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Workshop Manual
Technical Data
TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE
TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE
TAD660VE, TD720GE TAD720GE, TD720VE, TAD720VE
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE
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General InformationGroup 20
Safety precautions ...............................................2
General information ............................................. 5
Repair instructions ............................................... 6
Location of identification plates
TD/TAD420-620, TD/TAD520-722 .......................9
TAD650/660, TAD750/760 .................................. 10
TD420VE, TAD420VE, TAD620VE, TAD650VE,
TAD660VE
General (420/620)................................................ 11
General (650/660)................................................ 12
Engine block ....................................................... 12
Valve mechanism ...............................................16
Crank mechanism ............................................... 19
Lubricating system .............................................. 22
Fuel system ........................................................ 24
Intake and exhaust system ................................. 32
Cooling system ................................................... 32
Tightening torque ................................................33
TD520GE, TAD520GE, TD520VE, TAD520VE,
TAD530-532GE
General ............................................................... 36
Engine block ....................................................... 37
TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE,
TD520GE, TAD520GE, TD520VE, TAD520VE,
TAD530/531/532GE, TD720GE, TAD720GE, TD720VE,
TAD720VE, TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE
Valve mechanism ............................................... 40
Crank mechanism ............................................... 43
Lubricating system .............................................. 46
Fuel system ........................................................ 48
Intake and exhaust system ................................. 55
Cooling system ................................................... 56
Tightening torque ................................................57
TD720GE, TAD720GE, TD720VE, TAD720VE,
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730-733GE, TAD750VE, TAD760VE
General (720-722GE ) ......................................... 59
General (720-722VE) ...........................................60
General (750/760)................................................ 60
Engine block ....................................................... 61
Valve mechanism ............................................... 64
Crank mechanism ............................................... 67
Lubricating system .............................................. 70
Fuel system ........................................................ 72
Intake and exhaust system ................................. 80
Cooling system ................................................... 81
Tightening torque ................................................82
Tightening diagram ............................................. 85
Contents
Technical Data
Industrial Engines
© 2007 AB VOLVO PENTA
All rights to changes or modifications reserved.
Printed on environmentally-friendly paper
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General Information Group 20
Introduction
Workshop Manuals contains technical specifications,
descriptions, and instructions for the repair of the specified Volvo Penta products or product types. Check
that you have the correct Workshop Manual and the
latest Service Bulletins for your engine.
Before starting work on the engine, read these
sections of the Workshop Manual:
Safety Precautions
General Information
Repair Instructions
Below is a summary of the risks involved and safety precautions you should always observe or
carry out when operating or servicing the engine.
Immobilize the engine by turning off the power
supply to the engine at the main switch (switches) before starting work. Put a warning notice at
the engine control panel.
Generally, all service operations must be carried out with the engine stopped.
However, some work, for example certain adjustments requires that the engine is running when
they are carried out.
Approaching an engine, which is operating, is a
safety risk. Loose clothing or long hair can fasten in rotating parts and cause severe personal
injury.
Take care to avoid contact with hot surfaces
(exhaust pipes, turbocharger, air intake pipe, starter element etc.) and hot liquids in lines and
hoses on an engine that is running or has just
been stopped. Reinstall all protective parts removed during service operations before starting
the engine.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels that have been damaged or painted over.
Never start the engine without installing the air
cleaner filter. Foreign objects entering the intake
ducts can also cause mechanical damage.
Never use ether or similar products when starting the engine. They may cause an explosion in
the inlet manifold and causing personal injuries.
Only start the engine in a well-ventilated area.
If operating the engine in an enclosed area make sure that the exhaust is leading out of the engine compartment and working area.
Avoid opening the coolant filler cap when the engine is hot, when hot steam or coolant might spray out. If the filler cap must be open, slowly release the pressure in the system. Be very careful, it is difficult to anticipate in which direction
hot steam or coolant can spray out.
Safety Precautions
Important
In this book and on the product you will find the following special warning symbols.
WARNING! Possible danger of personal injury,
extensive damage to property or serious mechanical malfunction if the instructions are not followed.
IMPORTANT! Used to draw your attention to something that can cause damage or malfunc-tions on a product or damage to property.
NOTE! Used to draw your attention to important
infor-mation that will facilitate the work or operation in progress.
Warning symbols used in the Workshop Manual are
not in any way comprehensive since it is impossible
to predict every circumstance under which service work or repairs may be carried out.
AB Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working
methods in a well-equipped workshop using working
methods and tools tested by AB Volvo Penta.
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General InformationGroup 20
Stop the engine before carrying out operations
on the engine cooling system.
Always use protective glasses or goggles, when
carrying out work where there is a risk of splinters, grinding sparks and acid splashes or when
other chemicals are in use. The eyes are extremely sensitive and an injury could result in blindness!
Avoid getting hot oil on your skin, it might cause
severe burns. Ensure that the lubrication system is not under pressure before carrying out any
work. Never start or operate the engine with the
oil filler cap removed, otherwise oil could be ejected.
Exposure to oil over a long period or repeatedly
will cause problems such as skin drying out, irritation and toxic eczema. Used oil is in a health
aspect even more dangerous than new oil. Use
protective gloves. Use protection creams, which
will ease up cleaning of the skin and counteract
drying out.
Many chemicals such as oils, glycol, diesel oil
and other chemicals, for example degreasing
agents, paint and solvents are dangerous to your health.
Always follow the safety precautions for the product, for example using protective mask, glasses, gloves etc. Make sure of good ventilation is
provided in the working area. Follow the instructions on the product, when disposing used chemicals.
Follow extreme care when working with/or checking the fuel system. Use eye protection. The
jet from a fuel injector nozzle is under extremely
high pressure and can cause severe personal
injury.
WARNING! Use new delivery pipes every time.
Be careful, delivery pipes should under no circumstances be bent.
All fuels and many chemical substances are flammable. Do not allow naked flame or sparks in
the working area!
Make sure that the working area is well ventilated and take the necessary safety precautions
before starting welding or grinding work.
Make sure that there always are fire extinguishers in the working area.
Ensure that rags soaked in oil or fuel are stored
safely. Rags soaked in oil can spontaneously
ignite. Used fuel filters, oil filters, lubricating oil,
contaminated fuel, solvent and degreasing agents are environmentally dangerous waste and must be deposited at an approved site for dest-ruction.
Never expose a battery to naked flame or electrical sparks. Batteries always produce hydrogen
gas, which mixed with air form an explosive gas
– oxyhydrogengas.
This gas is highly volatile and easily ignited. Incorrect connection of the battery can cause a
single spark that is sufficient to cause an explosion. Be very careful when attempting to ju-mpstart the engine and do not at any time lean over
the batteries.
Always ensure that the Plus (positive) and Minus (negative) battery leads are correctly installed. Incorrect installation can result in severe
damage to the electrical equipment. Refer to the
wiring diagrams.
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid, which is highly caustic.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately using plenty of water and soap and if it is exposed
to the eyes, immediately flush with plenty of water and obtain medical assistance at once.
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General Information Group 20
WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion.
The engine must not be run in areas where there
are explosive materials.
Always use the fuels recommended by AB Volvo Penta. Refer to the Instruction Book. Use of
fuels that are of a lower quality can damage the
engine. On a diesel engine, poor quality fuel can
cause the control rod to seize, which can result
in an over revving of the engine, risking of damaging to the engine and of personal injuries.
Poor fuel quality can also lead to higher maintenance costs.
Observe the following rules when cleaning with
high-pressure water jets. Never direct the water
jet at seals, rubber hoses, or electrical components. Never use a high-pressure jet when washing the engine.
Turn the engine off and turn off the power at the
main switch/switches before carrying out work
on the electrical system.
Clutch adjustments must be carried out with the
engine stopped.
Use the lifting eyes fitted on the engine when lifting the drive unit. Always check that the lifting
equipment is in good condition and has the correct load capacity to lift the engine (engine weight including gearbox, if fitted, and any extra equipment installed).
To make sure of safe handling and to avoid damage, use a lifting beam to raise the engine.
This lifting beam is installed on the top of the
engine, make sure that all chains and cables should run parallel to each other.
If extra equipment is installed on the engine that
would alter its center of gravity, it is required that the lifting device has to be altered for obtaining the correct balance for safe handling.
Never carry out work on an engine suspended
on a hoist without other supporting equipment
attached.
Never work alone when removing heavy engine
components, even when using lifting devices
such as locking tackle lifts. When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted clear and not damaged during the lifting operations.
Check before starting work if there is eno-ugh
room to carry out removal work without risk-ing
personal injury or damage to the engine or parts.
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General InformationGroup 20
About this Workshop Manual
This Workshop Manual contains technical data for the
repair of the following engines in standard format:
TD420VE, TAD420VE, TAD620VE, TAD650VE,
TAD660VE, TD520GE, TAD520GE, TD520VE,
TAD520VE, TAD530-532GE, TD720GE, TAD720GE,
TD720VE, TAD720VE, TAD721GE, TAD721VE,
TAD722GE, TAD722VE, TAD730-733GE, TAD750VE,
TAD760VE
The Engine Designation and Engine Numbers can be
found on the Identification plates. Please always include both the engine designation and the engine
number in all correspondence.
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service technicians. For this reason, the manual presupposes a certain basic knowledge and that the user can carry out
the mechanical/electrical work described to a general
standard of engineering competence.
Volvo Penta products are under a continual process of
development and we therefore reserve all rights regarding changes and modifications. All the information in
this manual is based on product specifications available at the time the book was published. Any essential
changes or modifications introduced into production or
updated or revised service methods introduced after
the date of publication will be provided in the form of
Service Bulletins
from AB Volvo Penta.
Power standards
The engine performance corresponds to:
ISO 3046, BS 5514, and DIM 6271.
Prime power rating corresponds to ISO standard power for continues operation. It is applicable for supplying electrical power at variable load for an unlimited
number of hours instead of commercial purchased power. A ten-percent overload capability is available for
this rating.
Standby Power rating corresponds to ISO Standard
Fuel Stop Power. It’s is applicable for supplying
standby electrical power at variable load in areas well
est-ablished electrical networks in event of normal utility power failure. No overload capability is available
for this rating.
NOTE! The technical data applies to an engine without cooling
fan and operating on a fuel with calorific value of 42.7 MJ/kg
(18360 BTU/lb.) and a density of 0.84 kg/liter (7.01 lb./US gal,
8.42 lb./lmp. gal) even when it involves a deviation from
standards.
Spare parts
Spare parts for the electrical and fuel systems are
subject to various national safety requirements. Volvo
Penta Original Spare Parts meet these specifications.
Any type of damage which is the result of using spare
parts that are not original Volvo Penta parts for the
product in question will not be covered under any warranty or guarantee provided by AB Volvo Penta.
Engine certificate
Engine certificates to meet national and regional environmental legislation carry with them an undertaking
from the manufacturer that both new and existing engines in use meet the environmental demands of the
legislation. The product must correspond to the validated example that was granted certification. In order for
AB Volvo Penta as the manufacturer to take responsibility for engines in use, certain requirements regarding service and spare parts must be met by the user
according to the following:
• The Service Intervals and maintenance operations
recommended by Volvo Penta must be followed.
• Only Volvo Penta Original Spare Parts intended
for the engine certificates may be used.
• Service work on the injection pump and injectors
must always be carried out by an authorized Volvo Penta workshop.
• The engine may not be altered or modified in any
way, with the exception of accessories and service kits developed by Volvo Penta for that engine.
• No modifications to the exhaust pipes and air
supply ducts for the engine room (ventilation
ducts) may be undertaken as this may effect exhaust emissions.
• Any seals on the engine may not be broken other
than by authorized persons.
IMPORTANT! If replacement parts are required,
use only AB Volvo Penta Original Parts.
Use of replacement parts other than AB Volvo Penta Original Parts will result in AB Volvo Penta being unable to assume any liability that the engine
corresponds to the engine certificates variant.
AB Volvo Penta excludes any liability for all and any
type of damage or costs caused by the use of replacement parts that are not Volvo Penta Original Parts
for the product in question.
General Information
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General Information Group 20
Introduction
The working methods described in the Workshop
Manual apply to work carried out in a workshop.
The engine has been removed and is installed in
an engine fixture.
Unless otherwise stated reconditioning work that
can be carried out with the engine in place follows
the same working method.
All operations described in the Workshop Manual for
which there are Volvo Penta Special Tools available
assume that the service technician or person carrying
out the repair uses these tools.
Volvo Penta Special Tools have been specifically developed to ensure as safe and rational working methods as possible.
Person or persons using other than Volvo Penta Special Tools or approved Volvo Penta working methods
(as described in a Workshop Manual or Service Bulletin). Has the responsibility to acquaint themselves of
the risk of personal injury or actual mechanical damage or malfunction.
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, always follow these precautions, as there are no specific instructions given in the Workshop Manual.
By following these basic recommendations and using
common sense it is possible, to avoid most of the
risks involved in the work. A clean work place and a
clean engine will eliminate many risks of personal injury and engine malfunction.
Above all when working on the fuel system, lubrication
system, intake system, turbocharger, bearings and
seals. It is extremely important to observe the highest
standards of cleanliness and avoid dirt or foreign objects entering the parts or systems, since this can result in reduced service life or malfunctions.
Our joint responsibility
Every engine consists of many systems and components that work together. If one component deviates
from the technical specifications, than this can have
dramatic consequences on the environmental impact,
even if it is otherwise in good running order.
It is therefore critical that the stated wear tolerances
are observed, that systems which can be adjusted are
correctly set up and that only Volvo Penta Original
Parts are used.
The stated service intervals in the Maintenance Schedule must be followed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance.
Some components are factory sealed for environ-mental and product specific reasons. Don’t under no circumstances attempt to service or repair a sealed component, unless it is done by a authorized service technician.
Bear in mind that most chemical products, incorrectly
used, are hazardous to the environment.
AB Volvo Penta recommends the use of biodegradable degreasing agents for all cleaning of engine components, unless otherwise is stated in the Workshop
Manual.
Pay special attention to make sure that oils and washing residue are handled correctly for destruction, and
not end up in the nature.
Repair instructions
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General InformationGroup 20
Tightening torque
For the correct tightening torque for critical joints,
which must be tightened using a torque wrench is listed under chapter “Tightening Torque”. For correct
tightening torque, is it important to apply cleaned threads, bolt heads and mating surfaces, with lightly oiled or dry threads. In places where grease, locking or
sealing agents is required for screwed joints, the correct torque is stated in “Tightening Torque”.
When no tightening torque is stated, use the general
tightening torque, according to the table below.
Dimension Tightening torque
Nm (lbf.ft.)
M5 ......................................................... 6 (4.4)
M6 ......................................................... 10 (7.4)
M8 ......................................................... 25 (18.4)
M10 ....................................................... 50 (36.9)
M12 ....................................................... 80 (59.0)
M14 ....................................................... 40 (103.3)
Lock nuts
Do not reuse lock nuts that have been removed during
disassembly operations as these have reduced
service life when reused. Use new nuts when
assembling or reinstalling.
For lock nuts with a plastic insert such as Nylock®
the tightening torque stated in the table is reduced if
the Nylock® nut has the same head height as a standard hexagonal nut without plastic insert.
Reduce the tightening torque by 25% for bolt size M8
or larger.
If Nylock® nuts are higher, or of the same height as a
standard hexagonal nut, the tightening torque’s given
in the table applies.
Tightening torque with
protractor tightening
(angle tightening)
Tightening using both a torque setting and a protractor
angle requires that first the recommended torque is
applied using a torque wrench and then the recommended angle is added according to the protractor
scale. Example: A 90° protractor tightening means
that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied.
Strength classes
Bolts and nuts are divided up into different classes of
strength, the number on the bolt head indicates the
class. A high number indicates stronger material, for
example a bolt marked 10-9 indicates a higher
strength than one marked 8-8.
It is therefore important that bolts removed during the
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint.
When replacing a bolt, check in the spare parts catalogue to make sure the correct bolt is used.
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General Information Group 20
Sealant
It is therefore important that bolts removed during the
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint. When
replacing a bolt, check in the spare parts catalogue to
make sure the correct bolt is used.
To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type
is used on the joint where the agents are required as
described in the Workshop Manual or the Service Bulletin.
