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M25 Engineer's Handbook

MaK M25 Engineers handbook

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0% found this document useful (0 votes)

180 views211 pages

M25 Engineer's Handbook

MaK M25 Engineers handbook

Uploaded by

stewfroese67

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Edition March 2013

cvb2

Engineer’s Handbook
M 25

Coloured marking in the table of contents:

Changes

Supplements
m
M 25
Engineer’s Handbook
Contents c2
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder arrangement according to DIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Data / Engine Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Firing orders - valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil filling quantities for deep oil pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil filling quantities for flat oil pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil filling quantities for diesel generator sets on base frames . . . . . . . . . . . . . . . 27
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tightening torques for screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Covers and crankcase doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation of bearing bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil nozzle installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Crankshaft bearing studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation of brackets for main bearing temperature monitoring . . . . . . . . . . . . 30
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine block studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Plug installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tightening torques for screw plugs on the cylinder head . . . . . . . . . . . . . . . . . . 32
Rocker arm bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjustment of the valve bridges with respect to the valve spindles . . . . . . . . . . . 36
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Guide bolts for the valve bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Indicator and relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sleeve for the fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel delivery pipe removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fuel delivery pipe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Transverse thrust piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contact pattern check on inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . 42
Valve rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Valve spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Radial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Valve projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation of valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Refinishing of the valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oversize steps for valve seat rings and valve guides . . . . . . . . . . . . . . . . . . . . . 47

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Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Composite piston 2500.7-26.70.00-01 / -02 / -03 / -04 / -05 / -06 . . . . . . . . . . . . 50
Piston 2500.7-26.70.00-01 / 02 / 03 for gas oil and heavy fuel operation . . . . . . 51
Piston 2500.7-26.70.00-07 IMO2 350 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Anti-polishing ring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wear limits and limit clearances of the ring grooves . . . . . . . . . . . . . . . . . . . . . . 52
Weight tolerance when replacing connecting rod / piston . . . . . . . . . . . . . . . . . . 53
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Evaluation of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Big end bearing for connecting rod variant 2500.7-28.10.00-50 (Dragonfly) . . . . 55
Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Weight tolerance when replacing connecting rod / piston . . . . . . . . . . . . . . . . . . 55
Small end bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Permissible wedge shapes, canyons, score marks, and pockets . . . . . . . . . . . . 57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Evaluation of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Tightening torques for bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Measurement of the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Markingof the crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Locating bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inserting the set screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Limit dimensions of the crankshaft bearing shells . . . . . . . . . . . . . . . . . . . . . . . . 61
Balance weight installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Alternative manufacture of the M27x2 threads for fitting the balance weights . . 63
Crank web deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Vibration damper installation without power take-off . . . . . . . . . . . . . . . . . . . . . . 65
Vibration damper installation with power take-off . . . . . . . . . . . . . . . . . . . . . . . . 66
Permissible rework dimensions Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Surface hardness of the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gear wheel on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Intermediate gear wheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Replacement of the bush in the intermediate gear wheel . . . . . . . . . . . . . . . . . . 69
Camshaft gear wheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Backlash values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Lubricating oil nozzles for timing gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Governor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Governor drive, old design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Governor drive, new design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
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Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Flange indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Camshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adjusting the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Radial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Vibration damper installation 6 M 25 / 8 M 25 . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Vibration damper installation 9 M 25 (var. -05). . . . . . . . . . . . . . . . . . . . . . . . . . 77
Vibration damper installation 9 M 25 (var. -05). . . . . . . . . . . . . . . . . . . . . . . . . . 78
Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Camshaft bearings of M 25 C / M 25 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Evaluation of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Adjustment instruction for starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lower Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assembly of valve drive for M 25: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assembly of valve drive for M 25 C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assembly of valve drive with FCT
(split bearing brackets without extension sleeves) . . . . . . . . . . . . . . . . . . . . . . . 84
Assembly of valve drive w. FCT
(single piece bearing brackets w.extension sleeves) . . . . . . . . . . . . . . . . . . . . . 85
Adjusting unit: Note regarding removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Adjusting unit: Assembly for M 25 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Position switches on the valve drive and FCT drive . . . . . . . . . . . . . . . . . . . . . . 90
Camshaft adjusting instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cam follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Push-rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Note regarding the leak rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Tightening torques for PF1WX230V-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Mixed oil drain / leak fuel pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Tightening torques 0.00.6-43.13.00-27 (M 25 E) . . . . . . . . . . . . . . . . . . . . . . . . . 95
Removal and installation M 25, M 25 C, M 25 E . . . . . . . . . . . . . . . . . . . . . . . . . 96
Stop cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fuel distributing and collecting Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fuel injector delivery pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Starting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Pre-lift and assembly reference dimension M 25 E . . . . . . . . . . . . . . . . . . . . . . . 99
Pre-lift and assembly reference dimension M 25 C . . . . . . . . . . . . . . . . . . . . . . 100
Checking the start of fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adjustment of start of fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adjusting the start of fuel delivery (FCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m
M 25
Engineer’s Handbook
Contents c2
IMO Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Note regarding the certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
IMO engine adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
IMO adjustment: Check (M 25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
IMO adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
IMO adjustment: Check (M 25 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
IMO adjustment: Marking of the flywheel (M 25 C) . . . . . . . . . . . . . . . . . . . . . . .112
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Cooling water pipe M 25 C IMO II with FCT . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cooling water distributing pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Leak fuel pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Special oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Deep oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Oil pan installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Star grip at pump coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Barring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Starting fuel limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Oil filter arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Fuel rack position transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Governor arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Water drain hose pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Hydraulic jack: Installation instruction for replacing gaskets . . . . . . . . . . . . . . . 120
Pressure switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Adjusting instructions for pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Level probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Installation of brackets for main bearing temperature monitoring . . . . . . . . . . . 122
Media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Pump Support with Attached Pumps . . . . . . . . . . . . . . . . . . . . . . . . . 123
Installation of the pump mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Expander installation and check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Pump support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Gear wheel installation:
Lubricating oil pumps, suction and pressure
cooling water centrifugal pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pump, 124
Gear wheel installation: Fuel feed pump drive . . . . . . . . . . . . . . . . . . . . . . . . . 125
Coupling between drive and fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Installation of the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Flywheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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M 25
Engineer’s Handbook
Contents c2
Flexible Flange Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Flexible flange connections for diesel generator sets . . . . . . . . . . . . . . . . . . . . 130
Vulkan RATO DG29D8, series 2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PTO coupling hub with Vulkan RATO-R 1G191WR030 . . . . . . . . . . . . . . . . . . 133
Vulkan RATO-S 1G252Q0154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Vulkan RATO-R 1G262TR090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Vulkan RATO-R G1920R, series 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Vulkan RATO-DS A3418G, series 2100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Vulkan RATO-DS A3411A, series 2100, 1A3410A035 . . . . . . . . . . . . . . . . . . . 138
Vulkan RATO-DS A3410A, series 2100, 1A3410A046 . . . . . . . . . . . . . . . . . . . 138
Vulkan RATO-R 262 TR, series 2200 on 9 M 25 C . . . . . . . . . . . . . . . . . . . . . . 139
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Installation - 2500.7-72.40.00-01 driving end . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Installation 2500.7-72.40.00-03 / -04 / -05 driving end
2500.7-72.80.00-03 / -05 free end . . . . . . . . . . . . . . . . . . . . . . . . 140
Installation 2500.7-72.80.00-05 / -06 / -09 free end . . . . . . . . . . . . . . . . . . . . . 143
2500.7-72.40.00-07 driving end . . . . . . . . . . . . . . . . . . . 143
Installation of 2500.7-72.80.00-07 driving end (M 25 E) . . . . . . . . . . . . . . . . . . 145
Screw plug tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Charge air, bypass, M 25 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Air injection, M 25 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installation of KBB R4-3 turbocharger on 6 M 25 . . . . . . . . . . . . . . . . . . . . . . . 149
Installation of KBB R5-3 turbocharger on 8 M 25 and 9 M 25 . . . . . . . . . . . . . . 150
Installation of KBB HPR6000 turbocharger on 6 M 25, 8 M 25, and 9 M 25 . . . 151
Installation of KBB HPR6000 turbocharger on
6 M 25 C, 8 M 25 C, and 9 M 25 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Turbocharger installation: ABB TPS61D on 9
M 25 / ABB TPS61 on 8 M 25 and 9 M 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Installation of ABB TPS61 turbocharger on 6 M 25 . . . . . . . . . . . . . . . . . . . . . . 154
Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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M 25
Engineer’s Handbook
Contents c2
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Screws for fastening on the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Connecting links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Expansion joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Gaskets between cylinder head and exhaust manifold . . . . . . . . . . . . . . . . . . 159
6 M 25 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6 M 25 with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8 M 25 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8 M 25 with turbocharger at free end (variants 02 and 04) . . . . . . . . . . . . . . . . 161
8 M 25 with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9 M 25 with turbocharger at driving end (variant 01) . . . . . . . . . . . . . . . . . . . . . 162
9 M 25 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9 M 25 with turbocharger at free end (variant 02) . . . . . . . . . . . . . . . . . . . . . . . 164
9 M 25 with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6 M 25 C with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6 M 25 C with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8 M 25 C with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8 M 25 C with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9 M 25 C with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9 M 25 C with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Exhaust Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Assembly gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Installation sequence with turbocharger at driving end (var. -25, without ribs) . 172
Installation sequence with turbocharger at free end (var. -25, without ribs) . . . 175
Installation sequence with turbocharger at driving end (var. -26, with ribs) . . . . 179
Installation sequence with turbocharger at free end (var. -26, with ribs) . . . . . . 182
Installation sequence with turbocharger at driving end
(variants -27, -28, square shape) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Installation sequence with turbocharger at free end
(variants -27, -28, square shape) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Diesel Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Alignment instruction for diesel generator sets . . . . . . . . . . . . . . . . . . . . . . . . . 192
Alignment instruction for 9 M 25 C diesel generator sets
(engine numbers 45278, 45379, 45280) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Sealing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Engine and generator fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Installation of the support bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Installation of PTO coupling hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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M 25
Engineer’s Handbook
Contents c2
Resilient Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Locking device to be used in case of damage . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Conical elements: All engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Conical elements: 6 M 25, 8 M 25, 8 M 25 C . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Conical elements RD 214: 9 M 25 C
(engine numbers 45278, 45379, 45280 only) . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Conical elements RD 114: 9 M 25 C
(engine numbers 45278, 45379, 45280 only) . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Locking device: 9 M 25 C (engine numbers 45278, 45379, 45280 only) . . . . . 209
Generator fastening: 9 M 25 C (engine numbers 45278, 45379, 45280 only) . 209

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General Notes

Cylinder arrangement according to DIN

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data
Engine Data / Engine Operating
c2
Engine Data / Engine Operating Data

M 25
Bore 255 mm
Stroke 400 mm
Speed 720 and 750 rpm
Continuous rating of the engine accor-
ding to ISO 3046/1 316 kW/cylinder
720 rpm .............................................. 330 kW/cylinder
750 rpm ..............................................
Number of balance weights at crankshaft
6 M 25 .................................................... 12
8 M 25 .................................................... 16
9 M 25 .................................................... 12
Piston compression ratio 15.5 : 1
Start of fuel delivery 11° CA bef. TDC
Start of injection 8° CA bef. TDC
Turbocharger HPR6000
Injection pump PF1 WX230 V
Minimum operating speed
720 rpm .............................................. 240 rpm
750 rpm .............................................. 250 rpm

Charge air pressure

6 M 25 (720 rpm) .................................... 3.1 bar
6 M 25 (750 rpm) .................................... 3.2 bar

8 M 25 (720 rpm) .................................... 3.0 bar

8 M 25 (750 rpm) .................................... 3.2 bar

9 M 25 (720 rpm) .................................... 3.2 bar

9 M 25 (750 rpm) .................................... 3.2 bar
Compression pressure
720 rpm ............................................... 172 bar
750 rpm ............................................... 175 bar
Ignition pressure
720 rpm ............................................... 204 bar
750 rpm ............................................... 208 bar

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
Fuel
Fuel consumption 184 g/kWh
Fuel pressure before injection pumps
MDO operation 3.0 - 5.0 bar
.......................................... 4.0 - 10.0 bar
HFO operation ..........................................
Lubricating oil
Lubricating oil consumption at full 0.6 ± 0.3 g/kWh
load
Lubricating oil temperature at engine 60 - 65 °C
inlet
Lubricating oil temperature rise 10 - 14 °C
Operating pressure at the engine 4 - 5 bar
Content of circulation tank / dry sump
6 M 25 (720 rpm) .................................... 2.6 m3
6 M 25 (750 rpm) .................................... 2.7 m3

8 M 25 (720 rpm) .................................... 3.4 m3

8 M 25 (750 rpm) .................................... 3.6 m3

9 M 25 (720 rpm) .................................... 3.9 m3

9 M 25 (750 rpm) .................................... 4.0 m3
Cooling water
Fresh water circulation cooling pres- 2.5 - 6.0 bar (at min. 4 mWC)
sure
Min./max. FW pressure at engine inlet 2.5 - 6.0 bar
Cooling system warming-up 7 - 10 °C
FW temperature after engine 80 - 90 °C
Content of the expansion tank
6 M 25 ...................................................... 0.20 m3
8 M 25 ...................................................... 0.25 m3
9 M 25 ...................................................... 0.30 m3
Water content in engine
6 M 25 ...................................................... 0.4 m3
8 M 25 ...................................................... 0.5 m3
9 M 25 ...................................................... 0.6 m3

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
Two-circuit system:
FW temperature at charge air cooler 38 °C
inlet
Two-circuit system:
Required FW volume for charge air
cooler 40 m3/h
6 M 25 ...................................................... 45 m3/h
8 M 25 ...................................................... 50 m3/h
9 M 25 ......................................................
Air
Charge air temperature at engine inlet 45 - 60 °C
Min. starting air pressure 10 bar
Max. starting air pressure 30 bar
Air consumption per start (warm 0.8 m3 N.C.
engine)
Max. permissible crankcase pressure, 15 mmWC,
nom. diam. of vent pipe 80 mm
Exhaust gas
Max. exhaust gas resistance after tur- 0.03 bar
bine
Temperature at cylinder / after turbine
6 M 25 (720 rpm) .................................... 360 / 305 °C
6 M 25 (750 rpm) .................................... 360 °C

8 M 25 (720 rpm) .................................... 370 °C

8 M 25 (750 rpm) .................................... 370 °C

9 M 25 (720 rpm) .................................... 380 °C

9 M 25 (750 rpm) .................................... 380 °C

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2

M 25 C IMO II
Continuous rating of the engine accor- 333 kW/cylinder
ding to ISO 3046/1
Rated engine speed 720 and 750 rpm
Minimum operating speed
Rated speed 720 rpm ........................ 240 rpm
Rated speed 750 rpm ........................ 250 rpm

Fuel consumption at 100 %

6 M 25 C (720 rpm) ................................ 188 g/kWh
6 M 25 C (750 rpm) ................................ 186 g/kWh
8 M 25 C, 9 M 25 C (720 rpm) 189 g/kWh
................... 187 g/kWh
8 M 25 C, 9 M 25 C (750 rpm)
...................
Ignition pressure 210 bar
Turbocharger type
6 M 25 C, 8 M 25 C, 9 M 25 C KBB HPR 6000

Fuel filter:
Mesh size of MDO fine filter .................. 0.025 mm
Mesh size of HFO automatic filter ......... 0.010 mm
Mesh size of HFO fine filter .................. 0.034 mm
Cooling water
Content of expansion tank
6 M 25 C 0.20 m3
................................................... 0.25 m3
8 M 25 C 0.30 m3
...................................................
9 M 25 C
...................................................
Water content of the engine
6 M 25 C 0.4 m3
................................................... 0.5 m3
8 M 25 C 0.6 m3
...................................................
9 M 25 C
...................................................
FW temperature after engine 80 - 90 °C

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 C IMO II
FW pressure at engine inlet 4.5 - 6.0 bar
Two-circuit system:
FW temperature at charge air cooler 38 °C
inlet
Two-circuit system: Required fresh
water quantity for charge air cooler
6 M 25 C 40 m3/h
................................................... 55 m3/h
8 M 25 C 60 m3/h
...................................................
9 M 25 C
...................................................
Air
Charge air pressure
6 M 25 C, 8 M 25 C (all) 3.2 bar
.............................. 3.3 bar
9 M 25 C (720 rpm) ................................. 3.2 bar
9 M 25 C (750 rpm) .................................
Max. permissible crankcase pressure, 15 mmWC,
nom. diam. of vent pipe 80 mm
Min./max. starting air pressure 7 bar / 30 bar
Air consumption per start (warm 0.8 m3 N.C.
engine)

Air requirement (ta = 20 °C)

6 M 25 C (720 rpm) ................................ 11390 m3/h
6 M 25 C (750 rpm) ................................ 11505 m3/h

8 M 25 C (720 rpm) ................................ 14460 m3/h

8 M 25 C (750 rpm) ................................ 14605 m3/h

9 M 25 C (720 rpm) ................................ 17035 m3/h

9 M 25 C (750 rpm) ................................ 17190 m3/h
Lubricating oil
Lubricating oil operating pressure at 4 - 5 bar
engine

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 C IMO II
Content of circulation tank / dry sump
6 M 25 C (720 rpm) .................................. 2.6 m3
6 M 25 C (750 rpm) .................................. 2.7 m3

8 M 25 C (720 rpm) .................................. 3.4 m3

8 M 25 C (750 rpm) .................................. 3.6 m3

9 M 25 C (720 rpm) ................................... 3.9 m3

9 M 25 C (750 rpm) ................................... 4.0 m3
Lubricating oil temperature before 60 - 65 °C
engine
Lubricating oil consumption at full 0.6 ± 0.3 g/kWh
load
Mesh size of duplex filter 0.08 mm
Mesh size of automatic filter 0.03 mm
Exhaust gas
NOx emission 9,6 g/kWh
(Marpol 73/78 Annex VI Cycle E2, E3, D2)
Max. exhaust gas resistance after tur- 0.03 bar
bine
Exhaust Gas Temperature after Turbine
25 °C intake temp., rel. air humidity 60 %
6 M 25 C (720 rpm) .................................. 333 °C (tolerance: 10%)
6 M 25 C (750 rpm) .................................. 333 °C (tolerance: 10%)

8 M 25 C (720 rpm) .................................. 335 °C (tolerance: 10%)

8 M 25 C (750 rpm) .................................. 333 °C (tolerance: 10%)

9 M 25 C (720 rpm) ................................... 360 °C (tolerance: 10%)

9 M 25 C (750 rpm) ................................... 342 °C (tolerance: 10%)

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2

M 25 E IMO II
Continuous rating of the engine accor- 350 kW/cylinder
ding to ISO 3046/1
rated engine speed 720 and 750 rpm
Minimum operating speed
Rated speed 720 rpm ......................... 240 rpm
Rated speed 750 rpm ......................... 250 rpm

Fuel consumption at 100 % 190 / 187 g/kWh

Ignition pressure 220 bar
Turbocharger type
6 M 25 E KBB ST5
.................................................... KBB ST6
8 M 25 E, 9 M 25 E
.......................................
Fuel filter:
Mesh size of MDO fine filter ................. 0.025 mm
Mesh size of HFO automatic filter ......... 0.010 mm
Mesh size of HFO fine filter .................. 0.034 mm

Cooling water
Content of expansion tank
6 M 25 E 0.20 m3
................................................... 0.25 m3
8 M 25 E 0.30 m3
...................................................
9 M 25 E
...................................................
Water content of the engine
6 M 25 E 0.4 m3
................................................... 0.5 m3
8 M 25 E 0.6 m3
...................................................
9 M 25 E
...................................................
FW temperature after engine 80 - 90 °C

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 E IMO II
Min./max. FW pressure at engine inlet 4.5 - 6.0 bar
Two-circuit system:
FW temperature at charge air cooler 38 °C
inlet
Two-circuit system: Required fresh
water quantity for charge air cooler
6 M 25 E 40 m3/h
................................................... 55 m3/h
8 M 25 E 60 m3/h
...................................................
9 M 25 E
...................................................
Air
Charge air pressure
6 M 25 E, 8 M 25 E (all) 3.35 bar
.............................. 3.40 bar
9 M 25 E (720 rpm) ................................. 3.35 bar
9 M 25 E (750 rpm) .................................
Max. permissible crankcase pressure, 15 mmWC,
nom. diam. of vent pipe 80 mm
Min./max. starting air pressure 7 bar / 30 bar
Charge air consumption per start 0.8 m3 N.C.
(warm engine)

Air requirement (ta = 20 °C)

6 M 25 E (720 rpm) ................................ 11850 m3/h
6 M 25 E (750 rpm) ................................ 11965 m3/h

8 M 25 E (720 rpm) ................................ 15040 m3/h

8 M 25 E (750 rpm) ................................ 15200 m3/h

9 M 25 E (720 rpm) ................................ 17715 m3/h

9 M 25 E (750 rpm) ................................ 17880 m3/h

Lubricating oil
Lubricating oil operating pressure at 4 - 5 bar
engine

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 E IMO II
Content of circulation tank / dry sump
6 M 25 E (720 rpm) .................................. 2.6 m3
6 M 25 E (750 rpm) .................................. 2.7 m3

8 M 25 E (720 rpm) .................................. 3.4 m3

8 M 25 E (750 rpm) .................................. 3.6 m3

9 M 25 E (720 rpm) ................................... 3.9 m3

9 M 25 E (750 rpm) ................................... 4.0 m3
Lubricating oil temperature before 60 - 65 °C
engine
Lubricating oil consumption at full 0.6 ± 0.3 g/kWh
load
Mesh size of duplex filter 0.08 mm
Mesh size of automatic filter 0.03 mm
Exhaust gas
NOx emission 9,6 g/kWh
(Marpol 73/78 Annex VI Cycle E2, E3, D2)
Max. exhaust gas resistance after tur- 0.03 bar
bine
Exhaust Gas Temperature after Turbine
25 °C intake temp., rel. air humidity 60 %
6 M 25 E (720 rpm) .................................. 345 °C (tolerance: 10%)
6 M 25 E (750 rpm) .................................. 345 °C (tolerance: 10%)

8 M 25 E (720 rpm) .................................. 348 °C (tolerance: 10%)

8 M 25 E (750 rpm) .................................. 345 °C (tolerance: 10%)

9 M 25 E (720 rpm) ................................... 365 °C (tolerance: 10%)

9 M 25 E (750 rpm) ................................... 363 °C (tolerance: 10%)

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 EPG
Fuel consumption at 100 %
6 M 25 ...................................................... 183 g/kWh
8 M 25, 9 M 25 182 g/kWh
............................................
Continuous rating of the engine accor-
ding to ISO 3046/1 300 kW/cylinder
6 M 25 (720 rpm) .................................... 308 kW/cylinder
6 M 25 (750 rpm) .................................... 290 kW/cylinder
8 M 25, 9 M 25 (720 rpm) 300 kW/cylinder
..........................
8 M 25, 9 M 25 (750 rpm)
..........................
Speed 720 and 750 rpm
Minimum operating speed
Rated speed 720 rpm ........................ 240 rpm
Rated speed 750 rpm ........................ 250 rpm
Ignition pressure
720 rpm ............................................... 188 bar
750 rpm ............................................... 190 bar
Start of fuel delivery 11° CA bef. TDC
Start of injection 8° CA bef. TDC
Turbocharger type KBB HPR 6000
Fuel filter:
Mesh size of MDO fine filter ................. 0.025 mm
Mesh size of HFO automatic filter ......... 0.010 mm
Mesh size of HFO fine filter .................. 0.034 mm
Air
Charge air pressure
6 M 25 (720 rpm) .................................... 2.88 bar
6 M 25 (750 rpm) .................................... 2.93 bar

