2 Maintenance

Maintenance A0
c2
Maintenance
8 M 25 E
Engine No.: 48048 Record No.: 271448
en / 15.12.2014 AA047801 1/2

Total Index
c2 A0.01
Maintenance A0
Total Index A0.01
Introduction A0.02
Specification A0.04
Unit Conversion Table A0.06
Maintenance A5
Table of Contents A5.01
Introduction A5.02
Tightening Torques (Standard) A5.03
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Total Index
c2 A0.01
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Introduction A0.02
c2
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is
matched with the equipment condition and the type of fuel sold.
Since the type of fuel used considerably influences the service life of the components, the Caterpillar after-
sales service has to be consulted when it is required to change from destillate fuel operation to heavy fuel
oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary docu-
mentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar after-
sales service should also be consulted for a longer period of time so that a documentation with extended
maintenance intervals can be made available.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the
operating instructions are subdivided into the following chapters:
Operating Instructions
Maintenance
Technical Engine Data
Operating Media
Tool Catalogue
Spare Parts Catalogue
Control and Monitoring
External Documentation (Subsupplier Documentation)
With the respective information contained in the individual chapters, the technical personnel is able to
maintain the engine in such a manner that regarding its output, reliability, economy and service life opti-
mum operating results can be achieved.
If you need further information or if you have any other questions, we kindly ask you to contact our respon-
sible service organization.
The operating instructions do not release the personnel in charge of this engine plant from their duty to take
care. The recognized rules of technology are to be observed, taking into account overriding regulations,
observance of the general safety measures and locally applicable accident prevention regulations. Data or
explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not
contained.
Caterpillar Motoren GmbH Co. KG is not responsible for damage caused by improper operation and
maintenance.
These operating instructions are only intended for our customers. All rights reserved for this docu-
ment. All technical data contained in these operating instructions must neither be reproduced, dis-
tributed nor utilized for competitive purposes or disclosed to third parties without our express
approval.
Postal address: Caterpillar Motoren GmbH & Co. KG, P.O. Box, D-24157 Kiel
Telephone: +49(0)431- 3995-01(chief operator)
Telefax: +49(0)431-3995-2193(after-sales service only)
http://www.cat.com
http://www.cat.com/marine
http://www.cat.com/oilandgas
http://www.catpowerplants.com
en / 02.01.2015 AA047587 1/1

Introduction A0.02
c2
en / 02.01.2015 AA047587 1/1

c2 Specification
Engine Design
A0.04
GCM34
1. Designation of the engine sides 0

In-line engine V-engine
Free end
Camshaft side
Exhaust side
A side
B side
Driving end
NOTE
The turbocharger can be arranged at both the driving end and the free end.
For stationary applications, the turbocharger is always arranged at the free end.
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Specification A0.04
c2 Engine Design
2. Cylinder counting method 0
NOTE
The cylinder counting method described in this document is in according with the
German Industrial Standard (DIN ISO 1204).
NOTE
The number of main bearing 1 is stamped on the camshaft side or B side in the engine
block.
For M 43 and M 46 engines, there are two main bearings (radial and axial bearing)
between flywheel and cylinder 1.
2.1 In-line engines
Counting of the cylinders starts at the driving end.
1 2 3 4 5 6 7 8
2.2 V-engines
Counting of the cylinders starts at the driving end.

The sides of the engines are designated A side or B side. Accordingly, the cylinders are
designated A1 and B1 etc.
A side A1 A2 A3 A4 A5 A6
B side B1 B2 B3 B4 B5 B6
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Specification A0.04
c2 Engine Design
3. Position of the inlet and exhaust valve drives in the cylinder head 0
Engine type
M 20 C
M 25 C / M 25 E 1 2
1 Exhaust valve rocker arm

2 Inlet valve rocker arm
M 32 C / M 32 E
VM 32 C 1 2
M 34 DF
1 Inlet valve rocker arm
GCM34 2 Exhaust valve rocker arm
M 43 C
VM 43 C
M 46 DF
VM 46 DF
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Specification A0.04
c2 Engine Design
4. Counting method for the inlet and exhaust valves 0

The following figures show the schematic way of counting the inlet and exhaust valves.
The grey fields show the exhaust valves, the blue fields show the inlet valves (in accordance with
the graphics in chapter 3).
A Inlet valve, exhaust side C Exhaust valve, camshaft side

(intake inboard) (exhaust outboard)
B Inlet valve, camshaft D Exhaust valve, exhaust side

(intake outboard) (exhaust inboard)
4.1 In-line engines
1 2 3 4 5 6 7 8
M 20 C D A D A D A D A D A D A D A D A
M 25 C / E C B C B C B C B C B C B C B C B
M 32 C to A D A D A D A D A D A D A D A D
M 46 DF B C B C B C B C B C B C B C B C
4.2 V-engines
C B C B C B C B C B C B
D A D A D A D A D A D A
A side A1 A2 A3 A4 A5 A6
B side B1 B2 B3 B4 B5 B6
A D A D A D A D A D A D
B C B C B C B C B C B C
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Specification A0.04
c2 Engine Design
5. Direction of rotation of the engine 0

The direction of rotation of the engine is determined from the driving end.
Counter-clockwise direction of rotation Clockwise direction of rotation

(left) (right)
6. Nameplate of the engine
The nameplate of the engine is usually located at central position on the camshaft side /
A side of the engine above the crankcase door.
The figure shows a nameplate by way of example. The appearance may vary.
7. Firing order
Firing order (injection sequence), see Engine Documentation, chapter “Technical Engine
Data”, Acceptance Test Record.
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c2 Specification
Engine Design
A0.04
GCM34
en / 18.03.2020 6/6
c2
GCM34
Unit Conversation factor Unit
mm x 0,03937 inch
inch x 25,4 mm
m³ x 35,3147 ft³
ft³ x 0,0283 m³
µm x 3,937 10-6 in
in x 2,54 105 µm
m³/h x 35,315 ft³/h
ft³/h x 0,0283 m³/h
m³/h x 4,4028 gpm

gpm x 0,2271 m³/h
kg x 2,2046 lb (pounds)
lb (pounds) x 0,4536 kg
g x 0,0022 lb (pounds)
lb (pounds) x 453,59 g
°C x 9/5 +32 °F
°F -32 x 5/9 °C
bar x 14,504 psi
psi x 0,069 bar

Pa x 0,000145 psi
psi x 6894,757 Pa
kPa x 0,145 psi

psi x 6,894 kPa
mmWS x 0,0393 WC
WC x 25,641 mmWS
mbar x 0,4019 WC
WC x 2,4882 mbar
mm²/s x1 cSt
cSt x1 mm²/s
mPas x1 cSt
cSt x1 mPas
en / 19.06.2018 1/4
Nm³/h x 35,3147 SCF/h
SCF/h x 0,02831 Nm³/h
kg/h x 2,2046 lb/h
lb/h x 0,4536 kg/h
kJ/kWh x 0,9478 BTU/kWh
BTU/kWh x 1,0551 kJ/kWh

Nm x 0,73756 pound-force feet
pound-force feet x 1,35582 Nm
Liter x 1,06 quart

quart x 0,95 Liter
Liter x 0,26 gallone
gallon x 3,79 Liter

l/kW x 0,197 gal/hp
gal/hp x 5,076 l/kW
kW x 1,341 hp
hp x 0,745 kW
1/min x1 rpm
rpm x1 1/min
kJ/kg x 0,4299 BTU/lb
BTU/lb x 2,3261 kJ/kg
kg/m² x 23,7304 lb/ft²
lb/ft² x 0,0421 kg/m²
kg/m³ x 0,0624 lb/ft³
lb/ft³ x 16,0256 kg/m³
Nms/rad x 0,7376 ftlbs/rad
ftlbs/rad x 1,3558 Nms/rad
MJ/Nm³ x 26,8392 BTU/SCF

BTU/SCF x 0,0347 MJ/Nm³
mg/kJ x 2,326 10-6 lb/BTU
lb/BTU x 4,299 105 mg/kJ
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c2
GCM34
mmol/l x 10 mg/dl
mg/dl x 0,1 mmol/l

°dGH x 17,9 °US-Hardness
°US-Hardness x 0,056 °dGH
pH-Wert x1 PH value
PH value x1 pH-Wert
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Maintenance
c2 A5
Maintenance
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Maintenance
c2 A5
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c2
M 25 E
Maintenance A5
Introduction A5.02
Tightening Torques (Standard) A5.03
Engine, Cylinder Head A5.05.01

Valve Clearance
Inspection / Adjustment A5.05.01.01.01.10
Valve Projection (for MDO- and gas engines only)
Maintenance / Inspection A5.05.01.01.02.10
Rocker Arm Bracket
Disassembly / Installation A5.05.01.02.01.10
Valve Rockers
Maintenance / Removal and Installation A5.05.01.02.02.10
Valve Rotator
Valve Guide / Oil Control Ring
Inspection / Replacement A5.05.01.05.01.10
Media Guide
Cylinder Head
Maintenance / Removal A5.05.01.06.01.11
Relief Valve / Indicator Valve
Maintenance / Replacement A5.05.01.06.70.11
Inet and Exhaust Valve Spindle
Removal and Installation A5.05.01.07.01.10
Valve Spindle - Non Seat Nitrided
Maintenance / Evaluate A5.05.01.08.01.10
Valve Spindle - Seat Nitrided
Valve Seat Ring
Starting Valve
Starting Valve
Cylinder Head
Maintenance / Check A5.05.01.10.00.10
Cylinder Head
Maintenance / Cleaning A5.05.01.10.01.10
Cylinder Head
Maintenance / Installation A5.05.01.11.01.11
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c2
M 25 E
Engine, Gear A5.05.02

Running Gear / Engine Timing
Inspection / Checking A5.05.02.01.01.10
Crank Web Deflection
Inspection / Measuring A5.05.02.02.01.10
Big-end Bearings
Inspection / Removal and Installation A5.05.02.04.01.10
Crankshaft Bearing
Removal / Installation A5.05.02.05.01.10
Measuring the Gap
Piston
Piston Crown
Piston Rings and Grooves
Piston Pin
Small-end Bearing
Maintenance / Measuring A5.05.02.09.01.10
Engine, Housing A5.05.03

Explosion Relief Valve
Cooling Collar
Cylinder Liner
Inspection / Measuring A5.05.03.03.01.10
Cylinder Liner
Engine Fasteners and Connections
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c2
M 25 E
Engine, Control A5.05.04

Camshaft Bearing
Camshaft Bearing
Lower Valve Drive
Lower Valve Drive FCT (optional)
Adjusting Device FCT (optional)
Adjusting Device FCT (optional)
Maintenance / Lubrication A5.05.04.02.12.10
Camshaft
Speed Pick-up
Replacement / Adjustment A5.05.04.06.01.11
Timing Gear Train
Maintenance / Control A5.05.04.08.01.10
Timing Gear Train
Governor Drive
Camshaft Vibration Damper
Engine, Regulation A5.05.05

Control Shaft Bedding
Master Starting Valve
Control Linkage
Compressed Air System
Maintenance Unit
Engine, Exhaust Gas System / Supercharging A5.05.06

Exhaust Manifold
Charge Air Cooler
Exhaust Gas Turbocharger
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c2
M 25 E
SCR - Selective Catalytic Reduction (optional)

Measures Regarding the SCR System
Measures Regarding the SCR System
DEF Level Sensor
DEF- und Air Filter
Cleaning / Removal and Installation A5.05.06.60.04.10
Compressed Air Regulator DEF
Compressed Air Sensor DEF
Injector Nozzle DEF
Temperature Sensor DEF
Solenoid Valve DEF
Dosing Pump DEF
NOx Sensor
Exhaust Gas Pressure Sensor CEM
Temperature Sensor CEM
Catalyst Elements CEM
Soot Blower CEM
Urea Concentration
Engine, Fuel System A5.05.07

Injection Pump
Injection Pump
Fuel Injector
Injection Valve
Maintenance / Adjustment A5.05.07.08.01.11
Injection Valve
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c2
M 25 E
Fuel Duplex Filter

Fuel Feed Pump
Fuel Feed Pump Drive
Fuel Distributor Manifold
Engine, Lubricating Oil System A5.05.08

Lubricating Oil System
Maintenance / Oil change A5.05.08.02.01.10
Pressure Limitation Valve
Lubricating Oil Pump
Lubricating Oil Pump
Lubricating Oil Duplex Filter
Prelubricating Pump / Prelubrication
Maintenance / Checking A5.05.08.10.00.10
Engine, Cooling Water System A5.05.09

Cooling Water Centrifugal Pump
Engine, starting system A5.05.10

Stop Piston
Condensate Trap
Repair / Removal and Installation A5.05.10.51.00.10
Engine Control Equipment A5.05.11

Lubricating Oil / Cooling Water Thermostat
Maintenance / Checking A5.05.11.06.01.10
Pressure Switch
Replacement / Functional Check A5.05.11.06.05.10
Pressure Switch
Crankcase Monitoring (for 8 and 9 Cyl. only)
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c2
M 25 E
Engine Auxiliary Units A5.05.12

Barring Device
Maintenance / Operation and Check A5.05.12.08.01.10
Additional Equipment A5.05.13

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

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

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

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

• evaluation criterion and
• performance checks
The information given by us gives no rise to legal claims.
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Introduction A5.02
c2
2.2 Maintenance system
The maintenance system consists of:
• maintenance plan
• job cards
While the maintenance plan indicates the date when inspection, maintenance or repair
shall be carried out, the job cards indicate the manner in which the work is to be carried
out.
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Introduction A5.02
c2
2.2.1 Maintenance Plan
The maintenance plan shall provide for a quick summary of all intended inspection,
maintenance and repair work occurring up to 90,000 operating hours.
The maintenance plan is subdivided into the following areas:
• Daily inspection and control work
• Periodic maintenance work
A list of all recurrent inspection, maintenance and repair work to be carried out at the
scheduled date.
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Introduction A5.02
c2
3. Safety instructions
3.1 Safety symbols
In the present operating instructions the following warning notices are used:
DANGER
A warning notice of this risk level signals the threat of a dangerous situation.
If the dangerous situation is not prevented, it will lead to death or serious injury.
Follow the instructions in this warning notice to prevent the risk of death or serious injury to
persons.
WARNING
A warning notice of this risk level signals a potentially dangerous situation.

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

If the dangerous situation is not prevented, this could lead to minor or moderate injury.
Follow the instructions in this warning notice to prevent injury to persons.
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Introduction A5.02
c2
CAUTION
or
CAUTION
A warning notice of this risk level signals possible damage to property.

If the situation is not prevented, this could lead to damage to property.
Follow the instructions in this warning notice to prevent damage to property.
NOTE
A note identifies additional information that facilitates the handling of the engine.
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Introduction A5.02
c2
3.2 General safety instructions
Our engine is equipped with a monitoring system and an emergency stop system to prevent da-
mage caused to the operators' health as well as damages to the engine.
Within the scope of commissioning all mechanical, electric and pneumatic equipment and sy-
stems allowing the engine to be stopped for safety reasons will be demonstrated and explained
by our commissioning personnel.
Participants in this acceptance procedure are the authorized personnel of Caterpillar Motoren
GmbH & Co. KG, the managing and operating personnel of the operator and also representatives
of the insurance companies.
This important system is subject to recurrent inspections and tests in order to ensure proper
function of its individual components.
In the section "Scheduled Maintenance" you will find the respective test frequencies and related
job instructions that should be followed to protect the personnel from injuries and prevent material
damages.
NOTE
The provisions of the relevant accident prevention regulations of the appro-

priate employer's liability insurance association are to be observed any time
operation and repair work is carried out.
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Introduction A5.02
c2
WARNING
Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil,
grease, fuel!
Use only suitable and technically perfect lifting gear and suspension systems
with adequate lifting capacity!
Never work or stand under suspended loads!
During replacement work, individual parts and large assemblies are to be ca-
refully fastened and secured on hoists to avoid risks of accidents!
Re-install removed guards and protecting devices on completion of work.
When carrying out overhead assembly work, the specially designed or safe-
ty-oriented climbing aids are to be used only!
Do not use engine/plant parts for climbing on!
Use personal protective equipment as far as necessary or as required by the

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

be taken care that this material is not overheated even by accident e.g. du-
ring combustion and welding operations. If this should however has happen-
ed, the gases emitted must not be inhaled. Skin contact with decomposed
VITONR is to be avoided at all times. After a fire with VITONR, it is essential
that neoprene gloves are worn during the clearing up operations.
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Introduction A5.02
c2
CAUTION
Seals made of VITONR have been used at various locations in the engine.
With normal engine operation this material is completely harmless, however it
should not be exposed to temperatures above 300 °C (572 °F), since above
325 °C (617 °F) a thermal decomposition and the formation of hydrofluoric
acid can occur.
CAUTION
Maintenance and repair work must only be carried out by skilled and autho-
rized personnel!
NOTE
Any residues have to be neutralized before their disposal, i.e. saturated with
calcium hydroxide.
Clean the engine parts, especially connections and threaded unions of any
traces of oil, fuel or preservatives before carrying out maintenance/repair (di-
sassembly, assembly)!
Never use aggresive detergents and preservatives!
Use non-fuzzy cleaning rags!
Observe all indicating labels attached to the engine!
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Introduction A5.02
c2
3.3 Working on electrical equipment
CAUTION
Work on the electrical equipment of the engine/plant must be carried out only
by a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician in accordance with the electrical engineering
rules and regulations!
Use only original fuses with the specified current raiting! Switch off the engi-
ne/plant immediately if trouble occurs in the electrical system!
The electrical equipment is to be inspected/checked at regular intervals.

Defects such as loose connections or scorched cables must be rectified imme-
diately!
DANGER
Engine or plant parts on which inspection and maintenance work is being car-
ried out have to be - if prescribed - shut off at the power supply and provided
with the notice “Do not switch on” or the corresponding warning sign!
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Introduction A5.02
c2
3.4 Working with hydraulic devices
WARNING
Do not place any parts of your body above the pressurized hydraulic tools!
Replace hydraulic hose lines at regular intervals, even if no safety relevant

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

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

mechanical, thermal or chemical influences!
3.5 Checking and adjustment of injection valve
CAUTION
During testing make sure that no parts of your body are positioned in the area of the
fuel jet!
Do not inhale the fuel mist - respiratory mask!
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Introduction A5.02
c2
3.6 Handling of liquid nitrogen or carbon dioxide snow
WARNING
When handling liquid nitrogen or carbon dioxide snow, safety shoes, safety
gloves and safety glasses are to be worn in order to avoid injuries. Observe
protection against cold!
CAUTION
Parts of the skin which have come into contact with liquid nitrogen or carbon
dioxide snow must not be rubbed but covered with sterile surgical bandage
3.7 Cleansing agents/chemicals
NOTE
Use only cleansing agents with a flash point above 65 °C (149 °F)!
Observe instructions for use in accordance with safety data sheet for dangerous sub-
stances!
Observe the specialist disposal of all cleansing agents and chemicals in accordance
with the regulations for dangerous substances!
In case of accident, observe the accident leaflets including first-aid actions for
dangerous substances in accordance with the regulations for dangerous substances!
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Introduction A5.02
c2
3.8 Proposition 65 Warning
NOTE
California / USA
Proposition 65 Warning
Engine exhaust and some of its constituents are known to the state of Califor-
nia to cause cancer, birth defects, and other reproductive harm.
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Tightening Torques A5.03
c2
Tightening torques for threaded connections
Engine Type Tools and Auxiliary Materials Pos. Tool No.
All engine types Engine oil / lubricating oil

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

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

[Nm] [Nm]
Strength 8.8 10.9 12.9 8.8 10.9 12.9
class
Fine thread
M8 x 1 21 32 37 16 24 28
M10 x 1 44 65 76 33 49 57
M10 x 1.25 42 61 72 32 47 55
M12 x 1.25 75 110 130 57 83 98
M12 x 1.5 72 105 125 55 80 93
M14 x 1.5 120 175 205 89 135 155
M16 x 1.5 180 265 310 140 200 230
M18 x 1.5 270 385 455 205 290 340
M20 x 1.5 380 540 630 280 400 470
M22 x 1.5 520 740 850 380 540 630
M24 x 2 640 930 1050 480 680 800
M27 x 2 930 1350 1550 690 980 1150
M30 x 2 1300 1850 2200 980 1400 1600
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Valve Clearance A5.05. 01.01.01.10
c2 Check / Adjustment
1500
See also: 01
Spare parts sheets:
Personnel requirement: 1 pers./ 0,50 h
Personnel qualification: Skilled engine hand
Operating medium: Every fuel

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

2. Adjustment of valve clearance
Engine type Tools and auxiliary materials Pos. Tool No.
All engines Feeler gauge W1 1.9075-003 *
M 20 C Barring rod W2 2.9100-380 *
M 20 C / M 25 C Socket wrench W3 1.9100-060 *

M 25 E / M 32 C (for indicator valve, decompression valve)
VM 32 C / M 32 E
M 34 DF / M 43 C
VM 43 C / M 46 DF
VM 46 DF
* no picture
2 3 1
CAUTION
Specific feature of VM 46 DF
engines“
(Does not apply to in-line
engines)
Before adjusting / checking the
valve clearances the switching
positions of the two FCT adjusting
units must be determined. It has to
be taken into account that the valve
clearances are different depending
on the switching position (“0“ or
“1“).
Through the two holes (1/1) in the
cover (1/2) the position of the
indicator pin (1/3) can be read off.
Fig. 1 shows the FCT adjusting unit
in switching position “0” (diesel
operation).
1 Schematic diagram
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1500
01
NOTE
1 2
Valve clearance “S“ is the distance
between the adjusting screw (2/1) of the
3
rocker arm (2/2) and the valve bridge (2/3).
Before each adjustment of valve clearance S
“S“ eliminate any existing valve bridge
clearances “X“ or “Y“ between the stem
ends of the valve spindles and the
corresponding contact surfaces of the valve
bridge. Y
NOTE X
Adjustments of valve clearance “S“ are

necessary before putting into operation a
new or reconditioned cylinder head and at
further defined measuring intervals, see
Maintenance Plan.
NOTE 2 Schematic diagram
Valve bridge clearances and valve

clearances are to be adjusted when the
engine is still warm, i.e. approximately
15 min. after stopping the engine.
1. Adjustment of the valve bridge clearance
1.1 Secure the engine to prevent unintentional starting.
Conventional diesel engine:

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

Gas engine:
- Set the key switch at the “Local Data Board“ to “OFF”.
- Remove the key.
1.2 Engage the barring device (not provided for the M 20 C).
1.3 Insert the barring rod (W2) into the hole in the flywheel (for M 20 C).
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1500
1.4 Remove the valve cover. 01

1
1.5 Open the indicator valves/decompression
valves with the socket wrench (W3) (not
provided for the GCM34).
1.6 Bar the piston of the cylinder unit to be

checked to firing TDC. 2
• The rollers (3/1) of the inlet and exhaust

cam followers are on the base circle (3/2)
of the camshaft.
• The rocker arms are relieved.
3 Schematic diagram
• There is perceptible clearance at the
push-rods.
1.7 Loosen the locknut (4/2) at the rocker arm

(4/1).
1.8 Unscrew the adjusting screw (4/3) upward 2 1

3
until reaching the limit stop.
1.9 Loosen the locknut (4/5). 4
1.10 Press the valve bridge (4/4) on one side

S
against the guide bolt (4/7) to eliminate the
guide clearance. 6
1.11 Adjust the adjusting screw (4/6) so as to 5

obtain zero clearance contact at positions
Y
“X“ and “Y”.
X
1.12 Fix the adjusting screw (4/6) for the valve bridge
clearance and tighten the locknut
(4/5) in accordance with the table below.
Engine type Tightening torque for

locknut (4/5)
M 20 C 30 Nm (22 lb ft)
M 25 C, M 25 E 60 Nm (44 lb ft)
M 32 C, VM 32 C, M 32 E 150 Nm (111 lb ft)
M 34 DF, GCM34
4 7
M 43 C, VM 43 C 250 Nm (184 lb ft)
M 46 DF, VM 46 DF* 4 Schematic diagram
1.13 Using the feeler gauge (W1) check for

zero clearance contact at positions
“X“ and “Y“ (max. 0,02 mm).
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1500
2. Adjustment of valve clearance “S” 01

2.1 Press the rocker arms onto the push-rods.
2.2 Screw in the adjusting screw for valve clearance “S“ until the following valve clearances
are reached.
Exhaust valve
Engine type Inlet valve mm
mm
M 20 C 0.6 +0.1 0.65 +0.1

M 25 C, M25 E 0.5 +0.1 0.9 +0.1
M 32 C, VM 32 C, M 32 E, M 34 DF 0.4 +0.1 1.1 +0.1
GCM34 0.4 +0.1 1.2 +0.1
M 43 C, VM 43 C 0.4 +0.1 1.1 +0.1
M 46 DF (in-line engine) 0.4 +0.1 1.1 +0.1
*VM 46 DF (FCT position “0”) 0.85 +0.1 1.2 +0.1
*VM 46 DF (FCT position “1”) 0.4 +0.1 1.1 +0.1
* Specific feature of “VM 46 dual fuel engines”:

Before adjusting / checking the valve clearances the switching positions of the two FCT adjusting
units (bank A and bank B) must be determined.It has to be taken into account that the valve
clearances are different depending on the switching position (“0” or “1”).
2.3 Fix the adjusting screw (4/3) and tighten the locknut (4/2) with the following tightening torques.
Engine type Tightening torque for

locknut (4/2)
M 20 C 90 Nm (66 lb ft)
M 25 C, M 25 E 100 Nm (74 lb ft)
M 32 C, VM 32 C 250 Nm (184 lb ft)

M 32 E, M 34 DF
GCM34
M 43 C, VM 43 C 400 Nm (295 lb ft)
M 46 DF, VM 46 DF
2.4 Check clearance “S“ once again with the feeler gauge (W1).
2.5 Close the indicator valves/decompression valves with the socket wrench (W3) (not provided for
the GCM34).
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1500
2.6 Check and, if necessary, replace the gasket of the valve cover. 01
2.7 Install the valve cover.
2.8 Disengage the barring device (not provided for the M 20 C).
DANGER
Danger when starting the M 20 C engine with barring rod still inserted.
For barring the M 20 C engine a barring rod is used.
The inserted barring rod is not monitored by the control system and, therefore, does
not cause a starting interlock. If all other starting conditions are met, the engine could
be started with an inserted barring rod!
There is danger to life due to the barring rod striking around or being hurled out.
Remove the barring rod from the hole in the flywheel before starting the engine.
2.9 Remove the barring rod (W2) from the hole in the flywheel (M 20 C).
2.10 Lift the measures for securing the engine to prevent unintentional starting.

- Reestablish starting air supply.
- Set the emergency stop lever to operating position.
- Set the selector switch at the control stand to “Engine” or “Remote”.
Dual fuel engine:

Gas engine:
- Insert the key into the key switch at the “Local Data Board“.
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1500
01
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Valve Projection A5.05. 01.01.02.10
c2 Maintenance / Check
1500
See also: 01
Spare parts sheets:
Personnel requirement: 1 pers.0.20h
Operating medium: Gas and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
Check the valve projection at all inlet and exhaust valves.
Engine type Tools Pos. Tool No.
M 20 C Barring rod W1 2.9100-380 *

M 25 E / M 32 C (for indicator valve)
M 32 E / VM 32 C
M 43 C / VM 43 C
M 20 C / M 25 C Depth gauge W3 251042 A *

M 25 E
GCM34 Depth gauge W3 341033 A *

M 32 C / VM 32 C
M 32 E / M 34 DF
M 43 C / VM 43 C
M 46 DF / VM 46 DF
* no picture
NOTE
The so-called “valve projection” is used to identify premature wear of the valves and
valve seat insertsValve projection is measured at regular intervals at a defined point,
and the measured values are documented and evaluated.
The valve height shall be measured upon recommissioning, after installation of new
or overhauled cylinder heads, and at the required measuring intervals.Use the depth
gauge (1/W3) for the measurement. The obtained measuring values shall be
recorded on the attached measuring records and then transferred to the “Valve
Projection“ evaluation chart received upon commissioning. Please forward the
completed evaluation chart to your responsible authorized Caterpillar dealer for an
evaluation of the measuring values.
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1500
1. Check the valve projection at all inlet and exhaust valves 01

1.1 Take safety measures prior to maintenance work (see A5.05.00.nn) and ensure that the safety
measures are not disabled until all maintenance work is completed.
1.2 M 20 C only:
Insert the barring rod (W1) into the hole in the flywheel.
1.3 Remove the valve cover of the cylinder unit to be checked.
1.4 If provided:
Open the indicator valves with the socket wrench (W2).
1.5 Bar the piston of the cylinder head to be checked to firing TDC.
• The rocker arms are relieved.

• There is perceptible clearance at the push-rods.
NOTE
Thoroughly clean the contact surfaces before measuring and check them for
damage.
For the measurement, the temperature of the engine should be as uniform as

possible and temperatures of different measurements should be the same. This is
ensured by waiting until the temperatures have dropped to preheating level.
In this way, comparable measuring results are obtained, which are absolutely
required for a long-term comparison.
Measure the temperature between the valves on the cylinder head casting.
1.6 Put the measuring bridge of the depth gauge (W3) onto the valve spring retainer as shown in Fi-
gure 1, i.e. in upright position, covering a large surface and without tilting, and push the depth
gauge onto the sealing surface at the top edge of the cylinder head. The depth gauge must form
a right angle with the sealing surface.
Enter the measured value on the
attached measuring record.
W3
The measuring accuracy is 1/10 mm.
1.7 Repeat step 1.6 at the other valves of the

cylinder head.
1 Schematic diagram
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1500
1.8 Replace the corresponding valves and 01

valve seat inserts if valve projection ex-
ceeds the values indicated in the table
below since commissioning or the last re-
placement (valve spindle/valve seat).
Engine type Limit value “G“
M 20 C > 2.0 to 3.0 mm
M 25 C, M 25 E > 2.5 to 3.5 mm
M 32 C, VM 32 C, > 3.0 to 4.0 mm

M 32 E, M 34 DF
GCM34 > 3.0 to 3.5 mm
M 43 C, VM 43 C > 3.5 to 4.5 mm
M 46 DF, VM 46 DF > 3.5 to 4.5 mm
G Valve guide
Cylinder head
(cooling water duct)
Measure of valve and
valve seat wear
Cylinder head
(casting)
G
Valve and valve seat Valve and valve seat
- worn out - - normal -
1.9 If provided:
Close the indicator valves with the socket wrench (W2).
1.10 Check and, if necessary, replace the gaskets of the valve cover.
1.12 Repeat steps 1.3 to 1.11 at the other cylinder heads.
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1500
01
DANGER
Danger when starting the M 20 C engine with barring rod inserted.
The inserted barring rod is not monitored by the engine control and does not cause a
starting interlock. If all other starting conditions are met, the engine can be started with
an inserted barring rod. There is danger to life due to the barring rod striking around
or being hurled out.
• Make sure the barring rod has been removed from the hole in the flywheel prior to
purging and starting the engine.
1.13 M 20 C only:
Remove the barring rod (W1) from the hole in the flywheel.
1.14 Remove the safety measures after completing the maintenance work, see A5.05.00.nn.
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c2
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Measuring records
1 2 3 4 5 6 7 8 9
D A D A D A D A D A D A D A D A D A
C B C B C B C B C B C B C B C B C B
In-line engines M 20 C and M 25 C/E
Flywheel
T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C
* * * * * * * * *
Engine type Measuring accuracy for valve projection 1/10 mm

Valve Projection
Maintenance / Check
Engine number Measure theengine temperature at a point as central as
Operating hours possible
Date
A inlet valve, exhaust side (intake inboard)

B inlet valve, camshaft side (intake outboard)
C exhaust valve, camshaft side (exhaust outboard)
* Casting number of cylinder head D exhaust valve, exhaust side (exhaust inboard)
5/8
1500
A5.05. 01.01.02.10
01
c2
en / 18.03.2020
1 2 3 4 5 6 7 8 9
Other in-line engines
A D A D A D A D A D A D A D A D A D
B C B C B C B C B C B C B C B C B C
Flywheel
T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C
* * * * * * * * *

Valve Projection
Maintenance / Check
Engine number Measure the engine temperature at a point as central as
Date

6/8
1500
A5.05. 01.01.02.10
01
A D A D A D A D A D A D A D A D A D A D
V-engines
c2
B C B C B C B C B C B C B C B C B C B C
en / 18.03.2020
Flywheel
T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C
* * * * * * * * * *
A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
A D A D A D A D A D A D A D A D A D A D
Flywheel
B C B C B C B C B C B C B C B C B C B C
Valve Projection
Maintenance / Check
T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C T= °C
* * * * * * * * * *
Engine number Measure the engine temperature at a point as central as
Date Name / Position

7/8
1500
A5.05. 01.01.02.10
01
1500
01
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Rocker Arm Bracket A5.05. 01.02.01.10
c2 Disassembly / Installation
See also: A5.05.01.01.01.nn 01

Spare parts list:
Personnel requirement: 1 Pers.
Personnel qualification: skilled engine hand

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

2. Reassembly of the rocker arm bracket
M 20 C Barring rod W1 2.9100-380 *
M 20 C Torque wrench, 40 - 180 Nm (30 - 133 lb ft) W2 1.9454-040 *
M 25 C / M 25 E Torque wrench, 60 - 320 Nm (45 - 236 lb ft) W2 1.9454-320 *
M 32 C / VM 32 C Torque wrench, 100 - 400 Nm (74 - 295 lb ft) W2 1.9454-400 *

M 32 E / M 34 DF
GCM 34 Torque wrench, 100 - 400 Nm (74 - 295 lb ft) W2 1.9454-400 *

M 25 E / M 32 C (for indicator valve, decompression valve)
VM 32 C / M 32 E
M 34 DF
All engines Molykote paste “G-Rapid Plus“ **

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

- Set the selector switch on the control stand to “Repair” (depending on equipment).
Common rail diesel engine and dual fuel engine:

Gas engine:
- Set the key switch at the “Local Data Board” to “OFF”
- Remove the key.
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1.2 Engage the barring device and secure it against unintentional operation 01
(not provided for the M 20 C).
1.3 Insert the barring rod (W1) into the hole in the flywheel (for M 20 C).
1.4 Disassemble valve cover.
1.5 Open the indicator valves/decompression valves with the socket wrench (W3)
(not provided for the GCM34).
1.6 Bar the piston of the cylinder unit to be checked to firing TDC.
- The rollers of the inlet and exhaust cam followers are on the base circle of the camshaft.
- The rocker arms are relieved.
- There is perceptible clearance at the push-rods.
1.7 Remove hexagon nuts (Fig. 1/1).
1.8 Common rail diesel engine only: Remove the cable for injector control.
1.9 Remove the complete rocker arm bracket (Fig. 1/2)

with rocker arm shaft (Fig. 1/3) and rocker arms (Fig. 1/4).
6 4
3
2
8
5
Principle representation
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2. Reassembly of the rocker arm bracket 01

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

M 32 E / M 34 DF
GCM34 300 Nm (221 lb ft)
2.6 Tighten both hexagon nuts (Fig. 1/1) on the studs (Fig. 1/5) alternately in three even steps until
reaching the torque indicated in the table below.
Engine type Torque
M 20 C 120 Nm (89 lb ft)
M 25 C / M 25 E 160 Nm (118 lb ft)

M 32 C / VM 32 C 300 Nm (221 lb ft)
M 32 E / M 34 DF
GCM34 300 Nm (221 lb ft)
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01
Subsequent work
Title Maintenance sheet No. Note
Adjust the valve clearance A5.05.01.01.01.nn
2.7 Carry out an oil flow check.

For this purpose, switch on the prelubrication pump.
2.8 Close the indicator valves/decompression valves with the socket wrench (W3)
(not provided for the GCM34).
2.9 Check and, if necessary, replace the gaskets of the valve cover.
2.9.1 Install the valve cover.
2.10 Disengage the barring device (not provided for the M 20 C).
DANGER
Danger when starting the M 20 C engine with barring rod still inserted.
For barring the M 20 C engine a barring rod is used.
The inserted barring rod is not monitored by the control system and, therefore, does
not cause a starting interlock. If all other starting conditions are met, this engine could
be started with an inserted barring rod!
There is danger to life due to the barring rod striking around or being hurled out.
Remove the barring rod from the hole in the flywheel before starting the engine.
2.11 Remove barring rod (W1) from the hole in the flywheel (for M 20 C).

- Set the selector switch on the control stand to “Engine” or “Remote”.

Gas engine:
- Insert the key into the key switch at the the “Local Data Board”.
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Valve Rockers A5.05. 01.02.02.10
c2 Maintenance / Removal and Installation
30000
See also: A5.05.01.02.01.nn 01

Spare parts list:

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

2. Check of bearing clearances
3. Replacement of rocker arm bush
4. Replacement of ball pin
5. Installation of inlet and exhaust rocker arms
Engine type Tools and auxiliary material Pos. Tool No.
M 20 C / M 25 C Brass mandrel W1 *
M 25 E / M 32 C **
VM 32 C / M 32 E
M 34 DF / GCM34
M 43 C / VM 43 C Liquid nitrogen *
M 46 DF / VM 46 DF
Oil *
* no picture
** not included in the tool kit
1. Removal of inlet and exhaust rocker arms
Preparatory works
Title Maintenance sheet Notice
Rocker arm bracket disassembly A5.05.01.02.01.nn
1.1 Remove circlips (Fig. 1/4) and thrust 1 2

washers (Fig. 1/5) from the respective
ends of the rocker arm shaft (Fig. 1/3).
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30000
1.2 M 20 C, M 25 C, M 25 E: 01
Remove inlet rocker arm (Fig. 1/2) and
exhaust rocker arm (Fig. 1/1) from rocker
arm shaft (Fig. 1/3).
M 32 C/VM 32 C, M 32 E, M 34 DF,
GCM34, M 43 C/VM 43 C,
M 46 DF/VM 46 DF:
Remove inlet rocker arm (Fig. 1/1) and
exhaust rocker arm (Fig. 1/2) from rocker
arm shaft (Fig. 1/3).
1.3 Clean all parts thoroughly and check them

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

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

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

M 25 E
M 32 C/ 0,02 - 0,159 0,25
VM 32 C,
M 32 E
M 34 DF
GCM34 0,02 - 0,159 0,25
M 43 C/ 0,056 - 0,208 0,30

VM 43 C
M 46 DF/ 0,056 - 0,208 0,30

VM 46 DF
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30000
3. Replacement of rocker arm bush 01
CAUTION
The rocker arm bushes (Fig. 3/8) may only be lubricated with oil.
It is not allowable to use Molykote paste for installing the rocker arm bushes!
Care has to be taken to ensure that the plastic coated running surface of the new
rocker arm bush will not be damaged.
3.1 Drive rocker arm bush (Fig. 3/8) out of rok-

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

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

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

(Fig. 3/10) towards the top. The oil hole
(Fig. 3/9) will then be automatically positio-
ned in the correct way.
10
Make sure there is a projection at both
ends of the rocker arm with regard to the
rocker arm bush (see Z) :
s = approx. 0.2 mm
4. Replacement of ball pin
4.1 Drive out worn ball pin by means of a brass mandrel (Fig. 2/6).
WARNING
Risk of injury due to frostbites when handling liquid nitrogen!
Observe the safety regulations when handling liquid nitrogen.
It is absolutely required to wear protective clothing (long trousers, long-sleeved outer-
wear, face protection with safety glasses, and protective gloves).
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30000
4.2 Cool the new ball pin down to -195 °C (-319 °F) with liquid nitrogen. 01
4.3 When installing a new ball pin make sure marking X (if provided) is correctly
positioned, see Fig. 4.
5. Installation of inlet and exhaust rocker arms
NOTE
It has to be absolutely made sure that the rocker arm shaft is undamaged and free of
burrs.
5.1 Oil the contact surfaces of the rocker arm bushes of inlet rocker arm (Fig. 1/1), exhaust valve arm
(Fig. 1/2) and the rocker arm shaft.
5.2 Slide the rocker arms carefully onto the rocker arm shaft. In doing so, make sure not to tilt the rok-
ker arms.
5.3 Lock the rocker arms axially by means of thrust washers (Fig. 1/5) and circlips (Fig. 1/4).
Subsequent works
Title Maintenance sheet Notice
Rocker arm bracket reassembly A5.05.01.02.01.nn
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Valve Rotator A5.05. 01.03.01.10
c2 Maintenance / Inspection
150, 1500
See also: 01
Spare parts list:
Personnel requirement: 1 Pers./ 0,10 h

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

250 ml (mixture ratio 1:1)
Torch
* no picture
NOTE
An inspection of the valve rotators and ball races can only be carried out while the
engine is running!
When commissioning a new or overhauled cylinder head, the valve speed must be
measured relative to the engine speed.
In order to have a comparison basis to later measurements, these data must be
written down.
NOTE
On gas engines the valve rotators are to be inspected through the two openings in the
valve cover [blind plug (Fig. 1/1) located to the left and right of the firing coil (Fig. 1/3).
On diesel engines and dual fuel engines the valve rotators/ball races are to be
inspected through the central opening in the valve cover [sealing cap (Fig. 1/2) or blind
plug (Fig. 1/1, M 20 C)].
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150, 1500
1 3 1 2 1 01
4
4
Gas engine Diesel engine (M 25 C - M 46 DF) Diesel engine (M 20 C)
1. Inspection of the valve rotators
2. Remove blind plug/sealing cap of the valve cover (Fig. 1/4) of the corresponding cylinder head.
CAUTION
On a gas engine only max. two blind plugs must be removed at a time, otherwise the
rising internal engine pressure may trigger an engine stop.
3. Observe the valve rotation by means of a torch using marking “X” on the spring plate (Fig. 2/5) as
a reference.
The valve rotators or ball races are working properly if an even rotation depending on engine
speed can be observed.
NOTE
If the rotational speed of the valve should be found to be noticeably slower than
compared to new condition, lubricate valve rotator/ball race and valve stem with a few
splashes of lubricating oil/diesel oil mixture to increase the valve speed.
Use the lubricating oil/diesel oil mixture sparingly.
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150, 1500
4. If the valve rotational speed slows down to n < 1 rpm at rated engine speed, the valve rotator or 01
the ball race must be replaced.
5. Clean the thread of the blind plugs (Fig. 1/1) and the inside of the sealing caps (Fig. 1/1) and
lightly lubricate them with Molykote.
5.1 Tighten blind plug (Fig. 1/1) with a torque of 120 Nm (89 lb ft).
5.2 Tighten sealing caps (Fig. 1/2) finger tight.
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150, 1500
01
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Valve Guide / Oil Control Ring A5.05. 01.05.01.10
c2 Inspection / Replacement
15000
See also: A5.05.01.06.01.nn, A5.05.01.02.01.nn, A5.05.01.07.01.nn, A5.05.01.11.01.nn 01

Spare parts list:

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

M 25 C / M 25 E **
M 32 C / VM 32 C
M 32 E / M 34 DF Strong wire (e. g. welding wire) *
M 43 C / VM 43 C
M 46 DF / VM 46 DF
* no picture
1. Measure valve guide clearance and replace oil control rings
1.1 Remove cylinder head (A5.05.01.06.01.nn).
1.2 Dismantle rocker arm bracket (A5.05.01.02.01.nn) and remove valve bridge.
1.3 Remove inlet and exhaust valve stem (A5.05.01.07.01.nn).
1.4 Remove oil control rings (1) from the ring grooves (2) using a bent pointed piece of wire.
1.5 Measure the outside diameter of the valve stem in the guide area of valve guide bush (3).
1.6 Measure the inside diameter of valve guide bush (3) in transverse direction of the engine.
NOTE
We recommend to have the valve guide bush (3) replaced by a Caterpillar dealer
during a cylinder head overhaul.
If the clearance limit is reached, please contact your Caterpillar workshop.
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15000
01
Engine Valve Normal clearance (mm) Clearance limit (mm)
Exhaust 0.10 - 0.17 0.3

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

M 32 C / VM 32 C
M 32 E / M 34 DF Inlet 0.11 - 0.17 0.3
Exhaust 0.22 - 0.29 0.4

M 43 C / VM 43 C
Inlet 0.15 - 0.22 0.35
Exhaust 0.22 - 0.29 0.4

M 46 DF / VM46 DF
Inlet 0.15 - 0.22 0.35
CAUTION
Engine damage due to incorrect or incorrectly fitted spare parts.
The oil control ring controls the valve lubrication and may only be replaced by a new
genuine Caterpillar spare part.
The oil control rings (1) must be inserted into the ring grooves lubricated with grease
and untwisted.
1.7 Clean the ring grooves (2).
1.8 Lubricate new oil control rings (1) with a thin layer of Petro Gel Amber and insert them into the
ring grooves untwisted.
en / 02.01.2015 2/4
15000
01
1
1
2
1.9 Install inlet and exhaust valve cone (A5.05.01.07.01.nn).
1.10 Put on valve bridge and install rokker arm brakket (A5.05.01.02.01.nn).
1.11 Install cylinder head (A5.05.01.11.01.nn).
en / 02.01.2015 3/4
15000
01
en / 02.01.2015 4/4
Media Guide A5.05. 01.05.50.10
See also: 01
Spare parts list:
Operating medium: Heavy fuel and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the media guide

2. Installation of the media guide
Engine Type Tools and Auxiliary Materials Pos. Ord. No.
M 20 C / M 25 C Petro Gel Amber *

M25 E **
M 32 C / VM 32 C
M 32 E / M 34 DF Molykote paste “G-Rapid Plus“ *
M 43 C / VM 43 C **
M 46 DF / VM 46 DF
* no picture
1. Removal of the media guide

- Switch off and block the fuel supply to the engine.

1.2 Switch off the prelubrication pump.
1.3 Remove the pump coverings of the cylinder units to be serviced.
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Media Guide A5.05. 01.05.50.10
01
NOTE
Depending on the engine type two or three screws (Fig. 1/1) per connection flange
(2) and three or four sleeves (3) are provided.
1.4 Loosen and remove the screws (Fig. 1/1).
1.5 Remove any pipes (4) connected to the connection flange (2).
1.6 Remove the connection flanges (2) with sleeves (3) and gasket (Fig. 2/5).
CAUTION
Risk of damage to the engine due to dirt!
Dirt in the pipes may cause engine damage.
The sealing surfaces and openings of the removed pipings and their connections are
to be sealed against dirt and protected against damage!
1.7 Seal the open connections by means of suitable sealing material.
Media guide at the end of a cylinder bank Media guide between two cylinders
4
1
2 2
1 3
en / 02.01.2015 2/4
Media Guide A5.05. 01.05.50.10
2. Installation of the media guide 01
NOTE
Depending on the engine type two or three screws (Fig. 2/1) per connection flange
(2) and three or four sleeves (3) are provided.
CAUTION
Twisted O-rings may cause leaks and damage.
If O-rings are inserted into their grooves in dry condition and/or twisted, this may
cause damage to the O-rings or cause the O-rings to be squeezed out of the groove
during installation.
Such assembly errors will cause leaks and malfunctions on the engine after being put
into service, up to engine damage.
Before installation, lubricate the O-rings with Petro Gel Amber and insert them into the
corresponding grooves untwisted.
2.1 Coat new O-rings (Fig. 2/4) with Petro Gel Amber and insert them into the grooves untwisted.
2.2 Clean the O-ring grooves, media holes in the connection flanges (2) and the sealing surfaces
for gasket (5) and check them for damage.
B B
A E E A
1
A-A B-B
5 V E-E 3
6 V V
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Media Guide A5.05. 01.05.50.10
2.3 Center a new gasket (Fig. 2/5) by means of the spring dowel pins (6). 01
2.4 Lightly coat the thread and head contact surfaces of the screws (1) with Molykote-Paste “G-
Rapid Plus”.
2.5 Position the sleeves (3) in the corresponding holes of the connection flanges (2) making sure
the O-rings (4) are correctly seated.
2.6 Install the connection flanges (2) with sleeves (3) and screws (1) making sure the gaskets (5)
are correctly seated.
2.7 Install any pipes (4) that had been connected to the connection flange (Fig. 1/2).
2.8 Install the pump coverings.

- Reestablish fuel supply to the engine.
- Set the emergency stop lever to operating position .
- Set the selector switch at the control stand to “Engine” or “Remote“.

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Cylinder Head A5.05. 01.06.01.11
c2 Maintenance / Removal
See also: A5.05.02.06.01.nn, A5.05.01.05.50.nn, A5.05.06.01.01.nn, A5.05.13.01.01.00 01

Spare parts sheets:
Personnel requirement: 1 pers.

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the cylinder head
M 25 C / M 25 E Hydraulic kit: W1
High-pressure pump W1.1 0.9204 D
High-pressure hose (1 m) (4 pcs.) W1.2 0.9205 B
Hydraulic jack W1.3 0.9213 C
Hydraulic distributor W1.4 0.9203-008
Support ring W1.5 0.9203-018
Support ring (short) W1.6 0.9203-209

Threaded sleeve W1.7 0.9206-003
Threaded sleeve (short) W1.8 0.9206-001
Cylinder head mounting and removal device W2 0.9221 B *
Socket wrench for indicator valve W3 1.9100-060 *
Pin Ø8 W4 0.9203-110
* no picture
WARNING
Risk of injury in case of improper handling of the hydraulic unit!
In case of leaks, hydraulic oil leaking under high pressure may cause severe injuries
up to death.
• Do not place any parts of the body above the pressurized devices.
• Use personal protective equipment.
• The bending radius of the high-pressure hoses must not be less than the minimum
bending radius r = 150/250 mm.
• Use only hydraulic oil as operating medium (see engine documentation, chapter
“Operating Media”).
• Store the devices protected against corrosion.
en / 07.01.2020 1/4
1. Remove the cylinder head 01

Secure the components that have been shut down against being switched on inadvertently.
• Interrupt the starting air supply.

• Switch off and block the fuel supply to the engine.
• Switch off the cooling water preheating.
• Switch off the lubricating oil stand-by pump / prelubrication pump.
• Throw and secure the emergency stop lever (if provided).
• Set the control stand selector switch to “Engine Blocking” (aMACS) or “Repair” (MACS).
1.2 Open all indicator valves by means of the socket wrench (W3).
1.3 Bar the piston of the cylinder to be removed to ignition TDC.

Inlet and exhaust valves are closed, rocker arms are relieved.
1.4 Engage the barring device and secure it against unintentional operation.
1.5 Remove the valve cover and the pump chamber covering at the cylinder head to be dismounted.
1.6 Drain the cooling water completely into the drain tank. For checking purposes, loosen the screw
plug in the return pipe of the charge air cooler (outer pipe) below the thermometer.
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1.7 Remove the media guide (1/1) (A5.05.01.05.50.nn). 01
4 2
1 Schematic diagram
1.8 Loosen the thrust screw (1/3) of the

transverse thrust piece.
1.9 Push the sleeve (1/2) to the left into the

cylinder head.
1.10 Loosen the threaded connection below

1
the sleeve. Disengage the transverse
thrust piece with cap (1/4) and pull it to the
left out of the injection pump and the
cylinder head.
NOTE
For removal of the last cylinder
head at the free end, unscrew
the fuel return (2/1) from the
blank flange.
2 Schematic diagram
1.11 Remove the covering between exhaust manifold and cylinder head.
Remove the fixing screws of the exhaust manifold (A5.05.06.01.01.nn).
1.12 Loosen the four round nuts with the hydraulic kit (W1) (A5.05.13.01.01.00).
en / 07.01.2020 3/4
1.13 Lift the cylinder head:

01
W2
1.13.1 Install the cylinder head mounting and
removal device (3/W2) on the fuel injector.
3 Schematic diagram
CAUTION
Property damage possible due to improper removal.
In case of improper lifting of a cylinder head, there is a risk of damaging the cooling
water transfer sockets, cylinder head studs, push-rods, and charge air inlet nozzles.
• Lift the cylinder head carefully and slowly, pay attention to the passage of the
cylinder head studs and the push-rod duct.
• Cooling water passage socket and charge air inlet nozzle remain in the cooling
collar; if necessary, position them there again.
1.13.2 Attach the cylinder head to the crane, lift it carefully and horizontally.
1.13.3 Put the cylinder head onto a suitable base.
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Relief Valve / Indicator Valve A5.05. 01.06.70.11
c2 Maintenance / Replacement
See also: A5.05.01.06.01.nn 01

Spare parts sheets:
Personnel requirement: 1 pers./ 0.20 h

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Replace the relief valve

2. Replace the indicator valve
Engine type Tools and auxiliary materials Index Tool No.
M 25 C / M 25 E Torque wrench (60 - 320 Nm) W1 1.9454-320 *
VM 32 C
M 43 C (M 46 DF) Torque wrench (60 - 320 Nm) W1 1.9454-320 *
VM 43 C (VM 46 DF)
M 25 C / M 25 E High-temperature thread paste “Rivolta 1.1002-359 */**

G.W.F.”
M 32 C / M 32 E
Molykote paste “G-Rapid Plus” 1.9493-001 */**
VM 32 C
M 43 C (M 46 DF)
VM 43 C (VM 46 DF)
* no picture
en / 19.12.2019 1/6
1. Replace the relief valve 01


• Set the selector switch at the control stand to “Repair”.
Engine type 1 Schematic diagram
M 25 C / M 25 E
10
8
2
3
7
4
en / 19.12.2019 2/6

01
M 32 C / M 32 E
VM 32 C
1
M 43 C
M 43 DF
10 1
(VM 43 C)
(VM 43 DF)
2
8
3
4
A
5
7
6
en / 19.12.2019 3/6
1.2 Remove the protection cover (1/10) of the indicator valve (if provided). 01
1.3 Remove the protection cover (1/3) of the relief valve (if provided):
1.3.1 Remove the hexagon nut (1/2).
1.3.2 Take off the protection cover.
1.4 Loosen and remove the relief valve (1/1).
1.5 For M 43 C (M 46 DF) / VM 43 C (VM 46 DF) only:

Remove the disc spring (1/5) from the stud (1/4).
1.6 Coat the thread of the new relief valve with Rivolta G.W.F. high-temperature thread paste.
1.7 Install the new relief valve with new sealing ring (1/6).
1.8 Tighten the relief valve with a torque of 130 Nm.
1.9 For M 43 C (M 46 DF) / VM 43 C (VM 46 DF) only:

Put the disc spring (1/5) onto the stud (1/4) again.
1.10 Install the protection cover of the relief valve (1/3):
1.10.1 Put on the protection cover.
1.10.2 Apply a thin coat of Molykote to the thread of the hexagon nut (1/2).
1.10.3 Tighten the hexagon nut with a torque of 50 Nm.
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2. Replace the indicator valve 01

2.1 Remove the protection cover (if provided).
2.1.1 For M 25 C / M 25 E only:

Remove the protection cover (1/10).
2.1.2 For M 43 C (M 46 DF) / VM 43 C (VM 46 DF) only:

Pull off the protection cover (1/10).
2.2 Counterhold the union (1/7) with a suitable tool. Loosen and remove the indicator valve (1/9).
2.3 Install the new indicator valve with new sealing ring (1/8:
2.3.1 Make sure that the indicator valve is still easily accessible in the installed condition and with valve
cover installed.
2.3.2 Apply a thin coat of Rivolta G.W.F. high-temperature thread paste to the thread of the new
indicator valve.
2.3.3 Preassemble the new indicator valve.
2.3.4 Counterhold the union with a suitable tool. Tighten the new indicator valve with a torque of
125 Nm.
2.4 Install the protection cover (if provided).
2.4.1 For M 25 C / M 25 E only:

Install the protection cover (1/10).
2.4.2 For M 43 C (M 46 DF) / VM 43 C (VM 46 DF) only:

Press on the protection cover (1/10) again. In doing so, make sure that the resilient lateral thrust
pieces (1/A) engage.
• Reestablish starting air supply.

