Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts.. Any type of damage which is the result of using spare parts that ar
Trang 3Industrial engines
TD420VE, TAD420VE,
TAD620VE
Contents
Safety Precautions 2
General information 5
Service procedures 6
Special tools 9
Description of engine 12
Engine plate placement 12
Engine plate 12
Engine serial number 13
Cylinder numbering 13
Engine, component placement 14
Start motor side 14
Service side 15
Lubrication system 16
Fuel system 17
Cooling system 19
Technical data 20
Engine 20
Tables 24
Checks and adjustments 28
Compression test 28
Injectors, Checking/adjustment 29
Exposing engine 31
Installing fixture 32
Crankshaft, measuring 89
Connecting rod, measuring 92
Piston 95
Camshaft 98
Camshaft bearing, Checking 100
Balance shaft bearing 102
Cylinder head 104
Valve seat, replacing 107
Valve seat, grinding 108
Valves, grinding 108
Rocker bridge 109
Control rod 110
Component repair 114
Group 21: Flywheel ring gear, replacing 114
Valve clearance, Checking/adjustment 116
Crankshaft seal, replacing (complete engine) 118
Crankshaft seal, front (front casing), replacing 120
Group 22: Pressure regulating and bypass valves, checking 122
Front casing, oil pump 124
Oil cooler 125
Group 23: Fuel pump 127
Injection pump, replacing 128
Group 25: Charge air pressure, checking 129
Group 26: Coolant pump, checking/replacing 130
Trang 4Safety Precautions
Introduction
This Workshop Manual contains descriptions and
ins-tructions for the repair of the Volvo Penta products or
product types Check that you have the correct
Work-shop Manual for your engine
Before starting work on the engine, read these
sa-fety precautions with care as well as ”General
in-formation” and ”Service procedures”.
Important
In this book and on the product you will find the
follo-wing special warning symbols
WARNING! Possible danger of personal injury,
extensive damage to property or serious
mecha-nical malfunction if the instructions are not
follo-wed
IMPORTANT! Used to draw your attention to
so-mething that can cause damage or malfunctions
on a product or damage to property
NOTE: Used to draw your attention to important
infor-mation that will facilitate the work or operation in
pro-gress
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
when operating or servicing the engine
Immobilize the engine by turning off the power
supply to the engine at the main switch
(switches) and lock it (them) turned off before
starting work Set up a warning notice at the
main circuit breaker
As a general rule all service operations must be
If working in proximity of an engine which isoperating, careless movements or a droppedtool can result in personal injury
Take care to avoid contact with hot surfaces(exhaust pipes, Turbocharger (TC), air intakepipe, starter heater etc.) and hot liquids in linesand hoses on an engine which is running orwhich has just been stopped Reinstall allprotective parts removed during serviceoperations before starting the engine
Check that the warning or information labels onthe product are always clearly visible Replacelabels which have been damaged or paintedover
Never start the engine without installing the aircleaner (ACL) filter The rotating compressor inthe Turbo can cause serious personal injury Fo-reign objects entering the intake ducts can alsocause mechanical damage
Never use start spray products or similar whenstarting the engine They may cause an explo-sion in the inlet manifold Danger of personalinjury
Only start the engine in a well-ventilated area Ifoperating the engine in an enclosed area ensurethat there is exhaust ventilation leading out ofthe engine compartment or workshop area.Avoid opening the coolant filler cap when theengine is hot Steam or hot coolant can sprayout and the system pressure will be lost Whenneeded, open the filler cap slowly and releasethe pressure in the system Be very careful if acock or plug or engine coolant line must beremoved when the engine is hot It is difficult toanticipate in which direction steam or hotcoolant can spray out
Hot oil can cause burns Avoid getting hot oil on
Trang 5Always use protective glasses or goggles when
carrying out work where there is a risk of
splint-ers, grinding sparks, acid splashes or where
oth-er chemicals are used The eyes are extremely
sensitive An injury could result in blindness!
Avoid getting oil on the skin! Repeated exposure
to oil or exposure over a long period can result
in the skin becoming dry Irritation, dryness and
eczema and other skin problems can then
oc-cur Used oil is more dangerous than fresh oil
from a health aspect Use protective gloves and
avoid oil soaked clothes and shop rags Wash
regularly, especially before eating There are
special skin creams which counteract drying out
of the skin and make it easier to clean off dirt
after work is completed
Many chemicals used on the product (for
ex-ample engine and transmission oils, glycol,
ga-soline and diesel oil), or chemicals used in the
workshop (for example degreasing agents, paint
and solvents) are dangerous to health Read the
instructions on the product packaging with care!