During service operations use the same agent or an
alternative.
Make sure that mating surfaces are dry and free from
oil, grease, paint and anticorrosion agent before applying sealant or locking fluid.
Always follow the manufacturer’s instructions for use
regarding temperature range, curing time and any other instructions for the product.
Two different basic types of agent are used:
RTV agent (Room Temperature Vulcanizing)
Used for gaskets, sealing gasket joints or coating
gaskets. RTV is visible when a part has been
disassembled; old RTV must be removed before
resealing the joint.
Old sealant can be removed using methylated spirits
in all cases.
Anaerobic agents:
These agents cure in an absence of air. They are used when two solid parts, for example cast components,
are installed face-to-face without a gasket. They are
also commonly used to secure plugs, threads in stud
bolts, petcocks, oil pressure switches, and so on.
The cured material is glass like and it is therefore colored to make it visible. Cured anaerobic agents are
extremely resistant to solvents and the old agent cannot be removed. When reinstalling the part is carefully
degreased and then new sealant is applied.
Safety rules for fluorocarbon
rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings.
When fluorocarbon rubber is subjected to high temperatures (above 300°C or 572°F),
hydrofluoric acid
can
be formed, which is highly corrosive.
Skin contact can give severe chemical burns. Splashes in eyes can give severe chemical burns.
Breathing of fumes can be permanently damaged
lungs.
WARNING! Be very careful when working on
engines that have been exposed to high temperatures, e.g. overheating during a seizure or fire.
Seals must never be cut with an oxy-acetylene
torch, or be burned up afterwards in an uncontrolled manner.
Always use gloves made of chloroprene rubber
(gloves for handling chemicals) and protective
goggles.
Handle the removed material like corrosive acid.
All residues, including ash, can be highly corrosive.
Never use compressed air to blow anything clean.
Put the remains in a plastic box which is sealed
and provided with a warning label. Wash the gloves under running water before removing them.
These following seals are probably made out of fluorocarbon rubber:
Seal rings for crankshaft, camshaft, and intermediate shafts.
O-rings irrespective of where they are installed.
O-rings for cylinder liner sealing are usually made
out of fluorocarbon rubber.
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General InformationGroup 20
1. Engine model
2. Engine specification number
3. Engine serial number (10 digits)
4. Engine output without fan
5. Rated engine speed
6. Injection timing and type of camshaft
7. Manufacturers identification code
8. Indication of standard and /or regulation
9. ISO 3046, reference test conditions
10. ISO 3046, reference test conditions
11. Injection pump code (EP code)
12. Piston class
13. Prime output, without fan, at rated speed
Identification plates
Location of identification
plates (420-620, 520-722)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one should be mounted in a suitable location adjacent to the engine.
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General Information Group 20
1. Engine model
2. Engine specification number
3. Engine serial number (10 digits)
4. Engine output, without fan
5. Rated engine speed
6. Engine code (linked to EPA/EU Tier III approval)
7. Rated power, standard (peak power according to
Tier III)
8. Air temperature in °C (°F), in accordance with
ISO 3046
9. Altitude above mean sea level, in accordance with
ISO 3046
10. EU Tier III approval number
Identification plates
Location of identification
plates (TAD650/660, 750/760)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one is mounted up
on the valve cover.
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Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
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Group 20
General
Type designation .................................................... TD420VE TAD420VE TAD620VE
Rotation direction, facing flywheel: .........................Counterclockwise
Number of cylinders ............................................... 4 4 6
Bore, mm (inch) .....................................................101 (3.97") 101 (3.97") 98 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96") 126 (4.96")
Displacement, dm3 (inch3) ....................................... 4.04 (246.5) 4.04 (246.5) 5.7 (347.8)
Number of valves ...................................................8 8 12
Compression ratio:
EPA 1 .................................................................19:1 19:1 18.4:1
COM 2 ................................................................ 19:1 19:1 18.4:1
Firing sequence ..................................................... 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Engine performance at 2500 rpm, kW (hp) ............. 75 (102)
1, 3)
103 (140)
1, 3)
155 (209)
1, 3)
Max torque, Nm (lbf.ft) ........................................... 390 (288)
3)
493 (364)
3)
700 (516)
3)
At speed, rpm ..................................................... 1500 1500 1500
Low idle, rpm ......................................................... 800 800 800
Max, full load speed, rpm .......................................2000 – 25001)2000 – 25001)2000 – 2500
1)
Weight. engine (dry) kg (lb) .................................... 380 (838)
2)
380 (838)
2)
495 (1091)
2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
Technical Data
TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE
Page 14
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
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Group 20
General
Type designation .................................................... TAD650VE TAD660VE
Rotation direction, facing flywheel: .........................Counterclockwise Counterclockwise
Number of cylinders ............................................... 6 6
Bore, mm (inch) .....................................................101 (3.97") 98 (3.85")
Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96")
Displacement, dm3 (inch3) ....................................... 5.7 (347.8) 5.7 (347.8)
Number of valves ...................................................12 12
Compression ratio: ................................................. 18.4:1 18.4:1
Firing sequence ..................................................... 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 147 (200)
1, 3)
147 (200)
1, 3)
Max torque, Nm (lbf.ft) ........................................... 750 (553)
3)
800 (590)
3)
At speed, rpm ..................................................... 1600 1600
Low idle, rpm.......................................................... 600-800 600-800
Max, full load speed, rpm ....................................... 2400
1)
2400565
Weight. engine (dry) kg (lb) .................................... 565 (1246)
2)
565 (1246)
2)
Weight. engine (wet) kg (lb) ....................................585 (1290)
2)
585 (1290)
2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
Engine block
Cylinder head
Type ...................................................................... Common cylinder head
Max surface unevenness ....................................... 0.1 mm (0.0039")
Cylinder head bolts
Thread size ............................................................ M 12
Quantity and length:
TD420VE/TAD420VE .......................................... 13 x 108 mm (13 x 4.3")
TD420VE/TAD420VE .......................................... 5 x 178 mm (5 x 7")
Quantity and length:
TAD620VE, TAD650/660VE ............................... 19 x 108 mm (19 x 4.3")
TAD620VE, TAD650/660VE ............................... 7 x 178 mm (7 x 7")
Page 15
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
13
Group 20
Type:
TD420VE/TAD420VE/TAD650VE ....................... Parent bore
TAD620VE/TAD660VE ....................................... Dry, replaceable
Bore:
TD420VE/TAD420VE/TAD650VE ....................... 101
+0.02
mm (3.976"
+0.00078"
)
TAD620VE/TAD660VE ....................................... 98
+0.02
mm (3.858"
+0.00078"
)
Max bore wear:
TD420VE/TAD420VE/TAD650VE ....................... 101.1 mm (3.98")
TAD620VE .......................................................... 98.1 mm (3.86")
TAD660VE .......................................................... 98.1 mm (3.86")
Sealing surface: Height, see picture (A):
TAD620VE/TAD660VE ....................................... 4.5
-0.02
mm (0.177"
-0.0008"
)
Liner collar seating depth in block:
TAD620VE/TAD660VE ....................................... 4.38
+0.03
mm (0.1724"
+0.0012"
)
Projection of liner above block surface:
TAD620VE/TAD650/TAD660VE .......................... 0.012 – 0.07 mm (0.00047"– 0.0027")
Parent bore
TD420VE, TAD420VE
TAD650VE
Replaceable, dry
TAD620,
TAD660VE
Cylinder liners
A
Page 16
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
14
Group 20
• Set the dial gauge in the level of the crankcase surface to ”zero”.
• Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
• Measuring points between A and B on each piston is the distance X.
• Measure all pistons.
• Determine the maximum projection on each piston.
The highest piston projection number, determines the thickness of the cylinder head
gasket. The different head gaskets are identified by the hole identification on each of
the three different thickness available, see picture below.
Measuring points, distance X: ............................. Ø 90 mm (3.5")
Cylinder head gasket
Measuring piston projection
A dial gauge with a fixture (special tool: 999 8678) is needed to measure
the piston projection. The piston is in its TDC above the block surface.
Identification
1 Hole ....................................................................0.33 – 0.55 mm (0.012" – 0.021")
2 Holes .................................................................. 0.56 – 0.65 mm (0.022" – 0.025")
3 Holes .................................................................. 0.66 – 0.76 mm (0.026" – 0.03")
Page 17
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
15
Group 20
Piston rings
Compression rings
Number of rings ..................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ................................. Keystone
Lower compression ring (2) ................................. 0.17 mm (0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................. 0.8 mm (0.03")
Lower compression ring (2) ................................. 2.5 mm (0.0984")
Oilscraper ring (3)
Number: ................................................................. 1
Width, including springcoil: ..................................... 3 mm (0.12")
Piston ring clearance, height: ................................. 0.1 mm (0.0039")
Piston ring gap, wear limit: ..................................... 1.15 mm (0.045”)
Pistons
Number of piston ring grooves ................................ 3
Combustion chamber:
Diameter Ø ......................................................... 61
±0.1
mm (2.402"
±0.0039
”)
Combustion chamber depth:
TD420VE/TAD420VE .......................................... 18
±0.1
mm (0.7087"
±0.0039
”)
TAD620VE, TAD650/TAD660VE ........................ 17.5
±0.1
mm (0.689"
±0.0039
”)
Gudgeon pin diameter Ø ........................................ 38
-0.006
mm (1.496"
-0.0002"
)
Piston front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
1
2
3
Page 18
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
16
Group 20
Valve disc edge:
Inlet, min ............................................................. 1.8 mm (0.071")
Exhaust, min ...................................................... 1.1 mm (0.043")
Seat angle, cylinder head:
Inlet .................................................................... 30°
Exhaust .............................................................. 45°
Valve seat width, max:
Inlet, min ............................................................. 2.7 mm (0.106")
Exhaust, min ....................................................... 2.1 mm (0.083")
Valve mechanism
Valves
Disc diameter Ø:
Inlet .................................................................... 41.7
±0.1
mm (1.642"
±0.004"
)
Exhaust .............................................................. 35.9
±0.1
mm (1.413"
±0.004"
)
Stem diameter Ø:
Inlet .................................................................... 7.98
-0.015
mm (0.3142"
-0.0006"
)
Exhaust .............................................................. 7.96
-0.015
mm (0.3134"
-0.0006"
)
Valve seat angle:
Inlet, min ............................................................. 29.5°
Exhaust, min ....................................................... 44.5°
Min 1.8 mm Min 1.1 mm
45°
30°
29.5°
44.5°
Valve clearance (not apply for TAD660VE)
Inlet .................................................................... 0.35
±0.05
mm (0.014"
±0.002"
)
Exhaust .............................................................. 0.55
±0.05
mm (0.022"
±0.002"
)
Important! Control and adjusting of valve clearance is done with an engine oil
temperature between 20 – 80°C (68 – 176°F)
Page 19
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
17
Group 20
Diameter Ø (C), standard:
Inlet .................................................................... 42.7
-0.025
mm (1.681"
-0.001"
)
Exhaust .............................................................. 36.9
-0.025
mm (1.453"
-0.001"
)
Depth (D):
Inlet/Exhaust ...................................................... 10+1 mm (0.4"
+0.04"
)
Seat bottom radius (R):
Inlet/Exhaust ...................................................... 1
-0.3
mm (0.04"
-0.0118"
)
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ...................................................... Min 1.4 mm (0.055")
Valve guides
Inner diameter Ø:
Inlet/Exhaust ...................................................... 8.008
+0.0025
mm (0.3153"
0.00098"
)
Wear limit valve stem – guide:
Inlet .................................................................... 0.1 mm (0.0039")
Exhaust .............................................................. 0.13 mm (0.0051")
Valve springs
Type: ..................................................................... Single
Length: Unloaded: .................................................. 59
±1.9
mm (2.323"
±0.075"
)
Wire diameter Ø: .................................................... 4
±0.03
mm (0.16"
±0.001"
)
Ø A
B
Ø C
R
D
Outer diameter Ø (A), standard:
Inlet .................................................................... 42.79
-0.02
mm (1.685"
-0.0008"
)
Exhaust .............................................................. 36.99
-0.02
mm (1.456"
-0.0008"
)
Height (B):
Inlet .................................................................... 6.8
±0.1
mm (0.2677"
±0.004
)
Exhaust .............................................................. 7.5
±0.1
mm (0.2953"
±0.004
)
Valve seats
Valve seat location
Page 20
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
18
Group 20
Flywheel
Type of flywheel, standard :
TD/TAD420,620,650,660VE ................................ Clutch 10" or 11.5"
Max, permitted axial runout
Measuring radius 150 mm (5.91") ........................ 0.1 mm (0.004")
Number of teeth on flywheel ................................... 129
Camshaft
Type of camshaft: .................................................. Three different types: K, L or H
Drive ...................................................................... Gear
Number of bearings:
TD420VE/TAD420VE .......................................... 5
TAD620VE, TAD650/TAD660VE ........................ 7
Inner diameter Ø, bearing journals
Standard ............................................................. 63
+0.054
mm (2.48"
+0.0021"
)
Wear limit ........................................................... 63.08 mm (2.483")
Camshaft bearing thickness: max .......................... 1.388
+0.012
mm (0.05465"
+0.0005"
)
Axial clearance ...................................................... 0.1-0.5 mm (0.004-0.02")
Radial clearance .................................................... 0.05-0.124 mm (0.002-0.0049")
Position of bearing bush at flywheel end ................ 3
+0.2
mm (0.118"
+0.008"
)
Timing gear
1. Governor drive (not apply for 650/660)
2. Idler gear (not apply for 650/660)
3. Camshaft gear
4. PTO gear B-C (not apply for 650/660)
5. PTO gear A (not apply for 650/660)
6. Crankshaft
Page 21
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
19
Group 20
Crank mechanism
Crankshaft length:
TD420VE/TAD420VE .......................................... 618.8 mm (24.36")
TAD620VE, TAD650/TAD660VE ........................ 846.8 mm (33.34")
Crankshaft axial clearance1)................................... 0.1-0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1)............................... 0.03
+0.062
mm (0.0012"
+0.0024"
)
Max, permissible ovality of main
bearing and crank pins ........................................ 0.01 mm (0.0004")
Max, run-out of center bearing: .............................. 0.1 mm (0.0039"
1)
Important! The dimensions apply to oiled parts
Main bearing journals
Diameter for machining (A): Standard..................... 84
-0.02
mm (2.9134"
-0.0008
)
Undersize:
0.25 mm (0.01") .................................................. 83.75
-0.02
mm (3.2972"
-0.0008
)
Main bearing journals:
Out-of-round: Max. .............................................. 0.01 mm (0.0004")
Taper: Max. ........................................................ 0.01 mm (0.0004")
Width, axial bearing journal (B): Standard ............... 32.2
+0.04
mm (1.1268"
+0.0016"
)
Oversize:
0.4 mm (0.0157") ................................................ 32.6
+0.04
(1.283"
+0.0016"
)
Thrust washers (axial bearing)
Width (C): Standard ................................................ 2
+0.1
mm (0.079"
+0.004"
)
Oversize:
0.2 mm (0.0079") ................................................ 2.2
+0.1
mm (0.087"
+0.004"
)
Width (D):............................................................... 14 mm (0.55")
Main bearing shells
Type: ..................................................................... Replaceable
Inner diameter Ø (E): ............................................. 84.03
+0.042
mm (3.308"
+0.0017"
)
Thickness (F): Standard ......................................... 2.475
+0.01
mm (2.903"-2.903")
Oversize:
0.25 mm (0.01") .................................................. 2.6
+0.01
mm (0.1024"
+0.0004"
)
B
C
D
E
F
A
Page 22
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
20
Group 20
Connecting rod bearing journals
Diameter Ø for machining (G):
Standard ................................................................ 62.994
-0.02
mm (2.48"
-0.0008”
)
Undersize:
0.25 mm (0.01") .................................................. 62.744
-0.02
mm (2.4714"
-0.0008”
)
Width, axial bearing journal (H): ............................. 35.7
±0.02
mm (1.4"
±0.0008"
)
Connecting rod-bearing journals:
Out-of-round: Max. .............................................. 0.01 mm (0.0004")
Taper: Max ......................................................... 0.01 mm (0.0004")
Connecting rod bearing shells
Innerdiameter Ø, bearing (J): .................................. 63.026
+0.039
mm (2.442"
+0.00154”
)
Oversize:
0.25 mm (0.01") .................................................. 62.724
+0.02
mm (2.4716"
+0.00079”
)
Thickness (K): Standard ........................................ 1.777
+0.01
mm (0.06996
+0.0004”
)
Inside bore .......................................................... 66.6
+0.02
mm (2.622"
0.0008"
)
J
K
H
G
Page 23
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
21
Group 20
Connecting rods
Length (L): Center – Center .................................... 192
±0.02
mm (7.559"
-0.0008”
)
Connecting rod bushing bore (M): ........................... 38.025
+0.01
mm (1.497"
+0.0004”
)
Wear limit ............................................................ 0.08 mm (0.0031")
Axial clearance, connecting rod – crankshaft1)....... 0.2-0.3 mm (0.00787"-0.0118")
Connecting rod bearing: radial clearance1).............. 0.03-0.09 mm (0.00118"-0.00354")
Parallelism: Tolerans
Over a length of 100 mm..................................... 0.05 mm (0.002")
Squareness: Tolerans
Over a length of 100 mm .................................... 0.05 mm (0.002")
1)
Important! The dimensions apply to oiled parts.
