Adjusting The Camshaft: Tion" in Chapter "Lower Valve Drive"

m
M 25
Engineer’s Handbook
Camshaft c2
Adjusting the camshaft
For adjusting the camshaft please refer to paragraph “Camshaft adjustment instruc-
tion“ in chapter “Lower Valve Drive“.
Radial runout
Measure the radial runout of the camshaft in the preassembly fixture at all bearing positi-
ons (X) of the preassembled camshaft. Maximum radial runout: 0.04 mm.
Vibration damper installation 6 M 25 / 8 M 25

Tighten 8 screws (1) (M14x65-10.9) with ⇒ M = 140 Nm
Molykote
Tighten screws (2) (M12x70-8.8) with ⇒ M = 50 Nm

Molykote
Hole arrangement for Hole arrangement for

for 6M25 for 8M25
en / 26/4/10 Caterpillar confidential: yellow 51/128

©2010
Caterpillar Motoren GmbH & Co. KG - All rights reserved
m
M 25
Camshaft c2
Vibration damper installation 9 M 25
Tighten screws (4) (M12x70-8.8) with ⇒ M = 50 Nm
Molykote
If dimension X = 23 mm:
Tighten 8 screws (3) (M14x65-10.9) with extension sleeves with ⇒ M = 140 Nm
Molykote
If dimension X = 38 mm:
Tighten 8 screws (3) (M14x80-10.9) with extension sleeves with ⇒ M = 140 Nm
Molykote
or (new):
Tighten 8 screws (3) (M14x75-10.9) with washers with ⇒ M = 140 Nm
Molykote
Attention:
When carrying out work on this vibration damper check whether screws (3) are
of property class 8.8. If so, replace them by corresponding screws of property
class 10.9 with washers and tighten these with 140 Nm.
Camshaft bearings
Tighten locating screws (1) for the camshaft bearings with ⇒ M = 100 Nm
Molykote
Hexagon socket head cap screws ISO4762-M16x100-8.8

©2010
m
M 25
Lower Valve Drive
Lower Valve Drive
c2
Installation of valve drive for M 25:
Tighten screws (1) for the bearing brackets with ⇒ M = 130 Nm

Molykote
End clearances (not for first bearing bracket at cyl.1) ⇒ 0.20 mm
End clearance (for first bearing bracket at cyl. 1 only) ⇒ 0.30 mm
Determine the existing end clearance by

shifting the respective bearing bracket.
At the contact points of the cam follower

shafts no gap is admissible.
Loosen the bearing caps and push cam

follower shafts together from both sides so
as to be flush.

©2010
m
M 25
Lower Valve Drive c2
Installation of valve drive for M 25 C:
Tighten screws (1) for the bearing brackets with ⇒ M = 130 Nm

Molykote
If provided, tighten screw plugs (4) with ⇒ M = 85 Nm
Min. end clearance ⇒ 0.10 mm
Installation of the plugs at the ends of cam follower shafts (3):

Make sure that the sealing faces of the plugs and the corresponding holes are clean and
free of grease. Lubricate sealing faces with Loctite 270. For mounting the plugs use the
provided drive-in mandrel. The plug edges must be located 2 ± 0.5 mm deep in the cam
follower shaft.
When replacing IMO shims (2) of any cylinder bar the engine until all rollers of the respec-
tive cylinder unit are on the base circle of the camshaft. Then adjust as described below
under “Camshaft adjustment instruction“. Record the IMO shims for the corresponding
cylinders. Pay attention to the position of the shims.
When removing/mounting the lower valve drive make sure the IMO shims are not remo-
ved. If for any reason removal of the shims is necessary, mark them with the correspon-
ding cylinder number.
The thickness of the IMO shims of the individual cylinders is indicated on the acceptance
test record.
Camshaft
base circle

