Top M25
Top M25
Top M25
c
M25
m
Engineer ´s Handbook
M25 c
Contents
Camshaft
Camshaft bearings 31
Mounting of camshaft 30
Tightening torques 30
Vibration damper mounting 31
Connecting rod
Reference dimension 18
Tightening torques 18
Crankshaft
Counterweight mounting 23
Crank web deflection 23
Crankshaft bearing
Gap - measurement 21
Located main bearing 22
Marking 22
Tightening torque 21
Cylinder head
Exhaust gas manifold 12
Fitted valve stems: 14
Fitting of inlet and exhaust valve seats 15
Fuel delivery pipe connection 11 - 12
Fuel injection valve 9 - 10
Grinding of inlet and exhaust valves 13 - 14
Guiding bolts - valve bridges 8
Indicating and safety valve 8
Sleeve for the fuel injection valve 9
Starting valve 8
Tightening torques 6
Valve clearance 7-8
Valve guide 8
Valve rocker bracket 6-7
Engine data 5
Firing sequences 57
Flywheel mounting
Clearances 45
Dismounting of flywheel 44
Mounting 46
Tightening torques 44 - 45
Gear train
Backlash 27
Camshaft gear wheel 26
Gear wheel on crankshaft 24
Intermediate wheel mounting 25
Lub. oil injectors for the gear drive 26
Gear wheel mounting 27
Governor drive
Bushes in the cylinder crankcase 29
Clearances 28
Tightening torqes 28
Liners
Assembly 20
Canyon 19 - 20
Nominal size 19
Pocket 19 - 20
Score 19 - 20
Wear limits 19
Wedge shape 19 - 20
Piston
Dismounting of the firering 17
Mounting 16
Piston rings 17
Tightening torques 16
Wear and clearance limits 17
Sundries
Barring gear 39
Cooling water distributing pipi 38
Regulating shaft 37
Starting fuel limiter 40
Turbocharger mounting
Tightening torques 50 - 55
Valve timing 57
Ø 59.99 + 0.12
0.20+0.10
Before pressing-in slightly coat the bushes with oil, Molykote must not be used.
Radial clearance
Original size → 0.02 - 0.159 mm
Measure diameter of the valve shaft in the guide area. Measure guide in cross direction of
engine.
Joint ring
Starting valve
Tighten locking screw - 1 - with → 1 M = 250 Nm
2
Tighten safety nut - 2 - with → M = 35 Nm
Molykote
Safety nut VM 10x1 DIN 980
Reference dimension
307,5
O-ring Perbunan
Slightly coat
o-rings with Molykote Nozzle cooling supply
and distribute it equally
Fuel pressure pipe connection
Nozzle leak fuel
Attention !
Insert the injection
valve into the cylinder Insert nozzle
head without joint element with high-
ring ! temperature paste
3. The joint ring must be checked visually once more for correct fitting.
Otherwise, the before-mentioned procedure is to be repeated with a new joint ring.
6. Push sleeve - 2 - into the fuel injection pump for locking. Tighten nuts of the fuel
injection valve with prescribed torque.
Coat thread and contact surfaces of screwing - 4 -, transverse pressure piece - 3 -, radial
pressure piece - 5 - and thrust bolt - 6 - with Molykote paste G.
6
1
5
Gasket
Gaskets between cylinder head and
exhaust gas manifold
When fitting the gasket take care that the bead in
the gasket shows to the exhaust gas pipe flange.
29° 59’ - 2’
29° 87’ + 2’
min. 1.5 mm
min. 1.5 mm
Inlet valve
29° 52’ + 2’
min. 0.2 mm
0.05 mm
20 20
s
0.025 mm
S
Fitted valve stems:
MDO operation 2500.7-22.10.01-01 Inlet valve
2500.7-22.10.01-02 Exhaust valve
Y1
Y2
3. When the valve seat rings are tight,
press themon with the pressure
device.
4. Check the bearing surface „Y 2 "; between inlet valve seat ring and cylinder head
no air gap is admissible.
5. Check the air gap „Y 1" between exhaust valve seat ring and cylinder head.
Admissible air gap 0.40 + 0.30 mm
Pressure test: Cooling water spaces 10 bar for 8 min.
’
5’+5
5’+5
a a
ØX
30°+
ØX
30°+
Refinishing is possible with Mak valve seat ring turning machine or with MaK valve seat
milling fixture. After grinding the bearing portion shall be 30- 50 %, beginning from the
outer diameter.
