This is a very practical manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Description 200 Service Information 2014/5/4 0
Profile:
Description
The L90D is equipped with an engine having the designation TD63KBE and the L120D is equipped with an engine having the
designation TD73KDE. Both engines are low-emission, six-cylinder, four-stroke, direct-injected, turbocharged diesel engines
with intercooler.
The engine has wet replaceable cylinder liners and two separate cylinder heads that cover three cylinders each. The cylinder
heads are interchangeable.
Lubrication is achieved with a force-feed lubrication system where an oil pump presses lubricating oil to all lubrication
points.
The turbocharger supplies the engine with pressurised fresh air, resulting in a surplus of air. Thus, the injected fuel amount
can be increased, giving more engine power. The turbocharger is lubricated and cooled by the engine’s lubricating oil, and is
driven by the engine exhausts and makes use of energy that otherwise would remain unused.
The intercooler, located in the induction manifold, cools the air which contributes to cleaner exhausts and improved engine
power.
A separate pump circulates coolant counter-clockwise in the intercooler.

2. Service Information
Document Title: Function Group: Information Type: Date:
Engine,
installing
200 Service Information 2014/5/4 0
Profile:
Engine, installing
Op nbr 21072
Lifting sling, 3 m (9.8 ft)
Shackle 3/8"
Ratchet block, 750 kg (1654 lbs)
Figure 1
Attaching a lifting device (outline diagram)
1.
2.
3.
Lifting sling, 3 m (9.8 ft)
Shackle 3/8"
Ratchet block, 750 kg (1654 lbs)
1. Attach a lifting device to the engine, see [Invalid linktarget] .
Weight: approx. 750 kg (app. 1653.5 lbs)
2. Lower the engine into the machine.
NOTE!
Make sure that no air conditioning hoses are damaged.
3. Fit the engine in with the hydraulic transmission and refit the screws.

3. Tightening torque: 85 ±8 Nm (63 ±6 lbf ft)
Remove the supports from under the transmission.
4. Refit the screws between the engine mounts and the rubber elements.
Tightening torque: 220 ±22 Nm (162 ±16 lbf ft)
5. Screw the transmission oil cooler to the bracket on the engine.
6. Refit the belt pulley, hub, bracket, and tension wheel.
Figure 2
Fitting belt parts.
1.
2.
3.
4.
Belt pulley
Bracket
Tensioning wheel
Hub
7. Bolt on the air conditioning compressor, if any, and fit its drive belt and fan belts.
8. Refit the rod between the engine and the air deflection disc.
9. Refit the fan.
10. Install the coolant pipe between the water pump and the transmission oil cooler; change the o-ring.
Connect the hose of the expansion tank and the air conditioning to the pipe and any coolant filter hose.
11. Screw the water trap of the fuel system to the bracket on the frame.
Attach the fuel lines to the fuel pump and the fuel injection pump.
12. Connect the cables to the B+ generator, connector BB to the stop solenoid, and SE1 to the temperature sensor.
Clamp the cables in the screw clips.
13. Attach the throttle control to the fuel injection pump.

4. Figure 3
14. Screw in the preheating coil’s relay console and console for any air conditioning receiver-drier to the bracket at the
inlet line of the engine. Connect the lead to the preheating coil.
15. Connect the ground lead to the starter motor (black connection).
Connect the red leads of the cable harnesses to the starter motor (red connections).
16. Connect the leads to the oil pressure sensor and the air cleanliness indicator. Clamp the cables in the screw clips.
17. Refit the upper radiator hose.
18. Refit the breather filter and screw in any pumps for secondary steering.
19. Refit the cover unit.
Weight: approx. 100 kg (app. 220 lbs)
Figure 4

5. Installing the cover unit
20. Connect the following:





The exhaust pipe to the silencer.
The hoses to the expansion tank, 3 pcs.
The hose to the hydraulic oil tank breather filter.
The suction hose to the turbocharger.
The hoses to the air cleanliness indicator.
21. Refit the hood plates on top of and on both sides of the hydraulic oil tank.
22. Fill the coolant.
Volume: 53 litre (11.66 US gal.)
Fill the engine oil.
Volume: 16 litre (3.52 US gal.)
23. Remove the joint locks. Start the engine and make sure there are no leaks.

6. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 200 Service Information 2014/5/4 0
Profile:
Engine, removing
Op nbr 21070
Lifting sling, 3 m (9.8 ft)
Shackle 3/8"
Ratchet block, 750 kg (1654 lbs)
1. Secure the frame joint with the joint lock.
2. Cut the current with the battery disconnect switch.
3. WARNING
Pressure in the cooling system may cause burns when the cap of the expansion tank (radiator cap) is
opened.
Open the expansion tank filler cap and drain the coolant.
Volume: 53 litre (11.66 US gal.)
Drain the engine oil.
Volume: 16 litre (3.52 US gal.)
4. Remove the hood plates on top of and from both sides of the hydraulic oil tank.
5. Loosen the following:





Exhaust pipe from the silencer.
Hoses from the expansion tank.
Hose from hydraulic oil tank breather filter.
Suction hose from the turbocharger.
Hoses from the air cleanliness indicator.
6. Remove the hood plate above the engine and the side covers as a unit together with the silencer, air cleaner, and
expansion tank.
Weight: approx. 100 kg (app. 220 lbs)

7. Figure 1
Removing hood plate
7. Disconnect the throttle control from the fuel injection pump.
8. Disconnect the necessary cables and clamps from:





the starter motor
the preheating coil
the alternator
the temperature sensor
the oil pressure sensor and the stop solenoid.
9. Disconnect the preheating coil’s relay console and console for any air conditioning receiver-drier from the bracket
at the inlet line of the engine.
Place the receiver-drier on the frame without loosening the hoses.
10. WARNING
Do not loosen hoses of the air conditioning unit (AC) because gas will leak out.
Disconnect the compressor of the air conditioning unit, including brackets and hoses, and place it on the fuel tank.
11. Loosen the bracket for the engine’s oil and coolant drain hoses.
Disconnect the fuel lines from the fuel injection pump and feed pump.
Loosen the water trap and lay it on the frame.
12. Swing out the radiator and condenser, if any. Remove the fan.
Remove the attachment rods of the air deflection disc, 3 pcs.
Remove the fan belts.
13. Remove the belt pulley of the fan, including hub, bracket, and tension wheel.

8. Figure 2
The belt pulley of the fan complete with hub, bracket, and tension wheel
14. Remove the axle ventilation filter and loosen any secondary steering pumps.
15. Remove the lead for the air filter’s air cleanliness indicator from the tank.
16. Attach a lifting device to the engine, see [Invalid linktarget] .
Remove the screws between the engine mounts and the rubber elements.
Remove the screws between the engine and the transmission.
Figure 3
Attaching a lifting device (outline diagram)
1.
2.
3.
Lifting sling, 3 m (9.8 ft)
Shackle 3/8"
Ratchet block, 750 kg (1654 lbs)
17. Place supports against the front rear axle mounting to support the transmission.

9. Figure 4
Supporting the transmission
1. Wood blocks
18. Lift out the engine.
Weight: approx. 750 kg (app. 1653.5 lbs)
Figure 5
Lifting out the engine (outline diagram)

10. Service Information
Document Title: Function Group: Information Type: Date:
Specifications,
capacities
200 Service Information 2014/5/4 0
Profile:
Specifications, capacities
Engine, when changing oil incl. filter 16 l (4.2 US gal)

11. Service Information
Document Title: Function Group: Information Type: Date:
Specifications,
general
200 Service Information 2014/5/4 0
Profile:
Specifications, general
Engine
Type designation TD63KBE, part no. 8188107
Flywheel output at 2100 rpm 113 kW SAE J 1349 Net
113 kW DIN 70020
Gross output at 2100 rpm 118 kW SAE J 1349 Gross
Max. torque at 1100 rpm 690 Nm (508.9 lbf ft) SAE J 1349 Net
695 Nm (512.6 lbf ft) SAE J 1349 Gross
690 Nm (508.9 lbf ft) DIN 70020
Number of cylinders 6
Cylinder bore 98.43 mm (3.875 in)
Stroke 120 mm (4.72 in)
Cylinder displacement, total 5.48 dm³ ⁽³³⁴ ³⁾
Compression ratio 18.3:1
Compression at
starter motor speed, 200 rpm
2.4 MPa (348 psi)
Max. pressure difference allowed between cylinders at
starter motor speed
0.3 MPa (44 psi)
Injection sequence 1-5-3-6-2-4
Idle speed, low 670 ±50 rpm
Idle speed, high 2420 ±60 rpm
Stall speed 2190 ±75 rpm

12. Service Information
Document Title: Function Group: Information Type: Date:
Specifications,
tightening torques
200 Service Information 2014/5/4 0
Profile:
Specifications, tightening torques
Engine Nm
Engine - engine mount 85 ±8 Nm (63 ±6 lbf ft)
Flywheel housing - hydraulic transmission 85 ±8 Nm (63 ±6 lbf ft)
Engine mount - tapered rubber damper 220 ±22 Nm (162 ±16 lbf ft)
Tapered rubber damper - frame 45 ±4.5 Nm (33 ±3 lbf ft)

13. Service Information
Document Title: Function Group: Information Type: Date:
Specifications, capacities 200 Service Information 2014/5/4 0
Profile:
Specifications, capacities
Engine, when changing oil incl. filter 21 l (5.5 US gal)