©2010
m
M 25
Installation of valve drive with FCT
1. Start the assembly of the lower valve drive at the free end of the engine and proceed
towards driving end. During assembly and removal of the valve drive of a cylinder abso-
lutely make sure that the cam follower bracket piece parts (8) are kept together accor-
ding to their marking. It is not admissible to interchange cam follower piece parts with
parts of other cylinder units!
2. Install the first cylinder unit. Tighten screws (1) for the bearing brackets finger tight.
3. After assembly of the first unit (free end) mount intermediate shaft (2). The intermediate
shaft can be shifted.
4. Mount the next cylinder until the same way.
5. Connect the cylinder units by means of intermediate shaft (2). In doing so, pay attention
to the position of cam follower shafts (3) and (4): Hole (∅ 8 mm) in the cam follower
shaft must point vertically upward (see illustrations).Use a mandrel for orientation. As
an alternative to the position of the holes: Limit stop of the cam follower shaft rests
against stopper (5) (for last cylinder only).
6. Mount all cylinder units. Tighten screws (1) for bearing brackets with 130 Nm and Moly-
kote starting from the centre of the engine and proceeding towards the outside and
check the cam followers for ease of movement. If necessary, loosen cylinder unit and
realign it.
7. Finally, install plates (6) with screws (7) as per drawing. The plates must be located in
the groove of intermediate shaft (2). Only this way proper fixation of the intermediate
shaft is ensured.
Upon assembly of correct
of the drilling to by observed
(all Cylinder)
Attention:
Position of grooves: overhead

©2010
m
M 25
Camshaft adjustment instruction
for IMO engine version with shims, sense of rotation: counterclockwise and clockwise.
Shims with increments of ± 0.2 mm - corresponding to changes in crank angle of approxi-
mately ± 0.23°.
1. Adjust the assembly reference dimension as per drawing 2500.7-35.80.00-01 by

means of shims on all cylinders.
(see also paragraph “Prelift and assembly reference dimension“ under chapter
“Injection Pump“).
The lower valve drive is installed with a 2.0 mm basic shim.
2. Rotate the camshaft in direction of rotation of the engine until the injection pump of
cylinder 1 is at commencement of fuel delivery.
3. Loosen the camshaft gear wheel and bar the engine until the graduated disc indicates
the corresponding engine adjustment value for cylinder 1 (see chapter “IMO
Adjustment“). Fix the camshaft gear wheel.
4. Bar the engine for the other cylinders to the same position and check the commence-
ment of fuel delivery (see chapter “Injection Pump“). Correct the commencement of
fuel delivery on the lower valve drive in the following way only if necessary:
4.1 Unscrew the upper M16x120 screws.
4.2 Unscrew the lower M16x120 screw only by max. 3 mm.
4.3 Replace the shim (basic adjustment is 2.0 mm).
4.4 If a subsequent check after replacement of the shims shows that the adjustment
with respect to cylinder 1 is not okay, readjust starting from step 2.
From step 3 rotate the camshaft to the left/right until all cylinders are within the
tolerance range with respect to cylinder 1.
4.5 Install the lower valve drive.
Assembly step 4.1
Assembly step 4.3
Assembly step 4.2

©2010
m
M 25
Cam followers
Cool down with liquid nitrogen ball sockets (1) or ball pieces (2) of the cam followers for
installation and press in up to limit stop.

©2010
m
M 25
Fuel Injection Pump
Fuel Injection Pump
c2
Note: During operation injection pumps are subject to lube oil leakage. This is due to design
characteristics and operation, so that the leak rate may vary between the individual pumps.
The upper limt at the collecting pipe is
number of cylinders x 2.5 litres / 24 hours
Reuse of the leak oil is not possible because it is contaminated with HFO.
Tightening torques
Insert the studs with ⇒ M = 120 Nm
Molykote
Type: PF1WX230V-C
Tighten fastening nuts with ⇒ M = 200 Nm
Molykote
Pretighten screws (1) with ⇒ M = 10 Nm

and then
finally tighten with ⇒ M = 90 ± 3 Nm
Molykote-Multiglis
Tighten screws (2) with ⇒ M = 53 ± 2 Nm

Molykote-Multiglis

Molykote-Multiglis
Tighten screws (6) with ⇒ M = 155 Nm
Tighten M12 thread (7)

for pump transportation
with max. ⇒ M = 20 Nm
Pay attention to mounting position!

