Volvo TAD1240GE, TAD1241GE, TAD1241VE, TAD1242GE, TAD1242VE Workshop Manual

Workshop Manual

Technical Data

TAD1240GE, TAD1241GE/VE

TAD1242GE/VE, TWD1240VE

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Technical data

Engine

TAD1240GE, TAD1241GE/VE

TAD1242GE/VE, TWD1240VE

Contents

Safety information ................................................ 2

Introduction ......................................................... 2

Important ............................................................ 2

General information ............................................. 5

About the Service Manual ................................... 5

Spare parts ......................................................... 5

Certificated engines ............................................ 5

Technical data ...................................................... 6

References to Service Bulletins .......................... 31

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Safety information

Group 20

The Service Manual contains technical data,
descriptions and repair instructions relating to the
Volvo Penta products or product versions included in
the list of contents. Make sure you use the right
workshop literature.

Read the safety information, “General
information” and “Repair instructions” carefully
before starting any service work.

Important

The following special warning symbols occur in the
Service Manual and on the product.

WARNING! Warns of the risk of injury and
extensive damage to the product or property,
or that serious functional faults could arise if
the instructions are not followed.

IMPORTANT! Used to draw attention to any­thing that could cause damage to the product or
property or functional disorders in the same.

NOTE: Used to draw attention to important information

for facilitating work operations or handling.

If work is carried out near an engine that is run­ning, an incautious movement or a dropped tool
could in the worst case lead to bodily harm. Be
mindful of hot surfaces (exhaust pipes, the
turbocharger, charge air pipes, starter elements,
etc.) and hot liquids in lines and hoses on an
engine that is running or has just been stopped.
Before starting the engine, refit all guards and
protective elements that were removed in the
course of carrying out service work.

Make sure that the warning and/or information
decals affixed to the product are always in plain
sight. Replace decals that are damaged or have
been painted over.

Never start the engine unless the air filter is
fitted. The rotating impeller in the turbo could
cause serious injuries. Foreign objects in the in­let line could additionally cause machinery dam­age.

To provide an overview of the risks you should always
be aware of and the precautionary measures that
should always be adopted, we have listed them here.

Make it impossible for the engine to start. Turn
off the current by means of the main switch (or
switches) and lock it (them) in the OFF position
before starting service work. Affix a warning
sign in the driver’s area.

As a rule, all service work should be carried out
when the engine is stationary. Some work,
including certain adjustments, nonetheless
requires the engine to be running. Approaching
an engine that is running could be dangerous.
Bear in mind that loose-fitting clothes or long
hair may get caught in rotating parts and cause
serious injury.

Never use a starter spray or the like to help start
the engine. It could cause an explosion in the in­let manifold. Danger of injury.

Start the engine in well-ventilated premises only.
If the engine is run in a confined space, exhaust
gases and crankcase gases should be conduc­ted away from the engine bay or workshop area.

Avoid opening the coolant filler cap when the
engine is still hot. Steam or hot coolant could
squirt out while the built-up pressure will be lost.
If necessary, open the filler cap slowly and re­lease the pressure in the cooling system. Be
extremely careful if a cock, plug or coolant line
has to be removed while the engine is still hot.
Steam or hot coolant could squirt out in an un­expected direction.

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General instructionsGroup 20

Hot oil can cause burns, Avoid getting hot oil on
your skin. Make sure that the lubricating system
is depressurized before starting any work on it.
Never start or run the engine with the oil filler
cap removed as oil under pressure could then
escape.

Stop the engine before doing any work on the
cooling system.

Always use protective goggles when carrying
out work where splinters, grinding sparks and
splashes of acid or other chemicals could occur.
The eyes are especially sensitive and an injury
could result in loss of sight.

Avoid getting oil on your skin. Prolonged or re­curring contact with oil can remove the skin’s
natural moisture with irritation, dehydration, ec­zema and other skin disorders as a result. From
a hygienic point of view, used oil is more harm­ful than fresh oil. Wear protective gloves and
avoid clothes and rags ingrained with oil. Wash
yourself regularly, particularly before mealtimes.
Use skin lotion intended for this purpose to
avoid dehydration and to facilitate cleansing of
the skin.

WARNING! Under no circumstances should the
engine’s pressure pipes be bent or reshaped.
Damaged pipes must be changed.

All fuels and many chemicals are flammable.
Make sure that they cannot be ignited by a
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 ad­equate ventilation and take the necessary safety
measures prior to the start of welding or grind­ing work in the vicinity. Always keep a fire ex­tinguisher easily accessible at the workplace.

Ensure that rags saturated with oil and fuel, as
well as used fuel and oil filters, are kept in a
safe place prior to their disposal. Under certain
conditions, spontaneous combustion can occur
in oil-ingrained rags. Used fuel and oil filters
comprise environmentally hazardous waste and,
together with used lubricating oil, contaminated
fuel, residual paint, solvents, degreasants and
residual detergents, should be taken to a suit­able plant for destruction.

