M601-M601C Engineer´s Handbook

m

c

M601 - M601C

Engineer´s HandbookM601 - M601C m

Edition12.02.1999

Page2

Service document ofCaterpillar Motoren GmbH & Co. KG

c

Contents

CamshaftCamshaft bearing 44Gap 44Reference dimension 44Starting cam 45 - 47Vibration damper 45Repair camsExhaust cams 49 - 50Fuel cams 48 - 49Inlet cams 50 - 51Tightening torques for inlet and exhaust cams 52Additional masses 53

Charge air cooler mounting 63

Connecting rodBig end bearing 28Big end bearing - reference dimension 29Gap, big end bearing 29Marking 29Piston pin bush 29Plugs 28Shank division 28

Connecting screws 63

Counterweight 31 - 32

Cylinder headExhaust gas manifold 11Exhaust valve rocker 9Exhaust valves, tightening torques 12Fitting valve stem 17Fuel injection valve 11Grinding of inlet and exhaust valves 16Inlet valve rocker 9Inlet valve seat ring 14Refinishing cyl. head - exhaust valve 13Refinishing of the valve cone surfaces 16Rocker arm bracket 9Starting valve 10


Edition12.02.1999

Page3


cContents

Cylinder headTightening torques 6 - 8Valve clearance 10Valve guide 10Valve stem 15

Engine data 5

Engine operating data 5

Firing sequences 67

Flange shaft mounting 57 - 60

Flywheel mounting 61

Fuel injection pump 54 - 55Basic setting 55Check of commencement of delivery 56

Fuel injection pump with drive 52

Gear driveAdjustment gear drive 39 - 41Backlashes 38Camshaft gear 37Gear box 42Gear wheel on crankshaft 33 - 34Gear wheels for gear drive 38Intermediate wheel mounting 35Mounting of camshaft gear withcoupling piece 36Step bearing, intermediate wheel 35Step wheel 35


Edition12.02.1999

Page4


cContents

Governor drive 43

Liners 25 - 27

Lower valve drive 52Fixing of roller tappet body 52

Main bearingGap 30Tightening specification 30

PistonPiston rings mounting 22Piston specification 21Piston, KS 20 - 21Piston, Mahle 18 - 20Ring grooves, wear limits 22Piston rings 24

Sizes and weights 68 - 70

Tie rod 64 - 66

Turbocharger mounting 62

Valve timings 67


Edition12.02.1999

Page5


cEngine data

Stroke: 600 mm

Bore: 580 mm

Speed: 425 rpm

Number of cylinders: 6 - 8 -9

Main bearing:

Inside Ø 430 mm

Outside Ø 450 mm

Big end bearing:

Inside Ø 410 mm

Outside Ø 425 mm

Valves (inlet)

Length 787 mm

Shaft Ø 39 mm

Valve disk Ø 184 mm

Valves (exhaust)

Length 787 mm

Shaft Ø 39 mm

Valve disk Ø 184 mm

Engine operating data

Temperatures

Lub. oil, inlet 50 - 55 °CStationary engines 50 - 60 °C

Temperature rise: 9 - 16 °C *1

Fresh water circulation cooling

Engine outlet: 80 - 85 °C

Temperature rise: 7 - 10 °C *1

Charge air, inlet: 45 - 60 °C

Nozzle cooling, inlet 65 - 75 °C

Pressures

Lub. oil, at the last

camshaft bearing: 4.0 - 5.0 bar *2

Fresh water circulation cooling:

2.5 - 5.0 bar

With attached pumps

minimum: 2.0 bar

Nozzle cooling: 1.5 - 3.0 bar

Fuel pressure beforeinjection pumps: MDO 1.5 - 3.0bar HFO 4.0 - 5.0

*1 = at rated engine output

*2 = at rated engine speed


Edition12.02.1999

Page6


c

The tightening torque for inserting thetie bolts is →→→→→

Tightening torqueOld typeInstruction for tightening with 8 hydraulic jacks.Lengthen cylinder head boltscontinuously with →→→→→hold pressure 2 minutes, thenreduce pressure to →→→→→and: In case of bolts M 52 x 3 tighten round nutswith pin by 8 slot lengths. In case of bolts M 56 x 4 tighten round nuts with pin by 6 slotlengths.Valid for the cylinder head variants : 1.80.7-21.41.00-03/05/07/09/11/12

Attention ! All 8 nuts must be tightened with the same number of slot lengths. If there is adifference, all nuts must be loosened again and newly tightened.

Instruction for tightening with 4 hydraulic jacks :1st step lengthen cyl. headbolts 1 - 3 - 5 - 7 with →→→→→hold pressure for 2 minutes,then reduce pressure to →→→→→and tighten round nuts manually with pin.

2nd step lengthen cyl. headbolts 2 - 4 - 6 - 8 with →→→→→hold pressure for 2 minutes,then reduce pressure to →→→→→and tighten round nuts manually with pin.

M = 1600 ± 200 Nm

P = 1300 bar

P = 1200 bar

P = 1300 bar

P = 1250 bar

P = 1300 bar

P = 1250 bar

Old hydraulic jack

Old nut, height 46 mm

Cylinder head


Edition12.02.1999

Page7


c

New typeInstruction for tightening with 8 hydraulic jacks:Tighten cylinder head nuts steadily with pin.Lengthen cylinder head bolts with →→→→→hold pressure 2 minutes, thenreduce the pressure to →→→→→and tighten round nuts continuously withpin by 6 slot lengths.Valid for the cylinder head variants: 1.80.7-21.41.00-08 / 10

Instruction for tightening with 4 hydraulic jacks:Lengthen cyl. head bolts 1 - 3 - 5 - 7 with →→→→→hold pressure for 2 minutes,then reduce to →→→→→and tighten round nuts steadily with pin.

Lengthen cyl. head bolts 2 - 4 - 6 - 8 with →→→→→hold pressure for 2 minutes,then reduce to →→→→→and tighten round nuts steadily with pin.Measure all 8 threads with depth gauge and compare with the values after manualtightening.

Tightening specification for the new hydraulic jack:After tightening by hand with pin measure dimension „S1“ with depth gauge. Then tightennuts acc. to specification and measure dimension „S2“.

The difference „S2 to S1“ is dimension „S3“.Measure all 8 thread ends with depth gauge and compare them with the valves aftermanual tightening. The difference of the individual valves shall not exceed or be lessthan 2.9 - 3.8 mm. If the difference is not within this range, repeat the tighteningprocess.

P = 1200 bar

P = 1100 bar

P = 1250 bar

P = 1150 bar

P = 1200 bar

P = 1100 bar

Cylinder head

S 3

S 1S 2


Edition12.02.1999

Page8


c

Attention ! All 8 nuts must be tightened with the samenumber of slot lengths. If there is a difference, all nuts mustbe loosened again and newly tightened.

New nut, height 56 mm

Cylinder head

New hydraulic jack


Edition12.02.1999

Page9


c

Rocker arm bracketTighten screw - 1 -with →→→→→Tighten screw - 2 -with →→→→→Tighten screws - 3 -with →→→→→

Inlet valve rockerTightening torque for thetaper pin nuts →→→→→

Original clearance →→→→→

Maximum clearance →→→→→

Clearance limit →→→→→

Axial clearance „S“ →→→→→

Exhaust valve rockerOriginal clearance →→→→→

Maximum clearance →→→→→


Both bushes shall recedeby (Size „X" ) →→→→→

1

23

M = 400 Nm

M = 550 Nm

M = 650 Nm

M = 230 Nm

0.048 mm

0.192 mm

0.32 mm

0.20 + 0.1 mm

0.057 mm

0.204 mm

0.32 mm

0.25 mm

Cylinder head

XX


Edition12.02.1999

Page10


c

Valve clearanceInlet valve →→→→→

Exhaust valve →→→→→

Setting under hot running conditions, abt. 15 min. after stopping the engine.