L
M
Connecting rod marking:
Connecting rod and cap number marking must be on one side and identical.
Page 24
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
22
Group 20
Viscosity
The viscosity should be selected from the adjacent
table.
NOTE! the temperatures refer to constant outside air
temperature. The tabell above refers to synthetic or
synthetic-based oil.
Fuel sulfur content in percent by weight
Lubricating system
Up to 0.5 % 0.5 – 1 % More than 1 %
1)
Oil change interval: In operation whichever reached first
Oil grade
2)
VDS-3, VDS-2
ACEA: E7, E5, E3 500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
API: CI-4, CH-4, CG-4
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
Page 25
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
23
Group 20
Engine oil quantity
With oil filter:
TD420VE/TAD420VE .......................................... 10 liter (2.64 US gal)
TAD620VE, TAD650/TAD660VE ........................ 16 liter (4.22 US gal)
TD420VE/TAD420VE TAD620VE, TAD650VE, TAD660VE
1. Oil pressure sensor
Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD420VE/TAD420VE .......................................... 400 kPa (58 psi)
TAD620VE, TAD650/TAD660VE ........................ 370 kPa (53.7 psi)
At idle speed (800 rpm), min .................................. 80 kPa (11.6 psi)
Shut down switch, at pressure lower than: ............. 50 kPa (7.2 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling .................................................. 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size ....................................................... 0.012 mm (0.0005")
By-pass valve oil filter
Opening pressure ................................................250
±50
kPa (35±7 psi)
8.By-pass valve oil cooler:
Opening pressure ................................................210
±30
kPa (30.5±4 psi)
9. Safety valve, opening pressure:
TD420VE/TAD420VE .......................................... 600
±75
kPa (87
±10.7
psi)
TD620VE, TAD650/TAD660VE ........................... 400
±40
kPa (58±2 psi)
10. Lube oil pump
Type ...................................................................... Rotary pump driven by the crankshaft
Rotary pump width:
TD420VE/TAD420VE .......................................... 12.3 mm (0.48")
TD620VE, TAD650/TAD660VE ........................... 16.5 mm (0.65")
Oil flow (2500 rpm)
TD420VE/TAD420VE .......................................... 65 l/min (17 US gal/hour)
TD620VE, TAD650/TAD660VE ........................... 90 l/min (24 US gal/hour)
11. Oil cooler
Normal oil temperature: .......................................... 80°C (176°F)
Max oil temperature: ..............................................125°C (257°F)
Page 26
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
24
Group 20
1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")
1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")
1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve
2)
12. Return fuel line to fuel tank.
Inside diameter, min 10 mm (0.39")
1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose.
2)
Used for bleeding.
Fuel system (420, 620)
Page 27
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
25
Group 20
1. Fuel tank
2. Hand pump (accessory)
3. Fuel line (to pump)
4. Fuel pump
5. Fuel filter
6. Pipe to highpressure
7. Rail
8. Highpressure pump
9. Fuelpipe, to injector
10. Injector
11. M-prop
12. Pressurevalve
13. Return fuel line, to fuel tank, A = Fuel pipes,
minimum distance 300 mm (11.8")
Fuel system (650, 660)
Page 28
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
26
Group 20
Fuel feed pump
Fuel system figures are corresponding to the picture above.
1. Overpressure relief valve:
Opening pressure ................................................ 0.6
±0.05
MPa (87±7 psi)
1)
2. Bypass valve:
Opening pressure ................................................ 50±5 kPa (7.2
±0.7
psi)
Fuel flow:
Min fuel flow at 1500 rpm. ...................................... 600 l/hour (158.5 gal/hour)
Firing sequence
TD420VE/TAD420VE .......................................... 1-3-4-2
TAD620VE/TAD650VE/TAD660VE ..................... 1-5-3-6-2-4
Feed pressure ........................................................ 0.5 MPa (72.5 psi)
Feed pressure after fuel filter
At 1500 rpm: Min ................................................ 0.28 MPa (40.6 psi)
In
Out
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (With environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in each country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in power
output of 5% and an increase in fuel consumption of 2–3%.
Page 29
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
27
Group 20
Injection pump (420, 620)
Manufacturer ..........................................................Bosch
Designation ............................................................PF 33
Length A: ............................................................... 59 mm (2.3")
Basic measurement length LO :.............................. 117.5 mm (4.6")
Min length mm L
FB
: (A/100+117.5) – 117.5............ >0
Injection pump (420,620)
Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing of
the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this is
called A/100.
The pump length is defined by adding the basic measurement L
O
with the tolerance A/100, that are written on the injection pump
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering fuel.
LO= Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 117.5 + 0.63
The total length LFB = 118.13
Injectors
Opening pressure:
TD420VE ............................................................ 22 MPa (3190 psi)
TAD420VE/TAD620VE ....................................... 25 MPa (3630 psi)
Max pressure: ........................................................ 160 MPa (23200 psi)
Check leakage (for 10 sek):
TD420VE ............................................................ 20 MPa (2900 psi)
TAD420VE/TAD620VE ....................................... 23 MPa (3340 psi)
Numbers/bore Ø:
TD420VE ............................................................ 6 x 0.205 mm (6 x 0.008")
TAD420VE/TAD620VE ....................................... 6 x 0.203 mm (6 x 0.0079")
Fuel filter
Filtering size: .........................................................0.005 mm (0.0002")
Pre-filter
Filtering size: .........................................................0.006 mm (0.00024")
Page 30
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
28
Group 20
Commencement of delivery (FB) 420/620
The engine is equipped with a separate injection pump for each cylinder. This means that the commencement of delivery (FB), when
necessary, has to be adjusted separate for each pump unit. The
commencement of delivery (FB) is adjusted with a shim, placed
between lifter and injection pump.
For exchange of injection pump without any parts of vital importance has been replaced, see chapter ”EP code”.
For renovation or when any parts of vital importance have been replaced, special tools (999 8685 and 999 8679) must be used, to be
able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is indicated on the identification plate, see ”General information”,
”Identification plate”. When calculating the shim thickness, apply
a mathematical formula, see ”Theoretical thickness for shim”,
where some values are from table 1 and other are measured on the
engine. For complete instruction, see ”Workshop Manual”.
FB
(Commencement of
delivery)
Camshaft
types
Vh
Pre-stroke
Vh
corr.factor
Pre-stroke
correction factor
Lo
Basic dimension
Injection pump
Table 1, Commencement of delivery
All measurements are in mm (1 mm = 0.0394")
Page 31
Tekniska data
29
Grupp 20
Theoretical thickness for a new shim (420/620)
Computation for determining the theoretical shim thickness (TS) :
TS= L - [ ( FB
actual
- FB
nom
) x Vh
corr.factor
+ Vh
nom
+ Lo + A/100 ] (mm)
The correction factor Vh
corr.factor
is taken from the table on previous page.
The individual steps:
· 1st step: E
1
= FB
actual
- FB
nom
(°C/A)
· 2nd step: E
2
= E1 x Vh
corr.factor
(mm/°C/A)
· 3rd step: E
3
= E2 + Vh
nom
· 4th step: E
4
= E3 + L
O
· 5th step: E
5
= E
4
+ A/100 (mm)
· 6th step: T
S
= L – E
5
· 7th step: The actual shim thickness (S
S
) is determined with the help of table 2.
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm.
When the theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim
thickness (Ss). Important! Use only one shim at the time.
Theor. thickness
(TS)
Shim thickness (SS) Theor. thickness(TS) Shim thickness (SS)
Table 2, Shim thickness
All measurements are in mm (1 mm = 0.0394")
Page 32
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
30
Group 20
How to use EP code (420/620)
For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified method, when there is only the tolerance between the new and old injection pump that is the difference.
TS = EK - (LO + A/100)
TS = Shim thickness
EK = Value from tabel 3 read with help of EP code from ”Identification plate”.
LO = Basic measurement for the injection pumps, 420/620 = 117.5 mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and with
help of this value it is possible to read the new EK value with help of table 3.
If read EP code is ”275” that gives a EK value of 120.375 and if the manufacturing tolerance for the new injection
pump is ”63” we will have following equation: TS = 120.375 – (117.5 + 0.63)
TS are in this case 2.245 and a control in table 2 gives: SS = 2.3 mm
Thickness on the new shim to be mounted is in this example will be 2.3 mm
Ek(mm)
EP code
Ek(mm) EP code Ek(mm) EP code Ek(mm) EP code
Table 3, EP code conversion table
All measurements are in mm (1 mm = 0.0394")
Page 33
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
31
Group 20
Governor (420/620)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer .......................................................... Heinzmann
Designation:
TD420VE/TAD420VE/TAD620VE: ...................... 2500 rpm
TD420VE/TAD420VE/TAD620VE: ...................... 2300 rpm
TD420VE/TAD420VE/TAD620VE: ...................... 2100 rpm
Engine speed droop at a load increase from 0 to 100 % at rated speed:
TD420VE/TAD420VE/TAD620VE: ...................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod (420/620)
Control rod (fuel rack) travel Y, without injection pumps
Start and stop: ....................................................... 17 – 17.5 mm (0.67" – 0.69")
Control rod (fuel rack) travel Y, with injection pumps
Min: ....................................................................... 16.8 mm (0.66")
The recess dimension X ........................................ 0.3 – 1.3 mm (0.012" – 0.051")
Note! It is absolutely necessary to measure and indicate the recess dimension X, between the fuel rack, in stop
position and the contact surface of the governor, see picture.
Page 34
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
32
Group 20
Intake and exhaust system
Turbocharger
Make and designation ............................................ Schwitzer S200
Boost pressure at rated speed1), ±10 %:
TD420VE ............................................................ 105 kPa (15.2 psi)
TAD420VE .......................................................... 143 kPa (20.7 psi)
TAD620VE,TAD650VE,TAD660VE ..................... 155 kPa (22.5 psi)
Lube system .......................................................... Pressure lubrication
Max, permitted radial clearance
(compressor side) ............................................... 0.88 mm (0.0346")
Max, permitted axial clearance .............................. 0.1 mm (0.0039")
Max allowed back pressure in exhaust line ............ 7.5 kPa (0.9 psi)
Exhaust gas temperatur, approx:
At engine speed1): .................................................. 1800 rpm 2100 rpm 2300 rpm 2500 rpm
TD420VE ............................................................ 555°C 540°C 540°C 540°C
(1031°F) (1004°F) (1004°F) (1004°F)
TAD420VE .......................................................... 490°C 470°C 475°C 475°C
(914°F) (878°F) (887°F) (887°F)
TAD620VE,TAD650VE,TAD660VE ..................... 485°C 465°C 460°C 455°C
(905°F) (869°F) (860°F) (851°F)
1)
See General information, Power standards.
Cooling system
Type ...................................................................... Pressurized, closed
Pressure valve opens at max2)............................ 90 kPa (13 psi)
2)
Versatile engines are not equipped with a pressure valve from factory
Capacity, engine:
TD420VE/TAD420VE .......................................... 4.7 liters (1.24 US gal)
TAD620VE,TAD650VE,TAD660VE ..................... 6 liters (1.58 US gal)
Thermostat:
Type ...................................................................... One piston thermostat
Begins to open at ...................................................83°C (181°F)
Fully open at .......................................................... 95°C (203°F)
Coolant pump:
Type ...................................................................... Belt-driven centrifugal pump
Glycol (Antifreeze)
Volvo Penta glycol (antifreeze) mixed 45/55 with clean water
Anti-corrosion agent
Used only in markets where there is no risk of freezing, mixed with water3).
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative consequences.
Water quality specification:
To avoid the risk of clogging in the cooling system, the coolant should be mixed with pure water to ASTM D4985.
If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead.
Air intake
Air intake restriction, clean filter .............................2.5 kPa (0.3 psi)
Max allowed air intake restriction ...........................6.5 kPa (0.9 psi)
Page 35
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
33
Group 20
Tightening torque
General tightening torques Nm (lbf.ft)
M6 standard screw 8.8 ........................................... 10
±1.5
(7.5
±1
lbf.ft)
M8 standard screw 8.8 ........................................... 25
±4
(18
±3
lbf.ft)
M10 standard screw 8.8 ......................................... 50
±8
(37
±6
lbf.ft)
M12 standard screw 8.8 ......................................... 80
±9
(59
±6.5
lbf.ft)
M14 standard screw 8.8 ......................................... 140
±25
(103
±18
lbf.ft)
Tightening torques Nm (lbf.ft)
Group 21 Engine
Engine mounting .................................................... 260 (192lbf.ft)
Starter motor .......................................................... 70 (51.6 lbf.ft)
Timing gear casing ................................................. 21
±2
(15.5
±1.5
lbf.ft)
Main bearing caps
Screws to main bearing caps are reusable only three times.
Step 1 .................................................................... 50 (37 lbf.ft)
Step 2 .................................................................... 90° angle tightening
Step 3 .................................................................... 90° angle tightening
Connecting rod big-end bearing
Use new screws every time.
Step 1 .................................................................... 30 (22 lbf.ft)
Step 2 .................................................................... 60° angle tightening
Step 3 .................................................................... 30° angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ................................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ................................................................... 60° angle tightening
Step 3: ................................................................... 30° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ................................................................... 60° angle tightening
Step 3: ................................................................... 60° angle tightening
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ................................................................... 30 – 40 (22 – 30 lbf.ft)
Step 2: ................................................................... 60° angle tightening
Step 3: ................................................................... 60° angle tightening
Flywheel housing, M12........................................... 99
±1
(73±7 lbf.ft)
Flywheel housing, M16........................................... 243
±25
(179
±18
lbf.ft)
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ................................................................... 40 – 50 (30 – 37 lbf.ft)
Step 2: ................................................................... 60° angle tightening
Step 3: ................................................................... 60° angle tightening
Vibration damper .................................................... 70 (51.6 lbf.ft)
Screw, rocker cover ............................................... 9
±1
(6.5
±0.7
lbf.ft)
Lock nut, valve clearance adjusting screw ............. 20
±2
(14.5
±1.5
lbf.ft)
Screws, rocker arm fixing ...................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation ................................ 9
±1
(6.6
±0.7
lbf.ft)
Page 36
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
34
Group 20
Tightening torques Nm (lbf.ft)
Cylinder head
Screws to cylinder head are reusable only three times.
