TD 420 Ve

Workshop Manual
Technical Data
I
1(0)
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
Downloaded from www.Manualslib.com manuals search engine
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
Contents
Safety precautions ............................................... 2
General information ............................................. 5
Repair instructions ............................................... 6
Location of identification plates
TD/TAD420-620, TD/TAD520-722 ....................... 9
TAD650/660, TAD750/760 .................................. 10
TD420VE, TAD420VE, TAD620VE, TAD650VE,
TAD660VE
General (420/620)................................................ 11
General (650/660)................................................ 12
Engine block ....................................................... 12
Valve mechanism ............................................... 16
Crank mechanism ............................................... 19
Lubricating system .............................................. 22
Fuel system ........................................................ 24
Intake and exhaust system ................................. 32
Cooling system ................................................... 32
Tightening torque ................................................ 33
TAD530-532GE
General ............................................................... 36
Engine block ....................................................... 37
Valve mechanism ............................................... 40

Crank mechanism ............................................... 43
Fuel system ........................................................ 48
Cooling system ................................................... 56
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730-733GE, TAD750VE, TAD760VE
General (720-722GE ) ......................................... 59
General (720-722VE) ........................................... 60
General (750/760)................................................ 60
Engine block ....................................................... 61
Valve mechanism ............................................... 64
Crank mechanism ............................................... 67
Fuel system ........................................................ 72
Cooling system ................................................... 81
Tightening diagram ............................................. 85
2007 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally-friendly paper
1
General Information
Group 20
Safety Precautions
Introduction
Workshop Manuals contains technical specifications,
descriptions, and instructions for the repair of the specified Volvo Penta products or product types. Check
that you have the correct Workshop Manual and the
latest Service Bulletins for your engine.
Before starting work on the engine, read these
sections of the Workshop Manual:
Safety Precautions
General Information
Repair Instructions
Important
In this book and on the product you will find the following special warning symbols.
WARNING! Possible danger of personal injury,
extensive damage to property or serious mechanical malfunction if the instructions are not followed.
IMPORTANT! Used to draw your attention to something that can cause damage or malfunc-tions on a product or damage to property.
NOTE! Used to draw your attention to important
infor-mation that will facilitate the work or operation in progress.
Warning symbols used in the Workshop Manual are
not in any way comprehensive since it is impossible
to predict every circumstance under which service work or repairs may be carried out.
AB Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working
methods in a well-equipped workshop using working
methods and tools tested by AB Volvo Penta.
2
Below is a summary of the risks involved and safety precautions you should always observe or
carry out when operating or servicing the engine.
Immobilize the engine by turning off the power
supply to the engine at the main switch (switches) before starting work. Put a warning notice at
the engine control panel.
Generally, all service operations must be carried out with the engine stopped.
However, some work, for example certain adjustments requires that the engine is running when
they are carried out.
Approaching an engine, which is operating, is a
safety risk. Loose clothing or long hair can fasten in rotating parts and cause severe personal
injury.
Take care to avoid contact with hot surfaces
(exhaust pipes, turbocharger, air intake pipe, starter element etc.) and hot liquids in lines and
hoses on an engine that is running or has just
been stopped. Reinstall all protective parts removed during service operations before starting
the engine.
Check that the warning or information labels on
the product are always clearly visible. Replace
labels that have been damaged or painted over.
Never start the engine without installing the air
cleaner filter. Foreign objects entering the intake
ducts can also cause mechanical damage.
Never use ether or similar products when starting the engine. They may cause an explosion in
the inlet manifold and causing personal injuries.
Only start the engine in a well-ventilated area.
If operating the engine in an enclosed area make sure that the exhaust is leading out of the engine compartment and working area.
Avoid opening the coolant filler cap when the engine is hot, when hot steam or coolant might spray out. If the filler cap must be open, slowly release the pressure in the system. Be very careful, it is difficult to anticipate in which direction
hot steam or coolant can spray out.
Group 20
Stop the engine before carrying out operations
on the engine cooling system.
Always use protective glasses or goggles, when
carrying out work where there is a risk of splinters, grinding sparks and acid splashes or when
other chemicals are in use. The eyes are extremely sensitive and an injury could result in blindness!
Avoid getting hot oil on your skin, it might cause
severe burns. Ensure that the lubrication system is not under pressure before carrying out any
work. Never start or operate the engine with the
oil filler cap removed, otherwise oil could be ejected.
Exposure to oil over a long period or repeatedly
will cause problems such as skin drying out, irritation and toxic eczema. Used oil is in a health
aspect even more dangerous than new oil. Use
protective gloves. Use protection creams, which
will ease up cleaning of the skin and counteract
drying out.
Many chemicals such as oils, glycol, diesel oil
and other chemicals, for example degreasing
agents, paint and solvents are dangerous to your health.
Always follow the safety precautions for the product, for example using protective mask, glasses, gloves etc. Make sure of good ventilation is
provided in the working area. Follow the instructions on the product, when disposing used chemicals.
Follow extreme care when working with/or checking the fuel system. Use eye protection. The
jet from a fuel injector nozzle is under extremely
high pressure and can cause severe personal
injury.
General Information
WARNING! Use new delivery pipes every time.
Be careful, delivery pipes should under no circumstances be bent.
All fuels and many chemical substances are flammable. Do not allow naked flame or sparks in
the working area!
Make sure that the working area is well ventilated and take the necessary safety precautions
before starting welding or grinding work.
Make sure that there always are fire extinguishers in the working area.
Ensure that rags soaked in oil or fuel are stored
safely. Rags soaked in oil can spontaneously
ignite. Used fuel filters, oil filters, lubricating oil,
contaminated fuel, solvent and degreasing agents are environmentally dangerous waste and must be deposited at an approved site for dest-ruction.
Never expose a battery to naked flame or electrical sparks. Batteries always produce hydrogen
gas, which mixed with air form an explosive gas
oxyhydrogengas.
This gas is highly volatile and easily ignited. Incorrect connection of the battery can cause a
single spark that is sufficient to cause an explosion. Be very careful when attempting to ju-mpstart the engine and do not at any time lean over
the batteries.
Always ensure that the Plus (positive) and Minus (negative) battery leads are correctly installed. Incorrect installation can result in severe
damage to the electrical equipment. Refer to the
wiring diagrams.
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid, which is highly caustic.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately using plenty of water and soap and if it is exposed
to the eyes, immediately flush with plenty of water and obtain medical assistance at once.
3
General Information
Turn the engine off and turn off the power at the
main switch/switches before carrying out work
on the electrical system.
Clutch adjustments must be carried out with the
engine stopped.
Use the lifting eyes fitted on the engine when lifting the drive unit. Always check that the lifting
equipment is in good condition and has the correct load capacity to lift the engine (engine weight including gearbox, if fitted, and any extra equipment installed).
To make sure of safe handling and to avoid damage, use a lifting beam to raise the engine.
This lifting beam is installed on the top of the
engine, make sure that all chains and cables should run parallel to each other.
If extra equipment is installed on the engine that
would alter its center of gravity, it is required that the lifting device has to be altered for obtaining the correct balance for safe handling.
Never carry out work on an engine suspended
on a hoist without other supporting equipment
attached.
Never work alone when removing heavy engine
components, even when using lifting devices
such as locking tackle lifts. When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted clear and not damaged during the lifting operations.
Check before starting work if there is eno-ugh
room to carry out removal work without risk-ing
personal injury or damage to the engine or parts.
4
Group 20
WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion.
The engine must not be run in areas where there
are explosive materials.
Always use the fuels recommended by AB Volvo Penta. Refer to the Instruction Book. Use of
fuels that are of a lower quality can damage the
engine. On a diesel engine, poor quality fuel can
cause the control rod to seize, which can result
in an over revving of the engine, risking of damaging to the engine and of personal injuries.
Poor fuel quality can also lead to higher maintenance costs.
Observe the following rules when cleaning with
high-pressure water jets. Never direct the water
jet at seals, rubber hoses, or electrical components. Never use a high-pressure jet when washing the engine.
Group 20
General Information
General Information
About this Workshop Manual
Spare parts
This Workshop Manual contains technical data for the

repair of the following engines in standard format:
TD420VE, TAD420VE, TAD620VE, TAD650VE,
TAD660VE, TD520GE, TAD520GE, TD520VE,
TAD520VE, TAD530-532GE, TD720GE, TAD720GE,
TD720VE, TAD720VE, TAD721GE, TAD721VE,
TAD722GE, TAD722VE, TAD730-733GE, TAD750VE,
TAD760VE
Spare parts for the electrical and fuel systems are

subject to various national safety requirements. Volvo
Penta Original Spare Parts meet these specifications.
The Engine Designation and Engine Numbers can be

found on the Identification plates. Please always include both the engine designation and the engine
number in all correspondence.
Engine certificate
The Workshop Manual is produced primarily for the

use of Volvo Penta workshops and service technicians. For this reason, the manual presupposes a certain basic knowledge and that the user can carry out
the mechanical/electrical work described to a general
standard of engineering competence.
Volvo Penta products are under a continual process of
development and we therefore reserve all rights regarding changes and modifications. All the information in
this manual is based on product specifications available at the time the book was published. Any essential
changes or modifications introduced into production or
updated or revised service methods introduced after
the date of publication will be provided in the form of
Service Bulletins from AB Volvo Penta.
Power standards
The engine performance corresponds to:
ISO 3046, BS 5514, and DIM 6271.
Prime power rating corresponds to ISO standard power for continues operation. It is applicable for supplying electrical power at variable load for an unlimited
number of hours instead of commercial purchased power. A ten-percent overload capability is available for
this rating.
Standby Power rating corresponds to ISO Standard
Fuel Stop Power. Its is applicable for supplying
standby electrical power at variable load in areas well
est-ablished electrical networks in event of normal utility power failure. No overload capability is available
for this rating.
NOTE! The technical data applies to an engine without cooling
fan and operating on a fuel with calorific value of 42.7 MJ/kg
(18360 BTU/lb.) and a density of 0.84 kg/liter (7.01 lb./US gal,
8.42 lb./lmp. gal) even when it involves a deviation from
standards.
Any type of damage which is the result of using spare

parts that are not original Volvo Penta parts for the
product in question will not be covered under any warranty or guarantee provided by AB Volvo Penta.
Engine certificates to meet national and regional environmental legislation carry with them an undertaking
from the manufacturer that both new and existing engines in use meet the environmental demands of the
legislation. The product must correspond to the validated example that was granted certification. In order for
AB Volvo Penta as the manufacturer to take responsibility for engines in use, certain requirements regarding service and spare parts must be met by the user
according to the following:
The Service Intervals and maintenance operations

recommended by Volvo Penta must be followed.
Only Volvo Penta Original Spare Parts intended

for the engine certificates may be used.
Service work on the injection pump and injectors

must always be carried out by an authorized Volvo Penta workshop.
The engine may not be altered or modified in any

way, with the exception of accessories and service kits developed by Volvo Penta for that engine.
No modifications to the exhaust pipes and air

supply ducts for the engine room (ventilation
ducts) may be undertaken as this may effect exhaust emissions.
Any seals on the engine may not be broken other

than by authorized persons.
IMPORTANT! If replacement parts are required,
use only AB Volvo Penta Original Parts.
Use of replacement parts other than AB Volvo Penta Original Parts will result in AB Volvo Penta being unable to assume any liability that the engine
corresponds to the engine certificates variant.
AB Volvo Penta excludes any liability for all and any
type of damage or costs caused by the use of replacement parts that are not Volvo Penta Original Parts
for the product in question.
5
General Information
Group 20
Repair instructions
Introduction
Our joint responsibility
The working methods described in the Workshop

Manual apply to work carried out in a workshop.
The engine has been removed and is installed in
an engine fixture.
Unless otherwise stated reconditioning work that
can be carried out with the engine in place follows
the same working method.
Every engine consists of many systems and components that work together. If one component deviates
from the technical specifications, than this can have
dramatic consequences on the environmental impact,
even if it is otherwise in good running order.
It is therefore critical that the stated wear tolerances
are observed, that systems which can be adjusted are
correctly set up and that only Volvo Penta Original
Parts are used.
All operations described in the Workshop Manual for

which there are Volvo Penta Special Tools available
assume that the service technician or person carrying
out the repair uses these tools.
Volvo Penta Special Tools have been specifically developed to ensure as safe and rational working methods as possible.
Person or persons using other than Volvo Penta Special Tools or approved Volvo Penta working methods
(as described in a Workshop Manual or Service Bulletin). Has the responsibility to acquaint themselves of
the risk of personal injury or actual mechanical damage or malfunction.
In some cases special safety precautions and user instructions may be required in order to use the tools
and chemicals mentioned in the Workshop Manual, always follow these precautions, as there are no specific instructions given in the Workshop Manual.
By following these basic recommendations and using
common sense it is possible, to avoid most of the
risks involved in the work. A clean work place and a
clean engine will eliminate many risks of personal injury and engine malfunction.
Above all when working on the fuel system, lubrication
system, intake system, turbocharger, bearings and
seals. It is extremely important to observe the highest
standards of cleanliness and avoid dirt or foreign objects entering the parts or systems, since this can result in reduced service life or malfunctions.
6
The stated service intervals in the Maintenance Schedule must be followed.

Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance.
Some components are factory sealed for environ-mental and product specific reasons. Dont under no circumstances attempt to service or repair a sealed component, unless it is done by a authorized service technician.
Bear in mind that most chemical products, incorrectly
used, are hazardous to the environment.
AB Volvo Penta recommends the use of biodegradable degreasing agents for all cleaning of engine components, unless otherwise is stated in the Workshop
Manual.
Pay special attention to make sure that oils and washing residue are handled correctly for destruction, and
not end up in the nature.
Group 20
General Information
Tightening torque
Lock nuts
For the correct tightening torque for critical joints,

which must be tightened using a torque wrench is listed under chapter Tightening Torque. For correct
tightening torque, is it important to apply cleaned threads, bolt heads and mating surfaces, with lightly oiled or dry threads. In places where grease, locking or
sealing agents is required for screwed joints, the correct torque is stated in Tightening Torque.
When no tightening torque is stated, use the general
tightening torque, according to the table below.
Dimension
Tightening torque
Do not reuse lock nuts that have been removed during

disassembly operations as these have reduced
service life when reused. Use new nuts when
assembling or reinstalling.
Nm
(lbf.ft.)
M5 ......................................................... 6
(4.4)
M6 ......................................................... 10
(7.4)
M8 ......................................................... 25
M10 ....................................................... 50
(18.4)
(36.9)
M12 ....................................................... 80
(59.0)
M14 ....................................................... 40
(103.3)
Tightening torque with

protractor tightening
(angle tightening)
Tightening using both a torque setting and a protractor
angle requires that first the recommended torque is
applied using a torque wrench and then the recommended angle is added according to the protractor
scale. Example: A 90 protractor tightening means
that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied.
For lock nuts with a plastic insert such as Nylock

the tightening torque stated in the table is reduced if
the Nylock nut has the same head height as a standard hexagonal nut without plastic insert.
Reduce the tightening torque by 25% for bolt size M8
or larger.
If Nylock nuts are higher, or of the same height as a
standard hexagonal nut, the tightening torques given
in the table applies.
Strength classes
Bolts and nuts are divided up into different classes of
strength, the number on the bolt head indicates the
class. A high number indicates stronger material, for
example a bolt marked 10-9 indicates a higher
strength than one marked 8-8.
It is therefore important that bolts removed during the
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint.
When replacing a bolt, check in the spare parts catalogue to make sure the correct bolt is used.
7
General Information
Sealant
It is therefore important that bolts removed during the
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint. When
replacing a bolt, check in the spare parts catalogue to
make sure the correct bolt is used.
To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type
is used on the joint where the agents are required as
described in the Workshop Manual or the Service Bulletin.
During service operations use the same agent or an
alternative.
Make sure that mating surfaces are dry and free from
oil, grease, paint and anticorrosion agent before applying sealant or locking fluid.
Always follow the manufacturers instructions for use
regarding temperature range, curing time and any other instructions for the product.
Two different basic types of agent are used:
RTV agent (Room Temperature Vulcanizing)
Used for gaskets, sealing gasket joints or coating
gaskets. RTV is visible when a part has been
disassembled; old RTV must be removed before
resealing the joint.
Old sealant can be removed using methylated spirits
in all cases.
Anaerobic agents:
These agents cure in an absence of air. They are used when two solid parts, for example cast components,
are installed face-to-face without a gasket. They are
also commonly used to secure plugs, threads in stud
bolts, petcocks, oil pressure switches, and so on.
The cured material is glass like and it is therefore colored to make it visible. Cured anaerobic agents are
extremely resistant to solvents and the old agent cannot be removed. When reinstalling the part is carefully
degreased and then new sealant is applied.
8
Group 20
Safety rules for fluorocarbon

rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings.
When fluorocarbon rubber is subjected to high temperatures (above 300C or 572F), hydrofluoric acid can
be formed, which is highly corrosive.
Skin contact can give severe chemical burns. Splashes in eyes can give severe chemical burns.
Breathing of fumes can be permanently damaged
lungs.
WARNING! Be very careful when working on
engines that have been exposed to high temperatures, e.g. overheating during a seizure or fire.
Seals must never be cut with an oxy-acetylene
torch, or be burned up afterwards in an uncontrolled manner.
Always use gloves made of chloroprene rubber
(gloves for handling chemicals) and protective
goggles.
Handle the removed material like corrosive acid.
All residues, including ash, can be highly corrosive.
Never use compressed air to blow anything clean.
Put the remains in a plastic box which is sealed
and provided with a warning label. Wash the gloves under running water before removing them.
These following seals are probably made out of fluorocarbon rubber:
Seal rings for crankshaft, camshaft, and intermediate shafts.
O-rings irrespective of where they are installed.
O-rings for cylinder liner sealing are usually made
out of fluorocarbon rubber.
Group 20
General Information
Location of identification
plates (420-620, 520-722)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one should be mounted in a suitable location adjacent to the engine.
Identification plates
1.
2.
3.
4.
5.
6.
7.
Engine model
Engine specification number
Engine serial number (10 digits)
Engine output without fan
Rated engine speed
Injection timing and type of camshaft
Manufacturers identification code
8.
9.
10.
11.
12.
13.
Indication of standard and /or regulation

ISO 3046, reference test conditions
ISO 3046, reference test conditions
Injection pump code (EP code)
Piston class
Prime output, without fan, at rated speed
9
General Information
Group 20
Location of identification
plates (TAD650/660, 750/760)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one is mounted up
on the valve cover.
Identification plates
1.
2.
3.
4.
5.
6.
7.
Engine model
Engine specification number
Engine serial number (10 digits)
Engine output, without fan
Rated engine speed
Engine code (linked to EPA/EU Tier III approval)
Rated power, standard (peak power according to
Tier III)
10
8. Air temperature in C (F), in accordance with

ISO 3046
9. Altitude above mean sea level, in accordance with
ISO 3046
10. EU Tier III approval number
Group 20
Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE
Technical Data
TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE
General
Type designation .................................................... TD420VE
TAD420VE
Rotation direction, facing flywheel: ......................... Counterclockwise
Number of cylinders ............................................... 4
4
Bore, mm (inch) ..................................................... 101 (3.97")
101 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96")
126 (4.96")
4.04 (246.5)
Displacement, dm3 (inch3) ....................................... 4.04 (246.5)
Number of valves ................................................... 8
8
Compression ratio:
EPA 1 ................................................................. 19:1
19:1
COM 2 ................................................................ 19:1
19:1
Firing sequence ..................................................... 1-3-4-2
1-3-4-2
Engine performance at 2500 rpm, kW (hp) ............. 75 (102)1, 3)
103 (140)1, 3)
Max torque, Nm (lbf.ft) ........................................... 390 (288)3)
493 (364)3)
At speed, rpm ..................................................... 1500
1500
Low idle, rpm ......................................................... 800
800
Max, full load speed, rpm ....................................... 2000 25001) 2000 25001)
Weight. engine (dry) kg (lb) .................................... 380 (838)2)
380 (838)2)
TAD620VE
6
98 (3.97")
126 (4.96")
5.7 (347.8)
12
18.4:1
18.4:1
1-5-3-6-2-4
155 (209)1, 3)
700 (516)3)
1500
800
2000 25001)
495 (1091)2)
1)
See identification plate for correct specification

Weight according to DIN 70020-A
3)
See General information, Power standards.
2)
11
Group 20
General
Type designation .................................................... TAD650VE
Bore, mm (inch) ..................................................... 101 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96")
Displacement, dm3 (inch3) ....................................... 5.7 (347.8)
Number of valves ................................................... 12
Compression ratio: ................................................. 18.4:1
Firing sequence ..................................................... 1-5-3-6-2-4
Max torque, Nm (lbf.ft) ........................................... 750 (553)3)
At speed, rpm ..................................................... 1600
Low idle, rpm .......................................................... 600-800
Max, full load speed, rpm ....................................... 24001)
Weight. engine (wet) kg (lb) .................................... 585 (1290)2)
1)

3)
2)
Engine block
Cylinder head
Type ...................................................................... Common cylinder head
Max surface unevenness ....................................... 0.1 mm
(0.0039")
Cylinder head bolts

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

TAD620VE, TAD650/660VE ............................... 19 x 108 mm
TAD620VE, TAD650/660VE ............................... 7 x 178 mm
(19 x 4.3")
(7 x 7")
12
TAD660VE
Counterclockwise
6
98 (3.85")
126 (4.96")
5.7 (347.8)
12
18.4:1
1-5-3-6-2-4
147 (200)1, 3)
800 (590)3)
1600
600-800
2400565
565 (1246)2)
585 (1290)2)
Group 20
Cylinder liners
Parent bore
Replaceable, dry
A
TD420VE, TAD420VE
TAD650VE
TAD620,
TAD660VE
Type:
TD420VE/TAD420VE/TAD650VE ....................... Parent bore
TAD620VE/TAD660VE ....................................... Dry, replaceable
Bore:
TD420VE/TAD420VE/TAD650VE ....................... 101+0.02 mm
TAD620VE/TAD660VE ....................................... 98 +0.02 mm
(3.976"+0.00078")
(3.858"+0.00078")
Max bore wear:

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

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

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

TAD620VE/TAD650/TAD660VE .......................... 0.012 0.07 mm
(0.00047" 0.0027")
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: ............................. 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
Group 20
Group 20
Pistons
Number of piston ring grooves ................................ 3
Combustion chamber:
Diameter ......................................................... 610.1 mm
Combustion chamber depth:
TD420VE/TAD420VE .......................................... 180.1 mm
TAD620VE, TAD650/TAD660VE ........................ 17.50.1 mm
Gudgeon pin diameter ........................................ 38-0.006 mm
(2.402"0.0039)
(0.7087"0.0039)
(0.689"0.0039)
(1.496"-0.0002")
Piston front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
Piston rings
Compression rings
Number of rings ..................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ................................. Keystone
Lower compression ring (2) ................................. 0.17 mm
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................. 0.8 mm
Lower compression ring (2) ................................. 2.5 mm
(0.067")
(0.03")
(0.0984")
2
3
Oilscraper ring (3)

Number: ................................................................. 1
Width, including springcoil: ..................................... 3 mm
Piston ring clearance, height: ................................. 0.1 mm
Piston ring gap, wear limit: ..................................... 1.15 mm
(0.12")
(0.0039")
(0.045)
15
Group 20
Valve mechanism
Valves
Disc diameter :
Inlet .................................................................... 41.70.1 mm
Exhaust .............................................................. 35.90.1 mm
Stem diameter :
Inlet .................................................................... 7.98-0.015 mm
Exhaust .............................................................. 7.96-0.015 mm
Valve seat angle:
Inlet, min ............................................................. 29.5
Exhaust, min ....................................................... 44.5
Min 1.8 mm
(1.642"0.004")
(1.413"0.004")
(0.3142"-0.0006")
(0.3134"-0.0006")
Min 1.1 mm
45
30
29.5
44.5
Valve disc edge:

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

Inlet .................................................................... 0.350.05 mm
Exhaust .............................................................. 0.550.05 mm
(0.014"0.002")
(0.022"0.002")
Important! Control and adjusting of valve clearance is done with an engine oil
temperature between 20 80C (68 176F)
16
Group 20
Valve seats
A
B
Outer diameter (A), standard:

Inlet .................................................................... 42.79-0.02 mm
Exhaust .............................................................. 36.99-0.02 mm
Height (B):
Inlet .................................................................... 6.80.1 mm
Exhaust .............................................................. 7.50.1 mm
(1.685"-0.0008")
(1.456"-0.0008")
(0.2677"0.004)
(0.2953"0.004)
Valve seat location

C
R
Diameter (C), standard:

