TD 420 Ve

Workshop Manual I
Technical 1(0)
Data
TD420VE, TAD420VE, TD520GE, TAD520GE,
TD520VE TAD520VE, TAD530/531/532GE, TAD620VE,
TAD650VE TAD660VE, TD720GE TAD720GE,
TD720VE, TAD720VE TAD721GE, TAD721VE,
TAD722GE, TAD722VE, TAD730/731/732/733GE,
TAD750VE, TAD760VE
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Group 20 General Information
Technical Data
Industrial Engines
TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE,

TD520GE, TAD520GE, TD520VE, TAD520VE,
TAD530/531/532GE, TD720GE, TAD720GE, TD720VE,
TAD720VE, TAD721GE, TAD721VE, TAD722GE,
TAD722VE, TAD730/731/732/733GE, TAD750VE,
TAD760VE
Safety precautions
Contents
Valve mechanism
2 General information 40 Crank mechanism
5 Repair instructions 43 Lubricating system
6 Location of identification plates 46 Fuel system
TD/TAD420-620, TD/TAD520-722 48 Intake and exhaust system
55 Cooling system
9
56 Tightening torque
TAD650/660,
TD420VE, TAD750/760
TAD420VE, TAD620VE, TAD650VE, 57
TAD660VE
TD720GE, TAD720GE, TD720VE, TAD720VE,
10
General (420/620) TAD721GE, TAD721VE, TAD722GE, TAD722VE,
11 General (650/660) TAD730-733GE, TAD750VE, TAD760VE
12 Engine block General (720-722GE )
12 Valve mechanism 59 General (720-722VE)
16 Crank mechanism 60 General (750/760)
19 Lubricating system 60 Engine block
22 Fuel system 61 Valve mechanism
24 Intake and exhaust system 64 Crank mechanism
32 Cooling system 67 Lubricating system
32 70 Fuel system
Tightening torque 72 Intake and exhaust system
33
TD520GE, TAD520GE, TD520VE, TAD520VE, 80 Cooling system
TAD530-532GE 81 Tightening torque
General 82
36 Engine block Tightening diagram
37 85
© 2007 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally-friendly paper

General Information Group 20
Safety Precautions
Below is a summary of the risks involved and
Introduction safety precautions you should always observe
Workshop Manuals contains technical specifications, or carry out when operating or servicing the
descriptions, and instructions for the repair of the engine.
spe- cified Volvo Penta products or product types.
Immobilize the engine by turning off the power
Check that you have the correct Workshop Manual
supply to the engine at the main switch
and the latest Service Bulletins for your engine.
(switches) before starting work. Put a warning
Before starting work on the engine, read notice at the engine control panel.
these sections of the Workshop Manual: Generally, all service operations must be
Safety Precautions carried out with the engine stopped.
However, some work, for example certain adju-
General Information stments requires that the engine is running
Repair Instructions when they are carried out.
Approaching an engine, which is operating, is
a safety risk. Loose clothing or long hair can
fas- ten 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
Important just been stopped. Reinstall all protective parts
removed during service operations before
In this book and on the product you will find the starting the engine.
following special warning symbols.
Check that the warning or information labels
WARNING! Possible danger of personal injury,
on the product are always clearly visible.
extensive damage to property or serious
Replace labels that have been damaged or
mechanical malfunction if the instructions are
painted over.
not followed.
Never start the engine without installing the air
IMPORTANT! Used to draw your attention to cleaner filter. Foreign objects entering the
so- mething that can cause damage or malfunc- intake ducts can also cause mechanical
tions on a product or damage to property. damage.
Never use ether or similar products when start-
NOTE! Used to draw your attention to ing the engine. They may cause an explosion
important infor-mation that will facilitate the in the inlet manifold and causing personal
work or operation in progress. injuries.
Only start the engine in a well-ventilated area.
Warning symbols used in the Workshop Manual are If operating the engine in an enclosed area
not in any way comprehensive since it is impossible ma-
to predict every circumstance under which service ke sure that the exhaust is leading out of the
work or repairs may be carried out. engine compartment and working area.
AB Volvo Penta can only indicate the risks conside- Avoid opening the coolant filler cap when the
red likely to occur as a result of incorrect working engine is hot, when hot steam or coolant
methods in a well-equipped workshop using might spray out. If the filler cap must be open,
working methods and tools tested by AB Volvo slowly re- lease the pressure in the system. Be
Penta. very careful, it is difficult to anticipate in which
direction hot steam or coolant can spray out.

Stop the engine before carrying out WARNING! Use new delivery pipes every
operations on the engine cooling system. time. Be careful, delivery pipes should under no
circu- mstances be bent.
Always use protective glasses or goggles,
when carrying out work where there is a risk of All fuels and many chemical substances are
splint- ers, grinding sparks and acid splashes fla- mmable. Do not allow naked flame or
or when other chemicals are in use. The eyes sparks in the working area!
are extremely sensitive and an injury could Make sure that the working area is well
result in blin- dness! ventilated and take the necessary safety
precautions before starting welding or grinding
Avoid getting hot oil on your skin, it might work.
cause severe burns. Ensure that the lubrication Make sure that there always are fire
syste- m is not under pressure before carrying extinguish- ers in the working area.
out any work. Never start or operate the engine Ensure that rags soaked in oil or fuel are stored
with the oil filler cap removed, otherwise oil safely. Rags soaked in oil can spontaneously
could be eje- cted. ignite. Used fuel filters, oil filters, lubricating oil,
contaminated fuel, solvent and degreasing
Exposure to oil over a long period or repeatedly agents are environmentally dangerous waste
will cause problems such as skin drying out, ir- and must be deposited at an approved site for
ritation and toxic eczema. Used oil is in a dest-ruc- tion.
health aspect even more dangerous than new
oil. Use protective gloves. Use protection Never expose a battery to naked flame or
creams, which will ease up cleaning of the skin electrical sparks. Batteries always produce
and counteract drying out. hydrogen gas, which mixed with air form an
explosive gas
Many chemicals such as oils, glycol, diesel oil – oxyhydrogengas.
and other chemicals, for example degreasing This gas is highly volatile and easily ignited. In-
agents, paint and solvents are dangerous to correct connection of the battery can cause a
your health. single spark that is sufficient to cause an explo-
Always follow the safety precautions for the sion. Be very careful when attempting to ju-mp-
product, for example using protective mask, start the engine and do not at any time lean
glasses, gloves etc. Make sure of good over the batteries.
ventilation is provided in the working area. Always ensure that the Plus (positive) and Min-
Follow the instructions on the product, when us (negative) battery leads are correctly insta-
disposing used chemicals. lled. Incorrect installation can result in severe
damage to the electrical equipment. Refer to
Follow extreme care when working with/or the wiring diagrams.
chec- king the fuel system. Use eye protection.
The jet from a fuel injector nozzle is under Always use protective goggles when charging
extremely high pressure and can cause severe and handling the batteries. Battery electrolyte
personal injury. 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.

Turn the engine off and turn off the power at WARNING! The components in the electrical
the main switch/switches before carrying out system and in the fuel system on Volvo Penta
work on the electrical system. products are designed and manufactured to
minimi- ze the risk of fire and explosion.
Clutch adjustments must be carried out with The engine must not be run in areas where
the engine stopped. there are explosive materials.
Use the lifting eyes fitted on the engine when Always use the fuels recommended by AB Vol-
lifting the drive unit. Always check that the vo Penta. Refer to the Instruction Book. Use of
lifting equipment is in good condition and has fuels that are of a lower quality can damage
the correct load capacity to lift the engine the engine. On a diesel engine, poor quality
(engine weight including gearbox, if fitted, and fuel can cause the control rod to seize, which
any extra equipment installed). can result in an over revving of the engine,
To make sure of safe handling and to avoid risking of da- maging to the engine and of
damage, use a lifting beam to raise the personal injuries.
engine. Poor fuel quality can also lead to higher
This lifting beam is installed on the top of the maintenance costs.
engine, make sure that all chains and cables Observe the following rules when cleaning with
should run parallel to each other. high-pressure water jets. Never direct the
If extra equipment is installed on the engine water jet at seals, rubber hoses, or electrical
that would alter its center of gravity, it is components. Never use a high-pressure jet
required that the lifting device has to be when was- hing the engine.
altered for obtain- ing the correct balance for
safe handling.
Never carry out work on an engine
suspended on a hoist without other
supporting
Never workequipment
alone when attached.
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
cle- ar 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.

General Information
About this Workshop Manual Spare parts
This Workshop Manual contains technical data for the Spare parts for the electrical and fuel systems are
repair of the following engines in standard format: subject to various national safety requirements. Volvo
TD420VE, TAD420VE, TAD620VE, TAD650VE, Penta Original Spare Parts meet these
TAD660VE, TD520GE, TAD520GE, TD520VE, specifications.
TAD520VE, TAD530-532GE, TD720GE, TAD720GE, Any type of damage which is the result of using
TD720VE, TAD720VE, TAD721GE, TAD721VE, spare parts that are not original Volvo Penta parts for
TAD722GE, TAD722VE, TAD730-733GE, TAD750VE, the product in question will not be covered under any
TAD760VE war- ranty or guarantee provided by AB Volvo Penta.
The Engine Designation and Engine Numbers can
be found on the Identification plates. Please always
Engine certificate
in- clude both the engine designation and the Engine certificates to meet national and regional en-
engine number in all correspondence. vironmental legislation carry with them an undertaking
The Workshop Manual is produced primarily for the from the manufacturer that both new and existing
use of Volvo Penta workshops and service technici- eng- ines in use meet the environmental demands of
ans. For this reason, the manual presupposes a cer- the legislation. The product must correspond to the
tain basic knowledge and that the user can carry out valida- ted example that was granted certification. In
the mechanical/electrical work described to a order for AB Volvo Penta as the manufacturer to take
general standard of engineering competence. responsibility for engines in use, certain
requirements regarding service and spare parts
Volvo Penta products are under a continual process
must be met by the user according to the following:
of development and we therefore reserve all rights
regarding changes and modifications. All the
• The Service Intervals and maintenance
operations recommended by Volvo Penta must
information in this manual is based on product
be followed.
specifications available at the time the book was
published. Any essential changes or modifications • Only Volvo Penta Original Spare Parts
introduced into production or updated or revised intended for the engine certificates may be
service methods introduced after the date of used.
publication will be provided in the form of Service
Bulletins from AB Volvo Penta.
• Service work on the injection pump and
injectors must always be carried out by an
Power standards authorized Vol- vo Penta workshop.
The engine performance corresponds • The engine may not be altered or modified in
to: ISO 3046, BS 5514, and DIM 6271. any way, with the exception of accessories and
service kits developed by Volvo Penta for that
Prime power rating corresponds to ISO standard po- engine.
wer for continues operation. It is applicable for
supplying electrical power at variable load for an • No modifications to the exhaust pipes and air
unlimited number of hours instead of commercial supply ducts for the engine room (ventilation
purchased power. A ten-percent overload capability ducts) may be undertaken as this may effect
is available for this rating. exhaust emissions.
Standby Power rating corresponds to ISO Standard • Any seals on the
IMPORTANT! engine may
If replacement notare
parts be broken
Fuel Stop Power. It’s is applicable for supplying other than by
required, authorized
use persons.
only AB Volvo Penta Original
standby electrical power at variable load in areas Parts.
well est-ablished electrical networks in event of
normal uti- lity power failure. No overload capability is Use of replacement parts other than AB Volvo
available for this rating. Pen- ta Original Parts will result in AB Volvo
Penta be- ing unable to assume any liability that
NOTE! The technical data applies to an engine without cooling
fan and operating on a fuel with calorific value of 42.7 MJ/kg the engine corresponds to the engine certificates
(18360 BTU/lb.) and a density of 0.84 kg/liter (7.01 lb./US gal, variant.
8.42 lb./lmp. gal) even when it involves a deviation from
standards.
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.

