Mak M25

m
c
M25
m
Engineer ´s Handbook
M25 c
Engine data Engine operating data
Stroke = 400 mm Temperatures
Bore = 255 mm Lub. oil
Speed, rpm = 720 - 750 Engine inlet 60 - 65° C
Main bearing Temperature rise 10 - 14° C
Inside Ø = 240 mm Fresh water circulation cooling
Outside Ø = 252 mm Engine outlet 80 - 90° C
Big end bearing Temperature rise 7 - 10° C
Inside Ø = 193 mm Charge air
Outside Ø = 204 mm Engine inlet 45 - 60° C
Valves, inlet and exhaust Pressures
Length = 446 mm Lub. oil 4.0 - 5.0 bar
Shaft Ø = 18.50 mm Fresh water circulation cooling

With min. 4 mWc 2.5 - 5.0 bar
Valve disk Ø = 84 mm
Valve guide Fuel pressure before injection pumps
Length = 235 mm MDO-operation 3.0 - 5.0 bar
Inside Ø = 19.10 mm HFO-operation 4.0 - 5.0 bar
Details for rated engine output and

nominal engine speed.
Edition Service document of Page

10.08.2001 Caterpillar Motoren GmbH & Co. KG 2
m
M25 c
Cylinder head
Tightening torques
The tightening torque for inserting the
tie bolts is → M = 450 Nm
Molykote
1. Tighten round nuts with pin by hand.
2. Lengthen bolts with → P = 820 bar

and tighten round nuts with pin taking
care of easy motion.
Check: Reduce pressure to → P = 770 bar
Loosening the nuts must not be possible any more.
The pressure must remain constant, when the pump is not operated, otherwise faulty
tightening.
Dismounting: If the cylinder head nuts cannot be loosened with P = 820 bar, an increase by 50
bar is possible. Further pressure increase involves the risk that the thread will expand and the
nuts will jam.
At the control bore 1 - leakages between

cylinder head, flame ring and cooling water
distributing housing can be detected.
Valve rocker bracket

The tightening torque for inserting
the studs - 1 - is → M = 100 Nm
Oil
Tighten nuts - 2 - with → M = 160 Nm
Molykote

m
M25 c
Cylinder head
Reference size for the bush after
pressing-in → Ø 59.99 + 0.12 mm
The bush shall recede after

pressing-in by → 0.20 + 0.10 mm
Ø 59.99 + 0.12
0.20+0.10
Before pressing-in slightly coat the bushes with oil, Molykote must not be used.
Radial clearance
Original size → 0.02 - 0.159 mm
Limit clearance → 0.359 mm
Setting of valve bridges and valve clearances 1
1. Turn out adjusting screws - 1 - of the valve

rockers to obtain a sufficient clearance.
2. Turn out adjusting screws - 2 - of the valve

bridges to obtain a clearance when
valve bridge „X“ touches „Y“.
3. Screw in adjusting screws - 2 - until the

valve bridges rest on the valves without
clearance.
4. Hold adjusting screws - 2 - fast and lock

them. 2
5. Adjust valve clearance. Y X

m
M25 c
Cylinder head
Valve clearance
+ 0.10
Inlet → 0.50 mm
Exhaust → 0.90 + 0.10

mm
Valve guide: Inlet - Exhaust

Nominal clearance → 0.10 - 0.15 mm
Measure diameter of the valve shaft in the guide area. Measure guide in cross direction of
engine.
Guiding bolts for the valve bridges

The tightening torque for the guiding bolts is → M = 180 Nm
Insert guiding bolts with Loctite 243 and provide
the contact faces with Molykote.
Indicating and safety valve

The tightening torque for inserting the studs - 1 - is → M = 50 Nm
Oil

Molykote
2 studs M12 x 95 DIN939 2
2 nuts M12 DIN 934
1
Joint ring
Starting valve
Tighten locking screw - 1 - with → 1 M = 250 Nm
2
Tighten safety nut - 2 - with → M = 35 Nm
Molykote
Safety nut VM 10x1 DIN 980

m
M25 c
Cylinder head
Tighten the sleeve for the
fuel injection valve with → M = 140 Nm
Reference dimension
307,5
O-ring Viton, green
O-ring Perbunan
Fuel injection valve

The tightening torque for inserting
the studs - 1 - is → M = 50 Nm
Oil
Molykote paste G.
Tighten nozzle nut with → M = 750 Nm

Oil
1
2
Reference dimension 29.5

Nozzle cooling return
Slightly coat
o-rings with Molykote Nozzle cooling supply
and distribute it equally
Fuel pressure pipe connection
Nozzle leak fuel
Attention !
Insert the injection
valve into the cylinder Insert nozzle
head without joint element with high-
ring ! temperature paste

m
M25 c
Cylinder head
Fuel injection valve
Tighten counternut - 1 - for the adjusting screw - 2 -
with → M = 70 - 90 Nm
4
With intermediate plate
3
Fuel injection valve Joint ring
Tighten counternut - 1 - for the
adjusting screw - 2 - with → M = 60 ± 10 Nm
Without intermediate plate
The injection valve has proven

optimum reliability in both 1
operation modes, MDO and HFO.
2
This injection valve, however, must
be carefully completed.
During assembly of the locking
screw deformations to the joint ring
might occur. This could lead to leak
fuel with following contamination of
the lubricating oil. When completing
an injection valve, attention must
be paid to the following:
1. The joint ring must be centered.