©2010
m
M 25
Fuel Injection Pump c2
Tighten screws (1) for the
leak fuel drain with max. ⇒ M = 30 Nm
Tighten screws (2) with max. ⇒ M = 50 Nm
Tighten counter-sunk screws (3) for the
control travel indicator with ⇒ M = 3.50 + 0.50 Nm
Thighten screws (4) for mixed oil drain/fuel leak pipe
for the M 25 with max. ⇒ M = 50 Nm
for the M 25 C with max. ⇒ M = 40 Nm
Installation
Before installing the injection pump make sure that the roller of the cam follower rests on
the camshaft base circle.
Before installing the injection pump check the air passage sleeves for correct position in
the cooling collar.
Removal - Installation
During removal / installation make sure that the related shims are not removed.
If for any reason removal of the shims is necessary, they are to be marked with the relevant
cylinder number.
The thickness of the shims for each cylinder is indicated on the testbed record.

©2010
m
M 25
Fuel distributing and collecting pipe
2 loose flanges
installation
1 loose flange
installation
Tighten screws (1) DIN933-M10x35-8.8 and (2)

DIN933-M10x20-8.8 with ⇒ M = 20 + 5 Nm
Tighten screws to DIN933-M10x30-8.8 with ⇒ Standard torque
Tighten screw (3) with ⇒ M = 80 Nm

Loctite 542.
Reference dimension a for all throttle tubes is ⇒ 3 mm

©2010
m
M 25
Starting process
The engine starting process is controlled via the injection pumps.
Roller of the cam follower on cam base circle Starting process is initiated
Pump plunger at BDC position
Start initiated
Control air inlet
Pump plunger at TDC position Venting is initiated
Starting process Start of venting

©2010
m
M 25
Prelift and assembly reference dimension
Engine version without eccentrics, sense of rotation CCW or CW
1. Adjust the assembly reference dimension (determine 24.6 mm with device, inclu-
ding 0.2 mm clearance, max. limit clearance of 0.6 mm permissible) with shims
on all cylinders. Max. deviation between shim and measured value: 0.1 mm.
2. Rotate camshaft in direction of rotation of the engine until the injection pump of
cylinder 1 is at commencement of fuel delivery (port closing).
3. Loosen camshaft gear wheel and bar the engine until the graduated disc indica-
tes 10.5° +0.5° / -1.5° crank angle before TDC for cylinder 1. Fix the camshaft
gear wheel.
Engine version with eccentrics, sense of rotation CCW or CW
1. Eccentric position: vertically upwards
2. Check the initial position of the adjustment device: adjusting lever horizontal
3. Steps 1 to 3 as above
Tighten nuts (1) with ⇒ M = 200 Nm

Molykote
Commencement of delivery
Firing TDC
Position of
commencement
of delivery

©2010
m
M 25
Check of commencement of fuel delivery
1. Remove the injection pump delivery valve.
2. Install the dial gauge with extension.
3. Bar the engine so that the roller rests on the cam base circle and the TDC mark is
approximately 45° before dead centre indicator.
4. Set the dial gauge to “0“, turn the engine in direction of rotation until the gauge
indicates 5 mm (5 mm on the gauge correspond to 11° on the flywheel).
5. Check on the flywheel the dimension from TDC mark to dead centre indicator.
Adjustment of commencement of fuel delivery
1. Place the gauge with measuring device on a level support with the adjusting bush
(dimension = 24.6 mm) and set the gauge to “0“.
2. Insert the measuring device into the injection pump hole in the engine block and
read off the value on the dial gauge.
The roller shall always rest on the cam base circle
(For versions with cam follower eccentrics the eccentric position has to be vertically
upwards.)
3. Indicated value = thickness of the shims.

