Mak Engineer’s Handbook M451 - M453C Contents Engine data 4 Engine operating data 5 (M453 - M453C, Cylinder head nuts 6-7 Cylinder head tie bolts 7 M452 Cylinder head nuts 7-8 M451 Cylinder head nuts 8 Cylinder head tie bolts 8 M452-M453C Rocker arm bracket 8 M452 Rocker arm bracket, old type 8 Mast Rocker arm bracket Q M452 - M4530 Rocker arm bracket, radial clearances 9 M451 - M453C Valve clearances 10 M452 - M4530, Valve guide bushes 10 Valve stems it M451 - M4530 Fitted valve stems 12 Valve seat rings 13 M452 - M453C Fuel injection valve 13 M452 Fuel injection valve, old type 3 M451 oss: Fuel injection valve ty M452-M453C = Nut for nozzle 4 Connection piece for fuel delivery pipe 4 M451 - M4530 Starting valve 4 M453-M453C Cyl. head - exhaust gas manifold 4 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 1Mak Engineer's Handbook _M451- M453C Contents M452 - M453 Landing surface cylinder head 4 KS piston 15-16 Mahle piston 16 M4530 KS piston 1 Mahle piston 18 M452 - M4536 Piston, dimensionand clearances 18 Ring carrier type Position of the oil drain 19 Piston check 19 M451 Wear limits 9 M452 - M453. Wear limits 20-21 M453C Wear limits 21-22 M451 Piston B M452 - M453 Piston a M453 Piston 24-25 must Piston rings a Ma52 Piston rings 25-26 M453 Piston rings 26-27 Ma53C, Piston rings 21-28 M451 - M453C Piston pin 2 Piston pin bush a Liner 30-31 M453 - M4536 Connecting rod 32-33 M452 Big end bearing 33-34 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 2Mak Engineer's Handbook _M451-M453C Contents M451 Big end bearing Hw M453 - M453C Main bearing 35-38 Bedplate 9 M452 Main bearing 0 M451 Main bearing a M452 - M453 Counterweight 42-44 M452 - M453C Gear drive 45-55 Governor drive 56 - 58 M451 - M453C Camshaft 59-60 Main starting air valve 61 Starting fuel limiter 61 Stop cylinder 61 M452- M4530 Lower valve drive 62 Fuel injection pump Drive Setting 4 Commencement of delivery 64-65 M452-M453C Flanged shaft mounting, without power take-off 66-67 with power take-off 68-69 M451 - M453C Flywheel mounting , 0 yee Coupling bolts 10-73 M453 - M453 Connecting screws 4 Tie rods 74-75 M451 - M452 Connecting screws 16 M451 - M453C Firing sequences 7 Sizes and weights 78-83 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 3Mak Engineer's Handbook M451 -M453C Engine data Type 451 Type 452 Type 453 - 453 ¢ Stroke mm 450 450 420 Bore mm 320 320 320 Speed pm 300-425, 375-500 540-600 Number of cylinders 6/8 6/8/9 6/8/0/12/16 Main bearing Inside 6 mm 25 25 25 Outside 6 mm 239/245 239/245 259 Big on rin: Inside 6 mm 25 25 25 Outside 8 mm 239/245 239/245 259 Valves (inlet) Length mm 470 467/470 467/470 Shaft mm 21,90 21,92 21,92 Valvedisk@ = mm 122 16 1065 Valves (exhaust), Length mm 470 4967 /468,5/470 467 /468,5/470 Shaft 8 mm 21,90 21,92 2192 Valvedisk = mm 12 105 105 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 4Mak _Engineer’s Handbook _M451-M453C Engine operating data Type 451 Type 452 Type 453 - 453 C Temperatures Lub. oil, inlet Sy 50-55 50-55 Stationary engines *c 50-60 50-60 Temperature rise * °c 10-20 10-20 Fresh water circulation coolini Engine outlet °c 80-85 80-85 Temperature rise * °c 7-10 7-10 Charge air inlet °C 45-60 45-60 Nozzle cooling before nozzle °c 65-75 65-75 *=atrated engine output Pressures Lub, oi! #1 bar = -3,0-3,5 3,0-3,5 4,0-5,0 Fresh water circulation cooling bar 225 225 25-5,0 with attached pumps minimum bar 2.0 *2 20 *2 Fuel before pumps MDO bar 1,5-3,0 1,5-4,0 1,5-3,0 HFO ae bar 15-40 40-50 Control air bar 75 15 15 Starting air bar = 12-30 12-30 12-30 “1=atthe last crankshaft bearing. *2= min. head at pump inlet 4m water column. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 5Mak Engineer’s Handbook M451-M453C [ Cylinder head M 453 - M453 C Cylinder head nuts M 453 1.60.1-21.09.00-02 Tightening after transport of the engine to the mounting site ‘only the nuts loosened for transport. Pretighten nuts with —> M = Nm then Ist step > Dw = 60° 2nd step > Dw = 180° 3rd step > Dw = 225° The following is valid tor M 453 and M 453 C. Coat thread and contact surface of the nuts with Molykote (Paste G). Attention ! No Molykote between washer and cylinder head. Retightening after reconditionings. Pretighten nuts with —> M = 530 Nm then ist step > Hes 250° Dw -= 60° 2nd step > KT Dw = 180° 4 — 31d step > SS 2 Dw = 250° 3 Tighten alternately and steadily in the sequence 1-2 3-4 5-6 7-8 M 453 1,60.1-21.09,00-03 Pretighten ruts with —» then 7) 1st step > (Continued on page: Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 6Mak Engineer’s Handbook _M451-M453C ( Cylinder head | 2nd step 3rd step > After tranport to the mounting site all nuts on the cylinder heads with the transport devices have to 4e loosened and tightened ace. to the before mentioned specitication, Cylinder head tie bolts M453 in-line The tightening torque is : Up to drawing No. 1.63. / 64. /69.7-11.01.00-12 Drawing No. 1.63. / 64. / 69. 7- 11.01.00 - 13 to 1.63. / 64. / 69.7 -11.01.00-17 —> M 453 Vee The tightening torque is : Drawing No. 1.66. /68.7- 11.15.00 - 01/03/04 /05/ 06/07 > 1.66. / 68. 7-11.15.00-02 i. 1.60.1-21.09.00-01 Tightening after transport of the engine to the mounting site, only the nuts loosened for transport. Peta naw > ie ee) Ist step > Dw = 60° (Continued on page: 8) Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG qtMak Engineer's Handbook _M451- M453C | Cylinder head 2nd step > “ Dw = 120° 3rd step > Dw = 190° Retightening after reconditioning. Pretighten nuts with —> M = 50 Nm then Ist step > Dw = 60° 2nd stop —> Dw = 120° ee rd step» > Dw = 210° corresponding to 3 1/2 hexagons. Cylinder head nuts Pretighten nuts with —> M 50 Nm then transfer marking from the cyl. head on the nuts. Then tighten crosswise in 2 steps up to. —> Dw 210° Cylinder head studs 1.63. /64.7-11.01.00-02 The tightening torque for inserting the studs is —> M i= 550+50 Nm M 452 - M453 C Rocker arm bracket Pretighten nuts with —> M = 10 Nm thentighten with > Dw = 60° ———— Tightening torque tor the taper pin nuts —> M = Nm ee ee Rocker arm bracket Old type —> M Nm Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 8Mak Engineer’s Handbook M451 - M453C | Cylinder head M451 Rocker arm bracket M 16 Molykote Rucker urm bracket Radial rocker arm clearances Nominal clearances —> Clearance limit —> Projection of bush on rocker arm bracket Dimension" S1* —> Exhaust valve rocker bush Dimension" $2" —> $1. Axial clearance Dimension*S3* — Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 9Mak Engineer’s Handbook M451 - M453C | Cylinder head Valve clearance, with cold engine Cooling water temperature below 50° C With warm engine Cooling water temperature above 50°C Inlet valve. —> 0.40% mm Exhaust valve —> 0.70 +8" mm Before measuring ( in warm state] the engine must have been stopped for at least 15 min. for equalizing the valves. Valve guide bushes The valve guides are marked on the circumference with IN“ and QUT”. Insert O-rings only after inserting the bushes in supercooled condition, The 0 - ring doses the valve lubrication and must only he replared by an original Mak sparo part. Supercool buishes to - 195 °C (liquid nitrogen) and insert them, pay attention to projection of bush acc. to sketch. Valve guide te Inlet valve Nana cease Cont > Exhaust valve Nominal clearance —> 0.43- 0.16 mm Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 10Mak Engineer’s Handbook —_M451- M453 { Cylinder head Valve stom The deviations from true running on the valve cone must not exceed the follow- ing values Laan = Inlet valve stem sa 0.04 mm Exhaust valve stem) —> 0.03 mm —— S—_-! Measuring distance * S * = 287 mm, supporting points for the measuring device are on the measuring track, 20 mm from its end points. The valves cannot be reused when: The valve cone face is damaged (cracks, blow-bys). The wear caused by corrosive material exceeds > 2% 8 of the valve hoad diameter. High temperature corrosion »S" at the valve plate bottom exceeds > 1.5 mm, Grinding of inlet and exhaust valves Apply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or remachined valve cone and distribute the paste equally. Thereafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in order to increase the grip. Insert the oiled valve stem into the guide bush. Fasten the device at the valve disk and grind the valve face and seat by hand applying a moderate pressure, rotating the devicé. The contact reflection a” which is visible by the smooth grinding process shall not exceed 30% of the seat width starting from the outside diameter. If the bearing characteristics described above are not reached, remachining of both sealing surfaces is necessary. After machining both seats have to be checked with a luminous magnifier. The fillet must not be refinished. Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 1Mak Engineer's Handbook _M451- M453C | Cylinder head Fitted valve stems: 1,60.7-22.10.01-50* Inlet and exhaust valve stem (M452 - M453, 1.60.7-22.10.01-45 ** Inlet and exhaust valve stem M452 - M453 1.60.7-22.10.01-44 *** Exhaust valve stem, heavy fuel operation M452 - M 453 1,60.7-22.10.01-41 **** Exhaust valve stem, heavy fuel operation M452 - M453C 1,60,7-22.10.01-52 Alternatively -41, without armoring M452 - M453 1,60,7-22.10.01-54 Inlet valve stem M453 C = Repl. for 1.60.6-22.10.01-02 /-10/-14/-27/-30 Repl. for 1.60.6-22.10.01-23 /+29 Repl. for 1.60.6-22.10.01-31 + 1.60.7-22.10,01-34 / 47 Repl. for 1.60.7-22.10.01-48 /-49 Attention! If vaned stem var. -47, -48 oder -49 was fitted before, a conversion to valve rotator far var. -44, -41 or -52 must be carried out ia case of replacement. Following parts must be included in the delivery: 1.60.7-22.25.00-02 - repl. -04, valve rotator 1.60.7-22.10.06-05 - sprina plate (if exhaust valve was fitted with vane var. -21 ). Z+M 451 Fitting valve stems: 1,60.6-22.10.01-51 * Inlet and exhaust valve stem ‘ = Repl. for 1.60.6-22.10.01-03 / -04 /-05 /-06 /-08/-11/-12/ 13/26 Replacement for 7 4f1 in operatinn with heavy fuel and on request of custamer 1,60.6-22.10.01-16, Nimonic Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 12Mak Engineer’s Handbook M451 -M453C { Cylinder head Valve seatrings The valve seat ring is supercooled in liquid nitrogen ( - 195° C ) and inserted in the bore in the cylinder head. Abt. 3 min. after insertion the seat ring is pressed on with device 1.60. 