Volvo Penta TAD940GE Workshop Manual Download

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Summary of Contents for TAD940GE

Page 1: ...Workshop Manual Group 20 Technical Data TAD940GE TAD941GE TAD940VE TAD941VE TAD942VE TAD943VE TAD950VE TAD951VE TAD952VE I 1 0 ...

Page 2: ......

Page 3: ...tents Safety information 2 General information 5 Technical data 6 General 6 Engine 8 Valve mechanism 10 Timing gear 14 Reciprocating components 16 Lubrication and oil systems 19 Fuel system 22 Inlet and exhaust system 23 Cooling system 24 Engine control system 25 Tightening torque 27 References to Service Bulletins 36 ...

Page 4: ...xhaust pipes turbocharger charge air pipe starter heater etc and hot fluids in pipes and hoses in an engine which is running or has just been stopped Reinstall all protective parts removed during service operations before starting the en gine Read the available safety information General in formation and Repair instructions in the work shop manual before you start to do any service work Check that...

Page 5: ...stances be bent Damaged pipes must be replaced All fuels and many chemicals are flammable Do not allow naked flame or sparks in the vicini ty Certain thinners and hydrogen from batteries can be extremely flammable and explosive when mixed with air in the right proportions No Smoking Ensure that the work area is well ven tilated and take the necessary safety precau tions before starting welding or ...

Page 6: ...le are used When using a lifting devise two people are usu ally required to do the work one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting operations Always make sure that there is enough space for disassembly where you are working with no risk for personal or material damage WARNING Components in the electrical and fuel...

Page 7: ... responsible for guaranteeing that the engine complies with the certified version Any damage injury and or costs which arise due to the use of non original Volvo Penta spares for the product in question will not be compensated by Volvo Penta About the workshop manual This workshop manual contains technical data for the TAD940GE TAD941GE TAD940VE TAD941VE TAD942VE TAD943VE TAD950VE TAD951VE and TAD...

Page 8: ... 1015 1015 1015 Weight wet kg 1065 1065 1065 1065 Injection sequence 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Technical data General Type designation TAD940GE TAD941GE Power Prime Stand by See Sales Guide Generating Set Engines Torque Prime Stand by See Sales Guide Generating Set Engines Compression ratio 20 2 1 17 4 1 Low idle rpm 600 1200 600 1200 High idle rpm 1500 1620 1800 1920 1500 16...

Page 9: ...1 Low idle rpm 600 600 600 High idle rpm 2250 2250 2250 No of valves 24 24 24 No of cylinders 6 6 6 Cylinder bore mm inch 120 4 72 120 4 72 120 4 72 Stroke mm inch 138 5 43 138 5 43 138 5 43 Swept volume dm3 US quart 9 36 9 89 9 36 9 89 9 36 9 89 Weight dry kg lb 1015 2238 1015 2238 1015 2238 Weight wet kg lb 1065 2348 1065 2348 1065 2348 Injection sequence 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 ...

Page 10: ...ion thread M16 Length 200 mm 7 874 Cylinder liner Type Wet replaceable Height total 250 mm 9 8425 Sealing surface height above block plane 0 15 0 20 mm 0 0059 0 0079 No of seal rings per cylinder liner 3 Cylinder bore 120 00 120 02 mm 4 72 4 73 Piston Type aluminium Height above engine block plane 0 15 0 65 mm 0 0059 0 0256 Diameter combustion chamber TAD940GE TAD940 943VE 77 mm 3 032 TAD941GE 78 ...

Page 11: ... ring 0 09 0 13 mm 0 0035 0 0051 Piston ring gap measured at ring opening upper compression ring 0 35 0 55 mm 0 013779 0 021653 lower compression ring 1 15 1 3 mm 0 045275 0 051181 Oil scraper ring Quantity 1 Width including spring 4 3 mm 0 011811 Piston ring clearance in groove 0 05 0 10 mm 0 001968 0 003937 Piston ring gap measured at ring opening 0 35 0 75 mm 0 013779 0 029527 ...

Page 12: ... head plane Inlet min 0 95 mm 0 037401 Exhaust min 1 25 mm 0 049212 NOTE When the valve seats are changed the valves must be changed at the same time Valve clearance cold engine setting value Inlet 0 2 mm 0 007874 Exhaust TAD940 941GE TAD940 943VE 0 5 mm 0 019685 TAD950 952VE 0 8 mm 0 031496 Valve clearance cold engine check value Inlet 0 15 0 25 mm 0 005905 0 009842 Exhaust TAD940 941GE TAD940 94...

