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Volvo Penta TD420VE Workshop Manual

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Workshop Manual
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Technical Data
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TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE
TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE
TAD660VE, TD720GE TAD720GE, TD720VE, TAD720VE
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE

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Summary of Contents for Volvo Penta TD420VE

  • Page 1 Workshop Manual Technical Data 1(0) TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE TAD660VE, TD720GE TAD720GE, TD720VE, TAD720VE TAD721GE, TAD721VE, TAD722GE, TAD722VE, TAD730/731/732/733GE, TAD750VE, TAD760VE...

  • Page 3: Table Of Contents

    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 Valve mechanism ..........40 Crank mechanism ..........43 General information ..........

  • Page 4: Safety Precautions

    Avoid opening the coolant filler cap when the en- AB Volvo Penta can only indicate the risks conside- gine is hot, when hot steam or coolant might sp- red likely to occur as a result of incorrect working ray out.
  • Page 5 Group 20 General Information Stop the engine before carrying out operations WARNING! Use new delivery pipes every time. on the engine cooling system. Be careful, delivery pipes should under no circu- mstances be bent. Always use protective glasses or goggles, when carrying out work where there is a risk of splint- All fuels and many chemical substances are fla- ers, grinding sparks and acid splashes or when...
  • Page 6 Turn the engine off and turn off the power at the WARNING! The components in the electrical sy- main switch/switches before carrying out work stem and in the fuel system on Volvo Penta pro- on the electrical system. ducts are designed and manufactured to minimi- ze the risk of fire and explosion.

  • Page 7: General Information

    TAD660VE, TD520GE, TAD520GE, TD520VE, Any type of damage which is the result of using spare TAD520VE, TAD530-532GE, TD720GE, TAD720GE, parts that are not original Volvo Penta parts for the TD720VE, TAD720VE, TAD721GE, TAD721VE, product in question will not be covered under any war- TAD722GE, TAD722VE, TAD730-733GE, TAD750VE, ranty or guarantee provided by AB Volvo Penta.

  • Page 8: Repair Instructions

    It is therefore critical that the stated wear tolerances the same working method. are observed, that systems which can be adjusted are correctly set up and that only Volvo Penta Original All operations described in the Workshop Manual for Parts are used.
  • Page 9 Group 20 General Information Tightening torque Lock nuts For the correct tightening torque for critical joints, Do not reuse lock nuts that have been removed during which must be tightened using a torque wrench is lis- disassembly operations as these have reduced ted under chapter “Tightening Torque”.
  • Page 10 General Information Group 20 Sealant Safety rules for fluorocarbon rubber It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in Fluorocarbon rubber is a common material in seal their original position when assembling the joint. When rings for shafts, and in O-rings.

  • Page 11: Location Of Identification Plates

    Group 20 General Information Location of identification plates (420-620, 520-722) Each engine is supplied with two identical identifica- tion plates, of which one is mounted on the right side of the cylinder block and the other one should be mou- nted in a suitable location adjacent to the engine.

  • Page 12: Tad650/660, Tad750/760

    General Information Group 20 Location of identification plates (TAD650/660, 750/760) Each engine is supplied with two identical identifica- tion plates, of which one is mounted on the right side of the cylinder block and the other one is mounted up on the valve cover.

  • Page 13: Td420Ve, Tad420Ve, Tad620Ve, Tad650Ve, Tad660Ve

    Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Technical Data TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE General Type designation ............ TD420VE TAD420VE TAD620VE Rotation direction, facing flywheel: ......Counterclockwise Number of cylinders ..........4 Bore, mm (inch) ............. 101 (3.97") 101 (3.97") 98 (3.97")

  • Page 14: General (650/660)

    Max surface unevenness ........0.1 mm (0.0039") Cylinder head bolts Thread size ............M 12 Quantity and length: TD420VE/TAD420VE .......... 13 x 108 mm (13 x 4.3") TD420VE/TAD420VE .......... 5 x 178 mm (5 x 7") Quantity and length: TAD620VE, TAD650/660VE ....... 19 x 108 mm (19 x 4.3")
  • Page 15 Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Cylinder liners Parent bore Replaceable, dry TD420VE, TAD420VE TAD620, TAD650VE TAD660VE Type: TD420VE/TAD420VE/TAD650VE ....... Parent bore TAD620VE/TAD660VE ........Dry, replaceable Bore: TD420VE/TAD420VE/TAD650VE ....... 101 +0.02 (3.976" +0.00078" +0.02 +0.00078" TAD620VE/TAD660VE ........98 (3.858"...