• Set the emergency stop lever to operating position (if provided).
• Reestablish fuel supply to the engine.
• Set the selector switch at the control stand to “Engine” or “Remote”.
en / 19.12.2019 5/6
01
en / 19.12.2019 6/6
Inlet and Exhaust Valve Spindle A5.05. 01.07.01.10
c2 Removal and Installation
15000, 7500
See also: A5.05.01.02.01.nn, A5.05.01.06.01.nn, A5.05.01.08.01.nn, A5.05.01.08.02.nn, 01

A5.05.01.05.01.00, A5.05.01.05.01.01, A5.05.01.11.01.nn
Spare parts sheets:


----------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the inlet and exhaust valve spindle

2. Installation of the inlet and exhaust valve spindle
Tools and auxiliary

Engine type Index Tool No.
materials
M 20 C / M 20 E Valve spring compressor W1 2.9222 A
M 25 C / M 25 E Valve spring compressor W1 259222 A
M 32 C / M 32 E / VM 32 C / M 34 DF / Valve spring compressor W1 9.9222 A

GCM34
M 43 C / M 46 DF / VM 43 C / VM 46 DF Valve spring compressor W1 439222 D

M 32 C / M 32 E / VM 32 C / M 34 DF / Circlip pliers 1.9067-440
GCM34 / M 43 C / M 46 DF / VM 43 C /
VM 46 DF
WARNING
Risk of injury due to spring tension!
In installed condition the valve springs are under strong preload.
Improper handling or using a defective tool may lead to severe injuries.
• Use personal protective equipment, check the tool before each use for possible
damage, and strictly follow the job instructions.
NOTE
The service life of the valve spindles depends on the fuel grade that is being used,
the operating conditions of the plant and the quality of repaired valve spindles / seat
inserts, and will thus differ from plant to plant.
For this reason the operator must determine the repair intervals valid for him
depending on the actual condition of the checked valve spindles. Each time a valve
spindle is removed check the seat geometry (see A5.05.01.08.01.nn,
A5.05.01.08.02.nn).
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15000, 7500
1. Removal of the inlet and exhaust valve spindle 01

Diesel engine:
• Throw and secure the emergency stop lever.
• Set the selector switch at the control stand to “Repair” (depending on equipment).
Dual fuel engine:

Gas engine:
• Mechanically block the main shut-off valve of the gas valve unit.
• Set the key switch at the “Local Data Board“ to “OFF”.
• Remove the key.
1.2 Dismantle the rocker arm bracket (A5.05.01.02.01.nn) and remove the valve bridges.
1.3 Remove the cylinder head (A5.05.01.06.01.nn).
1.4 For M 32 C / M32 E / VM 32 C / M 34 DF / GCM34 / M 43 C / M 46 DF / VM 43 C / VM 46 DF

remove the circlip (1/6).
1.5 Before putting on the valve spring compressor lubricate the contact surfaces (1/a) with Molykote
paste “G-Rapid”.
1.6 Put the sleeve (1/2) of the valve spring compressor (1/W1) onto the valve spindle (1/3) but not on
a possibly existing casting lug (1/b) and screw it on so as to be finger tight.
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15000, 7500
1.7 Put the valve spring compressor (1/W1) onto the spring plate (1/4). 01
In doing so, make sure that the sleeve head is captured with the valve spring compressor (1/W1)
and the valve spring compressor (1/W1) rests flatly on the spring plate (1/4).
For M 43 C / M 46 DF / VM 43 C / VM 46 DF additionally secure the sleeve (1/2) with a split
pin (1/7).
M 20 C
M 25 C 1
M 25 E
M 32 C
M 32 E
M 34 DF
VM 32 C
VM 32 E
GCM34 a
W1
4
b
en / 26.09.2017 3/6
15000, 7500

01
M 43 C /
M 46 DF /
VM 43 C / 1
VM 46 DF
W1
7 2
3
6
5 4
1.8 Screw on the valve spring compressor (1/W1) so as to be finger tight.
1.9 Compress the valve spring by turning the nut (1/1) of the valve spring compressor (1/W1) and
remove the clamping cone halves (1/5).
1.10 Relieve the valve spring by loosening the nut (1/1).
1.11 For M 43 C / M 46 DF / VM 43 C / VM 46 DF extract the split pin (1/7).
1.12 Remove the valve spring compressor (W1), the spring plate (1/4), the vale spring and the valve
rotator or ball races and, if applicable, spacers from the cylinder head.
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15000, 7500
1.13 Pull the valve spindle (1/3) out of the cylinder head. 01
NOTE
Valve spindles with severe wear marks in the clamping area and clamping cone
halves (1/4) on which significant burr has formed must be replaced by new parts.
For assessment and repair of valve spindle / valve seat insert see:
A5.05.01.08.01.nn / A5.05.01.08.02.nn.
2. Installation of the inlet and exhaust valve spindle
2.1 Check the valve guide clearance (A5.05.01.05.01.00 / A5.05.01.05.01.01).
2.2 Lubricate the valve spindle stem (free of burrs) well before installing and insert the valve spindle
with a screwing motion.
2.3 Put the valve rotator or ball races and, if applicable, spacers, valve spring and spring plate (1/4)
onto the cylinder head.
2.4 Put the sleeve (1/2) of the valve spring compressor (1/W1) onto the valve spindle (1/3) but not
on a possibly existing casting lug (1/b) and screw it on so as to be finger tight.
For M 43 C / M 46 DF / VM 43 C / VM 46 DF additionally secure the sleeve (1/2) with a split
pin (1/7).
2.5 Put the valve spring compressor (1/W1) onto the spring plate (1/4).
In doing so, make sure that the sleeve head is captured with the valve spring compressor (1/W1)
and the valve spring compressor (1/W1) rests flatly on the spring plate (1/4).
2.6 Screw on the valve spring compressor (1/W1) so as to be finger tight.
2.7 Compress the valve spring by turning the nut (1/1) of the valve spring compressor (1/W1) and
insert the clamping cone halves (1/5).
2.8 Relieve the valve spring by loosening the nut (1/1). In doing so, make sure the clamping cone
halves (1/5) are correctly seated.
2.9 For M 43 C / M 46 DF / VM 43 C / VM 46 DF extract the split pin (1/7).
2.10 Remove the valve spring compressor (1/W1) and the sleeve (1/2).
2.11 For M 32 C / M32 E / VM 32 C/ M 34 DF / GCM34 / M 43 C / M 46 DF / VM 43 C / VM 46 DF

install the circlip (1/6).
2.12 Install the cylinder head (A5.05.01.11.01.nn).
2.13 Install valve bridges and rocker arms (A5.05.01.02.01.nn)
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15000, 7500
2.14 Lift the measures for securing the engine to prevent unintentional starting. 01
Diesel engine:
• Set the emergency stop lever to operating position.
• Set the selector switch on the control stand to “Engine” or “Remote“.
Dual fuel engine:

• Set the selector switch on the control stand to “Engine” or “Remote“.
Gas engine:
• Open the main shut-off valve of the gas valve unit.
• Insert the key into the key switch at the “Local Data Board“.
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Valve Spindle - Non Seat Nitrided A5.05. 01.08.01.10
c2 Maintenance / Assessment
See also: A5.05.01.08.02.n5 01

Spare parts sheets:
Personnel qualification: Chief engineer / skilled engine hand

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Cleaning of the valve spindle

2. Assessment
3. Repair (refinishing of the valve spindle sealing surface)
4. Check of contact pattern/grinding-in
5. Final inspection
Engine type Tools and auxiliary materials Index Ord. No.
M 20 C Valve jig W1 2.9224 A
M 25 C / M 25 E Valve jig W1 259224 A
M 32 C / VM 32 C Valve jig W1 6.9224 B

M 32 E / M 34 DF
M 43 C / VM 43 C Valve jig W1 439224 A

M 46 DF / VM 46 DF
M 20 C / M 25 C, Illuminated magnifier (8-fold magnification) */
M 25 E / M 32 C ***
VM 32 C / M 32 E
M 34 DF - Dye penetrant inspection (Met-L-Chek) */
M 43 C V / M 43 C - Magnetic particle inspection **/
M 46 DF / VM 46 DF ***
Diamond paste Dp 30/10 - 15 µm 1.9493-002

Thinner DIAPLASTOL */
**/
***
Brass brush */
***
* no picture
*** not included in scope of supply
en / 19.09.2017 1/10
01
NOTE
The term valve refers to the combination of valve spindle and valve seat insert. The
latter is firmly inserted into the cylinder head.
CAUTION
It is not allowable to grind in valve spindles with nitrided sealing surface (seat
nitrided), see also A5.05.01.08.01.n5.
In case of doubt, please contact your authorized Caterpillar dealer.
en / 19.09.2017 2/10
01
NOTE
During regular maintenance of the engine (e.g. after 15,000 hours), we recommend to
refinish the valve seat inserts and the valve spindles.
Refinishing or replacement of the valves may become necessary if during non-
scheduled maintenance or after a partial check the findings are not okay.
Examples of negative findings

Fig. 1 shows a valve spindle with damage to the sealing surface all around (1/a) and
dents by coke suggesting blow-by (1/b) extending over more than 40 % of the
height of the sealing surface.
Fig. 2 shows the sealing surface of a valve seat insert with deep pits in the left and a
jagged sealing surface area in the right half of the picture.
Both figures show severe damage to the valve sealing surfaces which, therefore, require
refinishing. If the refinishing limits are reached, the parts must be replaced.
Always refinish both sealing surfaces (valve spindle and valve seat insert).
When the sealing surfaces of a non seat nitrided valve Fig. 1 and 2) show uneven
contact patterns or deeper pits, always refinish both sealing surfaces.
1 a
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1. Cleaning of the valve spindle 01
CAUTION
A wrong tool may cause damage to the sealing surfaces!
Cleaning with sharp-edged tools and pickling with inorganic acids (such as hydro-
chloric acid, sulphuric acid, hydrofluoric acid, etc.) as well as sand blasting and other
material removing methods are not allowable.
1.1 Clean the valve spindle: Spray coke deposits with clean fresh water. After a short exposure time
wipe them off with a cleaning rag.
NOTE
More tenacious incrustations may also be carefully removed by means of a brass
brush.
1.2 If necessary, blast with glass beads.
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2. Assessment 01
Valve spindles may only be reused when all of the criteria specified under 2.1, 2.2 and 2.3 are
met.
2.1 Valve spindle sealing surface
• The valve spindle sealing surface must show a bare metal finish all around.
• The valve spindle sealing surface must not show any dents by coke suggesting blow-by (1/b)
extending over more than 40 % of the height of the sealing surface; refinish where appropriate.
• Carry out a crack test by means of dye penetrant inspection (Met-L-Chek) or magnetic particle
inspection. This test must not reveal any cracks in the valve spindle sealing surface
2.2 Bottom side of the valve spindle

head
• Slight high-temperature corrosion

extending over the entire bottom side
of the valve head is allowable (Fig. 3,
for burnout limits please also refer to
2.4.)
2.3 Valve spindle stem and sealing

surface
• Valve spindle stem free of corrosion

pits
• Straightness deviation and radial run-

out of the valve spindle stem and
radial run-out of the valve spindle
sealing surface must not exceed the
following values.
Engine Measuring Run-out, Run-out, Straightness,

type distance L measured at C measured at D measured at D over length L
M 20 C 200 mm 0.02 mm 0.04 mm 0.02 mm
M 25 C 264 mm 0.025 mm 0.05 mm 0.025 mm

M 25 E
M 32 C
VM 32 C 390 mm 0.03 mm 0.08 mm 0.04 mm
M 32 E
M 34 DF
GCM34
M 43 C
VM 43 C 495.6 mm 0.03 mm 0.08 mm 0.04 mm
M 46 DF
VM 46 DF 495.6 mm 0.03 mm 0.08 mm 0.04 mm
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For measuring run-out of the sealing surface C arrange the valve spindle with supporting points at 01
A and B so that it can be rotated but not shifted in axial direction. Reset the dial gauge to zero at
valve spindle sealing surface C and rotate the valve spindle by one turn. The maximum deflection
at the dial gauge must not exceed the value indicated above.
For measuring run-out of the stem under D arrange the valve spindle with supporting points at A
and B so that it can be rotated. Reset the dial gauge to zero in the middle area of measuring
distance L at the valve stem D and rotate the valve spindle by one turn. The maximum deflection
at the dial gauge must not exceed the value indicated above. If necessary, repeat the
measurement at other points within measuring distance L.
For measuring straightness at D, arrange the valve spindle with supporting points at A and B so
as to be parallel to the base surface (e.g. tracing plate). Reset the dial gauge to zero at one end of
measuring distance L at the top of the valve spindle stem D and move the dial gauge in axial
direction along the valve spindle stem until reaching the other end of measuring distance L. Do
not rotate the valve spindle during this process. The maximum deflection at the dial gauge must
not exceed the value indicated above. After that, rotate the valve spindle by 1/4 turn and repeat
the measurement until 4 measuring distances evenly distributed around the circumference of the
valve stem have been covered.
20 20
A B
L
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2.4 Valve spindles cannot be reused in the following 01

cases:
• Damage to the valve spindle sealing

surface (cracks, blow-by).
• The refinishing limit of the valve spindle

hard facing has been exceeded (see
dimension Z in the table on page 9).
• Severe pitting on the bottom side of the valve spindle

head (formation of so-called “paving stones, Fig. 7).).
S
• Corrosive material erosion of more than
1 % of the outside surface of the valve
spindle head diameter (Fig. 6)
[compared to new valve spindles].
• When exceeding the allowable burnout “S“ (Fig. 5 and 7) due to high-temperature corrosion on
the bottom side of the valve spindle head of:
- 2.5 mm (M 43 C, VM 43 C, M 46 DF, VM 46 DF)
- 1.5 mm (M 20 C, M 25 C, M 25 E, M 32 C, VM 32 C, M 32 E, M 34 DF, GCM34)
• Corrosion pits and/or mechanical damage in the area of valve spindle stem, valve spindle
stem transition (Fig. 8 and 9) and valve spindle head.
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3. Repair (refinishing of the valve spindle sealing surface) 01
NOTE
Refinishing of valve spindles has to take place in a professional manner and
exclusively by using a high-precision valve spindle grinding machine. If no such
machine is available, the valve spindles should be sent to a an authorized Caterpillar
workshop for refinishing.
If the valve spindle sealing surface is refinished, also the related valve seat insert must
be refinished (A5.05.01.08.02.nn).
3.1 Regrind the valve spindle sealing surface

according to the specified angle a (Fig. 10). A H
minimal fillet (H) still has to remain.
3.2 When performing the grinding, observe the a

relevant instructions of the grinding device
manufacturers.
Z
3.3 After the grinding process determine
dimension Z between the visible transition of
base material hard facing (X) and the outside X
edge of the sealing surface. If the measured
value is below the minimum dimension,
replace the valve spindle.
3.4 Round off the outside edge (r = 1) and smooth it with an oil stone.
Refinishing limits
Inlet valve spindle Exhaust valve spindle

Engine
Angle “a“ Dim. Z Angle “a“ Dim. Z
M 20 C 19° 54’ ±3’ min. 1 mm 29° 54’ ±3’ min. 1 mm

M 25 C / M 25 E 29° 54’ ±3’ min. 1 mm 29° 54’ ±3’ min. 1 mm
M 32 C / VM 32 C 29° 54’ ±3’

min. 1 mm 29° 54’ ±3’ min. 1.5 mm
M 32 E
seat nitrided valve spindles
(no refinishing permissible) 19° 54’ ±3’
GCM34 seat nitrided valve spindles seat nitrided valve spindles
(no refinishing permissible) (no refinishing permissible)
M 34 DF seat nitrided valve spindles 29° 54’ ±3’ min. 1.5 mm

(no refinishing permissible)
M 43 C, VM 43 C 29° 54’ ±3’

min. 1 mm 29° 54’ ±3’ min. 1.5 mm
seat nitrided valve spindles
19° 54’ ±3’
M 46 DF, VM 46 DF seat nitrided valve spindles 29° 54’ ±3’ min. 1.5 mm
en / 19.09.2017 8/10
4. Check of contact pattern/grinding-in 01

4.1 Using a syringe, evenly apply small dots of
diamond paste (Dp 30/10 - 15 µm) to the valve
spindle sealing surface of the new or
refinished valve spindle (Fig. 11). Thereafter,
to dilute the paste and increase the grip,
spray the entire valve spindle sealing
surface with the thinner belonging to the
diamond paste (DIAPLASTOL).
4.2 Insert the oiled valve spindle stem into the

valve guide. Fasten the device (12(W1) on the
valve spindle head. Grind the sealing surfaces
of the valve spindle and the valve seat insert
for a short time by rotating the device (W1) by
hand back and forth 6 to max. 8 times.
For this purpose, shortly lift the valve spindle
several times and put it back in displaced W1
position. After that, clean the valve thoroughly.
Any remainders of paste would promote wear.
The percentage contact area a (Fig. 13) made

visible through the smooth grinding process
shall amount to
30 - 50 % of width b
all around and starting from the outside

diameter.
Schematic diagram
en / 19.09.2017 9/10
4.3 In case of a poor contact pattern do not 01

repeat this process but remachine both
sealing surfaces.
4.4 Make sure that the combination of valve

spindle and valve seat insert is
maintained.
5. Final inspection
5.1 Check whether the refinishing limits have

been observed.
5.2 Thoroughly clean the valve spindle and

check the valve spindle sealing surface
with an illuminated magnifier
(8-fold magnification) for cracks in the hard
facing and the adjacent areas. In case of
signs of crack formation replace the valve
spindle.
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Valve Spindle - Seat Nitrided A5.05. 01.08.01.15
See also: A5.05.01.08.02.n0 01

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Cleaning of the valve spindle

2. Assessment
3. Repair
4. Check of contact pattern
M 25 C / M 25 E Valve jig W1 259224 A

M 32 E / M 34 DF
GCM34

M 46 DF / VM 46 DF
M 20 C / M 25 C, Illuminated magnifier (8-fold magnification) */
M 25 E / M 32 C ***
VM 32 C / M 32 E
M 34 DF - Dye penetrant inspection (Met-L-Chek) */
M 43 C V / M 43 C - Magnetic particle inspection **/
M 46 DF / VM 46 DF ***
Blue paste */
***
Brass brush */
***
* no picture
NOTE
The term valve refers to the combination of valve spindle and valve seat insert. The
latter is firmly inserted into the cylinder head.
en / 19.09.2017 1/8
01
CAUTION
It is not allowable to grind in valve spindles with nitrided sealing surface (seat
nitrided).
Material removal, whether by grinding-in or refinishing of the sealing surface of

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

MaK 10-09 IN MaK 10N09 IN
MaK 34-16 IN MaK 34N16
------------------- MaK 34N70
-------------------- MaK 43N73 IN
In case of doubt, please contact your authorized Caterpillar dealer.
en / 19.09.2017 2/8
01
NOTE
During regular maintenance of the engine after 15,000 hours it should normally not be
necessary to refinish valve seat inserts or replace valve spindles. If the findings are
okay, valve spindle and valve seat insert can be used up to max. 30,000 operating
hours.
Refinishing or replacement of the valves may become necessary if during non-
scheduled maintenance or after a partial check the findings are not okay.
It is not allowable to refinish nitrided valve spindle sealing surfaces.

When reaching one or several replacement criteria, the valve spindle must be replaced
and the valve seat insert must be refinished (or replaced).
Examples of negative findings

Fig. 1 shows a valve spindle with dents by coke suggesting blow-by (1/a) extending over
more than 40 % of the height of the sealing surface.
Fig. 2 shows a valve spindle with palpable wear score marks in the sealing surface and
a dent by coke (2/b) in the outer sealing surface area.
Fig. 3 shows a cleaned and glass bead blasted valve spindle with completely worn
sealing surface.
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1. Cleaning of the valve spindle 01
CAUTION
Cleaning with sharp-edged tools and pickling with inorganic acids (such as hydrochlo-
ric acid, sulphuric acid, hydrofluoric acid, etc.) as well as sand blasting and other ma-
terial removing methods are not allowable.
1.1 Clean the valve spindle: Spray coke deposits with clean fresh water. After a short exposure time
wipe them off with a cleaning rag.
NOTE
More tenacious incrustations may also be carefully removed by means of a brass brush.
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2. Assessment 01
Valve spindles may only be reused when the criteria specified under 2.1 and 2.2 are met.
2.1 Valve spindle sealing surface
• The valve spindle sealing surface must be smooth and free of score marks all around, and
• the valve spindle sealing surface may only show a few dents by coke and no dents suggesting
blow by (1/a) that extend over 40 % of the height of the sealing surface.
• Carry out a crack test by means of dye penetrant inspection (Met-L-Chek) or magnetic particle
inspection. This test must not reveal any cracks in the valve spindle sealing surface
Examples of positive findings

Fig. 4 shows a relatively smooth valve spindle sealing surface with contact pattern located in the
outer third.
Fig. 5 shows a relatively smooth valve spindle sealing surface with outer contact pattern and
minor dents by coke. The contact pattern already extends over 50 % of the sealing surface,
nevertheless this valve spindle can be reused.
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2.2 Valve spindle stem and sealing surface 01

• Valve spindle stem free of corrosion pits (Fig. 7 and 8)
• Straightness deviation and radial run-out of the valve spindle stem and radial run-out of the
valve spindle sealing surface must not exceed the following values.
Engine Measuring Run-out, Run-out, Straightness,

type distance L measured at C measured at D measured at D over length L
M 20 C 200 mm 0.02 mm 0.04 mm 0.02 mm

M 25 C 264 mm 0.025 mm 0.05 mm 0.025 mm
M 25 E
M 32 C
VM 32 C 390 mm 0.03 mm 0.08 mm 0.04 mm
M 32 E
M 34 DF
GCM34
M 43 C
495.6 mm 0.03 mm 0.08 mm 0.04 mm
VM 43 C
M 46 DF
VM 46 DF 495.6 mm 0.03 mm 0.08 mm 0.04 mm
For measuring run-out of the sealing surface C arrange the valve spindle with supporting points at A and B
so that it can be rotated but not shifted in axial direction. Reset the dial gauge to zero at valve spindle
sealing surface C and rotate the valve spindle by one turn. The maximum deflection at the dial gauge must
not exceed the value indicated above.
For measuring run-out of the stem under D arrange the valve spindle with supporting points at A and B so
that it can be rotated. Reset the dial gauge to zero in the middle area of measuring distance L at the valve
stem D and rotate the valve spindle by one turn. The maximum deflection at the dial gauge must not
exceed the value indicated above. If necessary, repeat the measurement at other points within measuring
distance L.
For measuring straightness at D, arrange the valve spindle with supporting points at A and B so as to be
parallel to the base surface (e.g. tracing plate). Reset the dial gauge to zero at one end of measuring
distance L at the top of the valve spindle stem D and move the dial gauge in axial direction along the valve
spindle stem until reaching the other end of measuring distance L. Do not rotate the valve spindle during
this process. The maximum deflection at the dial gauge must not exceed the value indicated above. After
that, rotate the valve spindle by 1/4 turn and repeat the measurement until 4 measuring distances evenly
distributed around the circumference of the valve stem have been covered.
20 20
A B
L
C 6
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2.3 Valve spindles cannot be reused in the following 01

cases:
• Damage to the valve spindle sealing

surface (cracks, blow-by).
• Dents by coke suggesting blow-by

extending over more than 40 % of the
height of the valve spindle sealing
surface.
• Palpable wear marks all around on the valve spindle

sealing surface, see also Fig. 1, 2, and 3.
• Corrosion pits and/or mechanical damage in the

area of valve spindle stem, valve spindle stem
transition (Fig. 7 and 8) and valve spindle head.
7 8
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3. Repair 01
CAUTION
Avoid destroying the nitrided valve stem sealing surface!
Valve spindles with nitrided sealing surface must be neither ground in nor refinished!
When reaching one or several replacement criteria, only the valve seat insert may be
refinished (see A5.05.01.08.02.nn), the valve spindle must in this case be replaced by
a new one.
4. Check of contact pattern

(for valve spindles with seat nitrided sealing surface)
4.1 Apply a thin and even film of blue paste onto the sealing surface of the valve spindle.
4.2 Insert the oiled valve spindle stem into the valve guide. Fasten the device (Fig. 12/W1) to the
valve spindle head. Carry out the valve spindle and valve seat ring contact area check by rotating
the device in both directions by hand for a short time. There shall be a continuous contact pattern
all around, starting from the outside diameter. After that, thoroughly clean valve spindle and seat
ring.
4.3 Make sure that the combination of valve spindle and valve seat insert is maintained.
en / 19.09.2017 8/8
Valve Seat Ring A5.05. 01.08.02.10
c2 Maintenance / Evaluate
See also: A5.05.01.05.01.nn 01

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

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

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

M 32 E / GCM34

M 46 DF / VM 46 DF
M 20 C / M 25 C Illuminated magnifier (8-fold magnification) */
M 25 E / M 32 C ***
VM 32 C / M 32 E
M 34 DF Dye penetrant method (Met-L-Chek) */**/
M 43 C / VM 43 C ***
M 46 DF / VM 46 DF Diamond paste Dp 30/10 - 15 µm 1.9493-002
Blue paste */
***
Thinner DIAPLASTOL */**/

***
Brass brush */
***
* no picture
en / 02.01.2015 1/8
01
NOTE
The term valve refers to the combination of valve stem and valve seat ring. The latter
is firmly inserted into the cylinder head.
ATTENTION
It is not allowable to grind in valve stems with nitrided sealing surfaces.
Material removal, whether by grinding-in or refinishing of the sealing surface of

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

In case of doubt, please contact your authorized Caterpillar workshop.
en / 02.01.2015 2/8
01
NOTE
During regular maintenance of the engine, (e.g. after 15,000 hours), the valve seat rings
should if possible be refinished and the valve stem should be replaced. On non nitrided
valve stems also the valve stem sealing surface may be refinished.
Refinishing / replacement may also become necessary if during non-scheduled

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

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

Fig. 1 shows a valve stem with damage to the sealing surface all around.
Fig. 2 shows the sealing surface of a valve seat ring with deep pits in the left and a
jagged sealing surface area in the right half of the picture.
Both figures show severe damage to the valve sealing surfaces. The sealing surfaces
need to be refinished. If the refinishing limits are reached, the parts must be replaced.
When the sealing surfaces of a non nitrided valve (valve stem/valve seat ring Fig. 1
and 2) show uneven contact patterns or deeper pits, always refinish both sealing
surfaces.
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1. Cleaning of the valve seat rings 01
ATTENTION
Do not use any material removing tools or materials.
1.1 Spray coke deposits with clean freshwater. After a short exposure time wipe them off with a
cleaning rag. More tenacious incrustations may also be carefully removed by means of a brass
brush.
2. Evaluation of sealing surfaces
NOTE
The hardness of the valve seat ring sealing surface is designed in such a manner
that it possesses a certain adaptability with regard to the valve stem sealing surface.
Dents by coke are, therefore, a normal phenomenon and of no concern (Fig. 3). If,
however, the dents by coke should extend over the entire width of the sealing
surface, as shown in Fig. 4, there is a risk of "blow by" and the valve sealing
surfaces must be refinished or the valves must be replaced, as the case may be.
en / 02.01.2015 4/8
01
2.1 Valve seat rings are re-usable without refinishing when
• the sealing surface shows a bare metal finish all around, dark discoloration is allowable,
• there are no dents by coke suggesting blow-by or visible wear,
• a check by means of illuminated magnifier (8-fold magnification) or

dye penetrant inspection (Met-L-Chek) has not revealed any cracks in the sealing surface.
2.2 Valve seat rings are not re-usable when
• there are cracks in the sealing surface
• there is blow-by
• the limit for refinishing has been exceeded.
3. Repair (refinishing of valve seat rings))
ATTENTION
Risk of damage due to a wrong assumption regarding the sealing surface angle!
This note applies to inlet valves of distillate fuel engines (MDO) only.
The inlet valve sealing surfaces of distillate fuel engines (MDO) may have different
sealing surface angles depending on their equipment status (see following tables). If
different angular degrees are indicated for the inlet valves your engine type, check
which sealing surface angle is the correct one for your specific engine before carrying
out any refinishing work or ordering spare parts.
Inlet valves of heavy fuel engines (HFO) always have an angle of 30° 5’ .
ATTENTION
Avoid destroying the nitrided valve stem sealing surface!
It is not allowable to grind in valves with nitrided valve stem sealing surface!
When reaching one or several replacement criteria, only the valve seat ring of a
nitrided valve combination may be refinished, the valve stem has to be replaced by a
new one.
Refinishing has to take place in a professional manner using a special Caterpillar
valve seat refinishing tool (not included in the scope of supply). If the refinishing limit is
reached, the valve seat ring must be replaced. These jobs should be carried out by an
authorized Caterpillar workshop.
en / 02.01.2015 5/8
01
Exhaust valve seat ring Inlet valve seat ring
a a
ØX ØX
Principle representation Principle representation
Exhaust valve seat ring Inlet valve seat ring

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

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

M 32 C, 30° 5’ + 5’ 107 +0.2 M 32 C, 30° 5’ + 5’ 107 +0.2
VM 32 C, M 32 E, VM 32 C, M 32 E
M 34 DF M 34 DF
M 43 C, 30° 5’ + 5’ 148.5 +0.2 M 43 C, 30° 5’ + 5’ 148.5 +0.2
VM 43 C VM 43 C
M 46 DF, 30° 5’ + 5’ 148.5 +0.2 M 46 DF, 20° 5’ + 5’ 148.5 +0.2

VM 46 DF VM 46 DF
GCM34 20° 5’ + 5’ 107 +0.2
Inlet valve seat ring

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

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

VM 43 C
M 25 C, M 25 E 30° 5’ + 5’ 85 +0.2
M 32 C, 20° 5’ + 5’ 107 +0.2 M 46 DF, 20° 5’ + 5’ 148.5 +0.2
VM 32 C, M 32 E, VM 46 DF
M 34 DF, GCM34
en / 02.01.2015 6/8
4. Check of contact pattern/grinding-in 01

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

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

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

guide bush.
4.4 Fasten the valve jig (Fig. 6/W1) to the
valve stem head.
4.5 Grind the sealing surfaces of valve stem and valve seat ring for a short time applying a modera-
te pressure by rotating the valve jig in both directions. The percentage contact area (Fig. 7/a)
made visible through the smooth grinding-in process shall, over the entire circumference, not
exceed 30 - 50 % of the seat width “b“ starting from the outside diameter.
ATTENTION
Ensure that the components (valve stem and valve seat ring) ground in together will
stay together.
NOTE
In case of a poor contact pattern do not continue to regrind but check whether the two
sealing surface angles of valve stem and valve seat ring really match each other.
W1
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5. Check of contact pattern 01

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

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

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

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

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

turning in both directions by hand for a
short while. There shall be a continuous
contact pattern all around, starting from
the outside diameter.
6. Final check
6.1 Clean the valve stem and valve seat ring sealing surfaces thoroughly and check the sealing faces
with an illuminated magnifier (8-fold magnification) for cracks in the hard facing and the adjacent
area.
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Starting Air Valve A5.05. 01.09.01.10
1500
See also: 01
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Starting air valve - check for ease of movement
M 25 C / M 25 E Petro Gel Amber 461114-041 */**
M 32 C / M 32 E Molykote paste “G-Rapid Plus” 1.9493-001 */**
VM 32 C
* no picture
NOTE
On V-engines this check is only possible on the A side.
1. Starting air valve - check for ease of movement


WARNING
Risk of injury due to compressed air!
Suddenly escaping starting air may cause injuries.
• Make sure the main valves at the compressed air receivers are closed and the pipes
are vented so that the master starting valve is blocked.
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1500
M 25 C / M 25 E M 32 C / M 32 E / VM 32 C
01
1 Schematic diagram
1.2 For M 25 C / M 25 E only:

Loosen the screw plug (1/1) and take it off with the sealing ring (1/3).
For M 32 C / M 32 E / VM 32 C only:
Loosen the fixing screws (1/1) and remove the cover (1/2) with sealing ring (1/3).
1.3 Using an appropriate auxiliary device (e.g. handle of a hammer), lightly press down the piston
(1/5) and the valve spindle (1/6).
During this, piston and valve spindle must be easy to move.
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1500
1.4 Check whether piston and valve spindle are returning to the original position quickly and smooth- 01
ly.
NOTE
Do not move the valve spindle (1/6) by turning the clamping nut (1/4).
1.5 If the starting air valve is not moving smoothly, ease of movement must be reestablished
(A5.05.01.09.02.nn).
NOTE
If moisture, rust, dirt or other contamination is identified between the screw plug /
cover and piston, check the treatment / drainage of the starting air.
1.6 For M 25 C / M 25 E only
1.6.1 Apply a thin coat of Petro Gel Amber to the new sealing ring (1/3) and insert it untwisted into the
groove of the screw plug (1/1).
1.6.2 Lightly oil the thread of the screw plug and tighten it with a torque of 250 Nm.
1.7 For M 32 C / M 32 E / VM 32 C only
1.7.1 Apply a thin coat of Petro Gel Amber to the new sealing ring (1/3) and insert it untwisted into the
groove of the cover (1/2).
1.7.2 Put on the cover with sealing ring.
1.7.3 Apply a thin coat of Molykote to the thread of the fixing screws (1/1) and tighten them with a
torque of 50 Nm.

• Switch on the cooling water preheating.
• Switch on the lubricating oil stand-by pump / prelubrication pump.
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1500
01
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15000
See also: A5.05.01.06.01.nn, A5.05.01.11.01.nn 01

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Starting air valve removal and rework of sealing surfaces

2. Starting air valve installation
Engineer’s blue *
Diamond paste Dp 30/10 - 15 µm 1.9493-002 **
Thinner DIAPLASTOL ***
Petro Gel Amber 461114-041 */**
* no picture
1. Starting air valve removal and rework of sealing surfaces
1.1 Remove the cylinder head concerned (A5.05.01.06.01.nn).
1.2 Loosen the screw plug (1/1) and take it off with the sealing ring (1/3).
1.3 Loosen the clamping nut (1/2) and, in doing so, hold tight the valve spindle (1/9) with a
screwdriver.
1.4 Take the conical spring washer (1/4), piston (1/6), spacer sleeve (1/5), spring (1/7), bush (1/8)
and valve spindle (1/9) out of the cylinder head.
1.5 Clean all parts thoroughly in gas oil.
1.6 Check the piston (1/6), seat surface of the valve spindle (1/9) and valve seat (1/10). If the piston
shows any score marks, carefully smooth it.
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15000
1.7 Turn the cylinder head and put it down. 01

1
2
3
4
5
6
7
10
1 Schematic diagram
1.8 Check the tightness of the starting air valve by checking the contact pattern of the sealing surface
of the valve spindle on the valve seat in the cylinder head as follows:
1.8.1 Apply a thin film of engineer’s blue onto the sealing surface of the valve spindle (1/9).
1.8.2 Insert the valve spindle with conical spring washer (1/4), lightly oiled piston (1/6) and non self-
locking nut. Turn the valve spindle by approx. 60 - 70.
1.8.3 Carefully pull out the valve spindle and check the contact pattern. All around, at least 50 % of the
sealing surface height shall be visible. Remove the engineer’s blue.
1.9 In case of a poor contact pattern rework the starting air valve seat.
1.9.1 Carefully clean the valve seat and the guide of the valve spindle.
1.9.2 Using the syringe, evenly apply 4 to 6 small dots of diamond paste to the sealing surface of the
valve spindle. Thereafter, to dilute the paste and increase the grip, spray the entire sealing
surface with the corresponding thinner (F25).
1.9.3 Insert the valve spindle with conical spring washer, lightly oiled piston and non self-locking nut.
1.9.4 Grind the starting air valve seat for a short time by rotating the valve spindle back and forth by
hand with a screwdriver at moderate pressure 6 to max. 8 times. In doing so, briefly lift the cone
several times so that the grinding paste can flow back onto the sealing surface.
1.9.5 Carefully pull out the valve spindle and check again the bearing pattern made visible through the
smooth grinding process. All around, a closed sealing surface must be visible. If the contact
pattern is still poor, repeat the grinding process.
1.10 Thoroughly clean the valve spindle (1/9) and the valve seat (1/10) in the cylinder head.
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15000
2. Starting air valve installation 01

2.1 Clip the valve spindle (1/9), bush (1/8), spring (1/7), spacer sleeve (1/5) and piston (1/6) onto the
spindle.
2.2 Position the conical spring washer (2/4) as

shown in Fig. 2 and insert it into the
cylinder head.
2.3 Lightly oil the thread of the new clamping 4

nut (1/2) and tighten it with a torque of
35 Nm.
2.4 Replace the sealing ring (1/3), apply a

thin coat of Petro Gel to it and insert it
untwisted into the sealing ring groove. 2 Schematic diagram
2.5 Lightly oil the screw plug (1/1) and tighten

it with a torque of 250 Nm.
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15000
01
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150
See also: A5.05.01.03.01.nn, 01

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. General inspection of all cylinder heads
WARNING
Risk of injury due to hot surfaces!
Cooling water and/or combustion gas leaking out of the cylinder head may cause
burns in case of skin contact.
Particular caution is required when carrying out work during engine operation. Always
wear personal protective equipment.
WARNING
Risk of injury due to engine parts under high pressure!
Risk of skin injuries due to possible leaks on components under high pressure.
Particular caution is required when carrying out work during engine operation. Always
wear personal protective equipment.
1. General inspection of all cylinder heads
1.1 Remove the pump covering while the engine is running.
1.2 Check the control bore (Fig. 1/1):
NOTE
Depending on the engine type the control bore (Fig. 1/1) may also be located to the
left of the push-rod duct or laterally on the left on the cylinder head.
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150
1.2.1 In case of leaking combustion gas, replace the joint ring between cylinder head and cylinder liner. 01
1.2.2 In case of leaking cooling water replace the O-ring between cylinder head and cylinder liner.
Schematic diagram
1.3 Check all connection points on the cylinder head for leaks.
1.3.1 In case of leaks check the fastening screws of the corresponding connection point for tight fit. If
necessary, replace the gaskets.
1.4 The valve rotator for proper function (A5.05.01.03.01.nn).
1.5 Remove the valve cover when the engine is stopped:
1.5.1 Check the upper valve drive (rocker arms, contact surfaces, valve bridges, etc.) for damage.
1.5.2 Check the valve springs for fracture.
1.5.3 Check the lubricating oil supply of the rocker arms and the rocker arm bearings.
1.7 Install the pump covering.
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c2 Maintenance / Cleaning
15000
See also: 01
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
NOTE
Put the cylinder head bottom only on a wooden base.
Sequence of operations:
The following parts have been removed:
Inlet valve, outlet valve, injection valve (Injector), starting valve and rocker arm bracket.
1. Wash the cylinder head with a cold cleaner.
2. Clean the inlet and outlet ports and the cylinder head underside (not the valve seats!) of carbon
deposits with a wire brush or scraper. Do not damage seat recess.
3. Clean cooling water inlet ports and cooling water outlet.
4. Check underside of cylinder head, especially at the valve webs, for cracks.
5. Clean the sealing surface for the injection valve (Injector).
6. Check in and outlet holes of the media supply for free passage.
(especially leak fuel of pressure pipe monitor)
7. Check the function of the alarm probe for fuel leakage in the distributor plate at the connecting
piece of the media supply (cyl. 1).
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15000
01
en / 02.01.2015 2/2
c2 Maintenance / Installation

A5.05.13.01.01.00
Spare parts sheets:


--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Install the cylinder head
M 25 C / M 25 E Hydraulic kit: W1
High-pressure pump W1.1 0.9204 D
High-pressure hose (1 m) (4 pcs.) W1.2 0.9205 B
Hydraulic jack W1.3 0.9213 C
Hydraulic distributor W1.4 0.9203-008
Support ring W1.5 0.9203-018
Support ring (short) W1.6 0.9203-209

Threaded sleeve W1.7 0.9206-003
Threaded sleeve (short) W1.8 0.9206-001
Cylinder head mounting and removal device W2 0.9221 B *

Pin Ø8 W4 0.9203-110

High-temperature thread paste “Rivolta G.W.F.” 1.1002-359 */**
Loctite 510 */**

* no picture
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01
WARNING
Risk of injury in case of improper handling of the hydraulic unit!
In case of leaks, hydraulic oil leaking under high pressure may cause severe injuries
up to death.
• Do not place any parts of the body above the pressurized devices.
• The bending radius of the high-pressure hoses must not be less than the minimum
bending radius r = 150/250 mm.
• Use only hydraulic oil as operating medium (see engine documentation, chapter
“Operating Media”).
• Store the devices protected against corrosion.
1. Installthe cylinder head
1.1 Make sure that all indicator valves are

open. 1
1.2 Check whether the barring device is

engaged and secured against
2
unintentional operation.
1.3 Bar the piston of the cylinder to be

installed to ignition TDC.
Inlet and exhaust valves are closed,
3
rocker arms are relieved.
1.4 Thoroughly clean the sealing and contact

surfaces of cylinder head and cylinder
liner and check them for damage.
1.5 Check and clean the sealing surface on

the exhaust manifold
(A5.05.06.01.01.nn).
1.6 Insert a new sealing ring (1/7) into the 8 7 6 5

cylinder liner collar.
1.7 Replace the following O-rings, apply a

thin coat of Petro Gel Amber to them and
insert them untwisted into the grooves:
• Upper O-ring at the cylinder liner collar

(1/8),
• at the cylinder head (1/4),
• at the push-rod duct (1/6),
• at the cooling water transfer, at the
starting air inlet, at the control air inlet
(1/3),
• and at the charge air inlet nozzle (1/2). 4
1 Schematic diagram
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1.8 Align the transfers for cooling water, 01

control air, and starting air in the cooling W2
collar so as to be vertical and check for
completeness.
1.9 Install the cylinder head mounting and

removal device (2/W2) on the fuel injector.
2 Schematic diagram
CAUTION
Property damage possible due to improper installation.
If a cylinder head is put down in an improper manner, there is a risk of damaging the
cooling water transfer socket, cylinder head studs, push-rods, and charge air inlet
nozzle.
• Put down the cylinder head carefully and slowly, pay attention to the passage of the
cylinder head studs and the push-rod duct.
• Make sure that the cooling water transfer socket and charge air inlet nozzle are po-
sitioned in the cooling collar.
• Do not tilt the cooling water transfer at the push-rod duct. Pay attention to the fixing
pin in the cooling collar.
1.10 Put the cylinder head onto the cooling collar carefully and so as to be horizontal by means of the
mounting and removal device (W2) and the crane.
1.11 Insert a new paper gasket (1/1) for the exhaust gas flange and align the cylinder head at the
exhaust gas flange.
1.12 Apply a thin coat of “Rivolta G.W.F.” high-temperature thread paste to the screws for the exhaust
manifold and screw them in loosely with extension sleeves.
1.13 Continue to lower the cylinder head, align it at the parallel pin (1/5) and put it down onto the
cooling collar.
1.14 Tighten the four cylinder head nuts with the hydraulic kit (W1) (A5.05.13.01.01.00).
1.15 Mount the screws for the exhaust manifold (A5.05.06.01.01.nn).
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1.16 Install the covering between exhaust manifold and cylinder head. 01
3 Schematic diagram
1.17 Install the media guide (3/1) (A5.05.01.05.50.nn).
1.18 Install the transverse thrust pieces of the respective injection pump (3/2).
It is critical to observe the installation instruction, tighten thrust screw and threaded
connection to the specified torque (A5.05.07.07.01.nn).
NOTE
Upon installation of the last cylinder head at the free end, mount the fuel return at the
blank flange.
1.19 Make sure that the screw plug in the return pipe of the charge air cooler (outer pipe) below the
thermometer is tightened.
Refill cooling water.
Vent at the end of the cooling water return pipe opposite the turbocharger side.
1.20 Adjust the valve clearance (A5.05.01.0101.nn).
1.21 Close the indicator valves by means of the socket wrench (W3).
1.22 Clip the protective caps onto the cylinder head studs.
1.23 Install the valve cover and the pump chamber covering.
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• Set the selector switch at the control stand to “Local”.
1.25 After putting the engine into service, check all connections for leaks.
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01
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Running Gear / Engine Timing A5.05. 02.01.01.10
c2 Inspection / Checking
3750, 7500
See also: 02
Spare parts list:

----------------------------------------------------------------------------------------------------------------------------------
Activities:
Inspect the crankcase and the timing gear
NOTE
The temperature check for the bearings must be carried out with engine at operating
temperature after switching off the circulatory lubrication system. The remaining
tasks are to be carried out after a period of ventilation.
1. Open indicator valves / decompression valves (M 20 C) and engage the barring gear.
2. Open the crankcase doors about 10 minutes after shutting down the engine.
3. Check the crankshaft and big-end bearings for even and normal temperature.
4. Check bolts and nuts for tight fit.
5. Check the extent of soiling of the crankcase (sludge deposits, corrosion, bearing metal particles,
detached paint).
6. Check the cylinder liner surface on running gear side. Carry out a lubricating oil flow check and
check oil leakage at the bearing points.
7. Remove the camshaft cover. Check the screws of the camshaft sections and the lower valve drive
for tight fit.
8. Bar the engine and check the running surfaces of cams and rollers for damage or wear.
9. Check the lubricating oil flow for camshaft bearings and valve drive.
10. Check the timing gear train.
11. Check oil pan and crankcase for any left-behind tools, cleaning rags, etc. Check the seals of all
crankcase doors and plugs and refit the covers.
12. Check valve seals, valve bridges with guides, and rocker arms for wear and proper function. Car-
ry out a visual inspection regarding oil and water leaks.
en / 02.01.2015 1/2
Running Gear / Engine Timing A5.05. 02.01.01.10
3750, 7500
02
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Crank Web Deflection A5.05. 02.02.01.10
c2 Inspection / Measuring
See also: 02
Spare parts list:
Personnel qualification: skilled engine hand / chief engineer

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

M 25 C / M 25 E ing of:
M 32 C / M 32 E
M 34 DF Crank web deflectiondial gauge W1.1 1.9425-300
M 43 C / M 46 DF (dial gauge, extension, hanging weight)
Centering magnets (2 x) W1.2 1.9425-316
VM 32 C / VM 43 C Crank web deflectiondial gauge compl., consist- W1 1.9425 B

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

(dial gauge, extension, hanging weight)
Centering magnets (2 x) W1.2 1.9425-325
NOTE
Crank web deflection is the change in distance between a web pair during one rotation
of the crankshaft (Fig. 1). It is primarily used for measuring and evaluating the align-
ment of an engine with respect to its shafting.
Severe crank web deflection will subject crankshaft and main bearings to additional
load, i.e. the admissible crank web deflection level essentially depends on the engine
load.
Highly loaded engines will allow less crank web deflection than engines subjected to
low load.
Depending on the installation site of the engine, the rigidity of the foundation, and
whether the engine is in warm or cold condition, differing values are obtained. Crank
web deflection should, therefore, always be measured at the same conditions.
Changes that suddenly appear or appear after a longer period under otherwise
unchanged conditions are indicative of deformation or settling phenomena in the foun-
dation.
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02
NOTE
It is, therefore, suggested to collect the measurement sheets extra, because this is the
only way to get a clear picture of the chronological allocation of the measuring values
and their changes.If the limits are reached, the main bearings must be inspected and
the engine must be realigned.
Measurements are to be carried out in the following cases:
When there is suspicion or danger of deformation of the foundation, e.g.:

• after a major damage
• settling phenomena of the foundation
• bearing or crankshaft damage
_ +
a) Initial position b) Negative deflection c) Positive deflection
NOTE
In order to get a clear measurement result, crank web deflection is to be measured
on an engine at operating temperature only.
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02
CAUTION
Absolutely make sure that the
magnets (Fig. 2/W1.2) for fixa-
tion of the dial gauge tips are
completely contacting the crank
webs (Fig. 2/1) and not the
balance weights (Fig. 3/2).
1. Open all indicator/decompression valves.
2. Engage the barring gear.
3. Insert magnets (Fig. 2/W1.2) with crank

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

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

flections outside of the speci- 2
fied measuring points, these
must also be recorded.
2
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6. Slowly bar the engine and pass through measuring points M2 - M5 one after the other. Read and 02
record the indicated measuring values.
M5 M4 M2 M1
M3
M1 1st measuring point initial position
M2 2nd measuring point crank pin - exhaust side

M3 3rd measuring point crank pin - top dead centre (TDC)
M4 4th measuring point crank pin - camshaft side
M5 5th measuring point crank pin - bottom dead centre (BDC)
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02
NOTE
The values indicated below must be observed, unless there is a possibility to enquire
the crank web limits permissible for the specific plant from Caterpillar.
Only the deflection values measured on an engine at normal operating temperature

are to be used for the assessment. Values from a cold engine are of minor relevance.
Values for crank web deflection in mm:
M 20 C M 25 C M 32 E M 32 C GCM34 M 43 C VM 43 C
M 25 E M 34 DF VM 32 C M 46 DF VM 46 DF
Cylinder 1 or last + 0,04 / + 0,05 / + 0,05 / + 0,06 / + 0,06 / + 0,07 / + 0,07 /

cylinder with - 0,09 - 0,11 - 0,12 - 0,13 - 0,13 - 0,16 - 0,16
additional load
(flywheel/cou-
pling)
All cylinders wit- + 0,04 / + 0,05 / + 0,05 / + 0,06 / + 0,06 / + 0,07 / + 0,07 /
hout external load - 0,06 - 0,08 - 0,08 - 0,09 - 0,09 - 0,12 - 0,12
Permissible + 0,03 / + 0,03 / + 0,03 / + 0,04 / + 0,04 / + 0,06 / + 0,07 /

crank web deflec- - 0,03 - 0,03 - 0,03 - 0,04 - 0,04 - 0,06 - 0,07
tion
realignment of
base frame
genset in horizon-
tal direction
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02
Operating hours: Station/vessel: Date:
Engine type: Engine No.: Service station/Engineer:
Reading of dial gauge
down up
20
Engine cold
10 30
press
Shut down for hours
Preheated 0 40
°C
Measuring Cylinder
point
M1
M2
M3 negative
M4
M5
max positive
M5 M4 M2 M1
M3
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Big End Bearing A5.05. 02.04.01.10
c2 Removal / Installation
30000, 15000, 45000
See also: A5.05.01.06.01.nn, A5.05.02.06.01.nn, A5.05.01.11.01.nn 02

Spare parts sheets:
Operating medium: Heavy fuel oil and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the big end bearing with bearing shells

2. Install the big end bearing with bearing shells
M 20 C Piston suspension device W1 2.9226 A
Torque wrench 60 - 420 Nm W2 1.9454-400 */***
Mounting clamp W3 2.9125-B
Torque angle gauge W4 2.9180 A
Barring rod W5 2.9100-380
M 25 C / M 25 E Piston suspension device W1 259226 A
Torque wrench 300 - 800 Nm W2 1.9454-800 */***

Mounting clamp W3 252191-B
Reversible ratchet 3/4” W6 1.9495-036 *
Adapter, W 36 W7 1.9450-036 *
M 20 C Piston lifting device W8 259223 A
* no picture
*** not included in the standard tool kit
NOTE
Big end bearing cap, big end bearing bolts, and bearing shells are marked according to
the cylinder unit they belong to. It is not permissible to interchange them.
• Always replace the bearing shells in pairs; replace the connecting rod only together
with the big end bearing cap.
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30000, 15000, 45000
02
NOTE
For an evaluation of the crank pin and bearing shell running surfaces please contact
your authorized Caterpillar dealer.
1. Remove the big end bearing with bearing shells
• Interrupt the starting air supply. 1 2

• Throw and secure the emergency stop
lever.
• Switch off and block the fuel supply to Z
the engine. 6 3
• Set the selector switch at the control
stand to “Repair”.
1.2 Remove the cylinder head of the cylinder

unit to be serviced (A5.05.01.06.01.nn). 4
1.3 Make sure the crankshaft is at the 5

appropriate position for removal (crank pin
at 20° before / after “top dead centre” TDC 1/2
on the camshaft side of the cylinder unit to
be serviced).
If necessary, bar the crank pin Z
accordingly.
5/6
1.4 Remove the big end bearing cap (1/4): 1 Schematic diagram
1.4.1 Loosen the big end bearing bolts (1/1, 2, 5

and 6) and remove both lower big end
bearing bolts (1/5 and 6) as well as one of 1
the upper big end bearing bolts (1/1 or 2).
2
1.4.2 Hold the big end bearing cap, remove the
remaining big end bearing bolt and lift the 7
big end bearing cap out of the engine
block.
1.5 Check the serrations in the joint faces of

connecting rod (1/3) and big end bearing
6
cap for damage. W3
1.6 Push the mounting clamp (2/W3) over the

bearing shells and mount it:
1.6.1 The lower lug (2/4) of the mounting clamp 5

engages in the triangular groove of the
lower bearing shell and the lug of the 4 3
clamp bolt (2/2) engages in the hole of the
upper bearing shell.
2 Schematic diagram
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30000, 15000, 45000
1.6.2 Lightly tighten the clamp bolt. 02

1.7 For bearing shell removal bar the piston to
“top dead centre” TDC, install the piston W1
suspension device (3/W1) and carefully
bar the piston downwards again until the
piston skirt rests on the piston suspension 1
device.
1.8 After that, continue to bar until the crank

pin swivels out of the connecting rod (3/1).
The bearing shells fixed by means of the 2
mounting clamp (W3) remain on the crank
pin.
1.9 Remove the mounting clamp (W3); in

doing so, hold the bearing shells (3/2) and 3
then withdraw them.
1.10 Remove the piston (A5.05.02.06.01.nn).

3 Schematic diagram
2. Install the big end bearing with bearing

1
shells
2.1 Install the piston (A5.05.02.06.01.nn).
2.2 Clean and oil the crank pin.
2.3 Make sure the piston suspension device

(3/W1) is fitted.
a
NOTE
To facilitate their positioning,
the bearing shells (4/1 and 2)
are provided with holes (4/a).
The respective hole must be
oriented towards the exhaust 2
side.
2.4 Oil the bearing shells (4/1 and 2) on the

4 Schematic diagram
inside and put them onto the crank pin.
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30000, 15000, 45000
2.5 Hold the bearing shells in mounting 02

position and push the mounting clamp 1
(5/W3) over the bearing shells.
2
2.5.1 The lower lug (5/4) of the mounting clamp
engages in the triangular groove of the 7
lower bearing shell and the lug of the
clamp bolt (5/2) engages in the hole of the
upper bearing shell.
2.5.2 Only tighten the clamp bolt to such an

extent that the two bearing halves are still 6
W3
exactly positioned one over the other (no
offset permissible!).
2.6 Carefully bar the crankshaft upwards until

the connecting rod (5/1) lightly rests on
5
the bearing shells and the mounting clamp
contacts the lower joint face of the
4 3
connecting rod.
5 Schematic diagram
NOTE
For central guiding of the bearing shells the lug of the mounting clamp engages in the
lower joint face of the connecting rod.
CAUTION
Risk of damage to the bearing shells and the locating pin!
In case of wrong installation there is a risk of damaging the bearing shells and the
locating pin.
• Exactly follow step 2.7 in order to avoid damage to the bearing shells.
• If the locating pin is damaged, it must be replaced.
2.7 Displace the bearing shells (5/3 and 7) with the handle of the mounting clamp (5/W3) so that the
locating pin (5/5) of the connecting rod engages in the hole (4/a) of the lower and the upper
bearing shell and the bearing shells are resting in the connecting rod bore.
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30000, 15000, 45000
2.8 Remove the mounting clamp. 1 2 02

2.9 Bar the piston to 20° before “top dead
centre” TDC.
Z
2.10 Apply a thin coat of Molykote to the 6 3
threads and contact surfaces of the big
end bearing bolts (6/1, 2, 5 and 6).
2.11 Bring the big end bearing cap (6/4) into

4
mounting position and position it against
the connecting rod (6/3). 5
1/2
Z
5/6
6 Schematic diagram
Further procedure depending on engine type:

M 20 C: Continue with step 2.11.1
M 25 C / M25 E: Continue with step 2.11.8
Then continue for all engines: Continue with step 2.12
M 20 C:
2.11.1 Tighten all big end bearing bolts (6/1, 2, 5 and 6) in the order of 5 - 6 and 1 - 2 respectively with a
torque of 160 Nm.
2.11.2 Tighten the upper big end bearing bolts (6/1 and 2) once again in the order of 1 - 2 with a torque
of 160 Nm.
2.11.3 Mark the position of the bolts for the tightening check (e.g. with chalk).
2.11.4 Tighten all big end bearing bolts (6/1, 2, 5 and 6) with a torque of 350 Nm.
2.11.5 Tighten the lower big end bearing bolts (7/5 and 6) once again alternately with a torque of
350 Nm in order to prevent a loss of preload due to setting.
2.11.6 Carry out the tightening check:

The upper big end bearing bolts (6/1 and 2) must have turned by another 60° +/- 10°.
The lower big end bearing bolts (6/5 and 6) must have turned by another 60° +/- 10°.
2.11.7 If these values are not reached, check the components for damage and repeat the assembly. For
repeating the assembly, coat the threads and contact surfaces of the big end bearing bolts
(6/1, 2, 5 and 6) with Molykote again.
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30000, 15000, 45000
M 25 C / M 25 E: 02
2.11.8 Tighten the short big end bearing bolts (6/1 and 2) alternately in several steps with a torque of
300 Nm.
2.11.9 Tighten the long big end bearing bolts (6/5 and 6) alternately in several steps with a torque of
300 Nm.
2.11.10 Mark the position of the bolts for the torque angle check.
2.11.11 Tighten the short big end bearing bolts (6/1 and 2) alternately in several steps with a torque of
600 Nm.
2.11.12 Tighten the long big end bearing bolts (6/5 and 6) alternately in several steps with a torque of
600 Nm.
2.11.13 Carry out the torque angle check:

The short big end bearing bolts (6/1 and 2) must have turned by another 60° +/- 10°.
The long big end bearing bolts (6/5 and 6) must have turned by another 90° +/- 10°.
2.11.14 If these values are not reached, check the components for damage and repeat the assembly. For
repeating the assembly, coat the threads and contact surfaces of the big end bearing bolts
(6/1, 2, 5 and 6) with Molykote again.
All engines:
2.12 Remove the piston suspension device (1/W1) and check the connecting rod on the crank pin for
free passage.
2.13 Install the cylinder head of the cylinder unit to be serviced (A5.05.01.11.01.nn).

