td420ve

Workshop Manual Technical echnic al Data Dat a

I 1(0)

TD420VE, TAD420VE, TAD420VE, TD520GE, TD520G E, TAD520G TAD520GE, E, TD520VE TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE TAD660VE, TD720GE TD720G E TAD720GE, AD720G E, TD720VE, TAD720VE TAD720VE TAD721GE, AD721G E, TAD721VE, TAD722GE, AD722G E, TAD722VE, TAD730/731/732/ AD730/7 31/732/733G 733GE, E, TAD750VE, TAD750VE, TAD760VE TAD760VE

Group 20

General Information

Technical Data Industrial Engines TD420 VE, TAD420V TD420VE, TAD420VE, E, TAD620V TAD620VE, E, TAD650 TAD650VE, VE, TAD660V TAD660VE, E, TD520GE, TD520 GE, TAD520G TAD520GE, E, TD520VE, TAD520V TAD520VE, E, TAD530 AD530/531/ /531/532GE 532GE,, TD720 TD720GE, GE, TAD720G TAD720GE, E, TD720VE, TAD7 AD720V 20VE, E, TAD7 TAD721G 21GE, E, TAD7 TAD721V 21VE, E, TAD7 TAD722G 22GE, E, TAD7 TAD722V 22VE, E, TAD730/ AD730/731/7 731/732/73 32/733GE, 3GE, TAD750V TAD750VE, E, TAD760V TAD760VE E

Contents Safety precautions ......... .................... ..................... .................... .................2 .......2 General information .......... .................... .................... .................... ............... ..... 5 Repair instructions......... instructions .................... ..................... .................... .................6 .......6 Location of identification plates TD/TAD420-620, TD/TAD520-722 .......................9 TAD650/6 TAD6 50/660, 60, TAD750/ TAD750/760 760 ............... .............................. ................... .... 10 TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE General Gene ral (420 (420/620 /620)) ............... ............................. ............................. ................... .... 11 General Gene ral (650 (650/660 /660)) ............... ............................. ............................. ................... .... 12 Engine block .............. ............................ ............................. ........................... ............ 12 Valve mechanism ...............................................16 Crank mechanism ...............................................19 Lubricating system ............... ............................. ............................. ................. .. 22 Fuel syste system m .......... .................... .................... ................... ................... .................24 .......24 Intake and exhaust system ............. ............................. .................... .... 32 Cooling system ...................................................32 Tightenin Tigh tening g torqu torque e ......................... .......... ............................. ....................... ......... 33 TD520GE, TAD520GE, TD520VE, TAD520VE, TAD530-532GE General ...............................................................36 Engine block .............. ............................ ............................. ........................... ............ 37

Valve mechanism ............. ............................ ............................. ................... ..... 40 Crank mecha mechanism nism ............. ............................ ............................. ................... ..... 43 Lubricating Lubricatin g system .............. ............................ ............................. .................. ... 46 Fuel syste system m ......... ................... .................... .................... .................... .................48 .......48 Intake and exhaust system ............... .............................. .................. ... 55 Cooling system .............. ............................. .............................. ...................... ....... 56 Tightenin Tigh tening g torque torque ............................... ................ .............................. ................. .. 57 TD720GE, TAD720GE, TD720VE, TAD720VE, TAD721GE, TAD721VE, TAD722GE, TAD722VE, TAD730-733GE, TAD750VE, TAD760VE General Gene ral (720 (720-722 -722GE GE ) ................. ... ............................ ........................ .......... 59 General Gen eral (72 (720-72 0-722VE 2VE)) ............. ............................ ............................. ................ 60 General Gen eral (75 (750/76 0/760).. 0)................ ............................. .............................. ................. .. 60 Engine block .......................................................61 Valve mechanism ............. ............................ ............................. ................... ..... 64 Crank mecha mechanism nism ............. ............................ ............................. ................... ..... 67 Lubricating Lubricatin g system .............. ............................ ............................. .................. ... 70 Fuel syste system m ......... ................... .................... .................... .................... .................72 .......72 Intake and exhaust system ............... .............................. .................. ... 80 Cooling system .............. ............................. .............................. ...................... ....... 81 Tightenin Tigh tening g torque torque ............................... ................ .............................. ................. .. 82 Tightening diagram ............. ............................ .............................. ................. .. 85

© 2007 2007 AB VOLVO PENTA All rights to changes or modifications reserved.

General Information

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Safety Precautions 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

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.

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.

Group 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.

General Information 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.

General Information 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.

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 r esult in an over revving of the engine, risking of damaging to the engine and of personal injuries. Poor fuel quality can also lead t o 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.

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General Information

General Information About this Workshop Manual

Spare parts

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

Spare parts for the electrical and fuel systems are subject to various national safety requirements. Volvo Penta Original Spare Parts meet these specifications.

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.

Engine certificate

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.

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 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:

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The Service Intervals and maintenance operations recommended by Volvo Penta must be followed.

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Only Volvo Penta Original Spare Parts intended for the engine certificates may be used.

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Service work on the injection pump and injectors must always be carried out by an authorized Volvo Penta workshop.

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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.

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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.

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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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Repair instructions Introduction

Our joint responsibility

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.

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.

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 ob jects entering the parts or systems, since this can result in reduced service life or malfunctions.

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.

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General Information

Tightening torque

Lock nuts

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

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.

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)

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.

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.

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.

General Information

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.

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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 Information

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.

Identification plates 1. 2. 3. 4. 5. 6. 7.

Engine model Engine specification number Engine serial number (10 digits) Engine output without fan Rated engine speed Injection timing and type of camshaft Manufacturers identification code

8. 9. 10. 11. 12. 13.

Indication of standard and /or regulation ISO 3046, reference test conditions ISO 3046, reference test conditions Injection pump code (EP code) Piston class Prime output, without fan, at rated speed

General Information

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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.

Identification plates 1. 2. 3. 4. 5. 6. 7.

Engine model Engine specification number Engine serial number (10 digits) Engine output, without fan Rated engine speed Engine code (linked to EPA/EU Tier III approval) 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

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Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE

Technical Data TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE

General Type designation....................................................TD420VE TAD420VE Rotation direction, facing flywheel: ......................... Counterclockwise Number of cylinders ............................................... 4 4 Bore, mm (inch) ..................................................... 101 (3.97") 101 (3.97") Stroke, mm (inch) ..................................................126 (4.96") 126 (4.96") 3 3 Displacement, dm (inch ) .......................................4.04 (246.5) 4.04 (246.5) Number of valves ................................................... 8 8 Compression ratio: EPA 1 ................................................................. 19:1 19:1 COM 2 . ............................................................... 19:1 19:1 Firing sequence .....................................................1-3-4-2 1-3-4-2 Engine performance at 2500 rpm, kW (hp) ............. 75 (102)1, 3) 103 (140)1, 3) Max torque, Nm (lbf.ft) ........................................... 390 (288)3) 493 (364)3) At speed, rpm ..................................................... 1500 1500 Low idle, rpm ......................................................... 800 800 Max, full load speed, rpm ....................................... 2000 – 25001) 2000 – 25001) Weight. engine (dry) kg (lb) .................................... 380 (838)2) 380 (838)2) 1)

See identification plate for correct specification Weight according to DIN 70020-A 3) See ”General information, Power standards”. 2)

TAD620VE 6 98 (3.97") 126 (4.96") 5.7 (347.8) 12 18.4:1 18.4:1 1-5-3-6-2-4 155 (209)1, 3) 700 (516)3) 1500 800 2000 – 25001) 495 (1091)2)


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General Type designation....................................................TAD650VE Rotation direction, facing flywheel: ......................... Counterclockwise Number of cylinders ............................................... 6 Bore, mm (inch) ..................................................... 101 (3.97") Stroke, mm (inch) .................................................. 126 (4.96") Displacement, dm3 (inch3) ....................................... 5.7 (347.8) Number of valves ................................................... 12 Compression ratio: ................................................. 18.4:1 Firing sequence ..................................................... 1-5-3-6-2-4 Engine performance at 2300 rpm, kW (hp) ............. 147 (200)1, 3) Max torque, Nm (lbf.ft) ........................................... 750 (553)3) At speed, rpm ..................................................... 1600 Low idle, rpm .......................................................... 600-800 Max, full load speed, rpm ....................................... 24001) Weight. engine (dry) kg (lb) .................................... 565 (1246)2) Weight. engine (wet) kg (lb) .................................... 585 (1290)2) 1)


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 TD420VE/TAD420VE.......................................... 5 x 178 mm

(13 x 4.3") (5 x 7")

Quantity and length: TAD620VE, TAD650/660VE ............................... 19 x 108 mm TAD620VE, TAD650/660VE ............................... 7 x 178 mm

(19 x 4.3") (7 x 7")

TAD660VE Counterclockwise 6 98 (3.85") 126 (4.96") 5.7 (347.8) 12 18.4:1 1-5-3-6-2-4 147 (200)1, 3) 800 (590)3) 1600 600-800 2400565 565 (1246)2) 585 (1290)2)

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Cylinder liners Parent bore

Replaceable, dry A

TD420VE, TAD420VE TAD650VE

TAD620, TAD660VE

Type: TD420VE/TAD420VE/TAD650VE ....................... Parent bore TAD620VE/TAD660VE ....................................... Dry, replaceable Bore: TD420VE/TAD420VE/TAD650VE ....................... 101+0.02 mm TAD620VE/TAD660VE ....................................... 98 +0.02 mm

(3.976"+0.00078") (3.858"+0.00078")

Max bore wear: TD420VE/TAD420VE/TAD650VE ....................... 101.1 mm TAD620VE .......................................................... 9 8.1 mm TAD660VE .......................................................... 9 8.1 mm

(3.98") (3.86") (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")


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.