8 M 25 (720 rpm) .................................... 2.80 bar

8 M 25 (750 rpm) .................................... 3.00 bar

9 M 25 (720 rpm) .................................... 3.00 bar

9 M 25 (750 rpm) .................................... 3.00 bar
Min./max. starting air pressure 10 bar - 30 bar

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M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 EPG
Charge air consumption per start 0.8 m3
(warm engine)

Compression pressure
6 M 25 (720 rpm) .................................... 162 bar
6 M 25 (750 rpm) .................................... 168 bar

8 M 25, 9 M 25 (720 rpm) 160 bar

.......................... 167 bar
8 M 25, 9 M 25 (750 rpm)
..........................
Air requirement (ta = 20 °C)
6 M 25 (720 rpm) .................................... 10950 m3/h
6 M 25 (750 rpm) .................................... 11350 m3/h

8 M 25 (720 rpm) .................................... 13400 m3/h

8 M 25 (750 rpm) .................................... 14000 m3/h

9 M 25 (720 rpm) .................................... 16200 m3/h

9 M 25 (750 rpm) .................................... 17000 m3/h
Cooling water
Content of expansion tank
6 M 25 ..................................................... 0.20 m3
8 M 25 ..................................................... 0.25 m3
9 M 25 ..................................................... 0.30 m3
Water content of the engine
6 M 25 ..................................................... 0.4 m3
8 M 25 ..................................................... 0.5 m3
9 M 25 ..................................................... 0.6 m3
FW pressure at engine inlet 2.5 - 6.0 bar
FW temperature at charge air cooler 38 °C
inlet
FW temperature after engine 80 - 90 °C
Required FW volume for charge air
cooling 40 m3/h
6 M 25 ..................................................... 45 m3/h
8 M 25 ..................................................... 50 m3/h
9 M 25 .....................................................
Lubricating oil

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2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m
M 25
Engineer’s Handbook
Engine Data / Engine Operating Data c2
M 25 EPG
Lubricating oil operating pressure at 4 - 5 bar
engine
Mesh size of duplex filter 0.08 mm
Mesh size of automatic filter 0.03 mm
Lubricating oil consumption at full 0.6 ± 0.3 g/kWh
load
Lubricating oil circulation tank / dry
sump
Contents 2.5 m3
6 M 25 ..................................................... 3.3 m3
8 M 25 ..................................................... 3.7 m3
9 M 25 .....................................................
Exhaust gas
Temperature at cylinder / after turbine
6 M 25 (720 rpm) .................................... 360 °C
6 M 25 (750 rpm) .................................... 360 °C

8 M 25 (720 rpm) .................................... 350 °C

8 M 25 (750 rpm) .................................... 380 °C

9 M 25 (720 rpm) .................................... 370 °C

9 M 25 (750 rpm) .................................... 375 / 330 °C
Max. exhaust gas resistance after tur- 0.03 bar
bine

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2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Firing Orders - Valve Timing c2
M 25 Firing orders - valve timing

Firing orders - valve timing

Firing orders

6 M 25, 6 M 25 C, 6 M 25 Eclockwise 1-3-5-6-4-2

counter-clockwise 1-2-4-6-5-3

8 M 25, 8 M 25 C, 8 M 25 Eclockwise 1-2-4-6-8-7-5-3

counter-clockwise 1-3-5-7-8-6-4-2

9 M 25, 9 M 25 C, 9 M 25 Eclockwise 1-2-4-6-8-9-7-5-3

counter-clockwise 1-3-5-7-9-6-4-2

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©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Firing Orders - Valve Timing c2
M 25

Valve timing

Take into account the testbed record!

* = engines with clockwise rotation

Engine IMO Valve timing

6 M 25 IMO I
8 M 25 IMO I
9 M 25 IMO I

6 M 25 DNV Clean
8 M 25 DNV Clean
9 M 25 DNV Clean Exhaust opens 45° CA before BDC
Exhaust closes 50° CA after TDC
6 M 25 EPA Tier 2 Inlet opens 50° CA before TDC
8 M 25 EPA Tier 2 Inlet closes 10° CA after BDC
9 M 25 EPA Tier 2

6 M 25 330 kW
8 M 25 330 kW *
9 M 25 330 kW

Exhaust opens 40° CA before BDC

6 M 25 330 kW IMO II
Exhaust closes 50° CA after TDC
8 M 25 330 kW IMO II
Inlet opens 50° CA before TDC
9 M 25 330 kW IMO II
Inlet closes 10° CA before BDC
Exhaust opens 40° CA before BDC
Exhaust closes 50° CA after TDC
6 M 25 FCT IMO II
Inlet opens 50° CA before TDC (NORMAL pos.)
8 M 25 FCT IMO II Inlet closes 10° CA before BDC (NORMAL pos.)
9 M 25 FCT IMO II
Inlet opens 30° CA before TDC (EARLY pos.)
Inlet closes 10° CA after BDC (EARLY pos.)
Exhaust opens 45° CA before BDC
6 M 25 300 kW IMO II Exhaust closes 50° CA after TDC
8 M 25 300 kW IMO II Inlet opens 50° CA before TDC
9 M 25 300 kW IMO II Inlet closes 5° CA after BDC
Exhaust opens 45° CA before BDC
Exhaust closes 45° CA after TDC
6 M 25 FCT 350 IMO II Inlet opens 45° CA before TDC (NORMAL pos.)
kW IMO II Inlet closes 20° CA before BDC (NORMAL pos.)
8 M 25 FCT 350 IMO II Inlet opens 25° CA before TDC (EARLY pos.)
kW Inlet closes 0° CA before BDC (EARLY pos.)
9 M 25 FCT 350
kW

March 2013 Caterpillar confidential: yellow 23

©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Firing Orders - Valve Timing c2
M 25

Engine IMO Valve timing

Exhaust opens 45° CA before BDC

IMO II
6 M 25 350 kW * 9 Exhaust closes 45° CA after TDC
IMO II
M 25 350 kW * Inlet opens 45° CA before TDC
IMO II Inlet closes 10° CA before BDC

March 2013 Caterpillar confidential: yellow 24

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2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Dimensions and Weights c2
M 25
Dimensions and weights

Dimensions and Weights

Length Width mm Height Weight kg

Description
mm mm
Engine block:
(without studs, with bearing caps and bearing bolts)
6 M 25 3,287 1,300 1,475 6,640
8 M 25 4,147 1,300 1,475 8,460
9 M 25 4,577 1,300 1,475 9,460
Crankshaft with balance weights:
6 M 25 1,917
8 M 25 2,523
9 M 25 2,725
Crankshaft without balance weights:
6 M 25 3,171 456 1,445
8 M 25 4,031 456 1,850
9 M 25 4,461 456 2,082
Oil pan:
6 M 25 3,369 968 399 496
8 M 25 4,229 968 399 580
9 M 25 4,659 968 399 637
9 M 25 4,659 968 729 912
Crankshaft vibration damper:
6 M 25 200 Ø 850 980
6 M 25 E 177 Ø 900 768
8 M 25 145 Ø 900 632
9 M 25 145 Ø 850 558
Base frame of diesel generator sets:
6 M 25 7500
8 M 25 8700
9 M 25 9400
Inlet casing 1096 196 to 229

March 2013 Caterpillar confidential: yellow 25

Length Width mm Height Weight kg

Description
mm mm
Charge air cooler:
6 M 25 1,057 475 552 270
8 M 25 and 9 M 25 1,287 475 552 266 to 338
6 M 25 E 836 480 570 275
Vestas 0.00.6-41.80.00-72 1,279 475 552 314
Charge air cooler casing 690 to 747
Turbocharger (incl. exhaust nozzle)
KBB HPR 6000 1,427 565
KBB ST6 1,427 565
Crankshaft balance weight 400 88 215 53
Crankshaft bearing shell 88 Ø 252 3
Crankshaft bearing cap 500 to 507 100 295 57 to 70
Gear wheel on crankshaft 122 Ø 365 42
Intermediate gear with bush 95 Ø 356 62
Intermediate gear shaft 320 Ø 98 17.8
End bearing journal 305 Ø 255 76
Pump mounting plate (40 1,075 1,007 198
mm)
Cylinder liner Ø 354 780 150 or 162
Anti-polishing ring 58 Ø 266 2
Piston, composite Ø 255 390 47
Piston pin 220 Ø 120 22
Connecting rod, bare 979 118 82
Big-end bearing shell 96 Ø 204 3
Big end bearing cap 328 107 approx.
162
Vibration damper 62 Ø 330 29
Camshaft
Camshaft section 430 Ø 205 48
Camshaft bearing 55 Ø 224 2.8

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Length Width mm Height Weight kg

Description
mm mm
Camshaft end bearing 124 Ø 288 7.2
Gear wheel on camshaft 95 Ø 709 260
(complete with hub)
Cooling collar 426 263 118
Cylinder head, complete 265
Cylinder head
(without inlet and exhaust val- 725 428 351 194
ves
with valve guides)
Cylinder head var. -08 , bare 725 428 351 203
Rocker arm bracket with 160 215 11
shaft
Valve stem 446 Ø 84 1.5

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Oil filling quantities for deep oil pans

Min. oil level Max. oil level Min. oil level Max. oil level
Engine
(dipstick) (dipstick) alarm (sensor) alarm (sensor)
6 M 25 not applicable not applicable 1380 l 1620 l
6 M 25 C 1100 l 1620 l 820 l not applicable
8 M 25 not applicable not applicable 1750 l 2050 l
8 M 25 C 1400 l 2050 l 1040 l not applicable
9 M 25 not applicable not applicable 1930 l 2260 l
9 M 25 C 1550 l 2280 l 1150 l not applicable

Oil filling quantities for flat oil pans

Oil filling quantities for flat oil pans can only be Free end
measured in the sump tank or the base frame
(see below or plant-specific drawings).

Connection for
sensor

Oil filling quantities for diesel generator sets on base frames

Min. oil level Max. oil level Min. oil level Max. oil level
Engine
(dipstick) (dipstick) alarm alarm
6 M 25, 6 M 25 C 1420 l 1825 l 1130 l 2230 l
8 M 25, 8 M 25 C 1830 l 2340 l 1450 l 2560 l
9 M 25, 9 M 25 C 2030 l 2600 l 1615 l 3185 l

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Engine block

Tightening torques for screw plugs

Tighten the screw plugs M33x2 on the M 25 with ⇒ M = 200 Nm

and on the M 25 C with ⇒ M = 230 Nm
Tighten the screw plugs M18x1.5 on the M 25 with ⇒ M = 140 Nm
and on the M 25 C with ⇒ M = 50 Nm
Tighten the screw plugs M12x1.5 on the M 25 with ⇒ M = 70 Nm
and on the M 25 C with ⇒ M = 25 Nm
Tighten the screw plugs G1/2A on the M 25 with ⇒ M = 160 Nm
and on the M 25 C with ⇒ M = 85 Nm
Tighten the screw plugs G3/4A on the M 25 with ⇒ M = 70 Nm
Tighten the screw plugs (1) M22x1.5
on the M 25 C (without FCT) with ⇒ M = 85 Nm
Loctite 270

Tighten the screw plugs (1) M33x2

on the M 25 C (with FCT) with ⇒ M = 230 Nm
Loctite 270

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Covers and crankcase doors

Lightly grease the flat gaskets before inserting them.

Use Dirko No. 610.020 (Dirko grey) universal sealing
compound for covers without gasket.

For crankcase door with relief valve:

Tighten the screws (1) with ⇒ M = 25 Nm
Molykote

Installation of bearing bushes

Cool the bearing bush (1) with liquid nitrogen down to ⇒ -195 °C
and insert it so as to be flush with the engine block.

Reference dimension of the bush (1) after freeze fitting:

Inside diameter ⇒ 96.0 + 0.05 mm

Cool the bearing bush (2) with liquid nitrogen down to ⇒ -195 °C.

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Oil nozzle installation

Tighten the M16 screws for fastening of
the oil nozzles (3) for the gear wheels with ⇒ 160 Nm.

Crankshaft bearing studs

see chapter “Crankshaft”

Installation of brackets for main bearing temperature monitoring

see chapter “Miscellaneous”

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Cylinder head

Engine block studs

Screw the studs into the engine block with ⇒ M = 450 Nm

Molykote

1. Pretighten the round nuts with a pin so as to be finger tight.

2. Stretch the studs with ⇒ P = 820 bar

and finally tighten the round nuts with a pin.
Pay attention to ease of movement.

Check: Decrease the pressure to ⇒ P = 770 bar

Loosening of the nuts must not be possible any more.

The pressure must remain constant when the pump is not actuated, otherwise there will
be a tightening fault.

Removal: If the cylinder head nuts cannot be loosened at P = 820 bar, a pressure
increase by 50 bar is possible. If the pressure is increased further, there is a risk of
stretching the thread and jamming of the nuts.

At the control bore (1) leaks between

cylinder head, anti-polishing ring, and
cooling collar can be identified (e.g. black,
sooty film = gas leak).

Plug installation
When installing plugs (7) and (8) (see figures on the next page) make sure that the sealing
faces of the plugs and the corresponding holes are clean and free of grease. Lubricate the
sealing faces with Loctite 270. Use the provided drive-in mandrel for installation. The
plug edges must be located 1.5 + 0.5 mm deep in the cylinder head.

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Tightening torques for screw plugs on the cylinder head

Caution!
Mid 2010 a cylinder head with improved indicator valve with a simplified and easy-to-install
cover was implemented. For these cylinder heads other screw plug tightening values are
applicable, see below.

Tighten screw plugs (5) G1/2A with ⇒ M = 60 Nm

High-temperature paste

Tighten screw plugs (1) M10x1 with ⇒ M = 15 Nm

Loctite 270

Tighten screw plugs (2) M10x1 with ⇒ M = 30 Nm

Molykote

Tighten screw plugs (3) M36x2 with ⇒ M = 250 Nm

Hylomar

Tighten screw plugs (4) M42x2 with ⇒ M = 300 Nm

Hylomar

Tightening values for cylinder heads with improved indicator valve / cover:

Tighten screw plugs (5) G1/2A with ⇒ M = 85 Nm

High-temperature paste

Tighten screw plugs (1) M10x1 with ⇒ M = 22 Nm

Loctite 270

Tighten screw plugs (2) M10x1 with ⇒ M = 17 Nm

Molykote

Tighten screw plugs (3) M36x2 with ⇒ M = 270 Nm

Hylomar

Tighten screw plugs (4) M42x2 with ⇒ M = 430 Nm

Hylomar

Tighten screw plugs (6) M16x1.5 with ⇒ M = 40 Nm

Molykote

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4
7 8

3
5 3

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Rocker arm bracket

Screw in studs (1) with ⇒ M = 100 Nm
Oil

Tighten nuts (2) with ⇒ M = 160 Nm

Molykote

Cool ball pins (3) with liquid nitrogen down to ⇒ T = - 195 °C.

Turn hexagon nut (4) against stopper and secure with Loctite 270.

Mount stud (5) M12x90 with star knob by turning the knob against the stopper and secure
with Loctite 270.

When mounting the valve cover pay attention to the position of joint ring (6).

March 2013 Caterpillar confidential: yellow 35

Screw in studs (3) with ⇒ M = 50 Nm

Oil

Rocker arms
Reference dimension of the bush after pressing-in, ⇒ Ø 59.99 + 0.12 mm

After pressing-in the bushes shall recede by ⇒ 0.20 + 0.10 mm

Before pressing-in coat the bushes lightly with oil. Do not use Molykote.

Radial clearance

Clearance in new condition ⇒ 0.02 - 0.159 mm

Limit clearance ⇒ 0.359 mm

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Adjustment of the valve bridges with respect to the valve spindles

1. Open the indicator valves. Bar the piston of the cylinder to be adjusted to ignition TDC.
Inlet and exhaust valves are closed, rocker arms are relieved.

2. Relieve the valve bridge from the load caused by the rocker arm. Increase clearance S
between rocker arm and valve bridge and/or fold back the rocker arm.

3. Loosen locknut (3) of the valve bridge and unscrew adjusting screw (2) so as to obtain
zero-clearance contact at X.

4. At this position of the valve bridge screw in the adjusting screw (2) so as to obtain zero-
clearance contact at Y. Do not tilt the valve bridge!

5. Hold adjusting screw (2) and

tighten locknut (3) with ⇒ M = 60 Nm

6. Check for zero clearance at X and Y with a 0.02 mm feeler gauge. After that, adjust the
valve clearance S in accordance with the instructions.

Valve clearance
On a warm engine (shut down for at least 15 minutes):
Inlet ⇒ 0.50 + 0.10 mm

Exhaust ⇒ 0.90 + 0.10 mm

After that, tighten locknut (4) with ⇒ M = 100 Nm

and check clearance Sonce more.
Valve guides

March 2013 Caterpillar confidential: yellow 37

Drive out the old valve guides by means of removal drift 252181A. Cool the valve guides
down to -195 °C and insert them into the cylinder head. Insert the O-rings after freeze
fitting. Measure the diameter of the valve stem in the guided area. Measure the guide in
transverse direction of the engine.

Normal clearance (inlet + exhaust) ⇒ 0.10 - 0.15 mm

Limit clearance (inlet + exhaust) ⇒ 0.30

)mm

Guide bolts for the valve bridges

with thread
Tighten the guide bolts with ⇒ M = 180 Nm
Molykote

without thread
Cool the guide bolts down to -195 °C with liquid nitrogen and insert them into the cylinder
head.

Indicator and relief valve

Screw in studs Stiftschrauben (1) and (3) (M12) with ⇒ M = 50 Nm
Oil
Tighten nuts (2) and (4) (M12) with ⇒ M = 50 Nm
Molykote

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Starting valve
Tighten screw plug (1) with ⇒ M = 250 Nm
Molykote

Tighten locknut (2) with ⇒ M = 35 Nm

Molykote

Sleeve for the fuel injection valve

Tighten the sleeve for the fuel injection valve with ⇒ M = 140 Nm

Loctite 510 (thread+sealing face). Use a

special wrench!

Insert the O-rings with Petro Gel Amber,

liquid suet or green soft soap.
Reference dimension

Before installing the sleeve make sure the

insertion hole in the cylinder head is free of
burrs. Viton O-ring,
307.5

green

O-ring
Perbunan

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Fuel injection valve

Screw in studs (1) with ⇒ M = 50 Nm
Oil

First tighten nuts (2) evenly by hand (without any tool). Ensure flush contact of flange to
nozzle holder.

Then tighten nuts (2) in two steps with ⇒ M = 50 Nm

Molykote

Tighten the nozzle nut with ⇒ M = 750 Nm

Oil

Insert the injection valve into the cylinder head without joint ring!
Reference dimen-
sion

Ensure flush contact of

flange to nozzle holder

Nozzle cooling return

Nozzle cooling supply

Apply a thin coat of
Petro Gel Amber Fuel pressure pipe
to the O-rings connection
Nozzle leak fuel

Insert nozzle element with

high-temperature paste

Nozzle nut / cap

March 2013 Caterpillar confidential: yellow 40

Fuel injection valve

With intermediate plate:
Tighten the locknut (1) for the adjusting screw (2) with ⇒ M = 70 - 90 Nm
Without intermediate plate:
Tighten the locknut (1) for the adjusting screw (2) with ⇒ M = 60 ± 10 Nm

The injection valve has shown optimum reliability under

both MDO and HFO operation. This injection valve,
however, must be carefully completed. During assembly
of the screw plug there is a risk of deforming the joint Joint ring
ring. This may cause fuel to leak out, which will
ultimately contaminate the lubricating oil. When
completing an injection valve, attention must be paid to
the following:

With intermediate plate: Without intermediate plate:

1. Center the joint ring:

With intermediate plate:

Tighten nut (3) with screw plug (4) with ⇒ M = 90 - 130 Nm

Without intermediate plate:

Tighten nut (3) with screw plug (4) with ⇒ M = 90 - 30 Nm

2. Check the joint ring once more for correct seating.

If necessary, repeat the above procedure with a new joint ring.

March 2013 Caterpillar confidential: yellow 41

Fuel delivery pipe removal

Always first loosen the threaded connection of the transverse thrust piece (3), then loosen
that of the thrust screw (6), because otherwise the sealing faces between radial thrust
piece (5) and transverse thrust piece (3) will be damaged.

Fuel delivery pipe installation

Lubricate thread and contact surfaces at * with Molykote paste G.
1. Tighten the nuts of the nozzle holder with the
specified tightening torque.
Then loosen by one turn and tighten with ⇒ M = 10 Nm.
2. Put the parts together ensuring correct position of cover (1). The sleeve (2) is in a
pushed back position inside the cylinder head.
3. Tighten the threaded connection (4)of the transverse thrust piece (3) and the thrust
screw (6) so as to be finger tight (without wrench).
4. First tighten the thrust screw (6) and then the threaded connection (4)
of the transverse thrust piece (3) with ⇒ M = 10 Nm
each.
5. Tighten the threaded connection (4) of the transverse thrust piece (3) with ⇒M = 150 ±
5Nm .
Tighten the thrust screw (6) with ⇒ M = 130 ± 5 Nm.
Keep the transverse thrust piece (3) in position by means of a fork wrench (to avoid
damaging the individual connections).

6. Push the sleeve Hülse

(2) into the fuel *
injection pump so that
it engages.

7. Tighten the nuts of the

nozzle holder with the
specified tightening
torque.

March 2013 Caterpillar confidential: yellow 42

Transverse thrust piece

Projection (1) must not be less than 4.7 mm (e.g. when reworking the sealing face),
because otherwise the first thread pitch may abut against the pump casing. This may
cause the pretensioning force to drop below the required limit, which in turn may cause a
leak.

Injection pumps supplied from March 2000 are not affected by this problem, because an
undercut was then implemented on the pump casing.

Contact pattern check on inlet and exhaust valves

Using a syringe, evenly apply small dots of Dp 30/10-15
my diamond paste to the seat face of a new or refinished
valve cone. Thereafter, for reasons of dilution and to
increase the grip, spray the entire seat ring surface with
a thinner (F25) belonging to the diamond paste. Insert the
oiled valve stem into the guide bush. Fasten the device
on the valve head and grind the valve cone and seat by
hand for a short time turning the device back and forth
while applying a moderate pressure.

The percentage contact area a made visible through

the smooth grinding process shall, over the entire circumference, not exceed 30 - 50 % of
the seat width starting from the outside diameter. If a bearing pattern as described above
is not reached, remachining of both sealing faces is required.

After machining check both seats by means of an illuminated magnifying glass. Round off
the outside edge with a stone after machining.

Valve rotators
MDO operation: On inlet and exhaust valves

HFO operation: On inlet and exhaust valves

March 2013 Caterpillar confidential: yellow 43

Valve spindles

Observe the dimensions and angles indicated in the sketches. The valves are identified
by variant identifications (e.g. 25-19, 25-02 ...) on the circumference of the stem end. The
table below shows dimension Y in new condition and as wear limit dimension, each
measured at reference diameter X. Measure dimension Z (height of the hard facing). The
height of the hard facing on inlet and exhaust valves must be at least 1 mm .

