Tech. Info M 25

Register 14

14M 25

m cTechn. Information

index

Prepared by : CZ 24/Schu. Issued on : Verified : Gneiser Edition :

Service document of Caterpillar Motoren GmbH & Co.KG

Cat

erpi

llarc

onfid

entia

l:yel

low

Bl. 1

11.3.98 15/3.07

Nr. 01 cylinder head

Nr. 01.05. Bl. 1 valveguides

Nr. 01.06. Bl. 5 rework at cylinder head ( guide bolt )

Nr. 01.06. Bl. 10 O-rings for bush ( nozzle holder )

Nr. 01.06. Bl. 11 overview for cylinder heads

Nr. 01.08. Bl. 1 - Bl. 2 valve stems

Nr. 01.08. Bl. 21 inlet valve seat inserts

Nr. 01.08. Bl. 22 exhaust valve seat inserts

Nr. 01.08. Bl. 41 sequence of operations for the insertion of thevalve seat inserts

Nr. 01.08. Bl. 51 - Bl. 53 valve seat grinding machine

Nr. 01.09. Bl. 1 - Bl. 2 starting valve

Nr. 01.11. Bl. 21 - Bl. 22 set of gaskets for cyl.head

Nr. 02 driving mechanism

Nr. 02.06. Bl. 1 - Bl. 3 piston

Nr. 02.09. Bl. 1 connecting rod

Nr. 03 engine housing

Nr. 03.03. Bl. 1 cylinder liner, arrangement of O-rings

Nr. 03.03. Bl. 2 cylinder liner

Nr. 03.06. Bl. 1 fire ring

Register 14

14

M 25


index



Cat

erpi

llar c

onfid

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l: ye

llow

Nr. 04 engine control

Nr. 04.04. Bl. 1 rocking lever, inlet and exhaust

Nr. 04.04. Bl. 2 rocking lever, fuel

Nr. 04.08. Bl. 1 - Bl. 2 camshaft, spiral-toothed gearwheel

Nr. 05 regulation

Nr. 05.20. Bl. 1 - Bl. 2 hinged lever

Nr. 06 exhaust gas system / supercharging

Nr. 06.01. Bl. 1 gaskets

Nr. 07 fuel system

Nr. 07.15. Bl.1 fuel distributing and fuel collecting pipe

Nr. 08 lubricating oil system

Nr. 08.02. Bl. 1 pump support, rework

Bl. 2

18.04.01 5/3.06

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.05. Bl. 1

valve guides

for inlet2500.7-21.23.01-01 , 193 375 014

1,0mm oversize2500.7-21.23.01-05 , 193 375 006

markinge.g. IN 25-01

markinge.g. OUT 25-02

for exhaust2500.7-21.23.01-02 , 193 375 015

1,0mm oversize2500.7-21.23.01-06 , 193 375 007

* normal size

measures for rework see 2500.7-99.21.00-04

ø 34,045-0,015 *

ø 34,045-0,015 *

235-

0,5

235-

0,5

O-ring 19x4967 082 517install after icing

O-ring 19x4967 082 517install after icing

24.01.01 3/8.05

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.06. Bl. 5

rework at cylinder headwith guide bolt frozen in

measures for rework see2500.7-99.21.51-02

guide bolt, thread M38x22500.7-21.07.01-03

O-ringDIN3771-33,5x3,55967 084 642

06.03.06 1/3.06

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.06. Bl. 10

O-rings for bush

15.6.98 2/6.06

hole for nozzle holder

O-ring 1.7082-51961,5x2,65Viton

O-ring 1.7082-91061,5x2,65Perbunan

bush 252151-1032500.7-21.51.01-02

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.06. Bl. 11

overview for cylinder heads

series cylinder head cylinder head withinlet and exhaust valves

repl.-cylinder head

2500.7-21.51.00-02 2500.7-21.07.00-53 ** 2500.7-21.07.00-61 *2500.7-21.51.00-03 repl. 2500.7-21.07.00-62 *2500.7-21.51.00-04 2500.7-21.07.00-55 # 2500.7-21.07.00-63 **

repl.2500.7-21.07.00-64 #

2500.7-21.51.00-05 2500.7-21.07.00-54 ** 2500.7-21.07.00-63 **2500.7-21.51.00-06 repl. repl.

