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EngineerbeHandbook

taK M2o CAT


cear Train
- fiornllng ot lntom.di.t. gear wh€€r
The locklngplale - 2 - mustr6sl fmly in th6 grooveroot of the hternediateg6arwheel
Anen0onlWhenexchanging theGnnq on the intermediato
gearwheetaxt€take@b
lhstlhe iniermodiate gearwhetronainBtn themeshing of @mshanandcrankshangear.
OiheMis€, lhereis tho st of misaaJostgd
limi.gdata.

- Lub, oll inloctoc lor th6 gear drtv.


Tightenhollowsc€ws wlth -+ ll-40 Nm

g€ar- intemsdlatg
Crankshan gear wh66l -+ o.2o- 0.a0

gear whool,csmshan
inremedrala g€ar "+ 0.20- o,4.tt
- Intorn.dilte ge.r whoel
0.20.0.80

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11.11.2004 CaterpillarMotorencmbH & Co. KG 34
c8terpillar
cDnrdential:
yettow
Engineer6SHandbook
M20 CAI
Gear Train
- Camshaftgear wheel
Tightenscrews- I -with -) M=85 Nm
Molykote

Tightenscrews- 2 - with -+ M=100 Nm


Molykote

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15.M.2ffi CaterpillarMotorenGmbH& Co. KG 35
Caterpillar
confidential:
vellow
EngineerfiSHandbook
M20 CAT
GovernorDrive
- Governordrive gear
Tightenfixingscrews- 1 - for -+ M=60 Nm
governor drivegearwith
Molykote

Tightencastellated nutfor fixingthe helicalgear


w h e e-l 2 - w i t h - - ) M=30 Nm
andtightenfurtherto the nextsplitpin hole.Molykote
- Backlash
Smallgovernor gearwheel)-big
drivegear(helical
governordrivegear(helicalgearwheel) -t 0 . 1 5- 0 - 2 0 mm
. End clearance
End clearance. 3 - betweengovernorconsoleand
couplingbush --) 0.10- 0.30 mm

Betweenthe big governordrive gear (helicalgear wheel)


andthe end coverthere must be a clearance- 4 - of --) 0.30- 0.75 mm

to changethe bushes- 5 - und- 6 - in the engineblock,so observe


Wennit'snessecary
the measurements
in the sketch.Oilthe bushesa littlebefofefitting.Useno Molykote.

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15.U.2M CaterpillarMotorenGmbH& Co.KG 36
Caterpillar
confidential:
yellow
Engineer{B Handbook
taK M20 EAI
Camshaft

Tigften nxing scrcws for lhe €mshaff beadngswith -+ fl-30 Nm

. Vlb..tlon damper for camshaft


1.10.7-31.40,00-01-
r€pl5c€dby 1.10.7-31.40.00-05
(6M20)
Tighten sftws with -+ fl-50 Nm

as.|ffi 12r1,5X55ISO4762

1.10.7-31.40.0G02Epla@d by 1.10.731 40 00-06


(8M20/ 2 vibraliondampers)
Tlghten sfiows with -t lU-60 Nm

1.10,7-31.40.00-03 €placed by 1.10.7-31.40.00-07


( 9 M 2 0 / 3 v i b r a t i odn. m p a c )
Tighienssews - l - and - 2 - w h J lU-50 Nm
Molykote
1 = 4 allenscreE M12I1,5:130lSOa762 3.3.A3C
2 = 2all6nscM M12xt,5x45rso4752 3.3-A3c

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'11.11.2OO4CaterpillarMotorenGmbH& Co. KG 37
CateDillarconlidential:
vell@
EngineerfiCHandbook
IiETK M20 CAI
Camshaft
- Tlghtenlng torqu.s camshan
Tighten6ll6n sc.ews - 1 - with M -'l0O Nn