Always follow the safety precautions for the
pro-duct (for example use of protective mask,
glas-ses, gloves etc.) Make sure that other
person-nel are not exposed to hazardous chemicals, for
example in the air Ensure good ventilation in
the work place Follow the instructions provided
when disposing of used or leftover chemicals
Exercise extreme care when leak detecting on
the fuel system and testing the fuel injector
nozzles Use eye protection The jet from a fuel
injector nozzle is under extremely high pressure
and has great penetrative energy, so the fuel
can penetrate deep into the body tissue and
cause serious personal injury Danger of blood
poisoning
WARNING! The delivery pipes must under no
circumstances be bent Damaged pipes should
be replaced
All fuels and many chemical substances are
flammable Do not allow naked flame or sparks
in the vicinity Certain thinner products and
hy-Ensure that the work area is well ventilated andtake the necessary safety precautions beforestarting welding or grinding work Always ensurethat there are fire extinguishers at hand whenwork is being carried out
Ensure that rags soaked in oil or fuel and usedfuel or oil filters are stored safely Rags soaked
in oil can spontaneously ignite under certain cumstances Used fuel and oil filters are envi-ronmentally dangerous waste and must be depo-sited at an approved site for destruction togetherwith used oil, contaminated fuel, paint remnants,solvent, degreasing agents and waste fromwashing parts
cir-Never expose a battery to naked flame or trical sparks Do not smoke close to the batte-ries The batteries give off hydrogen gas duringcharging which when mixed with air can form anexplosive gas - oxyhydrogen This gas is easilyignited and highly volatile A spark, which can
elec-be formed if the batteries are wrongly ted, is enough to make a battery explode andcause damage Do not shift the connectionswhen attempting to start the engine (spark risk)and do not lean over any of the batteries
connec-Always ensure that the Plus (positive) and nus (negative) battery cables are correctly in-stalled on the corresponding terminal posts onthe batteries Incorrect installation can result inserious damage to the electrical equipment Re-fer to the wiring diagram
Mi-Always use protective goggles when chargingand handling the batteries Battery electrolytecontains sulfuric acid which is highly corrosive.Should the battery electrolyte come into contactwith unprotected skin wash off immediatelyusing plenty of water and soap If battery acidcomes in contact with the eyes, immediatelyflush with plenty of water and obtain medical as-sistance at once
Turn the engine off and turn off the power at themain switch(es) before carrying out work on theelectrical system
Trang 6ar and not damaged during the lifting operations.Always check before starting work if there isenough room to carry out disassembly work wit-hout risking personal injury or damage to theengine or parts.
WARNING! The components in the electrical
system and in the fuel system on Volvo Pentaproducts are designed and manufactured to mi-nimize the risk of fire and explosion The enginemust not be run in areas where there are explo-sive materials
Always use the fuels recommended by VolvoPenta Refer to the Instruction Book Use of fu-els that are of a lower quality can damage theengine On a diesel engine poor quality fuel cancause the control rod to seize and the engine tooverrev with resulting risk of damage to the eng-ine and personal injury Poor fuel quality canalso lead to higher maintenance costs
Remember the following when washing with ahigh pressure washer: Never direct the water jet
at seals, rubber hoses, electrical components orthe radiator Never use the high pressure featurewhen cleaning an engine
Use the lifting eyes fitted on the engine when
lifting the drive unit Always check that the
lifting equipment used is in good condition and
has the load capacity to lift the engine (engine
weight including gearbox, if fitted, and any extra
equipment installed) Use an adjustable lifting
beam or lifting beam specifically for the engine
to raise the engine to ensure safe handling and
to avoid damaging engine parts installed on the
top of the engine All chains and cables should
run parallel to each other and as perpendicular
as possible in relation to the top of the engine If
extra equipment is installed on the engine which
alters its center of gravity a special lifting device
is required to obtain the correct balance for safe
handling
Never carry out work on an engine suspended
on a hoist
Never work alone when removing heavy engine
components, even when using lifting devices
such as locking tackle lifts When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted
Trang 7cle-General information
About this Workshop Manual
This Workshop Manual contains descriptions
and instructions for the repair of standard engine
ver-sions TD/TAD 420 and 620
The Engine Designation and Engine Numbers can be
found on the product plate (see page 12)
Please always include both the engine designation
and the engine number in all correspondence
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service
technici-ans For this reason the manual presupposes a
cer-tain basic knowledge and that the user can carry out
the mechanical/electrical work described to a general
standard of engineering competence
AB Volvo Penta products are under a continual
pro-cess of development and we therefore reserve all
rights regarding changes and modifications All the
information in this manual is based on product
specifi-cations available at the time the book was published
Any essential changes or modifications of the product
or revised service methods introduced after the date
of publication will be provided in the form of Service
Bulletins
Flat Rates
Operation numbers that show in instruction headings
refer to Volvo Penta Flat Rates
Spare parts
Spare parts for the electrical and fuel systems are
sub-ject to various national safety requirements Volvo
Pen-ta Original Spare Parts meet these specifications Any
type of damage which is the result of using spare parts
that are not original Volvo Penta parts for the product in
question will not be covered under any warranty or
guar-antee provided by AB Volvo Penta
require-be met:
• Service and maintenance intervals recommended
by Volvo Penta must be followed
• Only Volvo Penta Original Spare Parts intended forthe certified engine version may be used
• Service work that covers injection pumps, pumpsettings, and injectors must always be carried out
by an authorized Volvo Penta workshop
• The engine must not be altered or modified in anyway, except for accessories and service kitsdeveloped by Volvo Penta for that engine
• No modifications to the exhaust pipes and engineroom air intake pipes are allowed
• Any seals on the engine may not be broken byunauthorized persons
IMPORTANT! When spare parts are required,
use only Volvo Penta original parts
Use of non-original parts will result in AB Volvo Penta being unable to warrant that the engine corresponds to the certificated engine version.
Any type of damages or costs which are theresult of using spare parts that are not originalVolvo Penta parts for the product in question willnot be paid for by AB Volvo Penta
Trang 8Our joint responsibility
Every engine consists of many systems and nents that work together If one component deviatesfrom the technical specifications this can have drama-tic consequences on the environmental impact of theengine even if it is otherwise in good running order It
compo-is therefore critical that the stated wear tolerances areobserved, that systems which can be adjusted arecorrectly set up and that only Volvo Penta OriginalParts are used on the engine The stated service in-tervals in the Maintenance Schedule must be follo-wed
Some systems, such as the components in the fuelsystem, require special expertise and special testingequipment for service and maintenance Some com-ponents are factory sealed for environmental and pro-duct specific reasons Under no circumstances at-tempt to service or repair a sealed component unlessthe service technician carrying out the work is authori-zed to do so
Bear in mind that most chemical products, incorrectlyused, are hazardous to the environment Volvo Pentarecommends the use of bio-degradable degreasingagents for all cleaning of engine components unlessotherwise stated in the Workshop Manual Pay specialattention to make sure that oils and washing residueetc are handled correctly for destruction, and do notunintentionally end up in nature
Torque
Correct torque for critical joints which must be ned using a torque wrench are listed under ”TechnicalData - Torque” and stated in the method descriptions
tighte-in the Workshop Manual All torque data apply to ned threads, bolt heads and mating surfaces Torquedata stated apply to lightly oiled or dry threads Wheregrease, locking or sealing agents are required for scre-wed joints this is stated in both the operation descrip-
clea-The working methods described in the Workshop
Ma-nual apply to work carried out in a workshop The
eng-ine has been removed and is installed in an engeng-ine
fix-ture Unless otherwise stated reconditioning work
which can be carried out with the engine in place
fol-lows the same working method
Warning symbols used in this Workshop Manual (for
full explanation of the symbols refer to the section;
”Safety Precautions”
WARNING!
IMPORTANT!
