Engineers Hand Book M25 PDF

m
c
M25
Caterpillar confidential: yellow

Engineer ´s Handbook
m M25 c
Table of Contents
Table of Contents .......................................................................... 2
Engine Data .................................................................................... 6
Engine Operating Data .................................................................. 6
Engine Block .................................................................................. 7

- Tightening torques for screw plugs ............................................................................. 7
- Crank case cover ................................................................................................................ 7
Cylinder Head ................................................................................. 8

- Tie bolts engine block ....................................................................................................... 8
- Tightening torques ............................................................................................................. 8
- Tightening torques for screw plugs at cylinder head ............................................... 8
- Valve rocker bracket .......................................................................................................... 9
- Valve rocker ......................................................................................................................... 9
- Radial clearance ................................................................................................................... 9
- Setting of valve bridges and valve clearances .......................................................... 10
- Valve clearance .................................................................................................................. 10
- Valve guide ......................................................................................................................... 10
- Guiding bolts for the valve bridges ............................................................................... 11
- Indicating and safety valve ............................................................................................... 11
- Starting valve ...................................................................................................................... 11
- Sleeve for the fuel injection valve ................................................................................ 12
- Fuel injection valve ........................................................................................................... 12
- Fuel pressure pipe dismounting .................................................................................. 14
- Fuel pressure pipe mounting ........................................................................................ 14
- Pressure piece .................................................................................................................. 15
- Grinding of inlet and exhaust valves ............................................................................ 16
- Fitted valve stems: ........................................................................................................... 17
- Fitting of inlet and exhaust valve seats ....................................................................... 18
- Valve seat ring ................................................................................................................... 18
Piston ............................................................................................ 19
- Built-up piston 2500.7-26.70.00-01 / -02 / -03 ................................................................ 19
- Fitting ................................................................................................................................... 19
- Wear and clearance limits ............................................................................................... 20
- Dismounting of fire ring .................................................................................................. 20
Edition Service document of Page

15.04.2005 Caterpillar Motoren GmbH & Co. KG 2
m M25 c
Table of Contents
Connecting Rod ........................................................................... 21

- Big end bearing ................................................................................................................. 21
- Piston pin bush - piston pin ........................................................................................... 21
Liner .............................................................................................. 22
- Wear limits .......................................................................................................................... 22
- Assembly ............................................................................................................................ 23
Crankshaft .................................................................................... 24
- Tightening torque bearing caps .................................................................................... 24
- Measurement of gap ....................................................................................................... 24
- Marking ............................................................................................................................... 25
- Located main bearing ...................................................................................................... 25
- Counterweight mounting ............................................................................................... 26
- Crank web deflection ...................................................................................................... 26
Gear Train ..................................................................................... 27

- Gear wheel on crankshaft .............................................................................................. 27
- Intermediate gear wheel mounting ............................................................................. 28
- Camshaft gear wheel assembly ................................................................................... 29
- Backlash .............................................................................................................................. 30
- Lub. oil injectors for the gear drive .............................................................................. 30
Governor Drive ............................................................................ 31

- Governor drive .................................................................................................................. 31
- Bushes in the crankshaft housing ............................................................................... 32
Camshaft ....................................................................................... 33
- Camshaft mounting ......................................................................................................... 33
- Vibration damper mounting ........................................................................................... 34
- Camshaft bearings ........................................................................................................... 34
Lower Valve Drive ....................................................................... 35

- Lower valve drive mounting .......................................................................................... 35
Fuel Injection Pump ..................................................................... 36

- Dismounting - mounting ................................................................................................. 37
- Fuel distributing and collecting pipe ............................................................................ 37
- Starting process ............................................................................................................... 38
- Check of commencement of fuel delivery ................................................................. 39

m M25 c
Table of Contents
IMO Adjustment ............................................................................ 40

- Engine adjustment IMO ................................................................................................... 40
- IMO - adjustment, check ................................................................................................. 41
Sundries ....................................................................................... 42
- Regulating shaft ................................................................................................................ 42
- Cooling water distributing pipe .................................................................................... 42
- Barring gear ....................................................................................................................... 43
- Starting fuel limiter ........................................................................................................... 44
- Fuel rack sensor ............................................................................................................... 45
- Governor arrangement ................................................................................................... 45
Opposite Side of Coupling (Free End) ...................................... 46