Step 1: ................................................................... 30 (22 lbf.ft)
Step 2: ................................................................... 80 (59 lbf.ft)
Step 3: ................................................................... 90° angle tightening
Group 22 Oil system
Oil cooler, screws .................................................. 21
±2
(15.5
±1.5
lbf.ft)
Oil cooler, screw plug ............................................. 80 (59 lbf.ft)
Front/oil pump housing ........................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil suction pipe ...................................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil sump ................................................................ 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure pipe turbo ........................................... 29
±3
(21.4
±2.2
lbf.ft)
Oil pressure pipe engine block ............................... 39
±4
(29±3 lbf.ft)
Screws, oil return pipe turbo
A) with tube fitting ............................................... 40
±2
(29.5
±1.5
lbf.ft)
B) with flange fitting ............................................ 21
±2
(15.5
±1.5
lbf.ft)
Screws, oil return pipe engine block ....................... 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure switch ................................................ 18
±2
(13
±1.5
lbf.ft)
Group 23 Fuel system
Screw, governor, idler gear (420/620):
Step 1: ................................................................... 30 (22.1 lbf.ft)
Step 2: ................................................................... 90° angle tightening
Screw, control rod hose ......................................... 10
±2
(7
±5
lbf.ft)
Screw, governor ..................................................... 17
±1.5
(12.5
±1
lbf.ft)
Flange screws, Injection pump
Step 1: Torque ....................................................... 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange ... 60° counterclockwise
Step 3: Turn injection pump to stop ....................... Counterclockwise
Step 4: ................................................................... 60° angle tightening
Step 5: ................................................................... 7 (5 lbf.ft)
Step 6: ................................................................... 10 (7.4 lbf.ft)
Step 7: ................................................................... 30 (22 lbf.ft)
Flange screw, injector ............................................ 16
+5
(12
+4
lbf.ft)
Injector cap nut ...................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Use a new delivery pipe after every disassembly
Step 1: ................................................................... 5 (3.7 lbf.ft)
Step 2: ................................................................... 25
±3.5
(18.4
±2.6
lbf.ft)
Screw, stop magnet ............................................... 21 (15.5 lbf.ft)
Overflow valve ....................................................... 30 (22 lbf.ft)
Common Rail, TAD650/660
Safety valve ........................................................ 100 (74 lbf.ft)
Rail pressuree sensor ......................................... 70 (51.6 lbf.ft)
Common rail unit ................................................. 30 (22.1 lbf.ft)
Fuel hose ............................................................ 39 (29±3 lbf.ft)
IEGR, TAD650/660
IEGR-unit: ........................................................... 20 (14.5 lbf.ft)
Solenoid valve: ................................................... 24 (18 lbf.ft)
Highpressure fuel pump, TAD650/660
Step 1: ................................................................ 10 (7.4 lbf.ft)
Step 2: ................................................................ 50 (37 lbf.ft)
Page 37
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
35
Group 20
Tightening torques Nm (lbf.ft)
Group 25 Inlet and exhaust system
Exhaust manifold nuts ........................................... 25
±2.5
(18.5
±1.8
lbf.ft)
M8 Nuts, turbo to exhaust manifold ....................... 21
±2
(15.5
±1.5
lbf.ft)
M10 Nuts, turbo to exhaust manifold ...................... 40.5
±4
(30±3 lbf.ft)
Screws, Inlet manifold ............................................ 11
±1
(8
±0.7
lbf.ft)
Group 26 Cooling system
Thermostat housing ............................................... 30 (22.1 lbf.ft)
Water temp sensor ................................................. 21
±2
(15.5
±1.5
lbf.ft)
Water pump ........................................................... 21
±2
(15.5
±1.5
lbf.ft)
NOTE! See also ”Tightening diagrams”.
Page 38
Technical Data: TD/TAD520, TAD530/531/532
36
Group 20
Technical Data
TD520GE, TAD520GE, TD520VE, TAD520VE
TAD530/531/532GE
General
Type designation ................................................... TD520GE TAD520GE TD520VE TAD520VE
Rotation direction, facing flywheel: ....................... Counterclockwise
Number of cylinders.............................................. 4 4 4 4
Bore, mm (inch) .................................................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ................................................. 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 ( inch3) .................................... 4.76 (290) 4.76 (290) 4.76 (290) 4.76 (290)
Number of valves ................................................. 8 8 8 8
Compression ratio: ............................................... 17.5:1 17.5:1 18.4:1 18.1:1
Firing sequence ................................................... 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Engine performance:
At 1500 rpm, kW (hp) ........................................ 77.5 (104)
1, 3)
94 (126)
1, 3)
——
At 1800 rpm, kW (hp) ........................................ 81.5 (109)
1, 3)
101 (135.5)
1, 3)
81 (110)
1, 4)
—
At 2300 rpm, kW (hp) ........................................ — — — 118 (158)
1, 4)
Engine torque, Nm ( lbf.ft)..................................... 493 (394)
3)
598 (441)
3)
430 (317)
4)
577 (425)
4)
At speed, rpm .................................................... 1500 1500 1800 1400
Engine torque, Nm ( lbf.ft)..................................... 432 (319)
3)
536 (395)
3)
——
At speed, rpm .................................................... 1800 1800 — —
Max speed at full load, rpm ................................... 1500/1800
1)
1500/1800
1)
1800
1)
2000 – 2300
1)
Weight engine (dry) kg (lb) ................................... 550 (1213)
2)
575 (1268)
2, 5)
430 (948)
2)
432 (952)
2)
Weight engine (wet) .............................................. 580 (1279)
2)
606 (1336)
2, 5)
725 (1336)
2, 6)
—
1)
See identification plate for specification
2)
Weight according to DIN 70020-A
3)
Measured at Prime Power, see ”General information”, ”Power standards”.
4)
See ”General information”, ”Power standards”.
5)
Extra weight on TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
6)
Including clutch and frame
Page 39
Technical Data: TD/TAD520, TAD530/531/532
37
Group 20
Type: .................................................................... Wet, replaceable
Number of seals per liner: ..................................... 2
Bore: ..................................................................... 108
+0.02
mm (4.252"
+0.0008"
)
Max bore wear: ..................................................... 108.1 mm (4.256")
Height sealing surface (A): .................................... 9
-0.02
mm (0.3543"
-0.0008"
)
Liner collar seating depth in block: ........................ 8.92
+0.03
mm (0,3512"
+0.0012"
)
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0.0012" – 0.0031")
A
Cylinder liners
TD520GE/TAD520GE
TD520VE/TAD520VE
TAD530/531/532GE
Engine block
Cylinder head
Type: ........................................ Common cylinder head
Max surface unevenness: ......... 0.085 mm (0.00335")
Cylinder head bolts
Thread size: .............................. M 14
Quantity and length: .................. 18 x 141 mm ( 18 x 5.55")
1)
See engine plate for specifications.
2)
Weight according to DIN 70020-A
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
Including clutch and frame
General
Type designation ..............................................
Direction of rotation (seen from flywheel)
No. of cylinders ................................................
Cylinder bore mm (inch) ...................................
Stroke mm (inch) .............................................
Cylinder volume liter (inch 3 ) .............................
No. of valves....................................................
Compression ratio:
EPA1 ............................................................
EPA2 ............................................................
EU2 ..............................................................
Injection sequence ...........................................
Engine power:
At 1500 rpm kW (hp) .....................................
At 1800 rpm kW (hp) .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Low idle rpm .....................................................
Highest full load speed rpm ..............................
Weight, dry (lb) .................................................
Gross weight, dry (lb)
TAD531GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
18.0:1
1-3-4-2
102 (139)
1)
110 (150)
1)
649 (479)
1500
584 (430)
1800
800 – 950
1500/1800
1)
575 (1268)
2,3)
606 (1336)
2,3)
TAD530GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
18.0:1
1-3-4-2
89 (139)
1)
95 (150)
1)
567 (479)
1500
504 (430)
1800
800 – 950
1500/1800
1)
575 (1268)
2,3)
606 (1336)
2,3)
TAD532GE
Anti- clockwise
4
108 (4.25”)
130 (5.12”)
4.76 (290)
8
18.0:1
1-3-4-2
129 (139)
1)
136 (150)
1)
821 (479)
1500
722 (430)
1800
800 – 950
1500/1800
1)
575 (1268)
2,3)
606 (1336)
2,3)
Replacable, wet
Page 40
Technical Data: TD/TAD520, TAD530/531/532
38
Group 20
• Set the dial gauge in the level of the crankcase surface to ”zero”.
• Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
• Measuring points between A and B on each piston is the distance X.
• Measure all pistons.
• Determine the maximum projection on each piston.
The highest piston projection number, determines the thickness of the cylinder head
gasket. The different head gaskets are identified by the hole identification on each of
the three different thickness available, see picture below.
Measuring points, distance X: ........................... Ø 95 mm (3.74")
Cylinder head gasket
Measuring piston projection
A dial gauge with a fixture (special tool: 999 8678) is needed to measure
the piston projection. The piston is in its TDC above the block surface.
Identification
1 Hole ................................................................... 0.28 – 0.53 mm (0.011" – 0.0201")
2 Holes ................................................................. 0.54 – 0.63 mm (0.0212" – 0.0248")
3 Holes ................................................................. 0.64 – 0.75 mm (0.0252" – 0.0295")
Page 41
Technical Data: TD/TAD520, TAD530/531/532
39
Group 20
Piston rings
Compression rings
Number of rings .................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ............................... Keystone, no clearance
Lower compression ring (2) ............................... 0.17 mm (0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ............................... 0.8 mm (0.03")
Lower compression ring (2) ............................... 2.5 mm (0.0984")
Oilscraper ring (3)
Number: ................................................................ 1
Width, including springcoil: ................................... 3 mm (0.12")
Piston ring clearance in groove: ........................... 0.1 mm (0.0039")
Piston ring gap, wear limit: .................................... 1.15 mm (0.045")
Pistons
Number of piston ring grooves .............................. 3
Combustion chamber:
Diameter ............................................................ 71
±0.1
mm (2.795"
±0.0039"
)
Depth ................................................................. 16.66
±0.1
mm (0.6559"
±0.0039"
)
Gudgeon pin diameter .......................................... 42
-0.006
(1.6535"
-0.0002"
)
Piston front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
1
2
3
Page 42
Technical Data: TD/TAD520, TAD530/531/532
40
Group 20
Outer diameter Ø (A), standard:
Inlet ................................................................... 49.09
-0.02
mm (1.933"
-0.0008"
)
Exhaust ............................................................. 43.06
-0.02
mm (1.717"
-0.0008"
)
Height (B):
Inlet ................................................................... 7.5
±0.1
mm (0.295"
±0.004"
)
Exhaust ............................................................. 7.9
±0.1
mm (0.311"
±0.004"
)
Valve disc edge:
Inlet, min ............................................................ 2.1 mm (0.0827")
Exhaust, min ...................................................... 1.8 mm (0.0709")
Seat angle, cylinder head:
Inlet ................................................................... 30°
Exhaust ............................................................. 45°
Valve seat width, max:
Inlet ................................................................... 2.8 mm (0.1102")
Exhaust ............................................................. 2.2 mm (0.0866")
Valve clearance:
Inlet ................................................................... 0.35
±0.05
mm (0.014"
±0.002"
)
Exhaust ............................................................. 0.55
±0.05
mm (0.022"
±0.002"
)
Important! Control and adjusting of valve clearance is done with an engine oil
temperature between 20 – 80°C (68 – 176°F)
Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48
±0.1
mm (1.8898"
±0.0039"
)
Exhaust ............................................................. 42
±0.1
mm (1.6535"
±0.0039"
)
Stem diameter Ø:
Inlet ................................................................... 8.98
-0.015
mm (0.3535"
-0.0006"
)
Exhaust ............................................................. 8.96
-0.015
mm (0.3528"
-0.0006"
)
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ...................................................... 44.5°
Ø A
B
Valve seats
Min 2.1 mm Min 1.8 mm
45°
30°
29.5°
44.5°
Page 43
Technical Data: TD/TAD520, TAD530/531/532
41
Group 20
Diameter Ø (C), standard:
Inlet ................................................................... 49
+0.025
mm (1.929"
-0.001"
)
Exhaust ............................................................. 43.5
+0.025
mm (1.712"
-0.001"
)
Depth (D):
Inlet/Exhaust ...................................................... 11+1 mm (0.43"
+0.04"
)
Seat bottom radius (R):
Inlet/Exhaust ...................................................... 1
-0.3
mm (0.04"
-0.012"
)
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ...................................................... Min 1.5 mm (0.059")
Ø C
R
D
Valve guides
Length:
Inlet/Exhaust ...................................................... 63
-0.5
mm (2.48"
-0.02"
)
Inner diameter Ø:
Inlet/Exhaust ...................................................... 9.025–9.04 mm (0.3553–0.3559")
Height above cylinder head spring surface:
Inlet/Exhaust ...................................................... 23
-0.5
mm (0.9"
-0.02"
)
Wear limit valve stem – guide:
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 ................................... 64.7
±1.3
mm (2.55"
±0.05"
)
Wire diameter Ø ................................................... 4.5 mm (0.18")
Valve seat location
Design 1
without flange
Design 2
On later models the o-ring seal is exchange to a valve
stem sealing, according to the picture for design 2.
Design 1
with flange
Flange
Production Exchange
O-ring
Page 44
Technical Data: TD/TAD520, TAD530/531/532
42
Group 20
Camshaft
Type of camshaft: ................................................. A
Drive ..................................................................... Gear
Number of bearings .............................................. 5
Inner diameter Ø, bearing journals
Standard ............................................................ 65
+0.054
mm (2.559"
+0.0021"
)
Wear limit .......................................................... 65.08 mm (2.5622")
Camshaft bearing thickness: max ......................... 1.988
+0.12
mm (0.7827"
+0.0005"
)
Axial clearance ..................................................... 0.1–0.5 mm (0.004–0.02")
Radial clearance ................................................... 0.05–0.124 mm (0.002–0.0049")
Position of bearing bush at flywheel end ............... 2
+0.5
mm (0.079"
+0.0197"
)
Flywheel
Type of flywheel :
TD520VE/TAD520VE ........................................ Clutch 10" or 11.5"
TD520GE/TAD530-532GE ................................. Gen set 1500 rpm
TD520GE/TAD520GE, TAD530-532GE .............. Gen set 1800 rpm
Max, permitted axial runout
Measuring radius 150 mm (5.91") ...................... 0.1 mm (0.00394")
Number of teeth on flywheel ................................. 129
Timing gear
1. Governor drive
2. Idler gear
3. Camshaft gear
4. PTO gear B-C
5. PTO gear A
6. Crankshaft
Page 45
Technical Data: TD/TAD520, TAD530/531/532
43
Group 20
Crank mechanism
Crankshaft length ................................................. 709.2 mm (27.92")
Crankshaft axial clearance1)................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1)............................. 0.03
+0.062
mm (0.0012"
+0.0024"
)
Max, permissible ovality of main
bearing and crank pins ...................................... 0.01 mm (0.0004")
Max, run-out of center bearing .............................. 0.07 mm (0.0027")
1)
Important! The dimensions apply to oiled parts
Main bearing journals
Diameter Ø for machining (A): Standard .............. 85
-0.02
mm (2.9134"
-0.0008"
)
Undersize:
0.25 mm (0.01") ................................................. 84.75
-0.02
mm (3.3366"
-0.0008"
)
0.5 mm (0.02") ................................................... 84.5
-0.02
mm (3.3268"
-0.0008"
)
Main bearing journals:
Out-of-round: Max. ............................................ 0.01 mm (0.0004")
Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal : standard ............ 38
+0.06
mm (1.496"
+0.0024"
)
Oversize:
0.4 mm (0.0157") ............................................... 38.4
+0.06
(1.5118"
+0.0024"
)
Thrust washers (axial bearing)
Width (C): Standard .............................................. 2.9
+0.05
mm (0.1142"
+0.0039"
)
Oversize:
0.2 mm (0.0079") ............................................... 3.1
+0.05
mm (0.122"
+0.002"
)
Width (D): ............................................................. 10 mm (0.4")
Main bearing shells
Type ..................................................................... Replaceable
Outer diameter Ø (E) ............................................ 85.03
+0.036
mm (2.9035"
+0.0014"
)
Thickness (F): Standard ....................................... 2.727
+0.008
mm (0.1074"
+0.0003"
)
Oversize:
0.25 mm (0.01") ................................................. 2.852
+0.008
mm (0.1123"
+0.0003"
)
0.5 mm (0.02") ................................................... 2.977
+0.008
mm (0.1172"
+0.0003"
)
B
C
A
D
E
F
Page 46
Technical Data: TD/TAD520, TAD530/531/532
44
Group 20
Connecting rod bearing journals
Diameter Ø (G) for machining:
Standard ............................................................... 68
-0.02
mm (2.6772"
-0.0008"
)
Undersize:
0.25 mm (0.01") ................................................. 67.75
-0.02
mm (2.6673"
-0.0008"
)
0.5 mm (0.02") ................................................... 67.5
-0.02
mm (2.6575"
-0.0008"
)
Width (H), axial bearing journal............................. 35.5
±0.04
mm (1.397"
±0.0016"
)
Connecting rod-bearing journals:
Out-of-round: Max. ............................................ 0.01 mm (0.0004")
Taper: Max ........................................................ 0.01 mm (0.0004")
Connecting rod bearing shells
Diameter Ø (J): Bearing ....................................... 68.03
+0.04
mm (2.6783"
+0.0016"
)
Oversize:
0.25 mm (0.01") ................................................. 67.78
+0.04
mm (2.6685"
+0.0016"
)
0.5 mm (0.02") ................................................... 67.53
+0.04
mm (2.6587"
+0.0016"
)
Diameter Ø: Bearing shell..................................... 72.5
+0.05
mm (2.854"
+0.002"
)
Thickness (K): Standard ....................................... 2.222
+0.01
mm (0.0875"
-0.0004"
)
J
K
H
G
Page 47
Technical Data: TD/TAD520, TAD530/531/532
45
Group 20
Connecting rods
Length (L): Center – Center .................................. 210
±0.06
mm (8.2677"
±0.00236"
)
Connecting rod (M) bushing bore ......................... 42.04
+0.01
mm (1.6551"
0.0004"
)
Wear limit .......................................................... 0.08 mm (0.0031")
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5
+0.02
mm (1.7913"
0.0008"
)
Small end bush outer diameter .......................... 45.58
+0.04
mm (1.7945"
+0.0016"
)
Axial clearance, connecting rod – crankshaft1)...... 0.3 – 0.4 mm (0.0118 – 0.0157")
Connecting rod bearing: radial clearance1)............ 0.036
+0.06
mm (0.00142"
+0.0024"
)
Parallelism: Tolerans
Over a length of 100 mm ................................... 0.05 mm (0.002")
Squareness: Tolerans
Over a length of 100 mm ................................... 0.05 mm (0.002")
1)
The dimensions apply to oiled parts
L
M
Connecting rod marking:
Connecting rod and cap number marking must be on one side
and identical
Page 48
Technical Data: TD/TAD520, TAD530/531/532
46
Group 20
Viscosity
The viscosity should be selected from the adjacent
table.