7 - 92. 22. 00- 07 for a short time. In shrunk condition there must not be any clearance between seat ring and contact surface in the cylinder head. Carefully smooth projecting edges of the seat ring and of inlet and exhaust duct. ar In case of first exchange of the exhaust valve seat rings without refinishing, however, with O-rings, the following must be taken into account: Receiving bore in cylinder head free from corrosion residues, possibly polish with emery. No axial scores. Sequence of operation Warm up cylinder head to 130 - 140 ° C (heating furnace or in exceptional cases by means of a soft, big welding flame). After warming-up and before inserting the rings apply a thin coat of Molykote Paste G in the bore in the cylinder head (only exhaust). Supercool valve seat ring to abt. - 20 °C (freezer compartment), mount 0 - rings and apply a thin coat of Molykote or grease. Insert valve seat ting and, if necessary, drive in with old valve stem and hammer. Press on seat ring with device for a short time. Check the air gap between contact surface of the seat ring and cold cylinder head. If the clearance is > 0.02 mm, press on with device once more Pressure test : 10 bar Valve seat ring cooled type without 0 - ring: Refinishing to oversizes only in authorized Mak workshops. On principle, repaired cylinder heads have to be marked with stamped seat ring variant and workshop sign near the existing cylinder head drawing number. Valve rotator Measure and note valve speed on commissioning. The valve speed depends on the engine speed, in case of speed drop to n= 1 rpm remove and overhaul valve rotator. Injection valve (__Mase-messc Pretighten nuts by,hand with —> then tighten ortighten Molykote "Paste 6" Injection valve Old type (3 nuts) —> Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 13Mak Engineer's Handbook _M451- M453C | Cylinder head Injection valve M 12 Molykote Nut for nozzle Apply two marks, one on the nozzle holder, one on the nut, at a distance of —> and tighten or tighten nozzle nut with > M = 300+50 Nm Oil lubrication Connection piece for fuel delivery pipe The tightcning torque is’ > ee Starting valve Tighten screws with —> Cyl. head - exhaust gas manifold Tightening torque for the screws to the cyl. head — High temperature! Use paste DAG 5080 Landing surface cylinder head M 452 - M 453 (not M 453 C) Recutting of landing surface possible up tu a imaximum of 0.8 mm. If further reduction is required, the level cylinder bottom surface must be recut at the same time togesther up to a maximum of 1 mm. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 14Mak Engineer's Handbook M451 - M453C | Piston KS piston 1,60.6-26.70.00-01 The tightening torque for inserting the studs is. —> M = @ Nm Tighten nuts crosswise twice with —> M = 110 Nm and loosen again, then tighten definitely with > M = 110 Nm The following applies to all piston installations: Coat threads and contact surtaces of the nuts with Molykote - paste. 1.60.6-26.70.00-03 * / 05 /08* / 09 The tightening torque for inserting the studs is —> = 80 im Tighten nuts crusswise =e) and loosen again, then check tightening torque for inserting the studs of —> Ni Pretighten nuts crosswise with —> M = 3% Nm and tighten crosswise pie eats eT with > Dw = 60° Check: The nuts must not turn further at a tightening torque of > M = 110 Nm * Var. - 03 and - 08 for M452, too The following applies to all piston installations: Coat threads and contact surfaces of the nuts with Molykote - paste. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 15Mak Engineer's Handbook M451 - M453C | Piston 1.60.6-26.70.00-12*/13* The tightening torque for inserting the studs is > Tighten nuts crosswise with and loosen again, then check tightening torque for inserting the studs of —> Pretighten nuts crosswise with —> and tighten crosswise with —> Check: The nuts must not turn further at a tightening torque of > “Attention | Var, - 12 only used by PLN now. ** Var. - 13 for M452, too. The following applies to all piston installations: Coat threads and contact surfaces of the nuts with Molykote - paste. M 453 Mahle 1.60.6-26.70.00-02 * / 04/06 * /07/10*/11* The tightening torque for inserting the studs is —> Tighten nuts crosswise twice with —> and loosen again, then tighten definitely with > * Var. - 02 / -06 / -10 /-11 for M452, too Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 16Mak Engineer's Handbook M451 - M453 C 1.60.6-26.70.00-17 / 18 / 21 / 22/24 and 1.60.7-26.70.00-26 / -27 /-28 KS piston The tightening torque for inserting the studs is —> Tighten nuts crosswise with > and loosen again. Check tightening torque for inserting the studs, then pretighten nuts crosswise with > and tighten nuts crosswise with > Check: Immediately after tightening the nuts must not turn turther at a tightening torque ot > Attention f When fitting pistons of the types stated below, before tightening the nuts the gap between piston crowa and piston skirt must be measured. On the pistons 1.60.6-26.70.00-21 /22/24 of Mossrs. KS the gap size is 0.09-0.13 mm. On the pistons 1,60.6-26.70,00-20 /23 of Mossrs, Mahle the gap size is 0.04 - 0.08 mm. wolare ms Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 7Mak Engineer's Handbook M451 - M453C | Piston Mahle piston 1,60.6-26.70.00-19/ -23 pan Sin pln The tightening torque for inserting the studs is. —» M = 6 Nm Tighten nuts crosswise oo with — M 100 Nm and loosen again, then pretighten nuts crosswise SSS with > M Nm and tighten with > Dw Check: The nuts must not turn further at a tightening torque a reer of > M = 100 Nm Attention | Replace studs it projecting length from bottom Sa contact surface exceeds 189 mi M 452 - M453 C Dimension of pin bosses 8 135.00 +401 ee mm Dimension between pin arent eaeeniyneronnte bosses standard type KS dimension * a" —> 130.25 *°7 mm Mahle dimension *a* —> 130.20 «™* mm Stepped type poe et KS dimension *b* —> 90.20 +" mm dimension" c* > 168.00 mm Mahle dimension" b" —> 90.20 * mm dimension" ¢* > 165.00! mm Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 18Mak Engineer's Handbook M451 - M453C J { Piston Ring carrier type Position of the oil drain for piston cooling in case of: Sense of rotation left” port engine : on exhaust gas side starboard engine : on camshaft side Sense of rotation ,right” port engine ; on camshaft side starboard engine : on exhaust gas side Built-up piston: The position of the oil drain for the piston cooling doas nat depand an the sense of rotation Piston check After piston checks operate engine with reduced output for approx. 10 hours. Pistonrings During piston checks, particular attention must be paid that the piston rings are being installed ina way that the ring butts are arranged in longitudinal engine direction, alternately opposed. During removal of a piston the found position of the ring butts with reference to the fitting position of the piston is to be recorded in the measuring sheet, in any case. Wear limits Piston 1.60.7-26.10.01-01 / -02 / - 03 / - 04 1,60.6-26.30.01-01 / -02/ -03 / -04/ - 05 /-06 /- 07 /-08 /-09 /-10 1.60.7-99,26.01-32 Grooves Groovesheight Ring height Wearlimit Clearance limit 1 8,08 17.987 - 7.972 830 0.35 2 8.08 20" 7.987 - 7.972 830 035 3 8.06 20% 7.981 - 7.972 8.30 0.35 4 8.0600 7.987 - 7.972 830 035 5 10.04 7" 9.987 545 10.20 030 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KGMak Engineer's Handbook M451 - M453 | Piston Piston 1,60.6-26.40.01-01 / -02/- 03 /- 05 /-06 /-07/-08 1.60.6-26.60.01-03 /-04 Grooves Groovesheight Ring height Wear limit Clearance limit 1 8.08 +2 7.987 - 7.972 8.30 0.35 2 8,06 +0 7,987 - 7.972 8.30 0.35 3 8.06 7,987 - 7.972 8.30 0.35 4 8.04 08 7.987 - 7.972 8.30 0.35 5 10.06 9.987 sans 10.20 030 Piston 1,60.6-26.60.01-05/ -06 1.60.6-26.70.00-01 / -02 / -03 / -06 / -08 /-10 Grooves Groovesheight — Ring height Wear limit Clearance limit 1 6.08 5.95 sone 650 0.60 2 6.06 5.95 son 650 0.60 3 8.06 8 7,987 - 7.972* 830 0.35 4 10.06 BOOT gi 2 10.20 0.30 * also ring -86 = 7.987 yy, ** also ring 87 = 9.987 4... Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 20Mak Engineer’s Handbook M451 - M453C Piston Piston 1,60.6-26.70.00-04 / -05 / -07 / -09/-11/-13 Grooves Groovesheight Ring height Wear limit Clearance limit 1 616 5.95 sere 635 050 2 6.16%" 5.95 owe 650 0.60 3 8.06 7.987 545 850 060 4 10.06 9.987 as 10,20 0.30 Piston 1,60.6-26,70.00-18 /-22 und 1.60.7-26.70,00-27 Grooves Groavesheight Ring height Wear limit Clearance limit 1 6.16" 5.95 “san 650 0.60 2 6.16 e# 5.95 sen 650 0.60 3 6.168 5.95 gaye 6.50 0.60 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 2Mak Engineer's Handbook _M451- M453C : | Piston Piston 1.60.6-26.70.00-17 /-19 /-21 / -23 /-24 and 1.60.7-26.70.00-26 /-28 Grooves Groovesheight — Ring height Wear limit 1 6.1602 5.95 gus 635 a 6.15 #@ 5.95 on 650 0.60 3 6.16" 5.95 son 6.50 0.60 4 10.06 +0 9.987 | 10.20 030 Piston 1.60.6-26.70.00-24/-28 Grooves Groovesheight Ring height Wear limit Clearance limit 1 8.16 7.937 gen 830 2 6.16 6.95 on2 650 0.60 3 6.16 0 5.95 ee 650 0.60 4 10.06 +98 9.987 sors 10.20 030 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 22Mak Engineer's Handbook _M451- M453C | Piston M451 Cast iron piston, old form of combustion space 1.60.7-26.10.01-01 1.60.7-26.10.01-02 1,60.7-26.10.01-03 Cast iron piston, new form of combustion space 1,60.7-26.10.01-04 1,60.6-26.30.01-09 Al-pistun, uld form of combustion space 1.60.6-26.30.01-01 without ring support 1.60,6-26.30.01-02 without ring support 1.60.6-26.30.01-05 with ring support 1.60.6-26.30.01-07 without ring support 1,60.6-26.30.01-08 with ring support - new form of combustion space 1.60.6-26.30.01-10 with double ring support - new form of combustion space 1.60.6-26.30.01-09 with double ring support - new form of combustion space 1.60.7-99.26.01-32 Al-piston, new form of combustion space 1.60.6-26.30.01-03 without ring support 1.60.6-26.30.01-04 with ring support 1,60,6-26.30.01-06 with ring support 1,60.6-26.30.01-08 with ring support 1.60.6-26.30.01-10 with double ring support —_1.60.6-26.30.01-09 with double ring support Al-piston : 1.60.6-26.40.01-01 without ring support 1.60.6-26.40.01-02 with ring support 1,60.6-26.40.01-03 without ring support 1,60.6-26.40,01-05 without ring support 1,60.6-26.40.01-06 without ring support 1,60.6-26.40.01-08 with double ring support 1,60.6-26.40.01-07 with double ring support Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 23Mak Engineer’s Handbook M451 - M453C ( Piston Al-piston, with double ring support 1,60.6-26,60.01-04 1,60.6-26.60.01-03 Al-piston, with double ring support 1.60.6-26.60.01-05 8g g g Built-up piston, gas oil and heavy fuel operation 1,60.6-26.70.00-01 1.60.6-26.70.00-02 1.60.6-26.70.00-03 1.60.6-26.70.00-06 1,60.6-26.70.00-08 1.60.6-26.70.00-10 1,60.6-26.70.00-11 ; 1.60.6-26.70.00-13 M453 Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1.60.6-26.70.00-04 1,60.6-26.70.00-U5 1.60.6-26.70,00-07 1.60.6-26.70.00-09 1.60.6-26.70.00-11 1.60.6-26.70.00-13 M453 C : Built-up piston - ring groves flame-hardened - gas oil operation 1.60.6-26.70.00-18 1.60.6-26.70.00-22 1,60.7-26.10.00-27 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 24Mak Engineers Handbook M451 - M453C | Piston ] Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1,60.6-26.70.00-17 1,60.6-26.70.00-19 1.60.6-26.70.00-21 1.60.6-26.70.00-23 1,60.7-26.70.00-26 Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1,60.6-26,70.00-24 1,60.7-26.70.00-28 M451 Piston rings Piston 1.60.7-26.10.01-01 /-02/-03 /-04 and 1.60.6-26.30.01-09 Ring groove ring 1 Compression ring, convexly chromium-plated _0.00.6-35.41.00-06 2-4 Compression ring 0,00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-09 Piston 1.60.6-26.30.01-01 / -02 /-03 /-04 /-05 / -06/-07 /-08/-09 /-10 Ning groove ring 1+2 Compression ring, convexly chromium-plated .00.6-35.41.00-06 3+4 Compression ring 0,00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-07 < 350 1/min Oil scraper ring 0.00.6-35.41.01-09 > 350 1/min M452 Piston rings Piston 1.60.6-26.40.01-01 / -02 / -03/-05 / -06 /-07 /-08 and 1.60.6-26.60.01-03 / -04 Ring groove ring 1+2 Compression ring, convexlychromium-plated —_0,00.6-35.41.00-06 3+4 Compression ring 0.00.6-35.41.01-11 5 Oil scraper ring 0.00. .41,01-07 < 350 1/min Oil scraper ring 0.00.6-35.41.01-09 > 350 1/min Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 25Mak Engineer’s Handbook _M451- M453C | Piston M452 Piston rings ‘iston 1.60.6-26.60.01-03 /-04 Ring groove ring 1-3 Compression ring, convexly chromium-plated —_0.00.6-35.41.00-06 4 Compression ring 0.00.6-35.41.01-22 5 Oil scraper ring 0.00.6-35.41.01-23 Piston 1.60.6-26,60.01-05 / -06 Ring groove ring 1+2 Compression ring, chromium-plated 0.00.6-35.41.01-32 3 Compression ring 0.00.6-35.41.01-30 4 Oil scraper ring 0,00.6-35.41.01-23 Piston rings Piston 1.60.6-26.60.01-03/-04 Ring groove ring 142 Compression ring, convexly chromium-plated —0.00.6-35.41.00-06 344 Compression ring 0.00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-09 Piston 1.60.6-26.60.01-03/-04 Ring groove ring 1-3 Compression ring, convexly chromium-plated —_0.00.6-35.41.00-06 4 Compression ring 0,00.6-35.41.01-22 5 Oil scraper ring 0.00.6-35.41.01-87 Piston 1.60.6-26.60.01-05 /-06 Ring groove ring 1+2 Compression ring, chromium-plated 0.00.6-35.41.01-32 3 Compression ring 0,00.6-35.41.01-86 4 Oilscraperring 0.00.6-35.41.01-87 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 26Mak M451 - M453 C ( Piston | Piston rings Built-up piston, gas oil and heavy fuel operation 1.60.6-26.70.00-01 /-02/-03 /-06/ -08 /-10 1-11 /-13 Ring groove ring Engineer’s Handbook Pane Compression ring, chromium-plated Compression ring, chromium-plated Compression ring, chromium-plated Oil scraper ring with tubular spring chromium-plated 0,00.6-35.41.01-32 0.00.6-35.41.01-71 (0.00.6-35.41.01-86 0.00.6-35.41,01-87 Built-up piston, heavy fuel operation 1.60.6-26.70.00-04 / -05/-07 /-09/-11/-13 Ring groove ring 1 Compression ring, three-side chromium-plated — 0.00.6-35.41.01-70.1 2 Compression ring, chromium-plated 0.00.6-35.41.01-71 3 Compression ring, chromium-plated 0.00.6-35.41.01-86 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated Ring groove 1 Compression ring, chromium-plated ‘up piston, gas oil operation - ring groves flame-hardened 1.60.6-26.70.00-27 ring 0.00.6-35.41.01-98.1 or 0.00.6-35.41.01-98.3 4 Compression ring, chromium-plated 0.00.6-35.41.01-89 3 Compression ring, chromium-plated 0,00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated Built-up piston, heavy fuel operation - tst ring groove chromium-plated 1.60.6-26.70.00-17 / +19/-23/-26 Ring groove 1 Compression ring, three-side chromium-plated ring 0.00.6-35.41.01-99.1 or 0,00.6-35.41.01-98.1 2 Compression ring, chromium-plated 0.00.6-35.41.01-89 3 Compression ring, chromium-plated 0.00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0,00.6-35.41.01-87 chromium-plated Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 27Mak Engineer’s Handbook _M451- M453C ( Piston | Built-up piston, heavy fuel operation - 1st ring groove chromium-plated 1.60.6-26.70,00-28 Ring groove ring 1 Compression ring, three-side chromium-plated —1.90.7-26.17.01-01 2+3 Compression ring, chromium-plated 0.00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 28Mak Engineers Handbook _M451- M453C Piston Piston pin 8 —> 135.00 soir mm Piston pin bush Attention | Exchange only at Mak - Kio! Inside —> 135.235 +00 mm Outside —> 153.11 as mm Width —> 130.00 ,, mm 1,60.6-28.10.03-10 Inside B —> 135.24 +0075 mm Outside > 151.125 gay mm Width —> 146.00 ,, mn Width — 90.00 _,, mn Piston pin bush Removal and fitting: Piston pin bushes must only be exchanged by an authorized workshop. The bushes must not be pressed out. The bushes are to be inserted in supercooled condition. For this purpose a temperature difference of 140° C is required, that means warm up connecting rod to abt, 80 °C, supercool bush to abt. - 60°C. Edition 28.11.1998 Service document of Page MaK Motoren GmbH & Co. KG 29Mak Engineer’s Handbook _M451-M453C | Liner Nominal size @ (original size) —> 320.00 - 320.057 mm Wear limits Wear and tear value —> Max. ovality —> Wedge shape Height —> Depth* — Wedga-shaped indentation across the entire circumference, beginning at TOC Ist piston ving. Length 8.00 mm Individual deep blow-through ducts in the area of the tst piston ring ( TOC ) Wedge shape Pocket Score TDC tstring Canyon Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 30Mak Engineer's Handbook _M451-M453C | Liner Score Number fee Length —> 180.00 a Hard vertical, linoar friction marks. Pocket Number — (oes) Length —> 90,00 mm Areal irregular indentations. * Radiusr 2 3mm ** In circumferential direction When reaching the wear limit in the area of the Feversing point of the upper piston ring or other wear limits acc. to specification on pages 26-27 the liner has to be replaced. Refinishing is only possible at Mak in Kiel, During installation attention must be paid that the marks on the liner and the cylinder block coincide. Sealing liner - cylinder head M 452/M 453 Correct position of the joint ring Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 31Mak Engineer’s Handbook M451 - M453C ( Connecting rod M 453 - M453 C Big end bearing Bolts without bores Pretighten lower big end bearing bolts 3 +4 with —> upper big end bearing bolts 1 +2 twice in the sequence 1 -2/ 1-2with > Tighten lower big end bearing bolts 3 +4 with > Tighten upper big end bearing bolts 1 +2 with > Tightening from pretorgque to final tightening torque corresponds to an angle of 45 ° to 60 ° for tho bolts 1 and 2.and 60 ° to 85 ° for the bolts 3 and 4, The minimum tightening angle has to be checked. The tightening specification is also valid for bolts with one bore. Bolts with several bores Pretighten lower big end bearing bolts 3+ 4 with —> Pratighten upper big end bearing bolts 1+2with — Tighten big end bearing bolts in the sequence 3-4 and 1-2 with —> Gap M453 In-line+Vee Gap > Limit value. — Journal diameter (h,) —> Bearing clearance. —> ‘The frst figure isthe cylinder umber (hare cyl.) se 11 Figg 12 spa Tha second figure is he —— bolt numbering. M = 30 Nm M = 60 Nm 0.70- 1.00 mm 244.971 - 245.00 mm 0,24 - 0.32 mm (Continued on page: 33) Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 32Mak Engineer's Handbook M451 - M453 | Connecting rod Gap of the big end bearings Measure and note the measuring distance between the bores on the top side of the connecting rod. Remove the upper big end bearing bolts. Measure the measuring distance again, the difference size Al is the gap, K*. If the value falls below the limit renew the bearing shells in pairs. Bink Se Big end bearing 1.60.7-26.01.00-07 /10/11/12/13/15 Pretiahten both sides with —> then tighten both sides with > 1.60.7-26.01.00-16 / 17/18/19 Pretighten nut on camshaft side with —> Measure gap on exhaust gas side. Tighten nut on exhaust gas side with — Tighten nut on camshaft side with —> Check, if remaining gap on camshaft and exhaust gas side is smaller than —> If the remainig gap exceeds this value, tighten nuts further until gap is smaller than —> then tighten bolts as follows: without split pin locking Ist step +: * Use tightoning angle gauge. 