  • Page 16: Cylinder Head Gasket

    Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Cylinder head gasket Measuring piston projection A dial gauge with a fixture (special tool: 999 8678) is needed to measure the piston projection. The piston is in its TDC above the block surface. •...

  • Page 17: Piston Rings

    Number of piston ring grooves ........ 3 Combustion chamber: ±0.1 ±0.0039 Diameter Ø ............61 (2.402" ”) Combustion chamber depth: ±0.1 ±0.0039 TD420VE/TAD420VE .......... 18 (0.7087" ”) ±0.1 ±0.0039 TAD620VE, TAD650/TAD660VE ......17.5 (0.689" ”) Gudgeon pin diameter Ø ........38 -0.006 (1.496"...

  • Page 18: Valve Mechanism

    Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Valve mechanism Valves Disc diameter Ø: Inlet ..............41.7 ±0.1 (1.642" ±0.004" Exhaust .............. 35.9 ±0.1 (1.413" ±0.004" Stem diameter Ø: -0.015 -0.0006" Inlet ..............7.98 (0.3142" Exhaust .............. 7.96 -0.015 (0.3134" -0.0006"...

  • Page 19: Valve Seats

    Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Valve seats Ø A Outer diameter Ø (A), standard: -0.02 -0.0008" Inlet ..............42.79 (1.685" -0.02 -0.0008" Exhaust .............. 36.99 (1.456" Height (B): Inlet ..............6.8 ±0.1 (0.2677" ±0.004 ±0.1 ±0.004 Exhaust .............. 7.5 (0.2953"...

  • Page 20: Timing Gear

    Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Camshaft Type of camshaft: ..........Three different types: K, L or H Drive ..............Gear Number of bearings: TD420VE/TAD420VE .......... 5 TAD620VE, TAD650/TAD660VE ......7 Inner diameter Ø, bearing journals Standard ............. 63 +0.054 (2.48"...

  • Page 21: Crank Mechanism

    Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Crank mechanism Crankshaft length: TD420VE/TAD420VE .......... 618.8 mm (24.36") TAD620VE, TAD650/TAD660VE ......846.8 mm (33.34") Crankshaft axial clearance ........0.1-0.3 mm (0.0039"– 0.0118") +0.062 +0.0024" Main bearing radial clearance ....... 0.03 (0.0012"...
  • Page 22 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Connecting rod bearing journals Diameter Ø for machining (G): -0.02 -0.0008” Standard ..............62.994 mm (2.48" Undersize: -0.02 -0.0008” 0.25 mm (0.01") ..........62.744 mm (2.4714" Width, axial bearing journal (H): ......35.7 ±0.02 (1.4"...

  • Page 23: Connecting Rods

    Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Connecting rods ±0.02 -0.0008” Length (L): Center – Center ........192 (7.559" +0.01 +0.0004” Connecting rod bushing bore (M): ......38.025 mm (1.497" Wear limit ............0.08 mm (0.0031") Axial clearance, connecting rod – crankshaft ..

  • Page 24: Lubricating System

    Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Lubricating system Oil grade Fuel sulfur content in percent by weight Up to 0.5 % 0.5 – 1 % More than 1 % Oil change interval: In operation whichever reached first VDS-3, VDS-2 ACEA: E7, E5, E3 500 hours or 12 months 250 hours or 12 months...
  • Page 25 Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Engine oil quantity With oil filter: TD420VE/TAD420VE .......... 10 liter (2.64 US gal) TAD620VE, TAD650/TAD660VE ......16 liter (4.22 US gal) TD420VE/TAD420VE TAD620VE, TAD650VE, TAD660VE 1. Oil pressure sensor Oil pressure, at operation temperature, min 120°C (248°F) At rated speed: TD420VE/TAD420VE ..........

