Volvo TAD 620VE Workshop Manual Technical Data

Workshop Manual I
Technical Data 1(0)
TD420VE, TAD420VE, TD520GE, TAD520GE

TD520VE, TAD520VE, TAD620VE, TD720GE
TD720VE, TAD720GE, TAD720VE, TAD721GE
TAD721VE, TAD722GE, TAD722VE
Group 20 General Information
Technical Data
Industrial Engines
TD420VE, TAD420VE, TAD620VE, TD520GE, TAD520GE,

TD520VE, TAD520VE, TD720GE, TAD720GE, TD720VE,
TAD720VE, TAD721GE, TAD721VE, TAD722GE, TAD722VE
Contents
Safety precautions ............................................... 2 Lubricating system .............................................. 42
General information ............................................. 5 Fuel system ........................................................ 44
Repair instructions ............................................... 6 Intake and exhaust system ................................. 51
Location of identification plates .......................... 9 Cooling system ................................................... 52
Tightening torque ................................................ 53
TD420VE, TAD420VE, TAD620VE
General ............................................................... 10 TD720GE, TAD720GE, TD720VE, TAD720VE,
Engine block ....................................................... 11 TAD721GE, TAD721VE, TAD722GE, TAD722VE
Valve mechanism ............................................... 14 General ............................................................... 55
Crank mechanism ............................................... 17 Engine block ....................................................... 57
Lubricating system .............................................. 20 Valve mechanism ............................................... 60
Fuel system ........................................................ 22 Crank mechanism ............................................... 63
Intake and exhaust system ................................. 29 Lubricating system .............................................. 66
Cooling system ................................................... 29 Fuel system ........................................................ 68
Tightening torque ................................................ 30 Intake and exhaust system ................................. 75
Cooling system ................................................... 76
TD520GE, TAD520GE, TD520VE, TAD520VE Tightening torque ................................................ 77
General ............................................................... 32
Engine block ....................................................... 33 Tightening diagram ............................................. 79
Valve mechanism ............................................... 36
Crank mechanism ............................................... 39 References to Service Bulletines ......................... 83
1
General Information Group 20
Safety Precautions
Below is a summary of the risks involved and sa-
Introduction fety precautions you should always observe or
Workshop Manuals contains technical specifications, carry out when operating or servicing the engine.
descriptions, and instructions for the repair of the spe-
Immobilize the engine by turning off the power
cified Volvo Penta products or product types. Check
supply to the engine at the main switch (switch-
that you have the correct Workshop Manual and the
es) before starting work. Put a warning notice at
latest Service Bulletins for your engine.
the engine control panel.
Before starting work on the engine, read these
sections of the Workshop Manual: Generally, all service operations must be car-
• Safety Precautions ried out with the engine stopped.
However, some work, for example certain adju-
• General Information
stments requires that the engine is running when
• Repair Instructions they are carried out.
Approaching an engine, which is operating, is a
safety risk. Loose clothing or long hair can fas-
ten in rotating parts and cause severe personal
injury.
Take care to avoid contact with hot surfaces

(exhaust pipes, turbocharger, air intake pipe, st-
arter element etc.) and hot liquids in lines and
hoses on an engine that is running or has just
Important been stopped. Reinstall all protective parts re-
moved during service operations before starting
In this book and on the product you will find the follo- the engine.
wing special warning symbols.
WARNING! Possible danger of personal injury, Check that the warning or information labels on
extensive damage to property or serious mech- the product are always clearly visible. Replace
anical malfunction if the instructions are not fol- labels that have been damaged or painted over.
lowed.
Never start the engine without installing the air
IMPORTANT! Used to draw your attention to so- cleaner filter. Foreign objects entering the intake
mething that can cause damage or malfunc-ti- ducts can also cause mechanical damage.
ons on a product or damage to property.
Never use ether or similar products when start-
NOTE! Used to draw your attention to important ing the engine. They may cause an explosion in
infor-mation that will facilitate the work or opera- the inlet manifold and causing personal injuries.
tion in progress.
Only start the engine in a well-ventilated area.
Warning symbols used in the Workshop Manual are If operating the engine in an enclosed area ma-
not in any way comprehensive since it is impossible ke sure that the exhaust is leading out of the en-
to predict every circumstance under which service wo- gine compartment and working area.
rk or repairs may be carried out.
AB Volvo Penta can only indicate the risks conside- Avoid opening the coolant filler cap when the en-
red likely to occur as a result of incorrect working gine is hot, when hot steam or coolant might sp-
methods in a well-equipped workshop using working ray out. If the filler cap must be open, slowly re-
methods and tools tested by AB Volvo Penta. lease the pressure in the system. Be very car-
eful, it is difficult to anticipate in which direction
hot steam or coolant can spray out.
2
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 mmable. Do not allow naked flame or sparks in
other chemicals are in use. The eyes are extre- the working area!
mely sensitive and an injury could result in blin- Make sure that the working area is well ventilat-
dness! ed and take the necessary safety precautions
before starting welding or grinding work.
Avoid getting hot oil on your skin, it might cause Make sure that there always are fire extinguish-
severe burns. Ensure that the lubrication syste- ers in the working area.
m is not under pressure before carrying out any
work. Never start or operate the engine with the Ensure that rags soaked in oil or fuel are stored
oil filler cap removed, otherwise oil could be eje- safely. Rags soaked in oil can spontaneously
cted. ignite. Used fuel filters, oil filters, lubricating oil,
contaminated fuel, solvent and degreasing agen-
Exposure to oil over a long period or repeatedly ts are environmentally dangerous waste and mu-
will cause problems such as skin drying out, ir- st be deposited at an approved site for dest-ruc-
ritation and toxic eczema. Used oil is in a health tion.
aspect even more dangerous than new oil. Use
protective gloves. Use protection creams, which Never expose a battery to naked flame or elect-
will ease up cleaning of the skin and counteract rical sparks. Batteries always produce hydrogen
drying out. gas, which mixed with air form an explosive gas
– oxyhydrogengas.
Many chemicals such as oils, glycol, diesel oil This gas is highly volatile and easily ignited. In-
and other chemicals, for example degreasing correct connection of the battery can cause a
agents, paint and solvents are dangerous to yo- single spark that is sufficient to cause an explo-
ur health. sion. Be very careful when attempting to ju-mp-
Always follow the safety precautions for the pro- start the engine and do not at any time lean over
duct, for example using protective mask, glass- the batteries.
es, gloves etc. Make sure of good ventilation is
provided in the working area. Follow the instruc- Always ensure that the Plus (positive) and Min-
tions on the product, when disposing used che- us (negative) battery leads are correctly insta-
micals. lled. Incorrect installation can result in severe
damage to the electrical equipment. Refer to the
Follow extreme care when working with/or chec- wiring diagrams.
king the fuel system. Use eye protection. The
jet from a fuel injector nozzle is under extremely Always use protective goggles when charging
high pressure and can cause severe personal and handling the batteries. Battery electrolyte
injury. contains sulfuric acid, which is highly caustic.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately us-
ing plenty of water and soap and if it is exposed
to the eyes, immediately flush with plenty of wa-
ter and obtain medical assistance at once.
3
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.
Clutch adjustments must be carried out with the The engine must not be run in areas where there
engine stopped. are explosive materials.
Use the lifting eyes fitted on the engine when lif- Always use the fuels recommended by AB Vol-
ting the drive unit. Always check that the lifting vo Penta. Refer to the Instruction Book. Use of
equipment is in good condition and has the cor- fuels that are of a lower quality can damage the
rect load capacity to lift the engine (engine wei- engine. On a diesel engine, poor quality fuel can
ght including gearbox, if fitted, and any extra eq- cause the control rod to seize, which can result
uipment installed). in an over revving of the engine, risking of da-
To make sure of safe handling and to avoid da- maging to the engine and of personal injuries.
mage, use a lifting beam to raise the engine. Poor fuel quality can also lead to higher mainte-
This lifting beam is installed on the top of the nance costs.
engine, make sure that all chains and cables sh-
ould run parallel to each other. Observe the following rules when cleaning with
If extra equipment is installed on the engine that high-pressure water jets. Never direct the water
would alter its center of gravity, it is required th- jet at seals, rubber hoses, or electrical compo-
at the lifting device has to be altered for obtain- nents. Never use a high-pressure jet when was-
ing the correct balance for safe handling. hing the engine.
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 cle-
ar and not damaged during the lifting operations.
Check before starting work if there is eno-ugh
room to carry out removal work without risk-ing
personal injury or damage to the engine or parts.
© 2004 AB VOLVO PENTA

