M43 Maint Dec2011

Maintenance A0
Maintenance
M 43 / M 43 C
en / 21.12.2011 AA044756 1/1

Total Index A0.01
Maintenance A0
Total Index A0.01
Introduction A0.02
Maintenance A5
Table of Contents A5.01
Introduction A5.02
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Introduction A0.02
M20/M25/M32/M43
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 9009, D-24157 Kiel
Telephone: +49(0)431- 3995-01(chief operator)
Telefax: +49(0)431-3995-2010(after-sales service only)
http://www.marine.cat.com
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Maintenance A5
Maintenance
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Maintenance A5
Introduction A5.02
Periodical schedule
Distillate fuel A5.04.01
Periodical schedule
Heavy fuel A5.04.02
01 Engine, cylinder head A5.05.01

Valve clearance
Inspection / Adjustment A5.05.01.01.01.00
Valve clearance
Valve projection
Inspection / Measuring A5.05.01.01.02.00
Valve Rocker Brackets
Maintenance / Disassembly and reassembly A5.05.01.02.01.00
Valve Rockers
Valve Rocker Bush
Inspection / Replacement A5.05.01.02.03.00
Valve Rotor
Inspection / Evaluate A5.05.01.03.01.00
Valve Rotor
Valve guide/Oil scraper ring
Valve guide/Oil scraper ring
Media guiding system
Cylinder Head
Maintenance / Disassembly A5.05.01.06.01.00
Cylinder Head
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Cylinder Head
Nozzle sleeve
Nozzle sleeve
Relief Valve
Maintenance / Replacement A5.05.01.06.70.00
Relief Valve
Inlet and Exhaust Valve Cone
Inspection / Disassembly and reassembly A5.05.01.07.01.02
Inlet and Exhaust Valve Cone
Inlet and Exhaust Valve Cones
Repair / Checking A5.05.01.08.01.00
Valve Seat Ring
Repair / Checking A5.05.01.08.02.00
Valve Seat Ring (Intake/Exhaust)
Repair / Replacement A5.05.01.08.03.00
Starter Valve
Inspection / Checking A5.05.01.09.01.00
Starter Valve
Starter Valve
Starter Valve
Starter Valve
Cylinder Head
Cylinder Head
Maintenance / Cleaning A5.05.01.10.01.00
Cylinder Head
Cylinder Head
Repair / Reassembly A5.05.01.11.01.00
Cylinder Head
Cylinder Head
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02 Engine, gear A5.05.02

Running Gear / Engine Timing
Crank Web Deflection
Bearing Shells and Bearing Bushes
Bearing Shells
Big End Bearings
Inspection / Disassembly A5.05.02.04.01.00
Big End Bearings
Big End Bearings
Big End Bearings
Inspection / Reassembly A5.05.02.04.02.00
Big End Bearings
Big End Bearings
Hydraulic Jack
Hydraulic Jack
Main Bearings
Main Bearings
Main Bearings
Main Bearings
Maintenance / Reassembly A5.05.02.05.02.00
Main Bearings
Main Thrust Bearings
Piston
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Piston
Piston
Piston
Piston Crown
Piston Crown
Piston Crown
Piston Rings and Grooves
Piston Pin
Piston Pin
Piston
Piston
Piston
Piston
Balance weight
Repair / Disassembly and reassembly A5.05.02.11.00.00
Measures for emergency operation
03 Engine, housing A5.05.03

Crankcase Explosion Safety Valve
Explosion relief valve
Explosion relief valve
Coolant Distributor Housing
Cylinder Liner
Cylinder Liner
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Cylinder Liner
Cylinder Liner
Cylinder Liner
Engine Fasteners and Connections
04 Engine, control A5.05.04

Camshaft Bearing
Camshaft Bearing
Camshaft Bearing
Bottom part for Valve Mechanism
Bottom part for Valve Mechanism FCT
Adjusting Device FCT
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
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Camshaft
Camshaft
Camshaft
Camshaft
Camshaft
Timing Gear Train
Timing Gear Train
Timing Gear Train
Timing Gear Train
Timing Gear Train
Timing Gear Train
Governor Drive
Governor Drive
Vibration Damper on Camshaft
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05 Engine, regulation A5.05.05

Control Shaft Bearings
Maintenance / Checking A5.05.05.01.02.00
Starting Valve
Starting Fuel Limiter
Control Rod
Control Rod
Compressed-Air Filter
Compressed-Air Filter
Regleröl
Inspection / Oil change A5.05.05.25.00.01
06 Engine, exhaust gas system/supercharging A5.05.06

Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
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Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Exhaust Line
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
Charge Air Cooler
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Charge Air Cooler
Exhaust gas turbocharger
Turbocharger
07 Engine, fuel system A5.05.07

Injection Pump
Injection Pump
Injection Pump
Injection Pump
Injection Pump
Injection Pump
Injection Pump
Injection Pump
Injection Pump
Deflector Bolts
Pressure Valve
Injection Pump
High-Pressure Injection Pipe
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Fuel Injector
Fuel Injector
Fuel Injector
Maintenance / Adjustment A5.05.07.08.01.00
Fuel Injector
Fuel Injector
Fuel Injector
Fuel Injector
Fuel Duplex Filter
Fuel Duplex Filter
Duplex Fuel Preliminary Filter
Fuel Distributor/Collector Line
Fuel Pipe Mounting
Fuel Pressure Damper
08 Engine, lubricating oil system A5.05.08

Lubricating Oil System
Maintenance / Oil change A5.05.08.02.01.00
Lubricating Oil Pump
Lubricating Oil Duplex Filter
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Lubricating Oil Duplex Filter
Oil pressure control valve
Prelubricating pump/Prelubrication
Leak oil pipe
Leak oil pipe
09 Engine, cooling water system A5.05.09

Cooling Water Centrifugal Pump
10 Engine, starting system A5.05.10

Stop Piston
11 Engine control equipment A5.05.11

Pressure Switches
Pressure Switches
RPM Switch
Fuel rack position monitoring
Lubricating Oil/Cooling Water Thermostat
Lubricating Oil/Cooling Water Thermostat
Pressure Switch
Pressure Switch
Crankcase Monitoring Device
Crankcase Monitoring Device
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12 Engine auxiliary units A5.05.12

Vibration Damper
Turning Device
Turning Device
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Introduction A5.02
M20/M25/M32/M43
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 diesel engines. For this rea-
son and in the interest of clearness we did not go too much into details in the
maintenance documents.
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
Most of the work to be carried out does not have a fixed deadline since the service life of
individual components is highly influenced by environmental and operating conditions,
fuel qualities and their care.
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Introduction A5.02
M20/M25/M32/M43
Therefore the present interval schedule shall not be considered stringent in the long run,
but it is left to the user to modify the maintenance schedule in accordance with own
experiences.
But in any case a sufficient safety margin - even if the mean wearing levels are well-
known - is to be calculated in order to cover the always occurring variations.
It is recommended to consult Caterpillar Motoren GmbH & Co. KG with regard to exten-
ded intervals in order to maintain the guarantee.
The information given by us gives no rise to legal claims.
2.2 Maintenance system
The maintenance system consists of:
• work interval schedule
• job cards
• maintenance schedule (large-scale plan) *
While the work interval schedule 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.
* will be handed during commissioning of the engine
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Introduction A5.02
M20/M25/M32/M43
2.2.1 Work interval schedule
The work interval schedule shall provide for a quick summary of all intended inspection,
maintenance and repair work occurring up to 90,000 operating hours.
The interval schedule is subdivided into the following four areas:
• Daily inspection and control work
• Initial inspection and maintenance work
Work which has to be carried out after first commissioning or commissioning after
major repair work.
• Periodic maintenance work
A list of all recurrent inspection, maintenance and repair work to be carried out at the
scheduled date.
The indicated intervals are statistical mean values. Other values may be obtained,
depending on equipment condition, operating and maintenance conditions.
• Maintenance work to be carried out independent of deadlines
List of work which may be required in the scope of scheduled work which cannot be
allocated to a deadline.
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Introduction A5.02
M20/M25/M32/M43
2.2.2 Job cards
The job cards are instructions for inspection, maintenance, repair and safety check.
¬
Title of the job card
Maintenance work Activity
Discharge valve A5.05.01.04.01.03

Inspection / Dismounting and mounting
Operating hours/maintenance deadline
M20/M25/M32/M43
6,000 / 12,000
Engine type 01
Register
Main maintenance group
See also: 01.01.01.nn, 01.02.01.nn, 01.08.01.nn

Spare parts list: B1.05.01.7.2104, B1.05.01.7.2220
Time requirement: 1 Pers. / 3 h
Personnel qualification: skilled engine hand
Operating medium: Heavy fuel and destillate fuel
Breakdown
Chapter maintenance Subchapter
Operating Instructions Job cards
Job cards
Document number
A5.05. 01.04.01.03
Main maintenance group
Maintenance group
Subgroup
Variant
en / 30.01.10 IB000003 1/1
Date of issue
Registration number Page/number of pages
Language
The job card number consists of the index breakdown (A5.05) and the maintenance
number (bold) subdivided into four pairs of digits.
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Introduction A5.02
M20/M25/M32/M43
• The first pair of digits indicates the engine main maintenance group:
01. Cylinder head 08. Lube oil system
02. Driving mechanism 09. Cooling water system
03. Engine housing 10. Starting air system
04. Engine control 11. Monitors
05. Regulation 12. Auxiliary generator sets and tools
06. Exhaust gas system/ 13. Additional installation

supercharging
07. Fuel system
In order to facilitate the finding of the engine main group, the pair of digits on the right
margin has been set as register 01 .
• The second and third pair of digits indicates the subgroups of the main group and
the titles of the job card where maintenance work is required.
• The fourth pair of digits indicates the type of variant.
• See job card: Reference is made to other job cards required for maintenance work.
At this point the types of variants (fourth pair of digit) are marked “nn”.
• Spare parts sheets: For easy finding of necessary comsumables and spare parts for
the maintenance group in the Spare parts catalogue, indicating other design details
in the illustrations, if necessary.
The third pair of digits in the index breakdown in the spare parts number indicates the
main group/register.
• Fuel: Documenting the sold type of fuel of the engine plant.
• In the maintenance sheets the checks, maintenance, cleaning and repair works of the
maintenance sheets are briefly designated
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Introduction A5.02
M20/M25/M32/M43
• Under the designation "tools (W)" only special and additional tools are listed with the
tool No. Not all of these tools are included in the normal scope of supply.
• Together with the engine type it will be indicated for what engine the job card is valid.
• The indicated personnel and time requirement does not define the working time of
the individual person.
• The indicated time is based on estimated mean values which may deviate according
to the equipment of the plant and its maintenance conditions. Wherever the required
working time depends on the number of cylinders the indicated time of the mainte-
nance sheets refers to one cylinder unit only.
2.2.3 Maintenance schedule (Periodic maintenance work)
A large-scale plan showing all maintenance work up to the largest maintenance interval
clearly indicating all occurrences and the future work expenditure for the individual
components.
It would be useful to mount the plan on a wall; when this is not possible for space rea-
sons, it has to be folded and filed in the map “maintenance forms” *.
We cannot and will not give instructions for handling this plan but we will only give you
some guidelines how to use this plan as an aid for the maintenance system.
The work already carried out will be countersigned in fields intended for this purpose.
Different colours can be used to differentiate between the results, e.g.: green = no
defects/o.k.; yellow = readjustment/correction (e.g. clearances); red = damage/replace-
ment of parts.
Typical consumption parts which are replaced routinely or any time mounting is carried
out (O-ring seals, O-rings etc.) are not considered defective parts.
* The map will be handed during commissioning of the engine
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Introduction A5.02
M20/M25/M32/M43
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
M20/M25/M32/M43
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
M20/M25/M32/M43
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
M20/M25/M32/M43
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
M20/M25/M32/M43
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, since above 325 °C 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
M20/M25/M32/M43
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
M20/M25/M32/M43
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
M20/M25/M32/M43
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!
Observe instructions for use in accordance with DIN safety data sheet of the regulati-
ons for dangerous substances!
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
M20/M25/M32/M43
3.8 Proposition 65 Warning
NOTE
California / USA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the state of
California to cause cancer, birth defects, and other reproductive harm.
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Periodical schedule A5.04.01
Distillate fuel
M43/VM43
Interval Designation / Doc-Nr.

Work to be carried out
Remarks
Daily inspection and monitoring procedures

(if it is not automated)
--------------------------------------------------------------------------------------------------------------------------------
General Engine operating data Chapter 3
Compare with acceptance test records: Technical engine data
Speed, rating Acceptance test record
Temperature Lubricating oil Chapter 3

Engine inlet; Temperature rise at rated output Technical engine data
see also acceptance test record Temp. of operating medias
Temperature Cooling water Chapter 3

Engine outlet; Temperature rise at rated output Technical engine data

Upstream charge air cooler; Technical engine data
downstream charge air cooler Acceptance test record
Temperature Charge air Chapter 3

Temperature Exhaust gas Chapter 3

After cylinder; downstream turbocharger Technical engine data
Acceptance test record
Pressure Lubricating oil Chapter 3

At the main bearing or at the camshaft bearing Technical engine data
see also acceptance test record Press. of operating medias
Pressure Cooling water Chapter 3

Upstream engine Technical engine data
Pressure Fuel Chapter 3

Upstream pumps Technical engine data
Press. of operating medias
Pressure Charge air Chapter 3

Pressure Control air Chapter 3

Technical engine data
Pressure Starting air Chapter 3

Lube oil Lube oil circulation tank Chapter 1

system Check of the lube oil level Operating instructions
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Distillate fuel
M43/VM43

Remarks
Lube oil Lubricating oil duplex filter A5.05.08.04.01.nn

system Maintenance/Cleaning
at 50 % differential pressure
Cooling Expansion tank Chapter 1

water system Check of the cooling water level Operating instructions
Fuel Day tank Chapter 1

system Check of the fuel level Operating instructions
Fuel Fuel duplex filter A5.05.07.12.01.nn

Pressure air Air bottles Chapter1

Drain Operating instructions
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Distillate fuel
M43/VM43

Remarks
First inspection and maintenance procedures

Work to be carried out after the first commissioning or after major repairs.
--------------------------------------------------------------------------------------------------------------------------------
24 h Duplex fuel filter A5.05.07.12.01.nn
Maintenance/Cleaning
Strainer
24 h Lubricating oil system A5.05.08.02.01.00

Maintenance/Oil change
24 h Lubricating oil duplex filter A5.05.08.04.01.nn
Cartridges
150 h Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Tight fit and leaks
150 h Compressed air strainer A5.05.05.09.06.nn

150 h Exhaust gas turbocharger
Function check
see engine documentation, chapter "External Documentation"
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Distillate fuel
M43/VM43

Remarks
Periodical maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------

24 h Exhaust gas turbocharger A5.05.06.05.00.nn

150 h Valve rotor A5.05.01.03.01.nn

Inspection/Evaluate
150 h Cylinder head A5.05.01.10.00.00
Inspection/Checking
150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00

Maintenance/Checking
750 h Control shaft bearings A5.05.05.01.02.00

750 h Duplex fuel prefilter A5.05.07.12.02.04

750 h Cooling water system Chapter 1

Inspection/Corrosion inhibitors Operating instructions
750 h Stop piston A5.05.10.03.01.00

Inspection/Checking
750 h Oil mist detector A5.05.11.09.01.nn

Inspection/Checking
750 h Turning device A5.05.12.08.01.nn

Maintenance/Disassembly and reassembly
1,500 h Governor
Governor behaviour/governor control rod
see engine documentation, chapter "Control and Monitoring“
1,500 h Valve clearance A5.05.01.01.01.nn

Inspection/Adjustment
1.500 h Valve projection A5.05.01.01.02.00
Inspection/Measuring
1,500 h Crankcase explosion safety valve A5.05.03.01.01.nn

Inspection/Checking
1,500 h Oil mist detector A5.05.11.09.01.nn
Inspection/Checking
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Distillate fuel
M43/VM43

Remarks
3.750 h Starter valve A5.05.01.09.01.00

Inspection/Checking
3,750 h Pressure switch A5.05.11.01.03.00

3,750 h Governor
Oil change
3,750 h Monitors
Checking of alarm and safety system
3,750 h Running gear/engine timing A5.05.02.01.01.00
Inspection/Checking
3,750 h Timing gear train A5.05.04.08.01.nn

Inspection/Checking
3,750 h Deflector bolts A5.05.07.03.02.00

Inspection/Replacement
of the deflector bolts of two injection pumps
3,750 h Turning device A5.05.12.08.01.nn

7,500 h Inlet and exhaust valve cone A5.05.01.07.01.nn

Inspection/Disassembly and reassembly
of one cylinder unit
7,500 h Piston rings and grooves A5.05.02.07.01.01

Inspection/Checking
of one piston
7,500 h Starting valve A5.05.05.02.01.02

7,500 h Control shaft A5.05.05.08.01.nn

7,500 h Compressed air filter A5.05.05.09.06.nn

7,500 h Exhaust gas line A5.05.06.01.01.nn

Inspection/Checking
7,500 h Injection pump A5.05.07.03.01.nn

of one pump

Replacement of all deflector bolts
7,500 h Injection valve A5.05.07.09.01.nn

Repair/Disassembly and reassembly
en / 21.12.2011 AA000647 5/11

Distillate fuel
M43/VM43

Remarks
7,500 h Fuel Distributor/Collector line A5.05.07.15.01.nn

7.500 h Fuel pressure damper A5.05.07.17.00.01

Maintenance/Replacement
7,500 h Anti-corrosion oil emulsion Chapter 1

Change Operating instructions
7,500 h RPM-switch A5.05.11.05.01.nn

7,500 h Lubricating oil/cooling water thermostat A5.05.11.06.01.nn

Inspection/Checking
12,000 h Exhaust gas turbocharger A5.05.06.14.01.00

15,000 h Nozzle sleeve A5.05.01.06.50.nn

15,000 h Inlet and exhaust valve cones A5.05.01.07.01.nn

of all valve cones
15,000 h Big-end bearing A5.05.02.04.01.nn

Inspection/Disassembly
of one big-end bearing
15,000 h Main bearings A5.05.02.05.01.nn

of two main bearings
15,000 h Cylinder liner A5.05.03.03.01.01

at one cylinder unit
15,000 h Camshaft bearing A5.05.04.01.01.00

Inspection/Checking
of one bearing
15,000 h Camshaft bearings A5.05.04.01.02.nn


Inspection/Checking
15,000 h Governor drive A5.05.04.08.03.nn
en / 21.12.2011 AA000647 6/11

Distillate fuel
M43/VM43

Remarks
15,000 h Vibration damper on camshaft A5.05.04.09.01.nn

15,000 h Exhaust gas turbocharger

Maintenance/Cleaning resp. revision of turbocharger

of all pumps
15,000 h Oil pressure regulating valve A5.05.08.05.01.01
Maintenance/Adjustment
15,000 h Cooling water centrifugal pump A5.05.09.07.01.00




30,000 h Valve rockers A5.05.01.02.02.00

30,000 h Valve guide/Oil scraper ring A5.05.01.05.01.nn

30,000 h Relief Valve A5.05.01.06.70.nn

30,000 h Starter valve A5.05.01.09.02.nn

30,000 h Cylinder head A5.05.01.10.01.nn


exchange all big-end bearings

exchange all bearings
en / 21.12.2011 AA000647 7/11

Distillate fuel
M43/VM43

Remarks
30,000 h Main thrust bearings A5.05.02.05.05.nn


Inspection/Checking
of all pistons

at all cylinder units
30,000 h Cylinder liner A5.05.03.04.01.nn
Maintenance/Disassembly
30,000 h Camshaft bearings A5.05.04.01.01.00

Inspection/Checking
at all bearings

30,000 h Vibration damper on camshaft A5.05.04.09.02.30



45,000 h Vibration damper A5.05.12.04.02.00

en / 21.12.2011 AA000647 8/11

Distillate fuel
M43/VM43

Remarks
Non-interval dependent maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
Valve rocker brackets A5.05.01.02.01.nn

Valve rocker bush A5.05.01.02.03.00

Media guiding system A5.05.01.05.50.nn

Cylinder head A5.05.01.06.01.nn

Inlet and exhaust valve cones A5.05.01.08.01.00
Repair/Checking
Valve seat ring A5.05.01.08.02.00

Repair/Checking
Valve seat ring (inlet/outlet) A5.05.01.08.03.00

Repair/Replacement

Repair/Reassembly
Crank web deflection A5.05.02.02.01.00

Inspection/Checking
Bearing shells and bearing bushes A5.05.02.03.03.01

Inspection/Evaluate
Bearing shells A5.05.02.03.07.01

Inspection/Evaluate
Big-end bearings A5.05.02.04.02.nn

Inspection/Reassembly
Hydraulic clamping element A5.05.02.04.50.00

Main bearings A5.05.02.05.02.nn

Maintenance/Reassembly
Main thrust bearings A5.05.02.05.06.nn

Pistons A5.05.02.06.01.nn
Piston crown A5.05.02.06.02.nn
en / 21.12.2011 AA000647 9/11

Distillate fuel
M43/VM43

Remarks
Piston pin A5.05.02.08.01.nn

Piston A5.05.02.10.01.nn
Counter-balance A5.05.02.11.00.00
Measures for emergency operation A5.05.02.12.00.00
Cooling water distributor housing A5.05.03.02.00.00

Cylinder liner A5.05.03.04.02.nn

Adjusting device A5.05.04.02.10.nn

Camshaft A5.05.04.04.01.nn
Timing Gear Train A5.05.04.08.02.nn

Charge air cooler A5.05.06.04.02.nn

Injection pump A5.05.07.02.01.00

Pressure valve A5.05.07.03.03.00


Fuel injector A5.05.07.07.01.nn


Duplex fuel filter A5.05.07.12.01.nn

Lube oil system A5.05.08.02.01.00

Lubricating oil pump A5.05.08.03.02.nn

Lubricating oil duplex filter A5.05.08.04.01.nn

en / 21.12.2011 AA000647 10/11

Distillate fuel
M43/VM43

Remarks
Leak oil pipe A5.05.08.15.01.nn

Pressure switch A5.05.11.06.06.02

Crankcase monitoring device A5.05.11.09.01.nn

Inspection/Checking
en / 21.12.2011 AA000647 11/11

Heavy fuel
M43/VM43

Remarks
Daily inspection and monitoring procedures

(if it is not automated)
--------------------------------------------------------------------------------------------------------------------------------
General Engine operating data Chapter 3
Compare with acceptance test records: Technical engine data
Speed, rating Acceptance test record
Temperature Lubricating oil Chapter 3

Engine inlet; Temperature rise at rated output Technical engine data

Engine outlet; Temperature rise at rated output Technical engine data

Temperature Charge air Chapter 3

Temperature Exhaust gas Chapter 3

After cylinder; downstream turbocharger Technical engine data
Acceptance test record
Pressure Lubricating oil Chapter 3

At the main bearing or at the camshaft bearing Technical engine data
Pressure Cooling water Chapter 3

Upstream engine Technical engine data
Pressure Fuel Chapter 3

Upstream pumps Technical engine data
Pressure Charge air Chapter 3

Pressure Control air Chapter 3

Pressure Starting air Chapter 3

Lube oil Lube oil circulation tank Chapter 1

system Check of the lube oil level Operating instructions
en / 21.12.2011 AA000649 1/11

Heavy fuel
M43/VM43

Remarks
Lube oil Lubricating oil duplex filter A5.05.08.04.01.nn

Cooling Expansion tank Chapter 1

water system Check of the cooling water level Operating instructions
Fuel Day tank Chapter 1

system Check of the fuel level Operating instructions
Fuel Fuel duplex filter A5.05.07.12.01.nn

Pressure air Air bottles Chapter1

Drain Operating instructions
en / 21.12.2011 AA000649 2/11

Heavy fuel
M43/VM43

Remarks
First inspection and maintenance procedures

Work to be carried out after the first commissioning or after major repairs.
--------------------------------------------------------------------------------------------------------------------------------
24 h Duplex fuel filter A5.05.07.12.01.nn
Strainer
24 h Lubricating oil system A5.05.08.02.01.00

24 h Lubricating oil duplex filter A5.05.08.04.01.nn
Cartridges
150 h Engine bolting and unions A5.05.03.07.01.00

Inspection/Checking
Tight fitand leaks

150 h Exhaust gas turbocharger
Function check
en / 21.12.2011 AA000649 3/11

Heavy fuel
M43/VM43

Remarks
Periodical maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------


150 h Valve rotor A5.05.01.03.01.nn

Inspection/Evaluate
150 h Cylinder head A5.05.01.10.00.00
Inspection/Checking

150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00

750 h Control shaft bearings A5.05.05.01.02.00

750 h Duplex fuel prefilter A5.05.07.12.02.04

750 h Cooling water system Chapter 1

Inspection/Corrosion inhibitors Operating instructions
750 h Stop piston A5.05.10.03.01.00

Inspection/Checking
750 h Oil mist detector A5.05.11.09.01.nn

Inspection/Checking
750 h Turning device A5.05.12.08.01.nn

1,500 h Governor
Governor behaviour/Governor control rod
see engine documentation, chapter "Control and Monitoring "
1,500 h Valve clearance A5.05.01.01.01.nn
1,500 h Crankcase explosion safety valve A5.05.03.01.01.nn
Inspection/Checking

Inspection/Checking
en / 21.12.2011 AA000649 4/11

Heavy fuel
M43/VM43

Remarks
3.750 h Starter valve A5.05.01.09.01.00

Inspection/Checking

3,750 h Governor
Oil change
see engine documentation, chapter "Control and Monitoring"
3,750 h Monitors
Checking of alarm and safety system
see engine documentation, chapter "Control and Monitoring"
3,750 h Running gear/engine timing A5.05.02.01.01.00
Inspection/Checking

Inspection/Checking

of the deflector bolts of two injection pumps

7,500 h Anti-corrosion oil emulsion Chapter 1

Change Operating instructions
7,500 h Inlet and exhaust valve cone A5.05.01.07.01.nn

of one cylinder unit

Inspection/Checking
of one piston
7,500 h Starting valve A5.05.05.02.01.02

7,500 h Control shaft A5.05.05.08.01.nn

7,500 h Compressed air filter A5.05.05.09.06.nn

7,500 h Exhaust gas line A5.05.06.01.01.nn

Inspection/Checking

of one pump
Replacement of all deflector bolts
en / 21.12.2011 AA000649 5/11

Heavy fuel
M43/VM43

Remarks
7,500 h Fuel pressure damper A5.05.07.17.00.01

7,500 h Fuel Distributor/Collector line A5.05.07.15.01.nn

7,500 h Injection valve A5.05.07.09.01.nn

7,500 h RPM-switch A5.05.11.05.01.nn

7,500 h Lubricating oil/Cooling water thermostat A5.05.11.06.01.nn


Inspection/Checking

15,000 h Valve guide/Oil scraper ring A5.05.01.05.01.nn

15,000 h Nozzle sleeve A5.05.01.06.50.nn

15,000 h Inlet and exhaust valve cones A5.05.01.07.01.nn

of all valve cones
15,000 h Starter valve A5.05.01.09.02.nn

15,000 h Cylinder head A5.05.01.10.01.nn


of one big-end bearing

of 2 main bearings

at one cylinder unit
15,000 h Camshaft bearing A5.05.04.01.01.00

Inspection/Checking
of one bearing
en / 21.12.2011 AA000649 6/11

Heavy fuel
M43/VM43

Remarks


Inspection/Checking
15,000 h Governor drive A5.05.04.08.03.nn

15,000 h Vibration damper on camshaft A5.05.04.09.01.nn

15,000 h Exhaust gas turbocharger
Maintenance/Cleaning resp.
revision of turbocharger

of all pumps
15,000 h Oil pressure regulating valve A5.05.08.05.01.01

15,000 h Cooling water centrifugal pump A5.05.09.07.01.00




30,000 h Valve rockers A5.05.01.02.02.00

30,000 h Relief Valve A5.05.01.06.70.nn


exchange all big-end bearings
exchange all bearings
en / 21.12.2011 AA000649 7/11

Heavy fuel
M43/VM43

Remarks
30,000 h Main thrust bearings A5.05.02.05.05.nn

Inspection/Disassesmbly

Inspection/Checking
of all pistons

at all cylinder units
30,000 h Cylinder Liner A5.05.03.04.01.nn
30,000 h Camshaft bearings A5.05.04.01.01.00

Inspection/Checking
at all bearings

30,000 h Vibration damper on camshaft A5.05.04.09.02.30



45,000 h Vibration damper A5.05.12.04.02.00

en / 21.12.2011 AA000649 8/11

Heavy fuel
M43/VM43

Remarks
Non-interval dependent maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
Valve rocker brackets A5.05.01.02.01.nn

Valve rocker bush A5.05.01.02.03.00

Media guiding system A5.05.01.05.50.nn


Inlet and exhaust valve cones A5.05.01.08.01.00
Repair/Checking
Valve seat ring A5.05.01.08.02.00

Repair/Checking
Valve seat ring (inlet/outlet) A5.05.01.08.03.00

Repair/Replacement

Repair/Reassembly
Crank web deflection A5.05.02.02.01.00

Inspection/Checking
Bearing shells and bearing bushes A5.05.02.03.03.01

Inspection/Evaluate
Bearing shells A5.05.02.03.07.01

Inspection/Evaluate
Big-end bearings A5.05.02.04.02.nn

Inspection/Reassembly

Main bearings A5.05.02.05.02.nn

Main thrust bearings A5.05.02.05.06.nn

Pistons A5.05.02.06.01.nn
Piston crown A5.05.02.06.02.nn
en / 21.12.2011 AA000649 9/11

Heavy fuel
M43/VM43

Remarks
Piston pin A5.05.02.08.01.nn

Piston A5.05.02.10.01.nn
Counter-balance A5.05.02.11.00.00
Measures for emergency operation A5.05.02.12.00.00
Cooling water distributor housing A5.05.03.02.00.00

Cylinder liner A5.05.03.04.02.nn

Adjusting device A5.05.04.02.10.nn

Camshaft A5.05.04.04.01.nn
Timing Gear Train A5.05.04.08.02.nn

Charge air cooler A5.05.06.04.02.nn

Maintenance/disassembly and reassembly

Pressure valve A5.05.07.03.03.00




Duplex fuel filter A5.05.07.12.01.nn

Lube oil system A5.05.08.02.01.00

Lubricating oil pump A5.05.08.03.02.nn

Lubricating oil duplex filter A5.05.08.04.01.nn

en / 21.12.2011 AA000649 10/11

Heavy fuel
M43/VM43

Remarks
Leak oil pipe A5.05.08.15.01.nn

Pressure switch A5.05.11.06.06.02

Crankcase monitoring device A5.05.11.09.01.nn

Inspection/Checking
en / 21.12.2011 AA000649 11/11

Valve clearance A5.05. 01.01.01.00
Inspection / Adjustment
M43/VM43
1500
See also: 02.01.01.nn 01

Spare parts list: B1.05.01.432107
Time requirement: 1 Pers./ 0,50 h
Operating medium: Heavy fuel and distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
The valve clearance must be checked every 1,500 operating hours and adjusted if
necessary.
Tools:
Feeler gauge W2 * 1.9075-003
* no picture
NOTE
Valve clearance may only be checked with the engine at operating tempe-
rature, i.e. 15 minutes after the engine has been stopped.
Valve clearance (Fig. 1/S):
Intake: 0.4 mm
Exhaust: 1.1 mm
The valve fitting position must be set correctly relative to the valve cone before adjusting
valve clearance during regular maintenance or after work on the valve train.
Procedure:
1. Set valve fitting.
1.1 Open indicator valves.
1.2 Engage the rotor.
1.3 Remove the cylinder head (valve) cover, do not damage the gaskets.
1.4 Turn the crankshaft until the cylinder to be set reaches ignition TDC.
en / 06.05.2011 IB004792 1/2

M43/VM43
1500
1.5 Release valve bridge of rocker arm 01

(Fig. 1/1). Enlarge clearance „S“ and/or
flap back rocker arm (1).
1.6 Release locknut (Fig. 2/3) and unsrew set-

ting bolt (4) until a contact in „X”
without clearance is reached.
1.7 At this position of the valve bridge screw in

setting bolt (4) until contact at „Y” without
any clearance is reached.
Valve bridge must not be tited.
1.8 Hold tight setting bolt (4) and tighten lock-

nut (3) with
M = 250 Nm.
1.9 Check absence of clearance at „X“ and „Y“

with feeler gauge of 0.02 mm (W2).
Afterwards adjust valve clearance „S“ as
per instruction.
2. Set valve clearance
2.1 Measure the clearance (Fig. 1/S) with the

feeler gauge. Depress the push rod while
measuring the clearance.
2.2 Correct the clearance “S“.
2.2.1 Loosen counternut (5).
2.2.2 Turn the valve adjusting screw (2) until the

valve reaches the indicated clearance.
2.2.3 Retighten the counternut (5)
M = 400 Nm
to lock the adjusting screw into place.
2.2.4 Check the clearance again after tightening

the counternut.
2.2.5 Remove the turning mechanism and close the indicator valves.
2.2.6 Install valve cover.
en / 06.05.2011 IB004792 2/2

M43/VM43
1500
See also: 02.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
The valve clearance must be checked every 1,500 operating hours and adjusted if
necessary.
Tools:
* no picture
Note:
Valve clearance may only be checked with the engine at operating temperature, i.e. 15 minutes
after the engine has been stopped.
Valve clearance (S):
Intake: 0.4 mm
Exhaust: 1.1 mm
The valve fitting position must be set correctly relative to the valve cone before adjusting
valve clearance during regular maintenance or after work on the valve train.
Procedure:
1. Set valve fitting.
1.3 Remove the cylinder head (valve) cover, do not damage the gaskets.
1.4 Turn the crankshaft until the cylinder to be set reaches ignition TDC.
en / 24.10.2008 IB026096 1/2

M43/VM43
1500
1.5 Release valve bridge of rocker arm 01

(1). Enlarge clearance „S“ and/or flap back
rocker arm (1).
1.6 Release locknut (3) and unsrew setting

bolt (4) until a contact in „X”
without clearance is reached.
1.7 At this position of the valve bridge screw in

setting bolt (4) until contact at „Y” without
any clearance is reached.
Valve bridge must not be tited.
1.8 Hold tight setting bolt (4) and tighten lock-

nut (3) with
M = 250 Nm.
1.9 Check absence of clearance at „X“ and „Y“

with feeler gauge of 0.02 mm (W2).
Afterwards adjust valve clearance „S“ as
per instruction.
2. Set valve clearance
2.1 Measure the clearance (S) with the feeler

gauge. Depress the push rod while
measuring the clearance.
2.2 Correct the clearance “S“.
2.2.1 Loosen counternut (5).
2.2.2 Turn the valve adjusting screw (2) until the valve reaches the indicated clearance.
2.2.3 Retighten the counternut (5)
M = 400 Nm
to lock the adjusting screw into place.
2.2.4 Check the clearance again after tightening the counternut.
2.2.5 Remove the turning mechanism and close the indicator valves.
2.2.6 Install valve cover.
en / 24.10.2008 IB026096 2/2

Valve projection A5.05. 01.01.02.00
Inspection / Measuring
M43/VM43
1500
See also: 01
Spare parts list: B1.05.01.432107 nn
Operating medium: Distillate fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check inlet and exhaust valve projection every 1500 h
Tools:
Depth gauge W1 341033 A
NOTE
Valve projection out of the cylinder head is measured, documented, and evaluated to
determine premature wear of valve and valve seat insert.
The valve height is to be measured upon commissioning, installation of new or over-

hauled cylinder heads, and then every 1500 hours by means of depth gauge (W1)
and to be entered on the corresponding form.
Sequence of operations:
1. Measuring the valve height
1.1 Remove valve cover.
1.2 Turn the engine until the valves to be

measured are relieved.. W1
1.3 Put on depth gauge (W1) as shown in

Fig. 1 and enter the measured value in the
attached table..
CAUTION
Thoroughly clean the con-
tact faces before measuring
and check them for dama-
ge.
en / 30.08.2010 IB026631 1/2

Valve projection A5.05. 01.01.02.00
M43/VM43
1500
1.4 In case of a valve projection of 01

s ≥ 3,5 - 4,5mm
since commissioning or the last replace-

ment (valve stem/valve seat) the respec-
tive valves and valve seats are to be
exchanged.
Valve Guide
Measure of Valve Cylinder Head

and Seat Recession
Cooling water passage
S Cylinder Head
Valve and Seat Valve and Seat Casting
Recessed Normal
1.5 To allow clear assessment of the valve projection data please use "Valve projection M 43" pro-
vided by the responsible Caterpillar Service representative.
Instruction on how to use this worksheet are included in the worksheet.
en / 30.08.2010 IB026631 2/2

Valve Rocker Brackets A5.05. 01.02.01.00
Maintenance / Disassembly and reassembly
M43
See also: 01.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Hydraulic unit W1 1.9213 H
Auxiliary materials:
Molykote Paste "G-Rapid Plus" **
** or equivalent product
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit may
only be operated with hydraulic oil. Protect the unit from corrosion during storage.
~ Attention!
Do not place any body parts under equipment which is under pressure. Ensure that the en-
gine cannot be started.
Procedure:
1. Disassembly
1.4 Turn piston to ignition TDC. Intake and exhaust valves are closed, rocker arms subject to no for-
ce.
en / 12.05.2009 IB004794 1/4

M43
1.5 Remove the four rocker arm nuts with the hydraulic clamping unit. 01
1.5.1 Place the hydraulic clamping elements on the round nuts (1), unscrew threaded bush up to the li-
mit stop and pull. Ensure that the slits are easily accessible.
1.5.2 Connect the clamping elements with the high pressure pump (6) by means of the high pressure li-
nes (5).
1.5.3 Pull the hydraulic piston completely down via the threaded sleeve and with the hydraulic valve of
the high-pressure pump (6) open.
4,5 turns + 90° total screw-in depth!

An increased effort is possible!
Loosen threaded sleeve by 3 holes.
1.5.4 Close the valve on the high pressure pump and extend both rocker arm bracket bolts evenly and
smoothly with a pressure of
p = 2250 bar.
1.5.5 Loosen the round nuts with a pin. Turn the round nut back four holes.
1.5.6 Depressurize the clamping elements, dismantle the clamping device and remove the round nuts.
en / 12.05.2009 IB004794 2/4

M43
Note: 01
If the round nuts cannot be removed, the pressure on the nuts can be increased by ca.
50 bar
more.
If the round nuts are subject to higher pressure, the pin threading may stretch, which can cause
the round nuts to lock into place.
1.5.7 Repeat dismantling procedure 1.5.1 to 1.5.5 for the upper round nuts (2).
1.6 Remove rocker arm bracket with intake and exhaust rocker arms.
2. Assembly
2.1 Clean the contact surface for the rocker arm bracket.
2.2 Blow out the oil outlet with compressed air.
2.3 Place the rocker arm bracket on the cylinder over the studs and position.
The bracket is fastened by means of studs.
2.4 Apply Molykote paste “G-Rapid Plus“ to the threads and contact surface for the nuts and tighten
by hand.
2.5 Tighten the four rocker arm bracket bolts with the hydraulic clamping unit.
2.5.1 Place the hydraulic clamping elements on the round nuts (2) and tighten. Ensure that the slits are
easily accessible.
2.5.2 Connect the clamping elements with the high pressure pump (6) by means of the high pressure li-
nes (5)
the high-pressure pump (6) open.

p = 2250 bar.
Attention:
The pressure must remain constant when the pump is not being actuated to prevent incor-
rect tightening.
2.5.5 Tighten the round nut firmly with a pin (7). Check to ensure good action (no stiffness).
en / 12.05.2009 IB004794 3/4

M43
2.5.6 Check to ensure that the round nut is seated properly. 01

• Reduce pressure by 50 bar.
• The round nuts must be tight enough that they cannot be loosened with the pin.
2.5.7 Depressurize the clamping elements, dismantle the clamping unit.
2.5.8 Repeat installation procedure 2.5.1 to 2.5.6 for lower round nuts (1).
2.6 Set valve clearance (01.01.01.nn).
2.7 Diengage the rotor.
2.8 Install valve cover. (Check gasket!)
2.9 Close indicator valves.
en / 12.05.2009 IB004794 4/4

M43/VM43
See also: 01.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Store hydraulic device kit W1 consisting of

clamping cylinder W1.1 1.9213 H
high pressure hose W1.2 433420 A
high pressure hose W1.3 433420 E
CAUTION
High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit
may only be operated with hydraulic oil. Protect the unit from corrosion during storage.
WARNING
Do not place any body parts under equipment which is under pressure.
Ensure that the engine cannot be started.
Procedure:
1. Disassembly
ce.
en / 03.05.2011 IB024440 1/4

M43/VM43
1.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (1), unscrew threaded bush up
to the limit stop and pull. Ensure that the slits are easily accessible.
1.5.2 Connect the clamping elements with the high pressure pump by means of the high pressure lines
(W1.2, W1.3).
the high-pressure pump open.

Loosen threaded sleeve by 3 holes.
p = 2250 bar.
en / 03.05.2011 IB024440 2/4

M43/VM43
01
NOTE
If the round nuts cannot be removed, the pressure on the nuts can be increased by
ca.50 bar more.
If the round nuts are subject to higher pressure, the pin threading may stretch, which
can cause the round nuts to lock into place.
2. Assembly
2.4 Fasten the round nuts (1, 2) finger tight.
2.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (2) and tighten. Ensure that the
slits are easily accessible.
(W1.2, W1.3).

p = 2250 bar.
NOTE
The pressure must remain constant when the pump is not being actuated to
prevent incorrect tightening.
2.5.5 Tighten the round nut firmly with a pin. Check to ensure good action (no stiffness).
en / 03.05.2011 IB024440 3/4

M43/VM43
01
NOTE
Check to ensure that the round nut is seated properly.
2.6 Set valve clearance (A5.05.01.01.01.nn).
en / 03.05.2011 IB024440 4/4

M43/VM43
See also: 01.01.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:

clamping cylinder W1.1 1.9213 L
CAUTION
High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit
may only be operated with hydraulic oil. Protect the unit from corrosion during storage.
WARNING
Ensure that the engine cannot be started.
Procedure:
1. Disassembly
ce.
en / 20.05.2011 IB026474 1/4

M43/VM43
1.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (1), unscrew threaded bush up
to the limit stop and pull. Ensure that the slits are easily accessible.
(W1.2, W1.3).

Loosen threaded sleeve by 270°.
p = 2250 bar.
en / 20.05.2011 IB026474 2/4

M43/VM43
01
NOTE
ca.50 bar more.
If the round nuts are subject to higher pressure, the pin threading may stretch, which
can cause the round nuts to lock into place.
2. Assembly
2.4 Fasten the round nuts (1, 2) finger tight.
2.5.1 Place the hydraulic clamping elements (W1.1) on the round nuts (2) and tighten. Ensure that the
(W1.2, W1.3).

p = 2250 bar.
NOTE
The pressure must remain constant when the pump is not being actuated to
prevent incorrect tightening.
2.5.5 Tighten the round nut firmly with a pin. Check to ensure good action (no stiffness).
en / 20.05.2011 IB026474 3/4

M43/VM43
01
NOTE
Check to ensure that the round nut is seated properly.
2.6 Set valve clearance (A5.05.01.01.01.nn).
en / 20.05.2011 IB026474 4/4

Valve Rockers A5.05. 01.02.02.00
M43/VM43
30000
See also: 01.02.01.nn, 01.02.03.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassemble intake and exhaust rocker arms

and check bearing clearance every 30,000 h
CAUTION
The liners may only be lubricated with oil.
Molykote paste may not be used for installing the bushings.
Procedure:
1. Disassembly
1.1 Remove securing rings (Fig. 1/4) and thru-

st washers (5) from the rocker arm shaft
(3).
1.2 Remove the intake valve rocker arm (1)

and the exhaust valve rocker arm (2) from
the rocker arm shaft (3).
NOTE
All additional maintenance work
is identical for the intake and
exhaust valve rocker arms.
2. Clean all parts and check for damage.

Blow out oil bores with compressed air
and check to ensure that they are clear.
en / 07.09.2011 IB004796 1/2

Valve Rockers A5.05. 01.02.02.00
M43/VM43
30000
3. Check the bearing surfaces of the ball pin 01

(Fig. 2/10) and the adjusting screw (12) for
wear and damage. Replace parts as ne-
cessary. Cool ball pins to
-195 °C with liquid nitrogen and slide into
place.
WARNING
Note and follow all safety
instructions when handling
liquid nitrogen.
4. Measure the rocker arm bush (Fig. 2 /13)

and shaft (Fig. 1/3) and replace the bush
when the clearance meets or exceeds the
wear limit (A5.05.01.02.03.nn).
New clearance Wear limit

(mm) (mm)
0.056 - 0.208 0.30
5. Assembly
NOTE
Rocker arm shaft must be undamaged and may have no burrs or scratches.
5.1 Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker arm
shaft and slide the rocker arms onto the shaft carefully. Do not tilt the rocker arms.
5.2 Reinstall the rocker arm bracket and rocker arms on the cylinder cover (A5.05.01.02.01.nn) and
check the oil flow through the components.
en / 07.09.2011 IB004796 2/2

Valve Rocker Bush A5.05. 01.02.03.00
Inspection / Replacement
M43/VM43
See also: 01.02.01.nn, 01.02.02.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Copper punch W1 *
* no picture
CAUTION
The liners may only be lubricated with oil.
Molykote paste may not be used for installing the liners.
Procedure:
1. Measure the rocker arm bush (1) and
(A5.05.01.02.02.nn).
2. Replace.
2.1 Drive out the bush (1) with the proper cop-
per punch (W1).
2.2 Oil the new bush lightly and

press into rocker arm.
NOTE
Note the position of the oil
bores (2) and the separating
joint (3) when pressing the new
bush into place. The rokker arm
must protrude past the
liner (Z) s = ca. 0.2 mm
on both sides.
Be careful not to damage the
plastic coated contact surface.
en / 03.05.2011 IB004798 1/1

Valve Rotor A5.05. 01.03.01.00
Inspection / Evaluate
M43/VM43
150
See also: 01.07.01.nn, 01.10.00.nn 01

Spare parts list: B1.05.01.432107, B1.05.01.432225

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve rotor and the free-wheels every 150 h
NOTE
The valve rotational speed in relation to the engine speed must be measured and
documented when the new or overhauled cylinder cover is taken into service in order
to allow comparisons to be made over the course of subsequent inspections. The
intake valves are equipped with valve rotors and the exhaust valves with vanes and a
free-wheel.
Procedure:
1. Open the valve cover and note the turning of the valves.
The mark “X” on the valve spring plate (1) is provided for this purpose.
en / 03.05.2011 IB004800 1/2

Valve Rotor A5.05. 01.03.01.00
M43/VM43
150
2. The valve rotor or free-wheel is functioning correctly when the valves rotate evenly in relation to 01
the engine speed.
The valve rotor and free-wheel must be lubricated with a few drops of oil-gas oil mixture (mixture
ratio 1:1) if the rotational speed is noticeably slower than the speed indicated for new valves.
2.1 If the valve rotational speed slows to n ≤ 1 min-1 at the rated engine speed, the valve rotor or
free-wheel must be replaced.
NOTE
The valve rotation speed can also be slowed by stiffness of the valve shaft in the valve
guide. Solution: spray small amounts of gas-gas oil mixture on the valve shaft.
CAUTION
Use the gas-gas oil mixture sparingly! Excess use can dilute the engine oil!
en / 03.05.2011 IB004800 2/2

Valve Rotor A5.05. 01.03.01.01
M43/VM43
150
See also: 01.07.01.nn, 01.10.00.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve rotor every 150 h
Note:
The valve rotational speed in relation to the engine speed must be measured and documented
when the new or overhauled cylinder cover is taken into service in order to allow comparisons to
be made over the course of subsequent inspections.
Procedure:
1. Open the valve cover and note the turning of the valves.
The mark “X” on the valve spring plate (1) is provided for this purpose.
en / 24.10.2008 IB026091 1/2

Valve Rotor A5.05. 01.03.01.01
M43/VM43
150
2. The valve rotor is functioning correctly when the valves rotate evenly in relation to the engine 01
speed.
The valve rotor and must be lubricated with a few drops of oil-gas oil mixture (mixture ratio 1:1) if
the rotational speed is noticeably slower than the speed indicated for new valves.
2.1 If the valve rotational speed slows to n ≤ 1 min-1 at the rated engine speed, the valve rotor must
be replaced.
Note:
The valve rotation speed can also be slowed by stiffness of the valve shaft in the valve guide. So-
lution: spray small amounts of gas-gas oil mixture on the valve shaft.
Attention:
Use the gas-gas oil mixture sparingly! Excess use can dilute the engine oil!
en / 24.10.2008 IB026091 2/2

Valve guide/Oil scraper ring A5.05. 01.05.01.00
M43/VM43
30000
See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve guide clearance for the intake and exhaust valves every 30,000 h
Molykote Paste “G-Rapid Plus” **
Procedure:
1. Replace the oil wiper rings (O-rings).
1.1 Disassemble valve cone, clean valve shaft carefully.
1.2 Remove O-ring (1) from groove with wire hook carefully.
en / 03.05.2011 IB004802 1/2

M43/VM43
30000
01
CAUTION
The O-ring meters the valve lubrication and may only be replaced with a new CAT
replacement ring.
1.3 Clean the groove.
1.4 Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during instal-
lation!
2. Measuring the valve guide clearance
2.1 Measure the outer diameter of the valve shaft in the guide area of the bush.
2.2 Measure the inner diameter of the guide across the engine block.
2.3
Normal clearance Wear limit

(mm) (mm)
Exhaust 0.22 - 0.29 0.4

Intake 0.15 - 0.22 0.4
3. Valve guide replacement
CAUTION
The valve guides should be replaced by a certified CAT workshop within the scope of
a cylinder cover overhaul if possible. The cylinder cover may be damaged when remo-
ving the old valve guides.
en / 03.05.2011 IB004802 2/2

M43/VM43
15000

Operating medium: Heavy fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve guide clearance of the intake and exhaust valves after 15,000 h
Procedure:
1. Replace the oil scraper rings (O-rings).
1.1 Disassemble valve cone, clean valve shaft carefully.
1.2 Remove O-ring (1) from groove with wire hook carefully.
en / 03.05.2011 IB004804 1/2

M43/VM43
15000
01
CAUTION
The O-ring meters the valve lubrication and may only be replaced with a new CAT
replacement ring.
1.3 Clean the groove.
1.4 Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during instal-
lation!
2. Measuring the valve guide clearance
2.1 Measure the outer diameter of the valve shaft in the guide area of the bush.
2.2 Measure the inner diameter of the guide across the engine block.
2.3
Normal clearance Wear limit

(mm) (mm)
Exhaust 0.22 - 0.29 0.4

Intake 0.15 - 0.22 0.4
3. Valve guide replacement
CAUTION
The valve guides should be replaced by a certified CAT workshop within the scope of
a cylinder cover overhaul if possible. The cylinder cover may be damaged when remo-
ving the old valve guides.
en / 03.05.2011 IB004804 2/2

Media guiding system A5.05. 01.05.50.00
M43
See also: 01.06.01.nn, 01.11.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Vaseline *
* or equivalent product
Procedure:
1. Disassembly
~ Attention!
Depressurize the system before beginning work!
1.1 Loosen the cap screws (Fig. 2/10) and remove the connecting flange (Fig. 1/2, 3) together with
the bushings (11).
en / 21.07.1999 IB004806 1/3

M43
1.2 Remove the bushings (Fig. 2/11) from the connecting flanges (2, 3). 01
1.3 Check the O-rings (15). Replace any damaged O-rings (15) with new ones.
Insert O-rings into the grooves with Vaseline without twisting them!
1.4 Check the seals (16) on the sealing flange (2, 3) and the connecting flange seals
(Fig. 1/1) on the first cylinder and the connecting flange (4) on the last cylinder.
Clean the sealing surface.
en / 21.07.1999 IB004806 2/3

M43
2. Assembly 01
2.1 Install the connecting flange (Fig. 2/2 and 3) with bushings (11) and new seals (16) and dowel
pins (17).
2.2 Install connecting piece and connecting flange (Fig. 1/1 and 4).
Replace and defective or damaged gaskets before installation (Fig. 2/16).
Attention:
When installing new gaskets (16), ensure that they are centered on the dowel pins (17)!
3. Check the function of the fuel leakage

sensor (Fig. 3/20).
3.1 Remove the leakage sensor, reconnect

the signal cable and dip the tip of the sen-
sor into a medium.
If an alarm is triggered, cancel it.
If no alarm is triggered, replace the sensor
and repeat the test.
3.2 Reinstall the leakage sensor.
4. Look for defective pressure line if

the”Fuel Leak” alarm is triggered.
Note:
The fuel leak can be caused by a
- defective fuel line or

a defective
- gasket between
the fuel line and injection pump
or
fuel line and fuel injector
which must be replaced.
4.1 If a “Fuel Leak“ alarm is triggered, cancel the alarm and remove the bolt (Fig. 2/12) with the seal
(13) for each cylinder starting at cylinder 1.
4.2 Check the bore in the connecting flange (2) for fuel.
If fuel is found at cylinders 1, 2 and 3 but none at cylinder 4, replace the fuel line to cylinder 3
(07.02.01.nn).
4.3 Reinstall the bolt (12) with a new seal (13).
en / 21.07.1999 IB004806 3/3

M43
See also: 01.06.01.nn, 01.11.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Vaseline *
* or a product of equal standard
1. Disassembly
WARNING
The system must be depressurized before disassembly!
1.1 Loosen the cheese head screws (fig. 2/18) and the connecting flanges (fig. 1/1, 2) together with
the sleeves (9).
en / 18.05.2011 IB024333 1/4

M43
1.2 Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2). 01
1.3 Check the O-rings (14). Replace faulty O-rings (14).
Insert the O-rings in the grooves using vaseline and making sure that they are not
twisted!
1.4 Remove hexagon screws (Fig. 1/21) and end flange (7).
1.5 Check gaskets (Fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the end flan-
ge (7) on the last cylinder. Clean the sealing faces.
en / 18.05.2011 IB024333 2/4

M43
1.6 Remove the cheese head screws (Fig. 3/22) with connecting flange (8). 01
1.7 Pull the sleeves (10) out of the media block (6).
1.9 Remove lubricating oil pipe (4).
1.10 Remove hexagon screws (20, 23) with media block (6).
1.11 Clean all sealing faces.
en / 18.05.2011 IB024333 3/4

M43
2. Reassembly 01
2.1 Mount the connecting flanges (fig. 2/1 and 2) with inserted sleeves (9).
Replace faulty gaskets (13) beforehand.
2.2 Mount the media block (fig. 3/6). Insert sleeves (10) with new O-rings (15).
2.3 Mount lubricating oil pipe (4).
2.4 Put the connecting flange (8) onto the sleeves (10) and mount it.
Replace faulty gasket (13) beforehand.
2.5 Mount the blank flange (fig. 1/7).

