Repair manual en

Diesel engine
D934 A7 SCR / D936 A7 SCR / D946 A7 SCR
upwards of serial number 2012-03-0000 / 2012-04-0000

Document identification
Order number: 11160830
Issued: 30.04.2012
Valid for: D934 A7 SCR / D936 A7 SCR / D946 A7 SCR
Compiled by: LMB - Department BE-MD3
Version: 00_A

Product identification
Manufacturer: Liebherr Machines Bulle SA
Type: D934 A7 SCR / D936 A7 SCR / D946 A7 SCR
Serial number: 2012-03-0000 / 2012-04-0000

Address
Address: Liebherr Machines Bulle SA
45, rue de l‘Industrie
CH - 1630 Bulle

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 Repair manual

Machine data
The following data must be supplemented upon obtaining your diesel engine.
This will also be helpful when ordering spare parts.
Details indicated with * are printed on the company nameplate of the diesel en-
gine.
Diesel engine identification number *:
. . . . . . . . . . . . . . . . . .
Diesel engine serial number *:
. . . . . . . . . . . . . . . . . .
Date of initial start-up:
. . / . . / . .

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 Foreword

Target group
This repair manual has been compiled specifically for the mechanics and the workshop personnel of the LIEBHERR
dealers and LIEBHERR subsidiaries, whose task it is to ensure that the diesel engines are in perfect working order.

Contents
This repair manual provides you with technical documentation regarding the installation and removal, disassembly
and assembly, adjustment tasks and technical data for Liebherr diesel engines.

The operating instructions D934 A7 SCR / D936 A7 SCR / D946 A7 SCR are an integral part of the repair manual,
within which descriptions regarding maintenance and servicing can be obtained.

Notes on safety
The accident-prevention guidelines and all generally recognised safety-technical and occupational-medicinal regu-
lations are to be observed before commencing any maintenance and repair tasks on Liebherr diesel engines. Nati-
onal guidelines applicable for the respective country of use and/or for the application site must be observed wherever
necessary.
Furthermore, the notes on safety regarding diesel engines in the chapter "Notes on Safety" are to be observed.

Modifications to the diesel engine

The manufacturer does not bear responsibility for any material damage or injury to persons which occurs as a result
of unauthorised modifications to the diesel engine.
This applies in particular for manipulations of the injection and regulation systems, as this will influence the output
and exhaust characteristics of the diesel engine. Maintenance of the legal environmental regulations can no longer
be guaranteed if modifications are carried out arbitrarily by the customer.

Notes on operation
Prerequisite for reliable repair is a complete basic tool in sound condition, as well as any necessary devices and spe-
cial tools.

Only use clean and undamaged tools.

Damaged tools may not be reused, replace damaged tools immediately.

Cleanliness and order contribute toward safety in the workplace.

Clean the diesel engine of oil, fuel or detergents, in particular connections and threaded unions, before commencing
maintenance/repair tasks. Do not use any aggressive cleaning agents. Use fibre-free cleaning rags. Do not use any
flammable liquids for cleaning the diesel engine.

Sealing components (e.g. O-rings, seals, etc.) should essentially be replaced.

Dismantled parts should be checked for reusability and replaced as required.

If no specific torques and tightening specifications are prescribed, screw connections should be tightened to the stan-
dard torques which can be obtained in the chapter "Technical Data".
Special torques, tightening specifications and mounting instructions can be obtained in the chapter "Technical Data"
and in the respective job specifications.

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 Repair manual

Spare parts
Only original LIEBHERR spare parts, or spare parts purchased by LIEBHERR should be used for repairing LIEB-
HERR diesel engines.

LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees,
service orders, etc. null and void without advance notice if spare parts other than original LIEBHERR spare parts or
spare parts purchased by LIEBHERR are used for maintenance or repair.

All „parts information“ in this manual, e.g. ID number, thread sizes, dimensions, etc. have been provided for informa-
tion only, orders for spare-parts may only be placed using spare-parts catalogue relevant to the scope of delivery.

Fuels and lubricants

Only fuels and lubricants which have been authorised by LIEBHERR may be used for operation of LIEBHERR diesel
engines.

LIEBHERR will declare all possible undertakings carried out by LIEBHERR and/or their dealers, such as guarantees,
service orders, etc. null and void without advance notice if fuels and lubricants other than those authorised by LIEB-
HERR are used.

Notes on utilisation
A summary of the structure of this manual can be obtained in chapter 1 "General Information".

Several types and construction levels are described in this manual. The information applies for the types specified
in the footer. Any details which deviate from this information are details specific to the type number or serial number
and are specified in the respective descriptions.

Some diagrams in this manual may feature particulars which differ from your diesel engine. The respective tasks
should be carried out in correspondence with the job specifications at hand.

Any improvements which are to be undertaken on the diesel engines may lead to changes which have possibly not
yet been mentioned in this manual.

Should you require further explanations or information, the After-Sales-Service and After-Sales-Service training cen-
tre departments of the LIEBHERR Company can be contacted at any time to answer any queries.

The repair manual is not subject to updating. The repair manual will undergo revision in accordance with the technical
requirements, and then published in the actual version.

The service information released by Liebherr Machines Bulle will serve as a supplement following publication of one
edition of the repair manual.

This repair manual is available in German, English and French.

Modifications, requirements and copyright

Modification of the technical details of the diesel engines, as regards details and illustrations of the manual at hand
remain reserved.

Conditions for warranty and liability of the general terms of trade for the LIEBHERR Company are not extended by
the aforementioned details.

Details and pictures within this manual may not be reproduced and distributed, nor used for the purposes of the com-
petition. All rights remain exclusively reserved in accordance with copyright laws.

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 Repair manual Table of Contents

1 General information................................................................................................................................. 1-9

1.1 Structure of this manual................................................................................................................. 1-12

1.2 Important notes within this manual ................................................................................................ 1-14

1.2.1 Designation of activity-related notes on safety ................................................................ 1-14

1.2.2 Further designations........................................................................................................ 1-14

1.3 Symbols in this manual.................................................................................................................. 1-15

1.4 Notes on safety.............................................................................................................................. 1-16

1.4.1 General notes on safety .................................................................................................. 1-16

1.4.2 Preventing injury to persons............................................................................................ 1-17
1.4.3 Preventing damage to property ....................................................................................... 1-19

1.5 Notes regarding working on the fuel system and injection system ................................................ 1-21

1.5.1 General notes on safety .................................................................................................. 1-21

1.5.2 Preventing injury to persons............................................................................................ 1-21
1.5.3 Preventing damage to property ....................................................................................... 1-21

1.6 Notes on safety for working on the exhaust after-treatment system (SCR system) ...................... 1-23

1.6.1 Carbamide solution ......................................................................................................... 1-23

1.6.2 General notes on safety .................................................................................................. 1-23
1.6.3 Preventing injury to persons............................................................................................ 1-23
1.6.4 Preventing damage to property ....................................................................................... 1-24

1.7 Technical Data............................................................................................................................... 1-25

1.7.1 Engine in general ............................................................................................................ 1-25

1.7.2 Standard tightening torques for screw connections ........................................................ 1-30
1.7.3 Standard torques for locking screws and banjo bolts...................................................... 1-32
1.7.4 Standard torques for metric threaded unions .................................................................. 1-33
1.7.5 Standard torques for imperial threaded unions ............................................................... 1-35
1.7.6 Standard torques for cutting ring threaded unions .......................................................... 1-37
1.7.7 Standard torques for Triple Lock threaded unions .......................................................... 1-38
1.7.8 Standard torques for VSTI screw plugs........................................................................... 1-39
1.7.9 Special torques, tightening specifications, installation specifications and
installation instructions .................................................................................................... 1-40
General notes............................................................................................................ 1-40
Tightening specification for main bearing.................................................................. 1-40
Tightening specification for aggregate carrier ........................................................... 1-40
Tightening specification for piston cooling nozzle ..................................................... 1-41
Tightening specification for final regulating valve and cold start valve...................... 1-41
Tightening specification for oil intake ........................................................................ 1-41
Tightening specification for oil drain valve ................................................................ 1-41
Tightening specification for oil sump (D934) ............................................................. 1-42

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 Table of Contents Repair manual

Tightening specification for oil sump (D936 / D946).................................................. 1-43

Tightening specification for crankshaft accessories .................................................. 1-44
Tightening specification for connecting rod ............................................................... 1-44
Tightening specification for cylinder head ................................................................. 1-45
Installation and tightening specification for counterbalancing shafts (D934)............. 1-46
Tightening specification for rocker arm support ........................................................ 1-48
Installation and tightening specification for cam shaft ............................................... 1-49
Tightening specification for oil cooler ........................................................................ 1-51
Tightening specification for oil cooler housing (D934)............................................... 1-51
Tightening specification for oil cooler housing (D936 / D946) ................................... 1-51
Tightening specification for fitting in oil filter bracket ................................................. 1-51
Installation and tightening specification for high-pressure pump............................... 1-52
Installation and tightening specification for injector and pressure pipe tube ............. 1-54
Installation instruction for cable harness on injector.................................................. 1-56
Tightening specification for sensors .......................................................................... 1-57
Installation instruction for cable harness ................................................................... 1-59
Installation instruction for throttle valve ..................................................................... 1-60
Tightening specification for heater flange.................................................................. 1-60
Tightening specification for idler ................................................................................ 1-60
Tightening specification for air compressor gear....................................................... 1-60
Installation instruction for coolant pump .................................................................... 1-61
Tightening specification for exhaust manifold (D934) ............................................... 1-62
Tightening specification for thermal protection plate (D934) ..................................... 1-62
Tightening specification for exhaust manifold (D936 / D946) .................................... 1-62
Tightening specification for thermal protection plate (D936 / D946) ......................... 1-62
Tightening specification for coolant pump ................................................................. 1-63
Tightening specification for turbocharger and flange on turbocharger ...................... 1-63
Tightening specification for generator belt pulley ...................................................... 1-64
Tightening specification for flywheel housing ............................................................ 1-64
Tightening specification for flywheel.......................................................................... 1-65
Tightening specification for control unit-mount.......................................................... 1-66
Tightening specification for power take-off................................................................ 1-66
Tightening specification for SCR module (installed machine side) ........................... 1-67
1.7.10 Cleaning agents, thread-locking adhesives and greases ................................................ 1-69

1.8 Representations of the engine and engine components ............................................................... 1-70

1.8.1 Gear train (D934)............................................................................................................. 1-70

1.8.2 Gear train (D936 / D946) ................................................................................................. 1-71

