Workshop Manual 1 Group 21-26 TAD1 250VE, TAD1251VE, TAD1252VE 921518.0269QONO00090 000090 00 0 09000090000Workshop manual Group 21-26 ss Industrial engines ; TAD1250VE, TAD1251VE, TAD1252VE Contents - Safety information.. Introduction 4 - General information ‘About this Workshop Manual. Standard times (Flat Rate) € ‘Spare parts Cortiied engines ... Repair instructions. ‘Our common responsibilty...» D Torque TTorque-analetighteing LOCK MUS nnn { Strength classes... Sealant Safety rules for Fiuorocarbon Rubber When working with chemicals, fuel and lubricating oil Before iting the engine ... Actions after lting the engine Instructions for work on engines with ‘electronic fuel injection eet Special tools Other special equipment Introduction sss Identification numbers. 7 7 Component location .. Design and function Group 21: Engine body. Engine... Cylinder head .. Engine block... Cylinder ine Pistons and con rods... Crankshaft Camshatt.. Valve mechanism Internal EGR Transmission : Group 22 Lubrication system Function description, lubrication system Ol valves Group 23 Fuel system. Function desoription, fuel system Filler housing... Unit injector, summary... Trim code, injector .. Unitinjector, working phases Group 25 Inlet and exhaust system.. Turbocharger Group 26: Cooling system Function description, cooling system 39 Intercooler... elie 40 Group 30: Electrical systom EMS 2 a Control unit... nis Electrical component diagram 42.Fault tracing ‘Symptoms and possible causes Malfunctions sen Blockage 8 Tests and settings Charge pressure, fait tring evn Turbocharger, inspection . ‘Supply pressure Service work. Compression test Timing marks . Adjustment, general . : Valves, adjustment Double rocker arm, inspection (IEGR) Double rocker arm, adjustment Engine oft, changing... Oil fiter/By-pass iter, change Fuel fiter, change Primary fuel fier, change Fuel system, draining... Draining condensate Venting the fuel system f Instructions for operating the starter motor. Exhaust system, inspection... Pressure drop indicator/air titer, inspection/change : Cooling system, draining... Cooling system, cleaning .. See Cooling system, pressure testing... ‘ Cooling system, filing Coolant fiter, change Alternator belt / Drive Delt, inspection wes Alternator belts, change Drive belt, change Checking the pressure test unit. BANNAIIBLSR RRSRRISSBYHBRVSS BSGH RRS Installing the engine fixture... Overhaul / Change components. Group 21: Engine body. Cylinder head, removing Cylinder head, installation Cylinder liners and piston, inspection Cylinder liners and pistons, change (al). Cylinder liners, installation Pistons, change Camshatt, inspection and overhaul sas.nn ‘Camshaft, wear check RSSSKBBAAa a Bearing housing for camshatt, change «nme 108 Camshaft, installation 104 CCrankshatt, inspection and overhaul 108 Main bearings, change (All) sun msmnnnnsnnews 10 Big end bearings, change (All) nnn NAS Flywheel bearing, change Flywheel, change Gear ring, change.. Flywheel, indication Crankshaft seal, front, change Crankshaft seal rear, change ... Con tod, inspection Gudgeon pin bushing, check measurement, Valves, removing Valves, installation. Valve seat, change Valve guides, inspection Valve guides, replacing .n.rmnnn Valve stem seals, change. Valve seats, grinding Valves, grinding .. Cylinder head, pressure testing... Copper sleeve for injector, changing Timing gear, changing .. Group 22: Lubrication system ven When working with chemicals, fuel and lubrication oil. Reduction valve, change sums Safety vaive, change ... Piston cooling valve, change Bypass valve, oil fiter, change By-pass valve, by-pass filter, change ... Bypass valve, oil cooler, change .. Sump gasket, change Piston cooling nozzle, change Oilfiter, change. Lube oil pressure, check... il cooler, Change en snnee Oil cooler, leakage test Group 23: Fuel system. Control unit, change Feed pump, changing Feed pump, renovation .. Bypass valve, changing Unit injector, change .. Group 25: Inlet/ Exhaust systems .. Inlet pipe, gasket change .. Manifold, gasket change Turbo, replacing198 Group 26; Cooling system Coolant pump, change ‘Thermostat, function check.. ‘Thermostat, change ... 204 a Charge air cooler, change sense 205 Charge air cooler, leakage test sv 208 Charge air cooler, cleaning 208 Radiator matrix, change .... 209 Technical data . General. 214 Torque .. oo 15 References to Service Bulleti 219 ~ Alphabetical registeSafety information Safety information Introduction ‘The workshop manual contains descriptions and repair instructions for products or product versions noted in the table of contents, supplied by Volvo Penta. This manual should be used together with the workshop manual Technical data for each engine. Check that ‘you have the correct workshop manual for your en- gine. lead this safety information and the workshop manual General information and Repair instructions care- fully before service work is started. Important In this book and on the product you wil find the follow- ing special warning symbols. ZX WARNING! Warns for the tisk of personal injury, major damage to product or property, or serious ‘malfunctions if the instruction is ignored, ZX. IMPORTANT! Is used to call attention to things which could cause damage or malfunctions to product or property. NOTE! Is used to call attention to important informa- 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 have to be taken, we have noted them below. LX 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 ser- vice work. Set up a waming notice by the helm station. AX Ailservice work should normally be done on a stationary engine. Some work, such as adjust- ments, need the engine to be running, however. Approaching an engine which is operating is a safety hazard. Remember that loose clothing or Jong hair can fasten in rotating parts and cause serious personal injury. ZA ttworkis done adjacent toa running engine, a careless movement ora dropped tool can lead ~ to personal injury in the worst case, Take care to avoid contact with hot surfaces (exhaust pipes, Turbocharger, air intake pipe, starter heater etc.) and fluids in pipes and hoses in an engine which is sunning or has just been stopped. Reinstall all protective parts removed ~ ‘during servicework before starting the engine. ‘Check that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start the engine without installing the air cleaner fiter. The rotating compressor turbine in the turbocharger can cause severe injury. For- ‘eign objects entering the intake ducts can also ‘cause mechanical damage. Never use start spray or similar products as @ g starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury. Only start the engine in a well- ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated 7 from the engine bay or workshop area, ‘Avoid opening the coolant filing cap when the engine is hot. Steam or hot coolant can spray out and the system pressure will be lost. When needed, open the filer cap slowly and release the pressure in the system, Be extremely care- ful if@ tap, plug or coolant hose has to be re- moved from a hot engine. Steam or hot coolant might spray out in an unexpected direction, Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not 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. Stop the engine before carrying out operations ‘on the engine cooling system.Safety information AX Ifother equipment