2 Maintenance B

Maintenance A0
Maintenance
9 M 25 C
Engine No. 45401 Record No. 271283

45402
en / 28.01.2014 AA047801 1/1

Total Index A0.01
Maintenance A0
Total Index A0.01
Introduction A0.02
Maintenance A5
Table of Contents A5.01
Introduction A5.02
Tightening Torques (Standard) A5.03
en / 28.01.2014 AA047652 1/1

Introduction A0.02
M20/M25/M32/M43/M46DF/GCM34
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is
matched with the equipment condition and the type of fuel sold.
Since the type of fuel used considerably influences the service life of the components, the Caterpillar after-
sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel
oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary docu-
mentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar after-
sales service should also be consulted for a longer period of time so that a documentation with extended
maintenance intervals can be made available.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the
operating instructions are subdivided into the following chapters:
Operating Instructions
Maintenance
Technical Engine Data
Operating Media
Tool Catalogue
Spare Parts Catalogue
Control and Monitoring
External Documentation (Subsupplier Documentation)
With the respective information contained in the individual chapters, the technical personnel is able to
maintain the engine in such a manner that regarding its output, reliability, economy and service life opti-
mum operating results can be achieved.
If you need further information or if you have any other questions, we kindly ask you to contact our respon-
sible service organization.
The operating instructions do not release the personnel in charge of this engine plant from their duty to take
care. The recognized rules of technology are to be observed, taking into account overriding regulations,
observance of the general safety measures and locally applicable accident prevention regulations. Data or
explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not
contained.
Caterpillar Motoren GmbH Co. KG is not responsible for damage caused by improper operation and
maintenance.
These operating instructions are only intended for our customers. All rights reserved for this docu-
ment. All technical data contained in these operating instructions must neither be reproduced, dis-
tributed nor utilized for competitive purposes or disclosed to third parties without our express
approval.
Postal address: Caterpillar Motoren GmbH & Co. KG, P.O. Box, D-24157 Kiel
Telephone: +49(0)431- 3995-01(chief operator)
Telefax: +49(0)431-3995-2010(after-sales service only)
http://www.marine.cat.com
en / 28/1/14 AA047587 1/1

Maintenance A5
Maintenance
en / 28.01.2014 AA000026 1/1

Maintenance A5
Introduction A5.02
Tightening Torques (Standard) A5.03
Engine, cylinder head A5.05.01

Valve clearance
Inspection / Adjustment A5.05.01.01.01.00
Valve projection
Maintenance / Inspection A5.05.01.01.02.00
Rocker Arm Bracket
Disassembly / Reassembly A5.05.01.02.01.00
Valve Rockers
Maintenance / Disassembly and reassembly A5.05.01.02.02.00
Valve Rotator
Valve Guide/Oil Control Ring
Inspection / Replacement A5.05.01.05.01.00
Media supply system
Cylinder head
Maintenance / Disassembly A5.05.01.06.01.00
Nozzle Sleeve
Relief Valve
Maintenance / Replacement A5.05.01.06.70.02
Inlet and exhaust valve cones
Inspection / Disassembly and reassembly A5.05.01.07.01.02
Valve cones
Valve Seat Ring
Maintenance / Evaluate A5.05.01.08.02.00
Starting valve
Cylinder head
Cylinder head
Maintenance / Cleaning A5.05.01.10.01.00
Cylinder head
Maintenance / Reassembly A5.05.01.11.01.00
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Engine, gear A5.05.02

Crank Web Deflection
Inspection / Measuring A5.05.02.02.01.00
Big-end bearings
Inspection / Disassembly A5.05.02.04.01.00
Big-end bearings
Inspection / Reassembly A5.05.02.04.02.00
Crankshaft bearing
Crankshaft bearing/-thrust bearing
Crankshaft bearing/-thrust bearing
Inspection / Reassembly A5.05.02.05.02.00
Piston
Piston crown
Piston Rings and Grooves
Piston pin
Small end bearing
Maintenance / Measuring A5.05.02.09.01.00
Piston
Engine, housing A5.05.03

Explosion relief valve
Cylinder Liner
Inspection / Measuring A5.05.03.03.01.00
Cylinder liner
Cylinder liner
Engine Fasteners and Connections
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Engine, control A5.05.04

Camshaft Bearing
Camshaft bearing
Camshaft
Timing gear train
Timing gear train
Governor Drive
Camshaft vibration damper
Engine, regulation A5.05.05

Control shaft bedding
Starting Valve
Control shaft
Compressed Air System
Control Valves
Maintenance Unit
Engine, exhaust gas system/supercharging A5.05.06

Exhaust Manifold
Charge air cooler
Exhaust gas turbocharger
Exhaust gas turbocharger
Repair / Replacement A5.05.06.14.02.00
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Engine, fuel system A5.05.07

Injection pump
Injection pump
Fuel Injector
Injection valve
Maintenance / Adjustment A5.05.07.08.01.00
Injection valve
Fuel Duplex Filter
Duplex Fuel Preliminary Filter
Fuel Feed Pump
Fuel feed pump drive
Fuel Distributor Manifold
Engine, lubricating oil system A5.05.08

Lubricating Oil System
Maintenance / Oil change A5.05.08.02.01.00
Lubricating oil pump
Oil pressure control valve
Prelubricating pump/Prelubrication
Maintenance / Checking A5.05.08.10.00.00
Engine, cooling water system A5.05.09

Cooling Water Centrifugal Pump
Engine, starting system A5.05.10

Stop Piston
Inspection / Checking A5.05.10.03.01.00
Condensate Trap
Repair / Disassembly and reassembly A5.05.10.51.00.00
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Engine control equipment A5.05.11

Pressure Switches
Inspection / Adjustment A5.05.11.01.03.00
Lubricating Oil/Cooling Water Thermostat
Maintenance / Checking A5.05.11.06.01.01
Pressure Switch
Inspection / Replacement A5.05.11.06.05.02
Pressure Switch
Crankcase Monitoring
Engine auxiliary units A5.05.12

Vibration Damper
Vibration Damper
Turning Device
Additional equipment A5.05.13

Round Nuts / Loosening and Fixing
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c2 Introduction A5.02
M20-VM46DF
1. General
It is assumed that the engine room personnel has the necessary knowledge and experi-
ence required for the proper maintenance and servicing of engines. For this reason and
in the interest of clearness we did not go too much into details in the maintenance docu-
ments.
No claims can be raised owing to missing instructions in the maintenance documents, if

damage is caused by improper handling.
All information refers to the date of printing.
2. Explanation of the maintenance system
2.1 Scheduled maintenance
Without “Scheduled maintenance” the economic operation of supercharged engine is in

the long run not possible at today's state of art.
The explanations are used to make the user of this engine plant familiar with the existing
maintenance system of Caterpillar Motoren GmbH & Co. KG and to interest and deepen
the understanding of the user for the problems and importance of the “Scheduled
maintenance”.
It is the purpose of the maintenance to replace parts subject to wear and tear or to repair
these parts before they are damaged.
The “Scheduled maintenance” is thereby supported by inspections according to fixed

deadlines. These inspections are decision criteria for the need and extend of mainte-
nance and servicing.
The following is used as parameter:
• data on wear and tear

• evaluation criterion and
• performance checks
It is recommended to consult Caterpillar Motoren GmbH & Co. KG with regard to exten-
ded intervals in order to maintain the guarantee.
The information given by us gives no rise to legal claims.
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M20-VM46DF
2.2 Maintenance system
The maintenance system consists of:
• maintenance plan
• job cards
While the maintenance plan indicates the date when inspection, maintenance or repair
shall be carried out, the job cards indicate the manner in which the work is to be carried
out.
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M20-VM46DF
2.2.1 Maintenance Plan
The maintenance plan shall provide for a quick summary of all intended inspection,
maintenance and repair work occurring up to 90,000 operating hours.
The maintenance plan is subdivided into the following areas:
• Daily inspection and control work
• Periodic maintenance work
A list of all recurrent inspection, maintenance and repair work to be carried out at the
scheduled date.
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M20-VM46DF
3. Safety instructions
3.1 Safety symbols
In the present operating instructions the following warning notices are used:
DANGER
A warning notice of this risk level signals the threat of a dangerous situation.
If the dangerous situation is not prevented, it will lead to death or serious injury.
Follow the instructions in this warning notice to prevent the risk of death or serious injury to
persons.
WARNING
A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to death or serious injury to persons.
Follow the instructions in this warning notice to prevent the possible risk of death or serious injury
to persons.
CAUTION
A warning notice of this risk level signals a potentially dangerous situation.

If the dangerous situation is not prevented, this could lead to minor or moderate injury.
Follow the instructions in this warning notice to prevent injury to persons.
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M20-VM46DF
CAUTION
or
CAUTION
A warning notice of this risk level signals possible damage to property.

If the situation is not prevented, this could lead to damage to property.
Follow the instructions in this warning notice to prevent damage to property.
NOTE
A note identifies additional information that facilitates the handling of the engine.
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M20-VM46DF
3.2 General safety instructions
Our engine is equipped with a monitoring system and an emergency stop system to prevent da-
mage caused to the operators' health as well as damages to the engine.
Within the scope of commissioning all mechanical, electric and pneumatic equipment and sy-
stems allowing the engine to be stopped for safety reasons will be demonstrated and explained
by our commissioning personnel.
Participants in this acceptance procedure are the authorized personnel of Caterpillar Motoren
GmbH & Co. KG, the managing and operating personnel of the operator and also representatives
of the insurance companies.
This important system is subject to recurrent inspections and tests in order to ensure proper
function of its individual components.
In the section "Scheduled Maintenance" you will find the respective test frequencies and related
job instructions that should be followed to protect the personnel from injuries and prevent material
damages.
NOTE
The provisions of the relevant accident prevention regulations of the appro-

priate employer's liability insurance association are to be observed any time
operation and repair work is carried out.
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M20-VM46DF
WARNING
Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil,
grease, fuel!
Use only suitable and technically perfect lifting gear and suspension systems
with adequate lifting capacity!
Never work or stand under suspended loads!
During replacement work, individual parts and large assemblies are to be ca-
refully fastened and secured on hoists to avoid risks of accidents!
Re-install removed guards and protecting devices on completion of work.
When carrying out overhead assembly work, the specially designed or safe-
ty-oriented climbing aids are to be used only!
Do not use engine/plant parts for climbing on!
Use personal protective equipment as far as necessary or as required by the

regulations!
Pressurized plant components (lube oil, hydraulic oil, fuel, cooling water, star-
ting and control air) must be depressurized. Shut-off valves are to be secured
by a plate “Do not open”!
When work is being carried out on engines and systems, the switch-on de-
vices have to be switched off and protected. In order to prevent reconnection,
the engines and systems have to be marked with a plate “Do not switch” or
an appropriate pictogram plate!
Mounting openings are to be protected!
Replaced seals should be disposed of immediately, and above all, it should

be taken care that this material is not overheated even by accident e.g. du-
ring combustion and welding operations. If this should however has happen-
ed, the gases emitted must not be inhaled. Skin contact with decomposed
VITONR is to be avoided at all times. After a fire with VITONR, it is essential
that neoprene gloves are worn during the clearing up operations.
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M20-VM46DF
CAUTION
Seals made of VITONR have been used at various locations in the engine.
With normal engine operation this material is completely harmless, however it
should not be exposed to temperatures above 300 °C (572 °F), since above
325 °C (617 °F) a thermal decomposition and the formation of hydrofluoric
acid can occur.
CAUTION
Maintenance and repair work must only be carried out by skilled and autho-
rized personnel!
NOTE
Any residues have to be neutralized before their disposal, i.e. saturated with
calcium hydroxide.
Clean the engine parts, especially connections and threaded unions of any
traces of oil, fuel or preservatives before carrying out maintenance/repair (di-
sassembly, assembly)!
Never use aggresive detergents and preservatives!
Use non-fuzzy cleaning rags!
Observe all indicating labels attached to the engine!
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M20-VM46DF
3.3 Working on electrical equipment
CAUTION
Work on the electrical equipment of the engine/plant must be carried out only
by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician in accordance with the electrical engineering
rules and regulations!
Use only original fuses with the specified current raiting! Switch off the engi-
ne/plant immediately if trouble occurs in the electrical system!
The electrical equipment is to be inspected/checked at regular intervals.

Defects such as loose connections or scorched cables must be rectified imme-
diately!
DANGER
Engine or plant parts on which inspection and maintenance work is being car-
ried out have to be - if prescribed - shut off at the power supply and provided
with the notice “Do not switch on” or the corresponding warning sign!
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M20-VM46DF
3.4 Working with hydraulic devices
WARNING
Do not place any parts of your body above the pressurized hydraulic tools!
Replace hydraulic hose lines at regular intervals, even if no safety relevant

defects are detectable!
Operating instructions, tightening torques and setting dimensions specified in

the appropriate job card are to be carefully observed!
The minimum bending radius of the high-pressure hoses are to be strictly ob-
served!
The hose lines are to be protected against damage caused by external

mechanical, thermal or chemical influences!
3.5 Checking and adjustment of injection valve
CAUTION
During testing make sure that no parts of your body are positioned in the area of the
fuel jet!
Do not inhale the fuel mist - respiratory mask!
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M20-VM46DF
3.6 Handling of liquid nitrogen or carbon dioxide snow
WARNING
When handling liquid nitrogen or carbon dioxide snow, safety shoes, safety
gloves and safety glasses are to be worn in order to avoid injuries. Observe
protection against cold!
CAUTION
Parts of the skin which have come into contact with liquid nitrogen or carbon
dioxide snow must not be rubbed but covered with sterile surgical bandage
3.7 Cleansing agents/chemicals
NOTE
Use only cleansing agents with a flash point above 65 °C (149 °F)!
Observe instructions for use in accordance with DIN safety data sheet of the regulati-
ons for dangerous substances!
Observe the specialist disposal of all cleansing agents and chemicals in accordance
with the regulations for dangerous substances!
In case of accident, observe the accident leaflets including first-aid actions for
dangerous substances in accordance with the regulations for dangerous substances!
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M20-VM46DF
3.8 Proposition 65 Warning
NOTE
California / USA
Proposition 65 Warning
Engine exhaust and some of its constituents are known to the state of Califor-
nia to cause cancer, birth defects, and other reproductive harm.
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c2 Tightening Torques (Standard) A5.03
M20-VM46DF
Tightening torques for threaded connections
Engine Type Tools and Auxiliary Materials Pos. Tool No.
All engine types Engine oil / lubricating oil

Molykote paste “G-Rapid Plus“ *
*or equivalent product
NOTE
The tables below are applicable only to threaded connections for which no tightening
torques were specified in the maintenance sheets.
The tightening torques listed for threaded connections with screws/bolts are in
accordance with the tightening rules as per DIN 835, DIN 938, DIN 939, DIN 960,
DIN 961, ISO 4762 (DIN 912), ISO 4014 (DIN 931), ISO 4017 (DIN 933), ISO 8785
(DIN 960) and ISO 8676 (DIN 961).
Tightening torques for coarse pitch threads
Tightening torque with oil Tightening torque with Molykote

[Nm] [Nm]
Strength class 8.8 10.9 12.9 8.8 10.9 12.9
Coarse pitch
thread
M8 20 29 35 15 23 27
M10 40 59 68 30 45 52
M12 68 100 120 52 77 89
M14 110 160 185 84 125 145
M16 170 250 295 130 190 220
M18 245 345 405 185 265 310
M20 340 490 570 260 375 435
M22 470 670 780 355 510 600
M24 590 840 980 455 640 750
M27 870 1250 1450 660 930 1100
M30 1200 1700 1950 890 1300 1500
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c2 Tightening Torques (Standard) A5.03
M20-VM46DF
Tightening torques for fine threads
Tightening torque with oil Tightening torque with Molykote

[Nm] [Nm]
Strength 8.8 10.9 12.9 8.8 10.9 12.9
class
Fine thread
M8 x 1 21 32 37 16 24 28
M10 x 1 44 65 76 33 49 57
M10 x 1.25 42 61 72 32 47 55
M12 x 1.25 75 110 130 57 83 98
M12 x 1.5 72 105 125 55 80 93
M14 x 1.5 120 175 205 89 135 155
M16 x 1.5 180 265 310 140 200 230
M18 x 1.5 270 385 455 205 290 340
M20 x 1.5 380 540 630 280 400 470
M22 x 1.5 520 740 850 380 540 630
M24 x 2 640 930 1050 480 680 800
M27 x 2 930 1350 1550 690 980 1150
M30 x 2 1300 1850 2200 980 1400 1600
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c2 Valve clearance
Inspection / Adjustment
A5.05. 01.01.01.00
M20/M25/M32/M43/M46DF/GCM34
1500
See also: 01
Spare parts list:
Personnel requirement: 1 Pers.
Personnel qualification: skilled engine hand
Operating medium: Every fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Adjustment of valve bridge clearance

2. Adjustment of valve clearance
Engine type Tools and auxiliary materials Pos. Tool No.
All engines Feeler gauge W1 1.9075-003 *
M 20 C Barring rod W2 2.9100-380 *

M 20 C, M 25 C, Socket wrench W3 1.9100-060 *
M 32 C, VM 32 C, (for indicator valve, decompression valve)
M 43 C, VM 43 C,
M 46 DF, VM 46 DF
* no picture
1 2
3
NOTE
S
Valve clearance “S” is the distance
between the adjusting screw (Fig. 1/1) in
the rocker arm (Fig. 1/2) and the valve
bridge (Fig. 1/3).
Y X
Before each adjustment of valve clearance

“S” any valve bridge clearances “X” or “Y”
between the stem ends of the valves and
the corresponding contact surfaces of the
valve bridge are to be eliminated.
Principle representation
en / 04.11.2013 IB027519 1/5

c2 Valve clearance
A5.05. 01.01.01.00
M20/M25/M32/M43/M46DF/GCM34
1500
01
NOTE
An adjustment of valve clearance “S” is necessary before putting into operation a new
or reconditioned cylinder head as well as at further defined measuring intervals.
NOTE
Valve bridge and valve clearances are to be adjusted when the engine is still warm,
i.e. approximately 15 min. after stopping the engine.
1. Adjustment of valve bridge clearances
1.1 Secure the engine to prevent unintentional starting.
Conventional diesel engine:

- Interrupt the starting air supply.
- Throw and secure the emergency stop lever.
- Set the selector switch on the control stand to “Repair” (depending on equipment).
Common rail diesel engine and dual fuel engine:

Gas engine:
- Set the key switch at the “Local Data Board” to “OFF”
- Remove the key.
1.2 Engage barring device

(not provided for the M 20 C)
1
1.3 Insert the barring rod (W2) into the hole in 2
the flywheel (for M 20 C).
1.4 Disassemble valve cover.
1.5 Open the indicator valves/decompression

valves with the socket wrench (W3)
(not provided for the GCM34). Principle representation
1.6 Bar the piston of the cylinder unit to be checked to firing TDC.
- The rollers (Fig. 2/1) of the inlet and exhaust cam followers are on the base circle (Fig. 2/2)
of the camshaft.
- The rocker arms are relieved.
- There is perceptible clearance at the push-rods.
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c2 Valve clearance
A5.05. 01.01.01.00
M20/M25/M32/M43/M46DF/GCM34
1500
1.7 Loosen locknut (Fig. 3/2) on the rocker arm (Fig. 3/1). 01
1.8 Unscrew adjusting screw (Fig. 3/3) for the valve clearance upward until reaching the limit stop to
increase valve clearance “S”.
1.9 Loosen locknut (Fig. 3/5) on the valve bridge (Fig. 3/4).
1.10 Turn adjusting screw (Fig. 3/6) for the valve bridge clearance so as to obtain contact at zero clea-
rance at position “X”.
1.11 Screw in adjusting screw (Fig. 3/6) for the valve 2

bridge clearance so as to obtain contact at zero 1
3
clearance at position “Y”.
4
1.12 Hold tight adjusting screw (Fig. 3/6) for the val-
S
ve bridge clearance and tighten
6
locknut (Fig. 3/5) in accordance with the table
below. 5
Y X
Engine type Torque for
locknut (Fig. 3/5)
M 20 C 30 Nm (22 lb ft)
7
M 25 C 60 Nm (44 lb ft)
8
M 32 C, VM 32 C 150 Nm (111 lb ft)
GCM34 150 Nm (111 lb ft)
M 43 C, VM 43 C 250 Nm (184 lb ft) Principle representation

M 46 DF, VM 46 DF 250 Nm (184 lb ft)
1.13 Check that there is contact at zero clearance at positions “X” and “Y” by means of feeler gauge
(W1) 0.02 mm.
2. Adjustment of valve clearance “S”
2.1 Press rocker arms onto the push-rods.
2.2 Screw in adjusting screw for valve clearance “S” until the following valve clearances are reached.
Engine type Inlet mm Exhaust mm
M 20 C 0.6 0.8
M 25 C 0.5 + 0.1 0.9 + 0.1
M 32 C, VM 32 C 0.4 + 0.1 1.1+ 0.1
GCM34 0.4 + 0.1 1.2 + 0.1

M 43 C, VM 43 C 0.4 + 0.1 1.1+ 0.1
M 46 DF, VM 46 DF 0.4 + 0.1 1.1+ 0.1
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c2 Valve clearance
A5.05. 01.01.01.00
M20/M25/M32/M43/M46DF/GCM34
1500
2.3 Hold tight adjusting screw (Fig. 3/3) for the valve clearance and tighten locknut (Fig. 3/2) with 01
the following torques.
Engine type Torque for

locknut (Fig. 3/2)
M 20 C 90 Nm (66 lb ft)
M 25 C 100 Nm (74 lb ft)

M 32 C, VM 32 C 250 Nm (184 lb ft)
GCM34 250 Nm (184 lb ft)
M 43 C, VM 43 C 400 Nm (295 lb ft)

M 46 DF, VM 46 DF 400 Nm (295 lb ft)
2.4 Check clearance “S” once again with the corresponding feeler gauge (W1).
2.5 Close the indicator valves/decompression valves with the socket wrench (W3)
(not provided for the GCM34).
2.6 Check and, if necessary, replace the gaskets of the valve covers.
2.7 Reinstall valve covers.
2.8 Disengage the barring device (not provided for the M 20 C).
DANGER
Danger when starting the M 20 C engine with barring rod still inserted.
For barring the M 20 C engine a barring rod is used.
The inserted barring rod is not monitored by the control system and, therefore, does
not cause a starting interlock. If all other starting conditions are met, this engine could
be started with an inserted barring rod!
There is danger to life due to the barring rod striking around or being hurled out.
Remove the barring rod from the hole in the flywheel before starting the engine.
2.9 Remove barring rod (W2) from the hole in the flywheel (for M 20 C).
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c2 Valve clearance
A5.05. 01.01.01.00
M20/M25/M32/M43/M46DF/GCM34
1500
2.10 Lift the measures for securing the engine to prevent unintentional starting. 01
- Reestablish starting air supply.
- Set the emergency stop lever to operating position.
- Set the selector switch on the control stand to “Engine” or “Remote”.

Gas engine:
- Insert the key into the key switch at the the “Local Data Board”
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c2 Valve projection
Maintenance / Inspection
A5.05. 01.01.02.00
M20/M25/M32/M43/M46DF/GCM34
1500
See also: 01
Spare parts list:
Operating medium: Gas and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check valve projection on inlet and exhaust valves
Engine type Tools Pos. Tool No.
M 20 C Barring rod W1 2.9100-380 *
M 20 C, M 25 C, Socket wrench W2 1.9100-060

M 32 C, VM 32 C, (for indicator valve, decompression valve)
M 43 C, VM 43 C
M 20 C, M 25 C Depth gauge W3 251042 A
GCM34 Depth gauge W3 341033 A

M 32 C, VM 32 C,
M 43 C, VM 43 C,
M 46 DF, VM 46 DF
* no picture
NOTE
So-called valve projection is used to identify premature wear of the valves and valve
seat inserts. It is measured at regular intervals at a defined location, and the measu-
red values are documented and evaluated.
The valve height is to be measured upon commissioning, after installation of new or

overhauled cylinder heads, and at further defined measuring intervals by means of a
depth gauge (Fig. 1/W3). The obtained measuring values are to be recorded on the
attached measuring sheet and then copied into the “Valve ProjectionFalsePlease
forward the filled in evaluation chart to your responsible Caterpillar Customer
Service for an evaluation of the measuring values.
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c2 Valve projection
A5.05. 01.01.02.00
M20/M25/M32/M43/M46DF/GCM34
1500
1. Check of valve projection on inlet and exhaust valves 01



Gas engine:
- Set the key switch at the “Local Data Board” to “OFF”.
- Remove the key.
1.2 Engage the barring device and secure it against unintentional operation
(not provided for the M 20 C).
1.3 Insert the barring rod (W1) into the hole in the flywheel (for M 20 C).
1.5 Open the indicator valves/decompression valves with the socket wrench (W2)
- The rollers of the inlet and exhaust cam followers are on the base circle of the camshaft.
CAUTION
W3
Thoroughly clean the con-
tact surfaces before measu-
ring and check them for
damage.
1.7 Put on depth gauge (W3) as shown in

Fig. 1 so as to cover a large surface and
without tilting it and enter the measured
value in the attached table.
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c2 Valve projection
A5.05. 01.01.02.00
M20/M25/M32/M43/M46DF/GCM34
1500
1.8 The corresponding valves and valve seat inserts are to be replaced if valve projection exceeds 01
the values indicated in the table below since commissioning or the last replacement (valve stem/
valve seat).
Engine type Limit value “GFalse
M 20 C > 2.0 to 3.0 mm
M 25 C > 2.5 to 3.5 mm

M 32 C, VM 32 C > 3.0 to 4.0 mm
GCM34 > 3.0 to 3.5 mm
M 43 C, VM 43 C > 3.5 to 4.5 mm
M 46 DF, VM 46 DF > 3.5 to 4.5 mm
Valve guide
Measure of valve and Cylinder head

valve seat wear (cooling water duct)
G
Cylinder head
Valve and valve seat Valve and valve seat (casting)
- Worn out - - Normal -
en / 04.11.2013 IB027515 3/5

c2 Valve projection
A5.05. 01.01.02.00
M20/M25/M32/M43/M46DF/GCM34
1500
1.9 Close the indicator valves/decompression valves with the socket wrench (W2) (not provided for 01
the GCM34).
1.10 Check and, if necessary, replace the gaskets of the valve covers.
1.11 Install valve cover.
DANGER
1.14 Lift the measures for securing the engine to prevent unintentional starting.


Gas engine:
- Insert the key into the key switch at the the “Local Data Board”.
en / 04.11.2013 IB027515 4/5

c2 Valve projection
A5.05. 01.01.02.00
M20/M25/M32/M43/M46DF/GCM34
1500
01
en / 04.11.2013 IB027515 5/5

Rocker Arm Bracket A5.05. 01.02.01.00
Disassembly / Reassembly
M20/M25/M32/GCM34
See also: A5.05.01.01.01.nn 01

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Disassembly of the rocker arm bracket

2. Reassembly of the rocker arm bracket
M 20 C Barring rod W1 2.9100-380 *
M 20 C Torque wrench, 40-180 Nm W2 1.9454-040 *
M 25 C Torque wrench, 60 - 320 Nm W2 1.9454-320 *
M 32 C, VM 32 C Torque wrench, 100-400 Nm W2 1.9454-400 *
GCM 34 Torque wrench, 100-400 Nm W2 1.9454-400 *
M 20 C, M 25 C, Socket wrench W3 1.9100-060 *

M 32 C, VM 32 C (for indicator valve, decompression valve)
All engines Molykote paste “G-Rapid Plus“ **

* no picture
** or equivalent product
1. Disassembly of the rocker arm bracket


Gas engine:
- Set the key switch at the “Local Data Board” to “OFF”
- Remove the key.
en / 04.11.2013 IB028237 1/4

M20/M25/M32/GCM34
1.2 Engage the barring device and secure it against unintentional operation 01
(not provided for the M 20 C).
1.3 Insert the barring rod (W1) into the hole in the flywheel (for M 20 C).
1.5 Open the indicator valves/decompression valves with the socket wrench (W3)
- The rollers of the inlet and exhaust cam followers are on the base circle of the camshaft.
1.7 Remove hexagon nuts (Fig. 1/1).
1.8 Common rail diesel engine only: Remove the cable for injector control.
1.9 Remove the complete rocker arm bracket (Fig. 1/2)

with rocker arm shaft (Fig. 1/3) and rocker arms (Fig. 1/4).
6 4
3
2
8
5
en / 04.11.2013 IB028237 2/4

M20/M25/M32/GCM34
2. Reassembly of the rocker arm bracket 01

2.1 Clean the seat faces on the cylinder head and the rocker arm bracket and check them for
damage.
2.2 Place the complete rocker arm bracket (Fig. 1/2) with rocker arm shaft (Fig. 1/3) and rocker arms
(Fig. 1/4) over the studs (Fig. 1/5) onto the cylinder head.
2.3 Align the rocker arm bracket in such a way that the adjusting screws (Fig. 1/6) are positioned
centrally above the discs of the thrust pieces (Fig. 1/7) on the valve bridges (Fig. 1/8).
2.4 Apply Molykote paste “G-Rapid Plus” to the threads and contact surfaces of the hexagon nuts
(Fig. 1/1).
CAUTION
Uneven tightening may result in engine damage.
Stepless and/or uneven tightening of the hexagon nuts (Fig. 1/1) on the rocker arm
bracket may cause warping of the rocker arm bracket and damage.
The hexagon nuts (Fig. 1/1) are always to be tightened alternately in three evenly
divided torque steps in order to prevent warping of the rocker arm bracket.
2.5 Tighten both hexagon nuts (Fig. 1/1) at the foot of the rocker arm bracket (Fig. 1/9) alternately in
three even steps until reaching the torque indicated in the table below.
Engine type Torque
M 20 C 60 Nm (44 lb ft)
M 25 C 160 Nm (118 lb ft)
M 32 C, VM 32 C 300 Nm (221 lb ft)
GCM34 300 Nm (221 lb ft)
2.6 Tighten both hexagon nuts (Fig. 1/1) on the studs (Fig. 1/10) alternately in three even steps until
reaching the torque indicated in the table below.
Engine type Torque
M 20 C 120 Nm (89 lb ft)
M 25 C 160 Nm (118 lb ft)

M 32 C, VM 32 C 300 Nm (221 lb ft)
GCM34 300 Nm (221 lb ft)
en / 04.11.2013 IB028237 3/4

M20/M25/M32/GCM34
01
Subsequent work
Title Maintenance sheet No. Note
Adjust the valve clearance A5.05.01.01.01.nn
2.7 Carry out an oil flow check.

For this purpose, switch on the prelubrication pump.
2.8 Close the indicator valves/decompression valves with the socket wrench (W3)
2.9 Check and, if necessary, replace the gaskets of the valve cover.
2.9.1 Install the valve cover.
DANGER


Gas engine:
- Insert the key into the key switch at the the “Local Data Board”.
en / 04.11.2013 IB028237 4/4

c2 Valve Rockers
Maintenance / Disassembly and reassembly
A5.05. 01.02.02.00
M20/M25/M32/M43/M46DF/GCM34
30000
See also: A5.05.01.02.01.nn 01

Spare parts list:

----------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of inlet and exhaust rocker arms

2. Check of bearing clearances
3. Replacement of rocker arm bush
4. Replacement of ball pin
5. Installation of inlet and exhaust rocker arms
Engine type Tools and auxiliary material Pos. Tool No.
M 20 C, M 25 C, Brass mandrel W1 *
M 32 C,VM 32 C, **
GCM34,
M 43 C, VM 43 C
M 46 DF, VM 46 DF Liquid nitrogen *
Oil *
* no picture
** not included in the tool kit
1. Removal of inlet and exhaust rocker arms
Preparatory works
Title Maintenance sheet Notice
Rocker arm bracket disassembly A5.05.01.02.01.nn
1.1 Remove circlips (Fig. 1/4) and thrust 1 2

washers (Fig. 1/5) from the respective
ends of the rocker arm shaft (Fig. 1/3).
en / 04.11.2013 IB027528 1/4

c2 Valve Rockers
A5.05. 01.02.02.00
M20/M25/M32/M43/M46DF/GCM34
30000
1.2 M 20 C/ M 25 C: 01
Remove inlet rocker arm (Fig. 1/2) and
exhaust rocker arm (Fig. 1/1) from rocker
arm shaft (Fig. 1/3).
M 32 C/VM 32 C,GCM34,M 43 C/VM 43C,

M 46 DF/VM 46 DF:
Remove inlet rocker arm (Fig. 1/1) and
exhaust rocker arm (Fig. 1/2) from rocker
arm shaft (Fig. 1/3).
1.3 Clean all parts thoroughly and check them

for damage. Blow through the oil holes
with compressed air and check them for
free passage.
1.4 Check the contact surfaces of the ball pins

(Fig. 2/6) and adjusting screws (Fig. 2/7) for
wear and damage. Replace parts as 7 8 6
necessary.
2. Check of bearing clearance
2.1 Measure rocker arm bush (Fig. 2/8) and rocker arm shaft (Fig. 1/3). In doing so, observe the
values of the following table. When reaching the limit clearance, replace the rocker arm bush.
Clearance in new Limit clearance

Engine
condition mm mm
M 20 C 0,015 - 0,14 0,20
M 25 C 0,02 - 0,159 0,359

M 32 C/ 0,02 - 0,159 0,25
VM 32 C
GCM34 0,02 - 0,159 0,25
M 43 C/ 0,056 - 0,208 0,30

VM 43 C
M 46 DF/ 0,056 - 0,208 0,30
VM 46 DF
en / 04.11.2013 IB027528 2/4

c2 Valve Rockers
A5.05. 01.02.02.00
M20/M25/M32/M43/M46DF/GCM34
30000
3. Replacement of rocker arm bush 01
CAUTION
The rocker arm bushes (Fig. 3/8) may only be lubricated with oil.
It is not allowable to use Molykote paste for installing the rocker arm bushes!
Care has to be taken to ensure that the plastic coated running surface of the new
rocker arm bush will not be damaged.
3.1 Drive rocker arm bush (Fig. 3/8) out of rok-

ker arm using a suitable brass mandrel.
3.2 Lightly oil new rocker arm bush and press

into rocker arm.
When pressing in the new rocker arm bush

pay attention to the position of the oil holes 8
(Fig. 3/9) and the joint (Fig. 3/10).
In doing so, axially align the joint 9

(Fig. 3/10) towards the top. The oil hole
(Fig. 3/9) will then be automatically positio-
ned in the correct way.
10
Make sure there is a projection at both
ends of the rocker arm with regard to the
rocker arm bush (see Z) :
s = approx. 0.2 mm
4. Replacement of ball pin
4.1 Drive out worn ball pin by means of a brass mandrel (Fig. 2/6).
WARNING
Risk of injury due to frostbites when handling liquid nitrogen!
Observe the safety regulations when handling liquid nitrogen.
It is absolutely required to wear protective clothing (long trousers, long-sleeved outer-
wear, face protection with safety glasses, and protective gloves).
en / 04.11.2013 IB027528 3/4

c2 Valve Rockers
A5.05. 01.02.02.00
M20/M25/M32/M43/M46DF/GCM34
30000
4.2 Cool the new ball pin down to -195 °C (-319 °F) with liquid nitrogen. 01
4.3 When installing a new ball pin make sure marking X (if provided) is correctly
positioned, see Fig. 4.
5. Installation of inlet and exhaust rocker arms
NOTE
It has to be absolutely made sure that the rocker arm shaft is undamaged and free of
burrs.
5.1 Oil the contact surfaces of the rocker arm bushes of inlet rocker arm (Fig. 1/1), exhaust valve arm
(Fig. 1/2) and the rocker arm shaft.
5.2 Slide the rocker arms carefully onto the rocker arm shaft. In doing so, make sure not to tilt the rok-
ker arms.
5.3 Lock the rocker arms axially by means of thrust washers (Fig. 1/5) and circlips (Fig. 1/4).
Subsequent works
Title Maintenance sheet Notice
Rocker arm bracket reassembly A5.05.01.02.01.nn
en / 04.11.2013 IB027528 4/4

c2 Valve Rotator
A5.05. 01.03.01.00
M20/M25/M32/M43/M46DF/GCM34
150, 1500
See also: 01
Spare parts list:
Personnel requirement: 1 Pers./ 0,10 h

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Inspection of the valve rotators / ball races
Engine type Tools and auxiliary material Pos. Tool No.
GCM34 Torque wrench, 40-180 Nm W1 1.9454-040 *
M 20 C Torque wrench, 40-200 Nm W2 1.9454-200 *
Molykote paste “G-Rapid Plus” **
Lubricating oil/diesel oil mixture, approximately

250 ml (mixture ratio 1:1)
Torch
* no picture
NOTE
An inspection of the valve rotators and ball races can only be carried out while the
engine is running!
When commissioning a new or overhauled cylinder head, the valve speed must be
measured relative to the engine speed.
In order to have a comparison basis to later measurements, these data must be
written down.
NOTE
On gas engines the valve rotators are to be inspected through the two openings in the
valve cover [blind plug (Fig. 1/1) located to the left and right of the firing coil (Fig. 1/3).
On diesel engines and dual fuel engines the valve rotators/ball races are to be
inspected through the central opening in the valve cover [sealing cap (Fig. 1/2) or blind
plug (Fig. 1/1, M 20 C)].
en / 09.12.2013 IB027875 1/3

c2 Valve Rotator
A5.05. 01.03.01.00
M20/M25/M32/M43/M46DF/GCM34
150, 1500
1 3 1 2 1 01
4
4
Gas engine Diesel engine (M 25 C - M 46 DF) Diesel engine (M 20 C)
1. Inspection of the valve rotators / ball races
2. Remove blind plug/sealing cap of the valve cover (Fig. 1/4) of the corresponding cylinder head.
CAUTION
On a gas engine only max. two blind plugs must be removed at a time, otherwise the
rising internal engine pressure may trigger an engine stop.
3. Observe the valve rotation by means of a torch using marking “X” on the spring plate (Fig. 2/5) as
a reference.
The valve rotators or ball races are working properly if an even rotation depending on engine
speed can be observed.
NOTE
If the rotational speed of the valve should be found to be noticeably slower than
compared to new condition, lubricate valve rotator/ball race and valve stem with a few
splashes of lubricating oil/diesel oil mixture to increase the valve speed.
Use the lubricating oil/diesel oil mixture sparingly.
en / 09.12.2013 IB027875 2/3

c2 Valve Rotator
A5.05. 01.03.01.00
M20/M25/M32/M43/M46DF/GCM34
150, 1500
4. If the valve rotational speed slows down to n < 1 rpm at rated engine speed, the valve rotator or 01
the ball race must be replaced.
5. Clean the thread of the blind plugs (Fig. 1/1) and the inside of the sealing caps (Fig. 1/1) and
lightly lubricate them with Molykote.
5.1 Tighten blind plug (Fig. 1/1) with a torque of 120 Nm (89 lb ft).
5.2 Tighten sealing caps (Fig. 1/2) finger tight.
en / 09.12.2013 IB027875 3/3

c2 Valve Guide/Oil Control Ring
Inspection / Replacement
A5.05. 01.05.01.00
M20/M25/M32/M43/M46DF
15000
See also: A5.05.01.06.01.nn, A5.05.01.02.01.nn, A5.05.01.07.01.nn, A5.05.01.11.01.nn 01