NOTE:
are not in any way comprehensive since it is
impos-sible to predict every circumstance under which
servi-ce work or repairs may be carried out AB Volvo
Pen-ta can only indicate the risks considered likely to
oc-cur as a result of incorrect working methods in a well
equipped workshop using working methods and tools
tested by AB Volvo Penta
All operations described in the Workshop Manual for
which there are Volvo Penta Special Tools available
assume that these tools are used when carrying out
the repair Volvo Penta Special Tools have been
spe-cifically developed to ensure as safe and rational
wor-king methods as possible It is therefore the
responsi-bility of anyone using other tools or other working
met-hods than we recommend to determine that there is
no risk of personal injury or mechanical damage or
malfunction as a result
In some cases special safety precautions and user
in-structions may be required in order to use the tools
and chemicals mentioned in the Workshop Manual
Always follow these precautions There are no
speci-fic instructions given in the Workshop Manual
By following these basic recommendations and using
common sense it is possible to avoid most of the
Service procedures
Trang 9Torquing with Protractor
tight-ening (angle tighttight-ening)
When torquing with protractor (angle tightening), the
fastener is tightened to a predetermined torque and
then turned a predetermined angle Example: a 90°
protractor tightening means that the joint is tightened
a further 1/4 turn in one operation after the stated
tor-que has been applied
Lock nuts
Do not re-use lock nuts that have been removed
during disassembly operations as these have reduced
service life when re-used For lock nuts with a plastic
insert such as Nylok® the torque stated in the table is
reduced if the Nylok® nut has the same head height
as a standard hexagonal nut without plastic insert
Re-duce the torque by 25% for bolt size 8 mm or larger
Where Nylok® nuts are higher, where the metallic
th-read is of the same height as a standard hexagonal
nut, the torques given in the as shown in table apply
Strength classes
Bolts and nuts are divided up into different classes of
strength; the class is indicated by the number on the
bolt head A higher number indicates a material with
greater strength For example, a bolt marked 10-9
indi-cates a higher strength than one marked 8-8 It is
the-refore important that bolts removed during the
disas-sembly of a bolted joint must be reinstalled in their
ori-ginal position when assembling the joint If a bolt must
be replaced check in the spare parts catalogue to
make sure the correct bolt is used
Sealant
A number of sealants and locking liquids are used onthe engines The agents have varying properties andare used for different types of jointing strengths, ope-rating temperature ranges, resistance to oil and otherchemicals and for the different materials and gap si-zes in the engines
To ensure service work is correctly carried out it is portant that the correct sealant and locking fluid type
im-is used on the joint where the agents are required
In this Volvo Penta Workshop Manual the user willfind that each section where these agents are applied
in production states which type was used on the ne
engi-During service operations, use the same agent or analternative from a different manufacturer
Make sure that mating surfaces are dry and free fromoil, grease, paint and anti-corrosion agent before app-lying sealant or locking fluid
always follow the manufacturer’s instructions for useregarding temperature range, curing time and any oth-
er instructions for the productTwo different basic types of agent are used on theengine and these are:
RTV agent (Room temperature vulcanizing) Used forgaskets, sealing gasket joints or coating gaskets.RTV is visible when a part has been disassembled;old RTV must be removed before resealing the joint.The following RTV agents are mentioned in the Work-shop Manual: Loctite® 574, Permatex® No 3, Perma-tex® No 77 Old sealant can be removed using denatu-red alcohol in all cases
Anaerobic agents These agents cure in an absence
of air They are used when two solid parts, for ample cast components, are installed face-to-face wit-hout a gasket They are also commonly used to secu-
ex-re plugs, thex-reads in stud bolts, cocks, oil pex-ressuex-reswitches etc The cured material is glass-like and it istherefore colored to make it visible Cured anaerobicagents are extremely resistant to solvents and the oldagent cannot be removed When reinstalling the part,degrease it carefully and then apply new sealant.The following anaerobic agents are mentioned in theWorkshop Manual: Loctite® 572 (white), Loctite® 241(blue)
Trang 10Safety rules for
fluorocarbon rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example
When fluorocarbon rubber is subjected to high
temperatures (above 300 °C/572°F), hydrofluoric
acid can be formed, which is highly corrosive Skin
contact can result in severe chemical burns Splashes
in your eyes can result in severe chemical burns If
you breathe in the fumes, your lungs can be
permanently damaged
WARNING! Be very careful when working on
engines which have been exposed to high
temperatures, e.g overheating during a seizure
or fire Seals must never be cut with an
oxy-acetylene torch, or be burned up afterwards in
an uncontrolled manner
• Always use gloves made of chloroprene rubber(gloves for handling chemicals) and protectivegoggles
• Handle the removed seal in the same way as rosive acid All residue, including ash, can be high-
cor-ly corrosive Never use compressed air to blowanything clean
• Put the remains in a plastic jar which is sealed andprovided with a warning label Wash the gloves un-der running water before removing them
The following seals are probably made from bon rubber:
fluorocar-Seal rings for the crankshaft, camshaft, intermediateshafts
rings, irrespective of where they are installed rings for cylinder liner sealing are almost always madefrom fluorocarbon rubber
O-Note that seals which have not been subjected to high temperature can be handled normally.