All rights to changes or modifications reserved.
4
Printed on environmentally-friendly paper
General Information
About this Workshop Manual Spare parts
This Workshop Manual contains technical data for the Spare parts for the electrical and fuel systems are
repair of the following engines in standard format: subject to various national safety requirements. Volvo
TD420VE, TAD420VE, TAD620VE, TD520GE, Penta Original Spare Parts meet these specifications.
TAD520GE, TD520VE, TAD520VE, TD720GE, Any type of damage which is the result of using spare
TAD720GE, TD720VE, TAD720VE, TAD721GE, parts that are not original Volvo Penta parts for the
TAD721VE, TAD722GE och TAD722VE. product in question will not be covered under any war-
The Engine Designation and Engine Numbers can be ranty or guarantee provided by AB Volvo Penta.
found on the Identification plates. Please always in-
clude both the engine designation and the engine
number in all correspondence.
Engine certificate
The Workshop Manual is produced primarily for the Engine certificates to meet national and regional en-
use of Volvo Penta workshops and service technici- vironmental legislation carry with them an undertaking
ans. For this reason, the manual presupposes a cer- from the manufacturer that both new and existing eng-
tain basic knowledge and that the user can carry out ines in use meet the environmental demands of the
the mechanical/electrical work described to a general legislation. The product must correspond to the valida-
standard of engineering competence. ted example that was granted certification. In order for
AB Volvo Penta as the manufacturer to take respons-
Volvo Penta products are under a continual process of
ibility for engines in use, certain requirements regar-
development and we therefore reserve all rights regar-
ding service and spare parts must be met by the user
ding changes and modifications. All the information in
according to the following:
this manual is based on product specifications availa-
ble at the time the book was published. Any essential • The Service Intervals and maintenance operations
changes or modifications introduced into production or recommended by Volvo Penta must be followed.
updated or revised service methods introduced after • Only Volvo Penta Original Spare Parts intended
the date of publication will be provided in the form of for the engine certificates may be used.
Service Bulletins from AB Volvo Penta.
• Service work on the injection pump and injectors
must always be carried out by an authorized Vol-
Power standards vo Penta workshop.
The engine performance corresponds to: • The engine may not be altered or modified in any
ISO 3046, BS 5514, and DIM 6271. way, with the exception of accessories and servi-
Prime power rating corresponds to ISO standard po- ce kits developed by Volvo Penta for that engine.
wer for continues operation. It is applicable for supply- • No modifications to the exhaust pipes and air
ing electrical power at variable load for an unlimited supply ducts for the engine room (ventilation
number of hours instead of commercial purchased po- ducts) may be undertaken as this may effect ex-
wer. A ten-percent overload capability is available for haust emissions.
this rating.
• Any seals on the engine may not be broken other
Standby Power rating corresponds to ISO Standard than by authorized persons.
Fuel Stop Power. It’s is applicable for supplying
standby electrical power at variable load in areas well IMPORTANT! If replacement parts are required,
est-ablished electrical networks in event of normal uti- use only AB Volvo Penta Original Parts.
lity power failure. No overload capability is available
for this rating. Use of replacement parts other than AB Volvo Pen-
NOTE! The technical data applies to an engine without cooling
ta Original Parts will result in AB Volvo Penta be-
fan and operating on a fuel with calorific value of 42.7 MJ/kg ing unable to assume any liability that the engine
(18360 BTU/lb.) and a density of 0.84 kg/liter (7.01 lb./US gal, corresponds to the engine certificates variant.
8.42 lb./lmp. gal) even when it involves a deviation from
standards. AB Volvo Penta excludes any liability for all and any
type of damage or costs caused by the use of repla-
cement parts that are not Volvo Penta Original Parts
for the product in question.
5
Repair instructions
Introduction Our joint responsibility
The working methods described in the Workshop Every engine consists of many systems and compo-
Manual apply to work carried out in a workshop. nents that work together. If one component deviates
The engine has been removed and is installed in from the technical specifications, than this can have
an engine fixture. dramatic consequences on the environmental impact,
Unless otherwise stated reconditioning work that even if it is otherwise in good running order.
can be carried out with the engine in place follows It is therefore critical that the stated wear tolerances
the same working method. are observed, that systems which can be adjusted are
All operations described in the Workshop Manual for correctly set up and that only Volvo Penta Original
which there are Volvo Penta Special Tools available Parts are used.
assume that the service technician or person carrying The stated service intervals in the Maintenance Sche-
out the repair uses these tools. dule must be followed.
Volvo Penta Special Tools have been specifically de- Some systems, such as the components in the fuel
veloped to ensure as safe and rational working met- system, require special expertise and special testing
hods as possible. equipment for service and maintenance.
Person or persons using other than Volvo Penta Spe- Some components are factory sealed for environ-men-
cial Tools or approved Volvo Penta working methods tal and product specific reasons. Don’t under no cir-
(as described in a Workshop Manual or Service Bulle- cumstances attempt to service or repair a sealed co-
tin). Has the responsibility to acquaint themselves of mponent, unless it is done by a authorized service te-
the risk of personal injury or actual mechanical dama- chnician.
ge or malfunction.
Bear in mind that most chemical products, incorrectly
In some cases special safety precautions and user in- used, are hazardous to the environment.
structions may be required in order to use the tools
and chemicals mentioned in the Workshop Manual, al- AB Volvo Penta recommends the use of biodegrada-
ways follow these precautions, as there are no speci- ble degreasing agents for all cleaning of engine com-
fic instructions given in the Workshop Manual. ponents, unless otherwise is stated in the Workshop
Manual.
By following these basic recommendations and using
common sense it is possible, to avoid most of the Pay special attention to make sure that oils and wash-
risks involved in the work. A clean work place and a ing residue are handled correctly for destruction, and
clean engine will eliminate many risks of personal inju- not end up in the nature.
ry and engine malfunction.
Above all when working on the fuel system, lubrication
system, intake system, turbocharger, bearings and
seals. It is extremely important to observe the highest
standards of cleanliness and avoid dirt or foreign ob-
jects entering the parts or systems, since this can re-
sult in reduced service life or malfunctions.
6
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”. For correct service life when reused. Use new nuts when
tightening torque, is it important to apply cleaned th- assembling or reinstalling.
reads, bolt heads and mating surfaces, with lightly oi- For lock nuts with a plastic insert such as Nylock®
led or dry threads. In places where grease, locking or the tightening torque stated in the table is reduced if
sealing agents is required for screwed joints, the cor- the Nylock® nut has the same head height as a stan-
rect torque is stated in “Tightening Torque”. dard hexagonal nut without plastic insert.
When no tightening torque is stated, use the general Reduce the tightening torque by 25% for bolt size M8
tightening torque, according to the table below. or larger.
Dimension Tightening torque If Nylock® nuts are higher, or of the same height as a
Nm (lbf.ft.) standard hexagonal nut, the tightening torque’s given
M5 ......................................................... 6 (4.4) in the table applies.
M6 ......................................................... 10 (7.4)
M8 ......................................................... 25 (18.4)
M10 ....................................................... 50 (36.9)
M12 ....................................................... 80 (59.0)
M14 ....................................................... 40 (103.3)
Tightening torque with Strength classes

protractor tightening Bolts and nuts are divided up into different classes of
strength, the number on the bolt head indicates the
(angle tightening) class. A high number indicates stronger material, for
Tightening using both a torque setting and a protractor example a bolt marked 10-9 indicates a higher
angle requires that first the recommended torque is strength than one marked 8-8.
applied using a torque wrench and then the recom- It is therefore important that bolts removed during the
mended angle is added according to the protractor disassembly of a bolted joint must be reinstalled in
scale. Example: A 90° protractor tightening means their original position when assembling the joint.
that the joint is tightened a further 1/4 turn in one ope- When replacing a bolt, check in the spare parts cata-
ration after the stated tightening torque has been app- logue to make sure the correct bolt is used.
lied.
7
Sealant Safety rules for fluorocarbon

It is therefore important that bolts removed during the rubber
disassembly of a bolted joint must be reinstalled in
their original position when assembling the joint. When Fluorocarbon rubber is a common material in seal
replacing a bolt, check in the spare parts catalogue to rings for shafts, and in O-rings.
make sure the correct bolt is used. When fluorocarbon rubber is subjected to high tempe-
To ensure service work is correctly carried out it is im- ratures (above 300°C or 572°F), hydrofluoric acid can
portant that the correct sealant and locking fluid type be formed, which is highly corrosive.
is used on the joint where the agents are required as Skin contact can give severe chemical burns. Splas-
described in the Workshop Manual or the Service Bul- hes in eyes can give severe chemical burns.
letin. Breathing of fumes can be permanently damaged
lungs.
During service operations use the same agent or an
alternative. WARNING! Be very careful when working on
Make sure that mating surfaces are dry and free from engines that have been exposed to high tempe-
oil, grease, paint and anticorrosion agent before apply- ratures, e.g. overheating during a seizure or fire.
ing sealant or locking fluid. Seals must never be cut with an oxy-acetylene
Always follow the manufacturer’s instructions for use torch, or be burned up afterwards in an uncon-
regarding temperature range, curing time and any oth- trolled manner.
er instructions for the product. • Always use gloves made of chloroprene rubber
Two different basic types of agent are used: (gloves for handling chemicals) and protective
RTV agent (Room Temperature Vulcanizing) goggles.
Used for gaskets, sealing gasket joints or coating • Handle the removed material like corrosive acid.
gaskets. RTV is visible when a part has been All residues, including ash, can be highly corro-
disassembled; old RTV must be removed before sive.
resealing the joint. Never use compressed air to blow anything clean.
Old sealant can be removed using methylated spirits • Put the remains in a plastic box which is sealed
in all cases. and provided with a warning label. Wash the glov-
Anaerobic agents: es under running water before removing them.
These agents cure in an absence of air. They are use- These following seals are probably made out of fluoro-
d when two solid parts, for example cast components, carbon rubber:
are installed face-to-face without a gasket. They are
also commonly used to secure plugs, threads in stud • Seal rings for crankshaft, camshaft, and interme-
bolts, petcocks, oil pressure switches, and so on. diate shafts.
The cured material is glass like and it is therefore co- • O-rings irrespective of where they are installed.
lored to make it visible. Cured anaerobic agents are O-rings for cylinder liner sealing are usually made
extremely resistant to solvents and the old agent can- out of fluorocarbon rubber.
not be removed. When reinstalling the part is carefully
degreased and then new sealant is applied.
8
Location of identification
plates
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.
Identification plates
1. Engine model 8. Indication of standard and /or regulation
2. Engine specific number 9. ISO 3046, reference test conditions
3. Engine serial number (10 digits) 10. ISO 3046, reference test conditions
4. Engine output without fan 11. Injection pump code (EP code)
5. Rated engine speed 12. Piston class
6. Injection timing and type of camshaft 13. Prime output, without fan, at rated speed
7. Manufacturers identification code
© 2004 AB VOLVO PENTA

All rights to changes or modifications reserved.
Printed on environmentally-friendly paper
9
Technical data: TD420VE, TAD420VE, TAD620VE Group 20
Technical Data
TD420VE, TAD420VE, TAD620VE
General
Type designation .................................................... TD420VE TAD420VE TAD620VE
Rotation direction, facing flywheel: ......................... Counterclockwise
Number of cylinders ............................................... 4 4 6
Bore, mm (inch) ..................................................... 101 (3.97") 101 (3.97") 98 (3.97")
Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96") 126 (4.96")
Displacement, dm3 (inch3) ....................................... 4.04 (246.5) 4.04 (246.5) 5.7 (347.8)
Number of valves ................................................... 8 8 12
Compression ratio:
EPA 1 ................................................................. 19:1 19:1 18.4:1
COM 2 ................................................................ 19:1 19:1 18.4:1
Firing sequence ..................................................... 1-3-4-2 1-3-4-2 1-5-3-6-2-4
Engine performance at 2500 rpm, kW (hp) ............. 75 (102)1, 3) 103 (140)1, 3) 155 (209)1, 3)
Max torque, Nm (lbf.ft) ........................................... 390 (288)3) 493 (364)3) 700 (516)3)
At speed, rpm ..................................................... 1500 1500 1500
Low idle, rpm ......................................................... 800 800 800
Max, full load speed, rpm ....................................... 2000 – 25001) 2000 – 25001) 2000 – 25001)
Weight. engine (dry) kg (lb) .................................... 380 (838)2) 380 (838)2) 495 (1091)2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
10
Group 20 Technical data: TD420VE, TAD420VE, TAD620VE
Engine block
Cylinder head
Type ...................................................................... Common cylinder head
Max surface unevenness ....................................... 0.1 mm (0.0039")
Cylinder head bolts

Thread size ............................................................ M 12
Quantity and length TD420VE/TAD420VE:
........................................................................... 13 x 108 mm (13 x 4.3")
........................................................................... 5 x 178 mm (5 x 7")
Quantity and length TAD620VE:
........................................................................... 19 x 108 mm (19 x 4.3")
........................................................................... 7 x 178 mm (7 x 7")
Cylinder liners
Parent bore Dry, replaceable
A
TD420VE/TAD420VE TAD620VE
Type:
TD420VE/TAD420VE ......................................... Parent bore
TAD620VE ......................................................... Dry, replaceable
Bore:
TD420VE/TAD420VE ......................................... 101+0.02 mm (3.976"+0.00078")
+0.02
TAD620VE ......................................................... 98 mm (3.858"+0.00078")
Max bore wear:
TD420VE/TAD420VE ......................................... 101.1 mm (3.98")
TAD620VE ......................................................... 98.1 mm (3.86")
Sealing surface: Height, see picture (A):
TAD620VE ......................................................... 4.5-0.02 mm (0.177"-0.0008")
Liner collar seating depth in block:
TAD620VE ......................................................... 4.38+0.03 mm (0.1724"+0.0012")
Projection of liner above block surface:
TAD620VE .......................................................... 0.012 – 0.07 mm(0.00047" – 0.0027")
11
Cylinder head gasket

Measuring piston projection
A dial gauge with a fixture (special tool: 999 8678) is needed to measure
the piston projection. The piston is in its TDC above the block surface.
• Set the dial gauge in the level of the crankcase surface to ”zero”.
• Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
• Measuring points between A and B on each piston is the distance X.
• Measure all pistons.
• Determine the maximum projection on each piston.
The highest piston projection number, determines the thickness of the cylinder head
gasket. The different head gaskets are identified by the hole identification on each of
the three different thickness available, see picture below.
Measuring points, distance X: ............................. Ø 90 mm (3.5")
Identification
1 Hole .................................................................... 0.33 – 0.55 mm (0.012" – 0.021")
2 Holes .................................................................. 0.56 – 0.65 mm (0.022" – 0.025")
3 Holes .................................................................. 0.66 – 0.76 mm (0.026" – 0.03")
12
Pistons
Number of piston ring grooves ................................ 3
Combustion chamber:
Diameter Ø ......................................................... 61±0.1 mm (2.402"±0.0039”)
Combustion chamber depth:
TD420VE/TAD420VE ......................................... 18±0.1 mm (0.7087"±0.0039”)
TAD620VE ......................................................... 17.5±0.1 mm (0.689"±0.0039”)
Gudgeon pin diameter Ø ........................................ 38-0.006 mm (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 (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")
Oilscraper ring (3)