2nd step > With split pin locking Ist step > and step —> < 0.05 3 a > 0.05 Dw = 40°” Dw i If there is no split pia holo, tighten nut turther in the tightening angle range trom 55 ° to 80° up to the next split pin hole, The tightening angle must not be less than 55°. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 33Mak Engineer's Handbook _M451- M453 f ; Connecting rod Big end bearing Gap > 0.44 - 0.57 mm Journal diameter —> 224,971 - 225.00 mm Gap of the big end bearings Loosen big end bearing nuts on camshaft side by 55 ° angle of rotation, loosen opposite side completely and measure gap ,K". Big end bearing Fitting Tighten nut on camshaft side with Md = 100 Nm and tighten further by 55 °torsional angle. Measure gap .K" on exhaust gas side, then tighten nuts until gap is < 0.05 mm. Check an camshaft sida, if tha hearing cap has lifted, if necessary, tighten nuts until gap is $0.05 mm (bearing is pretightened), Big end bearing 1.60.7-26.01.00-08/ 09 Pretighten nuts with —> and tighten with > Gap > 0.44 - 0.57 im Limit value —>+« Journal diameter —> 224,971 - 225.00 mm Tighten both sides ace. to specification. Loosen on one side and measure gap between bearing cap and connecting rod. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 34Mak Engineer’s Handbook _M451- M453C | Main bearings M 453 in-line Coat threads and contact surfaces of the nuts with Molykote. Tighten nut on camshaft side with —> M = 20 Nm Tighten nut on exhaust gas side with — M = 550 Nm lighten nut on camshaft side with > M = 50 Nm Check, if remaining gap on camshaft and exhaust gas side is smaller than —> 0.05 mm If the remaining gap exceeds this value, tighten nuts further until the gap is smaller than 0.05 mm. Then tighten both nuts: Ist step > 2nd step > Tightoning torque is valid for all engines M 453 in-line. Use torsional angle gauge, Normal main bearing M453 in-line Gap > limit value. —> Journal diameter (h6) — Bearing clearance —> Located main bearing M453 in-line Gap > Limit value —> Axial clearance —> 0.55 - 0.75 mm —— 0.50 mm 244,971 - 245.00 mm 0.28 +# a 0.30 - 0.53 mm eee ty 0.30 mm A oe 5 sen 2G HENS mm (Continued on page: 36) Edition 28.11.1998 Service document of MaK Motoren GmbH & Co. KG Page 35Mak Engineer's Handbook _M451- M453C | Main bearings Journal diameter (h6) — Bearing clearance —> Gap of the main bearings M453- M 453 in-line 244,971 - 245.00 mm 0.28 +9 mn Loosen the bearing bolts on exhaust gas side by 60° ( acc. to torsional angle gauge). Loosen the bearing bolts on camshaft side complotoly. Measure gap ,, K * on camshaft side. M 453 V - type 1.66. / 68, 7-12.00.00-01 Pretighten nuts with —> Check gap, must be" 0". Tighten nuts with —> 1.66. /68.7-12.00.00-02 Pretighten nut on B - side with —> Measure gap on A - side with loosened nut. Tighten nut on A - side with — Tighten nut on B - side with —> Tighten nut on A - side with —> Tighten nut on B - side with —> Check, if remaining gap on A - side and B - side is. —> If the remaining gap exceeds this value, tighten nut further until the gapis —> then tighten alternately on A - side and B - side: Ist stan 2nd step —> Use torsional angle gauge. (Continued on page: 37) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 36Mak Engineer's Handbook ( Main bearings 1.66. / 68.7-12.00.00-03 Pretighten nut on B-side with —> Measure gap on A - side with loosened nuts. Tighten nut on A - side with —> Tighten nut on B- side with —> Tighten nut on A-side with —> Tighten nut on B - side with —> Check, if remaining gap on A - side and B - side is > If the remaining gap exceeds this value, tighten nuts further until gapis —> then tighten alternately on A - side and B - side : Ist step 2nd step —> Use torsional angle gauge. Normal main bearing M453 V-type Gap > Limit value. —> Journal diameter (h6) —> Bearing clearance. > M = Nm M = 40 Nm M = 400 Nm M = 10 < 0.05 mm Ow Dw = 110° 0.70 - 0.90 mm 0.60 mm 299.977 - 300.00 mm 030°0 mm M451 - M453 C Edition Service document of 28.11.1998 Mak Motoren GmbH & Co. KG Page 37Mak Engineer’s Handbook _ M451 - M453 | Main bearings Located main bearing M453 V-type Gap > 0.35 - 0.50 mm Limt value —> Journal diameter (h6) —> 299,997 - 300.00 mm Bearing clearance —> Gap of main bearings M453 Veo Loosen the bearing bolts, e. g. on A-side by 110 ° (acc. to torsional angle gauge). Loosen the bearing bolts , @. g. on B - side completely. Measure gap ,, K" on B-side. The main bearings with maximum stress : 6M 452 8 4and5 6M 453 8 Sands 8M 452 @ 5 and7 8M 453 6 Gand8 9M 452 8 5and9 9M 453 & Gand 10 12M 453 6 4and5 16M 453 6 Sand7 In case of inadmissible crank web deflection, piston seizures or other irregularities as well as faults in the oil system (filter or oil supply failure) the bearings must be removed immediately, checked and replaced, if necessary. Direct-coupled.units with thrust bearing are equipped with located main bearings with increased axial clearance. Removal of bottom bearing shell : Sense of rotation of the crankshaft to the right (view on the flywheel from the tail shaft), because otherwise the bearing shell lug will be sheared off. When fitting a normal main bearing instead of a located main bearing thrust rings are screwed on the located main bearing cap. Before and after every removal of the main bearings the crank web deflection must be measured and recorded, If a bottom shell is removed, the adjacent bearings must be fitted. Attention: When removing the located bearing: Supporting is necessary in case of an overhung flywheel. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 38Mak Engineer’s Handbook _M451- M453 { Main bearings Bedplate The material quality of the bedplates was improved to GGG 50. Before turning in main bearing shells, attention must be paid that on the turning-in side the edge of the bearing pocket is chamfered by means of emery cloth. Otherwise there is a danger that the bearing shell seizes during turning- in Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG a9Mak Engineer’s Handbook M451 - M453 | Main bearings Tightening torques 1.53. / 54. /59.7-12.00,00-04 Pretighten nuts with — M = 400 Nm Check gap, must be *0*. Tighten nuts with > Dw = 65° Use tightening angle gauge. 1.53. / 54. / 59.7-12.00.00.-05 Pretighten nuts on camshaft side with —> M = 0 Nm Measure gap on exhaust gas side on 2 bearings of a bedplate. Tighten nut on exhaust gas side with —> M = 450 Nm Tighten nut on camshaft side with > M = 450 Nm Check, if remaining gap on camshaft and exhaust gas side is smaller than —> < 0.05 mm if the remaining gap exceeds this value, tighten SSS nuts further until gap is smaller than —> < 0.05 mm then Ist step > Dw = 40° 2nd step — Dw = “65° Use tightening angle gauge. Gap Normal and located main bearing Gap > 0.65 - 0.83 mm Limit value —>: « 0.65 mm pees Journal diameter. —> 224.971 - 225.00 mn Bearing clearance —> 0,22 - 0.31 mm Located main bearing Axial clearance. —> 0.25- 0.30 mm Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 40Mak Engineer's Handbook _M451- M453 | Main bearings Tightening torques 1.53. / 54. / 59.7-12.00-02 / 03 Tighten both sides with —> M = 1300-1350 Nm 1.83. /54, / 59.7-12.00-04 Pretighten nuts with —> M = 400 Nm Check gap, must be * 0". Tighten nuts with — Dw = 65° Use torsional angle gauge, Gap 1.53. /54.7-12.00-02 / 03 Gap > 0.36 - 0.49 mm Limit value —> 0.36 mm 1.53, /4.7-12.00-04 Gap > 0.65 - 0.83 mm Limit value —> 0.65 mm Journal diameter —> 224,971 - 225.00 mm Tighten nuts ace. to spocitication. Loosen nuts on one side and measure gap between bearing cap and bedplate. Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 4}Mak Engineer's Handbook _M451- M453C | Counterweight M452 1.63.7-25.20.00-02 / 03 M453 1.63.7-25.20.00-04 M453 1.64.7-25.20.00-01 / 02 M452 - 453 1.69.7-25.20.00-01 =a, ighten screws with —> M = 30 Nm aoeaaa Additional torque to reach the correct position of the screw head. 6 M452 - 453 1.63.7-25.20.00-05 / 06 / 07 8 M452 - 453 1.64.7-25.20.00-03 / 04 9 M453 1.69.7-25.20.00-02 rs Tighten screws with —> M 440 Nm Additional torque to reach the correct position of the screw head. 6 M453 1.63.7-25.20.00-08 /09/ 10 8 M453 1.64.7-25.20.00-05 / 06 / 07 9 M453 1.69.7-25.20.00-03 / 04 ———————————————, Tighten screws with —> M = 530 Nm 12 M453 1.66.7-25.20.00-01 lighten screws with —> M = 50 Nm 12 M453 1.66.7-25.20.00-02 /03 / 04 16 M453 1.68.7-25.20.00-02 / 04 Tighten screws with —> M = 600 Nm 12 M453 1.66.7-25.20,00-05 16 M453 1.68:7-25.20.00-05 —_———_——_., Tighten screws with —> M = 700 Nm Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 42Mak Engineer's Handbook _ M451 - M453C [ Counterweight The following bolts are used for counterweight mounting: Bolt Thread Length Totallength © Spanner size 1.70.7 - 28. 10. 04 - 04 M24x2 226 250 a 1.00, 7 - 88, 50. 50 - 92 M24x2 251 215 2 1. 00. 7 - 88. 50. 55 - 80 M24x2 262 292 6 1.00. 7 - 88. 50. 50 - 62 M27x2 232 m2 36 1, 00.7 - 88. 50. 55 - 06 M27 x2 292 322 36 The bolts are used for the following counterweight mountings: 1.70.7 - 28. 10. 04-04 1,63. 7 - 25. 20. 00 - 02/03 /04 . 64.7 - 25. 20. 00 - 01/02 1.69. 7-25. 20. 00-01 1.00. 7 - 88. 50. 50 - 92 63.7 - 25. 20. 00 - 09 / 06 / 07 1.64.7 - 25. 20. 00 - 03°/ 04 1, 69.7 - 25. 20. 00 - 02 1.00.7 - 88. 50. 55 - 80 1,63. 7- 25. 20. 00-08 / 09/10 1,64. 7 - 25, 20. 00 - 05 / 06/07 1, 69.7 - 25. 20. 00 - 03 / 04 1,00. 7 - 88. 50. 50 - 62 1.66.7 - 25. 20. 00-01 1.00.7 - 88. 50. 55 - 06 1.66.7 - 25. 20. 00 - 02/03 / 04/05 1.68.7 - 25. 20. 