TlghtenscEws - 2 - tor tange - 3 - wllh ilt = t00 Nm

fo!allensftws-4-see

- Mo!ntlng camshaft
Ou.ingevery assemblyofthe @m8hafllake care lhat a cylindri€ipl. - 2 - ls insertedup
to stop positon in th€ camshaflnanges- 1 . The cylindricalpin must alwaysbe insened
near the nangecode numbef- 3 - a@.to therolowing E
6 cyl. Flangs code I cyl. Flansecod. I 9 cyr. Frrnqo cod.
Part nunb€r i
1 5 1 1
2 2 2 2 2 1
3 3 3 3 3 2
4 3
5 5 5 5
6 6 6 6
7 3
8 8 a 2
1 9 1
n-.
,$l+Hj
3
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1'1.11-2004 CaterpillarMotorenGmbH& Co. KG 38
CaleDilla.@nfdenlial:vsllow
Engineer@Handbook
till,K M20 GAT
Lower Valve Drive
berweenrso adja@ntbearhg
o.to- 0.20

Iounting ltrstnrction
Al lhe iunciionpolntsot the rocktngte@rshaftsno an is admtssibte.
wh6n lhe beartno
capsar€loosened, lhe rockinsr6vershafrsmJslbe pLshedlogether frombothsid6s:

Edition SorviceDocumentof Page


11.11.2004 CaterpillarMotorencmbH & Co. KG 39
CalslDilla.confdentiat:vettow
Engineer
{e Handbook
liaK M20 EN
FuelInjectionPumps
Thelightening
torquefor inseding
:40 ND

Tighten nutswrrh -)
lastening M= 50 Nm

- Injectlonpunp 0,00.6-43,12.00-72type: DSFPltu


torquesarc alsovalidtor 0.00.6-43.12.00-97
Tightenscrews- t -wilh -+ il=45 Nm

Tightens6Gws- 2 -w h --t llil = 50 Nm

Tighlenscrews" 3. with -+ M-45 Nm

- 4s- w i t h - - )
TiqhtenscEw M=2s Nm

@
)o
lo

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11.11.2004 CaterpillarMotorencmbH & Co. KG 40
CaleDillarconlidentiatr
vettow
{EHandbook
Engineer
liaK M20 CAT
FuelIniectionPumps
- hlection purnp0.00.6.a3,12,00-79tyP6:DSFPtll/lvr
toquesaroalsovalidfor0,00,6-43.12.m-93
Tlghtensc€w -'l -and - 2 -wilh -+ M-45 Nm

T i g h t e n s c € w - 3 - w n h- + M-25 Nm

Tighen bafflesc€{ - a - wilh -+ ll - 50 !'lm

Ins€ncour&60nk sdews - 5 - with Loctlte243


il=s Nm

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11.11.2004 CaterpillarMotorenGmbH& Co.KG 41
yellow
Caierpillarconlidential:
Engineer{€ Handbook
lf,atK M20 IAT
FuelInjectionPumps
- Injectlonpump0.00.6-4t.r2.OO-92 type:OSFPtMW
T i g h t ernc E w- ' l . a n d - 2 - w i l h - + M=46 Nm

Tiohtensc€w - 3 - wilh -+ lU=25 Nd

Tlghtenbafflescrew- 4 . wilh -+ lU=90 Nn

Insertountelsunkscrews- 5 - withLoctite243
M=5 Nm

Thr. fu.l hj.crion punp ls Epl.c.a th€ tu€rhlectio. pump0,00.6{3,t2.00-79

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11.11.2004 CaterpillarMotorencmbH & Co. KG 42
CaierDlllar
@nfidenlial:vellow
Engin€erAEHandbook
TETK M20 IAI
FuelIniectionPumps
- Fu.l dl.lrllu0ng and cottocttngptp.
orpaNlotr plp* / old derlgn
Tlghlanscr€wE- | - to tuel injectjonpomp
M=60 Nm

- Fueldlstrlbutlngplp€for tuel Inlectlonpunp wdrnt' -79 .nd -92

Clrcllp- 1 - mGl be remowd bior€ lhe ptug-inpipescan b6 ara y shiitedand emov€d,

Edition ServicoDocumentof Page


11.'11.2OO4CaterpillarMotorencmbH & Co.KG
Cal€roillar@nfidenialr v€llow
Engineer6SHandbook
iiEIK M20 DAI
Fuel Injection pumps
. Disdountlng / nountinq
Duringdismounling/mountingaltentionmustbe paidthatthe appedainingdislan@steel
praresae nol removed
li for any reasonremovatotthe disiancesleetptatesis fecessary,lheyhave ro be
ma.kedwith lhe relevantcltinder nlmber
Tnethlckmssdth. dt.t rce steetltate ror eachcytind.ris statodIn the acc€ptance
rest

- check ol commencem6ntof fuet d6tivery


1 Dismounr theinjeciorpumpdetvery
2. Mounrdial gaugewilh extension.
3. Turn engineso lhat rolterresls on
lhe base circleoJcam and the TDC
mark is abt 45 ?beforethe de.