Repair instructions
Introduction Our joint responsibility

The working methods described in the Every engine consists of many systems and compo-
Workshop Manual apply to work carried out in a nents that work together. If one component deviates
workshop. The engine has been removed and is from the technical specifications, than this can have
installed in an engine fixture. dramatic consequences on the environmental
Unless otherwise stated reconditioning work that impact, even if it is otherwise in good running order.
can be carried out with the engine in place It is therefore critical that the stated wear tolerances
follows the same working method. are observed, that systems which can be adjusted
All operations described in the Workshop Manual for are correctly set up and that only Volvo Penta
which there are Volvo Penta Special Tools available Original Parts are used.
assume that the service technician or person The stated service intervals in the Maintenance
carrying out the repair uses these tools. Sche- dule must be followed.
Volvo Penta Special Tools have been specifically de- Some systems, such as the components in the fuel
veloped to ensure as safe and rational working met- system, require special expertise and special
hods as possible. testing equipment for service and maintenance.
Person or persons using other than Volvo Penta Some components are factory sealed for environ-
Spe- cial Tools or approved Volvo Penta working men- tal and product specific reasons. Don’t under no
methods (as described in a Workshop Manual or cir- cumstances attempt to service or repair a sealed
Service Bulle- tin). Has the responsibility to acquaint component, unless it is done by a authorized
themselves of the risk of personal injury or actual service technician.
mechanical damage or malfunction.
Bear in mind that most chemical products,
In some cases special safety precautions and user incorrectly used, are hazardous to the environment.
instructions may be required in order to use the
tools and chemicals mentioned in the Workshop AB Volvo Penta recommends the use of
Manual, always follow these precautions, as there biodegrada- ble degreasing agents for all cleaning
are no specific instructions given in the Workshop of engine components, unless otherwise is stated
Manual. in the Workshop Manual.
By following these basic recommendations and using Pay special attention to make sure that oils and
common sense it is possible, to avoid most of the wash- ing residue are handled correctly for
risks involved in the work. A clean work place and a destruction, and not end up in the nature.
clean engine will eliminate many risks of personal
injury and engine malfunction.
Above all when working on the fuel system,
lubrication system, intake system, turbocharger,
bearings and seals. It is extremely important to
observe the highest standards of cleanliness and
avoid dirt or foreign objects entering the parts or
systems, since this can result in reduced service life
or malfunctions.

Tightening torque Lock nuts

For the correct tightening torque for critical joints, Do not reuse lock nuts that have been removed
which must be tightened using a torque wrench is during disassembly operations as these have
lis- ted under chapter “Tightening Torque”. For reduced service life when reused. Use new nuts
correct tightening torque, is it important to apply when assembling or reinstalling.
cleaned threads, bolt heads and mating surfaces, For lock nuts with a plastic insert such as Nylock®
with lightly oiled or dry threads. In places where the tightening torque stated in the table is reduced if
grease, locking or sealing agents is required for the Nylock® nut has the same head height as a
screwed joints, the correct torque is stated in standard hexagonal nut without plastic insert.
“Tightening Torque”. Reduce the tightening torque by 25% for bolt size
When no tightening torque is stated, use the M8 or larger.
general tightening torque, according to the table If Nylock® nuts are higher, or of the same height as
below. Nm (lbf.ft.) a standard hexagonal nut, the tightening torque’s
Dimension Tightening torque given in the table applies.
M (4.4)
5 6 (7.4)
M6 (18.4)
10 M8 (36.9)
25 M10 (59.0)
50 M12 (103.
80 M14 3)
40
Tightening torque with Strength classes

protractor tightening Bolts and nuts are divided up into different classes
of strength, the number on the bolt head indicates
(angle tightening) the class. A high number indicates stronger material,
Tightening using both a torque setting and a for example a bolt marked 10-9 indicates a higher
protractor angle requires that first the recommended strength than one marked 8-8.
torque is applied using a torque wrench and then the It is therefore important that bolts removed during
recommended angle is added according to the the disassembly of a bolted joint must be reinstalled
protractor scale. Example: A 90° protractor tightening in their original position when assembling the joint.
means that the joint is tightened a further 1/4 turn in When replacing a bolt, check in the spare parts
one operation after the stated tightening torque has catalogue to make sure the correct bolt is used.
been applied.

Sealant Safety rules for fluorocarbon

It is therefore important that bolts removed during the rubber
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint. Fluorocarbon rubber is a common material in
When replacing a bolt, check in the spare parts seal rings for shafts, and in O-rings.
catalogue to make sure the correct bolt is used. When fluorocarbon rubber is subjected to high
To ensure service work is correctly carried out it is temperatures (above 300°C or 572°F), hydrofluoric
important that the correct sealant and locking fluid acid can be formed, which is highly corrosive.
type is used on the joint where the agents are Skin contact can give severe chemical burns. Splas-
required as described in the Workshop Manual or the hes in eyes can give severe chemical burns.
Service Bul- letin. Breathing of fumes can be permanently
damaged lungs.
During service operations use the same agent or
an alternative. WARNING! Be very careful when working on
engines that have been exposed to high
Make sure that mating surfaces are dry and free from
temperatures, e.g. overheating during a
oil, grease, paint and anticorrosion agent before
seizure or fire. Seals must never be cut with an
apply- ing sealant or locking fluid.
oxy-acetylene torch, or be burned up
Always follow the manufacturer’s instructions for use
afterwards in an uncon- trolled manner.
regarding temperature range, curing time and any
other instructions for the product. Always use gloves made of chloroprene
Two different basic types of agent are used: rubber (gloves for handling chemicals) and
protective goggles.
RTV agent (Room Temperature Vulcanizing)
Used for gaskets, sealing gasket joints or Handle the removed material like corrosive
coating gaskets. RTV is visible when a part has acid. All residues, including ash, can be highly
been disassembled; old RTV must be removed corrosive.
before resealing the joint. Never use compressed air to blow anything
clean.
Old sealant can be removed using methylated
spirits in all cases. Put the remains in a plastic box which is sealed
Anaerobic agents: and provided with a warning label. Wash the
These agents cure in an absence of air. They are gloves under running water before removing
use- d when two solid parts, for example cast them.
components, are installed face-to-face without a These following seals are probably made out of
gasket. They are also commonly used to secure fluorocarbon rubber:
plugs, threads in stud bolts, petcocks, oil pressure
Seal rings for crankshaft, camshaft, and
switches, and so on.
interme- diate shafts.
The cured material is glass like and it is therefore co-
lored to make it visible. Cured anaerobic agents are O-rings irrespective of where they are installed.
extremely resistant to solvents and the old agent O-rings for cylinder liner sealing are usually
can- not be removed. When reinstalling the part is made out of fluorocarbon rubber.
carefully degreased and then new sealant is applied.

Location of identification
plates (420-620, 520-722)
Each engine is supplied with two identical identifica-
tion 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. Engine model 8. Indication of standard and /or regulation
2. Engine specification number 9. ISO 3046, reference test conditions
3. Engine serial number (10 digits) 10. ISO 3046, reference test conditions
4. Engine output without fan 11. Injection pump code (EP code)
5. Rated engine speed 12. Piston class
6. Injection timing and type of 13. Prime output, without fan, at rated
camshaft speed
7. Manufacturers identification code

Location of identification
plates (TAD650/660,
750/760)
Each engine is supplied with two identical identifica-
tion 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. Engine model 8. Air temperature in °C (°F), in accordance
2. Engine specification number with ISO 3046
3. Engine serial number (10 digits) 9. Altitude above mean sea level, in accordance
4. Engine output, without fan with ISO 3046
5. Rated engine speed 10. EU Tier III approval number
6. Engine code (linked to EPA/EU Tier III approval)
7. Rated power, standard (peak power according
to Tier III)
10

Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
Technical Data
TD420VE, TAD420VE, TAD620VE, TAD650VE,
TAD660VE
General
Type designation .................................................... TD420VE TAD420VE TAD620VE
Rotation direction, facing flywheel: ......................... Counterclockwise
Number of cylinders 4 4 6
Bore, mm (inch) ..................................................... 101 (3.97") 101 (3.97") 98 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96") 126 (4.96")
Displacement, dm3 (inch3) ....................................... 4.04 (246.5) 4.04 (246.5) 5.7 (347.8)
Number of valves 8 8 12
Compression ratio:
EPA 1 19:1 19:1 18.4:1
COM 2 19:1 19:1 18.4:1
Firing sequence 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Engine performance at 2500 rpm, kW (hp) ............. 75 (102)1, 3) 103 (140)1, 3) 155 (209)1, 3)
Max torque, Nm (lbf.ft) ........................................... 390 (288)3) 493 (364)3) 700 (516)3)
At speed, rpm 1500 1500 1500
Low idle, rpm 800 800 800
Max, full load speed, rpm ....................................... 2000 – 2000 – 25001) 2000 – 25001)
25001)
Weight. engine (dry) kg (lb) .................................... 380 (838)2) 380 (838)2) 495 (1091)2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
11

Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20
General
Type designation .................................................... TAD650VE TAD660VE
Counterclockwise Number of cylinders 6 6
Bore, mm (inch) ..................................................... 101 (3.97") 98 (3.85")
Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96")
Displacement, dm3 (inch3) ....................................... 5.7 (347.8) 5.7 (347.8)
Number of valves 12 12
Compression ratio: 18.4:1 18.4:1
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 147 (200)1, 147 (200)1, 3)
3)
Max torque, Nm (lbf.ft) ........................................... 750 (553)3) 800 (590)3)
At speed, rpm 1600 Low idle, rpm 600- 1600
800 Max, full load speed, rpm ....................................... 600-800
24001) 2400565
Weight. engine (dry) kg (lb) .................................... 565 565 (1246)2)
(1246)2) 585 (1290)2)
Weight. engine (wet) kg (lb) .................................... 585
(1290)
1)
See identification
2)
plate for correct specification
2)
3)
Engine block
Cylinder head
Type ...................................................................... Common cylinder head
Max surface unevenness ....................................... 0.1 mm
(0.0039")
Cylinder head bolts

Thread size ............................................................ M 12
Quantity and length:
TD420VE/TAD420VE .......................................... 13 x 108 mm (13 x 4.3")
TD420VE/TAD420VE .......................................... 5 x 178 mm (5 x 7")
Quantity and length:

TAD620VE, TAD650/660VE ............................... 19 x 108 mm (19 x 4.3")
TAD620VE, TAD650/660VE ............................... 7 x 178 mm (7 x 7")
12

Cylinder liners
Parent bore Replaceable, dry
TD420VE, TAD420VE TAD620,

TAD650VE TAD660VE
Type:
TD420VE/TAD420VE/TAD650VE ....................... Parent bore
TAD620VE/TAD660VE ....................................... Dry, replaceable
Bore:
TD420VE/TAD420VE/TAD650VE ....................... 101+0.02 mm (3.976"+0.00078")
TAD620VE/TAD660VE ....................................... 98 +0.02 mm (3.858"+0.00078")
Max bore wear:

TD420VE/TAD420VE/TAD650VE ....................... 101.1 mm (3.98")
TAD620VE .......................................................... 98.1 mm (3.86")
TAD660VE .......................................................... 98.1 mm (3.86")
Sealing surface: Height, see picture (A):

TAD620VE/TAD660VE ....................................... 4.5-0.02 mm
(0.177"-0.0008")
Liner collar seating depth in block:

TAD620VE/TAD660VE ....................................... 4.38+0.03 mm (0.1724"+0.0012")
Projection of liner above block surface:

TAD620VE/TAD650/TAD660VE .......................... 0.012 – 0.07 mm (0.00047"– 0.0027")
13

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 the 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")
14

Pistons
Number of piston ring grooves
3 Combustion chamber:
Diameter Ø ......................................................... (2.402"±0.0039”)
61±0.1 mm
Combustion chamber depth: (0.7087"±0.0039”)
TD420VE/TAD420VE .......................................... 18±0.1 mm (0.689"±0.0039”)
TAD620VE, TAD650/TAD660VE ........................ 17.5±0.1 mm (1.496"-0.0002")
Gudgeon pin diameter Ø ........................................ 38-0.006 mm
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) ................................. (0.067")
Keystone
Lower compression ring (2) ................................. (0.03")
0.17 mm (0.0984")
Piston ring gap measured in ring opening, wear
limit:
Upper compression ring (1) .................................
0.8 mm
1
Lower compression ring (2) .................................
2.5 mm
Oilscraper ring (3)

Number: 1
Width, including springcoil: ..................................... 3 (0.12")
mm (0.0039")
Piston ring clearance, height: ................................. 0.1 (0.045”)
mm
Piston ring gap, wear limit: ..................................... 1.15
mm
15

Valve mechanism
Valves
Disc diameter Ø:
Inlet .................................................................... 41.7±0.1 mm (1.642"±0.004")
Exhaust .............................................................. 35.9±0.1 mm (1.413"±0.004")
Stem diameter Ø:
Inlet .................................................................... 7.98-0.015 mm (0.3142"-0.0006")
Exhaust .............................................................. 7.96-0.015 mm (0.3134"-0.0006")
Valve seat angle:
Inlet, min ............................................................. 29.5°
Exhaust, min ....................................................... 44.5°
Min 1.8 mm Min 1.1 mm

45°
30°
29.5°
44.5°
Valve disc edge:

Inlet, min ............................................................. 1.8 mm (0.071")
Exhaust, min ...................................................... 1.1 mm (0.043")
Seat angle, cylinder head:
Inlet .................................................................... 30°
Exhaust .............................................................. 45°
Valve seat width, max:
Inlet, min ............................................................. 2.7 mm (0.106")
Exhaust, min ....................................................... 2.1 mm (0.083")
Valve clearance (not apply for TAD660VE)

Inlet .................................................................... 0.35±0.05 mm (0.014"±0.002")
Exhaust .............................................................. 0.55±0.05 mm (0.022"±0.002")
Important! Control and adjusting of valve clearance is done with an engine
oil temperature between 20 – 80°C (68 – 176°F)
16