connected to the engine has altered its centre of gravity, special liting devie- es may be needed to obtain the correct balance and safe handling LX Never do any work on an engine which ust hangs froma lifting device. ZX Never work alone when heavy components are {tobe dismantied, even when safe iting devices such as lockable blocks & tackie are used. When using aliting device 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 liting operations. AX Always make sure that there is enough space. for disassembly where you are working, with no risk for personal or material damage. ZX WARNING! Components in the electrical and fuel systems on Volvo Penta products have been designed to minimize the risks of explo ‘sion and fire. The engine must not be run in ar- eas where there are explosive materials, AX 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- gine. On a diesel engine poor quality fuel can cause the control rod to bind and the engine to overtev with resulting risk of damage to the en- gine and personal injury. Poor fuel can also lead to higher maintenance costs. ZX Remember the following when washing with a power washer: Never aim the water jet at seals, rubber hoses, electrical components or radia~ tors, Never use @ power washer for engine cleaning. ZX Atways use protective glasses or goggles when carrying out work where there is a risk of splin- ters, grinding sparks, acid splashes or where other chemicals are used. Your eyes are ex- ‘tremely sensitive, injury could cause blindness! ZX Avoid getting oil on your skin! Repeated expo- sure to oil or exposure over a long period can re- suitin the skin becoming ary. Initation, dryness and eczema and other skin problems can then occur. Used oil is more dangerous than fresh oll ‘rom a health aspect. Use protective gloves and avoid oll-soaked clothes and rags. Wash regu- latly, especially before eating. There are special skin creams which counteract drying out of the skin and make it easier to clean off dit after work is completed. ZX Most chemicals intended for the product (e.g ‘engine and transmission oils, lycol, petrol (gas- line) and diese! ol) or chemicals for workshop Use (e.g. degreasers, paints and solvents) are hazardous. Read the instructions on the product packaging with care! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.). Make sure that other personnel are not inadvertently ‘exposed to hazardous chemicals, for example in the air, Ensure good ventilation in the work place. Follow the instructions provided when cis- posing of used or leftover chemicals. ZX Exercise extreme care when leak detecting on 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 way deep into body tissues and cause serious injury. Danger of blood poisoning (septicemia). ZX WARNING! Fuel delivery pipes on the engine must not be bent or re-aligned under any circum- stances. Damaged pipes must be replaced. AX Alituels, and many chemicals, are flammable. Do not allow naked flame or sparks in the vicint- ty. Petrol (gasoline), some thinners and hydro- gen gas from batteries are extremely fammabie and explosive when mixed with airin the correct ratio. No Smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work. Always ensure that there are fire extin- uishers at hand when work is being carried out.Safety information ZX Make sure that oll and fuel soaked rags, and used fuel and ol fiters are stored na safe place. Rags soaked in oil can spontaneously ig- nite under certain circumstances. Used fuel and oil fiters are polluting waste and must be hand- ed to an approved waste management facility for destruction, together with used lubrication cl, contaminated fuel, pant residue, solvents, de- greasers and wash residue. AX Batteries must never be exposed to open flames or electric sparks. Never smoke close to the batteries. The batteries generate hydrogen ‘gas when charged, which forms an explosive gas when mixed with air. This gas is easily ignit ed and highly volatile. A spark, which can be formed if the batteries are wrongly connected, is enough to make a battery explode and cause damage. Do not shift the connections when at- tempting to start the engine (spark risk) and do not lean over any ofthe batteries. ZX Aiways ensure that the Plus (positive) and Mi- nus (negative) battery cables are correctly in- stalled on the corresponding terminal posts on the batteries. incorrect installation can result in serious damage to the electrical equipment. Re- ferto the wiring diagram. ZX Aiways use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. ‘Shouid 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, fiush at once with a lot of wa- ter, and get medical assistance at once. AX Tur the engine off and tum off the power at the main switches) before carrying out work on the electrical system. ZX The clutch must be adjusted with the engine shut off AX The existing lugs on the engine should be used for lifting. Always check that the lifting devices are in good condition and that they have the cor- rect capacity forthe lft (the weight of the engine plus the gearbox and extra equipment) ZX The engine should be lifted with @ customized or adjustable ling boom for safe handling and to avoid damaging components on top of the er gine. All chains or cables must be paralel to each other and should be as square as possible tothe top of the engine,General information General information About this workshop manual This workshop manual contains descriptions and re- pai instructions for the standard versions of the ‘TAD1250VE, TAD1251VE and TAD1252VE engines. The workshop manual can illustrate tasks done on any of the engines noted above. This means that the ilustrations and photographs which clarify certain de- {ails might not entirely correspond, The repair meth- ‘ods are similar in all important respects, however. The engine designation and number are noted on the type plete (please referto "Technical Data TAD1250VE, TAD1251VE, TAD1252VE", ‘The engine designation and number must always be given in all correspondence about an engine. The workshop manual is produced primarily for the use of Volvo Penta workshops and service techni- cians. For this reason the manual presupposes a cer- tain basic knowledge and that the user can carry out the mechanicalelectrical work described to a general standard of engineering competence. Volvo Penta constantly improves its products, so we reserve the right to make modifications without prior notification. All information in this manual is based on product data which was available up to the date on ‘which the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins. Standard times (Flat Rate) Ininstructions where operation numbers are found in the headings, this is a reference to the Volvo Penta standard times list ("Flat Rate"). Spare parts Spare parts for electrical and fuel systems are subject to various national safety requirements. Volvo Penta, Original Spare Parts mest these specifications. Any kind of damage whatsoever, occasioned by use of non-original Volvo Penta spares for the product in question, will not be compensated by the warranty of fered by Volvo Penta, Certified engines ‘The manufacturer certifes that both new engines and those in use, which are cerified for national or region- al legislation, comply with the environmental requite: ments. Each product must correspond with the unit Used for certification. The