Workshop Manual: Group 20 Technical Data I

Workshop Manual I
Group 20 Technical Data 1(0)
TAD940GE, TAD941GE
TAD940VE, TAD941VE, TAD942VE, TAD943VE
TAD950VE, TAD951VE, TAD952VE
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Technical data
Industrial Engines
TAD940GE, TAD941GE
TAD940VE, TAD941VE, TAD942VE, TAD943VE
TAD950VE, TAD951VE, TAD952VE
Contents
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

Group 20
Safety information
This workshop manual contains technical data, de- Read the available safety information, General in-
scriptions and repair instructions for the Volvo Penta formation and Repair instructions in the work-
products or product versions noted in the table of con- shop manual before you start to do any service
tents. Make sure that you use the correct workshop work.
literature.
Important
The following special warning signs are used in the Check that the warning or information labels on
workshop manual and on the product. the product are always clearly visible. Replace
labels which have been damaged or painted
WARNING! Warns for the risk of personal injury, over.
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things Never start the engine without installing the air
which could cause damage or malfunctions to cleaner (ACL) filter. The rotating compressor tur-
product or property. bine in the turbocharger can cause severe inju-
ry. Foreign objects entering the intake ducts can
NOTE! Is used to call attention to important informa- also cause mechanical damage.
tion, to facilitate work processes or operation.
To give you a perspective on the risks which always

need to be observed and precautions which always
Never use start spray or similar products as a
have to be taken, we have noted them below.
starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
Make it impossible to start the engine by cutting
system current with the main switch(es) and
lock it (them) in the off position before starting
service work. Fix a warning sign by the control Only start the engine in a well- ventilated area.
station. When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
All service work should normally be done on a

stationary engine. Some work, such as adjust-
ments, need the engine to be running, however. Avoid opening the coolant filling cap when the
Going close to a running engine is a safety risk. engine is hot. Steam or hot coolant can spray
Remember that loose clothes, long hair etc. can out and the system pressure will be lost. When
catch on rotating components and cause severe needed, open the filler cap slowly and release
injury. the pressure in the system. Be extremely care-
If work is done adjacent to a running engine, a ful if a tap, plug or coolant hose has to be re-
careless movement or a dropped tool can lead moved from a hot engine. It is difficult to antici-
to personal injury in the worst case. Take care pate in which direction steam or hot coolant can
to avoid contact with hot surfaces (exhaust spray out.
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 Hot oil can cause burns. Avoid skin contact with
during service operations before starting the en- hot oil. Ensure that the lubrication system is not
gine. under pressure before carrying out any work.
Never start or operate the engine with the oil fill-
er cap removed, otherwise oil could be ejected.

Group 20 General instructions
Stop the engine before carrying out operations All fuels, and many chemicals, are flammable.
on the engine cooling system. 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
Always use protective glasses or goggles when Smoking! Ensure that the work area is well ven-
carrying out work where there is a risk of splin- tilated and take the necessary safety precau-
ters, grinding sparks, acid splashes or where tions before starting welding or grinding work. Al-
other chemicals are used. Your eyes are ex- ways ensure that there are fire extinguishers at
tremely sensitive, injury could cause blindness! hand when work is being carried out.
Avoid getting oil on your skin! Repeated expo- Make sure that oil and fuel soaked rags, and
sure to oil or exposure over a long period can re- used fuel and oil filters are stored in a safe
sult in the skin becoming dry. Irritation, dryness place. Rags soaked in oil can spontaneously ig-
and eczema and other skin problems can then nite under certain circumstances. Used fuel and
occur. Used oil is more dangerous than fresh oil oil filters are polluting waste and must be hand-
from a health aspect. Use protective gloves and ed to an approved waste management facility
avoid oil soaked clothes and shop rags. Wash for destruction, together with used lubrication oil,
regularly, especially before eating. There are contaminated fuel, paint residue, solvents, de-
special skin creams which counteract drying out greasers and wash residue.
of the skin and make it easier to clean off dirt
after work is completed.
Batteries must never be exposed to open