  • Page 26: Fuel System

    Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Fuel system (420, 620) 1. Fuel tank. Max height above fuel pump. 2 meter (6.5 ft) Max suction height to fuel pump. 1.5 meter (4.9 ft) 2. Fuel line (to pump). Inside diameter. min 12 mm (0.47") 3.
  • Page 27 Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Fuel system (650, 660) 1. Fuel tank 8. Highpressure pump 2. Hand pump (accessory) 9. Fuelpipe, to injector 3. Fuel line (to pump) 10. Injector 4. Fuel pump 11. M-prop 5. Fuel filter 12.

  • Page 28: Fuel Specification

    Fuel flow: Min fuel flow at 1500 rpm........600 l/hour (158.5 gal/hour) Firing sequence TD420VE/TAD420VE .......... 1-3-4-2 TAD620VE/TAD650VE/TAD660VE ..... 1-5-3-6-2-4 Feed pressure ............0.5 MPa (72.5 psi) Feed pressure after fuel filter At 1500 rpm: Min ..........0.28 MPa...
  • Page 29 Check leakage (for 10 sek): TD420VE ............20 MPa (2900 psi) TAD420VE/TAD620VE ........23 MPa (3340 psi) Numbers/bore Ø: TD420VE ............6 x 0.205 mm (6 x 0.008") TAD420VE/TAD620VE ........6 x 0.203 mm (6 x 0.0079") Fuel filter Filtering size: ............0.005 mm (0.0002")
  • Page 30 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Commencement of delivery (FB) 420/620 The engine is equipped with a separate injection pump for each cy- linder. This means that the commencement of delivery (FB), when necessary, has to be adjusted separate for each pump unit. The commencement of delivery (FB) is adjusted with a shim, placed between lifter and injection pump.
  • Page 31 Grupp 20 Tekniska data Theoretical thickness for a new shim (420/620) Computation for determining the theoretical shim thickness (T = L - [ ( FB - FB ) x Vh + Vh + A/100 ] (mm) actual corr.factor The correction factor Vh is taken from the table on previous page.
  • Page 32 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 How to use EP code (420/620) For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified met- hod, when there is only the tolerance between the new and old injection pump that is the difference. - (L + A/100) = Shim thickness...
  • Page 33 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).

  • Page 34: Intake And Exhaust System

    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 water The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative consequences.

  • Page 35: Tightening Torque

    Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Tightening torque General tightening torques (lbf.ft) ±1.5 ±1 M6 standard screw 8.8 ........... 10 (7.5 lbf.ft) ±4 ±3 M8 standard screw 8.8 ........... 25 lbf.ft) ±8 ±6 M10 standard screw 8.8 ......... 50 lbf.ft) M12 standard screw 8.8 .........
  • Page 36 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Group 20 Tightening torques (lbf.ft) Cylinder head Screws to cylinder head are reusable only three times. Step 1: ..............30 (22 lbf.ft) Step 2: ..............80 (59 lbf.ft) Step 3: ..............90° angle tightening Group 22 Oil system Oil cooler, screws ..........
  • Page 37 Group 20 Technical data: TD/TAD420VE, TAD620VE, TAD650VE, TAD660VE Tightening torques (lbf.ft) Group 25 Inlet and exhaust system Exhaust manifold nuts ........... 25 ±2.5 (18.5 ±1.8 lbf.ft) M8 Nuts, turbo to exhaust manifold ....... 21 ±2 (15.5 ±1.5 lbf.ft) M10 Nuts, turbo to exhaust manifold ...... 40.5 ±4 ±3 lbf.ft)

  • Page 38: Td520Ge, Tad520Ge, Td520Ve, Tad520Ve, Tad530-532Ge

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Technical Data TD520GE, TAD520GE, TD520VE, TAD520VE TAD530/531/532GE General Type designation ........... TD520GE TAD520GE TD520VE TAD520VE Rotation direction, facing flywheel: ....... Counterclockwise Number of cylinders ..........4 Bore, mm (inch) ............ 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25") Stroke, mm (inch) ..........