2500.7-21.07.00-55 # 2500.7-21.07.00-64 #

2500.7-21.51.00-07 2500.7-21.07.00-55 # 2500.7-21.07.00-64 #

* guide bolt 2500.7-21.07.01-01 - screwed in

** guide bolt 2500.7-21.07.01-02 - frozen in

# guide bolt 2500.7-21.07.01-04 - frozen in, reinforced

28.09.06 1/9.06

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

inlet valve stem

30.8.99 2/6.06

Nr. 01.08. Bl. 1

Regrinding of the valve stemsee operating instructions

marking25-01

valve stem2500.7-22.10.01-01

ø 84-0,2

446

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

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l: ye

llow

exhaust valve stem

30.8.99 3/6.06

Nr. 01.08. Bl. 2

Regrinding of the valve stemsee operating instructions

marking e.g.25-02 OUT

ø 84-0,2

446

valve stemMDO operation2500.7-22.10.01-02

HFO operation2500.7-22.10.01-03repl.2500.7-22.10.01-05

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

26.10.01 3/6.06

Nr. 01.08. Bl. 21

inlet valve seat inserts

marking25-01

Regrinding of the inlet valve seat inserts see operating instructions.

Sequence of works for the insertion of the inlet valve seat inserts see Register 9.

Measures for rework see 2500.7-99.21.00-04

ø 89+0,02 bore

R 1,6

42,5

+0,2

drawing No. srock No. remark

2500.7-21.51.02-01 273 210 011 normal size

2500.7-21.51.02-21 193 375 008 0,5mm oversize

2500.7-21.51.02-22 193 375 009 1,0mm oversize

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

exhaust valve seat inserts

26.01.01 3/6.06

Nr. 01.08. Bl. 22

Regrinding of the exhaust valve seat inserts see operating instructions.

Sequence of works for the insertion of the exhaust valve seat inserts see Register 9.

Measures for rework see 2500.7-99.21.00-04

marking25-01

59,5

+0,2

ø 93+0,02 bore

ø 83+0,02 bore

2500.7-21.51.03-01 273 210 012 normal size

2500.7-21.51.03-21 193 375 010 0,5mm oversize

2500.7-21.51.03-22 193 375 011 1,0mm oversize

drawing No. stock No. remark

Register 14

14

m �Techn. Information

cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.08. Bl. 41M 25

Insert inlet and exhaust valve seat inserts before pressure testing.

1. Undercool valve seat inserts in liquid nitrogen to -195°C.2. Insert inlet and exhaust valve seat inserts.3. After fixing the valve seat inserts press them for a short moment

on the nut by means of the device 2500.7-92.22.00-02 andtighten them with the torque stated, see below.

4. Checking of the contact face Y2 between inlet valve seat insertand cylinder head.No clearance admissible !

5. Checking of clearance Y1 between exhaust valve seat insert andcylinder head.Admissible clearance 0,4+0,5mm

Pressure test : cooling water chambers 10 bar maintainedover a period of 8 min.

sequence of operations for the insertion of the valve seat inserts

Tighten nut with 50 Nm(pretension 29 kN).Treat thread and surfaceslightly with Molycote paste G.

pressure applying device2500.7-92.22.00-02 259222 B

28.10.99 3/3.07

Register 14


cylinder head



Cat

erpi

llarc

onfid

entia

l:yel

low

M 25

14Nr. 01.08. Bl. 51

valve seat grinding machine

1.00.7-92.24.00-02repl.1.00.7-92.24.00-04

5/3.07

drawn var. -04

2.11.88

cleaning device for valve guides

Before grinding the valve seat, the chamfer of the valve guide must becleaned by means of the device shown above.

