Technical data TWD1240VE

Group 20 Technical data ~ - ;:;;: ~ •.• '- -==: :'l~:U I ~-=~L -':.;-:.~'=~ "":.d'1J _C~ r": ~ rt!u j"' C't: t • :.:c=-H=-':':-~"- p- v_t - •••.••• ''' •• _ ••••• _I : _•.• ~, -I _ ~ W,' •••• ••••• _ , ~ _ , tIfOI& •• "'"" ••••••• •• m aIU ~ , ••• •• , - ~ •• ~lCIIIt" •.•• tJII •.-fL •• Ut, _1 &Ift'.n _ General T AD1241/42GE TWD1240VE Type desIgnation • • •.•.•.• • Number of cylinders • • •.• • T AD1240GE Cyflnder bore ••••.• •••.• Stroke ••.• • •• •.••••.•.• • • •.• •.•.• 131 mm (5.16*) 150 mm (5.91*) Swept volume • • • • • Number of valves •.• •.• • •.••.•.•.•.• • •• •.• 1213 dm3(740.20 Inch3) 24 DJrE~ctJonof rotation (viewed from front) •• • • Compression ratio • • • • .•.•.• • Flnng order • • .•.• • Clockwise 18.5:1 1-5-3-6-2-4 175:1 Slow idling speed (rpm) •• , •.• •.•••.•.•.• • 600-1200 600-1200 600-900 Fast Idling speed (rpm) • •• • •• •.• •• •.•••.• • • • •• •.•••• • • • 1500-1620 /1800-1920 1500-1620 2100 Highest full-load engine speed (rpm) • • •• Dry weight (kg) •.•••.•.• • •.• • ••••• 150011800 1230* /1800-1920 1500/1800 1230* 2100 1270 (2706100) (2706lbs) (27941bs) 18.5:1 Weight TAD engines without radiator assembly and air filter Engine block Cylinder head Type •••.• •••.••.• •• •• •• Length • • •.••••.• •.•.• •.•• ••••.• • Width •.••.• •.• • • .• •• HE!!Qht • •• • •• .•.• • •.• • Max surface unevenness One cylinder head for all cylinders with single overhead camshaft 1078 mm (42.44*) 397 mm (15.63*) '" ••.• ••• •.•••• •.•• 135 mm (5 32*) (bottom surface) .• • 0.1 mm (0 004") Cylinder head bolts Number of bolts per cylinder head •• •• 38 Thread size • • • M1? Length •••• ••• • • • ••.•••• •••• •• ••.•••• • • • 200 mm (7 87*) Group 20 Technical data Cylinder liners Type • Wet, replaceable Sealing surface height above block surface •• Number of sealing nngs per cylinder liner • 0.15-{).20 rnm (0.0Q6-{).0079") 0"15-0.20 mm Pistons Height above cylmder block surface • •• Diameter, combustion chamber •.•••.•.••••••••• a OS-O45 mm (0 002-0 89 mm (3.S") Depth, piston bowl • •• •.•.•.• ••• Number of nng grooves •.• •.•• ••••.• ••••• 18 SS mm (0 73") (E=17.5.1) Front mariong .•.•.•••••.•.• •• • 018") 17.14 (E=18 5.1) Arrow pointing forwards Gudgeon pin diameter •.••.•••••.• •• • •• • 5S mm (2.17") Piston rings Compression rings Number .• • • •.•• Piston nng clearance In groove: upper compression lower compression Piston nng gap nng • : •• • ring, vertical ••• •.• • ••• upper compression nng .• • wear tolerance •.• •.•.••• : •• lower compression nng •• ••.••.• •••• ••••••.• wear tolerance •• Trapezoidal section, no clearance 0.05-0.08 mm (0.002-0 0031") 0425-0.575 mm (0.0167-0 mm (0 04") 0226") a mm (0.032") 1.3 mm (0 051~) Oil control ring Number •••••••••.•• •••• • • •.•.•.•• •.••.••.•• Width, Incl spnng ••.• • .•.•• Piston nng clearance, vertical • • • • • • Piston nng gap ••.• •••• •• •.• mm (0 17") 003-0.08 mm (0.0012-0.0031") 035-0.75 mm (0 014-0 03") Group 20 T echmcal data Valve mechanism Valves Valve head diameter Inlet •••••••••••.•• ••••••••.••••• .••.••••••••••••• Exhaust ••.••••.••••.• •.••.••••.•• 40 mm (1 58") 40 mm (1.5S") Stem daameter Inlet ••••••••••••••••• • •••••.•.•• • Exhaust •.• • •• •.••• •••• Valve face angle Inlet •.•.••••••.