flames or electric sparks. Do not smoke close
Most chemicals intended for the product (e.g. to the batteries. The batteries generate hydro-
engine and transmission oils, glycol, petrol (gas- gen gas when charged, which forms an explo-
oline) and diesel oil) or chemicals for workshop sive gas when mixed with air. This gas is easily
use (e.g. degreasers, paints and solvents) are ignited and highly volatile. A spark, which can
hazardous. Read the instructions on the product be formed if the batteries are wrongly connect-
packaging with care! Always follow the safety ed, is enough to make a battery explode and
precautions for the product (for example use of cause damage. Do not shift the connections
protective mask, glasses, gloves etc.). Make when attempting to start the engine (spark risk)
sure that other personnel are not exposed to and do not lean over any of the batteries.
hazardous chemicals, for example in the air. En-
sure good ventilation in the work place. Follow
the instructions provided when disposing of
used or leftover chemicals. Never mix up the battery positive and negative
poles when the batteries are installed. Incorrect
installation can result in serious damage to the
electrical equipment. Refer to the wiring dia-
Exercise extreme care when leak detecting on gram.
the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet from a fuel in-
jector is under very high pressure, and has con-
siderable penetration ability; fuel can force its Always use protective goggles when charging
way deep into body tissues and cause serious and handling the batteries. Battery electrolyte
damage. Danger of blood poisoning (septice- contains sulfuric acid, which is highly corrosive.
mia). Should the battery electrolyte come into contact
with unprotected skin wash off immediately us-
ing plenty of water and soap. If you get battery
acid in your eyes, flush it off at once with a gen-
WARNING! The delivery pipes must under no erous amount of water, and get medical assis-
circumstances be bent. Damaged pipes must be tance at once.
replaced.

General instructions Group 20
Turn the engine off and turn off the power at the WARNING! Components in the electrical and
main switch(es) before carrying out work on the fuel systems on Volvo Penta products have
electrical system. been designed to minimize the risks of explo-
sion and fire. The engine must not be operated
in environments with adjacent explosive media.
The clutch must be adjusted with the engine

shut off.
Only use the fuels recommended by Volvo Pen-
ta. Refer to the Instruction Book. Use of fuels
that are of a lower quality can damage the en-
The existing lugs on the engine should be used gine. In a diesel engine, poor fuel can cause the
for lifting. Always check that the lifting devises control rod to bind and the engine will over- rev,
are in good condition and that they have the cor- entailing a strong risk of personal injury and ma-
rect capacity for the lift (the weight of the engine chinery damage. Poor fuel can also lead to
plus the reversing gear and extra equipment). higher maintenance costs.
The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
avoid damaging components on top of the en-
gine. All chains or cables must be parallel to Remember the following when washing with a
each other and should be as square as possible high pressure washer: Never aim the water jet at
to the top of the engine. air filters, seals, rubber hoses or electrical com-
If other equipment connected to the engine has ponents. Never use a high pressure washer for
altered its center of gravity, special lifting devis- engine cleaning.
es may be needed to obtain the correct balance
and safe handling.
Never do any work on an engine which just
hangs from a liftingdevise. The injectors can leak fuel when the engine is
stationary, if the tank is higher than the engine
and the fuel pressure is positive.
Never work alone when heavy components are

to be dismantled, even when safe lifting devises
such as lockable blocks & tackle 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.

