I - T - I ENGINEERS HANDBOOK I M 451145214 PDF

-I ENGINEERS HANDBOOK
I M 45114521453
Contents 0O.Q
I -t
BOO GENERAL ENGINE DATA
1.0 Sectional views

2.0 Dimensions and weights
3.0 Engine handling
4.0 Tables of tightening moments
BOl CYLINDER COVER
1.0 Valve rocker, removal/fitting

1.1 Valve rocker brackets
1.2 Blank
i 2.0 Valve guide

2.1 Valve guide clearance and fitting
3.0 inlet and exhaust valves (table of variants), valve housings

3.1 Maintenance and overhaul of valves
13.2 Valve rotator M 452453
4.0 Starting valve

4.1 Blank
5.0 Cylinder cover assembly

5.1 Cylindercover, mechanical reconditioning
6. Blank
B 02 RUNNING GEAR
1.0 Big-end bearing, inspection and fitting M 4511452

1.1 Big-end bearing, inspection M 453 in-line and Vee
1.2 Big-end bearing, fitting M 453 in-line and Vee
1.3 Blank
1.4 Blank
2.0 Main bearing, inspection M 451/452

2.1 Main bearing, removal- and fitting M 4511452
2.2 Main bearing, inspection M 453 in-line and Vee
2.3 Main bearing, removal- and fitting M 453 in-line and Vee
2.4 Main- and big- end bearing- storing
2.5 Reboring of main bearing oilways and single and main bearing- cap
3.0 Crankshaft
3.1 Counter-weights, tightening moment, 6/8 and 9 cyl.
M 452/M 453 and 12 and 16 cyl. M 453
3.2 Blank
4.0 Liner (wear measurement and reconditioning)

4.1 Liner fitting and removal
4.2 Blank
4.3 Blank
h I I
Edition SERVICE DOCUMENT OF
31. Oktober 1988 KRUPP MaK MASCHINENBAU GMBH

ENGINEERS HANDBOOK tvl 45114521453
Conten3s00.1
5.0 Piston pin and bush removal and fitting

5.1 Piston assembly (built-up piston)
5.2 Ring lay-out and grooves Z 451/M 451 - 452 - 453 in-line and V
5.3 Piston removal and fitting Z and M 451/452/453 in-line and V
5.4 Blank
BO3 ENGINE HOUSING
1.0 Bedplate, engine housing M 451,452,453 and M 453 V

1.1 Blank
1.2 Foundation plan
1.3 Cylinder block
1.4 Tightening instructions for tie-rod, hydr. tools
1.5 Gear case
1.6 Pump end cover, flanged shaft incl. vibration damper arrangement
1.7 Crankcase ventilation
804 TIMING GEAR
1.0 Triming gear - inspection

1.1 Timing gear train incl. gear wheel setting M 452/453 in-line and V engine
1.2 Fitting of camshaft
1.3 Cam setting
1.4 Repaircam for fuel, inlet and exhaust
1.5 Exhaust cam setting
1.6 Reversing gear
1.7 Blank
1.8 Blank
1.9 Blank
805 CONTROL
1.0 Governor drive

1.1 Governor linkage
1.2 Speed setting, emergency stop, fuel injection limitation according to charge air
B 06 EXHAUST SYSTEM/SUPERCHARGING
1.0 Exhaust system

1.1 Exhaust gas turbocharger
1.2 Exhaust pipe
1.3 Charge air cooler/charge air shaft
28. February 1989 KRUPP MaK MASCHINENBAU GMBH

ENGINEERS HANDBOOK M 45ll452l453
-
Contents 00.2
B07 FUEL SYSTEM
1.0 Fuel system

1.1 Injection pump, basic setting
1.2 Injection pump fitting/removal
1.3 Injection valve
1.4 Nozzle cooling
2.1 Blank
2.2 Blank
2.3 Blank
2.4 Blank
B 08 LUBOIL SYSYEM
1.0 Luboil circuit

1.1 Blank
1.2 Luboil pump, fitting M 451/452/453
1.3 Blank
BO9 COOLING WATER SYSTEM
1.0 Blank
1.1 Conventional sea-/fresh water cooling
1.2 Single-circuit cooling
1.3 Two-circuit charge-air cooling
1.4 Cylinder cooling
1.5 Central cooling with low- and high-temperature cycle
2.1 Cooling water centrifugal pump

2.2 Cooling water piston and bilge pumps
BlO STARTING AIR SYSTEM
1.0 Blank
1.1 Starting air system
1.2 Starting air tank
1.3 Starting air capacity
2.1 Master starting valve M 451/452/453 hydraulic starting aid /starting fuel limiter
2.2 Blank
811 MONITORS
1.0 Blank
1.1 Blank
r4
30.November1987 KRUPP MaK MASCHINENBAU GMBH

ENGINEERS HANDBOOK-
I M 451/452/453
Contents 00.2
812 ANCILLARIES
1.0 Blank
1.1 Barring ge,s!
1.2 Blank
1.3 Air combressor
1.4 Blank
813 SPECIAL TOOLS /DEVICES

-+.
1.0 Topls equipment
1.1 Basic set of standard tools RM 452; 453lVM 453
1.2 Additional set of basic tools RM 452
1.3 Additional set of basic tools RM 453
1.4 Additional set of basic tools VM 453
,.I

ENGINEERS HANDBOOK General
Engine data
Sectional views B 00-l ,Q
Cross-section Z 451 in-line
\ W_)] Valve control mechanism;
Exhausl opens = 90 f 2 befor, e BDC

i I Exhaust closes = 45 - 60 alter BDC
\ I Commencement of delivery =
Coincidence of line marks
I I J3.Y- 1 la before TDC
Direct injection
Ejection pressure = 260 bar
I Valve clearance = 0.4 - 0.5 mm
9 Mean effective pressure:

pmc = 8,3 - 9,25 bar
.
F--
Piston displacement: 36,2 I /cyl
Bore : 0 320 mm
Slorke:450 mm
Speed: 300 - 375 rpm
31.January1988 KRUPP MaK MASCHINENBAU GMBH

Engine data
Section view B 00-l .I_

Cross-section M 451 in-line
Speed revul. per minue - 300 - 425 r. p.m.

Bore: 0 320 mm Woke: 450 mm
Trim@ v&es:
UnsuDercharaedw
IflIe opens: 22 before T.D.C. W belor:T.D.C.
Inlet closes: 36* after B.D.C. 40 atier B.D.C.
Exhaust opens: 36before B.D.C. 57 belore B.D.C.
Exhaust closes: 22 afierT.D.C. 40 after T.D.C.
Conveyor [riming: 17 before T.D.C. ll-14 before T.D.C.
Pre stroke length X - 4.3 mm 4.0 mm
Valve ciearance _ O.5mn
Mean elienive pressure _ 6 bar 9.2 - 12.1 bar
Compression pressure - 33 - 34bar 60-62bar
Combustion pressure -56-5Qbar 64-92bar
Ejecting pressure - 26O bar
Firing order : (cbckwise rotation)

6M-l-4-2-6-3-5
6M*1-4-7-6-6-5-2-3
31 a January 1989 KRUPP MaK MASCHINENBAU GMBH

General
ENGINEERS HANDBOOK Englne data A
&ctional vlews B 00-1.2
KRUPP MaK MASCHINENBAU GMBH

31. August 1987
General
ENGINEERS HANDBOOK
Engine data
I
Sectional views B 00-l .3

31. August 1987
Engine data
Dimensions and weiahts B 00 -.

2p
Designation length width height0 weigh!

mm mm mm kI
_----_--__-____--_-~_-----------l-----
Bedplate (cpl.)
6Zu. 6M451/6M452 3000 1280 842 2250
6M 453 3108,5 1280 965 3200
8Z u. 8M 451 l8M 452 3900 1280 642 3064
8M4-53 4008,5 1280 965 4200
9z 451 u. 9M 452 4350 1280 842 3260
9M453 4458,5 1280 965 4700
12M 453 3689,5 1600 1060 5080
16M 453 4829,5 1600 1060 6650
Crankshaft
6M451 3204 225 1890
6Z 451 u. 6M 452 3204 225 2020
6M 453 3344 2451672 2540
8M 451 4104 225 2650
8Z 451 u. 8M 452 4104 225 2504
8M453 4244 24551672 3360
9Z451 u. 9M 452 4554 225 2830
9M 453 4694 2451672 3700
12M 453 3975 3001672 3000
16M 453 5115 3001672 3950
Countherweight
6,8 u.9M 453 448 110 222 60,5/61
12u.16M453 550 89 296 66169
Engine housingwithouff
with liners and studs
6Z45116M451 u.452 2810 1030 1380 4000/4900
6M453 2810 1030 13801-1718 475015600
'6840
8Z45118M451 u.452 3710 1030 1380 510016300
8M453 3710 1030 1380/-1718 6100/7300
l8960
9Z451 u.9M452 4160 1030 1380 5800/7150
9M453 4160 1030 1380/-1718 672018200
12M453 3542 1788 i425ri735 9800/10600
'12200
16M453 4682 1788 1425l.1735 129OOl131OO
Camshaft
6Z45116M451 u.453
(reversible) 3375 90 162
(non-reversible) 3145 90 154
12M453
16M453
31.
Edition
May 1988 I
SERVICE
KRUPP MaK
DOCUMENT
MASCHINENBAU
OF
GMBH
1-
General
ENGINEERS HANDBOOK Engine data
~tlonal views B 00-l .4
Cross-section M 453 Vee engine
31. August 1987 KRUPP MaK MASCHINENBAU GMBH

General
ENGINEERS HANDBOOK
Engine data
pim
g n i n
Designation length width height 0 weight

mm mm mm kg
-----_------__-_____-__-__-_I----------
Reversing gear
Z u. M451-453 in line 380 750 93
M453 Vee 334-5 799 94
Gear box
12 u.16M 453 2000 285 1136 2701291
Governor
Woodward UG 40 197 266,7 540 45
Woodward PGA 36O/432 248Q18 569f69O
528/565,5 60
Woodward EGB 317 210 4571495 50
Lub.oil pump Var.

WD4/WDU4 (double-acting) -02 730 240 285 71
Werdohl ( double-acting ) -19 540 273 285 90
WDU5 (single-acting) -27 423 280 340 83
WD5/WDU5 (double-acting ) -28 592 280 340 125
Werdohl ( single-acting ) -33 513 280 340 99
Werdohl ( double-acting ) -34 710 280 340 145
Lub.oil fitter/with support

NW65 520 260 530 89/180
NW80 680 530 786 186r302
Turbochargerlwith support
BBC VTR 200 819 465 550 16or277
BBC VTR 250 1040 580 610 360 /600
BBC VTR 251 1170 688 655 432 r 778
BBC VTR 320 1351 751 730 no rio50
BBC VTR 321 1466 938 949 87or116O
Carge alr cooler

6 u.9Z 451 360 373 675 152
8Z451 / 6 u. 8M 451 295 395 826 160
6M 452 1007 580 700 270
8M 452 420 395 843 185
9M 452 420 510 904 275
M453 in-line (Var.-14) 1344 420 700 570

and Vee (Var.-27) 1244 420 565 450
(Var.-28) 1044 420 565 400
(Var.-30) 1069 568 660 540
(Var.-34 u. 66) 1324 610 865
31. May 1988 KRUPP MaK MASCHINENBAU GMBH

MaKI ENGINEERS HANDBOOK
I General
Engine data I LI.
Dimensions and weights B 00-2.0.2
Designation length width height 0 weight

mm mm mm ks
_-l--------------------- _____----_-_
Bend with insulation

(charge air cooler-turbocharger)
M453 in-line (Var.-27) 869,5 363,5 661 112
(Var.-31) 1110 505 974 154
(Var.-34) 840 478 900 213
(Var.-35) 1110 505 880 136
(Var.-37) 9?0,5 52O 880 192
M453 Vee (Var.-03) 494 1870 1010 200
Vibration damper
6M451 I452 96 820 500
8M4.521453 135 855 444
8 u. 9Z 45119M 452-453 130 850 500
12 u.16M 453 (MaK) 200 850 975
Flanged shaft with 485 450 180

power
take - off
12 u.16M 453 without 236 450 65
Flywheel
6u.82451 410 1500 3750
9Z 451 u. 9M 452 I453 410 1350 2800
9Z 451 u. 9M 452 I453 510 1500 4690
6~.8M451/452/453 400 1500 3750
12 u. 16M 453 160 1200 895
12 u. 16M 453 248 1283 1318

General
ENGINEERS HANDBOOK
Engine data
Dimensions and weiahts B 00-2.0.3
L&lFNSIONS AND WFIGHTS (storage of spare parts) ,0320,
Cylinder liner 163 kg I 187 kg Cylinder 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. 11.5 kg Double wheel 97 kg

12.16 cyl. 15.5 kg
Gear wheel on carr6iWt 70 kg
Main tearing I Bottom end bearing

6,6,9cyl. 4ko 12.16 cyi. 609 Q
Gearriqon crpnkshah 6Oka
NOTE: 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.

MONTEUR-HANDBUCH
I Allgemeine
Motordaten
ENGINE HANDLING
IN-LINE ENGINE V ENGINE
D --
/
I -r-----7
Engine E A B c D Sling length ,,*,, Weight of

at least engine
type Device at least max.
with excluding
rWrXll ftit
2 cranes flywheel
M 453
mm mm mm mm mm mm m f-ml
6 cyl. t 2490 2345 1545 720 3500

2600
1000 4400
3500
1700 257 210
190
150
a CY~.
9 cyl.
12 cyl.
16 cyl.
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 SERVICEUNTERLAGE DER
30. September 1988 KRUPP MaK MASCHINENBAU GMBH

-1 ENGINEERS HANDBOOK
I General
Englne data
I -
see: 802-2.0 Z+M451 R Old Z+M451/M452R NEW
0,36 - 0.49 (fur 7,0 mm 0,71 - 1.0

.-p GapKvalue
0,32 [mm] bearing shells) 065
[mm1
2
x Bearing play 0.2;,6-$.33 ImmI
B limit value Radial
$&
= z TQhtening moment up to K< 0,05 mm + 65 Q Pre-load
up to a~< 0,05 mm + 653
$
P
0,25 - 0,313 (fur 1O,Omm 0.70 _ 0,90 [mm]
$_r GapKvalue
022 [mm] bearing shells) 065
2
n
p Bearing clearance o250j6034 [mm]
Axial y,, o34[mm]
= limit value
!!. Pre-load Pre-load
A Tightening moment
up to K< O,O5mm + 65 Q. up to Kc0,05 mm + 65 3
044 - 0,75 Bearing play 0,26
Gap K value
035 limit value-O.36 Imml
F
5 Big-end bolts
$ Pre-load up to gap < 0,05 mm
z tightening: min. torsion angle P 55 max. = 80
?
.s Tightening moment @cured by splints)
al Bofts without splints = 65
Counter-weighs
Valve clearance
The tightening values apply only in conjunction with Mo2 (Molykote Paste Rapid G) as lubricant.
31 . January 1991 KRUPP MaK MASCHINENBAU GMBH

Engine data
M453R M453V
m
: .E Gap K value oy5i075 [mm] 0,70-0,90
L
0,60 [mm1
Q
8% Bearing play 0,;,41 [mm]
ng limit value
;g
P TigMening moment 550Nm+60 9 700Nm+110 g
=
B
SP 0,33 - 053 35&O, [mm]
5 f Gap K value
0,30 [mm1
22
Bearing clearance 2; -234 Imm] 0,24-0.51
$ 1 o. [mm1
= limit value ,
1 Tightening moment 700Nm+110 3
550Nm+60 3
GapKvalue 0,7- 1,o Bearing play 0,24 -0,32

F 060 limit value 045
-=
3
0 Big-end bolts with multipledrilled head,
Z hQ=6OONm
? Tightening moment
.9,
m Big-end bolts with one hole or no holes,
Md=750Nm
Limit value 0,1,;,15 lmm]

4
g
1 Adjusting screws 130f10Nm
s Packing rings 0,05 - 0,15 mm (if still available)
Axial-clearance
M453C
Cylinder cover 50Nm+250g 180Nm2500 a
Injection valve 130 Nm with pre-load of

fasting 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 440 Nm plus 600 Nm plus

additional moment for additiinal moment for
see: B 02-3.1 correct bolt head position correct bolt head position
Cold clearance Hot clearance

Inlet: 0,3 + 0,l m 0,4+0,1 mm
Valve clearance
Exhaust: 0,6 + 0,l nxn 0,7+0,1 m-n
The tightening values apply only in conjunction with MO 2 (Molykote Paste Rapid G) as lubricant.
30 . September 1990 I KRUPP MaK MASCHINENBAU GMBH

Valve rocker bracket B 01-l .O
- Axial- clearance valve rocker I

MINIMUM 0,03 mm NEW
lo,ll
MAXIMUM 0,07 mm CLEARANCE
- Diametral valve rocker bearing plays:
- Oil grooves of the bearing bush are 30 LlMlT 0,30 mm
I
to the vertical axis
- Bush projection = 2 mm
ROCKER SHAFT
Freeze the rocker shaft into the rocker bracket.

