Professional Documents
Culture Documents
VOLVO
Diesel engine
TAD1241GE
TAD1242GE
7741112 – 7741102
33525056801_1_1
7741302 - 7741312
Workshop Manual
Technical Data
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
Technical data
Engine
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
Contents
Safety information
The Service Manual contains technical data, If work is carried out near an engine that is run-
descriptions and repair instructions relating to the ning, an incautious movement or a dropped tool
Volvo Penta products or product versions included in could in the worst case lead to bodily harm. Be
the list of contents. Make sure you use the right mindful of hot surfaces (exhaust pipes, the
workshop literature. turbocharger, charge air pipes, starter elements,
Read the safety information, “General etc.) and hot liquids in lines and hoses on an
information” and “Repair instructions” carefully engine that is running or has just been stopped.
before starting any service work. Before starting the engine, refit all guards and
protective elements that were removed in the
course of carrying out service work.
Important
The following special warning symbols occur in the Make sure that the warning and/or information
Service Manual and on the product. decals affixed to the product are always in plain
sight. Replace decals that are damaged or have
WARNING! Warns of the risk of injury and been painted over.
extensive damage to the product or property,
or that serious functional faults could arise if
the instructions are not followed.
Never start the engine unless the air filter is
IMPORTANT! Used to draw attention to any-
fitted. The rotating impeller in the turbo could
thing that could cause damage to the product or
cause serious injuries. Foreign objects in the in-
property or functional disorders in the same.
let line could additionally cause machinery dam-
age.
NOTE: Used to draw attention to important information
for facilitating work operations or handling.
Hot oil can cause burns, Avoid getting hot oil on WARNING! Under no circumstances should
your skin. Make sure that the lubricating system the engine’s pressure pipes be bent or
is depressurized before starting any work on it. reshaped. Damaged pipes must be changed.
Never start or run the engine with the oil filler
cap removed as oil under pressure could then
escape.
All fuels and many chemicals are flammable.
Stop the engine before doing any work on the Make sure that they cannot be ignited by a
cooling system. naked flame or spark. Petrol, certain diluents
and hydrogen from batteries, when mixed with
air in the right proportions, are highly flammable
and explosive. No smoking! Arrange for ad-
Always use protective goggles when carrying equate ventilation and take the necessary safety
out work where splinters, grinding sparks and measures prior to the start of welding or grind-
splashes of acid or other chemicals could occur. ing work in the vicinity. Always keep a fire ex-
The eyes are especially sensitive and an injury tinguisher easily accessible at the workplace.
could result in loss of sight.
Stop the engine and cut off the current with the WARNING! Electrical system and fuel system
main switch (or switches) before starting to work components on Volvo Penta products are de-
on the electrical system. signed and manufactured to minimize the risk of
explosion and fire. The engine must not be run
The clutch should be adjusted with the engine in environments where they will be surrounded
switched off. by explosive media.
4
Group 20
General information
5
Group 20
Technical data
General
Type designation ................................................... TAD1240GE TAD1241/42GE TWD1240VE TAD1241/42VE
Number of cylinders .............................................. 6
Cylinder bore ......................................................... 131 mm (5.16")
Stroke .................................................................... 150 mm (5.91")
Swept volume ........................................................ 12.13 dm3 (740.20 inch3)
Number of valves .................................................. 24
Direction of rotation (viewed from front) ................. Clockwise
Compression ratio ................................................. 18.5:1 17.5:1 18.5:1 17.5:1
Firing order ............................................................ 1-5-3-6-2-4
Slow idling speed (rpm) ......................................... 600-1200 600-1200 600-900 600-900
Fast idling speed (rpm) .......................................... 1500-1620 1500-1620 2100 1000
/1800-1920 /1800-1920
Highest full-load engine speed (rpm) ..................... 1500/1800 1500/1800 2100 1800
Dry weight (kg) ..................................................... 1230* 1230* 1270 1230
(2706 lbs) (2706 lbs) (2794 lbs) (2706 lbs)
Engine block
Cylinder head
Type ..................................................................... One cylinder head for all cylinders with single overhead camshaft
Length ................................................................... 1078 mm (42.44")
Width ..................................................................... 397 mm (15.63")
Height .................................................................... 135 mm (5.32")
Max. surface unevenness (bottom surface) .......... 0.1 mm (0.004")
6
Group 20 Technical data
Cylinder liners
Type ...................................................................... Wet, replaceable
Sealing surface height above block surface .......... 0.15–0.20 mm (0.006–0.0079")
Number of sealing rings per cylinder liner .............. 4
Pistons
Height above cylinder block surface ....................... 0.05-0.45 mm (0.002–0.018")
Diameter, combustion chamber .............................. 89 mm (3.5")
Depth, piston bowl ................................................. 18.55 mm (0.73") (E=17.5:1) 17.14 (E=18.5:1)
Number of ring grooves ......................................... 3
Front marking ........................................................ Arrow pointing forwards
Gudgeon pin diameter ........................................... 55 mm (2.17")
Piston rings
Compression rings
Number .................................................................. 2
Piston ring clearance in groove:
upper compression ring ....................................... Trapezoidal section, no clearance
lower compression ring, vertical .......................... 0.05-0.08 mm (0.002–0.0031")
Piston ring gap:
upper compression ring ....................................... 0.425-0.575 mm (0.0167–0.0226")
wear tolerance .................................................. 1 mm (0.04")
lower compression ring ....................................... 0.8 mm (0.032")
wear tolerance .................................................. 1.3 mm (0.051")
7
Technical data Group 20
Valve mechanism
Valves
Valve head diameter
Inlet .................................................................... 40 mm (1.58")
Exhaust .............................................................. 40 mm (1.58")
Stem diameter
Inlet .................................................................... 7.960–7.975 mm (0.3134–0.3140")
Exhaust .............................................................. 7.947–7.962 mm (0.3129–0.3135")
Valve face angle
Inlet .................................................................... 29.5°
Exhaust .............................................................. 44.5°
Valve head face, (see illustration below)
Inlet (new valve) .................................................. Min.1.8 mm (0.07")
wear tolerance ..................................................... 1.4 mm (0.055")
Exhaust (new valve) ........................................... Min.1.6 mm (0.063")
wear tolerance ..................................................... 1.2 mm (0.0472")
Seat angle in cylinder head
Inlet .................................................................... 30°
Exhaust .............................................................. 45°
The valve seat should be ground down until
the distance from the valve head (new valve)
to the cylinder head surface is:
Inlet ...................................................................... 0.9–1.4 mm (0.035–0.055")
wear tolerance ..................................................... Max. 1.5 mm (0.06")
8
Group 20 Technical data
Valve seats
Outer diameter (dimension A) Standard:
Inlet .................................................................... 43.1 mm (1.697")
Exhaust .............................................................. 43.1 mm (1.697")
Oversize:
Inlet .................................................................... 43.3 mm (1.710")
Exhaust .............................................................. 43.3 mm (1.710")
Height (dimension B):
Inlet .................................................................... 8.4-8.6 mm (0.331–0.339")
Exhaust .............................................................. 7.9-8.1 mm (0.311–0.319")
Valve guides
Length:
Inlet .................................................................... 83.2–83.5 mm (3.28–3.29")
Exhaust .............................................................. 83.2–83.5 mm (3.28–3.29")
Inner diameter:
Inlet .................................................................... 8.0 mm (0.032")
Exhaust .............................................................. 8.0 mm (0.032")
Height above cylinder head spring plane:
Inlet .................................................................... 26.5±0.4 mm (1.04±0.016")
Exhaust .............................................................. 18.5±0.4 mm (0.73±0.016")
Clearance, valve stem - guide:
Inlet .................................................................... 0.03–0.05 mm (0.001–0.002")
Wear tolerance ................................................... 0.2 mm (0.008")1
Exhaust .............................................................. 0.04-0.07 mm (0.002–0.003")
Wear tolerance ................................................... 0.3 mm (0.012")1
1
Max. permissible clearance between valve stem and valve guide:
(according to the method described in ”Service Manual Engine block D12CA: valve guides, inspection”)
9
Technical data Group 20
Valve springs
Valve springs, exhaust/inlet
Valve springs:
Length without load ............................................. 72-73 mm (2.8-2.9")
With 600 N (61.2 kgfm (134.6 lbs)) load .............. 56 mm (2.2")
With 1076 N (109.7 kgfm (241.3 lbs)) load ........... 43 mm (1.7")
Rigid length max. ................................................ 41 mm (1.6")
Inner valve spring (exhaust):
Length without load ............................................. 67-68 mm (2.6-2.7")
With 243 N (24.8 kgfm (54.6 lbs)) load ................ 52 mm (2.1")
With 447 N (45.6 kgfm (100.3 lbs)) load .............. 39 mm (1.5")
Rigid length max. ................................................ 36 mm (1.4")
Timing
10
Group 20 Technical data
Camshaft
Checking camshaft setting. The engine should be cold and the No. 1 cylinder valves should be adjusted to a
clearance of 0. At a flywheel position of 6° ATDC the No. 1 cylinder inlet valve should have opened 1.6±0.3 mm
(0.063±0.012").
When checking this the timing mechanism must be rotated in the right direction (clockwise viewed from the front)
to take up any backlash.
NOTE: Do not forget to adjust the valve clearance back to the correct value after the test.
Camshaft bearings
Camshaft bearing thickness, standard: .................. 1.9 mm (0.075")
Oversize:
0.25 .................................................................... 2.0 mm (0.079")
0.50 .................................................................... 2.2 mm (0.087")
0.75 .................................................................... 2.3 mm (0.091")
Diameter, camshaft bearing housings:
Bearings 1-7 ........................................................ 73.9 mm (2.91")
11
Technical data Group 20
Crank movement
Crankshaft
Length .................................................................... 1203 mm (47.36")
Crankshaft axial clearance1 .................................... 0.10–0.40 mm (0.0039–0.0157")
Main bearing radial clearance1 ................................ 0.01–0.15 mm (0.0004–0.0059")
Max. permissible ovality
of main bearing journals and crankpins .................. 0.08 mm (0.003")
Max. permissible conicity
of main bearing journals and crankpins .................. 0.05 mm (0.002")
Max. runout of centre bearing ................................. 0.15 mm (0.006")
1
The dimensions apply to oiled parts
12
Group 20 Technical data
13
Technical data Group 20
Connecting rod
Length, centre-to-centre (E) .................................. 260 mm (10.236")
Marking:
Connecting rod and cap1 ....................................... 1 to 6
”FRONT” on the shank to face .............................. Forwards
Connecting rod bush inside diameter (G) .............. 55 mm (2.165")
Axial clearance, big-end - crankshaft, max.2 ......... 0.35 mm (0.014")
Big-end bearing, radial clearance, max.2 ................ 0.10 mm (0.004")
Straightness, max. deviation per 100 mm (3.94")
measured length .................................................... 0.06 mm (0.002")
Warping, max. deviation per 100 mm (3.94")
measured length .................................................... 0.15 mm (0.006")
1
Marking on same side
2
The measurements apply to oiled parts
Flywheel. fitted
Max. permissible axial runout,
test radius 150 mm (5.91") ...................................... 0.20 mm (0.008")
Number of teeth on starter ring ............................... 153
Sensor grooves on flywheel ................................... 3 x 18
14
Group 20 Technical data
Lubricating system
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)
The engine oil must fullfil both requirements. For markets outside Europe, API: CG-4 and CH-4 can be used instead of
ACEA: E3.
Viscosity
The viscosity should be selected from the adjacent
table. Note: the temperatures refer to constant outside
air temperature.
* Refers to synthetic or synthetic-based oil.
Oil
Change volume including changing three filters:
For horizontal installation ....................................... 35 litres (9.2 US gal)
Oil pressure
Operating engine speed 1100 rpm or higher ........... 400–550 kPa (58–80 psi)
Idling speed, minimum ........................................... 175 kPa (25 psi)
Oil filters
Number .................................................................. 3
Full-flow filter (tightened 1/2–3/4 turn after fitting) ... 2
Bypass filter (tightened 3/4–1 turn after fitting) ....... 1
Oil pump
Type ...................................................................... Gear driven
15
Technical data Group 20
Oil valves
1. Safety valve
Marking .................................................................. Yellow
Safety valve opening pressure ............................... 700 kPa (101 psi)
16
Group 20 Technical data
Fuel system
Injection order
Injection order ........................................................ 1-5-3-6-2-4
Feed pump
Feed pressure after fuel filter at 1000 rpm, min. ..... 350 kPa (51 psi)
Feed pressure after fuel filter at full load, min. ....... 350 kPa (51 psi)
Overflow valve
Opening pressure ................................................... 400–450 kPa
(58–65 psi)
Sensor spacing
Camshaft ............................................................... 0.3–1.0 mm (0.012–0.040")
Flywheel ................................................................ 0.75–2.1 mm (0.030–0.083")
Unit injectors
Prestress (setting with gauge) ................................ 68.9±0.1 mm (2.712±0.004")
17
Technical data Group 20
Cooling system
General
Type ...................................................................... Overpressure, closed
Pressure cap valve opens at ................................. 75 kPa (11 psi)
Capacity (engine) .................................................. 20 litres (5.3 US gal)
Capacity (engine + radiator and hoses) ................. 44 litres (11.6 US gal)
Coolant pump
Type ...................................................................... Geared centrifugal pump
18
Group 20 Technical data
Coolant
Type ...................................................................... Volvo Penta Coolant
Consisting of .......................................................... Ethylene glycol + corrosion inhibiting additives
Colour .................................................................... Blue-green
Mixed with .............................................................. Pure water
IMPORTANT! Coolant must be mixed with pure water, use distilled - de-ionized water. The water must ful-
fill the requirements specified by Volvo Penta, see “Water quality”.
IMPORTANT! Coolant must be used all year round. This applies even if there is never any risk for frost , to
ensure that the engine has an adequate protection against corrosion. Using anti-corrosion aditive exclusively
is not permitted in Volvo Penta’s engines. Never use water by itself as coolant.
Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has
been used or if the instructions concerning coolant mixing have not been followed.
Water quality
ASTM D4985:
Total solid particles ...................................... < 340 ppm
Total hardness: ............................................ < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ........................................................... < 100 ppm
pH value ........................................................ 5,5– 9
Silica (acc. ASTM D859) .............................. < 20 mg SiO2/l
Iron (acc. ASTM D1068) .............................. < 0.10 ppm
Manganese (acc. ASTM D858) ................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................ < 500 µS/cm
Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l
19
Technical data Group 20
Tightening torques
General tightening torques Nm (kgfm)
M6 standard bolt 8.8 .............................................. 10±1.5 (1.0±0.15)
M8 standard bolt 8.8 .............................................. 24±4 (2.4±0.4)
M10 standard bolt 8.8 ............................................ 48±8 (4.8±0.8)
M12 standard bolt 8.8 ............................................ 85±15 (8.5±1.5)
M14 standard bolt 8.8 ............................................ 140±25 (14.0±2.5)
20
Group 20 Technical data
Bolts for camshaft bearing caps should be tightened in 5 stages, see tightening diagram “Bearing caps, camshaft/
rocker arm shaft” page 23.
Timing cover, upper (see tightening diagram ”Timing cover, upper” page 25)
Timing gear incl. toothed wheel (see tightening diagram ”Timing gear” page 25)
Timing plate (see ”Timing plate” page 24) ............. 34±4 (3.4±0.4)
Group 22
Oil nozzle in timing gear
(see ”Timing gear” page 25) .................................... 34±4 (3.4±0.4)
Oil cooler, retaining bolts ........................................ 27±4 (2.7±0.4)
Cover, oil cooler (see tightening diagram
”Cover, oil cooler” page 27) ................................... 24±4
Delivery oil pipe (see ”Delivery oil pipe” page 26) .. 180° new pipe 60° used pipe
Bolt, piston cooling nozzle
(see Piston cooling nozzle” page 26) ...................... 24±4 (2.4±0.4)
Drain plug, oil sump ............................................... 60±10 (6.0±1.0)
Group 23
Bolt, retaining yoke, unit injector
(new copper sleeve)
First tightening
Stage 1 .................................................................. 20±5 (2.0±0.5)
Stage 2 .................................................................. 180°±5°
Undo the bolt for the unit injector retaining yoke
before the second tightening
Second tightening
Stage 1 .................................................................. 20±5 (2.0±0.5)
Stage 2 .................................................................. 60°±5°
Bolt, retaining yoke, unit injector
(old copper sleeve)
Stage 1 .................................................................. 20±5 (2.0±0.5)
Stage 2 .................................................................. 60°±5°
Lock nut for adjusting screw, unit injector .............. 52±4 (5.2±0.4)
Nut, connection, unit injector .................................. 1.5±0.5 (0.15±0.05)
Clamping and tightening torques for fuel lines
(see ”Fuel lines” page 28).
IMPORTANT! Pay attention and do NOT tighten the nut for the electrical
connections (on the unit injector) to a higher torque than specified above.
21
Technical data Group 20
Tightening diagram
Flywheel
Rocker cover
22
Group 20 Technical data
Cylinder head
NOTE: Tightening in stage 2 should be carried out gradually to ensure that the rocker arm shaft bottoms against
the bearing housings without bending.
NOTE: In stage 4 undo the marked bolts before continuing to stage 5. If the rocker arm shaft has been loosened
or removed, only the bolts retaining the shaft should be tightened according to the diagram on refitting.
