Maintenance MAK M43C

Maintenance A5
Maintenance
en / 03.03.2009 AA000026 1/1

Table of Contents A5.01
Maintenance A5
Introduction A5.02
Safety instructions A5.03
Periodical schedule
Heavy fuel A5.04.02
Engine, cylinder head A5.05.01

Valve clearance A5.05.01.01.01.00
Valve Rocker Brackets A5.05.01.02.01.30
Valve Rockers A5.05.01.02.02.00
Valve Rocker Bush A5.05.01.02.03.00
Valve Rotor A5.05.01.03.01.00
Valve guide/Oil scraper ring A5.05.01.05.01.01
Media guiding system A5.05.01.05.50.01
Cylinder Head A5.05.01.06.01.30
Nozzle sleeve A5.05.01.06.50.03
Relief Valve A5.05.01.06.70.01
Inlet and Exhaust Valve Cone A5.05.01.07.01.03
Inlet and Exhaust Valve Cones A5.05.01.08.01.00
Valve Seat Ring A5.05.01.08.02.00
Valve Seat Ring (Intake/Exhaust) A5.05.01.08.03.00
Starting Valve A5.05.01.09.01.00
Starter Valve A5.05.01.09.02.03
en / 03.03.2009 AA020041 1/4

Engine, gear A5.05.02

Running Gear / Engine Timing A5.05.02.01.01.00
Crank Web Deflection A5.05.02.02.01.00
Bearing Shells and Bearing Bushes A5.05.02.03.03.01
Bearing Shells A5.05.02.03.07.01
Big End Bearings A5.05.02.04.01.30
Big End Bearings A5.05.02.04.02.30
Hydraulic Jack A5.05.02.04.51.00
Main Bearings A5.05.02.05.01.30
Main Bearings A5.05.02.05.02.30
Main Thrust Bearings A5.05.02.05.05.30
Main Thrust Bearings A5.05.02.05.06.30
Piston A5.05.02.06.01.30
Piston Crown A5.05.02.06.02.04
Piston Rings and Grooves A5.05.02.07.01.01
Piston Pin A5.05.02.08.01.00
Small End Bearing A5.05.02.09.01.01
Piston A5.05.02.10.01.30
Balance weight A5.05.02.11.00.00
Measures for emergency operation A5.05.02.12.00.00
Engine, housing A5.05.03

Explosion relief valve A5.05.03.01.01.02
Coolant Distributor Housing A5.05.03.02.00.00
Cylinder Liner A5.05.03.03.01.01
Engine Fasteners and Connections A5.05.03.07.01.00
Engine, control A5.05.04

Camshaft Bearing A5.05.04.01.01.00
Camshaft Bearing A5.05.04.01.02.00
Bottom part for Valve Mechanism A5.05.04.02.00.30
Camshaft A5.05.04.04.01.08
Timing Gear Train A5.05.04.08.01.02
Governor Drive A5.05.04.08.03.02
Vibration Damper on Camshaft A5.05.04.09.01.00
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Engine, regulation A5.05.05

Control Shaft Bearings A5.05.05.01.02.00
Starting Valve A5.05.05.02.01.02
Control Rod A5.05.05.08.01.00
Compressed-Air Filter A5.05.05.09.06.00
Compressed-Air Filter A5.05.05.09.06.01
Engine, exhaust gas system/supercharging A5.05.06

Exhaust Line A5.05.06.01.01.12
Charge Air Cooler A5.05.06.04.02.30
Exhaust gas turbocharger A5.05.06.05.00.30
Exhaust gas turbocharger A5.05.06.13.01.30
Turbocharger A5.05.06.14.01.00
Engine, fuel system A5.05.07

Injection Pump A5.05.07.02.01.00
Deflector Bolts A5.05.07.03.02.00
Pressure Valve A5.05.07.03.03.00
High-Pressure Injection Pipe A5.05.07.05.01.00
Fuel Injector A5.05.07.07.01.02
Fuel Duplex Filter A5.05.07.12.01.08
Fuel Distributor/Collector Line A5.05.07.15.01.30
Fuel Pressure Damper A5.05.07.17.00.01
Engine, lubricating oil system A5.05.08

Lubricating Oil Pump A5.05.08.03.02.04
Lubricating Oil Duplex Filter A5.05.08.04.01.01
Oil pressure control valve A5.05.08.05.01.01
Prelubricating pump/Prelubrication A5.05.08.10.00.00
Engine, starting system A5.05.10

Stop Piston A5.05.10.03.01.00
en / 03.03.2009 AA020041 3/4

Engine control equipment A5.05.11

Pressure Switches A5.05.11.01.02.01
RPM Switch A5.05.11.05.01.02
Lubricating Oil/Cooling Water Thermostat A5.05.11.06.01.01
Pressure Switch A5.05.11.06.05.02
Pressure Switch A5.05.11.06.06.02
Crankcase Monitoring Device A5.05.11.09.01.03
Engine auxiliary units A5.05.12

Vibration Damper A5.05.12.04.01.00
Vibration Damper A5.05.12.04.02.00
Turning Device A5.05.12.08.01.01
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Introduction A5.02
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.
All information refers to the date of printing.
2. Explanation of the maintenance system
2.1 Scheduled maintenance
Without “Scheduled maintenance” the economic operation of supercharged engine is in the long
run not possible at today's state of art.
The explanations are used to make the user of this engine plant familiar with the existing 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.
The “Scheduled maintenance” is thereby supported by inspections according to fixed deadlines.

These inspections are decision criteria for the need and extend of maintenance and servicing.
The following is used as parameter:
• data on wear and tear
• evaluation criterion and
• performance checks
Most of the work to be carried out does not have a fixed deadline since the service life of 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.
The information given by us gives no rise to legal claims.
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Introduction A5.02
M20-M601C
2.2 Maintenance system
The maintenance system consists of:
• work interval schedule
• job cards
• maintenance schedule (large-scale plan) *
While the work interval schedule indicates the date when inspection, maintenance or repair shall
be carried out, the job cards indicate the manner in which the work is to be carried out.
2.2.1 Work interval schedule
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.
The interval schedule is subdivided into the following four areas:
• Daily inspection and control work
• Initial inspection and maintenance work
Work which has to be carried out after first commissioning or commissioning after major repair
work.
• Periodic maintenance work
A list of all recurrent inspection, maintenance and repair work to be carried out at the schedu-
led date.
The indicated intervals are statistical mean values. Other values may be obtained, depending
on equipment condition, operating and maintenance conditions.
• Maintenance work to be carried out independent of deadlines
List of work which may be required in the scope of scheduled work which cannot be allocated
to a deadline.
* will be handed over by the MaK service department for commissioning of the engine
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Introduction A5.02
M20-M601C
2.2.2 Job cards
The job cards are instructions for inspection, maintenance, repair and safety check.
¬
Title of the job card
Maintenance work Activity
Discharge valve A5.05.01.04.01.03

Inspection / Dismounting and mounting
Operating hours/maintenance deadline
M 551 / M 552
6,000 / 12,000
Engine type 01
Register
Main maintenance group
See also: 01.01.01.nn, 01.02.01.nn, 01.08.01.nn

Spare parts list: B1.05.01.7.2104, B1.05.01.7.2220
Time requirement: 1 Pers. / 3 h
Personnel qualification: skilled engine hand
Operating medium: Heavy fuel and destillate fuel
Breakdown
Chapter maintenance Subchapter
Vol. A operating instructions Job cards
Job cards
Document number
A5.05. 01.04.01.03
Main maintenance group
Maintenance group
Subgroup
Variant
en / 30.09.91 IB000003 1/1
Date of issue
Registration number Page/number of pages
Language
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Introduction A5.02
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:
01. Cylinder head 08. Lube oil system
02. Driving mechanism 09. Cooling water system
03. Engine housing 10. Starting air system
04. Engine control 11. Monitors
05. Regulation 12. Auxiliary generator sets and tools
06. Exhaust gas system/ 13. Additional installation

supercharging
07. Fuel system
In order to facilitate the finding of the engine main group, the pair of digits on the right margin
has been set as register 01 .
• The second and third pair of digits indicates the subgroups of the main group and the titles
of the job card where maintenance work is required.
• The fourth pair of digits indicates the type of variant.
• See job card: Reference is made to other job cards required for maintenance work. At this
point the types of variants (fourth pair of digit) are marked “nn”.
• Spare parts sheets: For easy finding of necessary comsumables and spare parts for the
maintenance group in 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).
• Attention: Marking technical regulations or measures to be strictly observed in order to avoid

damage or destruction of equipment or components of the engine plant or other material.
• Note: Gives the personnel information which optimize the work process.
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Introduction A5.02
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.
2.2.3 Maintenance schedule (Periodic maintenance work)
A large-scale plan showing all maintenance work up to the largest maintenance interval clearly
indicating all occurrences and the future work expenditure for the individual components.
It would be useful to mount the plan on a wall; when this is not possible for space 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
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M20-M601C
1. Safety instructions
1.1 Work safety symbol
~ 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!
1.2 General safety instructions
The provisions of the relevant accident prevention regulations of the appropriate

employer's liability insurance association are to be observed any time operation and
repair work is carried out. In addition, the following is to be observed:
• 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!
• Use personal protective equipment as far as necessary or as required by the

regulations!
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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!
• Re-install removed guards and protecting devices on completion of work.
• 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!
• Never work or stand under suspended loads!
• When carrying out overhead assembly work, the specially designed or safety-oriented
climbing aids are to be used only!
• Do not use engine/plant parts for climbing on!
• 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)!
• Never use aggresive detergents and preservatives!
• Use non-fuzzy cleaning rags!
• 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”!
• Mounting openings are to be protected!
• Perfect hoists, tools and devices are to be used only!
• Observe all indicating labels attached to the engine!
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M20-M601C
1.3 Working on electrical equipment
• 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!
• The electrical equipment is to be inspected/checked at regular intervals. Defects such

as loose connections or scorched cables must be rectified immediately!
• 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!
1.4 Working with hydraulic devices
• Operating instructions, tightening torques and setting dimensions specified in the

appropriate job card are to be carefully observed!
• Do not place parts of your body above/below pressurized hydraulic tools!
• 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!
1.5 Checking and adjustment of injection valve
• During testing make sure that no parts of your body are positioned in the area of the
fuel jet!
• Do not inhale the fuel mist - respiratory mask!
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M20-M601C
1.6 Handling of liquid nitrogen or carbon dioxide snow
• 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!
1.7 Cleansing agents/chemicals
• Use only cleansing agents with a flash point above 65 °C!
• Observe instructions for use in accordance with DIN safety data sheet of the regulati-
ons for dangerous substances!
• Observe the specialist disposal of all cleansing agents and chemicals in accordance
with the regulations for dangerous substances!
• In case of accident, observe the accident leaflets including first-aid actions for
dangerous substances in accordance with the regulations for dangerous substances!
2. The non-observance of the safety instructions may cause danger to per-

sons and failure of important functions of engine/system!
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.
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Periodical schedule A5.04.02
Heavy fuel
M43/VM43
Intervall Designation / Doc-Nr.

Work to be carried out
Remarks
Daily inspection and monitoring procedures

(if it is not automated)
--------------------------------------------------------------------------------------------------------------------------------
General Engine operating data A1.10
Compare with acceptance test records:
Speed, rating
Temperature Lubricating oil A1.06

Engine inlet; Temperature rise at rated output
see also A1.10
Temperature Cooling water A1.06
Engine inlet; Temperature rise at rated output
see also A1.10
Temperature Cooling water A1.10

Upstream charge air cooler;
downstream charge air cooler
Temperature Charge air A1.10

Temperature Exhaust gas A1.10
After cylinder; downstream turbocharger
Pressure Lubricating oil A1.05

At the main bearing or at the camshaft bearing
see also A1.10
Pressure Cooling water A1.05

Upstream engine
see also A1.10
Pressure Fuel A1.05

Upstream pumps
Pressure Charge air A1.10

Pressure Control air A1.05
Pressure Starting air A1.05
Lube oil Lube oil circulation tank A3.05.08.00

system Check of the lube oil level
Lube oil Lubricating oil duplex filter A5.05.08.04.01.01

system Maintenance/Cleaning
at 50 % differential pressure
Cooling Expansion tank A3.05.09.00

water system Check of the cooling water level
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Heavy fuel
M43/VM43

Remarks
Fuel system Fuel duplex filter A5.05.07.12.01.08

Maintenance/Cleaning
at 50 % differential pressure
Pressure Air bottles A3.06.10.00

air Drain
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Heavy fuel
M43/VM43

Remarks
First inspection and maintenance procedures

Work to be carried out after the first commissioning or after major repairs.
--------------------------------------------------------------------------------------------------------------------------------
24 h Duplex fuel filter A5.05.07.12.01.08
Strainer
24 h Lubricating oil duplex filter A5.05.08.04.01.01

Cartridges
150 h Engine bolting and unions A5.05.03.07.01.00
Inspection/Checking
Tight fitand leaks
150 h Compressed air strainer A5.05.05.09.06.nn

Maintenance/cleaning
150 h Exhaust gas turbocharger

Function check
see book C
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Heavy fuel
M43/VM43

Remarks
Periodical maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
24 h Compressed air strainer A5.05.05.09.06.nn

24 h Exhaust gas turbocharger A5.05.06.05.00.30

see book C
150 h Valve rotor A5.05.01.03.01.00

Inspection/Evaluate
150 h Cylinder head A5.05.01.10.00.00
Inspection/Checking
150 h Exhaust gas turbocharger A5.05.06.13.01.30

see book C
150 h Prelubricating pump/Prelubrication A5.05.08.10.00.00

Maintenance/Checking
750 h Control shaft bearings A5.05.05.01.02.00

750 h Cooling water system A4.05.09.01

Inspection/Corrosion inhibitors
750 h Stop piston A5.05.10.03.01.00

Inspection/Checking
750 h Oil mist detector A5.05.11.09.01.03

Inspection/Checking
750 h Turning device A5.05.12.08.01.01
Maintenance/Disassembly and reassembly
1,500 h Governor
Governor behaviour/governor control rod
see book C
1,500 h Valve clearance A5.05.01.01.01.00

Inspection/Adjust
1,500 h Crankcase explosion safety valve A5.05.03.01.01.02
Inspection/Checking
1,500 h Oil mist detector A5.05.11.09.01.03
Inspection/Checking
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Heavy fuel
M43/VM43

Remarks
3.750 h Starting valve A5.05.01.09.01.00

Inspection/Checking
3,750 h Governor
Oil change
see book C
3,750 h Monitors
Checking of alarm and safety system
see book C
3,750 h Running gear/engine timing A5.05.02.01.01.00

Inspection/Checking
3,750 h Timing gear train A5.05.04.08.01.02
Inspection/Checking
3,750 h Deflector bolts A5.05.07.03.02.00

Inspection/Replace
of the deflector bolts of two injection pumps
3,750 h Turning device A5.05.12.08.01.01

7,500 h Anti-corrosion oil emulsion A4.05.09.02

Change
7,500 h Inlet and exhaust valve cone A5.05.01.07.01.03

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

Inspection/Checking
of one piston
7,500 h Starting valve A5.05.05.02.01.02
7,500 h Control shaft A5.05.05.08.01.00

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

7,500 h Exhaust gas line A5.05.06.01.01.12
Inspection/Checking
7,500 h Injection pump A5.05.07.03.01.03

of one pump
7,500 h Deflector bolts A5.05.07.03.02.00

Inspection/Replace
Replacement of all deflector bolts
7,500 h Fuel pressure damper A5.05.07.17.00.01

Maintenance/Replace
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Heavy fuel
M43/VM43

Remarks
7,500 h Injection valve A5.05.07.09.01.30

Repair/Disassembly and reassembly
7,500 h RPM-switch A5.05.11.05.01.02

Inspection/Adjust
7,500 h Lubricating oil/Cooling water thermostat A5.05.11.06.01.01

7,500 h Oil mist detector A5.05.11.09.01.03

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

15,000 h Valve guide/Oil scraper ring A5.05.01.05.01.01

Inspection/Replace
15,000 h Nozzle sleeve A5.05.01.06.50.03

15,000 h Inlet and exhaust valve cones A5.05.01.07.01.03

of all valve cones
15,000 h Starting valve A5.05.01.09.02.03

15,000 h Cylinder head A5.05.01.10.01.01
15,000 h Big-end bearing A5.05.02.04.01.30

Inspection/Disassembly
of one big-end bearing
15,000 h Main bearings A5.05.02.05.01.30

of 2 main bearings
15,000 h Cylinder liner A5.05.03.03.01.01
Inspection/Measuring
at one cylinder unit
15,000 h Camshaft bearing A5.05.04.01.01.00

Inspection/Checking
of one bearing
15,000 h Camshaft bearings A5.05.04.01.02.00

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Heavy fuel
M43/VM43

Remarks
15,000 h Timing gear train A5.05.04.08.01.02

Inspection/Checking
15,000 h Governor drive A5.05.04.08.03.02

15,000 h Vibration damper on camshaft A5.05.04.09.01.00

15,000 h Exhaust gas turbocharger

Maintenance/Cleaning resp.
revision of turbocharger
see book C
15,000 h Injection pump A5.05.07.03.01.03
of all pumps
15,000 h Oil pressure regulating valve A5.05.08.05.01.01

Maintenance/adjust

22,500 h Pressure switch A5.05.11.06.05.02

Inspection/Replace

30,000 h Valve rockers A5.05.01.02.02.00

30,000 h Relief Valve A5.05.01.06.70.01

Maintenance/Replace
30,000 h Big-end bearing A5.05.02.04.01.30

exchange all big-end bearings
30,000 h Main bearings A5.05.02.05.01.30

exchange all bearings
30,000 h Main thrust bearings A5.05.02.05.05.30

Inspection/Disassesmbly
30,000 h Piston rings and grooves A5.05.02.07.01.01
Inspection/Checking
of all pistons
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Heavy fuel
M43/VM43

Remarks
30,000 h Small-end bush A5.05.02.09.01.01

Maintenance/Measuring
30,000 h Cylinder liner A5.05.03.03.01.01

Inspection/Measuring
at all cylinder units
30,000 h Cylinder Liner A5.05.03.04.01.00

Maintenance/Disassembly

Inspection/Checking
at all bearings
30,000 h Vibration damper A5.05.12.04.01.00



45,000 h Vibration damper A5.05.12.04.02.00

Maintenance/Replace
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Heavy fuel
M43/VM43

Remarks
Non-interval dependent maintenance procedures

--------------------------------------------------------------------------------------------------------------------------------
Valve rocker brackets A5.05.01.02.01.30

Valve rocker bush A5.05.01.02.03.00

Inspection/Replace
Media guiding system A5.05.01.05.50.01

Cylinder head A5.05.01.06.01.30

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

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

Repair/Replace
Cylinder head A5.05.01.11.01.30

Repair/Reassembly
Crank web deflection A5.05.02.02.01.00

Inspection/Checking
Bearing shells and bearing bushes A5.05.02.03.03.01

Inspection/Evaluate
Bearing shells A5.05.02.03.07.01

Inspection/Evaluate
Big-end bearings A5.05.02.04.02.30

Inspection/Reassembly
Hydraulic clamping element A5.05.02.04.51.00

Maintenance/Replace
Main bearings A5.05.02.05.02.30

Maintenance/Reassembly
Main thrust bearings A5.05.02.05.06.30

Pistons A5.05.02.06.01.30
Piston crown A5.05.02.06.02.04

Maintenance/Replace
Piston pin A5.05.02.08.01.00
en / 03.03.2009 AA000649 9/10

Heavy fuel
M43/VM43

Remarks
Piston A5.05.02.10.01.30
Counter-balance A5.05.02.11.00.00
Measures for emergency operation A5.05.02.12.00.00

Cooling water distributor housing A5.05.03.02.00.00
Cylinder liner A5.05.03.04.02.00

Camshaft A5.05.04.04.01.08
Charge air cooler A5.05.06.04.02.30

Maintenance/disassembly and reassembly
Injection pump A5.05.07.02.01.00

Pressure valve A5.05.07.03.03.00

Injection pump A5.05.07.04.01.00

Maintenance/Replace
Fuel injector A5.05.07.07.01.02

Fuel injector A5.05.07.08.01.30

Maintenance/Adjust
Duplex fuel filter A5.05.07.12.01.08
Fuel distributor/collection pipe A5.05.07.15.01.30

Lubricating oil pump A5.05.08.03.02.04

Lubricating oil duplex filter A5.05.08.04.01.01

Pressure switch A5.05.11.06.06.02

Maintenance/Adjust
Crankcase monitoring device A5.05.11.09.01.03

Inspection/Checking
en / 03.03.2009 AA000649 10/10

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

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

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
The valve clearance must be checked every 1,500 operating hours and adjusted if
necessary.
Tools:
Feeler gauge W2 * 1.9075-003
* no picture
Note:
Valve clearance may only be checked with the engine at operating temperature, i.e. 15 minutes
after the engine has been stopped.
Valve clearance (Fig. 1/S):
Intake: 0.4 mm
Exhaust: 1.1 mm
The valve fitting position must be set correctly relative to the valve cone before adjusting
valve clearance during regular maintenance or after work on the valve train.
Procedure:
1. Set valve fitting.
1.1 Open indicator valves.
1.2 Engage the rotor.
1.3 Remove the cylinder head (valve) cover, do not damage the gaskets.
1.4 Turn the crankshaft until the cylinder to be set reaches ignition TDC.
en / 06.09.2006 IB004792 1/2

Valve clearance A5.05. 01.01.01.00
Inspection / Adjust
M43/VM43
1500
1.5 Release valve bridge of rocker arm 01

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

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

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

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

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

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

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

the counternut.
2.2.5 Remove the turning mechanism and close the indicator valves.
2.2.6 Install valve cover.
en / 06.09.2006 IB004792 2/2

Valve Rocker Brackets A5.05. 01.02.01.30
Maintenance / Disassembly and reassembly
M43/VM43
See also: 01.01.01.nn 01


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

clamping cylinder W1.1 1.9213 H
high pressure hose W1.2 433420 A
high pressure hose W1.3 433420 E
Auxiliary materials:
Molykote Paste "G-Rapid Plus" **
** or equivalent product
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! Unit may
only be operated with hydraulic oil. Protect the unit from corrosion during storage.
~ Attention!
Do not place any body parts under equipment which is under pressure. Ensure that the en-
gine cannot be started.
Procedure:
1. Disassembly
1.1 Engage the rotor.
1.2 Open indicator valves.
1.3 Remove valve cover.
1.4 Turn piston to ignition TDC. Intake and exhaust valves are closed, rocker arms subject to no for-
ce.
en / 03.05.2004 IB024440 1/4

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.
en / 03.05.2004 IB024440 2/4

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.
2.2 Blow out the oil outlet with compressed air.
2.3 Place the rocker arm bracket on the cylinder over the studs and position.
The bracket is fastened by means of studs.
2.4 Apply Molykote paste “G-Rapid Plus“ to the threads and contact surface for the nuts and tighten
by hand.
2.5 Tighten the four rocker arm bracket bolts with the hydraulic clamping unit.
2.5.1 Place the hydraulic clamping elements (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).
en / 03.05.2004 IB024440 3/4

M43/VM43
2.5.5 Check to ensure that the round nut is seated properly. 01

• Reduce pressure by 50 bar.
• The round nuts must be tight enough that they cannot be loosened with the pin.
2.5.6 Depressurize the clamping elements, dismantle the clamping unit.
2.5.7 Repeat installation procedure 2.5.1 to 2.5.6 for lower round nuts (1).
2.6 Set valve clearance (01.01.01.nn).
2.7 Diengage the rotor.
2.8 Install valve cover. (Check gasket!)
2.9 Close indicator valves.
en / 03.05.2004 IB024440 4/4

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


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

and check bearing clearance every 30,000 h
Note:
The liners may only be lubricated with oil.

