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Volvo Penta TAD420VE, Workshop Manual

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Volvo Penta TAD420VE Workshop Manual Download Page 40

Technical Data: 

TD/TAD520, TAD530/531/532

38

Group 20

•

Set the dial gauge in the level of the crankcase surface to ”zero”.

•

Position the dial gauge at the measuring points 

A

 and 

B 

on the top of the piston,

inline with the gudgeon pin.

•

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 95 mm

(3.74")

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.

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")

Summary of Contents for TAD420VE

Page 1: ...al Technical Data TD420VE TAD420VE TD520GE TAD520GE TD520VE TAD520VE TAD530 531 532GE TAD620VE TAD650VE TAD660VE TD720GE TAD720GE TD720VE TAD720VE TAD721GE TAD721VE TAD722GE TAD722VE TAD730 731 732 733GE TAD750VE TAD760VE ...

Page 2: ......

Page 3: ...AD520VE TAD530 531 532GE TD720GE TAD720GE TD720VE TAD720VE TAD721GE TAD721VE TAD722GE TAD722VE TAD730 731 732 733GE TAD750VE TAD760VE Valve mechanism 40 Crank mechanism 43 Lubricating system 46 Fuel system 48 Intake and exhaust system 55 Cooling system 56 Tightening torque 57 TD720GE TAD720GE TD720VE TAD720VE TAD721GE TAD721VE TAD722GE TAD722VE TAD730 733GE TAD750VE TAD760VE General 720 722GE 59 G...

Page 4: ...abels that have been damaged or painted over Never start the engine without installing the air cleaner filter Foreign objects entering the intake ducts can also cause mechanical damage Never use ether or similar products when start ing the engine They may cause an explosion in the inlet manifold and causing personal injuries Only start the engine in a well ventilated area If operating the engine i...

Page 5: ... delivery pipes every time Be careful delivery pipes should under no circu mstances be bent All fuels and many chemical substances are fla mmable Do not allow naked flame or sparks in the working area Make sure that the working area is well ventilat ed and take the necessary safety precautions before starting welding or grinding work Make sure that there always are fire extinguish ers in the worki...

Page 6: ...se the lifting eyes fitted on the engine when lif ting the drive unit Always check that the lifting equipment is in good condition and has the cor rect load capacity to lift the engine engine wei ght including gearbox if fitted and any extra eq uipment installed To make sure of safe handling and to avoid da mage use a lifting beam to raise the engine This lifting beam is installed on the top of th...

Page 7: ...fuel with calorific value of 42 7 MJ kg 18360 BTU lb and a density of 0 84 kg liter 7 01 lb US gal 8 42 lb lmp gal even when it involves a deviation from standards Spare parts Spare parts for the electrical and fuel systems are subject to various national safety requirements Volvo Penta Original Spare Parts meet these specifications Any type of damage which is the result of using spare parts that ...

Page 8: ...nction 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 Our joint responsibility Every engine consists of many systems and compo nents that ...

Page 9: ...eight as a stan dard hexagonal nut without plastic insert Reduce the tightening torque by 25 for bolt size M8 or larger If Nylock nuts are higher or of the same height as a standard hexagonal nut the tightening torque s given in the table applies Tightening torque with protractor tightening angle tightening Tightening using both a torque setting and a protractor angle requires that first the recom...

Page 10: ...lts petcocks oil pressure switches and so on The cured material is glass like and it is therefore co lored to make it visible Cured anaerobic agents are extremely resistant to solvents and the old agent can not be removed When reinstalling the part is carefully degreased and then new sealant is applied Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for ...

Page 11: ... or regulation 9 ISO 3046 reference test conditions 10 ISO 3046 reference test conditions 11 Injection pump code EP code 12 Piston class 13 Prime output without fan at rated speed Identification plates Location of identification plates 420 620 520 722 Each engine is supplied with two identical identifica tion plates of which one is mounted on the right side of the cylinder block and the other one ...

Page 12: ...peak power according to Tier III 8 Air temperature in C F in accordance with ISO 3046 9 Altitude above mean sea level in accordance with ISO 3046 10 EU Tier III approval number Identification plates Location of identification plates TAD650 660 750 760 Each engine is supplied with two identical identifica tion plates of which one is mounted on the right side of the cylinder block and the other one ...

