Maintenance Plan

Version 1.1 / 14.08.
2013
Wartungsplan
Maintenance Plan
Plan de Mantenimiento
Plan de Maintenance
План техобслуживания
Plano de manutenção
维护计划
Maintenance Jobs Depending on Operating Hours
Select from the table below the operating hours that apply to your engine and click on the corresponding colour button below the table to visualize the maintenance work that has to
be carried out.
150 300 450 600 750 900 1.050 1.200 1.350 1.500 1.650 1.800 1.950 2.100 2.250 2.400 2.550 2.700 2.850 3.000
3.150 3.300 3.450 3.600 3.750 3.900 4.050 4.200 4.350 4.500 4.650 4.800 4.950 5.100 5.250 5.400 5.550 5.700 5.850 6.000
6.150 6.300 6.450 6.600 6.750 6.900 7.050 7.200 7.350 7.500 7.650 7.800 7.950 8.100 8.250 8.400 8.550 8.700 8.850 9.000
9.150 9.300 9.450 9.600 9.750 9.900 10.050 10.200 10.350 10.500 10.650 10.800 10.950 11.100 11.250 11.400 11.550 11.700 11.850 12.000
12.150 12.300 12.450 12.600 12.750 12.900 13.050 13.200 13.350 13.500 13.650 13.800 13.950 14.100 14.250 14.400 14.550 14.700 14.850 15.000
15.150 15.300 15.450 15.600 15.750 15.900 16.050 16.200 16.350 16.500 16.650 16.800 16.950 17.100 17.250 17.400 17.550 17.700 17.850 18.000
18.150 18.300 18.450 18.600 18.750 18.900 19.050 19.200 19.350 19.500 19.650 19.800 19.950 20.100 20.250 20.400 20.550 20.700 20.850 21.000
21.150 21.300 21.450 21.600 21.750 21.900 22.050 22.200 22.350 22.500 22.650 22.800 22.950 23.100 23.250 23.400 23.550 23.700 23.850 24.000
24.150 24.300 24.450 24.600 24.750 24.900 25.050 25.200 25.350 25.500 25.650 25.800 25.950 26.100 26.250 26.400 26.550 26.700 26.850 27.000
27.150 27.300 27.450 27.600 27.750 27.900 28.050 28.200 28.350 28.500 28.650 28.800 28.950 29.100 29.250 29.400 29.550 29.700 29.850 30.000
30.150 30.300 30.450 30.600 30.750 30.900 31.050 31.200 31.350 31.500 31.650 31.800 31.950 32.100 32.250 32.400 32.550 32.700 32.850 33.000
33.150 33.300 33.450 33.600 33.750 33.900 34.050 34.200 34.350 34.500 34.650 34.800 34.950 35.100 35.250 35.400 35.550 35.700 35.850 36.000
36.150 36.300 36.450 36.600 36.750 36.900 37.050 37.200 37.350 37.500 37.650 37.800 37.950 38.100 38.250 38.400 38.550 38.700 38.850 39.000
39.150 39.300 39.450 39.600 39.750 39.900 40.050 40.200 40.350 40.500 40.650 40.800 40.950 41.100 41.250 41.400 41.550 41.700 41.850 42.000
42.150 42.300 42.450 42.600 42.750 42.900 43.050 43.200 43.350 43.500 43.650 43.800 43.950 44.100 44.250 44.400 44.550 44.700 44.850 45.000
45.150 45.300 45.450 45.600 45.750 45.900 46.050 46.200 46.350 46.500 46.650 46.800 46.950 47.100 47.250 47.400 47.550 47.700 47.850 48.000
48.150 48.300 48.450 48.600 48.750 48.900 49.050 49.200 49.350 49.500 49.650 49.800 49.950 50.100 50.250 50.400 50.550 50.700 50.850 51.000
51.150 51.300 51.450 51.600 51.750 51.900 52.050 52.200 52.350 52.500 52.650 52.800 52.950 53.100 53.250 53.400 53.550 53.700 53.850 54.000
54.150 54.300 54.450 54.600 54.750 54.900 55.050 55.200 55.350 55.500 55.650 55.800 55.950 56.100 56.250 56.400 56.550 56.700 56.850 57.000
57.150 57.300 57.450 57.600 57.750 57.900 58.050 58.200 58.350 58.500 58.650 58.800 58.950 59.100 59.250 59.400 59.550 59.700 59.850 60.000
60.150 60.300 60.450 60.600 60.750 60.900 61.050 61.200 61.350 61.500 61.650 61.800 61.950 62.100 62.250 62.400 62.550 62.700 62.850 63.000
63.150 63.300 63.450 63.600 63.750 63.900 64.050 64.200 64.350 64.500 64.650 64.800 64.950 65.100 65.250 65.400 65.550 65.700 65.850 66.000
66.150 66.300 66.450 66.600 66.750 66.900 67.050 67.200 67.350 67.500 67.650 67.800 67.950 68.100 68.250 68.400 68.550 68.700 68.850 69.000
69.150 69.300 69.450 69.600 69.750 69.900 70.050 70.200 70.350 70.500 70.650 70.800 70.950 71.100 71.250 71.400 71.550 71.700 71.850 72.000
72.150 72.300 72.450 72.600 72.750 72.900 73.050 73.200 73.350 73.500 73.650 73.800 73.950 74.100 74.250 74.400 74.550 74.700 74.850 75.000
75.150 75.300 75.450 75.600 75.750 75.900 76.050 76.200 76.350 76.500 76.650 76.800 76.950 77.100 77.250 77.400 77.550 77.700 77.850 78.000
78.150 78.300 78.450 78.600 78.750 78.900 79.050 79.200 79.350 79.500 79.650 79.800 79.950 80.100 80.250 80.400 80.550 80.700 80.850 81.000
81.150 81.300 81.450 81.600 81.750 81.900 82.050 82.200 82.350 82.500 82.650 82.800 82.950 83.100 83.250 83.400 83.550 83.700 83.850 84.000
84.150 84.300 84.450 84.600 84.750 84.900 85.050 85.200 85.350 85.500 85.650 85.800 85.950 86.100 86.250 86.400 86.550 86.700 86.850 87.000
87.150 87.300 87.450 87.600 87.750 87.900 88.050 88.200 88.350 88.500 88.650 88.800 88.950 89.100 89.250 89.400 89.550 89.700 89.850 90.000
To return from the individual pages to the starting page (maintenance table), just click on the CAT Logo.
Daily Maintenance
Work
Daily Maintenance Work
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
MDO HFO MDO HFO MDO HFO MDO HFO MDO HFO
pression Power
Activity Note
Visually check the engine fasteners and connections for leaks (cooling
water system, lubricating oil system, fuel system, gas pipes, starting and
X X X X X X X X X X X X
control air, pneumatic control, exhaust manifold, turbocharger, hydraulic
system for wastegate or VTG drive)
Compare the engine operating data in steady state
with the commissioning protocol and the data in the document "Technical X X X X X X X X X X X X
Engine Data".
Check the oil level of the lubricating oil system according to the actual
installation (on dipstick or external lubricating oil sump tank).
Read the differential pressure off the lubricating oil duplex filters.
If the differential pressure exceeds 50 %, clean the filter. X X X X X X X X X X X X
(A5.05.08.04.01.nn).
Check the level of the freshwater expansion tank of the cooling water
system according to the actual installation. If necessary, refill cooling water X X X X X X X X X X X X
(add anti-corrosive or anti-freeze agent as required).
Check the level of the day tank of the fuel system according to the actual
X X X X X X X X X X
installation.
Read the differential pressure off the fuel duplex filters.
If the differential pressure exceeds 50 %, clean the filter. X X X X X X X X X X
(A5.05.07.12.01.nn).
Drain the starting air receivers of the starting air system according to the
actual installation. X X X X X X X X X X X X
(A5.05.10.51.00.nn)
Drain the compressed air filter of the system according to the actual
X X X X X X X X X X
installation (A5.05.05.09.06.nn)
Clean the turbocharger on compressor side
(A5.05.06.05.00.nn)
Check the hydraulic oil level of the governor
X X X X X X X X X X
(A5.05.05.25.00.nn)
Check the function of the steam trap X X X X X X X X X X X X
Check the hydraulic oil level in the compensation receiver of the VTG drive
(A5.05.06.15.03.nn) X
Wastegate
Check the hydraulic oil level in the compensation receiver of the wastegate
X
(A5.05.06.15.02.nn)
Clean the intake air filter according to the actual installation. X X

