Manual de Motor D9406 Liebherr

Service·Maaual
Diesel Engine
D 9306/9308
D 9406/9408
Foreword
This manual contains a short description of maintenance.adjustment and repair procedures,

technical data infonnation and tightening torques for the 0 9306/9308 and D 9406/9408
LIEBHERR Diesel engines.
However, only skilled mechanics already familiar with most standard engine repairs should
perform these procedures.
This manual will not be updated. For any changes we therefore recommend that you refer
to any Service lnfonnation bulletins we issue periodically in this regard. When the manual is
reissued we will automatically incorporate any applicable changes.
No part of this manual may be reproduced or copied in any form or handed to outsiders
without our written permission.
This Service manual was written by Liebherr-Machines Bulle S.A , Dept Service-Diesel-
Engine and issued by the Service Dept., Liebherr-HydrauHkbagger GmbH, Kirchdorf/IHer,
Dept. vs.
Information is subject to change. LIEBHERR-MACHINES-BULLE S.A.
All rights reserved Dept.: Service-Diesel-Engine
Issue: Order No.:
03.2002 8717504 (english)

Index
1 Engine illustrations
2 Technlcal description
3 Engine description, engine data tag, cylinder description, direction of rotation and
engine identification number
4 Engine data, adjustment values, operating pl"888ures, operating temperatures and
fluid quantities
5 Torque specifications
8 Valve adjustment
7 Cylinder head gaskets
8 Cylinder head
9 Cylinder liner
10 Pl8ton and connecting rod
11 Check pt&ton clearance
12 Crankshaft and bearing
13 Camshaft and vaJve drtve
14 Lube oil circuit
15 011 pans
16 Lube oll pump
17 Lube oil filter and oil cooler
18 Coolant drcult
19 Water fitter
20 Coolant pump
21 Fan drive
22 Fuel •ystem
23 Fuelpump
24 Fuel fitter
25 lnj«tion pump
26 Injection pump drive, adjust begin of delivery
27 Fuel injector
28 Engine exhaust
29 Fan Md flywheel side crankshaft seal
30 Hydraulic pump auxlllary drive
31 Air compressor
32 Starter
33 Air conditioner compressor and alternator
34 Starting aid
35 Turbo charger
36 Gear drive - flywheel •Ide
37 Gear drive- fan aide
38 Maintenance and inspections
39 Service fluids
40 Troubleshooting
41 Special tools
1 Engine illustrations
Engine view: Left, as seen from the flywheel side onto the engine
1 Intake pipe - left

2 Starter
3 Exhaust pipe - left
4 Coolant outlet
5 Thermostat housing cover
6 Coolant intake
7 Oil pan
8 Coolant pump
9 Vibration damper
10 Fan
Engine view: B!sl!!l, as seen from the flywheel side onto the engine
11 Air compressor drive or hydraulic pumps - auxiliary driVe

12 Hydraulic pumps- auxiliary drive or air compressor drive
13 Oil separator
14 Flame glow plug
15 Fuel injection pump
16 Alternator
17 Dipstick
18 Oil filler neck
19 Injector nozzle
20 Intake pipe - right
21 Exhaust pipe - right
22 Valve caver
23 Cylinder head
24 Flywheel housing
25 Flywheel
26 Turbocharger
......
Datum I Edition I Date
03/2002
Benennung I Description / Denomination
Engine· illustrations
Typ
Model
Type
Blatt
0 930619308
D 9406/9408
Page
Feuille 1
2 Technical Description
Engine design
Water-cooled, 6- and 8-cylinder V-engine with LIEBHERR Direct Injection and turbocharger.
Characteristics
A simple sturdy basic construction and generous dimensions provide the foundation for high
operating safety and long service life. Low fuel consumption, low noise and exhaust emission are
achieved through a combustion process >Mlich is especially adapted to the engine requirements.
The overall cost efficiency cl the engine is enhanced by the low maintenance requirements of the
easily accessible components and by a diverse range of optional accessories.
Transmission
6-cylinder engines are equipped with a 4. way mounted steel cl8nkshaft (Split-Pin) I 8-cylinder
engines with a 5-way mounted steel crankshaft, with inductive hardened running surfaces and 4 I
8 bolted on counterweights. A vibration damper is installed on the fan side at the crankshaft.
Forge-pressed, beveled connecting rod, leaded bronze trimetal slide bearings, smooth shaft three
ring pistons made <:A alt.minium aDoy with ring support and combustion recess in the piston base.
Exchangeable, wet cylinder liners.
Housing
Crankcase accommodated in one unit made of alloy cast iron. Single cylinder heads with integral
intake guide channel and detachable valve seat rings and valve stem guides.
Flywheel casing, front timing case and oil pan on the underside form the engine boundary.
Engine timing
Per cylinder, one intake and exhaust valve, located on the cylinder head (ohv.).
Actuated by a steel camshaft with 4 or 5 bearings via steel tappets, push rod and rocker ann.
Drive of cam shaft, injection pump, lube oil pump, air compressor, water pump and auxiliary
hydraulic pumps by crankshaft via nitride gears on flywheel and fan side.
Lubrication
Force-fee lubrication through gear pump for crankshaft, connecting rod and camshaft bearings,
as well as piston pin bushing, tappet and rocker ann.
Oil filtration through tv.o disposable fitter cartlidges in the main circuit Auxiliary components, such
as injection pump and air compressor are connected to the engine lubrication circuit.
The engine oil cooler is integrated in the coolant circuit.
Cooling
Dual thermostatically regulated fluid cooling with centrifugal pump. Individual supply of each
cylinder unit via distributor channels in the crankcase. The pistons are cooled via oil spray from
the lubrication circuit of the engine.
Fuel injection system and regulation
Maintenance-free BOSCH in-line fuel injection pump with mechanical BOSCH centrifugal
regulator or electronic regulator (EDC), fuel pump with fuel filter, BOSCH four to six hole nozzles.
Flame starter
The flame starter is a cold starting assistance for low ambient temperature. It minimize the
emission of white smoke after starting the diesel engine. By reducing the starting period, the
starter and the batteries will be saved.
The flame spark plug, mounted in the air intake, will get fuel via a solenoid valve with dosaging
nozzle and oould set fire.
Electrical equipment
Starter and alternator: 24 Volt
Electronic sensors controHing the engine parameters

Air charge pressure sensor, temperature sensor at cooling agent and air charge, rotation sensor
and oil pressure sensor are indicators for the external control functions. Each function and error
signal are described in the corresponding user manual.
Benennung I Description I Denomination Typ

II' H*Rll Model
09306/9308
Type 9406/9408
Technical description
Blatt
03/2002 Page
Feuilte 2
Cross section
' i'
.......-~---,•
Ui II' •
Benennung I Description I Denomination
~I 0 9406/9408 Tm-E
Type
Blatt
03/2002 Page 2
FeuUle
Length section
•••4111811 Benennung I Description I Denomination
Typ
Model
Type
D 9406 TITl-E
Datum I Edition I Date Blatt

03/2002 Page
Feullle 2.1
3 Engine description, engine data tag, cylinder description,
direction of rotation and engine identification number
Engine description:
D 9306T • E A3
I I --i[Version I
I I
Emission
0 ptimized
jadded identification
Bore Stroke Number of

Diesel engine Year
(mm) (mm) cylinders
V·engine 93. 130 150 6/8

94. 135 150 6/ 8
Additional identification:
TB =moderately turbo charged

T =Turbo charged engine
Tl "' Turbo charged and intercooled engine
Version
A3 =P 7800 - Injection Pump
A 4 = P 7800-lnjection Pump+ EDC (Electronic regulation)
A5 =H-RP43-Control..sleeve injection pump
+ EOC (Electronic regulation)
Engine data tag:
The engine data tag is installed on the egine block on the left hand side of the crankase, as seen
from the flywheel. In some engines an additionel second data tag is installed on the air intake
pipes.
Data: Type =D 9306, 9308, 9406, 9408 TB, T, Tl
Mot.Nr. =Engine No.
Code =Output perfonnance code
t<:>N =Engine output in kW
1/min =Rated engine speed
Lieterumfang =Id. No. of engine configuration
In addition, the engine performance standard is noted in the lower left field.
Additional identification plate:
For additional data, an second identification plate might be installed.
Data: Code =Output perfonnance code

Field 1 = Id. No. Of the EU member country
Field 2 =Output per EU regulation R 24 or R 49
Field 3 =Authortzatlon No.
._ ....
03/2002
Beoennung I Description I Deoomination
Engine description, engine datatag,

cylinder description, direction of rotation
Typ
Model
Type
Blatt
09306/9308
9406/9408
Page
and engine identification number Feuille 3
Engine data tag
* lllBBE88 $-
[-. . . il~ - -... ....

1 _1~: cmwm :
__ckLU,..w
$ 1.-l_ _ _ _ ----JI I I $
Additional data tag
e l.IEBBE•8 $
CODEI
0 2 I 3
01 Et) (
2 I 3
:J e
I
.......
,
0312002
Engine description, engine data tag,

cylinder description, direction of rotation
Typ
Model
Type
Blatt
09306/9308
D 9406/9408
Page
and engine identiftcation number Feuille 3
3.1. Engine description, engine data tag, cylinder description,
direction of rotation and engine identification number
Engine data tag for ,,E" (emission optimized) engines from 1997:
Note
The text on the engine data tags on the engines is English. For clarification the text is
translated in German for the Service Manual.
Cylinder descriptiOn, directton of rotation
The cylinders are identified in mmber sequence, starting with cylinder 1 on the left, when facing
the flywheel. The cylinder numbers are engraved on the top of the crankcase, also in firing
sequence. The engine rotates counterciockv.rise when facing the flywheel.
Engine ldenttftcation number
The engine identification number is engraved in the engine data tag and in the crankcase.
On the crankcase the engine identification number is located on the top of cylinder 4 (on the 6
cylinder engine) or on cylinder 5 (on the 8 cylinder engine).
Engine number - example
2002 11 0050
year 6 cylinder running number

=
12 8 cylinder
0 IMPORTANT ENGINE INFORMATION 0
eHGtNE NUMBER ;:M::::;OOEl.=l'----....- - - . J' C:J
ENGifE OISPlACEMENT (LITERS)
IHJECTIOH TIMlNG (DEOAEES BTDC) t.
AJa. AATfi tCU81C mml.ST~>-
INTAKE VN..Vf. lASH (mm) . _ l-~ EXHAU5'T 'llALV! LASH (mml
ua a>AAND<:At.IFOANIAA/e
REGUlATION FOA NO~
COMPRESSION·IGNmON 'ENGINES.
LIEBHERR MACHINES BULLE S..A. MADE IN SWITZ£RLAND
0 0
Engine data tag
Cylinder description
Turning direction
8
4
6 7
3 3
5 6
2 2
4 5
1 1
Typ
uwm Benennung I Deacription I Denomination
Model
Type
09306/9308
D 9406/9408
Engine description, engine data tag,
Blatt
0312002 cylinder description, direction of rotation Page
and engine identification number Feuille 3.1
Engine data: D 9306/9308
Working procedure: Four cycle Diesel engine
Combustion procedure: Direct injection
Bore: 130mm
Stroke: 150mm
Total volume: D 9306= 12dm3

D 9308= 16 dm3
(2 dm3 per cyl.)
Nominal RPM: 1500, 1800, 1900, 2000, 2100 RPM
Compntnion ratio: 09306TB = 17,0 : 1

09306Tffl = 15,5 : 1
D 9308TITI = 15,5 : 1
Firing order: 6cyl. = 1-6-3-5-2-4

8 cyl. = 1-8-4-2-7-3-6-5
Firing distance in°KW: 6 cyl. = 150-90-150-90-150-90 = 720°
6 cyl. with split pin crankshaft

= 120-120-120- 120-120-120 = 720°
......
0312002
Benennung I Des~tioo I DenominatiOn
Engine data, adjustment values,

operating pressures, operating
Typ
Model
Type
Blatt
Page
09306/9308
temperatures and fluid quantities Feoille 4

Adjustment values:
Begin of delivery in °KW v .OT: 09306TB = 20 :t 1

D 9306 TfTI n = 1500/1800 RPM =20± 1
D 9306 TfTI n = 2100 RPM = 15± 1
D 9308 T n = 1800 RPM =24± 1
D 9308 Tl =
n 1500/1800 RPM = 20± 1
09308 Tl =
n 2100 1/min =15±1
Valve play: Intake cold = 0,25 mm

Exhaust cold =0.30 mm
Operating pressures:
Compression pressure: 09306TB = 20-28 bar

D 9306 TfTI, D 9308 TfTI = 18-26 bar
Injection pressure: New = 225 • bar
8
Operating pressure = 217 •a bar
Minimum lube oil pressures at at nominal RPM = 3,5 bar

Engine operating temperature: at 1400 RPM =2,5 bar
at 800 RPM = 1,5 bar
Minimum pressure in cooling system at nominal RPM = 1,5 bar
With engine at operating temperature
(thennostats open) measured on the
coolant pump outlet:
Operating temperatures:
Coolant temperature, maximum: 100°C
Thennostats-opening temperature: 71 °C, 80°C
Lube oil temperature, maximum: 115°C
Oil quantities:
Lube oil in oil pan : 6 cyl. =max/min 21/12 ltr.
8 cyl. =max/min 25,5115,5 ttr. ) depending on oil
28,0/16,5 ltr. ) pan version
Marks on dipstick are the determining factor
Benennung I Descri>llon I Denomination Typ

lllllHIRll Model
09306/9308
Type
Blatt
03/2002 operating pressures, operating Page
temperatures and fluid quantities Feuffle 4.1.
Engine data: D 9406/9408
Working procedure: Four cycle Diesel engine
Combustion system: Direct injection
Bore: 135mm
Stroke: 150mm
Total volume: 0 9406= 12,9 dm3

0 9408= 17,2 dm'
(2,15 dm3 per cyl.)
Nominal RPM: 1500, 1800, 1900, 2000, 2100 RPM
Compression ratio: 0 9406 TfTl-E = 17,2 : 1

0 9408 Trrl-E =17,2: 1
Firing order: 6 cyl. =
1- 6 - 3- 5 - 2 - 4
8 cyl. = 1 - 8 - 4 - 2 - 7 - 3 - 6 - 5
Firing distance in °KW: 9 cyl. = 120-120-120- 120-120-120 = 720°

(split pin crankshaft)
8 cyl. = 90 - 90 - 90 - 90 - 90 - 90 - 90 - 90 =720°
•••••••
Datum f Edition f Dale

Typ
Model
Type
Blatt
09406/9408
0312002 operating pressures, operating Page

temperatures and fluid quantities Feuille
4.2 .
Adjustment values:
Begin of delivery in °KW v. OT: 0 9406 T/Tl-E A3 n =1800/1900 RPM =16 ± 1

D 9406 T/Tl-E A3 n =200012100 RPM =14 ± 1
D 9408 T/Tl-E A3 n =180012000/2100 RPM =16 ± 1
For data, see engine data tag.By A5-engines is the
delivery begin in degress crank angle according to OT
(= upper death point).
Valve play: Intake cold =0,25 mm

Exhaust cold =0,30 mm
Operating pressures:
Comprenlon pressure: 0 9406 T/Tl-E = 20-28 bar
D 9408 TfTl-E = 20-28 bar
Injection pressure: New = 225 +a bar

Operating pressure = 217 +a bar
0 9406Tl-E from 320kW and D 9408 TI-E from 440 WI

New = 300 ..a bar
Operating pressure = 292 •a bar
Minimum lube oil pressures at at nominal RPM = 3,5 bar

engine operating temperature: at 1400RPM = 2,5 bar
at 800RPM = 1,5 bar
Minimum pressure in cooling system at nominal RPM = 1,5 bar

with engine at operating temperature
(thermostats open} measured on the
cooland pump outlet:
Operating temperatures:
Coolant temperature, maximum: 100"C
Thennostats-opening temperature: 71°C, 60°C
Lube oil temperature. maximum: 115°C
Oil quantities:
Lube oil In oil pan: S cyl. = max/min 21/12 ltr.
42/32 ltr. ) depending on
8 cyl. =max/min 25,5115,5 ltr. ) oil pan version
28116,5 ltr. )
52142 ltr. )
Marks on dipstick are the determining factor
·-==·
0312002

operating pressures, operating
temperatures and fluid quantities
Typ
Model
Type
Blatt
Page
Feuilie
09406/9408
4.3
For sequence
· · · -Deacri.ption · 'Torque specifications and data,
.
:~SJ~
,s·; "'· . .
~, ~·
:.~s -~ . -:
.
f-.. '
~... ;. . ,. .
~;_:A· , .. ' ........ seepaae
" '
pretorque
Cylinder head screws Nm30 Nm 90 + 4"60 + 60 +60 + 60 = 240 8
Cylinder head screws. retorque ~ 0 90 8
Screws for rocker ann support M 10x 70 M 10 x 120 (ZBS) 13