00 - 02 / 04/05 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 43M451 - M453 C Counterweight @ |e 0|0|0|0|e@ ene 2x21 Og @ | Fes biorwurzec 2x iZ7W 498 So- | vo-| 20-| SO-| vO-| €0- Z0- 1o- -00'07'S7-L'89"L ~00'02°S2-2'99"L Sununow yyS!amie\wn0g Bupunow iBremuauneg GE 25 buoy wd ZOz eee 2X2 W HOE 727s buoy wu 187 @ @ 2X42 Mg @ 42.7S Guo} wus 9277 2X2 Hog £0-| 90- | SO- v0 el 2 -OVOZ'SZ-L'99'L Gununow yyhiamuaunoy Engineer’s Handbook 9€ ZS Buo] ws zoz @\|e @e|e\e 7x42 Moe 27S Buo} ww 1¢2 ® e\ee 2x97 WW Hoe 22 7S Buoy ww 977 e @|e@ |e: ZXyZWN HOE ¥0-| e0-| 20- -| 60-} 80-| 40+] 90-} s0-) v0-] €0-| z0- ONT Sz" yor'se-veg' Gununow yyS1amuswn0g Bununow yyfienuayunog Page 44 Service document of MaK Motoren GmbH & Co. KG Edition 28.11.1998Mak Engineer's Handbook M451 -M453C | Gear drive Gear wheel on crankshaft Tighten screws with —> Tighton further up to the nxt split pin hole. Also on M453 Vee-engines, Gear wheel on crankshaft Fixing on the crankshaft is effected hy 6 studs and 4 fitted bolts. The fitted bolts are arranged beside the joint faces. Reamed bores 17 - 17.0018 mm (H7). ‘Twin wheel Tighten screws for bearing bracket with —> M 20x 55 mm, SK DIN 933, locked by wire 820mm Tighten screws for the thrust ring twin wheel - bearing bracket with > M 12x40 SK DIN 933 Camshaft gear Mechanical tightening Pretighten nut with —> then tighten with > Hydraulic tightening Pretighten nut with and tighten with > : Ow = 240° 2 : § Hydraulic pressure to be applied 1400 bar, at the same time tighten slotted aut with a tightening angle of 240° M453 only. (Continued on page: 46) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 45Mak Engineer's Handbook M451 - M453C ( Gear drive Twin wheel Radial clearance — 0.19 - 0.24 mm Clearance limit —> 0.30 mm See Axial clearance. > 0.35 - 0.65 mm Measure backlash with fesler gauge. Measure axial clearance with feeler gauge or dial gauge. Pump drive gear ese Radial clearance —> 0.05 - 0.10 mm pa eoure accra Clearance limit > 0.25 mm Axial clearance —> 0.15 - 0.35 mm Clearance limit —> 0.50 mm Backlashes ee Crankshaft gear - twin wheel —> 0.20 - 0.28 mm ‘Twin wheel - camshaft gear —> 0.13 - 0.20 mm =e Camshaft gear - governor drive gear —> 0,20 - 0.25 mm Crankshaft gear - intermediate wheel for cooling water pots ccenlcanacan ia a pump —> 0.20 - 0.28 mm Intermediate wheel for cooling water pump - gear wheel on — cooling water pump —> 0.200% mm Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 46Mak Engineer's Handbook M451 - M453 ( Gear drive Twin wheel If possible, a bath-nitrided twin wheel shall be used with a bath-nitrided camshaft gear. the same applies to hardened gear wheels. In individual cases a bath-nitrided twin wheel may be replaced by a hardened twin wheel. A hardened twin wheel must not at all be replaced by a bath-nitrided twin wheel. Camshaft gear Before fitting the cone seat is to be checked by blue paste and possibly to be ground in. The gear wheel is mounted in dry state. Governor drive, backlashes Pair of bevel gears —> 0.20 mm Pair of spur gears —> Attached cooling water pump Clearance "S ," —» Clearance" ," —> Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 47MakK Engineer’s Handbook M451 - M453 { Gear drive } Instructions for adjustment: ‘Tooth 26- Long-interval and short-interval firing 1. Turn piston A1 and camshaft (cam At) into TOC position. Then insert left-hand twin wheel and camshaft gear. 2. Turn piston B1 and camshaft (cam B1) into TDC position. Then insert right-hand twin wheel and camshatt gear. ound Kk 3. Adjust inlet and exhaust valve timing and check firing sequence. Hoan = 4, Mark position of the gear wheels to each “Tooth $6 other on the twin wheels. Instructions for fitting: M 453 in-line 1. Turn piston cyl. 1 into TOC position. 2. Mount gear wheel on crankshaft, tooth 1 (marked on gear wheel) is directly at the joint face of the gear wheel. Also marked are tooth 26 with ,0” stb and the teeth 32 and 33 with ,00" port side, The gear wheel joint face with tooth 1 must point horizontally to the left. The joint face of the bedplate may serve as help. 3. Mount twin wheel on bearing journal, bearing journal is only loosely mounted , not tightened. 4, Turn camshaft so that keyway and key are pointing straight upward. 5. Mount camshaft gear, gear is manufactured so that tooth No. ,.1” is exactly on the center line of the fitted key groove. 6. Basic setting is finished. Now it is absolutely necessary to check the inlet and exhaust valve timing. 7. Incase of deviations turn camshaft gear or gear wheel on crankshaft. 8. Adjust backlash and tighten and secure bearing journal for the twin wheel. Possibility of checking the adjustment 1. Turn piston cyl. 1 in TOC position. 2. Gear box with dead center indicator and flywheel casing are removed. 3. Fit the auxiliary dead center indicator anywhere (e.g. frame of the floor plates) and apply auxiliary marking on the flywheel. Measure with depth gauge ona cylinder of your choice from the spring plate of a half-open valve toa level surface in the cylinder head, and note the measured dimension. Replace gear drive. Tooth 68 (Continued on page: 43) Tooth 47 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 48Mak Engineer's Handbook M451 - M453 [ ’ Gear drive 6. After completion of adjustment, in position auxiliary marking on flywheel in coincidence with the auxiliary dead center indicator the noted dimension must result again. Adjustment aid: If e.g. on the port type tooth 1 of the big twin wheel is in mesh with the teeth 32 - 33 of the crankshaft gear wheel, tooth 1 on the small twin wheel can be ascertained by means of the bore (sketch). Then the teeth 32 - 33 with which tooth 68 of the camshaft gear is in mesh can be ascertained by counting. Important! It is absolutely necessary to take cara that you start counting at tooth 1. Tooth Vis aot zero zero Engine countorclockwiee 00 Check of inlet and exhaust valve timing ZA) 1. The bottom dead center of cyl. 1 has to be ascertained. This is possible by the following methods: With removed gear box an auxiliary dead center indicator is to be fitted. From the approximate BDC position turn bottom side of the piston to the camshaft side until it is flush with the bottom edae of the liner. Apply mark on the flywheel. Then turn bottom side of the piston to the exhaust gas side until it is flush with the bottom edge of the liner. Apply mark on the flywheel. Half-way between the two marks is the bottom dead center. This can also be carried out with a Inlet cams magnetic gauge. With the piston in BDC position the cams of cyl. 1 must have the position as shown in the accompanying sketches. b) By means of agraduated disk which is mounted on a threaded rod with a 5/8" thread for in-line and Vee engines. This threaded rod is screwed into the flanged shaft on the opposite side of the coupling. On the flywheel the TOC of cyl. 1 has to be Inet valve ascertained, then position ,0” is to be marked on the = graduated disk by means of an auxiliary indicator, then turn by 180°. The BOC of cyl. 1 is reached. Too al Engine clockwise: (Continued on page: 50) Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 49Mak Engineer's Handbook _M451-M453C | Gear drive } This method is only applicable on engines without power take-olt, 2. Check drawing numbers of the fitted inlet and exhaust cams. The abice ssuamstaeniags drawing numbers are stamped into the cam sides. 3. Fixdial gauge on the roller tappet of the inlet cam of cyl.1.1o facilitate the work it is possible to place a second roller tappet inversely-roller pointing upwards - on the existing roller tappet, taking care of the dead center position (sketch). 4. See the value of the cam lift ,S" from the table below and turn LZ stracoene crankshaft in direction of engine rotation until the value can be read — from the dial gauge. |he crankshaft must now have turned on by the ‘ees ++ Control angle stated for the cam lift ,S". Attention! The opening and closing angles stated, too, are irrelevant for these works and are only stated for regularity’s — sake. Exhaust cams 5. The same procedure can be used for the exhaust valves, taking care of the different dead center position as compared to the inlet valves (sketch). Example Engine has:Inlet cam 1.60.7-32.10.01-15 Control angle 131° +3° Cam lift .S* 5.90 mm Exhaust cam 1.60.7-32.20.01-15 Control angle 161°+3° Cam lift ,S" 8.290 mm Flywheel diameter 1200 mm 1° = 1200 x 3.14 / 360 = 10.47 mm. If the crankshaft is turned in direction of engine rotation until the dial gauge on the inlet cam shows the dimension 5.90 mm, the flywheel ‘must have turned on by 131° x 10.47 mm = 1372 mm from the BDC Seuss clectwhe position. In case of the exhaust cam the flywheel must have turned on by 161° x 10.47 mm = 1686 mm from the TOC position when the Dead center indication on'the dial gauge is 8.290 mm. indicator - ‘Mark before turning. (At random, important is the BDC position cy. 1.) Example inlet valve timing Mack ater tring Dial gauge {rom the fail posiven by 134» 1372 om In direction of cation. orient position Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 50Mak Engineer's Handbook M451 - M453 | Gear drive Check of the inlet and exhaust val 3c. to 1,60.7-32.07. Inlet cam opens closes control cam lift" S " angle Drawing No. ° crank angle ° crank angle ° crank angle mm 1.60.7-32.10.01-05 70° bef. TOC 40° aft. BDC 131 °23° 59 1,60.7-32.10.01-06 115 ° bef. TOC 30° aft. BOC 95° T° 8079 1,60.7-32.10.01-07 70° bef. TOC 40° aft. BDC 140 °2 3° 8079 1,60.7-32.10.01-08 70° bef. IDE 40° alt. BUC WO°t3° 7361 1.60.7-32,10.01-09 90° bef. TOC 40° aft. BDC 130 °# 3° 8730 1.60.7-32.10.01-15 58° bef. TOC 45° aft. BDC 162°23° 8730 1,60.7-32.10.01-11 90 ° bef. TOC 40° aft. BDC 130°#3° 8730 1.60.7-32.10.01-12 70° bef. TOC 40° aft. BOC 40°23" 7961 1,60.7-32.10.01-13 115 ° bef. TOC 30° aft. BOC 95°45" 8079 1,60.7-32.10.01-14 50 ° bef. TOC 45° aft. BOC 160°£3° 7961 1.60.7-32.12.01-03 70° bef. TOC 40° aft. BDC 131 °#3° 590 1.60.7-32.12.01-04 115 ° bef. TDC 30° aft. BDC 95 °t 3? | 8079 1,60.7-32.12.01-05 70° bef. TOC 40° aft. BDC 140°23° 8079 1.60.7-32.12.01-06 70° bef. TOC 40° aft. BDC 140°x3° 7961 1,60.7-32.12.01-07 120° bef. TOC 40° aft. BDC 100°#3° 8730 1,60.7-32.12.01-08, 90 ° bef. TOC 40° aft. BOC 130°#3° 8730 1.60.7-32.12.01-14 50° bef. TOC 45° aft. BOC 160°*3° 19861 1,60.7-32.12.01-10 115° bef. TOC 30° aft. BOC 95 °#3° 4079 1,60.7-32.12.01-11 70° bef. TOC 40° aft. BOC 140°#3° THI 1.60.7-32.12.01-12 90 ° bef. TOC 40° aft. BOC 130°23° 8730 1.60.7-32.12.01-13. 