Workshop Manual Volvo - TAD760VE

Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760
General
Type designation .................................................... TAD750VE TAD760VE
Rotation direction, facing flywheel: ......................... Counterclockwise Counterclockwise
Number of cylinders ............................................... 6 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 ....................................... 24001) 24001)
Weight. engine (dry) kg (lb) .................................... 650 (1433)2) 650 (1433)2)
Weight. engine (wet) kg (lb) .................................... 681 (1501)2) 680 (1496)2)
1)
See identification plate for correct specification
2)
Weight according to DIN 70020-A
3)
See ”General information, Power standards”.
Cylinder liners Engine block

Replacable, wet Cylinder head
A 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”)
TD720GE, TAD720GE, TAD721GE,

TAD722GE, TAD720VE, TAD720VE,
TAD721VE, TAD722VE, TAD730-733GE,
TAD750, TAD760VE
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”)
61
Technical Data: TD/TAD720-722, TAD730-733, TAD750/760 Group 20
Cylinder head gasket

Measuring piston projection
A dial gauge with a fixture (special tool: 999 8678) is needed to measure
the piston projection. The piston is in its TDC above the block surface.
• 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, in-
line 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")
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")
62
Group 20 Technical Data: TD/TAD720-722, TAD730-733, TAD750/760
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 picture: Flywheel symbol on the piston top faces the flywheel.
Guiding pins on the connecting rod, must face flywheel symbol on the piston.
Piston rings
Compression rings
Number of rings .................................................... 2
Piston ring clearance measured in groove, wear limit:
Upper compression ring (1) ................................ Keystone, no clearance
Lower compression ring (2) ................................ 0.17 mm (0.067")
Piston ring gap measured in ring opening, wear limit:
Upper compression ring (1) ................................ 0.8 mm (0.03")
Lower compression ring (2) ................................ 2.5 mm (0.0984")
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”)
63
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°
Valve disc edge:

Inlet, min ............................................................ 2.1 mm (0.0827")
Exhaust, min ..................................................... 1.8 mm (0.0709")
Seat angle, cylinder head:
Inlet ................................................................... 30°
Exhaust ............................................................. 45°
Valve seat width, max:
Inlet, min ............................................................ 2.8 mm (0.1102")
Exhaust, min ..................................................... 2.2 mm (0.0866")
Valve clearance (not apply for TAD760VE)

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
Outer diameter Ø (A), standard:

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")
64
Valve seat location

ØC
R
D
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")
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")
Wear limit valve stem – guide:
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")
65
Technical Data: TD/TAD720-722, TAD730/733, TAD750/760 Group 20
Camshaft
Type of camshaft:
TD720GE, TAD720GE, TAD730GE ................... A
TD720VE, TAD720VE, TAD721VE .................... A or M
TAD721/722GE, TAD722VE, TAD731-733GE
TAD750/760VE .................................................. S
Drive ..................................................................... Gear
Number of bearings ............................................... 7
Inner diameter Ø, bearing journals
Standard ............................................................ 65+0.054 mm (2.559"+0.0021")
Wear limit ........................................................... 65.08 mm (2.5622")
Camshaft bearing thickness: max ......................... 1.988+0.012 mm (0.7827"+0.0005")
Axial clearance ..................................................... 0.1– 0.5 mm (0.004 – 0.02")
Radial clearance ................................................... 0.05 – 0.124 mm(0.002 – 0.0049")
Position of bearing bush at flywheel end ............... 2+0.5 mm (0.079"+0.0197")
Timing gear
1. Governor drive (not apply for 750/760)
2. Idler gear (not apply for 750/760)
3. Camshaft gear
4. PTO gear B-C (not apply for 750/760)
5. PTO gear A (not apply for 750/760)
6. Crankshaft gear
Flywheel
Type of flywheel :
TD/TAD720/721/722/750/760VE ........................ Clutch 10" or 11.5"
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1500 rpm
TD720GE, TAD720/721/722GE/TAD730-733GE Gen set 1800 rpm
Max, permitted axial throw:
Measuring radius 150 mm (5.91") ....................... 0.1 mm (0.00394")
Number of teeth on flywheel .................................. 129
66
Crank mechanism
Crankshaft length .................................................. 973.2 mm (38.31")
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 (0.00394")
1)
Important! The dimensions apply to oiled parts
E
F
C B
A
Main bearing journals