Molykote paste may not be used for installing the bushings.
Procedure:
1. Disassembly
1.1 Remove securing rings (Fig. 1/4) and thru-

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

and the exhaust valve rocker arm (2) from
the rocker arm shaft (3).
Note:
All additional maintenance work is identi-
cal for the intake and exhaust valve rocker
arms.
2. Clean all parts and check for damage.

Blow out oil bores with compressed air
and check to ensure that they are clear.
en / 05.06.2003 IB004796 1/2

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

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

and shaft (Fig. 1/3) and replace the bush
when the clearance meets or exceeds the
wear limit (01.02.03.nn).
New clearance Wear limit

(mm) (mm)
0.056 - 0.208 0.30
5. Assembly
Note:
Rocker arm shaft must be undamaged and may have no burrs or scratches.
5.1 Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker arm
shaft and slide the rocker arms onto the shaft carefully. Do not tilt the rocker arms.
5.2 Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.02.01.nn) and check
the oil flow through the components.
en / 05.06.2003 IB004796 2/2

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


--------------------------------------------------------------------------------------------------------------------------------
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).
2.2 Oil the new bush lightly and

press into rocker arm.
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.
en / 05.06.2003 IB004798 1/1

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

Spare parts list: B1.05.01.432107, B1.05.01.432225

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve rotor and the free-wheels every 150 h
Note:
The valve rotational speed in relation to the engine speed must be measured and documented
when the new or overhauled cylinder cover is taken into service in order to allow comparisons to
be made over the course of subsequent inspections. The intake valves are equipped with valve
rotors and the exhaust valves with vanes and a free-wheel.
Procedure:
1. Open the valve cover and note the turning of the valves.
The mark “X” on the valve spring plate (1) is provided for this purpose.
en / 05.06.2003 IB004800 1/2

Valve Rotor A5.05. 01.03.01.00
M43/VM43
150
2. The valve rotor or free-wheel is functioning correctly when the valves rotate evenly in relation to 01
the engine speed.
The valve rotor and free-wheel must be lubricated with a few drops of oil-gas oil mixture (mixture
ratio 1:1) if the rotational speed is noticeably slower than the speed indicated for new valves.
2.1 If the valve rotational speed slows to n ≤ 1 min-1 at the rated engine speed, the valve rotor or
free-wheel must be replaced.
Note:
The valve rotation speed can also be slowed by stiffness of the valve shaft in the valve guide. So-
lution: spray small amounts of gas-gas oil mixture on the valve shaft.
Attention:
Use the gas-gas oil mixture sparingly! Excess use can dilute the engine oil!
en / 05.06.2003 IB004800 2/2

Valve guide/Oil scraper ring A5.05. 01.05.01.01
M43/VM43
15000
See also: 01.01.01.nn, 01.02.01.nn, 01.06.01.nn, 01.07.01.nn 01

Operating medium: Heavy fuel

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the valve guide clearance of the intake and exhaust valves after 15,000 h
Molykote Paste “G-Rapid Plus” **
Procedure:
1. Replace the oil scraper rings (O-rings).
1.1 Disassemble valve cone, clean valve shaft carefully.
1.2 Remove O-ring (1) from groove with wire hook carefully.
en / 05.06.2003 IB004804 1/2

Valve guide/Oil scraper ring A5.05. 01.05.01.01
M43/VM43
15000
01
Attention:
The O-ring meters the valve lubrication and may only be replaced with a new MaK replace-
ment ring.
1.3 Clean the groove.
1.4 Oil the new O-ring lightly and place in groove carefully. The ring may not be twisted during instal-
lation!
2. Measuring the valve guide clearance
2.1 Measure the outer diameter of the valve shaft in the guide area of the bush.
2.2 Measure the inner diameter of the guide across the engine block.
2.3
Normal clearance Wear limit

(mm) (mm)
Exhaust 0.22 - 0.29 0.4

Intake 0.15 - 0.22 0.4
3. Valve guide replacement
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.
en / 05.06.2003 IB004804 2/2

Media guiding system A5.05. 01.05.50.01
M43
See also: 01.06.01.nn, 01.11.01.nn 01


--------------------------------------------------------------------------------------------------------------------------------
Auxiliary material:
Vaseline *
* or a product of equal standard
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).
en / 24.03.2004 IB024333 1/4

M43
1.2 Pull the sleeves (fig. 2/9) out of the connecting flanges (1, 2). 01
1.3 Check the O-rings (14). Replace faulty O-rings (14).
Insert the O-rings in the grooves using vaseline and making sure that they are not
twisted!
1.4 Remove hexagon screws (Fig. 1/21) and end flange (7).
1.5 Check gaskets (Fig. 2/13) of the connecting flanges (1, 2) as well as gaskets (13) of the end flan-
ge (7) on the last cylinder. Clean the sealing faces.
en / 24.03.2004 IB024333 2/4

M43
1.6 Remove the cheese head screws (Fig. 3/22) with connecting flange (8). 01
1.7 Pull the sleeves (10) out of the media block (6).
1.8 Check the O-rings (15). Replace faulty O-rings (15).
1.9 Remove lubricating oil pipe (4).
1.10 Remove hexagon screws (20, 23) with media block (6).
1.11 Clean all sealing faces.
en / 24.03.2004 IB024333 3/4

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

Replace faulty gaskets (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.
3.2 Mount the alarm probe.
4. Determine the defective fuel delivery pipe in the event of a "leakage fuel" alarm.
Note:
Leakage fuel can result from
- a defective fuel delivery pipe or

- a faulty gasket between the
fuel delivery pipe/injection pump
or between the
fuel delivery pipe/injection nozzle.
4.1 Acknowledge the alarm when a "leakage fuel" alarm is given and, beginning with cylinder 1, re-
move the screw (fig. 2/25) with gasket (24).
4.2 Check the bore in the connecting flange (1) for leakage fuel.
If, for example, leakage fuel is discerned on cylinders 1, 2 and 3 but not on cylinder 4, then repla-
ce the fuel delivery pipe for cylinder 3 (07.02.01.nn).
4.3 Mount the screw (25) with a new gasket (24).
en / 24.03.2004 IB024333 4/4

Cylinder Head A5.05. 01.06.01.30
Maintenance / Disassembly
M43
See also: 01.02.01.nn, 02.06.01.nn, 03.04.01.nn, 06.01.01.nn, 07.05.01.nn 01


----------------------------------------------------------------------------------------------------------------------------------
Tools:
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).
2. Drain cooling water: Disconnect

connection pipe from reserve pump
to cooling water manifold pipe.
Inspection:
Thermometer connection above the cool-
ing water pump
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.
en / 13.02.2009 IB024287 1/4

M43
3. Disconnect and remove connecting flange of the media conduit for the cylinder head to be re- 01
moved (01.05.50.nn).
4. Remove rocker arm bracket (01.02.01.nn).
Note
To prevent damage and ensure trouble-free assembly and disassembly, the complete rocker arm
bracket must be removed!
5. Remove injection pressure pipe (07.05.01.nn).
6. Remove injection valve (07.07.01.nn).
7. Remove covering cap between exhaust pipe and cylinder head.
8. Screw hexagon screws (Fig. 2/W5) into cooling water blocks to support the exhaust pipe.
9. Loosen clamp on exhaust pipe (06.01.01.nn).
en / 13.02.2009 IB024287 2/4

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.
en / 13.02.2009 IB024287 3/4

M43
11. Screw ring screws (Fig. 4/W3) into cylinder head. Fit cylinder head lifting device (W2). Lift cylin- 01
der head with hoist. Watch for push rod bushing!
W2
W3
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).
en / 13.02.2009 IB024287 4/4

Nozzle sleeve A5.05. 01.06.50.03
VM43
15000
See also: 01.06.01.nn, 07.07.01.nn 01


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

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

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

and unscrew nozzle sleeve until the
threads of nozzle sleeve and cylinder head
(2) are exposed.
en / 30.01.2008 IB024107 1/2

Nozzle sleeve A5.05. 01.06.50.03
VM43
15000
01
Attention:
The threads of the nozzle sleeve and the cylinder head may no longer mesh.
1.4 Remove flange (3).
1.5 Use a brass mandrel (W3) and carefully drive out the nozzle sleeve.
1.6 Remove the O-rings (4 and 5).
2. Install nozzle sleeve (1).
2.1 Insert new O-ring (71 x 3,55) with Vaseline in the lower groove (5) without twisting.
2.2 Insert new O-ring (72,69 x 2,62) with Vaseline in the upper groove (4) without twisting.
Attention:
The O-rings must be installed in the proper grooves (4 and 5)!
2.3 Coat “Loctite 510“ to the nozzle sleeve threads.
2.4 Slide the nozzle sleeve into the cylinder head.
2.5 Place the torque wrench on the nozzle sleeve wrench and tighten the nozzle sleeve to
M =300 Nm
en / 30.01.2008 IB024107 2/2

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


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of relief valve every 30,000 h
Tools:
Torque wrench 20 - 200 Nm W1 * 1.9454-202
* no picture
Auxiliary Material:
High-temperature thread paste “Dag 5420 A“ *
Sequence of Operations:
1. Unscrew hexagon nut (1).
2. Remove cover (2).
en / 31.01.2008 IB023661 1/2

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

4. Lubricate the thread of the new relief valve with high-temperature thread paste
“Dag 5420 A“ .
5. Mount new relief valve (3) with new joint ring (4).
6. Firmly tighten the relief valve by means of a wrench.
7. Mount cover (2).
8. Tighten hexagon nut (1) with a torque of
M = 50 Nm.
en / 31.01.2008 IB023661 2/2

Inlet and Exhaust Valve Cone A5.05. 01.07.01.03
Inspection / Disassembly and reassembly
M43/VM43
15000, 7500


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

Pliers for circlips W2* 1.9067-440
* no picture
Molykote Paste “G-Rapid Plus“ **
Note:
The service life of a valve cone is dependent on the quality of the fuel used, the operating conditi-
ons under which the equipment is used and the grade of repaired valve cones/seat rings and va-
ries from system to system.
For this reason, the system operator must determine the maintenance intervals required for his
equipment after inspecting the valve cones. Every time a valve cone is removed, the seat geome-
try must be checked and milled if necessary (01.08.01.nn, 01.08.02.nn).
en / 05.06.2003 IB023934 1/3

M43/VM43
15000, 7500
Sequence of operations: 01
1. Disassembly
13
1.1 Disassemble the cylinder head
(01.06.01.nn).
1.2 Disassemble the rocker arms

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

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

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

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

(W1). To this end:
1.6.1 Pull pin (10) out of spindle (11).

3
1.6.2 Sleeve (12) must rest above the split
spindle end.
1.6.3 Pull the valve spring compressor unit off

the valve cone stem.
1.7 Take valve spring retainer (2), valve spring (3) and valve rotator, freewheel or valve spring washer
off the cylinder head.
en / 05.06.2003 IB023934 2/3

M43/VM43
15000, 7500
1.8 Pull the valve cone out of the cylinder head. 01

Note:
Valve cones which display a large degree of wear in the clamping area and clamping piece haves
with excessive burring must be replaced with new parts. All burrs must be removed from such val-
ve cones before disassembly.
Valve cone/valve seat repair (01.08.01.nn/01.08.02.nn).
2. Assembly
2.1 Check valve guide clearance, replace O-ring (01.05.01.nn).
2.2 Oil the de-burred valve cone well before installation and insert valve cone with a twisting motion
to prevent damage to the O-ring.
2.3 Installation is completed in the reverse order as disassembly.
2.4 After inserting clamping cone halves (4) and assembling circlip (5) by means of pliers (W2) slowly
relieve valve spring (3). In doing so, make sure that the clamping cone halves are seated correct-
ly.
en / 05.06.2003 IB023934 3/3

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

Personnel qualification: Chief engineer / skilled engine hand

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

Thinner F25 *
* 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):
• after longer operating time,
• the inspection reveals damaged sealing surfaces, deep graining, uneven

wear pattern on the valve cone /seat.
1. Cleaning
1. Clean the valve stem. Experience has shown that a thorough cleaning, such as an assessment of
the valve cones requires, is only possible by blasting with material like glass beads. The stems
may not be cleaned with sharp tools or cleaned with inorganic acids (hydrochloric acid, sulfuric
acid, hydrofluoric acid, etc.) or by sandblasting.
2. Inspection
2.1 Valves can be reused without being reworked when
• the valve cone surface is bright and polished around the entire cone
• the valve cone surface has no carbon deposits which may indicate blow-by
• no cracks are found in the valve cone surface when checked with an illuminated
magnifying glass (8 x magnification), or during a pulse spray test (Met L’Check) or a
flux test.
en / 05.06.2003 IB004814 1/5

Repair / Checking
M43/VM43
• there is HT corrosion as shown below, i. e. no deep craters over the entire area of the bottom 01
side of the valve heads.
• the straightness deviation does not exceed the following values (Fig. 1)
Span “s“ = 495.6 mm
= Contact point for measurement device
• the radial deviation of the valve cone does not exceed the following values:
en / 05.06.2003 IB004814 2/5

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

terval when
• the valve cone surface is damaged

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

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

de of the valve head (so-called co-
bblestone formation)
• there are corrosion pits and mechanical damages in the vicinity of the valve stem, the
root of the stem and the valve head
• the indicated reworking limits have been exceeded.
en / 05.06.2003 IB004814 3/5

Repair / Checking
M43/VM43
3. Repair (reworking the sealing surface) 01

Note:
The rework must be completed properly on precision spindle grinding machines. If such a machi-
ne is not available, the valve cone should be sent to a CAT workshop for regrinding.
3.1 Regrind the sealing surface in accordance

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

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

grinding machine manufacturer.
3.3 After grinding, measure the distance

between the visible edge of the plating “X“
and outer edge of the seat surface. The
valve cone must be replaced when the di-
stance is smaller than the wear
limit.
(Fig. 3, Exhaust valve Fig. 3a, inlet
valve).
3.4 Outer edge rounded with stone.
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)
4.1 Apply small dots of diamond paste Dp 30/

10 - 15 µm to the seating new or reworked
valve cone with a syringe and spread
evenly. (Fig. 4). Next, spray the entire val-
ve seat ring with a thinner which corre-
sponds to the diamond paste (F25) to thin
the paste and increase the grip.
en / 05.06.2003 IB004814 4/5

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

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

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

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

check the sealing surfaces with an illumi-
nated magnifying glass
(8 x magnification) for cracks in the plating
and in the neighboring areas.
en / 05.06.2003 IB004814 5/5

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


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Precision seat grinding machine W1 * 1.9224 M
Valve milling unit W2 439224 B
* no picture
Illuminated magnifying glass (8x magnification)
Diamond paste Dp 30/10 - 15 µm **
Thinner DIAPLASTOL **
Note:
If the sealing surface of the valve seat/valve cone has an uneven wear pattern or deep graining,
both sealing surfaces must be reworked.
Grind new or reworked valve seats as described in procedure 4.
It may be necessary to rework the seats when:
• the engine has not been run for a long period of time,
• the inspection reveals damaged sealing surfaces, deep graining, uneven

wear pattern on the valve seat /cone (Fig. 1 and 2).
en / 18.05.2006 IB004816 1/5

Repair / Checking
M43/VM43
01
Procedure:
1. Inspection
The grade (hardness) of the valve seat is designed to allow the seat to adapt to the valve cone to
a certain extent. Carbon deposits are therefore normal and pose no danger with adequate cooling
(Fig. 3, 4 and 5).
en / 18.05.2006 IB004816 2/5

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

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

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

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

contact area (3) of the centering disk (4) in
order to ensure that the guide punch (5) is
centered exactly. Remove the
O-ring from the guide bush.
en / 18.05.2006 IB004816 3/5

Repair / Checking
M43/VM43
3.1.2 Insert the centering disk (4) with the guide punch (5) and tighten with a star handle (6). 01
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.
3.1.6 Maximum permissible dimension Ø (x) for reworking (Fig. 7):
148+0.2
a = no material may be removed
exhaust valve seat ring = Fig. 7

intake valve seat ring = Fig. 7a
3.1.7 Remove milling unit. Smooth the sharp edges with a fine emery cloth.
en / 18.05.2006 IB004816 4/5

Repair / Checking
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
30 - 50 % of the seat width “b“
around the entire edge of the entire circumference. (01.08.01.nn).
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.
en / 18.05.2006 IB004816 5/5

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


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

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

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

shaft by striking firmly, clean the bore by
hand with 120 grit emery cloth, or with 260
serrated lock washer if the bore is extreme-
ly dirty.
en / 05.06.2003 IB004818 1/2

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

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

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

seat grinding machine or valve seat milling
unit. Grind the valve cone lightly with
Diamond paste Dp 30/10 -15 µm and
check the contact surface (01.08.02.nn).
6. Install valve cone.
en / 05.06.2003 IB004818 2/2

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


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

for easy movement all 3.750 h
For V-engines only on cyl. bank A
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.
en / 27.10.2003 IB024089 1/2

M43/VM43
3750
4. Ensure that the piston (5) and spindle (9) return to the original position quickly and easily. 01
Note:
Do not move spindle (9) by turning locknut (3).
5. If the parts do not move freely, lubricate the piston (5) and guide in the cylinder head with engine
oil.
6. Fit cover (1) with new O-ring (3).
Note:
If there is moisture, rust, dirt or other soiling between the cover (1) and piston (5),
the treatment / dehumidification of the starting air should be checked.
en / 27.10.2003 IB024089 2/2

Starter Valve A5.05. 01.09.02.03
M43/VM43
15000
See also: 01.06.01.nn, 01.11.01.nn 01


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Remove starter valve, disassemble and rework if necessary every 15,000 h
Tools:
Insertion ring for starting valve piston W1 * 439227 A

Starting valve reseating tool W2 439224 C
* not shown
Molykote Paste “G-Rapid“ **

Attention:
When working on the starter system, close the main valves on the pressure tanks, bleed
the line and block the starting valve.
Procedure:
1. Disassembly
1.1 Remove the rocker arm bracket (01.02.01.nn).
1.2 Lay the cylinder head on its side.
1.3 Remove the cover (1) and O-ring (2) with the help of an M8 bolt.
1.4 Remove circlip (12).
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.
1.7 Clean all parts carefully with gas oil.
1.8 Check the piston (5), compression ring (10) and valve seat carefully. Smooth scored piston (5) ca-
refully with emery cloth (240 grain or higher).
en / 11.02.2005 IB022699 1/3

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

1.9.1 Carefully clean valve seat and guide of valve spindle.
1.9.2 Loosen adjusting screw (20) on reseating tool (W2). Lightly oil valve canon. Insert reseating tool
in valve guide and fix with spanner (21).
1.9.3 Tighten adjusting screw (20) until a slight resistance is felt. Then tighten adjusting screw another
1/4 turn to set cutting pressure.
1.9.4 Turn reseating tool evenly and slowly without additional pressure. Repeat process until valve seat
is clean.
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
en / 11.02.2005 IB022699 2/3

M43/VM43
15000
2. Assembly 01
2.1 Apply thin coat of Molykote paste “G-Rapid” to piston (5), distribute ring joints evenly around peri-
phery. Insert piston using insertion ring (W1).
2.2 Installation is completed in the reverse order as disassembly.

Replace O-ring (2). Make sure that the clamping ring (4) is installed correctly. Tighten the hexa-
gon nut (3) until the hexagon nut (3) and valve shaft (9) cannot be moved separately (solid con-
nection). Tighten the hexagon nut to
M = 80 Nm.
2.3 Mount circlip (12).
2.4 Check the starter valve for leaks before starting the engine.
en / 11.02.2005 IB022699 3/3

M43/VM43
150


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
inspect the cylinder head every 150 h
Procedure:
1. Check gasket between cylinder head, cylinder liner and coolant distributor housing for combusti-
on gas leaks and check for coolant at the inspection bore (1).
If leaks are found, remove the cylinder head (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).
en / 05.06.2003 IB004824 1/2

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

2.1 If oil leaks are found, check the valve cover bolts to ensure that they are tight and check the rub-
ber profile for damage.
2.2 If leaks are found at the media supply connecting flanges, check all bolts to ensure that they are
tight. Replace gaskets as needed.
3. Remove valve cover. Inspect the top of the cylinder head.
3.1 Check to ensure that the valves move identically. Irregularities can be seen most easily at low en-
gine speeds.
3.2 Check the function of the valve rotor or free-wheel (01.03.01.nn).
3.3 Check valve springs for damage.
3.4 Check the oil supply to the valve rockers and rocker arm bearings.
en / 05.06.2003 IB004824 2/2

Maintenance / Cleaning
M43/VM43
15000


----------------------------------------------------------------------------------------------------------------------------------
Note:
The cylinder head may only be placed on the bench upright on a wood block.
Procedure:
The following parts must be dismantled:
Intake, exhaust, injector valve, starter valve and rocker arm bracket.
1. Clean cylinder block with cold cleaning solution.
2. Clean intake and outlet ports, underside of cylinder head (not the valve seats!) with a wire brush
and scraper, all combustion deposits must be removed. Do not damage the gasket depression/
groove.
3. Clean coolant intake and outlet ports.
4. Inspect the underside of the cylinder head carefully for cracks at the valve fittings.
5. Clean the sealing surface for the injector valve.
6. Check the intake and outlet bores for media supply for blockage.
7. Check function of leakage sensor for fuel leaks at the connection piece for media supply on the
distributor plate (Cyl. 1).
en / 05.06.2003 IB004828 1/1

Repair / Reassembly
M43


-------------------------------------------------------------------------------------------------------------------------------
Tools:
See maintenance sheet 01.06.01.nn.
Ancillary materials:
High temperature threading paste “Dag S-5080“ *

Molykote paste “G-Rapid Plus“ *
Vaseline *
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.
en / 13.02.2009 IB024290 1/4

Repair / Reassembly
M43
Procedure: 01
1. Turn pistons to ignition TDC.
2. Thoroughly clean sealing and bearing surfaces of cylinder head and cylinder bushing and check
for damage. Insert new sealing ring (Fig. 1/1) into cylinder bushing collar.
Check and clean sealing surface at exhaust pipe (06.01.01.nn).
3. Replace the following O rings: Top O ring at cylinder bushing collar (2), at cylinder head (3), at the
push rod bushing (4), at the cooling water conduit, at the starting air inlet, at the control air inlet
and at the charger air inlet connection.
en / 13.02.2009 IB024290 2/4

Repair / Reassembly
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.
en / 13.02.2009 IB024290 3/4

Repair / Reassembly
M43
6.1 Store hydraulic traction elements (Fig. 2/ W1.1) onto round nuts and tighten. Ensure good acces- 01
sibility of the slots (3).
6.2 Store hydraulic traction elements via high pressure hoses (W1.2) to each other. Connect
element 1 to pump. Fit test manometer (W1.4) onto element 6.
Secure the coupling that is not connected by means of plug (8).
6.3 Close valve on high pressure pump and extend all 6

cylinder head screws simultaneously and continuously using a hydraulic pressure of
p = 2250 bar -25 bar
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.
6.5 Check the firm contact of the round nut.

