Maintenance MAK M43C
Maintenance MAK M43C
Maintenance MAK M43C
Maintenance
Maintenance A5
Table of Contents A5.01
Introduction A5.02
Safety instructions A5.03
Periodical schedule
Heavy fuel A5.04.02
M20-M601C
1. General
It is assumed that the engine room personnel has the necessary knowledge and experience
required for the proper maintenance and servicing of diesel engines. For this reason 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.
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 mainte-
nance system of MaK 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.
• performance checks
Most of the work to be carried out does not have a fixed deadline since the service life of indivi-
dual components is highly influenced by environmental and operating conditions, fuel qualities
and their care.
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 MaK with regard to extended intervals in order to maintain the gua-
rantee.
M20-M601C
• job cards
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.
The work interval schedule shall provide for a quick summary of all intended inspection, mainte-
nance and repair work occurring up to 90,000 operating hours.
Work which has to be carried out after first commissioning or commissioning after major repair
work.
A list of all recurrent inspection, maintenance and repair work to be carried out at the schedu-
led date.
The indicated intervals are statistical mean values. Other values may be obtained, depending
on equipment condition, operating and maintenance conditions.
List of work which may be required in the scope of scheduled work which cannot be allocated
to a deadline.
* will be handed over by the MaK service department for commissioning of the engine
M20-M601C
The job cards are instructions for inspection, maintenance, repair and safety check.
¬
Title of the job card
M 551 / M 552
6,000 / 12,000
Engine type 01
Register
Main maintenance group
Breakdown
Chapter maintenance Subchapter
Job cards
Document number
A5.05. 01.04.01.03
Main maintenance group
Maintenance group
Subgroup
Variant
Date of issue
Registration number Page/number of pages
Language
M20-M601C
The job card number consists of the index breakdown (A5.05) and the maintenance number
(bold) subdivided into four pairs of digits.
• The first pair of digits indicates the engine main maintenance group:
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.
• 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 Vol. B “Spare parts catalogue”, indicating other design details in the illu-
strations, 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 (see also: introduction A0.02).
• Safety note: Each safety note is additionally marked with a symbol ~ in order to draw special
attention to the text (see A5.03).
• Note: Gives the personnel information which optimize the work process.
M20-M601C
• In the maintenance sheets the checks, maintenance, cleaning and repair works of the mainte-
nance sheets are briefly designated
• Under the designation "tools (W)" only special and additional tools are listed with the MaK 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 indi-
vidual 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 maintenance sheets refers to
one cylinder unit only.
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 reasons, 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 gui-
delines 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/replacement 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 over by the MaK service department for commissioning of the engine
M20-M601C
1. Safety instructions
~ All texts marked with this symbol in the maintenance sheets are safety
instructions which have to be observed in all cases in order to eliminate
danger to life and limb of the user or of third parties!
• 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 expo-
sed to temperatures above 300 °C, since above 325 °C a thermal decomposition and the
formation of hydrofluoric acid can occur.
• 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. during combustion and
welding operations. If this should however has happened, 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.
• Any residues have to be neutralized before their disposal, i.e. saturated with calcium
hydroxide.
• Maintenance and repair work must only be carried out by skilled and authorized
personnel!
M20-M601C
• When work is being carried out on engines and systems, the switch-on devices 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!
• During replacement work, individual parts and large assemblies are to be carefully
fastened and secured on hoists to avoid risks of accidents!
• Use only suitable and technically perfect lifting gear and suspension systems with
adequate lifting capacity!
• When carrying out overhead assembly work, the specially designed or safety-oriented
climbing aids are to be used only!
• Keep all handles, steps, handrails, platforms, ladders free from dirt, e.g. oil, grease,
fuel!
• Clean the engine parts, especially connections and threaded unions of any traces of oil,
fuel or preservatives before carrying out maintenance/repair (disassembly, assembly)!
• Pressurized plant components (lube oil, hydraulic oil, fuel, cooling water, starting and
control air) must be depressurized. Shut-off valves are to be secured by a plate “Do not
open”!
M20-M601C
• 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 engine/plant
immediately if trouble occurs in the electrical system!
• Engine or plant parts on which inspection and maintenance work is being carried 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!
• The minimum bending radii r = 250 mm of the high-pressure hoses are to be strictly
observed!
• The hose lines are to be protected against damage caused by external mechanical,
thermal or chemical influences!
• Replace hydraulic hose lines at regular intervals, even if no safety relevant defects are
detectable!
• During testing make sure that no parts of your body are positioned in the area of the
fuel jet!
M20-M601C
• 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!
• 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!
• 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!
3. 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.
M43/VM43
M43/VM43
M43/VM43
M43/VM43
1,500 h Governor
Governor behaviour/governor control rod
see book C
M43/VM43
3,750 h Governor
Oil change
see book C
3,750 h Monitors
Checking of alarm and safety system
see book C
M43/VM43
M43/VM43
M43/VM43
M43/VM43
Pistons A5.05.02.06.01.30
Maintenance/Disassembly
M43/VM43
Piston A5.05.02.10.01.30
Maintenance/Reassembly
Counter-balance A5.05.02.11.00.00
Repair/Disassembly and reassembly
Camshaft A5.05.04.04.01.08
Repair/Disassembly and reassembly
Timing Gear Train A5.05.04.08.02.02
Maintenance/Disassembly and reassembly
M43/VM43
1500
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.
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.
M43/VM43
1500
M = 250 Nm.
M = 400 Nm
2.2.5 Remove the turning mechanism and close the indicator valves.
M43/VM43
Tools:
Auxiliary materials:
** 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.
M43/VM43
1.5 Remove the four rocker arm nuts with the hydraulic clamping unit. 01
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.
Loosen hydraulic clamping elements by 3 holes.
1.5.2 Connect the clamping elements with the high pressure pump (6) by means of the high pressure li-
nes (W1.2, W1.3).
1.5.3 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.
1.5.4 Loosen the round nuts with a pin. Turn the round nut back four holes.
1.5.5 Depressurize the clamping elements, dismantle the clamping device and remove the round nuts.
M43/VM43
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.
1.5.6 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.
2.3 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 (W1.1) 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 by means of the high pressure lines
(W1.2, W1.3).
2.5.3 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.
Attention:
The pressure must remain constant when the pump is not being actuated to prevent incor-
rect tightening.
2.5.4 Tighten the round nut firmly with a pin. Check to ensure good action (no stiffness).
M43/VM43
2.5.7 Repeat installation procedure 2.5.1 to 2.5.6 for lower round nuts (1).
M43/VM43
30000
Maintenance:
Note:
Procedure:
1. Disassembly
Note:
All additional maintenance work is identi-
cal for the intake and exhaust valve rocker
arms.
M43/VM43
30000
~ Attention!
Note and follow all safety instructions
when handling liquid nitrogen.
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 (01.02.01.nn) and check
the oil flow through the components.
M43/VM43
Tools:
Copper punch W1 *
* no picture
Note:
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
(01.02.02.nn).
2. Replace.
2.1 Drive out the bush (1) with the proper cop-
per punch (W1).
Attention:
Note the position of the oil bores (2)
and the separating joint (3) when pres-
sing the new bush into place. The rok-
ker 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.
M43/VM43
150
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.
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. 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!
M43/VM43
15000
Inspection:
of the valve guide clearance of the intake and exhaust valves after 15,000 h
Auxiliary materials:
** or equivalent product
Procedure:
1. Replace the oil scraper rings (O-rings).
1.2 Remove O-ring (1) from groove with wire hook carefully.
M43/VM43
15000
01
Attention:
The O-ring meters the valve lubrication and may only be replaced with a new MaK replace-
ment ring.
1.4 Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during instal-
lation!
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
Note:
The valve guides should be replaced by a certified MaK workshop within the scope of a cylinder
cover overhaul if possible. The cylinder cover may be damaged when removing the old valve
guides.
M43
Auxiliary material:
Vaseline *
Sequence of operations:
1. Disassembly
~ Safety note:
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).
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.
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).
1.10 Remove hexagon screws (20, 23) with media block (6).
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).