Undercool rocker shaft to - 60%.
Heat rocker bracket up to 100C.
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

I ENGINEERS 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-nickel-
bronze bush
4 SK-5804

ENGINEERS HANDBOOK Cylinder head
Valve rocker bracket B 01-l .0.2

Valve rocker bracket M 452/452!
i I
i
J
7-T 1
-__
.---. _f--
1
I
!
-.
+--.
Valve shaft 0 55 h6
(insert hardened): -e-e
1
L,
la) -
Pay attention to marks - y--
on valve rocker bracket /

and shaft! 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.

Valve rocker bracket / valve rocker B 01-1.0.3

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
I
= 0.2-0.5 mm
Mark in the direction
of the oil bore
JFMARK;
When inserting a new bush, pay attention to the radial position!

ENGINEERS HANDBOOK
I Cylinder head
I
Valve rocker backet /valve rocker B 01-1.1
INLET AND EXHAUST VALVE CLEARANCFS
- Tappet clearance s between valve stem (2) and adjusting screw (4) must be re-cut differs from the values in
the tables.
- The engine must have stood for at least 15 min. prior to the measurement
(hot clearance) in order to even out the valve temperatures.
Cold clearance mm Hot clearance mm
I Cooling water temp. I Cooling water temp.

1 less than 50 C ! more than 50 C
I
InktvaJve s = 0,3 + 0,l s = 0,4 + 0,l
valve s = 0,6 + 0,l s = 0,7 + 0,l

I Cylinder cover
I
VALVE STEM GUIDES Will-i O-RING SEALS

for Z 451/M 451/M 462/M 453
Exhaust valve Inlet valve

1.60.7-21.23.00-l 1 1.60.7-21 .OO-12
1 mm oversize l-06 1 mm oversize 01-07
NOTE: Upper O-ring seal dropped with wick lubrication of the exhaust valves.
WARNING! Insert O-ring after the supercooling.
Exhaust valve Inlet valve

1.60.7-21.23.00-13 1.60.7-21.23.00-14 1 mm
1 mm oversize 01-l 0 1 mm oversize 01-l 1

31. August 1987
I
~
ENGINEERS HANDBOOK Cylinder cover
I
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. Remove adjusting screw.

2 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
SERVICEUNTERLAGE DER

ENGINEERS 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 Normal clearance = 0.12 to 0.18 mm
Limitclearance = 0.4Omm I
Z+M 451 Normal clearance = 0.10 to 0.15 mm Inlet I 5000 I 10000
Limitdearance I 0.35mm Exhaust 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.

ms, Xh valv valv es-Q .l-3.
INLET AND EXHAUST VALVE STEM Z + M 451
Valve stem
1.60.6.22.10.01.08(M
451/i!451) Lettering
out 10-03
Replacement for Z 451 and M 451 out lo-06
10-08
with gasoil 1.60.6-22.10.01-26 out 10-12
out lo-16
Replacement for Z 451 with in lo-11
heavy fuel and at clients in lo-13
request (recent addition: Exclusively!) lo-26
1.60.6-22.10.01-16 (material Nimonic)
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.

lOlet and exhaust valves. valve 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
l WARNING
Check thickness of hard-
facing after the grinding;
if required dimension has
not been reached,
replace stem.

31. August 1987
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
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
l
Check hard-facing after

the grinding; if required
dimension has not been
reached, replace the
stem.

31. August 1987
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
Valve stem
1.60.7-22.10.01-31 use
/ 1.60.7-22.10.01-34 -44
until worn out
replace with -47
I
l WARNING
Check thickness of the hard-
facing after the grinding; if
required dimension has not
been reached, replace stem.
DETAIL Z DETAIL Z
for variant -31 for variant -34
The first stems of for variant -34

were unchamfered.
rounded manually rounded manually

with stone R 1.6 with stone R 1.6

Mac ENGINEERS 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 ball

bearing
1.00.7-88.50.86-01
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 l
a
1.60.7-22 26.00-02 l *
I
I I I
l with valve stem var. -47
l * with vaive stem var. -48

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.
29.February1988 KRUPP MaK MASCHINENBAU GMBH

blet and exhaust valves. valve seats B o.l-3.u
MAX. REGRINDING OF THE VALVE SEATS M 452, M 453
Max. regrinding
Valve seat ring max. dimension

1.60.7-21.40.08- X
-12 to -15, -41 to -45

-28 to -35
4-SK-14105-l to -4 0 108
-20 to -23 0 107
-24 to -27 0 106
-51 to -54 0 108
No material removed here

31. August 1987
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..

ENGINEERS HANDBOOK
I 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 -190C.
4. Undercool new seat ring in carbon dioxide snow to

approx. -70C and heat cylinder head to approx.+70C
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-20C (refrigerator) and heat
cylinder head to 130C (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.

Maintenanggt_md overhaul 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)
Ed ition SERVICE DOCUMENT OF

I I
Maintenance and overhaul 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
II valid for var. -41, between base
metal and hard-
-47, -48, -49
facing
(see valve stem)

31. August 1987
I
JVlaintenance and overhaul of valves B 0.1-3.13

VA1 VI= CUTTING EQUIPMENT. CUTTf=R RFPI ACFMENT M + 7 4.51. M 452. M 453
(6.9224-C)
8
c
5
Fitting position of the cutters
max.
Cylinder head variant dimension
X Y
4-Sk-12181 108 1,25
-21/-25108 108 1,25
-22 l-25108 107 l,o
-23 106,2 0,8
-24 I -31 108 1.25
removed here
1) Setbolt 5) Pilot rod

2) Ratchet brace 6) Centering bush
3) Cutter head 7) Clamping ring
4) Valve seat ring 6) Outlet pipe
Valve cutting equipment: 6.9224 (Drawing No. 1.607-92.24.00-03)

I
Maintenance and overhaul of valves B 0.1-3.1.4
1. 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 MaKs 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.

31. August 1987
I
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) Spring plate

(2) Balls
(3) Bearing plate
(4) Plate springs
(5) Snap ring
(6) Springs
(7) supports
7
6
4
Wire ends resting

against the spring plate. Circlip J 33x1.2
, Observe fitting position!
\
/
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

Starting valve B 01-4.4
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) Molykote Nm (kpm)

1
1 180 (18) 110 (11)

31. August 1987
ENGINEERS HANDBOOK
Cvlinder head gssembly B Ol-5.4

IY 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 of cylinder head from the
cylinder liner).
Screw in ring bolts (1.9076) at marked positions (10).
~__ 9
d
R = in-line engine
R+V = Veeengine bad
0
seauence
0
cc
TIGHTFNING TORQUFS FOR CYI INDFR HFAD
210
MM51 lM452
J$=$ 6;@o 250 Initial moment =50 Nm

Torision angle a =210
M 453
1
2 2
Initial moment =50 Nm
3 3
Torision angle a =250
M453C
6.9100-22 First assembly: Initial momet 180 Nm + a 270
(6.9180 F) Repeated assembly: 180Nm+ 0Z 250

Initial moment
Indicating label on gear case
Retightening of the cylinder head nuts which had been loosend for the transport device
180 Nm+ a 225

4
Cvlinder head assembly B 01-5.0.1
Sealing between cylinder liner and cylinder head
recess top
Joint ring 2451, M451, M452, M 453
1.60.6 -16.10.02 - 01
t
Joint ring galvanic-coppered
layer thickness 10 - 15 pm
Joint ring
1.60.6 -16.10.02 - 26
M 453 C
Joint ring galvanic-coppered

layer thickness 15 - 20 pm
t

Cylinder 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
supercooled
,$I+ 033
I+0387
030
038
0 38
r6 + 50
+34
t

Cylinder heamemblv B Ol-5.1J
RECONDITIONING OF CYLINDER HEAD JOINT FACE
0391 h8
I-12) 405
NOTE: 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
time 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).

I
pi-n
IQ rn
Checking of one big-end bearing = 5000h

all big-end bearings =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
Load nut with Md = 100 Nm (camshaft side) and tighten further by 55 torsion angle.
Measure gap k on exhaust side.
Tighten exhaust side until gap is P 0.05 mm. rq
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.
4

ENGINEERS HANDBOOK
Bottom-end bearin g. in soection M 451/452 B 02-1.0.1
7. 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
Exhaust side Camshaft side
6.9185

31. August 1987
-
-4
Bia-end bearina. lnsoection M 453 in-line and V 802-l .l
Diametral Bearing play 0,24-0,32mm

clearance
Limit 0,45mm
s for bra-end bo&

(lubricant: Molykote Paste G-Rapid)
1. Pre-load bofts 3 and 4 with 330 Nm.

2 Measure dimension k 1 with sliding caliper.
3. Pre-load bolts 1 and 2 with 330 Nm.
4. 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).
5. Measure dimension k 2.
kl- k2=gap
Gap on final assembly: 0.7 - 1 mm
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!
31. July 1988 KRUPP MaK MASCHINENBAU GMBH

I Running gear
I
bearing. fitting M 453 in-line + V 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.

2 Measure k 1 with sliding caliper.
4. 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).
Md = 750 Nm
m0
0
0
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: 0.7 - 1 mm
After lengthy operation minimum: 0.6 mm

Maln bearina irmection M 4511452 B 02-2.4
After 15000 ooeratina hours check the two highest-loaded main bearings: 6 M = bearings 4 and 5
8 M = bearings 5 and 7
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 = 0,26 - 0,33 mm (M + Z 451)

Radial clearance = 0,22-0,31 mm (M452)
Limit clearance = 0,45 mm
I
axial clearance
0,25...0,34 mm 1,O mm M 452
mc?asured at -
bearing
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.
A+2451 M+Z451 M+Z451Jvl452

New New Old
(10 mm (7 mm
bearing bearing
shells) shells)
Normal + Normal +
locating locating
.!j 6,84 mm bearing shells
bearing bearing
The whole The whole
8 line of main line of main
and
bearing bearing the whole line of

bores bores main bearing bores =
-0239H6 =0239H6 0 238,90 + 0.03
0,25 bis 0,36 bis Norm. bear. : 0,71 - l,Omm

0,38 mm 0,49 mm Lot. bear. : 0,70 - 0,9 mm
.= Normal + lacating bearing

022 mm 0,32 mm
EZ 065 mm
3 3
tf the limit is not reached, it is essential that ebes tg shells be renewed infz s (extremely high risk of induced
rotation!)

l-l ENGINEERS HANDBOOK
I 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 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!
31. Oktobet 1988 KRUPP MaK MASCHINENBAU GMBH

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 in-line 1 km 453 v
Bearing bolt one side 600 12o

slacken opposite side completly completly
Normal Gapx 0.55 - 0.75 mm 0.70 - 0.90 mm

bearing k limit value 0.50 mm 0.60 mm
i Locating Gapx 0.33 - 0.53 mm 0.35 - 0,50 mm

, bearing k limit value 0.30 mm 0.30 mm
M 453 R In line M 453 v
Axial clearance I M 453 in - line I

M 453 v
Locating New clearance 0.25 - 0.34 mm 0.24 - 0.51 mm

bearing Limit 1 .OO mm 1 .OO mm
Direct-coupled plants with thrust bearing are fitted with clearance cut locating bearings.
The above clearances do not apply.

30. June 1991 I KRUPP MaK MASCHINENBAU GMBH
g3 rin r m B 02-2.
Fitting and removal tools: 6.9111 B Power amplifier 14 1.9455-394

6.9112A Power amplifier 1:16 1.9455-7
6.911481 Torque wrench 1.9454-l 00
6.911482
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.

Mad ENGINEERS HANDBOOK
I Running gear
Removal and assemblv of main bearinas M 453 in fine + Vee B 02-3.1
M 453 in line M 453 Vee

I
Smear thread and contact surface of nut with paste Molykote G-Rapid. Tighten nuts
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 with 400 Nm
Tighten nuts of the exhaust gas side or Tighten nuts of A-side and subsequently nuts
nuts of camshaft side and subsequently of B-side with 700 Nm
nuts of exhaust gas side with 550 Nm
Note:
Counternut must be in direction of
I rotation against 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 of
60 110
Turning angle gauge Turning angle gauge
6.9100-l 00 (6.9180 B) 6.9100-7 (6.9180 C)
M 453 R
loosen tighten
Position of the torque multiplier B C
Position of the brake lever D E
Position of the

31. January 1989 KRUPP MaK MASCHINENBAU GMBH
Running gear
ENGINEERS HANDBOOK
I
Main bearina removal + fittina M 453 In-fine and Vee 6 02-2.3.2
Direction of removing bearing covers
16M453 12M453
Flywheel side Flywheel side
Position of the torque wrench

Stockina of main and big-end bearings B 02 I 24
7 + M 451/M 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
Normal main bearing Var. Located main bearing Var.