• It should no longer be possible to loosen the round nuts with the pin.
6.6 Relieve hydraulic traction element (W1.1) and remove.
7. Tighten clamp for exhaust pipe. The clamp is held in position by a locking screw from
below (06.01.01.nn).
8. Remove hexagon screws (W5) (01.06.01.nn).
9. Fit removed connecting flanges of the media conduit with new seals. Ensure proper fitting of dow-
el pins.
10. Fit removed manometer pipes and fill with cooling water. Vent cooling water return line from turbo
charger.
11. Insert push rods into cylinder head.
12. Fit rocker arm bracket (01.02.01.nn).
13. Fit injection pressure pipe (07.05.01.nn).
14. Adjust valve clearance (01.01.01.nn) and fit pump chamber cover.
15. Check all connections for tightness after starting the motor.
en / 13.02.2009 IB024290 4/4

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


----------------------------------------------------------------------------------------------------------------------------------
Note:
The temperature check for the bearings must be carried out with the engine at operating
temperature after switching off the circulation system lubrication. The remaining tasks are to be
carried out after allowing a period of ventilation.
1. Open indicator valve and engage turning gear.
2. Open crank case cover approx. 10 min. after shutting down the engine.
3. Check crankshaft bearings and big end bearings for even and normal temperatures.
4. Visually check screws and nuts.
5. Check extent of soiling of the engine room (silt deposits, corrosion, bearing metal particles, de-
tached paint).
6. Check cylinder liner surface on engine side. Carry out lubrication oil flow check and check oil de-
livery at bearing points.
7. Remove camshaft cover. Check screws of camshaft components and the lower valve mechanism
for proper tightness.
7.1 Turn engine and check bearing surfaces of cams and rollers for scoring, pitting or other damage.
7.2 Check lubricating oil flow for camshaft bearing and valve mechanism.
8. Check wheel mechanism (04.08.01.nn).
9. Check oil tray and crank case for left-behind tools, cloths etc. Check seals of all crank case and
sealing lids and refit cover.
en / 28.10.2003 IB020107 1/1

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

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

If there may be a foundation deformation, e.g.:
• after sea damage to the ship
• when the foundation appears to have settled
• damage to the bearings or crankshaft
• before and after docking the ship.
Tools:
Crankshaft measuring unit W1 1.9425-300
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
en / 24.04.2006 IB020114 1/4

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

2 = 2nd Measurement point (Journal - exhaust side)
3 = 3rd Measurement point (Journal - TDC)
4 = 4th Measurement point (Journal - control side)
5 = 5th Measurement point (Journal - BDC control side)
en / 24.04.2006 IB020114 2/4

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.
Web deflection values in mm:
RM43
Cylinder 1 or last cylinder

with additional load + 0,07 / - 0,16 mm
(flywheel/coupling)
All cylinders
without external load + 0,07 / - 0,12 mm
en / 24.04.2006 IB020114 3/4

M43
02
en / 24.04.2006 IB020114 4/4

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


-------------------------------------------------------------------------------------------------------------------------------
Note:
Oil contamination, foreign objects, water and faulty tools cause
85 % of all bearing damage.
Dirt is the enemy of all bearings!
In order to avoid unnecessarily shortening bearing life, note the following:

• Oil temperature and pressure requirements, see A1.05 and A1.06
• Oil brand recommendations (viscosity class), see A4.05.08.nn
• Information on oil care, see A4.05.08.nn
• Oil change / additives, see A4.05.08.nn
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.
These bearings consist of a protective steel shell and a running layer.
en / 25.08.2003 IB020119 1/2

Bearing Shells and Bearing Bushes A5.05. 02.03.03.01
M43/VM43
The corrosion-resistant flash on the bearing (ca. 3 µm) is worn through after a short operating 02
period.
The bearing need only be replaced after
- heavy scoring,
- a clearance limit has been exceeded or
- in accordance with the applicable evaluation criteria (02.03.07.nn).
Attention:
If a replacement criterion is found during an inspection, all bearings must be checked.
en / 25.08.2003 IB020119 2/2

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


-------------------------------------------------------------------------------------------------------------------------------
Note:
The following evaluation catalog contains different wear stages caused by mechanical wear and
overloading the bearing shells.
Evaluation catalog:
Criteria for reinstallation
Fig. 1 -The wear pattern is even across the entire width of the bearing surface.
Any streaks caused by foreign bodies in the engine oil do not tend to have a significant
influence on the operating safety of a sliding bearing.
This bearing shell can be reused.
Fig. 2 -The wear pattern is even across the entire width of the bearing surface. This bearing shell
can be reused.
Fig. 3 -The wear pattern is even across the entire width of the bearing surface.
The scoring along the bearing surface is caused by fine solid particles in the engine oil.
If these scores cannot be felt or the depth of these scores cannot be measured, the
bearing shell can be reused.
If the number, depth and length of such scoring has an adverse affect on the formation
of the oil film, both bearing pairs must be replaced.
Achtung:
When replacing bearings in the crankcase, note that all bearing shells must generally be
replaced in pairs (upper and lower bearing shell)!
en / 05.06.2003 IB020121 1/4

M43/VM43
Criteria for replacement 02

Fig. 4 -The wear pattern includes severe scoring and the aluminum alloy sliding layer is fretted.
This bearing shell can not be used again, both bearing shells must be replaced. Find
and eliminate the cause for the increased scoring.
Fig. 5 -The wear pattern includes a large area of damage with varying degrees of fretting.
This bearing shell can not be used again, both bearing shells must be replaced. Find
and correct the cause of this damage. Check all other bearing shells.
Fig. 6 -Bearing metal is missing in the loaded area of this bearing as a result of overloading. There
may also be loose pieces of bearing metal in the
affected area.
This bearing shell can not be used again, both bearing shells must be replaced. The
cause for the flaking must be determined and corrected. Check all other bearing
shells.
en / 05.06.2003 IB020121 2/4

M43/VM43
02
en / 05.06.2003 IB020121 3/4

M43/VM43
02
en / 05.06.2003 IB020121 4/4

Big End Bearings A5.05. 02.04.01.30
Inspection / Disassembly
M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn, 02.06.01.nn 02


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

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

High pressure pump W1
High pressure line W2 433420 A
High pressure line W3 433420 E
Hydraulic clamping elements W4 1.9213 N
Pin W5
Big end bearing installation and disassembly set W6 439228 A
Molykote Paste “G-Rapid Plus“ *
Attention:
High pressure lines may not be bent below minimum bending radius r = 250 mm! The high
pressure pump may only be operated with hydraulic oil. Protect hydraulic equipment from
corrosion during storage.
~ Attention!
Do not place any body parts under equipment which is under pressure! Ensure that the en-
en / 03.05.2004 IB024444 1/6

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

Both round nuts (2) must be accessible.
3. Loosen the round nuts (2) with the hydraulic rig.
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.
en / 03.05.2004 IB024444 2/6

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.
7. Wait until no pressure is left, dismount hydraulic devices (W4).
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
9.2 Suspend guide rail (11).
en / 03.05.2004 IB024444 3/6

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

10 11 12
9.4 Mount guide rail extension (13) with carriage (14) on camshaft side.
13
18
15 3
19
en / 03.05.2004 IB024444 4/6

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

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

Secure connecting rod (17) additionally with screw (20) at connecting rod holder.
en / 03.05.2004 IB024444 5/6

M43
30000, 15000
16. Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to 02
the camshaft side.
17. Mount suspension (16) for connecting rod (17) and connect with carriage.
18. Dismount connecting rod holder at the counterweight (02.06.01.nn).
19. Drive connecting rod (17) to the camshaft side out of the crankcase. Remove bearing shell (20).
16
20
17
20. Sling suspension (16) with suspended connecting rod (17) at the crane. Dismount connection to
the carriage (14).
21. Deposit connecting rod (17) on suitable support.
22. Evaluate the condition of the big end bearing shells (02.03.03.nn and 02.03.07.nn).
Note:
If the bearings are scored, the neighboring bearings must also be checked.
en / 03.05.2004 IB024444 6/6

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


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W6 see 02.04.01.nn
Note:
Bearing caps, bearing shells, connecting rod eyes and connecting rods are labeled according to
the cylinder to which they belong and may not be switched around. New parts must be labeled
accordingly.
Procedure:
1. Bearing shell installation
1.1 Clean and oil crank journals.
1.2 Oil the inside and outside of the bearing

shells.
Attention:
The bearing shells are equipped with a
positioning nose (Fig. 1/X) to allow
them to be positioned properly in the
connecting rod and big end bearing
cap. The bearing shells must be instal-
led with the positioning nose to the
control side!
en / 03.05.2004 IB024448 1/8

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

1.4 Fasten suspension (16) with suspended connecting rod (17) at the crane and lift. Mount connec-
tion to the carriage (14).
16
20
17
1.5 Remove sling.
1.6 Push connecting rod (17) towards the crank pin up to approx. 20 mm.
1.7 Put upper bearing shell (without holes) on the crank pin and turn below the connecting rod by
180°.
1.8 Press connecting rod (17) carefully against bearing shell (20). The fixing lug of the bearing shell
must be exactly positioned in the notch of the connecting rod.
en / 03.05.2004 IB024448 2/8

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

Secure connecting additionally with screw (20) at connecting rod holder.
1.10 Dismount suspension (16).
1.11 Turn connecting rod (17) downward by 180°° so that the connecting rod shank division shows to
the exhaust side.
1.12 Mount suspension (18) at big end bearing cap (15).
13
18
15 3
19
en / 03.05.2004 IB024448 3/8

M43
1.13 Fasten big end bearing cap (15) at crane and connect suspension (18) with carriage (14) at guide 02
rail extension (13).
13
19
15
1.14 Remove sling.
1.15 Push big end bearing cap (15) towards the crank pin up to approx. 160 mm.
Attention:
Pay attention to the appropriate bores (50 / connecting rod) and clamping pin (51 / big end
bearing cap)!
en / 03.05.2004 IB024448 4/8

M43
1.16 Push big end bearing cap (15) forward towards the crank pin up to approx. 100 mm and insert, 02
align and press lower bearing shell (19) into the big end bearing bore.
1.17 Push big end bearing cap (15) carefully against bearing shell (19) and bottom end of connecting
rod. The lug of the bearing shell must be exactly positioned in the notch of the big end bearing
cap (15).
10 11 12
Attention :
Pay attention that the bearing shell halves on exhaust and camshaft side are axially
aligned. Displacement of the bearing shell halves to each other in axial direction is not
admissible.
en / 03.05.2004 IB024448 5/8

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

Assemble washer (4) with chamfer pointing towards bottom end of connecting rod.
1.19 Install round nuts (5) and tighten by hand.
1.20 Remove installation / disassembly unit (W6).
1.21 Check bearing shell pairs for axial misalignment on the exhaust side. Align shells if necessary.
11
10
14
18
15
en / 03.05.2004 IB024448 6/8

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

hydraulic rig.
2.1 Turn the connecting rod with the connec-
ting rod shank joint by about 15-30° down-
wards, see indicated position
(Fig. 11). Both round nuts (5) must be ea-
sily accessible.
2.2 Place the hydraulic clamping element (W4)
over the round nut (5) at camshaft side and
screw onto big-end bearing bolt (6) so as to
be finger tight. Make sure that the slits (8)
are easily accessible.
2.3 Connect the hydraulic clamping element
(W4) to the high-pressure pump (W1) by
means of the high-pressure line (W2).
2.4 Close the valve of the high-pressure pump

(W1) and extend the big-end bearing bolt
at camshaft side steplessly, hydraulic
pressure:
p = 85 bar
2.5 Firmly tighten the round nut (5) at cams-
haft side with a pin (W5).
2.6 Open the valve of the high-pressure pump

(W1), the clamping element is depressuri-
zed.
2.7 Wait until the pressure reduces complete-

ly.
2.8 Place the second clamping element (W4)

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

element (W4) to the high-pressure pump
(W1) by means of the high-pressure lines
(W3).
2.10 Close the valve of the high-pressure pump

(W1) and extend both big-end bearing
bolts steplessly and simultaneously, hy-
draulic pressure:
p = 2250 bar + 25 bar
Attention:
The pressure must remain constant when the hydraulic pump is not actuated, otherwise
they will be tightened incorrectly!
en / 03.05.2004 IB024448 7/8

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°°
2.12 Check to ensure that the round nut is seated properly

• Reduce pressure by 50 bar
• The round nuts must be tight enough so that they cannot be loosened with the pin
any more.
2.13 Open the valve of the high-pressure pump (W1), the clamping elements are depressurized.
2.14 Wait until the pressure reduces completely.
3. Mount the piston (02.10.01.nn).
en / 03.05.2004 IB024448 8/8

Hydraulic Jack A5.05. 02.04.51.00
M43/VM43
See also: 02.04.01.nn, 02.05.01.nn, 02.05.05.nn 02


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

* = no illustration
Auxiliary means:
Molykote paste "G-Rapid Plus" *
* or equivalent
1. Disassembly
1.1 Clamp hydraulic jack.
1.2 Loosen cover (1) using fork wrench (W1) and disassemble.
1.3 Remove cup spring pack (2).
1.4 Push piston (3) out.
1.5 Remove rubber rings (4 and 5) as well as joint rings (6 and 7).
2. Assembly
2.1 Clean all parts and slightly coat them with Molykote paste "G-Rapid Plus".
en / 31.01.2008 IB024004 1/2

Hydraulic Jack A5.05. 02.04.51.00
M43/VM43
2.2 Insert new seals in consideration of the order: 02

Order: At first rubber rings (4 and 5) and then joint rings (6 and 7).
Attention:
Do not press joint rings in too much.
2.3 Press piston (3) into the cylinder.
Attention:
Do not tilt the piston (3).
2.4 Mount cup spring pack (2).
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.
en / 31.01.2008 IB024004 2/2

Main Bearings A5.05. 02.05.01.30
M43
30000, 15000
See also: 02.03.03.nn, 02.03.07.nn 02


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

High pressure line (3 x 1m) W2 433420 A
Pin W3
Hydraulic tightening element
(lateral uniform strength bolts) W4 1.9213 F
(crankshaft bearing bolts) W5 1.9213 M
Threaded sleeve for crankshaft bearing 1.9203-108
High pressure line W6* 433420 E
Installation / disassembly unit for crankshaft bearings, consisting of

Rig W10 439214 A
Carrier W11 439225 B
* 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.
en / 04.05.2004 IB024452 1/9

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

pressure pump (W1) by means of the high pressure line
(W2).
Secure the coupling that is not connected by means of plug.
1.3.4 Close the valve on the high pressure pump (W1) and apply
force to uniform strength bolt with a pressure of
p = 2250 bar
en / 04.05.2004 IB024452 2/9

M43
30000, 15000
1.3.5 Loosen the round nut with a pin. Turn the round nut back 10 holes. 02
Note:
If the round nut cannot be loosened with the pin, the pressure on the uniform strength bolt can be
increased to
p = 50 bar
more.
If the pressure is increased further, the threading may stretch, which can cause the round nuts to
lock into place!
1.3.6 Open the valve on the high pressure pump, the hydraulic clamping element is depressurized.
1.3.7 Wait until the pressure drops completely. Remove the hydraulic clamping element.
1.3.8 Repeat sequence of operations 1.3.2 - 1.3.7 on the opposite side.
1.3.9 Loosen the uniform strength bolts and screw out completely.
1.3.10 Loosen the round nuts on the lateral uniform strength bolts on the neighboring bearing(s) with the
hydraulic rig (do not remove). ( if necesarry )
1.4 Insert rig.
1.4.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan.
Insert carrier arm.
W10
en / 04.05.2004 IB024452 3/9

M43
30000, 15000
1.4.2 Connect the hydraulic cylinder of the rig (W10) to the high pressure pump (W1) by means of the 02
high pressure line (W2).
14
W10
1.4.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
W5
10
23
en / 04.05.2004 IB024452 4/9

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
1.4.7 Repeat the installation procedure on the opposite side.
1.4.8 Connect the hydraulic clamping elements (W5) to the high pressure pump (W1) by means of the
1.4.9 Close the valve on the high pressure pump and subject both crankshaft bearing bolts to a pressu-
re of
p = 2250 bar
1.4.10 Loosen the round nuts (12) with a pin. Turn back the round nuts at least 8 holes.
en / 04.05.2004 IB024452 5/9

M43
30000, 15000
Note: 02
If the round nuts cannot be loosened with the pin, the pressure on the uniform strength bolts can
be increased to
p = 50 bar
more.
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
1.6 Measure gap, see procedure 2.
en / 04.05.2004 IB024452 6/9

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

the crankshaft until it stops.
1.11 Turn the upper bearing shell and remove.
Attention:
Do not turn until the rig is lowered com-
pletely to the lower stop! W11
en / 04.05.2004 IB024452 7/9

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

the wear reaches > 0.05 mm.
Nominal size = 8.820 - 0.025 mm
Attention:
If measurements indicate that the bea-
ring shells need to be replaced, the
neighboring bearings must also be
checked.
2. Measure the gap.
2.1 Remove the uniform strength bolts for the respective main bearing on the exhaust and control si-
de. (see procedure 1.4)
K K
A S
12
10
2.1.1 Loosen both round nuts (12) hydraulically as described in 1.5 and 1.6. Lower the rig.
en / 04.05.2004 IB024452 8/9

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

mm mm
1.4 - 1.65 1.2
en / 04.05.2004 IB024452 9/9

Maintenance / Reassembly
M43
See also: 02.05.01.nn 02


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

Reversible ratchet 1/2" W14 * 1.9459-033
* no picture
Attention:
~ Attention!
Note:
The bearing covers and bearing shares are numbered consecutively on the control side
from the coupling forward according to their respective cylinder and may not be ex-
changed. New parts must be labeled accordingly.
Damaged main bearing bolts and round nuts must be replaced in sets.
en / 31.01.2008 IB024459 1/6

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

ring shell thoroughly, dry the back of the
bearing and turn the bearing shell into the
bearing as far as possible. Place the carri-
er (W11) into the oil bore until it stops.
Attention:
Bearing shell designation on the opposite (control) side.
1.2 Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly at
the side. Raise the rig (W10) carefully until it stops at the bearing shell. Lock the turning mecha-
nism in place by hand with the round nuts (12). Lower the mechanism (W10) so that the bearing
cap can be turned as needed.
12
W10
en / 31.01.2008 IB024459 2/6

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

side to the high pressure pump (W1) by means of the high
pressure line (W2).
en / 31.01.2008 IB024459 3/6

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

• The round nut must be tight enough that it cannot be loosened with a pin.
3.14 Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.15 Repeat installation steps 3.8 to 3.14 on the operating side.
3.16 Tighten the round nuts (23) on the lateral uniform strength bolts on the neighboring
bearing(s) with the hydraulic rig, see steps 3.2 to 3.13.
3.17 Screw the protective caps onto the uniform strength bolts.
4. Tightening the main bearing bolts.
4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
en / 31.01.2008 IB024459 4/6

M43
02
13
W5
10
23
4.2 Place the hydraulic clamping element (W5) level on the plate above the chute. Remove the chute.
4.3 Raise the carrying arm. Place the hydraulic clamping element on the round nut (12) and tighten.
12
W5
13
W10
en / 31.01.2008 IB024459 5/6

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

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

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

The rig is dismantled in the reverse order as installation
(see 02.05.01.nn).
4.13 Check engine oil flow.
4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
en / 31.01.2008 IB024459 6/6

Main Thrust Bearings A5.05. 02.05.05.30
M43
30000
See also: 02.03.03.nn, 02.03.07.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
Main thrust bearings every 30,000 h
Tools:
Pin W3
(lateral uniform strength bolts) W4 1.9213 F
(crankshaft bearing bolts) W5 1.9213 M
High pressure line W6* 433420 E
Installation / disassembly unit for crankshaft bearings, consisting of

Rig W10 439214 A
Carrier W11 439225 B
Lashing eye M20 W12
* no picture
Attention:
~ Attention!
Note:
The main thrust bearing consists of the first main bearing (coupling side) and four thrust washer
segments which limit the axial clearance of the crankshaft.
Both lower thrust washer segments are fixed in the main bearing cover with dowel pins and the
two upper thrust washer segments are slid into grooves in the crankcase housing.
The bearing covers and bearing shells of the main bearings are numbered on the control side and
may not be exchanged. New parts must be labeled accordingly.
en / 04.05.2004 IB024463 1/9

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.
Set the dial gauge to “zero“ and slide the

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

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

the thrust washer segments and bearing
shells in pairs, see main thrust bearing
removal procedure.
Attention:
Label all thrust washer segments before
removal for inspection and measure-
ment to prevent them from being ex-
changed.
Thrust washer segments must be rein-
stalled immediately after measurement
and inspection!
en / 04.05.2004 IB024463 2/9

M43
30000
2. Removing main thrust bearing. 02

2.1 Turn the piston of the 1st cylinder 90° after crankshaft TDC or 90° before crankshaft TDC.
2.2 Loosen the round nuts (23) on the lateral uniform strength
bolts with the hydraulic rig.
2.2.1 Remove the protective caps.
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.
2.2.3 Connect the hydraulic clamping element (W4) to the high

pressure pump (W1) by means of the high pressure line
(W2).
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.
2.2.8 Repeat sequence of operations 2.2.2 - 2.2.7 on the opposite side.
en / 04.05.2004 IB024463 3/9

M43
30000
2.3 Insert rig. 02

2.3.1 Lift the rig (W10) into the crankcase collapsed and place in the guide rails of the oil pan. Insert
carrier arm.
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
en / 04.05.2004 IB024463 4/9

M43
30000
2.3.3 Bring the carrying arm into position and place the chute (10) between the crankcase and carrying 02
arm.
W5
10
23
2.3.4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig.
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.
12
13
W5
W10
en / 04.05.2004 IB024463 5/9