Page 13: ...atio 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 identificat...

Page 14: ... torque Nm lbf ft 750 553 3 800 590 3 At speed rpm 1600 1600 Low idle rpm 600 800 600 800 Max full load speed rpm 24001 2400565 Weight engine dry kg lb 565 1246 2 565 1246 2 Weight engine wet kg lb 585 1290 2 585 1290 2 1 See identification plate for correct specification 2 Weight according to DIN 70020 A 3 See General information Power standards Engine block Cylinder head Type Common cylinder hea...

Page 15: ...8 Max bore wear TD420VE TAD420VE TAD650VE 101 1 mm 3 98 TAD620VE 98 1 mm 3 86 TAD660VE 98 1 mm 3 86 Sealing surface Height see picture A TAD620VE TAD660VE 4 5 0 02 mm 0 177 0 0008 Liner collar seating depth in block TAD620VE TAD660VE 4 38 0 03 mm 0 1724 0 0012 Projection of liner above block surface TAD620VE TAD650 TAD660VE 0 012 0 07 mm 0 00047 0 0027 Parent bore TD420VE TAD420VE TAD650VE Replace...

Page 16: ...on 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 Cylinder head gasket Measuring piston projection A dial gauge with a fixture special tool 999 8678 is needed to measure the pisto...

Page 17: ...raper 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 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 TAD650 TAD660VE 17 5 0 1 mm 0 689 0 0039 Gudgeon pin diameter Ø 38 0 006 mm 1 496 0 0002 ...

Page 18: ...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 clearance not apply for TAD660VE Inlet 0 35 0 05 mm 0 014 0 002 Exhaust 0 55 0 05 mm 0 022 0 002 Important Control and adjusting of valve clear...

Page 19: ...d 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 Ø A B Ø C R D 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 Heigh...

Page 20: ...s TD420VE TAD420VE 5 TAD620VE TAD650 TAD660VE 7 Inner diameter Ø bearing journals Standard 63 0 054 mm 2 48 0 0021 Wear limit 63 08mm 2 483 Camshaft bearing thickness max 1 388 0 012 mm 0 05465 0 0005 Axial clearance 0 1 0 5 mm 0 004 0 02 Radial clearance 0 05 0 124 mm 0 002 0 0049 Position of bearing bush at flywheel end 3 0 2 mm 0 118 0 008 Timing gear 1 Governor drive not apply for 650 660 2 Id...

Page 21: ... 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 ...

Page 22: ...2 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 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 J K H G ...

Page 23: ...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 L M Connecting rod marking Connecting rod and cap number marking must be on one side and ...

Page 24: ... hours or 12 months 250 hours or 12 months 125 hours or 12 months API CI 4 CH 4 CG 4 1 If the sulfur content is 1 0 by weight use oil with TBN 15 2 For markets outside Europe API CG 4 and CH 4 can be used instead of ACEA E3 NOTE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above NOTE For 6 and 7 liter engines equipped with...

Page 25: ... for rocker arm lubrication 4 Rocker arm 5 Return line to oil sump 6 Piston cooling 2 hole nozzles for each cylinder 7 Oil filter full flow Filtering size 0 012 mm 0 0005 By pass valve oil filter Opening pressure 250 50 kPa 35 7 psi 8 By pass valve oil cooler Opening pressure 210 30 kPa 30 5 4 psi 9 Safety valve opening pressure TD420VE TAD420VE 600 75 kPa 87 10 7 psi TD620VE TAD650 TAD660VE 400 4...

Page 26: ...o fuel filter Inside diameter min 12 mm 0 47 1 5 Fuel filter 6 Fuel line to fuel duct 7 Injection pumps 420 520 4 620 720 721 6 8 Delivery pipe to injector 9 Injector 10 Fuel return line 11 Overflow valve 2 12 Return fuel line to fuel tank Inside diameter min 10 mm 0 39 1 13 Fuel pipes minimum distance 300 mm 11 8 14 Pre filter for water separating 15 Hand pump accessory 1 Depending on length of h...

