Volvo Penta TAD420VE Workshop Manual

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Workshop Manual

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

1

General InformationGroup 20

Safety precautions ...............................................2

General information ............................................. 5

Repair instructions ...............................................6

Location of identification plates

TD/TAD420-620, TD/TAD520-722 .......................9

TAD650/660, TAD750/760 .................................. 10

TD420VE, TAD420VE, TAD620VE, TAD650VE,

TAD660VE

General (420/620)................................................ 11

General (650/660)................................................ 12

Engine block ....................................................... 12

Valve mechanism ............................................... 16

Crank mechanism ............................................... 19

Lubricating system .............................................. 22

Fuel system ........................................................24

Intake and exhaust system .................................32

Cooling system ................................................... 32

Tightening torque ................................................33

TD520GE, TAD520GE, TD520VE, TAD520VE,

TAD530-532GE

General ...............................................................36

Engine block ....................................................... 37

TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE,

TD520GE, TAD520GE, TD520VE, TAD520VE,

TAD530/531/532GE, TD720GE, TAD720GE, TD720VE,

TAD720VE, TAD721GE, TAD721VE, TAD722GE, TAD722VE,

TAD730/731/732/733GE, TAD750VE, TAD760VE

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

General (720-722VE) ........................................... 60

General (750/760)................................................ 60

Engine block ....................................................... 61

Valve mechanism ............................................... 64

Crank mechanism ............................................... 67

Lubricating system .............................................. 70

Fuel system ........................................................72

Intake and exhaust system .................................80

Cooling system ................................................... 81

Tightening torque ................................................82

Tightening diagram ............................................. 85

Contents

Technical Data

Industrial Engines

All rights to changes or modifications reserved.

Printed on environmentally-friendly paper

2

General Information Group 20

Introduction

Workshop Manuals contains technical specifications,

descriptions, and instructions for the repair of the spe-

cified Volvo Penta products or product types. Check

that you have the correct Workshop Manual and the

latest Service Bulletins for your engine.

Before starting work on the engine, read these

sections of the Workshop Manual:

Safety Precautions

General Information

Repair Instructions

Below is a summary of the risks involved and sa-

fety precautions you should always observe or

carry out when operating or servicing the engine.

Immobilize the engine by turning off the power

supply to the engine at the main switch (switch-

es) before starting work. Put a warning notice at

the engine control panel.

Generally, all service operations must be car-

ried out with the engine stopped.

However, some work, for example certain adju-

stments requires that the engine is running when

they are carried out.

Approaching an engine, which is operating, is a

safety risk. Loose clothing or long hair can 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

been stopped. Reinstall all protective parts re-

moved during service operations before starting

the engine.

Check that the warning or information labels on

the product are always clearly visible. Replace

labels that have been damaged or painted over.

Never start the engine without installing the air

cleaner filter. Foreign objects entering the intake

ducts can also cause mechanical damage.

Never use ether or similar products when 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 in an enclosed area ma-

ke sure that the exhaust is leading out of the en-

gine compartment and working area.

Avoid opening the coolant filler cap when the en-

gine is hot, when hot steam or coolant might sp-

ray out. If the filler cap must be open, slowly re-

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.

Safety Precautions

Important

In this book and on the product you will find the follo-

wing special warning symbols.

WARNING! Possible danger of personal injury,

extensive damage to property or serious mech-

anical malfunction if the instructions are not fol-

lowed.

IMPORTANT! Used to draw your attention to so-

mething that can cause damage or malfunc-ti-

ons on a product or damage to property.

NOTE! Used to draw your attention to important

infor-mation that will facilitate the work or opera-

tion in progress.

Warning symbols used in the Workshop Manual are

not in any way comprehensive since it is impossible

to predict every circumstance under which service wo-

rk or repairs may be carried out.

AB Volvo Penta can only indicate the risks conside-

red likely to occur as a result of incorrect working

methods in a well-equipped workshop using working

methods and tools tested by AB Volvo Penta.

3

General InformationGroup 20

Stop the engine before carrying out operations

on the engine cooling system.

Always use protective glasses or goggles, when

carrying out work where there is a risk of splint-

ers, grinding sparks and acid splashes or when

other chemicals are in use. The eyes are extre-

mely sensitive and an injury could result in blin-

dness!

Avoid getting hot oil on your skin, it might cause

severe burns. Ensure that the lubrication syste-

m is not under pressure before carrying out any

work. Never start or operate the engine with the

oil filler cap removed, otherwise oil could be eje-

cted.

