Workshop Manual

Technical Data

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2(0)

TMD102A, TAMD102A/D TMD122A, TAMD122A/C/DIP-A/P-B

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Technical data
Marine engines TMD102A • TAMD102A1D TMD122A· TAMD122A1CID TAMD122P-A/P-B

Contents
Safety information......................................................... Introduction Important General information About the Workshop Spare parts Certified engines Technical data........ References to Service Bulletins Manual..............................

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34

Safety Information
Introduction
The Workshop Manual contains technical data, descriptions, and repair instructions forthe designated Volvo Penta products or product versions. Make sure that the correct workshop literature is used. Read the following safety information and the Generallnformation and Repair Instructions in the Workshop Manual carefully before starting service work. A careless movement or dropped tool while working in the vicinity of an engine that is running, can in the worst case lead to injury. Observe caution on hot surfaces (exhaust pipe, turbo, charge air pipe, starter element etc.) and hot fluids in the lines and hoses of an engine that is running, or has just been started. Refit all guards dismantled during service work before starting the engine. Make sure that the warning or information decals on the product are always clearly visible. Replace labels that have been damaged or painted over. Never start the engine unless the air filter is fitted. The rotating compressor wheel in the turbo can cause severe injury. Foreign objects in the inlet pipe can also damage the machine.

Important
The following special warning symbols are used in the Workshop Manual and on the product.

& &

Never use starter spray or the like. Explosion risk in the inlet pipe. Risk of personal injury. Avoid opening the filler cap for coolant when the engine is hot. Steam or hot coolant can spray out. Open the filler cap slowly and release the overpressure in the cooling system. Observe extreme caution if the cock or plug, or coolant pipe, must be dismantled on a hot engine. Steam or hot coolant can flow out unexpectedly. Hot oil can cause burn injuries. Avoid skin contact with hot oil. Make sure that the oil system is not pressurised before working on it. Never start, or run the engine with the oil filler cap removed in view of the risk of ejecting oil. Stop the engine and close the bottom valve before working on the cooling system. Only start the engine in a well-ventilated area. Exhaust fumes and crankcase gases should be led out of the engine compartment or workshop when working in closed environments. Always use protective glasses for work where there is a risk of splintering, sparks, or splashing of acid or other chemicals. The eyes are extremely sensitive, and an injury can cause blindness!

&.

WARNING! Warns of risk of bodily injury, serious damage to product or property, or that a serious malfunction can occur if the instructions are not followed. IMPORTANT! Used to attract attention to things that can cause damage or malfunction product or property.

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to

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NOTE! Used to attract attention to important information, to simplify work procedures or handling. The following list provides an overview of the risks and cautionary procedures that should always be observed.

&

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Prevent the engine from being started by disconnecting the power with the main switch (switches) and locking it (them) in disconnected mode before the service work is begun, Attach a warning sign in the cabin. As a rule, all service work should be performed on an idle engine. Some work, e.q. certain adjustments, require the engine to be running. Approaching an engine that is running is a safety risk. Remember that loose clothes or long hair can fasten in rotating parts and cause severe injury,

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Genera/Information

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Avoid skin contact with oil! Prolonged or frequent skin contact with oil can degrease the skin, resulting in irritation, drying out, eczema, and other skin complaints. Used oil is more dangerous than new oil from the health care point of view. Use protective gloves and avoid oil drenched clothes and rags. Wash your hands regularly, especially before meals. Use special hand cream to counteract drying out, and to simplify cleaning the skin.

&

Batteries must never be exposed to naked flames or electrical sparks. Never smoke in the vicinity of batteries. Hydrogen develops when batteries are charged, which in combination with air forms an explosive gas. This gas is highly inflammable and very explosive. One spark from connecting the batteries incorrectly is sufficient to cause the battery to explode and cause injury. Do not touch the connection when starting (risk of spark) and do not lean over the batteries.

s:

The majority of chemicals intended for the product (e.g. engine and timing gear oils, glycol, petrol and diesel oil) or chemicals for workshop use (e.g. degreasing agent, enamels and solvents) are hazardous to health. Read the instruction on the pack carefully. Always follow the given safety instructions (e.g. the use of breathing protection, protective glasses, or gloves, etc.) Make sure that other personnel are not exposed to hazardous substances, e.g. by inhaling the air. Make sure there is adequate ventilation. Handle consumed and surplus chemicals in the prescribed manner.

Never confuse the plus and minus terminals when fitting the batteries. This can cause serious damage to the electrical equipment. Check the wiring diagram.

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Always use protective glasses when charging and handling batteries. The battery electrolyte contains strongly corrosive sulphuric acid. On skin contact, wash with soap and plenty of water. If battery acid gets into the eyes, rinse immediately with water, and contact a doctor without delay.

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Observe extreme caution when tracing fuel leaks in fuel systems and when testing fuel nozzles. Wear protective glasses. The jet from a fuel nozzle has a very high pressure and penetrating force. The fuel can penetrate deeply into bodily tissue and cause serious injury. Risk of blood poisoning.

in.

Stop the engine and switch oft the power with the main switch (switches) before working on the electrical system.

.&.

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All fuels, in Similarity with chemicals, are inflammable. Make sure that naked flames, or sparks, cannot lead to ignition. Petrol, certain thinners, and hydrogen from batteries, are extremely inflammable and explosive when mixed with air. Smoking is prohibited! Ventilate well and take the necessary precautions before conducting welding or grinding work in the immediate vicinity. Always have a fire extinguisher handy in the workshop.

Adjustment of the clutch should be conducted when the engine is idle.

&

.&.

Make sure that rags drenched in oil and petrol, including old fuel and lubricant filters, are stored safety. Oil drenched rags can in certain conditions self-ignite. Old fuel and oil filters are environmentally hazardous waste, and together with spent lubricant, contaminated fuel, paint residue, solvent, degreasing agent and suds, should be handed in to a waste handling unit for destruction.

Use the lifting hooks mounted on the engine/reversing gear when lifting the drive unit. Always check that the lifting equipment is in good condition and has the correct capacity for the lift (weight of engine plus reversing gear and extra equipment where appropriate). For safe handling, and to avoid damaging the components mounted on top of the engine, the engine should always be lifted with a lifting bar adjusted to the engine. All chains or wires should run in parallel with each other and as perpendicular to the top of the engine as possible. Special lifting equipment may be required to ensure the right balance and safe handling if other equipment connected to the engine alters its centre of gravity. Never carry out work on an engine only supported by lifting equipment.

General Information

.&.

Never work alone when heavy components are to be dismantled, even when safe lifting (e.g. lockable block and tackle) equipment is used. In most cases, two persons are required even when lifting equipment is used: one to handle the equipment and one to make sure that components are not damaged. When working onboard a boat always make sure in advance that there is sufficient space to allow dismantling in situ, without the risk of personal injury or damage to materials.

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When cleaning with high-pressure wash, observe the following: Never point the jet of water at seals, rubber hoses, or electrical components. Never use the high-pressure function when washing the engine.

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NOTE! Pressure pipes must not bent, turned, or exposed to other strain. Replace damaged pressure pipes.

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WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimise the risks of explosion and fire. The engine must not be run in environments surrounded by explosive media.

Always use Volvo Penta recommended fuel. See the instruction handbook. The use of inferior quality fuel can damage the engine. The use of inferior fuel in a diesel engine can cause the control rod to jam and the engine to overspeed, with the risk of personal injury or damage to the machine. Inferior fuel can also lead to higher maintenance costs.

