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Group 20
General Information
Technical Data
Industrial Engines
TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE,
TD520GE, TAD520GE, TD520VE, TAD520VE,
TAD530/531/532GE, TD720GE, TAD720GE, TD720VE,
TAD720VE, TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE
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
TD520GE, TAD520GE, TD520VE, TAD520VE,
TAD530-532GE
General ............................................................... 36
Engine block ....................................................... 37
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General Information
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Safety Precautions
Introduction
Workshop Manuals contains technical specifications,
descriptions, and instructions for the repair of the specified Volvo Penta products or product types. Check
that you have the correct Workshop Manual and the
latest Service Bulletins for your engine.
Before starting work on the engine, read these
sections of the Workshop Manual:
Safety Precautions
General Information
Repair Instructions
Important
In this book and on the product you will find the following special warning symbols.
WARNING! Possible danger of personal injury,
extensive damage to property or serious mechanical malfunction if the instructions are not followed.
IMPORTANT! Used to draw your attention to something that can cause damage or malfunc-tions on a product or damage to property.
NOTE! Used to draw your attention to important
infor-mation that will facilitate the work or operation in progress.
Warning symbols used in the Workshop Manual are
not in any way comprehensive since it is impossible
to predict every circumstance under which service work or repairs may be carried out.
AB Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working
methods in a well-equipped workshop using working
methods and tools tested by AB Volvo Penta.
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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.
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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.
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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.
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WARNING! The components in the electrical system and in the fuel system on Volvo Penta products are designed and manufactured to 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.
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General Information
General Information
About this Workshop Manual
Spare parts
Engine certificate
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.
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:
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.
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General Information
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Repair instructions
Introduction
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.
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General Information
Tightening torque
Lock nuts
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)
Strength classes
Bolts and nuts are divided up into different classes of
strength, the number on the bolt head indicates the
class. A high number indicates stronger material, for
example a bolt marked 10-9 indicates a higher
strength than one marked 8-8.
It is therefore important that bolts removed during the
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint.
When replacing a bolt, check in the spare parts catalogue to make sure the correct bolt is used.
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General Information
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.
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General Information
Location of identification
plates (420-620, 520-722)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one should be mounted in a suitable location adjacent to the engine.
Identification plates
1.
2.
3.
4.
5.
6.
7.
Engine model
Engine specification number
Engine serial number (10 digits)
Engine output without fan
Rated engine speed
Injection timing and type of camshaft
Manufacturers identification code
8.
9.
10.
11.
12.
13.
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General Information
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Location of identification
plates (TAD650/660, 750/760)
Each engine is supplied with two identical identification plates, of which one is mounted on the right side
of the cylinder block and the other one is mounted up
on the valve cover.
Identification plates
1.
2.
3.
4.
5.
6.
7.
Engine model
Engine specification number
Engine serial number (10 digits)
Engine output, without fan
Rated engine speed
Engine code (linked to EPA/EU Tier III approval)
Rated power, standard (peak power according to
Tier III)
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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)
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General
Type designation .................................................... TAD650VE
Rotation direction, facing flywheel: ......................... Counterclockwise
Number of cylinders ............................................... 6
Bore, mm (inch) ..................................................... 101 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96")
Displacement, dm3 (inch3) ....................................... 5.7 (347.8)
Number of valves ................................................... 12
Compression ratio: ................................................. 18.4:1
Firing sequence ..................................................... 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 147 (200)1, 3)
Max torque, Nm (lbf.ft) ........................................... 750 (553)3)
At speed, rpm ..................................................... 1600
Low idle, rpm .......................................................... 600-800
Max, full load speed, rpm ....................................... 24001)
Weight. engine (dry) kg (lb) .................................... 565 (1246)2)
Weight. engine (wet) kg (lb) .................................... 585 (1290)2)
1)
Engine block
Cylinder head
Type ...................................................................... Common cylinder head
Max surface unevenness ....................................... 0.1 mm
(0.0039")
(13 x 4.3")
(5 x 7")
(19 x 4.3")
(7 x 7")
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TAD660VE
Counterclockwise
6
98 (3.85")
126 (4.96")
5.7 (347.8)
12
18.4:1
1-5-3-6-2-4
147 (200)1, 3)
800 (590)3)
1600
600-800
2400565
565 (1246)2)
585 (1290)2)
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Cylinder liners
Parent bore
Replaceable, dry
A
TD420VE, TAD420VE
TAD650VE
TAD620,
TAD660VE
Type:
TD420VE/TAD420VE/TAD650VE ....................... Parent bore
TAD620VE/TAD660VE ....................................... Dry, replaceable
Bore:
TD420VE/TAD420VE/TAD650VE ....................... 101+0.02 mm
TAD620VE/TAD660VE ....................................... 98 +0.02 mm
(3.976"+0.00078")
(3.858"+0.00078")
(3.98")
(3.86")
(3.86")
(0.177"-0.0008")
(0.1724"+0.0012")
(0.00047" 0.0027")
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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.