14. Service Information
Document Title: Function Group: Information Type: Date:
Specifications, general 200 Service Information 2014/5/4 0
Profile:
Specifications, general
Engine
Type designation TD73KDE, part no. 8188126
Flywheel output at 2100 rpm 148 kW SAE J 1349 Net
Gross output at 2100 rpm 153 kW SAE J 1349 Gross
Max. torque at 1100 rpm 920 Nm (678.5 lbf ft) SAE J 1349 Net
925 Nm (682.2 lbf ft) SAE J 1349 Gross
Number of cylinders 6
Cylinder bore 104.77 mm (4.124 in)
Stroke 130 mm (5.12 in)
Cylinder displacement, total 6.7 l (1.8 US gal)
Compression ratio 17.5:1
Compression at
starter motor speed, 200 rpm
2.4 MPa (348 psi)
Max. pressure difference allowed between cylinders at
starter motor speed
0.3 MPa (44 psi)
Injection sequence 1-5-3-6-2-4
Idle speed, low 670 ±50 rpm
Idle speed, high 2345 ±60 rpm
Stall speed 2120 ±75 rpm

15. Service Information
Document Title: Function Group: Information Type: Date:
Specifications, tightening
torques
200 Service Information 2014/5/4 0
Profile:
Specifications, tightening torques
Engine
Engine - engine mount 85 ±8 Nm (63 ±6 lbf ft)
Flywheel housing - hydraulic transmission 85 ±8 Nm (63 ±6 lbf ft)
Engine mount - tapered rubber damper 220 ±22 Nm (162 ±16 lbf ft)
Tapered rubber damper - frame 45 ±4.5 Nm (33 ±3 lbf ft)

16. Service Information
Document Title: Function Group: Information Type: Date:
Specifications, weight 200 Service Information 2014/5/4 0
Profile:
Specifications, weight
Engine, standard 660 kg (1455 lbs)

17. Service Information
Document Title: Function Group: Information Type: Date:
Specifications, weight 200 Service Information 2014/5/4 0
Profile:
Specifications, weight
Engine, standard 750 kg (1654 lbs)

18. Service Information
Document Title: Function Group: Information Type: Date:
Description,
cylinder head
211 Service Information 2014/5/4 0
Profile:
Description, cylinder head
The engine has two cylinder heads, each covering three cylinders. Each cylinder head is secured by 20 bolts (M11) equally
distributed round the cylinders.
In the surface of the cylinder head are channels formed by two wide concentric grooves recessed in the cylinder head
immediately above the cylinder liner collar, see [Invalid linktarget] . The size of the sealing surface is determined by these
grooves so that the necessary sealing pressure is obtained without necessitating such a high tightening torque as to
constitute a risk of deformation damage to the liner shoulder in the cylinder block. There is also a groove for the cylinder
liner’s flame lip.
Figure 1
Gasket, cylinder block – cylinder head
1.
2.
3.
Cylinder liner flame lip
Sealing groove in the gasket. The groove is made by the channel in the cylinder head.
Gasket (cylinder head)
The cylinder head gasket is made of solid sheet steel.
-The channels deform the gasket and hold it in place.
-The cylinder liner’s flame lip protects the gasket from the combustion pressure and temperature.
Due to emission requirements, the position of the injectors relative to the piston must be determined with extremely high
precision and for this reason the seat of the copper sleeve must not be milled and the cylinder head must not be surface
ground.

19. Figure 2
Cylinder head
A Inlet passage
B Exhaust passage

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21. Service Information
Document Title: Function Group: Information Type: Date:
Description,
cylinder block
212 Service Information 2014/5/4 0
Profile:
Description, cylinder block
The cylinder is a one-piece casting and has wet replaceable cylinder liners. The compression pressure gives rise to tensile
stresses in the cylinder head bolts and these stresses are carried directly to the main bearings through stiffening parts of the
cylinder block walls.
The camshaft bearings are drilled to the correct size after assembly.
Figure 1
Cylinder liner with flame lip
1.
2.
Flame lip
Sealing rings

22. Service Information
Document Title: Function Group: Information Type: Date:
Description, cylinder liner 212 Service Information 2014/5/4 0
Profile:
Description, cylinder liner
The cylinder liners are replaceable and of wet type. The cylinder liners have a "flame lip", see [Invalid linktarget] . This flame
lip, which fits in a groove in the cylinder head, reduces the stresses on the cylinder head gasket.
Four rubber O-rings are used for the outer sealing of the cylinder liner. The three lower rings fit in grooves machined in the
cylinder block. These rings are made of different materials. The two upper sealing rings are identical and made of fluor
rubber (black). The lower sealing ring is violet and made of ethylene propylene rubber (EPDM).
Sealing at the upper part of the cylinder liner is effected partly by an O-ring under the liner flange and partly through the
cylinder head gasket pressing the liner flange down against the shoulder in the cylinder block.
Figure 1
Cylinder block