Drain the charge air duct according to the actual installation. X X
Check the drive pinions of the starter for wear and make sure that drive
X X
pinions and the gear ring are sufficiently lubricated with grease.
1/1
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
Document Activities Note
A5.05.01.03.01.nn
Check the valve rotators and ball races X X X X X X X X X X
Valve Rotator
Check the valve guide clearances on all valve
A5.05.01.05.01.nn
guide bushes and valves of inlet and exhaust Carry out at 19.950, 40.050, 60.000 & 79.950
Valve Guide X
valves hrs only
Oil Control Ring
Replace all valve stem seals
A5.05.01.07.01.nn
Carry out at 19.950, 40.050, 60.000 & 79.950
Inlet and Exhaust Valve Service the inlet and exhaust valve cones X
hrs only
Cones
A5.05.01.10.00.nn
General inspection of all cylinder heads X X X X X X X X X X X X
Cylinder Head
A5.05.01.10.01.nn Carry out at 19.950, 40.050, 60.000 & 79.950
Clean all cylinder heads X
Cylinder Head hrs only
A5.05.06.13.01.nn
Turbine washing X X X X X
Turbocharger
Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

Check and, if necessary, retighten the fixing
21.000, 24.000, 27.000, 33.000, 36.000,
A5.05.06.14.02.nn screws on the
39.000, 42.000, 48.000, 51.000, 54.000, X X X X
Turbocharger (KBB) turbocharger mounting feet, all housing screws
57.000, 63.000, 66.000, 69.000, 72.000,
and pipe connections (KBB)
78.000, 81.000, 84.000 & 87.000 hrs only
Carry out at 4.950, 10.050, 19.950, 25.050,

A5.05.07.09.01.nn
Replace all nozzle elements of the fuel injectors 34.950, 40.050, 49.950, 55.050, 64.950, X X X X X
Fuel Injector
70.050, 79.950 & 85.050 hrs only
A5.05.07.23.03.nn Carry out at 4.950, 10.050, 19.950, 25.050,
Kraftstofffilter Einsatz (Ignition ??? 34.950, 40.050, 49.950, 55.050, 64.950, X X
Fuel) 70.050, 79.950 & 85.050 hrs only
A5.05.08.10.00.nn
Prelubricate and bar a stopped engine of a
Prelubrication Pump / X X X X X X X X X X X X
multi-engine plant
Prelubrication
Check the anti-corrosion and anti-freeze

Operating Media X X X X X X X X X X
emulsion content of the cooling water system
1/1
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

A5.05.06.14.02.nn Clean the air filter on the silencer of the
X X X X
Turbocharger (KBB) turbocharger (KBB)
1/1
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

A5.05.05.01.02.nn
Oil the control shaft X X X X
Control Shaft Bearings
Check tightness and proper function of control
A5.05.05.09.01.nn
pipes and X X X X
Compressed Air System
fittings of the compressed air system
A5.05.06.06.00.nn Check and clean the filter elements in the steam
X X X X X X X X
Drain / Charge Air trap
A5.05.07.12.01.nn Clean the filter elements of the fuel duplex
X X
Fuel Duplex Prefilter prefilter
X X X X X X X X
A5.05.10.03.01.nn Check the emergency stop function of the stop
X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
Check the negative pressure in the measuring
Crankcase X X X X X X X X X
chamber of the oil mist detector
Oil Mist Detector
A5.05.12.08.01.nn Lubricate the shaft and gear wheel of the
X X X X X X X X X X
Barring Device barring device
Operating Media Analysis of lubricating oil X X
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
Check the NOx sensors 47.250, 49.500, 51.750, 54.000, 56.250, X X
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only
1/1
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

X X X X
A5.05.05.01.02.nn
A5.05.05.09.01.nn
pipes and X X X X
X X X X X X X X
X X
X X X X X X X X
X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
Oil Mist Detector
X X X X X X X X X X
Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

21.000, 24.000, 27.000, 33.000, 36.000,
39.000, 42.000, 48.000, 51.000, 54.000, X X X X
57.000, 63.000, 66.000, 69.000, 72.000,
78.000, 81.000, 84.000 & 87.000 hrs only
A5.05.01.01.01.nn Check and, if necessary, adjust the valve

Valve Clearance clearance
A5.05.01.01.02.nn Check the valve projection on the inlet and
X X X X X X X
Valve Projection exhaust valves
A5.05.01.03.01.nn
Check the valve rotators X X
Valve Rotator
A5.05.01.09.01.nn Check the starting valves for ease of movement
X X
Starting Valve (for V-engines at cyl. bank A only)
A5.05.01.15.00.nn
Replace all Spark Plugs X X
Spark Plug
A5.05.03.01.01.nn Check the explosion relief valves
Explosion Relief Valve for ease of movement
1 v/ 3
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.03.07.01.nn Check the engine fasteners and connections for
Engine Fasteners and tight fit X X X X X X X X X X X X
Connections and leaks
A5.05.05.01.02.nn
Oil the control shaft X X X X X X
A5.05.06.15.03.nn Check the Hydrax cylinder for loss of oil
X
VTG Drive Check the linkage for lash
A5.05.11.09.01.nn Check the infrared filter of the oil mist detector

Crankcase and change the sintered bronze filter in X X X X X X X X X
Oil Mist Detector the measuring head
A5.05.12.08.01.nn Lubricate the spindle of the barring device via

X X X X X X X X X X
Barring Device lubricating nipple
Check the the anti-corrosion and anti-freeze
Operating Media X X
Check the governor linkage to the control shaft

