Volvo Penta TAD1240GE TAD1241GE-VE TAD1242GE-VE TWD1240VE Group 22-26 Workshop Manual _340008123 PDF

Volvo Penta TAD1240GE TAD1241GE-VE TAD1242GE-VE TWD1240VE Group 22-26 Workshop Manual _340008123 – PDF DOWNLOAD

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Volvo Penta TAD1240GE TAD1241GE-VE TAD1242GE-VE TWD1240VE Group 22-26 Workshop Manual _340008123 – PDF DOWNLOAD

Language : English
Pages : 104
Downloadable : Yes
File Type : PDF
Size: 3.2 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Volvo Penta TAD1240GE TAD1241GE-VE TAD1242GE-VE TWD1240VE Group 22-26 Workshop Manual _340008123 – PDF DOWNLOAD

Safety Information:
Introduction:

• The Service Manual contains descriptions and service instructions for the Volvo Penta products and versions of products listed in the list of contents. This manual should be used in conjunction with the Service Manual Technical Data for the engine in question.
• Make sure that the right service literature is used. Read the available safety information and the General information and Repair instructions sections in the Service Manual carefully before starting service work.

General Information :About the Service Manual :

This Service Manual contains descriptions of and repair instructions for the standard versions of the TAD1240GE, TAD1241GE/VE, TA1242GE/VE and TWD1240VE model engines. The Service Manual may show procedures performed on any of the engines listed above so the illustrations and photographs showing certain details may not be completely accurate in some cases. However, the repair methods are all essentially the same.

• The engine model and serial number are given on the data plate (see “Technical data TAD1240GE, TAD1241GE/VE, TAD1242GE/VE and TWD1240VE”). The engine model and serial number should always be given in all correspondence concerning any of the engines.
• The Service Manual is primarily produced for Volvo Penta service facilities and their qualified personnel. It is therefore assumed that persons using the manual have the necessary basic knowledge and can carry out the mechanical and electrical tasks that occur in their profession.
• 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 at press time. Any significant changes that have been introduced in the 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 requirements.
• All types of damage occurring as a result of using non-original Volvo Penta spare parts for the product in question will not be covered under the terms of warranty as provided by Volvo Penta.

TABLE OF CONTENTS:

Volvo Penta TAD1240GE TAD1241GE-VE TAD1242GE-VE TWD1240VE Group 22-26 Workshop Manual _340008123 – PDF DOWNLOAD

GROUP 20 GENERAL INFORMATION
Safety Information ……………………………………….. 2
General Information ………………………………………. 5
General repair instructions …………………………….. 6
GROUP 22 LUBRICATING SYSTEM
General ………………………………………………………. 8
Special tools ……………………………………………….. 9
Design and Operation
Lubrication system……………………………………… 10
Repair instructions
Working with chemicals, fuel and
lubricating oil ……………………………………………… 12
Oil filter, changing ………………………………………. 12
Oil sump gasket, changing …………………………… 13
Oil filter bypass valve, replacing …………………… 14
Safety valve, changing ……………………………….. 15
Reducing valve, changing ……………………………. 15
Piston cooling valve, changing ……………………… 16
Bypass filter (turbocharger) bypass valve,
changing …………………………………………………… 17
Bypass valve (pressure valve) oil cooler,
changing …………………………………………………… 17
Piston cooling nozzle, changing ……………………. 18
Oil pump, changing …………………………………….. 19
Oil pressure, checking ………………………………… 21
Engine oil, changing ……………………………………. 22
Oil cooler element, changing ………………………… 22
Oil cooler element, leakage test ……………………. 26
GROUP 23 FUEL SYSTEM
General …………………………………………………….. 28
Instructions for working with electronic
fuel injection ………………………………………………. 28
Special tools ……………………………………………… 29
Design and Operation
Unit injectors, overview ……………………………….. 31
Unit injectors, working phases ……………………… 32
Repair instructions
Control module (EDC III), changing ………………. 34
Fuel system, draining …………………………………. 36
Fuel filter, changing…………………………………….. 37
Fuel pump, changing ………………………………….. 38
Fuel pump, rebuilding ………………………………….. 39
Fuel system, bleeding …………………………………. 41
Bypass valve, changing ………………………………. 42
Fuel pressure, checking ………………………………. 43
Unit injectors, changing ……………………………….. 44
Draining condensate water …………………………… 48
Fuel pre-filter with water monitor, changing …….. 48
Copper sleeve for unit injector, change ………….. 49
GROUP 25 INTAKE AND EXHAUST SYSTEMS
General …………………………………………………….. 55
Design and Operation
Turbocharger ……………………………………………… 56
Repair instructions
Working with chemicals, fuel and
lubricating oil ……………………………………………… 57
Intake manifold (gasket), changing………………… 57
Exhaust manifold gasket, changing ………………. 63
Turbocharger, changing ……………………………….. 66
Pressure drop indicator, checking …………………. 69
GROUP 26 COOLING SYSTEM
General …………………………………………………….. 70
Special tools ……………………………………………… 71
Design and Operation
Cooling system (TAD) …………………………………. 72
Cooling system (TWD) ………………………………… 73
Charge air cooler ………………………………………… 74
Repair instructions
Cooling system, draining ……………………………… 75
Cooling system, filling …………………………………. 75
Coolant pump, changing ………………………………. 76
Coolant filter, changing ……………………………….. 79
Piston thermostat, changing ………………………… 80
Piston thermostat, functional check ………………. 81
Drive belts, changing ………………………………….. 82
Cooling system, cleaning …………………………….. 85
Charge air cooler, changing (TAD) …………………. 86
Charge air cooler, changing (TWD) ………………… 87
Charge air cooler, leakage test (TAD) …………….. 90
Charge air cooler, cleaning …………………………… 91
Radiator core, changing ………………………………. 92
Cooling system, leakage testing …………………… 96
Extra coolant pump, changing (TWD) …………….. 98