Fuel Delivery Pipe Removal: Engineer's Handbook Cylinder Head

m
M 25
Engineer’s Handbook
Cylinder Head c2
Fuel delivery pipe removal
First loosen screwed connection (4) of transverse thrust piece (3), then loosen screwed
connection (6).
Fuel delivery pipe installation
1. Tighten the nuts of the fuel injection valve with ⇒ M = 50 Nm

then loosen them by one turn and tighten with ⇒ M = 10 Nm
2. Put the parts together ensuring correct position of cover (1). Sleeve (2) is in a pushed
back position inside the cylinder head.
3. Tighten screwed connection (4) of transverse thrust piece (3) and thrust bolt (6) of
radial thrust piece (5) (without wrench).
4. Tighten thrust bolt (6) and screwed connection (4) of
transverse thrust piece (3) with ⇒ M = 10 Nm
5. Tighten screwed connection (4) of transverse thrust
piece (3) with ⇒ M = 150 ± 5 Nm
Tighten thrust bolt (6) with ⇒ M = 130 ± 5 Nm
Keep transverse thrust piece (3) in position using a wrench (to avoid damage to the
individual connections).
6. Push sleeve (2) into the fuel injection pump so that it engages.
7. Tighten the nuts of the fuel injection valve with ⇒ M = 50 Nm

Coat thread and contact surfaces of screwed connection (4), transverse thrust piece
(3), radial thrust piece (5) and thrust bolt (6) with Molykote paste G.
Coat thread and contact surfaces

with Molykote.
en / 26/4/10 Caterpillar confidential: yellow 26/128

©2010
Caterpillar Motoren GmbH & Co. KG - All rights reserved
m
M 25
Cylinder Head c2
Transverse thrust piece
Projection (1) must not be less than 4.7 mm (e.g. when reworking the sealing face),
because otherwise the first thread pitch may abut against the pump casing. This may
cause the pre-tension moment to drop below the required limit, which in turn may cause a
leak.
Injection pumps supplied as from March 2000 are not affected by this problem, because
an undercut was then implemented on the pump casing.
Contact pattern check on inlet and exhaust valves

Apply with a syringe small dots of the diamond paste
Dp 30/10-15 my to a new or remachined valve cone and
distribute the paste evenly. After that, for dilution and in
order to increase the grip, spray the entire seat ring sur-
face with a thinner (F25) belonging to the diamond paste.
Insert the oiled valve stem into the guide bush. Fasten the
device on the valve head and ’grind’ valve cone and seat
by hand for a short time applying a moderate pressure,
rotating the device.
The percentage contact area “a“ made visible through the smooth grinding process shall,
over the entire circumference, amount to 30 - 50 % of the seat width starting from the
outside diameter. If the contact pattern shown above is not reached, remachining of both
sealing faces is necessary.
After machining check both seats with a luminous magnifier. After machining, round off the
outside edge with a stone.

©2010
m
M 25
Cylinder Head c2
Observe the dimensions and angles indicated on the sketches. The valves are identified
by the variant marking (e.g. 25-19, 25-02, etc.) on the circumference of the stem end. The
table below shows dimension Y in new condition and as wear limit dimension, each mea-
sured at reference diameter X. These dimensions are applicable for all valve cones (inlet,
exhaust, HFO, MDO) alike.
Reference diameter X Dim. Y - new condition Dimension Y - wear limit
79.5-0.1 mm 8-0.4 mm 7.2 mm
Inlet valve 25-01 Inlet valve 25-19

Reference diameter
Reference diameter
Exhaust valve 25-02 (MDO) Exhaust valve 25-05 (HFO)
Reference diameter
Reference diameter
Exhaust valve 25-20 (MDO) Exhaust valve 25-22 (HFO)

