M451-M453C Har [PDF]

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m c M451 - M453C



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Engineer´s Handbook M451 - M453C



c



Engine data Type 451



Type 452



Type 453 - 453 C



Stroke



mm



450



450



420



Bore



mm



320



320



320



Speed



rpm



300-425



375-500



540-600



6/8



6/8/9



6 / 8 / 9 / 12 / 16



Number of cylinders Main bearing Inside Ø



mm



225



225



245



Outside Ø



mm



239 / 245



239 /245



259



Inside Ø



mm



225



225



245



Outside Ø



mm



239 / 245



239 / 245



259



Length



mm



470



467 / 470



467 /470



Shaft Ø



mm



21,90



21,92



21,92



Valve disk Ø



mm



122



105



105



Big end bearing



Valves (inlet)



Valves (exhaust) Length



mm



470



467 / 468,5 / 470



467 / 468,5 / 470



Shaft Ø



mm



21,90



21,92



21,92



Valve disk Ø



mm



122



105



105



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



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Engine operating data Type 451



Type 452



Type 453 - 453 C



Temperatures Lub. oil, inlet Stationary engines



°C °C



50-55 50-60



50-55 50-60



Temperature rise *



°C



10-20



10-20



80-85



80-85



Fresh water circulation cooling Engine outlet °C Temperature rise *



°C



7-10



7-10



Charge air inlet



°C



45-60



45-60



Nozzle cooling before nozzle



°C



65-75



65-75



* = at rated engine output Pressures Lub. oil *1



bar



3,0-3,5



3,0-3,5



4,0-5,0



bar



≥ 2,5



≥ 2,5



2,5-5,0



Fresh water circulation cooling with attached pumps minimum



bar



Fuel before pumps MDO



bar



HFO



bar



Control air



bar



Starting air



bar



2,0 *2



1,5-3,0



2,0 *2



1,5-4,0



1,5-3,0



1,5-4,0



4,0-5,0



7,5



7,5



7,5



12-30



12-30



12-30



*1 = at the last crankshaft bearing. *2 = min. head at pump inlet 4m water column.



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Cylinder head M 453 - M453 C Cylinder head nuts M 453 1.60.1-21.09.00-02 Tightening after transport of the engine to the mounting site only the nuts loosened for transport. Pretighten nuts with → then 1st step →



M



= 50



Nm



Dw = 60°



2 nd step



→



Dw = 180°



3 rd step



→



Dw = 225°



The following is valid for M 453 and M 453 C. Coat thread and contact surface of the nuts with Molykote (Paste G). Attention ! No Molykote between washer and cylinder head.



Retightening after reconditionings. Pretighten nuts with → then 1 st step → 2 nd step



→



3 rd step



→



M



180°



60°



250



= 50



Nm



Dw = 60° Dw = 180°



1 2 3



Dw = 250°



Tighten alternately and steadily in the sequence 1 - 2 3 - 4 5 - 6 7 - 8



M 453 C 1.60.1-21.09.00-03 Pretighten nuts with then 1 st step →



→



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



M



= 180



Nm



Dw = 60°



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Cylinder head 2 nd step



→



Dw = 180°



3 rd step



→



Dw = 250°



After tranport to the mounting site all nuts on the cylinder heads with the transport devices have to be loosened and tightened acc. to the before mentioned specification.



2



3 7



6



5



8 1



Cylinder head tie bolts M 453 in-line The tightening torque is : Up to drawing No. 1.63. / 64. / 69. 7-11.01.00 - 12



→



4



M



= 600



Nm



Drawing No. 1.63. / 64. / 69. 7- 11.01.00 - 13 to 1.63. / 64. / 69. 7 -11.01.00 - 17 →



M



= 550



Nm



M 453 Vee The tightening torque is : Drawing No. 1.66. / 68. 7 - 11.15.00 - 01 / 03 / 04 / 05 / 06 / 07 →



M



= 550



Nm



M



= 610



Nm



M



= 50



Nm



1.66. / 68.7-11.15.00-02



→ M 452



Cylinder head nuts 1.60.1-21.09.00-01 Tightening after transport of the engine to the mounting site, only the nuts loosened for transport. Pretighten nuts with → then 1st step →



Edition 28.11.1998



Dw = 60°



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Cylinder head 2nd step



→



Dw = 120°



3rd step → Retightening after reconditioning. Pretighten nuts with then 1st step → 2nd step



Dw = 190°



→



M



= 50



Nm



Dw = 60°



→



Dw = 120°



3rd step → corresponding to 3 1/2 hexagons.



Dw = 210°



M 451 Cylinder head nuts Pretighten nuts with → then transfer marking from the cyl. head on the nuts. Then tighten crosswise in 2 steps up to → Cylinder head studs 1.63. / 64.7-11.01.00-02 The tightening torque for inserting the studs is



→



M



= 50



Nm



Dw = 210°



M



= 550 + 50



Nm



M



= 100



Nm



M 452 - M453 C Rocker arm bracket Pretighten nuts with then tighten with →



→



Dw = 60°



Tightening torque for the taper pin nuts



→



M



= 25



Nm



M



= 250



Nm



M 452 Rocker arm bracket Old type →



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Cylinder head M 451 Rocker arm bracket Tighten nuts with → M16 Molykote



M



= 45



Nm



M 452 - M453 C Rocker arm bracket Radial rocker arm clearances Nominal clearances →



0.13



mm



0.30



mm



Projection of bush on rocker arm bracket Dimension " S 1 " →



0.50



mm



Exhaust valve rocker bush Dimension " S 2 " →



18 mm



Clearance limit



→



S2



S1



S2



Axial clearance Dimension " S 3 "



→



0.20



mm



S3



Edition 28.11.1998



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Cylinder head M 451 - M453 C Valve clearance, with cold engine Cooling water temperature below 50 ° C Inlet valve → Exhaust valve



→



With warm engine Cooling water temperature above 50 ° C Inlet valve → Exhaust valve



→



0.30



+ 0.1



mm



0.60



+ 0.1



mm



0.40



+ 0.1



mm



0.70



+ 0.1



mm



Before measuring (in warm state) the engine must have been stopped for at least 15 min. for equalizing the valves.



M 452 - M453 C Valve guide bushes The valve guides are marked on the circumference with „IN“ and „OUT“. Insert O-rings only after inserting the bushes in supercooled condition. The O - ring doses the valve lubrication and must only be replaced by an original Mak spare part. Supercool bushes to - 195 ° C (liquid nitrogen) and insert them, pay attention to projection of bush acc. to sketch.



Valve guide Inlet valve Nominal clearance Clearance limit



→



Exhaust valve Nominal clearance Clearance limit



Edition 28.11.1998



→



→



→



0.10 - 0.15



mm



0.40



mm



0.13 - 0.16



mm



0.40



mm



Service document of Caterpillar Motoren GmbH & Co. KG



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Cylinder head M 452 - M453 C Valve stem The deviations from true running on the valve cone must not exceed the following values: → Inlet valve stem 0.04 mm Exhaust valve stem → 0.03 mm



S



Measuring distance " S " = 287 mm, supporting points for the measuring device are on the measuring track, 20 mm from its end points.



s



Edition 28.11.1998



30° 30°



-8´



min. 2mm



Grinding of inlet and exhaust valves Apply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or remachined valve cone and distribute the paste equally. Thereafter the seat ring surface is to be sprayed with a thinner (F25) belonging to the diamond paste, for dilution and in order to increase the grip. Insert the oiled valve stem into the guide bush. Fasten Inlet valve the device at the valve disk and grind the valve face and seat by hand applying a moderate pressure, rotating the device. The contact reflection „a“ which is visible by the smooth grinding process shall not exceed 30 % of the seat width starting from the outside diameter. If the bearing characteristics described above are not reached, remachining of both sealing surfaces is necessary. After machining both seats have to be checked with a luminous magnifier. The fillet must not be refinished.



-8´



Exhaust valve



min. 1mm



The valves cannot be reused when: The valve cone face is damaged (cracks, blow-bys). The wear caused by corrosive material exceeds > 2% of the valve head diameter. High temperature corrosion „S“ at the valve plate bottom exceeds > 1.5 mm.



Service document of Caterpillar Motoren GmbH & Co. KG



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Cylinder head Fitted valve stems: 1.60.7-22.10.01-50 * 1.60.7-22.10.01-45 ** 1.60.7-22.10.01-44 ***



1.60.7-22.10.01-52 1.60.7-22.10.01-54



Inlet and exhaust valve stem Inlet and exhaust valve stem Exhaust valve stem, heavy fuel operation Exhaust valve stem, heavy fuel operation Alternatively -41, without armoring Inlet valve stem



* ** *** ****



Repl. Repl. Repl. Repl.



1.60.7-22.10.01-41 ****



= = = =



M452 - M453 M452 - M453 M452 - M 453 M452 - M453C M452 - M453C M453 C



for 1.60.6-22.10.01-02 / -10 / -14 / - 27 / - 30 for 1.60.6-22.10.01-23 / -29 for 1.60.6-22.10.01-31 + 1.60.7-22.10.01-34 / 47 for 1.60.7-22.10.01-48 / -49



Attention! If vaned stem var. -47, -48 oder -49 was fitted before, a conversion to valve rotator for var. -44, -41 or -52 must be carried out in case of replacement. Following parts must be included in the delivery: 1.60.7-22.25.00-02 - repl. -04, valve rotator 1.60.7-22.10.06-05 - spring plate (if exhaust valve was fitted with vane var. -21 ). Z+M 451 Fitting valve stems: 1.60.6-22.10.01-51 * *



Inlet and exhaust valve stem



=



Repl. for 1.60.6-22.10.01-03 / -04 / -05 / -06 / -08 / -11 / -12 / -13 / 26 Replacement for Z 451 in operation with heavy fuel and on request of customer 1.60.6-22.10.01-16, Nimonic



Edition 28.11.1998



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Cylinder head Valve seat rings The valve seat ring is supercooled in liquid nitrogen ( - 195 ° C ) and inserted in the bore in the cylinder head. Abt. 3 min. after insertion the seat ring is pressed on with device 1.60. 7 - 92. 22. 00- 07 for a short time. In shrunk condition there must not be any clearance between seat ring and contact surface in the cylinder head. Carefully smooth projecting edges of the seat ring and of inlet and exhaust duct. In case of first exchange of the exhaust valve seat rings without refinishing, however, with O-rings, the following must be taken into account: Receiving bore in cylinder head free from corrosion residues, possibly polish with emery. No axial scores. Sequence of operation Warm up cylinder head to 130 - 140 ° C (heating furnace or in exceptional cases by means of a soft, big welding flame). After warming-up and before inserting the rings apply a thin coat of Molykote Paste G in the bore in the cylinder head (only exhaust). Supercool valve seat ring to abt. - 20 °C (freezer compartment), mount O - rings and apply a thin coat of Molykote or grease. Insert valve seat ring and, if necessary, drive in with old valve stem and hammer. Press on seat ring with device for a short time. Check the air gap between contact surface of the seat ring and cold cylinder head. If the clearance is ≥ 0.02 mm, press on with device once more. Pressure test : 10 bar Valve seat ring cooled type without O - ring: Refinishing to oversizes only in authorized Mak workshops. On principle, repaired cylinder heads have to be marked with stamped seat ring variant and workshop sign near the existing cylinder head drawing number. Valve rotator Measure and note valve speed on commissioning. The valve speed depends on the engine speed, in case of speed drop to n = 1 rpm remove and overhaul valve rotator.