Number: ................................................................. 1
Width, including springcoil: ..................................... 3 mm (0.12")
Piston ring clearance, height: ................................. 0.1 mm (0.0039")
Piston ring gap, wear limit: ..................................... 1.15 mm (0.045”)
13
Valve mechanism
Valves
Disc diameter Ø:
Inlet .................................................................... 41.7±0.1 mm (1.642"±0.004")
Exhaust .............................................................. 35.9±0.1 mm (1.413"±0.004")
Stem diameter Ø:
Inlet .................................................................... 7.98-0.015 mm (0.3142"-0.0006")
Exhaust .............................................................. 7.96-0.015 mm (0.3134"-0.0006")
Valve seat angle:
Inlet, min ............................................................. 29.5°
Exhaust, min ....................................................... 44.5°
Min 1.8 mm Min 1.1 mm

45°
30°
29.5°
44.5°
Valve disc edge:

Inlet, min ............................................................. 1.8 mm (0.071")
Exhaust, min ...................................................... 1.1 mm (0.043")
Seat angle, cylinder head:
Inlet .................................................................... 30°
Exhaust .............................................................. 45°
Valve seat width, max:
Inlet, min ............................................................. 2.7 mm (0.106")
Exhaust, min ....................................................... 2.1 mm (0.083")
Valve clearance:
Inlet .................................................................... 0.35±0.05 mm (0.014"±0.002")
Exhaust .............................................................. 0.55±0.05 mm (0.022"±0.002")
Important! Control and adjusting of valve clearance is done with an engine oil
temperature between 20 – 80°C (68 – 176°F)
14
Valve seats
ØA
Outer diameter Ø (A), standard:

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

ØC
R D
Diameter Ø (C), standard:

Inlet .................................................................... 42.7-0.025 mm (1.681"-0.001")
Exhaust .............................................................. 36.9-0.025 mm (1.453"-0.001")
Depth (D):
Inlet/Exhaust ...................................................... 10+1 mm (0.4"+0.04")
Seat bottom radius (R):
Inlet/Exhaust ...................................................... 1-0.3 mm (0.04"-0.0118")
Measurement between valve disc and cylinder head face:
Inlet/Exhaust ...................................................... Min 1.4 mm (0.055")
Valve guides
Inner diameter Ø:
Inlet/Exhaust ...................................................... 8.008+0.0025 mm (0.3153"0.00098")
Wear limit valve stem – guide:
Inlet .................................................................... 0.1 mm (0.0039")
Exhaust .............................................................. 0.13 mm (0.0051")
Valve springs
Type: ..................................................................... Single
Length: Unloaded: .................................................. 59±1.9 mm (2.323"±0.075")
Wire diameter Ø: .................................................... 4±0.03 mm (0.16"±0.001")
15
Camshaft
Type of camshaft: .................................................. Three different types: K, L or H
Drive ...................................................................... Gear
Number of bearings:
TD420VE/TAD420VE ......................................... 5
TAD620VE ......................................................... 7
Inner diameter Ø, bearing journals
Standard ............................................................. 63+0.054 mm (2.48"+0.0021")
Wear limit ........................................................... 63.08 mm (2.483")
+0.012
Camshaft bearing thickness: max .......................... 1.388 mm (0.05465"+0.0005")
Axial clearance ...................................................... 0.1-0.5 mm (0.004-0.02")
Radial clearance .................................................... 0.05-0.124 mm (0.002-0.0049")
Position of bearing bush at flywheel end ................ 3+0.2 mm (0.118"+0.008")
Timing gear
1. Governor drive
2. Idler gear
3. Camshaft gear
4. PTO gear B-C
5. PTO gear A
6. Crankshaft
Flywheel
Type of flywheel, standard :
TD420VE/TAD420VE/TAD620VE ....................... 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
16
Crank mechanism
Crankshaft length:
TD420VE/TAD420VE ......................................... 618.8 mm (24.36")
TAD620VE ......................................................... 846.8 mm (33.34")
Crankshaft axial clearance1) .................................. 0.1-0.3 mm (0.0039"– 0.0118")
Main bearing radial clearance1) .............................. 0.03+0.062 mm (0.0012"+0.0024")
Max, permissible ovality of main
bearing and crank pins ....................................... 0.01 mm (0.0004")
Max, run-out of center bearing: .............................. 0.1 mm (0.0039"
1)
Important! The dimensions apply to oiled parts
E
F
C B
A
Main bearing journals

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

Type: ..................................................................... Replaceable
Inner diameter Ø (E): ............................................. 84.03+0.042 mm (3.308"+0.0017")
Thickness (F): Standard ......................................... 2.475+0.01 mm (2.903"-2.903")
Oversize:
0.25 mm (0.01") .................................................. 2.6+0.01 mm (0.1024"+0.0004")
17
Connecting rod bearing journals

Diameter Ø for machining (G):
Standard ................................................................ 62.994-0.02 mm (2.48"-0.0008”)
Undersize:
0.25 mm (0.01") .................................................. 62.744-0.02 mm (2.4714"-0.0008”)
Width, axial bearing journal (H): . ............................ 35.7±0.02 mm (1.4"±0.0008")
Connecting rod-bearing journals:
Out-of-round: Max. .............................................. 0.01 mm (0.0004")
Taper: Max ......................................................... 0.01 mm (0.0004")
H
G
J
K
Connecting rod bearing shells

Innerdiameter Ø, bearing (J): .................................. 63.026+0.039 mm (2.442"+0.00154”)
Oversize:
0.25 mm (0.01") .................................................. 62.724+0.02 mm (2.4716"+0.00079”)
Thickness (K): Standard ........................................ 1.777+0.01 mm (0.06996+0.0004”)
Inside bore .......................................................... 66.6+0.02 mm (2.622"0.0008")
18
Connecting rods
Length (L): Center – Center .................................... 192±0.02 mm (7.559"-0.0008”)
+0.01
Connecting rod bushing bore (M): ........................... 38.025 mm (1.497"+0.0004”)
Wear limit ............................................................ 0.08 mm (0.0031")
Axial clearance, connecting rod – crankshaft1) ....... 0.2-0.3 mm (0.00787"-0.0118")

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

Connecting rod and cap number marking must be on one side and identical.
19
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, VDS-2, VDS-3

ACEA E3, E2 500 hours or 12 months 250 hours or 12 months 125 hours or 12 months
NOTE! Mineral-based, semi and fully synthetic oils can be used provided that the above oil grade requirements
are fulfilled.
1)
At a sulfur content >1 percent by weight. oil with a TBN >15 should be used.
NOTE! API: CG-4 alt. CH-4 is acceptable in markets outside Europe.
2)
Lubricating oil with TBN 14–20 should be used.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
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.
20
Engine oil quantity

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

Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD420VE/TAD420VE .......................................... 400 kPa (58 psi)
TAD620VE .......................................................... 370 kPa (53.7 psi)
At idle speed (800 rpm), min .................................. 80 kPa (11.6 psi)
Shut down switch, at pressure lower than: ............. 50 kPa (7.2 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling .................................................. 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size ....................................................... 0.012 mm (0.0005")
By-pass valve oil filter
Opening pressure ................................................ 250±50 kPa (35±7 psi)
8.By-pass valve oil cooler:
Opening pressure ................................................ 210±30 kPa (30.5±4 psi)
9. Safety valve, opening pressure:
TD420VE/TAD420VE .......................................... 600±75 kPa (87±10.7 psi)
TD620VE ............................................................ 400±40 kPa (58±2 psi)
10. Lube oil pump
Type ...................................................................... Rotary pump driven by the crankshaft
Rotary pump width:
TD420VE/TAD420VE .......................................... 12.3 mm (0.48")
TD620VE ............................................................ 16.5 mm (0.65")
Oil flow (2500 rpm)
TD420VE/TAD420VE .......................................... 65 l/min (17 US gal/hour)
TD620VE ............................................................ 90 l/min (24 US gal/hour)
11. Oil cooler
Normal oil temperature: .......................................... 80°C (176°F)
Max oil temperature: .............................................. 125°C (257°F)
21
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.
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps, 420/520 (4) 620/720/721 (6)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve 2)
12. Return fuel line to fuel tank.
Inside diameter, min 10 mm (0.39")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose.
2)
Used for bleeding.
22
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (With environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in each country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in power
output of 5% and an increase in fuel consumption of 2–3%.
In
Out
Fuel feed pump

Fuel system figures are corresponding to the picture above.
1. Overpressure relief valve:
Opening pressure ................................................ 0.6±0.05 MPa (87±7 psi)1)
2. Bypass valve:
Opening pressure ................................................ 50±5 kPa (7.2±0.7 psi)
Fuel flow:
Min fuel flow at 1500 rpm. ...................................... 600 l/hour (158.5 gal/hour)
Firing sequence
TD420VE/TAD420VE ......................................... 1-3-4-2
TAD620VE ......................................................... 1-5-3-6-2-4
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter
At 1500 rpm: Min ................................................ 0.28 MPa (40.6 psi)
23
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 = 117.5 + 0.63
The total length LFB = 118.13
Injection pump
Manufacturer .......................................................... Bosch
Designation ............................................................ PF 33
Length A: ............................................................... 59 mm (2.3")
Basic measurement length LO : .............................. 117.5 mm (4.6")
Min length mm LFB : (A/100+117.5) – 117.5 ............ >0
Injectors
Opening pressure:
TD420VE ............................................................ 22 MPa (3190 psi)
TAD420VE/TAD620VE ....................................... 25 MPa (3630 psi)
Max pressure: ........................................................ 160 MPa (23200 psi)
Check leakage (for 10 sek):
TD420VE ............................................................ 20 MPa (2900 psi)
TAD420VE/TAD620VE ....................................... 23 MPa (3340 psi)
Numbers/bore Ø:
TD420VE ............................................................ 6 x 0.205 mm (6 x 0.008")
TAD420VE/TAD620VE ....................................... 6 x 0.203 mm (6 x 0.0079")
Fuel filter
Filtering size: ......................................................... 0.005 mm (0.0002")
Pre-filter
Filtering size: ......................................................... 0.006 mm (0.00024")
24
Commencement of delivery (FB)

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.
For exchange of injection pump without any parts of vital importan-
ce has been replaced, see chapter ”EP code”.
For renovation or when any parts of vital importance have been re-
placed, special tools (999 8685 and 999 8679) must be used, to be
able to calculate the thickness for the new shim.
The value for commencement of delivery and camshaft type is in-
dicated on the identification plate, see ”General information”,
”Identification plate”. When calculating the shim thickness, apply
a mathematical formula, see ”Theoretical thickness for shim”,
where some values are from table 1 and other are measured on the
engine. For complete instruction, see ”Workshop Manual”.
Table 1, Commencement of delivery

All measurements are in mm (1 mm = 0.0394")
FB Camshaft Vh Vhcorr.factor Lo
(Commencement of types Pre-stroke Pre-stroke Basic dimension
delivery) correction factor Injection pump
25
Tekniska data Grupp 20
Theoretical thickness for a new shim.