Valve guideExhaust HFO operationOriginal clearance →→→→→


Exhaust MDO operationOriginal clearance →→→→→


Inlet HFO + MDO operationOriginal clearance →→→→→


Starting valveTighten cap nut AFM 16 DIN 2510 with →→→→→

Tighten hexagon nut M16 DIN 934 with →→→→→

0.40 ± 0.10 mm

1.20 ± 0.10 mm

0.22 - 0.29 mm

0.45 mm

0.13 - 0.21 mm

0.45 mm

0.13 - 0.21 mm

0.45 mm

M = 110 Nm

M = 150 Nm

Cylinder head


Edition12.02.1999

Page11


c

Fuel injection valveTighten fixing nuts with →→→→→

The tightening torque for thenozzle nut is →→→→→

this corresponds to an arcmeasure of →→→→→

M = 110 Nm

M = 450 Nm

11 mm

11 mm

New nozzle nut, that meansM = 450 Nm correspond to 9mmat the circumference.

Fuel injection valve M 601 CInsert the injection valve in thecylinder head.Mount the flange and screwon the cap nuts loosely. Lightly coat the thread and theconical surfaces at the adapter- 1 - with Molykote paste„G - Rapid", screw it into thenozzle holder and

tighten with →→→→→

Exhaust gas manifoldPretighten tension screws to the cyl. head with →→→→→and tightenwith →→→→→this corresponds to 1 1/2 hexagons.

M = 400 Nm

M = 30 Nm

Dw = 90°

Cylinder head

1


Edition12.02.1999

Page12


c

Exhaust valves

Old type of exhaust valve cage withcooling water outlet. On all cylinderheads of this type the exhaust valvesare tightened as follows:

Tighten nuts steadily with →→→→→to adapt the joint ring to the seat, then lengthen screwswith →→→→→and tighten nuts.

New type of exhaust valve cage withcooling water outlet. On all cylinderheads of this type the exhaust valvesare tightened as follows:

Tighten nuts steadily with →→→→→to adapt the joint ring to the seat, then lengthen screwswith → → → → →and tighten nuts by hand.

On the engines with the Nos. 63156 - 63158 - 63165 - 63167 - 63168 and from No. 63170on the exhaust valves are inserted in the engine without joint ring. They are tightened asfollows:

Tighten nuts steadily in 3 steps up to →→→→→

then lengthen screws with →→→→→and tighten nuts by hand.

M = 100 Nm

P = 1050 bar

M = 100 Nm

P = 850 bar

P = 1000 bar

M = 100 Nm

Cylinder head


Edition12.02.1999

Page13


c

Refinishing cyl. head - exhaust valveMaximum refinishing of the seat in the cyl. head and onthe exhaust valve cage →→→→→

Refinishing on the valve cage seat and / or in the boreof the cyl. head is possible. Before removal measuredimension „L" from top edge of cyl. head to top edgeof exhaust valve cage flange. Carefully clean theexhaust valve bore in the cyl. head. Insert the reseatingtool and face slowly and uniformly with low contactpressure. After facing fit the exhaust valve cage andmeasure dimension „L" again.The difference of both measurements is the refinishingdimension.A maximum refinishing of 2.00 mm is possible,however, refinishing in the cylinder head should notexceed 1.25 mm, consequently refinishing of 0.75mm is possible on the exhaust valve cage.(Detail „X")

Attention: From engine No. 63156 on the exhaust valvecages are inserted in the cylinder heads without jointrings.

Exhaust valve seatMaximum admissible dimension:„X“ = 183.50 ± 0.20 mm.

2.00 mm

Cylinder head

L

X


Edition12.02.1999

Page14


c

Inlet valve seat ringRemoval: Cut off the old valve stem at the shaft end and chamfer the resulting joint faceagainst upsettings. Grind valve plate until it fits in the valve seat ring, connect the valveplate in the valve seat ring with 4 welding seams and extrude the valve seat.

Fitting on board: After extruding, clean the valve seat bore with fine emery cloth. Cool thevalve seat ring down to 20 ° C and heat the cylinder head up to 130 ° C. Put the valve seatring in the bore and force it in with the old valve stem. After about 5 minutes, move thevalve seat into its final position by means of a setting blow, afterwards there must be noclearance between seat ring and contact surface in the cylinder head.Another method is: Cool the valve seat ring down in liquid nitrogen (-190 ° C) or in dry ice(-70 ° C) and heat the cylinder head slowly up by a soft flame. Insert the valve seat ringand after about 5 minutes a valve stem and bring it into the final position by means of asetting blow. Afterwards there must be no clearance between seat ring and contact surfacein the cylinder head. Any protruding edges from the seat ring to the inlet port are to besmoothed off.

Fitting in the workshop1. Cool the valve seat ring down in liquid nitrogen to -190 ° C and insert it in the

cylinder head.2. Shortly press the valve seat ring on with the device 1.70.7-92.22.00-10.

Tighten nut of the pressing device with →→→→→

3. In cold shrunk-in condition there must be no clearance between valve seat ring and cylinder head.The bore for the inlet valve seat ring is Ø 196 + 0.029 mmExternal diameter of the valve seat ring = Ø 193.18 - 0.03 mm.

Inlet valve seat ringMaximum admissible dimension:„X“ = 190 ± 0.02 mm.

M = 300 Nm

Cylinder head


Edition12.02.1999

Page15


c

Valve stemValve stems can be reused without refinishing if:1. the valve cone surface is metallically bright on the whole circumference,

2. the valve cone surface does not show included coke particles which may result inblow-bys,

3. cracking was not detected in the valve cone surface by crack test with luminousmagnifying glass (eightfold magnification) or powder spraying method (Met-L-Chek) or by a magnaflux test,

4. the deviation from straight is not > 0.04 mm

Inlet valve stem

Measuring distance:„S“ = 415 mm

Exhaust valve stem

Measuring distance:„S“ = 510 mm

5. the deviation from true running of the valve cone is not > 0.03 mm

A valve stem is unusable in case of corrosive material wear of > 2 % of the valve diskdiameter and in case of high-temperature corrosion of > 2.5 mm on the bottom side of thevalve disk.

S

S

Cylinder head


Edition12.02.1999

Page16


c

Refinishing of the valve cone surfacesRefinish valve cone acc. to sketch. Do notrefinish the existing fillet. After grindingdetermine the dimension between the visibleedge base material - armouring „X“ and theoutside edge of the seat surface. When it isless than the minimum size exchange thevalve cone.Round off the outside edge with a stone.

If the valve cone is refinished the valve seatmust be refinished, too.

Grinding of inlet and exhaust valvesApply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or remachinedvalve cone and distribute the paste equally.Thereafter the seat ring surface is to be sprayedwith a thinner (F25) belonging to the diamondpaste, for dilution and in order to increase thegrip. Insert the oiled valve stem into the guidebush. Fasten the device at the valve disk andgrind the valve face and seat by hand applying amoderate pressure, rotating the device. Thecontact reflection „a“ which is visible by thesmooth grinding process shall not exceed30 % of the seat width starting from the outsidediameter. If the bearing characteristics describedabove are not reached, remachining of bothsealing surfaces is necessary.

Cylinder head


Edition12.02.1999

Page17


c

Fitting valve stems:

M601 - M601C Inlet valve stem Gas oil and heavy fuelExhaust valve stem Gas oil

1.80.7-22.10.01-20

M601C Inlet valve stem

1.80.7-22.10.01-20

M601 Exhaust valve stem Heavy fuel

1.80.7-22.10.01-19

M601C Exhaust valve stem Heavy fuel

1.80.7-22.10.01-17

Cylinder head


Edition12.02.1999

Page18


c

1.80.6-26.70.00-01 Mahle - M601Before tightening the nuts, the clearance betweenpiston crown and skirt must be →→→→→

The tightening torque for inserting the studs is →→→→→

Tighten nuts crosswise with →→→→→and loosen again.