Inlet .................................................................... 42.7-0.025 mm
Exhaust .............................................................. 36.9-0.025 mm
Depth (D):
Inlet/Exhaust ...................................................... 10+1 mm
Seat bottom radius (R):
Inlet/Exhaust ...................................................... 1-0.3 mm
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ...................................................... Min 1.4 mm
(1.681"-0.001")
(1.453"-0.001")
(0.4"+0.04")
(0.04"-0.0118")
(0.055")
Valve guides
Inner diameter :
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: .................................................. 591.9 mm
Wire diameter : .................................................... 40.03 mm
(2.323"0.075")
(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 , bearing journals
Standard ............................................................. 63+0.054 mm
(2.48"+0.0021")
Wear limit ........................................................... 63.08 mm
(2.483")
Camshaft bearing thickness: max .......................... 1.388+0.012 mm (0.05465"+0.0005")
Axial clearance ...................................................... 0.1-0.5 mm
(0.004-0.02")
Radial clearance .................................................... 0.05-0.124 mm (0.002-0.0049")
(0.118"+0.008")
Position of bearing bush at flywheel end ................ 3+0.2 mm
Timing gear
1.
2.
3.
4.
5.
6.
Governor drive (not apply for 650/660)

Idler gear (not apply for 650/660)
Camshaft gear
PTO gear B-C (not apply for 650/660)
PTO gear A (not apply for 650/660)
Crankshaft
Flywheel
Type of flywheel, standard :
TD/TAD420,620,650,660VE ................................ Clutch 10" or 11.5"
Max, permitted axial runout
Measuring radius 150 mm (5.91") ........................ 0.1 mm
(0.004")
Number of teeth on flywheel ................................... 129
18
Group 20
Group 20
Crank mechanism
Crankshaft length:
TD420VE/TAD420VE .......................................... 618.8 mm
TAD620VE, TAD650/TAD660VE ........................ 846.8 mm
Crankshaft axial clearance1) ................................... 0.1-0.3 mm
Main bearing radial clearance1) ............................... 0.03+0.062 mm
Max, permissible ovality of main
bearing and crank pins ........................................ 0.01 mm
Max, run-out of center bearing: .............................. 0.1 mm
1)
(24.36")
(33.34")
(0.0039" 0.0118")
(0.0012"+0.0024")
(0.0004")
(0.0039"
Important! The dimensions apply to oiled parts
E
F
C
B
A
Main bearing journals

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

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

Diameter for machining (G):
Standard ................................................................ 62.994-0.02 mm
Undersize:
0.25 mm (0.01") .................................................. 62.744-0.02 mm
Width, axial bearing journal (H): . ............................ 35.70.02 mm
Connecting rod-bearing journals:
Out-of-round: Max. .............................................. 0.01 mm
Taper: Max ......................................................... 0.01 mm
(2.48"-0.0008)
(2.4714"-0.0008)
(1.4"0.0008")
(0.0004")
(0.0004")
H
G
Connecting rod bearing shells

Innerdiameter , bearing (J): .................................. 63.026+0.039 mm
Oversize:
0.25 mm (0.01") .................................................. 62.724+0.02 mm
Thickness (K): Standard ........................................ 1.777+0.01 mm
Inside bore .......................................................... 66.6+0.02 mm
20
(2.442"+0.00154)
(2.4716"+0.00079)
(0.06996+0.0004)
(2.622"0.0008")
Group 20
Group 20
Connecting rods
Length (L): Center Center .................................... 1920.02 mm
(7.559"-0.0008)
+0.01
mm (1.497"+0.0004)
Connecting rod bushing bore (M): ........................... 38.025
Wear limit ............................................................ 0.08 mm
(0.0031")
L
M
Axial clearance, connecting rod crankshaft1) ....... 0.2-0.3 mm

Connecting rod bearing: radial clearance1) .............. 0.03-0.09 mm
Parallelism: Tolerans
Over a length of 100 mm ..................................... 0.05 mm
Squareness: Tolerans
Over a length of 100 mm .................................... 0.05 mm
1)
(0.00787"-0.0118")
(0.00118"-0.00354")
(0.002")
(0.002")
Important! The dimensions apply to oiled parts.
Connecting rod marking:

Connecting rod and cap number marking must be on one side and identical.
21
Group 20
Lubricating system
Oil grade2)
Fuel sulfur content in percent by weight

Up to 0.5 %
0.5 1 %
1)
More than 1 %
Oil change interval: In operation whichever reached first

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

ACEA = Association des Constructeurs Europenne dAutomobiles
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
Group 20
Engine oil quantity

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

Oil pressure, at operation temperature, min 120C (248F)
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 ................................................ 25050 kPa
(357 psi)
8.By-pass valve oil cooler:
(30.54 psi)
9. Safety valve, opening pressure:
TD420VE/TAD420VE .......................................... 60075 kPa
(8710.7 psi)
TD620VE, TAD650/TAD660VE ........................... 40040 kPa
(582 psi)
10. Lube oil pump
Type ...................................................................... Rotary pump driven by the crankshaft
Rotary pump width:
TD420VE/TAD420VE .......................................... 12.3 mm
(0.48")
TD620VE, TAD650/TAD660VE ........................... 16.5 mm
(0.65")
Oil flow (2500 rpm)
TD420VE/TAD420VE .......................................... 65 l/min
(17 US gal/hour)
TD620VE, TAD650/TAD660VE ........................... 90 l/min
(24 US gal/hour)
11. Oil cooler
Normal oil temperature: .......................................... 80C
(176F)
Max oil temperature: .............................................. 125C
(257F)
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)
2)
Depending on length of hose.

Used for bleeding.
24
Group 20
Group 20
Fuel system (650, 660)
1.
2.
3.
4.
5.
6.
7.
Fuel tank
Hand pump (accessory)
Fuel line (to pump)
Fuel pump
Fuel filter
Pipe to highpressure
Rail
8.
9.
10.
11.
12.
13.
Highpressure pump
Fuelpipe, to injector
Injector
M-prop
Pressurevalve
Return fuel line, to fuel tank, A = Fuel pipes,
minimum distance 300 mm (11.8")
25
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 23%.
In
Out
Fuel feed pump

Fuel system figures are corresponding to the picture above.
1. Overpressure relief valve:
Opening pressure ................................................ 0.60.05 MPa
2. Bypass valve:
Fuel flow:
Min fuel flow at 1500 rpm. ...................................... 600 l/hour
Firing sequence
TD420VE/TAD420VE .......................................... 1-3-4-2
TAD620VE/TAD650VE/TAD660VE ..................... 1-5-3-6-2-4
Feed pressure ........................................................ 0.5 MPa
Feed pressure after fuel filter
At 1500 rpm: Min ................................................ 0.28 MPa
26
(877 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
Group 20
Injection pump (420,620)

Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing of
the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this is
called A/100.
The pump length is defined by adding the basic measurement LO
with the tolerance A/100, that are written on the injection pump
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering fuel.
LO = Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 117.5 + 0.63
The total length LFB = 118.13
Injection pump (420, 620)

Manufacturer .......................................................... Bosch
Designation ............................................................ PF 33
Length A: ............................................................... 59 mm
Basic measurement length LO : .............................. 117.5 mm
Min length mm LFB : (A/100+117.5) 117.5 ............ >0
(2.3")
(4.6")
Injectors
Opening pressure:
TD420VE ............................................................ 22 MPa
TAD420VE/TAD620VE ....................................... 25 MPa
Max pressure: ........................................................ 160 MPa
Check leakage (for 10 sek):
TD420VE ............................................................ 20 MPa
TAD420VE/TAD620VE ....................................... 23 MPa
Numbers/bore :
TD420VE ............................................................ 6 x 0.205 mm
TAD420VE/TAD620VE ....................................... 6 x 0.203 mm
(3190 psi)
(3630 psi)
(23200 psi)
(2900 psi)
(3340 psi)
(6 x 0.008")
(6 x 0.0079")
Fuel filter
Filtering size: ......................................................... 0.005 mm
(0.0002")
Pre-filter
(0.00024")
27
Group 20
Commencement of delivery (FB) 420/620

The engine is equipped with a separate injection pump for each cylinder. This means that the commencement of delivery (FB), when
necessary, has to be adjusted separate for each pump unit. The
commencement of delivery (FB) is adjusted with a shim, placed
between lifter and injection pump.
For exchange of injection pump without any parts of vital importance has been replaced, see chapter EP code.
For renovation or when any parts of vital importance have been replaced, special tools (999 8685 and 999 8679) must be used, to be
able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is indicated on the identification plate, see General information,
Identification plate. When calculating the shim thickness, apply
a mathematical formula, see Theoretical thickness for shim,
where some values are from table 1 and other are measured on the
engine. For complete instruction, see Workshop Manual.
Table 1, Commencement of delivery

All measurements are in mm (1 mm = 0.0394")
FB
(Commencement of
delivery)
Camshaft
types
28
Vh
Vhcorr.factor
Lo
Pre-stroke
Pre-stroke
correction factor
Basic dimension
Injection pump
Grupp 20
Tekniska data
Theoretical thickness for a new shim (420/620)

Computation for determining the theoretical shim thickness (TS) :
TS= L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm)
The correction factor Vhcorr.factor is taken from the table on previous page.
The individual steps:
1st step: E1 = FBactual - FBnom (C/A)
2nd step: E2 = E1 x Vhcorr.factor (mm/C/A)

3rd step: E3 = E2 + Vhnom
4th step: E4 = E3 + LO
5th step: E5 = E4 + A/100 (mm)
6th step: TS = L E5
7th step: The actual shim thickness (SS) is determined with the help of table 2.
Table 2, Shim thickness

Theor. thickness
(TS)
Shim thickness (SS)
Theor. thickness(TS)
Shim thickness (SS)
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm.
When the theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim
thickness (Ss). Important! Use only one shim at the time.
29
Group 20
How to use EP code (420/620)

For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified method, when there is only the tolerance between the new and old injection pump that is the difference.
TS = EK - (LO + A/100)
TS = Shim thickness
EK = Value from tabel 3 read with help of EP code from Identification plate.
LO = Basic measurement for the injection pumps, 420/620 = 117.5 mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and with
help of this value it is possible to read the new EK value with help of table 3.
If read EP code is 275 that gives a EK value of 120.375 and if the manufacturing tolerance for the new injection
pump is 63 we will have following equation: TS = 120.375 (117.5 + 0.63)
TS are in this case 2.245 and a control in table 2 gives: SS = 2.3 mm
Thickness on the new shim to be mounted is in this example will be 2.3 mm
Table 3, EP code conversion table

Ek(mm)
EP code
Ek(mm)
30
EP code
Ek(mm)
EP code
Ek(mm)
EP code
Group 20
Governor (420/620)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer .......................................................... Heinzmann
Designation:
TD420VE/TAD420VE/TAD620VE: ...................... 2500 rpm
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
Control rod (fuel rack) travel Y, with injection pumps
Min: ....................................................................... 16.8 mm
The recess dimension X ........................................ 0.3 1.3 mm
(0.67" 0.69")
(0.66")
(0.012" 0.051")
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
Group 20
Intake and exhaust system

Turbocharger
Make and designation ............................................ Schwitzer S200
Boost pressure at rated speed1), 10 %:
TD420VE ............................................................ 105 kPa
(15.2 psi)
TAD420VE .......................................................... 143 kPa
(20.7 psi)
TAD620VE,TAD650VE,TAD660VE ..................... 155 kPa
(22.5 psi)
Lube system .......................................................... Pressure lubrication
Max, permitted radial clearance
(compressor side) ............................................... 0.88 mm
(0.0346")
Max, permitted axial clearance .............................. 0.1 mm
(0.0039")
Max allowed back pressure in exhaust line ............ 7.5 kPa
(0.9 psi)
Exhaust gas temperatur, approx:

At engine speed1): .................................................. 1800 rpm
TD420VE ............................................................ 555C
(1031F)
TAD420VE .......................................................... 490C
(914F)
TAD620VE,TAD650VE,TAD660VE ..................... 485C
(905F)
1)
2100 rpm
540C
(1004F)
470C
(878F)
465C
(869F)
2300 rpm
540C
(1004F)
475C
(887F)
460C
(860F)
2500 rpm
540C
(1004F)
475C
(887F)
455C
(851F)
Air intake
Air intake restriction, clean filter ............................. 2.5 kPa
Max allowed air intake restriction ........................... 6.5 kPa
(0.3 psi)
(0.9 psi)
Cooling system
Type ...................................................................... Pressurized, closed
Pressure valve opens at max2) ............................ 90 kPa
(13 psi)
2)
Versatile engines are not equipped with a pressure valve from factory
Capacity, engine:
TD420VE/TAD420VE .......................................... 4.7 liters
(1.24 US gal)
TAD620VE,TAD650VE,TAD660VE ..................... 6 liters
(1.58 US gal)
Thermostat:
Type ...................................................................... One piston thermostat
Begins to open at ................................................... 83C
(181F)
Fully open at .......................................................... 95C
(203F)
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
Group 20
Tightening torque
General tightening torques
Nm
1.5
M6 standard screw 8.8 ........................................... 10

M8 standard screw 8.8 ........................................... 254
M10 standard screw 8.8 ......................................... 508
M12 standard screw 8.8 ......................................... 809
M14 standard screw 8.8 ......................................... 14025
Tightening torques
Nm
(lbf.ft)
(7.51 lbf.ft)
(183 lbf.ft)
(376 lbf.ft)
(596.5 lbf.ft)
(10318 lbf.ft)
(lbf.ft)
Group 21 Engine
Engine mounting .................................................... 260
Starter motor .......................................................... 70
Timing gear casing ................................................. 212
(192lbf.ft)
(51.6 lbf.ft)
(15.51.5 lbf.ft)
Main bearing caps

Screws to main bearing caps are reusable only three times.
Step 1 .................................................................... 50
Step 2 .................................................................... 90 angle tightening
(37 lbf.ft)
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
Step 2: ................................................................... 60 angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................... 20 30
C) Flywheel with a screw length between 50 85 mm
Step 1: ................................................................... 30 40
Flywheel housing, M12 ........................................... 991
Flywheel housing, M16 ........................................... 24325
(15 22 lbf.ft)
(15 22 lbf.ft)
(22 30 lbf.ft)
(737 lbf.ft)
(17918 lbf.ft)
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ................................................................... 40 50
Vibration damper .................................................... 70
Screw, rocker cover ............................................... 91
Lock nut, valve clearance adjusting screw ............. 202
Screws, rocker arm fixing ...................................... 21
Screws, crankcase ventilation ................................ 91
(30 37 lbf.ft)
(51.6 lbf.ft)
(6.50.7 lbf.ft)
(14.51.5 lbf.ft)
(15.5 lbf.ft)
(6.60.7 lbf.ft)
33
Tightening torques
Nm
Group 20
(lbf.ft)
Cylinder head
Screws to cylinder head are reusable only three times.
Step 1: ................................................................... 30
Step 2: ................................................................... 80
(22 lbf.ft)
(59 lbf.ft)
Group 22 Oil system

Oil cooler, screws .................................................. 212
Oil cooler, screw plug ............................................. 80
Front/oil pump housing ........................................... 212
Oil suction pipe ...................................................... 212
Oil sump ................................................................ 212
Oil pressure pipe turbo ........................................... 293
Oil pressure pipe engine block ............................... 394
Screws, oil return pipe turbo
A) with tube fitting ............................................... 402
B) with flange fitting ............................................ 212
Screws, oil return pipe engine block ....................... 212
Oil pressure switch ................................................ 182
(15.51.5 lbf.ft)
(59 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(21.42.2 lbf.ft)
(293 lbf.ft)
(29.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(131.5 lbf.ft)
Group 23 Fuel system

Screw, governor, idler gear (420/620):
Step 1: ................................................................... 30
Screw, control rod hose ......................................... 102
Screw, governor ..................................................... 171.5
Flange screws, Injection pump
Step 1: Torque ....................................................... 5
Step 2: Loosen screws for injection pump flange ... 60 counterclockwise
Step 3: Turn injection pump to stop ....................... Counterclockwise
Step 5: ................................................................... 7
Step 6: ................................................................... 10
Step 7: ................................................................... 30
Flange screw, injector ............................................ 16+5
Injector cap nut ...................................................... 40 50
Delivery pipe
(22.1 lbf.ft)
(75 lbf.ft)
(12.51 lbf.ft)
(3.7 lbf.ft)
(5 lbf.ft)
(7.4 lbf.ft)
(22 lbf.ft)
(12+4 lbf.ft)
(30 37 lbf.ft)
Use a new delivery pipe after every disassembly
Step 1: ................................................................... 5
Step 2: ................................................................... 253.5
Screw, stop magnet ............................................... 21
Overflow valve ....................................................... 30
Common Rail, TAD650/660
Safety valve ........................................................ 100
Rail pressuree sensor ......................................... 70
Common rail unit ................................................. 30
Fuel hose ............................................................ 39
IEGR, TAD650/660
IEGR-unit: ........................................................... 20
Solenoid valve: ................................................... 24
Highpressure fuel pump, TAD650/660
Step 1: ................................................................ 10
Step 2: ................................................................ 50
34
(3.7 lbf.ft)
(18.42.6 lbf.ft)
(15.5 lbf.ft)
(22 lbf.ft)
(74 lbf.ft)
(51.6 lbf.ft)
(22.1 lbf.ft)
(293 lbf.ft)
(14.5 lbf.ft)
(18 lbf.ft)
(7.4 lbf.ft)
(37 lbf.ft)
Group 20
Tightening torques
Nm
(lbf.ft)
Group 25 Inlet and exhaust system

Exhaust manifold nuts ........................................... 252.5
M8 Nuts, turbo to exhaust manifold ....................... 212
M10 Nuts, turbo to exhaust manifold ...................... 40.54
Screws, Inlet manifold ............................................ 111
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)
Group 26 Cooling system

Thermostat housing ............................................... 30
Water temp sensor ................................................. 212
Water pump ........................................................... 212
(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 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
Rotation direction, facing flywheel: ....................... Counterclockwise
Number of cylinders .............................................. 4
4
Bore, mm (inch) .................................................... 108 (4.25")
108 (4.25")
Stroke, mm (inch) ................................................. 130 (5.12")
130 (5.12")
Displacement, dm3 ( inch3) .................................... 4.76 (290)
4.76 (290)
Number of valves ................................................. 8
8
Compression ratio: ............................................... 17.5:1
17.5:1
Firing sequence ................................................... 1-3-4-2
1-3-4-2
Engine performance:
At 1500 rpm, kW (hp) ........................................ 77.5 (104)1, 3)
94 (126)1, 3)
At 1800 rpm, kW (hp) ........................................ 81.5 (109)1, 3)
101 (135.5)1, 3)
At 2300 rpm, kW (hp) ........................................
Engine torque, Nm ( lbf.ft) ..................................... 493 (394)3)

598 (441)3)
At speed, rpm .................................................... 1500
1500
536 (395)3)
Engine torque, Nm ( lbf.ft) ..................................... 432 (319)3)
At speed, rpm .................................................... 1800
1800
Max speed at full load, rpm ................................... 1500/18001)
1500/18001)
Weight engine (dry) kg (lb) ................................... 550 (1213)2)
575 (1268)2, 5)
Weight engine (wet) .............................................. 580 (1279)2)
725 (1336)2, 6)
1)
See identification plate for specification

3)
Measured at Prime Power, see General information, Power standards.
4)
5)
Extra weight on TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
6)
Including clutch and frame
2)
36
606 (1336)2, 5)
TD520VE
TAD520VE
4
108 (4.25")
130 (5.12")
4.76 (290)
8
18.4:1
1-3-4-2
4
108 (4.25")
130 (5.12")
4.76 (290)
8
18.1:1
1-3-4-2
81 (110)1, 4)
430 (317)4)
1800
18001)
430 (948)2)
118 (158)1, 4)
577 (425)4)
1400
2000 23001)
432 (952)2)
Group 20
General
Type designation ..............................................
Direction of rotation (seen from flywheel)
No. of cylinders ................................................
Cylinder bore mm (inch) ...................................
Stroke mm (inch) .............................................
Cylinder volume liter (inch 3 ) .............................
No. of valves ....................................................
Compression ratio:
EPA1 ............................................................
EPA2 ............................................................
EU2 ..............................................................
Injection sequence ...........................................
Engine power:
At 1500 rpm kW (hp) .....................................
At 1800 rpm kW (hp) .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Torque Nm (lbf.ft) .............................................
At engine speed rpm .....................................
Low idle rpm .....................................................
Highest full load speed rpm ..............................
Weight, dry (lb) .................................................
Gross weight, dry (lb)
1)
2)
3)
4)
TAD530GE
Anti- clockwise
4
108 (4.25)
130 (5.12)
4.76 (290)
8
TAD531GE
Anti- clockwise
4
108 (4.25)
130 (5.12)
4.76 (290)
8
TAD532GE
Anti- clockwise
4
108 (4.25)
130 (5.12)
4.76 (290)
8
18.0:1
1-3-4-2
18.0:1
1-3-4-2
1-3-4-2
89 (139)1)
95 (150)1)
567 (479)
1500
504 (430)
1800
800 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
102 (139)1)
110 (150)1)
649 (479)
1500
584 (430)
1800
800 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
129 (139)1)
136 (150)1)
821 (479)
1500
722 (430)
1800
800 950
1500/1800 1)
575 (1268) 2,3)
606 (1336) 2,3)
18.0:1
See engine plate for specifications.

Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
Engine block
Cylinder liners
Replacable, wet
Cylinder head
A
Type: ........................................ Common cylinder head

Max surface unevenness: ......... 0.085 mm
(0.00335")
Cylinder head bolts

Thread size: .............................. M 14
Quantity and length: .................. 18 x 141 mm
( 18 x 5.55")
TD520GE/TAD520GE
TD520VE/TAD520VE
TAD530/531/532GE
Type: .................................................................... Wet, replaceable
Number of seals per liner: ..................................... 2
Bore: ..................................................................... 108+0.02 mm
(4.252"+0.0008")
Max bore wear: ..................................................... 108.1 mm
(4.256")
Height sealing surface (A): .................................... 9-0.02 mm
(0.3543"-0.0008")
+0.03
Liner collar seating depth in block: ........................ 8.92
mm
(0,3512"+0.0012")
Projection of liner above block surface: ................. 0.03 0.08 mm (0.0012" 0.0031")
37
Group 20

Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
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: ........................... 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
Group 20
Pistons
Number of piston ring grooves .............................. 3
Combustion chamber:
Diameter ............................................................ 710.1 mm
Depth ................................................................. 16.660.1 mm
Gudgeon pin diameter .......................................... 42 -0.006
(2.795"0.0039")
(0.6559"0.0039")
(1.6535"-0.0002")
Piston rings
Compression rings
Number of rings .................................................... 2
Upper compression ring (1) ............................... Keystone, no clearance
Lower compression ring (2) ............................... 0.17 mm
(0.067")
Upper compression ring (1) ............................... 0.8 mm
(0.03")
Lower compression ring (2) ............................... 2.5 mm
(0.0984")
2
3
Oilscraper ring (3)

Number: ................................................................ 1
Width, including springcoil: ................................... 3 mm
Piston ring clearance in groove: ........................... 0.1 mm
Piston ring gap, wear limit: .................................... 1.15 mm
(0.12")
(0.0039")
(0.045")
39
Group 20
Valve mechanism
Valves
Disc diameter :
Inlet ................................................................... 480.1 mm
Exhaust ............................................................. 420.1 mm
Stem diameter :
Inlet ................................................................... 8.98-0.015 mm
Exhaust ............................................................. 8.96-0.015 mm
Valve seat angle:
Inlet, min ............................................................ 29.5
Exhaust, min ...................................................... 44.5
Min 2.1 mm
(1.8898"0.0039")
(1.6535"0.0039")
(0.3535"-0.0006")
(0.3528"-0.0006")
Min 1.8 mm
45
30
29.5
44.5
Valve disc edge:

Inlet, min ............................................................ 2.1 mm
Exhaust, min ...................................................... 1.8 mm
Inlet ................................................................... 30
Exhaust ............................................................. 45
Inlet ................................................................... 2.8 mm
Exhaust ............................................................. 2.2 mm
(0.0827")
(0.0709")
(0.1102")
(0.0866")
Valve clearance:
Inlet ................................................................... 0.350.05mm
Exhaust ............................................................. 0.550.05mm
(0.014"0.002")
(0.022"0.002")
Important! Control and adjusting of valve clearance is done with an engine oil
temperature between 20 80C (68 176F)
Valve seats
A
B
Inlet ................................................................... 49.09-0.02 mm
Exhaust ............................................................. 43.06-0.02 mm
Height (B):
Inlet ................................................................... 7.50.1 mm
Exhaust ............................................................. 7.90.1 mm
40
(1.933"-0.0008")
(1.717"-0.0008")
(0.295"0.004")
(0.311"0.004")
Group 20
Valve seat location