0 225 h6 = standard 1.50.6-l 2.40.00 -03 1.50.6-l 2.40.00 -031-08
(h6 = 0 225.0 - 0 244.971 mm)
0 224.5 h6 = 1st undersize stage -04 -041-l 0
0 224 h6 = 2nd undersize stage -05 -05/- 11
0 223 h6 = 3rd undersize stage -07 -13
0 222 h6 = 4th undersize stage -13 -31
+ main bearing: 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 of main bearing bore of
245 mm H6. Stocked are bearings for the following pin diameters:
Normal main bearing Located main bearing

0 225 h6 = standard 1.50.6-12.40.00 -01 1.50.6-l 2.40.00 -01
0 224 h6 = 1st undersize stage -02 -02
0 223 h6 = 2nd undersize stage -06 -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 manufacturer: Fa. BHW

Fa. Miba
NOTE: 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.

I Running gear
I
4
Stockina of main and bia-end bearings B 02-2.4.1
M 453 inline + vee M 453 V

Main+big-end bearing: 0 external = Main bearing: 0 external = STANDARD
STANDARD
Main + big-end bearing bore: Main bearing bore:
0 259 H6 (H6 = 0 259,O bis 0 259,032) 0 316 H6 (H6 = 316,O - 316,032)
Undersize bearings are stocked for the Undersize bearings are stocked
crankpins 0: for the pins 0:
0 245 h6 = standard (h6 = 0 245,0-0 244,971) 0 300 h6 =standard (h6 = 0 300,0-0 299,968 )
0 244,5 h6 = 1st undersize stage 0 299,5 h6 = 1st undersitze stage
0 244 h6 = 2nd undersize stage 0 299 h6 = 2nd undersize stage
0 243,5 h6 = 3rd undersize stage 0 298 h6 = 3rd undersize stage
0 243 h6 = 4th undersize stage 0 297 h6 = 4th undersize stage
0 242 h6 = 5th undersize stage
+ main + big-end bearing: Main bearings:

external oversize of 0 1,O f 0 2,0 mm external oversize = 0 1,O mm (0 317 H6)
(0 260 H6) with 1.O internal 0 steps with 1,O mm internal 0 stepsup to pin 0
(0 261 H6) to 0242 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
Width of located main H7 Width of located main B7

bearing pocket = 98 mm bearing pocket = 104 mm
ImDortante Note: 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.

ENGINEERS HANDBOOK
I Running gear
Reborina 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).

31. August 1987
Running gear
ENGINEERS HANDBOOK
&borina of main bearlna lan@!s B 02-2.51
2 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 V-blocks an oilway and place the new cap to be
machined between them.
b) Align all three caps with each other and match up the bearing hole of the adjacent caps with the new
bearing cap. (Same happens with the joint faces).
c) Proceed as described in the first section.

31. August 1987
aft R 02 . 39
Main Connecting Hardness of Running surface Running surfaca

width Comxve fillets of
bearing rod bearinc runningsurface maln bsarlngkonnaclblg cormacting md
quality md baarIng bating jourrmls
journal 0 journal 0 HB surface nlm radludsurfacs
h6 * Lmnion si*
h6 Brine11
hardness roughness belwwn mughneas
pkmwstcpfsa
mmlvn
RT pll
110,o I 2O5,o
300 245 2 235 s 2,5 l5,O IS 2,5
ll 25fo.4 I 22of 0.4
99,0 I 97,0
245 245 2 205 S 2.5 15.0 I 4 2.5
l113*0.4/*111*0.4
2020 100,4 I 100,4
6,8+9
2540 225 225 2 215 12,5 I S 2,5
M 452
2830 13M0.3!130f0.3
6+8 1890 95.0 I95,O

225 225 ir 205 52 15.0 I S 2,5
M451 2650
113*0.3/113*0.3
6+8 2020 95,0 I95,O

225 225 2 205 s 1.5 15,01<2,5
t 451 2540
113f0.31113f0.3
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 mm

Face roughness = RT I 10
225 h6 = 225.000
224.971
245 h6 = 245.000
244.971
300 h6 = 300.000
299.966

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 247iQ.3 A
Preliminary cut tooth corners

-J 013
I+6L
Bore holes for fitting bolts removed up to bottom circle
drilled to 0 17H7 and and thoroughly chamfered
reamed during assembly with R 0.5.
13m6x20DIN7
Edition SERVICE DOCUMENT OF 4,

Crankshaft 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..)
30. April 1991 KRUPP MaK MASCHINENBAU GMBH

I Running gear
Counter-weiahts. tiahtenina moment B 02-3.1
6/6 and 9 CYL. M 4521453
.... I........ . . . . . . ..*.a . . . . . . . . . . . . . . . . . . . . .
M24x2
_-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: 600 Nm (60 kpm)
Molykote paste: Rapid-G

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:
Nominal- 0 320 H7mm
Limit 0321 mm
Roundness 0.35 mm
TDC of the piston
Measuring ruler for cyl. liner 6.2918

Precision inside micrometer 1.9219 B
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.

Running gear
ENGINEERS HANDBOOK
er ~measuringfreconditioningU+M 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

31. August 1987
ENGINEERS 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

than too low.

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
rner M 451 I452 rings (St 52-3) are to be used in
general).
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/

Running gear
ENGINEERS HANDBOOK
Liner ~measurlna/reconditioninCl)_&M 451/M 4521453 B 02-4-W
RECONDlTlONlNG OF LINER AND CYLBLOCK M 453 IN-LINE
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

than too low.
l+ NOTE
it may not be reused, since its
increased.
z+y = 0.7 mm x P 2.5 mm

z+y = 0.7 mm x = 2.7 mm
z+y=l,7mm x=3.5mm
z+y=1,7mm 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

31. Auaust 1987 I
ENGINEERS HANDBOOK
I Running gear
er lmeasurlna/reconditlonlngI 7+M 451/M 4521453 B 02-4.0.3
RECONDITIONING OF LINER AND CYL.BLOCK M 453 VEE
z+y=1.2mmx=1.5mm
z+y31.4mmx=1.7mm
z+y = 2.2 mm x = 2.5 mm

Chamfer bebw
z+y = 2.4 mm x = 2.7 mm
z+y = 3.2 mm x I 3.5 mm

z+y 3.4 mm x = 3.7 mm

than too low.

it may not be re-used, since its
increased.
z+y = 0.7 mm x = 2.5 mm

z+y = 0.7 mm x = 2.7 mm
z+y=1.7mm x=3.5mm
z+y=1.7mm 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
Liner 1.7 mm as standard.
1.60.6-16.11.01-06
machined true
(liner in cyl.block)

31. August 1987
Liner (measurlnalreconditionina) ZtM 451/M 4521453 B 02-4.0.4
RECONDITKINING OF LINER AND CY. BLOCK M 453
Limit- measure for re-con 1-I 0,03 1AB

N
peat+ IO- valley nelgnt 25
-
1.60.6-16.11.01-13
Sealing ring below the liner collar see Sheet -4.0.2-3
31 .Januaryl988 KRUPP MaK MASCHINENBAU GMBH

I Running gear
Liner (fittina) Z+M 451/M 452/453 B 02-4.1
fvl451/452f453
-==I !
,
,
,
/
,
/
/
{
/
/
L
4 I
/ 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

=I ENGINEERS HANDBOOK
Piston Din and bush. fittina and removal B 02-5.4
PISTON PIN RFMOVAVFIllI&
Manu- Min.- Max.- Turing

New and wear dimensions
fac- Limit Limit clear
dimen.
Piston pin Piston boss-0
;;;o 0,005 - 0,03 0,06
(Al piston) Piston pin-0
Piston Conn.rod-0 135:17
0,16 - 0,2 0,35
bearing Piston pin-0 135,o
End play Boss distance 130,35
0,25 - 0,65 0,8
X Bearing length 129,9
Removal
If the piston pin cannot be removed by hand, heat piston to approx. 80C. Do not use force!
If heat had to be applied for the removal, again heat piston head to 80C. Supercool pin if necessary.
Piston must be measured in TDCRlDC position.
Measure play a and b. The max. difference of these lateral clearances

31. August 1987
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. - 60C.
Check at standard temp. (20C) the oil drilligs, the oil groove
position and the dimensional accuracy P diam. of the piston.

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!;
1.60.7-28.10.00-l 1 II 1
4,
.63.7-28.10.00-
1.00.7-88.50.51-16 1.00.7-88.50.51-15
(nozzle plug) (screw plug)
NOTE: Shut-off nozzle or screw plug is secured by 4 x centre punching.

piston assemblv (built-uD Distonl B 02-5.1

PISTON TOP Fll-TlNG M 452/M 453
2. Assembly of the piston top 2. Assembly of the piston top
Manufacturer: m (Mahle) Manufacturer: SK (Kolben-Schmidt)
Applicable 00-06,00-07,00-10, Applicable 00 - 08,OO - 09, 00 - 12,

to variant: 00-11 to variant: 00 - 13
2.1 If necessary, screw the studs 2.1 If necessary, screw the studs
into the crown and tighten them with a into the crown and tighten them with a
Torque q 40 Nm Torque = 80 Nm
2.2 Insert a new O-ring in the groove without 2.2 Insert a new O-ring in the groove without
twisting it and coat it with soft soap or tallow twisting it and coat it with soft soap or tallow
2.3 Put the skirt on (the centering hole and pin 2.3 Put the skirt on (the centering hole and pin
must coincide) and place the extension must coincide) and place the extension
bushes over the studs (crowned ends bushes over the studs (crowned ends
towards the piston crown). towards the piston crown).
2.4 Tighten the nuts twice consecut ively with 2.4 Tighten nuts crosswise a
Torque = 65 Nm Torque = 110 Nm
torque of and slacken again. and slacken again.

2.5 Then tighten finally with torque of 2.5 Check the screwing-in of the studs.
2.6 Pretorque the nuts crosswise with a
Torque q 25 Nm
2.7 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 Smear threads and contact faces with
Molykote paste Gr-n. Molykote paste Gr-n.
JMPORTANT REMW
between piston crown and skin should be measured with regard to the following facts:
The clearance
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
LIMIT CLEARANCE = 0.19 mm
(Refinishing only possible at the manufacturers!)

4
piston assembly Ibuilt-yg piston) B 02 _5.1 .l

PISTONTOP FIJTNG M 453 C
2. Assembly of the piston top
Manufacturer: m (Mahle) Manufacturer: SK (Kolben-Schmidt)
Applicable Applicable 00-17,00-18,00-21,

to variant: 00 - 23 to variant: 00 - 22
2.1 If necessary, screw the studs 2.1 If necessary, screw the studs
into the crown and tighten them with a into the crown and tighten them with a
2.2 Insert a new O-ring in the groove without 2.2 Insert a new O-ring in the groove without
twisting it and coat it with soft soap or tallow twisting it and coat it with soft soap or tallow
2.3 Put the skirt on (the centering hole and pin 2.3 Put the skirt on (the centering hole and pin
must coincide) and place the extension must coincide) and place the extension
bushes over the studs (crowned ends bushes over the studs (crowned ends
towards the piston crown). towards the piston crown).
2.4 Tighten the nuts crosswise a 2.4 Tighten nuts crosswise a
Torque q 100 Nm Torque = 70 Nm
and slacken again. and slacken again.

2.5 Check the screwing-in of the stud. 2.5 Check the screwing-in of the stud.
2.6 Pretorque the nuts crosswise with a 2.6 Pretorque the nuts crosswise with a
2.7 Tighten the nuts crosswise through an 2.7 Tighten the nuts crosswise through an
Angle = 180 Angle 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
Smear threads and contact faces with Smear threads and contact faces with
Molykote paste Gr-n. Molykote paste Gr-n.
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 SERVICE DOCUMENT OF 4.

ENGINEERS HANDBOOK
I 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
Also applicable
pth 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

JW 1%outand arooves
I
B 02 _52
t 451 Groove Standard Oversize Design Coding Groove width

max.
Liner, Trapezoidal
chromium- I 9,6 mm 10,6 mm washer 01-18 +0,12+0,02
plated 0.00.6- 11,6 mm 01-19 also applies to
35.41 .oo-71 12,6 mm Plain 01-20 2nd groove
NOTE: compression
Chromium II-N 8,0 mm 9,0 mm ring 01-14 + 0,08+0,02
or soft- 35.41.01-04 10,O mm 01-15
nitrided
piston rings V 8,0 mm 10,O mm Gas 01-16 + 0,08+0,02
compressor
must not 35.41 .Ol-08
piston ring
be used!
liner, I 9,6 mm 10,6 mm Trapezoidal 00-55 +0,12+0,02

soft nitrided 35.41 .oo-05 11,6 mm washer 00-56 also applies to
12,6 mm (chromium 00-57 2nd groove
-plated)
II-IV 8,0 mm 8,75 mm 01-34 + 0,08+0,!2
35.41 .OO-06 9,O mm Plain 00-58
9,5 mm compression 01-36
10,O mm ring 00-59
11,0 mm 00-60
Gas
V 8,0 mm 10,O mm proof 01-16 + 0,08+0,02
35.41 .Ol-08 piston ring
Ring VI 35.41 .Ol-06 Oil scraper ring

layout Slotted,
for both VI 35.41 .Ol-07 taper-face + 0,08+0,02
oil control ring
Limit wear for all ring

grooves = + 0.40 mm
l If 50.8 dimension cannot

be observed with oversize ring,
wear ridge in liner must be
equalized.

ENGINEERS HANDBOOK
I Running gear
Pina lav-oul and arooves B 02. 5.2-t
M 451 Groove Standard Overslzs Design Groove width
Cast piston Plain +O,OEfO,Ol

(old + new I 8,0 mm 8,75 mm compression 01-34 also applies to
combustion 0.00.6- 9,0 mm ring 00-58
2nd groove
chamber 35.41 .OO-06 9,5 mm 01-36
(with chromium
type) 10,O mm 00-59
-plated crown)
TIP: 11,0 mm 00-60
Chromium
ring in the II-IV 8,0 mm 9.0 mm Compression 01-14 +0,06fO,Ol
the ring 35.41 .l l-l 1 WI
groove!
increases V 35.41 .Ol-09 Oil 0,04 to 0,07
the life of scraper ring
max.
Al piston I+11 Plain 01-34
8,0 mm 8,75 mm +0,08+0,02
(with and compression 00-58
0.00.6- 9,0 mm +0,06+0,02
without ring ring 01-36
35.41 .OO-06 9,5 mm
carrier, (with chromiurr 00-59
10,O mm
old and -plated crown) 00-60
11,0 mm
new corn
bustion 8,0 mm Compression 01-14
II-IV 9,0 mm +0,06+0,02
combustion
35.41.01-l 1 ring +0,04+0,02
chamber
Slotted,
type) V c = 350 rpm 01-07
taper-face
oil control ring
> = 350 rpm 01-09 +0,06 to 0,08
Oil scraper ring
soecial note: New combustion chamber type since start of 1969.
Limit wear of all ring grooves t + 0.40 mm

4

31. August 1987
and aroovesR 02 *5&i?
M 452 -Standard Oversize Design Marking Groove high

I
41 piston 8,75 mm Plain
8,0 mm 01-34 + 0,08 + 0,02
with a ring I+11 9,0 mm compression
0.00.6- ring (with 00-58 + 0,06 + 0,02
#srier) 9,5 mm
35.41 .OO-06 chromium- 01-36
10,O mm
plated crown) 00-59
11,0 mm
00-60
9,0 mm Compression 01-14 + 0,06 + 0,02
III-N 8,0 mm
35.41 .01-l 1 ring + 0,04 + 0,02
c - 350 Ulmin Slotted, 01-07

v
> = 350 U/min taper-face I
oil control ring 01-09 + 0,06 bis 0,08
Oil scraper ring I
J3ina aroove wear measurerwd

Piston ring Height of groove hN Limit clearance
height hR Wear limit nN-hR (mm)
Nominal size measure (mm)
(mm)
6 6.3 0.4
8 8.3 0.4
10 10.2 0.3
valid for piston rings in series!