Pretighten nuts crosswise with →→→→→andtighten with →→→→→

1.80.6-26.70.00-03 Mahle - M601 M601 CBefore tightening the nuts, the clearance betweenpiston crown and skirt must be →→→→→




Check:At →→→→→the screws must not be detachable.

0.06 mm

M = 10 Nm

M = 300 Nm

M = 50 Nm

Dw = 120 °

0.06 mm

M = 10 Nm

M = 400 Nm

M = 50 Nm

Dw = 160 °

M = 300 Nm

Piston


Edition12.02.1999

Page19


c

1.80.6-26.70.00-05 / -09 Mahle - M601 M601 CBefore tightening the nuts, the clearance betweenpiston crown and skirt must be →→→→→

For measuring the clearance between piston crown and skirt the spacer rings must be removed.





Spacer rings for the piston -05 and -09

Ø = 549.5 - 0.5 mm Ø = 383.3 - 0.3 mmØ = 505.3 + 0.2 mm Ø = 276.7 + 0.3 mmThickness = 6 ± 0.1 mm Thickness = 6 ± 0.1 mm

Attention ! The spacer rings are manufactured in one working process. They must be deliveredand fitted together.For the piston 1.80.6-26.70.00-09 the crown193874643 of piston 1.80.6-26.70.00-11 can bemounted, but with thrust pieces 193874654 only. The spacer rings are inapplicable.

0.06 - 0.12 mm

M = 10 Nm

M = 400 Nm

M = 50 Nm

Dw = 160 °

M = 300 Nm

Piston


Edition12.02.1999

Page20


c

1.80.6-26.70.00-11 Mahle - M601 M601 CBefore tightening the nuts, the clearance betweenpiston crown and skirt must be →→→→→



Check the tightening torque of the studs with →→→→→



At reassembly: Replace screws if protruding length from bottom support exceeds 367 mm.

1.80.6-26.70.00-02 / -04 KS - M601 / -06 KS - M601 und M601 C


Tighten nuts crosswise twicewith →→→→→and loosen again, thencheck the tightening torquefor inserting the studs.Before tightening the nuts the clearance betweenpiston skirt and piston crown must be →→→→→

For measuring the clearance between piston crown and skirt the spacer rings must be removed.

0.16 - 0.23 mm

M = 10 Nm

M = 160 Nm

M = 10 Nm

M = 70 Nm

Dw = 270 °

M = 160 Nm

M = 100 Nm

M = 300 Nm

0.12 + 0.04 mm

Piston


Edition12.02.1999

Page21


c

Pretighten nuts crosswise with →→→→→then turn nuts oncrosswise with →→→→→

then tighten nuts crosswise with →→→→→

Spacer rings for the piston -06

Ø = 549- 0.5 mm Ø = 393.3 ± 0.5 mm Ø = 505.2 + 0.2 mm Ø = 270 + 0.5 mm Thickness = 6 ± 0.1 mm Thickness = 6 ± 0.1 mm

Attention ! The spacer rings are manufactured in one working process. They must be deliveredand fitted together.Check:Var. -02 At →→→→→the screws must not be detachable.Var. -04 / -06 At →→→→→the screws must not be detachable.

Check of stud stretching by difference measurementA Measure unstretched studs from piston bottom up to the stud end.

Measure stretched studs from piston bottom up to the stud end.

B Sleeve measurement from tension sleeve up to the stud end.Stetching and upsetting with Mak measuring unit 1.80.7-92.03.00-13

M = 25 Nm

M = 80 Nm

Dw = 120 °

M = 300 Nm

M = 160 Nm

∆∆∆∆∆l = 0.72 ± 0.06 m m

∆∆∆∆∆l = 0.92 ± 0.06 m m

Piston


Edition12.02.1999

Page22


c

1.80.6-26.70.00-12 KS M601 CThe tightening torque for inserting the studs is →→→→→

Tighten nuts crosswise with →→→→→and loosen again.Check tightening torque for inserting the studs with →→→→→

Before tightening the nuts the clearance between piston skirt and

piston crown must be →→→→→

Pretighten nuts crosswise with →→→→→thenturn nuts on crosswise, →→→→→then tighten nuts crosswisewith →→→→→

At →→→→→the screws must not be detachable.

Attention: For all piston mountings treat threads and contact surfaces with Molykote paste G.

Piston specificationMahle: 1.80.6-26.70.00-01 repl. is 1.80.6-26.70.00-03 M601

1.80.6-26.70.00-05 repl. is 1.80.6-26.70.00-09 M601 - M601 C

1.80.6-26.70.00-11 M601 C

KS: 1.80.6-26.70.00-02 repl. is 1.80.6-26.70.00-04 M601

1.80.6-26.70.00-06 M601 - M601 C

1.80.6-26.70.00-12 M601 C

M = 100 Nm

Piston

M = 300 Nm

M = 100 Nm

0.12 - 0.18 mm

M = 25 Nm

M = 60 Nm

Dw = 120 °

M = 160 Nm


Edition12.02.1999

Page23


c

Piston rings - mountingWhen fitting the piston rings must be arranged so that the ring butts are opposite inlongitudinal direction of engine. The mounting device (hose clamp) must move freely overthe piston rings. When inserting the piston rings in the grooves take care that the „markingof the piston ring“ is pointing upwards.

Wear limitsBuilt-up piston, gas oil and heavy fuel operation - ring grooves flame-hardened

Grooves Grooves height Ring height Wear limit Clearance limit1 10,25 +0,03 9,897 - 0,032 10,60 0,75

2 10,19 +0,03 9,897 - 0,032 10,60 0,75

3 10,14 +0,03 9,897 - 0,032 10,60 0,75

4 10,14 +0,03 9,897 - 0,032 10,60 0,75

5 11,984 -0,017 ** 11,984 - 0,034 12,50 0,60

Built-up piston, heavy fuel operation - 1st ring grooeves chromium-plated

Grooves Grooves height Ring height Wear limit Clearance limit1 10,25 +0,03 9,897 - 0,032 10,48 0,60

2 10,19 +0,03 9,897 - 0,032 10,60 0,75

3 10,14 +0,03 9,897 - 0,032 10,60 0,75

4 10,14 +0,03 9,897 - 0,032 10,60 0,75

5 11,984 -0,017 ** 11,984 -0,034 12,50 0,60

All stated details for standard equipment. This does not apply to oversize rngs.

Piston


Edition12.02.1999

Page24


c

Piston 1.80.6-26.70.00-01 / -02 / -03 / -04Ring groove ring1 compression ring, chromium-plated 0.00.6-35.42.00-13.12 - 4 compression ring, chromium-plated 0.00.6-35.42.00-53.15 oil scraper ring, chromium-plated 0.00.6-35.42.00-44.1 / -44.3

Piston 1.80.6-26.70.00-03 / -04Ring groove ring1 compression ring, three-side chromium-plated 0.00.6-35.42.00-70.1 / -70.32 - 4 compression ring, chromium-plated 0.00.6-35.42.00-53.15 oil scraper ring, chromium-plated 0.00.6-35.42.00-44.1 / -44.3

Piston 1.80.6-26.70.00-05 / -09 / -06Ring groove ring1 compression ring, three-side chromium-plated 0.00.6-35.42.00-70.1 / -70.32 - 4 compression ring, chromium-plated 0.00.6-35.42.00-53.15 oil scraper ring, chromium-plated 0.00.6-35.42.00-44.1 / -44.3

Piston 1.80.6-26.70.00-11 / -12Ring groove ring1 compression ring, three-side chromium-plated 0.00.6-35.42.00-83.1 / -84.12 - 4 compression ring, chromium-plated 0.00.6-35.42.00-53.15 oil scraper ring, chromium-plated 0.00.6-35.42.00-44.1 / -44.3

Piston 1.80.6-26.70.00-11 / -12Ring groove ring1 compression ring, chromium-plated 0.00.6-35.42.00-13.12 - 4 compression ring, chromium-plated 0.00.6-35.42.00-53.15 oil scraper ring, chromium-plated 0.00.6-35.42.00-44.1 / -44.3

Cylinder head


Edition12.02.1999

Page25


c

Nominal size Ø (original size) →→→→→Wear limitsWear and tear value →→→→→

Max. ovality →→→→→

Wedge shape Height →→→→→

Depth * * →→→→→

Wedge-shaped indentation downwards across the entire circumference, beginning at TDC 1stpiston ring.