Valve seats
Ø
A
Outer diameter Ø (A), standard:

Inlet .................................................................... 42.79-0.02 mm
(1.685"-0.0008")
Exhaust .............................................................. 36.99-0.02 mm
Height (B): (1.456"-0.0008")
Inlet .................................................................... 6.8±0.1 mm (0.2677"±0.004)
Exhaust .............................................................. 7.5±0.1 mm (0.2953"±0.004)
Valve seat location

ØC
R
D
Diameter Ø (C), standard:

Inlet .................................................................... 42.7-0.025 mm (1.681"-0.001")
Exhaust .............................................................. 36.9-0.025 mm (1.453"-0.001")
Depth (D):
Inlet/Exhaust ...................................................... 10+1 mm
(0.4"+0.04")
Seat bottom radius (R):
Inlet/Exhaust ...................................................... 1-0.3 mm
(0.04"-0.0118")
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ...................................................... Min 1.4 mm (0.055")
Valve guides
Inner diameter Ø:
Inlet/Exhaust ...................................................... 8.008+0.0025 mm (0.3153"0.00098")
Wear limit valve stem – guide:
Inlet .................................................................... 0.1 mm (0.0039")
Exhaust .............................................................. 0.13 mm (0.0051")
Valve springs
Type: ..................................................................... Single
Length: Unloaded: .................................................. 59±1.9 mm (2.323"±0.075")
Wire diameter Ø: .................................................... 4±0.03 mm (0.16"±0.001")
17

Camshaft
Type of camshaft: .................................................. Three different types: K, L or H
Drive ...................................................................... Gear
Number of bearings:
TD420VE/TAD420VE 5 TAD620VE,
TAD650/TAD660VE 7
Inner diameter Ø, bearing journals
Standard ............................................................. 63+0.054 mm
(2.48"+0.0021")
Wear limit ........................................................... 63.08 mm
Camshaft bearing thickness: max .......................... 1.388+0.012 mm (2.483")
Axial clearance ...................................................... 0.1-0.5 mm (0.05465"+0.0005")
Radial clearance .................................................... 0.05-0.124 mm (0.004-0.02")
(0.002-0.0049")
Position of bearing bush at flywheel end ................ 3+0.2 mm (0.118"+0.008")
Timing gear
1. Governor drive (not apply for 650/660)
2. Idler gear (not apply for 650/660)
3. Camshaft gear
4. PTO gear B-C (not apply for 650/660)
5. PTO gear A (not apply for 650/660)
6. Crankshaft
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
18

Crank mechanism
Crankshaft length:
TD420VE/TAD420VE .......................................... 618.8 mm (24.36")
TAD620VE, TAD650/TAD660VE ........................ 846.8 mm (33.34")
Crankshaft axial clearance1) ................................... 0.1-0.3 (0.0039"– 0.0118")
mm (0.0012"+0.0024")
Main bearing radial clearance1) ............................... 0.03+0.062 mm
Max, permissible ovality of main (0.0004")
bearing and crank pins ........................................ 0.01 mm (0.0039"
Max, run-out of center bearing: .............................. 0.1 mm
1)
Important! The dimensions apply to oiled parts
E
F
C
B
A
Main bearing journals

Diameter for machining (A): Standard ..................... 84-0.02 (2.9134"-0.0008)
mm Undersize:
0.25 mm (0.01") .................................................. 83.75-0.02 (3.2972"-0.0008)
mm
Main bearing journals: (0.0004")
Out-of-round: Max. .............................................. 0.01 mm (0.0004")
Taper: Max. ........................................................ 0.01 mm (1.1268"+0.0016")
Width, axial bearing journal (B): Standard ............... 32.2+0.04
mm Oversize:
0.4 mm (0.0157") ................................................ 32.6+0.04 (1.283"+0.0016")
Thrust washers (axial bearing) (0.079"+0.004")
Width (C): Standard ................................................ 2+0.1 mm
Oversize: (0.087"+0.004")
0.2 mm (0.0079") ................................................ 2.2+0.1 mm (0.55")
Width (D): ............................................................... 14 mm
Main bearing shells

Type: ..................................................................... Replaceable
Inner diameter Ø (E): ............................................. 84.03+0.042 (3.308"+0.0017")
mm (2.903"-2.903")
Thickness (F): Standard ......................................... 2.475+0.01 (0.1024"+0.0004")
mm
Oversize:
0.25 mm (0.01") .................................................. 2.6+0.01 mm
19

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 (1.4"±0.0008")
mm Connecting rod-bearing journals:
Out-of-round: Max. .............................................. 0.01 mm (0.0004")
Taper: Max ......................................................... 0.01 mm (0.0004")
H
J G
K
Connecting rod bearing shells

Innerdiameter Ø, bearing (J): .................................. 63.026+0.039 mm (2.442"+0.00154”)
Oversize:
0.25 mm (0.01") .................................................. 62.724+0.02 mm
Thickness (K): Standard ........................................ 1.777+0.01 (2.4716"+0.00079”)
mm (0.06996+0.0004”)
Inside bore .......................................................... 66.6+0.02 mm (2.622"0.0008")
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 Wear limit ............................................................ 0.08 mm (1.497"+0.0004”)
(0.0031")
Axial clearance, connecting rod – crankshaft1) ....... 0.2-0.3 mm (0.00787"-0.0118")

Connecting rod bearing: radial clearance1) .............. 0.03-0.09 (0.00118"-0.00354")
mm Parallelism: Tolerans
Over a length of 100 mm ..................................... 0.05 mm (0.002")
Squareness: Tolerans
Over a length of 100 mm .................................... 0.05 mm (0.002")
1)
Important! The dimensions apply to oiled parts.
Connecting rod marking:

Connecting rod and cap number marking must be on one side and
identical.
21

Lubricating system
Oil grade2) Fuel sulfur content in percent by weight
1)
Up to 0.5 % 0.5 – 1 % More than 1 %
Oil change interval: In operation whichever reached first
VDS-3, VDS-2 500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
ACEA: E7, E5, E3
API: CI-4, CH-4,
CG-4
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the
quality requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy
Duty TBN = Total Base Number
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.
22

Engine oil quantity

With oil filter:
TD420VE/TAD420VE .......................................... 10 liter (2.64 US
TAD620VE, TAD650/TAD660VE ........................ 16 liter gal)
(4.22 US
gal)
TD420VE/TAD420VE TAD620VE, TAD650VE, TAD660VE
1. Oil pressure sensor

Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD420VE/TAD420VE .......................................... 400 kPa (58 psi)
TAD620VE, TAD650/TAD660VE ........................ 370 kPa (53.7 psi)
At idle speed (800 rpm), min .................................. 80 kPa (11.6 psi)
Shut down switch, at pressure lower than: ............. 50 kPa (7.2 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling .................................................. 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size ....................................................... 0.012 mm (0.0005")
By-pass valve oil filter
Opening pressure ................................................ 250±50 kPa (35±7 psi)
8.By-pass valve oil cooler:
Opening pressure ................................................ 210±30 kPa (30.5±4 psi)
9. Safety valve, opening pressure:
TD420VE/TAD420VE .......................................... 600±75 kPa (87±10.7 psi)
TD620VE, TAD650/TAD660VE ........................... 400±40 kPa (58±2 psi)
10. Lube oil pump
Type ...................................................................... Rotary pump driven by the crankshaft
Rotary pump width:
TD420VE/TAD420VE .......................................... 12.3 mm (0.48")
TD620VE, TAD650/TAD660VE ........................... 16.5 mm (0.65")
Oil flow (2500 rpm)
TD420VE/TAD420VE .......................................... 65 l/min (17 US
TD620VE, TAD650/TAD660VE ........................... 90 l/min gal/hour)
11. Oil cooler (24 US
Normal oil temperature: .......................................... 80°C gal/hour)
(176°F)
Max oil temperature: .............................................. 125°C (257°F)
23

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.
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve 2)
12. Return fuel line to fuel tank.
Inside diameter, min 10 mm (0.39")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose.
2)
Used for bleeding.
24

Fuel system (650, 660)
1. Fuel tank 8. Highpressure pump

2. Hand pump 9. Fuelpipe, to injector
(accessory) 10. Injector
3. Fuel line (to pump) 11. M-prop
4. Fuel pump 12. Pressurevalve
5. Fuel filter 13. Return fuel line, to fuel tank, A = Fuel
6. Pipe to highpressure pipes, minimum distance 300 mm (11.8")
7. Rail
25

Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE 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 (87±7 psi)1)
2. Bypass valve:
Opening pressure ................................................ 50±5 kPa (7.2±0.7 psi)
Fuel flow:
Min fuel flow at 1500 rpm. ...................................... 600 l/hour (158.5 gal/hour)
Firing sequence
TD420VE/TAD420VE 1-3-4-2
TAD620VE/TAD650VE/TAD660VE 1-5-3-6-
2-4 (72.5 psi)
Feed pressure ........................................................ 0.5 MPa
Feed pressure after fuel filter (40.6 psi)
At 1500 rpm: Min ................................................ 0.28 MPa
26

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 O
L
(L FB =
with LOtolerance
the + A/100, that are written on the injection pump
A/100).
Explanatio
LFB =n:The exact point when injection pumps starts delivering
fuel.
L = Basic measurement for the injection
O
pumps
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
If LO is 117.5 mm and A/100 is
This
63. gives us the equation: LFB = 117.5 +
0.63 total length LFB =
The
118.13
Injection pump (420, 620)

Manufacturer .......................................................... Bosch
Designation ............................................................ PF 33
Length A: ............................................................... 59 mm (2.3")
Basic measurement length LO : .............................. 117.5 (4.6")
Min length mm LFB : (A/100+117.5) – 117.5 ............
mm
>0
Injectors
Opening pressure:
TD420VE ............................................................ 22 MPa (3190 psi)
TAD420VE/TAD620VE ....................................... 25 MPa (3630 psi)
Max pressure: ........................................................ 160 (23200 psi)
MPa
Check leakage (for 10 sek): (2900 psi)
TD420VE ............................................................ 20 MPa (3340 psi)
TAD420VE/TAD620VE ....................................... 23 MPa
Numbers/bore Ø: (6 x 0.008")
TD420VE ............................................................ 6 x (6 x 0.0079")
0.205 mm
TAD420VE/TAD620VE ....................................... 6 x
0.203 mm (0.0002")
Fuel filter
Filtering size: ......................................................... 0.005 (0.00024")
mm
Pre-filter
Filtering size: ......................................................... 0.006
mm 27

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 in-
dicated 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 Camshaft Vh Vh corr.factor Lo
(Commencement of types Pre-stroke Pre-stroke Basic dimension
delivery) correction factor Injection pump
28

Grupp 20 Tekniska data
Theoretical thickness for a new shim (420/620)

Computation for determining the theoretical shim thickness S
(T
T =) L
: - [ ( FB - FB ) x Vh + Vh + L + A/100 ] (mm)
S actual nom corr.factor nom
o
The correction factor Vhcorr.factor is taken from the table on previous page.
·
The 1st
individual
step: Esteps:
1
= FB - FB (°C/A)
actual nom
· 2nd step: E = E x Vh (mm/°C/A)

2 1 corr.factor
· 3rd step: E = E + Vh
3 2 nom
· 4th step: E = E + L
4 3 O
· 5th step: E = E + A/100 (mm)

5 4
· 6th step: T = L – E
S 5
·Table
7th step: The actual shim thickness (S ) is determined with the help of table
2. 2, Shim thickness
S
Theor. thickness Shim thickness S Theor. thickness(TS) Shim thickness (SS )

(S ) (TS)
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10
When
mm. the theoretical shim thickness (Ts ) are in the 1/100 range, use table 2 to convert it into the correct
thickness
shim (Ss). Important! Use only one shim at the
time.
29

Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE 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
met-
T = Ehod,
- (Lwhen
+ there is only the tolerance between the new and old injection pump that is the difference.
S K O
A/100)
T = Shim thickness
S
EK = Value from tabel 3 read with help of EP code from ”Identification

plate”.
L = Basic measurement for the injection pumps, 420/620 = 117.5
O
mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and
with
help of this value it is possible to read the new EK value with help of table
3.
If read EP code is ”275” that gives a E value of 120.375 and if the manufacturing tolerance for the new
K
pump is ”63” we will have following equation:
injection S
T = 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

Ek(mm) EP code Ek(mm) EP code Ek(mm) EP code Ek(mm) EP code
30

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
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.
31