Page 13: ...m 1 61417 TAD950 952VE 40 0 mm 1 5748 Oversize dimension Inlet TAD940 941GE TAD940 943VE 40 3 mm 1 586611 TAD950 952VE 42 3 mm 1 665349 Exhaust TAD940 941GE TAD940 943VE 41 3 mm 1 625981 TAD950 952VE 40 3 mm 1 586609 Height B Inlet TAD940 941GE TAD940 943VE 7 3 mm 0 287401 TAD950 952VE 7 4 mm 0 291338 Exhaust TAD940 941GE TAD940 943VE 7 4 mm 0 291338 TAD950 952VE 6 4 mm 0 251968 ...

Page 14: ...43VE 41 0 mm 1 61417 TAD950 952VE 40 0 mm 1 5748 Diameter C oversize dimension Inlet TAD940 941GE TAD940 943VE 40 2 mm 1 582674 TAD950 952VE 42 2 mm 1 661412 Exhaust TAD940 941GE TAD940 943VE 41 2 mm 1 622044 TAD950 952VE 40 2 mm 1 582672 Depth D Inlet 11 5 mm 0 452755 Exhaust 11 9 mm 0 468503 Seat base radius R Inlet max 0 8 mm 0 031496 Exhaust max 0 8 mm 0 031496 ...

Page 15: ...er valve springs Unloaded length 73 8 mm 2 905506 With 590 N 132 6 lbf loading 58 4 mm 2 299208 With 1150 N 258 5 lbf loading 45 3 mm Coilbound length max 39 5 mm 1 555115 Inner valve spring Unloaded length 70 5 mm 2 775585 With 243 N 54 6 lbf loading 54 4 mm 2 141728 With 447 N 100 4 lbf loading 41 3 mm 1 625981 Coilbound length max 36 5 mm 1 437005 Exhaust Outer valve springs Unloaded length 73 ...

Page 16: ...73 4 Drive gear camshaft 84 5 Idler wheel servo pump 37 6 Drive wheel steering servo and fuel feed pump 31 7 Drive wheel air compressor 42 8 Drive wheel lubricating oil pump 23 Gear backlash min 0 05 mm 0 001968 max 0 17 mm 0 006692 Shaft stub for idler wheel diameter 100 mm 3 937 Bushing for idler wheel diameter 100 mm 3 937 Radial clearance for idler wheel max 0 05 mm 0 001968 ...

Page 17: ...es not for machining Diameter bearing journals undersize dimension 0 25 69 72 69 78 mm 2 744876 2 747238 0 50 69 47 69 53 mm 2 735033 2 737396 0 75 69 22 69 28 mm 2 725191 2 727553 Max end float 0 24 mm 0 009448 Max permissible ovality with new bearings 0 05 mm 0 001968 Bearing max permissible wear on diameter 0 05 mm 0 001968 Valve lift inlet 13 mm 0 51181 outlet EPG 12 mm 0 47244 Permissible wea...

Page 18: ...108 0 mm 4 25196 Undersize dimension 0 25 mm 107 85 107 87 mm 4 246054 4 246841 0 50 mm 107 73 107 75 mm 4 241330 4 242117 0 75 mm 107 60 107 62 mm 4 236212 4 236999 1 00 mm 107 48 107 50 mm 4 231487 4 232275 1 25 mm 107 35 107 37 mm 4 226369 4 227156 Surface finish main bearing journal Ra 0 25 Surface finish radius Ra 0 4 Width main bearing journal A standard 42 mm 1 65354 Oversize dimension 0 2 ...

Page 19: ...75 mm 2 8 2 9 mm 0 110236 0 114173 1 00 mm 2 9 3 0 mm 0 114173 0 11811 1 25 mm 3 1 3 2 mm 0 122047 0 125984 Radial clearance main bearings max 0 11 mm 0 004330 Big end bearing journal NOTE Only check values not for machining Diameter Ø 88 mm 3 46456 Undersize dimension 0 25 mm 87 85 87 87 mm 3 458654 3 459441 0 50 mm 87 73 87 75 mm 3 453930 3454717 0 75 mm 87 60 87 62 mm 3 448812 3449599 1 00 mm 8...

