allowed into the cylinders.
DISMANTLING THE INJECTION PUMP
(I)~~~~~
0-~-
2040
Note position of reference marks between spindle (2)

and lever (4).
Unscrew nut (3) and remove spindle (2), lever (4)
complete with plate (5) and control lever (I).
FIGURE 257
m-------==~
m---I'!,~~~==~~
19203
Fix injection pump (I) to plate (2) of Adjustable

Support 99365014.
Remove: cup (2), spring (3) and cup (4). Remove fixing
bolts and take off LDA cover (I).
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

relation to cover (2).Take off lead seal (3) and remove
stop pins (5) and turbocharge maximum flow screw (4).
Remove plug (6).
Unscrew spring load adjustment ring nut (I).
FIGURE 265
FIGURE 262
2r-------l
19207
Turn diaphragm (I) complete with adjustment pin (2)

and remove from housing.
FIGURE 263
Remove seal plug (2). remove bleed screw ( I ), unscrew

bolts (3) fixing cover to pump body.
.'"
19211
Remove diaphragm reaction spring ( I) and spacer bush
(2).
Remove cover (I) and pullout drive spindle (2) by

pressing downwards (in direction of arrow).
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

thrust washer and adjusting plate (2).
Turn the pump and using wrench 99352140 (I)

unscrew the hydraulic head closing plug. Unscrew the 4
delivery connections (2).
..... FIGURE 278,'
"'"
OJ------------:IIl'...,c""'IIII~
[I)-----------iIl~
m~
~
3O~1
The speed governor assembly (I) consists of an

adjustment sleeve (3) with adjusting plug with spring
clip, shim (4) and 4 centrifugal counterweights (2).
26~8
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
I UI'\DVU1'\IL I 11'4 I CI'\'-VVLCf\
CI'4UII'4C
FIGURE 282
OJ -,:.---=-----"-.:...:.....-----,,+-
-OJ-~-------r
~~
ml---'1L--if.SS~'f=::~~
/
m---=-:::::;;==,:~
m--~~-i?=2T-
0--4~~
19226
Using wrench (I) undo screws (2) fixing hydraulic head.
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 280
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
ring (4) from bottom of hydraulic head.
Using round nose pliers, take out cam disc (2) with start
delivery adjustment pad (I).
FIGURE 288
FIGURE 285
O]_....J
18609
19229
Again using round nose pliers remove cross (I).
FIGURE 286 ..
Take out roller ring (I), without .changing position of

rollers in their seats.
FIGURE 289
OJ-;;-;;..;n.~~~~
[IJ-+f-\\--W~---;":'~fnlr('
rn---ij~~~Ul--1Y18623
Remove spring clip (I) and locking pin (2).
19230
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

roller ring (3).
Take out complete advance unit (I).
I Ul'\DVUI'\IL I II'" I CI'\\..VVLCI'\
FIGURE 294
FIGURE 291
Unscrew nut (I) fixing connection (3) on pump drive

shaft; to do so, stop connection from turning by using
wrench 99365147 (2).
Refit drive shaft, turn injection pump and remove

transfer pump components (2) together with drive
shaft (I).
FIGURE 295
FIGURE 292
ITJI--~';:'
19233
Remove connection from pump drive shaft uSing

Extractor 99342138 (I).
18618
Remove drive gear (3), speed governor and spnng

. pads (2) from drive shaft (I).
FIGURE 293
CHECKS
18611
Temporarily pullout drive shaft and undo retaining

screws of transfer pump plate (I).
Thoroughly wash pump body and dismantled parts

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 303
FIGURE 300
Remove drive shaft again and secure retaining plate ( I )

with its screws.
Fit key on drive shaft and place assembly inside pump
body so that the key enters its seat in the vane impeller.
Insert bushing (I) into the piston (2) and fit it into the
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
18608
18620
Place advance unit drive pin (2) in its seat in roller ring
( I).
-~-~
FIGURE 302
Push drive pin (2) into unit plunger connecting pin (I fig.
303). Arrange the final section of the drive shaft as
shown in the figure.
FIGURE 305
OJ-ii'ii"m~~"'i'::=:\"t:\-1
rn----l~~~=::rv/T11T(
0----lt~~~t~
18621
Fit roller ring (I) into pump body.
18623
Insert lock pin (2) into connecting pin (3) together with
its spring clip (I).
-....-/1
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 determined on the test bench (see SVS measurement).
Place a dial gauge in tool 99365 150 (2), then set it to

zero on surface plate (I) with a pre-load of 6 mm.
FIGURE 310
FIGURE 307
1~----
.....
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 cam disc (I). taking care to position it with the

pumping element stop (2) facing the keyway in the
drive shaft. Fit delivery start pad (3).
Fit distributor plunger ( I) into hydraulic head complete

with spring support plate (4) and two shims (2 and 3).
CONTROL PLATE WITH NEGATIVE