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Main Bearings A5.05. 02.05.01.10
30000, 15000, 45000
See also: A5.05.13.01.01.nn, A5.05.02.05.07.nn 02

Spare parts sheets:
Personnel qualification: Skilled engine hand / chief engineer

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check of the end clearance at the thrust bearing

2. Measurement of the limit dimensions of the main bearing shells
3. Removal of the main bearing cap
4. Removal of the thrust washer segments
5. Removal of the main bearing shells
6. Installation of the main bearing shells
7. Installation of the thrust washer segments
8. Installation of the main bearing cap
M 20 C High-pressure pump W1 0.9204 D *
High-pressure hose W2 0.9205 C *
Hydraulic jack W3 0.9213 A
Support ring W4 0.9203-109

General purpose pin W6 0.9203-110 *
Main bearing mounting and removal device W7 *
Supporting arm (2x) W7.1 2.9214 B

Dog W7.3 2.9114 A
Socket wrench W10 1.9100-060 *

(for indicator valve, decompression valve)
Barring rod W11 2.9100-380 *

Torque wrench W12 1.9454-500 *
Socket wrench insert W 36 W14 1.9024-036 *

Set of feeler gauges W15 1.9075-003 *
Molykote paste “G-Rapid Plus” *

**
* no picture
*** optional / not included in the standard tool kit
en / 22.11.2017 1/12
30000, 15000, 45000
02
M 25 C, M 25 E High-pressure pump W1 0.9204 D *
High-pressure hose W2 0.9205 B *
Hydraulic jack W3 0.9213 C
Support ring W4 0.9203-209
Threaded sleeve W5 0.9206-001 *
General purpose pin W6 0.9203-110 *
Mounting and removal device W7 259214 A *

Supporting arm (2x) W7.1 259214-001
259214-002
Device for lowering main bearing cap W7.2 259214-003
Dog W7.3 259119 A

Mounting device W8 259214-005
Capturing plate W9 259214 B ***
Socket wrench W10 1.9100-060 *

(for indicator valve, decompression valve)
Torque wrench W12 1.9454-800 *
Reversible ratchet 3/4 W13 1.9495-036 *
Socket W 46 W14 1.9450-046 *

**
* no picture
CAUTION
Risk of bearing damage by interchanging the thrust washer segments and / or
main bearing shells!
Mark new thrust washer segments and main bearing shells prior to assembly against
interchanging.
Mark the thrust washer segments and main bearing shells latest upon removal against
interchanging.
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30000, 15000, 45000
Secure the engine to prevent unintentional starting. 02

NOTE
On the M 20 C the thrust bearing consists of the two main bearing shells (Fig. 1/4)
of the second main bearing (at driving end) and four thrust washer segments (1) that
limit the end clearance of the crankshaft.
On the M 25 C and M 25 E the thrust bearing consists of the two main bearing shells
(Fig. 1/4) of the first main bearing (at driving end) and four thrust washer segments
that limit the end clearance of the crankshaft.
The upper thrust washer segments are inserted between the engine block and the
thrust collar of the crankshaft.
The lower thrust washer segments (1) are fastened on the main bearing cap (3) with
spring dowel pins (2).
Engage the barring device and secure it

against unintentional operation
(M 25 C/ M 25 E only).
4
Insert the barring rod (W11) into the hole 1 1
in the flywheel (M 20 C only).
Open the indicator valves/decompression

valves with socket wrench (W10).
Remove the timing gear train covers.
Remove the crankcase doors on both

sides of the cylinder unit to be serviced.
s1 s2
3 2
Schematic diagram
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30000, 15000, 45000
1. Check of the end clearance at the thrust bearing 02

1.1 Check the end clearance “s“ between thrust washer segment and thrust collar of the
crankshaft:
1.1.1 Check the end clearance on both sides (Fig. 1/s1 and s2 ) between thrust washer segment (1)
and thrust collar of the crankshaft with the set of feeler gauges (W15).
1.2 Calculate the end clearance “s“: s = s1 + s2
1.2.1 Compare the end clearance “s“ to the values of the following table.
Engine type End clearance (s) new Limit value for end clearance
in mm (s) in mm
M 20 C 0.23 - 0.40 0.60
M 25 C / M 25 E 0.30 - 0.60 0.80
1.3 When the limit value is reached or exceeded, use new thrust washer segments (Fig. 1/1) and
new main bearing shells (4) (see (Fig. 1/1) Removal of the main bearing shells).
2. Measurement of the limit dimensions of the main bearing shell
2.1 The first measurement of the limit dimensions of the main bearing shell is carried out on the
bearing subjected to the highest load (see table).
Engine type Number of cylinders Bearing
M 20 C / M 25 C / M 25 E 6 4
8 5
9 6
2.2 Remove both main bearing shells of a bearing

(see Activity 5: Removal of the main bearing shells).
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2.3 Clean the main bearing shells. 02

2.4 Measure the wall thickness wear in the main load area of the main bearing shell at measuring
points (Fig. 2/x) by means of a micrometer caliper.
Wear = dimension in new condition - actual dimensions
Engine type Dimension in Limit dimension

new condition in mm
in mm
M 20 C 4.927-0.015 4.88
M 25 C / M 25 E 5.905-0.02 5.84
CAUTION
X
Action required when the limit
dimension is reached or
exceeded
If the measurement shows that the
limit dimension has been reached or
exceeded so that a main bearing
shell replacement is required, all
main bearings must be checked.
Schematic diagram
3. Removal of the main bearing cap
3.1 Remove the crankcase doors at the cylinder unit to be serviced.
3.2 Bar the crankshaft so that the round nuts (Fig. 3/12) of the main bearing cap (3) are easily
accessible and the hydraulic stretching devices (W3 to W5, also refer to A5.05.13.01.01.00)
can be installed unhindered.
NOTE
If the main bearing cap cannot be lowered or only with difficulties, loosening of the
lateral bolts (Fig. 3/11) of the adjacent cylinder units may facilitate the process.
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3.3 Remove both lateral bolts (Fig. 3/11) of the corresponding main bearing cap. 02
NOTE
The following figures show the devices as they are used on M 25 C / M 25 E engines.
Devices of our M 20 C engines are used the same way, but their design is different.
Due to the lower weight of the M 20 C assemblies and the related tools, some auxiliary
devices and fixtures are omitted.The mounting device (W7.2) and the capturing plate
(W9***) are not needed for M 20 C engines.
W7.1 W7.1
W7.2
11 11
4 W3 12
W9*** Schematic diagram
3.4 Loosening the round nuts (12) of M 20 C:
3.4.1 Install the supporting arms (W7.1) on the main bearing cap (3).
3.4.2 Place the hydraulic jacks (W3) over the round nuts (12) onto the studs and install them (see
A5.05.13.01.01.nn).
3.4.3 Loosen the round nuts (12) (see A5.05.13.01.01.nn).
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3.5 Loosening the round nuts (12) of M 25 C / M 25 E: 02

3.5.1 Install the supporting arms (W7.1) on the main bearing cap (3).
3.5.2 If applicable, insert the capturing plate (W9***).
3.5.3 By means of device (W7.2) place the hydraulic jack (W3) over the round nut (12) onto the stud
and install it (see A5.05.13.01.01.nn). Repeat this step also from the other side of the engine
for the second round nut.
3.5.4 Loosen the round nuts (12) in accordance with A5.05.13.01.01.nn.
3.6 Install the supporting arms (W7.1) on the main bearing cap (3).
3.7 Secure the main bearing cap (3) in the upper position.
3.8 Remove the round nuts (12).
3.9 Carefully lower the main bearing cap (3).
4. Removal of the thrust washer segments
4.1 Remove the main bearing cap (Fig. 1/3)

(see Activity 3: Removal of the main bearing cap).
NOTE
The lower halves of the thrust washer segments (1) are pinned to the main bearing
cap with spring dowel pins (2).
4.2 Take off the lower pinned thrust washer segments (1).
4.3 Push out the upper thrust washer segments between thrust collar of the crankshaft and the
main bearing block.
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5. Removal of the main bearing shells 02

5.1 Remove the main bearing cap
(see Activity 3: Removal of the main
bearing cap).
5.2 Take the lower main bearing shell out of

the main bearing cap.
5.3 Insert the dog (Fig. 4/W7.3) into the oil

hole of the crankshaft until reaching the
end stop and align it with one of the two
flat sides with respect to the bearing shell
edge.
5.4 Bar the engine so that the upper main

bearing shell slides out and take it out.
Schematic diagram
5.5 Remove the dog (W7.3).
W7.3
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6. Installation of the main bearing shells 02

6.1 Clean the stud threads (Fig. 5/4).
6.2 Oil the running surface of the upper main bearing shell (with lubrication groove and oil holes)
and wipe the bearing back dry.
6.3 Position the main bearing cap (Fig. 5/3) with the supporting arms (W7.1) underneath the studs
and lift it up. Screw on the round nuts (12) several revolutions.
6.4 Turn the marked upper bearing shell (Fig. 5/1) by hand as far as possible into the main
bearing block (2) so as to be centred.
W7.3
W7.1 W7.1
3 4 Schematic diagram 12 W8
6.5 Insert the dog (W7.3) into the oil hole of the crankshaft until it reaches end stop and align it
with one of the flat sides with respect to the bearing shell edge.
6.5.1 For M 25 C/ M 25 E engines only: Put the mounting device (W8) into the main bearing cap
(3) and make sure it reaches the lateral end stop position.
6.5.2 For M 25 C / M 25 E engines only: Carefully lift the main bearing cap (3) until the mounting
device (W8) rests against the main bearing block (2).
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6.6 Bar the engine so that the upper main bearing shell (1) slides into the main bearing block (2) 02
in direction of camshaft side so as to be centred.
6.7 The bearing guide lug points towards the exhaust side and must slide into the guide groove in
the main bearing block (2).
6.8 Remove the dog (W7.3).
6.9 For M 25 C/ M 25 E engines only: Remove the mounting device (W8).
6.10 Oil the running surface of the lower main bearing shell and wipe the bearing back dry.
6.11 Place the marked lower main bearing shell into the main bearing block so as to be centred.
6.12 The bearing guide lug points towards the camshaft side and must slide into the guide groove
in the main bearing cap.
6.13 After installing new main bearing shells the gap must be checked (see A5.05.02.05.07.nn).
7. Installation of the thrust washer segments
7.1 Oil the running surfaces of the thrust washer segments and ensure cleanliness towards the
thrust surfaces of the crankshaft.
7.2 Place the marked upper thrust washer segments in the guide grooves between thrust collar of
the crankshaft and the main bearing block onto the crankshaft.
7.3 Place the marked lower thrust washer segments (Fig. 1/1) in axial direction onto the spring
dowel pins (2).
8. Installation of the main bearing cap
8.1 Clean the supporting and contact surfaces of the main bearing block and the main bearing
cap.
8.2 Carefully lift the main bearing cap by means of the supporting arms (W7.1) up to the main
bearing block.
8.3 Evenly screw the round nuts (Fig. 3/12) onto the studs and tighten them with the pin (W6) so
as to be finger tight.
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8.4 Remove the supporting arms (W7.1). 02
CAUTION
After installing new main bearing shells the gap must be checked
(A5.05.02.05.07.nn).
After installing new thrust bearings the end clearance “s” must be checked
additionally (see Activity 1: Check of the end clearance at the thrust bearing).
8.5 If necessary, check the gap (A5.05.02.05.07.nn).
8.6 If necessary, check the end clearance (Activity 1).
8.7 Clean the threads and supporting surfaces of the lateral bolts (Fig. 3/11) and lubricate them
with Molykote.
8.8 Fixing of M 20 C lateral bolts (Fig. 3/11)
8.8.1 Install the lateral bolts (11) and tighten (also the lateral bolts of the adjacent cylinder units, if they
were loosened before) alternately in 3 steps, starting from camshaft side, with the following
torque.
Torque for M 20 C
in Nm
1. step 100
2. step 300
3. step 480
8.9 Fixing of M 20 C round nuts (Fig. 3/12)
8.9.1 Place the hydraulic jacks (W3) over the round nuts (12) onto the studs (4) and install them (see
A5.05.13.01.01.nn).
8.9.2 Fix the round nuts (Fig. 3/12) in accordance with A5.05.13.01.01.nn.
8.10 Preliminary fixing of M 25 C and M 25 E lateral bolts (Fig. 3/11) (step 1)
8.10.1 Install the lateral bolts (11) and preliminarily tighten (also the lateral bolts of the adjacent cylinder
units, if they were loosened before) alternately in 2 steps, starting from camshaft side, with the
following torque
Torque for M 25 C/ M 25 E
in Nm
1. step 140
2. step 550
8.11 Fixing of M 25 C/ M 25 E round nuts (Fig. 3/12)
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8.11.1 By means of the device (W7.2) place the hydraulic jack (W3) over the round nut (12) onto the 02
stud (4) and install it (see A5.05.13.01.01.nn). Carry out this step also from the other side of
the engine for the second round nut.
8.11.2 Remove the device (W7.2).
8.11.3 Apply a marking for torque angle.
8.11.4 Fix both round nuts (Fig. 3/12) simultaneously with a stretching pressure of (see
A5.05.13.01.01.nn).
8.11.5 Final torque angle check 135° (3 holes)
8.11.6 If applicable, remove the capturing plate (W9***).
8.12 Fixing of M 25 C and M 25 E lateral bolts (Fig. 3/11) (step 2)
8.13 Apply a marking for torque angle.
8.13.1 Finally tighten the lateral bolts (11) (and all other loosened lateral bolts) with a torque of 800 Nm.
8.13.2 Final torque angle check 30° ± 15°
8.14 Carry out an oil flow check.
8.15 Disengage the barring device or remove the barring rod.
8.16 Install the timing gear train covers and the crankcase doors.
8.17 Close the indicator valves/decompression valves with socket wrench (W10).

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Measuring the Gap A5.05. 02.05.07.10
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See also: A5.05.02.05.01.nn 02

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Measure the gap
Tools and Auxiliary Materials Pos. Ord. No.
M 20 C - VM 46 DF General purpose pin W1 0.9203-110 *
* no picture
1. Measuring the gap
NOTE
The term gap refers to the air gap between the contact surfaces of the main bearing
block (Fig.1/3) and the main bearing cap (4). This gap only closes when the round
nuts (2) are tightened to the specified torque.


Gas engine:
- Remove the key.
1.2 Engage the barring device and secure it against unintentional operation.
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1.3 Remove the lateral screws (Fig.1/1) of the cylinder unit to be serviced (see 02
A5.05.02.05.01.nn, Activity 3. Removal of the main bearing cap).
1.4 In addition, loosen the lateral screws (1) of the adjacent cylinder units.
NOTE
The first main bearing cap (locating bearing) of the engine series M 43 C/ VM 43 C
and M 46 DF/ VM 46 DF is installed without lateral screws.
1.5 Only loosen the round nuts on the main bearing cap of the cylinder unit to be serviced so
that the main bearing cap can be lowered (see A5.05.02.05.01.nn, Activity 3. Removal of
the main bearing cap).
1.6 Remove the hydraulic jacks from the main bearing cap.
1.7 Tighten the round nuts (Fig.1/2) on the main bearing cap alternately and evenly by means
of the pin (W1) until the joint faces of the bearing shells just touch each other.
1.8 Measure the gap “K1 and K2“ between main bearing block (3) and main bearing cap (4) by
means of the feeler gauge (W2).
1.9 Add the two measured values: K = K1 + K2
Gap “K” of new main bearing Limit

Engine type
shells in mm in mm
M 20 C 0.50 to 0.80 0.40
M 25 C / M 25 E 0.75 to 1.00 0.60

M 32 C / M 32 E / M 34 DF 1.00 to 1.25 0.80
VM 32 C / GCM34 1.00 to 1.20 0.90
M 43 C / M 46 DF 1.40 to 1.70 1.20

VM 43 C / VM 46 DF 1.70 to 2.00 1.50
1.10 When the gap value reaches or falls below the limit, new main bearing shells (5) must be used
(see A5.05.02.05.01.nn, Activity 5. Removal of the main bearing shells).
CAUTION
Risk of engine damage!
If the gap “K“ is not within the tolerance range after installing new main bearing shells,
troubleshooting in the area of the main bearing must be carried out!
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02
3 5
K1 K2
1 2 2 1
4
1.11 Install the main bearing cap and lift the measures for securing the engine to prevent unin-
tentional starting (see A5.05.02.05.01.nn, Activity 8. Installation of the main bearing
cap).
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02
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Piston A5.05. 02.06.01.10
30000, 15000, 45000

A5.05.01.11.01.nn
Spare parts sheets:


--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the piston

2. Check the piston rings
3. Install the piston
M 20 C Piston mounting/removal device W1 259223 A
Cylinder liner holding device W2 2.9216-103
Piston mounting sleeve W3 2.9220 B
Mounting collar / W4 2.9220 A

Piston ring mounting clamp
Anti-polishing ring removal device W5 2.9216 C
M 25 C / M 25 E Piston mounting/removal device W1 259223 A
Cylinder liner holding device W2 259217 B

Piston mounting sleeve W3 259220 B
Mounting collar / W4 259220 A

Piston ring mounting clamp
Anti-polishing ring removal device W5 259216 C

M 20 C / M 25 C / Molykote paste “G-Rapid Plus” (1 kg) 1.9493-001 */**
M 25 E
Textile round sling with shackle, taken 1.9321 D *
from mounting and removal device for
camshaft sections
* no picture
**) or equivalent product
DANGER
Danger to life in case of improper barring!
There is acute danger to life when staying in the crankcase while the engine is barred.
Before barring the engine make sure that no persons are in the crankcase of the
engine.
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Piston A5.05. 02.06.01.10
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02
CAUTION
Property damage possible during barring due to unintentional loosening of the
cylinder liner!
While barring the engine with removed cylinder head the cylinder liner may be
loosened by the piston and tilted.
In order to avoid loosening of the cylinder liner, always secure it by means of the
holding device.
NOTE
In the following text, tool W2 will be referred to as “cylinder liner holding device” and
tool W4 as “piston ring mounting clamp”.
1. Remove the piston
1.1 Check the measures to prevent unintentional starting.

1.2 Remove the cylinder head of the cylinder unit to be serviced (A5.05.01.06.01.nn).
1.3 Remove the crankcase doors on both sides of the cylinder unit to be serviced.
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1.4 Install the cylinder liner holding device 2 02

(Fig. 1/W2) on the opposite side on the
cylinder liner (4).
W2
1.5 Tighten the round nuts (2) finger tight.
4
1.6 Bar the crank pin to approximately 20°
before top dead centre (TDC).
1.7 Clean the cylinder liner wall above the top

piston ring up to the anti-polishing ring (5)
of coke. During this operation, do not
damage the surface of the cylinder liner.
1.8 Insert the anti-polishing ring removal

device (Fig. 2/W5) in such a manner that
the device is located underneath the anti-
polishing ring (5).
1.9 Slightly tension the anti-polishing

removal device (W5) by turning the
spindle nut (26).
1.10 By barring the piston (7) to top dead

centre (TDC) eject the anti-polishing
ring (5) and remove it. 1 Schematic diagram
1.11 Remove the anti-polishing ring removal 3

device (W5).
W5
2 Schematic diagram
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Piston A5.05. 02.06.01.10
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1.12 Install the piston mounting and removal

6 W1 02
device (Fig. 3/W1) on the piston (7).
For this purpose, clean the threaded
holes (M12) in the piston crown if
7
necessary and recut them if necessary
(see Table Thread depth M12).
Thread depth M12 4
Engine type Depth in mm
M 20 C 11
M 25 C / M 25 E 13.5
1.13 Remove the big-end bearing cap and the

big-end bearing shells 3 Schematic diagram
(A5.05.02.04.01.nn, steps 1 - 1.8).
1.14 Make sure that the eye bolt (Fig. 3/6) with the textile round sling is attached to the crane.
1.15 Carefully extract the piston (7).

While extracting the piston (7) make sure that the connecting rod does not hit the crank pin or the
inside of the cylinder liner (4).
1.16 Put the piston (7) onto a suitable fixture and secure it against tilting.
1.17 Remove the cylinder liner holding device (Fig. 1/W2).
NOTE
In case of longer storage time of the piston with connecting rod, disassemble the
connecting rod to prevent damage to the small-end bush.
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Piston A5.05. 02.06.01.10
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2. Check the piston rings 02

2.1 Service / check the piston rings and 8
grooves (A5.5.02.07.01.nn).
3. Install the piston
3.1 Make sure that the piston rings are W4

inserted with the ring joints displaced by
120° .
7
3.2 Apply Molykote to the thread and contact
surface of the clamping screw(s) (Fig. 4/
8).
3.3 Oil the piston ring package, the piston

skirt, and the inside of the piston ring
mounting clamp (W4) well.
4 Schematic diagram
3.4 Loosen the clamping screw(s) (8) until the

piston ring mounting clamp (W4) is
relieved and can be freely moved over the
piston rings.
3.5 Position the piston ring mounting clamp

(W4) over the piston ring zone and tighten
the clamping screw(s) (8) so as to be
finger tight.
In doing so, prevent possible jamming of
the piston rings at the outer ring groove
edge by slightly turning the piston ring
mounting clamp (W4) back and forth.
3.6 Make sure that the three retaining lugs of

the piston ring mounting clamp (W4) are 14
all evenly resting on the piston crown.
3.7 Loosen the clamping screw(s) (8) by one

to one and a half turns and check whether W3
5 Schematic diagram
the piston rings are freely moveable in the
ring grooves by turning the piston ring
mounting clamp (W4).
3.8 Make sure that the barring device is engaged and the cylinder liner holding device
(Fig. 1/W2) is removed.
3.9 Insert the piston mounting sleeve (Fig. 5/W3).
3.10 Install the piston mounting and removal device (Fig. 6(/W1).
3.11 Carefully bar the crank pin to a favourable installation position for the piston (20° before top dead
centre (TDC)).
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Piston A5.05. 02.06.01.10
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3.12 Attach the eye bolt (Fig. 6/6) with the 5 6 W1 02

textile round sling to the crane and
carefully lift the piston.
3.13 Carefully introduce the connecting rod

head with the cylinder number marking
pointing towards camshaft side into the
cylinder liner (4) and lower the piston (7)
precisely along the cylinder axis so that
the connecting rod head (7) does not to
get jammed in the cylinder liner (4).
During lowering make sure that the
connecting rod head does not collide with
the crank pin or the inside of the cylinder
liner (4).
4
3.14 Let the piston ring mounting clamp (Fig. 4/
W4) rest flat on the piston mounting 7
sleeve (Fig. 5/W3) and continue to lower
the piston (Fig. 4/7) carefully. During this
procedure, the piston ring mounting clamp
(W4) will be pulled off in upward direction.
3.15 Stop the connecting rod head shortly

above the crank pin.
3.16 Install the big-end bearing shells and the

lower big-end bearing cap
(A5.05.02.04.01.nn, steps 2 - 2.16). 6 Schematic diagram
3.17 Remove or take out the piston mounting and removal device (Fig. 6/W1), the piston mounting
sleeve (Fig. 5/W3), and the piston ring mounting clamp (Fig. 4/W4).
3.18 Insert the new anti-polishing ring (Fig. 6/5) into the cylinder liner (4).
3.20 Install the crankcase doors and disengage the barring rod or device.

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Piston Crown A5.05. 02.06.02.10

A5.05.02.10.01.nn, A5.05.01.11.01.nn
Spare parts sheets:


--------------------------------------------------------------------------------------------------------------------------------
Activity:
1. Remove the piston crown
2. Install the piston crown
Engine type Tools and auxiliary materials Tool No.
M 25 C Torque wrench 25 - 60 Nm */***

M 25 E Torque wrench 15 - 47 Nm */***
* no picture
NOTE
This job card covers the engine types indicated in the following table.
The marking (1/3a) is punched into the bottom side of the piston skirt (1/3).
Engine type Marking
M 25 C 25-05
M 25 E 25-07
M 25 E 25-08
NOTE
In case of questions / doubts regarding the installation of the piston crown (1/4) or
when the tightening instruction cannot be complied with, please contact your
authorized Caterpillar dealer.
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Piston Crown A5.05. 02.06.02.10
1. Remove the piston crown 02

1.1 Remove the cylinder head, piston, and piston pin
(A5.05.01.06.01.nn, A5.05.02.06.01.nn, A5.05.02.08.01.nn).
1.2 Measure the small-end bush (A5.05.02.09.01.nn).

For an evaluation of the bearing shell running surfaces please contact your authorized
Caterpillar dealer.
1.3 Loosen the hexagon socket head cap screws (1/1) or the hexagon nuts (1/1) and remove them
with extension sleeves (1/2) or spacer sleeves (1/2).
1.4 Guide a lifting strap through both piston pin bores and attach it to the crane.
Align the crane so as to be centred with respect to the piston and slowly lift the piston skirt (1/3)
off the piston crown (1/4).
Turn the piston skirt (1/3) and put it laterally onto a suitable base support.
1.5 Clean the piston crown (1/4) and piston skirt (1/3).
In doing so, pay attention to cleanliness
- of the sliding surfaces of the connecting rod in the piston skirt and
- of the contact surfaces of the piston parts and the extension sleeves (1/2) or spacer sleeves (1/
2).
1.6 Check sliding and contact surfaces for friction marks and signs of cold welding.
Engine Fig. 1 Schematic diagram

type
M 25 C
3a
s
4
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Piston Crown A5.05. 02.06.02.10

02
type
M 25 E 3a
3 1
6 5
2. Install the piston crown
CAUTION
Severe engine damage due to damaged contact surfaces possible!
If friction marks and/or signs of cold welding (2/Y and (2/Z) can be recognized on the
contact surfaces of piston crown (1/4) and skirt (1/3), this may lead to assembly errors
and, in the installed condition, severe engine damage.
In case of severe signs of cold welding please contact your authorized Caterpillar
dealer before assembling piston crown (1/4) and piston skirt (1/3).
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Piston Crown A5.05. 02.06.02.10
02
2 Schematic diagram
NOTE
Before assembly, clean the respective bearing and contact surfaces, carefully smooth
out any raised spots of the contact surfaces with an oil stone.
During the assembly, make sure not to contaminate the bearing and contact surfaces.
2.1 Clean the oil holes in the piston crown (1/4) and check them for free passage. Clean the bores for
extension sleeves (1/5) or piston screws (1/1).
2.2 M 25 E:
Clean the possibly removed studs (1/5), screw them in dry condition with extension sleeves (1/2)
into the piston crown (1/4) and tighten them with a torque of 39 Nm.
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Piston Crown A5.05. 02.06.02.10
2.3 M 25 C / M 25 E: 02
Insert a new spring dowel pin (1/6) into the fixation hole in the piston crown (1/4).
2.4 Guide the lifting strap through both piston pin bores and attach it to the crane.
Align the crane so as to be centred with respect to the piston and carefully lift the piston skirt (1/3)
off the base support.
Align the piston skirt (1/3) with respect to the crown (1/4) in such a manner that the studs (1/5)
will not be damaged during lowering and the spring dowel pin (1/6) is visibly inserted into the
fixation hole when the skirt is being put onto the crown.
2.5 Lightly lubricate the inside threads and bearing surfaces of the hexagon nuts (1/1) or hexagon
socket head cap screws (1/1) and spacer sleeves (1/2) with Molykote paste.
2.6 Install the hexagon socket head cap screws (1/1) with spacer sleeves (1/2) or the hexagon nuts
(1/1).
2.7 Tighten the hexagon socket head cap screws (1/1) or hexagon nuts (1/1) crosswise with the
torque indicated in the following table:
Engine type Component to be tightened Torque
M 25 C Hexagon socket head cap screws (1/1) 60 Nm
M 25 E Hexagon nuts (1/1) 47 Nm
2.8 Loosen the hexagon socket head cap screws (1/1) or hexagon nuts (1/1).
2.9 Check the gap dimension (1/s) in case of loosened hexagon socket head cap screws (1/1).
Desired value: 0.07 - 0.11 mm.
2.10 M 25 E:
Check tightening of the studs (1/5) with a torque of 39 Nm.
2.11 M 25 C / M 25 E:
Tighten the hexagon socket head cap screws (1/1) or hexagon nuts (1/1) crosswise with the
torque indicated in the following table and then continue to turn by the angle indicated in the table:
Engine type Component to be tightened Torque Torque angle
M 25 C Hexagon socket head cap screws (1/1) 25 Nm 60°

M 25 E Hexagon nuts (1/1) 15 Nm 90°
2.12 Check:
When applying the torque indicated in the following table in tightening direction the hexagon
socket head cap screws (1/1) or hexagon nuts (1/1) must not turn any further.
Engine type Component to be tightened Torque
M 25 C Hexagon socket head cap screws (1/1) 45 Nm
M 25 E Hexagon nuts (1/1) 38 Nm
2.13 Install the piston pin, piston and cylinder head

(A5.05.02.08.01.nn, A5.05.02.06.01.nn, A5.05.01.11.01.nn).
en / 26.04.2017 5/6
Piston Crown A5.05. 02.06.02.10
02
en / 26.04.2017 6/6
c2 Piston Rings and Grooves
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
See also: A5.05.02.06.01.nn, A5.05.02.10.01.nn 02

Spare parts sheets: 1.05.02.252617

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the piston rings and grooves
M 20 C Piston ring expander W1 2.9227 A *
Barring rod 2.9100-380 *

M 25 C / M 25 E Piston ring expander W1 259227 A
M 32 C / VM 32 C Piston ring expander W1 6.9227 B

M 32 E
GCM34 / M 34 DF Piston ring expander W1 349227 A *
M 43 C / VM 43 C Piston ring expander W1 431001 A *

M 46 DF / VM 46 DF Piston ring expander W1 461046 A *
* no picture
CAUTION
After installing new piston rings the engine has to be run in according to the
running-in instructions, see engine documentation, chapter “Operating
Instructions”!
en / 23.02.2018 1/6
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
1. Check the piston rings and grooves 02


Dual fuel engine:

Gas engine:
- Mechanically block the main shut-off valve of the gas valve unit.
- Set the key switch on the “Local Data Board“ to “OFF”.
- Remove the key.
1.2 Remove all crankcase doors.
1.3 Check the running surfaces of all cylinder liners from the crankcase.
1.4 Remove the piston with the worst running pattern (A5.05.02.06.01.nn).
NOTE
When inspecting a piston, particular attention has to be paid to the following:
- Sharp edges of piston rings
- Ring tension
- Sticking of rings due to coking
A full inspection of all pistons may be postponed to a later date, based on critical
judgement, but not beyond the operating hours indicated in the maintenance
schedule, if:
- the running surfaces of all cylinder liners do not show any score marks, blank spots
or other damage,
- the components of the removed pistons are in perfect condition,
- all piston rings are freely moveable in the grooves, and
- none of the components is affected by impermissible wear.
Do not remove the graphite layer on the piston skirt.
1.5 In case of sticking or burnt piston rings remove all pistons.
1.6 Record the position of the ring joints with regard to the installation position of the piston on the
measuring sheet.
en / 23.02.2018 2/6
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
02
CAUTION
Install/remove the piston rings only with the piston ring expander (W1) provided for
this purpose.
1.7 Remove and clean the piston rings.
1.8 Check the ring flanks and running surfaces of the piston rings for wear, especially at the joint and
the side opposite to the joint. In case of obvious wear and/or if the chrome layer is partly not
existing any more, all piston rings of the affected piston must be replaced by new ones.
1.9 In case of wear on one piston ring or the chrome layer, the piston rings of all pistons must be
checked.
1.10 Remove any oil or loose combustion residues from the piston by means of a soft rag.
1.11 Check the ring grooves for possible coke build-up in the groove root and the ring groove flanks
for wear. Dissolve and remove any coking by soaking with water or diesel oil. In case of
significant score marks on the ring groove flanks the affected piston crown (piston) must be
replaced/reconditioned.
NOTE
When the limit for piston ring groove height is exceeded, there is a possibility to
have the piston crowns (pistons) refinished. For this purpose, please contact your
authorized Caterpillar dealer.
1.12 Measure the groove height hN2 in the front area of the groove (approx. 1 mm from the outside
edge of the piston) on both sides in longitudinal and transverse axis of the engine and compare to
the wear limit (see table “Standard piston ring equipment“). If the wear limit is exceeded, the
corresponding piston crown (piston) may not be reused and has to be replaced or reconditioned.
1.13 Measure the piston ring height hR at four opposite points and note down the values.
1.14 Calculate the limit clearances (hN2 - hR = limit clearance), check it based on the table “Standard
piston ring equipment”, and replace if necessary.
hN1 = dimension in new condition (groove)

hN2 = wear limit
hR = dimension in new condition (ring)
hN2 hN1 hR
approx.1 mm
en / 23.02.2018 3/6
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
Permissible piston groove height and piston ring limit clearances 02
Wear limit - groove Limit clearance

M 20 C height hN2 hN2 - hR
[mm] [mm]
1st groove (top compression 5.60 0.65

ring)
2nd groove (compression 5.60 0.65

ring)
3rd groove (oil control ring) 6.50 0.50
M 25 C / M 25 E

ring)

ring)
M 32 C / VM 32 C / M 32 E / GCM34 / M 34 DF

ring)

ring)
M 43 C / VM 43 C

ring)

ring)
M 46 DF / VM 46 DF

ring)
ring)
en / 23.02.2018 4/6
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
1.15 Insert new (see 1.8) or reusable piston rings into the ring grooves with the marking pointing 02
upwards and ring joints alternately displaced by 120° in the longitudinal axis of the engine.
1.16 Install the piston (A5.05.02.10.01.nn) and all crankcase doors.

Dual fuel engine:

Gas engine:
- Open the main shut-off valve of the gas valve unit.
- Insert the key into the key switch at the the “Local Data Board“.
en / 23.02.2018 5/6
Check / Replacement
A5.05. 02.07.01.10
30000, 7500
02
en / 23.02.2018 6/6
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove and check the piston pin

2. Install the piston pin
M 20 C / M 25 C Piston mounting/removal device W1 259223 A
M 32 C Traverse W1 9.9223 A
M 32 E Piston lifting device W1 9.2254 A
M 34 DF Piston mounting/removal device W1 1.1067-016
GCM34 Piston mounting/removal device W1 349223 A
VM 32 C Piston removal device (lower W1 9.9223 B

shank division)
VM 32 C Piston mounting/removal device W1 9.2180 A

(upper shank division)
M 43 C Piston mounting/removal device W1 439223 A
M 46 DF Piston mounting/removal device W1 462226 A
432146 A
VM 43 C Traverse W1
432089 A
VM 46 DF Piston mounting/removal device W1 462212 A
M 43 C / M 46 DF / Piston pin removal device W2 439220 C

VM 43 C / VM 46 DF Circlip pliers W3 431019 A *
M 32 C / M 32 E /
Circlip pliers W3 1.9067-525 *
M 34 DF / VM 32 C
GCM34 Circlip pliers W3 349227 A *
* no picture
en / 07.05.2017 1/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
02
M 20 C / M25 C / Textile round sling (2x) */

M 32 C / M 32 E / (VM 32 C/M 32 E/M 34 DF only W4 ***
M 34 DF / M 43 C / 1x)
M 46 DF / VM 32 C /
GCM 34 / VM 43 C / Machine oil *
VM 46DF
* no picture
NOTE
In the following, tool W1 will be referred to as “piston mounting/removal device” for all
engine types.
1. Remove and check the piston pin
1.1 Make sure that the measures for securing the engine to prevent unintentional starting have been
taken.

Dual fuel engine:

Gas engine:
- Remove the key.
1.2 Remove cylinder head and piston (A5.05.01.06.01.nn and A5.05.02.06.01.nn).
1.3 Make sure that the piston mounting/removal device (1/W1) has been installed.
1.4 Attach the eye bolt (1/1) with the first textile round sling (W4) to the crane and lift the piston (1/3).
en / 07.05.2017 2/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
02
NOTE
For turning the piston with two textile round slings a distinction between different
engine types will be made in the next two steps (1.5 and 1.6); these are marked
accordingly.
For connecting rods with lower shank division (M 32 E, M 34 DF and VM 32 E) only
one textile round sling is used; furthermore, the unit consisting of piston (1/3) and
connecting rod (1/7) must be put onto a clean and level base to prevent the connecting
rod from buckling and subsequently hitting the piston skirt.
1.5 Prepare the piston for turning:
M 20 C / M 25 C / M 25 E:
Fasten the second textile round sling (W4) with a loop to the connecting rod (1/7) and attach it to
the second crane.
Make sure that the connecting rod 1/7) does not hit and thus damage the piston skirt.
M 32 E / M 34 DF / VM 32 E:
Carefully put the entire unit consisting of connecting rod (1/7) and piston (1/3) onto a clean and
level base. In doing so, make sure that the connecting rod (1/7) does not buckle or hit and thus
damage the piston skirt.
VM 32 C / GCM34:
Install the second piston removal device (1/W1.1) with eye bolt (1/2) at the small-end connection
flange (1/4) and attach the eye bolt (1/2) with the second textile round sling to a second crane.
In doing so, make sure that the small end does not hit and thus damage the piston skirt.
M 43 C / M 46 DF / VM 43 C / VM 46 DF:
Fasten the second textile round sling (W4) with a loop to the small-end connection flange (1/4)
and attach it to the second crane.
In doing so, make sure that the small end does not hit and thus damage the piston skirt.
1.6 Turn the piston:
All engines except M 32 E / M 34 DF / VM 32 C [upper shank division]:

By evenly lowering and raising the two cranes slowly turn the piston (1/3) into the position shown
in Fig. 1.
In doing so, make sure that the connecting rod (1/7) does not hit the piston (1/3).
M 32 E / M 34 DF / VM 32 C [lower shank division]:

Fasten the textile round sling (W4) with a loop to the connecting rod (1/7), attach it to the crane
and slowly turn the entire unit consisting of connecting rod (1/7) and piston (1/3) into the position
shown in Fig. 1.
en / 07.05.2017 3/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
1.7 All engines: 02

Separate the connection between piston mounting/removal device (1/W1) and crane and remove
the pistong mounting/removal device (1/W1).
1.8 Put the piston (1/3) with piston crown pointing downward onto a suitable base and secure it
against tilting.
M 20 C /
7
M 25 C /
M 25 E /
M 32 E / 6
M 34 DF / 6 5
VM 32 C
[lower shank division] 8
3
W1
M 32 C /
2
VM 32 C / W1.1
[upper shank division] 4
GCM34 6
6
5
8 3
W1
1
en / 07.05.2017 4/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000

02
M 43 C /
4
M 46 DF /
VM 43 C / 6
VM 46 DF 5
8
3
W1
1.9 Mark the connecting rod (1/7) / small-end connection flange (1/4), piston (1/3), and piston pin
(1/5) for correctly positioned reinstallation.
1.10 Slightly lift the connecting rod (1/7) or the small-end connection flange (1/4) with the crane in
order to relieve the piston pin (1/5).
1.11 Remove both circlips (1/6). For this purpose, use the circlip pliers (W3).
1.12 If necessary, provide a suitable base at the side of the piston (1/3) to support the weight of the
piston pin (1/5) (see Table 1, Weight of the piston pin).
Weight of the piston pin
Engine type Weight [kg]
M 20 C approx. 8
M 25 C / M 25 E approx. 17
M 32 C / M 32 E / M 34 DF / VM 32 C / GCM34 approx. 33
M 43 C / VM 43 C / M 46 DF / VM 46 DF approx. 84
en / 07.05.2017 5/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
02
NOTE
Step 1.13 (Utilization of the piston pin removal device) is relevant only for the following
engine types: M 43 C / M 46 DF / VM 43 C / VM 46 DF.
Starting with step 1.14 the instructions apply to all engine types again.
1.13 M 43 C / M 46 DF / VM 43 C / VM 46 DF:
Push the piston pin (2/5) out of the piston W2
bore and small-end bush without applying
5
any force until the second oil hole
becomes visible.
1.13.1 Install the piston pin removal device

(2/W2) on the second oil hole of the piston
pin (2/5) and attach it to the crane with
suitable means.
1.14 All engine types:

Push the piston pin (2/5) completely out of
the piston bore without applying any force,
put it onto a suitable base and secure it to
prevent sliding.
1.15 If necessary, separate the connection

between piston pin removal device (2/W2)
2 Schematic diagram
and crane and remove the piston pin
removal device (2/W2).
1.16 Check the surface of the piston pin (2/5) for cracks and damage.
1.17 Measure the piston pin (2/5), small-end bush, and piston pin bore (A5.05.02.09.01.nn).
en / 07.05.2017 6/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
2. Install the piston pin 02
CAUTION
Engine damage due to dirt possible!
When installing the piston pin 2/5) particular attention has to be paid to cleanliness of
the components. Even smallest contamination (such as sand, chips, etc.) between
piston pin (2/5) / small-end bush / piston pin bore or in the oil holes may cause major
engine damage after a short operating time
2.1 Carefully clean and lightly oil all removed components.

Check both circlips (1/6) and replace them if necessary.
2.2 Install one circlip (1/6) in the piston pin bore. For this purpose, use the circlip pliers (W3).
2.3 Check the oil holes in the small end (Fig. 1/8) and the small-end bush for cleanliness / free
passage and clean them if necessary.
2.4 Introduce the small-end connection flange (1/4) or the connecting rod (1/7) into the piston (1/3)
until the small-end bush aligns with the piston pin bore.
In doing so, make sure to prevent the small end (1/8) from tilting to avoid creating difficulties for
the subsequent installation of the piston pin.
NOTE
Steps 2.5 and 2.6 (Insertion of the piston pin) are different for the individual engine
types; starting with step 2.7 the instructions apply to all engine types again.
2.5 M 43 C / M 46 DF / VM 43 C / VM 46 DF:
Make sure that the piston pin removal device (2/W2) is installed on the second oil hole of the
piston pin (2/5).
Attach the piston pin removal device (2/W2) with suitable means to the crane.
2.5.1 Oil the piston pin (2/5) and insert it according to the markings applied under step 1.10 up to the
central oil hole into the piston and small-end bush without tilting.
2.5.2 Remove the piston pin removal device (2/W2) and push the piston pin (2/5) without tilting into the
final mounting position.
2.6 M 20 C / M 25 C / M 25 E / M 32 C / M 32 E / M 34 DF / VM 32 C / GCM34:
Oil the piston pin (1/5) and insert it according to the markings applied under 1.10 into the small-
end bush without tilting until reaching the final mounting position.
2.7 All engines:

Install the second circlip (1/6). For this purpose, use the circlip pliers (W3).
en / 07.05.2017 7/8
Piston Pin A5.05. 02.08.01.10
30000, 15000, 45000
2.8 Turn the piston (1/3) into its original position.For this purpose, fasten the textile round sling to the 02
connecting rod (1/7), eye bolt (1/2) or the small-end connection flange (1/4) depending on engine
type and attach it to the crane.
2.8.1 Lift the piston (1/3) and install the piston mounting/removal device (1/W1).
2.8.2 Attach the eye bolt (1/1) with the second textile round sling to the second crane.
2.8.3 By evenly lowering and raising the two cranes slowly turn the piston (1/3) until the connecting rod
(1/7) / small-end connection flange (1/4) points downward.
If necessary, make sure that the connecting rod (1/7) does not hit the piston (1/3).
2.8.4 Separate the connection between the connecting rod (1/7), the eye bolt (1/2) or the small-end
connection flange (1/4) and the crane and, if applicable, remove the second piston mounting/
removal device (1/W1.1).
2.8.5 Install piston and cylinder head (A5.05.02.06.01.nn and A5.05.01.11.01.nn).

Dual fuel engine:

Gas engine:
en / 07.05.2017 8/8
c2 Small-end Bush
Maintenance / Measurement
A5.05. 02.09.01.10
45000
See also: 02
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Measure the small-end bush clearance
NOTE
It is not possible to instal a small-end bush accurately with conventional means. This
job must be carried out by Caterpillar Kiel or an authorized Caterpillar workshop.
The decisive criteria for assessing the small-end bush are essentially the clearance
limits (see corresponding Table Clearance 1, 2 or 3).
A small-end bush shall only be replaced if:
• A clearance limit has been reached
• A clearance limit will probably be exceeded before the next maintenance
• There is mechanical damage such as severe score marks, crumbling or deep
cavitation pits
• The max. number of operating hours has been reached (see maintenance
schedule)
1. Measure the small-end bush clearance
1.1 Clean the piston pin (1), small-end bush (2), piston bosses (3a and 3b) and measure and record
dimensions A, B, C, D, and X with a suitable measuring tool such as an external micrometer and
an inside micrometer.
1.2 Dimension A has to be measured 20 mm behind the circlip groove on both sides.
1.3 The respective clearances are to be determined from the difference of the following measuring
values:
Dimension A (Ø of piston bosses /3a/3b) minus Dimension C

(Ø of piston pin/1) = Clearance 1
Dimension B (Ø of small-end bush /2) minus Dimension C

(Ø piston pin /1) = Clearance 2
Dimension D (distance between piston bosses /3a and 3 b) minus Dimension X

(Width of small-end bush /2) = Clearance 3
1.4 When reaching the clearance limits (see Table Clearance 1-3) or if the clearance limit will pro-
bably be exceeded before the next maintenance, the corresponding wear parts must be replaced.
en / 06.10.2016 1/4
c2 Small-end Bush
A5.05. 02.09.01.10
45000
02
3a 3b
D
B A
1.5 Table Clearance 1 (Dimension A minus Dimension C),
Min. clearance Max. clearance Clearance limit

Engine series
(mm) (mm) (mm)
M 20 C 0.005 0.025 0.05
M 25 C / M 25 E 0.05 0.08 0.10
M 32 C / VM 32 C / M 32 E 0.06 0.09 0.15

GCM34 / M 34 DF
M 43 C / M 46 DF 0.06 0.09 0.15
VM 43 C / VM 46 DF
M 43 C / VM 43 C 0,07 0,13 0,19

(For Mahle pistons only)
en / 06.10.2016 2/4
c2 Small-end Bush
A5.05. 02.09.01.10
45000
1.6 Table Clearance 2 (Dimension B minus Dimension C) 02

Engine series
(mm) (mm) (mm)
M 20 C 0.09 0.16 0.18
M 25 C / M 25 E 0.11 0.2 0.22
M 32 C / VM 32 C / M 32 E 0.14 0.24 0.26

GCM34 / M 34 DF
M 43 C / M 46 DF 0.20 0.30 0.34

VM 43 C / VM 46 DF
Table Clearance 3 (Dimension D minus Dimension X)

Engine series
(mm) (mm) (mm)
M 20 C 0.2 0.80 1.00
M 25 C / M 25 E 0.50 1.10 1.30

M 32 C / VM 32 C / M 32 E 0.50 1.10 1.30
GCM34 / M 34 DF
M 43 C / M 46 DF 0.70 1.20 1.50

VM 43 C / VM 46 DF
en / 06.10.2016 3/4
c2 Small-end Bush
A5.05. 02.09.01.10
45000
02
en / 06.10.2016 4/4
Explosion Relief Valve A5.05. 03.01.01.10
1500
See also: 03
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check all explosion relief valves for ease of movement

2. Remove the explosion relief valve
3. Install the explosion relief valve
GCM34 Torque wrench, 20-120 Nm 1.9454-120 *
M 43 C / VM 43 C Torque wrench, 20-200 Nm 1.9454-202 *

M 46 DF / VM 46 DF
M 20 C - VM 46 DF Molykote paste “G-Rapid Plus“ **
Universal sealing compound “Dirko No. 610.022“ **
* no picture
NOTE
A removal of the explosion relief valve (4) is only required when the spring tension is
not provided any more and/or in case of abnormal fouling by oil or if any leaks are
identified during operation.
en / 02.01.2015 1/4
1500
1. Check the explosion relief valve for ease of movement. 03



Gas engine:
- Remove the key.
1.2 Remove the crankcase door (1) or the explosion relief valve (4).
1.3 Check the explosion relief valve (4) from the inside of the crankcase door (1) for ease of move-
ment by actuating the valve by hand.
2. Remove the explosion relief valve
2.1 Secure the engine to prevent unintentional starting (see 1.1).
2.2 Remove the crankcase door (1) with explosion relief valve (4).
2.3 Remove the hexagon head bolts (10).
2.4 Remove the explosion relief valve (4) completely from the crankcase door (1).
en / 02.01.2015 2/4
1500
3. Install the explosion relief valve 03
CAUTION
Unclean sealing surfaces will cause leaks!
When mounting the explosion relief valve to the crankcase door ensure proper sealing
between seat and crankcase door.
CAUTION
Specific feature of dual fuel engines!
For the hexagon head bolts of the explosion relief valves at the charge air duct and
the exhaust gas collecting tube the standard tightening torques apply.
3.1 Slightly coat the threads of the hexagon head bolts (10) with Molykote.
3.2 Clean the sealing surface on the crankcase door (1) and lubricate with universal sealing com-
pound.
3.3 Install the explosion relief valve (4) with the hexagon head bolts (10).
3.4 Tighten the hexagon head bolts (10) crosswise with the following torque.
Hexagon head bolt (10) tightening torque
Engine Type Torque in Nm (Ib ft)
M 20 C 15 (11)
M 25 C 25 (19)
M 25 E
M 32 C
VM 32 C
M 32 E
M 34 DF
GCM34
M 43 C
M 46 DF
VM 43 C 42 (31)
VM 46 DF
3.5 After installation, check the explosion relief valve (4) for proper function by actuating it by hand.
3.6 Install the crankcase door (1) with explosion relief valve (4).
en / 02.01.2015 3/4
1500
03
4
10
Schematic diagram


Gas engine:
en / 02.01.2015 4/4
Cooling Collar A5.05. 03.02.00.10
See also: A5.05.01.06.01.nn, A5.05.03.04.01.nn 03

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the cooling collar.

2. Replacement of O-rings.
3. Installation of the cooling collar.
Engine Type Tools and Auxiliary Materials Index Tool No.
M 20 C - VM46DF Lifting eye bolt M16 W1 ***
M 20 C Cylinder liner holder W2 2.9217 A
M 25 C / M 25 E Cylinder liner holder W2 259250 B
M 32 C / VM 32 C / Cylinder liner holder W2 9.9217 D

M 32 E / M 34 DF
GCM 34 Cylinder liner holder W2 349217 A
M 43 C / VM 43 C / Cylinder liner holder W2 439217 A

M 46 DF / VM 46 DF
Torque wrench, 20 - 200 Nm 1.9454-202
Torque wrench, 200 - 500 Nm 1.9454-500
VM 43 C / VM 46 DF Mounting and removal device W3 432087 B
M 20 C - VM46DF Molykote paste “G-Rapid” */**

Petro Gel Amber */**
* no picture
*** optional / not included in the standard set of tools
en / 02.01.2015 1/6
1. Removal of the cooling collar. 03



Gas engine:
- Interrupt the starting air supply
- Remove the key.
1.2 Remove crankcase, exhaust gas, and pump covering of the cylinder unit to be serviced.
1.3 Remove the cylinder head of the cylinder unit to be serviced (A5.05.01.06.01.nn).
1.4 If necessary, remove the brackets on the cooling collar.
1.5 Remove the fixing screws (Fig. 2/1) of the cooling water distributing and collecting pipe.
1.6 Specific feature of GCM34 and M 34 DF

engines
Remove the cylinder liner of the cylinder
unit to be serviced (A5.05.03.04.01.nn).
1.7 Install the cylinder liner holder (Fig. 1/W2).
NOTE
For engine series M 20 C
and GCM34 steps 1.8 and
3.4 are to be omitted.
1.8 Loosen the sleeves (Fig. 2/2) from the

starting air duct and push them into the
adjacent cooling collars.
W2
Schematic diagram
en / 02.01.2015 2/6
1.9 Remove the fixing screws (3) of the cooling collar all around. 03
1.10 Install the eye bolts (Fig. 3/W1) on the cooling collar (6).
1.11 Specific feature of VM 43 C and VM 46 DF engines

Install the mounting and removal device (W3).
1.12 Carefully lift the cooling collar by means of the crane and, for a V-engine, continually follow up
according to the angle.
V
2
3
W V
6
Schematic diagram
en / 02.01.2015 3/6
2. Replacement of O-rings. 03
CAUTION
Risk of leaks!
Lightly coat new O-rings with Petro Gel Amber and insert them untwisted.
NOTE
Use new O-rings and new gaskets at all connection points.
2.1 Insert new O-rings (Fig. 3/4 and 5) into the grooves at the charge air and push-rod passages of
the cooling collar (6).
7 W3
W1
W1
Schematic diagram
en / 02.01.2015 4/6
3. Installation of the cooling collar. 03

3.1 Put in place a new gasket (Fig. 3/7) at the cooling water distributing and collecting pipe and lightly
fix it (Petro Gel Amber).
3.2 Place the cooling collar (6) with the crane onto the engine block.
3.3 Lubricate the fixing screws (Fig. 2/3 and 1) with Molykote and pre-install them.
NOTE
For engine series
M 20 C and GCM34 steps 1.8 and 3.4 are to be omitted.
3.4 Install and secure the sleeves (2) of the starting air duct.
3.5 Specific feature of GCM34 and M 34 DF engines

Install the cylinder liner (A5.05.03.04.01.nn).
3.6 Specific feature of M 43 C, VM 43 C, M 46 DF, and VM 46 DF engines

Tighten the fixing screws (Fig. 1/1) for the cooling water distributing and collecting pipe in two
steps: Step 1 = 100 Nm (74 Ib ft).
Step 2 = 260 Nm (192 Ib ft).
3.7 Firmly tighten the fixing screws (3 and 1) (standard tightening torque, see A5.03).
3.8 Remove the eye bolts (Fig. 3/W1).
3.9 If necessary, install the brackets on the cooling collar.
3.11 Remove the cylinder liner holder (Fig. 1/W2).
3.12 Install all covers.


Gas engine:
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03
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000

Spare parts sheets:

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

2. Check of the contact surfaces (cylinder liner and engine block)
3. Check of the radial fits (cylinder liner and engine block)
M 20 C Measuring ruler for cylinder liner W1 2.9216-022
M 25 C / M 25 E Measuring ruler for cylinder liner W1 259216-001
M 32 C / VM 32 C/ Measuring ruler for cylinder liner W1 9.2084 A

M 32 E / GCM34
M 34 DF Measuring ruler for cylinder liner W1 342253 A

M 43 C / VM 43 C Measuring ruler for cylinder liner W1 439218-001
M 46 DF / VM 46 DF
M 20 C High-precision inside micrometer W2 1.9419 M *
M 25 C / M 25 E High-precision inside micrometer W2 1.9419 K *

M 32 C / VM 32 C / High-precision inside micrometer W2 1.9419 B *
M 32 E / M 34 DF
GCM34 High-precision inside micrometer W2 1.9419 L *
M 43 C / VM 43 C High-precision inside micrometer W2 1.9419 G *

M 46 DF / VM 46 DF
* no picture
NOTE
For diesel oil (MDO) engines and gas engines it is recommended to replace all
cylinder liners after 90,000 h.
For heavy fuel oil (HFO) engines we recommend to replace all cylinder liners after
60,000 h already.
If cylinder liners with irregular or critical contact patterns of the contact surfaces are
found during the 15,000 h / 30,000 h (for gas engines 15,000 h / 45,000 h) standard
check, follow-up checks according to Table 2 are required.
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
03
NOTE
Every 15,000 h a standard check (see Table 1) at one cylinder liner must be carried
out.
If the checked cylinder liner presents irregularities, a follow-up check must be carried
out after another 7,500 h (Table 2) in which the irregular cylinder liner plus one more
cylinder liner must be checked. On V-engines the irregular cylinder liner and one more
liner per cylinder bank shall be checked.
The outer cylinder units are not suitable for the checks mentioned above and should
be left out.
Standard check (Table 1):
• of one cylinder liner every 15,000 h

• of all cylinder liners (diesel engines only) every 30,000 h
• of all cylinder liners (gas engines only) every 45,000 h
• of the cylinder liner after each piston removal (Activity 1.)
Table 1
Standard check In-line engines V-engines
Number of cylinder liners to be checked

15,000 h 1 1 x bank A
1 x bank B
30,000 h (diesel engine) All All

45,000 h (gas engine)
Follow-up check (Table 2):

Only required if irregularities according to Table 5 (Figure 2, Irregular contact patterns), are identified during
a standard check.
Table 2
Follow-up check In-line engines V-engines
Number of cylinder liners to be checked

7,500 h At least two At least three
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
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1. Check/measurement and evaluation of the cylinder liners. 03
NOTE
Depending on running time and operating conditions, the contact surfaces between
cylinder liner and engine block may exhibit extraordinary wear patterns that must be
assessed and measured (for orientation see Fig. 3).
CAUTION
Risk of damage to the engine due to dirt!
When a main running gear (piston and connecting rod) is removed, there is a risk of
dirt particles and other contaminants entering the crankcase.
Especially the crank pin and the oil guide bore must be carefully covered and
protected.
1.1 Remove the anti-polishing ring, see A5.05.02.05.50.nn.
1.2 Remove the piston, see A5.05.02.06.01.nn.
1.3 Remove the cylinder liner A5.05.03.04.01.nn D1

(Not required for each inspection, see Maintenance Plan).
1.4 Remove sealing ring and O-ring.
1.5 Cover the crankcase and protect the crank pin against
contamination.
1.6 Clean the cylinder liner (Fig. 1/1) inside.

D2 W1
1.7 Check the cylinder liner visually for traces of wear according to
Table 4.
1.8 Using the high-precision inside micrometer (W2) measure the

cylinder liner at the measuring points determined with the
measuring ruler (Fig. 1/W1) and shown in Table 3 lengthwise,
crosswise and 2 x diagonally to the engine axis.
1.9 Enter the measured values in Table 3 and then calculate the
wear value (D1 - D3). D3
1.10 When the wear limit is reached, which is usually in the area of 1
the top piston ring reversal point (TDC, 1st piston ring), or
another limit in Table 4 (Fig. 2), replace the cylinder liner.
1
Schematic diagram
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 3 03
Measuring Longitudinal Transverse Diagonal Diagonal Wear dimension
point direction direction
D1 = _______
D2 = _______
D3 = _______
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Check / Measurement
A5.05. 03.03.01.10
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Table 4 M 20 C - List of wear limits 03
Evaluation criteria Wear limits (mm) Explanation
Nominal Ø dimension (in Entire cylinder running surface

new condition)
200.0 +0.046
Wear dimension 0.5
Max. ovality 0.25

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

Length 45.0 * Probe radius r 3 mm
Width ** 15.0 ** In circumferential direction
Depth * 0.02
3. Score Number 3 to max. 19*** Severe vertical, linear friction marks interrup-
Length 140.0 ting the TDC area of the 1st piston ring.
Depth 0.5 *** See Note
4. Striping See 1.11
5. Canyon Max. number 3 Individual deep blow-by grooves in the area of

Length 6.0 the 1st piston ring (TDC)
Total width 3.0
3
4
2 5
***1
NOTE
*** If during a liner check no signs of wear in form of wedge shapes, canyons, pockets
or striping are identified, a quantity of up to 19 scores may be uncritical.
Contact your authorized Caterpillar dealer in this respect.
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 4 M 25 C / M 25 E - List of wear limits 03

new condition)
255.0 +0.052
Wear dimension 0.5
Max. ovality 0.25


Depth * 0.02
Depth 0.5 ***See Note

Total Width 3.5
3
4
2 5
***1
NOTE
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 4 M 32 C / VM 32 C / M 32 E - List of wear limits 03

new condition)
320.0 + 0.057
Wear dimension 0.5
Max. ovality 0.3


Depth * 0.02

Total Width 4.0
3
4
2 5
***1
NOTE
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 4 GCM34 / M 34 DF - List of wear limits 03

new condition)
340.0 +0.057
Wear dimension 0.5
Max. ovality 0.3


Depth * 0.02

Total Width 4.0
3
4
2 5
***1
NOTE
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 4 M 43 C / VM 43 C - List of wear limits 03

new condition)
430.0 +0.063
Wear dimension 0.5
Max. ovality 0.3


Depth * 0.03

Total Width 6.0
3
4
2 5
***1
NOTE
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Table 4 M 46 DF / VM 46 DF - List of wear limits 03

new condition)
460.0 +0.063
Wear dimension 0.5
Max. ovality 0.3


Depth * 0.03

Total Width 6.0
3
4
2 5
***1
NOTE
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
1.11 Striping 03
As a basic rule, there are three degrees of striping formation:
1. Faint striping (s-) / only visible = harmless

2. Normal striping (s) / only visible = harmless
3. Unacceptable striping (s+) / visible and palpable= replacement required
The most important wear criterion is the condition of the honing structure in the area of the striping. If the
honing structure is not destroyed, it can be assumed, based on insights gained to date, that such striping
will not lead to a critical condition and that the affected cylinder liner can remain in the engine. This also
applies in particular if there is a higher amount of stripes of this degree in one cylinder liner.
Vertical irregularities between top and bottom dead centre
View Evaluation Action

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

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

rings(A5.05.02.07.01.nn)
- Honing structure locally
destroyed. - Check the anti-polishing ring
and replace it if necessary
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
2. Check of the contact surfaces (cylinder liner and engine block) 03

2.1 Turn the cylinder liner and put down on a suitable support with the liner collar (anti-polishing ring
side) facing downward and secure against tipping.
Clean the contact surfaces (Fig. 3/X), evaluate them based on Table 5 and enter the results in Table 6.
3 Schematic diagram
Table 5
Evaluation table for contact surfaces (Fig. 3/X) [applies to cylinder liner and engine block]:
Fig. 1 Fig. 2 Fig. 3

Table 5 Irregular areas Irregular contact pat- Critical contact patterns
terns
Wear patterns =>
Continued next page Continued next page Continued next page
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
Fig. 1 Fig. 2 Fig. 3

03
Table 5 Irregular areas Irregular contact pat- Critical contact patterns
terns
Condition of the Corrosive/abrasive - Corrosive/abrasive - Corrosive/abrasive material
contact surfaces material erosion of material erosion of max. erosion of more than 25 %
max. 10 % of the total 25 % of the total contact of the total contact surface
contact surface up to a surface with up to 7 mm and/or more than 7 mm of
width of 7 mm from the of the width from the the width from
inside diameter of the inside diameter of the the inside diameter of the
contact surface. contact surface. contact surface.
- Material erosion is - Material erosion is clearly

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

mm mm
- Over the entire - Over the entire

circumference of the circumference of the
contact surface there is contact surface there is no
still a continuous ridge continuous ridge of a min.
of a min. width of 7 mm. width of 7 mm.
Evaluation of con- Harmless Basically harmless. Immediate refinishing of
tact surfaces engine block and cylinder
However, carefully liner required.
document and monitor
irregular cylinder units. In case of material erosion
of more than 0.3 mm
replace the corresponding
cylinder liners.
Refinishing is then no
longer possible.
Rework No No Yes
Check of other No No Yes
cylinder units (of all cylinder units)
Follow-up check As part of regular Shortened mainte- As part of regular mainte-
maintenance nance interval nance
Check of the irregular
cylinder units and one
additional unit per
bank.
Latest, however, after
7,500 h.
Installation instruc- Before installing the Before installing the Before installing the cylin-
tions cylinder liner clean the cylinder liner clean the der liner clean the rewor-
contact surfaces and contact surfaces and ked contact surfaces.
smooth any possible smooth any possible
material build-up. material build-up.
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
2.2 Documentation of the measuring results 03

Document the condition of the checked cylinder liner contact surfaces!
For this purpose, enter the cylinder unit, the operating hours, date and time of inspection as well as the
condition of the contact surface in the following table to be able to compare this data with subsequent
findings.
For examples and evaluation criteria see Table 5.
Table 6
_________ h check _________ h check

Cylinder unit
Illustration Remark Illustration Remark
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
3. Check of the radial fits (cylinder liner and engine block) 03
NOTE
Fig. 4 shows a schematic representation of the cylinder bore, upper and lower cylinder
liner fit. The non dashed lines show the main load area.
90°
3.1 Schematic representation (Fig. 4) of the
cylinder bore/upper and lower cylinder
liner fit.
3.2 Clean upper (Fig. 5/9) and lower (8) fit and
check the main load areas (Fig. 4) of the Engine axis
cylinder liner fits for corrosive/abrasive
material erosion.
3.3 Fretting (abrasive erosion)

90°
Criteria for reworking the radial fits of
cylinder liner and engine block:
1. Surface extension of fretting at the fits.
2. Degree of material erosion.