Reference Dimension Y Dimension Y

Variant (new condition) (wear limit)
diameter X
25-01 79.5 - 0.1 mm 8.03 mm -0.4 mm 7.2 - 0.1 mm
25-02 79.5 - 0.1 mm 8.03 mm -0.4 mm 7.2 mm
25-03 79.5 - 0.1 mm 8 mm +0.1 mm -0.3 mm 7.2 mm
25-05 79.5 - 0.1 mm 8.1 mm -0.4 mm 7.2 mm
25-19 79.5 - 0.1 mm 8.03 mm -0.4 mm 7.2 mm
25-20 79.5 - 0.1 mm 8.03 mm -0.4 mm 7.2 mm
25-22 79.5 - 0.1 mm 8 mm -0.4 mm 7.2 mm

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Inlet valve 25-01 Inlet valve 25-19

Reference diameter

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

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

Reference diameter

Exhaust valve 25-03

Reference diameter

March 2013 Caterpillar confidential: yellow 45

Radial runout
Radial runout on the valve stem must not exceed 0.05 mm over the measuring distance
S of 264 mm.
Radial runout on the valve cone must not exceed 0.025 mm.
For both measurements the valve spindle must rest on points A and B of the measuring
device.

Valve spindles cannot be used any further when:

1. There is severe pitting on the bottom side of the valve
head (formation of so-called “paving stones),
2. There are corrosion pits and mechanical damage in
the area of valve stem, stem transition, and valve
head,
3. The limit for refinishing has been exceeded,
4. There is corrosive material erosion of 2 % of the valve
head diameter;
5. There is high-temperature corrosion S on the bottom of
the valve head of 1.50 mm.

Valve projection
Due to valve and valve seat wear the valves are “growing” out of the cylinder head.
Therefore, in order to determine possible premature wear upon
• commissioning
• installation of new or overhauled cylinder heads, and
• replacement of valve spindles and seats
• and every 1,500 operating hours thereafter
measure the valve heights by means of a depth gauge and enter the measured values
on the “Valve Projection” measuring sheet.

The warning threshold/limit for valve projection on engines operated with distillate fuels
is 2.5 mm - 3.5 mm.

March 2013 Caterpillar confidential: yellow 46

Installation of valve seat rings

1. Cool the valve seat rings down to -195 °C with liquid
nitrogen. As an alternative (if necessary), cool the
valve seat ring down to at least -20 °C and heat up the
cylinder head to 130 °C to 140 °C .
2. After heating up and before putting in place the valve
seat rings apply a thin coat of Molykote paste G to the
exhaust holes.
2. Insert the inlet and exhaust valve seat rings.,
3. When the valve seat rings are firmly inserted, press them on with the pressing device.

Pressing force for the hydraulic device ⇒ F = 65 kN

4. Check the contact surface Y2: No air gap is admissible between the inlet valve seat ring
and the cylinder head.
5. Check the air gap Y1 between the exhaust valve seat ring and the cylinder head:
Admissible air gap: 0.40 + 0.50 mm.
Pressure test: 10 bar for cooling water chambers, maintain the pressure for 8 minutes
(with water and ESSO Rustban 310 anticorrosion oil).

Refinishing of the valve seat rings

Maximum admissible dimension Ø X for refinishing the exhaust valve seat
rings is 92.00 +0.20 mm and on the inlet valve seat rings 85.00 + 0.20 mm.
At a no material removal is permissible.

Exhaust valve seat ring Inlet valve seat ring 30.5° ± 30‘
30.5° ± 30‘

Refinishing can be done with an MaK valve seat refacing machine or an MaK valve
reseating tool.
After grinding there shall be a contact area of 30 - 50 %, starting from the outside diameter.

March 2013 Caterpillar confidential: yellow 47

Oversize steps for valve seat rings and valve guides

INLET VALVE SEAT RINGS

Oversize to Valve
Hole size (if required)
nom. dim. seat ring

Ø D1 a1 Ø mm
mm Variant Notes
+ 0.02 + 0.2 - 0.01

0.0 (89) (42.5) (89.08) -XX

Oversize step for
0.5 89.5 42.7 89.58 -21 manufacture
1.0 90 42.7 90.08 -22
0.5 89.5 42.7 89.58 -23 flow optimised
1.0 90 42.7 90.08 -24 flow optimised

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EXHAUST VALVE SEAT RINGS

Valve
Hole sizes in the cyl.
(if required) seat
head
ring

Ø D2 Ø D3 Ø D4 b1 Ø mm
Variant Notes
+ 0.02 + 0.2 + 0.02 + 0.2 - 0.01

(93) (84.5) (83) (35.5) (93.09) -XX

Oversize step for
93.5 85 83.5 35.7 93.59 -21 manufacture
94 85.5 84 35.7 94.09 -22

March 2013 Caterpillar confidential: yellow 49

VALVE GUIDES

Hole sizes in the cyl.

Guide bush
head

Ø d1 Ø d2 Ø mm Guide bush
Notes
H6 - 0.01 Drawing number

(34) (35) (34) XX

-04 (exhaust) Oversize step
26.5 27.5 26.5 -03 (inlet) for manufacture
-06 (exhaust)
27 28 27 -05 (inlet)

March 2013 Caterpillar confidential: yellow 50

Piston
Composite piston 2500.7-26.70.00-01 / -02 / -03 / -04 / -05 / -06

Lubricate thread and contact surfaces with Molykote paste G-n-plus.

Tighten the screws crosswise with ⇒ M = 60 Nm
Loosen the screws again.
Pretighten the screws crosswise with ⇒ M = 25 Nm
and finally tighten with ⇒ Dw = 60°

Check: When applying a torque of ⇒ M = 45 Nm

the nuts must not turn any further.

Gap X
2500.7-26.70.00-01 / -02 / -04 / -06 ⇒ 0.06 - 0.10 mm

2500.7-26.70.00-03 / -05 ⇒ 0.07 - 0.11 mm

Installation
Arrange the ring joints so that every other joint points to an alternate end of the engine.
Then, oil pistons and piston rings well.
Install the piston rings with the marking pointing upwards.

Measure gap X here,

screws not
tightened.

March 2013 Caterpillar confidential: yellow 51

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

Ring groove Ring Ring drawing number

1 Rectangular ring 2500.7-26.17.01-01

2 Taper-faced ring 2500.7-26.17.01-02
3 Bevelled-edge oil control 2500.7-26.17.01-03
ring

Min. Max. Clearance limit

clearance clearance
Piston bosses - 0.050 0.078 0.100
Piston boss distance -
0.500 1.100 1.300
small end bush width

Piston 2500.7-26.70.00-07 IMO2 350 kW

Screw studs with ⇒ M = 39 Nm
into the crown.

Lubricate thread and contact surfaces of

the nuts with Molykote paste G-n-plus.

Tighten the nuts crosswise with ⇒ M = 47 Nm

Loosen the nuts again.

Check proper fit of the studs in the crown applying ⇒ M = 39 Nm

Pretighten the nuts crosswise with ⇒ M = 15 Nm

and continue turning by ⇒ Dw = 90°

Check: When applying ⇒ M = 38 Nm

in tightening direction the screws must not turn any further.

Clearance between piston crown and skirt:

(screws not tightened) ⇒ 0.07 - 0.11 mm

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Anti-polishing ring removal

1. Bar the engine so that the piston top
edge is below the anti-polishing ring.

2. Place the removal device on the

piston so that the recess is inside the
anti-polishing ring.

3. Slightly tighten the removal device by

turning the spindle nut (1).

4. Press out the anti-polishing ring by

barring the piston upwards.

Wear limits and limit clearances of the ring grooves

Piston ring height

Groove
hR Groove height Limit clearance
Groove height
Nominal dimension hN2 Wear limit hN2 - hR
hN1 mm
mm

1 6.15 +0.03* 6 6.45 mm 0.50 mm

2 6.13 +0.03* 6 6.45 mm 0.50 mm

3 8.06 +0.03* 8 8.20 mm 0.30 mm

hN1 = dimension in new condition

hN2 = wear dimension

March 2013 Caterpillar confidential: yellow 53

* Variants 2500.7-26.70.00-01 and -02

Weight tolerance when replacing connecting rod / piston

In order to avoid any unbalance, the masses of piston / connecting rod must not differ
excessively between the individual cylinder units.
For tolerance data please refer to chapter “Connecting Rod”, paragraph “Weight tole-
rance when replacing connecting rod / piston”.

March 2013 Caterpillar confidential: yellow 54

©
2012 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Connecting Rod c2
M 25 Connecting rod

Connecting Rod
Evaluation of bearings
Refer to the General Part of the Engineer’s Handbook for the evaluation of bearings.

Big end bearing

1. Tighten the upper big end bearing bolts one after the other with⇒ M = 150 Nm
2. Tighten the upper big end bearing bolts one after the other up to⇒ M = 300 Nm
3. Tighten the lower big end bearing bolts one after the other with⇒ M = 150 Nm
4. Tighten the lower big end bearing bolts one after the other up to⇒ M = 300 Nm
5. Tighten the upper big end bearing bolts one after the other up to⇒ M = 600 Nm
6. Tighten the lower big end bearing bolts one after the other up to⇒ M = 600 Nm
7. Tighten the upper big end bearing bolts
once again one after the other with ⇒ M = 600 Nm

Coat the threads and contact surfaces with a thick layer of Molykote G Rapid Plus.

Reference dimension B
Reference dimension A

Cylinder No. here

Lower bolts Cylinder No. here

Upper bolts

Reference dimensions of the big end bearings after proper tightening

(Dimensions are applicable with fitted bearing shell measured in the bearing inside diam-
eter with completely assembled connecting rod). Do not measure in the joint area of the
bearing shells. Measure dimension B 10 degrees (or 17 mm on the circumference) away
from the joints of the bearing shells in clockwise direction.

DimensionA ⇒ 193.16 + 0.05 mm

Dimension B ⇒ A + 0.04 + 0.01 mm

The reference dimension of the small end bush

after freeze fitting is Ø ⇒ 120.11 + 0.08 mm

Freeze fit the small end bush with ⇒ < -160 °C

bush temperature.

March 2013 Caterpillar confidential: yellow 55

Big end bearing for connecting rod variant 2500.7-28.10.00-50 (Dragonfly)

Coat the threads and bolt head contact surfaces with Molykote G Rapid Plus.

1. Tighten the short big end bearing bolts in two steps

one after the other with ⇒ M = 300 Nm
2. Tighten the long big end bearing bolts in two steps
one after the other with ⇒ M = 300 Nm
3. Tighten the short big end bearing bolts one after the other with ⇒ M = 600 Nm
4. Tighten the long big end bearing bolts one after the other with ⇒ M = 600 Nm
5. Tighten the short big end bearing bolts
once again one after the other with ⇒ M = 600 Nm

Cool the small end bush down to -160 °C for fitting.

Marking
The connecting rods are marked with engine number and cylinder number. Upon assem-
bly make sure that the connecting rods are installed at the designated locations.

Weight tolerance when replacing connecting rod / piston

In order to avoid any unbalance, the masses of piston / connecting rod must not differ
excessively between the individual cylinder units.
To determine the mass per cylinder unit weigh the piston together with the connecting rod
(without piston rings and without big end bearing).
Permissible weight deviation within a set for one engine: 1100 g
When installing piston and connecting rod distribute them in such a way that the weights
are increasing in the following cylinder sequence:
6 M 25: 5 2 1 6 4 3
8 M 25: 6 3 5 1 8 2 7 4
9 M 25: 1 9 8 2 7 3 6 4 5

March 2013 Caterpillar confidential: yellow 56

Small end bush

Min. clearance Max. clearance Clearance limit

Piston bosses ∅ (A)

0.050 0.078 0.100
Piston pin ∅ (C)
Small end bush ∅ (B)
0.110 0.2 0.22
Piston pin ∅ (C)
Boss distance (D)
0.500 1.100 1.300
Bush width (X)

The service life limit of the small end bush is 60,000 hours.

Note:
Oversize bushes may only be used after consultation with VT5 and by submitting photos
and measuring values of the small end bush bores!

March 2013 Caterpillar confidential: yellow 57

©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Cylinder Liner c2
M 25 Cylinder liner

Cylinder Liner

Wear limits
Nominal dimension Ø (dim. in new condition) ⇒ 255.00 + 0.052 mm
Wear value TDC 1st ring ⇒ 0.90 mm

Max. ovality ⇒ 0.25 mm

Permissible wedge shapes, canyons, score marks, and pockets

Wedge (wedge-shaped indentation over the entire circumference, originating from

TDC of 1st piston ring and extending downward)
Height ⇒ 6.00 mm
Depth* ⇒ 0.03 mm

Canyons (individual deep blow-by grooves in the area of the 1st piston ring (TDC))
Max. number ⇒ 3
Length ⇒ 150.00 mm
Total width ⇒ 0.03 mm

Score marks (severe vertical, linear friction marks)

Number ⇒ 3
Length ⇒ 150.00 mm
Depth ⇒ 0.03 mm

Pockets (areal, irregular indentations)

Number ⇒ 3
Length ⇒ 60.00 mm
Width** ⇒ 20.00 mm
Depth * ⇒ 0.02 mm

* Probe radius r > 3 mm

** In circumferential direction

March 2013 Caterpillar confidential: yellow 58

Pocket Score TDC 1. ring

mark
Wedge shape Canyon

Installation
During installation make sure that marking (1) of the cylinder liner coincides with marking
(2) of the cooling collar.
The cylinder liner must slide into the engine block by its own weight.
Caution!
A wrongly inserted liner may cause extensive damage.

March 2013 Caterpillar confidential: yellow 59

Crankshaft
Evaluation of bearings
Refer to the General Part of the Engineer’s Handbook for the evaluation of bearings.

Tightening torques for bearing caps

Note: The bearing guide grooves are located on the right-hand side (operating side).

Screw in studs (1) with ⇒ M = 450 Nm

Molykote
Do not damage the stamps and numbers when inserting the studs.

Tighten the crankshaft bearing nuts (2) evenly by hand.

Insert hexagon bolts (3) with Molykote and tighten them alternately in three steps starting
from the right side (operating side).

1st step up to ⇒ M = 140 Nm

2nd step up to ⇒ M = 420 Nm

3rd step up to ⇒ M = 670 Nm

Stretch the studs (1) by means of the hydraulic device with ⇒ P = 980 bar
at a piston area of ⇒ A = 66 cm2
and tighten the crankshaft bearing nuts (2) with a
pin; pay attention to ease of movement.
Tighten both crankshaft bearing nuts of one bearing block in one operation!

Check: Decrease the pressure to ⇒ P = 930 bar

Loosening of the nuts must not be possible any more.
Note:
The pressure must remain constant when the pump is not actuated, otherwise there will
be a tightening fault.

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Measurement of the gap

1. Remove the hexagon bolts (3) of the crankshaft bearing. Loosen the hexagon bolts (3)
of the adjacent crankshaft bearings.

2. Loosen both crankshaft bearing nuts (2) of one bearing block in one operation.

3. Tighten the crankshaft bearing nuts alternately and evenly by means of a pin until the
joint faces of the bearing shells just touch each other.

4. Determine the projecting length of the bearing shell by measuring the gap between
engine block and bearing cap on operating side and exhaust side.

Gap total ⇒ 0.75 - 1.00 mm

After longer operation the total must not be less than ⇒ 0.60 mm

Dimension between bearing point 2 and web (crankshaft) ⇒ 2+1 mm

Markingof the crankshaft bearings

Bearing caps and bearing shells are mar-
ked on the operating side with the
Stamp bearing
respective cylinder numbers, starting number here
The locating lug of the
from the driving end. It is not allowable to bottom shell is on the
interchange the parts. operating side

March 2013 Caterpillar confidential: yellow 61

Locating bearing
Locating and normal bearings are identical. For
axial fixation at bearing 1 (locating bearing)
thrust washers (1) with spring dowel pins (2)
are fitted to the bearing cap (3).

End clearance (new) ⇒ 0.30 - 0.60 mm

Limit clearance ⇒ 0.80 mm

Inserting the set screws

For inserting the set screws (1) degrease
the threads, insert the set screws with
Loctite 270 and secure with a center
punch.

Limit dimensions of the crankshaft

bearing shells
The first measurement of the crankshaft bearing shells is carried out on the bearing
subjected to the highest load. The bearings subjected to highest load are:
6 M 25: Bearing 4
8 M 25: Bearing 5
9 M 25: Bearing 6
Measure the wall thickness in the main load area at measuring points (X).
Dimension in new condition ⇒ 5.905 - 0.02 mm

Limit value ⇒ 5.84 mm

If the limit value is reached, also check all other crankshaft bearings.

March 2013 Caterpillar confidential: yellow 62

Balance weight installation

Pretighten the screws with ⇒ M = 100 Nm
and then finally tighten with ⇒ Dw = 120°
Apply Molykote G-Rapid to threads and contact surfaces.

Contact pattern of the balance weight surface

Contact area absolutely required

Contact area permissible only in

combination with

No material build-up permissible

6 M 25: 12 balance weights

8 M 25: 12 balance weights:

Crank pin 1 2 pcs.
Crank pin 2 1 pc. left *
Crank pin 3 1 pc. right *
Crank pin 4 2 pcs.
Crank pin 5 2 pcs.
Crank pin 6 1 pc. left *
Crank pin 7 1 pc. right *
Crank pin 8 2 pcs.

9 M 25: 12 balance weights:

Crank pin 1 2 pcs.
Crank pin 2 1 pc. left *
Crank pin 3 none
Crank pin 4 2 pcs.
Crank pin 5 2 pcs.
Crank pin 6 2 pcs.
Crank pin 7 none
Crank pin 8 1 pc. right *
Crank pin 9 2 pcs.

* = seen from operating side

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Alternative manufacture of the M27x2 threads for fitting the balance weights

Glue with Loctite 275

Secure against rotation with set

screw M5x8 (DIN 913).
Glue with Loctite 648.

Before inserting the threaded bush:

- Measure the core diameter for the M38x1.5 thread in the shaft and document the result
on the measuring sheet
- Measure the M38x1.5 flank diameter with a two-ball gauge in the shaft and on the bush
and document the result
- Measure the outside diameter for M38x1.5 on the bush and document the result
- Check the M38x1.5 thread in the shaft with a mandrel and carry out a visual inspection
- Have the M38x1.5 thread accepted by the local surveyor through a visual inspection

After inserting the threaded bush:

- Measure the distance of the bush from the surface

- Check the M27x2 thread in the shaft with a mandrel and carry out a visual inspection
- Measure the core diameter for the M27x2 thread and document the result on the
measuring sheet
- Measure the M38x1.5 flank diameter with a two-ball gauge and document the result

Dimensions to be checked Desired value

Core diameter in the shaft M38x1.5 36.38 + 0.3

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

March 2013 Caterpillar confidential: yellow 64

Crank web deflection

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

Cylinders subjected to additional load (normally

cylinder 1, on account of the flywheel, and last cylinder
if power is actually taken off at the free end.) ⇒ 0.05 to - 0.11 mm

Vibration damper

Note: Maintenance intervals and replacement deadlines

are specified in the maintenance plan of the operating
instructions.

For installation and determination of the wear limits

please refer to the Geislinger instructions.

Clean the contact surfaces of all parts (free of oil and

grease).
Tighten screws (1) with the torque indicated in the table
below. Apply Molykote to the thread and Loctite 275 to
both sides of the disc springs. In case of damper D 90/
39 use Loctite 243 . If no torque is specified, tighten the
screws with the pre-torque moment: First tighten the
screws without pre-torque moment until the disc spring
rests flatly. Then continue to turn by the torque angle.

Pre-torque +
Damper Engine Tightening torque
torque angle

D 79/7 6 M 25 210 Nm
D 90/37 8 M 25 726 Nm
D 90/39 9 M 25 40° + 5°
D 90/48/M* (ex D90/CZ/X1) 6 M 25 553 Nm (+10% permis-
E sible)
D 90/48 (ex D90/CZ/X1) 6 M 25 553 Nm (+10% permis-
E sible)

* Measuring damper, installed in cost unit 297103 only

March 2013 Caterpillar confidential: yellow 65

Vibration damper installation without power take-off

Pretighten screws (1) with ⇒ M = 250 Nm
and finally tighten with ⇒ Dw = 90°
Apply Molykote to thread and screw head contact surfaces.

6 M 25 - 10 studs
8 M 25 - 12 studs
9 M 25 - 14 studs

Screw arrangement Screw arrangement Screw arrangement

6 M 25 8 M 25 9 M 25

March 2013 Caterpillar confidential: yellow 66

Vibration damper installation with power take-off

Pretighten screws (1) with ⇒ M = 250 Nm
and finally tighten with ⇒ Dw = 90°
Apply
Molykote to thread and screw head contact surface.

Note:
In case of power take-off at the free end of the engine, pay particular attention to crank
web deflection of the last cylinder.

Tighten screws (M12) with ⇒ M = 60 Nm

Molykote
Tighten screws (M16) with ⇒ M = 130 Nm
Molykote

For installation of support bearing please refer to chapter “Diesel Generator Set”

from 1,000 kW output

attached unit

up to 1,000 kW output
attached unit

Screw arrangement Screw arrangement

6 M 25 6 M 25, 8 M 25, and
with 10 studs 9 M 25

March 2013 Caterpillar confidential: yellow 67

Permissible rework dimensions Crankshaft

Main bearing journal Crank pin

Journal/pin diameter 240 mm 193 mm

1st undersize step 239.5 mm 192.5 mm
2nd undersize step 239 mm 192 mm
3rd undersize step --- 191 mm
4th undersize step 238 mm 190 mm
5th undersize step --- ---
6th undersize step 237 mm* ---
Tolerance for all values is h6.
* currently no bearing available

Surface hardness of the crankshaft

Hardness (HB)
Engine Drawing number
min. max.
2506.7-25.10.01-03 260 320
6 M 25
2506.7-25.10.01-04 265 325
2508.7-25.10.01-01 245 290
8 M 25
2508.7-25.10.01-02 265 325
2509.7-25.10.01-01 250 295
9 M 25
2509.7-25.10.01-02 280 340

November 2015 Caterpillar confidential: yellow 68

©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Timing Gear Train c2
M 25 Timing gear train

Timing Gear Train

Note: When removing gear wheels position the centre of gravity of the gear wheel with
mounting device as precisely as possible under the crane hook and counterhold to prevent
sudden swivelling out of the gear wheel with mounting device.

Gear wheel on crankshaft

Caution! The following jobs are to be executed by qualified MaK personnel only!
Contact Parts Operations in Kiel to hire the required tools and qualified professionals.
Press gear wheel with hand pump, device, and
oil press fit via connection Z with ⇒ P = 500 bar
onto the crankshaft cone until final position is reached.
Final position is reached when the gear wheel rests against the
spacer.
The spacer simulates a locating bearing.
It must be adjusted in such a way that
a dimension of ⇒ 126 + 0.1 mm
is reached between gear wheel and thrust collar
of crank web of cyl. 1 when the gear wheel has reached final position.

The slide-on distance is ⇒ 12 - 3.5 mm

The device must remain in place for 20 minutes after releasing the oil press fit.
Engine start-up earliest 2 hours after releasing the oil press fit. In case of an emergency
the engine can be put into operation after 30 minutes with 60 % of its rated power output.
Spacer

Connection Z 1/4“

March 2013 Caterpillar confidential: yellow 69

Intermediate gear wheel installation

O-ring

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

Molykote paste G Rapid Plus
End clearance S min. ⇒ 0.30 mm
max. ⇒ 0.60 mm
Wear limit for S ⇒ 1.20 mm

Gap dimension Y

Gap dimension Y between shaft and tab washer:

Gap dimension Y min. ⇒ 0.30 mm
max. ⇒ 1.40 mm

Insert and check the expanders in the intermediate gear wheel shaft according to the
instructions of the manufacturer and with the tools and tests specified by the manufacturer.