I
Running gear
ENGINEERS HANDBOOK
ping lay-out and amoves B 02~5.2.2-l.
M 4521453 Groove Standard Oversize Design Coding Groove width
Plain
11piston l+R 8,0 mm 675 mm compression 01-34 + 0,08 + 0,02
(with 0.00.6- rins (a 00-58 + 0,06 + 0,02
fuplex ring 35.41 .OO-06 2;, z chromium- 01-36
carrier) lo,0 mm plated crown) 00-59
00-60
ll mm Compression
III - Iv 8,0 mm 9,0 mm ring 01-14 + 0,06 + 0,02
35.41 .01-l 1 Slotted,
taper-face
oil control ring 01-07
V <=35Orpm
Oil scraper ring + 0,06 bis 0,08
>=350rpm
Plain 01-09
compression
I, 11+111 8,0 mm ring (with
chromium-
plated crown
IV 8,0 mm 9,o mm Tapered 01-26 + 0,04 + 0,02
10,O mm compression 01-27
piston ring
(Fitting
position: note
V TDC)
Narrow-
land drain oil-
control ring 01-23 + 0,06 bis 0,08
withgarter
spring
Al piston, I+11 6,0 mm 6,75 mm Plain Top + 0,08 + 0,02

luplex ring 0.00.6- 7,0 mm compression 01-38 + 0,06 + 0,02
arrier with 35.41 .Ol-28 7,5 mm ring (chromium- 01-39
LO mm 8,0 mm plated) 01-40
grooves 01-41
Plain
compression
ring (with 01-42 + 0,06 + 0,02
01-43
I 8,0 mm 8,75 mm chromium- 01-44
0.00.6- plated crown) 01-45
35.41 .Ol-30 9,O mm Nanow_ + 0,06 + 0,2
g15 mm land drain
10,O mm oil- control ring
with garter 01-31
IV 35.41 .Ol-31 spring Top

31. August 1987 I
ENGINEERS HANDBOOK
I Running gear
layom grooves 8 02 I 5,2.2.2
m 452iIJ452 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 Sharp edges burr
oil groove between II and Ill
Limit wear for all ring grooves = 0.30 mm
Note TDC fitting position of the piston rings.

31. August 1987
l-l .
ENGINEERS HANDBOOK
I
I
Runnlng gear
I
I 14
Ring = = Standard code Groove width

M 452l453 Groove Ring + groove Ring + Ring Ring Original
No groove
Puitt-uo.Diston I+11 6,0 mm 6,75 mm Plain 0138 Variant: -10

Piston top 0.00.6- 7,0 mm compression 01-39 Variant: -11
35.41 .Ol-21 7,5 mm . 01-40 Variant: -12
1 k 26 658/2
(Variant: -09) 8,O mm yifmmium- 01-41 Variant: -13
(42CrMo4v)
var.: -02 - Plated)
III 8,0 mm 8,75 mm. 01-42 + 0,06 + 0,02
1st ring groove 0.00.6- 9.0 mm 0143
flame- 35.41 .Ol-30 9.5 mm 0144
hardened 10,O mm 01-45
Var.: -04 I 11,O mm
1st ring groove N 10.0 mm Narrow- 01-96 + 0,06 + 0.2
land drain oil- 4r
chromium- 35.41.01-31 -97
plated -23 control ring
-87 withgarter
(O-ringseal - spring
255x5mm
dowel pin t
6x20mm)
M 453 (Deviations from the piston top: 1 k 26 658/2)
Piston top Plain

I+11 6,0 mm 6,75 mm 01-38 Variant: -15
0.44.39.8.40- compression
7.0 mm 01-39 Variant: -16
02.04 ring(with
75 mm 01-40 Variant: -17
Var.: -03 I chromium-
(Variant: -14) 8,0 mm 01-41 Variant: -18
1st ring groove plated crown)
flame- NOTE FOR RECONDITfOhING; IMPORTANT NOW
hardened The sides of the ring grooves 1. ff sides of ring groove I are
in the top of the built-up chromium-plated, a plain compression
piston are chromium-plated in ring chromium- plated on three sides must
Var.: -05 I ring roove I and flame- be fiied.
1st ring groove hardened in ring groove II. 2. A ring chromium-plated on three sides
chromium- Reconditioning of worn ring may not be fiied in a flame-hardened ring 4r
plated grooves can be carried out as follows: groove.
(0 ring seal I
Chromium-plating for thickness Limit wear for all ring grooves P f 0.30 mm!
255x5mm
of the sides to standard or
Dowel pin =
oversize (piston top inexchange).
6x20mm)
l Invalid for M 453

Binas 02.5.2.4
M453C Ring groove Standard ring+ oversize Ring Ring mark: Groove
NO. groove ring+gmove design Top! height
Built piston for Rsctangular 6,16 l 0,02

6,0 mm 6.75 mm ring (chromlwrc TOP
gasoil operation
I 0.00.6-35.41 .Ol-32 7,00 mm plated on three
750 mm sides)
6.00 mm chfQmhJmlayer
First ring groove: - 0,30,4mm
flame hardened
6.0 mm 6,75 mm 6,16 + 0,02
Rectangular
1.60.6-26.70.00-l 6 I 0.00.6-35.41.01-71 7,00 mm
dng (chromium
TOP
KS 7.50 mm
Plated 1
6.00 mm
(Piston top : 6.0 mm Compnaaion ring 6.16 mm
0.44.39.6.69-02.01) I (hmmlumplated ) TOP
0.00.6-35.41 .Ol-66 -
lo,06 mm
10,O mm Oil scraper
ml 0.00.6-35.41.01-67 - ring with tube
SPrfng
(chromium-plated)
6,0 mm 6,75 mm 6.16 + 0,02

Built piston for 0.00.6-35.41 .01.70 7.00 mm Rectangular TOP
heavy fuel operation ring (chromium
I 7,50 mm
plated on three
6,00 mm
First ring groove = sides) chromium
chromium-plated iayer I 0.30.6 mm
(Chromium layer = 5
6.0 mm 6.75 mm 6.16 + 0,02
0,25 f 0,05 mm ) Rectangular TOP
I 0.00.6-35.41 .Ol-71 7,00 mm ring chromium
7,50 mm layer - 0.30.5
1.60.6-26.70.00 - 15
6,00 mm
-16 ,
Compression ring 6,16 mm
-17 6.0 mm
0.00.6-35.41.01-68 chromium TOP
KS I
hyer- 0.160.3 mm
Piston top : 10,O mm 10.06 mm
Oil scraper
0.44.39.6.68-02.02 ) 0.00.6-35.41.01-67 ring mth tube
N aP%i
chromium-
phtad I 0.16 mm
Plav attention when refinishina;
The flanks of the ring grooves in the top of the buiff piston are 1. ff the flanks of the first groove am chromiumplaled.
chromium-plated in the first ring groove and fianm hardened in a rectangular ring, chromium-plated on three sides,
the second ring groove. Worn ring grooves may be refinished as must be fitted1
follows: 2. In hame hardened ring grooves, no ring, chromium-plated
on three sides. must fitted1
Chromiumphting of the flank to standard or oversize.
(Piston top in exchange).

Piaton flng
marking
III -wxo
Piston upper pm 6 -0.062
lK42315 -89
I 6.16 + D,D2 I Joint gap - 2.5-2.9I
chromium-plated -87
lo,06 +D,D2 Joint ~apl= 1.25-1.6
rapered compression piston ring
~anufacturerbEo coo Top 1 mPI TK)

41.01- 90.1 1 41.01-932 1 41.01*;3
wmbol I
Riken Dams 0,8x 460
_.__._.
mwim nunbbr
L 0.60.6 -36.41 .Ol-91 I

,
I TDp
h
w 41.01- a11
S
Chromium laver min.0,05
t
hnanufacturer Goetze
I
7hsignalim
Tapered compression piston ring
inrm ringQroovs:II+1II(MDO+IFOope~on]
Drwi~nurher
0,3..
0.00.6 -35.41.01-89
Chromium lay
NOTE
In general this ring hard-facing is only
applicable to new buildings, conversions and
repair! Regardless of the type of rings
previously mounted!

Wn 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
exhaust valve pocket!).
- coding of big-end bearings: vertical figures I camshaft side

horizontal figures = exhaust side
- ring cut distribution.
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)

Piston fittina and removal B 02 I 5.3.1
PISTON RFMOVAL M 453
Cross-piece for removing piston (6.9125 A)

Cylinder liner hold-down equipment (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)

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 v
M 453 R
6.9125 A
\6.9126
Position of the oil outlet Position of the oil outlet

for piston cooling with for piston cooling with
main direction main direction
k2f.t Kklht
with port engine on exhaust side with port engine on camshaft side
with starboard engine on camshaft side with starboard engine on exhaust side

ENGINEERS 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,
Edition SERVICE DOCUMENT OF 4

31. August 1987
I Engine housing
I
MDlate. box fm 03-l .Q
Tightening moment for bolts

Md = 400 Nm (40 kpm)
Lubricant : Molykote Paste G
M24x160mm M24x 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!

31. August 1987
ENGINEERS HANDBOOK Englna housing
M4511452 Ina B 03-l .O.i
Engine housing bolt

thread = on both sides M 39 x 3
Total length = 270 mm
(42 Cr MO 4V)
Tightening torque
T 1300 Nm (130 mkp)
Cap nut ( salt bath nitrided)
m39x3SW=41 b-J /
lubricant : Mofykote
( paste G)
i
QK
tightened by hand (50 Nm)
+120 a
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 View on flywheel side
Edition
30 . September 1990
SERVICE DOCUMENT OF
1-
ENGINEERS HANDBOOK
I Engine housing
Founw M 45114571453 R 03 _1.2
Foundation plan Dimensions of the base plate
In-line engine View A
Vee engine View A
I I
I-L
u b
e---r
510
J
----t--~-
a
Engine type A B Fiied bolts Found. bolts Thread Touque**

6 cyl. 3006 2250 4 24 M 24 500 Nm
6 cyl. 3906 3150 4 32 M 24 500 Nm
9 cyl. 4358 3600 4 36 M 24 500 Nm
12 cyl. 3650 2850 6 20 M 33 1350 Nm
16 cyl. 4790 3990 6 28 M33 1350 Nm
t
Material - tensile strength 142 CrMo4V 1 8,8 1 **bolts lubricated
*These holes at each side of the flywheel end must be holes fitted bolts.

ENGINEERS 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) Necked-down bolt

1.50.7-l 1 .10.07-02 with oversize
-03 (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 Necked-down bolt

1.50.7-l 1.10.07-05 with oversize
Stand by -08 (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.

tinder block 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)
Caped nut
(M30x2)
Screw- in of the stud bolt as Washer

usual only 195 mm high
\
Necked-down bolt (M 30)
1.50.7-l 1 .10.07-l 2

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
4

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)

ENGINEERS 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.

31. August 1987
tenlng Instructions for tiebolt$ hvc&, tools B 03 . 1.49
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

ns for tlebol~dr. tools B 03-l .4.?
ntna seauenca;
Tighten tie-bolts in pairs in the numbered sequence:
.
1st stage: 407.5 bar (415 kplcm2) 2nd stage: 815 bar (830 kp/cm2)
applies to 16 cyl. engine
4

31. August 1987
ENGINEERS 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
Equalizing plate -
flush-ground
with the flange
facing of the
gear box
/
10x60 During mounting pin hole
DIN 7977 bored 0 10 x 44 deep and
reamed by taper-pin reamer
3. 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). .

Mid ENGINEERS HANDBOOK
I Engine housing
end cover. flwd 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)

ENGINEERS HANDBOOK
Timlna aear train inspection B 04 -1.Q

Every 2 500 operating hours - visual inspection
Every 10 000 operating hours = visual inspection, measure back-lash on the gearwheels and running
clearance
Back-lash on Limit clearance

(rt-N gearwheels (r-nrr-4
eatwheel on crankshaft - large intermediste wheel

0,20 - 0,28 I 04
small intermediate wheel - gearwheel on camshaft
0,13 - 0,20 I 093
camshaft gear - governor drive gear
0,20 - 0,25 I OS3
geearwheel on crankshaft - pump drive wheel
0,20 - 0,28 I 0,4
pump drive wheel - pump pinion
0,20 - 0,25 I 093
Measure diametral clearance with feeler gauge or dial gauge.
Diametral Limit
clearance clearance
(rtJr@ (t-nr-4
lntermeediate wheel 0,17 - 0,24 093

Gearwheel on cam-shaft 0,l - 0,15 0,25
Pump drive wheel 0,05 - 0,l 0,25
If limit clearance is reached, replace bearings.

Measure end clearance with feeler gauage or dial gauge.
Axial Limit
clearance clearance
(rtw (mm)
Intermediate wtieel 0,15 - 0,45 086

Pump drive wheel 0,15 - 0,35 0,5
II limit clearance 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 l

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

I
ENGINEERS HANDBOOK Ttlming gear
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
31 .January1988 KRUPP MaK MASCHINENBAU GMBH

I -
ENGINEERS HANDBOOK Trlmlng gear
ar drive Incl. aear wheel B 04 -1 .lS
Gear drive adjustment 7 451

..
Port m (clockwise)
Piston1 in TDC 42 451 :1-S-2-4
6Z 451 :1-5-3-4-Z-6
8Z 451 :1-6-4-7-Z-5-3-8
9z 451 :l-6-9-Z-4-8-3-5-7
-7 lntermediatb pear wheel \
Crankshaft gear wheel

I

ENGINEERS HANDBOOK Trimlng gear
Gear drive incQ&ar wheel B 04-l .l .a

Gear drive adbtment 7 451
Piston 1 in TDC
Back lash see port design

ENGINEERS HANDBOOK
Timlna aear train inclgear setting B 04-l .I.4

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

I
I Trimlng gear
I 4
Timina aear train Incl.aear settlna B 04-1.1.5
j6 M 453 GFAR SFTIING FOR SHORT INTFRVAI I FIRING

I I: -
ENGINEERS HANDBOOK Trimlng gtsar
-
drive a-1 B 04-l .l&

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
-
Double l-
After 8Ilgnlng the bearing bra&et (backlash) the fixing bolts

-End of engine housing
M 20 x 55 SK (material: 10,9) am tightened with Ml - 300Nm
(3Okpm)andlockedbyawireof2mm0.
Lubrfcanc Molykote 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 Befor assembly running
0.15 mm, the bore in the double w-147- surface poliihed with emery.
gear wheel must be reground.
REMARK: 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
30 . September 1990 KRUPP MaK MASCHINENBAU GMBH

. *
Camshaft~.&RLWJ
Tools:
High-pressure hose 0.9205-B
High-pressure pump 0.9204-D
High-pressure Pipe Osgl 34-G camshaft
Hook spanner for slotted round nuts 6.9230
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 1. 100 Nm (initial moment)

M 451
452/453 2. 1200 angle of rotation
Frame economy 1. 100 Nm (initial moment)

M453
Fuel pump 2. 240 angle of rotation
plunger: 26 0
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.