Canyon Max. number →→→→→

Length →→→→→

Total width →→→→→

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

Score Number →→→→→


Depth →→→→→

Hard vertical, linear friction marks.

Pocket Number →→→→→


Width * * * →→→→→

Depth * * →→→→→

580.00-580.070 mm

1.00 - 1.20 * mm

0.30 mm

20.00 mm

0.08 mm

3

20.00 mm

8.00 mm

3

300.00 mm

0.08 mm

3

150.00 mm

60.00 mm

0.05 mm

Liners


Edition12.02.1999

Page26


c

Areal, irregular indentations.

* Limit value for conically honed cylinder liners.* * Radius r ³ 3 mm* * * In circumferential direction.

Wedge shape Pocket Score TDC 1st ring Canyon

Fitting of the liner:Lower the liner until it is just still turnable. Insert thecentering device - 1 - into the liner groove. Pass thescrews M12 x 130 DIN 931 - 2 - through the centeringdevice and turn the liner until the screws can be insertedin the tapholes of the water ring. Continue to lower theliner. To obtain the correct liner position, attention mustbe paid that the centering device remains in the linergroove. After lowering remove the screws - 2 -, tightenthe centering device with 2 hexagon screws M12 x 25DIN 933 and safety-wire it.

1

2

Liner


Edition12.02.1999

Page27


c

Arrangements of O-rings for the liners: 1.80.7-16.11.00-07, -09, -11, -14

O - ring1.80.6-16.11.03-02

O - ring, Perbunan1.80.6-16.11.04-01

O - ring, Viton1.80.6-16.11.03-03

Liners of the var. - 02 upto - 06 are not providedwith this O - ring.

O - ring, Viton1.80.6-16.11.03-03

Liners


Edition12.02.1999

Page28


c

Shank divisionTighten screws with →→→→→

Big end bearingTighten screws 1 + 4 with →→→→→

Tighten screws 2 + 3 with →→→→→



Check: After reducing the pressure by 50 bar, the nuts must not be detachable with a pin.

The tightening specification applies to all 601 engines. If the operating instructions for olderengines still show the value 800 bar, please change it to 900 bar.

Connecting rodTighten plug - 1 - with →→→→→

Tighten plugs - 2 - with →→→→→

Modern connecting rods withshank division haveno plug - 1 -.

Reference dimension aftertightening 223,3 mm

M = 750 Nm

M = 200 Nm

M = 150 Nm

P = 300 bar

P = 600 bar

P = 900 bar

P = 900 bar

1 2

3 4

Connecting rod

12


Edition12.02.1999

Page29


c

Big end bearingMeasurement of gap1. Tighten big end bearing bolts

as prescribed.2. Fasten dial gauge according

to sketch. Turn the scaleuntil the zero point coincideswith the pointer position.

3. Loosen both bolts on theside with the dial gauge andread off the gap size.

GapGap for Miba-bearing var. -10 →→→→→

After longer operation not below →→→→→

Gap for BHW-bearing var. -03 / -07 →→→→→

After longer operation not below →→→→→Big end bearingThe reference dimension of the big end bearing shell aftercorrect tightening is Ø →→→→→

Piston pin bushInsertion in supercooled conditionoperating temperature →→→→→The reference dimension after insertion in supercooledcondition shall be Ø →→→→→

DismountingOnly by MaK representatives!For removal the bush must be relieved, either by sawing or by milling. Never press the bush out.

Marking:On camshaft side of the connecting rods engine No. and cylinder No. are stamped in. Thegroove for centering the bearing shells must always show to the camshaft side.

1.60 - 1.85 mm

1.30 mm

1.08 - 1.24 mm

0.87 mm

410.38 + 0.10 mm

≤≤≤≤≤ - 160° C mm

240.21 + 0.09 mm

Connecting rod

Correct mountingof the dial gauge


Edition12.02.1999

Page30


c

Tightening specificationTighten nuts steadily by hand.1st step tighten screws 1 + 4 with →→→→→

2nd step tighten screws 2 + 3 with →→→→→

3rd step tighten screws 1 + 4 with →→→→→

4th step tighten screws 2 + 3 with →→→→→

Check: After the last tightening step the tight support of the round nuts is to be checked at apressure reduction of 50 bar. It must not be possible any more to loosen the nuts with a pin.Tightening specification is valid for a hydraulic jack area of 78,5 cm 2.

Gap1. Tighten screws on one side with the 2nd step - 680 bar -.2. Measure gap on the other side with loose nuts between bearing cap and bedplate.

Gap sizesMain bearing →→→→→


Located main bearing →→→→→


Located main bearingAxial clearance →→→→→

1

2

3

4

P = 340 bar

P = 680 bar

P = 1000 bar

P = 1000 bar

0.80 - 1.10 mm

0.70 mm

0.55 - 0.85 mm

0.45 mm

0.40 - 0.55 mm

Main bearing


Edition12.02.1999

Page31


c

Mechanical tightening with tie bolt M56 x 4 length 408mm, SW 65

1. Pretighten tie bolts with →→→→→

2. Transfer the 0-marking of the angle gauge 1.80.7-91.80.00-01 on the screw heads.3. Pretighten tie bolts

with →→→→→thentighten with →→→→→

Hydraulic tightening with tie boltThread M56 x 4, thread of nuts M48 x 3, length 520 mm SW 27

1. Screw tie bolts into the crankshaft with →→→→→

2. Lengthen tie bolts simultaneously with →→→→→and tighten nuts.Piston area A = 78,5 cm2 - Both tightening variants are valid for Molykote.

Dismounting andmounting counterweights.1. Turn crankshaft into position „a“

and loosen both screws asprescribed.Should it not be possible duringhydraulic tightening to loosenthe nuts at the prescribedpressure, increase thepressure by 50 bar.

2. Remove round nut, washerand tie bolt -1- from below.Insert fitting bolts into thefree bore and tighten itslightly.

M = 300 Nm

Dw = 45°

Dw = 90° ± 7.5°

M = 200 Nm

P = 960 bar

Position „a“

1

Counterweight


Edition12.02.1999

Page32


c

3. Remove second tie bolt.

4. Turn crankshaft into postion b. Fasten device -1- at the intermediate stand on thecamshaft side, move it over the counterweight and insert the bolt in the counterweightwithout tightening.

5. Turn the device until the fitting bolt can be removed, then turn it back into originalposition. Tighten the bolt.

6. Lift counterweight (loosen stuck counterweights) and move it out of the crankcase.

7. Fitting proceeds in reverse order.

Position „b“ 1

Counterweight


Edition12.02.1999

Page33


c

Gear wheel on crankshaftThe gear wheels are marked with the corresponding drawing No.1.80.7-25.30.00-02The two halves are tightened with 4 hexagon screws M20 x 170 DIN 609and the nuts M20 DIN 935.The tightening torque for the nuts is →→→→→Replacement for var. -02 is var. -05.

1.80.7-25.30.00-05 /-07The gear wheel is tightened with 4 hexagon studs M16 x 108 according to drawing No.1.00.7-88.50.55-72. Two studs are secured at the screw-in thread by means of a hexagonscrew M6 x 17.5 with pin, the two others with a threaded pin.The castle nuts are tightened with →→→→→

The gear wheels are fitted at the crankshaft with 4 reamed bolts M24 x 2 x 215 and 8 tiebolts M24 x 2 x 215.The castle nuts for the above bolts are tightened as follows:

Tightening torque min. →→→→→

Tightening torque max. →→→→→

plus →→→→→Then tighten up to the next split pin hole.