Control and
for tight fit X X X X X X X X X X
Monitoring
Check governor behaviour
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only
Carry out at 4.500, 9.000, 13.500, 18.000,
22.500, 27.000, 31.500, 36.000, 40.500,
A5.05.01.20.00.nn
Replace all pre-chamber valves 45.000, 49.500, 54.000, 58.500, 63.000, X X
Pre-chamber Valve
67.500, 72.000, 76.500, 81.000, 85.500 &
90.000 hrs only
Carry out at 6.000, 12.000, 18.000, 24.000,
A5.05.07.23.01.nn 30.000, 36.000, 42.000, 48.000, 54.000,
Replace all injectors (Common Rail) X
Injector 60.000, 66.000, 72.000, 78.000, 84.000 &
90.000 hrs only
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.16.00.nn
Replace all ignition sensors 45.000, 54.000, 63.000, 72.000, 81.000 & X
Ignition Sensor
90.000 hrs only
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.19.00.nn
Replace all lower pre-chamber parts 45.000, 54.000, 63.000, 72.000, 81.000 & X X
Pre-chamber
90.000 hrs only
A5.05.06.14.01.nn Carry out at 12.000, 24.000, 36.000, 48.000,
Clean and check the turbocharger (ABB) X X X X X X X X X
Turbocharger (ABB) 60.000, 72.000 & 84.000 hrs only
Clean the turbocharger (KBB)
A5.05.06.14.02.nn Carry out at 12.000, 24.000, 36.000, 48.000,
Check the rotor, bearings and housing of the X X X X
Turbocharger (KBB) 60.000, 72.000 & 84.000 hrs only
turbocharger (KBB)
A5.05.06.14.01.nn Replace the nozzle ring and diffuser of the
Carry out at 24.000, 48.000 & 72.000 hrs only X X X X X X X X X
Turbocharger (ABB) turbocharger (ABB)
A5.05.06.14.02.nn
Replace all bearings of the turbocharger (KBB) Carry out at 24.000, 48.000 & 72.000 hrs only X X X X
Turbocharger (KBB)
A5.05.07.20.01.nn
High-Pressure Pump ??? Carry out at 24.000, 48.000 & 72.000 hrs only X X
(Injection System)
2 v/ 3
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.07.21.01.nn
Pressure Check Valve ??? Carry out at 24.000, 48.000 & 72.000 hrs only X X
(High-Pressure Pipe)
A5.05.06.14.01.nn Change the axial and radial bearings of the
Carry out at 36.000 & 72.000 hrs only X X X X X X X X X
A5.05.06.14.02.nn
Replace the rotor of the turbocharger (KBB) Carry out at 48.000 hrs only X X X X
Turbocharger (KBB)
3 v/ 3
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

A5.05.05.01.02.nn
A5.05.05.09.01.nn
pipes and X X X X
X X X X X X X X
X X
X X X X X X X X
X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
Oil Mist Detector
X X X X X X X X X X
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only

X X X X
A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

Main Running Gear / (tightness, overheating, lube oil flow, X X X X X X X X X X
Engine Timing cleanliness, etc.)
A5.05.04.08.01.nn Check the tooth flanks and oil nozzles of the

X X X X X X X X X X
Timing Gear Train timing gear train
A5.05.05.04.01.nn Check the function and tightness of the servo
X X X X
Servo Actuator actuator
1/2
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.05.05.01.nn
Check function of the starting fuel limiter X X X X X X
Starting Fuel Limiter
A5.05.06.06.00.nn Check the throttles 13 and 32 of the air injection
X X X X
Air Injection for free passage
Alternately check the spill plugs of two injection

A5.05.07.03.02.nn pumps
X X X X
Spill Plugs (first check cyl. 1 and 3, second check cyl. 2
and 4, etc.)
A5.05.07.15.02.nn
Replace all o-rings of the fuel pipe X X X X X X X X X X
Fuel Pipe Assembly
A5.05.11.01.02.nn Check the pressure switch for adjusted
X X
Pressure Switches operating values
X X X X X X X X X X
A5.05.12.08.01.nn
Check the oil level of the barring device X X X X X X X X X X
Barring Device
Control and
Change the governor oil X X X X X X X X X X
Monitoring
Control and
Check the alarm and safety system X X X X X X X X X X
Monitoring
2/2
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

X X X X
A5.05.05.01.02.nn
A5.05.05.09.01.nn
pipes and X X X X
X X X X X X X X
X X
X X X X X X X X
X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
Oil Mist Detector
X X X X X X X X X X
X X X X X X X
A5.05.01.03.01.nn
Valve Rotator
X X
A5.05.01.15.00.nn
Spark Plug
A5.05.05.01.02.nn
1/4
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
X


X X X X X X X X X X
Operating Media X X
Control and
Monitoring
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only

X X X X


X X X X X X X X X X
X X X X
A5.05.05.05.01.nn
X X X X

A5.05.07.03.02.nn pumps
X X X X
and 4, etc.)
A5.05.07.15.02.nn
Fuel Pipe Assembly
X X
X X X X X X X X X X
A5.05.12.08.01.nn
Barring Device
Control and
Monitoring
Control and
Monitoring
2/4
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
Carry out at 4.500, 9.000, 13.500, 18.000,
22.500, 27.000, 31.500, 36.000, 40.500,
A5.05.01.20.00.nn
Pre-chamber Valve
67.500, 72.000, 76.500, 81.000, 85.500 &
90.000 hrs only
A5.05.07.23.02.nn
??? X X
Ignition Injector
A5.05.01.07.01.nn
Check the Inlet and exhaust valve cones of one
Inlet and Exhaust Valve X X X X X X X X X X
cylinder unit for contact pattern and deposits
Cones
A5.05.01.18.00.nn
??? X X
Gas Valve
A5.05.01.20.00.nn
??? X X
Cylinder Pressure Sensor

Main Running Gear / (tightness, overheating, lube oil flow, X X
A5.05.02.07.01.nn
Check one piston and its rings X X X X X X X X X X
Piston Rings and Grooves
A5.05.03.01.01.nn
Check all explosion relief valves X X
Explosion Relief Valve
X X
Timing Gear Train timimg gear train
A5.05.05.02.01.nn
Service the starting valve X X X X X X X X
Starting Valve
A5.05.05.08.01.nn
Change the bushes of the control linkage X X X X X X X X
Control Linkage
A5.05.05.09.06.nn
Disassemble and clean the compressed air filter X X X X X X X X X X
Compressed Air Filter
A5.05.06.01.01.nn
Check the exhaust manifold for leaks X X X X X X X X X X X X
Exhaust Manifold
A5.05.06.05.01.nn Check the turbocharger silencer for fouling and
X
Turbocharger Silencer clean
A5.05.06.15.01.nn
Wastegate Check the wastegate for proper function X X X
A5.05.06.16.01.nn
Check the actuator of the wastegate for proper
Actuator X X
function
(Wastegate)
A5.05.07.03.01.nn
Check one injection pump X X X X X X X X
Injection Pump
A5.05.07.03.02.nn
Replace all spill plugs X X X X
Spill Plugs
A5.05.07.09.01.nn
Replace all nozzle elements of the fuel injectors X X X X X
Fuel Injector
A5.05.07.15.01.nn
Replace all o-rings of the fuel distributing /
Fuel Distributing / X X X X
collecting pipe
Collecting Pipe
A5.05.07.17.00.nn
Replace the fuel pulsation dampers X X X X
Fuel Pulsation Dampers
A5.05.07.29.01.nn
Replace the flushing valve X X
Flushing Valve
3/4
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.08.04.03.nn Check and clean the filter element of the
X X X X
Lubricating Oil Safety Strainer lubricating oil safety strainer
A5.05.10.02.01.nn
Disassemble and clean the compressed air filter X X
A5.05.11.05.01.nn
Check the RPM switch for proper function X X X X X X X X X X
RPM Switch
Disassemble the lubricating oil / cooling water
A5.05.11.06.01.nn
thermostat
Lubricating Oil / X X X X X X X X X X
and carry out a functional check of the
Cooling Water Thermostat
thermostatic element
A5.05.11.09.01.nn Replace the sintered bronze filter in the
Crankcase pressure X X X X X X X X X X
Oil Mist Detector regulator of the oil mist detector
Change the anti-corrosion oil emulsion of the
cooling water system
Change the the cooling water
Operating Media Change the anti-corrosion and anti-freeze X X
emulsion of the cooling water system
A5.05.11.06.05.nn Carry out at 22.500, 45.000, 67.500 & 90.000
Replace all pressure switches X X X X X X X X
Pressure Switches hrs only
A5.05.12.15.01.nn Carry out at 22.500, 45.000, 67.500 & 90.000
Recondition the starter system X X
Starter hrs only
4/4
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.03.01.nn
Valve Rotator
A5.05.01.10.00.nn
Cylinder Head
A5.05.06.13.01.nn
Turbocharger
A5.05.08.10.00.nn
multi-engine plant
Prelubrication