4 . S e l d i a l g a u g e1 o , 0 . i u m e n g i n et n d r e c r i o o
ni r o t a t o n
unlilthe indlcationon lhe gaugeis 5 mm for 170 kwcy afd
4 mm for lS0 kwcyi.
5. Checklhe dimensionon rhe lrywheeliromTDC markio dead enrerinbicator

As io the @nmencemenloffuetdeliveiypleaselook intothe lestbedre@rd.

1. Placelhe gauqewtth measuringdevce of a levetsupoonbv heans of the


ad.usli.gbLsh /d me.sron= 44 2 r./ and 5ersa4F o o
2. InserlreasLn.g dFvie 'nto.re In.Fctonormo oore il rhe e1g ne hoJsng
and read valueon the diat gauge(ro er on cam base circte).
3 r l d c a r e dv 6 u e : t h ( { 1 e s so , t . F o q a r ( e s t e e o a r e s
The dlstane sleel platesare used for seftingihe pre sroke.

2 0 0m m2 . 1 0m m2 . 2 0m m2 3 0 m m2 . 4 0n m 2 . 5 0m m
2 . 6 0m m2 . 7 0m m2 . 8 0m m2 9 0 m m 3 . 0 0 h m

adlustment of th. commencem.nt or fuet ini.crion wtth buitt up inj.clion

The rolleroilhe pumpdriveot cytinder1 is ocaredon lhe base cncte.Removelhe con


nectingpieceand rhe presslre baancinqdetiveryvave from lhe tnjeclionpump. Fix a d al
gaugeon rhe pump (tolcheslhe plunger)Tun rhe enstnein senseot.oialon !.titihe
dial gaugeindicEtes5 mm (otdengines;170kwcyl.) {4 hh: few engines;j90 kwcy.)
Scrdwthe pressurepipe tnto the respecrve laphoe oi rhe camshaitand tightenit. Mount
hydraulcpumpand appy a pressureor approximatety 9OO- 10OObar Tur; ihe
crankshaft10lhe rcspedive commencement of fle njecton (see tesr bed ecod)

I necessary,the camshanoughllo be jixed (s norma[ynot necessarywlh bu]ft!p


inlectionpumps) Afier mounlinocrrnkshanqear wheeland f whee checkthe TDb
posiiionoi the liret cylinder I view ol corred nyvheet fiarki.gst ft necessary,new
markrnssmust be aootied.

Edition ServiceDocumentof Page


11.11.2004 Caterpillar
Motoren
GmbH& Co.KG 44
CslelDilar confidertat:veltow
Engineer
ie Handbook
iiEIK M20 EAI
Sundries

1. connect shait ofthe contro standwith lhe rcgulailngshaft by meansol coupting.


D0 not yet r€mow assemblypin ror lhe shaflning

2. Shiftconlrol.rck ollhe injeclionpumpai cyl 1 so that coincidenceoi line ma.k and


indl€lion is 69ch6d.

3 In lhis posllionclamparllculal6dl6v6riasl k66pingth6 dislanceo10.5mm


b€tweencontrolEck head and articulatedlever.
ir=25 Nh

Repeaiproedure on all rcmainlngcylindersa@. to insltuctlonsof points2 and 3.

5 . Removeassemblypin lor rhe shai li{ng in the onlror stand.