M 452 - M453 C Injection valve Pretighten nuts by hand with then tighten with → or tighten with → Molykote "Paste G"



→



M



= 25



Nm



Dw = 120° M



= 130



Nm



M



= 50



Nm



M 452 Injection valve Old type (3 nuts)



Edition 28.11.1998



→



Service document of Caterpillar Motoren GmbH & Co. KG



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Cylinder head M 451 Injection valve Tighten nuts with M 12 Molykote



→



M



= 18



Nm



M 452 - M453 C Nut for nozzle Apply two marks, one on the nozzle holder, one on the nut, at a distance of → and tighten or tighten nozzle nut with → Oil lubrication



14



Connection piece for fuel delivery pipe The tightening torque is →



mm



M



= 300 + 50



Nm



M



= 80



Nm



M



= 110



Nm



M



= 120



Nm



M 451 - M453 C Starting valve Tighten screws with



→ M 453 - M453 C



Cyl. head - exhaust gas manifold Tightening torque for the screws to the cyl. head High temperature! Use paste DAG 5080



→



Landing surface cylinder head M 452 - M 453 (not M 453 C) Recutting of landing surface possible up to a maximum of 0.5 mm. If further reduction is required, the level cylinder bottom surface must be recut at the same time togesther up to a maximum of 1 mm.



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



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Piston M 452 - M453 C KS piston 1.60.6-26.70.00-01 The tightening torque for inserting the studs is Tighten nuts crosswise twice with → and loosen again, then tighten definitely with →



→



M



= 80



Nm



M



= 110



Nm



M



= 110



Nm



The following applies to all piston installations: Coat threads and contact surfaces of the nuts with Molykote - paste. 1.60.6-26.70.00-03 * / 05 / 08 * / 09 The tightening torque for inserting the studs is Tighten nuts crosswise with → and loosen again, then check tightening torque for inserting the studs of →



→



M



= 80



Nm



M



= 110



Nm



M



= 80



Nm



Pretighten nuts crosswise with →



M



= 25



Nm



and tighten crosswise with →



Dw = 60°



Check: The nuts must not turn further at a tightening torque of →



M



= 110



Nm



* Var. - 03 and - 08 for M452, too The following applies to all piston installations: Coat threads and contact surfaces of the nuts with Molykote - paste.



Edition 28.11.1998



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Piston 1.60.6-26.70.00-12 * / 13 * The tightening torque for inserting the studs is Tighten nuts crosswise with → and loosen again, then check tightening torque for inserting the studs of → Pretighten nuts crosswise with → and tighten crosswise with → Check: The nuts must not turn further at a tightening torque of →



→



M



= 80



Nm



M



= 110



Nm



M



= 80



Nm



M



= 25



Nm



Dw = 65 ° M



= 75



Nm



*Attention ! Var. - 12 only used by PLN now. ** Var. - 13 for M452, too. The following applies to all piston installations: Coat threads and contact surfaces of the nuts with Molykote - paste. M 453 Mahle 1.60.6-26.70.00-02 * / 04 / 06 * / 07 / 10 * / 11 * The tightening torque for inserting the studs is → Tighten nuts crosswise twice with → and loosen again, then tighten definitely with →



M



= 40



Nm



M



= 65



Nm



M



= 65



Nm



* Var. - 02 / -06 / -10 / -11 for M452, too



Edition 28.11.1998



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Engineer´s Handbook M451 - M453C



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Piston M453 C KS piston 1.60.6-26.70.00-17 / 18 / 21 / 22 / 24 and 1.60.7-26.70.00-26 / -27 /-28



M The tightening torque for inserting the studs is → Tighten nuts crosswise with → M and loosen again. Check tightening torque for inserting the studs, then pretighten nuts crosswise M with → and tighten nuts crosswise Dw with → Check: Immediately after tightening the nuts must not turn further at a tightening torque of → M



= 80



Nm



= 70



Nm



= 25



Nm



= 75 ° = 60



Attention ! When fitting pistons of the types stated below, before tightening the nuts the gap between piston crown and piston skirt must be measured.



Nm



Measure gap here before fitting.



On the pistons 1.60.6-26.70.00-21 / 22 / 24 of Messrs. KS the gap size is 0.09-0.13 mm. On the pistons 1.60.6-26.70.00-20 / 23 of Messrs. Mahle the gap size is 0.04 0.08 mm. 90.2+0.4



130.25+0.2



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Piston Mahle piston 1.60.6-26.70.00-19 / -23 The tightening torque for inserting the studs is → Tighten nuts crosswise with → and loosen again, then pretighten nuts crosswise with → and tighten with → Check: The nuts must not turn further at a tightening torqueof →



M



= 60



Nm



M



= 100



Nm



M



= 25



Nm



Dw = 180 ° M



= 100



Nm



Attention ! Replace studs if projecting length from bottom contact surface exceeds 189 mm.



M 452 - M453 C Dimension of pin bosses Ø → Dimension between pin bosses standard type KS dimension "a" → Mahle dimension "a" →



135.00



+ 0.017 + 0.005



mm



130.25



+ 0.2



mm



130.20



+ 0.4



mm



„a“



Stepped type KS dimension "b" → dimension "c" → Mahle dimension "b" → dimension "c" →



90.20



+ 0.4



168.00



mm mm



„b“



90.20



+ 0.4



mm



±1



mm



165.00 „c“



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Piston Ring carrier type Position of the oil drain for piston cooling in case of : Sense of rotation „left" port engine : on exhaust gas side starboard engine : on camshaft side Sense of rotation „right"



port engine : on camshaft side starboard engine : on exhaust gas side



Built-up piston : The position of the oil drain for the piston cooling does not depend on the sense of rotation. Piston check After piston checks operate engine with reduced output for approx. 10 hours. Piston rings During piston checks, particular attention must be paid that the piston rings are being installed in a way that the ring butts are arranged in longitudinal engine direction, alternately opposed. During removal of a piston the found position of the ring butts with reference to the fitting position of the piston is to be recorded in the measuring sheet, in any case.



M451 Wear limits Piston



1.60.7-26.10.01-01 / -02 / - 03 / - 04 1.60.6-26.30.01-01 / -02 / -03 / -04 / - 05 / -06 / - 07 / -08 / -09 / -10 1.60.7-99.26.01-32



Grooves 1



Grooves height 8.08 ±0.01



2



8.08



3



Ring height 7.987 - 7.972



Wear limit 8.30



Clearance limit 0.35



±0.01



7.987 - 7.972



8.30



0.35



8.06



±0.01



7.987 - 7.972



8.30



0.35



4



8.06



±0.01



7.987 - 7.972



8.30



0.35



5



10.04



10.20



0.30



Edition 28.11.1998



±0.07



9.987 - 0.015



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Piston M452 - M453 Piston



1.60.6-26.40.01-01 / -02 / - 03 / - 05 / -06 / -07 / -08 1.60.6-26.60.01-03 / -04



Grooves 1



Grooves height 8.08 +0.02



2



8.06



3



Ring height 7.987 - 7.972



Wear limit 8.30



+0.02



7.987 - 7.972



8.30



0.35



8.06



+0.02



7.987 - 7.972



8.30



0.35



4



8.04



+0.02



7.987 - 7.972



8.30



0.35



5



10.06



10.20



0.30



Piston



1.60.6-26.60.01-05 / -06 1.60.6-26.70.00-01 / -02 / -03 / -06 / -08 / -10



Grooves 1



Grooves height 6.08 +0.02



2



6.06



+0.02



3



8.06



+0.02



4



10.06



+0.02



+0.02



* also ring -86 = 7.987



Edition 28.11.1998



-0.015



9.987 - 0.015



Clearance limit 0.35



Ring height 5.95 - 0.012



Wear limit 6.50



5.95



- 0.012



6.50



0.60



7.987 - 7.972 *



8.30



0.35



9.987 - 0.022 **



10.20



0.30



** also ring 87 = 9.987



Clearance limit 0.60



- 0.015



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Piston M453 Piston



1.60.6-26.70.00-04 / -05 / -07 / -09 / -11 / -13



Grooves 1



Grooves height 6.16 +0.02



2



6.16



+0.02



3



8.06



+0.02



4



10.06



+0.02



Ring height 5.95 - 0.012



Wear limit 6.35



5.95



6.50



0.60



7.987 - 0.015



8.50



0.60



9.987 - 0.015



10.20



0.30



- 0.012



Clearance limit 0.50



M453 C Piston



1.60.6-26.70.00-18 / -22 und 1.60.7-26.70.00-27



Grooves 1



Grooves height 6.16 +0.02



2



6.16



+0.02



3



6.16



+0.02



4



10.06



Edition 28.11.1998



+0.02



Ring height 5.95 - 0.015



Wear limit 6.50



5.95



- 0.012



6.50



0.60



5.95



- 0.012



6.50



0.60



10.20



0.30



9.987 - 0.015



Clearance limit 0.60



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Piston Piston 1.60.6-26.70.00-17 / -19 / -21 / -23 / -24 and 1.60.7-26.70.00-26 / -28 Grooves 1



Grooves height 6.16 +0.02



2



6.16



+0.02



3



6.16



+0.02



4



10.06



+0.02



Ring height 5.95 - 0.015



Wear limit 6.35



5.95



- 0.012



6.50



0.60



5.95



- 0.012



6.50



0.60



10.20



0.30



9.987 - 0.015



Clearance limit 0.50



Piston 1.60.6-26.70.00-24 / -28 Grooves 1



Grooves height 8.16 +0.02



2



6.16



+0.02



3



6.16



+0.02



4



10.06



+0.02



Edition 28.11.1998



Ring height 7.937 - 0.022



Wear limit 8.30



5.95



- 0.012



6.50



0.60



5.95



- 0.012



6.50



0.60



10.20



0.30



9.987 - 0.015



Clearance limit 0.35



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Piston M451 Cast iron piston, old form of combustion space 1.60.7-26.10.01-01 1.60.7-26.10.01-02 1.60.7-26.10.01-03 Cast iron piston, new form of combustion space 1.60.7-26.10.01-04 1.60.6-26.30.01-09 Al-piston, old form of combustion space 1.60.6-26.30.01-01 without ring support



1.60.6-26.30.01-02 without ring support



1.60.6-26.30.01-05 with ring support



1.60.6-26.30.01-07 without ring support



1.60.6-26.30.01-08 with ring support - new form of combustion space 1.60.6-26.30.01-10 with double ring support - new form of combustion space 1.60.6-26.30.01-09 with double ring support - new form of combustion space 1.60.7-99.26.01-32 Al-piston, new form of combustion space 1.60.6-26.30.01-03 without ring support



1.60.6-26.30.01-04 with ring support



1.60.6-26.30.01-06 with ring support



1.60.6-26.30.01-08 with ring support



1.60.6-26.30.01-10 with double ring support



1.60.6-26.30.01-09 with double ring support



M451 Al-piston 1.60.6-26.40.01-01 without ring support



1.60.6-26.40.01-02 with ring support



1.60.6-26.40.01-03 without ring support



1.60.6-26.40.01-05 without ring support



1.60.6-26.40.01-06 without ring support support



1.60.6-26.40.01-08 with double ring



1.60.6-26.40.01-07 with double ring support



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Piston M452 - M453 Al-piston, with double ring support 1.60.6-26.60.01-04



1.60.6-26.60.01-03



Al-piston, with double ring support 1.60.6-26.60.01-05



1.60.6-26.60.01-06



M452 Built-up piston, gas oil and heavy fuel operation 1.60.6-26.70.00-01 1.60.6-26.70.00-02 1.60.6-26.70.00-03



1.60.6-26.70.00-06



1.60.6-26.70.00-08



1.60.6-26.70.00-10



1.60.6-26.70.00-11



1.60.6-26.70.00-13



M453 Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1.60.6-26.70.00-04



1.60.6-26.70.00-05



1.60.6-26.70.00-07



1.60.6-26.70.00-09



1.60.6-26.70.00-11



1.60.6-26.70.00-13



M453 C Built-up piston - ring groves flame-hardened - gas oil operation 1.60.6-26.70.00-18 1.60.6-26.70.00-22 1.60.7-26.70.00-27



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Piston M453 C Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1.60.6-26.70.00-17 1.60.6-26.70.00-19 1.60.6-26.70.00-21



1.60.6-26.70.00-23



1.60.7-26.70.00-26 Built-up piston - 1st ring groove chromium-plated - heavy fuel operation 1.60.6-26.70.00-24 1.60.7-26.70.00-28