  • Page 39: Engine Block

    Group 20 Technical Data: TD/TAD520, TAD530/531/532 General TAD531GE TAD532GE TAD530GE Type designation ..........Anti- clockwise Anti- clockwise Anti- clockwise Direction of rotation (seen from flywheel) No. of cylinders ..........108 (4.25”) 108 (4.25”) 108 (4.25”) Cylinder bore mm (inch) ........130 (5.12”) 130 (5.12”) 130 (5.12”)
  • Page 40 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Cylinder head gasket Measuring piston projection A dial gauge with a fixture (special tool: 999 8678) is needed to measure the piston projection. The piston is in its TDC above the block surface. • Set the dial gauge in the level of the crankcase surface to ”zero”.
  • Page 41 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Pistons Number of piston ring grooves ......3 Combustion chamber: ±0.1 ±0.0039" Diameter ............71 (2.795" ±0.1 ±0.0039" Depth ..............16.66 (0.6559" -0.006 -0.0002" Gudgeon pin diameter .......... 42 (1.6535" 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.

  • Page 42: Valve Mechanism

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Valve mechanism Valves Disc diameter Ø: Inlet ..............48 ±0.1 (1.8898" ±0.0039" Exhaust ............. 42 ±0.1 (1.6535" ±0.0039" Stem diameter Ø: -0.015 -0.0006" Inlet ..............8.98 (0.3535" Exhaust ............. 8.96 -0.015 (0.3528" -0.0006" Valve seat angle: Inlet, min ............
  • Page 43 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Valve seat location Ø C Diameter Ø (C), standard: Inlet ..............49 +0.025 (1.929" -0.001" Exhaust ............. 43.5 +0.025 (1.712" -0.001" Depth (D): +0.04" Inlet/Exhaust ............11 (0.43" Seat bottom radius (R): -0.3 -0.012" Inlet/Exhaust ............
  • Page 44 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Camshaft Type of camshaft: ..........A Drive ..............Gear Number of bearings ..........5 Inner diameter Ø, bearing journals +0.054 +0.0021" Standard ............65 (2.559" Wear limit ............65.08 mm (2.5622") Camshaft bearing thickness: max ......1.988 +0.12 (0.7827"...

  • Page 45: Crank Mechanism

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Crank mechanism Crankshaft length ..........709.2 mm (27.92") Crankshaft axial clearance ......... 0.1– 0.3 mm (0.0039"– 0.0118") Main bearing radial clearance ......0.03 +0.062 (0.0012" +0.0024" Max, permissible ovality of main bearing and crank pins ........0.01 mm (0.0004") Max, run-out of center bearing ......
  • Page 46 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Connecting rod bearing journals Diameter Ø (G) for machining: -0.02 -0.0008" Standard ............... 68 (2.6772" Undersize: 0.25 mm (0.01") ..........67.75 -0.02 (2.6673" -0.0008" -0.02 -0.0008" 0.5 mm (0.02") ........... 67.5 (2.6575" ±0.04 ±0.0016" Width (H), axial bearing journal.
  • Page 47 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Connecting rods ±0.06 ±0.00236" Length (L): Center – Center ........210 (8.2677" +0.01 0.0004" Connecting rod (M) bushing bore ......42.04 (1.6551" Wear limit ............0.08 mm (0.0031") Replacing measurement for small end bush Bore for small end bush ........

  • Page 48: Lubricating System

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Lubricating system Oil grade Fuel sulfur content in percent by weight Up to 0.5 % 0.5 – 1 % More than 1 % Oil change interval: In operation whichever reached first VDS-3, VDS-2 ACEA: E7, E5, E3 500 hours or months 250 hours or months 125 hours or months...
  • Page 49 Group 20 Technical Data: TD/TAD520, TAD530/531/532 Engine oil quantity With oil filter: TD520GE/TAD520GE: ........10 liter (2.64 US gal) TD520VE/TAD520VE: ........13 liter (3.43 US gal) TAD530/531/532GE: .......... 13 liter (3.43 US gal) 1. Oil pressure sensor Oil pressure, at operation temperature, min 120°C (248°F) At rated speed: TD520GE/TAD520GE/TAD530-532GE : .

  • Page 50: Fuel System

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Fuel system 1. Fuel tank. Max height above fuel pump. 2 meter (6.5 ft) Max suction height to fuel pump. 1.5 meter (4.9 ft) 2. Fuel line (to pump). Inside diameter. min 12 mm (0.47") 3.
  • Page 51 Technical Data: TD/TAD520, TAD530/531/532 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.