23
Technical data Group 20
Timing plate
Centre the plate using tool 9998267. No special tightening sequence for marked bolts.
24
Group 20 Technical data
Timing
25
Technical data Group 20
26
Group 20 Technical data
Always use locating pins when positioning the cover on the engine.
27
Technical data Group 20
28
Group 20 Technical data
29
Group 20
Exhaust manifold
Intercooler (TWD)
Tightening diagram
Stage 1. Insert all of the screws; screw them down until they touch the surface.
Stage 2. Tighten the screws in accordance with the tightening diagram, to a torque of 20 ±2 Nm (14.7 ±1.5 lb. ft.).
30
Group 20
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Group 20
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address is at the bottom. We would prefer you to write in English or Swedish.
From: ............................................................................
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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7741112 English 07–2005
Workshop Manual
(Group 21)
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
Workshop Manual
Industrial Engines
TAD1240GE, TAD1241GE/VE,
TAD1242GE/VE, TWD1240VE
Contents
1
Group 21 Engine Safety information
Safety information
Introduction
This Service Manual contains descriptions and repair If work is performed near a running engine, an
instructions for the Volvo Penta products or product incautious movement or dropped tool could in
versions listed in the table of contents. This manual the worst case lead to bodily harm. Be mindful
should be used together with the Service Manual of hot surfaces (exhaust pipes, the turbochar-
Technical data for the relevant engine. Be sure to ger, charge air pipes, starter elements, etc.) and
use the correct service literature. hot liquids in lines and hoses on an engine that
Carefully read the safety information and General in- is running or has just been stopped. Before star-
formation and Repair instructions in the Service ting the engine, refit all guards and protective
Manual before starting service work. elements that were removed in the course of
performing service work.
As a rule, all service work should be performed Hot oil can cause burns. Avoid getting hot oil on
when the engine is switched off. However, some your skin. Make sure that the lubricating system
work, such as certain adjustments, requires the is depressurized before starting any work on it.
engine to be running. Approaching a running Never start or run the engine with the oil filler
engine could be dangerous. Bear in mind that cap removed as oil under pressure could then
loose-fitting clothes or long hair could get caught escape.
in rotating parts and cause serious injury.
Stop the engine before doing any work on the
cooling system.
2
Group 21 Engine Safety information
If other equipment connected to the engine Most chemicals intended for the product (such
changes its center of gravity, special lifting devi- as engine and transmission oils, glycol, gasoline
ces may be needed to obtain the right balance and diesel oil) or chemicals for workshop use
and ensure safe handling. (such as degreasers, paints and solvents) are
injurious to health. Read the instructions on the
Never perform any work on an engine that is package carefully. Always follow prescribed sa-
suspended solely from a lifting device. fety rules (such as the use of respirators, pro-
tective goggles, gloves, etc.). Make sure that
Never work alone when heavy components are other personnel are not unknowingly exposed to
to be removed, even if a safe lifting device such substances that are injurious to health such as
as a lockable block and tackle is used. Even if through the air they breathe. Make provision for
a lifting device is used, two people are generally good ventilation. Deal with used and surplus
required; one to handle the lifting device and the chemicals in the prescribed manner.
other to make sure that the components go cle-
ar and are not damaged when lifting. Exercise great care when detecting leaks in the
fuel system and testing fuel nozzles. Wear pro-
Always ensure in advance that there is suffi- tective goggles. The jets from a fuel nozzle are
cient space for dismantling to be done without under very high pressure and have great pene-
risk of injury or material damage. trative power; the fuel can penetrate deep into
body tissues and cause serious injury. Risk of
WARNING! Electrical system and fuel system blood poisoning.
components of Volvo Penta products are desig-
ned and manufactured to minimize the risk of WARNING! The engine’s pressure pipes should
explosion and fire. The engine must not be run not be bent or reshaped under any circumstanc-
in environments in which they will be surrounded es. Damaged pipes must be replaced.
by explosive media.
All fuels and many chemicals are flammable.
Always use fuel recommended by Volvo Penta. Make sure that they cannot be ignited by an
See the Owner’s Manual. Use of a lower grade open flame or spark. Gasoline, certain dilutants
fuel could damage the engine. On a diesel engi- and hydrogen from batteries, when mixed with
ne, a poor grade of fuel could lead to binding of air in the right proportions, are highly flammable
the control rod and overrevving of the engine, and explosive. No smoking! Provide for adequa-
causing risk of injury and damage. Poor fuel can te ventilation and take the necessary safety me-
also give rise to higher maintenance costs. asures prior to the start of welding or grinding
work in the vicinity. Always keep a fire ext-
Bear in mind the following when cleaning with inguisher easily accessible at the workplace.
high-pressure equipment: never direct the jet of
water on seals, rubber hoses, electrical compo- Ensure that rags saturated with oil and fuel,
nents or the radiator. Never use the high-pressu- used fuel and oil filters are kept in a safe place
re function when cleaning the engine. prior to their disposal. Under certain conditions,
spontaneous combustion can occur in oil-ingrai-
Always use protective goggles when performing ned rags. Used fuel and oil filters are environme-
work in which splinters, grinding sparks and ntally hazardous waste and, together with used
splashes of acid or other chemicals could occur. lubricating oil, contaminated fuel, residual paint,
The eyes are especially sensitive and an injury solvents, degreasers and residual detergents,
could result in loss of sight. should be taken to a suitable plant for destruc-
tion.
Avoid getting oil on your skin. Prolonged or re-
curring contact with oil can remove the skin’s Batteries should never be exposed to open fla-
natural moisture, resulting in irritation, dehydra- mes or electric sparks. Never smoke near the
tion, eczema and other skin disorders. From a batteries. When the batteries are being charged,
hygienic point of view, used oil is more harmful they give off hydrogen which, when mixed with
than fresh oil. Wear protective gloves and avoid air, forms oxyhydrogen gas. This gas is highly
clothes and rags ingrained with oil. Wash regu- flammable and very explosive. A spark, which
larly, particularly before mealtimes. Use skin lo- can occur if the batteries are connected incor-
tion intended for this purpose to avoid dehydra- rectly, could cause a battery to explode, resul-
tion and facilitate cleansing of the skin. ting in injury and damage. Do not disturb the
connections when attempting to start (risk of
sparks) and do not lean over any of the batte-
ries.
3
Group 21 Engine Safety information
Never mistake the positive and negative termin- Use the lifting eyes mounted on the engine
als for each other when installing the batteries. when lifting it. Always check that all lifting
This could cause serious damage to the electri- equipment is in good condition and that it has
cal equipment. Compare with the wiring dia- the right capacity for the job (engine weight plus
gram. transmission and extra equipment, if any).
Always wear protective goggles when charging To ensure safe handling and avoid damaging
and handling batteries. The battery electrolyte components mounted on the top of the engine,
contains highly corrosive sulfuric acid. If it gets it should be lifted using an adjustable lifting
on your skin, wash the area with soap and beam or one adapted to the engine. All chains
plenty of water. If the electrolyte gets in your or cables should run parallel to each other and
eyes, rinse them at once with plenty of water as perpendicular as possible to the top of the
and seek medical attention immediately. engine.
Stop the engine and cut off the current with the
main switch (or switches) before starting work
on the electrical system.
4
Group 21 Engine General
General information
5
Group 21 Engine Repair instructions
Repair instructions
6
Group 21 Engine Repair instructions
7
Group 21 Engine General
Group 21 Engine
8
Group 21 Engine Tools
Tools
Special tools
884994 Puller for polygon hub, vibration damper 9996159 Pin for hydraulic cylinder 9996161
885316 Tool for tilting of cylinder head 9996161 Hydraulic cylinder for changing cylin-
9991801 Drift for removing piston pin der liner, timing gear and valve gui-
des
9991821 Drift for removing flywheel bearing
9996222 Foot pump
9992000 Handle for drift 9998238
9996315 Spindle for fitting polygon hub and
9992013 Drift for removing and fitting piston pin
crankshaft gear
9992269 Drift for fitting flywheel bearing
9996394 Spacer for removing cylinder liner
9996395 Spacer for removing cylinder liner
9992479 Holder for dial indicator
9992564 Drift for fitting flywheel bearing
9996626 Adapter for hydraulic cylinder
9992584 Adapter for hydraulic cylinder 9992671 9992671
9996645 Puller for cylinder liner
9992671 Hydraulic cylinder
9996662 Pressure gauge
9992955 Plate for removing cylinder liner
9993590 Turning tool
9
Group 21 Engine Tools
9998255 9998258
9998260
9996965 Adapter for fitting polygon hub 9998258 Tool for securing cylinder head in engine
9996966 Press tool for cylinder liner stand
9998238 Drift for changing crankshaft seal
9998260 Press tool for removing and fitting valve
springs and valve guides
9998246 Tool for removing and fitting valve spring
9998261 Drift for fitting valve guide
9998248 Adapter
9998262 Drift for fitting valve guide
9998249 Protective sleeve for unit injector
10
Group 21 Engine Tools
9998266 Sealing washer for leakage check 9998599 Cleaning kit for unit injector
9998267 Guide pins for timing plate 9998601 Securing tool for cylinder head
9998272 Milling tool for cylinder liner seat 9998602 Press tool
9998335 Guide sleeve for valve stem seal 9998619 Drift for sealing ring
9998487 Puller for oil filter 9998624 Securing tool for cylinder head
9998506 Tool for removing and fitting valve spring 9998628 Press tool
11
Group 21 Engine Tools
980 9696 980 9697 980 9698 980 9699 980 9700 980 9701
12
Group 21 Engine Design and operation
Engine
The TAD1240GE, TAD1241GE/VE, TAD1242GE/VE The unit injectors are located in the center above the
andTWD1240VE are 12-liter engines with cast iron cy- pistons and are run by the control module. The control
linder blocks and wet cylinder liners. The one-piece module EDC III (Electronic Diesel Control) is located
cylinder head has a single overhead camshaft and a on the left-hand side of the cylinder block.
unit injector for each cylinder.
13
Group 21 Engine Design and operation
Cylinder head
The cylinder head, which covers all cylinders, has a
single overhead camshaft.
The cylinder head is held in place with 38 bolts spa-
ced evenly round the cylinders.
The cylinder head has separate inlet and exhaust
ports arranged for crossflow in each cylinder. The val-
ve guides are of alloyed cast iron; the steel valve se-
ats are replaceable. All valve guides have oil seals.
The unit injectors are centrally positioned and sur-
rounded by four valves per cylinder, which ensures
uniform combustion chamber geometry. The lower
part of the injectoris placed in a copper sleeve and
the fuel passage for the injectors is machined directly
in the cylinder head.
Top: Injectors
Center: Exhaust valves with double springs
Bottom: Inlet valves
14
Group 21 Engine Design and operation
Pistons
The pistons are of aluminum and are cooled by lubri-
cating oil sprayed from below by piston cooling nozz-
les and in the oil passage.
15
Group 21 Engine Design and operation
Crankshaft
The 7-bearing crankshaft is drop forged and induction
hardened on bearing surfaces and fillets. The
crankshaft has front and rear sealing rings and is usu-
ally equipped with double vibration dampers (depen-
ding on the engine variant).
Camshaft
The engine has a single overhead camshaft carried in
seven bearing housings bolted to the cylinder head.
There are two bearing housing versions, a production
housing and a spare part housing.
The bearing housings are numbered from the factory
and should not be mixed up if the engine is reconditio-
ned.
Also note that bearing housings and bearing caps are
machined together. This applies both to production
versions and spare parts versions.
The camshaft has three cams per cylinder: one for the
inlet valves, one for the exhaust valves and one for
the unit injectors.
16
Group 21 Engine Design and operation
Timing drive
The timing drive on the TAD1240GE, TAD1241GE/VE, Between the cylinder block and cylinder head is an
TAD1242GE/VE and TWD1240VE engines is located adjustable intermediate gear (13). This gear must be
at the front of the engine on a 10 mm thick steel plate. adjusted after every service measure that affects the
All gears are helical. The intermediate gears (3, 7, 9, timing. It is important that the correct flank clearance
13) are carried in bushes and pressure lubricated. Oth- is obtained between the upper and lower gears that
er lubrication is done via a nozzle (12). mesh with the adjustable intermediate gear.
17
Group 21 Engine Design and operation
1
Make sure that the ignition switch is in the “0” posi-
tion. If the ignition key is not used to start the engine,
ensure that the switch supplying the engine with the
start signal is in the “OFF” position.
2
3
Disconnect and remove the switch once you have
finished running the starter motor.
18
Group 21 Engine Repair instructions
Repair instructions
When work involves After lifting the engine
chemicals, fuel and lubricating
1
oil Clean the engine.
1 2
Turn off the battery current, remove the starter motor Pump out the engine oil (as needed).
connections.
2
Unplug the engine wiring connectors.
3
Remove the exhaust pipe.
4
Close the fuel cocks.
5
Detach the fuel connections.
6
Disconnect the cables from the engine.
7
Undo the engine mounts and lift out the engine.
19
Group 21 Engine Repair instructions
20
Group 21 Engine Repair instructions
2
Cylinder head, removing
Oil the valve yokes, camshaft cams and rocker arm
bridge.
IMPORTANT! Strict cleanliness must be
3 observed when working on the cylinder head.
Tighten the rocker arm bridge bolts successively so that
Dirt particles in the fuel passages could cause
the bridge does not bend or twist, see tightening diagram
breakdown or malfunction of the unit injectors.
”Technical data TAD1240GE, TAD1241GE/VE,
TAD1242GE/VE and TWD1240VE”. Then tighten the
bolt until it fits against the camshaft cams. Then tighten Special tools: 9993590, 9996966, 9998249, 9998251,
according to the tightening diagram. 9998255, 9998264, 9998511, 9998629
4 Prior conditions:
Check that the valve clearance of all valves is to spe- Fuel and coolant drained. See instructions in the Ser-
cification. vice Manual.
5 1
Connect a switch to the starter motor. See ”Instruc- Turn off the power by means of the main switch (swit-
tions for running the starter motor”. ches) and check that no current is supplied to the
6 engine.
2
21
Group 21 Engine Repair instructions
3 (TWD) 5
Remove the charge air pipe from between the turbo- Remove the turbocharger.
charger and the charge air cooler. 6
4
22
Group 21 Engine Repair instructions
7 9
10 (TAD)
23
Group 21 Engine Repair instructions
10 (TWD) 11 (TWD)
11 (TAD)
24
Group 21 Engine Repair instructions
12 (TAD) 14
Remove the charge air pipe between the inlet manifold Remove the intermediate bracket.
and charge air cooler. 15
13
Remove the cover from the wiring box. Remove the fuel connection and temperature sensor.
25
Group 21 Engine Repair instructions
16 (TAD) 18
Remove the protective plates round the drive belts.
19
17
26
Group 21 Engine Repair instructions
21 23
Undo the clamps and pull away the hose between the
pipes to the crankcase breather.
24
Remove the clamps and camshaft position sensor (1). Detach the water pipe from the coolant pump and radi-
22 ator hose connection.
27
Group 21 Engine Repair instructions
25 27
28
28
Group 21 Engine Repair instructions
29 31
Rotate the flywheel until the piston in cylinder 1 is at Remove the toothed wheel.
top dead center 0 ° on the flywheel and the camshaft 32
marking (TDC) is between the marks on the bearing
cap.
30
29
Group 21 Engine Repair instructions
33 35
Check that the camshaft bearing caps are factory
marked 1-7 against the relevant bearing bracket. Loo-
sen the camshaft bearing caps by tapping them care-
fully with a plastic mallet.
36
30
Group 21 Engine Repair instructions
37 40
38
Lift away the valve yokes between the inlet valves
and exhaust valves for all cylinders. Place them in the
right order for the respective cylinder.
39
31
Group 21 Engine Repair instructions
41 42
32
Group 21 Engine Repair instructions
44 46
Wipe up the engine oil that has collected in the
“bowls” under the camshaft. The oil could otherwise
run down into the coolant passages when the cylinder
head is lifted away.
47
Fit protective plug 9998251 in the hole for the unit in-
jector in the cylinder head.
45
Remove all cylinder head bolts.
Fit four lifting eyes 9998629 and attach lifting straps.
Carefully lift away the cylinder head.
33
Group 21 Engine Repair instructions
48
34
Group 21 Engine Repair instructions
3
Cylinder head, fitting/removing
jig 885316
When work does not include servicing of the cylinder
head or cylinder block, jig 885316 can be used when
replacing valves, pistons, cylinder head gaskets, etc.
When performing this work, the inlet manifold and
camshaft can remain in place.
35
Group 21 Engine Repair instructions
6 8
Pull back the catch on the jig and carefully lower the
cylinder head.
9
Remove jig 885316 and lifting eye 9998629 from the
cylinder head. Refit all removed engine components in
reverse order. See instructions ”Cylinder head, fitting”.
36
Group 21 Engine Repair instructions
2
Cylinder head, fitting
37
Group 21 Engine Repair instructions
4 5
38
Group 21 Engine Repair instructions
6 7
39
Group 21 Engine Repair instructions
9 13
Remove the lifting tools. Take protective plugs 9998251 out of the unit injector
10 holes.