Nm65 Nm75
Connecting rod screws 10

pretorque Nm 50 ~
0
60 + 60 + 60 = 180
Main bearing screws 12

For data, see page 12
Screws for counterweight to

crankshaft
pretorque Nm 30 ~ 0
45 + 35 + 35 =115 12
Screws for gear to balancer

•
Nm70
shaft (balancer)
Stud for fitting of balancer at Nm40

crankcase
Flywheel screws pretorque Nm 50 -« 0

50+50 = 100 29
Nm 190 - 320 320 =
Screws for fan side end of pretorque Nm 30 -« 30+200
= 50 29
crankshaft Nm 90-130 = 130
*
~
0
pretorque M 10x1.5x55 30+20=50
Screws for flywheel side gear on
Nm30 Nm40-75= 75
camshaft
~
0
M 12x1.5x55 30+30=60
Nm 90-150= 150
•
~
0
pretorque M 10x1.5x55 30+20=50
Screws for fan side gear on
Nm30 Nm40-75= 75
camshaft
M 12x1.5x55 -« 0
30+30=60
Nm 90-150= 150
· · --
Screws for connection of cam- pretorque Nm 10 Nm37

shaft gear to idler gear flywheel
side
.......
Datum I Edition f Date
0312002
Benennul'IQ I Description I Denomination
Torque specifications
Typ
Model
Tvoe
Blatt
Page
D 9306/9308
09406/9408
Feuille 5
For sequence
Description Torque specifications and data,
-
aee oaae
Screw on injection pump drive pretorque Nm 80 Nm 300 26, 26.1
Screws for connection gear

wheel injection pump pretorque Nm 20 Nm 75 26.1
drive-hub
Nut for gear shaft on i~ection M20x1,5 M24x 1,5 25126

pump Nm 150 • 10 Nm355
Injection valve mount Nm23 27

0 9306/9308 09406/9408
Union nut for injector nozzle Nm 50 • 20 Nm 40 +10 27.1
Injector lines Nm20

••
Piston cooling nozzle Nm30 10
••
Injector nozzle for gear
lubrication Nm30
Screw for coolant pump mount

•
Nm20 20, 20.1
Screw (lubrication nozzle) for

•
coolant pump mont. Nm20 20.2
Coolant end bearing
•
Coolant pump impeller wheel
Nm 30+4 20
retaining bolt
•
Coolant pump impeller wheel
Nm70+5 20.1, 20.2
nut
•
Coolant pump drive gear wheel
Nm 30.,. 20, 20.1
retaining bolts
Screw for hub on fan drive pretorque Nm 30 M 16x 1,5x80

21
Nm270
Screw for hub on fan drive with pretorque Nm 30 M 16x 1,5x 140
fan coupfing (2 speed) 21
Nm270
Screw for idler pulley on fan Nm 230

drive 21.4
Typ
'*' IWll
Datum I Edition I DMe
Benennurni I Deseti>lion I Denomination
Model
Tvne
09306/9308
09406 1 9408
Blatt
0312002 Page
Feuille
5.1
For sequence
Description Torque specifications and data,_
: ~' :><.; see paae
Screw for exhaust manifold on M 8x 50 M8x80

cylinder head Nm25 Nm36
•
Two hole nut on the hydraulic pretorque Nm 30 Nm240 30.3
pumodrive
Alternator pulley lock nut M14 x 1,5 M16 x 1,5 M24 x 1,5 M27 x 1,5
Nm 35+10 Nm 50:5 Nm 135±5 Nm 155:ttS
Air compressor drive gear wheef M 16x1,5 M 20x 1,5 M 20 x 1,5 31

lock nut Nm 00•10 (SW=30mm) (SW= 27 mm)
Nm 150 Nm200
• Screw retaining fluid = Loctite 243

•• Screw retaining fluid = Loctite 262
........
0312002
Benennuna I Descrjption I Denomination
Typ
Model
Tvoe
Blatt
Page
09306/9308
09406/9408
Feuille
5.2
Screw tightening torques
For screws per OIN912, 931, 933, 960. 961
Permissible tolerance ± 10%
Surfilce condition : Screw Mn or Zn phosphatized, not lubricated 0< oiled µ ges. • 0. 14
8.8 10.9 12.9 8.8 10.9 12.9

Standard Fine thread
thread Nm Nm Nm Nm Nm Nm
M6 10 15 18 M8x1 27 39 46
M8 25 36 43 M10x1.2S 52 76 90
M10 49 n 84 M12x1.25 93 135 160
M12 85 125 145 M 12x1.S 89 130 155
M14 135 200 23S M14xt.5 145 2 15 255

M16 210 310 365 U 16x1.S 225 330 390
M18 300 4 30 500 M 18x1 .5 340 485 570
M20 425 610 710 M20x1 .5 475 680 790

M22 580 820 960 M22xt.S 630 900 1050
M24 130 1050 1220 M24x2 800 1150 1350
Surfa~ condition: Screw galvanized, not lubricated or oiled p ges. =0.125
M6 9,6 14 16 M8x1 25 37 43
M8 23 34 40 M10xt25 49 71 83
M10 ~ 67 79 M12x1.25 87 130 150
M12 79 115 135 M12x1.5 83 120 . 145
M14 125 185 220 M14x1 .S 135 200 235
M16 195 290 340 M 1~1 .S 210 310 360
M18 280 400 470 M 18x1.5 315 450 530
M20 395 560 660 M20x1.5 440 630 730

M22 540 760 890 M22x1.5 590 840 980
M24 680 970 1150 M24x2 740 1050 1250
BenennunQ I Description I Denomination Typ

llWIW Model
09306/9308
TVDe D 9406/9408
Datum I Edition I Date Torque specifications Blatt
03/2002 Page
FeuMle
5.3
6 Valve adjustment
Valve play: Intake cold =0,25 mm
Exhaust, cold =0,30 mm
Valves of cylinder
D 9306 / 9406 D 9308/9408
Overlap Adjust Overlap Adjust
5 1 7 1
2 6 3 8
4 3 6 4
1 5 5 2
6 2 1 7
3 4 8 3
4 6
2 5
E : Intake valve
A • Exhaust valve
.......
03/2002
Benennu!lfl I Descriotlon I Denomination
Valve Adjustment
Typ
MOclel
Tvne
Blatt
Page
09306/9308
D 9406/9408
Feuille
6
6.1 Valve adjustment
Engine auxiliary brake system (ZBS)
Function ,,ZBS'' for engine brake operation:
If the engine brake flap is closed. pressure waves are building up in the exhaust pipe,
which cause the outlet valve to "reopen•. The outlet valve is reopened for a short time
every time the flap closes.
Due to the fact that the piston 5 is under pressure, it is ~pushed after" the opening outlet
valVe, but cannot return, since the adjustment screw 1 closes off the relief bore 6 ad the
check valve in piston 5 closes off the oil supply bore.
This causes the outlet valve to remain open by about 1,5 to 2 mm during the
compression stroke and the subsequent expansion cycle (downward movement of the
piston).
Check the valve clearance:
Inlet valve: Check as without nZBS".
Qutlet valve: Tum the crankshaft until the valves opposite the cylinder, which is to be
adjusted overlap (see chart, page 6).
Push the rocker lever with a screwdriver several times onto the valve in the area of
piston 5 until no more oil escapes from the relief bore 6.
Insert a feeler gauge between the outlet valve and piston 5 and check the valve
clearance.
Adjust the valve clearance:
Inlet valve: Adjust as without .zas·
OuUet valve: Loosen the lock nut 2 and tum the adjustment screw 1 out as far as
possible without using force.
Loosen the lock nut 4 and tum the adjustment screw 3 back until a 0,50 mm feeler gauge
can be inserted between piston 5 and the valve.
Tum in the adjustment screw 3 until it clamps on the feeler gauge. The piston 5 is pushed
back. Set the valve play of 0,50 mm on adjustment screw 3, tighten the !Ocie nut 4.
Push the feeler gauge 0,30 mm between piston 5 and the valve.
Push the rocker lever with the screw driver in the area of piston 5 onto the valve, until
piston 5 stops. Hold piston 5 down and tum in the adjustment screw until the valve
clearance is set. Tighten lock nut 2.
After adjustment, check the clearance by turning the plunger rod 7, it must have some
play.
2----'- r;-r-~~r--~.L..-"'-r-!.LL--4-...J...
1-_..........
3
\-+--7
'
.
\
\
1 Adjuetment screw
2 Lock nut
3 Adjus1ment screw
4 Locknut
5 Piston
6 Relief bore
7 Rod
1•·-
Datum f Edition I Date
BenennullA I Description I Denomination
Valve -adjustment ,,ZBS"

Typ
Model
Tvne
Blatt
0930619308
09406/9408
0312002 Page
Feuille
6.1
7 Cylinder head gaskets
At the D 9306 I 9308 I 9406 1 9408 engines asbestos-free soft material cylinder head gaskets
are installed.
The sealing to the combustion chamber will take place by a reinforcing ring of steel, Which is
reinforced by a steel lining.
The oil- and cooling agent bores are additionally seated on both sides by a silicon edge.
The cylinder head gaskets are the same for the engines D 9306 I 9308 I 9406 1 9408.
••••Wll BenennuM I Descriotlon I Denomination
Cylinder head gaskets

Typ
Model
Tvoe
D 930619308
09406/9408
Blatt
0312002 Page
Feulle
7
8 Cylinder head
Individual cylinder heads are installed in transverse current principle. The inlet Channel
is designed as a twist channel.
The connection to the crankcase is made via 6 screws. Valve guides 1 and seat rings 2
are inserted in the cylinder head and can therefore be replaced.
Depending on the engine type, one or two vcive springs are installed on the outlet vcive.
On D 9400 I 9408 engines the installation of vatve shaft seal rings is standard.
Valve seat angle:
D 930619308 09406 /9408

Inlet valve = 30° Inlet valve = 30°
Outlet valve = 30° Outlet valve =45°
Valve spring:
D 9306/9308 p 9406/9408
Outer spring: Length not tensioned, nonnal =
57 mm =67,5mm
Length not tensioned, fatigue limit = 55 mm =66mm
Inner spring: Length not tensioned, normal = 56,5 mm =55,5mm

Length not tensioned, fatigue limit = 55 mm =54mm
With engine brake, Outer spring:
Length not tensioned. normal = 58,6 mm

Length not tensioned, fatigue limit =
57 mm
Allen head screws: Length normal = 170 - 1,5 mm

Length limit value = 171,5 mm
Tightening torque specification:
Pretorque Nm 30 Nm 90 + 4 • 60 + 60 + 60 + 60 =240
After installation run the engine until warm, let it cool off and re-tighten When cold.
Re-tightening value: 4 ° 90
Sequence:
6
I
-r
1 Valve guides
2 Valve seat rings
3 Inlet valve
4 Outlet valve
5 Spring plate, bottom
6 Spring plate, top
7 Valve springs, out:lide
8 Valve spring, inside
9 Valve stem
10 Valve shaft seal rings
uw•.-•
BenennunQ I Description I Denomination
Cylinder head
Typ
Model
TVNI
D 9306 / 9308
09406/9408
Blatt
03/2002 Page
Feuille
8
9 Cylinder Liner
The cylinder liner 1 is a wet liner.

It is sealed to the engine block on the collar side with an 0-ring 2.
Two 0-ring 3 are used to seal the side on the bottom to the engine block.
To remove: Remove the cylinder head and oil pan, remove the piston with
connecting rod and pulJ out the cylinder liner with a special puller.
Note: In case the cylinder liner is reused, ma~ the cylinder liner and finer
bore before removal on the engine block.
lnetaUatlon: Clean the liner bore, the sealing surface and the recess for the liner
flange and the seat for the 0-rings in the engine block, lightly grease
the 0-rings and press the cylinder liner into the engine block.
Cylinder liner protrusion to crankcase:
The cylinder liner protrusion .A" to the crankcase is + 0,03 to + 0,08 mm.
A
" "
1 Cylinder liner
2 0-ring (collar side)
3 0-rings (bottom side)
1.11••--
•
Datum I E<fllion I Date

Benennurm f Oescr1>tlon I Denomination
Cylinder Liner
Typ
Model
Tvne
Blatt
D 9306 I 9308
0 9406 I 9408
03/2002 Page g
Feuille
10 Piston and connecting rod
Piston
All engine models use the 3-ring piston 1 with cast ring carrier 2 for the upper seal ring.
The difference between the pistons is a different combustion cavity 3, shabe and
diameter for individual engine models.
Piston rings: Different diameters: D 9306/9308 0 piston 130 mm

D 9406/9408 0 piston 135 mm
D 9306 TB - engines:
Ring 4 =Dual trapezoid ring, chrome-plated and convex

Ring 5 = Minute ring, all sides iron oxidized
Ring 6 = Hose spring ring chrome-plated (oil scraper ring)
D 9306/9308 TITI - engines:
Ring 4 = Dual trapezoid ring covered with Molybdan, convex

Ring 5 + 6 same as D 9306 TB-engines.
D 9406 / 9408 TITI - engines:

Ring 4 =Dual trapezoid ring covered with chrome-ceramics asymmetric convex
Ring 5 + 6 some as D 9306/9308 TB I T I Tl - engines
Note:
When installing the piston rings, the top mark must point to the piston bottom.
Piston pin:
The pin 7 (0 52 mm) is pressure lubricated via the bored connecting rod 8. It is floating
in the piston and attached with retaining rings.
Piston cooflng nozzle:
All engine models are equipped with piston cooling nozzles 9.
Opening pressure: 0,8 - 1 bar, Tightening torque= Nm 30, retaining fluid Loctite 262 or
Omnifrt 100 M.
Piston and connecting rod removal and instaHation:
Removal:
Remove the cylinder head and the oil pan. Loosen the mounting bolts 10, tum crankshaft
until the connecting rod bearing cap points in the direction of the piston cooling nozzles 9
or the counterweights points to the side of the oil pan.
Loosen the connecting rod screws 1Oand remove the bearing cap 11 . Push the piston 1
with connecting rod 8 through the cylinder liner. Remove the bearings shells from the
connecting rod/bearing cap..
Note:
If the pistons 1 or liners are reused, reinstall them as a pair. Do not mix up the connecting
rod bearing shells.
Installation:
When installing the piston onto the connecting rod 8, the side with the larger dimension -
swirl chamber 3 outside of the piston 1 must point towards the marked side of the
connecting rod. The marked connecting rod side must be positioned to the center of the
engine.
Position the piston rings on rods to each other and tighten with piston ring compressor.
Push the connecting rod 8 and piston 1 into the cylinder liner. First set the connecting rod
side of the bearing shell onto the crankshaft pin. The two recesses on the bearing shell
ending must point together and must point in direction of the pin on the bearing cover.
Then push the connecting rod 8 slighUy onto the bearing shell. Tum the bearing shell on
the pin until both marks (2 x V-marks) on the bearing shell are visible to the gear of the
connecting rod 8. Set the bearing shell on the bearing rxN« 11 side on the connecting
pin and install the bearing CCNer 11 in such a wa.y that the pin in the bearing cover 11
aligns with the bore of the bearing shells and the marks to the connecting rod 8 match.
Install the mounting screws 1O and tighten according to tightening torque.
Note:
With regard to the new motor generation the pin fixing of the connecting - rod bearing
has been changed into nose fixing. The described mounting instruction is valid for the pin
fixing. At the connecting - rod bearing with nose fixing the bearing box could already be
fitted in the connecting rod 8 resp. in the cover 11 of the connecting - rod bearing during
the mounting. Make sure that the nose of the bearing box is in the groove.
Mounting bolts: Length nonnal = 74 -0,6mm

Length limit value = 74,5mm
Tightening torque connecting rod: Pretorque Nm 50 ;('. 0 60 + 60 + 60 =180
Benennung f Description I Denomination Typ

Model
0 9306/9308
Type 09406/9408
Datum I Edition I Date Piston and Connecting Rod
Blatt
0312002 Page
Feuille 10
4 --_:,-,,.....;_;~~/
5 ---
6 --~
7 ~-~...,..=---'"'""""'...-_,....-.-
10
11
10
Mark
Connecting rod
1 Piston 1 Piston pin

2 Ring carrier 8 Connecting rod
3 Combustion chamber 9 Piston cooling nozzle
4 Dual trapezoid ring 10 Connecting rod bolts
5 Minute ring 11 Bearing cap
6 Scraper ring
Benennuni:i I DescriPtion I Denomination Typ D 9306/9308

IM'HW MOdel
Twe 09406/9408
Datum I Editlon I Date Piston and Connecting Rod Blatt
03/2002 Page
Feuille
10
11 Check piston clearance
The clearance between the piston and cylinder head should be 1, 17 to 1,76 mm.
Check the piston dearance when changing piston, connecting rod, crankshaft or
crankcase.
To "'9aaure:
Set a test bracket with 2 test gauges across the engine on the crankcase. Measure
the highest point of the piston to the crankcase.
Determine the medium value (measurement A) between the two measured values
and compare it with the chart below to determine the appropriate gasket size.
Note:
The t'M> test points must be at the given value of 120 mm.
The values in this chart are valid only for these test points.
Chan - Measurement- piston dearance
Menurement A (mm} Cylinder head Cylinder head

Medium value of 2 gasket "Thlckn888'' gasket
test DOints
- 0,241o + 0,09 1,3mm Soft gasket

~120 mm
t=r;Fft~~7?.-~--t~--....,...,~~~~~o I
<(
I
.........
0312002
BenennunA I Descr¥>tion I Denomination
Check piston clearance

Typ
Model
Tvoe
Blatt
P;ge
09306/9308
D 9406/9408
FeuRle
11
12 Crankshaft and bearings
On 6 cylinder engines, the crankshaft 1 has 4 bearings and on the 8 cylinder engine it has
5 bearings.
For each bearing pin 2, there are two counterweights 3 installed. A 6 cylinder split pin
crankshaft has only counterweights on the outer bearing pin (cylinder 1, 4 , 3, 6). A pressfit
bearing 4 with two thrust bearing caps 5 is in the crankcase side of the engine. At the new
engines generation also two butting rings are mounted in the lapped bearing cover.
When inserting thrust bearing caps 5, make sure that the lubrication pockets are installed
towards the crankshaft.
The main bearing pins 6 have a diameter of 108 mm. The connecting rod pins 2 at D 9306/
9306 engines have a diameter of 90 mm. On the 6 cylinder split pin crankshaft it has a
diameter of 97mm. At the D 9408 engines the connecting rod pins 2 haVe a diameter of
90 mm, the new engines generation have 97 mm.
To prevent vibrations, a vibration damper is installed on the fan side on all engine models.
Bearing cap numbers:

Starting from the flywheel side, the bearing caps are numbered 1, 2, 3 etc. In the
crankcase the bearing cap numbers are mari(ed on the first main bearing (flywheel side)
and on the last main bearing.
In addition, the crankcase number is marked on the underside of the crankcase, opposite
the fan side bearing seat.
All bearing caps are marked with the crankcase number.
The numbers are marked on the left side, when viewed from the flywheel side toward the
engine.
Crankcase position: Oil pan points upward.
Note:
The main bearing cap numbers and the crankcase numbers must match during installation.
Tightening torques - main bearings:
Sequence , 2 3 4
Pretorque so 60 60 50
Nm
1. stage 4 • - 45 45 -
2 . stage A • - 45 45 -
3 . rtage .4. - 45 45 -
4.stage A • 90 - - 90
tot.al A• 90 i3s 135 90
Crankcase view: from the fan side to the engine.