X X X X
A5.05.05.01.02.nn
A5.05.05.09.01.nn
pipes and X X X X
X X X X X X X X
X X
X X X X X X X X
X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
Oil Mist Detector
X X X X X X X X X X
Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

21.000, 24.000, 27.000, 33.000, 36.000,
39.000, 42.000, 48.000, 51.000, 54.000, X X X X
57.000, 63.000, 66.000, 69.000, 72.000,
78.000, 81.000, 84.000 & 87.000 hrs only

X X X X X X X
A5.05.01.03.01.nn
Valve Rotator
X X
A5.05.01.15.00.nn
Spark Plug
1/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.05.01.02.nn
X


X X X X X X X X X X
Operating Media X X

Control and
Monitoring
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only

X X X X


X X X X X X X X X X
X X X X
A5.05.05.05.01.nn
X X X X

A5.05.07.03.02.nn pumps
X X X X
and 4, etc.)
A5.05.07.15.02.nn
Fuel Pipe Assembly
X X
X X X X X X X X X X
A5.05.12.08.01.nn
Barring Device
2/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
Control and
Monitoring
Control and
Monitoring
Carry out at 4.500, 9.000, 13.500, 18.000,
22.500, 27.000, 31.500, 36.000, 40.500,
A5.05.01.20.00.nn
Pre-chamber Valve
67.500, 72.000, 76.500, 81.000, 85.500 &
90.000 hrs only
Carry out at 4.950, 10.050, 19.950, 25.050,
A5.05.07.09.01.nn
Replace all nozzle elements of the fuel injectors 34.950, 40.050, 49.950, 55.050, 64.950, X X X X X
Fuel Injector
70.050, 79.950 & 85.050 hrs only
A5.05.07.23.03.nn Carry out at 4.950, 10.050, 19.950, 25.050,
Kraftstofffilter Einsatz (Ignition ??? 34.950, 40.050, 49.950, 55.050, 64.950, X X
Fuel) 70.050, 79.950 & 85.050 hrs only
Carry out at 6.000, 12.000, 18.000, 24.000,
A5.05.07.23.01.nn 30.000, 36.000, 42.000, 48.000, 54.000,
Replace all injectors (Common Rail) X
Injector 60.000, 66.000, 72.000, 78.000, 84.000 &
90.000 hrs only
A5.05.07.23.02.nn
??? X X
Ignition Injector
A5.05.01.07.01.nn
Inlet and Exhaust Valve X X X X X X X X X X
Cones
A5.05.01.18.00.nn
??? X X
Gas Valve
A5.05.01.20.00.nn
??? X X

Main Running Gear / (tightness, overheating, lube oil flow, X X
A5.05.02.07.01.nn
Check one piston and its rings X X X X X X X X X X
A5.05.03.01.01.nn
Check all explosion relief valves X X
X X
A5.05.05.02.01.nn
Service the starting valve X X X X X X X X
Starting Valve
A5.05.05.08.01.nn
Change the bushes of the control linkage X X X X X X X X
Control Linkage
A5.05.05.09.06.nn
Disassemble and clean the compressed air filter X X X X X X X X X X
A5.05.06.01.01.nn
Check the exhaust manifold for leaks X X X X X X X X X X X X
Exhaust Manifold
X
A5.05.06.15.01.nn
Wastegate Check the wastegate for proper function X X X
A5.05.06.16.01.nn
Actuator X X
function
(Wastegate)
3/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.07.03.01.nn
Check one injection pump X X X X X X X X
Injection Pump
A5.05.07.03.02.nn
Replace all spill plugs X X X X
Spill Plugs
A5.05.07.09.01.nn
Replace all nozzle elements of the fuel injectors X X X X X
Fuel Injector
A5.05.07.15.01.nn
Fuel Distributing / X X X X
collecting pipe
Collecting Pipe
A5.05.07.17.00.nn
Replace the fuel pulsation dampers X X X X
A5.05.07.29.01.nn
Replace the flushing valve X X
Flushing Valve
X X X X
A5.05.10.02.01.nn
Disassemble and clean the compressed air filter X X
A5.05.11.05.01.nn
Check the RPM switch for proper function X X X X X X X X X X
RPM Switch
A5.05.11.06.01.nn
thermostat
Lubricating Oil / X X X X X X X X X X
Crankcase pressure X X X X X X X X X X
Operating Media Change the anti-corrosion and anti-freeze X X
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.16.00.nn
Replace all ignition sensors 45.000, 54.000, 63.000, 72.000, 81.000 & X
Ignition Sensor
90.000 hrs only
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.19.00.nn
Replace all lower pre-chamber parts 45.000, 54.000, 63.000, 72.000, 81.000 & X X
Pre-chamber
90.000 hrs only
A5.05.06.14.01.nn Carry out at 12.000, 24.000, 36.000, 48.000,
Clean and check the turbocharger (ABB) X X X X X X X X X
A5.05.06.14.02.nn Carry out at 12.000, 24.000, 36.000, 48.000,
Check the rotor, bearings and housing of the X X X X
turbocharger (KBB)
A5.05.01.05.01.nn
guide bushes and valves of inlet and exhaust
Valve Guide X X X X X X
valves
Oil Control Ring
A5.05.01.06.50.nn Change the o-rings of the nozzle sleeves on all

X X X X X X X X X X
Nozzle Sleeve cylinder heads (2 o-rings each)
A5.05.01.07.01.nn
Inlet and Exhaust Valve Service the inlet and exhaust valve cones X X X X X X X X X X X
Cones
A5.05.01.09.02.nn Dismantle all starting valves and regrind, if
X X X X
Starting Valve necessary
4/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.10.01.nn
Clean all cylinder heads X X X X X X
Cylinder Head
A5.05.01.18.00.nn
Replaceme the gas admission valve (GAV) X X
Gas Admission Valve (GAV)
A5.05.02.04.01.nn
Check one big-end bearing X X X X X X X X X X
Big-End Bearings
A5.05.02.05.01.nn
Check two crankshaft bearings X X X X X X X X X X
Crankshaft Bearings
A5.05.03.03.01.nn
Check one cylinder liner X X X X X X X X X X
Cylinder Liner
A5.05.04.01.01.nn Check the bearing clearance of one camshaft
X X X X X X X X X X
Camshaft Bearings bearing
Check the running surface of one camshaft
A5.05.04.01.02.nn
bearing and X X X X X X X X X
Camshaft Bearings
related camshaft section (from 1st cylinder)
A5.05.04.08.01.nn Check the step gear wheel of the timing gear
X X X X X X X X X X
Timing Gear Train train
Check the bearing pattern on helical gear pair