•

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 t he hole identification on each of the three different thickness available, see picture below.

Measuring points, distance X: ............................. Ø 90 mm

(3.5")

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")

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Pistons Number of piston ring grooves................................ 3 Combustion chamber: Diameter Ø ......................................................... 61±0.1 mm Combustion chamber depth: TD420VE/TAD420VE .......................................... 18±0.1 mm TAD620VE, TAD650/TAD660VE ........................ 17.5±0.1 mm Gudgeon pin diameter Ø ........................................ 38-0.006 mm

(2.402"±0.0039”) (0.7087"±0.0039”) (0.689"±0.0039”) (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.

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 Piston ring gap measured in ring opening, wear limit: Upper compression ring (1) ................................. 0.8 mm Lower compression ring (2) ................................. 2.5 mm

(0.067") (0.03") (0.0984")

1

2 3

Oilscraper ring (3) Number: ................................................................. 1 Width, including springcoil:.....................................3 mm Piston ring clearance, height: ................................. 0.1 mm Piston ring gap, wear limit: ..................................... 1.15 mm

(0.12") (0.0039") (0.045”)


Group 20

Valve mechanism Valves Disc diameter Ø: ±0.1 Inlet .................................................................... 41.7 mm ±0.1 Exhaust .............................................................. 35.9 mm Stem diameter Ø: Inlet .................................................................... 7.98-0.015 mm Exhaust .............................................................. 7.96-0.015 mm Valve seat angle: Inlet, min ............................................................. 29.5° Exhaust, min....................................................... 44.5°

Min 1.8 mm

(1.642"±0.004") (1.413"±0.004") (0.3142"-0.0006") (0.3134"-0.0006")

Min 1.1 mm 45° 30°

29.5°

44.5°

Valve disc edge: Inlet, min ............................................................. 1.8 mm Exhaust, min ...................................................... 1.1 mm Seat angle, cylinder head: Inlet .................................................................... 30° Exhaust .............................................................. 45° Valve seat width, max: Inlet, min ............................................................. 2.7 mm Exhaust, min....................................................... 2.1 mm

(0.071") (0.043")

(0.106") (0.083")

Valve clearance (not apply for TAD660VE) Inlet .................................................................... 0.35±0.05 mm Exhaust .............................................................. 0.55±0.05 mm

(0.014"±0.002") (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)

Group 20


Valve seats ØA B

Outer diameter Ø (A), standard: Inlet .................................................................... 42.79-0.02 mm Exhaust .............................................................. 36.99-0.02 mm Height (B): Inlet .................................................................... 6.8±0.1 mm Exhaust .............................................................. 7.5±0.1 mm

Valve seat location

R

(1.685"-0.0008") (1.456"-0.0008") (0.2677"±0.004 ) (0.2953"±0.004 )

ØC

D

Diameter Ø (C), standard: -0.025 Inlet .................................................................... 42.7 mm -0.025 Exhaust .............................................................. 36.9 mm Depth (D): Inlet/Exhaust ...................................................... 10+1 mm Seat bottom radius (R): Inlet/Exhaust ...................................................... 1-0.3 mm Measurement between valve disc and cylinder head face: Inlet/Exhaust ...................................................... Min 1.4 mm

(1.681"-0.001") (1.453"-0.001") (0.4"+0.04") (0.04"-0.0118") (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 Wire diameter Ø: .................................................... 4±0.03 mm

(2.323"±0.075") (0.16"±0.001")


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 ........................................................... 63.08mm (2.483") +0.012 Camshaft bearing thickness: max .......................... 1.388 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. 2. 3. 4. 5. 6.

Governor drive (not apply for 650/660) Idler gear (not apply for 650/660) Camshaft gear PTO gear B-C (not apply for 650/660) PTO gear A (not apply for 650/660) Crankshaft

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

Group 20

Group 20


Crank mechanism Crankshaft length: TD420VE/TAD420VE.......................................... 618.8 mm TAD620VE, TAD650/TAD660VE ........................ 846.8 mm Crankshaft axial clearance1) ................................... 0.1-0.3 mm Main bearing radial clearance 1) ............................... 0.03+0.062 mm Max, permissible ovality of main bearing and crank pins ........................................ 0.01 mm Max, run-out of center bearing: .............................. 0.1 mm 1)

(24.36") (33.34") (0.0039"– 0.0118") (0.0012"+0.0024") (0.0004") (0.0039"

Important! The dimensions apply to oiled parts

E F C

B A

D

Main bearing journals Diameter for machining (A): Standard..................... 84-0.02 mm Undersize: 0.25 mm (0.01") .................................................. 83.75-0.02 mm Main bearing journals: Out-of-round: Max. .............................................. 0.01 mm Taper: Max. ........................................................ 0.01 mm Width, axial bearing journal ( B): Standard ............... 32.2+0.04 mm Oversize: 0.4 mm (0.0157") ................................................ 32.6+0.04 Thrust washers (axial bearing) Width (C): Standard ................................................ 2+0.1 mm Oversize: 0.2 mm (0.0079") ................................................ 2.2+0.1 mm Width (D):............................................................... 14 mm

(2.9134"-0.0008) (3.2972"-0.0008) (0.0004") (0.0004") (1.1268"+0.0016") (1.283"+0.0016") (0.079"+0.004") (0.087"+0.004") (0.55")

Main bearing shells Type: ..................................................................... Replaceable Inner diameter Ø (E): ............................................. 84.03+0.042 m m (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")


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")

J

H G

K

Connecting rod bearing shells Innerdiameter Ø, bearing (J): .................................. 63.026+0.039 mm Oversize: 0.25 mm (0.01") .................................................. 62.724+0.02 mm Thickness (K): Standard ........................................ 1.777+0.01 mm Inside bore .......................................................... 66.6+0.02 mm

(2.442"+0.00154”) (2.4716"+0.00079”) (0.06996+0.0004” ) (2.622"0.0008" )

Group 20

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")

L M

Axial clearance, connecting rod – crankshaft1) ....... 0.2-0.3 mm Connecting rod bearing: radial clearance 1) .............. 0.03-0.09 mm Parallelism: Tolerans Over a length of 100 mm..................................... 0.05 mm Squareness: Tolerans Over a length of 100 mm .................................... 0.05 mm 1)

(0.00787"-0.0118") (0.00118"-0.00354") (0.002") (0.002")

Important! The dimensions apply to oiled parts.

Connecting rod marking: Connecting rod and cap number marking must be on one side and identical.


Group 20

Lubricating system Oil grade2)

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 API: CI-4, CH-4, CG-4

500 hours or 12 months



1) 2)

If the sulfur content is > 1.0% by weight, use oil with TBN > 15 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

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.

Group 20


Engine oil quantity With oil filter: TD420VE/TAD420VE.......................................... 10 liter TAD620VE, TAD650/TAD660VE ........................ 16 liter

TD420VE/TAD420VE

(2.64 US gal) (4.22 US gal)

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)


Fuel system (420, 620)

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) 2)

Depending on length of hose. Used for bleeding.

Group 20

Group 20


Fuel system (650, 660)

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

Fuel tank Hand pump (accessory) Fuel line (to pump) Fuel pump Fuel filter Pipe to highpressure Rail

8. 9. 10. 11. 12. 13.

Highpressure pump Fuelpipe, to injector Injector M-prop Pressurevalve Return fuel line, to fuel tank, A = Fuel pipes, minimum distance 300 mm (11.8")


Group 20

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%.

In

Out

Fuel feed pump Fuel system figures are corresponding to the picture above. 1. Overpressure relief valve: Opening pressure ................................................ 0.6±0.05 MPa 2. Bypass valve: Opening pressure ................................................ 50±5 kPa Fuel flow: Min fuel flow at 1500 rpm....................................... 600 l/hour Firing sequence TD420VE/TAD420VE.......................................... 1-3-4-2 TAD620VE/TAD650VE/TAD660VE ..................... 1-5-3-6-2-4 Feed pressure ........................................................ 0.5 MPa Feed pressure after fuel filter At 1500 rpm: Min ................................................ 0.28 MPa

(87±7 psi)1) (7.2±0.7 psi) (158.5 gal/hour)

(72.5 psi) (40.6 psi)

Group 20


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 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 = 117.5 + 0.63 The total length LFB = 118.13

Injection pump (420, 620) Manufacturer .......................................................... Bosch Designation ............................................................ PF 33 Length A: ...............................................................59 mm Basic measurement length LO : ..............................117.5 mm Min length mm LFB : (A/100+117.5) – 117.5 ............ >0

(2.3") (4.6")

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")


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”.

Table 1, Commencement of delivery All measurements are in mm (1 mm = 0.0394")

FB (Commencement of delivery)

Camshaft types

Vh Pre-stroke

Vhcorr.factor

Pre-stroke correction factor

Lo Basic dimension Injection pump

Grupp 20

Tekniska data

Theoretical thickness for a new shim (420/620) Computation for determining the theoretical shim thickness (TS) :

TS= L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm) The correction factor Vhcorr.factor is taken from the table on previous page. The individual steps: 1st step: E1 = FBactual - FBnom (°C/A)

· · · · · · ·

2nd step: E2 = E1 x Vhcorr.factor (mm/°C/A) 3rd step: E3 = E2 + Vhnom 4th step: E4 = E3 + LO 5th step: E5 = E4 + A/100 (mm) 6th step: TS = L – E5 7th step: The actual shim thickness (SS) is determined with the help of table 2.

