Volvo Penta TD1030ME VE- TAD1232GE Group 20-26 Workshop Manual_236694501 – PDF DOWNLOAD

Volvo Penta TD1030ME/VE, TAD1030G/GE/P/V/VE, TWD1030ME/VE,
TWD1031VE, TAD1031GE, TAD1032GE, TWD1210G/P/V,
TWD1211G/P/V, TWD1230ME/VE,TAD1230G/P/V,
TAD1231GE, TWD1231VE, TAD1232GE Group 20-26 Workshop Manual_236694501 – PDF DOWNLOAD

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Volvo Penta TD1030ME VE- TAD1232GE Group 20-26 Workshop Manual_236694501 – PDF DOWNLOAD

Language : English
Pages : 164
Downloadable : Yes
File Type : PDF
Size: 8.87 MB

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DESCRIPTION:

Volvo Penta TD1030ME VE- TAD1232GE Group 20-26 Workshop Manual_236694501 – PDF DOWNLOAD

TD1030ME/VE, TAD1030G/GE/P/V/VE, TWD1030ME/VE,
TWD1031VE, TAD1031GE, TAD1032GE, TWD1210G/P/V,
TWD1211G/P/V, TWD1230ME/VE,TAD1230G/P/V,
TAD1231GE, TWD1231VE, TAD1232GE

Introduction:

• This Workshop Manual contains descriptions and instructions for the repair of the Volvo Penta products or product types described in the Table of Contents.
• This manual should be used together with the Workshop Manual Technical Data for each engine concerned. Check that you have the correct Workshop Manual for your engine. Before starting work on the engine read the Safety Precautions, General Information and Repair Instructions sections of this Workshop Manual carefully.

About this Workshop Manual:

This Workshop Manual contains descriptions and instructions for the repair of the following engines in standard format: TD1030ME/VE, TAD1030G/GE/P/V/VE, TWD1030ME/VE, TWD1031VE, TAD1031GE, TAD1032GE, TWD1210G/P/V, TWD1211G/P/V, TWD1230ME/VE, TAD1230G/P/V, TAD1231GE, TWD1231VE, TAD1232GE. The Workshop Manual can show operations carried out on any of the engines listed above.

• As a result the illustrations and pictures in the manual that show certain parts on the engines, do not in some cases apply to all the engines listed. However the repair and service operations described are in all essential details the same. Where they are not the same this is stated in the manual and where the difference is considerable the operations are described separately.
• The Engine Designation and Engine Numbers can be found on the product plate (see page 10). Please always include both the engine designation and the engine number in all correspondance. The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service technicians.
• For this reason the manual presupposes a certain basic knowledge and that the user can carry out the mechanical/electrical work described to a general standard of engineering competence. Volvo Penta products are under a continual process of development and we therefore reserve all rights regarding changes and modifications.
• All the information in this manual is based on product specifications available at the time the book was published. Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins.

TABLE OF CONTENTS:

Volvo Penta TD1030ME VE- TAD1232GE Group 20-26 Workshop Manual_236694501 – PDF DOWNLOAD