ENGINEERS HANDBOOK
Camshaft bearing
Molykote G-Rapid paste
Bearing retaining bolt must be secured with wire!
Bearing play
New play Limit play
mm mm
2 0,lO 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.

Information for service Stations
After Sales Sedice internal : 4
Eng.-Type: M 453 Info.-No. 031

Smirr KT 23 1 28.02.1992 .
Tigtenina 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
i
The tightening torque of 80 Nm stated in the operating instructions sheet

04.01 .Ol is not applicable any more.
e
MONTEUR-HANDBUCH
I Motorsteuerung
4 B 04-l .4
SPLIT FUFL CAM FOR REVERSIBLE ENGINES

(repair cam) M 451,452,453 in-line
and V
Old design Standard model

Engine n Stroke Repaircam (split)
Engine (conicalonbase) (hydraulically
mounted)
I
M 4511452 20,6 1.60.7-32.30.01-02 1.60.7-32.32.01-04

-32.30.01-08 1.60.7-32.35.00-25
l.
l.
32.30.01-13 -32.35.00-31
M451/452 376-450 20,6 1.60.7-32.32.01-04

-32.30.01-08 1.60.7-32.35.00-26
l*
l * 33 30.01-13 -32.35.00-32
M 452 300-375 24 1.60.7-32.30.01-03 1.60.7-32.32.01-01

-32.30.01-05 1.60.7-32.35.00-27
rr
** .I
-32.30.01-10 -32.35.00-33
M 452 376-514 24 1.60.7-32.30.01-03 1.60.7-32.32.01-01
-32.30.01-05 1.60.7-32.35.00-28
l.
l*
-32.30.01-10 -32.35.00-34
till
end1981 1.60.7-32.32.01-02
M 5oo-600 24
=32.30.01=06= 1.60.7-32.35.00-29
452M from start
32.30.01-09 =32.35.00=30=
453R + 1982
I* -32.30.01-10 * 32.35.00-35
500-599
l
M453R+V 600-650 24 1.60.7-32.30.01-11 1.60.7-32.35.00-36
M 453 for C-tYPa

26 1.60.7-32.30.01-14 1.60.7-32.35.00-37
engtne
economical version
I I I
**stand-l
Duringassembly attention
must be paid to clearanceof the
headsscrew(senseof rotationabead and astern).To be
refinished
ifnecessary.
rq
Edition SERVICE DOCUMENT OF rrr

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
Engine Stroke Old design Standard model Repair cam

(conical on base) (hydraulically mounted (split)
M 451 17 I .60.7-32.30.01-01 1.60.7-32.32.01-03 1.60.7-32.35.00-03

stand -by -12 stand -by -05
-07
-11
M 451 I l7 I stand -by -15
1.60.7-32.32.01-04 1.60.7-32.35.00-21
M 451 20,6 1.60.7-32.30.01-02
-12 -04
M 452 stand -by
-08 -06
stand -by -16
24 1.60.7-32.30.01-03 1.60.7-32.32.01-01 1.60.7-32.35.00-23

M 452
-09 -01
-05 stand -by -07
stand -bv -13
1.60.7-32.32.01-02 1.60.7-32.35.00-02
M 452 24
-10 stand -by -08
M 453
-06
R+V 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 (direction of
rotation forward and back) and recut if necessary.
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 kpm).

Repair cam Ifuel. inlet and exhaust) B 04-1.4.2
SPLIT INLFTCAM FOR NON-REIIERSIBLE ENGINES

(REPAIRCAM)
1.60.7-32.12.01-03 1.60.7-32.13.00-02
1.60.7-32.12.01-08 1.60.7-32.13.00-03
M 453 8,16 stand -by -12 stand -by -06
M 453 6,8,9,12+16 18,8 1.60.7-32.12.01-13 1.60.7-32.13.00-07

stand -by -14
M453 C 6,8,9,12+16 18,8 1.60.7-32.12.01-15 1.60.7-32.13.00-08
NOTE ON ASSEMBLY: TIGHTENING INSTRUCTIONS:

Care must be taken when Treat thread and bolt on the
assembling the cam on the contact face lightly with
camshaft that the clamping sleeve Molykote Paste G. Pretighten the bolt
fits at the edge shown in the graph . manually and tighten it mutually in small
steps with 140+10 Nm (14+lkpm)
\
M14x45DIN912

cam (fuel. inlet mexhaustl B 04 _1.4.8
SPLIT JNI FT CAM FOR REVERSIBLE ENGINES

(REPAIRCAM)
Engine Number of Stroke Standard model Repair cam split
c
cylinder
M 452 639 18,5 1.60.7-32.10.01-05 1.60.7-32.13.00-23

M 453 6,8,9,12 + 16 18,8 I stand -by -12 stand -by -27
M 452 8 20,7 1.60.7-32.10.01-06 1.60.7-32.13.00-21

M 453 stand -by -13 stand -by -25
M 452 699 20,7 1.60.7-32.10.01-07 1.60.7-32.13.00-22

M 453 6, 9, 12 18,8 -08 -23
18,8 stand -by -12 stand -by -27
M 452 8 18,8 1.60.7-32.10.01-09 1.60.7-32.13.00-24

M 453 8, 16 stand -by -11 stand -by -26
6.8.9.12 + 16 18.8 -14 -28
) M453C 6,8,9,12 + 16 18,8 1.60.7-32.10.01-15 1.60.7-32.13.00-29

Drill t ole for pin In camshaft
with jig 00.00-2683
M 8 x 35 DIN 912
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).

I I
air cam (fuel. inlet! 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
J4OTF ON ASSEMBLYt_ JlGHTENING INSTRUCTIONS:

Care mustbetakenwhen Treat thread and bolt on the
assembling the cam on the contact face lightly with
camshaft that the clamping sleeve Molykote Paste G. Pretighten the bott
manually and tighten it mutually in small
steps with 140flO Nm (14klkpm)
M14x4SDIN912

I Trimlng gear
Reoair cam Ifuel.

inlet and exhaust) 6 04-l .4.5
SPLIT OUTI FT CAM FOR REVERSIBLE ENGINES

(REPAIRCAM)
Standard model Repair cam split
215 1.60.7-32.20.01-05 1.60.7-32.23.00-25*

-04 stand -by -28*
stand -by -14 -24
stand -by -27
22,5 1.60.7-32.20.01-07 1.60.7-32.23.00-24
-14 -27
M 452 22,5 1.60.7-32.23.00-23

I I
6, 9
I
1.60.7-32.20.01-06
-12 -26 I
M 452 6,8,9 22,8 .1.60.7-32.20.01-11 1.60.7-32.23.00-25

M 453 I 6,8,9,12,16 -13 -28
22,8 1.60.7-32.20.01-15 1.60.7-32.23.00-29

I
25 1.60.7-32.20.01-09
-08
Drill hole for pin in

camshaft with jig 00.00-2683
M 8 x 36 DIN 912
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).

MAC ENGINEERS HANDBOOK Triming gear
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
6
7
Position at Position
start of setting 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 6cyl. 6 cyl. 9 cyl. 12 cyl. 16cyl.

---p-v- ----- ----
reversible 8D 17030 17030 8 17030
non-reversible CP OD 00 00 00

31. August 1987
I
peversing B 04-M
FtFVFRSlNG RFMOVAI RITING
1L = b-c-a+0.3 in-line enaine I

I L = b-c-a Vee enaine
Pinion shaft 6 Axial deep-groove ball

O-rings bearing 7 Distance bush
Deep-groove ball bearing 6 Cover
Ring 9 Cover
Piston 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

Reversing 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).
capacity
approx. 2,2 I
ii ii

mvers&ya 04-l .6.2
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

l=P
or astern
2-A
3=B
4-z
5-Y
Engine will be reversed 6=C
N ahead or astern

31. August 1987
I 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
With correctly adjusted back lash
gear box.
the flanks of tooth must be flush.
M6x 1dSK
-.
8
\. h I/ I
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.

L
3l.January1988 KRUPP MaK MASCHINENBAU GMBH
u
m
C
rechtsdc
Motor
c
Ldhnsp iel : Kegetradpaar Mehe Einstellanweisung 1

Stirnradpaar = 0,2 mm titenz Japan
pJ_
>efct
OT4
M452iMdS3 2 9272
-__ -
_ . , ..,
.---
. .-._-
31
.a
:
_. ._ _____-
-.- --- --- 1
153.5 \ \ *
trhnrpicl:
m
St
20. STeil224,33
EinsteNanweisung ftir Reglerantrieb M452 I M453
fh UG8-Regler und Rc?gulateur Europa Typ 1104
ingelnberg Zyhto - PaIIoid-Verzahnung I
Reglerantriebnach 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 ge-
lagerten Welle. in horizontater Richtung (Man X 1 und Wahl der
Spiondicke *.:i?, yertikaler 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
Tragbildfalsch Tragbildrichtig Tragbiid falsch Tragbi id ril
Abb.3 iiijhenverlagerung des Abb. 4 tangsvertagerung des

fragbildes 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 c;
Distantsttick Pos. 8 = x
d. Reglerant rieb komp\c montieren
J
--JI I. c3 e7
-- _- I
MaId ENGINEERS HANDBOOK
I Control
44
Govern-1 _
GOVERNOR I INKA= 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

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: the stop position of the governor and the 0 position (+ two mark)
of the control rack must coincide and be set accordingly!
Edition SERVICE DOCUMENT OF I

ENGINEERS HANDBOOK Control
vernor drive and linkaae B 05 I 1 .lJ
IJJed grovenor path (type UG 40 L)

A4 a4& Q
lOO--38 I I I
go--36
Control rack path (mm)

of the injection pump
I I I I I I I I I I I 1 I I I I I I I ; I I t+
0 2 4 6 8 10 1214 16 18 2022 24 26 2830 3234 36 38 404244 46
lever in mid- position
bore and lead- sealed
Speed lever

31. August 1987
==I ENGINEERS HANDBOOK
Governor drive and linkaae B 05-l .1.9
KAGF. Heinzmann E 16 I E 30 M 463 Vee
Centre position
I
1~111IIIIIlIIIliiiii~iiii
0 2 4 6 810121416182022242628303234363840424446 I
Setting of injection pump (mm) 5:
1 0
Centre position A 90 angle should be reached at centreposition

max. setting between governor lever and spring member.
Drill and lead spring member after the setting.

4,
.
Governor drive and ilnkaae B 05 _1 .I.4
GOVERNOR EGB - 13 M 453 Vee
0 h
Spring member length
A3
84
A2
!?Y
82
traval (mm)
of the injection pump
I
I,~,lllIIlIllllIllllIII~
0 2 4 6 8 1012 1416162022 24262830 323436384042 44 46

L
vernor drive allnkaae 6 05 _1 .l .fj
GOVERNOR PGA-12 M453Vee
NOTE: Gavernar stroke 0 = 0 uD
0 2 4 6 8 101214161820222426283032343638404244~ f
Setting of the
Lever on Lever on the intermediate injection pump
. ..
governor

I
SDeedmeraency stpp. limitatior\

pf sema accordina to charge air B 05-1,2
LEVER FOR SPEED SETTING

WOODWARD GOVERNOR
Dowel pin
5 x 12 DIN 1481
1 Actuator
2 Piston rod

I
eed seana. emmncv stop. limitation Of

Settlna according to charge air B 05-1.2.1
Torque on nut (7)
Md= 7NmI (M 282133 l/332/452/453/551 I552 R)
71 (M 552 V, 601)
Torque on nut (8)
IMd = 12NmI

31. August 1987
.
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 + 70C
Design: bronze casing
Working and inner parts of
stainless steel
PRESSURE - TRAVEL DIAGRAM
Pressure at connection
6
Pressure -travel curve (control range) 5
can be adjusted by set screw X 4
anywhere between max. 1.5 - 6.011~0.3
bar and min. 0.2 - 4.7kO.3 bar,
but only in parallel. 5
Rotation to right I: pressure rise
Control accuracy: stepping max. 1%
hysteresis max. 3% OiZ3~56
(calculated on the differential pressure)
Travel on the roller in mm CI_)
31. August 1987

Exhaust system/
ENGINEERS HANDBOOK Supercharglng
Exhaust system. supercharaina B 06-l .O
Three-pulse supercharging 6 cyl. (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
\'
I
A5,A2
A3,AL @
85.82
Three-pulse supercharging 9 cyl. (Firing sequence: 1.3.5.7.9.8.6.4.2)
1
9 e
ai3
Crankposition
3
6
27
4 5
Four-pulse supercharging 8 cyl. (Firing sequence: 1.4.7.6.8.5.2.3)
5A
CD 2.7
6.3
Crank position 4.
Four-pulse supercharging 16 cyl. (Firing sequence: Al .A~JI~.A~.A~.A~=A~.A~)

81.B4.B7.86.B8.B5.B2.B3)
Crank position
4.

31. August 1987
I Exhaust system/
Supercharglng
maust system. smraina B 06 I 1.0.1
PJR-RORNFNOW=- MFASURINGSHYI
k&stslls~~plan:
Leistung/Output: 300-330 kW/Cyl.
hawing point d*gnm:
Drehzahl /Speed: 600 r.p.m.
-_
I f
1 ii
-@_ _ ,L -I+- J+*.
I -tl~dW
M&N: Priifstand
z,mm- Place: Test bed
El
+_yij-
I
/ i
+ Im + I MeRergebnisseiMeasuring results
Irn -t
I+
_@_._ - -:+qc*
I 4.
; P
3 -wt
-Wpm
-0
I
HbuluI- 6ntomntdl-nnoh
LbaitqpDn1-8ti.IMnpFnpwd Schwungrad/Flywheel
Oktavpegeldiagramm: Octave level graph:
In dlesem Dlagramm sendjewells die rnaxtimalenund rnlntmalen The max ahd rnfin octave levels of all 7 measuring po~nlshave
Dkravpegel alter 7 MeRounkte durch Lvwnzuge verbunrk~n been connected by lines in the graph
120 - 1 I 1 t
t 110
L c---
HA 4+
IdB] 100 -. 1 w-
F4
4
.
OH +H
,--=-------------- _L-__>L___.
90 -
\
\
80 -a
\
5o,..,TI*.-.........,...........
rn
c Z 8_Z#8# %
8 !3 j 8
6
Oktavmittenfrequen2 fm
WI -_)
Octave average frequency fm

Exhaust system/
ENGINEERS HANDBOOK Supercharging
mhaust gas turbocharaer B 06-l .l_
Before washing is started, engine power must be reduced. (Waste gas temp. after cyl. c 250%). The drain cock
of the turbocharger must be opened.
BBC charger
Washing time 5 minutes
Water pressure 1 bar
Charger type VTR 250/251 320/321 400/401 500/501 630/631

Water flow Vmin 5 a . 12 19 30
RR charger: set water pressure to 0.5 bar and wash for approx. 5 min.
Napier charger:
Wasing time 5 minutes

I
Water pressure 1 bar

I
Charger type NA 455

Water flow I Vmin I 12
0.5 or 1.O bar 4
4.