- Mounting without power take-off ................................................................................. 46
- Mounting pump carrier ................................................................................................... 46
- Mounting with power take-off ....................................................................................... 47
- Mounting PTO coupling hub ........................................................................................... 48
Pump Carrier with Attached Pumps ........................................... 49

- Pump carrier ...................................................................................................................... 49
- Gear wheel mounting ...................................................................................................... 49
Flywheel Mounting ...................................................................... 50

- Dismounting of flywheel ................................................................................................. 52
Flexible Flange Connection ....................................................... 53
Charge Air Cooler ........................................................................ 54

- Installation .......................................................................................................................... 54

m M25 c
Table of Contents
Turbocharger Mounting .............................................................. 57

- Mounting turbocharger KBB R4-3 to 6-cylinder engines ......................................... 57
- Mounting turbocharger KBB R5-3 to 8- and 9- cylinder engines ........................... 58
- Mounting turbocharger KBB HPR6000 to 6-, 8- and 9- cylinder engines .............. 59
- Mounting turbocharger ABB TPS61D to 9- cylinder engines ................................. 60
- Oil drain ............................................................................................................................... 61
Exhaust Gas Manifold ................................................................. 62

- Exhaust gas manifold ....................................................................................................... 62
- Gaskets between cylinder head and exhaust gas manifold .................................. 62
Generator GP-Engine ................................................................. 63

- Attachment engine and generator ............................................................................... 63
- Sealing surfaces ............................................................................................................... 63
Flexible Mounting ........................................................................ 64

- Locking device in case of average ............................................................................... 67
Firing Sequences - Valve Timing ............................................... 68
Dimensions and Weights ............................................................ 69

m 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
Valve disk Ø = 84 mm Fresh water circulation cooling

With min. 4 mWc 2.5 - 6.0 bar
Valve guide
Length = 235 mm Fuel pressure before injection pumps
Inside Ø = 19.10 mm MDO-operation 3.0 - 5.0 bar
HFO-operation 4.0 - 10.0 bar
Details for rated engine output and

nominal engine speed.

m M25 c
Engine Block
- Tightening torques for screw plugs

Tighten screw plugs M33x2 with → M = 200 Nm
Tighten screw plugs M18x1,5 with → M = 140 Nm
Tighten screw plugs M12x1,5 with → M = 70 Nm
Tighten screw plugs G1/2A with → M = 160 Nm
Tighten screw plugs G3/4A with → M = 70 Nm
- Crank case cover 1

Mount flat gaskets slightly greased.
Use Dirko, Nr.610.020 (Dirko, grey) for coverings
without any gasket.
Tighten the screws - 1 - for the cover with blow-off valve

(new variation 2500.7-16.33.00-02)
with → M = 24.5 Nm

m M25 c
Cylinder Head
- Tie bolts engine block

The tightening torque for inserting the
tie bolts into engine block is → M = 450 Nm
Molykote
- Tightening torques
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.
(e.g. black, sooty film = gas leakage)
1
- Tightening torques for screw plugs at cylinder head

The tightening torque for screw plugs with thread
G1/2A with high-temperature paste is → M = 60 Nm

M10x1 with Loctite 270 is → M = 15 Nm

M10x1 with Molykote is → M = 30 Nm

M36x2 with Hylomar is → M = 250 Nm

M42x2 with Hylomar is → M = 300 Nm

m M25 c
Cylinder Head
- Valve rocker bracket
The tightening torque for inserting
the studs - 1 - is → M = 100 Nm
Oil
Tighten nuts - 2 - with → M = 160 Nm
Molykote
- Valve rocker
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
0.20+0.10
Ø 59.99 + 0.12
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

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

mm
- Valve guide
(Inlet - Exhaust)
The valve guides are inserted into the cylinder head
undercooled to -195°C (liquid nitrogen)
Nominal clearance → 0.10 - 0.15 mm

Measure diameter of the valve shaft in the guide area.