M = 250 Nm

M = 100 + 20 Nm

M = 450 Nm

M = 450 Nm

Dw = 30 °

1

Tooth 24Tooth 23

Tooth 1

Gear drive


Edition12.02.1999

Page34


c

1.80.8-25.30.00-04The engines No. 63051 and 63057 are equipped with this variant. The two gear wheelhalves are fitted on a centering ring which is screwed at the crankshaft. Tightening torquessee page 64e. Replacement is the var. -05

The gear wheels 1.80.7-25.30.00-02 / -04 / -05 have 84 teeth.The gear wheel 1.80.7-25.30.00-07 has 82 teeth.

FittingThe 4 fitting bores above and below the joint are rough-drilled with Ø 23 mm. Afteralignment they are reamed to Ø 25 - 25.0021 mm (H7).

Step wheelPretighten tie bolts with →→→→→and tightenwith →→→→→Tightening check : min. 850 NmTie bolt - 1 - M27 x 101, SW41Tie bolt - 2 - M27 x 114, SW41

M = 200 Nm

Dw = 60° - 10°

1

Ø14

9,96

+

0,05

9

2

Tooth 1

Tooth 2

Tooth 1

Tooth 2

Gear drive


Edition12.02.1999

Page35


c

Intermediate wheel mountingBearing bracket for intermediate wheelUp to eng. No. 63123 tighten screws -1- with →→→→→

From eng. No. 63124 tighten screws -1- with →→→→→

Tie bolts M24 x 2 x 99 SW 36 with tension bush Ø 40, - Ø24,5 height 19

Step bearing intermediate wheelTighten hexagon srews -2- with →→→→→

M20 x 80 DIN 931

Tighten grooved nut -3- with →→→→→

The thickness of the laminium shim is as follows:

x = a - b + 0,4 + 0,1 mm

M = 450 Nm

M = 500 Nm

M = 230 + 20 Nm

Dw = 390° + 30°

1

Gear drive

2

3

ba

→→→→→ →→→→→x


Edition12.02.1999

Page36


c

Mounting of camshaft gear with coupling piece1. Cover cone of the coupling piece - 1 - with blue paste, then put it on the camshaft

cone.

2. Tighten nut - 2 - with approx. 100 Nm, then mark the position of the coupling piece onthe camshaft. Affix a second marking at a distance of 4.5 mm. (Final position)

3. Remove coupling piece - 1 - and check blueing appearance. If it deviates from the fullblueing appearance, only a contact pattern displaced to the thick end is admissible.

4. Place the parallel key - 3 - in the camshaft groove. Heat coupling piece up to 160°Cand move it on the camshaft cone into its final position (2nd marking 4.5 mm).

5. Fit thrust ring - 4 -, fasten nutwith a hook wrench and secure it.

1

2

3

4

Gear drive


Edition12.02.1999

Page37


c

Camshaft gearPretighten tension bolts - 1 - with →→→→→and tightenwith →→→→→Tightening check : min. 850 NmTie bolt M27 x 101, SW 41

Tooth 1 and parallel key groove must be in alignment.

M = 200 Nm

Dw = 60° - 10°

Gear dive

Tooth1

Tooth space1

1

Coupling pieceTooth1

Parallel keygroove


Edition12.02.1999

Page38


c

Gear wheels for gear driveThe engines up to engine No. 63146 as well as the engines No. 63150 and 63169 areequipped as follows:Gear wheel on crankshaft →→→→→ 84 teeth

Twin wheel →→→→→ 74 and 111 teeth

Camshaft gear →→→→→ 112 teeth

The engines from engine No. 63147 up to engine No. 63149, from engine No. 63151 upto engine No. 63168 and from engine No. 63170 are equipped as follows:

Gear wheel on crankshaft →→→→→ 82 teeth

Twin wheel →→→→→ 52 and 104 teeth

Camshaft gear →→→→→ 82 teeth

BacklashesCrankshaft gear - big intermediate wheel →→→→→

Small intermediate wheel - camshaft gear -→→→→→

Camshaft gear - governor drive gear →→→→→

Gear drive

0.32 - 0.40 mm

0.20 - 0.28 mm

0.20 - 0.29 mm


Edition12.02.1999

Page39


c

Adjustment of gear drive starboardtype Piston 1 in TDC.Crankshaft gear = 84 teeth,intermediate wheel = 74 and 111teeth,camshaft gear = 112 teeth

Tooth1

22

2

Tooth 42

Tooth 31

Tooth 30

Tooth 2 Tooth 1

Tooth 21Tooth 20

Tooth 1

Tooth 1

Tooth 84

Gear drive


Edition12.02.1999

Page40


c

Adjustment of gear drive port typePiston 1 in TDCCrankshaft gear = 84 teeth,intermediate wheel = 74 and 111 teeth,camshaft gear = 112 teeth

Tooth1

22

2

Tooth 72

Tooth 47

Tooth 46

Tooth 1Tooth 2

Tooth 24

Tooth 1

Tooth 23

Tooth 1

Tooth 84

Gear drive


Edition12.02.1999

Page41


c

Adjustment of gear drive port typePiston 1 in TDCCrankshaft gear = 82 teeth,intermediate wheel = 52 and 104 teeth,camshaft gear = 82 teeth

Tooth1

22

2

Tooth53

Tooth33

Tooth32

Tooth1Tooth2

Tooth23

Tooth1

Tooth22

Tooth1

Tooth82

Gear drive


Edition12.02.1999

Page42


c

Gear boxTighen screws M16 with →→→→→

Tighen screws M20 with →→→→→



Tighten tie bolt - 1 - with →→→→→Tie bolt M30 x 500 DIN 931 - 10.9

M = 140 Nm

M = 230 Nm

M = 400 Nm

M = 700 Nm

M = 650 Nm

1

Gear drive


Edition12.02.1999

Page43


c

Tighten screws - 1 -with →→→→→6 screws M10 x 35 DIN 912

Tighten nuts - 2 - with →→→→→4 hexagon nuts M12 DIN 934

Backlash at - 3 - →→→→→

Backlash at - 4 - →→→→→

4

1

2

3

M = 37 Nm

M = 60 Nm

0.12 - 0.20 mm

0.20 - 0.29 mm

Governor drive


Edition12.02.1999

Page44


c

With lug

Tighten camshaft bearingwithout lug with →→→→→corresponding to 90°

Pretighten camshaft bearingwith lug with →→→→→

and tighten with →→→→→corresponding to 850 Nm

GapAfter mounting →→→→→

After longer operation notbelow →→→→→

Reference dimensionAfter correct tightening →→→→→The gap of the bearing shells must be absolutely horizontalto guarantee sufficient oil supply.

M = 770 Nm

Without lug

M = 750 Nm

Dw = 30°

0.30 - 0.25 mm

0.20 mm

150.15 + 0.065 mm

Camshaft


Edition12.02.1999

Page45


c

Vibration damperTighten screws -1- with →→→→→M20 x 80 SK DIN 931

Tighten screws -2- with →→→→→M12 x 180 10.9 DIN 912

Tighten screws for additional weight on camshaftwith →→→→→

Starting camOld designPretighten tie bolt M20 with →→→→→

and tighten with →→→→→

Tie bolt secured with spring dowel pin 6 x 32 DIN 1481.

M = 270 Nm

M = 70 Nm

1

2

M = 480 Nm

M = 250 Nm

Dw = 60°

Camshaft


Edition12.02.1999

Page46


c

New designThe tightening torque for inserting the tie bolts is →→→→→

Pretighten castellated nut with →→→→→

and tighten with →→→→→

Tighten castellated nut up to the next split pin hole .In addition the castellated nut is secured with spring dowel pin 6 x 32 DIN 1481.

Starting cam for repair on non-reversible engines.Attention! The cam is only deliveredafter consultation with VK14.Mounting instruction1. Turn engine to position firing

TDC cyl. 1.