6. Ch€ckeasy motionoi conkollirkage.

7. Seal aniculatedleverwirh lead.

.5s.dbry
Durirg assemblyinserllhe egulalino shail wth qrease(do

Tighlensfiew | - ror lhe bearingbrackelwth --t M =60 Nm

Edition Service Documentof Page


11.11.2OO4Caterpillar
MotorenGmbH& Co.KG 45
CateDilar confidenlial:
ve low
Engin€er6BHandbook
iiETK M20 tul
Sundries
l -- a n d- 2 -
Tighlensc€w5
1f,.25 Nm

cam - t - muslb€ adjusted in 6 waythatin stop


potllionthe @n!arof ihe luelhdlcaloris i. tin6wlrh
tne slampgdpunchm8ft - 2 -,

EnEUEih6 cl€ara.ceof the swingEnge of ths cam


dlsc, Rewoft oamdbc if necessary,

Edition ServiceDocumentof page


11.11.2004 CaterpillarMotorenGmbH& Co.KG 46
calerpillar@nfdonliat:yelow
Englneer figHandbook
traK M20 GAT
Sundries
- Coollrg war.r dlstributingptp.
Tig en E@ws(M16x 100s,3,\3c)- 1 - wiih -+ lf, -l3O Nm

ngln€n scw8 - 2 - (ir onhand)sl€p by stepwith


M=20 Nm
M=60 Nn

Tlghlgnscws - 3 - (r onnand)witl 1U.15 Nm

Edition ServiceDocumentof page


11.'11.2004 CaterpillarMotorenGmbH& Co. KG 47
Caielpillar conf d€r{iali yellow
trSHandbook
Engineer
IAEIK M20 CAT
Opposite Side of coupling
- wlih and without power take.off with vibration
coal thread end scew head suface wilh Molykole
Prelightennxing s6ews - | - qilh -+ t =100 Nm

Wllh th. fixlns 5c.6s puhp hpetl€t c.rl€r and qearwheelror llb ollpump d v. aE tixed

The vibraliondamoeris connectedto lhe lub oilsyslemolihe engine.Eachspringpack


has its own supplybore.When checkingihe vibraliondampeflhe olbores have lo be
checkedior free passage

All tighteni.g torqu€ on this pag€ .r. v.lld ror


th€ fl.ng€d Eh.ftmountinq wilb or without

Edition ServiceDocumentof Page


11.11.2004 caterpillarMotorenGmbH& Co.KG 48
CaleDiilar@nfidenlial:veLlow
Engineerf$iHandbook
M20 CAI
PumpCarrier
- Pump carrier plate
Coatthreadand screw head surfacewith lvlolykote.
TightenscrewsM 12 with -+ M=60 Nm
Molykote

TightenscrewsM I with --) M=25 Nm


Molykote

- Pump carrier plate


Alignpumpcarrierplate- I - over
centering
of the pumpgear carrier- 2 ., and scrcw
it at the cylindercrankcasewith sealing
compound andpinit.

- Cooling water pump


Tightenscrewfor fasteningthe
gearwheelwith -+ M=60 Nm
Molykote
- Fuel feed pump
Tightenscrewfor fastenjngthe
gearwheelwith -) M=60 Nm
Molykote
. Lub. oil pump
Tightenscrewfor fasteningthe
gearwheelwith -+ M=60 Nm
M o l yk o t e
- Hydraulicdeliverypump
Tightenscrewfor fasteningthe
gearwheelwith -+ M=60 Nm
Mo
Edition ServiceDocumentof Page
15.U.2M CaterpillarMotorenGmbH& Co. KG 49
Caterpillar
confidential:
yellow
Engineer6SHandbook
M20 CAI
PumpCarrier
- P u m pm o u n t i n g
lub.oil pumpmounting, suctionandpressufe pumpas wellas coolingwaterpump
mounting HTandLTcircuit, fuelfeedpumpmounting andhydraulik pump
delivery
assemory
1. Checkcontactreflectionon the
appertaining pumpgearwheelconeby
bluepaste.Only a contactreflection
displaced to thethickendis admissible.
2. Heatgear wheelof the
- lub.oil pumpup to 90)E- 1008
- coolrng walerpump, 1
hydraulik deliverypumpand
fuelfeed pumpup to 120ffi - 130F*
- seawarerpumpup Io 1 0 0 &- 1 1 o t r
(Theothervaluesof the seawaterpumpare
likethevaluesof the coolingwaterpump.)
abovetemperature of the pumpshaftand mount
it firmlyon the pumpconeup to stopposition.
(forexample:Whenthere'sa temperature of 20'C
on the pumpshaftof a fuelfeedpump,the gearwheel
hasto be heatetto 14Ol* - 150.j-ry.)
The cone faces must be grease-freeand dry.
3. Fit andtightenscrew- I -,withwasher- 2 -