NOTE
Make sure that all gaskets (fig. 2/13) are centred properly by the dowel pins (19)!
3. Check operation of the alarm probe for leakage fuel (fig. 3/20).
3.1 Dismantle the alarm probe, refit the connector and submerge the tip of the alarm probe in a medi-
um.
Acknowledge the alarm if an alarm is triggered. If an alarm is not triggered, replace the alarm pro-
be and repeat the test.
3.2 Mount the alarm probe.
4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm.
NOTE
Leakage fuel can result from
- a defective fuel delivery pipe or

- a faulty gasket between the fuel delivery pipe/injection pump or between the
fuel delivery pipe/injection nozzle.
4.1 Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder 1, re-
move the screw (fig. 2/25) with gasket (24).
4.2 Check the bore in the connecting flange (1) for leakage fuel.
If, for example, leakage fuel is discerned on cylinders 1, 2 and 3 but not on cylinder 4, then repla-
ce the fuel delivery pipe for cylinder 3 (A5.05.07.02.01.nn).
4.3 Mount the screw (25) with a new gasket (24).
en / 18.05.2011 IB024333 4/4

M43
See also: 01.06.01.nn, 01.11.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Vaseline *
1. Disassembly
WARNING
1.1 Loosen the cheese head screws (fig. 2/18) and the connecting flanges (1, 2) together with the
sleeves (9).
en / 06.04.2010 IB026636 1/4

M43
1.2 Pull the sleeves (9) out of the connecting flanges (1, 2). 01
twisted!
1.4 Remove hexagon screws (fig. 1/20) and connecting flange (8).
1.5 Check gaskets (fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the connec-
ting flange (fig. 1/8) on the last cylinder. Clean the sealing faces.
en / 06.04.2010 IB026636 2/4

M43
1.6 Remove the cheese head screws (fig. 3/22) with connecting flange (7). 01
1.7 Pull the sleeves (fig. 3/10) out of the media block (6).
1.8 Check the O-rings (15). Replace faulty O-rings (15)..

twisted!
1.9 Remove hexagon screws (21) and cheese head screws (23) with media block (6).
en / 06.04.2010 IB026636 3/4

M43
2. Reassembly 01
NOTE
Make sure that all gaskets (13) are centred properly by the dowel pins (19)!
2.2 Mount the media block (fig. 3/6) with hexagon screws (21) and cheese head screws (23). Insert
sleeves (10) with new O-rings (15).
2.4 Mount the connecting flange (Fig. 1/8).

en / 06.04.2010 IB026636 4/4

M43
See also: A5.05.01.06.01.nn, A5.05.01.11.01.nn, A5.05.07.02.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Vaseline *
1. Disassembly
WARNING
1.1 Loosen the cheese head screws (fig. 2/18) and the connecting flanges (fig. 1/1, 2) together with
the sleeves (9).
en / 01.06.2011 IB027186 1/4

M43
1.2 Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2). 01
twisted!
1.4 Remove cheese head screws (Fig. 1/18) and end flange (7) with nozzle leak pipe (5).
1.5 Check gaskets (Fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the end flan-
ge (7) on the last cylinder. Clean the sealing faces.
en / 01.06.2011 IB027186 2/4

M43
1.6 Remove the cheese head screws (Fig. 3/22) with connecting flange (8). 01
1.7 Pull the sleeves (10) out of the media block (6).
1.9 Remove lubricating oil pipe (4).
1.10 Remove hexagon screws (20, 23) with media block (6).
en / 01.06.2011 IB027186 3/4

M43
2. Reassembly 01
2.2 Mount the media block (fig. 3/6). Insert sleeves (10) with new O-rings (15).
2.3 Mount lubricating oil pipe (4).
2.5 Mount the blank flange (fig. 1/7) with nozzle leak pipe (5).
NOTE
Make sure that all gaskets (fig. 2/13) are centred properly by the dowel pins (19)!
3. Check operation of the alarm probe for leakage fuel (fig. 3/20).
3.1 Dismantle the alarm probe, refit the connector and submerge the tip of the alarm probe in a medi-
um.
Acknowledge the alarm if an alarm is triggered. If an alarm is not triggered, replace the alarm pro-
be and repeat the test.
3.2 Mount the alarm probe.
4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm.
NOTE
Leakage fuel can result from
- a defective fuel delivery pipe or

- a faulty gasket between the fuel delivery pipe/injection pump or between the
fuel delivery pipe/injection nozzle.
4.1 Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder 1, re-
move the screw (fig. 2/25) with gasket (24).
4.2 Check the bore in the connecting flange (1) for leakage fuel.
If, for example, leakage fuel is discerned on cylinders 1, 2 and 3 but not on cylinder 4, then repla-
ce the fuel delivery pipe for cylinder 3 (A5.05.07.02.01.nn).
4.3 Mount the screw (25) with a new gasket (24).
en / 01.06.2011 IB027186 4/4

Cylinder Head A5.05. 01.06.01.00
Maintenance / Disassembly
M43
See also: 01.02.01.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Hydraulic set W1 439203 A
Cylinder head lifting unit W2 432005 A
Eye bolt W3
Cylinder liner retainer W4 439217 A
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit may
only be operated with hydraulic oil. Protect the unit from corrosion during storage.
~ Attention!
Do not place any body parts under equipment which is under pressure. Ensure that the
engine cannot be started.
Procedure:
1. Open the indicator valves, turn the piston to ignition TDC, re-
move the valve cover and pump area cover. Mount the cylin-
der liner retainer (Fig. 1/W4).
2. Drain the engine coolant: loosen the connecting line from the
reserve pump to the coolant distributor line.
Inspection:
Thermometer connector above the coolant pump.
Attention:
When removing the last cylinder head, remove the ma-
nometer line (oil jet cooling) from the connecting flange
on the coupling flange.
3. Loosen and remove the media supply connecting flange from the cylinder head to be removed.
(01.05.50.nn).
4. Disassemble rocker arm bracket (01.02.01.nn).
Note
In order to avoid damages and ensure trouble-free assembly and disassembly, the complete
rocker arm bracket must be disassembled.
en / 13.05.2008 IB004808 1/3

M43
5. Remove the fuel injector line (07.05.01.nn). 01

6. Remove the injector valve. (07.07.01.nn).
7. Remove the cover plate between the exhaust line and cylinder head.
Remove the exhaust line clamp (06.01.01.nn).
8. Loosen the six cylinder heads bolts with the hydraulic clamping unit.
8.1 Screw the round nut onto the central stud for the rocker arm bracket (Fig. 3/8) up to stop.
8.2 Place the pressure line distributor on a stand pipe (Fig. 2/1) over the round nut for the rocker arm
bracket.
8.3 Place the hydraulic clamping elements (2) over the round nuts and tighten. Ensure that the slits
(3) are easily accessible.
Loosen hydraulic clamping elements by 1 1/3 turns.
8.4 Connect the hydraulic clamping elements to the high pressure pump (5) by means of the high
pressure lines (4).
8.5 Close the valve (6) on the high pressure pump and extend all 6 cylinder head bolts simultaneous-
ly with a pressure of
p = 2250 bar.
8.6 Loosen the round nuts (7) with a pin. Turn back the round nuts at least 8 holes.
Note:
If the round nuts cannot be removed, the pressure on the nuts can be increased by ca.
50 bar
more.
If the pressure is increased further, the pin threading may stretch, which can cause the round nuts
to lock into place.
en / 13.05.2008 IB004808 2/3

M43
8.7 Depressurize the clamping elements, dismantle the clamping unit and remove the round nuts. 01
8
W2
W3
9. Screw the eye bolts (Fig. 3/W3) into the cylinder head. Mount the cylinder head lifting unit (W2).
Lift the cylinder head with a crane while keeping the cylinder head level. Watch the pushrods
while lifting the head!
Attention:
The protruding fittings, cylinder head bolts, pushrods, high pressure fuel line and the
charge air intake fittings may be damaged.
10. Place the cylinder head on a wood block (two beams since nozzle protrudes).
en / 13.05.2008 IB004808 3/3

M43


----------------------------------------------------------------------------------------------------------------------------------
Tools:
clamping cylinder W1.1 1.9213 P
test manometer W1.4 433420 G
cylinder head lifting gear W2 432005 A
ring screw W3
cylinder bushing holder W4 439217 A
Hexagon screw W5 431011 A
WARNING
Avoid bringing body parts above the pressurised devices. Secure motor against
involuntary starting.
CAUTION
Do not fall short of minimum bending radius r = 250 mm for high pressure hoses. Only
use hydraulic oil as operating medium. Store devices protected against corrosion.
Procedure:
1. Open indicator valves, turn piston to
ignition-TDC, remove cylinder head cover
and pump chamber cover.
Fit cylinder bushing holder (Fig. 1/W4).
2. Drain cooling water: Disconnect

connection pipe from reserve pump
to cooling water manifold pipe.
Inspection:
Thermometer connection above the cool-
ing water pump
en / 04.05.2011 IB024287 1/4

M43
01
NOTE
When removing the last cylinder head on the opposite side of the clutch unscrew the
manometer pipe (lubricating oil nozzle cooling) from the connecting flange.
3. Disconnect and remove connecting flange of the media conduit for the cylinder head to be re-
moved (A5.05.01.05.50.nn).
4. Remove rocker arm bracket (A5.05.01.02.01.nn).
NOTE
To prevent damage and ensure trouble-free assembly and disassembly, the complete
rocker arm bracket must be removed!
5. Remove injection pressure pipe (A5.05.07.05.01.nn).
6. Remove injection valve (A5.05.07.07.01.nn).
7. Remove covering cap between exhaust pipe and cylinder head.
8. Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe.
en / 04.05.2011 IB024287 2/4

M43
9. Loosen clamp on exhaust pipe (A5.05.06.01.01.nn). 01

10. Loosen the six cylinder head screws using the hydraulic torque device.
10.1 Store hydraulic traction elements (Fig. 3/ W1.1) onto round nuts and tighten. Ensure good acces-
sibility of the slots (3). Store hydraulic hydraulic traction elements by a 1 1/3 turn.
10.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect element
1 to pump. Fit test manometer (W1.4) onto element 6.
Secure the coupling that is not connected by means of plug (8).
10.3 Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and
continuously using a hydraulic pressure of
p = 2250 bar -25 bar
The pressure at the hydraulic pump must correspond to the pressure at the test manometer.
10.4 Loosen round nuts with pin. Turn round nuts back by at least 8 holes.
NOTE
If the round nuts cannot be loosend, the cylinder head screw can be pretensioned
further with approx. 50 bar
With further pressure increase there is a risk of the round nut becoming wedged due
to an expansion of the bolt thread
10.5 Relieve traction elements, remove hydraulic device and unscrew round nuts.
en / 04.05.2011 IB024287 3/4

M43
11. Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift cylin- 01
der head with hoist. Watch for push rod bushing!
W2
W3
CAUTION
Risk of damage for conduit connection, cylinder head screws, push rods, fuel pres-
sure pipe and charged air inlet connection.
12. Lower cylinder head onto wooden surface (two beams, as nozzle protrudes).
en / 04.05.2011 IB024287 4/4

M43
See also: 01.02.01.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn, 01

07.23.01.nn

----------------------------------------------------------------------------------------------------------------------------------
Tools:
clamping cylinder W1.1 1.9213 P
test manometer W1.4 433420 G
cylinder head lifting gear W2 432005 A
ring screw W3
cylinder bushing holder W4 439217 A
Hexagon screw W5 431011 A
WARNING
Avoid bringing body parts above the pressurised devices. Secure motor against
involuntary starting.
CAUTION
Do not fall short of minimum bending radius r = 250 mm for high pressure hoses. Only
use hydraulic oil as operating medium. Store devices protected against corrosion.
Procedure:
1. Open indicator valves, turn piston to
ignition-TDC, remove cylinder head cover
and pump chamber cover.
Fit cylinder bushing holder (Fig. 1/W4).
2. Drain cooling water: Disconnect

connection pipe from reserve pump
to cooling water manifold pipe.
Inspection:
Thermometer connection above the cool-
ing water pump
en / 30.03.2011 IB027087 1/4

M43
01
NOTE
When removing the last cylinder head on the opposite side of the clutch unscrew the
manometer pipe (lubricating oil nozzle cooling) from the connecting flange.
3. Disconnect and remove connecting flange of the media conduit for the cylinder head to be re-
moved (A5.05.01.05.50.nn).
4. Remove rocker arm bracket (A5.05.01.02.01.nn).
NOTE
To prevent damage and ensure trouble-free assembly and disassembly, the complete
rocker arm bracket must be removed!
5. Remove injection pressure pipe (A5.05.07.05.01.nn).
6. Remove injector cable (A5.05.07.23.01.nn).
7. Remove covering cap between exhaust pipe and cylinder head.
8. Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe.
en / 30.03.2011 IB027087 2/4

M43
9. Loosen clamp on exhaust pipe (A5.05.06.01.01.nn). 01

10. Loosen the six cylinder head screws using the hydraulic torque device.
10.1 Store hydraulic traction elements (Fig. 3/ W1.1) onto round nuts and tighten. Ensure good acces-
sibility of the slots (3). Store hydraulic hydraulic traction elements by a 1 1/3 turn.
10.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect element
1 to pump. Fit test manometer (W1.4) onto element 6.
10.3 Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and
continuously using a hydraulic pressure of
p = 2250 bar -25 bar
10.4 Loosen round nuts with pin. Turn round nuts back by at least 8 holes.
NOTE
If the round nuts cannot be loosend, the cylinder head screw can be pretensioned
further with approx. 50 bar
With further pressure increase there is a risk of the round nut becoming wedged due
to an expansion of the bolt thread
10.5 Relieve traction elements, remove hydraulic device and unscrew round nuts.
en / 30.03.2011 IB027087 3/4

M43
11. Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift cylin- 01
der head with hoist. Watch for push rod bushing!
W2
W3
CAUTION
Risk of damage for conduit connection, cylinder head screws, push rods, fuel pres-
sure pipe and charged air inlet connection.
12. Lower cylinder head onto wooden surface (two beams, as nozzle protrudes).
en / 30.03.2011 IB027087 4/4

Nozzle sleeve A5.05. 01.06.50.02
M43
15000
See also: 01.06.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenace:
Replacement of O-rings every 15.000 h
Tools:
wrench for nozzle sleeve W1 439222-001

torque wrench 200 - 500 Nm W2* 1.9454-500
brass mandrel W3*
* no illustration
Auxiliary material:
Vaseline **
Adhesive and sealant “ Loctite 510 “**
** or a product of equal standard
1. Remove nozzle sleeve (1).
1.1 Place wrench (W1) so that nozzle sleeve

(1) and wrench (W1) are engaged.
1.2 Mount the flange (3) (07.07.01.nn).
1.3 Attach torque wrench (W2) to wrench (W1)

and unscrew nozzle sleeve until the
threads of nozzle sleeve and cylinder head
(2) are exposed.
en / 30.01.2008 IB023234 1/2

M43
15000
01
Attention:
The threads of the nozzle sleeve and the cylinder head may no longer mesh.
1.4 Remove flange (3).
1.5 Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.
1.6 Remove the O-rings (4 and 5).
2. Install nozzle sleeve (1).
2.1 Insert new O-ring (71 x 3,55) with Vaseline in the lower groove (5) without twisting.
2.2 Insert new O-ring (72,69 x 2,62) with Vaseline in the upper groove (4) without twisting.
Attention:
The O-rings must be installed in the proper grooves (4 and 5)!
2.3 Coat “Loctite 510“ to the nozzle sleeve threads.
2.4 Slide the nozzle sleeve into the cylinder head.
2.5 Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to
M =300 Nm
en / 30.01.2008 IB023234 2/2

M43/VM43
15000
See also: 01.06.01.nn, 07.07.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenace:
Replacement of O-rings every 15.000 h
Tools:
wrench for nozzle sleeve W1 432119 A

torque wrench 200 - 500 Nm W2 1.9454-500
brass mandrel W3*
* no illustration
Auxiliary material:
Vaseline **
Adhesive and sealant “ Loctite 510 “**
1. Remove nozzle sleeve (1).
1.1 Place wrench (W1) so that nozzle sleeve

(1) and wrench (W1) are engaged.
1.2 Mount the flange (3) (A5.05.07.07.01.nn).
1.3 Attach torque wrench (W2) to wrench (W1)

and unscrew nozzle sleeve until the
threads of nozzle sleeve and cylinder head
(2) are exposed.
en / 10.05.2011 IB024107 1/2

M43/VM43
15000
01
CAUTION
The threads of the nozzle sleeve and the cylinder head may no longer mesh.
1.4 Remove flange (3).
1.5 Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.
1.6 Remove the O-rings (4 and 5).
2. Install nozzle sleeve (1).
2.1 Insert new O-ring (71 x 3,55) with Vaseline in the lower groove (5) without twisting.
2.2 Insert new O-ring (72,69 x 2,62) with Vaseline in the upper groove (4) without twisting.
CAUTION
The O-rings must be installed in the proper grooves (4 and 5)!
2.3 Coat “Loctite 510“ to the nozzle sleeve threads.
2.4 Slide the nozzle sleeve into the cylinder head.
2.5 Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to
M = 300 Nm
en / 10.05.2011 IB024107 2/2

Relief Valve A5.05. 01.06.70.00
Maintenance / Replacement
M43
30000
See also: 01.06.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of relief valve every 30,000 h
Auxiliary Material:
High-temperature thread paste “Dag S 5080“ *
Sequence of Operations:
1. Unscrew hexagon nut (1).
2. Remove cover (2).
en / 16.03.2001 IB023044 1/2

Relief Valve A5.05. 01.06.70.00
M43
30000
3. Slacken relief valve (3) by means of a wrench and remove it. 01

4. Lubricate the thread of the new relief valve with high-temperature thread paste
“Dag S 5080“.
5. Mount new relief valve (3) with new joint ring (4).
6. Firmly tighten the relief valve by means of a wrench.
7. Mount cover (2).
8. Firmly tighten hexagon nut (1).
en / 16.03.2001 IB023044 2/2

Relief Valve A5.05. 01.06.70.01
M43/VM43
30000
See also: 01.06.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of relief valve every 30,000 h
Tools:
Torque wrench 20 - 200 Nm W1 * 1.9454-202
* no picture
Auxiliary Material:
High-temperature thread paste “Dag 5420 A“ *
Sequence of Operations:
1. Unscrew hexagon nut (1).
2. Remove cover (2).
en / 04.05.2011 IB023661 1/2

Relief Valve A5.05. 01.06.70.01
M43/VM43
30000
3. Slacken relief valve (3) by means of a wrench and remove it. 01

4. Lubricate the thread of the new relief valve with high-temperature thread paste
“Dag 5420 A“ .
5. Mount new relief valve (3) with new joint ring (4).
6. Firmly tighten the relief valve by means of a wrench.
7. Mount cover (2).
8. Tighten hexagon nut (1) with a torque of
M = 50 Nm.
en / 04.05.2011 IB023661 2/2

Inlet and Exhaust Valve Cone A5.05. 01.07.01.02
Inspection / Disassembly and reassembly
M43
15000, 7500


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
check the wear pattern of the intake and exhaust valve cone
of the cylinder unit and check for deposits every 7,500 h
Maintenance:
all intake and exhaust valve cones every 15,000 h
Tools:
Valve spring compressor unit W1 439222 D
Molykote Paste “G-Rapid Plus“ **
Note:
The service life of a valve cone is dependent on the quality of the fuel used, the operating conditi-
ons under which the equipment is used and the grade of repaired valve cones/seat rings and va-
ries from system to system.
For this reason, the system operator must determine the maintenance intervals required for his
equipment after inspecting the valve cones. Every time a valve cone is removed, the seat geome-
try must be checked and milled if necessary (01.08.01.nn, 01.08.02.nn).
en / 28.02.2001 IB022795 1/3

M43
15000, 7500
Sequence of operations: 01
1. Disassembly
13
1.1 Disassemble the cylinder head
(01.06.01.nn).
1.2 Disassemble the rocker arms

(01.02.01.nn) and take off valve bridge.
11
1.3 Put the valve spring compressor unit (W1)
onto valve spring retainer (2). To this end:
W1
1.3.1 Pull pin (10) out of spindle (11).
1.3.2 Sleeve (12) must rest above the split

spindle end.
10
1.3.3 Put the split spindle end onto valve cone 12
stem so as to engage.
4
1.3.4 Press sleeve (12) above split spindle end 2
and mount pin (10).
1.4 Compress valve spring (3) by turning the

stem of device (13) and take out clamping
cone halves (4).
1.5 Relieve valve spring (3) by turning the

stem of device (13) in the other direction.
~ Attention!
Spring force
1.6 Remove the valve spring compressor unit

(W1). To this end:
1.6.2 Sleeve (12) must rest above the split 3

spindle end.
1.6.3 Pull the valve spring compressor unit off

the valve cone stem.
1.7 Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring washer
off the cylinder head.
1.8 Pull the valve cone out of the cylinder head.
en / 28.02.2001 IB022795 2/3

M43
15000, 7500
Note: 01
Valve cones which display a large degree of wear in the clamping area and clamping piece haves
with excessive burring must be replaced with new parts. All burrs must be removed from such val-
ve cones before disassembly.
Valve cone/valve seat repair (01.08.01.nn/01.08.02.nn).
2. Assembly
2.1 Check valve guide clearance, replace O-ring (01.05.01.nn).
2.2 Oil the de-burred valve cone well before installation and insert valve cone with a twisting motion
to prevent damage to the O-ring.
2.3 Installation is completed in the reverse order as disassembly.
2.4 After installing the clamping piece halves, decompress the valve springs slowly and check to en-
sure that the two halves of the clamping piece are seated correctly.
en / 28.02.2001 IB022795 3/3

M43/VM43
15000, 7500


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
check the wear pattern of the intake and exhaust valve cone
of the cylinder unit and check for deposits every 7,500 h
Maintenance:
all intake and exhaust valve cones every 15,000 h
Tools:
Valve spring compressor unit W1 439222 D

Pliers for circlips W2* 1.9067-440
* no picture
NOTE
The service life of a valve cone is dependent on the quality of the fuel used, the ope-
rating conditions under which the equipment is used and the grade of repaired valve
cones/seat rings and varies from system to system.
For this reason, the system operator must determine the maintenance intervals re-
quired for his equipment after inspecting the valve cones. Every time a valve cone is
removed, the seat geometry must be checked and milled if necessary
(A5.05.01.08.01.nn, A5.05.01.08.02.nn).
en / 04.05.2011 IB023934 1/3

M43/VM43
15000, 7500
1. Disassembly
13
1.1 Disassemble the cylinder head
(A5.05.01.06.01.nn).
1.2 Disassemble the rocker arms

(A5.05.01.02.01.nn) and take off valve
bridge. 11
1.3 Put the valve spring compressor unit (W1)

onto valve spring retainer (2). To this end: W1

spindle end. 10
12
1.3.3 Put the split spindle end onto valve cone
stem so as to engage. 5
4
2
1.3.4 Press sleeve (12) above split spindle end
and mount pin (10).
1.4 Remove circlip (5) by means of pliers

(W2). Compress valve spring (3) by
turning the stem of device (13) and take
out clamping cone halves (4).
1.5 Relieve valve spring (3) by turning the

stem of device (13) in the other direction.
CAUTION
Spring force
1.6 Remove the valve spring compressor unit

(W1). To this end: 3

spindle end.
1.6.3 Pull the valve spring compressor unit off

the valve cone stem.
1.7 Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring washer
off the cylinder head.
en / 04.05.2011 IB023934 2/3

M43/VM43
15000, 7500
1.8 Pull the valve cone out of the cylinder head. 01
NOTE
Valve cones which display a large degree of wear in the clamping area and clamping
piece haves with excessive burring must be replaced with new parts. All burrs must
be removed from such valve cones before disassembly.
Valve cone/valve seat repair (A5.05.01.08.01.nn/A5.05.01.08.02.nn).
2. Assembly
2.1 Check valve guide clearance, replace O-ring (A5.05.01.05.01.nn).
2.2 Oil the de-burred valve cone well before installation and insert valve cone with a twisting motion
to prevent damage to the O-ring.
2.4 After inserting clamping cone halves (4) and assembling circlip (5) by means of pliers (W2) slowly
relieve valve spring (3). In doing so, make sure that the clamping cone halves are seated correct-
ly.
en / 04.05.2011 IB023934 3/3

Inlet and Exhaust Valve Cones A5.05. 01.08.01.00
Repair / Checking
M43/VM43
See also: 01.07.01.nn, 01.08.02.nn 01

Personnel qualification: Chief engineer / skilled engine hand

----------------------------------------------------------------------------------------------------------------------------------
Tools:
Valve seat grinding unit W1 439224 A
Diamond paste Dp 30/10 - 15 µm *

Thinner F25 *
NOTE
New, reworked or undamaged used inlet and exhaust valve cones must be ground in
accordance with operation 4 before installation.
It may also be necessary to rework the valve cones (according to operation 3):
• after longer operating time,

• the inspection reveals damaged sealing surfaces, deep graining, uneven
wear pattern on the valve cone /seat.
1. Cleaning
1. Clean the valve stem. Experience has shown that a thorough cleaning, such as an assessment of
the valve cones requires, is only possible by blasting with material like glass beads. The stems
may not be cleaned with sharp tools or cleaned with inorganic acids (hydrochloric acid, sulfuric
acid, hydrofluoric acid, etc.) or by sandblasting.
2. Inspection
2.1 Valves can be reused without being reworked when
• the valve cone surface is bright and polished around the entire cone
• the valve cone surface has no carbon deposits which may indicate blow-by
• no cracks are found in the valve cone surface when checked with an illuminated
magnifying glass (8 x magnification), or during a pulse spray test (Met L’Check) or a
flux test.
en / 04.05.2011 IB004814 1/5

Repair / Checking
M43/VM43
• there is HT corrosion as shown below, i. e. no deep craters over the entire area of the bottom 01
side of the valve heads.
• the straightness deviation does not exceed the following values (Fig. 1)
Span “s“ = 495.6 mm
= Contact point for measurement device
• the radial deviation of the valve cone does not exceed the following values:
en / 04.05.2011 IB004814 2/5

Repair / Checking
M43/VM43
2.2 Valves may not be re-used for another in- 01

terval when
• the valve cone surface is damaged

(cracks, blow-by)
• there is burnout “s“ caused by high

temperature corrosion on the
underside of the valve head
> 2.5 mm (Fig. 2)
• there is coarse graining on the undesi-

de of the valve head (so-called co-
bblestone formation)
• there are corrosion pits and mechanical damages in the vicinity of the valve stem, the
root of the stem and the valve head
• the indicated reworking limits have been exceeded.
en / 04.05.2011 IB004814 3/5

Repair / Checking
M43/VM43
3. Repair (reworking the sealing surface) 01
NOTE
The rework must be completed properly on precision spindle grinding machines. If
such a machine is not available, the valve cone should be sent to a CAT workshop
for regrinding.
3.1 Regrind the sealing surface in accordance

with the indicated angle (Fig. 3). Do not
rework the groove.
Exhaust valve cone = Fig. 3

Inlet valve cone = Fig. 3a
3.2 Observe the instructions of the respective

grinding machine manufacturer.
3.3 After grinding, measure the distance

between the visible edge of the plating “X“
and outer edge of the seat surface. The
valve cone must be replaced when the di-
stance is smaller than the wear
limit.
(Fig. 3, Exhaust valve Fig. 3a, inlet
valve).
3.4 Outer edge rounded with stone.
NOTE
After the valve cone is rewor-
ked, the valve seat ring must
also be reworked
(A5.05.01.08.02.nn).
4. Maintenance
(Check wear pattern/grinding)
4.1 Apply small dots of diamond paste Dp 30/

10 - 15 µm to the seating new or reworked
valve cone with a syringe and spread
evenly. (Fig. 4). Next, spray the entire val-
ve seat ring with a thinner which corre-
sponds to the diamond paste (F25) to thin
the paste and increase the grip.
en / 04.05.2011 IB004814 4/5

Repair / Checking
M43/VM43
4.2 Slide the oiled valve stem into the guide. Attach the rig (Fig. 5/W1) to the valve head and grind 01
the cone and seat surface together briefly by turning the valve head with moderate pressure by
hand. The contact surface (Fig. 6/a), which is visible after the grinding procedure, should not
amount to more than
30 - 50 % of the seat width “b“
starting from the outside diameter.
4.3 If the contact surface does not appear to

be in good order, do not regrind any more,
but rework both sealing surfaces.
4.4 Components which have been ground to-

gether (valve cone and seat ring) must be
kept together.
5. Final inspection
5.1 Check that the reworking limit has not

been exceeded.
5.2 Clean the valve cone / seat thoroughly and

check the sealing surfaces with an illumi-
nated magnifying glass
(8 x magnification) for cracks in the plating
and in the neighboring areas.
en / 04.05.2011 IB004814 5/5

Valve Seat Ring A5.05. 01.08.02.00
Repair / Checking
M43/VM43
See also: 01.07.01.nn, 01.08.01.nn 01


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Precision seat grinding machine W1 * 1.9224 N
Valve milling unit W2 439224 B
* no picture
Illuminated magnifying glass (8x magnification)
Diamond paste Dp 30/10 - 15 µm **
Thinner DIAPLASTOL **
NOTE
If the sealing surface of the valve seat/valve cone has an uneven wear pattern or
deep graining, both sealing surfaces must be reworked.
Grind new or reworked valve seats as described in procedure 4.
It may be necessary to rework the seats when:

• the engine has not been run for a long period of time,
• the inspection reveals damaged sealing surfaces, deep graining, uneven
wear pattern on the valve seat /cone (Fig. 1 and 2).
en / 04.05.2011 IB004816 1/5

Repair / Checking
M43/VM43
01
Procedure:
1. Inspection
The grade (hardness) of the valve seat is designed to allow the seat to adapt to the valve cone to
a certain extent. Carbon deposits are therefore normal and pose no danger with adequate cooling
(Fig. 3, 4 and 5).
en / 04.05.2011 IB004816 2/5

Repair / Checking
M43/VM43
1.1 Valve rings can be reused without reworking when 01

• the seat surface is metallic and polished around the entire circumference
• no carbon deposits which may indicate blow-through are visible or no wear is visible
• no cracks are found when the seat surface is checked with an illuminated magnifying
glass (8x magnification) or in a pulse spray test (Met L’Check) or flux test.
1.2 Valve seat rings may not be reused when
• there are cracks in the seat surface

• the seat surface is burned through
• the reworking limit has been exceeded.
2. Cleaning
Clean all deposits and soil from the seat surface.
3. Repair (reworking the valve seat rings)
NOTE
The seat rings must be
machined properly with an CAT
precision-grinding machine
(W1). Consult the special
operating manual before
beginning work.
The seat rings can also be re-

worked with an CAT valve
seat milling unit (Fig. 6/W2).
Avoid removing too much ma-
terial, only the carbon deposits
in the contact area should be
removed.
Do not use oil.
3.1 Mill valve seat
3.1.1 Clean the valve seat ring carefully in the

contact area (3) of the centering disk (4) in
order to ensure that the guide punch (5) is
centered exactly. Remove the
O-ring from the guide bush.
en / 04.05.2011 IB004816 3/5

Repair / Checking
M43/VM43
3.1.2 Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6). , 01
CAUTION
Handle the cutting head (Fig. 6/2) carefully, milling blades can be damaged easily by
impact and hard or sudden contact can damage the valve seat surface.
3.1.3 Place the cutting head (2) on the greased guide punch, turn the knurled screw (1) in until there is
resistance.
3.1.4 Mill the valve seat in a single motion by turning to the right, turn the rig as far as possible. The bla-
des must cut noticeably. Adjust the cutting pressure depending on how the cut feels.
CAUTION
If the cutting pressure is too low or if the cut is made to rapidly, the milling unit may
chatter.
3.1.5 Before ending the milling procedure, back out the knurled screw (1) slowly while turning the cut-
ting head.
3.1.6 Maximum permissible dimension Ø (x) for reworking (Fig. 7):
148+0.2
a = no material may be removed
exhaust valve seat ring = Fig. 7

intake valve seat ring = Fig. 7a
en / 04.05.2011 IB004816 4/5

Repair / Checking
M43/VM43
3.1.7 Remove milling unit. Smooth the sharp edges with a fine emery cloth. 01
4. Contact surface check / grinding
4.1 Apply small dots of diamond paste DP 30/10 - 15 µm to the new or reworked vale shaft with a
small syringe and spread evenly. Next, spray the entire seat ring surface with thinner
(DIAPLASTOL). (A5.05.01.08.01.nn).
4.2 Slide the oiled valve shaft into the guide bush. Attach the rig (W1) (01.08.01.nn) to the valve head
and grind the cone and seat surface together briefly by turning the valve head back and forth with
moderate pressure. The contact surface “a“, which is visible after the grinding procedure, should
not amount to more than
30 - 50 % of the seat width “b“
around the entire edge of the entire circumference. (A5.05.01.08.01.nn).
NOTE
If the contact surface does not appear to be in good order, do not grind any more,
both sealing surfaces must be reworked on a grinding machine.
Components (valve cone and seat ring) which have been ground together must be
kept together.
5. Final inspection
5.1 Check that the indicated reworking limit has not been exceeded.
5.2 Clean the valve cone / seat thoroughly and check the sealing surfaces with an illuminated ma-
gnifying glass (8 x magnification) for cracks in the plating and in the neighboring areas.
en / 04.05.2011 IB004816 5/5

Valve Seat Ring (Intake/Exhaust) A5.05. 01.08.03.00
Repair / Replacement
M43/VM43
See also: 01.06.01.nn, 01.07.01.nn, 01.08.02.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Press W1 439222 C
Diamond paste Dp 30/10 - 15 µm *
Molykote Paste “G-Rapid“ *
Procedure:
1. Separate valve cones which can no longer
be used at the shaft end (Fig. 1/1) and be-
zel the resulting gap (2) to prevent defor-
mation. Turn the valve head to
ca. 116 mm
(inner diameter of seat ring).
2. Place the valve cone in the valve seat ring

and hold in the indicated position, connect
the cone and seat ring around the entire
circumference with a welded bead (electric
welder).
Grease the cylinder cover well outside of

the seat ring area to prevent damage from
flying sparks and slag.
3. Drive the valve seat ring out onto the valve

shaft by striking firmly, clean the bore by
hand with 120 grit emery cloth, or with 260
serrated lock washer if the bore is extreme-
ly dirty.
en / 13.05.2011 IB004818 1/2

Valve Seat Ring (Intake/Exhaust) A5.05. 01.08.03.00
Repair / Replacement
M43/VM43
4. Install new seat ring. 01

4.1 Cool seat ring to at least -20 °C, heat cylin-
der head evenly to 130 °C.
4.2 Tap the seat ring completely into the bore

with the help of a hammer and valve cone
(strike lightly). Apply a light coating of Mo-
lykote paste “G-Rapid“ to the threading
and contact surface of the nut (Fig. 2/1).
Tighten nut (1) to M = 150 Nm. Next, hold
the seat ring in this position with a press
(W1) until the cylinder head has cooled
completely.
5. Rework valve seat ring lightly with a valve

seat grinding machine or valve seat milling
unit. Grind the valve cone lightly with
Diamond paste Dp 30/10 -15 µm and
check the contact surface
(A5.05.01.08.02.nn).
6. Install valve cone.
en / 13.05.2011 IB004818 2/2

Starter Valve A5.05. 01.09.01.00
Inspection / Checking
M43/VM43
3750
See also: 01.02.01.nn, 01.09.02.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Checking:
Check starter valve of one cylinder

for easy movement all 3.750 h
For V-engines only on cyl. bank A
CAUTION
When working on the starter system, close the main valves on the pressure
tanks, bleed the line and block the starter valve.
Procedure:
1. Remove the rocker arm bracket (A5.05.01.02.01.nn).
2. Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
3. Push down piston (5) and spindle (9) approx. 7 mm using the handle of the hammer.
The piston and spindle should move freely when doing so.
en / 04.05.2011 IB024089 1/2

M43/VM43
3750
4. Ensure that the piston (5) and spindle (9) return to the original position quickly and easily. 01
NOTE
Do not move spindle (9) by turning locknut (3).
5. If the parts do not move freely, lubricate the piston (5) and guide in the cylinder head with engine
oil.
6. Fit cover (1) with new O-ring (3).
NOTE
If there is moisture, rust, dirt or other soiling between the cover (1) and piston (5),
the treatment / dehumidification of the starting air should be checked.
en / 04.05.2011 IB024089 2/2

M43
30000
See also: 01.06.01.nn, 01.11.01.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Remove starter valve, disassemble and rework if necessary every 30,000 h
Molykote Paste “G-Rapid“ **

Attention:
When working on the starter system, close the main valves on the pressure tanks, bleed
the line and block the starter valve.
Procedure:
1. Disassembly
1.1 Remove the rocker arm bracket (01.02.01.nn).
1.2 Lay the cylinder head on its side.
1.3 Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
1.4 Loosen the lock nut (3) while holding the valve shaft (9) with a wrench.
1.5 Remove the clamping ring (4), piston (5), spring (6), spring plate (8) and valve shaft (9)
with sleeve (7) from the cylinder head.
1.6 Clean all parts carefully with gas oil.
1.7 Check the piston (5), compression ring (10) and valve seat carefully.
Smooth scored piston (5) carefully with emery cloth (240 grain or higher); grind leaking valve
shaft (9) together with valve seat in cylinder head.
en / 18.06.2009 IB004820 1/2

M43
30000
2. Assembly 01
2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5).

Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the lock nut
(3) until the lock nut (3) and valve shaft (9) cannot be moved separately (solid connection). Tigh-
ten the lock nut to
M = 55 Nm.
2.3 Check the starter valve for leaks before starting the engine.
en / 18.06.2009 IB004820 2/2

M43
15000
See also: 01.06.01.nn, 01.11.01.nn 01


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Attention:
When working on the starter system, close the main valves on the pressure tanks, bleed
the line and block the starter valve.
Procedure:
1. Disassembly
1.1 Remove the rocker arm bracket (01.02.01.nn).
1.4 Loosen the lock nut (3) while holding the valve shaft (9) with a wrench.
1.7 Check the piston (5), compression ring (10) and valve seat carefully.
Smooth scored piston (5) carefully with emery cloth (240 grain or higher); grind leaking valve
shaft (9) together with valve seat in cylinder head.
en / 18.06.2009 IB004822 1/2

M43
15000
2. Assembly 01
2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5).

Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the lock nut
(3) until the lock nut (3) and valve shaft (9) cannot be moved separately (solid connection). Tigh-
ten the lock nut to
M = 55 Nm.
en / 18.06.2009 IB004822 2/2

M43/VM43
30000
See also: 01.06.01.nn, 01.11.01.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
Insertion ring for starter valve piston W1 * 439227 A

Starter valve reseating tool W2 439224 C
* not shown

CAUTION
Procedure:
1. Disassembly
1.1 Remove the rocker arm bracket (A5.05.01.02.01.nn).
1.4 Remove circlip (12).
1.5 Loosen the hexagon nut (3) while holding the valve shaft (9) with a wrench.
1.8 Check the piston (5), compression ring (10) and valve seat carefully. Smooth scored piston (5) ca-
refully with emery cloth (240 grain or higher).
en / 04.05.2011 IB022696 1/3

M43/VM43
30000
1.9 Rework starter valve seat with reseating tool (W2). 01

1.9.1 Carefully clean valve seat and guide of valve spindle.
1.9.2 Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseating tool
in valve guide and fix with spanner (21).
1.9.3 Tighten adjusting screw (20) until a slight resistance is felt. Then tighten adjusting screw another
1/4 turn to set cutting pressure.
1.9.4 Turn reseating tool evenly and slowly without additional pressure. Repeat process until valve seat
is clean.
is clean.
To do so, apply a thin layer of try-out paste to valve spindle. Press valve spindle onto valve seat
and turn through max. 90°°.
1.9.6 If the appearance of the bearing surface is not satisfactory, repeat steps 1.9.1 to 1.9.5.
21
20
en / 04.05.2011 IB022696 2/3

M43/VM43
30000
2. Assembly 01
2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly around peri-
phery. Insert piston using insertion ring (W1).

Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the hexa-
gon nut (3) until the hexagon nut (3) and valve shaft (9) cannot be moved separately (solid con-
nection). Tighten the hexagon nut to
M = 80 Nm.
2.3 Mount circlip (12).
en / 04.05.2011 IB022696 3/3

M43/VM43
15000
See also: 01.06.01.nn, 01.11.01.nn 01


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
Insertion ring for starter valve piston W1 * 439227 A

Starter valve reseating tool W2 439224 C
* not shown

CAUTION
Procedure:
1. Disassembly
1.1 Remove the rocker arm bracket (A5.05.01.02.01.nn).
1.4 Remove circlip (12).
1.5 Loosen the hexagon nut (3) while holding the valve shaft (9) with a wrench.
1.8 Check the piston (5), compression ring (10) and valve seat carefully. Smooth scored piston (5) ca-
refully with emery cloth (240 grain or higher).
en / 04.05.2011 IB022699 1/3

M43/VM43
15000
1.9 Rework starter valve seat with reseating tool (W2). 01

1.9.1 Carefully clean valve seat and guide of valve spindle.
1.9.2 Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseating tool
in valve guide and fix with spanner (21).
1.9.3 Tighten adjusting screw (20) until a slight resistance is felt. Then tighten adjusting screw another
1/4 turn to set cutting pressure.
is clean.
is clean.
To do so, apply a thin layer of try-out paste to valve spindle. Press valve spindle onto valve seat
and turn through max. 90°°.
1.10 If the appearance of the bearing surface is not satisfactory, repeat steps 1.9.1 to 1.9.5.
21
20
en / 04.05.2011 IB022699 2/3

M43/VM43
15000
2. Assembly 01
2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly around peri-
phery. Insert piston using insertion ring (W1).

Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the hexa-
gon nut (3) until the hexagon nut (3) and valve shaft (9) cannot be moved separately (solid con-
nection). Tighten the hexagon nut to
M = 80 Nm.
2.3 Mount circlip (12).
en / 04.05.2011 IB022699 3/3

M43/VM43
150


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
inspect the cylinder head every 150 h
Procedure:
1. Check gasket between cylinder head, cylinder liner and coolant distributor housing for combusti-
on gas leaks and check for coolant at the inspection bore (1).
If leaks are found, remove the cylinder head (A5.05.01.06.01.nn). Clean the sealing surfaces and
inspect - replace O-rings and joint ring and tighten to the indicated torque (A5.05.01.11.01.nn).
en / 04.05.2011 IB004824 1/2

M43/VM43
150
2. Check the outside of the cylinder head for leaks. 01

2.1 If oil leaks are found, check the valve cover bolts to ensure that they are tight and check the rub-
ber profile for damage.
2.2 If leaks are found at the media supply connecting flanges, check all bolts to ensure that they are
tight. Replace gaskets as needed.
3. Remove valve cover. Inspect the top of the cylinder head.
3.1 Check to ensure that the valves move identically. Irregularities can be seen most easily at low en-
gine speeds.
3.2 Check the function of the valve rotor or free-wheel (A5.05.01.03.01.nn).
3.3 Check valve springs for damage.
3.4 Check the oil supply to the valve rockers and rocker arm bearings.
en / 04.05.2011 IB004824 2/2

Maintenance / Cleaning
M43/VM43
30000


----------------------------------------------------------------------------------------------------------------------------------
NOTE
The cylinder head may only be placed on the bench upright on a wood block.
Procedure:
The following parts must be dismantled:
Intake, exhaust, injector valve, starter valve and rocker arm bracket.
1. Clean cylinder block with cold cleaning solution.
2. Clean intake and outlet ports, underside of cylinder head (not the valve seats!) with a wire brush
and scraper, all combustion deposits must be removed. Do not damage the gasket depression/
groove.
3. Clean coolant intake and outlet ports.
4. Inspect the underside of the cylinder head carefully for cracks at the valve fittings.
5. Clean the sealing surface for the injector valve.
6. Check the intake and outlet bores for media supply for blockage.
7. Check function of leakage sensor for fuel leaks at the connection piece for media supply on the
distributor plate (Cyl. 1).
en / 04.05.2011 IB004826 1/1

M43/VM43
15000


----------------------------------------------------------------------------------------------------------------------------------
NOTE
The cylinder head may only be placed on the bench upright on a wood block.
Procedure:
The following parts must be dismantled:
Intake, exhaust, injector valve, starter valve and rocker arm bracket.
1. Clean cylinder block with cold cleaning solution.
2. Clean intake and outlet ports, underside of cylinder head (not the valve seats!) with a wire brush
and scraper, all combustion deposits must be removed. Do not damage the gasket depression/
groove.
3. Clean coolant intake and outlet ports.
4. Inspect the underside of the cylinder head carefully for cracks at the valve fittings.
5. Clean the sealing surface for the injector valve.
6. Check the intake and outlet bores for media supply for blockage.
7. Check function of leakage sensor for fuel leaks at the connection piece for media supply on the
distributor plate (Cyl. 1).
en / 04.05.2011 IB004828 1/1

Repair / Reassembly
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
See repair sheet 01.06.01.nn.
High temperature threading paste "Dag S-5080“ *

Molykote Paste "G-Rapid Plus“ *
Vaseline *
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm!
Unit may only be operated with hydraulic oil.
~ Attention!
en / 21.04.2004 IB004830 1/4

Repair / Reassembly
M43
Procedure: 01
1. Turn piston to ignition TDC.
2. Clean the sealing and contact surfaces of the cylinder head and cylinder liner thoroughly and
check for damage. Install new gasket (Fig. 1/1) in cylinder liner collar.
Check and clean sealing surface in exhaust line (06.01.01.nn).
3. Replace the following O-rings: upper O-ring in cylinder liner collar (2), on the cylinder head (3), at
the valve lifter bore (4), at coolant overflow, at starting air intake, at control air intake and at char-
ge air intake fitting.
en / 21.04.2004 IB004830 2/4

Repair / Reassembly
M43
Note: 01
All O-rings must be inserted into the groove with Vaseline or green lubricant paste without
twisting.
Align the overflows for coolant and starting air in the coolant distributor housing
vertically and check for completeness.
4. Place the cylinder head on the coolant distributor housing carefully with a cylinder head lifting unit
and hoist. Make sure that the cylinder head is horizontal in relation to the surface on which
it is resting.
5. Place the cylinder head upright. Install the exhaust line clamp and thread the chain
links (06.01.01.nn). Apply high temperature threading paste "Dag S-5080“ to the bolt and hand
tighten (no gasket).
Attention:
Before using the hydraulic rig, mace sure that the cylinder head and the cylinder liner are
attached securely. Tighten the round nuts with a pin by hand in alternating sequence. If the
cylinder head and cylinder liner are not attached securely, the hydraulic rig may be dama-
ged.
6. Tighten the six cylinder head bolts at the same time with the hydraulic clamping unit.
6.1 Screw the round nut onto the central stud for the rocker arm bracket (Fig. 1/8) up to stop.
6.2 Place the pressure line distributor on a stand pipe (Fig. 2/1) over the round nut for the rokker arm
bracket.
en / 21.04.2004 IB004830 3/4

Repair / Reassembly
M43
6.3 Place the hydraulic clamping elements (Fig. 2/ 2) over the round nuts and tighten. Ensure that the 01
slits (3) are easily accessible.
6.4 Connect the hydraulic clamping elements (2) and the pressure line distributor (1) to the high pres-
sure pump (5) with the high pressure lines (4).
6.5 Close the valve on the high pressure pump (6) and extend all 6 cylinder head bolts simultaneous-
ly with a pressure of
p = 2250 bar
Attention:
The pressure must remain constant when the pump is not being actuated to prevent incor-
rect tightening.
6.6 Tighten the round nuts (7) firmly with a pin. Check to ensure good action (no stiffness).
6.7 Check to ensure that the round nut is seated properly.
• Reduce pressure by 50 bar .

• The round nuts must be tight enough that they cannot be loosened with a pin.
6.8 Depressurize the hydraulic clamping unit and remove.
7. Tighten the exhaust line clamp. The clamp is locked into place by means of the locking screw in
the lower part of the clamp (06.01.01.nn).
8. Reinstall the media supply connecting flange with new gaskets. Make sure that the dowel pins are
seated correctly.
9. Reattach the manometer line and fill the engine coolant. Bleeder from turbocharger on coolant re-
turn line.
10. Insert the pushrods into the cylinder head.
11. Assemble rocker arm bracket (01.02.01.nn).
12. Install fuel injector line (07.05.01.nn).
13. Set valve clearance (01.01.01.nn) and install pump area cover.
14. Check all connections for leaks after starting the engine.
en / 21.04.2004 IB004830 4/4

Repair / Reassembly
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
See maintenance sheet A5.05.01.06.01.nn.
Ancillary materials:
High temperature threading paste “Dag S-5080“ *

Molykote paste “G-Rapid Plus“ *
Vaseline *
WARNING
Avoid bringing body parts above the pressurised devices.
CAUTION
Do not fall below the minimum bend radius r =250 mm for the high pressure hoses.
Only use hydraulic oil as operating medium.
en / 30.03.2011 IB024290 1/4

Repair / Reassembly
M43
Procedure: 01
1. Turn pistons to ignition TDC.
2. Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check
for damage. Insert new sealing ring (Fig. 1/1) into cylinder bushing collar.
Check and clean sealing surface at exhaust pipe (A5.05.06.01.01.nn).
3. Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head (3), at the
push rod bushing (4), at the cooling water conduit, at the starting air inlet, at the control air inlet
and at the charger air inlet connection.
en / 30.03.2011 IB024290 2/4

Repair / Reassembly
M43
01
NOTE
Insert all O rings with Vaseline or green lubricating sopa into the grooves without
twisting. Align conduits for cooling water and starting air in cooling water manifold
housing vertically and check for completeness.
4. Carefully place cylinder head with cylinder head lifting device and hoist onto cooling water
manifold housing. Ensure horizontal position of cylinder head on supporting surface.
5. Align cylinder head. Fit clamp for exhaust pipe and hook in chain links (A5.05.06.01.01.nn).
Grease screw with high temperature threading paste “Dag S-5080“ and tighten by hand
(no seal).
NOTE
Before using the hydraulic device ensure that the cylinder head rests firmly on the
cylinder bushing. This is achieved by manually tightening the round nuts and pin
crosswise. Non-observance may cause damage to the hydraulic device.
6. Tighten the six cylinder head screws simultaneously using the hydraulic tightening de-
vice.
en / 30.03.2011 IB024290 3/4

Repair / Reassembly
M43
6.1 Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good acces- 01
sibility of the slots (3).
6.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect
element 1 to pump. Fit test manometer (W1.4) onto element 6.
6.3 Close valve on high pressure pump and extend all 6

cylinder head screws simultaneously and continuously using a hydraulic pressure of
p = 2250 bar -25 bar
NOTE
The pressure must remain constant with the pump not activated, otherwise the tight-
ening is wrong.
6.4 Tighten round nuts with pin firmly. Ensure smooth movement.
6.5 Check the firm contact of the round nut.

• It should no longer be possible to loosen the round nuts with the pin.
6.6 Relieve hydraulic traction element (W1.1) and remove.
7. Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from
below (A5.05.06.01.01.nn).
8. Remove hexagon screws (W5) (A5.05.01.06.01.nn).
9. Fit removed connecting flanges of the media conduit with new seals. Ensure proper fitting of dow-
el pins.
10. Fit removed manometer pipes and fill with cooling water. Vent cooling water return line from turbo
charger.
11. Insert push rods into cylinder head.
12. Fit rocker arm bracket (A5.05.01.02.01.nn).
13. Fit injection pressure pipe (A5.05.07.05.01.nn).
14. Adjust valve clearance (A5.05.01.01.01.nn) and fit pump chamber cover.
15. Check all connections for tightness after starting the motor.
en / 30.03.2011 IB024290 4/4

Repair / Reassembly
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
See maintenance sheet A5.05.01.06.01.nn.
High temperature threading paste “Dag S-5080“ *

Molykote paste “G-Rapid Plus“ *
Vaseline *
WARNING
Avoid bringing body parts above the pressurised devices.
CAUTION
Do not fall below the minimum bend radius r =250 mm for the high pressure hoses.
Only use hydraulic oil as operating medium.
en / 30.03.2011 IB027091 1/4

Repair / Reassembly
M43
Procedure: 01
1. Turn pistons to ignition TDC.
2. Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check
for damage. Insert new sealing ring (Fig. 1/1) into cylinder bushing collar.
Check and clean sealing surface at exhaust pipe (A5.05.06.01.01.nn).
3. Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head (3), at the
push rod bushing (4), at the cooling water conduit, at the starting air inlet, at the control air inlet
and at the charger air inlet connection.
en / 30.03.2011 IB027091 2/4

Repair / Reassembly
M43
01
NOTE
Insert all O rings with Vaseline or green lubricating sopa into the grooves without
twisting. Align conduits for cooling water and starting air in cooling water manifold
housing vertically and check for completeness.
4. Carefully place cylinder head with cylinder head lifting device and hoist onto cooling water
manifold housing. Ensure horizontal position of cylinder head on supporting surface.
5. Align cylinder head. Fit clamp for exhaust pipe and hook in chain links (A5.05.06.01.01.nn).
Grease screw with high temperature threading paste “Dag S-5080“ and tighten by hand
(no seal).
NOTE
Before using the hydraulic device ensure that the cylinder head rests firmly on the
cylinder bushing. This is achieved by manually tightening the round nuts and pin
crosswise. Non-observance may cause damage to the hydraulic device.
6. Tighten the six cylinder head screws simultaneously using the hydraulic tightening de-
vice.
en / 30.03.2011 IB027091 3/4

Repair / Reassembly
M43
6.1 Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good acces- 01
sibility of the slots (3).
6.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect
element 1 to pump. Fit test manometer (W1.4) onto element 6.
6.3 Close valve on high pressure pump and extend all 6

cylinder head screws simultaneously and continuously using a hydraulic pressure of
p = 2250 bar -25 bar
NOTE
The pressure must remain constant with the pump not activated, otherwise the tight-
ening is wrong.
6.4 Tighten round nuts with pin firmly. Ensure smooth movement.
6.5 Check the firm contact of the round nut.

• It should no longer be possible to loosen the round nuts with the pin.
6.6 Relieve hydraulic traction element (W1.1) and remove.
7. Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from
below (A5.05.06.01.01.nn).
8. Remove hexagon screws (W5) (A5.05.01.06.01.nn).
9. Fit removed connecting flanges of the media conduit with new seals. Ensure proper fitting of dow-
el pins.
10. Fit removed manometer pipes and fill with cooling water. Vent cooling water return line from turbo
charger.
11. Insert push rods into cylinder head.
12. Fit rocker arm bracket (A5.05.01.02.01.nn).
13. Fit injector cable (A5.05.07.23.01.nn).
14. Fit injection pressure pipe (A5.05.07.05.01.nn).
15. Adjust valve clearance (A5.05.01.01.01.nn) and fit pump chamber cover.
16. Check all connections for tightness after starting the motor.
en / 30.03.2011 IB027091 4/4

Running Gear / Engine Timing A5.05. 02.01.01.00
M43/VM43
3750
See also: 03.01.01.nn, 04.08.01.nn, 01.01.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
NOTE
The temperature check for the bearings must be carried out with the engine at oper-
ating temperature after switching off the circulation system lubrication. The remaining
tasks are to be carried out after allowing a period of ventilation.
1. Open indicator valve and engage turning gear.
2. Open crank case cover approx. 10 min. after shutting down the engine.
3. Check crankshaft bearings and big end bearings for even and normal temperatures.
4. Visually check screws and nuts.
5. Check extent of soiling of the engine room (silt deposits, corrosion, bearing metal particles, de-
tached paint).
6. Check cylinder liner surface on engine side. Carry out lubrication oil flow check and check oil de-
livery at bearing points.
7. Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism
for proper tightness.
7.1 Turn engine and check bearing surfaces of cams and rollers for scoring, pitting or other damage.
7.2 Check lubricating oil flow for camshaft bearing and valve mechanism.
8. Check wheel mechanism (A5.05.04.08.01.nn).
9. Check oil tray and crank case for left-behind tools, cloths etc. Check seals of all crank case and
sealing lids and refit cover.
en / 06.05.2011 IB020107 1/1

Crank Web Deflection A5.05. 02.02.01.00
M43
See also: 02

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Measurements must be made in the following cases:

If there may be a foundation deformation, e.g.:
• after sea damage to the ship
• when the foundation appears to have settled
• damage to the bearings or crankshaft
• before and after docking the ship.
Tools:
Crankshaft measuring unit W1 1.9425 A
NOTE
Crank web deflection is the change in distance beween a web pair during one rotati-
on of the crankshaft (Fig. 1). Depending on the location of the engine, the rigidness
of the foundation and the ship, different values are given in comparison with loaded
and unloaded condition of the ship as well as warm or cold engine. Measurements
should therefore be carried out when the engine is warm, with normal loading and
even keel; not in dock! Changes that suddenly appear or appear after a longer period
under otherwise uniform conditions point to a deformation or subsiding of the founda-
tion.
It is therefore suggested to collect the measurement sheets extra so that the chrono-
logical allocation of the values and changes are visible.
In the event of unpermissible changes, the installation must be realigned and the re-
spective main bearings inspected.
a)Initial position
b)Negative deflection
c)Positive deflection
en / 06.10.2010 IB020114 1/4

M43
Procedure: 02
1. Turn the crankshaft journal to the exhaust side so that the dial gauge is spread apart as far as
possible between the crankshaft webs and the connecting rod just passes the dial gauge
(Fig. 2/1. Measurement point).
2. Set the scale value 20 on the dial gauge: 1st measurement point (initial position).
3. Turn the crankshaft so that the journal turns in the direction of the exhaust side and the dial gauge
moves towards the control side.
4. Watch the dial gauge and read the values for measurement points 2 - 5 . If a value is read be-
fore or after a measurement point which is larger than the value at the measurement point, this
value must be entered.
1 = 1st Measurement point (Initial position)

2 = 2nd Measurement point (Journal - exhaust side)
3 = 3rd Measurement point (Journal - TDC)
4 = 4th Measurement point (Journal - control side)
5 = 5th Measurement point (Journal - BDC control side)
en / 06.10.2010 IB020114 2/4

M43
02
NOTE
The web deflection is primarily used to measure and evaluate the engine when ali-
gning it in relation to its shaft system.
A large degree of web deflection places a greater load on the crankshaft and the
main bearings, i.e. the permissible web deflection depends on the load which the en-
gine is subjected to.
(Engines which are subject to higher load allow less deflection as engines which are
subject to lower loads.)
The values indicated here may not be exceeded if permissible web deflection tole-
rance for the respective system cannot be obtained from Caterpillar Motoren GmbH
& Co. KG
Only web deflection values measured on an engine at operating temperature may be

used for evaluation.
The values measured on a cold engine are not necessarily indicative of the condition
of the engine.
Web deflection values in mm:
RM43
Cylinder 1 or last cylinder

with additional load + 0,07 / - 0,16 mm
(flywheel/coupling)
All cylinders
without external load + 0,07 / - 0,12 mm
en / 06.10.2010 IB020114 3/4

M43
02
en / 06.10.2010 IB020114 4/4

Bearing Shells and Bearing Bushes A5.05. 02.03.03.01
M43/VM43


-------------------------------------------------------------------------------------------------------------------------------
NOTE
Oil contamination, foreign objects, water and faulty tools cause
85 % of all bearing damage.
Oil contamination, foreign objects, water and faulty tools cause

85 % of all bearing damage.
Dirt is the enemy of all bearings!
In order to avoid unnecessarily shortening bearing life, note the following:

• Oil temperature and pressure requirements, see engine documentation, chapter
"Technical Engine Data"
• Oil brand recommendations (viscosity class), see engine documentation, chapter
„Operating Media“
• Information on oil care, see engine documentation, chapter „Operating Media“
• Oil change / additives, see engine documentation, chapter „Operating Media“
Heavy start-stop operation (mixed friction) can cause the bearings to wear more rapidly so that
the bearings must be replaced sooner.
NOTE
When replacing bearings in the crankcase, note that all bearing shells must generally
be replaced in pairs (upper and lower bearing shell)!
NOTE
Corrosion resistant two-component bearings are used for normal loads.
These bearings consist of a protective steel shell and a running layer.
en / 06.05.2011 IB020119 1/2

Bearing Shells and Bearing Bushes A5.05. 02.03.03.01
M43/VM43
The corrosion-resistant flash on the bearing (ca. 3 µm) is worn through after a short operating 02
period.
The bearing need only be replaced after
- heavy scoring,
- a clearance limit has been exceeded or
- in accordance with the applicable evaluation criteria (A5.05.02.03.07.nn).
NOTE
If a replacement criterion is found during an inspection, all bearings must be
checked.
en / 06.05.2011 IB020119 2/2

Bearing Shells A5.05. 02.03.07.01
M43/VM43
See also: 02.03.03.nn, 02.05.01.nn, 02.05.05.nn 02


-------------------------------------------------------------------------------------------------------------------------------
NOTE
The following evaluation catalog contains different wear stages caused by mechani-
cal wear and overloading the bearing shells.
Evaluation catalog:
Criteria for reinstallation
Fig. 1 -The wear pattern is even across the entire width of the bearing surface.
Any streaks caused by foreign bodies in the engine oil do not tend to have a significant
influence on the operating safety of a sliding bearing.
This bearing shell can be reused.
Fig. 2 -The wear pattern is even across the entire width of the bearing surface. This bearing shell
can be reused.
Fig. 3 -The wear pattern is even across the entire width of the bearing surface.
The scoring along the bearing surface is caused by fine solid particles in the engine oil.
If these scores cannot be felt or the depth of these scores cannot be measured, the
bearing shell can be reused.
If the number, depth and length of such scoring has an adverse affect on the formation
of the oil film, both bearing pairs must be replaced.
NOTE
When replacing bearings in the crankcase, note that all bearing shells must general-
ly be replaced in pairs (upper and lower bearing shell)!
en / 06.05.2011 IB020121 1/4

M43/VM43
Criteria for replacement 02

Fig. 4 - The wear pattern includes severe scoring and the aluminum alloy sliding layer is fretted.
This bearing shell can not be used again, both bearing shells must be replaced. Find
and eliminate the cause for the increased scoring.
Fig. 5 - The wear pattern includes a large area of damage with varying degrees of fretting.
This bearing shell can not be used again, both bearing shells must be replaced. Find
and correct the cause of this damage. Check all other bearing shells.
Fig. 6 - Bearing metal is missing in the loaded area of this bearing as a result of overloading.
There may also be loose pieces of bearing metal in the
affected area.
This bearing shell can not be used again, both bearing shells must be replaced. The
cause for the flaking must be determined and corrected. Check all other bearing
shells.
en / 06.05.2011 IB020121 2/4

M43/VM43
02
en / 06.05.2011 IB020121 3/4

M43/VM43
02
en / 06.05.2011 IB020121 4/4

Big End Bearings A5.05. 02.04.01.00
Inspection / Disassembly
M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn, 02.06.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
one big end bearing every 15,000 h

exchange all big end bearings every 30,000 h
Tools:
Hydraulic set consisting of

High pressure pump W1 1.9204 D
High pressure line W2 433420 A
Hydraulic clamping elements W3 1.9213 K
Pin W4
Threaded sleeve for big-end bearing 1.9203-109
Big end bearing installation and disassembly set W5 439228 A
Molykote Paste “G-Rapid Plus“ *
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! The high
pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from
corrosion during storage.
~ Attention!
Do not place any body parts under equipment which is under pressure! Ensure that the en-
en / 21.04.2004 IB020165 1/6

M43
30000, 15000
Procedure: 02
1. Remove piston (02.06.01.nn).
2. Turn the engine so that the connecting rod is horizontal.