NOTE! the temperatures refer to constant outside air
temperature. The tabell above refers to synthetic or
synthetic-based oil.
Lubricating system
Oil grade
2)
Fuel sulfur content in percent by weight
Up to 0.5 % 0.5 – 1 % More than 1 %
1)
Oil change interval: In operation whichever reached first
VDS-3, VDS-2
ACEA: E7, E5, E3 500 hours or months 250 hours or months 125 hours or months
API: CI-4, CH-4, CG-4
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
Page 49
Technical Data: TD/TAD520, TAD530/531/532
47
Group 20
1. Oil pressure sensor
Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD520GE/TAD520GE/TAD530-532GE (1500 rpm): . 280 kPa (40.6 psi)
TD520GE/TAD720GE/TAD530-532GE (1800 rpm): 330 kPa (47.9 psi)
TD520VE: .......................................................... 440 kPa (63.8 psi)
TAD520VE: ....................................................... 390 kPa (56.6 psi)
Idle speed (800 rpm), min: .................................... 90 kPa (13.1 psi)
Shut down switch, at pressure lower than:
TD520GE/TAD520GE: ...................................... 200 kPa (29 psi)
TD520VE/TAD520VE: ....................................... 50kPa (7.2 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling: ............................................... 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size: ...................................................... 0.012 mm (0.0005")
Bypass valve oil filter:
Opening pressure: .............................................. 250
±50
kPa (35±7 psi)
8. Pressure regulating valve:
Opening pressure: ..............................................400
±40
kPa (58±6 psi)
9. Pressure-relief valve:
Opening pressure: ............................................. 1
±0.1
MPa (145
±14
psi)
10. Lube oil pump:
Type: .................................................................... Rotary pump driven by the crankshaft
Rotary pump width: ............................................... 10.5 mm (0.413")
Oil flow (2500 rpm): .............................................. 60l/min (16 US gal/hour)
11. Oil cooler:
Normal oil temperature: ......................................... 80°C (176°F)
Max oil temperature: ..............................................125°C (257°F)
Engine oil quantity
With oil filter:
TD520GE/TAD520GE: ...................................... 10 liter (2.64 US gal)
TD520VE/TAD520VE: ........................................ 13 liter (3.43 US gal)
TAD530/531/532GE: .......................................... 13 liter (3.43 US gal)
Page 50
Technical Data: TD/TAD520, TAD530/531/532
48
Group 20
Fuel system
1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")
1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")
1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve
2)
12. Return fuel line to fuel tank.
Inside diameter, min 12 mm (0.47")
1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
Page 51
Technical Data: TD/TAD520, TAD530/531/532
49
Group 20
Fuel feed pump
Fuel system figures is corresponding to the picture above
1. Overpressure relief valve:
Opening pressure ...............................................0.6
±0.05
MPa (87±7 psi)
1)
2. Bypass valve
Opening pressure ...............................................50±5 kPa (7.2
±0.7
psi)
Fuel flow
Min fuel flow at 1500 rpm ....................................... 600 l/tim (158.5 gal/hour)
Firing sequence .................................................... 1-3-4-2
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter
1500 rpm: Min .................................................... 0.28 MPa (40.6 psi)
In
Out
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in each country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in
power output of 5% and an increase in fuel consumption of 2–3%.
Page 52
Technical Data: TD/TAD520, TAD530/531/532
50
Group 20
Injection pump
Manufacturer ........................................................ Bosch
Designation .......................................................... PF 33 L
Length A: .............................................................. 54 mm (2.12")
Basic measurement length LO : ............................ 143 mm (5.63")
Min length L
FB
: (A/100+143) – 143 ....................... >0 mm
Injection pump
Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
The pump length is defined by adding the basic measurement
LO with the tolerance A/100, that are written on the injection
pump (LFB = LO + A/100).
Explanation:
LFB= The exact point when injection pumps starts delivering fuel.
LO= Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 143 + 0.63
The total length LFB = 143.63
Page 53
Technical Data: TD/TAD520, TAD530/531/532
51
Group 20
Injectors
Opening pressure:
TD520GE, TAD530-532GE: ............................... 25 MPa (3600 psi)
TAD520GE/TD520VE/TAD520VE: .................... 27.5 MPa (4000 psi)
Max pressure ........................................................ 120 MPa (17400 psi)
Check leakage (for 10 min):
TD520GE, TAD530-532GE: ............................... 23 MPa (3340 psi)
TAD520GE/TD520VE/TAD520VE: .................... 25.5 MPa (3700 psi)
Numbers/bore Ø:
TD520GE, TAD530-532GE ................................ 5 x 0.234 mm (0.00921")
TAD520GE/TD520VE/TAD520VE: ..................... 5 x 0.25 mm (0.00984")
Fuel filter
Filtering size ......................................................... 0.005 mm (0.0002")
Pre-filter
Filtering size ......................................................... 0.006 mm (0.00024")
Commencement of delivery (FB)
The engine is equipped with a separate injection pump for each cylinder. This means that the commencement of
delivery (FB), when necessary, has to be adjusted separate for each pump unit. The commencement of delivery
(FB) is adjusted with a shim, placed between lifter and injection pump.
For exchange of injection pump without any parts of vital importance has been replaced, see chapter ”EP code”.
For renovation or when any parts of vital importance have been replaced, special tools (999 8685 and 999 8679)
must be used, to be able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is indicated on the identification plate, see ”General
information”, ”Identification plate”. When calculating the shim thickness, apply a mathematical formula, see
”Theoretical thickness for shim”, where some values are from table 1 and other are measured on the engine.
For complete instruction, see ”Workshop Manual”.
Table 1 (Commencement of delivery)
All measurements are in mm (1 mm = 0.0394")
FB
(Commencement of
delivery)
Camshaft
types
Vh
Pre-stroke
Vh
corr.factor
Pre-stroke
correction factor
Lo
Basic dimension
Injection pump
Page 54
Technical Data: TD/TAD520, TAD530/531/532
52
Group 20
Theoretical thickness for a new shim.
Computation for determining the theoretical shim thickness (Ts) :
Ts = L - [ ( FB
actual
- FB
nom
) x Vh
corr.factor
+ Vh
nom
+ Lo + A/100 ] (mm)
The correction factor Vh
corr.factor
is taken from the table on previous page.
The individual steps:
· 1st step: E
1
= FB
actual
- FB
nom
(°C/A)
· 2nd step: E
2
= E1 x Vh
corr.factor
(mm/°C/A)
· 3rd step: E
3
= E2 + Vh
nom
· 4th step: E
4
= E3 + Lo
· 5th step: E
5
= E4 + A/100 (mm)
· 6th step: Ts = L – E
5
· 7th step: The actual shim thickness (S
s
) is determined with the help of table 2 below.
Theor. thickness (TS) Shim thickness (SS) Theor. thickness (TS)
Shim thickness (SS)
Table 2 (Shim thickness)
All measurements are in mm (1 mm = 0.0394")
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm.
When the theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim
thickness (Ss). Important! Use only one shim at the time.
Page 55
Technical Data: TD/TAD520, TAD530/531/532
53
Group 20
How to use EP code
For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified method, when there is only the tolerance between the new and old injection pump that is the difference.
TS = EK - (LO + A/100)
TS = Shim thickness
EK = Value from tabel 3 read with help of EP code from ”Identification plate”.
LO = Basic measurement for the injection pumps, 420/620 = 117.5 mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and with
help of this value it is possible to read the new EK value with help of table 3.
If read EP code is ”364” that gives a EK value of 146.675 and if the manufacturing tolerance for the new injection
pump is ”63” we will have following equation: TS = 146.675 – (143 + 0.63)
TS are in this case 3.045 and a control in table 2 gives: SS = 3 mm
Thickness on the new shim to be mounted is in this example will be 3 mm
Ek(mm) EP
code
Ek(mm)
EP
code
Ek(mm) EP
code
Ek(mm) EP
code
Table 3, EP code conversion table
All measurements are in mm (1 mm = 0.0394")
Ek(mm) EP
code
Page 56
Technical Data: TD/TAD520, TAD530/531/532
54
Group 20
Governor
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer ........................................................ Heinzmann
Designation:
TD520GE/TAD520GE/TAD530-532GE: .............. 1500 rpm
TD520GE/TAD520GE/TAD530-532GE: .............. 1800 rpm
TD520VE: .......................................................... 1800 rpm
TAD520VE: ....................................................... 2100 rpm
TAD520VE: ....................................................... 2200 rpm
TAD520VE: ....................................................... 2300 rpm
Max, engine speed droop at a load increase from 0 to 100 % at rated speed:
TD520GE/TAD520GE: ...................................... <5 %
TD520VE: .......................................................... 8 – 12%
TAD520VE: ....................................................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated
power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod
Control rod (fuel rack) travel Y, without injection pumps
Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Control rod (fuel rack) travel Y, with injection pumps
Min: ...................................................................... 16.8 mm (0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm (0.012" – 0.051")
Note! It is absolutely necessary to measure and indicate the recess dimension X, between the fuel rack, in stop
position and the contact surface of the governor, see picture.
Page 57
Technical Data: TD/TAD520, TAD530/531/532
55
Group 20
Intake and exhaust system
Turbocharger
Make and designation ........................................... Schweitzer S2B
Boost pressure at rated speed1), ±10 %:
TD520GE/TAD530-532GE (1500 rpm): ............... 125 kPa (18 psi)
TD520GE/TAD530-532GE (1800 rpm): ............... 137 kPa (20 psi)
TAD520GE (1500 rpm):..................................... 127 kPa (18.4 psi)
TAD520GE (1800 rpm):..................................... 128 kPa (18.6 psi)
TD520VE: ..........................................................2) kPa (2) psi)
TAD520VE: ....................................................... 120 kPa (17.4 psi)
Lube system: ......................................................... Pressure lubrication
Max, permitted radial clearance
(compressor side): .............................................. 0.95 mm (0.0374")
Max, permitted axial clearance: ............................. 0.14 mm (0.00551")
Max allowed back pressure in exhaust line:
TD520GE/TAD530-532GE (1500 rpm): ............... 3 kPa (0.4 psi)
TD520GE/TAD530-532GE (1800 rpm): ............... 5 kPa (0.7 psi)
TAD520GE (1500 rpm):..................................... 5 kPa (0.7 psi)
TAD520GE (1800 rpm):..................................... 7 kPa (1 psi)
TD520VE/TAD520VE: ....................................... 7.5 kPa (1.1 psi)
Exhaust gas temperatur, approx:
At rated speed (standby power)
1)
: ......................... 1500 rpm 1800 rpm
TD520GE/TAD530GE: ....................................... 610°C (1130°F) 530°C (986°F)
TAD520GE/TAD531GE, TAD532GE: ................. 520°C (968°F) 448°C (838°F)
At rated speed: ..................................................... 1800 rpm 2100 rpm 2200 rpm 2300 rpm
TD520VE: .......................................................... 510°C (950°F) — — —
TAD520VE: ........................................................ 475°C (887°F) 470°C (878°F) 470°C (878°F) 470°C (878°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD520VE/TAD520VE: ....................................... 2.5 kPa (0.36 psi)
TD520GE/TAD520GE/TAD530-532GE: .............. 1 kPa (0.14 psi)
Max allowed air intake restriction
TD520VE/TAD520VE: ....................................... 6.5 kPa (0.94 psi)
TD520GE/TAD520GE/TAD530-532GE: .............. 3 kPa (0.43 psi)
Page 58
Technical Data: TD/TAD520, TAD530/531/532
56
Group 20
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD520GE/TAD520GE/TAD530/531GE ............... 90 kPa (13 psi)
TD520VE/TAD520VE, max: ............................... 90 kPa
1)
(13 psi)
TAD532GE: ....................................................... 60 kPa (8.7 psi)
1)
Versatile engines are not equipped with a pressure valve from factory
Capacity (engine): ................................................ 7.2 liters (1.9 US gal)
Capacity (engine and cooler):
TD520GE, TAD530/531GE: ............................... 17.5 liters (4.62 US gal)
TAD520GE: ....................................................... 19.7 liters (5.2 US gal)
TAD532GE: ....................................................... 23.8 liters (6.3 US gal)
Thermostat
Type ...................................................................... One piston thermostat
Begins to open at
TD520GE/TAD520GE/TD520VE/TAD530/531GE: 83°C (181°F)
TAD520VE: ....................................................... 87° C (189° F)
Fully open at
TD520GE/TAD520GE/TD520VE/TAD530/531GE: 95°C (203°F)
TAD520VE: ........................................................ 102°C (216° F)
Coolant pump
Type ...................................................................... Belt-driven centrifugal pump
Glycol (Antifreeze)
Volvo Penta glycol (antifreeze) mixed 45/55 with clean water
Anti-corrosion agent
Used only in markets where there is no risk of freezing, mixed with water3).
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative
consequences.
Water quality specification:
To avoid the risk of clogging in the cooling system, the coolant should be mixed with pure water to ASTM D4985.
If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
1. Coolan connection (inlet)
2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Page 59
Technical Data: TD/TAD520, TAD530/531/532
57
Group 20
Tightening torque
General tightening torques Nm (lbf.ft)
M6 standard screw 8.8 .......................................... 10
±1.5
(7.5
±1
lbf.ft)
M8 standard screw 8.8 .......................................... 25
±4
(18
±3
lbf.ft)
M10 standard screw 8.8 ........................................ 50
±8
(37
±6
lbf.ft)
M12 standard screw 8.8 ........................................ 80
±9
(59
±6.5
lbf.ft)
M14 standard screw 8.8 ........................................ 140
±25
(103
±18
lbf.ft)
Tightening torques Nm (lbf.ft)
Group 21 Engine
Engine mounting ................................................... 260 (192lbf.ft)
Starter motor ........................................................ 70 (51.6 lbf.ft)
Timing gear casing ............................................... 21
±2
(15.5
±1.5
lbf.ft)
Main bearing caps
Screws to main bearing caps are reusable only three times.