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")
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 mm (1.5118"+0.0024")
Thrust washers (axial bearing)
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")
67
Connecting rod bearing journals

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")
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

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")
68
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 clearance ............. 0.036-0.096 mm (0.00142-0.00378")
1)
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
Marking: Connecting rod and cap number marking must be on

one side and identical
69
Lubricating system
Sulfur content in fuel, by weight
Engine Oilgrade 2)
< 0,5 % 0,5 – 1,0 % > 1,0 %1)
Oil change interval, reached first in operation
T(A)D720-721VE VDS-3 500 h / 12 months 250 h / 12 months 125 h / 12 months
T(A)D720GE VDS-2
TAD730/731GE, ACEA: E7, E5, E3
TAD721/722GE, API: CI-4, CH-4, CG-4
TAD732/TAD733GE,
TAD750/760VE, open
crankcase ventilation
TAD721/722GE, ACEA: E4 500 h / 12 months 250 h / 12 months 125 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 used instead of ACEA: E3.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality
requirements above.
NOTE! For 6 and 7-liter engines equipped with low profile type oil pans, the oil change interval must be halved.
VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
Global DHD = Global Diesel Heavy Duty
TBN = Total Base Number
Viscosity
The viscosity should be selected from the adjacent
table.
NOTE! the temperatures refer to constant outside air

temperature. The tabell above refers to synthetic or
synthetic-based oil.
70
Engine oil quantity

With oil filter:
TD720/TAD720/TAD721VE: ............................... 20 liter (5.28 US gal)
TAD722VE/TAD750VE/TAD760VE .................... 23 liter (6.10 US gal)
TAD721GE/TAD722GE ...................................... 34 liter (8.98 US gal)
1. Oil pressure sensor

Oil pressure, at operation temperature, min 120°C (248°F)
At rated speed:
TD720GE, TAD720/721/722GE, TAD730-733GE:400 kPa (58 psi)
TD720VE/TAD722/750/760VE: .......................... 450 kPa (65 psi)
TAD720VE/TAD721VE: ..................................... 350 kPa (50.8 psi)
Idling speed (800 rpm), min: .................................. 80 kPa (11.6 psi)
Shut down switch, at pressure lower than:
TD720GE, TAD720/721/722GE, TAD730-731GE: 150 kPa (22 psi)
TD720VE, TAD720/721/722/750/760VE: ............ 50 kPa (7.2 psi)
TAD732/733GE .................................................. 200 kPa (29 psi)
2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Piston cooling: ................................................ 2-hole nozzles for each cylinder
7. Oil filter, full-flow:
Filtering size: ......................................................... 0.012 mm (0.0005")
Bypass valve oil filter:
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)
71
Fuel system (720– 733)
1. Fuel tank.
Max height above fuel pump. 2 meter (6.5 ft)
Max suction height to fuel pump. 1.5 meter (4.9 ft)
2. Fuel line (to pump).
Inside diameter. min 12 mm (0.47")1)
3. Fuel pump
4. Line to fuel filter.
Inside diameter. min 12 mm (0.47")1)
5. Fuel filter
6. Fuel line (to fuel duct).
7. Injection pumps,720/721/722 (6 ea.)
8. Delivery pipe to injector.
9. Injector
10. Fuel return line
11. Overflow valve2)
12. Return fuel line to fuel tank.
Inside diameter, min 12 mm (0.47")1)
13. Fuel pipes, minimum distance 300 mm (11.8")
14. Pre-filter for water separating
15. Hand pump (accessory)
1)
Depending on length of hose
2)
Can also be used as an air ventilation screw
72
Fuel system (750,760)
1. Fuel tank 8. Highpressure pump

2. Hand pump (accessory) 9. Fuelpipe, to injector
3. Fuel line (to pump) 10. Injector
4. Fuel pump 11. M-prop
5. Fuel filter 12. Pressure valve
6. Pipe to highpressure 13. Return fuel line, to fuel tank, A = Fuel pipes,
7. Rail minimum distance 300 mm (11.8")
73
Fuel specification
The fuel must be approved according to national and international standards for commercial fuels for example:
EN 590 (with environmental and sub-zero temperature specifications according to national requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in the respective country.
NOTE! Fuels with extremely low sulfur contents (ex City diesel in Sweden and Finland) can cause a drop in power
output of 5% and an increase in fuel consumption of 2–3%.
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
Filtering size ......................................................... 0.005 mm (0.0002")
Pre-filter
Filtering size ......................................................... 0.006 mm (0.00024")
74
Injection pump (720– 733)