31. August 1987
ENGINEERS HANDBOOK
s turbocharaer B 06 _1 .l .l
EXHAUST GAS TURfJCCf-fARGFEL SCRFPN TRAP M 451/4Z2U%
Insoection: after 2500 operating hours 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 screen
Tubine 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.

I Exhaust system/
Supercharging
-lDlpe B 06-u
Al IST GAS PIPF WITH EXPANSlQbl JOINTS
0.00.6-41 &LOO-01 1.00.6-66.50.01-37

-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.

31. August 1987
ENGINEERS HANDBOOK
IExhaust system/
Supercharging
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
AN Scavenging pump 6 m3/h, 2 bar

A Fitter NB 40
W Tank volume 0.7 m3
a Filling connection RlR
b Level control R 314
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.

31. August 1987
ENGINEERS HANDBOOK
MD0 system > 7cSWWC
BA Feed pump FP Pre-fitter

BB Feed pump (back-up) M Fine fitter
BC Feed pump GQ Thermostat
BK Separator pumps HP Separator
BL MC Day tank
DA Final prsheater ( not with gasoil) MD Intermediate tank (not with gasoil)
EO Pre-heater PD Dial gauge
Kl Protective filter SB Spring-loaded non-return valve

ENGINEERS HANDBOOK Fuel system
I
Fuel svstem R 07 . l.Q,l
LUBOlL SYSTW
Bunker tank - day tank
1
100%
*Or.
75% 75% MM1
50%
1 MN
50=x
25%
separate
25%
IIm!iI
6 12 16 24 h 6 12 18 24h 6 12 16 24h
BH Feed pump DK Steam pre-heater

FO Protective fitter ER Thermal fuel pre-heater
MA Settling tanks I + II W Fitter station, see text
BK Separator pump NN Day tank (heavy fuel)
HQ Separator MC Day tank (diesel fuel)
EJ Electric pre-heater

Fuel q+!skmB 07 I l.Q2
HFAVY FUFl SYSTFM

Day tank motor (z- 180 cSt)
r-
I
t
v T
MC
t---____
+-
M HR (FR)
-I, -
MC Day tank (diesel fuel) DJ Steam pre-heater

tm Day tank (heavy fuel) DS Thermal fuel final
BY Heavy oil pressure pump FR Automatic reversible
pre-heater (> 180 cStf50C) see text
PD Fuel measuring gauge flow filter, HFI Viscosity controller
tm Mixing tank (> 180 cSt/80C) FQ Duplex fine filter
Ml-f Mixing pipe (< 180 cSt6OC) KP Main engine
8M Centrifugal pump KR Auxiliary engine
EL Electric pre-heater

31. August 1987
mction DumD. Setthy R 07 _1.i
JNJFC-WN PUMP M 45m 4%
After assembly the control

rack & be easily moved!
A control rack without
lubrication must be greased
at weekly intervals when operational!
1 Baffle bush
2 Mounting flange
3 Bucket tappet
4 Circlip
5 Lower spring plate
6 Plunger
7 Spring
9 Control sleeve b-4
10 Spring plate
14 Control rack
/
15 Set screw
17 Discharge union
10 Delivery valve (opening p - 5.5 bar)
19 Spring
21 Barrel
22 Flange
I/
25 Flange bolt
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).

31. August 1987 I
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
Drilling shown rotated by 25 r

\
A L -T I
A
SEQUENCE OF OPERATIONS:
1. Dismantle pump
(do not dismantle pump element)
2 Recondition housing and zI

control sleeve 4
=
I
3. Clean parts and re-assemble pump.
Control sleeve A-A

31. August 1987
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 M452 M453

not supercharged supercharged
campitch 17 20,7 20,7124 24

Setdmension (y) 10,3 + 0,3 10,3 + 0,3 103 + 0,3 10,3 + 0,3
Ptiningstmke (x) 4-45 48 4,B 865

ENGINEERS HANDBOOK
I Fuel system
.
mtion 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!

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 Leak fuel connection
2 Hold-down
344 Union nuts
5 Adapter
5t7 Discharge unions
8 Connection
9 Pipe
lO+ll O-rings
M 452 0 3 mm
M 453 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&

31. August 1987
ENGINEERS HANDBOOK
mtion valve B 07 . 1.3

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).

31. August 1987
I
zzle cooling 6 07-l .4
NO771 E COOLING M 4571hl45Q

m
fresh water
Nozzle cooling (heavy fuel)
60 Cooling oil pump

BP Cooling oil pump (back-up)
DC Heat exchanger
HO Injection valve
MJ Circulation tank
PG Level switch
SV Spring-loaded non-return valve
l
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).

31. August 1987
ENGINEERS HANDBOOK Luboil system
bboil clrculatlon B 08-l .Q

PRF-HEATFR FOR LUROII SFPFRATOR
For the pre-heating of the luboil by approx. 40C to approx. 90-95C.
Flectrc ore-heater 0
5.6. Pe (kW)
Heating ouiput = kW
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 = ----------- m2
1000
95.Pe(kW)
Steam requirement DQ - ------------------- kg/h
loo0
P 6 8 10 (bar)
__--------_
fl 0.29 0.25 0.21
Thermal fuel throughput 50% greater than lubcil throughput
0.31 . Pe (kw)
Heating area DZ = ---------- m2
loo0
A0 Injection pump (fitted)

AP Back-up injection pump
Cooler
Regulator
Electric preheater
Protective screen
Non-return valve
FJ Fine filter back-flushing

FM Automatic filter
FN Protective screen
HK Separator
I -
LL Circulation tank
1
L
V I RP Oil pressure valve
DQ Steam preheater
DZ Thermal fuel preheater

-ation B 08-l .O.l_

Luboil outlet in the be-
A A
A 81
view AC viewe
-K-
Engine type 6,8,9 cyl.
Possible
connection D E F G H I K N
- -
705 805 585 440 196 255 300 320
- -
Engine type 12,16 cyl.
Possible
A B B CCDEFGHIKLMN
connection
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.

lyboll 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
from engine 4
~++4--+4--/\
\ to engine

-iI circulation B 08-l .O.a
,,/p= t...XI bar
Screen in the suction ling
Pressure settingscrew t
t
Over-oroduction!

31. August 1987
Ahad ENGINEERS HANDBOOK
I Luboil system
I
oil Dump. fima 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)

31. August 1987
Mad ENGINEERS HANDBOOK
I Luboil system
I
n fittina 451/4571453 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.

ENGINEERS HANDBOOK
I Luboil system
eclal armatures 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
Jechnical data
Drive -rotary
Direction of rotation -any
Driving speed I 300-3000 mm-l
rl
u
Ratio =lL3
Piston diameter =7mm
Full stroke =1,5 mm
Ouantity of delivery = 0,057 cm 3stroke
6200~RS (at full stroke)
DIN 625 Total quantity = 4 x 0,057 cm 3l stroke
Inlet pressure P 1 = max. 6 bar.
max. counterpressure *bar
Temperature = 100 c
I Testing oil = SAE 30
Inlet Ro6xl
Return Ffo4 x 0,5
I
6x16
3x2(4 -
DIN1481
30 x
for sorina cuolubncaflon

When
Commissioning the pump.
both 6elscrews must be closed (clockwise)
and then be opened by max.li2 turn anti-
Clockwise). Minimum openings should not
be less than 114 turn. Outlet 3 (SW 8)
Outlet 1 (SW 8)
Outlet 2 (SW 8)

Cooling water
ENGINEERS HANDBOOK system
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) Sea-water pumps GB Charge air temp.

GJ Thermostat valve
2
al
Fresh water cooler
Luboil cooler FA Sea-water filter
DN Charge air cooler LA Sea-chest
GA Charge air thermostat valve
Total rise in sea-water temp. = approx. 13% with full-load operation
Breakdown: Charge air mler -5C

Oil cooler 12C
Fresh water cooler =6C
With charge air thermostat control the sea-water inlet temperature in the charge air cooler must be between 15 ant
20%.

31. August 1987
Cooling water
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.
Disadvantages: 1. large fresh water retooler and luboil cooler.
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

ENGINEERS HANDBOOK
I Cooling water
system
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: SoMs 76 (CuZn 20 A I)

Cooling ribs: Cu tin-plated
Tube sheets: Muntz metal
Water compartments: gunmetal
water-side pressure loss: 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.

31. August 1987
ENGINEERS HANDBOOK
I Cooilng water
system
Fresh water coollna system tcvlinder 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).
Recommended cylinder cooling water outlet temperature 85 f 2C
AK Fresh water pumps CE Heat exchanger

AL DC Nozzle cooling oil heat
AM Preheater pump exchanger DN Charge air moler
AN Manual pump GE Thermostat valve
CL Reccoler GG Thermostat valve for
CF Heat cOnsumer LE Balancing tank
CF e.g. fresh water producer LH Drain tank
Drain tank Pre-heatina (AM+- 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.
Heating capacity (CE) Heating capacity for keeping

for preheating the engine the engine hot at 70C. Engine
from loo C to approx. 70 C room temp.approx.1 OV3OC.
in about 10 hrs. Engine
room temp. approx. 10/300C.
WV I m3h
6cyf. approx.1 a/i

2 approx. 916
819 CYI. 24/l 6 12fa
12 cyl. 26/l a 1319
16 cvl. 34122 17/l 1

Cooling water
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
______ LTar&
-.-.-. sea-water
AcSeawaterpumps DC Nozzle cooling oil heat exchanger

AF DN Charge oil cooler
AK F~~&v.&erpurps CW Three-way diaphragm valve
AL GE Thermostst valve
AM Preheating pump a Thermostat valve
CE Prehater FA Seawater filter
CF Heat consumer heating system IA Seachest
CNOilccder LE Balancing tank
CQ Gear oil oooler KP Main engine
CL Central cooler

Cooling water
I
Cooling watercentr
-09 I
21.
Change axial face seal after 10000 operating hours. CLEARANCE sl
CLEARANCE s
-1
2 CLEARANCE s
I s2 =l,OmmI
BACK-LASH ON GEAR-WHEELS
I 0,2 mm I
1) Screw 8) Slotted ring nut

Pump housing 9) Pressure compensation hole
:; Capped nut 10) Shaft
Pump wheel 11) Gear wheel
z Axial face seal 12) Circlp
Slotted ring nut 13) Ball bearing
z Assembly cover 14) Ball bearing
NOTE: If there is strong evidence of cavitation, exchange pump wheel (4) and if necessary pump
housing (2).
Replace all housing seals.

31. August 1987
I Cooling water
system
Coolina water Diston and bilae Dump B 09-2.2
Remark: 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
Relief valve:
2 x cup sleeves (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).

ENGINEERS HANDBOOK
I
Starting air system
Starting air system B lo-l.1
K KB
Startina air svsteq
KB Compressors
KE Typhon
Fr Air filter
MS Starting air tank
SG Main starting valve
SJ Pressure reducing valve
SK Oil and water separators
Starting air compressor (KB)
The required air flow 0 (I/h) of all compressors must not be less than
cl = 1.7 x I(PA - PE), current formula of German&her Lloyd,

I = total content of the starting air tank (litres)
PA = highest operating pressure in the starting air tank (30 bar)
PE I west operating pressure in the starting air tank, not reversible 9 bar
reversible 12bar
The flow delivered must be divided among atleast 2 compressors.

31. August 1987
ENGINEERS HANDBOOK
Starting air tank B lo-l.2
&rtina air &&..sltes recommended bv Krum MaK tlk
6cyl. 16cyl. cxxmlc?tlt

8~4.
gcyl
12cyi.
Typhon valve
Starting air tank shape B without auxiliary connection
Tank L D0 Weight
capacity
I mm rlml approx. Kl
30 1258 200 70
125 2050 320 180
180 1958 400 220
250 2010 480 1 260
500 3447 480 460
710 2995 650 750
1000 3803 650 900
1500 3703 800 1050 1 Filkgvalve
1650 4023 800 1170 2 Pressure gauge NB 8
4866 800 1500 3 Relef valve NB 7
3316 1100 1650 4 DrainvalveNB8
3000 3876 1100 1840 5 AuxiCary connection NB 8
3556 1500 2300 (by special order only)

31. August 1987
ENGINEERS HANDBOOK
Startina air fx@acitv B 1 O-l .3.
Classifiiion society 1. non-revers- engine 2. reversible ible engine
American Bureau of Shipping (ABS) 12

Bureau Veriias (BV) 12
Det Norske Veriias (NV) 12
Germanischer Lbyd (GL) 12
Lloyds Register of Shipping (LRS) 12
Fiegistro ftaliano Navale (RINA) 12
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 non-
reversible 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)
6 cyl. 8 cyl. 9cyl. 12 cyl. 16 cyl.
non- 389 403 410 431 458

Single-engine reversible
plant
reversible 1693 1752 1782 1872 -
With multi-engine installations these values must be increased as follows:
Twin-engine installation through clutches on 1 propeller, factor 1.5

l
Twin-engine installation, two propellers factor 1.5
Two twin-engine installations through clutches on two propellers factor 2.0
. -

31. August 1987
MA ENGINEERS HANDBOOK
I Starting air system
Master startlna valve M 4521453 B 10-2.1
screw (7) with Md = 350 Nm
screw (1) with Md = 24 Nm

El
(Lubricant: Molikote paste G-Rapid)
HYDRAULIC STARTING AUXILIARY
(1) Air lines

(2) Oil lines
(3) Check screw
(4) Cover (see figure)
(5) Piston
(6) Nuts
(7) Cover
(8) Spring

ENGINEERS 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.

ENGINEERS HANDBOOK Ancillaries
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

I 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).

31. August 1987
Air comrxessor B 12-1.3
AlPi CQMPRESSOFlAWNUW
Dismantle every 10 000 operating hours for an internal overhaul.
Compression spaces:
-1
LP delivery valve LP suction 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.

ENGINEERS HANDBOOK
/dir compressor B 12-1.3.1
Air compressor (internal overhaul) I 10 000 h
;roup Wear parts Manufacturing Minimum Maximum Limit Limit wear

dimension clearance clearance
iommpressor
Big-end 5502
bearing 0
Big-end 0,03 - 0,09 0,3
bearing bolt 0 54,96
Small-end 30,03 120,4

itage I bush
Piston 0 0,02 - 0,05 093
bolt 0 30,o 119,6
Cylinder 0 120,09 108,3

itage II
0,14 - 0,23 O,5
Piston 0
119,9 107,9
0
iston-rings Cylinder 108,09
0,14 - 023 0,4

Piston 0 107,9
Piston grooves
I-VIII 4,04
Piston rings 0,04 - 0,07 O,2

I-VIII
3.98
Oil scraper 6,04
ring
0,04 - 0,07 0,2
Piston
grooves X 5,98
cut slearance
1 for all rings 0,55 - 0,7 195

31. August 1987
Ancillaries
ENGINEERS HANDBOOK
I
m comnrfsw B 12. 1.3.2
SETTING OF THE SWITCHING PRESSURES OF THE COMPRESSOR PPESSIJPE CONTROLLERS M 451
Standard switching pressures: Changeover to switching pressures:

Switch-on pressure 18 bar Swith-on pressure 24 bar
Switch-off pressure 30 bar Switchoff 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.