Dip the cylinder head bolts in corrosion inhibitor, part IMPORTANT! Do NOTE remove all protective
no. 282036. Place them in a net or the like so that plugs at the same time but remove them one by
surplus corrosion inhibitor can run off. one as each unit injector is fitted in place.
11
14
Fit the cylinder head bolts.
Fit new sealing rings on the unit injectors. Lubricate
Tighten according to the tightening diagram. the sealing rings with engine oil. Fit the unit injectors
and press them down forcefully until they reach the
bottom; center them so that they do not touch the val-
ve springs.
Tighten the unit injectors to the specified torque. See
”Technical data TAD1240GE, TAD1241GE/VE,
TAD1242GE/VE and TWD1240VE”.
15
12
Carefully pull the wiring for the unit injectors into the Connect the electric leads to the unit injectors.
cylinder head. Tighten the wiring bracket on the cylin- NOTE: Tighten the nuts to a torque of max. 1.5 Nm.
der head.
IMPORTANT! Exercise great care when hand-
ling the unit injectors as they can easily sustain
damage if the nuts are cross-threaded or tighte-
ned too hard. If the bolts break, the entire unit
injector will have to be replaced.
40
Group 21 Engine Repair instructions
16 19
41
Group 21 Engine Repair instructions
20 22
Insert 7 bolts (M10 x 90 mm) in the holes for the rock- Fit the camshaft gear (1).
er arm bridge having no guide sleeves. 23
Tighten to M10 standard torque. Check and adjust the flank clearance, see “Timing
21 gear, changing”.
24
Fit the valve yokes between the inlet valves and ex-
haust valves for all cylinders.
42
Group 21 Engine Repair instructions
26
27
43
Group 21 Engine Repair instructions
28 32
Adjust the valves and unit injectors. See ”Valves and
unit injectors, adjusting”.
29
30
31
Clean the upper timing cover and the contact surfa-
ces.
44
Group 21 Engine Repair instructions
33 34
A = clearance mm
B = shim
C = toothed wheel
D = camshaft position sensor
NOTE: Leave the press tools in place. Allow the sea- –0.3 till 0.3 mm 1 1677894
lant to solidify for about 30 minutes. Do not forget that –0.6 till –0.3 mm 2 1677894
one of the bolts also secures the radiator fan drive.
35
Clean the threaded holes for the studs in the cylinder
head. Clean the studs, coat them with
Volvo Penta locking fluid, part no. 161053–2, and tigh-
ten them to 40±3 Nm.
Attach the wiring to the unit injectors by means of
straps round the studs.
45
Group 21 Engine Repair instructions
36 38
Apply a 2 mm thick bead of sealant, part no.
1161231–4, in the joint between the upper timing co-
ver and the cylinder block.
39
46
Group 21 Engine Repair instructions
40 43
Fit the hose between the crankcase breather pipes in
place and tighten the clamps.
41
44
NOTE: Center the holes for the studs with the pulley
and spacer.
45
Fit the drive belt, see “Group 26, Drive belts, chang-
ing”.
47
Group 21 Engine Repair instructions
46 50
48
Group 21 Engine Repair instructions
8
Cylinder head, leakage check
Prior conditions: Cylinder head removed
Special tools: 9996662, 9998258, 9998266, 9998511,
9998619, 9998666, 9998668, 9996485 Other special
equipment: 946173, 945408, 955894, 949873 (Inclu-
ded in 9998666 and 9998668: 980 9696, 980 9697,
980 9698, 980 9699, 980 9700, 980 9701)
49
Group 21 Engine Repair instructions
Check that the cock on the reducing valve (A) is Check that the knob on the reducing valve (A) is
unscrewed and attach leakage check tool 9996662 to unscrewed.
the pneumatic system. Open the cock (A) and set the 12
reducing valve so that a pressure of 100 kPa shows
on the pressure gauge. Fit the hose from the pressure gauge onto the connec-
tion nipple (980 9697).
OBS! The knob on the reducing valve can be locked 13
by turning the snap ring axially.
Remove the cylinder head from the engine stand.
NOTE: Always follow applicable safety regulations. 14
50
Group 21 Engine Repair instructions
17 23
Raise the pressure to 150 kPa. Lock the reducing val- Remove all sealing washers.
ve knob with the snap ring. Close the cock of the 24
pneumatic system.
Remove the plugs for the thermostat housing and fit
After one or two minutes, check that the air pressure the pipe connections on the cylinder head.
does not sink and that no air bubbles come from the
cylinder head. 25
18 Fit the exhaust manifold, see ”Group 25, Gasket, ex-
haust manifold, changing”.
26
51
Group 21 Engine Repair instructions
28 32
Check the seal on the piston thermostat. Replace as Fit the last two bolts on the exhaust manifold.
necessary. See ”Group 26, Piston thermostat, chang- 33
ing”.
Oil the handles of the valve yokes and fit them.
29
34
Fit the new piston thermostat in the cylinder housing.
Fit the cylinder head, see ”Cylinder head, fitting”.
30
52
Group 21 Engine Repair instructions
Removing valves
Cylinder head, valves
Special tools: 9996159, 9996161, 9996222, 9998246,
removing/fitting 9998258, 9998260, 9998335, 9998506
There are two methods of removing/fitting valves.
NOTE: It is extremely important to observe the strict- ● Fit press tool 9998260 together with the valves’
est cleanliness when working on the cylinder head. counterstay.
● Fit hydraulic cylinder 9996161 in press tool
Dirt particles in the fuel passages could cause a
9998260 and connect foot pump 9996222.
breakdown or malfunction of the unit injectors.
● Insert pin 9996159 in the hydraulic cylinder.
Depress the valve disc using tool 9998246.
Remove the valve collets.
● Remove the valve disc, the springs, the valve
yoke guide pins and the valves.
● Place the valves and springs in a marked stand
so that they can be refitted in the same cylinder
head places.
● Remove the remaining valves the same way
using the press tool.
● Remove the oil seals from the valve guides.
53
Group 21 Engine Repair instructions
Alternative removal 5
● Fit tool 9998335 and press the new oil seals down
over the valve guides.
NOTE: Make sure that the oil seals are firmly
pressed down into place.
Alternatively, tool 9998506 can be used instead of the ● Fit the spring or springs.
hydraulic cylinder. NOTE: The exhaust valves have double springs.
● Fit the valve disc using the same tool as for dis-
NOTE: Place the cylinder head on a clean, level sur-
mantling. Carefully depress the spring (springs)
face.
and fit the valve collets.
NOTE: Make sure that the cylinder head is not scrat- Alternative fitting
ched when the valves are removed.
6
Valves, fitting
3
Oil the valve stems and fit the valves.
4
Fit the valve yoke guide pins.
54
Group 21 Engine Repair instructions
4
Valve guides, inspecting
Cylinder head removed
1
Max. permissible clearance between valve handle
and valve guide.
55
Group 21 Engine Repair instructions
Fit press tool 9998260 in the holes for the cylinder Press in the valve guide for the inlet valve using tool
head retaining bolts. 9998261. Press in the exhaust valve guide using tool
NOTE: Place washers between the nuts and the cylin- 9998262.
der head surface. NOTE! Tool 9998261 is marked Inl. Tool 9998262 is
Tighten the nuts on the tool. marked Ex.
56
Group 21 Engine Repair instructions
3
Valve seat, changing Tap out the valve seat.
Special tool: 9992479
NOTE! Be careful not to damage the cylinder head.
Other special equipment: 9989876
4
Clean the valve seat meticulously and examine the
1
cylinder head for cracks.
5
6
Chill the seat in dry ice to between –60°C and –70°C
(-76°F and -94°F) and heat the cylinder head with hot
water from a hose or in some other way. Press the
valve seat into place using a drift.
NOTE: Turn the seat so that the seat angle faces the
tool.
7
Grind down the head of an old valve so that it comes Machine the seat to the correct angle and width.
about 1–3 mm further down in the seat.
Weld the old valve to the valve seat with four spot
welds (MAG welding).
57
Group 21 Engine Repair instructions
Exhaust valve
58
Group 21 Engine Repair instructions
59
Group 21 Engine Repair instructions
adjusting 2
Special tools: 9993590, 9998583, 9999696
Other special equipment: 9989876
Setting marks
Adjusting, general
3
The instructions cover adjustment of valves and unit
injectors in the following order:
Exhaust valves
Inlet valves
Unit injectors
60
Group 21 Engine Repair instructions
61
Group 21 Engine Repair instructions
9
Adjust the inlet valves the same way as the exhaust
valves but with a different clearance.
62
Group 21 Engine Repair instructions
12 Functionality check
13
Perform a functionality check by starting the engine
and running it until normal operating temperature is
attained.
Then run the engine another 4–10 minutes at idling
speed. Once idling speed is steady the cylinder balan-
cing system will have set the correct amount of fuel
for the unit injectors.
13
63
Group 21 Engine Repair instructions
3
Cylinder liners and pistons,
removing
Special tools: 9992955, 9993590, 9996394, 9996395,
9996645, 9996966
64
Group 21 Engine Repair instructions
4 2
Pistons
1
Pistons must be replaced if there are deep scratches
in the casing surface, piston ring stops are damaged
or cracked, piston ring grooves are worn or snap ring
grooves are damaged.
65
Group 21 Engine Repair instructions
1
Clean the liner seat and determine the extent of the
damage.
2
66
Group 21 Engine Repair instructions
7
Cylinder liners, fitting
Rotate the miller with even movements while rotating
the feed sleeve. Special tools: 9992479, 9996966
Other special equipment: 9989876
NOTE: Use a ratchet wrench and sleeve to rotate the
miller.
1
8 Make sure that the old sealing rings in the cylinder
When the correct height has been reached, disconti- block have been removed and that the seal faces
nue the feed and rotate the miller a few revolutions. are thoroughly cleaned. Use a brass wire brush and
cleaning fluid, part no. 11614401. Scraping tools
9
must not be used.
Remove the milling tool and clean the liner seat tho-
2
roughly.
67
Group 21 Engine Repair instructions
3 5
68
Group 21 Engine Repair instructions
7
Connecting rod small-end
The cylinder liner must be fitted within 20 minutes of
applying the sealant. bush, checking measurements
8 Before the connecting rod small-end bush is changed,
the connecting rod should be checked for cracks,
straightness and warping.
A cracked, bent or warped connecting rod must be
scrapped.
When changing connecting rod small-end bushes on
connecting rods with trapezoidal piston pin ends,
the bush must be machined.
The bush should be reamed. In a correct fit, an oiled
piston pin should slowly slide through the bush by its
own weight.
69
Group 21 Engine Repair instructions
2
Piston, changing
Special tools: 9991801, 9992013
1
Remove the snap rings from the old piston and tap out
the piston pin using tools 9991801 and 9992013. Rem-
ove the connecting rod.
2
Remove one of the snap rings from the new piston.
70
Group 21 Engine Repair instructions
3 7
Oil the piston pin, the piston bosses and the connec-
ting rod small-end bearing with engine oil.
4
71
Group 21 Engine Repair instructions
3
Timing gears, changing Remove the drive take-off, the generator and the fuel
Prior conditions: pump.
Oil sump removed, front engine mountings removed, 4
valve cover removed, upper timing cover removed and
coolant pump removed
1. Gear, camshaft 6
2. Gear, compressor
3. Intermediate gear
4. Gear, coolant pump
5. Gear, crankshaft
6. Gear, lubricating oil pump
7. Intermediate gear
8. Gear, hydraulic pump
9. Intermediate gear
10. Gear for drive belt and fuel pump
11. Gear, servo pump
12. Nozzle, gear lubrication
13. Intermediate gear, adjustable
72
Group 21 Engine Repair instructions
7 9
Use turning tool 9993590 with a ratchet wrench to stop
flywheel rotation. Secure the ratchet wrench to the
engine block.
10
73
Group 21 Engine Repair instructions
12 14
74
Group 21 Engine Repair instructions
ALT. 1
20
18
75
Group 21 Engine Repair instructions
21 ALT. 2
23
Fit the timing plate loosely on the new engine block.
Adjust the timing plate so that it is level with the bot-
tom of the engine block.
24
Fit the two (fixed) intermediate gears on the timing
plate.
25
Adjust the timing plate laterally so that the backlash
to the crankshaft gear is the same for both intermedia-
te gears. Fit dial indicator 9999683 in magnetic stand
9999696. Adjust and check until the backlash is
the same for both intermediate gears.
26
22
76
Group 21 Engine Repair instructions
28 29
77
Group 21 Engine Repair instructions
78
Group 21 Engine Repair instructions
34 38
Oil the plain bearing, fit the intermediate gear (7) and
tighten to 34±4 Nm.
Oil the plain bearings for intermediate gears (3) and
(9). Fit and tighten to 15±3 Nm. Then angle tighten to
120° ±5°.
NOTE: Use new bolts when refitting the intermediate
gears.
35
Fit the cylinder head’s adjustable intermediate gears
(13). Tighten the bolts by hand until they bottom
against the bearing bracket.
36
Place the heated polygon hub on spindle 9996315. Fit
adapter 9996626 and hydraulic cylinder 9992671. Fit
the nut on the spindle and connect foot pump 9996222
to the hydraulic cylinder. Press on the polygon hub.
Make sure that the camshaft marking for top dead cen-
NOTE: Heat the polygon hub to approx. 100°C
ter (TDC) is between the markings on the bearing cap.
(212°F).
40
37
Secure turning tool 9993590 to the engine block with a
ratchet wrench. Fit the crankshaft bolt together with
the washer and tighten to 645±25 Nm.
79
Group 21 Engine Repair instructions
41
80
Group 21 Engine Repair instructions
43 45
81
Group 21 Engine Repair instructions
47 48
49
Fit the inner vibration damper, the O-ring on the hub
and the driver. Tighten the two socket cap screws to
60±5 Nm and then angle tighten to 90° ±5°.
50
Fit the dust excluders and holder for the crankshaft
sealing ring.
82
Group 21 Engine Repair instructions
51 52
Fit the drive take-off, generator and fuel pump.
53
83
Group 21 Engine See Cylinder head, fitting/removing Repair instructions
1
Turn off the power by means of the main switch (swit-
ches) and check that no current is supplied to the
engine.
2
Remove the protective plates round the drive belts.
4
84
Group 21 Engine Repair instructions
5 7
Undo the clamps on the hose between the pipes to
the crankcase breather and pull the hose to the left.
8
Detach the water pipe from the coolant pump and radi-
ator hose connection.
85
Group 21 Engine Repair instructions
9 12
Remove the upper radiator hose connection from the Remove the exhaust pipe at the turbocharger.
cylinder head. 13
10 Remove the heat shield (three bolts) from the cylinder
Remove the front engine lifting bracket. head at the turbocharger.
11 (TWD) 14
86
Group 21 Engine Repair instructions
15 17
16
87
Group 21 Engine Repair instructions
19 22
Remove the oil pipe connected to the rocker arm bridge. Fit turning tool 9993590.
20 23
Undo the rocker arm bridge retaining bolts evenly over
the entire bridge to avoid uneven stress.
21
88
Group 21 Engine Repair instructions
25 27
Fit new camshaft bearing shells in the bearing brack-
ets and caps as necessary. Make sure that bearings
of the correct size are used and that they are fitted
correctly in their seats.
28
Lubricate the bearing surfaces with engine oil.
29
89
Group 21 Engine Repair instructions
30 33
Fit the caps on the relevant bearing brackets. Fit the NOTE: Do not forget to remove turning tool 9993590
bolts but do not tighten them. from the flywheel housing and refit the covers.
31 34
90
Group 21 Engine Repair instructions
35 38
91
Group 21 Engine Repair instructions
39 41
Adjust the valves and unit injectors. See “Valves and
unit injectors, adjusting”.
42
Clean the upper timing cover and the contact surfaces.
43
92
Group 21 Engine Repair instructions
44 45
Fit the upper timing cover. Insert the bolts in the cov- A B
er’s slotted holes. Tighten the bolts finger-tight but not Measured clearance Shim
to the specified torque.
Quantity Part no.
Fit press tools 9998602 and 9998628. Screw the tools
down so that the seal face of the timing cover against 0.2–1.0 mm – –
the valve cover is level with the seal face on the cylin- –0.3 till 0.3 mm 1 1677894
der head. Fit the other bolts and tighten to the speci- –0.6 till –0.3 mm 2 1677894
fied torque. See ”Cylinder head, fitting” step 33.
93
Group 21 Engine Repair instructions
46 48
94
Group 21 Engine Repair instructions
50 52
Pull the hose between the pipes to the crankcase
breather and secure the clamps.
51
Fit the water pipe to the coolant pump and the radiator
Mount the upper radiator hose connection on the cylin- hose connection using a new seal.
der head with new seals. 53 (TWD)
Fit the front water pipe between the charge air cooler
and the radiator hose connection.
95
Group 21 Engine Repair instructions
54 55
NOTE: Center the holes for the studs with the pulley
and spacer.
56
Fit the radiator fan (six studs) and drive belt. See
“Drive belts, changing”.
96
Group 21 Engine Repair instructions
57
Fit the protective plates round the drive belts.
58
Fit the radiator assembly, see “Radiator element,
changing”.
59
Fit the heat shield on the cylinder head.