• •••••• ••••••• • •• Exhaust 7.960-7 975 mm (0.3134-{).314O") ~.••.••.••• ••7.947-7.962 •••.••••••••• •.• •.• mm (0.3129-0.3135") 29.50 44 50 Valve head face, (see Illustration below) Inlet (new valve) •• •• •• •••••.••.•••••• •.• Mln.1.8 mm (O.O?") wear tolerance • •• •.• • ••• Exhaust (new valve) ••••• .••••••• ••.• ••••• mm (0.055") Mln.1 mm (0.063") wear tolerance •• •• •• ••• •.• Seat angle In cylinder head Inlet • • .• • ' • •.• • Exhaust •.••.•••.••.• •.•.•••.••.•.•.••• •.• •• •••• 1.2 mm (0.0472") 30" 45° The valve seat should be ground down untl' the distance from the valve head (new valve) to the cylinder head surface IS: Inlet • • • .• ••••••••••••.• wear tolerance • • •.••••• • •• ••• • Exhaust • •• .•.••.•• wear tolerance ••••••••••.•••••••.•.••••.••••.•.•• ••••••.••• If the dIstance IS greater the valve seats must be changed Valve clearances, 0.9-1.4 mm (0.035-0.055") Max mm (0.06") 2-1.7 mm (0.047-0.067") Max 1.8 mm (0.071") • cold engine, setting value Inlet •••••••••••••.•••••••.•.•.•••.•• •.•.••••• • •••• ••• 0.2 mm (0 OOS") Exhaust •.• •• • •.• .• • 05 mm (0.020") Valve clearance, cold engine, check value Inlet .•• .•.• .•• • • a 15-025 mm (0.006-0 Exhaust 0.45-055 mm (0.01 8-Q.022") ••• ••• • •• •.•• ••• •.•• •• 010") TechnIcal data Group 20 Valve seats Outer diameter (dimension A) Standard: Exhaust •.•••.•••• • •••• ••.• • •• •.• Oversize: Inlet • Inlet Exhaust Height (dimension B): Inlet • • • ' .• Exhaust J _ (1.697.).~.n 43.1 mm 43.1 mm (1 (1.697") 43.3 710") tD~_, -: -~ 43.3 mm (1.710") 8.4-8.6 mm (0.331-0.339") 79-8 mm (0.311-0.319") Valve face seat DIameter (dimension C) standard' Inlet ; •• • Exhaust • • DIameter (dimension C) oversize Inlet • Exhaust Depth (dimension D): Inlet • Exhaust Seat bottom radiUS(dimension R): Inlet max • .• Exhaust, max • : Jlrnenslon between valve head and ~yltnder head surface: Inlet • .• • Exhaust .• ~ ( c ( 43 mm (1.69") 43 mm (1 69") 43.200-43.225 43.200-43.225 mm (1.701-1.702") mm (1.701-1.702") 11 2±O.1 mm (0.441 ±0.004") 11 2±O.1 mm (0.441 ±O 004") mm (0 032") 0.8 mm (0.032") 09-1.4 mm (0 035-0.055") 2-1.7 mm (d:047-o.067") "alve guides Length: Inlet • Exhaust !nnerdlameter Inlet • Exhaust -ielght above cylinder head spnng plane Inlet Exhaust .• :Iearance, valve stem - guide Inlet Wear tolerance Exhaust • Weartolerance 83.2:-83.5 mm (3 28-3.29") 83.2-83.5 mm (3 28-3 29") mm (0.032") 8.0 mm (0.032") 26 5±O mm (1 04±O 016") 18.5±O mm (0 73±O 016") 003-005 mm (0 001-0.002") mm (0 008")1 004-0.07 mm (0.002-0.003") 0.3 mm (0.012")1 Max permissible clearance betw99n valve stem and valve gUide 'according to the method descnbed In "SeMce Manual Engine block D12CA valve gUides Inspection') Techmcal data Group 20 Valve springs Valve springs, exhaustllnlet Valve spnngs: Length wrthout load •.•.•.•.••••.••••••••••••••.••••.••••.•••••••72-73 mm (2.8-2.9") With 600 N (61.2 kgfm (134.6Ibs)) load ••••.•• 56 mm (2 2") With 1076 N (109 kgfm (241.3Ibs)) load • ••• 43 mm (1.7") Rigid length max ••.••• ••• •••••••.••••••• 41 mm (1 6") Inner valve spnng (exhaust)· Length without load •••••.•••••••••••••••••••.••.•.•••.•• 67-68 mm (2.6-2 r) With 243 N (24 kgfm (54 Ibs)) load •.••.• • 52 mm (2.1") With 447 N (45.6 kgfm (100 3lbs)) load •• • 39 mm (1 5") Rigid length max •• •• •••.••••.•.••••• •.