General Information
About the Workshop Manual
This Workshop Manual contains technical information, descriptions, and repair instructions for the standard versions of the engine units TMD1 02A, TAMD1 02A1D, TMD122A, TAMD122A1C/D, TAMD122P-AiP-B. The Workshop Manual may show work procedures conducted on an optional engine according to the above list. This implies that the illustrations and diagrams that present certain parts, may in some cases not agree with the other engines. The repair methods remain essentially the same, however. Wherever there is a difference, this is clearly indicated and important differences are reported separately. The engine designation and number are given on the number plate. The motor designation and number should always be given during all correspondence. The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel. It is therefore assumed that persons using this manual have a basic knowledge of marine drive systems, and can perform the relevant work of a mechanical and electrical nature. Volvo Penta continuously develops its products, and therefore reserves the right to introduce modifications. All the information in this manual is based on product data available prior to publication. Any amendments or service methods of essential importance that have been introduced for the product after this date are confirmed in the form of Service Bulletins.

Certificated engines
For service and repair on an engine certificated for any area where exhaust emissions are regulated by law, the following is important: Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine. This places special requirements and service as follows: • • • for maintenance

The maintenance and service intervals recommended by Volvo Penta must be observed. Only genuine Volvo Penta replacement be used. parts may

The service of injection pumps and injectors or pump settings must always be carried out by an authorized Volvo Penta workshop. The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta. No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken. Seals may only be broken by authorized personnel.

• •

Otherwise the general instructions contained in the Instruction Book concerning operation, service and maintenance must be followed.

Spare parts
Spare parts for the electrical and fuel systems are subject to different national safety requirements, e.g. U.S. Coast Guard Safety Regulations. Volvo Penta Genuine Spare Parts comply with these requirements. All types of damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be regulated by the warranty undertakings of Volvo Penta.

IMPORTANT! Late or inadequate maintenance/ service or the use of spare parts other than Volvo Penta original spare parts will invalidate AS Volvo Penta's responsibility for the engine specification being in accordance with the certificated variant. Volvo Penta accepts no responsibility or liability for any damage or costs arising due to the above.

Technical data
General
102-series Number of cylinders Bore Stroke Swept volume, total Compression ratio, TMD102A, TAMD102D TAMD102A TMD122A, TAMD122NC TAMD122D TAMD122P-NB Compression pressure, at starter speed 230 rpm, TMD102A TAMD102ND TMD122A,TAMD122NC, TAMD122P-NB TAMD122D Firing order (cyl. No.6 nearest the flywheel) Direction of rotation (see from front) Output High idling Low idling Weight, engine with heat exchanger, without reverse gear, approx., TMD102A TAMD102A TAMD102D TMD122A TAMD122NC/D TAMD122P-NB . . .. .. .. . . .. .. 122-series 6 130.175 mm (5.125") 150 mm (5.91 ") 11 .97litres (730.4 in3)

6
120.65 mm (4.75") 140 mm (5.51") 9.6 litres (585.7 in3) 14.3:1 15.0:1

14.2:1 14.0:1 15.1 :1

. . . . . .. . .. ..

2.4 MPa (348 lb/in") 2.6 MPa (377 lb/in") 2.5 MPa (363 lb/in") 2.4 MPa (348 Ib/W) 1-5-3-6-2-4 1-5-3-6-2-4 Clockwise Clockwise See current Sales Guide See current Sales Guide See current settings in SB file (Group 24-1 No.9) See current settings in SB file (Group 24-1 No.9)

.. . .. .. .. ..

1140 kg (2511 Ibs) 1190 kg (2621 Ibs) 1190kg(2621Ibs) 1320 kg (2907 Ibs) 1360 kg (2996 Ibs) 1310 kg (2885 Ibs)

Engine body
Cylinder liners
Type Bore (no oversize) Height, total Liner collar height over block plane (see Fig.) Liner collar height (at mating surface of gasket) Number of rubber rings, top liner seal Number of rubber rings, bottom liner seal 6 .. .. . .. .. .. .. Wet replaceable 120.65 mm (4.75") 287 mm (11 .3") 0.15-{).20 mm (0.006-{).008") 11.52 mm (0.454") 1 Wet replaceable 130.175 mm (5.125") 313.5 mm (12.34") 0.47-{).52 mm (0.019-0.020") 10.52 mm (0.414") 1

Technical data

Pistons
102-series Material Number of ring grooves " "." .."""".,, Height of piston over cylinder liner plane Piston clearance Front marking " . .. .. . .. Aluminium with cast iron ring 3 max. 0.55 mm (0.022") 0.15-0.18 mm (0.0059-0.0071 ") Arrow pointing forward 122-series Aluminium with cast iron ring 3 max. 0.55 mm (0.022") 0.12-0.15 mm (0.0047-{J.0059") Arrow painting forward

"

Combustion chamber (piston crown)

TMD102A Diameter (A) Depth (8)

. .

76 mm (2.992") 23.15 mm (0.911 ")

TAMD102AID Diameter (A) Depth (B)

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.

76 mm (2.992") 22 mm (0.866")

T{A)MD122A1C Diameter (A) Depth (B) "

.. .

79 mm (3.110") 27.2 mm (1.071 ")

TAMD122D Diameter (A) Depth (B)

. ..

83 mm (3.268") 25.8 mm (1.016")

TAMDl22P-A Diameter (A) Depth (B)

. .

80 mm (3.15") 25.4 mm (1")

TAMDl22P-B Diameter (A) Depth (B)

.. ..

80 mm (3.15") 24.4 mm (0.961

01

Technical data

Piston rings·

102-series TAMD122P-A, TAMD122P-8 . . . . . . . .

122-series

Compression rings, number upper compression ring, height (A) marking" 2nd compression ring, height (8) marking** Oil ring, number height (C) marking*' Other engines Compression rings, number.............................................................

2 pes 4.5 mm (0.177") TOPC2 3.137-3.15 mm (0.1235-Q.124") TOPCF 1 pes 4.724-4.737 mm (0.1860-0.1865") PC

2 pes 1 pes

2 pes
1 pes

Oil ring, number.... ......... ... .... ...... ..... .. .. ... .... ............. .... ..

Piston ring gap with diameter 120.65 mm (4.750"), 102-series and 130.17 mm (5.125"), 122-series, upper compression ring, T(A)MD102, TMD122A, TAMD122A1C/D ..... TAMD122P-A TAMD122P-B .. .

0.40-0.60 mm (0.0157-0.0236")

0.40-0.65 mm (0.0157-0.0256") 0.55-0.70 mm (0.0217-0.0276") 0.40-0.60 mm (0.0157- 0.0236") 0.35-0.55 mm (0.0138-0.0217") 0.70-0.90 mm (0.027fHl.0354") 0.40-0.80 mm (0.0157-0.0315") 0.43-0.78 mm (0.0169-0.0307")

2ndcompression ring, T(A)MD102, TMD122A. TAMD122A1C/D ..... TAMD122P-AiB oil ring, T(A)MD102, ..

0.35-0.55 mm (0.0138-0.0217")

TMD122A, TAMD122A1C/D ..... .

0.35-0.65 mm (0.0138-0.0256")

TAMD122P-AiB
• TAMD102A and TAMD122D have upper compression rings of Keystone type . •• TAMD122P-AlB: All rings should be fitted with markings upwards.

Technical data

Gudgeon pins
102-series TMD102, TAMD102 Clearance, gudgeon pin - connecting rod bushing . 0.018-0.026 mm (0.0007-0.001 0") 0-0.016 mm (0-0.0006") 0.005-0.021 mm (0.0002--0.0008") 51.998-52.004 mm (2.047-2.047") 52.000-52.008 mm (2.047-1.969") 122-series

gudgeon pin - gudgeon pin hole in piston, TMD102 TAMD102 Gudgeon pin diameter std Gudgeon pin hole diameter in piston

.. . .. .