Gap size
2500.7-26.70.00-01 / -02 → 0.06 - 0.10 mm
68+0,4
Fitting
Arrange the ring butts in longitudinal direction of engine alternately opposed, then oil
pistons and piston rings well.
Fit piston rings with marking upwards.
+0.03
2 6.13 6.00 -0.010 - 0.025 6.60 0.50
+0.03
3 8.06 8.00 -0.013 - 0.035 8.60 0.50
Piston bosses -
Piston pin 0.050 0.078 0.100
2. Place dismounting device on the piston so that the recess lies inside
the fire ring.
Reference size B
Reference size A
Upper screws
Depth * → 0.03 mm
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring.
Length → 150.00 mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC)
Score Number → 3
Length → 150.00 mm
Depth → 0.03 mm
Pocket Number → 3
Length → 60.00 mm
Width ** → 20.00 mm
Depth * → 0.02 mm
* Radius r ò 3 mm
** In circumferential direction
Assembly
During installation take care that 2
marking - 1 - of the liner coincides
with marking - 2 - of the cooling
water distributor casing.
The liner must slide into the cylinder
crankcase by its own weight.
2 1 2
Measurement of gap
1. Remove hexagon screws - 3 - of the crankshaft bearing. Loosen hexagon screws
- 3 - of the adjacent crankshaft bearing.
2. Loosen both crankshaft bearing nuts - 2 - of one bearing pocket in one operation.
3. Tighten crankshaft bearing nuts with a pin alternately and steadily until the joint faces
of the bearing shells are just touching each other.
4. Check the projecting length of the bearing shell by measuring the gap between
cylinder crankcase and bearing cap on camshaft and exhaust gas side.
Bearing No.
stamped here The protection against
torsion is on camshaft
side
X
X
The final position is reached when the gear wheel touches the spacer. The spacer simulates the
located bearing, it must be adjusted so that with the gear wheel in final position a dimension
of 126 + 0.1 mm results between gear wheel and crank web cyl.1.
Spacer
126 + 0.01
Connection„Z“ 1/4 ‘’
X
1
S
O-ring
max. → 0.60 mm
Gap size
Min. → 0.30 mm
Max. → 1.40 mm
4
Attention! Tighten screws - 4 -
steadily.
Final position: Draw helical
wheel - 3 - against bearing
journal - 1 -.
Slide-on distance: 10.5 - 2.9 mm
Attention !
During assembly of the helical gear wheel
attention must be paid to bore - 1 -, that means
cylinder 1 and injection cam ramp must be in 1
TDC position.
Backlash - 4 - → 1
0.15 - 0.50 mm
32
8
If the bushes - 1 - and - 2 - in
the cylinder crankcase must be
exchanged, take care that the 1
dimensions stated in the sketch
are observed.
Slightly oil the bushes before
pressing them in, do not use
Molykote.
302
336
2
Mounting of camshaft
9 cyl. engine
Cylinder section Flange code number
1 5
2 8
3 2
4 6
5 4
6 4
7 6
8 2
9 8
X 1
min. 0.20 min. 0.20
Attention!
Take care of the chamfer.
Valid for cy. 2 to cyl. 5/ 7/ 8l
Type: PF1WX230V-C
Tighten fastening nuts
with → M = 200 Nm
Molykote
M = 10 Nm
Pretighten screws - 1 -with →
and tighten
with → 3 M = 90 ± 3 Nm
5
Tighten counter-sunk
screws for
the indicator at
the fuel rack with → 4 M = 3.50 + 0.50 Nm
1 2
Mounting
Before mounting the injection pump take care that the roller of the rocking lever rests on
the cam base circle and that the air passage sleeves are correctly positioned in the
cooling water distributor casing.
Dismounting / mounting
During dismounting / mounting attention must be paid that the appertaining distance steel
plates are not removed.
If for any reason removal of the distance steel plates is necessary, they have to be
marked with the relevant cylinder number.
The thickness of the distance steel plates for each cylinder is stated in the acceptance test
record.
Start
Control air inlet
Starting
process Start of venting
4. Set dial gauge to „0“, turn engine in direction of rotation until the indication on the
gauge is 5 mm (5 mm on the gauge
correspond to 11° crank angle on the
flywheel).
24.6
5. Check the dimension on the flywheel from
TDC mark to dead center indicator.
Setting
1. Place the gauge with measuring device on
a level support by means of the adjusting
bush (dimension = 24.6 mm) and set
gauge to „0“.
The distance steel plates are used for setting the pre-stroke.
