M601-M601C Engineer S Handbook

m
c
M601 - M601C
Engineers Handbook
M601 - M601C
Contents
Camshaft
Camshaft bearing
44
Gap
44
Reference dimension
44
Starting cam
45
Vibration damper
45
Repair cams
Exhaust cams
49
Fuel cams
48
Inlet cams
50
Tightening torques for inlet and exhaust cams 52
Additional masses
53
Edition
12.02.1999
- 47
- 50
- 49
- 51
Charge air cooler mounting
63
Connecting rod
Big end bearing
Big end bearing - reference dimension
Gap, big end bearing
Marking
Piston pin bush
Plugs
Shank division
28
29
29
29
29
28
28
Connecting screws
63
Counterweight
31 - 32
Cylinder head
Exhaust gas manifold
Exhaust valve rocker
Exhaust valves, tightening torques
Fitting valve stem
Fuel injection valve
Grinding of inlet and exhaust valves
Inlet valve rocker
Inlet valve seat ring
Refinishing cyl. head - exhaust valve
Refinishing of the valve cone surfaces
Rocker arm bracket
Starting valve
11
9
12
17
11
16
9
14
13
16
9
10
Service document of
Caterpillar Motoren GmbH & Co. KG
Page
2
Engineers Handbook
M601 - M601C
Contents
Cylinder head
Tightening torques
Valve clearance
Valve guide
Valve stem
6-8
10
10
15
Engine data
Engine operating data
Firing sequences
67
Flange shaft mounting
57 - 60
Flywheel mounting
61
Fuel injection pump

Basic setting
Check of commencement of delivery
54 - 55
55
56
Fuel injection pump with drive
52
Gear drive
Adjustment gear drive
Backlashes
Camshaft gear
Gear box
Gear wheel on crankshaft
Gear wheels for gear drive
Intermediate wheel mounting
Mounting of camshaft gear with
coupling piece
Step bearing, intermediate wheel
Step wheel
Edition
12.02.1999
39 - 41
38
37
42
33 - 34
38
35
36
35
35
Service document of
Page
3
Engineers Handbook
M601 - M601C
Contents
Edition
12.02.1999
Governor drive
43
Liners
25 - 27
Lower valve drive

Fixing of roller tappet body
52
52
Main bearing
Gap
Tightening specification
30
30
Piston
Piston rings mounting
Piston specification
Piston, KS
Piston, Mahle
Ring grooves, wear limits
Piston rings
22
21
20 - 21
18 - 20
22
24
Sizes and weights
68 - 70
Tie rod
64 - 66
Turbocharger mounting
62
Valve timings
67
Service document of
Page
4
Engineers Handbook
M601 - M601C
Engine data
Engine operating data

Temperatures
Stroke:
600
mm
Bore:
580
mm
Lub. oil, inlet

Stationary engines
50 - 55
50 - 60
Speed:
425
rpm
Temperature rise:
9 - 16
C
C
C *1
Fresh water circulation cooling
Number of cylinders: 6 - 8 -9
Main bearing:
Engine outlet:
80 - 85
Temperature rise:
7 - 10
C *1
Inside
430
mm
Charge air, inlet:
45 - 60
Outside
450
mm
Nozzle cooling, inlet
65 - 75
Pressures
Big end bearing:
Lub. oil, at the last
Inside
410
mm
Outside
425
mm
camshaft bearing:
*2
4.0 - 5.0
bar
Fresh water circulation cooling:

2.5 - 5.0 bar
Valves (inlet)
With attached pumps
Length
787
mm
Shaft
39
mm
Valve disk
184
mm
minimum:
2.0
Nozzle cooling:
1.5 - 3.0 bar
Fuel pressure before

injection pumps: MDO
bar
HFO
Valves (exhaust)
Length
787
mm
Shaft
39
mm
*1 = at rated engine output
Valve disk
184
mm
*2 = at rated engine speed
Edition
12.02.1999
Service document of
bar
1.5 - 3.0
4.0 - 5.0
Page
5
Engineers Handbook
M601 - M601C
Cylinder head
The tightening torque for inserting the
tie bolts is
= 1600 200
Nm
Tightening torque
Old type
Instruction for tightening with 8 hydraulic jacks.
Lengthen cylinder head bolts
P
= 1300
bar
continuously with
hold pressure 2 minutes, then
reduce pressure to
P
= 1200
bar
and: In case of bolts M 52 x 3 tighten round nuts
with pin by 8 slot lengths. In case of bolts M 56 x 4 tighten round nuts with pin by 6 slot
lengths.
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 a
difference, all nuts must be loosened again and newly tightened.
Instruction for tightening with 4 hydraulic jacks :