Table 2, Shim thickness All measurements are in mm (1 mm = 0.0394")

Theor. thickness (TS)

Shim thickness (SS)

Theor. thickness(TS)

Shim thickness (SS)

NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When the theoretical shim thickness (T s) 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.


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 f rom ”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 r ead 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

Table 3, EP code conversion table All measurements are in mm (1 mm = 0.0394")

Ek (mm)

EP code

Ek (mm)

EP code

Ek (mm)

EP code

Ek (mm)

EP code

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.


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 TD420VE ............................................................ 555°C (1031°F) TAD420VE .......................................................... 490°C (914°F) TAD620VE,TAD650VE,TAD660VE ..................... 485°C (905°F) 1)

2100 rpm 540°C (1004°F) 470°C (878°F) 465°C (869°F)

2300 rpm 540°C (1004°F) 475°C (887°F) 460°C (860°F)

2500 rpm 540°C (1004°F) 475°C (887°F) 455°C (851°F)

See General information, Power standards.

Air intake Air intake restriction, clean filter ............................. 2.5 kPa Max allowed air intake restriction ........................... 6.5 kPa

(0.3 psi) (0.9 psi)

Cooling system Type ......................................................................Pressurized, closed Pressure valve opens at max2) ............................ 9 0 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.

Group 20


Tightening torque General tightening torques

Nm

M6 standard screw 8.8 ........................................... 10±1.5 M8 standard screw 8.8 ........................................... 25±4 M10 standard screw 8.8 ......................................... 50±8 M12 standard screw 8.8 ......................................... 80±9 M14 standard screw 8.8 ......................................... 140±25

Tightening torques

Nm

(lbf.ft) (7.5±1 lbf.ft) (18±3 lbf.ft) (37±6 lbf.ft) (59±6.5 lbf.ft) (103±18 lbf.ft)

(lbf.ft)

Group 21 Engine Engine mounting .................................................... 260 Starter motor .......................................................... 70 Timing gear casing................................................. 21±2

(192lbf.ft) (51.6 lbf.ft) (15.5±1.5 lbf.ft)

Main bearing caps Screws to main bearing caps are reusable only three times.

Step 1 . ................................................................... 50 Step 2 .................................................................... 90° angle tightening Step 3 .................................................................... 90° angle tightening

(37 lbf.ft)

Connecting rod big-end bearing Use new screws every time.

Step 1 . ................................................................... 30 Step 2 .................................................................... 60° angle tightening Step 3 .................................................................... 30° angle tightening

(22 lbf.ft)

Flywheel A) Flywheel with screws of max 30 mm length Step 1: ................................................................... 2 0 – 30 Step 2: ................................................................... 60° angle tightening Step 3: ................................................................... 30° angle tightening B) Flywheel with screws up to 45 mm length Step 1: ................................................................... 2 0 – 30 Step 2: ................................................................... 60° angle tightening Step 3: ................................................................... 60° angle tightening C) Flywheel with a screw length between 50 – 85 mm Step 1: ................................................................... 3 0 – 40 Step 2: ................................................................... 60° angle tightening Step 3: ................................................................... 60° angle tightening Flywheel housing, M12........................................... 99±1 Flywheel housing, M16........................................... 243±25

(15 – 22 lbf.ft)

(15 – 22 lbf.ft)

(22 – 30 lbf.ft)

(73±7 lbf.ft) (179±18 lbf.ft)

V-belt pulley Screws to V-belt pulley are reusable only three times.

Step 1: ................................................................... 4 0 – 50 Step 2: ................................................................... 60° angle tightening Step 3: ................................................................... 60° angle tightening Vibration damper .................................................... 70 Screw, rocker cover ............................................... 9±1 Lock nut, valve clearance adjusting screw ............. 20±2 Screws, rocker arm fixing ...................................... 21 Screws, crankcase ventilation................................ 9±1

(30 – 37 lbf.ft)

(51.6 lbf.ft) (6.5±0.7 lbf.ft) (14.5±1.5 lbf.ft) (15.5 lbf.ft) (6.6±0.7 lbf.ft)


Tightening torques

Nm

Group 20

(lbf.ft)

Cylinder head Screws to cylinder head are reusable only three times.

Step 1: ................................................................... 30 Step 2: ................................................................... 80 Step 3: ................................................................... 90° angle tightening

(22 lbf.ft) (59 lbf.ft)

Group 22 Oil system Oil cooler, screws .................................................. 21±2 Oil cooler, screw plug ............................................. 80 Front/oil pump housing ........................................... 21±2 Oil suction pipe ...................................................... 21±2 Oil sump ................................................................ 21±2 Oil pressure pipe turbo ........................................... 29±3 Oil pressure pipe engine block ............................... 39±4 Screws, oil return pipe turbo A) with tube fitting ............................................... 40±2 B) with flange fitting ............................................ 21±2 Screws, oil return pipe engine block ....................... 21±2 Oil pressure switch ................................................ 18±2

(15.5±1.5 lbf.ft) (59 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (21.4±2.2 lbf.ft) (29±3 lbf.ft) (29.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (13±1.5 lbf.ft)

Group 23 Fuel system Screw, governor, idler gear (420/620): Step 1: ................................................................... 30 Step 2: ................................................................... 90° angle tightening Screw, control rod hose ......................................... 10±2 Screw, governor ..................................................... 17±1.5 Flange screws, Injection pump Step 1: Torque ....................................................... 5 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 Step 6: ................................................................... 10 Step 7: ................................................................... 30 Flange screw, injector ............................................ 16+5 Injector cap nut ...................................................... 40 – 50 Delivery pipe

(22.1lbf.ft) (7±5 lbf.ft) (12.5±1 lbf.ft) (3.7lbf.ft)

(5lbf.ft) (7.4lbf.ft) (22lbf.ft) (12+4 lbf.ft) (30 – 37lbf.ft)

Use a new delivery pipe after every disassembly

Step 1: ................................................................... 5 ±3.5 Step 2: ................................................................... 25 Screw, stop magnet ............................................... 21 Overflow valve ....................................................... 30 Common Rail, TAD650/660 Safety valve ........................................................ 100 Rail pressuree sensor ......................................... 70 Common rail unit ................................................. 30 Fuel hose ............................................................ 39 IEGR, TAD650/660 IEGR-unit: ........................................................... 20 Solenoid valve: ................................................... 24 Highpressure fuel pump, TAD650/660 Step 1: ................................................................ 10 Step 2: ................................................................ 50

(3.7lbf.ft) (18.4±2.6 lbf.ft) (15.5lbf.ft) (22lbf.ft) (74 lbf.ft) (51.6 lbf.ft) (22.1lbf.ft) (29±3 lbf.ft) (14.5lbf.ft) (18lbf.ft) (7.4lbf.ft) (37 lbf.ft)

Group 20


Tightening torques

Nm

(lbf.ft)

Group 25 Inlet and exhaust system Exhaust manifold nuts ........................................... 25±2.5 M8 Nuts, turbo to exhaust manifold ....................... 21±2 M10 Nuts, turbo to exhaust manifold ...................... 40.5±4 Screws, Inlet manifold............................................ 11±1

(18.5±1.8 lbf.ft) (15.5±1.5 lbf.ft) (30±3 lbf.ft) (8±0.7 lbf.ft)

Group 26 Cooling system Thermostat housing ............................................... 30 Water temp sensor................................................. 21±2 Water pump ........................................................... 21±2

NOTE! See also ”Tightening diagrams”.

(22.1 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft)

Technical Data: TD/TAD520, TAD530/531/532

Group 20

Technical Data TD520GE, TAD520GE, TD520VE, TAD520VE TAD530/531/532GE

General Type designation...................................................TD520GE TAD520GE Rotation direction, facing flywheel: ....................... Counterclockwise Number of cylinders .............................................. 4 4 Bore, mm (inch) .................................................... 108 (4.25") 108 (4.25") Stroke, mm (inch) ................................................. 130 (5.12") 130 (5.12") Displacement, dm3 ( inch3) .................................... 4.76 (290) 4.76 (290) Number of valves ................................................. 8 8 Compression ratio: ............................................... 17.5:1 17.5:1 Firing sequence ................................................... 1-3-4-2 1-3-4-2 Engine performance: At 1500 rpm, kW (hp) ........................................ 77.5 (104)1, 3) 94 (126)1, 3) 1, 3) At 1800 rpm, kW (hp) ........................................ 81.5 (109) 101 (135.5)1, 3) At 2300 rpm, kW (hp) ........................................ — — Engine torque, Nm ( lbf.ft) ..................................... 493 (394)3) 598 (441)3) At speed, rpm .................................................... 1500 1500 Engine torque, Nm ( lbf.ft) ..................................... 432 (319)3) 536 (395)3) At speed, rpm .................................................... 1800 1800 1) Max speed at full load, rpm ................................... 1500/1800 1500/18001) Weight engine (dry) kg (lb) ................................... 550 (1213)2) 575 (1268)2, 5)

TD520VE

Weight engine (wet) .............................................. 580 (1279)2)

725 (1336)2, 6)

1)

See identification plate for specification 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 2)

606 (1336)2, 5)

TAD520VE

4 108 (4.25") 130 (5.12") 4.76 (290) 8 18.4:1 1-3-4-2

4 108 (4.25") 130 (5.12") 4.76 (290) 8 18.1:1 1-3-4-2

— 81 (110)1, 4) — 430 (317)4) 1800 — — 18001) 430 (948)2)

— — 118 (158)1, 4) 577 (425)4) 1400 — — 2000 – 23001) 432 (952)2) —

Group 20


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)