Trang 11Special tools
The following special tools are used when working on the engine The tools can be ordered from AB Volvo Penta by specifying the number shown.
885 490 17 mm (0,67 ”) wrench, delivery pipes
885 491 Tool for balance shafts
999 0144 Plate for removal and insertion of
cylinder liner
999 0145 Piston ring compressor, refitting
pistons in block (620 engine)
999 6645 Puller, for cylinder liner
999 6666 Nipple, Use together with
Trang 12Tool Designation – use
999 8007 Adapter, for removal of injectors
Use together with 999 6400
999 8671 Engine bracket, support 999 6485
999 9179 Filter puller, filter removal
11 668 400 Tool for front
Trang 13Other special equipment
998 5423 Piston ring tool, remove/install piston rings
998 5468 Valve spring clamp, remove/install valve
collet
998 5471 Depth slide gauge, for control rod
998 6485 Turning assembly fixture for engines
Trang 14Description of engine
Engine plate placement
Each engine is supplied with two identification plates,
of which one is mounted on the right side of the
cylin-der block
The other identification plate should be mounted in a
suitable location adjacent to the engine
Trang 15Engine serial number
Engine serial number is stamped on the engine blockand on the product plate The serial number consists
of 10 digits Only the last eight digits are stamped onthe engine block
Cylinder numbering
A = flywheel
A
A
Trang 16Start motor side
* Speed governor (Heinzmann)
The speed governors on engines series T(A)D 420/620 VEare mechanically adjustable speed governors with centrifugal
8 Outlet pipe, coolant
Engine, component placement
Trang 18Lubrication system
420 engine
620 engine
Trang 1910 Bypass valve with air vent screw
11 Return line to fuel tank
12 Fuel line, smallest distance 300 mm
13 Pre-filter, water separating
Trang 20Adjustment of injection angle, Fb
Engine is equipped with a separate injection pump foreach cylinder This means that the injection angle,
Fb, must be adjusted separately for each pump unit.
The injection angle is adjusted using a shim placedbetween the lifter and the injection pump The shimthickness is calculated using a mathematical formula
When replacing injection pump only, use the formula
T s =(L 0 +A/100), as shown in ”Calculation 1” in
”Technical data”
If engine block, camshaft or valve lifter have been
replaced, a new corrected installation dimension, E k ,
and a new EP code must be calculated, as shown in
”Calculation 2 and 3” in ”Technical data”
The new EP code must also be noted on the engineplate so that calculations during later replacement ofinjection pump will be correct
Fuel delivery pipe
IMPORTANT! The fuel delivery pipes must be
discarded once removedDelivery pipes are deformed when tightened andall delivery pipes must be tightened using thesame torque
If they are tightened using different torques, thecylinders may be unevenly loaded
Re-use of delivery pipes may cause the enginenot to perform at full power
If delivery pipes have been damaged for anyreason, such as transport, they must not bebent back, but must be replaced
Trang 216 Cylinder head cooling
7 Coolant connection (Outlet)
Trang 22Technical data
See also separate Workshop Manual, Technical data
Engine
Dry weight per DIN 70020–A 380 kg (837 lb) 380 kg (837 lb)
Displacement 4040 cm3 (247 cuin) 4040 cm 3 (247 cuin)
(247 cuin)Bore 101 mm (3.98 in) 101 mm (3.98 in)
Stroke 126 mm (4.96 in) 126 mm (4.96 in)
Rotational direction Counter-clockwise Counter-clockwise
Rated rpm 2000-2500 rpm 2000-2500 rpm
Low idle 800 rpm 800 rpm
Working cycle Four stroke diesel Four stroke diesel
Combustion system Fuel injection Fuel injection
Compression ratio 19:1 (step 1), 19:1 (step 2) 19:1 (step 1), 19:1 (step 2)Firing order 1-3-4-2 1-3-4-2
Valve clearance, intake/exhaust 0.35 /0.55 mm ±0.05 mm 0.35 /0.55 mm ±0.05 mm (0.0138 / 0.0215 in ±0,002 in) (0.0138 / 0.0215 in ±0,002 inOil pressure at low idle
Temperature about 120°C (248 °F) oil SAE 15W/40 400 kPa (58,01 Psi) 400 kPa (58,01 Psi)
Thermostat starts opening/fully open 83°C/95°C (181°F/203°F) 83°C/95°C (181°F/203°F)
Type designation TAD 620VE
Dry weight per DIN 70020–A 495 kg (1090 lb)
Working cycle Four stroke diesel
Combustion system Fuel injection
Compression ratio 18.4:1 (step 1), 18.4:1 (step 2)
Firing order 1-5-3-6-2-4
Valve clearance, intake/exhaust 0.35 /0.55 mm ±0.05 mm (0.0138 / 0.0215 in ±0,002 in)Oil pressure at low idle
Trang 23Volvo Penta anti-freeze, mixed 40/60% with water See specification below
Corrosion protection
Used on markets where there is no risk of freezing.2)
2) Corrosion protection additive must not be mixed with coolant or corrosion liquid of other type, since this can cause negative effects.