2. The nut - 3 - with the locking
screw - 4 - is to be tightened with a
torque of → M = 90 - 130 Nm
With intermediate plate
1. The joint ring must be centered.

2. The nut - 3 - with the locking
screw - 4 - is to be tightened with a
torque of → M = 90 + 30 Nm
Without intermediate plate
3. The joint ring must be checked visually once more for correct fitting.
Otherwise, the before-mentioned procedure is to be repeated with a new joint ring.

m
M25 c
Cylinder head
Fuel pressure pipe dismounting
First loosen screwing - 4 - of transverse pressure piece - 3 -, then screwing - 6 -.
Fuel pressure pipe mounting
1. Tighten nuts of the fuel injection valve with the prescribed torque, loosen them by one
turn and tighten with M = 10 Nm.
2. Put the parts together and care for the correct position of cover - 1 -.
Sleeve - 2 - is in a pushed back position inside the cylinder head.
3. Tighten screwing - 4 - of transverse pressure piece - 3 - and thrust bolt - 6 - of radial
pressure piece - 5 - (without spanner).
4. Tighten thrust bolt - 6 - and screwing - 4 - of transverse
pressure piece - 3 - with → M = 10 Nm
5. Tighten screwing - 4 - of transverse pressure

piece - 3 - with → M = 150 ± 5 Nm
Tighten thrust bolt - 6 - with → M = 130 ± 5 Nm

Warning ! Keep transverse pressure piece - 3 - in position
using a spanner (avoidance of damages to the individual connections)
6. Push sleeve - 2 - into the fuel injection pump for locking. Tighten nuts of the fuel
injection valve with prescribed torque.
Coat thread and contact surfaces of screwing - 4 -, transverse pressure piece - 3 -, radial
pressure piece - 5 - and thrust bolt - 6 - with Molykote paste G.
4 Coat thread and

2
contact surfes
3 withMolykote.
6
1
5

m
M25 c
Cylinder head
The projection dimension - 1 - must not be less than 4.7 mm (e. g. when reworking the
sealing surface), because otherwise the first thread pitch may abut against the pump
casing. As a result of this the pre-tension moment may drop below the rquired limit. This
may cause a leakage.
Injection pumps from March 2000 are not affected by this problem, because an undercut
has been introduced on the pump casing.
1 5 ± 0.3
Exhaust gas manifold

Tighten screws to cyl. head alternately in 2 steps.
1st step up to → M = 150 Nm

and
2nd step up to → M = 250 Nm

Paste DAG 5080
Screws B20 x 120 DIN 931; spacer E31 x 55 DIN 2510
Gasket
Gaskets between cylinder head and
exhaust gas manifold
When fitting the gasket take care that the bead in
the gasket shows to the exhaust gas pipe flange.

m
M25 c
Cylinder head
Grinding of inlet and exhaust valves
Apply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or
remachined valve cone and distribute the paste equally. Thereafter the seat ring surface
is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in
order to increase the grip. Insert the oiled valve stem into the
guide bush. Fasten the device at the valve disk and grind the
valve face and seat by hand applying a moderate pressure,
rotating the device. The contact reflection „a“ which is visible by
the smooth grinding process shall not exceed 30 % of the seat
width starting from the outside diameter. If the bearing
characteristics described above are not reached, remachining of
both sealing surfaces is necessary. After machining both seats
have to be checked with a luminous magnifier. The fillet must not
be refinished.
After machining round off the outside edge with a stone.
The dimensions specified in the sketch are to be observed.
Exhaust valve HFO operation Exhaust valve MDO operation
29° 59’ - 2’
29° 87’ + 2’
min. 1.5 mm
min. 1.5 mm
Inlet valve
29° 52’ + 2’
min. 0.2 mm

m
M25 c
Cylinder head
Deviations from true running
The deviation from true running on the valve stem must not exceed 0.05 mm on the
measuring distance "S" of 264 mm.
The deviation from true running on the valve cone must not exceed 0.025 mm.
For both measurements the valve stem must touch at points A and B in the measuring
device.
0.05 mm
20 20
s
0.025 mm
Reuse of a valve stem is not possible, if:

1. there is severe pitting on the bottom side of the valve head (formation of so-called
„paving stones"),
2. there are corrosion pits and

mechanical damages in the area of
the valve, stem, stem transition, and
valve head,
3. the limit for refinishing is exceeded or
4. in case of corrosive material wear

of 2 % from the valve disk diameter. In
case of high-temperature corrosion
„S“ of 1.50 mm.
S
Fitted valve stems:
MDO operation 2500.7-22.10.01-01 Inlet valve
2500.7-22.10.01-02 Exhaust valve
HFO operation 2500.7-22.10.01-01 Inlet valve

2500.7-22.10.01-03 Exhaust valve

m
M25 c
Cylinder head
Fitting of inlet and exhaust valve seats
1. Cool valve seat rings down to - 195° C
(liquid nitrogen)
2. Insert the inlet and exhaust valve seat

rings.
Y1
Y2
3. When the valve seat rings are tight,
press themon with the pressure
device.
Tightening torque for the pressure device is → M = 50 Nm
4. Check the bearing surface „Y 2 "; between inlet valve seat ring and cylinder head
no air gap is admissible.
5. Check the air gap „Y 1" between exhaust valve seat ring and cylinder head.
Admissible air gap 0.40 + 0.30 mm
Pressure test: Cooling water spaces 10 bar for 8 min.
Valve seat ring