•• 36 mm (1.4") Timing 11 10 13 58 -II f II \ nIdler \\\ ~~II I IIdnve \ (z=83) coolant pump (z=27) Dnve camshaft (z=76) Dnve (z=71) to belt and fuel pump (z=27) Dnve, Idler Dnve (z=44) hydraulic lubncatmg crankshaft compressor pump 011 (2=38) (z=29) pump (z=39) (z=23) Spray Idler, adjustable nozzle, (z=97) lubncatJon Dnve, sarvov,pump (z=23) v n - c,, O ~\ \' nllf\{cIr)'\ '(1\\ u\ 342 >''' Flank clearance, adjustable intermediate gear (7) • O~ Intermechate gear shaft Journal, diameter •.• '" 17 mm (0.0020-0.0067") 99 99±0 01 mm (3.937±O 0004") Intermecftate gear bush, diameter •.• •.•••••••.•.•.•.• 100.04±O.01 mm (3 939±0.0004") Radial clearance for Intermediate, max diameter 003-007 mm (0 0012-0 0028") Noal clearance for intermediate gear ••.• • 007-0.17 mm (0.0028-0 0067") 10 Technical data Group 20 Camshaft Checking camshaft setting The engine should be cold and the No cylinder valves should be adjusted to a clearance of At a flywheel position of 6° ATDC the No cylinder Inlet valve should have opened 1.6±O mm (0 063±0.012") When checking this the timing mechanism must be rotated In the nght 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 Dnve " , •• Number of beanngs • • • • DIameter of Journals, standard •.• Diameter of joumals, undersize: 025 050 075 on ••••••••••••••••••••• Wear tole'ranees Axial clearance, max •••.••.•• •.• • •.• • Radial clearance, max • •• •.• • •.• • • • Valve 11ft Inlet • • • • •.• •.• • • Exhaust .• • • ~ • • • Unit Injector (stroke) •.•.•.•.• •.•.•.• • • • ( Gears 70 mm (2.76 ") ( 69720-69.780 mm (2.7449-2.7472") 69.470 69.530 mm (2.7350-2.7374") 69.220 69280 mm (2.7252-2 7276") 035 mm (0.0014") 0.01 mm (0.0004") 13.1 mm (0.516") 131 mm (0 516") 17 mm (0.669") Camshaft bearings Camshaft beanng thickness, standard: •• .• Oversize: 025 o 50 0.75 Diameter, camshaft beanng hOUSings Bearings 1-7 .• mm (0.075") ( 2.0 mm (0 079") 2 mm (0 087") 2.3 mm (0 091") 73.9 mm (2.91") • 11 Technical data Group 20 Crank movement Crankshaft Length •••••.•.•• • • ••• • ••.•• •••.•.•••.•.• Crankshaft axIal clearance ••••••••••••••••• 1203 mm (47.36") 10-0 40 mm (0 0039-0 Main beanng radial clearance' •• •.• ••.•• • •.•••••• 0.01-0.15 Max permissible ovahty of mam beanng joumals and crankpins The dllnenslOl1S mm (0 0004-0.0059") •.••.•••••.•••• 0.08 mm (0.003") Max permissible COniCity of mam beanng Joumals and crankprns •• • • Max runout of centre beanng •• •.• •.• f 0157") 05 mm (0.002") 0.15 mm (0.006") apply to oded parts Main bearing journals DIameter (0) for machlnmg, standard Undersize' •• •• •.••• 108.0 mm (4 25") 025 mm (0.010") •.•.•••.•.••.••.•.• •.•.•••• 107.73-107.75 mm (4 2413-4 0.50 mm (0.020") ••.• ••• • 10748-107.50 mm (42315-42323") 075 mm (0.030") • •• ••••••• 107.23-10725 1.00 mm (0.040") 106.98-1070 • .•• •.• • mm (4.2216-4.2224") mm (4 2118-4.2126") 1.25 mm (0.050") •.• .•• Surface finISh, main beanng JOurnal • • • • Surface finish, radiUS ••• •.• • 106.73-106.75 Ra 025 Ra Width, thrust beanng Joumal (A) standard Oversize' 47 mm (1.85") 0.2 mrn (O.008")(thrust .•• • beanng 0.1) .• •••• 04 mm (0.016") (thrust bearing 0.2) 06 mm (0.024") (thrust beanng 0.3) Fillet radiUS (R) • • • • mm (4.2020-4 .• 47375-47425 • •••• 47575-47625 mm (1 8730-1.8750°) 3.75-4.00 mm (0 148-0 158") Width (B) standard .