Replacement of the bush in the intermediate gear wheel

Cool the bush down to -195 °C with liquid nitrogen and insert it.
Insert the bush into the intermediate gear wheel with a recession of 1 mm.
Reference dimension (bush inside diameter) after freeze fitting: 96.054 mm + 0.048 mm

March 2013 Caterpillar confidential: yellow 70

Camshaft gear wheel installation

Note: For installing the gear wheel on the
camshaft please also refer to paragraph
“Pre-lift and assembly reference
dimension“ in chapter “Injection Pump“.
1. The bearing journal (1) must not project into
the gear case.
2. Swing the camshaft gear wheel (2) into the
gear case with device 2103-1036.
3. Push the oiled journal until it contacts the
camshaft gear wheel cone.
4. Pre-assemble the helical gear wheel (or
thrust washer) (3) until it contacts the
camshaft gear wheel.(Pay attention to
mounting position, see next page).
5. Mount the camshaft gear wheel until it
contacts the end stop on the bearing journal
cone with the oil press fit by evenly
tightening screws (4).
Final position: Helical gear wheel (or thrust
washer) (3) pulled against bearing journal (1).
Pressing liquid: Hydraulic oil
Do not start the engine earlier than 2 hours
after releasing the press fit.
Caution!
When installing the helical gear wheel (3)
pay attention to the position of hole (7):
Cylinder 1 (on some 8 M 25 engines: cylinder 2) and fuel delivery ramp of the injection cam
must be at TDC position (for IMO check).
Slide-on distance ⇒ 10.5 mm - 2.9 mm
Hydraulic oil pressure with hand pump ⇒ P=
approx. 1200 bar
Tighten screws (4) evenly with ⇒ M = 130 Nm
Molykote G Rapid Plus
End clearance for M 25 engines at (6) ⇒ 0.30 - 0.70 mm
End clearance for M 25 C engines at (6) ⇒ 0.30 - 0.80 mm

Tighten screw plug (5) with ⇒ M = 195 Nm

Molykote G Rapid Plus
Tighten the screw plug M12x1.5 in the cover (8) with ⇒ M = 25 Nm
Oil (no illustration, only for engines featuring an incline)

March 2013 Caterpillar confidential: yellow 71

Screw the screw plug (2) into the

disc (1) and tighten it with ⇒ M = 150Nm
Molykote
Tighten screws (4) with ⇒ M = 130Nm
Molykote

Backlash values
Crankshaft gear wheel - intermediate gear wheel: 0.23 -
0.35 mm
Intermediate gear wheel - camshaft gear wheel: 0.23 -
0.35 mm
Check the gear flanks visually. In case of a suspicious
contact pattern measure the backlash.
Otherwise, a measurement of the backlash between
crankshaft and intermediate gear wheel is only required after replacing the crankshaft.
A measurement of the backlash between the intermediate and the camshaft gear wheel is
only required after carrying out work on the camshaft or replacing the camshaft bearings.

Lubricating oil nozzles for timing gear train

Tighten the screws with ⇒ M = 160 Nm

The arrows show the correct spraying direction of the lubricating oil nozzles.

Camshaft gear wheel

Intermediate gear wheel

Crankshaft gear wheel

March 2013 Caterpillar confidential: yellow 72

©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Governor Drive c2
M 25 Governor drive

Governor Drive

Governor drive, old design

Pretighten the castle nut (1) with ⇒ M = 30 Nm
then continue to tighten until reaching the next
split pin hole. Molykote

End clearance at (2) ⇒ 0.30 - 0.60 mm

Mount governor bracket (3) and cover (8) with liquid sealing compound (Hylomar).

Backlash at (4) ⇒ 0.15 - 0.50 mm

Before freeze fitting heat the coupling bush (5) up to ⇒ +50 °C

Cool the governor drive shaft (6) down to ⇒ -195 °C
with liquid nitrogen and freeze fit it in the coupling bush (5).

After freeze fitting:

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

March 2013 Caterpillar confidential: yellow 73

Bushes in the engine block

32
When replacing bushes (1) and (2) in the

8
engine block, keep the dimensions indicated
in the sketch. Before pressing-in lightly oil the
bushes, do not use Molykote.

302
335
Governor drive, new design

Cool the governor drive shaft (5)

down to -195 °C and heat the gear wheel (3)
up to +40°C for shrink fitting.

End clearance at a is 0.20 + 0.30 mm

Tighten the screw plug (8) for closing the opening

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

March 2013 Caterpillar confidential: yellow 74

Heat the gear wheel (2) up to +150 °C

for shrink fitting. Cool the intermediate
shaft (4) down to -195 °C with liquid
nitrogen. Heat the intermediate gear
wheel (6) up to +70 °C for shrink
fitting.

Clean and degrease the sealing

faces of the sealing caps (20) and the
corresponding holes. Lubricate the
sealing faces of the sealing caps with
Loctite 270. Use the provided drive-
in mandrel for installation. The
sealing cap edges must be located
1.5 ± 0.5 mm deep in the casing (1).

End clearance at c ⇒ 0.20 + 0.20 mm

Reference dimension d ⇒ 37 ± 0.5 mm

Reference dimension e ⇒ 101.1 ± 0.3 mm

When installing the governor drive pay attention to the backlash⇒ 0.25 + 0.15 mm
between intermediate gear wheel (6) and
camshaft gear wheel (not shown).

In case of a discrepancy, insert a spacer of appropriate thickness between governor drive

casing and engine block. Apply liquid sealing compound to both sides (casing (1) and
spacer).

Insert expander (7) according to the instructions of the manufacturer and with the tools and
tests specified by the manufacturer.

March 2013 Caterpillar confidential: yellow 75

Camshaft
Flange indexes
Before assembling the camshaft provide the camshaft flanges with one parallel pin each
according to the following table. Press in the parallel pins at the corresponding flange
indexes up to limit stop.

6 M 25, 6 M 25 C, 6 M 25 E

Section - cylinder 1 2 3 4 5 6
Flange index 5 1 6 5 3 7

8 M 25, 8 M 25 C, 8 M 25 E

Section - cylinder 1 2 3 4 5 6 7 8
Flange index 1 or 2 2 3 4 5 6 7 8

9 M 25, 9 M 25 C, 9 M 25 E

Section-cylinder 1 2 3 4 5 6 7 8 9
Flange index 5 8 2 6 4 4 6 2 8

Camshaft assembly
Tighten the screws (1) with ⇒ M = 140 Nm
Molykote
Tighten the screws (2) with ⇒ see chapter “Timing Gear Train“,
section “Camshaft gear wheel“

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

Flange index X
Position of parallel pin
(see table)

March 2013 Caterpillar confidential: yellow 76

Adjusting the camshaft

For adjusting the camshaft please refer to section “Camshaft adjustment instruction“
in chapter “Lower Valve Drive“.

Radial runout
Measure the radial runout of the camshaft in the preassembly device at all bearing sup-
ports (X) of the preassembled camshaft. Max. radial runout 0.04 mm.

Vibration damper installation 6 M 25 / 8 M 25

(Variant 2500.7-31.40.00-03)
Tighten 8 screws (1) (M14x65-10.9) with extension sleeves with ⇒ M = 140 Nm
Molykote paste G Rapid Plus
Tighten screws (2) (M12x70-8.8) with ⇒ M = 50 Nm
Molykote paste G Rapid Plus

Check whether extension sleeves N6003 15x24-8 are still used for screws (1). These
extension sleeves will work into the material when tightening the screws (1).
Therefore, change over to new extension sleeves N6003 15x30-8.

Hole arrangement Hole arrangement

for 6 M 25 for 8 M 25

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Vibration damper installation 9 M 25

(Variant 2500.7-31.40.00-05)

Tighten screws (4) (M12x70-8.8) with ⇒ M = 50 Nm

Molykote paste G Rapid Plus
If dimension X = 23 mm:
Tighten 8 screws (3) (M14x65-10.9) with extension sleeves with )⇒ M = 140 Nm
Molykote paste G Rapid Plus
If dimension X = 38 mm:
Tighten 8 screws (3) (M14x80-10.9) with extension sleeves with )⇒ M = 140 Nm
Molykote paste G Rapid Plus
or (new):
Tighten 8 screws (3) (M14x75-10.9) with washers with ⇒ M = 140 Nm.
Molykote paste G Rapid Plus
Caution!
When carrying out work on this vibration damper check whether screws (3) are of property
class 8.8. If so, replace them by corresponding screws of property class 10.9 with washers
and tighten these with 140 Nm.

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Vibration damper installation 9 M 25

(Variant 2500.7-31.40.00-04)

Tighten screws (4) with ⇒ M = 50 Nm

Molykote
Tighten screws (3) (M14x60-8.8) with ⇒ M = 85 Nm
Molykote

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Camshaft bearings
Tighten the locating screws (1) for the camshaft bearing shells with ⇒ M = 100 Nm
Molykote

Measure the camshaft bearing clearance between

bearing shell and bearing journal with a feeler
gauge.
Clearance in new condition: ⇒ 0.20 - 0.26 mm
Limit clearance: ⇒ 0.35 mm
When the limit clearance is reached or exceeded,
check the camshaft bearing clearance of all camshaft
bearings.

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Camshaft bearings of M 25 C / M 25 E
Camshaft bearings according to the new M 25 C / M 25 E engine structure with bearing
shell variant 2500.7-31.91.01-03:

Tighten the locating screws (5) for the camshaft bearing shells with ⇒ M = 130 Nm
Molykote paste G Rapid Plus

Align the locating hole of the bearing shells (1) with respect to the thread in the engine
block.
The notch at (Z) (if existing) on the face end of the bearing shell points towards the top
plate of the engine block.
Screw the pin of the locating screws (5) completely into the bearing shells.

Driving end Centre of

camshaft

Evaluation of bearings
Refer to the General Part of the Engineer’s Handbook for the evaluation of bearings.

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Starting Air Distributor

Adjustment instruction for starting air distributor

1. Move the piston of cylinder 1 to firing TDC.

2. Loosen the nut (1)
3. Turn disc (2) on the shaft cone in the indicated direction until the slot of the disc just
about intersects with the corresponding hole (cylinder 1) in the mirror. The intersection
with the bore of the preceding cylinder should be roughly the same. (Take into account
the sense of rotation of the engine).
4. Tighten the nut by hand.
5. Fasten the shaft (3) in a vice (soft jaws)
and tighten the nut with ⇒ M = 30 - 40 Nm
Molykote
6. Before assembly check the position of shaft and disc

Tighten screws (4) (M8x50 8.8) with ⇒ M = 17 Nm

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

Right
Cylinder 1

Left

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©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Lower Valve Drive c2
M 25 Lower valve drive

Lower Valve Drive

Assembly of valve drive for M 25:

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

Molykote

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

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

Determine the existing end clearance by

shifting the bearing brackets.

No clearance is admissible at the joints of the

cam follower shafts.

Loosen the bearing caps and push cam

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

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Assembly of valve drive for M 25 C:

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

Molykote

If existing, tighten screw plugs M22X1.5 (4) with ⇒ M = 85 Nm

Use a joint ring

End clearance at least ⇒ 0.10 mm

Installation of the sealing caps at the ends of cam follower shafts (3):
Make sure that the sealing faces of the sealing caps and the corresponding holes are
clean and free of grease. Lubricate the sealing faces with Loctite 270. Use the provided
drive-in mandrel for installation. The sealing cap edges must be located 2 ± 0.5 mm deep
in the cam follower shaft.

When replacing IMO shims (2) of any cylinder bar the engine until all rollers of the
respective cylinder unit are on the base circle of the camshaft. Then adjust as described
below under “Camshaft adjustment instruction“. Document the IMO shims for the
respective cylinder. Pay attention to the position of the shims.

During disassembly / assembly make sure that the respective IMO shims are not removed.
If the shims need to be removed, mark them with the corresponding cylinder number.
The thickness of the IMO shims of the individual cylinders is indicated in the acceptance
test record.

Base circle
Camshaft

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Assembly of valve drive with FCT (split bearing brackets without extension sleeves)
1. Start the assembly of the lower valve drive at the free end of the engine and proceed
towards the driving end. During assembly and removal of the valve drives of a cylinder
unit absolutely make sure that the individual parts of the cam follower bracket (8) are
kept together according to their marking. It is not admissible to interchange cam
follower parts with parts of other cylinder units!
2. Install the first cylinder unit.Tighten screws (1) for the bearing brackets finger tight.
3. After assembly of the first unit (free end) install the intermediate shaft (2). The
intermediate shaft can be shifted.
4. Install the next cylinder unit the same way.
5. Connect the cylinder units by means of the intermediate shaft(2). In doing so, pay
attention to the position of the cam follower shafts (3) and (4): The hole (ý8 mm) in the
cam follower shaft must be oriented vertically upward (see illustrations). Use a mandrel
for orientation. As an alternative to the position of the holes: End stop of the cam
follower shaft rests against stopper (5) (for last cylinder only).
6. Install all cylinder units.Tighten screws (1) for bearing brackets with 130 Nm and
Molykote starting from the centre of the engine and proceeding towards the outside
and check the cam followers for ease of movement. If necessary, loosen and realign
the cylinder unit.
7. Finally, install shims (6) with screws (7)as per drawing. Tighten screws (7) with 15 Nm
and Molykote. The shims must be located in the groove of the intermediate shaft (2).
Only this way proper fixation of the intermediate shaft is ensured.

During assembly pay attention

to the position of the holes
(all cylinders)

Caution:
Position of grooves: At the top

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Assembly of valve drive w. FCT (single piece bearing brackets w.extension sleeves)
Coat the threads and head contact surfaces of screws (11) and (15) with Molykote Paste
G Rapid Plus.
1. Start the valve drive assembly at the last cylinder (free end) and proceed towards the
driving end. Pretighten screws (11) for the bearing brackets with 20 Nm. Position of the
grooves on the bearing brackets: At the top.
2. Take into account the direction of rotation of the engine!
Turn the cam follower shaft to the specified position depending on direction of rotation.
The cam follower stopper X of the cylinder unit must rest against strap Y as shown in
the following views (depending on direction of rotation).
Tightening torque for stopper fastening screws (7): 45 Nm with Molykote Paste G
Rapid Plus.
Clockwise rotation - normal position: Counter-clockwise rotation - normal position:
Stopper “X”,
(engine inside) Strap “Y”

Strap “Y” Stopper “X”,

(engine outside)
3. Lubricate the toothed shaft (6) with oil and insert into the cam
follower shaft of the installed cam follower unit until reaching
the end stop, see figure A1 on the right.
4. Install the subsequent valve drive and pretighten the screws
(11) for the bearing brakkets with 20 Nm.
5. Turn the cam follower shaft with a mandrel to the specified
position depending on direction of rotation (see sectional A1
drawings B1 - B1:
Clockwise rotation Hole position at the top
(normal position)
B1 - B1

Counter-clockwise rotation
(normal position)
Hole position at the bottom

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6. Connect the cylinder units by shifting the oil

A-A
lubricated toothed shaft (6), see sectional
drawing A - A.

7. Install the tab washer (5) with screws (15

and extension sleeves (17) and tighten the
screws (15) with 15 Nm. Make sure the
toothed shaft is correctly positioned!

8. Lubricate the next toothed shaft (6) with oil

and insert it into the last installed valve
drive until reaching the end stop, see figure
A1 on the previous page.

Caution!
Tab washer (5) must be positioned
in the shown groove in
the intermediate shaft!
Check required!

9. Install the subsequent valve drives, in line with items 4 to 8.

Caution:
Only cylinder 2 with tab washers on both sides; no tab washer at cylinder 1!

10. After assembly of all valve units check the positions of the cam follower shafts and
tighten the screws (11) with 130 Nm.

11. Check the end clearance Sat the first, second, and last cylinder: min. 0.2 mm.
Check the cam followers for ease of movement.
If necessary loosen, realign, and retighten the cylinder units.

Apply a thin coat of Petro Gel Amber to all O-rings.

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Adjusting unit: Note regarding removal

Before removing the FCT adjusting unit the spring

(3) must be relieved by evenly loosening the nuts
(4)!

Adjusting unit: Assembly for M 25 C

for counter-clockwise and clockwise rotation

1. Preparation of the valve drive:

1.1 Check the position of the cam follower shafts with respect to each other; all eccentrics
of the cam follower shafts must point in one direction (mandrel, Ø 8 mm).

1.2 Adjust the cam follower shaft:

Engine turning counter-clockwise:

Turn the cam follower shafts of the lower valve drive so that the end stop at cylinders
6, 8, 9 points upward. This corresponds to “Normal” position.

Engine turning clockwise:

Turn the cam follower shafts of the lower valve drive so that the end stop at cylinders
6, 8, 9 rests on the inside. This corresponds to “Normal” position.

1.3 Fix the position of the end stop at cylinders 6, 8, 9 by means of a vice or a similar tool.

2. Preparation of the adjusting unit:

2.1 Remove the sheet claddings of lever and spring.

2.2 Relieve the spring (3) by evenly loosening the nuts (4) (see also section above:
„Adjusting unit: Note regarding removal“).

2.3 Move the lever of the adjusting unit upward until the upper mechanical end stop in the
pneumatic cylinder is reached.

2.4 Move the piston rod 10 to 15 mm* away from the end position and mark the position
of lever and piston rod (auxiliary marking).

2.5 Check the basic position of the eccentric bearing caps: Align “0”-position with marking
on the casing.

2.6 Take up the adjusting unit in mounting device or another lifting device.

* These dimensions may be too big.

Check for reasons of safety whether both mechanical end positions are reached.

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3. Assembly of the adjusting unit:

Assemble the adjusting unit with hexagon screws (centering of the adjusting unit via 2
pins). When doing so, ensure proper engagement of the gear of the adjusting unit in
the gear of the cam follower shaft, if necessary by slightly turning the lever in both
directions at the moment of engagement. For this purpose, the lever may only be
moved max. ± 2° from its initial position (next tooth space between adjusting unit gear
and cam follower shaft gear).

4. Check of the adjusting unit:

4.1 Check the backlash between the adjusting unit gear and the cam follower shaft gear
(cap or screw plug for backlash check).
Backlash < 0.7 mm: Eccentric bearing at position “0” (minimum backlash must not be
smaller than 0.21 mm).
Backlash > 0.7 mm: Eccentric bearing at position -1
If necessary, correct the backlash by turning the eccentric bearing caps (loosened on
both sides) correspondingly.
Caution! Only adjust to such an extent that the eccentric cap marking “-1” moves
around below (otherwise there is a risk of jamming).
4.2 Adjust the position of the lever on the adjusting unit to the auxiliary mark when starting
the assembly (see 2.4) of the adjusting unit.
Caution! The piston of the adjusting unit must not rest against the end positions of the
cylinder.
4.3 Check the connection positions of the hose connections between pneumatic
cylinder and 5/2-way valve depending on the direction of rotation of the engine:
Engine turning counter-clockwise: Hose connection with vent valve between connection 2
on the 5/2-way valve and lower connection on the pneumatic
cylinder.
Hose connection between connection 4 on the 5/2-way valve
and upper connection on the pneumatic cylinder.
Engine turning clockwise: Hose connection with vent valve between connection 2 on
the 5/2-way valve and upper connection on the pneumatic
cylinder.
Hose connection between connection 4 on the 5/2-way valve
and lower connection on the pneumatic cylinder.

Adjustment of the limit switches:

The limit switches are adjusted on the testbed when the engine is connected to the PLC
or when the PLC can process the signals of the limit switches.
5.1 Move the lever of the adjusting unit to “Normal” position (for engines turning counter-
clockwise: lever up, for engines turning clockwise: lever down).
Adjust the limit switch by turning the eccentric cap in such a way that the end position
can be safely detected.
5.2 Move the lever of the adjusting unit to “Early” position (for engines turning counter-
clockwise: lever down, for engines turning clockwise: lever up).
Adjust the limit switch by turning the eccentric cap in such a way that the end position
can be safely detected.

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6. Spring preload
6.1 Move the lever (2) of the adjusting unit to “Normal” position (for engines turning
counter-clockwise: lever up, for engines turning clockwise: lever down).
6.2 Preload the spring (3) by evenly tightening both nuts (4) until the clamp (5) rests on
the plate (6).
6.3 Install the claddings for lever and spring.

7. Durable marking of the lever on the adjusting unit for position identification later on
7.1 Engine turning counter-clockwise: Move the lever of the adjusting unit upward (to
“Lever up” position) until reaching the end stop of the cam
follower shaft.
Engine turning clockwise: Move the lever of the adjusting unit downward (to “Lever
down” position) until reaching the end stop of the cam
follower shaft.
Apply marking “P.N.” (normal position) on bearing cap and lever in accordance with
view V by means of an electric engraver or embossed figures (min. height 8 mm).

Engine turning counter-clockwise: Move the lever of the adjusting unit downward (to
“Lever down” position) until reaching the end stop of the
cam follower shaft.
Engine turning clockwise: Move the lever of the adjusting unit upward (to “Lever up”
position) until reaching the end stop of the cam follower
shaft.
Apply marking “P.E.” (early position) on bearing cap and lever in accordance with
view W by means of an electric engraver or embossed figures (min. height 8 mm).

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Position switches on the valve drive and FCT drive

Tighten position switches B1, B2, B4 with max. ⇒ M = 36 Nm

Distance dimension upon assembly of B4 is 9 mm.

The switching distance for B1 and B2 is 3 mm.
These values apply to both counter-clockwise and clockwise turning engines. The
illustrations below show an engine turning clockwise as an example.

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Camshaft adjusting instruction

for IMO engine version with shims, direction of rotation of the engine: Counter-clockwise
and clockwise.
Shims with ± 0.2 mm graduation corresponding to a change in crank angle of about ±
0.23°.

1. Adjust the assembly reference dimension according to drawing 2500.7-35.80.00-01 on

all cylinders by means of shims (see also paragraph “Pre-lift and assembly
reference dimension“ in chapter “Injection Pump“). The lower valve drive is
installed with a 2.0 mm basic shim.
2. Rotate the camshaft in direction of rotation of the engine until the injection pump of
cylinder 1 is at start of fuel delivery.
3. Loosen the camshaft gear wheel and bar the engine until the graduated disc on the
crankshaft indicates the value according to the engine adjustment (see chapter “IMO
Adjustment“) for cylinder 1. Block the camshaft gearwheel.
4. Bar the engine so that the other cylinders are at the same position and check the start
of fuel delivery (seechapter “Injection Pump“). Correct the start of fuel delivery on the
lower valve drive as follows only if required:
4.1 Unscrew the upper screws M16x120.
4.2 Unscrew the lower screws M16x120 only max. 3 mm.
4.3 Replace the shim (basic adjustment 2.0 mm).
4.4 If a subsequent check after replacement of the shims shows that the adjustment
with respect to cylinder 1 is not okay, readjust starting from step 2.
Starting with step 3 turn the camshaft again counter-clockwise/clockwise until all
cylinders
are within the tolerance range with respect to cylinder 1.
4.5 Install the lower valve drive.

Assembly step 4.1

Assembly step 4.3

Assembly step 4.2

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Cam follower
Cool down the ball sockets (1) or ball pieces (2) of the cam followers to -195 °C with liquid
nitrogen and press them in until reaching the end stop.

Cool the bolt (6) down to -195 °C with liquid nitrogen for installation in the cam follower.