1.9 Diagram of the fuel system ............................................................................................................ 1-72

1.9.1 Representation of overall system .................................................................................... 1-74

1.10 Diagram of lube oil system ............................................................................................................ 1-76

1.11 Diagram of coolant system ............................................................................................................ 1-78

1.12 Allocation of ducts in the crankcase and in the cylinder head ....................................................... 1-80

1.13 Tools .............................................................................................................................................. 1-81

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 Repair manual Table of Contents

1.13.1 Special tools .................................................................................................................... 1-81

Lifting beam............................................................................................................... 1-81
Engine assembly stand ............................................................................................. 1-85
Lifting device for flywheels (SAE0, SAE1 and SAE2) ............................................... 1-90
Turning gears ............................................................................................................ 1-92
Mounting bolts ........................................................................................................... 1-96
Angle of rotation devices ........................................................................................... 1-96
Torx tools .................................................................................................................. 1-97
Installing and dismantling the cylinder liner............................................................... 1-98
Checking excess length of the cylinder liners ........................................................... 1-99
Installing and dismantling the front crankshaft seal .................................................. 1-99
Installing and dismantling the crankshaft ................................................................ 1-100
Installing and dismantling the piston with connecting rod and piston rings ............. 1-100
Installing and dismantling the piston rings .............................................................. 1-100
Installing and dismantling valve stem seals, valve springs and valves ................... 1-100
Installing and dismantling the counterbalancing shafts ........................................... 1-101
Dismantling and installing the camshafts ................................................................ 1-101
Installing and dismantling the injection lines ........................................................... 1-101
Installing and dismantling the pressure pipe tube and injector ............................... 1-101
Installing and dismantling the flywheel.................................................................... 1-102
Installing and dismantling the rear crankshaft seal ................................................. 1-102

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 Repair manual Table of Contents

240003
1 General information

1.1 Structure of this manual................................................................................................................. 1-12

1.2 Important notes within this manual ................................................................................................ 1-14

1.2.1 Designation of activity-related notes on safety ................................................................ 1-14

1.2.2 Further designations........................................................................................................ 1-14

1.3 Symbols in this manual.................................................................................................................. 1-15

1.4 Notes on safety.............................................................................................................................. 1-16

1.4.1 General notes on safety .................................................................................................. 1-16

1.4.2 Preventing injury to persons............................................................................................ 1-17
1.4.3 Preventing damage to property ....................................................................................... 1-19

1.5 Notes regarding working on the fuel system and injection system ................................................ 1-21

1.5.1 General notes on safety .................................................................................................. 1-21

1.5.2 Preventing injury to persons............................................................................................ 1-21
1.5.3 Preventing damage to property ....................................................................................... 1-21

1.6 Notes on safety for working on the exhaust after-treatment system (SCR system) ...................... 1-23

1.6.1 Carbamide solution ......................................................................................................... 1-23

1.6.2 General notes on safety .................................................................................................. 1-23
1.6.3 Preventing injury to persons............................................................................................ 1-23
1.6.4 Preventing damage to property ....................................................................................... 1-24

1.7 Technical Data............................................................................................................................... 1-25

1.7.1 Engine in general ............................................................................................................ 1-25

1.7.2 Standard tightening torques for screw connections ........................................................ 1-30
1.7.3 Standard torques for locking screws and banjo bolts...................................................... 1-32
1.7.4 Standard torques for metric threaded unions .................................................................. 1-33
1.7.5 Standard torques for imperial threaded unions ............................................................... 1-35
1.7.6 Standard torques for cutting ring threaded unions .......................................................... 1-37
1.7.7 Standard torques for Triple Lock threaded unions .......................................................... 1-38
1.7.8 Standard torques for VSTI screw plugs........................................................................... 1-39
1.7.9 Special torques, tightening specifications, installation specifications and
installation instructions .................................................................................................... 1-40
General notes............................................................................................................ 1-40
Tightening specification for main bearing.................................................................. 1-40
Tightening specification for aggregate carrier ........................................................... 1-40
Tightening specification for piston cooling nozzle ..................................................... 1-41
Tightening specification for final regulating valve and cold start valve...................... 1-41
Tightening specification for oil intake ........................................................................ 1-41
Tightening specification for oil drain valve ................................................................ 1-41
Tightening specification for oil sump (D934) ............................................................. 1-42

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 Table of Contents Repair manual

Tightening specification for oil sump (D936 / D946).................................................. 1-43

Tightening specification for crankshaft accessories .................................................. 1-44
Tightening specification for connecting rod ............................................................... 1-44
Tightening specification for cylinder head ................................................................. 1-45
Installation and tightening specification for counterbalancing shafts (D934)............. 1-46
Tightening specification for rocker arm support ........................................................ 1-48
Installation and tightening specification for cam shaft ............................................... 1-49
Tightening specification for oil cooler ........................................................................ 1-51
Tightening specification for oil cooler housing (D934)............................................... 1-51
Tightening specification for oil cooler housing (D936 / D946) ................................... 1-51
Tightening specification for fitting in oil filter bracket ................................................. 1-51
Installation and tightening specification for high-pressure pump............................... 1-52
Installation and tightening specification for injector and pressure pipe tube ............. 1-54
Installation instruction for cable harness on injector.................................................. 1-56
Tightening specification for sensors .......................................................................... 1-57
Installation instruction for cable harness ................................................................... 1-59
Installation instruction for throttle valve ..................................................................... 1-60
Tightening specification for heater flange.................................................................. 1-60
Tightening specification for idler ................................................................................ 1-60
Tightening specification for air compressor gear....................................................... 1-60
Installation instruction for coolant pump .................................................................... 1-61
Tightening specification for exhaust manifold (D934) ............................................... 1-62
Tightening specification for thermal protection plate (D934) ..................................... 1-62
Tightening specification for exhaust manifold (D936 / D946) .................................... 1-62
Tightening specification for thermal protection plate (D936 / D946) ......................... 1-62
Tightening specification for coolant pump ................................................................. 1-63
Tightening specification for turbocharger and flange on turbocharger ...................... 1-63
Tightening specification for generator belt pulley ...................................................... 1-64
Tightening specification for flywheel housing ............................................................ 1-64
Tightening specification for flywheel.......................................................................... 1-65
Tightening specification for control unit-mount.......................................................... 1-66
Tightening specification for power take-off................................................................ 1-66
Tightening specification for SCR module (installed machine side) ........................... 1-67
1.7.10 Cleaning agents, thread-locking adhesives and greases ................................................ 1-69

1.8 Representations of the engine and engine components ............................................................... 1-70

1.8.1 Gear train (D934)............................................................................................................. 1-70

1.8.2 Gear train (D936 / D946) ................................................................................................. 1-71

1.9 Diagram of the fuel system ............................................................................................................ 1-72

1.9.1 Representation of overall system .................................................................................... 1-74

1.10 Diagram of lube oil system ............................................................................................................ 1-76

1.11 Diagram of coolant system ............................................................................................................ 1-78

1.12 Allocation of ducts in the crankcase and in the cylinder head ....................................................... 1-80

1.13 Tools .............................................................................................................................................. 1-81

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 Repair manual Table of Contents

1.13.1 Special tools .................................................................................................................... 1-81

Lifting beam............................................................................................................... 1-81
Engine assembly stand ............................................................................................. 1-85
Lifting device for flywheels (SAE0, SAE1 and SAE2) ............................................... 1-90
Turning gears ............................................................................................................ 1-92
Mounting bolts ........................................................................................................... 1-96
Angle of rotation devices ........................................................................................... 1-96
Torx tools .................................................................................................................. 1-97
Installing and dismantling the cylinder liner............................................................... 1-98
Checking excess length of the cylinder liners ........................................................... 1-99
Installing and dismantling the front crankshaft seal .................................................. 1-99
Installing and dismantling the crankshaft ................................................................ 1-100
Installing and dismantling the piston with connecting rod and piston rings ............. 1-100
Installing and dismantling the piston rings .............................................................. 1-100
Installing and dismantling valve stem seals, valve springs and valves ................... 1-100
Installing and dismantling the counterbalancing shafts ........................................... 1-101
Dismantling and installing the camshafts ................................................................ 1-101
Installing and dismantling the injection lines ........................................................... 1-101
Installing and dismantling the pressure pipe tube and injector ............................... 1-101
Installing and dismantling the flywheel.................................................................... 1-102
Installing and dismantling the rear crankshaft seal ................................................. 1-102

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 General information Repair manual
Structure of this manual

1.1 Structure of this manual 240004

The job specifications within this manual have been compiled around the following:
1 Chapter title
2 Tasks already carried out, with details regarding
the name and number of the page
3 General diagram displaying where the respecti-
ve subassemblies are located on the diesel en-
gine, as well as all components which make up
the respective subassemblies
4 Legend to the overview diagram with notes on
operation, notes on safety, special tools, tighte-
ning torques, lubricants etc.
5 Table of special tools
6 Table of commercially-approved tools
7 Table of lubricants
8 Table of tightening specifications
9 Table featuring technical data
10 Detailed job specifications featuring text and di-
agrams

The job specifications are presented in two different variants:

1. Brief job specification (A)

Comprises the aforementioned elements (1) to (4) and, if required by the respective operational procedure, also ele-
ments (5) to (9).

This type can be readily identified as the legend (4) features a „Notes on operation“ column in the table (magnification
A).
The operational procedure is described in the overview diagram. If necessary, notes on operation are provided. Dif-
ferent symbols are featured to differentiate between notes on installation and removal, as well as dismantling and
assembly.
An explanation of these symbols can be obtained in the following pages.

2. Detailed job specification (A)

Also comprises the aforementioned elements (1) to (4) and, if required by the respective operational procedure, also
elements (5) to (9), as well as element (10) with text and pictures.

This type can be readily identified as the legend (4) does not feature a „Notes on operation“ column in the table (ma-
gnification B).

Please read the complete job specifications through to the end of the chapter in order that all necessary information
is acquired.

Various symbols are used in the diagrams and in the text within this manual.
An explanation of these symbols can be obtained in the following pages.

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 Repair manual General information
Structure of this manual

140398

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 General information Repair manual
Important notes within this manual

1.2 Important notes within this manual 240005

1.2.1 Designation of activity-related notes on safety

This is a warning sign. It warns against potential risks of injury. All measures stipulated for this warning
_5 sign must be adhered to if injuries and fatalities are to be prevented.