Reference diameter
Reference diameter

©2010
m
M 25
Cylinder Head c2
Radial run-out
Radial run-out of the valve stem must not exceed 0.05 mm over the measuring distance
"S" of 264 mm.
Radial run-out of the valve cone must not exceed 0.025 mm.
For both measurements the valve stem must rest at points A and B in the measuring
device.
Reuse of a valve stem is not possible, if:

1. There is severe pitting on the bottom side of the valve
head (formation of so-called“paving stones")
2. There are corrosion pits and mechanical damage in

the area of the valve stem, stem transition, and valve
head
3. The limit for refinishing is exceeded, or
4. In case of corrosive material erosion of 2 % of the

valve head diameter. In case of high-temperature cor-
rosion “S“ of 1.50 mm.

©2010
m
M 25
Cylinder Head c2
Installation of inlet and exhaust valve seats
1. Cool the valve seat ring with liquid nitrogen down to

-195 °C. As an alternative (if necessary), cool the
valve seat ring down to at least -20 °C and heat up the
cylinder head to 130 °C.
2. Insert the inlet and exhaust valve seat rings.
3. When the valve seat rings are tight, press them on

with the hydraulic device.
Pressing force for the hydraulic device ⇒ F = 65 kN
4. Check bearing surface Y 2: Between inlet valve seat ring and cylinder head no air gap
is admissible.
5. Check air gap Y 1 between exhaust valve seat ring and cylinder head. Admissible air
gap: 0.40 +0.50 mm.
Pressure test: Cooling water spaces subjected to 10 bar for 8 minutes.
Valve seat ring

Maximum admissible dimension Ø X for refinishing the exhaust valve seat rings is
92.00 +0.20 mm and on the inlet valve seat rings 85.00 +0.20 mm
At “a“ no material may be removed
Exhaust valve seat ring Inlet valve seat ring

30° +5‘ +5‘
30° +5‘ +5‘
Refinishing is possible with an MaK valve seat ring lathe or MaK valve reseating tool.
After grinding the percentage contact area shall be 30- 50 %, beginning from the outside
diameter.

©2010
m
M 25
Piston
Piston c2
Composite piston 2500.7-26.70.00-01 / -02 / -03
Coat thread and contact surface with Molykote paste G-n-plus.
Tighten screws crosswise with ⇒ M = 60 Nm

Loosen screws again.
Pretighten screws crosswise with ⇒ M = 25 Nm
and then finally tighten with torque angle ⇒ Dw = 60°
Check: At ⇒ M = 45 Nm
it must not be possible to turn the screws any further.
Gap size
2500.7-26.70.00-01 / -02 ⇒ 0.06 - 0.10 mm
2500.7-26.70.00-03 ⇒ 0.07 - 0.11 mm
Measure gap here,

screws not tightened.
Installation
Arrange the ring joints so as to be alternately opposed in longitudinal direction of engine,
then oil piston and piston rings well.
Install the piston rings with marking pointing upwards.

©2010
m
M 25
Piston c2
Wear limits
Grooves Groove height Ring height Wear limit Clearance limit

1 6.15 +0.03 6.00 -0.010 - 0.025 6.60 0.50
2 6.13 +0.03 6.00 -0.010 - 0.025 6.60 0.50
3 8.06 +0.03 8.00 -0.013 - 0.035 8.60 0.50
Pistons 2500.7-26.70.00-01 / 02 / 03 for gas oil and heavy fuel operation

Grooves Rings
1 Rectangular ring 2500.7-26.17.01-01
2 Taper-faced ring 2500.7-26.17.01-02
3 Bevelled-edge oil control ring 2500.7-26.17.01-03
Minimum Maximum Limit

clearance clearance clearance
Piston bosses -
Piston pin 0.050 0.078 0.100
Piston boss distance -

Piston pin
bush width 0.500 1.100 1.300
Removal of anti-polishing ring

1. Bar the engine so that the piston top
edge is below the anti-polishing ring.
2. Place the removal device on the

piston so that the recess is located
inside the anti-polishing ring.
3. Slightly tighten the removal device by

turning spindle nut (1).
4. Press the anti-polishing ring out by

barring the engine so as to move the
the piston up.