Cool the bush (3) down to -195 °C with liquid nitrogen and press it in until it reaches the
end stop. Align the zero position of the scale with regard to the pin (10)

For inserting the headless screw M8x10 (13) grease the threads and insert the headless
screw with Loctite 243.

Push-rods
Variants 01 and 03:
Heat the push-rod tube (1) up to approximately 80 °C. Cool the ball socket (2) and ball
insert (3) down to -195 °C with liquid nitrogen. Assemble without locating blow. Risk of
cracking!

Variant -04:
Press in the ball socket (2) and ball insert (3) with ⇒ F = 80 kN

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©
2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
Injection Pump c2
M 25 Injection pump

Injection Pump

Note regarding the leak rate

Injection pumps are loosing lubricating oil during operation. This is due to their design and
operation, so that individual injection pumps may have a higher or a lower leak rate. The
max. limit at the collecting pipe is

Number of cylinders x 2.5 litres / 24 hours

Reuse of the leak oil is not possible because it is contaminated with HFO.

Tightening torques for PF1WX230V-C

Screw in the studs with ⇒ M = 120 Nm

Molykote
Tighten the fastening nuts with ⇒ M = 200 Nm
Molykote
Pretighten screws (1) with ⇒ M = 10 Nm
and then finally tighten with ⇒ M = 90 ± 3 Nm
Molykote-Multiglis
Tighten screws (2) with ⇒ M = 53 ± 2 Nm
Molykote-Multiglis
Tighten screws (3) with ⇒ M = 14 ± 1 Nm
Tighten screws (4) with ⇒ M = 22 ± 2 Nm
Molykote-Multiglis
Tighten screws (5) with ⇒ M = 85 ± 5 Nm
Loctite
Tighten screws (6) with ⇒ M = 155 Nm
Tighten M12 thread (7) for
pump transportation with max. ⇒ M = 20 Nm

Pay attention to
mounting position!

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Tighten screws (1) for the mixed oil drain with max. ⇒ M = 30 Nm
Tighten screws (2) with max. ⇒ M = 50 Nm
Tighten counter-sunk screws (3) for the
control travel indicator with ⇒ M = 3.50 ± 0.50 Nm

Mixed oil drain / leak fuel pipe

Screws (4) for mixed oil drain/leak fuel pipe:
Tighten flanges with elbow and hexagon (Y) with max. ⇒ M = 50 Nm
Tighten flanges with straight tube outlet (X) with max. ⇒ M = 40 Nm

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Tightening torques 0.00.6-43.13.00-27 (M 25 E)

Screw in studs (3) with ⇒ M = 120 Nm

Molykote

Tighten nuts (4) with ⇒ M = 200 Nm

Molykote

Tighten screws (6) with ⇒ M = 155 Nm

Tighten the M12 thread (7) with max. ⇒ M = 20 Nm

(for pump transportation).

Tighten screws (1) with max.⇒ M = 30 Nm

(mixed oil drain)

Tighten screws (2) with max.⇒ M = 50 Nm

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Removal and installation M 25, M 25 C, M 25 E

During removal / installation do not remove the respective spacer plates.
If for any reason the spacer plates have to be removed, mark them with the respective
cylinder number.
The thickness of the spacer plates for each cylinder is indicated in the testbed record.

Before installing the injection pump bar the engine until the roller of the cam follower rests
on the camshaft base circle.
Before installing the injection pump check the air passage sleeves for correct position in
the cooling collar.

Tightening torque of the studs in the engine block and of the fastening nuts see above,
paragraphs Tightening torques PF1WX230V-C and Tightening torques 0.00.6-
43.13.00-27 (M 25 E) respectively.

Stop cylinder
Degrease nut (1) and thread and secure with Loctite 243 .

March 2013 Caterpillar confidential: yellow 97

Fuel distributing and collecting Pipe

2 loose flange
Installation

1 loose flange
Installation

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

DIN933-M10x20-8.8 with ⇒ M = 20 + 5 Nm

Tighten screws DIN933-M10x30-8.8 with ⇒ standard

tightening torque

Tighten screw (3) with ⇒ M = 80 Nm

Loctite 542

Reference dimension a for all throttle tubes is ⇒ 3 mm

Fuel injector delivery pipe

Installation of the fuel injector delivery pipe is described in chapter “Cylinder Head“.

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Starting process
The engine starting process is controlled via the injection pumps.

Roller of cam follower on cam base circle Starting process is initiated

Pump plunger at BDC position

Control air inlet Beginning of

starting process
Pump plunger at TDC position Venting is initiated

Starting process Start of venting

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Pre-lift and assembly reference dimension M 25 E

Engine variant with eccentric, engine turning CCW or CW

1. Position of cam follower eccentric: vertically upwards.
2. If necessary, check the initial position of the adjusting device.
3. Determine dimension 24.6 mm (incl. 0.2 mm clearance) with device and adjust with
spacer plates (10) at all cylinders. Max. limit clearance of 0.6 mm permissible.
Deviation between spacer plate and measuring value max. 0.1 mm.

Top edge of engine block

Reference
dimension ∅ 25

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Pre-lift and assembly reference dimension M 25 C

Engine variant without eccentric, engine turning CCW or CW

1. Adjust the assembly reference dimension (determine 24.6 mm with device,

including 0.2 mm clearance, max. limit clearance of 0.6 mm permissible) with
spacer plates on all cylinders. Deviation between spacer plate and measuring
value max. 0.1 mm.

2. Rotate the camshaft in direction of rotation of the engine until the injection pump
of cylinder 1 is at start of fuel delivery.

3. Loosen the camshaft gear wheel and bar the engine until the graduated disc
indicates 10.5° +0,5° / -1,5° crank angle before TDC for cylinder 1. Block the
camshaft gearwheel.

Engine variant with eccentric, engine turning CCW or CW

1. Eccentric position: vertically upwards

2. Check the initial position of the adjusting device: adjusting lever horizontal

3. Steps 1 to 3 as above

Tighten nuts (1) with ⇒ M = 200 Nm

Molykote G Rapid Plus

Start of fuel delivery

Ignition
TDC

Start of fuel delivery

position

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Checking the start of fuel delivery

1. Remove the injection pump delivery valve.
2. Put on the dial gauge with extension.
3. Bar the engine so that the roller rests on the cam base circle and the TDC mark is
about 45° before the dead centre indicator.
4. Set the dial gauge to “0“, bar the engine in direction of rotation until the gauge
indicates 5 mm. (5 mm on the gauge correspond to 11° on the flywheel)
5. Check the dimension from TDC mark to dead centre indicator at the flywheel.

Adjustment of start of fuel delivery

1. Place the dial gauge with measuring device onto a level support with the adjusting
bush (dimension = 24.6 mm) and set the dial gauge to “0”.
2. Insert the measuring device into the injection pump hole in the engine block and
read the value off the dial gauge. The roller shall always rest on the cam base circle
(for versions with cam follower eccentrics the eccentric position has to be vertically
upward).
3. Displayed value = thickness of spacer plates.
The spacer plates are used for adjusting the pre-lift.
Available thicknesses:
2.10 mm 2.20 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm
2.80 mm 2.90 mm 3.00 mm 3.20 mm 3.40 mm 3.60 mm

4. Check: Dimension X for M 25 C IMO I engines: ⇒ 20.4 ± 0.05 mm

Dimension X for M 25 C IMO II engines: ⇒ 19.4 ± 0.05 mm
Caution!
Upon reinstallation of an
injection pump it is
imperative to use the
original spacer plate,
otherwise the IMO
certificate of the engine will
become invalid!
21

Reference dim. at BDC:

:24.4 ± 0.1 mm

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Adjusting the start of fuel delivery (FCT)

for counter-clockwise and clockwise engine rotation

1. Lower valve drive

1.1 Position of the miniature eccentric bush at the fuel cam follower of the lower valve
drive at “0 position” for all cylinders.

2. Adjust and check the cam follower shafts

2.1 Engine with clockwise rotation:
Adjust cam follower shaft to normal engine operation (full load position). Stopper
(X) abutting against strap (Y) from the engine inside.
Engine turning CCW:
Adjust cam follower shaft to normal engine operation (full load position). Stopper
(X) abutting against strap (Y) from the engine outside.

Normal position (engine turning CW) Normal position (engine turning CCW)

2.2 Check: All cam follower shafts must be in the same specified mounting position:

Normal position Normal position

(engine turning CW) (engine turning CCW)
Hole position
of the cam follower shaft
(hole Ø 8 mm
for mandrel) 18

2.3 Fix the cam follower shaft position by jamming together stopper (X) and strap (Y), e.g.
by means of a vice.

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3. Injection pumps
Adjust the injection pumps by means of shims, see paragraph “Prelift and assembly
reference dimension“ in this chapter.

4. Installation of the FCT adjusting unit

Install the adjusting unit as described in chapter “Lower valve drive”, paragraph
“Adjusting unit: Assembly of valve drive for M 25 C”. Take into account the direction
of rotation of the engine.
4.1 Fix the adjusted position of the cam follower shafts at “normal engine operation”
position (full load position) by pressurizing the pneumatic drive unit with 7.5 bar.
4.2 Remove clamp (e.g. vice).

5. Adjusting instructions for “Static start of fuel delivery”

please refer to the corresponding engine adjustmen tin chapter “IMO adjustment” , item
1, Start of fuel delivery
5.1 The fuel cam follower roller must be on the camshaft base circle. Bar the engine in
direction of rotation until the injection pump of cylinder 1 is at start of fuel delivery (pre-
lift dimension measured with device).
5.2 Fix the camshaft.
5.3 Loosen the camshaft gearwheel by hydraulic inflating with pump (about 1200 bar).
Maintain the hydraulic pressure and bar the engine in direction of rotation until
setpoint X before TDC (according to engine adjustment) of cylinder 1 is indicated at
the flywheel (device).

Engine turning CW Engine turning CCW

Flywheel Flywheel
19

TDC

5.4 Fix the camshaft gearwheel by relieving the hydraulic device to 0 bar. Remove the
hydraulic parts. After hydraulic relief observe the necessary waiting time: Do not start
the engine earlier than 2 hours after releasing the press fit.

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6. Check the ignition pressure at all cylinders (testbed adjustment)

Ignition pressure values according to the bill of materials.

6.1 Ignition pressure adjustment applicable to all cylinders. If the ignition pressure is not
within the tolerance range, adjust as follows:
Screw in the hydraulic pressure connections for the miniature eccentric of the fuel
cam follower at H and inflate with high-pressure pump until oil leaks out laterally.

6 Turn the miniature eccentric by means of a mandrel until reaching the ignition
pressure setpoint.
A table with the adjustment values is provided on the next page.
6.3 After the adjustment relieve the hydraulic device and remove the pressure
connections. The engine can be started immediately.

Hole for mandrel

Miniature eccentric

March 2013 Caterpillar confidential: yellow 105

Table with adjusting values for CW and CCW direction of rotation of the engine
(as viewed from driving end)

Engine turning CW Engine turning CCW

Miniature eccentric Adjustment °CA Miniature eccentric Adjustment °CA

turned CCW to turned CCW to

-90 normal -1.00 -90 early -1.00

-75 normal -0.93 -75 early -0.93
-60 normal -0.83 -60 early -0.83
-45 normal -0.68 -45 early -0.68
-30 normal -0.53 -30 early -0.53
-15 normal -0.31 -15 early -0.31
0 0.00 0 0.00
15 early 0.31 15 normal 0.31
30 early 0.53 30 normal 0.53
45 early 0.68 45 normal 0.68
60 early 0.83 60 normal 0.83
75 early 0.93 75 normal 0.93
90 early 1.00 90 normal 1.00
Miniature eccentric Adjustment °CA Miniature eccentric Adjustment °CA
turned CW to turned CW to

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2015 Caterpillar Motoren GmbH & Co. KG - All rights reserved
m Engineer’s Handbook
IMO Adjustment
IMO adjustment
c2
M 25

IMO Adjustment

Note regarding the certificate

If the IMO adjustment is changed the engine will loose its certificate!

IMO engine adjustments

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

1. Start of fuel delivery

Start of fuel delivery adjusted at cylinder 1.
Desired value: 10.5° (+0.5° -1.5°) before TDC
Measured according to overflow method (control travel >38 mm)
or pre-lift dimension 4.0 mm at the auxiliary device No. 11.01-1040

2. LT cooling water temperature

LT water inlet temperature
Desired value: 38 °C (± 2 °C)

3. HT cooling water temperature

HT engine cooling water outlet temperature:
Desired value: 90 °C (± 2 °C)

4. Charge air temperature

Desired value: 45 °C (± 5 °C)

5. Piston distance (check)

Desired value: X = 18.6 mm (+0.55 mm / -1.5 mm), see figure.

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

Adjustment of TDC mark according to job card AAMF 507.
Adjustment of start of fuel delivery of the injection pumps according to drawing 2500.7-
35.80.00-01 (see also chapter „Injection Pump“, paragraph Adjusting the start of fuel
delivery).
Application of the IMO marking according to drawing 2500.0-09.09.00-02 (see below)

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M 25 C 330/334 kW/cyl. 720/750 rpm IMO I

1. Start of fuel delivery
Start of fuel delivery adjusted at cylinder 1.
Desired value: 10.5° (+0.5° -1.5°) before TDC
Measured according to overflow method (control travel >38 mm)
or pre-lift dimension 4.0 mm at the auxiliary device No. 11.01-1040
2. Charge air temperature
Desired value: 45 °C (+ 5 °C)
3. Piston distance (check)
Desired value: X = 18.6 mm (+0.55 mm / -1.5 mm), see figure below
Adjustment of camshaft (250*.7-31.20.00-20).
Adjustment of TDC mark according to job card AAMF 507.
Adjustment of start of fuel delivery of the injection pumps according to drawing 2500.7-
35.80.00-01 (see also chapter “Injection Pump”, paragraph Adjusting the start of fuel
delivery).
Application of the IMO marking according to drawing 2500.0-09.09.00-20 (see below)

M 25 E IMO II 350 kW/cyl. 720/750 rpm

1. Start of fuel delivery
Start of fuel delivery adjusted at cylinder 1.
Desired value: 6.9° (+2° -1.5°) before TDC
Measured according to overflow method (control travel >38 mm)
or pre-lift dimension 5.0 mm at the auxiliary device No. 11.01-1040
3. Piston distance (check)
Desired value: X = 16.1 mm (+0.55 mm / -1.5 mm), see figure below
Adjustment of the camshaft (250X.7-31.20.00-XX).
Adjustment of TDC mark according to job card AAMF 507.
Adjustment of start of fuel delivery of the injection pumps according to drawing 2500.7-
35.80.00-XX (see also chapter “Injection Pump”, paragraph Adjusting the start of
fuel delivery).
Application of the IMO marking according to drawing 2500.0-09.09.00-XX (see below)

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M 25 / M 25 C 300/330/334 kW/cyl. 720/750 rpm D2 / E2 / E3

EPA Tier II / DNV Clean Design

1. Start of fuel delivery

Start of fuel delivery adjusted at cylinder 1.
Desired value: 9° (+0.5° -1.5°) before TDC
Measured according to overflow method (control travel >38 mm)
or pre-lift dimension 4.0 mm at the auxiliary device No. 11.01-1040

2. Charge air temperature

Desired value: 45 °C (± 5 °C)

3. Piston distance (check)

Desired value: X = 18.6 mm (+0.55 mm / -1.5 mm), see figure below

Adjustment of camshaft (250*.7-31.20.00-03 /-04 / -20).

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M 25 C 330/334 kW/cyl. with FCT 720/750 rpm IMO II

1. Start of fuel delivery

Engine type Speed Cycle E2 Cycle E3 Cycle D2

rpm °CA before °CA before °CA before

Unit
TDC TDC TDC
6 M 25 C 750 10.5 -3 9.5 -2 10.5 -3
8 M 25 C 750 9.5 -2 9.5 -2 9.5 -2
9 M 25 C 750 9.5 -2 9.5 -2 9.5 -2
6 M 25 C 720 8.8 -2 - 8.8 -2
8 M 25 C 720 8.8 -2 - 8.8 -2
9 M 25 C 720 8.8 -2 - 8.8 -2

Cycle E2: Diesel-electric or main propulsion with CP propeller

Cycle E3: FP propeller propulsion
Cycle D2: Auxiliary drive (generator sets)
Measured according to overflow method (control travel >38 mm) or pre-lift dimension
5.0 mm at the auxiliary device No. 11.01-1040

4. Charge air temperature

Desired value: 45 °C (± 5 °C)

5. Piston distance (check)

Desired value: X = 17.1 mm (+0.55 mm / -1.5
mm), see figure on the right

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

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M 25 C 330/334 kW/cyl. IMO II

1. Start of fuel delivery

Engine type Speed Cycle E2 Cycle E3 Cycle D2

rpm °CA before °CA before °CA before

Unit
TDC TDC TDC
6 M 25 C 750 10.2 -3 - 10.2 -3
8 M 25 C 750 9.5 -2 9.5 -2 9.5 -2
9 M 25 C 750 9.5 -2 9.5 -2 9.5 -2
6 M 25 C 720 9.5 -2 9.5 -2 9.5 -2
8 M 25 C 720 9.5 -2 9.5 -2 9.5 -2
9 M 25 C 720 8.2 -2 8.2 -2 8.2 -2

Cycle E2: Diesel-electric or main propulsion with CP propeller

4. Charge air temperature

Desired value: 45 °C (± 5 °C)

5. Piston distance (check)

Desired value: X = 17.1 mm (+0.55 mm / -1.5
mm), see figure on the right

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

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IMO adjustment: Check (M 25)

1. Unscrew the screw plug (1).

2. Bar the engine until the Ø 4 mm hole in the

helical gear is centrical with regard to the
M10x1 hole (2) in the cover (see figure).

3. Check at the flywheel whether the IMO mar-

king coincides with the dead centre indica-
tor.

4. Screw in the the screw plug.

IMO adjustment:
Marking of the flywheel (M 25)

1. Marking is only allowed when changing the

flywheel. Marking at
flywheel

2. Adjust the engine in accordance with the

testbed record. Especially make sure that
the IMO timing values are kept!

3. Bar the engine until the Ø 4 mm hole in the helical gear is centrical with regard to the
M10x1 hole (2) in the cover.

4. Stamp the IMO notch directly at the dead centre indicator of the flywheel.

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IMO adjustment: Check (M 25 C) IMO

check
1. Unscrew the screw plug (1). bore

2. Bar the engine until the Ø 6 mm IMO check

bore in the thrust washer is centrically below
the cover check bore.

3. Check at the flywheel: Thrust washer

The IMO notch on the flywheel must coincide Cover
(be congruent) with the dead centre indicator.
Flywheel
4. Screw in the screw plug (1). Dead centre
indicator

IMO
notch

IMO adjustment: Marking of the flywheel (M 25 C)

1. Unscrew the screw plug (1).

2. After adjusting the engine (IMO adjustment) bar the engine until the Ø 6 mm IMO
check bore of the thrust washer is centrically below the cover check bore.

3. Stamp the IMO notch at the dead centre indicator of the flywheel (see figure above)

4. Screw in the screw plug (1).

Thrust washer
Cover
Cover

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Miscellaneous

Control shaft
Tighten screws (1) with ⇒ M = 130 Nm
Molykote
Clearance at 2 is ⇒ 0.20 mm

Grease the bearing points of the control shaft and insert it.
Do not use Molykote or oil!
Check the shaft for ease of movement.
Afterwards, screw the articulated lever onto the shaft.

Tighten screw (3) for the link lever with ⇒ M = 20 Nm

Molykote
Tighten screw (4) with ⇒ M = 130 Nm
Molykote
Clearance at 5 is ⇒ 1.00 mm

When replacing the bushes in the bearing brackets of the control shaft lightly lubricate the
bushes with oil before pressing them in. Do not use Molykote.

Reference dimension of the bush (inside diameter) ⇒ 32.06 + 0.149 mm

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Cooling water pipe M 25 C IMO II with FCT

Tighten G1/2A-SW19 screw plugs (64) with ⇒ M = 85 Nm
Oil and joint ring
Pretighten the M12x70-10.9 screws (28) in a first step with ⇒ M = 35 Nm
and finally tighten them in a second step with ⇒ M = 75 Nm
Molykote paste G Rapid Plus
Insert screws (37), (26), (27), (29), (36), (42), (43), (33) with Molykote Paste G Rapid
Plus

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Cooling water distributing pipe

Tighten screws (1) (ISO4014-M16x110-8.8-A3C) with ⇒ M = 130 Nm
Molykote
Observe the “Installation instructions for rubber
expansion joints” in the General Part of the Engineer’s
Handbook!

Leak fuel pipe

For tightening torques to fasten the leak fuel pipe please refer to chapter “Injection
Pump”, paragraph Mixed oil drain / leak fuel pipe.

Special oil pan

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

Deep oil pan

Tighten the threaded connections (2) for the
baffle plates withM = 170 Nm

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Oil pan installation

Tighten screw plugs (1) with ⇒ M = 550 Nm
Tighten screw plugs (2) with ⇒ M = 230 Nm
Tighten screws (3) with ⇒ M = 200 Nm
Oil

Star grip at pump coverings

Screw the flange bolt (3) with Loctite 270 into the star grip (7). Degrease both threads
before. Do not forget the disc spring (6).

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Barring device
Tighten screws (1) with ⇒ M = 130 Nm
Loctite 243

Tighten screws (2) with ⇒ M = 130 Nm

Actuate the barring device

with a torque wrench up to
800 Nm, reversible ratchet,
and socket wrench insert.

Engine operation is only pos-

sible when the cover (3) is
screwed on.

Molykote

In case of an electric barring device put on the

barring gear (4) with liquid sealing compound.

In case of electric KATSA barring devices install

the micro switches (5) with Loctite 243.

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Starting fuel limiter

Installation instruction
1. For basic adjustment of lever (1)
extend the piston of cylinder (2) by
30 mm.

2. Set the control rods of the injection

pumps to mark 16 of the scale.
Full load
3. Lever (1) must come to a stop at
piston (3).
Mark 16
4. Retract the piston of cylinder (2). At
Stop
full load, lever (1) must not rest
against piston (3).

5. Drill through lever (1() with 6 mm,

pin it with a clamping sleeve and
seal it with lead.

Oil filter arrangement

Tighten studs (1) with ⇒ M=
50 Nm Molykote

Tighten nuts (2) with ⇒ M = 130 Nm

Molykote

March 2013 Caterpillar confidential: yellow 119

Fuel rack position transmitter

Adjust the cam (1) so that in stop position the centre of the fuel rack transmitter aligns with
centre punch mark (2).

Exception:
For applications with UG8 D MAS governors (designation: 8527-151) the fuel rack
transmitter need not be adjusted because this governor type is equipped with an
integrated fuel rack transmitter.

Sketch: Variant -03 Variant -04

Governor arrangement
Always follow the adjustment data on the governor data sheet. The governor adjustment
should be changed only in exceptional cases and only after consulting the Technical
Customer Service VT5. For further details please also refer to chapter “Speed
Governor“ in the General Part of this handbook.

Water drain hose pipe

Install the hose pipe with large bending radius and free of stress. The following adjustment
possibilities can be used:

1) Fastening of the bracket on the charge air cooler flange: Fixing point and hose position
can be chosen at discretion.

2) Fastening of the pipe in the clamps: To be chosen at discretion for fine adjustment.

3) Turn the elbow into appropriate position for stress-free assembly.

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Hydraulic jack: Installation instruction for replacing gaskets

Removal:
1. Loosen the screws in the cap.
Caution: The cap is under spring pressure! Remove cap and springs.