ENGINEERS HANDBOOK Special tools/
equipment
Sum- of tools RM 452: 453NM 453 813 _l.Q

Fig.No. Tool No. w
Sets of tools with individual list
PI Basic standard tools in M 452, 6.9100 - A set

RM 453, VM 453 (6.100 A)
PI Additional standard tools M 452 6.9100 - B set
(6.9100 B)
[31 Additional standard tools RM 453 6.9100-Cl set
(6.9100 - C)
[41 Additional standard tools VM 453 6.9100 - D set
(6.9100 D)
Basic standard tools RM 453 C 6.9100 - E set
:; Basic standard tools VM 453 C 6.9100 - F set
PI DIN standard tools, all types 0.9000 set
A Tools for engine structure
1 Torque multiplier 1 : 4 (M 452) 1.9455 - 394 1

(1.9146 B)
2 Torque arm l/2 (M 452 ) 1.9100-23 1
(1.9150)
3 Ratchet handle l/2 (M 452) 1.9100-24 1
(1.9149)
4 Extension lever for main bearing nuts ( M 452) 1.900 - 25 1
(1.9152 B)
5 Box wrench 24 : 314 (R + VM 453) 1.9100-26 1
(0.9211)
6 Extension 24/l 9 (RM 453) 1.9100 -27 1
0.9214 A)
7 Extension 24122 (VM 453) 1.9100-28 1
(0.9214 B)
a Device for mounting and extracting cylinder liners 6.9216 - C 1
(M 452) , confined (6.9216 C)
9 Device for mounting and extracting cylinder liners 6.9216 - D 1
R + VM 453, confinedgl (6.9216 D)
(10) Cross-piece for pistons and cylinder liners, confined, 6.9223 - A 1
consisting of: (6.9223)
10.1 Strop 6.9223-2
10.2 Cross-piece 6.9223 - 3
10.3 Shackle A 0,6 DIN 82101 1.9021 - 16
(0.9128 A - 5)
11 Ruler for cylinder liner micrometer 6.9100 - 32
(6.9218)
12 Cylinder liner micrometer 300 - 326 mm 0 1.9419 - B 1
(1.9219 B)
(13) Hydraulic tightener for tie-rods (RM 453) 6.9203 - A 1
(6.9203 A)
(14) Hydraulic tightener for tie-rods (VM 453) 6.9203 - C 1
(16) Hydraulic tightener for tie-rods (M 453 C) 6.9203 - D 1
(15) Components for Fg.No. U IAl.
15.1 Hydraulic jack 2 2 2 0.9213 - D 2
(0.9213 D)
15.2 Hose 2 2 2 0.9205 - A 2
(0.9205)
15.3 Reaction nut 2 2 0.9203 - 155 2
(0.9203 A - 3)

ENGINEERS HANDBOOK
I Special tools/
equipment
Surnmru of tools RM 452: 453NM 453 813-l .O.t
Fig.No. Description Tool No. QtY
Fg. No. la1416

15.4 Reactionnut 2 0.9203-185 2
(0.9203B -3)
15.5 Supportingsleeve 2 2 2 1.9203 -4 2
15.6 Pin 11 6.9203 - 9 1
(6.9203- 5)
15.7 Sealingbush 4 4 4 8.9203-15 4
15.8 Plug 111 0.9203-11 1
(0.9203L-29)
15.9 Pump 1 11 0.9204 - D 1
. (0.9204f3)
15.10 Reactionnut 2 0.9203-125 2
B Tools for cylinder heads
Socketwrench30:l" 1.9100-52 1
(1.9212)
Socket wrench 30 :3/4"(M452) 1.9100-53 1
(1.9121)
Boxwrench30:3/4"(M452) 1.9100-54 1
(1.9132)
4 Socketwrench SW30:l"(M 452) 1.9100-55 1
(0.9121)
5 Pneumaticimpactwrench(M452) 1.9100-56 1
(1.9261)
6 Spacer 1.9100-57 1
(1.9213)
0 Mounting devicefor valve guides, 6.9222 -E 1
consistingof: (6.9234)
7.1 Screw 6.9222- 1 1
(6.9234- 1)
7.2 Bridge 6.9222 - 2 1
(6.9234- 2)
7.3 Disc 1.9222 - 3 1
(6.9234- 3)
7.4 Nut 1.9222 -4 1
(6.9234- 4)
7.5 Washer 25DIN1440 1.9014-26 1
8 Driftforvaive
guides 6.9100-59 1
(6.9222)
9 Indicatortype
30 1.9410-c 1
(1.9215C)
10 Cantileverindicator
type S (Feder70) 1.9410-A 1
(1.9215A)
11 Cantileverindicator
typeS(Feder60) 1.9410 -B 1
(1.9215B)
12 Nozzle cleaner040 1.9124 -c 1
(1.9124C)
(12.1) Cleaningneedles 040(5 off) 1.9124-40 1
(1.9124C-2)
13 Nozzle cleaner050 1.9124-E 1
(1.9124 E)

31. August 1987
Special tools/
ENGINEERS HANDBOOK
equipment
I
matv of tools RM 452: 453NM 453 B13-1.02

Fig.No. Description Tool No. -
(13.1) Cleaning needles 050 (5 off) 1.9124-50 1

(1.9124 E - 2)
14 Nozzle cleaner 055 1.9124 - F 1
(1.9124 F)
(14.1) Cleaning needles 055 (5 off) 1.9124-S 1
(1.9124 F - 2)
15 Nozzle cleaner 045 1.9124 -D 1
(1.9124 D)
(15.1) Cleaning needles 045 (5 off) 1.924 - 45 1
(1.9124 D - 2)
(16) Needle handle (included in 12, 13, 14, 15) 1.9124 - 1 1
(17) Valve reseating tool, consisting of: 6.9224 - C 1
(17.1) Cutting head 6.9224 - 51 1
(17.2) Guide pin assembly 6.9224 - 52 1
(17.3) Tool case 6.9101 -C 1
(17.4) Knurled thumb screw assembly 1.9224 - 6 1
(17.5) Handle 1.9224 - 7 2
(17.6) Palm grip 1.9035 - 48 1
18 Pneumatic impact wrench1 12 0.9100 - 37 1
19 Flexible head wrench 0.9100 - 40 1
20 Flexible head wrench 0.9100 - 39 1
C Tools for running gear
1 Device for removing the pistons, confined 6.9220 - C 1

(6.9231)
2 Piston ring expander 6.9227 - A 1
(6.9229)
3 Crank web deflection dial gauge 1.9425 - 300 1
(1.9225)
(4) Mounting and removing device for main 6.9214 - C 1
bearing caps (16 M 453) (6.9112 C)
(5) Mounting and removing device for main 6.9214 - D 1
bearing caps (12 M 453) (6.9112 D)
(6) Componentsfor Fg.No. 4
6.1 Suspension bracket assembly 1 6.9214 - 1 1
(6.9112 - 1)
6.2 Arm 1 6.9214 - 2 1
(6.9112 - 2)
6.3 Arm 1 6.9214 - 3 1
(6.9112 - 3)
6.4 1 6.9214 - 5 1
(6.9112 - 5)
6.5 Bracket 6.9214 - 6 1
(6.9112 B - 2)
6.6 Plate 6.9214 - 7 1
(6.9112 - 7)
6.7 Plate 1 6.9214 - 8 1
(6.9112 - 8)
6.8 Plate 6.9214 - 9 1
(6.9112 C - 9)
6..9 Plate 6.9214 - 10 1
(6.9112 C - 10)

31. August 1987
maid ENGINEERS HANDBOOK
I Special tools/
equipment
Summarv of tools RM 452: 453lVM 453 813-l qO.3
Fig.No. Description Tool No.
A10 Cross-piece for pistons and cylinder liners, 6.9223 - A

confined (6.9223)
D Tools for timing gear
1 Delivery valve extractor 1.9471 -1 1

(1.9138)
2 Wrench for camshaft gearwheel ring nut 6.9100 - 105 1
(6.9230)
3 Clamping device for injectors 6.9122 - B 1
(6.9157 B)
Al 5.9 Pump 0.9204 - D 1
(0.9204 B)
5 Hose 1 m 0.9205 - B 1
(0.9205 A )
6 High-Pressure tube 0.9134 - G 1
A 15.8 Plug 0.9203 - 1I 1

(0.9203L - 29)
0 High-pressure oil injection tools for fuel cams, 1.9134 -F 1
consisting of:
7.1 Oil pump 1.9134 - 1 1
7.2 High-pressure tube 1.9134 - 2 1
E Tools for auxiliaries
1 Flare nut wrench 17 x 19 DIN 3118 1.9018- 17 1

(1.9027)
2 Ratchet handle 30 mm 1.9495 - 30 1
(1.9140 C)
3 Engineers wrench, single head, 70 DIN 894 1.9094 - 70 1
(1.9060)
4 Extension for emergency reversing 1.9100 - 1 1
(1.9140 B)
5 Key 1.9100 - 126 1
(1.9140 A)
6 Wrench for nut on cooling water pump shaft 6.9100 - 127 1
(6.9164)
7 Extractor for cooling water pump impeller 6.9264 - C 1
(6.9260)
8 Band spanner for oil centriiuge 1.9495 - 362 1
(1.9280)
9 Cleaning injector 250 cm 1.9490- 11 1
(1.9171 B)
10 Rubber hose 9 x 3,5 x 0,5 DIN 8541 1.9041 - 1 1
(1.9171 A)
11 Inflatable plug for charge air manifold, 6.9285 - A 1
consisting of: (6.9169 - B)
(11.1) Inflatable plug 1.9285 - 1 2
(6.9169 B - 1)

31. August 1987
ENGINEERS HANDBOOK
I Speclal tools/
equipment
~UKIIIIZtry of tools RM 452: 453NM 453 813-l .0.4
12 Cleaning gun 1.9100 - 110 1

(1.9235)
13 Filtre cartridge extractor 1.9100 - 120 1
(1.9361)
14 Screen VTR 251 (VM 453) 0.9169 - 5 1
15 Screen VTFI 321 (M 453) 0.9169 - 6 1
see also lists 6.9100 - A/B/C/D

31. August 1987
ENGINEERS HANDBOOK Speclal tools/
equipment
Standard Tools .
RM 452.453NM 453 B13-1 .l
Tool - set - No. 8.9100 - A
1 Cylinder liner hold-down 6.9217-A 2

(6.9117)
(1) Valve spring compressor, 6.9222-D 1

1.1 Hold-down assembly 6.9222-51
1.2 Lever 6.9222-52
1.3 Hope 6.9222-53
1.4 Shackel A 0,4 DIN 82101 1.9021-f 5
2 Extractor for protective pipes 6.9133-A 1

(6.9151)
3 Union for nozzle tester 3.9100-140 1
(1.9066)
4 Extension for indicator 1.941 o-1 1
(1.9232)
5 Nozzle tester 1.9470-B I
(1.9134)
6 Liiing eye bolt M 16 DIN 580 1.9080-l 6 2
(1.9076)
7 Valve grinding device for 103 und 105 dia. 6.9224-B 1
(6.9122 A)
8 Socket wrench 17 1.9100-60 1
1 Guide ring for mounting the pistons 6.9100-30

(6.9126)
D Tools for triming gear
1 Mounting and removing device for spring 6.9123-A

of injection pump tappet (6.9133)
2 Injection pump priming lever 6.9100-43
(6.9135)
(4) Extractor for injectors, 6.9122-A
4.1 Bridge 6.9122-l
4.2 Screw assembly 1.9122-2

31. August 1987
ENGINEERS HANDBOOK Special tools/
equipment
.
Standard Tools RM 452.4531 VM 453 B 13-1.1.1
Fig.No. Description Tool No. Qv

5 Hookwrench, AllO-115DIN 1810 1.9001-l 15 1
(1.9001)
6 Box wrench, double head, 22 x 24 1.9100-47 1
for injection pumps (0.9123)
7 Sliding tee bar A 14 DIN 900 1.9090-l 14 1
(1.9082)
8 Claw foot wrench 24 1.9497-24 1
(1.9058)
1 Grease gun 130 cm3 1.94024 1

(1.9141)
F Basic DIN standard tools
1 Tool box 1.9498-1 1

(1.9098)
2 Hook wrench A 40 - 42 DIN 1810 1.9001-42 1
(1.9006)
3 Hook wrench A 45 - 50 DIN 1810 19001-50 1
(1.9002)
4 Hook wrench A 68 - 75 DIN 1810 1.9001-75 1
(1.9005)
5 Single-head engineers wrench 36 DIN 894 1.9094-36 1
(1.9034)
(1.9035)
(1.9036)
(1.9037)
9 Double-head box wrench 36 x 41 DIN 838 1.9038-36 1
(1.9023)
10 Torque wrench 40 - 180 Nm 1.9454-40 1
(1.9147 B)
11 Adapter socket wrench A 25 x 20 DIN 3123 1.9023-l 8 1
(1.9106)
12 Adapter socket wrench A 20 x 12,5 DIN 3123 1.9023-l 7 1
(1.9118)
13 Set of feeler gauges C DIN 2275 1.9075-3 1
(1.9087)
14 Oil can 500 cm3 1.9490-l 1
(1.9090)
15 Grinding compound, 350 ml box 19491-l 1
(1.9091)
16 Sealing compound, 750 ml box 19492-l 1
(1.9092)
17 Grease paste 1.9493 - 1 1
See also 6.9100 - B/C/D

I Special tools/
equlpment
Additional Standard Tools RM 452 B 13-l .2
1 Jacking device for main bearing caps 6.9111 - C 1

(6.9111 A)
(2) Mounting and removing device for main bearing caps, 6.9214 - A 1
consisting of: (6.9112 A)
2.1 support 6.9214 - 51 1
(6.9112 A-l)
2.2 Lever assembly 6.9214 - 52 1
(6.9112A-2.1)
(6.9112 A - 2.2)
2.4 Link assembly 6.9214 - 53 1
(6.9112 A - 3)
3 Mounting and removing device for main bearing shells 6.9100 - 4 1
(6.9111 C)
4 Dog for bottom shells 6.9100 - 5 1
(6.9113)
(5) Box wrench 41 mm, consisting of: 6.9110-B 1
(6.9110)
5.1 Wrench, bent 6.9110 -1 1
5.2 Extension 6.9110 -2 1
(6.9110 - 2.1)
(6.9110 - 2.2)
6 Socket wrench 41 1.9100 - 7 1
(1.9107)
7 Tightening angle gauge for main bearing nuts 6.9100 - 8 1
(6.9180 A)
(8) Device for mounting, extracting and grinding the 6.9216 - A 1
cylinder liners, consisting of: (6.9116 A)
8.1 Extractor assembly 6.9216-l 1
(6.9116- 1)
8.2 Cross-piece 6.9216-2 1
(6.9116 - 2)
8.3 Pin assembly 6.9216 - 3 1
(6.9116 - 3)
8.4 Tie-rod assembly 6.9216 - 4 2
(6.9116 - 4)
8.5 Support assembly 6.9216 - 6 1
(6.9116 - 6)
8.6 Extension 6.9216-7 2
(6.9116 - 7)
1 Ratchet handle 1 1.9100-21