Water specification:
To avoid any risk of clogging the cooling system, coolant should be mixed with pure water per ASTM D4985
If there is any doubt about water purity, use distilled water or premixed coolant
Lubrication
Lubrication Pressure circulation lubrication
Oil SAE 15W 40
Oil temperature in oil pan Normal 80°C (176°F) Max 125°C (257.0°F)
Oil pressure at rated rpm:
TD 420VE/TAD 420VE 400 kPa (58,013 psi)
TAD 620VE 370 kPa (53,66 psi)
Adjustment, oil pressure switch 50 kPa (7.25 psi)
Oil volume, including filter:
TD 420VE/TAD 420VE 10 Liters (2.64 US Gal)
TAD 620VE 16 Liters (4.23 US Gal)
Torque order for cylinder head screws.
Intake manifold side TD/TAD 420 Intake manifold side TAD 620
Trang 24Torque applies to oiled screws and nuts Degreased (washed) parts should be oiled prior to assembly
Special torques Nm/Angle tightening
Step 2 angle tighten 90°
Step 3 angle tighten 90°
Step 2: angle tighten 60°
Step 3: angle tighten 30°
B) Flywheel with screws between 35 and 45 mm (1.38 in and 1.77 in) long
Step 1: 20 – 30 nm (14.76 - 22.14 lbf ft)
Step 2: angle tighten 60°
Step 3: angle tighten 60°
C) Flywheel with screws between 50 and 85 mm (1.97 in and 3.35 in) long
Step 1: 30 – 40 nm (22.14 - 29.52 lbf ft)
Step 2: angle tighten 60°
Step 3: angle tighten 60°
Trang 25Group 22 Lubrication system Nm / angle tightening
Oil cooler, retaining screws 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Oil cooling plugs 80 nm (59.04 lbf ft)
Front casing/oil pump case 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
System pressure valve 8 -9 nm (5.904-6.642 lbf ft)
Oil suction pipe 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Oil pan 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Oil pressure switch 18 nm (13.284 lbf ft) (±2 nm (1.476 lbf ft))
Oil pressure pipe, turbo 29 nm (21.402 lbf ft) (±2 nm (1.476 lbf ft))
Oil return pipe, turbo:
A) with pipe connection 40 nm (29.52 lbf ft) (±2 nm (1.476 lbf ft))
B) with baffle plate 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Group 23 Fuel system
Screw, governor, idler:
Step 1 30 nm (22.14 lbf ft)
Step 2 angle tighten 90°
Screw, control rod socket 10 nm (7.38 lbf ft) (±2 nm (1.476 lbf ft))
Screw, speed governor 17 nm (12.546 lbf ft) (±1.5 nm (1.107 lbf ft))
Flange screws, injection pump
Step 1: Torquing 5 nm (3.69 lbf ft)
Step 2: Loosen injection pump flange screws 60° (counter-clockwise)
Step 3: Turn the injection pump to stop Counter-clockwise
Step 4 angle tighten 60°
NOTE: Install new delivery pipes after each disassembly.
NOTE: Be careful to torque all delivery pipes to the same value.