2. Remove vent screw and ball.

3. Press out piston and remove damaged gasket.

Installation
1. Insert new gasket.In doing so, pay attention to the position of the support ring.
Sequence: First rubber ring, then support ring (see figure).

2. Lightly grease the gaskets.

3. Press piston completely into cylinder.

Attention: Do not tilt. Use a plastic assembly pin as guide.

4. Twist the piston according to the holes of the cap. Insert the compression springs and
screw down the cap. Tightening torque: 9 Nm

5. Vent the hydraulic jack.For this purpose connect it to the hydraulic pump and hold it in
such a way that the vent hole is at the highest point. Actuate the pump until oil emerges
without any bubbles.

6. Tightly close with ball and vent screw.

Support ring
Rubber

Support ring

March 2013 Caterpillar confidential: yellow 121

Pressure switch panel

Tighten SW27 (1) with ⇒ M = 3.5 ± 0.5 Nm
Tighten SW2.5 (2) with ⇒ M = 1 ± 0.5 Nm
Tighten screws (3) with ⇒ M = 4.5 ± 0.3 Nm
Tighten screws (4) with ⇒ M = 4.5 ± 0.5 Nm
Tighten adapter (5) with ⇒ M = 35 ± 3 Nm
Tighten swivel nut (6) with ⇒ M = 22 ± 2 Nm

IMO II generator set:

To install an MBS on an adapter, turn the MBS into the adapter. In doing so, make sure the
joint ring is correctly positioned. Then tighten the hexagon to fix the MBS. Screw the
headless screw out of the adapter (7). Turn the MSC in clockwise direction to align the
outgoing cable and the headless screw. Tighten the headless screw.

IMO II generator set:

Adjusting instructions for pressure switches

For adjusting the Trafag pressure switches
9BO.2877.750.02.15.16.58 (pressure range 0 - 6 bar)
9MO.2879.761.02.15.16.58 (pressure range 1 - 16 bar)
see “General Part” of the Engineer’s Handbook, section “Testing Electrical Compon-
ents”

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Level probes
Tighten the level probes of the electrical equipment with max. ⇒ M = 50 Nm

Installation of brackets for main bearing temperature monitoring

Tighten screws (4) with ⇒ M = 52
NmMolykote
Tighten screw plugs with joint ring (5) with ⇒ M = 70 Nm

Media guide
Insert the M16x1.5 screw plugs (26) and the M10x1 screw plugs (25) with Loctite 243
Degrease the threads beforehand.

Nozzle leakage outlet

Oil-rocker arm +
nozzle cooling

Leakage fuel-
pressure pipe

March 2013 Caterpillar confidential: yellow 123

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m Engineer’s Handbook
Pump Support with Attached Pumps
Pump support with attached pumps
c2
M 25

Pump Support with Attached Pumps

Installation of the pump mounting plate

Sealing compound in
Degrease all flange surfaces Apply the hatched area only
sealing compound to the pump support,
position it on the engine block using the
provided device and tighten it. Pin the
pump mounting plate.
Apply a thin coat of sealing compound in
the double-hatched area only. The
sealing compound must not clog the oil
ducts.

Expander installation and check

Insert and check the expanders
according to the instructions of the
manufacturer and with the tools and tests
specified by the manufacturer.

Pump support
Tighten screws (M16) with ⇒ M = 130 Nm

March 2013 Caterpillar confidential: yellow 124

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m Engineer’s Handbook
Pump Support with Attached Pumps c2
M 25

Gear wheel installation:

Lubricating oil pumps, suction and pressure pump, cooling water centrifugal
pumps

Check the contact surface on the related pump shaft cone by means of a gear wheel cone
covered with blue paste: Contact surface ≥ 80 %.

Heat the gear wheel

of lubricating oil pumps up to 90 °C to 100 °C
of seawater pumps up to 100 °C to 110 °C
of cooling water pumps 2500.7-64.51.00-01 up to 80 °C to 90 °C
of cooling water pumps 2500.7-64.40.00-01 and -02 up to 90 °C to 100 °C
above temperature of the pump shaft and firmly install on the related pump cone until
reaching the end stop. The cone surfaces must be free of grease and dry.

The slide-on distance is ⇒ 0.40 - 0.44 mm

For seawater pumps and cooling water pump

2500.7-64.51.00-01 the slide-on distance is ⇒ 0.29 - 0.32 mm

Tighten the screw for the gear wheel at room temperature with ⇒ M = 60 Nm
Molykote

For lubricating oil pumps 2500.7-64.15.00-04 and 2500.7-64.10.00-08:

Install the gear wheel only in vertical position of the pump shaft.
(cone pointing upwards).
Install the screw and washer for the gear wheel promptly
and tighten with ⇒ M = 45 Nm
After cooling down of the connection to
room temperature loosen the screw and tighten with ⇒ M = 60 Nm
Molykote (2500.7-64.15.00-04)
Loctite 270 (2500.7-64.10.00-08)

The backlash for all pumps is ⇒ 0.20 - 0.45 mm

Screw the pump flange onto the pump mounting plate using sealing compound.

March 2013 Caterpillar confidential: yellow 125

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m Engineer’s Handbook
Pump Support with Attached Pumps c2
M 25

Gear wheel installation: Fuel feed pump drive

For variant 2500.7-64.84.00-01 only:
Check the contact surface on the related pump shaft cone by means of a gear wheel cone
covered with blue paste. Only a contact surface displaced towards the thick end is
permissible.

All variants:
Heat the gear wheel (1) up to 30 to 40 °C above temperature of the drive shaft (2) and
firmly install it onto the related drive shaft cone until reaching the end stop. (Example: 20
°C shaft temperature → 50 to 60 °C gear wheel temperature). The cone surfaces must be
free of grease and dry.
The slide-on distance is ⇒ 0.14 - 0.18 mm

Install screw (3) with washer (4) and tighten with ⇒ M = 60 Nm

Molykote paste G Rapid Plus

Backlash ⇒ 0.20 - 0.45 mm

Insert screw (5) with Loctite 243.
Before pressing-in lightly lubricate the bush (6) with oil. Do not use any further lubricant.
The bush joint is to be located on the left side (seen from the gear wheel).

March 2013 Caterpillar confidential: yellow 126

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m Engineer’s Handbook
Pump Support with Attached Pumps c2
M 25

Coupling between drive and fuel feed pump

Heat the coupling halves (2) up to 100 °C and shrink fit them onto the related shaft journal
according to the drawing until reaching the end stop.

March 2013 Caterpillar confidential: yellow 127

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m Engineer’s Handbook
Flywheel Installation c2
M 25
Flywheel installation

Flywheel Installation

Installation of the flywheel

Insert studs (1) with Loctite 3 into the flywheel. Grind spring dowel pins (2) at the sharp-
edged end (approx. 2 x 15° chamfer) and insert them with this end into the gear wheel on
the crankshaft. Bar the crankshaft to TDC position of cylinder 1.

Guide oil thrower (3) over the crankshaft cone. Align and install the end plate (4) so as to
be centered to the crankshaft and flush with the bottom edge of the engine block. Oil the
crankshaft cone with hydraulic oil.

Hang the flywheel in the transfer port and slide it onto the crankshaft cone until contact is
reached. Fit the tightening device. Take care that the flywheel is fixed on the locating pin
of the device. In this position the projecting spring dowel pins of the gear wheel on
crankshaft are aligned to the corresponding receiving bores on the flywheel. Press the
flywheel with the tightening device and oil press fit (connection S) into its final position
(resting against crankshaft gear wheel).

March 2013 Caterpillar confidential: yellow 128

Tighten the nut on the device with ⇒ M = 1600 Nm

Hydraulic oil pressure with hand pump ⇒ P = 1200 bar

Pressing liquid: Hydraulic oil H36 DIN 515

The slide-on distance is ⇒ s = 23.0 - 3.5 mm

End clearance (7) ⇒ 0.30 - 0.60 mm

End clearance (8) ⇒ 0.10 - 0.30 mm

Do not loosen the device until 24 hours after releasing the oil press fit. Start the engine
at the earliest 72 hours after removing the device.

Fit the oil thrower ring to the flywheel.

Tighten screws (5) (13xISO4017-M16x45-8.8-A3C) with ⇒ M = 130 Nm
Molykote

Fit nuts (6) (10xDIN934-M10) with conical spring washers

(DIN6796-10-FST-A3C) and tighten with ⇒ M = 75 Nm
Loctite 3

Hydraulic connection in the crankshaft ⇒ 1/4“

March 2013 Caterpillar confidential: yellow 129

Flywheel removal
When installed, the device is 510 mm long. The length of the thread of the “threaded rod“
is 80 mm. For installing the device at least 590 mm are required.

Loosen the oil thrower on the crankshaft.

Secure the flywheel by appropriate means.
Remove the plug of hydraulic connection S in the crankshaft.
Install the device according to the illustration below (“threaded rod“ and guide plate).
Screw the hydraulic pipe into connection S and tighten it.
Install the pressure disc and the hydraulic jack.
Screw on the nut until there is a distance of approximately 25 mm to the hydraulic jack.
Connect the hand pump to the hydraulic jack and the maximator pump to the flywheel.
Extend the hydraulic jack by approximately 25 mm using the hand pump. Then loosen the
nut half a pitch so that there is a gap of approximately 1-2 mm between the hydraulic jack
and the nut.
Pump up the flywheel using the hydraulic pump (pressure approximately 1300 bar) until
the flywheel loosens.
Slowly lower the pressure of the hydraulic jack (flywheel is moving) and then dismount the
device completely.
Remove the flywheel.

Installation
Installation takes place in reverse order (see above). During the sliding-on operation take
care that the oil thrower is placed upon the studs.

M39 for the threaded rod Connection S

Connection Z

March 2013 Caterpillar confidential: yellow 130

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m Engineer’s Handbook
Flexible Flange Connection c2
M 25 Flexible Flange Connection

Flexible Flange Connection

Flexible flange connections for diesel generator sets

1. Take off fastening elements and remove preservatives from the components. For
installation hang the RATO-DS element in a suitable hoist. Hub (3) is fitted onto the
generator shaft journal.
2. Fasten the RATO-DS element on the hub by means of the fastening elements.
Tighten hexagon screws (9) with the appropriate torque. In doing so, use oil.
3. Push the generator with mounted hub and RATO-DS element towards the flywheel until
assembly reference dimension X is reached.
4. Fasten the RATO-DS element with the related fastening elements on the flywheel and
tighten the screws (6) with the appropriate torque. In doing so, use oil.
5. When tightening, check whether the RATO-DS element has metal-to-metal contact at
the outer circumference of the centering of the flywheel.

For further information on generator installation

see chapter “Diesel Generator Set”

March 2013 Caterpillar confidential: yellow 131

Reference Screws Tightening

dimension torque (Nm)
Engine RATO element
X
(6) (9) (6) (9)
(mm)

6 M 25 DS A3311A BR 2100 310 ± 0.5 M20x200-10.9 M24x60-10.9 490 675+75

6 M 25 DS A3310 BR 2100 260 ± 0.5 M20x160-10.9 M22x60-10.9 505+55 675+75

6 M 25 DS A3311 BR 2100 260 ± 0.5 M20x200-10.9 M22x60-10.9 490+75 675+75

1A3310A007

6 M 25 DS A3311 BR 2100 260 ± 0.5 M20x190-10.9 M22x60-10.9 505+55 675+75

1A3310A028

6 M 25 DS A3311 BR 2100 260 ± 0.5 M20x190-10.9 M22x60-10.9 505+55 675+75

1A3310A036

8 M 25 DS A3415A BR 2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3415A035

8 M 25 DS A3411A BR 2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3410A035

8 M 25 DS A3415A BR 2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3415A035
8 M 25 DS A3411A BR 2100 310 ± 0.5 M22x200-10.9 M24x60-10.9 495 675+75

8 M 25 DS A3410A BR2100 259.5 M22x210-10.9 M24x65-10.9 675+75 660+70

/ 1A3410A027 -0.5 or
9 M 25 260 ± 0.5

8 M 25 DS A3411A BR2100 260 ± 0.5 M22x200-10.9 M24x65-10.9 495 660+70

/ 1A3410A004
9 M 25

9 M 25 DS A3410A BR2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3410A036

9 M 25 DS A3415A BR 2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3415A036

9 M 25 DS A3415A BR2100 260 ± 0.5 M22x210-10.9 M24x65-10.9 675+75 660+70

1A3415A036

9 M 25 DS +3D1H BR 2100 360 ± 0.5 M20x190-10.9 M22x60-10.9 592 807

1A3D10A002

March 2013 Caterpillar confidential: yellow 132

Vulkan RATO DG29D8, series 2200

Tighten screws (1) (DIN931/1-M18x150-10.9) with ⇒ M = 350 + 40 Nm

Oil

Tighten screws (2) (DIN933-M22x90-10.9) with ⇒ M = 675 + 75 Nm

Oil

Tighten screws (3) (DIN933-M27x80-10.9) with ⇒ M = 960 + 110 Nm

Oil

Tighten screws (4) (DIN912-M18x140-12.9) with ⇒ M = 385 Nm

Oil

Assembly reference dimension Y is ⇒ 389 ± 0.5 mm

For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 133

PTO coupling hub with Vulkan RATO-R 1G191WR030

Tighten screws (1) with ⇒ M = 350 + 40 Nm

Oil
Tighten screws (2) with ⇒ M = 350 + 40 Nm
Oil
Tighten nuts (3) with ⇒ M = 60 + 8 Nm
Oil
Tighten nuts (4) with ⇒ M = 100 + 14 Nm
Oil
The assembly reference dimension Z is ⇒ 481.9 + 0.8 mm
and has to be corrected to make allowance for
plant-specific heat expansion.
The slide-on distance is ⇒ 6.0 + 1.3 mm
The pressing force in case of hydraulic assembly is ⇒ 402 kN
Note: Do not remove the diaphragm group (6)!

For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 134

Vulkan RATO-S 1G252Q0154

Tighten screws (1) and (2) with ⇒ M = 675 + 75 Nm

Oil
Tighten screws (3) with ⇒ M = 130 + 15 Nm
Oil
Tighten screws (4) with ⇒ M = 165 + 20 Nm
Oil
Tighten screws (5) with ⇒ M = 8.5 + 1 Nm
Oil
The assembly reference dimension A is ⇒ 524.7 ± 0.8 mm
and has to be corrected to make allowance for
plant-specific heat expansion.
The slide-on distance is ⇒ 7.1 + 1.4 mm
The pressing force in case of hydraulic assembly is ⇒ 575 kN
Note: Do not remove diaphragm assembly (6) and hexagon socket head cap screw
(5) for the connection of diaphragm package and inner cover ring (7)!

For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 135

Vulkan RATO-R 1G262TR090

Tighten screws (1) and (4) with ⇒ M = 660 + 70 Nm

Oil
Tighten screws (2) und (3) with ⇒ M = 250 + 30 Nm
Oil
Tighten screws (5) with ⇒ M = 100 + 14 Nm
Oil
The assembly reference dimension B is ⇒ 745 ± 0.8 mm
and has to be corrected to make allowance for
plant-specific heat expansion.
The slide-on distance is ⇒ 7.2 + 1.4 mm
The pressing force in case of hydraulic assembly is ⇒ 583 kN
Note: Do not remove the diaphragm group (6)!

For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 136

Vulkan RATO-R G1920R, series 2400

Tighten screws (22) and (23) with ⇒ M = 350 + 40 Nm
Oil
Tighten screws (28) with ⇒ M = 81 + 9
Nm Oil
Tighten screws (29) with ⇒ M = 100 + 14
Nm Oil
Tighten screws (47) with ⇒ M = 30 + 4
Nm Oil
The assembly reference dimension E is ⇒ 522 + 0.8 mm
and has to be corrected to make allowance
for plant-specific heat expansion.
The slide-on distance is ⇒ 4.3 + 1.3 mm
The pressing force in case of hydraulic assembly is ⇒ 307 kN
Note: Do not remove the diaphragm group (10)!
For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 137

Vulkan RATO-DS A3418G, series 2100

(installed on 9 M 25 DGS)

Tighten screws (2) M22x160-8.8 with ⇒ M = 500 Nm Oil

Tighten screws (4) M30x90-10.9 with ⇒ M = 1300 + 75 Nm
Oil
Assembly reference dimension C is ⇒ 260 ± 0.5mm

For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 138

Vulkan RATO-DS A3411A, series 2100, 1A3410A035

Vulkan RATO-DS A3410A, series 2100, 1A3410A046
(installed on 8 M 25 DGS)
1. Take off fastening elements (9), (11) and remove preservatives from the
components. For installation hang the RATO-DS element in a suitable hoist. Hub
(3) is fitted onto the generator shaft journal.
2. Bar the engine until the piston of cylinder 1 is at TDC. Bar the generator so that the
parallel key of the generator shaft is positioned vertically at the top.
3. Fasten the RATO-DS element on the hub by means of the fastening elements (9),
(11). Tighten hexagon screws (9) with the appropriate torque. In doing so, use oil.
4. Push the generator with mounted hub and RATO-DS element towards the flywheel until
assembly reference dimension D is reached.
5. Fasten the RATO-DS element with the related fastening elements on the flywheel and
tighten the screws (6) with the appropriate torque. In doing so, use oil.
6. When tightening, check whether the RATO-DS element has metal-to-metal contact at
the outer circumference of the centering of the flywheel.
Tighten screws (6) M22x210-10.9 with ⇒ M = 675 + 75 Nm
Oil
Tighten screws (9) M24x65-10.9 with ⇒ M = 660 + 70 Nm
Oil
Assembly reference dimension D is ⇒ 260 ± 0,5 mm
For further information on generator installation see chapter “Diesel Generator Set“

March 2013 Caterpillar confidential: yellow 139

Vulkan RATO-R 262 TR, series 2200 on 9 M 25 C

(only engine numbers 45278, 45379, 45280)
Insert the parallel pins (55) into the locating holes in the element (1) which are marked by
notches. After tightening the 30 threaded connections (19), (16), (28) replace the parallel
pins (55) by these threaded connections.
Tighten screws (20) with ⇒ M = 250 + 30 Nm
Oil
Tighten nuts (28) and (3) with ⇒ M = 250 + 30 Nm
Oil
Tighten nuts (36) with ⇒ M = 660 + 70 Nm
Oil
Tighten nuts (48) with ⇒ M = 100 + 14 Nm
Oil
Tighten screws (7) with ⇒ M = 8.5 + 1 Nm
Oil
Assembly reference dimension F is ⇒ 594 ± 0.8 mm
and has to be corrected to allow for
plant-specific heat expansion.

Note: Do not remove the diaphragm

group (10)!

For a complete description see

drawing MA_1G262TR108_DE.

March 2013 Caterpillar confidential: yellow 140

Charge Air Cooler

Installation - 2500.7-72.40.00-01 driving end

1. Fix angle section (1) with screws (2) on the charge air cooler.
2. Loosen the sealing strips (3) on the charge air cooler and press them against the cooler.
3. Push the charge air cooler into the casing.
4. Screw the charge air cooler to the casing; for this purpose tighten screws (4) first.
5. Fasten the charge air cooler to the casing with screws (5) and washers.
6. Push the sealing strips against the casing and fasten them with screws (6).

X = Install the charge air casing with DIRKO No. 610.020 sealing compound.

Tighten screws (2) with ⇒ M = 20 Nm

Molykote

Tighten screws (7)

for fixing the charge air cooler on the engine block with ⇒ M = 130 Nm
Molykote

When installing the plugs make sure that the sealing faces and the corresponding holes
are clean and free of grease. Coat the sealing faces with Loctite 270. Use the provided
drive-in mandrel for installation.
The plug edges must be located 1.5 ± 0.5 mm deep in the casing.

Installation 2500.7-72.40.00-03 / -04 / -05 driving end

March 2013 Caterpillar confidential: yellow 141

2500.7-72.80.00-03 / -05 free end

1. Fix angle section (1) with screws (2) on the charge air cooler.
2. Push the charge air cooler into the casing.
3. Pull the charge air cooler with screws (3) against the sealing surface (air inlet) of the
casing. Loosen the screws slightly again.
4. Fasten the charge air cooler to the casing with screws (4) and (5) and washers.
5. Pull the charge air cooler with screws (3) finally against the sealing surface of the air
inlet on the casing.
Y = Install this bracket on the charge air cooler contrary to its delivery condition, so as to
be turned by 180° (variants 2500.7-72.40.00-03, -04, -05).
When installing the plugs make sure that the sealing surfaces and the corresponding holes
are clean and free of grease. Coat the sealing surfaces with Loctite 270. Use the provided
drive-in mandrel for installation.
The plug edges must be located 1.5 ± 0.5 mm deep in the casing.

Tighten screws (2) with ⇒ M = 20 Nm

Molykote
Tighten screws (3) with ⇒ M = 45 Nm
Molykote

Tighten screws (6)

for fixing the charge air cooler casing on the engine block with⇒ M = 130 Nm
Molykote

Apply DIRKO No. 610.020 sealing compound to the contact surfaces at X.

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March 2013 Caterpillar confidential: yellow 143

Installation 2500.7-72.80.00-05 / -06 / -09 free end

2500.7-72.40.00-07 driving end
(var. -06, -07 = casing for optional air injection for ch. air cooler 0.00.6-41.80.00-68)
The figures show 2500.7-72.40.00-07
1. Fix the angle section (4) with screws (11) on the charge air cooler (2).
2. Only for variants -06, -07, -09: Install the bracket (5) with screws (7) and washers (6)
on the charge air cooler (2).
3. Push the charge air cooler into the casing (1).
4. Pull the charge air cooler with screws (17) against the sealing surface (air inlet) of the
casing. Loosen the screws (17) slightly again.
5. Fix the charge air cooler with screws (12) and (14) and washers (18) and (19) on the
casing.
6. Pull the charge air cooler with screws (17) finally against the sealing surface of the air
inlet on the casing.
When installing the plugs make sure that the sealing surfaces and the corresponding holes
are clean and free of grease. Lubricate the sealing surfaces with Loctite 270. Use the
provided drive-in mandrel for installation.
The plug edges must be located 1.5 ± 0.5 mm deep in the casing.

Tighten screws (16), (10) and (15) with ⇒ M = 130 Nm

Molykote paste G Rapid Plus
Tighten G1/2A-SW19 screw plugs (23) with ⇒ M = 85 Nm
Oil
Tighten G1/8A screw plugs (30) with ⇒ M = 14 Nm
Oil
Tighten M30x1.5 screw plugs (21) with ⇒ M = 195 Nm
Oil
Tighten M33x2 screw plugs (22) with ⇒ M = 230 Nm
Oil
Tighten M48x2 screw plugs (24) with ⇒ M = 550 Nm
Oil

Install the contact surfaces at X

with DIRKO No. 610.020 sealing
compound.