  • Page 52: Injection Pump

    Technical Data: TD/TAD520, TAD530/531/532 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.
  • Page 53 Group 20 Technical Data: TD/TAD520, TAD530/531/532 Injectors Opening pressure: TD520GE, TAD530-532GE: ....... 25 MPa (3600 psi) TAD520GE/TD520VE/TAD520VE: ....27.5 MPa (4000 psi) Max pressure ............120 MPa (17400 psi) Check leakage (for 10 min): TD520GE, TAD530-532GE: ....... 23 MPa (3340 psi) TAD520GE/TD520VE/TAD520VE: ....
  • Page 54 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Theoretical thickness for a new shim. Computation for determining the theoretical shim thickness (T = L - [ ( FB - FB ) x Vh + Vh + A/100 ] (mm) actual corr.factor The correction factor Vh is taken from the table on previous page.
  • Page 55 Technical Data: TD/TAD520, TAD530/531/532 Group 20 How to use EP code For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified met- hod, when there is only the tolerance between the new and old injection pump that is the difference. - (L + A/100) = Shim thickness...
  • Page 56 Technical Data: TD/TAD520, TAD530/531/532 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.

  • Page 57: Intake And Exhaust System

    Group 20 Technical Data: TD/TAD520, TAD530/531/532 Intake and exhaust system Turbocharger Make and designation ........... Schweitzer S2B Boost pressure at rated speed , ±10 %: TD520GE/TAD530-532GE (1500 rpm): ....125 kPa (18 psi) TD520GE/TAD530-532GE (1800 rpm): ....137 kPa (20 psi) TAD520GE (1500 rpm): ........

  • Page 58: Cooling System

    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 water The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative consequences.

  • Page 59: Tightening Torque

    Technical Data: TD/TAD520, TAD530/531/532 Group 20 Tightening torque General tightening torques (lbf.ft) ±1.5 ±1 M6 standard screw 8.8 .......... 10 (7.5 lbf.ft) ±4 ±3 M8 standard screw 8.8 .......... 25 lbf.ft) ±8 ±6 M10 standard screw 8.8 ........50 lbf.ft) M12 standard screw 8.8 ........
  • Page 60 Technical Data: TD/TAD520, TAD530/531/532 Group 20 Tightening torques (lbf.ft) Cylinder head Screws to cylinder head are reusable only five times. Step 1: ............... 50 (37 lbf.ft) Step 2: ............... 130 (96 lbf.ft) Step 3: ............... 90° angle tightening Group 22 Oil system ±2 ±1.5 Oil cooler, screws ..........

  • Page 61: Td720Ge, Tad720Ge, Td720Ve, Tad720Ve, Tad721Ge, Tad721Ve, Tad722Ge, Tad722Ve, Tad730-733Ge, Tad750Ve, Tad760Ve General (720-722Ge )

    Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Technical Data TD/TAD720GE, TD/TAD720VE, TAD721GE/VE, TAD722GE, TAD722VE, TAD730/731/732/733GE, TAD750VE, TAD760VE General Type designation ......TD720GE TAD720GE TAD721GE TAD722GE Rotation direction, facing flywheel: Counterclockwise Number of cylinders ..... 6 Bore, mm (inch) ......108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")

  • Page 62: General (720-722Ve)

    Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 General TAD732GE TAD733GE TAD730GE TAD731GE Type designation ........ Anti- clockwise Anti- clockwise Anti- clockwise Direction of rotation Anti- clockwise (seen from flywheel) No. of cylinders ........108 (4.25”) 108 (4.25”) 108 (4.25”) 108 (4.25”) Cylinder bore mm (inch) ......

  • Page 63: Engine Block

    Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 General Type designation ............ TAD750VE TAD760VE Rotation direction, facing flywheel: ......Counterclockwise Counterclockwise Number of cylinders ..........6 Bore, mm (inch) ............. 108 (4.25") 108 (4.25") Stroke, mm (inch) ..........130 (5.12") 130 (5.12") Displacement, dm (inch ) ........
  • Page 64 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20 Cylinder head gasket Measuring piston projection A dial gauge with a fixture (special tool: 999 8678) is needed to measure the piston projection. The piston is in its TDC above the block surface. •...
  • Page 65 Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Pistons Number of piston ring grooves ....... 3 Combustion chamber: ±0.1 ±0.0039" Diameter Ø ............71 (2.795" ±0.1 ±0.0039" Depth ..............16.66 (0.6559" -0.006 -0.0002" Gudgeon pin diameter Ø ........42 (1.6535" 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.