Page 27: ...nk 2 Hand pump accessory 3 Fuel line to pump 4 Fuel pump 5 Fuel filter 6 Pipe to highpressure 7 Rail 8 Highpressure pump 9 Fuelpipe to injector 10 Injector 11 M prop 12 Pressurevalve 13 Return fuel line to fuel tank A Fuel pipes minimum distance 300 mm 11 8 Fuel system 650 660 ...

Page 28: ...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 In Out 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 ...

Page 29: ... 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 Inj...

Page 30: ... 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...

Page 31: ...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 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...

Page 32: ...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...

Page 33: ...0 rpm TD420VE TAD420VE TAD620VE 2300 rpm TD420VE TAD420VE TAD620VE 2100 rpm Engine speed droop at a load increase from 0 to 100 at rated speed TD420VE TAD420VE TAD620VE 5 7 Important When ordering a governor as a spare part always state engine types serial number rated power and rated speed rpm Note It is absolutely necessary to measure and indicate the recess dimension X after exchange of the tra...

Page 34: ...ure valve opens at max2 90 kPa 13 psi 2 Versatile engines are not equipped with a pressure valve from factory Capacity engine TD420VE TAD420VE 4 7 liters 1 24 US gal TAD620VE TAD650VE TAD660VE 6 liters 1 58 US gal Thermostat Type One piston thermostat Begins to open at 83 C 181 F Fully open at 95 C 203 F Coolant pump Type Belt driven centrifugal pump Glycol Antifreeze Volvo Penta glycol antifreeze...

Page 35: ...2 lbf ft Step 2 60 angle tightening Step 3 30 angle tightening Flywheel A Flywheel with screws of max 30 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 30 angle tightening B Flywheel with screws up to 45 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening C Flywheel with a screw length between 50 85 mm Step 1 30 40 22 30 lbf ft Step 2 60...

Page 36: ...l system Screw governor idler gear 420 620 Step 1 30 22 1lbf ft Step 2 90 angle tightening Screw control rod hose 10 2 7 5 lbf ft Screw governor 17 1 5 12 5 1 lbf ft Flange screws Injection pump Step 1 Torque 5 3 7 lbf ft Step 2 Loosen screws for injection pump flange 60 counterclockwise Step 3 Turn injection pump to stop Counterclockwise Step 4 60 angle tightening Step 5 7 5 lbf ft Step 6 10 7 4l...

Page 37: ...old 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 ...

Page 38: ...ce At 1500 rpm kW hp 77 5 104 1 3 94 126 1 3 At 1800 rpm kW hp 81 5 109 1 3 101 135 5 1 3 81 110 1 4 At 2300 rpm kW hp 118 158 1 4 Engine torque Nm lbf ft 493 394 3 598 441 3 430 317 4 577 425 4 At speed rpm 1500 1500 1800 1400 Engine torque Nm lbf ft 432 319 3 536 395 3 At speed rpm 1800 1800 Max speed at full load rpm 1500 18001 1500 18001 18001 2000 23001 Weight engine dry kg lb 550 1213 2 575 ...

Page 39: ...ch and frame General Type designation Direction of rotation seen from flywheel No of cylinders Cylinder bore mm inch Stroke mm inch Cylinder volume liter inch 3 No of valves Compression ratio EPA1 EPA2 EU2 Injection sequence Engine power At 1500 rpm kW hp At 1800 rpm kW hp Torque Nm lbf ft At engine speed rpm Torque Nm lbf ft At engine speed rpm Low idle rpm Highest full load speed rpm Weight dry ...

Page 40: ...est piston projection number determines the thickness of the cylinder head gasket The different head gaskets are identified by the hole identification on each of the three different thickness available see picture below Measuring points distance X Ø 95 mm 3 74 Cylinder head gasket Measuring piston projection A dial gauge with a fixture special tool 999 8678 is needed to measure the piston projecti...

Page 41: ...wer compression ring 2 2 5 mm 0 0984 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 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 front marking according to picture Fl...

Page 42: ... width max Inlet 2 8 mm 0 1102 Exhaust 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 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 E...

Page 43: ...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 Wear limit valve stem guide Inlet 0 1 mm 0 039 Exhaust 0 13 mm 0 51 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 Valve seat location Design 1 without flange Design 2 On later mod...