March 2013 Caterpillar confidential: yellow 144

March 2013 Caterpillar confidential: yellow 145

Installation of 2500.7-72.80.00-07 driving end (M 25 E)

1. Install sheet (3) with plate (4) at the casing.

2. Screw two M16x130 hexagon screws into the holes into which the screw plugs (22) will
be screwed until a distance of 10 mm is reached between the screw head contact sur-
face and the machined surface on the charge air cooler casing.
3. Push the charge air cooler (1) into the casing.
4. Adjust the height of the cooler by means of the two M16x130 hexagon screws in such
a way that the 10 fixing holes on the cooler sealing surface coincide with the correspon-
ding holes in the charge air cooler casing.
5. Tighten the cooler with four screws (17) and extension sleeves in the first and last hole
of the upper and lower fastening row. Loosen the four screws again. Apply Molykote to
the screws (17) also under the head.
6. Tighten the charge air cooler in the casing with screws (16) and washers with 20 Nm
7. Tighten screws (17) with extension sleeves with 70 Nm starting from the cooler
flange surface and proceeding towards the centre of the engine.
8. Tighten screws (16) and washers with 70 Nm from inside to the outside.
9. Remove the two M16x130 screws and replace them by M24x1.5-SW22 screw
plugs (22) with joint ring.
10. Retighten screws (17) once again with 70 Nm starting from the cooler flange surface
and proceeding towards the centre of the engine.

Tighten screw plugs (21) and (22) with ⇒ M = 105 Nm

Oil
Tighten screws (16) and (17) with ⇒ M = 70 Nm
Apply Molykote paste G-Rapid Plus to head and thread

Cooler sealing surface towards charge air cooler casing

March 2013 Caterpillar confidential: yellow 146

Screw plug tightening torques

KBB HPR6000 turbocharger on 6 M 25 C:
Tighten M24x1.5-SW22 screw plugs (36) with ⇒ M = 105 Nm
Tighten G1/2A-SW19 screw plugs (35) with ⇒ M = 85 Nm

Charge air, bypass, M 25 E

Tighten screws (42) with ⇒ M = 140 Nm
Rivolta G.W.F.
Tighten screws (38) with ⇒ M = 130 Nm
Molykote paste G Rapid Plus

March 2013 Caterpillar confidential: yellow 147

Air injection, M 25 E
Tighten the relief valve with joint ring (19) with ⇒ M = 130 Nm
Oil

Tighten the G1/2A union with joint ring (28) with ⇒ M = 550 Nm
Oil

Tighten the M14x1.5 union with joint ring (25) with ⇒ M = 50 Nm

Oil

Tighten the throttle with joint ring (10) with ⇒ M = 50 Nm

Oil

Tighten screws (46) with ⇒ M = 15 Nm

Molykote paste G Rapid Plus

Adjust the pressure reducer (14) after pressure test to 5 bar.

Pressure test:
Max. permissible pressure ⇒ PS = 30 bar
Test pressure ⇒ PT = 45 bar
Test medium ⇒ air
Duration of test ⇒ 10 minutes
Permissible leak rate ⇒ 0

March 2013 Caterpillar confidential: yellow 148

Tighten the G1/4A union with joint ring (11) with ⇒ M = 30 Nm

Oil
Tighten the G1/2A union with joint ring (10) with ⇒ M = 550 Nm
Oil

March 2013 Caterpillar confidential: yellow 149

Turbocharger Installation

Installation of KBB R4-3 turbocharger on 6 M 25

2500.7-72.50.00-01 / -03 / -04 driving end
2500.7-72.55.00-01 / -03 free end

Tighten screws (1) (e.g. for turbocharger foot) with ⇒ M = 60 Nm

Molykote

2500.7-72.50.00-01: 1a: 10x DIN931-M12x55-8.8, 1b: 1x DIN933-M12x35-8.8

2500.7-72.50.00-03: 1a: 10x DIN931-M12x55-8.8, 1b: 1x DIN933-M12x35-8.8
2500.7-72.50.00-04: 1a: 10x DIN931-M12x55-8.8, 1b: 1x DIN933-M12x35-8.8,

1c: 9x DIN931-M12x65-8.8

2500.7-72.55.00-01: 1a: 11x DIN931-M12x55-8.8

2500.7-72.55.00-03: 1a: 11x DIN931-M12x55-8.8

No gaskets
1c here

1a 1b

March 2013 Caterpillar confidential: yellow 150

Installation of KBB R5-3 turbocharger on 8 M 25 and 9 M 25

2500.7-72.50.00-02 / -05 / -07 driving end
2500.7-72.55.00-04 / -07 free end

Tighten screws (1) with ⇒ M = 130 Nm

Molykote

Tighten screws (2) with ⇒ M = 60 Nm

Molykote

2500.7-72.50.00-02: 1: 8x ISO4014-M16x60-8.8
2500.7-72.50.00-05: 1: 8x ISO4014-M16x60-8.8, 2: 11x DIN 931-M12x65-8.8
2500.7-72.50.00-07: 1: 8x ISO4014-M16x60-8.8, 2: 11x DIN 931-M12x65-8.8
2500.7-72.55.00-04: 1: 8x ISO4014-M16x60-8.8, 2: 11x DIN 931-M12x65-8.8
2500.7-72.50.00-07: 1: 8x ISO4014-M16x60-8.8, 2: 11x DIN 931-M12x65-8.8

No gaskets
here

March 2013 Caterpillar confidential: yellow 151

Installation of KBB HPR6000 turbocharger on 6 M 25, 8 M 25, and 9 M 25

2500.7-72.50.00-08 / -09 / -10 driving end
2500.7-72.55.00-08 / -09 free end

Tighten screws (1) (2x ISO4014-Mx320-10.9) with ⇒ M = 640 Nm

Molykote

Tighten screws (2)

(driving end:21x / free end:24x ISO4014-M16x60-8.8) with ⇒ M = 130 Nm
Molykote

Tighten screws (3) (11x DIN933-M12x65-8.8) with ⇒ M = 60 Nm

Molykote

Expansion joint installation:

No gasket between
flange surfaces!

March 2013 Caterpillar confidential: yellow 152

Installation of KBB HPR6000 turbocharger on 6 M 25 C, 8 M 25 C, and 9 M 25 C

2500.7-72.50.00-20 / -21 / -22 / -26 / -27 / -28 / -29 driving end
2500.7-72.55.00-20 / -21 / -22 / -27 / -28 / -29 / -30 /-31 / -32 / -33 free end
Data applicable with and without cover plate between charge air cooler and turbocharger.
When installing the expansion joint insert bolts and nuts with Rivolta G.W.F. and pay
attention to the flow direction (arrow on the flange). Insert expansion joints without
gaskets.
Before installing bracket (4) fit the bottom plate of the exhaust cladding. The contact
surface of the bracket on the bottom plate of the exhaust cladding must be free of paint
and grease.
Apply Molykote to threads and bolt contact surfaces.

Tighten bolts and nuts (1) with ⇒ M = 60 Nm

Rivolta G.W.F.
Make sure bracket (4) and turbocharger are installed stress-free.

Tighten screws (2) with ⇒ M = 60 Nm

Molykote

Tighten screws (3) with ⇒ M = 130 Nm

Rivolta G.W.F.
In case of stationary engines apply Molykote to the outer screw (3)

Tighten screws (5) with ⇒ M = 640 Nm

Molykote

March 2013 Caterpillar confidential: yellow 153

Turbocharger installation: ABB TPS61D on 9 M 25 / ABB TPS61 on 8 M 25 and 9 M 25

2500.7-72.55.00-05 free end
2500.7-72.50.00-06 driving end

Tighten screws (1) (2x ISO4014-Mx320-10.9) with ⇒ M = 640 Nm

Molykote

Tighten screws (2) (24x ISO4014-M16x60-8.8) with ⇒ M = 130 Nm

Molykote

Tighten screws (3) (11x DIN933-M12x65-8.8) with ⇒ M = 60 Nm

Molykote

No gaskets
here

March 2013 Caterpillar confidential: yellow 154

Installation of ABB TPS61 turbocharger on 6 M 25

2500.7-72.55.00-23 free end

When installing the expansion joint insert bolts and nuts with Rivolta G.W.F. and pay
attention to the flow direction (arrow on the flange).

Tighten bolts and nuts (1) with ⇒ M = 60 Nm

Rivolta G.W.F.
Make sure bracket (4) and turbocharger are installed stress-free.

Tighten screws (2) with ⇒ M = 60 Nm

Molykote

Tighten screws (3) with ⇒ M = 130 Nm

Molykote

Tighten screws (5) with ⇒ M = 640 Nm

Molykote

March 2013 Caterpillar confidential: yellow 155

Casing cladding var. -02

(mounted on engines Nos. 045094, 045095, 045096, 045097, 045199, 045200, 045201)

Insert all screws with Rivolta G.W.F.

Installation sequence: 1, 2, 2, 3, 4, 5, 6, 7, 12, 8, 9, 10, 11

March 2013 Caterpillar confidential: yellow 156

Oil drain

Turbocharger oil drain:

O-ring

Engine block oil drain:

O-ring

March 2013 Caterpillar confidential: yellow 157

Exhaust Manifold

General
Before installing the exhaust manifold put the bottom plates of the exhaust cladding into
proper position (see chapter Exhaust Cladding).

Screws for fastening on the cylinder head

Always tighten the screws to the cylinder head alternately in 2 steps:

Tighten ISO4014-M20x120 screws (marking VW or TL)

in a 1st step with ⇒ M = 150 Nm
in a 2nd step up to ⇒ M = 250 Nm
Rivolta G.W.F.

Tighten ISO4014-M20x130 screws (marking V or VH)

in a 1st step with ⇒ M = 180 Nm
in a 2nd step up to ⇒ M = 330 Nm
Rivolta G.W.F.

Tightening torques
Tighten screws (M16) from connecting link / bracket
to engine block with ⇒ M = 130 Nm
Molykote

Tighten screws (M16) in the exhaust manifold with ⇒ M = 140 Nm

Rivolta G.W.F.

Tighten screws (M12) in the exhaust manifold with ⇒ M = 55 Nm

Rivolta G.W.F.

Tighten screws (1) (M20) on the exhaust tube with ⇒ M = 190 Nm

Rivolta G.W.F.

Tighten screws (2) (M16) on the converter bracket with ⇒ M = 190 Nm

Rivolta G.W.F.

Tighten screws (M16x55) on the turbocharger exhaust nozzle

to the flange with 645 mm outside diameter with ⇒ M = 90 Nm
Rivolta G.W.F.

March 2013 Caterpillar confidential: yellow 158

Connecting links
Spray connecting links, links and lamella Recession
brackets with graphite or molybdenum max. 5 mm
spray before installation.

For M 25 C engines: Before installation

apply to both sides of all links an even and
thin coat of Rivolta G.W.F. paste by means
of a brush that should not be too soft.

When installing the blank flanges put the machined surface of the blank flanges against
the gasket.

Expansion joints
Install the expansion joints in direction of arrow.

Do not insert any gaskets between the exhaust gas tubes and the expansion joints.
Make sure the screws are of correct length. Projection is not admissible.

March 2013 Caterpillar confidential: yellow 159

Gaskets between cylinder head and exhaust manifold

When installing the gasket make sure that
the bead in the gasket points towards the
exhaust gas tube flange.

Bring bracket (1) to limit stop against the Gasket

flange of the exhaust gas tube and lock by
means of a hexagon nut.

March 2013 Caterpillar confidential: yellow 160

6 M 25 with turbocharger at driving end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

6 M 25 with turbocharger at free end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 161

8 M 25 with turbocharger at driving end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

8 M 25 with turbocharger at free end (variants 02 and 04)

Install with 7 mm offset

Install with 9 mm offset
Install with 5 mm offset

March 2013 Caterpillar confidential: yellow 162

8 M 25 with turbocharger at free end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

9 M 25 with turbocharger at driving end (variant 01)

Install with 5 mm offset

Install with 6 mm offset

March 2013 Caterpillar confidential: yellow 163

9 M 25 with turbocharger at driving end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 164

9 M 25 with turbocharger at free end (variant 02)

Install with 5 mm offset

9 M 25 with turbocharger at free end

Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 165

6 M 25 C with turbocharger at driving end

Tighten M16 screws (50) (51) (52) (53) (54) (55) (56) (62) with ⇒ M = 140 Nm
Rivolta G.W.F.

Connecting link
quadruple Connecting link
quadruple

4x connecting link 4x connecting link

triple double

March 2013 Caterpillar confidential: yellow 166

6 M 25 C with turbocharger at free end

Tighten M16 screws (55) (58) (59) (60) (62) (66) with ⇒ M = 140 Nm
Rivolta G.W.F.
* Install these connecting links on bracket rail approximately 4 to 5 mm in direction
of free end.

Connecting link
double Connecting link
Connecting linktriple
triple

Connecting link
quadruple

Connecting link Connecting link

quadruple triple
Connecting link Connecting link
triple double
Connecting link Connecting link
double triple
Connecting link
double

March 2013 Caterpillar confidential: yellow 167

8 M 25 C with turbocharger at driving end

Tighten M16 screws (1) with ⇒ M = 140 Nm
Rivolta G.W.F.
Tighten screws (2) with ⇒ M = 190 Nm
Molykote
Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 168

8 M 25 C with turbocharger at free end

Tighten M16 screws (1) with ⇒ M = 140 Nm
Rivolta G.W.F.
Tighten screws (2) with ⇒ M = 190 Nm
Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 169

9 M 25 C with turbocharger at driving end

Tighten M16 bolts and nuts (1) with ⇒ M = 140 Nm
Rivolta G.W.F.
Tighten M12 screws (2) with ⇒ M = 55 Nm
Rivolta G.W.F.
Tighten screws (3) with ⇒ M = 130 Nm
Rivolta G.W.F.
Note A:
Install links on bracket rail approximately 4 to 5 mm in direction of driving end.
Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 170

9 M 25 C with turbocharger at free end

Note B:
Install links on bracket rail approximately 4 to 5 mm in direction of free end.

March 2013 Caterpillar confidential: yellow 171

Exhaust Cladding

Tightening torques
Insert all screws of the exhaust cladding with Rivolta G.W.F..

The table below shows the tightening torques and preload forces for threaded
connections with high-temperature screws (X22CRMOV) on the exhaust cladding:

Coarse pitch Tightening Pretreatment

thread torque

M8 11 Nm Rivolta G.W.F.
M10 21 Nm Rivolta G.W.F.
M12 36 Nm Rivolta G.W.F.
M14 58 Nm Rivolta G.W.F.
M16 90 Nm Rivolta G.W.F.
M18 128 Nm Rivolta G.W.F.
M20 179 Nm Rivolta G.W.F.
M24 313 Nm Rivolta G.W.F.

Assembly gap

Pay attention to the assembly gap between the sections:

March 2013 Caterpillar confidential: yellow 172

Installation sequence with turbocharger at driving end (var. -25, without ribs)

Before installing the exhaust manifold put the bottom plates of the exhaust cladding
(pos. 3, 4, 5) into position.

Install pos. 1, 2, 6, 7.

Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.

Insert pos. 19 between (2x) pos. 18 and bolt them together.

March 2013 Caterpillar confidential: yellow 173

Install rear panel in the following sequence: 20, 23, 21, 22, 33, 25, 36, 34, 35.

Shown without pos. 34

March 2013 Caterpillar confidential: yellow 174

Install front in the following sequence: 26, 27, 30, 31, 32, 40, 41, 45, 44.

For installing the rear first preassemble cover plate 42 on support plates 8 and 9 so as
to be finger tight.

Then preassemble support plates 8 and 9 so as to be finger tight.

After assembly of claddings 40 and 41 firmly bolt support plates 8 and 9 to cover
plates 42.

March 2013 Caterpillar confidential: yellow 175

Installation sequence with turbocharger at free end (var. -25, without ribs)

Before installing the exhaust manifold put the bottom plates of the exhaust cladding (pos.
3, 4, 5) into position.
After that, install pos. 1, 2, 6, 10, 7.
Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.
8 M 25: Insert pos. 46 between (2x) pos. 18 and bolt them together.
6 M 25 and 9 M 25: Insert pos. 46 between pos. 48 and 18 and bolt them together.
Insert pos. 47 between (2x) pos. 19 and bolt them together.

March 2013 Caterpillar confidential: yellow 176

Install rear panel in the following sequence:

8 M 25: 11, 12, 13, 14, 45, 33, 22, 23, 24, 26, 36, 34.
6 M 25 and 9 M 25: 20, 21, 22, 25, 45, 23, 24, 26, 36, 34.

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March 2013 Caterpillar confidential: yellow 178

Install front in the following sequence: 27, 28, 30, 31, 32, 40, 39, 41, 44

For installing the rear first preassemble cover plate 42 on support plate 8 so as to
be finger tight. Then preassemble support plates 8 and 9 so as to be finger tight.
After installing claddings 39, 40, and 41 firmly bolt support plates 8 and 9 to cover
plates 42.

March 2013 Caterpillar confidential: yellow 179

Installation sequence with turbocharger at driving end (var. -26, with ribs)

Before installing the exhaust manifold put the bottom plates of the exhaust cladding
(pos. 3, 4, 5) into position.

Install pos. 1, 2, 6, 7.

Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.

Insert pos. 19 between (2x) pos. 18 and bolt them together.

29a

March 2013 Caterpillar confidential: yellow 180

Install rear panel in the following sequence: 20, 28, 23, 21, 22, 33, 24, 25, 36, 34.

(Shown without pos. 34)

March 2013 Caterpillar confidential: yellow 181

Install front in the following sequence: 26, 27, 30, 31, 32, 40.

Continue assembly with 41, 45, 44.

29d

Install rear in the following sequence: 8, 9, 42, 43, 48, 49.

March 2013 Caterpillar confidential: yellow 182

Installation sequence with turbocharger at free end (var. -26, with ribs)
Before installing the exhaust manifold put the bottom plates of the exhaust cladding
(pos. 3, 4, 5) into position.
6 M 25 and 9 M 25: After that, install pos. 1, 2, 6, 10, 7 .
8 M 25: After that, install pos. 1, 20, 13, 2, 6, 10, 7.

Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.
8 M 25: Insert pos. 46 between (2x) pos.18 and bolt them together.
Insert claddings 11 and 12.
6 M 25 and 9 M 25: Insert pos. 46 between pos. 48 and 18 and bolt them together.
Insert pos. 47 between (2x) pos. 19 and bolt them together.
Insert cladding 20.

Install pos. 20 on
6 M 25 and 9 M 25:

8 M 25:

March 2013 Caterpillar confidential: yellow 183

rear panel in the following sequence:

8 M 25: 22,14, 45, 33, 26, 35, 23, 36.
6 M 25 and 9 M 25: 21, 22, 25, 45, 35, 26, 23, 36.
Bolt down cover plate 34.
Preassemble pos. 8 and 9 so as to be finger tight.
Shown without pos. 34

March 2013 Caterpillar confidential: yellow 184

Install front in the following sequence:

24, 27, 28, 30, 31, 32, 49, 40, (39 9 M 25 only), 41, 44.

Install rear in the following sequence:

Preassemble pos. 42 and 43 onto pos. 8 so as to be finger tight. Install cover plates
52 and 53. Preassemble pos. 51 onto pos. 9 so as to be finger tight. After installation
of pos. 49, 40 and 41 firmly bolt together pos. 8, 9, 42, 43 and 51.

March 2013 Caterpillar confidential: yellow 185

Installation sequence with turbocharger at driving end (variants -27, -28, square shape)
Before installing the exhaust manifold put the bottom plates of the exhaust cladding (pos.
3, 4, 5) into position.
Install bottom plates:
6 M 25: 1, 2, 6, 7
8 M 25: 1, 20, 13, 2, 6, 7
9 M 25: 1, 2, 6, 10, 7
Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.

March 2013 Caterpillar confidential: yellow 186

6 M 25 and 9 M 25: Bolt together pos. 18 and 19.

Insert cladding 20.
8 M 25: Insert pos. 46 between (2x) pos.18 and bolt them together.
Insert claddings 11 and 12.

March 2013 Caterpillar confidential: yellow 187

Install rear panel in the following sequence:

8 M 25: Install pos. 22, 14, 45, 33, 26, 35, 23, 36 .
6 M 25 and 9 M 25: Install pos. 21, 22, 25, 45, 35, 26, 23, 36 .
Bolt down cover plate 34 (see first figure at the top).
Preassemble pos. 8 and 9 so as to be finger tight.

Assembly gap between the

cladding sections

Assembly gap between the

support plate sections

March 2013 Caterpillar confidential: yellow 188

Install front in the following sequence:

24, 27, 28, 30, 31, 32.

Bolt together pos. 37 and 38 and install them together.

Only 6 M 25 and 8 M 25: Bolt together pos. 37 and 40 and install them together.

Install pos. 39.

Install rear in the following sequence:

Preassemble pos. 43 onto pos. 8 so as to be finger tight.

9 M 25: Preassemble pos. 44 and 47 onto pos. 37 and 38 so as to be finger tight.

6 M 25 and 8 M 25: Preassemble pos. 44 and 47 onto pos. 37, 38 and 40 so as to be finger
tight.

Preassemble pos. 51 onto pos. 9 so as to be finger tight.

After installation of pos. 37, 38, 39, 40 firmly bolt together pos. 8, 9, 43, 44, 47, 51
(on 9 M 25 without pos. 40).

March 2013 Caterpillar confidential: yellow 189

Installation sequence with turbocharger at free end (variants -27, -28, square shape)
Before installing the exhaust manifold put the bottom plates of the exhaust cladding
(pos. 3, 4, 5) into position.
Install bottom plates 1, 2, 6, 10, 7.
Insert pos. 15 and 16 between (2x) pos. 17 and bolt them together.

March 2013 Caterpillar confidential: yellow 190

Insert pos. 19 between (2x) pos. 18 and bolt them together.

Insert cladding 20.

Install rear panels in the following sequence:

6 M 25: Install pos. 25, 28, 23, 21, 22, 33, 36 .
8 M 25 and 9 M 25: Install pos. 28, 21, 23, 22, 33, 36, 25.
Bolt down cover plate 34 (see first figure at the top).
Preassemble pos. 8and 9 so as to be finger tight.

Assembly gap between the

cladding sections

Assembly gap between the

support plate sections

March 2013 Caterpillar confidential: yellow 191

Install front in the following sequence:

24, 26, 27, 30, 31, 32.
Bolt together pos. 37 and 38 and install them together.
Only 6 M 25 and 8 M 25: Bolt together pos. 37 and 40 and install them together.
Install pos. 39.

Install rear in the following sequence:

6 M 25: Preassemble pos. 43 onto pos. 8 so as to be finger tight.
8 M 25 and 9 M 25: Preassemble pos. 43 onto pos. 8 and9 so as to be finger tight.
9 M 25: Preassemble pos. 44, 47 and 49onto pos. 37, 38, 39 so as to be finger tight.
6 M 25 and 8 M 25: Preassemble pos. 44, 47 and 49onto pos. 37, 38, 39, 40 so as to be
finger tight.
Preassemble pos. 48 onto pos. 9 so as to be finger tight.
After installation of pos. 37, 38, 39, 40 firmly bolt together pos. 8, 9, 43, 44, 47, 48,
49 (on 9 M 25 without pos. 40).

March 2013 Caterpillar confidential: yellow 192

Diesel Generator Set

Alignment instruction for diesel generator sets
Alignment instructions are cost unit specific. The drawing number applicable in your case
can be found in PIDS from position 9000 (normally position 9212). The values belonging
to the drawing number are included in the table below. In the following alignment
instruction replace placeholders A, B, and C by the values from the table that apply to your
drawing number.
Align the generators in cold condition with respect to the engine as follows:
Axial alignment:
Push the generators towards the engine until the assembly reference dimension of the
coupling is A mm (see chapter “Flexible Flange Connection”).
Radial alignment:
Lift the generators by means of the jacking screws so that they are positioned B mm higher
than the engine. Take into account a settlement of about 0.1 mm of the Vibracon elements.
Angular alignment:
Angular ± 0.2 mm measured at coupling outside diameter C mm.