Group 20
General information
About the workshop manual Certified engines

This workshop manual contains technical data for the The manufacturer certifies that both new engines and
TAD940GE, TAD941GE, TAD940VE, TAD941VE, those in use, which are certified for national or region-
TAD942VE, TAD943VE, TAD950VE, TAD951VE and al legislation, comply with the environmental require-
TAD952VE engines. ments. Each product must correspond with the unit
The Workshop Manual, Technical Data, contains all used for certification. The following requirements for
the references from the workshop manuals to repair service and spare parts must be complied with, for
instructions for the TAD940GE, TAD941GE, Volvo Penta as a manufacturer to be responsible for
TAD940VE, TAD941VE, TAD942VE, TAD943VE, ensuring that engines in use comply with the stipulat-
TAD950VE, TAD951VE and TAD952VE series. ed environmental requirements:
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service techni- Maintenance and service intervals recommended
cians. For this reason the manual presupposes a cer- by Volvo Penta must be complied with.
tain basic knowledge and that the user can carry out Only Volvo Penta Original Spare Parts intended
the mechanical/electrical work described to a general for the certified engine version may be used
standard of engineering competence.
Service related to injection pumps and injectors
Volvo Penta constantly improves its products, so we must always be done by an authorized Volvo Pen-
reserve the right to make modifications without prior ta workshop.
notification. All information in this manual is based on
product data which was available up to the date on The engine must not be converted or modified in
which the manual was printed. Any material changes any way, except for the accessories and service
introduced into the product or service methods after kits which Volvo Penta has approved for the en-
this date are notified by means of Service Bulletins. gine.
Installation changes to the exhaust pipe and the
engine bay air inlet ducts (ventilation ducts) must
not be done without further discussion, since this
could affect exhaust emissions.
Spare parts No seals may be broken by unauthorized person-
nel.
Spare parts for electrical and fuel systems are subject
to various national safety requirements. Volvo Penta The general advice in the instruction book about oper-
Original Spares comply with these requirements. No ation, care and maintenance applies.
damage whatever, occasioned by use of non-original IMPORTANT! When spare parts are needed,
Volvo Penta spares for the product, will be compen- use only Volvo Penta Original Spares.
sated by the warranty offered by Volvo Penta.
Use of non-original spareparts means that AB
Volvo Penta can no longer be 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.

Group 20
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 1500-1620/1800-1920
No. of valves 24 24
No. of cylinders 6 6
Cylinder bore (mm) 120 120
Stroke (mm) 138 138

3
Swept volume (dm ) 9.36 9.36
Weight, dry (kg) 1015 1015
Weight, wet (kg) 1065 1065
Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4
Type designation TAD940VE TAD941VE TAD942VE TAD943VE
Power See Sales Guide Industrial Diesel Power
Torque See Sales Guide Industrial Diesel Power
Compression ratio 20.2:1 20.2:1 20.2:1 20.2:1
Low idle (rpm) 600 600 600 600
High idle (rpm) 2250 2250 2250 2250
No. of valves 24 24 24 24
No. of cylinders 6 6 6 6
Cylinder bore (mm) 120 120 120 120
Stroke (mm) 138 138 138 138
Swept volume (dm3) 9.36 9.36 9.36 9.36
Weight, dry (kg) 1015 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
(1 mm = 0.03937 inch)

Group 20 Technical data
Type designation TAD950VE TAD951VE TAD952VE

Power Please refer to the sales literature
Torque Please refer to the sales literature
Compression ratio 20.2:1 20.2:1 20.2:1

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

Group 20
Engine
Engine block
Length .................................................................... 967 mm (38.07")
Height, upper block plane - crankcase centerline ... 379 mm (14.92")
Height lower block plane - crankcase centerline ..... 120 mm (4.72")
Crankcase pressure
normal value, irrespective of engine speed ............. max 0.5 kPa (0.07 psi)
Cylinder head
Type ...................................................................... 6-cylinder
Length .................................................................... 996 mm (39.21")
Width ..................................................................... 410 mm (16.14")
Height .................................................................... 135 mm (5.32")
Max. flatness error (base plane) ............................. 0.4 mm (0.0158")
Cylinder head screws

No. of screws ......................................................... 26
Dimension, 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 ......................................................... 78,5 mm (3.090")
TAD950-52VE ..................................................... 77,1 mm (3.035")
Depth, piston bowl
TAD940GE, TAD940-943VE ............................... 15 mm (0.590")
TAD941GE ......................................................... 17,3 mm (0.681")
TAD950-952VE ................................................... 14,6 mm (0.575")
No. of ring grooves ................................................. 3
Front marking ......................................................... Arrow towards front
Gudgeon pin diameter ............................................ 54 mm (2.126")

Piston rings
Compression rings
Specification:
Quantity ................................................................. 2
Piston ring clearance in groove
upper compression ring ....................................... 0.12 -0.19 mm (0.0047 - 0.0075")
lower compression 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")

Technical data Group 20
Valve mechanism
Valves
Valve head, diameter:

Inlet .................................................................... 38 mm (1.49606")
Exhaust
TAD940-941GE, TAD940-943VE ...................... 38 mm (1.49606")
TAD950-952VE ................................................. 36 mm (1.41732")
Valve stem, diameter:
Inlet .................................................................... 8 mm (0.31496")
Exhaust .............................................................. 8 mm (0.31496")
Valve seat angle (A):

Inlet .................................................................... 29.5
Exhaust .............................................................. 29.5
Seat angle in cylinder head (B):

Inlet .................................................................... 30
Exhaust .............................................................. 30
Dimension between valve head and cylinder 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, TAD940-943VE ...................... 0.45 -0.55 mm (0.017716 - 0.021653")
TAD950-952VE ................................................. 0,75 - 0,85 mm (0.029527 - 0.033465")
TAD950-952VE
Clearance, double rocker arm
base circle on camshaft ...................................... using gauge tool
10

Valve seats
Outer diameter (A)

Standard:
Inlet ....................................................................
TAD940-941GE, TAD940-943VE ...................... 40.0 mm (1.5748")
TAD950-952VE ................................................. 42,0 mm (1.6535")
Exhaust
TAD940-941GE, TAD940-943VE ...................... 41.0 mm (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")
11

Valve seat bed
Diameter (C) standard:

Inlet
TAD940-941GE, TAD940-943VE ...................... 40.0 mm (1.5748")
TAD950-952VE ................................................. 42,0 mm (1.6535")
Exhaust
TAD940-941GE, TAD940-943VE ...................... 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")
12

Valve guides
Length:
Inlet .................................................................... 83.4 mm (3.283458")
Exhaust .............................................................. 83.4 mm (3.283458")
Inner diameter:
Inlet .................................................................... 8 mm (0.31496")
Exhaust .............................................................. 8 mm (0.31496")
Height above cylinder head spring plane:
Inlet .................................................................... 24.50.5 mm (0.964564 0.019685")
Exhaust .............................................................. 16.50.5 mm (0.6496043 0.019685")
Clearance, valve stem - guide:1
Inlet .................................................................... max 0.2 mm (0.007874")
Exhaust .............................................................. max 0.2 mm (0.007874")
1
The dimensions have been calculated for the method of measurement described in the workshop manual (group 21).
Rocker arms
Bearing clearance .................................................. max 0.08 mm
Valve springs
Inlet
Outer 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:
With 243 N (54.6 lbf) loading ............................... 54.4 mm (2.141728")
Exhaust
Outer valve springs:
With 1150 N (258.5 lbf) loading ........................... 45.3 mm (1.783461")
Inner valve spring:
With 243 N (54.6 lbf) loading ............................... 54.4 mm (2.141728")
13

Timing gear
Timing gear wheels
No. of teeth:
1. Drive gear, crankshaft .......................................... 54
2. Idler wheel, double, outer ...................................... 72
Idler wheel, double, inner ...................................... 56
3. Idler wheel, adjustable .......................................... 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")
14

Camshaft
Check camshaft setting, cold engine and valve clearance =0.
Inlet valve for cylinder 1 at flywheel position 6 ATDC must be open 1.30.3 mm (0.051180.0118").
During the check, you must turn the timing gear in the correct direction (clockwise seen
from the front), to take up all gear flank clearance.
Drive ...................................................................... gear wheel

No of bearings ........................................................ 7
Diameter, bearing journals, standard ...................... 69.97 -70.00 mm (22.754718 - .7559")
NOTE! Only check values, 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 wear between base circle
and max. lift ....................................................... max 0.1 mm (0.003937")
Unit injector, stroke ................................................ 13 mm (0.51181")
Camshaft bearings
Camshaft bearing thickness, standard ................... 1.92 mm (0.075590")
Oversize dimension:
0.25 .................................................................... 2.04 mm (0.080314")
0.50 .................................................................... 2.17 mm (0.085432")
0.75 .................................................................... 2.29 mm (0.090157")
15

Reciprocating components
Crankshaft
Length .................................................................... 1.066 mm (0.041968")