Both round nuts (2) must be accessible.
3. Loosen the round nuts (2) with the hydraulic rig.
Note:
The hydraulic clamping element is provided with a replaceable bush that must be exchanged ac-
cording to the case of application (02.04.50.nn).
3.1 Place and tighten the hydraulic clamping elements (W3) over the round nuts (2). Ensure that the
Loosen hydraulic clamping elements by 1 turn.
3.2 Connect the hydraulic clamping elements (W3) to the high pressure pump (W1) by means of the
high pressure lines (w2).
4. Close the valve (6) on the high pressure pump (W1) and apply force to both connecting rod bolts
with a pressure of
p = 1670 bar
5. Loosen the round nuts (2) with a pin (W4). Turn the round nuts back 10 holes.
en / 21.04.2004 IB020165 2/6

M43
30000, 15000
Note: 02
p = 50 bar
more.
If the pressure is increased further, the connecting rod bolt threading may stretch, which can cau-
se the round nuts to lock into place.
6. Open valve (6) of the high-pressure pump (W1), hydraulic jacks are relieved of tension.
7. Wait until no pressure is left, dismount hydraulic devices (W3).
8. Turn connecting rod (17) horizontally with the connecting rod shank division to the exhaust side.
9. Fit mounting and dismounting device (W5) for big end bearing.
9.1 Mount guide rail holder (10) on both sides of the cylinder crankcase.
11
10
14
18
15
9.2 Suspend guide rail (11).
en / 21.04.2004 IB020165 3/6

M43
30000, 15000
9.3 Tighten hexagon nuts (12). 02

10 11 12
9.4 Mount guide rail extension (13) with carriage (14) on camshaft side.
13
18
15 3
19
en / 21.04.2004 IB020165 4/6

M43
30000, 15000
10. Screw suspension (18) at big end bearing cap. 02

11. Connect suspension (18) with carriage (14).
12. Unscrew round nuts (2).
13. Drive big end bearing cap (15) to the camshaft side out of the crankcase. Remove bearing shell
(19).
13
19
15
14. Fix big end bearing cap (15) at the crane and deposit on suitable support.
15. Disassemble big-end bolts (3) and washers (4).

Secure connecting rod (17) additionally with screw (20) at connecting rod holder.
en / 21.04.2004 IB020165 5/6

M43
30000, 15000
16. Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to 02
the camshaft side.
17. Mount suspension (16) for connecting rod (17) and connect with carriage.
18. Dismount connecting rod holder at the counterweight (02.06.01.nn).
19. Drive connecting rod (17) to the camshaft side out of the crankcase. Remove bearing shell (20).
16
20
17
20. Sling suspension (16) with suspended connecting rod (17) at the crane. Dismount connection to
the carriage (14).
21. Deposit connecting rod (17) on suitable support.
22. Evaluate the condition of the big end bearing shells (02.03.03.nn and 02.03.07.nn).
Note:
If the bearings are scored, the neighboring bearings must also be checked.
en / 21.04.2004 IB020165 6/6

M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn, 02.06.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:

Tools:

Hydraulic clamping elements W3 1.9213 N
Pin W4
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! The high
pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from
corrosion during storage.
~ Attention!
en / 16.06.2004 IB024516 1/6

M43
30000, 15000
Procedure: 02
1. Remove piston (02.06.01.nn).

high pressure lines (w2).
with a pressure of
p = 2250 bar
en / 16.06.2004 IB024516 2/6

M43
30000, 15000
Note: 02
p = 50 bar
more.
If the pressure is increased further, the connecting rod bolt threading may stretch, which can cau-
se the round nuts to lock into place.
6. Open valve (6) of the high-pressure pump (W1), hydraulic jacks are relieved of tension.
11
10
14
18
15
en / 16.06.2004 IB024516 3/6

M43
30000, 15000

10 11 12
13
18
15 3
19
en / 16.06.2004 IB024516 4/6

M43
30000, 15000

(19).
13
19
15

en / 16.06.2004 IB024516 5/6

M43
30000, 15000
the camshaft side.
18. Dismount connecting rod holder at the counterweight (02.06.01.nn).
16
20
17
the carriage (14).
22. Evaluate the condition of the big end bearing shells (02.03.03.nn and 02.03.07.nn).
Note:
en / 16.06.2004 IB024516 6/6

M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn, 02.06.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:

Tools:

High pressure pump W1
High pressure line W3 433420 E
Hydraulic clamping elements W4 1.9213 N
Pin W5
CAUTION
Do not place any body parts under equipment which is under pressure! Ensure that
the engine cannot be started.
CAUTION
High pressure lines may not be bent below minimum bending radius r = 250 mm! The
high pressure pump may only be operated with hydraulic oil. Protect hydraulic equip-
ment from corrosion during storage.
en / 05.11.2010 IB024444 1/6

M43
30000, 15000
Procedure: 02
1. Remove piston (A5.05.02.06.01.nn).

high pressure lines (W2, W3).
with a pressure of
p = 2250 bar
en / 05.11.2010 IB024444 2/6

M43
30000, 15000
02
NOTE
p = 50 bar more.
If the pressure is increased further, the connecting rod bolt threading may stretch,
which can cause the round nuts to lock into place.
6. Open valve of the high-pressure pump (W1), hydraulic jacks are relieved of tension.
11
10
14
18
15
en / 05.11.2010 IB024444 3/6

M43
30000, 15000

10 11 12
13
18
15 3
19
en / 05.11.2010 IB024444 4/6

M43
30000, 15000

(19).
13
19
15

en / 05.11.2010 IB024444 5/6

M43
30000, 15000
the camshaft side.
18. Dismount connecting rod holder at the counterweight (A5.05.02.06.01.nn).
16
30
17
the carriage (14).
22. Evaluate the condition of the big end bearing shells (A5.05.02.03.03.nn and A5.05.02.03.07.nn).
NOTE
en / 05.11.2010 IB024444 6/6

Inspection / Reassembly
M43
See also: 02.04.01.nn, 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W5 see 02.04.01.nn
Note:
Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled according to
the cylinder to which they belong and may not be switched around. New parts must be labeled
accordingly.
Procedure:
1. Bearing shell installation
1.1 Clean and oil crank journals.
1.2 Oil the inside and outside of the bearing

shells.
Attention:
The bearing shells are equipped with a
positioning nose (Fig. 1/X) to allow
them to be positioned properly in the
connecting rod and big end bearing
cap. The bearing shells must be instal-
led with the positioning nose to the
control side!
en / 16.12.2009 IB020169 1/8

M43
1.3 Mount suspension (16) at dismounted connecting rod. 02

1.4 Fasten suspension (16) with suspended connecting rod (17) at the crane and lift. Mount connec-
tion to the carriage (14).
16
20
17
1.5 Remove sling.
1.6 Push connecting rod (17) towards the crank pin up to approx. 20 mm.
1.7 Put upper bearing shell (without holes) on the crank pin and turn below the connecting rod by
180°.
1.8 Press connecting rod (17) carefully against bearing shell (20). The fixing lug of the bearing shell
must be exactly positioned in the notch of the connecting rod.
en / 16.12.2009 IB020169 2/8

M43
1.9 Mount connecting rod holder at counterweight n (02.06.01.nn). 02

Secure connecting additionally with screw (20) at connecting rod holder.
1.10 Dismount suspension (16).
1.11 Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to
the exhaust side.
1.12 Mount suspension (18) at big end bearing cap (15).
13
18
15 3
19
en / 16.12.2009 IB020169 3/8

M43
1.13 Fasten big end bearing cap (15) at crane and connect suspension (18) with carriage (14) at guide 02
rail extension (13).
13
19
15
1.14 Remove sling.
1.15 Push big end bearing cap (15) towards the crank pin up to approx. 160 mm.
Attention:
Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 / big end
bearing cap)!
en / 16.12.2009 IB020169 4/8

M43
1.16 Push big end bearing cap (15) forward towards the crank pin up to approx. 100 mm and insert, 02
align and press lower bearing shell (19) into the big end bearing bore.
1.17 Push big end bearing cap (15) carefully against bearing shell (19) and bottom end of connecting
rod. The lug of the bearing shell must be exactly positioned in the notch of the big end bearing
cap (15).
10 11 12
Attention :
Pay attention that the bearing shell halves on exhaust and camshaft side are axially
aligned. Displacement of the bearing shell halves to each other in axial direction is not
admissible.
en / 16.12.2009 IB020169 5/8

M43
1.18 Insert big-end bolts (3) with washer (4). 02

Assemble washer (4) with chamfer pointing towards bottom end of connecting rod.
Attention:
Before hydraulic tightening it has to be made sure that the head of big-end bearing bolt (3)
is located in the recess of washer (4).
1.19 Install round nuts (5) and tighten by hand.
1.20 Remove installation / disassembly unit (W5).
1.21 Check bearing shell pairs for axial misalignment on the exhaust side. Align shells if necessary.
11
10
14
18
15
en / 16.12.2009 IB020169 6/8

M43
2. Tighten the round nuts (5) with the 02

hydraulic rig.
2.1 Turn the connecting rod with the connec-
ting rod shank joint by about 15-30° down-
wards, see indicated position
(Fig. 11). Both round nuts (5) must be ea-
sily accessible.
2.2 Place the hydraulic clamping element (W3)
over the round nut (5) at camshaft side and
screw onto big-end bearing bolt (6) so as to
be finger tight. Make sure that the slits (8)
are easily accessible.
2.3 Connect the hydraulic clamping element
(W3) to the high-pressure pump (W1) by
means of the high-pressure line (W2).
2.4 Close the valve (10) of the high-

pressure pump (W1) and extend the big-
end bearing bolt at camshaft side
steplessly, hydraulic pressure:
p = 75 bar
2.5 Firmly tighten the round nut (5) at cams-
haft side with a pin (W4).
2.6 Open the valve (10) of the high-pressure

pump (W1), the clamping element is de-
pressurized.
2.7 Wait until the pressure reduces complete-

ly.
2.8 Place the second clamping element (W3)

over the round nut (5) at exhaust gas
side and screw onto big-end bearing bolt
(6) so as to be finger tight. Make sure that
the slits (8) are easily
accessible.
2.9 Connect the second hydraulic clamping

element (W3) to the high-pressure pump
(W1) by means of the high-pressure line
(W2).
2.10 Close the valve (10) of the high-pressure

pump (W1) and extend both big-end bea-
ring bolts steplessly and simultaneously,
hydraulic pressure:
p = 1670 bar + 25 bar
Attention:
The pressure must remain constant when the hydraulic pump is not actuated, otherwise
they will be tightened incorrectly!
en / 16.12.2009 IB020169 7/8

M43
2.11 Firmly tighten the round nuts (5) with a pin (W4). While doing so the nuts must turn smoothly. 02
Visual check of angle of rotation 180°° ± 22°°
2.12 Check to ensure that the round nut is seated properly

• Reduce pressure by 50 bar
• The round nuts must be tight enough so that they cannot be loosened with the pin
any more.
2.13 Open the valve (10) of the high-pressure pump (W1), the clamping elements are depressurized.
2.14 Wait until the pressure reduces completely.
3. Mount the piston (02.10.01.nn).
en / 16.12.2009 IB020169 8/8

M43
See also: 02.04.01.nn, 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Note:
Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled according to
the cylinder to which they belong and may not be switched around. New parts must be labeled
accordingly.
Procedure:

shells.
Attention:
The bearing shells are equipped with a
positioning nose (Fig. 1/X) to allow
them to be positioned properly in the
connecting rod and big end bearing
cap. The bearing shells must be instal-
led with the positioning nose to the
control side!
en / 16.12.2009 IB024520 1/8

M43

16
20
17
1.5 Remove sling.
180°.
1.8 Press connecting rod (17) carefully against bearing shell (20). The fixing lug of the bearing shell
must be exactly positioned in the notch of the connecting rod.
en / 16.12.2009 IB024520 2/8

M43
1.9 Mount connecting rod holder at counterweight n (02.06.01.nn). 02

the exhaust side.
13
18
15 3
19
en / 16.12.2009 IB024520 3/8

M43
13
19
15
1.14 Remove sling.
Attention:
Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 / big end
bearing cap)!
en / 16.12.2009 IB024520 4/8

M43
rod. The lug of the bearing shell must be exactly positioned in the notch of the big end bearing
cap (15).
10 11 12
Attention :
aligned. Displacement of the bearing shell halves to each other in axial direction is not
admissible.
en / 16.12.2009 IB024520 5/8

M43

Attention:
Before hydraulic tightening it has to be made sure that the head of big-end bearing bolt (3)
is located in the recess of washer (4).
11
10
14
18
15
en / 16.12.2009 IB024520 6/8

M43

hydraulic rig.
sily accessible.
2.4 Close the valve (10) of the high-

pressure pump (W1) and extend the big-
end bearing bolt at camshaft side
steplessly, hydraulic pressure:
p = 75 bar
2.6 Open the valve (10) of the high-pressure

pump (W1), the clamping element is de-
pressurized.

ly.

accessible.

(W1) by means of the high-pressure line
(W2).
2.10 Close the valve (10) of the high-pressure

pump (W1) and extend both big-end bea-
ring bolts steplessly and simultaneously,
hydraulic pressure:
p = 2250 bar + 25 bar
Attention:
The pressure must remain constant when the hydraulic pump is not actuated, otherwise
they will be tightened incorrectly!
en / 16.12.2009 IB024520 7/8

M43
2.11 Firmly tighten the round nuts (5) with a pin (W4). While doing so the nuts must turn smoothly. 02

any more.
2.13 Open the valve (10) of the high-pressure pump (W1), the clamping elements are depressurized.
3. Mount the piston (02.10.01.nn).
en / 16.12.2009 IB024520 8/8

M43
See also: 02.04.01.nn, 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W6 see A5.05.02.04.01.nn
Note:
NOTE
Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled
according to the cylinder to which they belong and may not be switched around. Do
not turn the bearing shells. New parts must be labeled accordingly.
Procedure:

shells.
NOTE
For fixation in the big-end bearing
cap the lower bearing shells are
provided with locating lugs (Fig. 1/
X).
Install the upper and lower bearing
shells with marking towards cams-
haft side.
en / 03.05.2011 IB026940 1/8

M43

16
30
17
1.5 Remove sling.
180°.
1.8 Press connecting rod (17) carefully against bearing shell (30). .
NOTE
Lateral projection of upper bearing shell (30) must be the same.
en / 03.05.2011 IB026940 2/8

M43
1.9 Mount connecting rod holder at counterweight n (A5.05.02.06.01.nn). 02

the exhaust side.
13
18
15 3
19
en / 03.05.2011 IB026940 3/8

M43
13
19
15
1.14 Remove sling.
NOTE
Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 /
big end bearing cap)!
en / 03.05.2011 IB026940 4/8

M43
rod. The lugs of the bearing shell must be precisely positioned in the recesses of the big-end bea-
ring cap (15).
10 11 12
NOTE
aligned. Displacement of the bearing shell halves to each other in axial direction is
not admissible.
en / 03.05.2011 IB026940 5/8

M43

NOTE
Before hydraulic tightening it has to be made sure that the head of big-end bearing
bolt (3) is located in the recess of washer (4).
11
10
14
18
15
en / 03.05.2011 IB026940 6/8

M43

hydraulic rig.
sily accessible.
2.4 Close the valve of the high-pressure pump

(W1) and extend the big-end bearing bolt
at camshaft side steplessly, hydraulic
pressure:
p = 85 bar
2.6 Open the valve of the high-pressure pump

(W1), the clamping element is depressuri-
zed.

ly.

accessible.

(W1) by means of the high-pressure lines
(W3).
2.10 Close the valve of the high-pressure pump

(W1) and extend both big-end bearing
bolts steplessly and simultaneously, hy-
draulic pressure:
p = 2250 bar + 25 bar
en / 03.05.2011 IB026940 7/8

M43
02
NOTE
The pressure must remain constant when the hydraulic pump is not actuated, other-
wise they will be tightened incorrectly!
2.11 Firmly tighten the round nuts (5) with a pin (W5). While doing so the nuts must turn smoothly.

any more.
2.13 Open the valve of the high-pressure pump (W1), the clamping elements are depressurized.
3. Mount the piston (A5.05.02.10.01.nn).
en / 03.05.2011 IB026940 8/8

Hydraulic Jack A5.05. 02.04.50.00
M43
See also: 02.04.01.nn, 02.05.01.nn, 02.05.05.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Fork wrench W1 436500 C

Threaded sleeve for crankshaft bearing W2 1.9203-108
Threaded sleeve for big-end bearing W3 1.9203-109
Auxiliary material:
Molykote paste "G-Rapid Plus" *
1. Clamp the hydraulic jack.
2. Loosen cap (1) with fork wrench (W1) and

remove it.
3. Take out disk spring set (2).
4. Take out exchange bush (W2/W3).
5. Clean all parts and slightly grease them

with Molykote paste "G-Rapid Plus".
6. Insert replacement bush (W2/W3).
7. Insert disk spring set (2).
Attention:
The disk spring set must absolutely be

mounted according to (2).
8. Screw on cap (1) by means of fork wrench

(W1).
en / 03.04.2001 IB023074 1/1

M43/VM43
See also: 02.04.01.nn, 02.05.01.nn, 02.05.05.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Exchange of all seals
Tools:
Fork wrench W1 * 436500 C

* = no illustration
Auxiliary means:
* or equivalent
1. Disassembly
1.1 Clamp hydraulic jack.
1.2 Loosen cover (1) using fork wrench (W1) and disassemble.
1.3 Remove cup spring pack (2).
1.4 Push piston (3) out.
1.5 Remove rubber rings (4 and 5) as well as joint rings (6 and 7).
2. Assembly
2.1 Clean all parts and slightly coat them with Molykote paste "G-Rapid Plus".
en / 06.05.2011 IB024004 1/3

M43/VM43
2.2 Insert new seals in consideration of the order: 02

Order: At first rubber rings (4 and 5) and then joint rings (6 and 7).
CAUTION
Do not press joint rings in too much.
2.3 Press piston (3) into the cylinder.
CAUTION
Do not press joint rings in too much.
2.4 Mount cup spring pack (2).
2.5 Screw cover (1) on using fork wrench (W1) and tighten.
en / 06.05.2011 IB024004 2/3

M43/VM43
02
NOTE
Please note that the correct post-assembly position of the cup springs has to be
strictly observed.
2.6 When the hose coupling has been disassembled mount threaded adapter (8) and high-pressure
coupling nipple (9) and tighten with a torque wrench of
M = 50 Nm.
en / 06.05.2011 IB024004 3/3

Main Bearings A5.05. 02.05.01.00
M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of two crankshaft bearings every 15,000 h
Number of bearing
cylinders No.
6 5 and 7
7 5 and 7
8 6 and 8
9 7 and 9
b) exchange all crankshaft bearings every 30,000 h
Tools:

High pressure line (3 x 1m) W2 433420 A
Pin W3
Hydraulic tightening element
(lateral uniform strength bolts) W4 1.9213 F
(crankshaft bearing bolts) W5 1.9213 K
Threaded sleeve for crankshaft bearing 1.9203-108
Installation / disassembly unit for crankshaft bearings, consisting of

Rig W10 439214 A
Carrier W11 439225 B
Attention:
The high pressure pump may only be operated with hydraulic oil.
Protect hydraulic equipment from corrosion during storage.
en / 21.04.2004 IB020230 1/9

M43
30000, 15000
02
~ Attention!
Attention:
The neighboring bearings must be securely mounted during installation and for gap mea-
surements.
Note:
The bearing covers and bearing shells are numbered consecutively on the control side from the
coupling forward according to their respective cylinder and may not be exchanged. New parts
must be labeled accordingly.
The crankshaft bearings must be removed, inspected and measured within the indicated intervals
when:
- foundation deformations or
- web deflection changes occur after sea damage.
Procedure:
1. Remove crankshaft bearings.
1.1 Open the corresponding crankcase cover on the control and exhaust side.
1.2 Turn the crankshaft to the position which removal can be completed most easily.
1.2.1 Turn one of the connecting rods next to the crankshaft bearing to be removed to 90° after cranks-
haft TDC or 90° before crankshaft TDC.
1.3 Loosen the round nuts (23) on the lateral uniform strength
bolts with the hydraulic rig.
1.3.1 Remove the protective caps. 23
1.3.2 Place hydraulic clamping element (W4) over the round nut W4
(23) and tighten. Ensure that the slits are easily accessible.
Loosen hydraulic clamping element by 1 turn.
1.3.3 Connect the hydraulic clamping element (W4) to the high

pressure pump (W1) by means of the high pressure line
(W2).
1.3.4 Close the valve on the high pressure pump (W1) and apply
force to uniform strength bolt with a pressure of
W2
W1
p = 2250 bar
1
en / 21.04.2004 IB020230 2/9

M43
30000, 15000
1.3.5 Loosen the round nut with a pin. Turn the round nut back 10 holes. 02
Note:
If the round nut cannot be loosened with the pin, the pressure on the uniform strength bolt can be
increased to
p = 50 bar
more.
If the pressure is increased further, the threading may stretch, which can cause the round nuts to
lock into place!
1.3.6 Open the valve on the high pressure pump, the hydraulic clamping element is depressurized.
1.3.7 Wait until the pressure drops completely. Remove the hydraulic clamping element.
1.3.8 Repeat sequence of operations 1.3.2 - 1.3.7 on the opposite side.
1.3.9 Loosen the uniform strength bolts and screw out completely.
1.3.10 Loosen the round nuts on the lateral uniform strength bolts on the neighboring bearing(s) with the
hydraulic rig (do not remove). ( if necesarry )
1.4 Insert rig.
1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan.
Insert carrier arm.
W10
en / 21.04.2004 IB020230 3/9

M43
30000, 15000
1.4.2 Connect the hydraulic cylinder of the rig (W10) to the high pressure pump (W1) by means of the 02
high pressure line (W2).
14
W10
1.4.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
W5
10
23
en / 21.04.2004 IB020230 4/9

M43
30000, 15000
1.4.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig. 02
Note:
1.4.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove the
chute.
1.4.6 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten.
Make sure that the slits (13) are easily accessible.
12
13
W5
W10
1.4.7 Repeat the installation procedure on the opposite side.
1.4.8 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the
high pressure lines (W2).
1.4.9 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressu-
re of
p = 2250 bar
1.4.10 Loosen the round nuts (12) with a pin. Turn back the round nuts at least 8 holes.
en / 21.04.2004 IB020230 5/9

M43
30000, 15000
Note: 02
If the round nuts cannot be loosened with the pin, the pressure on the uniform strength bolts can
be increased to
p = 50 bar
more.
lock into place!
1.5 Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressu-
rized.
1.5.1 Wait until the pressure reduces completely. Remove the hydraulic clamping elements.
The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
1.5.2 Remove the clamping element support disk (14) from the carrying arm.
Place the spacer block (15) for the crankshaft bearing cover on the carrying arm.
15
W10
1.6 Measure gap, see procedure 2.
en / 21.04.2004 IB020230 6/9

M43
30000, 15000
1.7 Run the carrying arm of the rig (W10) to the crankshaft bearing cover. Bolt the bearing cover to 02
the plate. Remove the round nuts.
W10
W2
1.8 Lower the carrying arm carefully to the lower stop with the main bearing cover and lower bearing
shell.
1.9 Remove the lower bearing shell.
1.10 Place the carrier (W11) into the oil bore in

the crankshaft until it stops.
1.11 Turn the upper bearing shell and remove.
Attention:
Do not turn until the rig is lowered com-
pletely to the lower stop! W11
en / 21.04.2004 IB020230 7/9

M43
30000, 15000
1.12 Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn. 02
1.13 Check the wear and wall thickness with a
micrometer in the main wear zone at the
indicated measurement points (X).
Wear = Nominal size - current size
1.14 The bearing shells must be changed when

the wear reaches > 0.05 mm.
Nominal size = 8.820 - 0.025 mm
Attention:
If measurements indicate that the bea-
ring shells need to be replaced, the
neighboring bearings must also be
checked.
2. Measure the gap.
2.1 Remove the uniform strength bolts for the respective main bearing on the exhaust and control si-
de. (see procedure 1.4)
K K
A S
12
10
2.1.1 Loosen both round nuts (12) hydraulically as described in 1.5 and 1.6. Lower the rig.
en / 21.04.2004 IB020230 8/9

M43
30000, 15000
2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely 02
touch.
2.1.3 Measure the gap “K“ between the crankcase and the bearing cover on the exhaust and control
side and add both values.
K = KA + KS
Gap “K“ Operating limit

mm mm
1.4 - 1.65 1.2
en / 21.04.2004 IB020230 9/9

M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Number of bearing
cylinders No.
6 5 and 7
7 5 and 7
8 6 and 8
9 7 and 9
Tools:

Pin W3

Rig W10 439214 A
Attention:
en / 21.04.2004 IB020240 1/9

M43
30000, 15000
02
~ Attention!
Attention:
The neighboring bearings must be securely mounted during installation and for gap mea-
surements.
Note:
The bearing covers and bearing shells are numbered consecutively on the control side from the
coupling forward according to their respective cylinder and may not be exchanged. New parts
must be labeled accordingly.
The crankshaft bearings must be removed, inspected and measured within the indicated intervals
when:
Procedure:
1.2 Turn the crankshaft to the position at which removal can be completed most easily.
1.2.1 Turn one of the connecting rods next to the crankshaft bearing to be removed to 90° after cranks-
haft TDC or 90° before crankshaft before TDC.
1.3.1 Remove the protective caps.

23
1.3.2 Place hydraulic clamping elements(W4) over the round nut
(23) and tighten. Ensure that the slits are easily accessible. W4

(W2).
W2
p = 2250 bar W1
en / 21.04.2004 IB020240 2/9

M43
30000, 15000
1.3.5 Loosen the round nut with a pin. Turn back the round nut at 10 holes. 02
Note:
increased to
p = 50 bar
more.
lock into place!
1.3.7 Wait until the pressure reduces completely. Remove the hydraulic clamping element.
hydraulic rig (do not remove). ( if necessary )
1.4 Insert rig.
1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan. Insert
carrier arm.
W10
en / 21.04.2004 IB020240 3/9

M43
30000, 15000
14
W10
arm.
W5
10
23
en / 21.04.2004 IB020240 4/9

M43
30000, 15000
Note:
chute.
12
13
W5
W10
re of
p = 2250 bar
en / 21.04.2004 IB020240 5/9

M43
30000, 15000
Note: 02
be increased to
p = 50 bar
more.
lock into place!
rized.
1.5.1 Wait until the pressure drops completely. Remove the hydraulic clamping elements.
15
W10
en / 21.04.2004 IB020240 6/9

M43
30000, 15000
W10
W2
shell.
1.9 Remove lower bearing shell.

Attention:
Do not turn until the rig is lowered com- W11
pletely to the lower stop!
en / 21.04.2004 IB020240 7/9

M43
30000, 15000
1.12 Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn. 02
1.13 Check the wear and wall thickness in the
main wear zone at the indicated measure-
ment points (X) with a micrometer .

Attention:
checked.
2. Measure the gap.
de. (See procedure 1.4.)
K K
A S
12
10
en / 21.04.2004 IB020240 8/9

M43
30000, 15000
2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch. 02
K = KA + KS

mm mm
1.4 - 1.65 1.2
en / 21.04.2004 IB020240 9/9

M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn, 14.04.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Number of bearing
cylinders No.
6 5 and 7
7 5 and 7
8 6 and 8
9 7 and 9
Tools:

High pressure line (3 x 1m) W2 433420 A
Pin W3
High pressure line W6* 433420 E

Rig W10 439214 A
* no picture
WARNING
en / 12.11.2010 IB024452 1/9

M43
30000, 15000
02
CAUTION
CAUTION
The neighboring bearings must be securely mounted during installation and for gap
measurements.
NOTE
The bearing covers and bearing shells are numbered consecutively on the control
side from the coupling forward according to their respective cylinder and may not be
exchanged. New parts must be labeled accordingly.
The crankshaft bearings must be removed, inspected and measured within the indi-
cated intervals when:
Procedure:
1.2 Turn the crankshaft to the position which removal can be completed most easily.
1.2.1 Turn one of the connecting rods next to the crankshaft bea-
ring to be removed to 90° after crankshaft TDC or 90° before
crankshaft TDC.
1.3.2 Place hydraulic clamping element (W4) over the round nut
en / 12.11.2010 IB024452 2/9

M43
30000, 15000
1.3.3 Connect the hydraulic clamping element (W4) to the high pressure pump (W1) by means of the 02
Secure the coupling that is not connected by means of plug.
1.3.4 Close the valve on the high pressure pump (W1) and apply force to uniform strength bolt with a
pressure of
p = 2250 bar
1.3.5 Loosen the round nut with a pin. Turn the round nut back 10 holes.
NOTE
If the round nut cannot be loosened with the pin, the pressure on the uniform strength
bolt can be increased to p = 50 bar more.
If the pressure is increased further, the threading may stretch, which can cause the
round nuts to lock into place!
1.3.7 Wait until the pressure drops completely. Remove the hydraulic clamping element.
hydraulic rig (do not remove). ( if necesarry )
1.4 Insert rig.
1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan.
Insert carrier arm.
W10
en / 12.11.2010 IB024452 3/9

M43
30000, 15000
14
W10
arm.
W5
10
23
en / 12.11.2010 IB024452 4/9

M43
30000, 15000
chute.
12
13
W5
W10
re of
p = 2250 bar
en / 12.11.2010 IB024452 5/9

M43
30000, 15000
02
NOTE
If the round nuts cannot be loosened with the pin, the pressure on the uniform
strength bolts can be increased to p = 50 bar more.
If the pressure is increased further, the threading may stretch, which can cause the
round nuts to lock into place!
rized.
1.5.1 Wait until the pressure reduces completely. Remove the hydraulic clamping elements.
15
W10
en / 12.11.2010 IB024452 6/9

M43
30000, 15000
W10
W2
shell.

CAUTION
Do not turn until the rig is lowered
completely to the lower stop!
en / 12.11.2010 IB024452 7/9

M43
30000, 15000
1.12 Inspect and evaluate the bearing shells, see A5.05.02.03.03.nn and A5.05.02.03.07.nn. 02
1.13 Check the wear and wall thickness with a
micrometer in the main wear zone at the

CAUTION
If measurements indicate that the bearing shells need to be replaced, the neighboring
bearings must also be checked.
2. Measure the gap.
de. (see procedure 1.4)
en / 12.11.2010 IB024452 8/9

M43
30000, 15000
2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch. 02
K = KA + KS

mm mm
1.4 - 1.65 1.2
en / 12.11.2010 IB024452 9/9

Maintenance / Reassembly
M43
See also: 02.05.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W11 see maintenance sheet 02.05.01.nn
Turning unit W12 439225-001

Reversible ratchet 1/2" W14 * 1.9459-033
* no picture
Attention:
~ Attention!
Note:
The bearing covers and bearing shares are numbered consecutively on the control side
from the coupling forward according to their respective cylinder and may not be ex-
changed. New parts must be labeled accordingly.
Damaged main bearing bolts and round nuts must be replaced in sets.
en / 31.01.2008 IB020242 1/6

M43
Procedure: 02
1. Install bearing shells.
Note:
The upper bearing shell is equipped with a
lubrication groove and oil bore.
1.1 Oil the running surface of the upper bea-

ring shell thoroughly, dry the back of the
bearing and turn the bearing shell into the
bearing as far as possible. Place the carri-
er (W11) into the oil bore until it stops.
Attention:
Bearing shell designation on the opposite (control) side.
1.2 Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly at
the side. Raise the rig (W10) carefully until it stops at the bearing shell. Lock the turning mecha-
nism in place by hand with the round nuts (12). Lower the mechanism (W10) so that the bearing
cap can be turned as needed.
12
W10
en / 31.01.2008 IB020242 2/6

M43
1.3 Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The posi- 02
tioning nose must slide into the guide groove in the bearing seat.
1.4 Raise the rig (W10), remove the round nuts (12). Lower the rig (W10) again and remove the carri-
er (W11) and the turning unit (W12).
1.5 Oil the running surface of the lower bearing shell, dry the back of the bearing and insert in main
bearing cover. Raise the rig again.
Attention:
The positioning nose on the lower shell is on the control side.
2. Pre-install main bearing bolts.
2.1 Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the main
bearing bolts.
2.2 Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.
2.3 Remove bearing cap mounts on plate.
Note:
Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn).
2.4 Lower the rig (W10).
3. Remove the lateral uniform strength bolts.
3.1 Apply Molykote to the uniform strength bolts, screw in the bolts and tighten to
M = 200 Nm
3.2 Screw the round nuts (23) onto the uniform strength bolts
and tighten by hand.
3.3 Place the hydraulic clamping elements (W4) over the round
nuts (23) on the operating side and tighten by hand. Make
sure that the slits (13) are easily accessible.
3.4 Connect the hydraulic clamping elements on the operating

side to the high pressure pump (W1) by means of the high
pressure line (W2).
en / 31.01.2008 IB020242 3/6

M43
3.5 Close the valve on the high pressure pump and extend the uniform strength bolts with a pressure 02
of
p = 380 bar
Attention:
The pressure must remain constant when the hydraulic pump is not being actuated to pre-
vent the bolts from being tightened incorrectly!
3.6 Tighten the round nut (23) with a pin.
3.7 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.8 Remove hydraulic clamping elements (W4).
3.9 Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump
(W1) by means of the high pressure line (W2).
3.10 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of
p = 2250 bar
Attention:

• The round nut must be tight enough that it cannot be loosened with a pin.
3.14 Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.15 Repeat installation steps 3.8 to 3.14 on the operating side.
3.16 Tighten the round nuts (23) on the lateral uniform strength bolts on the neighboring
bearing(s) with the hydraulic rig, see steps 3.2 to 3.13.
3.17 Screw the protective caps onto the uniform strength bolts.
4. Tightening the main bearing bolts.
4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
en / 31.01.2008 IB020242 4/6

M43
02
13
W5
10
23
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.
4.3 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten.
12
W5
13
W10
en / 31.01.2008 IB020242 5/6

M43
4.4 Repeat the installation procedure on the opposite side. 02

4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of
p = 2250 bar
Attention:
4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).

4.9 Open the valve on the high pressure pump (W1), the clamping elements are depressurized.
4.10 Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5).
4.11 Lower the rig until it reaches the lower stop.
4.12 Remove the rig (W10).

The rig is dismantled in the reverse order as installation
(see 02.05.01.nn).
4.13 Check engine oil flow.
4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
en / 31.01.2008 IB020242 6/6

M43
See also: 02.05.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W11 see maintenance sheet A5.05.02.05.01.nn

* no picture
CAUTION
CAUTION
NOTE
The bearing covers and bearing shares are numbered consecutively on the control
en / 28.04.2011 IB024459 1/6

M43
Procedure: 02
NOTE
The upper bearing shell is
equipped with a lubrication
groove and oil bore.

NOTE
12
W10
en / 28.04.2011 IB024459 2/6

M43
NOTE
bearing bolts.
NOTE
Measure the gap “K“ after installing the bearing shells (see A5.05.02.05.01.nn).
3. Remove the lateral uniform strength bolts.
3.1 Apply Molykote to the uniform strength bolts, screw in the

bolts and tighten to
M = 200 Nm
3.2 Screw the round nuts (23) onto the uniform strength bolts
and tighten by hand.

pressure line (W2).
en / 28.04.2011 IB024459 3/6

M43
3.5 Close the valve on the high pressure pump and extend the uniform strength bolts with a pressure 02
of
p = 380 bar
CAUTION
The pressure must remain constant when the hydraulic pump is not being actuated to
prevent the bolts from being tightened incorrectly!
p = 2250 bar
CAUTION

3.16 Tighten the round nuts (23) on the lateral uniform strength bolts on the neighboring
bearing(s) with the hydraulic rig, see steps 3.2 to 3.13.
arm.
en / 28.04.2011 IB024459 4/6

M43
02
13
W5
10
23
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.
12
W5
13
W10
en / 28.04.2011 IB024459 5/6

M43
4.4 Repeat the installation procedure on the opposite side. 02

p = 2250 bar
CAUTION


(see A5.05.02.05.01.nn).
en / 28.04.2011 IB024459 6/6

Main Thrust Bearings A5.05. 02.05.05.00
M43
30000
See also: 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Main thrust bearings every 30,000 h
Tools:
Pin W3

Rig W10 439214 A
Lashing eye M20 W12
Attention:
~ Attention!
Note:
The main thrust bearing consists of the first main bearing (coupling side) and four thrust washer
segments which limit the axial clearance of the crankshaft.
Both lower thrust washer segments are fixed in the main bearing cover with dowel pins and the
two upper thrust washer segments are slid into grooves in the crankcase housing.
The bearing covers and bearing shells of the main bearings are numbered on the control side and
may not be exchanged. New parts must be labeled accordingly.
en / 21.04.2004 IB020250 1/9

M43
30000
The 1st main bearing must be removed, inspected and measured before the lapse of the indica- 02
ted intervals when:
Procedure:
1. Measure axial clearance “s“.
1.1 Open the cover under the gear drive and the first coupling side crankcase cover on the control
and exhaust sides.
1.2 Place a dial gauge on the flywheel with a magnetic retainer and place against crankcase.
1.3 Slide the crankshaft with a suitable hydraulic unit until it rests firmly against the thrust washer seg-
ments.
Set the dial gauge to “zero“ and slide the

crankshaft in the opposite direction, read the
axial clearance “s“ on the dial gauge.
1.4 Axial clearance “s“:
s = s1 + s2

mm mm
0.4 - 0-7 1.0
If the tolerance limit is exceeded, replace

the thrust washer segments and bearing
shells in pairs, see main thrust bearing
removal procedure.
Attention:
Label all thrust washer segments before
removal for inspection and measure-
ment to prevent them from being ex-
changed.
Thrust washer segments must be rein-
stalled immediately after measurement
and inspection!
en / 21.04.2004 IB020250 2/9

M43
30000
2. Removing main thrust bearing. 02

2.1 Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC.

(W2).
p = 2250 bar
2.2.5 Loosen the round nut with a pin. Turn the round nut back 10
holes.
Note:
increased to
p = 50 bar
more. If the pressure is increased further, the threading may stretch, which can cause the round
nut to lock into place!
en / 21.04.2004 IB020250 3/9

M43
30000
2.3 Insert rig. 02

carrier arm.
W10
2.3.2 Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means of the
14
W10
en / 21.04.2004 IB020250 4/9

M43
30000
2.3.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying 02
arm.
W5
10
23
2.3.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.
Note:
chute.
12
13
W5
W10
en / 21.04.2004 IB020250 5/9

M43
30000
2.3.7 Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of 02
the high pressure lines (W2).
re of
p = 2250 bar
2.3.9 Loosen the round nuts (12) with a pin. Turn the round nuts back 10 holes.
Note:
be increased to
p = 50 bar
more. If the pressure is increased further, the threading may stretch, which can cause the round
nuts to lock into place!
rized.
2.5 Wait until the pressure drops completely. Remove the hydraulic clamping elements.
2.6 Remove the clamping element support disk (14) from the carrying arm.
15
W10
2.7 Measure the gap, see step 3.
en / 21.04.2004 IB020250 6/9

M43
30000
W10
W2
2.9 Lower the carrying arm with main bearing cover and bottom bearing shell carefully as far as pos-
sible.
2.10 Screw the lashing eyes (W12) into the bearing cover.
W12
en / 21.04.2004 IB020250 7/9

M43
30000
2.11 Secure the bearing cover to the hoists on both sides (exhaust gas side and camshaft side). Ten- 02
sion the slings evenly.
2.12 Separate the carrying arm of the device (W10) from the bearing cover.
2.13 Shift the device (W10) towards cyl. 1, so that there is sufficient clearance below the bearing co-
ver.
2.14 Evenly lower the bearing cover by another 100 mm on both sides by means of the hoists.
2.15 Remove both lower thrust bearing seg-

ments (1) and replace them if there is a
high degree of axial clearance, see step 1.
Only remove the upper thrust washer seg-
ments if they need to be replaced.

2.18 Turn the upper bearing shell and

remove.
Attention:
Do not turn until the rig is lowered com-
pletely to the lower stop!
2.19 Inspect and evaluate the bearing shells, see 02.03..03.nn and 02.03..07.nn.

main wear zone with a micrometer at the

Attention:
checked.
en / 21.04.2004 IB020250 8/9

M43
30000
3. Measure the gap. 02

3.1 Loosen both round nuts (12) hydraulically. Lower the rig (see step 2.3).
3.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch.
3.3 Measure the gap “K“ between the crankcase and main bearing cover on the exhaust and control
side with a feeler gauge and add both values.
K = KA + KS

mm mm
1.4 - 1.65 1.2
en / 21.04.2004 IB020250 9/9

M43
30000
See also: 02.03.03.nn, 02.03.07.nn, 14.04.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Main thrust bearings every 30,000 h
Tools:
Pin W3
High pressure line W6* 433420 E

Rig W10 439214 A
Lashing eye M20 W12
* no picture
CAUTION
CAUTION
en / 28.04.2011 IB024463 1/9

M43
30000
02
NOTE
The main thrust bearing consists of the first main bearing (coupling side) and four
thrust washer segments which limit the axial clearance of the crankshaft.
Both lower thrust washer segments are fixed in the main bearing cover with dowel
pins and the two upper thrust washer segments are slid into grooves in the crankca-
se housing.
The bearing covers and bearing shells of the main bearings are numbered on the
control side and may not be exchanged. New parts must be labeled accordingly.
The 1st main bearing must be removed, inspected and measured before the lapse of
the indicated intervals when:
Procedure:
1. Measure axial clearance “s“.
1.1 Open the cover under the gear drive and the first
coupling side crankcase cover on the control and
exhaust sides.
1.2 Place a dial gauge on the flywheel with a magne-

tic retainer and place against crankcase.
1.3 Slide the crankshaft with a suitable hydraulic unit

until it rests firmly against the thrust washer seg-
ments.
1.4 Set the dial gauge to “zero“ and slide the cranks-
haft in the opposite direction, read the axial clea-
rance “s“ on the dial gauge.
1.5 Axial clearance “s“:
s = s1 + s2

mm mm
0.4 - 0-7 1.0
If the tolerance limit is exceeded, replace the thrust washer segments and bearing shells in
pairs, see main thrust bearing removal procedure.
en / 28.04.2011 IB024463 2/9

M43
30000
02
CAUTION
Label all thrust washer segments before removal for inspection and measurement to
prevent them from being exchanged.
Thrust washer segments must be reinstalled immediately after measurement and
inspection!
2. Removing main thrust bearing.
2.1 Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC.

(W2).
p = 2250 bar
2.2.5 Loosen the round nut with a pin. Turn the round nut back 10
holes.
NOTE
If the round nut cannot be loosened with the pin, the pressure on the uniform strength
bolt can be increased to p = 50 bar more. If the pressure is increased further, the
threading may stretch, which can cause the round nut to lock into place!
en / 28.04.2011 IB024463 3/9

M43
30000
2.3 Insert rig. 02

carrier arm.
W10
2.3.2 Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means of the
14
W10
en / 28.04.2011 IB024463 4/9

M43
30000
2.3.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying 02
arm.
W5
10
23
2.3.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.
chute.
12
13
W5
W10
en / 28.04.2011 IB024463 5/9

M43
30000
2.3.7 Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of 02
the high pressure lines (W2, W6).
re of
p = 2250 bar
2.3.9 Loosen the round nuts (12) with a pin. Turn the round nuts back 10 holes.
NOTE
If the round nuts cannot be loosened with the pin, the pressure on the uniform
strength bolts can be increased to p = 50 bar more. If the pressure is increased fur-
ther, the threading may stretch, which can cause the round nuts to lock into place!
rized.
2.5 Wait until the pressure drops completely. Remove the hydraulic clamping elements.
2.6 Remove the clamping element support disk (14) from the carrying arm.
15
W10
2.7 Measure the gap, see step 3.
en / 28.04.2011 IB024463 6/9

M43
30000
W10
W2
2.9 Lower the carrying arm with main bearing cover and bottom bearing shell carefully as far as pos-
sible.
2.10 Screw the lashing eyes (W12) into the bearing cover.
W12
en / 28.04.2011 IB024463 7/9

M43
30000
2.11 Secure the bearing cover to the hoists on both sides (exhaust gas side and camshaft side). Ten- 02
sion the slings evenly.
2.12 Separate the carrying arm of the device (W10) from the bearing cover.
2.13 Shift the device (W10) towards cyl. 1, so that there is sufficient clearance below the bearing co-
ver.
2.14 Evenly lower the bearing cover by another 100 mm on both sides by means of the hoists.
2.15 Remove both lower thrust bearing seg-

ments (1) and replace them if there is a
high degree of axial clearance, see step 1.
Only remove the upper thrust washer seg-
ments if they need to be replaced.

CAUTION
Do not turn until the rig is lowered
completely to the lower stop!
2.19 Inspect and evaluate the bearing shells, see A5.05.02.03..03.nn and A5.05.02.03..07.nn.

main wear zone with a micrometer at the

CAUTION
If measurements indicate that the
bearing shells need to be
replaced, the neighboring
bearings must also be checked.
en / 28.04.2011 IB024463 8/9

M43
30000
3. Measure the gap. 02

3.1 Loosen both round nuts (12) hydraulically. Lower the rig (see step 2.3).
3.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch.
3.3 Measure the gap “K“ between the crankcase and main bearing cover on the exhaust and control
side with a feeler gauge and add both values.
K = KA + KS

mm mm
1.4 - 1.65 1.2
en / 28.04.2011 IB024463 9/9

M43
See also: 02.05.05.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W12 see maintenance sheet 02.05.05.nn
Attention:
~ Attention!
Note:
The bearing covers and bearing shares are numbered consecutively on the control side
from the coupling forward according to their respective cylinder and may not be ex-
changed. New parts must be labeled accordingly.
en / 30.01.2008 IB020822 1/7

M43
Procedure: 02
Note:
The upper bearing shell is equipped with a
lubrication groove and oil bore. Insert up-
per thrust washer segments if removed.

Attention:
12
W10
en / 30.01.2008 IB020822 2/7

M43
Attention:
1.6 Place the lower thrust washer segments (1; only on main thrust bearings ) on the dowel pins (2) if
removed.
bearing bolts.
en / 30.01.2008 IB020822 3/7

M43
Note: 02
Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn).
After replacing the bearing shells or the thrust washer segments the axial clearance must also be
measured (see 02.05.01.nn).
3. Tighten the lateral round nuts of the adjacent bearing .
3.1 Screw the round nuts (23) of the adjacent bearing onto the
uniform strength bolts and tighten by hand.

pressure line (W2).
3.4 Close the valve on the high pressure pump and extend the
uniform strength bolts with a pressure of
p = 380 bar
Attention:
The pressure must remain constant when the hydraulic
pump is not being actuated to prevent the bolts from
being tightened incorrectly!
p = 2250 bar
en / 30.01.2008 IB020822 4/7

M43
02
Attention:

arm.
13
W5
10
23
en / 30.01.2008 IB020822 5/7

M43
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute. 02
12
W5
13
W10
4.4 Repeat the installation procedure on the opposite side.
p = 2250 bar
en / 30.01.2008 IB020822 6/7

M43
02
Attention:


(see 02.05.01.nn).
en / 30.01.2008 IB020822 7/7

M43
See also: 02.05.05.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W12 see maintenance sheet A5.05.02.05.05.nn
CAUTION
CAUTION
NOTE
The bearing covers and bearing shares are numbered consecutively on the control
en / 06.04.2010 IB024467 1/7

M43
Procedure: 02
NOTE
The upper bearing shell is equipped
with a lubrication groove and oil bore.
Insert upper thrust washer segments if
removed.

NOTE
12
W10
en / 06.04.2010 IB024467 2/7

M43
NOTE
1.6 Place the lower thrust washer segments (1; only on main thrust bearings ) on the dowel pins (2) if
removed.
bearing bolts.
en / 06.04.2010 IB024467 3/7

M43
02
NOTE
Measure the gap “K“ after installing the bearing shells (see A5.05.02.05.01.nn).
After replacing the bearing shells or the thrust washer segments the axial clearance
must also be measured (seeA5.05. 02.05.01.nn).
3. Tighten the lateral round nuts of the adjacent bearing .
3.1 Screw the round nuts (23) of the adjacent bearing onto the
uniform strength bolts and tighten by hand.

pressure line (W2).
3.4 Close the valve on the high pressure pump and extend the
uniform strength bolts with a pressure of
p = 380 bar
CAUTION
The pressure must remain constant when the hydraulic pump is not being actuated
to prevent the bolts from being tightened incorrectly!
p = 2250 bar
CAUTION
en / 06.04.2010 IB024467 4/7

M43
3.10 Tighten the round nut (23) with a pin. 02


arm.
13
W5
10
23
en / 06.04.2010 IB024467 5/7

M43
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute. 02
12
W5
13
W10
4.4 Repeat the installation procedure on the opposite side.
p = 2250 bar
NOTE
en / 06.04.2010 IB024467 6/7

M43
4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness). 02


(see A5.05.02.05.01.nn).
en / 06.04.2010 IB024467 7/7

Piston A5.05. 02.06.01.00
M43
See also: 01.06.01.nn, 02.07.01.nn, 03.04.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston lifting unit W1 439223 A

Hydraulic wrench consisting of
Hydraulic wrench W5 435100 A
Sockets W6 435102 A
Spud W7 435100 B
Piston rod holder W8 439228 B
Cylinder liner retainer W9 439217 B
Disassembly unit for gauging ring W10 439216 B
Note:
In order to prevent the cylinder liner from loosening during turning, the cylinder liner must be held
in place with the cylinder liner retainer (Fig. Y/W9).
en / 16.04.2004 IB020138 1/5

Piston A5.05. 02.06.01.00
M43
Procedure: 02
1. Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides.
2. Turn crank journal ca. 20° to the control side from TDC.
3. Remove cylinder head (01.06.01.nn).
4. Place cylinder liner retainer (Fig. Y/W9) on

coolant distributor housing (1). Tighten the
round nut (5) by hand. Tighten the adju-
sting bolts (6) on the cylinder liner retainer
against the cylinder liner (3) by hand.
5. Clean carbon deposits from the area above

TDC for 1st piston ring up to gauging ring.
Do not damage the cylinder liner surface.
6. Turn the upper piston edge up to just below

the gauging ring (Fig. 2/4).
7. Insert disassembly unit (W10) so that the

recess is inside the gauging ring.
8. Tighten the disassembly unit slightly by

turning the spindle nut.
9. Press out and remove the gauging ring by

turning the engine to raise the piston.
10. Remove disassembly unit.
11. Rethread the threaded holes (Fig. Z/2;

M16, 15 mm deep) in the piston crown.
12. Bolt the piston lifting unit (W1) onto the

piston crown.
13. Connect the crane to the eye of the lifting

unit, turn the piston to TDC together with
the crane.
Attention:
The crane and lifting eye must remain connected!
en / 16.04.2004 IB020138 2/5

Piston A5.05. 02.06.01.00
M43
14. Split the connecting rod shank. 02

14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5).
Mount the support (Fig. 4/W7) on the hydraulic wrench.
en / 16.04.2004 IB020138 3/5

Piston A5.05. 02.06.01.00
M43
02
Attention:
Note the direction of rotation, relocate the socket wrench with square head if necessary
and turn the hydraulic wrench.
14.2 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres-
sure lines (W4).
14.3 Place hydraulic wrench with socket wrench (W6) on the uniform strength bolt (20). Prop the
wrench on the connecting rod (22) or counterweight (30).
Attention:
The engine may not be turned when the hydraulic wrench is connected.
~ Safety note:
During pressure build-up no parts of the body between support of the hydraulic wrench
and connecting rod or balance weight.
14.4 Close the valve (Fig. 3/24) on the high pressure pump (W3) and (W3) and loosen the uniform
strength bolts one after another with a pressure of
p = 400 bar + 25 bar
It may be necessary to move the cylinder of the wrench back and forth several times by releasing
pressure [by opening the valve (24) and closing the valve (24) and pumping to build up pressure].
Attention:
Hold the hydraulic wrench securely when reducing pressure. (The wrench may slip from
the head of the bolt).
15. Remove the uniform strength bolts (20) with the segments (21).
16. Open the valve (24) on the high pressure pump (W3). Wait until the pressure abates completely.
Remove the hydraulic wrench (W5) with the socket wrench (W6).
17. Mount the connecting rod holder (W8) on the counterweight to secure the connecting rod (22).
18. Pull the piston carefully and place on a suitable surface.
en / 16.04.2004 IB020138 4/5

Piston A5.05. 02.06.01.00
M43
02
Attention:
Remove the big end if the piston will be stored for a longer period of time to prevent vibra-
tion damage in the cylinder liner area.
19. Seal off the oil bore in the connecting rod shank split with a protective cap.
en / 16.04.2004 IB020138 5/5

Piston A5.05. 02.06.01.05
M43
See also: 01.06.01.nn, 02.07.01.nn, 03.04.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:

Sockets W6 435102 A
Spud W7 435100 B
Note:
In order to prevent the cylinder liner from loosening during turning, the cylinder liner must be held
in place with the cylinder liner retainer (Fig. Y/W9).
en / 28.08.2007 IB025696 1/5

Piston A5.05. 02.06.01.05
M43
Procedure: 02
3. Remove cylinder head (01.06.01.nn).
4. Place cylinder liner retainer (Fig. Y/W9) on

coolant distributor housing (1). Tighten the





11. Rethread the threaded holes (Fig. Z/2;

M16, 15 mm deep) in the piston crown.

piston crown.

the crane.
Attention:
en / 28.08.2007 IB025696 2/5

Piston A5.05. 02.06.01.05
M43

14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5).
Mount the support (Fig. 4/W7) on the hydraulic wrench.
en / 28.08.2007 IB025696 3/5

Piston A5.05. 02.06.01.05
M43
02
Attention:
sure lines (W4).
Attention:
~ Safety note:
14.4 Close the valve (Fig. 3/24) on the high pressure pump (W3) and (W3) and loosen the uniform
strength bolts one after another with a pressure of
p = 400 bar + 25 bar
pressure [by opening the valve (24) and closing the valve (24) and pumping to build up pressure].
Attention:
Hold the hydraulic wrench securely when reducing pressure. (The wrench may slip from
the head of the bolt).
15. Remove the uniform strength bolts (20) with the segments (21).
16. Open the valve (24) on the high pressure pump (W3). Wait until the pressure abates completely.
Remove the hydraulic wrench (W5) with the socket wrench (W6).
19. Mind the intermediate plate between small end and connecting rod..
en / 28.08.2007 IB025696 4/5

Piston A5.05. 02.06.01.05
M43
02
Attention:
Remove the big end if the piston will be stored for a longer period of time to prevent vibra-
tion damage in the cylinder liner area.
en / 28.08.2007 IB025696 5/5

Piston A5.05. 02.06.01.30
M43
See also: 01.06.01.nn, 02.07.01.nn, 03.04.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sockets W6 435102 A
Spud W7 435100 B
NOTE
In order to prevent the cylinder liner from loosening during turning, the cylinder liner
must be held in place with the cylinder liner retainer (Fig. 1/W9).
en / 25.05.2011 IB024471 1/5

Piston A5.05. 02.06.01.30
M43
Procedure: 02
3. Remove cylinder head (A5.05.01.06.01.nn).
4. Place cylinder liner retainer (W9) on coo-

lant distributor housing (1). Tighten the





11. Rethread the threaded holes

(2; M16, 15 mm deep) in the piston crown.

piston crown.

the crane.
NOTE
en / 25.05.2011 IB024471 2/5

Piston A5.05. 02.06.01.30
M43

14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount the
support (Fig. 4/W7) on the hydraulic wrench.
en / 25.05.2011 IB024471 3/5

Piston A5.05. 02.06.01.30
M43
02
CAUTION
In order to avoid damages to the hydraulic wrench (W5), adjust a maximum pressure
of p = 425 bar on the high-pressure pump. Adjustment instructions see
A6.05.90.10.nn .
Note the direction of rotation, relocate the socket wrench with square head if neces-
sary and turn the hydraulic wrench.
sure lines (W4). Secure the coupling that is not connected by means of plug.
CAUTION
WARNING
During pressure build-up no parts of the body between support of the hydraulic
wrench and connecting rod or balance weight.
14.4 Close the valve on the high pressure pump (W3) and loosen the uniform strength bolts one after
another with a pressure of
p = 400 bar + 25 bar
pressure [by opening the valve and closing the valve and pumping to build up pressure].
CAUTION
Hold the hydraulic wrench securely when reducing pressure. (The wrench may slip
from the head of the bolt).
en / 25.05.2011 IB024471 4/5

Piston A5.05. 02.06.01.30
M43
15. Remove the uniform strength bolts (20) with the segments (21). 02
16. Open the valve on the high pressure pump (W3). Wait until the pressure abates completely. Re-
move the hydraulic wrench (W5) with the socket wrench (W6).
CAUTION
Remove the big end if the piston will be stored for a longer period of time to prevent
vibration damage in the cylinder liner area.
en / 25.05.2011 IB024471 5/5

Piston A5.05. 02.06.01.35
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sockets W6 435102 A
Spud W7 435100 B
NOTE
In order to prevent the cylinder liner from loosening during turning, the cylinder liner
must be held in place with the cylinder liner retainer (Fig. 1/W9).
en / 25.05.2011 IB025777 1/5

Piston A5.05. 02.06.01.35
M43
Procedure: 02
3. Remove cylinder head (A5.05.01.06.01.nn).
4. Place cylinder liner retainer (W9) on coo-

lant distributor housing (1). Tighten the





11. Rethread the threaded holes

(2; M16, 15 mm deep) in the piston crown.

piston crown.

the crane.
NOTE
en / 25.05.2011 IB025777 2/5

Piston A5.05. 02.06.01.35
M43

14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount the
support (Fig. 4/W7) on the hydraulic wrench.
en / 25.05.2011 IB025777 3/5

Piston A5.05. 02.06.01.35
M43
02
CAUTION
A6.05.90.10.nn .
CAUTION
WARNING
14.4 Close the valve on the high pressure pump (W3) and loosen the uniform strength bolts one after
another with a pressure of
p = 400 bar + 25 bar
pressure [by opening the valve and closing the valve and pumping to build up pressure].
CAUTION
Hold the hydraulic wrench securely when reducing pressure. (The wrench may slip
from the head of the bolt).
en / 25.05.2011 IB025777 4/5

Piston A5.05. 02.06.01.35
M43
15. Remove the uniform strength bolts (20) with the segments (21). 02
16. Open the valve on the high pressure pump (W3). Wait until the pressure abates completely. Re-
move the hydraulic wrench (W5) with the socket wrench (W6).
19. Mind the intermediate plate between small end and connecting rod.
CAUTION
Remove the big end if the piston will be stored for a longer period of time to prevent
vibration damage in the cylinder liner area.
en / 25.05.2011 IB025777 5/5

Piston Crown A5.05. 02.06.02.03
M43
See also: 02.06.01.nn, 02.07.01.nn, 02.08.01.nn 02