following requirements for service and spare parts must be complied with, for Volvo Penta as a manufacturer to be responsible for ensuring that engines in use comply with the stipulat- ed environmental requirements: — Maintenance and service intervals recommended by Volvo Penta must be complied with. — Only Volvo Penta Original Spare Paris intended for the certified engine version may be used, — Service related to injection pumps, pump settings ‘of unit injectors must always be done by an au- thorized Volvo Penta workshop. — The engine must not be converted or modified in ‘any way, except for the accessories and service kits which Volvo Penta has approved for the en- 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. No seals on the engine may be broken by unauthorized persons, ZA IMPORTANT! When spare parts are needed, use only Volvo Penta Original Spares. = The use of non-original spares means that AB Volvo Penta ceases to be responsible for ensur- ing that the engine corresponds with the certified version. — Any kind of damage whatsoever, occasioned by Use of non- original Volvo Penta spares for the product, will not be compensated by the warranty offered by Volvo Penta,Repair instructions Repair instructions ‘The working methods desoribed in the workshop man- ual apply to work carried out in a workshop. For this, reason, the engine is lifted out and mounted on an en- gine support. Unless otherwise stated reconditioning ‘work which can be carried out with the engine in place follows the same working method, The waming signs which ocour in the workshop manual {for their meanings, please refer to Safety information) ZA WARNING! LAmerorrant: NOTE! are not comprehensive in any way, since we can not of course foresee everything, because service work is done in highly varying circumstances. For this rea- son, all we can do Is to point out the risks which we believe could oocur due to incorrect work in a well- equipped workshop, using work methods and tools, tested by us. All operations described in the workshop manual for Which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been spe- Gitically developed to ensure the most safe and ratio- ral working methods possibie. Itis therefore the re- sponsibility of anyone using other tools or other work ing methods than we recommend to determine that there is no tisk of personal injury or mechanical dam- age or matfunction as a result. In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the workshop manual. ‘These rules must always be observed, so there are no special instructions about this in the workshop manual. By following these basic recommendations and using- using common sense it is possible to avoid most of the risks involved in the work. A clean workplace and a clean engine will eliminate many risks of personel injury and engine matfunetion. Above all, when work on fuel systems, lubrication systems, inlet systems, turbocharger, bearing caps and seals is done, itis extremely important that no dirt or other kinds of foreign panicles are able to get in, since this would otherwise cause malfunctions or shortened repair life Our common responsibility Each engine consists ofa large number of collaborat- ing systems and components. Any deviation of a component from its technical specification can dra- ‘matically increase the environmental impact of an oth- enwise good engine. For this reason, itis extremely important that specified wear tolerances are kept to, that systems with adjustment facilities are correctly adjusted and that Volvo Penta Original Spares are sed for the engine. The stated service intervals in the Maintenance Schedule must be observed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. Some com- ponents are sealed at the factory, for environmental reasons etc. Itis only permissible to work on sealed ‘components if you are authorized to do such work. Remember that most chemical products, incorrectly used, ‘damage the environment. Volvo Penta recommends the use ofbiodegradable degreasers whenever engine compo- nentsare de-greased, unless otherwise specified in the workshop manual. Be carefulto enure that ols, wash residue etc, are processed for destruction, and are notin- advertently discharged to the environment, Torque The tightening torque for vital fasteners, which should be tightened with a torque wrench, are isted in “Tech- nical Data: Tightening torque” and noted in the job de- scriptions in the book. All torque specifications apply toclean screws, sorew heads and mating faces. Torque data stated apply to lightly olled or dry threads. ff lubricants, locking fluids or sealants are needed on a fastener, the type of preparation to be Used willbe noted in the job deseription and in "Tight- ening Torques". Where a particular torque value is not specified for any fastener, the general tightening torques in the table below shall aoply. The torque specification is a target value and the fastener does not need to be tightened with a torque wrench, Dimension Torque Nm RgseReeRepair instructions Torque-angle tightening In torquefangle tightening, the fastener is tightened to the specified torque, and tightening then continues through a pre-determined angle. Example; for 90° an- gle tightening, the fastener is tightened a further 1/4 tum in one sequence, after the specified tightening torque nas been achieved. Lock nuts Disassembled locknuts shall not be re-used, they shall be replaced by new ones, since the locking prop- erties are impaired or lost when the nut is used sever- al times. On locknuts with plastic inserts, such as Ny- Jock? the tightening torque specified in the table must be reduced if the Nylock® nut has the same nut height asa standard fully metallic hexagonal nut, Reduce the torque by 25% for screw size 8 mm or larger. On Ny- Jock® nuts with higher nut height, where the fully me tallic thread is as high as on a standard hexagonal ‘nut, use the tightening torques in the table. Strength classes Sorews and nuts are sub-divided into different strength classes. Ciassification is indicated by mark- ings on the screw head. A marking with higher number indicates stronger material. For example, a screw marked 10-9 is stronger than one marked 8:8. For this reason, when fasteners are remioved, itis important that the screws are put back in the correct places when they are re-installed. Ia screw must be re- placed check in the spare parts catalogue to make sure the correct screw is used. Sealant Several different types of sealant and locking fluids are used on the engine. The properties of the prepara- tions differ, and they are intended for different strengths of fastener, temperature, resistance to oil and other chemicals, and for the different materials and gap thicknesses found in the engine. Itis therefore important that the correct types of seal- ant and locking fluids are used on the fasteners where needed, to give a fully acceptable service result Ia this Volvo Penta workshop manual the user wil find that each section where these agents are applied in production states which type was used on the engine. In service work, similar preparations, or preparations ‘of corresponding properties but of other makes, shall be used. ‘When sealants and locking fluids are used, itis impor- tant that the surfaces are free from oil, grease, paint and rust-protection, and that they are dry. Always fol- low