M451 Piston rings Piston 1.60.7-26.10.01-01 / -02 / -03 / -04 and 1.60.6-26.30.01-09 Ring groove ring 1 Compression ring, convexly chromium-plated 0.00.6-35.41.00-06 2 - 4 Compression ring 0.00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-09 Piston 1.60.6-26.30.01-01 / -02 / -03 / -04 / -05 / -06 / -07 / -08 / -09 / -10 Ring groove ring 1 + 2 Compression ring, convexly chromium-plated 0.00.6-35.41.00-06 3 + 4Compression ring 0.00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-07 ≤ 350 1/min Oil scraper ring 0.00.6-35.41.01-09 ≥ 350 1/min



M452 Piston rings Piston 1.60.6-26.40.01-01 / -02 / -03 / -05 / -06 / -07 / -08 and 1.60.6-26.60.01-03 / -04 Ring groove ring 1 + 2 Compression ring, convexly chromium-plated 0.00.6-35.41.00-06 3 + 4 Compression ring 0.00.6-35.41.01-11 5 Oil scraper ring 0.00.6-35.41.01-07 ≤ 350 1/min Oil scraper ring 0.00.6-35.41.01-09 ≥ 350 1/min



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Piston M453 C Piston rings Piston 1.60.6-26.60.01-03 / -04 Ring groove 1 - 3 Compression ring, convexly chromium-plated 4 Compression ring 5 Oil scraper ring



ring 0.00.6-35.41.00-06 0.00.6-35.41.01-22 0.00.6-35.41.01-23



Piston 1.60.6-26.60.01-05 / -06 Ring groove 1 + 2 Compression ring, chromium-plated 3 Compression ring 4 Oil scraper ring



ring 0.00.6-35.41.01-32 0.00.6-35.41.01-30 0.00.6-35.41.01-23



M453 Piston rings Piston 1.60.6-26.60.01-03 / -04 Ring groove 1 + 2 Compression ring, convexly chromium-plated 3 + 4 Compression ring 5 Oil scraper ring



ring 0.00.6-35.41.00-06 0.00.6-35.41.01-11 0.00.6-35.41.01-09



Piston 1.60.6-26.60.01-03 / -04 Ring groove 1 - 3 Compression ring, convexly chromium-plated 4 Compression ring 5 Oil scraper ring



ring 0.00.6-35.41.00-06 0.00.6-35.41.01-22 0.00.6-35.41.01-87



Piston 1.60.6-26.60.01-05 / -06 Ring groove 1 + 2 Compression ring, chromium-plated 3 Compression ring 4 Oil scraper ring



ring 0.00.6-35.41.01-32 0.00.6-35.41.01-86 0.00.6-35.41.01-87



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Piston M453 Piston rings Built-up piston, gas oil and heavy fuel operation 1.60.6-26.70.00-01 / -02 / -03 / -06 / 08 / -10 / -11 / -13 Ring groove ring 1 Compression ring, chromium-plated 0.00.6-35.41.01-32 2 Compression ring, chromium-plated 0.00.6-35.41.01-71 3 Compression ring, chromium-plated 0.00.6-35.41.01-86 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated Built-up piston, heavy fuel operation 1.60.6-26.70.00-04/ -05/ -07/ -09/ -11/ -13 Ring groove ring 1 Compression ring, three-side chromium-plated 0.00.6-35.41.01-70.1 2 Compression ring, chromium-plated 0.00.6-35.41.01-71 3 Compression ring, chromium-plated 0.00.6-35.41.01-86 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated



M453 C Piston rings Built-up piston, gas oil operation - ring groves flame-hardened 1.60.6-26.70.00-27 Ring groove ring 1 Compression ring, chromium-plated 0.00.6-35.41.01-98.1 or 0.00.6-35.41.01-98.3 2 Compression ring, chromium-plated 0.00.6-35.41.01-89 3 Compression ring, chromium-plated 0.00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated Built-up piston, heavy fuel operation - 1st ring groove chromium-plated 1.60.6-26.70.00-17 / -19 / -23 / -26 Ring groove ring 1 Compression ring, three-side chromium-plated 0.00.6-35.41.01-99.1 or 0.00.6-35.41.01-98.1 2 Compression ring, chromium-plated 0.00.6-35.41.01-89 3 Compression ring, chromium-plated 0.00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated



Edition 28.11.1998



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Page 25



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Engineer´s Handbook M451 - M453C



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Piston M453 C



Built-up piston, heavy fuel operation - 1st ring groove chromium-plated 1.60.626.70.00-28 Ring groove ring 1 Compression ring, three-side chromium-plated 1.90.7-26.17.01-01 2 + 3 Compression ring, chromium-plated 0.00.6-35.41.01-89 4 Oil scraper ring with tubular spring 0.00.6-35.41.01-87 chromium-plated



Edition 28.11.1998



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Page 26



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Piston M 451 - M453 C Piston pin Ø



→



135.00 -0.012



mm



Piston pin bush Attention ! Exchange only at MaK - Kiel Inside Ø



→ →



135.235



+ 0.025



mm



153.11



- 0.015



mm



→



130.00



- 0.2



mm



1.60.6-28.10.03-10 Inside Ø →



135.24



Outside Ø Width



Outside Ø



→



+ 0.025



151.125



Width



→



146.00



Width



→



90.00



- 0.015



- 0.5



- 0.2



mm mm mm mm



Piston pin bush Removal and fitting: Piston pin bushes must only be exchanged by an authorized workshop. The bushes must not be pressed out. The bushes are to be inserted in supercooled condition. For this purpose a temperature difference of 140 ° C is required, that means warm up connecting rod to abt. 80 ° C, supercool bush to abt. - 60 ° C.



Edition 28.11.1998



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Page 27



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Liner M 451 - M453 C →



Nominal size Ø (original size) Wear limits Wear and tear value → Max. ovality



→



Wedge shape



Height Depth *



→ →



320.00 - 320.057



mm



1.00



mm



0.30



mm



8.00



mm



0.03



mm



Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring. 3 Canyon Max. number → Length



→



Total width



→



8.00



mm



4.00



mm



Individual deep blow-through ducts in the area of the 1st piston ring ( TDC ) Wedge shape



Edition 28.11.1998



Pocket



Score



TDC 1st ring



Canyon



Service document of Caterpillar Motoren GmbH & Co. KG



Page 28



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Engineer´s Handbook M451 - M453C



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Liner Score



Number



→



3



Length



→



180.00



mm



0.03



mm



Depth → Hard vertical, linear friction marks. Pocket



→



Number Length



3



→



Width ** Depth * Areal irregular indentations.



90.00



mm



→



30.00



mm



→



0.02



mm



* Radius r ≥ 3 mm * * In circumferential direction



When reaching the wear limit in the area of the reversing point of the upper piston ring or other wear limits acc. to specification on pages 28-29 the liner has to be replaced. Refinishing is only possible at Mak in Kiel. During installation attention must be paid that the marks on the liner and the cylinder block coincide. Sealing liner - cylinder head M 452 / M 453 Correct position of the joint ring



Edition 28.11.1998



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Page 29



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Connecting rod M 453 - M453 C Big end bearing Bolts without bores Pretighten lower big end bearing bolts 3 + 4 with upper big end bearing bolts 1 + 2 twice in the sequence 1 - 2 / 1 - 2 with → Tighten lower big end bearing bolts 3 + 4 with → Tighten upper big end bearing bolts 1 + 2 with →



→



Tightening from pretorque to final tightening torque corresponds to an angle of 45 ° to 60 ° for the bolts 1 and 2 and 60 ° to 85 ° for the bolts 3 and 4. The minimum tightening angle has to be checked. The tightening specification is also valid for bolts with one bore.



Bolts with several bores Pretighten lower big end bearing bolts 3 + 4 with Pretighten upper big end bearing bolts 1 + 2 with → Tighten big end bearing bolts in the sequence 3 - 4 and 1 - 2 with →



Gap M453 In-line+Vee Gap → Limit value



→



Journal diameter ( h 6 )



Bearing clearance



Edition 28.11.1998



→



→



M



= 330



Nm



M



= 330



Nm



M



= 750



Nm



M



= 750



Nm



The first figure is the cylinder number (here cyl.1)



The second figure is the bolt numbering.



→



M



= 330



Nm



M



= 330



Nm



M



= 600



Nm



0.70 - 1.00



mm



0.60



mm



244.971-245.00



mm



0.24 - 0.32



mm



Service document of Caterpillar Motoren GmbH & Co. KG



Page 30



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Engineer´s Handbook M451 - M453C



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Connecting rod Gap of the big end bearings Measure and note the measuring distance between the bores on the top side of the connecting rod. Remove the upper big end bearing bolts. Measure the measuring distance again, the difference size ∆l is the gap „ K ". If the value falls below the limit renew the bearing shells in pairs.



M 452 Big end bearing 1.60.7-26.01.00-07 / 10 / 11 / 12 / 13 / 15 Pretighten both sides with → then tighten both sides with → 1.60.7-26.01.00-16 / 17 / 18 / 19 Pretighten nut on camshaft side with → Measure gap on exhaust gas side. Tighten nut on exhaust gas side with → Tighten nut on camshaft side with → Check, if remaining gap on camshaft and exhaust gas side is smaller than → If the remainig gap exceeds this value, tighten nuts further until gap is smaller than → then tighten bolts as follows: without split pin locking 1st step → Use tightening angle gauge. 2nd step → With split pin locking 1st step → 2nd step



→



M



= 700



Nm



M



= 1200



Nm



M



= 200



Nm



M



= 450



Nm



M



= 450



Nm



< 0.05



mm



> 0.05



mm



Dw = 40° Dw = 65° Dw = 40° Dw = 55°



If there is no split pin hole, tighten nut further in the tightening angle range from 55 ° to 80 ° up to the next split pin hole. The tightening angle must not be less than 55° .



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 31



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Engineer´s Handbook M451 - M453C



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Connecting rod Big end bearing Gap → Limit value



→



Journal diameter



→



0.44 - 0.57



mm



0.35



mm



224.971 - 225.00



mm



Gap of the big end bearings Loosen big end bearing nuts on camshaft side by 55 ° angle of rotation, loosen opposite side completely and measure gap „K“. Big end bearing Fitting Tighten nut on camshaft side with Md = 100 Nm and tighten further by 55 ° torsional angle. Measure gap „K“ on exhaust gas side, then tighten nuts until gap is ≤ 0.05 mm. Check on camshaft side, if the bearing cap has lifted, if necessary, tighten nuts until gap is ≤ 0.05 mm (bearing is pretightened).



M 451



Big end bearing 1.60.7-26.01.00-08 / 09 Pretighten nuts with → and tighten with → Gap



→



Limit value



→



Journal diameter



→



M



= 700



Nm



M



= 1200



Nm



0.44 - 0.57



mm



0.35



mm



224.971 - 225.00



mm



Tighten both sides acc. to specification. Loosen on one side and measure gap between bearing cap and connecting rod.