2.4 Put the connecting flange (8) onto the sleeves (10) and mount it.
Replace faulty gasket (13) beforehand.
Attention:
Make sure that all gaskets (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.
4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm.
Note:
Leakage fuel can result from
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 (07.02.01.nn).
M43
Tools:
Store hydraulic device kit W1 consisting of
clamping cylinder W1.1 1.9213 P
high pressure hose W1.2 433420 E
high pressure hose W1.3 433420 A
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
Attention:
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.
~ Safety notice:
Avoid bringing body parts above the pressurised devices. Secure motor against involun-
tary starting.
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).
Attention:
When removing the last cylinder head
on the opposite side of the clutch un-
screw the manometer pipe (lubricating
oil nozzle cooling) from the connecting
flange.
M43
3. Disconnect and remove connecting flange of the media conduit for the cylinder head to be re- 01
moved (01.05.50.nn).
Note
To prevent damage and ensure trouble-free assembly and disassembly, the complete rocker arm
bracket must be removed!
8. Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe.
M43
10. Loosen the six cylinder head screws using the hydraulic torque device. 01
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 ap-
prox.
50 bar
With further pressure increase there is a risk of the round nut becoming wedged due to an expan-
sion of the bolt thread.
10.5 Relieve traction elements, remove hydraulic device and unscrew round nuts.
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
Attention:
Risk of damage for conduit connection, cylinder head screws, push rods, fuel pressure
pipe and charged air inlet connection.
12. Lower cylinder head onto wooden surface (two beams, as nozzle protrudes).
VM43
15000
Maintenace:
Replacement of O-rings every 15.000 h
Tools:
* no illustration
Auxiliary material:
Vaseline **
Adhesive and sealant “ Loctite 510 “**
Sequence of operations:
VM43
15000
01
Attention:
The threads of the nozzle sleeve and the cylinder head may no longer mesh.
1.5 Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.
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)!
2.5 Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to
M =300 Nm
M43/VM43
30000
Maintenance:
Replacement of relief valve every 30,000 h
Tools:
* no picture
Auxiliary Material:
High-temperature thread paste “Dag 5420 A“ *
Sequence of Operations:
M43/VM43
30000
5. Mount new relief valve (3) with new joint ring (4).
M = 50 Nm.
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:
Tools:
* no picture
Auxiliary materials:
** or equivalent product
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).
M43/VM43
15000, 7500
Sequence of operations: 01
1. Disassembly
13
1.1 Disassemble the cylinder head
(01.06.01.nn).
~ Attention!
Spring force
1.7 Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring washer
off the cylinder head.
M43/VM43
15000, 7500
2. Assembly
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.
M43/VM43
Tools:
Auxiliary materials:
* or equivalent product
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):
Sequence of operations:
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
• 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.
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)
• the radial deviation of the valve cone does not exceed the following values:
M43/VM43
• there are corrosion pits and mechanical damages in the vicinity of the valve stem, the
root of the stem and the valve head
M43/VM43
Attention:
After the valve cone is reworked, the
valve seat ring must also be reworked
(01.08.02.nn).
4. Maintenance
(Check wear pattern/grinding)
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
5. Final inspection
M43/VM43
Tools:
Precision seat grinding machine W1 * 1.9224 M
Valve milling unit W2 439224 B
* no picture
Auxiliary materials:
Illuminated magnifying glass (8x magnification)
Diamond paste Dp 30/10 - 15 µm **
Thinner DIAPLASTOL **
** or equivalent product
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.
• the engine has not been run for a long period of time,
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).
M43/VM43
2. Cleaning
Note:
The seat rings must be machined properly
with an MaK precision-grinding
machine (W1). Consult the special
operating manual before beginning work.
M43/VM43
3.1.2 Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6). 01
Attention:
Handle the cutting head (Fig. 6/2) carefully, milling blades can be damaged easily by im-
pact 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.
Attention:
If the cutting pressure is too low or if the cut is made to rapidly, the milling unit may chat-
ter.
3.1.5 Before ending the milling procedure, back out the knurled screw (1) slowly while turning the cut-
ting head.
148+0.2
3.1.7 Remove milling unit. Smooth the sharp edges with a fine emery cloth.
M43/VM43
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). (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
4.3 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.
4.4 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.
M43/VM43
Tools:
Press W1 439222 C
Auxiliary materials:
Diamond paste Dp 30/10 - 15 µm *
Molykote Paste “G-Rapid“ *
* or equivalent product
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
M43/VM43
M43/VM43
3750
Checking:
Attention:
When working on the starter system, close the main valves on the pressure tanks, bleed
the line and block the starting valve.
Procedure:
1. Remove the rocker arm bracket (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.
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.
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.
M43/VM43
15000
Maintenance:
Tools:
* not shown
Auxiliary materials:
Attention:
When working on the starter system, close the main valves on the pressure tanks, bleed
the line and block the starting valve.
Procedure:
1. Disassembly
1.3 Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
1.5 Loosen the hexagon nut (3) while holding the valve shaft (9) with a wrench.
1.6 Remove the clamping ring (4), piston (5), spring (6), spring plate (8) and valve shaft (9)
with sleeve (7) from the cylinder head.
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).
M43/VM43
15000
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.
1.9.5 Turn reseating tool evenly and slowly without additional pressure. Repeat process until valve seat
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
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).
M = 80 Nm.
2.4 Check the starter valve for leaks before starting the engine.
M43/VM43
150
Inspection:
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 (01.06.01.nn). Clean the sealing surfaces and in-
spect - replace O-rings and joint ring and tighten to the indicated torque (01.11.01.nn).
M43/VM43
150
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.
3.1 Check to ensure that the valves move identically. Irregularities can be seen most easily at low en-
gine speeds.
3.4 Check the oil supply to the valve rockers and rocker arm bearings.
M43/VM43
15000
Note:
The cylinder head may only be placed on the bench upright on a wood block.
Procedure:
Intake, exhaust, injector valve, starter valve and rocker arm bracket.
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.
4. Inspect the underside of the cylinder head carefully for cracks at the valve fittings.
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).
M43
Tools:
Ancillary materials:
* or equivalent product
Attention:
Do not fall below the minimum bend radius r =250 mm for the high pressure hoses.
Only use hydraulic oil as operating medium.
~ Safety notice:
Avoid bringing body parts above the pressurised devices.
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.
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.
M43
Note: 01
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 (06.01.01.nn). Grease
screw with high temperature threading paste “Dag S-5080“ and tighten by hand
(no seal).
Attention:
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.
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.
Secure the coupling that is not connected by means of plug (8).
The pressure at the hydraulic pump must correspond to the pressure at the test manometer.
Attention:
The pressure must remain constant with the pump not activated, otherwise the tightening
is wrong.
6.4 Tighten round nuts with pin firmly. Ensure smooth movement.
7. Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from
below (06.01.01.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.
14. Adjust valve clearance (01.01.01.nn) and fit pump chamber cover.
15. Check all connections for tightness after starting the motor.
M43/VM43
3750
Note:
The temperature check for the bearings must be carried out with the engine at operating
temperature after switching off the circulation system lubrication. The remaining tasks are to be
carried out after allowing a period of ventilation.
Sequence of operations:
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.
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.
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.
M43
See also: 02
Spare parts list: B1.05.02.432520, B1.05.03.431110
Inspection:
Note:
Crank web deflection is the change in distance beween a web pair during one rotation 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
foundation.
It is therefore suggested to collect the measurement sheets extra so that the chronological alloca-
tion of the values and changes are visible.
In the event of unpermissible changes, the installation must be realigned and the respective main
bearings inspected.
a)Initial position
b)Negative deflection
c)Positive deflection
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 before
or after a measurement point which is larger than the value at the measurement point, this value
must be entered.
M43
Note: 02
The web deflection is primarily used to measure and evaluate the engine when aligning it in rela-
tion 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 engine is subjected to.
(Engines which are subject to higher load allow less deflection as engines which are subject to lo-
wer loads.)
The values indicated here may not be exceeded if permissible web deflection tolerance for the re-
spective system cannot be obtained from MaK.