9
Rework of the respective fits (Fig. 58 and
9) or replacement of the cylinder liner is
required if the fretting formation occurs on
more than 50 % of the surface of one of
the main load areas
with
local material erosion > 0.5 mm and
over the entire height of the respective fit.
NOTE
All refinishing work on the radial
fits must be carried out by an
authorized
Caterpillar dealer!
5 Schematic diagram
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c2 Cylinder Liner
Check / Measurement
A5.05. 03.03.01.10
30000, 15000, 45000
3.4 Schematic representation of critical and uncritical fretting marks 03

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

and the engine block must be
reworked!
3.5 Example photos of critical and uncritical fretting marks on radial fits
Fretting marks are critical

if
Uncritical fretting marks the total surface of material erosion amounts to > 50% of one of the
main load areas
and
local material erosion is > 0.5 mm.
3.6 Remove friction rust with fine emery cloth and carefully smooth material build-up of uncritical
friction rust marks.
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Cylinder Liner A5.05. 03.04.01.10
30000, 15000, 45000

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the cylinder liner, replace the O-ring

2. Install the cylinder liner
M 20 C Cylinder liner mounting device, con- W1 2.9216 A

sisting of:
Traverse, upper W1.1 2.9216-001
Traverse, lower W1.2 2.9216-001
Lifting rod W1.3 2.9216-002
Hexagon nut W1.4
M 25 C / M 25 E Cylinder liner mounting device, con- W1 259216 E

sisting of:
Traverse, upper W1.1 259216-201

Traverse, lower W1.2 259216-202
Lifting rod W1.3 259216-102
Hexagon nut W1.4

M 32 C / M 32 E Cylinder liner mounting device, con- W1 9.9216 E
sisting of:
Traverse, upper W1.1
Traverse, lower W1.2

Lifting rod W1.3
Hexagon nut W1.4
* or equivalent product
** optional / not included in the standard tool kit
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30000, 15000, 45000
03
M 34 DF Cylinder liner mounting and removal W1 342249 A

device, consisting of:
Lifting rod W1.3
Hexagon nut W1.4
M 43 C Cylinder liner mounting device, con- W1 439216-A

sisting of:
Traverse, upper W1.1 439216-101
Traverse, lower W1.2 439216-103

Lifting rod W1.3 439216-102
Lifting eye nut W1.5 439216-104
M 46 DF Cylinder liner mounting and removal W1 462229-A

device, consisting of:
Lifting rod W1.3

Lifting eye nut W1.5
M 20 C / M 25 C Petro Gel Amber *

M 25 E / M 32 C
M 32 E / M 34 DF Textile round sling **
M 43 C / M 46 DF
CAUTION
Risk of damage to the sealing and contact surface of the cylinder liner!
While extracting and inserting the cylinder liner (1/1) the sealing and contact surface
is especially endangered.
Therefore, the sealing and contact surface of the cylinder liner (1/1) must be protected
against any damage!
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30000, 15000, 45000
1. Remove the cylinder liner, replace the O-ring 03

1.1 Remove the piston of the cylinder unit to be
serviced (A5.05.02.06.01.nn).
1 W1.5 W1.1
3
1.2 Install the cylinder liner mounting device
(1/W1):
8 2
1.2.1 Firmly connect both traverse halves (1/W1.1,
W1.2) with the lifting rod (1/W1.3) and the
hexagon nut (1/W1.4) [for M 43 C and
M 46 DF eye nut, 1/W1.5]. In doing so, make
sure that the collar of the cylinder liner (1/1) is
not damaged.
CAUTION
Risk of engine damage due to
incomplete installation!
Depending on the equipment and
engine type, a compensation ring
may be inserted in the contact surface 4
(1/8) of one or several cylinder units.
Upon removal, these cylinder units
with the related compensation rings
must be marked in order to prevent
any interchanges upon reassembly.
1.3 Attach the cylinder liner mounting device

(W1) with a textile sling to the crane, extract
the cylinder liner (1/1) from the engine block,
place it onto a suitable support and secure it
to prevent shifting / tilting.
1.4 Remove and mark the compensation ring (1/

8), if any.
1.5 Take the O-ring (1/2) out of the cooling collar

5 W1.2 W1.4 W1.3
(1/3).
1 Schematic diagram
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30000, 15000, 45000
2. Install the cylinder liner 03
NOTE
Before installing a new cylinder liner a measurement has to be carried out
(A5.05.03.03.01.nn).
Observe the running-in instructions (engine documentation, chapter “Operating
Instructions“)!
2.1 Clean the cylinder liner landing, the upper and the lower fit (1/4) in the engine block (1/5).
2.2 Clean the inside of the cooling collar (1/3), the groove of the O-ring (1/2) and the cylinder liner (1/
1).
2.3 Check all sealing and contact surfaces of the engine block (1/5) and the cylinder liner (1/1) as well
as the upper and lower fit (1/4) in the engine block (1/5) for damage and fretting
(A5.05.03.03.01.nn).
Remove slight friction rust with fine emery cloth and carefully smooth material build-up of
uncritical friction rust marks.
2.4 If applicable, insert the compensation ring (1/8) provided for this cylinder unit.
2.5 Coat the new O-ring (1/2) with Petro Gel Amber and insert it untwisted into the groove of the
cooling collar (1/3).
2.6 Install the cylinder liner mounting device (W1) on the cylinder liner (1/1) as under 1.2.1.
2.7 Attach the cylinder liner mounting device (W1) with a textile sling to the crane and carefully
introduce the cylinder liner (1/1) into the engine block (1/5).
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30000, 15000, 45000
2.8 Insert the cylinder liner (1/1) so that the marking (2/6) on the cylinder liner collar points in 03
longitudinal direction towards the driving end.
NOTE
The marking (2/7) on the cooling collar (2/3) serves as an alignment aid.
3
X
2
X
7 6
2 Schematic diagram
2.9 Introduce the cylinder liner (1/1) completely.
NOTE
The cylinder liner (1/1) must slide into the upper and lower fit (1/4) of the engine block
(1/5) by its own weight!
2.10 Install the piston (A5.05.02.06.02.nn).
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30000, 15000, 45000
03
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Engine Fasteners and Connections A5.05. 03.07.01.10
1500, 750
See also: A5.05.06.01.01.nn, A5.05.02.02.01.nn 03

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the engine fasteners and connections for tight fit and leaks
NOTE
This precautionary measure must be completed to identify leaks or loose bolted
connections. "Settling“ connecting elements or seals may cause leaks which may
lead to subsequent damage.
The items described in the following are a guide to exclude most of the sources of
defects that may occur.
1. Check the engine fasteners and connections for tight fit and leaks
1.1 Check the flange connections of the engine connection points, filters, etc. and the pipe brackets
of the following systems for tight fit and leaks:
• Cooling water
• Lubricating oil
• Fuel
• Gas pipes (gas and dual fuel engines only)
• Starting and control air
• Pneumatic control (emergency stop)
• Exhaust gas incl. turbocharger
• Hydraulic system for waste gate or VTG drive (gas engines only)
• Actuators for waste gate and by-pass (optional)
• Electrical connections (sensors)
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Engine Fasteners and Connections A5.05. 03.07.01.10
1500, 750
1.2 Check the fastening screws of the bearing brackets for the control shaft of the injection pump and 03
check the connecting joints (does not apply to gas engines).
1.3 Check the control and monitoring devices for tight fit. Cables and impulse lines must not chafe.
1.4 Check the expansion joints for leaks and the exhaust line for proper suspension
(A5.05.06.01.01.nn).
1.5 For gas and dual fuel engines it is additionally required to check the linkage for waste gate or
VTG drive.
1.6 Check the connection flanges as well as the covers, brackets, and connection pieces of the char-
ge air cooler for tight fit.
1.7 Check the base frame fastening by tapping. After tightening loose foundation bolts (contact your
authorized Caterpillar workshop to obtain the tightening values) measure crank web deflection
(A5.05.02.02.01.nn).
1.8 Check the resilient mounting for damage.
NOTE
During engine operation it is required to pay regular attention to possible leaks.
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Camshaft Bearing A5.05. 04.01.01.10
See also: A5.05.04.04.01.nn 04

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check of the end clearance of the camshaft gear wheel

2. Check of the bearing clearance of one camshaft bearing
3. Check of the bearing clearance of all camshaft bearings
4. Check of the running surfaces of one camshaft bearing
5. Check of the running surfaces of all camshaft bearings
Engine Type Tools and Auxiliary Materials Index Ord. No.
M 20 C - VM 46 DF Feeler gauge 1.9075-003 *
* no picture
Secure the engine to prevent unintentional starting.


Gas engine:
- Remove the key.
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04
CAUTION
The camshaft bearings (Fig. 2/1) between the gear wheel (2) and camshaft section
(3) of the first cylinder unit may only be removed and installed by the Caterpillar
Customer Service Support!
CAUTION
For an evaluation of the running surfaces of the camshaft bearing shells (Fig. 2/4)
please contact your Caterpillar dealer.
NOTE
The camshaft bearings are not subjected to any load changes. The bearings are
subjected to load exclusively in the lower contact area, where load is relatively high.
Slight contact marks at the edges are normal.
1. Check of the end clearance of the camshaft gear wheel
1.1 For in-line engines only

Remove the camshaft gear wheel cover.
1.2 For V-engines only

Remove the camshaft gear wheel covers.
1.3 Measure the end clearance “S“ between cover (Fig. 1/1) and thrust washer (2) (see Table, End
Clearance “S“).
End clearance “S”
End Clearance “S” in 1 2

Engine Type
mm
M 20 C 0.30 - 0.70
M 25 C / M 25 E 0.30 - 0.80
M 32 C / VM 32 C 0.50 - 0.95
M 32 E / M 34 DF
GCM 34
M 43 C / M 46 DF 0.80 - 1.30
VM 43 C / VM 46 DF 0.60 - 1.20
1.4 When the end clearance “S“ is exceeded,

please contact your Caterpillar dealer.
Schematic diagram
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2. Check of the bearing clearance of one camshaft bearing 04
1 4 3 5
Schematic diagram
2.1 Remove the corresponding camshaft covers (A5.05.04.04.01.nn, Activity: 1. Removal of the
camshaft section).
2.2 Measure the camshaft bearing clearance between camshaft bearing shell (Fig. 2/4) and bearing
journal (5) with the feeler gauge.
2.3 Compare the measured camshaft bearing clearance to the values of the table:
Engine Type Clearance in New

Limit Clearance
Condition
in mm
in mm
M 20 C 0.11 - 0.165 0.22
M 25 C / M 25 E 0.20 - 0.26 0.35
M 32 C / VM 32 C 0.20 - 0.27 0.38

M 32 E / M 34 DF
GCM 34
M 43 C / VM 43 0.26 - 0.32 0.50
2.4 When the limit value is reached or exceeded, check the camshaft bearing clearance of all other
camshaft bearings and replace the camshaft bearing shell (4).
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3. Check of the bearing clearance of all camshaft bearings 04

3.1 Activity 2. Carry out the check of the bearing clearance of one camshaft bearing for all
camshaft bearings.
4. Check of the running surfaces of one camshaft bearing
4.1 Remove the corresponding camshaft bearing shell (Fig. 2/4) (A5.05.04.04.01.nn, Activity: 1.
Removal of the camshaft section).
4.2 Check the camshaft bearing:
4.2.1 Check the running surface of the camshaft bearing shell (4) for:
- poor running pattern (in the lower contact area),
- contact marks at the edges, and
- formation of score marks.
If necessary, replace the camshaft bearing shell (4).
4.2.2 Check the back of the camshaft bearing shell (4) for grinding marks and replace the shell, if
necessary.
4.2.3 Check the running surface of the bearing journal (5) (of the related camshaft bearing shell) for
score marks.
4.2.4 If necessary, replace the camshaft section (3) (or the bearing journal).
4.3 Install the bearing shell (4) and the camshaft section (3) (A5.05.04.04.01.nn, Activity: 2.
Installation of the camshaft section).
5. Check of the running surfaces of all camshaft bearings
5.1 Activity 4. Carry out the check of the running surfaces of one camshaft bearing for all
camshaft bearings.
Lift the measures for securing the engine to prevent unintentional starting.


Gas engine:
en / 02.01.2015 4/4
30000, 15000
See also: A5.05.04.04.01.nn, A5.05.04.09.01.nn 04

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- Check the running surface of one camshaft bearing and

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

camshaft sections from the first cylinder onwards
Tools:
Refer to A5.05.04.04.01.nn
NOTES
For an evaluation of the bearing shell running surfaces please contact your autho-
rized Caterpillar dealer.
NOTE
Camshaft bearings are not subject to load changes. The bearing load is exclusively in
the lower supporting area and is relatively high there. Slight carrying by the edges is
not unusual.
CAUTION
The camshaft bearings between the camshaft gear wheel and first cylinder are only
allowed to be disassembled and reassembled by Caterpillar-customer service!
1. Inspection of the running surface of one camshaft bearing and the corresponding
camshaft section from the first cylinder onwards.
1.1 Relieve and lift the rocker arm of the camshaft section of the respective cylinder and all camshaft
sections located on the right (A5.05.04.04.01.nn).
en / 02.01.2015 1/4
30000, 15000
1.2 Loosen the hexagon bolts (Fig. 1/1) on the left-hand flange of the camshaft section (2). 04
Turn the camshaft to loosen hidden hexagon bolts, and then remove all hexagon bolts.
1 1 3
5 1
NOTE
When removing the hexagon bolts, pay attention that the injection cam stands verti-
cally upwards after the last turning process (TDC).
CAUTION
The camshaft is only allowed to be turned with loosened screw connections if
-the rocker arms of the camshaft section to be replaced as well as all rocker arms lo-
cated to the right are relieved and
-the pin (5) has been pulled out of the bearing journal (6) / the fitted left-hand cams-
haft section!
1.3 Mount the buffer for the camshaft

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

(43), hexagon nut (42) and guide pin (40)
and set maximum displacement
of s (A5.05.04.04.01.nn).
40
37
Displacement s = 50 ± 0.5 mm
41
1.3.2 Tighten the hexagon nut and pull the 42
vibration damper with the loosened
camshaft onto the limit plate (41). The
camshaft is secured against axial
displacement.
s
44 43 W3
2
en / 02.01.2015 2/4
30000, 15000
04
CAUTION
Do not use force during displacement! If there is any binding, check the floating of the
rocker arms! The engine can be turned over again!
NOTE
To check the last camshaft bearing, fit the extractor to the last camshaft section
(A5.05.04.04.01.nn). Remove the vibration damper (A5.05.04.09.01.nn) and push it
to the right as far as possible!
1.4 Check the camshaft bearing and replace it (A5.05.04.04.01.nn) in the event of:
- bad contact reflection (running surface; lower contact area)

- edge contacts
- scoring.
For an evaluation of the bearing shell running surfaces please contact your authorized
Caterpillar dealer.
1.5 Check the fixation of the camshaft bearing. The cheese head screw (Fig. 2/37) at the bearing
point of the camshaft bearing to be checked must be tightened at a torque of
M = 100 Nm (74 Ib ft).
If necessary, remove the loosened cheese head screw and support the respective camshaft sec-
tion.
1.5.1 Push the camshaft bearing out to the left using a suitable piece of wood. Check for signs of abra-
sion on the back of the bearing and replace it if necessary (A5.05.04.04.01.nn).
1.6 Check the running surfaces of the bearing flanges of all accessible camshaft sections for scoring.
1.7 Replace defective camshaft sections and check the corresponding camshaft bearing
(A5.05.04.04.01.nn).
1.8 Mount the camshaft and remove the buffer for the camshaft (A5.05.04.04.01.nn).
NOTE
After checking the last camshaft bearing, remove the extractor for the camshaft
section on the last camshaft section (A5.05.04.04.01.nn) and mount the vibration
damper (A5.05.04.09.01.nn)!
en / 02.01.2015 3/4
30000, 15000
2. Check the running surfaces of all camshaft bearings and camshaft sections from the first 04
cylinder onwards.
2.1 Relieve and lift all rocker arms (A5.05.04.04.01.nn).
2.2 Loosen the hexagon bolts (Fig. 1/1) on the left-hand flange of the camshaft section (2) of the first
cylinder. Make the hidden hexagon bolts accessible by turning the camshaft. Loosen them
and remove all hexagon bolts.
2.3 Mount the buffer for the camshaft (Fig. 2/W3) and pull the camshaft off the bearing journal (Fig. 1/
6) (1.3 to 1.3.2).
2.4 Support the vibration damper and camshaft section of the first cylinder.
2.5 Remove the cheese head screws (Fig. 2/37) at the bearing points of the camshaft.
2.5.1 Press out the respective camshaft bearing to the left using a suitable piece of wood. Check it (1.4;
1.5.1) and replace it if necessary (A5.05.04.04.01.nn).
2.6 Check the running surfaces of the bearing flanges of all camshaft sections for scoring.For an
evaluation of the bearing shell running surfaces please contact your authorized Caterpillar dealer
2.7 Replace defective camshaft sections (A5.05.04.04.01.nn).
2.8 Mount the camshaft and remove the buffer for the camshaft (A5.05.04.04.01.nn).
2.9 Remove the turning rod, dismount the turning device.
2.10 Relieve the device used for supporting the rocker arm. Remove it and carry out final work
(A5.05.04.04.01.nn).
en / 02.01.2015 4/4
c2 Lower Valve Drive
Maintenance / Removal and Installation
A5.05. 04.02.00.10

Spare parts sheets:
Personnel qualification: Skilled engine hand / assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Lower valve drive - removal

2. Lower valve drive - installation
M 20 C Torque wrench 40 - 200 Nm W2 1.9454-200 *
Reversible ratchet W3 1.9495-033 *
M 25 C / M 25 E Mounting and removal device for lower valve drive W1 251045 A

consisting of: 2x guide bolt
Torque wrench 60 - 320 Nm W2 1.9454-320 *
M 20 C Textile sling */***
* no picture
CAUTION
Malfunction due to interchanged push-rods!
Risk of damage to the engine!
• Before removal, make a note of the position (cylinder number, inlet/exhaust) of
the push-rods to ensure that each push-rod is fitted at its original position upon
reinstallation.
CAUTION
Malfunction due to interchanged shims!
Risk of damage to the engine due to changed NOx settings!
• Before removing several lower valve drives make a note of the positions of the
shims under the valve drives to ensure that each shim is fitted at its original
position upon reinstallation.
en / 04.03.2019 1/4
A5.05. 04.02.00.10
04
NOTE
This job card exclusively describes the removal and installation of the complete lower
valve drive. For exchanging individual components or replacing the complete lower
valve drive, please contact your authorized Caterpillar dealer.


• Switch off and block the fuel supply to
the engine.
• Switch off cooling water preheating. 1
• Switch off the lubricating oil stand-by
pump / prelubrication pump.
lever (if provided).
1.2 Engage the barring device.
1.3 Open all indicator valves / decompression

valves (M 20 C) by means of the socket
wrench (W4).
1.4 Remove the camshaft cover and the valve

cover of the cylinder unit to be serviced.
1.5 Bar the cylinder unit to be serviced to

ignition TDC so that the inlet and exhaust 1 Schematic diagram
1.6 Remove the rocker arm bracket

(A5.05.01.02.01.nn) of the cylinder unit to
be serviced.
1.7 Mark the push-rods (1/1) and their

positions in the engine.
1.8 Take out the push-rods.
1.9 Continue to bar the engine until the

injection pump drive is relieved (Fig. 2).
1.10 Remove the injection pump with injection

pump drive (A5.05.07.02.01.nn).
2 Schematic diagram
en / 04.03.2019 2/4
A5.05. 04.02.00.10
1.11 For M 20 C only 04

Remove the lower hexagon socket head
cap screws (3/1).
1.12 For M 25 C / M 25 E only:

Remove the lower hexagon socket head
cap screws (3/1) and replace them by
guide bolts (W1/no figure), tighten these
finger tight.
1.13 Attach the lower valve drive to the crane

by means of the textile sling and lightly
1
pull.
1.14 To avoid damage to the track rollers upon

removal of the lower vale drive, suitable
3 Schematic diagram
protection of the cam followers (5/1) must
be provided, e.g. by means of a rubber
mat.
1
1.15 Remove the upper hexagon socket head
cap screws (4/2) with the related shims (4/
1).
1.16 For M 25 C / M 25 E only:

Pull the lower valve drive up to the end of
the guide bolts (W1).
1.17 Lift out the lower valve drive and place it

onto a suitable base. In doing so, make
sure at any moment that the track rollers 2
are not damaged!
4 Schematic diagram
1.18 If applicable, remove the guide bolts.
5 Schematic diagram
en / 04.03.2019 3/4
A5.05. 04.02.00.10
2. Lower valve drive - installation 04

2.1 Inspect all supporting surfaces and contact points for cleanliness and damage. Before installation,
apply a thin coat of Molykote to all screw threads.
2.2 For M 25 C / M 25 E only:

Insert the guide bolts (W1/no figure) into the two lower fixing holes of the engine block and tighten
them finger tight.
2.3 Attach the lower valve drive with the textile sling to the crane, lift the cam followers (5/1) and
carefully position the lower valve drive.
2.4 Insert the shims (4/1) with the lug pointing upwards.
2.5 Preinstall the upper hexagon socket head cap screws (4/2) so as to be finger tight.
2.6 For M 25 C / M 25 E only:

Remove the guide bolts (W1/no figure).
2.7 Preinstall the lower hexagon socket head cap screws (3/1) so as to be finger tight.
2.8 Tighten the hexagon socket head cap screws (3/1 and 4/2) crosswise in several steps
with a torque of 130 Nm.
2.9 Insert the push-rods (1/1) according to the marking.
2.10 Install the injection pump drive with injection pump (A5.05.07.02.01.nn).
2.11 Close all indicator valves / decompression valves by means of the socket wrench (W4).
2.12 Install the rocker arm bracket (A5.05.01.02.01.nn).
2.13 Check the valve clearance (A5.05.01.01.01.nn) and adjust it if necessary.
2.15 Start the prelubrication pump. Check the oil tubes for leaks.
2.16 Install the camshaft cover.

en / 04.03.2019 4/4
c2 Lower Valve Drive FCT
A5.05. 04.02.00.11

Spare parts sheets:
Personnel qualification: Skilled engine hand / assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Activities:

2. Lower valve drive - installation
M 25 C / M 25 E Mounting and removal device for lower valve W1 251045 A

driveconsisting of: 2x guide bolt
Socket wrench for indicator valve W2 1.9100-060
Textile sling */***
* no picture
WARNING
Risk of injury due to spring tension!
Before removing a unit of the lower valve drive the spring of the FCT adjusting unit
must be relieved.
Improper handling or using a defective tool may lead to severe injuries due to
crushing.
• Check the tool for possible damage before each use.
• Strictly follow the job instructions.
CAUTION
• Before removal, make a note of the position (cylinder number, inlet/exhaust) of
the push-rods to ensure that each push-rod is fitted at its original position upon
reinstallation.
en / 04.03.2019 1/6
A5.05. 04.02.00.11
04
NOTE
This job card exclusively describes the removal and installation of the complete lower
valve drive. For exchanging individual components or replacing the complete lower
valve drive, please contact your authorized Caterpillar dealer.


• Switch off cooling water preheating.

1
1.3 Open all indicator valves by means of the
socket wrench (W2).
1.4 Remove the camshaft cover and the valve

cover of the cylinder unit to be serviced.
1.5 In case of work being carried out on the

first cylinder unit, remove the adjusting
unit (A5.05.04.02.10.nn).
1.6 Bar the cylinder unit to be serviced to

ignition TDC so that the inlet and exhaust
1.7 Remove the rocker arm bracket

(A5.05.01.02.01.nn) of the cylinder unit to
be serviced.
1 Schematic diagram
1.8 Mark the push-rods (1/1) and their
positions in the engine.
1.9 Take out the push-rods.
1.10 Continue to bar the engine until the

injection pump drive is relieved (Fig. 2).
1.11 Remove the injection pump drive with

injection pump of the cylinder unit to be
serviced (A5.05.07.02.01.nn).
1.12 Relieve the spring of the adjusting unit

(A5.05.04.02.10.nn).
2 Schematic diagram
en / 04.03.2019 2/6
A5.05. 04.02.00.11
1.13 Remove the locking plates (3/2) and push 1 04

the oil shafts (3/1) into the adjacent lower
valve drives.
1.14 Remove the lower hexagon socket head

cap screws (4/1) and replace them by the
guide bolts (5/W1), tighten these finger
tight.
1.15 Remove the upoer hexagon socket head

cap screws (5/1). 2
1.16 To avoid damage to the track rollers upon

removal of the lower vale drive, suitable 3 Schematic diagram
protection of the cam followers (5/2) must
be provided, e.g. by means of a rubber
mat.
1.17 Pull the lower valve drive up to the end of

the guide bolts (6/W1) and secure it
axially so as to prevent the bearing
brackets from slipping off the cam follower
shaft. This may be done e.g. by means of
wire.
1.18 Attach the lower valve drive to the crane

by means of a textile sling.
1.19 Lift out the lower valve drive and place it 1

onto a suitable base. In doing so, make
sure at any moment that the track rollers 4 Schematic diagram
are not damaged.
1
W1
W1
6 Schematic diagram
5 Schematic diagram
en / 04.03.2019 3/6
A5.05. 04.02.00.11
2. Lower valve drive - installation 04

2.1 Inspect all supporting surfaces and contact points for cleanliness and damage. Before installation,
apply a thin coat of Molykote to all screw threads.
2.2 Insert the guide bolts (W1) into the two lower fixing holes of the engine block and tighten them
finger tight.
2.3 Attach the lower valve drive with the textile 1

sling to the crane and push the lower
valve drive onto the two guide bolts (6/
W1). In doing so, make sure that the
grooves (7/1) in the bearing brackets are
located at the top.
2.4 Remove the textile sling and the axial

securing device and position the lower
valve drive by hand with lifted cam
followers (5/2).
2.5 Preinstall the upper hexagon socket head

cap screws (5/1) so as to be finger tight.
7 Schematic diagram
2.6 Remove the guide bolts (6/W1) and replace
them by the lower hexagon socket head cap screws (4/1).
2.7 Preinstall the lower hexagon socket head cap screws (4/1) so as to be finger tight.
2.8 Tighten the hexagon socket head cap screws (4/1 and 5/1) crosswise in several steps with a
torque of 130 Nm.
CAUTION
Malfunction due to wrongly positioned lower valve drives!
• Before installing the oil shafts, make sure that the alignment holes (8/2) of the cam
follower shafts of all lower valve drives are in the same position.
1
A-A
2
A
8 Schematic diagram
en / 04.03.2019 4/6
A5.05. 04.02.00.11
2.9 Introduce the oil shafts (9/2) into the cam 1 04

follower shaft and install the locking plates
(9/3). In doing so, make sure that the
locking plates exactly engage in the
grooves (9/1) of the oil shaft.
Tighten the screws for the locking plates 2
2.10 Insert the push-rods (8/1) according to the

marking.
2.11 Install the injection pump drive with

3
injection pump (A5.05.07.02.01.nn).
2.12 Close all indicator valves by means of the

socket wrench (W2).
9 Schematic diagram
2.13 Install the rocker arm bracket
(A5.05.01.02.01.nn).
2.14 Check the valve clearance (A5.05.01.01.01.nn).
2.15 If applicable, install the adjusting unit (A5.05.04.02.10.nn).
2.17 Start the prelubrication pump. Check the oil tubes for leaks.
2.18 Install the camshaft cover.

en / 04.03.2019 5/6
A5.05. 04.02.00.11
04
en / 04.03.2019 6/6
c2 Adjusting Unit FCT
A5.05. 04.02.10.10
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the FCT adjusting unit

2. Install the FCT adjusting unit
M 25 C / M 25 E Torque wrench 20 - 200 Nm W1* 1.9454-202
Eye bolts M16 (2x) W2 ***
* no picture
NOTE
In the following, an engine turning counter-clockwise will be shown. On an engine
turning counter-clockwise the threaded connection of the spring is located above the
spring.
Deviations and specifics will be described as necessary.
The direction of rotation of your engine is indicated in the Engine Documentation,
chapter “Technical Engine Data” -> Engine Configuration.
1. Remove the FCT adjusting unit


en / 14.01.2020 1/6
A5.05. 04.02.10.10
04
WARNING
Risk of injury due to compressed air!
Suddenly escaping compressed air may cause injuries.
• Prior to the beginning of each disassembly close the supply air lines and
depressurize the compressed air system.In doing so, close the ball valve.
1.2 Engage the barring device and secure it 1
against unintentional operation.
2
1.3 Close the ball valve (1/3). Disconnect the
air supply (1/4) to the FCT adjusting unit.
1.4 Disconnect the electrical lines to the FCT 3

adjusting unit.
1.5 Remove the claddings (1/1, 2) of the

spring and the lever.
4
WARNING
Risk of injury due to pre-
loaded components!
The spring of the FCT adjusting 2 1 Schematic diagram
unit may suddenly relax when
loosening the threaded connec-
tion in an improper manner and
cause most serious injuries.
• Loosen the nuts slowly, even-
ly, and carefully.
1.6 Relieve the spring (2/1) by evenly

loosening the nuts (2/2).
1
2 Schematic diagram
en / 14.01.2020 2/6
A5.05. 04.02.10.10
1.7 Screw two eye bolts (3/1) to the FCT 04

adjusting unit.
1.8 Attach the FCT adjusting unit via the two

eye bolts to the crane and lightly pull.
1.8.1 Remove all the hexagon bolts (4/1) with

extension sleeves.
1.8.2 Capture the FCT adjusting unit with the

crane and carefully pull it off the engine
block. 1
The parallel pins (5/1) and the rubber
profile (5/2) on the rear side of the FCT 3 Schematic diagram
adjusting unit must not be damaged.
1.9 Carefully place the FCT adjusting unit onto a suitable base making sure it does not rest on the
compressed air cylinder (4/2).
1
2
2
4 Schematic diagram 5 Schematic diagram
en / 14.01.2020 3/6
A5.05. 04.02.10.10
2. Install the FCT adjusting unit 04
NOTE
Each time an FCT adjusting unit is reinstalled make sure the setting positions of the
FCT adjusting unit and the cam follower shaft are matching.
• For an engine turning counter-clockwise both must be at Normal position (PN).
• (For an engine turning clockwise: Early position (PE).
2.1 Check the setting position of the cam

follower shaft:
• For an engine turning counter-

clockwise, with Normal position (PN),
the end stop (6/1) rests against the
bracket (6/2) on the outside.
• (On an engine turning clockwise , with 1
Early position (PE), the end stop (6/1) 2
also rests against the bracket (6/2) on
the outside.
• Fix the end stop, e.g. by means of a
6 Schematic diagram
screw clamp.
2.2 Attach the FCT adjusting unit via the two

eye bolts (3/1) to the crane.
2.3 Check the sealing and contact surfaces of the FCT adjusting unit and the engine block for
damage, smooth with an oil stone if necessary.
NOTE
If the rubber profile is crushed or otherwise damaged, replace it.
2.4 Apply a thin coat of Petro Gel Amber to the rubber profile (5/2) and insert it untwisted into the
groove.
2.5 Check the parallel pins (5/1) for damage, replace them by new parallel pins if necessary.
2.6 Make sure the spring of the adjusting unit is relieved.
en / 14.01.2020 4/6
A5.05. 04.02.10.10
2.7 Bring the lever of the FCT adjusting unit into position (see Fig. 7): 04
• For an engine turning counter-clockwise move the lever upward (Normal position (PN).
• For an engine turning clockwise move the lever upward (Early position (PE).
7 Schematic diagram
2.8 Apply a thin coat of Molykote to the thread of the hexagon bolts (4/1).
2.9 Using the crane, carefully put the FCT adjusting unit in place at the engine block and position it by
means of the parallel pins (5/1). The parallel pins and the rubber profile (5/2) on the rear side of
the FCT adjusting unit must not be damaged.
2.10 Insert the hexagon bolts (4/1) with extension sleeves and lightly tighten them crosswise.
2.11 The gear of the FCT adjusting unit must mesh with the gear of the cam follower shaft. Move the
lever slightly to check for correct seating, correct if necessary.
2.12 Check the markings for Normal position (PN) on the bearing cap and the lever (see Fig. 7).
(On an engine turning clockwise check the Early position (PE).)
2.13 Tighten the hexagon bolts (4/1).
en / 14.01.2020 5/6
A5.05. 04.02.10.10
2.14 Tension the spring (9/3) by evenly and 1 2 04

alternately tightening the nuts (9/2) until
the clamp (9/1) is in full contact with the
plate (9/4) and rests on it flat. Tighten the
nuts.
4
2.15 Fasten the claddings (1/1, 2) of the spring
and the lever.
2.16 Connect the electrical lines.

3
2.17 Reestablish air supply (1/4). Open the ball
valve (1/3).
2.18 Disengage the barring device. 8 Schematic diagram
2.19 Lift the measures for securing the engine

to prevent unintentional starting.

en / 14.01.2020 6/6
c2 FCT Adjusting Unit
Maintenance / Lubrication
A5.05. 04.02.12.10
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Lubrication of the FCT adjusting unit
All engine types Grease gun W1 *

with FCT techno- **
logy
* no picture
1. Lubrication of the FCT adjusting unit

1
CAUTION
2
Risk of crushing during
switching of the FCT adjusting
unit!
While carrying out the jobs
described in the following it has
to be ensured that the FCT
adjusting unit does not switch.
Do not carry out any work during

periods in which the engine is
ramped up or down.
1.1 Dismantle cladding (Fig. 1/1 and 2).
Schematic diagram
en / 01.12.2015 1/2
c2 FCT Adjusting Unit
Maintenance / Lubrication
A5.05. 04.02.12.10
1.2 Lubricate the bearing of the pneumatic 04

cylinder and the joint head via the lubri- 4 5
cating nipples (Fig. 2/3 and 4) by means of
a grease gun.
1.3 Grease the points of contact of the spring

(5) to other components well by means of
a brush. 6
1.4 Lightly grease the thrust rod (6).
1.5 Install the cladding (Fig. 1/1 and 2).
Schematic diagram
en / 01.12.2015 2/2
Camshaft A5.05. 04.04.01.10

A5.05.04.09.01.nn, A5.05.04.01.02.nn
Spare parts sheets:


--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the camshaft section

2. Installation of the camshaft section
Inde
Engine Type Tools and Auxiliary Materials Tool No.
x
M 20 C Socket wrench for relief valve W1 1.9100-060 *
Torque wrench 40-200 Nm W2 1.9454-200 *
Barring rod W7 2.9100-380 *

M 25 E

M 32 E
M 34 DF Torque wrench 40-180 Nm W2 1.9454-040 *


M 46 DF
Mounting/removal device for camshaft section, W6 432032 A

consisting of:
Bolts (2x) W6.1
Round sling (textile) 2.5 m W5.2
* no picture
en / 02.01.2015 1/14
Camshaft A5.05. 04.04.01.10
04
Inde
x
M 20 C - M 32 C Mounting/removal device for camshaft section W5 1.9321 D

(for M 20 C engines not included in the tool kit),
consisting of:
Stopper plate (2 x) W5.1

Round sling (textile) 2.5 m W5.2
Shackle W5.3 *
M 20 C - M 46 DF Molykote paste “G-Rapid Plus“ ***

**
* no picture
1. Removal of the camshaft section


CAUTION
After loosening the threaded connections the camshaft may only be barred
when
- The lower valve drive of the camshaft section to be replaced as well as all valve
drives located to the right of it have been removed.
NOTE
In rare cases there is a chance that the camshaft section cannot be turned out
although all removal steps have been appropriately carried out.
In such a case please contact your authorised Caterpillardealer.
en / 02.01.2015 2/14
Camshaft A5.05. 04.04.01.10
04
Y Z
13 3
Y Z W5.1
1
5 (M25C/M32C
M25E/M32E/M34DF)
W6.1
(M43C/M46C)
s
Schematic diagram
1.2 Open all indicator valves (if existing).
1.3 Remove all camshaft covers on the camshaft side and, if necessary, also the cover of the
vibration damper.
1.4 Engage the barring device (A5.05.12.08.01.nn).
1.5 Remove the rocker arm bracket of the cylinder to be serviced and the rocker arm brackets of all
cylinder units located to the right of it for relieving the camshaft (A5.05.01.02.01.nn).
en / 02.01.2015 3/14
Camshaft A5.05. 04.04.01.10
04
CAUTION
Before removal, the push-rods and their positions in the engine must be marked to
ensure that the push-rods are inserted at their original positions upon reinstallation.
1.6 First, mark the push-rods of the camshaft section of the cylinder unit to be serviced and the push-
rods of all cylinder units located to the right of it to prevent any interchanges and then remove
them.
1.7 Remove the injection pump of the cylinder unit to be serviced and the injection pumps of all
cylinder units located to the right of it (A5.05.07.02.01.nn).
1.8 Remove the lower valve drive of the cylinder unit to be serviced and the lower valve drives of
all cylinder units located to the right of it (A5.05.04.02.00.nn).
1.9 For removal of the last and next to last camshaft section:
1.9.1 Remove the vibration damper (Fig. 2/10) 10

(A5.05.04.09.01.nn).
1.9.2 Remove the intermediate piece (12).
11
CAUTION 12
Risk of damage by tilting the

camshaft section!
When attaching the round sling
to the camshaft section pay
attention to the location of the 4
centre of gravity!
Schematic diagram
en / 02.01.2015 4/14
Camshaft A5.05. 04.04.01.10
1.10 Place the round sling (Fig. 3/W5.2) between the injection cam and the adjacent cam around the 04
camshaft section (3). Attach the other end of the noose to the crane through the push-rod duct of
the exhaust push-rod, the cooling collar, and the cylinder head.
W5.2
Schematic diagram
3 11
1.11 Pull the crane slightly so that it carries the weight of the camshaft section.
1.12 Remove the locating screw (11).
1.13 Using a device of suitable material and a rubber hammer drive out towards the right-hand side
the right camshaft bearing (Fig. 1/4/ Fig. 3/4) of the camshaft section to be removed and place
it onto the camshaft section.
1.14 Loosen the threaded connections except for two opposite connections (Fig. 1/1) on both flanges
(bearing journals) of the camshaft section (3).
CAUTION
In the following step the two stopper plates (
W5.1/ M 25 C and M 32 C, M 32 E, M 34 DF) or the bolts (W6.1/ M 43 C and M 46 DF)
must be installed so that the remaining camshaft (Fig. 3/3) cannot slip out of its bearings
during the maintenance work or the needed removal distance can be adjusted.
en / 02.01.2015 5/14
Camshaft A5.05. 04.04.01.10
1.15 For M 25 C / M25 E and M 32 C/ M 32 E / M34 DF only: 04

Install the two stopper plates (Fig. 1/W5.1) on both sides on a camshaft bearing (contrary to the
figure, not on the camshaft section to be removed) in direction of displacement. To this end
remove one or, if necessary, two threaded connections (Fig. 1/1) and bolt down with the stopper
plates (W5.1) as shown in Fig. 1.
1.16 For M 43 C and M 46 DF only (Fig. 1/ view “Z”):

Replace the two opposite hexagon bolts on the left camshaft section flange by bolts (W6.1) and
adjust dimension s = 68 mm.
1.17 Place suitable material for protection around the bearing journal of the camshaft section.
1.18 Line the camshaft casing with suitable material for protecting the camshaft section.
1.19 Now carefully loosen the two remaining left threaded connections, do not yet remove them
completely, because the remaining camshaft sections of M 43 C and M 46 DF could slip out of the
bearings. For M25 C / M25 E and M 32 C/ M 32 E / M 34 DF this is prevented by means of the
CAUTION
Risk of damage to the bearing and bearing journal!
Do not use any force when displacing the camshaft!
Generally, care has to be taken to ensure that the remaining camshaft remains
supported and cannot completely slip out of the bearings.
stopper plates.
1.20 Shift the remaining camshaft towards the right by means of a solid wooden rod until it reaches
end stop (bolts or stopper plates). Secure/fix the remaining sections on both sides.
NOTE
For M 25 C / M25 E and M 32 C/ M 32 E / M 34 DF only:
If the displacement path for the remaining camshaft is not sufficient to lift out the
camshaft section to be removed, the displacement can be increased by loosening the
stopper plates (Fig. 1/W5.1) and replacing the bolts by longer bolts.
1.21 Remove the remaining threaded connections (Fig. 1/1) of the camshaft section to be removed.
CAUTION
Do not tilt the camshaft section too much!
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Camshaft A5.05. 04.04.01.10
1.22 Pull the camshaft section (Fig. 4/3) towards the left out of the bearing block while 04
simultaneously lowering the crane. In doing so, swivel by 90 and lift it out of the camshaft
casing. Take into account the weight of the section (see table “Weight of the camshaft
sections“).
Weight of the camshaft sections
Engine type Weight in kg
M 20 C approx. 20
M 25 C / M 25 E approx. 50
M 32 C / M 32 E / approx. 77
M 34 DF
M 43 C / M 46 DF approx. 200
1.23 Remove the camshaft bearing (Fig. 4/4) hanging over the section, check the running surfaces
and, if necessary, replace it.
Schematic diagram
en / 02.01.2015 7/14
Camshaft A5.05. 04.04.01.10
2. Installation of the camshaft section 04

2.1 Press the parallel pin (Fig. 5/5) at the corresponding flange index (see following tables) at the
flange of the camshaft section (3) into the flange until reaching end stop.
1 7
3 6
4 5
3 Schematic diagram
5
M 20 C
Camshaft section / cylinder No. 1 2 3 4 5 6 7 8 9
Flange index 6 M 20 C 4 2 3 4 5 6 - - -
Flange index 8 M 20 C 5 2 3 4 5 6 7 8 -
Flange index 9 M 20 C 1 1 2 3 4 4 3 2 1
M 25 C / M 25 E
Flange index 6 M 25 C / 6 M 25 E 5 1 6 5 3 7 - - -
Flange index 8 M 25 C / 8 M 25 E 2 2 3 4 5 6 7 8 -
Flange index 9 M 25 C / 9 M 25 E 5 8 2 6 4 4 6 2 8
M 32 C / M 32 E / M 34 DF
Flange index 6 M 32 C/6 M 32 E/6 M 34 DF 5 1 6 5 3 7 - - -

Flange index 8 M 32 C/8 M 32 E/8 M 34 DF 1 2 3 4 5 6 7 8 -
en / 02.01.2015 8/14
Camshaft A5.05. 04.04.01.10
M 32 C / M 32 E / M 34 DF 04
Flange index 9 M 32 C 5 8 2 6 4 4 6 2 8
M 32 E
Flange index 9 M 32 E / 9 M 34 DF 5 3 8 4 2 2 4 8 3
M 43 C / M 46 DF
Flange index 6 M 43 C / 6 M 46 DF 5 1 6 5 3 7 - - -
Flange index 7 M 43 C / 7 M 46 DF 3 1 2 3 3 2 1 - -
Flange index 8 M 43 C / 8 M 46 DF 4 7 2 5 4 3 6 1 -
Flange index 9 M 43 C 900 kW / cylinder 5 6 2 4 8 8 4 2 6
Flange index 9 M 43 C 1000 kW / cylinder 1 3 8 4 2 2 4 8 3
Flange index 9 M 46 DF 1 3 8 4 2 2 4 8 3
2.2 Clean the camshaft bearing (Fig. 1/4) lubricate it with oil on the inside and outside and place it
onto the right camshaft section.
2.3 Place the camshaft section (3) in direction of the free end onto a suitable base in the camshaft
casing and secure it against rolling away.
2.4 Place the round sling (Fig. 3/W5.2) between exhaust cam and injection cam around the camshaft
section and attach it to the crane through the push-rod duct of the exhaust push-rod, through the
cooling collar, and the cylinder head.
2.5 Slowly raise the crane and carefully guide the bearing journal of the camshaft section into the
bearing bore of the engine block.
CAUTION
Do not tilt the camshaft section too much!
2.6 Align the camshaft section with the parallel pin (Fig. 5/5) with respect to the hole in the bearing
journal or bearing flange of the installed left camshaft section.
2.7 Bolt together the camshaft section and the right camshaft section flange by means of two
opposite bolts (Fig. 1/1) so as to be finger tight.
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Camshaft A5.05. 04.04.01.10
04
2.8 Carefully displace the camshaft by means of a solid wooden rod towards the left until the parallel
pin (5) and the recess are securely holding the camshaft section.
2.9 If necessary, loosen the stopper plates (Fig. 1/W5.1).
CAUTION
Risk of damage to the studs and inlet cam followers
(for M 32 C / M 32 E only)!
Wrongly inserted studs may collide with the cam follower during operation.
Observe the correct installation position of the studs and the thread engagement
depth in the hexagon nuts!
2.10 Use Molykote for all threaded connections (1).

Lubricate the threads and contact surfaces of bolts (and hexagon nuts) with Molykote.
2.11 Insert the bolts (1) at the left flange of the camshaft section (as far as possible) and tighten at
least 3 threaded connections crosswise in steps with a torque of
X Nm (see table “Bolt (1)“).
Holes that are not accessible are to be provided with bolts later!
Bolt (1)
Engine type Torque in Nm
6 / 8 / 9 M 20 C 100
6 / 8 / 9 M 25 C / M 25 E 140
6 / 8 / 9 M 32 C / M 32 E / M 34 DF 210
6 / 8 / 9 M 43 C / M 46 DF 420
7 M 43 C 560
7 M 46 DF (560 Nm = 250 Nm + 30° torque angle)
en / 02.01.2015 10/14
Camshaft A5.05. 04.04.01.10
2.11.1 Alternative tightening instructions for threaded connection (1): 04

Lubricate the threads and contact surfaces of the threaded connections (1) with Molykote and
tighten the bolts (1) or nuts in two steps as follows:
Example for 420 Nm:
Step 1:
Preload bolts to 176 Nm.
Step 2:
Mark the bolts and continue to turn by a torque angle of  = 30° with a ring spanner
(30  1/2 hexagon)
2.12 Remove the stopper plates (Fig. 1/W5.1).
2.13 Align the fixation hole of the camshaft bearing with respect to the hole for the locating
screw (Fig. 2/11) in the engine block. The notch in the bearing shell points upwards.
2.14 Insert the camshaft bearing (4) evenly using a device of suitable material and a rubber hammer.
Do not tilt the bearing. Align the bearing shell with respect to the fixation hole.
2.15 Lubricate the locating screw (11) with Molykote and insert it. Tighten the locating screw with a
torque of X Nm (see table “Locating screw (11)“).
Locating screw (11)
Torque in
Engine type
Nm
6 / 8 / 9 M 20 C 30
6 / 8 / 9 M 25 C / M 25 E 100
6 / 8 / 9 M 32 C / M 32 E / M 34 DF 100
6 / 7 / 8 / 9 M 43 C / M 46 DF 130
2.16 Lower the crane and remove the round sling (Fig. 3/W5.2).
2.17 Install the remaining bolts (Fig. 1/1) on the right and left bearing flange of the camshaft section by
hand (if necessary, bar the engine).
2.18 Tighten the bolts (1) or nuts crosswise in steps with a torque of X Nm (see table “Bolt (1)“).
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Camshaft A5.05. 04.04.01.10
2.19 After installing the last camshaft section: 04

2.19.1 Place the intermediate piece (Fig. 2/12) firmly against the camshaft section (3). The recess must
be fully inserted in the camshaft section.
2.19.2 Insert the bolts (1) in the connection between camshaft section and intermediate piece.
2.19.3 Tighten the bolts (1) or nuts so as to be finger tight.
2.19.4 Tighten the threaded connection crosswise in steps with a torque of X Nm (see table „Bolt (1) for
intermediate piece (12)“).
Bolt (1) for intermediate piece (12)
Engine type Torque in Nm
6 / 8 / 9 M 20 C 60
6 / 8 / 9 M 25 C / M 25 E 140
6 / 8 / 9 M 32 C / M 32 E / M 34 DF 210
6 / 8 M 43 C / M 46 DF 375
9 M 43 C / 9 M 46 DF 420
7 M 43 C / 7 M 46 DF 560
(560 Nm = 250 Nm + 30° torque angle)
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Camshaft A5.05. 04.04.01.10
2.19.5 Install the vibration damper (10) (A5.05.04.09.01.nn). 04

2.20 Install the valve drives and injection pump drives (A5.05.04.02.00.nn).
2.21 Install the injection pumps (A5.05.07.02.01.nn).
2.22 Install the push-rods.
2.23 Install the rocker arm brackets and check the valve clearance (A5.05.01.02.01.nn).
2.24 Check the lubricating oil flow through the camshaft.
2.25 Install the camshaft covers, if necessary the cover to the vibration damper, and the valve covers.
2.26 Close the indicator valves (if existing).
2.27 Disengage the barring device (A5.05.12.08.01.nn) or, for the M 20 C, remove the barring rod.

Common rail diesel engine and dual fuel engine

en / 02.01.2015 13/14
Camshaft A5.05. 04.04.01.10
04
en / 02.01.2015 14/14
Speed Pick-up A5.05. 04.06.01.11
c2 Replacement / Adjustment
30000, 15000, 45000
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Replace the speed pick-up
M 43 C / M 46 DF / VM 43 C Torque wrench 20-200 Nm W1 1.9454-202 **
M 20 C / M 25 C / M 32 C / Torque wrench 20-200 Nm W1 1.9454-202 ** /

M 32 E / M 34 DF / VM 32 C / ***
GCM34 / VM 46 DF
M 20 C / M 25 C / M 32 C / Molykote paste “G-Rapid Plus” 1.9493-001 *

M 32 E / M 34 DF / GCM34 /
M 43 C / M 46 DF / VM 32 C /
VM 43 C / VM 46 DF
**) no picture
***) not included in the standard tool kit
NOTE
Exactly observe the installation sequence to ensure correct function of the speed pick-
up (3/3). Pay particular attention to the alignment of the marking / LED (3/1) to the
travel of the gear.
NOTE
Both the measuring point number and the point of installation of the pick-up to be
replaced can be found in “Electrical Engine Equipment” and “List of Measuring
Points”, see engine documentation, chapter 7 “Control and Monitoring”, of the
respective engine.
As a rough orientation the following figures show examples of possible points of
installation (1/a) of the speed pick-ups for the different engine types.
en / 07.06.2019 1/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000
Engine type Fig. 1 Schematic diagram

04
M 20 C
M 25 C
M 32 C
M 25 E
M 32 E
en / 07.06.2019 2/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000

04
VM 32 C
a*
*On VM 32 C engines the point of installation may vary (right or left at the driving end).
M 34 DF
en / 07.06.2019 3/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000

04
M 43 C
VM 43 C
M 46 DF
VM 46 DF
GCM34
en / 07.06.2019 4/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000
1. Replace the speed pick-up 04


Dual fuel engine:

Gas engine:
- Remove the key.
1.2 Remove the cable clamps of the speed

pick-up cable.
1.3 Disconnect the electrical connector (3/5)

to the speed pick-up (3/3) and loosen the
locknut (3/2).
1.4 Unscrew the speed pick-up (3/3)

completely. In doing so, make sure the
pick-up cable is not twisted.
1.5 Bar the engine to the appropriate

installation position. The gear tooth (2/6)
must be fully visible and at central position
with respect to the installation hole of the
speed pick-up (3/3). 6
1.6 When replacing the speed pick-up (3/3)

make sure the new speed pick-up is
identical in construction to the pick-up
used before. 2 Schematic diagram
1.7 Apply a thin coat of Molykote to the thread of the new speed pick-up (3/3).
1.8 If necessary, screw the locknut (3/2) onto the new speed pick-up (3/3).
en / 07.06.2019 5/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000
04
Installation
Fig. 3 Schematic diagram
situation
Axial installation
1 2 3 s 4
Direction of rotation of the gear in the figure “Axial installation” is clockwise.
Radial installation
2 3 4
s
5
1
Direction of rotation of the gear in the figure “Radial installation” is clockwise.
CAUTION
Risk of cable break due to twisting!
Twisting of the pick-up cable while screwing in the speed pick-up may result in “cable
break”. Prevent twisting of the cable by appropriate measures.
In case of counter-clockwise direction of rotation the pick-up must be installed so as
to be turned by 180° (LED opposite).
en / 07.06.2019 6/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000
04
NOTE
The lead of the pick-up thread can be used as reference for correct adjustment of the
desired clearance.
Example: Thread lead: 1.5 mm; desired clearance: 1.5 mm
One full rotation of the pick-up corresponds to 1.5 mm.
1.9 Carefully screw in the new speed pick-up (3/3) until it contacts the gear.
1.10 Then unscrew the speed pick-up until the required clearance (s) between gear (3/4) and pick-up
surface is obtained.
The standard value is s = 1.5 ±0.5 mm; however, due to factors such as thread lead, necessary
alignment (marking / LED) and end clearance of the camshaft the adjustment value may differ.
The specified pick-up clearances can be found in the engine documentation, chapter 7
“Control and Monitoring” -> “Electrical Engine Equipment”.
CAUTION
Observe the flywheel pick-up clearance for M 46 DF / VM 46 DF!
The pick-up clearance for speed recording at the flywheel for M 46 DF engines must
be adjusted to s = 2.5 +/- 0.1 mm. If the pick-up clearance is not observed, the speed
recording signal may be inverted.
1.11 Check the installation position of the speed pick-up (3/3):
1.11.1 The marking / LED (3/1) must be positioned parallel to the travel path/direction of the respective
gear (see Fig. 3; pay attention to whether installation is axial or radial).
If necessary, unscrew or screw in the speed pick-up (3/3) somewhat more in order to reach the
correct position. In doing so, choose the shorter way. The maximum allowable deviation is +/- 15°.
1.12 Tighten the locknut (3/2) with a torque of 30 Nm (22 lb ft)

making sure that the speed pick-up (3/3) does not get twisted.
1.13 Connect the electrical connector (3/5) of the speed pick-up (3/3). In doing so, make sure the plug-
in contact is properly locked (palpable overcoming of the locking, crackling in the connector).
1.14 Mount the speed pick-up cable and the electrical connector properly with cable clamps / tie wraps
making sure not to damage the pick-up cable by kinking / pulling over edges.
en / 07.06.2019 7/8
Speed Pick-up A5.05. 04.06.01.11
30000, 15000, 45000
Dual fuel engine:

Gas engine:
en / 07.06.2019 8/8
Timing Gear Train A5.05. 04.08.01.10
M20C - VM46DF
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the tooth flanks and oil nozzles
All engine types Set of feeler gauges 1.9075-003 *
Molykote paste “G-Rapid” */**
Petro Gel Amber */**
* no picture
CAUTION
If damage to the tooth flanks is identified and / or the permissible desired value
(backlash) is not met, please contact your authorised Caterpillar dealer.
en / 11.06.2019 1/4
M20C - VM46DF
1. Check the tooth flanks and oil nozzles 04


Dual fuel engine:

Gas engine:
- Remove the key.
1.2 Remove the timing gear train covers on both sides.
1.3 Check the tooth flanks of the camshaft gear (Fig. 1/1), the intermediate gear (2), and the
crankshaft gear (3) (pitting, skewing, crumbling, etc.).
1.4 Measure the backlash and compare the measured values to the Backlash table.
1.4.1 Measure the backlash (x) of the intermediate gear (2) with respect to the camshaft gear (1).
1.4.2 Measure the backlash (z) of the intermediate gear (2) with respect to the crankshaft gear (3).
1.4.3 For VM 43 C / VM 46 DF
Measure the backlash (y) of the intermediate gear (2) with respect to the step wheel (4).
Backlash
Engine Backlash (x) in mm Backlash (z) in mm Backlash (y) in mm
M 20 C 0.20 - 0.40 0.20 - 0.40

M 25 C / M 25 E 0.23 - 0.35 0.23 - 0.35
M 32 C / M 32 E / M 34 DF 0.20 - 0.37 0.28 - 0.44
VM 32 C / GCM34 0.19 - 0.38 0.31 - 0.43

M 43 C / M 46 DF 0.23 - 0.40 0.23 - 0.41
VM 43 C / VM 46 DF 0.25 - 0.44 0.25 - 0.45 0.26 - 0.42
1.4.4 When the backlash is exceeded, please contact Caterpillar Kiel.
en / 11.06.2019 2/4
M20C - VM46DF
04
M 20 C
M 25 C / M 25 E
M 32 C / M 32 E
M 34 DF x
5 1
z
2
5 3 5
VM 32 C / GCM34
5
A B
1 1
2
3
x 5 z 5 x
M 43 C / M 46 DF
x
5
2
5
en / 11.06.2019 3/4
M20C - VM46DF

04
VM 43 C
VM 46 DF x 5 y 5 x
(On engines
turning clockwise A B
the step wheel (4)
and the inter-
mediate gear (2)
are arranged
mirror-inverted.)
1 2 4 1
5 3
z 5
1.5 Check the oil nozzles (Fig. 1/5) for proper function (direction and amount of oil) and secure fit.
1.6 Install the timing gear train covers on both sides. In doing so, check the gaskets and replace
them, if necessary.

