I -t -I ENGINEER'S HANDBOOK I M 45114521453

-I

ENGINEER’S

I

M

HANDBOOK

45114521453

Contents BOO

0O.Q

GENERAL ENGINE DATA 1.0 2.0 3.0 4.0

Sectional views Dimensions and weights Engine handling Tables of tightening moments

BOl

CYLINDER COVER 1.0 1.1 1.2

Valve rocker, removal/fitting Valve rocker brackets Blank

i 2.0 2.1

Valve guide Valve guide clearance

3.0 3.1 13.2

inlet and exhaust valves (table of variants), valve Maintenance and overhaul of valves Valve rotator M 452453

and fitting

4.0 4.1

Starting valve Blank

5.0 5.1

Cylinder cover assembly Cylindercover, mechanical

6.

Blank

housings

reconditioning

RUNNING GEAR

B 02 1.0 1.1 1.2 1.3 1.4

Big-end bearing, inspection and fitting M 4511452 Big-end bearing, inspection M 453 in-line and Vee Big-end bearing, fitting M 453 in-line and Vee Blank Blank

2.0 2.1 2.2 2.3 2.4 2.5

Main bearing, inspection M 451/452 Main bearing, removal- and fitting M 4511452 Main bearing, inspection M 453 in-line and Vee Main bearing, removal- and fitting M 453 in-line and Vee Main- and big- end bearing- storing Reboring of main bearing oilways and single and main bearing- cap

3.0 3.1 3.2

Crankshaft tightening moment, 6/8 and 9 cyl. Counter-weights, M 452/M 453 and 12 and 16 cyl. M 453 Blank

4.0 4.1 4.2 4.3

Liner (wear measurement Liner fitting and removal Blank Blank

h

and reconditioning)

I

I SERVICE

Edition

31.

I -t

Oktober

1988

KRUPP

MaK

DOCUMENT MASCHINENBAU

OF GMBH

ENGINEER’S

tvl

HANDBOOK

45114521453

Conten3s00.1 5.0 5.1 5.2 5.3 5.4

ENGINE HOUSING

BO3 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Bedplate, engine housing M 451,452,453 and M 453 V Blank Foundation plan Cylinder block Tightening instructions for tie-rod, hydr. tools Gear case Pump end cover, flanged shaft incl. vibration damper arrangement Crankcase ventilation

TIMING GEAR

804 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Triming gear - inspection Timing gear train incl. gear wheel setting M 452/453 in-line and V engine Fitting of camshaft Cam setting Repaircam for fuel, inlet and exhaust Exhaust cam setting Reversing gear Blank Blank Blank

CONTROL

805 1.0 1.1 1.2

B 06

Piston pin and bush removal and fitting Piston assembly (built-up piston) Ring lay-out and grooves Z 451/M 451 - 452 - 453 in-line and V Piston removal and fitting Z and M 451/452/453 in-line and V Blank

Governor drive Governor linkage Speed setting, emergency

EXHAUST SYSTEM/SUPERCHARGING 1.0 1.1 1.2 1.3

Exhaust Exhaust Exhaust Charge

February

system gas turbocharger pipe air cooler/charge air shaft

SERVICE

Edition

28.

stop, fuel injection limitation according to charge air

1989

KRUPP

MaK


OF GMBH

ENGINEER’S

M

HANDBOOK

45ll452l453 -

Contents B07

00.2

FUEL SYSTEM 1.0 1.1 1.2 1.3 1.4

Fuel system Injection pump, basic setting Injection pump fitting/removal Injection valve Nozzle cooling

2.1 2.2 2.3 2.4

Blank Blank Blank Blank

B 08

LUBOIL SYSYEM Luboil circuit Blank Luboil pump, fitting M 451/452/453 Blank

1.0 1.1 1.2 1.3

BO9

COOLING WATER SYSTEM 1.0 1.1 1.2 1.3 1.4 1.5

Blank Conventional sea-/fresh water cooling Single-circuit cooling Two-circuit charge-air cooling Cylinder cooling Central cooling with low- and high-temperature

2.1 2.2

Cooling water centrifugal pump Cooling water piston and bilge pumps

BlO

cycle

STARTING AIR SYSTEM 1.0 1.1 1.2 1.3

Blank Starting air system Starting air tank Starting air capacity

2.1 2.2

Master starting valve M 451/452/453 Blank

hydraulic starting aid /starting fuel limiter

MONITORS

811 1.0 1.1

Edition

30.November1987

Blank Blank

SERVICE KRUPP

MaK


OF GMBH

r4

ENGINEER’S

I

HANDBOOK-

M

451/452/453

Contents 812

ANCILLARIES 1.0 1.1 1.2 1.3 1.4

813

Blank Barring ge,s! Blank Air combressor Blank

SPECIAL TOOLS /DEVICES -+. 1.0 1.1 1.2 1.3 1.4

Topls equipment Basic set of standard tools Additional set of basic tools Additional set of basic tools Additional set of basic tools

RM 452; 453lVM 453 RM 452 RM 453 VM 453

,.I

Edition

30.November1987

SERVICE KRUPP

MaK


OF GMBH

00.2

ENGINEER’S

General Engine data

HANDBOOK

Sectional views B 00-l ,Q Cross-section Z 451 in-line

Valve control mechanism;

\ W_)]

i

Exhausl opens = 90” f 2” befor, e BDC Exhaust closes = 45” - 60” alter BDC

I \

I I

I

Commencement of delivery = Coincidence of line marks J3.Y- 1 la before TDC

I

Direct injection Ejection pressure = 260 bar Valve clearance = 0.4 - 0.5 mm

9 .

” “F--

Mean effective pressure: pmc = 8,3 - 9,25 bar

Piston displacement:

36,2 I /cyl

Bore : 0 320 mm

Slorke:450

mm

Speed: 300 - 375 rpm

Edition

31.January1988

SERVICE KRUPP

MaK


OF GMBH

ENGINEER’S

General Engine data

HANDBOOK

Section Cross-section

Speed revul. per minue Bore: 0 320 mm Trim@ v&es: IflIe opens: Inlet closes: Exhaust opens: Exhaust closes: Conveyor [riming: Pre stroke length ‘X’ Valve ciearance Mean elienive pressure Compression pressure Combustion pressure Ejecting pressure

- 300 - 425 r. p.m. Woke: 450 mm UnsuDercharaedw 22” before T.D.C. W belor:T.D.C. 36* after B.D.C. 40” atier B.D.C. 36’before B.D.C. 57” belore B.D.C. 22” afierT.D.C. 40’ after T.D.C. 17’ before T.D.C. ll”-14” before T.D.C. - 4.3 mm 4.0 mm _ O.5mn _ 6 bar 9.2 - 12.1 bar - 33 - 34bar 60-62bar -56-5Qbar 64-92bar 26O bar

Firing order : (cbckwise rotation) 6M-l-4-2-6-3-5 6M*1-4-7-6-6-5-2-3

SERVICE

Edition

31 a January

1989

view B 00-l .I_

M 451 in-line

KRUPP

MaK


OF GMBH

ENGINEER’S

General Englne data

HANDBOOK

&ctional Cross-section

31.

August

M 452 in-line

SERVICE

Edition

1987

vlews B 00-1.2

KRUPP

MaK


OF GMBH

A

ENGINEER’S

HANDBOOK I

General Engine data

Sectional views B 00-l .3 Cross-section M 453 in-line

SERVICE

Edition

31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

General Engine data

HANDBOOK

Dimensions Designation

length mm

width mm

Bedplate (cpl.) 6Zu. 6M451/6M452 6M 453 8Z u. 8M 451 l8M 452 8M4-53 9z 451 u. 9M 452 9M453 12M 453 16M 453

3000 3108,5 3900 4008,5 4350 4458,5 3689,5 4829,5

1280 1280 1280 1280 1280 1280 1600 1600

Crankshaft 6M451 6Z 451 u. 6M 452 6M 453 8M 451 8Z 451 u. 8M 452 8M453 9Z451 u. 9M 452 9M 453 12M 453 16M 453

3204 3204 3344 4104 4104 4244 4554 4694 3975 5115

_----_--__-____--_-~_-----------l-----

Countherweight 6,8 u.9M 453 12u.16M453

448 550

110 89

and weiahts

height0 mm

842

B 00 -. 2p weigh! kI

642 965 842 965 1060 1060

2250 3200 3064 4200 3260 4700 5080 6650

225 225 2451672 225 225 24551672 225 2451672 3001672 3001672

1890 2020 2540 2650 2504 3360 2830 3700 3000 3950

965

222 296

60,5/61 66169

Engine housingwithouff

with liners and studs 6Z45116M451 6M453

u.452

2810 2810

1030 1030

1380 13801-1718

8Z45118M451 8M453

u.452

3710 3710

1030 1030

1380 1380/-1718

9Z451 u.9M452 9M453 12M453

4160 4160 3542

1030 1030 1788

1380 1380/-1718 i425ri735

16M453

4682

1788

1425l.1735

Camshaft 6Z45116M451 u.453 (reversible) (non-reversible)

3375 3145

90 90

162 154

12M453 (reversible) (non-reversible)

4109 3654

90 90

197 185

16M453 (reversible) (non-reversible)

5249 4994

90 90

254 242

Edition

31.

May

1988

SERVICE I

KRUPP

MaK


OF GMBH

4000/4900 475015600 '6840 510016300 6100/7300 l8960 5800/7150 672018200 9800/10600 '12200 129OOl131OO

1-

ENGINEER’S

General Engine data

HANDBOOK

~tlonal Cross-section

Edition 31.

August

M 453 Vee engine

SERVICE

1987

KRUPP

views B 00-l .4

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

g pim Designation

General Engine data

HANDBOOK

length mm

n i n

width mm

height 0 mm

-----_------__-_____-__-__-_I---------Reversing gear Z u. M451-453 in line M453 Vee

380 334-5

Gear box 12 u.16M 453

2000

Governor Woodward UG 40 Woodward PGA

197 36O/432

(double-acting) ( double-acting ) (single-acting) (double-acting ) ( single-acting ) ( double-acting )

Lub.oil fitter/with NW65 NW80

(Var.-14) (Var.-27) (Var.-28) (Var.-30) (Var.-34 u. 66)

Edition May

2701291

45

317

210

730 540 423 592 513 710

240 273 280 280 280 280

285 285 340 340 340 340

71 90 83 125 99 145

520 680

260 530

530 786

89/‘180 186r302

819 1040 1170 1351 1466

465 580 688 751 938

550 610 655 730 949

16or277 360 /‘600 432 r 778 no rio50 87or116O

360 295 1007 420 420

373 395 580 395 510

675 826 700 843 904

152 160 270 185 275

1344 1244 1044 1069 1324

420 420 420 568 610

700 565 565 660

570 450 400 540 865

Var. -02 -19 -27 -28 -33 -34

266,7 248Q18

60 50

support

Carge alr cooler 6 u.9Z 451 8Z451 / 6 u. 8M 451 6M 452 8M 452 9M 452

31.

1136

support

Turbochargerl’with BBC VTR 200 BBC VTR 250 BBC VTR 251 BBC VTR 320 BBC VTR 321

M453 in-line and Vee

285

93 94

540 569f69O 528/565,5 4571495

Woodward EGB

Lub.oil pump WD4/WDU4 Werdohl WDU5 WD5/WDU5 Werdohl Werdohl

750 799

weight kg

SERVICE 1988

KRUPP

MaK


OF GMBH

MaKI

ENGINEER’S

Dimensions Designation

length mm

width mm

869,5 1110 840 1110 9?0,5 494

363,5 505 478 505 52O 1870

_-l--------------------Bend with insulation (charge air cooler-turbocharger) M453 in-line (Var.-27) (Var.-31) (Var.-34) (Var.-35) (Var.-37) M453 Vee (Var.-03)

shaft

12 u.16M 453

with

power

take - off without

31.

May

height 0 mm _____----_-_

B 00-2.0.2 weight ks

820 855 850 850

500 444 500 975

485

450

180

236

450

65

1500 1350 1500 1500 1200 1283

3750 2800 4690 3750 895 1318

96 135 130 200

410 410 510 400 160 248

SERVICE

1988

and weights

112 154 213 136 192 200

Flywheel 6u.82451 9Z 451 u. 9M 452 I453 9Z 451 u. 9M 452 I453 6~.8M451/452/453 12 u. 16M 453 12 u. 16M 453

Edition

General Engine data

661 974 900 880 880 1010

Vibration damper 6M451 I452 8M4.521453 8 u. 9Z 45119M 452-453 12 u.16M 453 (MaK) Flanged

I

HANDBOOK

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OF GMBH

I

LI.

ENGINEER’S

General Engine data

HANDBOOK

Dimensions and weiahts L&lFNSIONS AND WFIGHTS (storage of spare parts)

Cylinder liner 163 kg I 187 kg

Cylinder

B 00-2.0.3

,0320,

head compl. 253 kg / 274 kg

Piston with connecting rod 160 kg I208,5 (cast I iron-piston - 230 kg) Piston (buitl piston) - 66 kg Piston (coiled cooling channel piston) - 56 kg Piston (cast iron piston) .116kg

Locating bearing

6.6,9 cyl. 12.16 cyl.

11.5 kg 15.5 kg

Double wheel

97 kg

Gear wheel on carr6iWt

Main tearing 6,6,9cyl. 4ko

I

Bottom end bearing 12.16 cyi. 609 Q crpnkshah 6Oka

Gearriqon

NOTE:

70 kg

In principle pistons and connecting rods should be stored separately! Where this is impossible the weight of the connecting rod must be supported in such a way as to avoid contact between piston pin and bearings.

Edition

31. May 1988

SERVICE KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

I

MONTEUR-HANDBUCH

Allgemeine Motordaten

ENGINE HANDLING IN-LINE ENGINE

V ENGINE

D --

/

-r-----7

I

E

Engine type

A

B

c

Device rWrXll ftit

t 2490

6 cyl.

a CY~. 9 cyl. 12 cyl. 16 cyl.

mm 2345

mm 1545

mm 720

Sling length at least

,,*,,

at least

max. with 2 cranes

mm

mm

m

f-ml

3500 2600 1000

4400 3500 1700

257

210 190 150

M 453 mm

D

Weight of engine excluding flywheel

I

IMPORTANT REMARK: Retightening of the cylinder head nuts which were loosened for the engine transport device: see cylinder head assembly B 01-5.0 !

Ausgabe 30.

September

SERVICEUNTERLAGE 1988

KRUPP

MaK

MASCHINENBAU

DER GMBH

-1

ENGINEER’S

see: 802-2.0

.-p 2 x B $& ‘= z $ P $_r

Z+M451

Bearing play limit value

0,71 - 1.0 065

!!. A

Tightening moment

Axial

044 - 0,75 035

Tightening moment

NEW

[mm1

0.2;,6-$.33 ImmI Pre-load up to a~< 0,05 mm + 653

0,25 - 0,313 (fur 1O,Omm 022 [mm] bearing shells)

Bearing clearance limit value

General Englne data

Z+M451/M452R

up to “K”< 0,05 mm + 65” Q

GapKvalue

2 n p ‘=

$ z ? .s al

Old

Radial

TQhtening moment

F ‘5

R

(fur 7,0 mm 0,36 - 0.49 0,32 [mm] bearing shells)

GapKvalue

Gap K value

I

HANDBOOK

0.70 _ 0,90 [mm] 065

o’250j60’34 [mm]

“‘y,,

Pre-load up to “K”< O,O5mm + 65” Q. Bearing play 0,26 limit value-O.36

o’34[mm]

Pre-load up to “K”c0,05 mm + 65’ 3

Imml

Big-end bolts Pre-load up to gap < 0,05 mm tightening: min. torsion angle P 55” max. = 80” @cured by splints) Bofts without splints = 65”

Counter-weighs

Valve clearance

The tightening values apply only in conjunction with Mo2

SERVICE

Edition 31 . January

(Molykote Paste “Rapid G”) as lubricant.

1991

DOCUMENT

KRUPP MaK MASCHINENBAU

OF GMBH

I

-

ENGINEER’S

General Engine data

HANDBOOK

M453R ‘:

m .E L

Gap K value

o’y5i075

M453V 0,70-0,90 0,60

[mm]

Q 8% ng ;g P = B SP

5 ‘f 22

Bearing play limit value

0,;,41

TigMening moment

0,30

Bearing clearance limit value

1

Tightening moment GapKvalue

4 g 1 s

[mm]

9

0,33 - 053

Gap K value

$ ‘=

F -= 3 0 Z ? .9, m

550Nm+60”

“‘2; -234

[mm1

700Nm+110°

g

[mm1

“35&O,“”

[mm]

Imm]

0,24-0.51 1 o.

[mm1

, 550Nm+60°

700Nm+110°

3

3

Bearing play 0,24 -0,32 limit value 045

0,7- 1,o 060 Big-end bolts with multipledrilled hQ=6OONm

head,

Tightening moment Big-end bolts with one hole or no holes, Md=750Nm

Limit value

0,1,;,15

Adjusting screws Packing rings Axial-clearance

130f10Nm 0,05 - 0,15 mm (if still available)

lmm]

M453C 180Nm’2500 a

Cylinder cover

50Nm+250°g

Injection valve fasting

130 Nm with pre-load of 25 Nm and torsion angle = 120”

Starting-air valve fasting

110Nm

Valve rocker brackets

250 Nm

Triming gear train/back-lash

0,2 f 0,05 max. 0,4 rrrn

Counter-weighs see: B 02-3.1

Valve clearance

Cold clearance Inlet: 0,3 + 0,l m Exhaust: 0,6 + 0,l nxn

The tightening values apply only in conjunction with MO 2

Edition 30 . September 1990 I

600 Nm plus additiinal moment for correct bolt head position

440 Nm plus additional moment for correct bolt head position

Hot clearance 0,4+0,1 mm 0,7+0,1 m-n

(Molykote Paste ‘Rapid G”) as lubricant.

SERVICE

DOCUMENT


OF GMBH

-I

ENGINEER’S

HANDBOOK

Valve rocker bracket B 01-l .O

- Axial- clearance valve rocker lo,ll - Diametral valve rocker bearing plays: - Oil grooves of the bearing bush are 30” to the vertical axis - Bush projection = 2 mm

I

MINIMUM

0,03 mm NEW

MAXIMUM

0,07 mm CLEARANCE

LlMlT

0,30 mm

I

ROCKER SHAFT Freeze the rocker shaft into the rocker bracket. Undercool rocker shaft to - 60%. Heat rocker bracket up to 100°C. Free shaft ends 73.5 f 0.3 on each side. Gap between set collar and stopping face on the rocker brackets 52.2 fO.l.

Detail

X

Adjusting ring locking

Valve rocker bracket assembly: the value Md 115 Nm (11,s kpm) is applicable only with lubrication of Molykote paste “G-Rapid”

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

I

ENGINEER’S

HANDBOOK

Yalve rocker 6 01-l -0.1 VALVF ROCKER BEARINGS 7 451

Needle bearing

INA needle bearing NKS 50

DU Dry bush

Cast Al-nickelbronze bush

4 SK-5804

SERVICE

Edition

31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

Valve rocker bracket Valve

head

B 01-l .0.2

rocker bracket M 452/452! I i

i

J

7-T

1

I

1 -__

.---. _f--

! -.

Valve shaft 0 55 h6 (insert hardened): Pay attention to marks on valve rocker bracket and shaft!

+--.

1

la) -

L,

-e-e

-

y--

I

/

c

screwed-in with loctite

-

Position of lub. bores

Valve rocker bracket assembly Md = 250 Nm or formerly =100Nm+=60° with lubrication by paste Molykote “G-Rapid”.

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

head \

Valve rocker bracket

/ valve rocker

Outlet racker arm M452/4Q

Radial valve rocker clearance = 0.14 min Limit clearance I 0.30 mm

Dressed Position of the oil bores

Bush recssed on both sides by approx. 0.2 mm

screwed in with Loctite

Inlet

rocker

Tightening torque of the taper pin nuts = 25

\

axial clearance = 0.2-0.5 mm

I

Mark in the direction of the oil bore

JFMARK; When inserting a new bush, pay attention to the radial position!

SERVICE

Edition

31.

Oktober

1988

KRUPP

MaK


OF GMBH

B 01-1.0.3

ENGINEER’S

I

HANDBOOK

Cylinder

Valve rocker backet /valve

head I

rocker

B 01-1.1

INLET AND EXHAUST VALVE CLEARANCFS

-

Tappet clearance the tables.

“s” between valve stem (2) and adjusting

screw (4) must be re-cut differs from the values in

-

The engine must have stood for at least 15 min. prior to the measurement (hot clearance) in order to even out the valve temperatures.

Hot clearance mm

Cold clearance mm

I

I

I

!

Cooling water temp. 1 less than 50 “C InktvaJve valve

s = 0,3 + 0,l

s = 0,4 + 0,l

s = 0,6 + 0,l

s = 0,7 + 0,l

SERVICE

Edition

31.

Oktober

1988

Cooling water temp. more than 50 “C

KRUPP

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OF GMBH

-I

ENGINEER’S

I

HANDBOOK

Cylinder

cover I

VALVE STEM GUIDES Will-i O-RING SEALS for Z 451/M 451/M 462/M 453

Inlet valve 1.60.7-21 .OO-12 1 mm oversize 01-07

Exhaust valve 1.60.7-21.23.00-l 1 1 mm oversize l-06

NOTE: WARNING!

Upper O-ring seal dropped with wick lubrication of the exhaust valves. Insert O-ring after the supercooling.

Inlet valve 1.60.7-21.23.00-14 1 mm 1 mm oversize 01-l 1

Exhaust valve 1.60.7-21.23.00-13 1 mm oversize 01-l 0

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

~

ENGINEER’S

I

HANDBOOK

Cylinder

cover

I

Valve aulde B Ol-2.0.1 GUIDE BUSH with two internally loading rings (BOTTOM VALVE SEAL only with M 451/M 453)

L i

Adjusting screw 1.50.7-21.23.02-01 Packing ring 22x4 Guide bush 1.50.7-21.23.00-01 x=0.05+0.15 1.60.7-21.23.00-01 x=0.1+0.18 Secured by caulking 2x (see figure)

Instructions: 1. 2

Remove adjusting screw. Insert rings, tighten new adjusting screw with 13 kpm, check clearance, recut if necessary, caulk.

Note on the removal of a steel adjusting screw: In order to prevent damage to the guide bush, drilling away of some of the caulked material of the adjusting screw prior to removal is recommended.

Ausgabe 31.

Oktober

SERVICEUNTERLAGE

1986

KRUPP

MaK

MASCHINENBAU

DER GMBH

I

ENGINEER’S

HANDBOOK

Running

gear

Valve auide B 01-2.QJ

Pulling in a valve guide using auxiliary device (Z 451I M 451 /M 452/M 453)

I

/

1.60.7-92.2200-05 M 452453

1.60.7-92.22.01-03 / NOTE; Valve guides should be smeared lightly with Molykote paste prior to “pulling in”.

1.60.7-92.22.00-05 M451 Suoercool valve stem auidg Supercool to minus 195 “C (liquid nitrogen) and insert. 1.60.7-92.22.01-04

Valve auide clearances, measured in engine transverse direction. Operating hours M 452/453 Z+M 451

Normal clearance Limitclearance Normal clearance Limitdearance

= 0.12 to 0.18 mm = 0.4Omm = 0.10 to 0.15 mm I

I Inlet

0.35mm

I

Exhaust

5000

I

10000

10000 10000

ff clearance is greater, replace guide. NOTE;

O-ring proportions the valve lubrication and may be exchanged only for a genuine MaK spare part.

Edition 31.