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Measure valve guide clearance and replace oil control rings
M 20 C, M 25 C, Petro Gel Amber (1E1597) *

M 32 C, VM 32 C, **
M 43 C, VM 43 C,
M 46 DF, VM 46 DF Strong wire (e. g. welding wire) *
* no picture
1. Measure valve guide clearance and replace oil control rings
1.1 Remove cylinder head (A5.05.01.06.01.nn).
1.2 Dismantle rocker arm bracket (A5.05.01.02.01.nn) and remove valve bridge.
1.3 Remove inlet and exhaust valve stem (A5.05.01.07.01.nn).
1.4 Remove oil control rings (1) from the ring grooves (2) using a bent pointed piece of wire.
1.5 Measure the outside diameter of the valve stem in the guide area of valve guide bush (3).
1.6 Measure the inside diameter of valve guide bush (3) in transverse direction of the engine.
NOTE
We recommend to have the valve guide bush (3) replaced by a Caterpillar dealer
during a cylinder head overhaul.
If the clearance limit is reached, please contact your Caterpillar workshop.
en / 13.01.2014 IB028810 1/3

A5.05. 01.05.01.00
M20/M25/M32/M43/M46DF
15000
01
Engine Valve Normal clearance (mm) Clearance limit (mm)
Exhaust 0.10 - 0.17 0.3

M 20 C
Inlet 0.10 - 0.17 0.3
Exhaust 0.1 - 0.15 0.3
M 25 C
Inlet 0.1 - 0.15 0.3
Exhaust 0.18 - 0.24 0.35

M 32 C, VM 32 C
Inlet 0.11 - 0.17 0.3
Exhaust 0.22 - 0.29 0.4

M 43 C, VM 43 C
Inlet 0.15 - 0.22 0.35
Exhaust 0.22 - 0.29 0.4
M 46 DF, VM46 DF
Inlet 0.15 - 0.22 0.35
CAUTION
Engine damage due to incorrect or incorrectly fitted spare parts.
The oil control ring controls the valve lubrication and may only be replaced by a new
genuine Caterpillar spare part.
The oil control rings (1) must be inserted into the ring grooves lubricated with grease
and untwisted.
1.7 Clean the ring grooves (2).
1.8 Lubricate new oil control rings (1) with a thin layer of Petro Gel Amber and insert them into the
ring grooves untwisted.
en / 13.01.2014 IB028810 2/3

A5.05. 01.05.01.00
M20/M25/M32/M43/M46DF
15000
01
1
1
2
1.9 Install inlet and exhaust valve cone (A5.05.01.07.01.nn).
1.10 Put on valve bridge and install rocker arm bracket (A5.05.01.02.01.nn).
1.11 Install cylinder head (A5.05.01.11.01.nn).
en / 13.01.2014 IB028810 3/3

Media supply system A5.05. 01.05.50.00
M25
See also: 01.06.01.nn, 01.11.01.nn 01

Spare parts list: B1.05.01.252144
Operating medium: Heavy fuel and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Vaseline *
* or a product of equal standard
Sequence of operations:
1. Disassembly
CAUTION
The system must be depressurized before commencing disassembly!
1.1 Loosen the cheese head screws (Fig. 1/1) and remove the connecting flange (2) together with
the sleeves (3).
en / 19.12.2012 IB003176 1/3

M25
1.2 Pull the sleeves (Fig. 2/3) out of the connecting flange (2). 01
1.3 Check the O-rings (4). Replace faulty O-rings (4).
Insert O-rings in the grooves using vaseline. Rings must not be twisted!
Check the gaskets (5) of the connecting flange (2) as well as the gaskets of the connecting flange
(Fig. 1/6 and 7) at the first and last cylinder. Clean the sealing surfaces.
2. Reassembly
2.1 Mount the connecting flange (Fig. 3/2) with the sleeves inserted (3).
Replace faulty gaskets (5) beforehand.
2.2 Mount the connecting flange (Fig. 1/6 and 7) . Replace faulty gaskets (5) beforehand.
CAUTION
Make sure that all gaskets (5) are centered via the dowel pins (Fig. 3/8)!
3. Check operation of the alarm probe for leakage fuel (Fig. 4/50). To do :
3.1 Remove the alarm probe and place the tip in a medium with a test voltage connected.
Acknowledge the alarm if it is activated.
If an alarm is not activated, replace the alarm probe and repeat the test.
3.2 Mount the alarm probe.
en / 19.12.2012 IB003176 2/3

M25
01
en / 19.12.2012 IB003176 3/3

Cylinder head A5.05. 01.06.01.00
Maintenance / Disassembly
M25
See also: 01.05.50.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Hydraulic device consisting of :
High pressure pump W1 0.9204 D
High pressure hose (1 m) W2 0.9205 B
Hydraulic tightening element W3 0.9213 C
Distributor W4 0.9203-008
Support sleeve W5 0.9203-018
Support sleeve (short) W5.1 0.9203-209
Threaded sleeve W6 0.9206-002
Threaded sleeve (short) W6.1 0.9206-001
Pin W7 0.9203-110
Cylinder head lifting device W8 * 0.9221 A
Cylinder bush retaining device W9 * 259217 A
Tubular box wrench, indicator valve W10 * 1.9100-060
* not illustrated
NOTE
The cylinder liner must always be secured with the retaining device to prevent it from
coming lose when lifting the cylinder head or turning over.
CAUTION
A minimum bending radius of r = 120 mm must be maintained for the high pressure
hoses. Use hydraulic oil only as an operating medium, see engine documentation,
chapter "Operating Media"..
Store devices protected against corrosion.
DANGER
Do not position any parts of the body over devices which are under pressure. Secure
the engine against unintentional starting.
1. Mount the cylinder liner retaining device (W9) (A5.05.02.06.01.nn).
Open the indicator valves and turn the cylinder to be adjusted to firing TDC.
Inlet and exhaust valves closed, rocker arm relieved.
Remove the cylinder head cover and pump compartment covering.
en / 19.12.2012 IB003142 1/5

M25
2. Drain the cooling water on the plant side. 01

Inspection: Loosen the screw plug in the return pipeline of the compressor intercooler (pipeline)
below the thermometer.
3. Dismantle the media supply system (A5.05.01.05.50.nn).
4. Push the sleeve (Fig. 1/1) to the left into the cylinder head frame.
5. Completely unscrew the screw connection (Y) of the transverse thrust piece (2) out of the injec-
tion pump.
6. Loosen the pressure screw (3) and press up the traverse thrust piece (2) with cover (4) and pull to
the left out of the injection pump and the cylinder head.
7. Remove the trim panel between the exhaust pipe and cylinder head.
Remove the retaining screws for the exhaust pipe.
en / 19.12.2012 IB003142 2/5

M25
8. Loosen the four cylinder head nuts with 01

the hydraulic tightening device.
CAUTION
The maximum stroke indicator
(Fig. 2/2.1/10) must not
project above the upper limit
of the cover.
NOTE
put the short hydraulic units
onto the cylinder heat nuts
(12) at exhaust gas site
(Fig.3)
8.1 Place the hydraulic tightening elements

(Fig. 2/2.1/ W3) connected to the support
sleeves (W5/ W5.1) above the round nuts
(12). Pay attention to good accessibility of
the slits (13).
8.2 Screw the threaded sleeves (W6/W6.1)

onto the cylinder head screws (11) and
turn back until the shoulder
S = 3 mm
of the threaded sleeve to the upper edge

of the tightening element (W3) has been
attainedist.
8.3 Connect the hydraulic tightening elements

(Fig. 3/W3) and the distributor (W4) to the
high pressure pump (W1) via the high
pressure hoses (W2).
8.4 Connect the valve (Z) to the high pressure

pump (W1) and extend all four cylinder
head screws evenly and continuously at a
hydraulic pressure of
p = 820 bar .
8.5 Loosen the round nuts (Fig. 2/2.1 /12) with

pin (W7). Unscrew the round nuts by at
least 8 holes.
en / 19.12.2012 IB003142 3/5

M25
01
NOTE
If it is not possible to loosen the round nuts, the cylinder head screw can be preten-
sioned at approx. 50 bar higher.There is a danger of the round nut sticking through
the expansion of the bolt thread if the pressure is increased even further.
8.6 Relieve the tightening elements, remove the hydraulic devices and unscrew the round nuts.
8.7 Mount the cylinder head lifting device (W8)

on the injection valve. Lift the cylinder
head horizontally by means of a crane.
Pay attention to the push road bushing!
View “ X “ :
A = Exhaust gas site

S = Camshaft site
en / 19.12.2012 IB003142 4/5

M25
01
CAUTION
Danger of damage being caused to transfer connecting pieces, cylinder head screws,
push rods and intake connecting pieces.
9. Place the cylinder head on a wooden base.
10. Remove the turning rod, dismount the turning device.
en / 19.12.2012 IB003142 5/5

Nozzle Sleeve A5.05. 01.06.50.01
M25
15000
See also: 01.06.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Exchange of O-rings every 15,000 h
Tools:
Key for nozzle sleeve W1 259222-301

Torque wrench W2 1.9454-320
Auxiliary material:
Vaseline *
Adhesive and sealant “Loctite 510“ *
en / 29.05.2013 IB021115 1/3

M25
15000
Sequence of operations: 01
1. Nozzle sleeve removal
1.1 Put the key for nozzle sleeve (W1) onto the nozzle sleeve (Fig. 1/1), so that nozzle sleeve and
key are intermeshing.
1.2 Mount the flange (Fig. 1/3).
1.3 Put the torque wrench (W2) onto the key for nozzle sleeve and turn out the nozzle sleeve comple-
tely.
CAUTION
The threads of nozzle sleeve and cylinder head must not intermesh any more.
1.4 Dismantle the flange.
1.5 Use a brass mandrel and gently drive out the nozzle sleeve.
1.6 Remove the O-rings (Fig. 1/4 and 5).
en / 29.05.2013 IB021115 2/3

M25
15000
2. Nozzle sleeve reassembly 01

2.1 Insert new O-ring (buna N black) with vaseline untwisted into the groove (5) below.
2.2 Insert new O-ring (Viton green) with vaseline untwisted into the groove (4) above.
CAUTION
The positions of the O-rings (Fig. 1/4 and 5) must not be interchanged!
2.3 Apply a film of “Loctite 510 “ to the threads of the nozzle sleeve.
2.4 Introduce the nozzle sleeve.
2.5 Put on the key for nozzle sleeve and the torque wrench and tighten the nozzle sleeve with a tor-
que of
M =140 Nm
en / 29.05.2013 IB021115 3/3

Relief Valve A5.05. 01.06.70.02
Maintenance / Replacement
M25
30000
See also: 01.06.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of relief valve every 30,000 h
Auxiliary Material:
High-temperature thread paste “Dag S 5080“ *
Sequence of Operations:
1. Remove cover (1).
2. Slacken relief valve (2) by means of a wrench and remove it.
en / 19.12.2012 IB024293 1/2

Relief Valve A5.05. 01.06.70.02
M25
30000
3. Lubricate the thread of the new relief valve (2) with high-temperature thread paste 01
“Dag S 5080“.
4. Mount new relief valve (2) with new joint ring (3).
5. Firmly tighten the relief valve (2) by means of a wrench.
6. Mount cover (1).
en / 19.12.2012 IB024293 2/2

c2 Inlet and exhaust valve cones
Inspection / Disassembly and reassembly
A5.05. 01.07.01.02
M25
15000, 7500


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the inlet and exhaust valve cones of a

cylinder unit with regard to the contact
reflection and accumulation of deposits every 7,500 h
Maintenance:
of all inlet and exhaust valve cones after 15,000 h
Tools:
Valve spring tensioning device W1 259222 A
Auxiliary material:
Molykote paste "G-Rapid Plus"**
** or a product of equal standard
WARNING
Risk of injury due to spring tension!
In installed condition the valve springs are under strong preload.
Improper handling or a defective tool may cause severe injuries.
Check the tool for possible damage before each use.
Wear personal protective equipment.
NOTE
The service life of the valve cones depends on the quality of the fuel used, the opera-
ting conditions of the plant and the quality of the repaired valve cone/seating rings
and thus differs from plant to plant.For this reason the operator must determine the
appropriate repair intervals according to the findings of the inspections of the valve
cones. The seating geometry must be checked during every disassembly of the val-
ve cone and must be remilled if necessary (A5.05.01.08.01.nn, A5.05.01.08.02.nn).
en / 08.01.2014 IB024279 1/3

A5.05. 01.07.01.02
M25
15000, 7500
1. Disassembly
1.1 Remove the cylinder head

(A5.05.01.06.01.nn).
1.2 Remove the rocker arm

(A5.05.01.02.01.nn) and lift off the valve
bridge.
1.3 Mount the valve spring tensioning device

(W1).
1.4 Coat the contact surface (X) with Molykote

paste "G-Rapid-Plus" before using the
valve spring tensioning device (W1).
1.5 Turn back the nut (Fig. 1/1) to the limit.
1.6 Press the valve cone holder (2) into the

ring groove of the valve cone.
1.7 Turn the nut (Fig. 2/1) to the limit on the

valve cone holder (2).
1.8 Fit the draw spindle (Fig. 3/3) together

with the hoop (4) in the valve cone holder
(2).
The hoop must not rest on the cast
nose of the spring plate (6).
1.9 Turn back the nut (1) to the limit on the

draw spindle (3).
1.10 Tension the valve spring by turning the nut

(5).
1.11 Remove the clamping cone halves (7).

Relieve the valve spring (8) by turning the
nut (5).
WARNING
Spring tension
1.12 Lift the valve spring tensioning device

(W1), spring plate (6), valve spring (8) as
well as the valve turning device/valve
spring disk off the cylinder cover.
1.13 Pull the valve cone out of the cylinder

head.
en / 08.01.2014 IB024279 2/3

A5.05. 01.07.01.02
M25
15000, 7500
01
NOTE
Valve cones which show substantial signs of wear in the clamping area as well as
clamping cone halves on which heavy burr has formed must be replaced by new parts.
Remove any projecting burr before disassembling such valve cones.
Repair of valve cone/valve seat (A5.05.01.08.01.nn/ A5.05.01.08.02.nn).
2. Reassembly
2.1 Check valve clearance, replace O-rings (A5.05.01.05.01.nn).
2.2 Lubricate the valve stem (free from burr) well before installation and insert the valve cone by
screwing it in so that the O-ring is not damaged.
2.3 Assembly is effected in the reverse sequence of disassembly.
2.4 Slowly relieve the valve spring after inserting the clamping cone halves and check that the clam-
ping cone halves sit properly.
en / 08.01.2014 IB024279 3/3

c2 Valve cones
A5.05. 01.08.01.00
M25
See also: A5.05.01.07.01.nn, A5.05.01.08.02.nn 01

Personnel qualification: Chief engineer / skilled engine hand

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Valve refacer W1 259224 A
Auxiliary material:
Illuminated magnifying glass (8-fold magnification)

Diamond paste Dp 30/10 - 15 µm *
Thinner F25 *
Note:
New or refinished or used undamaged inlet and exhaust valve cones must be ground in
accordance with operating sequence 4 before being fitted.
Refinishing of the valve cones (operating sequence 3) can be necessary in the following cases:
• After extended operating times
• In the case of a negative result, e.g. damaged sealing surfaces, blow holes,
uneven contact reflections of the valve cone/seat.
1. Check of valve condition
1.1 The valve may by reused without refinishing if
• the circumference of the valve cone face is metallically polished

• the valve cone face does not indicate carbon pockets with blow holes
• no crack formation is established on the valve cone face when checking for cracks using
an illuminated magnifying glass (8-fold magnification) or a powder spraying method
(Met L'Check.
en / 04.10.2013 IB003152 1/7

c2 Valve cones
A5.05. 01.08.01.00
M25
• the deviation from the straightness is not greater than the following values (Fig. 1). 01
Measuring range "s" = 264 mm
= Supporting points for the test device
• the radial runout of the valve cones is not greater than the following values:
1.2 The valves cannot be reused in the

following cases
• if the valve cone face is damaged

(cracks, blow holes)
• the wear caused by corrosive material

is
>2%
of the valve head diameter
(compared with new valve)
• concave burn "s" caused by high

temperature corrosion at the
underside of the valve head is
> 1.5 mm (Fig. 2)
• the underside of the valve head

indicates severe pitting (formation of
so called paving stones
• corrosion pits and mechanical damage in the area of the valve stem, stem transition
and valve head
• the limit dimension for refinishing is exceeded.
en / 04.10.2013 IB003152 2/7

c2 Valve cones
A5.05. 01.08.01.00
M25
2. Cleaning 01
Clean the valve spindle, e.g. by blasting with glass beads.
NOTE
Cleaning with sharp edged tools as well as pickling with an organic acids
(hydrochloric acid, sulphuric acid, hydrofluoric acid etc.) not permissible!
en / 04.10.2013 IB003152 3/7

c2 Valve cones
A5.05. 01.08.01.00
M25
3. Repair (refinishing of sealing surface) 01
NOTE
Refinishing must be carried out professionally on precision spindle grinding machines.
If no suchmachine is available, then the valve cones should be send to an MaK work-
shop for regrinding.
3.1 Refinish the sealing surface according to the specified angle. Do not refinish any existing concave
fillets.The valves are identified by the variant marking (e.g. 25-19, 25-02, etc.) on the circumfe-
rence of the stem end. The table below shows dimension y in new condition and as wear limit di-
mension, each measured at reference diameter x. These dimensions are applicable for all valve
cones (inlet, exhaust, HFO, MDO) alike
.
Reference diameter x [mm] Dimension y [mm] Dimension y [mm] wear limit

new condition
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
en / 04.10.2013 IB003152 4/7

c2 Valve cones
A5.05. 01.08.01.00
M25
Exhaust valve 25-20 (MDO) Exhaust valve 25-22 (HFO) 01
Reference diameter
Reference diameter
3.2 The respective information of the grinding machine manufacturer must be observed when
grinding carried out.
3.3 The dimension between the visible edge of the base material armouring "P" and the outer edge
of the seat is to be determined upon completion of the grinding process. The valve cone must be
replaced if the actual dimension falls below the minimum dimension.
3.4 Outer edge rounded with stone.
NOTE
When the valve cone is refinished, the valve seating has to be refinished as well
(A5.05.01.08.02.nn).
en / 04.10.2013 IB003152 5/7

c2 Valve cones
A5.05. 01.08.01.00
M25
4. Maintenance 01
(Check of contact reflection / grinding)
4.1 Apply small dots of diamond paste Dp 30/

10 - 15 µm with a syringe to the valve cone
or the new or remachined valve cone and
distribute the paste evenly (Fig. 4). The
seat ring surface is then sprayed with a
thinner (F25) belonging to the diamond
paste for dilution in order to increase the
grip.
4.2 Push the lubricated valve stem into the

guide. Fix the device (Fig. 5/W1) to the
valve head.
4.3 Grind the cone and seating surface by

turning the device backwards and
forwards 6 to 8 times applying a moderate
pressure to the valve head.
Lift the cone several times thereby so that
the grinding paste can flow back onto the
grinding surface.
The contact area (Fig. 6/a), visible due to

the light grinding procedure should not
exceed
30 - 50 % of the seat width "b"
starting at the outer diameter
en / 04.10.2013 IB003152 6/7

c2 Valve cones
A5.05. 01.08.01.00
M25
01
4.4 If the contact reflection is poor, the valve
must not be reground anymore and both
sealing faces must be refinished on a
machine.
4.5 Ensure that the components (valve cone

and seat ring) refaced to one another are
kept together.
5. Final check
5.1 Ensure that the refinishing limits are main-

tained.
5.2 Carefully clean the valve cone/seat and

check the sealing surfaces using an
illuminated magnifying glass
(8-fold magnification) or powder spraying
method (Met L'Check) for cracks in the
armouring and in the adjacent zone
en / 04.10.2013 IB003152 7/7

Valve Seat Ring A5.05. 01.08.02.00
Maintenance / Evaluate
M20-VM46DF
See also: A5.05.01.05.01.nn 01

Spare parts list:
Personnel qualification: skilled engine hand / Cat/MaK-specialist

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Cleaning of the valve seat rings

2. Evaluation of sealing surfaces
3. Repair (rework of valve seat rings)
4. Check of contact pattern/grinding-in (for valve combinations with non nitrided valve steam
surface)
5. Check of contact pattern (for valve combinations with nitrided valve stem surface)
6. Final check
Engine type Tools and auxiliary materials Pos. Ord. No.
M 20 C Valve jig W1 2.9224 A
M 25 C Valve jig W1 259224 A
M 32 C, VM 32 C, Valve jig W1 6.9224 B

GCM34
M 43 C, VM 43 C, Valve jig W1 439224 A

M 46 DF, VM 46 DF
M 20 C, M 25 C, Illuminated magnifier (8-fold magnification) */
M 32 C, VM 32 C, ***
M 43 C, VM 43 C,
M 46 DF, VM 46 DF Dye penetrant method (Met-L-Chek) */**/
***
Diamond paste Dp 30/10 - 15 µm 1.9493-002

Blue paste */
***
Thinner DIAPLASTOL */**/

***
Brass brush */
***
* no picture
*** not included in scope of supply
en / 21.10.2013 IB028458 1/8

M20-VM46DF
01
NOTE
The term valve refers to the combination of valve stem and valve seat ring. The latter
is firmly inserted into the cylinder head.
ATTENTION
It is not allowable to grind in valve stems with nitrided sealing surfaces.
Material removal, whether by grinding-in or refinishing of the sealing surface of

a nitrided valve stem will necessarily destroy the valve stem which may then not
be used any more.
Valve stems with nitrided sealing surface manufactured after April 2013 are additionally
marked in the upper stem area. Previous marking for a nitrided M 25 C valve stem was
e.g. “MaK 25-07 IN“ (where “25“ indicates the engine type, “07“ the variant, and “IN“ is
the code for inlet valve). For valve stems with nitrided sealing surface the hyphen
(minus) is replaced by “N“ .
The markings listed in the following (old or new) are exclusively applied to valve stems
with nitrided sealing surface. These valves must not be ground in or refinished!
Old marking New marking

MaK 10-09 IN MaK 10N09 IN
In case of doubt, please contact your authorized Caterpillar workshop.
en / 21.10.2013 IB028458 2/8

M20-VM46DF
01
NOTE
During regular maintenance of the engine, (e.g. after 15,000 hours), the valve seat rings
should if possible be refinished and the valve stem should be replaced. On non nitrided
valve stems also the valve stem sealing surface may be refinished.
Refinishing / replacement may also become necessary if during non-scheduled

maintenance or a partial check of the valves the findings are not okay.
It is not allowable to refinish nitrided valve stem sealing surfaces.

When one or several replacement criteria are reached, it is always necessary to refinish
the valve seat ring and replace the valve stem by a new one.
Example of negative findings:

Fig. 1 shows a valve stem with damage to the sealing surface all around.
Fig. 2 shows the sealing surface of a valve seat ring with deep pits in the left and a
jagged sealing surface area in the right half of the picture.
Both figures show severe damage to the valve sealing surfaces. The sealing surfaces
need to be refinished. If the refinishing limits are reached, the parts must be replaced.
When the sealing surfaces of a non nitrided valve (valve stem/valve seat ring Fig. 1
and 2) show uneven contact patterns or deeper pits, always refinish both sealing
surfaces.
en / 21.10.2013 IB028458 3/8

M20-VM46DF
1. Cleaning of the valve seat rings 01
ATTENTION
A wrong tool may cause damage to the sealing surfaces!
Do not use any material removing tools or materials.
1.1 Spray coke deposits with clean freshwater. After a short exposure time wipe them off with a
cleaning rag. More tenacious incrustations may also be carefully removed by means of a brass
brush.
2. Evaluation of sealing surfaces
NOTE
The hardness of the valve seat ring sealing surface is designed in such a manner
that it possesses a certain adaptability with regard to the valve stem sealing surface.
Dents by coke are, therefore, a normal phenomenon and of no concern (Fig. 3). If,
however, the dents by coke should extend over the entire width of the sealing
surface, as shown in Fig. 4, there is a risk of "blow by" and the valve sealing
surfaces must be refinished or the valves must be replaced, as the case may be.
en / 21.10.2013 IB028458 4/8

M20-VM46DF
01
2.1 Valve seat rings are re-usable without refinishing when
• the sealing surface shows a bare metal finish all around, dark discoloration is allowable,
• there are no dents by coke suggesting blow-by or visible wear,
• a check by means of illuminated magnifier (8-fold magnification) or

dye penetrant inspection (Met-L-Chek) has not revealed any cracks in the sealing surface.
2.2 Valve seat rings are not re-usable when
• there are cracks in the sealing surface
• there is blow-by
• the limit for refinishing has been exceeded.
3. Repair (refinishing of valve seat rings))
ATTENTION
Risk of damage due to a wrong assumption regarding the sealing surface angle!
This note applies to inlet valves of distillate fuel engines (MDO) only.
The inlet valve sealing surfaces of distillate fuel engines (MDO) may have different
sealing surface angles depending on their equipment status (see following tables). If
different angular degrees are indicated for the inlet valves your engine type, check
which sealing surface angle is the correct one for your specific engine before carrying
out any refinishing work or ordering spare parts.
Inlet valves of heavy fuel engines (HFO) always have an angle of 30 5’ .
ATTENTION
Avoid destroying the nitrided valve stem sealing surface!
It is not allowable to grind in valves with nitrided valve stem sealing surface!
When reaching one or several replacement criteria, only the valve seat ring of a
nitrided valve combination may be refinished, the valve stem has to be replaced by a
new one.
Refinishing has to take place in a professional manner using a special Caterpillar
valve seat refinishing tool (not included in the scope of supply). If the refinishing limit is
reached, the valve seat ring must be replaced. These jobs should be carried out by an
authorized Caterpillar workshop.
en / 21.10.2013 IB028458 5/8

M20-VM46DF
01
Exhaust valve seat ring Inlet valve seat ring
a α a
α
ØX ØX
a = no material removal allowable
Exhaust valve seat ring Inlet valve seat ring

(For heavy fuel, distillate fuel, and gas engines) (For heavy fuel engines only)
Angle “α“ Limit Engine type Angle “α“ Limit

Engine type
“Ø X“ mm “Ø X“ mm
M 20 C 30° 5’ + 5’ 66 +0.2 M 20 C 20° 5’ + 5’ 67.5 +0.2
M 25 C 30° 5’ + 5’ 84.3 +0.2 M 25 C 30° 5’ + 5’ 85 +0.2
M 32 C, 30° 5’ + 5’ 107 +0.2 M 32 C, 30° 5’ + 5’ 107 +0.2

VM 32 C VM 32 C
M 43 C, 30° 5’ + 5’ 148.5 +0.2 M 43 C, 30° 5’ + 5’ 148.5 +0.2

VM 43 C VM 43 C
M 46 DF, 30° 5’ + 5’ 148.5 +0.2 M 46 DF, 30° 5’ + 5’ 148.5 +0.2
VM 46 DF VM 46 DF
GCM34 20° 5’ + 5’ 107 +0.2
Inlet valve seat ring

(For distillate and gas engines only)
Angle “α“ Limit Engine type Angle “α“ Limit

Engine type
“Ø X“ mm “Ø X“ mm
M 20 C 20° 5’ + 5’ 67.5 +0.2 M 43 C, 20° 5’ + 5’ 148.5 +0.2

VM 43 C
M 25 C 30° 5’ + 5’ 85 +0.2 M 43 C, 30° 5’ + 5’ 148.5 +0.2

VM 43 C
M 32 C, 20° 5’ + 5’ 107 +0.2 M 46 DF, 30° 5’ + 5’ 148.5 +0.2
VM 32 C, VM 46 DF
GCM34
en / 21.10.2013 IB028458 6/8

M20-VM46DF
4. Check of contact pattern/grinding-in 01

(for valve combinations with non nitrided
valve stem surface)
4.1 Remove the O-ring from the valve guide

bush (see A5.05.01.05.01.nn).
4.2 Using a syringe, apply small dots of

diamond paste (Dp 30/10 - 15 µm) to
the sealing surface (Fig. 5) of a new or
refinished valve stem and evenly distribute
them. After that, spray the entire vale seat
ring sealing surface with the thinner (DIA-
PLASTOL).
4.3 Insert the oiled valve stem into the valve

guide bush.
4.4 Fasten the valve jig (Fig. 6/W1) to the
valve stem head.
4.5 Grind the sealing surfaces of valve stem and valve seat ring for a short time applying a modera-
te pressure by rotating the valve jig in both directions. The percentage contact area (Fig. 7/a)
made visible through the smooth grinding-in process shall, over the entire circumference, not
exceed 30 - 50 % of the seat width “b“ starting from the outside diameter.
ATTENTION
Ensure that the components (valve stem and valve seat ring) ground in together will
stay together.
NOTE
In case of a poor contact pattern do not continue to regrind but check whether the two
sealing surface angles of valve stem and valve seat ring really match each other.
W1
en / 21.10.2013 IB028458 7/8

M20-VM46DF
5. Check of contact pattern 01

(for valve combinations with nitrided W1
valve stem surface)
5.1 Remove the O-ring from the valve guide

bush (see A5.05.01.05.01.nn).
5.2 Apply a thin and even film of blue paste

onto the sealing surface of the valve stem.
5.3 Insert the oiled valve stem into the valve

guide bush.
5.4 Fasten the valve jig (Fig. 8/W1) to the

valve stem head.
5.5 Carry out the contact area check by

turning in both directions by hand for a
short while. There shall be a continuous
contact pattern all around, starting from
the outside diameter.
6. Final check
6.1 Clean the valve stem and valve seat ring sealing surfaces thoroughly and check the sealing faces
with an illuminated magnifier (8-fold magnification) for cracks in the hard facing and the adjacent
area.
en / 21.10.2013 IB028458 8/8

c2 Starting valve
A5.05. 01.09.02.00
M25
15000
See also: 01
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
Remove starter valve, disassemble and rework if necessary
M 25 C Touch-up pain
Diamond paste Dp 30/10 -15 µm *
G-Rapid" Molykote paste *
CAUTION
Before doing any work on the
starting system, close the main
valves on the starting air bottles,
vent the pipes and block the
master starting valve.
1. Disassembly
1.1 Remove the cylinder head.
1.2 Loosen the screw plug (Fig. 1/1) and remove

it together with the sealing ring (2).
1.3 Loosen the locking nut (3) holding the valve

spindle (4) with a screw driver.
1.4 Remove cup cup springs (9a) or

spring washer (9b), piston (5), resilient
sleeve (6), pressure spring (7), valve spindle
(4) as well as the bush (8) from the cylinder
head.
1.5 Carefully clean all parts in gas oil.
en / 15.01.2014 IB028726 1/2

c2 Starting valve
A5.05. 01.09.02.00
M25
15000
1.6 Check the piston (5), seat face of the valve spindle (4) and valve seat (10). 01
1.7 Scored pistons (5) should be smoothed down using fine emery cloth.
1.8 Check the tightness of the starting valve. To do so, test the contact reflection of the seating of the
valve spindle (4) on the valve seat (10) in the cylinder head as follows:
1.8.1 Apply 7-8 streaks of touching-up paint at the same distance to the seating of the valve spindle (4).
1.8.2 Insert the valve spindle (4) with bush (8), resilient sleeve (6), piston (5) and non self-locking nut.
Turn the valve spindle approx. 60-70°.
1.8.3 Carefully remove the valve spindle and check the contact reflection. Remove the touching-up
paint.
1.9 If the contact reflection is bad:
1.9.1 Apply small dots of diamond paste equally distributed over the seating of the valve spindle (4) by
means of a syringe. Then spray the whole seat ring surface with a thinner (F25) for the diamond
paste for dilution and to increase the grip.
1.9.2 Insert the valve spindle (4) with piston (5), resilient sleeve (6) and non self-locking nut.
1.9.3 Grind the valve seat for a short moment. To do so, turn the valve spindle backwards and forwards
6-8 times by hand using a screwdriver under medium pressure. Lift the cone several times so that
the grinding paste can flow back onto the grinding surface.
Carefully remove the valve spindle and recheck the contact reflection which is visible as a result
of the grinding process.
1.9.4 Repeat the grinding process if the contact reflection is bad.
1.10 Carefully clean the valve spindle (4) and valve seat (10) in the cylinder head.
2. Reassembly
2.1 Rub the piston (5) in with "G-Rapid" Molykote paste.

Pay attention to the correct installation position of the cup springs (9a) or
spring washer (9b).
Tighten the new locking nut (3) at a torque of 35 Nm.
2.3 Replace the sealing ring (2). Tighten the screw plug (1) at a torque 250 Nm.
en / 15.01.2014 IB028726 2/2

M25
150


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Generally inspection of all cylinder heads
1. Check the gasket between the cylinder head, cylinder liner and cooling water distributor housing
for escaping combustion gases/check the cooling water at the inspection hole
(Fig. 1/1).
In the event of a leakage, loosen the cylinder head nuts and tighten them according to the
specification (A5.05.01.11.01.nn). If the leakage cannot be eliminated, remove the cylinder head
-clean and check the sealing surfaces - mount with new O-rings (if necessary) and tighten as
specified (A5.05.01.06.01.nn, A5.05.01.11.01.nn).
en / 30.07.2013 IB003168 1/2

M25
150
2. Check the outside of the cylinder head for leakage. 01

2.1 If lubricating oil is leaking out, check the tightness of the retaining screws of the cylinder head co-
ver / check the rubber seal for damage.
2.2 If there are leaks at the connecting flanges of the media supply lines, check the tightness of the
retaining screws. Replace the seals if necessary.
3. Remove the cylinder head cover. Check the upper side of the cylinder head.
3.1 Check the operation of the valve rotator (A5.05.01.03.01.nn).
3.2 Check the valve springs for damage.
3.3 Check the lubricating oil supply for the valve rockers and valve rocker bearings.
en / 30.07.2013 IB003168 2/2

Maintenance / Cleaning
M25
30000

Operating medium: Distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
NOTE
Place the underside of cylinder head on a wooden base only.
The following parts have been removed:
Inlet valve, exhaust valve, injection valve, starting valve and rocker arm bracket.
1. Wash down the cylinder head with a cold cleaner.
2. Clean the inlet and exhaust ports and the underside of the cylinder head (not the valve seats!) of
carbon deposits using a wire brush or scraper. Do not damage the sealing recess.
3. Clean the cooling water inlet ports and cooling water outlet.
4. Inspect the underside of the cylinder head for cracks, particularly at the valve stems.
5. Clean the sealing surface for the injection valve.
6. Check the free passage of the inlet and outlet bores for the media supply system.
en / 19.12.2012 IB021351 1/1

Maintenance / Reassembly
M25
See also: 01.05.50.nn, 01.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Refer to repair sheet A5.05.01.06.01.nn
Auxiliary material:
Vaseline *
CAUTION
The minimum bending radius r = 120 mm for the high pressure hoses must be
observed.
Use hydraulic oil only as an operating medium.
DANGER
Do not position any part of the body over devices which are under pressure.
1. Open the indicator valve and turn the piston to firing TDC.
2. Carefully clean the sealing and contact surfaces of the cylinder head and cylinder liner and check
for damage. Insert a new sealing ring (Fig. 1/1) in the collar of the cylinder liner.
Check and clean the sealing surface on the exhaust pipeline (A5.05.06.01.01.nn).
3. Replace the following O-rings: Upper O-ring at the collar of the cylinder liner (2), at the cylinder
head (3), at the push rod lead-through (4), at the cooling water transfer (7), at the starting air inlet,
at the control air inlet and at the air charge inlet connections (5).
en / 19.12.2012 IB003174 1/5

M25
01
6
3
1
4
2
5 7
1
NOTE
Use vaseline to insert the O-rings in the grooves making sure that they are not twisted.
Position the sockets for cooling water, control air and starting air vertically in the
cooling water distributor housing and check for completeness.
4. Carefully let down the cylinder head using the cylinder head lifting device (W8) and lifting gear.
Insert the push rods in the cylinder head.
Make sure that they are positioned correctly with respect to the rocker arm.
5. Continue to let down the cylinder head, align on the straight pin (6) and put it down on the cooling
water distributor housing.
6. Tighten the round nuts (Fig. 2/2.1/12) with pins (W7) by fingertight.
7. Tighten the four cylinder head nuts together using the hydraulic tightening device.
en / 19.12.2012 IB003174 2/5

M25
01
10
CAUTION s
The maximum stroke indicator

(Fig. 2/10) must not project
above the upper limit of the co-
ver
W3
7.1 Put the short hydraulik units onto the cylin-
der heat nuts (12) at exhaust gas site
(Fig.3).
7.2 Place the hydraulic tightening elements

(Fig.2 /2.1/ W3) connected to the
supporting sleeves (W5/ W5.1) over the
round nuts (12). Pay attention to good
11 W5
accessibility of the slits (13).
7.3 Screw the threaded sleeves (W6 /W6.1)

onto the cylinder head screws (11) finger- W6
tight.
7.4 Connect the hydraulic tightening elements 13

(Fig. 3/W3) and the distributor (W4) to the
W7
high pressure pump (W1) via the high 12
pressure hoses (W2).
7.5 Connect the valve (Z) to the high pressure 2

pump and extend all four cylinder head
screws simultaneously and continuously at
a hydraulic pressure of
p = 820 bar.
CAUTION
10 W6.1 W3
The pressure must remain con-
stant in the event of the pump s
not being operated as otherwi-
se tightening will be faulty.
11
7.6 Firmly tighten the round nuts (Fig. 2 /2.1/
12) with pin (W7). Pay attention to easy
movement.
7.7 Check firm seating of the round nuts.
7.8 • reduce the pressure by 50 bar. W7

• it should no longer be possible to loosen
the round nuts with the pin. 12 W5.1
2.1
en / 19.12.2012 IB003174 3/5

M25
01
W2
W3
W4
W2
W1 Z
3
7.9 Relieve the hydraulic tightening element

and remove it.
W6
7.10 Mount the exhaust pipe
(A5.05.06.01.01.nn).
W6.1
7.11 Mount the media supply pipeline
(A5.05.01.05.50.nn).
W5
7.12 Remount the pressure gauge lines and fill
up with cooling water. Venting at the end of
the cooling water return line opposite the W5.1
turbo charger side.
View “ X “
A X S
A = exhaust gas site
S = camshaft site
en / 19.12.2012 IB003174 4/5

M25
8. Mount the transverse thrust pieces for the respective injection pumps. 01
It is imperative that the assembly instructions are observed. Tighten the pressure screw and
screw connection at the specified torque (A5.05.07.07.01.nn).
9. Adjust the valve clearance (A5.05.01.01.01.nn).
10. Check the gaskets of the cylinder cover hoods, mount the cylinder cover hoods.
11. Mount the pump compartment casing.
12. Remove the turning rod, dismount the turning device, close the indicator valves.
13. Check all connections for leakage after starting up the engine.
en / 19.12.2012 IB003174 5/5

c2 Crank Web Deflection
Inspection / Measuring
A5.05. 02.02.01.00
M20-VM46DF
See also: 02
Spare parts list:
Personnel qualification: skilled engine hand / chief engineer