Dual fuel engine:

Gas engine:
en / 11.06.2019 4/4
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Replace the O-ring of the intermediate gear shaft.
M 20 C / M 25 C / Molykote paste “G-Rapid Plus” 1.9493-001 */**

M 25 E /
M 32 C / M 32 CCR/ Petro Gel Amber 461114-041 */**
M 32 E / M 34 DF
* no picture
CAUTION
Danger due to changed valve timing!
It is not allowable to change the existing meshing of the intermediate gear with respect
to the camshaft gear and the crankshaft gear.
CAUTION
If any damage to the gear flanks is identified, please contact your authorized
Caterpillar dealer!
1. Change the O-ring (Fig. 1/5) of the intermediate gear shaft (1).

Common rail diesel engine:

en / 22.09.2016 1/4
04
NOTE
For M 25 C and M 25 E bar the engine until the casting clearance in the flywheel is
positioned at the level of the intermediate gear shaft (Fig. 1/1).
For M 20 C, M 32 C, M 32 CCR, M 32 E and M 34 DF the work described in the
following is only possible with removed flywheel.
NOTE
For M 32 C, M 32 CCR, M 32 E and M 34 DF extension sleeves are installed instead
of spring washers (Fig. 1/3). Hereinafter, item (3) will be referred to as “spring washers
/ extension sleeves (3)”.
1.2 Remove the tab washer (Fig. 1/4) with the

hexagon bolts (2) and the spring washers /
extension sleeves (3).
1.3 Remove the crankcase doors and covers

at the timing gear train and the crankcase 4
of the first cylinder unit.
3
1.4 Relieve the intermediate gear shaft (1) by 2
means of an appropriate device. 1
1.5 Press the intermediate gear shaft (1) out
of the crankcase towards the driving end
only to such an extent that the O-ring (5) 5
is accessible.
1.6 Coat a new O-ring (5) with Petro Gel

Amber and insert it untwisted into the
cleaned groove.
1.7 Push the intermediate gear shaft (1) back 4

into original position. Y
3
1.8 Coat the threads and the contact surfaces 2 Y
of the hexagon bolts (2) with Molykote. x
1
1.9 Install the tab washer (4) with the hexagon
bolts (2) and the spring washers /
extension sleeves (3) so as to be finger 4 1
tight.
1 Schematic diagram
en / 22.09.2016 2/4
1.10 Press the tab washer (Fig. 1/4) onto the hexagon bolts (2) and tighten the hexagon bolts (2) with 04
the torque indicated in the table below.
Hexagon bolt (2)
Engine Torque in Nm (Ib ft)
M 20 C 52 (38 Ib ft)
M 25 C / M 25 E / 130 (96 Ib ft)
M 32 C / M 32 CCR /
M 32 E / M 34 DF
1.11 Check the gap (x) = 0.3 mm - 1.4 mm between the tab washer (4) and the intermediate gear shaft
(1).
1.12 If necessary, loosen the hexagon bolts (2) and realign the tab washer (4).
1.13 Withdraw the device for relieving the intermediate gear shaft (1) from the crankcase.
1.14 Install the crankcase doors and covers at the timing gear train and crankcase of the first cylinder
unit.

- Set the selector switch at the control stand to “Engine” or “Remote”

en / 22.09.2016 3/4
04
en / 22.09.2016 4/4
Governor Drive A5.05. 04.08.03.10
c2 Check / Removal and Installation
See also: 04
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the governor drive

2. Check of the governor drive
3. Installation of the governor drive
Engine Type Tools and Auxiliary Materials Index Ord. No.
M 20 C Torque wrench, 40 - 200 Nm 1.9454-200 *
M 25 C / M 25 E Torque wrench, 60 - 320 Nm 1.9454-320 *
M 32 C / VM 32 C Torque wrench, 40 - 180 Nm 1.9454-040 *

M 32 E / M 34 DF
M 43 C / VM 43 C / Torque wrench, 20 - 200 Nm 1.9454-202 *

M 46 DF / VM 46 DF
“Dirko” sealing compound */**
Molykote paste “G-Rapid“ */**
“Petro Gel Amber” */**
* no picture
en / 02.01.2015 1/6
1. Removal of the governor drive 1 3 5 4 04

1.1 Secure the engine to prevent unintentional
starting.
2
- Switch off and block the fuel supply
to the engine.
- Throw and secure the emergency stop
lever.
- Set the selector switch at the control
stand to “Repair” (depending on
equipment).
6
Dual fuel engine:
- Switch off and block the fuel supply to the
engine.
stand to “Repair” (depending on
equipment). 7
(12)
1.2 Disconnect the governor linkage from the
governor:
(14)
1.2.1 If there are several adjustment
possibilities, the position of the bolt (Fig. 1/
2) has to be marked/noted down.
Schematic diagram
1.2.2 Remove the upper bolt (2) with locknut (3),
spacer bush (4), and washer (5). Put aside
the spring element (6).
CAUTION
Risk of damage due to wrong lifting
When lifting the governor (Fig. 1/1), especially when working on a V-engine, care has
to be taken to follow up with the crane according to the cylinder inclination.
1.3 Remove the governor fastening screws (7), attach the governor (1) to the crane in an appropriate
manner, lift it up, put it down on a suitable base, and secure it against shifting.
en / 02.01.2015 2/6
04
CAUTION
Special feature of VM 43 C and VM 46 DF (Fig. 2/ Z1):
- Lubricating oil pipe (8) at the governor drive casing.
- There is no lubricating oil passage sleeve (9).
1.4 Only for VM 43 C and VM 46 DF

Remove the lubricating oil pipe (Fig. 2/8).
1.5 Remove the fastening screws (Fig. 2/10) all around with extension sleeves/washers (11)
10 11
13 Z (Z1)
12
14
13
18
15
Z
17
16 (Z1)
9
Schematic diagram
14
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04
CAUTION
The backlash is determined by the material thickness of the gasket (14).
If the existing gasket is damaged or destroyed upon removal, a new gasket featuring
exactly the same material thickness must be used!
1.6 Attach the governor drive casing (Fig. 2/12) in an appropriate manner to the crane by means of a
textile sling and carefully lift it off the engine block.
1.7 Put the governor drive casing onto a suitable base and secure it so as to prevent it from shifting.
1.8 Carefully remove the gasket (14) and clean the support surface on the engine block.
2. Check of the governor drive
2.1 Check the gear flanks of the helical gear wheels (Fig. 2/15 and 16) and the intermediate wheel
(17) for pitting, skewing, crumbling, and unusual signs of wear.
2.2 Check the serration of the governor drive shaft (18) and the governor (Fig. 1/1) for wear and
clean them, if necessary.
2.3 Make sure that all lubricating oil bores for the lubricating oil supply of the governor drive shaft and
the helical gear wheels are free so that proper lubricating oil supply can be ensured.
In case of doubt, please contact your authorised Caterpillar dealer.
3. Installation of the governor drive
3.1 Lightly coat new O-rings with Petro Gel Amber and insert them untwisted into the lubricating oil
passage sleeve (Fig. 2/9).
3.2 Insert the lubricating oil passage sleeve (9) into the governor drive casing (12).
CAUTION
Absolutely make sure to use the old gasket (Fig. 2/14) or a gasket with same material
strength to maintain the adjusted backlash!
If the preset backlash is only reached without gasket, the governor drive/engine block
contact surfaces must be coated with “Dirko” sealing compound.
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3.3 Position the gasket (Fig. 2/14) on the engine block. 04

3.4 Carefully position the governor drive casing (Fig. 2/12) with the crane on the engine block. In
doing so, pay attention to the lubricating oil passage sleeve (9), gasket (14), and the dowel pins
(13).
3.5 Lightly lubricate the threads of the screws (10) with Molykote.
3.6 Install the fastening screws (10) with extension sleeves/washers (11) and lightly tighten them
crosswise.
3.7 Determine the backlash between the intermediate wheel (17) and the camshaft gearwheel and
compare it with the values in the following table. If necessary, adjust the material thickness of the
gasket (14).
Engine Backlash in mm
type
M 20 C 0.2 to 0.38
M 25 C
M 32 E
M 32 C 0.25 +0.15
VM 32 C
M 32 E
M 34 DF
M 43 C
VM 43 C
M 46 DF
VM 46 DF
3.8 Install the fastening screws (10) with extension sleeves/washers (11) and tighten them crosswise
(standard tightening torques see A5.03).
3.9 Only for VM 43 C and VM 46 DF

Install the lubricating oil pipe (8) on the governor drive casing (12).
3.10 Coat the contact surface of the governor with Dirko sealing compound.
3.11 Put the governor (Fig. 1/1) onto the contact surface of the governor drive (Fig. 2/12).
NOTE
The serration of the governor shaft must easily slide into the serration of of the
governor drive shaft (Fig. 2/18).
3.12 Install and tighten the governor fastening screws (Fig. 1/7).
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3.13 Install the governor linkage: 04

3.13.1 Put in place the spring element (6).
3.13.2 Install the bolt (2) with locknut (3), spacer bush (4), and washer (5) at the position marked under
1.21.


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Camshaft Vibration Damper A5.05. 04.09.01.11
See also: 04
Spare parts sheets: B1.05.04.2.3140

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Camshaft vibration damper - removal

2. Camshaft vibration damper - installation
M 25 C / M25 E Torque wrench 300 - 800 Nm 1/2” W1 1.9454-800 *
Torque wrench 50 Nm 1/2” W2 ***
Molykote paste “G-Rapid” */**
* no picture
WARNING
Risk of injury due to components under pressure!
Camshaft vibration dampers can be under pressure and cause serious injuries.
• Do not open a camshaft vibration damper on any account.
NOTE
This job card covers the removal and installation of several variants of camshaft
vibration dampers on the above-mentioned engines.
The structural design is comparable for all variants. Specifics will be pointed out as
necessary.
1. Camshaft vibration damper - removal


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1.2 Remove the cover of the vibration damper chamber. 04

1.3 Catch / support the camshaft vibration damper (1/1) with a suitable sling gear.
1.4 Remove the hexagon head bolts (1/2) and, if applicable, the extension sleeves (1/3).
1.5 Attach the camshaft vibration damper (1/1) with a suitable sling gear to the crane and, if
applicable, pull it off the intermediate piece (1/4).
NOTE
When working on the last camshaft section, also the intermediate piece (1/4) may
have to be removed.
In case of an uneven arrangement of the hexagon head bolts (1/6) mark their
installation position prior to removal.
For the installation apply a thin coat of Molykote to the threads of the hexagon head
bolts, insert them with extension sleeves (1/5) if applicable. Tighten the hexagon head
bolts with a torque of 420 Nm (310 lb ft) in several steps and crosswise.
6 or 8 9 cylinder
cylinder
6 6
1
5 5 1
2
2
3
4
4
1 Schematic diagram
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2. Camshaft vibration damper - installation 04

2.1 Check and clean all contact surfaces.
2.2 Apply a thin coat of Molykote paste to the thread and contact surfaces of the hexagon head bolts
(1/2).
2.3 Attach the camshaft vibration damper (1/1) with a suitable sling gear to the crane and position it
on the intermediate piece (1/4).
2.4 Insert the hexagon head bolts (1/2), if applicable with extension sleeves (1/3) and tighten them
crosswise in two steps with a torque of 50 Nm (37 lb ft).
2.5 Install the cover of the vibration damper chamber.

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04
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Control Shaft Bearings A5.05. 05.01.02.10
750
See also: 05
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Lubricate the control shaft
Inde
x
M 20 C / M 25 C Multi-purpose grease and lubricating oil, see */**

M 25 E / M 32 C engine documentation, chapter “Operating
VM 32 C / M 32 E Media”
M 34 DF
M 43 C / VM 43 C
M 46 DF / VM 46 DF
* no picture
1. Lubricate the control shaft

Dual fuel engine:

1.2 Remove the covers of the control shaft at the control stand and all pump space covers.
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750
1.3 Clean the control shaft supports, if necessary. 05
CAUTION
After every cleaning with fat dissolving detergents all bare metal parts must be
protected again with a light oil film!
1.4 Check the control shaft (1) up to the emergency stop lever in the control stand (no picture) and
lightly oil it in the area of the bearing points.
1.5 1.5 to 1.7 are not applicable to M 20 C.

Regrease the following supports with multi-purpose grease:
• Joint heads of the connecting rod between the shaft in the control stand and the control shaft
(no picture)
• Both joint heads (2) of the spring element (3) between control shaft (1) and governor (4).
2 3
5 1
Schematic diagram
1.6 For V-engines only

Lubricate the joint heads of the intermediate shaft (5) of both control shafts.
1.7 Carefully remove any excessive multi-purpose grease.
1.8 Lightly oil the movable supports (6) of the articulated levers between the control shaft (1) and the
injection pump (7).
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750
1.9 For M 20 C only. 05

Lightly oil the movable supports of the following components:
- Joint heads of the spring element (3) between the control shaft (1) and the governor (4).
- Articulated lever between control shaft (1) and injection pump (7).
- Double ball-and-socket joint of the coupling between the shaft in the control stand and the
control shaft (no picture).
1.10 All pump space covers and other coverings.


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750
05
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Master Starting Valve A5.05. 05.02.01.10
7500
See also: 05
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the master starting valve

2. Cleaning of the master starting valve
3. Installation of the master starting valve
Inde
x
M 25 C/ M 25 E Pin wrench W1 0.9105 A *

M 32 C/ VM 32 C
M 32 E / M 34 DF Molykote paste “G-Rapid” **
M 43 C, VM 43 C/ Petro Gel Amber **
M 46 DF/ VM 46 DF
Multi-purpose grease, see engine **
documentation, chapter “Operating Media”
Gas oil **
Emery cloth **
* no picture
CAUTION
Risk of injury due to components under spring force!
The item (Fig. 2/17) is under spring tension.
Remove this component carefully!
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7500
05
CAUTION
All pneumatic elements are lubricated with a special grease (see engine
documentation, chapter “Operating Media”; multi-purpose grease) that ensures
lubrication for several years. In case of a repair use only this multi-purpose grease for
lubrication. If other lubricants are used, proper function of the components cannot be
guaranteed.
1. Removal of the master starting valve


1.2 The main shut-off valve for compressed air to the engine is closed.
1.3 Vent the compressed air pipes on the engine.
1.4 Remove all pipes and cable connections from the master starting valve.
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7500
1.5 Specific feature of VM 43 C and VM 46 DF engines 05

Remove the screws (Fig. 1/26) with extension sleeves (27).
1.6 Remove the screw (Fig. 1/28) with washer (29).
1.7 Draw out the sleeve (30) from the master starting valve.
1.8 Remove the screws (1) with extension sleeves (25).
1.9 Lift the master starting valve (Fig. 1/31) off the engine block.
1
25
31
28
29
31
30
28
29
1
25
1
25
26
27
32
Example: VM 46 DF/ M 46 DF Example: In-line engine
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7500
1.10 Remove the protective cover (Fig. 2/2). 05

1.11 Remove the silencer (3) and pull off the solenoid (4).
1.12 Remove the armature (5) by loosening the threaded connection (6). Pay attention to the spring
(7).
1.13 Loosen the threaded connection (8) and draw out the emergency actuation (9). Pay attention to
the spring (10).
NOTE
When removing the nut (Fig. 2/12) and the piston (13) secure the spindle (14)
against turning. For this purpose, insert an open-end wrench through the air duct (15)
and counterhold at the spanner flat (21) of the spindle (14).
1.14 Remove the threaded connection (11) and nut (12).

3 4
10 2 9
5
11 12 13
6
7
8
19
20
15
21
14
Schematic diagram
16 17 18
1.15 Loosen the hexagon socket screws (16) and remove the flange (17). Pay attention to the spring
(18).
1.16 Counterhold the spindle (14) with an open-end wrench through the air duct (15) and remove the
piston (13) with the pin wrench (W1).
1.17 Completely remove the spindle (14) from the casing.
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7500
2. Cleaning of the master starting valve 05

2.1 Clean the casing with gas oil. Check the sliding surfaces for rust deposits and damage. If
necessary, carefully refinish with emery cloth.
3. Installation of the master starting valve
CAUTION
Lightly coat the threads of all fixing screws with Molykote.
Lightly grease the O-rings with Petro Gel Amber and insert them untwisted.
3.1 Replace all O-rings, the piston guide strip (Fig. 2/19), and the joint rings.
3.2 Lightly grease the sliding surfaces with multi-purpose grease.
3.3 Insert a new completely assembled spindle (14).
CAUTION
Make sure to insert the spring (18) in correct mounting position.
If the spring is not inserted in the correct position, this will cause malfunctions or
components may be damaged during installation.
3.4 Install the flange (17) with spring (18) and hexagon socket screws (16).
NOTE
When installing the piston (Fig. 2/13) and the nut (12) secure the spindle (14) against
turning. For this purpose, insert an open-end wrench through the air duct (15) and
counterhold at the spanner flat of the spindle (14).
3.5 Install the piston (Fig. 2/13) with the pin wrench (W1).
3.6 Install the nut (12) and threaded connection (11).
3.7 Install the armature (5) with spring (7) and threaded connection (6).
3.8 Install the solenoid (4) with silencer (3).
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7500
3.9 Install the emergency actuation (9) with new spring (10), new O-ring (20), and threaded 05
connection (8).
3.10 Place the completely assembled master starting valve (Fig. 1/31) onto the engine block.
3.11 Preassemble the screws (1) and tighten them.
3.12 Install the sleeve (30) with new O-rings (32).
3.13 Tighten the screws (1).
3.14 Install all pipe connections and cable connections.
3.15 Install the protective cover (Fig. 2/2).
3.16 Carry out a functional and tightness check with starting air.


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Control Linkage A5.05. 05.08.01.10
7500
See also: 05
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the inner rings

2. Install the inner rings
Engine Type Tools and Auxiliary Materials Pos. Tool No.
M 20 C / M 25 C Multi-purpose grease *
M 25 E / M 32 C
VM 32 C / M 32 E
M 34 DF
M 43 C / VM 43 C
M 46 DF / VM 46 DF
* no picture
1. Remove the inner rings.

Dual fuel engine:

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7500
1.2 Remove both threaded bolts (1) with 05

5 7
washers (2) and nuts (3).
6
1.3 Press the inner rings (4) out of the links
(5).
X
CAUTION
Malfunction due to worn out
components!
If the links (5) or articulated
levers (6) are showing any signs
of wear that could affect their
function, these components also
have to be replaced.
2. Install the inner rings.
CAUTION
4 5 4
U(se self-locking nuts (3) only
once!
Do not use Molykote paste!
2.1 Lightly grease the components to be

installed, do not use Molykote paste.
2.2 Insert new inner rings (4) into the links (5).
CAUTION
Only tighten the nuts (3) to such
an extent that the connection 3 2 2 1
X
between the link (5) and the
articulated lever (6) is of easy
motion. While tightening the nuts Schematic diagram
(3) the inner rings (4) must not be
clamped.
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7500
2.3 Install the link (5), threaded bolts (1), washers (2), new nuts (3) with the articulated lever (6) and 05
the injection pump control rod (7) so as to be finger tight.
2.4 Lightly tighten the threaded bolts (1) and then loosen them again by 1/4 turn. The washers (2)
should now be easily turnable.
CAUTION
Check the articulation for ease of movement by pressing against the articulated lever
(6). If there is no ease of movement, the injection pump or articulation on the control
shaft must be readjusted.

Dual fuel engine:

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7500
05
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Compressed Air System A5.05. 05.09.01.10
See also: 05
Spare parts sheets:
Personnel requirement: 1 Pers./

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check tightness and function of control pipes and fittings.
1. Check tightness and function of control pipes and fittings.
NOTE
During these checks the piping system must be filled with air. In rare cases, leaks
manifest themselves by noise. The time interval for draining the pipes results from the
observed formation of water and depends on air consumption, temperature, and area
of deployment.
1.1 Drain the pipes. The drain valves are located at the lowest point on the sloping side of the pipes
upstream of the engine inlet.
1.2 Carry out a visual inspection of the compressed air system paying attention to proper tightening of
the fittings and tightness at the threaded connections and pipes.
CAUTION
Risk of failures due to dirt!
Even the smallest contamination in the pipes may cause a failure of the control
devices.
Ensure cleanliness during installation work.
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Compressed Air System A5.05. 05.09.01.10
05
en / 02.01.2015 2/2
Maintenance Unit A5.05. 05.09.06.10
See also: 05
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Drain the compressed air filter
2. Clean the filter cartridge
3. Replace all sealing elements
4. Check and adjust the pressure reducing station
M 20 C Loctite 241 *
M 25 C / M 25 E **
M 32 C / VM 32 C
M 32 E / M 34 DF Petro Gel Amber *
M 43 C / VM 43 C **
M 46 DF / VM 46 DF Nitro Solvents *
**
* no picture
NOTE
For maintenance and troubleshooting please refer to the engine documentation,
“Control and Monitoring”).
NOTE
Maintenance intervals
Provided the required compressed air quality and the allowable ambient conditions
are met, all sealing elements must be replaced latest after 22,500 h in order to
ensure safe operation of the pressure reducing station.
It is recommended to send the pressure reducing station to your responsible

Caterpillar dealer for overhauling.
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1. Draining of the compressed air filter 05

1.1 Move the handle of the drain valve (Fig. 1/5) slightly sideways and drain the filter completely.
WARNING
Risk of injury due to powerful blowing out of the condensate!
Compressed air is blown out with great force (30 bar)! Compressed air may entrain
dirt particles. Blown out dirt particles may injure the skin.
Do not actuate with bare hands!
Wear gloves and safety glasses!
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2. Cleaning of the filter cartridge 05
NOTE
The filter cartridge has to be cleaned regularly depending on the state of
contamination of the compressed air.
2.1 Disassembly and cleaning of the filter cartridge
WARNING
Risk of injury due to mounting parts under air pressure!
During disassembly pressurized mounting parts may come off at high speed.
Carry out all work in an unpressurized state.
Shut off the compressed air supply and vent the device!
Secure the device against unintentional operation!
NOTE
It has to be checked whether any downstream devices/plants (emergency stop) are
impaired in their function when carrying out the disassembly and cleaning tasks!
2.1.1 Close the shut-off valve in the compressed air supply pipe and secure it against unintentional
operation.
2.1.2 Depressurize the plant.
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05
2.1.3 Loosen the screw plug (Fig. 2/T1) and remove with sealing ring (1), filter (2) and O-ring (3).
2.1.4 Clean the filter with benzine or a solvent.
NOTE
If the filter cartridge is extremely dirty, replace it by a new one!
2.1.5 Clean the sealing surfaces and the seal seats.
2.2 Assemble the filter cartridge.
2.2.1 Dry the filter cartridge before reinstalling it.
2.2.2 Lightly grease a new sealing ring (Fig. 2/1) and new O-ring (3).
2.2.3 Insert sealing ring (1), filter (2) and O-ring (3) and assemble screw plug (T1).
2.2.4 Tighten the screw plug (T1) with a torque of 150 Nm.
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3. Replacing all sealing elements 05
WARNING
Risk of injury due to mounting parts under air pressure!
During disassembly pressurized mounting parts may come off at high speed.
Carry out all work in an unpressurized state.
Shut off the compressed air supply and vent the device! Interrupt the electric power
supply!
Secure the device against unintentional operation!
NOTE
It has to be checked whether any downstream devices/plants (emergency stop) are
impaired in their function when carrying out the disassembly and cleaning tasks!
3.1 Dismantling the filter and the drain val-

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

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

move sealing ring (4). Dismantle sealing
ring (7) and remove spring (6) as well as
valve (5) from the valve screw (T2).
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3.2 Dismantling the pressure switch 05

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

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

housing.
3.3.3 Remove O-rings (8, 9 and 10).
3.3.4 Unscrew the ventilation (13).
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3.4 Dismantling the pressure control valve 05

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

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

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

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

housing and remove collar (26).
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3.5 Dismantling the 3/2-way valve 05

(Versions: R417000844, R417000845, R417000888)
3.5.1 Loosen screw (Fig. 2/T25) and remove retaining plate (T26).
3.5.2 Dismantle servo valve (Fig. 7/33). For this purpose unscrew the ventilation (T13), remove the coil
(T14) and loosen the screw (T15 2x).
3.5.3 Remove gasket (27).
3.5.4 Loosen screw (T16 2x) and remove the cover plate (T17).
CAUTION
Risk of injury due to mounting parts under pressure!
Compression spring (T18) is under preload.
Counterhold when loosening.
3.5.5 Disassemble the following components:
Compression spring (T18), bush (T19), piston (T20), sleeve (T21), ram (T22), washer (T23 6x),
washers (32), spacer (T24 2x), sealing ring (28 4x) as well as grooved ring (29).
3.5.6 Dismantle circlips (24, 30) and filters (25, 31).
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3.6 Dismantling the 5/2-way valve (Version: R417000790) 05

3.6.1 Loosen screw (Fig. 2/T25) and remove retaining plate (T26).
3.6.2 Dismantle servo valve (Fig. 8/33). For this purpose unscrew the ventilation (T13), remove the coil
(T14) and loosen the screw (T15 2x).
3.6.3 Remove gasket (27).
3.6.4 Loosen screw (T16 2x) and remove the cover plate (T17).
CAUTION
Risk of injury due to mounting parts under pressure!
Compression spring (T18) is under preload.
Counterhold when loosening.
3.6.5 Disassemble the following components:
Compression spring (T18), bush (T19), piston (T20), sleeve (T21), ram (T22), washer (T23 6x),
washers (32), spacer (T24 2x), sealing ring (28 4x) as well as grooved ring (29).
3.6.6 Dismantle circlips (30 2x) and filters (31 2x).
B Principle representation
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3.7 Replacing the sealing elements 05
CAUTION
Sealing elements may get damaged if handled improperly.
Replace all sealing elements by new sealing elements and lightly grease them with
Petro Gel Amber. Insert the sealing elements undamaged and untwisted.
3.7.1 Clean all sealing surfaces and seal seats.
3.8 Assembly of the filter cartridge
3.8.1 Lightly grease a new sealing ring (Fig. 9/1) and new O-ring (3).
3.8.2 Insert sealing ring (1), new filter (2) and O-ring (3) and assemble screw plug (T1).
3.8.3 Tighten the screw plug (T1) with a torque of 150 Nm.
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3.9 Assembly of the drain valve 05

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

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

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

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

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

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

(12).
3.10.7 Assemble new ventilation (13).
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3.11 Assembly of the pressure control valve 05

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

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

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

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

ring (14).
3.11.7 Assemble cap (T8) and grub screw (T7).
NOTE
Keep the clearance of 13.6+0.2
mm for the valve nut (17). Use
adjusting sleeve (37) for
checking.
Secure the valve nut (17) with
a screw locking compound
(e.g. Loctite 241).
NOTE
Ensure correct assembly
position of the valve ring (19)!
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3.12 Assembly of the 3/2-way valve (Versions: 05

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

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

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

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

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

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

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

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

(T16 2x) with screw locking
compound (e.g. Loctite 241)
.
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3.13 Assembly of the 5/2-way valve 05

(Version: R417000790)
3.13.1 Lightly grease new gasket (Fig. 15/27) and new sealing rings (28 4x).
3.13.2 Replace servo valve (33), grooved ring (29), circlips (30 2x) and filters (31 2x) by new ones.
3.13.3 Assemble filters (31 2x) and circlips (30 2x).
3.13.4 Assemble the following components:
Grooved ring (29), sealing ring (28 4x), spacer (T24 2x), washer (32), washer (T23 6x), ram
(T22), sleeve (T21), piston (T20), bush (T19) and compression spring (T18).
NOTE
Bush (T19) and sleeve (T21) must project from the upper housing edge by 0.4+/-0.1 mm.
Use washers (32) accordingly.
3.13.5 Assemble cover plate (T17) with screw (T16 2x).
3.13.6 Assemble servo valve (33) with screw (T15 2x). Put on coil (T14) and screw on ventilation
(T13).
NOTE
In case of pressure reducing stations with retaining plate (Fig. 9/T26 new version) the
screw (T25) must be fixed by a screw locking compound (e.g. Loctite 241) during
assembly.
In case of pressure reducing stations without retaining plate (T26 old version) the
ventilation (Fig. 15/T13) is to be provided with screw locking compound (e.g. Loctite 241)
and tightened very lightly.
Secure screws (T15 2x) and (T16 2x) with screw locking compound (e.g. Loctite 241)
.
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05
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4. Check and adjust the pressure reducing station 05
CAUTION
Wear on the pressure control valve parts
In order to minimize wear on the pressure control valve turn the cap (Fig. 16/T8) only in
pressureless state.
4.1 After the dismantling/mounting of the pressure reducing station, it is required to readjust the
’operating pressure of the pressure control valves. In order to do so, the grub screw (Fig. 16/T7)
has to be loosened and the cap (T8) has to be screwed out of the housing with the exception of
the last five turns.
4.2 Adjust a pressure of 30 bar at connection (P). By turning the cap (T8) adjust the operating
pressure at the pressure control valve to 7.5 bar and tighten the grub screw (T7).
4.3 Check the 3/2-way valve for proper function by actuating it. Finally the complete pressure
reducing station has to be tested for leaks.
T7 T8
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c2 Exhaust Manifold
Check / Removal and Installation
A5.05. 06.01.01.10
7500
See also: 06
Spare parts sheets:

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

2. Removal of the exhaust manifold
3. Cleaning of the exhaust manifold
4. Installation of the exhaust manifold
Engine
Tools and auxiliary materials Index Tool No.
type

M 25 E

VM 32 C
M 32 E
M 34 DF
GCM34 Torque wrench 20 - 200 Nm W1 1.9454-202 *
M 43 C, Torque wrench 20 - 200 Nm W1 1.9454-202 *

VM 43 C
M 46 DF Torque wrench 200 - 500 Nm W2 1.9454-500 *
VM 46 DF Hexagon bolt W3 431011 A
(Mounting aid for exhaust manifold / max. 9 x)
M 20 C - High-temperature thread paste “Rivolta G.W.F.” **

VM 46 DF
Graphite or molybdenum spray **
* no picture
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c2 Exhaust Manifold
A5.05. 06.01.01.10
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06
WARNING
Risk of burns!
• Before carrying out any work on the exhaust manifold it is absolutely required to
check the exhaust gas temperature!
• Allow the exhaust manifold to cool down sufficiently!
CAUTION
• In order to prevent damage to the expansion joints, they must not be subjected to
bending or radial force during removal or installation. A slight prestress (stretching
of approximately 3-5 mm) in axial direction is achieved during installation by bolting/
clamping of the expansion joints into place.
• Insert all bolts with “Rivolta G.W.F.” high-temperature thread paste in order to
prevent sticking due to heat.
• In order to cope with the thermal load characteristics of the exhaust manifold, only
materials meeting these particularly stringent requirements are used for its
fastening. Therefore, use only genuine Caterpillar spare parts.
NOTE
The exhaust pipe after turbocharger must also be checked within the scope of
this inspection. If severe vibrations and noise occur at the turbocharger, the
flange connection of the exhaust pipe after turbocharger must also be
slackened and checked for tensions.
1. Check of the exhaust manifold for leaks
1.1 Remove the exhaust cladding.
1.2 Check all threaded connections and brackets for snug fit.
1.3 Visually inspect the flanges and expansion joints

(if possible, carry out this check while the engine is running).
NOTE
An accumulation of soot, which may occur particularly on flanges and expansion
joints, is indicative of leaks.
Unless these are caused by cracks in the piping system or loose threaded
connections, new gaskets must be used.
Expansion joints with cracked bellows must be replaced.
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c2 Exhaust Manifold
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2. Removalof the exhaust manifold 06
CAUTION
Avoid lowering of the exhaust manifold!
Never loosen all connections to the cylinder head at the same time on a fully fitted
exhaust manifold.Even partial loosening of the connections to the cylinder head may
lead to lowering of the exhaust manifold and thus destroy the expansion joints.
NOTE
• Before removal clearly mark the installation orientation and position of the
expansion joints and exhaust tube segments with chalk. Photos of the exhaust
manifold from different perspectives will make it easier to install the exhaust tube
segments and brackets at their proper location.
• Do not subject the expansion joints to bending or radial force!
2.1 Specific feature of M 43 C/VM 43 C and M 46 DF/VM 46 DF engines
2.1.1 Before removing the exhaust manifold each exhaust tube segment must be supported.
Depending on the design, either the hexagon bolt (Fig. 1/W3), or the bracket (Fig. 1/W3) must be
used to provide some support for the exhaust manifold.
W3 Schematic diagram W3
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c2 Exhaust Manifold
A5.05. 06.01.01.10
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2.2 Applicable to all engine series 06
CAUTION
Pay attention to hidden brackets and fasteners!
On engines with pulse charging further brackets and fasteners that are not indicated
in detail in this document must be removed.
2.3 Remove all expansion joints up to the turbocharger of the corresponding exhaust manifold.
2.4 Carefully unscrew from the sensor sleeve (Fig. 2/2) all thermal sensors (Fig. 2/1)
located directly before the flange connection between exhaust tube segment and cylinder head.
14 Schematic diagram
2.5 Attach the individual exhaust tube segments to the crane one after the other, loosen and remove
the flange connection to the cylinder head.
2.6 Put the exhaust tube segments down at a suitable place and secure them against slipping.
3. Cleaning of the exhaust manifold
3.1 Clean the exhaust tube segments from the inside, inspect them for cracks and replace them if
necessary.
3.2 Check the expansion joints for cracks and replace them if necessary.
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c2 Exhaust Manifold
A5.05. 06.01.01.10
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4. Installation of the exhaust manifold 06
NOTE
• During installation of the exhaust manifold bear in mind that no gasket
(Fig. 3/4) needs to be installed between flange connections adjoining an expansion
joint.
• Use gaskets only between two exhaust tube segments or between exhaust tube
segment and cover plate.
• Always insert the gaskets with the lug (Fig. 3/4a) pointing upwards.
• Gaskets always with bead (Fig. 3/4b) pointing towards exhaust tube segment.
• Self-locking nuts may not be reused after removal and must be replaced by new
ones.
• For a picture of the exhaust manifold please refer to the engine documentation,
chapter “Spare Parts Catalogue“.
4 4a
4b
A-A
A
CAUTION
Avoid breaking of the bracket packages!
Before installation, spray the individual plates of the bracket packages on both sides
with graphite or molybdenum spray.
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c2 Exhaust Manifold
A5.05. 06.01.01.10
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4.1 M 20 C, M 25 C, and M 25 E engines 06
NOTE
This note applies to M 20 C, M 25 C, and M 25 E engines only!
Between exhaust tube segment (Fig. 4/12) and cylinder head a new gasket (Fig. 4/
5) must be inserted before installation.
4.2 Apply “Rivolta G.W.F.” to the contact surfaces.
4.3 Position the exhaust tube segment on the cylinder head according to the markings provided upon
removal (installation orientation and position) with a new gasket (Fig. 4/5).
4.4 Insert hexagon bolts (Fig. 4/6) with extension sleeves (Fig. 4/7) (the flange surfaces of the
exhaust tube segments should be aligned so as to be parallel to each other if possible).
4.5 M 20 C
4.6 Tighten hexagon bolts (Fig. 4/6) alternately, first with a torque of 60 Nm (44 lb ft) and then
alternately with a torque of 110 Nm (81 lb ft).
4.7 M 25 C / M 25 E
4.8 Tighten hexagon bolts (Fig. 4/6) alternately, first with a torque of 180 Nm (133 lb ft) and then
alternately with a torque of 330 Nm (243 lb ft).
4.9 M 32 C/VM 32 C, M 32 E, M 34 DF, M 43 C/VM 43 C, M 46 DF/VM 46 DF, and GCM34 engines
NOTE
This note applies to M 43 C/VM 43 C, M 46 DF/VM 46 DF engines only:
Before installation, a new spiral wound gasket must be inserted between exhaust
tube segment and cylinder head.
4.10 Position the exhaust tube segment on the cylinder head and the support bolt according to the
markings provided upon removal (installation orientation and position).
4.11 Lubricate the contact surfaces of the clamps (Fig. 5/8) “sufficiently” with “Rivolta G.W.F.”.
4.12 By means of the clamp (Fig. 5/8) lightly tighten the exhaust tube segment.
4.13 Install all other exhaust tube segments in the same way.
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c2 Exhaust Manifold
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4.14 Adjust the exhaust tube segments so that all segments are in alignment. The flange surfaces of 06
the exhaust tube segments must be aligned so as to be parallel to each other if possible
(measure the distance).
CAUTION
Avoid leaks!
When tightening the clamps (Fig. 5/8) make sure that the connecting flanges of the
exhaust tube segments and those of the cylinder heads are parallel to each other.
After tightening, the flange surfaces must rest “flat”.
4.15 Tighten the hexagon bolt (Fig. 5/9) with a torque of 150 Nm (111 lb ft).
8
5 9
12 Principle representations
4.16 Installation of expansion joints
NOTE
• When installing the expansion joints pay attention to the flow direction (arrow on the
flange).
• Insert all fixing screws from expansion joint side.
• Lubricate the threads of the fixing screws with “Rivolta G.W.F.” before in order to
prevent sticking due to heat.
• Do not subject the expansion joints to bending or radial force!
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4.17 M 20 C engines with single-pipe exhaust manifold (constant-pressure charging) 06
NOTE
Contrary to the usual method for installing expansion joints (threaded connection), the
expansion joints for M 20 C single-pipe charging (constant pressure charging) (Fig. 6/10)
are fitted to the exhaust tube segment (Fig. 6/12) with clamps (Fig. 6/11). An exception
is the transition of the exhaust manifold to the turbocharger (no picture).
10 11
11
12
12
13
13
4.18 Insert the expansion joints according to the marking (arrow on the flange).
4.19 Lubricate the contact surfaces of the clamps (Fig. 6/11) “sufficiently” with “Rivolta G.W.F.”.
4.20 At the same time, fit two clamps (Fig. 6/11) to both sides of the expansion joint. By alternately
tightening the hexagon bolts (Fig. 6/13) the expansion joint is evenly pulled against the exhaust
tube segments (Fig. 6/12).
4.21 Tighten the hexagon nuts (Fig. 6/13) with a torque of 25 Nm (18 lb ft).
NOTE
For installation of the expansion joint adjoining the turbocharger please refer to the
following “General assembly instruction for expansion joints“.
4.22 The fixing screws of the last expansion joint before turbocharger are tightened with a torque of 90
Nm (66 lb ft).
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4.23 General assembly instruction for expansion joints. 06

4.24 Insert the expansion joints according to the marking (arrow on the flange) and fit the related
brackets if necessary. Insert the fixing screws from expansion joint side,
install the extension sleeves and lightly screw on the hexagon nuts.
4.25 By means of the fixing screws pull the expansion joints evenly against the flanges
of the exhaust tube segments (or turbocharger). After that, tighten the fixing screws crosswise
with a torque of X Nm (see table “General torques”)
.
CAUTION
Avoid tightening errors!
The following table (“General torques”) only applies to screws for which no specific
torque is indicated.
4.26 General torques (with “Rivolta G.W.F.” high-temperature thread paste)
Screws Torques
M12 60 Nm (44 lb ft)
M16 140 Nm (103 lb ft)

M20 270 Nm (199 lb ft)
4.27 Insert all removed thermal sensors (Fig. 2/1) with circlips (Fig. 2/14) into the sensor sleeves
(Fig. 2/2) and fit them.
4.28 Install the exhaust cladding.
4.29 Specific feature of M 43 C/VM 43 C and M 46 DF/VM 46 DF engines
4.30 After installation of the exhaust manifold the hexagon bolt (Fig. 1/W3) or bracket (Fig. 1/W3) must
be removed.
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06
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Charge Air Cooler A5.05. 06.04.02.11
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the charge air cooler

2. Cleaning of the charge air cooler
3. Installation of the charge air cooler
M 25 C / M 25 E Torque wrench 60 - 320 Nm 1.9454-320
M 32 E / M 34 DF Torque wrench 100 - 400 Nm 1.9454-400
M 25 E Clamping screw W1 1.1387-681
M 32 E / M 34 DF Clamping screw W1 1.1387-457
M 25 E Removal device, consisting of: W2
Supporting plate W2.1
Stopper plate (2 x) W2.2

Hexagon socket screw M12x20 (11x) W2.3
Shackle W2.4
Second shackle and textile sling from: 1.9321 D

Hoist (2x) W3 **
M 25 C / M 25 E Cleaning agent for charge air cooler see *

M 32 E / M 34 DF documentation of the manufacturer in engine
documentation, chapter “External Docu-
mentation”
Petro Gel Amber 461114-041 *
“Dirko Grey” silicone sealing compound *
Multi-purpose grease
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06
CAUTION
Remove and clean the charge air cooler on the air side when the differential pressure
upstream / downstream of the cooler reaches more than 1.5 times the testbed value
(refer to the acceptance test record, engine documentation, chapter “Technical
Engine Data”).
CAUTION
Dismount all relevant connection cables and lines for the removal!
Fix any freely suspended cables and lines!
Create the prerequisites for trouble-free removal!
NOTE
The figures show a charge air cooler arranged at the driving end of the engine.
At the free end the charge air cooler is installed so as to bemirror-inverted.
1. Removal of the charge air cooler

2
starting.

- Interrupt the starting air supply. 10
- Switch off and block the fuel supply to
the engine.
- Throw and secure the emergency stop
lever. 3
stand to “Repair” (depending on equip-
ment). 4
Dual fuel engine:

- Switch off and block the fuel supply to
the engine.
stand to “Repair” (depending on equip- 17
ment). 5
1.2 Completely drain and collect the cooling

water on module side (plant side, yard
side).
1 Schematic diagram
1.3 Remove the claddings, covers, and cables
required for removal of the charge air
cooler (Fig. 1/2).
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1.4 Remove the vent screws (Fig. 2/1, Fig. 6/1) or, if the engine is equipped with permanent venting, 06
make sure that the corresponding shut-off cocks are open.
1.5 Remove the drain plugs (Fig. 1/5, Fig. 2/5,

Fig. 6/5) and drain the charge air cooler
(Fig. 2/2) if necessary.
CAUTION
1 2
On M 25 E engines the cooling
water pipes (Fig. 1/4) must not
be removed.
The cooling water pipes are
disconnected at interface (17).
A
1.6 For M 25 E only:
1.6.1 Dismount the cooling water pipes (Fig. 1/

4) only at the interface (17). A
A-A
5
6
1.7 For M 25 C, M 32 E, and M 34 DF only:
2
1.7.1 Remove all cooling water pipes (Fig. 1/4)
at the charge air cooler (Fig. 1/2) and at
the interface (17). 7
2 Schematic diagram
1.7.2 Remove the screw plugs (Fig. 2/6) with
sealing ring.
1.8 For M 25 C only:
1.8.1 Remove the hexagon screws (Fig. 3/9).

9
3 Schematic diagram
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1.9 For M 25 E, M 32 E, and M 34 DF only: 06

1.9.1 Remove the screw plugs (Fig. 4/11) at the casing (3) and replace them by clamping screws (W1).
11 11
W1
W1
4 Schematic diagram
1.9.2 Lightly press the sliding plate (Fig. 5/12 installed in the casing 3) by means of the clamping
screws (W1) against the charge air cooler (2) so that the charge air cooler (Fig. 5/2) will be
supported during the further removal process and tilting in the casing (3) will be reduced.
1.9.3 Slightly loosen the hexagon socket head cap screws (Fig. 5/7) and the hexagon screws (10).
Adjust the charge air cooler (2) alternately with the clamping screws (W1) so that the hexagon
socket head cap screws (7) and the hexagon screws (10) can be loosened without any tension.
3
10
12
W1 W1
5 Schematic diagram
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1.9.4 Remove the hexagon screws (Fig. 1/10). 06

1.9.5 Remove the hexagon socket head cap screws (Fig. 2/7).
1.10 For M 25 C, M 32 E, and M 34 DF only:
CAUTION
Risk of injury in case of non-observance!
Step 1.13.1 is not applicable for M 25 E engines. For removal of the charge air cooler
of M 25 E engines a special device is required whose use is described as from step
1.17.
1.10.1 Pull the charge air cooler (Fig. 1/2) out of the casing (3), secure it with a suitable lifting gear and
make sure it cannot topple.
1.11 Special feature of split charge air cooler (Fig. 6):

Pull out the split charge air cooler (Fig. 6/2) until reaching the connection point, dismount the two
sections and put them down one after the other.
5
2 6 Schematic diagram
2
1.12 Special feature if a water separator is
installed (Fig. 7):
If the charge air cooler (Fig. 7/2) is
equipped with an optional water separator
(16) it may be required to remove this
separator to achieve good cleaning
results.
1.13 Put the charge air cooler (Fig. 7/2) down

for cleaning (if available, in a suitable
container).
16
7 Schematic diagram
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1.14 For M 25 E only: 06

1.14.1 Using a textile sling attach the charge air cooler (Fig. 8/2) to the cooling water pipes (4), hook into
the crane (if necessary, hoist) and carefully pull out by approximately 400 mm.
1.14.2 Put in place the supporting plate (Fig. 9/W2.1) as shown in the figure and fasten it on both sides
with two hexagon socket screws each (W2.3); additionally, another three hexagon socket screws
(W2.3) need to be installed in the lower area.
NOTE
Before installing the stopper plates the charge air cooler must be pulled out until the
stopper plates can be installed behind the centre strut (Fig. 9/18).
1.14.3 Install a stopper plate (Fig. 9/W2.2) on both sides by means of two hexagon socket screws
(W2.3) each.
2 18 W2.2
W2.3
W2.3
W2.1
4 W2.3
approx. 400 mm
(3x)
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06
CAUTION
Risk of damage to the charge air cooler fins!
There is a risk of the stopper plates (Fig. 9/W2.2) damaging the charge air cooler fins
due to lateral movement while pulling out the charge air cooler.
Pull out the charge air cooler without allowing any lateral movement; if necessary, ask
a third person to assist.
1.14.4 Pull the charge air cooler onto the stopper plates (Fig. 9/W2.2) as far as they will go.
CAUTION
Risk of injury in case of non-observance!
Before the next step the charge air cooler must be supported so that a safe change-
over of the slings is ensured.
If the charge air cooler is not additionally secured before changing over the slings, the
cooler may slip out and cause severe injuries.
1.14.5 Safely support the charge air cooler; if necessary, secure it with a third hoist in upward direction.
1.14.6 Sling the first hoist (Fig. 10/W3) to the crane and using two shackles (W2.4) attach the charge air
cooler at lifting point “A“, see Fig. 10/X.
CAUTION
Avoid tilting the charge air cooler!
To avoid tilting or tipping of the charge air cooler while pulling it out a second hoist
must be used.
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06
X
W2.4
W3
A B
W2.2 (2x)
2
1.14.7 Hook in the second hoist and align the charge air cooler horizontally.
1.14.8 Remove the stopper plates (Fig. 10/W2.2) on both sides, carefully pull out the charge air cooler
and put it onto a suitable base.
CAUTION
Removal in case of limited space
If space is not sufficient for removal with cooling water pipe still in place, this pipe can
be dismounted. In such a case, the lifting point for the shackles is “B”, see (Fig. 10/X)
To avoid tilting or tipping of the charge air cooler while pulling it out a second hoist
must be used.
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2. Cleaning of the charge air cooler 06
CAUTION
Risk of skin injuries and respiratory ailments due to solvents!
Strictly observe the handling instructions of the manufacturer of the used cleaning
agent, protect the skin against any contact with the cleaning agent!
Wear alkali and acid resistant rubber gloves, safety glasses, and, if necessary, a
respiratory mask or face protection!
Ensure proper ventilation!
2.1 Clean the charge air cooler (Fig. 10/2) according to the guidelines of the manufacturer (see
engine documentation, chapter “External Documentation”).
2.2 Inspect the charge air cooler casing and clean it if necessary.
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3. Installation of the charge air cooler 06

3.1 Lightly lubricate the threads and contact surfaces of all screws with Molykote.
NOTE
Depending on its configuration the charge air cooler is installed either with a flat
gasket (Fig. 11/8) or with silicone sealing compound (Fig. 11/8).
3.2 As the case may be, put on a new gasket

(Fig. 11/8) at the charge air cooler (2)
using multi-purpose grease and fix it or
apply silicone sealing compound.
1 8 2
3.3 If necessary, install the optional water
separator (Fig. 7/16).
3.4 Special features - M 25 E

5 3
3.4.1 Sling the charge air cooler as for removal, 11 Schematic diagram
see Fig. 10.
3.4.2 Place the charge air cooler if possible in

horizontal position onto the supporting
plate (Fig. 9/2.1) and position the charge
air cooler by means of constant releasing
and following up of crane and hoists.
3.4.3 Remove both shackles (Fig. 10/2.4).
3.4.4 Remove the supporting plate (Fig. 9/2.1).
3.4.5 Bring the charge air cooler into final

position and secure with at least two
screws.
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3.5 Taking into account the air flow carefully insert the charge air cooler (Fig. 11/2) into the casing (3) 06
by means of a suitable lifting gear.
3.6 Special feature of split charge air cooler (Fig. 12)

Insert the split charge air cooler (Fig. 12/2) until reaching the connection point and secure it
against toppling. Insert new O-rings (14, 15) with Petro Gel Amber and fix them.
When putting the two sections against each other take care that the O-rings (14, 15) remain in
proper mounting position.
Assemble the two sections and insert the charge air cooler completely into the casing (Fig. 11/3).
14 15
1
5
2
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NOTE
Basic adjustment for the clamping screws (Fig. 13/W1): Clearance (s) of 45 mm (in
case of M16 x 100 screws).
3.7.1 Adjust the charge air cooler (2) by means of the clamping screws (Fig. 13/W1) so that all
threaded holes for the hexagon socket head cap screws (7) are accessible.
s
W1 W1
3.7.2 Preinstall and lightly tighten new hexagon socket head cap screws (Fig. 14/7).
3.7.3 Preinstall and lightly tighten all hexagon screws (10).
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3.7.4 Tighten the hexagon socket head cap screws (7) from the cooling water connection flange in 06
direction of the engine centre by applying the torque indicated in the Tightening torque table
(last page).
3.7.5 Tighten the hexagon screws (Fig. 14/10) from the inside towards the outside by applying the
torque indicated in the Tightening torque table (last page).
A
A-A
10
7 6
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3.8 For M 25 C only: 06

3.8.1 Install and tighten the hexagon screws (Fig. 15/9).
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3.9.1 Remove the clamping screws (Fig. 16/W1).
Install the screw plugs (11) with new gaskets and tighten them with a torque of 105 Nm.
3
11 11
W1
W1
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3.10 Install the screw plugs (Fig. 14/6) with new sealing rings and tighten them with the torque 06
indicated in the Tightening torque table.
Tightening torque for screw plugs / hexagon socket head cap screws / hexagon screws
Hexagon socket
Screw plugs (Fig. Hexagon screws
head cap screws
14/6) (Fig. 14/10)
Engine type (Fig. 14/7)
tightening torque in tightening torque in
tightening torque in
Nm Nm
Nm
M 25 C 105 70 70
M 25 E 105 70 70
M 32 E / 195 190 130

M 34 DF
3.11 If necessary, install the cooling water pipes (Fig. 1/4) at the charge air cooler (2).
3.12 Install the drain plugs (Fig. 11/5), fill up the cooling water system completely with cooling water
and install the vent screws (Fig. 11/1, Fig. 12/1) or, if the engine is equipped with permanent
venting, make sure that the corresponding shut-off cocks are open.
3.13 Check the cooling water system at the charge air cooler (Fig. 1/2) for leaks.
3.14 Install the claddings, covers, and cables required for removal of the charge air cooler (Fig. 1/2).

Dual fuel engine:

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c2 Turbocharger / Compressor
Maintenance / Cleaning
A5.05. 06.05.00.10
24
See also: 06
Spare parts sheets:
Operating medium: Heavy fuel oil and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Clean the compressor
M 20 C
M 25 C / M 25 E
M 32 C / M 32 E
M 34 DF
M 43 C
M 46 DF
CAUTION
Hazard due to manipulation of the washing unit!
An uncontrolled supply of water to the turbocharger may cause injuries and major
property damage.
• Only use the dosing tank supplied by Caterpillar Motoren.
• Never connect the compressor washing unit directly to a water pipe.
CAUTION
Risk of corrosion and formation of deposits due to unclean water!
When using salt water, this may lead to corrosion inside the turbocharger.
• Only use clear water (drinking water).
• The water must be free of cooling water additives or other chemicals which may
form deposits in the flow ducts.
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A5.05. 06.05.00.10
24
Prerequisites: 06
1.1 Cleaning of the compressor stage must be carried out when the engine is at normal operating
temperature and, if possible, running at full load (approx. 75 % load), i.e. at high turbocharger
speed.
1.2 The dosing tank and the pipes from the cleaning system to the respective turbochargers must be
clean.
NOTE
Deposits and dirt particles in the washing system can clog the nozzles and thus affect
the success of the cleaning procedure.
1.3 The dosing tank (2/3) must be empty.
1.4 The sealing cap (2/3) must be closed.
1. Clean the compressor
1.1 Before washing, take a note of the following parameters to assess the success of the cleaning
procedure:
• Charge air pressure

• Turbocharger speed
• Temperature upstream of the turbocharger
• Engine speed
• Exhaust gas temperature downstream of the cylinder head
3
1 Schematic diagram
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A5.05. 06.05.00.10
24
1.2 Unscrew the sealing cap (2/2) from the the

M 20 C / M 25 C
06
dosing tank (2/3).
1
1.3 Fill the dosing tank completely with clean
water.
Engine Quantity
M 20 C 0.5 litre
M 25 C / M25 E
M 32 C 2
M 32 E 1.0 litre
M 34 DF
M 43 C 3
M 46 DF
1.4 Put on the sealing cap (2/2) and tighten it.