Oktober

SERVICE 1988

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

ms, INLET AND EXHAUST

Xh

Cylinder

valv

valv

cover

es-Q

.l-3.

VALVE STEM Z + M 451

Valve stem 1.60.6.22.10.01.08(M 451/i!451)

Lettering out 10-03 out lo-06

Replacement for Z 451 and M 451

10-08

with gasoil

1.60.6-22.10.01-26

out 10-12 out lo-16

Replacement for Z 451 with heavy fuel and at clients request (recent addition: “Exclusively”!) 1.60.6-22.10.01-16 (material Nimonic)

in in

Detail Z

WARNING Check hard-facing after the grinding; if required dimension has not been reached, replace stem. DETAIL “Z Var. -16 has no hard-facing.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

lo-11 lo-13 lo-26

ENGINEER’S

Cylinder

HANDBOOK

lOlet and exhaust

valves.

valve

cover

seats Ol-3.O.l_

INLET AND EXHAUST VALVE STEM M 452/453 Involute variant

Lettering 1O-02 10-10 10-14 1O-27 1O-30 1O-50

INLET AND EXHAUST VALVE STEM HARD-FACED NEW DESIGN involute variant Clamping conhalf 0.00.6-13.15.00-05 (all-round clamping)

Valve stem 1.60.6-22.10.01-23

WARNING Check thickness of hardfacing after the grinding; if required dimension has not been reached, replace stem. l

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

cover

I 1 I

n

. -

xh

EXHAUST VALVE STEM HARD-FACED FOR HEAVY FUEL M 452/453

Involute variant Clamping cone half 0.00.6-13.15.00-05 (all-round clamping)

Valve stem use 1.60.7-22.10.01-44 until worn out replace with -47

Valve stem use 1.60.7-22.10.01-41 (Nimonic) until worn out replace with -48

DETAIL X rounded with

WARNING Check hard-facing after the grinding; if required dimension has not been reached, replace the stem. l

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

cover

lcllet and exhaust valves. valve seats B 0,1-3.0.~ EXHAUST VALVE STEM HARD-FACED, REINFORCED DESIGN HEAVY FUEL M 4521453

(see figure) Involute variant Clamping cone half 0.00.6-13.15.00-05 (all-round clamping)

Valve stem 1.60.7-22.10.01-31 use / I

1.60.7-22.10.01-34 until worn out replace with -47

-44

WARNING Check thickness of the hardfacing after the grinding; if required dimension has not been reached, replace stem. l

DETAIL Z for variant -34

DETAIL Z for variant -31

The first stems of for variant -34 were unchamfered.

rounded manually with stone R 1.6

rounded manually with stone R 1.6

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

Mac

ENGINEER’S

HANDBOOK

Cylinder

cover

inlet and exhaust valves. valve seats B 01-3.0.4 EXHAUST VALVE WITH BLADE 1.60.7-22.20.00-21 M453

Circlip J 33x1.2 (see figure) Spring plate 1.60.7-22.10.06-06 Clamping cone half 0.00.6-l 3.15.00-05 Axial deepgroove bearing 1.00.7-88.50.86-01

ball

Spring plate 1.60.7-22.20.04-03 Snap ring A 50 DIN 7993 Valve spring 1.60.6-22.10.04-l

3.1 or -13.2

Spring pad 1.60.7-22.10.03-08

Valve with blade 1.60.7-22.26.00-01 a 1.60.7-22 26.00-02

I

I

I

I l l

Edition 31.

August

SERVICE 1987

KRUPP

MaK


l

l

*

with valve stem var. -47 * with vaive stem var. -48

OF GMBH

ENGINEER’S

HANDBOOK

Cylinder

cover

Jnlet and exhaust valves. valve seats 0.1-3.0.5 MAX. REGRINDING OF THE VALVE SEATS Z+M4!Y,M452,M453

0.128.14_0.03 outer ring 0

max. regrinding (M+Z451)

1.0 mm

I--

max. 0.108

The valve seat ring is undercooled in liquid nitrogen (-195” C) and inserted in the cylinder head. Abt. 3 min. after having inserted the seat ring press this, together with the device 1.60.7.92.2200-07, for a short time. Torque = 150 Nm No clearance in the shrunken state between seat ring and contact face in the cylinder cover. Finish off cleanly projecting edges of seat ring and intake or exhaust ports.

SERVICE

Edition

29.February1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

blet

and exhaust valves. valve seats B o.l-3.u

MAX. REGRINDING OF THE VALVE SEATS M 452, M 453

Max. regrinding max. dimension X

Valve seat ring 1.60.7-21.40.08-12 to -15, -28 to -35 4-SK-14105-l

-41

to -45

to -4

0 108

-20 to -23

0 107

-24 to -27

0 106

-51 to -54

0 108

No material removed here

SERVICE

Edition 31.

August

1987

KRUPP

MaK

cover


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

head

INSERTION OF NEW VALVE SEAT RINGS M 462, M 463 WARNING! When replacing the exhaust valve seat rings for the first time without reconditioning but with O-rings, the follow@ should be noted: Location hole in the cylinder head must be free of corrosion residues: fine-grind with emery if necessary. No axial sore marks.

1.

Heat cylinder head up to 130 - 140” C (by means of a heating furnace or in exceptional cases with a smooth big welding flame). After heating but before inserting the rings smear the bore in the cylinder head (only exhaust) with a thin coat of Molykote paste G.

2.

Undercool valve seat rings to 20” C. (ice box),

3.

Mount 0 - ring and smear them with a thin coat of Molykote or grease.

4.

Insert the exhaust valve seat rings and, if necessary, drive them in by means of an old valve stem and hammer.

5.

Press the seat ring, together with the device, for a short moment. Drawing No. 1.60.7-92.220007 Torque = 150 Nm

6.

Check the air gap between contact face of the seat ring and cold cylinder head. If gap is 2 0.02 mm, give another sharp blow. PRESSURE TEST: COOLING WATER SPACE 10 bar VALVE SEAT RING, COOLED TYPE, M 452/4!53 (without O-ring) RECQNDITICNINGCN OVERSIZESTEPS

Reconditioning of the seat-ring-cooled cylinder heads on OVERSIZE STEPS (previously permitted without exception only in MaK-Kiel) is extended to the following service stations: RW-Bremen Belier MaK-Scandinavia Krupp MaK-Toronto Krupp MaK-Mediterranee NOTE! Covers for repair must as a matter of principle be imprinted with seat ring variant and workshop code in the vicinity of the existing cylinder head drawing no..

SERVICE

Edition

31.

Oktober

1988

DOCUMENT


OF GMBH

ENGINEER’S

I

HANDBOOK

Cylinder

head

Valve seats 6 01-3.0.8

1.

Weld valve seat ring (2) together at abt. 4 spots with a valve stem (1) being useless and machined to the inside diameter of the ring and knock it out.

2.

Clean seat ring bore in cylinder head 100%.

3.

Undercool new seat ring by means of liquid nitrogen up to end point approx -190°C.

4.

Undercool new seat ring in carbon dioxide snow to approx. -70°C and heat cylinder head to approx.+70”C

5.

Fii undercooled seat ring carefully (attention: in this state the seat ring is very briile) and press it on until it adheres.

,

Fxchanae of valve seat rina M 452/M453 with 0-rina sealing 1.

Machine (see sketch) useless valve cone (1) fit it into the seat ring (2) up to the indicated depth, weld it at abt. 4 spots (3) and knock it out.

2.

Clean valve seat bore in cylinder head 100%. Refinish if necessary.

3.

Undercool seat ring to at least-20°C (refrigerator) and heat cylinder head to 130°C (heating furnace).

4.

Insert the O-rings in the undercooled seat ring and smear them slightly with paste Molykote-G.

5.

Insert seat ring, press it by means of a device until temperature exchange has taken place.

6.

Even seat ring projection, slightly machine seat. Machining of seat, see part General 00-l 6.

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Maintenanggt_md

Cylinder

overhaul

head

of valves B 0.1-3.1

VAI VF CONF RFMOVAf_ Z and M 451, M 452, M 453 6.9222 D ,‘(6.9123)

Maintenanceof all valves:

Valves cones with strong wear marks in the clamp area and heavily burred clamping cones, with cracked armoring, with high temperature corrosion on bottom side ~1.5 mm are to be rejected. P(OTE:

Judgement and machining of valve seat surfaces see in part: General 00-16

GRINDING-IN OF VALVES Z + M 451. M 452 and M 453 Grind-in new, reconditioned or used valves before fitting (fine grinding compound L 15 m). The light-grey bearing marks must lie on the outer circumference and cover about 30% of the seat area.

6.9224-B (6.91,22A)

SERVICE

Ed ition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

Maintenance

cover

I

and overhaul

I

of valves

B 0.1-3.1.1

VALVF RFCONDlTlONlNG M 453 M 453 Regrind valve according to angle specified (precision grinding machine). Do m reface existing chamfer! Establish dimension between visible edge (base metal and hard-facing) and diameter 102.5+0.5 mm given in figure! ff the minimum dimensions are not reached (see Fig. I = 0.3 mm and Fig. II P 0.2 mm), the valve must be replaced.

rounded manually with stone (R 1.6)

visible edge between base metal and hard- facing

A;M&jY=l I valii for var. II 34

rounded manually with stone (R 1.6)

visible edge between base metal and hardfacing

II valid for var. -41, -47, -48, -49 (see valve stem)

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

cover

I

JVlaintenance and overhaul VA1 VI= CUTTING EQUIPMENT. CUTTf=R RFPI ACFMENT M + 7 4.51. M 452. M 453

of valves

B 0.1-3.13

(6.9224-C)

8

c 5’ U

Fitting

position

of the

cutters

max.

Cylinder head variant

dimension

4-Sk-12181 -21/-25108 -22 l-25108 -23

X 108 108 107 106,2

Y 1,25 1,25 l,o 0,8

-24 I -31

108

1.25

removed here 5) Pilot rod 6) Centering bush 7) Clamping ring 6) Outlet pipe

1) Setbolt 2) Ratchet brace 3) Cutter head 4) Valve seat ring Valve cutting equipment: 6.9224 (Drawing No. 1.607-92.24.00-03)

Edition 31.

Oktober

SERVICE 1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Cylinder

HANDBOOK

cover

I Maintenance 1.

and overhaul

of valves

B 0.1-3.1.4

The cutters are exchangeable as a set. Clean groove for accomodating the cutters thoroughly before inserting them. Position of the cutters: The bevelled sides point to the centre of the cutting head! The cutters are displaced inwards about 3 mm from the outer edge of the cutting head.

2

The most recent cutting head has soldered cutters and can be exchanged only as a unfi (regrinding or exchange only in MaK’s Main Works in Kiel). NOtE:

Individual cutting heads can be sent to the Kiel Works in exchange for cutting heads with soldered cutters. Reason: “Improved seating quality”.

SERVICE

Edition 31.

August

1987

KRUPP I

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Cylinder

cover

Valve rotator B 01-3.2 YAl VF ROTATOR M 4531453 Measure valve speed on start-up and record in writing. Measure valve speed as a function of engine speed. lf speed has dropped to n 1 min.-l, remove valve rotator and overhaul it.

(1) (2) (3) (4) (5) (6) (7)

Spring plate Balls Bearing plate Plate springs Snap ring Springs supports

7 6 4

,

Wire ends resting against the spring plate. Observe fitting position!

Circlip J 33x1.2 \

/ Ensure free passage bet ween springs and spring plate (5 jamming rollers)

\

Rotator, for practical purposes shoulder to the blade. NOTE: “Replace the balls -only as a set”. (25 off) -

Axial deep-groove ball bearing 51 108

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Cylinder

Starting

NOTE: Castellated

nut (12) secured with dowel pin 3 x 24 mm or with splint.

Tightening

moment for holding-down

bolt and nut (20)

Oil Nm (kpm) 1 1 180 (18)

August

110 (11)

SERVICE

Edition

31.

Molykote Nm (kpm)

1987

KRUPP

MaK


OF GMBH

cover

valve B 01-4.4

ENGINEER’S

HANDBOOK

Cvlinder IY

head gssembly

B Ol-5.4

M451 /M457lM453/M453G

Slacken cylinder head nuts in the order 1 - 8 in two stages. Tighten cylinder head nuts (5) with Md = 300 Nm and slacken again (separation cylinder liner).

of cylinder head from the

~__ d

Screw in ring bolts (1.9076) at marked positions (10).

9

R = in-line engine R+V = Veeengine

bad 0

seauence

0

cc

TIGHTFNING

TORQUFS

FOR CYI INDFR HFAD

210”

J$=$

6;@o

1 2 3

250”

2 3

MM51 lM452 Initial moment Torision angle

=50 Nm a =210”

M 453 Initial moment Torision angle

=50 Nm =250”

a

M453C

6.9100-22

First assembly: Initial momet

180 Nm + a 270”

(6.9180 F)

Repeated assembly: Initial moment

180Nm+

0Z 250”

Indicating label on gear case

Retightening

of the cylinder head nuts which had been loosend for the transport

device 180 Nm+

Edition 30. September

SERVICE

1989

DOCUMENT


OF

GMBH

a

225”

ENGINEER’S

Cylinder cover

HANDBOOK

4

Cvlinder head assembly B 01-5.0.1 Sealing between cylinder liner and cylinder head

recess top Joint ring 1.60.6 -16.10.02

t

2451,

M451, M452, M 453

- 01

Joint ring galvanic-coppered layer thickness 10 - 15 pm

Joint ring 1.60.6 -16.10.02

M

- 26

453 C

Joint ring galvanic-coppered layer thickness 15 - 20 pm t

Edition

31.January1988

SERVICE

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

HANDBOOK

Cylinder

Cylinder

cover

cover B 01-5.1

“MECHAN. RECONDITIONING” OF THE COOLING WATER INLET CYLINDER COVER

2180.2

at centre

of cylinder

cover

Bush /04-Sk-0926

Rd 40 DIN 10 13 X22CrNi17

,$‘I+

supercooled

033 I+0387

030

038

0 38

r6

+

t

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

+34

50

ENGINEER’S

Cylinder

HANDBOOK

Cylinder

heamemblv

B Ol-5.1J

RECONDITIONING OF CYLINDER HEAD JOINT FACE

0391 h8 I-12)

NOTE: time

405

Re-cutting of the joint face up to max. 0.5 mm is possible! If a further reduction is required, the level cyl. head bottom surface must be re-cut at the same up to a common maximum 1.O mm. Besides, a repair is only possible on the Z and M 451 cylinder heads by means of an especially manufactured ring (see sketch).

SERVICE

Edition

30. September

1989

DOCUMENT


OF GMBH

head

ENGINEER’S

Running

HANDBOOK

gear

I pi-n IQ Checking

rn of one big-end bearing

all big-end bearings

= 5000h =lOOOOh

k Gap standard

k=0,44-0,75mm

Gap limit value

k=0,35mm

Gao (measured on exhaust side): _

Slacken big-end nut on one side by 55 torsion angle. Slacken opposite side completely and measure gap “k”.

(Assessment of the bearing shells see “General” section).

PISTON SUSPFNSION DEVICE. FlTTlNG It%!&

6.9185 A Piston suspension device

m Load nut with Md = 100 Nm (camshaft side) and tighten further by 55 torsion angle. Measure gap “k” on exhaust side.

rq

Tighten exhaust side until gap is P 0.05 mm. Check on camshaft side whether the cover has risen, if necessary tighten nut until gap is 20.05 mm (bearir is w-loaded). 5.

Tighten the big-end bolts.

6.

Bolts secured by splints: Tighten nuts in 2 stages alternately on exhaust und camshaft side. 1st stage 40” torsion angle 2nd stage 55” torsion angle If no splint hole is present, turn nut further in the torsion angle range 55” - 80” until splint hole becomes free. Maintain a torsion anale of at least 5Z Secure nuts with splint.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

4

ENGINEER’S

HANDBOOK

Bottom-end 7.

bearin g. in soection

M 451/452 B 02-1.0.1

Bolts not secured by splints: Tighten nuts in 2 stages alternately on exhaust and camshaft side. 1st stage 40° torsion angle 2nd stage 65” torsion angle

Camshaft side

Exhaust side

6.9185

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Running

HANDBOOK

gear -4

Bia-end bearina. lnsoection M 453 in-line and V 802-l .l Diametral clearance

Bearing play

0,24-0,32mm

Limit

0,45mm

s for bra-end bo& (lubricant: Molykote Paste G-Rapid”) 1. 2 3. 4. 5.

Pre-load bofts 3 and 4 with 330 Nm. Measure dimension “k 1” with sliding caliper. Pre-load bolts 1 and 2 with 330 Nm. Big-end bolts with multi-drilled heads must be tightened in the order 3,4 - 1,2with Md = 600 Nm (60 kpm). Bolt heads not drilled or drilled only once must be tightened with Md = 750 Nm (75 kpm). Measure dimension “k 2”. “kl”- “k2”=gap 0.7 - 1 mm Gap on final assembly: After lengthy operation minimum:

0.6 mm

245,24

+ 0,07 control

dimension

If limit value is not reached and visible lead-bronze is > 90 mm, insert woof

bearings immediately.

Lead-bronze Steel back

For definitive bearing assessment, see General00-013 section. PISTON SUSPFNSION DFVICF (6.9185 B) Codina on cover and bolts. Originally marked big-end bearings do not have to be tightened again for agreement of marking codes, but in accordance with the tightening regulations valid from Oct. 85: “Big-end bolts with multi-drilled heads Md = 600 Nm (60 kpm) and bolts with heads drilled once or not at all Md = 750 Nm (75 kpm)! Tightening moments apply only if Molykote paste “G-Rapid” is used”. NOTE: New big-end bearings are 6~ longer marked!

SERVICE

Edition 31.

July

1988

KRUPP

MaK


OF GMBH

-I

ENGINEER’S

I

HANDBOOK

I

Running

bearing. fitting M 453 in-line + V

gear

B 02-1.2

Assembly tools 6.9425 Set assembly strap (6.9425) to = 255 mm Guide pin (7) engages in the bearing shell. Stirrup bolt (4) catches in the blind hole of the upper bearing shell.

When using new connectina rods (forged shaft = unmachined or smoothed) with big-end bolts of 30 Cr Ni MO 8V the following tightening instructions must be observed by all means. 1. 2 3. 4.

Pre-load bolts 3 and 4 with 330 Nm. Measure “k 1” with sliding caliper. Pre-load bolts 1 and 2 with 330 Nm. Big-end bolts with multi-drilled heads must be tightened in the order 3,4-l ,2 with Md = 600 Nm (60 kpm). Tighten bolt head m drilled or drilled only once with Md = 750 Nm (75 kpm).

m 0

0 0

Md

= 750 Nm

Md

= 600 Nm

All orevious instructions are herebv rendered invalid and must be destroved,

Md = 600 Nm Upper bolts must have rotated by a further a = 30 - 40“ lower bolts must have rotated by a further a = 40 - 50”! Md = 750 Nm

Upper bolts must have rotated by a further a = 45 - 60“ lower bolts must have rotated by a further a = 60 - 85O 5.

Measure dimension “k 2”. “k l”- “k 2” = gap Gap on final assembly: After lengthy operation minimum:

SERVICE

Edition 31.

Oktober

0.7 - 1 mm 0.6 mm

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Running

HANDBOOK

Maln bearina

irmection

gear

M 4511452 B 02-2.4

6 M = bearings 4 and 5 8 M = bearings 5 and 7

After 15000 ooeratina hours check the two highest-loaded main bearings:

After 25000 weratina check all main bearings, e.g. if inadmissible web deflection differences, piston jamming and other irregularities are discovered, as well as faults in the oil system (filter or oil supply failure and similar) the bearings must be immediately removed, inspected and if necessary replaced. Hemedv the causes!

Radial clearance Radial clearance Limit clearance

axial clearance mc?asured at bearing

(M + Z 451) (M452)

= 0,26 - 0,33 mm = 0,22-0,31 mm 0,45 mm =

I

0,25...0,34

M 452

1,O mm

mm

-

Direct-coupled units with thrust bearing are equipped with faced locating bearings. Indicated clearances are not valid. If the limit is exceeded, renew bearing shells in&air& Measurement of aao Slacken bearing bolt on exhaust side by 60 (torsion angle gauge). Slacken completely bearing bolt on camshaft side. Measure gap “k” on camshaft side.

.!j

8’

A+2451 New (10 mm bearing shells)

M+Z451 New (7 mm bearing shells)

Normal + locating bearing The whole line of main bearing bores -0239H6

Normal + locating bearing The whole line of main bearing bores =0239H6

0,25 bis 0,38 mm

.=

M+Z451Jvl452 Old

6,84 mm bearing shells and the whole line of main bearing bores = 0 238,90 + 0.03

0,36 bis 0,49 mm

Norm. bear. : 0,71 - l,Omm Lot. bear. : 0,70 - 0,9 mm

0,32 mm

Normal + lacating bearing 065 mm

EZ

022 mm

ebes

tg shells be renewed infz

3 3

tf the limit is not reached, it is essential that rotation”!)

SERVICE

Edition

31.

Oktober

1988

KRUPP

s (extremely high risk of “induced

DOCUMENT

MaK MASCHINENBAU

OF GMBH

l-l

ENGINEER’S

I

HANDBOOK

Running

gear

jylaln bearlna fitting and removal M 4511452 B 02-2.1 Codina of the bearina covers/shells: _

Coding according to cylinder Normal bearing: mark points to the flywheel side. Locating bearing: mark points to the pump side.

NOTE:

_

Mark on the locating bearing covers determines whether the camshaft or exhaust side is coded.

Tighten camshaft side nuts by Md = 180 Nm. Measure gap on exhaust side. Tighten exhaust side up to “k” 5 0.05 mm Tighten camshaft side up to “k” < 0.05 mm Tigten nuts in two stages on exhaust gas and camshaft side with &Y angle of rotation. (Turing angle gauge : 6.9214A).

NOTE;

The crank web deflection must be measured and recorded before and after each removal of the main bearings.

1 1 Dog (6.9113) 2. Fitting device (6.9114 A) Shaft must always rotate to the right (viewed from the flywheel side), otherwise the positioning pin of the bearing shell will be sheared off. 7

General part.

00-013

WARNING! If a bottom shell is removed, the adjacent bearings must be in position. Removal of locatino bearing; Support the bearing if the flywheel is overhung!

SERVICE

Edition 31.

Oktobet

1988

KRUPP

MaK


OF GMBH

ENGINEER’S HANDBOOK

Running gear

MaIn bearlna lnsrxctlon M 453 in-line and V B 02-2.2

10 000 omWba hours,.

Checking of the two high-baded bearings 6 M453 bearings5 and 8 8 M463 bearings 6 and 8 9 M4.53 bearings 6 and 10 12 M453 bearings 4 and 5 16 M4!3 bearings 5 and 7

Note method of numbering! (e.g. locating bearing = bearing no. 2)

20000omt&blwurs,.

Removal of all main bearings. Precondition: “Satisfactory operating conditions f” lf irregularities are discovered, e.g. oil deficiency, the bearings must be checked immediately!

Gap

measuremen

1 M 453

one side

Bearing bolt slacken

completly

completly

k limit value

0.55 - 0.75 mm 0.50 mm

0.70 - 0.90 mm 0.60 mm

Gapx k limit value

0.33 - 0.53 mm 0.30 mm

0.35 - 0,50 mm 0.30 mm

M 453 v

M 453 R In line

Axial clearance New clearance Limit

Locating bearing

I M 453 in - line

I

0.25 - 0.34 mm 1 .OO mm

M 453 v 0.24 - 0.51 mm 1 .OO mm

Direct-coupled plants with thrust bearing are fitted with clearance cut locating bearings. The above clearances do not apply.