--------------------------------------------------------------------------------------------------------------------------------
Activities:
Check of crank web deflection
Engine Type Tools and auxiliary material Item Tool No.
M 20 C, M 25 C, Crank web deflection dial gauge compl., consist- W1 1.9425 A

M 32 C, M 43 C, ing of:
M 46 DF
Crank web deflectiondial gauge W1.1 1.9425-300
(dial gauge, extension, hanging weight)
Centering magnets (2 x) W1.2 1.9425-316
VM 32 C, VM 43 C Crank web deflectiondial gauge compl., consist- W1 1.9425 B

GCM34, VM 46 DF ing of:
Crank web deflectiondial gauge W1.1 1.9425-500

(dial gauge, extension, hanging weight)
Centering magnets (2 x) W1.2 1.9425-325
NOTE
Crank web deflection is the change in distance between a web pair during one rotation
of the crankshaft (Fig. 1). It is primarily used for measuring and evaluating the align-
ment of an engine with respect to its shafting.
Severe crank web deflection will subject crankshaft and main bearings to additional
load, i.e. the admissible crank web deflection level essentially depends on the engine
load.
Highly loaded engines will allow less crank web deflection than engines subjected to
low load.
Depending on the installation site of the engine, the rigidity of the foundation, and
whether the engine is in warm or cold condition, differing values are obtained. Crank
web deflection should, therefore, always be measured at the same conditions.
Changes that suddenly appear or appear after a longer period under otherwise
unchanged conditions are indicative of deformation or settling phenomena in the foun-
dation.
en / 08.11.2013 IB027237 1/6

A5.05. 02.02.01.00
M20-VM46DF
02
NOTE
It is, therefore, suggested to collect the measurement sheets extra, because this is the
only way to get a clear picture of the chronological allocation of the measuring values
and their changes.If the limits are reached, the main bearings must be inspected and
the engine must be realigned.
Measurements are to be carried out in the following cases:
When there is suspicion or danger of deformation of the foundation, e.g.:

• after a major damage
• settling phenomena of the foundation
• bearing or crankshaft damage
_ +
a) Initial position b) Negative deflection c) Positive deflection
NOTE
In order to get a clear measurement result, crank web deflection is to be measured
on an engine at operating temperature only.
en / 08.11.2013 IB027237 2/6

A5.05. 02.02.01.00
M20-VM46DF
02
CAUTION
Absolutely make sure that the
magnets (Fig. 2/W1.2) for fixa-
tion of the dial gauge tips are
completely contacting the crank
webs (Fig. 2/1) and not the
balance weights (Fig. 3/2).
1. Open all indicator/decompression valves.
2. Engage the barring gear.
3. Insert magnets (Fig. 2/W1.2) with crank

web deflection dial gauge (Fig. 2/W1) as
shown in Fig. 2 and determine the narro-
west point. W1
W1.2 W1.2 1
1
4. Bar the engine until the dial gauge
(Fig. 3/W1) nearly contacts the connecting Principle representation
rod (Fig. 3/3).
5. Adjust the dial gauge (Fig. 3/W1) to the

narrowest point and set the scale to a va-
lue of 20 at the pointer:
1. measuring point/M1 (initial position)
W1
.
NOTE 3
In case of significant pointer de-

flections outside of the speci- 2
fied measuring points, these
must also be recorded.
2
en / 08.11.2013 IB027237 3/6

A5.05. 02.02.01.00
M20-VM46DF
6. Slowly bar the engine and pass through measuring points M2 - M5 one after the other. Read and 02
record the indicated measuring values.
M5 M4 M2 M1
M3
M1 1st measuring point initial position
M2 2nd measuring point crank pin - exhaust side

M3 3rd measuring point crank pin - top dead centre (TDC)
M4 4th measuring point crank pin - camshaft side
M5 5th measuring point crank pin - bottom dead centre (BDC)
en / 08.11.2013 IB027237 4/6

A5.05. 02.02.01.00
M20-VM46DF
02
NOTE
The values indicated below must be observed, unless there is a possibility to enquire
the crank web limits permissible for the specific plant from Caterpillar.
Only the deflection values measured on an engine at normal operating temperature

are to be used for the assessment. Values from a cold engine are of minor relevance.
Values for crank web deflection in mm:
M 20 C M 25 C M 32 C und M 43 C und VM 43 C und GCM34

mm mm VM 32 C M 46 DF VM 46 DF mm
mm mm mm
Cylinder 1 or last + 0,04 / + 0,05 / + 0,06 / + 0,07 / + 0,08 / + 0,06 /
cylinder with - 0,09 - 0,11 - 0,13 - 0,16 - 0,19 - 0,13
additional load
(flywheel/cou-
pling)
All cylinders wit- + 0,04 / + 0,05 / + 0,06 / + 0,07 / + 0,08 / + 0,06 /

hout external load - 0,06 - 0,08 - 0,09 - 0,12 - 0,13 - 0,09
Permissible + 0,03 / + 0,03 / + 0,04 /

crank web deflec- - 0,03 - 0,03 - 0,04
tion
realignment of
base frame
genset in horizon-
tal direction
en / 08.11.2013 IB027237 5/6

A5.05. 02.02.01.00
M20-VM46DF
02
Operating hours: Station/vessel: Date:
Engine type: Engine No.: Service station/Engineer:
Reading of dial gauge
down up
20
Engine cold
10 30
press
Shut down for hours
Preheated 0 40
°C
Measuring Cylinder
point
M1
M2
M3 negative
M4
M5
positive
max
M5 M4 M2 M1
M3
en / 08.11.2013 IB027237 6/6

c2 Big-end bearings
Inspection / Disassembly
A5.05. 02.04.01.00
M25
30000, 15000
See also: 02.06.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of one big-end bearing
-Exchange of all big-end bearings after
Tools:
Holding device for pistons W1 *** 259226 A
300 - 800 Nm, 3/4 torque wrench W2 * 1.9454-800
3/4 changeover ratchet W3 * 1.9495-036
36 mm insert W4 * 1.9450-036
Socket wrench for indicator valve W6 * 1.9100-060
* not illustrated
*** not included in the toolset
Auxiliary material:
"G Rapid plus" Molykote paste **
NOTES
For an evaluation of the bearing shell running surfaces please contact your autho-
rized Caterpillar dealer.
1. Disassembly of the big-end bearing
cover
1.1 Open the indicator valves and mount the

4
turning device.
1.2 Dismantle the power unit cover of the 1

respective cylinder.
1.3 Turn the crank pin of the respective con-

rod (fig. 1/5) to the disassembly position
(approx. 20° before TDC on the control 2
side).
en / 06.12.2013 IB028667 1/2

c2 Big-end bearings
A5.05. 02.04.01.00
M25
30000, 15000
1.4 Loosen all con-rod bolts.Remove one of 02

the upper con-rod bolts (1) and the two
lower con-rod bolts (3).
1.5 Hold the big-end bearing cover (Fig. 1/2),

remove the upper con-rod bolt (1),
carefully remove the big-end bearing
cover (2) and lift it out of the crankcase.
1.6 Check the thread on the big-end bearing

bolts and the serrated joints of the con-rod
and big-end bearing cover for damage.
2. Disassembly of the bearing shells
2.1 Turn the piston to TDC.

W1
2.2 Mount the piston holding device (fig. 2/
W1).
2.3 Carefully turn the crankshaft to the control

side until the piston sits on the holding
device and the crank pin swivels out of the
bottom end of the con-rod.
2.4 Remove the bearing shells (fig. 1/4) from

the crank pin.
2.5 For an evaluation of the bearing shell 2

running surfaces please contact your
authorized Caterpillar dealer.
2.6 Remove the turning device.
en / 06.12.2013 IB028667 2/2

Big-end bearings A5.05. 02.04.02.00
Inspection / Reassembly
M25
See also: 02.04.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1-W6:Refer to A5.05.02.04.01.nn
Mounting clamp W7 259125 B
Auxiliary material:
"G-Rapid Plus" Molykote paste **
NOTE
The bearing caps, bearing shells and bearing bolts are always marked at the opera-
ting side according to which cylinder they belong (starting from the driving end) and
must not be interchanged. New parts must be marked accordingly.
Use "G-Rapid Plus" Molykote paste for greasing threads and screw contact surfaces.
Procedure:
1. Installing the bearing shells
1.1 Open the indicator valves, mount the barring device and turn
the crank pin to the assembly position (approx. 20° before
TDC).
1.2 Clean and lubricate the crank pin.
1.3 Lubricate the bearing shells on the inside and place them on
the crank pin..
CAUTION
Insert the bearing shells in such a way that the
hole (fig. 1/X) for locating the bearing shells is
positioned on the exhaust side.
The hole is in the bearing shell halves facing
towards the driving end
1
en / 19.12.2012 IB003560 1/4

M25
02
NOTE
The bearing shells should be replaced in pairs. Mark both halves with a punch accor-
ding to the cylinder number (operating side) (fig. 3/Z).
Always replace the connecting rod and bearing cap together and also mark them on
the operating side.
1.4 Hold the bearing shells in this position and push the mounting clamp (fig. 2/W7) over the bearing
shells from the assembly side (operating side).
NOTE
The lower peg (2) of the mounting
clamp must engage in the oil hole of 1
5
the lower bearing shell and the peg of
the mounting clamp bolt (1) must
engage in the blind hole of the upper
bearing shell.
1.5 Tighten the mounting clamp bolt (1)

slightly. 4
W7
1.6 Turn the crankshaft until the bottom end of
the connecting rod sits lightly on the
bearing shells and the mounting clamp lies
on the lower joint face of the bottom end of 3 2
the connecting rod (5).
2
NOTE
The nose (3) of the mounting clamp
engages in the groove in the lower
joint face of the bottom end (5) for
centric guidance of the bearing shells.
1.7 Turn the bearing shells in such a way by means of the grip on the mounting clamp so that the con-
necting rod locating pin (4) engages in the hole in the lower and upper bearing shell and the bea-
ring shells sit in the connecting rod bore.
CAUTION
There is a danger of the bearing shells being damaged if assembly is carried out incor-
rectly.
1.8 Turn the piston to TDC, remove the mounting clamp (W7) and piston suspension device (W1).
en / 19.12.2012 IB003560 2/4

M25
2. Installing the big-end bearing cover 02

(fig. 3/12).
2.1 Coat the thread and head contact surfaces

of the big-end bolts (11/13) with
"G-Rapid Plus" Molykote paste.
2.2 Press the big-end bearing cap (12) against

the bottom end (marking (Z) facing the
operating side) and screw in the big-end
bearing bolts.
3. Tightening the big-end bearing bolts.
3.1 Tighten the upper big-end bearing bolts

(11) alternately in two stages at a torque of
M = 300 Nm.
3.2 Tighten the lower big-end bearing W1

bolts (13) alternately in two stages at a
torque of
M = 300 Nm.
Z
11
12
13
en / 19.12.2012 IB003560 3/4

M25
3.3 Tighten the upper big-end bearing bolts (11) alternately at a torque of 02
M = 600 Nm.
3.4 Tighten the lower big-end bearing bolts (13) alternately at a torque of
M = 600 Nm.
3.5 Tighten the upper big-end bearing bolts (11) again alternately at a torque of
M = 600 Nm.
CAUTION
The upper big-end bearing bolts (11) have to be tightened again in operating
sequence 3.5 at a final torque of 600 Nm to prevent a loss of initial tension caused by
settling.
3.6 Remove the piston suspension device (W1) and the barring device.
3.7 Close the indicator valves and mount the crankcase doors.
en / 19.12.2012 IB003560 4/4

Crankshaft bearing A5.05. 02.05.01.01
M25
30000, 15000
See also: 02

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of one crankshaft bearing every 15,000 h
Number of cylinders Bearing no.
6 4
8 5
9 6
b) of all crankshaft bearings every 30,000 h
Tools:
Hydraulic equipment, W1
consisting of:
Support ring W1.1 0.9203-209
Hydraulic tensioning element W1.2 0.9213 C
High-pressure pump W1.3 0.9204 D
High-pressure hose (1 m) W1.4 0.9205 B
Pin W1.5 0.9203-110
Threaded sleeve W1.6 0.9206-001
Mounting / extraction device (crankshaft bearing, W2 259214 A

consisting of:
Support arms W2.1 259214-001
Receiver W2.2 259214-003
Carrier (bearing shells) W2.3 259119 A
Assembly device (crankshaft bearing) W2.4 259214-005
300 - 800 Nm torque wrench W11 * 1.9454-800

46 mm insert (side screws) W13 * 1.9450-046
Feeler gauge W14 * 1.9075-003
Socket wrench for indicator valves W15 * 1.9100-060
* not illustrated
NOTE
For an evaluation of the bearing shell running surfaces please contact your authorized
Caterpillar dealer.
en / 06.12.2013 IB021515 1/7

M25
30000, 15000
02
CAUTION
The smallest bending radius for high pressure hoses is r = 120 mm!
Use hydraulic oil only for the hydraulic equipment.
Store the hydraulic equipment protected against corrosion.
DANGER
Do not place any parts of the body over pressurized devices. Secure the engine
against unintentional starting!
NOTE
The crankshaft thrust bearing consists of the 1st crankshaft bearing (coupling end)
and 4 stop disk segments which limit the axial play of the crankshaft.
The two lower stop disk segments (fig. 1/ 1) are fixed on the crankshaft bearing
cover (3) by means of dowel pins (2). The two upper stop disk segments are pushed
into grooves in the cylinder crankcase.
The bearing cover and bearing shells of the crankshaft bearings are marked
consecutively according to which cylinder they belong to beginning at the coupling
end and are not allowed to be interchanged. New parts must be marked accordingly.
The crankshaft bearings have to be dismantled, checked and measured within the
specified interval in the event of:
-Distortions of the foundation or
-Changes in the crank web deflection
after damage at sea.
3 4
1
1. Measure the axial clearance "s"

(crankshaft thrust bearing).
1.1 Remove the cover below the timing gear 1

train and the power unit cover of cylinder 1
on the control side.
1.2 Measure the axial clearance "s1 + s2" at

the crankshaft thrust bearing with the fee-
ler gauge (fig. 1). 2
s1 s2
en / 06.12.2013 IB021515 2/7

M25
30000, 15000
1.2.1 Axial clearance „s“: 02

s = s1 + s2
Clearance when new Clearance limit

mm mm
0.3 - 0.6 0.8
When the clearance limit is exceeded, the stop disk segments (fig. 1/1) and bearing shells (4)
must be replaced in pairs ; refer to operating sequence 2, disassembly of crankshaft bearing.
CAUTION
Make sure the stop disks (1) are marked before removing them for inspection
purposes. Then mount them again without delay!
2. Dismantle the crankshaft bearing.
2.1 Open the indicator valves, mount the turning device and remove the corresponding power unit co-
ver (control side).
2.2 Turn the crankshaft to a favourable position. The round nuts (fig. 2/12) on the crankshaft bearing
bolts (13) must be freely accessible.
2.3 Loosen the round nuts (12) by means of the hydraulic tightening device.
14
W2.1 W2.1
W2.2 3
11
12
11
X
X
W1.1
W1.2
13
W1.6
2
en / 06.12.2013 IB021515 3/7

M25
30000, 15000
2.3.1 Remove the hexagon bolts (fig. 2/11) of the respective crankshaft bearing on the exhaust and 02
control sides.
2.3.2 Mount the support arms (W2.1) on the exhaust and control sides on the crankshaft bearing cover
(3). Tighten the bolts (14) to the limit stop.
2.3.3 Place the receivers (W2.2) successively in the cylinder crankcase (x) on both sides of the engine
and carry out the operating sequences 2.3.4 to 2.3.6.
2.3.4 Place the hydraulic tensioning element (W1.2) with the threaded sleeve (W1.6) and support ring
(W1.1) on the receiver (W2.2).
2.3.5 Swivel the receiver (W2.2) under the respective round nut (12) and raise the hydraulic tools
(W1.1, W1.2, W1.6) until the support ring (W1.1) lies flat on the crankshaft bearing cover (3). Pay
attention good accessibility of the slits (fig. 3/21).
2.3.6 Screw the threaded sleeve firmly onto the crankshaft bearing bolt and then screw it back by 3/4 of
a revolution. The ring surface (a) of the threaded sleeve is then flush with the upper surface (b) of
the hydraulic tensioning element (W1.2).
2.3.7 Connect the hydraulic tensioning elements (fig. 4/W1.2) to the high-pressure pump (W1.3) via the
high-pressure hoses (W1.4).
CAUTION
The pin (fig. 3/20), maximum stroke indicator) must not be driven out of the hydraulic
tensioning element (W1.2) when extending the crankshaft bearing bolts (13)!
2.3.8 Close the valve (fig. 4/Z) on the high pressure pump and extend both crankshaft bearing bolts si-
multaneously and stepless at a hydraulic pressure of
p = 980 bar. W1.1 21 12
2.3.9 Loosen the round nuts (fig. 3/12) with the W1.5
pin (W1.5). Turn the round nuts back by at
least 8 holes.
13
W1.2 W1.6 a b
20
en / 06.12.2013 IB021515 4/7

M25
30000, 15000
02
NOTE
If it is not possible to loosen the round nuts with the pin, then the crankshaft bearing
bolts can be pretensioned at a higher pressure of
p = 50 bar
If the pressure is increased even further, then there is a danger of the round nut
jamming as a result of the bolt thread expanding.
2.4 Open the valve (fig. 4/Z) on the high-pressure pump (W1.3). The tensioning elements (W1.2) are
relieved.
W1.2
W1.4 Z W1.3
4
2.4.1 Wait for the pressure to drop completely then remove the threaded sleeves (fig. 3/W1.6), hydrau-
lic tensioning elements (W1.2) and support rings (W1.1).
2.4.2 Only loosen the hexagon bolts (fig. 2/11) on the adjacent crankshaft bearings on the exhaust
and control sides.
2.4.3 Attach the support arms (W2.1) on the exhaust and control sides to a crane and secure them.
CAUTION
The crankshaft bearing cover (3) must be held securely in this position when remo-
ving the round nuts (12)!
en / 06.12.2013 IB021515 5/7

M25
30000, 15000
2.5 Measure the gap, refer to operating sequence 3. 02

2.6 Remove the round nuts (fig. 2/12) and carefully lower the crankshaft bearing cover (3) by means
of the crane.
2.7 Turn the crankshaft with the counter-weight towards the control side and remove the lower bea-
ring shell (fig. 1/4) from the crankshaft bearing cover (3).
2.8 Insert the carrier (fig. 5/W2.3) in the oil

bore on the crankshaft and turn the upper 30
bearing shell (30) out towards the exhaust
side.
2.9 Assess the bearing shells. Refer to For an

evaluation of the bearing shell running
surfaces please contact your authorized
Caterpillar dealer.
2.10 Measure the wear on the wall in the W2.3

crankshaft stress zone at the measuring
points (fig. 6/X) by means of a micrometer
gauge.
Wear = Measurement when new - 5

actual measurement
2.10.1 The bearing shells must be replaced if the-

re is a wear of > 0.05 mm in the crown
area (fig. 6/X).
Measurement when new:

5,905- 0,02 mm
CAUTION
If it is necessary to replace the
bearing shells, then the adja-
cent bearings must also be
checked.
en / 06.12.2013 IB021515 6/7

M25
30000, 15000
3. Measure the gap. 02

3.1 Remove the hexagon nuts (fig. 7/11) of the corresponding crankshaft bearing on the exhaust end
control sides and only loosen the hexagon bolts (11) on the adjacent crankshaft bearings.
KA KS
11 11
12
3.2 Loosen both round nuts hydraulically (12) according to operating sequence 2.3.
Relieve the hydraulic extraction device and remove it. Refer to 2.4.
3.3 Loosen the round nuts further, do not remove them. Then tighten the round nuts alternately and
evenly by hand until the joint faces of the bearing shells just make contact.
3.4 Use a feeler gauge to measure the gap "K" between the cylinder crankcase and crankshaft bea-
ring cover on the exhaust and control sides and add the two measures values
K = KA + KS
Gap "K" Operating limit value

mm mm
0.80 - 1.07 0.65
en / 06.12.2013 IB021515 7/7

Crankshaft bearing/-thrust bearing A5.05. 02.05.01.02
M25
30000, 15000
See also: 02
Operating medium: Distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of one crankshaft bearing every 15,000 h
Number of cylinders Bearing no.
6 4
8 5
9 6
b) exchange all crankshaft bearings every 30,000 h
Tools:
Hydraulic equipment, W1
consisting of:
Support ring W1.1 0.9203-209
Hydraulic tensioning element W1.2 0.9213 C
High-pressure pump W1.3 0.9204 D
High-pressure hose (1 m) W1.4 0.9205 B
Pin W1.5 0.9203-110
Threaded sleeve W1.6 0.9206-001
Mounting / extraction device (crankshaft bearing, W2 259214 A

consisting of:
Support arms W2.1 259214-001
Receiver W2.2 259214-003
Carrier (bearing shells) W2.3 259119 A
Assembly device (crankshaft bearing) W2.4 259214-005
Receiver plate W2.5 259214 B

46 mm insert (side screws) W13 * 1.9450-046
* not illustrated
NOTE
Caterpillar dealer.
en / 15.01.2014 IB021521 1/7

M25
30000, 15000
02
CAUTION
The smallest bending radius for high pressure hoses is r = 120 mm!
DANGER
against unintentional starting!
NOTE
The crankshaft thrust bearing consists of the 1st crankshaft bearing (coupling end)
and 4 stop disk segments which limit the axial play of the crankshaft.
The two lower stop disk segments (fig. 1/ 1) are fixed on the crankshaft bearing
cover (3) by means of dowel pins (2). The two upper stop disk segments are pushed
into grooves in the cylinder crankcase.
The bearing cover and bearing shells of the crankshaft bearings are marked
consecutively according to which cylinder they belong to beginning at the coupling
end and are not allowed to be interchanged. New parts must be marked accordingly.
The crankshaft bearings have to be dismantled, checked and measured within the
specified interval in the event of:
-Distortions of the foundation or
-Changes in the crank web deflection
after damage at sea.
Sequence of operations: 3 4
1
1. Measure the axial clearance "s"
(crankshaft thrust bearing).
1.1 Remove the cover below the timing gear 1

train and the power unit cover of cylinder 1
on the control side.
1.2 Measure the axial clearance "s1 + s2" at

the crankshaft thrust bearing with the fee-
ler gauge (fig. 1).
2
s1 s2
en / 15.01.2014 IB021521 2/7

M25
30000, 15000
1.2.1 Axial clearance „s“: 02

s = s1 + s2
Clearance when new Clearance limit

mm mm
0.3 - 0.6 0.8
When the clearance limit is exceeded, the stop disk segments (fig. 1/1) and bearing shells (4)
must be replaced in pairs ; refer to operating sequence 2, disassembly of crankshaft bearing.
CAUTION
Make sure the stop disks (1) are marked before removing them for inspection
purposes. Then mount them again without delay!
2. Dismantle the crankshaft bearing.
2.1 Open the indicator valves, mount the turning device and remove the corresponding power unit co-
ver (control side).
2.2 Turn the crankshaft to a favourable position. The round nuts (fig. 2/12) on the crankshaft bearing
bolts (13) must be freely accessible.
2.3 Loosen the round nuts (12) by means of the hydraulic tightening device.
14
W2.1 W2.1
W2.2 3
11
12
11
13
W1.1
W2.5 W1.2
W1.6
en / 15.01.2014 IB021521 3/7

M25
30000, 15000
2.3.1 Remove the hexagon bolts (fig. 2/11) of the respective crankshaft bearing on the exhaust and 02
control sides.
2.3.2 Mount the support arms (W2.1) on the exhaust and control sides on the crankshaft bearing cover
(3). Tighten the bolts (14) to the limit stop.
2.3.3 Place the receiver plate (W2.5) through the crankcaft bearing cover.
2.3.4 Place the receivers (W2.2) successively in the cylinder crankcase (x) on both sides of the engine
and carry out the operating sequences 2.3.5 to 2.3.7.
2.3.5 Place the hydraulic tensioning element (W1.2) with the threaded sleeve (W1.6) and support ring
(W1.1) on the receiver (W2.2).
2.3.6 Swivel the receiver (W2.2) under the respective round nut (12) and raise the hydraulic tools
(W1.1, W1.2, W1.6) until the support ring (W1.1) lies flat on the crankshaft bearing cover (3). Pay
attention good accessibility of the slits (fig. 3/21).
2.3.7 Screw the threaded sleeve firmly onto the crankshaft bearing bolt and then screw it back by 3/4 of
a revolution. The ring surface (a) of the threaded sleeve is then flush with the upper surface (b) of
the hydraulic tensioning element (W1.2).
2.3.8 Connect the hydraulic tensioning elements (fig. 4/W1.2) to the high-pressure pump (W1.3) via the
high-pressure hoses (W1.4).
CAUTION
The pin (fig. 3/20), maximum stroke indicator) must not be driven out of the hydraulic
tensioning element (W1.2) when extending the crankshaft bearing bolts (13)!
2.3.9 Close the valve (fig. 4/Z) on the high pres-

sure pump and extend both crankshaft W1.1 21 12
bearing bolts simultaneously and
stepless at a hydraulic pressure of W1.5
p = 980 bar.
2.3.10 Loosen the round nuts (fig. 3/12) with the

pin (W1.5). Turn the round nuts back by at
least 8 holes.
13
W1.2 W1.6 a b
20
en / 15.01.2014 IB021521 4/7

M25
30000, 15000
02
NOTE
If it is not possible to loosen the round nuts with the pin, then the crankshaft bearing
bolts can be pretensioned at a higher pressure of
p = 50 bar
If the pressure is increased even further, then there is a danger of the round nut
jamming as a result of the bolt thread expanding.
2.4 Open the valve (fig. 4/Z) on the high-pressure pump (W1.3). The tensioning elements (W1.2) are
relieved.
W1.2
W1.4 Z W1.3
4
2.4.1 Wait for the pressure to drop completely then remove the threaded sleeves (fig. 3/W1.6), hydrau-
lic tensioning elements (W1.2) and support rings (W1.1).
2.4.2 Only loosen the hexagon bolts (fig. 2/11) on the adjacent crankshaft bearings on the exhaust
and control sides.
2.4.3 Attach the support arms (W2.1) on the exhaust and control sides to a crane and secure them.
CAUTION
The crankshaft bearing cover (3) must be held securely in this position when removing
the round nuts (12)!
en / 15.01.2014 IB021521 5/7

M25
30000, 15000
2.5 Measure the gap, refer to operating sequence 3. 02

2.6 Remove the round nuts (fig. 2/12) and carefully lower the crankshaft bearing cover (3) by means
of the crane.
2.7 Turn the crankshaft with the counter-weight towards the control side and remove the lower bea-
ring shell (fig. 1/4) from the crankshaft bearing cover (3).
2.8 Insert the carrier (fig. 5/W2.3) in the oil

bore on the crankshaft and turn the upper 30
bearing shell (30) out towards the exhaust
side.
2.9 Assess the bearing shells.For an evalua-

tion of the bearing shell running surfaces
please contact your authorized Caterpillar
dealer.
W2.3
2.10 Measure the wear on the wall in the
crankshaft stress zone at the measuring
points (fig. 6/X) by means of a micrometer
gauge.
Wear = Measurement when new - 5

actual measurement
2.10.1 The bearing shells must be replaced if the-

re is a wear of > 0.05 mm in the crown
area (fig. 6/X).
Measurement when new:

5,905- 0,02 mm
CAUTION
If it is necessary to replace the
bearing shells, then the
adjacent bearings must also be
checked.
en / 15.01.2014 IB021521 6/7

M25
30000, 15000
3. Measure the gap. 02

3.1 Remove the hexagon nuts (fig. 7/11) of the corresponding crankshaft bearing on the exhaust end
control sides and only loosen the hexagon bolts (11) on the adjacent crankshaft bearings.
KA KS
11 11
12
3.2 Loosen both round nuts hydraulically (12) according to operating sequence 2.3.
Relieve the hydraulic extraction device and remove it. Refer to 2.4.
3.3 Loosen the round nuts further, do not remove them. Then tighten the round nuts alternately and
evenly by hand until the joint faces of the bearing shells just make contact.
3.4 Use a feeler gauge to measure the gap "K" between the cylinder crankcase and crankshaft bea-
ring cover on the exhaust and control sides and add the two measures values
K = KA + KS
Gap "K" Operating limit value

mm mm
0.80 - 1.07 0.65
en / 15.01.2014 IB021521 7/7

c2 Crankshaft bearing/-thrust bearing
A5.05. 02.05.02.00
M25
See also: 02.05.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1-W15: refer to worksheet A5.05.02.05.01.nn
Auxiliary material:
"G-Rapid plus" Molykote paste *
DANGER
against unintensional starting!
CAUTION
The smallest bending radius for high pressure hoses is r = 120 mm.
NOTE
The bearing cover and bearing shells of the crankshaft bearing are
consecutively marked on the control side according to which cylinder they
belong starting from the coupling end and must not be swapped. New parts
must be marked accordingly.
The specified torques are only valid when the threads and nuts are greased
with Molykote.
Damaged crankshaft bearing bolts and round nuts must be replaced together.
en / 01.10.2013 IB003575 1/6

A5.05. 02.05.02.00
M25
1. Mount bearing shells.
NOTE
The upper bearing shell has a lubrication groove and oil bores. If removed, reinsert
the upper stop disk segments (only in the case of the crankshaft thrust bearing).
1.1 Lubricate the running surface of the bearing shell. Dry the back of the bearing and turn the
bearing shell as far as possible into the bearing.
CAUTION
The bearing locating nose on the upper bearing shell faced towards the exaust
side. The bearing shells are marked on the control side.
1.2 Insert the carrier (fig. 1/W2.3) down to the limit stop in the oil bore.
1.3 Place the assembly device (W2.4) in the crankshaft bearing cover (3). Pay attention to the lateral
limit stop.
en / 01.10.2013 IB003575 2/6

A5.05. 02.05.02.00
M25
1.4 Slowly lift the crankshaft bearing cover by means of the crane and support arms (W2.1) until the 02
assembly device (fig. 1/W2.4) makes contact with the bearing block (x).
1.5 Tighten the round nuts (12) hand-tight; the assembly device is clamped.
1.6 Turn the upper bearing shell towards the control side. Pay attention to the centric position of the
bearing shell. The locating nose must glide into the guiding groove in the bearing block (exhaust
side).
1.7 Remove the round nuts and slowly lower the crankshaft bearing cover by means of the crane and
support arms (W2.1).
1.8 Remove the carrier (W2.3) and assembly device (W2.4).
1.9 Lubricate the running surface of the lower

bearing shell (fig. 2/4). Dry the back of the
bearing and insert it in the crankshaft
bearing cover (3).
CAUTION
The bearing locating nose on the
lower bearing shell is on the
control side!
1.10 If removed, put the lower stop disk

segments (1) (only on the crankshaft
thrust bearing) back on the dowel pins (2).
CAUTION
Pay attention to the marking (to be done during disassembly) on the stop disks!
en / 01.10.2013 IB003575 3/6

A5.05. 02.05.02.00
M25
2. Tightening the bearing shells. 02
CAUTION
Before mounting the crankshaft bearing cover, make sure that the crankshaft bearing
screws (Fig. 3/13) are securely tightened down to the bottom of the thread hole.
2.1 Slowly lift the crankshaft bearing cover by means of the crane and support arms (fig. 3/W2.1) until
it lies on the bearing block.
2.2 Screwsy the round nuts (12) evenly onto the crankshaft bearing bolts (13) and tighten them hand-
tight by means of the pin (fig. 4/W1.5).
NOTE
Measure the gap "K" after fitting new bearing shells.
The axial clearance must also be measured after replacing the bearing shells or the
stop disk segments on the crankshaft thrust bearing (A5.05.02.05.01.nn).
2.3 Remove the support arms (fig. 3/W2.1).
2.4 Apply Molykote paste "G-Rapid Plus" get to the thread and contact surfaces of the hexagon bolts
(11) and tighten them alternately in three stages with the following torques
1st stage: M = 140 Nm

2nd stage: M = 420 Nm
3rd stage: M = 670 Nm.
en / 01.10.2013 IB003575 4/6

A5.05. 02.05.02.00
M25
2.5 Mount the receivers (Fig. 3/W2.2) one of the other on both sides of the engine in the cylinder 02
crankcase (x) and carry out the operating sequences 2.5.1 to 2.5.3.
2.5.1 Place the hydraulic tensioning element

(W1.2) with the threaded sleeve (W1.6)
and support ring (W1.1) on the receiver.
2.5.2 Swing the receiver under the respective

round nut (12) and raise the hydraulic
tools (W1.1, W1.2, W1.6) until the support
ring (W1.1) lies flush on the crankshaft
bearing cover (3). Pay attention to good
accessibility of the slits (fig. 4/21).
2.5.3 Screw the threaded sleeve (W1.6) hand-

tight onto the crankshaft bearing
bolts (13).
2.6 Connect the hydraulic tensioning elements

(fig. 5/W 1.2) to the high pressure pump
(W1.3) via the high pressure hoses
(W1.4).
CAUTION
The pin (fig.4/20, maximum stroke indicator) must not be driven out of the
hydraulic tensioning element (W1.2) when extending the crankshaft bearing
bolts (13)!
2.6.1 Close the valve (fig. 5/Z) on the higher pressure pump and extend both crankshaft bearing bolts
simultaneously and stepless at a hydraulic pressure of
p = 980 bar.
en / 01.10.2013 IB003575 5/6

A5.05. 02.05.02.00
M25
02
PRECAUCIÓN
¡La presión debe permanecer constante si la bomba hidráulica no está funcionando,
de lo contrario, el apriete se realizará de forma defectuosa!
2.7 Tighten the round nuts (fig. 4/12) evenly with the pin (W1.5). Pay attention to smooth action.
2.8 Check firm seating of the round nuts

• Reduce the pressure by 50 bar
• It must no longer be possible to loosen the round nuts with the pin.
2.9 Open the valve (fig. 5/Z) on the high pressure pump (W1.3). The tensioning elements are
relieved.
2.10 Wait for the pressure to drop completely. Remove the threaded sleeves (fig. 4/W1.6), hydraulic
tensioning elements (W1.2) and support rings (W1.1).
2.11 Remove the receiver (fig. 3/W2.2).
2.12 Check the lubricating oil flow.
2.13 Close the indicator valves and mount the power unit cover as well as the cover under the timing
gear train, if removed.
2.14 Remove the turning device.
en / 01.10.2013 IB003575 6/6

Piston A5.05. 02.06.01.02
M25
See also: 01.06.01.nn, 02.07.01.nn, 03.04.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting /extraction device for pistons W1 259223 A

Cylinder liner holding device W2 259217 B
Disassembly unit W4 259216 C
* not illustrated
Auxiliary material:
Rust solvent „Caramba“ **
** or a produkt of equal standard
NOTE
The cylinder liner must always be secured by means of the cylinder liner holding
device (W2) to prevent the cylinder liner (2) from coming off when lifting the piston
or during turning of the engine.
1. Open the indicator valves and mount the turning device.
2. Remove the power unit cover of the respective cylinder on the control side and dismantle the cy-
linder head (01.06.01.nn).
3. Place a used joint ring (6) onto the cylinder liner collar to protect the sealing surface.
4. Mount the cylinder liner holding device (W2) as shown in the illustration.
5. Tighten round nuts (4) by hand.
6. Turn the crank pin to approx 20° before TDC on the control side.
7. Fill the ring clearance between piston (3) and cylinder liner (2) with grease.
8. Carefully scrape off and remove any carbon deposits in the cylinder liner between TDC of the 1st
piston ring and bottom edge of the calibrating ring (1), so that the edge of the calibrating ring can
be felt easily all round with a finger.
en / 19.12.2012 IB020062 1/3

Piston A5.05. 02.06.01.02
M25
9. Spray the ring clearance between calibrating ring and cylinder liner lwith rust solvent. 02
10. Allow the rust solvent to act.
CAUTION
Ensure that the calibrating ring is also pulled out without tilt when extracting the piston.
If the calibrating ring is tilted , lower the piston and readjust the calibrating ring ! Intro-
duce the big end carefully into the cylinder liner.The big-end bearing shells must be
dismantled!
11. Insert the disassembly unit (W4) so that the recess (Z) is inside the calibration ring (1).
12. Lightly tension the disassembly unit (W4) by turning the spindle nut (8).
13. Turn the piston to the TDC- position and pull out the piston.
14. Recut the tapped hole (M12, 13.5 mm deep) in the piston crown.
15. Screw the mounting-/ extraction device (W1) into the piston.
16. Dismantle the con-rod cover and con-rod bearing shells (02.04.01.nn).
17. Attach a crane to ring bolt and slowly pull out the piston.
18. Place the piston in a suitable device and secure it!
19. Clean the sealing and contact surfaces at the cylinder liner collar and the recess for the calibra-
ting ring (1) and check for damages.
en / 19.12.2012 IB020062 2/3

Piston A5.05. 02.06.01.02
M25
02
CAUTION
Disassemble the connecting rod if the piston with connecting rod is stored for a longer
period as otherwise vibration damage can occur in the area of the piston pin bush.
20. Check the cylinder liner and completely remove combustion deposits.
NOTE
Do not damage the cylinder liner!
21. Check / Measure the wear on the cylinder liner (03.03.01.nn).
en / 19.12.2012 IB020062 3/3

Piston crown A5.05. 02.06.02.00
M25


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting/extraction device for pistons W1 259223 A
Auxiliary material:
Molykote paste "G-n plus"**
1. Turn the piston. 1
1.1 Attach a crane to the mounting/extraction

device (fig. 1/W1) and raise the piston.
1.2 Fit a sling to the con-rod (1) and attach it to

a second crane.
2
1.3 Carefully turn the piston together with the
con-rod. The piston must not knock
3
against the con-rod.
1.4 Place the piston on a suitable base.