5

6

7

1.9224 Y

Register 14


cylinder head



Cat

erpi

llarc

onfid

entia

l:yel

low

M 25

14Nr. 01.08. Bl. 52

valve seat grinding machine1.00.7-92.24.00-04

31.10.88 4/3.07

1

3

2

8

1.9224 Y

Register 14


cylinder head



Cat

erpi

llarc

onfid

entia

l:yel

low

M 25

14Nr. 01.08. Bl. 53

valve seat grinding machine1.00.7-92.24.00-04

1 valve seat grinding machine 1.00.7-92.29.00-51 1.9229 Y 1

2 guide pin 2.10.7-92.29.00-03 12500.7-92.29.00-03

3 grinding disk 0.00.6-62.16.00-04 1.9224-994 1

5 drive 1.00.7-92.29.00-05 1.9224-505 1

6 reamer 1.00.6-92.24.09-02 1.9224-506 1

7 guide pin 2.10.7-92.29.01-01 12500.7-92.29.01-01

8 flexible element 782001 1.9224-581 4( Megi-U-bearing)

5.11.96 3/3.07

item description drawingNo. part No. qty

1.9224 Y

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.09. Bl. 1

starting valve

19.2.98 2/6.06

rework 2500.7-99.21.00-01on cyl. head 2500.7-21.07.00-01

AttentionThese cyl. heads were reworked.Component parts for starting valve see below.

self-locking hex.nut 1.2021-540DIN 980-VM10x1 screw plug 252107-137

2500.7-22.45.02-02

joint ring 1.7010-332DIN 7603-A42x49

conical spring washer 1.0068-225DIN 6796-10

piston 252107-1362500.7-22.45.04-02

valve spring 3.2245-0051.20.6-22.45.05-01

extension sleeve 252107-0352500.7-22.45.03-01

bush, frozen in2500.7-99.21.01-01

valve spindle 252107-0322500.7-22.45.01-02

Register 14

14

M 25


cylinder head



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 01.09. Bl. 2

starting valve

in cyl. head 2500.7-21.07.00-02

19.2.98 2/6.06

self-locking hex. nut 1.2021-540DIN980-VM10x1 screw plug 252107-137

2500.7-22.45.02-02

joint ring 1.7010-332DIN7603-A42x49

conical spring washer 1.0068-225DIN6796-10

piston 252107-1362500.7-22.45.04-02

valve spring 3.2245-0051.20.6-22.45.05-01

extension sleeve 252107-0352500.7-22.45.03-01

bush 252107-1332500.7-22.45.03-02

valve spindle 252107-0322500.7-22.45.01-02

Register 14

14

M 25 cylinder head

description drawing No. part No. qty. stock No.




Cat

erpi

llar c

onfid

entia

l: ye

llow

set of gaskets for cyl. head

252108 AA

Nr. 01.11. Bl. 21

11.3.98 5/6.06

continuation see Bl. 22

2500.7-99.20.00-01, 270 210 036 with O-ring 967 082 904repl.270 210 170 with O-ring 967 082 918

consisting of :

gasket 1.00.7-88.50.07-40 252144-013 3 273 885 004for mediums guide

O-ring DIN3771-16x2,65N 1.7084-631 8 967 084 631for mediums guide

O-ring 136x10 1.7082-909 1 967 082 909for distributing case

O-ring 315x5,3 1.7082-904 1 967 082 904for cyl.liner repl.

DIN3771-315x5,3N 967 082 918

O-ring DIN3771-30x3,55N 1.7084-643 4 967 084 643for sleeves-cyl. head

O-ring 10x2,5 1.7082-232 4 967 082 232for sleeves cyl. head

O-ring 143x10 1.7082-908 1 967 082 908for distributing case

O-ring 19x4 1.7082-517 4 967 082 517for valve guides

O-ring DIN3771-23,6x3,55N 1.7084-607 2 967 084 607for guide bolt-cyl. head

O-ring DIN3771-58x3,55N 1.7084-620 4 967 084 620for fuel injector

O-ring DIN3771-355x5,3N 1.7084-641 1 967 084 641for cyl. head

joint ring DIN7603-A39x46 1.7010-302 1 967 010 302for starting valve

joint ring DIN7603-A20x24 1.7033-105 1 967 033 105for indicator valve and relief valve

Register 14

14

M 25 cylinder head

description drawing No. part No. qty. stock No.