the manufacturer's instructions use regarding tem- perature range, curing time and any other instructions for the product. ‘Two different basic types of agent are used on the en- sine. These are: ITV preparations (Room Temperature Vuleanizing) Used for gaskets, sealing gasket joints or coating gaskets. RTV preparations are fully visible when the ‘component has been disassembled; old RTV com- pound must be removed before the joint is sealed again. ‘The following preparations are RTV-types: Loctite® 574, Volvo Penta 840879-1, Permatex® No. 3, Volvo Penta 1161099-5, Permatex @ No 77. Remove old sealant with denatured alcohol in each case. ‘Anaerobic agents. These agents cure in the absence of air. These preparations are used when two solid ‘components, such as two cast components, are fitted together without a gasket. Common uses are also to lock and seal plugs, stud threads, taps, oil pressure ‘monitors etc. Hardened anaerobic preparations are glassy and for this reason, the preparations are col- red to make them visible. Hardened anaerobic prepa- rations are highly resistant to solvents, and old com pound can not be removed. On re-instaliation, de- ‘grease carefully and then apply new sealant. The following preparations are anaerobic: Loctite ® 572 (white), Loctite @241 (blue). Note. Loctte® is 2 registered tacemark belonging to the Loctte Corporation, Permatax® is a registered tracemark belonging 10 tha Permatex Corporation,Repair instructions Safety rules for Fluorocarbon Rubber Fiuorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is exposed to high tempera- tures (above 300°C), hydrofluoric acid which is highly corrosive is formed, Contact with the skin can result in severe chemical bums. Splashes in your eyes can re- sult in severe chemical burns. f you breathe in the fumes, your lungs can be permanently damaged. ZX WARNING! Be very careful when working on en- gines which have been exposed to high tempera- tures, such as overheating or fire. Seals must never be cut with a flame torch during cisassem- bly, or burned in uncontrolled circumstances af- terwards. + Alvays use chloroprene rubber gloves (gloves for chemicals handling) and goggles. ‘+ Handle the removed seal in the same way as cor- rosive acid. Allresidue, including ash, can be high- ly corrosive. Never use compressed air to blow anything clean. ‘+ Putthe remains in a plastic container, seal it and apply a warning label. Wash the gloves under run- ning water before removing them. The following seals are most probably made from fluo- rocarbon rubber: Seal rings for crankshafts, camshafts, countershatts. O-rings, regardless of where they are installed. O-rings for cylinder liner sealing are almost always made of flu- ‘orocarraon rubber. Please note that seals which have not been ex- posed to high temperature can be handled normal- ly. 10 When working with chemicals, fuel and lubricating oil IMPORTANT! Apply barrier cream to your hands and always use protective gloves in work which involves contact with cil, fuel etc. Continuous skin contact with engine oil dries your skin and can be hazardous.Repair instructions Before lifting the engine 41. Turn the battery isolator off, undo the connections. on the starter motor. Remove the engine cable connector. Remove the exhaust pipe. lose the fuel taps. Remove the fuel connections. Undo the cable connectors from the engine. Unscrew the engine mountings and lit the engine away. Actions after lifting the engine 4. Clean the engine. ZX. WARNING! Remember the following when wash- ing with a power washer: Be extremely careful when cleaning, to avoid getting water inside en- gine components, When a power washers, Used, the water jot must never be aimed at seals, such as shaft seals, joints with gaskets, rubber hoses or electrical components. 2, Pump the engine oil out if necessary. Instructions for work on electronic fuel injection * Never undo the contro! unit connectors or a cable from any of the sensors when the engine is run- ring. The ignition key must be in posttion “0” and the engine must be stopped. + Never undo a battery cable when the engine is, running, + Always remove the control unit connectors from the control unit before doing any electric welding work, NOTE! The main current must be disconnected when the connectors are disconnected. + Only batteries may be used for starting help. ‘Quick starting units can give excess voltages and damage the electronics, ‘+ Always undo the battery cables during quick charging. (This does not apply to normal tickle charging.) + Ifaconnector is undone, make sure that itis put back correctly and that itis completely free from oll and other contamination which could cause poor contact. "Special tools Special tools 985231 885232 3899672 9986173 99886177 9986178 9990006 99990013 9990176 ea 2 9990185 9990210 e99te01 9991821 9992000 9992013 9992269 9992412 9992564 9992584 992670 885231 Seal washer with junction nipple 9990185 Lifting tool, rocker bridge 885232 Seal washer 9990210 Tool, removinglinstalling valve springs 885316 Tool, fortiting the oyinder head 9991801 Mandel, removal of gudgeon pin 3809090 Puller, polygon hub, vibration damper 9991821 Mandrel, removal of flywheel bearing 3883671 Installation sleeve, upper O-ring, injector 9892000 -—_Extension, mandre! 9998238 3883672 _ Installation sleeve, lower O-ring, injector «9882013 Mandrel, removal and installation of guc- 9986173 Puller, flywheel bearing geonpin 9986177 Puller 9992269 Mandel, instalation of flywheel bearing 9986179 Puller, flywheel bearing 9992412 Pin 9990006 Puller, injector 9992479 Holder, dial gauge 9990013 Side hammer ‘9992564 Mandel, installation of flywheel bearing 9990176 Press tool, removing/installing valve 9992584 = Adapter, hydraulic cylinder 9992671 springs and valve guides 9892670 Hand pump, used with 9996161, of with, 12 9996222Special tools 7 cower ease - c | 9996966 9996998 CE 9992985 9995028 9996159 g906ss 996965 alist 2 {eg 9998248 9998249 9992873 a ‘9993590 9995028 9996159 9996161 9996222, 9996315, 19996395, 9996398, 996441 Hydraulic eyinder Junction nipple Plate, removal of oyinder liners Tuming tool Mandral Pin, for hydraulic oylinder 9996161 Hydraulic eylinder, for changing cylinder liners, timing gear wheels and valve guides Foot pump Spindle, installation of polygon hub and crankshaft gear ‘Spacer, removal of oylinder liners ‘Spacer, removal of cylinder liners. Pressure gauge Cap, leakage test, cooling system 9996662 9998845 9996858 19996965 19996966 ‘9996998, 19998238 9998246 9998248 9998249 Adapter, hydraulic cylinder 9992671 Puller, cylinder liner Pressure gauge Screw clamp Tap, cooling system ‘Adapter, forinstaling polygon hub: Press tool, cylinder liner Pin Mandel, for changing orankshatt seal Tool, removal and instalation of valve springs Adapter. 6 pos. Protective sleeve, unit injector 8‘Special tools 7 19998250 ‘9998263 9998251 9998264 9998258 9998266 OY 9998267 9998261 s9e404 9998511 99esa1 s9geses 9998250 Seal ring, 2 pes. 9998494 = Junction nipple 9998251 ‘Seal plug, cylinder head, 6 pcs. 9998511 Crowbar 9998258 Tool, fixing cylinder headin engine stand 9988531 __Piston ring compressor 9998261 Mandel, for pressing in valve guides 9998583 Gauge, setting unit injector pre-load 9998262 Mandrel, for pressing in valve guides 9998599 Cleaning kit for unit injector. 