Edition 28.11.1998



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Main bearings M 453 - M453 C M 453 in - line Coat threads and contact surfaces of the nuts with Molykote. Tighten nut on camshaft side M = 200 with → Tighten nut on exhaust gas side M = 550 with → Tighten nut on camshaft side M = 550 with → Check, if remaining gap on camshaft and exhaust gas side is smaller than → 0.05 If the remaining gap exceeds this value, tighten nuts further until the gap is smaller than 0.05 mm. Then tighten both nuts: 1 st step



→



Dw = 30°



2 nd step



→



Dw = 60°



Nm Nm Nm mm



Tightening torque is valid for all engines M 453 in-line. Use torsional angle gauge. Normal main bearing M453 in-line Gap → Limit value



→



Journal diameter ( h 6 )



Bearing clearance



→



→



Located main bearing M453 in-line Gap → Limit value



→



Axial clearance



Edition 28.11.1998



→



0.55 - 0.75



mm



0.50



mm



244.971 - 245.00



mm



0.28



+ 0.1



mm



0.30 - 0.53



mm



0.30



mm



0.25 + 0.03 - 0.09



mm



Service document of Caterpillar Motoren GmbH & Co. KG



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Main bearings Journal diameter ( h 6 ) → Bearing clearance



244.971 - 245.00



→



0.28



mm



+ 0.1



mm



Gap of the main bearings M 453 - M 453 in - line Loosen the bearing bolts on exhaust gas side by 60 ° (acc. to torsional angle gauge). Loosen the bearing bolts on camshaft side completely. Measure gap „ K " on camshaft side. M 453 V - type 1.66. / 68. 7-12.00.00-01 Pretighten nuts with Check gap, must be " 0 ". Tighten nuts with → 1.66. / 68.7-12.00.00-02 Pretighten nut on B - side with → Measure gap on A - side with loosened nut. Tighten nut on A - side with →



→



M



= 700



Nm



Dw = 80° M



= 200



Nm



M



= 400



Nm



Tighten nut on B - side with



→



M



= 400



Nm



Tighten nut on A - side with



→



M



= 700



Nm



Tighten nut on B - side with



→



M



= 700



Nm



Check, if remaining gap on A - side and B - side is → If the remaining gap exceeds this value, tighten nut further until the gap is → then tighten alternately on A - side and B - side: 1st step → 2nd step → Use torsional angle gauge.



Edition 28.11.1998



< 0.05



mm



< 0.05



mm



Dw = 40° Dw = 80°



Service document of Caterpillar Motoren GmbH & Co. KG



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Main bearings 1.66. / 68.7-12.00.00-03 Pretighten nut on B - side with → Measure gap on A - side with loosened nuts. Tighten nut on A - side with →



M



= 200



Nm



M



= 400



Nm



Tighten nut on B - side with



→



M



= 400



Nm



Tighten nut on A - side with



→



M



= 700



Nm



M



= 700



Nm



Tighten nut on B - side with → Check, if remaining gap on A - side and B - side is → If the remaining gap exceeds this value, tighten nuts further until gap is → then tighten alternately on A - side and B - side : 1st step → 2nd step → Use torsional angle gauge. Normal main bearing M453 V-type Gap → Limit value



→



Journal diameter ( h 6 ) Bearing clearance



Edition 28.11.1998



→



→



< 0.05



mm



< 0.05



mm



Dw = 55° Dw = 110°



0.70 - 0.90



mm



0.60



mm



299.977 - 300.00



mm



0.30



+ 0.11



Service document of Caterpillar Motoren GmbH & Co. KG



mm



Page 35



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Engineer´s Handbook M451 - M453C



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Main bearings Located main bearing M453 V-type Gap → Limt value



→



Axial clearance



→



Journal diameter ( h 6 ) Bearing clearance



→



→



0.35 - 0.50



mm



0.30



mm



0.24 - 0.51



mm



299.997 - 300.00



mm



0.30



+ 0.11



mm



Gap of main bearings M 453 Vee Loosen the bearing bolts, e. g. on A-side by 110 ° (acc. to torsional angle gauge). Loosen the bearing bolts , e. g. on B - side completely. Measure gap „ K " on B-side. The main bearings with maximum stress : 6 M 452 Ø 4 and 5



6 M 453 Ø 5 and 8



8 M 452 Ø 5 and 7



8 M 453 Ø 6 and 8



9 M 452 Ø 5 and 9



9 M 453 Ø 6 and 10



12 M 453 Ø 4 and 5



16 M 453 Ø 5 and 7



In case of inadmissible crank web deflection, piston seizures or other irregularities as well as faults in the oil system (filter or oil supply failure) the bearings must be removed immediately, checked and replaced, if necessary. Direct-coupled units with thrust bearing are equipped with located main bearings with increased axial clearance. Removal of bottom bearing shell : Sense of rotation of the crankshaft to the right (view on the flywheel from the tail shaft), because otherwise the bearing shell lug will be sheared off. When fitting a normal main bearing instead of a located main bearing thrust rings are screwed on the located main bearing cap. Before and after every removal of the main bearings the crank web deflection must be measured and recorded. If a bottom shell is removed, the adjacent bearings must be fitted. Attention: When removing the located bearing: Supporting is necessary in case of an overhung flywheel.



Edition 28.11.1998



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Page 36



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Main bearings Bedplate The material quality of the bedplates was improved to GGG 50. Before turning in main bearing shells, attention must be paid that on the turning-in side the edge of the bearing pocket is chamfered by means of emery cloth. Otherwise there is a danger that the bearing shell seizes during turning-in.



Edition 28.11.1998



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Page 37



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Main bearings M 452 Tightening torques 1.53. / 54. / 59.7-12.00.00-04 Pretighten nuts with → Check gap, must be " 0 ". Tighten nuts with → Use tightening angle gauge. 1.53. / 54. / 59.7-12.00.00.-05 Pretighten nuts on camshaft side with → Measure gap on exhaust gas side on 2 bearings of a bedplate. Tighten nut on exhaust gas side with → Tighten nut on camshaft side with → Check, if remaining gap on camshaft and exhaust gas side is smaller than → If the remaining gap exceeds this value, tighten nuts further until gap is smaller than → then 1st step → 2nd step → Use tightening angle gauge. Gap Normal and located main bearing Gap → Limit value



Bearing clearance



Nm



Dw = 65°



M



= 200



Nm



M



= 450



Nm



M



= 450



Nm



< 0.05



mm



< 0.05



mm



Dw = 40° Dw = 65°



mm



0.65



mm



→



224.971 - 225.00



mm



→



0.22 - 0.31



mm



0.25 - 0.3



mm



Located main bearing Axial clearance →



Edition 28.11.1998



= 400



0.65 - 0.83



→



Journal diameter



M



Service document of Caterpillar Motoren GmbH & Co. KG



Page 38



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Main bearings M 451 Tightening torques 1.53. / 54. / 59.7-12.00-02 / 03 Tighten both sides with → 1.53. / 54. / 59.7-12.00-04 Pretighten nuts with → Check gap, must be " 0 ". Tighten nuts with → Use torsional angle gauge. Gap 1.53. / 54.7-12.00-02 / 03 Gap → Limit value



→



1.53. / 54.7-12.00-04 Gap → Limit value



→



Journal diameter



→



M



= 1300 - 1350 Nm



M



= 400



Nm



Dw = 65°



0.36 - 0.49



mm



0.36



mm



0.65 - 0.83



mm



0.65



mm



224.971 - 225.00



mm



Tighten nuts acc. to specification. Loosen nuts on one side and measure gap between bearing cap and bedplate.



Edition 28.11.1998



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Counterweight M 452- M453 C 6 M452 1.63.7-25.20.00-02 / 03 6 M453 1.63.7-25.20.00-04 8 M453 1.64.7-25.20.00-01 / 02 9 M452 - 453 1.69.7-25.20.00-01 Tighten screws with →



M



= 300



Nm



Additional torque to reach the correct position of the screw head. 6 M452 - 453 1.63.7-25.20.00-05 / 06 / 07 8 M452 - 453 1.64.7-25.20.00-03 / 04 9 M453 1.69.7-25.20.00-02 Tighten screws with →



M



= 440



Nm



Additional torque to reach the correct position of the screw head. 6 M453 1.63.7-25.20.00-08 / 09 / 10 8 M453 1.64.7-25.20.00-05 / 06 / 07 9 M453 1.69.7-25.20.00-03 / 04 Tighten screws with →



M



= 530



Nm



12 M453 1.66.7-25.20.00-01 Tighten screws with →



M



= 550



Nm



12 M453 1.66.7-25.20.00-02 / 03 / 04 16 M453 1.68.7-25.20.00-02 / 04 Tighten screws with →



M



= 600



Nm



12 M453 1.66.7-25.20.00-05 16 M453 1.68.7-25.20.00-05 Tighten screws with →



M



= 700



Nm



Edition 28.11.1998



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Page 40



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Counterweight The following bolts are used for counterweight mounting: Bolt



Thread



Length



Total length



Spanner size



1. 70. 7 - 28. 10. 04 - 04



M 24 x 2



226



250



27



1. 00. 7 - 88. 50. 50 - 92



M 24 x 2



251



275



27



1. 00. 7 - 88. 50. 55 - 80



M 24 x 2



262



292



36



1. 00. 7 - 88. 50. 50 - 62



M 27 x 2



232



272



36



1. 00. 7 - 88. 50. 55 - 06



M 27 x 2



292



322



36



The bolts are used for the following counterweight mountings: 1. 70. 7 - 28. 10. 04 - 04



1. 63. 7 - 25. 20. 00 - 02 / 03 / 04 1. 64. 7 - 25. 20. 00 - 01 / 02 1. 69. 7 - 25. 20. 00 - 01



1. 00. 7 - 88. 50. 50 - 92



1. 63. 7 - 25. 20. 00 - 05 / 06 / 07 1. 64. 7 - 25. 20. 00 - 03 / 04 1. 69. 7 - 25. 20. 00 - 02



1. 00. 7 - 88. 50. 55 - 80



1. 63. 7 - 25. 20. 00 - 08 / 09 / 10 1. 64. 7 - 25. 20. 00 - 05 / 06 / 07 1. 69. 7 - 25. 20. 00 - 03 / 04



1.00. 7 - 88. 50. 50 - 62



1. 66. 7 - 25. 20. 00 - 01



1.00. 7 - 88. 50. 55 - 06



1. 66. 7 - 25. 20. 00 - 02 / 03 / 04 / 05 1. 68. 7 - 25. 20. 00 - 02 / 04 / 05



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 41



- 02



- 03



- 04



- 05



m



Edition 28.11.1998



Counterweight mounting 1.69.7-25.20.00-



Counterweight mounting 1.63.7-25.20.00- 06



- 07



- 08



- 09



- 10



- 01



- 02



- 03



- 04



Bolt M 24 x 2 226 mm long SZ 27



Bolt M 24 x 2 262 mm long SZ 36



- 01



- 02



- 03



- 04



- 05



- 06



- 07



Bolt M 24 x 2 226 mm long SZ 27 Bolt M 24 x 2 251 mm long SZ 27 Bolt M 24 x 2 262 mm long SZ 36 Counterweight mounting 1.66.7-25.20.00- 01



- 02



- 03



- 04



Counterweight mounting 1.68.7-25.20.00- 05



- 02



- 04



Engineer´s Handbook M451 - M453C



Counterweight mounting 1.64.7-25.20.00-



SZ = Spanner size



Counterweight



Service document of Caterpillar Motoren GmbH & Co. KG



Bolt M 24 x 2 251 mm long SZ 27



- 05



Bolt M 27 x 2 232 mm long SZ 36



SZ = Spanner size



c



Page 42



Bolt M 27 x 2 292 mm long SZ 36



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Engineer´s Handbook M451 - M453C



c



Gear drive M 452 - M453 C Gear wheel on crankshaft Tighten screws with → Tighten further up to the next split pin hole. Also on M453 Vee-engines.



M



= 115



Nm



Gear wheel on crankshaft Fixing on the crankshaft is effected by 6 studs and 4 fitted bolts. The fitted bolts are arranged beside the joint faces. Reamed bores 17 - 17.0018 mm (H7).



Twin wheel Tighten screws for bearing bracket with → M 20 x 55 mm, SK DIN 933, locked by wire Ø 2.0 mm



M



= 300



Nm



Tighten screws for the thrust ring twin wheel bearing bracket with → M 12 x 40 SK DIN 933



M



= 40



Nm



Camshaft gear Mechanical tightening Pretighten nut with → then tighten with →



M



= 100



Nm



Hydraulic tightening Pretighten nut with and tighten with →



→



Dw = 120° M



= 100



Nm



Dw = 240°



Hydraulic pressure to be applied 1400 bar, at the same time tighten slotted nut with a tightening angle of 240° M453 only.