1st step lengthen cyl. head
bolts 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. head
bolts 2 - 4 - 6 - 8 with
then reduce pressure to
and tighten round nuts manually with pin.
= 1300
bar
= 1250
bar
= 1300
bar
= 1250
bar
Old nut, height 46 mm

Old hydraulic jack
Edition
12.02.1999
Service document of
Page
6
Engineers Handbook
M601 - M601C
Cylinder head
New type
Instruction for tightening with 8 hydraulic jacks:
Tighten cylinder head nuts steadily with pin.
Lengthen cylinder head bolts with
hold pressure 2 minutes, then
reduce the pressure to
and tighten round nuts continuously with
pin by 6 slot lengths.
= 1200
bar
= 1100
bar
= 1250
bar
= 1150
bar
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
then reduce to
and tighten round nuts steadily with pin.
P
= 1200
Lengthen cyl. head bolts 2 - 4 - 6 - 8 with
then reduce to
P
= 1100
and tighten round nuts steadily with pin.
Measure all 8 threads with depth gauge and compare with the values after manual
tightening.
bar
bar
Tightening specification for the new hydraulic jack:

After tightening by hand with pin measure dimension S1 with depth gauge. Then tighten
nuts 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 after
manual tightening. The difference of the individual valves shall not exceed or be less
than 2.9 - 3.8 mm. If the difference is not within this range, repeat the tightening
process.
S3
S2
S1
Edition
12.02.1999
Service document of
Page
7
Engineers Handbook
M601 - M601C
Cylinder head
Attention ! All 8 nuts must be tightened with the same
number of slot lengths. If there is a difference, all nuts must
be loosened again and newly tightened.
New nut, height 56 mm
Edition
12.02.1999
New hydraulic jack
Service document of
Page
8
Engineers Handbook
M601 - M601C
Cylinder head
Rocker arm bracket
Tighten screw - 1 with
Tighten screw - 2 with
Tighten screws - 3 with
= 400
Nm
= 550
Nm
= 650
Nm
= 230
Nm
3
2
Inlet valve rocker

Tightening torque for the
taper pin nuts
Original clearance
Maximum clearance
Clearance limit
Axial clearance S
Clearance limit
Both bushes shall recede

by (Size X" )
Edition
12.02.1999
mm
0.192
mm
0.32
mm
0.20
Exhaust valve rocker

Original clearance
Maximum clearance
0.048
+ 0.1
mm
0.057
mm
0.204
mm
0.32
mm
0.25
mm
Service document of
Page
9
Engineers Handbook
M601 - M601C
Cylinder head
Valve clearance
Inlet valve
Exhaust valve
0.40
0.10
mm
1.20
0.10
mm
Setting under hot running conditions, abt. 15 min. after stopping the engine.
Valve guide
Exhaust HFO operation
Original clearance
Clearance limit
Exhaust MDO operation

Original clearance
Clearance limit
Inlet HFO + MDO operation

Original clearance
Clearance limit
0.22 - 0.29
mm
0.45
mm
0.13 - 0.21
mm
0.45
mm
0.13 - 0.21
mm
0.45
mm
Starting valve
Tighten cap nut AFM 16 DIN 2510 with
= 110
Nm
Tighten hexagon nut M16 DIN 934 with
= 150
Nm
Edition
12.02.1999
Service document of
Page
10
Engineers Handbook
M601 - M601C
Cylinder head
Fuel injection valve
Tighten fixing nuts with
11 mm
= 110
Nm
The tightening torque for the

nozzle nut is
= 450
Nm
this corresponds to an arc

measure of
11
mm
New nozzle nut, that means

M = 450 Nm correspond to 9mm
at the circumference.
Fuel injection valve M 601 C

Insert the injection valve in the
cylinder head.
Mount the flange and screw
on the cap nuts loosely.
Lightly coat the thread and the
conical surfaces at the adapter
- 1 - with Molykote paste
G - Rapid", screw it into the
nozzle holder and
tighten with
Exhaust gas manifold

