Volvo Penta TD61G P V, TD TWD630ME VE, TD TWD730ME VE, TAD TWD740GE VE Workshop Manual_409016921 PDF

Volvo Penta TD61G P V, TD TWD630ME VE, TD TWD730ME VE, TAD TWD740GE VE Workshop Manual_409016921 – PDF DOWNLOAD

FILE DETAILS:

Volvo Penta TD610G/V, TWD610G/P/V, TD630ME/VE TWD630ME/VE, TD640VE, TWD710G/P/V, TD730ME/VE, TAD730G/P/V, TWD730ME/VE TWD731ME/VE, TAD740GE, TAD741GE, TWD740GE/VE Workshop Manual_409016921 – PDF DOWNLOAD

Language : English
Pages : 184
Downloadable : Yes
File Type : PDF
Size: 9.93 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Volvo Penta TD610G/V, TWD610G/P/V, TD630ME/VE TWD630ME/VE, TD640VE, TWD710G/P/V, TD730ME/VE, TAD730G/P/V, TWD730ME/VE TWD731ME/VE, TAD740GE, TAD741GE, TWD740GE/VE Workshop Manual_409016921 – PDF DOWNLOAD

TD610G/V, TWD610G/P/V, TD630ME/VE
TWD630ME/VE, TD640VE, TWD710G/P/V,
TD730ME/VE, TAD730G/P/V, TWD730ME/VE
TWD731ME/VE, TAD740GE, TAD741GE, TWD740GE/VE

Introduction:

• This Workshop Manual contains technical data, descriptions and repair instructions for the specified products or product variants from Volvo Penta. Ensure to use the correct workshop literature.
• Read this safety information as well as ”General information” and ”Repair instructions” thoroughly before commencing any service work.

About the Workshop Manual:

This Workshop Manual contains descriptions and directions for repair of standard models of engines TD610G/V, TWD610G/P/V, TD630ME/VE, TWD630ME/VE, TD640VE, TWD710G/P/V, TD730ME/VE, TAD730G/P/V, TAD741GE, TWD730ME/VE, TWD731ME/VE, TAD740GE and TWD740GE/VE.

• Engine designation and number are specified on the type plate (see page 12). The engine designation and number must always be provided in all correspondence concerning any of our engines. The Workshop Manual is produced primarily for qualified personnel at Volvo Penta service centres.
• This presupposes that the person using this manual possesses basic knowledge and can carry out the mechanical/electrical work associated with the trade. Volvo Penta employs continuous product development and therefore reserves the right to make technical changes.
• All the information contained in this manual is based on product data available at the time of going to press. Any changes or revisions of consequence that are introduced in the product or service methods after this date will be issued in Service Bulletins.

Spare parts:

• Spare parts for the electric and fuel systems are liable to various national safety requirements. Volvo Penta Original Spare Parts fulfil these requirements.
• Any damage arising from the use of parts that are not Volvo Penta Original Spare Parts will not be covered by any of the warranties provided by Volvo Penta.

TABLE OF CONTENTS:

Volvo Penta TD610G/V, TWD610G/P/V, TD630ME/VE TWD630ME/VE, TD640VE, TWD710G/P/V, TD730ME/VE, TAD730G/P/V, TWD730ME/VE TWD731ME/VE, TAD740GE, TAD741GE, TWD740GE/VE Woskshop Manual_409016921 – PDF DOWNLOAD