A5.05.04.08.03.nn and intermediate gear of the governor
X X X X X X X X X X
Governor Drive Check the serration of the governor drive shaft
Check the end clearance of the camshaft gear
A5.05.04.09.01.nn
Vibration Damper Replace the camshaft vibration damper X X X X X X X X X X
on Camshaft
A5.05.05.09.05.nn Carry out a sample check of the high-pressure
X X X X X X
Control Valves valves
A5.05.06.13.00.nn
Hydraulic Pump / Check the hydraulic fuel feed pump for wear X X
Coupling
A5.05.06.14.01.nn
Replace the turbochargers (ABB) X
Turbocharger (ABB)
A5.05.06.15.01.nn
??? X X
Control Valve (Blow Off)
A5.05.07.03.01.nn
Check all injection pumps X X X X X X X X X X
Injection Pump
A5.05.07.13.01.nn
Check the fuel feed pump for wear X X X X X X
Fuel Feed Pump
A5.05.07.13.02.nn
Fuel Feed Pump Drive Check the fuel feed pump drive for wear X X X X
A5.05.07.20.01.nn Replace the high-pressure pumps (Common

X
High-Pressure Pump Rail)
A5.05.07.22.01.nn
Replace the bearing shells of the high-pressure
Bearing Shells X
pump drive (Common Rail)
High-Pressure Pump Drive
A5.05.08.03.01.nn Check the relief valve of the lubricating oil pump
X X X X X X X X
Lubricating Oil Pump for proper function
A5.05.08.05.01.nn
Adjust the oil pressure limitation valve X X X X X X X X X X X X
Oil Pressure Limitation Valve
A5.05.09.07.01.nn
Check the cooling water centrifugal pump for
Cooling Water Centrifugal X X X X X X X X X X
wear
Pump
5/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.10.01.02.nn
Clean the starting air distributor X X X X X X
Starting Air Distributor
Check 2 x 3 damping packages of the
A5.05.12.04.02.nn vibration damper (sleeve spring damper /
X X
Vibration Damper crankshaft)
and the related thrust washers
Applicable exclusively to 20 cylinder GMC34

A5.05.12.04.03.nn
Service the crankshaft vibration damper X X
Vibration Damper
Carry out at 15.000, 45.000 & 75.000 hrs only

A5.05.01.05.01.nn
Valve Guide X
valves hrs only
Oil Control Ring
A5.05.01.07.01.nn
Carry out at 19.950, 40.050, 60.000 & 79.950
Inlet and Exhaust Valve Service the inlet and exhaust valve cones X
hrs only
Cones
A5.05.01.10.01.nn Carry out at 19.950, 40.050, 60.000 & 79.950
Clean all cylinder heads X
A5.05.11.06.05.nn Carry out at 22.500, 45.000, 67.500 & 90.000
Replace all pressure switches X X X X X X X X
A5.05.12.15.01.nn Carry out at 22.500, 45.000, 67.500 & 90.000
Recondition the starter system X X
Starter hrs only
Check the bearing clearances of the rocker

A5.05.01.02.02.nn arms
Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X X X
Rocker Arms Replace the rocker arm bushes
Replace the ball head pins of the rocker arms
A5.05.01.05.01.nn Check the valve guide clearances on all valve

Valve Guide guide bushes Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X
Oil Control Ring and valves of inlet and exhaust valves
A5.05.01.06.70.nn
Replace the relief valve Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X
Relief Valve
A5.05.01.09.02.nn Disassemble and, if necessary, regrind all
Carry out at 30.000, 60.000 & 90.000 hrs only X X X X
Starting Valve starting valves
A5.05.01.10.01.nn
Clean all cylinder heads Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X
Cylinder Head
A5.05.02.04.01.nn
Replace all big-end bearings Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
Big-End Bearings

A5.05.02.05.01.nn
Replace all crankshaft bearings X X X X X X X X X X X X
Crankshaft Bearings
Not GCM34 420kW/cyl.

A5.05.02.05.05.nn
Replace the crankshaft thrust bearing X X X X X X X X X X X X
Crankshaft Thrust Bearing
A5.05.02.07.01.nn
Check all piston and their rings Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
A5.05.02.09.01.nn Measure the bearing clearance of the small end
Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X
Small-End Bush bushes of all pistons
A5.05.03.01.01.nn
Replace all explosion relief valves Carry out at 30.000, 60.000 & 90.000 hrs only X X
A5.05.03.03.01.nn
Measure all cylinder liners Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
Cylinder Liner
6/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.03.04.01.nn
Replace the o-rings of all cylinder liners Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
Cylinder Liner
A5.05.04.01.01.nn Check the bearing clearance of all camshaft
Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
Camshaft Bearings bearings
Check the running surfaces of all camshaft
A5.05.04.01.02.nn
bearings and Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X
Camshaft Bearings
camshaft sections (from 1st cylinder)
A5.05.04.09.02.nn
Vibration Damper Replace the camshaft vibration damper Carry out at 30.000, 60.000 & 90.000 hrs only X X X X
on Camshaft
A5.05.05.09.05.nn
Check the high-pressure valves Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X
Control Valves
A5.05.06.04.02.nn
Clean the charge air cooler Carry out at 30.000, 60.000 & 90.000 hrs only X X
Charge Air Cooler
A5.05.07.15.02.nn
Replace the fuel tubes Carry out at 30.000, 60.000 & 90.000 hrs only X X X X
Fuel Pipe Assembly
A5.05.12.04.01.nn
Service the crankshaft vibration damper Carry out at 30.000, 60.000 & 90.000 hrs only X X
Vibration Damper

A5.05.12.04.02.nn
Replace the crankshaft vibration damper X X
Vibration Damper
A5.05.12.04.03.nn
Service the crankshaft vibration damper Carry out at 30.000 & 90.000 hrs only X X
Vibration Damper
A5.05.12.08.01.nn
Change the oil of the barring device Carry out at 30.000, 60.000 & 90.000 hrs only X X X X X X X X X X
Barring Device
A5.05.01.21.00.nn
Replace the ignition coil Carry out at 45.000 & 90.000 hrs only X X
Ignition Coil
A5.05.02.04.01.nn
Replace all big-end bearings Carry out at 45.000 & 90.000 hrs only X X
Big-End Bearings
A5.05.02.05.01.nn
Replace all crankshaft bearings (420 kW/cyl.) Carry out at 45.000 & 90.000 hrs only X X
Crankshaft Bearings
A5.05.02.05.05.nn Replace the crankshaft thrust bearing (420
Carry out at 45.000 & 90.000 hrs only X X
Crankshaft Thrust Bearing kW/cyl.)
A5.05.02.07.01.nn
Check all piston and their rings Carry out at 45.000 & 90.000 hrs only X X
A5.05.02.09.01.nn Measure the bearing clearance of all small-end
Carry out at 45.000 & 90.000 hrs only X X X
Small-End Bush bushes
A5.05.03.03.01.nn
Measure all cylinder liners Carry out at 45.000 & 90.000 hrs only X X
Cylinder Liner
A5.05.03.04.01.nn Replace the o-rings and gauging rings of all
Carry out at 45.000 & 90.000 hrs only X X
Cylinder Liner cylinder liners
A5.05.02.06.04.nn Replace all piston skirts
Carry out at 60.000 hrs only X X
Piston (pistons with casted skirt)
A5.05.04.01.02.nn
Replace all camshaft bearings Carry out at 60.000 hrs only X X
Camshaft Bearings
A5.05.12.04.02.nn
Service the crankshaft vibration damper Carry out at 30.000 & 90.000 hrs only X X X X X X X X
Vibration Damper
A5.05.12.04.02.nn
Replace the crankshaft vibration damper Carry out at 60.000 hrs only X X X X X X X X
Vibration Damper
A5.05.12.04.03.nn
Replace the crankshaft vibration damper Carry out at 60.000 hrs only X X
Vibration Damper
A5.05.02.06.04.nn Replace all piston crowns
7/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.02.06.05.nn Replace crowns and skirts of all pistons
Piston (steel pistons)
8/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
x x x x x x x x x x x x 150 h intervals
A5.05.01.03.01.nn
o o o o o o o X X X X X X X X X X Check the valve rotators and ball races
Valve Rotator
A5.05.01.10.00.nn
o o o o o o o X X X X X X X X X X X X General inspection of all cylinder heads
Cylinder Head
A5.05.06.13.01.nn
o o o o o o o X X X X X Turbine washing
Turbocharger
A5.05.08.10.00.nn
o o o o o o o X X X X X X X X X X X X Prelubrication Pump /
multi-engine plant
Prelubrication
o o o o o o o X X X X X X X X X X Operating Media
X X X X
A5.05.05.01.02.nn
o o o o o X X X X Oil the control shaft
A5.05.05.09.01.nn
o o o o o X X X X pipes and
o o o o o X X X X X X X X
o o o o o X X
o o o o o X X X X X X X X
o o o o o X X X X X X X X X X
Stop Piston piston
A5.05.11.09.01.nn
o o o o o X X X X X X X X X Crankcase
Oil Mist Detector
o o o o o X X X X X X X X X X
o o o o o X X Operating Media Analysis of lubricating oil
x x x x x x x x x x x x 1.000 h intervals
Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