9998263 Mandrel, for removing valve guides Consists of: 7 856238 Screw Mio 9998264 Lifting yoke, camsheft 9808570 Brush, white 9996265 Seal washer, leakage test SGQH500 Steevs wit holler and Oxing 9898267 Guide pins, timing gear pate oe ON 9998304 Measurement tool ‘Storage box 9008308 Halder Heo 9998335, Guide sleeve, valve stem seal cmeett React 9998939 Pressure gauge 9908547 Stoel bh, narew 9998487 Puller, oil filter 9808818 Stee! brush, coarse 14Special tools 998602 9998619 9998624 ce 9998628 9998629 ‘9998601 ‘9998602 9998619, ‘9998624 9998628 9998629 Fixing tool, oylinder head 9998648 Press tool 198820003 Mandrel, seal ring 198880003 Fixing tool, cylinder head, 2 pcs. Press tool Lifting lug Engine fixture Gauges, for adjusting the double rocker arm Holder kit, used together with 9990185 15Special tools Other special equipment 985648 9986485, 9988599 885633 885648 9812546 9988539 9989876 16 Torque amplifier Countethold, used together with 885633 Cleaning brush Engine stand ‘Compression gauge Dial gauge 998666 9998668 9999683, ‘Seal washers, kit: 9808696, ‘9809697, 9209699 Junction washers, kit: 9809698, ‘9809700, 9809701 Rooker dial gauge Magnetic standIntroduction TAD1250VE, TAD1251VE and TAD1252VE are in-line, direct injected, 6-cylinder industrial diesel engines with ad- justable internal EGR (Exhaust Gas Recirculation). They are equipped with electronically controlled fuel injection, turbochargers, intercoolers, thermostatically con- trolled cooling systems and electronic speed control Identification numbers Ry Be ieeeeey | cusses eae (0G A00DDX oO a SERIAL NO: ‘The sign above shows: 1 Engine designation 2 Serial number 3 Specttication number, engine block (six last figures) The sign above show: 1 Engine designation 2° Serial number 3. Specification number is 7 1 F aS so Q Oo \.02% vouvormwza| The sign shows: (a5 | A Engine designation snores[E3| B Engine power, net, (without fan) venom» ES] C Max. engine speed ws [05] D Software vn CEA) E Data set number 2 pS) F Productrumber ‘The sign above shows: (K) Engine family - () Cylinder volume ara (A) Engine designation Explanation of engine designation: (F1) Velve clearance, inlet | Eg. TADI250VE — (F2) Valve clearance, exhaust T = Turbo () Exhaust control units A Airto air intercooler \ (P) Only constant ppm D — Dieselengine - (E) Part no. decal 12 - Cylinder volume, liter (8) Engine code (in engine family) 5 — Generation a (©) Power f ppm © Version (0) Fue! quantity V_ = Stationary and mobile operation E Emission control (M) Engine speed - (H) Certification approval number (EU) 71. Expansion tank 2. Alternator 3. Control unit, EMS 2 4, Starter motor 5. Airfilter 18 Component location ete o ol » 0% 10 . Radiator package . Dipstick . Oil filer . Fuel fier with fuel pressure monitor . Secondary fuel fter with water monitorGroup 24 Engine Design and funotion Design and function Group 21: Engine Engine TAD1250VE, TAD1251VE are TAD1252VE insine, 6- cylinder, direct injected industrial diesel engines, The engines are equipped with adjustable, internal EGR, electronically controled fuel injection. The oylinder head is made in one piece, with @ unit injector for each cylin der and an overhead camshaft “The unit injectors are centrally located above the pis- tons, and are controlled by the EMS2 control module (Electronic Management System). The control module Is located on the left-hand side of the engine block. 19Group 21 Engine Cylinder head ‘The cylinder head is cast in one piece in cast iron, and covers all the cylinders Itis equipped with an overhead camshaft and is fixed with thirty eight M16 screws, which are evenly spaced round the eyinders. The cylinder head has separate inlet- and exhaust ducts with so-called “cross-flow’ for each cylinder. The valve guides and valve seats are made from al- Joyed cast iron, and all valve guides have oil seals. The valve seats are replaceable and made from steel 20 Design and function Four valve system, and the valves are displaced 12° in relation to the cross section of the cylinder. Valve diameter is 40 mm for both iniet and exhaust valves. Valve seat angle is 45° on the exhaust side and 30° on the induction side, ‘The engine is a ow-emission engine, and no machin- ing may be done which changes the position ofthe in- jeotors in relation to the combustion chamber, such as planing the cylinder head or miling the copper sleeve seats.Group 21 Engine Engine block The engine block is made of alloyed cast iron and is cast in one unit. Itis provided with wet, replaceable cylinder liners. ‘The sides of the engine block are arched around each cylinder, for best stifiness and good sound damping rc stiffening frame is mounted on the lower plane of the engine block, to reduce vibration and thus reduce ‘engine noise. ‘The sump is made of aluminum, and is fixed by 18 spring-loaded screws at the foot of the engine biock. A seal is installed in a groove in the sump. The main bearing caps in the engine block are made from malleable iron, and are machined together with the engine block. In order to prevent incorrect assem: bly, bearing caps 1-3, 5 and 6 are numbered and pro: vided with cast-in bosses on both the bearing cap and : block, The bearing caps are also located by sleeves pressed into the screw holes in the block. Design and function The lube oil pump is fixed to the rearmost main bear- ing cap, no. 7. The thrust bearing is fixed to the cen- tral cap, no. 4. ‘The cylinder head gasket is made from solid steel, in one piece for the entire engine. The gasket has rubber seals vulcanized in, for oll and coolant transfer. The ‘gasket has also a number of convex dimples to pre- vent the cylinder head from sliding on the gasket dur- ing installation, and damaging the rubber rings in the gasket, The cylinder head is lowed down onto the guide pins in the cylinder head, with a small gap against the tim- ing gear plate. After this, the cylinder head is pulled horizontally towards the timing gear plate. When this isin place, itis screwed down to the engine block, and the dimples are flattened out. 21Group 21 Engine Design and function Cylinder ‘The engine block's provided with wet, replaceable cylinder liners. The Coolant space round the cylinder liner is sealed by four seal rings. ‘The upper section is sealed with one ring under the liner collar. This ring is made from EPDM rubber. A thin line of silicone sealer is applied between the liner collars and the liner seats, before the liners are ap- plied, 22 ‘The lower patt of the oylinder liner is sealed by three rubber rings, which are installed in grooves in the en- gine block. The two upper rings are made from EPDM rubber and seal out the coolant. The third ring seals on the oll side, and is made from fluoride rubber (vio let), ‘The contact face of the liner against the steel gasket is convex in shape. Its height above the edge of the lock is 0.15-0.21 mm.Group 21 Engine Design and function Pistons and con rods ‘The pistons are made of aluminum and are cooled by lube oil which is sprayed through piston cooling noz- 2les in the engine block, into a gallery in the piston ‘which leads to a cooling coil. The oils drained via a duct between the piston and the con rod. ‘The gudgeon pin bush is lubricated via an oll groove in the bush, and the piston rings are lubricated in the usual manner. ‘The piston has three rings. At the top, there is a "key stone” type ring. The middle ring is a rectangular cross-section compression ring and the