Contents
Safety information ………………………………………. 3
Introduction ………………………………………………….. 3
Important ……………………………………………………… 3
General information ……………………………………. 6
About the Workshop Manual …………………………… 6
Spare parts ………………………………………………….. 6
Certified engines …………………………………………… 6
Repair instructions ………………………………………. 7
Our mutual responsibility ………………………………… 7
Tightening torques …………………………………………. 7
Torque-angle tightening ………………………………….. 8
Lock nuts …………………………………………………….. 8
Quality classes …………………………………………….. 8
Sealant ……………………………………………………….. 8
Safety regulations concerning fluorocarbon rubber . 9
Location of engine signs ……………………………….. 10
Tools ………………………………………………………… 11
Special tools ………………………………………………. 11
Other special equipment ………………………………. 16
Engine ……………………………………………………… 17
Design and function ………………………………….. 17
6 and 7 litre engines …………………………………….. 19
Cylinder head ……………………………………………… 19
Valves ……………………………………………………….. 19
Cylinder block/cylinder liners …………………………. 20
Sealed joints ………………………………………………. 20
Pistons ……………………………………………………… 20
Fuel delivery pipe 630, 640, 730, 731, 740, 741 .. 21
Crankshaft/camshaft ……………………………………. 21
Timing gear wheels 610, 710 …………………………. 21
Timing gear wheels 630, 640, 730, 731, 740, 741 21
Injection timing adjuster
(TWD630ME, TWD730ME) …………………………… 22
Repair instructions …………………………………….. 23
Mounting the engine fixture …………………………… 23
Fuel delivery pipe ………………………………………… 24
Compression test ………………………………………… 24
Cylinder head, removing ……………………………….. 25
Cylinder head, dismantling/assembling …………… 26
Cylinder head, leak test ……………………………….. 27
Cylinder head, inspection ……………………………… 28
Valve guides, inspection ……………………………….. 29
Valve guides, changing…………………………………. 29
Cylinder head, facing 610, 710 engines …………… 30
Cylinder head, machining sealing grooves, 610
and 710 engines ………………………………………….. 30
Setting cutter depth ………………………………….. 31
Changing cutter set ………………………………….. 32
Machining grooves …………………………………… 33
Valve seats, changing ………………………………….. 34
Valve seats, grinding ……………………………………. 34
Valves, grinding …………………………………………… 35
Rocker mechanism, reconditioning …………………. 35
Cylinder head, fitting…………………………………….. 37
Copper sleeve for injector, changing ……………….. 39
Valves, adjusting …………………………………………. 42
Cylinder liner with piston, removing …………………. 44
Cylinder liner with piston/piston rings, inspection 45
Cylinder liner …………………………………………… 45
Pistons ………………………………………………….. 46
Piston rings …………………………………………….. 46
Cylinder block …………………………………………….. 46
Cylinder liner, honing ……………………………………. 48
Cylinder liner seat, reconditioning …………………… 49
Cylinder liner, fitting ……………………………………… 50
Gudgeon bushing, changing ………………………….. 51
Piston, changing …………………………………………. 52
Pistons, fitting …………………………………………….. 53
Polygon hub, changing …………………………………. 54
Sealing ring for polygon hub, changing ……………. 55
Sealant for timing gear cover, changing …………… 55
Timing gear wheels, changing ……………………….. 56
Sealing ring in injection pump drive unit,
changing (710, TD730ME/VE, TWD731)………….. 59
Sealing ring in injection pump drive unit,
changing (730 and TWD630) …………………………. 60
Camshaft, changing …………………………………….. 62
Sealant for timing gear casing, changing …………. 64
Checking camshaft wear ………………………………. 65
Camshaft and valve tappets, inspection ……….. 66
Camshaft, measuring ……………………………….. 67
Camshaft bearings, changing ………………………… 67
Crankshaft………………………………………………….. 68
Big end bearings, change all …………………………. 71
Main bearings, change all …………………………….. 72
Flywheel bearing, changing …………………………… 74
Flywheel, checking trueness …………………………. 74
Flywheel, changing ……………………………………… 75
Ring gear, changing …………………………………….. 75
Rear crankshaft seal, changing ……………………… 76
Flywheel casing, changing sealant …………………. 77
Flywheel casing, checking trueness ……………….. 78
Lubricating system ……………………………………. 79
Design and function ………………………………….. 79
Oil valves ……………………………………………………. 79
Repair instructions…………………………………….. 80
Lubricant pressure, checking ………………………… 80
Oil filter, changing ……………………………………….. 80
Oil filter housing, changing ……………………………. 81
Oil cooler, changing …………………………………….. 81