21.000, 24.000, 27.000, 33.000, 36.000,
o o o X X X X 39.000, 42.000, 48.000, 51.000, 54.000,
57.000, 63.000, 66.000, 69.000, 72.000,
78.000, 81.000, 84.000 & 87.000 hrs only
o o o X X X X X X X X X X X X
o o o X X X X X X X
A5.05.01.03.01.nn
o o o X X Check the valve rotators
Valve Rotator
o o o X X
1/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.01.15.00.nn
o o o X X Replace all Spark Plugs
Spark Plug
o o o X X X X X X X X X X X X
o o o X X X X X X X X X X X X Engine Fasteners and tight fit
A5.05.05.01.02.nn
o o o X X X X X X Oil the control shaft
o o o X

o o o X X X X X X X X X Crankcase and change the sintered bronze filter in

o o o X X X X X X X X X X
o o o X X Operating Media

Control and
o o o X X X X X X X X X X for tight fit
Monitoring
Carry out at 2.250, 4.500, 6.750, 9.000, 11.250,
13.500, 15.750, 18.000, 20.250, 22.500,
24.750, 27.000, 29.250, 31.500, 33.750,
36.000, 38.250, 40.500, 42.750, 45.000,
A5.05.06.03.01.nn
o o o o o X X Check the NOx sensors 47.250, 49.500, 51.750, 54.000, 56.250,
NOx Sensor
58.500, 60.750, 63.000, 65.250, 67.500,
69.750, 72.000, 74.250, 76.500, 78.750,
81.000, 83.250 & 85.500, 87.750, 90.000 hrs
only
o o o X X X X

o o o X X X X X X X X X X Main Running Gear / (tightness, overheating, lube oil flow,

o o o X X X X
A5.05.05.05.01.nn
o o o X X X X X X Check function of the starting fuel limiter
o o o X X X X

A5.05.07.03.02.nn pumps
o o o X X X X
and 4, etc.)
2/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.07.15.02.nn
o o o X X X X X X X X X X Replace all o-rings of the fuel pipe
Fuel Pipe Assembly
o o o X X
A5.05.12.08.01.nn
o o o X X X X X X X X X X Check the oil level of the barring device
Barring Device
Control and
o o o X X X X X X X X X X Change the governor oil
Monitoring
Control and
o o o X X X X X X X X X X Check the alarm and safety system
Monitoring
Carry out at 4.500, 9.000, 13.500, 18.000,
22.500, 27.000, 31.500, 36.000, 40.500,
A5.05.01.20.00.nn
o o o X X Replace all pre-chamber valves 45.000, 49.500, 54.000, 58.500, 63.000,
Pre-chamber Valve
67.500, 72.000, 76.500, 81.000, 85.500 &
90.000 hrs only
Carry out at 4.950, 10.050, 19.950, 25.050,
A5.05.07.09.01.nn
o o X X X X X Replace all nozzle elements of the fuel injectors 34.950, 40.050, 49.950, 55.050, 64.950,
Fuel Injector
70.050, 79.950 & 85.050 hrs only
A5.05.07.23.03.nn Carry out at 4.950, 10.050, 19.950, 25.050,
o o X X Kraftstofffilter Einsatz (Ignition ??? 34.950, 40.050, 49.950, 55.050, 64.950,
Fuel) 70.050, 79.950 & 85.050 hrs only
Carry out at 6.000, 12.000, 18.000, 24.000,
A5.05.07.23.01.nn 30.000, 36.000, 42.000, 48.000, 54.000,
o o X Replace all injectors (Common Rail)
Injector 60.000, 66.000, 72.000, 78.000, 84.000 &
90.000 hrs only
A5.05.07.23.02.nn
o o X X ???
Ignition Injector
A5.05.01.07.01.nn
o o X X X X X X X X X X Inlet and Exhaust Valve
Cones
A5.05.01.18.00.nn
o o X X ???
Gas Valve
A5.05.01.20.00.nn
o o X X ???
o o X X Main Running Gear / (tightness, overheating, lube oil flow,
A5.05.02.07.01.nn
o o X X X X X X X X X X Check one piston and its rings
A5.05.03.01.01.nn
o o X X Check all explosion relief valves
o o X X
A5.05.05.02.01.nn
o o X X X X X X X X Service the starting valve
Starting Valve
3/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.05.08.01.nn
o o X X X X X X X X Change the bushes of the control linkage
Control Linkage
A5.05.05.09.06.nn
o o X X X X X X X X X X Disassemble and clean the compressed air filter
A5.05.06.01.01.nn
o o X X X X X X X X X X X X Check the exhaust manifold for leaks
Exhaust Manifold
o o X
A5.05.06.15.01.nn
o o X X X Wastegate Check the wastegate for proper function
A5.05.06.16.01.nn
o o X X Actuator
function
(Wastegate)
A5.05.07.03.01.nn
o o X X X X X X X X Check one injection pump
Injection Pump
A5.05.07.03.02.nn
o o X X X X Replace all spill plugs
Spill Plugs
A5.05.07.09.01.nn
o o X X X X X Replace all nozzle elements of the fuel injectors
Fuel Injector
A5.05.07.15.01.nn
o o X X X X Fuel Distributing /
collecting pipe
Collecting Pipe
A5.05.07.17.00.nn
o o X X X X Replace the fuel pulsation dampers
A5.05.07.29.01.nn
o o X X Replace the flushing valve
Flushing Valve
o o X X X X
A5.05.10.02.01.nn
o o X X Disassemble and clean the compressed air filter
A5.05.11.05.01.nn
o o X X X X X X X X X X Check the RPM switch for proper function
RPM Switch
A5.05.11.06.01.nn
thermostat
o o X X X X X X X X X X Lubricating Oil /
o o X X X X X X X X X X Crankcase pressure
o o X X X X X X X X X X Operating Media
o o X X Operating Media Change the anti-corrosion and anti-freeze
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.16.00.nn
o o X Replace all ignition sensors 45.000, 54.000, 63.000, 72.000, 81.000 &
Ignition Sensor
90.000 hrs only
Carry out at 9.000, 18.000, 27.000, 36.000,
A5.05.01.19.00.nn
o o X X Replace all lower pre-chamber parts 45.000, 54.000, 63.000, 72.000, 81.000 &
Pre-chamber
90.000 hrs only
4/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.06.14.01.nn Carry out at 12.000, 24.000, 36.000, 48.000,
o o X X X X X X X X X Clean and check the turbocharger (ABB)
A5.05.06.14.02.nn Carry out at 12.000, 24.000, 36.000, 48.000,
o o X X X X Check the rotor, bearings and housing of the
turbocharger (KBB)
A5.05.01.05.01.nn
guide bushes and valves of inlet and exhaust
o X X X X X X Valve Guide
valves
Oil Control Ring
A5.05.01.06.50.nn Change the o-rings of the nozzle sleeves on all