Personnel qualification: Cat/MaK-specialist

----------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston lifting unit (piston crown) W1 439223 A
Piston lifting unit (big end) W2 439223 A
* no picture
Molykote Paste “G-n plus” **
Procedure:
1. Turn the piston
1.1 Attach crane to piston lifting unit

(Fig. 1/W1) , lift piston.
1.2 Mount second piston lifting unit (W2) on

the big end (1) and attach second crane or
sling.
1.3 Turn the piston carefully and place on sui-

table surface.
2. Dismantling the piston crown
Note:
The piston crown should only be repla-
ced by the CAT Customer Service.
2.1 Connect piston lifting unit (W1) to crane,

remove piston pin (2) (02.08.01.nn).
2.2 Measure piston pin bearing (3)

(02.09.01.nn) and evaluate if necessary
(02.03.03.nn).
en / 30.04.2008 IB024879 1/5

Piston Crown A5.05. 02.06.02.03
M43
2.3 Loosen the piston screws (Fig. 3/5) and remove with piston skirt (12). 02
2.4 Clean piston crown (8) and piston skirt (12). Make sure that the contact surfaces of piston parts
and spacer sleeves (6) are clean.
Attention:
Check the contact surfaces for friction marks / cold welding (Fig. 2/Z), if necessary consult
the CAT Customer Service!
en / 30.04.2008 IB024879 2/5

Piston Crown A5.05. 02.06.02.03
M43
2.5 Clean and inspect the oil bores in the piston skirt (Fig. 3/12). 02
2.6 Piston assembly
~ It is imperative for piston assembly to use only new piston srews (5) and new
spacer sleeves (6)!
2.7 Clean the contact surfaces of piston skirt (12) and piston crown (8) and check for unevenness.
Carefully smooth out any raised spots with oil stone.
2.8 Clean bores for piston screws (5) and contact surfaces for spacer sleeves (6) in the piston skirt
(12).
en / 30.04.2008 IB024879 3/5

Piston Crown A5.05. 02.06.02.03
M43
2.9 Clean the 4 threaded holes in the piston crown (8). Turn tap drill M20x1,5 in until reaching the root 02
of the thread. After that clean again. By means of a limit plug gauge check for
35 mm thread depth (from main contact surface).
2.10 Insert new O ring (13) untwisted into groove.
2.11 Put on piton skirt (12), fixation hole and spring dowel pin (11) must match.
2.12 Lubricate new spacer sleeves (6) with Molykote paste “G-n plus“ on recess side and insert into
the screw bore of the piston crown (8) with recess up.
2.13 Lubricate thread and head contact surface of new piston pins (5) with Molykote paste
“G-n plus“ and screw by hand.
2.14 Tighten piston screws (5) crosswise to a torque of
M = 20 Nm.
Measure recession (Fig. 6/X) of the screw heads with regard to the lowest bolt bore contour.
X = 8 mm ± 1,5 mm
(Check whether all spacer sleeves (Fig. 3/6) have been inserted with recess up.)
M = 140 Nm.
2.16 Loosen piston screws (5) again crosswise.
2.17 Check clearance (Fig. 4/s) with non

tightened piston screws (5).
Clearance new: s = 0,24 - 0,28 mm
Clearance limit: s = 0,6 mm
2.18 Pretighten piston screws (Fig. 6/5) crosswise to

a torque of
M = 40 Nm.
en / 30.04.2008 IB024879 4/5

Piston Crown A5.05. 02.06.02.03
M43
2.19 Mark screw head (Fig. 5) 02

2.20 Continue tightening by
α = 120 ° (2 hexagon corners).
Α
α
2.21 Check by a second person:
Check visibly that the piston screw turned further by 2 hexagon corners.
When applying a torque of
M = 115 Nm
the piston screws must not turn any more in tightening direction!
en / 30.04.2008 IB024879 5/5

Piston Crown A5.05. 02.06.02.04
M43/VM43
See also: 02.06.01.nn, 02.07.01.nn, 02.08.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston lifting unit (piston crown) W1 439223 A
Piston lifting unit (big end) W2 439223 A
* no picture
Molykote Paste “G-n plus” **
Procedure:
1. Turn the piston
1.1 Attach crane to piston lifting unit

(Fig. 1/W1) , lift piston.
1.2 Mount second piston lifting unit (W2) on

the big end (1) and attach second crane or
sling.
1.3 Turn the piston carefully and place on sui-

table surface.
2. Dismantling the piston crown
NOTE
The piston crown should only be
replaced by the CAT Customer
Service.
2.1 Connect piston lifting unit (W1) to crane,

remove piston pin (2)
(A5.05.02.08.01.nn).
2.2 Measure piston pin bearing (3)

(A5.05.02.09.01.nn) and evaluate if ne-
cessary (A5.05.02.03.03.nn).
en / 28.04.2011 IB025184 1/4

Piston Crown A5.05. 02.06.02.04
M43/VM43
2.3 Loosen the hexagon nuts (Fig. 3/5) and remove with piston skirt (12). 02
Clean piston crown (8) and piston skirt (12). Make sure that the contact surfaces of piston parts and spacer
sleeves (6) are clean.
NOTE
Check the contact surfaces for friction marks / cold welding (Fig. 2/Z), if necessary
consult the CAT Customer Service!
z 2
en / 28.04.2011 IB025184 2/4

Piston Crown A5.05. 02.06.02.04
M43/VM43
2.4 Clean and inspect the oil bores in the piston skirt (Fig. 3/12). 02
2.5 Piston assembly
2.6 Clean the contact surfaces of piston skirt (12) and piston crown (8) and check for unevenness.
Carefully smooth out any raised spots with oil stone.
2.7 Clean bores for piston screws (7) and contact surfaces for spacer sleeves (6) in the piston skirt
(12).
2.8 Screw piston screws (if removed) into piston crown and tighten to a torque of
M = 40 Nm
en / 28.04.2011 IB025184 3/4

Piston Crown A5.05. 02.06.02.04
M43/VM43
2.9 Insert new O-ring (13) untwisted into groove. 02

2.10 Put on piston skirt (12), fixation hole and spring dowel pin (11) must match.
2.11 Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste.
M = 170 Nm.
2.13 Loosen hexagon nuts again.
2.14 Retighten piston screws (7) in the piston crown, torque:
M = 40 Nm
2.15 Tighten hexagon nuts (5) crosswise to a torque of
M = 60 Nm
and then continue tightening crosswise by
120°°.
2.16 Check:
At a torque of M = 115 Nm
the hexagon nuts must not turn any further!
2.17 Check by second person:
Carry out a visual check to confirm if the hexagon nuts have been turned further by
2 hexagon corners.
At a torque of
M = 115 Nm
the hexagon nuts must not turn any further in tightening direction!
en / 28.04.2011 IB025184 4/4

Piston Crown A5.05. 02.06.02.30
M43/VM43
See also: 02.06.01.nn, 02.07.01.nn, 02.08.01.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
High-pressure pump W1*
High-pressure hose W2*
Hydr. element W3 0.9213 C
Threaded sleeve W4 0.9203-106
Spindle W5 436103-002
Auxiliary tube for tightening nuts W6 436103-003
Pressure pipe W7 436103-001
Lifting gear for piston (piston crown) W8 432134 A
Lifting gear for piston (small end) W9 432134 A
Adapter W11* 0.6016-250
Pin W12* 0.9203-110
Socket W13* 1.9024-041
Converter for sockets W14* 1.9023-017
Extension W15* 1.9100-127
Reversible ratchet W16* 1.9459-033
* no picture
CAUTION
Hydraulic hoses may not be bent below a min. bending radius of r = 250 mm. As oper-
ating medium use exclusively hydraulic oil. Store the devices protected against corro-
sion.
en / 09.05.2011 IB024479 1/6

Piston Crown A5.05. 02.06.02.30
M43/VM43
Procedure: 02
1. Turn the piston.
1.1 Attach crane to lifting gear for piston

(Fig. 1/W8), lift piston.
1.2 Mount second lifting gear for piston (W9)

on small end (1) and attach to second cra-
ne or sling.
1.3 Carefully turn the piston and place on a

suitable surface.
en / 09.05.2011 IB024479 2/6

Piston Crown A5.05. 02.06.02.30
M43/VM43
2. Removal of piston crown. 02

2.1 Remove piston pin (A5.05.02.08.01.nn).
2.2 Measure piston pin bearing (A5.05.02.09.01.nn) and evaluate if necessary (A5.05.02.03.03.nn).
2.3 Loosen piston stud (Fig. 2/2).
2.4 For this purpose mount hydraulic set (Fig. 3).
2.4.1 Screw spindle (W5) into threaded hole of the stud (2).
2.4.2 Put auxiliary tube (W6) over spindle (W5). Make sure that pins slide into the pin bores of round
nut (3).
2.4.3 Put pressure pipe (W7) over auxiliary tube (W6).
2.4.4 Screw hydraulic element (W3) with threaded sleeve (W4) onto thread of spindle (W5) until a step
of
s = 15mm
is reached.
en / 09.05.2011 IB024479 3/6

Piston Crown A5.05. 02.06.02.30
M43/VM43
02
CAUTION
To avoid damages to piston stud and thread, adjust a maximum pressure of p = 640
bar on the high-pressure pump.
For adjustment instructions please refer to A6.05.90.10.00 chapter 3.2.4 .
2.5 Connect hydraulic element via high-pressure pipe (W2) and adapter (W11) with high-pressure
pump (W1). Secure the coupling that is not connected by means of plug.
2.6 Close valve on high-pressure pump (W1) and stretch piston bolt (2) with a hydraulic pressure of
p = 610 bar + 20 bar.
W4
s W3
W7
W5
W6
3
4
6
2
en / 09.05.2011 IB024479 4/6

Piston Crown A5.05. 02.06.02.30
M43/VM43
2.7 Loosen nut (3) by turning the auxiliary tube (W6) with pin. Turn back nut by 6 flank pitches. 02
2.8 Relive hydraulic element and remove complete tightening tool.
2.9 Remove nut (3) with thrust piece (4) and piston stud (2).
2.10 Clean piston crown and skirt. Make sure the contact faces of the piston components are clean.
CAUTION
Check contact faces for traces of friction and cold welding, if necessary consult the
Cat customer service.
2.11 Clean and check oil holes on piston crown.
3. Assembly of piston crown.
3.1 Lubricate thread and nut contact face with oil.
3.2 Put piston skirt (5) onto piston crown (6), fixation bore and spring dowel pin (7) must match.
NOTE
In case of reassembly of the piston stud measure stud length!
Replace stud if its length exceeds 218 mm.
3.3 Mount piston bolt and tighten to a torque of
M = 20 Nm.
3.4 Mount thrust piece (4) and nut (3). Turn nut by hand until it fits closely on the thrust piece.
Document bolt projection (Fig. 2/Z).
3.5 Mount hydraulic set (2.4 to 2.5).
3.6 Close valve on high-pressure pump (Fig. 3/W1) and stretch piston bolt (2) with a hydraulic pres-
sure of
p = 610 bar + 20 bar.
3.7 Tighten nut (3) by turning the auxiliary tube (W6) with pin. Document the number of flank pitches
by which nut was turned (200° angle = 5 flank pitches). In case of more than 6 flank pitches
repeat assembly.
3.8 Relive hydraulic element.
en / 09.05.2011 IB024479 5/6

Piston Crown A5.05. 02.06.02.30
M43/VM43
3.9 Close valve on high-pressure pump (W1) and stretch piston stud (2) with a hydraulic pressure of 02
p = 620 bar + 20 bar.
3.10 Loosen nut by the documented number of flank pitches plus 1.
3.11 Relieve hydraulic element. The nut must be free.
3.12 Put nut onto thrust piece.
3.13 Close valve on high-pressure pump and stretch piston stud with a hydraulic pressure of
p = 610 bar + 20 bar.
3.14 Tighten nut (2) by turning the auxiliary tube (W6) with pin. Document the number of flank pitches
by which nut was turned (200° angle = 5 flank pitches). In case of more than 6 flank pitches
repeat assembly.
3.15 Relive hydraulic element and remove complete tightening tool.
3.16 Document bolt projection (Fig. 2/Z). Increased projection height with regard to 3.3
Z = 0,7mm......0,9 mm.
en / 09.05.2011 IB024479 6/6

Piston Rings and Grooves A5.05. 02.07.01.01
M43/VM43
30000, 7500
See also: 02.06.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
one piston and its rings every 7,500 h
Maintenance:
all pistons and piston rings every 30,000 h
Tools:
Piston ring pliers W1 431001 A
NOTE
If the running surfaces of all cylinder liners have no scoring or polished areas and no
other damage and all components of the piston being inspected are in perfect order,
all piston rings loose in the grooves and if all parts have not been worn past the tole-
rance limits, the inspection of all pistons can be postponed to a later point in time if
the mechanic decides to do so; the inspection cannot be postponed for more than
30,000 operating hours. During the inspection, special attention must be paid to the
sharp-edgedness of the rings, ring tension or to any rings which may be stuck due to
carbon deposits.
Do not remove the graphite layer from the piston shaft.
After installing new piston rings, the engine must be broken in in accordance with the
break in procedure, see engine documentation, chapter "Operating Instruc-
tions"!.
Worked pistons with chromed 1st ring grooves may only be re-worked by Caterpillar
certified workshops.
Procedure:
1. Piston inspection (7,500 h)
1.1 Open all crankcase covers.
1.2 Check the running surfaces of all cylinder liners (cylinder liner appearance) from the crankcase.
1.3 Remove the piston with the worst running surface (A5.05.02.06.01.nn). If any piston rings are
stuck or burnt, remove all additional pistons.
en / 09.05.2011 IB020351 1/3

M43/VM43
30000, 7500
1.4 Piston rings may only be removed with the 02

piston ring pliers (Fig. 1/W1) intended for
this purpose. Record the position of the
ring joints relative to the installation positi-
on of the piston in the measurement re-
port.
1.5 Clean the piston rings.
1.6 Check wear in the chrome layer, especially

at the gap and on the opposite side.
If the chrome layer is worn away entirely or
in sections, all rings for the respective pi-
ston must be replaced.
If the chrome layer is worn on one of the

rings, the rings on all pistons must be
checked.
1.7 Clean the pistons, ring grooves and oil drain bores for the wiper ring.
1.8 Smooth light scoring and fretting with a fine emery cloth soaked in oil or a fine carborundum sto-
ne. Replace the piston if there is significant damage or scoring.
1.9 Measure the groove height hN (Fig. 2) in the forward groove area across and along the engine. If
the wear limit has been exceeded, have the ring grooves reworked by Caterpillar Motoren GmbH
& Co. KG.
1.10 Measure the ring height hR (Fig. 2) at four opposing points.
hN1 = Nominal size

hN2 = Wear
en / 09.05.2011 IB020351 2/3

M43/VM43
30000, 7500
1.11 Calculate the clearance limit and check according to the table for standard piston equipment. 02
Piston ring height hR Groove height hN2 Wear limit

Groove Nominal size Wear limit hN2 - hR
mm mm mm
1 10 10.8 0.9
2 10 10.5 0.6
3 10 10.3 0.4
1.12 Insert the rings in the grooves with the

labeling up (Fig. 3/X) and with the ring
gaps alternating to the front and back of
the engine.
2. Maintenance (30,000 h)
2.1 Remove all pistons (A5.05.02.06.01.nn).
2.2 Check the running surface of the piston

and clean the piston.
2.3 Remove the piston rings with the piston

ring pliers (Fig. 1/W1). Record the position
of the ring joints relative to the installation
position of the piston in the measurement
report.
2.4 Clean all rings and check the wear. If the

chrome layer is worn away entirely or in
sections, send the pistons to Caterpillar
Motoren GmbH & Co. KG for repair.
2.5 Measure the groove height hN as defined

in 1.9.
2.6 Replace wiper ring and all compression rings.
2.6.1 Place the rings in the grooves with the labeling (Fig. 3/X) up and with the ring gaps alterna-
ting to the front and back of the engine.
2.7 Install all pistons (A5.05.02.10.01.nn).
en / 09.05.2011 IB020351 3/3

Piston Pin A5.05. 02.08.01.00
M43
See also: 02.06.01.nn, 02.09.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston installation / disassembly unit W1 439223 A
Installation rig W3 439220 C
Procedure:
1. Turn the piston.
1.1 Connect crane to the piston installation unit (W1) and lift the piston.
1.2 Mount second installation unit (W2) on the connecting rod eye (1) and attach second crane or
strap.
1.3 Turn the piston and place on suitable surface.
W2
1
X
X
W3
3
6
2
4 5
W1
en / 29.04.2011 IB020353 1/2

Piston Pin A5.05. 02.08.01.00
M43
2. Disassembly 02
2.1 Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re-in-
stallation.
2.2 Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin.
2.3 Remove the circlips (4).
2.4 Remove the piston pin (3) from the piston bore and piston pin bush without applying excessive
force until the second oil bore is visible. Mount the rig (W3) and prop the piston with the crane.
NOTE
If the piston pin cannot be pressed out by hand, warm the piston to 80°C in
an oil bath.
The piston pin can usually be removed from and installed in the piston wit-
hout warming. When working with new parts, the clearance may not be suf-
ficient when the parts are cold. Full clearance is reached when the parts
are at operating temperature.
2.5 Check the oil bores (6) in the connecting rod eye and check the piston pin bush to ensure that it is
not stuck.
2.6 Check the piston pin surface for cracks and damage.
2.7 Measure the piston pin, piston pin bush and piston pin bore (A5.05.02.09.01.nn).
3. Assembly
3.1 Insert a circlip (4) into the piston pin bore.
3.2 Slide the connecting rod eye (1) into the piston until the piston pin bore and the piston pin bush
are flush.
3.3 Oil the piston pin (3) and insert into the piston and piston pin bush without tilting; the pin must be
installed in accordance with the markings. Remove the rig (W3). Slide the piston pin into position
NOTE
If necessary, warm the piston to 80°C in an oil bath or freeze the piston pin.
3.4 Secure the piston pin with the second circlip.
en / 29.04.2011 IB020353 2/2

Piston Pin A5.05. 02.08.01.30
M43
See also: 02.06.01.nn, 02.09.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Installation rig W3 439220 C
Procedure:
1. Turn the piston.
1.1 Connect crane to the piston installation unit (W1) and lift the piston.
1.2 Mount second installation unit (W2) on the connecting rod eye (1) and attach second crane or
strap.
1.3 Turn the piston and place on suitable surface.
en / 26.03.2010 IB024487 1/2

Piston Pin A5.05. 02.08.01.30
M43
2. Disassembly 02
2.1 Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re-in-
stallation.
2.2 Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin.
2.3 Remove the circlips (4).
2.4 Remove the piston pin (3) from the piston bore and piston pin bush without applying excessive
force until the second oil bore is visible. Mount the rig (W3) and prop the piston with the crane.
NOTE
If the piston pin cannot be pressed out by hand, warm the piston to 80 °C in an oil
bath.
The piston pin can usually be removed from and installed in the piston without war-
ming. When working with new parts, the clearance may not be sufficient when the
parts are cold. Full clearance is reached when the parts are at operating tempera-
ture.
2.5 Check the oil bores (6) in the connecting rod eye and check the piston pin bush to ensure that it is
not stuck.
2.6 Check the piston pin surface for cracks and damage.
2.7 Measure the piston pin, piston pin bush and piston pin bore (02.09.01.nn).
3. Assembly
3.1 Insert a circlip (4) into the piston pin bore.
3.2 Slide the connecting rod eye (1) into the piston until the piston pin bore and the piston pin bush
are flush.
3.3 Oil the piston pin (3) and insert into the piston and piston pin bush without tilting; the pin must be
installed in accordance with the markings. Remove the rig (W3). Slide the piston pin into position.
NOTE
If necessary, warm the piston to 80°C in an oil bath or freeze the piston pin.
3.4 Secure the piston pin with the second circlip.
en / 26.03.2010 IB024487 2/2

Piston A5.05. 02.10.01.00
M43
See also: 02.06.01.nn, 02.07.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston installation ring W12 439220 B

Piston installation guide (steel collar) W13 439220 A
Torque wrench 20 - 200 Nm W14* 1.9454-202
* no picture
Molykote Paste "G-Rapid Plus“ **
Note:
In order to prevent the cylinder liner from detaching during turning, the cylinder liner must be lok-
ked securely with the cylinder liner retainer!(Fig. 2/W9)
After installing a new piston, the engine must be broken in in accordance with the engine break-in
instructions! (A3.10.01.nn)
Procedure:
1. Insert all piston rings with the gap facing
lengthwise respective to the engine; ring
gaps must alternate to the front and back
of the piston! Oil the piston rings and the
outside of the piston well.
2. Loosen the clamping bolts (Fig. 1/1) until

the piston installation unit (W13) is open
wide enough that it can be slid freely over
the piston rings.
3. Apply Molykote paste "G-Rapid Plus“ to

the threads and contact surface of the
clamping bolts (1).
3.1 Oil the ring area well.
en / 30.01.2008 IB020140 1/5

Piston A5.05. 02.10.01.00
M43
4. Place the piston installation unit (Fig. 1/ 02

W13) over the piston ring zone and tighten
the clamping bolts (1).
Attention:
When tightening the clamping bolts,
make sure that the piston rings are not
on the outer edge of the ring groove.
Loosen any rings by tapping lightly on
the piston installation unit.
5. Make sure that the rings are not stuck by

turning the piston installation unit (W13).
6. Attach the piston lifting unit (Fig. 2/W1) to

the piston.
Attention:
Place the crank journal in TDC.
7. Mount cylinder liner retainer (W9).
8. Mount piston installation ring (W12).
9. Attach piston to crane and lift. Oil cylinder

liner and piston base well.
10. Place the piston into the cylinder liner ca-

refully; the piston must be inserted exactly
in line with the cylinder axis.
Attention:
Remove the protective cap from the oil bore in the connecting rod.
11. Lower the piston, being extremely careful that the cylinder does not catch in the cylinder li-
ner.
12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12) and
place the piston carefully on the connecting rod (6) with the connecting rod eye.
The connecting rod eye may not rest on the connecting rod with any force!
Note:
Lower the piston carefully until the cylinder pins (Fig. 3/8) are run completely into the bo-
res in the connecting rod eye (5).
en / 30.01.2008 IB020140 2/5

Piston A5.05. 02.10.01.00
M43
13. Install piston and connecting rod. 02

13.1 Apply Molykote to threads and contact sur-
faces of the uniform strength bolts (Fig. 3/
20).
13.2 Place segments (21) on the connecting

rod split and tighten uniform strength bolts
hand tight with ring wrench.
13.3 Remove connecting rod holder (W8)

(02.06.01.nn).
13.4 Tighten all uniform strength bolts (Fig. 4/

20) to
M = 50 Nm
Mark the position of each of the uniform

strength bolts with a chalk mark. Then
tighten all uniform strength bolts to
M = 250 Nm
en / 30.01.2008 IB020140 3/5

Piston A5.05. 02.10.01.00
M43
13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5). 02
Mount support (W7) on hydraulic wrench.
Attention:
sure lines (W4).
13.7 Place hydraulic wrench with socket wrench (Fig. 4/W6) on the uniform strength bolt (20).
Prop the wrench on the connecting rod (22) or counterweight (Fig. 5/30).
Attention:
The engine may not be started when the hydraulic wrench is connected!
en / 30.01.2008 IB020140 4/5

Piston A5.05. 02.10.01.00
M43
02
~ Safety note:
13.8 Close the valve (Fig. 4/24) on the high pressure pump (W3) and tighten all uniform strength bolts
(20) on one side at a time with a pressure of
p = 400 bar + 25 bar
If necessary, move the cylinder in the hydraulic wrench back and forth several times by releasing
the pressure [by opening the valve (24) and closing the valve (24) and pumping to build up pres-
sure].
Attention:
Hold the hydraulic wrench securely when reducing pressure. The wrench may slip from
the head of the bolt.
13.9 Note the position of the uniform strength bolts (chalk mark), it must be at
an angle of 55°° + 15°°
13.10 Open the valve (24) on the high pressure pump (W3). Wait for the pressure to subside completely
and remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
14. Turn the piston to TDC together with the crane.
15. Remove the piston insertion unit (Fig. 1/W13), piston installation ring (Fig. 2/W12) and piston lif-
ting unit (W1).
16. Clean the cylinder liner contact surface (3).
17. Install new gauging ring.
18. Install cylinder head (01.11.01.nn).
19. Remove cylinder liner retainer (Fig. 2/W9), replace crankcase cover and close indicator valves.
en / 30.01.2008 IB020140 5/5

Piston A5.05. 02.10.01.05
M43
See also: 02.06.01.nn, 02.07.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:

* no picture
Note:
In order to prevent the cylinder liner from detaching during turning, the cylinder liner must be lok-
ked securely with the cylinder liner retainer!(Fig. 2/W9)
After installing a new piston, the engine must be broken in in accordance with the engine break-in
instructions! (A3.10.01.nn)
Procedure:

the piston rings.

clamping bolts (1).
en / 30.01.2008 IB025705 1/5

Piston A5.05. 02.10.01.05
M43

Attention:
When tightening the clamping bolts,
make sure that the piston rings are not
on the outer edge of the ring groove.
Loosen any rings by tapping lightly on
the piston installation unit.


the piston.
Attention:


Attention:
ner.
12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12).
Put intermediate plate (Fig. 3/25) via dowel pins (8) onto connecting rod.
Place the piston carefully on the connecting rod (6) with the connecting rod eye.
Note:
Lower the piston carefully until the cylinder pins (8) are run completely into the bores in
the connecting rod eye (5).
en / 30.01.2008 IB025705 2/5

Piston A5.05. 02.10.01.05
M43
13. Install piston and connecting rod. 02

20).


(02.06.01.nn).

20) to
M = 50 Nm

M = 250 Nm
en / 30.01.2008 IB025705 3/5

Piston A5.05. 02.10.01.05
M43
13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5). 02
Attention:
sure lines (W4).
Attention:
en / 30.01.2008 IB025705 4/5

Piston A5.05. 02.10.01.05
M43
02
~ Safety note:
13.8 Close the valve (Fig. 4/24) on the high pressure pump (W3) and tighten all uniform strength bolts
(20) on one side at a time with a pressure of
p = 400 bar + 25 bar
the pressure [by opening the valve (24) and closing the valve (24) and pumping to build up pres-
sure].
Attention:
Hold the hydraulic wrench securely when reducing pressure. The wrench may slip from
the head of the bolt.
an angle of 55°° + 15°°
13.10 Open the valve (24) on the high pressure pump (W3). Wait for the pressure to subside completely
and remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
ting unit (W1).
en / 30.01.2008 IB025705 5/5

Piston A5.05. 02.10.01.30
M43
See also: 02.06.01.nn, 02.07.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W9 see A5.05.02.06.01.nn

* no picture
NOTE
In order to prevent the cylinder liner from detaching during turning, the cylinder liner
must be lokked securely with the cylinder liner retainer!(Fig. 2/W9)
After installing a new piston, the engine must be broken in in accordance with the en-
gine break-in instructions, see engine documentation, chapter "Operating In-
structions"
Procedure:

the piston rings.

clamping bolts (1).
en / 29.04.2011 IB024475 1/6

Piston A5.05. 02.10.01.30
M43

NOTE
When tightening the clamping
bolts, make sure that the piston
rings are not on the outer edge
of the ring groove. Loosen any
rings by tapping lightly on the
piston installation unit.


the piston.
NOTE


NOTE
ner.
12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12) and
place the piston carefully on the connecting rod (6) with the connecting rod eye.
en / 29.04.2011 IB024475 2/6

Piston A5.05. 02.10.01.30
M43
02
NOTE
Lower the piston carefully until the cylinder pins (Fig. 3/8) are run completely into the
bores in the connecting rod eye (5).
13. Install piston and connecting rod.
13.1 Apply Molykote to threads and contact surfaces of the uniform strength bolts (Fig. 3/20).
13.2 Place segments (21) on the connecting rod split and tighten uniform strength bolts hand tight with
ring wrench.
13.3 Remove connecting rod holder (W8) (02.06.01.nn).
en / 29.04.2011 IB024475 3/6

Piston A5.05. 02.10.01.30
M43
13.4 Tighten all uniform strength bolts (Fig. 4/20) to 02

M = 50 Nm
Mark the position of each of the uniform strength bolts with a chalk mark. Then tighten all uni-
form strength bolts to
M = 250 Nm
13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5).
CAUTION
of p = 425 bar on the high-pressure pump.
Adjustment instructions, see A6.05.90.10.00 Chapter 3.2.4.
en / 29.04.2011 IB024475 4/6

Piston A5.05. 02.10.01.30
M43
13.6 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres- 02
NOTE
WARNING
en / 29.04.2011 IB024475 5/6

Piston A5.05. 02.10.01.30
M43
13.8 Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) on one 02
side at a time with a pressure of
p = 400 bar + 25 bar
the pressure [by opening the valve and closing the valve and pumping to build up pressure].
NOTE
Hold the hydraulic wrench securely when reducing pressure. The wrench may slip
from the head of the bolt.
an angle of 55°° + 15°°
13.10 Open the valve on the high pressure pump (W3). Wait for the pressure to subside completely and
remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
ting unit (W1).
en / 29.04.2011 IB024475 6/6

Piston A5.05. 02.10.01.35
M43
See also: 02.06.01.nn, 02.07.01.nn 02


-------------------------------------------------------------------------------------------------------------------------------
Tools:

* no picture
** or equivalent productt
NOTE
In order to prevent the cylinder liner from detaching during turning, the cylinder liner
must be lokked securely with the cylinder liner retainer!(Fig. 2/W9)
After installing a new piston, the engine must be broken in in accordance with the en-
gine break-in instructions, see engine documentation, chapter "Operating In-
structions"
Procedure:


the piston rings.

clamping bolts (1).
en / 28.05.2010 IB025710 1/6

Piston A5.05. 02.10.01.35
M43

the clamping bolts (1)..
NOTE
When tightening the clamping
bolts, make sure that the piston
rings are not on the outer edge
of the ring groove. Loosen any
rings by tapping lightly on the
piston installation unit.


the piston..
NOTE


NOTE
ner.
12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12). Put in-
termediate plate (Fig. 3/25) via dowel pins (8) onto connect rod. Place the piston carefully on the
connecting rod (6) with the connecting rod eye.
en / 28.05.2010 IB025710 2/6

Piston A5.05. 02.10.01.35
M43
02
NOTE
Lower the piston carefully until the cylinder pins (Fig. 3/8) are run completely into the
bores in the connecting rod eye (5).
13. Install piston and connecting rod.

20).


(02.06.01.nn).

20) to
M = 50 Nm

M = 250 Nm
en / 28.05.2010 IB025710 3/6

Piston A5.05. 02.10.01.35
M43
02
13.5 Place socket wrench (Fig. 4/W6) with square head into the hydraulic wrench (W5).
CAUTION
of p = 425 bar on the high-pressure pump.
Adjustment instructions, see A6.05.90.10.00 Chapter 3.2.4.
en / 28.05.2010 IB025710 4/6

Piston A5.05. 02.10.01.35
M43
13.6 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres- 02
NOTE
WARNING
en / 28.05.2010 IB025710 5/6

Piston A5.05. 02.10.01.35
M43
13.8 Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) on one 02
side at a time with a pressure of
p = 400 bar + 25 bar
the pressure [by opening the valve and closing the valve and pumping to build up pressure]..
NOTE
Hold the hydraulic wrench securely when reducing pressure. The wrench may slip
from the head of the bolt.
an angle of 55°° + 15°°
13.10 Open the valve on the high pressure pump (W3). Wait for the pressure to subside completely and
remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
ting unit (W1).
en / 28.05.2010 IB025710 6/6

Balance weight A5.05. 02.11.00.00
Repair / Disassembly and reassembly
M43
See also: 02.12.00.nn 02


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Hydraulic device set, consisting ofs

High-pressure pump W1 433420 F
High-pressure hose W2 433420 A
Pin W3
Hydraulic tightening element W4 1.9213 P
Sealing element W5
Mounting and removal device for balance weights W7

M52x3 hexagon nut (4x) W8 *
Torque wrench 200-500 Nm W9* 1.9454-500
* not illustrated
Auxiliary material:
Molykote paste "G-Rapid Plus" **
WARNING
Do not place any part of your body over hydraulic components under pressure!
Secure the engine against unintentional starting!
CAUTION
The smallest allowable bending radius for the high-pressure hoses is 250 mm. For the
hydraulic device set use hydraulic oil only . Store the hydraulic device set protected
against corrosion.
en / 29.11.2010 IB022689 1/5

M43
1. Disassembly of balance weight.
1.1 Turn crankshaft to position according to

(Fig. 3).
1.2 Mount the mounting and removal device

for balance weights (Fig. 4/W7).
1.3 Attach the lugs (20) of device (W7) via

shackles and slings to hoists.
Pull the hoists so that the slings are slight-
ly tensioned.
1.4 Loosen both round nuts (Fig. 3/1) of the

studs (2) by means of the hydraulic de-
vice set.
1.5 Place hydraulic element (W4) over the

round nut (1) and tighten it. Make sure
the slits (Fig. 2/3) are easily accessible.
Loosen the hydraulic element by 1 turn.
1.6 Connect the hydraulic element (Fig. 3/W4)

via the high-pressure hose (W2) to the
high-pressure pump (W1).
Secure free hose coupling with sealing
element (W5).
1.6.1 Close valve (10) of the high-pressure

pump (W1) and stretch the stud steplessly
with a pressure of
p = 2050 bar
1.6.2 Loosen round nut (Fig. 2/1) with pin (W3).

Turn back round nut at least 8 holes.
NOTE
If the round nut cannot be loosened with the pin, the stud can be preloaded higher
with a pressure of
p = 50 bar
If the pressure is increased even more, there is a danger of the round nut becoming
stuck due to stretching of the screw thread!
en / 29.11.2010 IB022689 2/5

M43
1.6.3 Open valve (Fig. 3/10) of the high-pressure pump (W1), the hydraulic element will be relieved. 02
1.6.4 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4)
1.6.5 Loosen the second round nut (1), see sequence of operations 1.4.1 to 1.4.6.
1.6.6 Remove the round nuts completely.
1.7 Lower device (Fig. 4/W7) with the hoists slowly and evenly on both sides until the balance weight
gets clear of the studs.
1.8 Move the balance weight slowly out of the crankcase and place it on a suitable base.
1.9 Remove the mounting and removal device for balance weights (W7).
1.10 Screw hexagon nuts (W8) onto the studs (Fig. 2/2) and lock with a second nut.
1.11 Loosen studs and screw out of the crankshaft.
2. Reassembly of balance weight
2.1 Turn crankshaft to position according to (Fig. 3) .
2.2 Clean the contact surfaces on balance weight and crankshaft.
en / 29.11.2010 IB022689 3/5

M43
2.3 Apply a thin coat of Molykote paste to the studs (2) and insert in crankshaft. 02
2.4 Tighten the studs by means of locked hexagon nuts (W8) with a torque of
M = 400 Nm
2.5 Disassemble the hexagon nuts (W8).
2.6 Mount the mounting and removal device for balance weights (Fig. 4/W7).
W7
20
2.7 Lower the device with balance weight slowly into the crankcase by means of hoists.
2.8 Tension the slings slowly and put balance weight on crankshaft via the studs.
2.9 Screw the round nuts (Fig. 3/1) onto the studs (2) so as to be fingertight.
3. Tighten the round nuts (1) of the studs (2) with the hydraulic device set.
3.1 Place hydraulic element (W4) above the first round nut (1) and tighten it. Make sure the slits
(Fig. 2/3) are easily accessible.
en / 29.11.2010 IB022689 4/5

M43
3.2 Connect the hydraulic element (Fig. 3/W4) via the high-pressure hose (W2) to the high-pressure 02
pump (W1).
Secure free hose coupling with sealing element (W9).
3.2.1 Close valve (10) of the high-pressure

pump (W1) and stretch the first stud (2)
steplessly with a pressure of
p=
2050 bar + 25 bar
NOTE
When the hydraulic pump is not actuated the pressure must remain constant, other-
wise the tightening will be incorrect!
3.3 Firmly tighten round nut (1) with pin (Fig. 1/W3).
3.4 Open valve (10) of the high-pressure pump (W1), the hydraulic element will be relieved.
3.5 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4).
3.6 Place hydraulic element (W4) onto the second round nut (1) according to sequence of ope-
rations 3.1 to 3.3.
3.7 Close valve (10) of the high-pressure pump (W1) and stretch the second stud (2) steplessly with a
pressure of
p = 2050 bar + 25 bar
3.8 Firmly tighten round nut (1) with pin (Fig. 2/W3).
3.9 Decrease hydraulic pressure by p = 50 bar.
It must not be possible to loosen the round nut any more.
3.10 Relieve the hydraulic element according to sequence of operations 3.5 and 3.6.
en / 29.11.2010 IB022689 5/5

Measures for emergency operation A5.05. 02.12.00.00
M43

Spare parts list: B1.05.01.432107, B1.05.02.432520, B1.05.02.432601, B1.05.13.431510

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Retaining device for cam follower W1 439235 A

Plug for oil bore W2 439225 A
Lashing strap (2x) W3 1.9461-790
NOTE
In the case of resiliently mounted engines with one damaged running gear the follo-
wing measures must be carried out before putting the engine into service for emer-
gency operation!
Sequence of operations
1. Locking of the resilient mounting.
1.1 Disassemble nuts and washers (Fig. 1/20, 21 and 22).
1.2 Disassemble spring dowel pin (23).
1.3 Screw down locking ring (24) so that it abuts against pipe (25). To this end an auxiliary bore Ø 14
for a tool is provided in the locking ring.
1.4 Apply a thin coat of oil to the foundation bolts. Place washer (22) onto side stopper (26) and toge-
ther with nut (21) tighten with a torque of
M = 3000 Nm
As an alternative with
M = 150 Nm + 60 ° torque angle
2. Disassemble cylinder head (01.06.01.nn).
en / 29.11.2010 IB022678 1/5

M43
02
R = Shown in locked condition (running gear damage)

S = Shown under normal operation
en / 29.11.2010 IB022678 2/5

M43
3. Disassemble the push-rods for inlet and 02

exhaust valve.
Put up the cam followers for inlet and ex-

haust valve and secure by means of W3
lashing straps (Fig. 2/W3).
4. Insert retaining device for cam follower

(Fig. 3/W1) of the injection pump drive into
the engine block.
4.1 Screw in the hexagon head screw (2) until

there is clearance S between the cam fol-
lower and the injection cam
S = 1,0 - 2,0 mm
After lifting up the cam follower lock the

hexagon head screw (2) with a hexagon
nut (3).
5. Draw piston (02.06.01.nn).

2
5.1 Disassemble cylinder liner retainer.
6. Disassemble big-end bearing and big-end

bearing cap as well as connecting rod
(02.04.01.nn).
6.1 Place connecting rod onto a suitable

base.
6.2 Disassemble one balance weight of the

damaged running gear (02.11.00.nn).
en / 29.11.2010 IB022678 3/5

M43
7. Obturate the oil bore in the crank pin of the

13
02
damaged running gear by means of plug
(Fig. 4/W2). Make sure the gaskets (11) 12
and stuffing cones (12) are positioned cor-
rectly. 11
7.1 Tighten prevailing torque type nut (13) by

hand.
11
12
4 Y
8. Disassemble the control air pipe (Fig. 5/30) of the corresponding injection pump. Obturate con-
nection (31) on pump and connection (32) on the pipe with plug and swivel nut.
9. Mount cylinder head (01.11.01.nn).
10. Mount crankcase cover on camshaft and exhaust side.
11. Start the engine under emergency operation, see engine documentation, chapter "Operating
Instructions".
Continuously check the foundation bolts (Fig. 1/27) for tight fit during emergency
operation. Retighten if necessary.
en / 29.11.2010 IB022678 4/5

M43
12. Repairing a damaged engine. 02

12.1 Disassemble cylinder head, plug in the crank pin (Fig. 4/10), retaining device for cam follower of
the injection pump drive (Fig. 3/10) and the lashing straps (W3) used for the cam followers for in-
let and exhaust valve. Mount control air pipe (Fig. 5/30).
12.2 Deactivating the locking of the resilient mounting.
12.3 Exchange / repair any damaged parts.
12.4 Mount connecting rod, connecting rod bearing with bearing cap (02.04.02.nn), piston
(02.10.01.nn), balance weight (02.11.00.nn), push rods for inlet and exhaust valve and cylinder
head (01.11.01.nn).
12.5 Mount crankcase cover on camshaft and exhaust side.
12.6 Put the engine into service, see engine documentation, chapter "Operating Instructions".
en / 29.11.2010 IB022678 5/5

Crankcase Explosion Safety Valve A5.05. 03.01.01.00
M43
1500
See also: 02.01.01.nn 03


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Action of safety valve
Adhesive “JOWAT-CONTAXA 44400” and hardener “JOWAT 40469” *
Molykote Paste “G-Rapid” *
Procedure:
1. Check the safety valve from the inside of the crankcase cover (1) by actuating the valve head (6)
by hand; check to make sure the valve is not stuck.
en / 28.07.1999 IB020180 1/2

Crankcase Explosion Safety Valve A5.05. 03.01.01.00
M43
1500
2. If the safety valve does not operate properly, remove. 03

3. Check spring (3), replace if necessary.
4. Check the guide pin (7) and the valve head (6), rework if necessary.
5. Check O-ring on the guide pin, replace if necessary.
6. Before sliding the O-ring onto or off of the guide pin, cover the threads and guide pin shaft with a
smooth material.
7. Check the profile cord (5) on the valve head (6), replace if necessary (glue into place with adhesi-
ve and hardener). Apply Molykote paste to guide pin.
8. Install safety valve, secure with cotter pin (8) and check to ensure easy action.
9. Check profile cord (9) before installation, replace if necessary.
en / 28.07.1999 IB020180 2/2

Explosion relief valve A5.05. 03.01.01.02
M43
1500
See also: 02.01.01.nn 03


--------------------------------------------------------------------------------------------------------------------------------
Check:
Ease of movement of the explosion relief valve every 1,500 h
Tools:
Torque wrench 20 - 200 Nm W1 1.9454-202
Molykote Paste "G Rapid Plus“ *
Sealing compound "Dirko No. 610.020" *
NOTE
Removal of the explosion relief valve (5) is only required if the specified spring tensi-
on is not provided any more, in the event of abnormal oil contamination or if any
leaks should be identified during operation.
Procedure:
1. Check the relief valve from the inside of the crankcase door (1) for ease of movement by actua-
ting the valve by hand. For this purpose dismantle the crankcase door (1) or the explosion relief
valve (5).
2. Disassembly
2.1 Unscrew and remove screws (8) from crankcase door (1).
2.2 Remove explosion relief valve (5) completely from the crankcase cover (1).
en / 12.04.2010 IB026117 1/2

M43
1500
3. Assembly 03
3.1 Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2 Clean the sealing face (10) on the crankcase door (1) and lubricate with sealing compound "Dirko
No. 610.020".
3.3 Put the explosion relief valve (5) in place on the crankcase door (1).
3.4 Tighten screws (8) to a torque of
M = 25 Nm.
3.5 After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6 When mounting the explosion relief valve on the crankcase door care has to be taken to ensure
proper sealing between seat and crankcase door.
en / 12.04.2010 IB026117 2/2

M43
1500
See also: 03

--------------------------------------------------------------------------------------------------------------------------------
Check:
Ease of movement of the explosion relief valve every 1,500 h
Tools:
Torque wrench 20 - 200 Nm W1 1.9454-202
Molykote Paste "G Rapid Plus“ *
Sealing compound "Dirko No. 610.020" *
NOTE
Removal of the explosion relief valve (5) is only required if the specified spring tensi-
on is not provided any more, in the event of abnormal oil contamination or if any
leaks should be identified during operation.
Procedure:
1. Check the relief valve from the inside of the crankcase door (1) for ease of movement by actua-
ting the valve by hand. For this purpose dismantle the crankcase door (1) or the explosion relief
valve (5).
2. Disassembly
2.1 Unscrew and remove screws (8) from crankcase door (1).
2.2 Remove explosion relief valve (5) completely from the crankcase cover (1).
en / 19.10.2011 IB027683 1/2

M43
1500
3. Assembly 03
3.1 Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2 Clean the sealing face (10) on the crankcase door (1) and lubricate with sealing compound "Dirko
No. 610.020".
3.3 Put the explosion relief valve (5) in place on the crankcase door (1).
3.4 Tighten screws (8) to a torque of
M = 24,5 Nm.
3.5 After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6 When mounting the explosion relief valve on the crankcase door care has to be taken to ensure
proper sealing between seat and crankcase door.
en / 19.10.2011 IB027683 2/2

Coolant Distributor Housing A5.05. 03.02.00.00
M43


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace O-rings
Tools:
Eye bolts M16 W1
Cylinder liner retainer W2* 439217 A
* no picture
Vaseline **
Procedure:
1. Remove coolant distributor housing.
1.1 Remove mounting bolts (Fig. 2/1) on the coolant block.
en / 29.04.2011 IB020182 1/3

M43
1.2 Loosen the sleeves (2) from the starting air channel and slide into opposite distributor housing. 03
1.3 Remove the distributor housing mounting bolts (3). Screw the eye bolts (Fig. 3/W1) into the
coolant distributor housing (6) and lift housing with crane.
CAUTION
The lower cylinder liner retainer must be installed (A5.05.01.06.01.nn).
1.4 Replace O-ring (4) on the charge air passage and O-ring (5) on the valve lifter passage in the
coolant distributor housing (6).
NOTE
All O-rings must be inserted into the groove with Vaseline or green lubricant paste wi-
thout twisting.
en / 29.04.2011 IB020182 2/3

M43
2. Install coolant distributor housing. 03

2.1 Set coolant distributor housing (6) into pla-
ce on the crankcase with a crane. Replace
coolant block gasket (Fig. 2/7).
2.2 Tighten coolant distributor housing moun-

ting bolts (3).
2.3 Slide sleeves (2) for starting air channel

into place and secure.
2.4 Apply a light coat of Molykote to the coo-

lant block mounting bolts (1), slide into pla-
ce and tighten to
M = 100 Nm
Then tighten the bolts to
M = 260 Nm
2.5 Remove eye bolts (Fig. 3/W1).
2.6 Remove cylinder liner retainer (W2).
en / 29.04.2011 IB020182 3/3

Cylinder Liner A5.05. 03.03.01.01
M43/VM43
30000, 15000
See also: 03
Personnel qualification: Chief engineer

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
- of one cylinder liner every 15,000 h
- of all cylinder liners every 30,000 h
- of the cylinder liner each time a piston is removed, before the removal and installation of a
cylinder liner.
Tools:
Cylinder liner gauge rail W1 439218-001
Fine gauge inside micrometer W2 *, ** 1.9419 G
* no picture
** or equivalent measuring instrument
Procedure:
1. Check cylinder liner.
NOTE
Unusual forms of wear may be found in cylin-
der liners depending on the respective total
operating time and operating conditions; this
wear must be measured and evaluated, see
Fig. 3.
1.1 Remove gauging ring and remove piston.
1.2 Clean the inside of the cylinder liner, cover the crankcase
well.
1.3 Measure the cylinder liner with the fine gauge inside microm-
eter (W2) at the points indicated by the gauge rail (Fig. 1/
W1) and table (Fig. 2) along, across and 2 x diagonal to the
engine axis.
en / 28.11.2011 IB020186 1/3

M43/VM43
30000, 15000
1.4 03
Measu- Wear value
rement Along
point engine axis across engine axis diagonal diagonal
1
2 Refe-
3 rence
value
1.5 Enter the values measured into the table (Fig. 2) and calculate the wear values
(d1 - reference value d3, etc.), see also measurement sheet in folder “Forms for Maintenance Re-
ports”.
1.6 When the wear limit has been reached, normally at the point at which the top piston ring reverses
direction (TDC, 1st ring) or other threshold values in the table (Fig. 3 and Fig. 4)have been met,
replace the cylinder liner.
The cylinder liners can only be reworked by Caterpillar.
Cylinder liner wear chart
Evaluation criteria Wear limit Explanation

(mm)
Nominal Ø (new)) * Limit value for conically

honed cylinder liners
430,0 + 0,063 ** Radius r ≥ 3 mm
Max. out-or-round 0,30 *** in circumferencial direction
Wear 0,75 TDC. 1st Ring

4 0,90 *
Gusset Height 13,00 wedge-shaped indentation across the

1 Depth ** 0,05 entire circumference, beginning from
the TDC of 1st. piston ring.
Canyon max. number 3 Individual deep blow-through ducts

5 Length 13,00 in the area of the first piston ring (TDC).
total width 6,00
Scores Number 3 Vertical and linear scores.

3 Length 250,00
Depth 0,05
Pocket Number 3 Irregular indentations.

Length 120,00
2 Width *** 40,00
Depth ** 0,03
en / 28.11.2011 IB020186 2/3

M43/VM43
30000, 15000
03
en / 28.11.2011 IB020186 3/3

M43
30000
See also: 02.06.01.nn, 03.03.01.nn 03


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Remove cylinder liner,
replace O-ring every 30,000 h
Tools:
Cylinder liner rig W1 439216 A

CAUTION
The cylinder liner sealing surface must be protected from damage!
Procedure
1. Remove cylinder liner.
1.1 Remove piston (A5.05.02.06.01.nn). Remove cylinder liner retainer (W2).
1.2 Measure wear (A5.05.03.03.01.nn).
1.3 Insert rig (W1) with threaded rod and swivel cross arm (1) into the cylinder liner.
1.4 Fasten clamping plate (2) and swivel cross arm (1) securely with the nut (3).
NOTE
Make sure that the swivel cross arm (1) rests on the cylinder liner correctly.
1.5 Attach lifting unit to eye bolt (4) and pull cylinder liner out along cylinder axis and place on suitable
surface.
1.6 Remove the O-ring (13) in the coolant distributor housing (14).
en / 29.04.2011 IB020188 1/2

M43
30000
1.7 Clean the sealing surface and O-ring groove thoroughly and check for damage. 03
1.8 Clean coolant area on the cylinder liner collar thoroughly.
1.9 Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly.
en / 29.04.2011 IB020188 2/2

M43
30000
See also: 02.06.01.nn, 03.03.01.nn 03


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Remove cylinder liner,

replace O-ring every 30,000 h
Tools:

Cylinder liner clamp W3
Cross arm W4 6.9223 A
CAUTION
The cylinder liner sealing surface must be protected from damage!
Procedure:
1. Remove cylinder liner.
1.1 Remove piston (02.06.01.nn). Remove cylinder liner retainer (W2).
1.2 Measure wear (03.03.01.nn).
1.3 Insert rig (W1) with threaded rod and swivel cross arm (1) into the cylinder liner.
1.4 Fasten clamping plate (2) and swivel cross arm (1) securely with the nut (3).
NOTE
Make sure that the swivel cross arm (1) rests on the cylinder liner correctly.
1.5 Attach lifting unit to eye bolt (4) and pull cylinder liner out along cylinder axis until X = 1550 mm.
1.6 Mount cylinder liner clamp (W3). Make sure to maintain Y = 667 mm from lower edge of cylinder
liner.
1.7 Attach cross arm (W4) to clamp (W3).
en / 28.05.2010 IB020190 1/2

M43
30000
1.8 Tip cylinder liner slowly onto its side and place on suitable surface. 03
1.9 Remove the O-ring (13) in the coolant distributor housing (14).
1.10 Clean the sealing surface and O-ring groove thoroughly and check for damage.
1.11 Clean coolant area on the cylinder liner collar thoroughly.
1.12 Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly.
en / 28.05.2010 IB020190 2/2

M43
See also: 03.03.01.nn, 03.04.01.nn 03


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Cylinder liner rig W1
- Liquid beef suet or green potassium

soap
NOTE
Take complete measurements
after installing a new cylinder li-
ner.
After installing a new cylinder

liner, the engine must be bro-
ken in in accordance with the
break-in procedures, see engi-
ne documentation, chapter
"Operating Instructions".
Procedure:
1. Clean the inside of the coolant distributor
housing (Fig. 1/1).
2. Place new O-ring (4) into the groove in the

coolant distributor housing.
NOTE
Place O-ring in the groove with
fluid beef suet or green potas-
sium soap without twisting!
3. Clean the cylinder liner contact

surfaces (2) on the crankcase (3).
en / 29.03.2010 IB020192 1/2

M43
4. Connect hoisting unit to the eye bolt on the rig (Fig. 1/W1) and lower the cylinder liner into the 03
crankcase (3).
5. Mount rig onto the cylinder liner to be installed in accordance with steps 1.3 and 1.4 of the disas-
sembly instructions (A5.05.03.04.01.nn).
NOTE
Insert the cylinder liner so that the mark (5) (Fig. 2/X, top view cylinder liner collar)
faces the coupling side in the direction of the engine axis.
The mark (6) on the coolant distributor housing is intended to ease alignment.
NOTE
The cylinder liner must slide into the crankcase fitting bores (Fig. 1/3) by means of its
own weight!
6. Remove the rig (W1) from the cylinder liner and install piston (A5.05.02.10.01.nn).
en / 29.03.2010 IB020192 2/2

M43
See also: 03.03.01.nn, 03.04.01.nn 03


-------------------------------------------------------------------------------------------------------------------------------
Tools:

Cylinder liner clamp W2
Crosspiece W3 6.9223 A
- Liquid beef suet or potassium soap
NOTE
Take complete measurements after installing a new cylinder liner.
After installing a new cylinder liner, the engine must be broken in in accordance with
the break-in procedures, see engine documentation, chapter „Operating Instruc-
tions“!
Procedure:
1. Clean the inside of the coolant distributor housing (Fig. 1/1).
2. Place new O-ring (4) into the groove in the coolant distributor housing.
NOTE
Place O-ring in the groove with fluid beef suet or green potassium soap without
twisting!
3. Clean the cylinder liner contact surfaces (2) in the crankcase (3).
en / 13.07.2010 IB020194 1/3

M43
4. Mount the rig onto the cylinder liner to be installed in accordance with steps 1.3 to 1.7 of the di- 03
sassembly instructions (03.04.01.nn).
Make sure to maintain Y = 667 mm.
5. Connect lifting unit to clamp (Fig. 1/W2) and lift cylinder liner slowly.
6. When the cylinder liner position (III) has been reached, connect lifting unit to rig (W1) and slide
cylinder liner (2) into crankcase (3).
en / 13.07.2010 IB020194 2/3

M43
7. . 03
NOTE
Insert the cylinder liner so that the mark (5) (Fig. 2/X, top view cylinder liner collar)
faces the coupling side in the direction of the engine axis.
The mark (6) on the coolant distributor housing is intended to ease alignment.
NOTE
The cylinder liner must slide into the crankcase fitting bores (Fig. 1/3) by means of its
own weight!
8. Remove rig (W1, W2 and W3) from the cylinder liner and install piston (02.10.01.nn).
en / 13.07.2010 IB020194 3/3

Engine Fasteners and Connections A5.05. 03.07.01.00
M43/VM43
150
See also: 02.02.01.nn, 06.01.01.nn 03

Spare parts list:

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
all engine fasteners and connections for tightness and leaks.
NOTE
The preventative inspection must be completed once to find leaks or loose bolted
connections resulting from "settling“ connecting elements or seals which could lead
to subsequent damage.
After starting up a new system (150 h) or after large scale repairs, the engine connec-
ting elements must be checked to ensure that they are tight and that there are no
leaks.
Procedure:
1. Check the tightness and seal of the engine connecting flange, filter, control unit and the line con-
nections of the following systems:
• Coolant
• Engine oil
• Fuel
• Starting air
• exhaust gas
• Pneumatic control
2. Check the compensators for leaks and check the exhaust line (A5.05.06.01.01.nn) behind the ex-
haust turbocharger to ensure that it is suspended properly.
3. Check the brackets and connecting pieces of the charge air line for tightness and leaks.
4. Tighten the mounting bolts in the bearing blocks of the fuel pump regulating rod and check the
safety unit on the connection joints.
5. Check the control and monitoring equipment to ensure secure fit. Cables and impulse lines may
not chafe.
6. Check foundation bolts and fitted pieces by tapping. Check web deflection after tightening loose
foundation bolts (A5.05.02.02.01.nn). Obtain tightening values from Caterpillar customer service.
7. Check elastic bearing elements for damage.
en / 04.05.2011 IB020232 1/1

Camshaft Bearing A5.05. 04.01.01.00
M43
30000, 15000
See also: 02.01.01.nn, 04.01.02.nn 04


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
- of the clearance of one camshaft bearing 15,000 h
- of the clearance of all camshaft bearings every 30,000 h
NOTE
Camshaft bearings are subject to no load alternation. The bearings are only loaded
at the lower bearing area; the load here is relatively high. Light edging is not unusual.
Procedure:
1. Check camshaft bearing clearance
1.1 Remove the corresponding sight hole cover on the control side of the camshaft cover.
1.2 Check camshaft bearing /bearing journal clearance.

mm mm
0.26 - 0.32 0.5
NOTE
When the wear limit has been reached, replace camshaft bearing (Caterpillar cu-
stomer service) and check the bearing clearance of all camshaft bearings. Check
the bearing journal running surfaces of the corresponding camshaft bearing.
en / 29.03.2010 IB020303 1/1

M43
30000, 15000
See also: 02.03.03.nn, 04.04.01.nn 04


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

corresponding camshaft section after the 1st cylinder every 15,000 h
- Check the running surface of all camshaft bearings and

corresponding camshaft sections after the 1st cylinder every 30,000 h
Tools:
see A5.05.04.04.01.nn
NOTE
Camshaft bearings are subject to no load alternation. The bearings are only loaded
at the lower bearing area; the load here is relatively high. Light edging is not unusual.
Procedure:
CAUTION
The camshaft bearing between the camshaft gear and the 1st cylinder may only be
dismantled and installed by Caterpillar customer service!
1. Check the running surface of one camshaft bearing and the corresponding camshaft sec-
tion after the 1st cylinder.
1.1 Remove all rocker arms from the corresponding cylinder and the rocker arms of all cylinders loca-
ted to the right of the cylinder to be checked to relieve the load on the camshaft
(A5.05.01.02.02.nn).
Remove pushrods.
1.2 Remove the injection pump of the cylinder to be checked and all cylinders located to the right of
the cylinder to be checked (A5.05.07.03.01.nn).
1.3 Raise and secure the rocker arms of the cylinder to be checked and all cylinders to the right of the
cylinder to be checked (A5.05.04.04.01.nn).
en / 29.03.2010 IB020282 1/5

M43
30000, 15000
1.4 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the cams- 04
haft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Re-
place two opposing hex head bolts with longer bolts (W2).
Set measure “s“
s = 68 ± 0.5 mm
en / 29.03.2010 IB020282 2/5

M43
30000, 15000
04
NOTE
When removing the hex head bolts, make sure that the injector cam faces up verti-
cally (TDC) after turning the engine for the last time.
CAUTION
The camshaft may only be turned when the connecting bolts are loosened when
- the rocker arms of the camshaft section to be replaced and all rocker arms to
the right of the section to be replaced have been removed and
- the camshaft section is pulled out far enough, that the straight pin (5) and the
recess are no longer engaged!
1.5 Remove retaining bolt (Fig. 2/11).
1.6 Drive the camshaft bearing (4) out to the

right with a suitable wood block and rubber
mallet. Fill the bearing shell with card-
board.
1.7 Place cardboard or similar material around

the camshaft bearing journal.
1.8 Slide the camshaft to the right until it stops

(distance “s“) with a strip of wood.
Distance s = 68 ± 0.5 mm
1.9 Remove bolts (Fig. 1/W1).
CAUTION
Apply no excessive or sudden
force when sliding! Do not
damage the bearings or bearing
journals.
NOTE
To check the last camshaft bearing, remove the oscillation damper (Fig. 2/10)
(A5.05.04.09.01.nn) and slide to the right as far as possible!
en / 29.03.2010 IB020282 3/5