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 engi-
ne.
RM43
All cylinders
without external load + 0,07 / - 0,12 mm
M43
02
M43/VM43
Note:
Oil contamination, foreign objects, water and faulty tools cause
85 % of all bearing damage.
Heavy start-stop operation (mixed friction) can cause the bearings to wear more rapidly so that
the bearings must be replaced sooner.
Attention:
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.
M43/VM43
The corrosion-resistant flash on the bearing (ca. 3 µm) is worn through after a short operating 02
period.
- heavy scoring,
- a clearance limit has been exceeded or
- in accordance with the applicable evaluation criteria (02.03.07.nn).
Attention:
If a replacement criterion is found during an inspection, all bearings must be checked.
M43/VM43
Note:
The following evaluation catalog contains different wear stages caused by mechanical wear and
overloading the bearing shells.
Evaluation catalog:
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.
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.
Achtung:
When replacing bearings in the crankcase, note that all bearing shells must generally be
replaced in pairs (upper and lower bearing shell)!
M43/VM43
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.
M43/VM43
02
M43/VM43
02
M43
30000, 15000
Inspection:
Tools:
Auxiliary materials:
* or equivalent product
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-
gine cannot be started.
M43
30000, 15000
Procedure: 02
3.1 Place and tighten the hydraulic clamping elements (W4) over the round nuts (2). Ensure that the
slits are easily accessible.
Loosen hydraulic clamping elements by 1 turn.
3.2 Connect the hydraulic clamping elements (W4) to the high pressure pump (W1) by means of the
high pressure lines (W2, W3).
4. Close the valve (6) on the high pressure pump (W1) and apply force to both connecting rod bolts
with a pressure of
p = 2250 bar
5. Loosen the round nuts (2) with a pin (W5). Turn the round nuts back 10 holes.
M43
30000, 15000
Note: 02
If the round nuts cannot be removed, the pressure on the nuts can be increased by
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 of the high-pressure pump (W1), hydraulic jacks are relieved of tension.
8. Turn connecting rod (17) horizontally with the connecting rod shank division to the exhaust side.
9. Fit mounting and dismounting device (W6) for big end bearing.
9.1 Mount guide rail holder (10) on both sides of the cylinder crankcase.
11
10
14
18
15
M43
30000, 15000
9.4 Mount guide rail extension (13) with carriage (14) on camshaft side.
13
18
15 3
19
M43
30000, 15000
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.
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.
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).
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.
M43
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:
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!
M43
16
20
17
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.
M43
1.11 Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to
the exhaust side.
13
18
15 3
19
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
1.15 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)!
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.
M43
1.21 Check bearing shell pairs for axial misalignment on the exhaust side. Align shells if necessary.
11
10
14
18
15
M43
p = 85 bar
2.5 Firmly tighten the round nut (5) at cams-
haft side with a pin (W5).
Attention:
The pressure must remain constant when the hydraulic pump is not actuated, otherwise
they will be tightened incorrectly!
M43
2.11 Firmly tighten the round nuts (5) with a pin (W5). While doing so the nuts must turn smoothly. 02
Visual check of angle of rotation 180°° ± 22°°
2.13 Open the valve of the high-pressure pump (W1), the clamping elements are depressurized.
M43/VM43
Maintenance:
Tools:
* = no illustration
Auxiliary means:
* or equivalent
Sequence of operations:
1. Disassembly
1.2 Loosen cover (1) using fork wrench (W1) and disassemble.
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".
M43/VM43
Attention:
Do not press joint rings in too much.
Attention:
Do not tilt the piston (3).
2.5 Screw cover (1) on using fork wrench (W1) and tighten.
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.
M43
30000, 15000
Inspection:
Number of bearing
cylinders No.
6 5 and 7
7 5 and 7
8 6 and 8
9 7 and 9
Tools:
* no picture
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.
M43
30000, 15000
02
~ Attention!
Do not place any body parts under equipment which is under pressure! Ensure that the en-
gine cannot be started.
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.
1.3.2 Place hydraulic clamping element (W4) over the round nut
(23) and tighten. Ensure that the slits are easily accessible.
Loosen hydraulic clamping element by 1 turn.
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
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.
1.3.9 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 )
1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan.
Insert carrier arm.
W10
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
M43
30000, 15000
1.4.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig. 02
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.
Loosen hydraulic clamping elements by 1 turn.
12
13
W5
W10
1.4.8 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the
high pressure lines (W2, W6).
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.
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.
If the pressure is increased further, the threading may stretch, which can cause the round nuts to
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
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.
Attention:
Do not turn until the rig is lowered com-
pletely to the lower stop! W11
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).
Attention:
If measurements indicate that the bea-
ring shells need to be replaced, the
neighboring bearings must also be
checked.
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.
M43
30000, 15000
2.1.2 Raise the bearing cap with the rig. Tighten the round nuts until the bearing shells barely touch. 02
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
M43
Tools:
* no picture
Auxiliary materials:
** or equivalent product
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-
gine cannot be started.
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.
M43
Procedure: 02
Note:
The upper bearing shell is equipped with a
lubrication groove and oil bore.
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
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.
2.1 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.
Note:
Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn).
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.
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!
3.7 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
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).
Secure the coupling that is not connected by means of plug.
3.10 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of
p = 2250 bar
Attention:
The pressure must remain constant when the hydraulic pump is not being actuated to pre-
vent the bolts from being tightened incorrectly!
3.13 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.14 Wait until the pressure reduces completely. Remove the clamping elements (W4).
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.
4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
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.
Make sure that the slits (13) are easily accessible.
12
W5
13
W10
M43
4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of
p = 2250 bar
Attention:
The pressure must remain constant when the hydraulic pump is not being actuated to pre-
vent the bolts from being tightened incorrectly!
4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).
4.10 Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5).
The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
M43
30000
Inspection:
Main thrust bearings every 30,000 h
Tools:
Hydraulic set consisting of
High pressure pump W1
High pressure line W2 433420 A
Pin W3
Hydraulic tightening element
(lateral uniform strength bolts) W4 1.9213 F
Hydraulic tightening element
(crankshaft bearing bolts) W5 1.9213 M
* no picture
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-
gine cannot be started.
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.
M43
30000
The 1st main bearing must be removed, inspected and measured before the lapse of the indica- 02
ted intervals when:
- foundation deformations or
- web deflection changes occur after sea damage.
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.
s = s1 + s2
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!
M43
30000
2.2 Loosen the round nuts (23) on the lateral uniform strength
bolts with the hydraulic rig.
2.2.2 Place hydraulic clamping element (W4) over the round nut
(23) and tighten. Ensure that the slits are easily accessible.
Loosen hydraulic clamping element by 1 turn.
2.2.4 Close the valve on the high pressure pump (W1) and apply
force to uniform strength bolt with a pressure of
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!
2.2.6 Open the valve on the high pressure pump, the hydraulic clamping element is depressurized.
2.2.7 Wait until the pressure reduces completely. Remove the hydraulic clamping element.
M43
30000
W10
2.3.2 Connect the hydraulic cylinder in the rig (W10) with the high pressure pump (W1) by means of the
high pressure line (W2).
14
W10
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.
2.3.5 Place the hydraulic clamping element (W5) level on the plate above the chute (10). Remove the
chute.
2.3.6 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
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).
2.3.8 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressu-
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 further, the threading may stretch, which can cause the round
nuts to lock into place!
2.4 Open the valve on the high pressure pump, the hydraulic clamping elements (W5) are depressu-
rized.
2.5 Wait until the pressure drops completely. Remove the hydraulic clamping elements.
The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
2.6 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
M43
30000
2.8 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
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
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.
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.
Attention:
If measurements indicate that the bea-
ring shells need to be replaced, the
neighboring bearings must also be
checked.
M43
30000
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
M43
Tools:
Auxiliary materials:
** or equivalent product
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-
gine cannot be started.
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.
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:
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
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.
1.6 Place the lower thrust washer segments (1; only on main thrust bearings ) on the dowel pins (2) if
removed.