Leak test of oil cooler …………………………………… 83
Oil delivery pipe on inclined oil sump ………………. 85
Lubricant pump, changing …………………………….. 85
Lubricant pump, reconditioning ………………………. 88
Fuel system ………………………………………………. 91
Design and function ………………………………….. 91
General information ……………………………………… 91
EDC (TWD740VE) ……………… see separate manual
Injection pump …………………………………………….. 92
Governor ……………………………………………………. 92
Injection timing adjuster ……………………………….. 92
Feed pump …………………………………………………. 93
Smoke limiter (certain engines) ……………………… 93
Injectors …………………………………………………….. 93
Fuel delivery pipe ………………………………………… 94
Repair instructions…………………………………….. 95
Injection pump, removing ………………………………. 95
Injection pump, fitting …………………………………… 99
Injection pump, setting using meter
998 7057 ……………………………………………………108
Injection pump, sealing screw ……………………….110
Injectors, changing ………………………………………111
Copper sleeve for injector, cleaning ………………..112
Injectors, reconditioning ……………………………….113
Recommendations for adjusting opening
set pressure and changing injectors ……………….114
Opening pressure, adjusting ………………………….115
Fuel delivery pressure, checking ……………………116
Feed pump, changing…………………………………..116
Feed pump, reconditioning ……………………………117
Fuel filter, changing ……………………………………..120
Bleeding the fuel system ………………………………120
Fuel cut-off valve ………………………………………….121
Bleeding the fuel system ………………………………123
Troubleshooting …………………………………………..124
Intake and exhaust systems……………………….126
Design and function ………………………………….126
Intercooler ………………………………………………….126
Turbocharger ………………………………………………127
Starting heater ……………………………………………127
Air compressor ……………………………………………128
Repair instructions…………………………………….129
Turbocharger, changing ………………………………..129
Directions in case of turbo fault in intercooler
engines ……………………………………………………..130
Turbocharger, changing/fitting on engine………….130
Low-mounted turbo ………………………………………130
Boost pressure, checking …………………………….131
If the boost pressure is low ……………………………132
Checking exhaust back pressure …………………..133
Turbocharger, checking bearing play ………………134
Measuring axial play ………………………………..134
Measuring radial play ……………………………….134
Turbocharger, reconditioning …………………………135
Schwitzer S2A, S2B ………………………………..135
Holset H1E, H2A……………………………………..139
Exhaust manifold gaskets, changing ………………142
Intake manifold sealant/gasket, changing ………..144
Intercooler, changing ……………………………………145
Intercooler, leakage test ……………………………….145
Air compressor, changing …………………………….146
Cooling system …………………………………………148
Design and function ………………………………….148
Coolant pump ……………………………………………..149
Thermostat housing, thermostat …………………….149
Repair instructions…………………………………….150
Coolant pump, changing ……………………………….150
Coolant pump, reconditioning ………………………..151
Piston thermostat, changing …………………………153
Thermostat, functional check ………………………..155
Coolant manifold mounting seals,
changing ……………………………………………………156
Thermostat-controlled fan, functional check ……..159
Control unit ………………………………………………..159
Fan speed check, fan disengaged ………………….159
Fan speed check, fan engaged ……………………..160
Incorrect engagement temperature …………………160
Thermostat-controlled radiator fan, changing ……160
Coolant ……………………………………………………..161
Anti-freeze………………………………………………….161
Anti-corrosion additives ………………………………..161
Checking coolant level ………………………………….161
Draining coolant ………………………………………….162
Filling coolant ……………………………………………..162
Coolant temperature too high ………………………..162
Coolant temperature too low ………………………….163
Checking temperature sensor ………………………..163
Coolant leaks ……………………………………………..163
Checking radiator ………………………………………..163
Adjusting drive belts …………………………………….163
Cleaning cooling system ………………………………164
Test pressurising the cooling system ……………..165
Checking test pressurising equipment 6662 …….165
Pressure test ……………………………………………..165
Checking pressure valve ……………………………….166
Electrical system ……………………………………….167
Important ……………………………………………………167
Arc welding ………………………………………………..167
Starting with auxiliary battery ………………………..167
EDC system ………………………………………………167
Circuit diagram ……………………………………………168
Electronic engine speed governor …………………..172