60
97
Group 21 Engine Repair instructions
98
Group 21 Engine Repair instructions
4
Big-end bearings, changing all
Check the dimensions of the crankpins in regard to
Special tool: 9993590 maximum conicity and ovality. If any values exceed
the maximum permitted, the crankshaft must be
removed and remedied.
Prior conditions: See “Technical data TAD1240GE, TAD1241GE/VE,
Cylinder head and oil sump removed. TAD1242GE/VE and TWD1240VE”.
1 If uncertain, also check whether the crankshaft is
standard or undersize.
5
99
Group 21 Engine Repair instructions
4
Main bearings, changing all
This method describes changing main bearings
with the crankshaft in situ.
Prior conditions:
Oil sump removed.
3
Remove one main bearing cap at a time.
100
Group 21 Engine Repair instructions
6 10
Make sure that the right size is used when changing Change the other main bearings, one at a time, the
bearings. same way as the first one. After changing each main
bearing, check that the crankshaft does not bind. This
NOTE: If uncertain, check the specifications to see is done by rotating it with turning tool 9993590.
which oversizes occur. See “Technical data 11
TAD1240GE, TAD1241GE/VE, TAD1242GE/VE and Check the axial clearance of the crankshaft and
TWD1240VE”. change the axial bearing washers if the clearance is
excessive or if the washers are damaged.
7
NOTE: Measure the axial clearance using a dial indi-
cator. In regard to axial clearance, see ”Technical
data TAD1240GE, TAD1241GE/VE, TAD1242GE/VE
and TWD1240VE”.
12
101
Group 21 Engine Repair instructions
13 14
Once all main bearing caps have been tightened to the
specified torque, check the axial clearance of the
crankshaft. See “Technical data TAD1240GE,
TAD1241GE/VE, TAD1242GE/VE and TWD1240VE”.
15
Fit the oil suction pipe and oil delivery pipe. See the
instructions in the Service Manual.
16
Remove turning tool 9993590 from the flywheel hous-
ing and refit the covers.
102
Group 21 Engine Repair instructions
3
Flywheel, changing
Special tool: 9998629
1
Remove the flywheel sensor. NOTE: The flywheel weighs about 60 kg (132 lbs).
2 4
Thoroughly clean the crankshaft flange’s contact sur-
face against the flywheel.
5
Thoroughly clean the flywheel’s contact surface
against the crankshaft flange and check that the sur-
face at the location of the sensor grooves is comple-
tely free from impurities.
6
Check that the flywheel’s guide pin in the crankshaft
sits correctly in place and is free from damage.
103
Group 21 Engine Repair instructions
7 9
A = clearance mm
Attach 2 lifting eyes 9998629 and lift in the new fly- B = shim
wheel (see illustration) with a lifting strap threaded th-
rough the lifting eyes.
A B
NOTE: The flywheel weighs about 60 kg (132 lbs).
Measured clearance Shim
8
Quantity Part no.
0.2–1.0 mm – –
–0.3 till 0.3 mm 1 1677894
–0.6 till –0.3 mm 2 1677894
104
Group 21 Engine Repair instructions
Stationary engines
Flywheel bearings, changing
1
Special tools, Mobile engines: 9991801, 9991821,
Due to the tight fit, the flywheel must be removed to
9992564 Stationary engines: 9992269
be able to remove the flywheel bearing. Use a suitable
Mobile engines drift to pry out the bearing.
1 2
105
Group 21 Engine Repair instructions
2
Flywheel, marking
Checking axial runout
Special tool: 9993590
Other special equipment: 9989876, 9999696
1
106
Group 21 Engine Repair instructions
3
Gear ring, changing
1
107
Group 21 Engine Repair instructions
3
Crankshaft seal, rear, changing
Special tools: 9992000, 9998238
108
Index
B G
Bearing housing for camshaft, changing ................. 84 Gear ring, changing ................................................ 107
Before/after lifting the engine ................................. 19 General information ................................................ 5
Big-end bearings, changing .................................... 99
I
C Instructions for running the starter motor ................ 18
Camshaft ............................................................... 16
Camshaft, changing ............................................... 84 M
Camshaft, inspecting and reconditioning ................ 98 Main bearings, changing ........................................ 100
Compression test ................................................... 20
Connecting rod small-end bush, O
checking measurements ........................................ 69 Other special equipment ........................................ 12
Crankshaft seal, rear, changing .............................. 108
Crankshaft ............................................................. 16
P
Crankshaft, inspecting and reconditioning .............. 98
Piston, changing .................................................... 70
Cylinder block/cylinder liners .................................. 15
Pistons .................................................................. 15
Cylinder head ......................................................... 14
Cylinder head, fitting .............................................. 37
R
Cylinder head, fitting/removing jig 885316 .............. 35
Repair instructions ................................................. 6
Cylinder head, leakage check ................................ 49
Rocker arm mechanism, changing ......................... 59
Cylinder head, removing ......................................... 21
Cylinder head, valves removing/fitting .................... 53
Cylinder liner seat, reconditioning ........................... 66 S
Cylinder liners and pistons, inspecting ................... 65 Safety information .................................................. 2
Cylinder liners and pistons, removing ..................... 64 Special tools .......................................................... 9
Cylinder liners, fitting ............................................. 67
T
E Timing drive ........................................................... 17
Engine jig, attaching ............................................... 20 Timing gear, changing ............................................ 72
Engine ................................................................... 13
V
Valve guides, changing .......................................... 56
F
Valve guides, inspecting ........................................ 55
Flywheel bearings, changing .................................. 105
Valve seat, changing ............................................. 57
Flywheel, changing ................................................ 103
Valve seat, grinding ............................................... 58
Flywheel, marking .................................................. 106
Valves and unit injectors, adjusting ........................ 60
Valves, grinding ..................................................... 59
W
When work involves chemicals,
fuel and lubricating oil ............................................ 19
109
Notes
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Date: ...........................................................
Name: .........................................................
AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7741102-3 English 10-2001
Workshop Manual
(Group 22-26)
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
Industrial Engines
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
Contents
GROUP 20 GENERAL INFORMATION Fuel system, bleeding ........................................ 41
Safety Information ............................................... 2 Bypass valve, changing .................................... 42
General Information ............................................. 5 Fuel pressure, checking .................................... 43
General repair instructions .................................. 6 Unit injectors, changing ..................................... 44
Draining condensate water ................................ 48
GROUP 22 LUBRICATING SYSTEM Fuel pre-filter with water monitor, changing ........ 48
General ................................................................ 8
Special tools ........................................................ 9 GROUP 25 INTAKE AND EXHAUST SYSTEMS
Design and Operation General ............................................................. 49
Lubrication system ............................................. 10 Design and Operation
Repair instructions Turbocharger ..................................................... 50
Working with chemicals, fuel and Repair instructions
lubricating oil ...................................................... 12 Working with chemicals, fuel and
Oil filter, changing .............................................. 12 lubricating oil ...................................................... 51
Oil sump gasket, changing ................................. 13 Intake manifold (gasket), changing ..................... 51
Oil filter bypass valve, replacing ........................ 14 Exhaust manifold gasket, changing ................... 57
Safety valve, changing ...................................... 15 Turbocharger, changing ...................................... 60
Reducing valve, changing .................................. 15 Pressure drop indicator, checking ...................... 63
Piston cooling valve, changing ........................... 16
Bypass filter (turbocharger) bypass valve, GROUP 26 COOLING SYSTEM
changing ............................................................ 17 General .............................................................. 64
Bypass valve (pressure valve) oil cooler, Special tools ...................................................... 65
changing ............................................................ 17 Design and Operation
Piston cooling nozzle, changing ......................... 18 Cooling system (TAD) ........................................ 66
Oil pump, changing ............................................ 19 Cooling system (TWD) ....................................... 67
Oil pressure, checking ....................................... 21 Charge air cooler ................................................ 68
Engine oil, changing ........................................... 22 Repair instructions
Oil cooler element, changing .............................. 22 Cooling system, draining .................................... 69
Oil cooler element, leakage test ......................... 26 Cooling system, filling ........................................ 69
Coolant pump, changing ..................................... 70
GROUP 23 FUEL SYSTEM Coolant filter, changing ...................................... 73
General .............................................................. 28 Piston thermostat, changing .............................. 74
Instructions for working with electronic Piston thermostat, functional check ................... 75
fuel injection ....................................................... 28 Drive belts, changing ......................................... 76
Special tools ...................................................... 29 Cooling system, cleaning ................................... 79
Design and Operation Charge air cooler, changing (TAD) ...................... 80
Unit injectors, overview ...................................... 31 Charge air cooler, changing (TWD) ..................... 81
Unit injectors, working phases ........................... 32 Charge air cooler, leakage test (TAD)................. 84
Repair instructions Charge air cooler, cleaning ................................. 85
Control module (EDC III), changing ................... 34 Radiator core, changing ..................................... 86
Fuel system, draining ........................................ 36 Cooling system, leakage testing ........................ 90
Fuel filter, changing ............................................ 37 Extra coolant pump, changing (TWD) ................. 92
Fuel pump, changing ......................................... 38
Fuel pump, rebuilding ......................................... 39
Index .................................................................... 94
1
Group 20 Safety Information
Safety Information
Introduction
The Service Manual contains descriptions and service When working near a running engine, remember
instructions for the Volvo Penta products and versions that a careless movement or a dropped tool
of products listed in the list of contents. This manual could, in the worst case, lead to bodily harm. Be
should be used in conjunction with the Service Manual careful of hot surfaces (exhaust pipes, the tur-
Technical Data for the engine in question. Make sure bocharger, turbocharger air ducts, starter etc.)
that the right service literature is used. and hot liquids in lines and hoses on a running
Read the available safety information and the General engine or one that has just been stopped.
information and Repair instructions sections in the Before starting the engine, replace all guards
Service Manual carefully before starting service work. and protections that were removed during servi-
ce work.
As a rule, all service work should be carried out Hot oil can cause burns. Avoid getting hot oil on
when the engine is not running. However, some your skin. Make sure that pressure in the lubri-
tasks, such as certain adjustments, need the cating system is released before starting any
engine to be running. Approaching a running work on it. Never start or run the engine with the
engine can be dangerous. Keep in mind that loo- oil filler cap removed because oil under pressure
se-fitting clothes or long hair may get caught in could then escape.
rotating parts and cause severe injury.
Stop the engine before doing any work on the
cooling system.
2
Group 20 Safety Information
If other equipment attached to the engine chan- Most chemicals intended for the products (such
ges its center of gravity, special lifting devices as engine and transmission oils, glycol, gasoline
may be needed to obtain the right balance and and diesel fuel) or chemicals for shop use (such
ensure safe handling. as degreasers, paints and solvents) are
dangerous to your health. Carefully read the ins-
Never work on an engine that is only suspended tructions on the container. Always follow the
from a lifting device. prescribed safety rules (for the use of respira-
tors, protective goggles, gloves, etc.). Make
Never work alone when heavy components are sure that other personnel are not accidentally
to be removed, not even when a safe lifting de- exposed to substances that are dangerous to
vice like a lockable block and tackle is used. health—by breathing vapors, for example. Make
Two people will generally be required, one to provision for good ventilation. Dispose of used
handle the lifting device and the other to make and surplus chemicals in the prescribed way.
sure that the components are clear and are not
damaged during the lift. Take great care when looking for leaks in the
fuel system or testing fuel nozzles. Wear pro-
Always make sure in advance that there is tective goggles. The jets from a fuel nozzle are
enough room to work in with no danger of cau- under very high pressure and have great pene-
sing injury or material damage. trating power; the fuel can penetrate deep into
body tissues and cause serious injury, including
WARNING! The electrical system and fuel sys- the risk of blood poisoning.
tem on Volvo Penta products are designed and
manufactured to minimize the risk of explosion WARNING! Under no circumstances should the
and fire. The engine must not be run in an envi- engine’s high-pressure tubing be bent or resha-
ronment where it will be exposed to explosive ped. Damaged tubing must be replaced.
liquids or vapors.
All fuels and many chemicals are flammable.
Always use the fuel recommended by Volvo Make sure that they cannot be ignited by an
Penta. See the Owner’s Manual. The use of a open flame or spark. Gasoline, certain solvents
poorer grade of fuel could damage the engine. and hydrogen from batteries, when mixed with
On a diesel engine, a poor grade of fuel could air in the right proportions, are highly flammable
lead to binding of the control rod and overrev- and explosive. No smoking! Arrange for adequa-
ving of the engine with a consequent risk of inju- te ventilation and take the necessary safety pre-
ry and damage. Poor fuel can also cause higher cautions before starting welding or grinding in
maintenance costs. the vicinity. Always keep a fire extinguisher ea-
sily accessible at the workplace.
When cleaning with high-pressure equipment, re-
member: never direct the jet of water on seals, Make sure that rags contaminated with oil or
rubber hoses, electrical components or the radi- fuel, as well as used fuel or oil filters, are kept in
ator. Never use the high-pressure function when a safe place prior to their disposal. Under certain
cleaning the engine. conditions, spontaneous combustion can occur
in oily rags. Used fuel and oil filters, along with
Always use protective goggles when working used lubricating oil, contaminated fuel, left-over
where splinters, grinder sparks or splashes of paint, solvents, degreasers and detergents are
acid or other chemicals could occur. Eyes are all environmentally hazardous waste and should
especially sensitive and an injury could result in be taken to a recycling facility for proper treat-
loss of sight. ment.
3
Group 20 Safety Information
Batteries should never be exposed to open fla- Stop the engine and cut off the power at the
mes or electric sparks. Never smoke near batte- main switch (or switches) before starting to work
ries. When batteries are being charged they give on the electrical system.
off hydrogen gas, which combines with air to
form a mixture that is highly flammable and ex- The clutch should be adjusted with the engine
tremely explosive. If batteries are connected in- switched off.
correctly a spark can occur that could cause a
battery to explode with injury and damage as a Use the lifting eyes mounted on the engine
result. Do not disturb the connections when at- when lifting it. Always check that all lifting
tempting to start an engine (risk of sparks) and equipment is in good condition and that it has
do not lean over a battery. the right capacity for the job (weight of engine
plus gearbox and extra equipment, if any).
Never mix up the positive and negative termin-
als when installing batteries. A wrong connec- To ensure safe handling and to avoid damaging
tion could cause serious damage to the electri- components mounted on the top of the engine,
cal equipment. Check against the wiring dia- the engine should be lifted using a special-pur-
gram. pose fixture or an adjustable one set up for the
engine. All chains or cables should run parallel
Always wear protective goggles when charging to each other and be as perpendicular as pos-
and handling batteries. The battery electrolyte sible to the top of the engine.
contains highly corrosive sulfuric acid. If it gets
on your skin, wash the area with soap and
plenty of water. If the electrolyte gets in your
eyes, rinse them at once with plenty of water
and see a doctor as soon as possible.
4
Group 20 General
General Information
5
Group 20 General repair instructions
6
Group 20 General repair instructions
7
Group 22 Lubricating System General
8
Group 22 Lubricating System Tools
Tools
Special tools
9
Group 22 Lubricating System Design and Operation
10
Group 22 Lubricating System Design and Operation
11
Group 22 Lubricating System Repair instructions
Repair instructions
4
Working with chemicals, fuel
Spread a thin layer of engine oil onto the gasket of the
and lubricating oil new oil filter and install filter.
Important! Apply barrier cream to hands and always 5
wear protective gloves for work where there is a risk Install the new oil filters, see oil filter installation ins-
of contact with oil, fuel or the like. Continual skin con- tructions.
tact with engine oil dries out the skin and can be
harmful. 6
Top up engine oil and run the engine with the starter
until the lubricating oil pressure appears on the pres-
sure gauge. See “Instructions for running the starter
Oil filter, changing motor”.
Special Tool: 9998487 7
Start the engine and check for leaks around the oil
1 filters.
Clean the oil filter canister.
2
12
Group 22 Lubricating System Repair instructions
4
Oil sump gasket, changing
1
Pump out the engine oil.
See “Engine oil, changing”.
2
Remove the oil filler pipe and pull out the dipstick from
the oil pan.
13
Group 22 Lubricating System Repair instructions
6
Oil filter bypass valve,
replacing
1
14
Group 22 Lubricating System Repair instructions
6 4
Install a new oil filter, see oil filter installation instruc- Install the new reducing valve with new O-rings onto
tions. the engine block.
7 5
Start the engine and check for leaks. Start the engine and check for leaks.
15
Group 22 Lubricating System Repair instructions
4
Piston cooling valve, changing
1
Install the new valve with new O-rings in the oil filter
bracket.
5
Screw on the piston cooling valve cover.
6
Start the engine and check for leaks.
Clean the oil filter bracket and remove the cover from
the piston cooling valve, take out the O-ring.
2
Take out the piston cooling valve, clean it and check
that the old O-ring is not still in the oil filter bracket.
3
16
Group 22 Lubricating System Repair instructions
Clean the oil filter bracket and remove the cover from Clean the oil filter bracket and remove the bypass val-
the bypass valve. ve cover; take out the O-ring.
2 2
Remove the valve stem and spring. Take out the bypass valve, clean it and check that
3 the old O-ring is not still in the oil filter bracket.
Clean and check the valve seat. If the valve seat is 3
damaged the entire bracket must be replaced.
4
Install the new valve seat (1) and spring (2). Check that the new bypass valve is marked “124.”