Step 1 ................................................................ 50 (37 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................60° angle tightening
Connecting rod big-end bearing
Use new screws every time.
Step 1 ................................................................ 50 (22 lbf.ft)
Step 2 ................................................................ 60° angle tightening
Step 3 ................................................................ 60° angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 30° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ............................................................... 30 – 40 (22 – 30 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
Flywheel housing. M12 ......................................... 99
±1
(73±7 lbf.ft)
Flywheel housing. M16 ......................................... 243
±25
(179
±18
lbf.ft)
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ............................................................... 40 – 50 (30 – 37 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
Vibration damper .................................................. 70
Screw, rocker cover ............................................... 9
±1
(6.5
±0.7
lbf.ft)
Lock nut, valve clearance adjusting screw ............ 20
±2
(14.5
±1.5
lbf.ft)
Screws, rocker arm fixing ..................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation .............................. 9
±1
(6.6
±0.7
lbf.ft)
Page 60
Technical Data: TD/TAD520, TAD530/531/532
58
Group 20
Tightening torques Nm (lbf.ft)
Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50 (37 lbf.ft)
Step 2: ............................................................... 130 (96 lbf.ft)
Step 3: ............................................................... 90° angle tightening
Group 22 Oil system
Oil cooler, screws ................................................. 21
±2
(15.5
±1.5
lbf.ft)
Oil cooler, hollow screw
Step 1: ............................................................... 80 (59 lbf.ft)
Step 2: ............................................................... 160 (118 lbf.ft)
Oil cooler, screw plug ........................................... 80 (59 lbf.ft)
Front/oil pump housing ......................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil suction pipe ..................................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil sump ............................................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure pipe turbo ......................................... 29
±3
(21.4
±2.2
lbf.ft)
Oil pressure pipe engine block ............................. 39
±4
(29±3 lbf.ft)
Screws, oil return pipe turbo
A) with tube fitting .............................................. 40
±2
(29.5
±1.5
lbf.ft)
B) with flange fitting ........................................... 21
±2
(15.5
±1.5
lbf.ft)
Screws, oil return pipe engine block ..................... 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure switch ............................................... 18
±2
(13
±1.5
lbf.ft)
Group 23 Fuel system
Screw, governor, idler gear:
Step 1: ............................................................... 30 (22.1 lbf.ft)
Step 2: ............................................................... 90° angle tightening
Screw, control rod hose ........................................ 10
±2
(7
±5
lbf.ft)
Screw, governor ................................................... 17
±1.5
(12.5
±1
lbf.ft)
Flange screws, Injection pump
Step 1: Torque ................................................... 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange 60° counterclockwise
Step 3: Turn injection pump to stop ................... Counterclockwise
Step 4: ............................................................... 60° angle tightening
Step 5: ............................................................... 7 (5 lbf.ft)
Step 6: ............................................................... 10 (7.4 lbf.ft)
Step 7: ............................................................... 30 (22 lbf.ft)
Flange screw, injector ........................................... 16
+5
(12
+4
lbf.ft)
Injector cap nut ..................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Use a new delivery pipe after every disassembly
Step 1: ............................................................... 5 (3.7 lbf.ft)
Step 2: ............................................................... 25
+3.5
(18.4
±2.6
lbf.ft)
Screw, stop magnet .............................................. 21 (15.5 lbf.ft)
Overflow valve ...................................................... 30 (22 lbf.ft)
Group 25 Inlet and exhaust system
Exhaust manifold nuts .......................................... 25
±2.5
(18.5
±1.8
lbf.ft)
M8 Nuts, turbo to exhaust manifold ...................... 21
±2
(15.5
±1.5
lbf.ft)
M10 Nuts, turbo to exhaust manifold .................... 40.5
±4
(30±3 lbf.ft)
Screws, Inlet manifold .......................................... 11
±1
(8
±0.7
lbf.ft)
Group 26 Cooling system
Thermostat housing .............................................. 30 (22.1 lbf.ft)
Water temp sensor ............................................... 21
±2
(15.5
±1.5
lbf.ft)
Water pump .......................................................... 21
±2
(15.5
±1.5
lbf.ft)
NOTE! See also ”Tightening diagrams”.
Page 61
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
59
Group 20
Technical Data
TD/TAD720GE, TD/TAD720VE, TAD721GE/VE,
TAD722GE, TAD722VE, TAD730/731/732/733GE,
TAD750VE, TAD760VE
General
Type designation .......................... TD720GE TAD720GE TAD721GE TAD722GE
Rotation direction, facing flywheel: Counterclockwise
Number of cylinders ..................... 6 6 6 6
Bore, mm (inch) ........................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3) 7.15 (436.3) 7.15 (436.3) 7.15 (436.3)
Number of valves ......................... 12 12 12 12
Compression ratio:
EPA 1 ....................................... 17.1:1 17.5:1 — —
COM 2 ...................................... — — 18.1:1 18.1:1
Firing sequence ........................... 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 128
1, 3)
153
1, 3)
183
1, 3)
201
1, 3)
At 1800 rpm, kW (hp) ................ 134
1, 3)
163
1, 3)
204
1, 3)
225
1, 3)
Engine torque, Nm (lbf.ft) ............. 815
3)
974
3)
1165 1280
At speed, rpm ........................... 1500 1500 1500 1500
Engine torque, Nm (lbf.ft) ............. 711
3)
865
3)
1082 1193
At speed, rpm ........................... 1800 1800 1800 1800
Low idle, rpm................................ 850-950 850-950 800-950 800-950
Max speed at full load (rpm) ......... 1500/1800
1)
1500/1800
1)
1500/1800
1)
1500/1800
1)
Weight engine (dry) kg (lb) ........... 750 (1653)
2)
760 (1674)
2)
785
2)
785
2)
Weight engine (wet) kg (lb) ........... 790 (1742 lb)2)804 (1773 lb)2)826
2)
826
2)
1)
See identification plate for specification
2)
Weight according to DIN 70020-A
3)
Measured at Prime Power, see ”General information, Power standards”
Page 62
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
60
Group 20
General
Type designation .......................... TD720VE TAD720VE TAD721VE TAD722VE
Rotation direction, facing flywheel: Counterclockwise
Number of cylinders ..................... 6 6 6 6
Bore, mm (inch) ........................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3) 7.15 (436.3) 7.15 (436.3) 7.15 (436.3)
Number of valves ......................... 12 12 12 12
Compression ratio:
EPA 1 ....................................... 18.4:1 18.4:1 18.4:1 —
COM 2 ...................................... — 19.0:1 19.0:1 19.0:1
Firing sequence ........................... 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 122
1)
———
At 1800 rpm, kW (hp) ................ — 174
1)
195
1)
200
1)
Engine torque, Nm (lbf.ft) ............. 701 817 897 981
At speed, rpm ........................... 1500 1800 1800 1800
Low idle, rpm................................ 850-950 850-950 850-950 800-950
Max speed at full load (rpm) ......... 1800
1)
2000-2300
1)
2000-2300
1)
2100-2300
1)
Weight engine (dry) kg (lb) ........... 570
2)
572
2)
572
2)
680
2)
Weight engine (wet) kg (lb) ........... 920
2,3)
———
1)
See identification plate for specification
2)
Weight according to DIN 70020-A
3)
Including clutch and frame
TAD732GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7,15 (436)
12
18,0:1
1-5-3-6-2-4
201 (273)
1)
225 (306)
1)
1280 (944)
1500
1193 (880)
1800
800 – 950
1500/1800
1)
785 (1731)
2)
826 (1821)
2)
TAD733GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7,15 (436)
12
18,0:1
1-5-3-6-2-4
201 (273)
1)
225 (306)
1)
1280 (944)
1500
1193 (880)
1800
800 – 950
1500/1800
1)
785 (1731)
2)
826 (1821)
2)
Type designation ................................
Direction of rotation
(seen from flywheel)
No. of cylinders ..................................
Cylinder bore mm (inch) ......................
Stroke mm (inch) ................................
Cylinder volume liter
(inch 3 ) ...............
No. of valves ......................................
Compression ratio:
EPA1 ...............................................
EPA2 ...............................................
EU2 .................................................
Injection sequence .............................
Engine power:
At 1500 rpm kW (hp) .......................
At 1800 rpm kW (hp) .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Low idle rpm .......................................
Highest full load speed rpm ................
Weight, dry (lb) ...................................
Gross weight, dry (lb)
1)
See engine plate for specifications.
2)
Weight according to DIN 70020-A
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
Including clutch and frame
TAD731GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
17.1:1
17.1:1
1-5-3-6-2-4
153 (208)
1)
163 (222)
1)
974 (718)
1500
865 (638)
1800
800 – 950
1500/1800
1)
760 (1674)
2)
804 (1773)
2)
TAD730GE
Anti- clockwise
6
108 (4.25”)
130 (5.12”)
7.15 (436.3)
12
17.1:1
18.0:1
1-5-3-6-2-4
129 (208)
1)
136 (222)
1)
821 (718)
1500
722 (638)
1800
800 – 950
1500/1800
1)
760 (1674)
2)
804 (1773)
2)
General
Page 63
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
61
Group 20
Type: .................................................................... Wet, replaceable
Number of seals per liner: ..................................... 2
Bore: ..................................................................... 108
+0.02
mm (4.252”
+0.0008”
)
Max bore wear: ..................................................... 108.1 mm (4.256”)
Sealing surface. height (A): ................................... 9
-0.02
mm (0.3543”
-0.0008”
)
Liner collar seating depth in block: ........................ 8.92
+0.03
mm (0,3512”
+0.0012”
)
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0.0012 – 0.0031”)
Replacable, wet
A
Cylinder liners
TD720GE, TAD720GE, TAD721GE,
TAD722GE, TAD720VE, TAD720VE,
TAD721VE, TAD722VE, TAD730-733GE,
TAD750, TAD760VE
General
Type designation .................................................... TAD750VE TAD760VE
Rotation direction, facing flywheel: .........................Counterclockwise Counterclockwise
Number of cylinders ............................................... 6 6
Bore, mm (inch) ..................................................... 108 (4.25") 108 (4.25")
Stroke, mm (inch) .................................................. 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ....................................... 7.15 (436) 7.15 (436)
Number of valves ...................................................12 12
Compression ratio: ................................................. 18.1:1 18.1:1
Firing sequence ..................................................... 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 181 (246)
1, 3)
181 (246)
1, 3)
Max torque, Nm (lbf.ft) .......................................... 1050 (775)
3)
1100 (811)
3)
At speed, rpm .................................................... 1500 1500
Low idle, rpm......................................................... 600 - 800 600 - 800
Max, full load speed, rpm .......................................2400
1)
2400
1)
Weight. engine (dry) kg (lb) .................................... 650 (1433)
2)
650 (1433)
2)
Weight. engine (wet) kg (lb) ....................................681 (1501)
2)
680 (1496)
2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
Engine block
Cylinder head
Type: ........................................ Common cylinder head
Max surface unevenness: ......... 0.125 mm (0.00492")
Cylinder head bolts
Thread size: .............................. M 14
Quantity and length: .................. 26 x 141 mm (26 x 5.55”)
Page 64
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
62
Group 20
• Set the dial gauge in the level of the crankcase surface to ”zero”.
• Position the dial gauge at the measuring points A and B on the top of the piston, in-
line with the gudgeon pin.
• Measuring points between A and B on each piston is the distance X.
• Measure all pistons.
• Determine the maximum projection on each piston.
The highest piston projection number, determines the thickness of the cylinder head
gasket. The different head gaskets are identified by the hole identification on each of the
three different thickness available, see picture below.
Measuring points, distance X: ............................ Ø 95 mm (3.74")
Cylinder head gasket
Measuring piston projection
A dial gauge with a fixture (special tool: 999 8678) is needed to measure
the piston projection. The piston is in its TDC above the block surface.
Identification
1 Hole ................................................................... 0.28 – 0.53 mm (0.011" – 0.0201")
2 Holes ................................................................. 0.54 – 0.63mm (0.0212" – 0.0248")
3 Holes ................................................................. 0.64 – 0.75 mm (0.0252" – 0.0295")
Page 65
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
63
Group 20
Piston rings
Compression rings
Number of rings .................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ................................ Keystone, no clearance
Lower compression ring (2) ................................ 0.17 mm (0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................ 0.8 mm (0.03")
Lower compression ring (2) ................................ 2.5 mm (0.0984")
Oilscraper ring (3)
Number: ................................................................ 1
Width, including springcoil: .................................... 3 mm (0.12")
Piston ring clearance. height: ................................ 0.1 mm (0.0039")
Piston ring gap, wear limit: .................................... 1.15 mm (0.045”)
Pistons
Number of piston ring grooves ............................... 3
Combustion chamber:
Diameter Ø ........................................................... 71
±0.1
mm (2.795"
±0.0039"
)
Depth .................................................................... 16.66
±0.1
mm (0.6559"
±0.0039"
)
Gudgeon pin diameter Ø ....................................... 42
-0.006
mm (1.6535"
-0.0002"
)
Piston front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
1
2
3
Page 66
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
64
Group 20
Valve disc edge:
Inlet, min ............................................................ 2.1 mm (0.0827")
Exhaust, min ..................................................... 1.8 mm (0.0709")
Seat angle, cylinder head:
Inlet ................................................................... 30°
Exhaust ............................................................. 45°
Valve seat width, max:
Inlet, min ............................................................ 2.8 mm (0.1102")
Exhaust, min ..................................................... 2.2 mm (0.0866")
Valve clearance (not apply for TAD760VE)
Inlet ................................................................... 0.35
±0.05
mm (0.014"
±0.002"
)
Exhaust ............................................................. 0.55
±0.05
mm (0.022"
±0.002"
)
Important! Control and adjusting of valve clearance is done
with an engine oil temperature between 20 – 80°C (68 – 176°F)
Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48
±0.1
mm (1.8898"
±0.0039"
)
Exhaust ............................................................. 42
±0.1
mm (1.6535"
±0.0039"
)
Stem diameter Ø:
Inlet ................................................................... 8.98
-0.015
mm (0.3535"
-0.0006"
)
Exhaust ............................................................. 8.96
-0.015
mm (0.3528"
-0.0006"
)
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ..................................................... 44.5°
Min 2.1 mm
Min 1.8 mm
45°
30°
29.5°
44.5°
Outer diameter Ø (A), standard:
Inlet ................................................................... 49.09
-0.02
mm (1.933"
-0.0008"
)
Exhaust ............................................................. 43.06
-0.02
mm (1.695"
-0.0008"
)
Height (B):
Inlet ................................................................... 7.5
±0.1
mm (0.295"
±0.004"
)
Exhaust ............................................................. 7.9
±0.1
mm (0.311"
±0.004"
)
Ø A
B
Valve seats
Page 67
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
65
Group 20
Valve guides
Length:
Inlet/Exhaust ..................................................... 63
-0.5
mm (2.48"
-0.02"
)
Inner diameter Ø:
Inlet/Exhaust ..................................................... 9.025–9.04 mm (0.3553–0.3559")
Height above cylinder head spring surface:
Inlet/Exhaust ..................................................... 23
-0.5
mm (0.9"
-0.02"
)
Wear limit valve stem – guide:
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 .................................... 64.7
±1.3
mm (2.55"
±0.05"
)
Wire diameter Ø .................................................... 4.5 mm (0.18")
Diameter Ø (C), standard:
Inlet ................................................................... 49
-0.025
mm (1.929"
-0.001"
)
Exhaust ............................................................. 43.5
-0.02
mm (1.712"
-0.001"
)
Depth (D):
Inlet/Exhaust ..................................................... 11+1 mm (0.43"
+0.04"
)
Seat bottom radius (R):
Inlet/Exhaust ..................................................... 1
-0.3
mm (0.04"
-0.012"
)
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ..................................................... Min 1.5 mm (0.059")
Ø C
R
D
Valve seat location
Design 1
without flange
Design 2
On later models the o-ring seal is exchange to a valve
stem sealing, according to the picture for design 2.