o X X X X X X X X X X
Nozzle Sleeve cylinder heads (2 o-rings each)
A5.05.01.07.01.nn
o X X X X X X X X X X X Inlet and Exhaust Valve Service the inlet and exhaust valve cones
Cones
A5.05.01.09.02.nn Dismantle all starting valves and regrind, if
o X X X X
Starting Valve necessary
A5.05.01.10.01.nn
o X X X X X X Clean all cylinder heads
Cylinder Head
A5.05.01.18.00.nn
o X X Replaceme the gas admission valve (GAV)
Gas Admission Valve (GAV)
A5.05.02.04.01.nn
o X X X X X X X X X X Check one big-end bearing
Big-End Bearings
A5.05.02.05.01.nn
o X X X X X X X X X X Check two crankshaft bearings
Crankshaft Bearings
A5.05.03.03.01.nn
o X X X X X X X X X X Check one cylinder liner
Cylinder Liner
A5.05.04.01.01.nn Check the bearing clearance of one camshaft
Camshaft Bearings bearing
Check the running surface of one camshaft
A5.05.04.01.02.nn
o X X X X X X X X X bearing and
Camshaft Bearings
related camshaft section (from 1st cylinder)
A5.05.04.08.01.nn Check the step gear wheel of the timing gear
Timing Gear Train train
Check the bearing pattern on helical gear pair

A5.05.04.08.03.nn and intermediate gear of the governor
Governor Drive Check the serration of the governor drive shaft
Check the end clearance of the camshaft gear
A5.05.04.09.01.nn
o X X X X X X X X X X Vibration Damper Replace the camshaft vibration damper
on Camshaft
A5.05.05.09.05.nn Carry out a sample check of the high-pressure
o X X X X X X
Control Valves valves
A5.05.06.13.00.nn
o X X Hydraulic Pump / Check the hydraulic fuel feed pump for wear
Coupling
A5.05.06.14.01.nn
o X Replace the turbochargers (ABB)
Turbocharger (ABB)
A5.05.06.15.01.nn
o X X ???
Control Valve (Blow Off)
5/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.07.03.01.nn
o X X X X X X X X X X Check all injection pumps
Injection Pump
A5.05.07.13.01.nn
o X X X X X X Check the fuel feed pump for wear
Fuel Feed Pump
A5.05.07.13.02.nn
o X X X X Fuel Feed Pump Drive Check the fuel feed pump drive for wear
A5.05.07.20.01.nn Replace the high-pressure pumps (Common

o X
High-Pressure Pump Rail)
A5.05.07.22.01.nn
Replace the bearing shells of the high-pressure
o X Bearing Shells
pump drive (Common Rail)
High-Pressure Pump Drive
A5.05.08.03.01.nn Check the relief valve of the lubricating oil pump
o X X X X X X X X
Lubricating Oil Pump for proper function
A5.05.08.05.01.nn
o X X X X X X X X X X X X Adjust the oil pressure limitation valve
Oil Pressure Limitation Valve
A5.05.09.07.01.nn
Check the cooling water centrifugal pump for
o X X X X X X X X X X Cooling Water Centrifugal
wear
Pump
A5.05.10.01.02.nn
o X X X X X X Clean the starting air distributor
Starting Air Distributor
A5.05.12.04.03.nn
X X Service the crankshaft vibration damper
Vibration Damper
Check 2 x 3 damping packages of the

A5.05.12.04.02.nn vibration damper (sleeve spring damper /
o X X
Vibration Damper crankshaft)
and the related thrust washers
A5.05.01.05.01.nn
o o X Valve Guide
valves hrs only
Oil Control Ring
A5.05.01.07.01.nn
Carry out at 19.950, 40.050, 60.000 & 79.950
o o X Inlet and Exhaust Valve Service the inlet and exhaust valve cones
hrs only
Cones
A5.05.01.10.01.nn Carry out at 19.950, 40.050, 60.000 & 79.950
o o X Clean all cylinder heads
A5.05.11.06.05.nn Carry out at 22.500, 45.000, 67.500 & 90.000
o o X X X X X X X X Replace all pressure switches
A5.05.12.15.01.nn Carry out at 22.500, 45.000, 67.500 & 90.000
o o X X Recondition the starter system
Starter hrs only
A5.05.06.14.01.nn Replace the nozzle ring and diffuser of the
o X X X X X X X X X Carry out at 24.000, 48.000 & 72.000 hrs only
A5.05.06.14.02.nn
o X X X X Replace all bearings of the turbocharger (KBB) Carry out at 24.000, 48.000 & 72.000 hrs only
Turbocharger (KBB)
A5.05.07.20.01.nn
o X X High-Pressure Pump ??? Carry out at 24.000, 48.000 & 72.000 hrs only
(Injection System)
6/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.07.21.01.nn
o X X Pressure Check Valve ??? Carry out at 24.000, 48.000 & 72.000 hrs only
(High-Pressure Pipe)
Check the bearing clearances of the rocker

A5.05.01.02.02.nn arms
o X X X X X X X X X X X X Carry out at 30.000, 60.000 & 90.000 hrs only
Rocker Arms Replace the rocker arm bushes
Replace the ball head pins of the rocker arms
A5.05.01.05.01.nn Check the valve guide clearances on all valve

o X X X X X Valve Guide guide bushes Carry out at 30.000, 60.000 & 90.000 hrs only
Oil Control Ring and valves of inlet and exhaust valves
A5.05.01.06.70.nn
o X X X X X X X X Replace the relief valve Carry out at 30.000, 60.000 & 90.000 hrs only
Relief Valve
A5.05.01.09.02.nn Disassemble and, if necessary, regrind all
o X X X X Carry out at 30.000, 60.000 & 90.000 hrs only
Starting Valve starting valves
A5.05.01.10.01.nn
o X X X X X Clean all cylinder heads Carry out at 30.000, 60.000 & 90.000 hrs only
Cylinder Head
A5.05.02.04.01.nn
o X X X X X X X X X X Replace all big-end bearings Carry out at 30.000, 60.000 & 90.000 hrs only
Big-End Bearings
A5.05.02.05.01.nn
o X X X X X X X X X X X X Replace all crankshaft bearings
Crankshaft Bearings