Exposure to oil over a long period or repeatedly

will cause problems such as skin drying out, ir-

ritation and toxic eczema. Used oil is in a health

aspect even more dangerous than new oil. Use

protective gloves. Use protection creams, which

will ease up cleaning of the skin and counteract

drying out.

Many chemicals such as oils, glycol, diesel oil

and other chemicals, for example degreasing

agents, paint and solvents are dangerous to yo-

ur health.

Always follow the safety precautions for the pro-

duct, for example using protective mask, glass-

es, gloves etc. Make sure of good ventilation is

provided in the working area. Follow the instruc-

tions on the product, when disposing used che-

micals.

Follow extreme care when working with/or chec-

king the fuel system. Use eye protection. The

jet from a fuel injector nozzle is under extremely

high pressure and can cause severe personal

injury.

WARNING! Use new 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 working area.

Ensure that rags soaked in oil or fuel are stored

safely. Rags soaked in oil can spontaneously

ignite. Used fuel filters, oil filters, lubricating oil,

contaminated fuel, solvent and degreasing agen-

ts are environmentally dangerous waste and mu-

st be deposited at an approved site for dest-ruc-

tion.

Never expose a battery to naked flame or elect-

rical sparks. Batteries always produce hydrogen

gas, which mixed with air form an explosive gas

– oxyhydrogengas.

This gas is highly volatile and easily ignited. In-

correct connection of the battery can cause a

single spark that is sufficient to cause an explo-

sion. Be very careful when attempting to ju-mp-

start the engine and do not at any time lean over

the batteries.

Always ensure that the Plus (positive) and Min-

us (negative) battery leads are correctly insta-

lled. Incorrect installation can result in severe

damage to the electrical equipment. Refer to the

wiring diagrams.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid, which is highly caustic.

Should the battery electrolyte come into contact

with unprotected skin wash off immediately 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.

4

General Information Group 20

WARNING! The components in the electrical sy-

stem and in the fuel system on Volvo Penta pro-

ducts are designed and manufactured to minimi-

ze the risk of fire and explosion.

The engine must not be run in areas where there

are explosive materials.

Always use the fuels recommended by AB Vol-

vo Penta. Refer to the Instruction Book. Use of

fuels that are of a lower quality can damage the

engine. On a diesel engine, poor quality fuel can

cause the control rod to seize, which can result

in an over revving of the engine, risking of da-

maging to the engine and of personal injuries.

Poor fuel quality can also lead to higher mainte-

nance costs.

Observe the following rules when cleaning with

high-pressure water jets. Never direct the water

jet at seals, rubber hoses, or electrical compo-

nents. Never use a high-pressure jet when was-

hing the engine.

Turn the engine off and turn off the power at the

main switch/switches before carrying out work

on the electrical system.

Clutch adjustments must be carried out with the

engine stopped.

Use the lifting eyes fitted on the engine when 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 the

engine, make sure that all chains and cables sh-

ould run parallel to each other.

If extra equipment is installed on the engine that

would alter its center of gravity, it is required th-

at the lifting device has to be altered for obtain-

ing the correct balance for safe handling.

Never carry out work on an engine suspended

on a hoist without other supporting equipment

attached.

Never work alone when removing heavy engine

components, even when using lifting devices

such as locking tackle lifts. When using a lifting

device two people are usually required to do the

work, one to take care of the lifting device and

another to ensure that components are lifted 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.

5

General InformationGroup 20

About this Workshop Manual

This Workshop Manual contains technical data for the

repair of the following engines in standard format:

TD420VE, TAD420VE, TAD620VE, TAD650VE,

TAD660VE, TD520GE, TAD520GE, TD520VE,

TAD520VE, TAD530-532GE, TD720GE, TAD720GE,

TD720VE, TAD720VE, TAD721GE, TAD721VE,

TAD722GE, TAD722VE, TAD730-733GE, TAD750VE,

TAD760VE

The Engine Designation and Engine Numbers can be

found on the Identification plates. Please always in-

clude both the engine designation and the engine

number in all correspondence.

The Workshop Manual is produced primarily for the

use of Volvo Penta workshops and service technici-

ans. For this reason, the manual presupposes a cer-

tain basic knowledge and that the user can carry out

the mechanical/electrical work described to a general

standard of engineering competence.

Volvo Penta products are under a continual process of

development and we therefore reserve all rights regar-

ding changes and modifications. All the information in

this manual is based on product specifications availa-

ble at the time the book was published. Any essential

changes or modifications introduced into production or

updated or revised service methods introduced after

the date of publication will be provided in the form of

Service Bulletins

from AB Volvo Penta.