Design 1
with flange
Flange
Production Exchange
O-ring
Page 68
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
66
Group 20
Camshaft
Type of camshaft:
TD720GE, TAD720GE, TAD730GE ................... A
TD720VE, TAD720VE, TAD721VE .................... A or M
TAD721/722GE, TAD722VE, TAD731-733GE
TAD750/760VE .................................................. S
Drive ..................................................................... Gear
Number of bearings ............................................... 7
Inner diameter Ø, bearing journals
Standard ............................................................ 65
+0.054
mm (2.559"
+0.0021"
)
Wear limit ........................................................... 65.08 mm (2.5622")
Camshaft bearing thickness: max ......................... 1.988
+0.012
mm (0.7827"
+0.0005"
)
Axial clearance ..................................................... 0.1– 0.5 mm (0.004 – 0.02")
Radial clearance ................................................... 0.05 – 0.124 mm(0.002 – 0.0049")
Position of bearing bush at flywheel end ............... 2
+0.5
mm (0.079"
+0.0197"
)
Flywheel
Type of flywheel :
TD/TAD720/721/722/750/760VE ........................ Clutch 10" or 11.5"
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1500 rpm
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1800 rpm
Max, permitted axial throw:
Measuring radius 150 mm (5.91") ....................... 0.1 mm (0.00394")
Number of teeth on flywheel .................................. 129
Timing gear
1. Governor drive (not apply for 750/760)
2. Idler gear (not apply for 750/760)
3. Camshaft gear
4. PTO gear B-C (not apply for 750/760)
5. PTO gear A (not apply for 750/760)
6. Crankshaft gear
Page 69
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
67
Group 20
Main bearing journals
Diameter Ø (A) for machining: Standard ............... 85
-0.02
mm (2.9134"
-0.0008"
)
Undersize:
0.25 mm (0.01") ................................................. 84.75
-0.02
mm (3.3366"
-0.0008"
)
0.5 mm (0.02") ................................................... 84.5
-0.02
mm (3.3268"
-0.0008"
)
Main bearing journals:
Out-of-round: Max. ............................................. 0.01 mm (0.0004")
Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal: standard .............. 38
+0.06
mm (1.496"
+0.0024"
)
Oversize:
0.4 mm (0.0157") ............................................... 38.4
+0.06
mm (1.5118"
+0.0024"
)
Thrust washers (axial bearing)
Width (C): Standard ............................................... 2.9
+0.05
mm (0.114"
+0.002"
)
Oversize:
0.2 mm (0.0079") ............................................... 3.1
+0.05
mm (0.122"
+0.002"
)
Width (D):.............................................................. 10 mm (0.4")
Main bearing shells
Type ..................................................................... Replaceable
Outer diameter Ø (E) ............................................. 85.03
+0.036
mm (2.9035"
+0.0014"
)
Thickness (F): Standard ........................................ 2.727
+0.008
mm (0.1074"
+0.0003"
)
Oversize:
0.25 mm (0.01") ................................................. 2.852
+0.008
mm (0.1123"
+0.0003"
)
0.5 mm (0.02") ................................................... 2.977
+0.008
mm (0.1172"
+0.0003"
)
Crank mechanism
Crankshaft length .................................................. 973.2 mm (38.31")
Crankshaft axial clearance1).................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1).............................. 0.03
+0.062
mm (0.0012"
+0.0024"
)
Max, permissible ovality of main
bearing and crank pins ....................................... 0.01 mm (0.0004")
Max, run-out of center bearing ............................... 0.1 mm (0.00394")
1)
Important! The dimensions apply to oiled parts
B
C
A
D
E
F
Page 70
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
68
Group 20
Connecting rod bearing journals
Diameter Ø (G) for machining:
Standard ............................................................... 68
-0.02
mm (2.6772"
-0.0008"
)
Undersize:
0.25 mm (0.01") ................................................. 67.75
-0.02
mm (2.6673"
-0.0008"
)
0.5 mm (0.02") ................................................... 67.5
-0.02
mm (2.6575"
-0.0008"
)
Width (H), axial bearing journal. ............................. 35.5
±0.02
mm (1.397"
±0.0008"
)
Connecting rod-bearing journals:
Out-of-round: Max. ............................................. 0.01 mm (0.0004")
Taper: Max ........................................................ 0.01 mm (0.0004")
Connecting rod bearing shells
Diameter Ø (J): Bearing ........................................ 68.03
+0.04
mm (2.6783"
+0.0016"
)
Oversize:
0.25 mm (0.01") ................................................. 67.78
+0.04
mm (2.6685"
+0.0016"
)
0.5 mm (0.02") ................................................... 67.53
+0.04
mm (2.6587"
+0.0016"
)
Diameter Ø: Bearing shell ..................................... 72.5
+0.05
mm (2.854"
+0.002"
)
Thickness (K): Standard ....................................... 2.222
+0.01
mm (0.0875"
+0.0004"
)
G
J
K
H
Page 71
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
69
Group 20
Connecting rods
Length (L): Center – Center ................................... 210
±0.06
mm (8.2677"
±0.00236"
)
Connecting rod (M) bushing bore ........................... 42.04
+0.01
mm (1.6551"
0.0004"
)
Wear limit ........................................................... 0.08 mm (0.0031")
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5
+0.02
mm (1.7913"
0.0008"
)
Small end bush outer diameter Ø ....................... 45.58
+0.04
mm (1.7945"
+0.0016"
)
Axial clearance, connecting rod – crankshaft1)...... 0.3-0.4 mm (0.0118-0.0157")
Connecting rod bearing: radial clearance1)............. 0.036-0.096 mm (0.00142-0.00378")
Parallelism: Tolerans
Over a length of 100 mm.................................... 0.05 mm (0.002")
Squareness: Tolerans
Over a length of 100 mm.................................... 0.05 mm (0.002")
1)
Important! The dimensions apply to oiled parts
L
M
Marking: Connecting rod and cap number marking must be on
one side and identical
Page 72
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
70
Group 20
Viscosity
The viscosity should be selected from the adjacent
table.
NOTE! the temperatures refer to constant outside air
temperature. The tabell above refers to synthetic or
synthetic-based oil.
Lubricating system
Sulfur content in fuel, by weight
Engine Oilgrade
2)
< 0,5 % 0,5 – 1,0 % > 1,0 %
1)
Oil change interval, reached first in operation
T(A)D720-721VE VDS-3 500 h / 12 months 250 h / 12 months 125 h / 12 months
T(A)D720GE VDS-2
TAD730/731GE, ACEA: E7, E5, E3
TAD721/722GE, API: CI-4, CH-4, CG-4
TAD732/TAD733GE,
TAD750/760VE, open
crankcase ventilation
TAD721/722GE, ACEA: E4 500 h / 12 months 250 h / 12 months 125 h / 12 months
TAD732/733GE, API: CI-4, CH-4
TAD750/760VE, closed NOTE! Fully synthetic oil must be used
crankcase ventilation
TAD722VE ACEA: E4
power<200kW 500 h / 12 months 250 h / 12 months 125 h / 12 months
power>200kW 250 h / 12 months 125 h / 12 months 60 h / 12 months
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15 closed crankcase ventilation
2)
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
Page 73
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
71
Group 20
1. Oil pressure sensor
Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD720GE, TAD720/721/722GE, TAD730-733GE:400 kPa (58 psi)
TD720VE/TAD722/750/760VE: .......................... 450 kPa (65 psi)
TAD720VE/TAD721VE: ..................................... 350 kPa (50.8 psi)
Idling speed (800 rpm), min: .................................. 80 kPa (11.6 psi)
Shut down switch, at pressure lower than:
TD720GE, TAD720/721/722GE, TAD730-731GE: 150 kPa (22 psi)
TD720VE, TAD720/721/722/750/760VE: ............ 50 kPa (7.2 psi)
TAD732/733GE .................................................. 200 kPa (29 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling: ................................................ 2-hole nozzles for each cylinder
7. Oil filter, full-flow:
Filtering size: ......................................................... 0.012 mm (0.0005")
Bypass valve oil filter:
Opening pressure: ...............................................250
±50
kPa (35±7 psi)
8. Pressure regulating valve:
Opening pressure: ...............................................400
±40
kPa (58±6 psi)
9. Pressure-relief valve:
Opening pressure: .............................................. 1
±0.1
MPa (145
±14
psi)
10. Lube oil pump:
Type: .................................................................... Rotary pump driven by the crankshaft
Rotary pump width: ............................................... 14.5 mm (0.57")
Oil flow (2500 rpm): ............................................... 90 l/min (24 gal/hour)
11. Oil cooler:
Normal oil temperature: .......................................... 80°C (176°F)
Max o il temperature: ............................................. 125°C (257°F)
Engine oil quantity
With oil filter:
TD720/TAD720/TAD721VE: ............................... 20 liter (5.28 US gal)
TAD722VE/TAD750VE/TAD760VE .................... 23 liter (6.10 US gal)
TAD721GE/TAD722GE ...................................... 34 liter (8.98 US gal)
Page 74
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
72
Group 20
Fuel system (720– 733)
1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")
1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")
1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps,720/721/722 (6 ea.)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve
2)
12. Return fuel line to fuel tank.
Inside diameter, min 12 mm (0.47")
1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
Page 75
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
73
Group 20
1. Fuel tank
2. Hand pump (accessory)
3. Fuel line (to pump)
4. Fuel pump
5. Fuel filter
6. Pipe to highpressure
7. Rail
8. Highpressure pump
9. Fuelpipe, to injector
10. Injector
11. M-prop
12. Pressure valve
13. Return fuel line, to fuel tank, A = Fuel pipes,
minimum distance 300 mm (11.8")
Fuel system (750,760)
Page 76
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
74
Group 20
Fuel feed pump
Fuel system figures is corresponding to the picture above
Overpressure relief valve (1):
Opening pressure ............................................... 0.6
±0.05
MPa (87
±7.2
psi)
1)
Bypass valve (2)
Opening pressure ............................................... 50±5 kPa (7.2
±0.7
psi)
Fuel flow
Min fuel flow at 1500 rpm ...................................... 600 l/tim (158.5 gal/hour)
Firing sequence .................................................... 1-5-3-6-2-4
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter at
1500 rpm. min .................................................... 0.28 MPa (40.6 psi)
Fuel filter
Filtering size ......................................................... 0.005 mm (0.0002")
Pre-filter
Filtering size ......................................................... 0.006 mm (0.00024")
In
Out
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in the respective country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in power
output of 5% and an increase in fuel consumption of 2–3%.
Page 77
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
75
Group 20
Injection pump (720–733)
Manufacturer ......................................................... Bosch
Designation ........................................................... PF 33 L
Length A: .............................................................. 54 mm (2.12")
Basic measurement length LO :............................. 143 mm (5.63")
Min length L
FB
: (A/100+143) – 143........................ >0 mm
Injection pump (720– 733)
Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
The pump length is defined by adding the basic measurement L
O
with the tolerance A/100, that are written on the injection pump
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering
fuel.
LO= Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 143 + 0.63
The total length LFB = 143.63
Injectors
Opening pressure:
TD720GE/ EPA1, TD720VE/EPA1
TAD720VE/EPA1, TAD721VE/EPA1: ................ 25 MPa (3600 psi)
TAD720GE/COM2, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2
TAD721GE/COM2, TAD722GE/COM2: .............. 27,5 MPa (4000 psi)
Max pressure:
TD720GE/ EPA1, TAD720GE/EPA1/COM2
TAD720VE/EPA1, TAD721VE/EPA1
TAD721GE/COM2, TAD722GE/COM2: .............. 120 MPa (17400 psi)
TAD720VE/COM2, TAD721VE/COM2
TAD722VE/COM2: ............................................. 160 MPa (23200 psi)
Check leakage (for 10 min):
TAD720GE/EPA1, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2: .............. 23 MPa (3340 psi)
TAD720GE/EPA1, TAD720VE/EPA1
TAD721GE/COM2, TAD722GE/COM2
TAD721VE/EPA1: ............................................. 25,5 MPa (3700 psi)
Numbers/bore Ø:
TD720GE: .......................................................... 6 x 0.234 mm (6 x 0.00921")
TAD720GE/TD720VE/TAD720VE, EPA 1: ........ 6 x 0.25 mm (6 x 0.00921")
TAD721GE/TAD721VE/TAD722GE, EPA 1: ...... 6 x 0.264 mm (6 x 0.00921")
TAD720VE/TAD721GE/TAD721VE/TAD722GE
COM 2: .............................................................. 6 x 0.236 mm (6 x 0.00921")
Page 78
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
76
Group 20
Commencement of delivery (FB) 720–733
The engine is equipped with a separate injection pump for each cylinder.
This means that the commencement of delivery (FB), when necessary, has
to be adjusted separate for each pump unit. The commencement of delivery (FB) is adjusted with a shim, placed between lifter and injection pump.
For exchange of injection pump without any parts of vital importance has
been replaced, see chapter ”EP code”. For renovation or when any parts of
vital importance have been replaced, special tools (999 8685 and 999 8679)
must be used, to be able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is indicated on
the identification plate, see ”General information”, ”Identification plate”.
When calculating the shim thickness, apply a mathematical formula, see
”Theoretical thickness for shim”, where some values are from table 1
and other are measured on the engine. For complete instruction, see
”Workshop Manual”.
FB
(Commencement of
delivery)
Camshaft
types
Vh
Pre-stroke
Vh
corr.factor
Pre-stroke
correction factor
Lo
Basic dimension
Injection pump
Table 1 (Commencement of delivery)
All measurements are in mm (1 mm = 0.0394")
Page 79
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
77
Group 20
Theoretical thickness for a new shim (720–733)
Computation for determining the theoretical shim thickness (TS) :
T
S
= L - [ ( FB
actual
- FB
nom
) x Vh
corr.factor
+ Vh
nom
+ LO + A/100 ] (mm)
The correction factor Vh
corr.factor
is taken from the table on previous page.
The individual steps:
· 1st step: E
1
= FB
actual
- FB
nom
(°C/A)
· 2nd step: E
2
= E1 x Vh
corr.factor
(mm/°C/A)
· 3rd step: E
3
= E2 + Vh
nom
· 4th step: E
4
= E3 + L
O
· 5th step: E
5
= E4 + A/100 (mm)
· 6th step: Ts = L – E
5
· 7th step: The actual shim thickness (S
s
) is determined with the help of table 2.
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When the
theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim thickness (Ss)
Theor. thickness (TS) Shim thickness (SS) Theor. thickness(TS) Shim thickness (SS)
Table 2 (Shim thickness)
All measurements are in mm (1 mm = 0.0394")
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm.
When the theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim
thickness (Ss). Important! Use only one shim at the time.
Page 80
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
78
Group 20
How to use EP code (720–733)
For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified method, when there is only the tolerance between the new and old injection pump that is the difference.
T
S
= EK - (LO + A/100)
TS = Shim thickness
EK = Value from tabel 3 read with help of EP code from ”Identification plate”.
LO = Basic measurement for the injection pumps, 420/620 = 117.5 mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and with
help of this value it is possible to read the new EK value with help of table 3.
If read EP code is ”364” that gives a EK value of 146.675 and if the manufacturing tolerance for the new injection
pump is ”63” we will have following equation: TS = 146.675 – (143 + 0.63)
TS are in this case 3.045 and a control in table 2 gives: SS = 3 mm
Thickness on the new shim to be mounted is in this example will be 3 mm
Ek(mm) EP
code
Ek(mm) EP
code
Ek(mm) EP
code
Ek(mm) EP
code
Table 3, EP code conversion table
All measurements are in mm (1 mm = 0.0394")
EP
code
Ek(mm)
Page 81
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
79
Group 20
Governor (720–733)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer ......................................................... Heinzmann
Designation:
TD720GE/TAD720GE/TAD730–733GE: ............. 1500 rpm
TD720GE/TAD720GE/TAD730–733GE: ............. 1800 rpm
TD720VE: .......................................................... 1800 rpm
TAD720/721/722VE: .......................................... 2100 rpm
TAD720/721/722VE: .......................................... 2200 rpm
TAD720/721/722VE: .......................................... 2300 rpm
Max, engine speed droop at a load increase from 0 to 100 % at: rated speed
TD720GE/TAD720GE: ....................................... <5 %
TD720VE: .......................................................... 8 – 12 %
TAD720/721/722VE: .......................................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod (720–733)
Control rod (fuel rack) travel Y, without injection pumps
Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Control rod (fuel rack) travel Y, with injection pumps
Min: ...................................................................... 16.8 mm (0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm (0.012" – 0.051")
Note! It is absolutely necessary to measure and indicate the recess dimension X, between the fuel rack, in stop
position and the contact surface of the governor, see picture.