©2010
m
M 25
Connecting Rod c2
Connecting Rod
Big end bearing

1. Tighten upper big end bearing bolts successively
with ⇒ M = 150 Nm
up to ⇒ M = 300 Nm
3. Tighten lower big end bearing bolts successively
with ⇒ M = 150 Nm
up to ⇒ M = 300 Nm
up to ⇒ M = 600 Nm
up to ⇒ M = 600 Nm
7. Tighten upper big end bearing bolts once more
successively with ⇒ M = 600 Nm
Coat threads and contact surfaces with a thick layer of Molykote G Rapid Plus.
Reference dimension B
Reference dimension A
Cylinder No. here
Lower bolts Cylinder No. here
Upper bolts
Reference dimensions of the big end bearings after correct tightening.
Dimension A ⇒ 193.16 + 0.05 mm

Dimension B ⇒ A + 0.04 + 0.01 mm
The reference dimension of the piston pin bush

after freeze fitting is Ø ⇒ 120.11 + 0.08 mm
Freeze fit the piston bush at a bush temperature of ⇒ < -160 °C
en / 01.07.2008 Caterpillar confidential: yellow 33/128

©2009
m
M 25
Connecting Rod c2
Marking
The connecting rods are marked with engine number and cylinder number. Upon assem-
bly make sure that the connecting rods are installed at the designated locations.
Piston pin bush - piston pin

Minimum clearance ⇒ 0.113 mm
Maximum clearance ⇒ 0.199 mm
Limit clearance ⇒ 0.210 mm
Note:
Oversize bushes may only be used upon consultation with VT5 supported by photos and
dimensions of the small-end bush bores!
en / 01.07.2008 Caterpillar confidential: yellow 34/128

©2009
m
M 25
Cylinder Liner
Cylinder Liner c2
Wear limits
Nominal size Ø (original size) ⇒ 255.00 + 0.052 mm
Wear and tear value TDC of 1st ring ⇒ 0.90 mm
Max. ovality ⇒ 0.25 mm
Wedge shape (Wedge-shaped indentation across the entire circumference, beginning

at TDC of 1st piston ring.
Height ⇒ 6.00 mm
Depth * ⇒ 0.03 mm
Canyons (Individual deep blowby grooves in the area of the 1st piston ring (TDC))
Max. number ⇒ 3
Length ⇒ 150.00 mm
Total width ⇒ 0.03 mm
Scores (Severe vertical, linear friction marks)

Number ⇒ 3
Length ⇒ 150.00 mm
Depth ⇒ 0.03 mm
Pockets (Areal, irregular indentations)

Number ⇒ 3
Length ⇒ 60.00 mm
Width ** ⇒ 20.00 mm
Depth * ⇒ 0.02 mm
* Radius r > 3 mm
** In circumferential direction

©2010
m
M 25
Cylinder Liner c2
Pocket Score TDC of 1st ring
Wedge shape Canyon
Installation
During installation make sure that marking (1) of the liner coincides with marking (2) of
the cooling collar.
The liner must slide into the engine block by its own weight.
Attention:
Incorrectly inserted liners may cause considerable damage.

©2010
m
M 25
Crankshaft
Crankshaft c2
Tightening torques for bearing caps
Note: Bearing guide grooves are located on the right side (camshaft side).
Insert studs (1) with ⇒ M = 450 Nm

Molykote
When inserting the studs do not damage stamp and numbers.
Tighten crankshaft bearing nuts (2) evenly by hand.