Edition 28.11.1998



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Page 43



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Engineer´s Handbook M451 - M453C



c



Gear drive Twin wheel Radial clearance



→



0.19 - 0.24



mm



Clearance limit



→



0.30



mm



Axial clearance



→



0.35 - 0.65



mm



Measure backlash with feeler gauge. Measure axial clearance with feeler gauge or dial gauge. Pump drive gear Radial clearance



→



0.05 - 0.10



mm



Clearance limit



→



0.25



mm



Axial clearance



→



0.15 - 0.35



mm



Clearance limit



→



0.50



mm



0.20 - 0.28



mm



0.13 - 0.20



mm



0.20 - 0.25



mm



Crankshaft gear - intermediate wheel for cooling water pump →



0.20 - 0.28



mm



Intermediate wheel for cooling water pump - gear wheel on cooling water pump →



0.20



Backlashes Crankshaft gear - twin wheel Twin wheel - camshaft gear



→ →



Camshaft gear - governor drive gear



Edition 28.11.1998



→



± 0.05



Service document of Caterpillar Motoren GmbH & Co. KG



mm



Page 44



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Engineer´s Handbook M451 - M453C



c



Gear drive Twin wheel If possible, a bath-nitrided twin wheel shall be used with a bath-nitrided camshaft gear, the same applies to hardened gear wheels. In individual cases a bath-nitrided twin wheel may be replaced by a hardened twin wheel. A hardened twin wheel must not at all be replaced by a bath-nitrided twin wheel. Camshaft gear Before fitting the cone seat is to be checked by blue paste and possibly to be ground in. The gear wheel is mounted in dry state.



Governor drive, backlashes Pair of bevel gears → Pair of spur gears



→



Attached cooling water pump Clearance " S 1 " → Clearance " S 2 "



Edition 28.11.1998



→



0.20



mm



0.20



mm



1.00



mm



1.50



mm



Service document of Caterpillar Motoren GmbH & Co. KG



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Engineer´s Handbook M451 - M453C



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Gear drive Instructions for adjustment: Tooth 26 Long-interval and short-interval 0 St.B firing 1. Turn piston A1 and camshaft (cam A1) into TDC position. Then insert left-hand twin wheel and camshaft gear. 2. Turn piston B1 and camshaft (cam B1) into TDC position. Then insert right-hand twin wheel and camshaft gear. Tooth1 3. Adjust inlet and exhaust valve timing and check firing sequence. Tooth 113 4. Mark position of the gear wheels to each other on the twin wheels.



Tooth 32 Tooth 33 0 0 BB



Tooth 56



Instructions for fitting: M 453 in-line 1. Turn piston cyl. 1 into TDC position. 2. Mount gear wheel on crankshaft, tooth 1 (marked on gear wheel) is directly at the joint face of the gear wheel. Also marked are tooth 26 with „0“ stb and the teeth 32 and 33 with „00“ port side. The gear wheel joint face with tooth 1 must point horizontally to the left. The joint face of the bedplate may serve as help. 3. Mount twin wheel on bearing journal, bearing journal is only loosely mounted, not tightened. 4. Turn camshaft so that keyway and key are pointing straight upward. 5. Mount camshaft gear, gear is manufactured so that tooth No. „1“ is exactly on the center line of the fitted key groove. 6. Basic setting is finished. Now it is absolutely necessary to check the inlet and exhaust valve timing. 7. In case of deviations turn camshaft gear or gear wheel on crankshaft. 8. Adjust backlash and tighten and secure bearing journal for the twin wheel. Tooth 68



Possibility of checking the adjustment 1. Turn piston cyl. 1 in TDC position. 2. Gear box with dead center indicator and flywheel casing are removed. 3. Fit the auxiliary dead center indicator anywhere (e.g. frame of the floor plates) and apply auxiliary marking on the flywheel. 4. Measure with depth gauge on a cylinder of your choice from the spring plate of a half-open valve to a level surface in the cylinder head, and note the measured dimension. 5. Replace gear drive.



Edition 28.11.1998



Bb. 1



Tooth on center parallel key groove



St.B 1



Tooth 47



Service document of Caterpillar Motoren GmbH & Co. KG



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Gear drive 6. After completion of adjustment, in position auxiliary marking on flywheel in coincidence with the auxiliary dead center indicator the noted dimension must result again. Adjustment aid: If e.g. on the port type tooth 1 of the big twin wheel is in mesh with the teeth 32 - 33 of the crankshaft gear wheel, tooth 1 on the small twin wheel can be ascertained by means of the bore (sketch). Then the teeth 32 - 33 with which tooth 68 of the camshaft gear is in mesh can be ascertained by counting. Important! It is absolutely necessary to take care that you start counting at tooth 1. Tooth 1 is not zero



Check of inlet and exhaust valve timing 1. The bottom dead center of cyl. 1 has to be ascertained. This is possible by the following methods: a) With removed gear box an auxiliary dead center indicator is to be fitted. From the approximate BDC position turn bottom side of the piston to the camshaft side until it is flush with the bottom edge of the liner. Apply mark on the flywheel. Then turn bottom side of the piston to the exhaust gas side until it is flush with the bottom edge of the liner. Apply mark on the flywheel. Half-way between the two marks is the bottom dead center. This can also be carried out with a magnetic gauge. With the piston in BDC position the cams of cyl. 1must have the position as shown in the accompanying sketches. b) By means of a graduated disk which is mounted on a threaded rod with a 5/8" thread for in-line and Vee engines. This threaded rod is screwed into the flanged shaft on the opposite side of the coupling. On the flywheel the TDC of cyl. 1 has to be ascertained, then position „0“ is to be marked on the graduated disk by means of an auxiliary indicator, then turn by 180°. The BDC of cyl. 1 is reached.



Tooth 1 Engine counterclockwise



BDC



Inlet valve opens



TDC



TDC



BDC



Inlet cams Engine clockwise



BDC



Inlet valve opens



TDC



TDC



BDC



Edition 28.11.1998



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Engineer´s Handbook M451 - M453C



c



Gear drive Engine counterclockwise This method is only applicable on engines without power take-off. 2. Check drawing numbers of the fitted inlet and exhaust TDC cams. The drawing numbers are stamped into the cam sides. 3. Fix dial gauge on the roller tappet of the inlet cam of cyl.1. To facilitate the work it is possible to place a second roller tappet inversely-roller pointing upwards - on the existing Exhaust roller tappet, taking care of the dead center position valve opens (sketch). 4. See the value of the cam lift „S“ from the table below and turn crankshaft in direction of engine rotation until the BDC BDC value can be read from the dial gauge. The crankshaft must now have turned on by the control angle stated for the cam lift „S“. TDC Attention! The opening and closing angles stated, too, are irrelevant for these works and are only stated for Exhaust cams regularity’s sake. 5. The same procedure can be used for the exhaust Engine clockwise valves, taking care of the different dead center position as compared to the inlet valves (sketch). TDC



Example Engine has:Inlet cam 1.60.7-32.10.01-15 Control angle 131° + 3° Cam lift „S“ 5.90 mm Exhaust cam 1.60.7-32.20.01-15 Control angle 161° + 3° Cam lift „S“ 8.290 mm Flywheel diameter 1200 mm Exhaust 1° = 1200 x 3.14 / 360 = 10.47 mm If the crankshaft is turned in direction of engine rotation until the dial gauge on valve opens the inlet cam shows the dimension 5.90 mm, the flywheel must have turned on by 131° x 10.47 mm = 1372 mm from BDC the BDC position. In case of the exhaust cam the flywheel must have turned on by 161° x 10.47 mm = 1686 mm from the TDC position when the indication on the dial gauge is TDC 8.290 mm.



BDC



Dead center indicator



Example inlet valve timing



Mark before turning. (At random, important is the BDC position cyl. 1.)



Mark after turning. Dial gauge on the inlet cam has the value 5.90 mm. Mark has changed from the initial position by 131° = 1372 mm in direction of rotation.



Edition 28.11.1998



Cyl. 1 BDC position



Service document of Caterpillar Motoren GmbH & Co. KG



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Gear drive Check of the inlet and exhaust valve timing acc. to 1.60.7-32.07.01-01 Inlet cam opens closes control cam lift " S " angle Drawing No. ° crank angle ° crank angle ° crank angle mm 1.60.7-32.10.01-05 70 ° bef. TDC 40 ° aft. BDC 131 ° ± 3 ° 5,90 1.60.7-32.10.01-06



115 ° bef. TDC 30 ° aft. BDC



95 ° ± 3 °



8,079



1.60.7-32.10.01-07



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



8,079



1.60.7-32.10.01-08



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



7,961



1.60.7-32.10.01-09



90 ° bef. TDC



40 ° aft. BDC



130 ° ± 3 °



8,730



1.60.7-32.10.01-15



58 ° bef. TDC



45 ° aft. BDC



162 ° ± 3 °



8,730



1.60.7-32.10.01-11



90 ° bef. TDC



40 ° aft. BDC



130 ° ± 3 °



8,730



1.60.7-32.10.01-12



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



7,961



1.60.7-32.10.01-13



115 ° bef. TDC 30 ° aft. BDC



95 ° ± 3 °



8,079



1.60.7-32.10.01-14



50 ° bef. TDC



45 ° aft. BDC



160 ° ± 3 °



7,961



1.60.7-32.12.01-03



70 ° bef. TDC



40 ° aft. BDC



131 ° ± 3 °



5,90



1.60.7-32.12.01-04



115 ° bef. TDC 30 ° aft. BDC



95 ° ± 3 °



8,079



1.60.7-32.12.01-05



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



8,079



1.60.7-32.12.01-06



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



7,961



1.60.7-32.12.01-07



120 ° bef. TDC 40 ° aft. BDC



100 ° ± 3 °



8,730



1.60.7-32.12.01-08



90 ° bef. TDC



40 ° aft. BDC



130 ° ± 3 °



8,730



1.60.7-32.12.01-14



50 ° bef. TDC



45 ° aft. BDC



160 ° ± 3 °



7,961



1.60.7-32.12.01-10



115 ° bef. TDC 30 ° aft. BDC



95 ° ± 3 °



8,079



1.60.7-32.12.01-11



70 ° bef. TDC



40 ° aft. BDC



140 ° ± 3 °



7,961



1.60.7-32.12.01-12



90 ° bef. TDC



40 ° aft. BDC



130 ° ± 3 °



8,730



1.60.7-32.12.01-13



50 ° bef. TDC



40 ° aft. BDC



160 ° ± 3 °



7,961



1.60.7-32.12.01-15



58 ° bef. TDC



45 ° aft. BDC



162 ° ± 3 °



8,730



Edition 28.11.1998



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Engineer´s Handbook M451 - M453C



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Gear drive Check of the inlet and exhaust valve timing acc. to 1.60.7-32.07-01-01 Exhaust cam opens closes control cam lift " S " angle Drawing No. ° crank angle° crank angle ° crank angle 1.60.7-32.20.01-07 40 ° bef. BDC TDC 162 ° ± 3 °



mm 7,10



1.60.7-32.20.01-08



50 ° bef. BDC



50 ° aft. TDC



156 ° ± 3 °



7,031



1.60.7-32.20.01-09



50 ° bef. BDC



20 ° aft. TDC



156 ° ± 3 °



7,031



1.60.7-32.20.01-06



45 ° bef. BDC



35 ° aft. TDC



157 ° ± 3 °



7,10



1.60.7-32.20.01-11



50 ° bef. BDC



55 ° aft. TDC



166 ° ± 3 °



8,290



1.60.7-32.20.01-12



45 ° bef. BDC



35 ° aft. TDC



157 ° ± 3 °



7,10



1.60.7-32.20.01-13



50 ° bef. BDC



55 ° aft. TDC



166 ° ± 3 °



8,290



1.60.7-32.20.01-14



40 ° bef. BDC



TDC



162 ° ± 3 °



7,031



50 ° aft. TDC



161 ° ± 3 °



8,290



1.60.7-32.20.01-15



55 ° bef. BDC



1.60.7-32.22.01-04



45 ° bef. BDC



35 ° aft. TDC



157 ° ± 3 °



7,10



1.60.7-32.22.01-05



40 ° bef. BDC



TDC



162 ° ± 3 °



7,10



1.60.7-32.22.01-06



50 ° bef. BDC



20 ° aft. TDC



156 ° ± 3 °



7,031



1.60.7-32.22.01-07



50 ° bef. BDC



50 ° aft. TDC



156 ° ± 3 °



7,031



1.60.7-32.22.01-08



50 ° bef. BDC



55 ° aft. TDC



156 ° ± 3 °



8,987



35 ° aft. TDC



166 ° ± 3 °



8,290



1.60.7-32.22.01-09



50 ° bef. BDC



1.60.7-32.22.01-10



50 ° bef. BDC



55 ° aft. TDC



166 ° ± 3 °



8,290



1.60.7-32.22.01-11



45 ° bef. BDC



35 ° aft. TDC



157 ° ± 3 °



7,10



1.60.7-32.22.01-12



40 ° bef. BDC



TDC



162 ° ± 3 °



7,10



1.60.7-32.22.01-13



50 ° bef. BDC



55 ° aft. TDC



166 ° ± 3 °



8,290



1.60.7-32.22.01-15



55 ° bef. BDC



50 ° aft. TDC



161 ° ± 3 °



8,290



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 50



m



Edition 28.11.1998



Engineer´s Handbook M451 - M453C



Gear drive



Service document of Caterpillar Motoren GmbH & Co. KG



Setting for long-interval and short-interval firing. 1. Turn piston A 1 and camshaft (cam A 1) into TDC position. Then insert left twin wheel and camshaft gear. 2. Turn piston B 1 and camshaft (cam B 1) into TDC position. Then insert right twin wheel and camshaft gear. 3. Adjust inlet and exhaust valve timing and check firing sequence. 4. Mark position of the gear wheels to each other on the twin wheels.