slide-on lub.oilpumps- 0.33- 0.4'1mm


distance

slide-on coolingwaterpumps- 0.29- 0.32mm


distance

slide-on fuelfeedpumps- 0.44mm


distance
. Backlashes
lub. oil pump mounting
backlash -+ . 0,47
O,2O mm

fuelfeedpumpmounting
backlash -+ O,24- O,50 mm

c o o l i n gw a t e r p u m p m o u n t i n g
backlash -+ - 0,47
O,2O mm

hydraulikdelivery pump mounting


backlash -+ 0,24- 0,50 mm

Edition ServiceDocumentof Page


15.M.2@5 CaterpillarMotorenGmbH& Co. KG 50
Caterpillar yellow
confidentialt
Engineer
ie Handbook
If,EIK M20 CAI
Flywheel Mounting
. Mounling - dlsa.s.mbry
Turn crankshaninlo TDC cyt. 1. Inser.ilywheelveriicay suspendedinrolrsnspon hob
6nd purh n on fi6 crankshaftcone until@ntact s rcached lvount devi@,apptya

P - t3O0 b.r
and pre$ nywheelinto lhe fnal position.

Fln.r poenionn.ans flu8hwirhendofc..nkshaft.The


5rrd.-ondiltanc. 15: 15.5:rhh and16.sr05mm_

L Tum cErkshatl to TDC ryl 1 (ln this posilionihe


projectingscr6w heads al the sear whee on
crankshaftaE poinlingto lhe respective
pickuppocket5on lhe nywheel).

2. Inserlflyuheel veni@ltysuspendedrto
rransporlhole dia.50 mh and pushI on the
cEnkshaft6n€ until contactis reached.

3. P€ss flywhoelinto fnal positionby meafs oi


devi@ and ollhydEu ic mouniirg

4. Fjnal posrtion,as shown,nush wilh end oi

5. Realeasodevi@ earliesl24 h aner bteedng


iheoilhydraulicmounUng.
Molorslad up earrjeslT2 h afrerremoving

lryhendismounlinga ilywheet,s ma* shoutdbe apptiedo


fte nylvheeland on lhe cr.nkshaftin orderro avoidan

. G€ar rim on llywh€€t for pnelmatic starter


Tlghlen sd6w3 wiih -+ M=115 Nn

Edition ServiceDocumentof paoe


11.11.2004 CaterpillarMotorencmbH & Co.KG 51
CalelDillarconfidenlial:vellow
Engineer
fieHandbook
'IETK M20 DAT
Flywheel Mounting

Th€ lollowhg ntvheels


Flywheel1,10,7-73,'10.01-

dbtanc€ r.plac.d by
-03 ,09

.04 ,10

-05 - 1,1

-06

-07

. 13

-18

Th. lryrvh..r v.rr. . .E .ramp.d .t $€ tbni 5rd. ol rh. flywh..b, for lmi.n6 .1.09'.

Edition ServiceDocumentof Page


11.11.2004 CaterpillarMotorenGmbH& Co.KG 52
Cal€oillarconidonlial:yellow
Engineer{CHandbook
TETK M20 GAT
Flexible Flange connectlon
Fl.xlbl. tl.nge conn.ctlonfor g€noretor9p enghe