(1.9146 A)

31. August 1987
Special tools/
ENGINEERS HANDBOOK equipment
I
1 Cross-piece for drawing the pistons 6.9220 - A

(6.9125 A)
2 Pistons suspension device 6.9226 - E
(6.9185 A)
3 Socket wrench 55 x 25 DIN 3124 1.9024 - 55
(1.9127 B)
4 Tightening angle gauge for big-end bearing bolts 6.9100 - 35
(6.9180 E)
1 Single-head engineers wrench 75 DIN 894 1.9094 - 75 1

(1.9038)
See also Summary of tools and list 6.9100 A

I Special tools/
equipment
Additional Standard Tools RM 453 B 13-13
Tool -Set - No. 6.9100 - C
Fig&o. Description Tool No. QtY
1 Jacking device for main bearing caps 6.9111 -D 1

(6.9111 8)
(2) Mounting and removing device for main bearing 6.9214-A 1
caps, consisting of: (6.9112 A)
2.1 support 6.9214-51 1
(6.9112 A-l)
2.2 Lever assembly 6.9214-52 1
(6.9112 A-2.1)
(6.9112 A-2.2)
2.4 Link assembly 6.921553 1
(6.9112 A-3)
(3) Mounting and removing device for main bearing shells, 6.9114-B 1
consisting of: (6.9114 B)
3.1 Mounting device 6.9114-51 1
(6.9114 B-l)
3.2 Dog for bottom shells 6.9114-2 1
(6.9114 B-2)
4 Torque multiplier 1 : 4 1.9455-394 1
(1.9148 B)
5 Torque arm l/2 1.9100-23 1
(1.9150)
6 Ratchet handle l/2 1.9100-24 1
(1.9149)
7 Extension lever for main bearing nuts 1.9100-25 1
(1.9152 8)
8 Socket wrench 41 1.9100-7 1
(1.9107)
9 Tighening angle gauge for main bearing nuts 6.9100-l 0 1
(6.9180 B)
(10) Device for mounting, extracting and grinding the 6.9216-A 1
cylinder liners, consisting of: (6.9116 A)
10.1 Extractor assembly 6.9216-l 1
(6.9116-l)
10.2 Cross-piece 6.9216-2 1
(6.9116-2)
10.3 Pin assembly 6.9216-3 1
(6.9116-3)
10.4 Tie-rod assembly 6.9216-4 2
(6.9116-4)
10.5 Support assembly 6.9216-6 2
(6.9116-6)
10.6 Extension 6.9216-7 2
(6.9116-7)

Special tools/
ENGINEERS HANDBOOK equipment
&&Wonal Standard Tools RM 453 B 13-l .3.1
1 Tightening angle gauge for cylinder head nuts 6.9100-22 1

(6.9180 F)
2 Socket wrench 30 : 1 1.9100-55 1
(0.9121)
3 Pneumatic impact wrench 1.9100-56 1
(1.9261)
4 Ratchet handle 1 1.9100-21 1
(1.9146 A)
c Tools for runnlng gear
1 Cross-piece for drawing the pistons 6.9220-A

(6.9125 A)
2 Piston suspension device 6.9226-E
(6.9185 A)
3 Socket wrench 36 x 20 DIN 3124 1.9024-36
(1.9095 D)
4 Clamp for big-end bearing shells 6.9125-A
(6.9425)
5 Extension B 20 x 75 DIN 3123 1.9482-93
6 Torque wrench1 00 - 750 Nm 1.9454-l 00

(1.9186)
E Tools for auxlllaries
1 Single-head engineers wrench 1.9094-75 1

(1.9038)
See also Summary of tools and list 6.9100 -A

31. August 1987
nal Standard Tools VM 453 B 13-l .4
Tool-Set- No. 6.9100 - R
Fg.No. Description Tool No. QtY
1 Jacking dev& ic?:&lain bearing caps 6.9214 - B

(6.9111 C)
(2) Mounting awn;? removing device for main bearing 6.9114 - C
shells, consisting of: (6.9114 C)
2.1 Mounting devics 6.9114-101
(6,9114C-1)
2.2 Dog for bottom shefts 6.9114 - 52
(6.9114 C - 2)
3 Torque muitlplizr I : 46 1.9455 - 7 1
(1.9148 A)
4 Ratchet handio i!2 1.9100-5 I
(1.9149 A)
5 Extension fcr main bearing nuts 1.9100-6 1
(1.9152 A)
6 Torque wrench 20 - 90 Nm 1.9454 - 20 1
(1.9147 A)
7 Tightening angle galuge for main bearing nuts 6.9100- 7 1
(6.9180 C)
(8) Device for mounting, extracting and grinding the 6.9216 - B 1
cylinder liners, consisting of: (6.9116 B)
8.1 Extractor assembly 6.9216 - 1
(6.9116 - 1)
8.2 Support assembly 6.9216 - 6
8.3 Link 6.9216 - 53
(6.9176 B - 3)
8.4 Extension 6.9216 - 7 2
(6.9116 - 7)
8.5 Cross-piece 6.9216 - 2 1
(6.9116 - 2)
8.6 Tie-rod assen%y 6.9216 - 4 2
(6.9116 - 4)
8.7 Handle 6.9220 - 2 1
(6.9116 B -7)
9 Cylinder liner hold-down 6.9217 - B 2
(6.9117 A)
B Tools for cyikder heads
1 Tightening angle gauge for cylinder head nuts 6.9100 - 22

(6.9180 F)
2 Socket wrench 3C : y 1.9100-55
(0.9121)
3 Pneumatic impact wrcnui; 1.9100-56
(1.9261)
4 Ratchet handle 1 19!50-21
,--a _
I
I
E
e-w
31. August 1997 KRUPP MaK MASCHINENBAU E:-~tiH
r -_. &Jditional Standard Tools VM 453 B 13-1.4.1
:
Fii.Nli Description Twl No. QtY
c Tools for runnlng gear
(1) Device f+re\v;ng the pistons, 6.9220 - B 1

1.1 Cross-piare 6.9221) - I 1
(6.9125 B - 1)
A 8.7 Handls 6.9220 - 2 1
(6.9116 B -7)
1.2 Skid assembl: 6.922G - 3 1
(6.9125 B - 3)
1.3 Screw 1.9220 - 5 2
(6.91?5 B - 5)
(2) Piston suspension device, 6.9~26 - A 1
2.1 Support assembly 6.9226 - 1 1
(6.9185 B - 1)
2.2 Clamp assembly 6.9226 - 2 1
(6.9185 B - 2)
3 Socket wrench 38 : 1 0.9100 - 38 1
(1.9158)
(4) Lever for big-end bearing caps, 1.9100-45 1
4.1 Lever, part 1 1.9100 - 451 1
(1.9128 - 1)
4.2 Lever, part 2 1.9100 - 452 1
(1.9154)
5 Extension 1 1.9457 - 433 1
(1.9154)
6 Universal joint 1 1.9100-46 1
(1.9127 A)
7 Clamp for big-end bearing shells 6.9125 - A 1
(6.9425)
8 Torque wrench 100 - 750 Nm 1.9454 - 100 1
(1.9186)
1 Single-head engineers wrench 80 DIN 894 1.9094 - 80 1

(1.9061)
(2) Inflatable plug for charge air manifoki, 6.9285 - B 1
2.1 Bulkhead assembly 6.9285 - 1 1
(6.9169 - 1)
2.2 Union tee 6.9285 - 3 1
(6.9169 - 3)
2.3 Blank flange 1.9285 - 6 1
(1.9169 - 6)
2.4 Pressure gauge connector assembly 1.9285 - 9 1
(1.9169 - 9)
2.5 Pressure gauge 0 - 1.6 bar 1.9285 - 19 1
(1.9169 - 19)
. .
Edition 1 SERVICE DOCUMENT ;!F
4
ENG!NEW@ HANDBOOK equipment
al Stanc&gl Tools VM 453 B 13I 1.4.2
Fig.I$I. Description Tool No. QtY
2.6 Airtube 18x 1,75 1.9285 - 22 1

(1.9169 - 22)
2.7 PVC hose assembly with connector 1.9285 - 23 1
(1.9169 - 23)
2.8 PVC, hose assembly with plug end 1.9285 - 24 1
(1.9169 - 24.1)
2.9 PVC hose with valve 1.9285 - 74 1
(1.9169 - 24.2)
2.10 lllflatOf 1.9285 - 25 1
. (1.9169 - 25)
See also Summary of tools and list 6.9100 - A
. .
< c
Edition sERVlCE DOCUMENT OF
KRUPP MaK MASJZHINENBAU GMBH

31. +ug~t~ 1987
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
1.60.7-
32.1QOl- 11
32.10.01-12
1.60.7-
MO.7- 32.1QOl-13
-_
I.60.7-
32.10.01-14
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 16
-_
P
l.6Q7-32.12.01
-14 c/m d
l.60.7- 10
32.12.01- 11
l.6Q7-
32.12.01-
11 14 c
160.7-32.12.01-12
- 16
;06 :z
32.12.01-15
l.60.7-
1.60.7-32.20.01-07
.60.7-322QOl-08
--~
@i(!7-32.211.01-09
i.60.?-32.20.01-06
.60.7-
3~.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
.60.7-
32.22.01-09
.60.7-32.22.01-10
.6Q7-32.22.01-11 450v.uT 35On.oT. ..-. _1_-.7,90
157+3' - 05 ,
.6Q7-32.X01-12 UJ'uuT. OS 162"rF 7,'1$ _
.6Q?-.32.7X01-13
.60.7-32.2201-E
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103.5 1 - nI
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$2. ol
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iinlafinocken der Ein- und Auslafisteuerzeiten.
-_Xontrolle
7 Ze.chnungsnummern der eingebauten Ein- bzw, Auslan-
Motor rechtsdrehend nocken feststellen.
/
2 Kurbelzapfen vofl Zylinder 1 in u.T.- Ste\lunq tbinen f
(Nockenstellung , siehe Abb. 1 bzw 2 )
Abb. 2
,
3 6radschelbe am Kurbelwellenflansch entsprechene der
u.T.- Stellung von Zylinder 1 fixieren. I
I
b MeOuhr am Rollenfiihrungskorper des EjnlaRnockens vor I/__
Zylinder 3 des Kaster;gestells I Zylindel kurbelgehduse 1
montieren Esiehe Abb. 1 btw. 2 I
Wed Rollenhub Saus der TabeUe entnrhmen ti Notor in

Motordtehrichtung his z~;rmaqzeigten Wert an der Muhr
tic nen.
6. Dei eiry&ellfe Wetf ~7 innfvhalb der in der TabeUe
angegebenen zuk5ssi4en Konl n&inkelabweichung Liegen.
7 Menuhr demanticren und zur Hubmessung am Rollen-

ftihrungsktirper des Auslaflnockens vnn ZyYinder 1
montieren.
8. In gleicher Weise wie crter 5. und h besrhrieben

weitel verfohren. Hierbei Totpunktlage in Abb. 3
bzw. 4 beachten I KuMzapfm in aT !
9. In gleicher Welse wle unter 2 - 8 beschrieben , fur jeden

welteren Zylinder Hubmessung urchfuhren
I
\
10.
I
-AuslaOnocken
:nd Motor rechtsdrehend
Abb. 4
Minweis:
Korrigieren des gesamfen Nockenbtindels i:i durch

z e
Umstecken dss Steuerwellenrades, bzw. Zahnrad auf
2 burbelwelle, zom Ooppelrad maglich.
) 1 Zahn
1 Zahn
Steuerwellenrad
Zahnrad
= 3OlO L8Dreh
a.K W. = l3524 -
4
JI
Steuerw.
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24-MAI- FR 13:52 ii FAXNR, t49 431 3995827 s, 01
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MAKSPARE FAX: +49 431 39952926 s, OQ1
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-I ENGINEERS HANDBOOK

1.0 Sectional views

BOl CYLINDER COVER

1.0 Valve rocker, removal/fitting

i 2.0 Valve guide

3.0 inlet and exhaust valves (table of variants), valve housings

4.0 Starting valve

5.0 Cylinder cover assembly

1.0 Big-end bearing, inspection and fitting M 4511452

2.0 Main bearing, inspection M 451/452

4.0 Liner (wear measurement and re- conditioning)

31. Oktober 1988 KRUPP MaK MASCHINENBAU GMBH

5.0 Piston pin and bush removal and fitting

BO3 ENGINE HOUSING

1.0 Bedplate, engine housing M 451,452,453 and M 453 V

804 TIMING GEAR

1.0 Triming gear - inspection

1.0 Governor drive

1.0 Exhaust system

Edition SERVICE DOCUMENT OF

28. February 1989 KRUPP MaK MASCHINENBAU GMBH

1.0 Fuel system

1.0 Luboil circuit

BO9 COOLING WATER SYSTEM

2.1 Cooling water centrifugal pump

BlO STARTING AIR SYSTEM

30.November1987 KRUPP MaK MASCHINENBAU GMBH

813 SPECIAL TOOLS /DEVICES

Edition SERVICE DOCUMENT OF

30.November1987 KRUPP MaK MASCHINENBAU GMBH

Sectional views B 00-l ,Q

Cross-section Z 451 in-line

\ W_)] Valve control mechanism;

Exhausl opens = 90 f 2 befor, e BDC

9 Mean effective pressure:

Speed: 300 - 375 rpm

Edition SERVICE DOCUMENT OF

31.January1988 KRUPP MaK MASCHINENBAU GMBH

Section view B 00-l .I_

Speed revul. per minue - 300 - 425 r. p.m.

Firing order : (cbckwise rotation)

Edition SERVICE DOCUMENT OF

31 a January 1989 KRUPP MaK MASCHINENBAU GMBH

&ctional vlews B 00-1.2

Cross-section M 452 in-line

Edition SERVICE DOCUMENT OF

KRUPP MaK MASCHINENBAU GMBH

Sectional views B 00-l .3

Cross-section M 453 in-line

Edition SERVICE DOCUMENT OF

KRUPP MaK MASCHINENBAU GMBH

Dimensions and weiahts B 00 -.

Designation length width height0 weigh!

~tlonal views B 00-l .4

Cross-section M 453 Vee engine

Edition SERVICE DOCUMENT OF

31. August 1987 KRUPP MaK MASCHINENBAU GMBH

Designation length width height 0 weight

Lub.oil pump Var.

Lub.oil fitter/with support

Carge alr cooler

M453 in-line (Var.-14) 1344 420 700 570

Edition SERVICE DOCUMENT OF