Sequence:
z 3
4.- r\)
~
3 - -,,.:.-
6-----,,,..,..-
1 Crankshaft
2 Bearing pin
3 Counterweight
4 Prwsftt bearing
5 Thnaat bearing
6 Main bearing pins
.......
0312002
Benennuni:1 I Desc:r\?tion I Denomination
Crankshaft and Bearings

Typ
Model
Tvoe
Blatt
09306
Page
Feullle
12
6 Cylinder Split Pin Crankshaft
I
I .
l . ..
2 1 6 3
1 Crankshaft
2 Bearing pin
3 Counterweight
6 Main bearing pin
........
0312002
Benennu~ I Detcr1>tion I Denomination
Crankshaft and Bearings

Typ
Model
Tvne
Blatt
Page
D 9306 / 9406
Feuille
12.1
'----2
1 Crankshaft
2 Bearing pin
3 Counterweight
4 Pressfit bearing
6 Thrust bearing
6 Main bearing pin
Beneonuna I Description I Denomination Typ

1•1u11•• Model
Tvoe
09308 / 9408
Datum I Edition I Date Crankshaft and Bearings Stat
03/2002 Page 12.2
Feuille
13 Camshaft and valve drive
The camshaft 1 is made of tempered steel. The cams and surfaces of the bearing
pins are hardened.
The valves are driven via a plunger 2, steel push rods 3 and rocker arm 4.
These parts are the same for Intake or delivery valves.
camshaft bearing In 1he cnankcaee: 6 cylinder engine =4 x

8 cylinder engine =5 x
Cam stroke inlet = 8,Smm
Cam stroke outlet = 9mm
Control times: Inlet opens 15° KW from OT

Inlet closes 45° KW after UT
OuUetopens 54° KW from UT
Outlet doses 14° t<JN after OT
=
KW= Kurbelwinkel crank angle, OT = Oberer Totpunkt = upper TC,
UT= unterer Totpunkt = Lower TC.
Tightening torques for screw 5:
M 10 x 70 M 10 x 120 (ZBS)
Nm65 Nm 75
--1
1 Camshaft
2 Plunger
3 Steel push rods
4 Rockerami
5 Screws for rocker ann support
••••w•
Datum I E~ion I Date
Benennung I Oescllltion I Denomination
Camshaft and Valve Drive

Typ
Model
Type
Blatt
D 9306/9308
D 9406/9408
0312002 Page
Feullle 13
14 Lube oil circuit
Schematic view of a D 9308 I 9408 engine
1 Oil pan
2 Suction funnel
3 Lube oil pressure pump
4 Control valve (opening pressure 9 ± 1 bar)
5 Oil filter
6 Oil cooler
7 Bypass valve (opening pressure 6 :t: 1 bar)
8 Piston cooling nozzle
9 Main bearing - crankshaft
10 Connecting bearing
11 Piston pin
12 Camshaft mount
13 Valve plunger
14 Rod
15 Rockerann
16 Connection for fan drive
17 Connection for i~ection pump
18 Drive for injection pump
19 Connection for turbo charger - left
20 Connection for air compressor or hydraulic pump auxiliary dnve
21 Connection for hydraulic pump auxiliary drive or air compressor
22 Connection for turbo charger - right
23 Limit valve
20 21
19
Flywheel side
4
2 - -----
1
\
Benennuna / DescriPtlon I Denomination Typ

Model D 9306 / 9308
Tll!l9 0 9406/9408
Datum I Edition I Dale Lube Oil Circuit Blatt
0312002 Page 14
Feuille
15 Oil pans
Lube oil in oil pan: Permissible incline position to all sides:
D 9306/9406 max= 21 ltr. Oil pan - Standard execution = 45° (100 %)

min =12 ltr. Oil pan -flat execution = 25° (55 %)
09406 max= 42 ltr. = 45° (100 %}

min = 32 ltr.
D 930819408 max = 25.5 ltr. Oil pan - standard execution = 45° ( 100%)
min = 15,5 ltr. Oil pan-flat execution =20° (44%)
D 9308/9408 max =28 ltr. =30° (66%)

min = 16,5 ltr.
09408 max= 52 ltr. ·= 45° (100 %)

min =42 ltr.
6 cyl. oil pan
8 cyl. oil pan •
- - -·. . .-:.. ·-----·
Benennunsi I Description I Denomination Typ

IH. I U8 Model
TYO&
D 930619308
D 9406/9408
Datum I Edilioil I Date Oil Pans B1att
03/2002 Page
Feuille
15
16 Lube oil pumps
D 9306 I 9308: Pressure pump

D 9406/9408
RPM: Engine = 1500 11800 11900 12000 / 2100

1
n /min
Pressure pump n /min = 2250 / 2700 / 2850 13000 / 3150
1
Gear width: 27 / 36mm
Output: Gear width 27 mm= 95 Umin I 2250 1/min

1
114 1/min I 2700 /min
1
120 I/min I 2850 /min
127 1/min I 3000 11/min
135 IJmin I 3150 /min
36 mm = 1
127 I/min I 2250 /min
152 I/min I 2700 1/min
161 I/min I 2850 1/min
170 I/min I 3000 1/min
180 I/min I 3150 1/min
Axial play of gear, nonnal: 0,05 - 0,12 mm
Limit value: 0,22mm
Tooth gap of intennedlate gear 2: 0 ,15 - 0,25 mm

On pump to crankshaft gear
Motor position: Oil pan side points up
Relief valve 6, relief pressure: 9 ± 1 bar
Removal
Remove the oil pan and the suction pipe from flange 4 on the pump. Remove screws 5 and
remove the pump from the crankcase.
Installation
Install the pump to the crankcase. The surface 3 must touch the main bearing CCNer. Pay
attention to the tooth mesh between intermediate gear 2 and crankshaft gear. Lightly tighten
screws5.
Adjust the tooth gap between intermediate gear 2 and crankshaft gear with a depth gauge
by moving the pump. Tighten screws 5. Install the suction pipe with a seal to flange 4 and
install the oil pan.
Pressure pump
5 4 pressure chamber
1 Gear type lube oil pump

2 Intermediate gear for lube oil pump drive
3 Surface
4 Flange for suction pipe
5 Mounting screw suction chamber
6 Reflef valve
IM•DW•
Benennuno I Description I Denomination
~el D 9306 / 9308
Tme D 9406 I 9408
Datum I Edition I Date Lube Oil Pumps Blalt
03/2002 Page 16
Feuille
17 Lube oil filter and oil cooler
The oil cooler is installed on the oil cooler housing, to the right of the crankcase, if seen from
the flywheel.
The lube oil filter might be installed . hanging" on the oil cooler housing or away from it,
depending on the type of engine.
If it is installed aNay from the oil cooler housing, then the connections must be affixed as
shown on the following page.
Removal
Drain the coolant on plug 4. Remove the lube oil filter 5 from the oil cooler housing 2. If lube
oil filter are installed away from the oil cooler housing, remove the oil lines from the oil cooler
housing 2. Remove the connector screws from the oil cooler housing 2 to the crankcase.
Remove the oil cooler housing 2 with the oil cooler 1 from the crankcase.
Installation
Install the oil cooler housing 2 complete 'Nith oil cooler 1 and new seal to the crankcase.
Install the lube oil filter 5 or oil lines to oil lines to oil cooler housing 2. Install the coolant drain
plug 4 and add coolant. Check the engine oil level, add more oil if necessary.
Note
Depending on cooler size, it ls possible that an intermediate plate is installed between oil
cooler housing and crankcase.
Lube oil filter installed ,,hanging" on the oil cooler housing
Lube oil filter installed away from the oil cooler housing
Connection from fitter
ConnecUon to fllter
1 Oil cooler
2 011 cooler housing
3 Bypass valve
(opening pl"898ure 6 :.t 1 bar)
4 Coolant drain plug
5 Lube oll filter
u••c:w• BenennunQ I Descriotlon I OeoomlnatlOn Typ

~
D 9306 I 9308
D !M0& / 9408
Datum I Edition I Date Lube Oil Filter and Oil cooler Blatt
0312002 Page 17
Feuille
Lube oil filter installed ,,upright" on the oil cooler housing
----3
~-----5
6 Oil cooler
7 Oil cooler housing
8 Bypass valve
(opening p1888ure 6 :t 1 bar)
9 Coolant drain plug
10 Lube oil filter
IM W• BenennunQ I Descril>tlon I Denomination ~~ D 930619308

Tvoe 0 9406 / 9408
Datum I Edition I Date Lube Oil Filter and Oil cooler Blatt
0312002
~=lie 17.1
18 Coolant circuit
Schematic view on D 9308 I 9408 engines
1 Coolant pump
2 Line to heater
3 Return line from heater
4 Coolant drain
5 Oil cooler housing
6 Cylinder liner bushing, cylinder heads
7 connections for bleeder line
8 Thennostat housing, thermostats
9 Wat.er filter
10 Wat.er cooler
Opening begin of thermostats= 11 ·c, 80°C

4 5
10 , 6
.._
,
Benennun~ I DescriPtion I Denomination
C()()lant circuit
Typ
Model
Tvtl8
Blatt
D 9306/9308
p 9406/9408
0312002 Page
Feu~le
18
19 Water filter
To improve the quality of the coolant water filters are installed on the newer engines or on
E-engine.
Due to this measure, the coolant is filtered in the auxiliary flow and is cleared of dirt or rust
particles.
In addition, due to a chemical additive in the water filter (DCA 4 ), the coolant system or any
parts which come in contact with the coolant, such as coolant pump, cylinder liners etc. are
protected from cavitation, corrosion, scale deposits and foam fonnation.
Water fitters are installed ext~ly at the engine resp. at frame.
For water filter change intervalls, see maintenance and inspections.
For coolant mixture, see Service fluids.
To change the water fitter:
Close the shut off valves 1,2. Remove the water filter element 3. Clean the sealing surface
on the filter console.
Install new water filter element 3, lightly lubricate the rubber seal ring with oil and tlghten by
hand. Open the shut off valves 1, 2. Check the coolant level, add more coolant as nec:essary.
2
1 Shut off valve

2 Shut off valve
3 Water fitter
......
Datum I Edition f
Benennung f Description /Denomination
Water filter
Typ
Model
Type
0 9306 / 9308
D &406 /9408
Dale Blatt
Page
03/2002 Feuille 19
20 Coolant pump
to engine No. 9712 0299
The coolant pump is driven via a gear.

1
RPM: Engine n /min = 1500 / 1800 / 1900 / 2000 / 2100
Coolant pump n1/min = 2875 / 2468 12605 / 2742 / 2879
2829 3300
Output
approx. 4501/min/2468 1/min, approx. 480 Vmin/2605 1/min\ approx. 500 lfmin/2742 1/min,
approx. 520l/min/2829 1/min. approx. 530 Vmin/2875/2879 /min, approx. 6101/min/3300 1/min
Note
The coolant pump must be replaced or repaired if increased coolant or oil flow is found on
the two leakage bor on the timing case cover next to plug 2.
Removal
Drain the coolan~ remove the cover 1, loosen lock nut 9 and screws 2. Remove the screws 2
with lock nut 9, ca.rer 1Oand washer 11 from the timing case COi/er.
Pull the coolant pump with a puller from the timing case cover.
Installation
Install new 0-rings 3. UghUy grease the coolant FXJTIP on 0-rings 3 and the surface between
the 0-rings or the receptacle bore in the timing case cover with grease (staburags NBU 12).
Insert the coolant pump into the timing case until the cutout in the coolant pump housing and
the positioning screw 4 in the timing case are aligned YAlen the coolant pump is pushed in.
Apply Loctite 243 to the thread of screw 2 and screw it in and tighten according to tightening
torque.
Bring cover 1O into the correct position to the leakage bore, counter screw 2 and tighten the
lock nut 9.
Check the gap ~ gear and timing case with a depth gauge. Install cover 1 with new
0-ring 5 and add coolant
Tightening torque for screw 2 • Nm 20

Gap between gear and timing case =1 - 1,3 mm
Note
The gap dfmension is the complete dimension on both sides of the gear. When checking the
gap with a depth gauge, use haff the value.
Important
Before operating coolant pLRTlp, make sure that coolant has been added.
1
1- - - -·1
6--_,.:.:..~.;-'f
2 9 1011
1 Cover
2 Srew to hold coolant pump
3 0-rtnga
4 Positioning screw for
cootant pump housing
5 0-ring
6 Gear
7 Slip ring seals
8 Shaft seal ring
9 Locknut
10 Cover
........ 11 Washer

0312002
BenennunQ t OesoriPtion I Denomination
Coolant Pump
Typ
Model
Tvoe
Blatt
Page
D 9306/9308
0 9406/9408
Feullle
20
20.1 Coolant pump
from engine No. 9712 0300
The coolant pump is driven via a gear.
RPM: Engine
1
n /min = 1500/ 180011900 / 200012100
Coolant pump n 1/min = 2875 I 24681260512742 / 2879
2829 3300
Output:
1 1 1
approx. 450l/min/2468 /rnin, approx. 480 l/rnin/2605 /min, approx. 500 l/min/2742 /min,
1 1
approx. 520!/min/28291/min, approx. 530 l/min/2875/2879 /min, approx. 610!/min/3300 /min
Note
The coolant pump must be replaced or repaired if increased coolant or oil flow is found on
the two leakage bor on the timing case cover next to plug 2.
Removal
Drain the coolant, remove the cover 1, loosen lock nut 9 and screws 2. Remove the screws 2
with lock nut 9, cover 10 and washer 11 from the timing case <X7tfer.
Pull the coolant pump with a puller from the timing case cover.
Installation
Install new 0-rings 3. Lightly grease the coolant pump on 0-rings 3 and the surface between
the 0-rings or the receptade bore in the timing case cover with grease (Staburags NBU 12).
Insert the coolant pump into the timing case until the cutout in the coolant pump housing and
the positioning screw 4 in the timing case are aligned when the coolant pump is pushed in.
Apply Loctite 243 to the thread of screw 2 and screw it in and tighten according to tightening
torque.
Bring cover 10 into the correct position to the leakage bore, counter screw 2 and tighten the
lock nut 9.
Check the gap between gear and timing case with a depth gauge. Install cover 1 with new
O-ring 5 and add coolant
Tightening torque for srew 2 = Nm 20

Gap between gear and timing case ... 1 - 1,3 mm
Note
The gap dimension is the ccmplete dimension on both sides of the gear. When checking the
gap >Mth a depth gauge, use half the value.
Important
Before operating coolant pump, make sure that coolant has been added.
----;------,
'!~- -- -- -- --/ I
...---4-l-.. -- - -- - - -
( ) ( - - -----+-......__ _ 4
5
'i
1
11
10
9
2
1 Cover
2 Srew to hold coolant pump
3 0-rings
"4 P08ftioning acrew for
coolant pump housing
5 0-ring
6 Gear
7 Slip ring seals
8 Shaft seal ring
9 Lock nut
10 Cover
11 Washer
.......
Datum I Edition I Diie
0312002
Benennunsi I Deacmtion I Denomination
Coolant Pump
~el
Tvoe
Blatt
D 9306 I 9308
D 9406 / 9408
~=:le 20.1
20.2 Coolant pump
with collar bearing (bushings)
The coolant pump is driven by a gear.
RPM: Engine
1
n /min = 1500 / 1800 / 1900 / 2000 / 2100
Coolant pump
1
n /min = 2875 / 2468 / 26051274212879
2829 3300
1 1
Output approx. 450Vminl2468 /min, approx.480t/min/2605 /min
approx. 5001/min/27421/min, approx.520l/min/2629 1/min
1
approx. 530t/min12875128791/min, approx. 610l/min/3300 /min
Note
The coolant pump must be replaced or overhauled if increased cooland or oil discharge is
found on the two leakage bores in the timing case near the mounting screw 4 (lube oil
nozzle).
Removal
Drain the coolant. remove cover 1. Remove the hollow screw 2. Remove the lube oil line 3
on the crankcase. Loosen the mounting SCffNl4 (lube oil nozzle) and remove.
PuU the coolant puTip with the pu8ing device from the timing case.
Clean the threaded bore, leakage bore and intake bore in the timing case.
Installation
Install new Q-rings 5. Lubricate the coolant pump on the 0-rings 5 and on the surface
between the 0-rings 5 or the intake bore in the timing case with grease (Staburags NBU 12).
Push the coolant pump into the timing case in such a way that the recess in the coolant
pump housing and the positioning screw in the timing case match when the coolant pump is
pushed in.
Apply a new 0-ring to the mounting screw 4 (lube oil nozzle) and apply a retention fluid
(Loctite 243) to the threads insert and tighten according to torque specifications.
Measure the distance ,,AM between the installation surface CCNer 1 and the outer impeller 8
with a slip gauge.
Note
The coolant pump is installed correctfy if the noted gap is retained. Install the lube oil line
with new seal rings to the mounting screw (lube oil nozzle) and install on tne crankcase.
Measure the gap between the impeller 8 and the bore in the timing case with a feeler gauge.
Install cover 1 with new 0-ring 9 and add coolant.
Tightening torque for mounting screw" • Nm20
Distance ,,A" between the Installation surface cover 1 and the outer Impeller 8
=5 •11 -0.1 mm
Gap between the impeUer 8 and the bore in the timing case= 1 -1 ,3 mm
Note
The given dimension is the complete dimension on both sides of the impeller. When
checking the dimension with the feeler gauge, use half the value.
Caution
Make sure that coolant has been added before operating the coolant pump.
........
0312002
Benennullil I Descriotion I Denomination
Coolant Pump
Typ
Model
Tvoe
Blatt
0 9306/9308
0 9406/9408
Page
FeuHle
20.2
Au
"
1 5
8
12
11
1 Cover
2 Hollow screw
3 Lube oil line
4 Mounting screw
(lube oil nozzle)
S 0-rings
6 Positioning screw
7 0-ring
8 Idler
9 0-ring
10 Shaft sealring
11 SUpring seal
12 Gear
Benennunsi I Description I Denomination
Datum I Edition I Date Coolant Pump