Crankshaft, end float1 .............................................0.100.40 mm (0.00390.0157")
Ovality of main and big end bearings ..................... max 0.01 mm (0.000393")
Taper of main and big end bearings ....................... max 0.02
Runout on center bearing ....................................... 0.15 mm (0.005905")
1
Dimensions refer to oiled components.
Main bearing journal

Diameter () standard ............................................ 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 mm (thrust bearing 0.1) ................................. 42.17 -42.22 mm (1.660232 - 1.662201")
0.4 mm (thrust bearing 0.2) ................................. 42.37 -42.42 mm (1.668106 - 1.670075")
0.6 mm (thrust bearing 0.3) ................................. 42, 57-42.62 mm (1.65354 - 1.677949")
Fillet radius (R) ....................................................... 4.5 mm (0.177165")
16

Thrust washers (thrust bearing)

Width (B) standard ................................................. 3.2 mm (0.125984")
Oversize dimension:
0.1 mm ............................................................... 3.2 -3.3 mm (0.125984 - 0.129921")
0.2 mm ............................................................... 3.3 -3.4 mm (0.129921 - 0.133858")
0.3 mm ............................................................... 3.4 -3.5 mm (0.133858 - 0.137795")
Main bearing shells

Outer diameter (C) ................................................. 113 mm (4.44881")
Thickness (D) standard .......................................... 2.5 mm (0.098425")
Oversize dimension:
0.25 mm ............................................................. 2.6 -2.7 mm (0.102362 - 0.106299")
0.50 mm ............................................................. 2.7 -2.8 mm (0.106299 - 0.110236")
0.75 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

Diameter () .......................................................... 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 ............................................................. 87.48 -87.50 mm (3.444087 - 3.444875")
1.25 mm ............................................................. 87.35 -87.37 mm (3.438969 - 3.439756")
Surface finish, big end bearing journal .................... Ra 0.25
Surface finish, radius ............................................. Ra 0.4
Width (A) ................................................................ 54 mm (2.12598")
Fillet radius (R) ....................................................... 4.5 mm (0.177165")
17

Big end journal shells

Outer diameter (B) ................................................. 93 mm (3.66141")
Thickness (C) standard .......................................... 2.4 mm (0.094488")
Oversize dimension:
0.25 mm ............................................................. 2.5 -2.6 mm (0.098425 - 0.102362")
0.50 mm ............................................................. 2.6 -2.7 mm (0.102362 - 0.106299")
0.75 mm ............................................................. 2.7 -2.8 mm (0.106299 - 0.110236")
1.00 mm ............................................................. 2.8 -2.9 mm (0.110236 - 0.114173")
1.25 mm ............................................................. 3.0 -3.1 mm (0.11811 - 0.122047")
Diameter, bearing shell seat (D) ............................. 92.85 mm (3.655504")
Con rods
Length, center - center (E) ..................................... 225 mm (8.85825")
Small end bushing, internal diameter (G) ................ 54 mm (2.12598")
End float, con rod - crankshaft1: ............................. max 0.35 mm (0.013779")
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).
Flywheel, installed
Runout (manual gearbox), measurement
radius 150 mm (5.9055") . ...................................... max 0.20 mm (0.007874")
No. of teeth on starter gear ring .............................. 153
Sensor grooves in flywheel .................................... 54 pcs.
Flywheel housing, installed

Runout for mating face against bellhousing. ........... max 0.1 mm (0.003937")
Radial runout for alignment against bellhousing. ..... max 0.05 mm (0.001968")
18

Lubrication oil systems
TAD940-941GE, TAD940-943VE
Sulfur content in fuel, by weight
< 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 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, CH-4, CG-4
TAD950-952VE
Sulfur content in fuel, by weight
< 0.3 % 0.3 0.5 % > 0.5 %1)
Oil grade Oil change interval: Reached first in operation
VDS-3 500 hours / 12 month 250 hours / 12 month 125 hours / 12 month
VDS-2 and ACEA E7 2) 250 hours / 12 month 125 hours / 12 month 75 hours / 12 month
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) 125 hours / 12 month 75 hours / 12 month 50 hours / 12 month
ACEA: E7, E5, E4
API: CI-4, CH-4, CG-4
1)
If sulfur content is > 1.0 % by weight, use oil with TBN > 15.
2)
Lubrication oil must comply with both requirements. Note. API: CG-4 or CH-4 can be approved in markets outside Europe (instead of
ACEA A3).
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! Oil filter must be changed with every oil change.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Europenne dAutomobiles
API = American Petroleum Institute
TBN = Total Base Number
19