The shims are used for adjusting the prelift.
Available thicknesses:
2.10 mm 2.20 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm

2.80 mm 2.90 mm 3.00 mm 3.20 mm 3.40 mm 3.60 mm

©2010
m
M 25
IMO Adjustment
IMO Adjustment c2
Note: When the IMO adjustment is changed the engine will lose its certificate.
Engine IMO adjustments
M 25 290 / 300 / 330 kW/cyl. @ 720/750 rpm
1. Commencement of fuel delivery

Commencement of fuel delivery as arithmetic mean value over all cylinders
Nominal value: 10.5° (+0.5° -1.5°) before TDC
Measured according to the overflow method; control travel >38 mm
or prelift dimension 4.0 mm at auxiliary device No. 11.01-1040.
2. LT cooling water temperature

LT water inlet temperature
Nominal value: 38 °C (±2 °C)
3. HT cooling water temperature

HT engine outlet temperature
4. Charge air temperature

5. Piston distance
Distance: piston - cylinder liner:
Nominal value: 18.6 mm (+0.55 mm / -1.55 mm)
Measured: from edge of bowl to liner landing
Adjustment of camshaft (250*.7-31.20.00-03/-04)

Adjustment of TDC mark according to job card AAMF 507,
adjustment of commencement of fuel delivery of the injection pumps according to drawing
2500.7-35.80.00-01 (see also chapter “Injection Pump“, paragraph “Adjustment of
commencement of fuel delivery“).
IMO marking to be provided as per drawing 2500.0-09.09.00-02 (see below).

©2010
m
M 25
IMO Adjustment c2
M 25 C 330 / 334 kW/cyl. @ 720/750 rpm

Nominal value: 10.5° (+0.5° -1.5°) before TDC



5. Piston distance (check)
Nominal value: X = 18.6 mm (+0.55 mm / -1.55 mm), see illustra-

tion
Adjustment of camshaft (250*.7-31.20.00-20)

IMO marking to be provided as per drawing 2500.0-09.09.00-02 (see below).

©2010
m
M 25
IMO Adjustment c2
M 25 / M 25 C 300 / 330 / 334 kW/cyl. @ 720/750 rpm
EPA Tier II / DNV Clean Design

Nominal value: 9° (+0.5° -1.5°) before TDC



5. Piston distance (check)

Nominal value: X = 18.6 mm (+0.55 mm / -1.55 mm), see illustra-
tion
Adjustment of camshaft (250*.7-31.20.00-03/-04/-20)

IMO marking to be provided as per drawing 2500.0-09.09.00-02 / -20 (see below).

©2010
m
M 25
IMO Adjustment c2
IMO adjustment: check (M 25)
1. Remove screw plug (1).
2. Bar the engine until the Ø 4 mm hole in the

helical gear wheel is centrical with regard to
hole (2) M10 x 1 in the cover (see sketch).
3. Check at the flywheel whether the IMO

marking matches the dead centre mark.
4. After this check screw in the screw plug

again.
IMO adjustment: marking of flywheel (M 25)
1. Marking is only permitted when changing

the flywheel.
Marking on
flywheel
2. Adjust the engine in accordance with the
engine testbed record. Particularly observe
the IMO valve timing.
3. Bar the engine until the Ø 4 mm hole in the helical gear wheel is centrical with regard
to hole (2) M10 x 1 in the cover.
4. Stamp the IMO notch directly at the dead centre indicator on the flywheel.

©2010
m
M 25
IMO Adjustment c2
IMO adjustment: check (M 25 C) IMO-
Check
1. Unscrew screw plug (1). bore hole
2. Bar the engine until the Ø 6 mm IMO

check hole of the thrust washer is centrical
below the check hole in the cover.
3. Check at the flywheel: Washer-thrust

The IMO marking on the flywheel must Cover
match (coincide with) the dead centre indi-
cation. Flywheel Dead center
indicator
4. After this check screw in screw plug (1)
again.
IMO-
notch
IMO adjustment: marking of flywheel (M 25 C)
1. Unscrew screw plug (1).
2. After adjusting the engine (IMO adjustment) bar the engine until the Ø 6 mm IMO check
hole of the thrust washer is centrical below the check hole in the cover.
3. Stamp the IMO notch directly at the dead centre indicator on the flywheel (see illustra-
tion above).
4. Screw in screw plug (1).