Gear wheel setting 12 and 16 M



c



Page 51



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Engineer´s Handbook M451 - M453C



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Gear drive Adjustment of gear drive Port type Piston 1 in TDC Tooth 1



After adjustment of the inlet and exhaust valve timing, position of the teeth marked on the twin wheel.



Camshaft gear



Tooth 68 Tooth 32 Tooth 33 Twin wheel



Centrifugal pump Intermediate wheel to the centrifugal pump



Tooth 1



Tooth 32



Tooth 33



Crankshaft gear



Tooth 1



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



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Engineer´s Handbook M451 - M453C



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Gear drive Adjustment of gear drive Starboard type Piston 1 in TDC



After adjustment of the inlet and exhaust valve timing, position of the teeth marked on the twin wheel.



Tooth 1



Tooth 47St. B 1



1 1M



Tooth 22



Tooth 21 Tooth 53



Tooth 106



Tooth 105 M 0 0 0 St.B



Tooth 26



Tooth 1



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



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Engineer´s Handbook M451 - M453C



c



Governor drive



Edition 28.11.1998



Y



A



Instruction for adjustment of governor drive M452/453 with the governors PGA and EGB 10 Y=A-B 1. Assemble governor with new bevel wheels, i.e. instead of the ball bearings 1 and 2 and the spacer rings 3 and 4 first assembly rings are fitted. 2. Fit bevel wheels so that the backs are inalignment and the backlash is X 0.2 mm. 3. Measure dimension „X“ and determine width of spacer rings 1 andturn to size. Assemble horizontal drive. 3 4. Realign bevel wheel of the vertical drive. Measure dimension „Y“ and C determine height „C“ of the spacer bush. Turn spacer bush to size and B A assemble governor drive. Check backlash and position of the backs of the bevel wheels.



B



Instruction for adjustment of governor drive M452/453 with the governors UG8 and Regulateurs Europa 1104 Z 1. Mount governor drive acc. to the sketch. Use 4 thickness gauges of the same size. The backlash of 0.1 mm and alignment of the tooth ends are attained by horizontal displacement of the shaft with its bearing S (dimension „X“) and by choosing the size of the thickness gauges in vertical direction (dimension „S“). 2. Coat tooth flanks of a bevel wheel with engineer’s marking blue. Make several revolutions in running direction. If the X bearing pattern shown in figure 0 on page 56 is not attained, the position of Z the flanks resp. the bearing pattern must be corrected 3. After adjustment of the bearing pattern figure 0 on page 116 turn off spacer bush on the governor and spacer for dimension „X“. Turning-off dimension: Z Spacer bush = size of thickness gauge „S“ Spacer = dimension „X“ 4. Mount governor drive complete.



S



2



Z



B=A-X-C



Service document of Caterpillar Motoren GmbH & Co. KG



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c



Governor drive Governor drive V-type engines - exchange of bearings 1. Dismount governor from drive. 2. Remove grooved nut 1. 3. Remove circlip 2.



1 5



2



4. Remove cap 3 and circlip. 5. Drive gear wheel 4 with bearing 5 out of the casing. 4



6. Withdraw bearing 6 from the casing. 7. Remove castellated nut 7. 6



8. Draw spur wheel 8 from shaft 9. 3



9. Remove clamping plate 10. 10. Remove cap 11.



11



11. Loosen castellated nut 12.



12



14



12. Remove shaft 9 with bearing 13 and spur wheel 8 from the casing. 13. Replace bearing 14 after loosening the circlip. 9



Assembly is carried out in reverse order.



13 10 8 7



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 55



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Engineer´s Handbook M451 - M453C



c



Governor drive 0



Bearing pattern not loaded



1



2



3



4



5



6



7



8



1. Bearing pattern wrong 2. Bearing pattern correct



Vertical displacement of bearing pattern 3. Bearing pattern wrong 4. Bearing pattern correct



5. Bearing pattern wrong 6. Bearing pattern correct



Longitudinal displacement of bearing pattern 7. Bearing pattern wrong 8. Bearing pattern correct



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 56



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Engineer´s Handbook M451 - M453C



c



Camshaft M 451 - M453 C Camshaft bearing Tighten bolts with a maximum torque of → M = 60 Nm (After each tightening the bearing clearance must be checked by all means. The new clearance of bearing shall be ≥ 0.10 mm.) Fit bearing with new bolts which are included in the delivery. Camshaft The hydraulic pressure applied on the set collar for axial adjustment of the camshaft is →



P



= 800



bar



Normal camshaft bearing Original clearance →



0.10 - 0.15



mm



Bearing Ø Camshaft Ø



→



90.10



→



Camshaft step bearing Clearance between step bearing and camshaft set collar →



+ 0.03



mm



89.978 - 90.00



mm



0.50



mm



Clearance limit between step bearing and 1.00 mm camshaft set collar → If the clearance limit of 1 mm is reached, the set collar is to be rotated and newly bored. The set collar (hydraulic mounting) is to be readjusted by means of the hydraulic tool. Injection cams, reversible, non reversible Pretighten bolts by hand and tighten alternately in small steps with →



M



= 140 ± 10



Nm



Inlet cams, non reversible Pretighten bolts by hand and tighten alternately in small steps with →



M



= 140 ± 10



Nm



Inlet cams, reversible Pretighten bolts by hand and tighten alternately in small steps with →



M



= 24 - 26



Nm



Edition 28.11.1998



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Page 57



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Engineer´s Handbook M451 - M453C



c



Camshaft Inlet cams, reversible M 453 C Pretighten bolts by hand and tighten alternately in small steps with →



M



= 27 - 29



Nm



Exhaust cams, non reversible Pretighten bolts by hand and tighten alternately in small steps with →



M



= 140 ± 10



Nm



Exhaust cams, reversible Pretighten bolts by hand and tighten alternately in small steps with →



M



= 24 - 26



Nm



Exhaust cams, reversible M 453 C Pretighten bolts by hand and tighten alternately in small steps with →



M



= 27 - 29



Nm



For all cam assemblies: Slightly coat contact surface of bolts and threads with Molykote paste G. Inlet cam, split When fitting split inlet and exhaust cams pay attention that the clamping sleeve fits on the edge „X“.



X



X



Edition 28.11.1998



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Camshaft Starting cam Setting Turn engine until cyl. 1 is Firing TDC „X°“ after firing TDC. Fit starting air distributor (do not connect pipes). Remove locking screw - 1 - and pressure spring - 2 - from control piston for cyl. 1. Direct light beam from top into the bore - 3 - and observe control piston - 4 - through the bore - 5 - . Turn starting cam in the opposite direction to the rotation of the camshaft until the light gap is still just visible. Now the starting cam has reached the position 3 „starting valve opens“. Tighten well fixing screw - 6 - for the starting 5 cam - 7 -. Tighten headless screw 8 - and secure with centre punch.



Position at start of setting



Position „valve opens"



2 1 2



4



8 7



6



Dimension „X°“ reversible non-reversible



6 / 12 cyl. 8° 0°



8 / 9 / 16 cyl. 17 °, 30´ 0°



Main starting air valve Tightening torque of the big bottom nut (guide body) →



M



= 350



Nm



Tightening torque for the screws of the top flange →



M



= 24



Nm



Starting fuel limiter Tightening torque for the Allen screws



M



= 24



Nm



M



= 20



Nm



M



= 7



Nm



M



= 12



Nm



Tightening torque for throttle screw



→



→



Stop cylinder Tightening torque for the axial bottom nut Tightening torque for the nuts → 8 nuts, 4 at the top and 4 at the bottom.



Edition 28.11.1998



→



Service document of Caterpillar Motoren GmbH & Co. KG



Page 59



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Engineer´s Handbook M451 - M453C



c



Camshaft M 452 - M453 C Lower valve drive 1.60.7-35.02.00-13 Tighten bolts for the roller tappet housing with (M 12 x 40 DIN 912) Tighten nuts for the intermediate plate of the fuel injection pump with → (M 12 DIN 934) M 453 and M 453 C 1.60.7-35.02.00-14 Tighten bolts for the roller tappet housing with (M 12 x 40 DIN 912)



→



→



Tighten nuts for the intermediate plate of the fuel injection pump with → (M 12 DIN 934) M 453 C 1.60.7-35.02.00-15 / 16 Tighten bolts for the roller tappet housing with (M 16 x 90 DIN 931 with tension bush) Tighten nuts for the intermediate plate for the fuel injection pump with → (M 16 DIN 934) M 453 C 1.60.7-35.02.00-17 Tighten screws for the roller tappet housing with → (M 12 x 90 DIN 931 with tension bush) Tighten nuts for the intermediate plate of the fuel injection pump with → (M 12 DIN 934)



Edition 28.11.1998



→



M



= 45



Nm



M



= 45



Nm



M



= 45



Nm



M



= 65



Nm



M



= 145



Nm



M



= 145



Nm



M



= 65



Nm



M



= 65



Nm



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Fuel injection pumps M 452 - M453 C Injection pumps M 453 Tighten fixing bolts with



→



M



= 120



Nm



(Tie bolt 1.00.7-88.50.59-25 with tension bush E26 x 18 DIN 2510) M 453 C Tighten fixing bolts with



→



M



= 120



Nm



(Tie bolts 1.00.7-88.50.59-25 with spacer bush 1.00.7-88.50.63-65) Tightening torque is valid for the following pump types: PF 1W



240 BS 1722



PF 1W



220 BS 1710



PF 1W



240 BS 1733



PF 1W



220 BS 1766



PF 1W



240 BS 1781



PF 1W



240 BS 1785



PF 1WV 260 / 7



PF 1WV 260 V 16277



PF 1WV 260 / 8 Tighten bolts / nuts for the delivery valve - pressure balancing valve with →



M



= 100



Nm



Fuel injection pump M 453 C Practice has shown that the fixing screws are difficult of access and cannot be tightened as prescribed with normal tools. Therefore, a short offset box wrench with welded-on button die is included in the delivery now. With this tool it is possible to tighten the screws with the prescribed tightening torque of 120 Nm, provided that on all cylinders the right protective tube and on the relative cylinders mounted parts as stop cylinder, limit switch, starting fuel limiter etc. are removed. Fuel delivery pipes In case of possible upsetting on the cones the pipes must be rebored to the original dimension : M 452 = 3 mm M 453 = 4 mm



Edition 28.11.1998



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Page 61



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Fuel injection pumps Injection pump setting In case of new installations all pumps are adjusted with dimension „Y“ = 10.3 mm (from supporting flange to top edge of thrust piece, roller on base circle of cam). Before fitting an overhauled or new injection pump, this dimension must be checked and, if necessary, readjusted. Setting : 10.3 + 0.3 mm On 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 -line mark must be visible in the window during the pump stroke - does not apply here. Pre-stroke Engine type



M451 not super charged Pre-stroke 4 - 4.5



M451 super charged 4.8



Setting dimension „Y“



M452



M453



4.8



6 - 6.5



It is possible to use the M 453 injection on M 452 engines, in that case the pre-stroke must be set to 6 - 6.5 mm. New M453 C - engines have roller tappets with thrust piece and shims. On this pump type the dimension „Y" = 10.3 mm, from supporting flange to top edge of thrust piece, roller on base circle of cam, is adjusted by means of shims. Shims are available as follows: 1 ; 2 ; 2.2 ; 2.4 ; 2.6 and 2.8 mm thick. Commencement of delivery Check See commencement of delivery from the acceptance test record and measure the respective arc on the flywheel and mark commencement of delivery. Bar engine in direction of rotation until the line mark - 1 - on 1 the spring cup coincides with the line mark - 2 on the pump casing. Check on flywheel, if the commencement of delivery mark is below the dead centre indicator.