50° bef. TOC 40° aft. BDC 160°£3° 7961 1,60.7-32.12.01-15 58° bef. TOC 45 ° aft. BOC 162°£3° 8730 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 51MAK __ Engineer's Handbook _M451-M453C ( Gear drive ) inlet and exhaust valve timi to 1,60,7-32.07- Exhaust cam opens closes control cam lift" S$“ angle Drawing No. ° crank angle ° crank angle ° crank angle mm 1.60.7-32.20,01-07 40 ° bef. BDC Toc 162°23° 7.10 1.60.7-32.20.01-08, 50° bef. BOC s0° afl. TOC 88°#S° 708 1.60.7-32.20.01-09 50° bef. BOC 20° afl. TOC 185 °H9° = 7.087 1,00.7-32.20.01-06 45° bef. DDC 35° aft. TOC 157° 49° 710 1.60.7-32.20.01-11 50° bof. BDC S52afl.T0C © 1683° 8.290 1,60.7-32.20.01-12 45° bef. BOC Beaf. TOC © 157°#3° 710 1,60.7-32.20.01-13 50° bef. BOC S6°aft. TDC 16°23 = 8290 1.60.7-32.20.01-14 40° bef. BDC Toc 162°23° = 1,031 1.60.7-32.20.01-15 55° bef. BOC 50° aft. TOC —161°s3° = 8.290 1.60.7-32.22.01-04 45 ° bef. BDC 95° aft. TOC 157 °£ 3° 710 4.60.7-32.22.01-05 40° bef. BDC Toc 162°23° 7.10 1.60.7-32.22.01-08 50° bef. BDC 2afl.TOC 19° HORT 1.60.7-32.22.01-07 50° bef. BDC S0° aft. TDC 158° 3° 1088 1.60.7-32.22.01-08, 50° bef. BDC S5eaft.TOC | 188 °#9° 8987 1.60.7-32.22.01-08 50° bef. BOC 3eafl. TOC 18°39" = 8.290 1.60:7-92.22.01-10_ 50° bef. BDC 86° aff. TDC — 165%#3° = 8290 1.60,7-32.22.01-11 45° bef. BOC 35° aft. TDC e7°#9° 710 1.60.7-32.22.01-12 40° bef. BDC Toc 162°23° 7,10 1.60.7-32.22.01-13 50° bef. BDC S5°aft.T0C 16829 8.290 1.60.7-32.22.01-15 55° bef, BOC 50° aft.T0C —67°23° 290 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 52M451 - M453 C Engineer’s Handbook * Gear drive Sb WW OL pue Z} Bumas jaaymseag “ye08 yeysases pue 004 oun (, y wes) yoyswes pu Gury easonup-LoYs pur jeasonn Page 53 Service document of Mak Motoren GmbH & Co. KG Edition 28.11.1998Mak Engineer’s Handbook _M451- M453C | Gear drive =| Adjustment of gear drive Boe Port type After adjustment of the inlet and exhaust valve 1 timing, position of the teeth Piston 1 in TOC marked on the twin wheel. mo gear HF} a ae : Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 54Mak Engineer's Handbook M451 - M453C Gear drive ] Adjustment of gear drive Starboard type Piston 1 in TOC After adjustment of the inlet and exhaust valve timing, position of the teeth \ marked on the twin wheel. Ye ae Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 55.Mak Engineer’s Handbook M451 - M453C ( Governor drive } Instruction for adjustment of governor drive M452/453 with the governors UG8 and Regulateurs Europa 1104 1. Mount governor drive acc. to the sketch. Use 4 thickness gauges z { of the same size. The backlash of 0.1 mm and alignment of the tooth ends are attained by horizontal displacement of the shaft with its bearing (dimension X") and by choosing the size of the thickness gauges in vertical direction (dimension .S"). 2. Coat tooth flanks of a bevel wheel with engineer's marking blue. Make several revolutions in running direction. If the bearing pattern shown in figure 0 on page 58 is not attained, the position of the flanks resp. the bearing pattern must be corrected in this connection see page 58}. 3. After adjustment of the bearing pattern figure 0 on page 53 turn off spacer bush on the governor and spacer for dimension ,X". ‘Turning-off dimension: Spacer bush = size of thickness gauge .S” Spacer = dimension ,X" 4, Mount governor drive complete. YE oy Instruction for adjustment of governor drive M452/453 with the governors PGA and EGB 10 1. Assemble governor with new bevel wheels, i.e. instead of the ball bearings 1 and 2 and the spacer rings 3 and 4 first assembly rings are fitted. 2. Fit bevel wheels so that the backs are in alignment,and the backlash is 0.2 mm. 3. Measure dimension ,X" and determine width of spacer rings and turn to size. Assemble horizontal drive. 4. Realign bevel wheel of the vertical drive. Measure dimension ,Y" and determine height ,.C” of the spacer bush. Turn spacer bush to size and assemble governor drive. Check backlash and position of the backs of the bevel wheels. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 56Mak Engineer's Handbook M451 - M453 | Governor drive Governor drive V-type engines - exchange of bearings 1, Dismount governor from drive. 2. Remove grooved nut 1. 3. Remove circlip 2. 4, Remove cap 3 and circlip. 5. Drive gear wheel 4 with bearing 5 out of the casing. 6. Withdraw bearing 6 from the casing. 7. Remove castellated nut 7. 6. Draw spur wheel 8 from shaft 9. 9. Remove clamping plate 10. 10. Remove cap 11. 11. Loosen castellated nut 12. 12. Remove shaft 9 with bearing 13 and spur wheel 8 from the casing. 13. Replace bearing 14 after loosening the circlip. Assembly is carried out in reverse order. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 57Mak Engineer's Handbook M451 - M453 Governor drive | Bearing pattern not loaded ea 1 2 1. Bearing pattern wrong |\__—_=< — 2. Bearing pattern correct Vertical displacement of bearing pattern 3 4 | . Bearing pattern wrong ~ 4, Bearing pattern correct Y 5 6 5. Bearing pattern wrong pil 6. Bearing pattern correct A Longitudinal displacement of bearing pattern 7 8 Bearing pattern wrong 8. Bearing pattern correct ar YT » ~ Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 58Mak Engineer's Handbook M451 - M453C | Camshaft Camshaft bearing Tighten bolts with a maximum torque of —> M = 60 Nm (After each tightening the bearing clearance must be checked by all means. The now clearance of bearing shall be = 0.10 mm.) Fit bearing with new bolts which are included in the delivery. Camshaft The hydraulic pressure applied on the set collar for axial adjustment of the camshaft is —> Normal camshaft bearing Original clearance Bearing —> Camshaft 8. Camshaft step bearing Clearance between step bearing and camshaft set collar —> Clearance limit between step bearing and camshaft set collar > 010-015 mm 90.10 +8 mm 89.978 - 90.00 mm 0.50 mm ee ee Uf the clearance limit of 1 mm is reached, the set collar is to be rotated and newly bored. The sat collar ( hydraulic mounting ) is to be readjusted by means of the hydraulic tool, Injection cams, reversible, non reversible Pretighten bolts by hand and tighten alternately in small steps with Inlet cams, non reversible Pretighten bolts by hand and tighten alternately in small steps with — Inlet cams, reversible Pretighten bolts by hand and tighten alternately in small 1.00 mn M = 140210 Nm M = 140210 Nm ee steps with > M = 24-26 Nm Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 59Mak Engineer's Handbook M451 - M453 ( Camshaft Inlet cams, reversible M 453 C Pretighten bolts by hand and tighten alternately in small steps with Exhaust cams, non reversible Pretighten bolts by hand and tighten alternately in small steps with > Exhaust cams, reversible Protighten bolts by hand and tighten alternately in small steps with Exhaust cams, reversible M 453 C Pretighten bolts by hand and tighten alternately in small steps with > M = 27-29 Nm For all cam assemblies: Slightly coat contact surface of bolts and threads with Molykote paste G. Inlet cam, split When fitting split inlet and exhaust cams pay attention that the clamping sleeve fits on the edge .X". Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 60Mak Engineer's Handbook M451 - M453C | Camshaft } Starting cam ¢ Setting , () Turn engine until cyl. 1 is Firing TDC Kp =X?" after firing TOC. Fit starting air distributor (do not connect pipes). Remove locking screw - 1 - and pressure spring - 2 - from control piston for cyl. 1. Direct light beam from top into the bore - 3 - and observe control piston - 4- through the bore - §-. Turn starting cam in the opposite direction to the rotation of the camshaft until the light gap is still just visible. Now the starting cam has reached the position «Starting valve opens”. Tighten well fixing screw - 6 - for the starting cam - 7 -. Tighten headless screw - 8 - and secure with centre Position at start Position .valve of setting opens” punch. Dimension,X°” 6/12 cyl. 8/9/ 16 cyl. reversible 8° 17°, 30° non-reversible = 0° o> Main starting air valve Tightening torque of the big bottom nut (guide body) —> Tightening torque for the screws of the top flange —> Starting fuel limiter ene hai o> Tightening torque for throttle screw —> Stop cylinder Tightening torque for the axial bottom nut > Tightening torque for the nuts > Sauts, 4 at the top aad 4 at the bottom. Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 61Mak Engineer's Handbook _M451- M453C ( Camshaft Lower valve drive 1.60.7-35.02.00-13 Tighten bolts for the roller tappet housing with —> M 5 Nm (M4 12x 40 DIN 912) Tighten nuts for the intermediate plate of the fuel injection —_— pump with —> M % Nm (M 12 DIN 934) M 453 and M 453 C 1,60.7-35.02.00-14 Tighten bolts for the roller tappet housing with —> M 6 Nm (M 12x 40 DIN 912) Tighten nuts for the intermediate plate of the fuel injection pump with —> (M4 12 DIN 934) M453 1,60.7-35.02.00-15 / 16 Tighten bolts for the roller tappet housing with —> (M 16 x 90 DIN 931 with tension bush) Tighten nuts for the intermediate plate for the fuel injection pump with —> M = 145 Nm (i 16 DIN 934) M453 C 1.60.7-35.02.00-17 Tighten screws for the roller tappet housing with —> M = 15 Nm (04 12 x 90 DIN 931 with tonsion bush) Tighten nuts for the intermediate plate of the fuel injection pump with —> M = 4 ~ Nm (M 12 DIN 934) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 62Mak Engineer's Handbook M451 - M453 | Fuel injection pumps | Injection pumps M 453 Tighten fixing bolts with —> (Tie bolt 1.00.7-88.50.59-25 with tension bush E26 x 18 DIN 2510) M 453 C Tighten fixing bolts with —> (Tie bolts 1.00.7-88.50.59-25 with spacer bush 1.00.7-88.50.63-65) Tightening torque is valid for the following pump types: PF IW 240 BS 1722 PF IW 220 BS 1710 PF IW 240 BS 1733 PF IW 220 BS 1766 PF IW 240 BS 1781 PF IW 240 BS 1785 PF IWY 260/7 PF 1WV 260 V 16277 PF IWV 260/8 Tighten bolts / nuts for the delivery valve - pressure balancing Fuel injection pump M 453 C Practice has shown that the fixing screws are difficult of access and cannot be tightened as prescribed with normal tools. Therefore, a short offset box wrench with welded-on button die is included in the delivery now. With this tool it is possible to tighten the screws with the prescribed tightening torque of 120 Nm, provided that on all cylinders the right protective tube and on the relative cylinders mounted parts as stop cylinder, limit switch, starting fuel limiter etc. are removed. Fuel delivery pipes In case of possible upsetting on the cones the pipes must be rebored to the original dimension M452 = 3mm M453 = 4mm Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 63Mak Engineer's Handbook | M451-M453C | Fuel injection pumps Injection pump setting In case of new installations all pumps are adjusted with dimension w¥" = 10.3 mm (from supporting flange to top edge of thrust piece, roller on base circle of cam). Before fitting an overhauled or new injection pump, this dimension must be checked and, if necessary, readjusted. ¥ Setting : 10.3 + 0.3mm On the new pumps PF1 w 220 BS 1710 and W 240 BS 1722 the line Setting dimension .Y~ previous rule -line mark must be visible in the window during the pump stroke - does not apply here. Pre-stroke Engine type M451 Mast masz M453 not super - super - charged charged Pre-stroke 4-45 48 48 6-65 Itis possible to use the M 453 injection on M 452 engines, in that case the pre-stroke must be set to 6 - 6.5 mm. New M463 C - engines have roller tappets with thrust piece and shims. On this pump type the dimension Y" = 10.3 mm, from supporting flange to top edge of thrust piece, roller on base circle of cam, is adjusted by means of shims. Shims are available as follows: 1 ; 2; 2.2; 2.4; 2.6 and 2.8 mm thick. Commencement ofdalivery, Q - Fiting too Commencement of delivery Position of Check commencement, See commencement of delivery from the acceptance test of delivery record and measure the respective arc on the flywheel and mark commencement of delivery. Bar engine in direction of rotation until the line mark - 1 - on the spring cup coincides with the line mark - 2- on the pump casing. Check on flywheel, if the commencement of delivery mark is below the dead centre indicator. “ “ 3 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 64Mak Engineer’s Handbook M451 -M453C { Fuel injection pumps } Basicsetting ‘Turn until the roller rests on the base circle of cam, then check whether the line mark 1 - on the spring cup coincides with the line mark - 3 - on the pump casing. If there is no coincidence any more, all parts concerned must be checked with regard to their condition and have to be replaced, if necessary. Then restore coincidence of the marks - 1 - and 3 (basic setting) by turning the setscrew - 4 -, tighten screws - § - , now it must not be possible any more to turn the setscrew - 4 -. Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 65Mak Engineer's Handbook _M451- M453C | Flanged shaft mounting Flanged shaft mounting without power take-off M452-M453 In-line 1.60.7-63.45.00-07 / 08 Tighten nuts for flanged shaft and vibration damper or spacer ting with > M = 140 Nm Castollated nut M 18 x 1,5 DIN 935, split pin 4 x 32 DIN 94, washer B 19 DIN 125, Jangth of the bolts 279 mm. Tighten screws for gear rim on flanged shaft with —> M = 50 Nm M 12x45 SK DIN 933 M453 1.60.7-63.45.00-09 Tighten nuts for flanged shaft and vibration damper with —> M = 19 Nm Castallated nut M 20 x 2 DIN 935, split pin 4.x 35 DIN 94, washer 21 DIN 125, Jength of the bolts 285 mm. Tighten screws for gear rim on flanged shaft with —> M = 9 Nm M 12x 45 SK DIN 933 M453 1,60.7-63.45.00-10 Pretighten nuts for flanged shaft and vibration damper with —> M = 30 Nm and tighten with > Dw = 30° possibly tighten further to the next split pin hole. Castellated nut M 20 x 2 DIN 935, split pin 4 x 36 DIN 94, length of the bolts 285 mm. Cost thread and contact surface of the aut on gear whee! side with Molykoto, thread and contact surface of nut on crankshaft side romain dry. Tighten fixing screws for vibration damper with > M = 130 Nm M 16x 70 DIN 912 Tighten screws for gear rim on flanged shaft with —» M = 590 Nm M 12x 45 SK DIN 933 (Continued on page: 67) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 66Mak Engineer's Handbook M451 - M453C ( Flanged shaft mounting M453 Vee 1.61.7-63.45.00-11 / 12 Tighten nuts for flanged shaft and vibration damper with M = 20 Nm + 11 with vibration damper, - 12 without vibration damper. Fixing screw for vibration damper M 20x 110 DIN 912, castellated nut M 24 x 2 DIN 935, split pin 5x 45 DIN 94 Tighten screws for gear rim on flanged shaft with —> M = 50 Nm M 12x 35 SK DIN 933 1.61.7-63.45.00-13 Pretighten nuts for flanged shaft and vibration damper with > |M = 360 Nm and tighten with > Dw = 30° possibly tighten further up to the next split pin hole. Castellated nut M 24 x 2 DIN 935, split pin 5x 45 DIN 94 Tighten screws for gear rim on flanged shaft with —> M = 50 Nm M 12x 35 SK DIN 933 Tighten fixing screws for vibration damper with —> M = 20 Nm M20x 110 01M 912 Coat thread and contact surface of nut on gear wheel side with Molykote, thread and contact surface of nut on crankshaft side remain dry. Flanged shaft mounting with power take-off 1.60.7-63.40.00-02 / 03 Tighten nuts for flanged shaft and vibration damper or spacer ting with > M 20x 20IN 935 The following is valid for the flanged shaft mounting: Tighten all screws and nuts crosswise in2 steps. Tighten screws for gear rim on flanged shaft with —> Mi 12x 45 SK 933 Tighten clamping bolts for flanged bearing in 2 steps with —> M 20x 20IN 935 (Continued on page: 68) Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 67Mak Engineer's Handbook M451 - M453 C | Flanged shaft mounting 1.60.7-63.40.00-04 / 05 Tighten nuts for flanged shaft and vibration damper or spacer ring with —> M20x 2DIN 935 Tighten screws for gear rim on flanged shaft with —> M 12x 45 SK DIN 933 1.60.7-63.40.00-06 / 07 Tighten nuts for flanged shaft and vibration damper or spacer ring with M 20x 2 DIN 935 Attention | Tightening torque is valid for oil. M452-M453 1.60.7-63.40.00-08 / 09 Tighten nuts for flanged shaft and vibration damper with —> M 20x 2DIN 935 Tighten screws for gear rim on flanged shaft with —> M 12x 45 SK DIN 933 Tighten clamping bolts for flanged bearing in 2 steps with —> M453 1,60.7-63.40.00-10/ 11/12 Tighten nuts for flanged shaft and vibration damper or spacer ring with —> Nm M = 2 Nm M = 50 Nm Se M = 20 Nm M 190 Nm Castellated nut M 20 x 2 DIN 935, split pia 4 x 36 DIN $4, washer 21 DIN 125, length of the bolts 281 mm fixing scraws Mi 16 x 70 DIN 912 Tighten screws for gear rim on flanged shaft with —> M 12x45 SK DIN 933 Tighten clamping bolts for flanged bearing with —> M 20x 2DIN 934 Nm (Continued on page: 69) Edition 28.11.1998 Service document of Mak Motoren GmbH & Co. KG Page 68Mak Engineer's Handbook _M451-M453C | Flanged shaft mounting ‘J 1.60.7-63.40.00-13 /14 Pretighten nuts for flanged shaft and vibration damper with > M = 300 Nm and tighten with > Dw = 30° Castellated nut M 20x 2 DIN 935, split pin 4 x 36 DIN 94, length of the bolts 285 mm - Coat thread and contact surface of nut on gear wheel side with Molykote, aut on crankshaft side remain dry. Tighten screws for gear rim on flanged shaft with —> M 12x 45 SK DIN 933 Tighten clamping bolts for flanged bearing in 2 steps up to. > M20x20IN 609 Tighten fixing screws for vibration damper with —> M 16x 700IN 912 M453 V-type 1.61.7-63.40.00-11 Tighten nuts for flanged Shaft and vibration damper with —> Castollated nut M 24 x 2 DIN 935, split pin § x 45 DIN 94 Tighten screws for gear rim on flanged shaft with —> M 12x 35 DIN 933 Fixing screws for the vibration damper: M 20x 110 DIN 912 161.7-63.40.00-12 Pretighten nuts for flanged shaft and vibration damper with and tighten with > Castellated nut M 24 x 2 DIN 835, split pin 5 x 45 DIN 94, length of the bolts 277 mm - instead of washer. strap over 2 bolts. Tighten screws for gear rim on flanged shaft with —> M 12x35 DIN 933 Tighten fixing screws with —> M 20x 110 DIN 912 Hint for fitting | Before fitting the flanged shaft it is absolutely thread and contact surface of M = 50 Nm M = 19 Nm ee M = 130 Nm M = 400 Nm pes ea M = 50 Nm M = 350 Nm Ow = 30° pe a M 50 Nm M = 20 Nm Ree eee Rt necessary to take care that the oil bore on the crankshaft is open and the pin 13 x 70 DIN 1970 is driven in, Edition 28.11.1998 Service document of MaK Motoren GmbH & Co. KG Page 69Mak Engineer's Handbook M451 - M453C | Flywheel mounting M451-M453 In-line + Vee Tighten nuts with —> Attention ! Tightening torque is valid for ait, M451-M452 1,50.7-73.10.00-06 / 07 wah mien > Attention | Tightening torque is valid for oil. masz 1.50.7-73.10.00-09 When using oil tighten nuts with > M = 1600 Coupling bolts for the flywheel mounting Coupling bolts Fixing screws Total length Clamped length mm mm DIN 960 1,50.7-73.10.00-01 318 235 M20X2X 130 Intermediate shaft with located main bearing or relieved located main bearing 1,50.7-73.10.00-02 * 193 110 M20X2X70 Flexible flange coupling 1.50.7-73.10.00-03 243 160 M20X2X70 Intermediate shaft 1,50.7-73.10.00-04 318 235 M 20X2X 130 Intermediate shaft with located main bearing or relieved located main bearing, disk brake. (Continued on page: 71) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 70Mak Engineer's Handbook _M451-M453C | Flywheel mounting Coupling bolts Fixing screws Total length Clamped length mm mm DIN 960 1.50.7-73.10.00-05 318 235 M20X2X 130 Intermediate shaft with located main bearing or relieved located main bearing 1,50.7-73.10.00-06 224 160 *1 M 20X2X 150 Rigid coupling 1.50.7-73.10.00-07 318 235 *2 M 20X2X 130 Geislinger coupling 1.50.7-73.10.00-08 263 180 M 20X2X 150 Flexible flange coupling 1.50.7-73.10.00-09 250 218 1 M452 and 161 1.50.7-73.10.00-10 468 385 *3 M20X2X 150 Intermediate shaft with located main bearing All coupling bolts have a thread M 36 X 3, with castellated nut and split pin. “1 =head screws *2 =with 2 O-rings ace. to order *3 =with shim 1.60.7-73.10.00-01 318 235 Intermediate shaft with located main bearing or relieved located main bearing 1.60.7-73.10.00-02 285 202 Geislinger coupling; oil supply through the crankshaft 1.60.7-73.10.00-03 262 170 Overhung flexible coupling 1.60.7-73.10.00-04 262 170 Overhung flexible coupling (Geislinger coupling) 1.60.7-73.10.00-05 318 235 Intermediate shaft with located main bearing or relieved located main bearing, disk brake. (Continued on page: 72) Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG ra}Mak Engineer's Handbook _M451- M453C | Flywheel mounting Coupling bolts Total length Clamped length mm mm 1.60.7-73.10.00-06 318 235 Intermediate shaft with located main bearing or relieved located main bearing 1.60.7-73.10.00-07 262 170 Overhung flexible coupling 1,60.7-73.10.00-08 262 170 e123 Overhung flexible coupling (Geislinger coupling) 1.60.7-73.10.00-10 318 235 *6 Connection 8 M453 > generator 1.60.7-73.10.00-11 318 235 and 318 25 Intermediate shaft with located main bearing or relieved located main bearing. 