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

’
’
5’+5
5’+5
a a
ØX
30°+
ØX
30°+
Refinishing is possible with Mak valve seat ring turning machine or with MaK valve seat
milling fixture. After grinding the bearing portion shall be 30- 50 %, beginning from the
outer diameter.

m
M25 c
Piston
Built-up piston 2500.7-26.70.00-01 / -02 / -03
Coat thread and contact surface with Molykote paste G-n-plus.
Tighten screws crosswise with → M = 60 Nm

Loosen screws again.
Pretighten screws crosswise with → M = 25 Nm
and tighten with → Dw = 60°

Check:
At → M = 45 Nm
the nuts must not turn further.
Gap size
2500.7-26.70.00-01 / -02 → 0.06 - 0.10 mm
2500.7-26.70.00-03 → 0.07 - 0.11 mm
Measure gap here,

screws not
tightened.
68+0,4
Fitting
Arrange the ring butts in longitudinal direction of engine alternately opposed, then oil
pistons and piston rings well.
Fit piston rings with marking upwards.

m
M25 c
Piston
Wear and clearance limits
Grooves Groove height Ring height Wear limit Clearance limit
1 6.15 +0.03 6.00 -0.010 - 0.025 6.60 0.50
+0.03
2 6.13 6.00 -0.010 - 0.025 6.60 0.50
+0.03
3 8.06 8.00 -0.013 - 0.035 8.60 0.50
Pistons 2500.7-26.70.00-01/ 02 for gas oil and heavy fuel operation

Grooves Rings
1 Rectangular ring 2500.7-26.17.01-01
2 Compression ring 2500.7-26.17.01-02
3 Oil scraper ring 2500.7-26.17.01-03
Minimum Maximum Limit

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

Piston pin
bush width 0.500 1.100 1.300
Dismounting of fire ring

7
1. Turn piston top edge below the fire ring.
2. Place dismounting device on the piston so that the recess lies inside
the fire ring.
3. Slightly tighten the dismounting device by turning spindle nut - 1 -.
4. Press fire ring out by turning the piston up.

m
M25 c
Connecting rod
Big end bearing
1. Tighten upper big end bearing bolts successively
with → M = 150 Nm
up to → M = 300 Nm
3. Tighten lower big end bearing bolts successively
M = 150 Nm
with →
up to → M = 300 Nm
up to → M = 600 Nm
up to → M = 600 Nm
7. Tighten upper big end bearing bolts once more
M = 600 Nm
successively up to →
Coat threads and contact surfaces with a thick layer of Molykote G Rapid Plus.
Reference size B
Reference size A
Here cylinder No.

Here cylinder No.
Lower screws
Upper screws
Reference dimension of the big end bearings after correct tightening.
Size „A“ → 193.16 + 0.05 mm
Size „B“ → A + 0.04 + 0.01 mm

The reference dimension of the piston pin bush
after shrinking-in into cooled state is Ø → 120.11 + 0.08 mm
Piston pin bush - piston pin
Minimum clearance → 0.1110 mm
Maximum clearance → 0.160 mm

m
M25 c
Liner
Nominal size Ø (original size) → 255.00 + 0.052 mm

Wear limits
Wear and tear value → TDC 1st ring 0.90 mm
Max. ovality → 0.25 mm
Wedge shape Height → 6.00 mm
Depth * → 0.03 mm
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring.
Canyon Max. number → 3
Length → 150.00 mm
Total width → 0.03 mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC)
Score Number → 3
Length → 150.00 mm
Depth → 0.03 mm
Hard vertical, linear friction marks.
Pocket Number → 3
Length → 60.00 mm
Width ** → 20.00 mm
Depth * → 0.02 mm
Areal, irregular indentations.
* Radius r ò 3 mm
** In circumferential direction

m
M25 c
Liner
Wedge shape Pocket Sore TDC 1st ring Canyon
Assembly
During installation take care that 2
marking - 1 - of the liner coincides
with marking - 2 - of the cooling
water distributor casing.
The liner must slide into the cylinder
crankcase by its own weight.
Attention! Incorrectly inserted liners

may cause considerable damages.
1

m
M25 c
Crankshaft
Tightening torque
The tightening torque for inserting the studs - 1 - is → M = 450 Nm
Molykote
Tighten crankshaft bearing

nuts - 2 - steadily by hand.
Insert hexagon screws - 3 - 3 3
with Molykote and tighten
alternately in 3 steps.
2 1 2
Tighten 1st step up to → M = 140 Nm
Tighten 2nd step up to → M = 420 Nm
Tighten 3rd step up to → M = 670 Nm
Lengthen studs - 1 - with → P = 980 bar

and tighten crankshaft bearing nuts - 2 - .
Check: Reduce pressure to → P = 930 bar