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")
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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
(0.12")
(0.0039")
(0.045)
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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
(0.071")
(0.043")
(0.106")
(0.083")
(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)
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Valve seats
A
B
(1.685"-0.0008")
(1.456"-0.0008")
(0.2677"0.004)
(0.2953"0.004)
(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")
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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.
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
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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"
E
F
C
B
A
(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")
(3.308"+0.0017")
(2.903"-2.903")
(0.1024"+0.0004")
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(2.48"-0.0008)
(2.4714"-0.0008)
(1.4"0.0008")
(0.0004")
(0.0004")
H
G
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(2.442"+0.00154)
(2.4716"+0.00079)
(0.06996+0.0004)
(2.622"0.0008")
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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
(0.00787"-0.0118")
(0.00118"-0.00354")
(0.002")
(0.002")
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Lubricating system
Oil grade2)
0.5 1 %
1)
More than 1 %
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.
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.
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TD420VE/TAD420VE
(2.64 US gal)
(4.22 US gal)
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:
Opening pressure ................................................ 21030 kPa
(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)
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1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve 2)
12. Return fuel line to fuel tank.
Inside diameter, min 10 mm (0.39")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
2)
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Group 20
Group 20
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")
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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
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(877 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
Group 20
(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
Filtering size: ......................................................... 0.006 mm
(0.00024")
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Group 20
FB
(Commencement of
delivery)
Camshaft
types
28
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Vh
Vhcorr.factor
Lo
Pre-stroke
Pre-stroke
correction factor
Basic dimension
Injection pump
Grupp 20
Tekniska data
Theor. thickness
(TS)
Theor. thickness(TS)
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.
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Group 20
Ek(mm)
EP code
Ek(mm)
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EP code
Ek(mm)
EP code
Ek(mm)
EP code
Group 20
Governor (420/620)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer .......................................................... Heinzmann
Designation:
TD420VE/TAD420VE/TAD620VE: ...................... 2500 rpm
TD420VE/TAD420VE/TAD620VE: ...................... 2300 rpm
TD420VE/TAD420VE/TAD620VE: ...................... 2100 rpm
Engine speed droop at a load increase from 0 to 100 % at rated speed:
TD420VE/TAD420VE/TAD620VE: ...................... 5 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
(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.
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Group 20
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.
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Group 20
Tightening torque
General tightening torques
Nm
1.5
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)
Step 1 .................................................................... 50
Step 2 .................................................................... 90 angle tightening
Step 3 .................................................................... 90 angle tightening
(37 lbf.ft)
Step 1 .................................................................... 30
Step 2 .................................................................... 60 angle tightening
Step 3 .................................................................... 30 angle tightening
(22 lbf.ft)
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ................................................................... 20 30
Step 2: ................................................................... 60 angle tightening
Step 3: ................................................................... 30 angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................... 20 30
Step 2: ................................................................... 60 angle tightening
Step 3: ................................................................... 60 angle tightening
C) Flywheel with a screw length between 50 85 mm
Step 1: ................................................................... 30 40
Step 2: ................................................................... 60 angle tightening
Step 3: ................................................................... 60 angle tightening
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
Step 2: ................................................................... 60 angle tightening
Step 3: ................................................................... 60 angle tightening
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)
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Tightening torques
Nm
Group 20
(lbf.ft)
Cylinder head
Screws to cylinder head are reusable only three times.
Step 1: ................................................................... 30
Step 2: ................................................................... 80
Step 3: ................................................................... 90 angle tightening
(22 lbf.ft)
(59 lbf.ft)
(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)
(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)
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
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(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)
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)
(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
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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) ........................................