2. Remove starting air distributor.

3. Dismount starting cam, removecentering piece - 2x M6 -.

4. Check position of the thrust ring forcamshaft gear. In firing TDC cyl.1onescrew - M12 - must be exactlyon top.Otherwise ascertain thedisplacement angle,transfer it to therepair cam and bore anew6x13,5mm on pitch circle

Ø142mm (engraved on back)

5. Mount repair cam and safety-wire it.

6. Modify intermediate plate with oil

guide pipe. Shorten oil guide pipe to overall dimension plate - pipe end 18mm.

7. Mount intermediate plate and starting air distributor with sealing compound.

8. Remove control piston for cyl. 1 and check that position „starting valve opens 8° afterTDC“ acc. to job card.

M = 200 Nm

M = 200 Nm

Dw = 60°

18 Ø 1

42

Camshaft


Edition12.02.1999

Page47


c

Starting cam - setting:Turn cylinder 1 into position 8° after firing TDC.Direct light beam from top into the bore - 1 -and observe control piston - 2 - through bore - 3 - . Turnstarting cam in the opposite direction to the rotation ofcamshaft until the light gap is still just visible. Now thestarting cam has reached the position „starting valveopens"

Repair camsFuel cams - non-reversible enginesengine stroke series design repair camon cam holder splitM601 40 1.80.7-32.30.01-04 1.80.7-32.35.00-03 *

1.80.7-32.35.00-07 **M601 + M601C 45 1.80.7-32.30.01-05 1.80.7-32.35.00-10 **M601 45 1.80.7-32.30.01-06 1.80.7-32.35.00-04 *

1.80.7-32.35.00-10 **M601C 45 1.80.7-32.30.01-09 1.80.7-32.35.00-09 **

* Cams are mounted on cam holder.** Cam is directly mounted on the camshaft. For this purpose the cam holder must be

removed.

1

2

3

Camshaft

Position at startof setting

Position "startingvalve opens"


Edition12.02.1999

Page48


c

Fuel cams - reversible enginesengine stroke series design repair cam

on cam holder splitM601 40 1.80.7-32.30.01-01 1.80.7-32.35.00-01 *M601 40 1.80.7-32.30.01-02 1.80.7-32.35.00-03 *

Ers. -03M601 + M601C 45 1.80.7-32.30.01-07 1.80.7-32.35.00-05 ** Cams are mounted on cam holder.

Tightening torque for fuel repair camsCams 1.80.7-32.35.00-01 / 03 / 04 / 05 (Cam holder)Tighten screws alternately and steadily with →→→→→MolykoteCam 1.80.7-32.35.00-06 / 07 (On camshaft)Pretighten screws manually andtighten alternately in small steps with →→→→→MolykoteCams 1.80.7-32.35.00-09 / 10 / 11 / 12 / 13 / 14 (On camshaft)Pretighten screws manually andtighten alternately in small steps with →→→→→Molykote

MountingMounting instruction for split fuel cams on non-reversible engines:1.80.7-32.35.00-07 / -09 / 10 / 13 / 14

M = 90 Nm

M = 800 Nm

M = 900 Nm

Exhaust cam

94,5

Fitti

ng d

epth

20

Dep

th o

f bor

e 23

232

127

Spring dowel pin 4x28 DIN 1481

Parallel pin 20m6x50 DIN 7Parallel pin 16m6x50 DIN 7

Camshaft


Edition12.02.1999

Page49


c

The dimensions for the distance between fuel cam and exhaust cam apply to thecams 1.80.7-32.35.00-06 -10For the cams 1.80.7-32.35.00-13 and -14 the following is valid:Align fuel cam to center of roller and take care of free passage from the tie bolts to the roller.

Bore camshaft to Ø 19,8 mm or Ø 15,5 and 23 mm deep, then ream jointly with the cam toØ 20 H7 or Ø 16 H7 The fitting depth is 20 mm, the boreholes in the camshaft are to berounded off with R = 2. Mount the cam, pin and secure it with a spring dowel pin.

Pin Ø 20m6 for the variants. - 06 to -10Pin Ø 16m6 for the variants -11 to -14Are the variants -11 to -14 delivered in exchange for the variants -06 / -08 to -10, pin Ø 20m6 mustbe used.Cams -11 to -14 are delivered with both pins.

Exhaust cams - non-reversible enginesengine stroke series design repair cams, splitM601 34 1.80.7-32.22.01-01 1.80.7-32.23.00-04

repl. -02M601 + M601C 34 1.80.7-32.22.01-03 1.80.7-32.23.00-05M601C 34 1.80.7-32.22.01-04M601C 34 1.80.7-32.22.01-05 1.80.7-32.23.00-06

MountingMounting instruction for split exhaust cams on non-reversible engines:1.80.7-32.23.00-04 / -05 / 06

94

Exhaust repair cam Inlet cam

1x45

° Ø16H7

Dep

th o

f fit

14 17D

epth

of b

ore

109

Camshaft


Edition12.02.1999

Page50


c

Exhaust cams - reversible enginesengine stroke series design repair cams, split

M601 34 1.80.7-32.20.01-06 1.80.7-32.23.00-01repl. -07 repl. -02

M601 34 1.80.7-32.20.01-08 1.80.7-32.23.00-03

M601C 34 1.80.7-32.20.01-09 1.80.7-32.23.00-07

Inlet cams - non-reversible enginesengine stroke series design repair cams, splitM601 30 1.80.7-32.12.01-01 1.80.7-32.13.00-06

repl. -03M601 30 1.80.7-32.12.01-04 1.80.7-32.13.00-07M601 34 1.80.7-32.12.01-05 1.80.7-32.13.00-08

repl. -06M601 + M601C 34 1.80.7-32.12.01-07 1.80.7-32.13.00-08M601C 34 1.80.7-32.12.01-09 1.80.7-32.13.00-09

Camshaft

Inlet cam

Dep

th o

f fit

Dep

th o

f bor

e

124

44

Ø16H7

14 11

Exhaust repair cam


Edition12.02.1999

Page51


c

MountingMounting instruction for split inlet cams on non-reversible engines:1.80.7-32.13.00-06/-07-08/-09

Attention !After reaming the bore Ø16 H7, but before mounting the cam remove the positioningpin Ø8 from the camshaft. Otherwise the cam cannot be fitted.Ø 16 H7 = Ø 16.000 - Ø 16.018

Inlet cams - reversible enginesengine stroke series design repair cams, splitM601 30 1.80.7-32.10.01-05 1.80.7-32.13.00-02

repl. -08 repl. -03M601 30 1.80.7-32.10.01-07 1.80.7-32.13.00-01

repl. -09 repl. -04M601 34 1.80.7-32.10.01-10 1.80.7-32.13.00-05

repl. -11M601 + M601C 34 1.80.7-32.10.01-12 1.80.7-32.13.00-05

Camshaft

Ø 16 H7

Fitti

ng d

epth

14

Dep

th o

f bor

e 17

1 x

45°

Inlet cam, split94

109

Exhaust cam


Edition12.02.1999

Page52


c

Tightening torque for inlet and exhaust cams - reversible - non-reversiblePretighten screws by hand and tighten alternately insmall steps with →→→→→

For all cam mountings treat contact surfaces and threads with Molykote.

Lower valve driveTighten screws for roller tappet housing with →→→→→M20 x 60 DIN 912ATTENTION! The set screws for lifting the roller tappet bodies may only be used in the area of theinlet and exhaust valves if at the same time the valve rocker bracket is removed. Otherwise, thevalves touch in TDC on the piston, shearing off the screws.

Fuel injection pump with driveTightening torque for inserting the tie bolts →→→→→

Pretighten nuts with →→→→→and tightenwith →→→→→

M = 180 Nm

M = 210 Nm

M = 300 Nm

M = 50 Nm

Dw = 90°

Camshaft

44 124

Exhaust cam Inlet repair cam

Ø16H7

Dep

th o

fbo

re Dep

th o

f fit

1411


Edition12.02.1999

Page53


c

Camshaft with additional masses1100 KW/cyl. engines

The camshaft of the 1100 KW engines is provided with additional masses at the cylinders5, 6, 7 and 8 which are mounted between the fuel and exhaust cams.