Loosening the nuts must not be possible any more.
Tighten both crankshaft bearing nuts of one bearing pocket in one operation.
Measurement of gap
1. Remove hexagon screws - 3 - of the crankshaft bearing. Loosen hexagon screws
- 3 - of the adjacent crankshaft bearing.
2. Loosen both crankshaft bearing nuts - 2 - of one bearing pocket in one operation.
3. Tighten crankshaft bearing nuts with a pin alternately and steadily until the joint faces
of the bearing shells are just touching each other.
4. Check the projecting length of the bearing shell by measuring the gap between
cylinder crankcase and bearing cap on camshaft and exhaust gas side.
Sum of gap → 0.75 - 1.00 mm
After longer operation the sum of gap

shall not be less than → 0.60 mm

m
M25 c
Crankshaft
Marking
Bearing caps and bearing shells are marked on camshaft side with relative cylinder
numbers counted from flywheel side. The parts must not be mixed up.
Bearing No.
stamped here The protection against
torsion is on camshaft
side
X
X
Located and normal main bearings are

identical, for axial fixing on bearing 1 (located
main bearing) thrust washers - 1 - with
clamping pins - 2 - are mounted on bearing
cap - 3 -.
3 2
Located main bearing

End clearance → 0.30 - 0.60 mm

m
M25 c
Crankshaft
Counterweight mounting
Pretighten screws with → M = 100 Nm
and tighten
with → Dw = 120°
Lubricant Molykote (G-Rapid) on thread and screw contact surface.
6 cyl. engine 12 counterweights

Crankpin 1 2 pcs.
Crankpin 2 1 pc. left side *
Crankpin3 1 pc. right side *
Crankpin 4 2 pcs.
Crankpin 5 2 pcs.
Crankpin 7 1 pc. right side *
Crankpin 8 2 pcs.

Crankpin 1 2 pcs.
Crankpin 3 without counterweight
Crankpin 4 2 pcs.
Crankpin 5 2 pcs.
Crankpin 6 2 pcs.
Crankpin 7 without counterweight
Crankpin 8 1 pc.. right side *
Crankpin 9 2 pcs.
* = seen from camshaft side.
Crank web deflection

Limit values
Cylinder 1 → - 0.11 mm
Other cylinders → 0.05 bis - 0.08 mm

m
M25 c
Gear train
Gear wheel on crankshaft
Press gear wheel with device and oil hydraulic mounting
-
connection Z - → M = 500 Nm
on the crankshaft cone into its final position.
The final position is reached when the gear wheel touches the spacer. The spacer simulates the
located bearing, it must be adjusted so that with the gear wheel in final position a dimension
of 126 + 0.1 mm results between gear wheel and crank web cyl.1.
The slide-on distance is 12 -3,5

mm.
The device must remain fitted 20 minutes after pressure relief.
Engine start 2 hours after pressure relief at the earliest.
Spacer
126 + 0.01
Connection„Z“ 1/4 ‘’

m
M25 c
Gear train
Intermediate gear wheel mounting
Tighten screws - 1 - with → M = 130 Nm
Molykote
X
X
1
S
O-ring
End clearance S min. → 0.30 mm
max. → 0.60 mm
Gap size
Gap size between axle and locking sheet see - Y -
Min. → 0.30 mm
Max. → 1.40 mm

m
M25 c
Gear train
Camshaft gear wheel assembly
gear wheel mounting new design
Journal - 1 - must not extend into the
gear box.
Turn the camshaft gear wheel - 2 -
with the device into the gear box.
Push the journal until it touches the 2
camshaft gear wheel cone. Prefit
helical gear - 3 - until it touches the 3
camshaft gear wheel. Mount the
camshaft gear wheel hydraulically on
the bearing journal cone by tightening 1
screws - 4 - up to the end of the
cone.
4
Attention! Tighten screws - 4 -
steadily.
Final position: Draw helical
wheel - 3 - against bearing
journal - 1 -.
Slide-on distance: 10.5 - 2.9 mm

Molykote
M16 x 80 DIN 931 8.8

Molykote
M14 x 60 DIN 931 10.9
End clearance at - 6 - → 0.30 - 0.70 mm
Oil pressure → P = 1200 bar

m
M25 c
Gear drive
Backlash
Crankshaft gear wheel - intermediate gear wheel → 0.23 - 0.35 mm
Intermediate gear wheel - camshaft gear wheel → 0.23 - 0.35 mm
Lub. oil injectors for the gear drive

Tighten screws with → M = 160 Nm
Attention !
During assembly of the helical gear wheel
attention must be paid to bore - 1 -, that means
cylinder 1 and injection cam ramp must be in 1
TDC position.

m
M25 c
Gonernor drive
Tighten castle nut - 1 -
with → M = 30 Nm
further up to the next
split pin hole.
Molykote
3
End clearance - 2 - → 0.30 - 0.60 mm
2
Mount bracket - 3 - with
sealinf compound.
Backlash - 4 - → 1
0.15 - 0.50 mm

m
M25 c
Governor drive
32
8
If the bushes - 1 - and - 2 - in
the cylinder crankcase must be
exchanged, take care that the 1
dimensions stated in the sketch
are observed.
Slightly oil the bushes before
pressing them in, do not use
Molykote.
302
336
2

m
M25 c
Camshaft
Tighten screws - 1 -
with → M = 140 Nm
Molykote
M14 x 60 DIN 931 10.9
Flange code number „X“ (see table below)

Position of cylinder pin
Cyl.1 Cyl.2 Cyl.6/8/9
Flange code number „X“ (see table below)

Position of cylinder pin
Mounting of camshaft
6 cyl. engine 8 cyl. engine

Cylinder section Flange code number Cylinder section Flange code number
1 5 1 1
2 1 2 2
3 6 3 3
4 5 4 4
5 3 5 5
6 7 6 6
7 7
8 8
9 cyl. engine
Cylinder section Flange code number
1 5
2 8
3 2
4 6
5 4
6 4
7 6
8 2
9 8

m
M25 c
Camshaft
Vibration damper mounting
Molykote 1
Screws M14 x 60 DIN 931 8.8

Molykote
Srcews M12 x 70 DIN 931 8.8
Bore arrangement for 8 M25

Bore arrangement for
6 / 9 M25
Tighten fixing screws - 1 - for the camshaft bearings

with → M = 130 Nm
Molykote
Allen screws M16 x 100-ZA DIN 912

m
M25 c
Lower valve drive
Tighten screws - 1 - for the bearing
brackets with → M = 130 Nm
Molykote
End clearances → 0.20 mm
X 1
min. 0.20 min. 0.20
Determine the end clearance by shifting the bearing brackets.
At the contact points of the rocking lever shafts no gap is admissible.