Step 1 5 nm (3.69 lbf ft)
Step 2 25 nm (3.69 lbf ft) (±2,5 nm (1.845 lbf ft))
Stop solenoid 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Bypass valve 30 nm (22.14 lbf ft)
Group 25 Intake and exhaust system
Nuts for exhaust manifold 25 nm (3.69 lbf ft) (±2,5 nm (1.845 lbf ft))
M8 Nuts turbo to exhaust manifold 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
M10 Nuts turbo to exhaust manifold 40,5 nm (29.889 lbf ft)(±4 nm (2.952 lbf ft))
Group 26 Cooling system
Thermostat housing 30 nm (22.14 lbf ft)
Temperature sensor 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Coolant pump 21 nm (15.498 lbf ft) (±2 nm (1.476 lbf ft))
Trang 26Determining shim thickness when replacing injection pump
Mathematical formula for new shim thickness: TS = Ek - (L0+ A/100)
Actual shim thickness, Ss, obtained from table 2 SS → TS
NOTE: This formula applies when replacing INJECTION PUMP only
Example: Replacing injection pump for cylinder 3 on a TD/TAD 420 engine.
1 Read EP code for cylinder 3 from the engine plate in column ”EP”, ex 305
(Read sequence from above: row 1 = cyl 1, row 2 = cyl: 2, etc.)
2 Read the injection pump’s corrected install dimension using EP code, E k, from Table 3
Ex EP code = 305 →→ Ek = 121.125 mm
4 Read the standard dimension for the injection pump, L, from table 1
Tolerance value A is divided by 100 in calculations
3 Read mfg tolerance for the injection pump’s
length, A, from the new injection pump,
Ex 26 (see illustration)
NOTE: If the value is not readable, remove any dirt
without scraping.
A/100
Corrected install dimension, see table 3 E k 121.125
Basic dimension on inj pump, see table 1 L 0 - 117.5
Actual shim thickness, see table 2 S S ~ 3.4
Trang 27Determining shim thickness when injection valve shall open
Performed when replacing engine block, camshaft or roller pin.
Mathematical formula for new shim thickness:
Ts = L-[(Fbcurr- Fbnom)x Vhcorr+ Vhnom+ Lo+ A/100)]
Actual shim thickness is obtained from table 2 TS→ SS
NOTE: When shim thickness has been determined, new EP code MUST ALWAYS be developed per ”Calculation
3”, so that a later pump replacement will be correct
Actual shim thickness, see table 2 S S ~ 3.4
Injection angle, measured with protractor Fb curr 3.5
Injection angle, see engine plate∠° Fb nom - 4
pre-load, corr factor, see table 1 Vh corr x 0.14
Basic dimension of inj pump, see table 1 L 0 + 117.5
FACTOR UNIT EXPLANATION
Fbcurr ºC/A Injection angle, measured with protractor per method
Fbnom ºC/A Injection angle, read from the engine plate
Vhcorr mm/ºC/A Pre-load, correction factor, read from table 1
Lfb mm The exact point when the injection pump starts delivering fuel
Trang 28Determining corrected install dimension, Ek, and EP code for injection pump
When replacing engine block, camshaft or roller pin, the corrected installation dimension, Ek, must be determinedagain and the EP code on the engine plate must be changed
Mathematical formula for the corrected installation dimension, E k :
Ek = L - [(Fbcurr- Fbnom) x Vhcorr+Vhnom)]
New EP code is obtained from table 3.2 Ek→ EP code
Table 1 (Injection angle)
Injection angle, measured with protractor Fb curr 3.5
Injection angle, see engine plate∠° Fb nom - 4.0
Correction factor, see table 1 Vh corr x 0.14
Ek rounded to closest value in table 3 E k ~ 121.125
Trang 30Injectors have been removed Valve clearance has been checked.
1 Fit the adapter, 999 8694
2 Use existing diffuser holder
Tighten the screw to 16 +5 Nm (11.808+3,69 lbf ft).