Edition 28.11.1998



2



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3



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Engineer´s Handbook M451 - M453C



c



Fuel injection pumps Basic setting Turn until the roller rests on the base circle of cam, then check whether the line mark - 1 on the spring cup coincides with the line mark - 3 - on the pump casing. If there is no coincidence any more, all parts concerned must be checked with regard to their condition and have to be replaced, if necessary. Then restore coincidence of the marks - 1 - and - 3 - (basic setting) by turning the setscrew - 4 - , tighten screws - 5 - , now it must not be possible any more to turn the setscrew - 4 -.



4



5



Edition 28.11.1998



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Engineer´s Handbook M451 - M453C



c



Flanged shaft mounting M 452 - M453 C Flanged shaft mounting without power take-off M452-M453 In-line 1.60.7-63.45.00-07 / 08 Tighten nuts for flanged shaft and vibration damper or spacer ring with →



M



= 140



Nm



Castellated nut M 18 x 1,5 DIN 935, split pin 4 x 32 DIN 94, washer B 19 DIN 125, length of the bolts 279 mm. Tighten screws for gear rim on flanged shaft with M 12 x 45 SK DIN 933



→



M453 1.60.7-63.45.00-09 Tighten nuts for flanged shaft and vibration damper with →



M



= 50



Nm



M



= 190



Nm



Castellated nut M 20 x 2 DIN 935, split pin 4 x 35 DIN 94, washer 21 DIN 125, length of the bolts 285 mm. Tighten screws for gear rim on flanged shaft with M 12 x 45 SK DIN 933



→



M



= 50



Nm



M453 1.60.7-63.45.00-10 Pretighten nuts for flanged shaft and vibration M = 300 Nm damper with → and tighten Dw = 30° with → possibly tighten further to the next split pin hole. Castellated nut M 20 x 2 DIN 935, split pin 4 x 36 DIN 94, length of the bolts 285 mm. Coat thread and contact surface of the nut on gear wheel side with Molykote, thread and contact surface of nut on crankshaft side remain dry. Tighten fixing screws for vibration damper with M 16 x 70 DIN 912



→



Tighten screws for gear rim on flanged shaft with M 12 x 45 SK DIN 933



Edition 28.11.1998



→



M



= 130



Nm



M



= 50



Nm



Service document of Caterpillar Motoren GmbH & Co. KG



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Engineer´s Handbook M451 - M453C



c



Flanged shaft mounting M453 Vee 1.61.7-63.45.00-11 / 12 Tighten nuts for flanged shaft and vibration M = 200 Nm damper with → - 11 with vibration damper, - 12 without vibration damper. Fixing screw for vibration damper M 20 x 110 DIN 912, castellated nut M 24 x 2 DIN 935, split pin 5 x 45 DIN 94 Tighten screws for gear rim on flanged shaft with M 12 x 35 SK DIN 933



→



1.61.7-63.45.00-13 Pretighten nuts for flanged shaft and vibration damper with → and tighten with → possibly tighten further up to the next split pin hole. Castellated nut M 24 x 2 DIN 935, split pin 5 x 45 DIN 94 Tighten screws for gear rim on flanged shaft with M 12 x 35 SK DIN 933



→



M



= 50



Nm



M



= 360



Nm



Dw = 30°



M



= 50



Nm



M = 260 Nm Tighten fixing screws for vibration damper with → M 20 x 110 DIN 912 Coat thread and contact surface of nut on gear wheel side with Molykote, thread and contact surface of nut on crankshaft side remain dry.



M 452 - M453 C Flanged shaft mounting with power take-off 1.60.7-63.40.00-02 / 03 Tighten nuts for flanged shaft and vibration damper or spacer ring with → M = 190 Nm M 20 x 2 DIN 935 The following is valid for the flanged shaft mounting: Tighten all screws and nuts crosswise in 2 steps. Tighten screws for gear rim on flanged shaft with M 12 x 45 SK 933 Tighten clamping bolts for flanged bearing in 2 steps with → M 20 x 2 DIN 935



Edition 28.11.1998



→



M



= 50



Nm



M



= 190



Nm



Service document of Caterpillar Motoren GmbH & Co. KG



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Engineer´s Handbook M451 - M453C



c



Flanged shaft mounting 1.60.7-63.40.00-04 / 05 Tighten nuts for flanged shaft and vibration damper or spacer ring with → M 20 x 2 DIN 935 Tighten screws for gear rim on flanged shaft with M 12 x 45 SK DIN 933



→



M



= 190



Nm



M



= 50



Nm



= 220



Nm



M



= 220



Nm



M



= 50



Nm



M



= 220



Nm



1.60.7-63.40.00-06 / 07 Tighten nuts for flanged shaft and vibration damper M or spacer ring with → M 20 x 2 DIN 935 Attention! Tightening torque is valid for oil. M452-M453 1.60.7-63.40.00-08 / 09 Tighten nuts for flanged shaft and vibration damper with → M 20 x 2 DIN 935 Tighten screws for gear rim on flanged shaft with → M 12 x 45 SK DIN 933 Tighten clamping bolts for flanged bearing in 2 steps with →



M453 1.60.7-63.40.00-10 / 11 / 12 Tighten nuts for flanged shaft and vibration damper or spacer ring with → M = 190 Nm Castellated nut M 20 x 2 DIN 935, split pin 4 x 36 DIN 94, washer 21 DIN 125, length of the bolts 281 mm fixing screws M 16 x 70 DIN 912 Tighten screws for gear rim on flanged shaft with → M = 50 Nm M 12 x 45 SK DIN 933 Tighten clamping bolts for flanged bearing with M 20 x 2 DIN 934



Edition 28.11.1998



→



M



= 190



Service document of Caterpillar Motoren GmbH & Co. KG



Nm



Page 66



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Engineer´s Handbook M451 - M453C



c



Flanged shaft mounting 1.60.7-63.40.00-13 / 14 Pretighten nuts for flanged shaft and vibration damper with → M = 300 Nm and tighten with → Dw = 30° Castellated nut M 20 x 2 DIN 935, split pin 4 x 36 DIN 94, length of the bolts 285 mm - Coat thread and contact surface of nut on gear wheel side with Molykote, thread and contact surface of nut on crankshaft side remain dry. Tighten screws for gear rim on flanged shaft with M 12 x 45 SK DIN 933



→



Tighten clamping bolts for flanged bearing in 2 steps up to → M 20 x 2 DIN 609 Tighten fixing screws for vibration damper with M 16 x 70 DIN 912



→



M



= 50



Nm



M



= 190



Nm



M



= 130



Nm



= 400



Nm



= 50



Nm



= 350



Nm



M453 V-type 1.61.7-63.40.00-11 Tighten nuts for flanged shaft and vibration damper with → M Castellated nut M 24 x 2 DIN 935, split pin 5 x 45 DIN 94 M Tighten screws for gear rim on flanged shaft with → M 12 x 35 DIN 933 Fixing screws for the vibration damper: M 20 x 110 DIN 912 161.7-63.40.00-12 Pretighten nuts for flanged shaft and vibration damper with → M and tighten with → Dw Castellated nut M 24 x 2 DIN 935, split pin 5 x 45 DIN 94, length the bolts 277 mm - instead of washer: strap over 2 bolts.



= 30°



Tighten screws for gear rim on flanged shaft with → M = 50 Nm M 12 x35 DIN 933 Tighten fixing screws with → M = 260 Nm M 20 x 110 DIN 912 Hint for fitting ! Before fitting the flanged shaft it is absolutely necessary to take care that the oil bore on the crankshaft is open and the pin 13 x 70 DIN 1470 is driven in.



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 67



m



Engineer´s Handbook M451 - M453C



c



Flywheel mounting M 451 - M453 C M451-M453 In-line + Vee Tighten nuts with → Attention! Tightening torque is valid for oil. M451-M452 1.50.7-73.10.00-06 / 07 Tighten nuts with → Attention! Tightening torque is valid for oil. M452 1.50.7-73.10.00-09 When using oil tighten nuts with



→



When using Molykote tighten nuts with



→



M



= 1730



Nm



M



= 1750



Nm



M



= 1600



Nm



M



= 1200



Nm



M 451 - M453 C Coupling bolts for the flywheel mounting Coupling bolts Total length mm



Fixing screws Clamped length mm



DIN 960



1.50.7-73.10.00-01 318 235 M 20 X 2 X 130 Intermediate shaft with located main bearing or relieved located main bearing 1.50.7-73.10.00-02 Flexible flange coupling



193



110



M 20 X 2 X 70



1.50.7-73.10.00-03 Intermediate shaft



243



160



M 20 X 2 X 70



1.50.7-73.10.00-04 318 235 M 20 X 2 X 130 Intermediate shaft with located main bearing or relieved located main bearing, disk brake.



Edition 28.11.1998



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Page 68



m



Engineer´s Handbook M451 - M453C



c



Flywheel mounting Coupling bolts



Fixing screws



Total length Clamped length mm mm DIN 960 1.50.7-73.10.00-05 318 235 M 20 X 2 X 130 Intermediate shaft with located main bearing or relieved located main bearing 1.50.7-73.10.00-06 Rigid coupling



224



160



*1



M 20 X 2 X 150



1.50.7-73.10.00-07 Geislinger coupling



318



235



*2



M 20 X 2 X 130



1.50.7-73.10.00-08 Flexible flange coupling



263



180



1.50.7-73.10.00-09 M452 and



250 161



218



M 20 X 2 X 150



*1



1.50.7-73.10.00-10 468 385 * 3 M 20 X 2 X 150 Intermediate shaft with located main bearing All coupling bolts have a thread M 36 X 3, with castellated nut and split pin. * 1 = head screws * 2 = with 2 O-rings acc. to order * 3 = with shim 1.60.7-73.10.00-01 318 235 Intermediate shaft with located main bearing or relieved located main bearing 1.60.7-73.10.00-02 285 Geislinger coupling, oil supply through the crankshaft



202



1.60.7-73.10.00-03 Overhung flexible coupling



170



262



1.60.7-73.10.00-04 262 Overhung flexible coupling (Geislinger coupling)



170



1.60.7-73.10.00-05 318 235 Intermediate shaft with located main bearing or relieved located main bearing, disk brake.



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 69



m



Engineer´s Handbook M451 - M453C



c



Flywheel mounting Coupling bolts Total length mm



Clamped length mm



1.60.7-73.10.00-06 318 235 Intermediate shaft with located main bearing or relieved located main bearing 1.60.7-73.10.00-07 Overhung flexible coupling



262



170



1.60.7-73.10.00-08 262 Overhung flexible coupling (Geislinger coupling)



170



*1 *3



1.60.7-73.10.00-10 Connection 8 M453 > generator



235



*5



318



1.60.7-73.10.00-11 318 235 and 318 235 Intermediate shaft with located main bearing or relieved located main bearing. 1.60.7-73.10.00-12 and Overhung flexible coupling



262 262



1.60.7-73.10.00-13 262 and 262 and 253 Overhung flexible coupling (Geislinger coupling). Oil supply through the crankshaft. Plug must be removed.