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.
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).
3.1 Screw the round nuts (23) of the adjacent bearing onto the
uniform strength bolts and tighten by hand.
3.2 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 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!
3.6 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.8 Connect the hydraulic clamping elements (W4) on the exhaust side with the high pressure pump
(W1) by means of the high pressure line (W2).
Secure the coupling that is not connected by means of plug.
3.9 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of
p = 2250 bar
M43
02
Attention:
The pressure must remain constant when the hydraulic pump is not being actuated to pre-
vent the bolts from being tightened incorrectly!
3.12 Open the valve on the high pressure pump (W1), the clamping elements (W4) are depressurized.
3.13 Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.15 Screw the protective caps onto the uniform strength bolts.
4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
13
W5
10
23
M43
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute. 02
4.3 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
W5
13
W10
4.5 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the
high pressure lines (W2, W6).
4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of
p = 2250 bar
M43
02
Attention:
The pressure must remain constant when the hydraulic pump is not being actuated to pre-
vent the bolts from being tightened incorrectly!
4.7 Tighten the round nuts (12) with a pin. Check to ensure good action (no stiffness).
4.10 Wait until the pressure reduces completely. Remove the hydraulic clamping elements (W5).
The hydraulic clamping elements (W5) are removed in the reverse order as assembly.
4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
M43
Tools:
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).
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.
Attention:
The crane and lifting eye must remain connected!
M43
M43
02
Attention:
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 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). Secure the coupling that is not connected by means of plug.
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 on the high pressure pump (W3) and loosen the uniform strength bolts one after
another with a pressure of
It may be necessary to move the cylinder of the wrench back and forth several times by releasing
pressure [by opening the valve and closing the valve 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 on the high pressure pump (W3). Wait until the pressure abates completely. Re-
move 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).
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.
M43/VM43
Tools:
Piston lifting unit (piston crown) W1 439223 A
Piston lifting unit (big end) W2 439223 A
Torque wrench 20 - 200 Nm W3 * 1.9454-202
Torque wrench 200 - 500 Nm W4 * 1.9454-500
* no picture
Auxiliary materials:
Molykote Paste “G-n plus” **
** or equivalent product
Procedure:
1. Turn the piston
Note:
The piston crown should only be repla-
ced by the CAT Customer Service.
M43/VM43
2.3 Loosen the hexagon nuts (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!
z 2
M43/VM43
2.5 Clean and inspect the oil bores in the piston skirt (Fig. 3/12). 02
2.6 Piston assembly
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 (7) and contact surfaces for spacer sleeves (6) in the piston skirt
(12).
2.9 Screw piston screws (if removed) into piston crown and tighten to a torque of
M = 40 Nm
M43/VM43
2.12 Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste.
M = 170 Nm.
M = 40 Nm
M = 60 Nm
120°°.
2.17 Check:
At a torque of M = 115 Nm
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!
M43/VM43
30000, 7500
Inspection:
Maintenance:
Tools:
Note:
If the running surfaces of all cylinder liners have no scoring or polished areas and no other dama-
ge 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 tolerance limits, the inspection of all pi-
stons 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 atten-
tion must be paid to the sharp-edgedness of the rings, ring tension or to any rings which may be
stuck due to carbon deposits.
After installing new piston rings, the engine must be broken in in accordance with the break in
procedure A3.10.01.nn!.
Worked pistons with chromed 1st ring grooves may only be re-worked by MaK or MaK certified
workshops.
Procedure:
1. Piston inspection (7.500 h)
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 (02.06.01.nn). If any piston rings are stuck or
burnt, remove all additional pistons.
M43/VM43
30000, 7500
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 MaK.
M43/VM43
30000, 7500
1.11 Calculate the clearance limit and check according to the table for standard piston equipment. 02
1 10 10.8 0.9
2 10 10.5 0.6
3 10 10.3 0.4
2. Maintenance (30,000 h)
X
2.1 Remove all pistons (02.06.01.nn).
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.
M43
Tools:
Piston installation / disassembly unit W1 439223 A
Piston installation / disassembly unit W2 439223 A
Installation rig W3 439220 C
Procedure:
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.
W2
1
X
X
W3
3
6
2
4 5
W1
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.
2.4 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 warming. When
working with new parts, the clearance may not be sufficient when the parts are cold. Full clearan-
ce 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 (02.09.01.nn).
3. Assembly
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.
M43/VM43
30000
Maintenance/Repair:
Measure bearing clearance: every 30,000 h
Replace small end bearing: when replacement criteria met
Note:
The exact installation of a small end bearing is generally impossible with the equipment normally
found on board. This must be completed at the MaK plant or at an MaK certified workshop.
The small end bearing in the offset connecting rod eye has an electroplated running surface, see
02.03.03.nn.
The small end bearing is evaluated on the basis of the operating wear limits (see table).
- the wear limit will more than likely be exceeded before the next overhaul.
Procedure:
1. Measure the small end bearing
1.1 Clean the piston pin (Fig. 2/1), small end bearing (2) and piston bosses and measure dimensions
A, B and C with a suitable measuring instrument such as an external and internal micrometer.
1.2 Determine the axial clearance [piston boss clearance (D) and bearing width (X)].
If the wear limit has been reached (see Fig. 1), the corresponding wearing parts must be repla-
ced.
M43/VM43
30000
02
Smallest Largest Operational
clearance clearance clearance limit
D A B
U V
U V
Z Z
M43/VM43
30000
2.1 When removing the small end bearing, be sure to use as litt-
le force as possible.
Achtung:
Be extremely careful not to damage the surface of the small end bearing bore in the con-
necting rod eye!
After removing the small end bearing, inspect the bore surface carefully for cracks, corro-
sion damage or other damage. Appropriate crack test material such as Magna-Flux and a
magnifying glass must be used for this. Carefully remove any material deposits first.
Connecting rod eyes with a damaged bore surface in the small end bearing bore may not
be used without being reworked.
The connecting rods can normally be re-worked by MaK.
3.1 Small end bushing to ca. -160°°C in C02 snow and warm connecting rod eye to ca. 80°C in a cle-
an oil bath (note safety regulations!).
Achtung:
• Make sure that the small end bearing is installed correctly in the connecting
rod eye!
• The lateral protrusion (Fig. 2/z) of the bushing must be the same on both
sides!
3.3 After the parts have reached normal temperature, the dimensional accuracy and the position of
the oil bores and oil grooves must be checked.
M43
Tools:
* no picture
Auxiliary materials:
Molykote Paste "G-Rapid Plus“ **
** or equivalent product
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
W13
of the piston! Oil the piston rings and the
outside of the piston well. 1
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.
M43
Attention:
When tightening the clamping bolts, 7
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
Attention:
Place the crank journal in TDC.
Y
7. Mount cylinder liner retainer (W9). Z
8. Mount piston installation ring (W12).
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).
M43
M = 50 Nm
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:
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 necessary
and turn the hydraulic wrench.
13.6 Connect the hydraulic wrench (W5) with the high pressure pump (W3) by means of the high pres-
sure lines (W4). Secure the coupling that is not connected by means of plug.
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).
X
30
22
20
W5 W7
Attention:
The engine may not be started when the hydraulic wrench is connected!
M43
02
~ Safety note:
During pressure build-up no parts of the body between support of the hydraulic wrench
and connecting rod or balance weight.
13.8 Close the valve on the high pressure pump (W3) and tighten all uniform strength bolts (20) on one
side at a time with a pressure of
If necessary, move the cylinder in the hydraulic wrench back and forth several times by releasing
the pressure [by opening the valve and closing the valve 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.
13.9 Note the position of the uniform strength bolts (chalk mark), it must be at
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).
15. Remove the piston insertion unit (Fig. 1/W13), piston installation ring (Fig. 2/W12) and piston lif-
ting unit (W1).
19. Remove cylinder liner retainer (Fig. 2/W9), replace crankcase cover and close indicator valves.
M43
Tools:
* not illustrated
Auxiliary material:
Attention:
The smallest allowable bending radius for the high-pressure hoses is 250 mm. For the hy-
draulic device set use hydraulic oil only . Store the hydraulic device set protected against
corrosion.