=el
Typ
Blatt
0 9306 I 9308
D 940619408
0312002 Page 20• 2
Feuilte
21 Fan drive
The fan can be driven on the motor via a gear drive, gear drive and fan coupling or via a
V-belt.
Drive with gear and V-belt for alternator
Removal I Disaasembly
Loosen screw 1 and remove it Remove the fan drive from the timing case CCNer. Remove
screw 2 and remove fan hub 3 with V-bett pulley 4 from the bearing hoillMng 5 or from the fan
shaft 6.
Remove the fan shaft 6 from the bearing housing 5 and lift out the shaft seal ring 1o.
Note
For fan drive installed on motor, to disassemble and assemble the fan drive we recommend
to loosen and tighten screw 2, v.tiile holding the gear on the flywheel .
Assembly / Installation
Press in new shaft seal ring 1O into the bearing housing 5. Lubricate the sealing and
protective lip lighUy with grease (Barrierta L 5513).
Insert thrust washer 7 into the bearing housing 5 and push in the fan shaft 6. Insert the fan
hub 3 with V-belt pulley 4 onto fan shaft 6, paying attention to the pin. Insert screw 2 and
tighten according to tightening torque. Set new 0-rings 8 or 9 with grease into the grooves of
the bearing housing 5 and timing case cover. Push the fan drive Into the timing case cover,
making sure that gear teeth mesh. Insert screws 1 and tighten.
Tightening torque for screw 2: Pretorque Nm 30 Nm 270

3 10 5 1
1 Screws to mount fan drive to timing case

2 Screw to mount fan hub to fan shaft
3 Fan hub
4 V-belt pulley
6 Bearing houeing
6 Fan shaft
1 Thrust washer
8 ()-ring
9 0-rlng
......
10 Shaft seal ring
Benennuni:i / Oescric>tloo I Denomination Typ

Model
D 9306/9308
Tvoe D 9406/9408
Datum I Edition I Date Fan Drive Blalt
0312002 Page
Feuille
21
21.1 Fan drive
Fan drive with gear
Removal I Disassembly
Loosen screw 1 and remove it Remove the fan drive from the timing case cover. Remove
screw 2 and remove fan hub 3 from the bearing housing 4 or from the fan shaft 5.
Remove the fan shaft 5 from the bearing housing 4 and lift out the shaft seal ring 10.
Note
For fan drive installed on motor, to disassemble and assemble the fan drive we recommend
to loosen and tighten screw 2, while holding the gear on the flywheel.
Assembly/ lna1allation
Press in new shaft seal ring 9 into the bearing housing 4. Lubricate the sealing and
protective lip lightly with grease (Barrierta L 55/3).
Insert thrust washer 6 into the bearing housing 4 and push in the fan shaft 5. Insert the fan
hub 3 onto fan shaft 5, paying attention to the pin. Insert saew 2 and tighten according to
tightening torque. Set nem 0-rings 7 or 8 with grease into the grooves c:A the bearing
housing 4 and timing case cover. Push the fan drive into the timing case cover, making sure
that gear teeth mesh. Insert screws 1 and tighten.
Tightening torque for tlCl"9W 2: Pretorque Nm 30 Nm270

3 9 4 8 7 6 5
1 Screw to mount fan drive to timing case

2 Screw to mount fan hub to fan shaft
3 Fan hub
4 Bearing housing
5 Fan shaft
6 Thrust washer
7 0-ring
8 0-ring
9 Shaft seal ring
Benennunsi I De&cr1>tion I Denomination Typ

Model D 9306/9308
Tvoe 09406/9408
Datum I Edition I Date Fan Drive Blatt
0312002 Page
FeuUle
21.1
21.2 Fan drive
Drive with gear and fan coupling
Note
If the fan drive does not reach the required RPM, for exam ple if there is a problem in the
current supply, etc., then the fan coupling can be blocked mechanicaly. Insert two
screws M 6x10 tightly through a hole in the angle 1 into the threads in the cooling fin
ring 2.
Removal I Disassembly
Remove the cable 3 from the distributor point. Loosen nuts 4 and remove. Remove the
fan drive from the timing case CCNer. Remove SCfeN 5, remove washer 6 and remove
fan hub 7 with fan coupling 8 from the bearing houSing 9 or from the fan shaft 10.
Remove the fan shaft 10 from the bearing housing 9 and lift out the shaft seal ring 11.
Note
For fan drive installed on motor, to disassemble and assemble the fan drive we
recommend to loosen and tighten screw 5, while holding the gear on the flywheel.
.A9aembly I Installation
Press in new shaft seal ring 11 into the bearing housing 9. Lubricate the sealing and
protective lip lightly with grease (Barrierta L55/3). Insert thrust washer 12 into the
bearing housing 9 and push in the fan shaft 10. Insert the fan hub 7 with fan coupling 8
onto fan shaft 10, paying attention to the pin. Attach washer 6, insert screw 5 and
tighten according to tightening torque. Set new 0-rings 13 or 14 iMth grease into the
grooves of the bearing housing 9 and timing case CCNer. Push the fan drive into the
timing case CCNer, making sure that gear teeth mesh. Install nuts 4 and tighten. Connect
the cable 3 to the distributor point.
Tightening torque for screw 5: Pretorque Nm 30 Nm 270

7 1 2 14 13 12 10
5 11 8 4 3 9
1 Angle 8 Fan coupling

2 Cooling fin ring 9 Bearing housing
3 Cable 10 F•n ahaft
4 Nuts 10 mount fan drive- 11 Shaft seal ring
timing case
5 Screw to mount fan hub-fan 12 Thrust washer

•haft
6 Washer 13 0-ring
7 Fan hub 14 0-rtng
u•••IBlll BenennuOQ I Oesctlotion I Denomination
Fan Drive
Typ
MOdel
Tvoe
D 9306/9308
09406/9408
03/2002 Page
Feu~le
21.2
21.3 Fan drive
Fan drive with V-bett
Check V-belt tension
Check by hand
The fan belts are tightened property If they can be pushed down in the center of the
pulley of crankshaft and fan drive by about 10 mm.
Checking with test measurement
The correct tension of the fan belt can be checked 'Nith the test measurement given on
next page.
Adjustment
Loosen screws 1, 2, 3 tum the tension screN 5 counterclockwise until the correct belt
tension Is reached. Retlghten screws 1, 2, 3.
Recheck belt tension.
To replace the V-belt
Remcwe the fan, loosen screws 1, 2, 3, 4 tum the tension scrf!N/ 5 clockwise until the
tension pulley 6 is turned in the direction of the crankshaft. Remove the V-belt, install
new V-belt and retighten everything. Reinstall fan.
To lubricate the fm1 drtve
Lubricate the tensioning device according to the maintenance directions with multi
purpose grease.
7
5----:::~W+Di
1----.
2
3
1 Screw to tighten tensioning device

2 Same
3 Screw for vibration damper
4 Same
5 Tensionlng screw
6 Tension pulley
7 V-belt for fan drive
BenennunQ I Descrl>tion I Denomination ~el 0 9306 I 9308

Tvoe 0 9406 I 9408
Datum I Edition I Date Fan Drive Blatt
0312002
~=le 21.3
21.4 Fan drive
Fan drive with V-belt
Check V-belt tension
Check by Hand
The V-belt is tensioned correctiy if it can be pushed down on the given measuring point
with a force of 75 N by 6 mm.
Check with "Krlkit 2" tester ld.-Nr. 8042829:
Lower the indicator arm A in the test unit, set the fest unit on the given measuring point.
Push the button O evenly at a right angle to the V-belt until the spring disengages.
Carefully remove the test unit and read the value on the point of intersection of the
.KG" scale and the indicator arm A
Compare the test value with the chart.
16 50-55 35-40
Adjustment
Loosen the screws 1, 2, 3 loosen the lock nut 4 on adjustment screw 5 and tum the
adjustment screw 5 in clockwise direction until the correct V-belt tension is obtained.
Retlghten all screws / lock nut Check the V-belt tension again.
Change V~elt
Loosen screws 1,2, 3 loosen the lock nut 4 on adjustment screw 5 and tum the
adjustment screw 5 in counterclockwise direction to the stop. Remove the V-beft. Place
new V-belt and adjust Retighten everything.
Important
Let new V-belt run approx. 15 - 20 minutes, then recheck the tension and retension, as
necessary.
7
5 2
1 Screw
2 Screw
3 Screw
4 Locknut
5 Adjustment screw
6 Tension pulley
7 V-belt for fan drive
........
03/2002
BenennunQ I Oescri>tioo I Denomination
Fan Drive
Typ
~~
Blatt
D 9306 I 9308
D 9406 I 9408
~=le 21.4
22 Fuel system
The fuel pump 3 draws fuel from the tank 1 through the precleaner 2 and pumps it under
Pressure via the fuel prefilters 4 and the fuel fine filter 5 to the suction chamber of the
injection pllllp 6 .
The fuel is held there at a pressure of approx. 1,3 to 2 bar via the overflow valve. The fuel is
Pressurized and flows from the injection pump 6 via the iflectlon lines to the fuel injectors 7.
From there it is atomized and sprayed into the combustion chamber.

Excess fuel from the injection pump 6 and from the fuel injectors 7 is returned to the fueJ
tank 1.
On fuef systems with prefilter 4 with water separator between the fuel tank 1 and the fuel
pump 3, the precleaner 2 and the prefilter 4 between fuel pump 3 and injection pump 6 are
not Installed. This design protects the fuel pump 3 from wear.
To bleed the fUel system:
Proceed as follows in that order.
1 Loosen the bleeder screw on the fuel prefilter 4 .

2 Loosen the bleeder screw on the fuel fine filter 5.
3 Loosen the fuel line from the fuel fine filter 5 to the injection pump 6 on the injection
pump.
4 Loosen the overflow valve 8.
5 Loosen the union nuts on the injection lines on the fuel injectors 7.
From point 1 to 4, actuate the hand pump on the fuel pump 3 until fuel emerges without air
bubbles. Retighten the screws.
At point 5, actuate the starter until fuel emerges without air bubbles. Retighten the lines.
Note
If there is a prefilter 4 between the fuel tank 1 and the fuel pump 3, the bleeder screw on the
fuel filter does not have to be opened.
7 -----
........ ....
4 5
t
·1 .:
1 Fuel tank Preeaurized

2 Pre-cleaner
3 Fuel pump - - - - • Retum pipe
4 Fuet pre.filter
5 Fuel fine fitter
6 Injection pump
7 Fuel Injector nozzle
8 Overflow vlave
Benennu~ I OeseriPtion I Denomination Typ

1""11&111 Model
D 9306/9308
Tvoe D 9406/9408
Datum I Edition I Date Fuel system 8la1
0312002 Page
Feuille
22
23 Fuel pump
On the engines. a simple supply pump made by Bosch is installed on the injection pump. It is
actuated via a dual cam on the camshaft of the injection pump. Due to the dual cams, two
cam lifts are made per revolution.
Function
During the cam lift. the pt.mp piston 13 with the integrated suction valve 2 is moved by the
glide plunger 9 against the force of the spring 7. Due to the vacuc.m created in the chamber,
the suction vaJve 2 is opened and fuel flows through the openings in the piston bottom into
the chanber between suction valve 2 and pressure valve 6.
During the return stroke by the spring 7, the suction valve 2 closes, the pressure valve 6 is
opened and the fuel is supplied via the pressure line and on via the filter to the injection
pump.
Note
If the 0-ring 10 on the fuel pLmp leaks, Diesel fuel will get into the engine oil via the injection
pump!
Design
9
1 Pump housing 10
2 Suction valve
3 Spring cup 11
4 0-ring
5 Pressure
12
connection 13
6 Pressure valve
7 Pressure spring 14
8 Spring cup
9 Glide plunger 6 __• __. jjc~~HJI) -- ~
10 0-ring 15
11 Plunger housing
12 0-ring 7~~~~~~~---.~ 1
13 Pump piston (3=~9~
14
15
Spacer
Suction
8------
connection
Function Spring stroke

Cam lift 1 Working chamber
2 Suction chamber
IWlllll8
BenennunQ I Descri>tion I Denomination ~I 0 930619308
Tvoe 0 9406 I 9408
Datum I Edition I Dae Fuel Pump Blatt
03/2002
~=le 23
24 Fuel filter
On eariier engine models, the fuel filter was installed as a fuel stage box filter between the
fuel p1.n1p and the injection pooip.
The prefilter 1 had a filter sensitivity of 50 - 60 µm, the fine filter 2 of 7 - 8 µm.
Drain plugs (see arrows) are Installed on the underside of the filter.
On neY1er engine models, the prefilter 3 is installed between the fuel tank and the fuel pump
and the fine filter 4 between fuel pump and Injection pump. This design protects the fuel
pump from wear.
The prefilter 3 has a fitter sensitivity of 3Qi.m, the fine filter 4 cJ 7 - 8 µm.
Drain plugs (see arrows) are installed on the underside of the filter.
On fuel filter 3 iMth inspection possibilities for water content, check water level. Drain off
water, as necessary.
For maintenance inteJVals to drain condensation, refer to the Maintenance Schedule.
To change the fuel fitter
For change intervals, see Maintenance Schedule.
1,3 = Prefilter 2,4 =Fine filter

Remove the filter elements and clean the sealing surface on the filter console.
Remove the container d water separator 5 from the pre-filter 3, dean and attach it with new
oiled sealing ring on the new filter element.
Install new filter elements, lubricate the rubber seal ring lightly with oil and tighten by hand.
To bleed the fuel system, see page 22.
Stage box filter
Typ
lllBHEllll Modt i D 9306 19308
TVOO 0 940$/9408
Oat.um I Edltiort I Oate Fuel Filter
0312002
24
25 Injection pumps
On Engine models D 9306/930819406/9408 in - tine injection pumps made by Bosch, pump
size 0 P" are installed.
Depending on the engine version, injection pumps, size P 3000 or P 7800 are also used.
Engine models D 9406/9408 Tl-E A S are also made with other injection pumps.
·. , ,
• ~. .'f.. ·' -. - .•·
' EngtM RPMthniO' . . lnjec1ion · .,.Pump Injection pump ·.