SERVICE

Edition

30. June 1991

I

v

12o”

Gapx

i Locating , bearing

km 453

1

600

opposite side

Normal bearing

in-line

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

g3 Fitting and removal tools:

6.9111 B 6.9112A 6.911481 6.911482

rin

Running

HANDBOOK

r m

gear

B 02-2.

Power amplifier Power amplifier Torque wrench

1.9455-394 1.9455-7 1.9454-l 00

14 1:16

Tightening torque (M 453 in line) ~750 Nm

(9) Dog (b.9114B-2 or C-2) ROTE;

Removal of lower bearing shell: direction of rotation of the crankshaft to the right (viewed from flywheel side), otherwise the bearing shell nose will be sheared off.

Bearina assessment; “General Part” Replace the bearing shell if the max. admissible wear limit is exceeded. WARNING! If a bottom shell is removed, the adjacent bearing must be in place. Support end of crankshaft if the end bearing is removed.

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

Mad

ENGINEER’S

Removal and assemblv M

453

in

I

HANDBOOK

of main bearinas M 453

line

Running

gear

M 453 in fine + Vee B 02-3.1 Vee

I

Smear thread and contact surface of nut with paste Molykote “G-Rapid”. Tighten of camshaft or A-side with 200 Nm. Nuts of exhaust gas or B-side = completely loosened! Measure gap “K”! Tighten

nuts of exhaust

gas or B-side

Tighten nuts of the exhaust gas side or nuts of camshaft side and subsequently nuts of exhaust gas side with 550 Nm

with 400 Nm

Tighten nuts of A-side and subsequently of B-side with 700 Nm Note: Counternut must rotation against

I

be in direction stop.

Check whether gap on both sides “K” I 0.05 mm, otherwise retighten up to “KY 0.05 mm! Tighten nuts mutually in two stages with an angle of rotation 60” Turning angle gauge 6.9100-l 00 (6.9180

nuts

nuts

of

of

110”

Turning angle gauge 6.9100-7 (6.9180 C)

B)

M 453 R loosen

tighten

Position of the torque multiplier

B

C

Position of the brake lever

D

E

Position of the

SERVICE

Edition

31.

January

1989

KRUPP

MaK


OF GMBH

ENGINEER’S

Main bearina

Running

HANDBOOK

removal

+ fittina

M 453 In-fine and Vee

Direction of removing bearing covers 16M453

12M453

Flywheel side

Flywheel side

Position of the torque wrench

SERVICE

Edition

31.

August

1987

KRUPP

MaK


gear

I

OF GMBH

6 02-2.3.2

ENGINEER’S

Stockina

7 + M 451/M

Running

HANDBOOK

of main and big-end

bearings

gear

B 02 I 24

452

Main (incl. locating bearings) and big-end bearings: external

= STANDARD

Main bearing bore = 0 238.90 + 0.03 mm Big-end bearing bore = 0 238.94 + 0.03 mm Stocked are bearings for the following crankpin diameters

0 225 0 0 0 0

h6 (h6 224.5 h6 224 h6 223 h6 222 h6

+ main bearing:

= standard = 0 225.0 - 0 244.971 mm) = 1st undersize stage = 2nd undersize stage = 3rd undersize stage = 4th undersize stage

Normal main bearing 1.50.6-l 2.40.00

Var. -03

Located main bearing 1.50.6-l 2.40.00

-04 -05 -07 -13

Var. -031-08 -041-l 0 -05/- 11 -13 -31

External undersize of 0 1.O mm= 0 239.00 + 0.029 mm and with 0 1.O mm internal steps down to 0 222 h6. (The axial relief areas of the locating bearings are allowed for in the delivery range). The bedplates act. to drawing No.l.53.7-12.10.00-01 have a diameter 245 mm H6. Stocked are bearings for the following pin diameters:

0 225 h6 = standard 0 224 h6 = 1st undersize stage 0 223 h6 = 2nd undersize stage

of main bearing bore of

Located main bearing 1.50.6-l 2.40.00 -01 -02 -06

Normal main bearing 1.50.6-12.40.00 -01 -02 -06

Special feature:

“If normal bearings are fitted instead of locating bearings, thrust rings must be fitted to the bearing cover”. During the alignment process the distance plates supplied for axial fixing must be fitted!

Bearing

Fa. BHW Fa. Miba

manufacturer:

If grinding-down is decided on, an attempt will be made in practice to reach a zero dimension of not more than 0.03 mm.

NOTE:

SERVICE

Edition

30. September

1989

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

-I

ENGINEER’S

Stockina

of main and bia-end

bearings

bearing: 0 external =

gear

I

B 02-2.4.1

Main bearing: 0 external = STANDARD

Main + big-end bearing bore: 0 259 H6 (H6 = 0 259,O bis 0 259,032)

Main bearing bore: 0 316 H6 (H6 = 316,O - 316,032)

Undersize bearings are stocked for the crankpins 0:

Undersize bearings are stocked for the pins 0:

0 0 0 0 0 0

0 0 0 0 0

245 244,5 244 243,5 243 242

Running

M 453 V

M 453 inline + vee Main+big-end STANDARD

I

HANDBOOK

h6 = standard (h6 = 0 245,0-0 244,971) h6 = 1st undersize stage h6 = 2nd undersize stage h6 = 3rd undersize stage h6 = 4th undersize stage h6 = 5th undersize stage

+ main + big-end bearing: external oversize of 0 1,O f 0 2,0 mm (0 260 H6) with 1.O internal 0 steps (0 261 H6) to 0242

300 299,5 299 298 297

h6 =standard (h6 = 0 300,0-0 299,968 ) h6 = 1st undersitze stage h6 = 2nd undersize stage h6 = 3rd undersize stage h6 = 4th undersize stage

Main bearings: external oversize = 0 1,O mm (0 317 H6) with 1,O mm internal 0 stepsup to pin 0 0 297 h6

NOTE The oversise stage 0 +2.0 mm (0 261 H6) is currently stocked only with inside 0 = STANDARD = 0 245 h6 H7 Width of located main bearing pocket = 98 mm

ImDortante Note:

Edition

30. September

B7 Width of located main bearing pocket = 104 mm

Before any grinding down of a crankpin, the Technical After- sales Depatment (responsible official) in Kiel must be contacted and consulted for the purpose of checking the vibration situation.

SERVICE DOCUMENT OF 1989

KRUPP MaK MASCHINENBAU GMBH

4

ENGINEER’S

I

HANDBOOK

Reborina

Running

gear

of main bearina oilways 6 02-2.5

IMPORTANT NOTE Reboring (oversize diameter) of the main bearing oilways or the individual bearing seats is feasible in principle! Stock Of oversizes suppliable from MaK store in some cases! (Enquiries to the Technical After-sales Department in Kiel). This measure is usually required if bearing damage accompanied by rotation of the bearing shell pair or similar has taken place. Extensive material testing in the immediate vicinity of the damage is absolutely essential! The further measure: “Reboring of the bedplate-bearing oilway as a repair or discarding of the bedplate” is dependent on the discoven of cracks, bearing seat collapse, increased hardening etc.. (Excessive influx of heat into the bearing seat can lead to concealed thermal stresses, which emerge as cracks only after a lengthy operating period!) The tightening values of the fixing bolts during the “boring” and under operating conditions are nnt identical! As there are also several bedplate variants, the tightening values during the ‘boring” are also different. The engine no. and the cast integral drawing no. must therefore be given to the Main Works After-sales Department, who will then consult the original drawing and determine the correct values. The bedplate must be made stress-free prior to the “boring” (e.g. on board, slacken all foundation bolts and completely withdraw the locating bolts) and align if necessary. Boring must always be without superimposed box frame! (Except for models M282/M332 = single unit)).

BORING OUTOF INDIVIDAL BEARING CAPS 1.

If the old bearing cap is chipped and has not suffered further damage through heat etc.: “These fragments must be placed in a precision horizontal boring machine”. a)

Make a mosaic out of the fragments and place them with the mating surfaces on two opposite V-block (bearing hole on top!).

b)

Place the new bearing cap for machining at the side, align the two caps with each other, determine the dimensions of the old cap and then bore out the new bearing cap. (In some cases over-grinding of the joint faces is necessary).

c)

Fit the newly-bored bearing cap and establish the dimension “K”. 1st example:

Desired “K” = 1.0 mm Actual “K” I 0.6 mm Result: “The bearing cap must be re-adjusted by 0.2 mm on both joint faces!”

2nd example:

Desired ‘K’ = 1.0 mm Actual “K” I 1.4 mm Result: “The bearing hole must penetrate 0.4 mm deeper into the bearing (Possible by interposing differential shim between V-block and joint face).

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

&borina 2

Running

HANDBOOK

of main bearlna

gear

lan@!s B 02-2.51

The old bearing cap is no longer usable for taking off dimensions (e.g. due to rotation of the bearing shell pair, excessive heat etc.). ff the two adjacent bearing caps also have to be removed, place them in a precision horizontal boring machine. Repair or remachining procedure:

a3

Form with the two good bearing caps on two parallel machined between them.

b)

Align all three caps with each other and match up the bearing cap. (Same happens with the joint faces).

c)

Proceed as described in the first section.

SERVICE

Edition 31.

August

1987

KRUPP

MaK

V-blocks an oilway and place the new cap to be

bearing hole of the adjacent caps with the new


OF GMBH


Running

gear

aft R 02 . 39

Main bearing journal 0 h6

Connecting Hardness of rod bearinc runningsurface journal 0 “HB’ h6 Brine11 hardness

300

245

2 235

Running surfaca width Comxve fillets of maln bsarlngkonnaclblg cormacting md

Running surface quality surface roughness “RT pll

bating

md baarIng * Lmnion

nlm belwwn

si*

pkmwstcpfsa

jourrmls

radludsurfacs mughneas mmlvn

110,o I 2O5,o

s 2,5

l5,O IS 2,5 ll 25fo.4 I ‘22of 0.4 99,0 I 97,0

245

245

2 205

15.0 I 4 2.5

S 2.5

l113*0.4/*111*0.4 6,8+9

M 452

6+8 M451

2020 2540 2830

225

1890 2650

225

225

100,4 I 100,4 2 215

12,5 I S 2,5 ‘13M0.3!‘130f0.3

225

95.0 I95,O

52

ir 205

15.0 I S 2,5 ‘113*0.3/‘113*0.3

6+8 t 451

95,0 I95,O

2020 2540

225

225

s 1.5

2 205

15,01<2,5 ‘113f0.31’113f0.3

I

A

Except fittingbearing running surfaces and widths

All oil bore hole outlets smoothly roundedwith R6 and polished. Y!Zi? Front deviation

= max. 0.02

Face roughness

= RT I 10

225 h6

=

225.000 224.971

245 h6

=

245.000 244.971

300 h6

=

300.000 299.966

Edition

28. February 1990

mm

SERVICE DOCUMENT OF KRUPP MaK MASCHINENBAU GMBH

-I

I


Runnlng gear 44

Tooth 1 is 90” to crank gap 1 in OT. Z 451, M 451 and 452 (number of teeth: 113) inside 0 = 260H6, pitch circfe = 310 mm, outside 0 - 580.5-O-2 mm, weight - 82 kg M 453 (number of teeth: 113) inside 0 = 360, pitch circle I 400 mm, outside 0 = 580.5-0.2 mm, weight = 75 kg All fastening screws are tightened at a tightening torque Md - 115 Nm + compliance of the castillated nut groove with split pin hole. (Lubricant: Molycote paste %“)

Todh 26 \

TCXh32 .\

TO&33

M13k6x105DIN609 Tightening torque Md I 100 Nm for lubricant Molycote paste G

l-

247 99.3

Bore holes for fitting bolts drilled to 0 17H7 and reamed during assembly

247iQ.3

A

Preliminary cut tooth corners removed up to bottom circle and thoroughly chamfered with R 0.5.

-J

013

I+6L

13m6x20DIN7

Edition

28. February 1990

SERVICE DOCUMENT OF KRUPP MaK MASCHINENBAU

GMBH

4,

ENGINEER’S

Running

HANDBOOK

Crankshaft

gear

B 02-3.0.5

All enaim model rangi%

.

. .

wn of tndrvrdual main or bia-end -Is

.

.

In the ena ine readv for oberation.”

Feasible and already widely practised! After grinding the journals must be free of cracks and age-hardening! Pre-condition: “Careful examination of material in the damaged area and its vicinity.” ess test The normal hardness of our shafts is between 205 HB and 235 HB. Age-hardening up to maximum of 350 HB is admissible! if there are hardness spots caused by damage the difference in hardness must not exceed 10 HB/mm. That means the measured difference in hardness of two points one 10 mm apart from the other must not exceed 100 HB! The fillets and the roundings of the oil bores must not show any age-hardenings! Only ff the result of the examination is clear and positive does “grinding down make sense!” If there is the slightest doubt: “Remove the crankshaft!” Only a firm specializing in this field should be entrusted with the work. Take care when “aligning” the grinder! The grooves need not extend to the journal! (Hollowing out of the grooves and grinding of the journals are two quite separate processes!) The grinding usually takes place “in diameter stages of one millimetre”. The after-sales department in the Kiel Main Works must be informed and consulted in acases. (Undersize stocks, vibration situation, max. degree of grinding etc..)

Edition 30. April 1991


-1

ENGINEER’S

I

HANDBOOK

Counter-weiahts.

tiahtenina

Running

moment B 02-3.1

6/6 and 9 CYL. M 4521453 ....

I........

M24x2

. . . . . .

..*.a

. . . . . . . . . . . . . . .

. . . . . .

_-II Lockina oin; l30x40mm

“Flatten all over the whole surface or saw in a groove for air resp.oil escape!”

Tightening

moment: 440 Nm (44 kpm) plus additional

moment for safety agreement.

16cyj, M45Q Tightening

moment:

Molykote paste:

600 Nm (60 kpm)

“Rapid-G”

Edition

30.November1987

SERVICE KRUPP

DOCUMENT

MaK MASCHINENBAU

gear

OF GMBH

ENGINEER’S

Running

HANDBOOK

Liner tmeasurinalreconditionina

Z + M 451/M 452/453 B 02-4-Q

CYLINDFR LlNFq Round down wear edge in the cyl. liner (reversal mark of the topmost ring TDC).

Limit wear: NominalLimit Roundness

0 320 H7mm 0321 mm 0.35 mm

TDC of the piston

Measuring

ruler for cyl. liner 6.2918 1.9219 B

Precision inside micrometer Enter dimensions

in the measuring sheet (Form No. 0 5-6).

lf the wear limit is reached, change the liner. Check non-return

valves between cylinder liner and luboil line, replace valves as a unit if necessary.

Edition 30.

September 1989

SERVICE

gear

DOCUMENT

OF


ENGINEER’S

Running

HANDBOOK

er ~measuringfreconditioningU+M

gear

451/M 4571453 B 02-4.0-l.

RECONDITKINING OF LINER AND CYL.BLOCK Z + M 451/M 452 Position sealing ring dry z+y=1.2mmx=1.5mm z+y11.4mmx=1.7mm z+y=1.7mmx=2.0mm z+y = 2.0 mm x I 2.3 mm z+y = 2.7 mm x = 3.0 mm z+y - 2.5 mm x = 2.8 mm The x values were calculated with respect to the wear ridge of the upper piston ring in the liner, i.e. rather the liner slightly higher than too low.

Once a conical ring has been used, it may not be reused, since its worn surface is permanently deformed and its hardness has beer increased.

z+y = 0.8 mm x = 2.8 mm z+y=1.8mm x=3.8mm

Engine m 452 with liner 1.60.6-l 6.11 .Ol-12 or with reconditioning 1.60.7-99.16.00-01 (collar height 33.5 mm) must be equipped with sealing ring 1.5 or 1.7 mm as standard.

1.60.7-99.1 S.OO_Ol * l

Liner

depth 15 mm

machined tru (liner in the cy1.b

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Runninggear rq

7 + M 45~/453J

92 -4.0.1

RECCNDtTlONlNG OF LINER AND CYL BLOCK Z + M 4517 M 452 Position sealing rtng dry z+y=1.2mmx=1.5mm z+y=1.4mmx=1.7mm z+y=1.7mmx=2.0mm z+y = 2.0 mm x = 2.3 mm z+y = 2.7 mm x = 3.0 mm z+y = 2.5 mm x = 2.8 mm The x values were calculated wtth respect to the wear ridge of the upper piston ring in the liner, i.e. rather the liner slightly higher than too low.

Once a conical ring has been used, it may not be reused, since its worn surface is permanently deformed and its hardness has been increased. From Juli 1989 only fiat nitrided joint rings (St 52-3) are to be used in general).

rner M 451 I452

z+y = 0.8 mm x = 2.8 mm z+y=1.8mm x=3,8mm

Engine m 452 with liner 1.60.6-l 6.11 .01-l 2 or with reconditioning iner M 452 with reconditioning 1.60.7-99.16.00-01 1.60.7 -99.16.00-01 (collar height 33.5 mm) must be Liner 1.60.6 -16.11 .01-l 2 (nitided ) equipped with sealing ring 1.5 or 20 1.7 mm as standard. ___O

402 + 0.34

original depth

machined true (liner in the cyl.block) cyl.block/

Edition

30. September 1990


ENGINEER’S

Running

HANDBOOK

Liner ~measurlna/reconditioninCl)_&M

gear

451/M 4521453 B 02-4-W

RECONDlTlONlNG OF LINER AND CYLBLOCK M 453 IN-LINE Position sealing ring dry z+y31.2mmx=1.5mm z+y=1.4mmx=1.7mm z+y - 2.2 mm x I 2.5 mm z+y = 2.4 mm x I 2.7 mm z+y = 3.2 mm x = 3.5 mm z+y = 3.4 mm x 3 3.7 mm The x values were calculated with respect to the wear ridge of the upper piston ring in the liner, i.e. rather the liner slightly higher than too low. + NOTE Once a conical ring has been used, it may not be reused, since its worn surface is permanently deformed and its hardness has beer increased.

l

z+y = 0.7 mm x P 2.5 mm z+y = 0.7 mm x = 2.7 mm z+y=l,7mm z+y=1,7mm

x=3.5mm x=3.7mm

z+y = 2.7 mm x = 4.5 mm z+y = 2.7 mm x = 4.7 mm ‘NOTE Engine M 453 with liner 1.60.6-l 6.11 .Ol-06/07 with collar height 33.5 mm must be equipped with sealing ring 1.5 orl.7 mm as standard.

machined true (liner in cyl.b

SERVICE

Edition 31.

Auaust

1987

I

KRUPP

MaK


OF GMBH

ENGINEER’S

I

HANDBOOK

er lmeasurlna/reconditlonlngI

Running

gear

7+M 451/M 4521453 B 02-4.0.3

RECONDITIONING OF LINER AND CYL.BLOCK M 453 VEE Position sealing ring dry z+y=1.2mmx=1.5mm z+y31.4mmx=1.7mm z+y = 2.2 mm x = 2.5 mm z+y = 2.4 mm x = 2.7 mm

Chamfer bebw

z+y = 3.2 mm x I 3.5 mm z+y 3.4 mm x = 3.7 mm The x values were calculated with respect to the wear ridge of the upper piston ring in the liner, i.e. rather the liner slightly higher than too low.

Once a conical ring has been used, it may not be re-used, since its worn surface is permanently deformed and its hardness has beer increased. z+y = 0.7 mm x = 2.5 mm z+y = 0.7 mm x = 2.7 mm z+y=1.7mm z+y=1.7mm

x=3.5mm x=3,7mm

z+y = 2.7 mm x = 4.5 mm z+y = 2.7 mm x = 4.7 mm

Engine M 453 with liner 1.60.6-16.11.01-06107 with collar height 33.5 mm must be equipped with sealing ring 1.5 or 1.7 mm as standard.

Liner 1.60.6-16.11.01-06’

machined true (liner in cyl.block)

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Running gear

HANDBOOK

Liner (measurlnalreconditionina)

ZtM 451/M 4521453 B 02-4.0.4

RECONDITKINING OF LINER AND CY. BLOCK M 453

Limit- measure for re-con

N

1-I

0,03

1AB

\

peat+ IO- valley nelgnt 25

-

1.60.6-16.11.01-13

Sealing ring below the liner collar see Sheet -4.0.2-3

Edition 31 .Januaryl988

SERVICE KRUPP

MaK


OF GMBH

MaKI

ENGINEER’S

I

HANDBOOK

Running

gear

Liner (fittina) Z+M 451/M 452/453 B 02-4.1

fvl451/452f453

-==I !

, , , / , / / { / /

4

L

I

1

4

/

All rubber rings must be inserted with liquid beef dripping or fresh soft soap. When fitting the O-rings ensure that the rings are not twisted in the grooves. Before fitting the liner ensure that the liner guides in the box frame are free of burr. Liner should slide into or onto its seat under its own weight1


SERVICE KRUPP

MaK


OF GMBH

=I

ENGINEER’S

HANDBOOK

Piston Din and bush. fittina and removal B 02-5.4 PISTON PIN RFMOVAVFIllI&

Piston pin (Al piston) Piston bearing

Conn.rod-0 Piston pin-0

End play “X”

Boss distance Bearing length

Piston Piston

Min.Limit

Manufacdimen.

New and wear dimensions

boss-0 pin-0

;;;‘“o’

Max.Limit

Turing clear

0,005

-

0,03

0,06

0,16

-

0,2

0,35

0,25

-

0,65

0,8

135:17 135,o 130,35 129,9

Removal If the piston pin cannot be removed by hand, heat piston to approx. 80°C. Do not use force!

If heat had to be applied for the removal, again heat piston head to 80°C. Supercool pin if necessary. Piston must be measured in TDCRlDC position. Measure play “a” and ‘b”. The max. difference of these lateral clearances

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

-I

ENGINEER’S

HANDBOOK

mn

Din and bush. flttina and.mWal

B 02 I !LiLl

Bush for connecting-rod big end must be supercooled. Temp. diff. approx. 140% between bush and big end required, i.e. heat connecting-rod big end to approx. 80X, supercool bush to approx. - 60°C. Check at standard temp. (20°C) the oil drilligs, the oil groove position and the dimensional accuracy P diam. of the piston.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Running

HANDBOOK

Eston

pin and bush. fitting and removal B 02-5.02

CONNECTING ROD f$&.

Screw plug I or II

1.60.7-28.10.03-02 M 45ll462

I!;

II 1

1.60.7-28.10.00-l 1

4,

.63.7-28.10.00-

1.00.7-88.50.51-15

1.00.7-88.50.51-16

(screw plug)

(nozzle plug)

NOTE: Shut-off nozzle or screw plug is secured by 4 x centre

Edition 31.

August

SERVICE 1987

KRUPP

MaK

gear

punching.


OF GMBH

ENGINEER’S

Running

HANDBOOK

gear

piston assemblv (built-uD Distonl B 02-5.1 PISTON TOP Fll-TlNG M 452/M 453 2.

2.

Assembly of the piston top

Manufacturer:

m

2.1

2.2 2.3

2.4

Applicable to variant:

If necessary, screw the studs into the crown and tighten them with a

Torque

q

Torque = 80 Nm

40 Nm

Insert a new O-ring in the groove without twisting it and coat it with soft soap or tallow Put the skirt on (the centering hole and pin must coincide) and place the extension bushes over the studs (crowned ends towards the piston crown). Tighten the nuts twice consecut ively with

torque of and slacken again. Then tighten finally with torque of

00 - 08,OO - 09, 00 - 12, 00 - 13

If necessary, screw the studs 2.1 into the crown and tighten them with a

2.2 2.3

2.4

Insert a new O-ring in the groove without twisting it and coat it with soft soap or tallow Put the skirt on (the centering hole and pin must coincide) and place the extension bushes over the studs (crowned ends towards the piston crown). Tighten nuts crosswise a

Torque = 110 Nm

Torque = 65 Nm

2.5

of the piston top

Manufacturer: SK (Kolben-Schmidt)

(Mahle)

00-06,00-07,00-10, 00-11


Assembly

2.5

and slacken again. Check the screwing-in

of the studs.