M43
30000
2.3.7 Connect the hydraulic clamping elements (W5) with the high pressure pump (W1) by means of 02
the high pressure lines (W2, W6).
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.
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
2.7 Measure the gap, see step 3.
en / 04.05.2004 IB024463 6/9

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
en / 04.05.2004 IB024463 7/9

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

ments (1) and replace them if there is a
high degree of axial clearance, see step 1.
Only remove the upper thrust washer seg-
ments if they need to be replaced.
2.16 Remove the lower bearing shell.
2.17 Place the carrier (W11) into the oil bore in

the crankshaft until it stops.
2.18 Turn the upper bearing shell and remove.
Attention:
Do not turn until the rig is lowered com-
pletely to the lower stop!
2.19 Inspect and evaluate the bearing shells, see 02.03..03.nn and 02.03..07.nn.
2.20 Check the wear and wall thickness in the

main wear zone with a micrometer at the
indicated measurement points (X).
Wear = Nominal size - current size
2.21 The bearing shells must be changed when

the wear reaches > 0.05 mm.
Nominal size = 8.820 - 0.025 mm
Attention:
If measurements indicate that the bea-
ring shells need to be replaced, the
neighboring bearings must also be
checked.
en / 04.05.2004 IB024463 8/9

M43
30000
3. Measure the gap. 02

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

mm mm
1.4 - 1.65 1.2
en / 04.05.2004 IB024463 9/9

M43
See also: 02.05.05.nn 02


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W12 see maintenance sheet 02.05.05.nn
Turning unit W12 439225-001
Attention:
~ Attention!
Note:
The bearing covers and bearing shares are numbered consecutively on the control side
from the coupling forward according to their respective cylinder and may not be ex-
changed. New parts must be labeled accordingly.
Damaged main bearing bolts and round nuts must be replaced in sets.
en / 30.01.2008 IB024467 1/7

M43
Procedure: 02
1. Install bearing shells.
Note:
The upper bearing shell is equipped with a
lubrication groove and oil bore. Insert up-
per thrust washer segments if removed.
1.1 Oil the running surface of the upper bea-

ring shell thoroughly, dry the back of the
bearing and turn the bearing shell into the
bearing as far as possible. Place the carri-
er (W11) into the oil bore until it stops.
Attention:
Bearing shell designation on the opposite (control) side.
1.2 Insert turning mechanism (W12) into the bearing cover. Make sure that the unit seats properly at
the side. Raise the rig (W10) carefully until it stops at the bearing shell. Lock the turning mecha-
nism in place by hand with the round nuts (12). Lower the mechanism (W10) so that the bearing
cap can be turned as needed.
12
W10
en / 30.01.2008 IB024467 2/7

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. Pre-install main bearing bolts.
2.1 Raise rig (W10) with the main bearing cover to the upper stop. Be careful not to damage the main
bearing bolts.
2.2 Screw round nuts onto main bearing bolts evenly and tighten by hand with pin.
2.3 Remove bearing cap mounts on plate.
en / 30.01.2008 IB024467 3/7

M43
Note: 02
Measure the gap “K“ after installing the bearing shells (see 02.05.01.nn).
After replacing the bearing shells or the thrust washer segments the axial clearance must also be
measured (see 02.05.01.nn).
2.4 Lower the rig (W10).
3. Tighten the lateral round nuts of the adjacent bearing .
3.1 Screw the round nuts (23) of the adjacent bearing onto the
uniform strength bolts and tighten by hand.
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.
3.3 Connect the hydraulic clamping elements on the operating

side to the high pressure pump (W1) by means of the high
pressure line (W2).
3.4 Close the valve on the high pressure pump and extend the
uniform strength bolts with a pressure of
p = 380 bar
Attention:
The pressure must remain constant when the hydraulic
pump is not being actuated to prevent the bolts from
being tightened incorrectly!
3.7 Remove hydraulic clamping elements (W4).
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).
3.9 Close the valve on the high pressure pump, extend the uniform strength bolts with a pressure of
p = 2250 bar
en / 30.01.2008 IB024467 4/7

M43
02
Attention:

• The round nut must be tight enough that it cannot be loosened with a pin.
3.13 Wait until the pressure reduces completely. Remove the clamping elements (W4).
3.14 Repeat installation steps 3.8 to 3.13 on the operating side.
3.15 Screw the protective caps onto the uniform strength bolts.
4. Tightening the main bearing bolts.
4.1 Run the carrying arm into position and place the chute (10) between the crankcase and carrying
arm.
13
W5
10
23
en / 30.01.2008 IB024467 5/7

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.
12
W5
13
W10
4.4 Repeat the installation procedure on the opposite side.
4.6 Close the valve on the high pressure pump and extend both main bearing bolts with a pressure of
p = 2250 bar
en / 30.01.2008 IB024467 6/7

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

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

The rig is dismantled in the reverse order as installation
(see 02.05.01.nn).
4.13 Check engine oil flow.
4.14 Close the crankcase covers on the control and exhaust side and the covers under the gear drive.
en / 30.01.2008 IB024467 7/7

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


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston lifting unit W1 432134 A

Hydraulic wrench consisting of
Hydraulic wrench W5 435100 A
Sockets W6 435102 A
Spud W7 435100 B
Piston rod holder W8 439228 B
Cylinder liner retainer W9 439217 B
Disassembly unit for gauging ring W10 439216 B
Note:
In order to prevent the cylinder liner from loosening during turning, the cylinder liner must be held
in place with the cylinder liner retainer (Fig. Y/W9).
en / 05.05.2004 IB024471 1/5

Piston A5.05. 02.06.01.30
M43
Procedure: 02
1. Open the indicator valves, remove the crankcase cover for the respective cylinder on both sides.
2. Turn crank journal ca. 20° to the control side from TDC.
3. Remove cylinder head (01.06.01.nn).
4. Place cylinder liner retainer (Fig. Y/W9) on

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

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

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

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

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

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

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

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

unit, turn the piston to TDC together with
the crane.
Attention:
The crane and lifting eye must remain connected!
en / 05.05.2004 IB024471 2/5

Piston A5.05. 02.06.01.30
M43
14. Split the connecting rod shank. 02

14.1 Insert a socket wrench with a square head (Fig. 3/W6) in the hydraulic wrench (W5). Mount the
support (Fig. 4/W7) on the hydraulic wrench.
en / 05.05.2004 IB024471 3/5

Piston A5.05. 02.06.01.30
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
p = 400 bar + 25 bar
It may be necessary to move the cylinder of the wrench back and forth several times by releasing
pressure [by opening the valve 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).
18. Pull the piston carefully and place on a suitable surface.
en / 05.05.2004 IB024471 4/5

Piston A5.05. 02.06.01.30
M43
02
Attention:
Remove the big end if the piston will be stored for a longer period of time to prevent vibra-
tion damage in the cylinder liner area.
19. Seal off the oil bore in the connecting rod shank split with a protective cap.
en / 05.05.2004 IB024471 5/5

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

Personnel qualification: Cat/MaK-specialist

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

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

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

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

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

(02.09.01.nn) and evaluate if necessary
(02.03.03.nn).
en / 19.11.2008 IB025184 1/4

Piston Crown A5.05. 02.06.02.04
M43/VM43
2.3 Loosen the hexagon nuts (Fig. 3/5) and remove with piston skirt (12). 02
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
en / 19.11.2008 IB025184 2/4

Piston Crown A5.05. 02.06.02.04
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
en / 19.11.2008 IB025184 3/4

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

2.11 Put on piston skirt (12), fixation hole and spring dowel pin (11) must match.
2.12 Lubricate inside thread and bearing surfaces of the hexagon nuts (5) with Molykote paste.
2.13 Tighten piston screws (5) crosswise to a torque of
M = 170 Nm.
2.14 Loosen hexagon nuts again.
2.15 Retighten piston screws (7) in the piston crown, torque:
M = 40 Nm
2.16 Tighten hexagon nuts (5) crosswise to a torque of
M = 60 Nm
and then continue tightening crosswise by
120°°.
2.17 Check:
At a torque of M = 115 Nm
the hexagon nuts must not turn any further!
2.18 Check by second person:
Carry out a visual check to confirm if the hexagon nuts have been turned further by
2 hexagon corners.
At a torque of
M = 115 Nm
the hexagon nuts must not turn any further in tightening direction!
en / 19.11.2008 IB025184 4/4

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


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
one piston and its rings every 7,500 h
Maintenance:
all pistons and piston rings every 30,000 h
Tools:
Piston ring pliers W1 431001 A
Note:
If the running surfaces of all cylinder liners have no scoring or polished areas and no other 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.
Do not remove the graphite layer from the piston shaft.
After installing new piston rings, the engine must be broken in in accordance with the break in
procedure 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)
1.1 Open all crankcase covers.
1.2 Check the running surfaces of all cylinder liners (cylinder liner appearance) from the crankcase.
1.3 Remove the piston with the worst running surface (02.06.01.nn). If any piston rings are stuck or
burnt, remove all additional pistons.
en / 19.08.2004 IB020351 1/3

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

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

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

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

hN2 = Wear
en / 19.08.2004 IB020351 2/3

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

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

labeling up (Fig. 3/X) and with the ring
gaps alternating to the front and back of
the engine.
2. Maintenance (30,000 h)
X
2.1 Remove all pistons (02.06.01.nn).
2.2 Check the running surface of the piston

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

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

chrome layer is worn away entirely or in
sections, send the pistons to MaK for re-
pair. 3
2.5 Measure the groove height hN as defined

in 1.9.
2.6 Replace wiper ring and all compression rings.
2.6.1 Place the rings in the grooves with the labeling (Fig. 3/X) up and with the ring gaps alterna-
ting to the front and back of the engine.
2.7 Install all pistons (02.10.01.nn).
en / 19.08.2004 IB020351 3/3

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


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Piston installation / disassembly unit W1 439223 A
Piston installation / disassembly unit W2 439223 A
Installation rig W3 439220 C
Procedure:
1. Turn the piston.
1.1 Connect crane to the piston installation unit (W1) and lift the piston.
1.2 Mount second installation unit (W2) on the connecting rod eye (1) and attach second crane or
strap.
1.3 Turn the piston and place on suitable surface.
W2
1
X
X
W3
3
6
2
4 5
W1
en / 28.07.1999 IB020353 1/2

Piston Pin A5.05. 02.08.01.00
M43
2. Disassembly 02
2.1 Mark the connecting rod eye (1), piston (2) and piston pin (3) for proper alignment during re-in-
stallation.
2.2 Lift the connecting rod eye slightly with the crane to relive pressure on the piston pin.
2.3 Remove the circlips (4).
2.4 Remove the piston pin (3) from the piston bore and piston pin bush without applying excessive
force until the second oil bore is visible. Mount the rig (W3) and prop the piston with the crane.
Note:
If the piston pin cannot be pressed out by hand, warm the piston to 80°C in an oil bath.
The piston pin can usually be removed from and installed in the piston 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
3.1 Insert a circlip (4) into the piston pin bore.
3.2 Slide the connecting rod eye (1) into the piston until the piston pin bore and the piston pin bush
are flush.
3.3 Oil the piston pin (3) and insert into the piston and piston pin bush without tilting; the pin must be
installed in accordance with the markings. Remove the rig (W3). Slide the piston pin into position.
Note:
If necessary, warm the piston to 80°C in an oil bath or freeze the piston pin.
3.4 Secure the piston pin with the second circlip.
en / 28.07.1999 IB020353 2/2

Small End Bearing A5.05. 02.09.01.01
Maintenance / Measuring
M43/VM43
30000
See also: 02.03.03.nn 02


-------------------------------------------------------------------------------------------------------------------------------
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).
A small end bearing is only replaced when
- a wear limit has been reached or
- 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.
en / 29.07.2008 IB020357 1/3

M43/VM43
30000
02
Smallest Largest Operational
clearance clearance clearance limit
Connecting rod eye Ø (A) 0.06 0.092 0.12

Piston pin Ø (C)
Small end bushing Ø (B) 0.2 0.302 0.31

Piston pin Ø (C)
Eye clearance (D) 0.7 1.2 1.5

Bushing width (X)
D A B
U V
U V
Z Z
en / 29.07.2008 IB020357 2/3

M43/VM43
30000
2. Removal of the small end bearing 02

Note:
The following work should only be completed by MaK or by
an MaK certified workshop.
This work may only be completed on board in an emer-
gency!
2.1 When removing the small end bearing, be sure to use as litt-
le force as possible.
The small end bearing may not be pressed out, it must be

released by carefully sawing or milling the indicated position
Y
(Fig. 3/Y).
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. Small end bearing installation
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!
3.2 Slide the bushing into the connecting rod eye.
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.
en / 29.07.2008 IB020357 3/3

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


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Tools W1 - W9 see 02.06.01.nn
Piston installation ring W12 439220 B

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

the threads and contact surface of the
clamping bolts (1).
3.1 Oil the ring area well.
en / 30.01.2008 IB024475 1/5

Piston A5.05. 02.10.01.30
M43
4. Place the piston installation unit (Fig. 1/ 02

W13) over the piston ring zone and tighten W1 W12
the clamping bolts (1).
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
5. Make sure that the rings are not stuck by

turning the piston installation unit (W13). Y
6 Z
6. Attach the piston lifting unit (Fig. 2/W1) to
the piston.
Attention:
Place the crank journal in TDC.
Y
7. Mount cylinder liner retainer (W9). Z
8. Mount piston installation ring (W12).
9. Attach piston to crane and lift. Oil cylinder

liner and piston base well.
10. Place the piston into the cylinder liner ca- W9

refully; the piston must be inserted exactly W8
in line with the cylinder axis. 2
Attention:
Remove the protective cap from the oil bore in the connecting rod.
11. Lower the piston, being extremely careful that the cylinder does not catch in the cylinder li-
ner.
12. Place the piston insertion unit (Fig. 1/W13) flat on the piston installation ring (Fig. 2/W12) and
place the piston carefully on the connecting rod (6) with the connecting rod eye.
The connecting rod eye may not rest on the connecting rod with any force!
Note:
Lower the piston carefully until the cylinder pins (Fig. 3/8) are run completely into the bo-
res in the connecting rod eye (5).
en / 30.01.2008 IB024475 2/5

Piston A5.05. 02.10.01.30
M43
13. Install piston and connecting rod. 02

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

rod split and tighten uniform strength bolts
hand tight with ring wrench. 5
13.3 Remove connecting rod holder (W8)

(02.06.01.nn). 8
13.4 Tighten all uniform strength bolts (Fig. 4/

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

strength bolts with a chalk mark. Then 6
tighten all uniform strength bolts to
3
M = 250 Nm
en / 30.01.2008 IB024475 3/5

Piston A5.05. 02.10.01.30
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:
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!
en / 30.01.2008 IB024475 4/5

Piston A5.05. 02.10.01.30
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
p = 400 bar + 25 bar
If necessary, move the cylinder in the hydraulic wrench back and forth several times by releasing
the pressure [by opening the valve 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
an angle of 55°° + 15°°
13.10 Open the valve on the high pressure pump (W3). Wait for the pressure to subside completely and
remove the hydraulic wrench (W5), high pressure lines (W4) and high pressure pump (W3).
14. Turn the piston to TDC together with the crane.
15. Remove the piston insertion unit (Fig. 1/W13), piston installation ring (Fig. 2/W12) and piston lif-
ting unit (W1).
16. Clean the cylinder liner contact surface (3).
17. Install new gauging ring.
18. Install cylinder head (01.11.01.nn).
19. Remove cylinder liner retainer (Fig. 2/W9), replace crankcase cover and close indicator valves.
en / 30.01.2008 IB024475 5/5

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


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

High-pressure pump W1 1.9204 D
High-pressure hose W2 433420 A
Pin W3
Hydraulic tightening element W4 1.9213 G
Sealing element W9
Mounting and removal device for balance weights W7

M52x3 hexagon nut (4x) W8 *
* not illustrated
Auxiliary material:
Molykote paste "G-Rapid Plus" **
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!
en / 21.04.2004 IB022689 1/5

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

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

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

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

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

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

via the high-pressure hose (W2) to the
high-pressure pump (W1).
Secure free hose coupling with sealing
element (W9).
1.6.1 Close valve (10) of the high-pressure

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

Turn back round nut at least 8 holes.
Note:
If the round nut cannot be loosened with
the pin, the stud can be preloaded higher
with a pressure of
p = 50 bar
If the pressure is increased even more,

there is a danger of the round nut beco-
ming stuck due to stretching of the screw
thread!
en / 21.04.2004 IB022689 2/5

M43
1.6.3 Open valve (Fig. 3/10) of the high-pressure pump (W1), the hydraulic element will be relieved. 02
1.6.4 Wait until the pressure has dropped completely, and then remove the hydraulic element (W4)
1.6.5 Loosen the second round nut (1), see sequence of operations 1.4.1 to 1.4.6.
1.6.6 Remove the round nuts completely.
1.7 Lower device (Fig. 4/W7) with the hoists slowly and evenly on both sides until the balance weight
gets clear of the studs.
1.8 Move the balance weight slowly out of the crankcase and place it on a suitable base.
1.9 Remove the mounting and removal device for balance weights (W7).
1.10 Screw hexagon nuts (W8) onto the studs (Fig. 2/2) and lock with a second nut.
1.11 Loosen studs and screw out of the crankshaft.
2. Reassembly of balance weight
2.1 Turn crankshaft to position according to (Fig. 3) .
2.2 Clean the contact surfaces on balance weight and crankshaft.
en / 21.04.2004 IB022689 3/5

M43
2.3 Apply a thin coat of Molykote paste to the studs (2) and insert in crankshaft. 02
2.4 Tighten the studs by means of locked hexagon nuts (W8) with a torque of
M = 400 Nm
2.5 Disassemble the hexagon nuts (W8).
2.6 Mount the mounting and removal device for balance weights (Fig. 4/W7).
W7
20
2.7 Lower the device with balance weight slowly into the crankcase by means of hoists.
2.8 Tension the slings slowly and put balance weight on crankshaft via the studs.
2.9 Screw the round nuts (Fig. 3/1) onto the studs (2) so as to be fingertight.
3. Tighten the round nuts (1) of the studs (2) with the hydraulic device set.
3.1 Place hydraulic element (W4) above the first round nut (1) and tighten it. Make sure the slits
(Fig. 2/3) are easily accessible.
en / 21.04.2004 IB022689 4/5

M43
3.2 Connect the hydraulic element (Fig. 3/W4) via the high-pressure hose (W2) to the high-pressure 02
pump (W1).
Secure free hose coupling with sealing element (W9).
3.3 Close valve (10) of the high-pressure pump (W1) and stretch the first stud (2) steplessly with a
pressure of
p = 2050 bar + 25 bar
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
p = 2050 bar + 25 bar
3.9 Firmly tighten round nut (1) with pin (Fig. 2/W3).
3.10 Decrease hydraulic pressure by p = 50 bar.
It must not be possible to loosen the round nut any more.
3.11 Relieve the hydraulic element according to sequence of operations 3.5 and 3.6.
en / 21.04.2004 IB022689 5/5

Measures for emergency operation A5.05. 02.12.00.00
M43


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

Plug for oil bore W2 439225 A
Lashing strap (2x) W3 1.9461-790
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. Locking of the resilient mounting.
1.1 Disassemble nuts and washers (Fig. 1/20, 21 and 22).
1.2 Disassemble spring dowel pin (23).
1.3 Screw down locking ring (24) so that it abuts against pipe (25). To this end an auxiliary bore Ø 14
for a tool is provided in the locking ring.
1.4 Apply a thin coat of oil to the foundation bolts. Place washer (22) onto side stopper (26) and toge-
ther with nut (21) tighten with a torque of
M = 3000 Nm
As an alternative with
M = 150 Nm + 60 ° torque angle
2. Disassemble cylinder head (01.06.01.nn).
en / 21.11.2000 IB022678 1/5

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

S = Shown under normal operation
en / 21.11.2000 IB022678 2/5

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

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

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

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

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

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

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

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

base.
6.2 Disassemble one balance weight of the

damaged running gear (02.11.00.nn).
en / 21.11.2000 IB022678 3/5

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

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

hand.
11
12
4 Y
8. Disassemble the control air pipe (Fig. 5/30) of the corresponding injection pump. Obturate con-
nection (31) on pump and connection (32) on the pipe with plug and swivel nut.
9. Mount cylinder head (01.11.01.nn).
10. Mount crankcase cover on camshaft and exhaust side.
11. Start the engine under emergency operation (A3.12.02.nn).