Dismantle the mounting/extraction device
if applicable (W1).
2. Disassembly of the piston crown
2.1 Dismantle the piston pin (2)

(A5.05.02.08.01.nn).
2.2 Measure the small and bearing (3)

(A5.05.02.09.01.nn).
4
W1
en / 19.12.2012 IB003758 1/2

Piston crown A5.05. 02.06.02.00
M25
2.3 Loosen the cheese head screws (fig. 2/ 02

13) and remove them together with the re-
silient sleeves (12) and piston end (10).
2.4 Clean the piston crown (11) and piston 10

end (10).
Pay attention to the cleanliness of the
• slide faces of the con-rod in the piston
end as well as
• the contact surfaces of the piston
parts and resilient sleeves (12).
13
CAUTION 12
Check the slide and contact

surfaces for signs of friction as
well as signs of cold welding.
s 11
Consult Caterpillar customer
services if necessary!
2.5 Assembly of the piston
2.6 Mount the piston end (10). The locating

bore and dowel pin (4) must align.
2
2.7 Apply Molykote paste to the thread and
contact surfaces of the cheese head
screws (13).
2.8 Mount the cheese head screws (13) together with the resilient sleeves (12).
2.9 Tighten the cheese head screws (13) cross-wise at a torque of
M = 60 Nm
and then loosen them again.
2.10 Check clearance dimension (s) with cheese head screws (13) loosened:
0.06 - 0.10 mm
2.11 Tighten the cheese head screws (13) cross-wise at a torque of
M = 25 Nm
and then turn them a further 60°°.
2.12 Check:
It should not be possible to turn the cheese head screws any further at a torque of
M = 45 Nm!
en / 19.12.2012 IB003758 2/2

c2 Piston Rings and Grooves
A5.05. 02.07.01.00
M25
30000, 7500
See also: A5.05.02.10.01.nn, A5.05.02.06.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of one piston and its rings all 7,500 h
Maintenance:
of all pistons and their rings all 30,000 h
Tools:
Piston ring expander W1 259227 A
NOTE
During piston inspection, pay special attention to any sharp edges of the piston rings,
ring tension, or rings sticking due to carbon deposits.
Depending on the personnel’s own critical judgement the complete check of all pi-
stons may be postponed to a later date, however, not beyond a maxium of 30,000
operating hours and subject to the following conditions:
•the running surfaces of all cylinder liners are without marks, polished spots, and wi-
thout any other damages,
•the parts of the drawn piston must be in perfect condition,
•all piston rings must be free in the grooves, and
•no part must present unpermissible wear
Do not remove the graphite coating on the piston skirt.
After fitting new piston rings, the engine must be run in according to the running-in re-
gulation, see engine documentation, chapter "Operating Instructions"
Built up pistons with chromium-plated first ring groove must only be reconditioned by
Caterpillar contract workshops.
en / 15.01.2014 IB028649 1/4

A5.05. 02.07.01.00
M25
30000, 7500
1. Piston inspection (7,500 h)
1.1 Open all crankcase covers.
1.2 Check the running surfaces of the cylinder liners from the crank chamber.
1.3 Draw the piston from the liner with the worst running pattern (A5.05.02.06.01.nn). Draw the other
pistons too, if the piston rings are stuck or burnt.
1.4 Remove piston rings only with the piston

ring expander (Fig. 1/W1). Record
position of ring joints with regard to the
installation position of the piston on
measuring sheet.
1.5 Clean the piston rings.
1.6 Check the chromium layer for wear,

particularly at the joint and the opposite
side. Renew all rings of this piston if there
is no chromium visible in some spots.
1.7 If there is one ring wrong or if the

chromium layer of one ring is worn, check
the rings of all pistons
1.8 Clean the piston, ring grooves and oil re-

turn holes for the oil control ring.
1.9 Smooth light friction and seazing marks with a fine oily emery cloth or a fine carborandum stone.
In case of heavy damage or deep scores renew the piston.
en / 15.01.2014 IB028649 2/4

A5.05. 02.07.01.00
M25
30000, 7500
1.10 Measure the groove width hN (Fig. 2) in the front area of the groove in the longitudinal and 02
transverse directions of the engine. When exceeding the limits, have the grooves reconditioned
by Caterpillar.
1.11 Measure the ring thickness hR (Fig. 2) at 4 opposite points.
hN1 = new
hN2 = worn
1.12 Calculate the limit clearances and check according to the chart for standard piston ring sets.
Ring thickness hR Groove width hN2 Limit clearance

Groove Nominal Wear limit hN2 - hR
mm mm mm
1 (Piston junk ring) 6 6.45 0.50
2 (Compression ring) 6 6.45 0.50
3 (Oil control ring) 8 8.20 0.30
1.13 Insert the piston rings into the grooves with the marking pointing upwards and ring joints
pointing alternately towards flywheel end and free end of the engine respectively.
1.14 Mount the piston (A5.05.02.10.01.nn) and all crankcase covers.
en / 15.01.2014 IB028649 3/4

A5.05. 02.07.01.00
M25
30000, 7500
2. Maintenance (30,000 h) 02
2.1 Open all crankcase covers and draw the pistons (A5.05.02.06.01.nn).
2.2 Check the state of lubrication and appearance of the running surface of the piston and
clean it.
2.3 Remove the piston rings only by means of the expander (Fig. 1/W1). Record the position of the
ring joints with regard to the installation position of the piston on the measuring sheet.
2.4 Clean all ring grooves and check wear of the chromium layer. If the chromium layer is worn away
in some places, send the piston to Caterpillar-Kiel for reconditioning.
2.5 Measure the groove width hN according to operation sequence 1.9.
2.6 Replace oil control rings and compression rings.
2.7 Insert the piston rings into the grooves with the marking pointing upwards and ring joints
pointing alternately towards flywheel end and free end of the engine respectively.
2.8 Mount all pistons (A5.05.02.10.01.nn) and crankcase covers.
en / 15.01.2014 IB028649 4/4

Piston pin A5.05. 02.08.01.00
M25
See also: 02.09.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting / extraction device for pistons W1 259223 A
NOTES
1. Turn the piston.
1.1 Attach a crane to the mounting/extraction

device (W1) and raise the piston.
1.2 Fit a sling to the con-rod (1) and attach it to 1

a second crane.
1.3 Carefully turn the piston together with the 2

con-rod. The piston must not knock
against the con-rod.
1.4 Place the piston on a suitable base.

Dismantle the mounting/extraction device
if applicable (W1). 3
5
2. Dismantle the piston crown 4
2.1 Mark the con-rod (1), piston (2) and piston

pin (3) for assembly on the correct side.
2.2 Raise the con-rod slightly by means of a

crane to relieve the piston pin.
2.3 Remove the locking rings (4).
2.4 Carefully push the piston pin (3) out of the

piston bore and small end bearing bush
without using force. W1
en / 06.12.2013 IB003773 1/2

Piston pin A5.05. 02.08.01.00
M25
02
NOTE
If the piston pin cannot be pushed out by hand, heat up the piston to 80 °C in an oil
bath.
In most cases, the piston pin can be fitted and removed without heating up the piston.
The clearances of new parts could be too small in a cold condition. The actual overall
clearance is only given at operating temperature.
2.5 Place the con-rod on a suitable base.
2.6 Assess the small end bearing bush (5). For an evaluation of the bearing shell running surfaces
please contact your authorized Caterpillar dealer.
2.7 Check the bearing pin surface for cracks and damage.
2.8 Measure out the piston pin, piston pin bush and piston pin bore in the piston (A5.05.02.09.01.nn).
3. Mount the piston pin
3.1 Fit a locking ring (4) in the piston bore.
3.2 Raise the con-rod (1) and push it into the piston until the piston bore and piston pin bush align.
3.3 Lubricate the piston pin (3) and push it into the piston and piston pin bush according to the side
markings and without tilting it.
NOTE
If necessary, heat up the piston to 80 °C in an oil bath/freeze the piston pin.
3.4 Secure the piston pin by means of a second locking ring (4).
en / 06.12.2013 IB003773 2/2

Small end bearing A5.05. 02.09.01.00
Maintenance / Measuring
M25
45000
See also: 02
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/repair:
Measure the bearing clearance
Replace the small end bearing once a replacement criterion has been met
NOTE
The small end bearing consists of the bearing pin (fig. 2/1) and the small end bearing
bush (2).
Inserting a small end bearing bush is hardly possible with conventional equipment.
This work should only be carried out by Caterpillar or an authorized workshop.
The small end bearing bush in the stepped con-rod has a galvanic running code.
The service limit values (fig. 1) are decisive for assessment of the small end bearing.
A small end bearing should only be replaced if
-a clearance limit has been reached or

-the clearance limit will probably be exceeded before the next service.
Minimum clea- Maximum clea- Service

rance rance clearance limit
Piston boss Ø (A) 0.050 0.078 0.100

Piston pin Ø (C)
Small end bearing bush Ø (B) 0.110 0.2 0.22

Piston pin Ø (C)
Boss distance (D) 0.500 1.100 1.300
Bush width (X)
en / 18.11.2013 IB021665 1/3

M25
45000
1. Measure the small end bearing
1.1 Clean the piston pin (fig. 2/1), small end bearing bush (2) and piston boss.
1.2 Measure dimensions A, B and C by means of suitable measuring instruments such as external or
internal micrometers.
1.3 Determine the axial clearance [measure the piston boss distance (dimension D) and bearing
width (dimension X)].
The respective wearing parts have to be replaced when the service clearance limit (fig. 1) has
been attained.
en / 18.11.2013 IB021665 2/3

M25
45000
2. Disassembly of the small end bearing 02
NOTE
The following work should only be carried out by Caterpillar or an authorized work-
shop. Only do it yourself in an emergency!
2.1 Do not use force when dismantling the small end bearing bush.
The small end bearing bush (fig. 2/2) is not allowed to be pressed out. It has to be made ten-
sion-free by carefully sawing or milling it and then it is removed.
CAUTION
Attention must be paid that the surface of the small end bearing bore in the con-rod is
not damaged!
After removing the small end bearing, the surface of the bore has to be carefully
examined for cracks, corrosive scares or other damage. Only suitable crack detectors
such as Magna-Flux and a magnifying glass should be used. Accumulations of mate-
rial should carefully be removed.
Con-rods with a damaged bore surface in the small end bearing bore are not allowed
to be used again without being refinished.
Refinishing is usually possible by Caterpillar Replacement con-rods are available from
Caterpillar for such cases.
3. Assembly of the small end bearing
3.1 Undercool the small end bearing bush to approx. -60 °C in liquid nitrogen and heat up the con-rod
to approx. 100 °C in a clean oil bath.
WARNING
Working with liquid nitrogen can cause burns! Pay attention to safety regulations!
3.2 Insert the small end bearing bush in the con-rod.
CAUTION
•Pay attention to the correct position of the small end bearing bush in the con-rod!
•The lateral projection (fig. 2/Z) of the small end bearing bush must be equal!
•Pay attention to the position of the oil bores and oil grooves!
3.3 Check the dimensional accuracy and the position of the oil bores and oil grooves after reaching
the normal temperature.
en / 18.11.2013 IB021665 3/3

Piston A5.05. 02.10.01.01
M25
See also: 02.04.02.nn, 02.06.01.nn, 02.07.01.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting/extraction device for pistons W1 259223 A

Cylinder liner holder W2 259217 B
Piston assembly ring W3 259220 B
Piston insertion device (sheet metal sleeve) W4 259220 A
* not illustrated
Auxiliary material:
Molykote paste "G-Rapid Plus“ **
NOTE
The cylinder liner must always be secured by means of the cylinder liner holder (fig.
3/W2) to prevent the cylinder liner from coming loose when turning the engine (wit-
hout dismantled cylinder head)!
Pay attention to the cylinder number mark on the bottom end.
Drive in the engine according to the driving-in regulation (A3.10.01) after fitting a new
piston/new piston rings!
1. Replace the piston rings as required.
2. Fit the new piston rings with the ring joints in a longitudinal direction to the engine alternately
arranged opposite each other! Lubricate the piston rings and pistons well on the outside.
en / 19.12.2012 IB020215 1/3

Piston A5.05. 02.10.01.01
M25
3. Slacken the tightening screw (fig. 1/10) 02

until the piston insertion device (W4) has
been relieved and can be guided freely
over the piston rings.
4. Apply Molykote paste "G-Rapid Plus" to

the thread and contact surface of the
tightening screw (10).
5. Place the piston insertion device (W4)

over the piston ring zone and tighten the
tightening screw (10).
CAUTION
Make sure the piston rings do
not sit on the outer edge of the
ring groove when tightening
the tightening screw. Eliminate
any faulty gripping by tapping
the piston inse tion device
slightly.
6. Check the floating position of the rings by

turning the piston insertion device (W4).
7. Mount the piston assembly ring (fig. 2/

W3). W3
8. Open the indicator valves. Mount the

turning device and piston mounting/
extraction device (fig. 3/W1).
CAUTION
Turn the crank pin to a favou-
rable installation position. The
bottom end must not knock 2
against the crank pin when
being lowered.
9. Attach the piston (3) to the crane and raise it.
10. Carefully insert the bottom end in the cylinder liner with the cylinder number mark towards the
control side and lower the piston exactly in the cylinder axis so that the bottom end does
not jam in the cylinder liner.
11. Let the piston insertion device (fig. 1/W4) lie flush on the piston assembly ring (fig. 2/W3) and ca-
refully lower the piston further guiding the bottom end over the crank pin by hand.
12. Dismantle the piston insertion device (fig.

1/W4), piston assembly ring (fig. 2/W3) as
well as the piston mounting/extraction
device (fig. 3/W1).
en / 19.12.2012 IB020215 2/3

Piston A5.05. 02.10.01.01
M25
13. Mount the cylinder liner holder (fig. 3/W2) 02

on the cylinder liner (2).
14. Clean the contact surface on the cylinder W2

liner collar.
CAUTION
W1
Insert the calibrating ring (1)
only after the piston has been
mounted!
1
15. Insert a new calibrating ring carefully into 2
the cylinder liner and lower it down to the
recess. W5
Do not tilt the calibrating ring ! 3
16. Mount the con-rod (02.04.02.nn).
17. Dismantle the cylinder liner holder (W2).
18. Mount the cylinder head (01.11.01.nn).
19. Mount the power unit cover and close the 3

indicator valves.
20. Dismantle the turning device.
en / 19.12.2012 IB020215 3/3

Explosion relief valve A5.05. 03.01.01.04
M25
1500
See also: 02.01.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Check:
Ease of movement of the explosion relief valve every 1,500 h
Tools:
Torque wrench 20 - 200 Nm W1 1.9454-202
Auxiliary materials:
Molykote Paste "G Rapid Plus“ *
Sealing compound "Dirko No. 610.020" *
* or equivalent product
NOTE
Removal of the explosion relief valve (5) is only required if the specified spring tension
is not provided any more, in the event of abnormal oil contamination or if any leaks
should be identified during operation.
Procedure:
1. Check the relief valve from the inside of the crankcase door (1) for ease of movement by actua-
ting the valve by hand. For this purpose dismantle the crankcase door (1) or the explosion relief
valve (5).
2. Disassembly
2.1 Unscrew and remove screws (8) from crankcase door (1).
2.2 Remove explosion relief valve (5) from the crankcase cover (1).
3. Assembly
3.1 Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2 Clean the sealing face (10) on the crankcase door (1) and lubricate with sealing compound "Dirko
No. 610.020".
3.3 Put the explosion relief valve (5) in place on the crankcase door (1).
en / 19.12.2012 IB026509 1/2

Explosion relief valve A5.05. 03.01.01.04
M25
1500
3.4 Tighten screws (8) to a torque of 03

M = 25 Nm.
3.5 After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6 When mounting the explosion relief valve on the crankcase door care has to be taken to ensure
proper sealing between seat and crankcase door.
en / 19.12.2012 IB026509 2/2

Cylinder Liner A5.05. 03.03.01.00
M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
See also: A5.05.02.05.50.nn, A5.05.02.06.01.nn, A5.05.03.04.01.nn, A5.05.02.07.01.nn 03

Spare parts list: B1.05.03.nn1110, B1.05.03.nn1611
Personnel qualification: skilled engine hand / chief engineer

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Inspection/measurement and evaluation of the cylinder liners

2. Inspection of contact surfaces
3. Inspection of radial fits
Engine Type Tools and auxiliary material Item Tool No.
M 20 C Measuring ruler for cylinder liner W1 2.9216-022

M 25 C Measuring ruler for cylinder liner W1 259216-001
M 32 C / VM 32 C Measuring ruler for cylinder liner W1 9.2084 A

GCM34
M 43 C / VM 43 C Measuring ruler for cylinder liner W1 439218-001

M 46 DF / VM 46 DF
M 20 C Cylinder liner micrometer W2 1.9419 M *

M 25 C Cylinder liner micrometer W2 1.9419 K *
M 32 C / VM 32 C Cylinder liner micrometer W2 1.9419 B *
GCM34 Cylinder liner micrometer W2 1.9419 L *

M 43 C / VM 43 C Cylinder liner micrometer W2 1.9419 G *
M 46 DF / VM 46 DF
* no picture
en / 15.01.2014 IB027873 1/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
Standard inspection (table 1): 03

• of one cylinder liner every 15,000 h
• of all cylinder liners (diesel engines only) every 30,000 h
• of all cylinder liners (gas engines only) every 45,000 h
• of a cylinder liner after every piston removal
• before every removal and after every installation of the cylinder liner
NOTE
For diesel oil (MDO) engines and gas engines it is recommended to replace all
cylinder liners after 90,000 h.
For heavy fuel (HFO) engines we are recommending to replace all cylinder liners after
60,000 h already.
If cylinder liners with irregular or critical contact patterns of the contact surfaces are
found at the 15,000 h / 30,000 h (for gas engines 15,000 h / 45,000 h) standard inspec-
tion, carry out follow-up inspections according to Table 2.
Follow-up inspection (Table 2), only in case of irregularities identified during a standard inspection:
• of at least two cylinder liners after 22,500 h
• of at least one cylinder liner after 37,500 h
Table 1
Standard inspection In-line engines V-engines
Number of cylinder liners to be inspected
1 x bank A
15,000 h 1
1 x bank B
Allowable cylinder units
Bank A All - except for the respective outer cylinder units

(e.g. for 8-cyl. engines only cylinder units 2 to 7,
Bank B for 16-cyl. engines A2 to A7 and B2 to B7)
30,000 h(diesel engine)
45,000 h (gas engine) All All
Table 2
Follow up-inspection In-line engines V-engines
22,500 h At least two At least three
37,500 h At least one At least one

Allowable cylinder units
Bank A 2,3,4,5,6,7,8 2,3,4,5,6,7
Bank B - 2,3,4,5,6,7
en / 15.01.2014 IB027873 2/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
03
NOTE
At the 22,500 h follow-up inspection inspect the irregular cylinder liners of the 15,000
h inspection and one other cylinder liner (on V-engines one additional cylinder liner
per bank).
At the 37,500 h follow-up inspection inspect at least those irregular cylinder liners
which showed irregular contact surface wear patterns at the 30,000 h inspection.
en / 15.01.2014 IB027873 3/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
Documentation of the measuring results 03

Document the condition of the inspected cylinder liner contact surfaces!
For this purpose, enter the cylinder unit, the operating hours, date and time of inspection as well as the
condition of the contact surface in the following table to be able to compare this data with subsequent
measuring results.
Please refer to table 3 for an example.
Table 3
_________ h inspection _________ h inspection

Cylinder unit
Illustration Remark Illustration Remark
en / 15.01.2014 IB027873 4/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
1. Cylinder liner inspection 03
NOTE
Depending on running time and operating conditions, cylinder liners can exhibit extra-
ordinary wear patterns that must be assessed and measured (see Fig. 3).
Preparatory works
Title Job card No. Remark
Remove the anti-polishing ring A5.05.02.05.50.nn
Draw the piston A5.05.02.06.01.nn
Remove the cylinder liner A5.05.03.04.01.nn
1.1 Remove joint ring and O-ring.
1.2 Clean the cylinder liner on the inside, when doing so, cover
the crankcase well.
1.3 Using the cylinder liner micrometer (W2) measure cylinder

liner at the measuring points determined with the measuring
ruler (Fig. 1/W1) and shown in Table 4 lengthwise, crosswise
and 2 x diagonally to the engine axis.
1.4 Enter the measured values in Table 4 and then calculate the
wear value (d1 - reference dimension d3, etc.). Please also
refer to the measurement sheet in folder “Forms for Mainte-
nance Reports”.
1.5 When the wear limit is reached, which is usually in the range
of the top piston ring reversal point (TDC, 1st piston ring), or
another limit in Table 5 (Fig. 2), replace cylinder line
en / 15.01.2014 IB027873 5/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
Table 4 03
Measuring Longitudinal Transverse Diagonal Diagonal Wear dimension
point direction direction
Reference
dimension
1__________
2__________
3 Reference
dimension
___________
NOTE
The essential criterion for deciding whether or not to replace a cylinder liner is the
running pattern left by the piston rings in the liner. If no excessive wear and no scuffing
is visible on the running surface, a replacement of the cylinder liner is not necessary!
en / 15.01.2014 IB027873 6/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
Table 5 03
List of M 20 C wear limits
Evaluation criteria Wear limits (mm) Explanation
Nominal Ø dimension (in

new condition)
200.0 +0.046
Max. ovality 0.25
Striping Please refer to 1.6

1. Wedge shape Height 6.0 Wedge-shaped indentation across the entire
Depth * 0.03 circumference, beginning at TDC of 1st piston
ring and extending downward.
* Probe radius r ≥ 3 mm
2. Pocket Max. number 3 Extensive, irregular indentations

Length 45.0 * Probe radius r ≥ 3 mm
Width ** 15.0 ** In circumferential direction
Depth * 0.02
3. Score number 3 to max. 19*** Severe vertical, linear friction marks interrupt-
Length 140.0 ing the TDC area of the 1st piston ring.
Depth 0.5 *** see Note
4. Wear dimension 0.8 TDC 1st piston ring
5. CanyonMax. number 3 Individual deep blow-by grooves in the area of

Length 6.0 the 1st piston ring (TDC)
Total width 3.0
NOTE
*** If during a liner inspection no signs of wear in form of wedge shapes, canyons,
pockets or striping are identified, a quantity of up to 19 scores may be uncritical.
Contact your Caterpillar Service Station in this respect.
en / 15.01.2014 IB027873 7/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
List of M 25 C wear limits 03

new condition)
255.0 +0.052
Max. ovality 0.25


Depth * 0.02
5. CanyonMax. number 3 Individual deep blow-by grooves in the area of

Total width 3.5
NOTE
en / 15.01.2014 IB027873 8/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
List of M 32 C / VM 32 C wear limits 03

new condition)
320.0 + 0.057
Max. ovality 0.3


Depth * 0.02
5. Canyon: Max.number 3 Individual deep blow-by grooves in the area of

Total width 4.0
NOTE
en / 15.01.2014 IB027873 9/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
List of M 43 C / VM 43 C wear limits 03

new condition)
430.0 +0.063
Max. ovality 0.3


Depth * 0.03

0,9**** **** Limit value for cylinder liners that have
already been conically honed
5. Canyon: Max. number 3 Individual deep blow-by grooves in the area of

Total Width 6.0
NOTE
en / 15.01.2014 IB027873 10/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
List of GCM34 wear limits 03

new condition)
340.0 +0.057
Max. ovality 0.3


Depth * 0.02

Total width 4.0
NOTE
en / 15.01.2014 IB027873 11/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
List of M 46 DF / VM 46 DF wear limits 03

new condition)
460.0 +0.063
Max. ovality 0.3


Depth * 0.03

0,9**** **** Limit value for cylinder liners that have
already been conically honed

Total Width 6.0
NOTE
en / 15.01.2014 IB027873 12/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
1.6 Striping 03
As a basic rule, there are three degrees of striping formation:
1. Faint striping (s-) = harmless

2. Normal striping (s) = harmless
3. Unacceptable striping (s+) = replacement required
The most important wear criterion is the condition of the honing structure in the area of the striping. If the
honing structure is not destroyed, it can be assumed, based on insights gained to date, that such striping
will not lead to a critical condition and that the affected cylinder liner can remain in the engine. This also ap-
plies in particular if there is a higher amount of stripes of this degree in one cylinder liner.
Illustration Evaluation Measure

1
-Faint striping (s-)
-Striping clearly visible.

None
-Honing structure preserved.
-Normal striping (s)
-Striping clearly visible. None
-Honing structure preserved.
-Unacceptable striping (s+) -Replace the cylinder liner
-Pronounced striping. -Inspect piston and piston rings

(A5.05.02.07.01.nn)
-Honing structure locally destroyed.
-Inspect the anti-polishing ring
and replace it, if necessary
en / 15.01.2014 IB027873 13/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
2. Inspection of contact surfaces 03

2.1 Turn the cylinder liner and put down on a suitable support
with the liner collar (anti-polishing ring side) downward and
secure against tipping.
2.2 Clean the cylinder liner contact surface (Fig. 3/ X) and as-
sess according to Table 6.
X
8
X2 X1
X
9
Engine type Cylinder liner contact surface (Fig. 3/X1) Free size (Fig. 3/X2)
M 20 C 11.15 mm 3 mm
M 25 C 14.4 mm 3 mm
M 32 C 14 mm 3 mm
GCM34 14 mm 3 mm
M 43 C 19 mm 2,5 mm
M 46 DF 19 mm 2.5 mm
3. Inspection of radial fits
3.1 Clean top (9) and bottom (8) fit and check the main load ar-
eas (Fig. 4/ 10) of the cylinder liner fits for corrosive/abra-
sive material erosion.
3.2 Sketch of the cylinder bore/upper, lower liner fit.
en / 15.01.2014 IB027873 14/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
03
3.3 Fretting
Criteria for reworking the radial fits of cylin- 90°

der liner and engine block:
1. Surface extension of fretting at the fits.
2. Degree of material erosion.

Engine axis
Rework of the respective fits (Fig. 5) or re-
placement of the cylinder liner is required
if the fretting formation occurs on more
than 50 % of the surface of one of the
main load areas
with 90°
local material erosion > 0.5 mm
and
over the entire height of the respective fit.
Height of fit
NOTE
All refinishing work on the radial fits must be carried out by an authorized
Caterpillar service station!
en / 15.01.2014 IB027873 15/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
3.4 Sketch showing critical and uncritical fretting marks 03

Radial fit, developed view.
Main load area Main load area
Uncritical Critical
Material erosion > 0.5 mm
Engine axis Cylinder liner must be replaced

and the engine block must be
reworked!
3.5 Example photos of critical and uncritical fretting marks on ra-

dial fits
Fretting marks are critical

if
Uncritical fretting marks the total surface of material erosion amounts to > 50% of one of the
main load areas
and
local material erosion is > 0.5 mm.
en / 15.01.2014 IB027873 16/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
03
NOTE
All refinishing work on the radial fits must be carried out by an authorized
3.6 Remove slight friction rust with fine emery cloth and carefully
smooth material build-up of uncritical friction rust marks.
en / 15.01.2014 IB027873 17/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
Table 6 03
Evaluation table for contact surfaces (applies to cylinder liner and engine block):
Figure 1 Figure 2 Figure 3

Irregular areas Irregular contact pat- Critical contact patterns
terns
Condition of the - - Corrosive/abrasive - Corrosive/abrasive - Corrosive/abrasive material

contact surfaces material erosion of material erosion of max. erosion of more than 25 %
max. 10 % of the total 25 % of the total contact of the total contact surface
contact surface up to a surface with up to 7 mm and/or more than 7 mm of
width of 7 mm of the of the width of the inside the width of
inside diameter of the diameter of the contact the inside diameter of the
contact surface. surface. contact surface.
- Material erosion is - Material erosion is clearly

clearly palpable palpable
- Measurable max. 0.2 - Measurable more than 0.2

mm mm
- Over the entire - Over the entire

circumference of the circumference of the
contact surface there is contact surface there is no
still a continuous ridge continuous ridge of a min.
of a min. width of 7 mm. width of 7 mm.
Evaluation of contact Harmless Basically harmless. Prompt refinishing of engine
surfaces block and cylinder liner
However, carefully required.
document and monitor
irregular cylinder units. In case of material erosion
of more than 0.3 mm
replace the corresponding
cylinder liners. Refinishing
is then no longer possible.
en / 15.01.2014 IB027873 18/19

M20/M25/M32/M43/M46DF/GCM34
30000, 15000, 45000
03
NOTE
All refinishing work on the contact surfaces must be carried out by an authorized
Table 7
Measures:
Figure 1 Figure 2 Figure 3

Irregular areas Irregular contact pat- Critical contact pat-
terns terns
Rework No No Yes
Inspection of other No No Yes
cylinder units (of all cylinder units)
Follow up-inspection As part of regular main- Shortened mainte- As part of regular main-
tenance ance interval tenance
Inspection of irregular
cylinder units and an
additional one per bank
or no later than after
7,500 h.
Installation instruc- Before installing the cyl- Before installing the cyl- Before installing the cyl-
tions inder liner clean the inder liner clean the inder liner clean the
contact surfaces and contact surfaces and reworked contact sur-
smooth any possible smooth any possible faces.
material build-up. material build-up.
en / 15.01.2014 IB027873 19/19

Cylinder liner A5.05. 03.04.01.00
M25
30000
See also: 02.06.01.nn, 03.03.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Dismantle the cylinder liner,

Replace the O-ring every 30,000 h
Tools:
Mounting device-cylinder liner, W1 259216 A

consisting of:
Ring nut W1.1
Cross-piece W1.2
Lifting rod W1.3
Cross-piece W1.4
Hexagon nut W1.5
Holding device-cylinder liner W2* 259217 A
* not illustrated
Auxiliary material:
"G-Rapid Plus" Molykote paste **
CAUTION
The sealing surfaces of the cylinder liner must be protected against being damaged!
en / 19.12.2012 IB021732 1/2

M25
30000
03
W1.1 W1.2
1. Dismantle the cylinder liner (3).
1.1 Dismantle the calibrating ring.

3
1.2 Dismantle the piston and holding device 2
(cylinder liner, piston).
1
1.3 Measure the wear.
1.4 Place the cross-piece (W1.2) on the

cylinder liner and introduce the lifting rod
(W1.3) with the ring nut (W1.1).
9
1.5 Position the second cross-piece (W1.4),
tighten by means of the hexagon nuts
(W1.5) and secure it.
1.6 Attach the lifting gear and extract the

cylinder liner in the direction of the cylinder
axis and place it on a suitable base.
1.7 Remove the O-ring (1) from the cooling

water manifold housing (2).
1.8 Carefully clean the sealing surface and

ring groove of the O-ring and check for da-
mage.
W1.3 W1.4
1.9 Carefully clean the cooling water zone at W1.5
the cylinder liner collar.
1.10 Clean the cylinder liner support, upper and

lower fitting in the cylinder crankcase (9).
en / 19.12.2012 IB021732 2/2

M25
See also: 03.03.01.nn, 03.04.01.nn 03

Spare parts list: B1.05.03.251110, B1.05.03.251611

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Extraction device (cylinder liner) W1 259216 A

consisting of:
Ring nut W1.1
Cross-piece W1.2
Lifting rod W1.3
Cross-piece W1.4
Hexagon nut W1.5
Auxiliary material:
W1.1 W1.2
- Vaseline *

3
2
NOTE
1
Measure the new cylinder liner
after fitting a new one and
before fitting the calibrating
ring.
Pay attention to the driving-in
regulation (see engine docu- 9
mentation, chapter „Opera-
ting Instructions“) in the
operating instructions!
1. Clean the inside of the cooling water mani-
fold housing (fig. 1/2). If necessary, repla-
ce the O-rings on the push rod bushing
and the air charge opening to the cylinder
crankcase (A5.05.03.02.00.nn).
2. Insert a new O-ring (1) in the groove on

the cooling water manifold housing.
W1.3 W1.4
W1.5
en / 19.12.2012 IB003823 1/2

M25
03
CAUTION
Use vaseline to fit the O-ring in the groove making sure it is not twisted!
3. Dismantle the extraction device (W1) from the drawn cylinder liner.
4. Place the cross-piece (W1.2) on the cylinder liner which is to be fitted and introduce the lifting rod
(W1.3) with the ring nut (W1.1).
5. Position the second cross-piece (W1.4) and tighten it by means of the hexagon nuts (W1.5) and
secure it.
6. Attach the lifting gear to the ring nut (W1.1) and insert the cylinder liner in the cylinder crankcase
(9).
NOTE
nsert the cylinder liner in such a way that the mark (15) (fig. 2/X, top view of cylinder
liner collar) points towards the coupling end in a longitudinal direction.
The mark (16) on the cooling water manifold housing can be used for alignment.
CAUTION
Cylinder liners which have been
fitted incorrectly can lead to
engine damage as a result of
the con-rod making contact!
The cylinder liner must slide into
the upper and lower fitting of the X
cylinder crankcase by its own
weight (fig. 1/9)!
7. Dismantle the extraction device (W1) and

measure the new cylinder liner.
8. Mount the piston and calibrating ring. X
16
15
2
en / 19.12.2012 IB003823 2/2

c2 Engine Fasteners and Connections
A5.05. 03.07.01.00
M20/M25/M32/M43/M46DF/GCM34
1500, 750
See also: A5.05.06.01.01.nn, A5.05.02.02.01.nn 03

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the engine fasteners and connections for tight fit and leaks
NOTE
This precautionary measure must be completed to identify leaks or loose bolted
connections. "Settling“ connecting elements or seals may cause leaks which may
lead to subsequent damage.
The items described in the following are a guide to exclude most of the sources of
defects that may occur.
1. Check the engine fasteners and connections for tight fit and leaks
1.1 Check the flange connections of the engine connection points, filters, etc. and the pipe brackets
of the following systems for tight fit and leaks:
• Cooling water
• Lubricating oil
• Fuel
• Gas pipes (gas and dual fuel engines only)
• Starting and control air
• Pneumatic control (emergency stop)
• Exhaust gas incl. turbocharger
• Hydraulic system for waste gate or VTG drive (gas engines only)
• Actuators for waste gate and by-pass (dual fuel engines only)
• Electrical connections (sensors)
en / 21.10.2013 IB028348 1/2

c2 Engine Fasteners and Connections
A5.05. 03.07.01.00
M20/M25/M32/M43/M46DF/GCM34
1500, 750
1.2 Check the fastening screws of the bearing brackets for the control shaft of the injection pump and 03
check the connecting joints (does not apply to gas engines).
1.3 Check the control and monitoring devices for tight fit. Cables and impulse lines must not chafe.
1.4 Check the expansion joints for leaks and the exhaust line for proper suspension
(A5.05.06.01.01.nn).
1.5 For gas and dual fuel engines it is additionally required to check the linkage for waste gate or
VTG drive.
1.6 Check the connection flanges as well as the covers, brackets, and connection pieces of the char-
ge air cooler for tight fit.
1.7 Check the base frame fastening by tapping. After tightening loose foundation bolts (contact your
authorized Caterpillar workshop to obtain the tightening values) measure crank web deflection
(A5.05.02.02.01.nn).
1.8 Check the resilient mounting for damage.
NOTE
During engine operation it is required to pay regular attention to possible leaks.
en / 21.10.2013 IB028348 2/2

Camshaft Bearing A5.05. 04.01.01.00
M25
30000, 15000
See also: 04.01.02.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Bearing clearance of one camshaft bearing after 15,000 h
- Bearing clearance of all camshaft bearings after 30,000 h
NOTE
Camshaft bearings are not subjected to load changes. The load on the bearing occurs
exceptionally in the lower contact area and is relatively heavy in this area. Smooth
overload along the edges is not unusual.
NOTES
1. Check the camshaft bearing clearance.
1.1 Open corresponding inspection glass lid of the camshaft door on the control side.
1.2 Measure clearance camshaft bearing / bearing neck.
New clearance Clearance limit

mm mm
0,20 - 0,26 0,35
NOTE
With reaching the clearance limit the camshaft bearing is to be replaced (Caterpillar-
customer support) and the clearance of all camshaft bearings are to be checked.
Check running surface of the bearing necks of the corresponding camshaft
bearings.For an evaluation of the bearing shell running surfaces please contact your
authorized Caterpillar dealer.
en / 07.01.2014 IB026577 1/1

Camshaft bearing A5.05. 04.01.02.00
M25
30000, 15000
See also: 04.04.01.nn, 04.09.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Check the running surface of one camshaft bearing and 15,000 h

the corresponding camshaft section from
the first cylinder onwards
- Check the running surfaces of all camshaft bearings and 30,000 h

camshaft sections from the first cylinder onwards
Tools:
Refer to A5.05.04.04.01.nn
NOTES
NOTE
Camshaft bearings are not subject to load changes. The bearing load is exclusively in
the lower supporting area and is relatively high there. Slight carrying by the edges is
not unusual.
CAUTION
The camshaft bearings between the camshaft gear wheel and first cylinder are only
allowed to be disassembled and reassembled by Caterpillar-customer service!
1. Inspection of the running surface of one camshaft bearing and the corresponding
camshaft section from the first cylinder onwards.
1.1 Relieve and lift the rocker arm of the camshaft section of the respective cylinder and all camshaft
sections located on the right (A5.05.04.04.01.nn).
en / 06.12.2013 IB021816 1/4

M25
30000, 15000
1.2 Loosen the hexagon bolts (Fig. 1/1) on the left-hand flange of the camshaft section (2). 04
Turn the camshaft to loosen hidden hexagon bolts, and then remove all hexagon bolts.
1 1 3
5 1
NOTE
When removing the hexagon bolts, pay attention that the injection cam stands verti-
cally upwards after the last turning process (TDC).
CAUTION
The camshaft is only allowed to be turned with loosened screw connections if
-the rocker arms of the camshaft section to be replaced as well as all rocker arms lo-
cated to the right are relieved and
-the pin (5) has been pulled out of the bearing journal (6) / the fitted left-hand cams-
haft section!
1.3 Mount the buffer for the camshaft

(Fig. 2/W3) on the cylinder crank case (vi-
bration damper). This is not for checking
the last camshaft bearing.
1.3.1 Mount the plate (44) with hexagon bolt

(43), hexagon nut (42) and guide pin (40)
and set maximum displacement
of s (A5.05.04.04.01.nn).
40
37
Displacement s = 50 ± 0.5 mm
41
1.3.2 Tighten the hexagon nut and pull the 42
vibration damper with the loosened
camshaft onto the limit plate (41). The
camshaft is secured against axial
displacement.
s
44 43 W3
2
en / 06.12.2013 IB021816 2/4

M25
30000, 15000
04
CAUTION
Do not use force during displacement! If there is any binding, check the floating of the
rocker arms! The engine can be turned over again!
NOTE
To check the last camshaft bearing, fit the extractor to the last camshaft section
(A5.05.04.04.01.nn). Remove the vibration damper (A5.05.04.09.01.nn) and push it
to the right as far as possible!
1.4 Check the camshaft bearing and replace it (A5.05.04.04.01.nn) in the event of:
- bad contact reflection (running surface; lower contact area)

- edge contacts
- scoring.
Caterpillar dealer.
1.5 Check the fixation of the camshaft bearing. The cheese head screw (Fig. 2/37) at the bearing
point of the camshaft bearing to be checked must be tightened at a torque of
M = 130 Nm.
If necessary, remove the loosened cheese head screw and support the respective camshaft sec-
tion.
1.5.1 Push the camshaft bearing out to the left using a suitable piece of wood. Check for signs of abra-
sion on the back of the bearing and replace it if necessary (A5.05.04.04.01.nn).
1.6 Check the running surfaces of the bearing flanges of all accessible camshaft sections for scoring.
1.7 Replace defective camshaft sections and check the corresponding camshaft bearing
(A5.05.04.04.01.nn).
1.8 Mount the camshaft and remove the buffer for the camshaft (A5.05.04.04.01.nn).
NOTE
After checking the last camshaft bearing, remove the extractor for the camshaft
section on the last camshaft section (A5.05.04.04.01.nn) and mount the vibration
damper (A5.05.04.09.01.nn)!
en / 06.12.2013 IB021816 3/4