Torque = 80 Nm

Torque = 65 Nm 2.6

Pretorque

the nuts crosswise

Torque 2.7

q

with a

25 Nm

Tighten the nuts crosswise through an

Angle = 65” 2.8

Check: Immediately after tightening the nuts must not move futher when applying a

Torque = 75 Nm Smear threads and contact faces with Molykote paste Gr-n.

Smear threads and contact faces with Molykote paste Gr-n.

JMPORTANT REMW between piston crown and skin should be measured with regard to the following facts: The component parts of piston ought to be in an absolutely clean, cold (approx. + 22” C) and assembled but J-& yet tightened condition! NEW CLEARANCE = 0.06 too.1 0 mm

The clearance

LIMIT CLEARANCE = 0.19 mm (Refinishing only possible at the manufacturers!)

Edition

30. April 1991


ENGINEER’S

Running

HANDBOOK

gear 4

piston assembly Ibuilt-yg piston) B 02 _5.1 .l PISTONTOP FIJTNG M 453 C 2.

Assembly of the piston top

Manufacturer:

m


00 - 23

2.1

Manufacturer: SK (Kolben-Schmidt)

(Mahle)

Applicable to variant: 2.1


2.3

2.4

2.5

2.2

Insert a new O-ring in the groove without twisting it and coat it with soft soap or tallow Put the skirt on (the centering hole and pin must coincide) and place the extension bushes over the studs (crowned ends towards the piston crown). Tighten the nuts crosswise a

Torque

q

2.3

2.4

and slacken again. Check the screwing-in of the stud.

2.5

and slacken again. Check the screwing-in of the stud.

Torque = 80 Nm

Pretorque the nuts crosswise with a

2.6

Pretorque the nuts crosswise with a

Torque = 25 Nm

Torque = 25 Nm 2.7

Insert a new O-ring in the groove without twisting it and coat it with soft soap or tallow Put the skirt on (the centering hole and pin must coincide) and place the extension bushes over the studs (crowned ends towards the piston crown). Tighten nuts crosswise a

Torque = 70 Nm

100 Nm

Torque = 60 Nm 2.6


Torque = 80 Nm

Torque = 60 Nm 2.2

00-17,00-18,00-21, 00 - 22

2.7



Angle

Angle = 180”

q

75”

Check: Immediately after tightening the

Check: Immediately after tightening the nuts must not move futher when applying a

nuts must not move futher when applying a

Torque = 60 Nm

Torque = 100 Nm



The clearance between piston crown and skirt should be measured with regard to the following facts: The component parts of piston ought to be in an absolutely clean, cold (approx. + 22” C) and assembled but net yet tightened condltlon! NEW CLEARANCE = 0.06 too.10 mm LIMIT CLEARANCE = 0.19 mm (Refinishing only possible at the manufacturers!)

Edition

28. February

SERVICE

1989

KRUPP

DOCUMENT

MaK MASCHINENBAU

4.

OF

GMBH

ENGINEER’S

I

HANDBOOK

Running gear

es R 02 . W Shape and position tolerance according to built pistons, ring groove I+11 Applicable to: M 453, M 35, M 55112, M 601

Edge breaking as chamfer or radius (Applies to chromium-plated compression snap ring grooves) The snap ring grooves areto be finished by pistonsupplier Mahle or Kolbenschmidt. Edge breaking as chamfer or radius (Applies to all hardened compression snap ring grooves) ove II hardene

pth

Also applicable to groove I I

. 1 shaft on l/2 circumference I

-crown (repair) Recutting of snap ring groove I up to max. = 10.8 mm ! Clean ! Chromium plating for thickness - produce standard groove (10.16 mm) and operate the piston ring provided for groove I SERVICE

Edition 28. February

1990

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

-1

ENGINEER’S

HANDBOOK

JW 1%’outand arooves I

t

451

Groove

Liner, chromiumplated NOTE: “Chromium or softnitrided piston rings must not be used!”

I

II-N

Standard

Oversize

9,6 mm 0.00.635.41 .oo-71

10,6 mm 11,6 mm 12,6 mm

8,0 mm 35.41.01-04

9,0 mm 10,O mm

V

8,0 mm 35.41 .Ol-08

10,O mm

I

9,6 mm 35.41 .oo-05

10,6 mm 11,6 mm 12,6 mm

II-IV

8,0 mm 35.41 .OO-06

8,75 9,O 9,5 10,O 11,0

mm mm mm mm mm

V

8,0 mm 35.41 .Ol-08

10,O

mm

VI

35.41 .Ol-06

VI

35.41 .Ol-07

liner, soft nitrided

Ring layout for both

Design Trapezoidal washer Plain compression ring

Groove

Coding

01-14 01-15

+ 0,08+0,02

Gas compressor piston ring

01-16

+ 0,08+0,02

Trapezoidal washer (chromium -plated)

00-55 00-56 00-57

+0,12+0,02 also applies to 2nd groove

01-34 00-58 01-36 00-59 00-60

+ 0,08+0,!2

Plain compression ring Gas proof piston ring

01-16

+ 0,08+0,02

Oil scraper ring Slotted, taper-face oil control ring

+ 0,08+0,02

If 50.8 dimension cannot be observed with oversize ring, wear ridge in liner must be equalized. l

SERVICE

31.

August

1987

KRUPP

MaK

width

max. +0,12+0,02 also applies to 2nd groove

01-18 01-19 01-20

Limit wear for all ring grooves = + 0.40 mm

Edition

B 02 _52


OF GMBH

ENGINEER’S

Pina M

451

Groove

Cast piston (old + new combustion chamber type) TIP: “Chromium ring in the the ring groove! increases the life of Al piston (with and without ring carrier, old and new corn bustion combustion chamber type)

I

II-IV

Standard

Overslzs

8,0 mm 0.00.635.41 .OO-06

8,75 9,0 9,5 10,O 11,0

8,0 mm 35.41 .l l-l 1

9.0 mm

35.41 .Ol-09

I+11

8,0 mm 0.00.635.41 .OO-06

II-IV

8,0 mm 35.41.01-l

Plain compression ring (with chromium -plated crown) Compression

note:

Groove width +O,OEfO,Ol also applies to 2nd groove

01-34 00-58 01-36 00-59 00-60 01-14

+0,06fO,Ol

WI

8,75 9,0 9,5 10,O 11,0

mm mm mm mm mm

9,0 mm 1

0,04 to 0,07 max.

Plain compression ring (with chromiurr -plated crown)

01-34 00-58 01-36 00-59 00-60

+0,08+0,02 +0,06+0,02

Compression ring

01-14

+0,06+0,02 +0,04+0,02

Slotted, taper-face oil control ring Oil scraper ring

c = 350 rpm > = 350 rpm

soecial

gear

lav-oul and arooves B 02. 5.2-t

Design

mm mm mm mm mm

Running

Oil scraper ring

V

V

I

HANDBOOK

01-07 01-09

+0,06 to 0,08

New combustion chamber type since start of 1969.

Limit wear of all ring grooves t + 0.40 mm 4

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Running

HANDBOOK

gear

and aroovesR 02 *5&i?

M 452

-Standard

41 piston with a ring #srier)

I+11

8,0 mm 0.00.635.41 .OO-06

III-N

8,0 mm 35.41 .01-l 1

v

c - 350 Ulmin > = 350 U/min

Design

Oversize 8,75 mm 9,0 mm 9,5 mm 10,O mm 11,0 mm

Plain compression ring (with chromiumplated crown)

9,0 mm

Marking

I

Groove high

01-34 00-58 01-36 00-59 00-60

+ 0,08 + 0,02 + 0,06 + 0,02

Compression ring

01-14

+ 0,06 + 0,02 + 0,04 + 0,02

Slotted, taper-face oil control ring Oil scraper ring

01-07 I 01-09

I

J3ina aroove wear measurerwd Height of groove hN Wear limit measure (mm)

Piston ring height hR Nominal size (mm) 6 8 10

Limit clearance nN-hR (mm)

6.3 8.3 10.2

0.4 0.4 0.3

valid for piston rings in series!

Edition 28.

February

SERVICE 1989

I

KRUPP

MaK


OF GMBH

+ 0,06 bis 0,08

ENGINEER’S

Running

HANDBOOK

ping lay-out and amoves

M

4521453

11piston (with fuplex ring

Groove l+R

Standard 8,0 mm 0.00.635.41 .OO-06

carrier) III - Iv

8,0 mm 35.41 .01-l 1

I, 11+111 IV

2;, lo,0

z mm

‘ll”

mm

9,0 mm

8,0 mm 8,0 mm

Plain compression rins (a chromium-

675 mm

<=35Orpm >=350rpm

V

Design

Oversize

I+11

6,0 mm 0.00.635.41 .Ol-28

6,75 mm mm 7,5 mm 8,0 mm

ring Slotted, taper-face oil control ring Oil scraper ring Plain compression ring (with chromiumplated crown

01-14

+ 0,06 + 0,02

Tapered compression piston ring (Fitting position: note “TDC”) Narrowland drain oilcontrol ring withgarter spring

01-26 01-27

+ 0,04 + 0,02

01-23

+ 0,06 bis 0,08

Plain compression ring (chromiumplated)

“Top” 01-38 01-39 01-40 01-41

+ 0,08 + 0,02 + 0,06 + 0,02

01-42 01-43 01-44 01-45

+ 0,06 + 0,02

plated crown) Compression

Plain compression ring (with I

8,0 mm 0.00.635.41 .Ol-30

8,75 mm 9,O mm g15 mm 10,O mm

35.41 .Ol-31

IV

Edition 31.

August

chromiumplated crown) Nanow_ land drain oilcontrol ring with garter spring

SERVICE 1987

I

KRUPP

Groove width

Coding

+ 0,08 + 0,02 + 0,06 + 0,02

9,o mm 10,O mm

7,0

B 02~5.2.2-l.

01-34 00-58 01-36 00-59 00-60

V

Al piston, luplex ring arrier with LO mm grooves

gear

MaK

01-07 + 0,06 bis 0,08 01-09

+ 0,06 + 0,2

01-31 “Top”


OF GMBH

ENGINEER’S

I

HANDBOOK

layom m 452iIJ452

Running

grooves

Important details and tips

Piston with single ring carrier

Piston with double ring carrier 8 mm ring grooves

,6 mm ring grooves

DETAIL X Wnh beaw fuem Reconditioning of the oil groove between II and Ill

Sharp edges burr

Limit wear for all ring grooves = 0.30 mm Note “TDC” fitting position of the piston rings.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

gear

8 02 I 5,2.2.2

l-l

ENGINEER’S .

I+11

Puitt-uo.Diston Piston top 1 k 26 658/2 (42CrMo4v) var.: -02 1st ring groove flamehardened Var.: -04 I 1st ring groove chromiumplated

8,0 mm 0.00.635.41 .Ol-30

N

10.0 mm 35.41.01-31 -23’ -87

l

gear I

I

Ring + groove

Ring

6,75 mm 7,0 mm 7,5 mm 8,O mm 8,75 mm. 9.0 mm 9.5 mm 10,O mm 11,O mm

Plain compression . yifmmiumPlated)

Narrowland drain oilcontrol ring withgarter spring

code Ring

Groove width

0138 01-39 01-40 01-41

Variant: -10 Variant: -11 Variant: -12 Variant: -13

01-42 0143 0144 01-45

+ 0,06 + 0,02

01-96 -97

+ 0,06 + 0.2

01-38 01-39 01-40 01-41

Variant: Variant: Variant: Variant:

14

Original

4r

(Deviations from the piston top: 1 k 26 658/2)

M 453

(0 ring seal I 255x5mm Dowel pin = 6x20mm)

6,0 mm 0.00.635.41 .Ol-21 (Variant: -09)

III

(O-ringseal 255x5mm dowel pin t 6x20mm)

Var.: -05 I 1st ring groove chromiumplated

Runnlng

I

Ring = = Standard Groove Ring + groove No

M 452l453

Piston top 0.44.39.8.4002.04 Var.: -03 I 1st ring groove flamehardened

I

HANDBOOK

I+11

6,0 mm

(Variant: -14)

Plain compression ring(with chromiumplated crown)

6,75 mm 7.0 mm 75 mm 8,0 mm

NOTE FOR RECONDITfOhING;

-15 -16 -17 -18

IMPORTANT NOW

The sides of the ring grooves 1. in the top of the built-up piston are chromium-plated in ring roove I and flamehardened in ring groove II. 2. Reconditioning of worn ring grooves can be carried out as follows:

ff sides of ring groove I are chromium-plated, a plain compression ring chromium- plated on three sides must be fiied. A ring chromium-plated on three sides may not be fiied in a flame-hardened ring groove.

Chromium-plating for thickness of the sides to standard or oversize (piston top inexchange).

Limit wear for all ring grooves P f 0.30 mm!

Invalid for M 453

Edition 30. September 1990

SERVICE

DOCUMENT


OF GMBH

4r

-I

ENGINEER’S

HANDBOOK

Binas 02.5.2.4

NO.

Standard ring+ groove

oversize ring+gmove

I

6,0 mm 0.00.6-35.41 .Ol-32

6.75 mm 7,00 mm 750 mm 6.00 mm

Ring groove

M453C

Built piston for gasoil operation

First ring groove: flame hardened

6,75 mm

6.0 mm 1.60.6-26.70.00-l

6

KS

7,00 mm

0.00.6-35.41.01-71

I

7.50 mm 6.00 mm

(Piston top : 0.44.39.6.69-02.01)

6.0 mm

ml

0.00.6-35.41.01-67

.Ol-66

-

10,O mm

6,0 mm 0.00.6-35.41

Built piston for

heavy fuel operation

1.60.6-26.70.00

5 I

- 15 -16 -17

.Ol-71

I

Rectangular

TOP

dng (chromium Plated 1

(hmmlumplated

lo,06 mm

Rectangular ring chromium layer - 0.30.5

mm

mm mm mm

Compression ring chromium hyer- 0.160.3 mm

TOP

TOP

10.06 mm

1. ff the flanks of the first groove am chromiumplaled. a rectangular ring, chromium-plated on three sides, must be fitted1 2. In hame hardened ring grooves, no ring, chromium-plated on three sides. must fitted1

1988

KRUPP

MaK


6.16 + 0,02

6,16 mm

Oil scraper ring mth tube aP%i chromiumphtad I 0.16 mm

SERVICE

6.16 + 0,02

TOP

Chromiumphting of the flank to standard or oversize. (Piston top in exchange).

Oktober

6,16 + 0,02

TOP

Plav attention when refinishina;

31.

0,02

6.16 mm

)

6.75 7,00 7,50 6,00

N

Edition

l

chfQmhJmlayer - 0,30,4mm

7,50 mm 6,00 mm

6.0 mm 0.00.6-35.41.01-68

The flanks of the ring grooves in the top of the buiff piston are chromium-plated in the first ring groove and fianm hardened in the second ring groove. Worn ring grooves may be refinished as follows:

6,16

sides)

Rectangular ring (chromium plated on three sides) chromium iayer I 0.30.6 mm

10,O mm 0.00.6-35.41.01-67

)

Groove height

ring with tube SPrfng (chromium-plated)

6,75 mm 7.00 mm

.01.70

,

KS Piston top : 0.44.39.6.68-02.02

6.0 mm 0.00.6-35.41

TOP

Oil scraper -

I

First ring groove = chromium-plated (Chromium layer = 0,25 f 0,05 mm )

Rsctangular ring (chromlwrc plated on three

Compnaaion ring

I

0.00.6-35.41

Ring mark: ‘Top!”

Ring design

OF GMBH

ENGINEER’S

HANDBOOK

Running

Piaton flng marking

-wxo 6 -0.062

III

Piston upper pm lK42315

I 6.16 + D,D2 I Joint

chromium-plated

-89

gap - 2.5-2.9I

-87

lo,06 +D,D2 Joint ~apl= 1.25-1.6

rapered compression piston ring

I

~anufacturerbEo coo Top 1 41.01- 90.1 1 wmbol I

mPI

41.01-932

TK) 1 41.01*;3

Riken

_.__._.

0,8x 460

I

mwim nunbbr

L 0.60.6 -36.41 .Ol-91 ,

h w S

Dams

I TDp 41.01- a11

t

hnanufacturer

I

Chromium laver min.0,05

Goetze

7hsignalim

Tapered compression piston ring inrm ringQroovs:II+1II(MDO+IFOope~on] Drwi~nurher

0,3.. Chromium lay

0.00.6 -35.41.01-89

NOTE

In general this ring hard-facing is only applicable to new buildings, conversions and repair! Regardless of the type of rings previously mounted!

Edition 28. February

SERVICE 1990

DOCUMENT


OF GMBH

gear

ENGINEER’S

HANDBOOK

Wn

Running

gear

flttina and removal B 02-5.3

PlsTCN Pl-f-ffNG M 451~57 Insertion ring : (6.9126) Measure: M 4511452 =OorlOmm M453 = 7,0 mm look for acceptance rearrd Difference not more than 0.2 mm NOTE:

-

After overhauling on the cylinder, it run for about 10 h at reduced power.

-

2-valve engines (M 451): be sure to fit piston on correct side (inlet valve pocket lower than valve pocket!).

-

coding of big-end bearings:

-

ring cut distribution.

exhaust

vertical figures horizontal figures

I camshaft side = exhaust side

Attention must be paid to perfect deburring of the ring cuts! When fitting the oil scraper ring the spring connection to the ring cut must be displaced by 180”.

Oil outlet pipe always points to the direction of rotation side! Cuts must be properly trued! (There is the risk of “hooking” in the inlet ports). Dimension: Piston crown-top edge liner =5,tiO,5 mm (see acceptance test record)

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

=I

ENGINEER’S

HANDBOOK

Piston

fittina and removal

PISTON RFMOVAL M 453 Cross-piece for removing piston Cylinder liner hold-down equipment

(6.9125 A) (6.9117)

Overhaul interval:

5 000 h approx. of one piston 10 000 h approx. of all pistons

Liner hold-down equipment (4 sleeves, of which 2 with slide rails (1.9117Aand 1.9117) Cylinder cover nut Threaded holes (M 12,22 deep) Cross-piece (6.9125) Plastic slide rails (1.9125)

SERVICE

Edition 31.

August

1987

KRUPP

MaK

DOCUMENT

MASCHINENBAU

OF GMBH

B 02 I 5.3.1

ENGINEER’S

Running gear

HANDBOOK

Cyl. code no. on the big-end camshaft side (assembly side). Distribute ring cuts uniformly. . . .. rttrna wsrtlon Bar piston pin 17 before or after TDC (camshaft side). M 453 Vee piston pin = vertical “at top”, engine centre.

M 453 R

M 453 v

6.9125 A

4

\6.9126

Position of the oil outlet for piston cooling with main direction Kklht with port engine on camshaft side with starboard engine on exhaust side

Position of the oil outlet for piston cooling with main direction k2f.t with port engine on exhaust side with starboard engine on camshaft side

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

HANDBOOK

Piston fittina and removal B 02-5.3.2.3 M 452/M 453 - Vee crying for direction of rotation right and left

NOTE:

Oil outlet must remain open. The cover affixed for transport and storage must be removed orior to fitting,

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

4

-1

ENGINEER’S

I

HANDBOOK

MDlate.

Tightening Md = 400

moment

Engine

box fm

for bolts

Nm (40 kpm) Lubricant : Molykote Paste G

M24x

M24x160mm

110mm

2 holes for taper pin 0 16 mm drilled and reamed on assembly (hooles are pre-dilled in the box frame)

16x 120 mm

Ream hoe after the alignment for 032 mm fitted bolts.

M30x120mm

NOTE; After the “alignment” first tighten bolts! Then the tie-rods!

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

housing I

03-l .Q

Englna housing


Ina B 03-l .O.i

M4511452 Engine housing bolt thread = on both sides M 39 x 3 Total length = 270 mm (42 Cr MO 4V)

Tightening torque 1300 Nm (130 mkp) lubricant : Mofykote ( paste G) QK tightened by hand (50 Nm) +120” a

T

b-J

Cap nut ( salt bath nitrided) m39x3SW=41 i

/

Bored and reamed here and diagonally at the other end of the engine housing 0 15 through the bedplate. 0 25 bored for locking.

Groove with clamping sleeve Pay attention to a fast seat of the Clamping sleeve!

,

,

During assembly 0 2 bored for locking Bore for tapered pin 0 10 bored in engine housing 20 deep and reamed. M20x55 Tiihtening torque 300 Nm (30 kpm) lubricant: Molykote (paste G)

Attention! Bolt material 10.9

I Edition

30 . September 1990

View on flywheel side


1-

ENGINEER’S

I

HANDBOOK

Dimensions of the base plate

In-line engine

View A

Vee engine

View A

I’ ‘I

I-L u

b e---r

6 cyl. 6 cyl. 9 cyl. 12 cyl. 16 cyl.

----t--~-

510 J

Engine type

B

A 3006 3906 4358 3650 4790

2250 3150 3600 2850 3990

Material - tensile strength

a

Fiied bolts 4 4 4 6 6

24 32 36 20 28

142 CrMo4V

Thread

Found. bolts

1

8,8

M 24

t 1

M 24 M 24 M 33 M33

Touque** 500 Nm 500 Nm 500 Nm 1350 Nm 1350 Nm

**bolts lubricated

*These holes at each side of the flywheel end must be holes fitted bolts.

Edition 31.

August

SERVICE

1987

housing

M 45114571453 R 03 _1.2

Founw Foundation plan

Engine

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

HANDBOOK

Engine housing

tinder block B 03 I 1.3 NFCKED-DOWN BOLTS IN THF CYL.- BLOCK 7 and M451.453_and&I

Necked-down bolt (kl30 x2) 1.50.7-l 1 .10.07-02 -03

Necked-down bolt with oversize (M33x2) 1.50.7-l 1.10.07-07

Before applying the paint, careful cleaning (surface grease-free) of the bolt barrel and thread is necessary. Apply paint directly prior to screwing-in of the necked- down bolts, from the 1st thread up to height of approx. 150 mm. The bottom threads including contact pins remain unpainted and are sprayed with Tech4 S. In-line and V M 453

-01

Necked-down bolt (M30 1.50.7-l 1.10.07-05 Stand by -08

Necked-down bolt with oversize (M33x2) 1.50.7-l 1.10.07-09

Insertion of the painted necked-down bolts, see above. Difference: from the 1st thread up to height of approx. 180 mm.

Edition

31.January1988

SERVICE KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

HANDBOOK

Engine

tinder block

housing

B 03 - 1 .3 .1

In the event of stand-by delivery of var. -08109 for var. -05, 6 threads must be painted. Paint 055 000 369 (crankcase paint 5248) Tectyl S 081 002 442 (slushing oil) Reboring equipment for damaged necked-down bolts 11.Ol-0388.

Assemblv:

Necked-down bolt is screwed in using stud driver, nut and pneumatic hammer until the necked-down bolt has visibly come to a stop.

JMPORTANT!