Computation for determining the theoretical shim thickness (TS) :
TS= L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm)
The correction factor Vhcorr.factor is taken from the table on previous page.
The individual steps:
· 1st step: E1 = FBactual - FBnom (°C/A)
· 2nd step: E2 = E1 x Vhcorr.factor (mm/°C/A)
· 3rd step: E3 = E2 + Vhnom
· 4th step: E4 = E3 + LO
· 5th step: E5 = E4 + A/100 (mm)
· 6th step: TS = L – E5
· 7th step: The actual shim thickness (SS) is determined with the help of table 2.
Table 2, Shim thickness

Theor. thickness Shim thickness (SS) Theor. thickness(TS) Shim thickness (SS)
(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.
26
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.
TS = EK - (LO + A/100)
TS = Shim thickness
EK = Value from tabel 3 read with help of EP code from ”Identification plate”.
LO = Basic measurement for the injection pumps, 420/620 = 117.5 mm.
A/100 = Manufacturing tolerance
Example:
On Identification plate there is an EP code value for each cylinder. Read the EP code for actual cylinder and with
help of this value it is possible to read the new EK value with help of table 3.
If read EP code is ”275” that gives a EK value of 120.375 and if the manufacturing tolerance for the new injection
pump is ”63” we will have following equation: TS = 120.375 – (117.5 + 0.63)
TS are in this case 2.245 and a control in table 2 gives: SS = 2.3 mm
Thickness on the new shim to be mounted is in this example will be 2.3 mm
Table 3, EP code conversion table

Ek(mm) EP code Ek(mm) EP code Ek(mm) EP code Ek(mm) EP code
27
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:
TD420VE/TAD420VE/TAD620VE: ...................... 2500 rpm
Engine speed droop at a load increase from 0 to 100 % at rated speed:
TD420VE/TAD420VE/TAD620VE: ...................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod
Control rod (fuel rack) travel Y, without injection pumps
Start and stop: ....................................................... 17 – 17.5 mm (0.67" – 0.69")
Control rod (fuel rack) travel Y, with injection pumps
Min: ....................................................................... 16.8 mm (0.66")
The recess dimension X ........................................ 0.3 – 1.3 mm (0.012" – 0.051")
Note! It is absolutely necessary to measure and indicate the recess dimension X, between the fuel rack, in stop
position and the contact surface of the governor, see picture.
28
Intake and exhaust system

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

At engine speed1): .................................................. 1800 rpm 2100 rpm 2300 rpm 2500 rpm
TD420VE ............................................................ 555°C 540°C 540°C 540°C
(1031°F) (1004°F) (1004°F) (1004°F)
TAD420VE .......................................................... 490°C 470°C 475°C 475°C
(914°F) (878°F) (887°F) (887°F)
TAD620VE .......................................................... 485°C 465°C 460°C 455°C
(905°F) (869°F) (860°F) (851°F)
1)
See General information, Power standards.
Air intake
Air intake restriction, clean filter ............................. 2.5 kPa (0.3 psi)
Max allowed air intake restriction ........................... 6.5 kPa (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 ......................................................... 6 liters (1.58 US gal)
Thermostat:
Type ...................................................................... One piston thermostat
Begins to open at ................................................... 83°C (181°F)
Fully open at .......................................................... 95°C (203°F)
Coolant pump:
Type ...................................................................... Belt-driven centrifugal pump
Glycol (Antifreeze)
Volvo Penta glycol (antifreeze) mixed 45/55 with clean water
Anti-corrosion agent
Used only in markets where there is no risk of freezing, mixed with water3).
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative consequences.
Water quality specification:
To avoid the risk of clogging in the cooling system, the coolant should be mixed with pure water to ASTM D4985.
If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead.
29
Tightening torque
General tightening torques Nm (lbf.ft)
M6 standard screw 8.8 ........................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 ........................................... 25±4 (18±3 lbf.ft)
M10 standard screw 8.8 ......................................... 50±8 (37±6 lbf.ft)
M12 standard screw 8.8 ......................................... 80±9 (59±6.5 lbf.ft)
M14 standard screw 8.8 ......................................... 140±25 (103±18 lbf.ft)
Tightening torques Nm (lbf.ft)
Group 21 Engine
Engine mounting .................................................... 260 (192lbf.ft)
Starter motor .......................................................... 70 (51.6 lbf.ft)
Timing gear casing ................................................. 21±2 (15.5±1.5 lbf.ft)
Main bearing caps

Screws to main bearing caps are reusable only three times.
Step 1 .................................................................... 50 (37 lbf.ft)
Step 2 .................................................................... 90° angle tightening
Connecting rod big-end bearing

Use new screws every time.
Step 1 .................................................................... 30 (22 lbf.ft)
Step 3 .................................................................... 30
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ................................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ................................................................... 60° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................... 20 – 30 (15 – 22 lbf.ft)
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ................................................................... 30 – 40 (22 – 30 lbf.ft)
Flywheel housing, M12 ........................................... 99±1 (73±7 lbf.ft)
±25
Flywheel housing, M16 ........................................... 243 (179±18 lbf.ft)
V-belt pulley
Screws to V-belt pulley are reusable only three times.
Step 1: ................................................................... 40 – 50 (30 – 37 lbf.ft)
Vibration damper .................................................... 70
Screw, rocker cover ............................................... 9±1 (6.5±0.7 lbf.ft)
±2
Lock nut, valve clearance adjusting screw ............. 20 (14.5±1.5 lbf.ft)
Screws, rocker arm fixing ...................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation ................................ 9±1 (6.6±0.7 lbf.ft)
30

Cylinder head
Screws to cylinder head are reusable only three times.
Step 1: ................................................................... 30 (22 lbf.ft)
Step 2: ................................................................... 80 (59 lbf.ft)
Group 22 Oil system

Oil cooler, screws .................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, screw plug ............................................. 80 (59 lbf.ft)
Front/oil pump housing ........................................... 21±2 (15.5±1.5 lbf.ft)
Oil suction pipe ...................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ................................................................ 21±2 (15.5±1.5 lbf.ft)
Oil pressure pipe turbo ........................................... 29±3 (21.4±2.2 lbf.ft)
Oil pressure pipe engine block ............................... 39±4 (29±3 lbf.ft)
Screws, oil return pipe turbo
A) with tube fitting ............................................... 40±2 (29.5±1.5 lbf.ft)
B) with flange fitting ............................................ 21±2 (15.5±1.5 lbf.ft)
Screws, oil return pipe engine block ....................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure switch ................................................ 18±2 (13±1.5 lbf.ft)
Group 23 Fuel system

Screw, governor, idler gear:
Step 1: ................................................................... 30 (22.1 lbf.ft)
Screw, control rod hose ......................................... 10±2 (7±5 lbf.ft)
±1.5
Screw, governor .................................................... 17 (12.5±1 lbf.ft)
Flange screws, Injection pump
Step 1: Torque ....................................................... 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange ... 60° counterclockwise
Step 3: Turn injection pump to stop ....................... Counterclockwise
Step 5: ................................................................... 7 (5 lbf.ft)
Step 6: ................................................................... 10 (7.4 lbf.ft)
Step 7: ................................................................... 30 (22 lbf.ft)
Flange screw, injector ............................................ 16+5 (12+4 lbf.ft)
Injector cap nut ...................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Use a new delivery pipe after every disassembly
Step 1: ................................................................... 5 (3.7 lbf.ft)
Step 2: ................................................................... 25±3.5 (18.4±2.6 lbf.ft)
Screw, stop magnet ............................................... 21 (15.5 lbf.ft)
Overflow valve ....................................................... 30 (22 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 (30±3 lbf.ft)
Screws, Inlet manifold ........................................... 11±1 (8±0.7 lbf.ft)
Group 26 Cooling system

Thermostat housing ............................................... 30 (22.1 lbf.ft)
Water temp sensor ................................................ 21±2 (15.5±1.5 lbf.ft)
Water pump ........................................................... 21±2 (15.5±1.5 lbf.ft)
NOTE! See also ”Tightening diagrams”.
31
Technical Data: TD520GE, TAD520GE, TD520VE, TAD520VE Group 20
Technical Data
TD520GE, TAD520GE, TD520VE, TAD520VE
General
Type designation ................................................... TD520GE TAD520GE TD520VE TAD520VE
Rotation direction, facing flywheel: ........................ Counterclockwise
Number of cylinders .............................................. 4 4 4 4
Bore, mm (inch) .................................................... 108 (4.25") 108 (4.25") 108 (4.25") 108 (4.25")
Stroke, mm (inch) ................................................. 130 (5.12") 130 (5.12") 130 (5.12") 130 (5.12")
Displacement, dm3 ( inch3) ..................................... 4.76 (290) 4.76 (290) 4.76 (290) 4.76 (290)
Number of valves .................................................. 8 8 8 8
Compression ratio: ................................................ 17.5:1 17.5:1 18.4:1 18.1:1
Firing sequence ................................................... 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Engine performance:
At 1500 rpm, kW (hp) ......................................... 77.5 (104)1, 3) 94 (126)1, 3) — —
1, 3)
At 1800 rpm, kW (hp) ......................................... 81.5 (109) 101 (135.5)1, 3) 81 (110)1, 4) —
At 2300 rpm, kW (hp) ......................................... — — — 118 (158)1, 4)
Engine torque, Nm ( lbf.ft) ..................................... 493 (394)3) 598 (441)3) 430 (317)4) 577 (425)4)
At speed, rpm .................................................... 1500 1500 1800 1400
Engine torque, Nm ( lbf.ft) ..................................... 432 (319)3) 536 (395)3) — —
At speed, rpm .................................................... 1800 1800 — —
Max speed at full load, rpm ................................... 1500/18001) 1500/18001) 18001) 2000 – 23001)
Weight engine (dry) kg (lb) .................................... 550 (1213)2) 575 (1268)2, 5) 430 (948)2) 432 (952)2)
Weight engine (wet) ............................................... 580 (1279)2) 606 (1336)2, 5) 725 (1336)2, 6) —
1)
See identification plate for specification
2)
3)
Measured at Prime Power, see ”General information”, ”Power standards”.
4)
See ”General information”, ”Power standards”.
5)
Extra weight on TAD520GE SAE 2 (1800 rpm) 36 kg (80 lb)
6)
Including clutch and frame
32
Group 20 Technical Data: TD520GE, TAD520GE, TD520VE, TAD520VE
Engine block
Cylinder head
Type: .................................................................... Common cylinder head
Max surface unevenness: ..................................... 0.085 mm (0.00335")
Cylinder head bolts

Thread size: .......................................................... M 14
Quantity and length: .............................................. 18 x 141 mm ( 18 x 5.55")
Cylinder liners
Replacable, wet
A
TD520GE/TAD520GE
TD520VE/TAD520VE
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")
Liner collar seating depth in block: ........................ 8.92+0.03 mm (0,3512"+0.0012")
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0.0012" – 0.0031")
33

• Position the dial gauge at the measuring points A and B on the top of the piston,
inline with the gudgeon pin.
gasket. The different head gaskets are identified by the hole identification on each of
the three different thickness available, see picture below.
Measuring points, distance X: ............................ Ø 95 mm (3.74")
Identification
1 Hole ................................................................... 0.28 – 0.53 mm (0.011" – 0.0201")
2 Holes ................................................................. 0.54 – 0.63 mm (0.0212" – 0.0248")
3 Holes ................................................................. 0.64 – 0.75 mm (0.0252" – 0.0295")
34
Pistons
Number of piston ring grooves ............................... 3
Combustion chamber:
Diameter ............................................................ 71±0.1 mm (2.795"±0.0039")
Depth ................................................................. 16.66±0.1 mm (0.6559"±0.0039")
Gudgeon pin diameter ........................................... 42 -0.006 (1.6535"-0.0002")
Piston rings
Compression rings
Number of rings .................................................... 2
Upper compression ring (1) ................................ Keystone, no clearance
Lower compression ring (2) ................................ 0.17 mm (0.067")
Upper compression ring (1) ................................ 0.8 mm (0.03")
Oilscraper ring (3)

Number: ................................................................ 1
Width, including springcoil: .................................... 3 mm (0.12")
Piston ring clearance in groove: ............................ 0.1 mm (0.0039")
Piston ring gap, wear limit: .................................... 1.15 mm (0.045")
35
Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48±0.1 mm (1.8898"±0.0039")
Exhaust ............................................................. 42±0.1 mm (1.6535"±0.0039")
Stem diameter Ø:
Inlet ................................................................... 8.98-0.015 mm (0.3535"-0.0006")
Exhaust ............................................................. 8.96-0.015 mm (0.3528"-0.0006")
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ..................................................... 44.5°