Cat

erpi

llar c

onfid

entia

l: ye

llow

set of gaskets for cyl. head

2500.7-99.20.00-01

consisting of :252108 AA

Nr. 01.11. Bl. 22

11.3.98 5/6.06

joint ring DIN7603-A21x26 1.7033-102 1 967 033 102for indicator valve and relief valve

joint ring 2500.7-16.10.02-01 251110-007 1 270 160 002for cyl.liner

gasket 1.00.7-88.50.07-59 257210-015 1 273 885 009for exhaust manifold

O-ring 61,5x2,65 1.7082-910 1 967 082 910for sleeve-fuel injector

O-ring DIN3771-61,5x2,65 1.7082-519 1 967 082 519for sleeve-fuel injector

joint ring DIN7603-A42x49 1.7010-332 1 967 010 332for starting valve

Register 14

14

M 25


driving mechanism



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 02.06. Bl. 1

built pistongas oil and heavy fuel operation

03.11.98 4/6.05

fire ring, chromium-plated2500.7-26.17.01-01 x = 6mm

compression ring,chromium-plated2500.7-26.17.01-02 y = 6mm

oil scraper ring with tubular spring,chromium-plated2500.7-26.17.01-03 z = 8mm

piston pin2500.7-26.68.00-01repl.2500.7-26.68.00-02

circlip0.00.6-13.31.01-09repl.0.00.6-13.31.01-04

224

4

390

52x

yz

ø 255

TOP25-01

TOP25-02

TOP25-03

2500.7-26.70.00-01 KSrepl.2500.7-26.70.00-02

Register 14

14

M 25


driving mechanism



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 02.06. Bl. 2

single parts for piston

2500.7-26.70.00-012500.7-26.70.00-02

2500.7-26.70.00-03

2

5

4

1

03.12.02 2/6.05

Assembly tools and tightening valuessee operating instructions

1 piston skirt 044.53.8.00-01.03 252670-101repl.044.53.8.01-01.00 1 193 375 021 #

piston skirt 044.53.8.02-01.00 193 375 042 ##

2 piston crown 044.53.8.00-02.01 252670-102 1 193 375 020

3 spring dowel pin Connex Typ S, 6x20 252670-103 1 193 874 2291.2670-004

4 stud 52.011.87.01 252670-104 4 193 375 023

5 extension bush 51.102.40.01 252670-105 4 193 375 022

3

item description drawing No. order No. qty. stock No.

KS

# for piston var. -01, -02

## for piston var. -03

on this place drawing No.e.g. 25-01

Register 14

14

M 25


driving mechanism



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 02.06. Bl. 3

built pistongas oil and heavy fuel operation

08.06.05 1/6.05

fire ring, chromium-plated2500.7-26.17.01-01 x = 6mm

compression ring,chromium-plated2500.7-26.17.01-02 y = 6mm

oil scraper ring with tubular spring,chromium-plated2500.7-26.17.01-03 z = 8mm

piston pin2500.7-26.68.00-03

circlip0.00.6-13.31.01-09repl.0.00.6-13.31.01-04

224

4

390

52x

yz

ø 255

TOP25-01

TOP25-02

TOP25-03

2500.7-26.70.00-03 KS

Register 14

14

M 25




driving mechanism

Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 02.09. Bl. 1

connecting rod

2500.7-28.10.00-012500.7-28.10.00-02repl.2500.7-28.10.00-04 190 375 027 Test SN BV, DNV, SZ