lowest ring is a spring-loaded oll scraper ring. ‘The con rods are made of forged steel. The big end bearing is “split, ie. divided by a plain, un-machined surface. ‘The top of the con rod has machined sides and a trap- ezoidal cross-section, which distributes forcas from the piston to the con rod in an optimum fashion.Group 21 Engine Design and function Crankshaft The crankshatt is drop forged in one piace, and the bearing surlaces are induction hardened for increased strength and reduced risk of cracking. ‘The crankshaft has 7 main bearings. Each big end bearing has a main bearing on each side. The thrust bearing is integrated into the center main bearing. Both the main and big end bearings have steel shells which ate plated with lead/nickel and lined with lead bronze, ‘The crankshaft can be re-ground to five undersize di- mensions. Both at front and rear, the crankshaft is provided with integrated hubs for fixing the timing gear wheels (rear) and vibration damper/pulleys (front). In the front cover, a Teflon seal seals the front end of the crankshaft, The Teflon seal has an outer felt ayer Which serves as a dust shield. The vibration damper housing contains a freely rotat- ing stee! ring which serves as a flywheel, The space between the steel ring and the damper housing is filled with highly viscous silicone oil, Vioration is damped out by the oil, which evens out the pulsating motion of the crankshaft and the even movement ofthe stee! ring. 24 The crankshaft timing gear is located at the rear of the crankshaft. A guide pin in the crankshaft ensures ‘that the whee! can not be wrongly installed. A silicone rubber seal ring is located at the end of the crank- shatt, to seal between the crankshaft and the timing gear wheel. ‘The combined timing gear housing flywheel housing is fixed round the crankshaft timing gear. A Teflon seal seals between the flywheel housing and the Crankshaft timing gear wheel, with an outer felt layer as a dust seal. The crankshaft timing gear wheel has a guide dowel at the rear which fits in the flywheel, so that it can not be wrongly installed. The flywheel screws pass through the flywheel, crankshaft timing gear and the crankshaft. ‘There are a number of grooves millad into the periph- ery of the flywheel, for the injection system speed sensor.Group 21 Engine Design and function Camshaft ‘The camshaft is mounted on top of the oylinder head, ands induction hardened. The bearing journals can be ground down, and have replaceable bearing shells as spare parts. The camshattis supported by seven bearing hous- ings, which are machined together and are numbered 1-7, seen from the front of the engine. The bearing housings and bearing caps are also machined togeth- er. This applies to both production versions and spare part housings. ‘The front bearing is a thrust bearing. ‘The carnshatt has three lobes per cylinder. One for the inlet valves, one for the exhaust valves, and a lobe in the middle for the unit injector. ‘The camshaft drive gearis mounted on the front flange of the camshaft, with an external hydraulic vi- bration damper. Both the camshaft gear and the vibra~ tion damper have holes for a guide dowel mounted in the camshaft, o prevent incorrect assembly, There are teeth on the vibration damper, which generate sig- nals in the camshatt sensor. In front of the front bearing housing, there is a flange with the camshaft marking, the numbers 1-6 and TDC (Top Dead Center). TOC is used for basic setting of the camshaft, and must be between the two matks on the bearing housing when the flywheel is at the O° mark. The number markings are used for adjusting the valves and injectors. A rocker atm bridge is screwed to the camshaft bear- caps, which serves as the bearing journal for the rocker arms with their pressed-in, surface-treated steel bushings. A floating valve yoke transfers the rocker arm movement to the valves. The rocker arm, thas a roller in contact with the camshaft, and a ball socket and adjuster screw in contact with the valve yoke, ‘The valve guides ate made of alloyed castiron, the valve seats are made of steel, and both are replace- able as spare parts. All valve guides are equipped with oil seats 25Group 21 Engine Valve mechanism ‘The engines have a 4-valve system with overhead camshatt, vibration damper (1), a spacer (2) and a gear wheel (8) for the position sensor are screwed to the front of the camshaft, on the outside of the camshaft gear. The vibration damper is a hydraulic type ‘The rocker arms are mounted on the rocker arm shaft, and have pressed in bushes (6). The rocker arm has a roller (6) in contact with the camshaft, and a ball sock- et (8) in contact with the valve yoke (7). Design and function “The vaive yoke is floating, without a guide pin. ‘The exhaust valves have twin valve springs, whereas, the inlet valves have single valve springs.Group 21 Engine Design and function 5 1. Exhaust rocker arm 5 Drain nipple 2. Following arm 6. Lock nut 3. Stop nut 7. Piston 4, Socket Internal EGR The engines are equipped with intemal EGR (Exhaust Gas Recirculation). This means that the double rocker arm has an extra folowing arm that makes the ex- aust vaive lift an extra time. This extra lift allows exhaust gas to flow back into the cylinder at the beginning of each filing phase. The double rocker atm is controlled by the control unt, via oil pressure from the IEGR valve. The IEGA valve is located between the cylinder head and the rocker arm shalt, and supplies the rocker arm shaft with oil. “The double rocker arm consists of two main sections, the exhaust rocker arm (1) on which the following erm (2)is mounted. The control vaive in the rocker arm, which is controlled by the EGR vaive, distributes oll pressure to either the upper or the lower side of the piston, and thus either activates or de-activates the EGR function. 27Group 21 Engine Design and function Inactive Oil pressure presses the piston to its lower position. The following arm follows it, The camshaft lobe now only contacts the roller. Active Oil pressure presses the piston to its upper position. ‘The following arm follows it and the rocker is now acti- vated twice by the camshaft lobe; first via the main lobe and then via the following arm. ‘When the camshaft rotates, the lobe first activates the roller to activate the exhaust valve. Then the lobe ‘comes into contact with the following arm contact sur- face, which gives the exhaust valve a small lift.Group 21 Engine Design and function Gear, camshaft (2276) Gear, compressor (2x28) kor whee! (2-85) Gear, coolant purnp (2=27) rankshatt (2238) Lube ol pump (2=23) ier wines! 2-40) Timing gear The timing gearis mounted on a 10 mm thick steel plate, mounted on the front of the engine block. The steel plate is mounted edge-to-edge against the front of the cylinder head and has a reinforced rubber seal against the cylinder head. The seal between the steel plate and the engine biock is made of silicone rubber. All gear wheols have helical teeth. The idler wheels (3,7, 8, 13) rotate on pressure lubricated bushes. Other lubrication is supplied via a spray nozzle (12). 8. Gear, hysraulc oll pump (2-39) 9. Idler whee (2=71) 40. Gear for bels and fue! pump (2=27) 14. Gear, servo pump (223) 12. Nozzle, gear lubrication 13. Idler wheet, agustable (2=97) Between the engine biock and the cylinder head, there is an adjustable idler wheel (13). The wheel must be adjusted after all work that affects the timing gear. It is important to ensure the correct flank clearance be- tween the upper and lower gear wheels which engage ‘on the adjustable idler wheel. 