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 (0.0039")
mm Max allowed back pressure in exhaust line ............ (0.9 psi)
7.5 kPa
Exhaust gas temperatur, approx: 2100 rpm 2300 rpm 2500 rpm
At engine speed1): .................................................. 1800 540°C 540°C 540°C
rpm (1004°F) (1004°F) (1004°F)
TD420VE ............................................................ 555°C 470°C 475°C 475°C
(1031°F (878°F) (887°F) (887°F)
) 465°C 460°C 455°C
TAD420 (869°F) (860°F) (851°F)
VE .......................................................... 490°C
(914°F)
TAD62
Air intake
0VE,TAD650VE,TAD660VE ..................... 485°C
Air intake restriction, clean filter ............................. (905°F) 2.5 (0.3 psi)
kPa 1)
See (0.9 psi)
General information, Power standards.
Max allowed air intake restriction ........................... 6.5
kPa
Cooling system
Type ...................................................................... Pressurized, closed
Pressure valve opens at max2) ............................ 90 kPa (13 psi)
2)
Versatile engines are not equipped with a pressure valve from factory
Capacity, engine:
TD420VE/TAD420VE .......................................... 4.7 liters (1.24 US
TAD620VE,TAD650VE,TAD660VE ..................... 6 liters gal)
Thermostat: (1.58 US
gal)
Type ...................................................................... One piston thermostat
Begins to open at ................................................... (181°F)
83°C (203°F)
Fully open at .......................................................... 95°C
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.
32

Tightening torque
General tightening torques Nm (lbf.ft)
M6 standard screw 8.8 ........................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 ........................................... 25±4 (18±3 lbf.ft)
M10 standard screw 8.8 ......................................... 50±8 (37±6 lbf.ft)
M12 standard screw 8.8 ......................................... 80±9 (59±6.5 lbf.ft)
M14 standard screw 8.8 ......................................... 140±25 (103±18 lbf.ft)
Tightening torques (lbf.ft)
Nm Group 21 Engine
Engine mounting 260 (192lbf.ft)
Starter motor 70 (51.6 lbf.ft)
Timing gear casing ................................................. 21±2 (15.5±1.5
lbf.ft)
Main bearing caps
Screws to main bearing caps are reusable only three times.
Step 1 50 (37 lbf.ft)
Step 2 .................................................................... 90° angle tightening
Connecting rod big-end bearing

Use new screws every time.
Step 1 30 (22 lbf.ft)
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: 20 – 30 (15 – 22 lbf.ft)
Step 2: ................................................................... 60° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: 20 – 30 (15 – 22 lbf.ft)
C) Flywheel with a screw length between 50 – 85 mm
Step 1: 30 – 40 (22 – 30 lbf.ft)
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)
Vibration damper 70 (51.6 lbf.ft)
Screw, rocker cover ............................................... 9±1 (6.5±0.7 lbf.ft)
Lock nut, valve clearance adjusting screw ............. (14.5±1.5 lbf.ft)
20±2 Screws, rocker arm fixing 21 (15.5 lbf.ft)
Screws, crankcase ventilation ................................ 9±1 (6.6±0.7 lbf.ft)
33

Tightening torques Nm (lbf.ft)

Cylinder head
Screws to cylinder head are reusable only three times.
Step 1: (22 lbf.ft)
30 Step 2: (59 lbf.ft)
80
Step 3: ...................................................................
90° angle tightening
Group 22 Oil system
Oil cooler, screws .................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, screw plug 80 (59 lbf.ft)
Front/oil pump housing ........................................... (15.5±1.5 lbf.ft)
21±2 (15.5±1.5 lbf.ft)
Oil suction pipe ...................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ................................................................ 21±2 (21.4±2.2 lbf.ft)
Oil pressure pipe turbo ........................................... 29±3 (29±3 lbf.ft)
Oil pressure pipe engine block ...............................
39±4 Screws, oil return pipe turbo (29.5±1.5 lbf.ft)
A) with tube fitting ............................................... 40±2 (15.5±1.5 lbf.ft)
B) with flange fitting ............................................ 21±2 (15.5±1.5 lbf.ft)
Screws, oil return pipe engine block ....................... (13±1.5 lbf.ft)
21±2 Oil pressure switch ................................................
18±2
Group 23 Fuel system
Screw, governor, idler gear (420/620):
Step 1: 30 (22.1
Step 2: ................................................................... 90° angle tightening lbf.ft)
Screw, control rod hose ......................................... 10±2 (7±5 lbf.ft)
Screw, governor ..................................................... 17±1.5 (12.5±1 lbf.ft)
Flange screws, Injection pump
Step 1: Torque 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange ... 60°
counterclockwise Step 3: Turn injection pump to stop .......................
Counterclockwise Step 4: ................................................................... 60°
angle tightening (5 lbf.ft)
Step 5: 7 (7.4 lbf.ft)
Step 6: 10 (22 lbf.ft)
Step 7: 30 (12+4 lbf.ft)
Flange screw, injector ............................................ 16+5 (30 – 37
Injector cap nut 40 lbf.ft)
– 50
Delivery pipe (3.7 lbf.ft)
Use a new delivery pipe after every disassembly (18.4±2.6 lbf.ft)
Step 1: 5 (15.5 lbf.ft)
Step 2: ................................................................... (22 lbf.ft)
25±3.5
Screw, stop magnet (74 lbf.ft)
21 Overflow valve (51.6 lbf.ft)
30 (22.1 lbf.ft)
Common Rail, TAD650/660 (29±3 lbf.ft)
Safety valve
100 Rail pressuree sensor (14.5
70 Common rail unit lbf.ft)
30 Fuel hose (18 lbf.ft)
39 (7.4 lbf.ft)
IEGR, TAD650/660 (37 lbf.ft)
IEGR-unit:
20
Solenoid valve:
24
34
Highpressure fuel pump, TAD650/660
Step 1:
Group 25 Inlet and exhaust system

Exhaust manifold nuts ........................................... 25±2.5 (18.5±1.8 lbf.ft)
M8 Nuts, turbo to exhaust manifold ....................... 21±2 (15.5±1.5 lbf.ft)
M10 Nuts, turbo to exhaust manifold ...................... (30±3 lbf.ft)
40.5±4 Screws, Inlet manifold ............................................ (8±0.7 lbf.ft)
11±1
Group 26 Cooling system

Thermostat housing 30 (22.1 lbf.ft)
Water temp sensor ................................................. 21±2 (15.5±1.5 lbf.ft)
Water pump ........................................................... 21±2 (15.5±1.5 lbf.ft)
NOTE! See also ”Tightening diagrams”.
35

Technical Data: TD/TAD520, TAD530/531/532 Group 20
Technical Data
TD520GE, TAD520GE, TD520VE,
TAD520VE TAD530/531/532GE
General
Type designation ................................................... TD520GE TAD520GE TD520VE TAD520VE
Rotation direction, facing flywheel: ....................... Counterclockwise
Number of cylinders 4 4 4 4
Bore, mm (inch) .................................................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ................................................. 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm ( inch ) .................................... 4.76 (290)
3 3
4.76 (290) 4.76 (290) 4.76 (290)
Number of valves 8 8 8 8
Compression ratio: 17.5:1 17.5:1 18.4:1 18.1:1
Firing sequence 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Engine performance:
At 1500 rpm, kW (hp) ........................................ 77.5 (104)1, 3) 94 (126)1, 3) — —
At 1800 rpm, kW (hp) ........................................ 81.5 (109)1, 3) 101 (135.5)1, 3) 81 (110)1, 4) —
At 2300 rpm, kW (hp) ........................................ — — — 118 (158)1, 4)
Engine torque, Nm ( lbf.ft) ..................................... 493 (394)3) 598 (441)3) 430 (317)4) 577 (425)4)
At speed, rpm 1500 1500 1800 1400
Engine torque, Nm ( lbf.ft) ..................................... 432 (319)3) 536 (395)3) — —
At speed, rpm .................................................... 1800 1800 — —
Max speed at full load, rpm ................................... 1500/18001) 1500/18001) 18001) 2000 – 23001)
Weight engine (dry) kg (lb) ................................... 550 (1213) 2)
575 (1268)2, 5) 430 (948)2) 432 (952)2)
Weight engine (wet) .............................................. 580 (1279)2) 606 (1336)2, 5) 725 (1336)2, 6) —
1)
See identification plate for specification
2)
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
36

Group 20 Technical Data: TD/TAD520, TAD530/531/532
General TAD530GE TAD531GE TAD532GE
Type designation ..............................................
Direction of rotation (seen from flywheel) Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders ................................................ 4 4 4
Cylinder bore mm (inch) ................................... 108 (4.25”) 108 (4.25”) 108 (4.25”)
Stroke mm (inch) ............................................. 130 (5.12”) 130 (5.12”) 130 (5.12”)
Cylinder volume liter (inch 3 ) ............................. 4.76 (290) 4.76 (290) 4.76 (290)
No. of valves .................................................... 8 8 8
Compression ratio:
EPA1 ............................................................
EPA2 ............................................................ 18.0:1 18.0:1 18.0:1
EU2 ..............................................................
Injection sequence ........................................... 1-3-4-2 1-3-4-2 1-3-4-2
Engine power: 89 (139)1) 102 (139)1) 129 (139)1)
At 1500 rpm kW (hp) .....................................
At 1800 rpm kW (hp) ..................................... 95 (150)1) 110 (150)1) 136 (150)1)
Torque Nm (lbf.ft) ............................................. 567 (479) 649 (479) 821 (479)
At engine speed rpm ..................................... 1500 1500 1500
Torque Nm (lbf.ft) ............................................. 504 (430) 584 (430) 722 (430)
At engine speed 1800 1800 1800
rpm ..................................... Low idle 800 – 950 800 – 950 800 – 950
rpm .....................................................
Highest full load speed rpm .............................. 1500/1800 1) 1500/1800 1) 1500/1800 1)
Weight, dry (lb) ................................................. 575 (1268) 2,3) 575 (1268) 2,3) 575 (1268) 2,3)
Gross weight, dry (lb) 606 (1336) 2,3) 606 (1336) 2,3) 606 (1336) 2,3)
1)
See engine plate for specifications.
2)
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
Cylinder liners Engine block

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 ( 18 x 5.55")
mm
TD520GE/TAD520GE
TD520VE/TAD520VE
TAD530/531/532GE
Type: ...................................................
................. Wet, replaceable
Bore: .....................................................................
Number of seals per liner: 108+0.02 mm
(4.252"+0.0008")
Max bore wear: ..................................................... 108.1 mm (4.256")
2
Height sealing surface (A): .................................... 9-0.02 mm (0.3543"-0.0008")
Liner collar seating depth in block: ........................ 8.92+0.03 mm (0,3512"+0.0012")
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0.0012" – 0.0031")
37


surface.
• Position the dial gauge at the measuring points A and B on the top of the
piston, inline with the gudgeon pin.
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")
38

Pistons
Diameter ............................................................
71±0.1 mm (2.795"±0.0039")
Depth ................................................................. (0.6559"±0.0039")
16.66±0.1 mm (1.6535"-0.0002")
Gudgeon pin diameter
42 -0.006
Piston rings
Compression rings
Number of rings 2
limit:
Upper compression ring (2)
Lower (1) ............................... 0.17 mm (0.067")
Keystone, no clearance
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ............................... 0.8 (0.03")
mm (0.0984")
Lower compression ring (2) ............................... 2.5
mm
Oilscraper ring (3)

Number: 1
Width, including springcoil: ................................... 3 mm (0.12")
Piston ring clearance in groove: ........................... 0.1 (0.0039")
mm (0.045")
Piston ring gap, wear limit: .................................... 1.15
mm
39

Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48±0.1 mm (1.8898"±0.0039")
Exhaust ............................................................. 42±0.1 mm (1.6535"±0.0039")
Stem diameter Ø:
Inlet ................................................................... 8.98-0.015 mm (0.3535"-0.0006")
Exhaust ............................................................. 8.96-0.015 mm (0.3528"-0.0006")
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ...................................................... 44.5°

45°
30°
29.5°
44.5°
Valve disc edge:

Inlet, min ............................................................ 2.1 mm (0.0827")
Exhaust, min ...................................................... 1.8 mm (0.0709")
Inlet ................................................................... 30°
Exhaust ............................................................. 45°
Inlet ................................................................... 2.8 mm (0.1102")
Exhaust ............................................................. 2.2 mm (0.0866")
Valve clearance:
Inlet ................................................................... 0.35±0.05mm (0.014"±0.002")
Exhaust ............................................................. 0.55±0.05mm (0.022"±0.002")
Important! Control and adjusting of valve clearance is done with an engine
oil temperature between 20 – 80°C (68 – 176°F)
Valve
seats
Ø
A
Outer diameter Ø (A), standard: B

Inlet ................................................................... 49.09-0.02 mm
(1.933"-0.0008")
Exhaust ............................................................. 43.06-0.02 mm
Height (B): (1.717"-0.0008")
Inlet ................................................................... 7.5±0.1 mm (0.295"±0.004")
Exhaust ............................................................. 7.9±0.1 mm (0.311"±0.004")
40