Page 20: ...9 Big end bearing radial clearance 1 max 0 10 mm 0 003937 Straightness max deviation on 100 mm 3 937 measured length 0 06 mm 0 002362 Twist max deviation on 100 mm 3 937 measured length 0 15 mm 0 005905 1 Dimensions refer to oiled components Marking FRONT on the con rod faces forwards The con rods and caps are marked in pairs using a three digit serial number please refer to the illustration Flywh...

Page 21: ...0 5 0 5 1 0 1 0 1 Oil grade Oil change interval Reached first in operation VDS 3 600 hours 12 month 300 hours 12 month 150 hours 12 month VDS 2 and ACEA E7 2 VDS 2 and ACEA E5 2 VDS 2 and Global DHD 1 2 VDS 2 and API CI 4 2 VDS 2 and API CH 4 2 VDS and ACEA E3 2 400 hours 12 month 200 hours 12 month 100 hours 12 month ACEA E7 E5 E4 200 hours 12 month 100 hours 12 month 50 hours 12 month API CI 4 C...

Page 22: ...Cold engine engine stopped ambient temperature Hot engine engine running coolant temperature 75 95 C 167 203 F 90 115 C 194 239 F Lubricating oil pump Type Gear driven No of teeth drive wheel 23 Oil filter Full flow filter 2 Turbo filter By pass filter 1 Viscosity Select the viscosity from the adjacent table for the appropriate continuous ambient air temperature Refers to synthetic or semi synthet...

Page 23: ...ee length 63 mm 2 48031 Loaded 124 Nm 91 4 lbf ft 44 mm 1 73228 4 Reduction valve oil pressure Marking Blue 5 Bypass valve full flow filter Spring free length 69 mm 2 71653 Loaded 13 15 Nm 9 6 11 0 lbf ft 40 mm 1 5748 6 Opening valve piston cooling Spring free length 122 mm 4 80314 Loaded 94 Nm 69 3 lbf ft 62 mm 2 44094 7 Control valve piston cooling Spring free length 122 mm 4 80314 Loaded 47 Nm ...

Page 24: ...ning pressure 400 550 kPa 58 0 79 7 psi Fuel quantity At low idle and with the engine unloaded the fuel quantity should be inside area B The engine should be run in at least 600 h Unit injector Pre load 3 4 spanner flats 0 75 0 1 mm 0 029527 0 003937 please refer to the illustration Tighten the adjustment screw to zero clearance against the camshaft then turn 3 4 spanner flats ...

Page 25: ...gine running coolant temperature 75 95 C 167 203 F 10 30 C 18 54 F above ambient temperature Pressure drop indicator Pressure drop indicator indication lamp lights up at a pressure drop of 5 kPa 0 7 psi Boost pressure 1500 1800 r min TAD940GE 230 kPa 33 36 psi TAD941GE 250 kPa 36 26 psi 2100 r min TAD940VE 145 kPa 21 03 psi TAD941VE 166 kPa 24 08 psi TAD942VE 185 kPa 23 83 psi TAD943VE 187 kPa 27 ...

Page 26: ...al Pressure cap opens at 75 kPa 10 8 psi Thermostat Quantity 1 Opening temperature 82 C 180 F Fully open 92 C 198 F Coolant Type Volvo Original Consists of Glycol and corrosion inhibiting additives Color Green Mix with Water according to ASTM D4985 ...

Page 27: ...l data 25 Group 20 Engine control system Engine control unit No of pins 2 x 36 Sensor Charge pressure sensor Check value 1 05 1 30 V at 100 kPa 14 5 psi Charge air temperature sensor Coolant temperature sensor ...

Page 28: ...ical data 26 Group 20 Inlet temperature sensor Engine oil temperature sensor Camshaft sensor Distance to camshaft 0 3 1 0 mm 0 011811 0 03937 Flywheel sensor Distance to flywheel 0 7 2 1 mm 0 027559 0 082677 ...

Page 29: ...ld not be re installed 10 9 can be re installed 12 9 can be re installed IMPORTANT Check screws which are to be re installed Damaged screws with marks of seizure etc under the heads must be scrapped Tightening torque group 21 Engine body Front engine mounting engine block 275 45 Nm 202 33lbf ft Front engine mounting front engine pad 150 30 Nm 111 22 lbf ft Main bearing caps Stage 1 150 20 Nm 111 1...