M25
30000, 15000
2. Check the running surfaces of all camshaft bearings and camshaft sections from the first 04
cylinder onwards.
2.1 Relieve and lift all rocker arms (A5.05.04.04.01.nn).
2.2 Loosen the hexagon bolts (Fig. 1/1) on the left-hand flange of the camshaft section (2) of the first
cylinder. Make the hidden hexagon bolts accessible by turning the camshaft. Loosen them
and remove all hexagon bolts.
2.3 Mount the buffer for the camshaft (Fig. 2/W3) and pull the camshaft off the bearing journal (Fig. 1/
6) (1.3 to 1.3.2).
2.4 Support the vibration damper and camshaft section of the first cylinder.
2.5 Remove the cheese head screws (Fig. 2/37) at the bearing points of the camshaft.
2.5.1 Press out the respective camshaft bearing to the left using a suitable piece of wood. Check it (1.4;
1.5.1) and replace it if necessary (A5.05.04.04.01.nn).
2.6 Check the running surfaces of the bearing flanges of all camshaft sections for scoring.For an
evaluation of the bearing shell running surfaces please contact your authorized Caterpillar dealer
2.7 Replace defective camshaft sections (A5.05.04.04.01.nn).
2.8 Mount the camshaft and remove the buffer for the camshaft (A5.05.04.04.01.nn).
2.9 Remove the turning rod, dismount the turning device.
2.10 Relieve the device used for supporting the rocker arm. Remove it and carry out final work
(A5.05.04.04.01.nn).
en / 06.12.2013 IB021816 4/4

Camshaft A5.05. 04.04.01.02
M25


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Device for rocker arm (injection cam) W1 259235 B

Extractor for camshaft section W2 259230 A
Camshaft buffer W3 259230-003
Torque wrench 60 - 320 Nm W4 * 1.9454-320
Reversible ratchet 3/4 W5 * 1.9495-036
Adapter (3/4 to 1/2) W6 * 1.9459-035
Ring spanner W7 * 1.9459-022
Socket wrench W9 * 1.9100-060
* not illustrated
Auxiliary material:
Molykote paste ”G-Rapid Plus” **
CAUTION
The camshaft is only allowed to be turned with loosened screw connections if
-the rocker arms of the camshaft section to be replaced as well as all rocker arms
located to the right are relieved
and
-the pin (Fig. 2/26) has been pulled out of the bearing journal (27) / the fitted left-hand
camshaft section!
1. Disassembly
1.1 Open the indicator valves and remove the camshaft cover with housing covers and seals on the
control side.
1.2 Remove all rocker arms of the respective cylinder and all cylinders located to the right to relieve
the camshaft.
en / 09.06.2010 IB003218 1/8

Camshaft A5.05. 04.04.01.02
M25
1.3 Remove the push rods of the camshaft section of the respective cylinder and all camshaft sec- 04
tions located to the right of it. Lift the rocker arm of the inlet and exhaust valve drives from the
cam and secure with wire.
1.4 Relieve the injection cam of the respective cylinder and successively relieve all cylinders to the
right of it, to do so:
1.4.1 Turn the injection cam (Fig. 1/14) to just before (approx. 30°) the TDC point.
10 11
12
W1
16
15
14 1
13
1.4.2 Place a brass plate (0.8 up to 1.0 mm thick) in front of the roller (15) on the injection cam.
1.4.3 Turn the injection cam to the TDC position. Follow up with the brass plate, it must press the roller
off the injection cam.
1.4.4 Turn the injection cam to the TDC position.
1.4.5 Loosen the hexagon nut (10) and suspend the device for the rocker arm (W1) with the toggle (11)
in the cylinder crank case.
1.4.6 Screw the hexagon bolt (12) only in so far until the holder (13) makes firm contact with the rok-
ker arm (16) and the rocker arm lifts off the injection cam with a clearance of x.
x = 0.8 - up to 1.0 mm
1.4.7 Secure the setting with the hexagon nut (10) and remove the brass plate.
en / 09.06.2010 IB003218 2/8

Camshaft A5.05. 04.04.01.02
M25
1.5 To disassemble the last camshaft section: 04

1.5.1 Remove the vibration damper (Fig. 2/23) and push it to the right as far as possible (04.09.01.nn)!
20 20 22
21
27 26 2 25 24 23
1.5.2 Remove the intermediate piece (25).
1.6 Loosen the hexagon bolts (20) on both flanges of the camshaft section (21). Make the hidden
hexagon bolts accessible by turning the camshaft. Loosen them and then remove all hexagon
bolts.
1.7 Mount the device for extracting the camshaft section (Fig. 3/W2).
A A-A
30
31
31 36
32
37 35
21 33
32
34
W2
34 33 A
3
1.7.1 Mount the table (Fig. 3/34) on the cylinder crank case of the respective cylinder.
en / 09.06.2010 IB003218 3/8

Camshaft A5.05. 04.04.01.02
M25
1.7.2 Mount the carriage (33) on the table and push it under the camshaft section together with the de- 04
livery plate (32). Adjust the star grip (35) if necessary and tilt the delivery plate forwards.
1.7.3 Place the clamp (31) over the camshaft section and onto the extractor and mount it.
1.7.4 Use the star grip (35) to align the carriage so that the three ball bearings of the carriage lie on the
table without pressure.
1.8 Mount the buffer for the camshaft

(Fig. 4/W3) on the cylinder crank case
(vibration damper). (Not for disassembly of
the last camshaft section).
1.8.1 Mount the plate (44) with the hexagon bolt

(43) and guide pin (40) and set the maxi-
mum displacement of s (04.04.01.nn).
Displacement s = 50 ± 0.5 mm
40
1.8.2 Tighten the hexagon nut (42) and pull the 37
vibration damper with the loose camshaft 41
up to the limit plate (41). The camshaft is
secured against axial displacement. 42
CAUTION
Do not use any force when dis- s
placing! If there is any binding, 44 43 W3
check the clearance of the rok- 4
ker arm!
1.9 Remove the cheese head screw (Fig. 3/37) from the right-hand bearing point of the camshaft
section to be replaced.
1.10 Push out the camshaft bearing (Fig. 2/22) to the left with a suitable piece of wood.
1.11 Pull the camshaft section (Fig. 3/21) to the left with the carriage (33) until the pin (Fig. 2/26) of the
right-hand camshaft section is free.
1.12 Turn the injection cam to a horizontal position.
1.13 Loosen the screw connection (Fig. 3/36), carefully slide the camshaft section out of the right-hand
bearing point in the cylinder crank case.
Tilt the camshaft section to the left with the delivery plate (32) around the center of motion (screw
connection; 36) and lower using the star grip (35).
en / 09.06.2010 IB003218 4/8

Camshaft A5.05. 04.04.01.02
M25
04
NOTE
The camshaft section must be lowered beneath the bearing point (Fig. 3/30) of the
lower valve drive.
CAUTION
Do not tilt the camshaft section too much! Extreme care is of paramount importance!
1.14 Pull the carriage with the camshaft section forwards up to the limit of the table turning it by 180°,
see Fig. 5.
a b
c d
1.15 Remove the clamp (31) and take out the camshaft section. Pay attention to the weight (approx.
48 kg)!
1.16 Remove the camshaft bearing (Fig. 2/22). Check it (04.01.02.nn) and replace it if necessary.
en / 09.06.2010 IB003218 5/8

Camshaft A5.05. 04.04.01.02
M25
2. Reassembly 04
2.1 Press the pin (Fig. 6/26) into the flange of the camshaft section (21) at the respective reference
number until it bottoms.
Camshaft section Insert pin at

for cylinder reference number
1 5
2 8
3 2
4 6
5 4
6 4
7 6
8 2
9 8
8
1 7
3 6
21 4 5
26 6
2.2 Slightly oil the camshaft bearing on the inside and outside and place it on the injection cam of the
camshaft section.
2.3 Place the camshaft section with pin on the delivery plate (Fig. 3/32) facing the opposite end of the
coupling and secure it with the clamp (31).
2.4 Turn the injection cam into a horizontal position and swivel the camshaft section into the cylinder
crank case. Tilt the camshaft section with the delivery plate around the point of motion (screw
connection; 36) and lower it with the star grip (35).
2.5 Carefully guide the bearing journal for the camshaft section into the bearing bore in the cylinder
crank case.
CAUTION
Do not tilt the camshaft section too much! Extreme care is of paramount importance!
en / 09.06.2010 IB003218 6/8

Camshaft A5.05. 04.04.01.02
M25
04
2.6 Align the locating hole for the camshaft bearing (Fig. 2/22) with the bore for the cheese head
screw (Fig. 3/37) in the cylinder crank case and press in evenly using a suitable piece of wood.
Do not tilt it!
2.7 Rub the cheese head screw (37) in with Molykote, insert it and tighten it at a torque of
M = 130 Nm.
2.8 Align the camshaft section with pin (Fig. 2/26) with the bore in the bearing journal (27) / in the
bearing flange in the fitted left-hand camshaft section.
2.9 Push the camshaft section to the left until the cheese head screw (Fig. 6/26) the recess (y) of the
camshaft section hold securely.
CAUTION
Do not use any force when displacing! The camshaft gear wheel must not be
displaced by the camshaft section!
2.10 Insert all hexagon bolts (Fig. 2/20) using Molykote.
2.11 Insert the hexagon bolts (20) as far as possible in the left-hand flange of the camshaft section and
tighten at least three hexagon bolts stepwise and crosswise at a torque of
M = 140 Nm.
Bores which cannot be reached must be equipped later!
2.12 Remove the plate (Fig. 4/44) with the hexagon bolt (43) and guide pin (40) and push the rest of
the camshaft with the vibration damper carefully to the left up to the camshaft section until the cy-
linder pin and recess have been inserted completely in the left-hand camshaft section.
CAUTION
Do not use any force when displacing! The camshaft gear wheel must not be
displaced by the camshaft section! In the event of any binding, check the clearance of
the rocker arms!
2.13 Insert the hexagon bolts (20) as far as possible in the bearing flange of the camshaft section and
tighten at least three hexagon bolts stepwise and crosswise at a torque of
M = 140 Nm.
Bores which cannot be reached can be equipped later.
en / 09.06.2010 IB003218 7/8

Camshaft A5.05. 04.04.01.02
M25
2.14 Remove the extractor (Fig. 3/W2) and buffer (Fig. 4/W3). 04
2.15 Insert the other hexagon bolts (Fig. 2/20) (using Molykote), turn the engine and tighten all loose
hexagon bolts stepwise and crosswise at a torque of
M = 140 Nm.
2.16 After assembly of the last camshaft section:
2.16.1 Place the intermediate piece (Fig. 2/25) firmly on the camshaft section. The recess (z) must be
fully inserted in the camshaft section.
2.16.2 Insert the hexagon bolts (Fig. 2/24) (using Molykote) and tighten stepwise and crosswise at a tor-
que of
M = 85 Nm.
2.16.3 Mount the vibration damper (04.09.01.nn).
2.17 Turn all injection cams upwards individually (TDC position). Relieve the device for the rokker
arms (Fig. 1/W1) and remove it.
2.18 Lift all rocker arms of the inlet and exhaust valve drives, remove the wire and lower the rocker
arms onto the respective cams.
2.19 Mount the push rods.
2.20 Mount the rocker arms and check the valve clearance.
2.21 Remove the cover of the wheel casing (control side), check the axial clearance of the camshaft
and remount the cover.
2.22 Check the lubricating oil flow.
2.23 Check the seals and remount the camshaft cover as well as the cover of the wheel housing.
2.24 Remove the turning rod, dismount the turning device.
2.25 Close the indicator valves.
en / 09.06.2010 IB003218 8/8

Timing gear train A5.05. 04.08.01.00
M25
15000, 3750
See also: 02.01.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the tooth profile and oil nozzles after 3,750 h
of the axial play of the intermediate wheel after 15,000 h
Tools:
* not illustrated
Auxiliary material:
2
1. Inspection of the tooth profiles and oil 1
nozzles.
1.1 Remove the cover for the wheel casing 6

(control side).
1.2 Check the tooth profiles of the camshaft 5

gearwheel (Fig. 1/2, intermediate wheel
(1) and crank-shaft gearwheel (3) for
pitting, slanted running, breakage etc.
1.3 Use a feeler gauge to measure the play

4
between the teeth of the intermediate
wheel and the cam and crank shaft
gearwheel.
Target value 0.23 - 0.35 mm 3
1.4 Check the operation and firm seating of 1

the oil nozzles (4, 5 and 6).
en / 19.12.2012 IB021823 1/2

M25
15000, 3750
2. Measure the axial play (Fig. 2/s) of the intermediate wheel (1) with a feeler gauge. 04
Target value s = 0.3 - 0.6 mm
NOTE
Caterpillar customer service must be informed if the tooth profiles are damaged or if
one of the permissible target values (backlash, axial play) are exceeded.
3. Check the seals and mount the cover on the wheel casing on the control side.
X
X
en / 19.12.2012 IB021823 2/2

M25
See also: 02.01.01.nn 04


--------------------------------------------------------------------------------------------------------------------------------
Tools:

Adapter (3/4 to 1/2) W3 * 1.9459-035
* not illustrated
Auxiliary material:
1. Open the indicator valves.
1.1 Replace the O-ring (Fig. 2/10) for the in-

termediate wheel axle (Fig. 1/1).
1.2 Turn the engine so that the axle of the in-

termediate wheel can be accessed throu-
gh the fly-wheel.
1
1.3 Remove the turning rod/disengage the
turning rod.
Close the indicator valves.
1.4 Loosen the hexagon bolts (Fig. 2/11) and

remove them together with the curved
washers (12) and locking plate (13).
1.5 Remove the power unit cover of the first

1
cylinder (exhaust side).
1.6 From the power unit, push the

intermediate wheel axle (1) out of the
wheel casing towards the coupling end
only so far that the O-ring (10) is
accessible.
en / 19.12.2012 IB003222 1/2

M25
1.7 Renew the O-Ring (Fig. 2/10). 04

1.8 Rub the thread and contact surfaces of the
hexagon bolts (11) in with Molykote paste. 13 1
1.9 Mount the hexagon bolts (11) with curved 12
washers (12) and locking plate (13) and
tighten them by hand.
11
1.10 Press the locking plate (13) onto the
hexagon bolts and tighten the bolts (11) at 10
a torque of
M = 130 Nm.
1.11 Check the size of the gap (Fig. 3/X) between the locking plate (13) and intermediate wheel axle
(1):
Xmin. = 0.3 mm Xmax. = 1.4 mm
1.12 If necessary, loosen the hexagon bolts and realign the locking plate.
13
1
Y
13
Y x
en / 19.12.2012 IB003222 2/2

Governor Drive A5.05. 04.08.03.02
M25
15000
See also: 04
Spare parts list: B1.05.03.251110 , B1.05.04.254111, B1.05.04.254110, B1.05.04.254118

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Contact pattern on helical gear wheel every 15.000 h

- Contact pattern on intermediate gear wheel
- Serration of governor drive shaft
- End float of camshaft gear wheel
Tools:
Torque wrench 40 - 180 Nm W1 * 1.9454-040
Shift ratchet 1/2" W2 * 1.9459-033
* not illustrated
Auxiliary material:
Molykote paste “G-Rapid Plus” **
Sealing compound “Dirco 610.020” **
1. Disassembly
1.1 Loosen the governor linkage from the

governor (fig. 1/1), to this end:
1.1.1 Arrest the stop lever in stop position.
1.1.2 Remove the prevailing torque type nut (17)

with spacer sleeve (8), bolt (14) and was-
her (21).
1.1.3 Put aside the spring element (3).
1.2 Remove hexagon head screws (19) and

lift up the governor (1).
en / 19.12.2012 IB026135 1/4

M25
15000
1.3 Remove hexagon head screws (fig. 2/7) with spacers (6). 04
1.4 Attach the governor drive housing (1) to a crane by means of a sling and carefully lift up from the
engine block
CAUTION
Danger of damage to lubricating oil passage sleeve (8) and O-rings (9). Mind the
cylindrical pin (4).
1.5 Put the governor drive housing (1) onto a suitable base.
1.6 Remove spacer plate (13) and clean the contact face on the engine block.
en / 19.12.2012 IB026135 2/4

M25
15000
1.7 Check the gear flanks of the helical gear wheel (fig. 3/3) for pittings, skewing or break off. Check 04
the intermediate gear wheel (6).
1.8 Check the serration of governor drive shaft (5) and governor (fig. 1/1) for wear, if necessary clean
it.
1.9 Check all oil lubrication bores for lubrication of the governor drive shaft and the helical gear
wheels for free passage.
2. Reassembly
2.1 Provide the lubricating oil passage sleeve (fig. 2/8) with new O-rings (9).
2.2 Put spacer plate (13) onto the engine block.
2.3 Carefully put the governor drive housing (1) onto the engine block by means of a crane. In doing
so absolutely mind the lubricating oil passage sleeve (8), spacer plate (13) and cylindrical pin (4).
2.4 Insert screws (7) with spacers (6).
2.5 Firmly tighten screws (7) crosswise.
2.6 Daub the contact face for the governor with "Dirko 610.020". Put the governor (fig. 1/1) onto the
contact face of the governor drive.
en / 19.12.2012 IB026135 3/4

M25
15000
04
NOTE
The serration of the governor shaft must smoothly slide into the serration of the
governor drive shaft (fig. 3/4).
2.7 Insert and firmly tighten screws (fig. 1/19).
2.8 Mount the governor linkage in reversed disassembly sequence. If required readjust the
governor (see also Governor adjustment, engine documentation, chapter "Control and Moni-
toring".
en / 19.12.2012 IB026135 4/4

Camshaft vibration damper A5.05. 04.09.01.01
M25
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Molykote paste ”G-Rapid Plus” *

NOTE
The vibration damper must be replaced every 15,000 operating hours.
WARNING
Attention, there is a risk of injury! Never open a vibration damper
Sequence of operation:
1. Disassembly
1.1 Remove the camshaft cover with the hou-

sing covers and seals.
2
1.2 Secure the vibration damper (1) against
falling down.
3
1.3 Remove the bolts (2).
1.4 Attach the vibration damper (1) to a crane,

pull it off the transition piece (3) and lift it
out.
en / 13.09.2012 IB004373 1/2

Camshaft vibration damper A5.05. 04.09.01.01
M25
15000
2. Reassembly 04
2.1 Clean the contact surface of the damper (1) and transition piece (3) (free from grease).
2.2 Apply Molycote paste ”G-Rapid Plus” to the threads of the bolts (2).
2.3 Push the vibration damper (1) onto the transition piece (3) and screw in the bolts (2).
2.4 Tighten the bolts (2) crosswise and stepwise at a torque of
M = 50 Nm.
2.5 Mount the camshaft cover together with the housing covers and seals.
en / 13.09.2012 IB004373 2/2

Control shaft bedding A5.05. 05.01.02.00
M25
1500
See also: - 05

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil control shaft every 1.500 h
Auxiliary material:
Multi-purpose grease or lubricating oil according, see engine documentation, chapter

"Operating Media".
1. Remove control shaft/injection pumps and control station covers.
2. Check control shaft and spindle to emergency-off lever and oil bearing areas slightly with lubrica-
ting oil.
CAUTION
After cleaning with fat dissolving agents, all bright-metallic components are to be oiled
slightly. Care has to be taken that all cleaned bearings are thoroughly greased.
3. Grease the following bearings with multi-purpose grease:
- swivel heads of the intermediate shaft between shaft and control station
and control shaft
- swivel head of spring link between control shaft and regulator
Remove excessive gease.
4. Oil all moving bearings of the swivel arm between control shaft and
injection pump slightly.
5. Assemble covers.
en / 19.12.2012 IB021863 1/1

Starting Valve A5.05. 05.02.01.02
M25
7500
See also: Operating Instruction section 6 Commissioning 05

Spare parts list: B1.05.05.1.4906

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
of the starting valve every ´7.500 h
Tools:
Pin wrench W1* 0.9105 A
* not available as figure
Auxiliary material:
Molykote paste “ G-Rapid “ **
WARNING
Danger of accident! Be careful during disassembly! Position (Fig. 2/17) is under spring
tension.
NOTE
All pneumatic elements are lubricated with a special grease (see engine documen-
tation, chapter „Operating Media“; multi-purpose grease) which ensures sufficient
lubrication for several years. In the event of a repair only this grease may be used. If
other lubricants are used, the function of the components cannot be guaranteed.
en / 19.12.2012 IB021872 1/4

M25
7500
1. Close the main shut-off valve on the air receiver.
1.1 Vent the air pipes on the engine.
1.2 Disassemble all pipework and cable connections from the starting valve.
Disassembly:
2. Unscrew the screws (Fig. 1/1) and disassemble the starting valve from the engine.
en / 19.12.2012 IB021872 2/4

M25
7500
3. Disassemble the protective cover (Fig. 2/2). 05

3.1 Disassemble the silencer (3) and remove the solenoid (4).
3.2 Disassemble the armature (5) by slackening the screw connection (6).
Pay attention to the spring (7).
3.3 Slacken the screw connection (8) and pull out the emergency actuation knob (9).
3.4 Disassemble screw connection (11) and nut (12).
3.5 Disassemble piston (13) by means of the fork wrench (W1).
NOTE
When disassembling nut (12) and piston (13) secure the spindle (14) against being
dragged along. To this end put a wrench through the air duct (15) on the key face of
the spindle (14) and counterhold it.
3.6 Unscrew the hexagon socket screws (16) and disassemble flange (17).
3.7 Remove the spindle (14) completely from the casing.
4. Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, if necessary
carefully rework with polishing cloth.
en / 19.12.2012 IB021872 3/4

M25
7500
Reassembly: 05
5. Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces
slightly.
5.1 Insert a new, completely assembled spindle (14).
5.2 Assemble all valve parts in inverse disassembly order.
5.3 Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).
NOTE
Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid".
5.4 Put the finish assembled valve onto the engine. Firmly tighten the screws (Fig. 1/1)..
5.5 Mount all pipe and cable connections.
5.6 Mount the protective cover (Fig. 2/2).
6. Open the main shut-off valve on the air receiver.
7. Carry out a functional and leakage test with starting air.
en / 19.12.2012 IB021872 4/4

Control shaft A5.05. 05.08.01.00
M25
7500
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of inner rings every 7.500 h
6 7
1. Dismount the inner rings(Fig. 2/1). 8
1.1 Dismount linkage between injection pump

control shaft (Fig. 1/7) and hinged lever
(Fig. 2/8) of control shaft.
1.2 Remove bracket (Fig. 1/6) from hinged le-

ver.
1.3 Remove inner rings (Fig. 2/1) from bracket

(6).
2. Mounting of inner rings (Fig. 2/1).
NOTE
As a matter of principle, new
nuts (2) are to be used after
each loosening operation
[turning back of the nuts (2)]
2.1 Insert new inner rings(1) in bracket (6). X

2.2 Mount bolt (3), washers (4 and 5) and nut
(2) to connect the bracket (6) to the hinged
lever. 1
CAUTION
Tighten the nut (2) until the connection between bracket (6) and hinged lever is
smooth. When you tighten the nut make sure the inner rings(1) are not twisted.
en / 19.12.2012 IB026223 1/2

Control shaft A5.05. 05.08.01.00
M25
7500
2.3 Mount bolt (3), washers (4 and 5) and nut (2) to connect the bracket (6) to the injection pump 05
control shaft.
2
4
8
1
5
3
2
CAUTION
Align the parts perpendicular to the control shaft. Tighten the nut (2) until the connec-
tion between bracket (6) and injection pump control shaft is smooth. When you tighten
the nut make sure the inner rings (1) are not twisted.
en / 19.12.2012 IB026223 2/2

Compressed Air System A5.05. 05.09.01.01
M25
750
See also: - 05

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check control air lines and fittings for tightness and proper function.
NOTE
During the checks air must be admitted to the piping. In rather rare cases leakages
can be stated by noise; normally an air detector will be required to find the leakages.
The interval for draining results from the water quantity stated that depends on air
consumption, temperature and operating site.
Drain pipes and air vessel. The drain cocks are fitted at lowest points on the inclined side of
the pipes.
lnspect the piping visually and check for tight fit of the fittings and tightness of the screwed
connections.
NOTES
When fitting new pipes, the following must be observed:
Use either seamless steel pipes or copper pipes (against corrosion) for the
control piping. Steel pipes must not be corroded nor have any other fault im-
pairing their good operation. Only copper pipes are permitted for the pneuma-
tic remote control.
All pipes have to be laid as straightlined as possible without water pockets.

Water pockets which cannot be avoided must have a draining socket with plug
at the lowest point. The radius of pipe bends must be as large as possible.
All pipes are to be bent in a cold condition. Never fill the pipes with sand or si-
milar material for bending.
Fit the bent pipes carefully and free them from any scale or other impurities before
mounting them on the engine.
en / 19.12.2012 IB021884 1/2

Compressed Air System A5.05. 05.09.01.01
M25
750
05
NOTES
Keep the number of pipe connections and the resulting sealing points as low
as possible. The use of red lead, varnish or white lead is not permitted becau-
se this would make a later undoing of the connections more difficult and disin-
tegrated particles might enter the air ducts and cause damage.
If any pipes do not properly fit together they must be rebent so that they can be laid
without tension. Blow through them with compressed air after bending.
CAUTION
Assembly work must be done with extreme care and cleanliness. Even the slightest
dirt particles in the lines could entail failure of the control units.
en / 19.12.2012 IB021884 2/2

Control Valves A5.05. 05.09.05.01
M25
30000, 15000
See also: 05
Spare parts list: B1.05.10.25861n

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
After two years carry out a random test of the high pressure valves, after four years of the low
pressure valves.
In case of deficiencies reconditon all control valves.
NOTE
Low pressure valves: < 10 bar
High pressure valves: > 10 bar
Special grease for all control units see Caterpillar Lubricant Recommendations, see
engine documentation, chapter "Operating Media". The use of other lubricants
may be in detriment of the function of the fittings.
General instructions for maintenance see “Description to Functional Diagram” in sec-

tion 7.
There will result a certain cycle for control or inspection depending on kind and
function of the individual control units.
Regulating units (pressure reducers) must be checked in their circuit after mainte-
nance work for their setting values and must be reset if required.
See to it that no air is available at the components to be disassembled or that no air
can be admitted to these.
Prior to disassembly operations and where required measure and mark the position
of valves, lengths of levers and lever travels of, e.g., actuators, limitations by set
screws, and so on.
Do not dismantle control fittings at random since the built-in springs are sometimes
prestressed. In case there is available a screw or nut for adjustment of the prestress,
slacken these completely. Thoroughly clean the individual parts and exchange wear
parts. During assembly slightly grease rubber rings and their sliding surfaces with the
grease prescribed.
en / 19.12.2012 IB021895 1/1

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
See also: 05
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Drain the compressed air filter
2. Clean the filter cartridge
3. Replace all sealing elements
4. Check and adjust the pressure reducing station
Engine Type Tools and Auxiliary Materials Pos. Ord. No.
M 20 C, M 25 C, Loctite 241 *
M 32 C, VM 32 C **
M 43 C, VM 43 C,
M 46 DF, VM 46 DF Petro Gel Amber (1E1597) *
**
Nitro Solvents *
**
* no picture
NOTE
For maintenance and troubleshooting please refer to the engine documentation,
“Control and Monitoring”).
NOTE
Maintenance intervals
Provided the required compressed air quality and the allowable ambient conditions
are met, all sealing elements must be replaced latest after 22,500 h in order to
ensure safe operation of the pressure reducing station.
It is recommended to send the pressure reducing station to your responsible

Caterpillar dealer for overhauling.
en / 09.01.2014 IB029010 1/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
1. Draining of the compressed air filter 05

1.1 Move the handle of the drain valve (Fig. 1/5) slightly sideways and drain the filter completely.
WARNING
Risk of injury due to powerful blowing out of the condensate!
Compressed air is blown out with great force (30 bar)! Compressed air may entrain
dirt particles. Blown out dirt particles may injure the skin.
Do not actuate with bare hands!
Wear gloves and safety glasses!
en / 09.01.2014 IB029010 2/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
2. Cleaning of the filter cartridge 05
NOTE
The filter cartridge has to be cleaned regularly depending on the state of
contamination of the compressed air.
2.1 Disassembly and cleaning of the filter cartridge
WARNING
Risk of injury due to mounting parts under air pressure!
During disassembly pressurized mounting parts may come off at high speed.
Carry out all work in an unpressurized state.
Shut off the compressed air supply and vent the device!
Secure the device against unintentional operation!
NOTE
It has to be checked whether any downstream devices/plants (emergency stop) are
impaired in their function when carrying out the disassembly and cleaning tasks!
2.1.1 Close the shut-off valve in the compressed air supply pipe and secure it against unintentional
operation.
2.1.2 Depressurize the plant.
en / 09.01.2014 IB029010 3/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
05
2.1.3 Loosen the screw plug (Fig. 2/T1) and remove with sealing ring (1), filter (2) and O-ring (3).
2.1.4 Clean the filter with benzine or a solvent.
NOTE
If the filter cartridge is extremely dirty, replace it by a new one!
2.1.5 Clean the sealing surfaces and the seal seats.
2.2 Assemble the filter cartridge.
2.2.1 Dry the filter cartridge before reinstalling it.
2.2.2 Lightly grease a new sealing ring (Fig. 2/1) and new O-ring (3).
2.2.3 Insert sealing ring (1), filter (2) and O-ring (3) and assemble screw plug (T1).
2.2.4 Tighten the screw plug (T1) with a torque of 150 Nm.
en / 09.01.2014 IB029010 4/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3. Replacing all sealing elements 05
WARNING
Risk of injury due to mounting parts under air pressure!
During disassembly pressurized mounting parts may come off at high speed.
Carry out all work in an unpressurized state.
Shut off the compressed air supply and vent the device! Interrupt the electric power
supply!
Secure the device against unintentional operation!
NOTE
It has to be checked whether any downstream devices/plants (emergency stop) are
impaired in their function when carrying out the disassembly and cleaning tasks!
3.1 Dismantling the filter and the drain val-

ve
3.1.1 Loosen the screw plug (Fig. 2/T1) and re-

move sealing ring (1), filter (2) and O-
ring (3).
3.1.2 Unscrew valve screw (Fig. 3/T2) and re-

move sealing ring (4). Dismantle sealing
ring (7) and remove spring (6) as well as
valve (5) from the valve screw (T2).
en / 09.01.2014 IB029010 5/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.2 Dismantling the pressure switch 05

3.2.1 Disassemble the pressure switch (Fig. 4/
T3). For this purpose loosen screw (T4
2x). Remove O-ring (36).
3.3 Dismantling the adjusting screw
3.3.1 Dismantle circlip (Fig. 4/12) and remove

washer (T5).
3.3.2 Unscrew adjusting screw (T6) from the

housing.
3.3.3 Remove O-rings (8, 9 and 10).
3.3.4 Unscrew the ventilation (13).
en / 09.01.2014 IB029010 6/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.4 Dismantling the pressure control valve 05

3.4.1 Loosen grub screw (Fig. 5/T7) and un-
screw cap (T8) from the housing.
3.4.2 Remove spring (T9) and piston (35) with

O-ring (14).
3.4.3 Disassemble circlip (15) and extract valve

(16) together with valve nut (17), bush
(18), valve ring (19), O-ring (21) and O-
ring (34) from the hole. Remove spring
(20).
3.4.4 Dismantle circlips (22, 24) and filters (23,

25).
3.4.5 Unscrew banjo plug (Fig. 6/T11) from the

housing and remove collar (26).
en / 09.01.2014 IB029010 7/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.5 Dismantling the 3/2-way valve 05

(Versions: R417000844, R417000845, R417000888)
3.5.1 Loosen screw (Fig. 2/T25) and remove retaining plate (T26).
3.5.2 Dismantle servo valve (Fig. 7/33). For this purpose unscrew the ventilation (T13), remove the coil
(T14) and loosen the screw (T15 2x).
3.5.3 Remove gasket (27).
3.5.4 Loosen screw (T16 2x) and remove the cover plate (T17).
CAUTION
Risk of injury due to mounting parts under pressure!
Compression spring (T18) is under preload.
Counterhold when loosening.
3.5.5 Disassemble the following components:
Compression spring (T18), bush (T19), piston (T20), sleeve (T21), ram (T22), washer (T23 6x),
washers (32), spacer (T24 2x), sealing ring (28 4x) as well as grooved ring (29).
3.5.6 Dismantle circlips (24, 30) and filters (25, 31).
en / 09.01.2014 IB029010 8/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.6 Dismantling the 5/2-way valve (Version: R417000790) 05

3.6.1 Loosen screw (Fig. 2/T25) and remove retaining plate (T26).
3.6.2 Dismantle servo valve (Fig. 8/33). For this purpose unscrew the ventilation (T13), remove the coil
(T14) and loosen the screw (T15 2x).
3.6.3 Remove gasket (27).
3.6.4 Loosen screw (T16 2x) and remove the cover plate (T17).
CAUTION
Risk of injury due to mounting parts under pressure!
Compression spring (T18) is under preload.
Counterhold when loosening.
3.6.5 Disassemble the following components:
Compression spring (T18), bush (T19), piston (T20), sleeve (T21), ram (T22), washer (T23 6x),
washers (32), spacer (T24 2x), sealing ring (28 4x) as well as grooved ring (29).
3.6.6 Dismantle circlips (30 2x) and filters (31 2x).
B Principle representation
en / 09.01.2014 IB029010 9/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.7 Replacing the sealing elements 05
CAUTION
Sealing elements may get damaged if handled improperly.
Replace all sealing elements by new sealing elements and lightly grease them with
Petro Gel Amber (1E1597). Insert the sealing elements undamaged and untwisted.
3.7.1 Clean all sealing surfaces and seal seats.
3.8 Assembly of the filter cartridge
3.8.1 Lightly grease a new sealing ring (Fig. 9/1) and new O-ring (3).
3.8.2 Insert sealing ring (1), new filter (2) and O-ring (3) and assemble screw plug (T1).
3.8.3 Tighten the screw plug (T1) with a torque of 150 Nm.
en / 09.01.2014 IB029010 10/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.9 Assembly of the drain valve 05

3.9.1 Lightly grease a new sealing ring (Fig. 10/
4) and insert it.
3.9.2 Insert valve (5), spring (6) and a new

circlip (7).
3.9.3 Tighten the screw plug (T2) with a torque

of 60 Nm.
3.10 Assembly of the pressure switch and
the adjusting screw
3.10.1 Lightly grease a new O-ring (Fig. 11/36).
3.10.2 Assemble pressure switch (T3) with O-ring

(36) and screw (T4 2x).
3.10.3 Lightly grease new O-rings (8, 9, 10, 11).
3.10.4 Assemble adapter (T12) with O-ring (11)

and screw (T24 2x) (depending on
version).
3.10.5 Assemble adjusting screw (T6) with O-

rings (8, 9, 10).
3.10.6 Assemble washer (T5) and new circlip

(12).
3.10.7 Assemble new ventilation (13).
en / 09.01.2014 IB029010 11/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.11 Assembly of the pressure control valve 05

3.11.1 Replace circlip (Fig. 12/15), valve (16),
valve nut (17), bush (18), valve ring (19),
spring (20) and piston (35) by new ones.
3.11.2 Lightly grease new O-rings (14, 21, 34).
3.11.3 Assemble banjo plug (Fig. 13/T11) with

new collar (26).
3.11.4 Assemble a new filter (Fig. 12/23, 25) and

new circlips (22, 24).
3.11.5 Insert valve (16) together with valve nut

(17), bush (18), valve ring (19), O-
ring (21), O-ring (34) and spring (20).
3.11.6 Insert spring (T9) and piston (35) with O-

ring (14).
3.11.7 Assemble cap (T8) and grub screw (T7).
NOTE
Keep the clearance of 13.6+0.2
mm for the valve nut (17). Use
adjusting sleeve (37) for
checking.
Secure the valve nut (17) with
a screw locking compound
(e.g. Loctite 241).
NOTE
Ensure correct assembly
position of the valve ring (19)!
en / 09.01.2014 IB029010 12/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.12 Assembly of the 3/2-way valve (Versions: 05

R417000844, R417000845, R417000888)
3.12.1 Lightly grease new gasket (Fig. 14/27)

and new sealing rings (28 4x).
3.12.2 Replace servo valve (33), grooved ring

(29), circlips (24, 30) and filters (25, 31) by
new ones.
3.12.3 Assemble filter (25, 31) and circlips (24,

30).
3.12.4 Assemble the following components:
Grooved ring (29), sealing ring (28 4x),

spacer (T24 2x), washer (32), washer (T23
6x), ram (T22), sleeve (T21), piston (T20),
bush (T19) and compression spring (T18).
NOTE
Bush (T19) and sleeve (T21)
must project from the upper
housing edge by 0.4+/-0.1 mm.
Use washers (32) accordingly.
3.12.5 Assemble cover plate (T17) with screw

(T16 2x).
3.12.6 Assemble servo valve (33) with screw

(T15 2x). Put on coil (T14) and screw on
ventilation (T13).
NOTE
In case of pressure reducing
stations with retaining plate
(Fig. 9/T26 new version) the
screw (T25) must be fixed by a
screw locking compound (e.g.
Loctite 241) during assembly.
In case of pressure reducing

stations without retaining plate
(T26 old version) the ventilation
(Fig. 14/T13) is to be provided
with screw locking compound
(e.g. Loctite 241) and tightened
very lightly.
Secure screws (T15 2x) and

(T16 2x) with screw locking
compound (e.g. Loctite 241)
.
en / 09.01.2014 IB029010 13/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
3.13 Assembly of the 5/2-way valve 05

(Version: R417000790)
3.13.1 Lightly grease new gasket (Fig. 15/27) and new sealing rings (28 4x).
3.13.2 Replace servo valve (33), grooved ring (29), circlips (30 2x) and filters (31 2x) by new ones.
3.13.3 Assemble filters (31 2x) and circlips (30 2x).
3.13.4 Assemble the following components:
Grooved ring (29), sealing ring (28 4x), spacer (T24 2x), washer (32), washer (T23 6x), ram
(T22), sleeve (T21), piston (T20), bush (T19) and compression spring (T18).
NOTE
Bush (T19) and sleeve (T21) must project from the upper housing edge by 0.4+/-0.1 mm.
Use washers (32) accordingly.
3.13.5 Assemble cover plate (T17) with screw (T16 2x).
3.13.6 Assemble servo valve (33) with screw (T15 2x). Put on coil (T14) and screw on ventilation
(T13).
NOTE
In case of pressure reducing stations with retaining plate (Fig. 9/T26 new version) the
screw (T25) must be fixed by a screw locking compound (e.g. Loctite 241) during
assembly.
In case of pressure reducing stations without retaining plate (T26 old version) the
ventilation (Fig. 15/T13) is to be provided with screw locking compound (e.g. Loctite 241)
and tightened very lightly.
Secure screws (T15 2x) and (T16 2x) with screw locking compound (e.g. Loctite 241)
.
en / 09.01.2014 IB029010 14/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
05
en / 09.01.2014 IB029010 15/16

c2 Maintenance Unit
A5.05. 05.09.06.00
M20-VM46DF
4. Check and adjust the pressure reducing station 05
CAUTION
Wear on the pressure control valve parts
In order to minimize wear on the pressure control valve turn the cap (Fig. 16/T8) only in
pressureless state.
4.1 After the dismantling/mounting of the pressure reducing station, it is required to readjust the
’operating pressure of the pressure control valves. In order to do so, the grub screw (Fig. 16/T7)
has to be loosened and the cap (T8) has to be screwed out of the housing with the exception of
the last five turns.
4.2 Adjust a pressure of 30 bar at connection (P). By turning the cap (T8) adjust the operating
pressure at the pressure control valve to 7.5 bar and tighten the grub screw (T7).
4.3 Check the 3/2-way valve for proper function by actuating it. Finally the complete pressure
reducing station has to be tested for leaks.
T7 T8
en / 09.01.2014 IB029010 16/16