Power standards

The engine performance corresponds to:

ISO 3046, BS 5514, and DIM 6271.

Prime power rating corresponds to ISO standard po-

wer for continues operation. It is applicable for supply-

ing electrical power at variable load for an unlimited

number of hours instead of commercial purchased po-

wer. A ten-percent overload capability is available for

this rating.

Standby Power

rating corresponds to ISO Standard

Fuel Stop Power. It’s is applicable for supplying

standby electrical power at variable load in areas well

est-ablished electrical networks in event of normal uti-

lity power failure. No overload capability is available

for this rating.

NOTE! The technical data applies to an engine without cooling

fan and operating on a fuel with calorific value of 42.7 MJ/kg

(18360 BTU/lb.) and a density of 0.84 kg/liter (7.01 lb./US gal,

8.42 lb./lmp. gal) even when it involves a deviation from

standards.

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 are not original Volvo Penta parts for the

product in question will not be covered under any war-

ranty or guarantee provided by AB Volvo Penta.

Engine certificate

Engine certificates to meet national and regional en-

vironmental legislation carry with them an undertaking

from the manufacturer that both new and existing eng-

ines in use meet the environmental demands of the

legislation. The product must correspond to the valida-

ted example that was granted certification. In order for

AB Volvo Penta as the manufacturer to take respons-

ibility for engines in use, certain requirements regar-

ding service and spare parts must be met by the user

according to the following:

• The Service Intervals and maintenance operations

recommended by Volvo Penta must be followed.

• Only Volvo Penta Original Spare Parts intended

for the engine certificates may be used.

• Service work on the injection pump and injectors

must always be carried out by an authorized Vol-

vo Penta workshop.

• The engine may not be altered or modified in any

way, with the exception of accessories and servi-

ce kits developed by Volvo Penta for that engine.

• No modifications to the exhaust pipes and air

supply ducts for the engine room (ventilation

ducts) may be undertaken as this may effect ex-

haust emissions.

• Any seals on the engine may not be broken other

than by authorized persons.

IMPORTANT! If replacement parts are required,

use only AB Volvo Penta Original Parts.

Use of replacement parts other than AB Volvo Pen-

ta Original Parts will result in AB Volvo Penta be-

ing unable to assume any liability that the engine

corresponds to the engine certificates variant.

AB Volvo Penta excludes any liability for all and any

type of damage or costs caused by the use of repla-

cement parts that are not Volvo Penta Original Parts

for the product in question.

General Information

6

General Information Group 20

Introduction

The working methods described in the Workshop

Manual apply to work carried out in a workshop.

The engine has been removed and is installed in

an engine fixture.

Unless otherwise stated reconditioning work that

can be carried out with the engine in place follows

the same working method.

All operations described in the Workshop Manual for

which there are Volvo Penta Special Tools available

assume that the service technician or person carrying

out the repair uses these tools.

Volvo Penta Special Tools have been specifically de-

veloped to ensure as safe and rational working met-

hods as possible.

Person or persons using other than Volvo Penta Spe-

cial Tools or approved Volvo Penta working methods

(as described in a Workshop Manual or Service Bulle-

tin). Has the responsibility to acquaint themselves of

the risk of personal injury or actual mechanical dama-

ge or malfunction.

In some cases special safety precautions and user in-

structions may be required in order to use the tools

and chemicals mentioned in the Workshop Manual, al-

ways follow these precautions, as there are no speci-

fic instructions given in the Workshop Manual.

By following these basic recommendations and using

common sense it is possible, to avoid most of the

risks involved in the work. A clean work place and a

clean engine will eliminate many risks of personal inju-

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.

Our joint responsibility

Every engine consists of many systems and compo-

nents that work together. If one component deviates

from the technical specifications, than this can have

dramatic consequences on the environmental impact,

even if it is otherwise in good running order.

It is therefore critical that the stated wear tolerances

are observed, that systems which can be adjusted are

correctly set up and that only Volvo Penta Original

Parts are used.

The stated service intervals in the Maintenance Sche-

dule must be followed.

Some systems, such as the components in the fuel

system, require special expertise and special testing

equipment for service and maintenance.

Some components are factory sealed for environ-men-

tal and product specific reasons. Don’t under no cir-

cumstances attempt to service or repair a sealed co-

mponent, unless it is done by a authorized service te-

chnician.