••• • •.•.•.• Oversize (0.004") •• ••••••• •.• .• .• .• • ••.• mm (1.8652-1.8651") 3.1-3.2 mm (0.122-0 126") 2-3.3 mm (0.126-0 130") o mm (0.008") 3.~.4 03 mm (0.012°) •.••• •.•• • 4-3 mm (0 134-0 138°) 12 2027") 47 175-47 225 mm (1.857:3-1 8592") Thrust washers (thrust bearing) o mm 2421") mm (0.130-0.134°) Group 20 Technical data , Main bearing shells Type • • Outer diameter (C) •• Thickness (D) standard .• • Oversize: replaceable 1130 mm (4.45") 2.5 mm (0:098") 0.25 mm (0 010") • " •• • • 0.75 mm (0.030') • • • 1.00 mm (0040") • •• 1.45 mm (0 050") • •• ••••.•• • •••• Crankplns 2.6-27 mm (0.102-0 106") 7-2 mm (0.106-{) 110") 8-2.9 mm (0.110-0.114") 2.9-30 mm (0114-0118") 3.1-3.2 mm (0 122-0.126") Diameter (0) for machining, standard • • • UndersIZe' 92.0 mm (3.62') 0.25 mm (a 010") ••.•• •.•••.••.••••.•.• a 50 mm (O 020") ••.•.•.•••.•• 0.75 mm (0.030") .• ••.• • _.• •.•.• 1.00 mm (0.040") • •.•.•• •• •• 1.25 mm (0.050·) .••.••.•• •.••.••.• Surface finiSh, crankpln • •.•• Surface finiSh, radiUS •• • •• •.•••.•.• •.• • •• Width (A) thrust beanng Joumal •.•• Fillet radlus.{R) (5.25-5.5) •.•• •• • ~.• • 91.73-91.75 mm (3.6114-3.612") 91.4B-91 50 mm (3 6016-3 6024") 91.23-9125 mm (3.5917-3.5925') 90 98-91.00 mm (3 5819-3 5827') 90.73-90 75 mm (3 572D-3.5728·) Ra 0.25 Ra 0.4 56.9-57.0 mm (2.24~2 244") 3.75-4.00 mm (0.148-0.158") Big-end bearing shells OutSide diameter (B) Thickness (C) standard • •••••••• •••.•• • Oversize' 96 85 mm (3 8130") 39-2.40 mm (0.0941-0 0945") o 25 mm (0010") •.••.•.••.•.•.•.• • • 0.50 mm (0.020") • • • •.•••.• ••• .••• 075 mm (O 030") • • ••.•.• • 1.00 mm (0.040") .• • 1.25mm{0050") •.• •• •.•• • Diameter, beanng shell seat (D) • • • 51-2.52 mm (0.0988-0.0992') 2.64-2.65 mm (01039-0.1043") 276-2.77 mm (O 1087-0 1091") 89-2 90 mm (0 1138-0 1142") 01-3 02 mm (0 1185-0 1189") 96 84-96 85 mm (3.8126-3 8130") a 50 mm (0.020") ( {\ ( ' ( 13 Technical Group 20 data Connecting rod Length, centre-to-centre (E) • ••.•.•••.•.•• Marking: Connecting rod and cap1 • "FRONT" on the shank to face • • •.• Connecting rod bush inside diameter (G) • • Axial clearance, blg-end - crankshaft, max •••••• Big-end beanng, radial clearance, max.2 •••••••••••• Straightness, max deViation per 100 mm (3.94') measured length • • • Warping, max deVIation per 100 mm (3.94") measured length • : • • •.• •.•• 260 mm (10236") to , Forwards 55 mm (2.165·) 035 mm (0.014') 0.10 mm (0.004') 0.06 mm (0.002") 15 mm (0.006') , Marlmg on same Side The measurements apply to Oiled parts Flywheel fitted Max permissible axial runout, test radiUS 150 mm (5.91') Number of teeth on starter nng • .• 0.20 mm (0.008") 153 Sensor grooves on flywheel •.•• • • •• •.•.• x 14 18 Group 20 Techntcal data Lubricating system ( ( 011 grade Fuel sulphur content in per cent by weight ( 'J 300 hours or 12 months 150 hours or 12 months VDS and ACEA E3 200 hours or 12 months 100 hours or 12 months3! 