Washer-thrust
Cover
Cover

©2010
m
M 25 Miscellaneous
Miscellaneous c2
Control shaft
Molykote
Clearance at (2) is ⇒ 0.20 mm

Lubricate the bearing areas of the control shaft
with grease and then insert it.
Do not use Molykote nor oil. Check the shaft for ease of movement.
Then screw the articulated lever onto the shaft.
Tighten screw (3) for the articulated lever with ⇒ M = 20 Nm

Molykote
Tighten screw (4) with ⇒ M = 130 Nm

Molykote
Clearance at 5 is ⇒ 1.00 mm
When replacing the bushes in the bearing brackets of the control shaft slightly lubricate
the bushes with oil before pressing them in. Do not use Molykote.
Reference dimension of the bush (inside diameter) ⇒ 32.06 + 0.149 mm

©2010
m
M 25
Miscellaneous c2
Cooling water distributing pipe
Tighten screws (1) (ISO4014-M16x110-8.8-A3C) with ⇒ M = 130 Nm
Molykote
Level probes
Tighten the level probes of the
electrical equipment with max. ⇒ M = 50 Nm
Special oil pan:

Tighten the 8 screwed connections (1)
for the middle plate with ⇒ M = 250 Nm

©2010
m
M 25
Miscellaneous c2
Barring gear
Loctite 243
Molykote
Actuate barring gear with

torque wrench up to 800 Nm,
reversible ratchet and socket
wrench insert.
Engine operation is only

possible when cover (3) is
screwed on.
In case of an electric barring gear put on barring

gear (4) with liquid sealing compound.

©2010
m
M 25
Miscellaneous c2
Starting fuel limiter
Installation instruction
1. For basic adjustment of lever (1) extend the piston of cylinder (2) by 30 mm.
2. Set the fuel racks of the injection pumps to position 16.
3. Lever (1) must come to a stop at the mechanical limit stop at piston (3).
4. Retract the piston of cylinder (2).

At full load lever (1) must not rest against piston (3).
5. Drill lever (1) with 6 mm, pin it with a clamping sleeve and seal it with lead.
Full load
Position 16
Stop

©2010
m
M 25
Miscellaneous c2
Fuel rack sensor
Adjust cam (1) so that in stop position the centre punch mark (2) aligns with the axis of the
fuel sensor.
Sketch: variation -03 variation -04
Governor arrangement
Always follow the adjustment data of the governor data sheet. Only in exceptional cases
and only after consulting the technical customer service VT5 the setting of the governor
may be changed. For further information please refer to chapter “Speed Governor“ in
the General Part of this Handbook.

©2010
m
M 25
Miscellaneous c2
Installation instruction for the water drain hose pipe
Install the hose pipe with large bending radius and free of stress. The following adjustment
possibilities can be used:
1) Fastening of the bracket on the charge air cooler flange: Fixing point and positioning of
the hose can be chosen at discretion.
2) Fastening of the pipe in the clamps: Can be chosen at discretion for fine adjustment.
3) Turn pipe elbow into appropriate position for stress-free mounting.
Hydraulic jack: Installation instruction for replacing gaskets

Removal:
1. Loosen screws in the cap.
Caution: Cap is under spring pressure! Remove cap and springs.
2. Remove vent screw and ball.
3. Press out piston and remove damaged gasket.
Installation:
1. Insert new gasket. Ensure correct position of the support ring. Sequence: First rubber
ring, then support ring (see illustration below).
2. Slightly grease the gaskets.
3. Press piston completely into cylinder.
Attention: Make sure the piston does not get jammed. Use a plastic assembly pin
as guide.
4. Twist piston according to the holes of the cap. Insert compression springs and screw
down cap. Tightening torque: 9 Nm
5. Vent the hydraulic jack. For this purpose connect it to the hydraulic pump and hold it in
such a way that the vent hole is at the highest point. Actuate the pump until oil emerges
without any bubbles.
6. Firmly close with ball and vent screw.
Support ring
Rubber
Support ring

©2010
m
M 25
Free End of the Engine
Free End of the Engine
c2
Adjustment instruction for starting air distributor
1) Set the piston of cylinder 1 to firing TDC
2) Loosen nut (1)
3) Turn disc (2) on the shaft cone in the indicated direction until the slot of the disc just
about intersects with the corresponding hole (cylinder 1) in the mirror. The intersection
with the bore of the preceding cylinder should be roughly the same. (Take into account
the sense of rotation of the engine)
4) Tighten the nut by hand
5) Fasten shaft (3) in a vice (soft jaws)

and tighten nut with ⇒ M = 30 - 40 Nm
Molykote
6) Before assembly check the position of shaft and disc
Tighten screws (4) (M8x50 8.8) with ⇒ M = 17 Nm