The warning sign is always displayed in correlation with the signal words
DANGER
WARNING
ATTENTION

DANGER Signifies an imminent hazardous situation which could result in fatalities or serious
_5 injury if it is not prevented.

WARNING Signifies a dangerous situation which could result in fatalities or serious injury if it is
_6 not prevented.

ATTENTION Signifies a dangerous situation which could result in minor or significant injury if it
_7 is not prevented.

CAUTION Signifies a dangerous situation which could result in material damage if it is not pre-
vented.

1.2.2 Further designations

Note Signifies useful notes and tips.

9

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 Repair manual General information
Symbols in this manual

240006
1.3 Symbols in this manual

Symbol Explanation Symbol Explanation

Remove, disassemble Seal, fasten, grease

a J
Dismantle Special tool
b t
Assemble Special tightening torque or tightening
c 0 specification

Install, mount
d

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 General information Repair manual
Notes on safety

1.4 Notes on safety 240408

Working on the diesel engine can be hazardous to mechanics and workshop personnel.

Dangerous predicaments and accidents can be avoided if the notes on safety are read and observed carefully.

The activity-related notes on safety featured in the repair manual are highlighted by red bordered boxes and are cha-
racterised with symbols.

There are four different types of activity-related notes on safety:

DANGER Signifies an imminent hazardous situation which could result in fatalities or serious
_5 injury if it is not prevented.

WARNING Signifies a dangerous situation which could result in fatalities or serious injury if it is
_6 not prevented.

ATTENTION Signifies a dangerous situation which could result in minor or significant injury if it
_7 is not prevented.

CAUTION Signifies a dangerous situation which could result in material damage if it is not pre-
vented.

Adherence to these notes on safety does not relieve you of the responsibility of observing the additional
rules and regulations!

The accident-prevention guidelines and all generally recognised safety-technical and occupational-medicinal regu-
lations are to be observed before commencing any maintenance and repair tasks on Liebherr diesel engines. Nati-
onal guidelines applicable for the respective country of use and/or for the application site must be observed wherever
necessary.

Notes on safety for the diesel engine are listed as follows. These notes must be strictly adhered to if the safety of
yourself and others is to be guaranteed, as well as preventing damage to the diesel engine.

The notes on safety in this chapter are structured in accordance with the subject. In the job specifications, the activity-
related notes on safety are provided wherever there are scenarios of potential danger.

1.4.1 General notes on safety

• Repairs to the diesel engine may only be carried out by authorised, specialist personnel.
Observe the legal, permissible minimum age!

• Employ trained, or instructed personnel only, ensure that all personnel are fully aware of their responsibilities.

• Ensure that personnel are familiar with the repair manual before commencing any repair tasks. It is of utmost
importance that the entire job specifications are read through to the end of each respective chapter, as only then
can all necessary information be acquired.

• Personnel who are undergoing training, instruction or are currently involved in a general apprenticeship may
only be allowed to work on the diesel engine under constant supervision of an experienced person.

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 Repair manual General information
Notes on safety

• Ensure at regular intervals that the personnel are conscientious of safety and dangers while carrying out their
duties, and are observing the accident-prevention guidelines, the generally recognised safety-technical and
occupational-medicinal regulations and the repair manual.

• Ensure that personnel wear safe working clothes.

The wearing of rings, wrist watches, ties, scarves, open jackets, loose fitting clothes, etc. is not permitted. There
is risk of injury, for example, getting caught up in or dragged into machinery.

• Prerequisite for a reliable repair is a complete basic tool in sound condition, as well as any necessary devices
and special tools.

• Only use clean and undamaged tools.

Damaged tools may not be reused, replace damaged tools immediately.

• Cleanliness and order contribute toward safety in the workplace.

• Ensure that all preparations have been made for any accidents which may occur.
Ensure that fire extinguisher and first-aid kit are on-hand.
Ensure that the phone numbers for emergency situations are on-hand.

• Ensure that the workplace has sufficient lighting.

• Repair tasks may only be carried out while the diesel engine is switched off.
Ensure that the diesel engine can not be inadvertently started by unauthorised personnel.

1.4.2 Preventing injury to persons

Crushing
• Do not try to lift heavy parts.

• Fasten and secure individual components and larger subassemblies carefully to lifting gear when carrying out
replacements.

• Do not use load-carrying equipment which is damaged, or which does not feature sufficient lift capacity.

• Remaining and working beneath suspended loads is prohibited.

• Ensure that no objects come into contact with rotating parts while the diesel engine is running. Objects could be
flung back out again.

Burns and scalding

The diesel engine is hot when running at operating temperature.
• Avoid direct contact with hot engine parts.

When the diesel engine is at operating temperature the cooling system is hot and is highly pressurised.
• Avoid any contact with parts carrying cooling water.

• Only check the level of the cooling water if the sealing cap of the expansion tank has cooled sufficiently that it
can be touched.
Open the cap carefully to relieve any excess pressure.

The engine oil is hot when the diesel engine is at operating temperature.
• Avoid skin contact with hot oil or with parts carrying oil.

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 General information Repair manual
Notes on safety

Fires and explosions

• Do not smoke and avoid fires, sparks and naked flames when handling fuels and flammable liquids.

• Only start up the diesel engine in accordance with the guidelines prescribed in the operating and maintenance
instructions.

• Remedy leaks and replace any damaged components.

Oil spraying out of points which are not properly sealed is highly flammable.

• Wear protective glasses and industrial gloves when working on the batteries.
Avoid sparks and naked flames and do not smoke.

• Do not keep any oil-soaked cleaning rags stored anywhere. These may ignite of their own accord.

• Disconnect the batteries while working on the electrical system.

Toxication
• Only allow the diesel engine to run in enclosed areas if sufficient ventilation has been provided.
If necessary, open doors and windows to guarantee a sufficient supply of fresh air.

• When draining fuels, never use receptacles originally intended for food or drink as somebody may inadvertently
drink the liquid.

Escaping liquids can penetrate the skin and cause blood poisoning.
• Do not open any pressurised lines or hoses.

• Do not remove any pressurised lines or hoses.

• When searching for leakages in pressurised lines and hoses, protect the hands, face and body from escaping
liquids.

High-pressure injection (jets of highly-pressurised liquids could squirt out)

The fuel lines are under a constant fuel pressure of up to 2400 bar while the diesel engine is running.
Escaping liquids can penetrate the skin and cause injury.

• Only work on the fuel system and injection system while the diesel engine is switched off.
Prior to commencing work:
After shutting down the diesel engine, wait for at least 20 minutes until pressure in the injection system has dis-
sipated and then check the build-up of pressure using the „Sculi“ diagnostics program.

• Wear suitable protective equipment (e.g. industrial gloves, protective glasses, etc.) when carrying out any tasks
on the fuel system and injection system.

• Do not open any pressurised fuel lines or hoses.

• Do not remove any pressurised fuel lines or hoses.

• When searching for leakages in pressurised fuel lines and hoses, protect the hands, face and body from esca-
ping liquids.

Electrical energy
• Persons with pacemakers should not approach within 20 cm of the running diesel engine.

• Do not touch parts which are carrying voltage.

• Disconnect the batteries before commencing work on the electrical system.

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 Repair manual General information
Notes on safety

1.4.3 Preventing damage to property

• Sealing components (e.g. O-rings, seals, etc.) should essentially be replaced.

• Dismantled parts should be checked for reusability and replaced as required.

• If no specific torques and tightening specifications are prescribed, screw connections should be tightened to the
standard torques which can be obtained in the chapter "Technical Data".

• Special torques, tightening specifications and mounting instructions can be obtained in the chapter "Technical
Data" and in the respective job specifications.

• Clean the diesel engine thoroughly of oil, fuel or preserving agents, and in particular, connections and threaded
unions, before commencing repair tasks. Do not use any aggressive cleaning agents. Use fibre-free cleaning
rags. Do not use any flammable liquids for cleaning the diesel engine.

• For reasons of safety and/or functionality, cover or seal all openings which may be penetrated by water, steam
or cleaning agents before cleaning the diesel engine with water, steam jet (high-pressure cleaner) or other clea-
ning agents.
Crankcase vents, engine control unit, sensors, actuators, starters and generator are at particular risk.
Following cleaning:
After cleaning, remove the covers/bondings completely.
Inspect all fuel lines, diesel engine oil lines and hydraulic oil lines for leaks, loose connections, points of wear
and damage upon completion of cleaning.
Determined faults must be remedied immediately.

• Only start up the diesel engine with the batteries securely connected.

• Do not disconnect batteries while the diesel engine is running.

• The diesel engine may only ever be started with the engine control unit connected.

• Do not use a fast charger to start the diesel engine. Only use jump leads with separate batteries.

• The battery terminals must be removed for fast charging of the batteries.
Refer to the operating instructions of the fast charger.

• Disconnect the batteries while working on the electrical system.

• When carrying out electrical welding work, the batteries must be disconnected and both cables (+ and -) joined
securely with each other. Connection to the engine control unit must be isolated via the interface plug.

• The interface plugs of the engine control unit may only be removed with the batteries disconnected or removed.

• Incorrect polarity of the engine control units voltage or supply voltage (e.g. via incorrect polarity of the batteries)
can lead to ruination of the engine control units.

• Tighten the connections to the injection system with the prescribed tightening torque.

• If temperatures exceeding 80 °C (e.g. drying kiln) are expected, the engine control units must be removed.

• Only use suitable test leads for measurements at the plug connections.

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 General information Repair manual
Notes on safety

• Sensors or actuators may not be connected individually, or between external voltage sources for test purposes
or inspection purposes, but rather only in connection with the engine control unit, otherwise there is a serious
risk of ruination, or possibly a risk of the diesel engine behaving erratically.

• The engine control unit is only sufficiently protected against dust and water with the mating connector mounted
and connected. If the mating connectors are not connected, the engine control unit must be sufficiently protected
against dust and water.

• Telephones and radio equipment which are not connected to an external aerial could lead to functional failure of
the vehicle's electronics, and thus jeopardise operational safety of the diesel engine.

• Ensure a safe and environmentally-friendly disposal of fuels, lubricants and auxiliary agents, as well as "old"
parts.

• When handling fuels, ensure that these fuels do not mix into the soil, sewer systems or bodies of water. Use
sealed containers for draining fuels and lubricants.
Under no circumstances should containers for food or drinks be used as the liquids could be drunk inadvertently.

• Different fuels are to be collected and disposed of in separate receptacles.

• Before disposing of or recycling waste materials, make enquiries at your local environmental centre or recycling
centre as to the correct methods for such procedures. Incorrect disposal of waste products can harm the envi-
ronment and the ecology.