TAD530GE Anti- clockwise 4 108 (4.25”) 130 (5.12”) 4.76 (290) 8



18.0:1 18.0:1 1-3-4-2

18.0:1 1-3-4-2

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)

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)

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)

1)

See engine plate for specifications. Weight according to DIN 70020-A 3) Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb) 4) Including clutch and frame 2)

Engine block

Cylinder liners Replacable, wet

Cylinder head A

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

TD520GE/TAD520GE TD520VE/TAD520VE TAD530/531/532GE Type: .................................................................... Wet, replaceable Number of seals per liner: ..................................... 2 +0.02 Bore: ..................................................................... 108 mm (4.252"+0.0008") Max bore wear: ..................................................... 108.1 mm (4.256") -0.02 Height sealing surface (A): .................................... 9 mm (0.3543"-0.0008" ) +0.03 Liner collar seating depth in block: ........................ 8.92 mm (0,3512"+0.0012" ) Projection of liner above block surface: 0.03 – 0.08 mm (0.0012" – 0.0031")

( 18 x 5.55")


Group 20


•


•


•


•


•


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")

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")

Group 20


Pistons Number of piston ring grooves .............................. 3 Combustion chamber: Diameter ............................................................ 71±0.1 mm Depth ................................................................. 16.66±0.1 mm Gudgeon pin diameter .......................................... 42-0.006

(2.795"±0.0039" ) (0.6559"±0.0039" ) (1.6535"-0.0002" )

Piston front marking, according to picture: Flywheel symbol on the piston top f aces the flywheel. Guiding pins on the connecting rod, must face flywheel symbol on the piston.

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")

1

2 3

Oilscraper ring (3) Number:................................................................ 1 Width, including springcoil: ................................... 3 mm Piston ring clearance in groove: ........................... 0.1 mm Piston ring gap, wear limit:.................................... 1.15 mm

(0.12") (0.0039") (0.045")


Group 20

Valve mechanism Valves Disc diameter Ø: Inlet ................................................................... 48±0.1 mm Exhaust ............................................................. 42±0.1 mm Stem diameter Ø: Inlet ................................................................... 8.98-0.015 mm Exhaust ............................................................. 8.96-0.015 mm Valve seat angle: Inlet, min ............................................................ 29.5° Exhaust, min...................................................... 44.5°

Min 2.1 mm

(1.8898"±0.0039" ) (1.6535"±0.0039" ) (0.3535"-0.0006" ) (0.3528"-0.0006" )

Min 1.8 mm 45° 30°

29.5°

44.5°

Valve disc edge: Inlet, min............................................................ 2.1 mm Exhaust, min...................................................... 1.8 mm Seat angle, cylinder head: Inlet ................................................................... 30° Exhaust ............................................................. 45° Valve seat width, max: Inlet ................................................................... 2.8 mm Exhaust ............................................................. 2.2 mm

(0.0827") (0.0709")

(0.1102") (0.0866")

Valve clearance: Inlet ................................................................... 0.35±0.05mm Exhaust ............................................................. 0.55±0.05mm

(0.014"±0.002" ) (0.022"±0.002" )


Valve seats ØA

B Outer diameter Ø (A), standard: -0.02 Inlet ................................................................... 49.09 mm -0.02 Exhaust ............................................................. 43.06 mm Height (B): Inlet ................................................................... 7.5±0.1 mm Exhaust ............................................................. 7.9±0.1 mm

(1.933"-0.0008" ) (1.717"-0.0008" ) (0.295"±0.004" ) (0.311"±0.004" )

Group 20


Valve seat location ØC

R

D

Diameter Ø (C), standard: Inlet ................................................................... 49+0.025 mm Exhaust ............................................................. 43.5+0.025 mm Depth (D): Inlet/Exhaust ...................................................... 11+1 mm Seat bottom radius (R): Inlet/Exhaust ...................................................... 1-0.3 mm Measurement between valve disc and cylinder head face: Inlet/Exhaust...................................................... Min 1.5 mm

(1.929"-0.001" ) (1.712"-0.001" ) (0.43"+0.04" ) (0.04"-0.012" ) (0.059")

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")

Design 1 without flange

Design 1 with flange

Design 2

O-ring Flange

On later models the o-ring seal is exchange to a valve stem sealing, according to the picture for design 2.

Production

Exchange

Valve springs Type ..................................................................... Single Length: Unloaded: n=2300 ................................... 64.7±1.3 mm Wire diameter Ø ................................................... 4.5 mm

(2.55"±0.05" ) (0.18")


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 .......................................................... 65.08mm (2.5622") +0.12 Camshaft bearing thickness: max ......................... 1.988 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" )

Timing gear 1. 2. 3. 4. 5. 6.

Governor drive Idler gear Camshaft gear PTO gear B-C PTO gear A Crankshaft

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

Group 20

Group 20


Crank mechanism Crankshaft length ................................................. 709.2 mm Crankshaft axial clearance 1) ................................. 0.1– 0.3 mm Main bearing radial clearance 1) ............................. 0.03+0.062 mm Max, permissible ovality of main bearing and crank pins ...................................... 0.01 mm Max, run-out of center bearing.............................. 0.07 mm 1)

(27.92") (0.0039"– 0.0118") (0.0012"+0.0024" ) (0.0004") (0.0027")


E F C

B A

D

Main bearing journals Diameter Ø for machining ( A): Standard .............. 85-0.02 mm Undersize: 0.25 mm (0.01") ................................................. 84.75-0.02 mm 0.5 mm (0.02") ................................................... 84.5-0.02 mm Main bearing journals: Out-of-round: Max. ............................................ 0.01 mm Taper: Max. ....................................................... 0.01 mm Width (B), axial bearing journal : standard ............ 38+0.06 mm Oversize: 0.4 mm (0.0157") ............................................... 38.4+0.06 Thrust washers (axial bearing) Width (C): Standard .............................................. 2.9+0.05 mm Oversize: 0.2 mm (0.0079") ............................................... 3.1+0.05 mm Width (D): ............................................................. 10 mm

(2.9134"-0.0008" ) (3.3366"-0.0008" ) (3.3268"-0.0008" )

(0.0004") (0.0004") (1.496" +0.0024" ) (1.5118" +0.0024" ) (0.1142"+0.0039" ) (0.122"+0.002" ) (0.4")

Main bearing shells Type ..................................................................... Replaceable Outer diameter Ø (E) ............................................ 85.03+0.036 m m Thickness (F): Standard ....................................... 2.727+0.008 m m Oversize: 0.25 mm (0.01") ................................................. 2.852+0.008 m m 0.5 mm (0.02") ................................................... 2.977+0.008 m m

(2.9035"+0.0014" ) (0.1074"+0.0003" ) (0.1123"+0.0003" ) (0.1172"+0.0003" )


Group 20

Connecting rod bearing journals Diameter Ø (G) for machining: Standard................... Stan dard............................. .................... ..................... ..................... ............. ... 68-0.02 mm mm Undersize: 0.25 mm (0.01") (0.01") .......... .................... .................... .................... ................... ......... 67.75-0.02 mm mm -0.02 0.5 mm (0.02") (0.02") ......... ................... .................... .................... .................... ............ .. 67.5 mm m m ±0.04 Width (H), axial axial bearing bearing journal................ journal......................... ............. .... 35.5 mm mm Connecting rod-bearing journals: OutOut-of of-r -rou ound nd:: Max Max.. .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 0.01 0.01 mm Tape Taper: r: Ma Max x .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 0.01 0.01 mm

(2.6772"-0.0008" ) (2.6673"-0.0008" ) (2.6575"-0.0008" ) (1.397"±0.0016" ) (0.0 (0.000 004" 4")) (0.0 (0.000 004" 4"))

H G K

J

Connecting rod bearing shells Diameter Ø (J): Bearing Bearing .......... ................... ................... .................... .......... 68.03+0.04 mm mm Oversize: 0.25 mm (0.01") (0.01") .......... .................... .................... .................... ................... ......... 67.78+0.04 mm mm +0.04 0.5 mm (0.02") (0.02") .......... .................... ................... ................... .................... ............ .. 67.53 mm mm +0.05 Diameter Diameter Ø: Bearing Bearing shell shell ......... ................... ................... .................. ......... 72.5 mm Thickness (K): Standard Standard .......... ................... ................... .................... .......... 2.222+0.01 mm mm

(2.6783"+0.0016" ) (2.6685"+0.0016" ) (2.6587"+0.0016" ) (2.854"+0.002" ) (0.0875"-0.0004" )

Group 20


Connecting rods Length (L): Center – Center ......... ................... ................... ............... ...... 210±0.06 mm m m +0.01 Connecting rod (M) bushin bushing g bore bore .......... ................... ............... ...... 42.04 mm mm Wear We ar limi limitt .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 0.08 0.08 mm Replacing measurement for small end bush Bore for small end bush ......... ................... ................... .................. ......... 45.5+0.02 mm mm +0.04 Small Small end bush outer diameter diameter .......... .................... ................ ...... 45.5 45.58 8 mm mm

(8.2677"±0.00236" ) (1.6551"0.0004" ) (0.0 (0.003 031" 1")) (1.7913"0.0008" ) (1.7945"+0.0016" )

L M

Axial clearance, connecting rod – crankshaft1) .... ...... .. 0.3 0.3 – 0.4 0.4 mm 1) +0.06 Connecting rod bearing: radial clearance ......... ............ ... 0.036 mm mm Parallelism: Tolerans Over Over a len lengt gth h of of 100 100 mm .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 0.05 0.05 mm Squareness: Tolerans Over Over a len lengt gth h of of 100 100 mm .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 0.05 0.05 mm 1)

The dimensions apply to oiled parts

Connecting rod marking: Connecting rod and cap number marking must be on one side and identical

(0.0 (0.011 118 8 – 0.01 0.0157 57") ") +0.0024" (0.00142" ) (0.0 (0.002 02") ") (0.0 (0.002 02") ")


Group 20

Lubricating system

Oil grade2)

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 API: CI-4, CH-4, CG-4

1)

500 hours or months

250 hours or months

125 hours or months

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



Group 20


Engine oil quantity With oil filter: TD520GE/TAD520GE: ...................................... 10 liter TD520VE/TAD520VE:........................................ 13 liter TAD530/531/532GE: .......................................... 13 liter

(2.64 US gal) (3.43 US gal) (3.43 US gal)


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)


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) 2)

Depending on length of hose Can also be used as an air ventilation screw

Group 20

Group 20


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%.