Loosen the bearing caps and push rocking lever shaft flush together from both sides.
Attention!
Take care of the chamfer.
Valid for cy. 2 to cyl. 5/ 7/ 8l

m
M25 c
Fuel injection pump
Das Eindrehmoment für die Stiftschrauben
beträgt → M = 120 Nm
2
Molykote 1
Type: PF1WX230V-C
Befestigungsmuttern mit → M = 200 Nm
festziehen. Molykote
Schrauben - 1 - mit → M = 10 Nm
vorziehen und
mit → M = 90 ± 3 Nm
3
festziehen. 5
Schrauben - 2 - mit → M = 53 ± 2 Nm
festziehen.
festziehen.
festziehen.
festziehen.
Senkschrauben für den

Zeiger an der
Regelstange mit → M = 3.50 + 0.50 Nm
festziehen. 4
Mixed oil drain

Tightening
torque
max. 30 Nm

m
M25 c
Fuel injection pump
Fuel distributing and collecting pipe
Tighten screws - 1 - and - 2 - with → M = 20 + 5 Nm
1 2
1 = Hexagon screws M10 x 35 DIN933

2 = Hexagon screws M10 x 20 DIN933
Tighten screw - 3 - with → M = 80 Nm

Insert screw with Loctite 542
Mounting
Before mounting the injection pump take care that the roller of the rocking lever rests on
the cam base circle and that the air passage sleeves are correctly positioned in the
cooling water distributor casing.
Dismounting / mounting
During dismounting / mounting attention must be paid that the appertaining distance steel
plates are not removed.
If for any reason removal of the distance steel plates is necessary, they have to be
marked with the relevant cylinder number.
The thickness of the distance steel plates for each cylinder is stated in the acceptance test
record.

m
M25 c
Fuel injection pump
Starting process
The engine starting process is controlled via the injection pumps.
Roller of rockiing lever on

cam base circle Starting process is released
Plunger in BDC-position
Start
Control air inlet
Plunger in TDC-position Venting is released
Starting
process Start of venting

m
M25 c
Fuel injection pump
Check of commencement of fuel
delivery
1. Dismount the injection pump Commencement of Firing TDC
delivery
delivery valve.
2. Mount dial gauge with Position of

extension. commencement
of delivery
3. Turn engine so that the roller
rests on the cam base and
the TDC mark is abt. 45° before
the dead center indicator.
4. Set dial gauge to „0“, turn engine in direction of rotation until the indication on the
gauge is 5 mm (5 mm on the gauge
correspond to 11° crank angle on the
flywheel).
24.6
5. Check the dimension on the flywheel from
TDC mark to dead center indicator.
Setting
1. Place the gauge with measuring device on
a level support by means of the adjusting
bush (dimension = 24.6 mm) and set
gauge to „0“.
2. Insert measuring device into the injection

pump bore in the engine housing
and read value on the dial gauge (roller on
the cam base).
3. Indicated value = thickness of the

distance steel plates.
The distance steel plates are used for setting the pre-stroke.
Available sizes:
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

m
M25 c
IMO adjustment
The IMO adjustment can be checked as follows:
1. Remove screw plug - 1 -.
2. Turn the engine until the bore Ø 4 mm in the helical gear

wheel is centrical with regard to the bore - 2 - M10 x 1
in the cover (see sketch). 1
3. Check at the flywheel whether

the IMO marking matches the dead
center indication.
Marking on I
flywheel M
O
When mounting the helical gear wheel for the governor drive take care of the position of
bore - 1 -, i.e. cylinder 1 and injection cam ramp must be in TDC position.

m
M25 c
Sundries
Regulating shaft
Tighten screws - 1 - with → 1 M = 130 Nm

Molykote
Clearance at - 2 - → 0.20 mm
Before inserting the regulating shaft
lubricate the bearing areas.
Do not use Molykote nor oil.
2
Tighten screw - 3 - for the articulated lever with → M = 20 Nm
Molykote
Cooling water distributing pipe

Molykote
M16 x 110 ISI4014

m
M25 c
Sundries
Barring gear
Tighten screws - 1 - and - 2 - with → M = 130 Nm
Insert screws - 1 - with Loctite 243 .

Screws - 2 - Molykote
Actuate barring gear with torque

wrench up to 800 Nm, reversible
ratchet and socket wrench insert.
Engine operation is
1 only possible with
screwed on cover - 2 -.

m
M25 c
Sundries
Starting fuel limiter
Fitting instruction
1. For basic adjustment of lever - 1 - pull the piston of cylinder - 2 - by 30 mm.
2. Set the fuel rack of the injection pumps to position 16.
3. Lever - 1 - must by stopped by mechanical limit at piston - 3 -.
4. Push piston of cylinder - 2 - back.