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 Repair manual General information
Notes regarding working on the fuel system and injection system

240403
1.5 Notes regarding working on the fuel system and injection system

1.5.1 General notes on safety

• Only authorised personnel may undertake any work on the fuel system and injection system.

1.5.2 Preventing injury to persons

• Persons with pacemakers should not approach within 20 cm of the running diesel engine.

• Parts of the fuel system and injection system carrying voltage are not to be touched.

The fuel lines are under a constant fuel pressure of up to 2400 bar while the diesel engine is running.
Escaping liquids can penetrate the skin and cause injury.
• Only work on the fuel system and injection system while the diesel engine is switched off.
Prior to commencing work:
After shutting down the diesel engine, wait for at least 20 minutes until pressure in the injection system has dis-
sipated and then check the build-up of pressure using the „Sculi“ diagnostics program.

• Wear suitable protective equipment (e.g. industrial gloves, protective glasses, etc.) when carrying out any tasks
on the fuel system and injection system.

• When searching for leakages in pressurised fuel lines and hoses, protect the hands, face and body from esca-
ping liquids.

• Tighten the connections to the injection system with the prescribed tightening torque.

1.5.3 Preventing damage to property

Ensure environmentally compatible disposal of fuels and "old" parts removed while carrying out tasks on the fuel sys-
tem and injection system.
• Fuel may not be allowed to seep into the soil, sewers or bodies of water.

• Catch the fuel in suitable containers and dispose of as prescribed.

• Before disposing of or recycling waste materials, make enquiries at your local environmental centre or recycling
centre as to the correct methods for such procedures. Incorrect disposal of waste products can harm the envi-
ronment and the ecology.

Components of the fuel system and injection system are high-precision parts which are subjected to extreme stres-
ses. Dirt particles exceeding 0.2 mm in size are enough to cause the failure of components.
• Utmost cleanliness is to be observed at all times when working on the fuel system and injection system.

The following should be observed before commencing work:

• Only carry out tasks on the fuel system and injection system in areas in which there is no possibility of dust being
raised (for example as a result of grinding or welding work) or where other dirt particles can infiltrate the working
area. Use the respective workshop or assembly hall.

• If necessary, hang a clean cover sheet over the engine cover.

• Before removing parts, clean the respective area of the engine thoroughly and then dry.

• Perform a visual inspection of the fuel system and injection system for leaks or damages.

• Only use clean and undamaged tools.

Damaged tools may not be reused, replace damaged tools immediately.

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 General information Repair manual
Notes regarding working on the fuel system and injection system

• Do not wear work clothes which have been used beforehand to carry out dusty tasks (for example, as a result of
grinding or welding work). If necessary, change work clothes.

• Clean your hands before commencing work.

• Only use fibre-free cleaning rags.

The following must be observed when carrying out this work:

• The utilisation of compressed air is not permissible once the clean side of the fuel system has been opened.

• Remove any dirt which may loosen and detach itself (e.g. flakes of dried paint) using an industrial vacuum clea-
ner for example.

• Materials such as cloth, cardboard or wood may not be used to remove components of the fuel system and
injection system as they could release particles and fibres.

• Seal open line connections (e.g. on engine control unit, fuel prefilter, fuel fine filter, fuel delivery pump, high-pres-
sure pump, pressure pipe tube, injector and cylinder head) to eliminate infiltration of dust or moisture.

• Package removed parts (e.g. fuel line, injection line, engine control unit, fuel prefilter, fuel fine filter, fuel delivery
pump, high-pressure pump, pressure pipe tube, injector and cylinder head) so that they are protected against
dust and moisture, and put into storage.
Alternatively, removed parts (e.g fuel line, injection line, fuel prefilter, fuel fine filter, fuel delivery pump, high-
pressure pump, pressure pipe tube, injector and cylinder head) can also be stored in a receptacle filled with
clean diesel fuel (as protection against fine dust and corrosion).

• Removed parts of the injection system (high-pressure pump, pressure pipe tube, injector) may not be dis-
mantled, but rather must be replaced wherever necessary.

• „New“ parts should only be removed from their original packaging directly prior to installation, check for reusabi-
lity.

• Utmost cleanliness must also be ensured when working on dismantled components.

• Clean used components thoroughly before reinstalling (e.g. with cleaning solvent) and check for reusability.
Do not clean with used cleaning fluids!

• If dismantled components are to be posted, always use the original packaging of the „new“ part.

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 Repair manual General information
Notes on safety for working on the exhaust after-treatment system (SCR system)

240418
1.6 Notes on safety for working on the exhaust after-treatment system
(SCR system)

1.6.1 Carbamide solution

• For the SCR system (Selective Catalytic Reduction), a carbamide solution (registered trade name: AdBlue®) is
used to reduce elements of nitrogen oxide (NOx) in the exhaust gas.
AdBlue® is a registered trademark of the German Association of the Automotive Industry (VDA).

1.6.2 General notes on safety

• Only authorised, specialist personnel may undertake any work on the exhaust after-treatment system.

1.6.3 Preventing injury to persons

The lines and hoses for the carbamide solution are pressurised with up to 15 bar when the diesel engine is running.
Escaping carbamide solution can lead to injuries.
• Only work on the exhaust after-treatment system while the diesel engine is switched off.
Prior to commencing work:
After shutting down the diesel engine, wait for at least 20 minutes until the pressure has dissipated in the
exhaust after-treatment system.

• The carbamide solution has an aggressive effect on the unprotected body.

It must be ensured, therefore, that hands, face and body do not come into contact with the carbamide solution.
Wear suitable protective equipment (e.g. protective glasses, industrial gloves etc.) when carrying out any tasks
on the exhaust after-treatment system.

• Tighten the connections to the exhaust after-treatment system with the prescribed tightening torque.

• Ensure that the carbamide solution is kept at a safe distance from heat sources.
As the carbamide solution heats up, it produces ammonia vapours which are hazardous to health.
Ensure sufficient ventilation.

The following must be observed when carrying out this work:

• At room temperature, the carbamide solution degrades over time and produces ammonia vapours.
Ensure that the working area is sufficiently ventilated.

• In the event that ammonia vapours are inhaled:

Ensure an ample supply of fresh air, if necessary seek medical attention.

• If carbamide solution comes into contact with skin:

Wash the respective body parts with soap and water, if necessary seek medical attention.

• If work garments become contaminated with carbamide solution:

Remove the work garments and wash the respective areas with soap and water.

• If carbamide solution comes into contact with eyes:

Rinse the eyes (including under the eyelids) with plenty of water, if necessary seek medical attention.

• If carbamide solution is swallowed:

Do not induce vomiting. Drink plenty of water, if necessary seek medical attention.

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 General information Repair manual
Notes on safety for working on the exhaust after-treatment system (SCR system)

1.6.4 Preventing damage to property

Ensure environmentally compatible disposal of carbamide solution and "old" parts removed while carrying out tasks
on the exhaust after-treatment system.
• Carbamide solution may not be allowed to seep into the soil, sewers or bodies of water.

• Catch the carbamide solution in suitable containers and dispose of as prescribed.

• Before disposing of or recycling waste materials, make enquiries at your local environmental centre or recycling
centre as to the correct methods for such procedures. Incorrect disposal of waste products can harm the envi-
ronment and the ecology.

• The carbamide solution has an aggressive effect on susceptible materials (e.g. glass, paint, aluminium, copper,
brass etc.).
It should therefore be ensured that parts of the engine do not come into contact with the carbamide solution.
Cover the parts of the engine prior to commencing the respective work.

• The components of the exhaust after-treatment system are made up of high-precision parts. Even the smallest
of dirt particles are enough to cause the failure of components.
Utmost cleanliness is to be observed at all times when working on the exhaust after-treatment system.

The following should be observed before commencing work:

• Only carry out tasks on the exhaust after-treatment system in areas in which there is no possibility of dust being
raised (for example as a result of grinding or welding work) or where other dirt particles can infiltrate the working
area.

• Before removing parts, clean the respective area of the engine thoroughly and then dry.

The following must be observed when carrying out this work:

• Perform a visual inspection for leaks or damage on the exhaust after-treatment system, replace faulty parts as
required.

• In the event of the carbamide solution hardening:

Do not allow the carbamide solution to seep into the soil, sewers or bodies of water.
Soak up using a suitable binding agent and dispose of the contaminated binding agent as prescribed.

• Rinse the removed parts (e.g. cables, injector etc.) with water and then dry.

• Package any removed parts to protect against dust and moisture and place into storage.

• „New“ parts should only be removed from their original packaging directly prior to installation, check for reusabi-
lity.

• If dismantled parts are to be posted, always use the original packaging of the „new“ part.

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 Repair manual General information
Technical Data

240404
1.7 Technical Data

1.7.1 Engine in general

Engine type description

D 93 4 A7 SCR Engine type description

D Engine type: D = Diesel engine
93 93 = Bore: 122 mm, stroke: 150 mm
94 = Bore: 130 mm, stroke: 150mm
4 Number of cylinders:
4 = 4 cylinders
6 = 6 cylinders
A7 Injection system:
A7 = Liebherr Common Rail
SCR Exhaust after-treatment system:
SCR = Selective Catalytic Reduction

Engine company nameplate

The engine company nameplate is mounted on the right-hand

side of the crankcase, as viewed looking at the flywheel. A se-
cond company nameplate is mounted on the air induction pi-
pe.

140846

Engine serial number

The engine serial number is stamped on the engine company

nameplate and in the crankcase.
2011 03 0001 Engine serial number
2011 Year of manufacture
03 Number of cylinders:
03 = 4 cylinders
04 = 6 cylinders
0001 Progressional manufacturing number

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 General information Repair manual
Technical Data

The engine serial number is stamped on the engine company

nameplate in the field
„Engine Number“.

140826

The engine serial number is stamped on the crankcase joint

face to the cylinder heads.

140896

Firing sequence, cylinder classification, rotational direc-

tion and TDC mark

The firing sequence and the cylinder numbers are cast on the
side of the crankcase.

140897

Cylinder 1 is located on the same side as the flywheel.

The rotational direction is to the left, as viewed when looking

at the flywheel.

Y D934
Z D936 / D946
1-4 Cylinder numbers D934
1-6 Cylinder numbers D936 / D946
A Exhaust valve
E Intake valve
Firing sequence D934: 1-3-4-2
Firing sequence D936 / D946: 1-5-3-6-2-4 140006

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 Repair manual General information
Technical Data

The TDC mark is located in the flywheel housing.