Valve seat location

ØC
R
D

Inlet ................................................................... 49+0.025 mm (1.929"-0.001")
Exhaust ............................................................. 43.5+0.025 mm (1.712"-0.001")
Depth (D):
Inlet/Exhaust ...................................................... 11+1 mm (0.43"+0.04")
Inlet/Exhaust ...................................................... 1-0.3 mm
(0.04"-0.012")
Inlet/Exhaust ...................................................... Min 1.5 mm (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")
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Design 1 Design 1 Design 2
without flange with flange
O-ring
Flang
e
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 ..................................................................... (2.55"±0.05")
Single Length: Unloaded: n=2300 ................................... (0.18")
64.7±1.3 mm
Wire diameter Ø ................................................... 4.5
mm
41

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 .......................................................... (2.5622")
65.08 mm (0.7827"+0.0005")
Camshaft bearing...................................................
Radial clearance thickness: max .........................0.05–0.124 1.988+0.12 mm
mm (0.004–0.02")
(0.002–0.0049")
Axial
Position of bearing bush at flywheel end ............... 2+0.5 mmmm
clearance ..................................................... 0.1–0.5
(0.079"+0.0197")
Timing gear
1. Governor drive
2. Idler gear
3. Camshaft gear
4. PTO gear B-C
5. PTO gear A
6. 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")
42

Crank mechanism
Crankshaft length ................................................. 709.2 mm (27.92")
Crankshaft axial clearance1) ................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1) ............................. 0.03+0.062 mm (0.0012"+0.0024")
Max, permissible ovality of main
bearing and crank pins ...................................... 0.01 mm (0.0004")
Max, run-out of center bearing .............................. 0.07 mm (0.0027")
1)
E
F
C
B
A

Diameter Ø for machining (A): Standard .............. 85-0.02 mm (2.9134"-0.0008")
Undersize:
0.25 mm (0.01") ................................................. 84.75-0.02 (3.3366"-0.0008")
mm (3.3268"-0.0008")
0.5 mm (0.02") ................................................... 84.5-0.02
mmbearing journals:
Main
Out-of-round: Max. ............................................ 0.01 mm (0.0004")
Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal : standard ............ 38+0.06 mm (1.496" +0.0024")
Oversize:
0.4 mm (0.0157") ............................................... 38.4+0.06 (1.5118" +0.0024")
Thrust washers (axial bearing)
Width (C): Standard .............................................. 2.9+0.05 mm (0.1142"+0.0039")
Oversize:
0.2 mm (0.0079") ............................................... 3.1+0.05 mm (0.122"+0.002")
Width (D): ............................................................. 10 mm (0.4")
Main bearing shells

Type ..................................................................... Replaceable
Outer diameter Ø (E) ............................................ 85.03+0.036 mm (2.9035"+0.0014")
Thickness (F): Standard ....................................... 2.727+0.008 mm (0.1074"+0.0003")
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm (0.1123"+0.0003")
0.5 mm (0.02") ................................................... 2.977+0.008 mm (0.1172"+0.0003")
43


Diameter Ø (G) for machining:
Standard ............................................................... 68-0.02 mm (2.6772"-0.0008")
Undersize:
0.25 mm (0.01") ................................................. 67.75-0.02 mm (2.6673"-0.0008")
0.5 mm (0.02") ................................................... 67.5-0.02 mm (2.6575"-0.0008")
Width (H), axial bearing journal. ............................ 35.5±0.04 mm (1.397"±0.0016")
Connecting rod-bearing journals:
Out-of-round: Max. ............................................ 0.01 mm (0.0004")
Taper: Max ........................................................ 0.01 mm (0.0004")
H
G
J
K

Diameter Ø (J): Bearing ....................................... 68.03+0.04 mm (2.6783"+0.0016")
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm (2.6685"+0.0016")
0.5 mm (0.02") ................................................... 67.53+0.04 mm (2.6587"+0.0016")
Diameter Ø: Bearing shell ..................................... 72.5+0.05 mm (2.854"+0.002")
Thickness (K): Standard ....................................... 2.222+0.01 (0.0875"-0.0004")
mm
44

Connecting rods
Length (L): Center – Center .................................. 210±0.06 mm
(8.2677"±0.00236")
Connecting rod (M) bushing bore ......................... 42.04+0.01 mm
Wear limit .......................................................... 0.08 mm (1.6551"0.0004")
Replacing measurement for small end bush (0.0031")
Bore for small end bush ..................................... 45.5+0.02 mm (1.7913"0.0008")
Small end bush outer diameter .......................... 45.58+0.04 mm (1.7945"+0.0016")
Axial clearance, connecting rod – crankshaft1) ...... 0.3 – 0.4 mm (0.0118 – 0.0157")
Connecting rod bearing: radial clearance1) ............ 0.036+0.06 mm (0.00142"+0.0024")
Parallelism: Tolerans
Over a length of 100 mm ................................... 0.05 mm (0.002")
Squareness: Tolerans
Over a length of 100 mm ................................... 0.05 mm (0.002")
1)
The dimensions apply to oiled parts
Connecting rod marking:

Connecting rod and cap number marking must be on one
side and identical
45

Lubricating system
Oil grade2) Fuel sulfur content in percent by weight

1)
Up to 0.5 % 0.5 – 1 % More than 1 %
Oil change interval: In operation whichever reached first
VDS-3, VDS-2 500 hours or months 250 hours or months 125 hours or months
ACEA: E7, E5, E3
API: CI-4, CH-4,
CG-4
1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
2)

Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
Viscosity
adjacent table.

46

Engine oil quantity

With oil filter:
TD520GE/TAD520GE: ...................................... 10 liter (2.64 US gal)
TD520VE/TAD520VE: ........................................ 13 liter (3.43 US gal)
TAD530/531/532GE: .......................................... 13 liter (3.43 US gal)

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)
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)
47

Fuel system
1. Fuel tank.
ft)
3. Fuel pump
5. Fuel filter
7. Injection pumps, 420/520 (4) 620/720/721 (6)
9. Injector
11. Overflow valve 2)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
48

Fuel specification
example: EN 590 (with environmental and sub-zero temperature specifications according to national
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 MPa
±0.05
(87 psi)1)
±7
2. Bypass valve
Opening pressure ............................................... 50 kPa
±5
(7.2 ±0.7
psi)
Fuel flow
Min fuel flow at 1500 rpm ....................................... 600 l/tim (158.5 gal/hour)
Firing sequence 1-3-4-2
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter
1500 rpm: Min .................................................... 0.28 (40.6 psi)
MPa
49

Injection pump
Basic measurements
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
pump (LFB = L +
injection
A/100). O
Explanation:
LFB= The exact point when injection pumps starts delivering
fuel.
L = Basic measurement for the injection pumps
O
A/100 = Manufacturing tolerances (written on the

injection pump).
Example:
This
63. 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 (2.12")
Basic measurement length LO : ............................ 143 mm (5.63")
Min length LFB : (A/100+143) – 143 ....................... >0 mm
50

Injectors
Opening pressure:
TD520GE, TAD530-532GE: ............................... 25 MPa (3600 psi)
TAD520GE/TD520VE/TAD520VE: .................... 27.5 MPa (4000 psi)
Max pressure ........................................................ 120 MPa (17400 psi)
Check leakage (for 10 min):
TD520GE, TAD530-532GE: ............................... 23 MPa (3340 psi)
TAD520GE/TD520VE/TAD520VE: .................... 25.5 MPa (3700 psi)
Numbers/bore Ø:
TD520GE, TAD530-532GE ................................ 5 x 0.234 mm (0.00921")
TAD520GE/TD520VE/TAD520VE: ..................... 5 x 0.25 mm (0.00984")
Fuel filter
Filtering size ......................................................... 0.005 mm (0.0002")
Pre-filter
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)

delivery) correction Injection pump
factor
51

Theoretical thickness for a new shim.

Computation for determining the theoretical shim thickness s
(T ) :L - [ ( FB
Ts = + L + A/100 ] (mm)
actual - FBnom ) x Vh corr.factor + Vhnom
o
·
The 1st
individual
step: Esteps:
= FB
1
- FB (°C/A)
actual nom
· 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)

Theor. thickness (T ) Shim thickness (S ) Theor. thickness (T S) Shim thickness (SS)
S
S
When
thickness
shim (Ss). Important! Use only
one shim at the time.
52

How to use EP code

method, when there is only the tolerance between the new and old injection pump that is the difference.
TS = E -K (L O+ 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.
Example:
with
3.
K
pump is ”63” we will have following equation: TS = 146.675 – (143 +
injection
0.63)
T S are in this case 3.045 and a control in table 2 gives: S = 3
mmS
Thickness on the new shim to be mounted is in this example will be 3
mm

E (mm) areEP
All measurements Ek(mm)
in mm (1 mm = 0.0394") EP Ek(mm) EP Ek(mm) EP Ek(mm) EP
k
code code code code code
53

Governor
Manufacturer ........................................................ Heinzmann
Designation:
TD520GE/TAD520GE/TAD530-532GE: .............. 1500 rpm
TD520GE/TAD520GE/TAD530-532GE: .............. 1800 rpm
TD520VE: .......................................................... 1800 rpm
TAD520VE: ....................................................... 2100 rpm
TAD520VE: ....................................................... 2200 rpm
TAD520VE: ....................................................... 2300 rpm
Max, engine speed droop at a load increase from 0 to 100 % at rated
speed: TD520GE/TAD520GE: ...................................... <5 %
TD520VE: .......................................................... 8 – 12%
TAD520VE: ....................................................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated
power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension
X,
Control rod
Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Min: ...................................................................... 16.8 mm (0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm (0.012" – 0.051")
54


Turbocharger
Make and designation ........................................... Schweitzer S2B
Boost pressure at rated speed1), ±10 %:
TD520GE/TAD530-532GE (1500 rpm): ............... 125 kPa (18 psi)
TD520GE/TAD530-532GE (1800 rpm): ............... 137 kPa (20 psi)
TAD520GE (1500 rpm): ..................................... 127 kPa (18.4 psi)
TAD520GE (1800 rpm): ..................................... 128 kPa (18.6 psi)
TD520VE: .......................................................... 2) kPa (2) psi)
TAD520VE: ....................................................... 120 kPa (17.4
psi)
Lube system: ......................................................... Pressure lubrication
Max, permitted radial clearance
(compressor side): .............................................. 0.95 mm (0.0374")
Max, permitted axial clearance: ............................. 0.14 (0.00551")
mm Max allowed back pressure in exhaust line:
TD520GE/TAD530-532GE (1500 rpm): ............... 3 kPa (0.4 psi)
TD520GE/TAD530-532GE (1800 rpm): ............... 5 kPa (0.7 psi)
TAD520GE (1500 rpm): ..................................... 5 kPa (0.7 psi)
TAD520GE (1800 rpm): ..................................... 7 kPa (1 psi)
TD520VE/TAD520VE: ....................................... 7.5 kPa (1.1 psi)
Exhaust gas temperatur, approx:

At rated speed (standby power)1) : ......................... 1500 rpm 1800 rpm
TD520GE/TAD530GE: ....................................... 610°C (1130°F) 530°C (986°F)
TAD520GE/TAD531GE, TAD532GE: ................. 520°C (968°F) 448°C
At rated speed: ..................................................... 1800 rpm (838°F) 2200 rpm 2300 rpm
TD520VE: .......................................................... 510°C 2100 rpm — —
(950°F) — 470°C 470°C
TAD520VE: ........................................................ 475°C 470°C (878°F) (878°F)
(887°F) (878°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD520GE/TAD520GE/TAD530-532GE: .............. 1 kPa (0.14 psi)
Max allowed air intake restriction
TD520GE/TAD520GE/TAD530-532GE: .............. 3 kPa (0.43 psi)
55

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)
Versatile engines are not equipped with a pressure valve from factory
Capacity (engine): ................................................ 7.2 liters (1.9 US gal)
Capacity (engine and cooler):
TD520GE, TAD530/531GE: ............................... 17.5 liters (4.62 US
TAD520GE: ....................................................... 19.7 liters gal)
TAD532GE: ....................................................... 23.8 liters (5.2 US gal)
Thermostat (6.3 US gal)
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
TAD520VE: ........................................................ 102°C (216°
F)
1. Coolan connection (inlet)

2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Coolant pump
Glycol (Antifreeze)
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.

instead
56

Tightening torque
M6 standard screw 8.8 .......................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 .......................................... 25±4 (18±3 lbf.ft)
M10 standard screw 8.8 ........................................ 50±8 (37±6 lbf.ft)
M12 standard screw 8.8 ........................................ 80±9 (59±6.5 lbf.ft)
Nm Group 21 Engine
Engine mounting 260 (192lbf.ft)
Timing gear casing ............................................... 21±2 (15.5±1.5
lbf.ft)
Main bearing caps
Step 1 (37 lbf.ft)
50 2 ................................................................. 60° angle tightening
Step
Step 3 ................................................................. 60° angle tightening
Connecting rod big-end bearing