1x parallel pin 2.2810-0561.00.7-88.50.80-49 2x con. rod screw 252810-055

2500.7-28.10.04-02

2x con. rod screw 252810-0542500.7-28.10.04-01

* The small-end bush must not be pressed out but should be released from stress by sawing or milling.

small-end bush * 252810-0532500.7-28.10.03-01repl.2500.7-28.10.03-03

11.04.01 3/1.05

markinge.g. 25-1

Register 14

14

M 25




engine housing

Cat

erpi

llar c

onfid

entia

l: ye

llow

27.05.04 2/6.06

Nr. 03.03. Bl. 1

cylinder linerarrangement of O-rings

5

1

2

4

3

1 O-ring 315x5,3 1.7082-904 967 082 904repl.

DIN3771-315x5,3N 967 082 918

2 O-ring 359x5,33 1.7082-905 967 082 905

3 O-ring 165,3x7,7 1.7082-520 967 082 520

4 O-ring 136x10 1.7082-909 967 082 909

5 O-ring DIN3771-30x3,55N 1.7084-643 967 084 643

AttentionInstall the O-rings with vaseline or green soft soap.When installing the O-rings please observe that the rings are not distorted in the grooves.

notestock No.drawing No. order No.descriptionitem

Register 14

14

M 25




engine housing

Cat

erpi

llar c

onfid

entia

l: ye

llow

2500.7-16.11.01-01 Harzer Werkerepl.2500.7-16.11.01-02 * Jürgensen 193 375 019 test BV, natural hardnessrepl.2500.7-16.11.01-03 Jürgensen natural hardness

cylinder liner

supplier stock No. notedrawing No.

Nr. 03.03. Bl. 2

* use up

measures for rework at cylinder head see :2500.7-99.21.51-01

measures for rework at the cylinder liner see :2500.7-99.16.11-01 for cylinder liner Var. -012500.7-99.16.11-02 for cylinder liner Var. -02

1/3.0607.03.06

Register 14

14

M 25




engine housing

Cat

erpi

llar c

onfid

entia

l: ye

llow

22.04.02 2/6.06

Nr. 03.06. Bl. 1

fire ring 251110-013

2500.7-16.14.01-01repl.2500.7-16.14.01-03

fire ring

Register 14

14

M 25


engine control



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 04.04. Bl. 1

10.11.98 3/6.06

rocking lever, inlet and exhaust 253566-100

2500.7-35.66.00-01 *repl.2500.7-35.66.00-03

* roller without bush

drawn var. -03

2

6

3

5

4

2 ball socket 2500.7-35.66.02-01 253566-102 1

3 roller 1.60.6-35.60.03-05 6.3560-101 1repl.roller 2500.7-35.66.03-01 253566-103 1and bush item 5

4 pin 2500.7-35.66.04-01 253566-104 1

5 bush 2500.7-35.66.05-02 253566-105 1

6 spring dowel pin ISO8752-6x60 1.0039-289 1

item description drawing No. order No. qty.

Register 14

14

M 25


engine control



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 04.04. Bl. 2

10.11.98 3/6.06

rocking lever, fuel 253565-200

2500.7-35.65.00-03 *2500.7-35.65.00-05repl.2500.7-35.65.00-06

* roller without bush

drawn var.-05

2 ball head 2500.7-35.65.02-01 253565-202 1

3 roller 2500.7-35.65.03-01 253565-203 1repl.roller 2500.7-35.65.03-02 253565-203 1and bush item 5

4 pin 2500.7-35.65.04-03 253565-204 1repl.2500.7-35.65.04-04 253565-204 1

5 bush 2500.7-35.65.05-02 253565-205 1

6 spring dowel pin ISO8752-6x60 1.0039-289 1

8 grub screw DIN913-M8x10 1.1100-046 1

2

6

8

35

4

item description drawing No. order No. qty.