TMD122A, TAMD122A1C/D
Clearance,

gUdgeon pin - connecting

rod bushing

gudgeon pin - gudgeon pin hole in piston ......... Gudgeon pin diameter std GudgMn pin nolo crametor in piston .. ..

0.022-0.034 mm (0.0009-0.0013") 0.007-0.023 mm (0.0003-0.0009") 54.992-55.000 mm (2.1650-2.1654") 55.007-55.015 mm (2.1656-2.1659")

TAMD122P-A/B Clearance, gudgeon pin - connecting rod bushing . . . . 0.022-0.032 mm (0.0087-0.0013") 0.005-0.019 mm (0.0002-0.0007") 54.994-55.000 mm (2.047-2.047") 55.005-55.013 mm (2.1655-2.1659")

gudgeon pin - gudgeon pin hole in piston Gudgeon pin diameter std Gudgeon pin hole diameter in piston

Cylinder heads
Type Height Sealing groove depth . . .. One per cylinder 115 mm (4.528") One per cylinder 125 mm (4.921") 0.20 mm (0.0079")

Cylinder head screws

Number per cylinder head Dimension of threads.......... Length..... 4 3/4"-10 UNC 200 mm (7.874") 8 9/16"-12 UNC 190 mm (7.480") 9

Technical data

Cylinder block

102-series Height, upper block surface - camshaft centre (A) Height, upper block surface - camshaft centre (8) 438.8 mm (17.276") 120 mm (4.724")

122-series 463.8 mm (18.26") 120 mm (4.724")

Crankshaft
Crankshaft, axial clearance

0.06-0.27 mm
(O.0024-D.0106")· 0.07-D.14 mm (O.0028-D.0055")

Main bearing, radial clearance....

• Max. 0.40 mm (0.0157"").

0.06-0.32 mm (0.0024-D.0126")* 0.07-D.14 mm (0.0028-D.0055")

Main bearing journals

10

Technical data
102-series Diameter (0) for processing standard undersize 0.25 mm (0.010") 0.50 mm (0.020
00 ) .

122-series 107.915-107.937 (4.2486-4.2495") 107.661-107.683 (4.2386-4.2395") 107.407-107.429 (4.2286-4.2295") 107.153-107.175 (4.2186-4.2195") mm mm mm mm

. .

0.75 mm (0.030") 1) 1.00 mm (0.040") 1) * 1.25 mm (0.050") 1) *

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.
.

99.978-100.00mm (3.9361-3.9370") 99.724-99.746 mm (3.9261-3.9270") 99.470-99.492 mm (3.9161-3.9170) 99.216-99.238 mm (3.9061-3.9070 98.962-98.984 mm (3.8961-3.8970") 98.708-98.730 mm (3.8861-3.8870")
00 )

Width axial bearing journal (A) standard

45.975-46.025 mm (1.8100-1.8120") 46.175-46.225 mm (1.8179-1.8199") 46.375-46.425 mm (1.8258-1.8278") 46.575-46.625 (1.8337-1.8356 3.75-4.0 mm (0.1476-0.1575 mm
00 )

45.975-46.025 mm (1.8100-1.8120") 46.175-46.225 mm (1.8179-1.8199") 46.375-46.425 mm (1.8258-1.8278")

oversize 0.2 mm (0.0079"), (axial bearing 0.1 mm (0.0039") os.) .. 0.4 mm (0.0157"), (axial bearing 0.2 mm (0.0079") os.) .. 0.6 mm (0.0236 (axial bearing 0.3 mm (0.0118") os.)* .
00 ),

Hole fillet radius (R)

1) Comment. The crankshaft must be re-rutro-carburtzac if grinding takes place to more than two undersizes . • Not on 122 series.

00 )

4.35-4.60 mm (0.1712~.1811 ")

Thrust washers (axial bearings)

Width (B), standard oversize, 0.1 mm (0_0039") oversize, 0.2 mm (0.0079") oversize, 0.3 mm (0.0118") _... 2.312-2.362 mm (0.091 ~.0930") 2.412-2.462 mm (0.095~.0969") 2.512-2.562 mm (0.0989-0.1009") 2.612-2.662 mm (0.1028-0.1048") 3.140-3.210 mm (0.1236-0.1264") 3.240-3.310 mm (0.1276-0.1303") 3.340-3.410 mm (0.1315-0.1342")

Main bearing shells

Thickness (D), standard oversize 0.25 0.50 0.75 1.00 1.25 mm mm mm mm mm (0.010") (0.020") (0.030") (0.040") (0.050") . .. .. .. . . .. 2.447 2.574 2.701 2.828 2.955 3.082 mm mm mm mm mm mm (0.0963") (0.1013") (0.1063") (0.1113") (0.1163") (0.1213") 2.510 2.637 2.764 2.891 mm mm mm mm (0.0988") (0.1038 (0.1088") (0.1138")
00 )

Diameter, bearing position in block, std

104.978 (+0.025) mm (4.1332" (+0.0010"»

113.040 (+0.025) mm (4.4504" (+0.0010"» 11

Technical data

Big end bearing journals

102-series Diameter (0) for processing standard undersize 0.25 mm (0.010") 0.50 mm (0.020") .. 0.75 mm (0.030")') 1.00 mm (0.040")') 1.25 mm (0.050")1) Width axial bearing joumal (A) Hole fillet radius (R)
') Comment The crankshaft must be rs-nltro-carburizsd if grinding takes place to more than two undersizes.

122-series 92.028-92.043 mm (3.6231-3.6237") 91.778-91.793 mm (3.6133-3.6139") 91 .528-91 .543 mm (3.6035-3.6040") 91.278-91.293 mm (3.5936-3.5942") 91.028-91.043 mm (3.5838-3.5844") 90.778-90.793 mm (3.5739-3.5745") 54.900-55.000 mm (2.161-2.165") 4.350-4.600 mm (0.171-0.181")

86.003-86.025 mm (3.3859-3.3868") 85.753-85.775 mm (3.3761-3.3770") 85.503-85.525 mm (3.3663-3.3671 ") 85.352-85.275 mm (3.3603-3.3573") 85.003-85.025 mm (3.3466--3.3474") 84.753-84.775 mm (3.3367-3.3376") 53.900-54.000 mm (2.122-2.126") 3.750-4.000 mm (0.14B-D.1S7")

Big end bearing shells

Thickness (C), standard undersize 0.25 0.50 0.75 1.00 1.25 12 . .. .. .. .. . 2.413 2.540 2.667 2.794 2.921 3.048 mm mm mm mm mm mm (0.0950") (0.1000") (0.1050") (0.1100") (0.1150") (0.1200") 2.357mm (0.0928") 2.482 mm (0.0978") 2.607mm (0.1026") 2.732 mm (0.1076") 2.857 mm (0.1125") 2.982 mm (0.1174")

mm mm mm mm mm

(0.010") (0.020") (0.030") (0.040") (0.050")

Technical data

Connecting

rods
102-series 122-series 275 mm (10.827") 1 to 6 Forwards 55.022-55.026 mm (2.1662-2.1664") 0.15-0.35 mm (0.006--0.014") 0.08-0.12 mm (0.003-0.005") . .. .. 260 mm (10.237") 1 to 6 Forwards 52.022-52.026 mm (2.0481-2.0483") 0.15-0.35 mm (0.006--0.014") 0.08--0.12 mm (0.003-0.005")

Length, centre-centre (E) Marking: Connecting rods and bearing cap "FRONT" on shaft must face Connecting rod bushing int. diameter (G) Axial clearance, connecting rod - crankshaft

.
.

Big end bearing, radial clearance

..