ADJUSTMENT
FIGURE 312
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 315
FIGURE 313
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 Measurement KF is 5.31 mm, if not, replace adjusting washers.
NOTE - Only one adjusting washer of the same size

should be fitted on each guide pin.
Continue assembly, fitting slider on distributor plunger
and ensuring that lubrication hole is turned towards
base of plunger.
m--r-~~~~~
f21
~---i--J
I
19239
Fit control plate (3) placing drive pin (2) in .seat (I) in
slider.
FIGURE 317
. ~.~
FIGURE 320 ,"';..
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")
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
FIGURE 318
Fit dial gauge into tool 99365150 (2) and zero it on

surface plate (I) with a pre-load of 6 mm.
If Measurement uK" is not to specification, replace

adjustment pad (2) under base of distributor plunger
(I ).
FIGURE 319
OJ------+(lJ------f-
26353
Place tool with dial gauge (I) on hydraulic head (2).
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 327
FIGURE 324
~~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.
Place counterweights (7), washers (5 and 8) and

adjustment sleeve (9) in governor body (6).
GOVERNOR SPINDLE SETTING

A+ -3
Exact adjustment is carried out later on test bench.
FIGURE 325
CD--------
...
~\\
c~
rf 1'1::
Place shim plate (4 Fig. 324) and governor in pump

body. Screw in spindle (I).
Using feeler gauge (I), check axial clearance of governor (3). This clearance should be 0.25 to 0.45 mm
between pin (2) and governor (3); if not, replace
adjustment shim.
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)
of valve body (5 Fig 330).
Temporarily fit cover (3) onto pump body, screw in

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
(4).
FIGURE 330
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

with a pre-load of I0 mm.
Screw adjustment ring nut (I) fully onto bush.
.FIGURE 338
FIGURE 336
19247
1924S
Using gauge (I), measure distance between ring nut ( I

Fig. 335) and top of cover then unscrew ring nut (I Fig.
335) until distance previously measured is reduced by 3
mm.
NOTE - Exact adjustment is carried out later on test
bench.
Rest dial gauge (I) on diaphragm (2); read and note

down Measurement C .
..
FIGURE 33~ ,
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
19252
If Measurement F is not to specification, correct by

turning adjustment screw (I) with allen key (2).
Remove cut-away cover and complete diaphragm,

then fil adjustment shim (2) and spring (I).
ADJUSTING LDA LIFT

FIGURE 344
FIGURE 341
19250
Fit spring (2) and diaphragm (I) complete with adjustment pin.
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.
FIGURE 342
30670
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 downwards, 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.
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 350
FIGURE 347
19257
Fit ring nut (2) and guide bush ( I), complete with sealing
ring and copper washer. onto special tool and place in
housing on pump body.
Remove cover ( I) from pump, fit stop lever (3) and fix
it to cover with guide pin (2).
.~
FIGURE 348
Fit feeler pin (I) with point facing inwards.
FIGURE 3_5I...............
Tighten side screws (I) with their seals. using a

screwdriver.
TURBODAILY IN I ~KLUUL~K
SETTING STARTER MEASUREMENT MS
..
FIGURE 352
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): Measurement A , e.g. 11.5 mm.
FIGURE 35<4
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
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).
Fit gasket (I) in housing on cover.
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
IVECO REF.: 48330159

SUPPLIER'S REF.: 460414078
SUPPLIER: Bosch
INJECTION PUMP: VER 393

GOVERNOR: ALL SPEEiS
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 42C
: ELECTRONIC = .......oC
INJECTION PUMP SETTINGS

NUMBERS GIVEN IN BRACKETS MUST BE USED ONLY AS CONTROL VALUES
I START OF DELIVERY
.1 Prelift (from BDC):

.2 Rotation
.3 Pump Injection Order
.4 Engine Firing Order
4 FLOW AT FULL LOAD WITH SUPERCHARGE PRESSURE

mm :00.02
:(0.04)
Clockwise
:A-B-C-D
. : 1-4-3-2
2 ADVANCE UNIT STROKE

Speed
Pressure on LDA
Settings
r.p.m.: 1800
hPa: 1000
cm) : 58.5 - 59.5
cm) :(3.0)
5 FLOW AT FULL LOAD WITHOUT

r.p.m.: I 100
hPa: 1000
mm: 1.2- 1.6
3 FUEL PUMP PRESSURE

Speed
Pressure on LDA
Settings
Speed
Pressure on LDA
Average Flow
per 1000 Deliveries
Max Imbalance
r.p.m.: I 100
hPa: 1000
bar: 5.0 - 5.6
SUPERCHARGE PRESSURE
Speed
Average Flow
per 1000 Deliveries
r.p.m.: 550
cm): 24.0 - 25.0
6 DEVIATION CURVE WITH GOVER

NOR AT IDLING
Speed
Average Flow
per 1000 Deliveries
Max Imbalance
r.p.m.: 375
cm): 9.8 - 10.2
cm):(3.0)
7 RESIDUAL FLOW SETIINGS:

Speed
Average Flow
per 1000 Deliveries
DATE: 01.12.90
r.p.m.
cm)
8 - DEVIATION CURVE WITH GOVER-
12 - SETTING AND CHECKING "LFB"
NOR AT MAXIMUM DELIVERY
Speed
Pressure on LDA
Average Flow
per 1000 Deliveries
r.p.m.: 2100
hPa: 1000
.1
cm 3 : 49.5-57.5
.2
9 - STARTING
Speed
Average Flow
per I 000 Deliveries
r.p.m.: 100
cm 3: 40-70
10 - DEVELOPMENT OF TRANSFERT
.1
.2
PRESSURE
.1
.2
J
.4
Pressure on LDA
Speed
Transfer Pump
Pressure
Speed
Trasfer Pump
Pressure
Speed
Trasfer Pump
Pressure
Speed
Transfer Pump
Pressure
hPa: 1000
r.p.m. : I 100
bar: 4.7-5J
r.p.m. : I sao
bar: 6.2-6.8
r.p.m. : 1900
bar: 7J-7.9
r.p.m.:
13
Speed
Pressure on LDA
Setting:
Average Flow
per 1000 Deliveries
Transfer Pressure
Average Flow
per 1000 Deliveries
Advance Stroke
Control:
Average Flow
per I 000 Deliveries
Advance Stroke
Average Flow
per 1000 Deliveries
Advance Stroke
-
FLOW
VALVE
ON
Speed
Pressure on LDA
Backflow
Flow
.1 Speed
Pressure on LDA
Backflow
Flow
r.p.m. : I 100
hPa: 1000
cm 3: minus 20 1.0
bar: minus 0.2 0.1
cm 3 : minus 25 4.0
mm: minus 0.8 0.1
cm 3: 5.0 3.0
mm:0.6OJ
BACKFLOW
r.p.m.: 550
hPa:O
:41-83
cm 3: (26-98)
r.p.m.: 1900
hPa: 1000
: 55-138
cm 3: (40-153)
bar:
II - DEVELOPMENT OF INJECTION
ADVANCE
Pressure on LDA
.1 Speed
Advance Stroke
.2 Speed
Advance Stroke
J Speed
Advance Stroke
.4 Speed
Advance Stroke
DATE: 01.12.90
hPa: iooo
r.p.m. : I 100
mm: 1.2- i.6
:(1.0-1.8)
r.p.m. : I sao
mm: 3J-4.1
:(3.0-4.4)
r.p.m. : 1900
mm: 5.2-6.0
:(4.9-6J)
r.p.m.:
mm:
-.....-II
14 - DEVELOPMENT OF FLOW RATES

.1 Speed
r.p.m. :700
Setting Point
hPa:(*) 400
Pressure on LDA
Average Flow
em 3 : 47.5-48.5
per 1000 Deliveries
r.p.m.: 500
.2 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 3: 56.5-60.3
per I000 Deliveries
r.p.m.:
800
.3 Speed
O
hPa:
Pressure on LDA
Average Flow
em 3: 32.0-36.0
per 1000 Deliveries
r.p.m.: 500
.4 Speed
hPa: O
Pressure on LDA
Average Flow
em 3: 24.0-25.0
per 1000 Deliveries
r.p.m.: 1500
.5 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 3: 55.5-60.5
per 1000 Deliveries
r.p.m.:
1800
.6 Speed
hPa:
1000
Pressure on LDA
Average Flow
em 3: 58.5-59.5
per 1000 Deliveries
r.p.m.: 1900
.7 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 3 : 55.8-59.8
per 1000 Deliveries
r.p.m.: 2000
.8 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 3: 53.0-59.0
per 1000 Deliveries
r.p.m.: 2100
.9 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 3: 49.5-57.5
per 1000 Deliveries
r.p.m.: 2300
.10 Speed
hPa: 1000
Pressure on LDA
Average Flow
em 34.5-9.5
per I000 Deliveries
r.p.m.:
.11 Speed
hPa:
Pressure on LDA
Average Flow
per I000 Deliveries
DATE: 01.12.90
15 - ZERO FLOW (STOP)

.1 Mechanical:
Speed
Average Flow
per 1000 Deliveries
.2 Electrical:
Speed
Voltage
Average Flow
per 1000 Deliveries
16 - FLOW AT IDLING
.1 Speed
Average Flow
per 1000 Deliveries
.2 Speed
Average Flow
per 1000 Deliveries
.3 Speed
Average Flow
per 1000 Deliveries
Radial Flow:
.4 Speed
Average Flow
per 1000 Deliveries
r.p.m.:
r.p.m.:
volt:
rpm.:500
em 3: 0.0-2.0
r.p.m.: 375
em 3: 13.0-14.0
r.p.m.: 300
em 3: 41.0-51.0
r.p.m.:
17 - EXTRA FLOW AUTOMATIC

STARTER
r.p.m.:
.1 Speed
Average Flow
per 1000 Deliveries
.2 Speed
Average Flow
per 1000 Deliveries
18 - SETTING AND CHECKING THE