Pretighten tension screws to the cyl. head with
and tighten
with
this corresponds to 1 1/2 hexagons.
Edition
12.02.1999
= 400
Nm
= 30
Nm
Dw = 90
Service document of
Page
11
Engineers Handbook
M601 - M601C
Cylinder head
Exhaust valves
Old type of exhaust valve cage with

cooling water outlet. On all cylinder
heads of this type the exhaust valves
are tightened as follows:
Tighten nuts steadily with

to adapt the joint ring to the seat, then lengthen screws
with
and tighten nuts.
= 100
Nm
= 850
bar
= 100
Nm
= 1000
bar
New type of exhaust valve cage with

cooling water outlet. On all cylinder
heads of this type the exhaust valves
are tightened as follows:
Tighten nuts steadily with

to adapt the joint ring to the seat, then lengthen screws
with
and tighten nuts by hand.
On the engines with the Nos. 63156 - 63158 - 63165 - 63167 - 63168 and from No. 63170
on the exhaust valves are inserted in the engine without joint ring. They are tightened as
follows:
Tighten nuts steadily in 3 steps up to
then lengthen screws with
and tighten nuts by hand.
Edition
12.02.1999
= 100
Nm
= 1050
bar
Service document of
Page
12
Engineers Handbook
M601 - M601C
Cylinder head
Refinishing cyl. head - exhaust valve
Maximum refinishing of the seat in the cyl. head and on
the exhaust valve cage
2.00
Refinishing on the valve cage seat and / or in the bore

of the cyl. head is possible. Before removal measure
dimension L" from top edge of cyl. head to top edge
of exhaust valve cage flange. Carefully clean the
exhaust valve bore in the cyl. head. Insert the reseating
tool and face slowly and uniformly with low contact
pressure. After facing fit the exhaust valve cage and
measure dimension L" again.
The difference of both measurements is the refinishing
dimension.
A maximum refinishing of 2.00 mm is possible,
however, refinishing in the cylinder head should not
exceed 1.25 mm, consequently refinishing of 0.75
mm is possible on the exhaust valve cage.
(Detail X")
mm
Attention: From engine No. 63156 on the exhaust valve

cages are inserted in the cylinder heads without joint
rings.
Exhaust valve seat

Maximum admissible dimension:
X = 183.50 0.20 mm.
Edition
12.02.1999
Service document of
Page
13
Engineers Handbook
M601 - M601C
Cylinder head
Removal: Cut off the old valve stem at the shaft end and chamfer the resulting joint face
against upsettings. Grind valve plate until it fits in the valve seat ring, connect the valve
plate 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 the
valve seat ring down to 20 C and heat the cylinder head up to 130 C. Put the valve seat
ring in the bore and force it in with the old valve stem. After about 5 minutes, move the
valve seat into its final position by means of a setting blow, afterwards there must be no
clearance 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 ring
and after about 5 minutes a valve stem and bring it into the final position by means of a
setting blow. Afterwards there must be no clearance between seat ring and contact surface
in the cylinder head. Any protruding edges from the seat ring to the inlet port are to be
smoothed off.
Fitting in the workshop
1. 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
= 300
Nm
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 196 + 0.029 mm
External diameter of the valve seat ring = 193.18 - 0.03 mm.
Maximum admissible dimension:
X = 190
0.02
mm.
Edition
12.02.1999
Service document of
Page
14
Engineers Handbook
M601 - M601C
Cylinder head
Valve stem
Valve 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 in
blow-bys,
3. cracking was not detected in the valve cone surface by crack test with luminous
magnifying 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 disk
diameter and in case of high-temperature corrosion of > 2.5 mm on the bottom side of the
valve disk.
Edition
12.02.1999
Service document of
Page
15
Engineers Handbook
M601 - M601C
Cylinder head
Refinishing of the valve cone surfaces
Refinish valve cone acc. to sketch. Do not
refinish the existing fillet. After grinding
determine the dimension between the visible
edge base material - armouring X and the
outside edge of the seat surface. When it is
less than the minimum size exchange the
valve cone.
Round off the outside edge with a stone.
If the valve cone is refinished the valve seat
must be refinished, too.
Grinding of inlet and exhaust valves

Apply small dots of the diamond paste Dp 30/1015 my with a syringe to the new or remachined
valve cone and distribute the paste equally.
Thereafter the seat ring surface is to be sprayed
with a thinner (F25) belonging to the diamond
paste, for dilution and in order to increase the
grip. Insert the oiled valve stem into the guide
bush. Fasten the device at the valve disk and
grind the valve face and seat by hand applying a
moderate pressure, rotating the 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.
Edition
12.02.1999
Service document of
Page
16
Engineers Handbook
M601 - M601C
Cylinder head
Fitting valve stems:
M601 - M601C
Inlet valve stem

Exhaust valve stem
Gas oil and heavy fuel

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
Edition
12.02.1999
Service document of
Page
17
Engineers Handbook
M601 - M601C
Piston
1.80.6-26.70.00-01 Mahle - M601
Before tightening the nuts, the clearance between
piston crown and skirt must be
The tightening torque for inserting the studs is