Bear in mind that most chemical products, incorrectly

used, are hazardous to the environment.

AB Volvo Penta recommends the use of biodegrada-

ble degreasing agents for all cleaning of engine com-

ponents, unless otherwise is stated in the Workshop

Manual.

Pay special attention to make sure that oils and wash-

ing residue are handled correctly for destruction, and

not end up in the nature.

Repair instructions

7

General InformationGroup 20

Tightening torque

For the correct tightening torque for critical joints,

which must be tightened using a torque wrench is lis-

ted under chapter “Tightening Torque”. For correct

tightening torque, is it important to apply cleaned th-

reads, bolt heads and mating surfaces, with lightly oi-

led or dry threads. In places where grease, locking or

sealing agents is required for screwed joints, the cor-

rect torque is stated in “Tightening Torque”.

When no tightening torque is stated, use the general

tightening torque, according to the table below.

Dimension Tightening torque

Nm (lbf.ft.)

M5 ......................................................... 6 (4.4)

M6 ......................................................... 10 (7.4)

M8 ......................................................... 25 (18.4)

M10 ....................................................... 50 (36.9)

M12 ....................................................... 80 (59.0)

M14 ....................................................... 40 (103.3)

Lock nuts

Do not reuse lock nuts that have been removed during

disassembly operations as these have reduced

service life when reused. Use new nuts when

assembling or reinstalling.

For lock nuts with a plastic insert such as Nylock®

the tightening torque stated in the table is reduced if

the Nylock® nut has the same head height as a 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 recommended torque is

applied using a torque wrench and then the recom-

mended angle is added according to the protractor

scale. Example: A 90°

protractor tightening means

that the joint is tightened a further 1/4 turn in one ope-

ration after the stated tightening torque has been app-

lied.

Strength classes

Bolts and nuts are divided up into different classes of

strength, the number on the bolt head indicates the

class. A high number indicates stronger material, for

example a bolt marked 10-9 indicates a higher

strength than one marked 8-8.

It is therefore important that bolts removed during the

disassembly of a bolted joint must be reinstalled in

their original position when assembling the joint.

When replacing a bolt, check in the spare parts cata-

logue to make sure the correct bolt is used.

8

General Information Group 20

Sealant

It is therefore important that bolts removed during the

disassembly of a bolted joint must be reinstalled in

their original position when assembling the joint. When

replacing a bolt, check in the spare parts catalogue to

make sure the correct bolt is used.

To ensure service work is correctly carried out it is im-

portant that the correct sealant and locking fluid type

is used on the joint where the agents are required as

described in the Workshop Manual or the Service Bul-

letin.

During service operations use the same agent or an

alternative.

Make sure that mating surfaces are dry and free from

oil, grease, paint and anticorrosion agent before apply-

ing sealant or locking fluid.

Always follow the manufacturer’s instructions for use

regarding temperature range, curing time and any oth-

er instructions for the product.

Two different basic types of agent are used:

RTV agent (Room Temperature Vulcanizing)

Used for gaskets, sealing gasket joints or coating

gaskets. RTV is visible when a part has been

disassembled; old RTV must be removed before

resealing the joint.

Old sealant can be removed using methylated spirits

in all cases.

Anaerobic agents:

These agents cure in an absence of air. They are use-

d when two solid parts, for example cast components,

are installed face-to-face without a gasket. They are

also commonly used to secure plugs, threads in stud

bolts, petcocks, oil pressure switches, and so on.

The cured material is glass like and it is therefore 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 shafts, and in O-rings.

When fluorocarbon rubber is subjected to high tempe-

ratures (above 300°C or 572°F),

hydrofluoric acid

can

be formed, which is highly corrosive.

Skin contact can give severe chemical burns. Splas-

hes in eyes can give severe chemical burns.

Breathing of fumes can be permanently damaged

lungs.

WARNING! Be very careful when working on

engines that have been exposed to high tempe-

ratures, e.g. overheating during a seizure or fire.

Seals must never be cut with an oxy-acetylene

torch, or be burned up afterwards in an uncon-

trolled manner.

Always use gloves made of chloroprene rubber

(gloves for handling chemicals) and protective

goggles.

Handle the removed material like corrosive acid.

All residues, including ash, can be highly corro-

sive.

Never use compressed air to blow anything clean.

Put the remains in a plastic box which is sealed

and provided with a warning label. Wash the glov-

es under running water before removing them.

These following seals are probably made out of fluoro-

carbon rubber:

Seal rings for crankshaft, camshaft, and interme-

diate shafts.