In

Out

Fuel feed pump Fuel system figures is corresponding to the picture above 1. Overpressure relief valve: Opening pressure ...............................................0.6±0.05 MPa 2. Bypass valve Opening pressure ............................................... 50±5 kPa Fuel flow Min fuel flow at 1500 rpm .......................................600 l/tim Firing sequence .................................................... 1-3-4-2 Feed pressure .......................................................0.5 MPa Feed pressure after fuel filter 1500 rpm: Min ....................................................0.28 MPa

(87±7 psi)1) (7.2±0.7 psi) (158.5 gal/hour) (72.5 psi) (40.6 psi)


Group 20

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

Injection pump Manufacturer ........................................................ Bosch Designation .......................................................... PF 33 L Length A: .............................................................. 54 mm Basic measurement length LO : ............................ 143 mm Min length LFB : (A/100+143) – 143 ....................... >0 mm

(2.12") (5.63")

Group 20


Injectors Opening pressure: TD520GE, TAD530-532GE: ............................... 25 MPa TAD520GE/TD520VE/TAD520VE:.................... 27.5 MPa Max pressure........................................................ 120 MPa Check leakage (for 10 min): TD520GE, TAD530-532GE: ............................... 23 MPa TAD520GE/TD520VE/TAD520VE:.................... 25.5 MPa Numbers/bore Ø: TD520GE, TAD530-532GE ................................ 5 x 0.234 mm TAD520GE/TD520VE/TAD520VE: ..................... 5 x 0.25 mm

(3600 psi) (4000 psi) (17400 psi) (3340 psi) (3700 psi) (0.00921") (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")


Camshaft types

Vh Pre-stroke

Vhcorr.factor

Lo

Pre-stroke Basic dimension correction factor Injection pump


Group 20

Theoretical thickness for a new shim. Computation for determining the theoretical shim thickness (Ts) :

Ts = L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm) The correction factor Vhcorr.factor is taken from the table on previous page. The individual steps: 1st step: E1 = FBactual - FBnom (°C/A)

· · · · · · ·

2nd step: E2 = E1 x Vhcorr.factor (mm/°C/A) 3rd step: E3 = E2 + Vhnom 4th step: E4 = E3 + Lo 5th step: E5 = E4 + A/100 (mm) 6th step: Ts = L – E5 7th step: The actual shim thickness (Ss) is determined with the help of table 2 below.

Table 2 (Shim thickness) All measurements are in mm (1 mm = 0.0394")


Shim thickness (SS)


Shim thickness (SS)

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.

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

Ek (mm)

EP code


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 t o 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 Control rod (fuel rack) travel Y, with injection pumps Min: ...................................................................... 16.8 mm The recess dimension X ....................................... 0.3 – 1.3 mm

(0.67" – 0.69") (0.66") (0.012" – 0.051")


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: ....................................................... 120kPa (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 TD520GE/TAD530GE: ....................................... 610°C (1130°F) TAD520GE/TAD531GE, TAD532GE: ................. 520°C (968°F) At rated speed: .....................................................1800 rpm TD520VE: .......................................................... 510°C (950°F) TAD520VE:........................................................ 475°C (887°F) 1) 2)

1800 rpm 530°C (986°F) 448°C (838°F) 2100 rpm 2200 rpm 2300 rpm — — — 470°C (878°F) 470°C (878°F) 470°C (878°F)

See in General information, Power standards. Information was not avaible at the time of printing.

Air intake Air intake restriction, clean filter(s) TD520VE/TAD520VE: ....................................... 2.5 kPa TD520GE/TAD520GE/TAD530-532GE:.............. 1 kPa Max allowed air intake restriction TD520VE/TAD520VE: ....................................... 6.5 kPa TD520GE/TAD520GE/TAD530-532GE:.............. 3 kPa

(0.36 psi) (0.14 psi) (0.94 psi) (0.43 psi)


Group 20

Cooling system Type ...................................................................... Pressurized, closed circuit Pressure valve opens at: TD520GE/TAD520GE/TAD530/531GE............... 90 kPa (13 psi) TD520VE/TAD520VE, max: ............................... 90 kPa1) (13 psi) TAD532GE: ....................................................... 60 kPa (8.7 psi) 1)


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)

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

Coolan connection (inlet) Thermastat housing Coolant pump Lubrication oil cooler Cylinder cooling Cylinder head cooling Coolant connection (outlet)

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 fr eezing, mixed with water3). 3)


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

Group 20



Nm

(lbf.ft)

M6 standard screw 8.8 .......................................... 10±1.5 M8 standard screw 8.8 .......................................... 25±4 M10 standard screw 8.8 ........................................ 50±8 M12 standard screw 8.8 ........................................ 80±9 M14 standard screw 8.8 ........................................ 140±25

(7.5±1 lbf.ft) (18±3 lbf.ft) (37±6 lbf.ft) (59±6.5 lbf.ft) (103±18 lbf.ft)

Tightening torques

(lbf.ft)

Nm

Group 21 Engine Engine mounting................................................... 260 Starter motor ........................................................ 70 Timing gear casing ............................................... 21±2

(192lbf.ft) (51.6 lbf.ft) (15.5±1.5 lbf.ft)


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, r ocker a rm f ixing ..................................... 21 (15.5 lbf.ft) ±1 Screws, crankcase ventilation .............................. 9 (6.6±0.7 lbf.ft)


Tightening torques

Group 20

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 Oil cooler, hollow screw Step 1: ............................................................... 80 Step 2:............................................................... 160 Oil cooler, screw plug ........................................... 80 Front/oil pump housing ......................................... 21±2 Oil suction pipe ..................................................... 21±2 Oil sump ............................................................... 21±2 Oil pressure pipe turbo ......................................... 29±3 Oil pressure pipe engine block ............................. 39±4 Screws, oil return pipe turbo A) with tube fitting .............................................. 40±2 B) with flange fitting ........................................... 21±2 Screws, oil return pipe engine block ..................... 21±2 Oil pressure switch ............................................... 18±2

(15.5±1.5 lbf.ft) (59 lbf.ft) (118 lbf.ft) (59 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (21.4±2.2 lbf.ft) (29±3 lbf.ft) (29.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (13±1.5 lbf.ft)

Group 23 Fuel system Screw, governor, idler gear: Step 1: ............................................................... 30 (22.1lbf.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 (3.7lbf.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 (5lbf.ft) Step 6: ............................................................... 10 (7.4lbf.ft) Step 7: ............................................................... 30 (22lbf.ft) +5 Flange screw, injector ........................................... 16 (12+4 lbf.ft) Injector cap nut ..................................................... 40 – 50 (30 – 37lbf.ft) Delivery pipe Use a new delivery pipe after every disassembly

Step 1: ............................................................... 5 Step 2: ............................................................... 25+3.5 Screw, stop magnet .............................................. 21 Overflow valve ...................................................... 30

(3.7lbf.ft) (18.4±2.6 lbf.ft) (15.5lbf.ft) (22lbf.ft)

Group 25 Inlet and exhaust system Exhaust manifold nuts .......................................... 25±2.5 M8 Nuts, turbo to exhaust manifold ...................... 21±2 M10 Nuts, turbo to exhaust manifold .................... 40.5±4 Screws, Inlet manifold .......................................... 11±1


Group 26 Cooling system Thermostat housing .............................................. 30 Water temp sensor ............................................... 21±2 Water pump .......................................................... 21±2 NOTE! See also ”Tightening diagrams”.