The notch in the flywheel must be aligned (arrows) with the pin
or the notch in the flywheel housing.

140898

Crankcase number

The crankcase number is stamped in the crankcase joint face

to the oil sump (flywheel side).
001 C 1 Crankcase number
001 Progressional manufacturing number
C Code letter for the year of manufacture
1 Bearing cap number of the main bearing
cap:
1 to 5 for D 934
1 to 7 for D 936 / D946

140004
Affiliation of the crankcase and main bearing cap can be iden-
tified via the crankcase number.

Connecting rod number (cracked connecting rod)

The connecting rod number is stamped on the connecting rod

and on the connecting rod bearing cap.
00001 C Connecting rod number
00001 Progressional manufacturing number
C Code letter for the year of manufacture

Connecting rod and connecting rod bearing cap can be iden-

tified as a match via the connecting rod number.

140009

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Technical Data

Turbocharger company nameplate

The turbocharger company nameplate is mounted on the tur-

bocharger.

140010

Injector identification

The injector identification is located in the area indicated with

an arrow.

11 20 000001 Serial number

11 Year of manufacture, here: 2011
20 Component code for injector
000001 Progressional manufacturing number

140894

High-pressure pumps identification

The high-pressure pumps identification is affixed to the high-

pressure pumps housing.

11 10 000001 Serial number

11 Year of manufacture, here: 2011
10 Component code for high-pressure
pump
000001 Progressional manufacturing number

140895

Engine control units company nameplate

The engine control units company nameplate is mounted on

the engine control unit.

140007

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 Repair manual General information
Technical Data

Piston number

The piston number and the indicators for the crankshaft (to in-
dicate the installation position) are located in the area on the
piston crown indicated with the arrow.

140237

Thermostat beginning of opening

Beginning of opening for the thermostat is engraved in the

area indicated with the arrow.

140379

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 General information Repair manual
Technical Data

1.7.2 Standard tightening torques for screw connections 240212

For hexagonal screws in accordance with: DIN EN ISO 4014 (previously DIN EN 24014, previously DIN 931),
DIN EN ISO 4017 (previously DIN EN 24017, previously DIN 933), DIN EN ISO 8765 (previously DIN EN 28765,
previously DIN 960), DIN EN ISO 8676 (previously DIN EN 28676, previously DIN 961).

For cheese-head screws in accordance with: DIN EN ISO 4762 (previously DIN 912).

For screws with external hexalobular driving (Torx screws) in accordance with: DIN 34800.

Values for a mean friction factor of k = 0.12.

Standard Nm Nm Nm Standard Nm Nm Nm
thread thread
8.8 10.9 12.9 8.8 10.9 12.9

M4 3 4 5 M 18 280 390 460

M5 6 8 10 M 20 390 560 650

M6 10 14 17 M 22 530 750 880

M7 16 23 27 M 24 670 960 1120

M8 23 34 40 M 27 1000 1400 1650

M 10 46 68 79 M 30 1350 1900 2250

M 12 79 117 135 M 33 1850 2600 3000

M 14 125 185 215 M 36 2350 3300 3900

M 16 195 280 330 M 39 3000 4300 5100

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 Repair manual General information
Technical Data

Fine Nm Nm Nm Fine Nm Nm Nm
thread thread
8.8 10.9 12.9 8.8 10.9 12.9

M8x1 25 36 43 M 24 x 1.5 760 1090 1270

M9x1 36 53 62 M 24 x 2 730 1040 1220

M 10 x 1 52 76 89 M 27 x 1.5 1110 1580 1850

M 10 x 1.25 49 72 84 M 27 x 2 1070 1500 1800

M 12 x 1.25 87 125 150 M 30 x 1.5 1540 2190 2560

M 12 x 1.5 83 122 145 M 30 x 2 1490 2120 2480

M 14 x 1.5 135 200 235 M 33 x 1.5 2050 2920 3420

M 16 x 1.5 205 300 360 M 33 x 2 2000 2800 3300

M 18 x 1.5 310 440 520 M 36 x 1.5 2680 3820 4470

M 18 x 2 290 420 490 M 36 x 3 2500 3500 4100

M 20 x 1.5 430 620 720 M 39 x 1.5 3430 4890 5720

M 22 x 1.5 580 820 960 M 39 x 3 3200 4600 5300

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Technical Data

1.7.3 Standard torques for locking screws and banjo bolts

For banjo bolts in accordance with DIN 7643 with copper sealing ring in accordance with DIN 7603,
locking screws in accordance with DIN 910 with copper sealing ring in accordance with DIN 7603,
locking screws in accordance with DIN 908 with copper sealing ring in accordance with DIN 7603.

Thread Nm Thread Nm

M6x1 7 M 36 x 1.5 155

M8x1 7.5 M 36 x 2 155

M 8 x 1.5 7.5 M 38 x 1.5 171

M 10 x 1 15 M 39 x 2 215

M 10 x 1.25 15 M 42 x 1.5 240

M 12 x 1.5 20 M 42 x 2 240

M 14 x 1.5 27 M 45 x 1.5 270

M 16 x 1.5 37 M 45 x 2 270

M 18 x 1.5 40 M 48 x 1.5 300

M 20 x 1.5 47 M 48 x 2 300

M 22 x 1.5 57 M 52 x 1.5 380

M 24 x 1.5 68 M 52 x 2 380

M 26 x 1.5 75 M 56 x 2 430

M 27 x 2 87 M 60 x 2 510
M 30 x 1.5 115 M 64 x 2 570

M 30 x 2 115 M 65 x 2 620

M 33 x 2 120

Note
9 Apply a coating of engine oil to threads and sealing faces.

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 Repair manual General information
Technical Data

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Technical Data

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 Repair manual General information
Technical Data

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Technical Data

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 Repair manual General information
Technical Data

1.7.6 Standard torques for cutting ring threaded unions

Dimension Nm

Series Pipe diameter Thread Z

X

LL 6 M 10 × 1 14

L 6 M 12 × 1.5 14
8 M 14 × 1.5 20

10 M 16 × 1.5 27-30

12 M 18 × 1.5 60

15 M 22 × 1.5 105

18 M 26 × 1.5 150

22 M 30 × 2 200
28 M 36 × 2 250

35 M 45 × 2 450

42 M 52 × 2 600

S 16 M 24 × 1.5 150

20 M 30 × 2 250

25 M 36 × 2 450

30 M 42 × 2 600

38 M 52 × 2 750

Note
• Tighten stud standpipe with prescribed torque.
• Hold stud standpipe tightly.
9 • Screw on the cap nut until an increase in force is clearly discernible (without wrench exten-
sion).
• Tighten the cap nut with the aforementioned torque.

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Technical Data

1.7.7 Standard torques for Triple Lock threaded unions

Dimension Nm

Series Pipe diameter X Thread Z

mm inch UN/UNF

4 6 1/4 7/17-20 15

5 8 5/16 1/2-20 20

6 10 3/8 9/16-18 45

8 12 1/2 3/4-16 60
10 14, 15, 16 5/8 7/8-14 75

12 18, 20 3/4 1 1/16-12 100

16 22, 25 7/8, 1 1 5/16-12 150

20 30, 32 1 1/4 1 5/8-12 180

24 38 1 1/2 1 7/8-12 200

28 42 - 2 1/4-12 220

32 - 2 2 1/2-12 250

Note
• Tighten stud standpipe with prescribed torque.
9 • Hold stud standpipe tightly.
• Screw on the cap nut until an increase in force is clearly discernible (without wrench extension).
• Tighten the cap nut with the aforementioned torque.

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1.7.8 Standard torques for VSTI screw plugs

Thread Nm Thread Nm

M 10 x 1 15,5 M 27 x 2 155

M 12 x 1.5 30 R 3/4" 155

M 14 x 1.5 40 M 30 x 1.5 155

M 16 x 1.5 57 M 33 x 2 215

M 18 x 1.5 68 M 42 x 2 370

M 20 x 1.5 93 M 48 x 2 490

M 22 x 1.5 110 M 52 x 2 580

M 26 x 1.5 130

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 General information Repair manual
Technical Data

1.7.9 Special torques, tightening specifications, in- 240405

stallation specifications and installation instruc-

tions

General notes

If screws need to be oiled, apply a coating of engine oil to the

screw thread and on the screw head.

Should a thread-locking adhesive be required, first clean, de-

grease and dry the respective screw thread and threaded bo-
re.

Particular notes regarding degreasing of the component con-

tact surfaces are indicated for certain tightening specificati-
ons, as this concerns connections with force transmission for
the respective screw connections.

Tightening specification for main bearing

CAUTION
Torx anti-fatigue bolts may not be used more than
once.

Torx anti-fatigue bolts M18x2x181-10.9

Lubricant Engine oil
Thread-locking adhesive -
Screws No
reusable?
140902
Stage Torque in Nm
1. 30
2. 110
Stage Angle of rotation in °
3. 90
4. 90
5. 45
Overall 225 ± 5

Tightening specification for aggregate carrier

Hexagonal screw M10-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 72

180045

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Tightening specification for piston cooling nozzle

Banjo bolt M12x1.5

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 30

140065

Tightening specification for final regulating valve and

cold start valve

Sealing nut M12

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 50

140899

Tightening specification for oil intake

Hexagon collar bolt M12x35-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 79

140906

Tightening specification for oil drain valve

Oil drain valve M30x1.5

Lubricant -
Thread-locking adhesive Omnivisc 1050
Stage Torque in Nm
1. 110

140075

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Technical Data

Tightening specification for oil sump (D934)

180041

Hexagon collar bolts M8-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 27

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Tightening specification for oil sump (D936 / D946)

180042

Hexagon collar bolts M8-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 27

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Technical Data

Tightening specification for crankshaft accessories

CAUTION
Torx anti-fatigue bolts may not be used more than
once.

Torx anti-fatigue bolt M16x1.5x-10.9

Lubricant Engine oil
Thread-locking adhesive -
Component contact sur- Degreased
faces
140375
Stage Torque in Nm
1. 30
2. 90
Stage Angle of rotation in °
3. 90
4. 90
Overall 180 ± 5

Tightening specification for connecting rod

CAUTION
Hexagon head anti-fatigue bolts may not be used
more than once.

Hexagon head anti-fatigue bolt M14x1.5x65-10.9

Lubricant Engine oil
Thread-locking adhesive -
Stage Torque in Nm
1. 5 140066
2. 30
3. 110
Stage Angle of rotation in °
4. 45
5. 45
Overall 90 ± 5

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Tightening specification for cylinder head

CAUTION
Torx anti-fatigue bolts may not be used more than
once.