A5.05.02.05.05.nn
o X X X X X X X X X X X X Replace the crankshaft thrust bearing
Crankshaft Thrust Bearing
A5.05.02.07.01.nn
o X X X X X X X X X X Check all piston and their rings Carry out at 30.000, 60.000 & 90.000 hrs only
A5.05.02.09.01.nn Measure the bearing clearance of the small end
o X X X X X X X Carry out at 30.000, 60.000 & 90.000 hrs only
Small-End Bush bushes of all pistons
A5.05.03.01.01.nn
o X X Replace all explosion relief valves Carry out at 30.000, 60.000 & 90.000 hrs only
A5.05.03.03.01.nn
o X X X X X X X X X X Measure all cylinder liners Carry out at 30.000, 60.000 & 90.000 hrs only
Cylinder Liner
A5.05.03.04.01.nn
o X X X X X X X X X X Replace the o-rings of all cylinder liners Carry out at 30.000, 60.000 & 90.000 hrs only
Cylinder Liner
A5.05.04.01.01.nn Check the bearing clearance of all camshaft
o X X X X X X X X X X Carry out at 30.000, 60.000 & 90.000 hrs only
Camshaft Bearings bearings
Check the running surfaces of all camshaft
A5.05.04.01.02.nn
o X X X X X X X X bearings and Carry out at 30.000, 60.000 & 90.000 hrs only
Camshaft Bearings
camshaft sections (from 1st cylinder)
A5.05.04.09.02.nn
o X X X X Vibration Damper Replace the camshaft vibration damper Carry out at 30.000, 60.000 & 90.000 hrs only
on Camshaft
A5.05.05.09.05.nn
o X X X X X X Check the high-pressure valves Carry out at 30.000, 60.000 & 90.000 hrs only
Control Valves
A5.05.06.04.02.nn
o X X Clean the charge air cooler Carry out at 30.000, 60.000 & 90.000 hrs only
Charge Air Cooler
A5.05.07.15.02.nn
o X X X X Replace the fuel tubes Carry out at 30.000, 60.000 & 90.000 hrs only
Fuel Pipe Assembly
A5.05.12.04.01.nn
o X X Service the crankshaft vibration damper Carry out at 30.000, 60.000 & 90.000 hrs only
Vibration Damper
7/8
GCM34 M20 M25 M32 M43 M46
Gas Com- Electric
pression Power
A5.05.12.04.02.nn
X X X X X X X X Service the crankshaft vibration damper Carry out at 30.000 & 90.000 hrs only
Vibration Damper
A5.05.12.04.02.nn
o X X Replace the crankshaft vibration damper
Vibration Damper
A5.05.12.04.03.nn
o X X Service the crankshaft vibration damper Carry out at 30.000 & 90.000 hrs only
Vibration Damper
A5.05.12.08.01.nn
o X X X X X X X X X X Change the oil of the barring device Carry out at 30.000, 60.000 & 90.000 hrs only
Barring Device
A5.05.06.14.01.nn Change the axial and radial bearings of the
o X X X X X X X X X Carry out at 36.000 & 72.000 hrs only
A5.05.01.21.00.nn
o X X Replace the ignition coil Carry out at 45.000 & 90.000 hrs only
Ignition Coil
A5.05.02.04.01.nn
o X X Replace all big-end bearings Carry out at 45.000 & 90.000 hrs only
Big-End Bearings
A5.05.02.05.01.nn
o X X Replace all crankshaft bearings (420 kW/cyl.) Carry out at 45.000 & 90.000 hrs only
Crankshaft Bearings
A5.05.02.05.05.nn Replace the crankshaft thrust bearing (420
o X X Carry out at 45.000 & 90.000 hrs only
Crankshaft Thrust Bearing kW/cyl.)
A5.05.02.07.01.nn
o X X Check all piston and their rings Carry out at 45.000 & 90.000 hrs only
A5.05.02.09.01.nn Measure the bearing clearance of all small-end
o X X X Carry out at 45.000 & 90.000 hrs only
Small-End Bush bushes
A5.05.03.03.01.nn
o X X Measure all cylinder liners Carry out at 45.000 & 90.000 hrs only
Cylinder Liner
A5.05.03.04.01.nn Replace the o-rings and gauging rings of all
o X X Carry out at 45.000 & 90.000 hrs only
Cylinder Liner cylinder liners
A5.05.06.14.02.nn
o X X X X Replace the rotor of the turbocharger (KBB) Carry out at 48.000 hrs only
Turbocharger (KBB)
A5.05.02.06.04.nn Replace all piston skirts
o X X Carry out at 60.000 hrs only
A5.05.04.01.02.nn
o X X Replace all camshaft bearings Carry out at 60.000 hrs only
Camshaft Bearings
A5.05.12.04.02.nn
o X X X X X X X X Replace the crankshaft vibration damper Carry out at 60.000 hrs only
Vibration Damper
A5.05.12.04.03.nn
o X X Replace the crankshaft vibration damper Carry out at 60.000 hrs only
Vibration Damper
A5.05.02.06.04.nn Replace all piston crowns
A5.05.02.06.05.nn Replace crowns and skirts of all pistons
Piston (steel pistons)
8/8

Maintenance Plan

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Maintenance Plan

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Version 1.1 / 14.08.

Clean the intake air filter according to the actual installation. X X

Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

Carry out at 4.950, 10.050, 19.950, 25.050,

Check the anti-corrosion and anti-freeze

Check the anti-corrosion and anti-freeze

Check the anti-corrosion and anti-freeze

Check the anti-corrosion and anti-freeze

Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

A5.05.01.01.01.nn Check and, if necessary, adjust the valve

A5.05.11.09.01.nn Check the infrared filter of the oil mist detector

A5.05.12.08.01.nn Lubricate the spindle of the barring device via

Check the governor linkage to the control shaft

Check the anti-corrosion and anti-freeze

A5.05.01.09.01.nn Check the starting valves for ease of movement

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

A5.05.04.08.01.nn Check the tooth flanks and oil nozzles of the

Alternately check the spill plugs of two injection

Check the anti-corrosion and anti-freeze

A5.05.11.09.01.nn Check the infrared filter of the oil mist detector

A5.05.12.08.01.nn Lubricate the spindle of the barring device via

A5.05.01.09.01.nn Check the starting valves for ease of movement

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

A5.05.04.08.01.nn Check the tooth flanks and oil nozzles of the

Alternately check the spill plugs of two injection

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

Check the anti-corrosion and anti-freeze

Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

A5.05.01.01.01.nn Check and, if necessary, adjust the valve

A5.05.11.09.01.nn Check the infrared filter of the oil mist detector

A5.05.12.08.01.nn Lubricate the spindle of the barring device via

Check the governor linkage to the control shaft

A5.05.01.09.01.nn Check the starting valves for ease of movement

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

A5.05.04.08.01.nn Check the tooth flanks and oil nozzles of the

Alternately check the spill plugs of two injection

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

A5.05.01.06.50.nn Change the o-rings of the nozzle sleeves on all

Check the bearing pattern on helical gear pair

A5.05.07.20.01.nn Replace the high-pressure pumps (Common

Applicable exclusively to 20 cylinder GMC34

Check the valve guide clearances on all valve

Check the bearing clearances of the rocker

A5.05.01.05.01.nn Check the valve guide clearances on all valve

Carry out at 30.000, 60.000 & 90.000 hrs only

Carry out at 30.000, 60.000 & 90.000 hrs only

Applicable exclusively to 20 cylinder GMC34

Carry out at 3.000, 6.000, 9.000 12.000, 18.000,

A5.05.11.09.01.nn Check the infrared filter of the oil mist detector

A5.05.12.08.01.nn Lubricate the spindle of the barring device via

Check the governor linkage to the control shaft

A5.05.02.01.01.nn Inspect the crankcase and engine timing gear

A5.05.04.08.01.nn Check the tooth flanks and oil nozzles of the

Alternately check the spill plugs of two injection

A5.05.01.06.50.nn Change the o-rings of the nozzle sleeves on all

Check the bearing pattern on helical gear pair

A5.05.07.20.01.nn Replace the high-pressure pumps (Common

Check 2 x 3 damping packages of the

Check the bearing clearances of the rocker

A5.05.01.05.01.nn Check the valve guide clearances on all valve

Carry out at 30.000, 60.000 & 90.000 hrs only

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