45°
30°
29.5°
44.5°
Valve disc edge:

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

Inlet ................................................................... 49.09-0.02 mm (1.933"-0.0008")
Exhaust ............................................................. 43.06-0.02 mm (1.717"-0.0008")
Height (B):
Inlet ................................................................... 7.5±0.1 mm (0.295"±0.004")
Exhaust ............................................................. 7.9±0.1 mm (0.311"±0.004")
36
Valve seat location

ØC
R
D

Inlet ................................................................... 49+0.025 mm (1.929"-0.001")
Exhaust ............................................................. 43.5+0.025 mm (1.712"-0.001")
Depth (D):
Inlet/Exhaust ..................................................... 11+1 mm (0.43"+0.04")
Inlet/Exhaust ..................................................... 1-0.3 mm (0.04"-0.012")
Inlet/Exhaust ..................................................... Min 1.5 mm (0.059")
Valve guides
Length:
Inlet/Exhaust ..................................................... 63-0.5 mm (2.48"-0.02")
Inner diameter Ø:
Inlet/Exhaust ..................................................... 9.025–9.04 mm (0.3553–0.3559")
Height above cylinder head spring surface:
Inlet/Exhaust ..................................................... 23-0.5 mm (0.9"-0.02")
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Design 1 Design 1 Design 2
without flange with flange
O-ring
Flange
On later models the o-ring seal is exchange to a valve

stem sealing, according to the picture for design 2.
Production Exchange
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 .................................... 64.7±1.3 mm (2.55"±0.05")
Wire diameter Ø .................................................... 4.5 mm (0.18")
37
Camshaft
Type of camshaft: ................................................. A
Drive ..................................................................... Gear
Number of bearings ............................................... 5
Standard ............................................................ 65+0.054 mm (2.559"+0.0021")
Wear limit ........................................................... 65.08 mm (2.5622")
Camshaft bearing thickness: max ......................... 1.988+0.12 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. Governor drive
2. Idler gear
3. Camshaft gear
4. PTO gear B-C
5. PTO gear A
6. Crankshaft
Flywheel
Type of flywheel :
TD520VE/TAD520VE ......................................... Clutch 10" or 11.5"
TD520GE/TAD750GE ........................................ Gen set 1500 rpm
Max, permitted axial runout
Measuring radius 150 mm (5.91") ....................... 0.1 mm (0.00394")
Number of teeth on flywheel .................................. 129
38
Crank mechanism
Crankshaft length .................................................. 709.2 mm (27.92")
Crankshaft axial clearance1) .................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Max, run-out of center bearing ............................... 0.07 mm (0.0027")
1)
E
F
C B
A

Diameter Ø for machining (A): Standard ................ 85-0.02 mm (2.9134"-0.0008")
Undersize:
0.25 mm (0.01") ................................................. 84.75-0.02 mm (3.3366"-0.0008")
0.5 mm (0.02") ................................................... 84.5-0.02 mm (3.3268"-0.0008")

Out-of-round: Max. ............................................. 0.01 mm (0.0004")
Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal : standard ............. 38+0.06 mm (1.496" +0.0024")
Oversize:
0.4 mm (0.0157") ............................................... 38.4+0.06 (1.5118" +0.0024")
Width (C): Standard ............................................... 2.9+0.05 mm (0.1142"+0.0039")
Oversize:
0.2 mm (0.0079") ............................................... 3.1+0.05 mm (0.122"+0.002")
Width (D): .............................................................. 10 mm (0.4")
Main bearing shells

Type ..................................................................... Replaceable
Outer diameter Ø (E) ............................................. 85.03+0.036 mm (2.9035"+0.0014")
Thickness (F): Standard ........................................ 2.727+0.008 mm (0.1074"+0.0003")
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm (0.1123"+0.0003")
0.5 mm (0.02") ................................................... 2.977+0.008 mm (0.1172"+0.0003")
39

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

Diameter Ø (J): Bearing ........................................ 68.03+0.04 mm (2.6783"+0.0016")
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm (2.6685"+0.0016")
0.5 mm (0.02") ................................................... 67.53+0.04 mm (2.6587"+0.0016")
Diameter Ø: Bearing shell ..................................... 72.5+0.05 mm (2.854"+0.002")
Thickness (K): Standard ....................................... 2.222+0.01 mm (0.0875"-0.0004")
40
Connecting rods
Length (L): Center – Center ................................... 210±0.06 mm (8.2677"±0.00236")
Connecting rod (M) bushing bore ........................... 42.04+0.01 mm (1.6551"0.0004")
Wear limit ........................................................... 0.08 mm (0.0031")
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5+0.02 mm (1.7913"0.0008")
Small end bush outer diameter ........................... 45.58+0.04 mm (1.7945"+0.0016")
Axial clearance, connecting rod – crankshaft1) ...... 0.3 – 0.4 mm (0.0118 – 0.0157")
Connecting rod bearing: radial clearance1) ............. 0.036+0.06 mm (0.00142"+0.0024")
1)
The dimensions apply to oiled parts
Connecting rod marking:

Connecting rod and cap number marking must be on one side
and identical
41
Lubricating system

Up to 0.5 % 0.5 – 1 % More than 1 %
VDS, VDS-2, VDS-3
ACEA E3, E2 500 hours or months 250 hours or months 125 hours or months
NOTE! Mineral-based, semi and fully synthetic oils can be used provided that the above
oil grade requirements are fulfilled.
1)
At a sulfur content >1.0 percent by weight. oil with a TBN >15 should be used.
NOTE! API: CG-4 alt. CH-4 is acceptable in markets outside Europe.
2)
Lubricating oil with TBN 14–20 should be used.

API = American Petroleum Institute
TBN = Total Base Number
Viscosity
table.

42
Engine oil quantity

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

At rated speed:
TD520GE/TAD520GE (1500 rpm): ..................... 280 kPa (40.6 psi)
TD520GE/TAD720GE (1800 rpm): ..................... 330 kPa (47.9 psi)
TD520VE: .......................................................... 440 kPa (63.8 psi)
TAD520VE: ........................................................ 390 kPa (56.6 psi)
Idle speed (800 rpm), min: .................................... 90 kPa (13.1 psi)
Shut down switch, at pressure lower than:
TD520GE/TAD520GE: ....................................... 200 kPa (29 psi)
TD520VE/TAD520VE: ........................................ 50kPa (7.2 psi)
4. Rocker arm
6. Piston cooling: ................................................ 2-hole nozzles for each cylinder
7. Oil filter, full-flow
Filtering size: ...................................................... 0.012 mm (0.0005")
Bypass valve oil filter:
Opening pressure: ............................................... 250±50 kPa (35±7 psi)
8. Pressure regulating valve:
Opening pressure: ............................................... 400±40 kPa (58±6 psi)
9. Pressure-relief valve:
Opening pressure: .............................................. 1±0.1 MPa (145±14 psi)
10. Lube oil pump:
Type: .................................................................... Rotary pump driven by the crankshaft
Rotary pump width: ............................................... 10.5 mm (0.413")
Oil flow (2500 rpm): ............................................... 60l/min (16 US gal/hour)
11. Oil cooler:
Normal oil temperature: .......................................... 80°C (176°F)
Max oil temperature: .............................................. 125°C (257°F)
43
Fuel system
1. Fuel tank.
3. Fuel pump
5. Fuel filter
7. Injection pumps, 420/520 (4) 620/720/721 (6)
9. Injector
11. Overflow valve 2)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
44
Fuel specification
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
JIS KK 2204
Sulfur content: According to current legislation in each country.
In
Out
Fuel feed pump

Fuel system figures is corresponding to the picture above
1. Overpressure relief valve:
Opening pressure ................................................ 0.6±0.05 MPa (87±7 psi)1)
2. Bypass valve
Opening pressure ................................................ 50±5 kPa (7.2±0.7 psi)
Fuel flow
Min fuel flow at 1500 rpm ....................................... 600 l/tim (158.5 gal/hour)
Firing sequence .................................................... 1-3-4-2
Feed pressure ........................................................ 0.5 MPa (72.5 psi)
Feed pressure after fuel filter
1500 rpm: Min ..................................................... 0.28 MPa (40.6 psi)
45
Injection pump
Basic measurements
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering
fuel.
A/100 = Manufacturing tolerances (written on the injection pump).
Example:
This gives us the equation: LFB = 143 + 0.63
Injection pump
Manufacturer ......................................................... Bosch
Designation ........................................................... PF 33 L
Length A: .............................................................. 54 mm (2.12")
Basic measurement length LO : ............................. 143 mm (5.63")
Min length LFB : (A/100+143) – 143 ........................ >0 mm
46
Injectors
Opening pressure:
TD520GE: .......................................................... 25 MPa (3600 psi)
TAD520GE/TD520VE/TAD520VE: ..................... 27.5 MPa (4000 psi)
Max pressure ........................................................ 120 MPa (17400 psi)
Check leakage (for 10 min):
TD520GE: .......................................................... 23 MPa (3340 psi)
TAD520GE/TD520VE/TAD520VE: ..................... 25.5 MPa (3700 psi)
Numbers/bore Ø:
TD520GE ........................................................... 5 x 0.234 mm (0.00921")
TAD520GE/TD520VE/TAD520VE: ..................... 5 x 0.25 mm (0.00984")
Fuel filter
Filtering size ......................................................... 0.005 mm (0.0002")
Pre-filter

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

47

Computation for determining the theoretical shim thickness (Ts) :
Ts = L - [ ( FBactual - FBnom ) x Vhcorr.factor + Vhnom + Lo + A/100 ] (mm)
· 4th step: E4 = E3 + Lo
· 5th step: E5 = E4 + A/100 (mm)
· 6th step: Ts = L – E5
· 7th step: The actual shim thickness (Ss) is determined with the help of table 2 below.
Table 2 (Shim thickness)

Theor. thickness (TS) Shim thickness (SS) Theor. thickness (TS) Shim thickness (SS)
48
How to use EP code

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

Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP

code code code code code
49
Governor
Manufacturer ......................................................... Heinzmann

Designation:
TD520GE/TAD520GE: ....................................... 1500 rpm
TD520GE/TAD520GE: ....................................... 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 %
Control rod
Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Min: ...................................................................... 16.8 mm (0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm (0.012" – 0.051")
50

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

At rated speed (standby power)1) : ......................... 1500 rpm 1800 rpm
TD520GE: .......................................................... 610°C (1130°F) 530°C (986°F)
TAD520GE: ....................................................... 520°C (968°F) 448°C (838°F)
At rated speed: ..................................................... 1800 rpm 2100 rpm 2200 rpm 2300 rpm
TD520VE: .......................................................... 510°C (950°F) — — —
TAD520VE: ........................................................ 475°C (887°F) 470°C (878°F) 470°C (878°F) 470°C (878°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TD520GE/TAD520GE: ....................................... 1 kPa (0.14 psi)
Max allowed air intake restriction
51
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD520GE/TAD520GE ........................................ 90 kPa (13 psi)
TD520VE/TAD520VE, max: ............................... 90 kPa1) (13 psi)
1)
Capacity (engine): ................................................. 7.2 liters (1.9 US gal)
Capacity (engine and cooler):
TD520GE: .......................................................... 17.5 liters (4.62 US gal)
TAD520GE: ....................................................... 19.7 liters (5.2 US gal)
Thermostat
Type ...................................................................... One piston thermostat
Begins to open at
TD520GE/TAD520GE/TD520VE: ....................... 83°C (181°F)
TAD520VE: ........................................................ 87° C (189° F)
Fully open at
TD520GE/TAD520GE/TD520VE: ....................... 95°C (203°F)
TAD520VE: ........................................................ 102°C (216° F)
1. Coolan connection (inlet)

2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Coolant pump
Glycol (Antifreeze)
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative
consequences.