29Group 22: Lube oil system Design and function Group 22: Lube oil system ‘The engine is pressure lubricated by means of a gear, ‘wheel pump connected to the engine timing geer. The cil flow is controlled by six valves. Two oll galleries are drilled along the engine block. ‘The gallery on the lett side of the engine is the lube oil duct which provides all bearings in the valve mecha- nism with oil ‘The other duct on the right side of the engine is the piston cooling duct, which provides the pistons with oll for lubrication and cooling. ‘The oil cooler is @ plate heat exchanger, located under 2 cast iron cover on the right side of the engine block. 30 ‘The engine is pressure lubricated by means of a gear wheel pump connected to the engine timing gear. The ump forces the oil to the fitter housing, via the oll cooler. The ollis directed from the two full-flow fiers to the by-pass fier and then into the main duct. Ifthe oils cold, the oil that should go to the oil cooler pass- €@s through the by-pass valve, directy to the fier housing. Piston cooling oil is sprayed onto the inside of the pis- tons via nozzles, one for each piston. ‘The camshaft and rocker mechanism is lubricated via ‘duct through the engine block, cylinder head and through the housing, ‘Three oil return holes are cried through the cylinder head and engine block,Group 22: Lube oil system Salaty valve By-pase valve for ol cooler Bypass valve for ol flier ston cooling valve Bypass valvo for by-pas (urbocharger) 8 Pressure ming valve Oil valves 1. Safety valve When the oil pressure drop across the safety valve ‘exceeds 8.6 bar, the valve opens and leads oil back to the oll pan 2. Bypass valve for oll cooler ‘When the pressure drop across the oil cooler is high, such as just after starting when the oil temperature Is, low, the bypass valve opens and oil passes through the oil coolers bypass valve. When the oil tempera- {ure rises and pressure drop across the oi cooler falls (< 8.0 bar), the bypass valve closes and oli passes through the oil cooler before its forced out into the lu- brication system, 3, 5. By-pass valve for oil filterby-pass (turbo- charger) ‘The bypass valve opens (> 2.1 bar) ifthe fiters be- come blocked, which ensures lubrication, but with, contaminated oil Design and function 4, Piston cooling valve ‘The piston cooling valve opens (3.0 bar) when engine ‘speed increases just above idling il then flows through the piston cooling duct to the six piston cooling nozzles. From here, the oil is sprayed up underneath the pistons and into the piston cooling ducts. 6. Pressure reduction valve “The pressure reduction valve controls the oil pressure by opening at high pressure (6.7 bar) and directing sutplus oll back to the oll pan. 3tGroup 23 Fuel system Design and function Group 23 Fuel system 43, 4a ty 1 40 There is an electronically controlled unit injector for each oylinder, which opens at very high pressure. The pressure is generated mechanically by the overhead ‘camshaft, via the rocker arms. The actual injection is controlled electronically by the control unit Fuel is sucked from the fuel tank by the feed pump (1) through the primary filter (3) with water trap (4), through the cooling coil forthe controt unit and up to the double banjo coupling, from where it passes, 10- gether with returned fuel, through the bypass valve (6) to the suction side of the feed pump. ‘The pump forces the fuel through the fitter housing (2) and then through the main filter (7) to the long drilling (8) in the oylinder head, which provides each unit in- jector (9) with fuel via an annular space around each unit injector. The bypass valve (6) maintains a con- stant pressure to the injectors, by opening at 3.5 to 4.5 bar, There are two valves in the feed pump. The pressure limiting vaive (10) allows fuel to flow back to the suc- tion side when pressure becomes too high, such as, when the fuel filter is blocked, The non-retum valve (11) opens when the hand pump (12) is used. If air has got into the system, itis automatically vented via the valve (13) on the rear ofthe cylinder head and the ‘uel return pipe (14) back to the tank. Venting of the system after a filter change is automatically controlled by valves in the fiter housing. The vaives also pre- vent fuel spillage during filter changes, The filters must be installed dry. 82 The hand pump (12) inthe fter housing is used to pump fuel in a stationary engine, if the system has to be completely drained. The non-return valve (15) for the hand pump is located in the filter housing, ‘The water-in-fuel sensor is located in the transparent body (4) under the primaty fier. The sensor indicates, when itis time to manually empty the body by using the drain valve (16). The fuel pressure sensor is located in the fiter hous- ing, where the measurement point for manuel pressure measurement is also located. ZX IMPORTANT! Observe the greatest possible ‘oleanliness when working on the fuel system, Aiways do an engine wash before you start ‘working. Protective plugs must always be in- stalled when connections are removed, to pre~ vent contamination from entering the fuel sys tem. Removed components must be stored in a sealed plastic bag until they are re-installed. IMPORTANT! If the engine is tumed with the starter motor, such as during valve adjustment, the cable in the terminal box for the engine man- ‘agement unit must be removed first, and the ig nition key must be in position “0”, to completely remove the risk of starting the engine inadvert- ently. Check the wiring diagram to ensure that you remove the correct cable. Please refer to “Instructions for operating the starter motor’Group 22: Lube oil system 1. In from tank to primary fter 2. Out from primary filter to fuel feed pump 3. In from fuel feed pump to secondary fer 4, Out from secondary fiter to unit injectors 5. Ventilation pipe Filter housing Both the primary and secondary fuel fitters are in- stalled in the filter housing. ‘The main components in the filter housing are: + Hand pump + Fuel pressure sensor * Valve units (the valve units are located inside the {iter nipples) Design and function The hand pump is only used when the fuel system is to be filled with fuel, such as after maintenance or if the engine has used up all the fuel, “The fuel pressure sensor is located downstream from the secondary fiter, and measures the fuel supply pressure for the unit injectors, Venting is not necessary when a fiter is changed. The fuel system is designed to manage the air in new fi- ters, thanks to the three vaives in the filter housings. Filters should be installed dry 33Group 23 Fuel system SERALWO TR CODE gS Design and function Unit injector, summary ‘Tho unit injectors are centrally located between the four valves and are fixed with a yoke (1). The fuel duct (2) is drilled through the cylinder head and forms aring around each injector. The lower part of the unit injector is insulated from coolant by a copper sleeve (8) which is belied out at its lower end and sealed with an O-ting at the top end ‘The injector has two integrated valves. A fuel valve which controls the start and duration of injection, and avalve which controls the