;>. ' . .,i . ~
;. pump_~ regulator,
' • ; !
:i
;~~~.;-:;jj,:··_.·,;~ ·. ,t~ piRon .,· . ..'
. :·~~: !v-~;~~~~1r;--~
I
·:~· . ~':; I ~ '"(,I
·~.lameter l.DA lnatlllhdlon
·;.: .. ~Ao;~t~;,~t}'' '. : . .., .· -~
.. . ·,0ftll· -
;
D9306TB 1800 P3000 11 RSV
D9306T 1600 P3000 11 RSUV
09306T 1800 P3000 11 RSV
09306TI 1800 P3000 11 RSV/LOA
D9306TI 2100 P7800 12 RQV/LOA
09308T 1800 P3000 11 RSV/LOA
09308TI 1500 P3000 11 RSV
09308T 2100 P7800 12 RQV/LOA
0 9406 Tl-E A3 1800 P7800 12 RSV/LOA
D 9406 Tt-E A3 1900/2000/2100 P7800 12 RQV-K/LOA
09406Tl-EM 1900/2100 P7800 12 EOC
D 9408 T-E A3 1800 P7800 12 RSV/LOA
D 9408 Tl-E A3 1800 P7800 12 RQV/LDA
0 9408 Tl-E A3 1800/1900 P7800 12 RQV-K/LDA

2000/2100
0 9408 Tl-E A3 1800/1900 P7800 12 RSV/LOA
09408Tl-EM 1800/1900/2100 P7800 12 EOC

Removal
Installation on Injection pump drive, page 26
For positioning, see page 26.
Remove RPM control, shut off device, electrical lines, air lines to suction pipe (LOA
installation), fuel lines, injection lines and lube oil lines. On A4-engines with EOC regulator,
remove the mounting screw for the electric plug on the EDC regulator and pull the plug from
the regulator. T he injection pump must be without power, tum the ignition off.
Remove the mounting screws on the injection pump. Pull the injection pump from the
crankcase. If the coupling ring 2 also comes out when the pump is removed, set it back onto
the hub 4 on the injection pump drive. The screws 6 on the coupling ring 2 must point in
direction of the flywheel. For positioning of coupling ring 2 to hub 4 in such a way that the
gap on the hub 4 and tension pin 5 in the coupling ring 2.
Installation
Install new O~ring 7 and lubricate it lightly with oil. Insert the injection pump with gear shaft 1
into the coupling ring 2 in such a way that the gap on the gear shaft 1 lines up 'lfith the
matching bore, which is closed with the tension pin 3 in the coupling ring 2. Push the
injection pump into the crankcase. Install mounting screws and tighten.
Install all parts, which were remofed before. Set begin of delivery, see page 26.
Removal
Installation on Injection pump drive, page 26.1
For positioning, see page 26.1
Remove RPM control, shut off device, etectr1cal lines, air lines to suction pipe (LOA
installation), fuel lines, i!1ection lines and lube oil line. On M - engines with EDC regulator,
remove the mounting screw for the electric plug on the EDC regulator and pull the plug from
the regulator. The injection pump must be without power, tum the ignition off.
Remove the mounting screws on the injection pump. Pull the injection pump from the
crankcase.
Installation
Install new O~ng 1 and lubricate it lightly with oil. Insert the injection pump with gear shaft 2
into the drive hub 3 in such a way that the recess on the gear shaft 2 {missing tooth) and the
gap in drive hub 3, which is closed off with tension pin 4 align.
Push the injection pump into the crankcase. Install mounting screws and tighten. Install all
parts, which were removed before. Set begin of delivery. see page 26.1.
Add about 1 liter of engine oil on into the regulator housing before using the new injection
pump.
On A4-engines with EDC regulator, add approx. 0, 1 liter and approx. 0,4 liter of engine oil
into the injection pump.
1-·-··
Datum I EdMion I Date
03/2002
Benennunii I DescriPtlon I Denomination
Injection Pump
Pump size ,,P"
Typ
Model
Twe
Blatt
Page
Feua1e
0 9306/9308
0 9406/9408
25
Benennuna I Oescriotion I Denomination TyP 0 9306 / 9308
IMllllMR
Injection Pump ~= D 940619408
03/2002 Pump size ,,P"
25.1 Injection pumps
On engine models D 9406 I 9408 Tl-E AS in - line injection pumps made by Bosch,
Control-sleeve injection pump (H-RP43) are installed .
..
Englfte ·_ -- '
. RPll
.. .
·Injection
~ . ·~ "';_ .
Pump piston Injection

. '
,
~hnln pump dlametBr -- pump
·~
0nim ntgulator
~
D 9406 TI-E AS 1800/1900 H - RP43 12 EDC

2000/2100
D 9408 Tl-E AS 1800/1900 H-RP 43 12 EDC

200012100
Removal
Installation on injection pump drive, page 26.1
For positioning, see page 26.1
Remove fuel tines. iJ1ection lines and lube oil lines.
Disconnect the electrical plug connection between the cable fran the injection pllllp
regulator (EDC) and the cable frcrn the engine control unit
The injection pump may not be enetgized. Tum the ignition off on the machine.
Remove the mounting screws on the it1edion pump. Pull the injection pump from the
crankcase.
Installation
Install new 0 -Ring 7 and lubricate it lightly with oil. Insert the injection pump with gear
shaft 2 into ttle drive hub 3 in such a way that the recess on the gear shaft 2 (missing
tooth) and the gap in drive hub 3, which is closed off with tension pin 4 align.
Push the injection pump into the crankcase. Install mounting screws and tighten. Install all
parts, which were remofed before. Set begin ct delivery, see page 26. 1. Before operating
a new injection pump, add approx. 0,1 liter engine oil into EDC regulator and approx. 0,6 I
into the injection pt.mp.
1 Pump piston
2 Control-eleeve
3 Control-eleeve, shaft
4 Regulating rod
Benennuna / Descr1>tlon I Denomination Typ

IMiiHWg Model
09406/9408
Twe
Injection Pump
Blatt
03/2002 H-RP43 (control-sleeve injection pump) Page
Feuille
25.1
26 Injection pump drive, adjust begin of delivery
In-tine injection pumps, size .P" are installed on this drive. The injection pump is
connected to the injection pump drive via gear shaft 1 and coupling ring 2.
To adjust begin of delivery (FB) with mechanical regulators:
For begin of delivery data, see engine data.
Remove the cover on top of coupling ring 2 from the crankcase. Set cylinder 1 to OT
(upper dead center). Rotate the crankshaft until the lower lock screws 6 on the coupling
ring 2 are by the opening of the crankcase and loosen the lock screws 6 , except the two
near the V-mark and the bore hole. Then tum the shaft back and set cylinder 1 to the
begin of delivery adjustment value.
Note
The center of the two threaded bores on the inspection window on the flywheel housing
are reference points. OT and 10° to 25° marks are marked on the flywheel.
Install a high pressure manual pump or overflow pipe on cylinder 1 of the injection pump.
Tum off the starting boost injection with a retainer device. Loosen the upper lock screws 6
on the coupling ring 2 . With a driver, tum the ring on the coupling ring 2 to the injection
pump to the right, as seen from the fly-Mleel. Actuate the hand pump, tum the ring back to
the left until the fuel flow decreases to drops on the overflow pipe, meaning the begin of
delivery is reached. Tighten screws 6 on coupling ring 2 and tum FB (begin of delivery)
again with the crankshaft and recheck. After exact adjustment, reinstall all parts.
To adjust begin of delivery (FB) with ,,EDC.. (Electronic regulation):
For data for begin of delivery, see Engine Data.

Remove the plug on the injection pump regulator (EDC) and install light signal transmitter
ld.-No. 6004308. Clamp the ground terminal of the light signal transmitter to the engine
ground. The injection pump must be without power. Tum the ignition off.
Proceed as described abouve, to adjust begin of delivery
With a driver. tum the ring on the coupling ring 2 to the injection pump to the left, as seen
from the flyv.tieel, until both lights on the light signal transmitter light up. The FB is now
set. Tighten screws 6 a coupling ring 2 and tum FB (begin of delivery) again with the
crankshaft and recheck. If adjustment is correct, reinstall everything.
Tum off the starting boost
Injection pump .P" with RSV, - RSUV-Ragulator
Set the shut off lever to shut off, attach retaining device ld.-No. 0527462 on the shut off
lever and move the shut off lever all the way back on the retaining device to the injection
pump. Set the control lever to full load.
Injection pump ,.P" with RSV-, RQV..ftegulator with solenoid for starting boost
release:
Solenoid may not be actuated with electrical current. Move the shut off lever from shut off
to normal position. Set the control lever to f ull load.
Injection pump ,,P" with RQV-K-Regulator:
Starting boost does not have to be turned off at begin of delivery adjustment
Injection pump ,,,P" wHh EOC (Electronic regulation):
Note
The injection pump and regulator descriptions are marked on the data tag for the injection
pump or the regulator.
u•••wa BenennunQ I Descr1>tion I Denomination
Injection Pump Drive

Typ
Model
Tvoe
09306/9308
0940619408
0312002 Adjust Begin of Delivery Page
FeuUle
26
9 8
6
7
12
13
10
I
. . . ._ - 1-- -~......._:1...\-_.l->~
I !
1 3 2 5 4 11
View X
1 Gear shaft
2 Coupling ring
3 Tension pin
4 Hub
5 Tension pin
6 Lock ecrews
7 0-ring
8 Gear
9 Collar bearing
10 Screw
11 Housing
12 Screws
........
13 Pin
BenennunQ I Description I Denomination Typ

Model
D 9306/9308
TllDe 09406/9408
Blatt
FeuMle
26
26.1 Injection pump drive, adjust begin of delivery
In - line injection pumps, size ,.P" and .H-RP43" (Control-sleeve injection pump) are
installed on this drive. The injection pump is connected to the drive via the gear shaft 2
and drive hub 3.
To adjust begin of delivery (FB) with mechanical regulators:
For begin of delivery data, see Engine Data.
Remove the cover on top of drive hub 3 from the crankcase. Set cylinder 1 to the exact
FB mark.
Note
The center of the two threaded bores on the inspection window on the flywheel housing
are reference points.
The fl)"Mleel is marked with the OT (upper dead center) and the 10° to 25° marks.
If the control-sleeve injection pump . H-RP43" is installed, there are marks from 25°
before OT until 25° after OT.
Install a high pressure manual pt.mp or ovef'flow pipe on cylinder 1 of the injection pump.
Tum off the starting boost injection with a retainer device. Remove the plug on the
flywheel housing.
Insert a screw driver insert for socked head screw 5 (SW 14) and loosen the screw 5,
while holding the flywheel gear ring.
Then tum out the screw 5 by two additional turns. The cone on the hub 6 must loosen
from the drive hub 3.
Insert a mandrel into the bore of the drive hub 3 and tum the drive hub 3 by approx.
10 mm to the right, as seen onto the flywheel. Actuate the hand pump, tum the drive
hub 3 to the left until the fuel flow decreases to trops on the overflow pipe, meaning the
begin of delivery is reached. Tighten the screw 5 according to the torque specification,
while holding the flywheel gear ring. Check the FB (begin of delivery) again by turning the
engine.
If adjustment is correct, reinstall everything.
Tightening torque for screw 6: pretorque Nm 80 Nm 300
To adjust begin of delivery (FB) with ,,EDC" (Electronic regulation):
For data for begin of delivery, see Engine Data.

Remove the plug on the injection pt.mp regulator (EDC) and install light signal transmitter
ld.-No. 6004308. Clamp the ground terminal of the light signal transmitter to the engine
ground. The injection pump must be without power. Tum the ignition off.
Proceed as described abouve, to adjust begin of delivery
With a driver, tum the drive hub 3 to the left, as seen from the flywheel, until both lights
on the light signal transmitter light up. The FB is OON set. Tighten the screw 5 according
to the torque specification and check the FB (begin of delivery) again by turning the
engine. If adjustment is correct, reinstall everything.
Tum off the starting boost:
Injection pump ,,P" with RSV-, RSUV-Regulator: see page 26
Injection pump ,,P" with RSV-, RQV-Regulator with solenoid for starting
booSt release: see page 26
Injection pump r•P" with RQV - K-Regulator: see page 26
Injection pump ,,P", ,,H-RP43" with EDC (Electronic regulation):
Note
The injection pump and regulator descriptions are marked on the data tag for the injection
pump or the regulator.
Benennung I DescriPtion t Denomination Typ

Model 09306/9308
Type D 940619408
Datum I Edition I Dale
Blatt
Feuille 26.1
3
10
1
5
2
11
1 0-ring 7 Gear
2 Gear shaft 8 Pin
3 Drive hub 9 Screws
4 Tension pin 10 Housing
5 Screw 11 Washer
6 Hub 12 Screws
.•..,...
03/2002
BenennunQ I Oescri>tion I Denomination

Adjust Begin of Delivery
~~I
Tvce
D 930619308
D 9406 I 9408
27 Fuel injector
The fuel injectors are easily accessible on the top of the cylinder heads and are installed
with a simple bracket and 2 screws or with a tension claw and a screw.
Removal
Remove the line from the injection pump and the leak oil return lines.
Installation with retainer: Remove screws 1, retainer bracket 2 and spacer sleeve 3.
Installation with tension claw: Remove screw 6, remove tension cfaw 7.
Knock the fuel injectors "With a special tool from the cylinder head. Remove the seal 4 from the
nozzle or from the bore in the cylinder head.
lnstauation:
Adhere the seal 4 with grease to the injector nozzle. Install 0-ring 5, apply grease to the
nozzle and push it into the bore in the cylinder head.
Installation with retainer: Install retainer 2, spacer sleeve 3 and SCfews 1 and tighten
according to tightening torques. When tightening, tighten first screw 1 on the spacer sleeve 3
and then the other screw 1.
Installation with tension claw: lnstatl tension daw 7, tum in screw 6 and tighten
according to tightening torques.
Tightening torques for screws 1, 6: Nm 23

Install injector lines and leak oil return lines.
Note
The leak oil return lines on the fuel i'1ectors on the engine. must point on the right side to the
flywheel, on the left side to the fan, when viewed onto the flywheel.
1 Mounting screws
2 Retainer bracket
3 Spacer sleeve
4 Seal
5 0-rlng
6 Mounting screw
7 Tension claw
BenennunR I Descri>tion I Denomination Typ

IM' IW• Model
09306 / 9308
Tvoe 09406 / 9408
03/2002 Fuel Injectors Page
Feuille
27
27.1 Fuel injectors
Function
The fuel coming from the injection pump 1 under high pressure via the injection line
flows via a rod filter 2 in the pressure channel 3 and from there to the nozzle seat 4.
Due to the high pressure, the nozzle needle 5 Is lifted and the fuel sprays into the
combustion chamber.
After a drop of the injection pressure, the spring 6 pushes the nozzle needle 5 back to the
nozzle seat 4, ending the injection procedure. The leaking fuel along the nozzle needle 5
flows via leek oil connection 7 on the nozzle retainer and through the leak oil line back to
the fuel tank.
The injection pressure can be adj usted via shims 8.
Fuel Injection
Engine Nozzle pressure (bar) Injection pump
description N•new regulator
B•opending
pressure . ..
D 9306 TB Bosch N = 225 +e 8 =217+8 RSV
OLLA 137$ 1154
Bosch
0 9306 TfTI
RSUV, RSV, RQV
D 9308 TfTI OLLA 134 S N = 225 +e B = 217+a
1155
Bosch
D 9406 TfTl-EA3
OLLA 145 P 439 N = 225 +e 8=217+8 RSUV, RSV, RQV,
OLLA 145 P 536 RQV-K
Stanadyne from 320KW
34166 N=300+a B =292 +e
0 9408 TfTl-EA3 Bosch

OLLA 145 P 439 N = 225 +e 8 =217•9 RSUV, RSV, RQV,
OLLA 145 P 538 RQV-K
Stanadyne from 440 ~
34166 N=300+e 8=292+8
0 9406 Tl-E A4
Bosch
OLLA 145 P 538 N = 225 +e 8=217+8 EDC
Stanadyne
34166 from 320 KW
N = 300 ..e 8=292+8
Bosch
D 9408 Tl-E A4
DUA 145 P536 N =225 ..e B =217+8 EDC
Stanadyne
34166 from 440 ~
N =300+e B = 292 +e
Fuel injection
Engine Nozzle pressure (bar) Injection pump
description N=new regulator
S • operating
..... ~=ure
D 9406 Tl-E A5 Bosch
OLLA 145 P 536 N = 225 +a =
B 217+8 EDC
from 320 t<.W
N=300 +8 B= 292 +a
D 9408 Tl-E AS Bosch

OLLA 145 P 536 N =225 +a B =217+a EDC
from 440~
N=300+a 8 = 292 +a
Torque specification for union nut 9:
D 9306/9308 = Nm 50• 20
0 9406/9408 = Nm 40•10
Benennunii I Descriotion I Denomination Typ

Ui&llLDI Model
D 9306/9308
TVl:Mt D 9406/9408
Dlium I Ecfltion I Dale Blatt
0312002 Fuel Injectors Page
Feuile
27.1
2
8
3
1 Injection line
2 Bar filter
3 Pressure channel
4 Nozzle seat
5 Nozzle pin
6 Spring
7 Leak oil connection
8 Adjustment shims
9 Union nut
.......
Daum I Edition I Oale
03/2002
BenennunQ / Description I Oenomilation
Fuel Injectors
Typ
Model
Time
Blatt
Page
D 9306/9308
DN06 / 9408
F111il1A
27.1
28 Engine exhaust
The engine exhaust is a dosed version. The oil separator is installed on the flywheel side
on the upper side of the injection pump drive on the crankcase.
Depending on the model, also 2 oil separators could be installed at the engine .
Function
The lower section of the oil separator is equipped with a filter section made of steel
woof 1. In the upper section is a membrane 2, which is controlled by a spring 3
(membrane valve). A membrane vent 4 in cover 5 is used to regulate the membrane
valve. Due to the vacuum pressure of the engine, oil flows from the crankcase to the oil
separator. Most of the oil is discharged in the filter 1 and runs via pipe 6 and cap 7 back
in to the oil pan. The discharge gases mixed with oil - air mixture are returned via the
membrane valve or via the pipe line 8 to the engine and burnt.
Check the crankcase vacuum pressure
Pun the dipstick and connect the gauge on the dipstick guide tube. Start the engine and
bring to maximum RPM. Read the crankcase vacuum pressure on the gauge and
compare with test values.
Note
The engine must be in horizontal position tor the test, it must be at operating temperature
and the oil level must be correct.
Test values
Flow quantity: 100 ± 20 I/min
Vacuum pressure: -200 ::1:: 20 mm WS
Crankcase vacuum pressure: -10to -80mm WS
Removal
Loosen the hose clamps on pipe 6 and push the hose from the oil separator.
Remove the mounting damp 9 and remove the oil separator from the crankcase.
Installation
Place a new 0-ring 10 into the oil separator. Push the oil separator onto the fitting in the
crankcase. Push hose onto pipe 8, attach hose clamps and tighten. Tighten mounting
clamp 9.
Note
A damaged oil separator, for example one with a damaged cover 5, emerging oil vapor
on w.o bleeder bores 4 of the membrane vent is not functioning proper1y and must be
replaced. Replace the oil seperator tf the given crankcase vacuum pressure cannot be
obtained or once f!!Very two years.
5 3 2 4 8
1 Filter section 6 Return pipe

2 Membrane 7 Cap
3 Spring 8 Pipe line
4 Membrane vent 9 Mounting clamp
5 Cover 10 0-ring
Benennuna I Descr1>tion I Denomination Typ