At full load lever - 1 - must not fit closly piston - 3 -.
5. Lever - 1 - must be bored through with 6 mm and be pinned and leaded by a clamping
sleeve.
2
ad
l lo
Ful
16
n
1
tio
si
Po
30 op
St

m
M25 c
Opposite side of coupling
Mounting without power take-off
Pretighten screws - 1 - with → M = 250 Nm

Molykote
6 cyl. engines - 10 tie bolts
8 cyl. engines - 12 tie bolts 1
Screw arrangement 6 Screw arrangement 8 Screw arrangement

cyl. engine cyl. engine 6 cyl. engine
Tighening torque for M16 screws → M = 130 Nm

Molykote
Mounting of pump carrier

Degrease all flange facings. Provide
pump carrier with sealing compound
and position it at the cylinder crankcase
using a device.
Screw the carrier on and pin it.
Apply a thin layer of the sealing
compound only in the double-hatched
area. Take care that no sealing
compound clogs the oil ducts.
Sealing compound in the

hatched area only

m
M25 c
Opposite side of coupling
Mounting with power take-off
Pretighten screws - 1 - with → M = 250 Nm

Molykote
Ø 157
From 1000 kW power
1
Ø 100
Up to1000 kW power
170
Screw arrangement Screw arrangement

6 cyl. engine 8 and 9 cyl. engine
Tighten screws M 12 with → M = 60 Nm

Molykote
Tighten screws M 16 with → M = 130 Nm
Molykote

m
M25 c
Pump carrier with attached pumps
Pump carrier
Tighten screws with → M = 130 Nm
On engines without power take-off: 20 screws M16 x 60 DIN 931

On engines with power take-off: 34 screws M16 x 60 DIN 931
Lub. oil pumps, suction and pressure pump, cooling water circulation pumps
Gear wheel mounting
Cover gear wheel cone with blue paste and check contact reflection on the appertaining
pump shaft cone with gear wheel cone, covered with blue paste.
Contact reflection ≥ 80°. Heat gear wheel up to 90°C-100°C above temperature of the
pump shaft and mount it firmly on the pump cone up to stop position. The cone faces must
be grease-free and dry.
Example: 20° C shaft temperature → 110 ° to 120 ° C gear wheel temperature.
The slide-on distance is 0,40 - 0,44 mm.
Tighten screw for the gear wheel with → M = 60 Nm

Lubricant: Molykote
Backlash → 0.20 - 0.45 mm
Drive - Fuel feed pump

Gear wheel assembly
Test contact reflection on the related pump shaft cone by means of gear cone covered
with blue paste. Only a contact reflection displaced to the thick end is admissible.
Heat gear wheel up to 30°-40°C above temperature of the pump shaft and mount it firmly
on the related pump cone up to stop position. The cone faces must be grease-free and
dry.
Example: 20° C shaft temperature → 50 ° to 60 ° C gear wheel temperature.

The slide-on distance is 0.14 - 0.18 mm.
Tighten screw for the gear wheel with → M = 60 Nm

Lubricant: Molykote
Backlash → 0.20 - 0.45 mm

m
M25 c
Flywheel mounting
Insert studs - 1 - with Loctite 243 into the flywheel. Grind clamping pins - 2 - at the sharp-
edged end (chamfer abt. 2 x 15ø) and insert them with this end into the gear wheel on
the crankshaft. Turn crankshaft into TDC cyl. 1 position. Guide splash ring - 3 - over the
crankshaft cone. Align end cover - 4 - centered to the crankshaft and flush with the
bottom edge of the cylinder crankcase before fitting it. Oil crankshaft cone with hydraulic
oil. Hang flywheel in the transfer port and slide it on the crankshaft cone until contact is
reached. Fit tightening device. Take care that the flywheel is fixed on the locating pin of
the device. In this position the projecting clamping pins at the gear wheel on the
crankshaft are aligned to the relative receiving bores at the flywheel.
Tighten nut on the device with → M = 1600 Nm
Press flywheel with tightening device and oil hydraulic mounting into its final position.
5 3

m
M25 c
Flywheel mounting
Oil pressure → P = 1200 bar
The slide-on distance is → 23 - 3.5

mm
End clearance - 7 - → 0.30 + 0.30 mm
The device must not be loosened earlier than 24 hours after pressure relief. Engine start
not before 72 hours after removal of the device.
Mount the splash ring on flywheel.

Molykote
13 screws M16 x 45 DIN 933
Mount nuts - 6 - with clamping disk 10 DIN 6796

and tighten them with → M = 75 Nm
10 nuts M10 DIN 934 secured with Loctite 243.
Hydraulic connection in the crankshaft → 1/4 ‘’

m
M25 c
Flywheel mounting
Dismounting of flywheel
While installed the device is 510 mm long. The length of the thread of the „threaded rod“ is
80 mm. For mounting the device at least 590 mm are required!
Loosen the oil slinger on the crankshaft.
Secure the flywheel by appropriate means.
Remove the plug of the hydraulic connection „S“ in the crankshaft.
Mount the device according to picture 1 („threaded rod“ and guide plate).
Screw the hydraulic pipe into the connection „S“ and tighten it.
Mount the pressure disk and the hydraulic jack.
Unscrew 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 hydraulic pump to the flywheel.
Extend the hydraulic jack to 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 the flywheel up using the hydraulic pump (pressure approximately 1300 bar)
until the flywheel loosens.
Lower the pressure of the hydraulic jack (flywheel is moving) and then dismount the
device completely.
Remove the flywheel.
Mounting proceeds in reverse order. The slide-on distance is 23 mm. When sliding on
take care that the oil slinger is placed upon the studs.
Hydraulic connection 1/4’’
M39 for the