~ Safety note:
Do not place any part of your body over hydraulic components under pressure! Secure the
engine against unintentional starting!
M43
Sequence of operations: 02
p = 2050 bar
Note:
If the round nut cannot be loosened with
the pin, the stud can be preloaded higher
with a pressure of
p = 50 bar
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.
1.7 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.
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
2.6 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.
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).
3.3 Close valve (10) of the high-pressure pump (W1) and stretch the first stud (2) steplessly with a
pressure of
Attention:
When the hydraulic pump is not actuated the pressure must remain constant, otherwise
the tightening will be incorrect!
3.4 Firmly tighten round nut (1) with pin (Fig. 1/W3).
3.5 Open valve (10) of the high-pressure pump (W1), the hydraulic element will be relieved.
3.6 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4).
3.7 Place hydraulic element (W4) onto the second round nut (1) according to sequence of ope-
rations 3.1 to 3.3.
3.8 Close valve (10) of the high-pressure pump (W1) and stretch the second stud (2) steplessly with a
pressure of
3.9 Firmly tighten round nut (1) with pin (Fig. 2/W3).
3.11 Relieve the hydraulic element according to sequence of operations 3.5 and 3.6.
M43
Tools:
Attention:
In the case of resiliently mounted engines with one damaged running gear the following
measures must be carried out before putting the engine into service for emergency opera-
tion!
Sequence of operations
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
M43
02
M43
S = 1,0 - 2,0 mm
M43
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.
M43
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).
M43
1500
Check:
Tools:
Auxiliary materials:
* or equivalent product
Note:
Removal of the explosion relief valve (5) is only required if the specified spring tension is not pro-
vided any more, in the event of abnormal oil contamination or if any leaks should be identified du-
ring 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).
3. Assembly
3.1 Coat the threads of screws (8) slightly with Molykote Paste "G-Rapid Plus".
3.2 Clean the sealing face 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).
M43
1500
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.
M43
Maintenance:
Replace O-rings
Tools:
Eye bolts M16 W1
Cylinder liner retainer W2* 439217 A
* no picture
Auxiliary materials:
Vaseline **
** or equivalent product
Procedure:
1. Remove coolant distributor housing.
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.
Attention:
The lower cylinder liner retainer must be installed (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 without
twisting.
M43
M = 100 Nm
M = 260 Nm
M43/VM43
30000, 15000
Inspection:
- of one cylinder liner every 15,000 h
W1
- of all cylinder liners every 30,000 h
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.
2
Note:
Unusual forms of wear may be found in cylinder liners de-
pending on the respective total operating time and operating
conditions; this wear must be measured and evaluated. (See
Fig. 3)
1.2 Clean the inside of the cylinder liner, cover the crankcase 3
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 1
engine axis.
1.4
Measu- Wear value
rement Along
point engine axis across engine axis diagonal diagonal
1
2 Refe-
3 rence
value
M43/VM43
30000, 15000
1.5 Enter the values measured into the table (Fig. 2) and calculate the wear values 03
(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/MaK .
3 4
2 5
***1
M43
30000
Maintenance:
Remove cylinder liner,
replace O-ring every 30,000 h
Tools:
Attention:
The cylinder liner sealing surface must be protected from damage!
Procedure
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).
Attention:
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).
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.
M43
Tools:
Auxiliary materials:
Note:
Take complete measurements after instal-
ling a new cylinder liner.
Procedure:
1. Clean the inside of the coolant distributor
housing (Fig. 1/1).
Attention:
Place O-ring in the groove with fluid
beef suet or green potassium soap
without twisting!
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 (03.04.01.nn).
Note:
Insert the cylinder liner so that the mark (5) (Fig. 2/X, top view cylinder liner collar) faces the cou-
pling side in the direction of the engine axis.
The mark (6) on the coolant distributor housing is intended to ease alignment.
Attention:
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 (02.10.01.nn).
M43/VM43
150
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 re-
sulting 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 connecting ele-
ments 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 (06.01.01.nn) behind the exhaust
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 (02.02.01.nn). Obtain tightening values from MaK customer service.
M43
30000, 15000
Inspection:
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.
Note:
When the wear limit has been reached, replace camshaft bearing (MaK customer service) and
check the bearing clearance of all camshaft bearings. Check the bearing journal running surfaces
of the corresponding camshaft bearing.
M43
30000, 15000
Inspection:
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 Remove the injection pump of the cylinder to be checked and all cylinders located to the right of
the cylinder to be checked (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 (04.04.01.nn).
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
Z
Y
13
Y Z
1
5
4
W2
s
1
M43
30000, 15000
Note: 04
When removing the hex head bolts, make sure that the injector cam faces up vertically (TDC) af-
ter turning the engine for the last time.
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!
Distance s = 68 ± 0.5 mm
4
1.9 Remove bolts (Fig. 1/W1).
Attention:
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!
M43
30000, 15000
- 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
(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 (04.04.01.nn).
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.
2.2 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.
M43
30000, 15000
2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring.
M = 130 Nm
2.12 Install rocker arms and complete all remaining work (04.04.01.nn).
M43
Tools:
* no picture
Auxiliary materials:
** or equivalent product
Procedure:
1. Disassembly:
1.3 Mark and disassemble push-rods (7). Push-rods may not be interchanged.
1.7 Loosen circlips (8) of oil pipes (9) and shift towards the centre of the pipe.
M43
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
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
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.
Attention:
Before that, roll out valve drive a bit on carriage (W1.4). Pay attention to spacer sheets (13).
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 adjust-
ing the arms (W1.5) with tubular hexagon box wrench (W1.8).
M43
W1.3
W1.5
W1.1
Attention:
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).
1.23 Lower complete valve drive with hoist and deposit on a suitable base support.
M43
2. Assembly: 04
2.1 Bring into position support (W1.1) and firmly mount to cam follower bracket.
2.2 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench
(W1.8).
2.8 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
2.10 Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correction by
adjusting the arms (W1.5).
Attention:
Spacer sheets (13) are adjusted to each
valve unit individually and may not be
interchanged upon reassembly.
M43
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.
M = 455 Nm.
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)
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).
2.32 Start prelubrication pump and check oil pipes (9) for leaks.
M43
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Torque wrench 20 - 200 Nm W3 * 1.9454-202
Torque wrench 200 - 500 Nm W4 * 1.9454-500
Insert W5 * 1.9424-030
Reversible ratchet W6 * 1.9459-033
* no picture
Auxiliary materials:
** or equivalent product
Procedure:
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.
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
M43
W1
3 3 11
M43
1.9 Drive the right camshaft bearing (Fig. 1/4) out of the camshaft section with a suitable wood block 04
and rubber mallet. Fill the camshaft bearing (4) with cardboard.
1.10 Loosen the hex head bolts (Fig. 1/1) on both camshaft section (3) flanges.
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.
Distance s = 68 ± 0.5 mm
3 3
a b
c
4
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!
1.15 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.
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
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:
Do not tilt the camshaft sections too much! Be very careful!
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!
2.10 Place the hex head bolts in the left camshaft section flange (as many as possible) and gradually
tighten at least three bolts to
M = 420 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.
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 = 420 Nm
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 = 420 Nm
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 = 176 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) 30 (30° ≈ 1/2 hexagon)
M43
04
2.19 Install the rocker arms and check valve clearance (01.01.01.nn).
M43
15000, 3750
Inspection:
Tools:
* no picture
Auxiliary materials:
** or equivalent product
Procedure:
1.1 Remove the timing cover from the control and exhaust side.
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).
1.4 Check the function and seat of the oil nozzles (4 and 5).
M43
15000, 3750
2. Measure the axial clearance of the step gear (Fig. 2/s) with a feeler gauge or dial gauge. 04
Nominal value s = 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, MaK customer service must be informed.
2.1 Check the gaskets and install the timing gear cover on the exhaust and control side.
M43
Tools:
* no picture
Auxiliary materials:
** or equivalent product
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 (2).