POTENTIOMETER
Supply
Setting:
Speed
Average Flow
per 1000 Deliveries
Potentiometer Output
Voltage
Control:
Speed
Average Flow
per 1000 Deliveries
Potentiometer Output
Voltage
volts:
r.p.m.:
em 3:
volts:
r.p.m.:
em 3:
volts:
19 - STOP ELECTROMAGNET
Minimum Working
Voltage
Rated Voltage
volts:
volts:
20 - FITTING AND SETTING MEASUREMENTS
Deseripeion:
K
KF
MS
SVS
XK
XL
LDASTROKE
mm: 3.3
mm:5.31
mm: 1.00
mm:max.
mm:
mm
mm:6.0+ 1.0
NOTES:
I) ENTRIES WITH NO ALPHANUMERIC VALUES
REFER TO OTHER TYPES OF INJECTION
PUMPS.
3) MEASUREMENTS MADE ON
INJECTION
PUMPS FITTED WITH "KSB" MUST BE TAKEN
WITH THE KSB OFF.
4) (*) TURN LDA SPRING PRELOAD ADjUSTMENT RING NUT (BOSCH REFERENCE N 46).
DAILY - TURBODAILY - TURBODAJLY 4X4
FEEDING
93
INJECTION PUMP TEST VALUES.
IVECO
No. 99478071
ENGINEERING
Edit 2
INJECTION ROTARY PUMP TEST VALUES

Injection pump: VE411 OF21 OOR675
Speed governor: MIN/MAX
IVECO PART N. 98492219

BOSCH PART N. 0460 404 08S
Engine
For:
8140.67F.3700
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
Pipes: 0 6 x 0 2 x 450 mm
Injectors: 1688 90 I 022
Calibrated hole pad: 0
mm
Injector setting: I 30 + 3 bar
Bacldlow chock 0
055 mm
IXI
Supply pressure:
O.3S 0.05 bar
Burette evacuation time:
30"
Test fiuid conforming to standard:
ISO 4113
Temperature
Infiux
Defiuxion
Thermometer : 45 I C
Electronic
4 C
IXI
"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
IVECO
DAlLY - TURBODAILY - TURBODAlLY 4X4
ENGINEERING
No. 99478071
Edit. 2

9- START
14 - DELIVERY RUN AND ADJUSTMENT
Speed
Delivery per 1000 shots
Minimum delivery
rpm:
cm 3:
em 3:
100
80.0 20
60.0
10 - "LFB" SETTING
Speed
Overcharging pressure
I. Delivery difference
per I000 shots
2. Transfer pump pressure
difference
rpm:
hPa:
1250
em 3;
-101.0
bar:
0.2 O.I
hPa:
rpm:
mm:
mm:
2 Speed
Advance travel
3 Speed
Advance travel
rpm:
mm:
mm:
rpm:
mm:
mm;
4 Speed
Advance travel
1250
VO.I
( 0.6)
2000
7.4 OJ
( 0.7)
1000
0.9 OJ
( 0.7)
hPa:
rpm:
bar:
rpm:
bar:
rpm:
bar:
rpm:
bar:
1250
5.8 OJ
2000
82 0.3
600
3J OJ
Speed
Bacldlow volume c.cl lOs:
c.cl lOs:
2 Speed
Backflow volume c.c./ lOs:
c.c./IOs:
Date:
04-04-1997
rpm:
hPa:
S Speed
6 Speed
rpm:
hPa:
em 3;
em 3;
rpm:
hPa:
em 3;
em 3;
rpm:
hPa:
em 3;
em 3;
rpm:
hPa:
em 3;
em 3;
rpm:
hPa:
cm3:
cm 3:
rpm:
hPa:
em 3;
em 3:
8 Speed
OverCharging pressure
9 Speed
10 Speed
Delivery per I000 shots
rpm:
hPa
em);
em 3;
rpm:
. hPa:
(0)
2600
1.5 1.5
( 1.5)
2300
32 2.0
( 6.0)
2100
44.0 1.5
( 2.5)
1500
43.5 0.5
(2.0)
1000
41.0 1.5
( 2.5)
600
36.5 1.5
( 3.0)
em 3;
cm l
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
em 3:
em);
13 - BACKFLOW VOLUME ON VALVE

I
3 Speed
7 Speed
rpm:
mm:
mm:
12 - TRANSFER PRESSURE RUN

I Speed
Transfer pump pressure
2 Speed
3 Speed
4 Speed
2 Speed
Overchargng pressure
4 Speed
I I -INJECTION ADVANCE RUN

I Speed
Advance travel
I Speed
600
41.4"' 85.5
(26.4", 100.5)
rpm:
2100
hPa:
55.2"' 138.0
(40.2", 153)
Sheet 2/4
DAILY - TURBODAILY - TURBODAILY 4X4
IVECO
Date:
ENGINEERING
04-04--1997
FEEDING
No. 99478071
95
Edit 2
Sheet 3/4
96
FEEDING
IVECO
DAILY - TURBODAlLY - TURBODAILY 4X4
ENGINEERING
INJECTION
ROTARY
No. 478071
Edit. 2
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

APPROVAL PROTOCOL N. 200-2195 OF 20.10.1995
CID.
DATE
04-04-97
Sheet 4/4
DAJLY - TURBODAJLY - TURBODAILY 4X4
IVECO
FEEDING
No, 99464658
ENGINEERING
INJECTION
ROTARY
97
Edit. 2
PUMP TEST VALUES
Injection pump: VE4/ 12F 1800R657