Continuously check the foundation bolts (Fig. 1/27) for tight fit during emergency
operation. Retighten if necessary.
en / 21.11.2000 IB022678 4/5

M43
12. Repairing a damaged engine. 02

12.1 Disassemble cylinder head, plug in the crank pin (Fig. 4/10), retaining device for cam follower of
the injection pump drive (Fig. 3/10) and the lashing straps (W3) used for the cam followers for in-
let and exhaust valve. Mount control air pipe (Fig. 5/30).
12.2 Deactivating the locking of the resilient mounting.
12.3 Exchange / repair any damaged parts.
12.4 Mount connecting rod, connecting rod bearing with bearing cap (02.04.02.nn), piston
(02.10.01.nn), balance weight (02.11.00.nn), push rods for inlet and exhaust valve and cylinder
head (01.11.01.nn).
12.5 Mount crankcase cover on camshaft and exhaust side.
12.6 Put the engine into service (A3.05.00.nn).
en / 21.11.2000 IB022678 5/5

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


--------------------------------------------------------------------------------------------------------------------------------
Check:
Ease of movement of the explosion relief valve every 1,500 h
Tools:
Torque wrench 20 - 200 Nm W1 1.9454-202
Molykote Paste "G Rapid Plus“ *
Sealing compound "Dirko No. 610.020" *
Note:
Removal of the explosion relief valve (5) is only required if the specified spring 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).
en / 18.11.2008 IB026117 1/2

Explosion relief valve A5.05. 03.01.01.02
M43
1500
3.4 Tighten screws (8) to a torque of 03

M = 25 Nm.
3.5 After assembly check the explosion relief valve for proper operation by actuating it by hand.
3.6 When mounting the explosion relief valve on the crankcase door care has to be taken to ensure
proper sealing between seat and crankcase door.
en / 18.11.2008 IB026117 2/2

Coolant Distributor Housing A5.05. 03.02.00.00
M43


----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace O-rings
Tools:
Eye bolts M16 W1
Cylinder liner retainer W2* 439217 A
* no picture
Vaseline **
Procedure:
1. Remove coolant distributor housing.
1.1 Remove mounting bolts (Fig. 2/1) on the coolant block.
en / 28.07.1999 IB020182 1/3

M43
1.2 Loosen the sleeves (2) from the starting air channel and slide into opposite distributor housing. 03
1.3 Remove the distributor housing mounting bolts (3). Screw the eye bolts (Fig. 3/W1) into the
coolant distributor housing (6) and lift housing with crane.
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.
en / 28.07.1999 IB020182 2/3

M43
2. Install coolant distributor housing. 03

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

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

into place and secure.
2.4 Apply a light coat of Molykote to the coo-

lant block mounting bolts (1), slide into pla-
ce and tighten to
M = 100 Nm
Then tighten the bolts to
M = 260 Nm
2.5 Remove eye bolts (Fig. 3/W1).
2.6 Remove cylinder liner retainer (W2).
en / 28.07.1999 IB020182 3/3

Cylinder Liner A5.05. 03.03.01.01
M43/VM43
30000, 15000
See also: 02.06.01.nn, 03.04.01.nn 03

Personnel qualification: Chief engineer

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
- of one cylinder liner every 15,000 h
W1
- of all cylinder liners every 30,000 h
- of the cylinder liner each time a piston is removed, before 1

the removal and installation of a cylinder liner.
Tools:
Cylinder liner gauge rail W1 439218-001
Fine gauge inside micrometer W2 *, ** 1.9419 G
* no picture
** or equivalent measuring instrument
Procedure:
1. Check cylinder liner.
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)
1.1 Remove gauging ring and remove piston.
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
en / 25.08.2003 IB020186 1/2

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 .
Cylinder liner wear chart
Evaluation criteria Wear limit Explanation

(mm)
Nominal Ø (new)) * Limit value for conically

honed cylinder liners
430,0 + 0,063 ** Radius r ≥ 3 mm
Max. out-or-round 0,30 *** in circumferencial direction
Wear 0,75 TDC. 1st Ring

4 0,90 *
Gusset Height 13,00 wedge-shaped indentation across the

1 Depth ** 0,05 entire circumference, beginning from
the TDC of 1st. piston ring.
Canyon max. number 3 Individual deep blow-through ducts

5 Length 13,00 in the area of the first piston ring (TDC).
total width 6,00
Scores Number 3 Vertical and linear scores.

3 Length 250,00
Depth 0,05
Pocket Number 3 Irregular indentations.

Length 120,00
2 Width *** 40,00
Depth ** 0,03
3 4
2 5
***1
en / 25.08.2003 IB020186 2/2

M43
30000
See also: 02.06.01.nn, 03.03.01.nn 03


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Remove cylinder liner,
replace O-ring every 30,000 h
Tools:
Cylinder liner rig W1 439216 A

Cylinder liner retainer W2 439217 A
Attention:
The cylinder liner sealing surface must be protected from damage!
Procedure
1. Remove cylinder liner.
1.1 Remove piston (02.06.01.nn). Remove cylinder liner retainer (W2).
1.2 Measure wear (03.03.01.nn).
1.3 Insert rig (W1) with threaded rod and swivel cross arm (1) into the cylinder liner.
1.4 Fasten clamping plate (2) and swivel cross arm (1) securely with the nut (3).
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).
en / 28.07.1999 IB020188 1/2

M43
30000
1.7 Clean the sealing surface and O-ring groove thoroughly and check for damage. 03
1.8 Clean coolant area on the cylinder liner collar thoroughly.
1.9 Clean cylinder liner collar seat, upper and lower fitting bore in crankcase thoroughly.
en / 28.07.1999 IB020188 2/2

M43
See also: 03.03.01.nn, 03.04.01.nn 03


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Cylinder liner rig W1
- Liquid beef suet or green potassium

soap
Note:
Take complete measurements after instal-
ling a new cylinder liner.
After installing a new cylinder liner, the en-

gine must be broken in in accordance with
the break-in procedures A3.10.01.nn!
Procedure:
1. Clean the inside of the coolant distributor
housing (Fig. 1/1).
2. Place new O-ring (4) into the groove in the

coolant distributor housing.
Attention:
Place O-ring in the groove with fluid
beef suet or green potassium soap
without twisting!
3. Clean the cylinder liner contact

surfaces (2) on the crankcase (3).
en / 28.07.1999 IB020192 1/2

M43
4. Connect hoisting unit to the eye bolt on the rig (Fig. 1/W1) and lower the cylinder liner into the 03
crankcase (3).
5. Mount rig onto the cylinder liner to be installed in accordance with steps 1.3 and 1.4 of the disas-
sembly instructions (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).
en / 28.07.1999 IB020192 2/2

Engine Fasteners and Connections A5.05. 03.07.01.00
M43/VM43
150
See also: 02.02.01.nn, 06.01.01.nn 03

Spare parts list:

----------------------------------------------------------------------------------------------------------------------------------
Inspection:
all engine fasteners and connections for tightness and leaks.
Note:
The preventative inspection must be completed once to find leaks or loose bolted connections 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.
7. Check elastic bearing elements for damage.
en / 25.08.2003 IB020232 1/1

Camshaft Bearing A5.05. 04.01.01.00
M43
30000, 15000
See also: 02.01.01.nn, 04.01.02.nn 04


----------------------------------------------------------------------------------------------------------------------------------
Inspection:
- of the clearance of one camshaft bearing 15,000 h
- of the clearance of all camshaft bearings every 30,000 h
Note:
Camshaft bearings are subject to no load alternation. The bearings are only loaded at the lower
bearing area; the load here is relatively high. Light edging is not unusual.
Procedure:
1. Check camshaft bearing clearance
1.1 Remove the corresponding sight hole cover on the control side of the camshaft cover.
1.2 Check camshaft bearing /bearing journal clearance.

mm mm
0.26 - 0.32 0.5
Note:
When the wear limit has been reached, replace camshaft bearing (MaK customer service) and
check the bearing clearance of all camshaft bearings. Check the bearing journal running surfaces
of the corresponding camshaft bearing.
en / 28.07.1999 IB020303 1/1

M43
30000, 15000
See also: 02.03.03.nn, 04.04.01.nn 04


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

corresponding camshaft section after the 1st cylinder every 15,000 h
- Check the running surface of all camshaft bearings and

corresponding camshaft sections after the 1st cylinder every 30,000 h
Tools:
see 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).
en / 09.10.2006 IB020282 1/5

M43
30000, 15000
1.4 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3). Turn the cams- 04
haft to access and remove all bolts which are inaccessible. Remove all hex head bolts. Re-
place two opposing hex head bolts with longer bolts (W2).
Set measure “s“
s = 68 ± 0.5 mm
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 09.10.2006 IB020282 2/5

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!
1.5 Remove retaining bolt (Fig. 2/11).

2 12
10
1.6 Drive the camshaft bearing (4) out to the
right with a suitable wood block and rubber
mallet. Fill the bearing shell with card-
board.
1
1.7 Place cardboard or similar material around
the camshaft bearing journal.
1.8 Slide the camshaft to the right until it stops 11

(distance “s“) with a strip of wood.
Distance s = 68 ± 0.5 mm
4
1.9 Remove bolts (Fig. 1/W1).
Attention:
Apply no excessive or sudden force

when sliding! Do not damage the bea-
rings or bearing journals.
2
Note:
To check the last camshaft bearing, remove the oscillation damper (Fig. 2/10) (04.09.01.nn) and
slide to the right as far as possible!
en / 09.10.2006 IB020282 3/5

M43
30000, 15000
1.10 Check crankshaft bearing. 04

Replace (04.04.01.nn) if:
- the wear pattern is bad (running surface, lower bearing area, scoring).
1.11 Check the camshaft bearing for scuffing on the back of the bearing and replace if necessary
(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).
1.14 Install camshaft (04.04.01.nn).
1.15 Install bearing and align with positioning bore.
1.16 Install retaining bolt (Fig. 2/11). Tighten bolt to
M = 130 Nm
Note:
Install the oscillation damper after checking the last camshaft bearing (04.09.01.nn)!
2. Check the running surface of all camshaft bearings and camshaft sections after
the 1st cylinder.
2.1 Release and raise all rocker arms (04.04.01.nn).
2.2 Loosen the hex head bolts (Fig.1/1) on the left flange of the camshaft section (3) of the 1st cylin-
der. Turn the camshaft to access and remove all bolts which are inaccessible. Remove all hex
head bolts. Replace two opposing hex head bolts with longer bolts (W1). Set measure “s“.
2.3 Remove the retaining bolts (Fig. 2/11) on the camshaft bearings one after the other.
2.4 Drive out the camshaft bearings (4) to the right with a suitable wood block and rubber mallet. Fill
the bearing shell with cardboard.
en / 09.10.2006 IB020282 4/5

M43
30000, 15000
2.5 Slide the camshaft to the side (1.4 to 1.7). 04

2.6 Prop up the oscillation damper and the camshaft section above the 1st cylinder.
2.7 Check the running surfaces of the bearing journals of all camshaft sections for scoring.
2.8 Replace defective camshaft sections (04.04.01.nn).
2.9 Install camshaft (04.04.01.nn).
2.10 Install retaining bolt (11). Tighten bolt to
M = 130 Nm
2.11 Disengage the rotor.
2.12 Install rocker arms and complete all remaining work (04.04.01.nn).
en / 09.10.2006 IB020282 5/5

Bottom part for Valve Mechanism A5.05. 04.02.00.30
M43
See also: 01.01.01.nn, 01.02.01.nn, 07.02.01.nn 04

Personnel qualification: skilled engine hand / Assistant engine hand

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Mounting and removal device for lower valve drive W1 432135 A

consisting of:
Support, compl. W1.1
Guide rail, compl. W1.2
Bracket with hexagon bolt W1.3
Carriage W1.4
Arm, compl. (3x) W1.5
Support (only on cyl.1) W1.6
Screw W1.7
Tubular hexagon box wrench W1.8 *
Torque wrench 200-500 Nm W2 * 1.9454-500
* no picture
Molykote Paste "G Rapid Plus" **

Vaseline **
Procedure:
1. Disassembly:
1.1 Engage barring device.
1.2 Disassemble corresponding rocker arm bracket (01.02.01.nn).
1.3 Mark and disassemble push-rods (7). Push-rods may not be interchanged.
1.4 Disassemble corresponding camshaft cover.
1.5 Disassemble corresponding injection pump (07.02.01.nn)
1.6 Disassemble injection pump drive.
1.7 Loosen circlips (8) of oil pipes (9) and shift towards the centre of the pipe.
en / 30.09.2008 IB024513 1/7

M43
1.8 Remove oil pipes (9). 04

1.9 Remove clamping screw (10) and both lower fastening screws (11).
12
12
10
11 11
1.10 Bring into position support (W1.1) and firmly mount to cam follower bracket.
1.11 Bring into position arms (W1.5) and tension them by means of tubular hexagon box wrench
(W1.8).
W1.5 W1.1
12
9
12
en / 30.09.2008 IB024513 2/7

M43
1.12 In case of disassembly and assembly at cylinder 1 mount support (W1.6). Here the camshaft cov- 04
er is bigger.
W1.6
1.13 Mount guide rail (W1.2). Firmly tighten the nuts only after having aligned all parts of the device.
W1.4
W1.2
1.14 Put on carriage (W1.4). By means of setscrew (15) adjust height if necessary so that the screw
en / 30.09.2008 IB024513 3/7

M43
holes coincide. 04
W1.7 W1.2
9
W1.4
15
1.15 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
1.16 Remover upper fastening screws (12) of the cam follower bracket.
1.17 Bring into position bracket with hoist (W1.3).
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).
en / 30.09.2008 IB024513 4/7

M43
1.18 Engage hoist in support (W1.1) and tension it. 04

1.19 Roll out valve drive completely on the carriage.
W1.3
W1.5
W1.1
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).
1.21 Disassemble carriage (W1.4).
1.22 Disassemble guide rail (W1.2).
1.23 Lower complete valve drive with hoist and deposit on a suitable base support.
1.24 Remove support (W1.1).
en / 30.09.2008 IB024513 5/7

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).
2.3 Raise complete valve drive with hoist up to limit stop.
2.4 Mount guide rail (W1.2).
2.5 Mount carriage (W1.4).
2.6 Deposit valve drive on carriage (W1.4).
2.7 Separate connection to hoist.
2.8 Screw together carriage (W1.4) and support (W1.1). Use screws (W1.7).
2.9 Carefully roll valve drive into camshaft casing.
2.10 Make sure there is sufficient clearance for inlet and exhaust cam followers. Possible correction by
adjusting the arms (W1.5).
2.11 Insert spacer sheets (13).
Attention:
Spacer sheets (13) are adjusted to each
valve unit individually and may not be
interchanged upon reassembly.
2.12 Insert the two upper fastening screws (12)

of the valve drive with extension sleeves
(14) and slightly tighten.
2.13 Lower cam follower and disassemble arms

(W1.5).
2.14 Separate carriage (W1.4) and support

(W1.1).
2.15 Disassemble carriage.
2.16 Disassemble guide rail (W1.2).
2.17 Disassemble bracket with hoist (W1.3).
en / 30.09.2008 IB024513 6/7

M43
2.18 Remove support (W1.1). 04

2.19 Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus".
2.20 Insert the two lower fastening screws (11) with extension sleeves (14) and slightly tighten them.
2.21 Tighten fastening screws (11, 12) "crosswise" gradually until a torque of
M = 455 Nm
is reached.
2.22 Assemble clamping screw (10) and tighten to a torque of
M = 455 Nm.
Alternative tightening instructions for screws (10,11,12):
Lubricate threads and contact faces of screws (10, 11, 12) with Molykote Paste "G Rapid Plus"
and tighten screws in two steps as follows:
Step 1:
Preload screws to M = 270 Nm.
Step 2:
Mark screws and continue turning by a torque angle of α = 30°° by means of box wrench SW 35
(spanner size) (30° ≤ 1/2 hexagon)
455 Nm = 270 Nm + 30°°
2.23 Slightly lubricate new O-rings (16) with Vaseline and insert into the oil pipe grooves untwisted.
2.24 Insert oil pipes (9) into the cam follower shaft and assemble circlips (8).
2.25 Insert push-rods according to their marking.
2.26 Assembly injection pump drive.
2.27 Assemble injection pump (07.02.01.nn) .
2.28 Assemble push-rods (7).
2.29 Assemble rocker arm bracket (01.02.01.nn).
2.30 Check valve clearance (01.01.01.nn) .
2.31 Assemble valve cover.
2.32 Start prelubrication pump and check oil pipes (9) for leaks.
2.33 Assemble camshaft cover.
en / 30.09.2008 IB024513 7/7

Camshaft A5.05. 04.04.01.08
M43


----------------------------------------------------------------------------------------------------------------------------------
Tools:
Sling W1 * 439230 A
Hex bolts W2 *
Insert W5 * 1.9424-030
Reversible ratchet W6 * 1.9459-033
* no picture
Molykote Paste “G-Rapid Plus” **
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.
en / 31.01.2008 IB025492 1/8

Camshaft A5.05. 04.04.01.08
M43
1.3 Remove the injection pump of the corresponding cylinder and for all cylinders to the right of the 04
cylinder being checked (07.03.01.nn).
1.4 Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft sec-
tions to the right of the camshaft section being removed. Raise and secure the rokker arms for the
intake and exhaust valves as well as for the injection pump drives for the corresponding cylinder
and all cylinders to the right of this cylinder.
Z
Y
13
Y Z
1
5
4
W2
s
1
en / 31.01.2008 IB025492 2/8

Camshaft A5.05. 04.04.01.08
M43
1.5 When removing the last camshaft section: 1 12 04

10
1.5.1 Remove the oscillation damper (Fig. 2/10)
(04.09.01.nn) and slide to the right as far
as possible.
1.5.2 Remove the intermediate piece (12).
1.6 Place the sling (Fig. 3/W1) around the

camshaft section (3) between the exhaust 11
cam and injector cam and connect to the
lifting unit through the injection pump bore
in the crankcase.
4
1.7 Tighten the sling (W1) with the lifting unit.
1.8 Remove the retaining bolt (11).
W1
3 3 11
en / 31.01.2008 IB025492 3/8

Camshaft A5.05. 04.04.01.08
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
en / 31.01.2008 IB025492 4/8

Camshaft A5.05. 04.04.01.08
M43
04
Attention:
Apply no excessive or sudden force when sliding! Do not damage the bearings or bearing
journals.
1.13 Secure the right end of the camshaft with wooden wedges.
Attention:
Do not tilt the camshaft sections too much! Be very careful!
1.14 Fill the camshaft trough with cardboard or a similar material.
1.15 Pull the camshaft section (Fig. 4/3) out of the bearing block to the left while lowering the lifting
unit. Swing the camshaft section 90° and lift from the camshaft trough. Note the weight of the sec-
tion (ca. 200 kg).
1.16 Remove camshaft bearing (4) and inspect (04.01.02.nn), replace if necessary.
2. Assembly
2.1 Press the straight pin (Fig. 5/5) into the flange until it stops in accordance with the numbering
(see table) on the camshaft section flange.
Camshaft section Insert straight pin

for cylinder for code
1 4
2 7
3 2
4 5
5 4
6 3
7 6
8 1
1 7
2 6
3 5
4
5 3
5
en / 31.01.2008 IB025492 5/8

Camshaft A5.05. 04.04.01.08
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!
2.9 Apply Molykote to all hex head bolts (1).
2.10 Place the hex head bolts in the left camshaft section flange (as many as possible) and gradually
tighten at least three bolts to
M = 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.
en / 31.01.2008 IB025492 6/8

Camshaft A5.05. 04.04.01.08
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 After installing the last camshaft section:
2.16.1 Place the intermediate piece (Fig. 2/12) on the camshaft section (3) securely. The recess must be
placed into the camshaft section completely.
2.16.2 Insert the hex head bolts (1) into the connection between the camshaft section and the interme-
diate piece. Tighten the bolts hand tight. Then tighten the bolts gradually crosswise to
M = 420 Nm
Alternative Tightening Instruction for Bolts (1):
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)
420 Nm = 176 Nm + 30°°
en / 31.01.2008 IB025492 7/8

Camshaft A5.05. 04.04.01.08
M43
04
2.16.3 Install the oscillation damper (10 ) (04.09.01.nn).
2.17 Install valve actuators and the injection pump drives.
2.18 Install the lifters.
2.19 Install the rocker arms and check valve clearance (01.01.01.nn).
2.20 Install injection pump (07.02.01.nn).
2.21 Check oil flow through camshaft.
2.22 Mount housing cover.
2.23 Close indicator valves.
2.24 Remove turning unit (12.08.01.nn).
en / 31.01.2008 IB025492 8/8

Timing Gear Train A5.05. 04.08.01.02
M43
15000, 3750
See also: 02.01.01.nn 04


-------------------------------------------------------------------------------------------------------------------------------
Inspection:
of the tooth profiles and oil nozzle every 3,750 h
the axial clearance of the step gear every 15,000 h
Tools:
Dial gauge with bracket

* no picture
Molykote Paste “G-Rapid“ **
Procedure:
1. Checking the tooth profiles and oil nozzles.
1.1 Remove the timing cover from the control and exhaust side.
en / 25.03.2004 IB024301 1/3

M43
15000, 3750
1.2 Check the tooth profiles on the camshaft gear (Fig. 1/2), step gear (1) and 04
crankshaft gear (3) for pitting, misaligned running, loose metal, etc.
1.3 Measure the tooth clearance between the step gear and the camshaft gear (2) and between the
step gear and the crankshaft gear (3).
Nominal values x = 0.23 - 0.40 mm

z = 0.23 - 0.41 mm
1.4 Check the function and seat of the oil nozzles (4 and 5).
en / 25.03.2004 IB024301 2/3

M43
15000, 3750
2. Measure the axial clearance of the step gear (Fig. 2/s) with a feeler gauge or dial gauge. 04
Nominal 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.
en / 25.03.2004 IB024301 3/3

M43
See also: 02.01.01.nn 04


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

Reversible ratchet 1/2" W2 * 1.9459-033
* no picture
Molykote Paste “G-Rapid” **
en / 31.01.2008 IB024305 1/3

M43
Note: 04
The work specified in the following can only be carried out when the flywheel is removed.
Procedure:
1. Replace the O-ring (Fig. 2/6) on the step gear shaft (2).
1.1 Loosen the hex head bolts

(7 and 8) and remove with sleeves (5) and locking plates (3 and 4).
1.2 Remove the crankcase cover for the 1st cylinder.
1.3 Press the step gear shaft (2) out of the gear housing towards the coupling only far enough that
the O-ring (6) is accessible.
1.4 Replace the O-ring (6) and slide the gear shaft back into place.
en / 31.01.2008 IB024305 2/3

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.
1.7 Tighten hex head bolts (7 and 8) to
M = 190 Nm
en / 31.01.2008 IB024305 3/3

Governor Drive A5.05. 04.08.03.02
M43
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
- contact pattern at hypoid gear pair every 15,000 h

- contact pattern at intermediate wheel
- channel toothing of governor drive shaft
- end play of cam shaft toothed wheel
Tools:
Reversible ratchet 1/2" W2* 1.9459-033
* not shown
Ancillary materials:
Sealant “Dirko 610.020“ **
Procedure:
1. Disassembly
1.1 Detach governor floater linkages from

governor (Fig. 1/10) This is achieved by:
1.1.1 Locking stop lever in stop position.
1.1.2 Removing locking nut (1) with distance

bushing (4), bolt (6) and washer (2).
1.1.3 Removing spring link (7).
1.2 Removing hexagonal screws (11) and

lifting governor (10).
en / 13.02.2009 IB023455 1/4

M43
15000
1.3 Removing hexagonal screws (Fig. 2/20) with resilient sleeves (21). 04
1.4 Lightly attach governor drive housing (23) with sling to hoist and carefully lift out of
cylinder crank housing.
Attention:
Risk of damage to lubricating oil passage sleeve (30) and O-ring (31).
1.5 Deposit governor drive housing (23) onto suitable surface.
1.6 Clean bearing surfaces on engine block.
en / 13.02.2009 IB023455 2/4

M43
15000
1.7 Check tooth profiles of hypoid gears (Fig. 3/40, 41) for pitting, off-track running or blow-outs. 04
Check intermediate wheel (42).
1.8 Check channel toothing of governor drive shaft (43) and governor (Fig. 1/10) for wear, clean if
necessary.
1.9 Check all oil lubrication holes for lubricating the governor drive gear and the hypoid gears for
proper flow.
en / 13.02.2009 IB023455 3/4

M43
15000
2. Assembly 04
2.1 Provide lubricating oil passage sleeve (Fig. 2/30) with new O-rings (31).
2.2 Place governor drive housing (23) carefully onto engine block by means of a crane. During this
operation absolutely pay attention to lubricating oil passage sleeve (30) and dowel pins (Fig. 3/
32).
2.3 Insert screws (Fig. 2/20) with resilient sleeves (21).
2.4 Tighten screws (20) crosswise.
2.5 Brush bearing surface of governor with “Dirko 610.020“. Put governor (Fig. 1/10) onto
bearing surface of governor drive (Fig. 2/23).
Note:
The channel toothing of the governor shaft must slide easily into the channel toothing of the gov-
ernor drive shaft (Fig. 3/43).
2.6 Insert screws (Fig. 1/11) and tighten firmly.
2.7 Fit governor floater linkages in reverse order to removal. If necessary, carry out readjustment of
governor (also see governor adjustment, Book C).
en / 13.02.2009 IB023455 4/4

Vibration Damper on Camshaft A5.05. 04.09.01.00
M43
15000
See also: 04

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not available as figure
Auxiliary material: 1
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
Attention, there is a risk of injury!