threaded rod Connection „S“
Connection „Z“

m
M25 c
Charge air cooler
Installation 2500.7-72.40.00-01 coupling side
1. Fix L-strap - 1 - with screws - 2 - at the charge air cooler without water separator.
2. Loosen landing surfaces - 3 - at the charge air cooler and press them against the
cooler.
3. Push the charge air cooler into the casing.
4. Before screwing the charge air cooler together with the casing, tighten screws - 4 -.
5. Fix the charge air cooler with screws - 5 - and washers at the casing.
6. Push the landing surfaces against the casing and fix them with screws - 6 -.
1 2
X
Tighten screws - 2 -
with → M = 20 Nm
Molykote
Fixing screws
Tighten charge air cooler casing -
cylinder crankcase with → M = 130 Nm
Molykote
X = Mount charge air cooler casing with sealing compound

m
M25 c
Charge air cooler
Y
5
3
6
Installation 2500.7-72.40.00-03 / 2500.7-72.40.00-04 / -05 coupling side

2500.7-72.80.00-03 / 2500.7-72.80.00-05 opposite side of coupling
1. Fix L-strap - 1 - with screws - 2 - at the charge air cooler.

2. Push the charge air cooler into the casing.
3. Draw the charge air cooler with screws - 3 - against the sealing surface.
Loosen screws a little again.
4. Fix the charge air cooler with screws - 4 - und - 5 - at the casing.
5. Now draw the charge air cooler with screws - 3 - finally against the sealing
surface at the air inlet of the casing.
Y = Mount this holder at the charge air cooler, contrary to its delivered condition, turned by 180°.

m
M25 c
Charge air cooler

Molykote
Fixing screws
Tighten charge air cooler casing -
cylinder crankcase with → M = 130 Nm
Molykote
1 2

m
M25 c
Turbocharger mounting
Mounting 2500.7-72.50.00-01 coupling side
2500.7-72.55.00-03 opposite side of coupling
M = 60 Nm
Tighten screws - 1 - with →
Molykote
For 2500.7-72.50.00-01 1 hexagon screw M12x35 ISO 4017 with washer 13-DIN 125
10 hexagon screws M12x55 ISO 4014 with washer 13-DIN 125
and 10 spacers E13x21 N 6003
For 2500.7-72.55.00-03 11 hexagon screws M12x55 ISO 4014

11 spacers 13x21 - 20 N 6003
No gaskets
here

m
M25 c
Mounting 2500.7-72.55.00-04 opposite side of coupling
2500.7-72.50.00-07 counpling side
2500.7-72.55.00-07 opposite side of coupling

Molykote

Molykote
2500.7-72.55.00-04
8 hexagon screws M16x60 ISO 4014 2500.7-72.50.00-07
8 spacer 17x26 - 20 N 6003 8 hexagon screws M16x60 ISO 4014
11 hexagon screws M12x65 ISO 4017 19 hexagon screws M12x40 ISO 4017
11 washers 13 DIN 125
2500.7-72.55.00-07
8 hexagon screws M16x60 ISO 4014
No gaskets here

m
M25 c
Mounting 2500.7-72.50.00-04 coupling side
Molykote

10 spacers 13x21 - 20 N 6003
9 hexagon screw M12x65 ISO 4014
9 spacers 13x21 - 20 N 6003
9 washer 13 - DIN 125
No gaskets here
1

m
M25 c
Mounting 2500.7-72.50.00-05 / -09 coupling side
2500.7-72.55.00-05 / -09 / -10 opposite side of coupling

Molykote

Molykote
For 2500.7-72.50.00-05 / -09 For 2500.7-72.55.00-09

8 spacers 17x26 - 18 N 6003 12 spacers 17x26 - 15 N 6003
11 hexagon screw M12x65 ISO 4014 11 hexagon screws M12x65 ISO 4017
7 spacer 13x21 - 23 N6003 11 washer 13 - DIN 125
11 washer 13 - DIN 125
For 2500.7-72.55.00-05 For 2500.7-72.55.00-10

2 washer acc. drawing-No. 2 washer acc. drawing-No.
8 spacers 17x26 - 15 N 6003 12 spacers 17x26 - 15 N 6003
11 washer 13 - DIN 125 11 washer 13 - DIN 125

m
M25 c
Mounting 2500.7-72.55.00-05 / -10 opposite side of coupling

Molykote

with washer according drawing No.