General instructions ……………………………………. 3
Safety precautions ……………………………………. 3
Introduction …………………………………………. 3
Important ……………………………………………. 3
General information …………………………………… 6
About this Workshop Manual …………………. 6
Spare parts …………………………………………. 6
Certificated engines ……………………………… 6
Repair instructions ……………………………………. 7
Our joint responsibility ………………………….. 7
Tightening torques ……………………………….. 7
Tightening torque w. Protractor tightening … 8
Lock nuts ……………………………………………. 8
Strength classes ………………………………….. 8
Sealant ………………………………………………. 8
Safety rules for fluorocarbon rubber ………… 9
Location of identification plates …………………… 10
Special tools ………………………………………………. 11
Other special equipment ……………………………. 15
Engine body ……………………………………………….. 16
Design and function ………………………………….. 16
Nitro-carburated timing gears …………………. 17
Service procedures …………………………………… 20
Cylinder head, removing………………………… 20
Cylinder head, dismantling …………………….. 21
Cylinder head, leakage test ……………………. 21
Cylinder head, inspection ………………………. 23
Cylinder head, surface grinding ………………. 23
Cylinder head, milling of sealing
grooves, 12 ltr engines ………………………….. 24
Valve guides, inspection ……………………….. 26
Valve guides, replacement …………………….. 27
Valve seats, replacement ……………………… 28
Valve seats and valves, grinding ……………. 29
Valve springs, checking ………………………… 30
Rocker mechanism, overhauling …………….. 30
Cylinder head, assembly ……………………….. 31
Cylinder head, fitting …………………………….. 31
Valves, adjustment ………………………………. 33
Cylinder liners and pistons, removing ………. 33
Cylinder liner, inspection ……………………….. 34
Cylinder liners, honing …………………………… 35
Cylinder liner seats, overhauling …………….. 36
Cylinder block, surface grinding ……………… 38
Pistons, checking ………………………………… 38
Piston rings, checking ………………………….. 38
Connecting rods, checking …………………….. 38
Connecting rod bushings, replacement …….. 39
Pistons, rings and connecting rods,
assembly ……………………………………………. 39
Cylinder liners and pistons, fitting …………… 40
Front crankshaft seal, replacement …………. 43
Timing gear cover, removing ………………….. 43
Timing gear cover, fitting ………………………. 44
Timing gears, removing …………………………. 45
Timing gears, inspection ……………………….. 46
Timing gears, fitting ……………………………… 46
Timing gear casing, removing and fitting ….. 47
Camshaft, checking of wear …………………… 48
Valve timing, checking ………………………….. 49
Camshaft, removing ……………………………… 49
Camshaft and tappets, inspection …………… 50
Camshaft, measurement ……………………….. 51
Camshaft bearings, replacement …………….. 51
Camshaft, fitting ………………………………….. 51
Crankshaft, removing ……………………………. 52
Crankshaft, inspection ………………………….. 53
Crankshaft, grinding ……………………………… 55
Crankshaft, fitting ………………………………… 55
Main bearings, replacement …………………… 56
Rear crankshaft seal, replacement ………….. 57
Flywheel bearing, changing ……………………. 58
Flywheel ring gear, replacement ……………… 59
Flywheel, checking for warp …………………… 60
Flywheel casing, checking for warp…………. 60
Flywheel casing, removing/fitting …………… 61
Lubricating system ……………………………………… 62
Design and function ………………………………….. 62
General ………………………………………………. 62
Service procedures …………………………………… 64
Oil pressure, checking ………………………….. 64
Oil pump, removing ………………………………. 64
Oil pump, reconditioning………………………… 65
Oil pump, fitting …………………………………… 67
Oil pump, fitting …………………………………… 69
Oil cooler, changing ……………………………… 70
Oil cooler, leakage test …………………………. 71
Fuel system ………………………………………………… 72
Design and function ………………………………….. 72
General ………………………………………………. 72
Injection pump …………………………………….. 72
Injection timing adjuster ………………………… 73
Governors …………………………………………… 74
Fuel delivery pipes ……………………………….. 74
Feed pump………………………………………….. 75
Hand primer pump ………………………………… 75
Injectors ……………………………………………… 76
Smoke limiter ………………………………………. 76
Fuel shut-off valve for stopping the
engine ………………………………………………… 77
Service procedures …………………………………… 80
Injection pump, removing ………………………. 80
Injection pump, fitting and adjusting ………… 80
Injection pump, setting on the engine ………. 83
Pump coupling, checking and
replacement of laminates ………………………. 86
Injection pump’s drive …………………………… 86
Injection pump’s drive , replacement of
sealing ring …………………………………………. 87
Revs, adjustment …………………………………. 89
Feed pressure, checking ……………………….. 91
Feed pump, replacement ………………………. 92
Feed pump, reconditioning …………………….. 92
Smoke limiter, replacement of diaphragm … 93
Fuel shut-off valve, cleaning ………………….. 94
Fuel shut-off valve, troubleshooting ………… 95
Fuel filter, replacement …………………………. 97
Bleeding ……………………………………………… 97
Injectors, replacement ………………………….. 100
Recommendations for adjusting opening
pressure, setting pressure and changing
injectors ……………………………………………… 100
Injectors, reconditioning ………………………… 102
Opening pressure, adjusting …………………… 102
Copper sleeve for injectors, replacement …. 103
Removal of sealing screw ……………………… 105
Intake and exhaust systems …………………………. 107
Design and function ………………………………….. 107
Starting heater …………………………………….. 107
Turbocharger ……………………………………….. 107
Charge air cooler (Intercooler) ………………… 108
Service procedures …………………………………… 109
Boost pressure, checking ……………………… 109
Exhaust back pressure, checking …………… 111
Bearing clearance, checking ………………….. 111
Turbocharger, removing ………………………… 112
Holset turbocharger ………………………………. 112
KKK Turbocharger ……………………………….. 115
Schwitzer turbocharger …………………………. 119
Turbocharger, cleaning ………………………….. 121
Turbocharger, inspection ……………………….. 121
Turbocharger, fitting ……………………………… 122
Exhaust manifold, changing gaskets ………. 123
Charge air cooler, checking for
leakage (TAD) ……………………………………… 125
Cooling system …………………………………………… 126
Design and function ………………………………….. 126
Cooling system ……………………………………. 127
Coolant pump………………………………………. 127
Thermostat, thermostat housing …………….. 127
Service Procedures …………………………………… 128
Coolant pump, changing………………………… 128
Coolant pump, overhauling …………………….. 129
Changing thermostat …………………………….. 132
Thermostat, function check …………………… 135
Coolant distributor pipe, changing
(Only 12 ltr engines) ……………………………… 136
Thermostatically controlled cooling fan,
function check …………………………………….. 137
Thermostatically controlled cooling fan,
changing …………………………………………….. 138
Coolant ………………………………………………. 139
Checking the coolant level …………………….. 140
Draining the coolant ……………………………… 140
Filling the coolant …………………………………. 140
Checking the temperature gauge …………….. 141
Coolant loss ………………………………………… 141
Charge air cooler insert, changing (TWD) …. 141
Checking the radiator (TAD/TWD) …………… 143
Cleaning the cooling system ………………….. 143
Pressure-testing the cooling system ……….. 144
Checking the pressure valve ………………….. 145
Electrical system …………………………………………. 146
Important ………………………………………………… 146
Arc welding ……………………………………………… 146
Starting with auxiliary battery ……………………… 146
Electronic speed governor ………………………….. 148
Wiring diagrams ……………………………………….. 149
Troubleshooting………………………………………….. 153
References to service bulletines …………………… 160