Flywheel
Ring gear on flywheel............................................ 156 teeth 156 teeth

Camshaft
front bearing journal, min 2nd bearing journal, min 3rdbearing journal, min 4thbearing journal, min 5th bearing journal, min 6th bearing journal, min ]lh bearing journal, min Axial clearance Radial clearance Diameter, .. .. .. . .. .. . . .. 68.94 mm (2.714") 66.56 mm (2.620") 64.17 mm (2.526") 63.39 mm (2.496") 60.99 mm (2.401 ") 60.21 mm (2.370") 56.25 mm (2.215") 0.05-0.18 mm (0002--0.007") 0.03-0.08 mm (0.001--0.003") 68.94 mm (2.714") 66.56 mm (2.620") 64.17 mm (2.526") 63.39 mm (2.496") 60.99 mm (2.401 ") 60.21 mm (2.370") 56.25 mm (2.215") 0.05-0.18 mm (0.002--0.007") 0.03-0.08 mm (0.001--0.003")

Checking of camshaft setting (cold engine and valve clearance = 0), The inlet valve for cylinder No.1 should at flywheel position 10° after T.D.C. have opened Max. valve lift: inlet outlet Min. valve lift: inlet... outlet Lift height, camshaft (new), inlet outlet. Lift height, camshaft, inlet outlet min., . .

. .. . . . . .

4.5 ±0.3 mm (0.177 ±0.012") 13.3 mm (0.524") 14.3 mm (0.0563") 13.0 mm (0.512") 14.0 mm (0.551") 8.6 mm (0.339") 9.2 mm (0.362") 8.4 mm (0.331 ") 9.0 mm (0.354")

4.5 ±0.3 mm (0.177 ±0.012") 13.3 mm (0.524") 14.2 mm (0.559") 13.0 mm (0.512") 13.9 mm (0.547") 8.6 mm (0.339") 9.2 mm (0.362") 8.4 mm (0.331 ") 9.0 mm (0.354") 13

Technical data

Camshaft bearings
102-series Diameter for processing, front bearing 2ndbearing 3rdbearing 4ti1bearing 5ti1 bearing 6th bearing ,. . .. . . . . 69.05Q-69.075 mm (2.7185-2.7195") 66.675-66.700 mm (2.6250-2.6260") 64.287~.312 mm (2.5310-2.5320") 63.50Q-63.525 mm (2.5000-2.5010") 61.112-61.137 mm (2.4060-2.4070") 60.325-60.350 mm (2.3750-2.3760") 56.350-56.375 mm (2.2150-2.2195") 122-series 69.050-69.075 mm (2.7185-2.7195") 66.675-66.700 mm (2.6250-2.6260") 64.287--64.312 mm (2.5310-2.5320") 63.50Q-63.525 mm (2.5000-2.5010") 61.112--61.137 mm (2.4060-2.4070") 60.325-60.350 mm (2.3750-2.3760") 56.350-56.375 mm (2.2150-2.2195")

rt' bearing

Valves
Valve disc diameter, Inlet (TAMD122P) Outlet (TAMD122P) Inlet (other engines) Outlet (other engines) Stem diameter, Inlet, min. (TAMD122P) Outlet, min. (TAMD122P) Inlet, min. (other engines) Outlet, min. (other engines) Marking (TAMD122P) .. .. .. .. . .. . . . 55 mm (2.17") 55 mm (2.17") 54 mm (2.13") 50 mm (1.97") 10.991 mm (0.433") 10.991 mm (0.433") 10.91 mm (0.430") 10.90 mm (0.429") green colour spot on valve disc

50 mm (1.97") 46 mm (1.81")

10.91 mm (0.430") 10.90 mm (0.429")

Inlet

1.9mm

29.5°

_~
Valve seat angle, Inlet Outlet Seat angle in cylinder head, Inlet Outlet............................................................... 14

tr
.'

Mi.". ~/(fMi~..
ao"
44.5°

Outlet

45° as

n . _'

~' ,
299

29.5° 44.5
0

29.5° 44.so

30°

45

30° 45°

Technical data

Inlet

• Outlet

102-series

122-series

102-series Valve clearance

Inlet (TAMD102,

122-series 0.50 0.80 0.40 0.70

(cold engine or warm after use)

TAMD122P) .

Outlet (TAMD102, TAMD122P) Inlet (other engines)

. .

Outlet (other engines)

0.50 mm (0.02") 0.80 mm (0.032") DAD mm (0.016") 0.70 mm (0.028")

mm (0.02") mm (0.032") mm (0.016") mm (0.028")

Valve seats

Outer diameter (A) standard Inlet Outlet ,.. " Oversize Inlet " .., ,,, Outlet ., ,,, ,, Height (B) Inlet " " Outlet " "

. ,.. ,.. " .. .. . . ,.

54 mm (2.126") 49 mm (1.929") 54.2 49.2

59.1 56.6

mm mm

(2.327") (2.228")

mm mm

(2.134") (1.937")

59.3 mm (2.335") 56.8 mm (2.236") 6.8 9.5

6.8 mm (0.0268") 9.5 mm (0.374")

mm mm

(0.268") (0.374")

Recess for valve seats

Diameter (C), standard, Inlet "., " Outlet ,

"

, "

"

. " ..

54.000-54.030 mm (2.1260-2.1272") 49.000-49.025 mm (1.9291-1.9301 ") 54.200-54.230 mm (2.1339-2.1350") 49.200--49.225 mm (1.9370-1.9380")

59.000-59.030 (2.3228-2.3240") 56.500-56.530 (2.2244-2.2256")

mm mm

Diameter (C) oversize, Inlet "."" .. "" Outlet "

" "

. " ..

59.200-59.230 mm (2.3307-2.3319") 56.700-56.730 mm (2.2323--2.2335")

15

Technical data

102-series Depth (D), Inlet Outlet Bottom radius (R), Inlet Outlet Measurement between valve disc and cylinder head surface, Inlet Outlet . . 9.8-9.9 mm (0.386-0.390") 11.8-11.9 mm (0.465-0.469") 0.5-0.8 mm (0.020-0.031 0.5-0.8 mm (0.020-0.031
10 )

122-series 8.8-8.9mm (0.347-0.350") 10.8-10.9 mm (0.425-0.429") 0.5-0.8 mm (0.020-0.031 ") 0.5-0.8 mm (0.020-0.031 ")

. .

10

. .

1.2-1.7 mm (0.05-0.07") 1.2-1.7 mm (0.05-0.07")

0.2-1.2 mm (0.008-0.050") 0.2-1.2 mm (0.008-0.050")

Valve guides
Length, guide for inlet valve (TAMD 102) inlet valve (other engines) outlet valve Inner diameter, Inlet, outlet (spare part) (TAMD1 02) Inlet, outlet (spare part) (other engines) Height over cylinder head spring plane (outer spring), Inlet Outlet .. .. . . .. 72 mm (2.83") 82 mm (3.23") 66 mm (2.60") 11.022-11.049 mm (0.4339-Q.4350") 11.032-11.059 mm (0.4343-(].4354") 82 mm (3.23") 66 mm (2.60")

11.032-11.059 mm (0.4343-{) .4354")

.. ..

17 mm (O.67") 21 mm (0.83")

19.7 mm (0.78") 19.7 mm (0.78")

Valve springs
Outer valve springs Length without load, min. With load 300-390 N (67.5-87.8 Ibf) for 102 series and 342-383 N (76.9-82.2 Ibt) for 122 series ........ 61 mm (2.40") 49.6 mm (1.95") 73.1 mm (2.88") 54 mm (2.13")

Inner valve springs Length without load, min. With load 80-170 N (18.0-38.3 Ibf) for 102 series and 137-157 N (30.8-35.3 Ibf) for 122 series ........ 16 53 mm (2.09") 42.6 mm (1.68") 67.1 mm (2.64") 48 mm (1.89")

Technical data

Timing gears
Note that TAM01 020 and TAM0122P-AiB are fitted with nitro-carburized See also information in Workshop Manual, Engine body. timing gears.