Viscosity
Select the viscosity from the adjacent table, for the
appropriate continuous ambient air temperature.
* *Refers to synthetic or semi-synthetic oils.
Oil
Oil change volume, including filters ........................ 35 liter (9.2 US gallon)
Oil pressure
Operating speed (above 1100 rpm) ......................... 300 -550 kPa (43.5-79.7 psi)
Low idle .................................................................. min 270 kPa (39.1 psi)
Oil temperature
Cold engine, engine stopped .................................. ambient temperature
Hot engine, engine running
(coolant temperature 75-95 C) (167-203F) .......... 90-115 C (194-239F)
Lubricating oil pump

Type ...................................................................... Gear driven
No. of teeth, drive wheel ........................................ 23
Oil filter
Full flow filter .......................................................... 2
Turbo filter (By-pass filter) ...................................... 1
20

Oil valves
1. Safety valve, lube oil pump

Marking ............................................................. Violet
2. Bypass valve, bypass filter
Spring, free length ............................................. 69 mm (2.71653")
Loaded 13-15 Nm (9.6-11.0 lbf-ft) ...................... 40 mm (1.5748")
3. Bypass valve, oil cooler
Loaded 124 Nm (91.4 lbf-ft) ............................... 44 mm (1.73228")
4. Reduction valve, oil pressure
Marking ............................................................. Blue
5. Bypass valve, full flow filter
Loaded 13-15 Nm (9.6-11.0 lbf-ft) ...................... 40 mm (1.5748")
6. Opening valve, piston cooling
Loaded, 94 Nm (69.3 lbf-ft) ................................ 62 mm (2.44094")
7. Control valve, piston cooling
Loaded, 47 Nm (34.6 lbf-ft) ................................ 92 mm (3.62204")
21

Fuel system
Feed pump
Feed pressure at:
600 r/min ............................................................. min 400 kPa (58.0 psi)
1200 r/min ........................................................... min 400 kPa (58.0 psi)
full load ............................................................... min 400 kPa (58.0 psi)
By-pass valve
Opening 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.
22

Inlet and exhaust system

Turbocharger
Manufacturer/type
TAD940GE, TAD940-943VE ............................... 3K/K29
TAD941GE ......................................................... 3K/K31
TAD950-952VE ................................................... Holset
End float, turbine shaft ........................................... max 0.15 mm (0.005905")
Charge air temperature indicator

Cold engine, engine stopped .................................. Ambient temperature
Hot engine, engine running
(coolant temperature 75-95C (167-203F)) .......... 10-30C (18-54F) 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 (27.12 psi)
TAD950VE ............................................................. 187 kPa (27.12 psi)

TAD951VE ............................................................. 207 kPa (30.02 psi)
TAD952VE ............................................................. 212 kPa (30.75 psi)
23

Cooling system
General
Pressure cap opens at ........................................... 75 kPa (10.8 psi)
Thermostat
Quantity ................................................................. 1
Opening temperature .............................................. 82C (180F)
Fully open .............................................................. 92C (198F)
Coolant
Type ...................................................................... Volvo Original
Consists of ............................................................ Glycol and corrosion-inhibiting additives
Color ...................................................................... Green
Mix with ................................................................. Water (according to ASTM D4985)
24

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
25

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")
26

Tightening torque
General tightening torque Nm

M6 standard screw 8.8 ........................................... 10 1.5 (1.1 lbf-ft)
M8 standard screw 8.8 ........................................... 25 4 (18.52.9 lbf-ft)
M10 standard screw 8.8 ......................................... 508 (36.95.9 lbf-ft)
M12 standard screw 8.8 ......................................... 85 15 (62.711.0 lbf-ft)
M14 standard screw 8.8 ......................................... 140 25 (10318.4 lbf-ft)
M16 standard screw 8.8 ......................................... 220 35 (16225.8 lbf-ft)
Only torqued screws can be re-installed.