Never open a vibration damper
1. Disassembly
1.1 Remove lateral and face casing covers.
1.2 Release screws (2) and remove together with 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).
2.2 Lubricate the thread of screw (2) with Molykote-Paste "G-Rapid".
en / 31.01.2008 IB020809 1/2

Vibration Damper on Camshaft A5.05. 04.09.01.00
M43
15000
2.3 Mount distance ring (5).. 04

2.4 Push new damper (1) onto intermediate piece (4) and screw in screws (2) with extension sleeves.
2.5 Tighten screws (2) with a torque of
M = 130 Nm
2.6 Mount lateral and face casing covers.
en / 31.01.2008 IB020809 2/2

Control Shaft Bearings A5.05. 05.01.02.00
Maintenance / Checking
M43/VM43
750
See also: 05.08.01.nn 05

Spare parts list: B1.05.04.434110, B1.05.05.434210, B1.05.05.434523

----------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil control shaft every 750 h
Multi-purpose grease as per A4.05.08.nn
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!
3. Grease the following bearings with multi-purpose grease:
• Jointed heads on the connecting rod between the shaft in the operating console and
the control shaft.
• Jointed heads on the spring member between the control shaft and the control unit.
Remove all grease which exits the bearing carefully.
4. Oil all movable bearings on the jointed lever between the control shaft and injection pump lightly.
5. Reinstall cover.
en / 12.06.2008 IB020299 1/1

M43
7500
See also: A3.05.nn 05

Spare parts list: B1.05.05.1.4906

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
of the starting valve every 7.500 h
Tools:
Fork wrench W1* 0.9105 A
Auxiliary material:
Molykote paste “ G-Rapid “ **
~ 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.
en / 30.11.1999 IB020586 1/4

M43
7500
1. Close the main shut-off valve on the air receiver.
1.1 Vent the air pipes on the engine.
1.2 Disassemble all pipework and cable connections from the starting valve.
Disassembly:
2. Unscrew the screws (Fig. 1/1) and disassemble the starting valve from the engine.
en / 30.11.1999 IB020586 2/4

M43
7500
3. Disassemble the protective cover (Fig. 2/2). 05

3.1 Disassemble the silencer (3) and remove the solenoid (4).
3.2 Disassemble the armature (5) by slackening the screw connection (6).
Pay attention to the spring (7).
3.3 Slacken the screw connection (8) and pull out the emergency actuation knob (9).
3.4 Disassemble screw connection (11) and nut (12).
3.5 Disassemble piston (13) by means of the fork wrench (W1).
Note:
When disassembling nut (12) and piston (13) secure the spindle (14) against being dragged 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).
3.7 Remove the spindle (14) completely from the casing.
4. Clean the casing by means of gas oil. Check the sliding surfaces for rust formation, if necessary
carefully rework with polishing cloth.
en / 30.11.1999 IB020586 3/4

M43
7500
Reassembly: 05
5. Renew all O-rings, piston guide ring (19) and other sealing rings. Grease the sliding surfaces
slightly.
5.1 Insert a new, completely assembled spindle (14).
5.2 Assemble all valve parts in inverse disassembly order.
5.3 Assemble the emergency actuation knob (9) with a new spring (10) and a new O-ring (20).
Note:
Daub the threads of all fixing screws slightly with Molykote paste "G-Rapid".
5.4 Put the finish assembled valve onto the engine. Firmly tighten the screws (Fig. 1/1)..
5.5 Mount all pipe and cable connections.
5.6 Mount the protective cover (Fig. 2/2).
6. Open the main shut-off valve on the air receiver.
7. Carry out a functional and leakage test with starting air.
en / 30.11.1999 IB020586 4/4

Control Rod A5.05. 05.08.01.00
M43
7500
See also: 05.01.02.nn 05


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace the bushings every 7,500 h
Procedure:
6
8
7
1. Remove bushings (1).
1.1 Disassemble the connection between the

injection pump control rod (Fig. 1/7) and
jointed lever (8) on the control shaft.
1.2 Remove the bracket (6) from the jointed

lever.
X
1.3 Remove the bushings (Fig. 2/1) from the
bracket (6).
2. Install bushings (1).
Note:
As a matter of principle, new nuts (2)
are to be used after each loosening
operation [turning back of the nuts (2)]
2.1 Place new bushings (1) into the

bracket (6).
1
2.2 Connect the bracket (6) to the jointed shaft
by installing the pin (3), the washers
(4 and 5) and a new nut (2).
2.3 Tighten the nut (2) with a torque of

M = 40 Nm
en / 06.08.2008 IB020301 1/2

Control Rod A5.05. 05.08.01.00
M43
7500
2.4 Connect the bracket (6) to the injection pump control rod by installing the pin (3), the washers (4 05
and 5) and a new nut (2).
2.5 Tighten the nut (2) with a torque of

M = 40 Nm
Attention:
Check the linkage for ease of movement by pressing against the jointet lever. If the linkage
is sluggisch, readjust the injection pump and / or the linkage on the control shaft.
X
4 1 6
6 1 5 3
2
8
en / 06.08.2008 IB020301 2/2

Compressed-Air Filter A5.05. 05.09.06.00
M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
See also: 05

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
Auxiliary material:
Nitro-Solvents *
~ 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!
en / 30.05.2000 IB021438 1/2

M20/M25/M32/M43/M453C/M552C/M601C
24, 7500
1. Drain compressed-air filte

1
1.1 Loosen drain plug (7) and empty filter
completely.
1.2 Close drain plug.
2. Disassemble compressed-air filter and 2

clean
2.1 Loosen drain plug (7) and drain filter 3

completely.
4
2.2 Close compressed-air feed line and
secure. 5
2.3 Relieve compressed-air filter via drain

plug.
2.4 Loosen housing cap (5) and remove, 6

check O-ring (1) and replace if necessary.
8 7
2.5 Loosen Phillips screw (4), remove with
guide (3) and filter element (2).
2.6 Remove locking ring (8), unscrew drain

plug and check O-ring (6), replace if ne-
cessary.
2.7 Clean all disassembled parts and check for reuse.
2.8 Assemble compressed-air filter in reverse sequence. Open shut-off valve in the compressed-air
supply line.
2.9 Close drain plug after a short while.
en / 30.05.2000 IB021438 2/2

M20/M25/M32/M43
24, 7500
See also: C5.05.05.45.23.nn 05


--------------------------------------------------------------------------------------------------------------------------------
Maintenance/cleaning:
Drain compressed-air filter: every 24 h
Disassemble and clean compressed-air filter: initially 150 h
Disassemble and clean compressed-air filter: every 7,500 h
Maintenance and trouble shooting: refer to manual C

C5.05.05.45.23.nn
en / 23.03.2007 IB024847 1/1

Exhaust Line A5.05. 06.01.01.12
M43
7500
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Inspection:
The exhaust line must be checked for leaks every 7,500 operating hours.
High temperature thread paste "B & W Rivolta G.W.F“ *
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.
en / 28.04.2004 IB024377 1/3

Exhaust Line A5.05. 06.01.01.12
M43
7500
3. Carbon, which can especially be found at flange connections and compensators, is a sign 06
of leaks.
Note:
If leaks are not caused by cracks in the lines or loose bolted connections, new gaskets must be
installed, see 4.8.
4. Replace any defective exhaust lines as follows:
4.1 Loosen and remove adjacent compensators (4).

Compensators may not be subjected to bending or radial forces!
4.2 Loosen the hex head bolts (1) far enough that the upper sections of the clamps (3) are still con-
nected but can be slid easily.
4.3 Slide the upper sections of the clamps aside, remove the chain links (2) from the lower clamp sec-
tion on both sides.
4.4 Lift both upper clamp sections simultaneously, replace defective exhaust line.
4.5 Prepare fitted pieces (x or y) for the installation of the new exhaust line.
Fitted piece length e x = 130 mm

Y = 195 mm
en / 28.04.2004 IB024377 2/3

Exhaust Line A5.05. 06.01.01.12
M43
7500
4.6 Bolt fitted piece or pieces to new exhaust line. 06

4.7 Mount exhaust gas pipe with new seal (5) and clamp tops.
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.
5. Replace any compensators with cracks in the bellows, see 4.8.
6. Install shroud.
en / 28.04.2004 IB024377 3/3

Charge Air Cooler A5.05. 06.04.02.30
M43
See also: 06

-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
The charge air cooler must be removed and cleaned on the air side when the differential pressure
before/after the cooler exceeds 1.5 times the test bench value (see acceptance brake certificate
A1.10).
Cleaning agent as recommended by the manufacturer, such as:
• Vecom GmbH, Hamburg *

• Drew Ameroid GmbH, Hamburg *
• UNITOR chemicals *
Molykote Paste "G-Rapid Plus“ *
Procedure:
1. Disassembly
1.1 Loosen the bleeder bolts, or for engines with continual bleeding, ensure that the corresponding
cock valves are open, remove the drain bolts (Fig. 1/5) and drain water from charge air cooler.
1.2 Remove the coolant feed and return lines(4) from the charge air cooler.
en / 17.04.2008 IB024499 1/3

M43
1.3 Remove hexagon screws (Fig. 2/28) with washers (37). 06
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!
en / 17.04.2008 IB024499 2/3

M43
2. Assembly 06
2.1 Install charge air cooler in the reverse order as disassembly.
2.2 Insert new O-ring (8) into O-ring sheet (9).
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.
2.4 Insert hexagon screws (28) with washers (37).
2.5 Tighten hexagon screws (28) one after the other to a torque of
M = 130 Nm.
2.6 Attach coolant supply and return lines (4) to the charge air cooler.
2.7 Tighten drain bolts (5) and fill engine completely with coolant.
2.8 Tighten bleeder bolts or the corresponding cock valves tightly.
en / 17.04.2008 IB024499 3/3

Exhaust gas turbocharger A5.05. 06.05.00.30
M43
24
See also: A5.05.06.13.01.nn, A3.06.06.nn 06

Spare parts list: B1.05.06.437259 nn

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Compressor cleaning RM43C every 24 h
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.
Operation of the air-side washing device:
Basic position
- Washing water container (2) : EMPTY
- Cap (1) : closed
Washing procedure:
1. Remove cap (1) from water container (2).
1.1 Fill water container (2) with clean water.
1.2 Return cap (1) to its position and tighten.
Attention:
A water container that has not been closed or closed incorrectly may cause injury of the
operator.
en / 22.11.2007 IB024495 1/3

M43
24
06
1
3
2. Push valve handle (3) against the spring and hold for approx. 10 seconds until the entire
water volume has been injected.
Note:
After cleaning the air side, the engine should be run under load for at least 5 minutes.
When the compressor impeller was contaminated, the success of a cleaning can be told by the
charge air pressure after the turbocharger.
Cleaning parameters for ABB TPL 76-C33 turboloader are as follows :
Turbocharger rpm: Full load – speed (at least 85 % )

hydrostatic pressure: none
diaphragm : yes
water injection time : 10 seconds
water volume : 1.0 liters
en / 22.11.2007 IB024495 2/3

M43
24
06
Attention:
Because of the increased risk of corrosion, only clear water (drinking water) - never salt
water - may be used for cleaning. This water should not contain any coolant treatments or
other chemicals which may form deposits in the air ducts.
Attention:
The injection tube must never be connected directly to city water, to a different or larger
metering device or a larger water container than those provided by Caterpillar Engines.
Attention:
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can
cause personal injury and major damage.
Additional details on the exhaust turbocharger may be found in the maintenance instructions in book C or
in the operator’s manual from the turbocharger manufacturer.
Instructions for emergency engine operation with a defective turbocharger see User Manual A3.12.01.nn.
en / 22.11.2007 IB024495 3/3

M43
150
See also: A5.05.06.05.00.nn, A3.06.06.nn 06

Spare parts list: B1.05.06.437259 nn

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Turbine cleaning RM43C every 150 h
Prerequisites: - wet cleaning
wet cleaning of the turbine and the nozzle ring requires low exhaust temperatures and low engine
load*.
Note
The cleaning effect during turbine washing is caused by the mechanical impact of the water drop-
lets as well as by the water solubility of the deposits.
Attention:
Please note that these cleaning instructions apply only to the engines listed on cover A0
and thus, only the “low load washing“ cleaning type:
“WASHING OF TURBINE AND NOZZLE RING AT LOW EXHAUST GAS TEMPERATURE OR

AT LOW ENGINE LOAD *“
may be used.
* Definition of low engine load:
Low engine load means either that the engine
- is running either, at zero pitch and rated speed

- or, on the grid at rated speed and a max. of 20 % load
- or, disengaged at rated speed.
en / 27.11.2008 IB024491 1/4

M43
150
Requirements for water and air feeds for washing turbine and nozzle ring: 06
Note:
Water flow is controlled by a diaphragm (2) upstream from control valve (1).
These are the cleaning parameters for ABB TPL 76-C33 turbocharger:
temperature before turbine intake: < 430 ° C

=
injection time: a min. of 10 minutes
water pressure before control valve : 2.0 bar ± 0.2 bar
volume flow: 0.43 to 0.50 Liter/sec
needle valve opening diameter no needle valve
diaphragm: yes
pressure after pressure reducer: 1.0 bar
Quality requirements for water for washing turbine and nozzle ring:
Clear freshwater (drinking water) without cleaners or solvents is to be used.
The wash water used should have minimal mineral and salt content.
Notes on the cleaning procedure:
During cleaning, the water should be drained from the gas outlet casing. The water flow must be
controllable, and the water drain line must regularly be checked for deposits.
The exhaust gas temperature after the turbocharger will decrease considerably during cleaning
(down to between 50° and 100°C).
Attention:
At rated speed and zero load, washing water must flow from the drain line (7); if the wash-
ing water does not drain, 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.
en / 27.11.2008 IB024491 2/4

M43
150
Cleaning procedure 06
Note
After start of engine or reduction of engine load.
The exhaust gas temperature before the turbine may not exceed 430 °C.
Lower values will yield improved washing results.
Sequence:
1. Wait for 10 to 15 minutes until after the exhaust gas temperature has stabilized and is below
430 °C.
2. Control valve (1) on the control panel is locked in the “Operation (air)“position.
3. Shut-off valve (4) is closed.
4. Connecting the water supply to shut-off valve (4) before pressure meter (5).
Check if the water supply is ensured.
Note:
Before washing check the basic function of the drain (funnel duct) (3). To this end, open drain val-
ve (3) for a short time and then close it again. In doing so, a distinct flow of exhaust gas must be
noticeable.
Attention:
The emerging exhaut gas may cause burns, therefore never check the drain with unpro-
tected body parts.
3 1
7
2
5
en / 27.11.2008 IB024491 3/4

M43
150
5. Open drain valve (3). 06

Note
Along the funnel duct at drain valve (3), the operator may see the results of the cleaning from the
cleanliness of the draining water.
6. Open shut-off valve (4); pressure meter (5) should indicate a pressure of
p = 2,0 ± 0, 2 bar
.
7. Pull up on control valve (1) on the control panel and hold for 10 minutes.
8. Check if exhaust gas temperature after turbocharger decreases.
9. Closing shut-off valve (4).
10. Return control valve (1) on the control panel to its “Operation (air)“position.
Attention:
After washing, the water supply must be disconnected completely; i.e., including shut-off
valve (4) pressure meter (5) from the fitting on control valve (1).
11. After approx. 5 minutes, close drain valve (3), completing this cleaning procedure.
12. Disconnect the water supply completely, including shut-off valve (4) and pressure meter (5) from
the fitting on control valve (1).
13. If necessary, the cleaning procedure may be repeated.
14. If the engine will not be operated for an extended period of time, the drying air may be turned off
at valve (6) on the control panel in order to save pressurized air.
Attention:
Avoid getting uncontrolled amounts of water into the turbocharger or the engine. This can
cause personal injury and major damage.
In order to prevent corrosion on the inside surfaces of the housing, the engine must be
run at the same load stage for ten more minutes.
Due to increased corrosion risk from wash water residues in the exhaust system, we rec-
ommend not performing the washing procedure before longer engine standstill periods.
For additional instructions, see User Manual A3.06.06.nn.
en / 27.11.2008 IB024491 4/4

Turbocharger A5.05. 06.14.01.00
M43/VM43
12000, 24000, 36000
See also: C5.05.06.10.2n.nn 06

Spare parts list: B1.05.06.43725n, B1.05.06.437259

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Exhaust gas turbocharger:
Dismount, clean and check every 12.000 h

Exchange the nozzle ring and the diffuser after 24.000 h
Exchange the axial and radial bearing after 36.000 h
Note:
Caterpillar points out that this maintenance sheet has only been configurated for the 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.
Book C contains the operating and maintenance instructions for the
ABB Exhaust Gas Turbocharger Types TPL 71/73/76/77
The manufacturer recommends to carry out the maintenance measures when reaching
the above-mentioned operating periods.
Attention:
Please observe the particular safety and assembly instructions in "Book C" of the
manufacturer's documentation!
en / 31.10.2007 IB024902 1/1

Injection Pump A5.05. 07.02.01.00
M43

Spare parts list: B1.05.04.433580, B1.05.07.438510, B1.05.07.438540, B1.05.08.438480

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Lifting device for injection pump W1 439235 B
Torque wrench W2 * 435100 A
Socket , width across flats 41 W3 * 435102 B
Socket wrench for indicator valve W5 * 1.9100-060
Auxiliary material:
1. Disassembly
1.1 Open the indicator valves.
1.2 Remove corresponding camshaft casing

cover on camshaft side.
1.3 Remove the high-pressure injection pipe

(07.05.01.nn) .
1.4 Mount the injection pump lifting device

(Fig. 1/W1). To this end use the threaded
holes for fastening the high-pressure pipe.
1.5 Turn the engine so that the cam follower

(2) of the corresponding injection pump
drive is on the base circle of the fuel cam
(1).
en / 16.02.2009 IB020380 1/6

M43
1.6 Close the shut-off valves. 07

1.7 Drain the fuel distributing/collecting line on
the fuel duplex filter.
1.8 Remove the lubricating oil leakage line

(Fig. 2/10), fuel leakage line (Fig. 3/20,
21) and control air pipes (Fig. 4/30, 31) of
the corresponding injection pump.
Note:
To remove the two outer 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).
1.9 Remove the fuel distributing/collecting line (07.15.01.nn).
en / 16.02.2009 IB020380 2/6

M43
07
1.10 Disassemble the connection (Fig. 5/40) between injection pump control rack (41) and control
shaft.
en / 16.02.2009 IB020380 3/6

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:
1.12 Put on the torque wrench (W2) and evenly slacken the nuts (5).
Hydraulic pressure p = 500 bar
1.13 Attach the injection pump (6) with lifting device (W1) to a crane and lift from the engine block.
1.14 Remove the sleeve (Fig. 5/50) with O-rings (51).
en / 16.02.2009 IB020380 4/6

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.
2.3 Mount sleeve (Fig. 6/50) with new O-rings (51).
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
p = 500 bar ( 740 Nm )
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).
2.9 Mount the high-pressure injection pipe (07.05.01.nn).
2.10 Mount the fuel distributing/collecting line (07.15.01.nn).
2.11 Mount the screws of the fuel filter lines (admission and return).
en / 16.02.2009 IB020380 5/6

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).
2.14 Mount the camshaft casing cover on camshaft side.
2.15 Open the shut-off valves.
2.16 Fill the fuel system by means of the stand-by pump and have it circulate the fuel for about 10 mi-
nutes to vent the system.
2.17 Close the indicator valves.
en / 16.02.2009 IB020380 6/6

M43/VM43
15000, 7500
See also: 07.02.01.nn, 07.03.02.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
a) of one injection pump every 7,500 h
b) of all injection pumps every 15,000 h
Tools:
Pressure pipe W1 * 1.9470-051
Nozzle testing device W2 * 1.9470 H
2 x cheese head screw M16x150 DIN 912 W5 *
Adapter for injection pump W6 * 432147 A
* no picture
Molykote Paste "G-Rapid Plus“ **
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.
en / 29.01.2009 IB022649 1/6

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.
en / 29.01.2009 IB022649 2/6

M43/VM43
15000, 7500
2. Disassembly 07
2.1 Clean the outside of the injection pump.
2.2 Remove deflector bolts (Fig. 1/6).
2.3 Check defector bolts for cavitation in the

deflector surface, replace deflector bolts if
necessary (07.03.02.nn).
2.4 Clamp the injection pump with the valve

support (20) down.
~ Attention!
Caution! The spring tension of the
pump spring (9) presses against the lo-
wer pump housing section (4)!
2.5 Release and dismantle two opposite

screws (Fig. 3/36)
2.6 Replace by longer screws (W5). (Assem-

bly aid).
2.7 Slowly dismantle the remaining screws

(36).
2.8 Slowly dismantle the assembly aid screws

(W5).
2.9 Carefully lift the bottom pump housing (4)

by means of a crane, until the slotted disk
(26) of the pump spring (9) is clear.
Note:
Take care that the tappet body (2) is also
lifted up.
2.10 Take the slotted disk (26) sideways out of

the foot of the pump plunger (50).
en / 29.01.2009 IB022649 3/6

M43/VM43
15000, 7500
2.11 Remove the pump spring and check for corrosion. 07

2.11.1 Remove the control sleeve (5) with spring plate (7).
2.11.2 Check the toothing in the control housing for damage.
2.11.3 Loosen guide bolt (11), remove control rod (Fig. 2/10) and check control rod toothing for damage.
2.12 Remove stop piston (15):
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.
2.18 Replace all O-rings and gaskets.
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.
Check all injection pump parts for damage and wear.
In particular, check for the following wear:
Pump piston Grooving on the running surface, metering edge wear (cavitation or erosi-
on). Blackening or spots on the piston indicate water in the fuel.
Piston guide Grooving in the running surface; damage in the pump element sealing sur-
face. Cavitation in the feed bore.
Deflector bolts Cavitation in the deflection surfaces.
en / 29.01.2009 IB022649 4/6

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).
Lower spring Grooving / damage in the contact surface.

plate
3. Assembly
3.1 The pump is assembled in the reverse order as disassembly.
Attention:
As is the case with all injection pump parts, the sealing surfaces cannot and may not be re-
worked on board!
During the assembly absolutely make sure that the pump plunger (50) is in correct positi-
on with respect to the guide in the control sleeve (5).
When installing the injection pump, make sure that the control rod is positioned exactly in
relation to the control sleeve and that the markings on the control sleeve and pump piston
match up!
A tooth is milled into the control sleeve in order to allow the control sleeve to be positio-
ned in relation to the control rod. The control rod is equipped with a double tooth.
The control rod double tooth must mesh with the tooth gap in the control sleeve!
3.1.1 Coat the thread and contact faces of all screws with Molykote-Paste „G-Rapid Plus“ and tighten to
the respective torque:
Deflector bolts (Fig. 1/6) M = 200 Nm
Cheese head screws (27) M = 45 Nm
Cheese head screws (35) M = 60 Nm
Choke screws (Fig. 2/14 and 17) M = 60 Nm
3.1.2 Tighten cheese head screws (Fig. 4/33) - outer hole circle - according to the sequence
(1, 7, 4, 10, 2, 8, 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.
1. Step according to the sequence by applying M = 60 Nm
en / 29.01.2009 IB022649 5/6

M43/VM43
15000, 7500
3.1.3 Tighten cheese head screws (Fig. 4/36) according to the sequence 07
(19, 21, 22, 20)
in three steps.
3.1.4 Check the action of the control rod (Fig. 2/10); must be smooth.
en / 29.01.2009 IB022649 6/6

Deflector Bolts A5.05. 07.03.02.00
M43/VM43
3750, 7500
See also: 07.03.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Alternate inspection of the deflector bolts of two injection pumps every 3.750 h
Replacement of all deflector bolts after 7.500 h
Tools:
Caliper gauge W1*
* no picture
1. Remove deflector bolts.
1.1 Check deflector bolts (6) for cavitation (Y) of the deflection surfaces (X).
1.2 Maximum permissible wear value s = 4 mm.
X Y
en / 31.01.2008 IB024554 1/2

Deflector Bolts A5.05. 07.03.02.00
M43/VM43
3750, 7500
1.3 To check this use the depth gauge of the caliper gauge. 07
1.4 When the above wear value is reached, replace deflector bolts (6) with new ones.
2. Mount deflector bolts.
2.1 Lightly lubricate thread and contact faces of the deflector bolts with engine lubricating oil.
2.2 Tighten new deflector bolts (6) by hand.
2.3 After that, tighten deflector bolts to a torque of
M = 200 Nm.
en / 31.01.2008 IB024554 2/2

Pressure Valve A5.05. 07.03.03.00
M43/VM43
See also: 07.05.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
* 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
1.1 Close shut-off valves of the fuel line.
1.2 Empty the fuel distributing and collecting pipe on the fuel duplex filter.
1.3 Remove the fuel injector delivery pipe of the corresponding injection pump (07.05.01.nn).
en / 31.01.2008 IB024603 1/2

Pressure Valve A5.05. 07.03.03.00
M43/VM43
1.4 Remove cheese head srews (1 und 2).. 07

1.5 Remove valve support (3). Pay attention to
dowel pins (5).
1.6 Remove pressure valve (4).
2. Assembly
2.1 Insert new pressure valve (4) into valve

support (3).
2.2 Replace O-ring (6).
2.3 Put valve support (3) onto injection pump.