M 32 C / M 43 C / M 46 DF
CAUTION
Risk of injury due to 2
improper handling
If the dosing tank is not closed
or closed improperly, this may 3
result in injuries to the
operator.
• Make sure the sealing cap
is closed properly.
1
1.5 Open the ball valve / gate valve (2/1) 20
seconds until the entire amount of water
is injected.
1.6 After cleaning of the compressor side the

M 32 E / M 34 DF
engine must continue to operate under 1
load for at least 5 minutes .
2
NOTE
The success of the cleaning of 3
a dirty compressor wheel can
be recognized by the charge
air pressure downstream of
the turbocharger.
2 Schematic diagram
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A5.05. 06.05.00.10
24
1.7 Compare the values noted under item 1.1 to those obtained after the cleaning. 06
After successful cleaning the temperatures and speeds should have dropped.
NOTE
If no significant changes can be recognized, another washing procedure can take
place after the temperatures and speeds have stabilized for at least 10 minutes. If
after the second washing procedure still no significant changes are recognizable, the
turbocharger must be cleaned mechanically.
For this purpose please contact your Caterpillar dealer.
For further details regarding the turbocharger please refer to the maintenance instructions or operating in-
structions of the turbocharger manufacturer included in the chapter “External Documentation”.
For instructions regarding emergency operation with a damaged turbocharger see engine documenta-
tion, chapter “Operating Instructions”.
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c Measures Regarding the SCR System
Maintenance / Check
A5.05. 06.60.01.10
Daily Check
See also: 03
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. General visual inspection for tight fit and leaks

2. Check the DCU display
3. Check the level of the DEF main tank
NOTE
These precautionary measure must be completed to identify leaks or loose bolted
connections. “Settling“ connecting elements or seals may cause leaks which may
lead to subsequent damage.
The items described in the following are a guide to exclude most of the sources of
defects that may occur.
1. General visual inspection on the outside for tight fit and leaks
1.1 Check the flange, pipe and hose connections as well as the electrical connections, fastening
arrangements, cladding and insulation components of the following SCR systems for tight fit,
leaks, and completeness:
• DEF main tank

• Compressed air station
• DEF transfer pump skid
• Dosing cabinet
• Catalyst tower
• Exhaust gas piping
• Mixing and injection unit
1.2 Tighten or fasten loosened connections and mounting parts.
1.3 Replace missing, damaged or porous components.
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Maintenance / Check
A5.05. 06.60.01.10
Daily Check
2. Check the DCU display 03
NOTE
The SCR control unit DCU (Diesel Control Unit) uses the display panel of the control
stand to display possible error message.
2.1 If one or several error messages are displayed on the display panel of the control stand, the error
message can be decrypted via the SCR Troubleshooting Guide and the appropriate repair
procedures can be initiated.
3. Check the level of the DEF main tank
CAUTION
It has to be ensured that the level in the main tank is sufficiently high to cover the
planned operating period with activated SCR system.
3.1 Check the level at the DCU.
NOTE
During engine operation attention has to be paid regularly to possible leaks.
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Maintenance / Check
A5.05. 06.60.02.10
250 h
See also: 06
Spare parts sheets:

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Activities:
1. Check the hoses and fastenings between dosing cabinet and mixing and injection unit.
2. Check the internal cabling and hose connections of the dosing cabinet.
NOTE
Crystallization is a sure sign of leakage. Any leakage should be localized and
eliminated immediately.
1. Check the hoses and fastenings between dosing cabinet and mixing and injection unit
1.1 Carry out a thorough check of all connecting hoses with respect to chafing marks, porosity, cracks
or other damage. Damaged hoses must be replaced.
1.2 Check all fixing screws on brackets, clamps, connection and coupling flanges and retighten if
necessary.
1.3 Check the insulation at the catalyst tower and the mixing and injection unit for damage and
repair if necessary.
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Maintenance / Check
A5.05. 06.60.02.10
250 h
2. Check the internal cabling and hose connections of the dosing cabinet. 06
WARNING
Danger to life due to electrical shocks!
Alternating voltages in excess of 50 V and direct voltages in excess of 120 V may be
dangerous to life just like current intensities in excess of 50 mA.
Therefore, the following check shall only be carried out by trained personnel.
2.1 Remove the housing covers (1/1, 1/2 and 1/3).
2.2 Check all internal hoses and cabling for possible damage and replace if necessary.
2.3 Check all internal hose connections for proper tightening, retighten if necessary.
1 Schematic diagram
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DEF Level Sensor A5.05. 06.60.03.10
150
See also: 06
Spare parts sheets:

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Activities:
1. Remove the level sensor
2. Install the level sensor
M 20 C / M 25 E
M 32 C / VM 32 C
M 32 E / VM 32 E
M 43 C / VM 43 C
M 34 DF / M 46 DF
VM 46 DF
CAUTION
Health hazard due to “Diesel Exhaust Fluid” (DEF)!
Direct skin and eye contact with “Diesel Exhaust Fluid” (DEF) may cause health
impairments.
• When handling DEF, use the personal protective equipment.
CAUTION
Damage due to leaking “Diesel Exhaust Fluid” (DEF)!
While carrying out any work (e.g. maintenance, adjustment work, etc.) on the system,
there is “Diesel Exhaust Fluid” in the pipes, containers, etc.. Leaking DEF can cause
property and environmental damage.
• Before removing any pipes or disassembling components containing liquid DEF,
collect the DEF in suitable containers!
• Wipe up any spilt or leaking DEF with suitable binding agents or absorbent material
(e.g. rag, fleece)!
• For the disposal of contaminated objects, observe the national and local laws and
directives!
• Do not allow DEF to enter the sewage system, ground water or surface water.
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DEF Level Sensor A5.05. 06.60.03.10
150
1. Remove the level sensor 2 06

1 1
1.1 Shut off the DEF supply to the dosing
cabinet.
1.2 Switch off the power supply to the dosing

cabinet.
1.3 Wait 30 seconds, then shut off the

compressed air supply to the dosing
cabinet.
1.4 Dismount the housing cover (1/2) of the

dosing cabinet by removing the fixing
screws (1/1).
1.5 Disconnect the plug-and-socket

connection (1/3) of the level sensor.
1.6 Screw out the fixing screws (1/4) of the 5

level sensor (1/5).
4
1.7 Take out the level sensor (1/5) and
dispose of it properly.
3
1.8 Remove the gasket (1/6) and dispose of it
properly.
2. Install the level sensor
2.1 Put on the new gasket (1/6). 4
2.2 Insert the new level sensor (1/5) and

mount it with the fixing screws (1/4).
2.3 Connect the plug-and-socket connection

(1/3) of the level sensor.
2.4 Install the housing cover (1/2) of the

dosing cabinet.
2.5 Establish compressed air supply to the

dosing cabinet.
2.6 Establish power supply to the dosing cabinet.
2.7 Establish DEF supply to the dosing cabinet. 6
1 Schematic diagram
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DEF and Air Filter A5.05. 06.60.01.10
c2 Cleaning / Removal and Installation
7500
See also: 06
Spare parts sheets:

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Activities:
1. Remove the filter

2. Clean the filter
3. Install the filter
1. Remove the filter.
NOTE
Smallest dirt particles may impair
the function of the inner valves of
the dosing cabinet and thus lead
to malfunction. Therefore, one
fine filter each has been
arranged immediately upstream
of the inlet into the dosing
cabinet for compressed air and
DEF. 1 1 Schematic diagram
1.1 Block the DEF supply to the dosing

cabinet.
1 2 3
1.2 Block the compressed air supply to the
dosing cabinet.
1.3 Carefully loosen the hexagon screw plug

(1/1) and wait until the pressure has
decreased.
1.4 Completely unscrew the hexagon screw

plug (2/1).
1.5 Remove sealing ring (2/2) and filter basket

(2/3) and deposit them on a clean base.
2 Schematic diagram
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DEF and Air Filter A5.05. 06.60.01.10
c2 Cleaning / Removal and Installation
7500
2. Clean the filter 06

2.1 Clean the filter basket in the DEF supply line:
2.1.1 In case of crystallization place the filter basket (3/3) for about 5 minutes in hot water and then
blow out with compressed air.
2.1.2 Check the hexagon screw plug (3/1) for crystallization. If necessary, dissolve the crystals in hot
water and then remove them by means of compressed air.
2.1.3 Clean the filter support (3/4) in the line.
2.2 Clean the filter basket in the compressed air supply line:
2.2.1 Clean the filter basket and blow it out with compressed air.
2.2.2 Clean the hexagon screw plug (3/1) and blow it out with compressed air.
2.2.3 Clean the filter support (3/4) in the line.
3. Install the filter.
3.1 Insert the filter basket (3/3) into the

hexagon screw plug (3/1) (opening
pointing upwards), insert a new sealing
ring (3/2) and tighten the hexagon screw
plug.
3 1 2 4
3 Schematic diagram
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Compressed Air Regulator DEF A5.05. 06.60.05.10
7500
See also: 06
Spare parts sheets:
Operating medium: Distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the pressure regulator

2. Install the pressure regulator
All engines Torque wrench 140 Nm */**
* no picture
1. Remove the pressure regulator
1.1 Block the compressed air supply to the dosing cabinet (1/1).
1.2 Remove the side covering (1/2).
1.3 Remove the pressure regulator (1/3).
1 2
1 Schematic diagram
3
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Compressed Air Regulator DEF A5.05. 06.60.05.10
7500
2. Install the pressure regulator 06

2.1 Lightly coat the O-rings (2/4 and 2/5) with
Petro Gel Amber and insert them
4
untwisted into the corresponding grooves.
2.2 Install a new pressure regulator and

tighten it with a torque of 140 ± 14 Nm.
2.3 Install the side covering (1/2).

5
2.4 Open the compressed air supply to the
dosing cabinet (1/1).
2 Schematic diagram
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Compressed Air Sensor DEF A5.05. 06.60.06.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the compressed air sensor

2. Install the compressed air sensor
* no picture
1. Remove the compressed air sensor
1.1 Block the compressed air supply to the dosing cabinet (1/1).
1.3 Loosen the plug lock and remove the connector plug (1/3).
1.4 Remove the compressed air sensor (1/4).
1 2
1 Schematic diagram
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Compressed Air Sensor DEF A5.05. 06.60.06.10
7500
2. Install the compressed air sensor 06

2.1 Lightly coat the O-ring (2/5) with Petro Gel
corresponding grooves. 3
2.2 Install a new compressed air sensor (1/3)

and tighten it with a torque of 10 ± 2 Nm.
2.3 Clip on the connector plug (1/3) and

secure it.
2.5 Open the compressed air supply to the

dosing cabinet (1/1).
2 Schematic diagram
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Injector Nozzle DEF A5.05. 06.60.07.10
7500
See also: 06
Spare parts sheets:

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Activities:
1. Remove the injector nozzle

2. Clean the injector nozzle and injector lance
3. Install the injector nozzle
All engines High-temperature thread paste “Rivolta G.W.F.” 1.1002-359 */**/***
Torque wrench 17.6 Nm */**
* no picture
*** or equivalent product
CAUTION
Risk of burns due to hot components!
Direct skin contact with hot surfaces may cause burns.
Before carrying out any work on the exhaust gas system it has to be ensured that the
components to be removed have cooled down sufficiently.
Wear the personal protective equipment.
CAUTION
Risk of property damage due to Diesel Exhaust Fluid (DEF) spills!
During removal work the DEF that is still present in the pipes may spill. Provide
suitable collecting containers and a sufficient number of cleaning rags before start of
the removal work. Immediately wipe up any spilt DEF.
Observe the locally applicable disposal regulations!
1. Remove the injector nozzle
1.1 Block the DEF supply to the dosing cabinet.
1.2 Switch off the power supply to the dosing cabinet.
1.3 Wait 30 seconds, then block the compressed air supply to the dosing cabinet.
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7500
1.4 Shut down the engine. 06



1.6 Remove the connections for DEF (1/1)

and compressed air (1/2). Collect any
leaking DEF.
2 1 1 Schematic diagram
1.7 Remove all fixing screws (2/4) and

washers (2/5)
1.8 Extract the injector lance (2/6) with gasket

(2/7). If necessary, loosen the gasket with
a suitable tool.
2 Schematic diagram
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7500
1.9 Remove the injector nozzle (3/8) and 06

washer (3/9).
2. Clean the injector nozzle and injector

lance
2.1 Place the injector nozzle (3/8) in hot water,

after about 5 minutes the DEF crystals
should have dissolved. After that, clean
with compressed air.
2.2 Make sure that the injector nozzle and

especially the nozzle ducts are free of
deposits. If necessary, repeat the cleaning.
NOTE 6 10 9 8
Particularly tenacious
deposits (crystallization) may 3 Schematic diagram
also be carefully removed by
means of a brass brush.
2.3 Check the injector nozzle support (3/10),

injector lance (3/6), and connections for
deposits and clean them if necessary.
2.4 Install the injector nozzlel
2.5 Lightly coat the injector nozzle thread with

“Rivolta G.W.F.” and screw it with a new X
gasket (3/9) into the injector lance (3/6). 6
2.6 Tighten the injector nozzle (3/8) with a 7

torque of 17.6 ± 2 Nm.
X
2.7 Lightly coat the new gasket (4/7) on both
sides with “Rivolta G.W.F.” and insert it
with the injector lance (4/6) into the mixing 5
and injection unit. In doing so, ensure
correct alignment, see markings (4/X) in 4
the flanges.
4 Schematic diagram
2.8 Lightly coat the threads of the fixing
screws (4/4) with “Rivolta G.W.F.” and
screw them in with the washers (4/5).
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7500
2.9 Tighten all fixing screws crosswise. 06

2.10 Install the connections for DEF (5/1) and
compressed air (5/2).

Dual fuel and common rail diesel engine

2.12 Start the engine.
2.13 Establish compressed air supply to the dosing cabinet.
2.14 Establish power supply to the dosing cabinet.
2.15 Establish DEF supply to the dosing cabinet.
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Temperature Sensor DEF A5.05. 06.60.08.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the temperature sensor

2. Install the temperature sensor
* no picture
CAUTION

cabinet (1/1).

cabinet.
1.3 Wait 30 seconds, then block the

cabinet.

2
1
1 Schematic diagram
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Temperature Sensor DEF A5.05. 06.60.08.10
7500
1.5 Remove the connector plug (2/3). 4 3 06

1.6 Remove the temperature sensor (2/4).
2.1 Lightly coat the O-ring (3/5) with Petro Gel

corresponding grooves.
2.2 Install a new temperature sensor (2/

4) and tighten it with a torque of 48 ±
5 Nm.
2.3 Clip on the connector plug (2/3).

2 Schematic diagram
2.5 Establish compressed air supply to the 5

dosing cabinet.
2.6 Establish power supply to the dosing

cabinet.
2.7 Establish DEF supply to the dosing

cabinet.
3 Schematic diagram
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Solenoid Valve DEF A5.05. 06.60.09.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the solenoid valve

2. Install the solenoid valve
Inch tool kit */**
* no picture
CAUTION
NOTE
The dosing cabinet (1/1) includes, among others, three solenoid valves. One each is
located in the supply line (1/2) of the DEF circuit and in the return line (1/3), a third
valve is located in the compressed air supply line (1/4).
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7500
1. Remove the solenoid valve 06
2 3 4
5 5 5
1 Schematic diagram
1.1 Block the DEF supply to the dosing cabinet (1/1).
1.3 Wait 30 seconds, then disconnect the compressed air supply to the dosing cabinet.
1.4 Remove the corresponding side covering of the dosing cabinet (1/1).
1.5 Loosen tie wraps or other cable fastening arrangements.
1.6 Remove the corresponding connector plug (1/5).
1.7 Remove the corresponding solenoid valve.
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7500
2. Install the solenoid valve 06

2.1 Apply a thin coat of Petro Gel Amber to the O-rings and insert them untwisted into the
corresponding groove.
2.2 Install the new solenoid valve and tighten it with a torque of 60 ± 5 Nm.
2.3 Clip on the corresponding connector plug (1/5).
2.4 Fasten cable with tie wraps.
2.6 Reestablish compressed air supply to the dosing cabinet.
2.7 Reestablish power supply to the dosing cabinet.
2.8 Reestablish DEF supply to the dosing cabinet.
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7500
06
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Dosing Pump DEF A5.05. 06.60.10.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the dosing pump

2. Replace the dosing pump diaphragm and non-return valves
3. Install the dosing pump
All engines Textile round sling W1 **
Petro Gel Amber W2 461114-041 */**
* no picture
CAUTION
1. Remove the dosing pump 2

cabinet.

cabinet.
1.3 Wait 30 seconds, then disconnect the

cabinet.
1.4 Remove / disconnect the connections in

the area of the front covering (1/2).
1.5 Remove the side (1/1), front (1/2) and top 1

covering (1/3). 3
1 Schematic diagram
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7500
06
1.6 Remove all eight hexagon socket head cap screws (2/4) with washers (2/5).

6 7
1.7 Loosen and slightly lower the dosing pump distributor cap (3/6).
1.8 Remove the dosing pump cabling (4/7).
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7500
06
6 5 Schematic diagram 7 6 Schematic diagram
1.9 Remove all four wing nuts (5/8) with

washers, remove the cable brackets (5/9)
and take off the fastening struts (5/10).
1.10 Remove all four threaded rods (6/11).
1.11 Attach the dosing pump (7/12) with the

textile sling (7/W1) to the crane. In doing
so, make sure that the dosing pump is
hanging in horizontal position and stable.
1.12 Carefully raise the dosing pump (7/12), lift

it out of the dosing cabinet with care and
put it onto a suitable base.
12 W1 7 Schematic diagram
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7500
2. Replace the dosing pump diaphragm and non-return valves 06

16b
15
16a
16a
14 15
16b
8 Schematic diagram
13
2.1 Remove all fixing screws (8/13) with washers and take off the valve support (8/14).
2.2 Take out the non-return valves (8/15) and O-rings (8/16a and 16b).
18
17 17
9 Schematic diagram
19
2.3 Remove the dosing pump diaphragm (9/17) by turning in counter-clockwise direction.
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7500
06
NOTE
When replacing the complete pump drive (electric motor / 9/18) also the fastening
supports (9/19) must be removed and fitted to the new pump drive.
2.4 Screw on the new dosing pump diaphragm (9/17) and tighten it.
CAUTION
Avoid malfunction and property damage due to incorrect installation!
As the two non-return valves are of identical construction, attention must be paid to
ensure correct flow direction (direction of arrow) upon installation. The pressure
connection is at the top (arrow pointing away from the pump), the suction connection
is at the bottom (arrow pointing into the pump).
2.5 Clean the contact surfaces, put on the valve support (8/14), clip on the washers and tighten
the fixing screws (8/13) crosswise in several steps.
2.6 Apply a thin coat of Petro Gel Amber (W2) to new O-rings (8/16a) and insert them with the
new non-return valves (8/15) into the valve support (8/14), pay attention to the flow direction.
3. Install the dosing pump
3.1 Remove any DEF residues from the

sealing surfaces (10/20) of the dosing
pump distributor cap (10/6) with warm
water.
3.2 Attach the dosing pump (7/12) with the

textile sling (7/W1) to the crane. In doing
so, make sure that the dosing pump is
hanging in horizontal position and stable.
3.3 Position the dosing pump (7/12) with care

in the dosing cabinet.
3.4 Install the threaded rods (6/11).
3.5 Put on the two fastening struts (5/10), clip

on the cable brackets (5/9), install the wing
nuts (5/8) with washers and tighten them.
10 6
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7500
3.6 Insert a new O-ring (8/16b) each into the grooves of the non-return valves, apply a thin coat 06
of Petro Gel Amber (W2) to them beforehand.
3.7 Position the dosing pump distributor cap (3/6). In doing so, make sure the O-rings are
correctly positioned.
3.8 Install all eight hexagon socket head cap screws (2/4) with washers (2/5) and tighten them
crosswise in several steps.
3.9 Install the dosing pump cabling (4/7).
3.10 Install the side (1/1), front (1/2) and top covering (1/3).
3.11 Install the removed connections in the area of the front covering (1/2).
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NOx Sensor CEM A5.05. 06.60.11.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. NOx sensor removal

2. NOx sensor installation
* no picture
CAUTION
Before carrying out any work on the exhaust gas system it must be ensured that the
NOTE
After switching off the SCR system the engine can continue to operate. However, in
this case it has to be taken into account that only the IMO II limits will be kept.
NOTE
The NOx sensors are permanently checked for proper function by the engine control
software. This software automatically sends an error message if a defect of a sensor,
sensor cable, etc. is identified.
NOx sensors are always supplied with the related buffer (3/8). This sensor/buffer unit
is individually calibrated before delivery.
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NOx Sensor CEM A5.05. 06.60.11.10
7500
Stop the engine. 06


Dual fuel engine:

- Set the selector switch at the control stand to “Repair” (depending on equipment)
1. NOx sensor removal
NOTE
The SCR system is monitored among others by two NOx sensors (2/7). One sensor is
located at the inlet to the mixing and injection unit (1/1), the other is located at the
outlet of the SCR catalyst tower (1/2). This job instruction describes the replacement
of the NOx sensors using the example of a pure MDO engine.
On engines designed also for HFO operation, the NOx sensors (1/7) are located in
additional mounting groups, as shown under (1/A).
MDO Installation HFO Installation 2
2 (7)
A
1
A
1 Schematic diagram
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NOx Sensor CEM A5.05. 06.60.11.10
7500
06
3 7 3
2 Schematic diagram
1.1 Open the corresponding connection box (2/3).
4
6
8 3 3 Schematic diagram 5
1.2 Unlock the connector lock (3/4) and remove the connector (3/5).
1.3 Remove the fixing screws (3/6) and then remove the complete sensor/buffer unit (3/7
and 3/8).
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NOx Sensor CEM A5.05. 06.60.11.10
7500
1.4 Loosen cable clamps and fasteners (4/9). 06

10 9 11
1.5 Remove the corresponding NOx sensor
(4/7).
2. NOx sensor installation
NOTE
The thread of the sensor is
coated with a high-temperature
resistant grease ex works.
During the installation do not
use any additional agents.
7 4 Schematic diagram 3
2.1 Screw in the new NOx sensor (4/7).
In doing so, make sure not to twist the sensor cable (4/10).
2.2 Tighten the NOx sensor (4/7) with a torque of 50 ± 10 Nm.
2.3 Insert the buffer (3/8) into the connection box (3/3) and install it with the fixing screws (3/6).
2.4 Lay the sensor cable (4/10) so that it is not subjected to any stress and fasten it according
to local conditions.
2.5 Install the cover (4/11) of the connection box (4/3)

Dual fuel engine:

en / 26.01.2018 4/4
Exhaust Gas Pressure Sensor CEM A5.05. 06.60.12.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the exhaust gas pressure sensor

2. Install the exhaust gas pressure sensor
Inch tool kit */**
* no picture
CAUTION
Before carrying out any work on the exhaust gas system it has to be ensured that the
NOTE
en / 19.01.2017 1/4
7500
Stop the engine. 06



1. Remove the exhaust gas pressure sensor.
NOTE
The exhaust gas pressure sensor 1
is permanently checked for
proper function by the engine
control software.This software
automatically sends an error
message if a defect of a sensor,
sensor cable, etc. is identified.
NOTE
The SCR system is monitored
among others by an exhaust
gas pressure sensor. This sen-
sor is located in the connection
box of the mixing and injection
unit (1/1).
1 Schematic diagram
en / 19.01.2017 2/4
7500
. 06
2 3
7 8 5 6
1.1 Remove the cover (2/2) of the connection box.
1.2 Loosen the connector plug (2/3).
1.3 Remove the exhaust gas pressure sensor (2/5).
2. Install the exhaust gas pressure sensor
2.1 Check the pressure sensor seat (2/6), flexible tube (2/7), and connections (2/8) for cleanli-
ness and functionality. Remove any cross-section reducing deposits or replace the affected
components.
2.2 Apply a thin coat of Petro Gel Amber to the O-ring of the exhaust gas pressure sensor (2/5)
and insert it untwisted into the groove.
2.3 Apply a thin coat of Rivolta to the thread of the new exhaust gas pressure sensor (2/5), in-
stall it and tighten it with a torque of 10 ± 2 Nm.
2.4 Fasten the connector plug (2/3).
en / 19.01.2017 3/4
7500
2.5 Install the cover (2/2) of the connection box. 06



en / 19.01.2017 4/4
Temperature Sensor CEM A5.05. 06.60.13.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:

* no picture
CAUTION
NOTE
en / 19.01.2017 1/4
7500
Stop the engine. 06



1. Remove the temperature sensor.
NOTE 2
The temperature sensors are

permanently checked for
proper function by the engine
control software.This software
automatically sends an error
message if a defect of a
1
sensor, sensor cable, etc. is
identified.
NOTE
The SCR system is monitored,
amongst others, by two
temperature sensors.One is
located at the inlet to the SCR
catalyst tower (1/1), the other is
located at its outlet (1/2).
1 Schematic diagram
en / 19.01.2017 2/4
7500
. 06
3 (1/1) 7 7 3 (1/2)
2 Schematic diagram
1.1 Open the corresponding connection box (2/3).
1.2 Unlock the plug lock (3/4) and remove the sensor plug (3/5).
1.3 Loosen cable clamps and fasteners (3/6).
1.4 Remove the corresponding temperature sensor (2/7) with cable (3/8) and connection
socket (3/9).
4 5
8 6 9 3 Schematic diagram
en / 19.01.2017 3/4
7500
2. Install the temperature sensor 06
NOTE
The thread of temperature sensor is coated with a high-temperature resistant
grease ex works.
Do not use any additional agents during the installation!
2.1 Screw in the new temperature sensor (2/7). In doing so, make sure not to twist the sensor
cable (3/8).
2.2 Tighten the temperature sensor with a torque of 45 ± 5 Nm.
2.3 Lay the sensor cable (3/8) with connection socket (3/9) free of stress into the corresponding
connection box (2/3) and fix with cable clamps and tie wraps (3/6).
2.4 Plug in the sensor plug (3/5) and secure with the plug lock (3/4).
2.5 Install the cover of the connection box (2/3)


en / 19.01.2017 4/4
Catalyst Elements CEM A5.05. 06.60.14.10
7500
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the catalyst elements

2. Install the catalyst elements
All engines High-temperature thread paste “Rivolta G.W.F.” 1.1002-359 */**/***
* no picture
WARNING
Risk of injury due to poisonous exhaust gas!
Exhaust gas accumulating in the catalyst tower may cause severe respiratory
disorder.
• Before start of any maintenance work the catalyst tower must be ventilated.
• The exhaust gas system must always be in good order to carry off the exhaust
gas into the atmosphere.
• Wear respiratory protection and protective clothing when staying in the catalyst
tower.
• Never remain in the hazard area longer than necessary.
CAUTION
en / 19.01.2017 1/8
7500
06
CAUTION
Risk of injury due to sharp edges and projections.
Sharp edges and projections inside the catalyst housing may cause cutting and
concussion damage. When working inside the catalyst housing always wear personal
protective equipment, especially a hard hat, protective forearm cuffs, and gloves.
1. Remove the catalyst elements
1.1 Block the DEF supply to the dosing cabinet.
1.3 Wait 30 seconds, then disconnect the compressed air supply to the dosing cabinet.
1.4 Shut down the engine.


1a 1a
1.6 Remove all fixing screws (1/1) except for

two (1/1a) in the upper two corners. .
1.7 One person must hold the cover (1/2)

while a second person removes the last
two fixing screws (1/1a). Jointly lower the
cover and place it onto a suitable base.
1 Schematic diagram
en / 19.01.2017 2/8
7500
06
3
6
1.8 Extract the pin locks (2/3).
1.9 Remove the pins (2/4).
1.10 Remove the cross braces (2/5).
1.11 Remove the insertion rails (3/6).
NOTE
The individual catalyst elements must be stored in a dry environment. If the catalyst
elements should come into contact with moisture, they must be dried immediately.
Moisture will lead to corrosion in the catalyst elements and thus decrease the
efficiency of the exhaust gas cleaning system.
en / 19.01.2017 3/8
7500
06
7 8
10
4 Schematic diagram
1.12 Remove all catalyst elements (4/7) of the first layer and place them onto a suitable base.
CAUTION
Environmental damage due to wrong disposal.
Used catalyst elements are contaminated with toxic substances that must not get into
the environment.
If necessary, employ a specialized waste disposal company to dispose of packaging
materials.
1.13 Remove all pin locks (4/8).
1.14 Remove all pins (4/9) and take out the T hold-downs (4/10).
en / 19.01.2017 4/8
7500
06
15
11 12 13 14
5 Schematic diagram
NOTE
Depending on the number of catalyst elements on one layer, these are inserted into
two or three assembly frames (5/11, 5/12, 5/13) .
The assembly frames are connected to each other using two retaining pins each.
1.15 Pull out the pin locks at the bottom (5/14).
1.16 Remove the pins (5/15).
1.17 Lift the assembly frames (5/11,5/12 and, if applicable, 5/13/ depending on the equipment)
out of the catalyst tower.
CAUTION
Destruction of the catalyst elements due to mechanical load!
If subjected to point load, the catalyst element surface will be destroyed.
Before stepping on the catalyst elements, a sufficiently large tread/working surface
must be provided in form of wooden plates. When using devices such as ladders care
has to be taken to ensure that these are never resting directly on the catalyst
elements. Always line sufficiently with wood.
1.18 Repeat steps 1.8 through 1.17 for all layers of the catalyst.
en / 19.01.2017 5/8
7500
2. Install the catalyst elements 06
11 12
14 15
13
6 Schematic diagram
CAUTION
SCR failure due to wrong equipment!
All layers must by equipped with the catalyst elements designed for your catalyst type.
Incomplete or mixed equipment is not permissible and will lead to malfunction or
destruction of the catalyst elements.
2.1 Before inserting the first assembly frame layer, general cleaning and visual inspection of the
catalyst tower must be carried out. For this purpose, roughly remove any dust and other
deposits from the tower walls and points of contact. Extract any dirt particles that have
fallen down.
2.2 Carry out a thorough visual inspection of all disconnectable connections and welds inside
and outside of the catalyst tower and, if necessary, repair them.
2.3 Insert the assembly frames (6/11, 6/12 and, if applicable, 6/13/ depending on the
equipment) one after the other into the catalyst tower and align them.
2.4 Insert the pins (6/15) and lock them with the pin locks (5/14).
en / 19.01.2017 6/8
7500
06
10
7
14
15
7 Schematic diagram
2.5 Install all angles (7/10) of the layer to be installed with pins (7/15) and pin locks (7/14).
2.6 Insert all catalyst elements (7/7) of the first layer.
CAUTION
Destruction of the catalyst elements due to mechanical load!
If subjected to point load, the catalyst element surface will be destroyed.
Before stepping on the catalyst elements, a sufficiently large tread/working surface
must be provided, e.g. in form of wooden plates. When using devices such as ladders
care has to be taken to ensure that these are never resting directly on the catalyst
elements. Always line sufficiently with wood.
2.7 Repeat steps 2.3 through 1.6 for all layers of the catalyst.
en / 19.01.2017 7/8
7500
2.8 Check the gasket (8/16) of the cover (8/2) 06

for reusability and, if necessary, replace it
by a new one. .
2.9 Lightly coat the gasket (8/16) with Rivolta

G.W.F. on both sides.
2.10 Bring the cover (8/2) with gasket (8/16)

into installation position and install it in the
upper area to the left and to the right with
two fixing screws (8/1).
2.11 After that, insert the remaining fixing

screws (8/1) and tighten all fixing screws. 1
16 2
8 Schematic diagram

Dual fuel and common rail diesel engine

en / 19.01.2017 8/8
c2 Soot Blower CEM
A5.05. 06.60.15.10
See also: 07
Spare parts sheets:
Operating medium: Heavy fuel oil

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Diaphragm - removal
2. Diaphragm - installation
All engines
CAUTION
• Before carrying out any work on the exhaust gas system it must be ensured that
the components to be removed have cooled down sufficiently.
1a
1. Diaphragm - removal
1.1 Shut down the engine.

starting.
Secure the components that have been
shut down against being switched on
inadvertently.
1b
the engine.
lever (if provided).
1 Schematic diagram
en / 21.03.2018 1/4
c2 Soot Blower CEM
A5.05. 06.60.15.10
Dual fuel engine: 07

the engine.
1.3 Switch off the soot blower at the circuit

breaker and secure it against being 1
switched on again.
1.4 Disconnect the soot blower from the

power supply and secure it.
1.5 Switch off the compressed air supply. For

this purpose, set the lever of the shut-off
valve to rest position (1/1a).
1.6 At first, only loosen the three screws (2/1)

at the respective soot blower valve to
release the pressure. Wait until the
pressure has fully dropped.
2
1.7 Dismount the three screws and remove
the valve plate with valve (2/2).
1.8 Take out the diaphragm (2/4).
2. Diaphragm - installation
2.1 Position the diaphragm (2/4), with the

bulge facing towards the inside, centrally
onto the socket (2/5) and the threaded
holes. For this purpose, place the 2 lugs 3 4
(2/3) at the diaphragm onto the grooves in
the tank profile.
2.2 Position the valve plate with valve (2/2)

over it and install it. Tighten the screws
(2/1) alternately in several steps with a
torque of 8 Nm +/-10 %.
2.3 Reestablish compressed air supply. For

this purpose, set the lever of the shut-off
valve to operating position (1/1b).
2.4 Switch on the soot blower at the circuit

breaker. 5
2 Schematic diagram
en / 21.03.2018 2/4
c2 Soot Blower CEM
A5.05. 06.60.15.10
Dual fuel engine:

en / 21.03.2018 3/4
c2 Soot Blower CEM
A5.05. 06.60.15.10
07
en / 21.03.2018 4/4
c2 Urea Concentration
Maintenance / Check
A5.05. 06.60.16.10
150
See also: 06
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Adjust the refractometer
2. Check the urea concentration
3. Clean the refractometer
M 20 C / M 25 E Refractometer W1 1.9860-001 *
M 32 C / VM 32 C
M 32 E / VM 32 E
M 43 C / VM 43 C
M 34 DF / M 46 DF
VM 46 DF
* no picture
CAUTION
Health hazard due to “Diesel Exhaust Fluid” (DEF)!
Direct skin and eye contact with “Diesel Exhaust Fluid” (DEF) may cause health
impairments.
• Use personal protective equipment when carrying out work on the SCR system and
handling DEF.
CAUTION
Biassed measuring results!
Ambient / room temperature and sample temperature influence the measuring result of
the refractometer (W1). The scales are designed for an ambient temperature of +20 °C.
en / 27.03.2020 1/4
Maintenance / Check
A5.05. 06.60.16.10
150
1. Adjust the refractometer 06

1.1 Hold the refractometer (W1) against a sufficiently bright source of light and look through the
ocular (1/2). Keep the rubber eyecup close to the eye / glasses.
1.2 Turn the ocular (1/2) until the scale appears sharp.
1.3 Fold the prism cover (1/5) upwards.
1.4 Thoroughly clean the prism surface (1/4) and the bottom side of the prism cover (1/5) with a soft
cloth and pure alcohol and then wipe them dry.
1.5 Apply a few drops of calibration liquid to the prism surface (1/4).
1.6 Press on the prism cover (1/5). The liquid quantity should be sufficient to wet the essential part of
the prism surface (1/4). There must not be any air bubbles between the prism surface and the
prism cover.
1.7 Wait 30 seconds until the temperature of the calibrating liquid and the prism surface (1/4) have
become equal.
1.8 Look through the ocular (1/2) and direct the prism surface (1/4) of the refractometer (W1) against
a source of light that should be as bright as possible.
1.9 In the ocular, a bright field and a dark field are visible. The parting line indicates the measuring
value on the scale (2/1) visible in the ocular.
1.10 The refractometer (W1) can be adjusted optimally by means of the supplied adjustment tool. For
this purpose, shift the scale towards the parting line by turning the adjustment screw (1/1) (under
the rubber cap behind the prism surface).
Adjustment value: 0 % urea
1.11 Repeat steps 1.3 and 1.4.
2
1
1 Schematic diagram
en / 27.03.2020 2/4
Maintenance / Check
A5.05. 06.60.16.10
150
2. Check the urea concentration 06
NOTE
The measured samples are only average samples. In order to achieve accurate
measuring results, the samples should have the same temperature as the refracto-
meter (W1).
2.1 Take a sample from the buffer tank of the dosing cabinet by means of the supplied pipette.
2.2 Touch the refractometer (W1) with dry hands.
2.4 Apply a few drops of the sample to the prism surface (1/4).
2.5 Close the prism cover (1/5). By pressing-on the sample is distributed evenly and possible air
bubbles are removed.
2.6 Wait 30 seconds until the temperature of the sample and the prism surface (1/4) have become
equal.
2.7 Look through the ocular (1/2) and direct the prism surface (1/4) of the refractometer (W1) against
a source of light that should be as bright as possible.
2.8 Turn the adjusting ring (1/3) at the ocular (1/2) to focus the scale. The parting line on the scale
shifts depending on the concentration. The bright-dark boundary shows the result on the scale (2/
1).
2.9 The refractometer (W1) has a marking on the scale at 32.5 % (2/1). This marking indicates the
target value for urea concentration. The urea concentration must be between 32.5% and 40%.
2 Schematic diagram
2.10 Clean the refractometer (W1), see section 3 “Clean the refractometer”.
2.11 Take another sample from the main tank by means of the supplied pipette and repeat steps 2.2
through 2.10.
en / 27.03.2020 3/4
Maintenance / Check
A5.05. 06.60.16.10
150
3. Clean the refractometer 06

3.2 Remove liquids at the prism surface (1/4) and the bottom side of the prism cover (1/5) with a lint-
free, absorbent cloth.
3.3 After that, thoroughly clean the prism surface and the bottom side of the prism cover with a soft
cloth moistened with pure alcohol.
3.4 Dry the prism surface and the bottom side of the prism cover with a soft, dry and lint-free cloth. In
doing so, avoid rubbing on the prism.
en / 27.03.2020 4/4
c2 Injection Pump
Removal / Installation
A5.05. 07.02.01.12
See also: A5.05.07.15.01.nn 07

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Injection pump - removal

2. Injection pump - installation
M 25 C / M 25 E Torque wrench 60 - 320 Nm W1 1.9454-320 *
Adapter (3/4 to 1/2) W3 1.9459-035 *
Lifting device for injection pump W5 259235 A *

* no picture
CAUTION
Risk of injury due to pre-loaded components!
The spring force of the injection pump drive acts against the injection pump. The
compression spring may suddenly relax when loosening the threaded connection
without back pressure and cause injuries.
• Bar the crankshaft in such a way that the cam follower roller of the injection pump
drive is on the base circle of the injection cam.
1. Injection pump - removal


en / 19.12.2018 1/6
c2 Injection Pump
A5.05. 07.02.01.12
1.2 If equipped, open the indicator valves by 1 07

means of the socket wrench (W4).
2
1.3 Remove the pump chamber covering at
cylinder 1 and the cylinder head concerned.
1.4 Remove the camshaft covering with housing

covers and gaskets of the injection pump to 3
be serviced on camshaft side.
1.5 Engage the barring device. Bar the engine

so that the cam follower roller (1/3) of the 4
injection pump drive concerned is on the
base circle of the injection cam (1/4).
1.6 Close the shut-off cocks for fuel inlet and

outlet outside of the engine (plant specific).
1 Schematic diagram
1.7 Drain the fuel return pipe and the fuel feed
pipe. For this purpose, loosen the screw (2/2) at cylinder 1, DO NOT remove it.
1 4
5
3
12
2
6
11
8
10
2 Schematic diagram
1.8 Loosen the hexagon head bolts of the leak oil pipes (2/6) on both sides of the injection pump and
pull the flanges off the injection pump.
1.9 Only if working on the outer cylinders:

Remove the end piece (2/1), check the gaskets and replace them if necessary.
Disconnect from the leak fuel pipe (2/12).
1.10 Remove the fuel return pipe and the fuel feed pipe (A5.05.07.15.01.nn).
1.11 Remove the compressed air pipes (2/5) completely from the injection pump.
en / 19.12.2018 2/6
c2 Injection Pump
A5.05. 07.02.01.12
1.12 Remove the control air pipe (2/8). 07
NOTE
Remove the non-return valve (2/7) only for replacing the injection pump.
1.13 Push the sleeve (3/1) into the cylinder 1

head housing and remove the transverse
pressure tube of the fuel injector delivery
pipe. 2
1.14 Disconnect the control rod (2/4) from the 3

control shaft. For this purpose, loosen the
threaded connection (2/3).
1.15 Push the control rod (2/4) as far as pos- 4

sible into the injection pump.
1.16 Loosen the bracket (3/2) for the shut-

down cylinder (3/3) at the injection pump.
1.17 Fit the lifting device (W5) to the injection

pump.
3 Schematic diagram
CAUTION
The spring force of the injection pump drive acts against the injection pump. The
compression spring may suddenly relax when loosening the threaded connection
without back pressure and cause injuries.
• Do not bend over the injection pump while loosening the threaded connection.
• Carefully loosen the threaded connection.
1.18 Loosen the nuts (2/11) evenly.
NOTE
The cylinder-specific spacer sheets (2/10) must not be removed.
(If, however, they were removed e.g. for cleaning purposes, the required sheet
thicknesses for reinstallation can be found in the acceptance test record.)
1.19 Lift the injection pump off the engine block by means of the lifting device (W5).
1.20 Remove the air transfer sleeve (3/4) with O-rings.
1.21 Take out the thrust rod (1/1) and the compression spring (1/2), check them visually for damage
and dirt and reinsert them.
en / 19.12.2018 3/6
c2 Injection Pump
A5.05. 07.02.01.12
2. Injection pump - installation 07
NOTE
It is recommended to use MaK “Genuine Spare Parts”!
If spare parts of other origin are used, this may result in an expiry of the IMO approval
in the marine area up to a shutdown of the engine.
2.1 Check the throttle tubes for tight fit (A5.05.07.15.01.nn).
2.2 Bar the engine so that the cam follower roller (1/3) of the injection pump drive concerned is on the
base circle of the injection cam (1/4).
2.3 Clean the contact surfaces of injection pump, the spacer sheets (2/10), the thrust rod (1/1), and
the compression spring (1/2) in the injection pump.
2.4 Equip the air transfer sleeve (3/4) with new O-rings. Apply a thin coat of Petro Gel Amber to the
O-rings and insert them untwisted.
2.5 Install the air transfer sleeve. Pay attention to correct position of the control air transfer socket in
the cooling collar.
2.6 Replace the O-ring (2/9), apply a thin coat of Petro Gel Amber to the new O-ring and insert it
untwisted.
2.7 Lift the injection pump by means of the lifting device and put it over the fixing screws.
Insert the thrust rod with compression spring into the receiving hole of the injection pump.
2.8 Apply a thin coat of Molykote to the threads and contact surfaces of the nuts (2/11).
2.9 Pull the injection pump onto its seat by evenly and alternately tightening the nuts.
2.10 Tighten the nuts with a torque of 200 Nm.
2.11 Install the bracket (3/2) for the shut-down cylinder (3/3).
2.12 Connect the control shaft to the control rod (2/4) of the injection pump. First check the linkage
for ease of movement, then firmly tighten the screw (2/3).
2.13 Install the control air pipe (2/8) and, if previously removed, the non-return valve (2/7).
2.14 Install the transverse pressure tube of the fuel injector delivery pipe and push the sleeve (3/1) into
the injection pump housing (engaged position).
2.15 Only if working on the outer cylinders:

Install the end piece (2/1).
Install the leak fuel pipe (2/12).
2.16 Install the leak oil pipes (2/6) at the injection pump using new gaskets.
2.17 Install the compressed air pipes (2/5) for the shut-down cylinder (3/3).
en / 19.12.2018 4/6
c2 Injection Pump
A5.05. 07.02.01.12
2.18 Install the fuel return pipe and the fuel feed pipe (A5.05.07.15.01.nn). 07
2.19 Firmly tighten the drain screw (2/2) again at cylinder 1.
2.20 Open the shut-off cocks for fuel inlet and outlet outside of the engine (plant specific).
2.21 Fill the fuel system by means of the stand-by pump and vent it.
2.22 If equipped, close the indicator valves by means of the socket wrench (W4).
2.23 Install the camshaft covering and the pump space cladding.

en / 19.12.2018 5/6
c2 Injection Pump
A5.05. 07.02.01.12
07
en / 19.12.2018 6/6
Injection Pump A5.05. 07.03.01.11
c2 Check / Disassembly and Reassembly
15000, 7500
See also: A5.05.07.02.01.nn02.01.nn 07

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Disassembly
2. Check
3. Reassembly
M 25 C / M 25 E Torque wrench 60 - 320 Nm 1.9454-320 *
Reversible ratchet 3/4 1.9495-036 *
Adapter (3/4 to 1/2) 1.9459-035 *

Loctite */**
Log, gas oil, and hard brush */**
* no picture
CAUTION
Danger due to changed fuel delivery rate!
In case of overhaul work make sure that the individual components of an injection
pump remain assigned to the respective housing. Interchanging or replacing any
components will have a considerable influence on the fuel delivery rate.
Plunger guide (1/11) and pump plunger (1/12) may only be exchanged together.
If an exchange of individual components is required, the injection pump will have to
be readjusted on a test bench.
The permissible leak rate of the lubricating oil/fuel mixture per injection pump is:
max. 150 ml/h.
Reworking the sealing surfaces is not allowable on any part of the injection system!
en / 05.09.2017 1/6
15000, 7500
07
3 7 5
4
NOTE
In order to enable a cost- 11
efficient repair, pump elements
should only be overhauled as
a complete unit and measures 6
should be taken to exclude
any interchanges.
Preserve lapped surfaces and 2
avoid any skin contact.
In case of a significant drop 9
9
in cylinder power check the
injection pump and, if 10
necessary, replace the 10
pressure retention valve or the
plunger guide (1/11) together
12
with the pump plunger (1/12).
NOTE X
For the following steps the
injection pump (1) must be
removed from the engine
block (A5.05.07.02.01.nn).
1. Disassembly 22
1.1 Clean the outside of the injection pump

(1).
1.2 Remove the spill plugs (1/9) with the

sealing rings (1/10) and check them.
For removing the spill plugs (1/9) it may be
advantageous to heat them up in order to Y
loosen the Loctite locking compound.
1.3 Clamp the injection pump with the 30

fastening flange (1/23) pointing upwards.
23
28 1
1 Schematic diagram
en / 05.09.2017 2/6
15000, 7500
07
CAUTION
The spring force of the tappet spring (1/22) acts against the tappet (1/30) and may
suddenly relax when opening without back pressure and cause contusions.
Apply back pressure during disassembly.
1.4 Load the intermediate flange (1/1) axially

by means of a spindle device. X
1.5 Remove the hexagon socket head cap

screws (1/28) and slowly loosen the 21
spindle device. The compression spring 16
(1/22) will be relieved.
1.6 Remove the intermediate flange (2Y/1) 14

19
with O-rings (2Y/27 and 2Y/29), scraper
ring (2Y/26), and sealing ring (2Y/25).
33
1.7 Remove the tappet (2Y/30) with lower
spring plate (2Y/32), compression spring
(2Y/22), and pump plunger (2Y/12).
1.8 Remove the control sleeve (2X/16) with

spring plate (2X/33) and scraper ring (2X/
14).
1.9 Remove the locking bolt (2X/19) and the

governor thrust rod (2X/21).
Y
1.10 Clamp the injection pump housing (1/2)
with the flange (1/3) pointing upwards. 12
1.11 Loosen the hexagon socket head cap 22 32
screws (1/5) crosswise and remove them.
30
1.12 Remove the flange (1/3) with thrust piece
(1/7) and pressure retention valve (1/6).
25
1.13 Loosen the hexagon socket head cap
screws (1/4) crosswise and remove them. 26
1.14 Drive the plunger guide (1/11) with a 29

suitable log out of the injection pump
housing (1/2). 27 1
2 Schematic diagram
en / 05.09.2017 3/6
15000, 7500
2. Check 07
2.1 Clean all components with gas oil and a hard brush, blow them out with compressed air and
check them.
During the visual inspection pay particular attention to the following wear symptoms:
Pump plunger (1/12): Score marks in the running surface, control helix wear (due to cavitation or
erosion). Black discoloration or stains on the plunger are indicative of water in the fuel.
Plunger guide (1/11): Score marks in the running surface, damage at the sealing surface
towards the injection pump housing (1/2); cavitation in the inlet hole.
Injection pump housing (1/2): Loctite residues on the internal thread of the spill plug threads.
Spill plugs (1/9): Cavitation at the front surface; Loctite residues on the spill plugs.
Tappet (1/30): Score marks in the running surface, battered pump plunger receptacle.
Compression spring (1/22): Possible corrosion.
Control sleeve (2X/16) and governor thrust rod (2X/21): Check the toothing.
Pressure retention valve (1/6): Damaged sealing surfaces and valve spring, battered valve
seat.
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15000, 7500
3. Reassembly 07
3.1 Make sure that the injection pump housing (5/2) is clamped with the flange (5/3) pointing
upwards.
CAUTION
Risk of leaks!
Improper handling when installing the O-rings may cause leaks.
Do not pull the O-rings over sharp component edges.
Lightly coat new O-rings with Petro Gel Amber and insert them into the grooves
untwisted.
3.2 Lightly coat new O-rings (5/8, 5/15, 5/20, 5/27, and 5/34) with Petro Gel Amber and insert them
into the grooves untwisted.
3.3 Insert a new sealing ring (5/13) into the groove.
CAUTION
Risk of leaks!
Do not sharply bend the sealing ring (2/25) and scraper ring (2/26) upon assembly.
3.4 Insert the new sealing ring (2/25) and the

new scraper ring (2/26) into the
intermediate flange (2/1):
3.4.1 Bring the sealing ring (2/25) and the

scraper ring (2/26) into a “kidney shape”
(3) and, as shown in 2, insert it into the
groove in the intermediate flange (5/2).
3.4.2 Press the sealing ring (2/25) and the 3 Schematic diagram
scraper ring (2/26) in the groove back into
round shape (4).
3.4.3 Expand the sealing ring (2/25) and the

scraper ring (2/26) with a mandrel.
3.5 Lightly lubricate all screws and the

contact surfaces with Molykote.
3.6 Install the plunger guide (5/11) with the

hexagon socket head cap screws (5/4) in
the injection pump housing (5/2).
3.6.1 Tighten the hexagon socket head cap

screws (5/4) crosswise in two steps, with a
torque 10 Nm and in the second step with
4 Schematic diagram
90 ± 3 Nm.
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15000, 7500
3.7 Install the pressure retention valve (5/6) 07

and the thrust piece (5/7). 3 7 5
4
3.8 Install the flange (5/3) with the hexagon
s
socket head cap screws (5/5) so as to be
parallel to the plunger guide (5/11). 11
The clearance (5/s) shall be the same all
around; the tolerance is ±0.1 mm (check 8 6
by means of a feeler gauge).
3.8.1 Tighten the hexagon socket head cap

screws (5/5) crosswise with the following 2
torque: 10
9
9
M 25 C: 53 Nm
10
M 25 E: 43 Nm 13
3.8.2 Lubricate the threads and contact 15

surfaces of the spill plugs (5/9) with
Loctite, install them with new sealing rings
(5/10) and tighten them with a torque of
85 Nm. X
3.8.3 Clamp the injection pump with the

fastening flange (5/23) pointing upwards.
3.9 Install the governor thrust rod (2X/21) with

control sleeve (2X/16), spring plate (2X/
33), and scraper ring (2X/14). In doing so,
pay attention to the following:
- Matching between the groove in the
governor thrust rod (2X/21) and the
straight grooved pin of the control sleeve
(2X/16)
- Mounting position of the scraper ring
(2X/14) Y
23
3.10 Install the locking bolt (2X/19) and tighten
it with a torque of14 Nm.
3.11 Check the governor thrust rod (2X/21) for

20 27
ease of movement.
3.12 Install the pump plunger (2Y/12) with 34

compression spring (2Y/22), tappet (2Y/
30), lower spring plate (2Y/32), and
intermediate flange (2Y/1).
3.13 Axially load the fastening flange (5/1) with 28

a spindle device and tighten the hexagon
1
socket head cap screws (5/28) crosswise
3.14 Slowly open the spindle device and

remove it. 5 Schematic diagram
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c2 Fuel Injector
A5.05. 07.07.01.11
See also: A5.05.07.08.01.nn 07

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

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Fuel injector - removal

2. Fuel injector - installation
M 25 C / M 25 E Fuel injector removal device W1 0.9111 E
Seat cleaner for nozzle sleeve W2 259122 A *
* no picture
NOTE
When the engine is operated on heavy fuel it is necessary, prior to carrying out any
work on the injection system, to change over to distillate fuel for at least 0.5 hours to
thoroughly flush the fuel injector.
1. Fuel injector - removal


1.2 Remove the valve cover and the pump chamber covering of the corresponding cylinder head.
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c2 Fuel Injector
A5.05. 07.07.01.11
1.3 Push the sleeve (1/6) to the left into the 1 2 3 4 07

cylinder head frame.
1.4 Completely unscrew the threaded

connection (1/Y) of the transverse thrust
piece (1/7) out of the injection pump (1/5).
NOTE
10
Always loosen the threaded
connection (1/Y) first!
Z
The sealing surfaces of the radial
thrust piece (1/10) and the
transverse thrust piece (1/7) will
be damaged due to improper 5
removal!
1.5 Loosen the thrust screw (1/8), carefully

disengage the cap (1/9) and pull the
transverse thrust piece (1/7) to the left out 9
of the injection pump and the cylinder
head.
1.6 Pull out the radial thrust piece (1/10). 8 7 6 Y
1.7 Remove the hexagon nuts (2/1). 1 Schematic diagram
1.8 Take off the extension sleeves (2/2) and

the flange (2/4).
1
CAUTION 2
Risk of damage due to

sticking fuel injectors!
• Do not use any undue force!
• If the fuel injector cannot be
extracted, please contact
your authorized Caterpillar
dealer and / or install the
spare cylinder head.
4 3
2 Schematic diagram
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c2 Fuel Injector
A5.05. 07.07.01.11
1.9 Put in place the removal device (3/W1) as a complete unit. 07

1.9.1 Slightly loosen the hexagon head bolts (3/2) and firmly install the threaded pieces (3/3) on the
studs (3/4) until reaching the end stop.
1.9.2 Firmly tighten the hexagon head bolts.
1.9.3 Firmly screw the threaded rod with star knob (3/7) onto the adjusting screw (3/5).
1.9.4 Place the anti-twist device (3/6) over the hexagon of the threaded rod.
1.10 Loosen the fuel injector by turning the threaded sleeve (3/1)) with a wrench (3/8) and unscrew it
until the bottom O-ring (4/4) is exposed.
1.11 Remove the hexagon head bolts (3/2).
1.12 Extract the fuel injector by means of the removal device.
1.13 Unscrew the threaded sleeve (3/1) from the fuel injector, remove the threaded pieces (3/3) and
reassemble the removal device (W1).
1.14 Clean the fuel injector on the outside, mark it with the cylinder number and check correct
functioning of the injection nozzle (A5.05.07.08.01.nn).
1.15 Clean the valve seat in the sleeve (4/6) with the seat cleaner (W2).
Clean the sleeve on the inside.
W1 8
1
2
7
3
3 Schematic diagram
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c2 Fuel Injector
A5.05. 07.07.01.11
2. Fuel injector - installation 07

8
1
2.1 Apply a thin coat of Rivolta G.W.F. high-
temperature thread paste to the nozzle
element (4/5).
2
2.2 Apply a thin coat of Molykote paste to the
threads of the studs (4/2) and the contact 7
surfaces of the hexagon nuts (4/1) and a
3
thin coat of Petro Gel Amber to the new
O-rings (4/4).
CAUTION
Risk of damage due to an
excessive amount of Petro
Gel Amber!
If there is an excessive amount
of Petro Gel Amber, the O-rings
may get crushed in the locking
groove of the cylinder.
• Remove any excessive Petro 4
Gel.
2.3 Insert the new O-rings (4/4) untwisted into

the O-ring grooves.
There is no gasket between the fuel
injector and the sleeve (4/X)!
2.4 Carefully insert the fuel injector into the

sleeve (4/6) paying attention to the
position of the locating pin (1/4).
2.5 Put on the flange (4/3) with spring dowel 5

pin (4/7) towards exhaust gas pipe and
with ring lug downwards. X
6
2.6 Tighten the hexagon nuts (4/8) with a
torque of 50 Nm.
4 Schematic diagram
2.7 Loosen the hexagon nuts (4/8) by one turn
and then tighten them with a torque of
10 Nm.
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c2 Fuel Injector
A5.05. 07.07.01.11
2.8 Insert the radial thrust piece (5/10). 1 2 3 4 07

2.9 Install the transverse thrust piece (5/7)
ensuring correct position of the cap (5/9)!
2.10 Preinstall the threaded connection (5/Y)

and the thrust screw (5/3) so as to be
finger tight.
2.11 Tighten the thrust screw (5/8) and then the 10

threaded connection (5/Y) with a torque of
10 Nm.
Z
2.12 Tighten the threaded connection (5/Y)
with a torque of 150 ± 5 Nm. In doing so,
apply a fork wrench to the appropriate 5
surfaces (5/Z) and keep the transverse
thrust piece (5/7) in position.
2.13 Tighten the thrust screw (5/8) with a

torque of 130 ± 5 Nm. In doing so, apply a 9
fork wrench to the appropriate surfaces (5/
Z) and keep the transverse thrust piece (5/
7) in position.
8 7 6 Y
2.14 Push the sleeve (5/6) into the injection
pump until it reaches engaged position.
5 Schematic diagram
2.15 Tighten the hexagon nuts (5/3) in two

steps with a torque of 50 Nm.