Measure guide in cross direction of engine.

m M25 c
Cylinder Head
- Guiding bolts for the valve bridges
with thread
The tightening torque for the guiding bolts is → M = 180 Nm
Insert guiding bolts with Loctite 243
and provide the contact faces with Molykote.
without thread
The guiding bolts are inserted into the cylinder head for newer engines undercooled to
-195°C (liquid nitrogen)
- Indicating and safety valve

studs (M12) - 1 - is → M = 50 Nm
Oil
Tighten nuts (M12) - 2 - with → M = 50 Nm
Molykote
Joint ring
- Starting valve
Tighten locking screw - 1 - with → M = 250 Nm
Tighten safety nut - 2 - with 1 → M = 35 Nm

Molykote 2

m M25 c
Cylinder Head
- Sleeve for the fuel injection valve
Tighten the sleeve for the fuel injection valve with → M = 140 Nm
Loctite 510 (thread+sealing surface)
Use special wrench!
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
Tighten nuts - 2 - within 2 steps with → M = 50 Nm
Molykote paste G.
Tighten nozzle nut with
2
→ M = 750 Nm
Oil
dimension 29.5
1
Reference
Ensure flush
contact of flange
to nozzle holder.
Nozzle cooling return

Coat o-rings
slightly with Nozzle cooling supply
Molykote. Fuel pressure pipe connection
Nozzle leak fuel
Attention !
Insert the injection Insert nozzle element with
valve into the cylinder high-temperature paste
head without joint
ring !
Nozzle nut

m M25 c
Cylinder Head
- Fuel injection valve

Tighten counternut - 1 - for adjusting screw - 2 - with → M = 70 - 90 Nm
With intermediate plate
Tighten counternut - 1 - for adjusting screw - 2 - with → M = 60 ± 10 Nm

Without intermediate plate
The injection valve has proven optimum reliability in both operation

modes, MDO and HFO. This injection valve, however, must be 4
3
carefully completed. During assembly of the locking
screw deformations to the joint ring might occur. This could lead to Joint
leak fuel with following contamination of the lubricating oil. When ring
completing an injection valve, attention must be paid to the following:
with intermediate plate without intermediate plate

1
1. The joint ring must be centered.

2. The nut - 3 - with the locking
screw - 4 - is to be tightened with a M = 90 - 130 Nm
torque of →
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 M = 90 + 30 Nm
torque of →
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 surfaces
3 with Molykote.
6
1
5

m M25 c
Cylinder Head
- Pressure piece
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 required 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

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
2500.7-22.10.01-05 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). To cool down the valve seat ring to -20°C
and heat up the cylinder head to 130°C is also
possible (if necessary).
Y1
2. Insert the inlet and exhaust valve seat rings.
Y2
3. When the valve seat rings are tight, press them
on 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
30°+
ØX
30°+
ØX
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 / 03 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
with →
M = 150 Nm
up to → M = 300 Nm
up to → M = 600 Nm
up to → M = 600 Nm
7. Tighten upper big end bearing bolts once more
successively up to →
M = 600 Nm
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 → 0.113 mm
Maximum clearance → 0.199 mm

m M25 c
Liner
- Wear limits
Nominal size Ø (original size) → 255.00 + 0.052 mm
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 ≥ 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 bearing caps

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 without external load (generelly valid for all cylinders,

also for cylinder 1 if flywheel hub and flywheel are not yet
mounted, as well as for the last cylinder if the auxiliary PTO
with bearing in pump mounting plate is not connected.) → 0.05 to - 0.08 mm
Cylinder with additional load (normally cylinder 1

by means of flywheel and last cylinder if power is
actually taken of at the free end.) → 0.05 to - 0.11 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 camshaft gear 2
wheel cone. Prefit helical gear - 3 - until
it touches the camshaft gear wheel. 3
Mount the camshaft gear wheel
hydraulically on the bearing journal cone
by tightening screws - 4 - up to the end 1
of the cone.
Attention!
4
Tighten screws - 4 - steadily.
Final position: Draw helical wheel - 3 -

against bearing journal - 1 -.
Slide-on distance: 10.5 - 2.9 mm

Pressing liquid: hydraulic oil

Molykote G Rapid Plus
ISO4014-M16x80-8.8
See chapter
Tighten screws - 5 - with → camshaft - camshaft
Molykote G Rapid Plus mounting
End clearance at - 6 - → 0.30 - 0.70 mm
Hydraulic oil pressure with hand pump → P = approx. 1200 bar