Speed governor: All speeds
IVECO PART
BOSCH PART
Engine
For:
8140,233700
8140233800
N,994778S9
N, 0460 424 124
IVECO
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
CONFORMING TO STANDARDS ISO 4008/1 -/2
Rotation direction:
Right
Left
Pipes: 121 6 x 121 2 x 840 mm
Calibrated hole pad: O,S mm
Injector setting: 2S0 + 3 bar
Backflow chock: 121 0,60 mm
=
=
IXI
0.35 O,OS bar

Supply pressure:
KMM
Test fluid conforming to standard: ISO 41 13
Temperature
Influx
Thermometer
Electronic
Defluxion
: S5
I C
4C
Ixi

Date:
03 -06-1996
Sheet 1/4
98
FEEDING
IVECO
ENGINEERING
INJECTION
No. 99464658
ROTARY PU M P TEST VALUES
9- START
Speed
rpm:
em 3:
Minimum delivery
em 3;
100
8S.0 2S
60.0
10 - "LFB" SETIING
Speed
per I000 shots
difference
rpm:
hPa:
3 Speed
em 3:
bar:
2 Speed
Advance travel
hPa:
rpm:
mm:
mm:
rpm:
mm:
mm:
3 Speed
Advance travel
rpm:
mm:
mm:
4 Speed
Advance travel
1200
1200
1.1 O.I
( 0.7)
ISOO
32 05
( 0.7)
1800
4.9 OJ
( 0.5)
rpm:
hPa:
rpm:
bar:
rpm:
bar:
rpm:
bar:
rpm:
bar:
1200
1200
7.2 0.3
1800
9J OJ
600
4.7 0.3

I
Speed
Backflow volume c.c.lIOs:
c.c./IOs:
2 Speed
Backflow volume
c.c.lIOs:
c.c.lIOs:
Date:
03-D6-1997
4 Speed
5 Speed
6 Speed
7 Speed
mm:
mm:

I Speed
2 Speed
3 Speed
4 Speed
I Speed
2 Speed

I Speed
Advance travel
Edit. 2
8 Speed
9 Speed
10 Speed
rpm:
hPa:
em 3:
cm J
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
cm J
em 3;
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
cm J
em 3:
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
cm 3:
em 3:
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
800 (0)
SOO
S1.0 0.5
( 3.5)
2200
1200
2.0 2.0
( 2.0)
2100
1200
20.0 6.0
( 9.0)
2200
1200
430 30
( 45)
1800
1200
6152.0
(3.5)
1100
1200
58.5 05
( 35)
9S0
1200
58.0 3.0
( 5.0)
600
1200
625 3.5
( 6.0)
SSO
305 05
( 3.S)
em 3:
em 3:
rpm:
hPa:
600
1200
1104 + 132,5
(954 + 1465)
rpm:
1800
hPa:
1200
IS2.0 + 207.0
(137 + 222)
Sheet 2/4
IVECO
ENGINEERING
FEEDING
No. 99464658
99
Edit 2
INJECTION ROTARY PUMP TE5T VALUES
Date:
19--D2-1996
Sheet 3/4
100
FEEDING
IVECO
ENGINEERING
INJECTION
ROTARY
No. 99464658
Edit. 2
PUMP TEST VALUES
REMARKS:
designs.
2) For a correct adjustment of injection pumps on the electric bench, conform to the manual
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

TABEL BOSCH OF 02.04.1996
C.I.D.
77-9503-0501-085
DATE
03-06-1996
Sheet 4/4
DAILY - TURBODAJLY - TURBODAILY 4X4
IVECO
FEEDING
Edit 2
No. 99464659
ENGINEERING
101
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
Speed governor ALL SPEEDS
IVECO PART
BOSCH PART
Engine: 8140.433700
For:IVECO
N.99477860
N. 0460
.
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
CONFORMING TO STANDARDS ISO 4008/ I -/2
- Rotation direction:
Right
Left
Pipes: 0 6 x 0 2 x 450 mm
Calibrated hole pad: 0 = 05 mm
Injector settng : 250 + 3 bar
Backflow chock 0 = 0.7S mm
Supply pressure:

KMM
Test fluid conforming to standard: ISO 41 I 3
Temperature at
Influx
Defluxion
X
Thermometer:
55 I C
4C
Electronic
0.35 0.05 bar
II

1- START OF DELIVERY
r--
Pre-lift (from BD.C)
mm:
o 0.Q2
2- ADVANCE CHANGER TRAVEL

Speed
Adjustment values
rpm:
hPa:
mm:
1100
1200
1.6 0.1
3- TRANSFER PUMP PRESSURE

Speed
Adjustment values
rpm:
hP.:
bar:
1100
1200
7.4 0.3
4- DELIVERY AT FULL LOAD WITH OVERCHARGING

Speed
Max difference
rpm:
hPa:
em 3:
em 3:
1750
1200
63.0 05
4.0 (45)
S- DELIVERY AT FULL LOAD WITHOUT