Torque and angle tightened / plastic limit tightened screws:
8.8 ...................................................................... should 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 (20233lbf-ft)
Front engine mounting, front engine pad ................. 150 30 Nm (11122 lbf-ft)
Main bearing caps
Stage 1 ............................................................... 150 20 Nm (11115 lbf-ft)
Stage 2 ............................................................... 120 5 angle tightening
Big end bearing cap

Stage 1 ............................................................... 20 3 Nm (152 lbf-ft)
Stage 2 ............................................................... 35 3 Nm (262 lbf-ft)
Stiffening frame ..................................................... 48 8 Nm (356 lbf-ft)

NOTE! Tighten the screws in sequence, from the center and outwards.
27

Flywheel
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 (444 lbf-ft)

Bell housing
NOTE! Apply 2 mm silicone sealer as in the illustration.
28

12
1
10
3
8
6 5
7
2
4 9
Vibration damper, camshaft 11
Stage 1 ............................................................... 45 5 Nm (334 lbf-ft)
NOTE! The 8.8 screws on the vibration damper must not be re-used.
Housing, crankcase seal ............................. 24 4 Nm (183 lbf-ft)

NOTE! Apply 2mm (0,07874") silicone sealer as in the illustration.
Valve housing. .............................................. 24 4 Nm (183 lbf-ft)

29

Oil cooler, housing ...................................... 24 4 Nm (183 lbf-ft)

Cylinder head
Stage 1 ............................................................... 60 10 Nm (447 lbf-ft)

Stage 2 (check tightening) .................................. 60 10 Nm (447 lbf-ft)
Core plugs, cylinder head ....................................... 60 10 Nm (447 lbf-ft)

Lock nut, valve adjustment screw .......................... 60 5 Nm (444 lbf-ft)
30

Bearing caps, camshaft / rocker arm shaft

NOTE! Tighten the screws in stages, to ensure that the rocker arm shaft
comes down without being bent.
Stage 1: Torque screws 1-7 to ............................... 15 3 Nm (112 lbf-ft)
Stage 2: Torque screws 9, 11, 13. ......................... 60 5 Nm (444 lbf-ft)

Start with screw 11.
Stage 3: Torque screws 8, 10, 12, 14. ................... 60 5 Nm (444 lbf-ft)
Stage 4: Loosen screws 9, 11, 13. .........................
Stage 5: Torque screws 9, 11, 13. ......................... 60 5 Nm (444 lbf-ft)
Stage 6: Tighten screws 1-7. ................................. 90 5 angle tightening
Stage 7: Tighten screws 8-14. ............................... 120 5 angle tightening
31

Apply silicone sealer to the rear edge of the cylinder Tighten the screws in number order.
head and the engine block.
Timing gear plate ......................................... 24 4 Nm (133 lbf-ft)

NOTE! Apply silicone sealer and tighten the screws in number order, as in the illustration.
Timing gear cover, upper ............................ 24 4 Nm (133 lbf-ft)

NOTE! Apply 2 mm (0,07874") silicone sealer as in the illustration.
32

Timing
1 Drive gear, crankshaft ............................................................. 24 4 Nm (133 lbf-ft)
2 Idler wheel, double gear

Apply thread locking fluid 1161053 to the screws and tighten them in number order, as in the illustration.
Stage 1 ..................................................................................... 35 4 Nm (263 lbf-ft)
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 (263 lbf-ft)
4 Drive gear, camshaft

Tighten the screws in number order, as in the illustration.
Stage 1 ..................................................................................... 45 5 Nm (334 lbf-ft)
5 Drive wheel, steering servo and fuel feed pump ................... 100 10 Nm (747 lbf-ft)
6 Drive wheel, air compressor ................................................... 200+50

-0 Nm(148-037 lbf-ft)
33

Tightening torque group 22: Lubricating system

Oil sump ................................................................ 24 4 Nm (183 lbf-ft)
Drain plug, oil sump ............................................... 60 5 Nm (444 lbf-ft)

Bracket, oil pump/main bearing caps ..................... 24 4 Nm (133 lbf-ft)
Oil strainer, retaining screws .................................. 24 4 Nm (183 lbf-ft)
Oil cooler, retaining screws .................................... 27 4 Nm (183 lbf-ft)
Tightening torque group 23: Fuel system