Reinstall the bypass valve cover. Use a new 4
washer (3). Install the new bypass valve with new O-rings in the
5 oil filter bracket and screw on the cover.
Start the engine and check for leaks. 5
Start the engine and check for leaks.
17
Group 22 Lubricating System Repair instructions
4
Piston cooling nozzle, changing
Remove the piston cooling nozzle.
Special tool: 9993590 5
Install the new piston cooling nozzle with a new
1
screw.
Remove the oil pan. See “Oil pan gasket, replacing.”
NOTE: The setscrew for the piston cooling nozzle is
provided with a friction coating and can be used only
2 once.
6
Remove the twist tool and replace the cover.
7
Install the twist tool 9993590.
Make a thorough check of the installation before the
3 oil pan is replaced.
8
Replace the oil pan with a new gasket. See “Oil pan
gasket, replacement.”
9
Start the engine and check for leaks.
18
Group 22 Lubricating System Repair instructions
5
Oil pump, changing
1
Pump out the engine oil.
See “Engine oil, changing”.
2
Remove the oil pan. See “Oil sump gasket, changing”.
3
Oil the bearing with engine oil and install the idler gear
on the new oil pump.
Torque the bolts to 24 ± 4 Nm (18 ± 3 ft-lbf).
19
Group 22 Lubricating System Repair instructions
9 13
Install new O-rings for the oil strainer and oil pressure
tube.
NOTE: Check that there are no cracks on the oil strai-
ner.
14
Attach the oil strainer to the lubricating oil pump and
install the associated clamp. Tighten the bolts on the
lubricating oil pump to 27 ± 4 Nm (20 ± 3 ft-lbf).
15
20
Group 22 Lubricating System Repair instructions
17
Oil pressure, checking
Install the oil pan with a new gasket. See “Oil sump
gasket, changing”. Special Tools: 9992873, 9996398
18
Add engine oil according to specifications. See 1
“Technical data TAD1240GE, TAD1241GE/VE, The lubricating oil pressure is checked by attaching
TAD1242GE/VE, TWD1240VE”. pressure gauge 9996398 and nipple 9992873 to the rear
19 plug (M16 x 1.5) on the left-hand side of the engine.
Run the engine with the starter according to instruc- 2
tions until oil pressure appears on the pressure gauge.
See “Instructions for running on starter”.
20
Start the engine and check for leaks.
Oil pressure:
Operating speed, 1100 RPM 400-550 kPa
or higher (60-80 psi)
Idle, minimum 175 kPa (25 psi)
21
Group 22 Lubricating System Repair instructions
2
Pump out the oil.
3
Remove the drain hose.
4
Add engine oil according to specifications. See “Tech-
nical data TAD1240GE, TAD1241GE/VE,
TAD1242GE/VE, TWD1240VE”.
22
Group 22 Lubricating System Repair instructions
5 (TAD Engine) 6
23
Group 22 Lubricating System Repair instructions
8 11
Remove the rear cover plate (four bolts). Two of the- Remove the sealing rings on the engine block and re-
se are installed on the cover of the oil cooler element. move the seals in the cover. Clean all contact sur-
faces.
9
12
24
Group 22 Lubricating System Repair instructions
13 15
25
Group 22 Lubricating System Repair instructions
4
Oil cooler element, leakage
test
Special tools: 9996662, 9996845
1
Remove the oil cooler element, see “Oil cooler ele-
ment, changing.”
2
Rinse off the coolant side and the oil side of the oil
cooler with degreaser.
3
26
Group 23 Fuel System General
27
Group 23 Fuel System General
General
IMPORTANT! Ensure maximum cleanliness IMPORTANT! If the engine is turned over using
when working with the fuel system. Always cle- the starter, for valve adjustment, for example,
an the engine before starting repair work. To pre- first disconnect the cables at the junction boxes
vent contamination of the fuel system, always for the engine control system and turn the igni-
install protective plugs when connections are tion key to “0” to avoid any risk of accidentally
removed. Parts removed should be kept in a starting the engine. Check the wiring diagram to
closed plastic bag until they are reinstalled. be sure that the correct cables are disconnec-
ted. See “Instructions for running on starter”.
NOTE: For specifications, see “Technical Data,
TAD1240GE, TAD1241GE/VE, TAD1242GE/VE
and TWD1240VE”.
• Never remove the control module connectors or • Only batteries should be used for starting. Starter
any electrical cable from the sensors when the packs can cause voltage surges and damage the
engine is running. The ignition key should be in electronics.
the “0” position and the engine stopped. • For quick battery charging, disconnect the battery
• Never disconnect any battery cables when the cables. (This does not apply to normal maintenan-
engine is running. ce charging.)
• Disconnect the control module connector from the • If any connectors are disconnected, be sure that
control module when doing any electrical welding they are reconnected properly and that they are
work on the engine. free from oil and other contamination which can
cause poor contact.
NOTE: The main power must be turned off before
the connectors are disconnected.
28
Group 23 Fuel System Tools
Tools
Special Tools
29
Group 23 Fuel System Tools
30
Group 23 Fuel System Design and Operation
1. Camshaft
2. Rocker arm
3. Electrical connection for injector unit
4. Fuel passage
31
Group 23 Fuel System Design and Operation
Filling phase
During the filling phase, the pump piston (2) is moving
up to its top position.
The camshaft high point is passed and the cam follo-
wer is moving towards the base of the cam.
The fuel valve (1) is open and fuel can flow into the
pump cylinder from the lower fuel passage in the cy-
linder head and into the injector unit pump cylinder.
Filling continues until the pump piston reaches its top
position.
1 Fuel valve
2 Pump piston
Spill phase
The spill phase begins when the camshaft is turned to
the position where the cam, via the rocker arm, begins
to press the piston (2) down.
Fuel can now flow through the fuel valve (1), through the
hole in the injector and out through the fuel passage.
The spill phase continues as long as the fuel valve (1)
is open.
1 Fuel valve
2 Pump piston
32
Group 23 Fuel System Design and Operation
Injection phase
The injection phase begins when the fuel valve (1) clo-
ses. The cam on the camshaft continues to press the
piston (2) down via the rocker arm and injection takes
place as the passage through the fuel valve is closed.
The injection phase continues as long as the fuel val-
ve (1) is closed.
1 Fuel valve
2 Pump piston
33
Group 23 Fuel System Repair instructions
Repair instructions
4
Control module (EDC III),
changing
1
Disconnect power to engine.
2
34
Group 23 Fuel System Repair instructions
6 8
Connect the fuel cooling loop and the clamps for the
fuel lines on the control module.
35
Group 23 Fuel System Repair instructions
3
Fuel system, draining
Open the vent nipple on the cylinder head. Allow fuel
1 to drain into a container.
Clean carefully around the cylinder head vent nipple NOTE: For fuel filter, changing. Only perform steps
and fuel filter bracket draining nipple. 1–3 in the fuel draining procedure.
2 4
Connect a plastic hose to the fuel filter bracket drain- When the fuel has finished flowing out, open the vent
ing nipple and open the nipple (2). nipple (1) on the fuel filter bracket and allow the fuel to
drain into a container.
NOTE: Be careful when handling fuel and make sure
that it is disposed of properly.
36
Group 23 Fuel System Repair instructions
5
Fuel filter, changing
Spread a thin layer of engine oil onto the gasket and
NOTE: Do not fill the new filter with fuel before instal-
install the new fuel filter. Tighten the fuel filter accor-
ling as there is a risk of contamination entering the
ding to the instructions on the filter.
system and causing running problems or damage.
6
1 Bleed the fuel system at the filter, see “Fuel system,
bleeding”.
Clean around the fuel filter.
7
2
Run the engine at fast idle for about 10 minutes to
Drain the fuel filter, see “Fuel filter, draining”. evacuate any remaining air from the system. Perform
3 a leakage and functional check.
37
Group 23 Fuel System Repair instructions
4
Fuel pump, changing
1
38
Group 23 Fuel System Repair instructions
1
Remove the valves (4 and 7).
2
Remove the bolts (1) and take apart the housing.
3
Remove the pump impellers (6 and 8) and the gas-
ket (5).
39
Group 23 Fuel System Repair instructions
6 7
40
Group 23 Fuel System Repair instructions
4
Fuel system, bleeding
1
Clean the vent nipples on the cylinder head and on the
fuel filter bracket.
2
41
Group 23 Fuel System Repair instructions
Clean thoroughly around the bypass valve. Install a new bypass valve and gaskets. Torque to
55 ± 5 Nm (40 ± 4 ft-lbf)
2
5
Drain the fuel system, See “Fuel system, draining.”
Bleed the fuel system. See “Fuel system, bleeding.”
3 (TAD)
6
Run the engine at fast idle for about 10 minutes to
evacuate any remaining air from the system.
7
Perform a leakage check.
42
Group 23 Fuel System Repair instructions
Fuel pressure
After fuel filter at 1000 RPM, min 350 kPa
(50 psi)
After fuel filter at full load, min 350 kPa
(50 psi)
43
Group 23 Fuel System Repair instructions
3
Unit injectors, changing
Special tools: 9998249, 9998250, 9998251, 9998255,
9998511
Other special equipment: 9812546
1
Lift out the rocker arm bridge using lifting bar 9998255.
4
Drain the fuel from the cylinder head as instructed.
Remove valve cover. See “Fuel system, draining”.
5
NOTE: Do not use air tools as the studs can come
loose and the injector wiring insulation can be dama- Clean very carefully around the injectors to be repla-
ged. ced.
44
Group 23 Fuel System Repair instructions
6 8
9
Disconnect electrical wires from the injector.
45
Group 23 Fuel System Repair instructions
10 12
Clean the injector hole in the cylinder head very care-
fully and remove sealing rings 9998250.
11
46
Group 23 Fuel System Repair instructions
14 16
Adjust the valves and injectors. See “Valves and unit
injectors, adjustment”.
17
47
Group 23 Fuel System Repair instructions
18
Fuel pre-filter with water
If any stud has come loose, it must be removed, clea-
ned and coated with locking compound item no. monitor, changing
1610532 before being replaced and tightened.
Do not loosen the stud bolts or nuts until the locking
1
compound has set.
Clean around the fuel filter.
NOTE: Install the studs within 20 minutes after apply-
ing the locking fluid. 2
19
Bleed the fuel system. See “Fuel system, bleeding”.
20
Run the engine at fast idle for about 10 minutes to
evacuate any remaining air from the system.
21
Perform a leakage and function check.
48
Group 25 Intake and Exhaust Systems General
49
Group 25 Intake and Exhaust Systems Design and Operation
Turbocharger
The turbocharger is driven by exhaust gases which
pass through the turbine housing on their way out to
the exhaust system.
The exhaust gas flow causes the turbine wheel in the
housing to rotate. The compressor wheel is mounted
on the same shaft as the turbine wheel. The compres-
sor wheel is placed in a housing which is connected
between the air filter and the engine intake manifold.
When the compressor wheel rotates, air is drawn from
the air filter. The air is compressed and forced into the
engine cylinders after first being cooled while passing
through the charge air cooler.
50
Group 25 Intake and Exhaust Systems Repair instructions
Repair instructions
51
Group 25 Intake and Exhaust Systems Repair instructions
3 (TAD) 4 (TWD)
52
Group 25 Intake and Exhaust Systems Repair instructions
5 8 (TAD)
8 (TWD)
53
Group 25 Intake and Exhaust Systems Repair instructions
Installation 11 (TWD)
9
Carefully clean the contact surfaces on the intake ma-
nifold and cylinder head.
TAD: Scrape away the gasket with a wooden or plas-
tic scraper.
10 (TAD)
10 (TWD)
54
Group 25 Intake and Exhaust Systems Repair instructions
13 14 (TAD)
55
Group 25 Intake and Exhaust Systems Repair instructions
15 (TAD) 16 (TAD)
Reinstall the charge air temperature/boost pressure Reinstall the turbo delivery pipe.
sensor on the intake manifold and attach the wiring
with new ties. 17
16 (TWD) Start the engine and perform a functional test and leak
check.
56
Group 25 Intake and Exhaust Systems Repair instructions
changing
1
Turn off the main switch(es) and check that there is
no power to the engine.
2
57
Group 25 Intake and Exhaust Systems Repair instructions
5 Installation
9
Carefully clean the contact surfaces on the exhaust
manifold and cylinder head.
10
58
Group 25 Intake and Exhaust Systems Repair instructions
12 14 (TAD)
Install the turbocharger using a new gasket. Reinstall the turbo delivery pipe on the turbo.
13 14 (TWD)
59
Group 25 Intake and Exhaust Systems Repair instructions
15
Turbocharger, changing
Always troubleshoot and repair any cause of damage
to the turbo before installing a new unit.
17
1
Start the engine and perform a functional test and leak Open the main switch(es) and check that there is no
check. power to the engine.
2
60
Group 25 Intake and Exhaust Systems Repair instructions
3 (TAD) 4
61
Group 25 Intake and Exhaust Systems Repair instructions
Installation 9 (TAD)
6
Clean the contact surfaces carefully.
7
62
Group 25 Intake and Exhaust Systems Repair instructions
10
Pressure drop indicator, checking
1
Remove the pressure drop indicator. Check the pres-
Reinstall the air filter and air duct. sure drop indicator by applying a vacuum (reduced
pressure) until the indicator shows red. Press the but-
11
ton on top of the pressure drop indicator to reset.
Check the oil level and if necessary add engine oil
2
according to specifications. See “Technical data
TAD1240GE, TAD1241GE/VE, TAD1242GE/VE, When the air filter is clogged, for example, and the pres-
TWD1240VE”. sure falls, the pressure drop indicator indicates this by
showing red. If the pressure drop indicator is not wor-
12
king as described in step 1, it should be changed.
Start the engine and perform a functional test and leak
3
check.
Reinstall the pressure drop indicator.
63
Group 26 Cooling System General
64
Group 26 Cooling System Tools
Tools
Special tools
65
Group 26 Cooling System Design and Operation
66
Group 26 Cooling System Design and Operation
67
Group 26 Cooling System Design and Operation
68
Group 26 Cooling System Repair instructions
Repair instructions
2
Cooling system, draining
Check that all coolant runs out. There may be depo-
sits inside the valve/plug which must be cleaned out.
WARNING! Open the filler cap very carefully
Otherwise there is a risk that water can be trapped
when the engine is hot. Steam or hot coolant
and cause serious damage.
can spray out.
Check whether the system has any other valves or
NOTE: Before draining the cooling system, remove plugs on the lowest points of the coolant lines.
the expansion tank cap. 3
TAD
Close the valves and reinstall plugs.
69
Group 26 Cooling System Repair instructions
4
Coolant pump, changing
1
Open the main switch(es) and check that there is no
power to the engine.
2
Drain the cooling system, see “Cooling system, drain-
ing”.
3
70
Group 26 Cooling System Repair instructions
6 8
71
Group 26 Cooling System Repair instructions
10 12
Lubricate the sealing rings with a thin layer of engine
oil and install the new coolant filter. See installation
instructions on the filter canister.
Install the new gear unit in the coolant pump with new
sealing rings.
72
Group 26 Cooling System Repair instructions
15 17
73
Group 26 Cooling System Repair instructions
4
Piston thermostat, changing
1
Drain the cooling system, see “Cooling system, drain-
ing”.
2
3
Clean all contact surfaces.
74
Group 26 Cooling System Repair instructions
6
Piston thermostat, functional
Reinstall the two bolts on the exhaust manifold.
7
check
Add coolant according to specifications. See “Techni-
cal data TAD1240GE, TAD1241GE/VE, 1
TAD1242GE/VE, TWD1240VE”. Drain the cooling system, see “Cooling system, drain-
NOTE: Mix the correct volume in advance to be sure ing.”
that the system is filled. 2
8 Remove the piston thermostat, see “Piston thermo-
Start the engine and perform functional and leakage stat, changing.”
checks. 3
Closed thermostat
75
Group 26 Cooling System Repair instructions
1
Open the main switch(es) and check that there is no
power to the engine.
2
Open thermostat
76
Group 26 Cooling System Repair instructions
4 (TAD) 5
Install the new drive belt and tension the drive belt
with the tensioning screw (3) so that the slack is
about 5 mm (0.2").
6 Checking belt slack
4 (TWD)
77
Group 26 Cooling System Repair instructions
78
Group 26 Cooling System Repair instructions
6
Cooling system, cleaning
If any contamination remains, repeat the cleaning until
Part no.: 1141658-3 the system is free from contamination.
7
1 When the cooling system is completely free from con-
Drain the cooling system, see “Cooling system, drain- tamination, fill with fresh coolant. In areas where
ing”. Volvo Penta concentrated coolant is not available,
2 use water with a corrosion protection additive.
NOTE: If the cooling system is cleaned regularly by NOTE: Mix the correct volume in advance to be sure
draining and refilling with a rust-protection fluid, less that the system is filled.
cleaning additive or simply flushing with pure water
may be sufficient.
3
Flush the cooling system with fresh water.
4
Fill the cooling system with radiator cleaner, item no.
1141658-3 (see instructions on package).
Then run the engine up to normal working temperatu-
re and allow it to run for at least another 2 hours.
NOTE: Alternatively, fill the system with 15–20% con-
centrated coolant and drain it out after 1–2 days’ ope-
ration.
5
Drain the cooling system and then flush it out with a
mixture of neutralizer, part no. 1141658-3 (see instruc-
tions on package).