Exhaust Manifold A5.05. 06.01.01.00
M20/M25/M32/M43/M46DF/GCM34
7500
See also: 06
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check of the exhaust manifold for leaks

2. Removal of the exhaust manifold
3. Cleaning of the exhaust manifold
4. Reassembly of the exhaust manifold
Engine
Tools and auxiliary materials Pos. Tool No.
type
M 20 C Torque wrench 20 - 200 Nm W1 1.9454-202 *

M 25 C Torque wrench 20 - 200 Nm W1 1.9454-202 *
Torque wrench 200 - 500 Nm W2 1.9454-500 *
M 32 C, Torque wrench 100 - 400 Nm W1 1.9454-400 *

VM 32 C
GCM34 Torque wrench 20 - 200 Nm W1 1.9454-202 *
M 43 C, Torque wrench 20 - 200 Nm W1 1.9454-202 *

VM 43 C
M 43 DF, Torque wrench 200 - 500 Nm W2 1.9454-500 *
VM 46 DF Hexagon screw W3 431011 A
(Mounting aid for exhaust system/ max. 9 x)
High-temperature thread paste “Rivolta G.W.F.” **
Graphite or molybdenum spray **
* no picture
en / 22.11.2013 IB028075 1/9

M20/M25/M32/M43/M46DF/GCM34
7500
06
WARNING
Risk of burns.
• Before carrying out any work on the exhaust manifold it is absolutely required to
check the exhaust gas temperature!
• Allow the exhaust manifold to cool down sufficiently!
CAUTION
• In order to prevent damage to the expansion joints, they must not be subjec-
ted to bending or radial force during removal or installation.Bolting/clamping
of the compensators into place during installation results in a slight degree of
prestress (approximately 3-5 mm stretching) in axial direction.
• Insert all bolts with “Rivolta G.W.F.” high-temperature thread paste in order to
prevent sticking due to heat.
• In order to cope with the specific thermal load characteristics of the exhaust
manifold, only materials meeting these particularly stringent requirements
are used for its fastening. Therefore, use only genuine Caterpillar spare
parts.
NOTE
The exhaust pipe after turbocharger must also be checked within the scope of
this inspection. In case of severe vibrations or noise on the turbocharger, the
flange connections of the exhaust pipe after turbocharger must be slakkened
and checked for stress-free installation.
1. Check of the exhaust manifold for leaks
1.1 Remove the exhaust cladding.
1.2 Check all bolted connections and brackets for tightness.
1.3 Carry out a visual inspection on flanges and expansion joints (if possible, check while the engine
is running).
NOTE
Accumulation of soot, which may occur particularly on flanges and expansion joints,
is an indication of leaks.
Unless these are caused by cracks in the piping system or loose bolted connections,
new gaskets must be used.
Expansion joints with cracked bellows must be replaced.
en / 22.11.2013 IB028075 2/9

M20/M25/M32/M43/M46DF/GCM34
7500
2. Removal of the exhaust manifold 06
CAUTION
Avoid lowering of the exhaust manifold!
Never loosen all connections to the cylinder head at the same time on a fully fitted
exhaust manifold. Even partial loosening of the connections to the cylinder head may
lead to lowering of the exhaust manifold and thus destroy the expansion joints.
NOTE
• Before removal clearly mark the installation position and location of the expansion
joints and exhaust tube segments with chalk. Photos of the exhaust manifold from
different perspectives will make it easier to install the exhaust tube segments and
brackets at their proper location.
• Do not subject the expansion joints to bending or radial force!
2.1 Specific feature of the M 43/VM 43 and M 46 DF/VM 46 DF engines
2.1.1 Before removing the exhaust manifold each exhaust tube segment must be secured by screwing
in the retaining screw (W3) (see Fig. 1).
W3
en / 22.11.2013 IB028075 3/9

M20/M25/M32/M43/M46DF/GCM34
7500
2.2 Applicable to all engine series 06
CAUTION
Pay attention to hidden brackets and fasteners!
Engines with pulse charging system require the removal of further brackets and fa-
steners that are not indicated in detail.
2.3 Remove all expansion joints up to the turbocharger of the corresponding exhaust manifold.
2.4 Carefully unscrew and remove from the sensor sleeve (Fig. 2/2) all thermal sensors (Fig. 2/1)
located directly before the flange connection between exhaust tube segment and cylinder head.
14 Principle representation
2.5 Attach the individual exhaust tube segments to the crane one after the other, loosen and remove
the flange connection to the cylinder head.
2.6 Put the exhaust tube segments down at a suitable place and secure them against slipping.
3. Cleaning of the exhaust manifold
3.1 Clean the exhaust tube segments from the inside, inspect them for cracks and replace them, if
necessary.
3.2 Check the expansion joints for cracks and replace them, if necessary.
en / 22.11.2013 IB028075 4/9

M20/M25/M32/M43/M46DF/GCM34
7500
4. Reassembly of the exhaust manifold 06
NOTE
• As a basic rule for reinstalling the exhaust manifold it has to be borne in mind that
no gasket
(Fig. 3/4) needs to be installed between flange connections adjoining an expansion
joint.
• Use gaskets only between two exhaust tube segments or between exhaust tube
segment and cover plate.
• Always insert the gaskets with the lug (Fig. 3/4a) pointing upwards.
• Gaskets always with bead (Fig. 3/4b) pointing towards exhaust tube segment.
• Self-locking nuts may not be reused after removal and must be replaced by new
nuts.
• For a picture of the exhaust manifold please refer to the engine documentation,
chapter “Spare Parts CatalogueFalse
4 4a
4b
A-A
A
CAUTION
Avoid breaking of the bracket packages!
Before installation, spray the individual plates of the bracket packages on both sides
with graphite or molybdenum spray.
en / 22.11.2013 IB028075 5/9

M20/M25/M32/M43/M46DF/GCM34
7500
4.1 M 20 and M 25 engines 06
NOTE
This note is applicable to M 20 and M 25 engines only!
Between exhaust tube segment (Fig. 4/12) and cylinder head a new gasket (Fig. 4/
5) must be inserted before installation.
4.2 Lubricate the contact surface with “Rivolta G.W.F.”.
4.3 Position the exhaust tube segment on the cylinder head according to the markings provided upon
removal (installation position and location) with a new gasket (Fig. 4/5).
4.4 Insert hexagon bolts (Fig. 4/6) with extension sleeves (Fig. 4/7) (the flange surfaces of the ex-
haust tube segments should be aligned parallel to each other).
4.5 M 20
4.6 Tighten hexagon bolts (Fig. 4/6) alternately, first with a torque of 60 Nm (44 lb ft) and then alter-
nately with a torque of 110 Nm (81 lb ft).
4.7 M 25
4.8 Tighten hexagon bolts (Fig. 4/6) alternately, first with a torque of 180 Nm (133 lb ft) and then al-
ternately with a torque of 330 Nm (243 lb ft).
4.9 M 32/VM 32, M 43/VM 43, M 46 DF/VM 46 DF, and GCM34 engines
NOTE
This note is applicable to M 43/VM 43, M 46 DF/VM 46 DF engines only:
Before installation, a new spiral wound gasket must be inserted between exhaust
tube segment and cylinder head.
4.10 Position the exhaust tube segment on the cylinder head and the support bolt according to the
markings provided upon removal (installation position and location).
4.11 Lubricate the contact surfaces of the clamps (Fig. 5/8) “well” with “Rivolta G.W.F.”.
4.12 By means of the clamp (Fig. 5/8) lightly tighten the exhaust tube segment.
4.13 Install all other exhaust tube segments in the same way.
en / 22.11.2013 IB028075 6/9

M20/M25/M32/M43/M46DF/GCM34
7500
4.14 Adjust the exhaust tube segments so that all segments are in alignment. The flange surfaces of 06
the exhaust tube segments should be aligned parallel to each other if possible (measure the dis-
tance).
CAUTION
Avoid leaks!
When tightening the clamps (Fig. 5/8) make sure that the connecting flanges of the
exhaust tube segments and the cylinder heads are parallel to each other. After
tightening, the flange surfaces must rest flat.
4.15 Tighten hexagon bolt (Fig. 5/9) with a torque of 150 Nm (111 lb ft).
8
5 9
12 Principle representations
4.16 Installation of expansion joints
NOTE
• When installing the expansion joints pay attention to the flow direction (arrow on the
flange).
• Insert all fixing screws from expansion joint side.
• Lubricate the threads of the fixing screws with FalseRivolta G.W.F.” before in order
to prevent sticking due to heat.
• Do not subject the expansion joints to bending or radial force!
en / 22.11.2013 IB028075 7/9

M20/M25/M32/M43/M46DF/GCM34
7500
4.17 M 20 engines with single-pipe exhaust manifold (constant-pressure charging) 06
NOTE
Contrary to the usual method for installing expansion joints (threaded connection), the
expansion joints for M 20 single-pipe charging (constant pressure charging) (Fig. 6/10)
are fitted to the exhaust tube segment (Fig. 6/12) with clamps
(Fig. 6/11). An exception is the transition of the exhaust manifold to the turbocharger (no
picture).
10 11
11
12
12
13
13
4.18 Insert the expansion joints according to the marking (arrow on flange).
4.19 Lubricate the contact surfaces of the clamps (Fig. 6/11) “well” with “Rivolta G.W.F.”.
4.20 At the same time fit two clamps (Fig. 6/11) to both sides of the expansion joint. By alternately
tightening the hexagon bolts (Fig. 6/13) the expansion joint is evenly pulled against the exhaust
tube segments (Fig. 6/12).
4.21 Tighten hexagon nuts (Fig. 6/13) with a torque of 25 Nm (18 lb ft).
NOTE
For installation of the expansion joint adjoining the turbocharger please refer to the
following “General assembly instruction for expansion jointsFalse
4.22 The fixing screws of the last expansion joint before turbocharger are tightened with a torque
of 90 Nm (66 lb ft).
en / 22.11.2013 IB028075 8/9

M20/M25/M32/M43/M46DF/GCM34
7500
4.23 General assembly instruction for expansion joints. 06

4.24 Insert the expansion joints according to the marking (arrow on flange) and fit the related brackets
if necessary.Insert the fixing screws from expansion joint side, install the extension sleeves and li-
ghtly screw on the hexagon nuts.
4.25 By means of the fixing screws pull the expansion joints evenly against the flanges of the exhaust
tube segments (or turbocharger). After that, tighten the fixing screws crosswise with a torque
of X Nm (see table “General torques”).
CAUTION
Avoid tightening errors!
The following table (FalseGeneral torques”) only applies to bolts for which no
specific torque is indicated.
4.26 General torques (with High-temperature thread paste “Rivolta G.W.F).
Bolts Torque Torque

(M 20 C - VM 43 C only) (M 46 DF + VM 46 DF only)
M12 60 Nm (44 lb ft) -----------------
M16 140 Nm (103 lb ft) 130 Nm (96 lb ft)
M20 270 Nm (199 lb ft) 260 Nm (192 lb ft)
4.27 Reinsert all thermal sensors (Fig. 2/1) with circlip (Fig. 2/14) into the sensor sleeves
(Fig. 2/2) and fit them.
4.28 Install the exhaust cladding.
4.29 Specific feature of the M 43/VM 43 and M 46 DF/VM 46 DF engines
4.30 After installation of the exhaust manifold the hexagon screw (Fig. 1/W3) must be removed.
en / 22.11.2013 IB028075 9/9

Charge air cooler A5.05. 06.04.02.03
M25
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler has to be removed and cleaned at the air end when the differential pressure
before/after the cooler reaches more than 1.5 times the test bed value (see acceptance test re-
cord engine documentation, chapter "Technical Engine Data").
Auxiliary material:
Cleaning material according to the recommendation of the manufacturer, e.g. from:
• Fa. Vecom GmbH, Hamburg *

• Fa. Drew Ameroid GmbH, Hamburg *
• Fa. UNITOR chemicals *
Molycote paste ”G-Rapid Plus” *
1. Disassembly
1.1 Loosen the vent screws (Fig. 2/1) or, in the

case of engines with continuous
ventilation, make sure that the
corresponding stop cocks are opened,
remove the drain plugs (5) and drain the
charge air cooler.
1.2 Remove the cooling water feed and drain

pipelines (Fig. 1/4) from the charge air 4
cooler.
1.3 Loosen the hexagon bolts (Fig. 2/2, 10,

Fig. 3/11 and the hexagon-socket head
cap screws (Fig. 2/20).
6 6
7 7
1
en / 15.01.2014 IB004732 1/3

M25
1.4 Pull the charge air cooler (Fig. 2/9) out of the housing (3) and use lifting gear to place it in a suita- 06
ble vessel to be cleaned.
A 9
1
2
A
X
B
3
5
10
B 8
6
7 6
A-A / B-B 7
20
20
1.5 Clean the charge air cooler according to the specifications of the manufacturer
(see engine documentation, chapter "External Documentation").
1.6 Check the housing, drain the condensation water by loosening the screw plugs (6), replace the
sealing rings (7) if necessary.
WARNING
Pay close attention to the handling instructions of the manufacturer of the cleaning
material used. Protect the skin against contact with the cleaning material. Wear rubber
gloves, safety glasses and, if necessary, gas masks! Good ventilation must be
ensured!
en / 15.01.2014 IB004732 2/3

M25
2. Reassembly 06
2.1 Reassembly in reverse sequence of disassembly.
2.2 Replace the seal (Fig. 2/8).
2.3 Carefully place the charge air cooler (9) in the housing (3).
2.4 Pull the charge air cooler with socket head cap screws (Fig. 2/20) to the sealing face of the air
inlet casing.
CAUTION
Do not tighten the socket head cap screws now, but unscrew them a little bit
again !
2.5 Tighten the hexagon bolts (Fig. 3/11) first in the retaining bores.
X
11
11
3
2.6 Firmly tighten the hexagon bolts (Fig. 2/2).
2.7 Firmly tighten the socket-head cap screws (Fig. 2/20) so that the sealing surface of the air inlet
casing.
2.8 Mount the cooling water feed and drain pipelines (4) on the charge air cooler. Tighten the drain
plugs (5) and tighten the screw plugs (6) if it has been loosened and fill-up the engine with cooling
water.
2.9 Tighten the vent screws (1).
en / 15.01.2014 IB004732 3/3

c2 Exhaust gas turbocharger
A5.05. 06.05.00.00
M25
24
See also: A5.05.06.13.01.nn 06

Spare parts list: B1.05.06.nn7259 nn

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning M 25 every 24 h
Prerequisites:
-The compressor stage must be cleaned with the engine at operating temperature and under full
load (> 85% load ), if possible; i.e., at high turbocharger rpm.
- Clean pipes from the charge air system and after each turbocharger.
NOTE
Deposits or dirt praticles inside the washing system can plug the nozzles and nega-
tively impact cleaning success.
Air side washing device operating instructions:
Basic position:
- Washing water container (3) : empty
- Cap (2) : closed
Washing procedure:
1. Remove thumb nut (1) with cap (2).
1.1 Fill washing water container (3) with clean water.
1.2 Install cap (2) with thumb nut (1).
CAUTION
A washing water container that has been locked insufficiently or not at all may
cause injury or death of the operator.
en / 08.01.2014 IB028710 1/3

A5.05. 06.05.00.00
M25
24
06
2. Open ballcock (4) for about 20 seconds until the entire water volume has been injected.
NOTE
After the air-side has been cleaned, the engine must be operated at least another 5
minutes under load.
When the compressor impeller was contaminated, the success of a cleaning can be
told by the charge air pressure after the turbocharger.
The cleaning parameters for turbocharger model KBB-HPR 6000 are as follows:
turbocharger rpm: full load – rpm ( >85% )

water excess pressure: none
diaphragm: installed
water injection time: 20 seconds
water volume : 0.5 liter
en / 08.01.2014 IB028710 2/3

A5.05. 06.05.00.00
M25
24
The cleaning parameters for turbocharger model KBB-HPR 6000 are as follows:
06
KBB - HPR 6000 ABB - TPS61
turbocharger rpm: full load – rpm ( >85% )
water excess pressure: none
diaphragm: installed
water injection time: 20 seconds
water volume: 0,5 liter
CAUTION
Because of the increased risk of corrosion, only clear water (drinking water) -
never salt water - must be used for cleaning. This water should not contain any
coolant treatments or other chemicals that may form deposits in the air ducts.
CAUTION
The injection tube must never be connected directly to a water line, a different
or larger metering container or to a larger washing water containerother than
the one provided by Caterpillar Motoren.
CAUTION
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This
can cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in section 8
"External Documentation" or in the operator’s manual of the turbocharger manufacturer.
en / 08.01.2014 IB028710 3/3

Exhaust gas turbocharger A5.05. 06.14.02.00
Repair / Replacement
M20/M25
12000, 24000, 48000, 250, 1000
See also: 06
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
NOTE
The exhaust gas turbocharger must generally be maintained according to the main-
tenance instructions in Chap. 8 ("engine documentation, chapter "External Docu-
mentation") or the Operating Instructions.
Below is a list of maintenance tasks that must be performed using the work interval
schedule according to the operating instructions in Chap. 8 ("engine documentati-
on, chapter "External Documentation") after the number of operating hours listed.
The operating hours listed are guidelines that may need to be shortened or length-
ened depending on the operating conditions, as well as for adapting to engine main-
tenance intervals.
Instructions for emergency engine operation with a defective turbocharger see User
Manual Operating Instructions/Operational Monitoring.
en / 15.01.2014 IB024341 1/2

Exhaust gas turbocharger A5.05. 06.14.02.00
Repair / Replacement
M20/M25
12000, 24000, 48000, 250, 1000
06
Maintenance task Maintenance interval

Operating hours (h)
Clean air filter on muffler approx. 250 h

or as needed
Check mounting bolts on the once after

turbocharger legs, all housing bolts and Start-up
tighten pipe connections. then every 1000 h
Inspection 1 12 000 h
- Disassembly
- Cleaning (
- Check rotor and its bearings
- Check housings
- Assembly
- same as Inspection 1
- Replace bearings
- same as Inspection 2
- Exchange rotor
When ordering parts, please provide the information from the turbocharger serial plate.
en / 15.01.2014 IB024341 2/2

Injection pump A5.05. 07.02.01.00
M25
See also: 07.03.01.nn, 07.07.01.nn, 07.15.01.nn 07

Spare parts list: B1.05.04.253580, B1.05.07.258510, B1.05.07.258540, B1.05.08.258480

--------------------------------------------------------------------------------------------------------------------------------
Tools:

Adapter (3/4 to 1/2) W3 * 1.9459-035
* not illustrated
Auxiliary material:
6
5 7
1. Disassembly 4
1.1 Open the indicator valves.

3
1.2 Remove the camshaft cover with housing
covers and gaskets at the control and. 8
1.3 Turn over the engine so that the rocker

arm (Fig. 1/ 2) of the corresponding 2
injection pump drive rests on the base
circle of the injection cam (1).
1
en / 19.12.2012 IB003261 1/5

M25
1.4 Close the stop cocks, open the ball valve (Fig. 2/14) and drain the fuel distributor- collector pipe- 07
line.
10 6
m
11
15
12
14 13
2
1.5 Remove the pipe connections on the injection pump:
1.5.1 Loosen the hexagon bolts for the leakage pipelines on both sides of the injection pump (6) and
pull the flange off the injection pump. Check the O-rings and gaskets and replace them if neces-
sary.
NOTE
Remove the connecting flange from the outer injection pumps / loosen the flange for
the leakage oil pipeline (15).
1.5.2 Remove the leakage fuel pipeline (11) for the injection pump.
1.5.3 Remove the fuel distributor / collector pipeline (Fig. 3/20) (A5.05.07.15.01.nn).
20 6 21
en / 19.12.2012 IB003261 2/5

M25
07
NOTE
Remove the flange (Fig. 2/13) for the ball valve (14) / the flange for the fuel filter pipe-
lines (Fig. 3/21) on the outer injection pumps. Check the gaskets and replace them if
necessary.
1.6 Push the sleeve (Fig. 2/10) into the cylinder head housing and remove the transverse pressure
pipe for the injection pressure pipeline (A5.05.07.07.01.nn).
1.7 Loosen the screwed connection (12) and disconnect the connection between the injection pump
control rod (Fig. 4/30) and the control shaft.
31
30
12
32
11
33
34
35
34
36
37
4
1.8 Push the control rod (30) into the injection pump (6) as far as it goes.
1.9 Remove the hexagon bolt (31) for the stop cylinder (32).
DANGER
Careful! The spring tension of the injection pump drive acts against the injec-
tion pump. When disassembling, the rocker arm (Fig. 1/2) of the injection pump
drive must rest on the base circle of the injection cam (1). Turn over the engine
if necessary.
en / 19.12.2012 IB003261 3/5

M25
1.10 Remove the control air pipeline (Fig. 4/37). 07
NOTE
Only remove the check valve (36) if the injection pump is to be replaced.
1.11 Loosen the nuts (Fig. 1/5) evenly. Lift the injection pump (6) off the cylinder cankcase and remo-
ve the sleeve (Fig. 4/35) with O-rings (34).
CAUTION
The distance plates (Fig. 1/7) belonging to the cylinder are secured with semi-
circular grooved drive studs and must not be removed.
2. Reassembly
2.1 Check that the choke pipes are firmly in position (A5.05.07.15.01.nn).
2.2 Clean the contact surfaces of the injection pump (6) and the distance plates (7) as well as the
contact surface of the pressure spring (3) and the compression rod (8) in the injection pump.
2.3 Mount the sleeve (Fig. 4/35 with new O-rings (34).
2.4 Replace the O-ring (Fig. 1/4) and place the injection pump above the retaining screws. Insert the
compression rod (8) and pressure spring (3) in the locating hole of the injection pump.
NOTE
For assembly, the rocker arm (2) of the injection pump drive must rest on the base
circle of the injection cam (1). Turn over the engine if necessary.
DANGER
Careful! The spring tension of the injection pump drive acts against the injec-
tion pump.
2.5 Remove the turning rod/disengage the turning device.
2.6 Apply Molykote paste to the thread and contact surfaces of the nuts (5) and fix the injection pump
on its seat by evenly and alternately tightening the nuts.
2.7 Tighten the nuts (5) at a torque
M = 200 Nm.
en / 19.12.2012 IB003261 4/5

M25
2.8 Mount the stop cylinder (Fig. 4/32) together with the hexagon bolt (31). 07
2.9 Screw the control shaft to the control rod (30) of the injection pump. Check smooth movement
of link before tightening the screwed connection (12).
2.10 Mount the control air pipeline (37) and, the check valve (36) if it has been removed.
2.11 Insert the transverse pressure pipe for the injection pressure pipeline (A5.05.07.07.01.nn) and
the sleeve (Fig. 2/10) in the injection pump housing (lock-in position).
2.12 Mount the pipeline connections for the injection pump in the reverse sequence of disassembly.
Replace defective O-rings and sealing rings/rod seal.
Mount the fuel distributor / collector pipeline (Fig. 3/20) (A5.05.07.15.01.nn).
2.13 Check the compressed air pipelines (Fig. 4/33) for the stop cylinder (32) for leakage by means of
compressed air and the emergency stop system (function of the stop cylinders).
2.14 Check the seals and mount the camshaft cover at the control end.
2.15 Open the stop cocks, close the ball valve (Fig. 2/14), fill the fuel system with the stand-by pump,
vent and close the indicator valves.
en / 19.12.2012 IB003261 5/5

c2 Injection pump
A5.05. 07.03.01.02
M25
15000, 7500
See also: 07.02.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of one injection pump every 7,500 h
of all injection pumps every 15,000 h
Tools:
Reversible ratchet W2 * 1.9495-036
Adapter (3/4 to 1/2) W3 * 1.9459-035
* not illustrated
Auxiliary material:
Loctite 273 **
Hot bearing grease **
NOTE
All parts of the injection pump are manufactured with utmost precision in special
workshops. This is the only guarantee for proper functioning. When repairing a
pump, make sure that the various parts of one pump, e.g. the control sleeve remain
allocated to the respective housing. A renewal or exchange of the parts will consi-
derably influence the fuel delivery. The pump must therefore be reset on the test rig.
The pump plunger and the plunger barrel are only allowed to be replaced together. In
order to keep repair costs low, pump elements should be reworked only completely
and clearly marked to avoid confusion. Lapped surfaces must be preserved and not
touched with fingers.
In case of a significant drop of the cylinder output check the injection pump and if
necessary exchange the pressure maintaining valve or the plunger barrel.
The admissible lube oil leak rate of the fuel injection pump is
150 ml / h
en / 04.10.2013 IB026931 1/4

c2 Injection pump
A5.05. 07.03.01.02
M25
15000, 7500
1. Disassembly
1.1 Clean the outside of the injection pump.
1.2 Remove the impact screws (12) with

sealing rings (13) .Check them and repla-
ce them if necessary.
WARNING
Careful! The spring tension of
the pressure spring acts
against the guide pin (40)!
1.3 Place the injection pump in a spindle

device (e.g. vice) and apply axial pressure.
1.4 Remove the cheese head screws (35) and

slowly open the spindle device, the pres-
sure spring (60) is relieved.
1.5 Remove the intermediate flange (34) with

an O-ring (39) and scraper ring (14).
1.6 Take out the guide pin (40) with the spring
plate (41), pressure spring (60) and pump
plunger (50). Check the pressure spring
for corrosion.
1.7 Take out the control sleeve (73) with

spring plate (61) as well as the scraper
ring (74) and check the toothing of the
control sleeve.
1.8 Remove the control rod. Check the toot-

hing on the control rod.
1.9 Mount the injection pump housing with

flange (93) upwards.
1.10 Remove the flange (93) with thrust piece

(104) and pressure keeping valve (10).
1.11 Loosen the cheese head screws (20) alter-

nately and remove them.
en / 04.10.2013 IB026931 2/4

c2 Injection pump
A5.05. 07.03.01.02
M25
15000, 7500
1.12 Force the plunger barrel (30) out of the injection pump housing (71) with a suitable piece of round 07
wood.
1.13 Clean all parts with gas oil and a hard brush. Blow out with compressed air and check.
NOTE
When carrying out the visual check, special attention should be paid to the following
wear phenomena:
Plunger: Scores in the running surface, control helix

wear (by cavitation or erosion). A black plun-
ger or black spots on it indicate water in the
fuel.
Barrel: Scores in the running surface; damaged

sealing surface.
Impact screws: Cavitation in the inner bore mainly of the feed

bush.
Guide pin: Scores in the running surface, warn-out plun-

ger seat.
Pressure keeping valve:Damaged sealing surfaces, worn pressure rings (24, 27) and
dented valve seat (valve cone (25) with valve body (26)).
1.14 Replace both O-rings (52,53) and the sealing ring (51).
NOTE
All O-rings and the sealing ring (51) must be inserted in the grooves using hot bearing
grease and must not be twisted. Do not pull them over sharp edges of components.
en / 04.10.2013 IB026931 3/4

c2 Injection pump
A5.05. 07.03.01.02
M25
15000, 7500
2. Reassembly 07
2.1 Reassembly is effected in the reverse sequence of disassembly.
CAUTION
Refinishing of sealing surfaces is, as is the case for all injection parts, not possible on
board and is thus impermissible! When assembling, pay attention that the groove in
the control rod lines up with the straight grooved pin of the control sleeve (73)!
2.2 Insert the sealing rings (46,47).
2.3 Lubricate the following screws and tighten crosswise, partially stepwise, at the respective torque:
Cheese head screw (20) M = 10 - 90 ± 3 Nm
Cheese head screw (35) M = 22 ± 2 Nm
2.4 Lubricate the cheese head screws (95) and mount the flange (93) parallel to the element (30).
The circumferential spacing s should be 3 mm.
2.5 Tighten the cheese head screws (95) crosswise at a torque
M = 53 ± 2 Nm.
2.6 Coat the thread and contact surfaces of the impact screws (12) with Loctite and tighten the impact
screws at a torque of
M = 85 ± 5 Nm.
2.7 Tighten the screw (71) at a torque of
M= 14 ± 1 Nm.
2.8 Check free movement of the control rod.
en / 04.10.2013 IB026931 4/4

c2 Fuel Injector
A5.05. 07.07.01.00
M25
See also: A5.05.07.08.01.nn 07

Spare parts list: B1.05.01.252107, B1.05.07.252260, B1.05.07.258526

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Extractor for fuel injector W1 0.9111 E

Seat scraper for fuel injector seat W2 * 259122 A
* not illustrated
Auxiliary material:

”Dag S-5080” high temperature
thread paste **
NOTE
If work has to be carried out on
the injection system and the
engine is running on heavy
fuel, the system should be
switched over to distillate fuel
at least half an hour before-
hand so that the fuel injector is
flushed properly.
Sequence of operation:
1. Disassembly
1.1 Switch off the standby lubricating oil pump

for the main engine / the prelubricating
pump in the case of generator operation.
1.2 Push the sleeve (fig. 1/1) to the left in the

cylinder head frame.
1.3 Completely unscrew the screwed

connection (Y) of the transverse thrust
piece (2) out of the injection pump (10).
CAUTION
Always loosen the screwed connection (Y) first ! Sealing surfaces of the radial thrust
peace (5) and the transverse thrust peace (2) will be damaged by wrong dismantling !
en / 15.01.2014 IB028701 1/4

c2 Fuel Injector
A5.05. 07.07.01.00
M25
1.4 Loosen pressure screw (3), pry apart 07

transverse thrust piece (2) with cover (4) 32
and pull to the left out of injection pump 31
and cylinder head. 25
1.5 Pull out radial thrust piece (5) approxi-

mately 20 mm.
26
1.6 Disassemble nuts (fig. 5/8) and remove
flange (21). 28
27
ATTENTION
30
Sticking fuel injectors.
Do not apply any force. Contact
your authorized Caterpillar
workshop and/or install the
spare cylinder head.
1.7 Install device (fig. 2/ W1) in complete con-

dition.
1.8 Loosen hex head bolts (25) slightly and

screw threaded pieces (26) tightly on ex- 28
pansion screws (27) against the stop.
1.9 Tighten hex bolts (25) firmly. 31
1.10 Screw threaded rod (28) tightly on adjust-

ment bolt (fig. 5/29). 25
1.11 Place twist lock (fig. 2/30) over the hex

head of threaded rod (28).
1.12 Loosen injection valve by turning thread

sleeve (31) with wrench (32) until the low-
est O-Ring fig. 5/22) is exposed.
1.13 Disassemble hex head bolts (fig. 2/25).
1.14 Pull out injection valve with pulling device. 32

25
1.15 Completely disassemble and reassemble

pulling device. 26
1.16 Clean injection valve on the outside, mark

with cylinder number and perform a
functional test of the injection nozzle
(07.08.01.nn). 30
1.17 Scrape clean valve seat in sleeve (fig.5/

24) with tool W2.
Clean the inside of the sleeve.
en / 15.01.2014 IB028701 2/4

c2 Fuel Injector
A5.05. 07.07.01.00
M25
2. Reassembly 07
2.1 Replace the O-rings (22) and insert them
in the ring grooves making sure they are
not twisted.
Pay attention that the O-rings do not form
loops!
CAUTION
Use original MaK spare parts
only.
2.2 Apply a thin coating of high temperature

thread paste to the nozzle element (fig. 5/
23).
2.3 Carefully apply Molycote paste to the

thread of the studs (15), the contact
surfaces of the nuts (8) and the new
O-rings (22).
CAUTION
Excess paste must be remo-
ved! Excessive paste could
result in the
O-rings getting squeezed in
the retention groove of the cy-
linder head!
No gasket between the fuel

injector and sleeve in this
area (fig. 5/X).
2.4 Carefully insert the fuel injector with the

nozzle (23) in the sleeve (24). Pay
attention to the position of the positioning
pin (fig. 1/9).
2.5 Mount the flange (Fig. 5/21) with the

dowel pin (fig. 1/7) facing the exhaust end
and the ring collar facing downward.
2.6 Tighten the nuts (8) at a torque of

M = 50 Nm.
2.7 Loosen the nuts (8) again by one

revolution and then tighten at a torque of
M = 10 Nm.
en / 15.01.2014 IB028701 3/4

c2 Fuel Injector
A5.05. 07.07.01.00
M25
2.8 Push in the radial thrust piece (fig. 1/5). 07

2.9 Mount the transverse thrust piece (2), pay attention to the correct position of the cover (4)!
2.10 Tighten the screwed connection (Y) and the pressure screw (3) by hand (Without wrench !).
2.11 Tighten the pressure screw (3) and then the screwed connection (Y) at a torque of M = 10 Nm.
CAUTION
Apply the fork wrench at the surfaces “Z“ and keep the transverse thrust piece (2) in
position during tightening of the screwed connection (Y) and the pressure screw (3).
Beim folgenden Anziehen der Verschraubung (Y) und der Druckschraube (3) Gabel-
schlüssel an den vorgesehenen Flächen “Z“ ansetzen und Querdruckstück (2) in
Position halten.
2.12 Tighten the screwed connection (Y) at a torque of M = 150 ± 5 Nm.
2.13 Tighten the pressure screw at a torque of M = 130 ± 5 Nm.
2.14 Push the sleeve (1) into the injection pump until it reaches the locking position.
2.15 Tighten the nuts (8) again at a torque of M = 50 Nm.
2.16 Mount the cylinder head cover and check the lubricating and fuel circulation for leaks.
en / 15.01.2014 IB028701 4/4

Injection valve A5.05. 07.08.01.00
Maintenance / Adjustment
M25
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 G

Adapter/nozzle holder for nozzle tester W2 259208 B
Pressure pipe W3 1.9470 C
Socket wrench for nozzle opening pressure W4 *
* not illustrated
DANGER
When checking the injection pressure: Danger! Keep your hands off the fuel jet!
NOTE
Carbon trumpets at the nozzle are mostly caused by insufficient cooling. Corrosive
attack and erosion, however, are the consequence if the nozzle temperature is too
low and/or the charge air temperature is too low or water is in the charge air.
A perfect functioning of the injection nozzles can only be assessed by the behavior of
the exhaust gas temperatures/smoke behavior.
The injection valve should only be checked if there is a significant deviation of the ex-
haust gas temperature from the average value.
A bad injection in the test device in the case of heavy fuel nozzles is often caused by
insufficient flushing of the injection valve with diesel oil before the test. The injection
nozzle should be carefully cleaned again before replacing it.
A drop in the opening pressure of up to 20 bar is normal after a short period of opera-
tion (settling phenomena of the nozzle spring and needle).
en / 19.12.2012 IB003251 1/2

Injection valve A5.05. 07.08.01.00
M25
2
1. Use a hard brush (not a wire brush) to re-
1
move carbon residue from the nozzle.
2. Check the nozzle holes for sharp edges, W2

ovality, corrosion and damage.
3. Place the injection valve (Fig. 1/3) with the

adapter (W2) in the nozzle tester (W1).
4. Connect the pressure pipe (W3) and tigh- 3

ten it. W1
W3
5. Loosen the hexagon nut (1) and remove it
together with the screw plug (2).
6. Slowly increase the pressure by means of

a pump until the injection valve ejects.
Nozzle opening pressure: Refer to the
acceptance test certificate chapter
"Technical Engine Data".
1
NOTE
Repair (A5.05.07.09.91.nn)
the ejection valve if there is a
high volume of leakage fuel or
replace it
(A5.05.07.07.01.nn).
6.1 If there is a deviation in the injection pres-

sure, loosen the counter nut
(Fig. 2/10) and set the specified opening
pressure by means of the adjusting screw
(11).
6.2 Mount the counter nut (10) as well as the

screw plug (2) and tighten at the corre-
sponding torque (A5.05.07.09.01.nn).
6.3 Secure the screw plug (2) with the

hexagon nuts (1).
en / 19.12.2012 IB003251 2/2

c2 Injection valve
A5.05. 07.09.01.00
M25
7500
See also: 5.05.07.08.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace all injector elements every 7.500 h
Tools:

Adapter (3/4 to 1/2) W4 * 1.9459-035
Socket wrench insert W5 * 259222 D
* not illustrated
Auxiliary material:
Molykote Paste G Rapid plus **
NOTE
The injection valve should only be disassembled if the inspection
(A5.05.07.08.01.nn) reveals faults (e.g. leakage, insufficient ejection pressure, bad
ejection).
All parts of the injection system are manufactured with utmost precision in special
workshops. This is the only way ensure perfect operation. For this reason, it is not
possible for the operator to carry out repairs and the necessary maintenance work
should be restricted to the following
• cleaning
• checking the ejection pressure and tightness
• replacing wearing parts using original parts and replacement elements.
To keep repair costs low, any parts to be reconditioned should only be shipped
complete and the possibility of a mix-up should be excluded.
en / 15.01.2014 IB028685 1/3

c2 Injection valve
A5.05. 07.09.01.00
M25
7500
1. Disassembly:
1.1 Dismount the locking bolt (Fig. 1/1) with

joint ring (2).
1.2 Remove the counter nut (4) and relieve

the nozzle spring (6) by unscrewing the
adjusting screw (5).
1.3 Lock the nozzle holder (3) in position and

loosen the nozzle nut (10) with sokket
wrench insert (W5) by turning counter-
clockwise and remove it.
1.4 Take out the nozzle element (9) including

the nozzle needle (8) without damaging
the lapped surfaces!
Pay attention to the straight pins (Fig. 2/
20) for retaining the nozzle!
1.5 Dismount the adjusting screw (Fig. /5).
1.6 Remove the intermediate disk (11) with

nozzle spring (6) and thrust piece (7).
Pay attention to the straight pins for
retaining the intermediate disk!
1.7 Carry out a visual inspection of the nozzle

spring (6) and thrust piece (7).
1.8 Clean all parts with gas oil.
1.9 Carry out a visual check of all parts,

particularly the seat and sealing surfaces.
Replace defective parts.
1.10 Insert the nozzle needle (8) in the nozzle

element (9) using gas oil and check whe-
ther the nozzle needle falls onto the seat
due to its dead weight. Replace the nozzle
needle together with the nozzle element if
the needle sticks.
en / 15.01.2014 IB028685 2/3

c2 Injection valve
A5.05. 07.09.01.00
M25
7500
2. Reassembly 07
2.1 Dry all sealing surfaces with clean, fluff-free paper.
2.2 Apply ”Molykote Paste G Rapid plus” to the thread of the nozzle nut (10) and nozzle rest in the
nozzle nut.
2.3 Mount the intermediate disk (11).