Perfect contact must be ouaranteedt

Screw-in torque: 550 Nm (55 kpm)

M Caped nut (M30x2)

Screw- in of the stud bolt as usual only 195 mm high

Washer

\


SERVICE KRUPP

MaK

Necked-down bolt (M 30) 1.50.7-l 1 .10.07-l 2


OF GMBH

-I

ENGINEER’S

HANDBOOK

Enaine housina B 03 - 1 .3.2 Sift stud bolt in enaine housing M Cap nut ( M 30~2,006) 1.50.7-I 1 .10.03-06

I .70.7-l 1.30.1 l-01 Before priming 055 00 151 degrease spray gap with plastic sealing compound 081 00 126

Before installation coat the thread fully with Molykote

Cap nut ( M 30~2,006) 1.50.7-l 1 .10.03-06 Washer 1.70.7-l 1.30.1 l-01

Coat of paint before assembly (inctgroove) \

O-Ring 24x4 067 082 224

ti Before installation coat the thread fully with Molykote w Stud bolt ( M 30) 1.50.7-l 1 .10.07-15

Edition

31.January1988

SERVICE KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

4

ENGINEER’S

Engine

HANDBOOK

housing

I .

.

nina instructions for tte-bolts. hydr. tools B 03 _1.4

To load the tie-bolts, position the tool with pushed-in piston. (see figure)

To slacken the tie-bolts, press out piston 2.5 mm before tightening the nuts. (see figure)

NOTE: No Molykote on bolt and nut threads! (see figure)

SERVICE

Edition 31.

August

1987

DOCUMENT

OF


ENGINEER’S

HANDBOOK

structi~

tie-bolt$&dr.

tools B 03 w1.4.1

nahteninm Tighten tie-bolts in pairs in the numbered sequence. I 1st stage: 300 bar

2nd stage: 585 bar

When tightening in the 2nd stage check whether a groove of the nut agrees with the hole in the tie-bolt; if not, slacken nut again and align the next groove with the hole aa a safeguard. Unload the jack, press in piston of the tool and dismount the tool. In the case of nuts with forged-on lifters, turn with a screwdriver or similar tool in the manner shown.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Engine

HANDBOOK

housing

hvc&, tools B 03 . 1.49

tenlng Instructions for tiebolt$ TIF-ROLTS HYDR. TOOL S M 453 ”VFF I 12 ANl7 16 CYI

pump

NOTE:

Hydraulic oil H 36 DIN 51524 (4-5 E/50%) recommended as operating medium. Fuels are not admitted.

Threads: (old) = M 36x2 (new) I M 39x3

SERVICE

Edition

31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

HANDBOOK

Engine

ns for tlebol~dr.

housing

tools B 03-l .4.?

ntna seauenca; Tighten tie-bolts in pairs in the numbered sequence:

.

2nd stage: 815 bar (830 kp/cm2)

1st stage: 407.5 bar (415 kplcm2)

2

applies to 16 cyl. engine

4

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Triming

gear

r box Z+M 451/M 452 and 453 B 03-1.5

1.

Gear box is fitted by means of liquid sealing compound, flush - aligned on camshaft side to engine housing and locked by at least 2 pcs. tapered pins.

2

The protruding part to the bedplate is equalized by means of a plate ground to size (half moon shaped).

End of gear box When pinning the equalizing plate the edge must be flush with the bedplate

/ 10x60 DIN 7977

3.

Equalizing plate flush-ground with the flange facing of the gear box During mounting pin hole bored 0 10 x 44 deep and reamed by taper-pin reamer

The end housing is lined up with the crankshaft flange, (upper distance at least 0,lO mm greater! During operation crankshaft is lifting due to oil pressure!) bored and pinned. Camshaft supporting bearing flanged and pinned at the gear box. Alignment: Tighten and pin supporting bearing, fully pressed below the crankshaft. Important presupposition: Cams must not be force - locked! Remove blind plug R l/2” during aligment! (Inexactness caused by air cushion).


SERVICE KRUPP

MaK


OF GMBH

.

Mid

ENGINEER’S

I

HANDBOOK

end cover. flwd

Engine

shaft arranaement B 03 I 1.6.1

Re: Last flanged bearing

.

PITTENlON, Tighten both sides in 2 steps with 220 Nm. (For lubrication use Molykote)

SERVICE

Edition

28.

February

1989

housing

DOCUMENT


OF GMBH

ENGINEER’S

Every 2 500 operating hours Every 10 000 operating hours

=

HANDBOOK

Timlna aear train inspection B 04 -1.Q visual inspection visual inspection, measure back-lash on the gearwheels and running clearance

Back-lash on

Limit clearance gearwheels

(rt-N

(r-nrr-4

eatwheel on crankshaft - large intermediste wheel 0,20 - 0,28 0‘4 I small intermediate wheel - gearwheel on camshaft 0,13 - 0,20 093 I - governor drive gear camshaft gear 0,20 - 0,25 OS3 I geearwheel on crankshaft - pump drive wheel 0,20 - 0,28 0,4 I pump drive wheel - pump pinion 0,20 - 0,25 093 I Measure diametral clearance with feeler gauge or dial gauge.

Diametral clearance (rtJr@

lntermeediate wheel Gearwheel on cam-shaft Pump drive wheel

Limit clearance (t-nr-4

0,17 - 0,24 0,l - 0,15 0,05 - 0,l

093 0,25 0,25

If limit clearance is reached, replace bearings. Measure end clearance with feeler gauage or dial gauge.

Intermediate wtieel Pump drive wheel II limit clearance

Axial

Limit

clearance (rtw

clearance (mm)

0,15 - 0,45 0,15 - 0,35

086 0,5

is reached, renew thrust washers.

NOTE! Cylinder 1 in TDC (marks coincide) 1. Twin wheels: mark “0 2. Intermediate wheel/gearwheel on camshaft: mark “1

SERVICE

Edition

30.

April

l

1988

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

-1

ENGINEER’S

HANDBOOK

Gear drive adjustment

gear wheel B 04-l .l

Piston 1 in TDC -Back lash 0,20-0,25

Possible annex

lUll975

gear wheel.

Back lash 0,20-0,25

Double gear wheel

With engine M 453 the gear wheels 6, 7 and 8 are not applicable

SERVICE

Edition 30.

April

1988

I

KRUPP

MaK


OF GMBH

ENGINEER’S

Ttlming gear

HANDBOOK

Gear drive incl. gear wheel 6 04 . 1.1 .l_ Gear drive adiustment M 451/457/45Q

Piston 1 in TDC Back lash see port design

:

.-.I

Edition

31 .January1988

SERVICE KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH I

-

ENGINEER’S

Trlmlng

HANDBOOK

gear

ar drive Incl. aear wheel B 04 -1 .lS Gear drive adjustment

7 451 Port Piston1 in TDC

-7

.. m 42 6Z 8Z 9z

451 451 451 451

(clockwise) :1-S-2-4 :1-5-3-4-Z-6 :1-6-4-7-Z-5-3-8 :l-6-9-Z-4-8-3-5-7

lntermediatb pear wheel \

Crankshaft gear wheel I

Edition

31.January1988

SERVICE

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

HANDBOOK

Trimlng

Gear drive incQ&ar Gear drive adbtment

wheel B 04-l .l .a

7 451

Piston 1 in TDC Back lash see port design

Edition 31.January1988

SERVICE KRUPP

MaK

DOCUMENT

MASCHINENBAU

gear

OF

GMBH

ENGINEER’S

HANDBOOK

Timlna

aear train inclgear

setting

B 04-l .I.4

I GFAR SFITING FOR I LONG-INTFRVAI FIRNG 13 M 4%

-

-

SERVICE

Edition

31 .Januaryl988

I

DOCUMENT


OF GMBH

MaKI

ENGINEER’S

I

HANDBOOK

Trimlng

gear I

4

I:

-

Timina aear train Incl.aear settlna B 04-1.1.5 j6 M 453 GFAR SFTIING FOR “SHORT INTFRVAI I FIRING

f

SERVICE

Edition

KRUPP

31.January1988 I

MaK


OF GMBH


Trimlng gtsar -

B 04-l .l&

drive a-1

Gearwheela=embh!

Gear wheel (No.1) flanged on the crankshaft, is screwed with 4 filled bolts, assembled beside the joint faces ( reamed holes: 0 17 H7) and 6 through botts. Tightening torque: Torque-l 15 Nm + up to the next locking pin hole. Lubricant: Molykote paste G - Rapid

l-

Double After 8Ilgnlng the bearing bra&et (backlash) the fixing bolts M 20 x 55 SK (material: 10,9) am tightened with Ml - 300Nm (3Okpm)andlockedbyawireof2mm0. Lubrfcanc Molykote

-

-End

of engine housing

pasteG. -

end clearance 0.15-035

-

Before assembly mat the gliding surfaces with Motykote

Screws tightened wiU~40 Nm. Wead and screwhand contact surface coated wfth Mokkote. Screws only wired during final assembly. Check lub.oil connection and lub. oil Row.

,

O.l?+OJ

Is the dearance smaller than 0.15 mm, the bore in the double gear wheel must be reground.

REMARK:

w-147-

‘Befor

assembly running surface poliihed with emery.

ff possible insert, bath -nitrided double gear wheel with bath-nitrided camshaft gear wheel. The same is also applicable for hardened gear wheels. If required, hardened double gear wheel can be inserted in exchange for bath-nitrided double gear wheel. But pn no account bath-nitrided double gear wheel may be inserted in exchange for hardened double gear wheel1

Edition

30 . September 1990


ENGINEER’S

.

Trimlng

HANDBOOK

gear

*

Camshaft~.&RLWJ

Tools: 0.9205-B High-pressure hose 0.9204-D High-pressure pump High-pressure Pipe Osgl 34-G Hook spanner for slotted round nuts 6.9230

camshaft

End clearance Y = 0,5 mm WI

r

p = 800 bar

I

In the case of locating rings with positioning screws, attention must be paid to exact agreement with the positioning hole! Gearwheel on camshaft

Tightening moment of the slotted round nuts z 451 M 451 452/453 Frame economy M453 Fuel pump plunger: 26 0

-

1. 100 Nm (initial moment) 2. 1200 angle of rotation 1. 100 Nm (initial moment) 2. 240” angle of rotation

Bevel seat must be reconditioned and ground-in if necessaryf Gear wheel must be positioned “dry”! To achieve the 240° angle of rotation: “The gearwheel hub must be pumped up to not more than 1400 barl Molykote G-Rapid” paste must be used only for the thread and the contact faces. If the limit clearance of 1 mm is reached, the beating ring must be rotated slightly and re-bored. In the case of locating rings of the new design (hydraulically mounted), reset clearance with tool.

SERVICE

Edition

31. August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

HANDBOOK

Camshaft bearing

Molykote “G-Rapid” paste Bearing retaining bolt must be secured with wire!

Bearing play New play mm 2 0,lO

Limit play mm 0,25

NT NOTE,. Bath-nitriied camshaft gear should if possible be used with bath-nitrided twin wheel. This also applies to hardened gears. Hardened camshaft gear can where required be used in place of bath-nitrided camshaft gear. Bath-nitrided camshaft gear can under no circumstances, however, be used in place of hardened camshaft gear.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

Information

internal

After Sales Sedice Eng.-Type: Smirr

KT 23

1 28.02.1992

Tigtenina

for service

M 453

Stations 4

:

Info.-No. 031

.

of the fixina bolts of the camshaft bearinas

The tightening of the fixing bolts of the camshaft bearings ’ ’ has a great influence on the bearing clearance. In case of a too great tightening torque the bearing clearance may become too small. The maximum acfmissible tightening torque for the fixing bolts of the camshaft bearings is 60 Nm. After every tightening operation it is absolutely necessary to check the bearing clearance. ,

Check of bearing clearance

Fitting of bearing shell

Orlglnal clearance mm

0,lO - 0,15 .

4

.

4 i

The tightening torque of 80 Nm stated in the operating instructions sheet 04.01 .Ol is not applicable any more.

e

I

MONTEUR-HANDBUCH

Motorsteuerung

B 04-l .4

4 SPLIT FUFL CAM FOR REVERSIBLE ENGINES (repair cam) M 451,452,453 in-line and V

Engine

n

Stroke

Engine

I 20,6

M 4511452

M451/452

Old design (conicalonbase) 1.60.7-32.30.01-02

20,6

376-450

Standard model (hydraulically mounted)

Repaircam (split)

1.60.7-32.32.01-04 -32.30.01-08 l. 32.30.01-13

1.60.7-32.35.00-25 l. -32.35.00-31

1.60.7-32.32.01-04 -32.30.01-08 l

300-375

M 452

24

1.60.7-32.30.01-03

*

33 30.01-13

1.60.7-32.32.01-01 -32.30.01-05 -32.30.01-10

1.60.7-32.35.00-27

1.60.7-32.32.01-01 -32.30.01-05 l. -32.30.01-10

1.60.7-32.35.00-28

**

M 452

376-514

M 452M 453R +

till end1981 5oo-600 from start 1982 500-599

M453R+V

600-650

24

1.60.7-32.30.01-03

1.60.7-32.32.01-02 =32.30.01=06= 32.30.01-09 I* -32.30.01-10

24

M 453 for

C-tYPa engtne economical version I

1.60.7-32.35.00-26 l* -32.35.00-32

.I

l*

-32.35.00-33

-32.35.00-34

1.60.7-32.35.00-29 l

*

=32.35.00=30= 32.35.00-35

24

1.60.7-32.30.01-11

1.60.7-32.35.00-36

26

1.60.7-32.30.01-14

1.60.7-32.35.00-37

I

rr

I

**stand-l

Duringassembly attention must be paid to clearanceof the headsscrew(senseof rotation abead and astern).To be refinished ifnecessary.

Edition

30. September 1989

SERVICE

DOCUMENT


rq

rrr

OF GMBH

Motorsteuerung

MONTEUR-HANDBUCH

ReDair

cam (fuel. inlet and exhaust)

B 04-l .4.1

SPLIT FUEL CAM FOR NON-REVERSIBLE ENGINES (Repair cam) M 451,452,453 in-line and V

M 451

M 451 M 451 M 452

I .60.7-32.30.01-01

17

I

l7

24

stand -by

-09 -05 -13

stand -by

stand -by

-10 -06 stand -by

-14

1.60.7-32.32.01-l

7

~ 1.60.7-32.35.00-09

M14x45DIN912 (12 mm hexagon socket)

NOTE ON ASSEMBLY:

Ensure free passage of the bolt head when assembling rotation forward and back) and recut if necessary.

(direction of

TIGHTENING INSTRUCTIONS; 1.

Treat thread, bolt contact face and bolt with Molykote Paste G. Pre-load bolts manually and tighten afternately in small steps with M = 140 +lO Nm (14 fl

SERVICE

Edition

30. September

1989

KRUPP

DOCUMENT

MaK MASCHINENBAU

-01 -07

1.60.7-32.35.00-02

1.60.7-32.32.01-02

24

-04 -06

1.60.7-32.35.00-23

1.60.7-32.32.01-01

1.60.7-32.30.01-03

-05

1.60.7-32.35.00-21 -12 -08 -16

stand -bv M 452 M 453 R+V

stand -by

1.60.7-32.32.01-04

1.60.7-32.30.01-02

stand -by M 452

1.60.7-32.35.00-03

1.60.7-32.32.01-03 stand -by -12 -07 -11 stand -by -15

I

20,6

Repair cam (split)

Standard model (hydraulically mounted

Old design (conical on base)

Stroke

Engine

OF GMBH

kpm).

-08

ENGINEER’S

Triming

HANDBOOK

Repair cam Ifuel. inlet and exhaust)

gear

B 04-1.4.2

SPLIT INLFTCAM FOR NON-REIIERSIBLE ENGINES (REPAIRCAM)

M 453

8,16

M 453 M453

C

1.60.7-32.12.01-03

1.60.7-32.13.00-02

1.60.7-32.12.01-08 stand -by -12

1.60.7-32.13.00-03 -06 stand -by

6,8,9,12+16

18,8

1.60.7-32.12.01-13 stand -by -14

1.60.7-32.13.00-07

6,8,9,12+16

18,8

1.60.7-32.12.01-15

1.60.7-32.13.00-08

NOTE ON ASSEMBLY: Care must be taken when

TIGHTENING INSTRUCTIONS: Treat thread and bolt on the contact face lightly with Molykote Paste “G”. Pretighten the bolt manually and tighten it mutually in small steps with 140+10 Nm (14+lkpm)

assembling the cam on the camshaft that the clamping sleeve fits at the edge shown in the graph . \

M14x45DIN912 (12 mm hexagon socket)

SERVICE

Edition

30. September

1989

DOCUMENT


OF GMBH

ENGINEER’S

Triming

HANDBOOK

cam (fuel. inlet mexhaustl

gear

B 04 _1.4.8

SPLIT JNI FT CAM FOR REVERSIBLE ENGINES

(REPAIRCAM) Engine

Number of cylinder

c M 452 M 453

639

6,8,9,12

18,5 18,8

Standard

I

model

Repair cam split

1.60.7-32.10.01-05 stand -by -12

1.60.7-32.13.00-23 stand -by -27

M 452 M 453

8

20,7

1.60.7-32.10.01-06 stand -by -13

1.60.7-32.13.00-21 -25 stand -by

M 452 M 453

699

20,7 18,8 18,8

1.60.7-32.10.01-07

1.60.7-32.13.00-22

8 8, 16 6.8.9.12 + 16

18,8 18.8

1.60.7-32.10.01-09 stand -by -11 -14

1.60.7-32.13.00-24 stand -by -26 -28

6,8,9,12 + 16

18,8

1.60.7-32.10.01-15

1.60.7-32.13.00-29

6, 9, 12

M 452

M 453

)

+ 16

Stroke

M453C

stand -by

-08 -12

stand -by

Drill t ole for pin In camshaft with jig 00.00-2683

M 8 x 35 DIN 912 (6 mm hexagon socket)

TIGHTENING

INSTRUCTIONS;

Smear thread and bolt contact face lightly with Molykote. Pre-load bolts manually and tighten alternately in small steps with 24 - 26 Nm (2.4 f 2.6 kpm).

SERVICE


1989

DOCUMENT


OF

GMBH

-23 -27

ENGINEER’S

Triming

HANDBOOK

gear

I air cam (fuel. inlet!

I

B

04 _1.4.4

SPLrrOUTlFTC;eMFORNON-REVERSIBLEENGINES (REPAIRCAM)

1.60.7-32.23.00-01 1.60.7-32.23.00-05 1.60.7-32.22.01-09

1.60.7-32.23.00-05

1.60.7-32.22.01-15

1.60.7-32.23.00-09

stand -by

stand -by

_

_

*Inquiry in Kiel necessary

JlGHTENING INSTRUCTIONS:

J4OTF ON ASSEMBLYt_ Care mustbetakenwhen

Treat thread and bolt on the contact face lightly with Molykote Paste “G”. Pretighten the bott manually and tighten it mutually in small steps with 140flO Nm (14klkpm)

assembling the cam on the camshaft that the clamping sleeve

M14x4SDIN912 (12 mm hexagon socket)

Edition

30.

September 1989

SERVICE

DOCUMENT


OF GMBH

MaKI

ENGINEER’S

I

HANDBOOK

Trimlng gear

Reoair cam Ifuel. inlet and exhaust)

6 04-l .4.5

SPLIT OUTI FT CAM FOR REVERSIBLE ENGINES (REPAIRCAM)

Standard model

I

M 452

6, 9

215

1.60.7-32.20.01-05 -04 stand -by -14

1.60.7-32.23.00-25* stand -by -28* -24 stand -by -27

22,5

1.60.7-32.20.01-07 -14

1.60.7-32.23.00-24 -27

22,5

1.60.7-32.20.01-06

1.60.7-32.23.00-23 -26 I

I

-12

I

I M 452 M 453

6,8,9 6,8,9,12,16

Repair cam split

22,8

.1.60.7-32.20.01-11

1.60.7-32.23.00-25

-13 22,8

1.60.7-32.20.01-15

25

1.60.7-32.20.01-09 -08

-28 I

1.60.7-32.23.00-29

Drill hole for pin in camshaft with jig 00.00-2683

M 8 x 36 DIN 912 (6 mm hexagon socket) TIGHTFNING INSTRUCTIONS; Treat thread and bolt contact face lightly with Molykote. Pre-load bolts manually and tighten alternately in small steps with 24 - 26 Nm (2.4 f 2.6 kpm).

SERVICE


1989

DOCUMENT


OF GMBH

MAC

ENGINEER’S

Triming gear

HANDBOOK

M 451/453/45Q Project light into the hole (5) and observe the spool bush (6) through the hole (7). Rotate starting cam in the opposite direction to that of the camshaft until the light gap is still just visible. starting cam has now reached the position “starting valve opens”. Anti-clockwise rota

5 6 7

Position at start of setting

Position “Starting valve opens”

Jightan well starting-cam holding-down bolt (4). Re-tighten (headless) set screw (3) and secure with centre punch. The holding-down bolts of the starting air distributor must be tightened carefully cross-wise. DANGFR OF DJSTORTlr)N! Molvkote use “G-Rapid”.

x

6 cyl.

9 cyl.

12 cyl. ----

16cyl.

reversible

8D

17030’

17030’ 8”

17030

non-reversible

CP

OD

00

00

6cyl.

---p-v-

SERVICE

Edition 31.

August

-----

1987

KRUPP

MaK

00


OF GMBH

ENGINEER’S

Trimlng

HANDBOOK

gear

I peversing FtFVFRSlNG RFMOVAI RITING

1L = b-c-a+0.3 I L = b-c-a

in-line enaine Vee enaine

Pinion shaft O-rings bearing Deep-groove ball bearing Ring Piston

I

6 Axial deep-groove ball 7 Distance bush 6 Cover 9 Cover 10 Staftiicam

Dimension “b” measured in shown piston position (5) minus dimensions “a” and “c” gives the length “L” of the distance bush, tolerance: kO.1 mm

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

B 04-M

ENGINEER’S

HANDBOOK

Trlmlng

Reversing

gear

R 04-1.6.1

Clearance on assembly 0,2 + 0.05 produced by regrinding of the ring

Note fitting position of the deep-groove ball bearings!

For replenishing the reversing bottle the rule is: “Small cylinder space (see position of the reversing piston “5”) level with filling of the associated reversing bottle up to overflow plug “2”. (“1” P filling plug).

ii

capacity approx. 2,2 I

Edition 31.

Oktober

SERVICE

1988

KRUPP

MaK

ii


OF GMBH

ENGINEER’S

Trlmlng gear

HANDBOOK

mvers&ya

r

Control of the connections Positions I, Il,ect.

kztual posttlon of 78 connections

Engine is reversed ahead or astern

Engine will be reversed ahead or astern

Engine is reversed ahead or astern

l=P 2-A 3=B 4-z 5-Y 6=C

Engine will be reversed N ahead or astern

SERVICE

Edition 31.

August

1987

KRUPP

MaK


04-l .6.2

OF GMBH

=I

ENGINEER’S

I

HANDBOOK

Control

Provernor drive B 05-l .Q Attention! During installation attention must be paid to the correct number of teeth. The bevel and spur gears are markedby the end numbers of the drawing number (e.g. 04-01). For adjustment of the back lash between spur gear item 4 and the camshaft gear wheel, mount this machined edge in parallel position to the screw - on surface of the gear box.

With correctly adjusted back lash the flanks of tooth must be flush.

-. 8 I/ I

M6x 1dSK

\.

h

Pair of bevel gears Pair of spur gears = OS2mm

2 x 50 x 25,4 x 2,s Messrs. Schnoor

‘Nowadays ring nut M 24 x 15 DIN 70652 Remark:

For back lash adjustment (item 5 and 6) the spacer ring (item 8) must be adapted in view of its thickness.