725 (1336)2, 6)
1)
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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
Engine block
Cylinder liners
Replacable, wet
Cylinder head
A
( 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")
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Group 20
Set the dial gauge in the level of the crankcase surface to zero.
Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
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: ........................... 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")
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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 front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
Piston rings
Compression rings
Number of rings .................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ............................... Keystone, no clearance
Lower compression ring (2) ............................... 0.17 mm
(0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ............................... 0.8 mm
(0.03")
Lower compression ring (2) ............................... 2.5 mm
(0.0984")
2
3
(0.12")
(0.0039")
(0.045")
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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
(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
Outer diameter (A), standard:
Inlet ................................................................... 49.09-0.02 mm
Exhaust ............................................................. 43.06-0.02 mm
Height (B):
Inlet ................................................................... 7.50.1 mm
Exhaust ............................................................. 7.90.1 mm
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(1.933"-0.0008")
(1.717"-0.0008")
(0.295"0.004")
(0.311"0.004")
Group 20
(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
Wear limit valve stem guide:
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
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")
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Group 20
Camshaft
Type of camshaft: ................................................. A
Drive ..................................................................... Gear
Number of bearings .............................................. 5
Inner diameter , bearing journals
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
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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
Max, permissible ovality of main
bearing and crank pins ...................................... 0.01 mm
Max, run-out of center bearing .............................. 0.07 mm
1)
(27.92")
(0.0039" 0.0118")
(0.0012"+0.0024")
(0.0004")
(0.0027")
E
F
C
B
A
(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")
(2.9035"+0.0014")
(0.1074"+0.0003")
(0.1123"+0.0003")
(0.1172"+0.0003")
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Group 20
(2.6772"-0.0008")
(2.6673"-0.0008")
(2.6575"-0.0008")
(1.397"0.0016")
(0.0004")
(0.0004")
H
G
K
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(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
(0.0118 0.0157")
(0.00142"+0.0024")
(0.002")
(0.002")
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Group 20
Lubricating system
Oil grade2)
0.5 1 %
More than 1 %
1)
1)
2)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
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.
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Group 20
(2.64 US gal)
(3.43 US gal)
(3.43 US gal)
At rated speed:
TD520GE/TAD520GE/TAD530-532GE (1500 rpm): . 280 kPa
(40.6 psi)
TD520GE/TAD720GE/TAD530-532GE (1800 rpm): 330 kPa
(47.9 psi)
TD520VE: .......................................................... 440 kPa
(63.8 psi)
TAD520VE: ....................................................... 390 kPa
(56.6 psi)
Idle speed (800 rpm), min: .................................... 90 kPa
(13.1 psi)
Shut down switch, at pressure lower than:
TD520GE/TAD520GE: ...................................... 200 kPa
(29 psi)
TD520VE/TAD520VE: ....................................... 50kPa
(7.2 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling: ............................................... 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size: ...................................................... 0.012 mm
(0.0005")
Bypass valve oil filter:
Opening pressure: .............................................. 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)
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Fuel system
1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve 2)
12. Return fuel line to fuel tank.
Inside diameter, min 12 mm (0.47")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
2)
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Group 20
Group 20
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in each country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in
power output of 5% and an increase in fuel consumption of 23%.
In
Out
(877 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
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Group 20
Injection pump
Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
The pump length is defined by adding the basic measurement
LO with the tolerance A/100, that are written on the injection
pump (LFB = LO + A/100).
Explanation:
LFB= The exact point when injection pumps starts delivering fuel.
LO = Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 143 + 0.63
The total length LFB = 143.63
Injection pump
Manufacturer ........................................................ Bosch
Designation .......................................................... PF 33 L
Length A: .............................................................. 54 mm
Basic measurement length LO : ............................ 143 mm
Min length LFB : (A/100+143) 143 ....................... >0 mm
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(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
Filtering size ......................................................... 0.006 mm
(0.00024")
FB
(Commencement of
delivery)
Camshaft
types
Vh
Pre-stroke
Vhcorr.factor
Lo
Pre-stroke
Basic dimension
correction factor Injection pump
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Group 20
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.