m M25 c
Gear Train
- 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
Governor Drive
- Governor drive
Pretighten castle nut - 1 - M = 30 Nm
with →
further tightening up to the
next split pin hole.
Molykote 3
End clearance - 2 - → 2 0.30 - 0.60 mm
Mount governor bracket - 3 - with

liquid sealing compound.
1
Backlash - 4 - → 0.15 - 0.50 mm

m M25 c
Governor Drive
- Bushes in the crankshaft
32
housing
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
335
2

m M25 c
Camshaft
- Camshaft mounting
Tighten screws - 1 - (DIN931-M14 x 60-10.9)
with → M = 140 Nm
Molykote G Rapid Plus
Tighten screws - 2 - See chapter gear

with → train - camshaft gear
Molykote G Rapid Plus wheel assembly
Note: Upon assembly of the helical gear wheel correct position of the IMO bore is
observed! (cylinder 1 and rising curve for delivery of the injection cam in TDC)
Helical gear wheel
Flange code number

Exhaust
cam Position of parallel pin
Inlet Injection (see table below)
cam cam
1
2
1
Flange code number
Position of parallel pin
(see table below)
Flange Code Num bers
6 cyl. engine 8 cyl. engine 9 cyl. engine
Before assembly of the flange flange flange
camshaft provide each cylinder cylinder cylinder
code code code
camshaft flanges with one section section section
number number number
parallel pin according to
the table. 1 5 1 1 1 5
2 1 2 2 2 8
3 6 3 3 3 2
4 5 4 4 4 6
5 3 5 5 5 4
6 7 6 6 6 4
7 7 7 6
8 8 8 2
9 8

m M25 c
Camshaft
- Vibration damper mounting
1
Molykote
Screws DIN931-M14x60-8.8

Molykote
Screws DIN931-M12x70-8.8
Bore arrangement for Bore arrangement for 8 M25

6 / 9 M25
- Camshaft bearings
Tighten fixing screws - 1 - for the camshaft bearings
with → M = 130 Nm
Molykote
Allen screws ISO4762-M16x100-8.8

m M25 c
Lower Valve Drive
- Lower valve drive mounting
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
1
0.3 min. 0.2 min. 0.2
Determine the end

x 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

studs is → // 0,3 1 2 M = 120 Nm
Molykote
Type: PF1WX230V-C
Tighten fastening nuts
with → M = 200 Nm
Molykote
Pretighten screws - 1 -with → M = 10 Nm

and tighten
3
with → 5 M = 90 ± 3 Nm
Tighten screws - 2 -with → M = 53 ± 2 Nm
X
Tighten counter-sunk
screws for
the indicator at
the fuel rack with →
4 M = 3.50 + 0.50 Nm
leak fuel outlet X

tightening torque
max. 30 Nm
Pay
attention
to the
mounting
screws for
direction!
leak oil outlet
torque
max. 50 Nm

m M25 c
Fuel Injection Pump
- 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.
- Fuel distributing and collecting pipe

Tighten screws - 1 - DIN933-M10x35-8.8 and - 2 - DIN933-M10x20-8.8
with → M = 20 + 5 Nm
1 2
1 loose
flange 2 loose
installation flange
installation
Attention! For screws DIN933-M10x30-8.8 the standard torques are valid!
Tighten screw - 3 - with → M = 80 Nm

Insert screw with Loctite 542.

m M25 c
Fuel Injection Pump
- Starting process
The engine starting process is controlled via the injection pumps.
Roller of rocking 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 delivery valve.
Commencement of Firing TDC
2. Mount dial gauge with extension. delivery
3. Turn engine so that the roller rests on the Position of

cam base and the TDC mark is abt. 45° commencement
before the dead centre indicator. of delivery
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 centre 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
(For versions with eccentric cam follower
the eccentric position has to be vertically
upwards.)
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
- Engine adjustment IMO
290, 300, 330 kW/cyl. 720/750 min-1
1. Commencement of injection
Needle bouncing as arithmetic mean value over all cylinders
Nominal value: 3,5° (+0,5° -1,5°) before TDC
Measured with MaK-EB-Tester
2. Commencement of fuel delivery

Commencement of fuel delivery as arithmetic mean value over all cylinders
Nominal value: 10,5° (+0,5° -1,5°) before TDC
Measured according to the overflow method; control travel >38mm
or pre stroke dimension 4,2mm at the auxiliary device
3. Cooling water temperature NT