Page 30: ...NOTE Make sure that the flange is clean and dry NOTE Tighten the screws in number order as in the illustration Stage 1 60 5 Nm 44 4 lbf ft Stage 2 120 10 angle tightening Bell housing NOTE Apply 2 mm silicone sealer as in the illustration ...

Page 31: ...ws in number order as in the illustration NOTE The 8 8 screws on the vibration damper must not be re used Housing crankcase seal 24 4 Nm 18 3 lbf ft NOTE Apply 2mm 0 07874 silicone sealer as in the illustration Valve housing 24 4 Nm 18 3 lbf ft NOTE Tighten the screws in number order as in the illustration 3 1 4 2 5 6 7 8 10 9 12 11 ...

Page 32: ...d outwards Cylinder head NOTE Tighten the screws in number order as in the illustration Stage 1 60 10 Nm 44 7 lbf ft Stage 2 check tightening 60 10 Nm 44 7 lbf ft Stage 3 120 5 angle tightening Stage 4 90 5 angle tightening Core plugs cylinder head 60 10 Nm 44 7 lbf ft Lock nut valve adjustment screw 60 5 Nm 44 4 lbf ft ...

Page 33: ...ng bent Stage 1 Torque screws 1 7 to 15 3 Nm 11 2 lbf ft Stage 2 Torque screws 9 11 13 60 5 Nm 44 4 lbf ft Start with screw 11 Stage 3 Torque screws 8 10 12 14 60 5 Nm 44 4 lbf ft Stage 4 Loosen screws 9 11 13 Stage 5 Torque screws 9 11 13 60 5 Nm 44 4 lbf ft Stage 6 Tighten screws 1 7 90 5 angle tightening Stage 7 Tighten screws 8 14 120 5 angle tightening ...

Page 34: ...aler and tighten the screws in number order as in the illustration Tighten the screws in number order Apply silicone sealer to the rear edge of the cylinder head and the engine block Timing gear cover upper 24 4 Nm 13 3 lbf ft NOTE Apply 2 mm 0 07874 silicone sealer as in the illustration ...

Page 35: ... Stage 2 60 5 angle tightening 3 Idler wheel adjustable Tighten the screws in number order as in the illustration Stage 1 35 4 Nm 26 3 lbf ft Stage 2 120 5 angle tightening 4 Drive gear camshaft Tighten the screws in number order as in the illustration Stage 1 45 5 Nm 33 4 lbf ft Stage 2 90 5 angle tightening 5 Drive wheel steering servo and fuel feed pump 100 10 Nm 74 7 lbf ft 6 Drive wheel air c...

Page 36: ...system Feed pump steering servo pump 24 4 Nm 18 3 lbf ft Fixing yoke unit injector new copper sleeve First tightening Stage 1 20 5 Nm 15 4 lbf ft Stage 2 180 5 angle tightening Loosen the fastening yoke screw before doing the second tightening Second tightening Stage 1 20 5 Nm 15 4 lbf ft Stage 2 60 5 angle tightening Fixing yoke unit injector re used copper sleeve Stage 1 20 5 Nm 14 3 lbf ft Stag...

Page 37: ...s until they just touch 5 1 5 Nm 4 1 lbf ft Stage 2 Torque screws 1 and 8 10 1 5 Nm 7 1 lbf ft Stage 3 Torque screws 3 and 10 10 1 5 Nm 7 1 lbf ft Stage 4 Torque screws 5 and 12 10 1 5 Nm 7 1 lbf ft Stage 5 Torque screws 2 and 7 48 8 Nm 35 6 lbf ft Stage 6 Torque screws 4 and 9 48 8 Nm 35 6 lbf ft Stage 7 Torque screws 6 and 11 48 8 Nm 35 2 lbf ft Stage 8 Torque screws 1 and 8 48 8 Nm 35 2 lbf ft ...

Page 38: ...36 Group 20 Reference to Service bulletins Group No Date Refers to ...

Page 39: ...Notes ...

Page 40: ...Notes ...

Page 41: ... this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish From Refers to publication Publication No Date of issue Proposal motivation Date Signed AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 42: ...7745342 English 07 2009 ...

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