Group 20

Technical Data: TD/TAD720-722, TAD730/733, TAD750/760

Technical Data TD/TAD720GE, TD/TAD720VE, TAD721GE/VE, TAD722GE, TAD722VE, TAD730/731/732/733GE, TAD750VE, TAD760VE

General TAD720GE Type designation.......................... TD720GE Rotation direction, facing flywheel: 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 (436.3) 7.15 (436.3) Number of valves ......................... 12 12 Compression ratio: EPA 1 ....................................... 17.1:1 17.5:1 COM 2 ...................................... — — Firing sequence ........................... 1-5-3-6-2-4 1-5-3-6-2-4 Engine performance: At 1500 rpm, kW (hp) ................ 1281, 3) 1531, 3) 1, 3) At 1800 rpm, kW (hp) ................ 134 1631, 3) Engine torque, Nm (lbf.ft) ............. 8153) 9743) At speed, rpm ........................... 1500 1500 3) Engine torque, Nm (lbf.ft) ............. 711 8653) At speed, rpm ........................... 1800 1800 Low idle, rpm ................................ 850-950 850-950 1) Max speed at full load (rpm) ......... 1500/1800 1500/18001) 2) Weight engine (dry) kg (lb) ........... 750 (1653) 760 (1674)2) Weight engine (wet) kg (lb) ........... 790 (1742 lb)2) 804 (1773 lb)2)

See identification plate for specification Weight according to DIN 70020-A 3) Measured at Prime Power, see ”General information, Power standards” 1) 2)

TAD721GE

TAD722GE

6 108 (4.25") 130 (5.12") 7.15 (436.3) 12

6 108 (4.25") 130 (5.12") 7.15 (436.3) 12

— 18.1:1 1-5-3-6-2-4

— 18.1:1 1-5-3-6-2-4

1831, 3) 2041, 3) 1165 1500 1082 1800 800-950 1500/18001) 7852) 8262)

2011, 3) 2251, 3) 1280 1500 1193 1800 800-950 1500/18001) 7852) 8262)


Group 20

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)

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)

TAD731GE Anti- clockwise 6 108 (4.25”) 130 (5.12”) 7.15 (436.3) 12

TAD732GE Anti- clockwise 6 108 (4.25”) 130 (5.12”) 7,15 (436) 12

TAD733GE Anti- clockwise 6 108 (4.25”) 130 (5.12”) 7,15 (436) 12

17.1:1 17.1:1

18,0:1

18,0:1

1-5-3-6-2-4

1-5-3-6-2-4

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)

201 (273)1) 225 (306)1) 1280 (944) 1500 1193 (880) 1800 800 – 950 1500/18001) 785 (1731)2) 826 (1821)2)

201 (273)1) 225 (306)1) 1280 (944) 1500 1193 (880) 1800 800 – 950 1500/18001) 785 (1731)2) 826 (1821)2)

1)

See engine plate for specifications. Weight according to DIN 70020-A 3) Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb) 4) Including clutch and frame 2)

General Type designation.......................... TD720VE TAD720VE Rotation direction, facing flywheel: Counterclockwise Number of cylinders ..................... 6 6 Bore, mm (inch) ........................... 108 (4.25") 108 (4.25") Stroke, mm (inch) ........................ 130 (5.12") 130 (5.12") 3 3 Displacement, dm (inch ) ............. 7.15 (436.3) 7.15 (436.3) Number of valves ......................... 12 12 Compression ratio: EPA 1 ....................................... 18.4:1 18.4:1 COM 2 ...................................... — 19.0:1 Firing sequence ........................... 1-5-3-6-2-4 1-5-3-6-2-4 Engine performance: At 1500 rpm, kW (hp) ................ 1221) — At 1800 rpm, kW (hp) ................ — 1741) Engine torque, Nm (lbf.ft) ............. 701 817 At speed, rpm ........................... 1500 1800 Low idle, rpm ................................ 850-950 850-950 1) Max speed at full load (rpm) ......... 1800 2000-23001) Weight engine (dry) kg (lb) ........... 5702) 5722) 2,3) Weight engine (wet) kg (lb) ........... 920 — See identification plate for specification Weight according to DIN 70020-A 3) Including clutch and frame 1) 2)

TAD721VE

TAD722VE

6 108 (4.25") 130 (5.12") 7.15 (436.3) 12

6 108 (4.25") 130 (5.12") 7.15 (436.3) 12

18.4:1 19.0:1 1-5-3-6-2-4

— 19.0:1 1-5-3-6-2-4

— 1951) 897 1800 850-950 2000-23001) 5722) —

— 2001) 981 1800 800-950 2100-23001) 6802) —

Group 20


General Type designation....................................................TAD750VE Rotation direction, facing flywheel: .........................Counterclockwise Number of cylinders ............................................... 6 Bore, mm (inch) ..................................................... 108 (4.25") Stroke, mm (inch) .................................................. 130 (5.12") Displacement, dm3 (inch3) ....................................... 7.15 (436) Number of valves ................................................... 12 Compression ratio: . ................................................ 18.1:1 Firing sequence ..................................................... 1-5-3-6-2-4 Engine performance at 2300 rpm, kW (hp) ............. 181 (246)1, 3) Max torque, Nm (lbf.ft) .......................................... 1050 (775)3) At speed, rpm .................................................... 1500 Low idle, rpm ......................................................... 600 - 800 Max, full load speed, rpm ....................................... 24001) Weight. engine (dry) kg (lb) .................................... 650 (1433)2) Weight. engine (wet) kg (lb) .................................... 681 (1501)2)

TAD760VE Counterclockwise 6 108 (4.25") 130 (5.12") 7.15 (436) 12 18.1:1 1-5-3-6-2-4 181 (246)1, 3) 1100 (811)3) 1500 600 - 800 24001) 650 (1433)2) 680 (1496)2)

1)


Cylinder liners

Engine block

Replacable, wet

Cylinder head A

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

TD720GE, TAD720GE, TAD721GE, TAD722GE, TAD720VE, TAD720VE, TAD721VE, TAD722VE, TAD730-733GE, TAD750, TAD760VE 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”) -0.02 Sealing surface. height (A): ................................... 9 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”)

(26 x 5.55”)

Technical Data: TD/TAD720-722, TAD730-733, TAD750/760

Group 20


•


•


•


•


•


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")

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")

Group 20


Pistons Number of piston ring grooves............................... 3 Combustion chamber: Diameter Ø ........................................................... 71±0.1 mm Depth .................................................................... 16.66±0.1 mm Gudgeon pin diameter Ø ....................................... 42-0.006 mm

(2.795"±0.0039") (0.6559"±0.0039") (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.

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")

1

2 3

Oilscraper ring (3) Number: ................................................................ 1 Width, including springcoil:.................................... 3 mm Piston ring clearance. height: ................................ 0.1 mm Piston ring gap, wear limit: .................................... 1.15 mm

(0.12") (0.0039") (0.045”)


Group 20

Valve mechanism Valves Disc diameter Ø: Inlet ................................................................... 48±0.1 mm Exhaust ............................................................. 42±0.1 mm Stem diameter Ø: Inlet ................................................................... 8.98-0.015 mm Exhaust ............................................................. 8.96-0.015 mm Valve seat angle: Inlet, min ............................................................ 29.5° Exhaust, min ..................................................... 44.5°

(1.8898"±0.0039") (1.6535"±0.0039") (0.3535"-0.0006") (0.3528"-0.0006")

Min 1.8 mm

Min 2.1 mm

45° 30° 29.5° 44.5°

Valve disc edge: Inlet, min ............................................................ 2.1 mm Exhaust, min ..................................................... 1.8 mm Seat angle, cylinder head: Inlet ................................................................... 30° Exhaust ............................................................. 45° Valve seat width, max: Inlet, min ............................................................ 2.8 mm Exhaust, min ..................................................... 2.2 mm

(0.0827") (0.0709")

(0.1102") (0.0866")

Valve clearance (not apply for TAD760VE) Inlet ................................................................... 0.35±0.05 mm Exhaust ............................................................. 0.55±0.05 mm

(0.014"±0.002") (0.022"±0.002")


Valve seats ØA

B

Outer diameter Ø (A), standard: Inlet ................................................................... 49.09-0.02 mm Exhaust ............................................................. 43.06-0.02 mm Height (B): Inlet ................................................................... 7.5±0.1 mm Exhaust ............................................................. 7.9±0.1 mm

(1.933"-0.0008") (1.695"-0.0008") (0.295"±0.004") (0.311"±0.004")

Group 20


Valve seat location ØC

R

D

Diameter Ø (C), standard: Inlet ................................................................... 49-0.025 mm Exhaust ............................................................. 43.5-0.02 mm Depth (D): Inlet/Exhaust ..................................................... 11+1 mm Seat bottom radius (R): Inlet/Exhaust ..................................................... 1-0.3 mm Measurement between valve disc and cylinder head face: Inlet/Exhaust ..................................................... Min 1.5 mm

(1.929"-0.001") (1.712"-0.001") (0.43"+0.04") (0.04"-0.012") (0.059")

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")

Design 1 without flange

Design 2

Design 1 with flange O-ring Flange

On later models the o-ring seal is exchange to a valve stem sealing, according to the picture for design 2.

Production

Exchange

Valve springs Type ..................................................................... Single Length: Unloaded: n=2300 .................................... 64.7±1.3 mm Wire diameter Ø .................................................... 4.5 mm

(2.55"±0.05") (0.18")


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 ........................................................... 65.08mm (2.5622") +0.012 Camshaft bearing thickness: max ......................... 1.988 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")

Timing gear 1. 2. 3. 4. 5. 6.