Pay attention to dowel pins (5).
2.4 Lubricate threads and contact faces of

cheese head screws (1 und 2) with engine
lubricating oil.
2.5 Tighten cheese head screws (1) crosswise

to a torque of
M = 190 Nm.
2.6 Tighten cheese head screws (2) crosswise

to a torque of
M = 190 Nm.
2.7 Replace O-ring (7).
2.8 Mount fuel injector delivery pipe

(07.05.01.nn).
2.9 Open shut-off valves of the fuel line.
en / 31.01.2008 IB024603 2/2

M43/VM43
See also: 07.02.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
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.
The viscosity during HFO operation has to be within 12 - 13 cst.
en / 25.08.2003 IB023228 1/1

High-Pressure Injection Pipe A5.05. 07.05.01.00
M43/VM43
See also: 07.07.01.nn, 07.08.01.nn 07

Spare parts list: B1.05.01.432107, B1.05.07.432260, B1.05.07.438526

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

Open jawed spanner for torque wrench W3 * 1.9106 A
Auxiliary material:
Molykote-Paste “G-Rapid Plus“ **
Note:
In the event of heavy fuel 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.
1. Disassembly
1.1 Valve cover is removed.
en / 31.01.2008 IB020575 1/4

M43/VM43
1.2 Disassemble the fillister head screws (Fig. 2/1) with cover (3) and O-ring (2). 07
1.3 Loosen the clamping screw (4) (about 5 turns).
1.4 Loosen the pressure screw (6) and disassemble it.
1.5 Take the transverse thrust piece (15) out of the receptacle (14).
1.6 Screw the cap screw (8) out of the cylinder head/injection nozzle holder (20).
1.7 Take the complete radial thrust piece (13) with cap screw (8) out of the cylinder head
through the receptacle (14).
1.8 Disassemble the spring ring (10) from the cylinder head and take out the sleeve (12).
1.9 Remove the fillister head screws (16) and carefully draw the receptacle (14) off the injection pump
connection (17).
en / 31.01.2008 IB020575 2/4

M43/VM43
2. Reassembly 07
2.1 Renew the O-rings (2, 5, 7, 9, 11).
2.2 Daub the O-rings and sealing faces with "Molykote".
2.3 All high-pressure surfaces must be free of dirt and damages.
2.4 Daub the threads of cap screw (8), pressure screw (6), and clamping screw (4) slightly with "Mo-
lykote" as well as all high-pressure sealing faces and pressure faces (4 and 6).
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 !).
en / 31.01.2008 IB020575 3/4

M43/VM43
2.11 Tighten the pressure screw (6) and the clamping screw (4) alternately and step by step starting 07
with a torque of
M = 100 Nm
each, until the prescribed torque of
M = 250 Nm
is reached for pressure screw (6) and clamping screw (4).
2.12 Tighten the fillister head screws (16).
2.13 Tighten cover (3) and O-ring (2) by means of fillister head screws (1).
2.14 Check the injection system for leakage and reassemble the valve cover.
en / 31.01.2008 IB020575 4/4

Fuel Injector A5.05. 07.07.01.02
M43/VM43
See also: 07.02.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Tools:
Pulling unit for injector valve W1 439111 A
Cleaning tool for injector seat W2 * 439222 B
* no picture
Molykote Paste "G-Rapid“ **
High temperature thread paste
"Dag S 5420 A“ **
Note:
When operating the engine with heavy
fuel oil, the engine must be operated for at
least 0.5 hours with distillate fuel before
working on the injector system to rinse the
injector valve thoroughly.
1. Disassembly
1.1 Remove the valve cover.
~ Disassemble the high-pressure injec-

tion pipe only after complete mounting
of pulling unit (W1).
1.2 Loosen hexagon nuts (Fig. 1/1), remove

extension sleeves (12) and flange (3).
1.3 Reassemble extension sleeves (12).
1.4 Bolt the injector valve pulling unit

(Fig. 2/W1) securely to the adjuasting
screw (Fig. 1/8) of the injector valve (4).
To this end:
en / 29.02.2008 IB025651 1/3

M43/VM43
1.4.1 Put in place the complete unit. 07

25
1.4.2 Loosen the hexagon head bolts (Fig. 2/20) 24
a bit and firmly screw the threaded pieces 20
(21) onto the extension sleeves (2) up to
stop.
21
1.4.3 Firmly tighten the hexagon head bolts
(20).
22
1.4.4 Firmly screw the threaded rod (22) onto
the adjusting screw (Fig. 1/8). 2
1.4.5 Place the torsional lock (Fig. 2/23) on the

23
hexagon of the threaded rod (22).
1.5 Disassemble high-pressure injection pipe

(07.05.01.nn).
1.6 Loosen the injector valve by turning the

threaded sleeve (24) by means of wrench
(25) and screw out until the bottom O-ring
(Fig. 1/7) is exposed.
1.7 Remove hexagon head bolts (Fig. 2/20) 22
1.8 Pull out injector valve with pulling unit.

24
1.9 Remove the pulling unit completely and re-
assemble it.
20
1.10 Clean the injector valve externally, mark it
with the cylinder number and carry out a
functional check of the injector
(07.08.01.nn).
1.11 Clean the injector seat (Fig. 1/9) in the

sleeve (6) by scraping with tool (W2). Cle-
an the inside of the sleeve.
2. Assembly 25
20
2.1 Replace O-rings (7).
21
Attention:
Only use original MaK replacement
parts!
23
en / 29.02.2008 IB025651 2/3

M43/VM43
2.2 Apply a thin coat of high temperature thread paste to the injector seat, injector element (Fig. 1/5) 07
and nozzle holder.
2.3 Apply a thin coat of Molykote paste to the threads fo the studs (2), contact surfaces of the nuts (1)
and O-rings (7).
Note:
Excess paste must be removed! Excess paste may cause the O-rings to be 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.
2.6 Install the sleeves (Fig. 1/12).
2.7 Tighten the hex head nuts (1) evenly by hand. Make sure that the flange (3) rests flush on the in-
jector valve (4).
2.8 Install injector line (07.05.01.nn).
2.9 Tighten the nuts (1) to

M = 60 Nm
in two steps.
2.10 Check fuel line for leaks.
2.11 Install cylinder head cover.
en / 29.02.2008 IB025651 3/3

Maintenance / Adjust
M43/VM43
See also: 07.07.01.nn, 07.09.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Tools:
Nozzle tester W1 1.9470 H

Adapter/nozzle support nozzle tester W2 439206 A
Injector delivery pipe W3 1.9470-051
~ Safety note:
When checking the opening pressure: 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.
en / 10.09.2008 IB026029 1/2

M43/VM43
1. Remove carbon deposits from the nozzle
with a hard brush (no wire brush).
2. Check the nozzle hole for sharp edges,

ovalization, corrosion and damage.
3. Place the injector with the adapter (W2) in

the tester (W1).
4. Connect the injector delivery pipe (W3).
5. Increase the pressure by means of the

pump until the nozzle opens.
Determine injector opening pressure
and free passage of the nozzle holes.
Note:
If a high portion of fuel is leaking or if the
nozzle holes are clogged and the nozzle
already opens below the minimum nozzle
opening pressure of 390 bar, repair or
replace the injector according to
(07.09.01.nn).
5.1 For adjusting the opening pressure

slacken the lock nut (1) and turn the
adjusting screw (2) until the correct
opening pressure is adjusted (see 5.2 and
5.3). Tighten the lock nut (1).
5.2 When using a new fuel injector or a new

nozzle element (8, 12) and a new nozzle
spring (4) the nozzle opening pressure
is to be adjusted according to the
testbed record (A1.10.).
5.3 When continuing to use the old nozzle

element (8, 12) and/or the old nozzle
spring (4) the opening pressure is to be
adjusted according to the testbed record
value (A1.10.) minus 10%.
Ptest = 570 bar - 10% = 513 bar
en / 10.09.2008 IB026029 2/2

M43/VM43
7500
See also: 07.07.01.nn, 07.08.01.nn 07


-------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replace all injector elements every 7,500 h
Tools:
Retainer, fuel injector W1 439208 A

Torque wrench W2 435100 A
Insert SW55 W3 439208-001
Hexagon spanner W4 ** 0.9100-055
High temperature thread paste Dag S 5420 A“ *
Molykote Paste "G-Rapid‘‘ *
** not available as figure
Note:
The fuel injector must be removed / reassembled every 7,500 operating hours or when an inspec-
tion (07.08.01.nn) reveals faults.
All parts of the injection system are manufactured to high tolerances in special workshops. This is
the only way to ensure proper function. For this reason, repairs cannot be made by the operator
and maintenance work should be limited to:
• Cleaning
• Checking of nozzle opening pressure and seals
• Replacement of wearing parts with the use of OEM parts and

replacement elements
• Replacement of all injector elements (injector needle and element).
The CAT customer service permits low cost repair.
Injection valves that need to be overhauled are to be sent to the CAT customer service as a
complete unit.
en / 16.12.2008 IB026034 1/4

M43/VM43
7500
1. Disassembly
1.1 Insert fuel injector (Fig. 1/13) into retainer (W1). In doing so fit tightly into insert (W3).
1.2 Mount flange (2) with hexagon screws (1) and tighten the hexagon head screws.
Note:
Observe the mounting position of the fuel injector in the flange (2)!
(Position of the positioning pin Fig. 2/17).
1.3 Slacken nut (3) and relieve nozzle spring (4) by unscrewing the setting screw (11).
Attention:
To slacken the nozzle nut (6) only use hexagon spanner (W4), do not use torque wrench
(Fig. 3/W2).
1.4 Put hexagon spanner (W4) on the key face (Fig. 1/16) of insert (W3) and slacken nozzle nut (Fig.
2/6).
1.5 Take off hexagon spanner (W4) and remove nozzle nut.
1.6 Take out nozzle element (Fig. 2/8) including nozzle needle (12) without damaging the lapped sur-
faces.
1.7 Slacken hexagon head screws (Fig. 1/1) and remove with flange (2).
1.8 Take fuel injector out of retainer (W1).
en / 16.12.2008 IB026034 2/4

M43/VM43
7500
1.9 Remove adjusting screw (Fig. 2/11), remove spring guide 07

(10), injector spring (4) and pressure pin (5).
1.10 Inspect injector spring (4) and pressure pin (5).
1.11 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.
1.13 All parts, especially injector needle and sealing surfaces,

must be inspected. Replace any defective parts.
2. Assembly
2.1 Dry all sealing surfaces with lint free paper.
2.2 Install new O-rings (9) and (14) with Molykote paste.
2.3 The fuel injector is installed in the reverse order as

disassembly.
Attention:
When installing the adjusting spindle (1), note the slit
position (X) to the fuel injector housing (13)!
2.4 Apply high temperature paste to the outer threads of the fuel
injector (13).
2.5 Place fuel injector in retainer (Fig. 3/W1).
2.6 Mount flange (2) with hexagon head screws (1) and tighten
the screws.
en / 16.12.2008 IB026034 3/4

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:
2.9 Put torque wrench (Fig. 3/W2) on nozzle nut (Fig. 2/6) and tighten with a pressure of
p = 465 bar
(Equals a torque of M = 680 Nm)
2.10 Slacken hexagon head screws (Fig. 3/1) and remove with flange (2).
2.11 Take fuel injector out of retainer (W1).
2.12 Adjust fuel injector according to (07.08.01.nn), items 3,4, and 5.1.
en / 16.12.2008 IB026034 4/4

Fuel Duplex Filter A5.05. 07.12.01.08
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.
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from

operation and
50 % of the red mark
of the differential pressure gauge (Fig. 1/

1) becomes visible or a filter alarm is
given.
en / 05.03.2002 IB022553 1/4

M43
2.2 Cleaning the filter with built-in 07

cartridges.
~ Safety note:
Depressurize filter chambers!
2.2.1 Remove the cover (2) from the shut-off

filter chamber. Remove contaminated
liquid by opening the drain.
2.2.2 Remove filter insert.
2.2.3 Connect cleaning pistol (Fig. 2/W1) to

compressed-air supply and load.
(6 - max. 10 bar)
2.2.4 Shift the spouting guard (13) to the stop on

the pistol nozzle, put it into the cartridge
opening and hold it tight. Pull the trigger of
the pistol and introduce the nozzle
gradually down to the bottom of each
cartridge (14).
2.2.5 Replace seals and mount cover.
2.2.6 Fill the filter chamber and vent it (see the

plate on the filter cover).
2.3 Cleaning the filter with cartridges

removed (every 3rd cleaning).
2.3.1 Open sludge drain and empty filter

chamber.
2.3.3 Flush the filter chamber with gas oil.
en / 05.03.2002 IB022553 2/4

M43
2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must 07
only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated
liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze
must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but
maximum 4 h.
2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning
pistol (Fig. 2/W1) (operation sequence 2.2.4).
Air pressure max. 10 bar.
2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the
cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9 Fill filter chamber and vent (see plate on filter cover).
2.4 Cleaning of cartridges in the case of persistent fouling
Note:
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the
cartridges and clean them individually.
2.4.1 Soak filter insert in cleansing liquid (max. 4 h).
2.4.2 Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out.
Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings
must not come into contact with the cleansing liquid.
2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
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.
2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply.

en / 05.03.2002 IB022553 3/4

M43
07
2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
2.4.7 Remove sticking dirt with a soft brush.
Note:
If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle.
Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: warm water or
water with cleansing fluid.
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.
4. Mount filter insert in filter chamber.
5. Fit cover (replace seal).
6. Fill the filter chamber and vent it (see the plate on the filter cover).
en / 05.03.2002 IB022553 4/4

Fuel Distributor/Collector Line A5.05. 07.15.01.30
M43
See also: - 07

-------------------------------------------------------------------------------------------------------------------------------
Molykote Paste "G-Rapid‘‘ *
Procedure:
1. Disassembly
1.1 Remove pump area shroud.
1.2 Close shut-off valve.
1.3 Drain fuel distributor line by means of the leakage line.
1.4 Remove the fuel leakage line (Fig. 1/1) at the flange.
en / 11.05.2004 IB024483 1/3

M43
1.5 Remove the fuel line at the flange (Fig. 2/4). 07

1.6 Loosen the locking rings (6) and slide towards the middle of the line.
Note:
When loosening and sliding the locking rings, be careful not to damage the pipe sealing surfaces!
1.7 Slide the fuel line (Fig. 1/5) to the side with a 55mm open jawed wrench and then remove.
1.8 Loosen hex head bolts (Fig. 2/10).
1.9 Remove the hex head bolts and pull the flange (2) from the injection pump bushings (3).
1.10 Remove the bushings (3) with the O-rings (7) and support ring (11).
en / 11.05.2004 IB024483 2/3

M43
1.11 Remove fuel lines (supply and return). 07

1.12 Loosen cap screws (9).
1.13 Remove cap screws and pull the flange (4) from the injection pump bushing (3). Remove
O-rings (12).
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.
2.3 Apply Molykote to hex head bolts (10).
2.4 Install flange (2) with hex head bolts.
2.5 Tighten bolts to
M = 130 Nm
2.6 Insert bushings (3) with O-rings (7) and (8) and support ring (11) into the injection pump / flange.
2.7 Mount flange with cap screws (9).
2.8 Tighten cap screws to
M = 130 Nm
2.9 Insert O-rings (12). Install fuel lines (supply and return).
2.10 Insert fuel line with O-rings (8), support ring (11) and locking rings (6).
2.11 Turn locking rings firmly into locked position.
2.12 Mount fuel leakage line (Fig. 1/1) on flange (2).
2.13 Open shut-off valve.
2.14 Fill fuel system with reserve pump and bleed air from system by circulating fuel with reserve
pump.
2.15 Install pump area shroud.
en / 11.05.2004 IB024483 3/3

Fuel Pressure Damper A5.05. 07.17.00.01
M43
7500
See also: 07.15.01.nn 07


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of the fuel pulsation dampers every 7,500 h
Molykote-Paste "G-Rapid “ **
Procedure:
1. Disassembly
1.1 Close the fuel shut-off valves.
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.
en / 14.11.2007 IB025781 1/2

Fuel Pressure Damper A5.05. 07.17.00.01
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!
2.2 Open the fuel shut-off valves.
2.3 Fill the fuel system by means of the stand-by pump and vent it..
en / 14.11.2007 IB025781 2/2

Lubricating Oil Pump A5.05. 08.03.02.04
M43
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
* not shown
Also needed:
"G-Rapid Plus" ** Molykote paste
„Dirco Grau“ ** silicone sealant
** or comparable product
Note
If necessary, the lube oil pump should be removed from the engine to check the gears, gear
shafts and bushes for wear or replace them, if necessary.
Sequence:
1. Disassembly
1.1 Drain lube oil system.
1.2 Remove suction (Fig. 1/4) and pressure

lines (2).
1.3 Loosen hex nuts (1) and pull lube oil pump
(3) with gear (6) from the cylinder crank
case. Watch out for resilient sleeves.
en / 31.01.2008 IB025414 1/4

M43
1.4 Loosen hex bolt (7) and pull gear (6) from the drive gear shaft (Fig. 2/10) using puller. 08
1.5 Check tooth faces for wear (pitting, unevenness, spalling).
1.6 Loosen bolts (16,18). Remove cover (21) und cover (17) from pump housing (20).
1.7 Remove drive gear (10) and impeller shaft (19).
1.8 Check bushes (11, 14, and 15), bearing areas of drive and impeller gear shafts for wear and re-
place with genuine MaK parts, if necessary.
Replace O-rings (12).
Note
Cool new bushes before assembly.
en / 31.01.2008 IB025414 2/4

M43
2. Assembly: 08
2.1 Assemble lube oil pump by reversing above steps.
2.2 Mount cover (21). Tighten hex bolts (18) to a torque of
M = 410 Nm.
2.3 Mount cover flange (17). Tighten hex bolts (16) to a torque of
M = 206 Nm.
2.4 Before mounting gears, check wear pattern between gear cone (Fig. 1/6) and drive gear shaft
cone (Fig. 2/10) by applying ink.
The wear pattern should be even, and the wear pattern percentage > 80 %.
2.5 Clean, degrease and dry gear cone and drive gear cone shaft.
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.
en / 31.01.2008 IB025414 3/4

M43
2.10 Check distance S; it should be smaller than measured under 2.6 by 0.57 - 0.67 mm (sliding 08
travel).
2.11 Clean pump flange surface (Fig. 2/17) and pump support surface (Fig. 1/5) and coat with sealant.
2.12 Carefully insert lube oil pump (3) with gear (6) into the cylinder crankcase (tooth faces of drive
gears need to engage) and install.
2.13 Install resilient sleeves. Coat hex nuts (1) and bolt threads with „G-Rapid Plus“ Molykote paste
and tighten to a torque of
M = 130 Nm.
2.14 Install suction (4) and pressure (2) lines using new seals.
2.15 Fill with new lube oil (for lube oil quality see 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.
2.17 Check lube oil supply to gears.
en / 31.01.2008 IB025414 4/4

Lubricating Oil Duplex Filter A5.05. 08.04.01.01
M43
See also: 08

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Cleaning pistol W1 1.9100-114

Cartridge drift W2 1.9100-120
Auxiliary material:
Cleansing fluid "Filterclean" from Vecom *
Note:
Operation and servicing of the filter have to be carried out with atmost care. The ingress of dirt
from the tanks and piping could cause serious engine damage.
The cleaning interval of the filter is influenced by part load operation with heavy fuel, poor
combustion, poor centrifugal purifying or a defective automatic backflashing filter.
When starting up a new plant after major repairs or work on the lubricating oil piping, check the
filter after 24 - 48 h and clean it if necessary.
Disassemble the cartridge bundle on every 3rd cleaning (see operation sequence 2.3).
Ultrasonic cleaning of the filter cartridges is not permitted. An excessive cleaning period or
improper suspension during cleaning might cause damage to the gauze that cannot be detected
with the nacked eye.
1. Change the filter over (see the plate on the
filter cover).
2. Cleaning
2.1 Clean the filter when it is still warm from

operation and
50 % of the red mark
of the differential pressure gauge (Fig. 1/

1) becomes visible or a filter alarm is
given.
en / 23.03.2007 IB020307 1/4

M43
2.2 Cleaning the filter with built-in 08

cartridges.
~ Safety note:
Depressurize filter chambers!
2.2.1 Remove the cover (2) from the shut-off

filter chamber. Remove contaminated
liquid by opening the drain.
2.2.3 Connect cleaning pistol (Fig. 2/W1) to

compressed-air supply and load.
(6 - max. 10 bar)
2.2.4 Shift the spouting guard (13) to the stop on

the pistol nozzle, put it into the cartridge
opening and hold it tight. Pull the trigger of
the pistol and introduce the nozzle
gradually down to the bottom of each
cartridge (14).
2.2.5 Replace seals and mount cover.
2.2.6 Fill the filter chamber and vent it (see the

plate on the filter cover).
2.3 Cleaning the filter with cartridges

removed (every 3rd cleaning).
2.3.1 Open sludge drain and empty filter

chamber.
2.3.3 Flush the filter chamber with gas oil.
en / 23.03.2007 IB020307 2/4