52
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Group 20
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
53
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Group 20
Governor
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer ........................................................ Heinzmann
Designation:
TD520GE/TAD520GE/TAD530-532GE: .............. 1500 rpm
TD520GE/TAD520GE/TAD530-532GE: .............. 1800 rpm
TD520VE: .......................................................... 1800 rpm
TAD520VE: ....................................................... 2100 rpm
TAD520VE: ....................................................... 2200 rpm
TAD520VE: ....................................................... 2300 rpm
Max, engine speed droop at a load increase from 0 to 100 % at rated speed:
TD520GE/TAD520GE: ...................................... <5 %
TD520VE: .......................................................... 8 12%
TAD520VE: ....................................................... 5 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated
power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod
Control rod (fuel rack) travel Y, without injection pumps
Start and stop: ...................................................... 17 17.5 mm
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.
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Group 20
1800 rpm
530C (986F)
448C (838F)
2100 rpm
470C (878F)
2200 rpm
470C (878F)
2300 rpm
470C (878F)
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)
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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)
Versatile engines are not equipped with a pressure valve from factory
1.
2.
3.
4.
5.
6.
7.
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.
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Group 20
Tightening torque
General tightening torques
Nm
1.5
(lbf.ft)
(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)
Step 1 ................................................................ 50
(37 lbf.ft)
Step 2 ................................................................. 60 angle tightening
Step 3 ................................................................. 60 angle tightening
Connecting rod big-end bearing
Use new screws every time.
Step 1 ................................................................ 50
(22 lbf.ft)
Step 2 ................................................................ 60 angle tightening
Step 3 ................................................................ 60 angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 30 angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
C) Flywheel with a screw length between 50 85 mm
Step 1: ............................................................... 30 40
(22 30 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
Flywheel housing. M12 ......................................... 991
(737 lbf.ft)
25
(17918 lbf.ft)
Flywheel housing. M16 ......................................... 243
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ............................................................... 40 50
(30 37 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
Vibration damper .................................................. 70
Screw, rocker cover ............................................... 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)
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Tightening torques
Group 20
Nm
(lbf.ft)
Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50
(37 lbf.ft)
Step 2: ............................................................... 130
(96 lbf.ft)
Step 3: ............................................................... 90 angle tightening
(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)
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)
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)
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(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
Group 20
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 ......................................
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)
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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)
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)
1)
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TAD721VE
TAD722VE
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
6
108 (4.25")
130 (5.12")
7.15 (436.3)
12
18.4:1
19.0:1
1-5-3-6-2-4
19.0:1
1-5-3-6-2-4
1951)
897
1800
850-950
2000-23001)
5722)
2001)
981
1800
800-950
2100-23001)
6802)
Group 20
General
Type designation .................................................... TAD750VE
Rotation direction, facing flywheel: ......................... Counterclockwise
Number of cylinders ............................................... 6
Bore, mm (inch) ..................................................... 108 (4.25")
Stroke, mm (inch) .................................................. 130 (5.12")
Displacement, dm3 (inch3) ....................................... 7.15 (436)
Number of valves ................................................... 12
Compression ratio: ................................................. 18.1:1
Firing sequence ..................................................... 1-5-3-6-2-4
Engine performance at 2300 rpm, kW (hp) ............. 181 (246)1, 3)
Max torque, Nm (lbf.ft) .......................................... 1050 (775)3)
At speed, rpm .................................................... 1500
Low idle, rpm ......................................................... 600 - 800
Max, full load speed, rpm ....................................... 24001)
Weight. engine (dry) kg (lb) .................................... 650 (1433)2)
Weight. engine (wet) kg (lb) .................................... 681 (1501)2)
TAD760VE
Counterclockwise
6
108 (4.25")
130 (5.12")
7.15 (436)
12
18.1:1
1-5-3-6-2-4
181 (246)1, 3)
1100 (811)3)
1500
600 - 800
24001)
650 (1433)2)
680 (1496)2)
1)
Cylinder liners
Engine block
Replacable, wet
Cylinder head
A
(26 x 5.55)
Group 20
Set the dial gauge in the level of the crankcase surface to zero.
Position the dial gauge at the measuring points A and B on the top of the piston, inline with the gudgeon pin.