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.
M43
04
Attention:
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.
M = 190 Nm
M43
15000
See also: 04
Spare parts list: B1.05.03.431110, B1.05.04.434111
Inspection:
Tools:
Torque wrench 20 - 200 Nm W1* 1.9454-202
Reversible ratchet 1/2" W2* 1.9459-033
* not shown
Ancillary materials:
Molykote Paste “G-Rapid Plus“ **
Sealant “Dirko 610.020“ **
** or equivalent product
Procedure:
1. Disassembly
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.
Attention:
Risk of damage to lubricating oil passage sleeve (30) and O-ring (31).
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.
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).
2.5 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 gov-
ernor drive shaft (Fig. 3/43).
2.7 Fit governor floater linkages in reverse order to removal. If necessary, carry out readjustment of
governor (also see governor adjustment, Book C).
M43
15000
See also: 04
Spare parts list: B1.05.03.431112, B1.05.04.433140
Tools:
Torque wrench 20 - 200 Nm W1* 1.9454-202
Auxiliary material: 1
Molykote paste "G-Rapid Plus" **
2
** or a product of equivalent standard
Note:
After 15,000 operating hours the vibration damper must be 3
exchanged against a new one.
~ Safety note! 4 5
Sequence of operations:
1. Disassembly
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).
2. Reassembly
2.1 Clean contact face of damper (1) and intermediate piece (4) (fat free).
M43
15000
M = 130 Nm
M43/VM43
750
Maintenance:
Auxiliary materials:
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.
Attention:
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!
• 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.
4. Oil all movable bearings on the jointed lever between the control shaft and injection pump lightly.
5. Reinstall cover.
M43
7500
Maintenance:
Tools:
Auxiliary material:
~ Safety note:
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 A4.05.08.nn; 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 gua-
ranteed.
M43
7500
Sequence of operations: 05
1. Close the main shut-off valve on the air receiver.
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.
M43
7500
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).
Pay attention to the spring (10).
Note:
When disassembling nut (12) and piston (13) secure the spindle (14) against being dragged alo-
ng. 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).
Pay attention to the spring (18).
4. Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, if necessary
carefully rework with polishing cloth.
M43
7500
Reassembly: 05
5. Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces
slightly.
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)..
M43
7500
Maintenance:
Procedure:
6
8
7
1. Remove 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)]
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).
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
M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
See also: 05
Spare parts list: B1.05.05.1.4900
Maintenance/cleaning:
Auxiliary material:
Nitro-Solvents *
~ Safety note:
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 affec-
ted in their functioning by the execution of the disassembly and cleaning measures!
M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
Sequence of operations: 05
2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air
supply line.
M20/M25/M32/M43
24, 7500
Maintenance/cleaning:
M43
7500
See also: 06
Spare parts list: B1.05.06.437210
Inspection:
The exhaust line must be checked for leaks every 7,500 operating hours.
Auxiliary materials:
High temperature thread paste "B & W Rivolta G.W.F“ *
* or equivalent product
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 "B & W Rivolta G.W.F“ 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.
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:
4.2 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.
M43
7500
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!
M = 130 Nm.
M = 260 Nm.
6. Install shroud.
M43
See also: 06
Spare parts list: B1.05.06.437250, B1.05.09.438330
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).
Auxiliary materials:
Cleaning agent as recommended by the manufacturer, such as:
* or equivalent product
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.
M43
1.4 Pull the charge air cooler (9) out of the housing (3) on exhaust gas side, 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.
~ 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!
M43
2. Assembly 06
2.1 Install charge air cooler in the reverse order as disassembly.
2.3 Slide charge air cooler (2) 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.
2.5 Tighten hexagon screws (28) one after the other to a torque of
M = 130 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.
M43
24
Maintenance:
Prerequisites:
- The compressor stage must be cleaned with the engine at operating temperature and under full
load (at least 85 % 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.
Basic position
Washing procedure:
Attention:
A water container that has not been closed or closed incorrectly may cause injury of the
operator.
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.
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.
M43
150
Maintenance:
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:
may be used.
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 76-C33 turbocharger:
Quality requirements for water for washing turbine and nozzle ring:
The wash water used should have minimal mineral and salt content.
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, continue to decrease the speed until water drains; if still no wa-
ter will drain from the line, the washing device, including all its lines, must be checked.
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.
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
M43
150
6. Open shut-off valve (4); pressure meter (5) should indicate a pressure of
p = 2,0 ± 0, 2 bar
.
7. Pull up on control valve (1) on the control panel and hold for 10 minutes.
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).
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.
M43/VM43
12000, 24000, 36000
Maintenance:
Note:
Caterpillar points out that this maintenance sheet has only been configurated for the pur-
pose of maintenance planning. As to any other information regarding service, mainte-
nance, and trouble-shooting please look into the documentation of the manufacturer.
The manufacturer recommends to carry out the maintenance measures when reaching
the above-mentioned operating periods.
Attention:
Please observe the particular safety and assembly instructions in "Book C" of the
manufacturer's documentation!
M43
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:
Molykote paste "G-Rapid Plus" **
Sequence of operations:
1. Disassembly
M43
Note:
To remove the two outer injection pumps
(cylinder 1 and last cylinder) leave the cor-
responding flange in place. Remove lubri-
cating oil leakage line, fuel leakage line,
and control air line. Unscrew the screws of
the fuel filter lines (admission and return).
M43
07
1.10 Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control
shaft.
M43
1.11 Push the control rack (41) as far as possible into the injection pump. 07
~ Safety note:
Attention! 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.
Attention:
In order to avoid damages to the hydraulic wrench (W2), adjust a maximum pressure of
p = 500 bar on the high-pressure pump. Adjustment instructions see A6.05.90.10.nn .
1.12 Put on the torque wrench (W2) and evenly slacken the nuts (5).
1.13 Attach the injection pump (6) with lifting device (W1) to a crane and lift from the engine block.
M43
07
Attention:
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.
Note:
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 correctly positio-
ned in the cooling collar.
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.
~ Safety note:
Attention! 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
2.7 Screw together hinged lever (Fig. 5/42) and control rack (41) of the injection pump (05.08.01.nn).
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).
2.11 Mount the screws of the fuel filter lines (admission and return).
M43
2.12 Check the control air pipe (Fig. 4/30) for the stop piston for leakage by means of compressed air. 07
2.13 Check stop piston / emergency stop device for correct function (10.03.01.nn).
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.
M43/VM43
15000, 7500
Inspection:
a) of one injection pump every 7,500 h
b) of all injection pumps every 15,000 h
Tools:
Pressure pipe W1 * 1.9470-051
Nozzle testing device W2 * 1.9470 H
Torque wrench 20 - 200 Nm W3 * 1.9454-202
Torque wrench 200 - 500 Nm W4 * 1.9454-500
2 x cheese head screw M16x150 DIN 912 W5 *
Adapter for injection pump W6 * 432147 A
* no picture
Auxiliary materials:
Molykote Paste "G-Rapid Plus“ **
** or equivalent product
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.
If there is a significant decline in cylinder output, the pressure valve must be checked and repla-
ced if necessary.
M43/VM43
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 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!
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.
M43/VM43
15000, 7500
2. Disassembly 07
2.1 Clean the outside of the injection pump.
~ Attention!
Caution! The spring tension of the
pump spring (9) presses against the lo-
wer pump housing section (4)!
Note:
Take care that the tappet body (2) is also
lifted up.
M43/VM43
15000, 7500
2.11.3 Loosen guide bolt (11), remove control rod (Fig. 2/10) and check control rod toothing for damage.
2.12.1 Loosen cap screws (44), remove stop (16) and cap screws.
2.12.2 Remove stop piston and control rod spring (Fig. 2/18).
2.13 Place the injection pump in the clamp with the vale support (Fig. 1/20) up.
2.14 Loosen and remove the cap screws (33) - inner screw hole circle - cross-wise.
2.15 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).