Step 1 (22 lbf.ft)
50 2 ................................................................ 60° angle tightening
Step
Step 3 ................................................................ 60° angle tightening
Flywheel
Step 1: 20 – (15 – 22 lbf.ft)
Step
30 2: ............................................................... 60° angle tightening
Step 3: ............................................................... 30° angle tightening
Step 1: ............................................................... 20 – 30 (15 – 22
lbf.ft)
Step 1: ............................................................... 30 – 40 (22 – 30
lbf.ft)
Flywheel
Step 2: housing. M12 ......................................... 60°
............................................................... 99±1angle tightening
(73±7 lbf.ft)
Step 3: housing.
Flywheel ...............................................................
M16 ......................................... 60°243angle
±25 tightening
(179±18 lbf.ft)
V-belt pulley
Step 1: 40 – (30 – 37 lbf.ft)
50
Vibration damper 70
Screw, rocker cover ............................................... 9±1 (6.5±0.7 lbf.ft)
Lock nut, valve clearance adjusting screw ............ (14.5±1.5 lbf.ft)
20±2 Screws, rocker arm fixing 21 (15.5 lbf.ft)
Screws, crankcase ventilation .............................. 9±1 (6.6±0.7 lbf.ft)
57


Cylinder head
Screws to cylinder head are reusable only five times.
Step 2: (96 lbf.ft)
Step
Group 22 Oil system

Oil cooler, screws ................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, hollow screw
Step 1: 80 Step 2: 160 (59 lbf.ft)
Front/oil pump housing ......................................... 21±2 (59 lbf.ft)
Oil suction pipe ..................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ............................................................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure pipe turbo ......................................... 29±3 (15.5±1.5 lbf.ft)
Oil pressure pipe engine block ............................. 39±4 (21.4±2.2 lbf.ft)
Screws, oil return pipe turbo (29±3 lbf.ft)
A) with tube fitting .............................................. 40±2
B) with flange fitting ........................................... 21±2 (29.5±1.5 lbf.ft)
Screws, oil return pipe engine block ..................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure switch ............................................... 18±2 (15.5±1.5 lbf.ft)
(13±1.5 lbf.ft)
Screw, governor, idler gear:
Step 1: 30
(22.1 lbf.ft)
Screw, control rod hose ........................................ 10±2 (7±5 lbf.ft)
Screw, governor ................................................... 17 ±1.5
(12.5±1 lbf.ft)
Step 2: Loosen screws for injection pump flange 60°
counterclockwise Step 3: Turn injection pump to stop ...................
Counterclockwise Step 4: ............................................................... 60°
angle tightening
Step 5: 7 Step 6: 10 Step 7: (5 lbf.ft)
30 (7.4 lbf.ft)
Flange screw, injector ........................................... (22 lbf.ft)
16+5 (12+4 lbf.ft)
Injector cap nut (30 – 37
40 – 50 lbf.ft)
Delivery pipe
Use a new delivery pipe after every disassembly (3.7 lbf.ft)
Step 1: (18.4±2.6 lbf.ft)
5 (15.5 lbf.ft)
Step 2: ............................................................... (22 lbf.ft)
25+3.5
Screw, stop magnet
21 Overflow valve (18.5±1.8 lbf.ft)
30 (15.5±1.5 lbf.ft)
(30±3 lbf.ft)
Group 25 Inlet and exhaust system
(8±0.7 lbf.ft)
Exhaust manifold nuts ..........................................
25±2.5
M8 Nuts, turbo to exhaust manifold ...................... (22.1 lbf.ft)
21±2 (15.5±1.5 lbf.ft)
M10 Nuts, turbo to exhaust manifold .................... 40.5±4 (15.5±1.5 lbf.ft)
Screws, Inlet manifold .......................................... 11±1

Thermostat housing
58 30
Water temp sensor ............................................... 21±2
Water pump ..........................................................
Downloaded from www.Manualslib.com manuals search 21±2
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
Type designation .......................... TD720GE TAD720GE TAD721GE TAD722GE
Rotation direction, facing flywheel: Counterclockwise
Bore, mm (inch) ........................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3) 7.15 (436.3) 7.15 (436.3) 7.15 (436.3)
Compression ratio:
EPA 1 17.1:1 17.5:1 — —
COM 2 ...................................... — — 18.1:1 18.1:1
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 1281, 3) 1531, 3) 1831, 3) 2011, 3)
At 1800 rpm, kW (hp) ................ 134
1, 3)
1631, 3) 2041, 3) 2251, 3)
Engine torque, Nm (lbf.ft) ............. 8153) 9743) 1165 1280
At speed, rpm 1500 1500 1500 1500
Engine torque, Nm (lbf.ft) ............. 7113) 8653) 1082 1193
At speed, rpm ........................... 1800 1800 1800 1800
Low idle, rpm 850-950 850-950 800-950 800-950
Max speed at full load (rpm) ......... 1500/18001) 1500/18001) 1500/18001) 1500/18001)
Weight engine (dry) kg (lb) ........... 750 (1653)2) 760 (1674)2) 7852) 7852)
Weight engine (wet) kg (lb) ........... 790 (1742 804 (1773 lb)2) 8262) 8262)
lb)2)
1)
2)
3)
Measured at Prime Power, see ”General information, Power
standards”
59

Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20
General TAD730GE TAD731GE TAD732GE TAD733GE
Type designation ................................
Direction of rotation (seen from flywheel) Anti- clockwise Anti- clockwise Anti- clockwise Anti- clockwise
No. of cylinders .................................. 6 6 6 6
Cylinder bore mm (inch) ...................... 108 (4.25”) 108 (4.25”) 108 (4.25”) 108 (4.25”)
Stroke mm (inch) ................................ 130 (5.12”) 130 (5.12”) 130 (5.12”) 130 (5.12”)
Cylinder volume liter (inch 3 ) ............... 7.15 (436.3) 7.15 (436.3) 7,15 (436) 7,15 (436)
No. of valves ...................................... 12 12 12 12
Compression ratio:
EPA1 ............................................... 17.1:1 17.1:1 18,0:1 18,0:1
EPA2 ............................................... 17.1:1
EU2 ................................................. 18.0:1 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Injection sequence ............................. 1-5-3-6-2-4
Engine power: 129 (208)1) 153 (208)1) 201 (273)1) 201 (273)1)
At 1500 rpm kW (hp) .......................
At 1800 rpm kW (hp) ....................... 136 (222)1) 163 (222)1) 225 (306)1) 225 (306)1)
Torque Nm (lbf.ft) ............................... 821 (718) 974 (718) 1280 (944) 1280 (944)
At engine speed rpm ....................... 1500 1500 1500 1500
Torque Nm (lbf.ft) ............................... 722 (638) 865 (638) 1193 (880) 1193 (880)
At engine speed 1800 1800 1800 1800
rpm ....................... Low idle 800 – 950 800 – 950 800 – 950 800 – 950
rpm ....................................... 1500/1800 1) 1500/1800 1) 1500/18001) 1500/18001)
Highest full load speed
rpm ................
Weight, dry (lb) ................................... 760 (1674) 2) 760 (1674) 2) 785 (1731)2) 785 (1731)2)
Gross
1) weight,
See engine dry
plate for(lb)
specifications. 804 (1773) 2) 804 (1773) 2) 826 (1821)2) 826 (1821)2)
2)
3)
Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
4)
General
Type designation .......................... TD720VE TAD720VE TAD721VE TAD722VE
Rotation direction, facing flywheel: Counterclockwise
Bore, mm (inch) ........................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3) 7.15 (436.3) 7.15 (436.3) 7.15 (436.3)
Compression ratio:
EPA 1 18.4:1 18.4:1 18.4:1 —
COM 2 ...................................... — 19.0:1 19.0:1 19.0:1
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 1221) — — —
At 1800 rpm, kW (hp) ................ — 1741) 1951) 2001)
Engine torque, Nm (lbf.ft) 701 817 897 981
At speed, rpm 1500 1800 1800 1800
Low idle, rpm 850-950 850-950 850-950 800-950
Max speed at full load (rpm) ......... 18001) 2000-23001) 2000-23001) 2100-23001)
Weight engine (dry) kg (lb) ........... 570 2)
5722) 5722) 6802)
Weight engine (wet) kg (lb) ........... 920 2,3)
— — —
1)
2)
3)
60

General
Type designation .................................................... TAD750VE TAD760VE
Counterclockwise Number of cylinders 6 6
Bore, mm (inch) ..................................................... 108 (4.25") 108 (4.25")
Stroke, mm (inch) .................................................. 130 (5.12") 130 (5.12")
Displacement, dm3 (inch3) ....................................... 7.15 (436) 7.15 (436)
Number of valves 12 12
Compression ratio: 18.1:1 18.1:1
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 181 (246)1, 181 (246)1, 3)
3)
Max torque, Nm (lbf.ft) .......................................... 1050 1100 (811)3)
(775)3) 1500
At speed, rpm 1500 Low idle, rpm 600 - 600 - 800
800 Max, full load speed, rpm ....................................... 24001)
24001) 650 (1433)2)
Weight. engine (dry) kg (lb) .................................... 650 680 (1496)2)
(1433)2)
1)
Weight.
See engineplate
identification (wet) kg (lb)specification
for correct .................................... 681
Weight2) according to DIN 70020-A
(1501)
2)

3)
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 (26 x
mm 5.55”)
TD720GE, TAD720GE, TAD721GE,

TAD722GE, TAD720VE, TAD720VE,
TAD721VE, TAD722VE, TAD730-733GE,
TAD750, TAD760VE
Type: ....................................................................
Wet, replaceable
Number
Bore: of seals per liner:
..................................................................... 2 +0.02 mm
108
(4.252”+0.0008”)
Max bore wear: ..................................................... 108.1 mm
Sealing surface. height (A): ................................... 9-0.02 mm (4.256”)
Liner collar seating depth in block: ........................ 8.92 mm +0.03 (0.3543”-0.0008”)
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0,3512” )
+0.0012”
(0.0012 – 0.0031”)
61

Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20

surface.
• Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
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")
62

Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
Pistons
Diameter Ø ...........................................................
71±0.1 mm (2.795"±0.0039")
Depth .................................................................... 16.66±0.1 mm (0.6559"±0.0039")

Gudgeon pin diameter Ø ....................................... 42 -0.006 mm (1.6535"-0.0002")
Piston rings
Compression rings
Number of rings 2
limit:
Upper compression ring (2)
Lower (1) ................................ 0.17 (0.067")
Keystone, no clearance
mm Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................ 0.8 (0.03")
mm (0.0984")
Lower compression ring (2) ................................ 2.5
mm
Oilscraper ring (3)

Number: 1
Width, including springcoil: .................................... 3 (0.12")
mm (0.0039")
Piston ring clearance. height: ................................ 0.1 (0.045”)
mm
Piston ring gap, wear limit: .................................... 1.15
mm
63

Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48±0.1 mm (1.8898"±0.0039")
Exhaust ............................................................. 42±0.1 mm (1.6535"±0.0039")
Stem diameter Ø:
Inlet ................................................................... 8.98-0.015 mm (0.3535"-0.0006")
Exhaust ............................................................. 8.96-0.015 mm (0.3528"-0.0006")
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ..................................................... 44.5°
30° 45°
29.5°
44.5°
Valve disc edge:

Inlet, min ............................................................ 2.1 mm (0.0827")
Exhaust, min ..................................................... 1.8 mm (0.0709")
Inlet ................................................................... 30°
Exhaust ............................................................. 45°
Inlet, min ............................................................ 2.8 mm (0.1102")
Exhaust, min ..................................................... 2.2 mm (0.0866")
Valve clearance (not apply for TAD760VE)

Inlet ................................................................... 0.35±0.05 mm (0.014"±0.002")
Exhaust ............................................................. 0.55±0.05 mm (0.022"±0.002")
Important! Control and adjusting of valve clearance is
done
with an engine oil temperature between 20 – 80°C (68 –
176°F)
Valve
seats
Ø
A
Outer diameter Ø (A), standard: B

Inlet ................................................................... 49.09-0.02 mm
(1.933"-0.0008")
Exhaust ............................................................. 43.06-0.02 mm
Height (B): (1.695"-0.0008")
Inlet ................................................................... 7.5±0.1 mm (0.295"±0.004")
Exhaust ............................................................. 7.9±0.1 mm (0.311"±0.004")
64

Valve seat location

ØC
R
D

Inlet ................................................................... 49-0.025 mm (1.929"-0.001")
Exhaust ............................................................. 43.5-0.02 mm (1.712"-0.001")
Depth (D):
Inlet/Exhaust ..................................................... 11+1 mm (0.43"+0.04")
Inlet/Exhaust ..................................................... 1-0.3 mm
(0.04"-0.012")
Inlet/Exhaust ..................................................... Min 1.5 mm (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")
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Design 1 Design 1 Design 2

without flange with flange
O-ring
Flang
e
On later models the o-ring seal is exchange to a

valve stem sealing, according to the picture for
design 2.
Exchange
Production
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 .................................... 64.7±1.3 mm (2.55"±0.05")
Wire diameter Ø .................................................... 4.5 mm (0.18")
65