UiihllRll Model
D 9306/ 9308
Tvoe 09406/9408
Blatt
03/2002 Engine exhaust Page
FeuHle
28
29 Fan and flywheel side crankshaft seal
Crankshaft seal on fan side
The crankshaft seal ring 1 on the fan side is installed in a seal ring retainer 2.
Removal
Remove screws 3 and take off washer 4 and vibration damper 5. Remove screws 6 and
remove the seal ring retainer 2 with seal ring 1 from the crankshaft.
Note
Instead of washer 4, it is possible that a V-belt is installed to drive the alternator.
Installation
Press the new seal ring 1 into the seal ring retainer 2. Push the seal ring retainer 2 with seal
ring 1 and new, lubricated 0-ring 7 onto the crankshaft. Install screw 6 and tighten. Install
vibration damper 5 and washer 4. Insert screws 3 and tighten according to tightening torque.
Tightening torque for ecrewa 3: Pretorque Nm 30 ~ • 30 + 20 =

50
Nm90 - 130= 130
Note
If there are running grooves in the crankshaft, the seal ring 1 in the seal ring retainer 2 can
be offset towaros the engine side.
Crankshaft seal on the flywheel side
The flywheel side shaft seal ring 8 is also installed in a seal ring retainer 9.
Removal
Remove screws 10 on the flywheel and take the flywheel 11 from the crankshaft and pin 12.
Remove screws 13 and remove seal ring retainer 9 Ylith seal ring 8 from flywheel housing.
Installation
Press the new seal ring 8 into the seal ring retainer 9 to the given dimension. Push seal ring
retainer 9 with pressed in seal ring 8 and new lubricated 0 -ring 14 Into the flywheel housing.
Install screws 13 and tighten. Push flywheel 11 onto the crankshaft and pin 12. Install
screws 1O and tighten according to tightening torque.
Tightening torque for screws 10: Pretorque Nm 50 • • 50 + 50 100 =

Nm 190 - 320 320 =
Note
If there are grooves from seal ring 8 in the race 15 then the race can be replaced.
When installing the crankshaft seal rings 1 and 8, apply a little grease (Molykote
Longtt'lerm 2 PIUS) between the dust and sealing lips.
Fan side crankshaft seal
1 Shaft seal ring

5
2 Seal ring Ntainer
3 Scnrws for vibration damper 4
.. Washer 3
5 Vibration damper
6 Screws for seal ring retainer
7 ()..ring
I
6
Flywheel side crankshaft seal with one seal ring
8 Shaft 9Nl ring 8 ! 0 ,S mm

9 Seal ring retainer
~@~±jl/0, aA
10 Screws for flywheel
11 Flywheel
12 Pin ~ I
13 Screws for seal ring retainer -'-i--,--....___
1- 11
14 0-ring
15 Race
15
...••.,.
03/2002
Fan and flywheel

side crankshaft seal
Typ
Model
Type
Blatt
Page
09306/9308
09406/9408
Feuille 29
29.1 Fan and flywheel side crankshaft seal
Crankshaft seal on fan aide wtth two seaJ rings
If a torque converter is installed on the engine (wet installation). two seal rings are
installed in the seal ring retainers.
Removal
Remove screws 1 on flywheel 2 and remove flywheel 2 from crankshaft and pin 3.
Remove screws 4 and remove seal ring retainer 5 ~ seal rings 6, 7 from flywheel
housing. Press seal rings 6, 7 from the seal ring retainer 5. Clean vent bore holes in the
seal ring retainer 5 and in the flywheel housing.
lnstaAation
Push new seal rings 6, 7 to the given measurement into the seal ring retainer 5. When
pushing them in, make sure to note the given oil return flow twist .s·. Attach new,
lubricated 0-rings 8, 9 to the seal ring retainer 5 and push it with seal rings 6, 7 into the
flywheel housing.
Caution
When installing the seal ring retainer 5, make sure that the V·mark points in direction of
the oil pan.
Insert the screws 4 and tighten. Push the flywheel 2 onto the crankshaft and pin 3.
Insert screws 1 and tighten according to tightening torques.
Tightening torqu• for screws 1: Pretorque Nm 50 ~ 50 + 50

0
=100
Nm 190- 320 =320
If there are grooves from seal rings 6, 7 in the race 10, then the race can be replaced.
Do not apply any grease between the sealing lips on the tv.o seal rings 6, 7.
Flywheel side crankshaft seal with two seal rings
1 Sct'8WS for flywheel

8
2 Flywheel
3 Pin
9 2
Screws for seal ring 6
" retainer
5 Seal rtng retainer 3 7
6 Shaft seal ring
7 Shaft seal ring
8 0-ring
9 0-ring - -- ·
10 Race
10
~ 0,4 A ~ O,• A
v . II .
~- 5 .. ~I l ~
.........
0312002
Benennuna I Descrtotion I Denomination
Fan and flywheel

Typ
Model
Tvoe
Blatt
0930619308
0940619408
side crankshaft seal

Page
FeuUle
29.1
30 Hydraulic pumps - auxiliary drive
Installation on flywheel housing
Drive mount with collar mount
RPM: Engine n 1/min = 1500, 1800, 1900, 2000, 2100

Auxiliary drive n 1/min = 1913, 2295, 2423, 2550, 2678
Permissible continuous output 35 kW (47,5 PS)
at even operation
Note
If there are any changes on series installations, contact the engine manufacturer.
Removal
Remove lube oil line 1 and remove screws 2.
Remove auxiliary drive from flywheel housing.
Installation
Install new 0 -ring 3 and lightly grease it Push auxiliary drive into flywheel housing
(assure tooth mesh).
Install screws 2 and tighten. Install lube oil line 1.
Important
After eNery installation or repair, check the axial play on the auxiliary drive.
Axial play normal: 0, 12 - 0,37 mm
Limit value: 0,55mm

4
1 Lube oil line 5 Screws

2 Mounting screws 6 Hub
3 0-ring 7 Collar bearing
4 Gear
Benennunp / Description I Denomination Typ

UIBHIRR Model
09306/9308
Tv0tt 09406/9408
0312002 Hydraulic pump auxiliary drive P~e
Feuille
30
30.1 Hydraulic pump auxiliary drive
Installation on flywheel housing.

Drive mount with bearing bushings and thrust rings.
RPM: Engine n 1/min = 1500, 1800, 1900, 2000, 2100

1
Auxiliary driven /min = 1913, 2295, 2423, 2550, 2678
Permissible continuous output 35 kW (47,5 PS)
at even operation
Note
In case of changes on series installation, contact the engine manufacturer.
Removal
Remove lube oil line and remove screws 1. Remove auxiliary drive from flywheel
housing.
Installation
Install new 0-ring 2 and lightly grease it. Push auxiliary dri'le into flywheel housing
(assure tooth mesh). Install screws 1 and tighten. Install lube oil line.
Important
After every installation or repair, check the axial play on the aux.iliary drive.
Axial play nonnal: 0,1-0,3mm

Limit value: 0,55mm
3
4 5
7
2
1 Mounting screws
2 0-rlng
3 Gear
4 Screws
5 Hub
6 Bushing
7 Thrust rings
u•••w• Benennunr:i / Descrl>tion I Denomination Typ

Model
Tvoe
D 9306/9308
09406/9408
0312002 Hydraulic pump auxiliary drive Page
FeuUle
30.1
30.2 Hydraulic pump auxiliary drive
Installation on flywheel housing.
Drive- shift able
RPM: Engine n1/min = 1500, 1800, 1900,2000, 2100

1
Auxiliary drive n /min = 1913, 2295, 2423, 2550, 2678
Permissible continuous output 35 W'I (47,5 PS)
at even operation
Note
In case of changes on series installation, contact the engine manufacturer.
Removal
Remove lube oil line and air pressure lines. Disconnect cable to proximity switch 1.
Remove supports to flywheel housing and protective plate. Remove screws 2 and
remove auxiliary drive from flywheel housing.
lnatallation
Install new 0-ring 3 and lighUy grease it. Push auxrtiary drive into flywheel housing
(assure tooth mesh). Install ~f!NI 2 and tighten. Install cable from proximity switch 1,
lube oil line and air pressure lines.
Note
If the proximity switch 1 is removed, read just it to the given measurement after
relnstallation.
Important
After fNefY installation or repair, check the axial play on the auxiliary drive.
Axial play normal: 0,1 -0,3mm

Umitvalue: 0,55mm
4
10 3 2 11 10
1 Proximity switch 6 Coupling ring 11 Bushings

2 Mounting screws 7 Hub
3 0-ring 8 Shifting fork
4 Gear 9 Adjusting pfs1on
5 Screws 10 Thrust rings
Benennuna I Descri&>tion f Denomination Typ D 9306 I 9308

~I D 9406 / 9408
Datum I E<fltlon I Date Blatt
0312002 Hydraulic pump auxiliary drive
~='lie 30.2
30.3 Hydraulic pump - Auxiliary drive
Installation on timing case
Drive mount with collar mount, bearing bushing and thrust washer
Note
On engines with remote fan installation, a hydraulic pump auxiliary drive can be
installed on the timing case instead of a fan drive.
RPM: Engine 1
n /min = 1500, 1800, 1900, 2000, 2100
Auxiliary drive n1 /min; 1464, 1757, 1855, 1952, 2050
Pennissible continuous output: 20 WI/ (27 PS)

at even operation
Note
If there are any changes in senes installation. contact the engine manufacturer.
Removal
Loosen screw 1 and remove it Remove auxiliary drive from timing case.
Installation
Attach new 0-rings 2, 3 on auxiliary drive or insert into the groove in the timing case
and lightly grease them.
Push auxiliary drive into the timing case (note tooth mesh}.
Insert and tighten screws 1.
Note
The slotted nut 4 has a left handed thread.
Tightening torque for slotted nut 4: Pretorque Nm 30 Nm 240

Retainer: Loctite 243
Important
After every installation or repair on the auxiliary drive, check the axial play.
Axial play nonnal: 0,1-0,30mm

Limit value: 0,55 mm
3 2 7
1 Mounting screws
2 0-ring
3 0-ring
4 Slotted nut
5 Hub
6 Thrust ring
7 Buah Inga
Benennung I Oesa1>tion I Denomination Typ

IM•HW• Model
09306/9308
Tvoe 09406/9408
Oawm I Edition I Date Blatt
03/2002 Hydraulic pump auxiliary drive Page
Feuille
30.3
31 Air compressor
Depending on the type of engine, one or l'M> cylinder air compressors are installed. The
air compressors are connected to the cooling circuit on the cylinder heads.
The air compressor is driven via a gear

1
RPM: Engine n /min= 1500, 1800, 1900, 2000, 2100
1
Air compressor n /min = 1913,2295, 2423, 2550,2678
Removal
Remove the air intake hose and the pressure lines on the air compressor head.
Note
Mar1cings on the air compressor head:
0 = Suction (intake) connection

2 = Pressure connection
Remove the coolant intake, coolant return and lube oil intake lines. Remove the screws 1
and remove the air compressor 2 fr001 the flywheel housing. Remove nut 3 and pull the
gear 4 with a commercially available gear puller from the shaft. Remove the intennediate
flange 5 from the air compressor flange.
Note
Some air compressors are installed Mthout an intennedate flange 5.
For two cylinder air compressor, a support is installed to the flywheel housing.
Installation
Install new 0-rings 6.7 and lightly grease them. Push the intermediate flange 5 onto the air
compressor flange. Push the gear 4 onto the shaft, install the spring ring or nut 3 and
tighten according to tightening torque. Push the air compressor 2 into the flywheel housing
(assure tooth mesh). Install screws 1 and tighten. Install air, coolant and lube oil lines. Add
coolant.
Tightening torque for nut 3: M 18x 1,5 M 20x 1,5 M 20x 1,5
Nm ao• 10
(SW=30mm) (&N=27mm)
Nm150 Nm200
6 7
--------4
--- _~--~ t --·l

------3
--t-
--2
1 Mounting screws 5 lntennediate flange

2 Air compressor 6 0-ring
3 Nut 7 0-rlng
4 Gear
••mw• BenennunQ I Oes1;riotion I Denomination T~

Model
Tvne
09306/9308
09406/9408
Datum I Edition I Date Bi.I
0312002 Air compressor Page
Feu~le
31
32 Starter
Depending on engine type, a 6.6 kW or a 9 kW starter is installed.
Removal
Disconnect the battery and remove the electrical lines from the starter.
Loosen nuts 1 and take them off, remove spring cups 2. Remove the starter 3 from the
studs 4 in the flywheel housing.
Note
On starters, v.tiich are sealed to the flywheel housing, an 0-ring 5 is installed on the
starter flange. Check the 0-ring 5, replace it if necessary and tightly grease it before
installation
Installation
Push the starter 3 over the studs 4 onto the flywheel housing. Attach spring cups 2 and
nuts 1 and tighten.
Install the electrical lines on the starter and reattach the battery cables.
3---
<
',."'
4
...
;-;
, >
1 Nuts
2 Spring washers
3 Starter
4 Stud screws
5 0-ring
1 2
BenennunQ I DescrlPtlon I Oenominatlon Typ

l•IDWll Model
0 930619308
Tvoe 0 9406/9408
Blatt
0312002 Starter Page
Feuille
32
33 Air conditioner compressor and alternator
Note
This installation is self -tensioning and therefore maintenance free. The V-belt 2 only has
to be checked for wear.
To change the V-belt
Insert the ratchet according to DIN 3122 D 12,5 (112") into the square hole on the
tensioning device 1. Move the tensioning device 1 back against the spring force in
counter clockwise direction to the stop and remove the V-belt 2.
With the tensioning device 1 moved back, place a new V-belt 2 onto the pulleys of
crankshaft 3, air conditioner compressor 4, alternator 6 and tension pulley 6 and return
the tensioning device 1 again to tensioned position.
Note
When changing the V-belt 2, check the tension pulleys 6, 7 easy movement and play.
Replace defective tension pulleys 6, 7.
3
1 Tension device
2 V-belt
3 PuUey-crankshaft
4 Pulley-air conditioner compressor
5 Pulley-alternator
6 Tension pulley
7 Tension pulley
........
03/2002
Benennun~ I OescriDtion f Denomination
Air conditioner compressor and

Typ
Model
T v Oll
Blatt
Page
D 9406 19408
alternator Feuille
33
34 Starting aid-flame glow system
To improve cold start, a flame glow system is installed on all engines.
Function
In the preglow position, the solenoid valve 7 is opened and at the same time current flows
to the flame glow plugs 8. During the starting procedure, Diesel fuel is drawn from the fuel
tank 1 via the fuel pre-fitter 5 by the fuel pump 2 and is directed via the fuel fine filter 6 to
the injection pump 3. From the injection pump 3, fuel runs via the open soienoid valve 7 to
the glowing heating spirats of the flame gk:m plug 8. The passing air heats the fuel and the
warm fuel reaches the engine. The engine starts quicker, even in cold ambient
temperatures.
Note
If a control unit is instaled in the machine, then, ~ a engine temperature sensor, it takes
over this function and the monitoring of the flame glow system.
In the engine oil temperatures are higher than +20°C (+68°F), the control unit is not
functioning.
Check
To check the solenoid valve:
Remove the fuel lines on the flame glow plug 8. Set the shut off lever on the injection pump 3
to .Stop". Crank the engine with the starter to drain all fuel from the fuel lines. Bring the
shut off lever on the injection pump 3 from .Stop" to .Normar position and start the engine,
the fuel flowing from the fuel Knes must stop.
Note
If no fuel emerges when the engine is cranked or does not stop when the engine is running,
then replace the solenoid valve 7. During the exchange, pay attention to the arrow. which
shows the flow direction.
To check Ule flame glow plug:
Remove the flame fjow plug 8 and connect to fuel lines and electrical lines. Set the shut off
lever on the injection pump to ,,Stop" and preglow. After the preglow procedure, the heating
spirals on flame glow plug 8 must gtow red. Crank the engine With the starter, the fuel Which
reaches the glO\'Ving heating spirals must evaporate.
Note
If the flame glow plugs 8 does not glow red on the heater coif or if no fuel reaches the heater
coil when the engine is turned, then the flame glow plugs 8 must be replaced.
s_rn~==~o:-~~_..::~~----4TI~~a
r-r-- - 1
t
6 ' 4
r---------,
I
~
I
---a..+-~~'r-t I
I
I
3 2 5 - ------1---
-: ---- --_L-
- - -1-
1---~-
_: - -_ - ..:,-:_
1 Fuel tank
2 Fuel pump presaurized
3 Injection pump
4 Overflow valve
Fuel filter-prefilter
------- · unpressurized
5
6 Fuel filter- fine filter
7 Solenoid valve
8 Flame glow plug
9 Intake pipe
.......
Datum I Edhion I Date
0312002
BenennunQ I Oescriotion I Denomination
Starting Aid - Flame Glow

Typ
Model
Tvoe
Blatt
Page
09406/9408
D 9306/9308
System Feuille
34
34.1 Starting aid - Preheating the coolant
For extreme cold start requirements, an additional retrofit coolant preheat system can be
installed on all engines, in addition to the standard flame glow system.
Function
An immersion heater 1 preheats the coolant fluid and due to gravity, it starts to circulate in
the engine.
The preheated engine will start easier.
Installation on the engine
Drain the coolant and remove plugs from the threaded bore holes in the timing case 3.
Apply sealing compound Omnivisc 1050 to the threads on the reducer fitting 2 and install.
Atso apply sealing compound Omnivisc 1050 to the threads of the immersion heater 1 and
install. Connect the electrical connection and add coolant.
Note
Due to the larger amount of coolant in V-engines, two immersion heaters are required.
Mounting Thread
for Heater
3 2 1 1000W/ 240V
1000W / 120V
1 Immersion heater
2 Reducer fitti.ng
3 Timing case
BeoennunQ I Description I Denomination Typ

I • IWll Model
09306/9308
Tvne D 9406/9408
03/2002 Starting Aid -
Preheating the Conant
Page
Feuille
34.1
34.2 Starting aid - Oil Preheater
In additiOn to the standard flame glow system and the coolant preheating system, which
can be retrofitted, an oil preheater can be installed onto the engines.
Function
The oil preheater consists an immersion heater 1 and a thermostat 2.
The thennostat 2 opens approx. 76°C /168°F) and stops the current flow to the immersion
heater 1. As soon as the oil temperature has dropped to approx. 38°C (100"F), the
thermostat 2 closes, the current ftow is reestablished and the oil is heated.
This regulation prevents the engine oil from overheating (danger of coking).
Installation on the engine
Replace the standard oil pan 4 (if connections are not available) with the oil pan 4 with
connections for the immersion heater 1 and thermostat 2. Coat the threads of the tv.o
reducer fittings 3 with sealing compound (Omnivisc 1050) and install them. Also coat the
threads of the immersion oil heater 1 and I or thermostat 2 with sealing compound and
install them.
Connect the electrical connections and add coolant.