Page 44: ...ce 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 Flywheel Type of flywheel TD520VE TAD520VE Clutch 10 or 11 5 TD520GE TAD530 532GE Gen set 1500 rpm TD520GE TAD520GE TAD530 532GE Gen set 1800 rpm Max permitted axial runout Measuring radius 150 mm 5 91 0 1 mm 0 00394 Number of teeth on flywheel 129 Timing gear 1 Gover...

Page 45: ...08 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 Main bearing journals Out of round Max 0 01 mm 0 0004 Taper Max 0 01 mm 0 0004 Width B axial bearing journal standard 38 0 06 mm 1 496 0 0024 Oversize 0 4 mm 0 0157 38 4 0 06 1 5118 0 0024 Thrust washers axial bearing Width C Standard 2 9 0 05 mm 0 1142 0 0039 Oversize 0 2 mm 0 0079 3 1 0 05 mm 0 122 0 002...

Page 46: ... 0 0008 Width H axial bearing journal 35 5 0 04 mm 1 397 0 0016 Connecting rod bearing journals Out of round Max 0 01 mm 0 0004 Taper Max 0 01 mm 0 0004 Connecting rod bearing shells 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...

Page 47: ... 0 02 mm 1 7913 0 0008 Small end bush outer diameter 45 58 0 04 mm 1 7945 0 0016 Axial clearance connecting rod crankshaft1 0 3 0 4 mm 0 0118 0 0157 Connecting rod bearing radial clearance1 0 036 0 06 mm 0 00142 0 0024 Parallelism Tolerans Over a length of 100 mm 0 05 mm 0 002 Squareness Tolerans Over a length of 100 mm 0 05 mm 0 002 1 The dimensions apply to oiled parts L M Connecting rod marking...

Page 48: ...urs or months 250 hours or months 125 hours or months API CI 4 CH 4 CG 4 1 If the sulfur content is 1 0 by weight use oil with TBN 15 2 For markets outside Europe API CG 4 and CH 4 can be used instead of ACEA E3 NOTE Mineral based oil either fully or semi synthetic can be used on condition that it complies with the quality requirements above NOTE For 6 and 7 liter engines equipped with low profile...

Page 49: ...er arm lubrication 4 Rocker arm 5 Return line to oil sump 6 Piston cooling 2 hole nozzles for each cylinder 7 Oil filter full flow Filtering size 0 012 mm 0 0005 Bypass valve oil filter Opening pressure 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 cr...

Page 50: ...el filter Inside diameter min 12 mm 0 47 1 5 Fuel filter 6 Fuel line to fuel duct 7 Injection pumps 420 520 4 620 720 721 6 8 Delivery pipe to injector 9 Injector 10 Fuel return line 11 Overflow valve 2 12 Return fuel line to fuel tank Inside diameter min 12 mm 0 47 1 13 Fuel pipes minimum distance 300 mm 11 8 14 Pre filter for water separating 15 Hand pump accessory 1 Depending on length of hose ...

Page 51: ...Feed pressure after fuel filter 1500 rpm Min 0 28 MPa 40 6 psi In Out Fuel specification The fuel must be approved according to national and international standards for commercial fuels for example EN 590 with environmental and sub zero temperature specifications according to national requirements ASTM D 975 No 1 D and 2 D JIS KK 2204 Sulfur content According to current legislation in each country...

Page 52: ...ection 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 10...

Page 53: ...very 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 c...

Page 54: ... mm C A 3rd step E3 E2 Vhnom 4th step E4 E3 Lo 5th step E5 E4 A 100 mm 6th step Ts L E5 7th step The actual shim thickness Ss is determined with the help of table 2 below Theor thickness TS Shim thickness SS Theor thickness TS Shim thickness SS Table 2 Shim thickness All measurements are in mm 1 mm 0 0394 NOTE Shims Ss are only available in a calibrated thickness with a variation of steps in 1 10 ...

Page 55: ...ng 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 364 that gives a EK value of 146 675 and if the manufacturing tolerance for the new injection pump is 63 we will have following equation TS 146 675 143 0 63 TS are in...