O-rings irrespective of where they are installed.

O-rings for cylinder liner sealing are usually made

out of fluorocarbon rubber.

9

General InformationGroup 20

1. Engine model

2. Engine specification number

3. Engine serial number (10 digits)

4. Engine output without fan

5. Rated engine speed

6. Injection timing and type of camshaft

7. Manufacturers identification code

8. Indication of standard and /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 should be mou-

nted in a suitable location adjacent to the engine.

10

General Information Group 20

1. Engine model

2. Engine specification number

3. Engine serial number (10 digits)

4. Engine output, without fan

5. Rated engine speed

6. Engine code (linked to EPA/EU Tier III approval)

7. Rated power, standard (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 is mounted up

on the valve cover.

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

11

Group 20

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, dm

3

(inch

3

) .......................................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 – 2500

1)

2000 – 2500

1)

2000 – 2500

1)

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”.

Technical Data

TD420VE, TAD420VE, TAD620VE, TAD650VE, TAD660VE

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

12

Group 20

General

Type designation .................................................... TAD650VE TAD660VE

Rotation direction, facing flywheel: ......................... Counterclockwise Counterclockwise

Number of cylinders ............................................... 6 6

Bore, mm (inch) ..................................................... 101 (3.97") 98 (3.85")

Stroke, mm (inch) .................................................. 126 (4.96") 126 (4.96")

Displacement, dm

3

(inch

3

) .......................................5.7 (347.8) 5.7 (347.8)

Number of valves ...................................................12 12

Compression ratio: ................................................. 18.4:1 18.4:1

Firing sequence ..................................................... 1-5-3-6-2-4 1-5-3-6-2-4

Engine performance at 2300 rpm, kW (hp) ............. 147 (200)

1, 3)

147 (200)

1, 3)

Max 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 ....................................... 2400

1)

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 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")

TD420VE/TAD420VE .......................................... 5 x 178 mm (5 x 7")

Quantity and length:

TAD620VE, TAD650/660VE ............................... 19 x 108 mm (19 x 4.3")

TAD620VE, TAD650/660VE ............................... 7 x 178 mm (7 x 7")

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

13

Group 20

Type:

TD420VE/TAD420VE/TAD650VE ....................... Parent bore

TAD620VE/TAD660VE ....................................... Dry, replaceable

Bore:

TD420VE/TAD420VE/TAD650VE ....................... 101

+0.02

mm (3.976"

+0.00078"

)

TAD620VE/TAD660VE ....................................... 98

+0.02

mm (3.858"

+0.00078"

)

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

Replaceable, dry

TAD620,

TAD660VE

Cylinder liners

A

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

14

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 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 piston projection. The piston is in its TDC above the block surface.

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")

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

15

Group 20

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”)

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"

)

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.

1

2

3

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

16

Group 20

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 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 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 clearance is done with an engine oil

temperature between 20 – 80°C (68 – 176°F)

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

17

Group 20

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"

)

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"

)

Height (B):

Inlet .................................................................... 6.8

±0.1

mm (0.2677"

±0.004

)

Exhaust .............................................................. 7.5

±0.1

mm (0.2953"

±0.004

)

Valve seats

Valve seat location

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

18

Group 20

Flywheel

Type of flywheel, standard :

TD/TAD420,620,650,660VE ................................ Clutch 10" or 11.5"

Max, permitted axial runout

Measuring radius 150 mm (5.91") ........................ 0.1 mm (0.004")

Number of teeth on flywheel ................................... 129

Camshaft

Type of camshaft: .................................................. Three different types: K, L or H

Drive ...................................................................... Gear

Number of bearings:

TD420VE/TAD420VE .......................................... 5

TAD620VE, TAD650/TAD660VE ........................ 7

Inner diameter Ø, bearing journals

Standard ............................................................. 63

+0.054

mm (2.48"

+0.0021"

)

Wear limit ........................................................... 63.08

mm (2.483")

Camshaft bearing thickness: max .......................... 1.388

+0.012

mm (0.05465"

+0.0005"

)

Axial clearance ...................................................... 0.1-0.5 mm (0.004-0.02")

Radial clearance .................................................... 0.05-0.124 mm (0.002-0.0049")

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. Idler gear (not apply for 650/660)

3. Camshaft gear

4. PTO gear B-C (not apply for 650/660)

5. PTO gear A (not apply for 650/660)

6. Crankshaft

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Volvo Penta TAD420VE Workshop Manual

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