C

Inlet ................................................................... 49+0.025 mm
Exhaust ............................................................. 43.5+0.025 mm
Depth (D):
Inlet/Exhaust ...................................................... 11+1 mm
Inlet/Exhaust ...................................................... 1-0.3 mm
Inlet/Exhaust ...................................................... Min 1.5 mm
(1.929"-0.001")
(1.712"-0.001")
(0.43"+0.04")
(0.04"-0.012")
(0.059")
Valve guides
Length:
Inlet/Exhaust ...................................................... 63-0.5 mm
Inner diameter :
Inlet/Exhaust ...................................................... 9.0259.04 mm
Height above cylinder head spring surface:
Inlet/Exhaust ...................................................... 23-0.5 mm
Inlet ................................................................... 0.1 mm
Exhaust ............................................................. 0.13 mm
Design 1
without flange
(2.48"-0.02")
(0.35530.3559")
(0.9"-0.02")
(0.039")
(0.51")
Design 1
with flange
Design 2
O-ring
Flange
On later models the o-ring seal is exchange to a valve

stem sealing, according to the picture for design 2.
Production
Exchange
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 ................................... 64.71.3 mm
Wire diameter ................................................... 4.5 mm
(2.55"0.05")
(0.18")
41
Group 20
Camshaft
Type of camshaft: ................................................. A
Drive ..................................................................... Gear
Number of bearings .............................................. 5
Standard ............................................................ 65+0.054 mm
Wear limit .......................................................... 65.08 mm
Camshaft bearing thickness: max ......................... 1.988+0.12 mm
Axial clearance ..................................................... 0.10.5 mm
Radial clearance ................................................... 0.050.124 mm
Position of bearing bush at flywheel end ............... 2+0.5 mm
(2.559"+0.0021")
(2.5622")
(0.7827"+0.0005")
(0.0040.02")
(0.0020.0049")
(0.079"+0.0197")
Timing gear
1.
2.
3.
4.
5.
6.
Governor drive
Idler gear
Camshaft gear
PTO gear B-C
PTO gear A
Crankshaft
Flywheel
Type of flywheel :
TD520VE/TAD520VE ........................................ Clutch 10" or 11.5"
TD520GE/TAD530-532GE ................................. Gen set 1500 rpm
TD520GE/TAD520GE, TAD530-532GE .............. Gen set 1800 rpm
Max, permitted axial runout
Measuring radius 150 mm (5.91") ...................... 0.1 mm
(0.00394")
Number of teeth on flywheel ................................. 129
42
Group 20
Crank mechanism
Crankshaft length ................................................. 709.2 mm
Crankshaft axial clearance1) ................................. 0.1 0.3 mm
Main bearing radial clearance1) ............................. 0.03+0.062 mm
bearing and crank pins ...................................... 0.01 mm
Max, run-out of center bearing .............................. 0.07 mm
1)
(27.92")
(0.0039" 0.0118")
(0.0012"+0.0024")
(0.0004")
(0.0027")
E
F
C
B
A

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

Type ..................................................................... Replaceable
Outer diameter (E) ............................................ 85.03+0.036 mm
Thickness (F): Standard ....................................... 2.727+0.008 mm
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm
0.5 mm (0.02") ................................................... 2.977+0.008 mm
(2.9035"+0.0014")
(0.1074"+0.0003")
(0.1123"+0.0003")
(0.1172"+0.0003")
43
Group 20

Diameter (G) for machining:
Standard ............................................................... 68-0.02 mm
Undersize:
0.25 mm (0.01") ................................................. 67.75-0.02 mm
0.5 mm (0.02") ................................................... 67.5-0.02 mm
Width (H), axial bearing journal. ............................ 35.50.04 mm
Out-of-round: Max. ............................................ 0.01 mm
Taper: Max ........................................................ 0.01 mm
(2.6772"-0.0008")
(2.6673"-0.0008")
(2.6575"-0.0008")
(1.397"0.0016")
(0.0004")
(0.0004")
H
G
K

Diameter (J): Bearing ....................................... 68.03+0.04 mm
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm
0.5 mm (0.02") ................................................... 67.53+0.04 mm
Diameter : Bearing shell ..................................... 72.5+0.05 mm
Thickness (K): Standard ....................................... 2.222+0.01 mm
44
(2.6783"+0.0016")
(2.6685"+0.0016")
(2.6587"+0.0016")
(2.854"+0.002")
(0.0875"-0.0004")
Group 20
Connecting rods
Length (L): Center Center .................................. 2100.06 mm
Connecting rod (M) bushing bore ......................... 42.04+0.01 mm
Wear limit .......................................................... 0.08 mm
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5+0.02 mm
Small end bush outer diameter .......................... 45.58+0.04 mm
(8.2677"0.00236")
(1.6551"0.0004")
(0.0031")
(1.7913"0.0008")
(1.7945"+0.0016")
L
M
Axial clearance, connecting rod crankshaft1) ...... 0.3 0.4 mm

Connecting rod bearing: radial clearance1) ............ 0.036+0.06 mm
Over a length of 100 mm ................................... 0.05 mm
Over a length of 100 mm ................................... 0.05 mm
1)
(0.0118 0.0157")
(0.00142"+0.0024")
(0.002")
(0.002")
The dimensions apply to oiled parts
Connecting rod marking:

Connecting rod and cap number marking must be on one side
and identical
45
Group 20
Lubricating system
Oil grade2)
Fuel sulfur content in percent by weight

Up to 0.5 %
0.5 1 %
More than 1 %
1)
Oil change interval: In operation whichever reached first

VDS-3, VDS-2
ACEA: E7, E5, E3
1)
2)
500 hours or months
250 hours or months
125 hours or months
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
requirements above.

Viscosity
table.
46
Group 20
Engine oil quantity

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

At rated speed:
TD520GE/TAD520GE/TAD530-532GE (1500 rpm): . 280 kPa
(40.6 psi)
TD520GE/TAD720GE/TAD530-532GE (1800 rpm): 330 kPa
(47.9 psi)
TD520VE: .......................................................... 440 kPa
(63.8 psi)
TAD520VE: ....................................................... 390 kPa
(56.6 psi)
Idle speed (800 rpm), min: .................................... 90 kPa
(13.1 psi)
Shut down switch, at pressure lower than:
TD520GE/TAD520GE: ...................................... 200 kPa
(29 psi)
TD520VE/TAD520VE: ....................................... 50kPa
(7.2 psi)
4. Rocker arm
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: .............................................. 25050 kPa
(357 psi)
8. Pressure regulating valve:
Opening pressure: .............................................. 40040 kPa
(586 psi)
9. Pressure-relief valve:
Opening pressure: ............................................. 10.1 MPa
(14514 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: ......................................... 80C
(176F)
Max oil temperature: .............................................. 125C
(257F)
47
Fuel system
1. Fuel tank.
3. Fuel pump
5. Fuel filter
7. Injection pumps, 420/520 (4) 620/720/721 (6)
9. Injector
11. Overflow valve 2)
1)
2)
Depending on length of hose

Can also be used as an air ventilation screw
48
Group 20
Group 20
Fuel specification
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
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 23%.
In
Out
Fuel feed pump

Fuel system figures is corresponding to the picture above
1. Overpressure relief valve:
Opening pressure ............................................... 0.60.05 MPa
2. Bypass valve
Opening pressure ............................................... 505 kPa
Fuel flow
Min fuel flow at 1500 rpm ....................................... 600 l/tim
Firing sequence .................................................... 1-3-4-2
Feed pressure ....................................................... 0.5 MPa
Feed pressure after fuel filter
1500 rpm: Min .................................................... 0.28 MPa
(877 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
49
Group 20
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 injection
pump (LFB = LO + A/100).
Explanation:
LFB= The exact point when injection pumps starts delivering fuel.
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
This gives us the equation: LFB = 143 + 0.63
Injection pump
Manufacturer ........................................................ Bosch
Designation .......................................................... PF 33 L
Length A: .............................................................. 54 mm
Basic measurement length LO : ............................ 143 mm
Min length LFB : (A/100+143) 143 ....................... >0 mm
50
(2.12")
(5.63")
Group 20
Injectors
Opening pressure:
TD520GE, TAD530-532GE: ............................... 25 MPa
TAD520GE/TD520VE/TAD520VE: .................... 27.5 MPa
Max pressure ........................................................ 120 MPa
Check leakage (for 10 min):
TD520GE, TAD530-532GE: ............................... 23 MPa
TAD520GE/TD520VE/TAD520VE: .................... 25.5 MPa
Numbers/bore :
TD520GE, TAD530-532GE ................................ 5 x 0.234 mm
TAD520GE/TD520VE/TAD520VE: ..................... 5 x 0.25 mm
(3600 psi)
(4000 psi)
(17400 psi)
(3340 psi)
(3700 psi)
(0.00921")
(0.00984")
Fuel filter
Filtering size ......................................................... 0.005 mm
(0.0002")
Pre-filter
(0.00024")
Commencement of delivery (FB)

The engine is equipped with a separate injection pump for each cylinder. This means that the commencement of
delivery (FB), when necessary, has to be adjusted separate for each pump unit. The commencement of delivery
(FB) is adjusted with a shim, placed between lifter and injection pump.
For exchange of injection pump without any parts of vital importance has been replaced, see chapter EP code.
For renovation or when any parts of vital importance have been replaced, special tools (999 8685 and 999 8679)
must be used, to be able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is indicated on the identification plate, see General
information, Identification plate. When calculating the shim thickness, apply a mathematical formula, see
Theoretical thickness for shim, where some values are from table 1 and other are measured on the engine.
For complete instruction, see Workshop Manual.
Table 1 (Commencement of delivery)

FB
(Commencement of
delivery)
Camshaft
types
Vh
Pre-stroke
Vhcorr.factor
Lo
Pre-stroke
Basic dimension
correction factor Injection pump
51
Group 20
Theoretical thickness for a new shim.

Computation for determining the theoretical shim thickness (Ts) :
Ts = L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm)

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 (TS)
Shim thickness (SS)
Shim thickness (SS)
52
Group 20
How to use EP code

TS = EK - (LO + A/100)
TS = Shim thickness
Example:
pump is 63 we will have following equation: TS = 146.675 (143 + 0.63)
TS are in this case 3.045 and a control in table 2 gives: SS = 3 mm
Thickness on the new shim to be mounted is in this example will be 3 mm

Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
53
Group 20
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
Control rod
Start and stop: ...................................................... 17 17.5 mm
Min: ...................................................................... 16.8 mm
The recess dimension X ....................................... 0.3 1.3 mm
(0.67" 0.69")
(0.66")
(0.012" 0.051")
54
Group 20

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

At rated speed (standby power)1) : ......................... 1500 rpm
TD520GE/TAD530GE: ....................................... 610C (1130F)
TAD520GE/TAD531GE, TAD532GE: ................. 520C (968F)
At rated speed: ..................................................... 1800 rpm
TD520VE: .......................................................... 510C (950F)
TAD520VE: ........................................................ 475C (887F)
1)
2)
1800 rpm
530C (986F)
448C (838F)
2100 rpm
470C (878F)
2200 rpm
470C (878F)
2300 rpm
470C (878F)
See in General information, Power standards.

Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD520VE/TAD520VE: ....................................... 2.5 kPa
TD520GE/TAD520GE/TAD530-532GE: .............. 1 kPa
Max allowed air intake restriction
TD520VE/TAD520VE: ....................................... 6.5 kPa
TD520GE/TAD520GE/TAD530-532GE: .............. 3 kPa
(0.36 psi)
(0.14 psi)
(0.94 psi)
(0.43 psi)
55
Group 20
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD520GE/TAD520GE/TAD530/531GE ............... 90 kPa
(13 psi)
TD520VE/TAD520VE, max: ............................... 90 kPa1)
(13 psi)
TAD532GE: ....................................................... 60 kPa
(8.7 psi)
1)
Capacity (engine): ................................................ 7.2 liters

(1.9 US gal)
Capacity (engine and cooler):
TD520GE, TAD530/531GE: ............................... 17.5 liters
(4.62 US gal)
TAD520GE: ....................................................... 19.7 liters
(5.2 US gal)
TAD532GE: ....................................................... 23.8 liters
(6.3 US gal)
Thermostat
Type ...................................................................... One piston thermostat
Begins to open at
TD520GE/TAD520GE/TD520VE/TAD530/531GE: 83C
(181F)
TAD520VE: ....................................................... 87 C
(189 F)
Fully open at
(203F)
TAD520VE: ........................................................ 102C
(216 F)
1.
2.
3.
4.
5.
6.
7.
Coolan connection (inlet)

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

If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
56
Group 20
Tightening torque
Nm
1.5
(lbf.ft)
M6 standard screw 8.8 .......................................... 10

M8 standard screw 8.8 .......................................... 254
M10 standard screw 8.8 ........................................ 508
M12 standard screw 8.8 ........................................ 809
M14 standard screw 8.8 ........................................ 14025
(7.51 lbf.ft)
(183 lbf.ft)
(376 lbf.ft)
(596.5 lbf.ft)
(10318 lbf.ft)
Tightening torques
(lbf.ft)
Nm
Group 21 Engine
Engine mounting ................................................... 260
Starter motor ........................................................ 70
Timing gear casing ............................................... 212
(192lbf.ft)
(51.6 lbf.ft)
(15.51.5 lbf.ft)
Main bearing caps

Step 1 ................................................................ 50
(37 lbf.ft)
Step 2 ................................................................. 60 angle tightening
Connecting rod big-end bearing
Step 1 ................................................................ 50
(22 lbf.ft)
Step 2 ................................................................ 60 angle tightening
Flywheel
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 1: ............................................................... 30 40
(22 30 lbf.ft)
Flywheel housing. M12 ......................................... 991
(737 lbf.ft)
25
(17918 lbf.ft)
Flywheel housing. M16 ......................................... 243
V-belt pulley
Step 1: ............................................................... 40 50
(30 37 lbf.ft)
Vibration damper .................................................. 70
Screw, rocker cover ............................................... 91
(6.50.7 lbf.ft)
Lock nut, valve clearance adjusting screw ............ 202
(14.51.5 lbf.ft)
Screws, rocker arm fixing ..................................... 21
(15.5 lbf.ft)
Screws, crankcase ventilation .............................. 91
(6.60.7 lbf.ft)
57
Tightening torques
Group 20
Nm
(lbf.ft)
Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50
(37 lbf.ft)
Step 2: ............................................................... 130
(96 lbf.ft)
Group 22 Oil system

Oil cooler, screws ................................................. 212
Oil cooler, hollow screw
Step 1: ............................................................... 80
Step 2: ............................................................... 160
Oil cooler, screw plug ........................................... 80
Front/oil pump housing ......................................... 212
Oil suction pipe ..................................................... 212
Oil sump ............................................................... 212
Oil pressure pipe turbo ......................................... 293
Oil pressure pipe engine block ............................. 394
A) with tube fitting .............................................. 402
B) with flange fitting ........................................... 212
Screws, oil return pipe engine block ..................... 212
Oil pressure switch ............................................... 182
(15.51.5 lbf.ft)
(59 lbf.ft)
(118 lbf.ft)
(59 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(21.42.2 lbf.ft)
(293 lbf.ft)
(29.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(131.5 lbf.ft)

Screw, governor, idler gear:
Step 1: ............................................................... 30
(22.1 lbf.ft)
Screw, control rod hose ........................................ 102
(75 lbf.ft)
1.5
Screw, governor ................................................... 17
(12.51 lbf.ft)
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 5: ............................................................... 7
(5 lbf.ft)
Step 6: ............................................................... 10
(7.4 lbf.ft)
Step 7: ............................................................... 30
(22 lbf.ft)
Flange screw, injector ........................................... 16+5
(12+4 lbf.ft)
Injector cap nut ..................................................... 40 50
(30 37 lbf.ft)
Delivery pipe
Step 1: ............................................................... 5
Step 2: ............................................................... 25+3.5
Screw, stop magnet .............................................. 21
Overflow valve ...................................................... 30
(3.7 lbf.ft)
(18.42.6 lbf.ft)
(15.5 lbf.ft)
(22 lbf.ft)

Exhaust manifold nuts .......................................... 252.5
M8 Nuts, turbo to exhaust manifold ...................... 212
M10 Nuts, turbo to exhaust manifold .................... 40.54
Screws, Inlet manifold .......................................... 111
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)

Thermostat housing .............................................. 30
Water temp sensor ............................................... 212
Water pump .......................................................... 212
58
(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
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
Rotation direction, facing flywheel: Counterclockwise
Number of cylinders ..................... 6
6
Bore, mm (inch) ........................... 108 (4.25")
108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12")
130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3)
7.15 (436.3)
Number of valves ......................... 12
12
Compression ratio:
EPA 1 ....................................... 17.1:1
17.5:1
COM 2 ......................................
Firing sequence ........................... 1-5-3-6-2-4

1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 1281, 3)
1531, 3)
At 1800 rpm, kW (hp) ................ 1341, 3)
1631, 3)
Engine torque, Nm (lbf.ft) ............. 8153)
9743)
At speed, rpm ........................... 1500
1500
Engine torque, Nm (lbf.ft) ............. 7113)
8653)
At speed, rpm ........................... 1800
1800
Low idle, rpm ................................ 850-950
850-950
Max speed at full load (rpm) ......... 1500/18001)
1500/18001)
Weight engine (dry) kg (lb) ........... 750 (1653)2)
760 (1674)2)
2)
Weight engine (wet) kg (lb) ........... 790 (1742 lb) 804 (1773 lb)2)
TAD721GE
TAD722GE
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
18.1:1
1-5-3-6-2-4
18.1:1
1-5-3-6-2-4
1831, 3)
2041, 3)
1165
1500
1082
1800
800-950
1500/18001)
7852)
8262)
2011, 3)
2251, 3)
1280
1500
1193
1800
800-950
1500/18001)
7852)
8262)

3)
Measured at Prime Power, see General information, Power standards
1)
2)
59
Group 20
General
Type designation ................................
Direction of rotation (seen from flywheel)
No. of cylinders ..................................
Cylinder bore mm (inch) ......................
Stroke mm (inch) ................................
Cylinder volume liter (inch 3 ) ...............
No. of valves ......................................
Compression ratio:
EPA1 ...............................................
EPA2 ...............................................
EU2 .................................................
Injection sequence .............................
Engine power:
At 1500 rpm kW (hp) .......................
At 1800 rpm kW (hp) .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Torque Nm (lbf.ft) ...............................
At engine speed rpm .......................
Low idle rpm .......................................
Highest full load speed rpm ................
Weight, dry (lb) ...................................
Gross weight, dry (lb)
1)
2)
3)
4)
TAD730GE
Anti- clockwise
6
108 (4.25)
130 (5.12)
7.15 (436.3)
12
17.1:1
18.0:1
1-5-3-6-2-4
129 (208)1)
136 (222)1)
821 (718)
1500
722 (638)
1800
800 950
1500/1800 1)
760 (1674) 2)
804 (1773) 2)
TAD731GE
Anti- clockwise
6
108 (4.25)
130 (5.12)
7.15 (436.3)
12
TAD732GE
Anti- clockwise
6
108 (4.25)
130 (5.12)
7,15 (436)
12
TAD733GE
Anti- clockwise
6
108 (4.25)
130 (5.12)
7,15 (436)
12
17.1:1
17.1:1
18,0:1
18,0:1
1-5-3-6-2-4
1-5-3-6-2-4
1-5-3-6-2-4
153 (208)1)
163 (222)1)
974 (718)
1500
865 (638)
1800
800 950
1500/1800 1)
760 (1674) 2)
804 (1773) 2)
201 (273)1)
225 (306)1)
1280 (944)
1500
1193 (880)
1800
800 950
1500/18001)
785 (1731)2)
826 (1821)2)
201 (273)1)
225 (306)1)
1280 (944)
1500
1193 (880)
1800
800 950
1500/18001)
785 (1731)2)
826 (1821)2)
See engine plate for specifications.

Extra weight TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
General
Type designation .......................... TD720VE
TAD720VE
Rotation direction, facing flywheel: Counterclockwise
Number of cylinders ..................... 6
6
Bore, mm (inch) ........................... 108 (4.25")
108 (4.25")
Stroke, mm (inch) ........................ 130 (5.12")
130 (5.12")
Displacement, dm3 (inch3) ............. 7.15 (436.3)
7.15 (436.3)
Number of valves ......................... 12
12
Compression ratio:
EPA 1 ....................................... 18.4:1
18.4:1
COM 2 ......................................
19.0:1
Firing sequence ........................... 1-5-3-6-2-4
1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 1221)
At 1800 rpm, kW (hp) ................

1741)
Engine torque, Nm (lbf.ft) ............. 701
817
At speed, rpm ........................... 1500
1800
Low idle, rpm ................................ 850-950
850-950
Max speed at full load (rpm) ......... 18001)
2000-23001)
Weight engine (dry) kg (lb) ........... 5702)
5722)
Weight engine (wet) kg (lb) ........... 9202,3)
1)

3)
2)
60
TAD721VE
TAD722VE
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
18.4:1
19.0:1
1-5-3-6-2-4
19.0:1
1-5-3-6-2-4
1951)
897
1800
850-950
2000-23001)
5722)
2001)
981
1800
800-950
2100-23001)
6802)
Group 20
General
Type designation .................................................... TAD750VE
Bore, mm (inch) ..................................................... 108 (4.25")
Stroke, mm (inch) .................................................. 130 (5.12")
Displacement, dm3 (inch3) ....................................... 7.15 (436)
Number of valves ................................................... 12
Compression ratio: ................................................. 18.1:1
Firing sequence ..................................................... 1-5-3-6-2-4
Max torque, Nm (lbf.ft) .......................................... 1050 (775)3)
At speed, rpm .................................................... 1500
Low idle, rpm ......................................................... 600 - 800
Max, full load speed, rpm ....................................... 24001)
Weight. engine (wet) kg (lb) .................................... 681 (1501)2)
TAD760VE
Counterclockwise
6
108 (4.25")
130 (5.12")
7.15 (436)
12
18.1:1
1-5-3-6-2-4
181 (246)1, 3)
1100 (811)3)
1500
600 - 800
24001)
650 (1433)2)
680 (1496)2)
1)

3)
2)
Cylinder liners
Engine block
Replacable, wet
Cylinder head
A
Type: ........................................ Common cylinder head

Max surface unevenness: ......... 0.125 mm
(0.00492")
Cylinder head bolts

Thread size: .............................. M 14
Quantity and length: .................. 26 x 141 mm
(26 x 5.55)
TD720GE, TAD720GE, TAD721GE,

TAD722GE, TAD720VE, TAD720VE,
TAD721VE, TAD722VE, TAD730-733GE,
TAD750, TAD760VE
Type: .................................................................... Wet, replaceable
Number of seals per liner: ..................................... 2
Bore: ..................................................................... 108+0.02 mm
(4.252+0.0008)
Max bore wear: ..................................................... 108.1 mm
(4.256)
Sealing surface. height (A): ................................... 9-0.02 mm
(0.3543-0.0008)
+0.03
Liner collar seating depth in block: ........................ 8.92
mm
(0,3512+0.0012)
Projection of liner above block surface: ................. 0.03 0.08 mm (0.0012 0.0031)
61
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
Group 20

Position the dial gauge at the measuring points A and B on the top of the piston, inline with the gudgeon pin.
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: ............................ 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
Pistons
Number of piston ring grooves ............................... 3
Combustion chamber:
Diameter ........................................................... 710.1 mm
Depth .................................................................... 16.660.1 mm
Gudgeon pin diameter ....................................... 42 -0.006 mm
(2.795"0.0039")
(0.6559"0.0039")
(1.6535"-0.0002")
Piston rings
Compression rings
Number of rings .................................................... 2
Upper compression ring (1) ................................ Keystone, no clearance
Lower compression ring (2) ................................ 0.17 mm
(0.067")
Upper compression ring (1) ................................ 0.8 mm
(0.03")
Lower compression ring (2) ................................ 2.5 mm
(0.0984")
2
3
Oilscraper ring (3)