M43
30000, 15000
1.10 Check crankshaft bearing. 04

Replace (A5.05.04.04.01.nn) if:
- the wear pattern is bad (running surface, lower bearing area, scoring).
1.11 Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary
(A5.05.04.04.01.nn).
1.12 Check the running surfaces of the bearing journals of all available crankshaft sections for scoring.
1.13 Replace defective camshaft sections and check the corresponding bearings (A5.05.04.04.01.nn).
1.14 Install camshaft (A5.05.04.04.01.nn).
1.15 Install bearing and align with positioning bore.
1.16 Install retaining bolt (Fig. 2/11). Tighten bolt to
M = 130 Nm
NOTE
Install the oscillation damper after checking the last camshaft bearing
(A5.05.04.09.01.nn)!
2. Check the running surface of all camshaft bearings and camshaft sections after
the 1st cylinder.
2.1 Release and raise all rocker arms (A5.05.04.04.01.nn).
2.2 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3) of the 1st cylin-
der. Turn the camshaft to access and remove all bolts which are inaccessible. Remove all hex
head bolts. Replace two opposing hex head bolts with longer bolts (W1). Set measure “s“.
2.3 Remove the retaining bolts (Fig. 2/11) on the camshaft bearings one after the other.
2.4 Drive out the camshaft bearings (4) to the right with a suitable wood block and rubber mallet. Fill
the bearing shell with cardboard.
en / 29.03.2010 IB020282 4/5

M43
30000, 15000
2.5 Slide the camshaft to the side (1.4 to 1.7). 04

2.6 Prop up the oscillation damper and the camshaft section above the 1st cylinder.
2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring.
2.8 Replace defective camshaft sections (A5.05.04.04.01.nn).
2.9 Install camshaft (A5.05.04.04.01.nn).
2.10 Install retaining bolt (11). Tighten bolt to
M = 130 Nm
2.11 Disengage the rotor.
2.12 Install rocker arms and complete all remaining work (A5.05.04.04.01.nn).
en / 29.03.2010 IB020282 5/5

M43
30000, 15000
See also: 02.03.03.nn, 04.04.01.nn 04


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

corresponding camshaft section after the 1st cylinder every 15,000 h
- Check the running surface of all camshaft bearings and

corresponding camshaft sections after the 1st cylinder every 30,000 h
Tools:
see 04.04.01.nn
Note:
Camshaft bearings are subject to no load alternation. The bearings are only loaded at the lower
bearing area; the load here is relatively high. Light edging is not unusual.
Procedure:
Attention:
The camshaft bearing between the camshaft gear and the 1st cylinder may only be dis-
mantled and installed by MaK customer service!
1. Check the running surface of one camshaft bearing and the corresponding camshaft sec-
tion after the 1st cylinder.
1.1 Remove all rocker arms from the corresponding cylinder and the rocker arms of all cylinders loca-
ted to the right of the cylinder to be checked to relieve the load on the camshaft (01.02.02.nn).
Remove pushrods.
1.2 Raise and secure the rocker arms of the cylinder to be checked and all cylinders to the right of the
cylinder to be checked (04.04.01.nn).
en / 12.02.2010 IB026640 1/5

M43
30000, 15000
1.3 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the cams- 04
haft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Re-
place two opposing hex head bolts with longer bolts (W2).
Set measure “s“
s = 68 ± 0.5 mm
en / 12.02.2010 IB026640 2/5

M43
30000, 15000
04
Attention:
The camshaft may only be turned when the connecting bolts are loosened when
- the rocker arms of the camshaft section to be replaced and all rocker arms to
the right of the section to be replaced have been removed and
- the camshaft section is pulled out far enough, that the straight pin (5) and the recess
are no longer engaged!
1.4 Remove retaining bolt (Fig. 2/11).
1.5 Drive the camshaft bearing (4) out to the

right with a suitable wood block and rubber
mallet. Fill the bearing shell with card-
board.
1.6 Place cardboard or similar material around

the camshaft bearing journal.
1.7 Slide the camshaft to the right until it stops

(distance “s“) with a strip of wood.
1.8 Remove bolts (Fig. 1/W1).
Attention:
Apply no excessive or sudden force

when sliding! Do not damage the bea-
rings or bearing journals.
Note:
To check the last camshaft bearing, remove the oscillation damper (Fig. 2/10) (04.09.01.nn) and
slide to the right as far as possible!
en / 12.02.2010 IB026640 3/5

M43
30000, 15000
1.9 Check crankshaft bearing. 04

Replace (04.04.01.nn) if:
- the wear pattern is bad (running surface, lower bearing area, scoring).
1.10 Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary
(04.04.01.nn).
1.11 Check the running surfaces of the bearing journals of all available crankshaft sections for scoring.
1.12 Replace defective camshaft sections and check the corresponding bearings (04.04.01.nn).
1.13 Install camshaft (04.04.01.nn).
1.14 Install bearing and align with positioning bore.
1.15 Install retaining bolt (Fig. 2/11). Tighten bolt to
M = 130 Nm
Note:
Install the oscillation damper after checking the last camshaft bearing (04.09.01.nn)!
2. Check the running surface of all camshaft bearings and camshaft sections after
the 1st cylinder.
2.1 Release and raise all rocker arms (04.04.01.nn).
2.2 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3) of the 1st cylin-
der. Turn the camshaft to access and remove all bolts which are inaccessible. Remove all hex
head bolts. Replace two opposing hex head bolts with longer bolts (W1). Set measure “s“.
2.3 Remove the retaining bolts (Fig. 2/11) on the camshaft bearings one after the other.
2.4 Drive out the camshaft bearings (4) to the right with a suitable wood block and rubber mallet. Fill
the bearing shell with cardboard.
en / 12.02.2010 IB026640 4/5

M43
30000, 15000
2.5 Slide the camshaft to the side (1.4 to 1.6). 04

2.6 Prop up the oscillation damper and the camshaft section above the 1st cylinder.
2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring.
2.8 Replace defective camshaft sections (04.04.01.nn).
2.9 Install camshaft (04.04.01.nn).
2.10 Install retaining bolt (11). Tighten bolt to
M = 130 Nm
2.11 Disengage the rotor.
2.12 Install rocker arms and complete all remaining work (04.04.01.nn).
en / 12.02.2010 IB026640 5/5

Bottom part for Valve Mechanism A5.05. 04.02.00.30
M43
See also: 01.01.01.nn, 01.02.01.nn, 07.02.01.nn 04

Personnel qualification: skilled engine hand / Assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting and removal device for lower valve drive W1 432135 A

consisting of:
Support, compl. W1.1
Guide rail, compl. W1.2
Bracket with hexagon bolt W1.3
Carriage W1.4
Arm, compl. (3x) W1.5
Support (only on cyl.1) W1.6
Screw W1.7
Tubular hexagon box wrench W1.8 *
Torque wrench 200-500 Nm W2 * 1.9454-500
* no picture
Molykote Paste "G Rapid Plus" **

Vaseline **
Procedure:
1. Disassembly:
1.1 Engage barring device.
1.2 Disassemble corresponding rocker arm bracket (A5.05.01.02.01.nn).
1.3 Mark and disassemble push-rods (7). Push-rods may not be interchanged.
1.4 Disassemble corresponding camshaft cover.
1.5 Disassemble corresponding injection pump (A5.05.07.02.01.nn)
1.6 Disassemble injection pump drive.
1.7 Loosen circlips (8) of oil pipes (9) and shift towards the centre of the pipe.
en / 29.04.2011 IB024513 1/7

M43
1.8 Remove oil pipes (9). 04

1.9 Remove clamping screw (10) and both lower fastening screws (11).
12
12
10
11 11
1.10 Bring into position support (W1.1) and firmly mount to cam follower bracket.
1.11 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench
(W1.8).
W1.5 W1.1
12
9
12
en / 29.04.2011 IB024513 2/7

M43
1.12 In case of disassembly and assembly at cylinder 1 mount support (W1.6). Here the camshaft cov- 04
er is bigger.
W1.6
1.13 Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the device.
W1.4
W1.2
1.14 Put on carriage (W1.4). By means of setscrew (15) adjust height if necessary so that the screw
en / 29.04.2011 IB024513 3/7

M43
holes coincide. 04
W1.7 W1.2
9
W1.4
15
1.15 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
1.16 Remover upper fastening screws (12) of the cam follower bracket.
1.17 Bring into position bracket with hoist (W1.3)..
CAUTION
Before that, roll out valve mechanism a bit on carriage (W1.4).
Spacer sheets (13) are adjusted to each valve unit individually and must not be inter-
changed upon reassembly.
In order to have sufficient clearance, lower inlet and exhaust cam follower a bit by
adjusting the arms (W1.5) with tubular hexagon box wrench (W1.8).
en / 29.04.2011 IB024513 4/7

M43
1.18 Engage hoist in support (W1.1) and tension it. 04

1.19 Roll out valve drive completely on the carriage.
W1.3
W1.5
W1.1
WARNING
Rope of the hoist must be evenly coiled, otherwise there is a risk of injury.
1.20 Separate support (W1.1) from carriage (W1.4) by removing screws (W1.7).
1.21 Disassemble carriage (W1.4).
1.22 Disassemble guide rail (W1.2).
1.23 Lower complete valve drive with hoist and deposit on a suitable base support.
1.24 Remove support (W1.1).
en / 29.04.2011 IB024513 5/7

M43
2. Assembly: 04
2.1 Bring into position support (W1.1) and firmly mount to cam follower bracket.
(W1.8).
2.3 Raise complete valve drive with hoist up to limit stop.
2.4 Mount guide rail (W1.2).
2.5 Mount carriage (W1.4).
2.6 Deposit valve drive on carriage (W1.4).
2.7 Separate connection to hoist.
2.9 Carefully roll valve drive into camshaft casing.
2.10 Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correction by
adjusting the arms (W1.5).
2.11 Insert spacer sheets (13).
CAUTION
Spacer sheets (13) are adju-
sted to each valve unit indivi-
dually and may not be
interchanged upon reas-
sembly.
2.12 Insert the two upper fastening screws (12)

of the valve drive with extension sleeves
(14) and slightly tighten.
2.13 Lower cam follower and disassemble arms

(W1.5).
2.14 Separate carriage (W1.4) and support

(W1.1).
2.15 Disassemble carriage.
2.17 Disassemble bracket with hoist (W1.3).
en / 29.04.2011 IB024513 6/7

M43
2.18 Remove support (W1.1). 04

2.19 Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus".
2.20 Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten them.
2.21 Tighten fastening screws (11, 12) "crosswise" gradually until a torque of
M = 455 Nm
is reached.
2.22 Assemble clamping screw (10) and tighten to a torque of
M = 455 Nm.
Alternative tightening instructions for screws (10,11,12):
Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus"
and tighten screws in two steps as follows:
Step 1:
Preload screws to M = 270 Nm.
Step 2:
Mark screws and continue turning by a torque angle of α = 30°° by means of box wrench SW 35
(spanner size) (30° ≤ 1/2 hexagon)
455 Nm = 270 Nm + 30°°
2.23 Slightly lubricate new O-rings (16) with Vaseline and insert into the oil pipe grooves untwisted.
2.24 Insert oil pipes (9) into the cam follower shaft and assemble circlips (8).
2.25 Insert push-rods according to their marking.
2.26 Assembly injection pump drive.
2.27 Assemble injection pump (A5.05.07.02.01.nn) .
2.28 Assemble push-rods (7).
2.29 Assemble rocker arm bracket (A5.05.01.02.01.nn).
2.30 Check valve clearance (A5.05.01.01.01.nn) .
2.31 Assemble valve cover.
2.32 Start prelubrication pump and check oil pipes (9) for leaks.
2.33 Assemble camshaft cover.
en / 29.04.2011 IB024513 7/7

Bottom part for Valve Mechanism FCT A5.05. 04.02.00.31
M43
See also: 01.01.01.nn, 01.02.01.nn, 04.02.10.nn, 07.02.01.nn, A3.12.06.00 04

Spare parts list: B1.05.04.433502, B1.05.04.434480, B1.05.04.434481
Personnel qualification: skilled engine hand / Assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting and removal device for valve mechanism W1 432151 A

consisting of:
Support, compl. W1.1
Guide rail, compl. W1.2
Bracket with hoist W1.3
Carriage W1.4
Arm, compl. (3x) W1.5
Support (only on cyl.1) W1.6
Screw W1.7
Tubular hexagon box wrench W1.8 *
Stop bracket W1.9
Fork wrench (2x) W2 * 432112 B

Torque wrench 200-500 Nm W3 * 1.9454-500
* no picture
Molykote Paste "G Rapid Plus" **

Vaseline **
Procedure:
1. Disassembly:
1.2 Disassemble corresponding rocker arm

bracket (A5.05.01.02.01.nn).
1.3 Mark and disassemble push-rods (7).

Push-rods may not be interchanged.
en / 29.04.2011 IB025431 1/10

M43
1.4 Disassemble corresponding camshaft co- 04

ver.
1.5 Disassemble the adjusting unit

(A5.05.04.02.10.nn) at cyl. 1.
1.6 Make sure the connection screws of the

clamp halves (30) are easily accessible.
Bring cam follower shaft into position, if
necessary by means of fork wrench (W2).
1.7 Disassemble corresponding injection

pump (A5.05.07.02.01.nn)
1.8 Disassemble injection pump drive.
1.9 In case of assembly and reassembly on

the next to last and last cyl. disassemble li-
mit stops (31).
1.10 Disassemble clamp halves (30).
NOTE
Clamp halves (30) must not be
interchanged between the dif-
ferent cylinder units.
1.11 Loosen circlips (8) of oil pipes (9) and shift

towards the centre of the pipe.
1.12 Remove oil pipes (9).
en / 29.04.2011 IB025431 2/10

M43
1.13 Remove upper clamping screw (10) and both lower fastening screws (11). 04
1.14 Bring into position support (W1.1) and firmly mount to cam follower bracket with screw.
1.15 In order to prevent the inlet cam follower from slipping, mount bracket (W1.9).
(W1.8).
W1.5 W1.1
12
9
12
en / 29.04.2011 IB025431 3/10

M43
1.17 In case of disassembly and assembly at cylinder 1 mount support (W1.6). 04

Here adjusting unit / bigger opening.
1.18 Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the device.
W1.4
W1.2
1.19 Put on carriage (W1.4). Adjust height if necessary with setscrew (15) so that the screw holes
en / 29.04.2011 IB025431 4/10

M43
coincide. 04
W1.7 W1.2
9
W1.4
W1.6
15
1.21 Remover upper fastening screws (12) of the cam follower bracket.
1.22 Bring into position bracket with hoist (W1.3).
CAUTION
Before that, roll out valve mechanism a bit on carriage (W1.4).
Fuel cam followers (13) are adjusted to each valve unit individually and may not be
interchanged upon reassembly.
In order to have sufficient clearance, lower inlet and exhaust cam follower a bit by
adjusting the arms (W1.5) with tubular hexagon box wrench (W1.8).
en / 29.04.2011 IB025431 5/10

M43
1.23 Engage hoist in support (W1.1) and tension it. 04

1.24 Roll out valve mechanism completely on the carriage.
W1.3
W1.5
W1.1
WARNING
Rope of the hoist must be evenly coiled, otherwise there is a risk of injury.
1.25 Separate support (W1.1) from carriage (W1.4) by removing screws (W1.7).
1.26 Disassemble carriage (W1.4).
1.28 Lower complete valve mechanism with hoist and deposit on a suitable base support.
CAUTION
The piece parts of the cam follower bracket must not be interchanged.
1.29 Remove support (W1.1).
en / 29.04.2011 IB025431 6/10

M43
2. Assembly: 04
2.1 Bring into position support (W1.1) and firmly mount to cam follower bracket with screw.
2.2 In order to prevent the inlet cam follower from slipping, mount bracket (W1.9).
(W1.8).
2.4 Raise complete valve mechanism with hoist up to limit stop.
2.5 Mount guide rail (W1.2).
2.6 Mount carriage (W1.4).
2.7 Deposit valve mechanism on carriage (W1.4).
2.8 Separate connection to hoist.
2.10 Carefully roll valve mechanism into camshaft casing.
2.11 Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correction
by adjusting the arms (W1.5).
CAUTION
Injection cam followers (13) are adjusted to each valve unit individually and may not
be interchanged upon reassembly.
2.12 Insert the two upper fastening screws (12) of the valve mechanism with extension sleeves (14)
and slightly tighten.
2.13 Lower cam follower and disassemble arms (W1.5).
2.14 Separate carriage (W1.4) and support (W1.1).
2.15 Disassemble carriage.
2.17 Disassemble bracket with hoist (W1.3).
2.18 Disassemble support (W1.1) and bracket (W1.9).
en / 29.04.2011 IB025431 7/10

M43
2.19 Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus". 04
2.20 Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten them.
2.21 Tighten fastening screws (11, 12) "crosswise" gradually until a torque of
M= 455 Nm
is reached.
2.22 Assemble clamping screw (10) and tighten to a torque of
M = 455 Nm
en / 29.04.2011 IB025431 8/10

M43
Alternative tightening instructions for screws (10,11,12): 04

Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus"
and tighten screws in two steps as follows:
Step 1:
Preload screws to M = 270 Nm.
Step 2:
Mark screws and turn them by a torque angle of α = 30°° by means of ring spanner SW 35 (30° ≤
1/2 hexagon)
455 Nm = 270 Nm + 30°°
2.23 Slightly lubricate new O-rings (16) with Vaseline and insert into the oil pipe grooves untwisted.
2.24 Insert oil pipes (9) into the cam follower shaft and assemble circlips (8).
Check whether all circlips (8) are in place.
CAUTION
Push the cam follower shafts of each cylinder unit to the right up to limit stop.
Check control dimensions X and Y.
Dimension X (cyl.1) max = 132 mm

Dimension Y (all other cylinders) max = 0,5 mm
NOTE
Dimension Y is the projection of the eccentric of the cam follower shaft with respect
to the cam follower.
For the measurement push the cam follower onto the cam follower bracket.
en / 29.04.2011 IB025431 9/10

M43
2.25 In case of assembly and reassembly on the next to last and last cyl. assemble limit stops (31). 04
2.26 Mount clamp halves (30).
NOTE
Clamp halves (30) must not be interchanged between the different cylinder units.
2.27 Check the entire cam follower shaft for ease of movement (twisting) by means of fork wrench
(W2). It must be possible for one man to move the shaft without great effort.
2.28 Insert push-rods according to their marking.
2.29 Assemble injection pump drive.
2.30 Assemble injection pump (A5.05.07.02.01.nn).
2.31 Assemble push-rods (7).
2.32 Assemble rocker arm bracket (A5.05.01.02.01.nn).
2.33 Check valve clearance (A5.05.01.01.01.nn) .
2.34 Assemble valve cover.
2.35 Start prelubrication pump and check oil pipes (9) for leaks.
2.36 Mount camshaft cover and, at cylinder 1, adjusting unit (A5.05.04.02.10.nn).
en / 29.04.2011 IB025431 10/10

Adjusting Device FCT A5.05. 04.02.10.00
M43
See also: A3.12.06.nn, 04.02.00.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The adjusting unit (1) is to be disassembled and reassembled when carrying out maintenance
work on the valve mechanism of cyl. 1.
Tools:
Torque wrench 20 -200 Nm W1* 1.9454-202
* no picture
Molykote-Paste "G-Rapid" **
Procedure:
1. Disassembly
CAUTION
Prior to each disassembly the supply air lines are to be closed and the air sy-
stem is to be made pressureless.
1.2 Disassemble the air supply connection.
1.3 Attach the adjusting unit (1) with eye bolts (2) to a crane.
en / 30.03.2010 IB025450 1/3

M43
04
1.4 Remove hexagon nuts (3).
1.5 Secure adjusting unit (1) with crane and deposit on a suitable base support.
Pay attention to dowel pins (4). The rubber seal (5) must not be damaged.
NOTE
It is absolutely necessary for the adjustment positions of the adjusting unit and the
valve mechanism to remain unchanged.
en / 30.03.2010 IB025450 2/3

M43
2. Assembly 04
2.1 Coat the thread of the studs 86) on the engine block slightly with Molykote-Paste "G-Rapid Plus".
2.2 Place adjusting unit (1) onto studs (6) by means of the crane.
2.3 Pay attention to the position of the dowel pins (4).
2.4 Assemble nuts (3) and tighten to a torque of
M = 130 Nm.
2.5 Reestablish the air supply of the adjusting unit (1).
en / 30.03.2010 IB025450 3/3

M43
See also: A3.12.06.nn, 04.02.00.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
* no picture
Procedure:
1. Disassembly
CAUTION
en / 30.03.2010 IB025768 1/3

M43
04
NOTE
en / 30.03.2010 IB025768 2/3

M43
2. Assembly 04
M = 130 Nm.
en / 30.03.2010 IB025768 3/3

M43
See also: A3.12.06.nn, 04.02.00.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
* no picture
Procedure:
1. Disassembly
CAUTION
en / 28.05.2010 IB026649 1/3

M43
04
NOTE
en / 28.05.2010 IB026649 2/3

M43
2. Assembly 04
M = 130 Nm.
en / 28.05.2010 IB026649 3/3

M43
See also: A3.12.06.nn, 04.02.00.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:
* no picture
Procedure:
1. Disassembly
CAUTION
en / 01.11.2010 IB026653 1/3

M43
04
Attention:
It is absolutely necessary for the adjustment positions of the adjusting unit and the valve
mechanism to remain unchanged.
en / 01.11.2010 IB026653 2/3

M43
2. Assembly 04
M = 130 Nm.
en / 01.11.2010 IB026653 3/3

Camshaft A5.05. 04.04.01.00
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
Reversible ratchet W6 * 1.9459-033
* no picture
Attention:
The camshaft may only be turned after the bolted connection is loosened when
- the rocker arms of the camshaft section to be replaced and
- all rocker arms to the right of the section to be replaced have been removed or raised
and secured and
- the straight pin (Fig. 1/5) has been removed from the bearing journal (13)
or the left camshaft section is removed!
1. Disassembly
1.1 Open the indicator valves and remove the camshaft cover with housing covers and gaskets on
the control side.
1.2 Remove all rocker arms for the corresponding cylinder and the rocker arms of all cylinders loca-
ted to the right of the camshaft section to be removed to relieve the load on the camshaft.
en / 30.01.2008 IB020284 1/7

Camshaft A5.05. 04.04.01.00
M43
1.3 Remove the injection pump of the corresponding cylinder and for all cylinders to the right of the 04
cylinder being checked (07.03.01.nn).
1.4 Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft sec-
tions to the right of the camshaft section being removed. Raise and secure the rokker arms for the
intake and exhaust valves as well as for the injection pump drives for the corresponding cylinder
and all cylinders to the right of this cylinder.
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 30.01.2008 IB020284 2/7

Camshaft A5.05. 04.04.01.00
M43
1.5 When removing the last camshaft section: 1 12 04

10
1.5.1 Remove the oscillation damper (Fig. 2/10)
(04.09.01.nn) and slide to the right as far
as possible.
1.5.2 Remove the intermediate piece (12).
1.6 Place the sling (Fig. 3/W1) around the

camshaft section (3) between the exhaust 11
cam and injector cam and connect to the
lifting unit through the injection pump bore
in the crankcase.
4
1.7 Tighten the sling (W1) with the lifting unit.
1.8 Remove the retaining bolt (11).
W1
3 3 11
1.9 Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood block
and rubber mallet. Fill the camshaft bearing (4) with cardboard.
en / 30.01.2008 IB020284 3/7

Camshaft A5.05. 04.04.01.00
M43
1.10 Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges. 04
Turn the engine to make access any inaccessible hex head bolts and remove all bolts from
the left flange. Replace two opposing hex head bolts with longer bolts (W2). Set measure “s“.
s = 68 ± 0.5 mm
Remove all hex head bolts on the right flange of the camshaft section.
1.11 Place cardboard or similar material around the camshaft bearing journal.
1.12 Slide the camshaft to the right until it stops (distance “s“) with a strip of wood. Secure the remai-
ning sections.
3 3
a b
c
4
en / 30.01.2008 IB020284 4/7

Camshaft A5.05. 04.04.01.00
M43
04
Attention:
Apply no excessive or sudden force when sliding! Do not damage the bearings or bearing
journals.
1.13 Secure the right end of the camshaft with wooden wedges.
Attention:
Do not tilt the camshaft sections too much! Be very careful!
1.14 Fill the camshaft trough with cardboard or a similar material.
1.15 Pull the camshaft section (Fig. 4/3) out of the bearing block to the left while lowering the lifting
unit. Swing the camshaft section 90° and lift from the camshaft trough. Note the weight of the sec-
tion (ca. 200 kg).
1.16 Remove camshaft bearing (4) and inspect (04.01.02.nn), replace if necessary.
2. Assembly
2.1 Press the straight pin (Fig. 5/5) into the flange until it stops in accordance with the numbering
(see table) on the camshaft section flange.
Camshaft section Insert straight pin

for cylinder for code
1 5
2 1
3 6
4 5
5 3
6 7
1 7
3 6
4 5
5 3
5
en / 30.01.2008 IB020284 5/7

Camshaft A5.05. 04.04.01.00
M43
2.2 Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake cam 04
of the right camshaft section.
2.3 Place camshaft section (3) facing the coupling side in the corresponding camshaft trough on card-
board or similar material.
2.4 Place the sling (Fig. 3/W1) around the camshaft section between the exhaust cam and the injec-
tion pump cam and connect to lifting unit through the injection pump bore in the crankcase.
2.5 Raise the lifting unit slowly and slide the camshaft section bearing journal into the bearing bore in
the crankcase carefully.
Attention:
2.6 Align the camshaft section with the straight pin towards the bore in the bearing journal or in the
bearing flange built into the left end of the camshaft section.
2.7 Attach the camshaft section to the right camshaft section flange by tightening two opposing hex
head bolts (Fig. 1/1) hand tight.
2.8 Slide the camshaft section carefully to the left with a wood strip until the straight pin (5) and the re-
cess in the camshaft section engage securely. When sliding the camshaft section to the left,
the free-hanging camshaft section must be supported.
Attention:
Apply no excessive or sudden force when sliding! The camshaft gear may not be slid by
the camshaft section!
2.9 Apply Molykote to all hex head bolts (1).
2.10 Place the hex head bolts in the left camshaft section flange (as many as possible) and gradually
tighten at least three bolts to
M = 375 Nm
crosswise. Bolt the bores which cannot be reached at this time later!
2.11 Align the retaining bore in the camshaft bearing with the bore for the retaining bolt (11) in the
crankcase.
The notch in the bearing shell must be at the top.
en / 30.01.2008 IB020284 6/7

Camshaft A5.05. 04.04.01.00
M43
2.12 Drive the camshaft bearing (4) into place evenly with a suitable wood block and rubber mallet. Do 04
not tip the bearing. The bearing shell must face the retaining bore.
2.13 Apply Molykote to the retaining bolt (11) and install. Tighten the bolt to
M = 130 Nm
2.14 Lower the lifting unit and remove the sling (Fig. 1/W1).
2.15 Screw the remaining hex head bolts into the right and left camshaft section flanges by hand. (Turn
the engine if necessary). Tighten the bolts (1) gradually crosswise to
M = 375 Nm
2.16 After installing the last camshaft section:
2.16.1 Place the intermediate piece (Fig. 2/12) on the camshaft section (3) securely. The recess must be
placed into the camshaft section completely.
2.16.2 Insert the hex head bolts (1) into the connection between the camshaft section and the interme-
diate piece. Tighten the bolts hand tight. Then tighten the bolts gradually crosswise to
M = 375 Nm
2.16.3 Install the oscillation damper (10 ) (04.09.01.nn).
2.17 Install valve actuators and the injection pump drives.
2.18 Install the lifters.
2.19 Install the rocker arms and check valve clearance (01.01.01.nn).
2.20 Install injection pump (07.02.01.nn).
2.21 Check oil flow through camshaft.
2.22 Mount housing cover.
2.24 Remove turning unit (12.08.01.nn).
en / 30.01.2008 IB020284 7/7

Camshaft A5.05. 04.04.01.01
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure::
CAUTION
- all rocker arms to the right of the section to be replaced have been removed
or raised and secured and
- the straight pin (Fig. 1/5) has been removed from the bearing journal (13) or
the left camshaft section is removed!
1. Disassembly
the control side.
en / 29.04.2011 IB020286 1/8

Camshaft A5.05. 04.04.01.01
M43
cylinder being checked (A5.05.07.03.01.nn).
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 29.04.2011 IB020286 2/8

Camshaft A5.05. 04.04.01.01
M43

10
(A5.05.04.09.01.nn) and slide to the right
as far as possible.

in the crankcase.
4
W1
3 3 11
en / 29.04.2011 IB020286 3/8

Camshaft A5.05. 04.04.01.01
M43
1.9 Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood block 04
1.10 Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges.
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 29.04.2011 IB020286 4/8

Camshaft A5.05. 04.04.01.01
M43
04
CAUTION
Apply no excessive or sudden force when sliding! Do not damage the bearings or
bearing journals.
CAUTION
tion (ca. 200 kg).
1.16 Remove camshaft bearing (4) and inspect (A5.05.04.01.02.nn), replace if necessary.
2. Assembly

1 3
2 1
3 2
4 3
5 3
6 2
7 1
en / 29.04.2011 IB020286 5/8

Camshaft A5.05. 04.04.01.01
M43
04
3
5 3 5
2.2 Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake cam
CAUTION
cess in the camshaft section engage securely..
NOTE
When sliding the camshaft section to the left, the free-hanging camshaft section must
be supported.
en / 29.04.2011 IB020286 6/8

Camshaft A5.05. 04.04.01.01
M43
04
CAUTION
Apply no excessive or sudden force when sliding! The camshaft gear may not be slid
by the camshaft section!
M = 560 Nm
crankcase.
2.12 Drive the camshaft bearing (4) into place evenly with a suitable wood block and rubber mallet. Do
M = 130 Nm
M = 560 Nm
M = 560 Nm
en / 29.04.2011 IB020286 7/8

Camshaft A5.05. 04.04.01.01
M43
Alternative Tightening Instruction for Bolts (1): 04

Apply Molykote Paste "G-Rapid Plus" to threads and contact surfaces of the bolts (1) and tighten
them in two steps as follows:
Step 1:
Preload screws with a torque of M = 250 Nm.
Step 2:
Mark the screws and continue turning by a torque angle of α = 30°° by means of a single-end box
wrench SW (spanner size) 32 (30° ≈ 1/2 hexagon)
560 Nm = 250 Nm + 30°°
2.16.3 Install the oscillation damper (10 ) (A5.05.04.09.01.nn).
2.19 Install the rocker arms and check valve clearance (A5.05.01.01.01.nn).
2.20 Install injection pump (A5.05.07.02.01.nn).
2.24 Remove turning unit (A5.05.12.08.01.nn).
en / 29.04.2011 IB020286 8/8

Camshaft A5.05. 04.04.01.02
M43


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
Attention:
1. Disassembly
the control side.
en / 31.01.2008 IB020288 1/7

Camshaft A5.05. 04.04.01.02
M43
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 31.01.2008 IB020288 2/7

Camshaft A5.05. 04.04.01.02
M43

10
as possible.

in the crankcase.
4
W1
3 3 11
en / 31.01.2008 IB020288 3/7

Camshaft A5.05. 04.04.01.02
M43
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 31.01.2008 IB020288 4/7

Camshaft A5.05. 04.04.01.02
M43
04
Attention:
journals.
Attention:
tion (ca. 200 kg).
2. Assembly

1 4
2 7
3 2
4 5
5 4
6 3
7 6
8 1
1 7
2 6
3 5
4
5 3
5
en / 31.01.2008 IB020288 5/7

Camshaft A5.05. 04.04.01.02
M43
2.2 Oil the inside and outside of the camshaft bearing (Fig. 1/4) thoroughly and place on intake cam 04
Attention:
Attention:
M = 375 Nm
crankcase.
en / 31.01.2008 IB020288 6/7

Camshaft A5.05. 04.04.01.02
M43
M = 130 Nm
M = 375 Nm
M = 375 Nm
en / 31.01.2008 IB020288 7/7

Camshaft A5.05. 04.04.01.03
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
Attention:
1. Disassembly
the control side.
en / 31.01.2008 IB020290 1/7

Camshaft A5.05. 04.04.01.03
M43
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 31.01.2008 IB020290 2/7

Camshaft A5.05. 04.04.01.03
M43

10
as possible.

in the crankcase.
4
W1
3 3 11
en / 31.01.2008 IB020290 3/7

Camshaft A5.05. 04.04.01.03
M43
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 31.01.2008 IB020290 4/7

Camshaft A5.05. 04.04.01.03
M43
04
Attention:
journals.
Attention:
tion (ca. 200 kg).
2. Assembly

1 5
2 8
3 2
4 6
5 4
6 4
7 6
8 2
9 8
1 7
3 6
4 5
5 3
5
en / 31.01.2008 IB020290 5/7

Camshaft A5.05. 04.04.01.03
M43
04
Attention:
Attention:
2.10 Place the hex head bolts in the left camshaft section flange (as far as possible) and gradually tigh-
ten at least three bolts to
M = 375 Nm
Bolt the bores which cannot be reached at this time later!
crankcase.
en / 31.01.2008 IB020290 6/7

Camshaft A5.05. 04.04.01.03
M43
M = 130 Nm
M = 375 Nm
M = 375 Nm
Install the oscillation damper (10 ) (04.09.01.nn).
en / 31.01.2008 IB020290 7/7

Camshaft A5.05. 04.04.01.04
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
Attention:
1. Disassembly
the control side.
en / 31.01.2008 IB023665 1/7

Camshaft A5.05. 04.04.01.04
M43
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 31.01.2008 IB023665 2/7

Camshaft A5.05. 04.04.01.04
M43

10
as possible.

in the crankcase.
4
W1
3 3 11
en / 31.01.2008 IB023665 3/7

Camshaft A5.05. 04.04.01.04
M43
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 31.01.2008 IB023665 4/7

Camshaft A5.05. 04.04.01.04
M43
04
Attention:
journals.
Attention:
tion (ca. 200 kg).
2. Assembly

1 5
2 6
3 2
4 4
5 8
6 8
7 4
8 2
9 6
1 7
3 6
4 5
5 3
5
en / 31.01.2008 IB023665 5/7

Camshaft A5.05. 04.04.01.04
M43
04
Attention:
Attention:
M = 375 Nm
crankcase.
en / 31.01.2008 IB023665 6/7

Camshaft A5.05. 04.04.01.04
M43
M = 130 Nm
M = 375 Nm
M = 375 Nm
Install the oscillation damper (10 ) (04.09.01.nn).
en / 31.01.2008 IB023665 7/7

Camshaft A5.05. 04.04.01.05
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB024365 1/8

Camshaft A5.05. 04.04.01.05
M43
en / 29.04.2011 IB024365 2/8

Camshaft A5.05. 04.04.01.05
M43
1.5 When removing the last camshaft section: 04

as far as possible.

camshaft section (3) between the exhaust
in the crankcase.
en / 29.04.2011 IB024365 3/8

Camshaft A5.05. 04.04.01.05
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB024365 4/8

Camshaft A5.05. 04.04.01.05
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 1
2 3
3 8
4 4
5 2
6 2
7 4
8 8
9 3
en / 29.04.2011 IB024365 5/8

Camshaft A5.05. 04.04.01.05
M43
04
CAUTION
cess in the camshaft section engage securely.
NOTE
be supported.
en / 29.04.2011 IB024365 6/8

Camshaft A5.05. 04.04.01.05
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M = 420 Nm
en / 29.04.2011 IB024365 7/8

Camshaft A5.05. 04.04.01.05
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB024365 8/8

Camshaft A5.05. 04.04.01.06
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB024796 1/8

Camshaft A5.05. 04.04.01.06
M43
en / 29.04.2011 IB024796 2/8

Camshaft A5.05. 04.04.01.06
M43

as far as possible.

in the crankcase.
en / 29.04.2011 IB024796 3/8

Camshaft A5.05. 04.04.01.06
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB024796 4/8

Camshaft A5.05. 04.04.01.06
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 5
2 6
3 2
4 4
5 8
6 8
7 4
8 2
9 6
en / 29.04.2011 IB024796 5/8

Camshaft A5.05. 04.04.01.06
M43
04
CAUTION
NOTE
be supported.
en / 29.04.2011 IB024796 6/8

Camshaft A5.05. 04.04.01.06
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M = 420 Nm
en / 29.04.2011 IB024796 7/8

Camshaft A5.05. 04.04.01.06
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB024796 8/8

Camshaft A5.05. 04.04.01.07
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB025488 1/8

Camshaft A5.05. 04.04.01.07
M43
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 29.04.2011 IB025488 2/8

Camshaft A5.05. 04.04.01.07
M43

10
as possible.

in the crankcase.
4
W1
3 3 11
en / 29.04.2011 IB025488 3/8

Camshaft A5.05. 04.04.01.07
M43
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 29.04.2011 IB025488 4/8

Camshaft A5.05. 04.04.01.07
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 5
2 1
3 6
4 5
5 3
6 7
en / 29.04.2011 IB025488 5/8

Camshaft A5.05. 04.04.01.07
M43
04
8
1 7
3 6
4 5
5 3
5
CAUTION
cess in the camshaft section engage securely..
NOTE
be supported.
en / 29.04.2011 IB025488 6/8

Camshaft A5.05. 04.04.01.07
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M = 420 Nm
en / 29.04.2011 IB025488 7/8

Camshaft A5.05. 04.04.01.07
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB025488 8/8

Camshaft A5.05. 04.04.01.08
M43


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB025492 1/8

Camshaft A5.05. 04.04.01.08
M43
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 29.04.2011 IB025492 2/8

Camshaft A5.05. 04.04.01.08
M43

10
as far as possible.

in the crankcase.
4
W1
3 3 11
en / 29.04.2011 IB025492 3/8

Camshaft A5.05. 04.04.01.08
M43
s = 68 ± 0.5 mm
ning sections.
3 3
a b
c
4
en / 29.04.2011 IB025492 4/8

Camshaft A5.05. 04.04.01.08
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 4
2 7
3 2
4 5
5 4
6 3
7 6
8 1
en / 29.04.2011 IB025492 5/8

Camshaft A5.05. 04.04.01.08
M43
04
1 7
2 6
3 5
4
5 3
5
CAUTION
NOTE
be supported.
en / 29.04.2011 IB025492 6/8

Camshaft A5.05. 04.04.01.08
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M = 420 Nm
en / 29.04.2011 IB025492 7/8

Camshaft A5.05. 04.04.01.08
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB025492 8/8

Camshaft A5.05. 04.04.01.09
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
Attention:
1. Disassembly
the control side.
en / 30.03.2010 IB025496 1/8

Camshaft A5.05. 04.04.01.09
M43
en / 30.03.2010 IB025496 2/8

Camshaft A5.05. 04.04.01.09
M43

as possible.

in the crankcase.
en / 30.03.2010 IB025496 3/8

Camshaft A5.05. 04.04.01.09
M43
s = 68 ± 0.5 mm
ning sections.
en / 30.03.2010 IB025496 4/8

Camshaft A5.05. 04.04.01.09
M43
04
Attention:
journals.
Attention:
tion (ca. 200 kg).
2. Assembly

1 5
2 6
3 2
4 4
5 8
6 8
7 4
8 2
9 6
en / 30.03.2010 IB025496 5/8

Camshaft A5.05. 04.04.01.09
M43
04
Attention:
Attention:
M = 420 Nm
crankcase.
en / 30.03.2010 IB025496 6/8

Camshaft A5.05. 04.04.01.09
M43
M = 130 Nm
M = 420 Nm
M = 420 Nm
Alternative Tightening Instruction for Bolts (1):
Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 30.03.2010 IB025496 7/8

Camshaft A5.05. 04.04.01.09
M43
2.17 Install valve actuators and the injection pump drives. 04

en / 30.03.2010 IB025496 8/8

Camshaft A5.05. 04.04.01.10
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
ted to the right of this camshaft section to relieve the load on the camshaft.
en / 29.04.2011 IB026645 1/8

Camshaft A5.05. 04.04.01.10
M43
1.3 Remove the injection pump of the corresponding cylinder and for all cylinders to the right of this 04
cylinder (A5.05.07.03.01.nn).
1.4 Remove push-rods from the camshaft section of the corresponding cylinder and all camshaft sec-
tions to the right of this camshaft section being removed. Raise and secure the cam followers for
the intake and exhaust valves of the corresponding cylinder and all cylinders to the right of this cy-
linder.
en / 29.04.2011 IB026645 2/8

Camshaft A5.05. 04.04.01.10
M43

1.5.1 Remove the vibration damper (Fig. 2/10)
as far as possible.

camshaft section (3) and connect to the lif-
ting unit through the locating bore in the
crankcase.
en / 29.04.2011 IB026645 3/8

Camshaft A5.05. 04.04.01.10
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB026645 4/8

Camshaft A5.05. 04.04.01.10
M43
04
CAUTION
bearing journals.
CAUTION
1.14 Fill the camshaft casing with cardboard or a similar material.
unit. Swing the camshaft section 90° and lift from the camshaft casing. Note the weight of the sec-
tion (ca. 200 kg).
2. Assembly
2.1 Press the parallel pin (Fig. 5/5) into the flange until it stops in accordance with the numbering (see
table) on the camshaft section flange.
Camshaft section Insert parallel pin

1 5
2 1
3 6
4 5
5 3
6 7
en / 29.04.2011 IB026645 5/8

Camshaft A5.05. 04.04.01.10
M43
04
2.3 Place camshaft section (3) facing the coupling side in the corresponding camshaft casing on
cardboard or similar material.
tion pump cam and connect to lifting unit through the locating bore in the crankcase.
the engine block carefully..
CAUTION
2.8 Slide the camshaft section carefully to the left with a wood strip until the parallel pin (5) and the re-
cess in the camshaft section engage securely. .
NOTE
be supported.
en / 29.04.2011 IB026645 6/8

Camshaft A5.05. 04.04.01.10
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M=420 Nm
en / 29.04.2011 IB026645 7/8

Camshaft A5.05. 04.04.01.10
M43

Step 1:
Preload bolts with a torque of M = 176 Nm.
Step 2:
Mark the bolts and continue turning by a torque angle of α = 30°° by means of a single-end box
420 Nm = 176 Nm + 30°°
2.16.3 Install the vibration damper (10 ) (A5.05.04.09.01.nn).
2.17 Install valve mechanisms and the injection pump drives.
2.18 Install the push-rod.
2.20 Install injection pumps (A5.05.07.02.01.nn).
2.24 Disengage turning unit (A5.05.12.08.01.nn).
en / 29.04.2011 IB026645 8/8

Camshaft A5.05. 04.04.01.11
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB026886 1/8

Camshaft A5.05. 04.04.01.11
M43
cylinder (A5.05.07.03.01.nn).
linder.
en / 29.04.2011 IB026886 2/8

Camshaft A5.05. 04.04.01.11
M43

as far as possible.

crankcase.
en / 29.04.2011 IB026886 3/8

Camshaft A5.05. 04.04.01.11
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB026886 4/8

Camshaft A5.05. 04.04.01.11
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 3
2 1
3 2
4 3
5 3
6 2
7 1
en / 29.04.2011 IB026886 5/8

Camshaft A5.05. 04.04.01.11
M43
04
CAUTION
NOTE
be supported.
en / 29.04.2011 IB026886 6/8

Camshaft A5.05. 04.04.01.11
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M=420 Nm
en / 29.04.2011 IB026886 7/8

Camshaft A5.05. 04.04.01.11
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB026886 8/8

Camshaft A5.05. 04.04.01.12
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB026890 1/8

Camshaft A5.05. 04.04.01.12
M43
cylinder (A5.05.07.03.01.nn).
linder.
en / 29.04.2011 IB026890 2/8

Camshaft A5.05. 04.04.01.12
M43

as far as possible.

crankcase.
en / 29.04.2011 IB026890 3/8

Camshaft A5.05. 04.04.01.12
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB026890 4/8

Camshaft A5.05. 04.04.01.12
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 4
2 7
3 2
4 5
5 4
6 3
7 6
8 1
en / 29.04.2011 IB026890 5/8

Camshaft A5.05. 04.04.01.12
M43
04
CAUTION
NOTE
be supported.
en / 29.04.2011 IB026890 6/8

Camshaft A5.05. 04.04.01.12
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M=420 Nm
en / 29.04.2011 IB026890 7/8

Camshaft A5.05. 04.04.01.12
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB026890 8/8

Camshaft A5.05. 04.04.01.13
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
* no picture
Procedure:
CAUTION
1. Disassembly
the control side.
en / 29.04.2011 IB026894 1/8

Camshaft A5.05. 04.04.01.13
M43
cylinder (A5.05.07.03.01.nn).
linder.
en / 29.04.2011 IB026894 2/8

Camshaft A5.05. 04.04.01.13
M43

as far as possible.

crankcase.
en / 29.04.2011 IB026894 3/8

Camshaft A5.05. 04.04.01.13
M43
s = 68 ± 0.5 mm
ning sections.
en / 29.04.2011 IB026894 4/8

Camshaft A5.05. 04.04.01.13
M43
04
CAUTION
bearing journals.
CAUTION
tion (ca. 200 kg).
2. Assembly

1 1
2 3
3 8
4 4
5 2
6 2
7 4
8 8
9 3
en / 29.04.2011 IB026894 5/8

Camshaft A5.05. 04.04.01.13
M43
04
CAUTION
NOTE
be supported.
en / 29.04.2011 IB026894 6/8

Camshaft A5.05. 04.04.01.13
M43
04
CAUTION
M = 420 Nm
crankcase.
M = 130 Nm
M = 420 Nm
M = 420 Nm
en / 29.04.2011 IB026894 7/8

Camshaft A5.05. 04.04.01.13
M43

Step 1:
Step 2:
420 Nm = 176 Nm + 30°°
en / 29.04.2011 IB026894 8/8

Timing Gear Train A5.05. 04.08.01.00
M43
15000, 3750
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the tooth profiles and oil nozzle every 3,750 h
the axial clearance of the step gear every 15,000 h
Tools:
Dial gauge with bracket

* no picture
Procedure:
1. Checking the tooth profiles and oil nozzles.
1.1 Remove the timing cover from the control and exhaust side.
en / 01.11.1999 IB020343 1/3

M43
15000, 3750
1.2 Check the tooth profiles on the camshaft gear (Fig. 1/2), step gear (1) and 04
crankshaft gear (3) for pitting, misaligned running, loose metal, etc.
1.3 Measure the tooth clearance between the step gear and the camshaft gear (2) and between the
step gear and the crankshaft gear (3).
Nominal values x = 0.23 - 0.40 mm

z = 0.23 - 0.41 mm
1.4 Check the function and seat of the oil nozzles (4 and 5).
en / 01.11.1999 IB020343 2/3

M43
15000, 3750
2. Measure the axial clearance of the step gear (Fig. 2/s) with a feeler gauge or dial gauge. 04
Nominal values = 0.3 - 0.7 mm
If damage is found on the teeth or if one of the permissible nominal values (tooth or axial
clearance) is exceeded, MaK customer service must be informed.
2.1 Check the gaskets and install the timing gear cover on the exhaust and control side.
en / 01.11.1999 IB020343 3/3

M43
15000, 3750
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:

* no picture
Procedure:
en / 02.05.2011 IB020825 1/3

M43
15000, 3750

z = 0.23 - 0.41 mm
en / 02.05.2011 IB020825 2/3

M43
15000, 3750
Nominal values = 0.6 - 1.1 mm
If damage is found on the teeth or if one of the permissible nominal values (tooth or axial
clearance) is exceeded, CAT customer service must be informed.
en / 02.05.2011 IB020825 3/3

M43
15000, 3750
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:

* no picture
Procedure:
en / 02.05.2011 IB024301 1/3

M43
15000, 3750

z = 0.23 - 0.41 mm
en / 02.05.2011 IB024301 2/3

M43
15000, 3750
Nominal value s = 0.6 - 1.1 mm
CAUTION
If damage is found on the teeth or if one of the permissible nominal values (tooth or
axial clearance) is exceeded, Caterpillar customer service must be informed.
en / 02.05.2011 IB024301 3/3

M43
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Tools:

* no picture
Molykote Paste “G-Rapid” **

Note:
The work specified in the following can
only be carried out when the flywheel is re-
moved.
Procedure:
Z
1. Replace the O-ring (Fig. 2/6) on the step
gear shaft (Fig. 1/1).
1.1 Loosen the hex head bolts (Fig. 2/3) and

remove with sleeve (4) and locking plate
(5).
1
1.2 Remove the crankcase cover for the 1st
cylinder.
1.3 Press the step gear shaft (1) out of the

gear housing towards the coupling only
far enough that the O-ring (6) is accessi-
ble.
1.4 Replace the O-ring (6) and slide the gear

shaft back into place.
Attention:
Do not damage the O-ring (Fig. 3/6).
en / 31.01.2008 IB020345 1/2

M43
1.5 Apply Molykote to the contact surfaces 04

and threads of the hex head bolts (3). Z
1.6 Install hex head bolts (3) with sleeves (4)
and locking plate (5) and tighten hand
tight. 4
1.7 Press the locking plate (5) onto the hex

head bolts and tighten the bolts (3) to
M = 130 Nm
1.8 Check the gap (Fig. 3/X) between the lok-

3
king plate and step gear shaft.
5
Xmin. = 0.3 mm
Xmax. = 1.4 mm
1
Loosen the hex head bolts and adjust the
locking plate if necessary. 6
A-A A
3
5
1
4
3
Y
Y A
en / 31.01.2008 IB020345 2/2

M43
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Tools:

* no picture
en / 31.01.2008 IB023722 1/3

M43
Note: 04
The work specified in the following can only be carried out when the flywheel is removed.
Procedure:
1. Replace the O-ring (Fig. 2/6) on the step gear shaft (1).
1.1 Loosen the hex head bolts

(3 and 8) and remove with sleeves (4) and locking plates (5 and 7).
1.2 Remove the crankcase cover for the 1st cylinder.
1.3 Press the step gear shaft (1) out of the gear housing towards the coupling only far enough that
the O-ring (6) is accessible.
1.4 Replace the O-ring (6) and slide the gear shaft back into place.
en / 31.01.2008 IB023722 2/3

M43
04
Attention:
Do not damage the O-ring (Fig. 3/6).
1.5 Apply Molykote to the contact surfaces and threads of the hex head bolts (3).
1.6 Mount hex head bolts (3) and hex head bolts (8) with sleeves (4) and locking plates (5 and 7) and
tighten hand tight.
1.7 Press the locking plate (5) onto the hex head bolts and tighten the bolts (3) to
M = 190 Nm
1.8 Check the gap (X) between the locking plate and step gear shaft.
Xmin. =0.3 mm
Xmax. =1.4 mm
Loosen the hex head bolts and adjust the locking plate if necessary.
1.9 Tighten hex head bolts (8) to
M = 190 Nm
en / 31.01.2008 IB023722 3/3

M43
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Tools:

* no picture
NOTE
The work specified in the following can only be carried out when the flywheel is remo-
ved.
en / 30.03.2010 IB024305 1/3

M43
Procedure: 04
1. Replace the O-ring (Fig. 2/6) on the step gear shaft (2).
1.1 Loosen the hex head bolts

(7 and 8) and remove with sleeves (5) and locking plates (3 and 4).
1.2 Remove the crankcase cover for the 1st cylinder.
1.3 Press the step gear shaft (2) out of the gear housing towards the coupling only far enough that
the O-ring (6) is accessible.
1.4 Replace the O-ring (6) and slide the gear shaft back into place.
en / 30.03.2010 IB024305 2/3

M43
04
CAUTION
Do not damage the O-ring (6).
1.5 Apply Molykote to the contact surfaces and threads of the hex head bolts (7 and 8).
1.6 Mount hex head bolts (7) and hex head bolts (8) with sleeves (5) and locking plates
(3 and 4) and tighten hand tight.
1.7 Tighten hex head bolts (7 and 8) to
M = 190 Nm
en / 30.03.2010 IB024305 3/3

Governor Drive A5.05. 04.08.03.00
M43
15000
See also: 04

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
wear pattern on the helical gear pair and

serrated toothing on the governor drive shaft every 15,000 h
Tools:

* no picture
Procedure:
1. Disassembly
1.1 Remove filling mechanism from the governor (Fig. 2/11).
1.2 Loosen side cover on the crankcase and remove.
1.3 Remove hex head bolts (10) and lift governor (11) from crankcase.
1.4 Remove hex head bolts (Fig. 1/1) and remove governor drive shaft (2) upwards through the
crankcase.
1.5 Check the tooth profiles for pitting, misaligned running or loose metal.
1.6 Check the helical gearing on the governor drive shaft (2) and the governor (Fig. 2/11) for wear,
clean if necessary.
en / 31.01.2008 IB020305 1/3

M43
15000
1.7 Remove O-ring (Fig. 1/3) and clean contact surface in crankcase. 04
1.8 Check all oil bores for lubricating the governor drive shaft and the gears for blockage.
2. Assembly
2.1 Insert new O-ring (3).
2.2 Place governor drive shaft (2) into the crankcase by means of dowel pins (2).
2.3 Apply Molykote to the threads of the hex head bolts (1).
2.4 Insert bolts (1) and tighten hand tight.
2.5 Tighten the bolts (1) gradually crosswise to
M = 130 Nm
Z
1
Y
3
2 1 4
en / 31.01.2008 IB020305 2/3

M43
15000
2.6 Place the governor (Fig. 2/11) onto the governor drive flange. The serrated toothing on the go- 04
vernor shaft must slide easily into the serrated toothing on the governor drive shaft (Fig. 1/2).
2.7 Apply Molykote to the threads of the hex head bolts (Fig. 2/10).
2.8 Insert bolts and tighten.
2.9 Install filling mechanism in governor and recalibrate the mechanism if necessary (see also Go-
vernor Calibration, Book C).
11
10
en / 31.01.2008 IB020305 3/3

M43
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- contact pattern at hypoid gear pair every 15,000 h

- contact pattern at intermediate wheel
- channel toothing of governor drive shaft
- end play of cam shaft toothed wheel
Tools:
Reversible ratchet 1/2" W2* 1.9459-033
* not shown
Sealant “Dirko 610.020“ **
Procedure:
1. Disassembly
1.1 Detach governor floater linkages from

governor (Fig. 1/10) This is achieved by:
1.1.1 Locking stop lever in stop position.
1.1.2 Removing locking nut (1) with distance

bushing (4), bolt (6) and washer (2).
1.1.3 Removing spring link (7).
1.2 Removing hexagonal screws (11) and

lifting governor (10).
en / 11.10.2011 IB023455 1/4

M43
15000
1.3 Removing hexagonal screws (Fig. 2/20) with resilient sleeves (21). 04
1.4 Lightly attach governor drive housing (23) with sling to hoist and carefully lift out of
cylinder crank housing.
CAUTION
Risk of damage to lubricating oil passage sleeve (30) and O-ring (31).
1.5 Deposit governor drive housing (23) onto suitable surface.
1.6 Clean bearing surfaces on engine block.
en / 11.10.2011 IB023455 2/4

M43
15000
1.7 Check tooth profiles of hypoid gears (Fig. 3/40, 41) for pitting, off-track running or blow-outs. 04
Check intermediate wheel (42).
1.8 Check channel toothing of governor drive shaft (43) and governor (Fig. 1/10) for wear, clean if
necessary.
1.9 Check all oil lubrication holes for lubricating the governor drive gear and the hypoid gears for
proper flow.
en / 11.10.2011 IB023455 3/4

M43
15000
2. Assembly 04
2.1 Provide lubricating oil passage sleeve (Fig. 2/30) with new O-rings (31).
2.2 Place governor drive housing (23) carefully onto engine block by means of a crane. During this
operation absolutely pay attention to lubricating oil passage sleeve (30) and dowel pins (Fig. 3/
32).
2.3 Insert screws (Fig. 2/20) with resilient sleeves (21).
2.4 Tighten screws (20) crosswise.
2.5 Brush bearing surface of governor with “Dirko 610.020“. Put governor (Fig. 1/10) onto
bearing surface of governor drive (Fig. 2/23).
NOTE
The channel toothing of the governor shaft must slide easily into the channel toothing
of the governor drive shaft (Fig. 3/43).
2.6 Insert screws (Fig. 1/11) and tighten firmly.
2.7 Fit governor floater linkages in reverse order to removal. If necessary, carry out readjustment of
governor (also see governor adjustment, engine documentation, chapter "Control and Moni-
toring".
en / 11.10.2011 IB023455 4/4

Vibration Damper on Camshaft A5.05. 04.09.01.00
M43
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not available as figure
Auxiliary material:
** or a product of equivalent standard
1
NOTE
2
After 15,000 operating hours the vibration damp-
er must be exchanged against a new one.
CAUTION
Attention, there is a risk of injury!
Never open a vibration damper. 4 5
1. Disassembly
1.1 Remove lateral and face casing covers.
1.2 Release screws (2) and remove together with extension sleeves (3).
1.3 Lift the vibration damper (1) off the intermediate piece (4). Remove distance ring (5).
en / 13.07.2010 IB020809 1/2

M43
15000
2. Reassembly 04
2.1 Clean contact face of damper (1) and intermediate piece (4) (fat free).
2.2 Lubricate the thread of screw (2) with Molykote-Paste "G-Rapid".
2.3 Mount distance ring (5)..
2.4 Push new damper (1) onto intermediate piece (4) and screw in screws (2) with extension sleeves.
2.5 Tighten screws (2) with a torque of
M = 130 Nm
2.6 Mount lateral and face casing covers.
en / 13.07.2010 IB020809 2/2

M43
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:
1
3
** or a product of equivalent standard
NOTE 4
After 15,000 operating hours
the vibration damper must be 5
exchanged against a new one.
1
CAUTION
Attention, there is a risk of injury!
Never open a vibration damper.
1. Disassembly
1.1 Remove lateral and face casing covers.
1.2 Release screws (2) and remove together with washers (3).
1.3 Lift the vibration dampers (1) and distance ring (5) off the intermediate piece (4).
en / 27.04.2011 IB020816 1/2

M43
15000
2. Reassembly 04
2.1 Clean contact face of damper (1) and intermediate piece (4) (fat free).
2.2 Lubricate the thread of screw (2) with Molykote-Paste "G-Rapid".
2.3 Push new dampers (1) and distance ring (5) onto intermediate piece (4) and screw in screws (2)
with washers.
M = 295 Nm
2.5 Mount lateral and face casing covers.
en / 27.04.2011 IB020816 2/2

M43
30000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not shown
NOTE
After 30,000 operating hours
the vibration damper must be
exchanged against a new one.
Procedure:
1. Disassembly
1.1 Remove lateral housing cover on clutch

side.
1.2 Suspend vibration damper (1) by means of

a crane.
1.3 Loosen screws (2) and remove together

with extension sleeves (3).
1.4 Lift vibration dampers (1) from intermedite

piece (4).
en / 30.03.2010 IB025919 1/2

M43
30000
2. Assembly 04
2.1 Clean connecting surface of damper (1) and intermediate piece (4) (grease-free).
2.2 Lubricate thread of screws (2) with Molykote Paste “G-Rapid“.
2.3 Slide new dampers (1) onto intermediate piece (4) and fit screws (2) with
extension sleeves (3).
2.4 Tighten connecting bolts (2) using a torque of
M = 420 Nm
2.5 Fit lateral housing cover.
en / 30.03.2010 IB025919 2/2

Control Shaft Bearings A5.05. 05.01.02.00
Maintenance / Checking
M43/VM43
750
See also: 05.08.01.nn 05


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil control shaft every 750 h
Multi-purpose grease, see engine documentation, chapter „Operating Media“
Procedure:
1. Remove the control shaft, injection pump and operator stand covers.
2. Check the control shaft and shaft to emergency stop lever in the operating console and oil lightly
at the bearing surfaces.
NOTE
After cleaning with solvents, a light coat of oil must be applied to all glossy metal
parts to protect them from rust and corrosion!
Special attention must be paid to ensure that all bearing surfaces affected by the
cleaning procedure are oiled carefully!
3. Grease the following bearings with multi-purpose grease:
• Jointed heads on the connecting rod between the shaft in the operating console and
the control shaft.
• Jointed heads on the spring member between the control shaft and the control unit.
Remove all grease which exits the bearing carefully.
4. Oil all movable bearings on the jointed lever between the control shaft and injection pump lightly.
5. Reinstall cover.
en / 04.05.2011 IB020299 1/1

Starting Valve A5.05. 05.02.01.02
M43
7500
See also: A3.05.nn 05

Spare parts list: B1.05.05.1.4906

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
of the starting valve every 7.500 h
Tools:
Fork wrench W1* 0.9105 A
Auxiliary material:
Molykote paste “ G-Rapid “ **
WARNING
Danger of accident!
Be careful during disassembly! Position (Fig. 2/17) is under spring tension.
NOTE
All pneumatic elements are lubricated with a special grease (see engine documen-
tation, chapter „Operating Media“; multi-purpose grease) which ensures sufficient
lubrication for several years. In the event of a repair only this grease may be used. If
other lubricants are used, the function of the components cannot be guaranteed.
en / 13.07.2010 IB020586 1/4

M43
7500
1. Close the main shut-off valve on the air receiver.
1.1 Vent the air pipes on the engine.
1.2 Disassemble all pipework and cable connections from the starting valve.
Disassembly:
2. Unscrew the screws (Fig. 1/1) and disassemble the starting valve from the engine.
en / 13.07.2010 IB020586 2/4

M43
7500
3. Disassemble the protective cover (Fig. 2/2). 05

3.1 Disassemble the silencer (3) and remove the solenoid (4).
3.2 Disassemble the armature (5) by slackening the screw connection (6).
Pay attention to the spring (7).
3.3 Slacken the screw connection (8) and pull out the emergency actuation knob (9).
3.4 Disassemble screw connection (11) and nut (12).
3.5 Disassemble piston (13) by means of the fork wrench (W1).
NOTE
When disassembling nut (12) and piston (13) secure the spindle (14) against being
dragged along. To this end put a wrench through the air duct (15) on the key face of
the spindle (14) and counterhold it.
3.6 Unscrew the hexagon socket screws (16) and disassemble flange (17).
3.7 Remove the spindle (14) completely from the casing.
4. Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, if necessary
carefully rework with polishing cloth.
en / 13.07.2010 IB020586 3/4

M43
7500
Reassembly: 05
5. Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces
slightly.
5.1 Insert a new, completely assembled spindle (14).
5.2 Assemble all valve parts in inverse disassembly order.
5.3 Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).
NOTE
Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid".
5.4 Put the finish assembled valve onto the engine. Firmly tighten the screws (Fig. 1/1)..
5.5 Mount all pipe and cable connections.
5.6 Mount the protective cover (Fig. 2/2).
6. Open the main shut-off valve on the air receiver.
7. Carry out a functional and leakage test with starting air.
en / 13.07.2010 IB020586 4/4

Starting Fuel Limiter A5.05. 05.05.01.00
M20-M601C
3750
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Tools:
~ Safety note:
Vent the air system before doing any work.
Note:
All pneumatic elements are lubricated with a special grease (see operating media, section A4),
and it is not necessary to renew this for several years. Only this grease must be used for repairs.
Proper operation of all parts will no longer be ensured when other lubricants are used.
~ Safety note:
The piston is spring-loaded.
1. Functional check
1.1 Check the air connection for leaks.
1.2 Check whether the piston moves easily

under air pressure. If the movement is jer-
ky, vent the oil part (para 2).
1.3 Check the setting.
1.3.1 If maximum fuel limitation has been provi-

ded, check the setting (see the Accep-
tance Test Records).
1.3.2 Check whether 40 % fuel is admitted when

the piston is in the outer dead centre. Ad-
just by set screw (Fig. 1/11).
en / 30.05.2000 IB021410 1/3

M20-M601C
3750
05
1.4 Check whether full fuel is admitted within
15 seconds
after starting the engine. Adjust by throttle screw (Fig. 1/10).
2. Venting
2.1 Slip a transparent hose over vent screw (12) and put the other end into a an oil reservoir arranged
at a lower level. Turn the vent screw entirely in and then screw one turn back.
2.2 Remove plug (13), spring (14) and piston (15).
2.3 Fill oil in as far as 7 mm below the housing top edge (SAE 20).
2.4 Insert the piston. Drive the air out by screwing the plug in.
2.5 Proceed according to 2.3 and 2.4 until no air escapes any more. Unscrew the plug. Insert the
spring. Screw the plug in until it is flush with the housing top edge and secure it with locking
spring (16).
2.6 If the cylinder is of the older type, the air must be removed by the throttle screw.
3. Disassembly
3.1 Close the main air valve. Remove the air connection.
3.2 Remove the unit from the engine.
3.3 Measure and note down the position of throttle screw (10) and thrust screw (11).
3.4 Disassemble the unit entirely and clean it in spirit.
3.5 Inspect all parts.
en / 30.05.2000 IB021410 2/3

M20-M601C
3750
4. Reassembly 05
4.1 Renew all gaskets and seals
(Fig. 2/1 - 9).
4.2 Assemble the unit observing the following:
4.2.1 Tighten the socket head cap screws (17)

with a torque
M = 20 Nm.
4.2.2 Before fitting vent screw (12), plug (13),

spring (14), piston (15) and throttle screw
(10), apply a pressure of approximately
0,7 bar
to connection (A).
4.2.3 Fill oil (SAE 20) in as far as 7 mm below

the housing top edge at connection (B).
4.2.4 Tighten the throttle screw (10) and socket

head cap screw (18) with a torque
M = 20 Nm.
4.2.5 Vent the unit according para 2.
4.2.6 Adjust the unit and fit it on the engine.
4.2.7 Mount air connection.
4.2.8 Open main air shut-off valve
4.2.9 Check the operation according to para. 1.
Attention:
Do not shut off the air tank when the engine is in operation!
en / 30.05.2000 IB021410 3/3

Control Rod A5.05. 05.08.01.00
M43
7500
See also: 05.01.02.nn 05


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace the bushings every 7,500 h
Procedure:
6
8
7
1. Remove bushings (1).
1.1 Disassemble the connection between the

injection pump control rod (Fig. 1/7) and
jointed lever (8) on the control shaft.
1.2 Remove the bracket (6) from the jointed

lever.
X
1.3 Remove the bushings (Fig. 2/1) from the
bracket (6).
2. Install bushings (1).
Note:
As a matter of principle, new nuts (2)
are to be used after each loosening
operation [turning back of the nuts (2)]
2.1 Place new bushings (1) into the

bracket (6).
1
2.2 Connect the bracket (6) to the jointed shaft
by installing the pin (3), the washers
(4 and 5) and a new nut (2).
2.3 Tighten the nut (2) with a torque of

M = 40 Nm
en / 12.03.2010 IB020301 1/2

Control Rod A5.05. 05.08.01.00
M43
7500
2.4 Connect the bracket (6) to the injection pump control rod by installing the pin (3), the washers (4 05
and 5) and a new nut (2).