A Air induction pipe side

B Exhaust pipe side

Torx anti-fatigue bolt M16x1.5x210-10.9

Lubricant Engine oil
Thread-locking adhesive -
Stage Torque in Nm
1. 30
2. 120
3. 200
Stage Angle of rotation in °
4. 55
5. 120
6. 120
Overall 295 ± 5

140828

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Technical Data

Installation and tightening specification for counterbalancing shafts (D934)

140903

• t Insert pin (1) [9078118] (2x) through flange (4) into the counterbalancing shafts (3) and t insert pin (2)
[9078119] through main bearing cap (7) into the crankshaft (8).

• Degrease the contact surfaces of counterbalancing shafts (3) and gear wheels (5).

• Affix gear wheels (5), apply a coating of Loctite 270 / 2701 to hexagonal screws M14x50-8.8 (6) and tighten with
the respective tightening specification.

• Remove pins (1) and (2), apply a coating of Loctite 648 to the hexagon socket head screws M8x10-8.8 (9) and
tighten with the respective tightening specification.

t Special tool

140073 140074

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Hexagon socket head screw M14x50-10.9

Lubricant -
Thread-locking adhesive Loctite 270 / 2701
Component contact sur- Degreased
faces
Stage Torque in Nm
1. 185

Hexagon socket head screw M8x10-8.8

Lubricant -
Thread-locking adhesive Loctite 648
Stage Torque in Nm
1. 20

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Technical Data

Tightening specification for rocker arm support

Hexagon socket head screw M12x100-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 90
Stage Angle of rotation in °
2. 90
Overall 90 ± 5
140412

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Installation and tightening specification for cam shaft

141025

Pos. Designation Notes on operation

A Aggregate carrier side
B Flywheel side

1 Hexagon socket head screw M12x45-10.9 ...... d Renew and tighten, 0 see tightening specifica-
tion.
2 Camshaft gear wheel, aggregate carrier side .. d Remove grease from the contact face camshaft
gear wheel to camshaft.
3 Camshaft.......................................................... d t Tighten the cam shaft guide tool (11)
[11342234] and apply a coating of oil to the cam
shaft at the bearing points before fitting.
d Following installation: Turn the crankshaft
around another full turn and check for freedom-
of-movement and axial clearance.
4 Hexagon socket head screw M12x45-10.9 ...... d Renew and tighten, 0 see tightening specifica-
tion.

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Pos. Designation Notes on operation

5 Camshaft gear wheel, flywheel side................. d Degrease the contact face of gear wheel cam
shaft to camshaft and fit the gear wheel so that
the borehole aligns with the straight pin (arrows
A) and the marking (1 point) corresponds with
the marking (2 points) on the crankshaft gear
wheel (arrow C).
6 Thrust ring ........................................................ d Apply a light coating of grease before fitting.
7 Hexagon socket head screw M10x18-8.8
8 Flange .............................................................. d Fit in such a way that the lube oil bore aligns
with the lube oil bore in the crankcase (arrows
B).
9 O-ring 7.00x1.50............................................... d Replace, apply a coating of oil and fit in such a
way that it sits in the groove of the flange.
10 Straight pin

t Special tool

141067

CAUTION
Hexagon socket head screws may not be used
more than once.

Hexagon socket head screw M12x45-10.9

Lubricant Engine oil
Thread-locking adhesive -
Component contact sur- Degreased
faces
Screws No
reusable? 140047
Stage Torque in Nm
1. 40
Stage Angle of rotation in °
2. 40
Overall 40 ± 5

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Tightening specification for oil cooler

Hexagon collar bolts M8-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 27

180050

Tightening specification for oil cooler housing (D934)

Hexagon collar bolts M8-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 27

180046

Tightening specification for oil cooler housing (D936 /

D946)

Hexagon collar bolts M8-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 27

180047

Tightening specification for fitting in oil filter bracket

Fitting M30x2
Lubricant -
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 60 ± 15

140067

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 General information Repair manual
Technical Data

Installation and tightening specification for high-pressu-

re pump

• Set the engine to TDC.

(The notch in the flywheel must be aligned (arrows) with
the pin or the notch in the flywheel housing).

140898

• Unscrew the hexagon socket head screw and remove the

sealing ring.

• Twist the crankshaft of the high-pressure pump so that

the bore in the crankshaft aligns with the housing bore
(arrows).

141032

• Apply a light coating of lubricating compound [Altemp

QNB 50] to the O-rings.

141031

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• Push the high-pressure pump (2) into the high-pressure

pump drive (3) and tighten the hexagon socket head
screws (1), see tightening specification.

• Tighten the hexagon socket head screw with new sealing

ring, see tightening specification.

141033

Hexagon socket head screw M10x55-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 15
2. 68

141034

Hexagon socket head screw M8x12-8.8

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 22

141035

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Technical Data

Installation and tightening specification for injector and

pressure pipe tube

CAUTION
Pressure pipe tube and injector may not be dis-
mantled, replace as necessary.

• Fit the new O-ring (5) onto the injector (4) and apply a
coating of grease
to the O-ring (5).

Note
Use a new sealing washer in compliance with the
9 spare-parts catalogue, see spare-parts catalogue
group „Injection nozzle“.

• Insert the injector (4) with new sealing washer (11).

• t Continue to push the centring pin (12) [11213358] into

the bore of the pressure pipe tube until the face of the
centring pin (12) aligns with the face of the cylinder head
(arrows).

• Fit the lug (1) and spherical washer (2) and tighten the
hexagon socket head screw M8x50-10.9 (3), see tighte-
ning specification Stage 1 (A).
141075

• t Remove the centring pin (12) [11213358].

DANGER
_5 The pressure pipe tube must be replaced each
time it is removed.

• If necessary, fit a new O-ring (7) onto a new pressure pipe

tube (6) and apply grease.

• Install the pressure pipe tube (6) and align.

• Fit lug (8) and spherical washer (9), apply a coating of oil
to hexagon socket head screw M8x40-12.9 (10) and tigh-
ten, see tightening specification Stage 1 (B).

• Tighten hexagon socket head screw M8x50-10.9 (3), see

tightening specification Stage 2 (C).

• Tighten hexagon socket head screw M8x40-12.9 (10),

see tightening specification Stage 2 (D).

• Tighten hexagon socket head screw M8x40-12.9 (10),

see tightening specification Stage 3 (E).

140900

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Hexagon socket head screw M8x50-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. (A) 5
2. (C) 35

Hexagon socket head screw M8x40-12.9

Lubricant -
Thread-locking adhesive -
140901
Stage Torque in Nm
1. (B) 5
2. (D) 15
Stage Angle of rotation in °
3. (E) 90

t Special tool

140080 140081 141065 141066

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Technical Data

Installation instruction for cable harness on injector

CAUTION
Exposed cable connections.
Turning of the cable lug during tightening could
lead to short circuits.
• Hold the cable lug tightly.

141030

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Tightening specification for sensors

140907

Pos. Designation Notes on operation

1 Coolant temperature sensor M14x1.5.............. d 16 Nm.
2 Charge air temperature sensor M14x1.5 ......... d Hexagon socket head screw, 10 Nm.
3 Boost pressure sensor M18x1.5 ...................... d 40 +0 /-5 Nm.
4 Oil pressure sensor M14x1.5 ........................... d 40 +0 /-5 Nm.
5 Oil level sensor M18x1.5.................................. d 50 Nm.
6 Speed sensor (camshaft sprocket) .................. d Hexagon socket head screw, 10 Nm.
7 Speed sensor (flywheel)................................... d Hexagon socket head screw, 10 Nm.
(installed at the top or to the right in the flywheel
housing)

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Technical Data

140908

Pos. Designation Notes on operation

A Engine-side
B Machine side

1 Rail pressure sensor M12x1.5.......................... d 60 ± 3 Nm.

2 Fuel temperature sensor M14x1.5 ................... d 16 Nm.
(mounted on the distributor block or on the fuel
fine filter)
3 Fuel pressure sensor M14x1.5......................... d 40 +0 /-5 Nm.
(mounted on the distributor block or on the fuel
fine filter)
4 NOx sensor M20x1.5........................................ d Spray with J high-temperature spray [Anti
(installed on the machine side) Seize ASW], 50 ± 10 Nm.
5 Exhaust gas temperature sensor M14x1.5....... d Spray with J high-temperature spray [Anti
(installed on the machine side) Seize ASW], 35 Nm ± 5 Nm.

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Technical Data

Installation instruction for cable harness

141072

CAUTION
Before commencing work on the electrical system: Disconnect the batteries.

The interface plugs of the engine control unit may only be removed with the batteries disconnected or re-
moved.

Incorrect polarity of the engine control units voltage or supply voltage (e.g. via incorrect polarity of the bat-
teries) can lead to ruination of the engine control units.

• Secure all cable looms of the cable harness to the engine using clamps, without tension and without the risk of
shearing.

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Technical Data

Installation instruction for throttle valve

Note
Prior to removing the throttle valve, mark the re-
9 spective installation position (arrows) and insert
the throttle valve in accordance with this marking
during installation.

Note
9 A new throttle valve does not require calibrating.

141013

Tightening specification for heater flange

Hexagon ribbed nut M6

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 11

140077

Tightening specification for idler

Hexagonal screw M12x65-8.8

Lubricant -
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 83

Axial clearance (A) = 0.1 - 0.3 mm.