Should it be necessary to change a fuel cam of the above-mentioned cylinders therespective additional mass must be removed because the space for a repair cam is notsufficient. This proceeds as follows:

1. In case only one fuel cam is changed, the removed mass is to be mounted atcylinder 4. Drilling of a new pin hole is not necessary.

2. In case two fuel cams must be changed, all additional masses are to beremoved and a vibration damper assembly for the camshaft must be mountedaccording to drawing

No. 1.80.7-62.29.00-01.

Attention:The now open pin holes must not be sharp-edged. They must be rounded carefully.

Camshaft


Edition12.02.1999

Page54


c

Tighten nuts - 1 -crosswise with →→→→→

Tighten screws - 2 -crosswise with →→→→→

Tighten screws - 1 - with →→→→→

Tighten connecting piece - 2 - with →→→→→

M = 240 Nm

M = 50 Nm

M = 240 Nm

M = 900 + 30 Nm

Fuel injection pumps

12

12


Edition12.02.1999

Page55


c

Fuel injection pump M601CTighten screws - 1 - with →→→→→

Tighten screws - 2 - with →→→→→

Pretighten fixing nuts with →→→→→

and tighten with →→→→→The following fuel injection pumps are used:PGO - G006 aPGO - G008PGO - G008 aPGO - G008 bPGO - G015

MountingDuring assembly of the fuel injection pumps particular attention must be paid to thecoincidence of marks. After correct fitting you can look through from the inlet to the outletopening.

Basic settingThe basic setting must only be carried out if:1. the injection pump or the injection pump drive was exchanged,2. the mark commencement of fuel delivery does not coincide with the dead center

indicator. Turn roller on the base circle of cam, check if line mark - 1 - on the springcup coincides with line mark - 2 - on the pump casing. In case of deviations: Unscrewclamping screws - 4 - and adjust thrust bolt - 5 - until coincidence of line marks isreached. Tighten clamping screws again.After flywheel markingturn engine intoposition„commencement offuel delivery“,check if line mark- 3 - on the springcup coincides withline mark - 2 -.

Only in case of major deviations readjust cam.

M = 100 Nm

M = 210 Nm

M = 240 Nm

Dw = 90°


1 2

51

2

423


Edition12.02.1999

Page56


c

2

1

21

Firing TDCCommencement offuel delivery

Position ofcommencementof delivery

Check of commencement of fuel deliverySee commencement of fueldelivery from the acceptancetest record and enter therelevant arc on the measuringgroove of the flywheel and markcommencement of fuel delivery.Turn engine in direction ofrotation until line mark - 1 - onthe springcup coincides with line mark- 2 - on the pump casing.Check on the flywheel if the commencement of fuel delivery mark is below the dead centerindicator.

Fuel injection pump M 601 C - Basic settingTurn roller on the base circle of cam, check if the line mark - 1 - on thespring cup coincides with the line mark - 2 - on the pump casing.(for thispurpose remove locking screw - A -)In case of major deviations :Dismount the injection pump.Check dimension " a " between the upper housing edge of injection pump drive and thrustbolt.The nominal dimension is : 10 ± 0.1 mmIn case of deviations insert corresponding shims - 1 - between thrust bolt - 2 - and thrustpiece - 3 - of the roller tappet and adjust the dimension „a" of 10 ± 0.1 mm in this way.Mount the injection pump and repeat check of commencement of delivery.

Only in case of major deviations readjust cam.


13

2

Z

a

Z

A


Edition12.02.1999

Page57


c

1.80.7-63.45.00-01 6 + 8 cyl. enginesTighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nut M36x3 DIN 935 with →→→→→16 pcs. threaded bolts M36x3, length 286 mm

1.80.7-63.45.00-02 6 cyl. engines without power take-off1.80.7-63.40.00-01 6 cyl. engines with power take-offTighten hexagon srews M12x40 SK DIN 933with →→→→→

Tighten castellated nut M36x3 DIN 935 and M42x3 DIN 935with →→→→→4 pcs. reamed bolts M42x3, length 438 mm4 pcs. threaded bolts M36x3, length 427 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025One reamed bolt every 90°

1.80.7-63.45.00-03 8 + 9 cyl. engines without power take-off1.80.7-63.40.00-03 8 + 9 cyl. engines with power take-offTighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nut M36x3 DIN 935 and M42x3 DIN 935with →→→→→

4 pcs. reamed bolts M42x3, length 438 mm12 pcs. threaded bolts M36x3, length 427 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025One reamed bolt every 90°

1.80.7-63.45.00-04 with additional weight without vibration damperTighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nut M36x3 DIN 935 with →→→→→

16 pcs. threaded bolts M36x3, length 286 mm

M = 40 Nm

M = 1150 Nm

M = 40 Nm

M = 900 Nm

M = 40 Nm

M = 900 Nm

M = 40 Nm

M = 1150 Nm

Flange shaft mounting


Edition12.02.1999

Page58


c

1.80.7-63.45.00-05 8+9 cyl. engines without power take-off1.80.7-63.40.00-04 8+9 cyl. engines with power take-offTighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935with →→→→→8 pcs. reamed bolts M42x3, length 438 mm8 pcs. threaded bolts M36x3, length 427 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025One reamed bolt every 45°

1.80.7-63.45.00-06 6 cyl. engines - marine - without power take-off1.80.7-63.40.00-05 6 cyl. engines - marine - with power take-offTighten hexagon screws M12x40 SK DIN 933with →→→→→Pretighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935with →→→→→and tightenwith →→→→→Tighten up to the next split pin hole.4 pcs. reamed bolts M42x3, length 438 mm12 pcs. threaded bolts M36x3, length 427 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025One reamed bolt every 90°

1.80.7-63.45.00-07 8+9 cyl. engines - marine - without power take-off 9 cyl. engines - generator

1.80.7-63.40.00-06 8+9 cyl. engines - marine - with power take-off

Tighten hexagon screws M12x40 SK DIN 933with →→→→→

Pretighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935with →→→→→and tightenwith →→→→→Tighten up to the next split pin hole.8 pcs. reamed bolts M42x3, length 438 mm8 pcs. threaded bolts M36x3, length 427 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025One reamed bolt every 45°

M = 40 Nm

M = 900 Nm

M = 40 Nm

M = 1000 Nm

Dw = 30°

M = 40 Nm

M = 1000 Nm

Dw = 30°



Edition12.02.1999

Page59


c

1.80.7-63.45.00-08 8 cyl. engines - generatorTighten hexagon screws M12x40 SK DIN 933with →→→→→

Pretighten castellated nut M36x3 DIN 935 and M42x3 DIN 935with →→→→→and tightenwith →→→→→Tighten up to the next split pin hole.16 pcs. reamed bolts M42x3, length 438 mmBore of reamed bolt Ø 44 H 7 H7 = 44,000 - 44,025

1.80.7-63.45.00-09Tighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nut M36x3 DIN 935with →→→→→

16 pcs. threaded bolts M36x3, length 427 mm

All before mentioned tightening torques are valid when using Molykote.

1.80.7-63.45.00-10 6 + 8 cyl. engines - marine 6 cyl. engines - generator

Tighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten hexagon socket head cap screws M20x140 DIN 912with →→→→→

Pretighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935with →→→→→and tightenwith →→→→→Tighten up to next split pin hole.16 pcs. threaded bolts M36x3, length 427 mm

Flange shaft side: Coat thread and contact surface of nut with Molykote.The crankshaft side remains dry.