Pay attention to the straight pins for retaining the intermediate disk!
2.4 Do not damage the lapped surfaces

(nozzle element, nozzle needle)!
Align the nozzle element (9) together with
the nozzle needle (8) with the straight pins
(Fig. 2/20), position and retain with the
nozzle nut.
2.5 Insert the nozzle spring (6) with the thrust

piece (Fig. 1/7) and screw in the adjusting
screw (5).
2.6 Lock the nozzle holder (3) in position and

tighten the nozzle nut (10) with the socket
wrench insert (W5) at a torque of
M = 750 - 800 Nm.
2.7 Adjust the injection valve according to

A5.05.07.08.01.nn.
2.8 Screw in the counter nut (4) and tighten at a torque of
M = 60 +/-10 Nm.
2.9 The joint ring (2) must be centered.
2.10 Mount the locking bolt (1) and tighten the locking bolt at a tor-
que of
M = 90 +30 Nm
CAUTION
The joint ring (2) must be checket visually once more for correct fitting. Otherwise, the
before-mentioned procedure is to be repeated with a new joint ring.
en / 15.01.2014 IB028685 3/3

Fuel Duplex Filter A5.05. 07.12.01.09
M25/M32
See also: 07
Spare parts list: B1.05.07.n.7667
Personnel requirement: 1 Pers. / 0,50 h

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Cleaning gun W1 1.9100-114

High-pressure cleaner W2 *
* no picture
Ancillary materials:
Vecom „Filterclean“ cleaning fluid **
NOTE
The cleaning and maintenance of the filter must be completed with the greatest of
care in order to prevent faults in the fuel injection system.
Never allow the filter to cool when full when operating with distillate fuel.
The filter cleaning interval is primarily dependent on the engine operating conditions,
the fuel quality and the quality of fuel separation, and is therefore different for each
engine system.
The filter must be inspected, and cleaned if necessary, 24 hours after starting up a
new system or after completing work on the fuel line system.
The sieve cartridges should not be cleaned with an ultrasonic cleaning device, as
improper handling during cleaning and cleaning the cartridges too long may lead to
damage to the sieve that cannot be seen with the naked eye.
en / 22.10.2013 IB023283 1/4

M25/M32
Procedure: 07
1. Switch-over procedure (see plate on filter
cover).
2. Cleaning
2.1 Clean the filter at operating temperature

when
50 % of the red field
of the differential pressure gauge

(Fig. 1/1) is visible or when the filter alarm
is triggered.
2.2 Cleaning the filter when normally

soiled.
CAUTION
Depressurize the filter chamber
before beginning work!
2.2.1 Remove the cover (2) from the isolated fil-

ter chamber. Open the sludge drain and
drain the soiled fluid.
2.2.2 Remove the filter insert.
2.2.3 Connect the cleaning gun (Fig. 2/W1) to

the compressed air line and pressurize.
(6 - max. 10 bar)
2.2.4 Slide the spray guard (13) onto the nozzle

of the cleaning gun completely, slide into
the cartridge opening and hold securely.
Depress the actuating trigger on the clean-
ing gun and slowly slide the nozzle to the
base of each sieve cartridge (14).
2.2.5 Replace the O-ring (5) if necessary. Install

the filter insert. Install a new gasket and
replace the cover.
2.2.6 Fill and bleed the filter chamber (see plate

on filter cover).
en / 22.10.2013 IB023283 2/4

M25/M32
2.3 Filter cleaning (every 3rd cleaning). 07

2.3.1 Open the sludge drain and drain the filter chamber.
2.3.2 Remove the filter insert.
2.3.3 Rinse the filter chamber with gas oil.
2.3.4 Place the filter insert into a container that has been filled with a suitable cleaning fluid. The fluid
level may be no higher that the lower edge of the sieve plate (15) in order to prevent dirty
fluid from entering the sieve cartridge (14) (clean side) from above. The upper area of the
sieve must be visible inside the sieve cartridge. See the regulations of the cleaning fluid
manufacturer for the required soaking time. The soaking time may not exceed 4 h in any case.
2.3.5 Remove the filter insert from the cleaning container and blow out the sieve cartridges (14) with
the cleaning gun (W1) (procedure 2.2.4).
Air pressure max. 10 bar.
2.3.6 Immerse the filter insert in clean cleaning fluid again, allow to drip off and blow out with cleaning
gun (W1). Place the filter insert onto a suitable surface with the open side down so that the clean-
ing fluid can drain out.
2.3.7 Check the sieve cartridge for damage.
2.3.8 Replace the O-ring (5) if necessary. Place the filter insert into the filter chamber and replace the
cover. Install a new gasket if necessary.
2.3.9 Fill and bleed the filter chamber (see plate on filter cover).
2.4 Cleaning the sieve cartridge with heavy soiling
NOTE
If the filter insert is heavily soiled (varnish, caking, tar deposits, threads, filings), re-
move the sieve cartridges and clean individually.
2.4.1 Soak the filter insert in cleaning fluid (max. 4 h).
2.4.2 Inspect the sieve cartridges and replace the sieve if damage or significant wrinkles are
found.
CAUTION
Damage to a single sieve cartridge impairs the function of the entire filter.
en / 22.10.2013 IB023283 3/4

M25/M32
2.4.3 Connect the cleaning gun (W1) to the compressed air line. 07
Air pressure max. 10 bar.
2.4.4 Depress the actuating trigger and slide the nozzle of the cleaning gun to the bottom of every
sieve cartridge.
2.4.5 Remove any caking or other soil with a soft brush.
NOTE
If a high-pressure cleaner is available, clean the sieve cartridge from the outside with
a fan nozzle. Operating pressure of high-pressure cleaner max. 60 bar. Cleaning
agent: warm water or water mixed with cleaning fluid.
CAUTION
When cleaning with the high-pressure cleaner (W2), do not hold the nozzle too
close to the sieve in order to avoid damaging the sieve or shifting strands in the
mesh.
2.4.6 Rinse the sieve cartridges in clean cleaning fluid, blow out and set on suitable surface with
opening down to dry.
2.4.7 Hold the sieve up against a bright light and check to see if clean. Repeat the procedure if the
sieve is not clean.
3. Replace the O-ring (5) if necessary. Install the filter insert in the filter chamber.
4. Replace the cover (with new gasket).
5. Fill and bleed the filter chamber (see plate on filter cover).
en / 22.10.2013 IB023283 4/4

Duplex Fuel Preliminary Filter A5.05. 07.12.02.04
M20-M601C
750
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Cleaning of the filter every 750 h
Auxiliary material:
Cleaner “Filterclean” of Vecom *
NOTE
Operation and maintenance of the filter have to be carried out with utmost care to
avoid troubles in the fuel system.
The cleaning intervals of the filter mostly depend on the engine operation conditions
and the fuel quality and therefore are different from unit to unit.
When starting up a new plant or after doing some work on the fuel piping, check the
filter after 24 hours and clean it if necessary
en / 15.10.2012 IB022114 1/2

Duplex Fuel Preliminary Filter A5.05. 07.12.02.04
M20-M601C
750
4
1. Cleaning
1.1 Change over to operable filter chamber.

3 5
1.2 Open the vent screw (1) of the filter cham- 6
ber which has been cut off in order to vent 8
the system.
1.3 Remove the drain plug (2) of the filter

chamber which has been cut off. 1
1.4 Dismantle the housing cap (3) of the filter

chamber which has been cut off.
1.5 Withdraw the screen basket (7) vertically

upwards.
7
1.6 Remove coarse dirt by shaking the screen
basket (7).
1.7 Put the screen basket (7) into a solvent. An

application time of 8 hours must not be ex-
ceeded.
2
1.8 After taking the screen basket (7) out of the
solvent carefully blow it out with compres-
sed air from outside to inside.
1.9 Remove tenacious dirt by means of a soft brush.
1.10 Insert the screen basket (7) into the filter chamber.
1.11 Check the O-ring (8) and replace it if necessary. Mount the housing cap (3).
1.12 Insert and tighten the drain plug (2).
1.13 To vent the filter chamber carefully set the operating lever (4) in such a way that the nose (5) of
the plug points towards the nearest screw of the plate (6).
1.14 When the fuel emerges without bubbles at the vent screw (1), close this screw.
1.15 Reset the operating lever (4).
en / 15.10.2012 IB022114 2/2

Fuel Feed Pump A5.05. 07.13.01.00
M25/M32
15000
See also: 07.13.02.nn 07

Spare parts list: B1.05.07.n.6487

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The fuel feed pump is to be dismounted

and checked for wear every 15,000 h
NOTE
According to information of the manufacturer, the replacement of worn out individual
parts can result in the performance given no longer being attained (see engine docu-
mentation, chapter "Technical Engine Data"). The complete fuel feed pump must
be replaced in the event of excessive performance loss!
1. Disassembly
1.1 Remove fuel feed pump with coupling halves (Fig. 1/1) and feather key (2) (A5.05.07.13.02.nn).
4 5 6 7 5
3 8
1 2
9
10 11 10
en / 26.11.2013 IB021578 1/2

Fuel Feed Pump A5.05. 07.13.01.00
M25/M32
15000
1.2 Remove locking ring (3). 07

1.3 Loosen hexagon cap screws (9), pull off end cover (8) and wheel housing (7).
1.4 Replace O-rings (10).
1.5 Pull out drive wheel shaft (6) and running wheel axle (11).
1.6 Check bearing bushes (5), drive wheel shaft (6) and running wheel axle (11) for wear, replace if
necessary. Follow instructions!
1.7 Replace rotary shaft seal (4).
2. Assembly
2.1 Mount fuel feed pump with new O-rings (10) and new rotary shaft seal (4).
2.2 Tighten hexagon cap screws (9) with a torque of
M = 14 Nm.
2.3 Insert feather key (2), shrink on coupling halves (1) and mount fuel feed pump,
(A5.05.07.13.02.nn).
en / 26.11.2013 IB021578 2/2

Fuel feed pump drive A5.05. 07.13.02.00
M25
15000
See also: 07
Spare parts list: B1.05.07.25648n

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The fuel feed pump is to be disassembled every 15,000 operating hours and the drive is to be
checked for wear.
Tools:

Adapter (3/4 to 1/2) W3 * 1.9459-035
* not illustrated
Auxiliary material:
"G-Rapid Plus" Molycote paste**
"Dirco Grau" (grey) silicon sealing compound**
1. Disassembly
1.1 Close the stop cocks and drain the fuel from the lines (ball valve next to the injection pump of the
1st cylinder on the coupling side).
1.2 Loosen the lines on the pump.
en / 25.01.2013 IB022132 1/4

M25
15000
1.3 Loosen the hexagon bolts (Fig.1/3) and pull the fuel feed pump (2) with the coupling half (8) out of 07
the drive housing (5).
13 6
1
Z
2 X
X u
8
3
4 12
5
6 10
7
9 11 2
w
1.4 Extract the coupling half (8) and remove the rubber element (4) and feather key (12).
1.5 Loosen the hexagon bolts (1) and extract the drive housing (5) together with the gear wheel (7)
from the pump carrier plate (13).
1.6 Dismantle the hexagon bolt (Fig.2/21) and washer (20).
Y
22
a
s
15
21
5
20
16
7 17
19 18 10
en / 25.01.2013 IB022132 2/4

M25
15000
1.7 Extract the gear wheel (Fig.2/7) from the drive shaft (10) by means of an extractor. 07
1.8 Check the tooth profiles for wear (pitting, canted running, breakage).
1.9 Extract the coupling half (Fig.1/9) and remove the feather key (11).
1.10 Loosen the hexagon bolts (Fig.2/18) and press the drive shaft (10) together with the cover (19) to-
wards the gear wheel side out of the drive housing (5).
1.11 Remove the shaft seal (15).
1.12 Check the bushes (16 and 17) and the drive shaft for wear. Press out worn bushes. Replace the
drive shaft if it has scores.
1.13 Check the thrust bearing between the housing (5) and cover (19) for wear.
2. Reassembly
2.1 If necessary, fit the drive housing (Fig.2/5) with new bushes (16 and 17) making sure that the butt
joint of each bush is in a horizontal position. Lubricate the bushes slightly before pressing them in.
Do not use Molycote! Press in bush (16) flush with the rear shoulder and bush (17) at a distance
of
s = 2 mm.
The oil bore (22) must not be sealed off!
2.2 Check the contact pattern between the gear wheel cone and drive shaft cone before mounting the
gear wheel (7). The contact pattern must be even and have a quota of > 80 %!
2.3 Clean, degrease and dry the gear wheel cone as well as the drive shaft cone.
2.4 Mount the gear wheel (Fig.1/7) on the drive shaft cone and measure and note the distance a
(Fig.2/Y).
2.5 Erect the fuel feed pump with the drive shaft cone facing upwards.
2.6 Mount the cover (19) and heat up the gear wheel (7) by approx. 30 °C - 40 °C above the
temperature of the drive shaft cone and place it on the drive shaft cone.
NOTE
Do not heat the gear wheel up in an oil bath or by means of a direct flame!
Do not apply any pressure to the gear wheel when placing it on the drive shaft cone!
The dead weight of the gear wheel ensures that the necessary slip-on distance is
attained!
2.7 Let the gear wheel cool down to room temperature and check the dimension a. It must be 0.14 -
0.18 mm (slip-on distance) smaller than in a cold condition. If necessary, dismantle the gear
wheel and repeat the assembly procedure.
en / 25.01.2013 IB022132 3/4

M25
15000
2.8 Apply "G-Rapid Plus" Molycote paste to the thread as well as the contact surface of the hexagon 07
bolt (21) and washer (20). Tighten the hexagon bolt at a torque of
M = 60 Nm.
2.9 Insert a new shaft seal (Fig.2/15).
2.10 Push the drive shaft (10) into the drive housing (5) and mount the cover (19) on the drive housing
(5). Press down the shaft seal (15).
2.11 Clamp the drive housing vertically and insert the feather key (Fig.1/11).
2.12 Heat up the coupling half (9) to 100 °C. Push it on to the journal of the drive shaft (10) and let it
cool off.
2.13 Clean the contact surface on the drive housing (5) and the pump carrier plate and apply "Dirco-
Grey" sealing compound.
2.14 Carefully place the drive housing together with the gear wheel in the pump carrier plate (the tooth
profiles of the drive gear wheels must glide into each other) and assemble.
2.15 Insert the feather key (12), heat up the coupling half (8) to 100 °C and push it on to the shaft jour-
nal of the fuel feed pump (2). The dimension "w" must be observed.
w = u - 18,5 = ~ 40 mm
Dimensions w and u: refer to Fig. 1/X.
2.16 Mount the fuel feed pump (2) together with the rubber element (4) and connect the fuel lines.
2.17 Remove the cover together with the seals and check the tooth clearance of the gear wheel (7) to
the pump drive gear wheel by means of a feeler gauge.
Desired value 0,20 - 0,45 mm
2.18 Check the seal and mount the cover.
2.19 Check the lubricating oil supply to the gear wheels.
2.20 Open the stop cocks, close the ball valve, fill the fuel system by means of the standby pump and
bleed the system.
en / 25.01.2013 IB022132 4/4

Fuel Distributor Manifold A5.05. 07.15.01.02
M25
See also: - 07

--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Molykote-paste “G-Rapid Plus” **
** or a produkt of equal standard
1. Disassembly
1.1 Remove the covering of the fuel distributors.
1.2 Close the shut-off cocks.
1.3 Open the ball cock; beside the fuel distributor of the 1st cylinder) and drain the fuel distributor line.
1.4 Disassemble the hexagon cap screws (11 and 12) .
1.5 Hold tied the fuel distributor line (1), move the flanges (6, 7) to the right side and pull the fuel dis-
tributor line .
2. Assembly
2.1 Check the choking tube (8) of the fuel distributor (2), it must be tied ice-bound with an upstand of
s = ca. 3 mm
2.2 Check the joint ring (5) and O-ring (3, 4), replace if necassery.
2.3 Coat thread and contact surfaces of the hexagon cap screws (11, 12) with Molykote.
2.4 Mount the fuel distributor line (1) with flanges (6, 7), joint ring (5) and O-ring (3, 4, both side ) of
the fuel distributors (2). Mount the flange (7) at the chocking tube. Mount the flange (6) at the flan-
ge (7).
en / 19.12.2012 IB024816 1/2

Fuel Distributor Manifold A5.05. 07.15.01.02
M25
2.5 Mount the hexagon cap screws (Fig. 1/11, 12) and tighten with a torque of 07
M = 20 + 5 Nm .
2.6 Open the shut-off cocks, close the ball cock, fill fuel system with the reserve pump and vent.
2.7 Mount the covering.
en / 19.12.2012 IB024816 2/2

Lubricating Oil System A5.05. 08.02.01.00
Maintenance / Oil change
M20-VM46DF
See also: A5.05.08.04.01.nn, A5.05.08.04.03.nn, A5.05.08.05.01.nn 08

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Clean and fill up the lubricating oil system
NOTE
The lubricating oil safety strainer on the suction side of the lubricating oil pumps has
to be checked and, if necessary, cleaned after 24 - 50 hours of operation after the
start-up of a new installation or carrying out work on the suction side of the lubricating
oil piping system.
The interval applicable to your plant is indicated in the engine documentation,

“Operating Media, Lubricating Oil Change”.
The lubricating oil change interval depends on the following factors:
• Operating hours
• Lubricating oil quality
• Operating conditions of the engine
• Lubricating oil consumption
• Lubricating oil treatment or separation
• Volume of lubricating oil in the circulation system
The change interval can be extended if the results of the lubricating oil analysis permit.
Permissible analysis values (see engine documentation, “Operating Media,
Lubricating Oil Change”).
en / 10.01.2014 IB028614 1/3

M20-VM46DF
1. Clean and fill up the lubricating oil system 08

1.1 Stop and secure the engine to prevent unintentional starting.

Common rail diesel engine and dual fuel engine

Gas engine:
- Set the key switch on the “Local Data Board“ to “OFF”.
- Remove the key.
1.2 Switch off the lubricating oil prelubrication pump or the standby pump (depending on equipment
status).
1.3 Pump the lubricating oil from the lubricating oil circulation system and the lubricating oil circulation
tank into a suitable tank.
NOTE
Depending on the equipment the lubricating oil present in the engine will be pumped
out by the suction pump on plant side.
NOTE
The lubricating oil circulation volume is 1.36 l/kW* engine power output and,
depending on the variant, is stored either in the lubricating oil circulation tank on plant
side, the deep oil pan or the base frame (generator operation).
*(see engine documentation, “Operating Media, Lubricating Oil Change“).
1.4 Check the lubricating oil circulation tank and the oil pan/base frame for cleanliness and,
if necessary, remove any impurities and debris.
1.5 Check the strainer in the suction pipe and, if necessary, clean it.
1.6 Clean the lubricating oil duplex filter (A5.05.08.04.01.nn).
1.7 Clean the lubricating oil automatic filter (see engine documentation, “External Documentation”).
1.8 Specifics for V-engines
1.8.1 Check the lubricating oil safety strainer (A5.05.08.04.03.nn).
en / 10.01.2014 IB028614 2/3

M20-VM46DF
08
NOTE
We recommend to also remove and clean the lubricating oil cooler within the scope of
lubricating oil system maintenance (see engine documentation ,”External Docu-
mentation“).
1.9 Fill up the lubricating oil system with new lubricating oil (see engine documentation, “Operating
Media, Lubricating Oil Quality“) according to the existing installation, up to the dipstick mark
(depending on equipment).

Common rail diesel engine and dual fuel engine

- Set the selector switch on the control stand to “Engine” or “Remote“.
Gas engine:
- Insert the key into the key switch on the “Local Data Board“.
1.11 Start the engine systems and lift the starting interlock.
1.12 Start the engine.
NOTE
Observe the lubricating oil pressure and, if necessary, check the lubricating oil
pressure limitation valve (A5.05.08.05.01.nn).
NOTE
Disposal notes:
Observe the MARPOL Convention for Prevention of Pollution and / or the country-
specific disposal regulations for handling waste oil.
As a basic rule, waste oil has to be stored until it can be disposed of in an
environmentally compatible manner.
en / 10.01.2014 IB028614 3/3

Lubricating oil pump A5.05. 08.03.02.01
M25
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Adapter (3/4 to 1/2) W3 * 1.9459-035
* not illustrated
Auxiliary material:

”Dirco 610.020” universal sealant
NOTE
If necessary, the lubricating oil pump must be removed from the engine and the gear-
wheels, gearwheel shaft and bushes must be checked for wear and replaced if neces-
sary.
1. Disassembly
1.1 Drain the lubricating oil system.
1.2 Remove the suction (Fig. 1/4) and pressure line (2).
1 2
3 X
9
10
s
5 4 1
6
X 8 7
1
en / 19.12.2012 IB020068 1/3

M25
1.3 Loosen the hexagon nuts (Fig. 1/5) and pull the lubricating oil pump (3) with the gearwheel (8) off 08
the pump support plate (7).
1.4 Remove the hexagon bolt (10) and washer (9).
1.5 Use an extractor to pull the gearwheel (8) off the drive wheel shaft (Fig. 2/14).
1.6 Check the tooth profiles for wear (pitting, slanted running, breakage).
1.7 Loosen the cheese head screws (18) and remove the cover (19) from the wheel casing (16).
1.8 Remove the wheel casing (16) with the drive wheel shaft (14), impeller shaft (15) and the rear
bushes (11).
1.9 Check the bearing areas of the drive wheel shaft and impeller shaft in all bushes (11) for wear and
replace the bushes with original Caterpillar spareparts if necessary.
NOTE
Cool new bushes to - 20 °C before fitting them.
2. Reassembly
2.1 Mount the lubricating oil pump in the reverse sequence. Check the O-rings (Fig. 2/17) and repla-
ce them if necessary.
2.2 Tighten the cheese head screw (18) at a torque of
M = 150 Nm
en / 19.12.2012 IB020068 2/3

M25
2.3 Before assembling the gearwheels, check the contact reflection between the gearwheel cone 08
(Fig. 1/8) and the drive wheel shaft cone (Fig. 2/14) by spotting.
The contact reflection must be even and the proportion must be > 80%!
2.4 Clean, degrease and dry the gearwheel cone and the drive wheel shaft cone.
2.5 Fit the gearwheel (Fig. 1/8) on the drive wheel shaft cone. Measure the distance s (Fig. 1/X) and
note it.
2.6 Set-up the lubricating oil pump with the drive wheel shaft cone facing upwards.
2.7 Heat up the gearwheel (8) by approx. 90 °C to 100 °C above the temperature of the drive wheel
shaft and put it on the drive wheel shaft cone.
NOTE
Do not heat up the gearwheel in an oil bath or directly over a flame!
Do not apply pressure to the gearwheel when fitting the gearwheel on the drive wheel
shaft cone! The dead weight of the gearwheel ensures that the required slip-on
distance is attained!
2.8 Let the gearwheel cool down to room temperature and check the spacing s. It must be
0.40- 0.44 mm (slip-on distance) smaller then in a cold condition. If necessary, remove the gear-
wheel and repeat assembly.
2.9 Apply Molycote paste to the thread and contact surfaces of the hexagon bolt (10) and washer (9).
2.10 Tighten the hexagon bolt (10) at a torque of
M = 60 Nm.
2.11 Clean the contact surface of the drive cover (Fig. 2/12) and the pump support plate (Fig. 1/7) and
then apply sealant.
2.12 Carefully insert the lubricating oil pump (3) with gearwheel (8) in the pump support plate (the teeth
of the drive gearwheels must glide into each other) and mount.
2.13 Check the backlash 0.20 mm - 0,45mm through the opening of cover.
2.14 Mount the suction line (4) and pressure line (2) with new seals (1).
2.15 Fill new lubricating oil (lubricating oil quality, see engine documentation, chapter "Opera-
ting Media" up to the respective level mark on the circulation tank.
2.16 Fill up the lubricating oil system and take the lube oil pre-lubricating pump into operation.
2.17 Vent the system and check for leakage.
2.18 Check the lubricating oil supply for the gearwheels.
en / 19.12.2012 IB020068 3/3

Oil pressure control valve A5.05. 08.05.01.01
M20-VM46DF
15000
See also: 08
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Disassembly of the oil pressure control valve

2. Assembly of the oil pressure control valve
3. Adjustment of the oil pressure control valve
NOTE
Disassembly of the pressure control valve during the repair interval is only necessary
if the necessary lubricating oil pressure can no longer be set by adjusting the initial
tension of the spring.
The lubricating oil pressure is only allowed to be adjusted at the nominal engine
speed and at the specified lubricating oil temperature, see engine documentation,
chapter "Technical Engine Data".
The O-ring item 2 is not included in all versions!
1. Disassembly of the oil pressure control valve
CAUTION
Pay attention to the tension of the pressure spring (3) on the control valve (1)!
1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).
1.2 Remove and dismantle the control valve (1).
CAUTION
Pay attention to the tension of the pressure spring (13) on the screwed connection
(17)!
1.3 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter-clock-
wise and remove it together with the ball (16).
1.4 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).
en / 25.10.2013 IB022593 1/3

M20-VM46DF
15000
1.5 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring 08
(13).
1.6 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25),
washers (27), pressure spring (28) and ball (29).
en / 25.10.2013 IB022593 2/3

M20-VM46DF
15000
1.7 Clean all parts with gas oil and check them. 08
1.8 Check the free passage of the control oil bore (12) in the pressure control valve and in the set
screw (5) and remove any deposits.
1.9 Check the valve seats, balls, piston seating as well as the slide faces and grind them if
necessary.
2. Reassembly of the oil pressure control valve
2.1 Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.

Pay attention to the free movement of the pistons (4 and 11)!
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment of the oil pressure control valve
3.1 Pressure to be set, see engine documentation, chapter "Technical Engine Data".
3.2 Loosen the hexagon nut (18).
3.3 Regulate the pressure by turning the spindle (19).
Counter-clockwise:Oil pressure drops

Clockwise:Oil pressure increases
3.4 Secure the setting with the hexagon nut (18).
en / 25.10.2013 IB022593 3/3

Prelubricating pump/Prelubrication A5.05. 08.10.00.00
Maintenance / Checking
M20/M25/M32/M43
150
See also: 08
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Prelubrication and turning approximately every 150 h
NOTE
When multi-engine systems run on rigid bearings, the bearings might be damaged by
vibration when individual engines are shut down for more than 3 days.
Prelubrication alone is no guarantee that damage caused by vibration is prevented,

since the components which run on sliding bearings, are not able to float in the bea-
ring because of the prelubricating pressure. No or only a little quantity of oil is carried
to the endangered contact surfaces.
Damage caused by vibration during engine shut-down can only be avoided when the
engine is lubricated and turned simultaneously.
The following method is to be applied to avoid damage caused by engine shut-down,

without affecting the unattended operation of the system:
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
1.1 Start the stand-by pump
1.2 Turn the engine by means of the barring gear.
en / 13.12.2013 IB004168 1/1

Cooling Water Centrifugal Pump A5.05. 09.07.01.00
M25
15000
See also: 09
Spare parts list: B1.05.09.9.6437, B1.05.09.256440

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The cooling water centrifugal pump is to be disassembled every 15,000 operating hours and
checked for wear.
Auxillary material :
Molykote-Paste „G-Rapid Plus“ *

Universal Dichtung „Dirco 610.020“ * 7
Loctite 222 *
Loctite 270 *
Z
X
1. Disassembly
1.1 Drain cooling water; loosen connecting

pipeline from the reserve pump to the coo-
ling water distribution pipeline.
Inspection: 2 1
Thermometer muffs above the cooling wa-
ter pump.
1.2 Remove pipelines from the cooling water s Z

X
pump (Fig. 1/1).
1.3 Loosen hexagon cap screws (2) and pull

cooling water pump (1) with gearwheel (3) 3
out of the cylinder crankcase (7).
1.4 Remove O-ring (6).

4
1.5 Fix shaft (Fig. 2/23) in bore (u) with pin (10 6
mm).
5
1.6 Loosen hexagon cap screw (Fig. 1/4) and
remove with disk (5).
en / 19.03.2013 IB022154 1/13

M25
15000
1.7 Pull of gearwheel (Fig. 1/3) from shaft (Fig. 2/23) with extractor. 09
12
13 14
15
11
10 17 16 y
18
30
20
29
22 21
u
23
v w 24
28 27 26 25
1.8 Check tooth profile for wear (pitting, slanting run,splintering).
1.9 Loosen hexagon nuts (25), extract bearing housing (16) with seal plate (28) and running wheel
(11) from the spiral housing (12). Remove O-ring (27).
1.10 Loosen nut on running wheel (30) and remove with running wheel disk (29). Pull running wheel
(11) off shaft (23) with extractor.
1.11 Remove gasket set (10).
1.12 Loosen hexagon nuts (14) and remove sealing plate (28) from bearing housing (16) and pull off
centrifugal disk (15).
1.13 Loosen screws (21), disassemble end cover (18) and thrust washer (20).
1.14 Force shaft (23) out of bearing housing (16) with suitable tool, remove oil seal (24). entfernen.
en / 19.03.2013 IB022154 2/13

M25
15000
2. Inspection 09
2.1 Visual inspection of running wheel (Fig. 2/11), replace if there are signs of severe
cavitation.
2.2 Inspect front and rear bearing (17 and 22) as well as shaft for wear and corrosion, replace if
necessary.
2.3 Inspect all parts and the outlet openings (v, w), clean if necessary.
3. Assembly
3.1 Assembling is effected in the reverse sequence, taking notice of the following points:
3.2 Replace oil seal (24), gasket set (10) and O-ring (27). Mount centrifugal disk (15).
3.3 Apply a ring of silicone sealing compound around the oil bore (y) of the bearing housing, mount
the thrust disk (20) and end plate (18).
3.4 Insert screws (21) with screw lock "Loctite 270" and tighten.
3.5 Before mounting the running wheel (11), inspect contact reflection between running wheel cone
and shaft cone through spot grinding.
The contact reflection must be even and the contact reflection quota must be > 80 % !
3.6 Before mounting the gearwheel (Fig. 1 /3), inspect contact reflection between gear wheel cone
and shaft cone through spot grinding.
The contact reflection must be even and the contact reflection quota must be > 80 %!
3.7 Clean and dry running wheel, gearwheel and shaft cones after having removed grease.
3.8 Mount running wheel (Fig. 2/11) and running wheel disk (29), coat thread of the running wheel nut
(30) and the shaft (23) with screw lock.
3.9 Fix shaft with pin and tighten running wheel nut with a torque of
M = 60 Nm
and finally turn through an angle of 170°.
en / 19.03.2013 IB022154 3/13

M25
15000
3.10 Mount gearwheel (Fig. 1/3) on drive gearwheel shaft cone, measure distance “s“ ( X )and 09
note.
3.11 Place the cooling water pump with gearwheel shaft cone on top.
3.12 Heat up gearwheel to approx. 90 °C to 100 °C above the temperature of the shaft and mount
firmly to the limit on the shaft cone
NOTE
Do not heat up the gearwheel in oil-bath or with direkt flame !
Mount the drive gearwheel shaft cone without pressure at the gearwheel ! The weight
of the gearwheel makes shure, that the gearwheel will be mount correct!
3.13 Cool down the gearwheel to room temperature and check distance measurement“s“( X ), it must
be 0.40- 0.44 mm smaller than in the cold condition. If neccaessary dismount and mount the ge-
arwheel ones more.
3.14 Coat the thread and contact surface of the hexagon cap screw (4) and disk (5) with Molykote
paste "G-Rapid Plus" and tighten with a torque of
M = 60 Nm.
3.15 Replace O-ring (6), carefully insert cooling water pump with gearwheel (3) into cylinder crankcase
(tooth profiles of the drive gearwheels must slide into each other) and assemble.
3.16 Check the backlash 0.20 mm - 0,45mm through the opening of cover.
3.17 Mount pipelines and connecting lines of the reserve pump to the cooling water distribution line, fill
up cooling water system and vent.
3.18 Check lubricating oil supply of gearwheels, also check for leakage.
en / 19.03.2013 IB022154 4/13

TEREX POWERTRAIN
A Terex Company
INSTRUCTIONS
FOR THE INSTALLATION,
OPERATION & MAINTENANCE OF
80C65T/226TSC
ENGINE COOLING WATER PUMP
TEREX POWERTRAIN LTD., CATTO DRIVE, PETERHEAD, ABERDEENSHIRE, AB42 1RL, UNITED
KINGDOM
TELEPHONE +44(0) 1779 473 161 FAX +44 (0) 1779 477 424
EMAIL: sales@terexpowertrain.co.uk
DISMANTLING INSTRUCTIONS
General
Before dismantling any portion of the pump or carrying out any maintenance work,
ensure that the power unit is immobilised.
Examine the appropriate sectional arrangement drawing prior to starting.
For Anti-clockwise rotation, 80C65T/226TSC-C, use 3P17154

For Clockwise rotation, 80C65T/226TSC-D, use 3P17156
During dismantling, keep all bearings free from dirt and moisture and, when re-
assembling, replace any worn or damaged parts, particularly the shaft seal and
gaskets.
Tighten all nuts and bolts evenly to the torque specified below:
Nut torque settings
M6 M8 M10 M12 M16
Kgfm. 0.46 1.12 2.23 3.89 9.65
Nm. 4.54 11.0 22.0 38.0 95.0
Lbf ft. 3.35 8.14 16.13 28.0 70.0
Dismantling
Drain off all liquid from the pump and disconnect and remove the suction and
disconnect the discharge pipework.
If it is only required to replace the seal assembly the pump can be left on the power
unit.
Remove the volute and volute o-ring.
To gain access to the shaft seal, loosen and remove the impeller nut and washer,
The thread of the impeller nut is left hand for the –C pump and right hand for the –D
pump.
Using a suitable extractor plate, draw the impeller off the shaft – NB, the impeller has
3 x M10 tapped holes on 80mm P.C.D which can be used for this purpose.
The shaft seal is now accessible.

Remove the rotating seal assembly from the shaft and examine the faces.
The stationary half of the seal assembly can be removed form the seal plate
Remove the sealplate form the bearing housing and flinger from the shaft.
If it is necessary to inspect or replace the bearings or oil seal, disconnect the

lubrication pipes and detach the pump from the power unit by unbolting the mounting
flange and pulling the pump forward.
Remove the drive gear from the shaft assembly.

Remove the four socket set screws and the bearing end cap, then pull the shaft
assembly out carefully.
Note: The four socket setscrews are secured with loctite and will require higher than
usual breakout torque.
Inspect running faces of the shaft assembly. If one is scored, pitted or grooved, the
complete shaft assembly must be replaced.
Inspect the bearings and replace if necessary.
To remove the front bearing, remove the oil seal from the bearing housing.
This will reveal the bearing which can then be tapped out of the bearing housing.
Assembly
Drive in the front bearing and rear bearing.
Note:
1. Ensure that the bearings and bearing housing are free from dirt and moisture.
2. Maintain concentricity when driving bearing into bore.
3. The oil hole in the bearings are to be in line with the hole in the bearing housing.
4. Do not damage the working surfaces of the bearings.
5. Use a pipe or bar of the appropriate size to drive in the front bearing.
Carefully slide the shaft into the bearing housing and replace the end cap. Use loctite
242 to secure the socket screws when fitting the bearing cap and loctite flange sealnt
around the lubrication hole.
Fit the drive gear.

Press the oil seal into the bearing housing with the lip facing the bearing and taking
care not to damage the lip on the shaft.
Fit the sealplate on the bearing housing and re-fit the seal (refer to shaft seal
instruction sheet attached).
Clean the impeller bore and shaft taper and carefully fit the impeller onto the shaft.
Re-fit the washer and tighten impeller nut to 60Nm and tighten a further 170degrees
Fit o-ring around sealplate diameter.
Bolt volute to bearing housing.
Re-fit pump to engine and re-connect the suction and discharge pipework.
Fill the pump and pipework with the liquid to be pumped and inspect for any leaks.
GENERAL INSTALLATION RECOMMENDATIONS FOR STRAIGHT
CENTRIFUGAL PUMPS
Pipework
Independent supports must be provided for all pipework, the weight must not be
carried by the pump. Provision must be made for expansion and contraction when
pumping hot liquids.
The pipework system must have facilty for isolating, dismantling or removal of the
pump.
Pump Mounting
Before fitting the pump to the engine the drive gear should be securely fitted. If oil
lubrication is necessary the relevant pump bearing housing plugs should be removed
to allow lubrication pipes to be fitted. Before final fitting consult engine
manufacturers instructions.
Operation and Maintenance
Rotation
Check pump is running in the correct rotation as indicated on arrowed plate.
Priming
Before a straight centrifugal pump will operate, the suction line and impeller eye need
to be filled with liquid. This is also necessary to ascertain that pump internals are
lubricated by the liquid.
1. If a non-return valve or gate valve are fitted on the discharge side, air may
be exhausted from the suction line by hand or by mechanical means. During
this operation the gate valve should be kept closed, then liquid will fill the
pump under atmospheric pressure.
2. When the pump is operating under flooded suction conditions a gate valve
Should be fitted in the suction line and when the valve is opened liquid will be
forced by atmospheric pressure into the pump. The air must be able to escape
through the discharge line; alternatively an air vent should be provided in the
pump casing.
Gaskets
Replace pump and pipe gaskets if worn or ensure that they are of the correct thickness
and of a suitable material for the liquid being pumped.
Continued /…..
By-Pass Connection
When the pump is required to work against a closed discharge for a length of time, a
small amount of liquid should be recirculated from the pump to the source of supply.
This will eliminate any rise in temperature of the liquid within the pump. The amount
required increases with pump size and speed.
Bearings
Lubrication is provided by a supply of oil from the engine and requires no attention.
Note: Plugs are fitted to the bearing housing oilways to prevent the ingress of dirt
during transit and storage. Ensure that these are removed before the pump is fitted to
the engine.
Storage Of Pump
Store in a dry, well ventilated room.
All pump units should have the shaft rotated at regular intervals to keep the lubricant
distributed and prevent any build-up of rust.
Drain off all liquid.
Shaft Seal
When the shaft seal becomes worn, it is recommended that a complete new seal
assembly is fitted.
FAULT LOCATION
PUMP WILL NOT DISCHARGE Air leak in suction connection
AFTER STARTING Check for tightness
See that washer or gasket is in place
Replace if necessary.
Pump not primed
Hole in suction pipe – Replace pipe.
Air cannot escape on discharge side.
Leaking shaft seal.
Suction lift too high.
Wrong direction of rotation.
PUMP DISCHARGES THEN

CAPACITY DROPS
Debris in suction pipe.
Air leaking through shaft seal – see seal

instruction sheet, Appendix 1.
PUMP DELIVERY NOT MAX.

AMOUNT
Discharge head too high.
Faulty gaskets.
Worn impeller and wear rings.
Wrong direction of rotation.

PUMP OVERLOADING ENGINE Misalignment.
Capacity too high due to head being

lower than rated.
Specific gravity of liquid too high and /

or liquid viscosity too high.
Speed too high.
Clogged impeller.
Loose impeller nut resulting in impeller

binding on casing.
Seized shaft seal.
NOISY OPERATION System head too low.
OWNERS RECORD
Obtain the following information from the pump nameplate as a ready reference to
your pump set.
Pump Model:……………………………………………………………………………
Pump Serial No.:………………………………………………………………………..
Date Purchased:…………………………………………………………………………
When ordering pump spares, always state the part name and number, the pump
model and the pump serial number.
SELF LUBRICATING SHAFT SEAL INSTRUCTION SHEET
SHAFT DIA. / mm PART NO.

35 3P9340
INSTALLATION INSTRUCTIONS
1. When replacing the seal always replace complete assembly.