Most chemicals intended for the product (such
as engine and transmission oils, glycol, petrol
and diesel oil) or chemicals for workshop use
(such as degreasants, paints and solvents) are
injurious to the health. Carefully read the ins­tructions on the package. Always follow the
prescribed safety rules (such as the use of res­pirators, protective goggles, gloves, etc.). Make
sure that other personnel are not exposed with­out their knowledge to substances that are in­jurous to health, such as through the air they
breathe. Make provision for good ventilation.
Deal with used and surplus chemicals in the pre­scribed manner.

Exercise great care when detecting leaks in the
fuel system and testing fuel nozzles. Wear pro­tective goggles. The jets from a fuel nozzle are
under very high pressure and have great pen­etrative power; the fuel can penetrate deep into
body tissues and cause serious injury. Risk of
blood poisoning.

Batteries should never be exposed to naked
flames or electric sparks. Never smoke near the
batteries. When the batteries are being charged
they give off hydrogen which, when mixed with
air, forms oxyhydrogen gas. This gas is highly
flammable and extremely explosive. A spark,
which can occur if the batteries are connected
incorrectly, could cause a battery to explode
with injury and damage as a result. Do not dis­turb the connections when attempting to start
(risk of sparks) and do not lean over any of the
batteries.

Never mistake the positive and negative ter­minals for each other when installing the bat­teries. If this happens it could cause serious
damage to the electrical equipment. Compare
with the wiring diagram.

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General instructions

Group 20

Always wear protective goggles when charging
and handling batteries. The battery electrolyte
contains highly corrosive sulphuric acid. If it
gets on your skin, wash the affected 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.

Stop the engine and cut off the current with the
main switch (or switches) before starting to work
on the electrical system.

The clutch should be adjusted with the engine
switched off.

Use the lifting eyes mounted on the engine
when lifting it. Always check that all lifting
equipment is in good condition and that it has
the right capacity for the job (engine weight plus
reversing gear and extra equipment, if any). To
ensure safe handling and to avoid damaging
components mounted on the top of the engine,
it should be lifted using an adjustable lifting
beam or one suitably adapted to the engine. All
chains or cables should run parallel to each
other and as perpendicular as possible to the
top of the engine.
If other equipment that has been connected to
the engine changes its centre of gravity, special
lifting devices may be needed to obtain the right
balance and ensure safe handling.
Never carry out any work on an engine that is
suspended solely from a lifting device (hoist, etc.).

Never work alone when heavy components are
to be removed, not even when a safe lifting dev­ice like a lockable block and tackle is used.
Even when a lifting device is used two people
will generally be required, one to handle the lif­ting device and the other to make sure that the
components go clear and are not damaged when
lifted away.
Always make sure in advance that there is suf­ficient space for dismantling to be carried out in
the area with no danger of it causing injury or
material damage.

WARNING! Electrical system and fuel system
components on Volvo Penta products are de­signed and manufactured to minimize the risk of
explosion and fire. The engine must not be run
in environments where they will be surrounded
by explosive media.

Always use fuel recommended by Volvo Penta.
See the Owner’s Manual. The use of a poorer
grade of fuel could damage the engine. On a
diesel engine, a poor grade of fuel could lead to
binding of the control rod and overrevving of the
engine with a consequent risk of injury and dam­age. Poor fuel can also give rise to higher main­tenance costs.

Bear in mind the following when cleaning with
high-pressure equipment: never direct the jet of
water on seals, rubber hoses or electrical com­ponents. Never use the high-pressure function
when cleaning the engine.

4

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Group 20

General information

About the Service Manual

This Service Manual contains technical data for the
standard versions of the TAD1240GE, TAD1241GE/VE,
TA1242GE/VE and TWD1240VE engines.

All references from the service manuals containing
repair instructions for the TAD1240GE, TAD1241GE/
VE, TAD1242GE/VE and TWD1240VE engines will be
found in the “Technical data” Service Manual.

The Service Manual is primarily produced for Volvo
Penta’s service workshops and their qualified person­nel. It is therefore assumed that persons using the
manual have the necessary basic knowledge and can
carry out work of a mechanical/electrical nature that
forms part of their occupational duties.

Volvo Penta is continuously developing its products
and we therefore reserve the right to introduce
changes and modifications. All the information in this
manual is based on product data available up to the
time of going to press. Any changes of vital import­ance that have been introduced in product or service
methods after that date will be announced in the form
of Service Bulletins.

Spare parts

Spare parts for the electrical and fuel systems are
subject to different national safety requirements. Volvo
Penta Original Spare Parts meet these require-ments.
All types of damage occurring as a result of using
non-original Volvo Penta spare parts for the pro-duct
in question will not be covered under the terms of
warranty as undertaken by Volvo Penta.