Edition

3l.January1988

SERVICE

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

L

u m

C

rechtsdc Motor c

r

Ldhnsp iel : Kegetradpaar Mehe Einstellanweisung 1 Stirnradpaar = 0,2 mm

titenz

Japan

pJ_ >efct

M452iMdS3

OT4 2 9272 -__ _ . , .., .--. .-._-

31

:

.a

_. ._ _____-.-

---

---

1

153.5

\

\

* trhnrpicl: m St

20.

STeil224,33

EinsteNanweis’ung fh UG8-Regler

ftir Reglerantrieb M452 I M453 und Rc?gulateur Europa Typ 1104

ingelnberg Zyhto - PaIIoid-Verzah’nung

I

Reglerantrieb’nach

Abb.1 und Ansicht Z montieren. 4 SpionP gieicher Dicke verwenden. Das Zahnspiel von 0,I mm und ein Fluchten der Zahnenden wird erreichf durch verschieben der gelagerten Welle. in horizontater Richtung (Man X 1 und Wahl der Spiondicke *.:i?, ye’rtikaler Richtung (M a0 S), ‘.“,;;. ,‘:.*._, Zahnf Ian k@n’&?esKegelrades mit Tu Abb.2 schierpaste bestreichen. Tragbild unbefastet Einige Umdrehungen in Betriebsrichtung durchfiihren. Wird das in Abb.3 dargesie(lt& Tragbild nicht erreicht,so mu0 die Flankeniage bzw. das Trag bild korregiert wet-den, Korrekturmijglichkeiten

des Tragbildes

Tragbildrichtig

Tragbildfalsch

Tragbiid falsch

Abb.3 iiijhenverlagerung des fragbildes

Tragbi id ril

Abb. 4 tangsvertagerung Trag biides

G. Nach _EinsteUung des Tragbildes Abb.2) Distanzbuchse am Regler und Distanzsttick Pos. 8 abdrehen. AbdrehmaO

Distanzbtichse

am Regler = Spiond icke S

Abdrehman’ Distantsttick Pos. 8

--JI

I.

c3

e7

= x

Reglerant rieb komp\c montieren

d.

J

c;

--

_-

I

des

MaId

ENGINEER’S

I

HANDBOOK

Control

_

Govern-1 GOVERNOR I INKA=

44

UG end PGA M 451 I452 I453 “IN-LINE” Mean value 31 mm Mean value 23 mm

-

Governor

Control rack travel of the injection pump

Edition 28.

February

SERVICE 1989

KRUPP

MaK


OF GMBH

MaKI

ENGINEER’S

HANDBOOK

Governor

drive and linkaGe B 05-l.l .l.

JZOVERNOR LINKAGF FGB-10 GOVERNOR M 453/4Q

L 0

5

10

15

position

NOTE:

In all cases:

Edition 31.

January

the stop position of the governor and the “0” position (+ two mark) of the control rack must coincide and be set accordingly!

SERVICE 1989

KRUPP

MaK


OF I GMBH

ENGINEER’S

HANDBOOK

Control

vernor drive and linkaae B 05 I 1 .lJ

IJJed grovenor path (type UG 40 L) A4’ lOO--38

a4& I

I

Q I

go--36

Control rack path (mm) of the injection pump I I 0 2 4

I 6

I I I I I I I I 1 I I I I I I I ; I I t+ 8 10 1214 16 18 2022 24 26 2830 3234 36 38 404244 46

lever in mid- position

bore and lead- sealed

Speed lever

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

==I

ENGINEER’S

HANDBOOK

Governor KAGF.

drive and linkaae B 05-l .1.9

Heinzmann E 16 I E 30 M 463 Vee Centre position I

1~1’11IIIIIlIIIliiiii~iiii 0 2 4 6 810121416182022242628303234363840424446 Setting of injection pump (mm)

I 5:

1

A 90” angle should be reached at centreposition between governor lever and spring member. Drill and lead spring member after the setting.

Centre position max. setting

Edition 28.

February

SERVICE 1989

0

KRUPP

MaK


OF GMBH

ENGINEER’S

Control

HANDBOOK

4,

.

Governor drive and ilnkaae B 05 _1 .I.4 EGB - 13 M 453 Vee

GOVERNOR

0

h Spring member length

0

A3 84 A2 !?Y 82

traval (mm) of the injection pump I

I,~,lllIIlIllllIllllIII~ 0 2 4 6 8 1012 1416162022

SERVICE

Edition 28.

February

24262830

1989

KRUPP

MaK

323436384042


44 46

OF GMBH

L

=I

ENGINEER’S

HANDBOOK

vernor drive allnkaae GOVERNOR NOTE:

PGA-12

M453Vee

Gavernar stroke 0 = 0 uD

Lever on governor

0 2 4 6 8 101214161820222426283032343638404244~ f Setting of the Lever on the intermediate injection pump . ..

b

SERVICE

Edition 28.

February

1989

KRUPP

MaK


OF GMBH

6 05 _1 .l .fj

ENGINEER’S

HANDBOOK

Control

I SDeedmeraency stpp. limitatior\ accordina to charge air B 05-1,2

pf sema

LEVER FOR SPEED SETTING WOODWARD GOVERNOR

Dowel pin 5 x 12 DIN 1481

1 Actuator 2 Piston rod

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Control

I seana. emmncv stop. limitation Of Settlna according to charge air B 05-1.2.1

eed

Torque on nut (7)

Md=

7NmI

71

(M

282133 l/332/452/453/551

I552

(M 552 V, 601)

Torque on nut (8)

IMd

= 12NmI

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

R)

ENGINEER’S

HANDBOOK

Control .

eed settina. emwcv stotx limltation of S&Ma accordina m charae air B 05-l .u

Fine-adiustment v&e Set screw “x” forcontrol range

I

Travel 6mm

Connection P = main air Connection A = controlled line admissible media: compressed air max. admissible pressure: 12 bar Mounting position: any Ambient temperature: - 20” + 70°C Design: bronze casing Working and inner parts of stainless steel

PRESSURE - TRAVEL DIAGRAM

Pressure

at connection

6 5 4

Pressure -travel curve (control range) can be adjusted by set screw “X anywhere between max. 1.5 - 6.011~0.3 bar and min. 0.2 - 4.7kO.3 bar, but only in parallel. Rotation to right I: pressure rise stepping max. 1% Control accuracy: hysteresis max. 3% (calculated on the differential pressure)

5 OiZ3~56 Travel on the roller in mm CI_)

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

ENGINEER’S

system. supercharaina

Exhaust Three-pulse supercharging 6 cyl.

Exhaust system/ Supercharglng

HANDBOOK

B 06-l .O

(Firing sequence: 1.3.5.6.4.2)

Crank position

Three-pulse supercharging 12 cyl.

(Firing sequence:

Al .A~.II~.A~.A~.A!S) 86.83.85.81 .B4.82)

Al,Ab B3,84

Crank position

B1.86 \'

A3,AL @

I

A5,A2

85.82

Three-pulse supercharging 9 cyl.

(Firing sequence:

1.3.5.7.9.8.6.4.2) 1

9

e

ai3 3

27

Four-pulse supercharging 8 cyl.

(Firing sequence:

Crankposition

6

4

5

1.4.7.6.8.5.2.3)

5A

CD

Crank position

4.

6.3

2.7

Four-pulse supercharging

16 cyl.

(Firing sequence:

Al .A~JI~.A~.A~.A~=A~.A~) 81.B4.B7.86.B8.B5.B2.B3)

A

Crank position

B

4.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

-I

ENGINEER’S

I

Exhaust system/ Supercharglng

HANDBOOK

maust

B 06 I 1.0.1

system. smraina

PJR-RORNFNOW=- MFASURINGSHYI

k&stslls~~plan: hawing point d*gnm:

I 1 -@_

300-330 kW/Cyl. 600 r.p.m.

M&N: Place:

Priifstand Test bed

-_

f

ii ,L -I+-

_’

Leistung/Output: Drehzahl /Speed:

J+*.

I

-tl~dW z,m’mEl

+_yijI

/

I+ _@_._

i

+ Im + I

MeRergebnisseiMeasuring

Irn -t -

-:+qc*

I 3 -wt -Wpm

;

4. P

-0’

I HbuluI- 6ntomntdl-nnoh LbaitqpDn1-8ti.IMnpFnpwd

’ Schwungrad/Flywheel

Oktavpegeldiagramm: In dlesem Dlagramm sendjewells die rnaxtimalenund rnlntmalen

Octave level graph: The max ahd rnfin octave levels of all 7 measuring po~nlshave been connected by lines in the graph

Dkravpegel alter 7 MeRounkte durch Lvwnzuge verbunrk~n

1

120 -’

t

results

1

I

t

110

L IdB] 100 -.

1

HA

c---

4+

F4

4

. _L-__>L___. \ \

OH +H ,--=--------------

90 -

w-

80 -a

\

5o’,..,TI*.-...‘......,.‘....‘..’.... rn c Z 8_Z#8# %

8

!3

j

Oktavmittenfrequen2 fm Octave average frequency fm

WI

8 6 -_)

L

SERVICE

Edition

31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Exhaust system/ Supercharging

HANDBOOK

mhaust

gas turbocharaer

Before washing is started, engine power must be reduced. (Waste gas temp. after cyl. c 250%). of the turbocharger must be opened.

B 06-l .l_

The drain cock

BBC charger

Washing time

5 minutes

Water pressure

1 bar VTR 250/251 320/321 400/401 500/501 630/631 Vmin 5 a . 12 19 30

Charger type Water flow

RR charger: set water pressure to 0.5 bar and wash for approx. 5 min. Napier charger:

Wasing time Water pressure

1 bar

I

Charger type Water flow

5 minutes

I

I

NA Vmin

I

455 12

0.5 or 1.O bar

SERVICE

Edition

31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

4

4.

ENGINEER’S

HANDBOOK

s turbocharaer

B 06 _1 .l .l

EXHAUST GAS TURfJCCf-fARGFEL SCRFPN TRAP M 451/4Z2U% after 2500 operating hours

Insoection:

then every 5000 operating hours

VTI? 250

2 off exhaust gas inlets

139,5 mm 0

VTR 320/321

2 off exhaust gas inlets

199,5 mm 0

VTR 320/321

73 off exhaust gas inlets 1169,5 mm 0

Protective Tubine

screen inlet

Seal clean thoroughly protective screen seat in the turbine inlet. smear protective screen seat with DAG 5080 paste. insert protective screen, ensuring that ridge of the protective screen projects over the edge of the turbine inlet. fit pieces of exhaust gas pipe previously removed, ensuring that seal in the turbine inlet presses against ridge in order to achieve clamping effect.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

-1

ENGINEER’S

I


HANDBOOK

-lDlpe

B 06-u

Al IST GAS PIPF WITH EXPANSlQbl JOINTS

1.00.6-66.50.01-37

0.00.6-41 &LOO-01 -21

Ensure when fitting expansion joints that the flange-to- flange spacing of the exhaust gas pipes does not exceed 164 mm. The gap must not be more than 3 mm. Hgreater, an additional seal or a suitable shim must be fitted.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

I


HANDBOOK

Chargg&cooler/charae

air shaft R 06-l 3

Cl FANING SYSTEM FOR CHARGF AIR COOLFR

ft is advantageous for the air-side cleaning of the charge air cooler if the shipyard provides a cleaning system.

Example: in-line engine

I

a

Cleaning is due if the pressure difference (before/after cooler) => 200 mm WC.

AN

LJ

6 m3/h, 2 bar 40 0.7 m3 RlR R 314

AN Scavenging pump A Fitter NB W Tank volume a Filling connection b Level control d Tank discharge All pipes 35.2, St 35

The shut-off valves for the engine can be supplied by Krupp MaK as special equipment.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

MD0 system > 7cSWWC

BA BB BC BK BL DA EO Kl

Separator pumps

FP M GQ HP

Pre-fitter Fine fitter Thermostat Separator

Final prsheater ( not with gasoil) Pre-heater Protective filter

MC MD PD SB

Day tank Intermediate tank (not with gasoil) Dial gauge Spring-loaded non-return valve

Feed pump Feed pump (back-up) Feed pump

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Fuel system

I Fuel svstem R 07 . l.Q,l LUBOlL SYSTW Bunker tank - day tank

‘*Or. 1 75%

50%

1 6

BH FO MA BK HQ EJ

100%

MN

August

50=x 25%

12

16

24 h

separate IIm!iI

12

6

Feed pump Protective fitter Settling tanks I + II Separator pump Separator Electric pre-heater

Edition 31.

MM1

75%

25%

18

DK ER W NN MC

SERVICE 1987

KRUPP

MaK

24h

6

Steam pre-heater Thermal fuel pre-heater Fitter station, see text Day tank (heavy fuel) Day tank (diesel fuel)


OF GMBH

12

16

24h

ENGINEER’S

HANDBOOK

Fuel system

Fuel q+!skmB 07 I l.Q2 HFAVY FUFl SYSTFM Day tank motor (z- 180 cSt)

r-

I t

v MC

t---____

T

+-

-I,

M

MC

tm BY PD

tm Ml-f 8M EL

-

August

(FR)

DJ DS FR

Day tank (diesel fuel) Day tank (heavy fuel) Heavy oil pressure pump pre-heater (> 180 cStf50°C) Fuel measuring gauge flow filter, Mixing tank (> 180 cSt/80°C) Mixing pipe (< 180 cSt6O”C) Centrifugal pump Electric pre-heater

HFI FQ KP KR

SERVICE

Edition 31.

HR

1987

KRUPP

MaK

Steam pre-heater Thermal fuel final Automatic reversible see text Viscosity controller Duplex fine filter Main engine Auxiliary engine


OF GMBH

ENGINEER’S

Fuel system

HANDBOOK

mction

JNJFC-WN PUMP M 45m

DumD. Setthy

R 07 _1.i

4%

After assembly the control rack & be easily moved! A control rack without lubrication must be greased at weekly intervals when operational!

1 2 3 4 5 6 7 9 10 14 15 17 10 19 21 22 25

Baffle bush Mounting flange Bucket tappet Circlip Lower spring plate Plunger Spring Control sleeve Spring plate Control rack Set screw Discharge union Delivery valve (opening p - 5.5 bar) Spring Barrel Flange Flange bolt

b-4

/

I/

NOTE= bolts must be tightened with MA = 100 Nm. The pump fastening bolts must be tightened with MA = 120 Nm. (Values apply only in conjunction with Molykote paste “G-Rapid”).

SERVICE

Edition 31.

August

1987

I

KRUPP

MaK


OF GMBH

ENGINEER’S

Fuel system

HANDBOOK

ction

hump.

setting

B 07.1.l.t

RFCONDITIONING OF lN#CTlON PUMP M 453 0.00.6-43.10.00-67, -70, -72 FOR CONTROL RACK LUBRICATION

r

Drilling shown rotated by 25” \

A

L

-T

A

I

SEQUENCE OF OPERATIONS: 1. Dismantle pump (do not dismantle pump element) 2

3.

Recondition housing and control sleeve

zI 4 =

I

Clean parts and re-assemble pump.

J

A-A

Control sleeve

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Fuel

system

I CtlOn DumD.

settina

B 07 I 1.1.2

In the case of new installations, all pumps are set as before with the set dimension Y = 10.3 (from the supporting flange to top edge of thrust member, roller on base circuit of cam). Before fitting an overhauled or new fuel injection pump, this set dimension must be checked and if necessary readjusted. In order to achieve the distance required on safety grounds, with new installations the tolerance M.7 mm engraved on the pump must not be observed. Observe instead set dimension 10.3 + 0.3 mm.

dimension

.

Coinciding of line marks in the pump window.

Priming stroke dimension.

NOTE! With the new pumps PF 1 W 220 BS 1710 and W 240 BS 1722 the line mark passes out of the window even with a stroke of 21 mm. The previous rule - mark must be visible in the window during the pump stroke -11plonger applies here. The dimension (priming stroke) must be checked and adjusted if necessary.

M451 M451 not supercharged supercharged campitch

17

Setdmension (y)

10,3

Ptiningstmke (x)

4-45

+ 0,3

10,3

48

SERVICE

Edition

31. August

20,7

1987

KRUPP

M452

M453

20,7124 + 0,3

103

24

+ 0,3

865

4,B

DOCUMENT

MaK MASCHINENBAU

10,3 + 0,3

OF GMBH

ENGINEER’S

I

HANDBOOK

.

mtion

Fuel system

ouuing

6 07-l .1.3

In specifying which injection equipment could be used, the possibility of using the M 453 equipment for M 452 engines from 500 min-1 onwards was admitted. This can give rise to wrong stroke settings in practice. Currently only one M 452 engine has been supplied with the M 453 injection system: MS “Hyde Park”, 8 Mu 452, Engine No. 24 892. In this case, therefore, a priming stroke of 6 - 6.5 mm must be set JID for M 453 enaineq 1. Some M 453 engines are fitted with Bosch injection pumps PF 1 W 240 BS 1733 (plunger with curved leading edges). With these pumps, commencement and end of delivery vary in the fuel setting range 0 - 20 mm. There must therefore be a setting of at least 21 mm if setting of these pumps by the overflow method or checking of the start of injection with the EB tester is to be carried out. 2

The above-mentioned injection pump PF 1 W 240 BS 1733 has a luboil connection for bucket tappet lubrication, so that the pump bucket can be lubricated with circulating oil through a metering pump at fuel viscosities from 900 Redwood sec. onwards.

CHFCKING OF CQMMFNCFMFNT OF DFI IVFRY see the acceptance test records for the commencement of delivery. Measure the respective arc on the flywheel groove and mark the commencement of delivery. bar the engine in the direction of rotation until the line mark (1) of the bucket tappet coincides with line (2) on the pump housing. agreement of piston TDC and flywheel marks must be guaranteed. - check on the flywheel whether commencement of delivery mark is below the dead centre indicator.

Commencement of delivery

Elk

TDC

1

2

..’

Commencement of delivery position

. * aslc settrrtg - Rotate until roller rests on base circuit of cam. - Check whether line mark (1) on the bucket tappet coincides with line (3) on the pump housing.

5 1 ,a

3

4 @k Ifthere

is no more coincidence, all parts concerned must be checked in view of their reliability and replaced if necessary. Only then the coincidence of mark 1 and 3 is to be re-established by loosening the locking device (4) and turing of the setscrew (5). (Basic setting) Tighten locking device (4) and check! Setscrew (5) must mbe rotatable any more!

SERVICE

Edition

31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Fuel system

lk!FCTIONVA1VFWlUSDFMOVAL M~~1453

_

smear valve seat and valve stem thinly with “DAG-5080’ paste. smear nut (1) and contact face with “G-Rapid” Molykote paste.

_

(Removal device)

1. Tighten nut (1) finger-tight b 1

1 MA=25NmI 2. Tighten

[o(

= 120” Torsion angle 3

1

Injection pipe 1 2 344 5 5t7 8 9 lO+ll

M 452 M 453

Leak fuel connection Hold-down Union nuts Adapter Discharge unions Connection Pipe O-rings

0 3 mm 04 mm

NOTE: In the event of heading etc., the injection pipes must be rebored to their original internal bores. -

smear the contact faces of the cones and the thread of the bolted connections with Molykote paste “G-Rapid”. mount injection piping stress-fre&

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

mtion

lNJFCTlONVA1VF _

smear thread of the nozzle nut (4) Molykote paste “G- Rapid”.

_

tighten nozzle nut (4) manually (without wrench).

_

tightening moment (arc I - II)

Marking of the nozzles “K” moled oozzles “groove” yncooled nozzls

Injection pressure see the respective test bed certificate (usually p 260 bar).

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

valve B 07 . 1.3

ENGINEER’S

HANDBOOK

Fuel system

I zzle cooling

6 07-l .4

NO771 E COOLING M 4571hl45Q m

fresh water

Nozzle cooling (heavy fuel) 60 BP DC HO MJ PG SV l

Cooling oil pump Cooling oil pump (back-up) Heat exchanger Injection valve Circulation tank Level switch Spring-loaded non-return valve Connecting points on the engine

Nozzle cooling system The injection valves are cooled with iuboii or heated up at part load. The cooling oil inlet temperature is _ 75% ant is kept constant by thermostaticaliy-controlied cylinder cooling water. Accessories required: 2 pumps, of which 1 back-up pump, 1 tubular heat exchanger, 1 circulation tank with 2 level switches (technical data see data sheet). Installation below cylinder head level. The common supply of several engines with one system is possible. Advantages of the Krupp MaK system: no sea water for the recooiing of the cooling medium required, no thermostat valve required, cooling medium requires no anti-corrosion additive, use of a simple steel pipe for the piping system, resistant to contamination with heavy fuel oil (leak in the nozzle).

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Luboil

HANDBOOK

system ,

bboil PRF-HEATFR FOR LUROII SFPFRATOR For the pre-heating of the luboil by approx. 40°C to approx.

clrculatlon

B 08-l .Q

90-95°C.

Flectrc ore-heater 0 5.6. Pe (kW) kW

Heating ouiput = 1000 Heat transferred per unit area c 0.8 W/cm2

Steam-trace heated pre-heater (DO) Heating medium: saturated steam p - 6,8,10 bar Complete condensation of the steam is assumed; steam passes through the pipes; heat transfer coefficient k 360-i95 W/m2 degrees. fl .Pe(kW) Heating area DQ’ = ----------1000

m2

95.Pe(kW) Steam requirement DQ” - ------------------loo0

P 6 __--------_

8

10

fl

0.25

0.21

0.29

kg/h

(bar)

Thermal fuel throughput 50% greater than lubcil throughput 0.31 . Pe (kw) Heating area DZ = ---------loo0

m2

A0 AP

Injection pump (fitted) Back-up injection pump Cooler Regulator Electric preheater Protective screen Non-return

I -

1

I

L V

SERVICE

Edition 31.

August

1987

FJ FM FN HK LL RP DQ DZ

KRUPP

MaK


valve

Fine filter back-flushing Automatic filter Protective screen Separator Circulation tank Oil pressure valve Steam preheater Thermal fuel preheater

OF GMBH

-1

ENGINEER’S

HANDBOOK

-ation

B 08-l .O.l_

Luboil outlet in the be-

A

A

81

A’

viewe

view AC

-K-

Engine

type

Possible connection

6,8,9

D

E

cyl.

F

G

H

I

N -

K -

705 805 585

440

196 255 300

320

Engine Possible connection

A

B

B

type

12,16

-

cyl.

CCDEFGHIKLMN

1 x flywheel side or front sideor

x

570

555,5 5655

436

-

755 650 630 440

196 255

300

220

280 320

below bedplate B’ = vertical nozzle arrangement c’ = horizontal nozzle arrangement

Note transverse position of the engine! Provide expansion joint between engine connecting strip and oil sump tank! Outlet beneath each cylinder possible.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Luboil

lyboll

system

systemB 08 1.02 I

J&oil circulation tank II I.) Standard luboil amount 1.36 VkW Oil filling max. 80% of the tank volume (important for adequate degassing, avoidance of backpressure on high seas). Recommended layout of the piping for pumps and separators, see diagram. Height of the suction line of the oil pump at least ~100 mm above tank bottom. Runback of the oil from the engine below the oil level. Suction line of separator approx. 20 mm above tank bottom at the deepest point in the tank. Layout of water hole! as prescribed by the classification society. The position of the free oil outlets in the engine bedplate is shown in the diagram. One outlet per end is recommended, so that the bedplate is emptied with any trim of the ship. tf there is insufficient space for installing the circulation tank below the bedplate, the latter will be designed as a high-level tank and the engine equipped with a built-in recirculating pump and a stand-by unit. (Output of the recirculating pump see technical data). ff the high-level luboil tank is located > 0.8 m above crankshaft centre, the fitting of a spring-loaded flap valve in the suction line of the luboil pressure pump is required. Volume luboil circulation tank LL:

1.7. Pe(kW) LL=

m3 lOCKI

Proposal for the design of the luboil circulation tank (LL) to separator’

om separator +

from engine 4

Edition 31.