M = 40 Nm
Attention:
Check the linkage for ease of movement by pressing against the jointet lever. If the linkage
is sluggisch, readjust the injection pump and / or the linkage on the control shaft.
X
4 1 6
6 1 5 3
2
8
en / 12.03.2010 IB020301 2/2

Control Rod A5.05. 05.08.01.01
M43
7500
See also: 05.01.02.nn 05


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace the bushings every 7,500 h
Procedure:
1. Remove bushings (1).
1.1 Disassemble the connection between the

injection pump control rod (Fig. 1/7) and
jointed lever (8) on the control shaft.
1.2 Remove the bracket (6) from the jointed

lever.
1.3 Remove the bushings (Fig. 2/1) from the

bracket (6).
2. Install bushings (1).
NOTE
As a matter of principle, new
nuts (2) are to be used after
each loosening operation
[turning back of the nuts (2)]
2.1 Place new bushings (1) into the

bracket (6).
2.2 Connect the bracket (6) to the jointed shaft

by installing the pin (3), the washers
(4 and 5) and a new nut (2).
en / 30.03.2010 IB026500 1/2

Control Rod A5.05. 05.08.01.01
M43
7500
2.3 Tighten the nut (2) with a torque of 05

M = 40 Nm
2.4 Connect the bracket (6) to the injection pump control rod by installing the pin (3), the washers (4
and 5) and a new nut (2).
M = 40 Nm
CAUTION
Check the linkage for ease of movement by pressing against the jointet lever. If the
linkage is sluggisch, readjust the injection pump and / or the linkage on the control
shaft
en / 30.03.2010 IB026500 2/2

Compressed-Air Filter A5.05. 05.09.06.00
M20/M25/M32/M43/M453C/M552C/M601C
24, 150, 7500
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
Auxiliary material:
Nitro-Solvents *
CAUTION
Close feed air lines and depressurize air system before every disassembly!
NOTE
It is to be checked to what extent following units/systems (emergency stop) in the
circuit are affected in their functioning by the execution of the disassembly and
cleaning measures!
en / 18.10.2011 IB021438 1/2

M20/M25/M32/M43/M453C/M552C/M601C
24, 150, 7500
1. Drain compressed-air filte

1
1.1 Loosen drain plug (7) and empty filter
completely.
1.2 Close drain plug.
2. Disassemble compressed-air filter and 2

clean
2.1 Loosen drain plug (7) and drain filter 3

completely.
4
2.2 Close compressed-air feed line and
secure. 5
2.3 Relieve compressed-air filter via drain

plug.
2.4 Loosen housing cap (5) and remove, 6

check O-ring (1) and replace if necessary.
8 7
2.5 Loosen Phillips screw (4), remove with
guide (3) and filter element (2).
2.6 Remove locking ring (8), unscrew drain

plug and check O-ring (6), replace if ne-
cessary.
2.7 Clean all disassembled parts and check for reuse.
2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air
supply line.
2.9 Close drain plug after a short while.
en / 18.10.2011 IB021438 2/2

M20/M25/M32/M43
24, 7500
See also: C5.05.05.45.23.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
NOTE
Maintenance and trouble shooting see "engine documentation, chapter "Control
and Monitoring" C5.05.05.45.23.nn
en / 03.11.2011 IB024847 1/1

Regleröl A5.05. 05.25.00.01
Inspection / Oil change
M20/M25/M32/M43
24
See also: C5.05.04.20.27.nn 05

Spare parts list:
Operating medium: Every fuel

--------------------------------------------------------------------------------------------------------------------------------
Check:
Visual check of the governor oil every 24 h
Attention:
A visual check of the governor oil must be carried out every 24 hours on the oil level sight
glass of the governor.
If the governor oil should show obvious contamination, it must be changed forthwith.
Note:
For further information and evaluation criteria please refer to the oil specification
in Book C (C5.05.04.20.27.nn).
en / 25.08.2006 IB025366 1/1

Exhaust Line A5.05. 06.01.01.00
M43
7500
See also: 06

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
The exhaust line must be checked for leaks every 7,500 operating hours.
High temperature thread paste "Dag S 5080“ *
Note:
The exhaust line after the exhaust turbine must also be checked within the scope of this
inspection.
If there are significant oscillations and noised in the exhaust turbine, the flange connection
for the exhaust line after the turbine must be loosened and the pipe checked for distortion.
In order to prevent damage to the compensators, they may not be subjected to bending or
radial force during removal or installation. Bolting the compensators into place during in-
stallation results in a slight degree of tension (stretching; ca. 3-5 mm) in the axial direction.
All bolts must be installed with high temperature thread paste "Dag S 5080“ to prevent
them from burning into place.
Procedure:
1. Remove the exhaust line shroud.
~ Safety notice!
Be careful, not exhaust line may cause burns!
Before commencing work on the exhaust line, check the temperature of the line and allow
it to cool!
2. Check all bolted connections to make sure that they are tight.
en / 01.11.1999 IB020366 1/3

Exhaust Line A5.05. 06.01.01.00
M43
7500
3. Carbon, which can especially be found at flange connections and compensators, is a sign 06
of leaks.
Note:
If leaks are not caused by cracks in the lines or loose bolted connections, new gaskets must be
installed, see 4.8.
4. Replace any defective exhaust lines as follows:
4.1 Loosen and remove adjacent compensators (4).

Compensators may not be subjected to bending or radial forces!
4.2 Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still con-
nected but can be slid easily.
4.3 Slide the upper sections of the clamps aside, remove the chain links (2) from the lower clamp sec-
tion on both sides.
4.4 Lift both upper clamp sections simultaneously, replace defective exhaust line.
4.5 Prepare fitted pieces (x or y) for the installation of the new exhaust line.
Fitted piece length e x = 130 mm

Y = 195 mm
en / 01.11.1999 IB020366 2/3

Exhaust Line A5.05. 06.01.01.00
M43
7500
4.6 Bolt fitted piece or pieces to new exhaust line. 06

4.7 Install exhaust line and upper clamp sections.
4.8 Remove fitted piece or pieces, install compensator(s) and bolt securely into place.
- Note the indicated direction of flow when installing the compensators (4), see arrow on
the flange. Compensators may not be subjected to bending or radial forces!
- Insert bolts from the compensator side!
5. Replace any compensators with cracks in the bellows, see 4.8.
6. Install shroud.
en / 01.11.1999 IB020366 3/3

Exhaust Line A5.05. 06.01.01.01
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 01.11.1999 IB020368 1/3

Exhaust Line A5.05. 06.01.01.01
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

Y = 198 mm
en / 01.11.1999 IB020368 2/3

Exhaust Line A5.05. 06.01.01.01
M43
7500

6. Install shroud.
en / 01.11.1999 IB020368 3/3

Exhaust Line A5.05. 06.01.01.02
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 26.06.2000 IB020867 1/3

Exhaust Line A5.05. 06.01.01.02
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 198 mm
en / 26.06.2000 IB020867 2/3

Exhaust Line A5.05. 06.01.01.02
M43
7500

6. Install shroud.
en / 26.06.2000 IB020867 3/3

Exhaust Line A5.05. 06.01.01.03
M43
7500
See also: 06

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 26.06.2000 IB020870 1/3

Exhaust Line A5.05. 06.01.01.03
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 26.06.2000 IB020870 2/3

Exhaust Line A5.05. 06.01.01.03
M43
7500

6. Install shroud.
en / 26.06.2000 IB020870 3/3

Exhaust Line A5.05. 06.01.01.04
M43
7500
See also: 06

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
High temperature thread paste "Dag 5420 A“ *
Note:
inspection.
All bolts must be installed with high temperature thread paste "Dag 5420 A“ to prevent
Procedure:
~ Safety notice!
it to cool!
en / 02.10.2002 IB023858 1/3

Exhaust Line A5.05. 06.01.01.04
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 02.10.2002 IB023858 2/3

Exhaust Line A5.05. 06.01.01.04
M43
7500

4.7 Mount exhaust gas pipe with new seal (5) and clamp tops.
6. Install shroud.
en / 02.10.2002 IB023858 3/3

Exhaust Line A5.05. 06.01.01.05
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 02.10.2002 IB023862 1/3

Exhaust Line A5.05. 06.01.01.05
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 198 mm
en / 02.10.2002 IB023862 2/3

Exhaust Line A5.05. 06.01.01.05
M43
7500

6. Install shroud.
en / 02.10.2002 IB023862 3/3

Exhaust Line A5.05. 06.01.01.06
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 21.08.2003 IB023866 1/3

Exhaust Line A5.05. 06.01.01.06
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.
4.5 Prepare fitted pieces (x, y or z) for the installation of the new exhaust line.

y = 198 mm
z = 125 mm
en / 21.08.2003 IB023866 2/3

Exhaust Line A5.05. 06.01.01.06
M43
7500

Attention:
Make sure the orifice plate (15) is mounted correctly!
6. Install shroud.
en / 21.08.2003 IB023866 3/3

Exhaust Line A5.05. 06.01.01.07
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 21.08.2003 IB024053 1/3

Exhaust Line A5.05. 06.01.01.07
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 198 mm
en / 21.08.2003 IB024053 2/3

Exhaust Line A5.05. 06.01.01.07
M43
7500

Attention:
Make sure the orifice plate (15) is mounted correctly!
6. Install shroud.
en / 21.08.2003 IB024053 3/3

Exhaust Line A5.05. 06.01.01.08
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
High temperature thread paste "B & W Rivolta G.W.F“ *
Note:
inspection.
All bolts must be installed with high temperature thread paste "B & W Rivolta G.W.F“ to
prevent them from burning into place.
Procedure:
~ Safety notice!
it to cool!
en / 25.11.2010 IB024255 1/3

Exhaust Line A5.05. 06.01.01.08
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

Y = 198 mm
en / 25.11.2010 IB024255 2/3

Exhaust Line A5.05. 06.01.01.08
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 25.11.2010 IB024255 3/3

Exhaust Line A5.05. 06.01.01.09
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 15.03.2004 IB024259 1/3

Exhaust Line A5.05. 06.01.01.09
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 198 mm
en / 15.03.2004 IB024259 2/3

Exhaust Line A5.05. 06.01.01.09
M43
7500

M = 130 Nm.
M = 440 Nm.
6. Install shroud.
en / 15.03.2004 IB024259 3/3

Exhaust Line A5.05. 06.01.01.10
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
* or equivalent productt
NOTE
The exhaust line after the exhaust turbine must also be checked within the
scope of this inspection.
If there are significant oscillations and noised in the exhaust turbine, the flange
connection for the exhaust line after the turbine must be loosened and the pipe
checked for distortion.
CAUTION
In order to prevent damage to the compensators, they may not be subjected to
bending or radial force during removal or installation. Bolting the compensa-
tors into place during installation results in a slight degree of tension (stret-
ching; ca. 3-5 mm) in the axial direction.
All bolts must be installed with high temperature thread paste "B & W Rivolta G.W.F“
to prevent them from burning into place.
Procedure:
WARNING
Before commencing work on the exhaust line, check the temperature of the line
and allow it to cool!
en / 08.02.2011 IB024369 1/3

Exhaust Line A5.05. 06.01.01.10
M43
7500
of leaks..
HINWEIS
If leaks are not caused by cracks in the lines or loose bolted connections, new
gaskets must be installed, see 4.8

tion on both sides.

Y = 195 mm
en / 08.02.2011 IB024369 2/3

Exhaust Line A5.05. 06.01.01.10
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 08.02.2011 IB024369 3/3

Exhaust Line A5.05. 06.01.01.11
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
NOTE
CAUTION
Procedure:
WARNING
en / 14.05.2010 IB024373 1/3

Exhaust Line A5.05. 06.01.01.11
M43
7500
of leaks.
HINWEIS

tion on both sides.

Y = 195 mm
en / 14.05.2010 IB024373 2/3

Exhaust Line A5.05. 06.01.01.11
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 14.05.2010 IB024373 3/3

Exhaust Line A5.05. 06.01.01.12
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
NOTE
CAUTION
Procedure:
WARNING
en / 01.11.2010 IB024377 1/3

Exhaust Line A5.05. 06.01.01.12
M43
7500
of leaks.
HINWEIS

tion on both sides.

Y = 195 mm
en / 01.11.2010 IB024377 2/3

Exhaust Line A5.05. 06.01.01.12
M43
7500
06
4.6 Bolt fitted piece or pieces to new exhaust line.
M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 01.11.2010 IB024377 3/3

Exhaust Line A5.05. 06.01.01.13
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
NOTE
CAUTION
Procedure:
WARNING
en / 30.03.2010 IB024381 1/3

Exhaust Line A5.05. 06.01.01.13
M43
7500
of leaks.
HINWEIS

tion on both sides.

y = 195 mm
en / 30.03.2010 IB024381 2/3

Exhaust Line A5.05. 06.01.01.13
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 30.03.2010 IB024381 3/3

Exhaust Line A5.05. 06.01.01.14
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 19.10.2004 IB024614 1/3

Exhaust Line A5.05. 06.01.01.14
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 19.10.2004 IB024614 2/3

Exhaust Line A5.05. 06.01.01.14
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 19.10.2004 IB024614 3/3

Exhaust Line A5.05. 06.01.01.15
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 08.11.2004 IB024618 1/3

Exhaust Line A5.05. 06.01.01.15
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 08.11.2004 IB024618 2/3

Exhaust Line A5.05. 06.01.01.15
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 08.11.2004 IB024618 3/3

Exhaust Line A5.05. 06.01.01.16
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 08.11.2004 IB024622 1/3

Exhaust Line A5.05. 06.01.01.16
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 08.11.2004 IB024622 2/3

Exhaust Line A5.05. 06.01.01.16
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 08.11.2004 IB024622 3/3

Exhaust Line A5.05. 06.01.01.17
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
3. Carbon, which can especially be found at flange connections and compensators, is a sign
of leaks.
en / 23.03.2005 IB024839 1/3

Exhaust Line A5.05. 06.01.01.17
M43
7500
Note: 06
installed, see 4.8.

tion on both sides.

Y = 195 mm
en / 23.03.2005 IB024839 2/3

Exhaust Line A5.05. 06.01.01.17
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 23.03.2005 IB024839 3/3

Exhaust Line A5.05. 06.01.01.18
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
of leaks.
en / 23.03.2005 IB024843 1/3

Exhaust Line A5.05. 06.01.01.18
M43
7500
Note: 06
installed, see 4.8.

tion on both sides.

Y = 195 mm
en / 23.03.2005 IB024843 2/3

Exhaust Line A5.05. 06.01.01.18
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 23.03.2005 IB024843 3/3

Exhaust Line A5.05. 06.01.01.19
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
of leaks.
en / 01.06.2006 IB025322 1/3

Exhaust Line A5.05. 06.01.01.19
M43
7500
Note: 06
installed, see 4.8.

tion on both sides.

Y = 195 mm
en / 01.06.2006 IB025322 2/3

Exhaust Line A5.05. 06.01.01.19
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 01.06.2006 IB025322 3/3

Exhaust Line A5.05. 06.01.01.20
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 07.09.2009 IB026525 1/3

Exhaust Line A5.05. 06.01.01.20
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

Y = 195 mm
en / 07.09.2009 IB026525 2/3

Exhaust Line A5.05. 06.01.01.20
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 07.09.2009 IB026525 3/3

Exhaust Line A5.05. 06.01.01.21
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
Note:
inspection.
Procedure:
~ Safety notice!
it to cool!
en / 01.09.2009 IB026529 1/3

Exhaust Line A5.05. 06.01.01.21
M43
7500
of leaks.
Note:
installed, see 4.8.

tion on both sides.

y = 195 mm
en / 01.09.2009 IB026529 2/3

Exhaust Line A5.05. 06.01.01.21
M43
7500

M = 130 Nm.
M = 260 Nm.
6. Install shroud.
en / 01.09.2009 IB026529 3/3

Charge Air Cooler A5.05. 06.04.02.00
M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler must be removed and cleaned on the air side when the differential pressure
before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate
A1.10).
Cleaning agent as recommended by the manufacturer, such as:
• Vecom GmbH, Hamburg *

• Drew Ameroid GmbH, Hamburg *
• UNITOR chemicals *
Procedure:
1. Disassembly
1.1 Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the corresponding
cock valves are open, remove the drain bolts (Fig. 1/5) and drain water from charge air cooler.
1.2 Remove the coolant feed and return lines(4) from the charge air cooler.
en / 11.10.1999 IB020370 1/3

M43
1.3 Loosen the hex head bolts (Fig. 2/2) and (10). Remove drain plugs (11) and Allen keys (12). 06
1.4 Pull the charge air cooler (9) out of the housing (3), suspend with hoist and lower into suitable
container for cleaning.
1.5 Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C).
1.6 Inspect the housing, drain all condensation by opening the drain line (6).
~ Attention!
Follow the instructions contained in the handbook for the cleaning agent used, protect
skin from contact with cleaning agents, wear rubber gloves, safety goggles and
respiratory protection if necessary! Ensure adequate ventilation!
en / 11.10.1999 IB020370 2/3

M43
2. Assembly 06
2.1 Install charge air cooler in the reverse order as disassembly.
2.2 Replace gasket (8).
2.3 Slide charge air cooler (9) into the housing (3) carefully.
Note:
Apply a light coat of Molykote paste “G-Rapid Plus” to the contact surfaces and threads of all
bolts.
2.4 Pull the charge air cooler onto the sealing surface of the housing (3) with the bolts (12). Loosen
the bolts (12) slightly.
2.5 Tighten hex head bolts (10) and cap screws (12) with the corresponding washers. Install drain
plugs (11) and tighten to
M = 250 Nm
2.6 Attach coolant supply and return lines (4) to the charge air cooler.
2.7 Tighten drain bolts (5) and fill engine completely with coolant.
2.8 Tighten bleeder bolts or the corresponding cock valves tightly.
en / 11.10.1999 IB020370 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).

Procedure:
1. Disassembly
en / 23.06.2000 IB020873 1/3

M43
~ Attention!
en / 23.06.2000 IB020873 2/3

M43
2. Assembly 06
Note:
bolts.
2.5 Tighten hex head bolts (10) and cap screws (12) with the corresponding washers. Install drain
plugs (11) and tighten to
M = 250 Nm
en / 23.06.2000 IB020873 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).

Procedure:
1. Disassembly
en / 14.05.2004 IB024503 1/3

M43
~ Attention!
en / 14.05.2004 IB024503 2/3

M43
2. Assembly 06
Note:
bolts.
2.5 Mount hex head bolts (10) and cap screws (12) with the corresponding washers.
2.6 Tighten hex head bolts (10) and cap screws (12) with a torque of
M = 130 Nm
2.7 Install drain plugs (11) and tighten to
M = 200 Nm
en / 14.05.2004 IB024503 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).

Procedure:
1. Disassembly
en / 14.05.2004 IB024507 1/3

M43
~ Attention!
en / 14.05.2004 IB024507 2/3

M43
2. Assembly 06
Note:
bolts.
2.5 Mount hex head bolts (10) and cap screws (12) with the corresponding washers.
2.6 Tighten hex head bolts (10) and cap screws (12) with a torque of
M = 130 Nm
2.7 Install drain plugs (11) and tighten to
M = 200 Nm
en / 14.05.2004 IB024507 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).
Werkzeuge:
Fixierbolzen W1*
* keine bildliche Darstellung

Procedure:
1. Disassembly
en / 26.11.2010 IB024730 1/4

M43
1.2 Remove the coolant feed and return lines(4) from the charge air cooler. 06
1.3 Loosen the hex head bolts (Fig. 2/2) and (10). Remove drain plugs (11) and Allen keys (12).
en / 26.11.2010 IB024730 2/4

M43
1.5 Clean the charge air cooler in accordance with the manufacturer's instructions (see Book C). 06
~ Attention!
2. Assembly
2.2 Screw two positioning bolts (W1) into the closed end of the housing (3) until the thread M42x2 is
flush with the housing.
Note:
bolts.
2.6 Mount the charge air cooler with bolts (10) and the two outer studs (2) with corresponding was-
hers.
Note:
Check through the central bore whether the lug of the fastening plate is located in the countersin-
king of the housing.
2.7 Now tighten the charge air cooler finally with bolts (12) against the sealing surface to a torque of
M = 130 Nm.
2.8 Insert the third stud (2) and tighten all studs to a torque of
M = 260 Nm.
en / 26.11.2010 IB024730 3/4

M43
2.9 Remove both positioning bolts (W1) and mount drain plugs with sealing rings. 06
2.10 Insert drain plugs (11) and tighten to a torque of
M = 200 Nm.
en / 26.11.2010 IB024730 4/4

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).
Tools:
Fixing bolt W1*
* no picture

Procedure:
1. Disassembly
1.1 Loosen the bleeder bolts, or for engines

with continual bleeding, ensure that the
corresponding cock valves are open, re-
move the drain bolts (Fig. 1/5) and drain
water from charge air cooler.
1.2 Remove the coolant feed and return li-

nes(4) from the charge air cooler.
en / 04.03.2005 IB024835 1/3

M43
1.6 Inspect the housing, drain all condensation by opening the drain line.
~ Attention!
en / 04.03.2005 IB024835 2/3

M43
2. Assembly 06
2.2 Screw two positioning bolts (W1) into the closed end of the housing (3) until the thread M42x2 is
flush with the housing.
Note:
bolts.
2.6 Mount the charge air cooler with bolts (10) and the two outer studs (2) with corresponding was-
hers.
Note:
Check through the central bore whether the lug of the fastening plate is located in the countersin-
king of the housing.
2.7 Now tighten the charge air cooler finally with bolts (12) against the sealing surface to a torque of
M = 130 Nm.
2.8 Insert the third stud (2) and tighten all studs to a torque of
M = 260 Nm.
2.9 Remove both positioning bolts (W1) and mount drain plugs with sealing rings.
2.10 Insert drain plugs (11) and tighten to a torque of
M = 200 Nm.
en / 04.03.2005 IB024835 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
A1.10).

Procedure:
1. Disassembly
en / 05.10.2011 IB024499 1/3

M43
1.3 Remove hexagon screws (Fig. 2/28) with washers (37). 06
1.4 Pull the charge air cooler (2) out of the housing (3) on exhaust gas side, suspend with hoist and
lower into suitable container for cleaning.
~ Attention!
en / 05.10.2011 IB024499 2/3

M43
2. Assembly 06
2.2 Insert new O-ring (8) into O-ring sheet (9).
Note:
bolts.
2.4 Insert hexagon screws (28) with washers (37).
2.5 Tighten hexagon screws (28) one after the other to a torque of
M = 130 Nm.
en / 05.10.2011 IB024499 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
before/after the cooler exceeds 1.5 times the test bench value see engine documentation,
chapter "Technical Engine Data" (AcceptanceTest Record)

Procedure:
1. Disassembly
en / 05.10.2011 IB024609 1/3

M43
1.5 Clean the charge air cooler in accordance with the manufacturer's instructions see "engine do-
cumentation, chapter "External Documentation".
1.6 Inspect the housing, drain all condensation by opening the drain line..
CAUTION
skin from contact with cleaning agents, wear rubber gloves, safety goggles and respi-
ratory protection if necessary! Ensure adequate ventilation!
en / 05.10.2011 IB024609 2/3

M43
2. Assembly 06
NOTE
Apply a light coat of Molykote paste “G-Rapid Plus” to the contact surfaces and
threads of all bolts.
2.4
M = 130 Nm.
en / 05.10.2011 IB024609 3/3

M43
See also: 06

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
before/after the cooler exceeds 1.5 times the test bench value, see engine documentation,

Procedure:
1. Disassembly
en / 05.10.2011 IB026883 1/3

M43
1.4 Pull the charge air cooler (2) out of the housing (3) on exhaust gas side until the flange connec-
tion is visible.
The M16 (Fig. 3/13) threads on end cover can be used for pulling lugs.
Dismantle the water mist catcher by removal of screws (10). Remove tie-bars on both sides of the
cooler by removal of screws (11). Remove side plates by removal of screws
(06 and 14).
Mount lifting lugs to the inside of each tube plate end on M12 (12) and remove all hexagon
screws fixing the intermediate tube plates together.
Be careful on the O-rings when removing the first part of the cooler. Pull the other end of the char-
ge air cooler out. The cooler part can be lifted in the side plate (Fig. 3/view E).
Suspend with hoist and lower into suitable container for cleaning.
1.5 Clean the charge air cooler in accordance with the manufacturer's instructions, see "engine do-
en / 05.10.2011 IB026883 2/3

M43
06
CAUTION
2. Assembly
2.1 Install charge air cooler in the reverse order as disassembly. Be careful on the alignment of the
tube plate connection and the O-rings. Be sure that the tie-bars securely fasten and fix the ele-
ment support plates.
2.2 Insert new O-ring (Fig. 2/8) into O-ring sheet (9).
2.3 Slide charge air cooler (2) into the housing (3) carefully..
NOTE
M = 130 Nm.
2.6 Attach coolant supply and return lines (Fig. 1/4) to the charge air cooler.
en / 05.10.2011 IB026883 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB025332 1/3

M43
CAUTION
en / 05.10.2011 IB025332 2/3

M43
2. Assembly 06
NOTE
M = 130 Nm.
en / 05.10.2011 IB025332 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB026606 1/3

M43
CAUTION
en / 05.10.2011 IB026606 2/3

M43
2. Assembly 06
NOTE
M = 130 Nm.
en / 05.10.2011 IB026606 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB026610 1/3

M43
CAUTION
en / 05.10.2011 IB026610 2/3

M43
2. Assembly 06
NOTE
M = 130 Nm.
en / 05.10.2011 IB026610 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB026614 1/3

M43
CAUTION
en / 05.10.2011 IB026614 2/3

M43
2. Assembly 06
NOTE
M = 130 Nm.
en / 05.10.2011 IB026614 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB026618 1/3

M43
CAUTION
en / 05.10.2011 IB026618 2/3

M43
2. Assembly 06
NOTE
M = 130 Nm.
en / 05.10.2011 IB026618 3/3

M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:

Procedure:
1. Disassembly
en / 05.10.2011 IB026918 1/3

M43
1.4 Pull the charge air cooler (2) out of the housing (3) on exhaust gas side until the flange connec-
tion is visible.
The M16 (Fig. 3/13) threads on end cover can be used for pulling lugs.
Dismantle the water mist catcher by removal of screws (10). Remove tie-bars on both sides of the
cooler by removal of screws (11). Remove side plates by removal of screws
(06 and 14).
Mount lifting lugs to the inside of each tube plate end on M12 (12) and remove all hexagon
screws fixing the intermediate tube plates together.
Be careful on the O-rings when removing the first part of the cooler. Pull the other end of the char-
ge air cooler out. The cooler part can be lifted in the side plate (Fig. 3/view E).
Suspend with hoist and lower into suitable container for cleaning.
en / 05.10.2011 IB026918 2/3

M43
06
CAUTION
2. Assembly
2.1 Install charge air cooler in the reverse order as disassembly. Be careful on the alignment of the
tube plate connection and the O-rings. Be sure that the tie-bars securely fasten and fix the ele-
ment support plates.
2.2 Insert new O-ring (Fig. 2/8) into O-ring sheet (9).
2.3 Slide charge air cooler (2) into the housing (3) carefully..
NOTE
M = 130 Nm.
2.6 Attach coolant supply and return lines (Fig. 1/4) to the charge air cooler.
en / 05.10.2011 IB026918 3/3

Exhaust gas turbocharger A5.05. 06.05.00.02
M43
24
See also: 06.13.01.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning RM 43 every 24 h
Prerequisites:
- The compressor stage must be cleaned with the engine at operating temperature and under full
load (at least 50 % load ), if possible, i.e., at high turbocharger rpm.
- Clean pipes from the intake air system and downstream from each turbocharger.
Note:
Deposits and dirt particles may clog the nozzles, negatively impacting the washing results.
Operation of the air-side washing device:
Basic position
- Washing water container (2) : EMPTY
- Cap (1) : closed
Washing procedure:
1. Remove cap (1) from water container (2).
1.1 Fill water container (2) with clean water.
1.2 Return cap (1) to its position and tighten.
Attention:
A water container that has not been closed or closed incorrectly may cause injury of the
operator.
en / 22.11.2007 IB024028 1/3

M43
24
06
1
3
2. Push valve handle (3) against the spring and hold for approx. 10 seconds until the entire
water volume has been injected.
Note:
After cleaning the air side, the engine should be run under load for at least 5 minutes.
When the compressor impeller was contaminated, the success of a cleaning can be told by the
charge air pressure after the turbocharger.
Cleaning parameters for ABB TPL 73 and 77 turboloaders are as follows :
Turbocharger rpm: Full load – speed (at least 50 % )

hydrostatic pressure: none
diaphragm : yes
water injection time : 10 seconds
water volume : 1.0 liters
en / 22.11.2007 IB024028 2/3

M43
24
06
Attention:
Because of the increased risk of corrosion, only clear water (drinking water) - never salt
water - may be used for cleaning. This water should not contain any coolant treatments or
other chemicals which may form deposits in the air ducts.
Attention:
The injection tube must never be connected directly to city water, to a different or larger
metering device or a larger water container than those provided by Caterpillar Engines.
Attention:
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can
cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in book C or
in the operator’s manual from the turbocharger manufacturer.
Instructions for emergency engine operation with a defective turbocharger see User Manual A3.12.01.nn.
en / 22.11.2007 IB024028 3/3

M43
24
See also: 06.13.01.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning RM43C every 24 h
Prerequisites:
- Clean pipes from the intake air system and downstream from each turbocharger.
NOTE
Deposits and dirt particles may clog the nozzles, negatively impacting the washing
results.
Basic position
- Cap (1) : closed
Washing procedure:
1.2 Return cap (1) to its position and tighten.
CAUTION
A water container that has not been closed or closed incorrectly may cause
injury of the operator.
en / 30.03.2010 IB024495 1/3

M43
24
06
1
3
NOTE
After cleaning the air side, the engine should be run under load for at least 5 min-
utes.
When the compressor impeller was contaminated, the success of a cleaning can be
told by the charge air pressure after the turbocharger.
Cleaning parameters for ABB TPL 76-C33 turboloader are as follows :

hydrostatic pressure: none
diaphragm : yes
water injection time : 10 seconds
water volume : 1.0 liters
en / 30.03.2010 IB024495 2/3

M43
24
06
CAUTION
Because of the increased risk of corrosion, only clear water (drinking water) - never
salt water - may be used for cleaning. This water should not contain any coolant treat-
ments or other chemicals which may form deposits in the air ducts.
CAUTION
The injection tube must never be connected directly to city water, to a different or
larger metering device or a larger water container than those provided by
Caterpillar Engines.
CAUTION
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This
can cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in chapter
"External Documentation" or in the operator’s manual from the turbocharger manufacturer.
Instructions for emergency engine operation with a defective turbocharger see User Manual see engine
documentation, chapter "Operating Instructions".
en / 30.03.2010 IB024495 3/3

M43
24
See also: 06.13.01.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning RM43C every 24 h
Prerequisites:
- Clean pipes from the intake air system and downstream from each turbocharger..
NOTE
Deposits and dirt particles may clog the nozzles, negatively impacting the washing
results.
Basic position
- Cap (1) : closed
Washing procedure:
1.2 Return cap (1) to its position and tighten..
CAUTION
A water container that has not been closed or closed incorrectly may cause
injury of the operator.
en / 14.05.2010 IB024690 1/3

M43
24
1.3 06
1
3
NOTE
After cleaning the air side, the engine should be run under load for at least 5 min-
utes.
When the compressor impeller was contaminated, the success of a cleaning can be
told by the charge air pressure after the turbocharger.
Cleaning parameters for ABB TPL 71 C turboloader are as follows :

hydrostatic pressure:none
diaphragm : yes
water injection time :10 seconds
water volume :1.0 liters
en / 14.05.2010 IB024690 2/3

M43
24
06
CAUTION
Because of the increased risk of corrosion, only clear water (drinking water) - never
salt water - may be used for cleaning. This water should not contain any coolant treat-
ments or other chemicals which may form deposits in the air ducts.
CAUTION
The injection tube must never be connected directly to city water, to a different or
larger metering device or a larger water container than those provided by
Caterpillar Engines.
CAUTION
Additional details on the exhaust turbocharger may be found in the maintenance instructions in chapter
"External Documentation" or in the operator’s manual from the turbocharger manufacturer.
Instructions for emergency engine operation with a defective turbocharger see User Manual see engine
documentation, chapter "Operating Instructions".
en / 14.05.2010 IB024690 3/3

M43
150
See also: 06.05.00.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning RM 43 every 150 h
Prerequisites: - wet cleaning
wet cleaning of the turbine and the nozzle ring requires low exhaust temperatures and low engine
load*.
Note
The cleaning effect during turbine washing is caused by the mechanical impact of the water drop-
lets as well as by the water solubility of the deposits.
Attention:
Please note that these cleaning instructions apply only to the engines listed on cover A0
and thus, only the “low load washing“ cleaning type:
“WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERATURE OR

AT LOW ENGINE LOAD *“
may be used.
* Definition of low engine load:
Low engine load means either that the engine
- is running either, at zero pitch and rated speed

- or, on the grid at rated speed and a max. of 10 % load
- or, disengaged at rated speed.
en / 27.11.2008 IB024177 1/4

M43
150
Requirements for water and air feeds for washing turbine and nozzle ring: 06
Note:
Water flow is controlled by a diaphragm (2) upstream from control valve (1).
These are the cleaning parameters for ABB TPL 73 and 77 turbochargers:
temperature before turbine intake: < 430 ° C

=
injection time: a min. of 10 minutes
water pressure before control valve : 2.0 bar ± 0.2 bar
volume flow: 0.54 to 0.64 Liter/sec
needle valve opening diameter no needle valve
diaphragm: yes
pressure after pressure reducer: 1.0 bar
Quality requirements for water for washing turbine and nozzle ring:
Clear freshwater (drinking water) without cleaners or solvents is to be used.
The wash water used should have minimal mineral and salt content.
Notes on the cleaning procedure:
During cleaning, the water should be drained from the gas outlet casing. The water flow must be
controllable, and the water drain line must regularly be checked for deposits.
The exhaust gas temperature after the turbocharger will decrease considerably during cleaning
(down to between 50° and 100°C).
Attention:
At rated speed and zero load, washing water must flow from the drain line (7); if the wash-
ing water does not drain, the rated rpm can be reduced to 80%; if still no water will drain
from the line, the washing device, including all its lines, must be checked.
en / 27.11.2008 IB024177 2/4

M43
150
Cleaning procedure 06
Note
After start of engine or reduction of engine load.
The exhaust gas temperature before the turbine may not exceed 430 °C.
Lower values will yield improved washing results.
Sequence:
1. Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below
430 °C.
2. Control valve (1) on the control panel is locked in the “Operation (air)“position.
3. Shut-off valve (4) is closed.
4. Connecting the water supply to shut-off valve (4) before pressure meter (5).
Check if the water supply is ensured.
Note:
Before washing check the basic function of the drain (funnel duct) (3). To this end, open drain val-
ve (3) for a short time and then close it again. In doing so, a distinct flow of exhaust gas must be
noticeable.
Attention:
The emerging exhaut gas may cause burns, therefore never check the drain with unpro-
tected body parts.
3 1
7
2
5
en / 27.11.2008 IB024177 3/4

M43
150
5. Open drain valve (3). 06

Note
Along the funnel duct at drain valve (3), the operator may see the results of the cleaning from the
cleanliness of the draining water.
6. Open shut-off valve (4); pressure meter (5) should indicate a pressure of
p = 2 ± 0, 2 bar
.
7. Pull up on control valve (1) on the control panel and hold for 10 minutes.
8. Check if exhaust gas temperature after turbocharger decreases.
9. Closing shut-off valve (4).
10. Return control valve (1) on the control panel to its “Operation (air)“position.
Attention:
After washing, the water supply must be disconnected completely; i.e., including shut-off
valve (4) pressure meter (5) from the fitting on control valve (1).
11. After approx. 5 minutes, close drain valve (3), completing this cleaning procedure.
12. Disconnect the water supply completely, including shut-off valve (4) and pressure meter (5) from
the fitting on control valve (1).
13. If necessary, the cleaning procedure may be repeated.
14. If the engine will not be operated for an extended period of time, the drying air may be turned off
at valve (6) on the control panel in order to save pressurized air.
Attention:
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can
cause personal injury and major damage.
In order to prevent corrosion on the inside surfaces of the housing, the engine must be
run at the same load stage for ten more minutes.
Due to increased corrosion risk from wash water residues in the exhaust system, we rec-
ommend not performing the washing procedure before longer engine standstill periods.
For additional instructions, see User Manual A3.06.06.nn.
en / 27.11.2008 IB024177 4/4

M43
150
See also: 06.05.00.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning RM43C every 150 h
load*.
NOTE
The cleaning effect during turbine washing is caused by the mechanical impact of the
water droplets as well as by the water solubility of the deposits.
CAUTION
Please note that these cleaning instructions apply only to the engines listed on cover
A0 and thus, only the “low load washing“ cleaning type:
“WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERA-

TURE OR AT LOW ENGINE LOAD *“
may be used.

en / 23.09.2011 IB024491 1/4

M43
150
NOTE
These are the cleaning parameters for ABB TPL 76-C33 turbocharger:
temperature before turbine intake: < 430 ° C

=
diaphragm: yes
(down to between 50 °C and 100 °C).
CAUTION
At rated speed and zero load, washing water must flow from the drain line (7); if the
washing water does not drain, continue to decrease the speed until water drains; if
still no water will drain from the line, the washing device, including all its lines, must
be checked.
en / 23.09.2011 IB024491 2/4

M43
150
NOTE
Sequence:
430 °C.
NOTE
Before washing check the basic function of the drain (funnel duct) (3). To this end,
open drain valve (3) for a short time and then close it again. In doing so, a distinct
flow of exhaust gas must be noticeable.
WARNING
The emerging exhaut gas may cause burns, therefore never check the drain with
unprotected body parts.
3 1
7
2
5
en / 23.09.2011 IB024491 3/4

M43
150
NOTE
Along the funnel duct at drain valve (3), the operator may see the results of the
cleaning from the cleanliness of the draining water.
p = 2,0 ± 0, 2 bar
.
CAUTION
After washing, the water supply must be disconnected completely; i.e., including
shut-off valve (4) pressure meter (5) from the fitting on control valve (1).
13. If necessary, the cleaning procedure may be repeated..
WARNING
In order to prevent corrosion on the inside surfaces of the housing, the engine must
be run at the same load stage for ten more minutes.
Due to increased corrosion risk from wash water residues in the exhaust system, we
recommend not performing the washing procedure before longer engine standstill
periods.
For additional instructions, see engine documentation, chapter "Operating Instructions"
en / 23.09.2011 IB024491 4/4

M43
150
See also: A5.05.06.05.00.nn 06


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning RM43C every 150 h
load*.
NOTE
The cleaning effect during turbine washing is caused by the mechanical impact of the
water droplets as well as by the water solubility of the deposits.
CAUTION
Please note that these cleaning instructions apply only to the engines listed on cover
A0 and thus, only the “low load washing“ cleaning type:
“WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERA-

TURE OR AT LOW ENGINE LOAD *“
may be used.

en / 23.09.2011 IB024693 1/4

M43
150
NOTE
<
=
These are the cleaning parameters for ABB TPL 71 C turbocharger:
temperature before turbine intake: 430 ° C

diaphragm: yes
(down to between 50° and 100°C)..
CAUTION
At rated speed and zero load, washing water must flow from the drain line (7); if the
washing water does not drain, continue to decrease the speed until water drains; if
still no water will drain from the line, the washing device, including all its lines, must
be checked.
en / 23.09.2011 IB024693 2/4

M43
150
NOTE
Sequence:
430 °C.
NOTE
Before washing check the basic function of the drain (funnel duct) (3). To this end,
open drain valve (3) for a short time and then close it again. In doing so, a distinct
flow of exhaust gas must be noticeable.
WARNING
The emerging exhaut gas may cause burns, therefore never check the drain with
unprotected body parts.
3 1
7
2
5
en / 23.09.2011 IB024693 3/4

M43
150
NOTE
Along the funnel duct at drain valve (3), the operator may see the results of the
cleaning from the cleanliness of the draining water.
p = 2,0 ± 0, 2 bar
.
CAUTION
After washing, the water supply must be disconnected completely; i.e., including
shut-off valve (4) pressure meter (5) from the fitting on control valve (1).
13. If necessary, the cleaning procedure may be repeated..
WARNING
In order to prevent corrosion on the inside surfaces of the housing, the engine must
be run at the same load stage for ten more minutes.
Due to increased corrosion risk from wash water residues in the exhaust system, we
recommend not performing the washing procedure before longer engine standstill
periods.
For additional instructions, see engine documentation, chapter "Operating Instructions"
en / 23.09.2011 IB024693 4/4

Turbocharger A5.05. 06.14.01.00
M43/VM43
12000, 24000, 36000
See also: C5.05.06.10.2n.nn 06

Spare parts list: B1.05.06.43725n, B1.05.06.437259

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Exhaust gas turbocharger:
Dismount, clean and check every 12.000 h

Exchange the nozzle ring and the diffuser after 24.000 h
Exchange the axial and radial bearing after 36.000 h
NOTE
Caterpillar points out that this maintenance sheet has only been configurated for the
purpose of maintenance planning. As to any other information regarding service,
maintenance, and trouble-shooting please look into the documentation of the manu-
facturer.
Engine documentation, chapter "External Documentation" contains the operat-

ing and maintenance instructions for the ABB Exhaust Gas Turbocharger Types
TPL 71/73/76/77
The manufacturer recommends to carry out the maintenance measures when reach-
ing the above-mentioned operating periods.
NOTE
Please observe the particular safety and assembly instructions in engine documen-
tation, chapter "External Documentation"!
en / 22.09.2011 IB024902 1/1

Injection Pump A5.05. 07.02.01.00
M43

Spare parts list: B1.05.04.433580, B1.05.07.438510, B1.05.07.438540, B1.05.08.438480

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Lifting device for injection pump W1 439235 B
Torque wrench W2 * 435100 A
Socket , width across flats 41 W3 * 435102 B
Socket wrench for indicator valve W5 * 1.9100-060
Auxiliary material:
1. Disassembly
1.1 Open the indicator valves.
1.2 Remove corresponding camshaft casing

cover on camshaft side.
1.3 Remove the high-pressure injection pipe

(A5.05.07.05.01.nn) .
1.4 Mount the injection pump lifting device

(Fig. 1/W1). To this end use the threaded
holes for fastening the high-pressure pipe.
1.5 Turn the engine so that the cam follower

(2) of the corresponding injection pump
drive is on the base circle of the fuel cam
(1).
en / 29.04.2011 IB020380 1/6

M43
1.6 Close the shut-off valves. 07

1.7 Drain the fuel distributing/collecting line on
the fuel duplex filter.
1.8 Remove the lubricating oil leakage line

(Fig. 2/10), fuel leakage line (Fig. 3/20,
21) and control air pipes (Fig. 4/30, 31) of
the corresponding injection pump.
NOTE
To remove the two outer injec-
tion pumps (cylinder 1 and last
cylinder) leave the correspon-
ding flange in place. Remove
lubricating oil leakage line, fuel
leakage line, and control air li-
ne. Unscrew the screws of the
fuel filter lines (admission and
return)..
1.9 Remove the fuel distributing/collecting line (A5.05.07.15.01.nn).
en / 29.04.2011 IB020380 2/6

M43
07
1.10 Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control
shaft.
en / 29.04.2011 IB020380 3/6

M43
1.11 Push the control rack (41) as far as possible into the injection pump. 07
CAUTION
The spring tension of the injection pump drive acts against the injection pump. For
removal the cam follower (Fig. 1/2) of the injection pump drive must be on the base
circle of the fuel cam (1), if necessary turn the engine.
CAUTION
A6.05.90.10.nn.
1.12 Put on the torque wrench (W2) and evenly slacken the nuts (5).
Hydraulic pressure p = 500 bar
1.13 Attach the injection pump (6) with lifting device (W1) to a crane and lift from the engine block.
1.14 Remove the sleeve (Fig. 5/50) with O-rings (51).
CAUTION
The cylinder-specific spacer plates (7) are secured with round head grooved pins
and must not be removed.
2. Assembly
2.1 Clean the contact surfaces of the injection pump (Fig. 1/6) and the spacer plates (7).
2.2 Clean the contact surfaces of the pressure spring (3) and the pushrod (8) on the tappet body and
the bottom spring plate of the injection pump respectively.
HINWEIS
For assembly of the injection pump the cam follower (2) of the injection pump drive
must be on the base circle of the fuel cam (1), if necessary turn the engine.
When mounting the injection pump make sure the control air transition sleeve is cor-
rectly positioned in the cooling collar.
en / 29.04.2011 IB020380 4/6

M43
2.3 Mount sleeve (Fig. 6/50) with new O-rings (51). 07
2.4 Renew O-ring (Fig. 1/4) and put the injection pump over the fastening screws. Insert pushrod (8)
and pressure spring (3) into the receptacle provided on the injection pump.
CAUTION
The spring tension of the injection pump drive acts against the injection pump.
2.5 Lubricate thread and contact surfaces of the nuts (5) with Molykote paste and tighten the injection
pump by even, alternate tightening of the nuts. Upon assembly, align the injection pump with
respect to the hinged lever (Fig. 5/42).
2.6 Put on the torque wrench (W2) and tighten the nuts (Fig. 1/5) one after the other with a hydraulic
pressure of
p = 500 bar (740 Nm)
en / 29.04.2011 IB020380 5/6

M43
2.7 Screw together hinged lever (Fig. 5/42) and control rack (41) of the injection pump 07
(A5.05.05.08.01.nn).
NOTE
Before assembly check hinged lever and control shaft (43) for ease of movement.
2.8 Mount lubricating oil leakage line (Fig. 2/10), fuel leakage line (Fig. 3/20, 21) and control air pipes
(Fig. 4/30, 31).
2.9 Mount the high-pressure injection pipe (A5.05.07.05.01.nn).
2.10 Mount the fuel distributing/collecting line (A5.05.07.15.01.nn).
2.11 Mount the screws of the fuel filter lines (admission and return).
2.12 Check the control air pipe (Fig. 4/30) for the stop piston for leakage by means of compressed air.
2.13 Check stop piston / emergency stop device for correct function (A5.05.10.03.01.nn).
2.14 Mount the camshaft casing cover on camshaft side.
2.15 Open the shut-off valves.
2.16 Fill the fuel system by means of the stand-by pump and have it circulate the fuel for about 10 mi-
nutes to vent the system.
2.17 Close the indicator valves.
en / 29.04.2011 IB020380 6/6

M43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of one injection pump every 7,500 h
b) of all injection pumps every 15,000 h
Tools:
Pressure pipe W1 *
Nozzle testing device W2 * 1.9470 H
2 x cheese head screw M16x150 DIN 512 W5 *
2 x eye bolt M8
* no picture
Note:
All components in the injection pump are manufactured to high tolerances in special workshops.
This is the only way to ensure proper function. When overhauling a pump, it is important to make
sure that the individual pump components such as control sleeve, control rod, etc. are kept with
the proper housing. Exchanging or replacing parts can have a significant effect on the fuel flow
and may require that the pump is recalibrated on a test bench.
Pump elements and pressure valves may only be replaced in complete sets! When repla-
cing complete pump elements or pressure valves, the fuel feed volume is not changed.
In order to keep repair costs as low as possible, all elements needing to be overhauled should be
sent as a complete set in a manner which prevents them from being exchanged.
Protect lapped surfaces, do not touch them.
The pump springs are subject to higher wear through corrosion because they are not preheated
and must be checked every 7,500 operating hours. Replace springs if they are severely corroded
(Fig.1/9).
If there is a significant decline in cylinder output, the pressure valve must be checked and repla-
ced if necessary.
The maximum allowable lube oil leak rate at the collecting pipe is
number of cylinders x 3,0 l / day
en / 03.09.2009 IB020542 1/5

M43
15000, 7500
Procedure: 07
1. Check the pressure valve
1.1 Place the injection pump next to the injector testing unit (W2) with the help of a crane.
1.2 Mount pressure pipe on valve support (Fig. 1/20) and connect to testing unit (W2). The cap
screws (33) must be tight!
1.3 Pump to raise pressure to opening pressure pO and see if the pressure valve maintains the set
pressure
pO = 120 + 5 bar / - 15 bar (new value pO = 120 +/-5 bar)
If the pressure valve opens before the the lower opening pressure limit, replace the valve.
en / 03.09.2009 IB020542 2/5

M43
15000, 7500
2. Disassembly 07
2.1 Clean the outside of the injection pump.
2.2 Remove deflector bolts (Fig. 1/6).
2.3 Check defector bolts for cavitation in the

deflector surface, replace deflector bolts if
necessary (07.03.02.nn).
2.4 Clamp the injection pump with the valve

support (20) down in the clamping unit.
~ Attention!
Caution! The spring tension of the
pump spring (9) presses against the lo-
wer pump housing section (4)!
2.5 Release and dismantle two opposite

screws (Fig. 3/36)
2.6 Replace by longer screws (W5). (Assem-

bly aid).
2.7 Slowly dismantle the remaining screws

(36).
2.8 Slowly dismantle the assembly aid screws

(W5).
2.9 Mount the eye bolts (W6) on the lower

pump casing (Fig. 1/4).
2.10 Carefully lift the bottom pump housing (4)

by means of a crane, until the slotted disk
(26) of the pump spring (9) is clear.
Note:
Take care that the tappet body (2) is also
lifted up.
2.11 Take the slotted disk (26) sideways out of

the foot of the pump plunger (50).
en / 03.09.2009 IB020542 3/5

M43
15000, 7500
2.12 Remove the pump spring and check for corrosion. 07

2.12.1 Remove the control sleeve (5) with spring plate (7).
2.12.2 Check the toothing in the control housing for damage.
2.12.3 Loosen guide bolt (11), remove control rod (Fig. 2/10) and check control rod toothing for damage.
2.13 Remove stop piston (15):
2.13.1 Loosen cap screws (44), remove stop (16) and cap screws.
2.13.2 Remove stop piston and control rod spring (Fig. 2/18).
2.14 Place the injection pump in the clamp with the vale support (Fig. 1/20) up.
2.15 Loosen and remove the cap screws (33) - inner screw hole circle - cross-wise.
2.16 Loosen and remove the cap screws (33) - outer screw hole circle - cross-wise and lift the valve
support (20) carefully. Be careful with the pressure valve (22).
2.17 Drive the pump element (1) out of the housing with a suitable wooden dowel.
2.18 Clean all parts with gas oil and a stiff brush and blow out with compressed air.
2.19 Replace all O-rings and gaskets.
2.20 Remove the pressure piece (24) completely with the cap screws (27), slotted disks (26) and spa-
cer plate to replace gaskets (31) and (32).
2.21 Reinstall the complete pressure piece after replacing the gaskets.
Note
Insert the O-rings into the grooves with Vaseline without twisting, do not pull the rings over sharp
edges.
Check all injection pump parts for damage and wear.
In particular, check for the following wear:
Pump piston Grooving on the running surface, metering edge wear (cavitation or erosi-
on). Blackening or spots on the piston indicate water in the fuel.
Piston guide Grooving in the running surface; damage in the pump element sealing sur-
face. Cavitation in the feed bore.
Deflector bolts Cavitation in the deflection surfaces.
en / 03.09.2009 IB020542 4/5

M43
15000, 7500
Tappet Grooving in the running surface, worn out pressure bar bed. 07
Pressure valve Damaged sealing surfaces, worn out seat, worn pressure
valve spring.
Stop piston Worn control rod spring (18), grooving in the stop piston (15).
Lower spring Grooving / damage in the contact surface.

plate
3. Assembly
3.1 The pump is assembled in the reverse order as disassembly.
Attention:
As is the case with all injection pump parts, the sealing surfaces cannot and may not be re-
worked on board!
During the assembly absolutely make sure that the pump plunger (50) is in correct positi-
on with respect to the guide in the control sleeve (5).
When installing the injection pump, make sure that the control rod is positioned exactly in
relation to the control sleeve and that the markings on the control sleeve and pump piston
match up!
A tooth is milled into the control sleeve in order to allow the control sleeve to be positio-
ned in relation to the control rod. The control rod is equipped with a double tooth.
The control rod double tooth must mesh with the tooth gap in the control sleeve!
3.1.1 Apply Molykote-Paste „G-Rapid Plus“l to the threads and contact surfaces of the following bolts
and tighten to the indicated torque crosswise:
Cap screws (Fig.1/33) M = 170 Nm
Deflector bolts (6) M = 200 Nm
Cap screws (27) M = 45 Nm
Choke screws (Fig.2/14 and 17) M = 60 Nm
3.1.2 Check the action of the control rod (10); must be smooth.
en / 03.09.2009 IB020542 5/5

M43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
Pressure pipe W1 *
2 x eye bolt M8
* no picture
Note:
ced if necessary.
en / 03.09.2009 IB020541 1/5

M43
15000, 7500
Procedure: 07
1.2 Mount pressure pipe on valve support (Fig. 1/20) and connect to testing unit (W2). The cap
screws (33) must be tight!
pressure
en / 03.09.2009 IB020541 2/5

M43
15000, 7500
2. Disassembly 07


support (20) down in the clamping unit.
~ Attention!

screws (Fig. 3/36)

bly aid).