OVERCHARGING
Speed
Max difference
rpm:
cm 1
SSO
34.0 05
em 3:
6- IDLE SPEED ADJUSTMENT

Speed
Max difference
rpm:
em 3:
em3:
375
7.0 2.0
60 (65)
7- ADJUSTING THE RESIDUAL DELIVERY

Speed
rpm:
em 3:
8- MAXIMUM SPEED ADJUSTMENT

Speed
rpm:
hPa:
em 3:
2100
1200
20 5
Date:
03-06-1996
Sheet 1/4
102
FEEDING
IVECO
DAlLY - TURBODAlLY - TURBODAlLY 4X4
ENGINEERING
No. 99464659
INJECTION ROTARY
9- START
P U M P T EST VALUES
Speed
Minimum delivery
rpm:
em 3:
em 3:
100
85.0 25
60.0
10 - "LFB" SETTING
per 1000 shots
bar:
4 Speed

I Speed
Advance travel
hPa:
rpm:
mm:
mm:
rpm:
2 Speed
Advance travel
mm:
mm:
rpm:
3 Speed
Advance travel
mm:
mm:
4 Speed
Advance travel
rpm:
mm:
Speed
3 Speed
em 3:

difference
2 Speed
rpm:
hPa:
Speed
1200
1100
1.6 0.1
( 0.7)
1600
4 0.3
( 0.7)
1400
2.B 0.3
( 0.7)
1800
S.I Ol
5 Speed
6 Speed
7 Speed
Overchar~ng
pressure
mm:

I Speed
Transfer pump
2 Speed
Transfer pump
3 Speed
Transfer pump
4 Speed
Transfer pump
Edit. 2
pressure
pressure
presSUre
pressure
hPa:
rpm:
bar:
rpm:
bar:
rpm:
bar:
rpm:
bar:
1200
110
6.B 0.3
1800
B.8 0.3
600
52 0.3
8 Speed
9 Speed
10 Speed
rpm:
hPa:
em 3:
cm 1
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
em 3:
cm 1
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
em 3:
em 3:
rpm:
hPa:
cm 1
em 3;
rpm:
hPa:
cm 1
cm 1
rpm:
hPa:
em 3:
em 3;
rpm:
hPa:
em 3;
em 3:
800(')
500
54.0 0.5
( 3.5)
2200
1200
2.0 2.0
( 2.0)
2100
1200
2.0 5.0
( 7.0)
2200
1200
43.0 3
( 4.5)
1800
1200
63.0 2.0
( 3.S)
1750
1200
3.0 0.5
( 3.5)
1400
1200
61.02.5
( 5.0)
900
1200
58.0 2.5
5.0)
600
1200
64.0 2.0
( 6.0)
550
0
34.0 0.5
( 3.5)

I Speed
Backflow volume eel lOs:
eel lOs:
2 Speed
Backflow volume
eell Os:
ec.! lOs:
Date:
03--D6-1996
rpm:
hPa:
600
1200
75.0.;- 18.7
(60.5.;- 133.7)
1800
rpm:
1200
hPa:
96.6.;- 179.4
(82.3.;- 195.7)
Sheet 214
."
DAilY - TURBODAllY - TURBODAllY 4X4
IVECO
ENGINEERING
INJECTION
Date:
FEEDING
03-06-1996
No. 99464659
103
Edrt:.2
ROTARY PUMP TE5T VALUES
Sheet 3/4
104
fEEDING
IVECO
No. 99464659
ENGINEERING
Edit. 2

REMARKS:
designs.
2) For a correct adjustment of injection pumps on the electric bench, conform to the manual
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

TABLE BOSCH OF 9.2.1996
C.I.D.
77-9503-0501-085
DATE
03-06-96
Sheet 4/4
DAlLY - TURBODAILY - TURBODAlLY 4X4
IVECO
FEEDING
Edit. 2
No. 98496232
ENGINEERING
105

Injection pump: VE4/ I IE 1900R565
Speed governor: ELECTRONIC
IVECO PART
BOSCH PART
N.98475855
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
CONFORMING TO STANDARDS ISO 400811 -/2
-
Pipes: I 680 750 073 (6X2X450)

Injectors: 1688 90 I I 16
Calibrated hole pad: d
mm
Injector setting: 207 + 3 bar
Backfiow chock: '" = 0.75 mm
Test cables:
I) Delivery actuator: KDEP 1865/5
2) Injection start electromagnetic valve: KDEP 1865/6
='"
Bench test control box: EPS 865

Signal converter: EPS 9 10
Supply pressure
bar
Burette emptyng time
Test fluid
Temperature at:
Defluxion:
Electronic
Influx:
Thermometer
Wa~ing state
Recovery signaling voltage
0.35
0.05
30"
ISO 4113
45C
35 + 40C
1100
2500 mv
1- ACTUATOR
r---
Connections 4 and 7
Test temperature:
15 + 30C
50 + 70C
2 Connection 4 and earth
4 Connections 2 and 7
5 Connections 4 and 6
0.40 - 1.0
Ohm:
0.45-1.1
Ohm:
1.0 min.
MOhm:
1.0 min.
MOhm:
1.0min.
MOhm:
MOhm:
1.0 min.
3- FUEL TEMPERATURE DETECTOR