2.16 Drive the pump element (1) out of the housing with a suitable wooden dowel.
2.17 Clean all parts with gas oil and a stiff brush and blow out with compressed air.
2.19 Remove the pressure piece (24) completely with the cap screws (27), slotted disks (26) and spa-
cer plate to replace gaskets (31) and (32).
2.20 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.
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.
M43/VM43
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).
3. Assembly
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 Coat the thread and contact faces of all screws with Molykote-Paste „G-Rapid Plus“ and tighten to
the respective torque:
3.1.2 Tighten cheese head screws (Fig. 4/33) - outer hole circle - according to the sequence
(1, 7, 4, 10, 2, 8, 15, 11, 3, 9, 12)
and cheese head screws (33) - inner hole circle - according to the sequence
(13, 16, 14, 17, 15, 18)
in three steps.
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.
3.1.4 Check the action of the control rod (Fig. 2/10); must be smooth.
M43/VM43
3750, 7500
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*
Torque wrench 20 - 200 Nm W2* 1.9454-202
* no picture
Sequence of operations:
1. Remove deflector bolts.
1.1 Check deflector bolts (6) for cavitation (Y) of the deflection surfaces (X).
X Y
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.
2.1 Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil.
M = 200 Nm.
M43/VM43
Tools:
Torque wrench 20 - 200 Nm W4 * 1.9454-202
* no picture
Note:
When the engine is operated on heavy fuel it is necessary, prior to carrying out any work
on the injection system, to run the engine for at least 0.5 hours on distillate fuel to thorou-
ghly flush the entire injection system.
In case of overhaul work care has to be taken to ensure that the individual components of an in-
jection 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 necessary, ex-
change it completely!
Procedure:
1. Disassembly
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 (07.05.01.nn).
M43/VM43
2. Assembly
M = 190 Nm.
M = 190 Nm.
M43/VM43
Attention:
After mounting a new injection pump it has to be made sure that the pump is preheated
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.
M43/VM43
Tools:
Auxiliary material:
Note:
In the event of heavy fuel operation the engine is to be operated on distillate fuel for at least 0.5 h
before carrying out any work on the injection system in order to thoroughly flush the entire injec-
tion system.
Sequence of operations:
1. Disassembly
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).
1.5 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).
M43/VM43
2. Reassembly 07
2.1 Renew the O-rings (2, 5, 7, 9, 11).
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).
Attention:
Use only original MaK 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.
Attention:
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
Attention:
The clamping sleeve (18) has a recess (19) in the aperture on one side which must point to-
wards 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 !).
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
M = 250 Nm
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.
M43/VM43
Tools:
Pulling unit for injector valve W1 439111 A
Cleaning tool for injector seat W2 * 439222 B
* no picture
Auxiliary materials:
Molykote Paste "G-Rapid“ **
High temperature thread paste
"Dag S 5420 A“ **
** or equivalent product
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.
Sequence of operations:
1. Disassembly
M43/VM43
2. Assembly 25
20
2.1 Replace O-rings (7).
21
Attention:
Only use original MaK replacement
parts!
23
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 squeezed off in
the locking groove of the cylinder head!
Attention:
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 dowel pin (Fig. 5/11) to the exhaust side and the ring shoulder
down.
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).
M43/VM43
Tools:
~ Safety note:
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 purpose 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 reproduced,
because the flow rates and the related pressure build-up are not comparable 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.
M43/VM43
Sequence of operations: 07
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
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
replace the injector according to
(07.09.01.nn).
M43/VM43
7500
Maintenance:
Replace all injector elements every 7,500 h
Tools:
Auxiliary materials:
High temperature thread paste Dag S 5420 A“ *
Molykote Paste "G-Rapid‘‘ *
* or equivalent product
** 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
Injection valves that need to be overhauled are to be sent to the CAT customer service as a
complete unit.
M43/VM43
7500
Sequence of operations: 07
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).
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.
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.
2. Assembly
2.2 Install new O-rings (9) and (14) with Molykote paste.
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).
2.6 Mount flange (2) with hexagon head screws (1) and tighten
the screws.
M43/VM43
7500
2.7 Put on complete nozzle element (Fig. 2/8+12). Observe position of the pins (7). 07
2.8 Screw on 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 .
2.9 Put torque wrench (Fig. 3/W2) on nozzle nut (Fig. 2/6) and tighten with a pressure of
p = 465 bar
2.10 Slacken hexagon head screws (Fig. 3/1) and remove with flange (2).
2.12 Adjust fuel injector according to (07.08.01.nn), items 3,4, and 5.1.
M43
See also: 07
Spare parts list: B1.05.07.n.7667
Tools:
Cleaning pistol W1 1.9100-110
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 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.
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 period or
improper suspension during cleaning might cause damage to the gauze that cannot be detected
with the nacked eye.
Sequence of operations:
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
M43
~ Safety note:
Depressurize filter chambers!
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.
2.3.8 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).
Note:
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the
cartridges and clean them individually.
2.4.2 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.
Attention:
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.
M43
07
2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
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.
Attention:
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.
6. Fill the filter chamber and vent it (see the plate on the filter cover).
M43
See also: - 07
Spare parts list: B1.05.07.438510
Auxiliary materials:
Molykote Paste "G-Rapid‘‘ *
Procedure:
1. Disassembly
1.4 Remove the fuel leakage line (Fig. 1/1) at the flange.
M43
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.
1.9 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).
M43
1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove
O-rings (12).
1.14 Remove the bushings (3) with the O-rings (7) and support ring (11).
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.
M = 130 Nm
2.6 Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / flange.
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).
2.14 Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserve
pump.
M43
7500
Maintenance:
Auxiliary materials:
Molykote-Paste "G-Rapid “ **
** or equivalent product
Procedure:
1. Disassembly
1.2 Drain the fuel distributing pipe via the corresponding leakage pipe.
1.3 Dismantle the leakage monitoring pipe on the fuel pulsation damper (1) (counterhold the union).
1.4 Loosen fastening clamps (2). Loosen locknut (4) (right-hand thread) and dismantle fuel pulsation
damper.
M43
7500
2. Assembly 07
2.1 Assemble new fuel pulsation dampers (1) in reverse order.
Attention:
When mounting the leakage monitoring pipe the valve body (3) of the fuel pulsation dam-
per must not be twisted.
Hold in place the valve body by means of a second wrench!
2.3 Fill the fuel system by means of the stand-by pump and vent it..
M43
See also: 08
Spare parts list: B1.05.08.436417
Tools:
Torque wrench 20 - 200 Nm W1 * 1.9454-202
Torque wrench 200 - 500 Nm W2 * 1.9454-500
* 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
1.3 Loosen hex nuts (1) and pull lube oil pump
(3) with gear (6) from the cylinder crank
case. Watch out for resilient sleeves.
M43
1.4 Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller. 08
1.6 Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20).
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.
M43
2. Assembly: 08
2.1 Assemble lube oil pump by reversing above steps.
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.
Attention:
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.
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 A4.05.08.nn) 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.
M43
See also: 08
Spare parts list: B1.05.08.437657
Tools:
Auxiliary material:
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 period or
improper suspension during cleaning might cause damage to the gauze that cannot be detected
with the nacked eye.
Sequence of operations:
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
M43
~ Safety note:
Depressurize filter chambers!
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).
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.
2.3.8 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).
Note:
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the
cartridges and clean them individually.
2.4.2 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.
Attention:
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.
M43
08
2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
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.
Attention:
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.
6. Fill the filter chamber and vent it (see the plate on the filter cover).
M20/M25/M32/M43
15000
See also: 08
Spare parts list: B1.05.08.n.7810
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 neces-
sary lubricating oil pressure can no longer be set by adjusting the initial tension of the spring.
The lubricating oil pressure (see A1.05, engine data) is only allowed to be adjusted at the nominal
engine speed (A1.10) and at the specified lubricating oil temperature (see A1.06).
Sequence of operations:
1. Disassembly
~ Safety note:
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).
~ Safety note:
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).
1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush (10).
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).
M20/M25/M32/M43
15000
08
1.3 Clean all parts with gas oil and check them.
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.