August

-

from engine

\

to engine

~++4--+4--/\

SERVICE 1987

-

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

Luboil

-iI

,,/p=

circulation

t...XI

bar

Screen in the suction ling

Pressure settingscrew

t

t Over-oroduction!

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

system

B 08-l .O.a

Ahad

ENGINEER’S

I

HANDBOOK

oil Dump. fima

Luboil

M 45114521453 B 08-l J

I\lian (back-lash on drivina wheel = 0.20 mml and D*Q Conical Dins = 8 x 50 mm and 10 x 75 mm,

“Mannheim” aeared oumos LBreviouslv “Nedi ia ”1 (see figures)

SERVICE

Edition 31.

August

1987

KRUPP

MaK


system

OF GMBH

I

Mad

ENGINEER’S

I

HANDBOOK

n

Luboil

fittina 451/4571453

system I

B 08 I 1.1 .I

JMPORTAN T! Note the fitting position of the shaft sealina ring! Otherwise risk of air entrainment! (BREAKDOWN IN OIL SUPPLY!)

]

Assembly dimension prior to fitting into the run-back housing

pma=lebar p ooeration - 8 bar p booster valve ooens I > 10 ba

It is recommended that the oil pump be primed before taking into service.

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

ENGINEER’S

I

HANDBOOK

Luboil

eclal armatures

system

B 08-l .11

Oil lubricatina oumo annex with IFor sorina cue and fuel rack lubrication.1

Size x = v + 3.3 The size x means an axial clearance of the coopting of 0,3 - 0,7 mm

rl u

6200~RS DIN 625

Jechnical data Drive Direction of rotation Driving speed

I

-any

I 300-3000 mm-l

Ratio Piston diameter Full stroke Ouantity of delivery (at full stroke) Total quantity Inlet pressure P 1

=lL3 =7mm =1,5 mm = 0,057 cm 3’stroke

max. counterpressure Temperature Testing oil Inlet Return

*bar = 100” c = SAE 30 Ro6xl Ffo4 x 0,5

I

6x16

-rotary

= 4 x 0,057 cm 3l stroke = max. 6 bar.

3x2(4 DIN1481

30 x for sorina cuolubncaflon

When Commissioning both 6elscrews

the pump.

must be closed (clockwise)

and then be opened by max.li2 Clockwise).

Minimum

openings

be less than 114 turn.

turn antishould not

Outlet 3 (SW 8) Outlet 1 (SW 8) Outlet 2 (SW 8)

SERVICE

Edition

30.November1987

KRUPP

MaK

DOCUMENT

MASCHINENBAU

OF GMBH

ENGINEER’S

Cooling water system

HANDBOOK

Conventional

sea/freshwater

coolina

B 09-l .I.

With this cooling system, usable for diesel fuel operation, the heat exchangers for charge air, l&oil and cylinder cooling water are loaded directly with sea-water.

AC)

2 al DN GA

Sea-water pumps Fresh water cooler Luboil cooler Charge air cooler Charge air thermostat valve

GB

Charge air temp.

GJ

Thermostat valve

FA LA

Sea-water filter Sea-chest

Total rise in sea-water temp. = approx. 13% with full-load operation Breakdown:

-5°C 12°C =6”C

Charge air mler Oil cooler Fresh water cooler

With charge air thermostat control the sea-water inlet temperature in the charge air cooler must be between 15 ant 20%.

SERVICE

Edition

31.

August

1987

KRUPP

MaK


OF GMBH

HANDBOOK

ENGINEER’S

I ~in~lecircuit


coollng B 09-l .2

With In-llne engines with 2-stage charge air cooling there is the possibility of designing the cooling water system as a branched single-circuit cooling system. Wiih this system the heat is transferred out of the box frame and the charge air cooler with the aid of thermostatically- controlled fresh water in an enclosed cooling circuit. The retooling takes place in a separately located fresh water retooler. The luboil cooler is normally situated in the sea-water circuit. The main advantages of this cooling system are: _ _ _ -

Heat transfer with a fresh water pump fitted to the engine is possible. There is no longer any expensive and maintenance-intensive sea-water piping on the engine. Relatively small fresh water retoolers required due to high flow temperatures. No special measures for heating the charge air required during part-load operation - advantageous when using heavy fuel. - Relatively small luboil cooler.

Alternatively the luboil cooler can be incorporated in the LTfresh water line. 1. large fresh water retooler and luboil cooler. Disadvantages: 2. fresh water pump as a unit is required.

HT circuit LT circuit sea-water AJ Fresh water pump CD Fresh water cooler DN I Charge air cooler HT stage DN II Charge air ccoler LT stage CN Luboil cooler GE Thermostat valve LE Balancing tank KP Main engine GW Three-way diaphragm valve

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S

I

HANDBOOK

F

_


air cooling

B 09-l -8

Two-stage cooling of the charge air with high- and low temperature fresh water cooler in the charge air cooling compartments DN I and DN II. Part-bad ooeration;

Disconnection of the low-temperaturee cooling water in DN II and heating of the charge air by means of high- temperature cooling water in DN I.

HT circuit LTcirwit -.-.-.-.-.-. sea-water _____-

AK Fresh water pump CL Plate cooler DN Charge air cooler CN Luboil cooler GE Thermostat valve GW Charge air thermostat P Pressure sensor

The oil cooler CN is connected in parallel to the charge air cooler DN II as standard. Connection in series after DN II is possible (larger oil cooler required). In order to reduce the cooling area of the cooler CL (LT) in the low-temperature circuit, the luboil cooler CN can alternatively be connected into the sea-water system. Charae air cooler IDN)

The cooler is generally fitted to the engine. Standard equipment: Inner pipe: Cooling ribs: Tube sheets: Water compartments: water-side pressure loss:

SoMs 76 (CuZn 20 A I) Cu tin-plated Muntz metal gunmetal approx. 0.3-0.4 bar

Charae air thermostat valve (GA)

For avoiding condensate build-up in the charge air passage. Design as valve with auxiliary energy, see thermostat valve

Thermostat vafve

e.g. MaK-Pleiger, Pfannenschmidt (electr.), AKO. AMOT

Fresh water coolina .svSram

The cooling in charge air cooler stage DN I is dropped.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

I

HANDBOOK

Fresh water coollna system tcvlinder

Cooilng water system

cooling)

B 09 I 1.4

The transfer of the amounts of engine heat takes place with prepared fresh water. The cooling of charge air 1st stage, for cylinder liners, cylinder heads, exhaust valves and turbochargers takes place in the cylinder cooling cycle (HTcycle). The cooling of the charge air 2nd stage and usually of the luboil takes place in the fresh water cycle of the low temperature stage (LT). 85 f 2°C

Recommended cylinder cooling water outlet temperature

AK AL AM AN CL CF CF

Fresh water pumps

CE

Heat exchanger

Preheater pump exchanger Manual pump Reccoler Heat cOnsumer e.g. fresh water producer

DC DN GE GG LE LH

Nozzle cooling oil heat Charge air moler Thermostat valve Thermostat valve for Balancing tank Drain tank

Pre-heating of the cylinder cooling water during docking periods to approx. 70% is strongly recommended. This is in any case a pre-condition for pier-to-pier operation with heavy fuel.

Drain tank Pre-heatina (AM+-

Heating capacity (CE) for preheating the engine ’ from loo C to approx. 70” C in about 10 hrs. Engine room temp. approx. 10°/300C. WV

6cyf.

m3h

approx. 916 12fa 1319 17/l 1

24/l 6 26/l a 34122

SERVICE

Edition

August

I

approx.1 a/i 2

819 CYI. 12 cyl. 16 cvl.

31.

Heating capacity for keeping the engine hot at 70°C. Engine room temp.approx.1 OV3O”C.

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

ENGINEER’S


HANDBOOK I etemDemre

circuit

6 09 I 13

Low- and high-temperature coolers are connected in series onthe sea-water side (reduction of the amount of sea-water). In the low-temperature circuit (LT) the transfer of heat from luboil, gear oil and charge air coolers (Stage II) etc. takes place. The high-temperature circuit (HT) is for the resoling of charge air cooler stage I and the cylinder cooling water.

-

HTdraJit ______ LTa’r& sea-water

-.-.-.

AcSeawaterpumps

DC Nozzle cooling oil heat exchanger

AF

DN Charge oil cooler CW Three-way diaphragm valve

AK F~~&v.&erpurps AL AM Preheating pump CE Prehater CF Heat consumer heating system CNOilccder CQ Gear oil oooler CL Central cooler

SERVICE

Edition 31.

August

GE a FA IA LE KP

1987

KRUPP

MaK

Thermostst valve Thermostat valve Seawater filter Seachest Balancing tank Main engine


OF GMBH

ENGINEER’S


HANDBOOK I

-09 Cooling watercentr Change axial face seal after 10000 operating hours.

I

21.

CLEARANCE sl

CLEARANCE s -1

2

CLEARANCE s

I s2

=l,OmmI

BACK-LASH ON GEAR-WHEELS

I

1) :; z z

NOTE:

Screw Pump housing Capped nut Pump wheel Axial face seal Slotted ring nut Assembly cover

August

I

Slotted ring nut Pressure compensation hole Shaft Gear wheel Circlp Ball bearing Ball bearing

If there is strong evidence of cavitation, exchange pump wheel (4) and if necessary pump housing (2). Replace all housing seals.

SERVICE

Edition 31.

8) 9) 10) 11) 12) 13) 14)

0,2 mm

1987

KRUPP

MaK


OF GMBH

-I

ENGINEER’S

Coolina

Remark:

I

HANDBOOK


water Diston and bilae Dump B 09-2.2

Piston rod must slowly slide by own weight and torsional motions. Spacers “x” are to be inserted accordingly.

Safty valve: opening pressure =2,5 bar

2 x cup sleeves

Relief valve: (valve lift: abt. 1mm)

r-

8

9

_-

i-

dellverv valvs _ _

’ loosen counter nuts (1 and 9 ). loosen (8) clamping bolt. tighten connection piece (3) manually by means of the lead screw (2) below the interlocking brackets. (The optimum seat must be guaranteed). tighten lead screw (2) tighten counter nut (1). tighten clamping bolt (8) (normal) (Valves must not become loose again hereby). tighten counter nut (9).

Remark:

The single-acting plungers can be metallited and remachined to original size. Damaged valve seats can be recut and provided with a new seat bush (freeze) (4 SK - 4951).

SERVICE

Edition

31 .Januaryl988

KRUPP

MaK


OF GMBH

ENGINEER’S

I

Starting

HANDBOOK

Starting

air system

K Startina air svsteq KB KE Fr MS SG SJ SK

Compressors Typhon Air filter Starting air tank Main starting valve Pressure reducing valve Oil and water separators

Starting air compressor (KB) The required air flow 0 (I/h) of all compressors must not be

less than

Lloyd, cl = 1.7 x I(PA - PE), current formula of German&her = total content of the starting air tank (litres) I PA = highest operating pressure in the starting air tank (30 bar) not reversible

PE I west operating pressure in the starting air tank,

reversible

9 bar 12bar

The flow delivered must be divided among atleast 2 compressors.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


air system

OF GMBH

KB

B lo-l.1

ENGINEER’S

HANDBOOK

Starting

&rtina

air tank B lo-l.2

air &&..sltes recommended bv Krum MaK tlk

6cyl.

16cyl.

cxxmlc?tlt

8~4.

gcyl 12cyi.

Typhon valve

shape B without auxiliary connection

Starting air tank Tank capacity I

3000

Edition August

D0

Weight

mm

rlml

approx. Kl

1258 2050 1958 2010 3447 2995 3803 3703 4023 4866 3316 3876 3556

30 125 180 250 500 710 1000 1500 1650

31.

L

200 320 400 480 480 650 650 800 800 800 1100 1100 1500

70 180 220 1 260 460 750 900 1050 1170 1500 1650 1840 2300

1 Filkgvalve

2 3 4 5

SERVICE 1987

KRUPP

MaK

Pressure gauge NB 8 Relef valve NB 7 DrainvalveNB8 AuxiCary connection NB 8 (by special order only)


OF GMBH

ENGINEER’S

HANDBOOK

Startina air fx@acitv B 1 O-l .3.

Classifiiion

2. reversible ible engine

society 1. non-revers- engine

12 12 12 12’ 12 12

American Bureau of Shipping (ABS) Bureau Veriias (BV) Det Norske Veriias (NV) Germanischer Lbyd (GL) Lloyds Register of Shipping (LRS) Fiegistro ftaliano Navale (RINA) l

Wiih cold engine, corresponds to 18 starts with warmed-up engine.

Startina air caw Maximum design pressure of the air tanks 30 bar. Minimum pressure for the starting or reversing 12 bar, with nonreversible engines 9 bar. The values given in the following table refer to the design regulations of Germanischer Lloyd. pre-determination of the startina air caoacitv in I flitres)

Single-engine plant

nonreversible reversible

6 cyl.

8 cyl.

9cyl.

12 cyl.

16 cyl.

389

403

410

431

458

1752

1782

1693

1872

-

With multi-engine installations these values must be increased as follows: Twin-engine installation through clutches on 1 propeller,

factor 1.5

Twin-engine installation, two propellers

factor 1.5

Two twin-engine installations through clutches on two propellers

factor 2.0

l

. ‘-

SERVICE

Edition 31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

MA

ENGINEER’S

I

Master

startlna

air system

Starting

HANDBOOK

valve M 4521453 B 10-2.1

screw (7) with screw (1) with

Md = 350 Nm Md

El

=

24 Nm

(Lubricant: Molikote paste “G-Rapid”)

HYDRAULIC STARTING AUXILIARY

(1) (2) (3) (4) (5) (6) (7)

(8)

SERVICE

Edition

31.

August

1987

KRUPP

MaK

Air lines Oil lines Check screw Cover (see figure) Piston Nuts Cover Spring


OF GMBH

ENGINEER’S

HANDBOOK

startina vale M 4571453 B 10-2.1 .l_ STARTING ANfJ FUFL LIMITFR .. osrtron durina start up

1) start position 2) adjusting screw check screw

3) maximum fuel injection

At an engine speed of

I n = 0,3 ...

0,5 n

max. I

bring the control lever to full load in jerks. Check whether the piston movement of the charge air pressure variation is smooth and jerk-free. If the piston is not working correctly, the actuator must be overhauled. The regulating distance is: 26 mm ff the exhaust gases exhibit strong turbidity or are black-coloured: Screw in adjusting screw (2) 1 ... 1.5 turns, which produces higher pre-loading of the control spring.

Edition 31. January’

SERVICE 1988

KRUPP

MaK


OF GMBH

ENGINEER’S

Ancillaries

HANDBOOK I

Barrlna gear B 12-1.1 J&l 451/4$7/453

Remove barring lever after the barring

Centre crankshaft

PARRING GFAR “SMALL” FLYWHFFI DIAM, < 1700 mm

prire

“Gears with electric motor” of BBC or SEW

NOTE; Specified limit switch is for start locking! For flvwheel diam. > 1700 mm the “bia” barrina brackets .. No. 1.70.7-7_3JQ.Q@13are soem Worm disengaged position

Edition 31.

August

SERVICE 1987

KRUPP

MaK


OF GMBH

=I

ENGINEER’S

I

HANDBOOK

Ancillaries

Barring gear B 12-1 .l .l.

EARRINGBWCKFTS NOTE:

To engage the barring gear, turn electric motor by hand until worm meshes in the gear and starts to rotate. Turning of the handwheel to the left causes the barring gear to engage. Stop engaged barring gear so that worm does not jam. Turning of the handwheel to the right causes the barring gear to disengage. Stop barring gear also in the disengaged state as a safety measure. Lubrication of the worm is necessary particularly with continuous operation of the barring gear (e.g. grinding of the crankshaft).

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

-I

ENGINEER’S

HANDBOOK

Air comrxessor

B 12-1.3

AlPi CQMPRESSOFlAWNUW Dismantle every 10 000 operating hours for an internal overhaul.

Compression spaces:

-1

LP suction valve

LP delivery valve

Hp suction valve

of the compression graced The compression space for high pressure = 0,6 - 0,7 mm must be achieved by means of the shim “x” and the compression space for low pressure - 0,8 - 1,O mm by recutting of the cylinder head or of the thickness of cylinder head gasket. NOTE:

The pressure screws and hence the valves must be tightened only when the flanges have been well tightened.

SERVICE

Edition 31.

Oktober

1988

KRUPP

MaK


OF GMBH

ENGINEER’S

HANDBOOK

/dir compressor

B 12-1.3.1

Air compressor (internal overhaul) I 10 000 h

;roup iommpressor

itage I

Wear parts

Minimum clearance

Manufacturing dimension

Big-end bearing 0 Big-end

5502

bearing bolt 0

54,96

Small-end

30,03

0,03 - 0,09

093

bolt 0

30,o

119,6

Cylinder 0

120,09

108,3

Cylinder

107,9

119,9 0

108,09

Piston 0

107,9

Piston grooves I-VIII

4,04

I-VIII Oil scraper ring Piston grooves X

0,4

0,04 - 0,07

O,2

0,04 - 0,07

0,2

0,55 - 0,7

195

6,04

5,98

SERVICE 1987

0,14 - 023

3.98

cut slearance 1 for all rings

Edition

O,5

0,14 - 0,23

Piston rings

August

0,3

0,02 - 0,05

bush Piston 0

Piston 0

31.

Limit wear

120,4

itage II

‘iston-rings

Limit

Maximum clearance

KRUPP

MaK


OF GMBH

ENGINEER’S

Ancillaries

HANDBOOK I

m comnrfsw

SETTING OF THE SWITCHING PRESSURES OF THE COMPRESSOR PPESSIJPE

B 12. 1.3.2

CONTROLLERS M 451

Changeover to switching pressures: Swith-on pressure 24 bar Switchoff pressure 30 bar

Standard switching pressures: Switch-on pressure 18 bar Switch-off pressure 30 bar

I

2.7 mm must be removed from the shims located at the place shown beneath spring 3. lf there is less than 2.7 mm shims beneath spring 3, the spring must be shortened by right-angled grinding away of the front sides.

II

1.7 mm shims must be added beneath springs 1 and 2 at place shown. Shims to 4-SK-4742. Since the values can vary due to tolerances, the swiching points must be monitored and corrected by suitable shims if necessary.

SERVICE

Edition 31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Special tools/ equipment

HANDBOOK

of tools RM 452: 453NM 453 813 _l.Q

SumFig.No.

Tool No.

w

6.9100 - A (6.100 A) 6.9100 - B (6.9100 B) 6.9100-Cl (6.9100 - C) 6.9100 - D (6.9100 D) 6.9100 - E 6.9100 - F 0.9000

set

1.9455 - 394 (1.9146 B) 1.9100-23 (1.9150) 1.9100-24 (1.9149) 1.900 - 25 (1.9152 B) 1.9100-26 (0.9211) 1.9100 -27 0.9214 A) 1.9100-28 (0.9214 B) 6.9216 - C (6.9216 C) 6.9216 - D (6.9216 D) 6.9223 - A (6.9223) 6.9223-2 6.9223 - 3 1.9021 - 16 (0.9128 A - 5) 6.9100 - 32 (6.9218) 1.9419 - B (1.9219 B) 6.9203 - A (6.9203 A) 6.9203 - C 6.9203 - D

1

Sets of tools with individual list

PI PI

Basic standard tools in M 452, RM 453, VM 453 Additional standard tools M 452

[31

Additional standard tools RM 453

[41

Additional standard tools VM 453

:; PI

Basic standard tools RM 453 C Basic standard tools VM 453 C DIN standard tools, all types

A

Tools for engine structure

1

Torque multiplier 1 : 4 (M 452)

2

Torque arm l/2” (M 452 )

3

Ratchet handle l/2” (M 452)

4

Extension lever for main bearing nuts ( M 452)

5

Box wrench 24 : 314” (R + VM 453)

6

Extension

24/l 9 (RM 453)

7

Extension

24122 (VM 453)

a

10.1 10.2 10.3

Device for mounting and extracting cylinder liners (M 452) , confined Device for mounting and extracting cylinder liners R + VM 453, confinedgl Cross-piece for pistons and cylinder liners, confined, consisting of: Strop Cross-piece Shackle A 0,6 DIN 82101

11

Ruler for cylinder liner micrometer

12

Cylinder liner micrometer 300 - 326 mm 0

(13)

Hydraulic tightener for tie-rods (RM 453)

(14) (16) (15) 15.1

Hydraulic tightener for tie-rods (VM 453) Hydraulic tightener for tie-rods (M 453 C) Components for Fg.No. Hydraulic jack

U 2

IAl. 2

2

15.2

Hose

2

2

2

15.3

Reaction nut

2

9 (10)

Edition

30. September 1989

2

0.9213 - D (0.9213 D) 0.9205 - A (0.9205) 0.9203 - 155 (0.9203 A - 3)


set set set set set set

1 1 1 1 1 1 1 1 1

1 1 1 1 2 2 2

ENGINEER’S

Surnmru Fig.No.

Description

15.4

Reactionnut

15.5 15.6

Supportingsleeve Pin

2 2 11

2

15.7 15.8

Sealingbush Plug

4 4 111

4

15.9

Pump

1

of tools

B

Tools for cylinder

la1416 2

11 2

Socket wrench 30 :3/4"(M452) Boxwrench30:3/4"(M452) 4

Socketwrench SW30:l"(M

5

Pneumaticimpactwrench(M452)

6

Spacer

0 7.1

Mounting devicefor valve guides, consisting of: Screw

7.2

Bridge

7.3

Disc

7.4

Nut

7.5 8

Washer 25DIN1440 Driftforvaive guides

9

Indicatortype 30

10

Cantileverindicator type S (Feder70)

11

Cantileverindicator typeS(Feder60)

12

Nozzle cleaner040

(12.1)

Cleaningneedles 040(5 off)

13

Nozzle cleaner050

31.

August

452)

SERVICE 1987

453 813-l .O.t

0.9203-185 (0.9203B -3) 1.9203 -4 6.9203 - 9 (6.9203- 5) 8.9203-15 0.9203-11 (0.9203L-29) 0.9204 - D (0.9204f3) 0.9203-125

2

1.9100-52 (1.9212) 1.9100-53 (1.9121) 1.9100-54 (1.9132) 1.9100-55 (0.9121) 1.9100-56 (1.9261) 1.9100-57 (1.9213) 6.9222 -E (6.9234) 6.9222- 1 (6.9234- 1) 6.9222 - 2 (6.9234- 2) 1.9222 - 3 (6.9234- 3) 1.9222 -4 (6.9234- 4) 1.9014-26 6.9100-59 (6.9222) 1.9410-c (1.9215C) 1.9410-A (1.9215A) 1.9410 -B (1.9215B) 1.9124 -c (1.9124C) 1.9124-40 (1.9124C-2) 1.9124-E (1.9124 E)

1

2 1 4 1 1 2

heads

Socketwrench30:l"

Edition

RM 452: 453NM

QtY

. Reactionnut


Tool No. Fg. No.

15.10

I

HANDBOOK

KRUPP

MaK


OF GMBH

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

ENGINEER’S


HANDBOOK I

matv of tools RM 452: 453NM Tool No. -

Fig.No.