M = 40 Nm

M = 1000 Nm

Dw = 30°

M = 40 Nm

M = 1150 Nm

M = 40 Nm

M = 310 Nm

M = 1000 Nm

Dw = 30°


Edition12.02.1999

Page60


c

1.80.7-63.40.00-02 6 cyl. engines with power take-offTighten hexagon screws M12x40 SK DIN 933with →→→→→

Tighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935with →→→→→8 pcs. reamed bolts M42x3, length 438 mmBore of reamed bolt Ø 44 H 7 H7 = 44.000 - 44.025One reamed bolt every 45°

All before mentioned tightening torques are valid when using Molykote.

M = 40 Nm

M = 900 Nm



Edition12.02.1999

Page61


c

Mechanic tighteningThe castellated nuts M56x4 for the flywheel mountingare tightened with →→→→→Lubricant: Molykote

Hydraulic tighteningTighten round nuts continuously with a pin by hand paying attention to the dimension of 64mm (sketch).Apply two tightening devices crosswise opposite,lengthen the screws with →→→→→and tighten the round nuts continuously with a pin.

M = 4000 Nm

P = 2420 bar

Flywheel mounting


Edition12.02.1999

Page62


c

The following screws are fitted on the turbocharger mounting:Tie bolt M20x88 mm SW 30Tightening torque →→→→→

Tie bolt M24x153 mm SW 36Tightening torque →→→→→

Tie bolt M30x164 mm SW 46Tightening torque →→→→→corresponding toa pretightening torque of →→→→→

and a →→→→→

Tie bolt M24x99 mm SW36Tightening torque →→→→→corresponding toa pretightening torque of →→→→→

and a →→→→→

Tie bolt M36xx2x203 mm SW50Tightening torque →→→→→corresponding toa pretightening torque of →→→→→

and a →→→→→

Hexagon screw M30x140 DIN 931 10.9Tightening torque →→→→→corresponding to manual tightening,

then tighten with →→→→→

M = 320 Nm

M = 330 Nm

M = 660 Nm

M = 50 Nm

Dw = 45°

M = 600 Nm

M = 50 Nm

Dw = 55° ± 5°

M = 1700 Nm

M = 100 Nm

Dw = 90° * 20°

M = 1000 Nm

Dw = 30° + 5°

Turbocharger mounting


Edition12.02.1999

Page63


c

On the charge air cooler mounting the following screws are inserted:Tie bolt M20x2x125 mm SW 30Tightening torque →→→→→

Tie bolt M24x153 SW 36Tightening torque →→→→→

Tie bolt M16x95 SW 24Tightening torque →→→→→

Hexagon screw M16x90 DIN 931 12.9Tightening torque →→→→→

Bedplate - intermediate frameTighten screws with →→→→→Screws M36 x 150 mm DIN 931

Intermediate frame - cylinder blockTighten screws with →→→→→Screws M36 x 150 mm DIN 931

M = 230 Nm

M = 300 Nm

M = 150 Nm

M = 150 Nm

M = 1150 Nm

M = 1300 Nm

Charge air cooler mounting

Connecting screws


Edition12.02.1999

Page64


c

Tightening sequence1.80.7-16.20.00-021st step →→→→→

2nd step →→→→→

3rd step →→→→→

1.80.7-16.20.00-031st step →→→→→



1.80.7-16.20.00-041st step →→→→→



Tightening sequence6 cylinders

1st step

2nd step

3rd step

1 32 4 5 6 7

8 109 11 12 13 14

15 1716 18 19 20 21

P = 300 bar

P = 600 bar

P = 820 bar

P = 370 bar

P = 740 bar

P = 960 bar

P = 370 bar

P = 740 bar

Tie rod

P = 1030 bar


Edition12.02.1999

Page65


c


1st step

2nd step

3rd step


1st step

2nd step

3rd step

Attention :If tie rods 1.80.7-16.20.00-03 are supplied as replacement for the tie rods 1.80.7-16.20.00-02, thefinal step 820 bar applies to tightening.

If tie rods 1.80.7-16.20.00-04 are delivered as replacement, the following final steps are applicableto the tightening instructions:As replacement for 1.80.7-16.20.00-02 final step 820 bar.As replacement for 1.80.7-16.20.00-03 final step 960 bar.

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 16 18

19 20 21 22 23 24 25 26 27

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30

Tie rod


Edition12.02.1999

Page66


c

S =

5

Application of the tighteningdeviceTightening of tie rods1. Tighten round nuts with a pin

steadily by hand.2. Setup according to sketch.3. Unscrew the device up to block

length until black line markcoincides with bottom edge guardring.

4. Lengthen tie rods according toinstructions.

5. Tighten round nuts with pin by hand.

6. Make the hydraulic device stress-free.

Loosening of tie rods1. Setup according to sketch.2. Set the device to gap size S = 5 (sketch).3. Lengthen the tie rod according to instructions.4. Loosen round nuts with pin by about 5 mm.5. Make the hydraulic device stress-free.

Max. stroke = 10 mm red ringmark must not be exceeded.

Tie rod


Edition12.02.1999

Page67


c

Firing sequences

6 cyl. clockwise: 1 - 3 - 5 - 6 - 4 - 2

counterclockwise: 1 - 2 - 4 - 6 - 5 - 3

8 cyl. clockwise: 1 - 4 - 7 - 6 - 8 - 5 - 2 - 3

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

9 cyl. clockwise: 1 - 2 - 4 - 6 - 8 - 9 - 7 - 5 - 3

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

Valve timings

Exhaust valve opens 60 ° before BDC

Exhaust valve closes 55 ° after TDC

Inlet valve opens 75 ° before TDC

Inlet valve closes 40 ° after BDC

Firing sequences - valve timings


Edition12.02.1999

Page68


cDesignation Length mm Width mm Height mm Weight kg

Bedplate (without bearing covers and bolts)

6 cyl. engines 6180 2100 1087 18500

8 cyl. engines 7900 2100 1087 23500

9 cyl. engines 8760 2100 1087 26000

Main bearing cover 726 212 425 220

Main bearing bolt 899 53,5 12,4

Crankshaft (without counterweights)

6 cyl. engines 6495 792 300 11600

8 cyl. engines 8215 792 300 14100

9 cyl. engines 9075 792 300 15550

Counterweight 893 193 420 284

Intermediate frame

6 cyl. engines 5500 1730 978 10700

8 cyl. engines 7220 1730 978 13900

9 cyl. engines 8080 1730 978 15600

Cylinder block (with liners and studs)

6 cyl. engines 5500 1365 1632 25900

8 cyl. engines 7220 1365 1632 33800

9 cyl. engines 8080 1365 1632 37700


Edition12.02.1999

Page69



Tie rod 3166 70 Ø 110Camshaft (with cams) non-reversible6 cyl. engine 6029 2117

8 cyl. engine 7744 2590

9 cyl. engine 8609 2825

Reversible

6 cyl. engine 6029 2320

8 cyl. engine 7744 2860

9 cyl. engine 8609 2952

Camshaft bearing 100 150/162 Ø 2,7

Piston 940 580 Ø 408

Piston pin 490 240 Ø 156

Connecting rod(compl.) 2087 615 175/180 480

Inlet and exhaust cams 46,5

Fuel cam 45,3

Valve drive 52

Drive for fuel injection pump 86

Gear box(old / new) 1665 380 1800 535/1253

TurbochargerVTR 454 2221 1427 1286 3250

VTR 501 2235 1320 3310


Edition12.02.1999

Page70



VTR 564 2591 1656 1712 6500

VTR 631 2660 1732 5960

Charge air cooler(two-circuit) 782 1620 1864 1005

Exhaust valve (compl.) 200 Ø 787 124

Injection valve 110 Ø 774 25

Cyl. head (compl.) 1280 1090 1690

Liner 757 Ø 1524 1146

Piston with connecting rod 615 2418 1357

Injection pum 78

Gear wheel on crankshaft 120 695 Ø 176

Twin wheel 270 913 Ø 765

Camshaft gear 215 921 Ø 462

Located main bearing shell 42

Main bearing shell 22,2

M601-M601C Engineer´s Handbook

Documents

Transcript of M601-M601C Engineer´s Handbook