m
M25 c
Oil drain turbocharger
Oil drain cylinder crankcase
Item 1 = O-ring 1

m
M25 c
Exhaust gas manifold
All screws in the exhaust gas manifold are inserted
with paste DAG 5080 and tightened with → M = 140 Nm
Screws M 16
Between the exhaust gas pipes and the expansion joints no gaskets are fitted.
The expansion joints are installed in the direction of arrow.
Take care of the correct screw length. No projection is admissible.
Recession max. 5 mm

m
M25 c
Firing sequences - valve timing
Firing sequences
6 cyl. engine clockwise 1-3-5-6-4-2
counterclockwise 1-2-4-6-5-3
8 cyl. engine clockwise 1-2-4-6-8-7-5-3
counterclockwise 1-3-5-7-8-6-4-2
9 cyl. engine clockwise 1-2-4-6-8-9-7-5-3
counterclockwise 1-3-5-7-9-8-6-4-2
Valve timing
Exhaust valve opens 45 ° before BDC
Exhaust valve closes 50 ° after TDC
Inlet valve opens 50 ° before TDC
Inlet valve closes 5 ° after BDC

m
M25 c
Designation Length mm Width mm Height mm Weight kg
Crankcase, without studs,

with bearing caps and bearing bolts
6 cyl. engine 3.287 1.300 1.475 6.640
8 cyl. engine 4.147 1.300 1.475 8.460
9 cyl. engine 4.577 1.300 1.475 9.460
Crankshaft
with counterweights
6 cyl. engine 1.917
8 cyl. engine 2.523
9 cyl. engine 2.725
Crankshaft
without counterweights
6 cyl. engine 3.171 456 1.445
8 cyl. engine 4.031 456 1.850
9 cyl. engine 4.461 456 2.082
Counterweight 400 88 215 53
Oil sump
6 cyl. engine 3.369 968 399 496
8 cyl. engine 4.229 968 399 580
9 cyl. engine 4.659 968 399 637
9 cyl. engine 4.659 968 729 912

m
M25 c
Liner Ø 354 780 162
Fire ring 58 Ø 266 2
Main bearing 88 Ø 252 3
Big end bearing 96 Ø 204 0,8
Intermediate gear wheel

with bush 95 Ø 356 62
Intermediate
gear wheel axle 320 Ø 98 17,8
Vibration damper
Crankshaft
6 cyl. engine 200 Ø 850 980
8 cyl. engine 145 Ø 900 632
9 cyl. engine 145 Ø 850 558
Vibration damper
Camshaft
6 - 8 - 9 cyl. engine 62 Ø 330 29
Camshaft section 430 Ø 205 48
Camshaft bearing 55 Ø 224 2,8
Camshaft end bearing 124 Ø 288 7,2
End bearing journal 305 Ø 255 76
Gear wheel on camshaft

compl. with hub 95 Ø 709 260

m
M25 c
Gear wheel on crankshaft 122 Ø 365 44
Charge air cooler

6 cyl. engine 1.057 345 486 270
8 - 9 cyl. engine 1.287 345 486 309
Cyl. head
compl. 265
Cyl. head
without inlet and exhaust valves
with valve guides 725 428 351 194
Valve stem 446 Ø 84 1,5
Cooling water distributor housing 263 90
Piston with connecting rod 125
Built-up piston Ø 255 390 47
Connecting rod 979 118 82
Piston pin 220 Ø 120 22
Pump carrier
Thickness 40 1.075 1.007 198


Mak M25

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Stroke = 400 mm Temperatures

Bore = 255 mm Lub. oil

Speed, rpm = 720 - 750 Engine inlet 60 - 65° C

Main bearing Temperature rise 10 - 14° C

Inside Ø = 240 mm Fresh water circulation cooling

Outside Ø = 252 mm Engine outlet 80 - 90° C

Big end bearing Temperature rise 7 - 10° C

Inside Ø = 193 mm Charge air

Outside Ø = 204 mm Engine inlet 45 - 60° C

Valves, inlet and exhaust Pressures

Length = 446 mm Lub. oil 4.0 - 5.0 bar

Shaft Ø = 18.50 mm Fresh water circulation cooling

Valve guide Fuel pressure before injection pumps

Length = 235 mm MDO-operation 3.0 - 5.0 bar

Inside Ø = 19.10 mm HFO-operation 4.0 - 5.0 bar

Details for rated engine output and

Edition Service document of Page

1. Tighten round nuts with pin by hand.

2. Lengthen bolts with → P = 820 bar

At the control bore 1 - leakages between

Valve rocker bracket

Edition Service document of Page

The bush shall recede after

Limit clearance → 0.359 mm

Setting of valve bridges and valve clearances 1

1. Turn out adjusting screws - 1 - of the valve

2. Turn out adjusting screws - 2 - of the valve

3. Screw in adjusting screws - 2 - until the

4. Hold adjusting screws - 2 - fast and lock

5. Adjust valve clearance. Y X

Edition Service document of Page

Exhaust → 0.90 + 0.10

Valve guide: Inlet - Exhaust

Limit clearance → 0.35 mm

Guiding bolts for the valve bridges

Indicating and safety valve

Tighten nuts - 2 - with → M = 50 Nm

Edition Service document of Page

O-ring Viton, green

Fuel injection valve

Tighten nozzle nut with → M = 750 Nm

Reference dimension 29.5

Edition Service document of Page

The injection valve has proven

1. The joint ring must be centered.

1. The joint ring must be centered.

Edition Service document of Page

5. Tighten screwing - 4 - of transverse pressure

Tighten thrust bolt - 6 - with → M = 130 ± 5 Nm

4 Coat thread and

Edition Service document of Page

Exhaust gas manifold

1st step up to → M = 150 Nm

2nd step up to → M = 250 Nm

Edition Service document of Page

Exhaust valve HFO operation Exhaust valve MDO operation

Edition Service document of Page

Reuse of a valve stem is not possible, if:

2. there are corrosion pits and

3. the limit for refinishing is exceeded or

4. in case of corrosive material wear