Governor drive (not apply for 750/760) Idler gear (not apply for 750/760) Camshaft gear PTO gear B-C (not apply for 750/760) PTO gear A (not apply for 750/760) Crankshaft gear

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

Group 20

Group 20


Crank mechanism Crankshaft length .................................................. 973.2 mm Crankshaft axial clearance1) .................................. 0.1– 0.3 mm Main bearing radial clearance 1) .............................. 0.03+0.062 mm Max, permissible ovality of main bearing and crank pins ....................................... 0.01 mm Max, run-out of center bearing............................... 0.1 mm 1)

(38.31") (0.0039"– 0.0118") (0.0012"+0.0024" ) (0.0004") (0.00394")


E F C

B A

D

Main bearing journals Diameter Ø (A) for machining: Standard............... 85-0.02 mm Undersize: 0.25 mm (0.01") ................................................. 84.75-0.02 mm 0.5 mm (0.02") ................................................... 84.5-0.02 mm Main bearing journals: Out-of-round: Max. ............................................. 0.01 mm Taper: Max. ....................................................... 0.01 mm Width (B), axial bearing journal: standard .............. 38+0.06 mm Oversize: 0.4 mm (0.0157") ............................................... 38.4+0.06 mm Thrust washers (axial bearing) Width (C): Standard ............................................... 2.9+0.05 mm Oversize: 0.2 mm (0.0079") ............................................... 3.1+0.05 mm Width (D):.............................................................. 10 mm

(2.9134"-0.0008") (3.3366"-0.0008") (3.3268"-0.0008")

(0.0004") (0.0004") (1.496"+0.0024") (1.5118"+0.0024") (0.114"+0.002") (0.122"+0.002") (0.4")

Main bearing shells Type ..................................................................... Replaceable Outer diameter Ø (E) ............................................. 85.03+0.036 m m Thickness (F): Standard........................................ 2.727+0.008 m m Oversize: 0.25 mm (0.01") ................................................. 2.852+0.008 mm 0.5 mm (0.02") ................................................... 2.977+0.008 mm

(2.9035"+0.0014") (0.1074"+0.0003") (0.1123"+0.0003") (0.1172"+0.0003")


Group 20

Connecting rod bearing journals Diameter Ø (G) for machining: Standard ............................................................... 68-0.02 mm Undersize: 0.25 mm (0.01") ................................................. 67.75-0.02 mm 0.5 mm (0.02") ................................................... 67.5-0.02 mm Width (H), axial bearing journal. ............................. 35.5±0.02 mm Connecting rod-bearing journals: Out-of-round: Max. ............................................. 0.01 mm Taper: Max ........................................................ 0.01 mm

J

(2.6772"-0.0008") (2.6673"-0.0008") (2.6575"-0.0008") (1.397"±0.0008") (0.0004") (0.0004")

H G

K

Connecting rod bearing shells Diameter Ø (J): Bearing ........................................ 68.03+0.04 mm Oversize: 0.25 mm (0.01") ................................................. 67.78+0.04 mm 0.5 mm (0.02") ................................................... 67.53+0.04 mm Diameter Ø: Bearing shell ..................................... 72.5+0.05 mm Thickness (K): Standard ....................................... 2.222+0.01 mm

(2.6783"+0.0016") (2.6685"+0.0016") (2.6587"+0.0016") (2.854"+0.002") (0.0875"+0.0004")

Group 20


Connecting rods Length (L (L): Center Center – Center Center .......... .................... .................... ............... ..... 210±0.06 mm mm +0.01 Connecting rod (M (M) bushin bushing g bore bore .......... ..................... ................. ...... 42. 42.04 04 mm m m Wear We ar limi limitt ...... ......... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ...... ..... .. 0.08 0.08 mm Replacing measurement for small end bush Bore for small small end bush .......... ................... ................... .................. ........ 45.5+0.02 mm mm +0.04 Small end bush outer diameter Ø ....................... .............. ......... 45.58 mm mm

(8.2677"±0.00236") (1.6551"0.0004") (0.0 (0.003 031" 1")) (1.7913"0.0008") (1.7945"+0.0016")

L M

Axial clearance, connecting rod – crankshaft1) .. .... .... .. 0.3.3-0.4 mm (0.0118-0.0157") 1) Connecting rod bearing: radial clearance ............. 0.036 0.036-0.09 -0.096 6 mm (0.0014 (0.00142-0 2-0.003 .00378" 78")) Parallelism: Tolerans Over Over a len lengt gth h of of 100 100 mm.. mm.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 0.05 0.05 mm (0.00 .002") Squareness: Tolerans Over Over a len lengt gth h of of 100 100 mm.. mm.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 0.05 0.05 mm (0.00 .002") 1)


Marking: Connecting Marking: Connecting rod and cap number marking must m ust be on one side and identical


Group 20

Lubricating system Sulfur content in fuel, by weight Engine

Oilgrade2)

< 0,5 %

0,5 – 1,0 %

> 1,0 % 1)

Oil change interval, reached first in operation T(A)D720-721VE T(A)D720GE TAD730/731GE, TAD721/722GE, TAD732/TAD733GE, TAD750/760VE, open crankcase ventilation

VDS-3 VDS-2 ACEA: E7, E5, E3 API: CI-4, CH-4, CG-4

500 h / 12 months

250 h / 12 months

125 h / 12 months

TAD721/722GE, TAD732/733GE, TAD750/760VE, closed crankcase ventilation

ACEA: E4 API: CI-4, CH-4

500 h / 12 months

250 h / 12 months

125 h / 12 months

TAD722VE power<200kW

ACEA: E4

500 h / 12 months

250 h / 12 months

125 h / 12 months

250 h / 12 months

125 h / 12 months

60 h / 12 months

NOTE! Fully synthetic oil must be used NOTE! Fully

power>200kW 1) 2)

If the sulfur content is > 1.0% by weight, use oil with T BN > 15 closed crankcase ventilation 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



Group 20


Engine oil quantity With oil filter: TD720 20/T /TA AD72 720 0/T /TAD AD72 721 1VE: .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 20 li lite terr TAD AD7 722 22V VE/T /TA AD75 750 0VE VE/T /TA AD76 760V 0VE E .. .... .... .... .... .... .... .... .... .... .. 23 li lite terr TAD721GE GE/T /TA AD722GE.. GE.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 34 li lite terr

(5.2 (5 .28 8 US ga gal) l) (6.10 (6.1 0 US ga gal) l) (8.9 (8 .98 8 US ga gal) l)


At rated speed: TD72 720G 0GE E, TA TAD7 D720 20/7 /72 21/ 1/72 722G 2GE E, TAD TAD7 730 30-7 -73 33G 3GE E:4 :400 00 kP kPa (58 (5 8 psi) psi) TD72 720V 0VE E/T /TA AD72 722/ 2/7 750 50/7 /760 60V VE: .. .... .... .... .... .... .... .... .... .... .... .... .... .. 45 450 0 kPa kPa (65 (6 5 psi psi)) TAD AD72 720V 0VE/ E/TA TAD D72 721V 1VE: E: .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 35 350 0 kPa kPa (50. (5 0.8 8 psi psi)) Idli Id ling ng sp spee eed d (8 (800 00 rp rpm) m),, mi min:... n:..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 80 kP kPa a (11. (1 1.6 6 ps psi) i) Shut down switch, at pressure lower than: TD720GE GE,, TA TAD720/721/722GE, TA TAD730-731GE: 15 150 0 kPa kPa (22 (2 2 psi) psi) TD720VE, TA TAD720/721/722/750/760VE: .. .... .... .... .... .... .. 50 kP kPa (7. 7.2 2 ps psi) TAD732/ 2/7 733G 3GE E .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 20 200 0 kP kPa a (29 (2 9 ps psii) 2. Tappet with pulse lubrication 3. Pushrod, oil supply for rocker arm lubrication 4. Rocker arm 5. Return line to oil sump ............................ .............................. .................... ..... 2-hole nozzles for each cylinder 6. Piston cooling: ............. 7. Oil filter , full-flow: Filt Fi lter erin ing g si size ze:: .. ..... ...... ...... ...... ...... ..... ..... ..... ..... ..... ..... ...... ...... ...... ...... ..... ..... ..... ..... ......0. ...0.01 012 2 mm (0.0 (0 .000 005" 5")) Bypass valve oil filter: Opening Open ing press pressure: ure: ............. ........................... ............................. .................... ..... 250±50 k kP Pa (35±7 psi) 8. Pressure regulating valve: Opening Open ing press pressure: ure: ............. ........................... ............................. .................... ..... 400±40 k kP Pa (58±6 psi) 9. Pressure-relief valve: Opening Open ing press pressure: ure: ............. ............................ .............................. .................. ... 1±0.1 M MP Pa (145±14 psi) 10. Lube oil pump: Type: Typ e: ......... .................... ..................... .................... ..................... ..................... ................. ....... Rota Rotary ry pump driven by the crank crankshaft shaft Rot otar ary y pu pump mp widt width: h: .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 14 14.5 .5 mm (0.5 .57" 7")) Oill fl Oi flow ow (2 (250 500 0 rp rpm) m):: ... ..... ..... ...... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... 90 l/ l/mi min n (24 (2 4 ga gal/ l/ho hour ur)) 11. Oil cooler: Normal oil te tem mperatu turre: .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....8 ..80 0°C (176°F) Max Ma x o il te temp mper erat atur ure: e: .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 125°C (257°F)


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 valve2) 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) 2)

Depending on length of hose Can also be used as an air ventilation screw

Group 20

Group 20


Fuel system (750,760)

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

Fuel tank Hand pump (accessory) Fuel line (to pump) Fuel pump Fuel filter Pipe to highpressure Rail

8. 9. 10. 11. 12. 13.

Highpressure pump Fuelpipe, to injector Injector M-prop Pressure valve Return fuel line, to fuel tank, A = Fuel pipes, minimum distance 300 mm (11.8")


Group 20

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%.

In

Out

Fuel feed pump Fuel system figures is corresponding to the picture above Overpressure relief valve (1): Opening pressure ............................................... 0.6±0.05 MPa Bypass valve (2) Opening pressure ............................................... 50±5 kPa Fuel flow Min fuel flow at 1500 rpm ...................................... 600 l/tim Firing sequence .................................................... 1-5-3-6-2-4 Feed pressure ....................................................... 0.5 MPa Feed pressure after fuel filter at 1500 rpm. min .................................................... 0.28 MPa

(87±7.2 psi)1) (7.2±0.7 psi) (158.5 gal/hour) (72.5 psi) (40.6 psi)

Fuel filter Filtering size ......................................................... 0.005 mm

(0.0002")

Pre-filter Filtering size ......................................................... 0.006 mm

(0.00024")

Group 20


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 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

Injection pump (720–733) Manufacturer ......................................................... Bosch Designation ........................................................... PF 33 L Length A: .............................................................. 54 mm Basic measurement length LO : . ............................ 143 mm Min length LFB : (A/100+143) – 143 ........................ >0 mm

(2.12") (5.63")

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")


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”.