1,60.7-73.10.00-12 262 170 and : 262 170 "2 Overhung flexible coupling 1.60.7-73.10.00-13 262 170 and 262 170 eed and 253 170 ma Overhung flexible coupling (Geislinger coupling). Oil supply through the crankshaft. Plug must be removed. 1,60.7-73.10.00-14 * 318 235 and 318 235 Intermediate shaft with located main bearing or relieved located main bearing. (Continued on page: 73) Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG WeMak Engineer's Handbook _M451- M453C { Flywheel mounting Coupling bolts Total length Clamped length mm mm 1.60.7-73.10.00-15 262 170 and 262 170 me Overhung flexible coupling All fixing screws M 24 x 130 DIN 931, all coupling bolts have a thread M 36 x 3, with castellated nut and split pin. * 1 = O- sing between flywheel and crankshaft flange * 2 = Notixing scrows * 3 = Fixing screws bored through * 4 = Fitted bolts bored through * § = In addition guide bolts 4 - SK - 13237 1.61,7-73.19.00-01 318 235 12 M453 1.61.7-73.19.00-02 262 170 Flywheel mounting 1,61.7-73.19.00-03 318 235 Intermediate shaft with located main bearing or relieved located main bearing, disk brake 1.61.7-73.19.00-04 318 235 Flywheel mounting 16 M453 1.61.7-73.19.00-05 318 235 and 318 235 Flywheel mounting 12 M453 1.61.7-73.19.00-06 262 170 eT and 262 170 Flywheel mounting 12 + 16 M453 All fixing screws M 24 x 130 DIN 931, all coupling bolts have the thread M 36 x 3, with castellated nut and split pin. * 1 = No fixing screws. Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 73Mak Engineer’s Handbook M451 - M453 C Connecting screws Engine housing - bedplate M453 in-line Tightening torque of the connecting screws —> M24 x 110 DIN 912 - M24 x 160 DIN 912 M 453 - M453 C Tightening torque of the tie rods M453 in-line Acc. to drawing No. 4 SK - 10077 Ist step > 2nd step > Ace. to drawing No. 1.60.7-92.03.00-01 1st step — 2nd step > Acc. to drawing No. 1.60.7-92.03.00-03 Ist step > 2nd step > P, Attention | On threads of tie rods and round nuts NO Molykote. (S PPE Ee On threads of tie rods and round nuts no Molykote. First tighten lateral connecting screws on the crankcase ports. After inserting the tie rods tighten bottom nuts steadily by hand. Applicable also for 6 + 8 cyl. engines accordingly. [ (Continued on page: 75) = 20 = = " 0 g 8 g E bai bar Edition 28. 1.1998 Service document of Mak Motoren GmbH & Co. KG Page 74Mak Engineer’s Handbook M451 - M453 C Connecting screws Engine housing - bedplate M453 Vee Tightening torque of the connecting screws Drawing No. 1.66. /68.7-11.19.00-01 /02 > Drawing No. 1.66. /68.7-11.19.00-03 —> M 30 x 120 SK DIN 931, Var. - 03 in addition M 30 x 120 DIN 912 Tightening torque of the tie rods M453 Vee Acc. to drawing No. 4 SK - 9478 Ist step > 2nd step > Acc. to drawing No. 1.61.7-92.03.00-01 Ist step —> 2nd step > Pos MT bar Pos bar Poo 3% bar Pos 70 bar Attention | On threads of tie rods and round nuts NO Molykote. On threads of tie rods and BHA | sournuts no Molyote. aera First tighten lateral connecting Oo” A, screws on the crankcase ports. After inserting the tie rods tighten bottom nuts steadily oe | by and Applicable also for 12 cyl. ot By engines accordingly. fae) eS Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 15Mak Engineer's Handbook _M451-M453C { Connecting screws Acc. to drawing No. 1.61.7-92.03.00-02 Ist step > P= 4075 bar 2nd step +> Pos 815 bar Acc. to drawing No. 1.61.7-92.03.00-03 ist step > Pos 470 bar 2nd step > P= 930 bar Engine housing - bedplate Tighten connecting screws with —> M = 400 Nm Tighten engine housing bolts with —> M = 130 Nm Or pretighten with > M = 50 Nm and tighten with > Dw = 120° Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 76Mak Engineer’s Handbook M451 - M453 6 cyl. - engines clockwise: counterclockwise: 6 cyl. - engines clockwise: counterclockwise: 8 cyl. - engines clockwise: counterclockwise: 9 cyl. - engines clockwise: counterclockwise: Firing sequences M 451 - M453 C 4-2 “5-3 12 cyl. - engines long-interval firing clockwise: counterclockwise: A1-B1-A4-B4- A2 - B2 - A6- BG - A3- B3- AS - BS Al -B5-A5-B3- A3- BB - A6-B2-A3-B4-A4-B1 16 cyl. - engines short-interval firing clockwise: counterclockwise: A1-B1-A4-B4- A7 -B7 - AG - BG - A8 - BB - A5 - BS - A2 - B2- A3 - B3 Al - B3- A3 - B2 - A2 - BS - AS - BB - A8 - BG - AG - B7 - A7 - B4- A4 - B1 12 cyl. - engines long-interval firing counterclockwise: Al-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 Edition 28.11.1998 Service document of Page MaK Motoren GmbH & Co. KG 77Mak Engineer's Handbook _M451- M453C Designation Lengthmm Widthmm Heightmm Weight kg Bedplate(compl.) 6M 452 3000 1280 BAZ 0 6M 453 3109 1280 65 3200 8M 452 3900 1280 842 3064 8M 453 4009 1280 965 4200 9M 452 4350 1280 B42 3260 9M 453 4459 1280 65 4700. 12M 453 360 1600 1060 5080 16 M 453 4830 1600 1060 6650 Crankshaft 6M 452 3204 25 2020 6M 453 3M 245 2540 8M 452 4104 mB 2504 8M 453 4244 245 3360 9M 452 4554 7.3) 2330 9M 453 4694 245 3700 12M 453 : 3975 300 3000 16 M 453 5115 300 380 Counterweight 6, Band 9M 453, 448 110 m2 2 12M and 16 M453 550 E) 296 @ Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 78Mak Engineer's Handbook _M451-M453C Designation Length mm Width mm Height mm Weight kg Engine housing withoutliners 6M 452 2810 1060 1380 4000 6M 453 2810 1030 1380 4750 8M 452 3710 1080 1380 5100 8M 453 3710 1080 1380 6100 9M 452 4160 1080 1380 5800 9M 453 4160 1080 1380 6720 12M 453 3542 1788 1425 9800 16 M 453 4682 1788 1425 12300 Engine housing withliners 6 M452 2810 1080 1380 4900 6 M 453 2810 1080 1380 6840 8M 452 a0 1080 1380 6300 8M 453 10 1080 1380" TRO 9M 452 4160 1080 1380 7150 9M 453 4160 1030 1380 8200 12 M 453 x 3542 1788 1425, 10600 16 M 453 4682 1788 1425, 13100 Camshaft, reversible 6 M 452 / 453 3375 90 162 8 M 452 / 453 4275 90 20 9M 452 / 453 4205 ct) 20 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 79Mak Engineer's Handbook _M451- M453C Designation Length mm Widthmm Heightmm Weight kg Camshaft, non- reversible 6 M 452/453 3145: 90 154 8M 452/453 4045, 90 200 9M 452/453 4495 9 mm Reversing gear M 452/453 380 350 750 3 M 453 V - type 35 435 799 4 Gear box 12 and 16 M 453 2000 285 1136 a Governor Woodward UG 40 197 BI 540 45 Woodward PGA 432° 248 690 Woodward EGB 37 210 495; 50 Lub. oil pump wo 4/wou4 730 240 285 n Werdohl 540 mB 25 WDUS : 423 260 0 wos 592 20 0 125 Werdohl (single - acting) 513 280 40 9 Werdohl (double - acting) n0 280 40 145 Edition Service document of Page 28.11.1998 Mak Motoren GmbH & Co. KG 80Mak Engineer’s Handbook M451-M453C Designation Length mm Width mm Height mm Weight kg Lub. oil filter with holder NW65 520 260 330 180 NW 80 680 530 785 302 Turbocharger BBC VTR 200 819 465 ‘550 160 BBC VTR 250 1040 580 610 360 BBC VTR 251 1170 655 32 BBC VTR 304 » 820 BBC VTR 320 1351 71 730 770 BBC VTR 321 1466 88 49 870 Napier NA 355 950 Turbocharger with bracket BBC VTR 200 819 965 0 m BBC VTR 250 1040 580 610 600 BBC VTR 251 1170 688 655 718 BBC VTR 320 : 1351 71 730 1050 BBC VTR 321 1466 938, 49 1160 Charge air cooler 6M 452 1007 580 700 20 8M 452 420 35 B43 185 9M 452 420 510 904 5 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 81Mak Engineer's Handbook M451 - M453C Designation Lengthmm § Widthmm Heightmm Weight kg M 453 in-line a. Veo Var. - 14 144 420 700 570 Var. - 27 1244 420 565 450 Var. - 28 1044 420 565 400 Var. - 30 1069 568 660 540 Var. - 34 and 66 1324 610 660 865 Transition housing with insulation (Turbocharger- charge air cooler) M453in-line Var. - 27 870 4 661 112 Var. - 31 1110 55 974 14 Var. - 34 840 478 900 213 Var. - 35 1110 505 830 136 Var. - 37 an 520 830 192 M 453 Vee 494 1870 1010 200 Vibrationdamper 6M 452 6 820 500 8 M 452 / 453 : 135 655 z “aA 9M 452/453 130. 850 500 12M and 16 M453 {Mak) 200 850 : 915 Flywheel 6M and 8 M 452/ 453 400 1500 3750 9M 452 / 453 410 1350 2300 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 82Mak Engineer’s Handbook —M451-M453C Designation Length mm Widthmm Heightmm Weight kg 8M 452 / 453 510 1500 4690 12M and 16M 453 248 1283 1318 Liner M 452 938 398 183 M453 938 398 187 Cylinderhead (compl.) za Piston with connecting rod Alpiston 1460 320 180 Piston grey cast iron 1460 320 209 Piston Built-up type 68 Piston with cooling coil Located main bearing shell 6,8,9M 453 12 12 , 16 M 453 16 Normal main bearing 6,8,9M 453. 4 12, 16 M 453 6 Geartrain Twinwheel ma 575 7 a Gear wheel on crankshaft 80 580 80 Camshaft gear i} 580 0 Edition Service document of Page 28.11.1998 MaK Motoren GmbH & Co. KG 83