Page 82
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
80
Group 20
Exhaust gas temperatur, approx:
At rated speed (standby power)1): .......................... 1500 rpm 1800 rpm
TD720GE, TAD730GE: ...................................... 560°C (1040°F) 505°C (941°F)
TAD720GE, TAD731GE:.................................... 476°C (914°F) 433°C (837°F)
TAD722GE, TAD732/733GE .............................. 557°C (1035°F) 520°C (968°F)
At rated speed: ..................................................... 1800 rpm 2100 rpm 2200 rpm 2300 rpm
TD720VE: .......................................................... 420°C (788°F) ———
TAD721VE: ........................................................ 420°C (788°F) 420°C (788°F) 425°C (797°F) 430°C (806°F)
TAD721VE: ........................................................ 490°C (914°F) 475°C (887°F) 480°C (896°F) 485°C (905°F)
TAD722/750/760VE: .......................................... 545°C (1013°F) 535°C (995°F) 540°C (1004°F) 545°C (1013°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD720GE/TAD720GE, TAD730GE: ................... 1 kPa (0.14 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 1.5 kPa (0.22 psi)
TD720VE/TAD720/721/722/750/760VE: ............. 2.5 (0.36 psi)
Max allowed air intake restriction
TD720GE/TAD720GE, TAD730GE: ................... 3 kPa (0.43 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 3.5 kPa (0.51 psi)
TD720VE/TAD720/721/722/750/760VE: ............. 6.5 (0.94 psi)
Intake and exhaust system
Turbocharger, make and designation:
TD720GE/TAD720GE/TD720VE/TAD730GE: .............................. Schwitzer S2B
TAD720/721/722/750/760VE:
EPA 1: ......................................................................................... Schwitzer S2B
COM 2: ........................................................................................ Schwitzer S200
TAD721/722GE, TAD731–733GE ................................................ Schwitzer S200
Boost pressure at rated speed1), ± 10%:
TD720GE, TAD730GE (1500 rpm): .............................................. 116 kPa (16.8 psi)
TD720GE, TAD730GE (1800 rpm): .............................................. 131 kPa (19.0 psi)
TAD720GE (1500 rpm): ................................................................ 136 kPa (19.7 psi)
TAD720GE (1800 rpm): ................................................................ 142 kPa (20.6 psi)
TAD721GE, TAD731GE (1500 rpm): ............................................ 161 kPa (23.4 psi)
TAD721GE, TAD731GE (1800 rpm): ............................................ 175 kPa (25.4 psi)
TAD722GE, TAD732/733GE (1500 rpm): ..................................... 178 kPa (25.8 psi)
TAD722GE, TAD732/733GE (1800 rpm): ..................................... 200 kPa (29.0 psi)
TD720VE: ....................................................................................2) kPa (
2)
psi)
TAD720VE (EPA 1): .................................................................... 133 kPa (18.9 psi)
TAD720VE (COM 2): ................................................................... 151 kPa (21.9 psi)
TAD721VE (EPA 1): .................................................................... 155 kPa (22.5 psi)
TAD721VE (COM 2): ................................................................... 163 kPa (23.6 psi)
TAD722VE (COM2, High power): ................................................. 198kPa (28.7 psi)
TAD750VE/TAD760VE: ............................................................... 198kPa (28.7 psi)
Lube system: .................................................................................. Pressure lubrication
Max, permitted radial clearance (compressor side)
Schwitzer S2B: ............................................................................ 0.95 mm (0.0374")
Schwitzer S200: ........................................................................... 0.88 mm (0.0346")
Max, permitted axial clearance
Schwitzer S2B: ............................................................................ 0.14 mm (0.00551")
Schwitzer S200: ........................................................................... 0.1 mm (0.0039")
Max, allowed back pressure in exhaust line:
TD/TAD720GE, TAD721/722GE, TAD730-733GE (1500 rpm): ..... 5 kPa (0.7 psi)
TD/TAD720GE, TAD721/722GE, TAD730-733GE (1800 rpm): ..... 7 kPa (1 psi)
TD720VE, TAD720/721/722/750/760VE: ...................................... 7.5 kPa (1.1 psi)
Page 83
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
81
Group 20
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD720GE/TAD720GE, TAD730/731GE: ............ 60 kPa (13 psi)
TAD721GE/TAD722GE
TD720VE/TAD720VE/TAD721VE,
TAD732-733GE, max1): ...................................... 90 kPa (13 psi)
1)
Versatile engines are not equipped with a pressure valve from factory
Capacity (engine):. ................................................. 9.8 liters (2.59 US gal)
Capacity (engine and cooler):
TD720GE: ...........................................................22 liters (5.8 US gal)
TAD720GE/TAD730/731GE: ............................... 23.8 liters (6.3 US gal)
TAD721GE/TAD722GE/TAD732/733GE: ............ 27.3 (7.2 US gal)
Thermostat
Type: ..................................................................... Piston thermostat
Begins to open at
TD720GE/TAD720GE/TD720VE/TAD730/731GE: 83°C (181°F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE,
TAD732/733GE: ................................................. 87° C (189° F)
Fully open at
TD720GE/TAD720GE/TD720VE: ....................... 95°C (203°F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE: ................... 102° C (216° F)
Coolant pump
Type ...................................................................... Belt-driven centrifugal pump
Glycol (Antifreeze)
Volvo Penta glycol (antifreeze) mixed 45/55 with clean water
Anti-corrosion agent
Used only in markets where there is no risk of freezing, mixed with water3).
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative
consequences.
Water quality specification:
To avoid the risk of clogging in the cooling system, the coolant should be mixed with pure water to ASTM D4985.
If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
TD/TAD720-722:
1. Coolan connection (inlet)
2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Page 84
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
82
Group 20
Tightening torque
General tightening torques Nm (lbf.ft)
M6 standard screw 8.8 .......................................... 10
±1.5
(7.5
±1
lbf.ft)
M8 standard screw 8.8 .......................................... 25
±4
(18
±3
lbf.ft)
M10 standard screw 8.8 ........................................ 50
±8
(37
±6
lbf.ft)
M12 standard screw 8.8 ........................................ 80
±9
(59
±6.5
lbf.ft)
M14 standard screw 8.8 ........................................ 140
±25
(103
±18
lbf.ft)
Tightening torques Nm (lbf.ft)
Group 21 Engine
Engine mounting ................................................... 260 (192 lbf.ft)
Starter motor ......................................................... 70 (51.6 lbf.ft)
Timing gear casing ................................................ 21
±2
(15.5
±1.5
lbf.ft)
Main bearing caps
Screws to main bearing caps are reusable only three times.
Step 1 ................................................................ 50 (37 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................60° angle tightening
Connecting rod big-end bearing:
Use new screws every time.
Step 1 ................................................................ 30 (22 lbf.ft)
Step 2 ................................................................ 60° angle tightening
Step 3 ................................................................ 60° angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 30° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ............................................................... 30 – 40 (22 – 30 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
Flywheel housing. M12.......................................... 99
±1
(73±7 lbf.ft)
Flywheel housing. M16.......................................... 243
±25
(179
±18
lbf.ft)
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ............................................................... 40 – 50 (30 – 37 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 60° angle tightening
Vibration damper ................................................... 70
Screw, rocker cover .............................................. 9
±1
(6.5
±0.7
lbf.ft)
Lock nut, valve clearance adjusting screw ............ 20
±2
(14.5
±1.5
lbf.ft)
Screws, rocker arm fixing ..................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation ............................... 9
±1
(6.6
±0.7
lbf.ft)
Page 85
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
83
Group 20
Tightening torques Nm (lbf.ft)
Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50 (37 lbf.ft)
Step 2: ............................................................... 130 (96 lbf.ft)
Step 3: ............................................................... 90° angle tightening
Group 22 Oil system
Oil cooler, screws ................................................. 21
±2
(15.5
±1.5
lbf.ft)
Oil cooler, hollow screw
Step 1: ............................................................... 80 (59 lbf.ft)
Step 2: ............................................................... 160 (118 lbf.ft)
Oil cooler, screw plug ............................................ 80 (59 lbf.ft)
Front/oil pump housing .......................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil suction pipe ..................................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil sump ............................................................... 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure pipe turbo .......................................... 29
±3
(21.4
±2.2
lbf.ft)
Oil pressure pipe engine block .............................. 39
±4
(29±3 lbf.ft)
Screws, oil return pipe turbo
A) with tube fitting .............................................. 40
±2
(29.5
±1.5
lbf.ft)
B) with flange fitting ........................................... 21
±2
(15.5
±1.5
lbf.ft)
Screws, oil return pipe engine block ...................... 21
±2
(15.5
±1.5
lbf.ft)
Oil pressure switch ............................................... 18
±2
(13
±1.5
lbf.ft)
Group 23 Fuel system
Screw, governor, idler gear:
Step 1: ............................................................... 30 (22.1 lbf.ft)
Step 2: ............................................................... 90° angle tightening
Screw, control rod hose ........................................ 10
±2
(7
±5
lbf.ft)
Screw, governor .................................................... 17
±1.5
(12.5
±1
lbf.ft)
Flange screws, Injection pump
Step 1: Torque ................................................... 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange 60° counterclockwise
Step 3: Turn injection pump to stop ................... Counterclockwise
Step 4: ............................................................... 60° angle tightening
Step 5: ............................................................... 7 (5 lbf.ft)
Step 6: ............................................................... 10 (7.4 lbf.ft)
Step 7: ............................................................... 30 (22 lbf.ft)
Flange screw, injector ........................................... 16
+5
(12
+4
lbf.ft)
Injector cap nut ..................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Use a new delivery pipe after every disassembly
Step 1: ............................................................... 5 (3.7 lbf.ft)
Step 2: ............................................................... 25
±3.5
(18.4
±2.6
lbf.ft)
Screw, stop magnet .............................................. 21 (15.5 lbf.ft)
Overflow valve ...................................................... 30 (22 lbf.ft)
Common Rail, TAD750/760
Safety valve ....................................................... 100 (74 lbf.ft)
Rail pressuree sensor ........................................ 70 (51.6 lbf.ft)
Common rail unit ................................................ 30 (22.1 lbf.ft)
Fuel hose ........................................................... 39 (29±3 lbf.ft)
IEGR, TAD750/760
IEGR-unit: .......................................................... 30 (22 lbf.ft)
Solenoid valve: .................................................. 24 (18 lbf.ft)
Highpressure fuel pump, TAD750/760
Step 1: ............................................................... 10 (7.4 lbf.ft)
Step 2: ............................................................... 50 (37 lbf.ft)
Page 86
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
84
Group 20
Tightening torques Nm (lbf.ft)
Group 25 Inlet and exhaust system
Exhaust manifold nuts .......................................... 25
±2.5
(18.5
±1.8
lbf.ft)
M8 Nuts, turbo to exhaust manifold ...................... 21
±2
(15.5
±1.5
lbf.ft)
M10 Nuts, turbo to exhaust manifold ..................... 40.5
±4
(30±3 lbf.ft)
Screws, Inlet manifold ........................................... 11
±1
(8
±0.7
lbf.ft)
Group 26 Cooling system
Thermostat housing .............................................. 30 (22.1 lbf.ft)
Water temp sensor ................................................ 21
±2
(15.5
±1.5
lbf.ft)
Water pump .......................................................... 21
±2
(15.5
±1.5
lbf.ft)
NOTE! See also ”Tightening diagrams”.
Page 87
Technical data
85
Grupp 20
Tightening torque diagram
Connecting rod big-end bearing:
TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Use new bolts every time.
Step 1 .................................................................30 Nm (22 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................30 Nm
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530–533GE
TAD750VE/760VE
Step 1 .................................................................50 Nm (37 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................60° angle tightening
Screws to main bearing caps are reusable only three times.
TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Step 1 .................................................................30 Nm (22 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................60° angle tightening
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530–533GE
TAD750VE/760VE
Step 1 .................................................................50 Nm (37 lbf.ft)
Step 2 .................................................................60° angle tightening
Step 3 .................................................................60° angle tightening
Main bearing caps:
Page 88
Technical data
86
Grupp 20
A) Flywheel with screws of max 30 mm length
Step 1: ................................................................20 – 30 Nm (15 – 22 lbf.ft)
Step 2: ................................................................60° angle tightening
Step 3: ................................................................30° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................20 – 30 Nm (15 – 22 lbf.ft)
Step 2: ................................................................60° angle tightening
Step 3: ................................................................60° angle tightening
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ................................................................30 – 40 Nm (22 – 30 lbf.ft)
Step 2: ................................................................60° angle tightening
Step 3: ................................................................60° angle tightening
V-belt pulley/vibration damper:
V-belt pulley/vibration damper:
Screws to V-belt pulley are reusable only three times.
Step 1: ................................................................40 – 50 Nm (30 – 37 lbf.ft)
Step 2: ................................................................60° angle tightening
Step 3: ................................................................60° angle tightening
Vibration damper .................................................... 70 Nm
Flywheel
Page 89
Technical data
87
Grupp 20
Cylinder head
Manifold sideManifold side
Put the pump flange in place with the side of the chamfered hole facing the pump. Oil the screws lightly and tighten the screws evenly to 5 Nm (3.7 lbf.ft). Loosen screws for injection pump flange 60° counterclockwise.
Use a torque wrench with gauge and the special Bosch socket (KDEP 2986). Turn the injection pump to stop
counterclockwise.
Observe the maximum torque required on the torque wrench gauge to turn the injection pump 3.5 Nm (2.6 lbf ft).
Stop turning when gauge has gone up by 1 Nm (0.74 lbf.ft), for example 3,5 + 1 = 4.5 Nm (2.6 + 0.74 = 3.33
lbf.ft). Tighten the screws alternately with a torque of 7 – 10 and 30 Nm (5.2 – 7.4 and 22.2 lbf.ft).
Start with the screw furthest away from the flywheel.
Check that the control rod (fuel rack) is moving freely after each injection pump has been installed.
TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Screws to cylinder head are reusable only five times.
Step 1: ................................................................30 Nm (22 lbf.ft)
Step 2: ................................................................80 Nm (59 lbf.ft)
Step 3: ................................................................90° angle tightening
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530–533GE
TAD750VE/760VE
Screws to cylinder head are reusable only five times.
Step 1: ................................................................50 Nm (37 lbf.ft)
Step 2: ................................................................130 Nm (96 lbf.ft)
Step 3: ................................................................90° angle tightening
Flange screws, Injection pump (not apply for 650/660, 750/760)
Step 1: Torque .................................................... 5 Nm (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange 60° counterclockwise
Step 3: Turn injection pump to stop .................... Counterclockwise
Step 4: ................................................................60° angle tightening
Step 5: ................................................................7 Nm (5 lbf.ft)
Step 6: ................................................................10 Nm (7.4 lbf.ft)
Step 7: ................................................................30 Nm (22 lbf.ft)
Page 90
Technical data
88
Grupp 20
4. Screw plug MA.................................................... 35
±3.5
Nm (26
±2.6
lbf ft)
6. Screw plug MA.................................................... 95
±9.5
Nm (70
±7
lbf ft)
7. Screw plug MA.................................................... 65
±6.5
Nm (48
±4.8
lbf ft)
8. Screw plug MA.................................................... 35
±3.5
Nm (26
±2.6
lbf ft)
13. Screw plug MA.................................................. 35
±3.5
Nm (26
±2.6
lbf ft)
24. Screw plug MA.................................................. 10±2 Nm (7
±1.5
lbf ft)
Screw plug
Delivery pipe (not apply for 650/660, 750/760)
Fit a new delivery pipe and rubber seal.
Tighten the nuts by hand.
When installing delivery pipes, be sure to fit the sealing cones
exactly in the pump and injector.
Delivery pipe
Step 1: ................................................................5 Nm (3.7 lbf.ft)
Step 2: ................................................................25
±3.5
Nm (18.4
±2.6
lbf.ft)
Use a new delivery pipe after every disassembly
WARNING! Do not bend the pressure pipes, they can only be used once.
Page 91
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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
Page 92
7742012 English 06–2007
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