M20/M25/M32/M43
15000
2. Reassembly 08
2.1 Check the O-rings (2 and 7) and sealing ring (14) and replace them if necessary.
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment
M20/M25/M32/M43/M453C/M552C/M601C
150
Maintenance:
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 bearing because of the pre-
lubricating pressure. No or only a little quantity of oil is carried to the endangered contact sur-
faces.
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 af-
fecting the unattended operation of the system:
Sequence of operations:
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
M43/VM43
750
Inspection:
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.
Attention:
The control rods must be in the "Zero
Filling“ position.
Note:
Check all injection pumps.
If individual or one control rod can be forced into the injection pump against the pressure of the
stop piston, check the stop piston in the respective injection pump and overhaul if necessary
(07.03.01.nn).
If all control rods can be pushed into the injection pump, check the control air lines for leaks or da-
mage.
Note:
The stop piston is reset and the emergency stop system depressurized.
M43/VM43
750
10
Attention:
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. (Please refer to (C5.05.05.10.50.nn) ).
13
2
T3
6. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control
stand.
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 1 - 16 bar mechanical switching differential: 0.4 bar
• Pressure range 0.9 - 1.5 bar mechanical switching differential: 0.08 bar
• Pressure range 2 - 25 bar mechanical switching differential: 1,5 bar
Sequence of operations:
1. Connection of the adjusting device
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).
M20-M601C
3750
11
Attention:
When loosen/thighten the union nut directly located at the pressure joint of the pressure
switch, it should be simultaneously counter acted at the key faces of the pressure joint.
1.3 Connect the hose (with union nut and cutting) with the adjusting device (Fig. 2).
Attention:
For setting the differential pressure switch, the adjusting device must be equipped with
two text connections (+, –, pressure difference) refer to view “X”.
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.
2.4 Deaerate the pressure switch slightly and simultaneously check the switch point via the test in-
strument. Inspect the displayed switch difference.
M20-M601C
3750
Note:
The scale accuracy is ± 2 % of the span.
The instrument is individually calibrated
(1 - 2 on) so that no gauge inspection is
necessary.
M20/M25/M32/M43
7500
Inspection:
Check the function of the rpm switches every 7,500 operating hours.
Note:
The engine speed must be constant whilst testing.
Sequence of operations:
1. Note the rpm switch point setting. Loosen
the pointer locking plate (2) and set the
pointer (1) at the highest engine speed.
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:
5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive).
M20/M25/M32/M43
7500
5.2 PICK UP IMPULSE (dependent upon engine speed up to 1500 Hz at contact b14 and d14). 11
If nothing could be detected whilst checking points 4 - 6, renew the plug-in card.
Attention:
Carry out the rpm adjustment of the new plug-in card. For this see the "Plant components
file (C), section 5, rpm switch".
M20-M601C
7500
See also: 11
Spare parts list: B1.05.11.1.7837
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 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 (3) and turn set screw (4) clockwisely in order to get a lower tempera-
ture. 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).
Sequence of operations:
1. Disassembly
M20-M601C
7500
11
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).
3. Assembly
3.3 Top up lubricating oil/cooling water system and check thermostat for leakages.
M32/M43
22500
Maintenance:
Replacement of all pressure switches after 22,500 h
Tools:
Metric standard tools.
Depending on the equipment status all other pressure switches are to be replaced as well.
Attention:
- 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.
M32/M43
22500
Procedure: 11
1. Put the engine and the related safety systems out of operation.
Attention:
Prior to replacing the pressure switches the shut-off cocks of the media must be closed.
Prior to installation the pressure switches are to be adjusted to the specified pressure va-
lues.
Note:
The measuring point designations are always provided on the engine cable and the engine.
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.
3.1.6 Simulate "Low lubricating oil pressure" by means of test valve (2).
The engine has to stop automatically without any delay.
3.1.8 The other pressure switches are to be tested according to the same procedure.
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" <-.
M20/M25/M32/M43
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 in
Book C.
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 readju-
sted, see item 3.
M20/M25/M32/M43
4. Assembly:
M20/M25/M32/M43/M453C/M552C/M601C
1500, 750, 7500
See also: 11
Spare parts list: B1.05.11.nn4810
Maintenance:
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
Attention:
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
M43/VM43
30000
Maintenance:
check size of gap "s" between the spring ends and the flanks of the interior grooves.
Renew all seals.
Auxiliaries:
The oscillation damper is connected to the engine lubrication system. The system must be bled
before the first operation and after maintenance work (operation sequence 5.1).
At every lubrication oil change, the system must be completely drained of oil (operation se-
quence 1.3), even in the case of self-bleeding dampers, and the oil replaced (operation se-
quence 5.1).
If running abnormalities appear at certain speeds, the cause may be a defective damper. To avoid
extensive damage, avoid critical speeds and attempt to narrow down the fault as soon as possible
by measuring the torsional oscillation.
The fastening screws of the pump bearing plate (4), the pump wheel carrier (15) and the pump
gear wheel (14) must be tightened at the torque values given (see Assembly, Molykote Lubricati-
on).
M43/VM43
30000
Sequence of operations: 12
1. Dismantling 0,3 C
C
1.1 Dismantle the lubricant pump 0,2 C
(08.03.02.nn).
24
M43/VM43
30000
1.12 Measure gap (Fig. 2/"s" ) between spring ends and groove flanks of the interior using a feeler 12
gauge.
Maximum permitted value for gap "s" between spring ends and groove flanks:
1.13 Apply an adequate quantity of "Loctite 275" to both sides of the cup spring (Fig. 1/22). Tighten he-
xagonal screw (23) until cup spring (22) lies flat, then continue turning to a tightening angle of
57°° - 62°°.
Attention:
In the case of one-sided positioning of groove flank: gap "s" x 2.
M43/VM43
30000
Note: 12
When critical values have been reached the damper should be replaced (AT procedure). If criti-
cal values have been exceeded, the engine should be operated only at reduced power and
avoiding critical speeds; the damper should be replaced as soon as possible.
2. Apply Molykote "Typ 60 G" across the inner side of the side plates (18).
4. Set the side plates so that the oil flow bore holes are positioned between the oil feed bore holes.
Screw the side plates tightly with the corresponding starting torque.
Seal screw threads and cup springs with oil-resistant sealant.
• Turn an oil flow bore hole (30) to the highest position (30).
• Operate reserve lubricant pump until oil flows evenly out of the oil feed bore hole.
• Turn the vibration damper through 180°.
• Operate reserve lubricant pump until oil flows evenly out of the second oil feed bore hole
• Wait until no more air bubbles are visible.
5.3 Further assembly procedure takes place in reverse order from dismantling procedure..
Apply Molykote "G-Rapid Plus" to the screw threads and screw head plates of the screws.
5.4 Apply "Dirco-Grau" silicon sealant to the pump bearer plate (4) , position over the tapered pins
(24) and tighten screws. Assemble lubricant piping.
5.5 Assemble the lubricant pump (08.03.02.nn), check systems for sealing and check lubricant supp-
ly to gearwheels.
M43
45000
See also: 12
Spare parts list: B1.05.02.432520, B1.05.12.436347
Maintenance/ replace:
Vibration damper:
Note:
We have to point out that this maintenance sheet was prepared only for the purpose of maintenance plan-
ning.
Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 45,000 hours deadline.
M43
30000, 750, 3750
See also: 12
Spare parts list: B1.05.12.437330, B1.05.12.437332
Maintenance:
Oil level check every 3.750 h or 6 months
Auxiliary material:
Bearing grease „Klüber Altemp. QNB 50“ *
Gear oil „Shell Omala Oil 460“ *
~ Safety note:
Protect engine against unintentional start-up!
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“.
Attention:
When the turning device is engaged, the position switch (11) is automatically set to
position “engine OFF“ . The engine cannot be started during turning !
M43
30000, 750, 3750
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“.
Attention:
The engine can only be started if the turning device is disengaged !
The position switch (11) is then in position „engine-ON“)
M43
30000, 750, 3750
2. Maintenance 12
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.
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).
Attention:
Grease the gearwheel toothing only if the turning device is disengaged.
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).