79
Group 26 Cooling System Repair instructions
5
Charge air cooler, changing
(TAD)
1
Open the main switch(es) and check that there is no
power to the engine.
2
Drain the cooling system, see “Cooling system, drain-
ing ”.
3
Remove the radiator assembly, see “Radiator, chang-
ing”.
4
Remove the fan cowling (10 bolts) from the charge air
cooler.
6
Install the fan cowling (10 bolts) on the new charge air
cooler.
7
Install the charge air cooler on the radiator.
8
Install the radiator, see “Radiator, changing”.
9
Add coolant according to specifications. See “Techni-
cal data TAD1240GE, TAD1241GE/VE,
TAD1242GE/VE, TWD1240VE”.
NOTE: Mix the correct volume in advance to be sure
that the system is filled.
Release the charge air cooler from the left and right
sides of the radiator assembly.
80
Group 26 Cooling System Repair instructions
4
Charge air cooler, changing
(TWD)
1
Open the main switch(es) and check that there is no
power to the engine.
2
Drain the cooling system, see “Cooling system, drain-
ing ”.
3
81
Group 26 Cooling System Repair instructions
5 7
Lift out the charge air cooler element.
Step 1. Insert all bolts and screw then down into con-
tact with the surface.
Step 2. Torque the bolts to 20 ± 2 Nm (15 ± 2 ft-lbf)
in the order shown in the diagram.
82
Group 26 Cooling System Repair instructions
10 12
83
Group 26 Cooling System Repair instructions
Leakage test
Charge air cooler, leakage test
3
(TAD)
Special tools: 9996662, 885231, 885232
84
Group 26 Cooling System Repair instructions
6
Charge air cooler, cleaning
Connect 999662 to a compressed air source. Open
valve (B) and adjust the reducing valve (A) until the Part no.: 1141658-3
pressure gauge shows a pressure of 100 kPa
(14.5 psi). Close valve (B). 1 (TWD)
7 Drain the cooling system, see “Cooling system, drain-
If the pressure does not fall within two minutes, the ing.”
charge air cooler and the connections are tight. 2
NOTE: If the pressure falls, check that there is no le- Remove the charge air cooler, see “Charge air cooler,
akage at the connections to the charge air pipe. Spray changing.”
or brush water with a little detergent added around the 3
connections to determine if they are leaking.
Clean the charge air element/cooler on the outside.
8 Rinse the air passages with fresh water. Clean the in-
If the pressure falls and the connections are not lea- side with cleaner part no. 1141658-3 and blow dry with
king, the charge air cooler should be replaced with a compressed air (or allow to stand and drain).
new one. Repeat the leakage test to be sure that the (TWD)
charge air cooler is leaking. Alternatively, the entire cooling system can be filled
9 with 15-20% concentrated coolant and drained after
After the leakage test is complete, shut of the com- 1-2 days of operation. Then remove the charge air ele-
pressed air supply, turn the knob on the reducing val- ment and clean the air passages separately as requi-
ve (A) fully counter-clockwise and release the com- red.
pressed air. 4
10 Rinse out the charge air cooler with neutralizer part
Remove the leakage tester 9996662 and the pressure no. 1141658-3 and blow dry with compressed air (or
plug 885231. Reinstall the charge air pipe on the inta- allow to stand and drain).
ke pipe using new gaskets and tighten the clamp. 5
11 Reinstall the charge air element/cooler.
Remove the pressure plug 885232. Reinstall the char- 6 (TWD)
ge air pipe between the turbo compressor and the con- Fill with coolant as specified. See “Technical data
nection and tighten the clamp. TAD1240GE, TAD1241GE/VE, TAD1242GE/VE,
12 TWD1240VE”.
Start the engine and perform a leakage check. NOTE: Mix the correct volume in advance to be sure
that the system is filled.
7
Start engine and perform functional and leakage
checks.
85
Group 26 Cooling System Repair instructions
6
Radiator core, changing
1
Open the main switch(es) and check that there is no
power to the engine.
2
Drain the cooling system, see “Cooling system, drain-
ing”.
3
86
Group 26 Cooling System Repair instructions
8 12
Remove the lower coolant hose from the radiator.
9
Loosen the charge air cooler at the left and right sides
of the radiator.
87
Group 26 Cooling System Repair instructions
13 14 (TAD)
Install the new radiator core, reinstall the frames and Reinstall the charge air cooler and tighten on the left
cover, tighten the bolts (16x). and right sides.
88
Group 26 Cooling System Repair instructions
15 18 (TAD)
NOTE: Do not forget the outer fan shroud. Clamp the lower turbo delivery pipe to the charge air
cooler.
NOTE: Fit the lower radiator hose and turbo delivery 19
pipe in before attaching the radiator to the engine sup-
port.
16
Tighten the lower radiator hose clamp.
17
89
Group 26 Cooling System Repair instructions
20 (TAD)
Cooling system, leakage
testing
Special tools: 9996433, 9996662
90
Group 26 Cooling System Repair instructions
Leakage test 6
3 Connect leak tester 9996662 to the air nipple on cap
9996433.
7
8
Remove the leak tester and open the drain on the ex-
pansion tank.
9
Check the coolant level in the expansion tank.
Connect the leak tester 9996662 to a source of com- 10
pressed air and check that the knob on the reducing Start the engine and perform a leak check.
valve (A) is turned fully counter-clockwise.
91
Group 26 Cooling System Repair instructions
92
Group 26 Cooling System Repair instructions
12 15
Mount the spacer washer (10) on the bearing axis Put a piece of metall that is wider then the coolant
(5A). pump housing (2) between the axle (5) and the mount
13 ing tool. When pressing in the axle (5) in the bearing
axis (5A) it will be mounted in line with the edges of
Press the pulley (4) on the axle (5), use gauge pin the coolant pump housing (2).
9992412. Place a pipe with a inner diameter of 27 mm
and a outer diameter of 34 mm to support the bearing Apply bearing grease on the axle (5) and press it in
axis (5A) from behind. the bearing axis (5A).
14 16
Mount gauge pin 9996315 in the bearing axis (5A)
Note! The sealing ring (11) is delivered as one unit then tighten the nut with your hands.
and not as the picture shows. Put a washer on the shovel wheel (12) so that the axle
(5) will come out 2 mm from the shovel wheel.
Press the new sealing ring (11) in to the coolant pump
The washer must be 2 mm thick and have a inner di-
housing (2), use gauge pin 9996998.
ameter that is wider then the axle (5).
Press the shovel wheel (12) on the axle (5).
17
Mount the gable (3) with a new O-ring (13).
93
Index
B I
Bypass filter (turbocharger) bypass valve, Intake manifold (gasket), changing ........................ 51
changing ............................................................... 17
Bypass valve (pressure valve) oil cooler, L
changing ............................................................... 17 Lubrication system ................................................ 10
C O
Charge air cooler ................................................... 68 Oil cooler element, leakage test ............................ 26
Charge air cooler, changing (TAD) ......................... 80 Oil filter bypass valve, replacing ........................... 22
Charge air cooler, changing (TWD) ........................ 81 Oil filter, changing ................................................. 12
Charge air cooler, cleaning .................................... 85 Oil pressure, checking .......................................... 21
Charge air cooler, leakage test (TAD) .................... 84 Oil pump, changing ............................................... 19
Control module (EDC III), changing ....................... 34 Oil sump gasket, changing .................................... 13
Coolant filter, changing .......................................... 73
Coolant pump, changing ........................................ 70 P
Cooling system (TAD) ........................................... 66 Piston cooling nozzle, changing ............................ 18
Cooling system (TWD) .......................................... 67 Piston cooling valve, changing .............................. 16
Cooling system, cleaning ...................................... 79 Piston thermostat, changing ................................. 74
Cooling system, draining ....................................... 69 Piston thermostat, functional check ...................... 75
Cooling system, filling ........................................... 69 Pressure drop indicator, checking ......................... 63
Cooling system, leakage testing ........................... 90
R
D Radiator core, changing ........................................ 86
Design and Operation, Lube oil system ................. 10 Reducing valve, changing ..................................... 15
Design and Operation, Fuel system ...................... 31
Design and Operation, Intake & exhaust system .. 50 S
Design and Operation, Cooling system ................. 66 Safety Information .................................................. 2
Drive belts, changing ............................................ 76 Safety valve, changing .......................................... 15
Special tools, Cooling system ............................... 65
E Special tools, Fuel system .................................... 29
Exhaust manifold gasket, changing ...................... 57 Special tools, Lube oil system ................................ 9
Extra coolant pump, overhaul (TWD) ...................... 92
T
F Turbocharger ......................................................... 50
Fuel filter, changing ............................................... 37 Turbocharger, changing ......................................... 60
Fuel pressure, checking ........................................ 43
Fuel pump, changing ............................................. 38 U
Fuel pump, rebuilding ............................................ 39 Unit injectors, changing ......................................... 44
Fuel system, bleeding ........................................... 41 Unit injectors, overview ......................................... 31
Fuel system, draining ............................................ 36 Unit injectors, working phases ............................... 32
G W
General Information ................................................. 5 Working with chemicals, fuel and
General repair instructions ...................................... 6 lubricating oil .................................................... 12, 51
Group 22 Lubricating System .................................. 8
Group 23 Fuel System .......................................... 27
Group 25 Intake and Exhaust Systems ................. 49
Group 26 Cooling System ..................................... 64
94
Notes
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95
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Date: ...........................................................
Name: .........................................................
AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7741302-9 English 10-2001
Workshop Manual
(Group 23) EDC III
TAD1240GE, TAD1241GE/VE
TAD1242GE/VE, TWD1240VE
EDC III
Contents
Safety information ................................................ 2 Repair instructions .............................................. 22
Introduction ......................................................... 2 When working with EDC III ................................. 22
Control unit (ECU), replacement ........................ 23
General information ............................................. 5 Start with booster batteries ................................ 24
About the Service Manual ................................... 5
Spare parts ......................................................... 5 Functionality check ............................................. 25
Certified engines ................................................. 5 PC diagnostics program ..................................... 25
1
Group 23 EDC III Safety information
Safety information
If work is performed near a running engine, an
Introduction incautious movement or dropped tool could in
This Service Manual contains descriptions and repair the worst case lead to bodily harm. Be mindful
instructions for the Volvo Penta products or product of hot surfaces (exhaust pipes, the turbochar-
versions listed in the table of contents. This manual ger, charge air pipes, starter elements, etc.) and
should be used together with the Service Manual hot liquids in lines and hoses on an engine that
Technical data for the relevant engine. Be sure to is running or has just been stopped. Before star-
use the correct service literature. ting the engine, refit all guards and protective
elements that were removed in the course of
Carefully read the safety information and General
performing service work.
information and Repair instructions in the Service
Manual before starting service work.
Make sure that the warning and/or information
decals affixed to the product are always in plain
sight. Replace any decals that have been dama-
Important ged or painted over.
The following special warning symbols are found in
the Service Manual and on the engine. Never start the engine unless the air filter is fitted.
The rotating impeller in the turbocharger could
WARNING! Warns for the risk of injury, damage cause serious injuries. Foreign objects in the inlet
to the product or property or that serious mal- line could also cause machinery damage.
functions could arise if the instructions are not
followed. Never use starter spray or the like to help start
the engine. It could cause an explosion in the
IMPORTANT! Used to draw attention to any- intake manifold. Danger of injury.
thing that could cause injury or the malfunction
of a product or property. Start the engine in well ventilated areas only. If
the engine is running in a confined space, ex-
NOTE: Used to draw attention to important information haust gases and crankcase gases should be
to facilitate work operations or handling. conducted away from the engine compartment
or workshop area.
To provide an overview of the dangers of which you
should always be aware and the precautionary measu- Avoid opening the coolant filler cap when the
res that should always be taken, we have listed them engine is still hot. Steam or hot coolant could
here. squirt out while the built-up pressure is lost. If
necessary, open the filler cap slowly and relea-
Make it impossible for the engine to start. Turn se pressure in the cooling system. Be extremely
off the current by means of the main switch (or careful if a cock, plug or coolant line must be
switches) and lock it (them) in the off position removed while the engine is still hot. Steam or
before starting service work. Affix a warning hot coolant could squirt out in an unexpected di-
sign in the driver’s area. rection.
As a rule, all service work should be performed Hot oil can cause burns. Avoid getting hot oil on
when the engine is switched off. However, some your skin. Make sure that the lubricating system
work, such as certain adjustments, requires the is depressurized before starting any work on it.
engine to be running. Approaching a running Never start or run the engine with the oil filler
engine could be dangerous. Bear in mind that cap removed as oil under pressure could then
loose-fitting clothes or long hair could get caught escape.
in rotating parts and cause serious injury.
Stop the engine before doing any work on the
cooling system.
2
Group 23 EDC III Safety information
If other equipment connected to the engine Most chemicals intended for the product (such
changes its center of gravity, special lifting devi- as engine and transmission oils, glycol, gasoline
ces may be needed to obtain the right balance and diesel oil) or chemicals for workshop use
and ensure safe handling. (such as degreasers, paints and solvents) are
injurious to health. Read the instructions on the
Never perform any work on an engine that is package carefully. Always follow prescribed sa-
suspended solely from a lifting device. fety rules (such as the use of respirators, pro-
tective goggles, gloves, etc.). Make sure that
Never work alone when heavy components are other personnel are not unknowingly exposed to
to be removed, even if a safe lifting device such substances that are injurious to health such as
as a lockable block and tackle is used. Even if through the air they breathe. Make provision for
a lifting device is used, two people are generally good ventilation. Deal with used and surplus
required; one to handle the lifting device and the chemicals in the prescribed manner.
other to make sure that the components go cle-
ar and are not damaged when lifting. Exercise great care when detecting leaks in the
fuel system and testing fuel nozzles. Wear pro-
Always ensure in advance that there is suffi- tective goggles. The jets from a fuel nozzle are
cient space for dismantling to be done without under very high pressure and have great pene-
risk of injury or material damage. trative power; the fuel can penetrate deep into
body tissues and cause serious injury. Risk of
WARNING! Electrical system and fuel system blood poisoning.
components of Volvo Penta products are desig-
ned and manufactured to minimize the risk of All fuels and many chemicals are flammable.
explosion and fire. The engine must not be run Make sure that they cannot be ignited by an
in environments in which they will be surrounded open flame or spark. Gasoline, certain dilutants
by explosive media. and hydrogen from batteries, when mixed with
air in the right proportions, are highly flammable
Always use fuel recommended by Volvo Penta. and explosive. No smoking! Provide for adequa-
See the Owner’s Manual. Use of a lower grade te ventilation and take the necessary safety me-
fuel could damage the engine. On a diesel engi- asures prior to the start of welding or grinding
ne, a poor grade of fuel could lead to overrev- work in the vicinity. Always keep a fire ext-
ving of the engine, causing risk of injury and da- inguisher easily accessible at the workplace.
mage. Poor fuel can also give rise to higher
maintenance costs. Ensure that rags saturated with oil and fuel, used
fuel and oil filters are kept in a safe place prior to
Bear in mind the following when cleaning with their disposal. Under certain conditions, sponta-
high-pressure equipment: never direct the jet of neous combustion can occur in oil-ingrained rags.
water on seals, rubber hoses, electrical compo- Used fuel and oil filters are environmentally hazar-
nents or the radiator. dous waste and, together with used lubricating oil,
contaminated fuel, residual paint, solvents, deg-
Always use protective goggles when performing reasers and residual detergents, should be taken
work in which splinters, grinding sparks and to a suitable plant for destruction.
splashes of acid or other chemicals could occur.
The eyes are especially sensitive and an injury Batteries should never be exposed to open fla-
could result in loss of sight. mes or electric sparks. Never smoke near the bat-
teries. When the batteries are being charged, they
Avoid getting oil on your skin. Prolonged or re- give off hydrogen which, when mixed with air,
curring contact with oil can damage the skin, re- forms oxyhydrogen gas. This gas is highly flam-
sulting in irritation, dehydration, eczema and mable and very explosive. A spark, which can oc-
other skin disorders. From a hygienic point of cur if the batteries are connected incorrectly,
view, used oil is more harmful than fresh oil. could cause a battery to explode, resulting in inju-
Wear protective gloves and avoid clothes and ry and damage. Do not disturb the connections
rags ingrained with oil. Wash regularly, particu- when attempting to start (risk of sparks) and do
larly before mealtimes. Use skin lotion intended not lean over any of the batteries.
for this purpose to avoid dehydration and facili-
tate cleansing of the skin.
3
Group 23 EDC III Safety information
Never mistake the positive and negative poles The engine should be switched off when adjus-
for each other when installing the batteries. This ting the clutch.
could cause serious damage to the electrical
equipment. Compare with the wiring diagram. Use the lifting eyes mounted on the engine
when lifting it. Always check that all lifting
Always wear protective goggles when charging equipment is in good condition and that it has
and handling batteries. The battery electrolyte the right capacity for the job (engine weight plus
contains highly corrosive sulfuric acid. If it gets transmission and extra equipment, if any).
on your skin, wash the area with soap and
plenty of water. If the electrolyte gets in your To ensure safe handling and avoid damaging
eyes, rinse them at once with plenty of cold wa- components mounted on the top of the engine, it
ter and seek medical attention immediately. should be lifted using an adjustable lifting beam or
one adapted to the engine. All chains or cables
Stop the engine and cut off the current with the should run parallel to each other and as perpendi-
main switch (or switches) before starting work cular as possible to the top of the engine.
on the electrical system.