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

and
tighten with

and
tighten with
Check:
At
the screws must not be detachable.
Edition
12.02.1999
mm
= 10
Nm
= 300
Nm
= 50
Nm
Dw = 120
1.80.6-26.70.00-03 Mahle - M601 M601 C


and loosen again.
0.06
0.06
mm
= 10
Nm
= 400
Nm
= 50
Nm
Dw = 160
= 300
Service document of
Nm
Page
18
Engineers Handbook
M601 - M601C
Piston
1.80.6-26.70.00-05 / -09 Mahle - M601 M601 C
0.06 - 0.12
mm
For measuring the clearance between piston crown and skirt the spacer rings must be removed.

and loosen again.

and
tighten with
Check:
At
= 10
Nm
= 400
Nm
= 50
Nm
Dw = 160
= 300
Nm
Spacer rings for the piston -05 and -09
= 549.5 - 0.5 mm
= 505.3 + 0.2 mm
Thickness = 6 0.1 mm
= 383.3 - 0.3 mm
= 276.7 + 0.3 mm
Attention ! The spacer rings are manufactured in one working process. They must be delivered
and fitted together.
For the piston 1.80.6-26.70.00-09 the crown193874643 of piston 1.80.6-26.70.00-11 can be
mounted, but with thrust pieces 193874654 only. The spacer rings are inapplicable.
Edition
12.02.1999
Service document of
Page
19
Engineers Handbook
M601 - M601C
Piston
1.80.6-26.70.00-11 Mahle - M601 M601 C
and loosen again.
Check the tightening torque of the studs with

and
tighten with
0.16 - 0.23
mm
= 10
Nm
= 160
Nm
= 10
Nm
= 70
Nm
Dw = 270
Check:
At
= 160
Nm
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 twice

with
and loosen again, then
check the tightening torque
for inserting the studs.
Before tightening the nuts the clearance between
piston skirt and piston crown must be
= 100
Nm
= 300
Nm
0.12
+ 0.04
mm
For measuring the clearance between piston crown and skirt the spacer rings must be removed.
Edition
12.02.1999
Service document of
Page
20
Engineers Handbook
M601 - M601C
Piston
then turn nuts on
crosswise with
then tighten nuts crosswise with
= 25
Nm
= 80
Nm
Dw = 120
Spacer rings for the piston -06
= 549- 0.5 mm
= 505.2 + 0.2 mm
= 393.3 0.5 mm
= 270 + 0.5 mm
Attention ! The spacer rings are manufactured in one working process. They must be delivered
and fitted together.
Check:
Var. -02 At
Var. -04 / -06 At
= 300
Nm
= 160
Nm
Check of stud stretching by difference measurement

A Measure unstretched studs from piston bottom up to the stud end.
Measure stretched studs from piston bottom up to the stud end.
l = 0.72 0.06
B
mm
Sleeve measurement from tension sleeve up to the stud end.

Stetching and upsetting with Mak measuring unit 1.80.7-92.03.00-13
l = 0.92 0.06
Edition
12.02.1999
Service document of
mm
Page
21
Engineers Handbook
M601 - M601C
Piston
1.80.6-26.70.00-12 KS M601 C
= 100
Nm

and loosen again.
Check tightening torque for inserting the studs with
= 300
Nm
= 100
Nm
Before tightening the nuts the clearance between piston skirt and
piston crown must be

then
turn nuts on crosswise,
then tighten nuts crosswise
with
0.12 - 0.18
mm
= 25
Nm
= 60
Nm
Dw = 120
At
= 160
Nm
Attention: For all piston mountings treat threads and contact surfaces with Molykote paste G.
Piston specification
Mahle:
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
KS:
1.80.6-26.70.00-02
M601 C
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
Edition
12.02.1999
Service document of
Page
22
Engineers Handbook
M601 - M601C
Piston
Piston rings - mounting
When fitting the piston rings must be arranged so that the ring butts are opposite in
longitudinal direction of engine. The mounting device (hose clamp) must move freely over
the piston rings. When inserting the piston rings in the grooves take care that the marking
of the piston ring is pointing upwards.
Wear limits
Built-up piston, gas oil and heavy fuel operation - ring grooves flame-hardened
Grooves
1
Grooves height
10,25 +0,03
Ring height
9,897 - 0,032
Wear limit
10,60
Clearance limit
0,75
10,19
+0,03
9,897
- 0,032
10,60
0,75
10,14
+0,03
9,897
- 0,032
10,60
0,75
10,14
+0,03
9,897
- 0,032
10,60
0,75
11,984
11,984
- 0,034
12,50
0,60
-0,017
**
Built-up piston, heavy fuel operation - 1st ring grooeves chromium-plated