Certificated engines

For engines that are certificated in compliance with
national and regional environmental legislation the
manufacturer undertakes to ensure that the environ­mental requirements are fulfilled both in new engines
and those already in use. The product must corres­pond to the specimen product that was approved for
certification. For Volvo Penta as the manufacturer to
be answerable for ensuring that engines in use meet
the stipulated environmental requirements, the follow­ing requirements in regard to service and spare parts
must be fulfilled:

€

€ The service intervals and maintenance measures

recommended by Volvo Penta must be followed.

€

€ Only Volvo Penta Original Spare Parts intended

for the certificated engine version may be used.

€

€ Service embracing injection pumps, pump set-

tings and injectors must always be carried out by
an authorized Volvo Penta workshop.

€

€ The engine must not be rebuilt or modified in any

way, except for the accessories and service kits
that Volvo Penta has developed for the engine in
question.

€

€ Installation changes to exhaust pipes and supply

air ducts for the engine bay (ventilation ducts)
must not be made indiscriminately as this could
affect exhaust emission levels.

€

€ Security seals, if any, must not be broken by non-

authorized personnel.

In other respects the general instructions for driving,
operation and maintenance given in the Owner’s Man­ual are applicable.

IMPORTANT! When spare parts are required,
use only Volvo Penta Original Spare Parts.

If non-original spare parts are used, AB Volvo
Penta will no longer be responsible for ensur­ing that the engine corresponds to the cer­tificated version.

All types of injury, damage and/or costs arising
due to the use of non-original Volvo Penta Original
Spare Parts for the product in question will not be
covered under the terms of warranty as under­taken by Volvo Penta.

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5

Technical data

Group 20

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)

*Weight TAD engines without radiator assembly and air filter

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")

Cylinder head bolts

Number of bolts per cylinder head ......................... 38

Thread size ........................................................... M16

Length ................................................................... 200 mm (7.87")

6

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Group 20

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

Technical data

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")

Oil control ring

Number .................................................................. 1

Width, incl. spring ..................................................4.3 mm (0.17")

Piston ring clearance, vertical ................................ 0.03-0.08 mm (0.0012–0.0031")

Piston ring gap ....................................................... 0.35-0.75 mm (0.014–0.03")

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7

Technical data

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")

Group 20

Exhaust .............................................................. 1.2–1.7 mm (0.047–0.067")

wear tolerance ..................................................... Max. 1.8 mm (0.071")

If the distance is greater the valve seats
must be changed.

Valve clearances, cold engine, setting value

Inlet .................................................................... 0.2 mm (0.008")

Exhaust .............................................................. 0.5 mm (0.020")

Valve clearance, cold engine, check value

Inlet .................................................................... 0.15–0.25 mm (0.006–0.010")

Exhaust .............................................................. 0.45–0.55 mm (0.018–0.022")

8

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Group 20

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 face seat

Diameter (dimension C) standard:

Inlet .................................................................... 43 mm (1.69")

Exhaust .............................................................. 43 mm (1.69")

Diameter (dimension C) oversize:

Inlet .................................................................... 43.200–43.225 mm (1.701–1.702")

Exhaust .............................................................. 43.200–43.225 mm (1.701–1.702")

Depth (dimension D):

Inlet .................................................................... 11.2±0.1 mm (0.441±0.004")

Exhaust .............................................................. 11.2±0.1 mm (0.441±0.004")

Seat bottom radius (dimension R):

Inlet. max. .......................................................... 0.8 mm (0.032")

Exhaust, max. .................................................... 0.8 mm (0.032")

Dimension between valve head and
cylinder head surface:

Inlet .................................................................... 0.9–1.4 mm (0.035–0.055")

Exhaust .............................................................. 1.2–1.7 mm (0.047–0.067")

Technical data

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"

Exhaust .............................................................. 0.04-0.07 mm (0.002–0.003")

Wear tolerance ...................................................0.3 mm (0.012"

1

Max. permissible clearance between valve stem and valve guide:

(according to the method described in ”Service Manual Engine Group 21: valve guides, inspection”)

)1

)1

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9

Technical data

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

Group 20

1. Drive, camshaft (z=76)

2. Drive, compressor (z=29)

3. Idler (z=83)

4. Drive, coolant pump (z=27)

5. Drive, crankshaft (z=38)

6. Drive, lubricating oil pump (z=23)

7. Idler (z=44)

8. Drive, hydraulic pump (z=39)

9. Idler (z=71)

10. Drive to belt and fuel pump (z=27)

11. Drive, servo pump (z=23)

12. Spray nozzle, drive lubrication

13. Idler, adjustable (z=97)

Flank clearance, adjustable intermediate gear (13) .. 0.05–0.17 mm (0.0020–0.0067")

Intermediate gear shaft journal, diameter ............... 99.99±0.01 mm (3.937±0.0004")

Intermediate gear bush, diameter ........................... 100.04±0.01 mm (3.939±0.0004")

Radial clearance for intermediate, max. diameter ...0.03–0.07 mm (0.0012–0.0028")

Axial clearance for intermediate gear ..................... 0.07–0.17 mm (0.0028–0.0067")

10

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