Basic measurements
The injection pumps are made by BOSCH and are of a single
type, that mean one for each cylinder. During the manufacturing
of the injection pumps, it is found that the length will varies from
pump to pump. This is due to manufacturing tolerances and this
is called A/100.
The pump length is defined by adding the basic measurement LO
with the tolerance A/100, that are written on the injection pump
(LFB = LO + A/100).
Explanation:
LFB = The exact point when injection pumps starts delivering
fuel.
LO = Basic measurement for the injection pumps
A/100 = Manufacturing tolerances (written on the injection
pump).
Example:
If LO is 117.5 mm and A/100 is 63.
This gives us the equation: LFB = 143 + 0.63
The total length LFB = 143.63
Injection pump (720–733)

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 0.00921")
TAD721GE/TAD721VE/TAD722GE, EPA 1: ...... 6 x 0.264 mm (6 x 0.00921")
TAD720VE/TAD721GE/TAD721VE/TAD722GE
COM 2: .............................................................. 6 x 0.236 mm (6 x 0.00921")
75
Commencement of delivery (FB) 720–733

The engine is equipped with a separate injection pump for each cylinder.
This means that the commencement of delivery (FB), when necessary, has
to be adjusted separate for each pump unit. The commencement of delive-
ry (FB) is adjusted with a shim, placed between lifter and injection pump.
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)

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
76
Theoretical thickness for a new shim (720–733)

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 = E 2 + Vh nom
· 4th step: E4 = E 3 + 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 (S S) Theor. thickness(TS) Shim thickness (SS)
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.
77
How to use EP code (720–733)

For exchange of injection pump without any parts of vital importance has been replaced, applies a simplified met-
hod, when there is only the tolerance between the new and old injection pump that is the difference.
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 ”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 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
Table 3, EP code conversion table

Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP Ek(mm) EP
code code code code code
78
Governor (720–733)
The governors are mechanical variable-speed governors with centrifugal measuring element
by M/s Heinzmann. The governor unique prepared for each engine. This means that the governor can not be
exchanged between different engines. An incorrect adjusted governor can result in that the engine will not fulfill
the regulations for emission and performance.
Important! Only trained personnel should make adjustments on the governor, using a
test bench specially set up for the Heinzmann governor.
Manufacturer ......................................................... Heinzmann

Designation:
TD720GE/TAD720GE/TAD730–733GE: ............. 1500 rpm
TD720GE/TAD720GE/TAD730–733GE: ............. 1800 rpm
TD720VE: .......................................................... 1800 rpm
TAD720/721/722VE: .......................................... 2100 rpm
TAD720/721/722VE: .......................................... 2200 rpm
TAD720/721/722VE: .......................................... 2300 rpm
Max, engine speed droop at a load increase from 0 to 100 % at: rated speed
TD720GE/TAD720GE: ....................................... <5 %
TD720VE: .......................................................... 8 – 12 %
TAD720/721/722VE: .......................................... 5 – 7 %
Important! When ordering a governor as a spare part always state engine types, serial number, rated power
and rated speed (rpm). Note! It is absolutely necessary to measure and indicate the recess dimension X,
after exchange of the transmission cover and/or the control rod.
Control rod (720–733)

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.
79
Intake and exhaust system

Turbocharger, make and designation:
TD720GE/TAD720GE/TD720VE/TAD730GE: .............................. Schwitzer S2B
TAD720/721/722/750/760VE:
EPA 1: ......................................................................................... Schwitzer S2B
COM 2: ........................................................................................ Schwitzer S200
TAD721/722GE, TAD731–733GE ................................................ Schwitzer S200
Boost pressure at rated 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): ............................................ 161 kPa (23.4 psi)
TAD721GE, TAD731GE (1800 rpm): ............................................ 175 kPa (25.4 psi)
TAD722GE, TAD732/733GE (1500 rpm): ..................................... 178 kPa (25.8 psi)
TAD722GE, TAD732/733GE (1800 rpm): ..................................... 200 kPa (29.0 psi)
TD720VE: .................................................................................... 2) kPa (2) psi)
TAD720VE (EPA 1): .................................................................... 133 kPa (18.9 psi)
TAD720VE (COM 2): ................................................................... 151 kPa (21.9 psi)
TAD721VE (EPA 1): .................................................................... 155 kPa (22.5 psi)
TAD721VE (COM 2): ................................................................... 163 kPa (23.6 psi)
TAD722VE (COM2, High power): ................................................. 198kPa (28.7 psi)
TAD750VE/TAD760VE: ............................................................... 198kPa (28.7 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, TAD730-733GE (1500 rpm): ..... 5 kPa (0.7 psi)
TD/TAD720GE, TAD721/722GE, TAD730-733GE (1800 rpm): ..... 7 kPa (1 psi)
TD720VE, TAD720/721/722/750/760VE: ...................................... 7.5 kPa (1.1 psi)
Exhaust gas temperatur, approx:

At rated speed (standby power)1): .......................... 1500 rpm 1800 rpm
TD720GE, TAD730GE: ...................................... 560°C (1040°F) 505°C (941°F)
TAD720GE, TAD731GE: .................................... 476°C (914°F) 433°C (837°F)
TAD722GE, TAD732/733GE .............................. 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)
TAD722/750/760VE: .......................................... 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)
TD720GE/TAD720GE, TAD730GE: ................... 1 kPa (0.14 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 1.5 kPa (0.22 psi)
TD720VE/TAD720/721/722/750/760VE: ............. 2.5 (0.36 psi)
Max allowed air intake restriction
TD720GE/TAD720GE, TAD730GE: ................... 3 kPa (0.43 psi)
TAD721GE/TAD722GE, TAD731-733GE: .......... 3.5 kPa (0.51 psi)
TD720VE/TAD720/721/722/750/760VE: ............. 6.5 (0.94 psi)
80
Cooling system
Type ...................................................................... Pressurized, closed circuit
Pressure valve opens at:
TD720GE/TAD720GE, TAD730/731GE: ............ 60 kPa (13 psi)
TAD721GE/TAD722GE
TD720VE/TAD720VE/TAD721VE,
TAD732-733GE, max1): ...................................... 90 kPa (13 psi)
1)
Versatile engines are not equipped with a pressure valve from factory
Capacity (engine):. ................................................. 9.8 liters (2.59 US gal)
Capacity (engine and cooler):
TD720GE: ........................................................... 22 liters (5.8 US gal)
TAD720GE/TAD730/731GE: ............................... 23.8 liters (6.3 US gal)
TAD721GE/TAD722GE/TAD732/733GE: ............ 27.3 (7.2 US gal)
Thermostat
Type: ..................................................................... Piston thermostat
Begins to open at
TD720GE/TAD720GE/TD720VE/TAD730/731GE: 83°C (181°F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE,
TAD732/733GE: ................................................. 87° C (189° F)
Fully open at
TD720GE/TAD720GE/TD720VE: ....................... 95°C (203°F)
TAD721GE/TAD722GE/TAD720VE/TAD721VE
TAD722VE/TAD750VE/TAD760VE: ................... 102° C (216° F)
TD/TAD720-722:
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
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
81
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 (192 lbf.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 ................................................................. 60° angle tightening
Connecting rod big-end bearing:

Use new screws every time.
Step 1 ................................................................ 30 (22 lbf.ft)
Step 2 ................................................................ 60° angle tightening
Step 3 ................................................................ 60° angle tightening
Flywheel
A) Flywheel with screws of max 30 mm length
Step 1: ............................................................... 20 – 30 (15 – 22 lbf.ft)
Step 2: ............................................................... 60° angle tightening
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)
Flywheel housing. M16 .......................................... 243 ±25
(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)
Lock nut, valve clearance adjusting screw ............ 20 ±2
(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)
82

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)
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)
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 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)
Common Rail, TAD750/760
Safety valve ....................................................... 100 (74 lbf.ft)
Rail pressuree sensor ........................................ 70 (51.6 lbf.ft)
Common rail unit ................................................ 30 (22.1 lbf.ft)
Fuel hose ........................................................... 39 (29±3 lbf.ft)
IEGR, TAD750/760
IEGR-unit: .......................................................... 30 (22 lbf.ft)
Solenoid valve: .................................................. 24 (18 lbf.ft)
Highpressure fuel pump, TAD750/760
Step 1: ............................................................... 10 (7.4 lbf.ft)
Step 2: ............................................................... 50 (37 lbf.ft)
83
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”.
84
Grupp 20 Technical data
Tightening torque diagram
Main bearing caps:
Screws to main bearing caps are reusable only three times.