8tu20
Tidn€n 8cr€w3- I - f,116as friclloml Bistane wiin it = 1?0 Nm

Tighte. Ecw! - 2 - M2.rwi$ M.675 Nn

hghren 3c€w3 - 3 - M22wlrh M.660 Nn

tM20
Trghien 6og5 - | - M18 as liiclioml reslslance wilh :231 Nm

TighienEc@s-2-M22wilh i1.675 Nm

Tlghton sor.ws - 3 - M27 wlth il = 160 Nn

6[20 ] 8lvt2o

valu€slor old€rr€danlswnh only 2 different

Tightanscr€vrs as fidional
M14x160-10.9

wnh
Tig €n 8cr€wsM1Or5G10.S
oll
Edition ServiceDocumentof Page
11.'11.2004 CaterpillarMotorenGmbH& Co. KG 53
C.lerplllar @nndenlial ydl
Engineer
@ Handbook
ilETK M20 GAT
ChargeAir Cooler

M=60 Nm

lU:60 Nm

Applic.blo to coupllng€ld. anrl oppostte€td..


Whenmounling th€dlarg€ai. @oterca€ is lo be takenthalthesqds , 3 -and-4 - aE
artemal€lylightenedin smal steps.
Fnd tghlsn rc@s - a - tlrmrya.d ontythensd6ws - 3 ,.

Edition ServiceDocumentof Page


'l'1.1'l.2OO4 CaterplllarMotoren
cmbH & Co. KG 54
C8laDillar @nf dootiati veltow
Engin6er iE Handbook
flEIK M20 GAT
ChargeAlr Cooter

JOL

h lh€ a@ptane €si e@rd the dlfferentlal pressur€ belore / afler charge ah @oler ls
stal€d.wrsn lhe value has €ached the 1.sJold,cleanlnghas to b6 caried out.

R€mov€ @oling waler inlet and ou ei pipes. Looson scrsws - t - and - 3 - and wilhdEw
lhe chargsan cool€rfrom lhe @6ing.
Fltling h rovsrs€ ord€!, tsking erc ot perteci fl of the sealing shlms.

Edition S€rvlceDocumentof Page


11.11.2OO4CaterpillarMotorcnGmbH& Co,KG 55
CaleDillar @nfideniial vellfl
Engineerie Handbook
TETK M20 EAI
Exhaust Gas Manifold

ngm€n all M12scr€w3$dth -t tt.60 Nm


Tlqht€nsor.ws - l - in 2 sieFswilh
fil = €0 m
t/t= 110 Nm

lnrort all rcrcwa wlth o€8t Rlvolt Gw.F.

Take€B ot lh€ cor€ct scrsw


A pojecitonIs lnadmlsslbl8.

Spdy.ll conn..li4 3t !. wlth gr.ghlt ot


olybdd lprry b.foF morntlng.
o g..*.b b?twan .xp.Blon joiri! .nd .xh.u31 t.5
plpc. dount .ll .rp.Blon lolnr! ln dlEerlon ol.r@w,

Tlghlgn screw8 - 2 -with -+ il = 200 Nm

Edition ServiceDocumentof Page


11.1'1.2004 CaterpillarMotorenGmbH& Co.KG 56
CateDlllarconnd6n&l:yello{
Engineer6€Handbook
M20 CAI
GeneratorGP-Engine
- Attachmentengine and generator
Tightenthe torquesfor the fixingscrewsstep by step.
step 'l -) 20 0/.

step 2 -+ 60%
step 3 -) 1 0 0%

Tightenboltsclassof strength8.8 - Mlo - with -+ M=40 Nm


oil
Tightenboltsclassof strength8.8 - M12 - with -) M=70 Nm
oil
Tightenboltsclassof strength8.8 - M16 - with --) M=170 Nm
oil
Tightenboltsclassof strength8.8 - M20 - with --) M=400 Nm
oil
- Tightenboltsclassof strength8.8 . M24 - with -+ M=500 Nm
oil
Tightenboltsclassof strength8.8 - M27 - with --t M=800 Nm
oil
Tightenboltsclassof strength8.8 - M30 - with -t M = 1200 Nm
oil
- Sealingsurfaces
Daubsealingsurfacesof engineand baseframewith sealingmaterialHylomar.Lay
GORETEX - seal:ngtowardsthe engineinside;overlapcuttingpointsapprox.200mm.