3 Connect compression tester, 998 8539 Crank theengine with the starter motor
Compression: 30 - 38 bars (435.11 - 551.14 psi)
NOTE: Check that the control rod is in the position for
no injection
The measured compression depends on starting rpmduring the measuring process and ambient airpressure
It is difficult to indicate exact limit values due to theinfluence of ambient air pressure We recommend thatthe measurement of compression pressure is used tocompare the compression pressure in the cylinders of
Trang 31WARNING! Be very careful when working on the
injector nozzle’s fuel spray The fuel spray canpenetrate deep into the skin and can causeblood-poisoning
1 Connect the injector to the nozzle tester
2 Check opening pressure
Check value for opening pressure, see ”Technicaldata”
NOTE: Opening pressure is different for used or
new injector or spring
3 Check for leak after the injector has opened.Pressure may drop no more than 50 bar/5 sec.Check that there is no pressure drop by holdingconstant pressure, 20 bar below openingpressure, for 10 sec
Injectors, Checking/
adjustment
(Operation number 23712, 23713)
NOTE: Extreme cleanliness must be observed when
working on the injection equipment Use only pure testoil per ISO 4113 or pure diesel to test the injector
NOTE: Have an authorized workshop perform test and
adjustments The test requires special equipment, notsold by Volvo Penta
Adjusting opening pressure on the injector IMPORTANT! Cleanliness and care are required
so that parts are not mixed up
4 Unscrew the cap nut and remove all parts
5 Wash the parts using ultrasonic cleaning
6 Inspect diffuser parts in a nozzle microscope
7 Dip parts in test oil before refitting
0 100 300 10 20 30
40
200 400 500
Trang 329 Check for leaksDry the nozzle and nozzle holder – blowoff with compressed air Press down handle on thetester until the pressure reads about 20 bar, less thanthe previously read opening pressure.
Example: Pressure gauge reading: 255 bar
12 Squeak and spray pattern test
NOTE: Turn of tester pressure gauge for this test.
The squeak test provides an audible check of how
Disassemble parts in this order:
Torque the cap nut to 40 –50 Nm
Again, check the injector on the nozzletester
0 100 300 10 20 30
40
200 400 500
(29.5 - 36.9 lbf ft).
Trang 331 Loosen all cable harnesses and junction boxes.Mark as needed.
Remove plug (1) for draining coolant Drain and
collect remaining oil and coolant and discardthese per applicable environmental regulations
Exposing engine
2 Remove the belt by turning the belt tensiondevice clockwise Remove the idler pulleycomplete with bearing block
3 Remove alternator, fuel line and the fuel pump
4 Remove fuel line between fuel filter and engineblock Remove nipple for banjo screw, located inthe engine block
5 Remove cooling water housing complete withcirculating pump and thermostat
Trang 34Installing fixture
Turbo unit and starter motor, removal
1 Remove delivery pipes (1) and return pipes (2)
from turbo unit Fit protection plugs on turbo unitconnections
3 Fit protection plugs (1) in connections for the
re-turn pipe and delivery pipe
2 Remove retaining nuts and remove turbo unit
Trang 354 Fit engine fixture 9998671 (1) on the engine and torque to 25 Nm (18.44 lbf ft).
the 420 engine is held by 5 screws.
the 620 engine is held by 6 screws.
NOTE: Use enclosed screws They are stronger than
standard screws
5 Secure the engine in the turning assembly fixture
Trang 36Cylinder head, removal
1 Remove the pipe to the crankcase ventilation and
unscrew (1) the oil trap.
2 Remove the pipe for the smoke limiter betweeninlet pipe and governor
Disassembly, complete engine
3 Remove ground wire to the preheating element
4 Remove preheat pipe (1) from the intake manifold (2).
Trang 375 Remove the valve cover.
NOTE: Make sure that any dirt between the intake
manifold and the valve cover do not drop into theengine Clean carefully before you remove thevalve cover
Delivery pipes, removal
8 Remove the nut and remove the delivery pipe (1).
NOTE: Discard the delivery pipe and fit protection
Trang 3811 Mark rocker arm holders (1) Remove rocker arm holders with rocker arms (2) and the push rods(3).
Note: Remove the small torx screws (Torx E10).
Remove the large torx screws (Torx E14) and removethe small torx screws
12 Remove the screws Use socket Torx E14
9 Remove diffuser holder (1) Use tool for Torx E10 (2).
10 Mark the diffusers and pull them out As needed,
use a glazing hammer 999 6400 (1) with adapter
999 8007 (2).
Trang 3913 Connect straps to the lifting eyes and lift cylinderhead to remove it.
Oil cooler, oil filters and oil cooler housing, removal
14 Remove retaining screws (7 ea) and remove theoil cooler
NOTE: The oil cooler flanges are sensitive to shocks.
15 Remove retaining screws (8 ea) and remove oil ter and oil cooler housing
Trang 40fil-16 Remove the coolant housing (1) with connecting pipe (2).
Applies only to the 620 engine.
17 Remove the starter motor (It can be removedlater, complete with transmission gear casing.)