TD420VE/TAD420VE/TAD620VE/TAD650VE/TAD660VE
Step 1 ................................................................. 30 Nm (22 lbf.ft)
TD520GE/TAD520GE/TD520VE/TAD520VE/TAD530–532GE
TD720GE/TAD720GE/TD720VE/TAD720VE
TAD721GE/TAD721VE/TAD722GE/TAD722VE/TAD530–533GE
TAD750VE/760VE
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
TAD750VE/760VE
Step 1 ................................................................. 50 Nm (37 lbf.ft)
85
Technical data Grupp 20
Flywheel
A) Flywheel with screws of max 30 mm length

Step 1: ................................................................ 20 – 30 Nm (15 – 22 lbf.ft)
Step 2: ................................................................ 60° angle tightening
B) Flywheel with screws up to 45 mm length
Step 1: ................................................................ 20 – 30 Nm (15 – 22 lbf.ft)
C) Flywheel with a screw length between 50 – 85 mm
Step 1: ................................................................ 30 – 40 Nm (22 – 30 lbf.ft)
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)
Vibration damper .................................................... 70 Nm
86
Grupp 20 Technical data
Cylinder head
Manifold side Manifold side
Step 1: ................................................................ 30 Nm (22 lbf.ft)
Step 2: ................................................................ 80 Nm (59 lbf.ft)
TAD750VE/760VE
Step 1: ................................................................ 50 Nm (37 lbf.ft)
Step 2: ................................................................ 130 Nm (96 lbf.ft)
Flange screws, Injection pump (not apply for 650/660, 750/760)
Step 1: Torque .................................................... 5 Nm (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 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.
87
Technical data Grupp 20
Delivery pipe (not apply for 650/660, 750/760)

Fit a new delivery pipe and rubber seal.
Tighten the nuts by hand.
When installing delivery pipes, be sure to fit the sealing cones
exactly in the pump and injector.
Delivery pipe
Step 1: ................................................................ 5 Nm (3.7 lbf.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 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 M A .................................................. 35±3.5 Nm (26 ±2.6 lbf ft)
24. Screw plug M A .................................................. 10±2 Nm (7±1.5 lbf ft)
88
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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Date: ................................................................
Signed: .............................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7742012 English 06–2007

Workshop Manual Volvo - TAD760VE

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Group 20 Technical Data: TD/TAD720-722, TAD730/733, TAD750/760

Cylinder liners Engine block

Cylinder head bolts

TD720GE, TAD720GE, TAD721GE,

Cylinder head gasket

Oilscraper ring (3)

Min 2.1 mm Min 1.8 mm

Valve disc edge:

Valve clearance (not apply for TAD760VE)

Outer diameter Ø (A), standard:

Valve seat location

Diameter Ø (C), standard:

Design 1 Design 1 Design 2

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

Axial clearance, connecting rod – crankshaft1) ...... 0.3-0.4 mm (0.0118-0.0157")

Marking: Connecting rod and cap number marking must be on

TAD721/722GE, ACEA: E4 500 h / 12 months 250 h / 12 months 125 h / 12 months

VDS = Volvo Drain Specification

NOTE! the temperatures refer to constant outside air

Engine oil quantity

1. Oil pressure sensor

Fuel system (720– 733)

Fuel system (750,760)

1. Fuel tank 8. Highpressure pump

Fuel feed pump

Injection pump (720– 733)

Injection pump (720–733)

Commencement of delivery (FB) 720–733

Table 1 (Commencement of delivery)

Theoretical thickness for a new shim (720–733)

Table 2 (Shim thickness)

How to use EP code (720–733)

Table 3, EP code conversion table

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

Control rod (720–733)

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

Tightening torques Nm (lbf.ft)

Group 25 Inlet and exhaust system

Group 26 Cooling system

Tightening torque diagram

Main bearing caps:

Screws to main bearing caps are reusable only three times.

Connecting rod big-end bearing:

A) Flywheel with screws of max 30 mm length

V-belt pulley/vibration damper:

Delivery pipe (not apply for 650/660, 750/760)

4. Screw plug MA .................................................... 35±3.5 Nm (26 ±2.6 lbf ft)

Refers to publication: .............................................................................................................................................

Publication No.: ............................................................. Date of issue: .................................................................

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