NT- water inlet temperature
Nominal value: 30°C (±2°C) with PI control valve
Working range: 20°C - 30°C with P control valve
4. Cooling water temperature HT

HT- water outlet temperature
Nominal value: 90°C (±2°C) with PI control valve
Working range: 82°C to 92°C with P control valve
5. Charge air temperature

Nominal value: 45°C (±5°C)
6. Piston distance
Distance: piston - cylinder liner:
Nominal value: 18,6 mm (+0,55
-1,55
mm)
Measured from border of bowl to liner support
Adjustment of TDC mark and adjustment of commencement of fuel delivery of the injection
pumps as well as the appropriate working sheets.

m M25 c
IMO Adjustment
- IMO - adjustment, check
1. Remove screw plug - 1 -.

2. Turn the engine until the bore Ø 4 mm in 1
the helical gear wheel is centrically with
regard to the bore - 2 - M10 x 1 in the
cover (see sketch).
3. Check at the flywheel whether the IMO
marking matches the dead center
indication.
2
- IMO - adjustment, marking of flywheel

1. Marking is only permitted when changing
the flywheel.
2. Adjust the engine in accordance with the
engine test bed record. Especially the IMO-valve
timing has to be observed.
3. Turn the engine until the bore Ø 4 mm in the helical
gear wheel is centrically with regard to the bore -
2 - M10 x 1 in the cover.
4. Stamp the IMO notch directly at the dead center
indicator on the flywheel.
Marking on
I flywheel
M
O

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
ISO4014-M16x110-8.8-A3C

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 closely piston - 3 -.
5. Lever - 1 - must be bored through with 6 mm and be pinned and leaded by a clamping
sleeve.
ad
2
l lo
Ful
16
n
tio
1
si
Po
30 op
St

m M25 c
Sundries
- Fuel rack sensor

Adjust cam -1- so that center punch mark aligns with axis of sensor -2- in stop position.
Sketch: variation -03 variation -04
1 2
1
3 3
Exception: For applications with the UG8 D MAS (designation: 8527-151) governor the
fuel rack sensor need not to be adjusted, because for this type of governor a fuel rack
sensor is integrated.
- Governor arrangement
Always follow the adjustment data of the governor data sheets. Only in exceptional
cases and only after consulting the technical service VT5 the setting of the governor may
be changed.

m M25 c
Opposite Side of Coupling (Free End)
- 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
9 cyl. engines - 14 tie bolts
Screw arrangement 6 Screw arrangement 8 Screw arrangement

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

Molykote
Sealing compound in the
hatched area only
- Mounting 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.
For mounting the pumps and
tightening torque see chapter:
Pump carrier with attached pumps

m M25 c
- Mounting with power take-off

Pretighten screws - 1 - with → M = 250 Nm

Molykote
Attention: For flywheel sided power take-off pay attention to the crank web deflection
of the last cylinder.
Ø 157
Subsequent unit
from 1000 kW power
Ø 100
Subsequent unit
up to1000 kW power
170
Screw arrangement Screw arrangement

6 cyl. engine 6, 8 and 9 cyl. engine
with 10 tie bolts with16 tie bolts
Tighten screws M 12 with → M = 60 Nm

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

m M25 c
- Mounting PTO coupling hub
The hub mounting is carried with an oil-hydraulic pressure unit. The oil-hydraulic pressure
unit is designed different for each application. For this reason a general statement about
push-up distances and hydraulic oil pressures is not possible.
Generally valid information:

- Hub has to be slid onto the shaft without pressure until the contact surfaces are fitting
closely.
- In standard cases hydraulic oil SAE10 is used as compression liquid.
- The hydraulic oil pressure, the push-up force and the push-up distance are varying in
according to the application.
(For that different devices can be used.)
- The push-up force may only be released after one hour at the earliest.
- After removal of the oil hydraulic pressure unit stress on the hub is not allowed for
at least 24 hours.

m M25 c
Pump Carrier with Attached Pumps
- Pump carrier
Tighten screws M16 with → M = 130 Nm
For further information for pump carrier mounting see chapter:
- Mounting pump carrier
- 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 (100°C-110°C for pump CLG
water) 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(0,29mm-0,32mm for pump CLG water).
M = 60 Nm
Tighten screw for the gear wheel with →
Lubricant: Molykote
0.20 - 0.45 mm
Backlash →
- 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.
M = 60 Nm
Tighten screw for the gear wheel with →
Lubricant: Molykote
0.20 - 0.45 mm
Backlash →