102-series Gear flank clearance Radial clearance for intermediate gear Axial clearance for intermediate gear Axial journal for intermediate gear, diameter Bushing for intermediate gear, diameter max Number of teeth, crankshaftgear intermediate gear camshaft gear gear of injection pump gear for fresh water pump and alternator intermediate gear, oil pump gear, oil pump gear for seawater pump .. .. .. .. 0.03--0.17 mm (0.001~.007") 0.03-0.09 mm (0.001~.004") 0.05~.15 mm (0.002~.006") 92.084-92.106 mm (3.6253-3.6262") 92.166 mm (3.6286") 30 53 60 60 17 48 21 33 teeth teeth teeth teeth teeth teeth teeth teeth

122-series 0.03--0.17 mm (0.001--0.007") 0.03-0.09 mm (0.001~.004") 0.0~.15 mm (0.002-0.006") 92.084-92.106 mm (3.6253-3.6262") 92.166 mm (3.6286") 30 53 60 60 17 48 21 33 teeth teeth teeth teeth teeth teeth teeth teeth

.. . . ' .. . .. .. .

45

1. 2. 3. 4. 5. 6. 7. 8.

Gear for seawater pump' Camshaft gear" Intermediate gear Gear for fresh water pump and alternator Gear for injection pump' Crankshaft gear Intermediate gear for oil pump Gear for oil pump
Nitro-carburized timing gears, TAMD102D,
TAMD122p·AfP-B

.J

17

Technical data

Lubrication system

122-series

102-series A. Reducing valve Marking Opening pressure . . yellow (TMD1 02: blue) yellow: 690 kPa (100.08Ibflin2) blue: 480 kPa (69.62 Ibf/in2)

122-series

yellow 690 kPa (100.08Ibf/in2)

B. Overflow valve for oil filters Opening pressure . Spring length . loaded with 13-15 N (2.93-3.38 Ibf) . 16.9-18.9 N (3.80-4.25 Ibf) 140 kPa (20.31 Ibf/in2) 68.8 mm (2.72") 40 mm (1.57") 32 mm (1.26") 140 kPa (20.31 lbt/in") 68.8 mm (2.72") 40 mm (157") 32 mm (1 .26")

C. Piston cooling valve Opening pressure Oil pressure, hot engine at operating speed (TAMD122P) .. 160 kPa (23.20 Ibf/in2) 330 kPa (47.86 Ibflin2)

..... 300-500kPa (43.50-72.50Ibf/in2) min. 150 kPa (21.76 lbt/ln") 50 litres 30 litres 351itres 291itres (13.21 US gals) (7.93 US gals) (9.25 US gals) (7.66 US gals)

hot engine at operating speed (other engines) .. idling speed (TAMD122P) idling speed (other engines) Oil volume engine engine shallow shallow incl. oil filter, approx., angle 0° angle 15° sump, engine angle 0° sump, engine angle 6
0

. .. .. . .
.

425-575 kPa (61.64-83.4 Ibf/in2) 300-500 kPa (43.50-72.50 Ibf/in2) min. 250 kPa (36.26 Ibf/in2) min. 150 kPa (21.76 Ibf/in2) 50 30 35 29 litres litres litres litres (13.21 US gals) (7.93 US gals) (9.25 US gals) (7.66 US gals)

18

Technical data 102-series 122-series

Oil quality Viscosity at different ambient air temperatures Temperature values refer to stable ambient temperatures. VDS-2 oil, Part No. 1141628-6, 20 litres .......

VDS (Volvo Drain Specification) per API system

al1. CD or CE as

°C
_25oc

(5.28 US gals.).
• Refers to synthetic NOTE! Only or semi-synthetic oil. SAE SW/30 must be used.

"S+E

1~W/3~

*
I I I

*'

'I
'

i
:
I
I

':&:' _'

-10o+SA~20~/30 : .ooct:SAE

: 30

SAE40

:-

68

Lubricating oil pump

Type axial clearance, pump gear gear flank clearance, pump gear diameter. intermediate gear journal diameter, bushing intermediate gear radial clearance, intermediate gear _. .. .. . . . GMr Gear

0.07-0.15 mm (0.003-0.006") 0.07-0.15 mm (0.003-0.006") 0.lS-D.30 mm (0.OO6-{).012")O.15-D.30 mm (0.006-0.012") 92.084-92.106 mm 92.084-92.106 mm (3.6253-3.6262") (3.6253-3.6262") 92.131-92.166 mm 92.131-92.166 mm (3.6272-3.6286") (3.6272-3.6286") 0.03-0.09 mm (0.OOl-D.004") 0.03-0.09 mm (O.OOl-D.004")

19

Technical data

Fuel system
102-series Direction of rotation of injection pump viewed from front Injection sequence Injection volume Feed pump working pressure . . . . Clockwise 122-series Clockwise

1-5-3-6-2-4
See current Sales Guide 100-150 kPa (14,50-21.75Ibf/in2)

1-5-3-6-2-4
See current Sales Guide 100-150 kPa (14.50-21,75 Ibflin2)

Injection pump
102l122-series TMD102A Injection pump Lift from basic circle Setting Governor Feed pump , ,
governor.

.. . .. . .

PE6P110A320RS3162 alt. PE6P120A300RS3075* 3.5 (+0.1) mm alt. 2,6 (+0,1) mm* (0,138" (+0,004") all. 0.1024" (+0.004")*) 22° B.T.D,C, RSV 200-900 P1/421 alt. electronic FP/KG 24P200

• Refers to engine with electronic

TAMD102A Injection pump Lift from basic circle Setting , Govemor ,.. , Feed pump

, ,', .. ,

. .. .. .. ..

PE6P120A320RS3261 3.4 (+0.1) mm (0,134"(+0,004"» 20° B.T.D,C, RSV 250-1100 POA374-11 FP/KG 24P200

TAMD102D Injection pump Lift from basic circle Setting Govemor '" "" ,.. , ' ,.. , Feed pump , ,,

, , ,',

' .' ,.. ,

. .. .. ,.", .., ,"', ,,'

PE6P120A320RS3301 3.4 (+0,1) mm (0.134"(+0.004"») 1S° BTD.C. RSV 250-1100 POA374-12 FP/KG 24P200

TMD122A Injection pump Lift from basic circle Setting ""', Govemor ,., ,

,,,

.. , .. .. '

,.," ", " "' ",.' ,' .,.,',.,"""""

,.. , ',., .".," '.,.,.". ,.. ," ,.,"""

Feed pump ..', ........ ,..,.. ,', .... ' ...... ,..,.... ,..... ,',.,' ... ,....
* Refers to engine with electronic governor. ') Refers to engine with RSV gOY, all. RQ gOY. with el. governor. ') Refers to engine with electronic governor only.

PE6P120A320RS3206 alt. PE6P120A300RS3075* 3,5 (+0,1) mm alt. 2.6 (+0.1) mm* (0.138"(+0.004") alt. 0,1024" (+0,004")*) 24°') all. 26°2) B.TD.C. RSV 250-900 P4A37 4-7, all. RQ 750PA 783-1, alt. electronic FP/KG 24P200

20

Technical data
102l122-series TAMD122A Injection pump Lift from basic circle Setting Govemor Feedpump
* Refers to engine with electronic governor. 3) Refers to engine with RSV governor. 4) Refers to engine with electronic governor.

. .. . . ..

PE6P120A320RS3206 alt. PE6P120A300RS3075* 3.5 (+0.1) mm alt. 2.6 (+0.1) mm* (0.138" (+0.004") alt. 0.1024" (+0.004")*) 21°3) alt. 2204) alt. 20°5) B.T.D.C. RSV 250-900 P4A374-6 alt. RQ 750PA783-1 alt. electronic FP/KG 24P200

S) Refers to engine with RQ govemor.