Molykote
Tighten screws (5) (M10x25 8.8) with ⇒ M = 34 Nm

Molykote
Right
Cyl. 1
Left

©2010

Adjusting The Camshaft: Tion" in Chapter "Lower Valve Drive"

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Adjusting The Camshaft: Tion" in Chapter "Lower Valve Drive"

Uploaded by

Copyright:

Available Formats

m

Vibration damper installation 6 M 25 / 8 M 25

Tighten screws (2) (M12x70-8.8) with ⇒ M = 50 Nm

Hole arrangement for Hole arrangement for

en / 26/4/10 Caterpillar confidential: yellow 51/128

en / 26/4/10 Caterpillar confidential: yellow 52/128

Tighten screws (1) for the bearing brackets with ⇒ M = 130 Nm

End clearances (not for first bearing bracket at cyl.1) ⇒ 0.20 mm

End clearance (for first bearing bracket at cyl. 1 only) ⇒ 0.30 mm

Determine the existing end clearance by

At the contact points of the cam follower

Loosen the bearing caps and push cam

en / 26/4/10 Caterpillar confidential: yellow 53/128

Tighten screws (1) for the bearing brackets with ⇒ M = 130 Nm

If provided, tighten screw plugs (4) with ⇒ M = 85 Nm

Min. end clearance ⇒ 0.10 mm

Installation of the plugs at the ends of cam follower shafts (3):

en / 26/4/10 Caterpillar confidential: yellow 54/128

en / 26/4/10 Caterpillar confidential: yellow 55/128

1. Adjust the assembly reference dimension as per drawing 2500.7-35.80.00-01 by

Assembly step 4.1

Assembly step 4.3

Assembly step 4.2

en / 26/4/10 Caterpillar confidential: yellow 56/128

en / 26/4/10 Caterpillar confidential: yellow 57/128

Pretighten screws (1) with ⇒ M = 10 Nm

Tighten screws (2) with ⇒ M = 53 ± 2 Nm

Tighten screws (3) with ⇒ M = 14 ± 1 Nm

Tighten screws (4) with ⇒ M = 22 ± 2 Nm

Tighten screws (5) with ⇒ M = 85 ± 5 Nm

Tighten screws (6) with ⇒ M = 155 Nm

Tighten M12 thread (7)

Pay attention to mounting position!

en / 26/4/10 Caterpillar confidential: yellow 58/128

en / 26/4/10 Caterpillar confidential: yellow 59/128

Tighten screws (1) DIN933-M10x35-8.8 and (2)

Tighten screws to DIN933-M10x30-8.8 with ⇒ Standard torque

Tighten screw (3) with ⇒ M = 80 Nm

Reference dimension a for all throttle tubes is ⇒ 3 mm

en / 26/4/10 Caterpillar confidential: yellow 60/128

Pump plunger at TDC position Venting is initiated

Starting process Start of venting

en / 26/4/10 Caterpillar confidential: yellow 61/128

Engine version without eccentrics, sense of rotation CCW or CW

Engine version with eccentrics, sense of rotation CCW or CW

1. Eccentric position: vertically upwards

Tighten nuts (1) with ⇒ M = 200 Nm

en / 26/4/10 Caterpillar confidential: yellow 62/128

1. Remove the injection pump delivery valve.

2. Install the dial gauge with extension.

Adjustment of commencement of fuel delivery

3. Indicated value = thickness of the shims.

2.10 mm 2.20 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm

en / 26/4/10 Caterpillar confidential: yellow 63/128

Engine IMO adjustments

M 25 290 / 300 / 330 kW/cyl. @ 720/750 rpm

1. Commencement of fuel delivery

2. LT cooling water temperature

3. HT cooling water temperature

4. Charge air temperature

Adjustment of camshaft (250*.7-31.20.00-03/-04)

en / 26/4/10 Caterpillar confidential: yellow 64/128

1. Commencement of fuel delivery