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.
Press flywheel with tightening device and oil hydraulic mounting into its final position (fit
closely to crankshaft gear wheel).
5 3

m M25 c
Flywheel Mounting
Tighten nut on the device with → M = 1600 Nm
Oil pressure (with hand pump) → 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.
Tighten screws -5- (13xISO4017-M16x45-8.8-A3C) with → M = 130 Nm

Molykote
Mount nuts -6- (10xDIN934-M10) with
clamping disk (DIN6796-16-FST-A3C)
and tighten them with → M = 75 Nm
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
Flexible Flange Connection
- Flexible flange connection for generator gp engine
Tighten screws - 1 - (DIN931-M22x200-10.9) with → M = 495 Nm

Oil
or
Tighten screws - 1 - (ISO4014-M20x200-10.9) with → M = 490 Nm
Oil
or
Tighten screws - 1 - (DIN6912-M22x160-8.8) with → M = 500 Nm
Oil
Tighten screws - 2 - (ISO4017-M24x60-10.9) with → M = 675+75 Nm

Oil
or
Tighten screws - 2 - (ISO4017-M30x90-10.9) with → M = 1300+75 Nm
Oil
For further information for 2

generator mounting see chapter:
Generator GP Engine

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 - M = 20 Nm
with →
Molykote
Fixing screws
Tighten charge air cooler casing - M = 130 Nm
cylinder crankcase with →
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 turbocharger KBB R4-3 to 6-cylinder engines

2500.7-72.50.00-01 / -03 / -04 flywheel side / 2500.7-72.55.00-01 / -03 free end
Tighten screws e.g. for turbocharger foot - 1 - 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
here!
1c
1a 1b

m M25 c
- Mounting turbocharger KBB R5-3 to 8- and 9- cylinder engines

2500.7-72.50.00 -02 / -05 / -07 flywheel side, 2500.7-72.55.00 -04 / -07 free end
Tighten screws - 1 - with →

Molykote M = 130 Nm
Tighten screws - 2 - with →

Molykote M = 60 Nm
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!

m M25 c
- Mounting turbocharger KBB HPR6000 to 6-, 8- and 9- cylinder engines

2500.7-72.50.00-08 / -09 / -10 flywheel side, 2500.7-72.55.00-08 / -09 / -10 free end
Tighten screws - 1 - (2x ISO4014-M24x320-10.9) with → M = 640 Nm

Molykote
Tighten screws - 2 -
(flywheel s.:21x / free e.:24x ISO4014-M16x60-8.8) with → M = 130 Nm
Molykote
Tighten screws - 3 - (11x DIN933-M12x65-8.8) with → M = 60 Nm
Molykote
1
Compensator
mounting:
No gasket between
flange surfaces!
2 3

m M25 c
- Mounting turbocharger ABB TPS61D to 9- cylinder engines

2500.7-72.55.00-05 free end

Molykote
Molykote
Tighten screws - 3 - (11x DIN933-M12x65-8.8) with → M = 60 Nm
Molykote
No gaskets
here!
2

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

m M25 c
Exhaust Gas Manifold
- Exhaust gas manifold
Tighten screws to cyl. head generally alternately in 2 steps.
Tighten screws ISO4014-M20x120 (marking VW)
for 1. step with → M = 150 Nm
and for 2. step with →
M = 250 Nm
Rivolta G.W.F.
Tighten screws ISO4014-M20x130 (marking V or VH)
for 1. step with → M = 180 Nm
and for 2. step with →
M = 330 Nm
Rivolta G.W.F.
Tighten screws (M16) from connecting links

to engine block with → M = 130 Nm
Molykote
Tighten screws (M16) of the exhaust gas manifold → M = 140 Nm
Rivolta G.W.F.
Spray all connecting links with graphite or molybdaen spray before mounting.
Mount compensators in direction of arrow.
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
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
Generator GP-Engine
- Attachment engine and generator