TAMD122C,D Injection pump Lift from basic circle Setting Govemor Feedpump

,.. ,

. . . . ..

PE6P120A320RS3206 3.5 (+0.1) mm (0.138" (+0.004")) 210 BT.D.C. RSV 250-900 P4A374-6 FP/KG 24P200

TAMD122P-A Injection pump Setting Govemor Stroke position*

, (on checking) (on adjusting) Pump element, diameter Feedpump

. .. . .. . . ..

PE6P130A320RS7368 j:OY B.T.D.C, RQV250-1125PA1210K 4.45 ±0.1 0 mm (0.175 ±0.004") 4.45 ±O.OS mm (0.175 ±0.002") 13 mm (0.512") FP/KG 22 P78

1r

• Lift from basic circle at start of delivery,

TAMD122P-B Injection pump Setting Govemor Stroke position"

(on checking) (on adjusting) Pump element, diameter Feedpump

.. . . . . . ..

PE6P130A320RS8046 16° ±OS B.T.D.C. RE30 4.45 ±O.1 0 mm (0.175 ±0.004") 4.45 ±0.05 mm (0.175 ±0.002") 13 mm (0.512") FP/KG 24 P307

• Lift from basic circle at start of delivery.

Injectors
TMD102A, TAMD102A Nozzle holder Nozzle Injector cornp. marked Opening pressure Setting pressure (new spring) Hole diameter . . .. . . . KBEL 117P7/4 DLLA 148P149 788 25.5 MPa (3698 lb/in") 26.0-26.8 MPa (3771-3887 5 pes 0.34 mm (0.0133")

Ibflin2)

21

Technical data 102l122-series TAM0102D Nozzle holder Nozzle Injector comp, marked (Volvo Penta No.) Opening pressure Setting pressure (new spring) Hole diameter .. .. .. . . .. KBEL 117P7/4 DLLA 148P149 470933 25.5 - 26.3 MPa (3698-3814Ibf/in2) 26.0-26.8 MPa (3771-3887Ibflin2) 5 pes 0.352 mm (0.0138")

TMD122A, TAMD122C,-0 Nozzle holder Nozzle Injector compo marked Opening pressure Setting pressure (new spring) Hole diameter

. .. . .. .. .

KBEL 117P7/4 DLLA 150 P76 834 25.0 MPa (3626 lbf/in") 25.5-26.3 MPa (3698-3814Ibflin2) 4 pcs 0.40 mm (0.0157")

TAMD122A Nozzle holder Nozzle Injector comp. marked Opening pressure Setting pressure (new spring) Hole diameter

. .. .. .. .. .

KBEl117P7/4 DlLA 148P149

788
25.5 MPa (3698 Ibf/in2) 26.0-26.8 MPa (3771-3887 5 pes 0.34 mm (0.0133") Ibf/in2)

TAM0122P-A Nozzle holder Nozzle Injector comp, marked Opening pressure Setting pressure (new spring) Hole diameter

.. . . . . ..

KBEL117P73 DLLA 150P550 614 27.5 MPa (3989 Ibf/in2) 28.0 (+0.8) MPa (4061 (+116) lbf/in") 5 pes 0.412 mm (0.0162")

TAM0122P-B Nozzle holder Nozzle Injectorcomp. marked Opening pressure Setting pressure (new spring) Hole diameter

. . . . .. ..

KBEl117P163 DLLA150P550 567 27.5 MPa (3989 Ibffin2) 28.0 (+0.8) MPa (4061 (+116) Ibf/in2) 5 pes 0.412 mm (0.0162")

22

Technical data

Intake and exhaust systems

102-series 122-series

Exhaust back pressure

Max. permissible in exhaust line, TMD102A 1500 rpm 1800 rpm 2000 rpm Genset: 1500 rpm 1800 rpm back pressure

. . .. .
..

4 kPa (0.58 psi) 5 kPa (0.73 psi) 6 kPa (0.87 psi)

4 kPa (0.58 psi)

5 kPa (0.73 psi)

TAMD10~AID 1500 rpm 1800 rpm 2000 rpm 2200 rpm

.. .

..
.

4 kPa (0.58 psi) 6 kPa (0.87 psi) 8 kPa (1.16 psi) 10 kPa (1.45 psi)

TMD122A 1500 rpm 1800 rpm Genset: 1500 rpm 1800 rpm

.
.. .. ..

5 kPa (0.73 psi) 6 kPa (0.87 psi)

5 kPa (0.73 psi) 6 kPa (0.87 psi)

TAMD122A 1500 rpm 1800 rpm 1900 rpm Genset: 1500 rpm 1800 rpm

.
.. .. . ..

4 kPa (0.58 psi) 5 kPa (0.73 psi) 6 kPa (0.87 psi) 5 kPa (0.73 psi) 6 kPa (0.87 psi)

TAMD122C 1500 rpm 1800 rpm 2000 rpm

.. .. .

3.5 kPa (0.51 psi) 5 kPa (0.73 psi) 7 kPa (1.02 psi)

TAMD122D 1500 rpm 1800 rpm 2000 rpm

. . .

5 kPa (0.73 psi) 8 kPa (1.16 psi) 10 kPa (1.45 psi)

TAMD122P-A,

TAMD122P-B . .. 15 kPa (2.18 psi) 10 kPa (1.45 psi)

Max. permissible back pressure in exhaust line Max. recommended back pressure in exhaust line

23

Technical data

Exhaust temperature*
102-series TMD102A Rating 1, 1500 rpm 1800 rpm Rating 2, 1500 rpm 1800 rpm 2000 rpm Gensel, 1500 rpm 1800 rpm 122-series

. .. .
.

424°C (795°F) 400°C (752°F) 437°C (819°F) 412°C (774°F) 412°C (774°F) 450°C (842°F) 415°C (779°F)

. .. ..

TAMD102A Rating 1, 1500 rpm 1800 rpm Rating 2, 1500 rpm 1800 rpm 2000 rpm

. . . . .

480°C (896°F) 414°C (777°F) 515°C (959°F) 470°C (878°F) 431°C (808°F)

TAMD102D Rating 3, 1800 rpm 2000 rpm 2200 rpm Rating 4, 1800 rpm 2000 rpm 2200 rpm

. . . . ..
.

455°C (851°F) 415°C (779°F) 410°C (770°F) 450°C (842°F) 430°C (806°F) 425°C (79rF)

TMD122A Rating 1, 1500 rpm 1800 rpm Rating 2,

1500

.. .. ..
.

470°C (878°F) 450°C (842°F) 4BO°C (B96°F) 470°C (878°F) 530°C (986°F) 490°C (914°F)

1800

rpm rpm

Genset, 1500 rpm 1800 rpm

• The temperatures of 27"C (81°F). are measured at an inlet air temperature

24

Technical data
102-series TAMD122A Rating 1 1500 rpm 1800 rpm Rating 2 1500 rpm 1800 rpm 2000 rpm Genset 1500 rpm 1800 rpm . .. . .. . . .. 437"e (819°F) 424°e (795°F) 442°e (828°F) 437°e (819°F) 429°e (804°F) 480 e (896°F) 440 e (824°F)
0 0

122-series

TAMD122C Rating 3 1800 rpm 2000 rpm 2200 rpm .. . . 450°C (84Z°F) 445°e (833°F) 450°C (842°F)

TAMD122D Rating 3 1800 rpm 2000 rpm Rating 4 1800 rpm 2000 rpm . . .. . 43SoC (81S°F) 435°C (815°F) 455°C (851°F) 450 e (842°F)
0

TAMD122P-A Rating 3 2100 rpm Rating 4 2250 rpm .. .