Description

(13.1)

Cleaning needles 050 (5 off)

14

Nozzle cleaner 055

(14.1) 15

Cleaning needles 055 (5 off) Nozzle cleaner 045

(15.1)

Cleaning needles 045 (5 off)

(17.1) (17.2) (17.3) (17.4) (17.5) (17.6) 18 19 20

Needle handle (included in 12, 13, 14, 15) Valve reseating tool, consisting of: Cutting head Guide pin assembly Tool case Knurled thumb screw assembly Handle Palm grip Pneumatic impact wrench1 12” Flexible head wrench Flexible head wrench

C

Tools for running

1

Device for removing the pistons, confined

2

Piston ring expander

3

Crank web deflection dial gauge

(4)

Mounting and removing device for main bearing caps (16 M 453) Mounting and removing device for main bearing caps (12 M 453) Fg.No. Componentsfor Suspension bracket assembly

(16) (17)

(5)

(6) 6.1 6.2 6.3

6.6 6.7 6.8 6..9

31.

1

1

Arm

1 Bracket Plate 1

Plate Plate Plate

August

SERVICE 1987

1 F) 1 F - 2) 1 D) 1 D - 2) 1 1 1 1 1 1 2 1 1 1 1

KRUPP

6.9220 - C (6.9231) 6.9227 - A (6.9229) 1.9425 - 300 (1.9225) 6.9214 - C (6.9112 C) 6.9214 - D (6.9112 D)

1

6.9214 - 1 (6.9112 6.9214 - 2 (6.9112 6.9214 - 3 (6.9112 6.9214 - 5 (6.9112 6.9214 - 6 (6.9112 6.9214 - 7 (6.9112 6.9214 - 8 (6.9112 6.9214 - 9 (6.9112 6.9214 - 10 (6.9112

1

1 1 1 1

4 1

Arm

Edition

1 E - 2)

gear

6.4 6.5

1.9124-50 (1.9124 1.9124 - F (1.9124 1.9124-S (1.9124 1.9124 -D (1.9124 1.924 - 45 (1.9124 1.9124 - 1 6.9224 - C 6.9224 - 51 6.9224 - 52 6.9101 -C 1.9224 - 6 1.9224 - 7 1.9035 - 48 0.9100 - 37 0.9100 - 40 0.9100 - 39

453 B13-1.02

MaK


- 1) 1 - 2) 1 - 3) 1 - 5) 1 B - 2) 1 - 7) 1 - 8) 1 C - 9) 1 C - 10)

OF GMBH

maid

ENGINEER’S

Summarv Fig.No.

Description

A10

Cross-piece for pistons and cylinder liners, confined

(6.9223)

1

Delivery valve extractor

2

Wrench for camshaft gearwheel ring nut

3

Clamping device for injectors

Al 5.9

Pump

5

Hose 1 m

6

High-Pressure tube

A 15.8

Plug

0 7.1 7.2

High-pressure oil injection tools for fuel cams, consisting of: Oil pump High-pressure tube

E

Tools for auxiliaries

1

Flare nut wrench 17 x 19 DIN 3118

2

Ratchet handle 30 mm

3

Engineer’s wrench, single head, 70 DIN 894

4

Extension for emergency reversing

5

Key

6

Wrench for nut on cooling water pump shaft

7

Extractor for cooling water pump impeller

8

Band spanner for oil centriiuge

9

Cleaning injector 250 cm

10

Rubber hose 9 x 3,5 x 0,5 DIN 8541

11

Inflatable plug for charge air manifold, consisting of: Inflatable plug

31.

August

’

SERVICE 1987

RM 452: 453lVM 453 813-l qO.3

6.9223 - A

Tools for timing gear

Edition

of tools


Tool No.

D

(11.1)

I

HANDBOOK

KRUPP

MaK

1.9471 -1 (1.9138) 6.9100 - 105 (6.9230) 6.9122 - B (6.9157 B) 0.9204 - D (0.9204 B) 0.9205 - B (0.9205 A ) 0.9134 - G

1

0.9203 - 1I (0.9203L - 29) 1.9134 -F

1

1.9134 - 1 1.9134 - 2

1 1

1.9018- 17 (1.9027) 1.9495 - 30 (1.9140 C) 1.9094 - 70 (1.9060) 1.9100 - 1 (1.9140 B) 1.9100 - 126 (1.9140 A) 6.9100 - 127 (6.9164) 6.9264 - C (6.9260) 1.9495 - 362 (1.9280) 1.9490- 11 (1.9171 B) 1.9041 - 1 (1.9171 A) 6.9285 - A (6.9169 - B) 1.9285 - 1 (6.9169 B - 1)

1


OF GMBH

1 1 1 1 1

1

1 1 1 1 1 1 1 1 1 1 2

ENGINEER’S

~UKIII’IZtry Fig.No.

Description

12

Cleaning gun

13

Filtre cartridge extractor

14 15

Screen VTR 251 (VM 453) Screen VTFI 321 (M 453)

I

HANDBOOK

of tools

Speclal tools/ equipment

RM 452: 453NM

Tool No.

453 813-l .0.4 QtY

1.9100 - 110 (1.9235) 1.9100 - 120 (1.9361) 0.9169 - 5 0.9169 - 6

1 1 1 1

see also lists 6.9100 - A/B/C/D

4

SERVICE

Edition

31.

August

1987

KRUPP

MaK


OF GMBH

ENGINEER’S

Speclal tools/ equipment

HANDBOOK

Standard

Tools

. RM 452.453NM

453 B13-1 .l

Tool - set - No. 8.9100 - A Fig.No.

Description

A

Tools for engine

1

Cylinder liner hold-down

B

Tools for cylinder

(1)

Valve spring compressor, consisting of: Hold-down assembly Lever

1.1 1.2 1.3 1.4

Extractor for protective pipes

3

Union for nozzle tester

4

Extension for indicator

5

Nozzle tester

6

Liiing eye bolt M 16 DIN 580

7

Valve grinding device for 103 und 105 dia.

8

Socket wrench 17

C

Tools for running

1

Guide ring for mounting the pistons

D

Tools for triming

1

Mounting and removing device for spring of injection pump tappet ’ Injection pump priming lever

31.

August

1987

6.9222-D (6.9123) 6.9222-51 6.9222-52 6.9222-53 1.9021-f 5

1

6.9133-A (6.9151) 3.9100-140 (1.9066) 1.941 o-1 (1.9232) 1.9470-B (1.9134) 1.9080-l 6 (1.9076) 6.9224-B (6.9122 A) 1.9100-60

1

6.9100-30 (6.9126)

gear 6.9123-A (6.9133) 6.9100-43 (6.9135) 6.9122-A (6.9157) 6.9122-l 1.9122-2

SERVICE

Edition

2

gear

Extractor for injectors, consisting of: Bridge Screw assembly

4.1 4.2

6.9217-A (6.9117)

heads

2

(4)

QtY

structure

Hope Shackel A 0,4 DIN 82101

2

Tool No.

KRUPP

MaK


OF GMBH

1

1 I 2 1 1

ENGINEER’S


HANDBOOK

. Standard Tools RM 452.4531 VM 453 B 13-1.1.1 Fig.No.

Description

5

Hookwrench,

6 7

Box wrench, double head, 22 x 24 for injection pumps Sliding tee bar A 14 DIN 900

8

Claw foot wrench 24

E


1

Grease gun 130 cm3

F

Basic DIN standard tools

1

Tool box

2

Hook wrench A 40 - 42 DIN 1810

3


4


5

Single-head engineer’s wrench 36 DIN 894

6


7


8


9

Double-head box wrench 36 x 41 DIN 838

10

Torque wrench 40 - 180 Nm

11

Adapter socket wrench A 25 x 20 DIN 3123

12

Adapter socket wrench A 20 x 12,5 DIN 3123

13

Set of feeler gauges C DIN 2275

14

Oil can 500 cm3

15

Grinding compound, 350 ml box

16

Sealing compound, 750 ml box

17

Grease paste

AllO-115DIN

1810

Tool No.

Qv

1.9001-l 15 (1.9001) 1.9100-47 (0.9123) 1.9090-l 14 (1.9082) 1.9497-24 (1.9058)

1

SERVICE

31.

August

1987

KRUPP

1 1

1.94024 (1.9141)

1

1.9498-1 (1.9098) 1.9001-42 (1.9006) 19001-50 (1.9002) 1.9001-75 (1.9005) 1.9094-36 (1.9034) 1.9094-41 (1.9035) 1.9094-46 (1.9036) 1.9094-50 (1.9037) 1.9038-36 (1.9023) 1.9454-40 (1.9147 B) 1.9023-l 8 (1.9106) 1.9023-l 7 (1.9118) 1.9075-3 (1.9087) 1.9490-l (1.9090) 19491-l (1.9091) 19492-l (1.9092) 1.9493 - 1

1

See also 6.9100 - B/C/D

Edition

1

DOCUMENT

MaK MASCHINENBAU

OF GMBH

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

-I

ENGINEER’S

Additional Fig.No.

Description

A


1

Jacking device for main bearing caps

(2) 2.1

Mounting and removing device for main bearing caps, consisting of: support

2.2

Lever assembly

2.4

Link assembly

3

Mounting and removing device for main bearing shells

4

Dog for bottom shells

(5)

Box wrench 41 mm, consisting of:

5.1 5.2

Wrench, bent Extension

6

Socket wrench 41

7

Tightening angle gauge for main bearing nuts

(8) 8.1

Device for mounting, extracting and grinding the cylinder liners, consisting of: Extractor assembly

8.2

Cross-piece

8.3

Pin assembly

8.4

Tie-rod assembly

8.5

Support assembly

8.6

Extension

B

Tools

1

Ratchet handle 1”

for cylinder

31. August

1987

Standard Tools

Special tools/ equlpment

RM 452 B 13-l .2

Tool No.

QtY

6.9111 - C (6.9111 A) 6.9214 - A (6.9112 A) 6.9214 - 51 (6.9112 A-l) 6.9214 - 52 (6.9112A-2.1) (6.9112 A - 2.2) 6.9214 - 53 (6.9112 A - 3) 6.9100 - 4 (6.9111 C) 6.9100 - 5 (6.9113) 6.9110-B (6.9110) 6.9110 -1 6.9110 -2 (6.9110 - 2.1) (6.9110 - 2.2) 1.9100 - 7 (1.9107) 6.9100 - 8 (6.9180 A) 6.9216 - A (6.9116 A) 6.9216-l (6.9116- 1) 6.9216-2 (6.9116 - 2) 6.9216 - 3 (6.9116 - 3) 6.9216 - 4 (6.9116 - 4) 6.9216 - 6 (6.9116 - 6) 6.9216-7 (6.9116 - 7)

1

heads 1.9100-21 (1.9146 A)

SERVICE

Edition

I

HANDBOOK

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

1 1 1

1 1 1 1 1 1

1 1 1 1 1 1 2 1 2

ENGINEER’S

HANDBOOK I

Fig.No.

Description

C

Tools for running gear

1

Cross-piece for drawing the pistons

2

Pistons suspension device

3

Socket wrench 55 x 25 DIN 3124

4

Tightening angle gauge for big-end bearing bolts


Tool No.

QtY

6.9220 - A

E


1


(6.9125 6.9226 - E (6.9185 1.9024 - 55 (1.9127 6.9100 - 35 (6.9180

A) A) B) E)

1.9094 - 75 (1.9038)

See also Summary of tools and list 6.9100 A

SERVICE

Edition

31.

August

1987

KRUPP

DOCUMENT

MaK MASCHINENBAU

OF GMBH

1

=I

ENGINEER’S

I

HANDBOOK


Additional Standard Tools

RM 453 B 13-13

Tool -Set - No. 6.9100 - C Fig&o.

Description

A


1

Jacking device for main bearing caps

(2) 2.1

Mounting and removing device for main bearing caps, consisting of: support

2.2

Lever assembly

2.4

Link assembly

(3) 3.1

Mounting and removing device for main bearing shells, consisting of: Mounting device

3.2

Dog for bottom shells

4

Torque multiplier 1 : 4

5

Torque arm l/2

6

Ratchet handle l/2

7

Extension lever for main bearing nuts

8

Socket wrench 41

9

Tighening angle gauge for main bearing nuts

(10) 10.1


10.2

Cross-piece

10.3

Pin assembly

10.4

Tie-rod assembly

10.5

Support assembly

10.6

Extension

SERVICE

Edition 31.

August

1987

KRUPP

Tool No.

QtY

6.9111 -D (6.9111 8) 6.9214-A (6.9112 A) 6.9214-51 (6.9112 A-l) 6.9214-52 (6.9112 A-2.1) (6.9112 A-2.2) 6.921553 (6.9112 A-3) 6.9114-B (6.9114 B) 6.9114-51 (6.9114 B-l) 6.9114-2 (6.9114 B-2) 1.9455-394 (1.9148 B) 1.9100-23 (1.9150) 1.9100-24 (1.9149) 1.9100-25 (1.9152 8) 1.9100-7 (1.9107) 6.9100-l 0 (6.9180 B) 6.9216-A (6.9116 A) 6.9216-l (6.9116-l) 6.9216-2 (6.9116-2) 6.9216-3 (6.9116-3) 6.9216-4 (6.9116-4) 6.9216-6 (6.9116-6) 6.9216-7 (6.9116-7)

1

DOCUMENT

MaK MASCHINENBAU

OF

GMBH

1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2

ENGINEER’S


HANDBOOK

&&Wonal Fig.No.

Description

B

Tools for cylinder

1

Tightening angle gauge for cylinder head nuts

2

Socket wrench 30 : 1”

3

Pneumatic impact wrench

4

Ratchet handle 1”

c

Tools for runnlng

1

Cross-piece for drawing the pistons

2

Piston suspension device

3

Socket wrench 36 x 20 DIN 3124

4

Clamp for big-end bearing shells

5

Extension B 20 x 75 DIN 3123

6

Torque wrench1 00 - 750 Nm

E

Tools for auxlllaries

1

Single-head engineer’s wrench

Standard

Tools

RM 453 B 13-l .3.1

Tool No.

QtY

6.9100-22 (6.9180 F) 1.9100-55 (0.9121) 1.9100-56 (1.9261) 1.9100-21 (1.9146 A)

1

heads

6.9220-A (6.9125 A) 6.9226-E (6.9185 A) 1.9024-36 (1.9095 D) 6.9125-A (6.9425) 1.9482-93

1.9094-75 (1.9038)

SERVICE 1987

1

1.9454-l 00 (1.9186)

Edition

August

1

gear

See also Summary of tools and list 6.9100 -A

31.

1

KRUPP

MaK


OF GMBH

1

nal Standard Tools VM 453 B 13-l .4 Tool-Set- No. 6.9100 - R Fg.No.

Description

A


1

Jacking dev&

(2) 2.1

Mounting awn;? removing device for main bearing shells, consisting of: Mounting devics

2.2

Dog for bottom shefts

3

Torque muitlplizr I : 46

4

Ratchet handio i!2”

5

Extension fcr main bearing nuts

6


7

Tightening angle galuge for main bearing nuts

(8) 8.1


8.2 8.3

Support assembly Link

8.4

Extension

8.5

Cross-piece

8.6

Tie-rod assen%y

8.7

Handle

9

Cylinder liner hold-down

B

Tools

1

Tightening angle gauge for cylinder head nuts

2

Socket wrench 3C : y“

3

Pneumatic impact wrcnui;

4

Ratchet handle 1”

Tool No.

ic?:&lain bearing caps

for cyikder

QtY

6.9214 - B (6.9111 C) 6.9114 - C (6.9114 C) 6.9114-101 (6,9114C-1) 6.9114 - 52 (6.9114 C - 2) 1.9455 - 7 (1.9148 A) 1.9100-5 (1.9149 A) 1.9100-6 (1.9152 A) 1.9454 - 20 (1.9147 A) 6.9100- 7 (6.9180 C) 6.9216 - B (6.9116 B) 6.9216 - 1 (6.9116 - 1) 6.9216 - 6 6.9216 - 53 (6.9176 B - 3) 6.9216 - 7 (6.9116 - 7) 6.9216 - 2 (6.9116 - 2) 6.9216 - 4 (6.9116 - 4) 6.9220 - 2 (6.9116 B -7) 6.9217 - B (6.9117 A)

heads 6.9100 - 22 (6.9180 F) 1.9100-55 (0.9121) 1.9100-56 (1.9261) 19!50-21

_

,--a

I

SERVICE

Edition

DOCUMENT

OF

I

E

31.

e-w

August

1997

KRUPP

MaK MASCHINENBAU

E’:-~tiH

1 I

1 1 1 1

2 1 2 1 2

.

&Jditional Standard Tools

r -_. : Fii.Nli

Description

c

Tools for runnlng gear

(1) 1.1

Device f+re\v;ng consisting of: Cross-piare

A 8.7

Handls

1.2

Skid assembl:

1.3

Screw

(2) 2.1

Piston suspension device, consisting of: Support assembly

2.2

Clamp assembly

3

Socket wrench 38 : 1”

(4) 4.1

Lever for big-end bearing caps, consisting of: Lever, part 1

4.2

Lever, part 2

5

Extension 1’

6

Universal joint 1”

7

Clamp for big-end bearing shells

8


E


1


(2) 2.1

Inflatable plug for charge air manifoki, consisting of: Bulkhead assembly

2.2

Union tee

2.3

Blank flange

2.4

Pressure gauge connector assembly

2.5

Pressure gauge 0 - 1.6 bar

the pistons,

Twl No.

QtY

6.9220 - B (6.9125 B) 6.9221) - I (6.9125 B - 1) 6.9220 - 2 (6.9116 B -7) 6.922G - 3 (6.9125 B - 3) 1.9220 - 5 (6.91?5 B - 5) 6.9~26 - A (6.9185 B) 6.9226 - 1 (6.9185 B - 1) 6.9226 - 2 (6.9185 B - 2) 0.9100 - 38 (1.9158) 1.9100-45 (1.9128) 1.9100 - 451 (1.9128 - 1) 1.9100 - 452 (1.9154) 1.9457 - 433 (1.9154) 1.9100-46 (1.9127 A) 6.9125 - A (6.9425) 1.9454 - 100 (1.9186)

1

1.9094 - 80 (1.9061) 6.9285 - B (6.9169) 6.9285 - 1 (6.9169 - 1) 6.9285 - 3 (6.9169 - 3) 1.9285 - 6 (1.9169 - 6) 1.9285 - 9 (1.9169 - 9) 1.9285 - 19 (1.9169 - 19)

. Edition

1 4

SERVICE

VM 453 B 13-1.4.1

DOCUMENT

;!F

1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1

ENG!NEW@

HANDBOOK

equipment

al Stanc&gl Tools VM 453 B 13I 1.4.2 Fig.I$I.

Description

Tool No.

2.6

Airtube 18x 1,75

1.9285 - 22 (1.9169 1.9285 - 23 (1.9169 1.9285 - 24 (1.9169 1.9285 - 74 (1.9169 1.9285 - 25 (1.9169

2.7

PVC hose assembly with connector

2.8

PVC, hose assembly with plug end

2.9

PVC hose with valve

2.10

lllflatOf

. See

.

.

<

QtY

1 - 22) 1 - 23) 1 - 24.1) 1 - 24.2) 1 - 25)

also Summary of tools and list 6.9100 - A

c

sERVlCE

Edition 31. +ug~t~

1987

KRUPP

MaK

DOCUMENT MASJZHINENBAU

OF GMBH

Steuerzelten als Zelchnungs- Nr Motor iinksdrt

.60.7-32.10.01-05 1.60.7-32.1QOl-06 .60.7-32.10.01-07 .60.7-32.10.01-08 .60.7-32.10.01-09 .60.7- 32.10.01-15 1.60.732.1QOl- 11 1.60.732.10.01-12

MO.7- 32.1QOl-13 -_ I.60.732.10.01-14 1.60.7-3212.01-03 .6Q7-32 iLQl-04 m.BQ7-32.1201-05 1.60.7-32.12.01-06 '.60.7-32.12.01-07-

161

l.60.7-32~~01-08 -_ l.6Q7-32.12.01 -14

16

P c/m d

10 l.60.732.12.01-

11

11 l.6Q732.12.01-

14

c

16

160.7-32.12.01-12 ;06 :z l.60.732.12.01-15

1.60.7-32.20.01-07 .60.7-322QOl-08 --~ @i(!7-32.211.01-09 i.60.?-32.20.01-06 .60.73~.20.01-l! .60.7 -32.20.01-12 .60.7 - 32.20.01-13 -. .6Q7- 32.20.01-14 AO.7- 32.iO.O1-'II -

--1.60.7-32.2X01-Oi -MO.7-32.22.01-05 .6Q7-32.kh-06 .60.7-32.22.01-07 !.60.7-32.22.01-08 .60.732.22.01-09 .60.7-32.22.01-10 .6Q7-32.22.01-11

450v.uT 35On.oT.

.6Q7-32.X01-12

UJ'uuT.

157+3' ..-. _1_-.7,90 162"rF

OS

-

05 ,

7,'1$ _

.6Q?-.32.7X01-13 .60.7-32.2201-E .___-__---

-

8

103.5 1‘

I

I

I

-

A

nI

$2. o’l ..~

_._~ ._____

-

iinlafinocken Motor

Abb. 2

Ein- und Auslafisteuerzeiten.

Ze.chnungsnummern nocken feststellen.

7

rechtsdrehend

2

Kurbelzapfen (Nockenstellung

b

der

vofl

1 in u.T.Abb. 1 bzw 2 )

am Kurbelwellenflansch von Zylinder 1 fixieren.

Ein-

bzw,

Auslan-

Ste\lunq

tbinen

entsprechene

der

/ f , I

I

MeOuhr am Rollenfiihrungskorper des EjnlaRnockens Zylinder 3 des Kaster;gestells I Zylindel kurbelgehduse montieren Esiehe Abb. 1 btw. 2 I

vor I/__ 1

Wed Rollenhub S’aus der TabeUe entnrhmen ti Notor in Motordtehrichtung his z~;rmaqzeigten Wert an der Muhr tic nen. Dei eiry&ellfe Wetf ~7 innfvhalb der in der TabeUe angegebenen zuk5ssi4en Konl n&inkelabweichung Liegen.

’ 6.

7

Menuhr demanticren ftihrungsktirper des montieren.

8.

In gleicher Weise weitel verfohren. bzw.

9.

eingebauten

Zylinder

, siehe

6radschelbe u.T.- Stellung

3

\’

der

-_Xontrolle

4

wie crter 5. und h besrhrieben Hierbei Totpunktlage in Abb. 3 I KuMzapfm in aT !

beachten

In gleicher Welse welteren Zylinder

und zur Hubmessung am RollenAuslaflnockens vnn ZyYinder 1

, fur jeden

wle unter 2 - 8 beschrieben Hubmessung ‘urchfuhren

I

10.

I

-AuslaOnocken Motor

:nd

rechtsdrehend

Abb. 4 Minweis: Korrigieren

z

Umstecken

e 2

) ,-

burbelwelle,

des dss zom

gesamfen

Nockenbtindels

Steuerwellenrades, Ooppelrad

bzw.

i:i

durch

Zahnrad

auf

maglich.

1 Zahn

Steuerwellenrad

1 Zahn

Zahnrad

= 3OlO’ L8”Dreh

a.K W. = l”35’24”

3

4 -

Steuerw. JI

-._. r

U.T

Ii

1’.

7,.

-

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,..:

--

-

_

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+49 431 3995827

24-MAI- FR 13:52

-MAI._‘96[FR)

ii

.

.-_i6

,62 i_ -

Loa8,$_

’ yl-

ulw

m6/s

54+

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s, OQ1

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s, 01

FAX: +49 431 39952926

KRUPP MAKSPARE PART

Lb45

FAXNR, t49 431 3995827

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I -t -I ENGINEER'S HANDBOOK I M 45114521453

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