Tighten the torques for the fixing screws step by step.
step 1 → 20 %
step 2 → 60 %
step 3 → 100 %
Tighten bolts class of strength 8.8 - M10 - with → M = 40 Nm

oil
oil
oil
(engine) oil
Tighten bolts class of strength 8.8 - M30 - with → Ask VT5 for value!
(generator) oil
- Sealing surfaces
Daub sealing surfaces of engine and base frame with sealing material Hylomar. Lay
GORETEX - sealing towards the engine inside; overlap cutting points.
- Alignment instruction diesel gensets

only valid for: 6M25 on base frame with Vulkan RATO-DS 3311A, series 2100
8/9M25 on base frame with Vulkan RATO-DS 3411A, series 2100
Consultation of VT5 is necessary for all other combinations.
The generators are to be aligned as follows in cold condition.

Axial alignment: The generators are to be shifted in direction of the engine until the
mounting reference dimension of the coupling is 260± ±0.5mm.
Radial alignment: The generators are to be lifted by means of the jacking screws so that
they are on a level 1.00mm higher than the engine. In this a settlement of about 0.1mm of
the vibracon elements has to be taken into account.
Angular alignment: Angular clearance ± 0,2mm measured at coupling outside diameter
1070mm → 8/9M25 on base frame with Vulkan RATO-DS 3411A, series 2100 and
995mm → 6M25 on base frame with Vulkan RATO-DS 3311A, series 2100.
In this position place the vibracon elements onto the topp plate, put through the foundation
bolts and fasten finger tight (about 20Nm). Centre the vibracon elements with regard to the
bolt and raise by turning until the spherical cap fits closely without any clearance (about
20Nm). Slacken the jacking screws and tighten the foundation bolts to the prescribed
torque.
After a test run of the gensets the crank web deflection is to be measured at operating
temperature (10 minutes after shut down from full load), checked and recorded.
For information for coupling tightening torques see chapter:
Flexible Flange Connection

m M25 c
Flexible Mounting
Assembly
Casting resin: Clean unmachined top plates.
Steel chocks: Top plates must be machined by milling or planing.
1. Align engine with jacking screws:

Vertically approx. 2.00 mm above the gear shaft (gearbox with vertical shaft
offset) and horizontally approx. 2.20 mm above the gear shaft (gearbox with
horizontal shaft offset).
In true alignment diagonally to the gearbox.
Axial coupling axially relieved.
2. Bore top plates for bonded rubber rail fixation - 1 - and - 2 -.
3. Screw bonded rubber rails - 1 - and - 2 - with screws - 3 - and washers - 4 -

below the engine.
Oil
The contact surfaces of the bonded rubber rails must be absolutely clean.
Contaminations by scale, rust or suchlike are to be mechanically removed before
screwing.
1
2
3
Secure with 4
Loctite 242
max. 13
≥ 17
6
5

m M25 c
Flexible Mounting
4.1 Pourable resin: Pour the resin around the bonded rubber rails according to the
instructions of the resin manufacturer (resin must not touch the rubber). Lower the
engine after curing of the resin. That means relieve jacking screws completely.
After relieving/disassembly of the jacking screws, the jacking screws are to be
inserted again with spacer sleeves
and tightened with → M = 150 Nm
Statical spring deflection approx. 1.50 mm.
4.2 Steel chocks: Measure distance between plate and bonded rubber rails. Manu-
facture steel chocks and insert them. Lower engine according to 4.1.
5. Further settlement (lowering of the engine after 24 h approx. 0.40 mm). The engine
is then in line with the gear shaft.
6 Fix bonded rubber rails with screws - 5 - and washers - 6 - on top plate.

Oil
7. Before fitting stoppers - 7 - in the stopper area machine a chamfer of 1 x 45°on a

length of 350 mm at the engine mount.
Adjust 2.0 mm during assembly 15

16
18 14
12
11
9
R
H
10
8
13 17

m M25 c
Flexible Mounting
8. Mount lateral stoppers - 7 - and holders - 8 -. Fasten screws finger tight. Before
screwing on the locking ring on the stopper pipe insert screws - 9 - and
washers - 10 -.
9. Measure the distance top plate – bottom edge locking ring. Dimension - H -.
Add 7 mm to the measured dimension - H -. The calculated dimension is the
pipe length - R
10. Remove lateral stoppers -7 -and holders - 8 -.
11. Mount lateral stoppers - 7 - and holders - 8 - above the pipe.