Feed pump - steering servo pump .......................... 24 4 Nm (183 lbf-ft)
Fixing yoke, unit injector (new copper sleeve)
First tightening
Stage 1 ............................................................... 20 5 Nm (154 lbf-ft)
Loosen the fastening yoke screw before doing the second tightening.
Second tightening
Stage 1 ............................................................... 20 5 Nm (154 lbf-ft)
Fixing yoke, unit injector (re-used copper sleeve)

Stage 1 ............................................................... 20 5 Nm (143 lbf-ft)
Locknut for rocker adjuster screw, unit injector

Stage 1 ............................................................... tighten until contact
Stage 2 .............................................................. 45 5 angle tightening
Hollow screw M16 x 1.5 ......................................... 50 8 Nm

Hollow screw M10 x 1 ............................................ 25 4 Nm
34

Tightening tourqe group 25, Intake and exhaust system
Inlet pipe ......................................................... 24 4 Nm (183 lbf-ft)

NOTE! Apply 2mm silicone sealer as in the illustration.
Plug, M10 .............................................................. 20 3 Nm (153 lbf-ft)

Pressure/temperature sensor, charge air ................ 12 2 Nm (92 lbf-ft)
Exhaust collector pipe

Stage 1: Tighten the screws until they just touch ...................... 5 1.5 Nm (41 lbf-ft)
Stage 2: Torque screws 1 and 8 ................................................ 10 1.5 Nm (71 lbf-ft)
Stage 3: Torque screws 3 and 10 .............................................. 10 1.5 Nm (71 lbf-ft)
Stage 4: Torque screws 5 and 12 .............................................. 10 1.5 Nm (71 lbf-ft)
Stage 5: Torque screws 2 and 7 ................................................ 48 8 Nm (356 lbf-ft)
Stage 7: Torque screws 6 and 11 .............................................. 48 8 Nm (352 lbf-ft)
Stage 9: Torque screws 3 and 10 .............................................. 48 8 Nm (352 lbf-ft)
Stage 10: Torque screws 5 and 12 ............................................ 48 8 Nm (352 lbf-ft)
35

Group 20
Reference to Service bulletins

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Date: ..................................................................................
Signed: ..............................................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gteborg
Sweden

7745342 English 072009

Workshop Manual: Group 20 Technical Data I

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Workshop Manual I

Group 20 Technical Data 1(0)

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To give you a perspective on the risks which always

All service work should normally be done on a

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Batteries must never be exposed to open

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The clutch must be adjusted with the engine

Never work alone when heavy components are

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About the workshop manual Certified engines

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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 1500-1620/1800-1920

Cylinder bore (mm) 120 120

Stroke (mm) 138 138

Weight, dry (kg) 1015 1015

Weight, wet (kg) 1065 1065

Injection sequence 1-5-3-6-2-4 1-5-3-6-2-4

Type designation TAD940VE TAD941VE TAD942VE TAD943VE

Power See Sales Guide Industrial Diesel Power

Torque See Sales Guide Industrial Diesel Power

Compression ratio 20.2:1 20.2:1 20.2:1 20.2:1

Low idle (rpm) 600 600 600 600

High idle (rpm) 2250 2250 2250 2250

Cylinder bore (mm) 120 120 120 120

Stroke (mm) 138 138 138 138

Swept volume (dm3) 9.36 9.36 9.36 9.36

Weight, dry (kg) 1015 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

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Type designation TAD950VE TAD951VE TAD952VE

Compression ratio 20.2:1 20.2:1 20.2:1

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Cylinder head screws

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Oil scraper ring:

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Valve head, diameter:

Valve seat angle (A):

Seat angle in cylinder head (B):

Dimension between valve head and cylinder head plane:

Valve clearance, cold engine, setting value:

Valve clearance, cold engine, check value:

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Outer diameter (A)

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Valve seat bed

Diameter (C) standard:

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Drive ...................................................................... gear wheel

Diameter, bearing journals, undersize dimension

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Length .................................................................... 1.066 mm (0.041968")