  • Page 66: Valve Mechanism

    Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20 Valve mechanism Valves Disc diameter Ø: Inlet ..............48 ±0.1 (1.8898" ±0.0039" Exhaust ............. 42 ±0.1 (1.6535" ±0.0039" Stem diameter Ø: -0.015 -0.0006" Inlet ..............8.98 (0.3535" Exhaust ............. 8.96 -0.015 (0.3528" -0.0006" Valve seat angle: Inlet, min ............
  • Page 67 Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Valve seat location Ø C Diameter Ø (C), standard: Inlet ..............49 -0.025 (1.929" -0.001" -0.02 -0.001" Exhaust ............. 43.5 (1.712" Depth (D): +0.04" Inlet/Exhaust ............. 11 (0.43" Seat bottom radius (R): Inlet/Exhaust ............. 1 -0.3 (0.04"...
  • Page 68 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 Camshaft Type of camshaft: TD720GE, TAD720GE, TAD730GE ....A TD720VE, TAD720VE, TAD721VE ....A or M TAD721/722GE, TAD722VE, TAD731-733GE TAD750/760VE ..........S Drive ..............Gear Number of bearings ..........7 Inner diameter Ø, bearing journals +0.054 +0.0021"...

  • Page 69: Crank Mechanism

    Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Crank mechanism Crankshaft length ..........973.2 mm (38.31") Crankshaft axial clearance ........0.1– 0.3 mm (0.0039"– 0.0118") Main bearing radial clearance ......0.03 +0.062 (0.0012" +0.0024" Max, permissible ovality of main bearing and crank pins ........0.01 mm (0.0004") Max, run-out of center bearing .......
  • Page 70 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20 Connecting rod bearing journals Diameter Ø (G) for machining: Standard ............... 68 -0.02 (2.6772" -0.0008" Undersize: -0.02 -0.0008" 0.25 mm (0.01") ..........67.75 (2.6673" -0.02 -0.0008" 0.5 mm (0.02") ........... 67.5 (2.6575" Width (H), axial bearing journal......35.5 ±0.02 (1.397"...
  • Page 71 Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Connecting rods Length (L): Center – Center ........210 ±0.06 (8.2677" ±0.00236" +0.01 0.0004" Connecting rod (M) bushing bore ......42.04 (1.6551" Wear limit ............0.08 mm (0.0031") Replacing measurement for small end bush +0.02 0.0008"...

  • Page 72: Lubricating System

    Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 Lubricating system Sulfur content in fuel, by weight Engine Oilgrade < 0,5 % 0,5 – 1,0 % > 1,0 % Oil change interval, reached first in operation T(A)D720-721VE VDS-3 500 h / 12 months 250 h / 12 months 125 h / 12 months T(A)D720GE...
  • Page 73 Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Engine oil quantity With oil filter: TD720/TAD720/TAD721VE: ....... 20 liter (5.28 US gal) TAD722VE/TAD750VE/TAD760VE ....23 liter (6.10 US gal) TAD721GE/TAD722GE ........34 liter (8.98 US gal) 1. Oil pressure sensor Oil pressure, at operation temperature, min 120°C (248°F) At rated speed: TD720GE, TAD720/721/722GE, TAD730-733GE:400 kPa (58 psi)

  • Page 74: Fuel System

    Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 Fuel system (720– 733) 1. Fuel tank. Max height above fuel pump. 2 meter (6.5 ft) Max suction height to fuel pump. 1.5 meter (4.9 ft) 2. Fuel line (to pump). Inside diameter. min 12 mm (0.47") 3.
  • Page 75 Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Fuel system (750,760) 1. Fuel tank 8. Highpressure pump 2. Hand pump (accessory) 9. Fuelpipe, to injector 3. Fuel line (to pump) 10. Injector 4. Fuel pump 11. M-prop 5. Fuel filter 12. Pressure valve 6.