~
i Installation position of immersion
oil heater and thermostat. •
Immersion oll heater I desired
Thermostat 2
J>OW /115 V 115 V

300W/ 230V 230 v
View A-B
1 3
1 Immersion oil heater

2 Thermoatat 4
3 Reducer fitting
.t OH pan
·--·
03/2002
BeoennunQ I Descriotion I Denomination
Starting Aid -
Oil Preheater
Typ
Model
Tvoe
Blatt
Page
Feullte
09306/9308
09406/9408
34.2
35 Turbocharger
Turbochargers from KOhnle, Kopp & Kausch (KKK) or Schwitzer are installed on these
engines.
Turbocharger made by KKK Type = K 26, K27, K 28, K 29
Turbocharger made by Schwitzer = S2A
0 9306 TBfT = K26, S2A

09306 TI = K26, K27
0 9308 T = K27
D 9308 Tl = K27, K29
D 9406 Tl = K27
09408 Tl = K27, K28, K29
Charge system: Boost pressure

Charge pressures: 0, 7 to 2 bar, depending on engine type
Removal and Installation
Remove the lube oil supply lines and the lube oil discharge Jines. Remove the air intake
manifold hose from the air filter and the hose at the exhaust manifold to the muffler. Remove
the elbow pipe to the exhaust pipe or the charge air cooler. Remove the screws on the exhaust
elbow pipe and remove the turbocharger.
See page 35.1, 35.2 , 35.3, 35.4 for data of the bearing play.
Install in reverse order.
Note
Before lube oil supply lines are installed, fill the bearing housing with clean engine oil.
Oil Input
1---:.--
2 8
3
t-- 7
6
Oil return
1 Compressor housing
2 Compresaor gear
3 Piston ring
4 011 deftector
5 Turbine housing
6 Heatshleld
7 Piston ring
8 T.:r~negear
•• ••••
Datum I Edition I Date ·
Benennung I Oescr1>tlon I Denomination Typ
Model
TVDe
09306/9308
09406/9408
. . 03/2002 Turb~harger
35
DETERMINATION
OF BEARING PLAY
measuring point
Turbocharger - l(J(K (Kuhnle. Kopp & Kausch)
1. Meaeurlng the u111 play

• Place measuring point of clock gauge on top face of turbine
wheel hub.
llluatratlon t.1
1.1
• Press down shaft and turbine wheal assy. and set the clock
gauge at ·o·.
• Press shaft and turbine wheel assy. against clock gauge and
note indicator •throw•.
• The permlasible axial plays can be seen In the data sheet
2. Measuring the radial pllly

• Determinatlon of radial play Is only necenary at turbine side.
• Place cfook gauge measuring point on the centl8 of the cone
on the turbine wheel. ·
llluatratlone 2.1, 2.2
2 .1
• Pull turbine wheel downwards using apring ecale. Measuring

force: 50 N. Set clock gauge at •.0•1
contact surface
• Pull turbine wheel upwards using spring scaJe. Measuring force for clock gauge
50 N.
• Note the clock gauge "throw".
• Take this measurement again, with shaft and turbine wheel
8SS'J. tumed trough 90 °.
• The penntsslble ~dial playS can be seen In the data sheet.
2.2
......
,
Dmum I Edition I Date
03/2002
Benennun11 / Description I Denomination
Turbocharger
Typ
Model
Tvoe
Blatt
Page
D 930619308
0940619408
Feuille
35.1
DATA SHEET
Turbocharger· KKK (KOhnle, Kopp & Kausch}
1. Tsghtening torques in Nm
~e
!
K14/16 K24 K 26 K27 i K26 K 29
I
AF 1M2mm
self..focklng
ligi'*Jolrlg torque
after prehaal.ing
- 5 +2 -
M6
tlglUning torque - 12+1 -
AF 10/'12 mm
M6
tlghlenlng t.orqus
aftar ~ig
- I 7•2 - -
tlg!Jtanlng torque
... angle lltting
- S+eo• ...!!• - -
'S
c
AF 14 mm
M6
tightening torque
after pteheeting - 7 +2
-a tightening torque
- s..6(,.-6•
i + angle~
AF 15 mm
,,,., (left)
tiglllening 10tqU8
alter prehaatlng
- 7 +2 -
tlghlienlng torque
+ angle S8lting - 5 +50" -6•
-
AF 10 mm
M5
tightening 10l'qUe
after pnthNting
5 +2 -
~ngtorQUe 6+0.S -
backplate fixing
without washer - 8 -
backplate fixing
with washer
6 10
compressor housing 7 I
turbine housing (M 6) 8
I - .
turbine housing (M 8) 20
2. Axial play in mm
size K 14116 K24 I K26 I K27 I K28 I K29
max. play 0,10 0,16 !

i
3. Radial play in mm
size K 14116 K 24 I K 26 K 27 I K28 I K29
mai\ play 0,35 0,40 0,43 I
''·
···-··
0312002
Benennunq I Description I Denomination
Turbocharger
Typ
Model
Tvoe
Bfatt
Page
FeuUle
09306/9308
09406/ 9408
35.2
Determination of bearing play
Turbocharger· Schwitzer
Measuring the axial plav:

Place mea$Urin9 point of d ial gauge on the top of
the turbine gear hub. measuring point
Press down the shaft and the turbine gear assembly
and set the dial gauge to ·o·.
Press the shaft and the turbine gear as.sembJy
against the dial gauge and observe the dial
deflettion.
The permissible •1Cial plays are noted in th• data
sheet.
Measuring the radial play:

The radial play needs to be determined only on the
side of the compressor.
Place the point of the dial gauge in the center of
the hex nut of the the turbine gear.
Pull the turbine gear hub downward. using a spring
scale. Test force: so N. Setthe dial gauge to ·o·.
Pull the turbine gear hub w ith the spring scale
upward. Test force: SON.
Check the dial deflection.
Repeat this measurement, turning the turbine
gear assembly by 90".
2
The permissible radi'I play is noted on the data
sheet.
......
,
0312002
Benennuni:i I Oeecriotion I Denomination
Turbocharger
Typ
Model
Tvoe
Blatt
Page
D 9306/9308
D 940619408
Feuile
35.3
Data page
Turbocharger - Schwitzer
Axial play In mm
Size s 1A I
I
S1B S2A S2B S3A S4T
max. play 0.14 0.17 0.20
Rodiel play in mm
Size S 1A S18 S2A S2B S3A S4T
max. play 0.61 0.51 0.82 0.95 0.70 0.72
Benennuna I Description I Denomination

~el 0 9306 / 9308
Tvtie D !MOS / 9408
Blatt
0312002 Turbocharger
~:eille 35.4
36 Gear drive - flywheel side
Turning direction as viewed from flywheel to engine
I Crankshaft gear
II Camshaft gear
Ill lntennediate gear to connect canshaft and injection pump drive
IV Geer - Injection pump drive
V Intermediate gear for drive - lube oil pressure pump
VI Gear - Lube oil pressure pump
VII Gear - Air compressor or hydraulic pump drive
VIII Gear - Hydraulic pump drive or air compressor
Important
When working on the gears, make sure to observe the gear markings.
Note
The drives for gears VII, VIII are identical. Air compressors or hydraulic pumps can be installed.
~- ~
II ~ - I
If~"\ 1
tif ,. '4 i
'I
Il
I
\ ·,
•••••••
Benennu~ I Desajption I Denomination
~et
Twe
Blstt
D 9306 / 9308
0 9406 / 9408
03/2002 Gear drive - flywheel side Page 36

Feuille
37 Gear drive - fan side
Turning direction as viewed from fan side to engine.
Gear for coolant pump drive on camshaft

11 Gear for fan drive on camshaft
Ill Gear - coolant pump
IV Gear - fan drive
Note
Gears I, II, Ill and IV can be different sizes, depending on RPM configuration.
-·---·
03/2002
BenennunQ I Description I Denomination
Gear Drive - fan side

Typ
Model
Tvoe
. Blatt
~=le
D 9306 / 9308
D 9406 / 9408
37
38 Maintenance and Inspection
Any maintenance requirements can be seen on the following chart. These procedures are also
explained in the Operation and Maintenance Manual.
Only proper maintenance assures engine operation 1Mth the minimum of problems and a high
service life expectancy for your engine.
!
~I
I I
l I I
IIil .I
Cl .
~
I I .. I
I
i
I
,g I
i
I! ..: s
.i
c ~ i::
~ ~
..... .c
!! !!
.c § • Work to be carried out
.. g
ti .,. I , ~ II ......f. IO .,
I.
-·E~ -
• 0
?: ' i' ?: ...
~
l ja :sI.a ! ! .
i ..... .I 8 1i
f!! ~ •~l
:g 1!i'
> ... 0 I .a ~
•c ~! i
< < !<
1i0 1f J
c
.!!
< u• 0
c;f
~ ~ -:C c 0 ~
1
0 Check engine .o il level 0 dally 0 0 0

0 Check coot.nt level 0 dally 0 0 0
I 0
0
Yllual lnaptelion (contamlnallon, llama;.)
, . ruter-vecuuin iadlcmw
0
0
dally
daily
0
0
0
0
0
0
I 0 Waiter separator 011 fuef ftltler
Fvel tank-ckaln waar and Mdlments (Ill l..t 1xper
0 0 dally 0 0 0 24
0 ·- } 0 fi0..100 0 0 0
I
0 Dust collector on eit flltet' 10 &0-100 0 0 0

0 Engtne brW 0 fiOO 0 0
0 CMck oll, coolant. fuel ayat.m for leaks, condition 0 500 0 0 0
0 Radlatof. P f - . n relief V111ve. fan 0 0 500 0 0 0
0 Watw filer (If iostalled) 0 500 0 0 0 19
w Conoslon lnhlbltorllntlfNeZe, DCA 4 (in a.u of
500 38
0 0 -s.t' fill« Installation 0 0 0 0
z
soo
~ 0 Lube fan dr1¥e (V-belt dfiYe) 0 0 21.3
~In. off (first at SOO hl's.) lmpoft8nt - 39 SDO 31
~ 0 0 0 0 0
z 0 Lube olttlbr' 0 500 0 0 0 17, 11.1
4 0 ..._,, Ind cable ccmrwdlons 0 500 0 0 0
:E Fuel pre-filter...creen (or aae of drop in engl,,.
0 mrfQf'M1mee} 0 0 1000 0 0 0
f'uel ~ll:eT (or in - of drop in ensthw 24
0 rmforlftMCe) 0 1000 0 0 0
0
IFuel fine fltlw(or
nett\
in cme of drop in lnlJlne
I 0 2000 0 0 0 2A
0 Gl'NN ge• on flyWhMI 0 0 1000 0 0 0
0 MCIUl'lllng of oU pan and engine bnlekela 0 1000 0 0 0
Clleclt .ir lntae and nhauat sy--.tor IMll&,
0 0 condllon tnr&t 8fter 500 hrs.I 0 1000 0 0 0
N.r ftlt9' fft11111 el8menl (KC:Ofdlng to ~
Indicator I 0 0 0 0
Alr fitter Mfety elem.t (at_,, 3 rd chan941 of the
mllln element I a nuallv I n ever cleenl 0 0 0 0
Coolant wtttt corroalon lnhlbllor/antlfnMze 2years 0 0 39
. 0 0 0
0 Tenelon + c:ondillon of Y-Wt (alternator) 0 0 0 eoo 0 0 0

21 .3,
0 T.-Jon + condilicn otV~ (Fan drtve) 0 0 0 MIO lo 21.4
T-ion+condltton of V·belt (air conditioner compr.) 0 500 33
...z 0
0 Val•eplay 0
0
0 500 0
0
6
w D 0 VI/Ne pt.y (1. A~ustment at 500 hrs.) 0 0 1000 0 6
,_
:Iii
0 Vain play 0 0 1000 0 • • 6.1
..,¥5Q 0 I Englne f'99Ulatlon (engine R.PM)
Flam• gJow plug (at begin of cold season)
0 0 1000
1000
0 0 0
34
0 0 0 0 0 0
c(
0 lnfector valve (or in case of drop In engine 0 0 0 3000 0 0 0 %1,27.1
c
z
c(
l
i 0
nc:el
Oil aepcwtOr 0 ,,..... 0 0 0 28
~ I
0
w
:z: 0 First and only maintenance interval 0 Repeat interval
0
BenennunQ I Oesctil>tion f Denomination Typ

Model
0 9306 / 9308
Tvoe D 9406/9408
Blatt
03/2002 Maintenance and inspection Page
Feuille
38
Service Fluids
Lubricants:
lube oilspedification
In modern Diesel engines, only high alloyed lube oils are used. They consists of b~ic oil with additives.
The lube oil recommendation for Liebherr Diesel engines is based on the following specifications and
guidelines.
API - classification CG-4, CF-4, CH-4
(American Petroleum Institute)
ACEA (CCMq- classification E2-96, (04), E3-96, ( 05), E4-98, £5-99

(Association des Constructeurs Europ~ns de I'Automobile)
Naturally aspirated
CG-4, CF-4, CH-4, E2-96, (D4)
engines
Turbo charged
CG-4, CF-4, CH-4, E2·96, (04), E3-96, (OS), E4--98, ES-99
engines
wbe oil viscosity
The selection of the lube oil viscosity is made according to SAE classification (Society of Automotive
Engineers).
The ambient temperture is the determining factor for the correct selection of the SAE classification.
The selection ofthe SAE dassification gives no information about the quality of a lube oil.
If the viscosity is too high, it can lead to starting problems, if it is too low, the lubrication efficiency can
be endangered.
The temperature ranges shown In the chart below are guidelines and can be exceeded or fallen below
for a short time.
SAE15W-30
SAE15W-40
SAE 10W--'O
SAE10W·30
SAESW-40
oc -30 -20 -10 0 +10 +20 +30 +40 +so +60
OF -22
I ...I I I I I I I ~ I ~ I ~
5
14
23
32
41
50 69 86
J
104
,J3 I I
122
I
140
.......
0312002
Benennuna I Oescrir>tion I Denomination
Service fluids
Typ
Model
Tvoe
Blatt
Page
D 9306 19308
D 940619408
FeuUle
39
Oil change intervals
The first oil and filter change is due after 250 - 500 operating hours when using or oils ac.cording to the
lubrication guidelines. Additional filter changes are due every 500 hrs. and oil changes are due
depending on the temperature zone, sulfur content in the fuel and oil quality, as shown in the chart
below.
When using E3-96, (05), E4-98, ES-99 oils in naturally aspirated engines, the change interval of 500 hrs.
may be be exceeded.
If the given operating hours are not reached within one year, then the engine oil and filters should be
changed at least once a year.
INTERVALS IN OPERATING HOURS

NA-enaine T -enaine
Oil specification Oil specification
CH-4 CH-4
CG-4 CG-4 E3-96
Operating conditions Sulfur content in fuel CF-4 CF-4 (OS)
E2-96 E2·96 E4-98
(04) (04) ES-99
Ambient temperature up to o.s % 500hrs. 2SOhrs. SOOhrs.
up to 14' F ( -10°C) above 0.5% 2.SOhrs. 125 hrs. 250 hrs.
up to 0.5 % 250hrs. 125 hrs. 250 hrs.
below 14° F ( -10°C) .
above 0.5 % 125 hrs. 125 hrs.
COOLANT
Too provde anti-corrosion protection In the cooling system, the coolant must contain at least 50 % of
the total volume of corrosion inhibitor I antifreeze flu id all year round. This mixture protects the
system to approx. -37°C.
In case coolant is lost, check the ratio. The percentage of antlfreeze should not fall below 50 % of the
total volume.
Do not exceed 60% corrosion inhibitor I antifreeze, since a higher ratio would actually reduce the
cooling efficiency and antifreeze protection.
Pure, undeluted antifreeze will freeze at -10"C (·23° F).
Check the ratio during maintenance, change the coolant at least once every two years.
Coolant with OCA 4 (DCA 4 =Diesel coolant additives).
To assure protection against corrosion of the cooling system, the coolant must contain at least 50%
corrosion I Antifreeze mixture all year round. This protects the cooling system to about - 3r C (35°
fl.
When fluid is added to the coolant mixture, it must be assured that the mixture maintains a 50%
antifreeze content.
Important: Do not use a mixture of more than 60% corrosion I antifreeze • as a high ratio would
actually reduce the cooling and antifreeze protection.
Check and correct the ratio of corrosion inhibitors I antifreeze mixture and DCA4 concentration
during maintenance work (every 500 hrs.).
The DCA 4 concentration must be between O.~ and 0.8 units per liter (per quart).
We recommend test lclt CC 2602 M, made by Fleetguard .
The coolant must be changed ~ry 2 years. Check the cooling system, flush, if necessary, before
adding new coolant.
Refilling the cooling system
When refilling the cooling system after repairs. add liquid DCA 4 in addition to the DCA4
concentration In the water filttrto the corrosion I antifreeze mixture.
Cooling system
Required amount of liquid DCA 4 DCA 4 water filter
capacity
Liter No. of units per0.5 liter liter Description Id.No.
24-39 3 or 1,4 WF 2071 7367045