Available sizes:
2.10 mm 2.20 mm 2.40 mm 2.50 mm 2.60 mm 2.70 mm
2.80 mm 2.90 mm 3.00 mm 3.20 mm 3.40 mm 3.60 mm
Marking on I
flywheel M
O
When mounting the helical gear wheel for the governor drive take care of the position of
bore - 1 -, i.e. cylinder 1 and injection cam ramp must be in TDC position.
Clearance at - 2 - → 0.20 mm
Before inserting the regulating shaft
lubricate the bearing areas.
Do not use Molykote nor oil.
2
Tighten screw - 3 - for the articulated lever with → M = 20 Nm
Molykote
Engine operation is
1 only possible with
screwed on cover - 2 -.
5. Lever - 1 - must be bored through with 6 mm and be pinned and leaded by a clamping
sleeve.
2
ad
l lo
Ful
16
n
1
tio
si
Po
30 op
St
Ø 157
From 1000 kW power
1
Ø 100
Up to1000 kW power
170
Lub. oil pumps, suction and pressure pump, cooling water circulation pumps
Gear wheel mounting
Cover gear wheel cone with blue paste and check contact reflection on the appertaining
pump shaft cone with gear wheel cone, covered with blue paste.
Contact reflection ≥ 80°. Heat gear wheel up to 90°C-100°C above temperature of the
pump shaft and mount it firmly on the pump cone up to stop position. The cone faces must
be grease-free and dry.
Example: 20° C shaft temperature → 110 ° to 120 ° C gear wheel temperature.
The slide-on distance is 0,40 - 0,44 mm.
Press flywheel with tightening device and oil hydraulic mounting into its final position.
5 3
The device must not be loosened earlier than 24 hours after pressure relief. Engine start
not before 72 hours after removal of the device.
Mount the splash ring on flywheel.
Mounting proceeds in reverse order. The slide-on distance is 23 mm. When sliding on
take care that the oil slinger is placed upon the studs.
Hydraulic connection 1/4’’
Connection „Z“
1. Fix L-strap - 1 - with screws - 2 - at the charge air cooler without water separator.
2. Loosen landing surfaces - 3 - at the charge air cooler and press them against the
cooler.
3. Push the charge air cooler into the casing.
4. Before screwing the charge air cooler together with the casing, tighten screws - 4 -.
5. Fix the charge air cooler with screws - 5 - and washers at the casing.
6. Push the landing surfaces against the casing and fix them with screws - 6 -.
1 2
X
Tighten screws - 2 -
with → M = 20 Nm
Molykote
Fixing screws
Tighten charge air cooler casing -
cylinder crankcase with → M = 130 Nm
Molykote
Y
5
3
6
Y = Mount this holder at the charge air cooler, contrary to its delivered condition, turned by 180°.
1 2
For 2500.7-72.50.00-01 1 hexagon screw M12x35 ISO 4017 with washer 13-DIN 125
10 hexagon screws M12x55 ISO 4014 with washer 13-DIN 125
and 10 spacers E13x21 N 6003
No gaskets
here
2500.7-72.55.00-04
8 hexagon screws M16x60 ISO 4014 2500.7-72.50.00-07
8 spacer 17x26 - 20 N 6003 8 hexagon screws M16x60 ISO 4014
11 hexagon screws M12x65 ISO 4017 19 hexagon screws M12x40 ISO 4017
11 washers 13 DIN 125
2500.7-72.55.00-07
8 hexagon screws M16x60 ISO 4014
19 hexagon screws M12x40 ISO 4017
11 hexagon screws M12x65 ISO 4017
No gaskets here
No gaskets here
1
Item 1 = O-ring 1
Screws M 16
Between the exhaust gas pipes and the expansion joints no gaskets are fitted.
The expansion joints are installed in the direction of arrow.
Recession max. 5 mm
counterclockwise 1-2-4-6-5-3
counterclockwise 1-3-5-7-8-6-4-2
counterclockwise 1-3-5-7-9-8-6-4-2
Valve timing
Crankshaft
with counterweights
6 cyl. engine 1.917
Crankshaft
without counterweights
6 cyl. engine 3.171 456 1.445
Oil sump
6 cyl. engine 3.369 968 399 496
Intermediate
gear wheel axle 320 Ø 98 17,8
Vibration damper
Crankshaft
6 cyl. engine 200 Ø 850 980
Vibration damper
Camshaft
6 - 8 - 9 cyl. engine 62 Ø 330 29
Cyl. head
compl. 265
Cyl. head
without inlet and exhaust valves
with valve guides 725 428 351 194
Pump carrier
Thickness 40 1.075 1.007 198