Page 56: ...E 1800 rpm TD520VE 1800 rpm TAD520VE 2100 rpm TAD520VE 2200 rpm TAD520VE 2300 rpm Max engine speed droop at a load increase from 0 to 100 at rated speed TD520GE TAD520GE 5 TD520VE 8 12 TAD520VE 5 7 Important When ordering a governor as a spare part always state engine types serial number rated power and rated speed rpm Note It is absolutely necessary to measure and indicate the recess dimension X ...

Page 57: ... 4 psi TD520GE TAD530 532GE 1800 rpm 5 kPa 0 7 psi TAD520GE 1500 rpm 5 kPa 0 7 psi TAD520GE 1800 rpm 7 kPa 1 psi TD520VE TAD520VE 7 5 kPa 1 1 psi Exhaust gas temperatur approx At rated speed standby power 1 1500 rpm 1800 rpm TD520GE TAD530GE 610 C 1130 F 530 C 986 F TAD520GE TAD531GE TAD532GE 520 C 968 F 448 C 838 F At rated speed 1800 rpm 2100 rpm 2200 rpm 2300 rpm TD520VE 510 C 950 F TAD520VE 47...

Page 58: ...20GE TD520VE TAD530 531GE 95 C 203 F TAD520VE 102 C 216 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 neg...

Page 59: ... lbf ft Step 2 60 angle tightening Step 3 60 angle tightening Flywheel A Flywheel with screws of max 30 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 30 angle tightening B Flywheel with screws up to 45 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening C Flywheel with a screw length between 50 85 mm Step 1 30 40 22 30 lbf ft Step 2 60 ...

Page 60: ... idler gear Step 1 30 22 1lbf ft Step 2 90 angle tightening Screw control rod hose 10 2 7 5 lbf ft Screw governor 17 1 5 12 5 1 lbf ft Flange screws Injection pump Step 1 Torque 5 3 7 lbf ft Step 2 Loosen screws for injection pump flange60 counterclockwise Step 3 Turn injection pump to stop Counterclockwise Step 4 60 angle tightening Step 5 7 5 lbf ft Step 6 10 7 4lbf ft Step 7 30 22lbf ft Flange ...

Page 61: ... 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 ...

Page 62: ...08 4 25 130 5 12 7 15 436 12 18 0 1 1 5 3 6 2 4 201 273 1 225 306 1 1280 944 1500 1193 880 1800 800 950 1500 18001 785 1731 2 826 1821 2 TAD733GE Anti clockwise 6 108 4 25 130 5 12 7 15 436 12 18 0 1 1 5 3 6 2 4 201 273 1 225 306 1 1280 944 1500 1193 880 1800 800 950 1500 18001 785 1731 2 826 1821 2 Type designation Direction of rotation seen from flywheel No of cylinders Cylinder bore mm inch Str...

Page 63: ... of cylinders 6 6 Bore mm inch 108 4 25 108 4 25 Stroke mm inch 130 5 12 130 5 12 Displacement dm3 inch3 7 15 436 7 15 436 Number of valves 12 12 Compression ratio 18 1 1 18 1 1 Firing sequence 1 5 3 6 2 4 1 5 3 6 2 4 Engine performance at 2300 rpm kW hp 181 246 1 3 181 246 1 3 Max torque Nm lbf ft 1050 775 3 1100 811 3 At speed rpm 1500 1500 Low idle rpm 600 800 600 800 Max full load speed rpm 24...

Page 64: ...he highest piston projection number determines the thickness of the cylinder head gasket The different head gaskets are identified by the hole identification on each of the three different thickness available see picture below Measuring points distance X Ø 95 mm 3 74 Cylinder head gasket Measuring piston projection A dial gauge with a fixture special tool 999 8678 is needed to measure the piston p...

Page 65: ...3 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 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 front marking according to pi...

Page 66: ...ontrol and adjusting of valve clearance is done with an engine oil temperature between 20 80 C 68 176 F 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 Min 2 1 mm Min 1 8 mm 45 30 29 5 44 5 Outer diameter Ø A sta...