Register 14

14

M 25


engine control



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 04.08. Bl. 1

camshaft2506/8/9.7-31.20.00-02

15.09.05 1/9.05

spiral-toothed gearwheel2500.7-41.11.02-02stock No.270 410 009 or273 410 009repl.2500.7-41.11.02-02stock No.273 410 148withwasher2500.7-41.11.04-02andscrew plugDIN908-M22x1,5961 040 362

Old design

New designapprox. since Sept. 2005

washer

screw plug

Register 14

14

M 25


engine control



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 04.08. Bl. 2

camshaft2506/8/9.7-31.20.00-03

2508.7-31.20.00-04

15.09.05 1/9.05

spiral-toothed gearwheel2500.7-41.11.02-03repl.2500.7-41.11.02-04withwasher2500.7-41.11.04-02andscrew plugDIN908-M22x1,5961 040 362

spiral-toothedgearwheel var.-04

washer

screw plug

Register 14

14

M 25


regulation



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 05.20. Bl. 1

hinged lever

2500.7-42.12.00-01repl.2500.7-42.12.00-03 see Nr. 05.20. Bl. 2

11.11.98 3/6.06

spring dowel pin 1.0039-880ISO8752-6x28 1.0039-261

lever 254212-1012500.7-42.12.01-01

tension spring 254212-1052500.7-42.12.05-01repl.2500.7-42.12.05-02

spring dowel pin 1.0039-275ISO8752-6x40

bracket 254212-1022500.7-42.12.02-01

thrust piece 254212-1042500.7-42.12.04-01

hexagon screw 1.1367-241ISO4014-M8x50

bolt 1.0015-047DIN1445-8f8x29x40

washer 1.0040-222DIN125-8,4ISO7089-8

strap 254212-1032500.7-42.12.03-01

inner ring 254212-114LR8x12x10,5

hexagon screw 1.2021-104ISO7042-M6

washer 1.0058-457DIN9021-6,4

Register 14

14

M 25


regulation



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 05.20. Bl. 2

hinged lever

2500.7-42.12.00-02repl.2500.7-42.12.00-03

23.04.02 2/6.06

washer 1.0040-222DIN125-8,4ISO7089-8

bolt 1.0015-047DIN1445-8F8x29x40

inner ring 254212-114LR8x12x10,5

shim 254212-1041.90.7-42.12.03-01

hexagon screw 1.1367-241ISO4014-M8x50

hexagon nut 1.2021-104ISO7042-M6

washer 1.0058-457DIN9021-6,4

strap 254212-1032500.7-42.12.03-01

lever 254212-1012500.7-42.12.01-02

tension spring 254212-1052500.7-42.12.05-01repl.2500.7-42.12.05-02

bracket 254212-1021.90.7-42.12.01-02

B

B

B - B

Register 14

14

M 25




exhaust gas system / supercharging

Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 06.01. Bl. 1

gaskets

9.8.99 2/6.06

drawing No. part No. remark

for series designonly

for series designand replacement delivery

* steel ** steel

1.00.7-88.50.07-65 * 257260-285 exhaust gas pipe,repl. before turbocharger1.00.7-88.50.07-80 **

Register 14

14

M 25




fuel system

Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 07.15. Bl.1

fuel distributing and fuel collecting pipe

2506/08/09.7-85.10.00-02

07.03.06 1/3.06

X

X

low-pressure piping2500.7-85.12.00-01repl.2500.7-85.12.00-02 with double flange, see below

mixed equipment is possible

2500.7-85.12.00-02

Register 14

14

M 25


lubricating oil system



Cat

erpi

llar c

onfid

entia

l: ye

llow

Nr. 08.02. Bl. 1

10.06.04 1/6.04

pump support2500.7-63.10.00-02

256340-004

In the future there will be no more bore for the oil return - thisis not required for lub. oil pump 0.00.6-73.13.00-43 and -44respectively.If the a.m. pump support should be required for a version withoil return, a rework must be carried out.Dimensions for the bore and required parts see2500.7-99.64.10-01.

oil return bore

Documents

Tech. Info M 25