In this position place the Vibracon elements onto the top plate, put through the foundation
bolts and fasten them finger tight (about 20 Nm). Centre the Vibracon elements with regard
to the bolt and raise them by turning until the spherical cap fits closely without any
clearance (about 20 Nm). Slacken the jacking screws and tighten the foundation bolts with
the prescribed torque.
After a test run of the generator sets measure and record the crank web deflection at
operating temperature (about 10 minutes after shutdown from full load).

For tightening torques of the coupling see chapter “Flexible Flange Connection”.

Vulkan coupling
Drawing number A B C
used

2500.7-15.33.00-01 RATO-DS 3311A series 2100 260 ± 0.5 mm 1.00 mm 995 mm

2500.7-15.33.00-02 RATO-DS 3410A series 2100 260 ± 0.5 mm 1.00 mm 1070 mm
2500.7-15.33.00-03 RATO-DS 3418G series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-04 RATO-DG 29D8 series 2200 389 ± 0.5 mm 0.2 mm 870 mm
2500.7-15.33.00-05 RATO-DS 3311A series 2100 260 ± 0.5 mm 0.2 mm 995 mm
2500.7-15.33.00-06 RATO-DS 3415A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-07 RATO-DS 3410A series 2100 259.5 + 0.5mm 0.2 mm 1070 mm
2500.7-15.33.00-08 RATO-DS 3410A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-09 RATO-DS 3415A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-10 RATO-DS 3411A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm

March 2013 Caterpillar confidential: yellow 193

Vulkan coupling
Drawing number A B C
used

2500.7-15.33.00-11 RATO-DS 3411A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm

2500.7-15.33.00-12 RATO-DS 3411A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-13 RATO-DS 3311A series 2100 260 ± 0.5 mm 0.2 mm 995 mm
2500.7-15.33.00-14 RATO-DS 3411A series 2100 360 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-15 RATO-DS 3411A series 2100 260 ± 0.5 mm 0.2 mm 1070 mm
2500.7-15.33.00-16 RATO-DS 3311A series 2100 260 ± 0.5 mm 0.2 mm 995 mm
2500.7-15.33.00-17 RATO-DS +3D1H series 2100 360 ± 0.5 mm 0.2 mm 995 mm

Alignment instruction for 9 M 25 C diesel generator sets (engine numbers 45278,

45379, 45280)
1. Move the generator intended for the generator set by means of a crane to its appropriate
position on the base frame and place it onto its jacking screws.
2. For axial alignment push the generator towards the engine until the assembly reference
dimension of the RATO-R 262 TR coupling of 594 ± 0.6 mm is reached.
3. For vertical alignment lift the generator by means of its jacking screws so that the
generator shaft axis is 0.1 mm higher than the crankshaft axis. Due to creeping effects,
thermo shock of the conical elements, settling of the Vibracon elements, and thermal
expansion of engine and generator the crankshaft axis is 0.5 mm above the generator
shaft during operation of the engine.
4. For horizontal alignment align the generator shaft axis so that it is in true alignment with
the crankshaft axis.
5. For angular alignment position the generator in such a way that, when measured on the
diameter of the flywheel recess D = 800 mm, a deviation of max. 0.5 mm is obtained.
For notes regarding fastening of the generator on the base frame see chapter “Resilient
Mounting”, section “Generator fastening”: 9 M 25 C (engine numbers 45278, 45379,
45280 only)“
For notes regarding the installation of the coupling see chapter “Flexible Flange
Connection”, section “Vulkan RATO-R 262 TR, series 2200 on 9 M 25 C”

For notes regarding the installation of the engine on the base frame and genset arrange-
ment see drawing 2509.1-15.12.00-01.

Sealing surfaces
Apply Hylomar universal sealing compound to the sealing surfaces of engine and
base frame. Lay the GORETEX flat gasket between them towards the engine inside;
intersections are to overlap.

March 2013 Caterpillar confidential: yellow 194

Engine and generator fastening

Alignment instructions are cost unit specific. The drawing number applicable in your case
can be found in PIDS. To the generators listed in the table the following applies:
Apply the tightening torques for the fixing screws in three steps:
Step 1 ⇒ 20 %
Step 2 ⇒ 60 %
Step 3 ⇒ 100 %

Tighten screws of strength class 8.8 - M10 - with ⇒ M = 40 Nm

Oil
Tighten screws of strength class 8.8 - M12 - with ⇒ M = 70 Nm
Oil
Tighten screws of strength class 8.8 - M16 - with ⇒ M = 150 Nm
Oil
Tighten screws of strength class 8.8 - M24 - with ⇒ M = 600 Nm
(engine). Oil
Tighten screws of strength class 8.8 - M30 - with ⇒ See table below
(generator). Oil or enquire value from VT5.

Engine Generator Tightening torque [Nm]

6 M 25 AEM SE 710 SA10 1465

6 M 25 AEM SE 630 SA10 1460
6 M 25 AEM SE 630 M10 1460
6 M 25 Siemens 1460
6 M 25 AEM SE 710 SB10 1460
6 M 25 C AvK DSD 114K1-10W 1465
6 M 25 AEM SE 710 SA8 1465
6 M 25 C Siemens 1DB1032-8AY05-Z 1465
6 M 25 C Siemens 1DC1032-8AY05-Z 1465
6 M 25 C Marelli MJR 710 M 1465
6 M 25 C Marelli MJH 710 SC8 1465
6 M 25 C AEM S71B20-019 1465

8 M 25 AEM SE 710 M10 1465

March 2013 Caterpillar confidential: yellow 195

Engine Generator Tightening torque [Nm]

8 M 25, 8 M 25 C AvK DSG 114 L1-10W 1465

8 M 25 ABB AMG630 S10 DBSBC 1370
8 M 25 AEM SE 630 LL10 1465
8 M 25 LEROY SOMER 1460
8 M 25 LEROY SOMER LSA 56 UL 85 1465
8 M 25, 8 M 25 C AEM SE 710 SA10 1465
8 M 25 HYUNDAI 1465
8 M 25 C AEM SE 710 S10 1465
8 M 25 C Marelli MJR 710 L 1465
8 M 25 C AEM SE 710 S10 1465
8 M 25 C AEM SE 710 M10 1460

9 M 25 Siemens 1FJ3 713-10 1370

9 M 25 Siemens 1FJ2 713-10SB92 1370
9 M 25 ABB AMG 0710SM08 LSE 1460
9 M 25 LEROY SOMER LSA 56 ZL 11 1465
9 M 25 AEM SE 710 M10 1200
9 M 25 AEM SE 710 S10 1200
9 M 25 C AvK DSG 114 L1-10W 1465
9 M 25 C Siemens 1DC1237-8AW04-Z 1465
9 M 25 C Siemens 1DC1237-8AY05-Z 1465
9 M 25 C Marelli MJRM 710 MB8 1465
9 M 25 C Siemens 1DC1238-8AJ05-Z 1465

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Installation of the support bearings

Determine crank web deflection at the last cylinder, lift bearing plate (5) up to 1/2 gap value
of TDC to BDC. Align gear wheel for true running to max. 0.03 mm.

Tighten screws (11) and (14) with ⇒ M = 130 Nm

Tighten screws (12) with ⇒ M = 60 Nm

Pretighten screws (10) with ⇒ M = 250 Nm

and then finally tighten with a torque angle of ⇒ 90°
Apply Molykote to thread and screw head contact surface.

March 2013 Caterpillar confidential: yellow 197

Installation of PTO coupling hubs

Vulkan RATO-R G262 / 2400

Vulkan RATO-R G252W BR2400
Vulkan RATO-S G252 Q / 2400

Hub installation by means of an oil press fit for the coupling hubs mentioned above.
- Push the hub onto the shaft journal without applying any pressure until the contact
surfaces are close-fitting.
- Pressing liquid: SAE 10 hydraulic oil
- Oil pressure, slide-on distance and assembly force: see table.
- Relieve the assembly force indicated in the table earliest after one hour.
- Subject the oil press fit to stress earliest after 24 hours.
Observe the hydraulic installation instruction E11198-1-5 of Vulkan.

Assembly
Coupling hub Drawing Dimen- Oil pressure Slide-on force
sion X distance
Vulkan RATO-R
G262 / 2400 1G2620R090 235 mm max. 2500 bar 7.2 + 1.4 mm 583 kN

Vulkan RATO-R
G252W Br. 2400 1G2520R108 240 mm max. 3000 bar 8.4 + 1.4 mm 655 kN

Vulkan RATO-S
G252 Q / 2400 1G25200154 240 mm max. 2500 bar 7.1 +1.4 mm 575 kN

March 2013 Caterpillar confidential: yellow 198

Vulkan RATO-R 192W / 2400

Vulkan RATO-K 6011 / 2400
Vulkan RATO-R G191WR / 2400
Vulkan RATO-R G1920R / 2400
Vulkardan E
Hub installation by means of an oil press fit for the coupling hubs mentioned above.
- Push the hub onto the shaft journal without applying any pressure until the contact
surfaces are close-fitting.
- Pressing liquid: SAE10 hydraulic oil
- Oil pressure: max. 2500 bar
- Slide-on distance and assembly force: see table.
- Relieve the assembly force indicated in the table earliest after one hour.
- Subject the oil press fit to stress earliest after 24 hours.
Observe the hydraulic installation instruction E11198-1-5 of Vulkan.

Coupling hub Drawing Dim. Y Slide-on dist. Assembly force

Vulkan RATO-R
192W / 2400 1G1920R097 170 mm 6.0 + 1.3 mm 400 kN

Vulkan RATO-K
6011 / 2400 1K60100027 170 mm 6.0 + 1.1 mm 400 kN

Vulkan RATO-R
G191WR / 2400 1G1910R030 170 mm 6.0 + 1.3 mm 402 kN

Vulkan RATO-R
G1920R / 2400 1G1920R137 170 mm 4.3 + 1.3 mm 307 kN

Vulkardan E 1K49100379 135 mm 2.1 + 1.3 mm 127.1 kN

March 2013 Caterpillar confidential: yellow 199

Stromag TEW 2000...

Stromag TEW 10000...
Stromag TEW 12500...
Stromag TEW 25000...
Hub installation by means of an oil press fit for the coupling hubs mentioned above.
Obtain the following additional work documents:
flange shaft drawing: see table
Arrangement of Stromag disc flange - group drawing 872...
Description of the hydraulic installation DB 870.020
- Check the arrangement of the disc flange (1)
- End position as shown, pressed onto engine PTO journal so as to be flush.
- Pressing liquid: SAE10 hydraulic oil
- Oil pressure: max. 2500 bar
- Slide-on distance: see table.
- When using SAE 10 relieve the assembly force earliest after one hour.
- Commissioning: Earliest 24 hours after releasing the oil press fit.

Coupling hub Drawing Dim. Z Slide-on dist. ∅ Dimension A

Stromag TEW 2000... 2500.7-63.40.01-01 170 mm 3.2 + 0.6 mm 100 - 0.01

Stromag TEW 10000... 2500.7-63.40.01-01 170 mm 5.4 + 0.9 mm 100 - 0.01
Stromag TEW 12500... 2500.7-63.40.01-01 170 mm 5.1 + 1.0 mm 100 - 0.01
Stromag TEW 25000... 2500.7-63.40.01-02 240 mm 7.1 + 1.1 mm 157 - 0.01

March 2013 Caterpillar confidential: yellow 200

Resilient Mounting
Installation

Pourable resin: Clean the unmachined top plates.

Steel chocks: Machine the top plates by milling or planing.

1. Align the engine with jacking screws:

In vertical direction: approx. 2.00 mm above gearbox shaft (gearbox with vertical shaft
offset) approx. 2.20 mm above gearbox shaft (gearbox with horizontal shaft
offset)
In transverse direction: so as to be in true alignment with the gearbox
In axial direction: coupling to be axially relieved.

2. Drill the top plates for bonded rubber rail fixation (1) and (2).

3. Screw the bonded rubber rails (1) and (2) underneath the engine with screws (3) and
washers (4).
Tighten screws (3) with ⇒ M = 350 Nm
Oil

The contact surfaces of the bonded rubber rails must show a bright metal finish.
Mechanically remove any contamination by scale, rust or suchlike before bolting them
down.

Secure with Loctite 242

March 2013 Caterpillar confidential: yellow 201

4.1 Pourable resin: Pour the resin around the bonded rubber rails according to the
instructions of the resin manufacturer (resin must not contact the rubber). Lower the
engine after curing of the resin. That means, relieve the jacking screws completely.
After relieving/removal of the jacking screws, reinsert the screws again with spacer
sleeves
and tighten them with ⇒ M = 150 Nm
Static deflection about 1.50 mm.

4.2 Steel chocks: Measure the distance between top plate and bonded rubber rails.
Manufacture steel chocks and insert them. Lower the engine according to 4.1.

5. Further settling (subsidence of the engine after 24 hours) about 0.40 mm. The engine
will then be in line with the gearbox shaft.

6. Fasten the bonded rubber rails with screws (5) and washers (6) onto the top plate.
Tighten screw (5) with ⇒ M = 350 Nm
Oil

7. Before installing the stoppers (7) machine a chamfer (1 x 45°) on the engine mount in
the area of the stoppers over a length of 350 mm.

2 mm adjusted upon installation

8. Install side stoppers (7) and brackets (8). Fasten the screws finger tight. Insert the
screws (9) and washers (10) before screwing the locking ring onto the stopper tube.

March 2013 Caterpillar confidential: yellow 202

Screw the locking ring (11) up until it reaching the end-stop.

9. Measure the distance between top plate and bottom edge of locking ring (= dimension
H).
Add 7 mm to the measured dimension H. The calculated dimension is the tube length
R.

10. Remove side stoppers (7) and brackets (8).

11. Mount side stoppers (7) and brackets (8) above the tube.Fasten the screws finger
tight.

12. Centre the tube by screwing down the locking ring (11). The conical surfaces must
come to rest with a positive fit. Level any unevenness of the top plates, tack the tube
and weld it.

13. Remove the side stoppers (7) and brackets (8).

14. Drill the top plates for the tie rods (12).

15. Insert the rubber lining (13) into the welded tube. Install the side stoppers (7) and
brackets (8).

16. Screw the locking ring (11) upward until it reaches the end stop and secure it with 2
headless screws.

17. At operating temperature the engine stands about 1.00 mm above the gearbox shaft
(due to thermal expansion of bonded rubber rail, engine, gearbox, and foundation).
The flexible coupling is designed to compensate this. Later re-alignment is not
necessary.

18. After reaching operating temperature adjust the vertical clearance of 2.00 mm
between stopper (7) and nut/washer (14) and secure with nut (15) and washer (16).

Tighten screws (9) with ⇒ M = 650 Nm

Apply oil to the contact surfaces,
Loctite 242 to the thread

Tighten nuts (17) with ⇒ M = 800 Nm

Loctite 242

Tighten nuts (18) with ⇒ M = 640 Nm

Oil
or
tighten nuts (18) with ⇒ M = 210 Nm + 60°
Oil

March 2013 Caterpillar confidential: yellow 203

Locking device to be used in case of damage

(not possible for all variants)

1. Remove nuts and washers (15), (16), (14).

2. Loosen hexagon socket set screws M12 (not shown below).

3. Screw the locking ring (11) downward until it rests against the tube.
An auxiliary hole ∅10 mm for a tool is provided in the locking ring.

4. Put washer and nut (14) onto the side stopper (6) and

tighten with ⇒ M = 1250 Nm

or ⇒ M = 300 Nm + 60°
Oil

In locked condition Under normal operation

2 mm adjusted
upon installation

March 2013 Caterpillar confidential: yellow 204

Conical elements: All engines

This version is applicable to the following engines and the corresponding variants of the
drawings 250X.7-15.10.00-XX:

All engines: Variants -04, -05

6 M 25 C: Variant -08
6 M 25 C, 8 M 25 C: Variant -07
9 M 25 C: Variants -06, -07, -08
8 M 25: Variants -08, -09

Remove all jacking screws after alignment and curing of the resin.
Tighten screws (1) with ⇒ M = 650 Nm + 50 Nm
Oil

Tighten nuts (2) with ⇒ M = 850 Nm + 50 Nm

Oil

Tighten nuts (3) with ⇒ M = 1650 Nm

Oil

Tighten nuts (4) with ⇒ M = 350 Nm + 30 Nm

Oil
Tighten nuts (7) with ⇒ M = 400 Nm
Oil
Insert stud (6) with Loctite 243.
Thread engagement of the stud (6) is ⇒ 20 mm

March 2013 Caterpillar confidential: yellow 205

Conical elements: 6 M 25, 8 M 25, 8 M 25 C

Applicable to the following engines and variants of the drawings 250X.7-15.10.00-XX

Engine Variant

6 M 25 -02, 03
8 M 25, 8 M 25 C -02

Remove all jacking screws (5) after alignment and curing of the resin.
Tighten screws (1) with ⇒ M = 500 Nm
Tighten screws (2) with ⇒ M = 300 Nm
Tighten nuts (3) with ⇒ M = 1000 Nm
Tighten nuts (4) with ⇒ M = 390* Nm
Tighten nuts (7) with ⇒ M = 400 Nm
For 6 M 25 variant -03 insert stud (6) with Loctite 243.
For all other variants insert stud (6) with Loctite 242.
*Caution!
For 6 M 25 variant -02 the tightening torque for nut (4) has to be as specified by the resin
supplier!

March 2013 Caterpillar confidential: yellow 206

Conical elements RD 214: 9 M 25 C (engine numbers 45278, 45379, 45280 only)

Installation of the bearing brackets on the engine

1. Install the clamping plate (3) with screws (9) on the bearing bracket (3) so as to be finger
tight.
2. Place the bearing bracket against the engine mount by means of a hoist and install it
with studs (8), washers (11), and hexagon nuts (7) so as to be finger tight.
3. Tighten the hexagon socket screws (9) for fastening of the clamping plate (3) with the
indicated tightening torque.
4. When the bearing bracket (2) rests against the engine mount without leaving any lateral
gap, tighten the bearing bracket on the engine mount with the indicated torque by
tightening the hexagon nuts (7).
Tighten nuts (7) with ⇒ M = 850 + 50 Nm
Oil
Tighten hexagon socket screws (9) with ⇒ M = 650 + 50 Nm
For a complete description see drawing 2509.1-15.12.00-01.

March 2013 Caterpillar confidential: yellow 207

Installation of the conical elements RD 214 on the top plate of the base frame:
1. Position the conical elements on the weld-on plates provided for this purpose on the top
plate of the base frame. The nameplate of the conical element must be visible from
outside.Insert the three M20 threaded bolts (7) with Loctite 243 (thread engagement 20
mm) and fix them with the hexagon nuts (6) so as to be finger tight.
2. Turn the central buffer (3) in counter-clockwise direction by means of the upper hexagon
until reaching the upper end stop. Turn the central buffer spindle downward 2 turns to
move the central buffer to central position.
3. Check the clearance (5 mm) of the height adjustment nut (5) with respect to the upper
element part (4).
If necessary, readjust the clearance.
Tighten nuts (6) with ⇒ M = 400 Nm
Oil
Tighten nut (2) with ⇒ M = 1650 Nm
Oil

Check the alignment and central buffer clearance

(after alignment / fastening of the generator and installation of the coupling)
1. Check the alignment at the coupling and crank web deflection at cylinder 1 and record
the values.
2. Measure and record the distance between element foot (8) and upper element part (4)
at all four machined corner surfaces designated for the fixing screws. Check the lower
central buffer clearance by means of steel chocks in the notch provided for this purpose
on the conical element and record it. At operating temperature, the lower clearance
should be 5.5 mm.
For a complete description see drawing 2509.1-15.12.00-01.

March 2013 Caterpillar confidential: yellow 208

Conical elements RD 114: 9 M 25 C (engine numbers 45278, 45379, 45280 only)

Preassembly of the conical elements RD 114 on the foundation:
1. Position the conical elements on the bolted-on steel plates of the foundation provided
for this purpose. The nameplate of the conical element must be visible from outside. Fix
the conical element with the four M24 screws so as to be finger tight.
2. Turn the central buffer in counter-clockwise direction by means of the upper hexagon
until reaching the upper end stop. Turn the central buffer spindle down 2 turns to move
the central buffer to central position.
3. Push the washers (15) onto the central buffer spindle.
Tighten nut M48x3 (17) with ⇒ M = 2300 ± 100 Nm
Oil
Tighten screws (18) with ⇒ M = 800 ± 50 Nm
Oil
Insert screws (6) with Loctite 243 and tighten them with ⇒ M = 650 + 50 Nm
Lubricate the screw head contact surface with oil
Remove the jacking screws (19) after alignment and curing of the resin.
For a complete description see drawing 2509.1-15.12.00-01.

March 2013 Caterpillar confidential: yellow 209

Locking device: 9 M 25 C (engine numbers 45278, 45379, 45280 only)

1. For transporting the complete generator set a rigid connection between engine and
base frame must be established by means of a locking device. This locking device has
to be fitted on both sides at the locations marked with a Y.

2. Insert the threaded rods (20) from above through the engine mount and screw a washer
(20) and two nuts (21) onto the threaded rod between engine mount and base frame.
3. Turn the threaded rod (20) into the thread of
the top plate of the base frame so that there
are sufficient turns of the thread above the
engine mount to accommodate nut (21) and
washer (22).
4. Turn the lower nut (21) between engine mount
and base frame downward to the top plate of
the base frame and tighten it with the torque
indicated below.
5. Turn the upper nut (21) with washer (22)
between engine mount and base frame
upward to the engine mount and fasten it
finger tight.
6. Screw the nuts (21) with washers (22) onto the
upper end of the threaded rod up to the engine
mount and tighten the nut the with the torque indicated below.
Tighten nuts (21) with ⇒ M = 350 Nm
Oil

Loosening the locking device:

1. Loosen the nuts (21) and turn the threaded rod (20) upward so that sufficient clearance
(approx. 10 mm) is ensured between the end of the threaded rod and the base frame.
2. Turn the upper nut downward to the engine mount and turn the lower nut against the
engine mount to fix the threaded rod in this position. Lock the nuts and threaded rod in
such a way that the locking device cannot loosen during operation of the engine.
Generator fastening: 9 M 25 C (engine numbers 45278, 45379, 45280 only)

1. Align the generator to the engine, see chapter “Diesel Generator Set”, section
“Alignment instruction for 9 M 25 C diesel generator sets (engine numbers 45278,

March 2013 Caterpillar confidential: yellow 210

45379, 45280)”
2. Check whether the plates welded on for accommodating the Vibracon elements (8) and
the mounting feet of the generator are free of paint and grease in the area of the
Vibracon elements.
3. Position all Vibracon elements (8) on the weld-on plates provided for this purpose below
the mounting feed of the generator. In as-delivered condition the Vibracon elements are
adjusted to central position.
4. Insert the foundation bolts of the Vibracon elements from below through the top plate,
through the Vibracon elements, and the mounting feet and tighten the related nuts with
washers so as to be finger tight.
5. Centre the Vibracon elements with respect to the foundation bolts and turn them upward
to the mounting foot of the generator with an appropriate tool until the spherical upper
part of the Vibracon element rests against the engine mount without any clearance.
6. Loosen the jacking screws of the generator and turn them upward.
7. Tighten the nuts of the foundation bolts with the prescribed tightening torque.
8. Install the RATO-R 262 TR coupling, see chapter “Flexible Flange Connection”,
section “Vulkan RATO-R 262 TR, series 2200 on 9 M 25 C” or drawing
MA_1G262TR108_DE
For a complete description see drawing 2509.1-1-015.12.00-01.
14

March 2013 Caterpillar confidential: yellow 211

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