TAMD122P-B Rating 3 2100 rpm Rating 4 2250 rpm .. .

• The temperatures are measured at an inlet air temperature of 27°C (81°F).

25

Technical data

Turbocharger
102l122-series TMD102A TAMD102A TAMD102D TMD122A, TAMD122A TAMD122C/D T AMD122P-AlP-B Lubrication system (turbine side) . . .. . . . .. . KKK K28-3464MOAl14.72 KKK K28-3767MXAll 6.72 Holset HX50-D9881 H/HA20LC15 Holset 4LGK 267/3.0WS2 Holset 4LGK 0870/3.0WS2 Schwitzer S4DW/l OOH.51XBEM/O.94FB2 Pressure lubrication from engine Holset: KKK: Schwitzer: Holset: KKK: Schwitzer: 0.58 mm (0.023") 0.46 mm (0.0181 ") 0.71 mm (0.028") 0.10-0.15 mm (0.004"- 0.006") max. 0.16 mm (0.006") max.0.20 mm (0.008")

Max. radial clearance

The axial clearance

should lie within

Boost pressure
Boost pressure, min. value (measured in the engine's inlet pipe) at 100% load and full throttle and approx. +25°C (77°F) air temperature. If measuring is conducted at other temperature the measured charge pressure must be corrected, see Workshop Manual "Intake, Exhaust and Cooling Systems". If full power cannot be used the pressure will be considerably lower. (100 kPa '" 1 kp/crn-).

102-series

122-series

Min_ boost pressure

TMD102A Rating 1 1500 rpm 1800 rpm Rating 2 1500 rpm 1800 rpm 2000 rpm , Genset 1500 rpm 1800 rpm .. . . .. . . . 78 kPa (11.3 Ib/in2) 102 kPa (14.8 Ib/in2) 90 kPa (13.1 lb/in") 113 kPa (16.4 Ib/in2) 125 kPa(18.1 lb/in-') 97 kPa (14.1Ib/in2) 128 kPa (18.6Ib/in2)

,.,'

TAMD102A Rating 2 1500 rpm 1800 rpm 2000 rpm Rating 3 1500 rpm 1800 rpm 2000 rpm 2200 rpm .. .. .. .. . .. ..

88 kPa (12.8 Ib/in2) 115 kPa (16.7 lb/in")

127 kPa (18.4 lb/in") 104 132 140 144 kPa kPa kPa kPa (15.1 (19.1 (20.3 (20.9 lb/ln") lb/in") lb/in") lb/in")

26

Technical data
102-series TAMD102D Rating 3 1500 rpm 1800 rpm 2000 rpm 2200 rpm Rating 4 1500 rpm 1800 rpm 2000 rpm 2200 rpm .. .. .. .. .. .. .. .. 150 200 220 230 175 220 240 250 kPa kPa kPa kPa kPa kPa kPa kPa (21.8 Ib/in2) (29 lb/in") (31.9 Ib/in2) (33.4 lb/in") (25.4 (31.9 (34.8 (36.3 Ib/in") Ib/in2) 122-series

lb/in") lb/in")

TMD122A Rating 1 1500 rpm 1800 rpm Rating 2 1500 rpm 1800 rpm Genset 1500 rpm 1800 rpm . .. . . .. . 75 kPa (10.9 lb/in") 94 kPa (13.6 Iblin2) 79 kPa (11 .5 Ib/in2) 100 kPa (14.5 lb/in-) 90 kPa (13.1Ib/W) 115 kPa (16.7 Ib/in2)

TAMD122A Rating 1 1500 rpm 1800 rpm Rating 2 1500 rpm 1900 rpm Genset 1500 rpm 1800 rpm .. 98 kPa (14.2 Ib/in2) 94 kPa (13.6 lb/in") 104 kPa (15.1 Ib/in2) 128 kPa (18.6 lb/in") 123 kPa (17.8Ib/in2) 151 kPa (21.9Ib/in2)

. ..
. . ..

TAMD122C Rating 3 1500 rpm 1800 rpm 2000 rpm .. .. .. 110 kPa (16 lb/in") 133 kPa (19.33 lb/in") 144 kPa (20.9Ib/in2)

TAMD122D Rating 3 1500 rpm 1800 rpm 2000 rpm Rating 5 1500 rpm 1800 rpm 2050 rpm .. .. .. . .. . 110 kPa (16 Ib/in2) 137 kPa (19.9 Ib/in") 151 kPa (21.9Ib/in2) 118 kPa (17.1 Ib/in2) 147 kPa (21.3Ib/in2) 163 kPa (23.6 lb/in")

27

Technical data
102-series TAMD122P-A Rating 3 1600 rpm 1800 rpm 2100rpm Rating 5 1600 rpm 1800 rpm 2100 rpm .. .. .. . . . 170 kPa (24.7Ib/in2) 200 kPa (29 Ib/in2) 225 kPa (32.6 lb/in") 200 kPa (29 lb/in") 220kPa (31.9Ib/in2) 245 kPa (35.5 Ib/in2) 122-series

TAMD122P-B Rating 3 2100 rpm Rating 5 1700 rpm 1900 rpm 2250 rpm .. . .. .. 220 kPa (31.9 Ib/in2) 230 kPa (33.4 Ib/in2) 235 kPa (34.1 lb/in") 245 kPa (35.5 Ib/in2)

28

Technical data

Cooling system
102-series Type.......................... The valve on the filler cap opens at: TAMD122P-NB other engines Volume of fresh water system incl. heat exchanger . .. .. Overpressure, enclosed 122-series Overpressure, enclosed

43-53 kPa (6.24-7.69 approx. 40 litres (10.6 US gals)

75 kPa (10.88 Ibf/in2) Ibfli n2) 43-53 kPa (6.24-7.69Ibflin2) approx. 50 lit res (13.2 US gals)

Thermostats

- heat exchangers

of tube type,

All engines Number

start opening at

..
.. ..

fully open at colour marking

3 pcs 81°C (178°F) 94°e (201°F) Red

3 pes 81°C (178°F) 94°C (201°F) Red

Thermostats - keel cooler and radiator cooler, TMD102, TMD122 Number start oponmq at fully open at colour marking Number start opening at fully open at . .

..
.. . . ..

2 pes 76°e (169°F) 90 e (194°F) Blue

0

2 pes 76°e (169°F) 90 e (194°F) Blue

0

zo-e

1 pes

(158°F) 84°e (183°F)

1 pes 70 e (158°F) 84°e (183°F)

0

Thermostats TAMD102

- keel cooler and radiator cooler, . .. . . . . .. 2 pes 81°e (178°F) 94°C (201°F)

Number start opening at fully open at Number start opening at fully open at colour marking

1 pcs 76°e (169°F) 90 e (194°F) Blue

0

Thermostats TAMD122

- keel cooler and radiator cooler, . .. .. .. . .. ..

Number start opening at fully open at colour marking Number start opening at fully open at

2 pcs
76°e (169°F) 90 e(194°F) Blue
0

1 pes 70 (158°F) 84 De (183°F)

0

29

Technical data

Electrical system
102-series System voltage Battery ( 2 connected capacity, max in series 12V) . 152Ah 152 Ah . 24V 122-series 24V

Battery electr. density at +20°C (68°F), fully charged battery battery recharged at Stop solenoid for injection pump - breaker point setting: Contact gap with fully returned pull rod Electric starter element, output approx

. .

1.280-1.285 glcm3 1.200 g/cm3

1.280-1.285 glcm3 1.200 g/cm3

. .