Page 67: ... Unloaded n 2300 64 7 1 3 mm 2 55 0 05 Wire diameter Ø 4 5 mm 0 18 Diameter Ø C standard 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 Seat bottom radius R Inlet Exhaust 1 0 3 mm 0 04 0 012 Measurement between valve disc and cylinder head face Inlet Exhaust Min 1 5 mm 0 059 Ø C R D Valve seat location Design 1 without flange Design 2 On late...

Page 68: ...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 Flywheel Type of flywheel TD TAD720 721 722 750 760VE Clutch 10 or 11 5 TD720GE TAD720 721 722GE TAD730 733GE Gen set 1500 rpm TD720GE TAD720 721 722GE TAD730 733GE Gen set 1800 rpm Max permitted axial throw Measuring radius 150 mm 5 91 0 1 mm 0 00394 Number of teeth on ...

Page 69: ... 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 Crank mechanism Crankshaft length 973 2 mm 38 31 Crankshaft axial cleara...

Page 70: ...2 6575 0 0008 Width H axial bearing journal 35 5 0 02 mm 1 397 0 0008 Connecting rod bearing journals Out of round Max 0 01 mm 0 0004 Taper Max 0 01 mm 0 0004 Connecting rod bearing shells 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...

Page 71: ...h 45 5 0 02 mm 1 7913 0 0008 Small end bush outer diameter Ø 45 58 0 04 mm 1 7945 0 0016 Axial clearance connecting rod crankshaft1 0 3 0 4 mm 0 0118 0 0157 Connecting rod bearing radial clearance1 0 036 0 096 mm 0 00142 0 00378 Parallelism Tolerans Over a length of 100 mm 0 05 mm 0 002 Squareness Tolerans Over a length of 100 mm 0 05 mm 0 002 1 Important The dimensions apply to oiled parts L M Ma...

Page 72: ... h 12 months TAD732 733GE API CI 4 CH 4 TAD750 760VE closed NOTE Fully synthetic oil must be used crankcase ventilation TAD722VE ACEA E4 power 200kW 500 h 12 months 250 h 12 months 125 h 12 months power 200kW 250 h 12 months 125 h 12 months 60 h 12 months 1 If the sulfur content is 1 0 by weight use oil with TBN 15 closed crankcase ventilation 2 For markets outside Europe API CG 4 and CH 4 can be ...

Page 73: ...supply for rocker arm lubrication 4 Rocker arm 5 Return line to oil sump 6 Piston cooling 2 hole nozzles for each cylinder 7 Oil filter full flow Filtering size 0 012 mm 0 0005 Bypass valve oil filter Opening pressure 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 d...

Page 74: ... 4 Line to fuel filter Inside diameter min 12 mm 0 47 1 5 Fuel filter 6 Fuel line to fuel duct 7 Injection pumps 720 721 722 6 ea 8 Delivery pipe to injector 9 Injector 10 Fuel return line 11 Overflow valve2 12 Return fuel line to fuel tank Inside diameter min 12 mm 0 47 1 13 Fuel pipes minimum distance 300 mm 11 8 14 Pre filter for water separating 15 Hand pump accessory 1 Depending on length of ...

Page 75: ... 2 Hand pump accessory 3 Fuel line to pump 4 Fuel pump 5 Fuel filter 6 Pipe to highpressure 7 Rail 8 Highpressure pump 9 Fuelpipe to injector 10 Injector 11 M prop 12 Pressure valve 13 Return fuel line to fuel tank A Fuel pipes minimum distance 300 mm 11 8 Fuel system 750 760 ...

Page 76: ...pm min 0 28 MPa 40 6 psi Fuel filter Filtering size 0 005 mm 0 0002 Pre filter Filtering size 0 006 mm 0 00024 In Out 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 ...

Page 77: ...ection pumps A 100 Manufacturing tolerances written on the injection pump Example If LO is 117 5 mm and A 100 is 63 This gives us the equation LFB 143 0 63 The total length LFB 143 63 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 TD72...

Page 78: ...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 so...

Page 79: ...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 Theor thickness TS Shim thickness SS Theor thickness TS Shim thickness SS Table 2 Shim thickness All measurements...

Page 80: ...anufacturing 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 364 that gives a EK value of 146 675 and if the manufacturing tolerance for the new injection pump is 63 we will have following equation TS 146 675 143 0 63...