Table 1 (Commencement of delivery) All measurements are in mm (1 mm = 0.0394")


Camshaft types

Vh Pre-stroke

Vhcorr.factor

Lo

Pre-stroke Basic dimension correction factor Injection pump

Group 20


Theoretical thickness for a new shim (720–733) Computation for determining the theoretical shim thickness (TS) : TS= L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + LO + A/100 ] (mm)

The correction factor Vhcorr.factor is taken from the table on previous page. The individual steps: 1st step: E1 = FBactual - FBnom (°C/A)

· · · · · · ·

2nd step: E2 = E1 x Vhcorr.factor (mm/°C/A) 3rd step: E3 = E2 + Vhnom 4th step: E4 = E3 + LO 5th step: E5 = E4 + A/100 (mm) 6th step: Ts = L – E5 7th step: The actual shim thickness (Ss) 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)

Table 2 (Shim thickness) All measurements are in mm (1 mm = 0.0394")


Shim thickness (SS)

Theor. thickness(TS)

Shim thickness (SS)

NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When the theoretical shim thickness (T s) 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.


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. TS = EK - (LO + A/100) TS = Shim thickness EK = Value from tabel 3 read with help of EP code f rom ”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 t he 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

Ek (mm)

EP code

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 Control rod (fuel rack) travel Y, with injection pumps Min: ...................................................................... 16.8 mm The recess dimension X ....................................... 0.3 – 1.3 mm

(0.67" – 0.69") (0.66") (0.012" – 0.051")



Group 20

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 (29.0psi) TD720VE: ....................................................................................2) kPa (2) psi) TAD720VE (EPA 1): .................................................................... 133kPa (18.9 psi) TAD720VE (COM 2): ................................................................... 151kPa (21.9 psi) TAD721VE (EPA 1): .................................................................... 155kPa (22.5 psi) TAD721VE (COM 2): ................................................................... 163kPa (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)

Exhaust gas temperatur, approx: At rated speed (standby power)1): ..........................1500 rpm TD720GE, TAD730GE: ...................................... 560°C(1040°F) TAD720GE, TAD731GE:.................................... 476°C(914°F) TAD722GE, TAD732/733GE .............................. 557°C (1035°F) At rated speed: .....................................................1800 rpm TD720VE: .......................................................... 420°C (788°F) TAD721VE: ........................................................ 420°C(788°F) TAD721VE: ........................................................ 490°C(914°F) TAD722/750/760VE: .......................................... 545°C (1013°F)

1800 rpm 505°C (941°F) 433°C (837°F) 520°C (968°F) 2100 rpm — 420°C (788°F) 475°C (887°F) 535°C (995°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 TAD721GE/TAD722GE, TAD731-733GE: .......... 1.5 kPa TD720VE/TAD720/721/722/750/760VE: . ............ 2.5 Max allowed air intake restriction TD720GE/TAD720GE, TAD730GE: ................... 3 kPa TAD721GE/TAD722GE, TAD731-733GE: .......... 3.5 kPa TD720VE/TAD720/721/722/750/760VE: . ............ 6.5

(0.14 psi) (0.22 psi) (0.36 psi) (0.43 psi) (0.51 psi) (0.94 psi)

2200 rpm — 425°C (797°F) 480°C (896°F) 540°C (1004°F)

2300 rpm — 430°C (806°F) 485°C (905°F) 545°C (1013°F)

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 k Pa (13 p si) 1)


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)

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

TD/TAD720-722: Coolan connection (inlet) Thermastat housing Coolant pump Lubrication oil cooler Cylinder cooling Cylinder head cooling Coolant connection (outlet)

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)


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


Group 20


Nm

(lbf.ft)

M6 standard screw 8.8 .......................................... 10±1.5 M8 standard screw 8.8 .......................................... 25±4 M10 standard screw 8.8 ........................................ 50±8 M12 standard screw 8.8 ........................................ 80±9 M14 standard screw 8.8 ........................................ 140±25

(7.5±1 lbf.ft) (18±3 lbf.ft) (37±6 lbf.ft) (59±6.5 lbf.ft) (103±18 lbf.ft)

Tightening torques

(lbf.ft)

Nm

Group 21 Engine Engine mounting ................................................... 260 Starter motor ......................................................... 70 Timing gear casing ................................................ 21±2

(192 lbf.ft) (51.6 lbf.ft) (15.5±1.5 lbf.ft)


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)

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 Oil cooler, hollow screw Step 1: ............................................................... 80 Step 2: ............................................................... 160 Oil cooler, screw plug............................................ 80 Front/oil pump housing .......................................... 21±2 Oil suction pipe ..................................................... 21±2 Oil sump ............................................................... 21±2 Oil pressure pipe turbo .......................................... 29±3 Oil pressure pipe engine block .............................. 39±4 Screws, oil return pipe turbo A) with tube fitting .............................................. 40±2 B) with flange fitting ........................................... 21±2 Screws, oil return pipe engine block ...................... 21±2 Oil pressure switch ............................................... 18±2

(15.5±1.5 lbf.ft) (59 lbf.ft) (118 lbf.ft) (59 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (21.4±2.2 lbf.ft) (29±3 lbf.ft) (29.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (15.5±1.5 lbf.ft) (13±1.5 lbf.ft)

Group 23 Fuel system Screw, governor, idler gear: Step 1: ............................................................... 30 (22.1lbf.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 (3.7lbf.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 (5lbf.ft) Step 6: ............................................................... 10 (7.4lbf.ft) Step 7: ............................................................... 30 (22lbf.ft) +5 Flange screw, injector ........................................... 16 (12+4 lbf.ft) Injector cap nut ..................................................... 40 – 50 (30 – 37lbf.ft) Delivery pipe Use a new delivery pipe after every disassembly

Step 1: ............................................................... 5 Step 2: ............................................................... 25±3.5 Screw, stop magnet .............................................. 21 Overflow valve ...................................................... 30 Common Rail, TAD750/760 Safety valve....................................................... 100 Rail pressuree sensor ........................................ 70 Common rail unit ................................................ 30 Fuel hose ........................................................... 39 IEGR, TAD750/760 IEGR-unit: .......................................................... 30 Solenoid valve: .................................................. 24 Highpressure fuel pump, TAD750/760 Step 1: ............................................................... 10 Step 2: ............................................................... 50

(3.7lbf.ft) (18.4±2.6 lbf.ft) (15.5lbf.ft) (22lbf.ft) (74 lbf.ft) (51.6 lbf.ft) (22.1lbf.ft) (29±3 lbf.ft) (22lbf.ft) (18lbf.ft) (7.4lbf.ft) (37 lbf.ft)


Tightening torques

Nm

Group 20

(lbf.ft)

Group 25 Inlet and exhaust system Exhaust manifold nuts .......................................... 25±2.5 M8 Nuts, turbo to exhaust manifold ...................... 21±2 M10 Nuts, turbo to exhaust manifold..................... 40.5±4 Screws, Inlet manifold........................................... 11±1


Group 26 Cooling system Thermostat housing .............................................. 30 Water temp sensor ................................................ 21±2 Water pump .......................................................... 21±2 NOTE! See also ”Tightening diagrams”.


Grupp 20

Tightening torque diagram Main bearing caps:

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

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

Technical data

Technical data

Grupp 20

Flywheel

A) Flywheel with screws of max 30 mm length Step 1: ................................................................20 – 30 Nm Step 2: ................................................................ 60° angle tightening Step 3: ................................................................ 30° angle tightening B) Flywheel with screws up to 45 mm length Step 1: ................................................................20 – 30 Nm 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 Step 2: ................................................................ 60° angle tightening Step 3: ................................................................ 60° angle tightening

(15 – 22 lbf.ft)

(15 – 22 lbf.ft)

(22 – 30 lbf.ft)

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 Step 2: ................................................................ 60° angle tightening Step 3: ................................................................ 60° angle tightening Vibration damper .................................................... 70 Nm

(30 – 37 lbf.ft)

Grupp 20

Technical data

Cylinder head Manifold side

Manifold side

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 (3.7lbf.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 (5lbf.ft) Step 6: ................................................................10 Nm (7.4lbf.ft) Step 7: ................................................................30 Nm (22lbf.ft)

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.

Technical data

Grupp 20

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 Step 2: ................................................................ 25±3.5 Nm

(3.7lbf.ft) (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.

Screw plug

4. Screw plug MA .................................................... 35±3.5 Nm 6. Screw plug MA .................................................... 95±9.5 Nm 7. Screw plug MA .................................................... 65±6.5 Nm 8. Screw plug MA .................................................... 35±3.5 Nm 13. Screw plug MA ..................................................35±3.5 Nm 24. Screw plug MA ..................................................10±2 Nm

(26±2.6 lbf ft) (70±7 lbf ft) (48±4.8 lbf ft) (26±2.6 lbf ft) (26±2.6 lbf ft) (7±1.5 lbf ft)

Report form Do you have any complaints or other comments about t his manual. Please make a copy of this page, write your comments down and send them to us. The address is at the bottom. We would prefer you to write in English or Swedish.

From: ............................................................................ ...................................................................................... ...................................................................................... ......................................................................................

Refers to publication:............................................................................................................................................. Publication No.: ............................................................. Date of issue: .................................................................

Proposal/motivation: .............................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

Date: ................................................................ Signed: .............................................................

AB Volvo Penta Technical Information Dept. 42200

td420ve

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