Insert hexagon screws (3) with Molykote and tighten them alternately in three steps star-
ting from the right side (operating side).
1st step - tighten up to ⇒ M = 140 Nm
2nd step - tighten up to ⇒ M = 420 Nm
3rd step - tighten up to ⇒ M = 670 Nm
Stretch studs (1) by means of the hydraulic device with ⇒ P = 980 bar
at a piston surface of ⇒ A = 66 cm2
and tighten crankshaft bearing nuts (2).
Check:
Reduce pressure to ⇒ P = 930 bar
Loosening of the nuts must not be possible any more.
Tighten both crankshaft bearing nuts of a bearing pocket in one operation.

©2010
m
M 25
Crankshaft c2
Measurement of gap
1. Remove hexagon screws (3) of the crankshaft bearing. Loosen hexagon screws
(3) of the adjacent crankshaft bearings.
2. Loosen both crankshaft bearing nuts (2) of a bearing pocket in one operation.
3. Tighten crankshaft bearing nuts alternately and evenly with a pin until the joint faces
of the bearing shells just touch each other.
4. Check the projecting length of the bearing shell by measuring the gap between engine
block and bearing cap on camshaft and exhaust side.
Total of gap ⇒ 0.75 - 1.00 mm
After longer operation the total of gap shall not be less than ⇒ 0.60 mm
Dimension between bearing point 2 and web (crankshaft) ⇒ 2 + 1 mm
Marking
Bearing caps and bearing shells are mar-
ked on camshaft side with the related Stamp bearing Locating lug of the
No. here bottom shell
cylinder numbers counted from driving
end. The parts must not be mixed up.

©2010
m
M 25
Crankshaft c2
Locating bearings
Locating and normal main bearings are
identical, for axial fixation thrust washers
(1) with spring dowel pins (2) are fitted to
bearing cap (3) of bearing 1 (locating-
bearing).
End clearance ⇒ 0.30 + 0.30 mm
Limit clearance ⇒ 0.80 mm
Inserting the set screws

For inserting set screws (1)
grease the threads. Insert the set screws with
Loctite 270 and secure them with a
centre punch.

©2010
m
M 25
Crankshaft c2
Counterweight mounting
Pretighten screws with ⇒ M = 100 Nm
and then
finally tighten with ⇒ Dw = 120°
Apply Molykote G-Rapid to thread and contact surfaces.
Contact pattern of counterweight surface
Minimum critical contact surfaces
Contact surfaces permissible in

connection with
No project material permissible
6 M 25 12 counterweights
Crank pin 1 2 pcs.
Crank pin 2 1 pc left side *
Crank pin 3 1 pc right side *
Crank pin 4 2 pcs.
Crank pin 5 2 pcs.
Crank pin 6 1 pc. left side *
Crank pin 7 1 pc. right side *
Crank pin 8 2 pcs.
Crank pin 1 2 pcs.
Crank pin 2 1 pc. left side *
Crank pin 3 no counterweight
Crank pin 4 2 pcs.
Crank pin 5 2 pcs.
Crank pin 6 2 pcs.
Crank pin 7 no counterweight
Crank pin 8 1 pc. right side *
Crank pin 9 2 pcs.
* = seen from camshaft side.

©2010
m
M 25
Crankshaft c2
Alternative manufacture of the M27x2 threads for fitting the counterweights:
Glue with Loctite 275
Secure against rotation with set

screw M5x8 (DIN 913).
Glue with Loctite 648.
Before inserting the threaded bush:
- Measure the core diameter for thread M38x1.5 in the shaft and document the result on
the measuring sheet
- Measure the M38x1.5 flank diameter with a two-ball gauge in the shaft and on the bush
and document the result
- Measure the outside diameter for M38x1.5 on the bush and document the result
- Check the M38x1.5 thread in the shaft with a mandrel and carry out a visual inspection
- Have the M38x1.5 thread accepted by the local surveyor through a visual inspection
After inserting the threaded bush:
- Measure the distance of the bush from the surface

- Check the M27x2 thread in the shaft with a mandrel and carry out a visual inspection
- Measure the core diameter for the M27x2 thread and document the result on the
measuring sheet
- Measure the M38x1.5 flank diameter with a two-ball gauge and document the result
Dimensions to be checked Desired value
Core diameter in the shaft M38x1.5 36.38 + 0.3