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: ............................ 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")
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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 front marking, according to picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
Piston rings
Compression rings
Number of rings .................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ................................ Keystone, no clearance
Lower compression ring (2) ................................ 0.17 mm
(0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................ 0.8 mm
(0.03")
Lower compression ring (2) ................................ 2.5 mm
(0.0984")
2
3
(0.12")
(0.0039")
(0.045)
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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
(0.0827")
(0.0709")
(0.1102")
(0.0866")
(0.014"0.002")
(0.022"0.002")
Valve seats
A
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(1.933"-0.0008")
(1.695"-0.0008")
(0.295"0.004")
(0.311"0.004")
Group 20
(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
Wear limit valve stem guide:
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
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")
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Camshaft
Type of camshaft:
TD720GE, TAD720GE, TAD730GE ................... A
TD720VE, TAD720VE, TAD721VE .................... A or M
TAD721/722GE, TAD722VE, TAD731-733GE
TAD750/760VE .................................................. S
Drive ..................................................................... Gear
Number of bearings ............................................... 7
Inner diameter , bearing journals
Standard ............................................................ 65+0.054 mm
(2.559"+0.0021")
Wear limit ........................................................... 65.08 mm
(2.5622")
Camshaft bearing thickness: max ......................... 1.988+0.012 mm (0.7827"+0.0005")
Axial clearance ..................................................... 0.1 0.5 mm
(0.004 0.02")
Radial clearance ................................................... 0.05 0.124 mm(0.002 0.0049")
Position of bearing bush at flywheel end ............... 2+0.5 mm
(0.079"+0.0197")
Timing gear
1.
2.
3.
4.
5.
6.
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
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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
Max, permissible ovality of main
bearing and crank pins ....................................... 0.01 mm
Max, run-out of center bearing ............................... 0.1 mm
1)
(38.31")
(0.0039" 0.0118")
(0.0012"+0.0024")
(0.0004")
(0.00394")
E
F
C
B
A
(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")
(2.9035"+0.0014")
(0.1074"+0.0003")
(0.1123"+0.0003")
(0.1172"+0.0003")
67
Group 20
(2.6772"-0.0008")
(2.6673"-0.0008")
(2.6575"-0.0008")
(1.397"0.0008")
(0.0004")
(0.0004")
H
G
68
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(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
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Group 20
Lubricating system
Sulfur content in fuel, by weight
Engine
Oilgrade
2)
< 0,5 %
0,5 1,0 %
VDS-3
VDS-2
ACEA: E7, E5, E3
API: CI-4, CH-4, CG-4
500 h / 12 months
250 h / 12 months
125 h / 12 months
TAD721/722GE,
TAD732/733GE,
TAD750/760VE, closed
crankcase ventilation
ACEA: E4
API: CI-4, CH-4
500 h / 12 months
250 h / 12 months
125 h / 12 months
TAD722VE
power<200kW
ACEA: E4
500 h / 12 months
250 h / 12 months
125 h / 12 months
250 h / 12 months
125 h / 12 months
60 h / 12 months
power>200kW
1)
2)
If the sulfur content is > 1.0% by weight, use oil with TBN > 15 closed crankcase ventilation
For markets outside Europe, API: CG-4 and CH-4 can be used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification
ACEA = Association des Constructeurs 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.
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Group 20
(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)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling: ................................................ 2-hole nozzles for each cylinder
7. Oil filter, full-flow:
Filtering size: ......................................................... 0.012 mm
(0.0005")
Bypass valve oil filter:
(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)
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1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps,720/721/722 (6 ea.)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve2)
12. Return fuel line to fuel tank.
Inside diameter, min 12 mm (0.47")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
2)
72
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Group 20
Group 20
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")
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Group 20
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in the respective country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in power
output of 5% and an increase in fuel consumption of 23%.
In
Out
(877.2 psi)1)
(7.20.7 psi)
(158.5 gal/hour)
(72.5 psi)
(40.6 psi)
Fuel filter
Filtering size ......................................................... 0.005 mm
(0.0002")
Pre-filter
Filtering size ......................................................... 0.006 mm
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(0.00024")
Group 20
(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")
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Group 20
FB
(Commencement of
delivery)
Camshaft
types
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Vh
Pre-stroke
Vhcorr.factor
Lo
Pre-stroke
Basic dimension
correction factor Injection pump
Group 20
NOTE! Shims (Ss) are only available in a calibrated thickness, with a variation of steps in 1/10 mm. When the
theoretical shim thickness (Ts) are in the 1/100 range, use table 2 to convert it into the correct shim thickness (Ss)
Theor. thickness(TS)
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.