If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
52
Tightening torque
M6 standard screw 8.8 .......................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 .......................................... 25±4 (18±3 lbf.ft)
M10 standard screw 8.8 ........................................ 50±8 (37±6 lbf.ft)
M12 standard screw 8.8 ........................................ 80±9 (59±6.5 lbf.ft)
Group 21 Engine
Engine mounting ................................................... 260 (192lbf.ft)
Starter motor ......................................................... 70 (51.6 lbf.ft)
Timing gear casing ................................................ 21±2 (15.5±1.5 lbf.ft)
Main bearing caps

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

Step 1 ................................................................ 50 (22 lbf.ft)
Step 2 ................................................................ 60° angle tightening
Flywheel
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 1: ............................................................... 30 – 40 (22 – 30 lbf.ft)
Flywheel housing. M12 .......................................... 99±1 (73±7 lbf.ft)
±25
Flywheel housing. M16 .......................................... 243 (179±18 lbf.ft)
V-belt pulley
Step 1: ............................................................... 40 – 50 (30 – 37 lbf.ft)
Vibration damper ................................................... 70
Screw, rocker cover .............................................. 9±1 (6.5±0.7 lbf.ft)
±2
Lock nut, valve clearance adjusting screw ............ 20 (14.5±1.5 lbf.ft)
Screws, rocker arm fixing ..................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation ............................... 9±1 (6.6±0.7 lbf.ft)
53

Cylinder head
Screws to cylinder head are reusable only five times.
Step 1: ............................................................... 50 (37 lbf.ft)
Step 2: ............................................................... 130 (96 lbf.ft)
Group 22 Oil system

Oil cooler, screws ................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, hollow screw
Step 1: ............................................................... 80 (59 lbf.ft)
Step 2: ............................................................... 160 (118 lbf.ft)
Oil cooler, screw plug ............................................ 80 (59 lbf.ft)
Front/oil pump housing .......................................... 21±2 (15.5±1.5 lbf.ft)
Oil suction pipe ..................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ............................................................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure pipe turbo .......................................... 29±3 (21.4±2.2 lbf.ft)
Oil pressure pipe engine block .............................. 39±4 (29±3 lbf.ft)
A) with tube fitting .............................................. 40±2 (29.5±1.5 lbf.ft)
B) with flange fitting ........................................... 21±2 (15.5±1.5 lbf.ft)
Screws, oil return pipe engine block ...................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure switch ............................................... 18±2 (13±1.5 lbf.ft)

Step 1: ............................................................... 30 (22.1 lbf.ft)
Screw, control rod hose ........................................ 10±2 (7±5 lbf.ft)
±1.5
Step 1: Torque ................................................... 5 (3.7 lbf.ft)
Step 2: Loosen screws for injection pump flange 60° counterclockwise
Step 3: Turn injection pump to stop ................... Counterclockwise
Step 5: ............................................................... 7 (5 lbf.ft)
Step 6: ............................................................... 10 (7.4 lbf.ft)
Step 7: ............................................................... 30 (22 lbf.ft)
Flange screw, injector ........................................... 16+5 (12+4 lbf.ft)
Injector cap nut ..................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Step 1: ............................................................... 5 (3.7 lbf.ft)
Step 2: ............................................................... 25+3.5 (18.4±2.6 lbf.ft)
Screw, stop magnet .............................................. 21 (15.5 lbf.ft)
Overflow valve ...................................................... 30 (22 lbf.ft)

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)

Thermostat housing .............................................. 30 (22.1 lbf.ft)
Water pump .......................................................... 21±2 (15.5±1.5 lbf.ft)
54
Group 20 Technical Data: TD/TAD720GE, TD/TAD720VE, TAD721/722GE, TAD721/722VE
Technical Data
TD720GE, TAD720GE, TD720VE,TAD720VE,
TAD721GE, TAD721VE, TAD722GE, TAD722VE
General
Type designation .......................... TD720GE TAD720GE TAD721GE TAD722GE
Rotation direction, facing flywheel: Counterclockwise
Number of cylinders ..................... 6 6 6 6
Bore, mm (inch) ........................... 108 108 108 108
Stroke, mm (inch) ........................ 130 130 130 130
Displacement, dm3 (inch3) ............. 7.5 7.15 7,15 7,15
Number of valves ......................... 12 12 12 12
Compression ratio:
EPA 1 ....................................... 17.1:1 17.5:1 — —
COM 2 ...................................... — — 18.1:1 18.1:1
Firing sequence ........................... 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine performance:
At 1500 rpm, kW (hp) ................ 1281, 3) 1531, 3) 1831, 3) 2011, 3)
At 1800 rpm, kW (hp) ................ 1341, 3) 1631, 3) 2041, 3) 2251, 3)
Engine torque, Nm (lbf.ft) ............. 8153) 9743) 1165 1280
At speed, rpm ........................... 1500 1500 1500 1500
Engine torque, Nm (lbf.ft) ............. 7113) 8653) 1082 1193
At speed, rpm ........................... 1800 1800 1800 1800
Low idle, rpm ................................ 850 – 950 850 – 950 800 – 950 800 – 950
Max speed at full load (rpm) ......... 1500/18001) 1500/18001) 1500/18001) 1500/18001)
Weight engine (dry) kg (lb) ........... 7502) 7602) 7852) 7852)
Weight engine (wet) kg (lb) ........... 7902) 8042) 8262) 8262)
1)
See identification plate for specification.
2)
Weight according to DIN 70020-A.
3)
Measured at Standby Power, see ”General information”, ”Power standards”.
55
Technical Data: TD/TAD720GE, TD/TAD720VE, TAD721/722GE, TAD721/722VE Group 20
Type designation .......................... TD720VE TAD720VE TAD721VE TAD722VE

Direction of rotation (seen from flywheel):Anti- clockwise
No. of cylinders ............................ 6 6 6 6
Cylinder bore mm (inch) ............... 108 108 108 108
Stroke mm (inch) ......................... 130 130 130 130
Cylinder volume liter (inch 3 ) ......... 7.15 7.15 7.15 7.15
No. of valves ................................ 12 12 12 12
Compression ratio:
EPA1 ........................................ 18.4:1 18.4:1 18.4:1 —
EPA2 ........................................ — 19.0:1 19.0:1 19,0:1
Injection sequence ....................... 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Engine power
At 1500 rpm kW (hp) ................. 1221) — — —
At 1800 rpm kW (hp) ................. — 1741) 1951) 2001)
Torque Nm (lbf.ft)) ........................ 701 817 897 981
At engine speed rpm ................. 1500 1800 1800 1800
Low idle rpm ................................. 850 – 950 850 – 950 850 – 950 800 – 950
Highest full load speed rpm .......... 18001) 2000 – 23001) 2000 – 23001) 2100 – 23001)
Weight, dry (lb) ............................. 5702) 5722) 5722) 6802)
Gross weight, dry (lb) ................... 9202, 3) — — —
1)
See engine plate for specifications.
2)
3)
Including clutch and frame
56
Engine block
Cylinder head
Type: .................................................................... Common cylinder head
Max surface unevenness: ..................................... 0.125 mm (0.00492")
Cylinder head bolts

Thread size: .......................................................... M 14
Quantity and length: .............................................. 26 x 141 mm (26 x 5.55”)
Cylinder liners
Replacable, wet
Type: .................................................................... Wet, replaceable

Number of seals per liner: ..................................... 2
Bore: ..................................................................... 108+0.02 mm (4.252”+0.0008”)
Max bore wear: ..................................................... 108.1 mm (4.256”)
Sealing surface. height (A): ................................... 9-0.02 mm (0.3543”-0.0008”)
Liner collar seating depth in block: ........................ 8.92+0.03 mm (0,3512”+0.0012”)
Projection of liner above block surface: ................. 0.03 – 0.08 mm (0.0012 – 0.0031”)
57

• Position the dial gauge at the measuring points A and B on the top of the piston, in-
line with the gudgeon pin.
gasket. The different head gaskets are identified by the hole identification on each of the
three different thickness available, see picture below.
Measuring points, distance X: ............................ Ø 95 mm (3.74")
Identification
1 Hole ................................................................... 0.28 – 0.53 mm (0.011" – 0.0201")
2 Holes ................................................................. 0.54 – 0.63mm (0.0212" – 0.0248")
3 Holes ................................................................. 0.64 – 0.75 mm (0.0252" – 0.0295")
58
Pistons
Number of piston ring grooves ............................... 3
Combustion chamber:
Diameter Ø ........................................................... 71±0.1 mm (2.795"±0.0039")
Depth .................................................................... 16.66±0.1 mm (0.6559"±0.0039")
Gudgeon pin diameter Ø ....................................... 42 -0.006 mm (1.6535"-0.0002")
Piston rings
Compression rings
Number of rings .................................................... 2
Upper compression ring (1) ................................ Keystone, no clearance
Upper compression ring (1) ................................ 0.8 mm (0.03")
Oilscraper ring (3)

Number: ................................................................ 1
Width, including springcoil: .................................... 3 mm (0.12")
Piston ring clearance. height: ................................ 0.1 mm (0.0039")
Piston ring gap, wear limit: .................................... 1.15 mm (0.045”)
59
Valve mechanism
Valves
Disc diameter Ø:
Inlet ................................................................... 48±0.1 mm (1.8898"±0.0039")
Exhaust ............................................................. 42±0.1 mm (1.6535"±0.0039")
Stem diameter Ø:
Inlet ................................................................... 8.98-0.015 mm (0.3535"-0.0006")
Exhaust ............................................................. 8.96-0.015 mm (0.3528"-0.0006")
Valve seat angle:
Inlet, min ............................................................ 29.5°
Exhaust, min ..................................................... 44.5°

45°
30°
29.5°
44.5°
Valve disc edge:

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

Inlet ................................................................... 49.09-0.02 mm (1.933"-0.0008")
Exhaust ............................................................. 43.06-0.02 mm (1.695"-0.0008")
Height (B):
Inlet ................................................................... 7.5±0.1 mm (0.295"±0.004")
Exhaust ............................................................. 7.9±0.1 mm (0.311"±0.004")
60
Valve seat location

ØC
R
D

Inlet ................................................................... 49-0.025 mm (1.929"-0.001")
Exhaust ............................................................. 43.5-0.02 mm (1.712"-0.001")
Depth (D):
Inlet/Exhaust ..................................................... 11+1 mm (0.43"+0.04")
Inlet/Exhaust ..................................................... 1-0.3 mm (0.04"-0.012")
Inlet/Exhaust ..................................................... Min 1.5 mm (0.059")
Valve guides
Length:
Inlet/Exhaust ..................................................... 63-0.5 mm (2.48"-0.02")
Inner diameter Ø:
Inlet/Exhaust ..................................................... 9.025–9.04 mm (0.3553–0.3559")
Height above cylinder head spring surface:
Inlet/Exhaust ..................................................... 23-0.5 mm (0.9"-0.02")
Inlet ................................................................... 0.1 mm (0.039")
Exhaust ............................................................. 0.13 mm (0.51")
Design 1 Design 1 Design 2