170 170



*2



170 170 170



*1 *2 *4



1.60.7-73.10.00-14 318 235 and 318 235 Intermediate shaft with located main bearing or relieved located main bearing.



Edition 28.11.1998



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Page 70



m



Engineer´s Handbook M451 - M453C



c



Flywheel mounting Coupling bolts



1.60.7-73.10.00-15 and Overhung flexible coupling



Total length mm 262 262



Clamped length mm 170 170 *2



All fixing screws M 24 x 130 DIN 931, all coupling bolts have a thread M 36 x 3, with castellated nut and split pin. * 1 = O - ring between flywheel and crankshaft flange * 2 = No fixing screws * 3 = Fixing screws bored through * 4 = Fitted bolts bored through * 5 = In addition guide bolts 4 - SK - 13237 1.61.7-73.19.00-01 12 M453



318



235



1.61.7-73.19.00-02 Flywheel mounting



262



170



1.61.7-73.19.00-03 318 235 Intermediate shaft with located main bearing or relieved located main bearing, disk brake. 1.61.7-73.19.00-04 Flywheel mounting 16 M453



318



235



1.61.7-73.19.00-05 and Flywheel mounting 12 M453



318 318



235 235



1.61.7-73.19.00-06 and Flywheel mounting 12 + 16 M453



262 262



170 170



*1



All fixing screws M 24 x 130 DIN 931, all coupling bolts have the thread M 36 x 3, with castellated nut and split pin. * 1 = No fixing screws.



Edition 28.11.1998



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Page 71



m



Engineer´s Handbook M451 - M453C



c



Connecting screws M 453 - M453 C Engine housing - bedplate M453 in-line Tightening torque of the connecting screws M 24 x 110 DIN 912 - M 24 x 160 DIN 912



→



M



= 400



Nm



Tightening torque of the tie rods M453 in-line Acc. to drawing No. 4 SK - 10077 1st step →



P



= 270



bar



P



= 530



bar



P



= 300



bar



P



= 585



bar



P



= 300



bar



P



= 700



bar



2nd step → Acc. to drawing No. 1.60.7-92.03.00-01 1st step → 2nd step → Acc. to drawing No. 1.60.7-92.03.00-03 1st step → 2nd step



→



Attention! On threads of tie rods and round nuts NO Molykote.



On threads of tie rods and round nuts no Molykote.



9 9 8 7 6 5 4



2



First tighten lateral connecting screws on the crankcase ports.



11



After inserting the tie rods tighten bottom nuts steadily by hand.



14



Applicable also for 6 + 8 cyl. engines accordingly.



3



1



1



Edition 28.11.1998



10



9



12 13



15 16 17 18 19



1



Service document of Caterpillar Motoren GmbH & Co. KG



Page 72



m



Engineer´s Handbook M451 - M453C



c



Connecting screws Engine housing - bedplate M453 Vee Tightening torque of the connecting screws Drawing No. 1.66. / 68.7-11.19.00-01 / 02 → Drawing No. 1.66. / 68.7-11.19.00-03



→



M



= 710



Nm



M



= 850



Nm



P



= 347



bar



P



= 694



bar



P



= 365



bar



P



= 730



barr



M 30 x 120 SK DIN 931, Var. - 03 in addition M 30 x 120 DIN 912 Tightening torque of the tie rods M453 Vee Acc. to drawing No. 4 SK - 9478 1st step → 2nd step



→



Acc. to drawing No. 1.61.7-92.03.00-01 1st step → 2nd step



→



Attention! On threads of tie rods and round nuts NO Molykote.



A8 8 A7 7 A6 6



B8 B7 B6



A5 5



B5



4



B4



A4 A3 3



B3



A2 2



B2



1



B1



On threads of tie rods and round nuts no Molykote.



9 A8 10



B8



11



B7



12



B6



13



B5



14



B4



15



B3



A7



First tighten lateral connecting screws on the crankcase ports. After inserting the tie rods tighten bottom nuts steadily by hand.



A6 A5 A4 A3 A2 16



A1



A1 17



B2 B1



Applicable also for 12 cyl. engines accordingly.



Edition 28.11.1998



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Page 73



m



Engineer´s Handbook M451 - M453C



c



Connecting screws Acc. to drawing No. 1.61.7-92.03.00-02 1st step → 2nd step



→



Acc. to drawing No. 1.61.7-92.03.00-03 1st step → 2nd step



→



P



= 407.5



bar



P



= 815



bar



P



= 470



bar



P



= 930



bar



M



= 400



Nm



M



= 1300



Nm



M



= 50



Nm



M 451 - M452 Engine housing - bedplate Tighten connecting screws with



→



Tighten engine housing bolts with or pretighten with → and tighten with →



Edition 28.11.1998



→



Dw = 120°



Service document of Caterpillar Motoren GmbH & Co. KG



Page 74



m



Engineer´s Handbook M451 - M453C



c



Firing sequences M 451 - M453 C 6 cyl. - engines clockwise: counterclockwise:



1-3-5-6-4-2 1-1-4-6-5-3



6 cyl. - engines clockwise: counterclockwise:



1-4-2-6-3-5 1-5-3-6-2-4



8 cyl. - engines clockwise: counterclockwise:



1-4-7-6-8-5-2-3 1-3-2-5-8-6-7-4



9 cyl. - engines clockwise: counterclockwise:



1-2-4-6-8-9-7-5-3 1-3-5-7-9-8-6-4-2



12 cyl. - engines long-interval firing clockwise: A1 - B1 - A4 - B4 - A2 - B2 - A6 - B6 - A3 - B3 - A5 - B5 counterclockwise: A1 - B5 - A5 - B3 - A3 - B6 - A6 - B2 - A3 - B4 - A4 - B1 16 cyl. - engines short-interval firing clockwise: A1 - B1 - A4 - B4 - A7 - B7 - A6 - B6 - A8 - B8 - A5 - B5 - A2 B2 - A3 - B3 counterclockwise: A1 - B3 - A3 - B2 - A2 - B5 - A5 - B8 - A8 - B6 - A6 - B7 - A7 B4 - A4 - B1 12 cyl. - engines long-interval firing counterclockwise: A1 - B2 - A5 - B4 - A3 - B1 - A6 - B5 - A2 - B3 - A4 - B6



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 75



m



Designation Bedplate (compl.)



Engineer´s Handbook M451 - M453C



c



Length mm



Width mm



Height mm



Weight kg



6 M 452



3000



1280



842



2250



6 M 453



3109



1280



965



3200



8 M 452



3900



1280



842



3064



8 M 453



4009



1280



965



4200



9 M 452



4350



1280



842



3260



9 M 453



4459



1280



965



4700



12 M 453



3690



1600



1060



5080



16 M 453



4830



1600



1060



6650



Crankshaft 6 M 452



3204



225



2020



6 M 453



3344



245



2540



8 M 452



4104



225



2504



8 M 453



4244



245



3360



9 M 452



4554



225



2830



9 M 453



4694



245



3700



12 M 453



3975



300



3000



16 M 453



5115



300



3950



Counterweight 6, 8 and 9 M 453



448



110



222



62



12 M and 16 M 453



550



89



296



69



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 76



m



Designation Engine housing without liners 6 M 452



Engineer´s Handbook M451 - M453C



c



Length mm



Width mm



Height mm



Weight kg



2810



1030



1380



4000



6 M 453



2810



1030



1380



4750



8 M 452



3710



1030



1380



5100



8 M 453



3710



1030



1380



6100



9 M 452



4160



1030



1380



5800



9 M 453



4160



1030



1380



6720



12 M 453



3542



1788



1425



9800



16 M 453



4682



1788



1425



12900



2810



1030



1380



4900



6 M 453



2810



1030



1380



6840



8 M 452



3710



1030



1380



6300



8 M 453



3710



1030



1380



7300



9 M 452



4160



1030



1380



7150



9 M 453



4160



1030



1380



8200



12 M 453



3542



1788



1425



10600



16 M 453



4682



1788



1425



13100



Engine housing with liners 6 M 452



Camshaft, reversible 6 M 452 / 453



3375



90



162



8 M 452 / 453



4275



90



210



9 M 452 / 453



4275



90



240



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 77



m



Designation



Engineer´s Handbook M451 - M453C Length mm



Width mm



c



Height mm



Weight kg



Camshaft, nonreversible 6 M 452 / 453



3145



90



154



8 M 452 / 453



4045



90



200



9 M 452 / 453



4495



90



222



Reversing gear M 452 / 453



380



350



750



93



M 453 V - type



335



435



799



94



2000



285



1136



291



Woodward UG 40



197



267



540



45



Woodward PGA



432



248



690



60



Woodward EGB



317



210



495



50



WD 4 / WDU 4



730



240



285



71



Werdohl



540



273



285



90



WDU 5



423



280



340



83



WD 5



592



280



340



125



Werdohl (single - acting)



513



280



340



99



Werdohl (double - acting)



710



280



340



145



Gear box 12 and 16 M 453 Governor



Lub. oil pump



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 78



m



Designation Lub. oil filter with holder



Engineer´s Handbook M451 - M453C



c



Length mm



Width mm



Height mm



Weight kg



NW 65



520



260



530



180



NW 80



680



530



785



302



BBC VTR 200



819



465



550



160



BBC VTR 250



1040



580



610



360



BBC VTR 251



1170



688



655



432



Turbocharger



BBC VTR 304



820



BBC VTR 320



1351



751



730



770



BBC VTR 321



1466



938



949



870



Napier NA 355



850



Turbocharger with bracket BBC VTR 200



819



465



550



277



BBC VTR 250



1040



580



610



600



BBC VTR 251



1170



688



655



778



BBC VTR 320



1351



751



730



1050



BBC VTR 321



1466



938



949



1160



6 M 452



1007



580



700



270



8 M 452



420



395



843



185



9 M 452



420



510



904



275



Charge air cooler



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 79



m



Designation M 453 in-line a. Vee Var. - 14



Engineer´s Handbook M451 - M453C



c



Length mm



Width mm



Height mm



Weight kg



1344



420



700



570



Var. - 27



1244



420



565



450



Var. - 28



1044



420



565



400



Var. - 30



1069



568



660



540



Var. - 34 and 66



1324



610



660



865



Var. - 27



870



364



661



112



Var. - 31



1110



505



974



154



Var. - 34



840



478



900



213



Var. - 35



1110



505



880



136



Var. - 37



971



520



880



192



M 453 Vee Vibration damper 6 M 452



494



1870



1010



200



96



820



500



8 M 452 / 453



135



855



444



9 M 452 / 453



130



850



500



200



850



975



400



1500



3750



410



1350



2800



Transition housing with insulation (Turbocharger charge air cooler) M 453 in-line



12 M and 16 M 453 (Mak) Flywheel 6 M and 8 M 452 / 453 9 M 452 / 453



Edition 28.11.1998



Service document of Caterpillar Motoren GmbH & Co. KG



Page 80



m



Designation 8 M 452 / 453



Engineer´s Handbook M451 - M453C Length mm



12 M and 16 M 453



c



Width mm 510



Height mm 1500



Weight kg 4690



248



1283



1318



Liner M 452



938



398



183



M 453



938



398



187



Cylinder head (compl.)



274



Piston with connecting rod Al piston



1460



Piston grey cast iron



1460



320



320



180



209



Piston Built - up type



68



Piston with cooling coil



58



Located main bearing shell 6 , 8 , 9 M 453



12



12 , 16 M 453



16



Normal main bearing 6 , 8 , 9 M 453



4



12 , 16 M 453



6



Gear train Twin wheel Gear wheel on crankshaft Camshaft gear



Edition 28.11.1998



222



575



97



80 90



580 580



80 40



Service document of Caterpillar Motoren GmbH & Co. KG



Page 81