2. Thoroughly clean the shaft surface and all the surfaces of the seal cavity.
3. With the stationary seat (B) fitted into the rubber seat cup (C) lubricate the outer
diameter of the cup and push the seat assembly into the seal cavity.
4. Lubricate the shaft and the inside diameter of the rubber friction ring of the
rotating seal assembly, using the liquid to be pumped. Put the rotating assembly
(A) onto the shaft with the carbon face towards the stationary seat (B). Slide the
assembly along the shaft until the sealing faces meet.
5. Replace the impeller, impeller washer and impeller nut.
c2 Stop Piston
Inspection / Checking
A5.05. 10.03.01.00
M20-VM46DF
750
See also: A5.05.07.03.01.nn, C5.05.05.10.50.nn, C5.05.05.45.23.nn 10

Spare parts list:

-------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the emergency function of the stop piston
NOTE
The functional check may only be
completed when the engine is stopped
for other maintenance or repair work!
1. Check the emergency function of the stop piston
2. Actuate emergency stop.
3. Check the position of the control rods.
NOTE
The control rods must be in the "Zero
Filling“ position.
4. Check the stop piston (3) in the injection

pump, press the control rod (2) into the in-
jection pump by applying pressure to the
jointed lever (1) on the control rod.
NOTE
Check all injection pumps.
If individual or one control rod can be forced into the injection pump against the pres-
sure of the stop piston, check the stop piston in the respective injection pump and
overhaul if necessary (A5.05.07.03.01.nn).
If all control rods can be pushed into the injection pump, check the control air lines for
leaks or damage.
5. Actuate the "Reset“ button on the safety system.
en / 25.10.2013 IB020372 1/3

c2 Stop Piston
A5.05. 10.03.01.00
M20-VM46DF
750
10
NOTE
The stop piston is reset and the emergency stop system depressurized.
NOTE
This document only describes the pneumatic and mechanical release of an engine
stop.
In connection with this inspection work all of the emergency stop equipment on the
engine is to be checked for proper function, see "engine documentation, chapter
"Control and Monitoring" C5.05.05.10.50.nn.
6. (Fig. 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit, see
"engine documentation, chapter "Control/Regulation" C5.05.05.45.23.nn.
7. Loosen headless screw (T7). By turning cap (T8) adjust the working pressure on the pressure
regulating valve to 6 bar. If the shutdown air pressure is decreased below the switching value of
6 bar an alarm “Low shutdown pressure” will be released.
8. At an air receiver pressure of 30 bar adjust the working pressure on the pressure regulating valve
to 7.5 bar by turning cap (T8) and tighten headless screw (T7).
T7 T8
10
T3
en / 25.10.2013 IB020372 2/3

c2 Stop Piston
A5.05. 10.03.01.00
M20-VM46DF
750
9. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control 10
stand.
en / 25.10.2013 IB020372 3/3

Condensate Trap A5.05. 10.51.00.00
Repair / Disassembly and reassembly
M20/M25/M32/M43
See also: 10
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Construction of the condensate trap

2. Check of the condensate trap
3. Maintenance of the condensate trap
4. Care of the condensate trap
5. Start-up of the condensate trap
CAUTION
Hazard to persons due to leaking operating medium, high pressure and high tempe-
ratures. Failure to comply with these warnings may lead to accidents.
Avoid any unsafe working methods.
Condensate trap weight approx. 13 kg
ATTENTION
Any improper use, intervention in the design and deviation from the design data auto-
matically lead to termination of the warranty. The float-controlled condensate trap is
designed for the discharge of condensate from steam, compressed air and pressure
gas systems. Any other use is not permissible. The manufacturer is not liable for
damage resulting from any other use. The user or operator bears the risk in this case.
This also applies to incorrect assembly, use and maintenance.
NOTE
Due to its gravity, the condensate flows down to the deepest point, i.e. into the
condensate trap housing. A rising condensate level lifts the float and through the float
fork / rotary valve connection the flow cross-section is opened. When the condensate
level drops, the control closes.
en / 22.10.2013 IB028459 1/4

M20/M25/M32/M43
1. Construction of the condensate trap 10
Additional equipment
Water level indicator (RWG)
Additional equipment
1 Housing cover 9 Float with fork
2 Housing gasket 10 Seal for G 1/4

3 Housing with connections 11 Seal for G 1/2
4 Check valve G 1/4 for type WO-1210 12 Sight glass
5 Set of studs with nuts 13 Set of studs with nuts

6 Screw plug G 1/2 14 RWG cover
7 Float control, complete 15 2 RWG seals
8 Supporting structure with rotary slide valve, 16 RWG frame

complete
2. Check of the condensate trap
2.1 Malfunctions arise as condensate backup in the condensate system.

Condensate backup can be identified by means of the check valve (4):
2.2 Loosen the check valve (4) by only a quarter turn while ensuring that no condensate escapes. If
condensate escapes, it has to be assumed that the float (9) is jammed. In this case the following
maintenance has to be carried out.
en / 22.10.2013 IB028459 2/4

M20/M25/M32/M43
3. Maintenance of the condensate trap 10
CAUTION
The condensate trap must be depressurized!
3.1 The condensate trap must be depressurized. Close the shut-off valve before and (if provided)
after the condensate trap.
3.2 Release any residual pressure in the housing by loosening (4) by only a quarter turn.
3.3 By removing the screw plug (6) drain condensate from the condensate trap.
3.4 Loosen flange connections and carefully lift the condensate trap out of the pipeline.
3.5 By turning and jerky shaking of the trap the float can most often be made movable again. If this
procedure should be successful, a clear
click can be heard.
3.6 If no click is heard, the trap must be opened:
3.7 Loosen hexagon nuts (5) evenly crosswise. Remove cover (1).
3.8 Carefully clean the trap housing so as to make the float movable again.
3.9 Check the housing gasket (2) and replace it if required.
3.10 Put in place the housing cover (1).
3.11 Tighten the housing screws (5) evenly crosswise with a torque of 60 Nm.
3.12 Tighten the screw plug (6) with a torque of 173 Nm.
3.13 Tighten the check valve (4) with a torque of 50 Nm.
4. Care of the condensate trap
4.1 In the case of a great risk of dirt accumulation, the housing should be rinsed thoroughly from
time to time in depressurized condition. If necessary, the float control (7) should also be
checked. Dirt that has collected in the housing can be removed after taking off the screw plug
(6).The float control (7) usually does not require special care.
en / 22.10.2013 IB028459 3/4

M20/M25/M32/M43
5. Start-up of the condensate trap 10
ATTENTION
The pressure build-up and heating-up of the housing should not take place abruptly.
NOTE
The pressure build-up and heating-up of the housing should not take place abruptly.
In case of bigger damage and for ordering spare parts please contact your authorized
Caterpillar workshop.
en / 22.10.2013 IB028459 4/4

c1 Pressure Switches
A5.05. 11.01.03.00
M20/M25/M32/M43/M46DF
3750
See also: 11
Spare parts list:
Personnel qualification: E-specialist

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Connect the hand pump and the multimeter or the test lamp
2. Check the adjustment value
3. Correct the adjustment (design without scale)
4. Correct the adjustment (design with scale)
5. Dismount the hand pump and measuring devices
Engine type Tools and auxiliary materials Pos. Ord. No.
M 20 C, M 25 C, Hand pump with micrometer pressure gauge *

M 32 C, VM 32 C,
M43 C, VM 43 C, Multimeter (test lamp) *
M 46 DF, VM46 DF
* no picture
NOTE
The test and adjusting instructions below apply to the following types:
• Pressure range 0.2 - 2.5 bar, mech. switching differential: 0.15 bar
• Pressure range 0 - 4 bar, mech. switching differential: 0.2 bar
• Pressure range 0.9 - 1.5 bar, mech. switching differential: 0.08 bar
•Pressure range 2 - 25 bar, mech. switching differential: 1.5 bar
en / 15.01.2014 IB028836 1/4

A5.05. 11.01.03.00
M20/M25/M32/M43/M46DF
3750
1. Connection of the hand pump and the multimeter or test lamp 11

1.1 Set cock (Fig. 1/1) of the high-pressure line to test position (downwards).
1.2 Remove blind plug (Fig. 1/2) (G1/8”) (to depressurize the line, in case of liquid medium collect
with a rag) and connect the hand pump to the test connection.
1.3 Connect the multimeter for the continuity test.
NOTE
Connection of test lamp (Fig.2): Connect terminals 1, 2, 3 in the connector plug.
en / 15.01.2014 IB028836 2/4

A5.05. 11.01.03.00
M20/M25/M32/M43/M46DF
3750
2. Check the adjustment value 11

2.1 Pressurize the pressure switch with the hand pump.
2.2 Check the switching point via the micrometer pressure gauge of the hand pump and multimeter or
test lamps.
NOTE
In case of a deviation from the adjusted value (see engine documentation,
“Control and Monitoring” List of Measuring Points) correct in accordance with
sequence of operations 3 or 4. Adjust the pressure switch when pressure is
dropping.
2.3 Slowly depressurize the pressure switch. In doing so, observe the switching point on the
micrometer pressure gauge of the hand pump and the multimeter or the test lamp. Check of the
displayed switching differential (see engine documentation, “Control and Monitoring”, List of
Measuring Points).
NOTE
In case of a deviation from the adjusted value (see engine documentation,
“Control and Monitoring” List of Measuring Points) correct in accordance with
sequence of operations 3 or 4. Adjust the pressure switch when pressure is
dropping.
3. Correct the adjustment (design without scale)
3.1 Remove the led seal.
3.2 Loosen the casing cover (Fig.3/20) of the pressure switch.
3.3 Adjust the switching point to the value specified in the List of Measuring Points by means of a
hexagon wrench (W5).
en / 15.01.2014 IB028836 3/4

A5.05. 11.01.03.00
M20/M25/M32/M43/M46DF
3750
4. Correct the adjustment (design with 11

scale) (version with fixed switching
differential) (Fig. 4)
NOTE
The scale is calibrated to the
switching point (1 - 2 on) at de-
creasing pressure. Scale
accuracy is ± 2% of the range.
A pressure gauge check is not
necessary.
4.1 Remove the casing cover by loosening the

four fixing screws.
4.2 Connect terminal (Fig. 4/1 + 4) with the

measuring device via a cable.
4.3 Loosen locking screw (A).
4.4 Swing the cover aside by loosening fixing

screw (B).
4.5 Adjust the upper or lower switching point
(differential pressure switch) with range
spindle (C).
The lower or upper switching point

(differential pressure switch) results from
the fixed switching differential.
4.6 Tighten locking screw (A).
4.7 Dismount the hand pump and measuring

devices
4.8 Loosen the cable connections and loosen

the pressure connection of the hand
pump.
4.9 Close test connection with blind plug and

set cock (Fig. 1/1) to operating position.
4.10 Screw on casing cover and reseal.
en / 15.01.2014 IB028836 4/4

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01
M20-VM46DF
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly of lubricating oil/cooling water thermostat,
making a funcional check of thermostatic element
NOTE
The thermostatic elements (Fig. 1/5) are adjusted by the manufacturer to the requi-
red temperature. Modification of the adjustment or repair is impossible. Defective ele-
ments must be exchanged completely.
Controlling the thermostatic elements in case of failure is enabled by a manual con-

trol facility. Hereto slacken counter nut (3) and turn set screw (4) clockwisely in order
to get a lower temperature. After setting counter again.
The cooling line is fully opened and the bypass closed when the set screw (4) flushes
with the surface of the counternut (3).
This setting procedure may only be carried out if the thermostat fails.
With mounting a new thermostat, the set screw (4) must be set to its initial position by
the nut (3).
1. Disassembly
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew hexagon nuts (2) of housing co-

ver (6).
1.3 Remove cover (6) with O-ring (1).
1.4 Turn out thermostatic element (5)

from valve housing (7).
en / 13.12.2013 IB021750 1/2

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01
M20-VM46DF
7500
1.5 Wash parts in gas oil and blow them clean. 11

1.6 Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits.
2. Functional check of thermostatic element
2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K above the
temperature specified on the strap (XX) (specification in degree C).
2.2 The thermostatic element (5) must open steadiliy.
3. Assembly
3.1 Repalce O-rings (1 and 9) and gasket (8).
3.2 Assembly is done in reverse order of disassembly.
3.3 Top up lubricating oil/cooling water system and check thermostat for leakages.
en / 13.12.2013 IB021750 2/2

Pressure Switch A5.05. 11.06.05.02
M20/M25/M32/M43/M46DF
22500
See also: 11
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all pressure switches
Tools:
Metric standard tools.
Set of replacement parts:

Pressure switch M2103 (emergency stop - cooling water pressure)
Pressure switch M1106 (emergency stop - lubricating oil pressure)
Depending on the equipment status all other pressure switches are to be replaced as well.
WARNING
- Ensure that the engine cannot be started!
- When exchanging the pressure pipe or draining off the cooling water it is
possible that "hot" cooling water leaks out.
- There is a danger of scalding.
- Avoid skin contact with cooling water emulsions, observe the safety data
sheets of the manufacturers.
en / 13.12.2013 IB026248 1/3

M20/M25/M32/M43/M46DF
22500
Procedure: 11
1. Put the engine and the related safety systems out of operation.
- > Notify the engine to be ’’unserviceable’’ < -.
CAUTION
Prior to replacing the pressure switches the shut-off cocks of the media must
be closed.
Prior to installation the pressure switches are to be adjusted to the specified
pressure values.
2. Replacement of the pressure switches.
NOTE
The measuring point designations are always provided on the engine cable and the
engine.
2.1 Remove the old pressure switch.
2.2 Mount the new pressure switch. When

doing so, slightly grease the O-ring
(Fig. 1/1) at the foot of the new pressu-
re switch before inserting it.
2.3 Replacement of the plug.
3. Testing of the completed work:
3.1 Cooling water system

1
3.1.1 Start the engine and run up to nominal speed.
3.1.2 Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2).
The engine has to stop automatically latest after 20 seconds.
3.1.3 Put test valve (2) into "Operation" position again.
3.1.4 Lubricating oil system
3.1.5 Start the engine and run up to nominal speed.
3.1.6 Simulate "Low lubricating oil pressure" by means of test valve (2).
The engine has to stop automatically without any delay.
3.1.7 Put test valve (2) into "Operation" position again.
3.1.8 The other pressure switches are to be tested according to the same procedure.
en / 13.12.2013 IB026248 2/3

M20/M25/M32/M43/M46DF
22500
11
3.1.9 Put the engine and the safety system into normal operating condition again.
-> Notify the engine to be "ready for operation" <-.
en / 13.12.2013 IB026248 3/3

M20/M25/M32/M43/M46DF
See also: 11.06.05.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Pressure calibrating device W1*
Electric continuity tester (multimeter) W2*
* no picture
Procedure:
1. Mount new pressure switch, see A5.05.11.06.05.nn.
2. Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
2.1 Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to
the test connection. The adjustment value is to be inferred from the list of measuring points, see
"engine documentation, chapter "Control and Monitoring".
2.2 In pressureless state the pressure switch contacts (Fig. 1)

1 + 2 are closed and contacts 1 + 3 are open (ohmic flow).
2.3 When the pressure drops, the pressure switch should switch at the measuring point value, in this
state contacts 1 + 2 are open and contacts 1 + 3 are closed.
2.4 If a pressure switch is replaced, the switching value is to be inferred from the list of measuring
points.
(The measuring point number is indicated on the cable or the related nameplate.)
NOTE
If the pressure switch responds before or after the read limit, the switching point has
to be readjusted, see item 3.
en / 13.12.2013 IB025583 1/2

M20/M25/M32/M43/M46DF
3. Adjustment of switching point 11

3.1 Remove cover (Fig. 2/4).
3.2 By turning the hexagon socket screw

(5) the switching point can be adjusted
correspondingly.
4. Assembly:
4.1 Mount cover (4).
4.2 Remove pressure calibrating device (W1).
4.3 Clip on plug to the pressure switch.
4.4 Open shut-off valve (Fig. 3/6) of the

corresponding medium to the pressure pipe.
NOTE
Replacement of the complete
switch, see A5.05.11.06.05.nn.
en / 13.12.2013 IB025583 2/2

c2 Crankcase Monitoring
A5.05. 11.09.01.03
M20/M25/M32/M43/M46DF
1500, 750, 7500
See also: 11
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Check the underpressure in the measuring chamber
b) Clean the infrared filter and replace the sintered bronze filter
in the measuring attachment
c) Replace the sintered bronze filter in the pressure control
Tools:
Test equipment and spare parts.
Service box
NOTE
Maintenance and trouble shooting, refer, see "engine documentation, chapter "Ex-
ternal Documentation".
CAUTION
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
en / 04.11.2013 IB021758 1/1

Vibration Damper A5.05. 12.04.02.01
M32/VM32/GCM34
30000, 60000
See also: 12
Spare parts list: B1.05.02.nn2520
Personnel qualification: Cat/MaK-specialist

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/ exchange:
Vibration damper:
Maintenance after 30,000 h

Replacement after 60,000 h
NOTE
We have to point out that this maintenance sheet was prepared only for the purpose
of maintenance planning.
Please contact a Caterpillar workshop in time before reaching the 30,000 hours and
60,000 hours deadline.
en / 11.12.2013 IB024263 1/1

c2 Vibration Damper
A5.05. 12.04.03.00
M25
30000, 60000
See also: 12
Personnel qualification: Cat/MaK-specialist

--------------------------------------------------------------------------------------------------------------------------------
Maintenance / exchange:
Vibration damper:
Maintenance after 30,000 h

Replacement after 60,000 h
NOTE
We have to point out that this maintenance sheet was prepared only for the purpose
of maintenance planning.
Please contact a Caterpillar workshop in time before reaching the 30,000 hours and
60,000 hours deadline.
en / 01.10.2013 IB028315 1/1

Turning Device A5.05. 12.08.01.01
M25
30000, 750, 3750
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil level check every 3.750 h
Lubricating / greasing of shaft and gearwheel every 750 h
Oil change every 30.000 h
Auxiliary material:
Bearing grease „Klüber Altemp. QNB 50“ *
Gear oil „Shell Omala Oil 460“ *
*or a product of equal standard
1. Operating the turning device
WARNING
Protect engine against unintentional start-up!
Apart from these instructions, the operating- and maintenance instructions of the ma-
nufacturer of the turniing device have to be observed too !
1.1 Engaging the turning device
1.1.1 Move blockinglever (1) to position “V“ and hold.
1.1.2 Move lever (2) to position“ X“, so that the gearwheel of the turning device engages completely in
the flywheel toothing.
1.1.3 Let off blockinglever and make sure that the blockinglever engages in position “Z“.
CAUTION
When the turning device is engaged, the position switch (11) is automatically set to
position “engine OFF“ . The engine cannot be started during turning !
1.1.4 Turn the engine.
en / 31.10.2012 IB022181 1/3

M25
30000, 750, 3750
1.2 Disengaging the turning device 12

1.2.1 Move blockinglever (1) to position “V“ and hold.
1.2.2 Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged from the
flywheel toothing.
1.2.3 Let off blockinglever and make sure that the blockinglever is engaged in position “Z“.
CAUTION
The engine can only be started if the turning device is disengaged ! The position
switch (11) is then in position „engine-ON“)
en / 31.10.2012 IB022181 2/3

M25
30000, 750, 3750
2. Maintenance 12
2.1 Oil level check
NOTE
If a topping up should be necessary, only the prescribed gear oil is to be used !
2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ) up to the oil
level marke.
2.2 Lubricating / greasing of shaft and gearwheel
NOTE
Grease the notch on the output shaft and the gearwheel only if the turning device is
engaged.
2.2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of
the grease nipple (4).
CAUTION
Grease the gearwheel toothing only if the turning device is disengaged.
2.2.2 Coat toothing of gearwheel thinly with bearing grease.
2.3 Oil change
2.3.1 Remove screw plug (5) on the driving gear of the turning device.
2.3.2 Drain the oil from the driving gear of the turning device.
2.3.3 Mount the screw plug (5) with new gasket (6).
2.3.4 Remove screw plug (7)ont the driving gear of the turning device.
2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ca.7,5 l) up to the oil level mark (10).
2.3.6 Mount the screw plug (7) with new gasket (8).
en / 31.10.2012 IB022181 3/3

Round Nuts / Loosening and Fixing A5.05. 13.01.01.00
M25-VM46DF
See also: 13
Spare parts list:
Personnel qualification: skilled engine hand / Assistant engine hand
Operating medium:Every fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Preparatory work for loosening or fixing of round nuts

2. Loosening of round nuts
3. Fixing of round nuts
4. Troubleshooting
5. Appendix (tables)
DANGER
Risk of injury caused by hydraulic oil leaking under high pressure
For loosening and fixing of the round nuts the studs are stretched by means of
high hydraulic pressure.
If leaks occur due to misuse or improper handling, oil leaking under pressure may
cause severe injuries.
- It is absolutely required to wear personal protective equipment (especially safety
glasses).
- Do not place any parts of the body above the pressurized devices.
- Establish or loosen connections only in depressurized condition.
- In case of injuries immediately see a doctor!
CAUTION
Property damage due to misuse or improper handling.
The use of unsuitable or worn parts and inappropriate application may cause property
damage!
- High-pressure hoses and their protective jackets must not show any damage.
- Do not let any objects fall onto the high-pressure hoses and do not step on hoses
lying on the floor.
- Do not bend the high-pressure hoses sharply.
Observe the following minimum bending radii:
-- up to 2000 bar (29008 psi) at least 150 mm.
-- above 2000 bar (29008 psi) at least 250 mm.
- Replace high-pressure hoses latest after 6 years, even if they do not yet show
any damage.
- Do not subject the hose couplings to any bending stress.
en / 15.01.2014 IB028502 1/15

M25-VM46DF
13
NOTE
- For the tools needed for the individual jobs please refer to the relevant job cards.
- The illustrations on the following pages are principle representations only. They do
not pretend to accurately reproduce the concrete case of application.
- The components reproduced in this document are only intended to illustrate setup
and function and may differ in form and size.
1. Preparatory work for loosening or

fixing of round nuts
1.1 Put in place support ring

(Fig. 1/1) over the
round nut (Fig. 1/4).
1.2 Put the hydraulic jack

(Fig. 1/2) onto the
support ring.
1.3 Insert threaded sleeve

(Fig. 1/3) through hydraulic jack
and support ring.
en / 15.01.2014 IB028502 2/15

M25-VM46DF
13
1.4 Screw threaded sleeve (Fig. 2/3) finger 1
tight onto the stud by means of assembly 3
pins (Fig. 2/1) until it reaches end-stop
position.
1.5 Check the round nut holes for accessibility.

It must be easily possible to insert pin
(Fig. 3/2) through the slots in the support
ring (Fig. 3/1) into the holes of the round
nut.
If necessary, align support ring (Fig. 3/1)
accordingly.
2
1.6 Connect high-pressure pump (Fig. 4/1)

with high-pressure hose(s) to the hydraulic
jack(s). 2
1.7 When using several hydraulic jacks at the

same time an appropriate distributor 3 1
(Fig. 4/2) is to be used.
1.8 Open valve (Fig. 4/3) of the high-pressure

pump.
en / 15.01.2014 IB028502 3/15

M25-VM46DF
13
CAUTION
Leaks and stretching errors may occur
Before using a stretching device the basic position of the hydraulic jack must be
established. Steps 1.1 to 1.9.
If this basic position is not ensured, there is still oil from a previous application in the
pressure chamber of the cylinder. This will increase the prelift of the piston in
the hydraulic jack with each use, which will cause leaks and stretching errors.
If several hydraulic jacks are to be pressurized simultaneously, e.g. when
disassembling or assembling cylinder head studs, the jacks must be connected to
the high-pressure pump one after the other and set to basic position. Only after this
procedure the hydraulic jacks are to be connected among each other. Otherwise,
there is a risk of the excess oil not being pressed back into the high-pressure pump
but into another hydraulic jack.
NOTE
As the hydraulic connection of a hydraulic jack is provided with a non-return valve, the
oil can only be removed from the pressure chamber when the high-pressure hose is
connected and the valve on the high-pressure pump is open.
1.9 Put in place a suitable lever between

assembly pins (Fig. 5/1) and turn threaded
sleeve (Fig. 5/3) onto the stud until it
reaches end-stop position.
The ring surface of the threaded sleeve

must be flush with the bottom surface of
the hydraulic jack or slightly below bottom
surface level. 1
en / 15.01.2014 IB028502 4/15

M25-VM46DF
2. Loosening of round nuts 13

2.1 Turn back threaded sleeve (Fig. 6/3) by
the value indicated in Table A (see
Appendix) for the respective position or
adjust the distance by means of a feeler 3
gauge.
DANGER
Danger to life due to parts breaking off!
Due to improper handling and / or material failure pressurized components or parts of
components may break off, strongly accelerate and cause severe injuries or even
death!
- Do not bend over pressurized devices.
- During pressure build-up and 15 seconds thereafter a minimum safety distance of
3 m is to be maintained.
- The pressure indicated in Table B (see Appendix) "Stretching Pressure /
Prestretching Pressure" for the respective position must not be exceeded.
2.2 Close the valve on the high-pressure pump.
2.3 Actuate the high-pressure pump and for the time being build up a pressure of 50 - 100 bar
(725 psi - 1450 psi).
2.4 Check all connections of the high-pressure hoses on the hydraulic jacks, on the high-pressure
pump and, if applicable, on the distributor for complete locking.
2.5 After this check actuate the high-pressure pump again and build up the pressure indicated in
Table B (see Appendix) for the respective position.
All connected hydraulic jacks are pressurized simultaneously.
en / 15.01.2014 IB028502 5/15

M25-VM46DF
2.6 Only after at least 15 seconds loosen the 13

round nuts through the slot in the support
ring by means of pin (Fig. 7/1).
2.7 Loosen the round nut with the pin until the
pin cannot be inserted any more into the
holes of the round nut.
If, in doing so, the round nut reaches the
upper end-stop position, turn it back by 3 1
holes.
CAUTION
Stretching of the screw threads
If loosening of the round nuts is not possible under the specified pressure, the
pressure may be increased by max. 50 bar (725 psi).
If the pressure is increased further, there is a risk of overstretching the stud threads,
which would require the studs to be replaced.
2.8 Slowly open the valve on the high-pressure pump.
2.9 Wait until the pressure has fully dropped.
2.10 It must still be possible to turn the round nuts easily by means of the pin (Fig. 7/1). If necessary,
build up pressure again and turn the round nuts back by further holes, see steps 2.2 and 2.5 to
2.9.
CAUTION
Risk of injury caused by hydraulic oil leaking under high pressure
If connections of high-pressure hoses under pressure are loosened, hydraulic oil may
leak under high pressure. Oil leaking under pressure may cause severe injuries.
- It is absolutely required to wear personal protective equipment (especially safety
glasses).
- Observe the pressure gauge and wait until the pressure has fully dropped.
- Establish or loosen hydraulic connections only in depressurized condition.
CAUTION
Establish the basic position of the stretching device.
Before dismounting the hydraulic stretching devices and placing them into the storage
box the basic position of the stretching devices has to be established,
see steps 1.1 to 1.9.
en / 15.01.2014 IB028502 6/15

M25-VM46DF
13
CAUTION
Damage and malfunctions due to contamination
Contamination on connections of hydraulic components causes leaks. There may
occur problems when connecting or loosening the connections as well as
malfunctions in the hydraulic system.
Hydraulic connections are to be plugged upon disassembly of the components.
2.11 Loosen high-pressure hoses from

hydraulic jacks, high-pressure pump
and, if applicable, distributor.
2.12 Plug the connections of the high-

pressure hoses, hydraulic jacks, high-
pressure pump and, if applicable, the
distributor by means of caps (Fig. 8/
1).
2.13 Remove threaded sleeve, hydraulic

jacks, and support rings.
2.14 Clean all used components and place 1 1

them into the storage box.
en / 15.01.2014 IB028502 7/15

M25-VM46DF
3. Fixing of round nuts 13

3.1 Tighten round nuts (Fig. 9/1) finger tight
with pin (Fig. 9/2)before assembly of the
hydraulic stretching device.
1 2 Principle representation
DANGER
Danger to life due to parts breaking off!
Due to improper handling and / or material failure pressurized components or parts of
components may break off, strongly accelerate and cause severe injuries or even
death!
- Do not bend over pressurized devices.
- During pressure build-up and 15 seconds thereafter a minimum safety distance of
3 m is to be maintained.
- The pressure indicated in Table B (see Appendix) "Stretching Pressure /
Prestretching Pressure" for the respective position must not be exceeded.
3.2 Carry out steps 1.1 to 1.9.
3.3 Close the valve on the high-pressure pump.
3.4 Actuate the high-pressure pump and for the time being build up a pressure of 50 - 100 bar
(725 psi - 1450 psi).
3.5 Check all connections of the high-pressure hoses for complete locking.
3.6 Open the valve on the high-pressure pump and wait until pressure has fully dropped.
CAUTION
When fixing round nuts for crankshaft bearings and balance weights a prestretching
pressure has to be applied. For details please refer to the respective job cards.
en / 15.01.2014 IB028502 8/15

M25-VM46DF
13
CAUTION
Risk of tightening errors due to dropping pressure.
When building up the pressure, pause at intervals and observe the pressure gauge.
The pressure that is then reached must remain constant when the high-pressure
pump is not actuated. If the pressure drops, this will cause tightening errors.
If necessary, check the lockings of the connections of the high-pressure hoses and
the high-pressure pump.
3.7 Close the valve on the high-pressure pump and build up the stretching pressure indicated in
Table B (see Appendix) for the respective position.
3.8 After about 15 seconds (after pressure

build-up) firmly tighten the round nut
through the slot in the support ring with the
pin (Fig. 10/1) and, in doing so, make sure
there is ease of movement.
1
3.9 By slowly opening the valve on the high-
pressure pump decrease the pressure by
50 bar (725 psi).
Loosening of the round nut by means of
the pin must not be possible any more.
3.10 Slowly open the valve on the high-

pressure pump and wait until the pressure
has fully dropped.
CAUTION
Establish the basic position of the stretching device.
Before dismounting the hydraulic stretching devices and placing them into the storage
box the basic position of the stretching devices has to be established,
see steps 1.1 to 1.9.
CAUTION
Damage and malfunctions due to contamination
Contamination on connections of hydraulic components causes leaks due to
increased wear. There may occur problems when establishing and loosening
connections and malfunctions in the hydraulic system.
Hydraulic connections are to be plugged upon disassembly of the components.
en / 15.01.2014 IB028502 9/15

M25-VM46DF
3.11 Loosen high-pressure hoses from hydraulic jacks, high-pressure pump and, if applicable, 13
distributor.
3.12 Plug the connections of the high-pressure hoses, hydraulic jacks, high-pressure pump and, if
applicable, the distributor by means of caps (Fig. 8/1).
3.13 Disassemble the threaded sleeve of the stretching device.
3.14 Remove hydraulic jacks and support rings.
3.15 Clean all used components and place them into the storage box.
en / 15.01.2014 IB028502 10/15

M25-VM46DF
4. Troubleshooting 13
CAUTION
In case of locking errors (Fig. 11B, 11C) open the valve on the high-pressure pump
until pressure has fully dropped.
Loosen the corresponding hose couplings and connect them again.
Repeat the test (steps 1.2.2 to 1.2.4).
CAUTION
No pressure build-up in the hydraulic jacks
If the connections of the high-pressure hoses are not completely locked, there will be
no oil leaks but the internal valves in the hose connections will remain closed.
No pressure will be built up in the corresponding stretching device.
The stud will not be stretched.
The round nut cannot be loosened.
Fig. 11/A: Hose connection fully locked.
Fig. 11/B: Hose connection not fully locked.
Fig. 11/C: In case of continued pressure build-up the connection will partly slip off.
The internal valve will be closed.
A B C
en / 15.01.2014 IB028502 11/15

M25-VM46DF
4.1 For troubleshooting proceed according to the following table: 13
Fault Possible cause Action
Piston return mechanism Send the hydraulic jack to the

damaged. manufacturer.
After pressure decrease the
piston of the hydraulic jack There is still hydraulic oil in Mount the hydraulic stretching device
does not move back to end the pressure chamber of completely on a corresponding stud.
position / basic position. the hydraulic jack. Connect the device to the high-pressure
pump.
Establish basic position according to
step ...
Basic position according to step Piston in hydraulic jack Send the hydraulic jack to the
... cannot be established. tilted. manufacturer.
Connections of the high- Reduce pressure completely. Check the

pressure hoses are leaky. connections of the high-pressure hoses.
Built-up pressure is not In case of a leak:

maintained. Loosen and reconnect the connections.
If necessary, replace high-pressure
hoses.
Max. stroke was exceeded. Reduce pressure completely.

An overflow valve opens - The overflow valve is relieved.
and allows oil to drain from Clean the hydraulic jack.
Oil leaking from the hydraulic the pressure chamber. Build up a test pressure of 250 bar
jack. The hydraulic jack is not (3626 psi).
defective. - If no oil is leaking and the test pressure
is maintained for more than 5 minutes
the hydraulic jack is usable.
- If there is an oil leak again, the gaskets

are defective.
Hydraulic jack leaky. Gaskets defective. Replace the gaskets.
en / 15.01.2014 IB028502 12/15

M25-VM46DF
5. Appendix (tables) 13
Table A: Adjusting Values for Threaded Sleeve
NOTE
For loosening a round nut the threaded sleeve that was fastened finger tight has to
be turned back by a distance specific to the respective case of application. To avoid
inaccuracies this distance is mostly adjusted by means of a feeler gauge (Fig. 12/1)
between support ring and contact surface. In some cases of application, however,
experience has shown that it is more practical to turn back the threaded sleeve (Fig.
12/2) by a certain number of turns (see Table A).
This prevents jamming of the components of the hydraulic stretching device on the
stud after decreasing the stretching pressure.
Table A, M 25 C - GCM34
Engine type M 25 C M 32 C VM 32 C GCM34
Cylinder head 3.0 mm 3.5 mm 3.5 mm 3.5 mm

Lateral studs / crankshaft bearing ----- 1.5 mm 1/2 turn 1/2 turn
Crankshaft bearing bolts 2,0 mm 2.0 mm 1/2 turn 1/2 turn
Big-end bearing cap ----- 2.0 mm 3/4 turn 3/4 turn
Table A, M 43 C - VM46 DF
Engine type M 43 C VM 43 C M 46 DF VM 46 DF
Cylinder head 1 1/3 turn 1 1/3 turn 1 1/3 turn 1 1/3 turn
en / 15.01.2014 IB028502 13/15

M25-VM46DF
Table A, M 43 C - VM46 DF
13
1 1/4 turn or 1 1/4 turn or 1 1/4 turn or 1 1/4 turn or

Lateral studs / crankshaft bearing 10 holes 10 holes 10 holes 10 holes
back back back back
1 Umdr.- 1 Umdr.- 1 Umdr.- 1 Umdr.-
oder oder oder oder
Crankshaft bearing bolts
8 holes 8 holes 8 holes 8 holes
back back back back
1 1/4 turn or 1 1/4 turn or 1 1/4 turn or 1 1/4 turn or
Big-end bearing cap 10 holes 10 holes 10 holes 10 holes
back back back back
en / 15.01.2014 IB028502 14/15

M25-VM46DF
Table B: Stretching Pressure / Prestretching Pressure 13
CAUTION
When fixing round nuts for crankshaft bearings and balance weights a prestretching
pressure has to be applied. For details please refer to the respective job cards.
Table B, M 25 C - GCM34
GCM34 GCM34
Engine type M 25 C M 32 C VM 32 C
420 kW/Cyl. 500 kW/Cyl.
820 bar 850 bar 850 bar 712 bar 757 bar
Cylinder head
11893 psi 11893 psi 11893 psi 10327 psi 10327 psi
Prestret-
150 bar 150 bar 150 bar 150 bar
ching
Lateral studs / pressure 2176 psi 2176 psi 2176 psi 2176 psi
crankshaft bearing
Stretching 650 bar 680 bar 680 bar 680 bar
pressure 9428 psi 9863 psi 9863 psi 9863 psi
Crankshaft bearing 980 bar 1150 bar 1025 bar 1025 bar 1025 bar
bolts 14214 psi 16679 psi 16317 psi 16317 psi 16317 psi
1200 bar 1200 bar 1025 bar 1025 bar
Standard
17405 psi 17405 psi 16317 psi 16317 psi
Big-end bearing cap
1050 bar
Marine
15229 psi
Table B, M 43 C - VM 46 DF
2250 bar 2250 bar 2250 bar 2250 bar

Cylinder head
32633 psi 32633 psi 32633 psi 32633 psi
Prestretching 380 bar 240 bar 380 bar 240 bar
Lateral studs / pressure 5511 3481 psi 5511 3481 psi

crankshaft bearing 2250 bar 1900 bar 2250 bar 1900 bar
Stretching
pressure 32633 psi 27557 psi 32633 psi 27557 psi
Crankshaft bearing 2250 bar 2250 bar 2250 bar 2250 bar
bolts 32633 psi 32633 psi 32633 psi 32633 psi
2250 bar 2250 bar 2250 bar 2250 bar
Big-end bearing cap
32633 psi 32633 psi 32633 psi 32633 psi
en / 15.01.2014 IB028502 15/15

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Maintenance A0

Engine No. 45401 Record No. 271283

en / 28.01.2014 AA047801 1/1

en / 28.01.2014 AA047652 1/1

en / 28/1/14 AA047587 1/1

en / 28.01.2014 AA000026 1/1

Engine, cylinder head A5.05.01

en / 28.01.2014 AA020041 1/5

Engine, gear A5.05.02

Engine, housing A5.05.03

en / 28.01.2014 AA020041 2/5

Engine, control A5.05.04

Engine, regulation A5.05.05

Engine, exhaust gas system/supercharging A5.05.06

en / 28.01.2014 AA020041 3/5

Engine, fuel system A5.05.07

Engine, lubricating oil system A5.05.08

Engine, cooling water system A5.05.09

Engine, starting system A5.05.10

en / 28.01.2014 AA020041 4/5

Engine control equipment A5.05.11

Engine auxiliary units A5.05.12

Additional equipment A5.05.13

en / 28.01.2014 AA020041 5/5

No claims can be raised owing to missing instructions in the maintenance documents, if

All information refers to the date of printing.

2. Explanation of the maintenance system

2.1 Scheduled maintenance

Without “Scheduled maintenance” the economic operation of supercharged engine is in

The “Scheduled maintenance” is thereby supported by inspections according to fixed

The following is used as parameter:

• data on wear and tear

The information given by us gives no rise to legal claims.

en / 21.10.2013 AA047605 1/12

2.2 Maintenance system

The maintenance system consists of:

en / 21.10.2013 AA047605 2/12

2.2.1 Maintenance Plan

The maintenance plan is subdivided into the following areas:

• Daily inspection and control work

• Periodic maintenance work

en / 21.10.2013 AA047605 3/12

3.1 Safety symbols

A warning notice of this risk level signals a potentially dangerous situation.

A warning notice of this risk level signals a potentially dangerous situation.

en / 21.10.2013 AA047605 4/12

A warning notice of this risk level signals possible damage to property.

en / 21.10.2013 AA047605 5/12

3.2 General safety instructions

The provisions of the relevant accident prevention regulations of the appro-

en / 21.10.2013 AA047605 6/12

Never work or stand under suspended loads!

Re-install removed guards and protecting devices on completion of work.

Do not use engine/plant parts for climbing on!

Use personal protective equipment as far as necessary or as required by the

Mounting openings are to be protected!

Replaced seals should be disposed of immediately, and above all, it should

en / 21.10.2013 AA047605 7/12