1-2 mm (0.0394-0.0787") 4000W

1-2 mm (0.0394-0.0787") 4000W

Alternator
Make Voltage/max. current Output, approx Brush length Make (alternative equipment) Voltage/max. current Output, approx Brush length . . . . .. . . . Valeo 28V150A 1700W min. 8 mm (0.32") MotorolaiPrestolite 28V/100A 2aOOW min. 5 mm (0.2") Valeo 28V/60A 1700W min. 8 mm (0.32") MotorolaJPrestolite 28V/100A 2800W min. 5 mm (0.2")

Starter motor
Make, type Brush length Brush spring force .. . .. Bosch KB 24V min. 17.5 mm (0.7") 12-14 N (2.7-3.2Ibf) Bosch KB 24V min. 17.5 mm (0.7") 12-14 N (2.7-3.2 Ibt)

30

Technical data

Wear tolerances
102-series 122-series

Cylinder heads
Height: min. 114.65 mm (4.514")

min.

124.65

mm

(4.907")

Cylinder
Cylinder liner (and pistons with piston rings) should be replaced at OAO-D.45 mm (0.0158-0.0177") wear.

Crankshaft
Permissible ovality on main and

big and bearinq journals, max Permissible conicity on main and big end journals, max Max. axial clearance on crankshaft

. . .

0.08 mm (0.0032") 0.05

0.08

mm

(0.0032")

mm

(0.0020")

0040 mm (0.0157")

0.05 mm (0.0020") 0040 mm (0.0157")

Valves
Valve stems, max. permissible wear Permissible clearance between valve stem and valve guide: Inlet valve, max Outlet valve, max The valve disc edge should be at least, Inlet Outlet The valve seat can be ground down until the distance from the valve disc (new valve) to the cylinder head surface is max
• Over these values the seats should be replaced.

0.07

mm mm mm

(0.0028")

0.07 mm (0.0028")

.. . .. ..

0.20 0.30

(0.0079") (0.0118")

0.20 mm (0.0079") 0.30 mm (0.0118") 1.9 104

1.9 mm (0.075")

104 mm (0.055")

mm mm

(0.075") (0.055")

2.5

mm

(0.098")*

1.5 mm (0.059")*

Camshaft
Permissible ovality (with new bearing), max Bearing, permissible wear, max Lift height, min. Inlet Outlet Valve lifter, max. permissible radial clearance .. . . . .. 0.05 0.05

mm mm

(0.0020") (0.0020")

0.05 mm (0.0020") 0.05 mm (0.0020")

8.4 mm (0.331 ") 9.0 mm (0.3543") 0.08 mm (0.0032")

804 mm (0.331 ")

9.0 mm (0.3543") 0.08 mm (0.0032")

31

Technical data

Tightening

torques
102-series 122-series See next page. 340 Nm (250 Ibf.ft) See next page. 40 Nm (30 Ibf.ft) 3/8": 45 Nm (33 IbUt), M10: 60 Nm (44Ibf.ft) 3/8": 45 Nm (33 Ibf.ft) , M10: 70 Nm (S2Ibf.ft) 60 Nm (44 IbUt) 20 Nm (15 Ibf. ft) 40 Nm (30 Ibf.ft) 17 Nm (13Ibf.ft) 40 Nm (30 Ibf.ft) 17 Nm (13 Ibf.ft) 60 Nm (44Ibf.ft) 40 Nm (30 Ibf.ft) 10 Nm (7 Ibf.ft) 50 Nm (37 Ibt.tt) 175 Nm (129Ibf.ft) 140 Nm (103Ibf.ft) 60 Nm (44 Ibf.ft) 550 Nm (406 Ibf.ft) 85 Nm (63 Ibf.ft) 180 Nm (133Ibf.ft) 50 Nm (37 Ibf.ft) 60 Nm (44 IbUt) 150 Nm (111 IbUt) 60 Nm (44 IbUt) 20 ±5 Nm (15 ±4Ibf.ft) 90 ±9 Nm (66 ±S.S IbUt) 114 ±1 0 Nm (84 ±7Ibf.ft) 30 ±3 Nm (22 ±2Ibf.ft) 62 ±5 Nm (46 ±4Ibf.ft) . . . bearings . . . . . . . . . .. . .. . .. .. . .. .. . . . . . .. See next page. 340 Nm (250 Ibf.ft) See next page. 40 Nm (30 Ibf.ft) 3/8": 45 Nm (33 IbUt), M1 0: 60 Nm (44Ibf.ft) 3/8": 45 Nm (33 IbUt), M10: 70 Nm (52Ibf.ft) 60 Nm (44 Ibf.ft) 20 Nm (15 Ibf.ft) 40 Nm (30 Ibf.ft) 17 Nm (13 Ibf.ft) 40 Nm (30 Ibf.ft) 17 Nm (13Ibf.ft) 60 Nm (44 Ibf.ft) 40 Nm (30 Ibf.ft) 10 Nm (7 Ibf.ft) 50 Nm (37 IbUt) 175 Nm (1291bUt) 140 Nm (103 IbUt) 60 Nm (44 Ibf.ft) 550 Nm (406 IbUt) 85 Nm (63 Ibf.ft) 180 Nm (133 IbUt) 50 Nm (37 Ibf. tt) 60 Nm (44 Ibf.ft) 150 Nm (111 Ibf.ft) 60 Nm (44 Ibf.ft) 20 ±5 Nm (15 ±4 Ibf.ft) 90 ±9 Nm (66 ±6.5 Ibf.ft) 114 ±1 0 Nm (84 ±7 Ibf.ft) 30 ±3 Nm (22 ±2 Ibf.ft) 62 ±S Nm (46 ±4 Ibf.ft)

Cylinder head screws ') Main bearing screws Connecting rod screws

Flange, front camshaft Gear, camshaft Gear, pump drive Intermediate bearing

Pump housing, oil pump Bracket, oil pump Intermediate gear, oil pump

Bearing housing, rocker shaft.. Oil pan Drain plug, oil pan Timing gear cover Valve cover Exhaust pipe Flywheel Flywheel cover Vibration damper, fixing screws centre screws for hub Injection pump, pressure valve holder Injection pump camshaft, Injector, nut for stud Clamp screw, injection pump companion flange Pulley on drive outlet for alternator and fresh water pump Mud plugs in cylinder head and block Piston cooling nozzle TAMD122P-AlP-B Clamp screw, injection pump coupling, TMD102A, TAMD102A, TAMD122A1C/D TAMD102D, TAMD122P-AlP-B Screw, disks pump coupling, TMD102A, TAMD102A, TAMD122A1C/D TAMD102D, TAMD122P-AlP-B
1) Dip cylinder head screws completely (incl. heads) in
anti-corrosive agent for max. 24 hours before fitting.

nut

.
..

.
..

The screws should not drip when titled.

32

Technical data Cylinder head screws, 102-series 50 Nm (37 Ibf.ft) 200 Nm (148 Ibf.ft) 370 Nm (273 lbf.ft) angular tightening 90 Cylinder head screws, 122-series

Tighten cylinder head screws in 4 stages. - 1st tightening - 2nd tightening - 3,d tightening - 4th tightening:

Tighten cylinder head screws in 4 stages. - 15t tightening 50 Nm (37 Ibf.ft) - 2nd tightening 150 Nm (111 IbUt) - 3,d tightening 190 Nm (140 Ibf.ft) 4th tightening: angular tightening 60

Tightening diagram

Tightening diagram

Connecting rod screws l.ator version

Previous version

1st tightening: 40 Nm (30 IbUt) 2nd tightening: 75 Nm (55 Ibf.ft) 3,d tightening: angular tightening 90

Tightening torque: 230 Nm (170 Ibf.ft)

0

Where angular tightening is not possible a torque of 260 Nm (192 IbUt) should be applied.

33

References to Service Bulletins

Group No. Date Conceming

34

Notes

35

Notes

36

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