Flank diameter in the shaft M38x1.5 37.06 + 0.2
Outside diameter of the bush M38x1.5 37.73 + 0.24
Flank diameter on the bush M38x1.5 36.84 + 0.15
Core diameter on the bush M27x2 24.83 + 0.37
Flank diameter on the bush M27x2 25.74 + 0.22
Distance of bush from surface 0.5 + 0.2

©2010
m
M 25
Crankshaft c2
Degrease the threads of the lube oil holes, insert set screws with Loctite 270 and secure
them with a centre punch.
Crank web deflection

Limit values:
Cylinders not subjected to any external load (generally
applicable to all cylinders, also to cylinder 1 if flywheel hub
and flywheel are not yet mounted, as well as to the last cylinder
if the secondary PTO shaft including bearing in pump mounting
plate is not yet connected.) ⇒ 0.05 to - 0.08 mm
Cylinders subjected to additional load (normally cylinder 1,

on account of the flywheel, and last cylinder if power is
actually taken off at the free end.) ⇒ 0.05 to - 0.11 mm

©2010
m
M 25 Gear Train
Gear Train c2
Gear wheel on crankshaft
Press gear wheel with device and oil press fit
connection Z ⇒ P = 500 bar

onto the crankshaft cone into its final position.
The final position is reached when the gear wheel rests against the spacer. The spacer
simulates the locating bearing, it must be adjusted in such a way that with the gear wheel
in final position a dimension of ⇒ 126 + 0.1 mm
is obtained between gear wheel and crank web of cylinder1.
The slide-on distance is ⇒ 12 - 3.5 mm
The device must remain in place 20 minutes after relieving the pressure.
Engine start-up earliest 2 hours after relieving the oil pressure.
Spacer
Connection Z 1/4 ‘’

©2010
m
M 25
Gear Train c2
Intermediate gear wheel installation
Tighten screws (1) with ⇒ M = 130 Nm
Molykote
O-ring
End clearance S min. ⇒ 0.30 mm

max. ⇒ 0.60 mm
Gap size
Gap size between shaft and locking plate (see Y)
min. ⇒ 0.30 mm
max. ⇒ 1.40 mm
Replacement of the bush in the intermediate gear wheel:

Cool the bush down to -195 °C with liquid nitrogen and insert it.
Reference dimension after freeze fitting: ⇒ 96.054 mm + 0.048 mm
(bush inside diameter)

©2010
m
M 25
Gear Train c2
Camshaft gear wheel installation
Note: For installing the gear wheel on the

camshaft please also refer to paragraph
“Pre-stroke and assembly reference
dimension“ in chapter “Injection
Pump“
Gear wheel installation (new design):

Journal (1) must not project into the gear case.
Swing camshaft gear wheel (2) into the gear
case with device 2103-1036. Push the oiled
journal until it contacts the camshaft gear
wheel cone. Prefit helical gear (3) so that it
contacts the camshaft gear wheel. (Ensure
correct mounting position, see next page)
Install the camshaft gear wheel by evenly
tightening screws (4) up to the stopper on the
bearing journal cone by means of an oil press
fit. Final position: Helical wheel (3) pulled
against bearing journal (1).
Pressing liquid: hydraulic oil
Engine start-up earliest 2 hours after relieving the oil pressure.
Attention!
When installing helical gear (3) pay attention to
the position of hole (1):
Cylinder 1 (on some 8 M 25 engines: cylinder 2)
and fuel delivery ramp of the injection cam must
be at TDC position (for IMO check).
Slide-on distance ⇒ 10.5 mm - 2.9 mm