I Connections 5 and 6
Test temperature:
kOhm:
15 + 30C
50 + 70C
kOhm:
MOhm:
MOhm:
4- INJECTION START ELECTROMAGNETIC VALVE

Connections I and 2
Test temperature:
2- HDK TRANSDUCER
15 + 30'C
50 + 70C
Transducer coils
Test temperature
I Connections 2 and 3
2 Connections I and 2
3 Connections I and 3
4 Connection I and earth
Date:
17-03-1995
1.2 - 4.0
0.3 - 1.2
1.0
1.0
15 + 70C
4.9 - 6.5
Ohm:
Ohm:
9.8 - 13.0
4.9 - 6.5
Ohm:
1.0 min.
MOhm:
1.0 min.
MOhm:
MOhm:
1.0min.
5- STANDSTILL START
I
STANDSTILL STOP
Ohm:
Ohm:
14.3- 17.3
15.5 - 21.0
mV:
4120 - 4650
mV:
650 - 850
Sheet 1/4
106
FEEDING
IVECO
ENGINEERING
No. 98496232
Edit. 2

"THE NUMBERS GIVEN IN BRACKETS SHOULD BE USED ONLY AS CONTROL VALUES"
6- START OF DELIVERY
Pre-lif\ (from B.D.C)
mm:
7- TRANSFER PUMP PRESSURE

Speed
Adjustment value
Injection start
rpm:
mV:
bar:
electromagnetic valve
vo~:
500
1950
6.9 004
0
8- INJECTION ADVANCE CALIBRATOR TRAVEL

rpm:
Speed
mV:
Injection advance calibrator travel mm:
Injection start
volt:
SOO
1950
9A 1.0
0
rpm:
mY:
em 3:
volt
rpm:
I Speed:
mY:
Feed pump pressure
bar:
Injection start electromagnetic
valve
volt
rpm:
2 Speed:
mY:
Feed pump pressure
bar:
Injection start
volt
rpm:
3 Speed:
mV:
bar:
Feed pump pressure
Injection start
volt:
17-03-1995
electro--magnetic valve
volt
I I -INJECTION ADVANCE CALIBRATOR RUN

I Speed:
Injection advance calibrator
travel
rpm:
mV:
mm:
1900
3S00
1104 0.6
volt:
rpm:
mY:
0
750
2050
mm:
10A 1.5
volt:
rpm:
mY:
0
1300
1420
calibrator travel
Injection start
mm:
1.5 max.
volt:
rpm:
mY:
12
2 Speed:
Injection advance
calibrator travel
Injection start
750
2050
39.7 1.5
0
2.5
10 - TRANSFER PUMP PRESSURE RUN
Date:
rpm:
mV:
bar:
Injection start
9- DELIVERY AT FULL LOAD

Speed
Injection start
Leakage per I000 shots
Speed:
Feed pump pressure
Injection start
100
2870
1.9 0.3
0
500
1950
6.9 004
3 Speed:
Injection advance
4 Speed:
Recovery signaling vo~age
Injection advance
calibrator travel
mm:
Injection start
5 Speed:
volt
rpm:
mV:
Injection advance
calibrator travel
Injection start
mm:
volt:
0
1900
350
8.8 004
0
Sheet 214
DAILY - TURBODAJLY - TURBODAILY 4X4
IVECO
FEEDING
ENGINEERING
No. 98496232
107
Edit. 2
INJECTION ROTARY PU M P T EST VALUES
12 - OVERFLOW DELIVERY ON BACKFLOW VALVE
Speed:
Injection start
Delivery
cm 3/1 Os:
2 Speed:
Injection start
Delivery
rpm:
mV:
1900
3S00
volt:
0
96.6 - 179.4
rpm:
mV:
volt:
cm 3/IOs:
Speed:
Injection start
rpm:
mV:
vo~:

2 Speed:
Injection start
em 3:
em 3:
cm 1
rpm:
mV:
volt:
em 3:
em 3:
em 3:
Leakage per 1000 shots

3 Speed:
Injection start
rpm:
mV:
volt:
em 3:
em 3:
em 3:

4 Speed:
Injection start
rpm:
mV:
volt:

Date:
I7--D3-1 995
rpm:
mV:
500
1360
volt:
cm 1
cm 1
em 3:
rpm:
mV:
12
I 1.5
( 3.5)
(4.0)
13 - DELIVERY RUN
I
5 Speed:
Injection start
em 3:
em 3:
em 3:
1900
3S00
0
66.7
( 2.3)
(30)
1185
2170
0
36.5
( 2.3)
(2.5)
900
2900
0
70.2
( 2.0)
(30)
500
1950

6 Speed:
Injection start
electromag~etic valve
7 Speed:
Inject:on start
volt:
em 3:
em 3:
em 3:
rpm:
mV:
vo~:
em 3:
em 3:

8 Speed:
Injection start
em 3:
rpm:
mV:
volt
cm 1

9 Speed:
Injection start
em 3:
em 3:
rpm:
mV:
vo~:
em 3:
em 3:
em 3:
0
41.5
( 2.5)
(2.5
Sheet 3/4
108
FEEDING
IVECO
ENGINEERING
INJECTION
14 -STARTING
I Speed:
Injection start
2 Speed:
Injection start
electromagnetic valve volt
No. 98496232
ROTARY
Edit. 2
PUMP TEST VALUES
IS - STOP CHECK
rpm:
mV:
cm J
100
2870
82.0 15
volt
cm 3:
rpm:
mV:
cm 3:
12
Speed:
LEAB
rpm:
mV:
vo~
cm J
I 6 - ELECTROMAGNET FOR STOP

Operating minimum voltage
Rated voltage
volt
10
12
vo~
17 - ASSEMBLY AND ADJUSTMENT DIMENSIONS

Denomination:
K
KF
SVS max
FH
3.74
K-oT
mm:
mm:
mm:
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
Date:
17-03-1995
C.I.D.
77 9S33 0003 085
77 9533 0004 085
DATE
21/0211994
17/0311995
Sheet 4/4
fEEDING
COLD
INJECTION
ADVANCE
BETRIEBSEINRICHTUNG]
AUTOMATIC
(KSB)
[KALT
START
C-c
figu.e I
DEVICE
109
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
(6) to move, thus producing an increase of advance with
respect to the value of fitting static advance. At engine start
the resistance existing in the thermal bulb (I) is fed by
alternator 0+. The heat generated by the flow of current,
heats the wax that expands and causes pushing rod to come
out, resetting the lever (2) to position "b" by degrees.
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

minutes of operation.
Check and adjustment

The check and adjustment, if required, of K5B tool is
carried out with the injection pump placed on a test
bench.
'''''I/'~~_::::::r4+1\.7)
1420341
Remove the cover of advance changer piston. fit tool

99365143 (7) and set it to zero.
5upplya 12V voltage to the thermal bulb (I) ofKSB to cut out
this lattec
~.I
..........--
--'--
KSB device is cut out when the lever (2) is released.
........
Shift the lever (2) leftward, so as to put the pin (4, Fig. 246) in
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
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 prescribed value, otherwise loosen the clamp (6) and
tighten it again after placing it conveniently on the cable (5). Fit
then thermal bulb (I).
110
FEEDING
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:
~--
ENGINE
814067F
--~ ' - '
SmlNG
PRESSURE
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 =
=
=
XI
,X2
2.6 mm push rod stroke

15.4 mm push rod end-of-stroke
18 0.1 mm push rod beginning of stroke

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How does the fuel system work?

How does the fuel system work?

What are the components of the fuel system?

What are the components of the fuel system?

66

FUEL SYSTEM DIAGRAM

The fuel system comprises:

When the pressure of the excess fuel is greater than

The air filter cartridge is replaced by operating from

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

o unscrew knob (I) and remove protective cover;

NOTE: When one or more fuel pipes are replaced or

FUEL LIFT PUMP

240'\, ;", -FIGURE

o unscreW wing nut (I), pull out the cartridge and

Block the injector in a vice, unscrew nozzle retaining nut

Injectors (I) are checked and calibrated with special

STARTING THE ENGINE AT LOW

NOTE: The variable pitch spring (I) is fitted correctly

Insert key in the commutator and turn it to position I

INJECTION PUMP VER 293

LONGITUDINAL SECTION OF INJECTION PUMP

END OF DELIVERY STAGE

I. Fuel Inlet - 2. Solenoid Valve - 3. Axial Groove - 4. Compression

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

As it moves towards TDe. distributor plunger (6)

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

STOPPING THE ENGINE

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

The engine is stopped by cutting out the starter

I. Plunger - 2. Spring - 3. Connecting Pin - 4. Roller Ring - 5. Locking Pin - 6.

The automatic injection advance unit is embodied in the

AUTOMATIC ADVANCE UNIT

AUTOMATIC ADVANCE UNIT COMPONENTS

I UI\DVU/'\IL I II'! 1l:I\\..VVLl:1\

When solenoid valve (6) is supplied with power, fuel

Thus the full stroke of the pumping element is utilised

STARTER CUT OFF

Once the engine has started, the effect of centrifugal

In this condition slider (4) moves across and causes

START OF DELIVERY TO MATCH LOAD (LFB)

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

As the r.p.m. of the injection pump increase. regardless

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

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

LDA DEVICE (ADJUSTMENT OF FLOW RELATIVE

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

DISMANTLING THE INJECTION PUMP

Note position of reference marks between spindle (2)

Fix injection pump (I) to plate (2) of Adjustable

Mark fitting position (see arrow) of diaphragm (I) in

Unscrew spring load adjustment ring nut (I).

Turn diaphragm (I) complete with adjustment pin (2)

Remove seal plug (2). remove bleed screw ( I ), unscrew

Remove diaphragm reaction spring ( I) and spacer bush

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

I U~DVLJI'\IL I 11'\1 I CI"\.\",.VVLCI'\.

Measure distance between top of bush (I) and surface

Pull out feeler pin (I) using pliers.