  • Page 76: Fuel Filter

    Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 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.
  • Page 77 Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Injection pump (720– 733) Basic measurements The injection pumps are made by BOSCH and are of a single type, that mean one for each cylinder. During the manufacturing of the injection pumps, it is found that the length will varies from pump to pump.
  • Page 78 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 Commencement of delivery (FB) 720–733 The engine is equipped with a separate injection pump for each cylinder. This means that the commencement of delivery (FB), when necessary, has to be adjusted separate for each pump unit. The commencement of delive- ry (FB) is adjusted with a shim, placed between lifter and injection pump.
  • Page 79 Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Theoretical thickness for a new shim (720–733) Computation for determining the theoretical shim thickness (T = L - [ ( FB - FB ) x Vh + Vh + A/100 ] (mm) actual corr.factor The correction factor Vh is taken from the table on previous page.
  • Page 80 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 How to use EP code (720–733) For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified met- hod, when there is only the tolerance between the new and old injection pump that is the difference. - (L + A/100) = Shim thickness...
  • Page 81 Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Governor (720–733) The governors are mechanical variable-speed governors with centrifugal measuring element by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill the regulations for emission and performance.

  • Page 82: Intake And Exhaust System

    Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20 Intake and exhaust system Turbocharger , make and designation: TD720GE/TAD720GE/TD720VE/TAD730GE: ......Schwitzer S2B TAD720/721/722/750/760VE: EPA 1: ..................Schwitzer S2B COM 2: ..................Schwitzer S200 TAD721/722GE, TAD731–733GE ..........Schwitzer S200 Boost pressure at rated speed , ±...

  • Page 83: Cooling System

    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 water The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative consequences.

  • Page 84: Tightening Torque

    Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20 Tightening torque General tightening torques (lbf.ft) ±1.5 ±1 M6 standard screw 8.8 .......... 10 (7.5 lbf.ft) ±4 ±3 M8 standard screw 8.8 .......... 25 lbf.ft) ±8 ±6 M10 standard screw 8.8 ........50 lbf.ft) M12 standard screw 8.8 ........
  • Page 85 Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Tightening torques (lbf.ft) Cylinder head Screws to cylinder head are reusable only five times. Step 1: ............... 50 (37 lbf.ft) Step 2: ............... 130 (96 lbf.ft) Step 3: ............... 90° angle tightening Group 22 Oil system Oil cooler, screws ..........
  • Page 86 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20 Tightening torques (lbf.ft) Group 25 Inlet and exhaust system Exhaust manifold nuts .......... 25 ±2.5 (18.5 ±1.8 lbf.ft) ±2 ±1.5 M8 Nuts, turbo to exhaust manifold ...... 21 (15.5 lbf.ft) M10 Nuts, turbo to exhaust manifold ..... 40.5 ±4 ±3 lbf.ft)

  • Page 87: Tightening Diagram

    Grupp 20 Technical data Tightening torque diagram Main bearing caps: Screws to main bearing caps are reusable only three times. TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE Step 1 ..............30 Nm (22 lbf.ft) Step 2 ..............60° angle tightening Step 3 ..............60° angle tightening TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE...
  • Page 88 Technical data Grupp 20 Flywheel A) Flywheel with screws of max 30 mm length Step 1: ..............20 – 30 Nm (15 – 22 lbf.ft) Step 2: ..............60° angle tightening Step 3: ..............30° angle tightening B) Flywheel with screws up to 45 mm length Step 1: ..............
  • Page 89 Grupp 20 Technical data Cylinder head Manifold side Manifold side TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE Screws to cylinder head are reusable only five times. Step 1: ..............30 Nm (22 lbf.ft) Step 2: ..............80 Nm (59 lbf.ft) Step 3: ..............90° angle tightening TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE...
  • Page 90 Technical data Grupp 20 Delivery pipe (not apply for 650/660, 750/760) Fit a new delivery pipe and rubber seal. Tighten the nuts by hand. When installing delivery pipes, be sure to fit the sealing cones exactly in the pump and injector. Delivery pipe Step 1: ..............
  • Page 91 From: ....................................................................Refers to publication: ............................. Publication No.: ............. Date of issue: ..............Proposal/motivation: ....................................................................................................................................................................................................................................................................................................................Date: ..............Signed: ............. AB Volvo Penta Technical Information Dept. 42200 SE-405 08 Göteborg Sweden...

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