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
(2.559"+0.0021")
Standard ............................................................
65+0.054 mm (2.5622")
Wear limit ........................................................... (0.7827"+0.0005")
65.08 mm
Radial clearance ................................................... 0.05 – 0.124 mm(0.002(0.004 –– 0.0049")
Camshaft
Position ofbearing
bearingthickness: max .........................
bush at flywheel end ............... 1.988
2+0.5 mm mm
+0.012 0.02")
Axial clearance ..................................................... 0.1– 0.5 mm (0.079"+0.0197")
Timing gear
1. Governor drive (not apply for 750/760)
2. Idler gear (not apply for 750/760)
3. Camshaft gear
4. PTO gear B-C (not apply for 750/760)
5. PTO gear A (not apply for 750/760)
6. Crankshaft gear
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")
66

Crank mechanism
Crankshaft length .................................................. 973.2 mm (38.31")
Crankshaft axial clearance1) .................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1) .............................. 0.03+0.062 mm (0.0012"+0.0024")
Max, permissible ovality of main
bearing and crank pins ....................................... 0.01 mm (0.0004")
Max, run-out of center bearing ............................... 0.1 mm (0.00394")
1)
E
F
C
B
A

Diameter Ø (A) for machining: Standard ............... 85-0.02 (2.9134"-0.0008")
mm Undersize:
0.25 mm (0.01") ................................................. 84.75-0.02 (3.3366"-0.0008")
mm (3.3268"-0.0008")
0.5 mm (0.02") ................................................... 84.5-0.02
mmbearing journals:
Main
Out-of-round: Max. ............................................. 0.01 mm (0.0004")
Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal: standard .............. 38+0.06 (1.496"+0.0024")
mm Oversize:
0.4 mm (0.0157") ............................................... 38.4+0.06 (1.5118"+0.0024")
mm
Thrust washers (axial bearing) (0.114"+0.002")
Width (C): Standard ............................................... 2.9+0.05
mm (0.122"+0.002")
Oversize: (0.4")
0.2 mm (0.0079") ............................................... 3.1+0.05 mm
Width (D): .............................................................. 10 mm
Main bearing shells (2.9035"+0.0014")

Type ..................................................................... Replaceable (0.1074"+0.0003")
Outer diameter Ø (E) ............................................. 85.03+0.036
mm (0.1123"+0.0003")
Thickness (F): Standard ........................................ 2.727+0.008 (0.1172"+0.0003")
mm
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm 67
0.5 mm (0.02") ................................................... 2.977+0.008 mm

Diameter Ø (G) for machining:
Standard ............................................................... 68-0.02 mm (2.6772"-0.0008")
Undersize:
0.25 mm (0.01") ................................................. 67.75-0.02 mm (2.6673"-0.0008")
0.5 mm (0.02") ................................................... 67.5-0.02 mm (2.6575"-0.0008")
Width (H), axial bearing journal. ............................. 35.5±0.02 (1.397"±0.0008")
mm Connecting rod-bearing journals:
Out-of-round: Max. ............................................. 0.01 mm (0.0004")
Taper: Max ........................................................ 0.01 mm (0.0004")
H
J G
K

Diameter Ø (J): Bearing ........................................ 68.03+0.04 mm (2.6783"+0.0016")
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm (2.6685"+0.0016")
0.5 mm (0.02") ................................................... 67.53+0.04 mm (2.6587"+0.0016")
Diameter Ø: Bearing shell ..................................... 72.5+0.05 mm (2.854"+0.002")
Thickness (K): Standard ....................................... 2.222+0.01 (0.0875"+0.0004")
mm
68

Connecting rods
Length (L): Center – Center ................................... 210±0.06 mm
(8.2677"±0.00236")
Connecting rod (M) bushing bore ........................... 42.04+0.01
mm Wear limit ........................................................... 0.08 mm (1.6551"0.0004")
Replacing measurement for small end bush (0.0031")
Bore for small end bush ..................................... 45.5+0.02 mm (1.7913"0.0008")
Small end bush outer diameter Ø ....................... 45.58+0.04 mm (1.7945"+0.0016")
Axial clearance, connecting rod – crankshaft1) ...... 0.3-0.4 mm (0.0118-0.0157")

Connecting rod bearing: radial clearance1) ............. 0.036-0.096 mm (0.00142-
0.00378") Parallelism: Tolerans
Over a length of 100 mm .................................... 0.05 (0.002")
mm
Squareness: Tolerans (0.002")
Over a length of 100 mm .................................... 0.05
mm
1)
Marking: Connecting rod and cap number marking must be

on one side and identical
69

Lubricating system
Engine Oilgrade2) Sulfur content in fuel, by weight
< 0,5 % 0,5 – 1,0 % > 1,0 %1)
Oil change interval, reached first in operation
T(A)D720-721VE VDS-3 500 h / 12 months 250 h / 12 months 125 h / 12
T(A)D720GE VDS-2 months
TAD730/731GE, ACEA: E7, E5, E3
TAD721/722GE, API: CI-4, CH-4, CG-
TAD732/TAD733GE, 4
TAD750/760VE,
open
crankcase
ventilation
TAD721/722GE, ACEA: E4 500 h / 12 months 250 h / 12 months 125 h / 12
TAD732/733GE, API: CI-4, CH-4 months
TAD750/760VE, NOTE! Fully synthetic oil must be used
closed crankcase
ventilation
TAD722VE ACEA: E4 500 h / 12 months 250 h / 12 months 125 h / 12
power<200kW months
power>200kW 250 h / 12 months 125 h / 12 months 60 h / 12 months

1)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15 closed crankcase ventilation
2)

Global DHD = Global Diesel Heavy
Duty TBN = Total Base Number
Viscosity
adjacent table.

70

Engine oil quantity

With oil filter:
TD720/TAD720/TAD721VE: ............................... 20 liter (5.28 US
TAD722VE/TAD750VE/TAD760VE .................... 23 liter gal)
TAD721GE/TAD722GE ...................................... 34 liter (6.10 US
gal)
(8.98 US
gal)

At rated speed:
TD720GE, TAD720/721/722GE, TAD730-733GE:400 kPa (58 psi)
TD720VE/TAD722/750/760VE: .......................... 450 kPa (65 psi)
TAD720VE/TAD721VE: ..................................... 350 kPa (50.8 psi)
Idling speed (800 rpm), min: .................................. 80 (11.6 psi)
kPa
Shut down switch, at pressure lower than: (22 psi)
TD720GE, TAD720/721/722GE, TAD730-731GE: 150 kPa (7.2 psi)
TD720VE, TAD720/721/722/750/760VE: ............ 50 (29 psi)
kPa TAD732/733GE .................................................. 200
kPa
4.
6. Rocker arm
Piston cooling: ................................................ 2-hole nozzles for each cylinder
5.
7. Return line
Oil filter, to oil sump
full-flow:
Filtering size: ......................................................... 0.012 mm (0.0005")
Bypass valve oil filter:
Opening pressure: ............................................... 250±50 kPa (35±7 psi)
8. Pressure regulating valve:
Opening pressure: ............................................... 400±40 kPa (58±6 psi)
9. Pressure-relief valve:
Opening pressure: .............................................. 1±0.1 MPa (145±14 psi)
10. Lube oil pump:
Type: .................................................................... Rotary pump driven by the crankshaft
Rotary pump width: ............................................... 14.5 mm (0.57")
Oil flow (2500 rpm): ............................................... 90 l/min (24 gal/hour)
11. Oil cooler:
Normal oil temperature: .......................................... 80°C (176°F)
Max o il temperature: ............................................. 125°C (257°F)
71

Fuel system (720– 733)
1. Fuel tank.
ft)
3. Fuel pump
5. Fuel filter
7. Injection pumps,720/721/722 (6 ea.)
9. Injector
11. Overflow valve2)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
72

Fuel system (750,760)
1. Fuel tank 8. Highpressure pump

2. Hand pump 9. Fuelpipe, to injector
(accessory) 10. Injector
3. Fuel line (to pump) 11. M-prop
4. Fuel pump 12. Pressure valve
5. Fuel filter 13. Return fuel line, to fuel tank, A = Fuel
6. Pipe to highpressure pipes, minimum distance 300 mm (11.8")
7. Rail
73

Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group
20
Fuel specification
example: EN 590 (with environmental and sub-zero temperature specifications according to national
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 (87±7.2 psi)1)
Bypass valve (2)
Opening pressure ............................................... 50±5 kPa (7.2±0.7 psi)
Fuel flow
Min fuel flow at 1500 rpm ...................................... 600 l/tim (158.5 gal/hour)
Firing sequence 1-5-3-6-2-4
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter at
1500 rpm. min .................................................... 0.28 MPa (40.6 psi)
Fuel filter
Pre-filter
74

Injection pump (720– 733)

Basic measurements
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 O
L
(L FB =
with LOtolerance
the + A/100, that are written on the injection pump
A/100).
Explanatio
n:
LFB = The exact point when injection pumps starts
fuel.
delivering
LO = Basic measurement for the injection
pumps= Manufacturing tolerances (written on the
A/100
injection pump).
Example:
This gives us the equation: LFB = 143 +
63.
0.63 total length LFB =
The
143.63
Injection pump (720–733)
Manufacturer ......................................................... Bosch
Designation ........................................................... PF 33 L
Length A: .............................................................. 54 mm (2.12")
Basic measurement length LO : ............................. 143 (5.63")
mm
Min length LFB : (A/100+143) – 143 ........................ >0
mm
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, (4000 psi)
TAD722GE/COM2: .............. 27,5
MPa
Max pressure:
TD720GE/ EPA1, TAD720GE/EPA1/COM2 (17400 psi)
TAD720VE/EPA1, TAD721VE/EPA1
TAD721GE/COM2, (23200 psi)
TAD722GE/COM2: .............. 120 MPa
TAD720VE/COM2, TAD721VE/COM2
TAD722VE/ (3340 psi)
COM2: ............................................. 160
MPa
Check leakage (for 10 min): (3700 psi)
TAD720GE/EPA1, TAD720VE/COM2
TAD721VE/COM2,
TD720GE: .......................................................... 6 x 0.234 mm (6 x 0.00921")
TAD722VE/COM2: .............. 23 MPa
TAD720GE/TD720VE/TAD720VE, EPA 1: ........ 6 x 0.25 mm (6 x 0.00921")
TAD720GE/EPA1, TAD720VE/EPA1 EPA 1: ...... 6 x 0.264 mm (6 x 0.00921")
TAD721GE/TAD721VE/TAD722GE,
TAD721GE/COM2, TAD722GE/COM2
TAD720VE/TAD721GE/TAD721VE/TAD722GE
TAD721VE/
COM 2: .............................................................. 6 x 0.236 mm (6 x 0.00921")
EPA1: .............................................
25,5 MPa
75
Numbers/bore Ø:
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)

delivery) correction factor Injection pump
76

Theoretical thickness for a new shim (720–733)

Computation for determining the theoretical shim thickness S
(T
TS=) L
: - [ ( FB + L O + A/100 ] (mm)
actual - FBnom ) x Vh corr.factor + Vh nom
·
The 1st
individual
step: Esteps:
= FB
1
- FB (°C/A)actual nom
· 2nd step: E = E x Vh (mm/°C/A)

2 1 corr.factor
· 3rd step: E = E + Vh
3 2 nom
· 4th step: E = E + L
4 3 O
· 5th step: E = E + A/100 (mm)

5 4
· 6th step: Ts = L – E 5
·NOTE!
7th step: The actual shim thickness (S ) is determined with the help of table
2.
s
Shims (S ) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When
s
theoretical
the 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)

Theor. thickness (T ) Shim thickness Theor. thickness(TS) Shim thickness (SS )
(S )
S
S
When
thickness
shim (Ss). Important! Use only one shim at the
time.
77

Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group
20
How to use EP code (720–733)

met-
TS = Ehod,
- (Lwhen there is only the tolerance between the new and old injection pump that is the difference.
K O+
A/100)
T = Shim thickness
S
EK = Value from tabel 3 read with help of EP code from ”Identification

plate”.
L = Basic measurement for the injection pumps, 420/620 = 117.5
O
mm.
Example:
with
3.
K
pump is ”63” we will have following equation: TS = 146.675 – (143 +
injection
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)
All measurements EPin mm (1Emm
are k(mm)
= 0.0394")EP Ek(mm) EP Ek(mm) EP Ek(mm) EP
code code code code code
78

Governor (720–733)
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,
Control rod (720–733)

Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Min: ...................................................................... 16.8 mm
(0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm
(0.012" –
0.051")
79