Fasten screws finger-tight.
12. The pipe is centered 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 pipe and weld it.
13. Remove lateral stoppers - 7 - and holders - 8 -
14. Bore top plates for the tie rods - 12 -.
15. Insert rubber cladding - 13 - into the welded pipe. Mount lateral stoppers - 7 -
and holders - 8 -.
16. Screw the locking ring upward up to the limit stop and secure it with 2 grub
screws.
17. At normal operating temperature the engine stands by about 1.00 mm higher than
the gear shaft (due to growth of bonded rubber rail, engine, gearbox and
foundation). The flexible coupling is designed accordingly. Re-alignment is not
necessary.
18. After reaching the normal 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 -.
Tightening torques:
Screws - 9 - 650 Nm Oil on spot face, Loctite 242 on thread

Nuts - 17 - 800 Nm Secure with Loctite 242
Screws - 18 - 640 Nm Oil
or alternative
Screws - 18 - 210 Nm + 60° Oil

m M25 c
Flexible Mounting
- Locking device in case of average
(not possible in all modifications)
1. Dismantle nuts and washer - 15 - , - 16 - , - 14 - .
2. Release grub screws M12 with hexagon socket (not shown in view).
3. Screw down locking ring - 11 - until it rests against the tube. Auxiliary bore ∅10mm
for tool is provided in the locking ring.
4. Put washer with nut - 14 - on to side stopper - 6 - and
tighten it with → M = 1250 Nm

or alternative with → M= 300 Nm + 60°
Öl.
shown in locked condition (average) shown in normal operation
assembly
2.0 mm
during
Adjust
15
16
18 14
12
11
7
10 9
17

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
Please observe always the acceptance test record!
Exhaust valve opens 45 ° before BDC
Exhaust valve closes 50 ° after TDC
Inlet valve opens 50 ° before TDC
Inlet valve closes 5 ° or 10 ° after BDC

m M25 c
Dimensions and Weights
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

m M25 c


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Caterpillar confidential: yellow

Table of Contents .......................................................................... 2

Engine Data .................................................................................... 6

Engine Operating Data .................................................................. 6

Engine Block .................................................................................. 7

Cylinder Head ................................................................................. 8

Edition Service document of Page

Connecting Rod ........................................................................... 21

Gear Train ..................................................................................... 27

Governor Drive ............................................................................ 31

Lower Valve Drive ....................................................................... 35

Fuel Injection Pump ..................................................................... 36

Edition Service document of Page

IMO Adjustment ............................................................................ 40

Opposite Side of Coupling (Free End) ...................................... 46

Pump Carrier with Attached Pumps ........................................... 49

Flywheel Mounting ...................................................................... 50

Flexible Flange Connection ....................................................... 53

Charge Air Cooler ........................................................................ 54

Edition Service document of Page

Turbocharger Mounting .............................................................. 57

Exhaust Gas Manifold ................................................................. 62

Generator GP-Engine ................................................................. 63

Flexible Mounting ........................................................................ 64

Firing Sequences - Valve Timing ............................................... 68

Dimensions and Weights ............................................................ 69

Edition Service document of Page

Engine Data Engine Operating Data

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

Valve disk Ø = 84 mm Fresh water circulation cooling

Length = 235 mm Fuel pressure before injection pumps

Inside Ø = 19.10 mm MDO-operation 3.0 - 5.0 bar

HFO-operation 4.0 - 10.0 bar

Details for rated engine output and

Edition Service document of Page

- Tightening torques for screw plugs

Tighten screw plugs M18x1,5 with → M = 140 Nm

Tighten screw plugs M12x1,5 with → M = 70 Nm

Tighten screw plugs G1/2A with → M = 160 Nm

Tighten screw plugs G3/4A with → M = 70 Nm

- Crank case cover 1

Tighten the screws - 1 - for the cover with blow-off valve

Edition Service document of Page

- Tie bolts engine block

2. Lengthen bolts with → P = 820 bar

At the control bore 1 - leakages between

- Tightening torques for screw plugs at cylinder head

The tightening torque for screw plugs with thread

The tightening torque for screw plugs with thread

The tightening torque for screw plugs with thread

The tightening torque for screw plugs with thread

Edition Service document of Page

The bush shall recede after