actual needle. Trim code, injector There is also a code on the electrical connector which is used in production. it contains the part number, se- rial number, date, trim code type, manufacturer and trim code. When one or more injectors are changed, the control nit must be programmed with the tim code(s) for the new injector(s). The code consists of 9 digits. Trim code programming is done with VODIA and only needs to be done for the cylinder whose injecior is changed.Group 28 Fuel system Design and function Unit injector working phases 1. Pump piston 2, Fuel gallery 3. Injector nesdle 1, Pump piston 2, Fuel gallery 3. Injector needle The working sequence of the unit injector can be di- vided into four phases: * Filling phase * Spill phase * Injection phase * Pressure reduction phase ‘The pump piston always pumps the same volume of fuel forwards and backwards through the injector. itis only when the fuel valve is closed that pressure is built up and injection takes place. The duration and timing of the current impulse determines the volume of fuel injected and its timing, Filling phase During the filling phase, the pump piston travels to- wards its upper position ‘The highest point on the camshaft lobe is passed and the rocker is on the way down towards the camshaft base circle. ‘The fuel valve is open, since the solenoid valve is not powered. This means that fuel can be sucked from the fuel duct, past the fuel valve, and into the pump cylinder, Filing continues until the pump piston reaches its up- per position. Spill phase ‘The spill phase starts when the camshaft has turned to the position where the cam lobe operates the rocker and starts to press the pump piston down. Fuel flows back through the fuel valve and out into the fuel duct. ‘The spill phase continues for as long as the fuel valve Is open. 35Group 23 Fuel system 4. Pump piston 2.Fuel gallery 3. Injector needle 1. Pump piston 2. Fuel gallery 3. Injector needle 36 Design and function Injection phase ‘The injection phase starts when the solenoid valve is activated by the control unit, and the fuel vaive clos- es. The camshaft lobe continues to press the pump pis- ton down, via the rocker arm. Since the passage through the fuel vaive is closed, pressure quickly builds up. The pressure lifts the injector needle and in- Jection takes piace. ‘The injection phase continues for as long as the fuel valve is closed. Pressure reduction phase ‘The pressure reduction phase starts when the control unit thinks thet the engine has received the amount of fuel it needs, and then cuts the current impulse to the solenoid valve. The fuel valve opens and the fuel flows back out into the fuel duct. The pressure falls rapidly and the injector needle closes, so that injec- ~ tion is stopped.Group 25 Inlet and exhaust system Design and function Group 25 Inlet and exhaust system EYGroup 25 Inlet and exhaust system Design and function 38 Turbo ‘The turbocharger is driven by the exhaust gas which passes through the turbine housing on its way out of the exhaust system. “The stream of exhaust gas makes the turbine whee! in the turbine housing rotate. The compressor whee! is mounted on the same shaft as the turbine wheel. The ‘compressor turbine is located in a housing which is connected between the air fter and the inlet manifold ‘on the engine ‘When the compressor wheel rotates, airis sucked in from the air fit. The air is compressed and is pressed into the cylinders of the engine, after it has first been cooled by its passage through the intercoo!- er.Group 26 Cooling system Design and function Group 26 Cooling system ‘Thermostat Radiator When the thermostat is open ‘The cootant system is a sealed fresh water system, with a piston thermostat which regulates the water temperature, Coolant is pumped directly into the engine by the Cootant pump, from the pump housing on the right side of the engine block. The majority of the coolant passes between the oll cooler plates, whereas partis forced into the lower cooting housings surrounding the cylinder tiners. After the ofl cooler, the coolant is distributed to the upper oylinder cooling housings via calibrated holes, and to the cylinder head. The cylinder head also re~ ceives returned coolant from the oylinder cooling housings. Circulation Coolant fter When the coolant is cold, the thermostat is closed and coolant passes directly down through the thermostat housing to the coolant purnp and back into the engine again. ‘When the cootant is hot, the coolant passes to the front outlet on the thermostat housing, and to the up- per radiator inlet. Coolant is forced down through the duct at the same time as itis cooled down, and then it is returned to the lower inlet of the pump. The coolant pump then forces the coolant back into the engine again. 39Group 26 Cooling system 40 Design and function Intercooler ‘The intercooler is located beside the radiator an cooled. “The purpose of the intercooler isto cool the induction air, which means that the volume ofthe air falls and a larger volume of air can be pressed into the combt tion chambers. This gives better combustion of the fuel, and better fuel utilization, Intercooling the engine gives a power increase of about 10%. Engine torque increases and fuel con- sumption falls. A diesel engine with turbocharger and intercooler has better specific efficiency than any other internal com- ‘ustion engine. airFault tracing Group 30 Electrical system EMS 2, Engine Management System EMS 2's the electronic engine management system ‘The system consists of 6 unit injectors, a number of sensors that supply the control module with measure- ments, a socket for diagnosis (VODIA) and functional checks. The control unit - ‘The central component in the injection system is the control unit. This receives continual information from a number of sensors on the engine, so that it can de: - cide the fuel volume and injection timing. Control sig nals to the unit injector fuel vaives via electric cables. The control unit stores any faults and non-conform- ‘ance which occurs in the system, Intermittent faults are also stored so that they can be traced at a later date. ‘The control unitis designed for instalation directly on the engine block, with four M8 screws. The control unit has drain holes by the comers of the long sides, ‘0 prevent water from collecting inside the unit. The holes are also needed to obtain correct measurement Values from the intemal atmospheric pressure sensor, and must therefore never be covered over. ‘A coolant loop is fixed to the outside of the control unit housing with six M6 screws. The control unit has two, individually coded 62-pin connectors. The connectors are locked with a catch ~ ‘onthe connector. ‘The control unit is also equipped with vibration damp- et, to resist engine vibration. The vibration dampers also insulate the unit from the engine block. aFault tracing Electrical component diagram 41. Coolant level sensor 1 2 Peston sensor, camshaft 12) Outlet for diagnaste oo), 6-in 3. Unit injector (one for each eytinder) 13. Bipin connector (Data bis) 4 Extra Stop 14. Water in fuel, fue fter 5. Chargo prossure and temporature sonsor 18. Control unit & Main olay 18. il tomperature and level sensor 7, Fuel pressure alarm 17. Crankease pressure 8. Coolant temperature sensor 18. Oil pressure sensor 9, Starter motor 18, Fuso 10, 40, Starter motor relay 20. Alternator