Turbocharger, make and designation:
TD720GE/TAD720GE/TD720VE/TAD730GE: .............................. Schwitzer S2B
TAD720/721/722/750/760VE:
EPA 1: ......................................................................................... Schwitzer S2B
COM 2: ........................................................................................ Schwitzer S200
TAD721/722GE, TAD731–733GE ................................................ Schwitzer S200
Boost pressure at rated speed1), ± 10%:
TD720GE, TAD730GE (1500 rpm): .............................................. 116 kPa (16.8 psi)
TD720GE, TAD730GE (1800 rpm): .............................................. 131 kPa (19.0 psi)
TAD720GE (1500 rpm): ................................................................ 136 kPa (19.7 psi)
TAD720GE (1800 rpm): ................................................................ 142 kPa (20.6 psi)
TAD721GE, TAD731GE (1500 rpm): ............................................ 161 kPa (23.4 psi)
TAD721GE, TAD731GE (1800 rpm): ............................................ 175 kPa (25.4 psi)
TAD722GE, TAD732/733GE (1500 rpm): ..................................... 178 kPa (25.8 psi)
TAD722GE, TAD732/733GE (1800 rpm): ..................................... 200 kPa (29.0 psi)
TD720VE: .................................................................................... 2) kPa (2) psi)
TAD720VE (EPA 1): .................................................................... 133 kPa (18.9 psi)
TAD720VE (COM 2): ................................................................... 151 kPa (21.9 psi)
TAD721VE (EPA 1): .................................................................... 155 kPa (22.5 psi)
TAD721VE (COM 2): ................................................................... 163 kPa (23.6 psi)
TAD722VE (COM2, High power): ................................................. 198kPa (28.7 psi)
TAD750VE/TAD760VE: ............................................................... 198kPa (28.7
Lube system: .................................................................................. Pressure lubrication
psi)
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: 1800 rpm

At rated speed (standby power) : .......................... 1500 rpm
1)
TD720GE, TAD730GE: ...................................... 560°C (1040°F) 505°C (941°F)

TAD720GE, TAD731GE: .................................... 476°C (914°F) 433°C (837°F)
TAD722GE, TAD732/733GE .............................. 557°C (1035°F) 520°C (968°F)
At rated speed: ..................................................... 1800 rpm 2100 rpm 2200 rpm 2300 rpm
TD720VE: .......................................................... 420°C (788°F) — — —
TAD721VE: ........................................................ 420°C (788°F) 420°C (788°F) 425°C (797°F) 430°C (806°F)
TAD721VE: ........................................................ 490°C (914°F) 475°C (887°F) 480°C (896°F) 485°C (905°F)
TAD722/750/760VE: .......................................... 545°C (1013°F) 535°C (995°F) 540°C (1004°F) 545°C (1013°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD720GE/TAD720GE, TAD730GE: ................... 1 kPa (0.14 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 1.5 kPa (0.22 psi)
TD720VE/TAD720/721/722/750/760VE: 2.5 (0.36 psi)
Max allowed air intake restriction
TD720GE/TAD720GE, TAD730GE: ................... 3 kPa (0.43 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 3.5 kPa (0.51 psi)
TD720VE/TAD720/721/722/750/760VE: 6.5 (0.94 psi)
80

Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD720GE/TAD720GE, TAD730/731GE: ............ 60 kPa (13 psi)
TAD721GE/TAD722GE
TD720VE/TAD720VE/TAD721VE,
TAD732-733GE, max1): ...................................... 90 kPa (13 psi)
1)
Versatile engines are not equipped with a pressure valve from
factory (2.59 US
Capacity (engine):. ................................................. 9.8 gal)
liters (5.8 US
Capacity (engine and cooler): gal)
TD720GE: ........................................................... 22 liters (6.3 US
TAD720GE/TAD730/731GE: ............................... 23.8 liters gal)
TAD721GE/TAD722GE/TAD732/733GE: 27.3 (7.2 US
Type: ..................................................................... Piston thermostat
Thermostat gal)
Begins to open at
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE,
TAD732/733GE: ................................................. 87° (189° F)
C
Fully open at (203°F)
TD720GE/TAD720GE/TD720VE: ....................... 95°C
TAD721GE/TAD722GE/TAD720VE/TAD721VE (216°
TAD722VE/TAD750VE/TAD760VE: ................... 102° C F)
TD/TAD720-722:
1. Coolan connection (inlet)
2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Coolant pump
Glycol (Antifreeze)
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.
instead
81

Tightening torque
M6 standard screw 8.8 .......................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 .......................................... 25±4 (18±3 lbf.ft)
M12 standard screw 8.8 ........................................ 80±9 (59±6.5 lbf.ft)
Nm Group 21 Engine
Engine mounting 260 (192 lbf.ft)
Timing gear casing ................................................ 21±2 (15.5±1.5 lbf.ft)
Main bearing caps

Step 1 (37 lbf.ft)
50 2 ................................................................. 60° angle tightening
Step
Connecting rod big-end bearing:

Step 1 (22 lbf.ft)
30 2 ................................................................ 60° angle tightening
Step
Step 3 ................................................................ 60° angle tightening
Flywheel
Step 1: 20 – (15 – 22 lbf.ft)
Step
Step 1: ............................................................... 20 – 30 (15 – 22
lbf.ft)
Step 1: ............................................................... 30 – 40 (22 – 30
lbf.ft)
Flywheel
Step 2: housing. M12 ..........................................60°
............................................................... 99±1angle tightening
(73±7 lbf.ft)
Step 3: housing.
Flywheel ...............................................................
M16 ..........................................60° 243angle
±25 tightening
(179±18 lbf.ft)
V-belt pulley
Step 1: 40 – (30 – 37 lbf.ft)
50
Vibration damper 70
Screw, rocker cover .............................................. 9±1 (6.5±0.7 lbf.ft)
Lock nut, valve clearance adjusting screw ............ (14.5±1.5 lbf.ft)
20±2 (15.5 lbf.ft)
Screws, rocker arm fixing 21 (6.6±0.7 lbf.ft)
Screws, crankcase ventilation ............................... 9±1
82


Cylinder head
Step 2: (96 lbf.ft)
130
Group 22 Oil system

Oil cooler, screws ................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, hollow screw
Step 1: 80 Step 2: 160 (59 lbf.ft)
Front/oil pump housing .......................................... 21±2 (59 lbf.ft)
Oil suction pipe ..................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ............................................................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure pipe turbo .......................................... 29±3 (15.5±1.5 lbf.ft)
Oil pressure pipe engine block .............................. 39±4 (21.4±2.2 lbf.ft)
Screws, oil return pipe turbo (29±3 lbf.ft)
A) with tube fitting .............................................. 40±2
B) with flange fitting ........................................... 21±2 (29.5±1.5 lbf.ft)
Screws, oil return pipe engine block ...................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure switch ............................................... 18±2 (15.5±1.5 lbf.ft)
(13±1.5 lbf.ft)
Screw, governor, idler gear:
Step 1: 30
(22.1
lbf.ft)
Screw, control rod hose ........................................ 10±2 (7±5 lbf.ft)
Screw, governor .................................................... 17±1.5 (12.5±1 lbf.ft)
counterclockwise Step 3: Turn injection pump to stop ...................
Counterclockwise Step 4: ............................................................... 60°
angle
Step 5:tightening 7 Step 6: (5 lbf.ft)
10 Step 7: 30 Flange screw, (7.4 lbf.ft)
injector ........................................... 16+5 (22 lbf.ft)
Injector cap nut 40 (12+4 lbf.ft)
– 50 (30 – 37
Delivery pipe lbf.ft)
Use a new delivery pipe after every disassembly
Step 1: 5 (3.7 lbf.ft)
Step 2: ............................................................... 25±3.5 (18.4±2.6 lbf.ft)
Screw, stop magnet (15.5 lbf.ft)
21 Overflow valve (22 lbf.ft)
30
Common Rail, TAD750/760 (74 lbf.ft)
Safety valve (51.6 lbf.ft)
100 Rail pressuree sensor (22.1 lbf.ft)
70 Common rail unit (29±3 lbf.ft)
30 Fuel hose
39 (22
IEGR, TAD750/760 lbf.ft)
IEGR-unit: (18
30 lbf.ft)
(7.4 lbf.ft)
Solenoid valve: (37 lbf.ft)
24
Highpressure fuel pump, TAD750/760
83
Step 1:
10 Step 2:
Nm Group 25 Inlet and exhaust system

Exhaust manifold nuts .......................................... 25±2.5 (18.5±1.8 lbf.ft)
M8 Nuts, turbo to exhaust manifold ...................... 21±2 (15.5±1.5 lbf.ft)
M10 Nuts, turbo to exhaust manifold ..................... (30±3 lbf.ft)
40.5±4 Screws, Inlet manifold ........................................... (8±0.7 lbf.ft)
11±1

Thermostat housing 30 (22.1 lbf.ft)
Water temp sensor ................................................ 21±2 (15.5±1.5 lbf.ft)
Water pump .......................................................... 21±2 (15.5±1.5 lbf.ft)
NOTE! See also ”Tightening diagrams”.
84

Grupp 20 Technical data
Tightening torque diagram
Main bearing caps:

TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Step 1 ................................................................. 30 Nm (22 lbf.ft)
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:

Use new bolts every time.
Step 1 ................................................................. 30 Nm (22 lbf.ft)
Step 3 ................................................................. 30 Nm
TAD750VE/760VE
Step 1 ................................................................. 50 Nm (37 lbf.ft)
Step 2 ................................................................. 60° angle
tightening
Step 3 ................................................................. 60° angle
tightening
85

Technical data Grupp 20
Flywheel

Step 1: ................................................................ 20 – 30 Nm (15 – 22 lbf.ft)
Step 2: ................................................................ 60° angle tightening
Step 1: ................................................................ 20 – 30 Nm (15 – 22 lbf.ft)
Step 1: ................................................................ 30 – 40 Nm (22 – 30 lbf.ft)
V-belt pulley/vibration damper:

V-belt pulley/vibration damper:
Step 1: ................................................................ 40 – 50 Nm (30 – 37 lbf.ft)
Vibration damper .................................................... 70 Nm
86

Grupp 20 Technical data
Cylinder head
Manifold side Manifold side
Step 1: ................................................................ 30 Nm (22 lbf.ft)
Step 2: ................................................................ 80 Nm (59 lbf.ft)
TAD750VE/760VE
Step 1: ................................................................ 50 Nm (37 lbf.ft)
Step 2: ................................................................ 130 Nm (96 lbf.ft)
Step 3: ................................................................ 90° angle
tightening
Flange screws, Injection pump (not apply for 650/660, 750/760)
Step 1: Torque .................................................... 5 Nm (3.7 lbf.ft)
counterclockwise Step 3: Turn injection pump to stop ....................
Counterclockwise Step 4: ................................................................
60° angle
Step tightening
5: ................................................................ 7 Nm (5 lbf.ft)
Step 6: ................................................................ 10 Nm (7.4 lbf.ft)
Step 7: ................................................................ 30 Nm (22 lbf.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.
87

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 (3.7 lbf.ft)
Step 2: ................................................................ 25±3.5 Nm (18.4±2.6 lbf.ft)
Use a new delivery pipe after every disassembly
WARNING! Do not bend the pressure pipes, they can only be used
once.
Screw plug
4. Screw plug MA .................................................... 35±3.5 Nm (26±2.6 lbf ft)

6. Screw plug MA .................................................... 95±9.5 Nm (70±7 lbf ft)
13. Screw plug MA .................................................. 35±3.5 Nm (26±2.6 lbf ft)
24. Screw plug MA .................................................. 10±2 Nm (7±1.5 lbf ft)
88

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Do you have any complaints or other comments about this 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: ............................................................................
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Refers to publication: .............................................................................................................................................
Publication No.: ............................................................. Date of issue: .................................................................
Proposal/motivation: ..............................................................................................................................................
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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7742012 English 06–2007

TD 420 Ve

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Workshop Manual I

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TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE,

© 2007 AB VOLVO PENTA

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Take care to avoid contact with hot surfaces

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Introduction Our joint responsibility

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Tightening torque Lock nuts

Tightening torque with Strength classes

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Sealant Safety rules for fluorocarbon

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Cylinder head bolts

Quantity and length:

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Parent bore Replaceable, dry

TD420VE, TAD420VE TAD620,

Max bore wear:

Sealing surface: Height, see picture (A):

Liner collar seating depth in block:

Projection of liner above block surface:

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Cylinder head gasket

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Oilscraper ring (3)

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Min 1.8 mm Min 1.1 mm

Valve disc edge:

Valve clearance (not apply for TAD660VE)

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Outer diameter Ø (A), standard:

Valve seat location

Diameter Ø (C), standard:

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Main bearing journals

Main bearing shells

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Connecting rod bearing journals

Connecting rod bearing shells

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Axial clearance, connecting rod – crankshaft1) ....... 0.2-0.3 mm (0.00787"-0.0118")

Connecting rod marking:

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VDS = Volvo Drain Specification

NOTE! the temperatures refer to constant outside

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Engine oil quantity

1. Oil pressure sensor

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Fuel system (420, 620)

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Fuel system (650, 660)

1. Fuel tank 8. Highpressure pump