- Alignmentinstruction diesel gensets


only valid for:1) 618M20on baseframewithVulkanRATO-DS A2511142515, series2100
2) 6M20on baseframewithVulkanMTO-R Gl92 T/TR,series2200
3) 9M20on baseframewiih VulkanRATO-DS A2911,se es 2100/2200
Consultation of VTs is necessaryfor all othercombinations.
Thegenerators areto be alignedas followsin coldcondition.
Axial alignment:
- The generators are to be shifiedin directionof the engineuntilthe mountingreference
dimension of the coupling is for l) as wellas 3) 265t0,5mmandfor 2) 367t0.5mm.
Radial alignment:
The generators are to be liftedby meansof the jackingscrewsso that the generatorshaft
is 0.2t0.lmm abovethe crankshaft.
Angular alignment:
Angularclearancet0,2mm measuredat couplingoutsidediameter1)730mm2)585mm
3)820mm. In this positionplacethe vibraconelementsontothe top plate,putthroughthe
foundation boltsandfastenfingertight(about20Nm).Centrethe vibraconelementswith
regardto the boltand raiseby turninguntilthe sphericalcap fits closlywithoutany
clearance(about20Nm).Slackenthe jackingscrewsandtightenthe foundationboltsto the
prescribedtorque.
\Men carryingout the electricaltestsof the gensetsthe crankweb deflectionis to be
measuredat operatingtempeEture('10minutesaftershutdownfromfull load),checked
and recorded-
Edition ServiceDocumentof Page
15.M.2W GaterpillarMotorenGmbH& Go.KG 57
Caterpillarconfidentialtvellow
EngineerdSHandbook
M20 DAI
FlexibleMounting
- Assembly

casting resin: top plates


ceanunmachined

steel chocks: top plates


machine

1. Alignenginewithjackingscrews:
Verticallyapprox.3.30 mm abovethe gear shaft (gearboxwith verticalshaft
offset)and horizontallyapprox.3.10 mm abovethe gear shaft (gearboxwith
horizontalshaft offset).

in truealignment to the gearbox


diagonally

axialcoupling
axiallyrelieved

2. Boretop platesfor bondedr u b b erra i lf i x a t i o-n1 - a n d - 2 - ( m a x?. 2 0 m m ) .

Mountbondedrubber
rails-1.and-2-
andtightennuts- 3 .
with -) M=160 Nm
oil

Edition ServiceDocumentof Page


15.U.2Cf,l5 CaterpillarMotorenGmbH& Co. KG 58
Cateroillar
confidential:
vellow
Engineer
ie Handbook
iiEIK M20 CAI
FlexibleMounting
1.1 Castlng 6€in: Cast the bondedrubb€rEit! a@ordtngto the instrucrionsoi th6
produ@ror th6 ceslinglesin (@stingresinnGt not touch th6 .ubber).Lowerthe
onoineafler cu.ingrhe €s1ing re6in(€ ievejackinsscews comptelety).staii@l
sprnq deffeclion6pprox.2.90mm.

Stsl chocls: Measuredistancebetweer pate and bondedrubberraits.


Manuracluresteel chocksand insed rhem.Lowerenginea@rding to 4.1.

Fix bondedrlbber rairsw(h screws- 4 - and washeB - s - on iop ptate.

Tighte. sq€ws -4 -with -+ M = 200 Nm


otl

Fit slopper.6 . accordrnsto ihe oder {are harked with nunbers)ar rhe engine
mounlandlighlenwithnlls - ? ,
M= t6O Nm
otl
Wdd pipe- 8 - @nticatty
lo.lheslopper

Edition ServiceDocumentof Page


11.1'l.2004 CaterpillarMotorenGmbH
& Co. KG 59
c8l€lpillar@nfdential:vellow
Engineerlr$Handbook
litrK M20 CAI
FlexibleMounting
7. Boretop plaresfor re rcd.9 - (Thelie rods are to be providedby the shlpyard)

8. Mounrtie bd - 9 -. Adjustrhe venicalclearanceor 1.50 mm between


slopper- 6 - and disk " 10 - and fix
locknut - 15 -with -+ M - 1400 Nm
Secure ii wiih Loctite 242 blue.
Jam locknul- 11 - wlh -) M = laOO Nm
otl

9, Fitinrubberliring.12..