Hydraulic oil pressure with hand pump ⇒ P = approx. 1200 bar
Tighten screws (4) (ISO4014-M16x80-8.8) with ⇒ M = 130 Nm
Molykote G Rapid Plus
End clearance at (6) ⇒ 0.30 - 0.70 mm
End clearance at (6) for M 25 C engines ⇒ 0.30 - 0.80 mm
Tighten screws (5) with ⇒ see chapter “Cam-
Molykote G Rapid Plus shaft“, paragraph
“Camshaft Assembly“

©2010
m
M 25
Gear Train c2
Screw the screw plug (2) into
washer (1) and tighten with ⇒ M = 150 Nm
Molykote
Tighten screws (4) with ⇒ M = 130 Nm

Molykote
Backlash values
Crankshaft gear wheel - intermediate gear wheel ⇒ 0.23 - 0.35 mm
Intermediate gear wheel - camshaft gear wheel ⇒ 0.23 - 0.35 mm
Lube oil nozzles for the gear train

Tighten screws with ⇒ M = 160 Nm

©2010
m
M 25
Governor Drive
Governor Drive c2
Governor drive (old design)
Pretighten castle nut (1) with ⇒ M = 30 Nm

then continue to tighten it up to the
next split pin hole. Molykote
End clearance at (2) ⇒ 0.30 - 0.60 mm
Mount governor bracket (3) and cover (8) with liquid sealing compound (Hylomar).
Backlash at (4) ⇒ 0.15 - 0.50 mm
Before freeze fitting heat coupling bush (5) up to ⇒ +50 °C
Cool governor drive shaft (6) with liquid nitrogen down to ⇒ -195 °C
and freeze fit in coupling bush (5).
After freeze fitting:

- Drill holes for spring dowel pin (7) and oil supply (∅ 6mm, staggered by 90°)
- Deburr and clean all holes on the inside and outsite
- Drive in spring dowel pin (7) DIN 1481-6x36 as shown (tight fit must be ensured)

©2010
m
M 25
Governor Drive c2
Bushes in the engine block
32
If bushes (1) and (2) in the engine block need
8
to be exchanged, keep the dimensions indica-
ted in the sketch. Slightly oil the bushes before
pressing them in, do not use Molykote.
302
335
Governor drive (new design)
Cool governor drive shaft (5) down to

-195 °C and heat gear wheel (3) up to
+40 °C for shrink fitting.
End clearance a is 0.20 + 0.30 mm
Tighten screw plug (8) for closing the opening

for the backlash check with 180 Nm. Put a
joint ring underneath.

©2010
m
M 25
Governor Drive c2
Heat gear wheel (2) up to +150 °C for shrink
fitting. Cool intermediate shaft (4) down to
-195 °C. Heat intermediate gear wheel (6) up to
+70 °C for shrink fitting.
Clean and degrease the sealing faces of plugs

(20) and the corresponding holes. Lubricate
the sealing faces of the plugs with Loctite 270.
For mounting use the provided drive-in man-
drel. The plug edges must be located
1.5 ± 0.5 mm deep in casing (1).
End clearance at c ⇒ 0.20 + 0.20 mm
Reference dimension d ⇒ 37 ± 0.5 mm
Reference dimension e ⇒ 101.1 ± 0.3 mm
When installing the governor drive pay

attention to the backlash ⇒ 0.25 +0.15 mm
between intermediate gear wheel (6) and camshaft gear wheel (not shown).
In case of a discrepancy, insert a spacer of appropriate thickness between governor drive

casing and engine block. Apply liquid sealing compound to both sides (casing (1) and
spacer).
Insert expander (7) according to the instructions of the manufacturer with the tools and
tests specifed by the manufacturer.