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Group 20
Ek(mm)
EP
code
Ek(mm)
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EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Ek(mm)
EP
code
Group 20
Governor (720733)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer ......................................................... Heinzmann
Designation:
TD720GE/TAD720GE/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
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.
(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.
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Group 20
1800 rpm
505C (941F)
433C (837F)
520C (968F)
2100 rpm
420C (788F)
475C (887F)
535C (995F)
1)
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
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(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)
Versatile engines are not equipped with a pressure valve from factory
1.
2.
3.
4.
5.
6.
7.
TD/TAD720-722:
Coolan connection (inlet)
Thermastat housing
Coolant pump
Lubrication oil cooler
Cylinder cooling
Cylinder head cooling
Coolant connection (outlet)
Coolant pump
Type ...................................................................... Belt-driven centrifugal pump
Glycol (Antifreeze)
Volvo Penta glycol (antifreeze) mixed 45/55 with clean water
Anti-corrosion agent
Used only in markets where there is no risk of freezing, mixed with water3).
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative
consequences.
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Group 20
Tightening torque
General tightening torques
Nm
1.5
(lbf.ft)
(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)
Step 1 ................................................................ 50
(37 lbf.ft)
Step 2 ................................................................. 60 angle tightening
Step 3 ................................................................. 60 angle tightening
Connecting rod big-end bearing:
Use new screws every time.
Step 1 ................................................................ 30
(22 lbf.ft)
Step 2 ................................................................ 60 angle tightening
Step 3 ................................................................ 60 angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 30 angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ............................................................... 20 30
(15 22 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
C) Flywheel with a screw length between 50 85 mm
Step 1: ............................................................... 30 40
(22 30 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
Flywheel housing. M12 .......................................... 991
(737 lbf.ft)
25
(17918 lbf.ft)
Flywheel housing. M16 .......................................... 243
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ............................................................... 40 50
(30 37 lbf.ft)
Step 2: ............................................................... 60 angle tightening
Step 3: ............................................................... 60 angle tightening
Vibration damper ................................................... 70
Screw, rocker cover .............................................. 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)
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Group 20
Tightening torques
Nm
(lbf.ft)
Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50
(37 lbf.ft)
Step 2: ............................................................... 130
(96 lbf.ft)
Step 3: ............................................................... 90 angle tightening
(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)
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)
(18.51.8 lbf.ft)
(15.51.5 lbf.ft)
(303 lbf.ft)
(80.7 lbf.ft)
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(22.1 lbf.ft)
(15.51.5 lbf.ft)
(15.51.5 lbf.ft)
Grupp 20
Technical data
TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Step 1 ................................................................. 30 Nm
(22 lbf.ft)
Step 2 ................................................................. 60 angle tightening
Step 3 ................................................................. 60 angle tightening
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530533GE
TAD750VE/760VE
Step 1 ................................................................. 50 Nm
(37 lbf.ft)
Step 2 ................................................................. 60 angle tightening
Step 3 ................................................................. 60 angle tightening
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Technical data
Grupp 20
Flywheel
(15 22 lbf.ft)
(15 22 lbf.ft)
(22 30 lbf.ft)
Step 1: ................................................................ 40 50 Nm
Step 2: ................................................................ 60 angle tightening
Step 3: ................................................................ 60 angle tightening
Vibration damper .................................................... 70 Nm
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(30 37 lbf.ft)
Grupp 20
Technical data
Cylinder head
Manifold side
Manifold side
TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Screws to cylinder head are reusable only five times.
Step 1: ................................................................ 30 Nm
(22 lbf.ft)
Step 2: ................................................................ 80 Nm
(59 lbf.ft)
Step 3: ................................................................ 90 angle tightening
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530533GE
TAD750VE/760VE
Screws to cylinder head are reusable only five times.
Step 1: ................................................................ 50 Nm
(37 lbf.ft)
Step 2: ................................................................ 130 Nm
(96 lbf.ft)
Step 3: ................................................................ 90 angle tightening
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.
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Technical data
Grupp 20
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
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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gteborg
Sweden
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