(36).

(W5).
2.9 Mount the eye bolts (W6) on the lower

pump casing (Fig. 1/4).

Note:
lifted up.

en / 03.09.2009 IB020541 3/5

M43
15000, 7500

Note
edges.
en / 03.09.2009 IB020541 4/5

M43
15000, 7500
valve spring.

plate
3. Assembly
Attention:
worked on board!
match up!
3.1.1 Apply Molykote-Paste „G-Rapid Plus“l to the threads and contact surfaces of the following bolts
and tighten to the indicated torque crosswise:
Deflector bolts (6) M = 200 Nm
Choke screws (Fig.2/14 and 17) M = 60 Nm
3.1.2 Check the action of the control rod (10); must be smooth.
en / 03.09.2009 IB020541 5/5

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
Pressure pipe W1 * 1.9470-051
Adapter for injection pump W6 * 434247 A
* no picture
Note:
(Fig.1/9).
ced if necessary.
en / 27.08.2010 IB022646 1/6

M43/VM43
15000, 7500
Procedure: 07
1.2 Mount adapter (W6) on valve support (Fig. 1/20) and connect to testing unit (W2) via pressure
pipe (W1). The cap screws (33) must be tight!
pressure
en / 27.08.2010 IB022646 2/6

M43/VM43
15000, 7500
2. Disassembly 07


support (20) down.
~ Attention!

screws (Fig. 3/36)

bly aid).

(36).

(W5).

Note:
lifted up.

en / 27.08.2010 IB022646 3/6

M43/VM43
15000, 7500

Note
edges.
en / 27.08.2010 IB022646 4/6

M43/VM43
15000, 7500
valve spring.

plate
3. Assembly
Attention:
worked on board!
match up!
3.1.1 Coat the thread and contact faces of all screws with Molykote-Paste „G-Rapid Plus“ and tighten to
the respective torque:
Deflector bolts (Fig. 1/6) M = 200 Nm
Cheese head screws (27) M = 45 Nm
Choke screws (Fig. 2/14 and 17) M = 60 Nm
3.1.2 Tighten cheese head screws (Fig. 4/33) - outer hole circle - according to the sequence
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
and cheese head screws (33) - inner hole circle - according to the sequence
(13, 16, 14, 17, 15, 18)
in three steps.
1. Step according to the sequence by applying M = 60 Nm
en / 27.08.2010 IB022646 5/6

M43/VM43
15000, 7500
07
3.1.3 Tighten cheese head screws (Fig. 4/36) according to the sequence
(19, 21, 22, 20)
in three steps.
3.1.4 Check the action of the control rod (Fig. 2/10); must be smooth.
en / 27.08.2010 IB022646 6/6

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
* no picture
NOTE
All components in the injection pump are manufactured to high tolerances in special
workshops. This is the only way to ensure proper function. When overhauling a
pump, it is important to make sure that the individual pump components such as con-
trol sleeve, control rod, etc. are kept with the proper housing. Exchanging or repla-
cing parts can have a significant effect on the fuel flow and may require that the
pump is recalibrated on a test bench.
Pump elements and pressure valves may only be replaced in complete sets!
When replacing complete pump elements or pressure valves, the fuel feed vo-
lume is not changed.
In order to keep repair costs as low as possible, all elements needing to be overhau-
led should be sent as a complete set in a manner which prevents them from being
exchanged.
If there is a significant decline in cylinder output, the pressure valve must be chek-
ked and replaced if necessary.
en / 27.08.2010 IB022649 1/6

M43/VM43
15000, 7500
Procedure: 07
pressure
en / 27.08.2010 IB022649 2/6

M43/VM43
15000, 7500
2. Disassembly 07


support (20) down.
CAUTION
Caution! The spring tension of
the pump spring (9) presses
against the lower pump
housing section (4)!

screws (Fig. 3/36)

bly aid).

(36).

(W5).
2.9 Carefully lift the bottom pump housing (4) by means of a crane, until the slotted disk (26) of the
pump spring (9) is clear.
NOTE
Take care that the tappet body (2) is also lifted up.

en / 27.08.2010 IB022649 3/6

M43/VM43
15000, 7500

2.19.1 Reinstall the complete pressure piece after replacing the gaskets.
en / 27.08.2010 IB022649 4/6

M43/VM43
15000, 7500
. 07
NOTE
Insert the O-rings into the grooves with Vaseline without twisting, do not pull the rings
over sharp edges.
Pump piston Grooving on the running surface, metering edge wear (cavita-
tion or erosion). Blackening or spots on the piston indicate
water in the fuel.
Piston guide Grooving in the running surface; damage in the pump ele-
ment sealing surface. Cavitation in the feed bore.
Tappet Grooving in the running surface, worn out pressure bar bed.
valve spring.
Stop pistonWorn control rod spring (Fig. 2/18), grooving in

the stop piston (15).

plate
3. Assembly
CAUTION
As is the case with all injection pump parts, the sealing surfaces cannot and may not
be reworked on board!
During the assembly absolutely make sure that the pump plunger (50) is in correct
position with respect to the guide in the control sleeve (5).
When installing the injection pump, make sure that the control rod is positioned exa-
ctly in relation to the control sleeve and that the markings on the control sleeve and
pump piston match up!
A tooth is milled into the control sleeve in order to allow the control sleeve to be posi-
tioned in relation to the control rod. The control rod is equipped with a double tooth.
en / 27.08.2010 IB022649 5/6

M43/VM43
15000, 7500
3.2 Coat the thread and contact faces of all screws with Molykote-Paste „G-Rapid Plus“ and tighten to 07
Deflector bolts (Fig. 1/6)M = 200 Nm
Cheese head screws (27)M = 45 Nm
Cheese head screws (35)M = 60 Nm
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
(13, 16, 14, 17, 15, 18)
in three steps.
(19, 21, 22, 20)
in three steps.
en / 27.08.2010 IB022649 6/6

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
* no picture
Note:
(Fig.1/9).
ced if necessary.
en / 27.08.2010 IB025419 1/6

M43/VM43
15000, 7500
Procedure: 07
pressure
en / 27.08.2010 IB025419 2/6

M43/VM43
15000, 7500
2. Disassembly 07


support (20) down.
~ Attention!

screws (Fig. 3/36)

bly aid).

(36).

(W5).

Note:
lifted up.

en / 27.08.2010 IB025419 3/6

M43/VM43
15000, 7500

Note
edges.
en / 27.08.2010 IB025419 4/6

M43/VM43
15000, 7500
valve spring.

plate
3. Assembly
Attention:
worked on board!
match up!
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
(13, 16, 14, 17, 15, 18)
in three steps.
en / 27.08.2010 IB025419 5/6

M43/VM43
15000, 7500
07
(19, 21, 22, 20)
in three steps.
en / 27.08.2010 IB025419 6/6

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
* no picture
Note:
ced if necessary.
en / 27.08.2010 IB025423 1/6

M43/VM43
15000, 7500
Procedure: 07
pressure
en / 27.08.2010 IB025423 2/6

M43/VM43
15000, 7500
2. Disassembly 07


support (20) down.
~ Attention!

screws (Fig. 3/36)

bly aid).

(36).

(W5).

Note:
lifted up.

en / 27.08.2010 IB025423 3/6

M43/VM43
15000, 7500

Note
edges.
en / 27.08.2010 IB025423 4/6

M43/VM43
15000, 7500
valve spring.

plate
3. Assembly
Attention:
worked on board!
match up!
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
(13, 16, 14, 17, 15, 18)
in three steps.
en / 27.08.2010 IB025423 5/6

M43/VM43
15000, 7500
3.1.3 Tighten cheese head screws (Fig. 4/36) according to the sequence 07
(19, 21, 22, 20)
in three steps.
en / 27.08.2010 IB025423 6/6

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
* no picture
** or equivalent productt
NOTE
exchanged.
Protect lapped surfaces, do not touch them.The pump springs are subject to higher
wear through corrosion because they are not preheated and must be checked every
7,500 operating hours. Replace springs if they are severely corroded (Fig.1/9).If the-
re is a significant decline in cylinder output, the pressure valve must be checked
and replaced if necessary.
en / 18.05.2011 IB026077 1/7

M43/VM43
15000, 7500
Procedure: 07
pressure
en / 18.05.2011 IB026077 2/7

M43/VM43
15000, 7500
2. Disassembly 07

necessary (A5.05.07.03.02.nn).

support (56) down.
CAUTION

screws (Fig. 3/53)

bly aid).

(53).

(W5).
2.9 Carefully lift the bottom pump housing (Fig. 1/200) by means of a crane, until the slotted disk (22)
of the pump spring (36) is clear.
NOTE
2.10 Take the slotted disk (22) sideways out of the foot of the pump plunger (100).
2.11 Remove the pump spring and check for corrosion.
en / 18.05.2011 IB026077 3/7

M43/VM43
15000, 7500
07
2.12 Remove stop piston (44).
2.12.2 Remove stop piston and control rod spring (46).
en / 18.05.2011 IB026077 4/7

M43/VM43
15000, 7500
2.13 Place the injection pump in the clamp with the vale support (Fig. 1/56) up. 07
NOTE
over sharp edges.
water in the fuel.
valve spring.


plate
en / 18.05.2011 IB026077 5/7

M43/VM43
15000, 7500
3. Assembly 07
CAUTION
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
(13, 16, 14, 17, 15, 18)
in three steps.
en / 18.05.2011 IB026077 6/7

M43/VM43
15000, 7500
(19, 21, 22, 20)
in three steps.
en / 18.05.2011 IB026077 7/7

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Tools:
* no picture
NOTE
exchanged.
If there is a significant decline in cylinder output, the pressure valve must be chek-
ked and replaced if necessary.
en / 10.05.2011 IB026081 1/7

M43/VM43
15000, 7500
Procedure: 07
pressure
en / 10.05.2011 IB026081 2/7

M43/VM43
15000, 7500
2. Disassembly 07

necessary (A5.05.07.03.02.nn).

support (56) down.
CAUTION

screws (Fig. 3/53)

bly aid).

(53).

(W5).
2.9 Carefully lift the bottom pump housing (Fig. 1/200) by means of a crane, until the slotted disk (22)
of the pump spring (36) is clear.
NOTE
2.10 Take the slotted disk (22) sideways out of the foot of the pump plunger (100).
2.11 Remove the pump spring and check for corrosion.
en / 10.05.2011 IB026081 3/7

M43/VM43
15000, 7500
07
2.12 Remove stop piston (44).
2.12.2 Remove stop piston and control rod spring (46).
en / 10.05.2011 IB026081 4/7

M43/VM43
15000, 7500
2.13 Place the injection pump in the clamp with the vale support (Fig. 1/56) up. 07
NOTE
over sharp edges.
water in the fuel.
valve spring.


plate
en / 10.05.2011 IB026081 5/7

M43/VM43
15000, 7500
3. Assembly 07
CAUTION
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
(13, 16, 14, 17, 15, 18)
in three steps.
en / 10.05.2011 IB026081 6/7

M43/VM43
15000, 7500
(19, 21, 22, 20)
in three steps.
en / 10.05.2011 IB026081 7/7

Deflector Bolts A5.05. 07.03.02.00
M43/VM43
3750, 7500
See also: 07.03.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Alternate inspection of the deflector bolts of two injection pumps every 3.750 h
Replacement of all deflector bolts after 7.500 h
Tools:
Caliper gauge W1*
* no picture
1. Remove deflector bolts.
1.1 Check deflector bolts (6) for cavitation (Y) of the deflection surfaces (X).
1.2 Maximum permissible wear value s = 4 mm.
X Y
en / 01.04.2010 IB024554 1/2

Deflector Bolts A5.05. 07.03.02.00
M43/VM43
3750, 7500
1.3 To check this use the depth gauge of the caliper gauge. 07
1.4 When the above wear value is reached, replace deflector bolts (6) with new ones.
2. Mount deflector bolts.
2.1 Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil.
2.2 Tighten new deflector bolts (6) by hand.
2.3 After that, tighten deflector bolts to a torque of
M = 200 Nm.
en / 01.04.2010 IB024554 2/2

Pressure Valve A5.05. 07.03.03.00
M43/VM43
See also: 07.05.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
* no picture
** or equivalent produc
NOTE
When the engine is operated on heavy fuel it is necessary, prior to carrying out
any work on the injection system, to run the engine for at least 0.5 hours on di-
stillate fuel to thoroughly flush the entire injection system.
In case of overhaul work care has to be taken to ensure that the individual compon-
ents of an injection pump remain assigned to the respective casing.
Only exchange complete pressure valves! When complete pressure valves are
exchanged delivery quantity will not be changed!
In case of a significant drop in cylinder output check the pressure valve and, if ne-
cessary, exchange it completely!
Procedure:
1. Disassembly
1.1 Close shut-off valves of the fuel line.
1.2 Empty the fuel distributing and collecting pipe on the fuel duplex filter.
1.3 Remove the fuel injector delivery pipe of the corresponding injection pump (A5.05.07.05.01.nn).
en / 10.05.2011 IB024603 1/2

Pressure Valve A5.05. 07.03.03.00
M43/VM43
1.4 Remove cheese head srews (1 und 2).. 07

1.5 Remove valve support (3). Pay attention to
dowel pins (5).
1.6 Remove pressure valve (4).
2. Assembly
2.1 Insert new pressure valve (4) into valve

support (3).
2.2 Replace O-ring (6).
2.3 Put valve support (3) onto injection pump.

Pay attention to dowel pins (5).
2.4 Lubricate threads and contact faces of

cheese head screws (1 und 2) with Moly-
kote-Paste „G-Rapid Plus“.
2.5 Tighten cheese head screws (2) - outer

hole circle - according to the sequence
(1, 7, 4, 10, 2, 8, 5, 11, 3, 9, 6, 12)
and cheese head screws (1) - inner hole
circle - according to the sequence
(13, 16, 14, 17, 15, 18)
in three steps.
1. Step according to the sequence by app-

lying M = 60 Nm

lying M = 120 Nm

lying M = 190 Nm
2.6 Replace O-ring (7).
2.7 Mount fuel injector delivery pipe

(A5.05.07.05.01.nn).
2.8 Open shut-off valves of the fuel line.
en / 10.05.2011 IB024603 2/2

M43/VM43
See also: 07.02.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
NOTE
After mounting a new injection pump it has to be made sure that the pump is prehea-
ted with circulating heavy fuel for at least 20 minutes.
After start the engine has to be operated for at least 10 minutes at no load.
In case that the engine will be switched over from HFO to MDO, it has to be made
sure that the max. permissible MDO temperature of 70° C is not exceeded.
The viscosity during HFO operation has to be within 12 - 13 cSt.
en / 10.05.2011 IB023228 1/1

High-Pressure Injection Pipe A5.05. 07.05.01.00
M43/VM43
See also: 07.07.01.nn, 07.08.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:

Open jawed spanner for torque wrench W3 * 1.9106 A
Auxiliary material:
Molykote-Paste “G-Rapid Plus“ **
NOTE
In the event of heavy fuel ope-
ration the engine is to be ope-
rated on distillate fuel for at
least 0.5 h before carrying out
any work on the injection sy-
stem in order to thoroughly
flush the entire injection sy-
stem.
1. Disassembly
1.1 Valve cover is removed.
en / 10.05.2011 IB020575 1/4

M43/VM43
1.2 Disassemble the fillister head screws (Fig. 2/1) with cover (3) and O-ring (2). 07
1.3 Loosen the clamping screw (4) (about 5 turns).
1.4 Loosen the pressure screw (6) and disassemble it.
1.5 Take the transverse thrust piece (15) out of the receptacle (14).
1.6 Screw the cap screw (8) out of the cylinder head/injection nozzle holder (20).
1.7 Take the complete radial thrust piece (13) with cap screw (8) out of the cylinder head
through the receptacle (14).
1.8 Disassemble the spring ring (10) from the cylinder head and take out the sleeve (12).
1.9 Remove the fillister head screws (16) and carefully draw the receptacle (14) off the injection pump
connection (17).
en / 10.05.2011 IB020575 2/4

M43/VM43
2. Reassembly 07
2.1 Renew the O-rings (2, 5, 7, 9, 11).
2.2 Daub the O-rings and sealing faces with "Molykote".
2.3 All high-pressure surfaces must be free of dirt and damages.
2.4 Daub the threads of cap screw (8), pressure screw (6), and clamping screw (4) slightly with "Mo-
lykote" as well as all high-pressure sealing faces and pressure faces (4 and 6).
NOTE
Use only original Caterpillar spare parts!
2.5 Insert the sleeve (12) into the cylinder head and lock by means of the spring ring (10).
2.6 Put the receptacle (14) onto the injection pump connection (17) and tighten the fillister head
screws (16) "by hand".
2.7 Introduce the complete radial thrust piece (13) with cap screw (8) through the receptacle (14) into
the cylinder head.
Dimension “X“ must be at least 25 mm.
NOTE
During subsequent tightening of the cap screw (8) and the pressure screws (4) and
(6) the indicated sequence of operations must be kept by all means!
2.8 Screw the cap screw (8) into injection nozzle holder (Fig. 1/20) with a torque of
M = 250 Nm
NOTE
The clamping sleeve (18) has a recess (19) in the aperture on one side which must
point towards the pressure screw (6)!
2.9 Insert the transverse thrust piece (15) into the receptacle (14).
2.10 Screw the pressure screw (6) and the clamping screw (4) evenly and alternately by hand into
the receptacle (14) until there is a contact between the transverse thrust piece (15) and the injec-
tion pump connection (17) and radial thrust piece (13) respectively (without wrench !).
en / 10.05.2011 IB020575 3/4

M43/VM43
2.11 Tighten the pressure screw (6) and the clamping screw (4) alternately and step by step starting 07
with a torque of
M = 100 Nm
each, until the prescribed torque of
M = 250 Nm
is reached for pressure screw (6) and clamping screw (4).
2.12 Tighten the fillister head screws (16).
2.13 Tighten cover (3) and O-ring (2) by means of fillister head screws (1).
2.14 Check the injection system for leakage and reassemble the valve cover.
en / 10.05.2011 IB020575 4/4

Fuel Injector A5.05. 07.07.01.03
M43/VM43
See also: 07.02.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Pulling unit for injector valve W1 439111 A
Cleaning tool for injector seat W2 * 439222 B
* no picture
Molykote Paste "G-Rapid“ **
High temperature thread paste
"Dag S 5420 A“ **
NOTE
When operating the engine with
heavy fuel oil, the engine must be
operated for at least 0.5 hours
with distillate fuel before working
on the injector system to rinse
the injector valve thoroughly.
1. Disassembly
1.1 Remove the valve cover.
NOTE
Disassemble the high-pressure
injection pipe only after complete
mounting of pulling unit (W1).
1.2 Loosen hexagon nuts (Fig. 1/1), remove

extension sleeves (12) and flange (3).
1.3 Reassemble extension sleeves (12).
en / 28.02.2011 IB027044 1/3

M43/VM43
1.4 Bolt the injector valve pulling unit 25 07

(Fig. 2/W1) securely to the adjuasting screw
(Fig. 1/8) of the injector valve (4). To this end: 24
20
1.4.1 Put in place the complete unit.
1.4.2 Loosen the hexagon head bolts (Fig. 2/20) a bit 21

and firmly screw the threaded pieces (21) onto
the extension sleeves (2) up to stop.
22
1.4.3 Firmly tighten the hexagon head bolts (20).
2
1.4.4 Firmly screw the threaded rod (22) onto the ad-
justing screw (Fig. 1/8). 23
1.4.5 Place the torsional lock (Fig. 2/23) on the hexa-

gon of the threaded rod (22).
1.5 Disassemble high-pressure injection pipe

(A5.05.07.05.01.nn).
1.6 Loosen the injector valve by turning the

threaded sleeve (24) by means of wrench (25)
and screw out until the bottom O-ring (Fig. 1/7)
is exposed. 22
1.7 Remove hexagon head bolts (Fig. 2/20)

24
1.8 Pull out injector valve with pulling unit.
1.9 Remove the pulling unit completely and reas- 20

semble it.
1.10 Clean the injector valve externally, mark it with

the cylinder number and carry out a functional
check of the injector (A5.05.07.08.01.nn).
1.11 Clean the injector seat (Fig. 1/9) in the sleeve

(6) by scraping with tool (W2). Clean the inside
of the sleeve.
25
20
2. Assembly
2.1 Replace O-rings (7). 21
NOTE
Only use original Caterpillar replace- 23
ment parts!
en / 28.02.2011 IB027044 2/3

M43/VM43
2.2 Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fig. 1/5) 07
and nozzle holder.
2.3 Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the nuts (1)
and O-rings (7).
NOTE
Excess paste must be removed! Excess paste may cause the O-rings to be squee-
zed off in the locking groove of the cylinder head!
No seal between the injector valve and sleeve in area (Fig. 1/X).
2.4 Place injector valve in sleeve, note the position of the locking pin (Fig. 5/10).
2.5 Install flange (Fig. 1/3) with the ring shoulder down.
2.6 Install the sleeves (12).
2.7 Tighten the hex head nuts (1) evenly by hand. Make sure that the flange (3) rests flush on the in-
jector valve (4).
2.8 Install injector line (A5.05.07.05.01.nn).
2.9 Tighten the nuts (1) to

M = 60 Nm
in two steps.
2.10 Check fuel line for leaks.
2.11 Install cylinder head cover.
en / 28.02.2011 IB027044 3/3

M43/VM43
See also: 07.02.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Pulling unit for injector valve W1 439111 A
Cleaning tool for injector seat W2 * 432120 A
* no picture
Molykote Paste "G-Rapid“ **
High temperature thread paste
"Dag S 5420 A“ **
NOTE
When operating the engine with
heavy fuel oil, the engine must be
operated for at least 0.5 hours
with distillate fuel before working
on the injector system to rinse
the injector valve thoroughly.
1. Disassembly
1.1 Remove the valve cover.
NOTE
Disassemble the high-pressure
injection pipe only after complete
mounting of pulling unit (W1).
1.2 Loosen hexagon nuts (Fig. 1/1), remove ex-

tension sleeves (12) and flange (3).
1.3 Reassemble extension sleeves (12).
en / 10.05.2011 IB027049 1/3

M43/VM43
1.4 Bolt the injector valve pulling unit 25 07

(Fig. 2/W1) securely to the adjuasting screw
(Fig. 1/8) of the injector valve (4). To this end: 24
20
1.4.1 Put in place the complete unit.
1.4.2 Loosen the hexagon head bolts (Fig. 2/20) a bit 21

and firmly screw the threaded pieces (21) onto
the extension sleeves (2) up to stop.
22
1.4.3 Firmly tighten the hexagon head bolts (20).
2
1.4.4 Firmly screw the threaded rod (22) onto the ad-
justing screw (Fig. 1/8). 23
1.4.5 Place the torsional lock (Fig. 2/23) on the hexa-

gon of the threaded rod (22).
1.5 Disassemble high-pressure injection pipe

(A5.05.07.05.01.nn).
1.6 Loosen the injector valve by turning the

threaded sleeve (24) by means of wrench (25)
and screw out until the bottom O-ring (Fig. 1/7)
is exposed. 22
1.7 Remove hexagon head bolts (Fig. 2/20)

24
1.8 Pull out injector valve with pulling unit.
1.9 Remove the pulling unit completely and reas- 20

semble it.
1.10 Clean the injector valve externally, mark it with

the cylinder number and carry out a functional
check of the injector (A5.05.07.08.01.nn).
1.11 Clean the injector seat (Fig. 1/9) in the sleeve

(6) by scraping with tool (W2). Clean the inside
of the sleeve.
25
20
2. Assembly
2.1 Replace O-rings (7). 21
NOTE
Only use original Caterpillar replace- 23
ment parts!
en / 10.05.2011 IB027049 2/3

M43/VM43
2.2 Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fig. 1/5) 07
and nozzle holder.
2.3 Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the nuts (1)
and O-rings (7).
NOTE
Excess paste must be removed! Excess paste may cause the O-rings to be squee-
zed off in the locking groove of the cylinder head!
No seal between the injector valve and sleeve in area (Fig. 1/X).
2.4 Place injector valve in sleeve, note the position of the locking pin (Fig. 5/10).
2.5 Install flange (Fig. 1/3) with the ring shoulder down.
2.6 Install the sleeves (12).
2.7 Tighten the hex head nuts (1) evenly by hand. Make sure that the flange (3) rests flush on the in-
jector valve (4).
2.8 Install injector line (A5.05.07.05.01.nn).
2.9 Tighten the nuts (1) to

M = 60 Nm
in two steps.
2.10 Check fuel line for leaks.
2.11 Install cylinder head cover.
en / 10.05.2011 IB027049 3/3

Maintenance / Adjustment
M43/VM43
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 H

Adapter/nozzle support nozzle tester W2 439206 A
Injector delivery pipe W3 1.9470-051
~ Safety note:
When checking the opening pressure: Danger! Keep your hands off the fuel jet!
Note:
The correct function of the fuel injectors can only be assessed from the behaviour of the exhaust
gas temperatures or smoke emission behaviour.
The fuel injector should only be checked in case of a significant deviation of the exhaust gas
temperature from the respective cylinder value.
By means of the nozzle tester the behaviour of the nozzle in operation cannot be reproduced,
because the flow rates and the related pressure build-up are not comparable with the real
conditions on the engine.
A poor spray pattern, therefore, is not an indicator of the function of the nozzle.
On the nozzle tester the specified opening pressure is to be adjusted after assembly of the
nozzle.
A drop in opening pressure of up to 50 bar - 80 bar after a short operating time (setting of nozzle
spring and needle) is normal.
Corrosive attack and erosion are the consequence of low charge air temperatures or water in the
charge air.
en / 25.08.2003 IB020335 1/2

M43/VM43
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
2. Check the nozzle hole for sharp edges,

ovalization, corrosion and damage.
3. Place the injector with the adapter (W2) in

the tester (W1).
4. Connect the injector delivery pipe (W3).
5. Increase the pressure gradually until the

nozzle opens. Injector opening
pressure, see acceptance test records
A1.10.
Note:
If a high portion of fuel is leaking, repair
(07.09.01.nn) or replace the injector.
5.1 If the opening pressure is not correct,

slacken the lock nut (1) and turn the
adjusting screw (2) until the pressure is
correct. Tighten the lock nut (1) again.
en / 25.08.2003 IB020335 2/2

M43/VM43
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 H

Adapter/nozzle support nozzle tester W2 439206 A
Injector delivery pipe W3 1.9470-051
CAUTION
When checking the opening pressure: Risk of accident! Keep your hands off the fuel
jet!
NOTE
Proper function of the injection nozzlescan only be assessed from the behaviour of
the exhaust gas temperatures or smoke emission behaviour.
The fuel injector should only be checked in case of a significant deviation of

the exhaust gas temperature from the respective cylinder value. For this pur-
pose the nozzle tester is provided, which can also be used for checking the
nozzle holes for unobstructed passage.
By means of the nozzle tester the behaviour of the nozzle in operation cannot be re-
produced, because the flow rates and the related pressure build-up are not compara-
ble with the real conditions on the engine, i.e. the spray pattern alone gives no
indication of the function of the nozzle.
On the nozzle tester the specified opening pressure is to be adjusted after assembly
of the nozzle.
A drop in opening pressure after a short operating time (setting of nozzle spring and
needle) is normal.
Corrosive attack and erosion are the consequence of low charge air temperatures or
water in the charge air.
en / 10.05.2011 IB026029 1/3

M43/VM43
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
2. Check the nozzle hole for sharp edges,

ovalization, corrosion and damage.
3. Place the injector with the adapter (W2) in

the tester (W1).
4. Connect the injector delivery pipe (W3).
5. Increase the pressure by means of the

pump until the nozzle opens.
Determine injector opening pressure and
free passage of the nozzle holes.
NOTE
If a high portion of fuel is leaking or
if the nozzle holes are clogged and
the nozzle already opens below
the minimum nozzle opening
pressure of 390 bar, repair or re-
place the injector according to
(A5.05.07.09.01.nn).
5.1 For adjusting the opening pressure slacken the lock nut (1) and turn the adjusting screw (2) until
the correct opening pressure is adjusted (see 5.2 and 5.3). Tighten the lock nut (1).
5.2 When using a new fuel injector or a new nozzle element (8, 12) and a new nozzle spring (4) the
nozzle opening pressure is to be adjusted according to the testbed record, see engine do-
cumentation, chapter "Technical Engine Data".
en / 10.05.2011 IB026029 2/3

M43/VM43
5.3 When continuing to use the old nozzle 07

element (8, 12) and/or the old nozzle spring
(4) the opening pressure is to be adjusted
according to the testbed record value, see
engine documentation, chapter
"Technical Engine Data",
minus 10%.
Ptest = 570 bar - 10% = 513 bar
en / 10.05.2011 IB026029 3/3

M43
7500
See also: 07.07.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace all injector elements every 7,500 h
Tools:
Retainer, fuel injector W1 439208 A

Torque wrench W2 435100 A
Insert SW55 W3 439208-001
Hexagon spanner W4 ** 0.9100-055
High temperature thread paste Dag S 5420 A“ *
Molykote Paste "G-Rapid‘‘ *
** not available as figure
Note:
The fuel injector must be removed / reassembled every 7,500 operating hours or when an inspec-
tion (07.08.01.nn) reveals faults.
All parts of the injection system are manufactured to high tolerances in special workshops. This is
the only way to ensure proper function. For this reason, repairs cannot be made by the operator
and maintenance work should be limited to:
• Cleaning
• Checking of nozzle opening pressure and seals
• Replacement of wearing parts with the use of OEM parts and

replacement elements
• Replacement of all injector elements (injector needle and element).
The CAT customer service permits low cost repair.
Injection valves that need to be overhauled should be sent to the CAT customer service as a com-
plete set and in a manner that presents them from being mixed up.
Address see B0.02.
en / 10.05.2004 IB022975 1/4

M43
7500
1. Disassembly
1.1 Insert fuel injector (Fig. 1/13) into retainer (W1). In doing so fit tightly into insert (W3).
1.2 Mount flange (2) with hexagon screws (1) and tighten the hexagon head screws.
Note:
Observe the mounting position of the fuel injector in the flange (2)!
(Position of the positioning pin Fig. 2/17).
1.3 Slacken nut (3) and relieve nozzle spring (4) by unscrewing the setting screw (11).
Attention:
To slacken the nozzle nut (6) only use hexagon spanner (W4), do not use torque wrench
(Fig. 3/W2).
1.4 Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut (Fig.
2/6).
1.5 Take off hexagon spanner (W4) and remove nozzle nut.
1.6 Take out nozzle element (Fig. 2/8) including nozzle needle (12) without damaging the lapped sur-
faces.
1.7 Slacken hexagon head screws (Fig. 1/1) and remove with flange (2).
1.8 Take fuel injector out of retainer (W1).
en / 10.05.2004 IB022975 2/4

M43
7500
1.9 Remove adjusting screw (Fig. 2/11), remove spring guide 07

(10), injector spring (4) and pressure pin (5).
1.10 Inspect injector spring (4) and pressure pin (5).
1.11 Clean all parts with gas oil.
1.12 Place injector needle (12) into nozzle (8) with gas oil and
check to see if the needle sinks to its seat of its own weight.
If the needle hangs or is stuck, the entire injector element
(8+12) must be replaced.
1.13 All parts, especially injector needle and sealing surfaces,

must be inspected. Replace any defective parts.
2. Assembly
2.1 Dry all sealing surfaces with lint free paper.
2.2 Install new O-rings (9) and (14) with Molykote paste.
2.3 The fuel injector is installed in the reverse order as

disassembly.
Attention:
When installing the adjusting spindle (1), note the slit
position (X) to the fuel injector housing (13)!
2.4 Apply high temperature paste to the outer threads of the fuel
injector (13).
2.5 Place fuel injector in retainer (Fig. 3/W1).
2.6 Mount flange (2) with hexagon head screws (1) and tighten
the screws.
en / 10.05.2004 IB022975 3/4

M43
7500
2.7 Put on complete nozzle element (Fig. 2/8+12). Observe position of the pins (7). 07
2.8 Unscrew nozzle nut (6) and tighten by hand.
Attention:
In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of
p = 545 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn .
2.9 Put torque wrench (Fig. 3/W2) on nozzle nut (Fig. 2/6) and tighten with a pressure of
p = 545 bar
(Equals a torque of M = 800 Nm)
2.12 Check / adjust fuel injector according to 07.08.01.nn .
en / 10.05.2004 IB022975 4/4

M43/VM43
7500
See also: 07.07.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:

Insert SW55 W3 439208-001
Note:
The fuel injector must be removed / reassembled every 7,500 operating hours or when an inspec-
tion (07.08.01.nn) reveals faults.
All parts of the injection system are manufactured to high tolerances in special workshops. This is
the only way to ensure proper function. For this reason, repairs cannot be made by the operator
and maintenance work should be limited to:
• Cleaning

The CAT customer service permits low cost repair.
Injection valves that need to be overhauled should be sent to the CAT customer service as a com-
plete set and in a manner that presents them from being mixed up.
Address see B0.02.
en / 16.12.2008 IB023795 1/4

M43/VM43
7500
1. Disassembly
Note:
Attention:
To slacken the nozzle nut (6) only use hexagon spanner (W4), do not use torque wrench
(Fig. 3/W2).
1.4 Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut (Fig.
2/6).
faces.
en / 16.12.2008 IB023795 2/4

M43/VM43
7500

1.11 Clean all parts with gas oil.

2. Assembly

disassembly.
Attention:
When installing the adjusting spindle (1), note the slit
position (X) to the fuel injector housing (13)!
injector (13).
the screws.
en / 16.12.2008 IB023795 3/4

M43/VM43
7500
2.8 Unscrew nozzle nut (6) and tighten by hand.
Attention:
In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of
p = 465 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn .
p = 465 bar
2.12 Check / adjust fuel injector according to 07.08.01.nn .
en / 16.12.2008 IB023795 4/4

M43/VM43
7500
See also: 07.07.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Tools:

Insert SW55 W3 439208-001
NOTE
The fuel injector must be removed / reassembled every 7,500 operating hours or
when an inspection (A5.05.07.08.01.nn) reveals faults.
All parts of the injection system are manufactured to high tolerances in special work-
shops. This is the only way to ensure proper function. For this reason, repairs cannot
be made by the operator and maintenance work should be limited to:
• Cleaning

The Caterpillar customer service permits low cost repair.
Injection valves that need to be overhauled are to be sent to the Caterpillar custo-
mer service as a complete unit.
en / 10.05.2011 IB026034 1/4

M43/VM43
7500
1. Disassembly
NOTE
NOTE
To slacken the nozzle nut (6) only use hexagon spanner (W4), do not use torque
wrench (Fig. 3/W2).
1.4 Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut
(Fig. 2/6).
faces.
en / 10.05.2011 IB026034 2/4

M43/VM43
7500

1.11 Carry out a visual inspection of nozzle spring (4) and pressu-
re pin (5). If any severe indicators of wear (cavitation) are
identified, replace them.

2. Assembly

disassembly.
NOTE
When installing the adjusting spindle (1), note
the slit position (X) to the fuel injector housing
(13)!
injector (13).
the screws.
en / 10.05.2011 IB026034 3/4

M43/VM43
7500
2.8 Screw on nozzle nut (6) and tighten by hand.
CAUTION
A6.05.90.10.nn.
p = 465 bar
2.12 Adjust fuel injector according to (A5.05.07.08.01.nn), items 3,4, and 5.1.
en / 10.05.2011 IB026034 4/4

Fuel Duplex Filter A5.05. 07.12.01.06
M32/M43/M552C
See also: - 07
Spare parts list: B1.05.07.n.7667

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Cleaning pistol W1 1.9100-110
Auxiliary material:
”Filter clean” cleaning fluid from Messrs. Vecom *
Note:
All maintenance and other work on the filter should be carried out with the greatest care to pre-
vent malfunctions from occurring in the fuel injection system.
Never let a full filter cool down when being operated on heavy fuel!
The cleaning interval for the filter will depend mainly on the engine operating conditions, fuel qua-
lity and the quality of the fuel separation and will thus differ from unit to unit.
After commissioning a new system or after working on the fuel pipeline system, the filter should
be checked after 24 hrs. and cleaned if necessary.
1. Changeover to the clean filter chamber. Changeover procedure (see plate on the filter cover).
en / 02.03.1999 IB003512 1/4

M32/M43/M552C
2. Cleaning 07
2.1 Clean the filter during normal operation of the engine when
50% of the red area
of the differential pressure indicator (Fig. 1/1) can be seen or when the filter alarm has been acti-
vated.
7
6 6
5 1
4
5
2
~ Safety note:
Depressurize the filter chamber!
2.2 Loosen the hexagon socket screw (6) and

compensate pressure.
2.3 Remove the cover (5) of the filter chamber

which has been taken out of operation.
2.4 Open the ball cock (8) for sludge drain.

Drain the filter chamber.
2.5 Loosen the self-locking nuts (2) on the tie

rod (3) and pull out the screen elements
(X) one after the other.
en / 02.03.1999 IB003512 2/4

M32/M43/M552C
2.6 Place the individual screen elements in a 07

vessel containing a cleaning agent and rub W1
them down with a soft brush.
2.7 Blow out the clean screen elements with

the cleaning pistol (Fig. 2/W1) by moving it
up and down on the inside (clean side). Air
pressure approx.
4 bar.
2.8 In the case of obstinate dirt (paint, crusts,

fibres, shavings), place the screen
elements in a vessel containing a cleaning
agent and let them soak for up to 4 hours
according to the instructions of the
cleaning agent manufacturer.
Note:
The liquid is only allowed to reach up to
the lower edge of the upper rim of the
screen so that no contaminated liquid can
flow onto the clean side from above.
2.9 Remove the screen elements and treat

them as described in sequence 2.5 and
2.6. 2
2.10 If necessary, repeat the cleaning

procedure according the sequences 2.7
and 2.8.
2.11 Rinse the screen elements in clean cleaning fluid and blow them out again.
2.12 Check the inside and outside of the cloth of the individual screen elements for damage and repla-
ce it if necessary.
Attention:
The individual screen elements are connected in parallel. The whole filter is not
serviceable if one screen element is damaged.
2.13 Use a powerful source of light behind the cloth to check whether cleaning has been carried our
successfully. Repeat cleaning if the result is bad.
2.14 Mount the screen elements (Fig. 1/X) in each other, insert in the filter chamber and tighten the nut
(2) slightly.
en / 02.03.1999 IB003512 3/4

M32/M43/M552C
2.15 Check the seal (Fig. 1/4), replace if necessary. Mount the cover. 07
2.16 Fill up the filter chamber and vent (see plate on the filter cover). To do so:
2.16.1 Turn the key (7) by 30°.
2.16.2 Fill up the filter chamber and turn the key (7) to the mark on filter chamber after appr. 10 s.
2.16.3 Fasten the hexagon socket screw (6).
en / 02.03.1999 IB003512 4/4

M43
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Cartridge drift W2 1.9100-120
Auxiliary material:
Cleansing fluid "Filterclean" from Vecom *
NOTE
All maintenance and other work on the filter should be carried out with the greatest
care to prevent malfunctions from occurring in the fuel injection system.
Never let a full filter cool down when being operated on heavy fuel!
The cleaning interval for the filter will depend mainly on the engine operating conditi-
ons, fuel quality and the quality of the fuel separation and will thus differ from unit to
unit.
After commissioning a new system or after working on the fuel pipeline system, the
filter should be checked after 24 hrs. and cleaned if necessary.
Disassemble the cartridge bundle on every 3rd cleaning (see operation sequence
2.3).
Ultrasonic cleaning of the filter cartridges is not permitted. An excessive cleaning pe-
riod or improper suspension during cleaning might cause damage to the gauze that
cannot be detected with the nacked eye.
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from

operation and
50 % of the red mark
of the differential pressure gauge (Fig. 1/

1) becomes visible or a filter alarm is
given.
en / 01.04.2010 IB022553 1/4

M43
2.2 Cleaning the filter with built-in 07

cartridges.
CAUTION
Depressurize filter cham-
bers!
2.2.1 Remove the cover (2) from the shut-off

filter chamber. Remove contaminated
liquid by opening the drain.
2.2.2 Remove filter insert.
2.2.3 Connect cleaning pistol (Fig. 2/W1) to

compressed-air supply and load.
(6 - max. 10 bar)
2.2.4 Shift the spouting guard (13) to the stop on

the pistol nozzle, put it into the cartridge
opening and hold it tight. Pull the trigger of
the pistol and introduce the nozzle
gradually down to the bottom of each
cartridge (14).
2.2.5 Replace seals and mount cover.
2.2.6 Fill the filter chamber and vent it (see the

plate on the filter cover).
2.3 Cleaning the filter with cartridges

removed (every 3rd cleaning).
2.3.1 Open sludge drain and empty filter

chamber.
2.3.3 Flush the filter chamber with gas oil.
en / 01.04.2010 IB022553 2/4

M43
2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must 07
only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated
liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze
must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but
maximum 4 h.
2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning
pistol (Fig. 2/W1) (operation sequence 2.2.4).
Air pressure max. 10 bar.
2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the
cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9 Fill filter chamber and vent (see plate on filter cover).
2.4 Cleaning of cartridges in the case of persistent fouling
NOTE
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips)
remove the cartridges and clean them individually.
2.4.1 Soak filter insert in cleansing liquid (max. 4 h).
2.4.2 Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out.
Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings
must not come into contact with the cleansing liquid.
2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
CAUTION
Damage to only one cartridge means malfunction of the whole filter.
When removed, do not stack the removed cartridges on top of each other as this
might damage the gauze.
2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply.

2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
en / 01.04.2010 IB022553 3/4

M43
2.4.7 Remove sticking dirt with a soft brush. 07
NOTE
If a high-pressure cleaner is available, blast the cartridges from the outside with a fan
jet nozzle. Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing
agent: warm water or water with cleansing fluid.
CAUTION
When cleaning with a high-pressure cleaner, do not hold the nozzle too close to the
gauze in order to prevent damage or displacement of the gauze wires.
2.4.8 Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the opening
facing downwards.
2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.4.10 Install cartridges in reverse sequence as described under 2.4.3. O-ring between element plate
and cartridge must be free from cracks and deformation.
3. Check the seal between the element plate and filter housing and replace if necessary.
4. Mount filter insert in filter chamber.
5. Fit cover (replace seal).
6. Fill the filter chamber and vent it (see the plate on the filter cover).
en / 01.04.2010 IB022553 4/4

Duplex Fuel Preliminary Filter A5.05. 07.12.02.04
M20-M601C
750
See also: 07

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Cleaning of the filter every 750 h
Auxiliary material:
Cleaner “Filterclean” of Vecom *
NOTE
Operation and maintenance of the filter have to be carried out with utmost care to
avoid troubles in the fuel system.
The cleaning intervals of the filter mostly depend on the engine operation conditions
and the fuel quality and therefore are different from unit to unit.
When starting up a new plant or after doing some work on the fuel piping, check the
filter after 24 hours and clean it if necessary
en / 02.11.2011 IB022114 1/2

Duplex Fuel Preliminary Filter A5.05. 07.12.02.04
M20-M601C
750
4
1. Cleaning
1.1 Change over to operable filter chamber.

3 5
1.2 Open the vent screw (1) of the filter cham- 6
ber which has been cut off in order to vent 8
the system.
1.3 Remove the drain plug (2) of the filter

chamber which has been cut off. 1
1.4 Dismantle the housing cap (3) of the filter

chamber which has been cut off.
1.5 Withdraw the screen basket (7) vertically

upwards.
7
1.6 Remove coarse dirt by shaking the screen
basket (7).
1.7 Put the screen basket (7) into a solvent. An

application time of 8 hours must not be ex-
ceeded.
2
1.8 After taking the screen basket (7) out of the
solvent carefully blow it out with compres-
sed air from outside to inside.
1.9 Remove tenacious dirt by means of a soft brush.
1.10 Insert the screen basket (7) into the filter chamber.
1.11 Check the O-ring (8) and replace it if necessary. Mount the housing cap (3).
1.12 Insert and tighten the drain plug (2).
1.13 To vent the filter chamber carefully set the operating lever (4) in such a way that the nose (5) of
the plug points towards the nearest screw of the plate (6).
1.14 When the fuel emerges without bubbles at the vent screw (1), close this screw.
1.15 Reset the operating lever (4).
en / 02.11.2011 IB022114 2/2

Fuel Distributor/Collector Line A5.05. 07.15.01.00
M43
See also: - 07

-------------------------------------------------------------------------------------------------------------------------------
Procedure:
1. Disassembly
1.1 Remove pump area shroud.
1.2 Close shut-off valve.
1.3 Drain fuel distributor line by means of the leakage line.
1.4 Remove the fuel leakage line (Fig. 1/1) at the flange.
en / 04.08.1999 IB020374 1/3

M43
1.5 Remove the fuel line at the flange (Fig. 2/4). 07

1.6 Loosen the locking rings (6) and slide towards the middle of the line.
Note:
When loosening and sliding the locking rings, be careful not to damage the pipe sealing surfaces!
1.7 Slide the fuel line (5) to the side with a 55mm open jawed wrench and then remove.
1.8 Loosen hex head bolts (10).
1.9 Remove the hex head bolts and pull the flange (2) from the injection pump bushings (3).
1.10 Remove the bushings (3) with the O-rings (7) and support ring (11).
en / 04.08.1999 IB020374 2/3

M43
1.11 Remove fuel lines (supply and return). 07

1.12 Loosen cap screws (9).
1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3).
2. Assembly
2.1 Check the O-rings (7) and (8) on the injection pumps for damage. Replace if necessary.
2.2 Insert bushings (3) with O-rings (7) and support ring (11) into the injection pump / flange.
2.3 Apply Molykote to hex head bolts (10).
2.4 Install flange (2) with hex head bolts.
2.5 Tighten bolts to
M = 190 Nm
2.6 Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / flange.
2.7 Mount flange with cap screws (9).
2.8 Tighten cap screws to
M = 130 Nm
2.9 Install fuel lines (supply and return).
2.10 Insert fuel line with O-rings (8), support ring (11) and locking rings (6).
2.11 Turn locking rings firmly into locked position.
2.12 Mount fuel leakage line (Fig. 1/1) on flange (2).
2.13 Open shut-off valve.
2.14 Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserve
pump.
2.15 Install pump area shroud.
en / 04.08.1999 IB020374 3/3

M43
See also: - 07

-------------------------------------------------------------------------------------------------------------------------------
Procedure:
1. Disassembly
1.1 Remove pump area shroud.
1.2 Close shut-off valve.
1.3 Drain fuel distributor line by means of the leakage line.
1.4 Remove the fuel leakage line (Fig. 1/1) at the flange.
en / 17.05.2010 IB024483 1/3

M43
1.5 Remove the fuel line at the flange (Fig. 2/4). 07

1.6 Loosen the locking rings (6) and slide towards the middle of the line.
NOTE
When loosening and sliding the locking rings, be careful not to damage the pipe
sealing surfaces!
1.7 Slide the fuel line (Fig. 1/5) to the side with a 55mm open jawed wrench and then remove.
1.8 Loosen hex head bolts (Fig. 2/10).
1.9 Remove the hex head bolts and pull the flange (2) from the injection pump bushings (3).
en / 17.05.2010 IB024483 2/3

M43
1.11 Remove fuel lines (supply and return). 07

1.12 Loosen cap screws (9).
1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove
O-rings (12).
2. Assembly
2.1 Check the O-rings (7) and (8) on the injection pumps for damage. Replace if necessary.
2.2 Insert bushings (3) with O-rings (7) and support ring (11) into the injection pump / flange.
2.3 Apply Molykote to hex head bolts (10).
2.4 Install flange (2) with hex head bolts.
2.5 Tighten bolts to
M = 130 Nm
2.6 Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / flange.
2.7 Mount flange with cap screws (9).
2.8 Tighten cap screws to
M = 130 Nm
2.9 Insert O-rings (12). Install fuel lines (supply and return).
2.10 Insert fuel line with O-rings (8), support ring (11) and locking rings (6).
2.11 Turn locking rings firmly into locked position.
2.12 Mount fuel leakage line (Fig. 1/1) on flange (2).
2.13 Open shut-off valve.
2.14 Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserve
pump.
2.15 Install pump area shroud.
en / 17.05.2010 IB024483 3/3

M43
See also: 07.02.01.nn, 07.03.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Rubber hammer W1*

Single-end wrench 55 mm W2*
* no picture
Vaseline **
Procedure:
1. Disassembly
1.1 Disassemble pump space cladding.
1.2 Close shut-off valves.
1.3 Drain the fuel distributor line via the fuel leakage pipe.
1.4 Disassemble fuel leakage pipe (9) on flange (2).
1.5 Disassemble the fuel lines on connection piece (4). Pay attention to the O-rings (15).
1.6 Disassemble cheese head screws (20) and flanges (6).
1.7 Push fuel pipes (1) towards one side by means of a 55 mm single-end wrench (W2) and disas-
semble them.
1.8 Disassembly sleeves (7) as well as O-rings (23) and joint rings (8).
1.9 Remove hexagon screws (18) with extension sleeves (19).
1.10 Disassemble flange (2) with sleeves (3) as well as O-rings (16) and joint rings (8).
1.11 Disassemble cheese head screws (17).
1.12 Disassemble connection piece (4) with sleeves (3) as well as O-rings (16) and joint rings (8).
en / 10.09.2008 IB025956 1/3

M43
07
en / 10.09.2008 IB025956 2/3

M43
07
2. Assembly
Note:
Before assembly provide all O-rings with a thin coat of Vaseline.
2.1 Check O-rings (15, 16, and 23) and joint rings (8) for damages
and replace them, if necessary.
2.2 Insert sleeves (3) with O-rings (23) and joint rings (8) on side of the injection pump.
2.3 Provide fuel pipe (1) at the opposite side with sleeve (39) and O-ring (23).
2.4 Insert joint ring (8) into injection pump.
2.5 Insert fuel pipe (1) into the pre-assembled side of the pump and drive in by means of a rubber
hammer.
2.6 Then drive fuel pipe (1) into the adjacent pump by means of rubber hammer (W1) and 55 mm
single-end wrench (W2).
2.7 Drive fuel pipe (1) in to such an extent that flanges (6) can be fitted in the groove between sleeve
(3) and pipe.
2.8 Mount cheese head screws (20) and tighten to a torque of
M = 60 Nm
.
2.9 At the outer side of the first and last injection pump mount sleeves (3), O-rings (16), and joint
rings (8).
2.10 Mount flange (2) and connection piece (4).
2.11 Mount the fuel lines on connection piece (4). If necessary, use new O-rings (15).
2.12 Assemble fuel leakage pipe (9) on flange (2).
2.13 Open the shut-off cocks.
2.14 Fill up the fuel system by means of the stand-by pump and vent by pumping over with the stand-
by pump.
2.15 Mount the pump space cladding.
en / 10.09.2008 IB025956 3/3

M43
7500
See also: 07.02.01.nn, 07.03.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all O-rings and joint rings after 7.500 h
Tools:
Rubber hammer W1*

* no picture
Vaseline **
Procedure:
1. Disassembly
1.5 Disassemble the fuel pipes on connection piece (4). Pay attention to the O-rings (7).
1.6 Disassemble cheese head screws (23 and 22) and clamps (20 and 21).
1.7 Disassemble circlips (6).
semble them.
en / 17.05.2010 IB026460 1/4

M43
7500
07
en / 17.05.2010 IB026460 2/4

M43
7500
1.9 Remove hexagon screws (10) with extension sleeves (11). 07

1.10 Disassemble flange (2) with sleeves (3) as well as O-rings (8).
1.12 Disassemble connection piece (4) with sleeves (3) as well as O-rings (8).
2. Reassembly
.
NOTE
2.1 Check O-rings (7 and 8) for damages and replace them, if necessary.
2.2 Check O-rings (31) and back-up rings (30) in injection pump/flange for damages and replace
them, if necessary.
2.3 Insert fuel pipe (1) with pre-assembled circlips (6) into the pre-assembled side of the pump and
drive in by means of a rubber hammer.
2.5 Fix circlips (6) in engaged position.
2.6 Assemble clamps (20 and 21) at both sides.
2.7 Mount cheese head screws (23) and pretighten to a torque of
M = 20 Nm.
M = 50 Nm
.
2.9 Mount cheese head screws (23) and finally tighten to a torque of
M = 100 Nm
.
2.10 At the outer side of the first and last injection pump mount sleeves (3), O-rings (8).
en / 17.05.2010 IB026460 3/4

M43
7500
2.12 Mount the fuel lines on connection piece (4). If necessary, use new O-rings (7). 07
by pump.
en / 17.05.2010 IB026460 4/4

Fuel Pipe Mounting A5.05. 07.15.01.33
M43
7500
See also: A5.05.07.02.01.nn, A5.05.07.03.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all O-rings and joint rings after 7.500 h
Tools:
Rubber hammer W1*

* no picture
Vaseline **
Procedure:
1. Disassembly
1.5 Disassemble the fuel pipes on connection piece (4). Pay attention to the O-rings (7).
1.6 Disassemble cheese head screws (23 and 22) and clamps (20 and 21).
semble them.
en / 01.06.2011 IB027190 1/4

M43
7500
07
en / 01.06.2011 IB027190 2/4

M43
7500
1.9 Remove hexagon screws (10) with extension sleeves (11). 07

1.10 Disassemble flange (2) with sleeves (3) as well as O-rings (8).
1.12 Disassemble connection piece (4) with sleeves (3) as well as O-rings (8).
2. Reassembly
.
NOTE
2.1 Check O-rings (7 and 8) for damages and replace them, if necessary.
2.2 Check O-rings (31) and back-up rings (30) in injection pump/flange for damages and replace
them, if necessary.
2.3 Insert fuel pipe (1) with pre-assembled circlips (6) into the pre-assembled side of the pump and
drive in by means of a rubber hammer.
2.6 Assemble clamps (20 and 21) at both sides.
2.7 Mount cheese head screws (23) and pretighten to a torque of
M = 20 Nm.
M = 50 Nm
.
2.9 Mount cheese head screws (23) and finally tighten to a torque of
M = 100 Nm
.
2.10 At the outer side of the first and last injection pump mount sleeves (3), O-rings (8).
en / 01.06.2011 IB027190 3/4

M43
7500
2.12 Mount the fuel lines on connection piece (4). If necessary, use new O-rings (7). 07
by pump.
en / 01.06.2011 IB027190 4/4

Fuel Pressure Damper A5.05. 07.17.00.01
M43
7500
See also: 07.15.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of the fuel pulsation dampers every 7,500 h
Procedure:
CAUTION
Risk of burns!
When replacing a fuel pulsation damper, particularly when removing a damaged

fuel pulsation damper, there is a risk of hot fuel leakage!
1. Disassembly
1.1 Close the fuel shut-off valves.
1.2 Drain the fuel distributing pipe via the corresponding leakage pipe.
1.3 Secure double nipple (3) with a suitable tool to prevent turning and
loosen union (5).
1.4 Remove leakage monitoring pipe (6) completely.
1.5 Remove clamp (2).
CAUTION
Loosening or tightening of the fuel pulsation damper must not be carried out by
means of threaded sleeve (7) or locknut (4). This may cause destruction of
bladder (8) and thus the warranty to be void!
en / 01.04.2010 IB025781 1/3

M43
7500
1.6 Secure double nipple (10) in connection piece (21) with a suitable tool to prevent turning and uns- 07
crew fuel pulsation damper (1) by hand.
21 9 1 2 3 3
10 5
2. Reassembly:
2.1 Slightly lubricate a new O ring with oil and put it untwisted onto the lower double nipple (10).
2.2 Screw fuel pulsation damper (1) onto double nipple (10) and tighten with both hands.
2.3 Mount clamp (2).
2.4 Mount leakage monitoring pipe (6) loosely.
en / 01.04.2010 IB025781 2/3

M43
7500
2.5 Secure double nipple (3) with a suitable tool to prevent turning and tighten union (5). 07
2.6 Tighten all clamps and connections of leakage monitoring pipe (6) loosened during disassembly.
2.7 Open the fuel shut-off valves.
2.8 Fill the fuel system by means of the stand-by pump and vent it.
en / 01.04.2010 IB025781 3/3

Lubricating Oil System A5.05. 08.02.01.00
Maintenance / Oil change
M43
See also: 08.04.01.nn, 08.05.01.nn 08

Spare parts list: B1.05.08.43641n

--------------------------------------------------------------------------------------------------------------------------------
NOTE
After commissioning a new plant or working on the induction side of the lubricating oil
piping system, the filtering screen on the induction side of the lubricating oil pumps
have to be checked after 24-50 operating hours and cleaned if necessary.
The lubricating oil change interval depends on the following factors:
• Quality of the lubricating oil