140083

Tightening specification for air compressor gear

Hexagonal nut M20x1.5

Lubricant Engine oil
Thread-locking adhesive -
Component contact sur- Degreased
faces
Stage Torque in Nm
1. 200+50

140076

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Installation instruction for coolant pump

141029

Pos. Designation Notes on operation

1 Coolant pump
2 O-ring 68.26x3.53 ............................................ d Replace, apply a coating of J grease [Stabu-
rags NBU 30]. Ensure that the O-ring is sitting
correctly in the groove of the coolant pump.
3 O-ring 113.89x3.53........................................... d Replace, apply a coating of J grease [Stabu-
rags NBU 30]. Ensure that the O-ring is sitting
correctly in the groove of the coolant pump.
4 O-ring 59.92x3.53 ............................................ d Replace, apply a coating of J grease [Stabu-
rags NBU 30]. Ensure that the O-ring is sitting
correctly in the groove of the aggregate carrier.
5 Hexagon collar bolt M8-8.8
6 Hose
7 Hexagon collar bolt M8-8.8

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Technical Data

Tightening specification for exhaust manifold (D934)

Torx screws M10 - SD (highly heat-resistant)

Lubricant Copper paste; Motorex 14
Thread-locking adhesive -
Screws Yes
reusable?
Stage Torque in Nm
1. 20
2. 54
180136

Tightening specification for thermal protection plate

(D934)

Torx screws M8 - SD (highly heat-resistant)

Lubricant Copper paste; Motorex 14
Thread-locking adhesive -
Screws Yes
reusable?
Stage Torque in Nm
1. 21
180136

Tightening specification for exhaust manifold (D936 /

D946)

Hexagonal screw M10x90-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 54

180129

Tightening specification for thermal protection plate

(D936 / D946)

Hexagon collar bolt M8x25

Lubricant Copper paste; Motorex 14
Thread-locking adhesive -
Stage Torque in Nm
1. 10
2. 23

140904

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Tightening specification for coolant pump

Connector
Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 25 ± 3

Hexagon socket head screw M8x18-8.8

Lubricant -
140905
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 25 ± 2

Tightening specification for turbocharger and flange on

turbocharger

Double hexagon head screw M8x25

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 10
2. 23

Double hexagon head screw M10x25 140235

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 10
2. 46

Hexagonal nut M8
Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 10
2. 23

Hexagonal nut M10

Lubricant -
Thread-locking adhesive - 140236
Stage Torque in Nm
1. 10
2. 46

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 General information Repair manual
Technical Data

Tightening specification for generator belt pulley

Hexagonal nut M14x1.5

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 35+10

Hexagonal nut M16x1.5

Lubricant -
140068
Thread-locking adhesive -
Stage Torque in Nm
1. 70

Hexagonal collar nut M16x1.5

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 80 ± 5

Tightening specification for flywheel housing

Hexagon socket head screw M12-10.9

Lubricant -
Thread-locking adhesive -
Stage Torque in Nm
1. 45
2. 110

180157

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 Repair manual General information
Technical Data

Tightening specification for flywheel

CAUTION
Torx anti-fatigue bolts may not be used more than
once.

Torx anti-fatigue bolt M16x1.5x72-10.9 or

Torx anti-fatigue bolt M16x1.5x88-10.9
Lubricant Engine oil
Thread-locking adhesive -
Component contact sur- Degreased
140377
faces
Stage Torque in Nm
1. 30
2. 90
Stage Angle of rotation in °
3. 90
4. 90
Overall 180 ± 5

CAUTION
Torx anti-fatigue bolts may not be used more than
once.

Torx anti-fatigue bolt M16x1.5x147-10.9

Lubricant Engine oil
Thread-locking adhesive -
Component contact sur- Degreased
faces
Stage Torque in Nm
1. 30 140377

2. 90
Stage Angle of rotation in °
3. 90
4. 90
5. 90
Overall 270 ± 5

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 General information Repair manual
Technical Data

Tightening specification for control unit-mount

Hexagonal screw M8-8.8

Lubricant -
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 10

140062

Tightening specification for power take-off

Thrust ring M40x1.5

Lubricant -
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 30
2. 240

Thrust ring M52x1.5

140063
Lubricant -
Thread-locking adhesive Loctite 243
Stage Torque in Nm
1. 30
2. 300

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 Repair manual General information
Technical Data

Tightening specification for SCR module (installed machine side)

141073

Pos. Designation Notes on operation

1 Input module (SCR catalytic converter) ........... d Installation position:
In compliance with the „FLOW DIRECTION“ ar-
row
2 Output module
3 Centring ring with seals.................................... d Replace screw plug wherever necessary.
4 Profile clamp .................................................... d 20 +/- 1 Nm.

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 General information Repair manual
Technical Data

141074

Pos. Designation Notes on operation

1 Sealing ring ...................................................... d Replace screw plug wherever necessary.
2 Profile clamp - input module............................. d 23 +/- 2 Nm.
3 Hinge bracket clamp......................................... d 12 +/- 1 Nm.
Installation point:
In areas A or B.
4 Profile clamp - output module........................... d 23 +/- 2 Nm.

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 Repair manual General information
Technical Data

240406
1.7.10 Cleaning agents, thread-locking adhesives and greases

This list includes all thread-locking adhesives and greases required for repair and maintenance tasks on the engine.
The application is described in the respective job specifications.

Note
9 Should a thread-locking adhesive be required, first clean, degrease and dry the respective screw thread
and threaded bore.

Cleaning agents and thread-locking adhesives

Designation ID no. Quanti- Designation

ty
Omniclean 10007113 500 ml or Loctite 7063
Omnivisc 1050 8627609 090 g or Loctite 601, Reinzoplast, Hylomar SQ 32 / M
Loctite 243 8628192 250 ml
Loctite 262 8700012 250 ml or Omnifit 100 M
Loctite 270 / 2701 8700011 250 ml or Omnifit 200 M
Loctite 278 811200908 050 ml
Loctite 577 8622905 250 ml
Loctite 648 8655023 250 ml or Omnifit 230 M

Greases

Designation ID no. Quanti-

ty
Molykote Longterm 2 Plus 8100714 1.00 kg
Staburags NBU 30 10285708 1.20 kg
Copper compound; 10002552 0.85 kg
Motorex 14
Lubricating compound; 10490569 80 g
Altemp QNB 50
High-temperature spray; 861203005 400 ml
Anti Seize ASW

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 General information Repair manual
Representations of the engine and engine components

1.8 Representations of the engine and engine components 240409

1.8.1 Gear train (D934)

140937

A Aggregate carrier side B Flywheel side

1 Gear wheel - power take-off 4 4 Gear wheel - power take-off 3
2 Gear wheel - cam shaft 5 Gear wheel - high-pressure pump
3 Gear wheel - coolant pump 6 Gear wheel - power take-off 1
7 Gear wheel - power take-off 2 or air compressor
8 Idler
9 Gear wheel - cam shaft
10 Gear wheel - crankshaft
11 Idler
12 Gear wheel - oil pump
13 Gear wheel - counterbalancing shaft left
14 Idler
15 Gear wheel - counterbalancing shaft right
16 Gear wheel - cam shaft

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 Repair manual General information
Representations of the engine and engine components

1.8.2 Gear train (D936 / D946)

140938

A Aggregate carrier side B Flywheel side

1 Gear wheel - power take-off 4 4 Gear wheel - power take-off 3
2 Gear wheel - cam shaft 5 Gear wheel - high-pressure pump
3 Gear wheel - coolant pump 6 Gear wheel - power take-off 1
7 Gear wheel - power take-off 2 or air compressor
8 Idler
9 Gear wheel - cam shaft
10 Gear wheel - crankshaft
11 Idler
12 Gear wheel - oil pump
13 Gear wheel - oil suction pump
14 Idler
15 Gear wheel - cam shaft

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 General information Repair manual
Diagram of the fuel system

1.9 Diagram of the fuel system 240410

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 Repair manual General information
Diagram of the fuel system

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 General information Repair manual
Diagram of the fuel system

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 Repair manual General information
Diagram of the fuel system

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 General information Repair manual
Diagram of lube oil system

1.10 Diagram of lube oil system

140036

1 Oil suction 14 Rocker arm, rocker arm support

2 Oil pump 15 Tappet
3 Oil duct 16 Cam shaft journal bearing
4 Oil pressure relief valve 17 Cam shaft thrust bearing
4.1 Piston 18 High-pressure pump with drive
4.2 Spring 19 Power take-off
A = Idle position 20 Oil duct crankshaft
B = Cut-off position 21 Crankshaft journal bearing
5 Cold-start valve 22 Turbocharger (one-stage or two-stage)
6 Oil cooler 23 Active pressure channel for oil pressure relief
valve
7 Bypass valve-oil cooler 24 Connecting rod bearing
8 Oil cooler housing 25 Small end bush
9 Coolant pump 26 Oil spray nozzle
10 Oil filter 27 Crankshaft thrust bearing
11 Power take-off 28 Air compressor or power take-off
12 Oil duct camshaft 29 Power take-off
13 Oil pressure sensor

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 Repair manual General information
Diagram of lube oil system

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 General information Repair manual
Diagram of coolant system

1.11 Diagram of coolant system

140044

1 Coolant pump
2 Thermostat housing
3 Cylinder liner
4 Hose connection - expansion tank supply
5 Hose connection - expansion tank supply
6 Vent line cylinder head
7 Cylinder head
8 Coolant collector rail
9 Coolant distributor rail
10 Oil cooler
11 Hose connection - return flow heater
12 Coolant drainage
13 Hose connection - supply heater

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 Repair manual General information
Diagram of coolant system

140935

1 Coolant pump
2 Thermostat housing
3 Cylinder liner
4 Hose connection - expansion tank supply
5 Hose connection - expansion tank supply
6 Vent line cylinder head
7 Cylinder head
8 Coolant collector rail
9 Coolant distributor rail
10 Oil cooler
11 Hose connection - return flow heater
12 Coolant drainage
13 Hose connection - supply heater
14 Coolant cooler (machine side)
15 Connection -
Inflow exhaust after-treatment system
16 Connection -
Return flow exhaust after-treatment system

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 General information Repair manual
Allocation of ducts in the crankcase and in the cylinder head

1.12 Allocation of ducts in the crankcase and in the cylinder head

140936

A Air induction pipe side 1 Push rod

B Exhaust pipe side 2 Oil supply (pressure oil)
3 Cylinder head bolt
4 Engine identification
5 Coolant return flow
6 Cylinder head bolt with insertion sleeve
7 Coolant supply 1
8 Oil return flow
9 Coolant supply 2
10 Combustion chamber

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 Repair manual General information
Tools

240411
1.13 Tools

1.13.1 Special tools

Lifting beam

WARNING
_6 Before starting up the lifting beam, read the description included in delivery, as well as the affiliated notes
on safety thoroughly, and ensure that all instructions are strictly adhered to.

180075

Pos. Designation Identifi- Comment

cation
number
1 Lifting beam 10815480 Lift capacity 2500 kg
1.1 T-spline None For three-point linkage
1.2 I-mounting pipe None
1.3 Chain suspension None With pink, fluorescent powder coating
1.4 I-spline None For two-point linkage
1.5 Sticker for slinging points None
Note: When ordering Pos. 1, all parts for Pos. 1.1 to 1.5 are delivered.