Number: ................................................................ 1
Width, including springcoil: .................................... 3 mm
Piston ring clearance. height: ................................ 0.1 mm
Piston ring gap, wear limit: .................................... 1.15 mm
(0.12")
(0.0039")
(0.045)
63
Group 20
Valve mechanism
Valves
Disc diameter :
Inlet ................................................................... 480.1 mm
Exhaust ............................................................. 420.1 mm
Stem diameter :
Inlet ................................................................... 8.98-0.015 mm
Exhaust ............................................................. 8.96-0.015 mm
Valve seat angle:
Inlet, min ............................................................ 29.5
Exhaust, min ..................................................... 44.5
(1.8898"0.0039")
(1.6535"0.0039")
(0.3535"-0.0006")
(0.3528"-0.0006")
Min 1.8 mm
Min 2.1 mm
45
30
29.5
44.5
Valve disc edge:

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

Inlet ................................................................... 0.350.05 mm
Exhaust ............................................................. 0.550.05 mm
(0.014"0.002")
(0.022"0.002")
Important! Control and adjusting of valve clearance is done

with an engine oil temperature between 20 80C (68 176F)
Valve seats
A

Inlet ................................................................... 49.09-0.02 mm
Exhaust ............................................................. 43.06-0.02 mm
Height (B):
Inlet ................................................................... 7.50.1 mm
Exhaust ............................................................. 7.90.1 mm
64
(1.933"-0.0008")
(1.695"-0.0008")
(0.295"0.004")
(0.311"0.004")
Group 20
Valve seat location

C

Inlet ................................................................... 49-0.025 mm
Exhaust ............................................................. 43.5-0.02 mm
Depth (D):
Inlet/Exhaust ..................................................... 11+1 mm
Inlet/Exhaust ..................................................... 1-0.3 mm
Inlet/Exhaust ..................................................... Min 1.5 mm
(1.929"-0.001")
(1.712"-0.001")
(0.43"+0.04")
(0.04"-0.012")
(0.059")
Valve guides
Length:
Inlet/Exhaust ..................................................... 63-0.5 mm
Inner diameter :
Inlet/Exhaust ..................................................... 9.0259.04 mm
Height above cylinder head spring surface:
Inlet/Exhaust ..................................................... 23-0.5 mm
Inlet ................................................................... 0.1 mm
Exhaust ............................................................. 0.13 mm
Design 1
without flange
(2.48"-0.02")
(0.35530.3559")
(0.9"-0.02")
(0.039")
(0.51")
Design 2
Design 1
with flange
O-ring
Flange
On later models the o-ring seal is exchange to a valve

stem sealing, according to the picture for design 2.
Production
Exchange
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 .................................... 64.71.3 mm
Wire diameter .................................................... 4.5 mm
(2.55"0.05")
(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
Standard ............................................................ 65+0.054 mm
(2.559"+0.0021")
Wear limit ........................................................... 65.08 mm
(2.5622")
Camshaft bearing thickness: max ......................... 1.988+0.012 mm (0.7827"+0.0005")
Axial clearance ..................................................... 0.1 0.5 mm
(0.004 0.02")
Radial clearance ................................................... 0.05 0.124 mm(0.002 0.0049")
Position of bearing bush at flywheel end ............... 2+0.5 mm
(0.079"+0.0197")
Timing gear
1.
2.
3.
4.
5.
6.
Governor drive (not apply for 750/760)

Idler gear (not apply for 750/760)
Camshaft gear
PTO gear B-C (not apply for 750/760)
PTO gear A (not apply for 750/760)
Crankshaft gear
Flywheel
Type of flywheel :
TD/TAD720/721/722/750/760VE ........................ Clutch 10" or 11.5"
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1500 rpm
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1800 rpm
Max, permitted axial throw:
Measuring radius 150 mm (5.91") ....................... 0.1 mm (0.00394")
Number of teeth on flywheel .................................. 129
66
Group 20
Group 20
Crank mechanism
Crankshaft length .................................................. 973.2 mm
Crankshaft axial clearance1) .................................. 0.1 0.3 mm
Main bearing radial clearance1) .............................. 0.03+0.062 mm
bearing and crank pins ....................................... 0.01 mm
Max, run-out of center bearing ............................... 0.1 mm
1)
(38.31")
(0.0039" 0.0118")
(0.0012"+0.0024")
(0.0004")
(0.00394")
E
F
C
B
A

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

Type ..................................................................... Replaceable
Outer diameter (E) ............................................. 85.03+0.036 mm
Thickness (F): Standard ........................................ 2.727+0.008 mm
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm
0.5 mm (0.02") ................................................... 2.977+0.008 mm
(2.9035"+0.0014")
(0.1074"+0.0003")
(0.1123"+0.0003")
(0.1172"+0.0003")
67
Group 20

Diameter (G) for machining:
Standard ............................................................... 68-0.02 mm
Undersize:
0.25 mm (0.01") ................................................. 67.75-0.02 mm
0.5 mm (0.02") ................................................... 67.5-0.02 mm
Width (H), axial bearing journal. ............................. 35.50.02 mm
Out-of-round: Max. ............................................. 0.01 mm
Taper: Max ........................................................ 0.01 mm
(2.6772"-0.0008")
(2.6673"-0.0008")
(2.6575"-0.0008")
(1.397"0.0008")
(0.0004")
(0.0004")
H
G

Diameter (J): Bearing ........................................ 68.03+0.04 mm
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm
0.5 mm (0.02") ................................................... 67.53+0.04 mm
Diameter : Bearing shell ..................................... 72.5+0.05 mm
Thickness (K): Standard ....................................... 2.222+0.01 mm
68
(2.6783"+0.0016")
(2.6685"+0.0016")
(2.6587"+0.0016")
(2.854"+0.002")
(0.0875"+0.0004")
Group 20
Connecting rods
Length (L): Center Center ................................... 2100.06 mm
Connecting rod (M) bushing bore ........................... 42.04+0.01 mm
Wear limit ........................................................... 0.08 mm
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5+0.02 mm
Small end bush outer diameter ....................... 45.58+0.04 mm
(8.2677"0.00236")
(1.6551"0.0004")
(0.0031")
(1.7913"0.0008")
(1.7945"+0.0016")
L
M
Axial clearance, connecting rod crankshaft1) ...... 0.3-0.4 mm

(0.0118-0.0157")
1)
Connecting rod bearing: radial clearance ............. 0.036-0.096 mm (0.00142-0.00378")
(0.002")
(0.002")
1)
Marking: Connecting rod and cap number marking must be on

one side and identical
69
Group 20
Lubricating system
Sulfur content in fuel, by weight
Engine
Oilgrade
2)
< 0,5 %
0,5 1,0 %
> 1,0 %1)
Oil change interval, reached first in operation

T(A)D720-721VE
T(A)D720GE
TAD730/731GE,
TAD721/722GE,
TAD732/TAD733GE,
TAD750/760VE, open
crankcase ventilation
VDS-3
VDS-2
ACEA: E7, E5, E3
500 h / 12 months
250 h / 12 months
125 h / 12 months
TAD721/722GE,
TAD732/733GE,
TAD750/760VE, closed
crankcase ventilation
ACEA: E4
API: CI-4, CH-4
500 h / 12 months
250 h / 12 months
125 h / 12 months
TAD722VE
power<200kW
ACEA: E4
500 h / 12 months
250 h / 12 months
125 h / 12 months
250 h / 12 months
125 h / 12 months
60 h / 12 months
NOTE! Fully synthetic oil must be used
power>200kW
1)
2)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15 closed crankcase ventilation
requirements above.
Viscosity
table.
70
Group 20
Engine oil quantity

With oil filter:
TD720/TAD720/TAD721VE: ............................... 20 liter
TAD722VE/TAD750VE/TAD760VE .................... 23 liter
TAD721GE/TAD722GE ...................................... 34 liter
(5.28 US gal)
(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 kPa
(11.6 psi)
Shut down switch, at pressure lower than:
TD720GE, TAD720/721/722GE, TAD730-731GE: 150 kPa
(22 psi)
TD720VE, TAD720/721/722/750/760VE: ............ 50 kPa
(7.2 psi)
TAD732/733GE .................................................. 200 kPa
(29 psi)
4. Rocker arm
6. Piston cooling: ................................................ 2-hole nozzles for each cylinder
7. Oil filter, full-flow:
(0.0005")
Bypass valve oil filter:
(357 psi)
Opening pressure: ............................................... 25050 kPa
8. Pressure regulating valve:
Opening pressure: ............................................... 40040 kPa
(586 psi)
9. Pressure-relief valve:
Opening pressure: .............................................. 10.1 MPa
(14514 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: .......................................... 80C
(176F)
Max o il temperature: ............................................. 125C
(257F)
71
Fuel system (720 733)
1. Fuel tank.
3. Fuel pump
5. Fuel filter
7. Injection pumps,720/721/722 (6 ea.)
9. Injector
11. Overflow valve2)
1)
2)
Depending on length of hose

Can also be used as an air ventilation screw
72
Group 20
Group 20
Fuel system (750,760)
1.
2.
3.
4.
5.
6.
7.
Fuel tank
Hand pump (accessory)
Fuel line (to pump)
Fuel pump
Fuel filter
Pipe to highpressure
Rail
8.
9.
10.
11.
12.
13.
Highpressure pump
Fuelpipe, to injector
Injector
M-prop
Pressure valve
Return fuel line, to fuel tank, A = Fuel pipes,
minimum distance 300 mm (11.8")
73
Group 20
Fuel specification
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
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 23%.
In
Out
Fuel feed pump

Fuel system figures is corresponding to the picture above
Overpressure relief valve (1):
Opening pressure ............................................... 0.60.05 MPa
Bypass valve (2)
Opening pressure ............................................... 505 kPa
Fuel flow
Min fuel flow at 1500 rpm ...................................... 600 l/tim
Firing sequence .................................................... 1-5-3-6-2-4
Feed pressure ....................................................... 0.5 MPa
Feed pressure after fuel filter at
1500 rpm. min .................................................... 0.28 MPa
(877.2 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
Fuel filter
(0.0002")
Pre-filter
74
(0.00024")
Group 20
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 LO
with the tolerance A/100, that are written on the injection pump
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering
fuel.
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
This gives us the equation: LFB = 143 + 0.63
Injection pump (720733)

Manufacturer ......................................................... Bosch
Designation ........................................................... PF 33 L
Length A: .............................................................. 54 mm
Basic measurement length LO : ............................. 143 mm
Min length LFB : (A/100+143) 143 ........................ >0 mm
(2.12")
(5.63")
Injectors
Opening pressure:
TD720GE/ EPA1, TD720VE/EPA1
TAD720VE/EPA1, TAD721VE/EPA1: ................ 25 MPa
(3600 psi)
TAD720GE/COM2, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2
TAD721GE/COM2, TAD722GE/COM2: .............. 27,5 MPa
(4000 psi)
Max pressure:
TD720GE/ EPA1, TAD720GE/EPA1/COM2
TAD720VE/EPA1, TAD721VE/EPA1
TAD721GE/COM2, TAD722GE/COM2: .............. 120 MPa
(17400 psi)
TAD720VE/COM2, TAD721VE/COM2
TAD722VE/COM2: ............................................. 160 MPa
(23200 psi)
Check leakage (for 10 min):
TAD720GE/EPA1, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2: .............. 23 MPa
(3340 psi)
TAD720GE/EPA1, TAD720VE/EPA1
TAD721GE/COM2, TAD722GE/COM2
TAD721VE/EPA1: ............................................. 25,5 MPa
(3700 psi)
Numbers/bore :
TD720GE: .......................................................... 6 x 0.234 mm (6 x 0.00921")
TAD720GE/TD720VE/TAD720VE, EPA 1: ........ 6 x 0.25 mm (6 x 0.00921")
TAD721GE/TAD721VE/TAD722GE, EPA 1: ...... 6 x 0.264 mm (6 x 0.00921")
TAD720VE/TAD721GE/TAD721VE/TAD722GE
COM 2: .............................................................. 6 x 0.236 mm (6 x 0.00921")
75
Group 20
Commencement of delivery (FB) 720733

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)

FB
(Commencement of
delivery)
Camshaft
types
76
Vh
Pre-stroke
Vhcorr.factor
Lo
Pre-stroke
Basic dimension
correction factor Injection pump
Group 20
Theoretical thickness for a new shim (720733)

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

4th step: E4 = E3 + LO
5th step: E5 = E4 + A/100 (mm)
6th step: Ts = L E5
7th step: The actual shim thickness (Ss) is determined with the help of table 2.
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When the
theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim thickness (Ss)
Table 2 (Shim thickness)

Shim thickness (SS)
Theor. thickness(TS)
Shim thickness (SS)
77
Group 20
How to use EP code (720733)