• Operating conditions of the engine
• Lubricating oil consumption
• Lubricating oil filtering and separation
• Lubricating oil volume in the circulation system
The interval can be extended if the analysis values of the lubricating oil allow this.
Permissible analysis values (regulations and care, engine lubricating oil, see engine
documentation, chapter "Operating Media").
1. Switch off lubricating oil prelubricating pump.
2. Drain the engine circulation system and lubricating oil circulation tank.
3. If necessary, clean the lubricating oil circulation tank and crankcase.
en / 02.12.2010 IB020319 1/2

Lubricating Oil System A5.05. 08.02.01.00
Maintenance / Oil change
M43
4. If necessary, remove and check lubricating oil pressure relief valve (A5.05.08.05.01.nn). 08
5. Check the filter in the suction lines of the lubricating oil pumps and the separator pump and clean
if necessary.
6. Clean the lubricating oil duplex filter (1) (A5.05.08.04.01.nn).
7. Clean the lubricating oil automatic filter.
8. Remove the lubricating oil cooler and clean it (see "engine documentation, chapter "External
Documentation").
9. Fill in new lubricating oil (lubricating oil quality, see engine documentation, chapter "Operating
Media") up to the respective mark on the circulation tank.
10. Fill up the lubricating oil system and take lubricating oil prelubricating pump into operation.
en / 02.12.2010 IB020319 2/2

Lubricating Oil Pump A5.05. 08.03.02.00
M43
45000
See also: 08.02.01.nn 08


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Removal of the lubricating oil pump from the engine, check of the gears, spiral gear shafts, bea-
ring bushes and ball bearings for damages and wear. every 45000 h
Tools:

Thickness gauge W2 * 1.9075-003
Special tool of Messrs. Houttuin
*not available as figure
Auxiliary material:

Silicone sealing compound "Dirco Grau" **

2 3
Note:
We recommend to replace the ball bea-

rings and bearing bushes every X
45.000 hours.
6
4
1. Disassembly 1
5
X
1.1 Drain the lubricating oil system.
s
1.2 Remove suction (Fig. 1/4) and delivery li- 7
nes (2).
1.3 Loosen hexagon nuts (1) and pull the lub- 8

ricating oil pump (3) with gear wheel (6)
out of the engine block. .
en / 31.01.2008 IB020385 1/4

M43
45000
1.4 Loosen hexagon cap screw (Fig. 1/8) and pull gear wheel (6) off the driving screw shaft 08
(Fig. 2/28) with extractor.
1.5 Check tooth flanks for wear (pittings, slanting run, break-off
1.6 Disassemble hexagon cap screws (10). Screw hexagon cap screw (10) into the jacking bore of
the cover (11) and press the cover with set of screw spindles towards the outside
1.7 Carefully pull the cover with set of screw spindles out of the casing (12) with a crane and put onto
a work bench.
1.7.1 Check the backlash between the gear wheels (13). The required backlash is
S1 = max 0,45 mm
If the measured backlash is higher, both gear wheels are to be replaced.
1.7.2 Measure the screw spindle backlash between the opposed spindle flanks by means of thickness
gauge (W2). There must be the same backlash between all geometrically different spindle flanks
(right and left).
S2 = max 0,2 mm
If the measured backlash is higher or uneven, inform the MaK Customer Service.
en / 31.01.2008 IB020385 2/4

M43
45000
1.8 Disassembly of screw spindles (27/28). 08

1.8.1 Disassemble screws (14). Disassemble the bearing cap (15). Disassemble screws (16/17). Seg-
ments (18) are released. Pull both screw spindles with gear wheels, bearings etc. out of the cover
(11).
1.9 Disassembly of the bearings (19).
1.9.1 Bend washers (20/21) backward. Disassemble bearing nuts (22/24). Disassembl bearings (19) by
means of the jacking device.
1.10 Disassembly of gear wheels (13)..
1.10.1 Disassemble shaft bushes (24). Disassemble gear wheels (13) by means of the jacking device.
Disassemble parallel keys (25). Disassemble bushes (26).
2. Reassembly
2.1 Before reassembly check all parts for wear and dirt. Clean the parts before assembly. If required,
exchange against original MaK spare parts. Always use new gaskets (29/30).
2.2 Reassemble the lubricating oil pump in reverse disassembly order.
2.3 Before mounting the gear wheel, check the contact pattern between gear wheel cone
(Fig. 1/6) and the driving screw shaft cone (Fig. 2/28) by inking.
The contact pattern must be even and the contact surface percentage must be > 80 %!
2.4 Clean, degrease, and dry the gear wheel cone and the driving screw shaft cone.
2.5 Put the gear wheel (Fig. 1/6) onto the driving screw shaft cone, measure distance S
(Fig. 1/X) and note it down.
2.6 Heat the gear wheel up in an oil bath so that its temperature is about 110 ×C to 120 ×C higher
than that of the driving screw shaft and firmly shrink-fit it onto the driving screw shaft cone up to li-
mit stop.
2.7 Check the distance S, it must be 0.60 - 0.67 mm (pushing-on distance) smaller than in cold
condition.
2.8 Lubricate thread and contact face of hexagon cap screw (Fig. 1/8) and washer (7) with Molykote
paste "G-Rapid Plus". Tighten the hexagon cap screw (8) with a torque of
M = 100 Nm
en / 31.01.2008 IB020385 3/4

M43
45000
2.9 Clean contact face of pump flange (Fig. 2/21) and pump mounting plate (Fig. 1/5) and daub with 08
sealing compound.
2.10 Carefully introduce the lubricating oil pump (3) with gear wheel (6) into the engine block (the gear
flanks of the driving gear wheels must engage with each other) and mount it.
2.11 Mount the suction (4) and delivery lines with new gaskets.
2.12 Replenish with new lubricating oil (for lubricating oil quality see A4.05.08.nn) up to
corresponding level mark on the circulation tank.
2.13 Replenish the lubricating oil system and put the prelubrication pump into service. Vent the
system. Check the system for leakages.
2.14 Check if the gear wheels are properly supplied with lubricating oil.
en / 31.01.2008 IB020385 4/4

M43
45000
See also: 08.02.01.nn 08


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Removal of the lubricating oil pump from the engine, check of the gears, spiral gear shafts, bea-
ring bushes and ball bearings for damages and wear. every 45000 h
Tools:

Thickness gauge W2 * 1.9075-003
Special tool of Messrs. Houttuin
*not available as figure
Auxiliary material:

Silicone sealing compound "Dirco Grau" **
Note:
We recommend to replace the ball bea-

rings and bearing bushes every
45.000 hours.
1. Disassembly
1.1 Drain the lubricating oil system.
1.2 Remove suction (Fig. 1/4) and delivery li-

nes (2).
1.3 Loosen hexagon nuts (1) and pull the lub-

ricating oil pump (3) with gear wheel (6)
out of the engine block. .
en / 31.01.2008 IB023277 1/4

M43
45000
1.4 Loosen hexagon cap screw (Fig. 1/8) and pull gear wheel (6) off the driving screw shaft 08
(Fig. 2/28) with extractor.
1.5 Check tooth flanks for wear (pittings, slanting run, break-off
1.6 Disassemble hexagon cap screws (10). Screw hexagon cap screw (10) into the jacking bore of
the cover (11) and press the cover with set of screw spindles towards the outside
1.7 Carefully pull the cover with set of screw spindles out of the casing (12) with a crane and put onto
a work bench.
1.7.1 Check the backlash between the gear wheels (13). The required backlash is
S1 = max 0,45 mm
If the measured backlash is higher, both gear wheels are to be replaced.
1.7.2 Measure the screw spindle backlash between the opposed spindle flanks by means of thickness
gauge (W2). There must be the same backlash between all geometrically different spindle flanks
(right and left).
S2 = max 0,2 mm
If the measured backlash is higher or uneven, inform the MaK Customer Service.
en / 31.01.2008 IB023277 2/4

M43
45000
1.8 Disassembly of screw spindles (27/28). 08

1.8.1 Disassemble screws (14). Disassemble the bearing cap (15). Disassemble screws (16/17). Seg-
ments (18) are released. Pull both screw spindles with gear wheels, bearings etc. out of the cover
(11).
1.9 Disassembly of the bearings (19).
1.9.1 Bend washers (20/21) backward. Disassemble bearing nuts (22/24). Disassembl bearings (19) by
means of the jacking device.
1.10 Disassembly of gear wheels (13)..
1.10.1 Disassemble shaft bushes (24). Disassemble gear wheels (13) by means of the jacking device.
Disassemble parallel keys (25).
2. Reassembly
2.1 Before reassembly check all parts for wear and dirt. Clean the parts before assembly. If required,
exchange against original MaK spare parts. Always use new gaskets (29/30).
2.2 Reassemble the lubricating oil pump in reverse disassembly order.
2.3 Before mounting the gear wheel, check the contact pattern between gear wheel cone
(Fig. 1/6) and the driving screw shaft cone (Fig. 2/28) by inking.
2.4 Clean, degrease, and dry the gear wheel cone and the driving screw shaft cone.
2.5 Put the gear wheel (Fig. 1/6) onto the driving screw shaft cone, measure distance S
(Fig. 1/X) and note it down.
2.6 Heat the gear wheel up in an oil bath so that its temperature is about 110 ×C to 120 ×C higher
than that of the driving screw shaft and firmly shrink-fit it onto the driving screw shaft cone up to li-
mit stop.
2.7 Check the distance S, it must be 0.60 - 0.67 mm (pushing-on distance) smaller than in cold
condition.
2.8 Lubricate thread and contact face of hexagon cap screw (Fig. 1/8) and washer (7) with Molykote
paste "G-Rapid Plus". Tighten the hexagon cap screw (8) with a torque of
M = 100 Nm
en / 31.01.2008 IB023277 3/4

M43
45000
2.9 Clean contact face of pump flange (Fig. 2/21) and pump mounting plate (Fig. 1/5) and daub with 08
sealing compound.
2.10 Carefully introduce the lubricating oil pump (3) with gear wheel (6) into the engine block (the gear
flanks of the driving gear wheels must engage with each other) and mount it.
2.11 Mount the suction (4) and delivery lines with new gaskets.
2.12 Replenish with new lubricating oil (for lubricating oil quality see A4.05.08.nn) up to
corresponding level mark on the circulation tank.
2.13 Replenish the lubricating oil system and put the prelubrication pump into service. Vent the
system. Check the system for leakages.
2.14 Check if the gear wheels are properly supplied with lubricating oil.
en / 31.01.2008 IB023277 4/4

M43
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not shown
Also needed:
"G-Rapid Plus" ** Molykote paste
„Dirco Grau“ ** silicone sealant
** or comparable product
NOTE
If necessary, the lube oil pump should be removed from the engine to check the
gears, gear shafts and bushes for wear or replace them, if necessary.
Sequence:
1. Disassembly
1.1 Drain lube oil system.
1.2 Remove suction (Fig. 1/4) and pressure

lines (2).
1.3 Loosen hex nuts (1) and pull lube oil pump
(3) with gear (6) from the cylinder crank
case. Watch out for resilient sleeves.
en / 02.12.2010 IB024069 1/4

M43
1.4 Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller. 08
1.5 Check tooth faces for wear (pitting, unevenness, spalling).
1.6 Loosen bolts (16,18). Remove pressure relief valve (21) und cover (17) from pump housing (20).
1.7 Remove drive gear (10) and impeller shaft (19).
1.8 Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and re-
place with genuine MaK parts, if necessary.
Replace O-rings (12).
NOTE
Cool new bushes before assembly.
en / 02.12.2010 IB024069 2/4

M43
1.9 Assembly: 08
1.10 Assemble lube oil pump by reversing above steps.
1.11 Mount pressure relief valve (21). Tighten hex bolts (18) to a torque of
M = 410 Nm.
1.12 Mount cover flange (17). Tighten hex bolts (16) to a torque of
M = 206 Nm.
1.13 Before mounting gears, check wear pattern between gear cone (Fig. 1/6) and drive gear shaft
cone (Fig. 2/10) by applying ink.
The wear pattern should be even, and the wear pattern percentage > 80 %.
1.14 Clean, degrease and dry gear cone and drive gear cone shaft.
NOTE
Gear should always be mounted with the drive gear shaft in the vertical position
(cone pointing up).
1.15 Place gear (Fig. 1/6) on drive gear shaft cone, measure dimension S (Fig. 1/X) and note down.
1.16 Heat gear by approx. 110 °C to 120 °C above the temperature of the drive gear shaft and shrink
firmly to the drive gear shaft cone all the way to the stop.
1.17 Then immediately mount hex bolt (7) with washer (8) and tighten to a torque of
M = 100 Nm
.
1.18 After the connection has cooled down to room temperature, loosen hex bolt (7). Then coat
threads with „G-Rapid Plus“ Molykote paste and tighten to a torque of
M = 140 Nm.
en / 02.12.2010 IB024069 3/4

M43
1.19 Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding 08
travel).
1.20 Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with sealant.
1.21 Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of drive
gears need to engage) and install.
1.22 Install resilient sleeves. Coat hex nuts (1) and bolt threads with „G-Rapid Plus“ Molykote paste
and tighten to a torque of
M = 130 Nm.
1.23 Install suction (4) and pressure (2) lines using new seals.
1.24 Fill with new lube oil (for lube oil quality see A4.05.08.nn) to the mark on the circulating tank.
1.25 Refill lube oil system and start lube oil prelube pump. Purge air from system. Check system for
leakage.
1.26 Check lube oil supply to gears.
en / 02.12.2010 IB024069 4/4

M43
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not shown
Also needed:
"G-Rapid Plus" ** Molykote paste
„Dirco Grau“ ** silicone sealant
** or comparable product
NOTE
If necessary, the lube oil pump should be removed from the engine to check the
gears, gear shafts and bushes for wear or replace them, if necessary.
Sequence:
1. Disassembly
1.1 Drain lube oil system.
1.2 Remove suction (Fig. 1/4) and pressure

lines (2).
1.3 Loosen hex nuts (1) and pull lube oil pump
(3) with gear (6) from the cylinder crank
case. Watch out for resilient sleeves.
en / 02.05.2011 IB025414 1/4

M43
1.4 Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller. 08
1.5 Check tooth faces for wear (pitting, unevenness, spalling).
1.6 Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20).
1.7 Remove drive gear (10) and impeller shaft (19).
1.8 Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and re-
place with genuine CAT parts, if necessary.
Replace O-rings (12).
NOTE
Cool new bushes before assembly.
en / 02.05.2011 IB025414 2/4

M43
2. Assembly: 08
2.1 Assemble lube oil pump by reversing above steps.
2.2 Mount cover (21). Tighten hex bolts (18) to a torque of
M = 410 Nm.
2.3 Mount cover flange (17). Tighten hex bolts (16) to a torque of
M = 206 Nm.
2.4 Before mounting gears, check wear pattern between gear cone (Fig. 1/6) and drive gear shaft
cone (Fig. 2/10) by applying ink.
The wear pattern should be even, and the wear pattern percentage > 80 %.
2.5 Clean, degrease and dry gear cone and drive gear cone shaft.
NOTE
Gear should always be mounted with the drive gear shaft in the vertical position
(cone pointing up).
2.6 Place gear (Fig. 1/6) on drive gear shaft cone, measure dimension S (Fig. 1/X) and note down.
2.7 Heat gear by approx. 110 °C to 120 °C above the temperature of the drive gear shaft and shrink
firmly to the drive gear shaft cone all the way to the stop.
2.8 Then immediately mount hex bolt (7) with washer (8) and tighten to a torque of
M = 100 Nm
.
2.9 After the connection has cooled down to room temperature, loosen hex bolt (7). Then coat
threads with „G-Rapid Plus“ Molykote paste and tighten to a torque of
M = 140 Nm.
en / 02.05.2011 IB025414 3/4

M43
2.10 Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding 08
travel).
2.11 Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with sealant.
2.12 Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of drive
gears need to engage) and install.
2.13 Install resilient sleeves. Coat hex nuts (1) and bolt threads with „G-Rapid Plus“ Molykote paste
and tighten to a torque of
M = 130 Nm.
2.14 Install suction (4) and pressure (2) lines using new seals.
2.15 Fill with new lube oil (for lube oil quality see engine documentation, chapter
„Operating Media“.) to the mark on the circulating tank.
2.16 Refill lube oil system and start lube oil prelube pump. Purge air from system. Check system for
leakage.
2.17 Check lube oil supply to gears.
en / 02.05.2011 IB025414 4/4

Lubricating Oil Duplex Filter A5.05. 08.04.01.00
VM32/M43/M552C/M601C
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Auxiliary material:
Cleansing liquid “Filterclean” from Vecom *
NOTE
Operation and servicing of the filter have to be carried out with utmost care. The
ingress of dirt from the tanks and piping could cause seriousengine damage.
The cleaning interval of the filter depends on part load operation with heavy fuel,
poor combustion, poor centrifugal purifying or a defective automatic backflushing
filter.
When starting up a new plant, after major repairs or work on the lubricating oil pi-
ping, check the filter after 24 to 48 hours and clean it if necessary.
Disassemble the filter candles on every third cleaning (see 2.3).
Ultrasonic cleaning of the filter filter candles is not permitted. An excessive cleaning
period or improper suspension on cleaning might cause damage on the gauze that
cannot be detected
1. Change the filter over (see the plate on the filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from operation and
of the differential pressure gauge (Fig. 1/4) becomes visible or if filter alarm is given.
en / 08.07.2010 IB000186 1/3

VM32/M43/M552C/M601C
2.2 Filter cleaning with mounted filter 08

candles.
WARNING
Depressurize the filter
chamber!
2.2.1 Remove the cover from the filter chamber

that has been cut out. Open the sludge
drain and drain the contaminated liquid.
2.2.2 Connect the cleaning pistol (Fig. 2/W1) to

the compressed air supply and impinge
the working pressure
(6 -max. 10 bar).
2.2.3 Shift the spouting guard (3) to the stop at

the pistol and introduce the nozzle gra-
dually down to the bottom of each filter
candles (Fig.1).
2.2.4 Fit the cover. Renew the gasket

if necessary.
2.2.5 Fit the cover. Renew the gasket if

necessary.

2.3 Filter cleaning with removed filter cand-

les (every third cleaning).
2.3.1 Empty the filter chamber by opening the

sludge drain.
2.3.2 Remove the filter element.
en / 08.07.2010 IB000186 2/3

VM32/M43/M552C/M601C
2.3.4 Put the filter element in a suitable cleansing liquid. The cleansing liquid must only reach up to 08
the bottom edge of the element plate so that no contaminated liquid can enter into the filter
candles from the top. The top area of the gauze must be visible in the filter candles. So-
aking time as required by the supplier of the cleanser, but maximum 4 hours.
2.3.5 Take the filter element out of the cleansing liquid and remove the protective shell.
2.3.6 Remove the filter candles with the drift (Fig. 2/W2) downwards and tilt them out. Remove the O-
rings between the filter candles and the element plate (1), because O-rings must have no
contact with the cleansing liquid.
Inspect the filter candles and renew them in the case of damage or heavy folding of the
gauze. Damage on only one filter candles means malfunction of the whole element. Do not
put the removed filter candles one upon another; this might damage the gauze.
2.3.7 Connect the cleaning pistol (Fig. 3/W1) to

the compressed air supply.
2.3.8 Introduce the pistol into the cartridge, pull

the trigger and move down to the bottom
of each filter candles.
2.3.9 Remove sticking dirt with a soft brush.
2.3.10 Rinse the filter candles in clean gas oil.

Make sure that no contaminated gas oil
can enter into the clean space from the
top.
2.3.11 Put a strong light behind the gauze and

check the cleaning operation. Repeat it if
necessary.
2.3.12 Fit the filter candles. The O-rings between

the element plate and the filter candles
must be free from cracks and deformation.
2.3.13 Check the seal between the element plate

and the filter housing. Renew it
if necessary.
Fit the element in the filter chamber.
2.3.14 Fit the cover. Renew the gasket if

necessary.

en / 08.07.2010 IB000186 3/3

M43
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:

Auxiliary material:
Cleansing fluid "Filterclean" from Vecom *
NOTE
Operation and servicing of the filter have to be carried out with atmost care. The
ingress of dirt from the tanks and piping could cause serious engine damage.
The cleaning interval of the filter is influenced by part load operation with heavy fuel,
poor combustion, poor centrifugal purifying or a defective automatic backflashing
filter.
When starting up a new plant after major repairs or work on the lubricating oil piping,
check the filter after 24 - 48 h and clean it if necessary.
Disassemble the cartridge bundle on every 3rd cleaning (see operation sequence
2.3).
Ultrasonic cleaning of the filter cartridges is not permitted. An excessive cleaning pe-
riod or improper suspension during cleaning might cause damage to the gauze that
cannot be detected with the nacked eye.
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from

operation and
of the differential pressure gauge (Fig. 1/

1) becomes visible or a filter alarm is
given.
en / 01.04.2010 IB020307 1/4

M43
2.2 Cleaning the filter with built-in 08

cartridges.
VORSICHT
Depressurize filter chambers!
2.2.1 Remove the cover (2) from the shut-off

filter chamber. Remove contaminated
liquid by opening the drain.
2.2.3 Connect cleaning pistol (Fig. 2/W1) to

compressed-air supply and load.
(6 - max. 10 bar)
2.2.4 Shift the spouting guard (13) to the stop on

the pistol and introduce the nozzle
gradually down to the bottom of each
cartridge (14).
2.2.5 Replace seals and mount cover.

2.3 Cleaning the filter with cartridges

removed (every 3rd cleaning).
2.3.1 Open sludge drain and empty filter

chamber.
en / 01.04.2010 IB020307 2/4

M43
2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must 08
only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated
liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze
must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but
maximum 4 h.
2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning
pistol (Fig. 2/W1) (operation sequence 2.2.4).
2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the
cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9 Fill filter chamber and vent (see plate on filter cover).
2.4 Cleaning of cartridges in the case of persistent fouling
NOTE
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips)
remove the cartridges and clean them individually.
2.4.1 Soak filter insert in cleansing liquid (max. 4 h).
2.4.2 Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out.
Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings
must not come into contact with the cleansing liquid.
2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
NOTE
Damage to only one cartridge means malfunction of the whole filter.
When removed, do not stack the removed cartridges on top of each other as this
might damage the gauze.
en / 01.04.2010 IB020307 3/4

M43
2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply. 08

2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
2.4.7 Remove sticking dirt with a soft brush.
Note:
If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle.
Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: warm water or
water with cleansing fluid.
NOTE
When cleaning with a high-pressure cleaner, do not hold the nozzle too close to the
gauze in order to prevent damage or displacement of the gauze wires.
2.4.8 Rinse the cartridges in clean cleaning fluid, blow them out and let them dry with the opening
facing downwards.
2.4.9 Put a strong light behind the gauze and check the cleaning operation. Repeat it if necessary.
2.4.10 Install cartridges in reverse sequence as described under 2.4.3. O-ring between element plate
and cartridge must be free from cracks and deformation.
3. Check the seal between the element plate and filter housing and replace if necessary.
4. Mount filter insert in filter chamber.
5. Fit cover (replace seal).
6. Fill the filter chamber and vent it (see the plate on the filter cover).
en / 01.04.2010 IB020307 4/4

Oil pressure control valve A5.05. 08.05.01.01
M20/M25/M32/M43
15000
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly and adjustment of the
oil pressure control valve every 15,000 h
NOTE
Disassembly of the pressure control valve during the repair interval is only necessary
if the necessary lubricating oil pressure can no longer be set by adjusting the initial
tension of the spring.
The lubricating oil pressure is only allowed to be adjusted at the nominal engine
speed and at the specified lubricating oil temperature, see engine documentation,
chapter "Technical Engine Data".
1. Disassembly
CAUTION
Pay attention to the tension of the pressure spring (Fig. 1/3) on the control valve (1)!
1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).
1.2 Remove and dismantle the control valve (1).
CAUTION
Pay attention to the tension of the pressure spring (13) on the screwed connection
(17)!
1.2.1 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter-
clockwise and remove it together with the ball (16).
en / 21.10.2011 IB022593 1/3

M20/M25/M32/M43
15000
1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10). 08
1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spring
(13).
1.2.4 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25),
washers (27), pressure spring (28) and ball (29).
en / 21.10.2011 IB022593 2/3

M20/M25/M32/M43
15000
1.3 Clean all parts with gas oil and check them. 08
1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the set
screw (5) and remove any deposits.
1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if
necessary.
2. Reassembly
2.1 Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.
2.2 Assembly is effected in the reverse sequence of disassembly.

Pay attention to the free movement of the pistons (4 and 11)!
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment
3.1 Pressure to be set, see engine documentation, chapter "Technical Engine Data".
3.2 Loosen the hexagon nut (18).
Regulate the pressure by turning the spindle (19).
Counter-clockwise: Oil pressure drops

Clockwise: Oil pressure increases
3.3 Secure the setting with the hexagon nut (18).
en / 21.10.2011 IB022593 3/3

Prelubricating pump/Prelubrication A5.05. 08.10.00.00
M20/M25/M32/M43
150
See also: 08
Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Prelubrication and turning approximately every 150 h
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 / 10.05.2011 IB004168 1/1

Leak oil pipe A5.05. 08.15.01.00
M43
See also: 07.02.01.nn, 07.03.01.nn 08


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Rubber hammer W1*

* no picture
Vaseline **
Procedure:
1. Disassembly
1.2 Disassemble hexagon screw (10) and washer (11).
1.3 Push plug-in pipe (2) towards one side by means of a 32 mm single-end wrench (W2) and di-
sassemble it.
1.4 Pay attention to O-rings (7) and (27).
1.5 Disassemble hexagon screws and hexagon nuts (13 and 14) as well as clamps (12).
1.7 Push leak oil pipes (1) towards one side by means of a 32 mm single-end wrench (W2) and di-
sassemble them.
en / 01.04.2010 IB026470 1/3

Leak oil pipe A5.05. 08.15.01.00
M43
08
en / 01.04.2010 IB026470 2/3

Leak oil pipe A5.05. 08.15.01.00
M43
2. Reassembly 08
NOTE
2.1 Check O-rings (7) and O-rings (27) in injection pump/flange for damages and replace them, if ne-
cessary.
2.2 Insert plug-in pipe (2) with assembled O-ring (7) into the pre-assembled side of the pump and
drive in by means of a rubber hammer (W1).
2.3 Then drive plug-in pipe (2) into the media block by means of rubber hammer (W1) and 32 mm
2.4 Fix plug-in pipe (2) with washer (11) and hexagon screw (10).
2.5 Insert leak oil pipes (1) with pre-assembled circlips (6) into the pre-assembled side of the pump
and drive in by means of a rubber hammer (W1).
2.6 Then drive leak oil pipes (1) into the adjacent pump by means of rubber hammer (W1) and 32
mm single-end wrench (W2).
2.8 Assemble clamps (12) at both sides so as to rest against the circlips (3).
en / 01.04.2010 IB026470 3/3

Leak oil pipe A5.05. 08.15.01.01
M43
See also: 07.02.01.nn, 07.03.01.nn 08


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Rubber hammer W1*

* no picture
Vaseline **
Procedure:
1. Disassembly
1.2 Disassemble hexagon screw (10) and washer (11).
1.3 Push plug-in pipe (2) towards one side by means of a 32 mm single-end wrench (W2) and di-
sassemble it.
1.4 Pay attention to O-rings (7) and (27).
1.5 Disassemble hexagon screws and hexagon nuts (13 and 14) as well as clamps (12).
1.7 Push leak oil pipes (1) towards one side by means of a 32 mm single-end wrench (W2) and di-
sassemble them.
1.8 Disassemble pipes (16).
en / 03.01.2011 IB026970 1/3

Leak oil pipe A5.05. 08.15.01.01
M43
08
en / 03.01.2011 IB026970 2/3

Leak oil pipe A5.05. 08.15.01.01
M43
2. Reassembly 08
NOTE
2.1 Check O-rings (7) and O-rings (27) in injection pump/flange for damages and replace them, if ne-
cessary.
2.2 Insert plug-in pipe (2) with assembled O-ring (7) into the pre-assembled side of the pump and
drive in by means of a rubber hammer (W1).
2.3 Then drive plug-in pipe (2) into the media block by means of rubber hammer (W1) and 32 mm
2.4 Fix plug-in pipe (2) with washer (11) and hexagon screw (10).
2.5 Insert leak oil pipes (1) with pre-assembled circlips (3) into the pre-assembled side of the pump
and drive in by means of a rubber hammer (W1).
2.6 Then drive leak oil pipes (1) into the adjacent pump by means of rubber hammer (W1) and 32
mm single-end wrench (W2).
2.8 Assemble clamps (12) at both sides so as to rest against the circlips (3).
2.9 Assemble pipes (16).
en / 03.01.2011 IB026970 3/3

Cooling Water Centrifugal Pump A5.05. 09.07.01.00
M43
15000
See also: 09

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The cooling water centrifugal pump is to be disassembled every 15,000 operating hours and
checked for wear.
Auxiliary material:

Silicone sealing compound "Dirco-Grau"
Loctite 222 *
Loctite 270 *
1. Disassembly
1.1 Drain cooling water; loosen connecting

line from the stand-by pump to the cooling
water distribution line.
Inspection:
Male connector above the cooling water
pump.
1.2 Remove pipes from the cooling water

pump.
1.3 Loosen hexagon cap screws (Fig. 1/2)

and pull cooling water pump (1) with gear
wheel (3) out of the engine block.
1.4 Remove O-ring (6).
1.5 Fix shaft (Fig. 2/23) in bore (u) with pin (10
mm).
1.6 Loosen hexagon cap screw (Fig. 1/4) and

remove with washer (5).
en / 01.04.2010 IB022263 1/4

M43
15000
1.7 Pull off gear wheel (Fig. 1/3) from shaft (Fig. 2/23) with extractor. 09
1.8 Check tooth flanks for wear (pitting, skewing, splintering).
1.9 Loosen hexagon nuts (25), extract bearing housing (16) with seal plate (28) and impeller (11)
from the volute (12). Remove O-ring (27).
1.10 Loosen impeller bolt (30) and remove with impeller washer (29). Pull impeller (11) off shaft (23)
with extractor.
1.11 Remove seal assembly (10).
en / 01.04.2010 IB022263 2/4

M43
15000
1.12 Loosen socket head cap screws (Fig. 2/14) and remove seal plate (28) with O-ring (33) from bea- 09
ring housing (16) and pull off flinger (15).
1.13 Loosen screws (21), disassemble end cap (18) with thrust ring (20).
1.14 Force shaft (23) out of bearing housing (16) with suitable tool, remove oil seal (24).
1.15 Remove hexagon nuts (31). Disassemble suction inlet (32) with O-ring (27).
2. Inspection
2.1 Inspect impeller (11) visually, replace if there are any signs of severe cavitation.
2.2 Inspect front and rear bearings (17 and 22) as well as shaft for wear and corrosion, replace if
necessary.
2.3 Inspect all parts and the outlet openings (v, w), clean if necessary.
3. Assembly
3.1 The assembly is carried out in the reverse sequence, observing the following items:
3.2 Replace oil seal (24), seal assembly (10) and O-rings (27) and (33). Mount flinger (15).
3.3 Apply a ring of silicone sealing compound "Dirco-Grau" around the oil bore (y) of the bearing
housing, mount the thrust ring (20) and end cap (18).
3.4 Insert screws (21) with screw locking agent "Loctite 270" and tighten.
3.5 Before mounting the impeller (Fig. 2/11), inspect contact pattern between impeller cone and shaft
cone through inking.
3.6 Before mounting the gear wheel (Fig. 1/3), inspect contact pattern between gear wheel cone and
shaft cone through inking
The contact pattern must be even and the contact surface percentage must be > 80
3.7 Clean, degrease and dry impeller, gear wheel, and shaft cones
3.8 Mount impeller (Fig. 2/11) and impeller washer (29), coat thread of the impeller bolt (30) and the
shaft (23) with screw locking agent "Loctite 222".
en / 01.04.2010 IB022263 3/4

M43
15000
3.9 Fix shaft with pin and tighten impeller bolt (30) with a torque of 09
M = 130 Nm
3.10 Mount gear wheel (Fig. 1/3) on drive gear wheel shaft cone, measure distance (s) and note.
3.11 Heat up gear wheel to approx. 80 °C to 90 °C above the temperature of the shaft and firmly push
up to the limit stop on the shaft cone.
3.12 Check distance (s), it must be 0.51 - 0.57 mm (pushing-on distance) smaller than in cold
condition.
3.13 Coat thread and contact surface of the hexagon cap screw (4) and washer (5) with Molykote pa-
ste "G-Rapid Plus" and tighten with a torque of
M = 100 Nm
3.14 Replace O-ring (6), carefully insert cooling water pump with gear wheel (3) into engine block
(tooth flanks of the drive gear wheels must softly mesh).
3.15 Coat thread and contact surface of the hexagon cap screws (2) and spacers (34) with Molykote
paste "G-Rapid Plus" and tighten with a torque of
M = 130 Nm
3.16 Mount pipes and connecting line from the stand-by pump to the cooling water distribution line, fill
up cooling water system and vent.
3.17 Check lubricating oil supply of gear wheels, also check for leakage.
en / 01.04.2010 IB022263 4/4

Stop Piston A5.05. 10.03.01.00
M43/VM43
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: B1.05.05.434210, B1.05.05.1.4523, B1.05.07.433597

-------------------------------------------------------------------------------------------------------------------------------
Activity:
Check the emergency stop function of the stop piston every 750 h
NOTE
The functional check may only be
completed when the engine is stopped
for other maintenance or repair work!
Procedure:
1. Actuate emergency stop.
2. Check the position of the control rods.
NOTE
The control rods must be in the "Zero
Filling“ position.
3. 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.
4. Actuate the "Reset“ button on the safety system.
en / 11.10.2011 IB020372 1/3

Stop Piston A5.05. 10.03.01.00
M43/VM43
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.
5. (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.
6. 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.
7. 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 / 11.10.2011 IB020372 2/3

Stop Piston A5.05. 10.03.01.00
M43/VM43
750
8. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control 10
stand.
en / 11.10.2011 IB020372 3/3

Pressure Switches A5.05. 11.01.02.01
M20-M601C
3750
See also: 11
Spare parts list: B1.05.11.nn.4843

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Adjusting device, electro test instrument
Inspection:
Inspect the pressure switch for the set operating values every 3,750 working hours.
NOTE
The following test and adjustment instruction is valid for the following types:
• Pressure range 0.2 - 2.5 bar, mechanical switching differential: 0.15 bar
• Pressure range 0 - 6 bar, mechanical switching differential: 0.2 bar
• Pressure range 0.9 - 1.5 bar, mechanical switching differential: 0.08 bar
1. Connection of the adjusting device
1.1 Close the cock of the pressure piping (Fig. 1/1).
1.2 Loosen the union nut (2) and remove the dummy plug (pressure release of the piping, at liquid
medium collect the liquid with a rag).
en / 29.08.2011 IB021686 1/3

M20-M601C
3750
11
CAUTION
When loosen/thighten the union nut directly located at the pressure joint of the pres-
sure switch, it should be simultaneously counter acted at the key faces of the pressu-
re joint.
1.3 Connect the hose (with union

nut and cutting) with the adju-
sting device (Fig. 2).
2. Inspection of the set values
2.1 Ventilate the pressure switch

via the adjustment device.
CAUTION
For setting the differential pressure switch, the adjusting device must be equipped
with two text connections (+, –, pressure difference) refer to view “X”.
Pressure monitor Difference pressure monitor
2.2 Inspect the pressure control via the pressure gauge (of the device) and simultaneously the switch
point at the instrument or alarm unit for coincidence of the switch point with the set value.
2.3 At any deviation correct the adjustment due to item 3.
2.4 Deaerate the pressure switch slightly and simultaneously check the switch point via the test in-
strument. Inspect the displayed switch difference.
en / 29.08.2011 IB021686 2/3

M20-M601C
3750
3. Correction of the adjustment (Perfor- 11

mance with fixed switch difference)
(Fig. 3)
NOTE
The scale accuracy is ± 2 % of
the span. The instrument is in-
dividually calibrated (1 - 2 on)
so that no gauge inspection is
necessary.
3.1 Remove the case cover by loosening the

4 locking screws.
3.2 Connect terminal (1 + 4) via cable with the

adjusting device.
3.3 Loosen the stop screw (A).
3.4 Remove the cover aside by loosening the

locking screw (B).
3.5 Set the upper or lower switching point (dif-

ferential pressure switch) by means of the
range spindle (C).
The lower or upper switching point

(differential pressure switch) results in the
fixed switching difference.
3.6 Tighten stop screw (A).
4. Removal of the adjusting device
4.1 Loosen the cable connection

(terminal 1 + 4).
4.2 Loosen the connection hose of the adjusting device screw on the union nuts with plug (Fig. 1/2).
4.3 Fit the cover.
4.4 Tighten the cover of the range spindle.
4.5 Mark or lead the impected or corrected pressure switches.
en / 29.08.2011 IB021686 3/3

M25/M32/M43
3750
See also: 11
Spare parts list: B1.05.11.9.4842, B1.05.11.254842, B1.05.11.434843

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Adjusting device, electric measuring instrument
Inspection:
Check the set operating values of the pressure switches every 3,750 operating hours.
NOTE
These testing and adjusting instructions apply to the following types:
Pressure range:0 -6 barSwitching difference:0.2 bar
Pressure range:0 -16 barSwitching difference: 0.8 bar
1. Connecting the adjusting device
1.1 Turn cock (Fig. 1/1) of the pressure line to test position (downwards).
1.2 Remove plug (2) (G1/8") (depressurizing the line, soaking up fluid with a rag) and connect
adjusting device to test connection according to Fig. 2 and Fig. 3.
2
Fig. 1
en / 02.11.2011 IB023083 1/3

M25/M32/M43
3750
1.3 Pneumatic connection (Fig. 2). 11

15
10 11 12 13 14 16
Fig. 2
10 Compressed-air flange > 16 bar

11 Pressure reducer
12 Shut-off valve
13 One-way restrictor
14 Volume 1 l
15 Precision pressure gauge
16 Pressure switch
1.4 Electrical connection (Fig. 3)
Connect terminals 1, 2, 3 in unit plug.
2 1
[–]
3
[+]
Fig. 3
2. Inspection
2.1 Vent pressure switch via adjusting device.
2.2 Check the switch point with the precision pressure gauge of the adjusting device and test lamps.
2.3 Slowly vent the pressure switch, thereby observing the switch point on the precision pressure
gauge of the adjusting device and test lamp(check the displayed switch difference according to
the measurement points list, see "engine documentation, chapter "Control/Regulation".)
en / 02.11.2011 IB023083 2/3

M25/M32/M43
3750
3. Correction of the adjustment 11
NOTE
In case of deviations from the set value (see
measuring point list in "engine documentation,
chapter "Control/Regulation" correct the set-
ting in accordance with sequence of operations
3. Pressure switch is set in the case of falling
pressure.
20
3.1 Remove lead seal.
3.2 Loosen housing cover (Fig. 4/20) of the pressure switch.
3.3 Set switch point to required value according to measurement + –

points list with a hexagon spanner (5 mm).
4. Removal of the adjusting device
4.1 Loosen the cable connections and pneumatic connection of

the test device.
4.2 Seal test connection with plug and turn cock (Fig. 1/1) to
operating position.
4.3 Screw on housing cover and seal with lead seal.
Fig. 4
en / 02.11.2011 IB023083 3/3

RPM Switch A5.05. 11.05.01.02
M20/M25/M32/M43
7500
See also: C5.05.05.70.06.43 11

Spare parts list:
Personnel qualification: E-specialist

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check the function of the rpm switches every 7,500 operating hours.
NOTE
The engine speed must be constant whilst testing.
1. Note the rpm switch point setting. Loosen
the pointer locking plate (2) and set the
pointer (1) at the highest engine speed.
The output relay on the plug-in card must

switch and the luminous diode (3) on the
dial will go out (Fig. 1).
2. Turn the pointer carefully to the left

towards 0 rpm. When reaching the engine
speed, the output relay will switch and the
diode on the dial must light up (switch
hysteresis ± 25 rpm).
3. Set the pointer again at the original rpm

switch point and lock it.
If the rpm switch does not work, proceed

as follows in order to locate the defect:
4. The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation must
be switched on.
At constant speed and with the setting as under point 1, continue as follows:
5. Voltage check at the plug-in socket contacts of the plug-in frame.
en / 02.11.2011 IB021724 1/2

RPM Switch A5.05. 11.05.01.02
M20/M25/M32/M43
7500
5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive). 11
5.2 PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14).
If nothing could be detected whilst checking points 4 - 6, renew the plug-in card.The engine speed must be
constant whilst testing.
NOTE
Carry out the rpm adjustment of the new plug-in card. For this see the "Engine Docu-
mentation, Chapter „Control and Monitoring“, rpm switch".
en / 02.11.2011 IB021724 2/2

Fuel rack position monitoring A5.05. 11.05.01.10
M32/M43
See also: 11
Spare parts list:
Personnel qualification: skilled engine hand / E-specialist

--------------------------------------------------------------------------------------------------------------------------------
Tools:
- A PC or Laptop with RS232 interface and with Win2000 or WinXP as operating system
- 3-core cable for the serial interface (custom made for customer service)
- MaK-FR software (which must already be installed, otherwise see help file on CD Rom)
Check:
Only in case of commissioning, new adjustment / readjustment of the MaK fuel rack card (stock
No. 283480230).
Note:
The adjustment software is integrated in the micro controller program located on the PC board of
the fuel rack card so that no switching operation or other kind of change-over is necessary.
For proper operation of the MaK fuel rack card some engine-specific values are to be
entered.
These are:
a) Operating mode (simple measurement of fuel rack position or measurement of fuel rack positi-
on with detection of engine lugging)
b) Number of teeth of the camshaft gear
c) Basic values for speed setpoints

- minimum engine speed (value for 4 mA)
- maximum engine speed (value for 20 mA)
d) Fuel rack blocking (indicated in mm or index points)
e) Reference points for transmitter linearization / end point adaptation (max. 11 points)
Note:
This assigns a transmitter position (mA) to the respective fuel rack position
(index points or mm).
f) Fuel rack position (in index points) for 100 % load and the related output current
Presetting: 50 index points correspond to 100 % load at 18 mA
en / 09.08.2005 IB024908 1/4

M32/M43
Procedure: 11
Establish a cable connection
between laptop / PC and the MaK fuel rack card.
Starting the MaK-FR program
Start the MaK-FR program via the existing link on

the desktop or via the menu program.
Input of the required values
Note:
After calling the MaK-FR software the current engine speed, speed setpoint, calculated fuel rack
position in percent and the measured current value of the fuel rack transmitter are displayed (in
the tab: "Information").
This function serves for checking the changes made by means of the following functions.
Operating mode
This functions allows to change between the operating mode „fuel rack sensor with overload
detection" and just plain fuel rack sensor without overload detection.
In the tab: "Configuration"
• Overload detection: Standard

• No overload detection: Only upon special
instruction
Number of teeth
in the tab: "Configuration_2"
With this function the tooth pitch requi-

red for calculating the speed is entered
on the MaK fuel rack card.
M43 → 60 teeth
M32 → 88 teeth
Editing only upon special instruction.
en / 09.08.2005 IB024908 2/4

M32/M43
Basic values for speed setpoints 11

im Tab: „Konfiguration_2“
Funktion für die minimale und maximale Drehzahl

nur auf besonderen Hinweis editieren.
Füllungsblockierung
in the tab: "Configuration_2“
Input of the value for blocked fuel rack, to be read

off from the mech. blocking of the rack
Reference points for transmitter linearization
Reference point input
Note:
The mechanics of fuel rack and governor linkage
must be adjusted before entering the reference
points
Reference point deletion
If the fuel rack transmitter is to be completely read-

justed, this function allows to delete all table refe-
rence points stored on the MaK fuel rack card.
Fuel rack position (in index points) for 100 % and the related output current
Input of number of index points for 100 % load and

the related output current.
en / 09.08.2005 IB024908 3/4

M32/M43
Check of the entered value 11

in the menu: "Tools" => Version / Pro-
perty Check)
This function allows a very quick check of

the settings made on the card and whe-
ther they have been taken over. Also, the
software version on the fuel rack card is
displayed.
Terminating the program
in the area: "below – right“)
Attention:
Before terminating the program via the menu or via the "Close" button, you should
always separate the connection to the MaK fuel rack card.
Separate the cable connection
between laptop / PC and the MaK fuel rack card. .
Example
of a tab
en / 09.08.2005 IB024908 4/4

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.00
M20-M601C
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly and functional check of the thermostatic
element of the lubricating oil/cooling water thermostat every 7,500 h
Note:
The thermostatic elements are adjusted by the manufacturer to the required temperature.
Modification of the adjustment or repair is impossible. Defective elements must be exchanged
completely.
Controlling the thermostatic elements in case of failure is enabled by a manual control facility.
Hereto slacken counter nut (1) and turn set nut (2) clockwisely in order to get a lower
temperature. After setting counter again.
The cooling line is fully opened and the bypass closed when the control pin (3) is in the upper
position.
This setting procedure may only be carried out if the thermostat fails.
With mounting a new thermostat, the control pin (3) must be set to its initial position by the nut (2).
1. Disassembly (Fig. 1)
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew nuts (5) of housing lower part (6)

and remove housing cover.
1.3 Unscrew counter nut (1) from regulating

spindle.
1.4 Remove thermostatic element out of hou-

sing lower part.
1.5 Wash parts in gas oil and blow them clean.
en / 31.05.2000 IB021739 1/2

M20-M601C
7500
11
1.6 Check lower seat and sealing faces of thermostatic element for damage.
1.7 Wipe clean thermostat housing with a lint-free rag and check for corrosion and deposits. Check
upper plate for erosion.
2. Functional Check of the Thermostatic Element
2.1 Put thermostatic element (1) into a water bath of a termpature of approx. 10 K above the mean
temperature specified on the insert (XX) (specification in degree Fahrenheit).
2.2 The thermostatic element must open steadily.
3. Assembly
3.1 Slightly grease inner side of O-ring (4) and upper face of element and regulating spindle. By the
clearance of the O-ring, heat elongations are compensated.
3.2 Top up lubricating oil/cooling water system and check thermostat for leakage.
en / 31.05.2000 IB021739 2/2

M20-M601C
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly of lubricating oil/cooling water thermostat,
making a funcional check of thermostatic element every 7,500 h
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 / 29.08.2011 IB021750 1/2

M20-M601C
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 / 29.08.2011 IB021750 2/2

Pressure Switch A5.05. 11.06.05.02
M32/M43
22500
See also: 11.06.06.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all pressure switches after 22,500 h
Tools:
Metric standard tools.
Set of replacement parts:

Pressure switch M2103 (emergency stop - cooling water pressure)
Pressure switch M1106 (emergency stop - lubricating oil pressure)
Depending on the equipment status all other pressure switches are to be replaced as well.
CAUTION
- Ensure that the engine cannot be started!
- When exchanging the pressure pipe or draining off the cooling water it is possible
that "hot" cooling water leaks out.
- There is a danger of scalding.
- Avoid skin contact with cooling water emulsions, observe the safety data sheets of
the manufacturers.
en / 29.08.2011 IB025581 1/3

M32/M43
22500
Procedure: 11
1. Put the engine and the related safety systems out of operation.
- > Notify the engine to be ’’unserviceable’’ < -.
NOTE
Prior to replacing the pressure switches the shut-off cocks of the media must be clo-
sed.
Prior to installation the pressure switches are to be adjusted to the specified pressure
values.
2. Replacement of the pressure switches.
NOTE
The measuring point designations are always provided on the engine cable and the
engine.
2.1 Remove the old pressure switch.
2.2 Mount the new pressure switch. When doing so,

slightly grease the O-ring (Fig. 1/1) at the foot of the
new pressure switch before inserting it.
2.3 Replacement of the plug.
3. Testing of the completed work:
3.1 Cooling water system

1
3.1.1 Start the engine and run up to nominal speed.
3.1.2 Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2).
The engine has to stop automatically latest after 20 seconds.
3.1.3 Put test valve (2) into "Operation" position again.
3.1.4 Lubricating oil system
3.1.5 Start the engine and run up to nominal speed.
3.1.6 Simulate "Low lubricating oil pressure" by means of test valve (2).
The engine has to stop automatically without any delay.
3.1.7 Put test valve (2) into "Operation" position again.
3.1.8 The other pressure switches are to be tested according to the same procedure.
en / 29.08.2011 IB025581 2/3

M32/M43
22500
4. Put the engine and the safety system into normal operating condition again. 11
-> Notify the engine to be "ready for operation" <-.
en / 29.08.2011 IB025581 3/3

M20/M25/M32/M43
See also: 11.06.05.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Pressure calibrating device W1*
Electric continuity tester (multimeter) W2*
* no picture
Procedure:
1. Mount new pressure switch, see A5.05.11.06.05.nn.
2. Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
2.1 Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to
the test connection. The adjustment value is to be inferred from the list of measuring points, see
"engine documentation, chapter "Control and Monitoring".
2.2 In pressureless state the pressure switch contacts (Fig. 1)

1 + 2 are closed and contacts 1 + 3 are open (ohmic flow).
2.3 When the pressure drops, the pressure switch should switch at the measuring point value, in this
state contacts 1 + 2 are open and contacts 1 + 3 are closed.
2.4 If a pressure switch is replaced, the switching value is to be inferred from the list of measuring
points.
(The measuring point number is indicated on the cable or the related nameplate.)
NOTE
If the pressure switch responds before or after the read limit, the switching point has
to be readjusted, see item 3.
en / 11.10.2011 IB025583 1/2

M20/M25/M32/M43
3. Adjustment of switching point 11

3.1 Remove cover (Fig. 2/4).
3.2 By turning the hexagon socket screw

(5) the switching point can be adjusted
correspondingly.
4. Assembly:
4.1 Mount cover (4).
4.2 Remove pressure calibrating device (W1).
4.3 Clip on plug to the pressure switch.
4.4 Open shut-off valve (Fig. 3/6) of the

corresponding medium to the pressure pipe.
NOTE
Replacement of the complete
switch, see A5.05.11.06.05.nn.
en / 11.10.2011 IB025583 2/2

Crankcase Monitoring Device A5.05. 11.09.01.03
M20/M25/M32/M43/M453C/M552C/M601C
1500, 750, 7500
See also: 11
Spare parts list: B1.05.11.nn4810

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Check the underpressure in the measuring chamber every 750 h
b) Clean the infrared filter and replace the sintered bronze filter
in the measuring attachment every 1.500 h
c) Replace the sintered bronze filter in the pressure control every 7.500 h
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 / 10.05.2011 IB021758 1/1

Crankcase Monitoring Device A5.05. 11.09.01.04
M43
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance and trouble shooting: refer to manual C
Attention:
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
en / 05.10.2000 IB022633 1/1

Vibration Damper A5.05. 12.04.02.00
M43
45000
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/ replace:
Vibration damper:
Replacement (on an exchange basis) after 45,000 h
NOTE
We have to point out that this maintenance sheet was prepared only for the purpose
of maintenance planning.
Please contact the Caterpillar/ Kiel Customer Service in time before reaching the
45,000 hours deadline.
en / 01.04.2010 IB024239 1/1

Turning Device A5.05. 12.08.01.00
M43
15000, 750, 3750
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Check oil level every 3,750 h
Lubricate/grease shaft and gear wheel every 750 h
Oil change every 15,000 h
Bearing grease „Klüber Altemp. QNB 50“ *
Gear oil „Shell Omala Öl 220“ *
Molykote paste „G-Rapid“ *
1. Operation of the turning device
~ Safety note:
Secure the engine against accidental starting!
Beside this direction the operating and maintenance instructions of the turning device
supplier are to be observed!
1.1 Engaging the turning device
en / 02.11.1999 IB020533 1/5

M43
15000, 750, 3750
1.1.1 Disassemble hexagon nut (Fig. 1/1), washer (2), tensioning sleeve (3), intermediate gear wheel 12
(4) and switch bridge (5).
15
16
12
X
13
14
4 3
11 5
X
2
10
5 4 3
en / 02.11.1999 IB020533 2/5

M43
15000, 750, 3750
1.1.2 Slightly lubricate the thread of the turning motor shaft (Fig. 2/10) with Molykote paste. Re-assem- 12
ble the parts in the following order: Intermediate gear wheel (4), switch bridge (5), tensioning slee-
ve (3), washer (2), and hexagon nut (1).
Make sure the tensioning sleeve (3) and switch bridge (5) are in correct assembly position.
Tighten the hexagon nut (1) with a torque of
M = 130 Nm
15
16
12
Y
13
14
4 3
Y
11
5
10
3
4 5
2
en / 02.11.1999 IB020533 3/5

M43
15000, 750, 3750
12
Attention:
Due to the new position of the intermediate gear wheel (4) and the switch bridge (5), the
position switch (11) switches to "Position engine OFF". During turning the engine cannot
be started.
1.1.3 The engine can be turned.
1.2 Disengaging the turning device
1.2.1 Disassemble hexagon nut (Fig. 2/1), washer (2), tensioning sleeve (3), switch bridge (5) and in-
termediate gear wheel (4).
1.2.2 Slightly lubricate the thread of the turning motor shaft (Fig. 1/10) with Molykote paste. Re-assem-
ble parts in the following order: Switch bridge (5), intermediate gear wheel (4), tensioning sleeve
(3), washer (2), and hexagon nut (1).
Make sure the tensioning sleeve (3) and switch bridge (5) are in correct assembly position.
Tighten the hexagon nut (1) with a torque of
M = 130 Nm
Attention:
Due to the new position of the intermediate gear wheel (4) and the switch bridge (5), the
position switch (11) switches to "Position engine ON". The engine can be started.
2. Maintenance
2.1 Checking the oil leve
Note:
If filling-up should be necessary use only the prescribed gear oil!
2.1.1 Check the oil level at the check bore (12) and if necessary add new gear oil (e.g. Shell Omala oil
220) up to the check bore.
2.2 Lubricating / greasing shaft and gear wheel
2.2.1 Lubricate output shaft and gear wheel with gear grease.
Attention:
Grease the toothing of the gear wheel only when the turning device is disengaged.
2.2.2 Slightly grease the toothing of the gear wheel with bearing grease.
en / 02.11.1999 IB020533 4/5

M43
15000, 750, 3750
2.3 Carrying out an oil change 12

2.3.1 Remove the screw plug (13) on the gear of the turning device.
2.3.2 Drain the oil from the gear of the turning device.
2.3.3 Mount screw plug (13) with new gasket (14).
2.3.4 Remove screw plug (15) on the gear of the turning device.
2.3.5 Fill in new oil (e.g. Shell Omala oil 220) up to the check bore (12).
2.3.6 Mount screw plug (15) with new gasket (16).
en / 02.11.1999 IB020533 5/5

M43
30000, 750, 3750
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil level check every 3.750 h or 6 months
Lubricating / greasing of shaft and gearwheel every 750 h or monthlys
Oil change every 30.000 h or 4 years
Auxiliary material:
Bearing grease „Klüber Altemp. QNB 50“ *
Gear oil „Shell Omala Oil 460“ *
*or a product of equal standard
1. Operating the turning device
NOTE
Protect engine against unintentional start-up!
1.1 Engaging the turning device
1.1.1 Move blockinglever (1) to position “V“ and hold.
1.1.2 Move lever (2) to position“ X“, so that the gearwheel of the turning device engages completely in
the flywheel toothing.
1.1.3 Let off blockinglever and make sure that the blockinglever engages in position “Z“.
NOTE
When the turning device is engaged, the position switch (11) is automatically set to
position “engine OFF“ . The engine cannot be started during turning!
1.1.4 Turn the engine.
en / 25.03.2010 IB023850 1/3

M43
30000, 750, 3750
1.2 Disengaging the turning device 12

1.2.1 Move blockinglever (1) to position “V“ and hold.
1.2.2 Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged from the
flywheel toothing.
1.2.3 Let off blockinglever and make sure that the blockinglever is engaged in position “Z“.
NOTE
The engine can only be started if the turning device is disengaged !
The position switch (11) is then in position „engine-ON“)
en / 25.03.2010 IB023850 2/3

M43
30000, 750, 3750
2. Maintenance 12
2.1 Oil level check
NOTE
If a topping up should be necessary, only the prescribed gear oil is to be used!
2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ) up to the oil
level marke.
2.2 Lubricating / greasing of shaft and gearwheel
NOTE
Grease the notch on the output shaft and the gearwheel only if the turning device is
engaged.
2.2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of
the grease nipple (4).
NOTE
Grease the gearwheel toothing only if the turning device is disengaged.
2.2.2 Coat toothing of gearwheel thinly with bearing grease.
2.3 Oil change
2.3.1 Remove screw plug (5) on the driving gear of the turning device.
2.3.2 Drain the oil from the driving gear of the turning device.
2.3.3 Mount the screw plug (5) with new gasket (6).
2.3.4 Remove the vent socket (7) on the gear of the turning device.
2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ca.9 l) up to the oil level mark (10).
2.3.6 Mount vent socket (7).
en / 25.03.2010 IB023850 3/3

Ambiguous Document References X0
en / 21.12.2011 QV020011 1/52

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M43 Maint Dec2011

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Maintenance A0

en / 21.12.2011 AA044756 1/1

en / 21.12.2011 AA047652 1/1

en / 21/12/11 AA047587 1/1

en / 21.12.2011 AA000026 1/1

01 Engine, cylinder head A5.05.01

en / 21.12.2011 AA020041 1/12

en / 21.12.2011 AA020041 2/12

02 Engine, gear A5.05.02

en / 21.12.2011 AA020041 3/12

03 Engine, housing A5.05.03

en / 21.12.2011 AA020041 4/12

04 Engine, control A5.05.04

en / 21.12.2011 AA020041 5/12

Repair / Disassembly and reassembly A5.05.04.04.01.08

en / 21.12.2011 AA020041 6/12

05 Engine, regulation A5.05.05

06 Engine, exhaust gas system/supercharging A5.05.06

en / 21.12.2011 AA020041 7/12

en / 21.12.2011 AA020041 8/12

Maintenance / Disassembly and reassembly A5.05.06.04.02.37

07 Engine, fuel system A5.05.07

en / 21.12.2011 AA020041 9/12

08 Engine, lubricating oil system A5.05.08

en / 21.12.2011 AA020041 10/12

Maintenance / Cleaning A5.05.08.04.01.00

09 Engine, cooling water system A5.05.09

10 Engine, starting system A5.05.10

11 Engine control equipment A5.05.11

en / 21.12.2011 AA020041 11/12

12 Engine auxiliary units A5.05.12

en / 21.12.2011 AA020041 12/12

No claims can be raised owing to missing instructions in the maintenance documents, if

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 “Scheduled maintenance” is thereby supported by inspections according to fixed

The following is used as parameter:

• data on wear and tear

en / 14.12.2011 AA047605 1/15

The information given by us gives no rise to legal claims.

2.2 Maintenance system

The maintenance system consists of:

• work interval schedule

• maintenance schedule (large-scale plan) *

* will be handed during commissioning of the engine

en / 14.12.2011 AA047605 2/15

2.2.1 Work interval schedule

The interval schedule is subdivided into the following four areas:

• Daily inspection and control work

• Initial inspection and maintenance work

• Periodic maintenance work

• Maintenance work to be carried out independent of deadlines

en / 14.12.2011 AA047605 3/15

2.2.2 Job cards

Maintenance work Activity

Discharge valve A5.05.01.04.01.03

Operating hours/maintenance deadline