4
Group 23 EDC III General information
General information
5
Group 23 EDC III Repair instructions
Repair instructions
The work methods described in the Service Manual
apply to a workshop environment. The engine is there-
Our common responsibility
fore lifted out of place and mounted on an engine Every engine consists of numerous interacting sys-
stand. Unless otherwise stated, reconditioning work tems and components. The deviation of a component
that does not require the engine to be removed can be from its technical specification could dramatically in-
performed in situ using the same work methods. crease the environmental impact of an otherwise good
See the ”Safety information” chapter for a closer ex- engine. It is therefore extremely important for speci-
planation of the warning symbols found in the Service fied wear tolerances to be maintained, for systems
Manual. with facilities for adjustment to be correctly set and for
Volvo Penta Original engine spare parts to be used.
The intervals in the engine maintenance schedule
WARNING!
must be followed.
Certain systems, such as fuel system components,
IMPORTANT! may require special competence and special testing
equipment. For environmental and other reasons, cer-
NOTE: tain components are sealed at the factory. Work on
these components must not be performed by persons
are by no means all embracing as we cannot of cour- not authorized for such work.
se foresee everything that could happen as service
work is performed under the most widely varying con- Bear in mind that the majority of chemical products, if
ditions. So we can only point out the risks we feel incorrectly used, are hazardous to the environment.
could arise as a result of incorrect handling when wor- Volvo Penta recommends the use of biologically de-
king in a well-equipped workshop using methods and gradable degreasers for all cleaning of engine compo-
tools that have been tested by us. nents unless otherwise expressly stated in the Servi-
ce Manual. Take care to ensure that oils and residual
All work operations for which there are Volvo Penta detergent, etc. are dispatched for destruction and do
special tools are described in the Service Manual not inadvertently end up in the environment.
using these tools. Special tools have been developed
to ensure as safe and efficient methods of working as
possible. It is therefore the obligation of anyone using
tools or work methods other than those recommended Tightening torques
by us to ensure that there is no risk of injury or materi-
al damage and that such use does not result in mal- Tightening torques for vital bolted joints that should be
function. tightened using a torque wrench are listed in ”Techni-
cal Data: Tightening torques” and are also given in the
In a number of cases, there may be special safety ru- Service Manual’s work descriptions. All tightening tor-
les and user instructions for the tools and chemicals ques refer to cleaned threads, bolt heads and contact
mentioned in the Service Manual. Such rules and ins- surfaces as well as lightly oiled or dry threads. If lubri-
tructions must always be followed and there are no cants, thread locking compounds or sealants are re-
special instructions for them in the Service Manual. quired for bolted joints, the type concerned is stated in
The majority of risks can be avoided by taking certain the work description and in ”Tightening torques”. The
elementary precautions and using common sense. A general tightening torques in the table below are appli-
clean workplace and a clean engine eliminate many cable to bolted joints for which no special tightening
risks of injury and faulty operation. torque is specified. The tightening torque is a guiding
It is extremely important, especially in connection to value and the joint need not in such case be tightened
work on fuel systems, lubrication systems, inlet sys- using a torque wrench.
tems, turbochargers, bearings and seals, to keep out
dirt and foreign particles of other kinds. If this is not
done, malfunction or a shorter repair life could be the Size Tightening torque
result. Nm lbf.ft.
M5 6 4.4
M6 10 7.4
M8 25 18.4
M10 50 36.9
M12 80 59.0
M14 140 103.3
6
Group 23 EDC III Repair instructions
7
Group 23 EDC III General
General
Location of engine plates
The plate below shows:
1 Engine designation The plate below shows:
2 Serial number 1 Engine designation
3 Specification number 2 Specification number
3 Serial number (last six digits) engine block
8
Group 23 EDC III Tools
Tools
Special tools
The following special tools are used when working with the engine. Special tools can be ordered from AB Volvo
Penta using the given number.
9
Group 23 EDC III Technical data
Technical data
Control unit
Voltage .................................................................. 24 V
Connector .............................................................. 2 x 36-pin
10
Group 23 EDC III Technical data
Unit injector
Voltage .................................................................. 90 V
Connection ............................................................. 2 poles
Injection pressure ................................................... 26100 psi
Generator
Voltage .................................................................. 24 V
Connection ............................................................. 2 poles
Capacity ................................................................ 60 A
Starter motor
Voltage .................................................................. 24 V
Connection ............................................................. 2 poles
Capacity ................................................................ 6 KW
11
Group 23 EDC III Design and operation
12
Group 23 EDC III Design and operation
Cylinder balance
When idling, the control module can provide the cylin-
ders with different amounts of fuel. This makes the
engine idle more evenly. At higher RPM, all cylinders
receive an equal amount of fuel.
Diagnostic function
The EDC III system has an internal diagnostic func-
tion that makes it possible to detect faults in the engi-
ne and sensor.
The role of the diagnostic function is to detect and lo-
calize disruptions in the EDC III system, protect the
engine and ensure that the machine remains in wor-
king order during serious disturbances.
If a disturbance arises, the diagnostic indicator on the
indicator panel begins blinking. When the diagnosis
button is pressed, an error code is given as guidance
for any fault detection. The diagnostic function can be
read out via the display using the PC diagnostics pro-
gram.
13
Group 23 EDC III Design and operation
Component description
The digits after the headings refer to ”Component dia-
gram and location”.
14
Group 23 EDC III Design and operation
15
Group 23 EDC III Design and operation
16
Group 23 EDC III Design and operation
Generator (8)
The belt-driven generator is located on the left-hand
front edge of the engine.
The voltage regulator of the generator is equipped with
a sensor system. The sensor system compares the
charging voltage between the generator connections,
B+ and B-, with the actual voltage between the positi-
ve and negative poles of the batteries. The voltage re-
gulator then compensates for any voltage drop in the
lines between the generator and the battery by increa-
sing the charging voltage from the generator as
needed.
17
Group 23 EDC III Design and operation
15
16
17
20 18
19
8 9 10 11 12 13 14
18
Group 23 EDC III Limit values
Limit values
Limit values, electronic control unit (ECU) TAD1240GE,
TAD1241-42GE/VE
Alarm values
The maximum permissible values for charge air and coolant temperatures, for example, can be adjusted with the
parameter setting tool and can thus vary within alarm limits.
If the alarm values are exceeded, the system reduces the amount of fuel until the value is once again within the
permissible interval.
This function is a customer parameter that can be completely disengaged.
Alarm limits TAD1240–42GE:
Coolant temperature: Alarm lamp lights Engine is switched off Engine output 50%
Standard value Volvo Penta 98°C / 208°F 100°C / 212°F
Parameter setting (can be set
by the customer) 95–101°C / 203-214°F +2°C / 36°F over the alarm value
Oil pressure:
Standard value Volvo Penta Idle: 0.7 bar (10,2 psi) For oil pressure 0.3 bar (4,4 psi)
lower than alarm value
>1500 RPM: 2.5 bar For oil pressure 0.3 bar (4,4 psi)
(36,3 psi) lower than alarm value
NOTE: Engine protection can be switched off.
Oil temperature:
Standard value Volvo Penta 125°C / 257°F 127°C / 261°F
Parameter setting (can be set
by customer) 120–130°C / 248-266°F+2°C / 36°F over alarm value
Fuel pressure:
Standard value Volvo Penta <2 bar (<29 psi) Engine not switched off
RPM:
Standard value Volvo Penta Max. operational RPM + 20%
Activates upon operational RPM +15%.
Parameter setting (can be set by customer)
Max. operational RPM + 10–20%
19
Group 23 EDC III Gränsvärden
Oil pressure:
Standard value Volvo Penta Idle: 0.7 bar (10,2 psi) For oil pressure 0.3 bar (4,4 psi)
lower than alarm value
>1500 RPM: 2.5 bar For oil pressure 0.3 bar (4,4 psi)
(36,3 psi) lower than alarm value
* See diagram: ”Oil pressure” below.
Oil temperature:
Standard value Volvo Penta 125°C / 257°F 127°C / 261°F
Parameter setting (can be
set by the customer) 120–130°C / 248-266°F +2°C / 36°F over
alarm value
Fuel pressure:
Standard value Volvo Penta <2 bar (<29 psi) Engine not switched off
Monitor, water in fuel: Alarm lamp lights
*Oil pressure
Alarm limit
rpm
20
Group 23 EDC III Limit values
3.0
Charge air
pressure
2.5
2.0
bar
1.5
1.0
rpm
21
Group 23 EDC III Repair instructions
Repair instructions
When working with EDC III
Follow the instructions below so as not to damage the control unit of the EDC system:
• Never cut off the main current when the engine is running.
• When quick charging the batteries, the main switch must be turned off or the battery cables must be discon-
nected.
During normal maintenance charging, the main switch does not need to be turned off.
• Only batteries should be used for jumping. Jumping devices may cause a surge and damage the
control unit.
• Cut off power to the EDC III system before disconnecting the 2 x 36-pin cable glove from the control unit.
• If damage to the wiring harness is detected, the cable glove should be disconnected from the control unit.
IMPORTANT! The cable glove should be disconnected from the control unit when welding.
• When removing a connector from a sensor, be careful not to expose the contact pin to oil or any
other fluid.
This could cause a contact problem or, if oil runs down to the pressure sensing membrane, the sensor could
show an incorrect value.
22
Group 23 EDC III Repair instructions
23
Group 23 EDC III Repair instructions
24
Group 23 EDC III Functionality check
Functionality check
PC diagnostics program
• This program can read error codes that are stored in the engine control unit, check input and
output signals, read current values from engine sensors and then store and print test results.
• The program enables service and workshop personnel to quickly localize and remedy errors in the
EDC III system.
• The role of the diagnostic function is to detect and localize disturbances in the EDC III system, protect the
engine and ensure that the machine remains in working order during serious disturbances.
• If a disturbance arises, the diagnostic indicator on the indicator panel begins blinking.
When the diagnosis button is pressed, an error code is given as guidance for any fault detection.
25
Group 23 EDC III Fault detection
Fault detection
A number of symptoms and possible causes for engine problems are described in the table below. Always contact
your Volvo Penta dealer if problems occur that you are not able to solve on your own.
WARNING! Read through the safety instructions for maintenance and service work in the chapter ”Safety in-
formation” before starting to work.
1. Discharged batteries 11. Air in fuel system 20. Faulty circulation pump
2. Poor contact/interruption on 12. Water/contaminates in the fuel 21. Defective thermostat
electrical line
13. Faulty unit injectors 22. Clogged intercooler
3. Main switch turned off
14. Insufficient air supply to 23. High oil level
4. Fuse on wiring box blown engine:
24. Generator drive belt is slipping
– clogged air filter
5. Faulty starter switch
– air leak between turbo- 25. Water in engine
6. Faulty main relay charger and engine’s intake 26. Great counterpressure in
manifold exhaust system
7. Faulty starter motor relay
– fouled compressor
8. Faulty starter motor/solenoid in turbocharger 27. Interruption, cable ”Pot+” to
– faulty turbocharger pedal
9. Fuel shortage:
– fuel cocks closed – poor engine compartment 28. High oil temperature
– fuel tank empty/wrong tank ventilation
29. High charge-air temperature
connected 15. High coolant temperature
10. Clogged fuel fine filter/pre-filter 16. Low coolant temperature
(due to contaminates or
17. Low oil level
paraffin deposits in the fuel at
low temperature) 18. Low coolant level
19. Air in coolant system
26
Group 23 EDC III Diagnostic function
Diagnostic function
Diagnostic function
The diagnostic function checks that the EDC III sys-
tem is functioning normally.
The diagnostic function performs the following
tasks:
• Detects and localizes disturbances
• Notifies when disturbances are detected
• Provides guidance for fault detection
• Protects the engine and ensures that the machine
remains in working order when serious disturbances
are detected.
Notification of disturbance If the diagnostic function
detects a disturbance in the EDC III system, the opera-
tor is notified by the diagnostic lamp (1), which begins
to blink.
Guidance for fault detection If the diagnosis button
(2) is depressed and then released the diagnostic lamp
(1) blinks out an error code. The code is found in the
error code list, with information on cause, response and
corrective action.
The diagnostic function affects the engine in the
following manner when:
1 The diagnostic function has detected a minor
disturbance that will not damage the engine:
Response: The engine is not affected.
2. The diagnostic function has detected a serious
disturbance that will not immediately damage the
engine:
Response: TAD1240–42GE/VE: Engine is
switched off.
TWD1240VE: Engine is switched off or engine
torque is lowered until the value is normalized.
3. The diagnostic function has detected a serious
disturbance that makes it impossible to control
engine operation:
Response: TAD1240–42GE/VE: RPM maintained.
TWD1240VE: The engine goes to idle. Idle or
freezing of RPM can be set using the Volvo Penta
Parameter Tool.
27
Group 23 EDC III Diagnostic function
28
Group 23 EDC III Diagnostic function
NOTE: The readout of the error codes below, such as 175 Code 2.1, means that 175 is read using the diagnostic tool.
2.1 is the blink code that is shown on the instrument box’s diagnostic lamp. See ”Reading out error codes”.
29
Group 23 EDC III Diagnostic function
• Check that the tachometer sensor is correctly fit- • Check that the wiring to the potentiometer is not
damaged.
ted in the upper timing cover.
• Check the function of the tachometer sensor. • Check the function of the potentiometer.
30
Group 23 EDC III Diagnostic function
• Check the contact pressure in sleeve 14 in the • Check that the connector of the coolant tempera-
ture sensor is fitted correctly.
black cable glove of the engine control unit
(ECU). • Check that the wiring to the coolant temperature
sensor is not damaged.
25 Code 3.2
• Check that the coolant temperature sensor is fit-
ted correctly.
Cause: Charge air temperature sensor. Interrupted or
shorted to positive (+).
• Check the function of the coolant temperature
sensor.
Response: None.
Corrective action:
28 Code 3.3
• Check that the connector of the charge air tempe-
rature sensor is fitted correctly. Cause 1: Coolant temperature sensor. Short to negati-
ve (-).
• Check that the wiring to the charge air temperature
sensor is not damaged. Response: Preheating is activated even if the engine
is warm.
• Check that the charge air temperature sensor is
fitted correctly. Corrective action:
• Check the function of the charge air temperature • Check that the wiring to the coolant temperature
sensor is not damaged.
sensor.
• Check the contact pressure in sleeve 2 in the • Check that the coolant temperature sensor is fit-
ted correctly.
black cable glove of the engine control unit
(ECU). • Check the function of the coolant temperature
sensor.
31
Group 23 EDC III Diagnostic function
(ECU).
32
Group 23 EDC III Diagnostic function
Response: Alarm lamp does not work. If the circuit is Corrective action:
interrupted during start-up, diagnostics are deacti-
vated.
• Check the alarm lamp.
Corrective action:
• Check that the wiring to the alarm lamp is not da-
maged.
• Check the alarm lamp for high coolant
temperature.
• Check sleeve ”O” in the 23-pin connector.
• Check the contact pressure in sleeve 36 in the
• Check that the wiring to the alarm lamp is not black cable glove of the engine control unit
damaged. (ECU).
• Check sleeve ”N” in the 23-pin connector.
224 Code 4.4
• Check the contact pressure in sleeve 33 in the
black cable glove of the engine control unit Cause: Overspeed alarm. Short to negative (-).
(ECU). Response: Alarm lamp lights constantly.
Corrective action:
220 Code 4.3 • Check that the wiring and connection to the alarm
lamp are not damaged.
Cause: Lamp to indicate operation. Interruption
Response: Indicator lamp does not work. If the circuit
is interrupted during start-up, diagnostics are deacti- 225 Code 4.4
vated. Cause: Overspeed alarm. Short to positive (+).
Corrective action: Response: Alarm lamp does not work. If the circuit is
• Check the alarm lamp. interrupted during start-up, diagnostics are deacti-
vated.
• Check that the wiring to the alarm lamp is not
damaged. Corrective action:
• Check sleeve ”N” in the 23-pin connector. • Check that the wiring and connection to the alarm
lamp are not damaged.
• Check the contact pressure in sleeve 33 in the
black connector of the engine control unit (ECU).
33
Group 23 EDC III Diagnostic function
• Checkthe contact pressure in sleeve 33 in the • Check that the wiring to the relay is not damaged.
black cable glove of the engine control unit
(ECU).
• Check the function of the relay.
Corrective action: • Check that the cable to the starter motor (yellow/
black) is correctly connected.
• Check that the wiring and connection to the alarm
lamp are not damaged. • Check that the cable to the starter motor (yellow/
black) is not damaged.
• Check that the relay on the starter motor is whole.
205 Code 4.5
• Check the contact pressure in sleeve 31 in the
Cause: Low coolant alarm. Short to positive (+). red cable glove of the engine control unit (ECU).
Response: Alarm lamp does not work. If the circuit is
interrupted during start-up, diagnostics are deacti-
108 Code 4.7
vated.
Corrective action: Cause: Start input, engine control unit (ECU).
Short to negative (-).
• Check that the wiring and connection to the alarm
lamp are not damaged. Response: Engine will not start.