TS = EK - (LO + A/100)
TS = Shim thickness
Example:
pump is 63 we will have following equation: TS = 146.675 (143 + 0.63)
TS are in this case 3.045 and a control in table 2 gives: SS = 3 mm
Thickness on the new shim to be mounted is in this example will be 3 mm

Ek(mm)
EP
code
Ek(mm)
78
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Group 20
Governor (720733)
Manufacturer ......................................................... Heinzmann
Designation:
TD720GE/TAD720GE/TAD730733GE: ............. 1500 rpm
TD720GE/TAD720GE/TAD730733GE: ............. 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
Control rod (720733)

Start and stop: ...................................................... 17 17.5 mm
Min: ...................................................................... 16.8 mm
The recess dimension X ....................................... 0.3 1.3 mm
(0.67" 0.69")
(0.66")
(0.012" 0.051")
79
Group 20

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, TAD731733GE ................................................ 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)
(23.6 psi)
TAD721VE (COM 2): ................................................................... 163 kPa
TAD722VE (COM2, High power): ................................................. 198kPa
(28.7 psi)
TAD750VE/TAD760VE: ............................................................... 198kPa
(28.7 psi)
Lube system: .................................................................................. Pressure lubrication
Max, permitted radial clearance (compressor side)
Schwitzer S2B: ............................................................................ 0.95 mm
(0.0374")
Schwitzer S200: ........................................................................... 0.88 mm
(0.0346")
Max, permitted axial clearance
Schwitzer S2B: ............................................................................ 0.14 mm
(0.00551")
Schwitzer S200: ........................................................................... 0.1 mm
(0.0039")
Max, allowed back pressure in exhaust line:
TD/TAD720GE, TAD721/722GE, TAD730-733GE (1500 rpm): ..... 5 kPa
(0.7 psi)
TD/TAD720GE, TAD721/722GE, TAD730-733GE (1800 rpm): ..... 7 kPa
(1 psi)
TD720VE, TAD720/721/722/750/760VE: ...................................... 7.5 kPa
(1.1 psi)

At rated speed (standby power)1): .......................... 1500 rpm
TD720GE, TAD730GE: ...................................... 560C (1040F)
TAD720GE, TAD731GE: .................................... 476C (914F)
TAD722GE, TAD732/733GE .............................. 557C (1035F)
At rated speed: ..................................................... 1800 rpm
TD720VE: .......................................................... 420C (788F)
TAD721VE: ........................................................ 420C (788F)
TAD721VE: ........................................................ 490C (914F)
TAD722/750/760VE: .......................................... 545C (1013F)
1800 rpm
505C (941F)
433C (837F)
520C (968F)
2100 rpm
420C (788F)
475C (887F)
535C (995F)
1)
See in General information, Power standards.

2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD720GE/TAD720GE, TAD730GE: ................... 1 kPa
TAD721GE/TAD722GE, TAD731-733GE: .......... 1.5 kPa
TD720VE/TAD720/721/722/750/760VE: ............. 2.5
Max allowed air intake restriction
TD720GE/TAD720GE, TAD730GE: ................... 3 kPa
TAD721GE/TAD722GE, TAD731-733GE: .......... 3.5 kPa
TD720VE/TAD720/721/722/750/760VE: ............. 6.5
80
(0.14 psi)
(0.22 psi)
(0.36 psi)
(0.43 psi)
(0.51 psi)
(0.94 psi)
2200 rpm
425C (797F)
480C (896F)
540C (1004F)
2300 rpm
430C (806F)
485C (905F)
545C (1013F)
Group 20
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD720GE/TAD720GE, TAD730/731GE: ............ 60 kPa
(13 psi)
TAD721GE/TAD722GE
TD720VE/TAD720VE/TAD721VE,
TAD732-733GE, max1): ...................................... 90 kPa
(13 psi)
1)
Capacity (engine):. ................................................. 9.8 liters

(2.59 US gal)
Capacity (engine and cooler):
TD720GE: ........................................................... 22 liters
(5.8 US gal)
TAD720GE/TAD730/731GE: ............................... 23.8 liters
(6.3 US gal)
TAD721GE/TAD722GE/TAD732/733GE: ............ 27.3
(7.2 US gal)
Thermostat
Type: ..................................................................... Piston thermostat
Begins to open at
(181F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE,
TAD732/733GE: ................................................. 87 C
(189 F)
Fully open at
TD720GE/TAD720GE/TD720VE: ....................... 95C
(203F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE: ................... 102 C
(216 F)
1.
2.
3.
4.
5.
6.
7.
TD/TAD720-722:
Coolan connection (inlet)
Thermastat housing
Coolant pump
Lubrication oil cooler
Cylinder cooling
Cylinder head cooling
Coolant connection (outlet)
Coolant pump
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.

If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
81
Group 20
Tightening torque
Nm
1.5
(lbf.ft)
M6 standard screw 8.8 .......................................... 10

M8 standard screw 8.8 .......................................... 254
M10 standard screw 8.8 ........................................ 508
M12 standard screw 8.8 ........................................ 809
M14 standard screw 8.8 ........................................ 14025
(7.51 lbf.ft)
(183 lbf.ft)
(376 lbf.ft)
(596.5 lbf.ft)
(10318 lbf.ft)
Tightening torques
(lbf.ft)
Nm
Group 21 Engine
Engine mounting ................................................... 260
Starter motor ......................................................... 70
Timing gear casing ................................................ 212
(192 lbf.ft)
(51.6 lbf.ft)
(15.51.5 lbf.ft)
Main bearing caps

Step 1 ................................................................ 50
(37 lbf.ft)
Connecting rod big-end bearing:
Step 1 ................................................................ 30
(22 lbf.ft)
Flywheel
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 1: ............................................................... 30 40
(22 30 lbf.ft)
Flywheel housing. M12 .......................................... 991
(737 lbf.ft)
25
(17918 lbf.ft)
Flywheel housing. M16 .......................................... 243
V-belt pulley
Step 1: ............................................................... 40 50
(30 37 lbf.ft)
Vibration damper ................................................... 70
Screw, rocker cover .............................................. 91
(6.50.7 lbf.ft)
Lock nut, valve clearance adjusting screw ............ 202
(14.51.5 lbf.ft)
Screws, rocker arm fixing ..................................... 21
(15.5 lbf.ft)
Screws, crankcase ventilation ............................... 91
(6.60.7 lbf.ft)
82
Group 20
Tightening torques
Nm
(lbf.ft)
Cylinder head
Step 1: ............................................................... 50
(37 lbf.ft)
Step 2: ............................................................... 130
(96 lbf.ft)
Group 22 Oil system

Oil cooler, screws ................................................. 212
Oil cooler, hollow screw
Step 1: ............................................................... 80
Step 2: ............................................................... 160
Oil cooler, screw plug ............................................ 80
Front/oil pump housing .......................................... 212
Oil suction pipe ..................................................... 212
Oil sump ............................................................... 212
Oil pressure pipe turbo .......................................... 293
Oil pressure pipe engine block .............................. 394
A) with tube fitting .............................................. 402
B) with flange fitting ........................................... 212
Screws, oil return pipe engine block ...................... 212
Oil pressure switch ............................................... 182
(15.51.5 lbf.ft)
(59 lbf.ft)
(118 lbf.ft)
(59 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(21.42.2 lbf.ft)
(293 lbf.ft)
(29.51.5 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
(131.5 lbf.ft)

Screw, governor, idler gear:
Step 1: ............................................................... 30
(22.1 lbf.ft)
Screw, control rod hose ........................................ 102
(75 lbf.ft)
1.5
Screw, governor .................................................... 17
(12.51 lbf.ft)
Step 1: Torque ................................................... 5
(3.7 lbf.ft)
Step 3: Turn injection pump to stop ................... Counterclockwise
Step 5: ............................................................... 7
(5 lbf.ft)
Step 6: ............................................................... 10
(7.4 lbf.ft)
Step 7: ............................................................... 30
(22 lbf.ft)
(12+4 lbf.ft)
Flange screw, injector ........................................... 16+5
Injector cap nut ..................................................... 40 50
(30 37 lbf.ft)
Delivery pipe
Step 1: ............................................................... 5
Step 2: ............................................................... 253.5
Screw, stop magnet .............................................. 21
Overflow valve ...................................................... 30
Common Rail, TAD750/760
Safety valve ....................................................... 100
Rail pressuree sensor ........................................ 70
Common rail unit ................................................ 30
Fuel hose ........................................................... 39
IEGR, TAD750/760
IEGR-unit: .......................................................... 30
Solenoid valve: .................................................. 24
Highpressure fuel pump, TAD750/760
Step 1: ............................................................... 10
Step 2: ............................................................... 50
(3.7 lbf.ft)
(18.42.6 lbf.ft)
(15.5 lbf.ft)
(22 lbf.ft)
(74 lbf.ft)
(51.6 lbf.ft)
(22.1 lbf.ft)
(293 lbf.ft)
(22 lbf.ft)
(18 lbf.ft)
(7.4 lbf.ft)
(37 lbf.ft)
83
Tightening torques
Nm
Group 20
(lbf.ft)

Exhaust manifold nuts .......................................... 252.5
M8 Nuts, turbo to exhaust manifold ...................... 212
M10 Nuts, turbo to exhaust manifold ..................... 40.54
Screws, Inlet manifold ........................................... 111
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)

Thermostat housing .............................................. 30
Water temp sensor ................................................ 212
Water pump .......................................................... 212
84
(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
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/TAD530532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530533GE
TAD750VE/760VE
Step 1 ................................................................. 50 Nm
(37 lbf.ft)
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)
85
Technical data
Grupp 20
Flywheel

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

V-belt pulley/vibration damper:
Step 1: ................................................................ 40 50 Nm
Vibration damper .................................................... 70 Nm
86
(30 37 lbf.ft)
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)
Flange screws, Injection pump (not apply for 650/660, 750/760)

Step 1: Torque .................................................... 5 Nm
(3.7 lbf.ft)
Step 3: Turn injection pump to stop .................... Counterclockwise
Step 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
Step 2: ................................................................ 253.5 Nm
(3.7 lbf.ft)
(18.42.6 lbf.ft)
WARNING! Do not bend the pressure pipes, they can only be used once.
Screw plug
4. Screw plug MA .................................................... 353.5 Nm

6. Screw plug MA .................................................... 959.5 Nm
7. Screw plug MA .................................................... 656.5 Nm
8. Screw plug MA .................................................... 353.5 Nm
13. Screw plug MA .................................................. 353.5 Nm
24. Screw plug MA .................................................. 102 Nm
88
(262.6 lbf ft)

(707 lbf ft)
(484.8 lbf ft)
(262.6 lbf ft)
(262.6 lbf ft)
(71.5 lbf ft)
Report form
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 Gteborg
Sweden
7742012 English 062007

TD 420 Ve

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TD 420 Ve

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Workshop Manual

TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE

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Valve mechanism ............................................... 40

2007 AB VOLVO PENTA

This Workshop Manual contains technical data for the

Spare parts for the electrical and fuel systems are

The Engine Designation and Engine Numbers can be

The Workshop Manual is produced primarily for the

Any type of damage which is the result of using spare

The Service Intervals and maintenance operations

Only Volvo Penta Original Spare Parts intended

Service work on the injection pump and injectors

The engine may not be altered or modified in any

No modifications to the exhaust pipes and air

Any seals on the engine may not be broken other

Our joint responsibility

The working methods described in the Workshop

All operations described in the Workshop Manual for

The stated service intervals in the Maintenance Schedule must be followed.

For the correct tightening torque for critical joints,

Do not reuse lock nuts that have been removed during

Tightening torque with

For lock nuts with a plastic insert such as Nylock

Safety rules for fluorocarbon

Indication of standard and /or regulation

8. Air temperature in C (F), in accordance with

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

See identification plate for correct specification

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

See identification plate for correct specification

Cylinder head bolts

Quantity and length:

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

Max bore wear:

Sealing surface: Height, see picture (A):

Liner collar seating depth in block:

Projection of liner above block surface:

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

Cylinder head gasket

Measuring points between A and B on each piston is the distance X.

Measure all pistons.

Determine the maximum projection on each piston.

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

Oilscraper ring (3)

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

Valve disc edge:

Valve clearance (not apply for TAD660VE)

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

Outer diameter (A), standard:

Valve seat location

Diameter (C), standard:

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

Governor drive (not apply for 650/660)

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

Important! The dimensions apply to oiled parts

Main bearing journals

Main bearing shells

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

Connecting rod bearing journals

Connecting rod bearing shells

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