• Connect the lubricating oil stand-by pump / prelubrication pump.
2.19 Check the lubricating oil and fuel circuits for leaks.
2.20 Install the pump chamber covering.
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c2 Fuel Injector
A5.05. 07.07.01.11
07
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c2 Fuel Injector
Maintenance / Adjustment
A5.05. 07.08.01.11
See also: A5.05.07.09.01.nn, A5.05.07.07.01.nn 07

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Fuel injector - maintenance

2. Fuel injector - check of the adjustment
M 25 C / M 25 E Nozzle tester W1 1.9470 G
Hand pump W1.1 1.9470-010
Collecting cup W1.2 1.9470-020
Bracket W1.3 1.9470-030
Support W1.4 1.9470-040
High-pressure hose W1.5 1.9470-070
Adapter for fuel injector W2 259208 B

* no picture
WARNING
Risk of injury!
The fuel exits the injection nozzle under very high pressure. In case of contact, it may
cause severe injuries or be forced under the skin and lead to blood poisoning.
• Do not reach into the fuel jet.
NOTE
The formation of “trumpets” (i.e. coke deposits) at the nozzles indicates that the fuel
is too warm. Corrosive attacks / erosion, however, are the consequence of
excessively cold fuel.
If necessary, contact your authorized Caterpillar dealer.
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c2 Fuel Injector
A5.05. 07.08.01.11
07
NOTE
Proper function of the injection nozzles can only be assessed on the basis of the
behaviour of the exhaust gas temperatures or the smoke emission characteristics.
The fuel injector should only be removed and checked in case of a significant
deviation of the exhaust gas temperature from the respective cylinder value.
With the nozzle tester the behaviour of the nozzle during operation cannot be
reproduced because the flow rate and the attendant pressure build-up cannot be
compared to the real conditions on the engine, i.e. the spray pattern alone is not
indicative of the function of the nozzle.
A drop in nozzle opening pressure after a short period of operation (settling
phenomena of the nozzle spring and needle) is normal
1. Fuel injector - maintenance
1.1 Remove the respective fuel injector (A5.05.07.07.01.nn).
1.2 Clean the nozzle with a hard brush (no wire brush) to remove coke residues.
1.3 Check the nozzle holes for corrosion and damage, replace the fuel injector if necessary.
2. Fuel injector - check of the adjustment
2.1 Remove the O-rings of the fuel injector.
2.2 Introduce the fuel injector into the bracket (1/W1.3).
2.3 Install the adapter (1/W2) at the fuel injector (1/3).
2.4 Insert the fuel injector into the support (1/W1.4) of the nozzle tester (W1).
2.5 Connect the high-pressure hose (1/W1.5) to the hand pump (1/W1.1) and the adapter.
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c2 Fuel Injector
A5.05. 07.08.01.11
2.6 Using the hand pump slowly build up 1 W1.3 07

pressure until the fuel injector starts to
spray. Read off the nozzle opening
pressure and compare it to the minimum
opening pressure. W2
Desired value: 390 bar
W1.5
2.7 If the nozzle opening pressure reading is
different:
W1.4
Check the nozzle holes for free passage.
NOTE 2
Do NOT readjust the fuel

injector.
In case of a high leak fuel percentage,

clogged nozzle holes and pressure W1.2
reading below the minimum nozzle
opening pressure, overhaul the fuel
injector (A5.05.07.09.01.nn) or replace it
(A5.05.07.07.01.nn).
1
2.8 Adjusting the fuel injector after

component replacement W2
2.8.1 When using a new fuel injector or a new W1.1

W1.4
nozzle element with a new nozzle spring,
adjust the nozzle opening pressure
according to the acceptance test record
(see engine documentation, “Technical
Engine Data”): 2
W1.5
For this purpose, loosen the adjusting

screw (1/1) and adjust it until the correct
nozzle opening pressure is reached.
Desired value: 450 +5/-2 bar .
2.9 Apply a thin coat of Petro Gel Amber to 1 Schematic diagram
new O-rings and insert them untwisted

into the O-ring grooves.
2.10 Install the fuel injector (A5.05.07.07.01.nn).
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c2 Fuel Injector
A5.05. 07.08.01.11
07
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c2 Fuel Injector
Maintenance / Disassembly and Assembly
A5.05. 07.09.01.11
7500
See also: A5.05.07.07.01.nn, A5.05.07.08.01.nn 07

Spare parts sheets: B1.05.07.252267

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Fuel injector - disassembly and servicing

2. Fuel injector - assembly
Adapter (3/4 to 1/2) W4 1.9459-035 *
Socket wrench insert W5 259222 D *
Molykote paste “G-Rapid Plus” 1.9493-001 *
* no picture
NOTE
The fuel injector should only be disassembled if a check (A5.05.07.08.01.nn) reveals
deficiencies (such as leaks, opening pressure too low, poor spraying).
All parts of the injection system are manufactured with utmost precision in special
workshops. This is the only way to ensure perfect function. For this reason, a repair at
the operator is impossible and the necessary maintenance work should be restricted
to
• Cleaning
• Checking the opening pressure and tightness
• Replacing of wear parts using original parts and replacement elements.
In order to enable a cost-efficient repair, the elements in need of an overhaul should
be shipped as complete units and in a way that excludes any mix-up.
NOTE
It is recommended to use MaK “Genuine Spare Parts”!
If spare parts of other origin are used, this may result in an expiry of the (IMO) approval
in the marine area up to a shutdown of the engine.
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c2 Fuel Injector
A5.05. 07.09.01.11
7500
07
CAUTION
Different fuel injectors (manufactured by CAT and Bosch) are being used.
• Never interchange parts of different fuel injectors.
• Check the marking at the fuel injector to be able to apply the correct tightening
torques.
1. Fuel injector - disassembly and servicing
1.1 Remove the fuel injector according to Bosch CAT

A5.05.07.07.01.nn. 1
1.2 Remove the screw plug (1/1) with sealing

ring (1/2) (if equipped). 2
1.3 For Bosch fuel injectors only:
Remove the locknut (1/3), relieve the
nozzle spring (1/10) by unscrewing the
adjusting screw (1/4). 11
1.4 Fix the nozzle holder (1/11) and loosen

and remove the nozzle nut (1/9) with the
socket wrench insert (W5) (counter-clock-
wise). 3
1.5 Take out the nozzle element (1/8) including 4

the nozzle needle (1/7) without damaging
the lapped surfaces. Pay attention to the
parallel pins (2/1) for fixation of the nozzle.
10
Remove the adjusting screw (1/4). 5
1.7 Remove the intermediate washer (1/6) (if 6

equipped), the nozzle spring (1/10), and
the thrust piece (1/5). Pay attention to the
parallel pins for fixation of the intermediate 9
washer!
7
1.8 Visually check the nozzle spring and the
thrust piece.
8
1.9 Clean all parts with clean gas oil.
1.10 Check all parts visually, especially the seat 1 Schematic diagram
and sealing surfaces.
Replace any defective parts.
1.11 Replace the nozzle element (1/8) including the nozzle needle (1/7).
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c2 Fuel Injector
A5.05. 07.09.01.11
7500
2. Fuel injector - assembly 07

2.1 Wipe all sealing surfaces dry with clean lint-free paper.
2.2 Apply a thin coat of Molykote to the thread of the nozzle nut (1/9) and the nozzle contact surface
in the nozzle nut.
2.3 Install the intermediate washer (1/6) (if equipped).

Upon assembly, pay attention to the fixation of the parallel pins!
2.4 Do not damage the lapped surfaces (nozzle element, nozzle needle)!
Align the nozzle element (1/8) with nozzle needle (1/7) with respect to the parallel pins (2/1), put
them in place and fix them with the nozzle nut.
2.5 Insert the nozzle spring (1/10) with thrust piece (1/5).

1
Screw in the adjusting screw (1/4).
2.7 Fix the nozzle holder (1/11) and tighten the

nozzle nut (1/9) with socket wrench insert
(W5) and the following torque.
Bosch CAT
750 Nm 650-680 Nm
2 Schematic diagram
Insert the locknut (1/3) and tighten it with a torque of 60 ± 10 Nm.

Centre the sealing ring (1/2).
2.10 Insert the screw plug (1/1) and tighten it with the following torque.
Bosch CAT
90 + 30 Nm 290-300 Nm
NOTE
For Bosch fuel injectors only: Check the sealing ring once again for correct
seating. It is absolutely required that it rests in the centre! Otherwise, repeat steps
2.9 and 2.10 with a new sealing ring.
2.11 Check and adjust the fuel injector according to A5.05.07.08.01.nn.
2.12 Install the fuel injector according to A5.05.07.07.01.nn.
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c2 Fuel Injector
A5.05. 07.09.01.11
7500
07
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Duplex Fuel Filter A5.05. 07.12.01.10
See also: 07
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Filter element - removal

2. Filter element - cleaning
3. Filter element - installation
M 43 C / VM 43 C / Ejector for filter candles W1 1.9100-120

M 46 DF / VM 46 DF
M 20 C / Cleaning gun W2 1.9100-114

M 25 C / M 25 E /
M 32 C / M 32 E / Cleaning tube (except for M 20 C) W2a 1.9100-115 *
M 34 DF / Collecting pan for fuel */***
VM 32 C / VM 32 E /
M 43 C / VM 43 C / BOLL CLEAN 2000 cleaning agent */**
M 46 DF / VM 46 DF
Brush / soft scrubber */***

High-pressure cleaning unit with flat scrub- */***
ber if necessary
Ultrasonic cleaning unit if necessary */***
* no picture
NOTE
• Clean the duplex fuel filter when
50 % of the red area on the differential pressure display are visible or a filter alarm
has been activated.
• Cleaning of the duplex fuel filter takes place during operation or in warmed-up con-
dition.
• When operating on heavy fuel, never let the filled duplex fuel filter cool down.
• After commissioning a new plant or after carrying out work on the fuel piping sys-
tem, check the filter after approximately 24 hours and clean it if necessary.
en / 15.05.2018 1/6
07
NOTE
In order to ensure full operational safety, it is recommended to use MaK “Genuine
Spare Parts”!
If spare parts of other origin are used, the operator has to ensure that full operational
safety is provided.
NOTE
Depending on engine type and equipment status, the filter elements of the duplex fuel
filters may vary. This Job Card describes the cleaning procedure for a duplex fuel filter
with filter candles as an example.
Filter candles Star-pleated element Multi-mantle element
1. Filter element - removal
WARNING
Risk of injury due to hot engine components!
Parts of the duplex fuel filter can become very hot during operation (up to 140 °C) and
cause serious burns in case of skin contact.
• Before beginning to work, make sure that the engine components have cooled
down to a normal temperature.
• Use personal protective equipment!
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07
NOTE
Depending on the duplex fuel filter version, a vent screw (1/B1) is fitted at one or two
locations of the filter housing (see Fig. 1).
1.1 By means of the change lever (1/4) disconnect the filter chamber to be cleaned from the fuel
system (turn the change lever towards the filter that is not being serviced). If applicable, pay
attention to the switching symbol on the filter cover.
WARNING
Risk of injury due to engine parts under high pressure!
Risk of skin injuries due to possible leaks on components under high pressure.
• Particular caution is required when carrying out work during engine operation.
1.2 Carefully loosen the vent screw/s (1/B1) 3

and slowly relieve the overpressure. 4
1.3 After that, slowly open the sludge drain (1/

6) of the filter chamber to be cleaned and 2
drain the issuing fuel via the drain plug (1/
5) into a suitable container. B1 B1
1.4 Completely dismount the vent screw of the

filter chamber to be cleaned and remove the
splash protection / screw locking device 1
(1/3).
1.5 Remove the cover (1/2) of the filter chamber 6

to be serviced.
5
1.6 Extract the filter element (2/4) with gasket
and allow it to drain.
1 Schematic diagram
2. Filter element - cleaning
NOTE
• In case of heavy fuel operation soak the dismounted filter element first in a diesel
bath.
• In case of severe contamination of the filter element (lacquering, incrustation, tar
residues, fibres, chips):
• Remove the filter candles and clean them individually (see step 2.11).
• Soak the filter element in a diesel bath.
• On each 3rd cleaning remove the filter candles and clean them individually (see
step 2.11).
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07
CAUTION
Risk of damage to the filter element due to improper cleaning!
If the pressure is too high when using a high-pressure cleaning unit and/or a cleaning gun
or the filter element is not handled properly, the filter element may be damaged.
• Carry out operation and maintenance of the duplex fuel filter with utmost care in order
to prevent damage to the filter element and malfunctioning of the fuel system.
• The maximum allowable cleaning temperature for using the cleaning agent is 60 °C.
• Apply a maximum pressure of 60 bar to a high-pressure cleaning unit with flat nozzle.
During the process, keep a min. distance of 20 cm to the surface of the filter element.
• Dirt particles must not reach the clean side of the filter element.
• Treat the filter mesh with care.
• Handle the cleaning gun with care.
• Do not place individual filter candles on top of one another.
2.1 Place the filter element (2/4) with inserted
filter candles (2/3) into a suitable container.
Add cleaning liquid max. up to the lower
edge of the upper filter plate (2/2).
I doing so, make sure that no contaminated
cleaning liquid can flow into the filter candles W2
from above.
The soaking time shall be in accordance

with the instructions of the manufacturer of
the cleaning agent.
If necessary, contact your authorized Cater-
pillar dealer additionally.
1 2
2.2 After removing coarse dirt, the filter element
can be cleaned by means of an ultrasonic
bath.
• For this purpose, fill the ultrasonic de- 3

vice with a mixture of water and cleaning
agent (mixing ratio 1:14) and place the
filter element into the bath. Observe the
instructions of the manufacturer of the
ultrasonic device.
4
• Put the filter element into the ultrasonic
device upside down and vertically.
• As soon as oil accumulates at the sur-
face of the cleaning agent, remove it (so
that the oil does not spread across the
filter element when extracting it).
• Extract the filter element.
2 Schematic diagram
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2.3 Apply compressed air to the cleaning gun W1 07

(2/W2).
Maximum pressure 2
Filter candles
Star-pleated
Multi-mantle
element
element
6 - 10 bar 4 bar 3
5
2.4 Withdraw the filter element from the
cleaning container and blow out the filter
candles as follows:
Push the splash protection (2/1) up to the
nozzle stop of the cleaning gun, put it over
4
the opening of the candle and hold it.
During compressed air cleaning, slowly
move the nozzle down to the bottom of the
filter candle.
Repeat this step for each filter candle.
3 Schematic diagram
2.5 Dip the filter element into clean cleaning

agent once again, pull it out, and allow it to
drain.
2.6 Blow out the filter element by means of

the cleaning gun.
2.7 Turn the filter element upside down so that W2

the remaining cleaning liquid can drain off.
2.8 By means of the ejector (3/W1) press one

filter candle down and swing it out laterally.
2.9 Illuminate the filter fabric and check

whether the cleaning was successful. 1
2.10 A sufficiently cleaned filter candle shows a

maximum mesh contamination of approxi-
mately 10 %. If the mesh contamination
exceeds 10 %, the cleaning process must 5
be repeated or the candles must be
cleaned one by one.
2.11 Individual cleaning:
2.11.1 Repeat step 2.1.

3
2.11.2 After that, remove all filter candles with the
ejector (3/W1).
4 Schematic diagram
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2.11.3 Make sure not to put the filter candles on top of one another to avoid damaging the mesh of the 07
filter candles.
2.11.4 Remove any tenacious dirt with a brush or a soft scrubber.
2.11.5 Rinse the filter candles in clean cleaning liquid, blow them out and allow them to dry with the
opening pointing downward.
3. Filter element - installation
3.1 Check the filter candles (4/3) and, if the candles are damaged or the fabric shows significant
folds, replace the affected candle.
3.2 Check the O-rings (4/5) and replace them if necessary. Apply a thin coat of Petro Gel Amber to
the (new) O-rings and insert them untwisted into the grooves of the filter candles.
3 4
3.3 Mount the dry filter candles in the filter ele-
ment. 2
3.4 Clean the filter chamber (5/5) on the in- 1

side and rinse it with gas oil if necessary.
3.5 Check the gasket at the cover (5/1) and

replace it if necessary.
3.6 Insert the filter element (3/4) and install

the cover. 5
3.7 Clip on the splash protection (5/2) and in-
stall the vent screw (5/3).
3.8 If applicable, tighten further vent screws.
3.9 Open the vent screw/s (5/3) slightly again

and carefully move the change lever (5/4)
towards the centre. 5 Schematic diagram
During this, fuel will slowly flow into the
serviced filter chamber.
3.10 As soon as fuel is leaking out of the vent screw (5/3), close it and set the change lever (5/4) back
to original position.
3.11 The serviced filter chamber is now ready for use and can be put into operation at any moment by
throwing the change lever (5/4).
en / 15.05.2018 6/6
Fuel Feed Pump A5.05. 07.13.01.10
c2 Maintenance / Removal / Installation
30000, 15000, 45000
See also: 07
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the fuel feed pump and check it for wear

2. Install the fuel feed pump
M 20 C / M 25 C/ Petro Gel Amber 461114-041 *

M 25 E / M 32 C /
VM 32 C Molykote paste “G-Rapid Plus” 1.9439-001 *
“Dirko Grey” silicone sealing compound *
Torque wrench 14 Nm **
CAUTION
Risk of severe engine damage!
If the fuel feed pump is connected wrongly (fuel supply and discharge) this may cause
severe damage to the engine.
It is absolutely required to observe the correct installation position of the fuel feed
pump. Therefore, mark the position of the pump before removing it.
NOTE
Repair of the fuel feed pump requires a high amount of expertise and can hardly be
carried out perfectly under field conditions. Even if genuine Caterpillar spare parts are
used, the original flow rate may not be achieved any more.
It is, therefore, recommend to have defective fuel feed pumps repaired by an
en / 29.08.2016 1/4
Fuel Feed Pump A5.05. 07.13.01.10
30000, 15000, 45000
1. Remove the fuel feed pump and check it for wear 07



1.2 Close the shut-off valves, drain the fuel from the pipes and collect it with appropriate means.
1.3 Mark the installation position of the fuel feed pump (Fig. 1/3) with the fuel supply pipe (Fig. 1/1)
and the fuel feed pipe (Fig. 1/2).
1.4 Remove the fuel pipes.
1.5 Dismount and extract the fuel feed pump (Fig. 1/3) from the drive casing (Fig. 1/6).
6 2 3
1 Schematic diagram
en / 29.08.2016 2/4
Fuel Feed Pump A5.05. 07.13.01.10
30000, 15000, 45000
1.6 Remove the parallel key (Fig. 2/5) and the circlip (Fig. 2/9). 07
1.7 Loosen the hexagon bolts (Fig. 2/13) and remove the cover plate (Fig. 2/14) as well as the fuel
feed pump casing (Fig. 2/15). In doing so, pay attention to the dowel pin (Fig. 2/8).
1.8 Remove the O-rings (Fig. 2/16).
1.9 Remove the driving gear shaft and impeller shaft (Fig. 2/17, 18).
1.10 Remove the shaft seal (Fig. 2/10).
1.11 Remove the bearing bushes (Fig. 2/19).
1.12 Check the driving gear shaft and the impeller shaft (Fig. 2/17, 18) and the bearing bushes (Fig. 2/
19) for wear and replace them if necessary.
1.13 Remove the drive casing (Fig. 1/6) (A5.05.07.13.02.nn).
10 19 X 15 18 19 13
14
17
16
11
X 8
2 Schematic diagram
en / 29.08.2016 3/4
Fuel Feed Pump A5.05. 07.13.01.10
30000, 15000, 45000
2. Install the fuel feed pump 07

2.1 Install the drive casing (Fig. 1/6) (A5.05.07.13.02.nn).
2.2 Install the bearing bushes (Fig. 2/19).
2.3 Coat the new O-rings (Fig. 2/16) with Petro Gel Amber and insert them into the grooves
untwisted.
2.4 Coat the new shaft seal (Fig. 2/10) with Petro Gel Amber and insert it into the drive cover (Fig. 2/
11).
2.5 Install the circlip (Fig. 2/9).
2.6 Insert the driving gear shaft and the impeller shaft (Fig. 2/17, 18) into the drive cover (Fig. 2/11).
In doing so, pay attention to the shaft seal (Fig. 2/10).
2.7 Put the fuel feed pump casing (Fig. 2/15) over the driving gear shaft and the impeller shaft (Fig. 2/
17, 18) onto the drive cover (Fig. 2/11). In doing so, pay attention to the O-ring (Fig. 2/16) and the
dowel pin (Fig. 2/8).
2.8 Install the cover plate (Fig. 2/14) with the hexagon screws (Fig. 2/13). In doing so, pay attention
to the O-ring (Fig. 2/16).
Lightly oil the threads of the hexagon screws (Fig. 2/13) and tighten with a torque of 14 Nm.
2.9 Clean the contact surfaces of the drive casing (Fig. 1/6) and the drive cover (Fig. 2/11) and apply
silicon sealing agent.
2.10 Insert the parallel key (Fig. 2/5).
2.11 Install the fuel feed pump (pump side, Fig. 1/3) at the drive casing (Fig. 1/6). In doing so, make
sure the fuel supply pipe (Fig. 1/1) and the fuel feed pipe (Fig. 1/2) are correctly positioned.
2.12 Install the fuel supply pipe (Fig. 1/1) and the fuel feed pipe (Fig. 1/2) at the fuel feed pump (Fig. 1/
3). In doing so, make sure the connections and pipes are correctly positioned.
2.13 Open the shut-off valves and vent the fuel pipes.
2.14 Check the fuel system for leaks.

- Set the selector switch at the control stand to “Engine” or “Remote” (depending on
equipment).

- Set the selector switch at the control stand to “Engine” or “Remote (depending on equipment).
en / 29.08.2016 4/4
Fuel Feed Pump Drive A5.05. 07.13.02.11
15000
See also: 07
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the fuel feed pump drive and check it for wear
2. Install the fuel feed pump drive

M 32 C
Adapter (3/4” to 1/2”) W3 1.9459-035 *
Feeler gauge W4 1.9075-003 *
Extractor ***
Petro Gel Amber 461114-041 **

Screw locking compound, medium strength
* no picture
CAUTION
Risk of severe engine damage!
If the fuel feed pump is connected wrongly (fuel supply and discharge), this may cause
severe damage to the engine.
• It is absolutely required to observe the correct installation position of the fuel feed
pump. Therefore, mark the position of the pump before removing it!
NOTE
An improper repair of the fuel feed pump drive can lead to a reduced flow rate. We
are, therefore, recommending to have defective fuel feed pump drives repaired by an
en / 27.04.2020 1/6
15000
1. Remove the fuel feed pump drive and check it for wear 07

• Throw and secure the emergency stop lever.
1.2 Close the shut-off cocks.

Drain the fuel from the pipes and collect it with suitable means.
1.3 Mark the installation position of the fuel feed pump (1/4), the connections and pipes.
1.4 Loosen the pipes at the fuel feed pump.
1.5 Remove the hexagon head screws (1/5) and pull the fuel feed pump with coupling half (1/9) out of
the drive casing (1/8).
3 4
M1=X
5 15 12 9 11 4
7 8
14
10 13
M2=X-1
1 Schematic diagram
NOTE
For some variants, additional headless screws have been fitted!
If applicable, remove/install these headless screws (1/14 and 15)!
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15000
1.6 If applicable, loosen the headless screw (1/14). 07

1.7 Pull off the coupling half (1/9), take out the rubber element (1/3) and parallel key (1/11).
1.8 Remove the fixing screws (1/2) and pull the drive casing (1/8) with gear (1/7) out of the engine
block.
1.9 Remove the O-ring (1/1).
1.10 If applicable, loosen the headless screw (1/15).
1.11 Pull off the coupling half (1/13) and take out the parallel key (1/12).
.
7 15 16 17 18
22
21
20 8 19 10
2 Schematic diagram
NOTE
In case of irregularities, replace the gear or contact your authorized Caterpillar
dealer.
1.12 Remove the hexagon head screw (2/21) and washer (2/22).
1.13 Pull off the gear (2/7) with a suitable extractor.
1.14 Check the tooth flanks of the gear for wear (pitting, skewing, crumbling, etc.).
1.15 Loosen the hexagon head screws (2/19) and press the driving shaft (2/10) with cover (2/20) out of
the drive casing (2/8).
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15000
1.16 Remove the shaft seal (2/18) and dispose of it properly. 07

1.17 Check the bushes (2/15 and 17) and the driving shaft for wear, press out worn bushes. If the
driving shaft (2/10) shows score marks, it also has to be replaced.
1.18 Check the axial thrust surfaces between casing (2/8) and cover (2/20) for wear.
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15000
2. Install the fuel feed pump drive 07
CAUTION
Damage to the fuel feed pump drive possible!
If the hole (2/16) is completely or partly blocked, the driving gear bearing will not be
supplied with sufficient lubricating oil. After a short time, this will lead to bearing
damage and failure of the fuel feed pump drive / fuel feed pump.
• Make sure that the oil hole (2/16) is not closed!
2.1 If necessary, equip the drive casing (2/8) with new bushes (2/15 and 17). Lightly lubricate the
bushes with oil before pressing them in. Do not use Molykote. Press in the bush (2/15) so as to be
flush with the rear shoulder and bush (/17) with a distance of s = 2 mm.
2.2 Before installing the gear (2/7), check the bearing pattern between the gear cone and the driving
shaft cone by means of blue paste. The contact pattern must be even and the percentage contact
area > 80%!
2.3 Clean, degrease, and dry the gear cone and the driving shaft cone.
2.4 Put the gear (2/7) onto the driving shaft cone, measure the distance a (2/a) and note it down.
2.5 Set up the fuel feed pump drive so that the driving shaft cone is pointing upwards.
2.6 Clip on the cover (2/20), heat up the gear (2/7) evenly (e.g. in an oven) by about 30 C to 40 C
above temperature of the driving shaft cone and place it onto the driving shaft.
CAUTION
Risk of damage to the gear due to improper handling and installation!
• When putting it onto the driving shaft cone do not apply any pressure! The dead
weight of the gear ensures that the required mounting distance is reached!
2.7 Let the gear (2/7) cool down to room temperature and check the distance a , it must be 0.14 - 0.18
mm (mounting distance) smaller than in cold condition. If necessary, remove the gear and repeat
the installation.
2.8 Coat the thread and contact surface of the hexagon head screw (2/21) and washer (2/22) with
Molykote paste “G-Rapid Plus”.
Tighten the hexagon head screw (2/21) with a torque of 60 Nm.
2.9 Insert a new shaft seal (2/18).
2.10 Push the driving shaft (2/10) with cover into the drive casing and install it with hexagon head
screws (2/19).
2.11 Firmly press in the shaft seal (2/18).
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15000
2.12 Clamp the drive casing (2/8) in vertical position and insert the parallel key (1/12). 07
2.13 Check the coupling half (1/13) for possible damage and replace it if necessary. After that, heat it
up to approx. 100 C, push it onto the journal of the driving shaft (1/10) until it reaches the end
stop and let it cool down.
2.14 If applicable, insert the headless screw (1/15) with medium-strength screw locking compound and
tighten to 5 Nm.
2.15 Clean the contact surface at the drive casing (1/8) and the pump mounting plate / engine block,
smooth possible damage with an oil stone.
2.16 Lightly coat a new O-ring (1/1) with “Petro Gel Amber” and insert it untwisted.
2.17 Carefully insert the preassembled pump drive into the pump mounting plate / engine block and
install it with fixing screws (1/2).
2.18 Determine dimension X (1/M1). Dimension M2 must be X minus 1 mm.
2.19 Insert the parallel key (1/11), check the coupling half (1/9) for possible damage and replace it if
necessary. After that, heat it up to 100 C, push it onto the shaft journal of the fuel feed pump
(1/4) and let it cool down. Dimension M2 must be observed.
2.20 Install the fuel feed pump (1/4) with a new rubber element (1/3) and hexagon head screws (1/5).
2.21 Install and tighten removed or loosened pipes.
2.22 Check the backlash between the gear (1/7) and the feed pump driving gear with a feeler gauge
(W4).
Desired value:0.20 - 0.45 mm
2.23 Check the lubricating oil supply of the gears.
2.24 Open the shut-off cocks, close the ball cock, fill the fuel system by means of the stand-by pump
and vent it.

• Set the selector switch at the control stand to “Engine” or “Remote” (depending on equipment).
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Fuel Distributing / Collecting Pipe A5.05. 07.15.01.11
See also: A5.05.07.02.01.nn 07

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Removal of the fuel distributing/collecting pipe

2. installation of the fuel distributing/collecting pipe
Engine Type Tools and Auxiliary Materials Index Tool No.
M 25 C / M 25 E Molykote paste “G-Rapid Plus“ *

**
Petro Gel Amber *

**
* no picture
CAUTION
Risk of engine damage and leaks due to dirt!
Dirt in the fuel pipes may cause engine damage.
Dirt on the sealing surfaces may cause leaks.
The sealing surfaces and openings of the fuel pipes and the injection pumps have to
be sealed against dirt!
1. Removal of the fuel distributing/collecting pipe

1.2 Remove the pump space cladding.
1.3 Open the shut-off valve (at the driving end next to the injection pump of cylinder 1) and drain the
fuel distributing pipe.
en / 02.01.2015 1/4
1.4 Remove the hexagon head bolts (11, 12). 07
CAUTION
Special feature of “crude oil” engines!
On “Crude oil“ engines an injection pump has to be removed in addition
(A5.05.07.02.01.nn) in order to be able to remove/install the fuel pipes.
1.5 Shift the flanges (6 and 7) on the fuel pipe and extract the fuel pipe.
Y 1 2
X
8 2
Y 4
7
1 Z 6
4 Z
3
5
s
4
7
6 1
X
3
5
11 12
en / 02.01.2015 2/4
2. Installation of the fuel distributing/collecting pipe 07

2.1 Check the throttle tube (8) in the injection pump (2), it must be firmly freeze fitted with a projection
of s = approximately 3 mm.
2.2 Check the rod seal (5) and replace it, if necessary.
2.3 Lightly lubricate new O-rings (3, 4) with Petro Gel Amber.
2.4 Apply Molykote to thread and contact surfaces of the hexagon head bolts (11, 12).
2.5 Put the fuel pipe (1) in place at the injection pumps (2) with flanges (6, 7), rod seal (5) and O-rings
(3,4, on both sides).
2.6 Push the flange (7) onto the throttle tube (8). Push the flange (6) to the flange (7).
2.7 Install the hexagon head bolts (11, 12) and tighten them with a torque of 25 Nm.
2.8 Close the shut-off valve (at the driving end, next to the injection pump of cylinder 1).
2.9 Lift the measures for securing the engine to prevent unintentional starting of the engine.

- Set the selector switch on the control stand to “Engine” or “Remote“.
2.10 Fill the fuel system by means of the stand-by pump and vent it.
2.11 Check for leaks.
2.12 Install the pump space cladding.
en / 02.01.2015 3/4
07
en / 02.01.2015 4/4
Lubricating Oil System A5.05. 08.02.01.10
c2 Maintenance / Oil change

Spare parts list:

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

“Operating Media, Lubricating Oil Change”.
The lubricating oil change interval depends on the following factors:
• Operating hours
• Lubricating oil quality
• Operating conditions of the engine
• Lubricating oil consumption
• Lubricating oil treatment or separation
• Volume of lubricating oil in the circulation system
The change interval can be extended if the results of the lubricating oil analysis permit.
Permissible analysis values (see engine documentation, “Operating Media,
Lubricating Oil Change”).
en / 02.01.2015 1/4
1. Clean and fill up the lubricating oil system 08

1.1 Stop and secure the engine to prevent unintentional starting.


Gas engine:
- Remove the key.
1.2 Switch off the lubricating oil prelubrication pump or the standby pump (depending on equipment
status).
1.3 Pump the lubricating oil from the lubricating oil circulation system and the lubricating oil circulation
tank into a suitable tank.
NOTE
Depending on the equipment the lubricating oil present in the engine will be pumped
out by the suction pump on plant side.
NOTE
The lubricating oil circulation volume is 1.36 l/kW* engine power output and,
depending on the variant, is stored either in the lubricating oil circulation tank on plant
side, the deep oil pan or the base frame (generator operation).
*(see engine documentation, “Operating Media, Lubricating Oil Change“).
1.4 Check the lubricating oil circulation tank and the oil pan/base frame for cleanliness and,
if necessary, remove any impurities and debris.
1.5 Check the strainer in the suction pipe and, if necessary, clean it.
1.6 Clean the lubricating oil duplex filter (A5.05.08.04.01.nn).
1.7 Clean the lubricating oil automatic filter (see engine documentation, “External
Documentation”).
1.8 Specifics for V-engines
1.8.1 Check the lubricating oil safety strainer (A5.05.08.04.03.nn).
en / 02.01.2015 2/4
08
NOTE
We recommend to also remove and clean the lubricating oil cooler within the scope of
lubricating oil system maintenance (see engine documentation ,”External Docu-
mentation“).
1.9 Fill up the lubricating oil system with new lubricating oil (see engine documentation, “Operating
Media, Lubricating Oil Quality“) according to the existing installation, up to the dipstick mark
(depending on equipment).


- Set the selector switch on the control stand to “Engine” or “Remote“.
Gas engine:
- Insert the key into the key switch on the “Local Data Board“.
1.11 Start the engine systems and lift the starting interlock.
NOTE
Observe the lubricating oil pressure and, if necessary, check the lubricating oil
pressure limitation valve (A5.05.08.05.01.nn).
NOTE
Disposal notes:
Observe the MARPOL Convention for Prevention of Pollution and / or the country-
specific disposal regulations for handling waste oil.
As a basic rule, waste oil has to be stored until it can be disposed of in an
environmentally compatible manner.
en / 02.01.2015 3/4
08
en / 02.01.2015 4/4
c Pressure Limitation Valve
A5.05. 08.03.01.11
15000
See also: 08
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Adjust the lubricating oil pressure

2. Disassemble the relief valve
3. Clean and, if necessary, refinish the relief valve
4. Assemble the relief valve
5. Disassemble and clean the pilot cartridge
6. Assemble the pilot cartridge
M 25 C / M 25 E Torque wrench (20 - 200 Nm) 1.9454-202 */***
* no picture
NOTE
The lubricating oil pressure limitation valve consists of a relief valve and a pilot
cartridge.
Lubricating oil pressure fluctuations may have different causes. According to
experience, in most cases the cause is attributable to a contaminated and / or dama-
ged sealing surface of the relief valve or a clogged control oil hole of the relief valve.
en / 02.01.2020 1/8
A5.05. 08.03.01.11
15000
1. Adjust the lubricating oil pressure 08
WARNING
Risk of injury due to rotating and hot engine components!
The lubricating oil pressure may only be adjusted at rated engine speed and the
prescribed lubricating oil temperature. Therefore, the engine is operating during the
adjustment!
• Stay clear of rotating and hot engine components.
• Ensure a safe posture while working.
1.1 For the prescribed lubricating oil temperature and the lubricating oil pressure to be adjusted, refer
to the Engine Documentation, chapter “Technical Engine Data / Pressures of Operating
Media”.
3 4 5
7 6
1 Schematic diagram
1.2 Remove the cap nut (1/1).
1.3 Loosen the hexagon sealing nut (1/3).
1.4 Adjust the lubricating oil pressure by turning the spindle (1/2).
• Turning counter-clockwise: Oil pressure drops

• Turning clockwise: Oil pressure rises
1.5 Tighten the hexagon sealing nut (1/3) to a torque of 35 Nm (26 lb ft)of. In doing so, hold the
spindle in position.
1.6 Replace the copper sealing ring (1/4).
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A5.05. 08.03.01.11
15000
1.7 Check the lubricating oil pressure at the control stand and, if necessary, readjust it. 08
• When the lubricating oil pressure is reached, apply a thin coat of Molykote to the thread of the
cap nut (1/1). Tighten the cap nut to a torque of 200 Nm (148 lb ft).
• If the lubricating oil pressure is still divergent, disassemble the lubricating oil pressure limitation
valve and check it (see Steps 2 et seq.).
2. Disassemble the relief valve


NOTE
When opening the relief valve, residual oil will leak out. Provide a sufficient number of
cleaning rags and suitable collecting containers.
Immediately wipe up any spilt residual oil and dispose of it according to the local en-
vironmental and waste disposal regulations.
2.2 Depending on design and mounting

2
position unscrew or open for venting a
screw plug or a pipe connection at a point
of the lubricating oil pressure limitation
valve that should be located as high as 1
possible. 3
2.3 For draining the residues in the lubricating 6 1

oil pressure limitation valve screw out a
screw plug or a pipe connection at a point
of the lubricating oil pressure limitation 4
valve that should be located as low as
possible. 1
2.4 Remove the control pipe (2/5) of the 1

lubricating oil pressure limitation valve and 53
seal the connection.
2 Schematic diagram
en / 02.01.2020 3/8
A5.05. 08.03.01.11
15000
08
CAUTION
The compression spring of the relief valve may suddenly relax when loosening the
threaded connection and cause injuries in case of improper disassembly.
• Counter-hold the pilot unit while loosening.
• Loosen the cap screws crosswise, 1 slowly,
2 3
evenly,4and carefully.
5 6 7 8
2.5 Unscrew two diagonally opposite cap screws (2/1) at the pilot unit (2/3).
2.6 By evenly loosening the two remaining

cap screws (2/1) relieve the compression
spring (3/3) of the relief valve.
2.7 Remove the pilot unit (2/3) with the pilot

cartridge (2/2). In doing so, also take out
the compression spring of the relief valve.
2.8 Remove the O-rings (3/1, 2).
2.9 Take the piston (3/4) out of the body (3/7).
3 Schematic diagram
3. Clean and, if necessary, refinish the

relief valve
3.1 Carefully clean the sealing surfaces (3/6) of the piston (3/4) and the piston guide in the body. If
necessary, regrind with diamond paste.
3.2 Check the control oil hole (3/5) and the control oil orifice (3/8) for free passage. If necessary,
remove any residues, e.g. by piercing with a piece of wire.
4. Assemble the relief valve
4.1 Lightly oil the piston (3/4) and the piston guide. Insert the piston, the sealing surfaces end with the
valve seat insert (3/6).
4.2 Insert the compression spring (3/3).
4.3 Apply a thin coat of Petro Gel Amber to the new O-rings (3/1, 2) and insert them untwisted into
the O-ring grooves.
4.4 Apply a thin coat of Molykote to the threads of the four cap screws (2/1).
en / 02.01.2020 4/8
A5.05. 08.03.01.11
15000
08
CAUTION
The compression spring of the relief valve may suddenly relax when loosening the
threaded connection and cause injuries in case of improper assembly.
• Counter-hold the pilot unit during assembly.
• Tighten the cap screws crosswise, slowly, evenly, and carefully.
4.5 Hold the pilot unit in position against the force of the compression spring of the relief valve and fix
it with two diagonally opposite cap screws (2/1).
In doing so, make sure the O-rings (3/1, 2) are correctly positioned.
4.6 Mount the other two cap screws. 9

10
4.7 Tighten all four cap screws crosswise to a
torque of 23 Nm (17 lb ft).
5. Disassemble and clean the pilot

cartridge 4 Schematic diagram
5.1 Screw the pilot cartridge (4/1) out of the

pilot unit (4/2) by turning counter-
clockwise. 1
5
5.2 Remove the cap nut (5/1).
2
CAUTION
4
Risk of injury due to pre-
loaded components!
The compression spring of the 17
pilot cartridge may suddenly 3
relax when loosening the
threaded connection and
cause injuries in case of
improper disassembly. 8
20
• Slowly and carefully loosen
the hexagon sealing nut.
19
10
5.3 Loosen the hexagon sealing nut (5/4).
5.4 Relieve the compression spring (5/16) by 16

means of the spindle (5/3) by turning it
counter-clockwise.
13
12
5 Schematic diagram
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A5.05. 08.03.01.11
15000
5.5 Remove the circlip (5/12). 08

5.6 Take out piston (5/13), compression spring (5/16), washer (5/19), and ball (5/20).
5.7 Clean all parts with clean engine oil and check them.
5.8 Check the control oil holes (5/8, 10) in the body (5/17) of the pilot cartridge for free passage. If
necessary, remove any residues, e.g. by piercing with a piece of wire.
6. Assemble the pilot cartridge
6.1 Apply a thin coat of Petro Gel Amber to the new O-ring (5/2) of the spindle and insert it untwisted
into the O-ring groove.
6.2 Replace all other O-rings (1/6, 7), apply a thin coat of Petro Gel Amber to them and insert them
untwisted into the O-ring grooves.
6.3 Apply a thin coat of Molykote to the thread of the hexagon sealing nut (5/4).
6.4 Insert the spindle (5/3) into the body and fix it with the hexagon sealing nut (5/4). Make sure that
the spindle can be pushed easily through the body (5/17).
6.5 Insert the ball (5/20) into the body and put it in place centrally on the bottom of the spindle.
6.6 Insert the washer (5/19) and compression spring (5/16) from the bottom into the body (5/17).
CAUTION
The compression spring of the pilot cartridge may suddenly relax when loosening the
threaded connection and cause injuries in case of improper assembly.
• Carefully insert the circlip.
6.7 Insert the piston (5/13) into the body, tension the compression spring (5/16) by compressing it and
fix it with the retaining ring (5/12).
6.8 Insert the pilot cartridge (4/1) into the pilot unit (4/2).
6.9 Tighten the hexagon sealing nut.
6.10 Tighten again or install the screw plug or the pipe connection loosened / removed for draining the
residues (cf. Step 2.3).
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A5.05. 08.03.01.11
15000
6.11 Remove the sealing material in the connections of the control pipes of the lubricating oil pressure 08
limitation valve and install the control pipes.
6.12 Tighten again or install the screw plug or the pipe connection loosened / removed for venting (cf.
Step 2.2).


After reaching operating temperature and rated engine speed, check the lubricating oil pressure
at the control stand and, if necessary, readjust it (see Step 1.).
6.15 Replace the copper sealing ring (5/5) if not yet done in Step 1.6.
6.16 Apply a thin coat of Molykote to the thread of the cap nut (5/1). Place the cap nut onto the body
and the copper sealing ring (5/5) and tighten to a torque of 200 Nm (148 lb ft).
en / 02.01.2020 7/8
A5.05. 08.03.01.11
15000
08
en / 02.01.2020 8/8
Lubricating Oil Pump A5.05. 08.03.02.10
See also: A5.05.08.02.01.nn, A5.05.07.13.01.nn 08

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the lubricating oil pump

2. Install the lubricating oil pump
M 20 C Torque wrench 40 - 200 Nm 1.9454-200
M 25 C / M 25 E Torque wrench 60 - 320 Nm 1.9454-320
Reversible ratchet 3/4” 1.9495-036
Adapter (3/4” to 1/2”) 1.9459-035
M 32 C / M 32 E / VM 32 C / Torque wrench 20 - 90 Nm 1/2” 1.9454-040

M 34 DF
GCM34 Torque wrench 20 - 120 Nm 1.9454-120
Torque wrench 100 - 400 Nm 1.9454-400

M 43 C / M 46 DF Torque wrench 20 - 200 Nm 1.9454-202
Torque wrench 200 - 500 Nm 1.9454-500
M 20 C / M 25 C / M 25 E / Feeler gauge 1.9075-003

M 32 C / M 32 E / VM 32 C /
GCM34 / M 34 DF / M 43 C / Molykote paste “G-Rapid Plus“ *
M 46 DF Petro Gel Amber *
“Dirko Grey” silicone sealing com- *

pound
Blue paste
Textile round sling, lifting capacity 300 **

kg
en / 18.12.2015 1/14
1. Removal of the lubricating oil pump 08


Dual fuel engine:

Gas engine:
- Set the key switch on the “Local Data Board” to “OFF (depending on equipment).
1.2 Drain the lubricating oil system (A5.05.08.02.01.nn).
1.3 For M 32 E / M 34 DF only:

Remove the fuel feed pump fitted to the lubricating oil pump (Fig. 1/4) (A5.05.07.13.01.nn).
1.4 For the further procedure please refer to the description applicable to the respective
engine type:
1.5 Remove the suction pipe (Fig. 1/1) and the pressure pipe (2).
1.6 Attach the lubricating oil pump (4) with the textile round sling to the crane (see Table Lubricating
oil pump weights). In doing so, pay attention to the position of centre of gravity of the lubricating
oil pump (4).
Lubricating oil pump weights
Engine type Weight in kg
M 20 C 83
M 25 C / M 25 E 115 - 229
M 32 C / M 32 E / M 34 DF 150 - 180
GCM34 / VM 32 C 203
M 43 C / M 46 DF 291
en / 18.12.2015 2/14
08
CAUTION
Risk of crushing!
The lubricating oil pump has a high dead weight.
Therefore, sudden proper motion of the pump during removal may cause injuries and
property damage.
Therefore, it is required to secure the lubricating oil pump during removal by means
of a suitable lifting gear.
1.7 Remove the hexagon nuts (Fig. 1/3) [for M 43 C / M 46 DF with extension sleeves (6)].
1.8 Extract the lubricating oil pump (4) with the gear wheel (5) carefully out of the engine block. In
doing so, use the jacking threads, if provided.
1.9 Remove the hexagon bolt (7) and the washer (8) and dismount the gear wheel
(5) with a suitable tool from the driving gear shaft (9). The gear wheel (5) may have to be heated
up in a targeted manner for the removal.
1.10 Check the tooth flanks of the driving gear and the vibration damper for wear (pitting, skewing,
crumbling).
en / 18.12.2015 3/14
08
M 20 C
4 2 8 9 X
3 1 7 5
M 25 C /
M 25 E 4 2 8 9
3 1 7 5
M 32 C /
M 32 E /
VM 32 C / 2 8 9
M 34 DF /
GCM34 X
3 4 1 7 5
en / 18.12.2015 4/14

08
M 43 C /
M 46 DF 9 6 3 2
5 1
1.11 For M 20 C only:

Remove the hexagon socket head cap screws (Fig. 2/1) and take off the cover plate (4) of the
lubricating oil pump casing (5).
1.12 For M 32 C / M 43 C / M 46 DF / VM 32 C / GCM34 only:

Remove the fastening screws (Fig. 2/1, 2) and take off the cover plate (4) of the lubricating oil
pump casing (5).
1.13 With the exception of M 20 C:

Remove the front cover (Fig. 2/3) of the pump casing (5).
1.14 Remove the O-rings (Fig. 2/9).
1.15 Remove the driving gear shaft (6) and the impeller shaft (7) and check them for wear.
1.16 Check the bearing bushes (8) of the driving gear shaft (6) and the impeller shaft (7) in installed
condition for wear and, if necessary, replace them by original Caterpillar spare parts.
en / 18.12.2015 5/14
08
type
M 20 C 7 8
1
4
6
8 5
M 20 C /
M 25 C /
2 5 8 1
M 32 C /
M 32 E /
VM 32 C /
GCM34 /
M 34 DF
6
3
8 7 9 9
M 43 C /
M 46 DF 2 5 1
4
6
8 9 8 7 9
en / 18.12.2015 6/14
2. Install the lubricating oil pump 08

2.1 Where necessary, install the new bearing bushes (Fig. 3/8) in the lubricating oil pump casing (5).
2.2 Install the driving gear shaft and the impeller shaft (6 and 7) in the lubricating oil pump casing (5).
2.3 With the exception of M 20 C

coat the new O-rings (Fig. 2/9) with Petro Gel Amber and insert them untwisted.
Install the front cover (Fig. 3/3) on the lubricating oil pump casing (5) and tighten the hexagon
socket head cap screws (2).
2.4 With the exception of M 32 E / M 34 DF

clean the cover plate (Fig. 3/4) and apply silicone sealing compound.
Install the cover plate (4) with fastening screws (1) and tighten by applying the torque indicated in
the Table Tightening torque 1.

type
M 20 C 7 8
1
4
6
8 5
M 20 C /
M 25 C / 2 5 8 1
M 32 C /
M 32 E /
VM 32 C /
GCM34 /
M 34 DF
6
3
8 7 9 9
en / 18.12.2015 7/14

08
type
M 43 C / 2 5 1
M 46 DF
4
6
8 9 8 7 9
Tightening torque 1
Hexagon nut (Fig. 3/1) tightening Hexagon bolt (Fig. 3/2) tightening
Engine type
torque in Nm (Ib ft) torque in Nm
M 20 C General tightening torque

(A5.03, “Tightening Torques (Stan-
dard)”)
M 25 C / M 25 E 150 (111 Ib ft) 150 (111 Ib ft)

M 32 C / M 32 E General tightening torque General tightening torque
M 34 DF (A5.03, “Tightening Torques (Stan- (A5.03, “Tightening Torques (Stan-
VM 32 C / GCM34 dard)”) dard)”)
M 43 C / M 46 DF 410 (302 Ib ft) 206 (152 Ib ft)
2.5 Before installing the gear wheel check the contact pattern between the cone of the gear wheel
(Fig. 4/5) and the cone of the driving shaft (9) by means of blue paste.
The contact pattern must be even and the percentage contact area shall be > 80 %!
2.6 Install the gear wheel (5) on the driving gear shaft (9):
2.6.1 Clean the gear wheel cone and the driving gear shaft cone.
2.6.2 Arrange the lubricating oil pump with the driving gear shaft cone pointing upwards and secure it
against tipping.
2.6.3 Place the gear wheel (5) on the driving gear shaft (9).Measure and note down the slide-on
distance (Fig. 4/s).
en / 18.12.2015 8/14
08
CAUTION
Risk of burns.
The heated-up gear wheel may cause injuries during installation.
Therefore, it is required to wear personal protective equipment (e.g. heat resistant
gloves) when installing the gear wheel.
2.6.4 Take off the gear wheel (Fig. 4/5) and heat it up in an oven by the value indicated in the Table
Temperatures.
Temperatures
Temperature above driving gear haft

Engine type
temperature in °C (°F)
M 20 C / M 25 C / M 25 E / M 43 C / M 46 DF 90 - 100 (194 - 212)
M 32 C / M 32 E / VM 32 C / M 34 DF / GCM34 110 - 120 (230 - 414)
NOTE
Steps 2.5.5 and 2.5.6 must follow each other immediately.
2.6.5 Put the gear wheel (Fig. 4/5) onto the driving gear wheel cone without using undue force. The
dead weight of the gear wheel ensures the required slide-on distance.
2.6.6 Immediately install the hexagon bolt (7) with washer (8) and tighten by applying the torque
indicated in Table Tightening torque 2.
2.6.7 Allow the gear wheel (5) to cool down to room temperature.
2.6.8 Remove the hexagon bolt (Fig. 4/7) cooled down to room temperature with washer (8).
2.6.9 Check the slide-on distance (s).
2.6.10 The slide-on distance (s) must be smaller than the value measured under 2.6.3 by the value
indicated in the Table Slide-on distance s. If necessary, repeat steps 2.6 to 2.6.9.
en / 18.12.2015 9/14
08
Slide-on distance s
Engine type Slide-on distance s in mm
M 20 C 0.33 - 0.41
M 25 C / M 25 E 0.40 - 0.44
M 32 C / M 32 E / VM 32 C / M 34 DF / GCM34 0.58 - 0.63
M 43 C / M 46 DF 0.57 - 0.67
2.7 Apply Molykote to the thread and contact surface of the hexagon bolt (7) and the washer
(8).
2.8 Install the hexagon bolt (7) with washer (8) and tighten by applying the torque indicated in the
Table Tightening torque 2.
Tightening torque 2
Hexagon nut (Fig. 4/3) Hexagon bolt (Fig. 4/7)

Engine type
tightening torque in Nm (Ib ft) tightening torque in Nm (Ib ft)
M 20 C / M 25 C / M 25 E / General tightening torque (A5.03. 45 (10) (heated up)

M 32 C / GCM34 / VM 32 C / “Tightening Torques (Standard)”)
M 34 DF / M 32 E 60 (14) (cooled down)
M 43 C / M 46 DF 130 (30) 100 (23) (heated up)
140 (32) (cooled down)
en / 18.12.2015 10/14
08
type
M 20 C
4 2 8 9 X
3 1 7 5
s
M 25 C /
M 25 E 4 2 8 9
3 1 7 s 5
M 32 C /
M 32 E / 2 8 5 9
VM 32 C /
GCM34 / X
M 34 DF
s
3 4 1 7
en / 18.12.2015 11/14

08
type
M 43 C /
M 46 DF 9 6 3 2
5 4
s
1
2.9 Clean the contact surfaces of the pump casing (Fig. 3/5) and the engine block and apply silicone
sealing compound to both sides.
2.10 Carefully introduce the lubricating oil pump (Fig. 4/4) into the engine block and install it. The gear
flanks of the gear wheels must mesh with each other!
2.11 For M 43 C / M 46 DF only:

Install the extension sleeves (6).
2.12 Coat the hexagon nuts (3) and the thread of the bolts with Molykote and tighten them by applying
the torque indicated in Table Tightening torque 2 .
2.13 Check the backlash by means of a feeler gauge. Permissible backlash for all engines:
0.20 - 0.45 mm.
2.14 Install the suction pipe (1) and the pressure pipe (2) with new gaskets.
2.15 For M 32 E / M 34 DF only:

Install the fuel feed pump (A5.05.07.13.01.nn).
2.16 Fill up the lubricating oil system (A5.05.08.02.01.nn)
2.17 Start the prelubrication pump.
en / 18.12.2015 12/14
2.18 Vent the lubricating oil system and check it for leaks. 08
2.19 Check the lubricating oil supply of the gear wheels.