©2010
m
M 25 Camshaft
Camshaft c2
Flange code numbers
Before assembling the camshaft provide each camshaft flange with one parallel pin
according to the following table. Press in the parallel pins at the corresponding flange code
numbers up to limit stop.
6 M 25
Cylinder section 1 2 3 4 5 6
Flange code No. 5 1 6 5 3 7
8 M 25
Cylinder section 1 2 3 4 5 6 7 8
Flange code No. 1 or 2 2 3 4 5 6 7 8
9 M 25
Cylinder section 1 2 3 4 5 6 7 8 9
Flange code No. 5 8 2 6 4 4 6 2 8
Camshaft assembly
Tighten screws (1) (DIN931-M14 x 60-10.9) with ⇒ M = 140 Nm
Molykote
Tighten screws (2) with ⇒ See chapter “Gear Train“

paragraph “Camshaft gear
wheel“
Flange code number

Position of parallel pin
Exhaust (see table)
Helical cam Injection
gear wheel Inlet cam
cam
Flange code number

Position of parallel pin
(see table)

©2010

Fuel Delivery Pipe Removal: Engineer's Handbook Cylinder Head

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m

Fuel delivery pipe installation

1. Tighten the nuts of the fuel injection valve with ⇒ M = 50 Nm

7. Tighten the nuts of the fuel injection valve with ⇒ M = 50 Nm

Coat thread and contact surfaces

en / 26/4/10 Caterpillar confidential: yellow 26/128

Contact pattern check on inlet and exhaust valves

en / 26/4/10 Caterpillar confidential: yellow 27/128

Reference diameter X Dim. Y - new condition Dimension Y - wear limit

79.5-0.1 mm 8-0.4 mm 7.2 mm

Inlet valve 25-01 Inlet valve 25-19

Exhaust valve 25-20 (MDO) Exhaust valve 25-22 (HFO)

en / 26/4/10 Caterpillar confidential: yellow 28/128

Reuse of a valve stem is not possible, if:

2. There are corrosion pits and mechanical damage in

3. The limit for refinishing is exceeded, or

4. In case of corrosive material erosion of 2 % of the

en / 26/4/10 Caterpillar confidential: yellow 29/128

1. Cool the valve seat ring with liquid nitrogen down to

2. Insert the inlet and exhaust valve seat rings.

3. When the valve seat rings are tight, press them on

Pressing force for the hydraulic device ⇒ F = 65 kN

Valve seat ring

Exhaust valve seat ring Inlet valve seat ring

en / 26/4/10 Caterpillar confidential: yellow 30/128

Tighten screws crosswise with ⇒ M = 60 Nm

and then finally tighten with torque angle ⇒ Dw = 60°

2500.7-26.70.00-03 ⇒ 0.07 - 0.11 mm

Measure gap here,

en / 26/4/10 Caterpillar confidential: yellow 31/128

Grooves Groove height Ring height Wear limit Clearance limit

2 6.13 +0.03 6.00 -0.010 - 0.025 6.60 0.50

3 8.06 +0.03 8.00 -0.013 - 0.035 8.60 0.50

Pistons 2500.7-26.70.00-01 / 02 / 03 for gas oil and heavy fuel operation

Minimum Maximum Limit

Piston boss distance -

Removal of anti-polishing ring

2. Place the removal device on the

3. Slightly tighten the removal device by

4. Press the anti-polishing ring out by

en / 26/4/10 Caterpillar confidential: yellow 32/128

Big end bearing

Cylinder No. here

Lower bolts Cylinder No. here

Reference dimensions of the big end bearings after correct tightening.

Dimension A ⇒ 193.16 + 0.05 mm

The reference dimension of the piston pin bush

en / 01.07.2008 Caterpillar confidential: yellow 33/128

Piston pin bush - piston pin

Maximum clearance ⇒ 0.199 mm

Limit clearance ⇒ 0.210 mm

en / 01.07.2008 Caterpillar confidential: yellow 34/128

Wear and tear value TDC of 1st ring ⇒ 0.90 mm

Max. ovality ⇒ 0.25 mm

Wedge shape (Wedge-shaped indentation across the entire circumference, beginning

Total width ⇒ 0.03 mm

Scores (Severe vertical, linear friction marks)

Pockets (Areal, irregular indentations)