2) ACEA E4, E3, E2 API' CE, CF, CF4, CG-4, CH 100 hours or 12 months NOTE: Minerai-based, fully-synthetIC or synthetic-based ments are fulfilled ') I ( VDS-2 and ACEA E3 2) 011 I 50 hours or 12 months3) can be used provided that the above 011 grade reqUire- At a sulpt.Jr content> per cent by weight, 011 With a TBN >15 should be used Lubncabng od should meet both reqUl~ments Note API CG-4 or CH-4 IS acceptable In markets outside Europe (IIlStead of ACEA A3) lubricating od With TBN 14-20 should be used :I) API ( ( ( VDS = Volvo Drain Specification ACEA= Association des Constructeurs ( Europeenne d'Automoblies ( = American Petroleum Institute TBN = Total Base Number ( 4D C Viscosity I ·wc The VISCOSity should be selected from the adjacent table Note the temperatures refer to constant outSide air temperature ± ·1O"C i ( ( I~ I I ( 1+100 OF ( • Refers to synthebc or synthebc-based od ( 011 Change volume including changing three filters For honzontal installatIOn • 35 htres (9.2 US gal) 011 pressure Operabng engine speed 1100 rpm or higher • Idhng speed, mintmum 400-550 kPa (58-80 pSI) 175 kPa (25 pSI) filters Number .• Full-flow filter (tightened 112-314 tum after fitting) Bypass filter (tIghtened 314-1 turn after fitting) •• ( ( 011 011 pump Type • •.• • Gear dnven 15 Technical data Group 20 ( Fuel system { Injection order Injection order • - .• • •.• 1-5-3-6-2-4 Feed pump Feed pressure after fuel filter at 1000 rpm, • 350 kPa (51 pSI) Feed pressure after fuel filter at full load, mln 350 kPa (51 pSI) Overflow valve 400-450 kPa Opening pressure • .• • • • (5fH55 pSI) Sensor spacing Camshaft •.• .•• • Flywheel • .• • 0.3-1 mm (0.012-0.040") 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 Group 20 data Inlet and exhaust system Engine •.• •.• •• TAD1240-42GE TWD1240VE K31 3971 QXAKB K31 3971 QXAKB 2421 27.21 DCAYD Turbocharger Manufacturer and type 3KiWamer LubncatJon system • •.• • • • • • Force-feed lubncatlon Max permissible • 16 mm (0.0063") Max permissIble radial clearance (turbocharger side) • .• .• .• • 0.45 mm (0.0177") axial clearance DCAYD Pressure drop indicator Air filter Level for indication (vacuum) 500 mm (19 7') w g Exhaust back pressure Exhaust back pressure, max 10 kPa 15 kPa (1.5 psi) (2,2 psi) Cooling system General Type .• •.• •.•.•.• .• • Overpressure, Delivery valve opens at • 75 kPa (11 pSI) CapaCity (engine) • ••.• •.• 20 htres (5 US gal) Capacity (engine + radiator and hoses) closed 44 htres (11 US gal) Thennostat Type •.• • • • • NurT1ber • ••.• • • ••.•.•• • Piston thermostat Opening temperature •• • .•.• Coolant filter Number •••.•• ••• • .•.• ••••.• .•.• Type • • •.•.•• • • Coolant pump 18 Geared centnfugal pump 86°C 75"C (18]OF) (16]OF) Technical data Group 20 Coolant Type Conslstmg of Colour Mixed with Volvo Penta glyco! Glycol + corrosion mhlbltlng additIves Blue-green Water" Corrosion Inhibitor Type .• Used .•.•• • Mixed with • .• Volvo onglnal corrosion inhibitor When Volvo Penta antI-freeze IS unnecessary Water* NOTE: The corrosIon mhlbrtor additive must not be mixed wrth coolant or any other type of corrosion Inhlbrtor as thiS could give nse to adverse effects • Water quality To aVOIdthe risk of cloggtng In the cooling system the coolant should be ITIIxed wrth pure water to ASTM 04985 If In any doubt about the punty of the water, distilled water or readymixed coolant should be used Instead ASTM 04985: Total solid particulate • Total hardness Chlonde Sulphate pH value SIlicon Iron < 340 ppm < 9.50 dH < 40 ppm < 100 ppm S 5-9 < 20 mg S,O/l «20 ppm < 0.10 ppm Manganese .• ConductivIty , Organiccontent,CODt.M\ < OSppm < 500 ~S/cm