M43
2.3.4 Put the filter insert in a container filled with a suitable cleansing liquid. The cleansing liquid must 08
only reach up to the bottom edge of the element plate (Fig. 3/26) so that no contaminated
liquid can enter the cartridges from the top (14) (clean side). The top area of the gauze
must be visible in the cartridge. Soaking time as required by the supplier of the cleanser, but
maximum 4 h.
2.3.5 Take the filter insert out of the cleansing container and blow out cartridges (14) with the cleaning
pistol (Fig. 2/W1) (operation sequence 2.2.4).
2.3.6 Submerge filter insert again in clean cleansing liquid, let it drip off and then blow it out with the
cleaning piston (W1). Place filter insert upside down so that cleansing liquid can drain off.
2.3.7 Intermittent check of cartridges for damage (operation sequence 2.4).
2.3.8 Place filter insert in filter chamber, mount cover, replace seals if necessary.
2.3.9 Fill filter chamber and vent (see plate on filter cover).
2.4 Cleaning of cartridges in the case of persistent fouling
Note:
In the case of heavy fouling of the filter insert (hardening, tar deposits, fibers, chips) remove the
cartridges and clean them individually.
2.4.1 Soak filter insert in cleansing liquid (max. 4 h).
2.4.2 Loosen base plate and carefully remove protective jacket from filter insert.
2.4.3 Remove cartridges (14) with the drift (Fig. 3/W2) downwards and tilt them out.
Remove the O-rings (25) between the cartridge and the element plate (26) because O-rings
must not come into contact with the cleansing liquid.
2.4.4 Inspect the cartridges and replace them if damaged or if the gauze is badly crinkled.
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.
2.4.5 Connect cleaning pistol (Fig. 2/W1) to compressed-air supply.

en / 23.03.2007 IB020307 3/4

M43
08
2.4.6 Introduce the cleaning pistol into the cartridge, pull the trigger and move down to the bottom of
each cartridge.
2.4.7 Remove sticking dirt with a soft brush.
Note:
If a high-pressure cleaner is available, blast the cartridges from the outside with a fan jet nozzle.
Operating pressure of the high-pressure cleaner max. 60 bar. Cleansing agent: warm water or
water with cleansing fluid.
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.
4. Mount filter insert in filter chamber.
5. Fit cover (replace seal).
6. Fill the filter chamber and vent it (see the plate on the filter cover).
en / 23.03.2007 IB020307 4/4

Oil pressure control valve A5.05. 08.05.01.01
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).
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).
1.2 Remove and dismantle the control valve (1).
~ 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).
en / 31.01.2008 IB022593 1/3

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.
en / 31.01.2008 IB022593 2/3

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.
2.2 Assembly is effected in the reverse sequence of disassembly.

Pay attention to the free movement of the pistons (4 and 11)!
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne-
cessary.
3. Adjustment
3.1 Pressure to be set (see engine data A1.05).
3.2 Loosen the hexagon nut (18).
Regulate the pressure by turning the spindle (19).
Counter-clockwise: Oil pressure drops

Clockwise: Oil pressure increases
3.3 Secure the setting with the hexagon nut (18).
en / 31.01.2008 IB022593 3/3

Prelubricating pump/Prelubrication A5.05. 08.10.00.00
M20/M25/M32/M43/M453C/M552C/M601C
150
See also: C5.05.08.10.00.nn 08

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Prelubrication and turning approximately every 150 h
Note:
When multi-engine systems run on rigid bearings, the bearings might be damaged by vibration
when individual engines are shut down for more than 3 days.
Prelubrication alone is no guarantee that damage caused by vibration is prevented, since the
components which run on sliding bearings, are not able to float in the 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:
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.
1.1 Start the stand-by pump
1.2 Turn the engine by means of the barring gear.
en / 18.11.1999 IB004168 1/1

Stop Piston A5.05. 10.03.01.00
M43/VM43
750
See also: 07.03.01.nn 10


-------------------------------------------------------------------------------------------------------------------------------
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.
2. Check the position of the control rods.
Attention:
The control rods must be in the "Zero
Filling“ position.
3. Check the stop piston (3) in the injection

pump, press the control rod (2) into the in-
jection pump by applying pressure to the
jointed lever (1) on the control rod.
Note:
Check all injection pumps.
If individual or one control rod can be forced into the injection pump against the 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.
4. Actuate the "Reset“ button on the safety system.
Note:
The stop piston is reset and the emergency stop system depressurized.
en / 31.07.2008 IB020372 1/2

Stop Piston A5.05. 10.03.01.00
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
5. (Fig. 2/T3) Measuring point 6105 (function 10

of the safety system) in the maintenance
unit (C5.05.05.45.23.01).
5.1 Venting by loosening screw (13). If the

shutdown air pressure is decreased below
the switching value of 6 bar an alarm "Low
shutdown pressure" will be released.
2
T3
6. Check the emergency stop by actuating the emergency stop lever (Fig. 3/20) on the control
stand.
en / 31.07.2008 IB020372 2/2

Pressure Switches A5.05. 11.01.02.01
Inspection / Adjust
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
1. Connection of the adjusting device
1.1 Close the cock of the pressure piping (Fig. 1/1).
1.2 Loosen the union nut (2) and remove the dummy plug (pressure release of the piping, at liquid
medium collect the liquid with a rag).
en / 31.05.2000 IB021686 1/3

Inspection / Adjust
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).
2. Inspection of the set values
2.1 Ventilate the pressure switch via the adjustment device.
Attention:
For setting the differential pressure switch, the adjusting device must be equipped with
two text connections (+, –, pressure difference) refer to view “X”.
Pressure monitor Difference pressure monitor
2.2 Inspect the pressure control via the pressure gauge (of the device) and simultaneously the switch
point at the instrument or alarm unit for coincidence of the switch point with the set value.
2.3 At any deviation correct the adjustment due to item 3.
2.4 Deaerate the pressure switch slightly and simultaneously check the switch point via the test in-
strument. Inspect the displayed switch difference.
en / 31.05.2000 IB021686 2/3

Inspection / Adjust
M20-M601C
3750
3. Correction of the adjustment (Perfor- 11

mance with fixed switch difference)
(Fig. 3)
Note:
The scale accuracy is ± 2 % of the span.
The instrument is individually calibrated
(1 - 2 on) so that no gauge inspection is
necessary.
3.1 Remove the case cover by loosening the 4

locking screws.
3.2 Connect terminal (1 + 4) via cable with the

adjusting device.
3.3 Loosen the stop screw (A).
3.4 Remove the cover aside by loosening the

locking screw (B).
3.5 Set the upper or lower switching point (dif-

ferential pressure switch) by means of the
range spindle (C).
The lower or upper switching point

(differential pressure switch) results in the
fixed switching difference.
3.6 Tighten stop screw (A).
4. Removal of the adjusting device
4.1 Loosen the cable connection

(terminal 1 + 4).
4.2 Loosen the connection hose of the

adjusting device screw on the union nuts
with plug (Fig. 1/2).
4.3 Fit the cover.
4.4 Tighten the cover of the range spindle.
4.5 Mark or lead the impected or corrected

pressure switches.
en / 31.05.2000 IB021686 3/3

RPM Switch A5.05. 11.05.01.02
Inspection / Adjust
M20/M25/M32/M43
7500
See also: C5.05.05.70.06.43 11

Spare parts list:
Personnel qualification: E-specialist

--------------------------------------------------------------------------------------------------------------------------------
Inspection:
Check the function of the rpm switches every 7,500 operating hours.
Note:
The engine speed must be constant whilst testing.
1. Note the rpm switch point setting. Loosen
the pointer locking plate (2) and set the
pointer (1) at the highest engine speed.
The output relay on the plug-in card must

switch and the luminous diode (3) on the
dial will go out (Fig. 1).
2. Turn the pointer carefully to the left

towards 0 rpm. When reaching the engine
speed, the output relay will switch and the
diode on the dial must light up (switch
hysteresis ± 25 rpm).
3. Set the pointer again at the original rpm

switch point and lock it.
If the rpm switch does not work, proceed

as follows in order to locate the defect:
4. The automatic cut-out F 1.1 and F 2.1 on the plug-in card A1 in the rpm switch installation must
be switched on.
At constant speed and with the setting as under point 1, continue as follows:
5. Voltage check at the plug-in socket contacts of the plug-in frame.
5.1 Supply (24 V DC at contact z16 and z20, contact z20 positive).
en / 25.05.2005 IB021724 1/2

RPM Switch A5.05. 11.05.01.02
Inspection / Adjust
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".
en / 25.05.2005 IB021724 2/2

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01
M20-M601C
7500
See also: 11

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Disassembly of lubricating oil/cooling water thermostat,
making a funcional check of thermostatic element every 7,500 h
Note:
The thermostatic elements (Fig. 1/5) are adjusted by the manufacturer to the 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).
1. Disassembly
1.1 Drain lubricating oil/cooling water lines.
1.2 Unscrew hexagon nuts (2) of housing co-

ver (6).
1.3 Remove cover (6) with O-ring (1).
1.4 Turn out thermostatic element (5)

from valve housing (7).
1.5 Wash parts in gas oil and blow them clean.
1.6 Wipe clean thermostat housing with lint-

free cloth and check for corrosion and de-
posits.
en / 31.05.2000 IB021750 1/2

Lubricating Oil/Cooling Water Thermostat A5.05. 11.06.01.01
M20-M601C
7500
11
2. Functional check of thermostatic element
2.1 Put thermostatic element (Fig. 1/5) into a water bath of temperature of approx. 15 K above the
temperature specified on the strap (XX) (specification in degree C).
2.2 The thermostatic element (5) must open steadiliy.
3. Assembly
3.1 Repalce O-rings (1 and 9) and gasket (8).
3.2 Assembly is done in reverse order of disassembly.
3.3 Top up lubricating oil/cooling water system and check thermostat for leakages.
en / 31.05.2000 IB021750 2/2

Pressure Switch A5.05. 11.06.05.02
M32/M43
22500
See also: 11.06.06.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Replacement of all pressure switches after 22,500 h
Tools:
Metric standard tools.
Set of replacement parts:

Pressure switch M2103 (emergency stop - cooling water pressure)
Pressure switch M1106 (emergency stop - lubricating oil pressure)
Depending on the equipment status all other pressure switches are to be replaced as well.
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.
en / 06.10.2008 IB025581 1/3

M32/M43
22500
Procedure: 11
1. Put the engine and the related safety systems out of operation.
- > Notify the engine to be ’’unserviceable’’ < -.
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.
2. Replacement of the pressure switches.
Note:
The measuring point designations are always provided on the engine cable and the engine.
2.1 Remove the old pressure switch.
2.2 Mount the new pressure switch. When

doing so, slightly grease the O-ring
(Fig. 1/1) at the foot of the new pressu-
re switch before inserting it.
2.3 Replacement of the plug.
3. Testing of the completed work:
3.1 Cooling water system

1
3.1.1 Start the engine and run up to nominal speed.
3.1.2 Simulate "Low cooling water pressure" by means of test valve (Fig. 2, 3, 4/2).
The engine has to stop automatically latest after 20 seconds.
3.1.3 Put test valve (2) into "Operation" position again.
3.1.4 Lubricating oil system
3.1.5 Start the engine and run up to nominal speed.
3.1.6 Simulate "Low lubricating oil pressure" by means of test valve (2).
The engine has to stop automatically without any delay.
3.1.7 Put test valve (2) into "Operation" position again.
3.1.8 The other pressure switches are to be tested according to the same procedure.
en / 06.10.2008 IB025581 2/3

M32/M43
22500
4. Put the engine and the safety system into normal operating condition again. 11
-> Notify the engine to be "ready for operation" <-.
en / 06.10.2008 IB025581 3/3

M20/M25/M32/M43
See also: 11.06.05.nn 11

Spare parts list:

--------------------------------------------------------------------------------------------------------------------------------
Tools:
Pressure calibrating device W1*
Electric continuity tester (multimeter) W2*
* no picture
Procedure:
1. Mount new pressure switch, see A5.05.11.06.05.nn.
2. Close shut-off valve (Fig. 3/6) of the corresponding medium to the pressure pipe.
2.1 Remove the plug from the pressure switch and connect the pressure calibrating device (W1) to
the test connection. The adjustment value is to be inferred from the list of measuring points in
Book C.
2.2 In pressureless state the pressure switch contacts (Fig. 1)

1 + 2 are closed and contacts 1 + 3 are open (ohmic flow).
2.3 When the pressure drops, the pressure switch should switch at the measuring point value, in this
state contacts 1 + 2 are open and contacts 1 + 3 are closed.
2.4 If a pressure switch is replaced, the switching value is to be inferred from the list of measuring
points.
(The measuring point number is indicated on the cable or the related nameplate.)
Note:
If the pressure switch responds before or after the read limit, the switching point has to be readju-
sted, see item 3.
en / 14.08.2008 IB025583 1/2

M20/M25/M32/M43
3. Adjustment of switching point 11

3.1 Remove cover (Fig. 2/4).
3.2 By turning the hexagon socket screw

(5) the switching point can be adjusted
correspondingly.
4. Assembly:
4.1 Mount cover (4).
4.2 Remove pressure calibrating device (W1).
4.3 Clip on plug to the pressure switch.
4.4 Open shut-off valve (Fig. 3/6) of the

corresponding medium to the pressure pipe.
Replacement of the complete switch,

see A5.05.11.06.05.nn.
.
en / 14.08.2008 IB025583 2/2

Crankcase Monitoring Device A5.05. 11.09.01.03
M20/M25/M32/M43/M453C/M552C/M601C
1500, 750, 7500
See also: 11
Spare parts list: B1.05.11.nn4810

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
a) Check the underpressure in the measuring chamber every 750 h
b) Clean the infrared filter and replace the sintered bronze filter
in the measuring attachment every 1.500 h
c) Replace the sintered bronze filter in the pressure control every 7.500 h
Tools:
Test equipment and spare parts.
Service box
Maintenance and trouble shooting: refer to manual C
Attention:
The engine is not monitored in the event of the device malfunctioning.
his can result in engine damage!
en / 12.12.2008 IB021758 1/1

Vibration Damper A5.05. 12.04.01.00
M43/VM43
30000
See also: 08.03.02.nn 12


--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
of the vibration damper after 30,000 h
check size of gap "s" between the spring ends and the flanks of the interior grooves.
Renew all seals.
Auxiliaries:
Molykote "G-Rapid Plus" *

Molykote lubricant "Typ 60 G" *
Silicon sealant "Dirco-Grau" *
Loctite 275
* or product of equivalent quality

Note:
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.
In damper replacement (possible in AT procedure) or damper assembly lubricate the screw

thread plate and screw head of the antifatigue screws (Fig. 1/1) with Molykote "G-Rapid Plus" pa-
ste and set with a
pre-torque of M = 600 Nm
and finally tighten at torque angle = 120°
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).
en / 15.01.2001 IB020552 1/4

M43/VM43
30000
1. Dismantling 0,3 C
C
1.1 Dismantle the lubricant pump 0,2 C
(08.03.02.nn).
1.2 Dismantle lubricant piping and pump bea-

4
rer plate (4), completely removing all sili-
con sealant. 30
1.3 Drain the oil:

14
• Turn oil flow boring to lower position
(30). 1
• For full drainage turn the damper
through 180° m several times.
12
1.4 Mark the position of the damper to the
crankshaft. 15
1.5 Remove the antifatigue screws and faste-

ning screws (1) (12).
1.6 Dismantle the pump wheel carrier (15) and 13

pump gear wheel (14).
20
1.7 Remove fastening screws (13).
18
1.8 Remove the oscillation damper and for-
cing screw from the crankshaft and dis-
mantle. X
1.9 Dismantle side plates (18); forcing may be
carried out through tapping bore holes.
22
1.10 Remove O rings (20 and 21). 18 21
23
1.11 Clean all parts thoroughly. Check oil flow

bores and oil feed bores are clear. X
24
en / 15.01.2001 IB020552 2/4

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:
Damper No. Tightening angle (Pos 23) Gap "s"

(mm)
D 134/5 57° - 62° 0,43
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.
en / 15.01.2001 IB020552 3/4

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).
3. Insert new greased O rings (20 and 21).
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.
5. Assembly of oscillation damper:
• Observe the marking of the damper position to the crankshaft!

5.1 Check the run-out tolerances of the vibration damper (Fig. 1).
5.2 Bleed the air from the oscillation damper:
• 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.
Starting torque of screws:
M16 = 130 Nm ; M20 = 260 Nm
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.
en / 15.01.2001 IB020552 4/4

M43
45000
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance/ replace:
Vibration damper:
Replacement (on an exchange basis) after 45,000 h
Note:
We have to point out that this maintenance sheet was prepared only for the purpose of maintenance plan-
ning.
Please contact the Caterpillar/ Kiel Customer Service in time before reaching the 45,000 hours deadline.
en / 25.02.2008 IB024239 1/1

Turning Device A5.05. 12.08.01.01
M43
30000, 750, 3750
See also: 12

--------------------------------------------------------------------------------------------------------------------------------
Maintenance:
Oil level check every 3.750 h or 6 months
Lubricating / greasing of shaft and gearwheel every 750 h or monthlys
Oil change every 30.000 h or 4 years
Auxiliary material:
Bearing grease „Klüber Altemp. QNB 50“ *
Gear oil „Shell Omala Oil 460“ *
*or a product of equal standard
1. Operating the turning device
~ Safety note:
Protect engine against unintentional start-up!
1.1 Engaging the turning device
1.1.1 Move blockinglever (1) to position “V“ and hold.
1.1.2 Move lever (2) to position“ X“, so that the gearwheel of the turning device engages completely in
the flywheel toothing.
1.1.3 Let off blockinglever and make sure that the blockinglever engages in position “Z“.
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 !
1.1.4 Turn the engine.
en / 25.09.2002 IB023850 1/3

M43
30000, 750, 3750
1.2 Disengaging the turning device 12

1.2.1 Move blockinglever (1) to position “V“ and hold.
1.2.2 Move lever (2) to position“ Y “, so that the gearwheel of the turning device is disengaged from the
flywheel toothing.
1.2.3 Let off blockinglever and make sure that the blockinglever is engaged in position “Z“.
Attention:
The engine can only be started if the turning device is disengaged !
The position switch (11) is then in position „engine-ON“)
en / 25.09.2002 IB023850 2/3

M43
30000, 750, 3750
2. Maintenance 12
2.1 Oil level check
Note:
If a topping up should be necessary, only the prescribed gear oil is to be used !
2.1.1 Check oil level at the oil level glas (10) and fill in gear oil ( e.g. Shell Omala Oil 460 ) up to the oil
level marke.
2.2 Lubricating / greasing of shaft and gearwheel
Note:
Grease the notch on the output shaft and the gearwheel only if the turning device is engaged.
2.2.1 Grease the notch on the output shaft (9) and the gearwheel (3) with bearing grease by means of
the grease nipple (4).
Attention:
Grease the gearwheel toothing only if the turning device is disengaged.
2.2.2 Coat toothing of gearwheel thinly with bearing grease.
2.3 Oil change
2.3.1 Remove screw plug (5) on the driving gear of the turning device.
2.3.2 Drain the oil from the driving gear of the turning device.
2.3.3 Mount the screw plug (5) with new gasket (6).
2.3.4 Remove the vent socket (7) on the gear of the turning device.
2.3.5 Fill in new oil (e.g. Shell Omala Oil 460 ; ca.9 l) up to the oil level mark (10).
2.3.6 Mount vent socket (7).
en / 25.09.2002 IB023850 3/3

Maintenance MAK M43C

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Maintenance A5

en / 03.03.2009 AA000026 1/1

Engine, cylinder head A5.05.01

en / 03.03.2009 AA020041 1/4

Engine, gear A5.05.02

Engine, housing A5.05.03

Engine, control A5.05.04

en / 03.03.2009 AA020041 2/4

Engine, regulation A5.05.05

Engine, exhaust gas system/supercharging A5.05.06

Engine, fuel system A5.05.07

Engine, lubricating oil system A5.05.08

Engine, starting system A5.05.10

en / 03.03.2009 AA020041 3/4

Engine control equipment A5.05.11

Engine auxiliary units A5.05.12

en / 03.03.2009 AA020041 4/4

All information refers to the date of printing.

2. Explanation of the maintenance system

2.1 Scheduled maintenance

The “Scheduled maintenance” is thereby supported by inspections according to fixed deadlines.

The following is used as parameter:

• data on wear and tear

• evaluation criterion and

The information given by us gives no rise to legal claims.

en / 27.02.2008 AA000021 1/5

2.2 Maintenance system

The maintenance system consists of:

• work interval schedule

• maintenance schedule (large-scale plan) *

2.2.1 Work interval schedule

The interval schedule is subdivided into the following four areas:

• Daily inspection and control work

• Initial inspection and maintenance work

• Periodic maintenance work

• Maintenance work to be carried out independent of deadlines

en / 27.02.2008 AA000021 2/5

2.2.2 Job cards

Maintenance work Activity

Discharge valve A5.05.01.04.01.03

Operating hours/maintenance deadline

See also: 01.01.01.nn, 01.02.01.nn, 01.08.01.nn

Vol. A operating instructions Job cards

en / 30.09.91 IB000003 1/1

en / 27.02.2008 AA000021 3/5

01. Cylinder head 08. Lube oil system

02. Driving mechanism 09. Cooling water system

03. Engine housing 10. Starting air system

04. Engine control 11. Monitors

05. Regulation 12. Auxiliary generator sets and tools

06. Exhaust gas system/ 13. Additional installation

07. Fuel system

• The fourth pair of digits indicates the type of variant.

• Attention: Marking technical regulations or measures to be strictly observed in order to avoid

en / 27.02.2008 AA000021 4/5

2.2.3 Maintenance schedule (Periodic maintenance work)

en / 27.02.2008 AA000021 5/5

1.1 Work safety symbol

1.2 General safety instructions

The provisions of the relevant accident prevention regulations of the appropriate

• Use personal protective equipment as far as necessary or as required by the

en / 29.05.2008 AA000022 1/4

• Re-install removed guards and protecting devices on completion of work.