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

stem sealing, according to the picture for design 2.
Production Exchange
Valve springs
Type ..................................................................... Single
Length: Unloaded: n=2300 .................................... 64.7±1.3 mm (2.55"±0.05")
Wire diameter Ø .................................................... 4.5 mm (0.18")
61
Camshaft
Type of camshaft:
TD720GE/TAD720GE ........................................ A
TD720VE/TAD720VE/TAD721VE ...................... A or M
TAD721GE/TAD722GE/TAD722VE ................... S
Drive ..................................................................... Gear
Number of bearings ............................................... 7
Standard ............................................................ 65+0.054 mm (2.559"+0.0021")
Wear limit ........................................................... 65.08 mm (2.5622")
+0.012
Camshaft bearing thickness: max ......................... 1.988 mm (0.7827"+0.0005")
Axial clearance ..................................................... 0.1– 0.5 mm (0.004 – 0.02")
Radial clearance ................................................... 0.05 – 0.124 mm(0.002 – 0.0049")
Position of bearing bush at flywheel end ............... 2+0.5 mm (0.079"+0.0197")
Timing gear
1. Governor drive
2. Idler gear
3. Camshaft gear
4. PTO gear B-C
5. PTO gear A
6. Crankshaft gear
Flywheel
Type of flywheel :
TD720VE/TAD720VE/TAD721VE ...................... Clutch 10" or 11.5"
Max, permitted axial throw
Measuring radius 150 mm (5.91") ....................... 0.1 mm (0.00394")
Number of teeth on flywheel .................................. 129
62
Crank mechanism
Crankshaft length .................................................. 973.2 mm (38.31")
Crankshaft axial clearance1) .................................. 0.1– 0.3 mm (0.0039"– 0.0118")
Max, run-out of center bearing ............................... 0.1 mm (0.00394")
1)
E
F
C B
A

Diameter Ø (A) for machining: Standard ............... 85-0.02 mm (2.9134"-0.0008")
Undersize:
0.25 mm (0.01") ................................................. 84.75-0.02 mm (3.3366"-0.0008")
0.5 mm (0.02") ................................................... 84.5-0.02 mm (3.3268"-0.0008")

Taper: Max. ....................................................... 0.01 mm (0.0004")
Width (B), axial bearing journal: standard .............. 38+0.06 mm (1.496"+0.0024")
Oversize:
0.4 mm (0.0157") ............................................... 38.4+0.06 mm (1.5118"+0.0024")
Width (C): Standard ............................................... 2.9+0.05 mm (0.114"+0.002")
Oversize:
0.2 mm (0.0079") ............................................... 3.1+0.05 mm (0.122"+0.002")
Width (D): .............................................................. 10 mm (0.4")
Main bearing shells

Type ..................................................................... Replaceable
Outer diameter Ø (E) ............................................. 85.03+0.036 mm (2.9035"+0.0014")
Thickness (F): Standard ........................................ 2.727+0.008 mm (0.1074"+0.0003")
Oversize:
0.25 mm (0.01") ................................................. 2.852+0.008 mm (0.1123"+0.0003")
0.5 mm (0.02") ................................................... 2.977+0.008 mm (0.1172"+0.0003")
63

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

Diameter Ø (J): Bearing ........................................ 68.03+0.04 mm (2.6783"+0.0016")
Oversize:
0.25 mm (0.01") ................................................. 67.78+0.04 mm (2.6685"+0.0016")
0.5 mm (0.02") ................................................... 67.53+0.04 mm (2.6587"+0.0016")
Diameter Ø: Bearing shell ..................................... 72.5+0.05 mm (2.854"+0.002")
Thickness (K): Standard ....................................... 2.222+0.01 mm (0.0875"+0.0004")
64
Connecting rods
Length (L): Center – Center ................................... 210±0.06 mm (8.2677"±0.00236")
Connecting rod (M) bushing bore ........................... 42.04+0.01 mm (1.6551"0.0004")
Wear limit ........................................................... 0.08 mm (0.0031")
Replacing measurement for small end bush
Bore for small end bush ..................................... 45.5+0.02 mm (1.7913"0.0008")
Small end bush outer diameter Ø ....................... 45.58+0.04 mm (1.7945"+0.0016")
Axial clearance, connecting rod – crankshaft1) ...... 0.3-0.4 mm (0.0118-0.0157")

Connecting rod bearing: radial clearance1) ............. 0.036-0.096 mm (0.00142-0.00378")
1)
Marking: Connecting rod and cap number marking must be on

one side and identical
65
Lubricating system

Up to 0.5 % 0.5 – 1 % More than 1 %
VDS, VDS-2, VDS-3
ACEA E3, E2 500 hours or months 250 hours or months 125 hours or months
NOTE! Fully synthetic oil must be used for the TAD721/722GE/TAD722VE engine. Mineral based oil, either fully
or semi-synthetic can be used in other engines, on condition that it complies with the quality requirements above.
If the 6 and 7 liter engines are equipped with a low-profile oil pan, the oil change intervals should be changed.

Viscosity
table.

66
Engine oil quantity

With oil filter:
TD720/TAD720/TAD721: .................................... 20 liter (5.28 US gal)
TAD722VE ......................................................... 23 liter (6.10 US gal)
TAD721GE/TAD722GE ...................................... 34 liter (8.98 US gal)

At rated speed:
TD720GE/TAD720GE/TAD721GE/TAD722GE : ...... 400 kPa (58 psi)
TD720VE/TAD722VE: .............................................. 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/TAD720GE/TAD721GE/TAD722GE:........ 200 kPa (29 psi)
TD720VE/TAD720VE/TAD721VE/TAD722VE: ......... 50 kPa (7.2 psi)
4. Rocker arm
6. Piston cooling: ...................................................... 2-hole nozzles for each cylinder
7. Oil filter, full-flow:
Filtering size: .............................................................. 0.012 mm (0.0005")
Bypass valve oil filter:
Opening pressure: .................................................... 250±50 kPa (35±7 psi)
8. Pressure regulating valve:
Opening pressure: .................................................... 400±40 kPa (58±6 psi)
9. Pressure-relief valve:
Opening pressure: .................................................... 1±0.1 MPa (145±14 psi)
10. Lube oil pump:
Type: .......................................................................... Rotary pump driven by the crankshaft
Rotary pump width: ..................................................... 14.5 mm (0.57")
Oil flow (2500 rpm): ..................................................... 90 l/min (24 gal/hour)
11. Oil cooler:
Normal oil temperature: ............................................... 80°C (176°F)
Max o il temperature: .................................................. 125°C (257°F)
67
Fuel System
Fuel system
1. Fuel tank.
3. Fuel pump
5. Fuel filter
7. Injection pumps, 420/520 (4) 620/720/721 (6)
9. Injector
11. Overflow valve2)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
68
Fuel specification
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
JIS KK 2204
Sulfur content: According to current legislation in the respective country.
In
Out
Fuel feed pump

Fuel system figures is corresponding to the picture above
Overpressure relief valve (1):
Opening pressure ............................................... 0.6±0.05 MPa (87±7.2 psi)1)
Bypass valve (2)
Opening pressure ............................................... 50±5 kPa (7.2±0.7 psi)
Fuel flow
Min fuel flow at 1500 rpm ...................................... 600 l/tim (158.5 gal/hour)
Firing sequence .................................................... 1-5-3-6-2-4
Feed pressure ....................................................... 0.5 MPa (72.5 psi)
Feed pressure after fuel filter at
1500 rpm. min .................................................... 0.28 MPa (40.6 psi)
Fuel filter
Pre-filter
69
Injection pump
Basic measurements
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering
fuel.
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
This gives us the equation: LFB = 143 + 0.63
Injection pump
Manufacturer ......................................................... Bosch
Designation ........................................................... PF 33 L
Length A: .............................................................. 54 mm (2.12")
Basic measurement length LO : ............................. 143 mm (5.63")
Min length LFB : (A/100+143) – 143 ........................ >0 mm
Injectors
Opening pressure:
TD720GE/ EPA1, TD720VE/EPA1
TAD720VE/EPA1, TAD721VE/EPA1 ................. 25 MPa (3600 psi)
TAD720GE/COM2, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2
TAD721GE/COM2, TAD722GE/COM2 ............... 27,5 MPa (4000 psi)
Max pressure
TD720GE/ EPA1, TAD720GE/EPA1/COM2
TAD720VE/EPA1, TAD721VE/EPA1
TAD721GE/COM2, TAD722GE/COM2 ............... 120 MPa (17400 psi)
TAD720VE/COM2, TAD721VE/COM2
TAD722VE¤/COM2 ............................................ 160 MPa (23200 psi)
Check leakage (for 10 min)
TAD720GE/EPA1, TAD720VE/COM2
TAD721VE/COM2, TAD722VE/COM2 ............... 23 MPa (3340 psi)
TAD720GE/EPA1, TAD720VE/EPA1
TAD721GE/COM2, TAD722GE/COM2
TAD721VE/EPA1............................................... 25,5 MPa (3700 psi)
Numbers/bore Ø:
TD720GE ........................................................... 6 x 0.234 mm (6 x 0.00921")
TAD720GE/TD720VE/TAD720VE, EPA 1 .......... 6 x 0.25 mm (6 x 0.00984")
TAD721VE, EPA 1 ............................................ 6 x 0.264 mm (6 x 0.0104")
TAD720VE, COM 2/TAD721VE, COM 2 ............ 6 x 0.236 mm (6 x 0.00929")
70

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

71

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

Theor. thickness (TS) Shim thickness (SS) Theor. thickness(TS) Shim thickness (SS)
72
How to use EP code

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

Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP
code code code code code
73
Governor
Manufacturer ......................................................... Heinzmann

Designation:
TD720GE/TAD720GE, TAD721/722GE: ............ 1500 rpm
TD720GE/TAD720GE, TAD721/722GE: ............ 1800 rpm
TD720VE: .......................................................... 1800 rpm
TAD720VE/TAD721VE/TAD722VE: ................... 2100 rpm
Max, engine speed droop at a load increase from 0 to 100 % at: rated speed
TD720GE/TAD720GE, TAD721/722GE: ............ <5 %
TD720VE: .......................................................... 8 – 12 %
TAD720VE/TAD721VE, TAD722VE: .................. 5 – 7 %
Control rod
Start and stop: ...................................................... 17 – 17.5 mm (0.67" – 0.69")
Min: ...................................................................... 16.8 mm (0.66")
The recess dimension X ....................................... 0.3 – 1.3 mm (0.012" – 0.051")
74

Turbocharger
Make and designation:
TD720GE/TAD720GE/TD720VE: ........................ Schwitzer S2B
TAD720VE/TAD721VE, TAD722VE:
EPA 1: ................................................................ Schwitzer S2B
COM 2: ............................................................... Schwitzer S200
TAD721/722GE ................................................... Schwitzer S200
Boost pressure at rated speed1), ± 10%:
TD720GE (1500 rpm): ...................... 116 kPa (16.8 psi) TD720VE: ........................................... 2) kPa (2) psi)
TD720GE (1800 rpm): ...................... 131 kPa (19 psi) TAD720VE (EPA 1): ........................... 133 kPa (18.9 psi)
TAD720GE (1500 rpm): .................... 136 kPa (19.7 psi) TAD720VE (COM 2): .......................... 151 kPa (21.9 psi)
TAD720GE (1800 rpm): .................... 142 kPa (20.6 psi) TAD721VE (EPA 1): ........................... 155 kPa (22.5 psi)
TAD721GE(1500 rpm) ...................... 161 kPa (23.4 psi) TAD721VE (COM 2): .......................... 163 kPa (23.6 psi)
TAD721GE (1800 rpm) ..................... 175 kPa (25.4 psi) TAD722VE (COM2, high power) .......... 198 kPa (28.7 psi)
TAD722GE (1500 rpm) ..................... 178 kPa (25.8 psi)
TAD722GE (1800 rpm) ..................... 200 kPa (29.0 psi)
Lube system .......................................................... Pressure lubrication

Max, permitted radial clearance (compressor side)
Schwitzer S2B: .................................................. 0.95 mm (0.0374")
Schwitzer S200: ................................................. 0.88 mm (0.0346")
Max. permitted axial clearance
Schwitzer S2B: .................................................. 0.14 mm (0.00551")
Schwitzer S200: ................................................. 0.1 mm (0.0039")
Max allowed back pressure in exhaust line:
TD/TAD720GE, TAD721/722GE (1500 rpm): ...... 5 kPa (0.7 psi)
TD/TAD720GE, TAD721/722GE (1800 rpm): ...... 7 kPa (1 psi)
TD720VE/TAD720VE/TAD721VE/TAD722VE: ... 7.5 kPa (1.1 psi)
Exhaust gas temperatur, approx:

At rated speed (standby power)1): .......................... 1500 rpm 1800 rpm
TD720GE: .......................................................... 560°C (1040°F) 505°C (941°F)
TAD720GE: ....................................................... 476°C (914°F) 433°C (837°F)
TAD721GE: ....................................................... 540°C (1004°F) 494°C (921°F)
TAD722GE: ....................................................... 557°C (1035°F) 520°C (968°F)
At rated speed: ..................................................... 1800 rpm 2100 rpm 2200 rpm 2300 rpm
TD720VE: .......................................................... 420°C (788°F) — — —
TAD721VE: ........................................................ 420°C (788°F) 420°C (788°F) 425°C (797°F) 430°C (806°F)
TAD721VE: ........................................................ 490°C (914°F) 475°C (887°F) 480°C (896°F) 485°C (905°F)
TAD722VE: ........................................................ 545°C (1013°F) 535°C (995°F) 540°C (1004°F) 545°C (1013°F)
1)
See in General information, Power standards.
2)
Information was not avaible at the time of printing.
Air intake
Air intake restriction, clean filter(s)
TAD721GE/TAD722GE: ..................................... 1.5 kPa (0.22 psi)
Max allowed air intake restriction
TAD721GE/TAD722GE: ..................................... 3.5 kPa (0.51 psi)
75
Fuel system
Cooling system
Type ................................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD720GE/TAD720GE: ..................................................... 60 kPa (13 psi)
TAD721GE/TAD722GE
TD720VE/TAD720VE/TAD721VE, max1): ........................ 90 kPa (13 psi)
1)
Capacity (engine):. .............................................................. 9.8 liters (2.59 US gal)
Capacity (engine and cooler):
TD720GE: ........................................................................ 22 liters (5.8 US gal)
TAD720GE: ..................................................................... 23.8 liters (6.3 US gal)
TAD721GE/TAD722GE .................................................... 27.3 liter (7.2 US gal)
Thermostat
Type ................................................................................... Piston thermostat
Begins to open at
TD720GE/TAD720GE/TD720VE: ..................................... 83°C (181°F)
TAD721GE/TAD722GE/TAD720VE
TAD721VE/TAD722VE: ................................................... 87° C (189° F)
Fully open at
TD720GE/TAD720GE/TD720VE: ..................................... 95°C (203°F)
TAD721GE/TAD722GE/TAD720VE
TAD721VE/TAD722VE: ................................................... 102° C (216° F)
1. Coolan connection (inlet)

2. Thermastat housing
3. Coolant pump
4. Lubrication oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection (outlet)
Coolant pump
Glycol (Antifreeze)
3)
The anti-corrosion agent must not be mixed with glycol or other types of anti-corrosion fluid as this could result in negative
consequences.
If any doubt about the purity of the water, distilled water or ready-mixed coolant should always be used instead
76
Tightening torque
M6 standard screw 8.8 .......................................... 10±1.5 (7.5±1 lbf.ft)
M8 standard screw 8.8 .......................................... 25±4 (18±3 lbf.ft)
M12 standard screw 8.8 ........................................ 80±9 (59±6.5 lbf.ft)
Group 21 Engine
Engine mounting ................................................... 260 (192 lbf.ft)
Starter motor ......................................................... 70 (51.6 lbf.ft)
Timing gear casing ................................................ 21±2 (15.5±1.5 lbf.ft)
Main bearing caps

Step 1 ................................................................ 50 (37 lbf.ft)
Connecting rod big-end bearing:

Step 1 ................................................................ 30 (22 lbf.ft)
Flywheel
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 1: ............................................................... 30 – 40 (22 – 30 lbf.ft)
Flywheel housing. M12 .......................................... 99±1 (73±7 lbf.ft)
±25
Flywheel housing. M16 .......................................... 243 (179±18 lbf.ft)
V-belt pulley
Step 1: ............................................................... 40 – 50 (30 – 37 lbf.ft)
Vibration damper ................................................... 70
Screw, rocker cover .............................................. 9±1 (6.5±0.7 lbf.ft)
±2
Lock nut, valve clearance adjusting screw ............ 20 (14.5±1.5 lbf.ft)
Screws, rocker arm fixing ..................................... 21 (15.5 lbf.ft)
Screws, crankcase ventilation ............................... 9±1 (6.6±0.7 lbf.ft)
77

Cylinder head
Step 1: ............................................................... 50 (37 lbf.ft)
Step 2: ............................................................... 130 (96 lbf.ft)
Group 22 Oil system

Oil cooler, screws ................................................. 21±2 (15.5±1.5 lbf.ft)
Oil cooler, hollow screw
Step 1: ............................................................... 80 (59 lbf.ft)
Step 2: ............................................................... 160 (118 lbf.ft)
Oil cooler, screw plug ............................................ 80 (59 lbf.ft)
Front/oil pump housing .......................................... 21±2 (15.5±1.5 lbf.ft)
Oil suction pipe ..................................................... 21±2 (15.5±1.5 lbf.ft)
Oil sump ............................................................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure pipe turbo .......................................... 29±3 (21.4±2.2 lbf.ft)
Oil pressure pipe engine block .............................. 39±4 (29±3 lbf.ft)
A) with tube fitting .............................................. 40±2 (29.5±1.5 lbf.ft)
B) with flange fitting ........................................... 21±2 (15.5±1.5 lbf.ft)
Screws, oil return pipe engine block ...................... 21±2 (15.5±1.5 lbf.ft)
Oil pressure switch ............................................... 18±2 (13±1.5 lbf.ft)

Step 1: ............................................................... 30 (22.1 lbf.ft)
Screw, control rod hose ........................................ 10±2 (7±5 lbf.ft)
±1.5
Step 1: Torque ................................................... 5 (3.7 lbf.ft)
Step 3: Turn injection pump to stop ................... Counterclockwise
Step 5: ............................................................... 7 (5 lbf.ft)
Step 6: ............................................................... 10 (7.4 lbf.ft)
Step 7: ............................................................... 30 (22 lbf.ft)
+5
Flange screw, injector ........................................... 16 (12+4 lbf.ft)
Injector cap nut ..................................................... 40 – 50 (30 – 37 lbf.ft)
Delivery pipe
Step 1: ............................................................... 5 (3.7 lbf.ft)
Step 2: ............................................................... 25±3.5 (18.4±2.6 lbf.ft)
Screw, stop magnet .............................................. 21 (15.5 lbf.ft)
Overflow valve ...................................................... 30 (22 lbf.ft)

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)

Thermostat housing .............................................. 30 (22.1 lbf.ft)
Water pump .......................................................... 21±2 (15.5±1.5 lbf.ft)
78
Grupp 20 Technical data
Tightening torque diagram
Main bearing caps:

TD420VE/TAD420VE/TAD620VE
Step 1 ................................................................. 30 Nm
TD520GE/TAD520GE/TD520VE/TAD520VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE
Step 1 ................................................................. 50 Nm (37 lbf.ft)
Connecting rod big-end bearing:

Use new bolts every time.
Step 1 ................................................................. 30 Nm (22 lbf.ft)
Step 3 ................................................................. 30 Nm
Step 1 ................................................................. 50 Nm (37 lbf.ft)
79
Technical data Grupp 20
Flywheel

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

V-belt pulley/vibration damper:
Step 1: ................................................................ 40 – 50 Nm (30 – 37 lbf.ft)
Vibration damper .................................................... 70 Nm
80
Grupp 20 Technical data
Cylinder head
Manifold side Manifold side
Step 1: ................................................................ 30 Nm (22 lbf.ft)
Step 2: ................................................................ 80 Nm (59 lbf.ft)
Step 1: ................................................................ 50 Nm (37 lbf.ft)
Step 2: ................................................................ 130 Nm (96 lbf.ft)
Step 1: Torque .................................................... 5 Nm (3.7 lbf.ft)
Step 3: Turn injection pump to stop .................... Counterclockwise
Step 5: ................................................................ 7 Nm (5 lbf.ft)
Step 6: ................................................................ 10 Nm (7.4 lbf.ft)
Step 7: ................................................................ 30 Nm (22 lbf.ft)
Put the pump flange in place with the side of the chamfered hole facing the pump. Oil the screws lightly and tigh-
ten 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.
81
Technical data Grupp 20
Delivery pipe
Fit a new delivery pipe and rubber seal.
Tighten the nuts by hand.
When installing delivery pipes, be sure to fit the sealing cones
exactly in the pump and injector.
Delivery pipe
Step 1: ................................................................ 5 Nm (3.7 lbf.ft)
Step 2: ................................................................ 25±3.5 Nm (18.4±2.6 lbf.ft)
WARNING! Do not bend the pressure pipes, they can only be used once.
Screw plug
4. Screw plug MA .................................................... 35±3.5 Nm (26±2.6 lbf ft)

6. Screw plug MA .................................................... 95±9.5 Nm (70±7 lbf ft)
13. Screw plug MA .................................................. 35±3.5 Nm (26±2.6 lbf ft)
24. Screw plug MA .................................................. 10±2 Nm (7±1.5 lbf ft)
82
Group 20
References to Service Bulletines
Group No. Date Regarding
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Report form
Do you have any complaints or other comments about this manual. Please
make a copy of this page, write your comments down and send them to us. The
address is at the bottom. We would prefer you to write in English or Swedish.
From: ............................................................................
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Refers to publication: .............................................................................................................................................
Publication No.: ............................................................. Date of issue: .................................................................
Proposal/motivation: ..............................................................................................................................................
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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7742012 English 03–2004

Volvo TAD 620VE Workshop Manual Technical Data

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Volvo TAD 620VE Workshop Manual Technical Data

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Workshop Manual I

Technical Data 1(0)

TD420VE, TAD420VE, TD520GE, TAD520GE

TD420VE, TAD420VE, TAD620VE, TD520GE, TAD520GE,

Take care to avoid contact with hot surfaces

Never work alone when removing heavy engine

© 2004 AB VOLVO PENTA

Tightening torque Lock nuts

Tightening torque with Strength classes

Sealant Safety rules for fluorocarbon

© 2004 AB VOLVO PENTA

Cylinder head bolts

Cylinder head gasket

Oilscraper ring (3)

Min 1.8 mm Min 1.1 mm

Valve disc edge:

Outer diameter Ø (A), standard:

Valve seat location

Diameter Ø (C), standard:

Main bearing journals

Main bearing shells

Connecting rod bearing journals

Connecting rod bearing shells

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

Connecting rod marking:

VDS, VDS-2, VDS-3

VDS = Volvo Drain Specification

NOTE! the temperatures refer to constant outside air

Engine oil quantity

1. Oil pressure sensor

Fuel feed pump

Commencement of delivery (FB)

Table 1, Commencement of delivery

Theoretical thickness for a new shim.

Table 2, Shim thickness

How to use EP code

Table 3, EP code conversion table

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

Manufacturer .......................................................... Heinzmann

Intake and exhaust system

Exhaust gas temperatur, approx.:

Tightening torques Nm (lbf.ft)

Main bearing caps

Connecting rod big-end bearing

Tightening torques Nm (lbf.ft)

Group 22 Oil system

Group 23 Fuel system

Group 25 Inlet and exhaust system

Group 26 Cooling system

Cylinder head bolts

Type: .................................................................... Wet, replaceable

Cylinder head gasket

Oilscraper ring (3)

Min 2.1 mm Min 1.8 mm

Valve disc edge:

Outer diameter Ø (A), standard:

Valve seat location

Diameter Ø (C), standard:

On later models the o-ring seal is exchange to a valve

Main bearing journals

Main bearing journals:

Main bearing shells

Connecting rod bearing journals

Connecting rod bearing shells