10, Flrlher statica sprng denecton(lowerlngof the enqineailer 24 h)


approx.0.40 mm
Th6 enginols lhen roughlyai€ned wilh lhe gear shafl.(Gearboxwilh v6rlical

'11, At operatinglemperatu€slhe enginesknds approx 0.50 mm higherihan the

(Ouelo growthoI bondedrubberrall, engine,gearbox and foundalion).


The neriblecooplingis designedlorths i.e luriherre-algnmenlis nol necessary.

T ghlennuis. 13 . and- t4 . wth -) M=160 Nm


N u l s- l ! - . O i l
Seclre nut ' 14 - wlih loctlte 242 blle
s.cur€l.ckhg.cr€ws.ft6r chocking with spdc.r lub.s b€1wo6
engine nount against uninlentionartightening and roosenins.

Tightenallbolls lvl16otiheilexlblemolnlingwitlr -+ M:200 Nm


oil

Edition ServiceDocumentof Page


11.11.2OO4 CaterpillarMotorenGmbH& Co.KG 60
Calemillarconfidenlal: vellow
EngineeriS Handbook
llEll( M20 CAI
Fi.ing Sequences- ValveTimingValues
fltlng.€quonces

6 cyl. ongln. clockwise 1-3-5-6-4-2

count6rclockwise 1-2-4-6-5-3

8 cyl. .nglnc cloclqis€ 1-2-4-6-8-7-5-i

co unt€ rclo ckwise 1-3-5-7-8-6-4-2

9 cyl. ongino clockwise 1-2-4-6-8-9-7-5-3

counterclockwi6e 1-3-5-7-9-8-6-4-2

valvetlnlng valuec
old outputl7O KW/ cyl,

nhaust valveopens 60 ?e. beioEBDc


valvecloses
Exhsu6t 55 ?€. aft€rTDC

tnlotvalwopens 55?ca.boioreTOC
'.-''
lnl€t valv6croses 40 ?ca. alt6r BDc

new output190kW / cyl,

Exhaustvalveopens 40 ?ca.b6fo6 BDc

Exhaustvalv6clo*s 45 ?ca. anetTDC

Inletvalveopens 45 ?@. befoeTDC

hl6t wlvs closes 5 ?ca. altor BDC

Edition ServiceDocum€ntof Page


11.1'l.2OO4 CaterpillarMotorenGmbH& Co. KG 61
cale.pillar conf d€nlial: yellow

, * :;- -
Engineer@ Handbook
llaK M20 l&I
Dimenslona
andWeights
deslgnetlon longrh mm width mm helght mm welghl kg

crankca3. wthout atual3


t190
4040
4530

6 cyl. englno 2a26 ? 374 730


3 cryl,.ngln. 3088 ? t74 t000
9 cyl, ..glno 3,116 ? 374 fl00

g.ar whoef on cr.ntshaft . A2 ? 273 16


linorvariatlon01 + 02 'l 277
60
llner from varlarlon04 to 08 594,4 ? 277 60
pbton wlth connecllngrod 60.6

? 1to 1,5
? r5l ,t,1

coontrgrat€r.llstrlbutlon
hourlng 602 328 170 43.5
fnj.ctlon pump 12a 138 t42 t8
c.m3h.tt.l3ft€lt 330 ? .t12 l9
40 ? 160 '1,3

ge.r wheel on crmlhatt 65 ? 533 t05


lnt.rmodlato g6arwh6el

Edition ServiceDocumentof paoe


11.11.2OO4 CaterpillarMotorencmbH & C6. KG 62
CaielDillar conf dential: vells
I Engineer@ Handbook
iiETK M20 CAI
andW6ights
Dimenslons
l€ngth mm width mm h.lght mm

hou3lnglo. cbargoalr
210

an 170

a2

78

217 ? to05 320

2U ? r00! to7

96.r rlm on flywh..l 38 .? t0l5

151 ? azo 264

44 2to 245 3a

c.ollng w|ter pump 864 270 335 42

Edition ServiceDocumentof Page


'11.11.2004 CaterpillarMotorenGmbH& Co.KG 63
c8lerpillar @nfidential Y€llw

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