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Tools

Lifting beam with two-point linkage for D934 and D936 / D946

180079

Pos. Designation Identifi- Comment

cation
number
1.2 I-mounting pipe None
1.3 Chain suspension None With pink, fluorescent powder coating
1.4 I-spline None For two-point linkage

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 Repair manual General information
Tools

Lifting eyes D934

WARNING
The lifting eyes of the diesel engine are designed
exclusively for lifting the respective weight of the
_6 engine.
Dismantle gears or other accessories prior to lifting
the diesel engine!

141052

Lifting eyes D936 / D946

WARNING
The lifting eyes of the diesel engine are designed
exclusively for lifting the respective weight of the
_6 engine.
Dismantle gears or other accessories prior to lifting
the diesel engine!

141053

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 General information Repair manual
Tools

Securing the lifting eyes onto the crankcase D934 / D936

/D946

Note
9 With the aggregate carrier and flywheel housing dismantled, the special tools prescribed as follows can
be attached to the crankcase for lifting of the crankcase.

t Special tool

140353 140354

WARNING
The lifting eyes are designed exclusively for lifting
_6 the crankcase together with the accessories.
It is not permissible to lift complete diesel engines
with these lifting eyes.

1 t Lifting eyes [9076633] (1x aggregate carrier side)

2 t Lifting eye [9076634] (1x flywheel side)

140355

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 Repair manual General information
Tools

Engine assembly stand

WARNING
_6 Before starting up the engine assembly stand, read the description included in delivery, as well as the af-
filiated notes on safety thoroughly, and ensure that all instructions are strictly adhered to.

140855

Pos. Designation Identifi- Comment

cation
number
1 Engine assembly stand 10471324 Lift capacity 2500 kg
(portable, mechanical drive)
1 Engine assembly stand 10467805 Lift capacity 2500 kg
(portable, electrical drive)
2 Universal linkage 10467810 Lift capacity 2500 kg

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Tools

Distinguishing characteristics of the engine assembly stands

180054

Technical Data

Engine assembly 10471324 10467805

stand

Lift capacity 2500 kg 2500 kg

Drive Mechanical Electrical

Portable Yes Yes

Oil drip tray Yes Yes

Height adjustment Yes, by 350 mm No

with compressed air

Dimensions Width (X) =1730 mm Width (X) =1730 mm

Length (Y)=2240 Length (Y)=2240
mm mm
Height (Z) =1365 Height (Z) =1510
mm mm
to 1715 mm

Unladen weight approx. 1250 kg approx. 1100 kg

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Tools

Working area widening for the engine assembly stand

180053

Pos. Designation Identifi- Comment

cation
number
14 Working area widening (500x1500 mm) 10472385 Left-hand and right-hand
15 Working area widening (800x1350 mm) 10472386 Front;
Additional working area extensions can be
mounted as required.

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 General information Repair manual
Tools

Fastening the engine onto the engine assembly stand

WARNING
_6 Engine and crankcase are heavy!
t Use a lifting beam [10815480] for lifting the engine or the crankcase.

t Special tool

140831 140832 141054 140834

D934
1 t Bracket [10471375] (1x right)
2 t Bracket [10471374] (1x left)

141055

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 Repair manual General information
Tools

D936 / D946
1 t Bracket [10471375] (1x right)
2 t Bracket [10471374] (1x left)

3 t Bracket [11321073] (1x right)

4 t Bracket [10471376] (1x left)

141056

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 General information Repair manual
Tools

Lifting device for flywheels (SAE0, SAE1 and SAE2)

WARNING
_6 Before starting up the lifting device, read the description included in delivery, as well as the affiliated notes
on safety thoroughly, and ensure that all instructions are strictly adhered to.

180138

Pos. Designation Identifi- Comment

cation
number
1 Lifting device 11067454
1.1 Locking device None
2 Shackle None
3 Fastening bracket None
4 Fastening bolt M10x19 None
5 Fastening bolt M10x30 None
6 Fastening bolt M12x19 None
7 Fastening bolt M12x1.5x19 None
8 Fastening bolt M16x19 None
Note: When ordering Pos. 1, all parts for Pos. 2 to 8 are delivered.

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 Repair manual General information
Tools

SAE1-flywheel

140868

SAE2-flywheel

140869

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Tools

Turning gears

t Special tool

140051 140356 141057 141058 141059

Turning gear on the flywheel housing

Turning gear can not be mounted to SAE 2-flywheel housings
(arrow).

180001

The turning gear can not be adapted via subsequent adjust-

ment (arrow).

180002

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 Repair manual General information
Tools

Subsequent adjustment on the special tool

Turning gear [0524045]
Previously

180003

Current

180004

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Tools

The axle (1.1) of the turning gear (1) can be applied to the fly-
wheel housing due to casting tolerances (arrow).

1 Turning gear [0524045]

1.1 Axle

180165

Reworking on the special tool

Turning gear [0524045]
Rework the axle (1.1) as much as possible (arrows).
A Axle (without reworking)
B Axle (with reworking)

Note
The groove for the snap ring may not sustain any damage.

180167

Turning gear on crankshaft pulley - V-belt (included in de-

livery for some engine variants)
Can only be mounted subsequently if the respective
crankshaft pulley is featured.

140360

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 Repair manual General information
Tools

Turning gear on air compressor

Can only be mounted if the respective air compressor is fea-
tured.

140361

Turning gear on power take-off 4

Can only be mounted if the respective power take-off is acces-
sible.

141060

Turning gear on power take-off 2

Can only be mounted if the respective power take-off is acces-
sible.

141061

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Tools

Mounting bolts

t Special tool

140246 140238 140689 140687 140690 140048

140688

The mounting bolts are available in the following sizes:

ID no. Thread Length
in
mm
0524059 M8 160
0528472 M10 105
0524054 M12 085
0528471 M12 130
0524055 M14x1.5 200
0528470 M16x1.5 180
10118882 M18x1.5 150

Angle of rotation devices

t Special tool

140126 140411

Angle of rotation device [0524062] features a 1/2“ drive.

Angle of rotation device [10023839] features a 3/4“ drive.

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 Repair manual General information
Tools

Torx tools

t Special tool

140364 140365 140366 140367 140368

t Special tool

140399 140400 140401 140402 140403 140404

t Special tool

140405 140406 140407 140408

Torx toolkit [7014716] includes:

Designation Size Drive Designation Size Drive
Socket E8 1/4“ Socket E 18 1/2“
Socket E10 1/4“ Double-ended ring spanner E6 - E8 -
Socket E10 3/8“ Double-ended ring spanner E10 - E12 -
Socket E12 3/8“

The Torx sockets are available in the following sizes:

ID no. Size Drive ID no. Size Drive
7019851 E14 1/2“ 10119716 E18 3/4“
7021668 E18 1/2“ 10119717 E20 3/4“
7019852 E20 1/2“ 10119718 E24 3/4“
10354009 E24 1/2“ 8008601 TX30 1/2“
10119713 E18 3/4“ 10014369 TX40 1/2“
10119714 E20 3/4“ 10014368 TX45 1/2“
10119715 E24 3/4“ 8041994 TX50 1/2“

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Tools

Installing and dismantling the cylinder liner

t Special tool

140227 140228 140217

Notes regarding the special tools

Parts to be used for the D934 / D936:

3.1 Threaded rod of extractor [0526855]
3.2 Hexagonal nut of extractor [0526855]
3.3 Bridge of extractor [0528462]
Dimension A=170 mm
3.4 Extraction plate of extractor [0526855]
Diameter B ã 119.9 mm

Fit the extraction plate (3.4) onto the threaded rod (3.1) so that
the side featuring a diameter of B ã 119.9 mm is facing toward
the bridge (3.3).

Parts to be used for the D946:

3.1 Threaded rod of extractor [0526855]
3.2 Hexagonal nut of extractor [0526855]
3.3 Bridge of extractor [0528462]
Dimension A=170 mm
3.4 Extraction plate of extractor [0528462]
Diameter B ã 129.8 mm

Fit the extraction plate (3.4) onto the threaded rod (3.1) so that
the side featuring a diameter of B ã 129.8 mm is facing toward
the bridge (3.3).
140229

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1 - 98 D934 A7 SCR
mjfcifss D936 A7 SCR / D946 A7 SCR
 Repair manual General information
Tools

Checking excess length of the cylinder liners

t Special tool

140217 140230

Technical Data

D934 / D936 D944 / D946

Protrusion of cylin- 0.07 +0.03 / -0.02 0.07 +0.04 / -0.04

der liners to crank-
case joint face
in mm

Installing and dismantling the front crankshaft seal

.

t Special tool

140147 140148 141062

Notes regarding the special tools -

Different zero offsets for the front crankshaft seal can be ap-
plied for the various engine types.
Zero offset A = 30 mm.
Zero offset B = 20 mm.

Special tool [10116249] is suitable for engines featuring a

zero offset of B = 20 mm.

Special tool [11341934] is suitable for engines featuring a

zero offset of A = 30 mm and B = 20 mm.

Special tool [11341934] replaces special tool [10116249]; It is

141063
no longer possible to order special tool [10116249].

A zero offset of B = 20 mm can be applied to the engine type

specified here; Special tool [10116249] or special tool
[11341934] can therefore be used.

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D934 A7 SCR 1 - 99
D936 A7 SCR / D946 A7 SCR mjfcifss
 General information Repair manual
Tools

Installing and dismantling the crankshaft

t Special tool

140074

Installing and dismantling the piston with connecting rod and piston rings

t Special tool

140051 140217 140218

Installing and dismantling the piston rings

t Special tool

140220

Installing and dismantling valve stem seals, valve springs and valves

t Special tool

140369 140339

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1 - 100 D934 A7 SCR
mjfcifss D936 A7 SCR / D946 A7 SCR
 Repair manual General information
Tools

Installing and dismantling the counterbalancing shafts

t Special tool

140073 140074

Dismantling and installing the camshafts

t Special tool

141067

Installing and dismantling the injection lines

t Special tool

140128 140693 141064

[10020852] has a 17 mm width across flats.

[10289118] has a 19 mm width across flats.
[11171015] has a 22 mm width across flats.

Installing and dismantling the pressure pipe tube and injector

.

t Special tool

140080 140081 141065 141066

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D934 A7 SCR 1 - 101
D936 A7 SCR / D946 A7 SCR mjfcifss
 General information Repair manual
Tools

Installing and dismantling the flywheel

.

t Special tool

140865

Installing and dismantling the rear crankshaft seal

.

t Special tool

140147 140156

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1 - 102 D934 A7 SCR
mjfcifss D936 A7 SCR / D946 A7 SCR