40 -59 4 or 1,9 WF2072 7381493
60 -79 5 or 2,4 WF2073 7367052
80 -11 5 8 or 3,8 WF2073 7367052
Water fitter change intervals
Change the water filter every 500 hrs.
If no coolant was lost in the cooling system, the DCM concentration in the cooling system is
adequate If the filter is changed every 500 hrs.
Using DCA 4 wittiout corrosion I antifreeze

In certain circumstances, and if ambient temperatures are constantly above ff1!er.ing, for instance in
tropical regions, and no corrosion I antifrffze is available, a mixture of watltl' and DCA4 may be
used.
To protect the cooling system from corrosion, use double the amount of DCA4 t han when using
corrosion I antifreeze and OCA4 to cool the system.
The DCA 4 concentration must be between 0.6 - 1.06 units per liter.
Check and correct the DCA4 concentration during maintenance work (every 500 hrs.).
The coolant must be changed once a year.
Benennung I Oesct1>tion I Denomination Typ

UMIMRR Model 09306/9308
09406/9408
Type
Datum I Edition I Dile Blatt
03/2002 Service fluids Page
Feuille 39.1
Fre.sh water guidelines:
To mix the coolant , only dean, preferably soft water should be used. Often, but not always, regular
drinking water can be used. Sea water, brackish waters, well water or industrial waste water may not be
used.
Fresh water quality for use with corrosion inhibitor I antifreeze :

Sum of earth alkalines (water hardness) 0.9 to 3. 6 mmol/I
(5 to 20"d)
ph-value at 200 C( 68" F) 6.5 to8.5
Chlorine content max. 100 mg/I
Sum of chloride + sulfates max. 200 mg/I
Fresh water quality for coolant wfth DCA4 or refiners (corrosion protective oils)
Sum of earth alkalines (water hardness) 0.9 to 2, 7 mmol/I
(5 bis 1S" d)
ph-va lue at 20" C( 68" F} 6,5 bis 8.0
Chlorine content max. 80mg!I
Sum of chloride + sulfates max. 160 mg/I
Mixture ratio
Corrosion inhibitor and
antifreeze
oc -40 -30 -20 -10 0
Protected to
I I I II I I
I I
°F -40 ·11 ·22 .n -4

14 u 32 5
The percentage of antifreeze should not exctec:l 60%, a hightr concentration

will adversely affect antifreeze protection and heat transfer rates!
RECOMMENDED CORROSION INHIBtTORS · ANTIFREEZE FLUIDS
BRAND MANUFACTURER
Agip Antifreeze Plus Aglp Petrol! S.p.A Rom ltalien

Agip-Auto Langzeit-Frostschut2 Agip Schmlertechnik GmbH, WOrzburg
Antigel 08 486 Sotraga l SA, St. Priest I Frankreich
Aral Antifreeze Extra Aral GmbH, Bochum
Aral Antifreeze T Aral GmbH, Bochum
Avia Antifreeze APN Deutsche Avia MineralOI GmbH, Munchen
BP Antifrost X 2270 A Deutsche BP AG, Hamburg

BP Napgel C 2270/1 BP Chemical$ l TD., London/England
DEA Kuhlerfrostschutz DEA Mineraloel AG/ Hamburg

DEUTZ KOhlschutzmittel 01011490 OE UTZ Sevice International GmbH, KOln
DOW Kuhlmittel 0 542 1 1993 BOSS Chemie AG, Wittenbach/Schweiz
Frostschutz 600 Mobil Schmierstoff GmbH, Hamburg
GlacelfSX Elf Lubrifiants Paris I Frankreich

Gly'o Shell Shell Chemie GMBH, Eschborn
Glysantin (G 48-00) BASF AG, Ludwigshafen
lgol Anti gel Type DB lgol France, Paris I Frankreich
Motul Anti-Freeze Motul SA, Aubervilliers Cedex I Frankrelch
t>MV - KOhlerfrosuchutzmittel 6MV AG, Wien/Osterreich

OZO Frostschutz S Total Oeutschland GmbH, Dllsseldorf
Total Multlprotect Total Deutschland GmbH, Dusseldorf
.......
0312002
Beneonuna I Oeseriotion I Denomination
Service fluids
Typ
Model
Tvoe
Blatt
Page
09306/9308
09406/9408
39.2
Feuille
Diesel fuels
Diesel fuels should meet the minimum requirements of t he listed permissible fuel s~cifications.
The sulfur content should not exceed 0.5 % .
A hig he r sulfur content affects the oil change intervals and engine service life.
Lubricating ability
Due to the teductlon of the sulfur content, the lubricating ability of the Diesel fuel has been
questioned. Tests have shown that Diesel fuels with a max. sulfur content of 0.05 ~. as is valid In
Europe, can cause wear In injection systems (es~ailly for distributor type injection pumps}.
UBrand name fuels '' (in Germany) contain these lubrication additives as part of their additive
package. The fuel lubricating ability must therefore be <400 µm according to HFRR (60"') Test .
The additive shoufd be added by the supplier as the responsible party for fuel quality. The
addition of secondary lubricatio n additives by the customer is not recommended.
Diesel fuets for low ambient temperatures

In ambient temperatures below approx. 32° F (0-C), the flow properties for summer Diesel fuel
can become insufficent due to paraffin excretion. The ~me applies for winter Diesel fuels at
temperatures below approx. •1 S"C (5" F) .
Often Diesel fuel with additives Is offered for use in temperatures to ·20"C (-4'" f) .
To prevent operational problems, the Diesel fuel must be mixed with regular 911soline or kerosene
at even lower temperatures.
Mixing r.gular gasoline with Diesel fuels should be considered a last resort. The ratio should not
exceed 30 % per volume.
Do not use Super gasoline to mix with Diesel fuel .
Depending on the ratio of Dlesel fuel and gasoliM or kerosene, the engine output may be
reduced to some degree. For that reason, keep the additives as low as possible, taking the
ambient temperature into consideration.
For safety reasons, always mix the fuel In the fuel tank.
When refueling, add the specifically lighter additive before adding the Diesel fuel. After
refueli ng, run the engine untll the mixed fuel Is d istributed throughout the complete fuel system.
For mixing ratio, see chart.
Additives for Diesel fuel (Flow improvers)
Commercially available flow improvers can also help to improve the Diesel fuel for cold
temperatures. When using these additives, observe the manufactu rer's Instructions
regarding quantities and use.
Approved f uel specifications: DIN ENS9<l

ASTM 0 975 - 89a 1 0 and 2
For additional fue l specifications consult the Engine design dept.
Diesel fuel mixing ratio (Vol.-%)
Winter Olesel fuel Additive

Ambient Summer Diesel Addit ive % %
temperature fuel
%
"C %
- 15"C -2o•c -1s-c -2o·c
0 bis - 10 70 30 100 100 - -
- 10bis-15 so •so 100 100 - -
- 15 bis . 20 - - 70 100 30 -
• 20 bis. 25 - - 50 70 •so 30
* tf more than 50% are necessary, use only kerosene, DO NOT USE regular gasoline .
........
03/2002
BenennunQ '/Oesctiotion I Denomination
Service fluids
Typ
Model
Tvt1e
Blat
Page
09306/9308
0 9406/9408
Feullle
39.3
40 Troubleshooting
Problem Cause Remedy
1) Engine does not Fuel tank is empty Add fuel and bleed fuel system
tum on
Fuel precleantr is stopped up Clean strainer
Fuel filter ls stopped up, in winter d ue Replace fuel filter and bleed fuel
to paraffin deposits system, use appropriate fuel for cold
temperatures
Fuel lines leak Check fuel line connections for leaks,

retighten fittings
Starter is defective Remove and have it checked at a

manufacturers service station or have it
fixed
Battery is deed Check and charge battery
Electric.al connections to battery, starter Check all electrical wires and cable1 and
or ignition are loose tignteo them, if necessary
Glow plug syst91n is defeaive (at cold Check solenoid volve .itnd flame g low
temperatures) plug, replace them if ne<essary
2) Engine turns on Check all cau• mentioned in point 1, see point 1

but then turns off except electrical and flame glow system
again
Vent in the fuel tank cap is plugged Oean fuel cap
3) £ngineruns Check all causes mentioned in point 1 see point 1 and 2

Irregularly, cuts and 2, except electrical and flame glow
off or does not system
reach full power
Air filter is dirty Oean air filter
Exhaust flap for engine brake is closed Check position of exhaust flap
or stuck
Overflow vah1• on injection pump Check valve, replace it, if necenary

outlet w ill not hold pressure
BenenounQ I Descrl>tion t Denomination Typ

IM•UWll Model
09306/9308
Tvne 09406/9408
0312002 Troubleshooting Page
Feuille
40
Problem Cause
Remedy
Valves in the fuel pump leak Have fue l pump ch ecked at a

specialized service center or replace it
Charge a ir cooler is dirty Oe.a n charge air cooler
Charge pressure is too low ng Check turbocharger
Begin of delivery for injection pump is Check and adjust begin o f delivery, if
not right necessary
fuel injectors are stuck o r do not spray Check fuel injectors, adjust or replace
the fuel them
Injection pump, fuel flow is Have fuel injector checked at a

misadjusted, or regulating rod is not specialized service center or replace
moving freely them
Acce lerator rod is notat full load point Check rod or adjust
Engine compression is too low Chedt and replace valves, piston and
cylinder, if nece5Sary
4) Exhaust fumes are Air filter Is dirty Oean air filter

black
Leeks in the intake system Check or replac• hos-. or lines
Exhaust flap for the engine brake is Check position of eichauu flap
d0$ed or stuck
Injector nozzles are ctamaged or Ch«k, adjust or rephm~ fuel injectors

clogged
Begin of delivery on the injection pump Che<k and adjust begin of delivery, if
is misadjusted necessary
Begin of delivery on tM injection pump Have fuel pump checked at a
is too large specialized service center
5) Exhaust fumes are TN lube oil level in the engine is too Correct t he oil lell@I
blue high
Lube oil reaches~ combustion Recondition cylinder heads or replace

chamber and burns them, change piston and bushings
Play between valve shaft and valve
guides are to large. piston rings are
worn, broken or too t ight. we~r on
piston and cylinder bushings
Seal on compressor side of the Check turbocharger, replace it if

turbocharger are defective necsary
40.1 Troubleshooting
Probfem cause Remedy
&} Exhaust fumes ere Cylinder head gasket is defective, Replace the cylinder head gasket
white allowing coolant into the combustion
chamt>.r .
The cylinder head broken or leaks Replace the cylinder head
7) Engine lcnoclcs Injector nozzles leak or do not properly Check injector nozzles. adjust them or
rapidly spray fut-I replace them
Begin or delivery of the injection pump Chedc begin of delivery, adjust. if

is misadjusted necessary
8) Engine knocks Fuel injectors ar.damaged or dogoed Check fuel injector noules,adjust or
replace them
Piston rings are worn or broken, piston Check piston rings and cylinder
worn bushings and replace them, If necessary
Main or connecting rod bearing is Install MW engine bHring or replace

defective
9) Coolant Not enough coolant in the cooling Add coolant

temperature is too system
high
Air in the cooling system Bleed the cooling system
Radiator is dirty externally Oean the cooling circuit
Radiator is dirty and dogged internally Clun the radiator
Thermostats are defective Check and replac.e thermostats, if

ne<es.sary
Coolant pump is d4tfective Chedc coolant pump. repair or replace
Fan is defective Ct'leck fan, replace it if necessary
10) Lubeoit Oil levtl in oil pan is too low Add oil to pro~ mark
temperature Is too
low Lube oil is too thin Drain oil, add specified oil
Benennuna I DesctiPtioo I Denomination Typ

Model 0 9306/9308
Tvoe D 9406 / 9408
Datum I Edition I Dale
Blatt
0312002 Troubleshooting Page
Feuille
40.1
Problem Cause Remedy
Oil pressure gauge or transmitter are Check oil pressure and replace defective
defective gauge or transmitt•r
Lube oil pre.sure pump is defective Replace lube o il pressure pump
Valve on lube oil pressure pump is stuck Check valve on lube oil pressure pump
in open position and replace it if necessary
Bearing play is too large, due to wear, Replace engine bearing or repair
or bearing is damaged
11) l.ube oil in cooling Oil coolM or cooJer plates leak Remove. replace if leaks are found
system
Cyli""-r head gasketslitak Replace cylinder h.ad gaskets
12) Coolant in lube .oil Cylindt!!r ti.ad gaskm le~ Replace cylinder head gaskets
O-rinos on cylinder liners leak Replace O·rings

41 Special tools
For inspections, adjustments, resealing ~ and repairs
- ~·
De9cription 'ld.-No. 09306 ·0904 0914 0924-E

. .
. -
., 09308 0916
~-
'
..
. .. .. - "
. ..
, . ..
.. 09406 0906 0926 D926-E
.. ' ... {- ~- ..,... :,~; ~ ·~, J>9408 .·. ..
Compreealon - tester 8008782 x x x x
Adapter 0524044 x x x x
for compression tester
Injector testing device 7361236 x x x x
High pl'M8Ure hand pump 7009318 x x x x

to test and adjust begin of delivery
Retaining device 0527462 x x x

to tum off starting boost
Light signal 6004308 x x

to test and adjust "Electronic regulation"
Pulllng device 0524072 x x x x

for fuel injector
Adapter 0524029 x x x x
for pulling device - fuel injector
Hand crank 0524045 x x x x

Installation on flywheel housing
Torque angle indicator 0524062 x x x x

for cylinder head, main and connecting rod
bearina
Benennuno I DescriPtion I Denomination Typ

Model
0 9306/9308
T\/08 09406/9408
Daum I Edition I Date Blatt
0312002 Special tools Page
Feume
41
, . .Description .·~ '>·• lc1-No. 09306 0904 0914 0924-E
. .
... 09308
~- .~..\i;.;.i ,. 0916
~·
.. .,·,,
• .:.'I;,'
.. .. ' ..•, ". . 09406 0906 0926 0926-E
"
•'
..,.,, "
Ji;!',
. .
~. ·~ " ><•· • ···~
.0 9408 . "
Piston ring pliers 700931 9 x x x x
Piston ring compressor 8000592 x x x x
Valve fixture
to install valves in cylinder head
0524048 x x x x
Dtal gauge holder 0528461 x

to measure piston clearance
Puller 0528462 x
for cylinder liner
to install crankshaft seals

Punch 0528463 x
Pul..r 0528473 x x
for iniection pUJllp gear .P" pump
Puller 0542220 x x
for injection pump gear control-sleeve
iniection DLmD (H-RP43)
Puller 0542222 x
for coolant pump
V-belt testing device - Krikit 2 8042829 x x x x

to test V-belt tension
.......
Datum f Edition f Date
03/2002
Benennuna I Oescri1tion I Denomination
Special tools
Typ
~!':'
Blatt
D 9306 I 9308
D 9406 / 9408
~::1e 41.1

Manual de Motor D9406 Liebherr

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Service·Maaual

This manual contains a short description of maintenance.adjustment and repair procedures,

Information is subject to change. LIEBHERR-MACHINES-BULLE S.A.

All rights reserved Dept.: Service-Diesel-Engine

Issue: Order No.:

03.2002 8717504 (english)

1 Intake pipe - left

11 Air compressor drive or hydraulic pumps - auxiliary driVe

Electronic sensors controHing the engine parameters

Benennung I Description I Denomination Typ

•••4111811 Benennung I Description I Denomination

Datum I Edition I Date Blatt

Bore Stroke Number of

V·engine 93. 130 150 6/8

TB =moderately turbo charged

Engine data tag:

Additional identification plate:

For additional data, an second identification plate might be installed.

Data: Code =Output perfonnance code

Engine description, engine datatag,

[-. . . il~ - -... ....

Additional data tag

Engine description, engine data tag,

Cylinder descriptiOn, directton of rotation

Engine ldenttftcation number

Engine number - example

year 6 cylinder running number

Working procedure: Four cycle Diesel engine

Combustion procedure: Direct injection

Total volume: D 9306= 12dm3

Nominal RPM: 1500, 1800, 1900, 2000, 2100 RPM

Compntnion ratio: 09306TB = 17,0 : 1

Firing order: 6cyl. = 1-6-3-5-2-4

Firing distance in°KW: 6 cyl. = 150-90-150-90-150-90 = 720°

6 cyl. with split pin crankshaft

Engine data, adjustment values,

temperatures and fluid quantities Feoille 4

Begin of delivery in °KW v .OT: 09306TB = 20 :t 1

Valve play: Intake cold = 0,25 mm

Compression pressure: 09306TB = 20-28 bar

Operating pressure = 217 •a bar

Minimum lube oil pressures at at nominal RPM = 3,5 bar

Marks on dipstick are the determining factor

Benennung I Descri>llon I Denomination Typ

Working procedure: Four cycle Diesel engine

Combustion system: Direct injection

Total volume: 0 9406= 12,9 dm3

Nominal RPM: 1500, 1800, 1900, 2000, 2100 RPM

Compression ratio: 0 9406 TfTl-E = 17,2 : 1

Firing distance in °KW: 9 cyl. = 120-120-120- 120-120-120 = 720°

Engine data, adjustment values,

0312002 operating pressures, operating Page

Begin of delivery in °KW v. OT: 0 9406 T/Tl-E A3 n =1800/1900 RPM =16 ± 1

Valve play: Intake cold =0,25 mm

Injection pressure: New = 225 +a bar

0 9406Tl-E from 320kW and D 9408 TI-E from 440 WI

Minimum lube oil pressures at at nominal RPM = 3,5 bar

Minimum pressure in cooling system at nominal RPM = 1,5 bar