Corrective action:
41 Code 4.6
• Check that the wiring to the ignition key/start but-
ton is not damaged.
Cause: Start relay on starter motor.
Short to positive (+).
• Check the contact pressure in sleeve ”E” in the
23-pin connector.
Response: Engine will not start. • Check the contact pressure in sleeve 17 in the
Corrective action: connector on the engine.
34
Group 23 EDC III Diagnostic function
• Check that the wiring to the relay is not damaged. • Check that the connections to the ignition key are
not damaged.
• Check the function of the relay.
• Check that the wiring to the ignition key is not
damaged.
208 Code 5.2
Cause: Start input on CIU. Short to negative (-). 214 Code 5.3
Response: The engine cannot be started. Cause: Stop input on CIU. Interrupted or activated too
Corrective action: long.
35
Group 23 EDC III Diagnostic function
• Check the function of the relay. • Check the function of the charge air temperature
sensor.
• Check the function of the thermostat.
183 Code 5.8
Cause Oil temperature is too high. 213 Code 6.4
Response: Limited engine output (if this protective Cause Datalink (CAN) error, CIU.
feature has not been disabled by the parameter set- Response: Instruments and alarm lamps stop working.
ting tool). Alarm lamp lights.
Corrective action:
Corrective action:
• Check the oil level. • Check that the 8-pin connector is not damaged.
• Check that the wiring between the CIU and the
• Check the oil temperature. engine control unit (ECU) is not damaged.
• Check the oil system thermostat. • Check that sleeves 11 and 12 in the CIU connec-
tor are not damaged.
• Check the function of the oil temperature sensor.
• Check the contact pressure in sleeves 1 and 2 in
the red cable glove of the engine control unit
(ECU).
36
Group 23 EDC III Diagnostic function
• Check that the 8-pin connector is not damaged. • Check that the 8-pin cable between the CIU and
the engine control unit (ECU) is not damaged.
• Check that the wiring between the CIU and the
engine control unit (ECU) is not damaged. • Check that sleeves 11 and 12 in the CIU connec-
tor are not damaged.
• Check that sleeves 11 and 12 in the CIU connec-
tor are not damaged. • Check the contact pressure in sleeves 1 and 2 in
the red cable glove of the engine control unit
• Check the contact pressure in sleeves 1 and 2 in
the red cable glove of the engine control unit
(ECU).
(ECU).
180 Code 6.6
Cause: Datalink error (CAN). Response: Engine is switched off (if this protective
feature has not been disabled by the parameter set-
Response: Engine not running -> The engine cannot ting tool).
be started. Engine running -> Engine goes to idle and Alarm lamp lights.
can only be stopped with the emergency stop.
Corrective action:
Corrective action:
• Check that the 8-pin connector is not damaged.
• Check the oil level.
engine control unit (ECU) is not damaged. • Check the system pressure valves and the safety
valve in the oil system.
• Check that sleeves 11 and 12 in the CIU connec-
tor are not damaged. • Check the function of the oil pressure sensor.
37
Group 23 EDC III Diagnostic function
38
Group 23 EDC III Diagnostic function
Response: The engine runs on 5 cylinders, sounds • Check that the wiring to the unit injectors is not
damaged.
uneven and has decreased performance.
Corrective action: • Check that the connections to the unit injector are
not damaged.
• Check the contact pressure in sleeve 22 in the
black cable glove of the engine control unit
(ECU).
• Check that the wiring to the unit injectors is not
damaged.
• Check that the connections to the unit injector are
not damaged.
39
Group 23 EDC III Diagnostic function
40
Group 23 EDC III Diagnostic function
41
Group 23 EDC III Diagnostic function
• Check that the connections to the unit injector are Cause: Unit injector cylinder #6. Electronic error.
not damaged. Response: The engine runs on 5 cylinders, sounds
uneven and has decreased performance.
160 Code 7.6 Corrective action:
Cause: Unit injector cylinder #6. Electronic error. • Check that the wiring to the unit injector is not da-
maged.
Response: The engine runs on 5 cylinders, sounds
uneven and has decreased performance. • Check that the connection to the unit injector is
not damaged.
Corrective action:
• Check that the wiring to the unit injector is not da-
maged.
• Check that the connection to the unit injector is
not damaged.
42
Group 23 EDC III Diagnostic function
43
Group 23 EDC III Diagnostic function
34 Code - 64 Code -
Cause: The diagnostic lamp (linked to the Stand Alone Cause: Voltage feed to sensor. Short to negative (-).
interface). Short to positive (+). Response: Several error codes for sensor error.
Response: The diagnostic lamp does not light during Corrective action:
a lamp test. No error codes can be read out.
Corrective action: • Check the contact pressure in sleeve 4 in the
black cable glove of the engine control unit
• Check that the wiring to the lamp is not damaged. (ECU).
• Check that the lamp is correctly mounted.
173 Code -
57 Code - Cause Datalink (J1708) error, engine control unit
Cause: The charge air pressure is too high. (ECU).
63 Code -
Cause: Voltage feed to sensor. Short to positive (+). 186 Code -
Response: Several error codes for sensor error. Cause: Memory error in the engine control module
(EMS).
Corrective action:
Response: Engine will not start.
• Check the contact pressure in sleeve 5 in the
black cable glove of the engine control unit Corrective action:
(ECU).
• Replace the engine control unit (ECU).
44
Group 23 EDC III Diagnostic function
Cause: Programming plug (EOL). Short to positive (+). Cause: Datalink error (J1708), CIU.
Response: Engine will not start; engine control unit Response: Diagnostic codes from the engine cannot
(ECU) is in programming mode. be read from the diagnostic lamp.
• Check that the EOL contact is not strapped. • Check that the 8-pin connector is not damaged.
• Check that the wiring to the EOL contact is not • Check that the wiring between the CIU and the
engine control unit (ECU) is not damaged.
damaged.
• Check pin/sleeve 22 and 37 in the connector on
the CIU.
189 Code -
Cause: Programming plug (EOL). Short to negative (-).
• Check the contact pressure in sleeves 25 and 26
in the red cable glove of the engine control unit
Response: None. (ECU).
Corrective action:
• Check that the wiring to the EOL contact is not
damaged.
45
Group 23 EDC III Electronic fault detection
46
Group 23 EDC III Electronic fault detection
• Carefully insert gauge 9998482 in the cable glove. • Shake the line if possible and pull on the connec-
Move the gauge back and forth a few times until tions while measuring to find where the damage is.
you feel that the cable glove clamps around the • If you cannot find the error, check the next wiring
harness following the wiring diagram.
gauge. If the cable glove does not clamp or
clamps weakly, the cable shoe must be replaced.
See ”Splicing electrical cable for cable glove”.
• Fill the sleeves that have been checked with low Contact resistance and oxidation
temperature grease (1161417-9). The resistance in the contacts, lines and connections
Important! DIN contacts to pressure sensors should be 0 Ω.
must not be filled with grease. There is some resistance, however, due to oxidation
on the connections.
• Check that the lines are really clamped. Avoid
clamping the lines too close to the contacts.
If resistance is too great, there will be disturbances in
the function. How large resistance can be without dis-
turbances arising varies depending on the size of the
load in the circuit.
Fault detection on cables and Check the following:
connectors • Look for oxidation, which can deteriorate the con-
tact in the connections.
Visually check the connections.
Check the following:
• Check that the cable shoes are not damaged, that
they are correctly fitted in the connector and that
• Look for oxidation, which can deteriorate the con-
tact in the connections.
the line is correctly connected to the cable shoe.
• Test that the sleeves provide good mechanical
• Check that the cable shoes are not damaged, that
they are correctly fitted in the connector and that
contact.
Use a loose pin to test.
the line is correctly connected to the cable shoe.
Important! DIN contacts to pressure sensors
• Test that the sleeves provide good mechanical
contact.
must not be filled with grease.
47
Group 23 EDC III Electronic fault detection
48
Group 23 EDC III Electronic fault detection
49
Group 23 EDC III Electronic fault detection
3. Submerge the sensor’s contact pins in a bowl of 1. Set multimeter 9510060-8 to measure
water. resistance. Use the multimeter to measure on the
The light bulb should light when the water connector pins. Resistance should lie between
is between the sensor’s contact pins. 775–945 Ω.
4. When the sensor is removed from the water, 2. Quickly pass a metal object close to the sensor.
the light bulb should go out. Check that the multimeter gives a reading. When
replacing and fitting a sensor, make sure that any
adjusting shims are refitted.
3. Check that the sensor is securely mounted
and that the distance between sensor and wheel
is correct.
Sensor Distance
Flywheel 0.75–2.1 mm (0.03–0.83’’)
Camshaft 0.3–1.0 mm (0.012–0.039’’)
NOTE: For adjustment of the sense clearence, plea-
se see Workshop Manual (Group 21).
50
Group 23 EDC III Electronic fault detection
Checking the function of oil pressure 1. Empty the coolant from the expansion tank.
1. Switch off the engine
Warning! NEVER open the expansion tank’s
2. Disconnect the connector from the oil pressure pressure cap when the engine is warm. Hot coo-
sensor and connect 4-pin adapter 9998534 bet- lant could spray out, causing burns.
ween the sensor connector and the engine wiring.
Then connect multimeter 9510060-8 between me- 2. Disconnect the connector from the coolant
asurement points 1-4. sensor.
3. Switch on the operating voltage. 3. Check that the contact is activated and sends
4. Measure using a multimeter set to measure volta- a signal when the expansion tank is empty.
ge. Check that the multimeter reads 5.0 volts. 4. Then fill the expansion tank with coolant and
5. Then connect the multimeter between measure- check that resistance remains the same.
ment points 2-4. The voltage should be about 0.5 V.
51
Group 23 EDC III Electronic fault detection
Error causes
The above error symptoms can have several causes:
• False sensor signals
• Worn piston rings
• Clogged air filter
• Poor quality fuel
• Water in fuel
• Air in fuel
• High exhaust counterpressure
• Clogged fuel system
• Low fuel pressure
• Incorrect valve clearance
• Defective unit injector
• Incipient shearing (breakdown)
52
Group 23 EDC III Electronic fault detection
Check
1. That error code 4.6 is not set.
2. That a start request is sent (using the PC
diagnostics program).
3. That the starter motor is activated (using the PC
diagnostics program).
Carbon brushes
Specifications for carbon brushes in the starter motor
are described below.
Carbon brush appearance
New = 23 mm (0.91’’)
Replace at 13 mm (0.51’’)
53
Group 23 EDC III Electronic fault detection
54
Group 23 EDC III Electronic fault detection
55
Group 23 EDC III Electronic fault detection
Carbon brushes
The length of carbon brushes is measured between
the contact surface and the brush holder. If the size of
the projecting portion is less than 0,2’’ or if the brushes
are damaged, they must be replaced.
Regulator
Checking the regulator:
1. Measure with a multimeter set for diode measure-
ment.
2. Connect the probes between the carbon brushes.
3. Switch the probes.
4. Check that there is no short-circuit.
56
Group 23 EDC III Electronic fault detection
57
Group 23 EDC III Electronic fault detection
58
Group 23 EDC III Electronic fault detection
59
Group 23 EDC III Electronic fault detection
60
Group 23 EDC III Electronic fault detection
61
Group 23 EDC III Electrical system
Electrical system
3. See ”Start with booster batteries” on how to jump
Important about the electrical start using booster batteries.
system 4. Connecting extra equipment
All extra equipment must be connected to a sepa-
Important! Stop the engine and cut off the po- rate junction box and fused.
wer with the main switch before working with the Extra outlets directly from the instrument boards
electrical system. should be avoided. Extra outlets are permissible
1. Main switch only up to a max. total of 5A (applies for all in-
Never open the circuit between the generator and strument boards together).
the batteries when the engine is running. Electric welding
The main switch/switches must never be swit-
ched off before the engine has stopped. Remove the positive and negative cables from the
If the circuit is opened when the engine is running, batteries.
the voltage regulator can be ruined and the gene- Then remove all connections to the generator.
rator can be badly damaged. Then remove the cable glove from the control module
For the same reason, charging circuits must not (EDC III). See the instructions in ”Control module
be switched when the engine is running. For si- (EMS), replacement”.
multaneous charging of two independent battery
circuits, a Volvo Penta charge distributor can be Always attach welding clamps to the part that is to be
mounted on the standard generator (accessory). welded as close to the welding area as possible. The
clamps must never be attached to the engine or in
2. Batteries
such a way that current can pass over any bearing.
Never mistake the positive and negative poles for
each other when installing the batteries. Important! After welding, the removed compo-
This could cause serious damage to the electrical nents, such as cable glove, generator cable and
equipment. battery cables, must be refitted in the correct or-
Compare with the wiring diagram. Battery poles der.
should be well cleaned and cable shoes should al-
ways be secured and well greased.
Avoid quick charging the batteries. If quick char-
ging must be used, the ordinary battery cables
must first be disconnected.
NOTE: Follow applicable safety regulations when
charging the batteries.
When charging, the cell plugs should be loosened but
remain in the cell hole. Ventilate well, especially if the
batteries are being charged in a confined area.
Never cut off the charging current before disconnec-
ting the charge clamps.
62
Group 23 EDC III Electrical system
63
Group 23 EDC III Electrical system
64
Group 23 EDC III Electrical system
65
66
Electrical system
39. Generator
40. Starter motor
41. Sensor, oil temperature/pressure
42. Battery (24 V)
Group 23 EDC III
Cable colors TWD1240VE (24 V system
BL = Blue P = Pink voltage, 2-pin)
LBL = Light blue R = Red
BN = Brown SB = Black 1. RPM potentiometer
LBN = Light brown VO = Violet 2. Droop contact
GN = Green W = White 3. Starter contact
GR = Gray Y = Yellow 4. Idle contact
OR = Orange 5. Preheating contact
6. Stop contact
7. Diagnostics
8. Low oil pressure alarm
9. High coolant temperature alarm
10. Low coolant level alarm
11. Preheating indicator
12. Voltage after key
13. Battery, negative
14. System to (key)
15. Battery, positive
16. J1587 (bus)
17. J1939 CAN (bus)
18. Battery, negative
19. Battery, positive
20. Voltage after key
21. Connector
22. Programming connector
23. Diode
24. Stop button
25. Monitor, water in fuel
26. Relay, socket
27. Relay
28. Programming plug
29. Monitor, fuel pressure
30. Monitor, coolant level
31. Connector 2 (red)
32. Connector 1 (black)
33. Control unit EDCIII (ECU)
34. Unit injectors (Cyl. 1–6)
35. Coolant temperature sensor
36. Sensor, Charge air temperature/
pressure
37. Preheating
38. Relay, preheating
39. Camshaft (RPM) sensor
Electrical system
40. Flywheel (RPM) sensor
41. Generator
42. Starter motor
43. Sensor, oil temperature/
pressure
44. Battery (24 V)
67
Group 23 EDC III Electrical system
68
Group 23 EDC III Electrical system
69
Group 23 EDC III Index
Index
A O
About the Service Manual ...................................... 5 Our common responsibility ..................................... 6
C P
Certified engines .................................................... 5 PC diagnostics program ........................................ 25
Check/fault detection of components .................... 49
Component description, sensors and monitors ...... 14 R
Component diagram and location .......................... 18 Reading out error codes ........................................ 27
Control Interface Unit (CIU) ................................... 16 Repair instructions ................................................. 6
Control module (EMS) ........................................... 16 Repair instructions ................................................ 22
Control module (EMS), replacement ...................... 23
S
D Safety information .................................................. 2
Design and operation ............................................ 12 Sealants ................................................................ 7
Diagnostic function affects the engine .................. 27 Spare parts ............................................................ 5
Diagnostic function ............................................... 27 Special tools .......................................................... 9
Splicing of electrical cable for cable glove ............. 48
E Start with booster batteries ................................... 24
Electrical system .................................................. 62 Starter motor ......................................................... 17
Electrical system, overview .................................. 63 Strength classes .................................................... 7
Electronic fault detection ....................................... 46 Symptoms and possible causes ........................... 26
Erasing error codes ............................................... 28 System description EDC III ................................... 12
F T
Fault codes EDC III .............................................. 29 Technical data ...................................................... 10
Fault detection of cables and connectors .............. 47 The role of diagnostic function .............................. 27
Fault detection ...................................................... 26 Tightening torques ................................................. 6
Functionality check of lines and connectors .......... 46 Torque-angle tightening ........................................... 7
Functionality check ............................................... 25
U
G Unit injectors ......................................................... 17
General .................................................................. 8
General information ................................................ 5 W
General ................................................................. 46 When working with EDC III .................................... 22
Generator .............................................................. 17 Wiring diagram TAD1240-42GE/VE ..................... 66
Wiring diagram TWD1240VE ................................ 67
I Wiring diagram, Control Interface Unit (CIU) -
Important about the electrical system ................... 62 Power pack ........................................................... 69
Introduction ............................................................ 2 Wiring diagram, Control Interface Unit (CIU) .......... 68
L
Limit values .......................................................... 19
Limit values, control unit (ECU)
TAD1240-42GE ..................................................... 19
Limit values, control unit (ECU)
TWD1240VE ......................................................... 20
Limp-home values ................................................. 21
Location of engine plates ....................................... 8
Lock nuts ................................................................ 7
70
Notes
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AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7741312-8 English 10-2001