Dual fuel engine:

Gas engine:
en / 18.12.2015 13/14
08
en / 18.12.2015 14/14
Duplex Lubricating Oil Filter A5.05. 08.04.01.10
See also: 08
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the filter cartridge

2. Clean the filter
3. Install the filter cartridge
M 20 C / Cleaning gun for lubricating oil filter W1 1.9100-114

M 25 C / M 25 E /
M 32 C / M 32 E / Ejector for filter candles W2 1.9100-120
VM 32 C / M 34 DF / Oil collecting pan W3 */***
GCM34 /
M 43 C / VM 43 C / “Filterclean” cleaning liquid of Vecom */**
M 46 DF / VM 46 DF
* no picture
CAUTION
Operation and maintenance of the filter must be carried out with utmost care because
the ingress of dirt from tanks and pipes may cause severe engine damage.
NOTE
The cleaning interval of the filter is influenced by part load operation with heavy fuel,
poor combustion, poor separation or a damaged automatic filter.
After commissioning a new plant, after major repair work or after work on the
lubricating oil piping system the filter has to be inspected after 24 - 48 hours and
cleaned if necessary.
On every 3rd cleaning remove the filter candles (step 2.2).
en / 02.01.2015 1/6
08
1
CAUTION 2
Risk of damage to the filter

candles due to improper
handling!
Observe the instructions of the
manufacturer for cleaning the 4
filter candles with ultrasound / 4
high-pressure cleaner.
Improper storage during
cleaning and excessive
duration of cleaning may
damage the filter fabric. Such 3 3
damage cannot be identified
with the unaided eye.
NOTE 9
9
Clean the filter in warm

condition when 50 % of the red 1
area on the differential
pressure gauge (Fig. 1/1) are
visible or a filter alarm has
been activated. 2
1. Remove the filter cartridge

3 3
1.1 By means of the change lever (Fig. 1/2)
disconnect the filter chamber to be
cleaned (9) from the circulating lubricating
oil system. Pay attention to the switching
4 4
symbol on the filter cover!
1 Schematic diagram
1.2 Slowly open the sludge drain (3) of the

filter chamber to be cleaned (9) and
decrease the overpressure in the filter
chamber (9).
1.3 Drain the lubricating oil and collect it with

the oil collecting pan (W3).
1.4 Remove the cover (Fig. 1/4) of the filter

chamber (9).
1.5 Remove the filter cartridge.
en / 02.01.2015 2/6
2. Clean the filter 08
NOTE
In case of severe conta-
mination of the filter cartridge W1
(lacquering, incrustation, tar
residues, fibres, chips) or on
each 3rd cleaning remove the
filter candles and clean them
individually (see step 2.2). 5
2.1 Cleaning the filter cartridge with installed

filter candles (Fig. 2/7):
6
2.1.1 Place the filter cartridge into a suitable
container. Add cleaning liquid max. up to
the lower edge of the filter plate (6) so
that no contaminated liquid can flow into
the filter candles (7) (clean side) from 7
above. The soaking time depends on the
instructions of the manufacturer of the
cleaning agent.
2.1.2 Connect the cleaning gun (W1) to the

compressed air supply and subject it to
working air pressure (p = 6 - max. 10 bar/
p = 87 - 145 psi).
2.1.3 Take the filter cartridge out of the cleaning

container and clean the filter candles (7)
by means of the cleaning gun (W1) as
follows:
Push the splash protection (5) up to the

nozzle stop of the cleaning gun (W1), 2 Schematic diagram
insert it into the opening of the filter candle
and hold it. Actuate the trigger of the
cleaning gun (W1) and slowly move the
nozzle down to the bottom of the filter
candle (7).
2.1.4 Dip the filter cartridge once again into

clean cleaning liquid, allow the liquid to
drip off and blow it through with the
cleaning gun (W1). Turn the filter cartridge
upside down so that the cleaning liquid
can drain off.
2.1.5 Check the filter candles (7) for damage.
en / 02.01.2015 3/6
2.2 Cleaning the filter cartridge with removed 08

filter candles (Fig. 3/7):
W2
2.2.1 Soak the filter cartridge in cleaning liquid.
Add cleaning liquid max. up to the lower
6
edge of the filter plate (6) so that no
8
contaminated liquid can flow into the filter
candles (7) (clean side) from above. The
soaking time depends on the instructions 7
of the manufacturer of the cleaning agent.
2.2.2 Loosen the base plate and carefully

remove the protective shell from the filter
cartridge.
2.2.3 Loosen the filter candles (7) by pressing

downward with the ejector (W2) and
remove them to the outside.
2.2.4 Remove the O-rings (8) between filter

candle (7) and filter plate (6).
2.2.5 Connect the cleaning gun (Fig. 4/W1) to

the compressed air supply and subject it to 3 Schematic diagram
working pressure
(p = 6 - max. 10 bar / p = 87 - 145 psi).
2.2.6 Push the splash protection (Fig. 4/5) up to

the nozzle stop of the cleaning gun (W1),
put it over the opening of the filter candle
and hold it. Actuate the trigger of the
cleaning gun (W1) and slowly move the W1
nozzle down to the bottom of the filter
candle (7).
2.2.7 Remove any tenacious dirt with a soft 5

scrubber / brush.
2.2.8 Rinse the filter candles (7) in clean

cleaning liquid, blow them through and
allow them to dry with the opening
pointing downward.
7
4 Schematic diagram
en / 02.01.2015 4/6
08
Caution
Risk of damage to the filter candles due to improper storage!
Damage to just one filter candle means the entire filter is inoperative.
Do not place the filter candles on top of each other after removal, otherwise the filter
fabric will be damaged.
2.2.9 Inspect the filter candles (Fig. 4/7) and replace them in case of damage or significant folds of the
fabric.
2.2.10 Check the success of the filter candle (7) cleaning against the light (illuminate). In case of a poor
cleaning success repeat the cleaning.
2.2.11 Insert new O-rings (Fig. 3/8).
2.2.12 Install all of the filter candles (7) in the filter cartridge.
2.2.13 Install the protective shell with base plate.
3. Install the filter cartridge
3.1 Clean the filter chamber (Fig. 1/9) and, if necessary, rinse it with gas oil.
3.2 Insert a new gasket in the cover (4).
3.3 Install the filter cartridge and the cover (4).
3.4 Fill up and vent the filter chamber (9) according to the instructions of the manufacturer
(see label on the filter cover and observe the instructions of the manufacturer as necessary).
en / 02.01.2015 5/6
08
en / 02.01.2015 6/6
Prelubricating Pump / Prelubrication A5.05. 08.10.00.10
c2 Maintenance / Checking
150
See also: 08
Spare parts list:

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

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

without affecting the unattended operation of the system:
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
1.1 Start the stand-by pump
1.2 Turn the engine by means of the barring gear.
en / 02.01.2015 1/2
Prelubricating Pump / Prelubrication A5.05. 08.10.00.10
150
08
en / 02.01.2015 2/2
Cooling Water Centrifugal Pump A5.05. 09.07.01.11
30000, 15000, 45000
See also: 09
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Remove the cooling water centrifugal pump

2. Check for wear
3. Install the cooling water centrifugal pump
M 25 C / M 25 E / Feeler gauge 1.9075-003 **

M 32 C / M 32 E /
M 34 DF / VM 32 C / Molykote paste “G-Rapid” 1.9493-001 */**
M 43 C / VM 43 C / “Dirko Grey” silicone sealing com- */**
M 46 DF / VM 46 DF pound
Screw locking compound “Loctite 243” */**

Screw locking compound “Loctite 574” */**
*) or equivalent product
**) no picture
WARNING
Risk of scalding!
During engine operation the cooling water becomes very hot. In case of skin contact,
the hot cooling water may cause scalding.
Before draining, let the cooling water cool down to less than 50 °C.
NOTE
This job card describes different engine types.
Therefore, some work steps only apply to one or several specific engine types. In
these cases, the respective engine(s) are highlighted in bold font.
Unless indicated otherwise, the work steps that follow again apply to all engine types
treated in this Job Card.
en / 26.09.2017 1/14
30000, 15000, 45000
1. Remove the cooling water centrifugal pump 09


Dual fuel engine:

1.2 Drain the cooling water and collect it with suitable means.
1.3 Disconnect the connecting pipe from the cooling water pump (1/1) to the cooling water distributing
pipe and check the thermometer socket above the cooling water pump (1/1).
1.4 Remove the pipes from the cooling water pump (1/1).
NOTE
On engine types M 43 C, M 46 DF, VM 32 C, VM 43 C, VM 46 DF extension sleeves
(1/17) are used in combination with the hexagon bolts (1/2).
Pay attention to the extension sleeves (1/17) when removing these hexagon bolts (1/
2).
1.5 Loosen the hexagon bolts (1/2) and extract the cooling water pump (1/1) with the gear (1/3) from
the engine block (1/4).
In doing so, use jacking threads (if provided), capture the cooling water pump (1/1) with the crane
and pay attention to the position of centre of gravity of the cooling water pump (1/1).
1.6 With the exception of VM 32 C remove the O-ring (1/5).
1.7 Insert a pin (10 mm diameter) into the hole (2/u) to fix the impeller wheel shaft (2/6).
1.8 Remove the hexagon bolt (1/7) with washer (1/8).
1.9 Remove the gear (1/3) from the impeller wheel shaft (1/6) with a suitable tool. The gear (1/3) may
have to be heated up for this in a targeted manner.
en / 26.09.2017 2/14
30000, 15000, 45000
09
type
M 25 C s
M 25 E X
M 32 C
M 32 E
M 34 DF
Y
7
X
8
Y
1 2 4 5
M 43 C 5 4
M 46 DF
1 2 17 6 8 7
en / 26.09.2017 3/14
30000, 15000, 45000

09
type
VM 43 C
5 4
VM 46 DF
X s
X 7
3
1 2 17
VM 32 C
4
s
X
7
X
3
1 2 17
en / 26.09.2017 4/14
30000, 15000, 45000
1.10 Loosen the hexagon nuts / hexagon bolts (2/9) and pull the bearing casing (2/10) with the sealing 09
plate (2/11) and the impeller wheel (2/12) out of the cooling water centrifugal pump casing (2/13)
and capture it with suitable means.
1.11 Remove the O-ring (2/14).
1.12 Loosen the impeller wheel nut or impeller wheel bolt (2/15) and remove with the impeller wheel
washer
(2/16).
1.13 Remove the impeller wheel (2/12) with a suitable tool from the impeller wheel shaft (2/6) and
capture it with suitable means.
1.14 For M 25 C / M 25 E / M 32 C / M 32 E / M 34 DF only:

Remove the mechanical seal (2/18).
1.15 Loosen the hexagon socket head cap screws / hexagon nuts (2/19), remove the sealing plate
(2/11) from the bearing casing (2/10) and pull off the flinger (2/20).
1.16 For VM 43 C, VM 46 DF only:

Loosen the hexagon socket head cap screws (2/29) and remove the oil sealing plate (2/30).
1.17 Loosen the hexagon socket head cap screws (2/21) and remove the cover plate (2/22).
1.18 Remove the thrust ring (2/23) and, if applicable, the thrust washer (2/34) and the pin (2/u).
1.19 Pull the impeller wheel shaft (2/6) out of the bearing casing (2/10) and remove the shaft seal
(2/24).
1.20 For VM 32 C, M 43 C, M 46 DF, VM 43 C, VM 46 DF only:

Remove the hexagon nuts (2/31) and the intake flange (2/32) as well as the O-ring (2/33).
en / 26.09.2017 5/14
30000, 15000, 45000
2. Check for wear 09

2.1 Gear (1/3):
Check the tooth flanks for wear (pitting, skewing, crumbling).
2.2 Impeller wheel(2/12):

Check it visually and replace it if severe signs of cavitation are identified.
2.3 Impeller wheel shaft (2/6):

Check for wear / corrosion and replace it if necessary.
Check the bearing seats. The surface must not be affected by palpable damage such as
circumferential scratching marks (finger nail test).
2.4 Bearing bushes (2/25 and 2/26):

Dispose of.
2.5 Outlet openings (2/v and 2/w):

Check for free passage and clean if necessary.
M 25 C 14 19 20 24 y
M 25 E 18
M 32 C
M 32 E 27 23
M 34 DF
28
17
15 17
16
17
6
34
22
21
13
v 12 9 11 w 10 26 u 25
en / 26.09.2017 6/14
30000, 15000, 45000

09
VM 32 C 19 14 24 y
M 43 C
M 46 DF
32 22
23
20
28
27
15
16
v 6
12
31 21
13
33 11 9 w 10 26 u 25
VM 43 C 33 19 14 9 24 26 y
31
VM 46 DF
22
32 23
28
v
15
16
27
20 6
21
13
12 11 29 30 10 w u 25
en / 26.09.2017 7/14
30000, 15000, 45000
3. Install the cooling water centrifugal pump 09

3.1 Insert the new bearing bushes (2/25 and 2/26) into the bearing casing (2/10).
3.2 Push the impeller wheel shaft (2/6) into the bearing casing (2/10) and install the new shaft seal
(2/24).
3.3 Insert a pin (10 mm diameter) into the hole (2/u) to fix the impeller wheel shaft (2/6).
3.4 For VM 43 C, VM 46 DF only: Install the oil sealing plate (2/30) on the impeller wheel shaft (2/6).
Tighten the hexagon socket head cap screws (2/29).
3.5 Install the flinger (2/20).
3.6 Insert the new O-ring (2/14) into the sealing plate (2/11). Push the sealing plate (2/11) onto the
impeller wheel shaft (2/6).
3.7 For M 25 C / M 25 E / M 32 C / M 32 E / M 34 DF only:Install the new mechanical seal (2/18).
3.8 Tighten the hexagon socket head cap screws (2/19).
3.9 Apply Loctite 574 to the flange of the oil hole (2/y). Install the thrust ring (2/23) and the cover plate
(2/22).
3.10 Apply Loctite 243 to the threads of the hexagon socket head cap screws (2/21), install and tighten
the hexagon socket head cap screws (2/21) so as to be finger tight.
3.11 Before installing the impeller wheel (2/12) and the gear (3/3) check the bearing pattern between
the impeller wheel cone / gear cone and the cones of the impeller wheel shaft (2/27 and 2/28) by
means of blue paste.
3.12 Clean, degrease, and dry the cone of the impeller wheel (2/12) and the impeller wheel shaft cone
(2/27).
3.13 Put on the impeller wheel (2/12) and the impeller wheel washer (2/16).
3.14 Apply screw locking compound (Loctite 243) to the thread turns and contact surface of the
impeller wheel bolt / impeller wheel nut (2/15) and thread turns of the impeller wheel shaft (2/6).
3.15 Tighten the impeller wheel bolt / impeller wheel nut (2/15) with a torque according to table
Tightening Torques (page 9).
3.16 Tighten the hexagon socket head cap screws (2/21).
3.17 Install the bearing casing (2/10) with the cooling water centrifugal pump casing (2/13).
If applicable, insert hexagon bolts (2/9) and tighten the hexagon nuts / hexagon bolts (2/9).
en / 26.09.2017 8/14
30000, 15000, 45000
3.18 For VM 32C / M 43 C / M 46 DF / VM 43 C / VM 46 DF only: Lightly coat the new O-ring (2/33) 09
with Petro Gel Amber and insert it untwisted.
Install the intake flange (2/32) and tighten the hexagon nuts (2/31) with a torque according to
table Tightening Torques (page 9).
3.19 Remove the pin inserted under 1.17.
Tightening Torques
Engine type Figure Tightening torque [Nm]
M 25 C 2/15 60, after that continue to turn by 170°

M 25 E
3/7 45 (warm condition)
M 32 C
M 32 E 3/7 60 (room temperature)
M 25 C
3/2 general tightening torque
M 25 E
M 32 C
3/2 52
M 32 E
VM 32 C 2/15 130
M 43 C
M 46 DF 3/7 75 (warm condition)
VM 43 C
VM 46 DF 3/7 100 (room temperature)
VM 32 C 3/2
M 43 C 130
M 46 DF 2/31
VM 43 C 3/2
280
VM 46 DF 2/31
3.20 Before installing the gear check the bearing pattern between the cone of the gear (3/3) and the
cone of the impeller wheel shaft (2/28) by means of blue paste.
3.21 Clean, degrease, and dry the cone of the gear (3/3) and the impeller wheel shaft cone (2/28).
3.22 Place the cooling water centrifugal pump (3/1) with the gear shaft cone (2/28) pointing upwards
on an even surface and secure it against tilting.
en / 26.09.2017 9/14
30000, 15000, 45000
3.23 Put the gear (3/3) onto the impeller wheel shaft cone (2/28) and note down the slide-on distance 09
(3/s) (= s1).
NOTE
Steps 3.24 - 3.26 must follow each other immediately!
3.24 Remove the gear (3/3) again and heat it up by the value indicated in the table Temperatures
above temperature of the impeller wheel shaft (3/6).In doing so, do not heat up the gear (3/3) with
a direct flame!
3.25 Push the gear (3/3) onto the cone of the impeller wheel shaft (3/6). In doing so, do not use any
undue force; the dead weight of the gear (3/3) ensures that the required slide-on distance is
reached.
3.26 Immediately install the washer (3/8) with the hexagon bolt (3/7) and tighten the hexagon bolt (3/
7) with a torque according to the table Tightening Torques (page 9) (choose the value for warm
condition).
Temperatures
Engine type Temperature above impeller shaft temperature in °C
M 25 C / M 25 E 110 - 120
M 32 C / M 32 E / M 34 DF 90 - 100
M 43 C / M 46 DF / VM 32 C 80 - 90
VM 43 C / VM 46 DF *
*) Contact your authorized Caterpillar dealer for the correct temperature!
en / 26.09.2017 10/14
30000, 15000, 45000

09
type
M 25 C s
X
M 25 E
M 32 C
M 32 E
M 34 DF
Y
7
X
8
Y
1 2 4 5
M 43 C 5 4
M 46 DF
1 2 17 6 8 7
en / 26.09.2017 11/14
30000, 15000, 45000

09
type
VM 43 C 5 4
VM 46 DF
X s
X 7
17 3
1 2
VM 32 C 4
s
X
7
X
3
1 2 17
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30000, 15000, 45000
3.27 After cooling down to room temperature check the slide-on distance (3/s) (= s2). 09
The difference s1 - s2 must be within the range indicated in the following table.
If necessary, repeat the installation.
Permissible Slide-on Distance
Engine type s1*- s2* [mm]
M25 C / M 25 E 0.58 - 0.68

M 32 C / M 32 E / M 34 DF 0.43 - 0.47
M 43 C / M 46 DF / VM 32 C 0.51 - 0.57
VM 43 C / VM 46 DF 0.55 - 0.62
*) s1 = slide-on distance, warm condition

**) s2 = slide-on distance, cooled down (room temperature)
3.28 Loosen the hexagon bolt (3/7) and lubricate the thread and contact surface of the hexagon bolt
(3/7) and the washer (3/8) with Molykote.
3.29 Tighten the hexagon bolt (3/7) with a torque according to the table Tightening Torques (choose
the value for room temperature).
3.30 For VM 32 C only:

Apply silicone sealing compound to the contact surfaces of the bearing casing flange and the
engine block (3/4).
3.31 With the exception of VM 32 C replace the O-ring (3/5).
3.32 Carefully insert the cooling water pump (3/1) with the gear (3/3) into the engine block (3/4). The
flanks of the gears must mesh with each other.
3.33 Apply silicone sealing compound to the thread and contact surfaces of the hexagon socket head
cap screws (3/2).
3.34 For VM 32 C, M 43 C, M 46 DF, VM 43 C, VM 46 DF only: Additionally apply the silicone sealing

compound to the contact surfaces of the extension sleeves (3/17).
3.35 Install the hexagon socket head cap screws (3/2) and tighten them with a torque according to the
table Tightening Torques.
3.36 Check the backlash between gear (3/3) and crankshaft with a feeler gauge.
Permissible backlash: 0.20 - 0.45 mm.
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30000, 15000, 45000
3.37 Install the connecting pipe to the cooling water distributing pipe, fill up and vent the cooling water 09
system.
3.38 Check the cooling water system for leaks and the lubricating oil supply of the gears.


en / 26.09.2017 14/14
Stop Piston A5.05. 10.03.01.10
750
See also: A5.05.07.03.01.nn, C5.05.05.10.50.nn, C5.05.05.45.23.nn 10

Spare parts list:

-------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Check the emergency function of the stop piston
NOTE
The functional check may only be
completed when the engine is stopped
for other maintenance or repair work!
1. Check the emergency function of the stop piston
2. Actuate emergency stop.
3. Check the position of the control rods.
NOTE
The control rods must be in the "Zero
Filling“ position.
4. Check the stop piston (3) in the injection

pump, press the control rod (2) into the in-
jection pump by applying pressure to the
jointed lever (1) on the control rod.
NOTE
Check all injection pumps.
If individual or one control rod can be forced into the injection pump against the pres-
sure of the stop piston, check the stop piston in the respective injection pump and
overhaul if necessary (A5.05.07.03.01.nn).
If all control rods can be pushed into the injection pump, check the control air lines for
leaks or damage.
5. Actuate the "Reset“ button on the safety system.
en / 02.01.2015 1/4
Stop Piston A5.05. 10.03.01.10
750
10
NOTE
The stop piston is reset and the emergency stop system depressurized.
NOTE
This document only describes the pneumatic and mechanical release of an engine
stop.
In connection with this inspection work all of the emergency stop equipment on the
engine is to be checked for proper function, see "engine documentation, chapter
"Control and Monitoring" C5.05.05.10.50.nn.
6. (Fig. 2/T3) Measuring point 6105 (function of the safety system) in the maintenance unit, see
"engine documentation, chapter "Control/Regulation" C5.05.05.45.23.nn.
7. Loosen headless screw (T7). By turning cap (T8) adjust the working pressure on the pressure
regulating valve to 6 bar. If the shutdown air pressure is decreased below the switching value of
6 bar an alarm “Low shutdown pressure” will be released.
8. At an air receiver pressure of 30 bar adjust the working pressure on the pressure regulating valve
to 7.5 bar by turning cap (T8) and tighten headless screw (T7).
T7 T8
10
T3
en / 02.01.2015 2/4
Stop Piston A5.05. 10.03.01.10
750
9. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control 10
stand.
en / 02.01.2015 3/4
Stop Piston A5.05. 10.03.01.10
750
10
en / 02.01.2015 4/4
Condensate Trap A5.05. 10.51.00.10
c2 Repair / Removal and Installation
See also: 10
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Construction of the condensate trap

2. Check of the condensate trap
3. Maintenance of the condensate trap
4. Care of the condensate trap
5. Start-up of the condensate trap
CAUTION
Hazard to persons due to leaking operating medium, high pressure and high tempe-
ratures. Failure to comply with these warnings may lead to accidents.
Avoid any unsafe working methods.
Condensate trap weight approx. 13 kg
ATTENTION
Any improper use, intervention in the design and deviation from the design data auto-
matically lead to termination of the warranty. The float-controlled condensate trap is
designed for the discharge of condensate from steam, compressed air and pressure
gas systems. Any other use is not permissible. The manufacturer is not liable for
damage resulting from any other use. The user or operator bears the risk in this case.
This also applies to incorrect assembly, use and maintenance.
NOTE
Due to its gravity, the condensate flows down to the deepest point, i.e. into the
condensate trap housing. A rising condensate level lifts the float and through the float
fork / rotary valve connection the flow cross-section is opened. When the condensate
level drops, the control closes.
en / 02.01.2015 1/4
1. Construction of the condensate trap 10
Additional equipment
Water level indicator (RWG)
Additional equipment
1 Housing cover 9 Float with fork
2 Housing gasket 10 Seal for G 1/4

3 Housing with connections 11 Seal for G 1/2
4 Check valve G 1/4 for type WO-1210 12 Sight glass
5 Set of studs with nuts 13 Set of studs with nuts

6 Screw plug G 1/2 14 RWG cover
7 Float control, complete 15 2 RWG seals
8 Supporting structure with rotary slide valve, 16 RWG frame

complete
2. Check of the condensate trap
2.1 Malfunctions arise as condensate backup in the condensate system.

Condensate backup can be identified by means of the check valve (4):
2.2 Loosen the check valve (4) by only a quarter turn while ensuring that no condensate escapes. If
condensate escapes, it has to be assumed that the float (9) is jammed. In this case the following
maintenance has to be carried out.
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3. Maintenance of the condensate trap 10
CAUTION
The condensate trap must be depressurized!
3.1 The condensate trap must be depressurized. Close the shut-off valve before and (if provided)
after the condensate trap.
3.2 Release any residual pressure in the housing by loosening (4) by only a quarter turn.
3.3 By removing the screw plug (6) drain condensate from the condensate trap.
3.4 Loosen flange connections and carefully lift the condensate trap out of the pipeline.
3.5 By turning and jerky shaking of the trap the float can most often be made movable again. If this
procedure should be successful, a clear
click can be heard.
3.6 If no click is heard, the trap must be opened:
3.7 Loosen hexagon nuts (5) evenly crosswise. Remove cover (1).
3.8 Carefully clean the trap housing so as to make the float movable again.
3.9 Check the housing gasket (2) and replace it if required.
3.10 Put in place the housing cover (1).
3.11 Tighten the housing screws (5) evenly crosswise with a torque of 60 Nm.
3.12 Tighten the screw plug (6) with a torque of 173 Nm.
3.13 Tighten the check valve (4) with a torque of 50 Nm.
4. Care of the condensate trap
4.1 In the case of a great risk of dirt accumulation, the housing should be rinsed thoroughly from
time to time in depressurized condition. If necessary, the float control (7) should also be
checked. Dirt that has collected in the housing can be removed after taking off the screw plug
(6).The float control (7) usually does not require special care.
en / 02.01.2015 3/4
5. Start-up of the condensate trap 10
ATTENTION
The pressure build-up and heating-up of the housing should not take place abruptly.
NOTE
The pressure build-up and heating-up of the housing should not take place abruptly.
In case of bigger damage and for ordering spare parts please contact your authorized
Caterpillar workshop.
en / 02.01.2015 4/4
Lubricating Oil / Cooling Water Thermostat A5.05. 11.06.01.10
7500
See also: 11
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly of lubricating oil/cooling water thermostat,
making a funcional check of thermostatic element
NOTE
The thermostatic elements (Fig. 1/5) are adjusted by the manufacturer to the requi-
red temperature. Modification of the adjustment or repair is impossible. Defective ele-
ments must be exchanged completely.
Controlling the thermostatic elements in case of failure is enabled by a manual con-

trol facility. Hereto slacken counter nut (3) and turn set screw (4) clockwisely in order
to get a lower temperature. After setting counter again.
The cooling line is fully opened and the bypass closed when the set screw (4) flushes
with the surface of the counternut (3).
This setting procedure may only be carried out if the thermostat fails.
With mounting a new thermostat, the set screw (4) must be set to its initial position by
the nut (3).
1. Disassembly
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew hexagon nuts (2) of housing co-

ver (6).
1.3 Remove cover (6) with O-ring (1).
1.4 Turn out thermostatic element (5)

from valve housing (7).
en / 02.01.2015 1/2
Lubricating Oil / Cooling Water Thermostat A5.05. 11.06.01.10
7500
1.5 Wash parts in gas oil and blow them clean. 11

1.6 Wipe clean thermostat housing with lint-free cloth and check for corrosion and deposits.
2. Functional check of thermostatic element
2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K above the
temperature specified on the strap (XX) (specification in degree C).
2.2 The thermostatic element (5) must open steadiliy.
3. Assembly
3.1 Repalce O-rings (1 and 9) and gasket (8).
3.2 Assembly is done in reverse order of disassembly.
3.3 Top up lubricating oil/cooling water system and check thermostat for leakages.
en / 02.01.2015 2/2
c2 Pressure Switch
Replacement / Functional Check
A5.05. 11.06.05.10
See also: A5.05.11.06.06.nn 11

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Pressure switch - replacement

2. Pressure switch - functional check on the running engine after replacement
All engines Hand pump with micrometer pressure gauge W1 0.9204 S *

(analog or digital, classes 1 - 1.5 - 2.5)
Digital multimeter: W2 *
Continuity test measuring range or
resistance measuring range
Plug (if necessary) *

* no picture
WARNING
Risk of injury due to hot cooling water or lubricating oil!
When opening / replacing the pressure pipe hot cooling water / lubricating oil may leak
out. Serious scalding is possible.
• Avoid skin contact with cooling water emulsions / lubricating oil.
• Observe the safety data sheets of the manufacturers.
1. Pressure switch - replacement


en / 18.06.2018 1/4
c2 Pressure Switch
A5.05. 11.06.05.10
Dual fuel engine: 11

Gas engine:
• Remove the key.
1.2 For the switching point of the pressure switch to be replaced, please refer to the list of measuring
points (see engine documentation, chapter “Control and Monitoring”).
The measuring point number can be found on the cable or the related label of the pressure
switch.
The position of the pressure switch is shown in the overview drawing of the measuring points or in
the document entitled “Electrical Engine Equipment” (see engine documentation, chapter
NOTE
Pay particular attention to whether the pressure switch shall trip on pressure fall or on
pressure rise. Depending on this characteristic, the adjustment of the pressure switch
has to be carried out by approaching the required switching point from either above or
below.
Approaching of the required switching point must take place in the same way as
tripping during operation.
• Tripping on pressure fall - release the pressure at the hand pump.
• Tripping on pressure rise - apply pressure to the hand pump.
1.3 If provided, set the test valve at the pressure

switch from operating position (1/1) to test
position (12).
1
Otherwise, dismount the pressure switch.
Seal the pressure pipe at the engine block
with a plug so that the media cannot escape
and no pollutants can enter.
1.4 Disconnect the electrical connection to the 2

alarm and protection system by pulling the
connector off the pressure switch.
1 Schematic diagram
en / 18.06.2018 2/4
c2 Pressure Switch
A5.05. 11.06.05.10
1.5 Remove the old pressure switch. For this 11

purpose, loosen hexagon socket screws
(2/1).
1.6 Coat a new O-ring (2/2) at the foot of the

new pressure switch with Petro Gel Am-
ber and insert it untwisted.
The O-ring must be positioned accurately,
otherwise the system will be leaky!
1.7 Install the new pressure switch, tighten

the hexagon socket screws (2/1).
1.8 Adjust the switching point of the replaced 1 2

pressure switch immediately after
installation (A5.05.11.06.06.00). 2 Schematic diagram
1.9 If provided, reset the test valve at the pressure switch from test position to operating position.
1.10 Reestablish the electrical connection to the alarm and protection system by clipping the connector
onto the pressure switch in accordance with the pressure switch contacts and tightening it.
2. Pressure switch - functional check on the running engine after replacement
NOTE
If the check was successful, the engine will be stopped!

Dual fuel engine:

en / 18.06.2018 3/4
c2 Pressure Switch
A5.05. 11.06.05.10
Gas engine: 11
2.2 Cooling water system
2.2.1 Start the engine and run it up to idle speed.
2.2.2 Connect the hand pump (W1) with suitable micrometer pressure gauge to the test connection.
2.2.3 Apply pressure to the pressure switch by means of the hand pump (W1). The pressure must be
higher than the cut-out pressure.
2.2.4 Set the test valve to test position.
2.2.5 “Cooling water pressure too low” - simulate the falling pressure by means of the test valve and
the hand pump (W1) with suitable micrometer pressure gauge.
The pressure switch must trip, in the protection system an alarm must be activated immediately.
The stop procedure of the engine is initiated immediately.
2.2.6 Reset the test valve to operating position.
2.3 Lubricating oil system
2.3.3 Apply pressure to the pressure switch by means of the hand pump (W1).
2.3.4 Set the test valve to test position.
2.3.5 “Lubricating oil pressure too low” - simulate the falling pressure by means of the test valve and
the hand pump (W1) with suitable micrometer pressure gauge.
The stop procedure of the engine will be initiated immediately.
2.3.6 Reset the test valve to operating position.
2.4 Test the other pressure switches according to the same procedure. Simulate the falling / rising
pressure by means of the hand pump (W1) with suitable micrometer pressure gauge and check
whether the pressure switch trips. Match the switching points with the list of measuring points
(see engine documentation, chapter “Control and Monitoring”).
en / 18.06.2018 4/4
c2 Pressure Switch
A5.05. 11.06.06.10
See also: A5.05.11.06.05.nn 11

Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Switching point - adjustment

2. Adjusted switching point - check
All engines Hand pump with micrometer pressure gauge W1 0.9204 S *

(analog or digital, classes 1 - 1.5 - 2.5)
Digital multimeter: W2 *
Continuity test measuring range or
resistance measuring range
Plug (if necessary) *
* no picture
WARNING
Risk of injury due to hot cooling water or lubricating oil!
When opening / replacing the pressure pipe hot cooling water / lubricating oil may leak
out.Serious scalding is possible.
• Avoid skin contact with cooling water emulsions / lubricating oil.
• Observe the safety data sheets of the manufacturers.
1. Switching point - adjustment


Dual fuel engine:

en / 18.06.2018 1/6
c2 Pressure Switch
A5.05. 11.06.06.10
Gas engine: 11
• Remove the key.
1.2 For the switching point of the pressure switch to be checked, please refer to the list of measuring
points (see engine documentation, chapter “Control and Monitoring”).
The measuring point number can be found on the cable or the related label of the pressure
switch.
The position of the pressure switch is shown in the overview drawing of the measuring points or in
the document entitled “Electrical Engine Equipment” (see engine documentation, chapter
HINWEIS
The test and adjusting instructions below apply to the following types:
• Pressure range: 0,2 - 2,5 bar (20 - 250 kPa / 2,9 - 36,7 psi)
mech. switching differential: 0,15 bar (15 kPa / 2,2 psi)
• Pressure range: 0 - 4 bar (0 - 400 kPa / 0 - 58 psi)



• Pressure range: 0,9 - 1,5 bar (90 - 150 kPa / 13 - 21,8 psi)

NOTE
Pay particular attention to whether the pressure switch shall trip on pressure fall or on
pressure rise. Depending on this characteristic, the adjustment of the pressure switch
has to be carried out by approaching the required switching point from either above or
below.
Approaching of the required switching point must take place in the same way as
tripping during operation.
• Tripping on pressure fall - release the pressure at the hand pump.
• Tripping on pressure rise - apply pressure to the hand pump.
en / 18.06.2018 2/6
c2 Pressure Switch
A5.05. 11.06.06.10
1.3 If provided, set the test valve at the pressure 11

switch to be checked from operating position
(1/1) to test position (1/2).
Otherwise, dismount the pressure switch.
Seal the pressure pipe at the engine block 1
with a plug so that the media cannot escape
and no pollutants can enter.
1.4 Disconnect the electrical connection to the

alarm and protection system by pulling the
connector (2/1) off the pressure switch
(2/2) and removing the rubber seal. Under 2
the rubber seal the designations of the
pressure switch contacts (2/3) can be
seen. 1 Schematic diagram
1.5 Check the switching states 1 + 2 and 1 + 3 with the multimeter (W2). In the unpressurized state,
• contacts 1 + 2 are closed (NC = normally closed) and
• contacts 1 + 3 are open (NO = normally open), see Fig. 2.
Connector with Connector view Electrical

pressure sensor from below wiring diagram
2 Schematic diagram
1.6 Connect the hand pump (W1) to the test

connection with asuitable micrometer
pressure gauge (see Fig. 3).
NOTE
In case of an analog micrometer
pressure gauge choose a suitable
measuring range (close to the
required switching point) to
minimize measuring errors.
Example switching point 2.6 bar:
• suitable measuring range:
0-3 bar
• unsuitable measuring range:
0-60 bar 3 Schematic diagram
en / 18.06.2018 3/6
c2 Pressure Switch
A5.05. 11.06.06.10
1.7 Connect the multimeter (W2) to pressure switch contacts 1 + 2 (NC) to observe the switching 11
point.
At the switching point, the display of the multimeter changes from electrical continuity (resistance
value) to open (OL = open line) (contacts 1 + 2 (NC) open and contacts 1 + 3 (NO) closed).
1.8 Checking and adjusting a pressure switch that switches on pressure fall:
1.8.1 Apply pressure to the pressure switch by means of the hand pump (W1). Slowly release the
pressure. Observe the multimeter and the micrometer pressure gauge at the same time. Take a
note of the pressure point on tripping.
1.8.2 In case of deviation from the switching point, remove the cover (4/1). By means of the hexagon
socket screw (4/2) readjust the switching point at the pressure switch according to the deviation.
Turn in “+” direction to increase the switching point.
Turn in “-” direction to decrease the switching point.
1.8.3 Reapply pressure and release it; if necessary, adjust the hexagon socket screw again. Repeat the
procedure until the pressure switch trips at the required switching point.
1.8.4 Release the pressure completely. Remove the multimeter and the hand pump.
4 Schematic diagram
1.9 Checking and adjusting a pressure switch that switches on pressure rise:
1.9.1 Slowly apply pressure to the pressure switch by means of the hand pump (W1). Observe the mul-
timeter and the micrometer pressure gauge at the same time. Take a note of the pressure point
on tripping.
1.9.2 In case of a deviation from the switching point remove the cover (4/1) and by means of the
hexagon socket screw (4/2) readjust the switching point at the pressure switch according to the
deviation.
Turn in “+” direction to increase the switching point.
Turn in “-” direction to decrease the switching point.
1.9.3 Release pressure again and reapply it; if necessary, adjust the hexagon socket screw again. Re-
peat the procedure until the pressure switch trips at the required switching point.
en / 18.06.2018 4/6
c2 Pressure Switch
A5.05. 11.06.06.10
1.9.4 Release the pressure completely. Remove the multimeter and the hand pump. 11
NOTE
Due to the mechanical tolerance of the pressure switch it is absolutely required to
check the adjusted switching point several times to ensure that the switching point is
exactly maintained.
2. Adjusted switching point - check
2.1 If the pressure switch was removed, reinstall the pressure switch at the appropriate location on
the engine.
2.2 Check correct functioning of the pressure switch with engine stopped:
2.2.1 Connect the hand pump (W1) to the test connection with a suitable micrometer pressure gauge
(see Fig. 3).
2.3 Check the switching states 1 + 2 and 1 + 3 with the multimeter (W2). In the unpressurized state,
• contacts 1 + 2 are closed (NC = normally closed) and
• contacts 1 + 3 are open (NO = normally open).
2.3.1 By means of the hand pump (W1) slowly increase the pressure or increase the pressure and
slowly release it, depending on the pressure switch to be checked.
At the required switching point the pressure switch must trip.
Check the switching status at the multimeter. In the pressurized state, upon tripping,
• contacts 1 + 2 (NC) are open and
• contacts 1 + 3 (NO) are closed.
2.3.2 When the test is finished, remove the hand pump (W1) and the multimeter (W1).
2.4 Check the stop function on the running engine:
NOTE
If the test is successful, the engine will be stopped!
2.4.1 Reestablish the electrical connection to the alarm and protection system by clipping the connector
with rubber seal onto the pressure switch in accordance with the pressure switch contacts.
en / 18.06.2018 5/6
c2 Pressure Switch
A5.05. 11.06.06.10
2.4.2 Lift the measures for securing the engine to prevent unintentional starting. 11
Dual fuel engine:

Gas engine:
2.4.5 Apply pressure to the pressure switch by means of the hand pump.
2.4.6 Set the test valve at the pressure switch from operating position (1/1) to test position (1/2).
2.4.7 By means of the hand pump (W1) slowly increase the pressure or increase the pressure and re-
lease it, depending on the pressure switch to be checked.
The stop procedure of the engine is initiated immediately.
2.4.8 After the test has been carried out, remove the hand pump (W1).
2.5 Reset the test valve at the pressure switch from test position to operating position.
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Oil Mist Detector A5.05. 11.09.01.11
1500, 750, 7500
See also: 11
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Check the underpressure in the measuring chamber
b) Clean the infrared filter and replace the sintered bronze filter
in the measuring attachment
c) Replace the sintered bronze filter in the pressure control
Tools:
Test equipment and spare parts.
Service box
NOTE
Maintenance and trouble shooting, refer, see "engine documentation, chapter "Ex-
ternal Documentation".
CAUTION
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
en / 01.02.2015 1/2
Oil Mist Detector A5.05. 11.09.01.11
1500, 750, 7500
11
en / 01.02.2015 2/2
Barring Device A5.05. 12.08.01.10
c2 Maintenance / Operation and Check
See also: 12
Spare parts sheets:
Operating medium: All

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Engage the barring device

2. Disengage the barring device
3. Check the filling level of the transmission oil
4. Lubricate / grease shaft and gear wheel
5. Carry out an oil change
M 25 C, M 25 E, Bearing grease “Klüber Altemp. QNB 50” */**

M 32 C, M 32 E,
M 34 DF, VM 32 C, Transmission oil approx. 7.5 litres “Shell Omala Oil */**
VM 32 E 460”
Oil collecting container */***
GCM34 Bearing grease “CAT Advanced 3Moly Grease” */**

Transmission oil approx. 10 litres “CAT TDTO” or */**
“CAT TDTO-TMS”
M 43 C, VM 43 C, Bearing grease “Klüber Altemp. QNB 50” */**

M 46 DF, VM 46 DF
M 43 C, M 46 DF Transmission oil approx. 9 litres “Shell Omala Oil 460” */**
VM 43 C, VM 46 DF Transmission oil approx. 10 litres “Shell Omala Oil */**

460”
* no picture
NOTE
The lever (1/2) can be moved to two positions:
1. “Disengaged position” (normal position): The drive pinion (1/3) of the barring device
is not in mesh with the flywheel gear ring.
2. “Engaged position”: The drive pinion (1/3) of the barring device is in mesh with the
flywheel gear ring.
en / 26.04.2017 1/4
Secure the engine to prevent unintentional starting. 12


Gas engine:
- Remove the key.
NOTE
The lever (1/2) either has to be pushed or pulled for engaging, depending on the
engine type.
Take notice of the drawing applicable to your engine.
NOTE
Starting interlock
The position switch (1/11) prevents starting of the engine with barring gear engaged.
1. Engagement of the barring device
1.1 Pull the locking lever (1/1) to position “V“ and hold it.
1.2 Move the lever (1/2) to position “X“ and completely engage the drive pinion (1/3) in the toothing of
the flywheel. If necessary, adjust the meshing of the gears at the hand wheel (1/12).
1.3 Release the locking lever (1/1) and engage it in position “Z“.
1.4 The main running gear can now be barred to the desired position.
2. Disengagement of the barring device
2.1 Pull the locking lever (1/1) to position “V“ and hold it.
2.2 Move the lever (1/2) to position “Y“ and completely disengage the drive pinion (1/3) from the
toothing of the flywheel.
2.3 Release the locking lever (1/1) and engage it in position “Z“.
en / 26.04.2017 2/4
12
M 25 C, M 25 E, 11
M 32 C, M 32 E,
M 34 DF, VM 32 C, x
VM 32 E, GCM34
y
7 z
8
v
1
10
2
3
9 4
12 5
6
M 43 C, M 46 DF, 11
VM 43 C,
y
VM 46 DF
x
2
z
v
1
7
8
5
6
12 9 4 10
en / 26.04.2017 3/4
3. Check the filling level of the transmission oil 12

3.1 Check the filling level of the transmission oil at the sight glass (1/10):
Maximum filling level: Up to the upper third of the sight glass (1/10)
Minimum filling level: Up to half of the sight glass (1/10)
3.2 If necessary, add new transmission oil (carry out steps 5.4 to 5.6).
4. Lubricate / grease shaft and gear wheel
4.2 Lubricate the output shaft (1/9) and the drive pinion (1/3) via lubricating nipple (1/4) with bearing
grease.
4.3 Disengage the barring device.
4.4 Lightly coat the toothing of the drive pinion (1/3) and the gear ring of the flywheel with bearing
grease all around.
5. Carry out an oil change
5.1 Keep oil binding agent ready and, if necessary, absorb any transmission oil spills.
5.2 Remove the screw plug (1/5) with gasket (1/6), drain the transmission oil and collect it with the oil
collecting container.
5.3 Install the screw plug (1/5) with new gasket (1/6).
5.4 Remove the screw plug / breather pipe (1/7) with gasket (1/8).
5.5 Fill in new transmission oil and check the filling level at the sight glass (1/10):
Maximum filling level: Up to the upper third of the sight glass (1/10)
Minimum filling level: Up to half of the sight glass (1/10)
5.6 Install the screw plug / breather pipe (1/7) with new gasket (1/8).


Gas engine:
en / 26.04.2017 4/4
Round Nuts / Loosening and Fixing A5.05. 13.01.01.10
See also: 13
Spare parts list:
Personnel qualification: skilled engine hand / Assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Preparatory work for loosening or fixing of round nuts

2. Loosening of round nuts
3. Fixing of round nuts
4. Troubleshooting
5. Appendix (tables)
DANGER
Danger to life due to parts breaking off!
Due to improper handling and / or material failure pressurized components or parts of
components may break off, strongly accelerate and cause severe injuries or even
death!
- Do not bend over pressurized devices.
- During pressure build-up and 15 seconds thereafter a minimum safety distance of
3 m is to be maintained.
- The pressure indicated in Table B (see Appendix) "Stretching Pressure /
Prestretching Pressure" for the respective position must not be exceeded.
WARNING
Risk of injury caused by hydraulic oil leaking under high pressure
For loosening and fixing of the round nuts the studs are stretched by means of
high hydraulic pressure.
If leaks occur due to misuse or improper handling, oil leaking under pressure may
cause severe injuries.
- It is absolutely required to wear personal protective equipment (especially safety
glasses).
- Do not place any parts of the body above the pressurized devices.
- Establish or loosen connections only in depressurized condition.
- In case of injuries immediately see a doctor!
en / 16.12.2019 1/14
13
CAUTION
Property damage due to misuse or improper handling.
The use of unsuitable or worn parts and inappropriate application may cause property
damage!
- High-pressure hoses and their protective jackets must not show any damage.
- Do not let any objects fall onto the high-pressure hoses and do not step on hoses
lying on the floor.
- Do not bend the high-pressure hoses sharply.
Observe the following minimum bending radii:
-- up to 2000 bar (29008 psi) at least 150 mm.
-- above 2000 bar (29008 psi) at least 250 mm.
- Replace high-pressure hoses latest after 6 years, even if they do not yet show
any damage.
- Do not subject the hose couplings to any bending stress.
NOTE
3
- For the tools needed for the
individual jobs please refer to
the relevant job cards.
- The illustrations on the
following pages are principle
representations only. They
do not pretend to accurately
reproduce the concrete case 2
of application.
- The components reproduced
in this document are only
intended to illustrate setup and
function and may differ in form
and size.
1. Preparatory work for loosening or

fixing of round nuts
1.1 Put in place support ring (Fig. 1/1) over the 1

round nut (4).
1.2 Put the hydraulic jack (2) onto the support

ring (1).
1.3 Insert threaded sleeve (3) through hydrau- 4

lic jack and support ring.
1 Principle representation
en / 16.12.2019 2/14
1.4 Screw threaded sleeve (Fig. 2/3) finger 5 13

tight onto the stud by means of assembly 3
pins (5) until it reaches end-stop position.
1.5 Check the round nut holes for accessibility.

It must be easily possible to insert pin
(Fig. 3/6) through the slots in the support
ring (1) into the holes of the round nut (4).
If necessary, align support ring (1) accor- 2
dingly.
1.6 Connect high-pressure pump (Fig. 4/7)

with high-pressure hose(s) to the hydraulic
jack(s) (2).
1.7 When using several hydraulic jacks at the

same time an appropriate distributor 2 Principle representation
(Fig. 4/8) is to be used.
1.8 Open valve (3) of the high-pressure pump

(7).
4
NOTE
Depending on the engine
variation, corner pieces may
be necessary to connect the
high-pressure pump (Fig. 4/7)
and hydraulic jacks.
1 6
9
7
en / 16.12.2019 3/14
1.9 Put in place a suitable lever between assembly pins (Fig. 5/5) and turn threaded sleeve (3) onto 13
the stud until it reaches end-stop position.
The ring surface of the threaded sleeve (3) must be flush with the bottom surface of the hydraulic
jack (2) or slightly below bottom surface level.
CAUTION
Leaks and stretching errors may occur
Before using a stretching device the basic position of the hydraulic jack (Fig. 5/2)
must be established. Steps 1.1 to 1.9.
If this basic position is not ensured, there is still oil from a previous application in the
pressure chamber of the cylinder. This will increase the prelift of the piston in
the hydraulic jack (2) with each use, which will cause leaks and stretching errors.
If several hydraulic jacks (2) are to be pressurized simultaneously, e.g. when
disassembling or assembling cylinder head studs, the jacks (2) must be connected to
the high-pressure pump (Fig. 4/7) one after the other and set to basic position. Only
after this procedure the hydraulic jacks (2) are to be connected among each other.
Otherwise, there is a risk of the excess oil not being pressed back into the high-
pressure pump (7) but into another hydraulic jack (2).
NOTE
As the hydraulic connection of a hydraulic jack (Fig. 5/2) is provided with a non-return
valve, the oil can only be removed from the pressure chamber when the high-pressure
hose is connected and the valve (Fig. 4/9) on the high-pressure pump (7) is open.
3
en / 16.12.2019 4/14
2. Loosening of round nuts 13
CAUTION
Damage and malfunctions due to contamination!
Contamination on connections of hydraulic components causes leaks.
There may occur problems when connecting or loosening the connections as well as
malfunctions in the hydraulic system.
Hydraulic connections are to be plugged upon disassembly of the components.
2.1 Turn back threaded sleeve (Fig. 6/3) by

the value indicated in Table A (see
3
Appendix) for the respective position or
adjust the distance by means of a feeler
gauge (Fig. 13/11).
2
2.2 Close the valve (Fig. 4/9) on the high-
pressure pump (7).
2.2.1 Actuate the high-pressure pump (7) and 1

for the time being build up a pressure of
50 - 100 bar (725 psi - 1450 psi).
2.2.2 Check all connections of the high-pressu-

re hoses on the hydraulic jacks (Fig. 6/2),
on the high-pressure pump (Fig. 4/7) and,
if applicable, on the distributor (8) for com- 6 Principle representation
plete locking (see Fig. 12).
2.3 After this check actuate the high-pressure

pump (Fig. 4/7) again and build up the 4
pressure indicated in Table B (see Appen-
dix) for the respective position.
All connected hydraulic jacks (Fig. 6/2)
are pressurized simultaneously. 6
2.4 Only after at least 15 seconds loosen the

round nuts (Fig. 7/4) through the slot in
the support ring by means of pin (6).
2.5 Loosen the round nut (4) with the pin (6)
until the pin (6) cannot be inserted any
more into the holes of the round nut (4).
If, in doing so, the round nut (4) reaches
the upper end-stop position, turn it back by 7 Principle representation
3 holes.
en / 16.12.2019 5/14
13
CAUTION
Risk of tear-off due to overstretching the stud threads!
If loosening of the round nuts (Fig. 7/4) is not possible under the specified pressure,
the pressure may be increased by max. 50 bar (725 psi).
If the pressure is increased further, there is a risk of overstretching the stud threads,
which would require the studs to be replaced.
2.6 Slowly open the valve (Fig. 4/9) on the high-pressure pump (7).
2.7 Wait until the pressure has fully dropped.
2.8 It must still be possible to turn the round nuts (Fig. 7/4) easily by means of the pin (6). If necessa-
ry, build up pressure again and turn the round nuts (4) back by further holes, see steps 2.2 to 2.7.
NOTE
Before dismounting the hydraulic stretching devices and placing them into the
storage box the basic position of the stretching devices has to be established,
see steps 1.1 to 1.9.
2.9 Loosen high-pressure hoses from hydrau-

lic jacks (Fig. 6/2), high-pressure pump
(Fig. 4/7) and, if applicable, distributor (8).
2.10 Plug the connections of the high-pressure

hoses, hydraulic jacks (Fig. 6/2), high-
pressure pump (Fig. 4/7) and, if applica-
ble, the distributor (8) by means of caps
(Fig. 8/10).
2.11 Remove threaded sleeve (Fig. 6/3), hy-

draulic jacks (2), and support rings (1).
2.12 Clean all used components and place

them into the storage box. 10
en / 16.12.2019 6/14
3. Fixing of round nuts 13
CAUTION
Damage and malfunctions due to contamination!
Contamination on connections of hydraulic components causes leaks.
There may occur problems when connecting or loosening the connections as well as
malfunctions in the hydraulic system.
Hydraulic connections are to be plugged upon disassembly of the components.
NOTE
When fixing round nuts for crankshaft bearings and balance weights a prestretching
pressure has to be applied. For details please refer to the respective job cards.
3.1 Tighten round nuts (Fig. 9/4) finger tight with pin (6)before assembly of the hydraulic stretching
device.
3.2 Carry out steps 1.1 to 1.9.
3.3 Close the valve (Fig. 11/9) on the high-

pressure pump (7).
3.3.1 Actuate the high-pressure pump (7) and

for the time being build up a pressure of
50 - 100 bar (725 psi - 1450 psi).
3.3.2 Check all connections of the high-pressu-

re hoses for complete locking
(see Fig. 12).
3.3.3 Open the valve (Fig. 11/9) on the high- 4 6

pressure pump (7) and wait until pressure 9 Principle representation
has fully dropped.
CAUTION
Risk of tightening errors due to dropping pressure.
When building up the pressure, pause at intervals and observe the pressure gauge.
The pressure that is then reached must remain constant when the high-pressure
pump (Fig. 11/7) is not actuated. If the pressure drops, this will cause tightening
errors.
If necessary, check the lockings of the connections of the high-pressure hoses and
the high-pressure pump (7).
en / 16.12.2019 7/14
3.4 Close the valve (Fig. 11/9) on the high- 13

pressure pump (7) and build up the stret-
ching pressure indicated in Table B (see
Appendix) for the respective position.
6
3.5 After about 15 seconds (after pressure
build-up) firmly tighten the round nut
(Fig. 10/4) through the slot in the support
ring (1) with the pin (6) and, in doing so,
make sure there is ease of movement. 4
3.6 By slowly opening the valve (Fig. 11/9) on 1

the high-pressure pump (7) decrease the
pressure by 50 bar (725 psi).
Loosening of the round (Fig. 10/4) nut by
means of the pin (6) must not be possible
any more.
3.7 Slowly open the valve (Fig. 11/9) on the high-pressure pump (7) and wait until the pressure has
fully dropped.
NOTE
Before dismounting the hydraulic stretching devices and placing them into the
storage box the basic position of the stretching devices has to be established, see
steps 1.1 to 1.9.
3.8 Loosen high-pressure hoses from hydrau-

lic jacks (Fig. 11/2), high-pressure pump 2
(7) and, if applicable, distributor (8).
3.9 Plug the connections of the high-pressure

hoses, hydraulic jacks (2), high-pressure
pump (7) and, if applicable, the distributor
(8) by means of caps (Fig. 8/10).
8
3.10 Disassemble the threaded sleeve
(Fig. 1/3) of the stretching device.
9
7
3.11 Remove hydraulic jacks (2) and support
rings (3).
3.12 Clean all used components and place

them into the storage box.
en / 16.12.2019 8/14
4. Troubleshooting 13
For troubleshooting proceed according to the following table:
Fault Possible cause Action
Open valve of the high-pressure pump

to bleed pressure completely.
Declamp relevant hose couplings,
No pressure build-up in the High-pressure hoses are
check couplings and reconnect
hydraulic jacks. not completely locked.
afterwards. Repeat test (work sequence
2.2 / 2.3).
Refer to Fig. 12 for orientation.
Piston return mechanism Send the hydraulic jack to the

damaged. manufacturer.
After pressure decrease the Mount the hydraulic stretching device
piston of the hydraulic jack completely on a corresponding stud.
does not move back to end There is still hydraulic oil in Connect the device to the high-pressure
position / basic position. the pressure chamber of pump.
the hydraulic jack.
Establish basic position according to
steps 1.1 - 1.9.
Basic position according to Send the hydraulic jack to the
Piston in hydraulic jack
steps 1.1 - 1.9 cannot be manufacturer.
tilted.
established.
Reduce pressure completely. Check the

connections of the high-pressure hoses.
Connections of the high-
Built-up pressure is not In case of a leak:
pressure hoses are leaky.
maintained. Loosen and reconnect the connections.
If necessary, replace high-pressure
hoses.
Reduce pressure completely.

- The overflow valve is relieved.
Clean the hydraulic jack.
Max. stroke was exceeded.
Build up a test pressure of 250 bar
An overflow valve opens
(3626 psi).
Oil leaking from the hydraulic and allows oil to drain from
- If no oil is leaking and the test pressure
jack. the pressure chamber.
is maintained for more than 5 minutes
The hydraulic jack is not
the hydraulic jack is usable.
defective.
- If there is an oil leak again, the gaskets
are defective.
Hydraulic jack leaky. Gaskets defective. Replace the gaskets.
en / 16.12.2019 9/14
13
Fig. 11/A: Hose connection fully locked.

Fig. 11/B: Hose connection not fully locked.
Fig. 11/C: In case of continued pressure build-up the connection will partly slip off.
The internal valve will be closed.
en / 16.12.2019 10/14
5. Appendix (tables) 13
Table A: Adjusting Values for Threaded Sleeve
3
NOTE
For loosening a round nut
(Fig. 10/4) the threaded
sleeve (Fig. 13/3) that was
fastened finger tight has to be
turned back by a distance
specific to the respective case
of application. To avoid
inaccuracies this distance is
mostly adjusted by means of a
feeler gauge (11) between
support ring (1) and contact
surface. In some cases of
application, however, 1
experience has shown that it is
more practical to turn back the
threaded sleeve (3) by a 11
certain number of turns (see
Table A).
This prevents jamming of the
components of the hydraulic 13 Principle representation
stretching device on the stud
after decreasing the stretching
pressure.
Table A, M 20 C - GCM34
M 25 C M 32 E
Engine type M 20 C M 32 C VM 32 C GCM34
M 25 E M 34 DF
Cylinder head 2,5 mm 3.0 mm 3.5 mm 3.5 mm 3.5 mm 3,5 mm

Lateral studs / crankshaft bea-
1.5 mm 1/2 turn 1/2 turn 1,5 mm
ring
Crankshaft bearing bolts 2,5 mm 2,0 mm 2.0 mm 1/2 turn 1/2 turn 2,0 mm
Big-end bearing cap (standard) 3/4 turn 3/4 turn 3/4 turn
Big-end bearing cap (Marine) 2,0 mm 2,0 mm
Table A, M 43 C - VM46 DF
Engine type M 43 C VM 43 C M 46 DF VM 46 DF
Cylinder head 1 1/3 turn 1 1/3 turn 1 1/3 turn 1 1/3 turn
1 1/4 turn or 1 1/4 turn or 1 1/4 turn or 1 1/4 turn or
Lateral studs / crankshaft bearing 10 holes 10 holes 10 holes 10 holes
back back back back
en / 16.12.2019 11/14
Table A, M 43 C - VM46 DF
13
1 turn or 1 turn or 1 turn or 1 turn or

Crankshaft bearing bolts 8 holes 8 holes 8 holes 8 holes
back back back back
1 1/4 turn or 1 1/4 turn or 1 1/4 turn or 1 1/4 turn or
Big-end bearing cap 10 holes 10 holes 10 holes 10 holes
back back back back
Table B: Stretching Pressure / Prestretching Pressure
CAUTION
When fixing round nuts for crankshaft bearings and balance weights a prestretching
pressure has to be applied. For details please refer to the respective job cards.
Table B, M 20 C / M 25 C / M 32 C / VM 32 C / GCM34
M 25 C GCM34 GCM34
Enginetyp M 20 C M 32 C VM 32 C
M 25 E 420 kW/cyl. 500 kW/cyl.
600 bar 820 bar 850 bar 850 bar 712 bar 757 bar
Cylinder head
8702 psi 11893 psi 12328 psi 12328 psi 10327 psi 10980 psi
Pre-
stret- 150 bar 150 bar 150 bar 150 bar
ching
Lateral studs / pres-
2176 psi 2176 psi 2176 psi 2176 psi
crankshaft bea- sure
ring
Stret- 650 bar 680 bar 680 bar 680 bar
ching
pres- 9428 psi 9863 psi 9863 psi 9863 psi
sure
750 bar 980 bar 1150 bar 1025 bar 1025 bar 1025 bar
Crankshaft bea-
ring bolts 10878 14214
16679 psi 16317 psi 16317 psi 16317 psi
psi psi
Big-end bearing 1200 bar 1200 bar 1200 bar 1200 bar
cap 17405 psi 17405 psi 17405 psi 17405psi
en / 16.12.2019 12/14
13
Table B, M 32 E / VM 32 E / VM 32 C LS* / M 34 DF (*LS = Long Stroke)
Enginetyp M 32 E VM 32 E VM 32 C LS* M 34 DF
900 bar 900 bar 850 bar 850 bar

Cylinder head
13053 psi 13053 psi 12328 psi 12328 psi
Prestretching 150 bar 150 bar 150 bar 150 bar
Lateral studs / pressure 2176 psi 2176 psi 2176 psi 2176 psi
crankshaft
bearing Stretching pres- 650 bar 680 bar 680 bar 650 bar
sure 9428 psi 9863 psi 9863 psi 9428 psi
Crankshaft 1150 bar 1025 bar 1025 bar 1150 bar
bearing
bolts 16679 psi 16317 psi 16317 psi 16679 psi
100 Nm (mechanically)
Big-end bea- Attention!

Prestretching
ring cap, First read the associated maintenance instructions, see
(Connecting A5.05.02.04.01.nn
rod with lower
shank division)
Stretching pres- 1050 bar 1050 bar 1050 bar 1050 bar
sure 15229 psi 15229 psi 15229 psi 15229 psi
Table B, M 43 C - VM 46 DF
2360 bar 2360 bar 2360 bar 2360 bar

Cylinder head
34229 psi 34229 psi 34229 psi 34229 psi
Prestretching 380 bar 240 bar 380 bar 240 bar
Lateral studs / pressure 5511 3481 psi 5511 3481 psi

crankshaft bearing 2250 bar 1900 bar 2250 bar 1900 bar
Stretching
pressure 32633 psi 27557 psi 32633 psi 27557 psi
Crankshaft bearing 2250 bar 2250 bar 2250 bar 2250 bar
bolts 32633 psi 32633 psi 32633 psi 32633 psi
2250 bar 2250 bar 2250 bar 2250 bar
Big-end bearing cap
32633 psi 32633 psi 32633 psi 32633 psi
en / 16.12.2019 13/14
13
en / 16.12.2019 14/14
c2 Resilient Mounting
Maintenance / Check
A5.05. 13.02.01.11
eSee also: 13
Spare parts sheets:

--------------------------------------------------------------------------------------------------------------------------------
Activities:
1. Resilient mounting - check
M 20 C - VM 46 DF *
* no picture
CAUTION
Risk of disintegration of the rubber elements due to aggressive media!
Avoid any contact of the rubber elements of the resilient mounting with oil, oily water,
fuel, and other aggressive media, because this would have a detrimental effect on the
service life of the elements.
Contaminated elements should be cleaned with a mild household detergent.
Elements showing damage such as cracks, crumbling or unusually deformed surfaces
must be replaced by new conical mounts.
1. Resilient mounting - check
2. Stop the engine.
3. Measure the central buffer clearance (1/Z).
4. If in cold condition (approx. 20 °C) the central buffer clearance (1/Z) should drop below the limit
indicated in the table, measures must be taken.
In such a case, contact your authorized Caterpillar dealer.
en / 03.06.2019 1/2
c2 Resilient Mounting
Maintenance / Check
A5.05. 13.02.01.11
5. Another indicator of the condition of the resilient mounting is the TB dimension (Top Bottom di- 13
mension).
6. Measure the TB dimension (1/Y) in the area of the machined surfaces at all four corners of each
resilient mounting. Form a mean value each time from the measured values.
7. If in cold condition (approx. 20 °C) the TB mean value should drop below the limit indicated in the
table, measures must be taken.
In such a case, contact your authorized Caterpillar dealer.
Bearing Central buffer “Top Bottom”

type clearance (Z) mm dimension (Y) mm
T75 4 29
T 230 4 42
RD314 3 20
RD214 3 29
RD214X 3 59
RD112 4 46
RD114 4 30
RD114X 4 40
Z Y
1 Schematic diagram
en / 03.06.2019 2/2

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Maintenance A0

Engine No.: 48048 Record No.: 271448

en / 15.12.2014 AA047801 1/2

en / 02.01.2015 AA047587 1/1

en / 02.01.2015 AA047587 1/1

1. Designation of the engine sides 0

2. Cylinder counting method 0

2.1 In-line engines

Counting of the cylinders starts at the driving end.

Counting of the cylinders starts at the driving end.

1 Exhaust valve rocker arm

4. Counting method for the inlet and exhaust valves 0

A Inlet valve, exhaust side C Exhaust valve, camshaft side

B Inlet valve, camshaft D Exhaust valve, exhaust side

4.1 In-line engines

5. Direction of rotation of the engine 0

Counter-clockwise direction of rotation Clockwise direction of rotation

6. Nameplate of the engine

Unit Conversation factor Unit

ft³/h x 0,0283 m³/h

m³/h x 4,4028 gpm

bar x 14,504 psi

psi x 0,069 bar

kPa x 0,145 psi

Unit Conversation factor Unit

Nm³/h x 35,3147 SCF/h

SCF/h x 0,02831 Nm³/h

kg/h x 2,2046 lb/h

lb/h x 0,4536 kg/h

kJ/kWh x 0,9478 BTU/kWh

BTU/kWh x 1,0551 kJ/kWh

pound-force feet x 1,35582 Nm

Liter x 1,06 quart

Liter x 0,26 gallone

gallon x 3,79 Liter

gal/hp x 5,076 l/kW

kJ/kg x 0,4299 BTU/lb

BTU/lb x 2,3261 kJ/kg

kg/m² x 23,7304 lb/ft²

lb/ft² x 0,0421 kg/m²

kg/m³ x 0,0624 lb/ft³

lb/ft³ x 16,0256 kg/m³

Nms/rad x 0,7376 ftlbs/rad

ftlbs/rad x 1,3558 Nms/rad

MJ/Nm³ x 26,8392 BTU/SCF

mg/kJ x 2,326 10-6 lb/BTU

lb/BTU x 4,299 105 mg/kJ

Unit Conversation factor Unit

mg/dl x 0,1 mmol/l

°US-Hardness x 0,056 °dGH

Engine, Cylinder Head A5.05.01

Engine, Gear A5.05.02

Engine, Housing A5.05.03

Engine, Control A5.05.04

Engine, Regulation A5.05.05

Engine, Exhaust Gas System / Supercharging A5.05.06

SCR - Selective Catalytic Reduction (optional)

Engine, Fuel System A5.05.07

Fuel Duplex Filter

Engine, Lubricating Oil System A5.05.08

Engine, Cooling Water System A5.05.09

Engine, starting system A5.05.10

Engine Control Equipment A5.05.11

Engine Auxiliary Units A5.05.12