Page 81: ...TD720VE 1800 rpm TAD720 721 722VE 2100 rpm TAD720 721 722VE 2200 rpm TAD720 721 722VE 2300 rpm Max engine speed droop at a load increase from 0 to 100 at rated speed TD720GE TAD720GE 5 TD720VE 8 12 TAD720 721 722VE 5 7 Important When ordering a governor as a spare part always state engine types serial number rated power and rated speed rpm Note It is absolutely necessary to measure and indicate th...

Page 82: ...harger make and designation TD720GE TAD720GE TD720VE TAD730GE Schwitzer S2B TAD720 721 722 750 760VE EPA 1 Schwitzer S2B COM 2 Schwitzer S200 TAD721 722GE TAD731 733GE Schwitzer S200 Boost pressure at rated speed1 10 TD720GE TAD730GE 1500 rpm 116 kPa 16 8 psi TD720GE TAD730GE 1800 rpm 131 kPa 19 0 psi TAD720GE 1500 rpm 136 kPa 19 7 psi TAD720GE 1800 rpm 142 kPa 20 6 psi TAD721GE TAD731GE 1500 rpm ...

Page 83: ...lly open at TD720GE TAD720GE TD720VE 95 C 203 F TAD721GE TAD722GE TAD720VE TAD721VE TAD722VE TAD750VE TAD760VE 102 C 216 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 o...

Page 84: ... 30 22 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening Flywheel A Flywheel with screws of max 30 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 30 angle tightening B Flywheel with screws up to 45 mm length Step 1 20 30 15 22 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening C Flywheel with a screw length between 50 85 mm Step 1 30 40 22 30 lbf ft Step...

Page 85: ...itch 18 2 13 1 5 lbf ft Group 23 Fuel system Screw governor idler gear Step 1 30 22 1lbf ft Step 2 90 angle tightening Screw control rod hose 10 2 7 5 lbf ft Screw governor 17 1 5 12 5 1 lbf ft Flange screws Injection pump Step 1 Torque 5 3 7 lbf ft Step 2 Loosen screws for injection pump flange 60 counterclockwise Step 3 Turn injection pump to stop Counterclockwise Step 4 60 angle tightening Step...

Page 86: ...ld 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 ...

Page 87: ...722VE TAD530 533GE TAD750VE 760VE Step 1 50 Nm 37 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening Screws to main bearing caps are reusable only three times TD420VE TAD420VE TAD620VE TAD650VE TAD660VE Step 1 30 Nm 22 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening TD520GE TAD520GE TD520VE TAD520VE TAD530 532GE TD720GE TAD720GE TD720VE TAD720VE TAD721GE TAD721VE TAD722GE TA...

Page 88: ...f ft Step 2 60 angle tightening Step 3 60 angle tightening C Flywheel with a screw length between 50 85 mm Step 1 30 40 Nm 22 30 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening V belt pulley vibration damper V belt pulley vibration damper Screws to V belt pulley are reusable only three times Step 1 40 50 Nm 30 37 lbf ft Step 2 60 angle tightening Step 3 60 angle tightening Vibration d...

Page 89: ...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 TD420VE TAD420VE TAD620VE TAD650VE TAD660VE Screws to cylinder head are reusable only five times Step 1 30 Nm 22 lbf ft Step 2 80 Nm 59 lbf ft Step 3 90 angle tightening TD520GE TAD520GE TD520VE TAD520VE TAD530 532GE TD720GE TAD720GE TD720VE TAD...

Page 90: ...rew plug MA 10 2 Nm 7 1 5 lbf ft Screw plug Delivery pipe not apply for 650 660 750 760 Fit a new delivery pipe and rubber seal Tighten the nuts by hand When installing delivery pipes be sure to fit the sealing cones exactly in the pump and injector Delivery pipe Step 1 5 Nm 3 7lbf ft Step 2 25 3 5 Nm 18 4 2 6 lbf ft Use a new delivery pipe after every disassembly WARNING Do not bend the pressure ...

Page 91: ... 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 Refers to publication Publication No Date of issue Proposal motivation Date Signed AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 92: ...7742012 English 06 2007 ...

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