Grooves
1
Grooves height
10,25 +0,03
Ring height
9,897 - 0,032
Wear limit
10,48
Clearance limit
0,60
10,19
+0,03
9,897
- 0,032
10,60
0,75
10,14
+0,03
9,897
- 0,032
10,60
0,75
10,14
+0,03
9,897
- 0,032
10,60
0,75
11,984
11,984
-0,034
12,50
0,60
-0,017
**
All stated details for standard equipment. This does not apply to oversize rngs.
Edition
12.02.1999
Service document of
Page
23
Engineers Handbook
M601 - M601C
Cylinder head
Piston 1.80.6-26.70.00-01 / -02 / -03 / -04
Ring groove
1
compression ring, chromium-plated
2-4
5
oil scraper ring, chromium-plated
ring
0.00.6-35.42.00-13.1
0.00.6-35.42.00-53.1
0.00.6-35.42.00-44.1 / -44.3
Piston 1.80.6-26.70.00-03 / -04

Ring groove
1
compression ring, three-side chromium-plated
2-4
5
ring
0.00.6-35.42.00-70.1 / -70.3
0.00.6-35.42.00-53.1
0.00.6-35.42.00-44.1 / -44.3
Piston 1.80.6-26.70.00-05 / -09 / -06

Ring groove
1
2-4
5
ring
0.00.6-35.42.00-70.1 / -70.3
0.00.6-35.42.00-53.1
0.00.6-35.42.00-44.1 / -44.3
Piston 1.80.6-26.70.00-11 / -12

Ring groove
1
2-4
5
ring
0.00.6-35.42.00-83.1 / -84.1
0.00.6-35.42.00-53.1
0.00.6-35.42.00-44.1 / -44.3
Piston 1.80.6-26.70.00-11 / -12

Ring groove
1
2-4
5
ring
0.00.6-35.42.00-13.1
0.00.6-35.42.00-53.1
0.00.6-35.42.00-44.1 / -44.3
Edition
12.02.1999
Service document of
Page
24
Engineers Handbook
M601 - M601C
Liners
Nominal size (original size)
Wear limits
Wear and tear value
Max. ovality
Wedge shape
Height
Depth * *
580.00-580.070
mm
1.00 - 1.20 *
mm
0.30
mm
20.00
mm
0.08
mm
Wedge-shaped indentation downwards across the entire circumference, beginning at TDC 1st
piston ring.
Canyon
Max. number
Length
Total width
3
20.00
mm
8.00
mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC).
Score
Number
Length
Depth
3
300.00
mm
0.08
mm
Hard vertical, linear friction marks.
Pocket
Number
Length
Width * * *
Depth * *
Edition
12.02.1999
3
150.00
mm
60.00
mm
0.05
mm
Service document of
Page
25
Engineers Handbook
M601 - M601C
Liner
Areal, irregular indentations.
*
**
***
Limit value for conically honed cylinder liners.

Radius r 3 mm
In circumferential direction.
Wedge shape Pocket
Score
TDC 1st ring
Canyon
1
2
Fitting of the liner:

Lower the liner until it is just still turnable. Insert the
centering device - 1 - into the liner groove. Pass the
screws M12 x 130 DIN 931 - 2 - through the centering
device and turn the liner until the screws can be inserted
in the tapholes of the water ring. Continue to lower the
liner. To obtain the correct liner position, attention must
be paid that the centering device remains in the liner
groove. After lowering remove the screws - 2 -, tighten
the centering device with 2 hexagon screws M12 x 25
DIN 933 and safety-wire it.
Edition
12.02.1999
Service document of
Page
26
Engineers Handbook
M601 - M601C
Liners
Arrangements of O-rings for the liners: 1.80.7-16.11.00-07, -09, -11, -14
O - ring
1.80.6-16.11.03-02
O - ring, Viton
1.80.6-16.11.03-03
Liners of the var. - 02 up

to - 06 are not provided
with this O - ring.
O - ring, Perbunan
1.80.6-16.11.04-01
O - ring, Viton
1.80.6-16.11.03-03
Edition
12.02.1999
Service document of
Page
27
Engineers Handbook
M601 - M601C
Connecting rod
Shank division
Tighten screws with
= 750
Nm
Reference dimension after

tightening 223,3 mm
Big end bearing

Tighten screws 1 + 4 with
= 300
bar
= 600
bar
= 900
bar
= 900
bar
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 older
engines still show the value 800 bar, please change it to 900 bar.
Connecting rod
Tighten plug - 1 - with
Tighten plugs - 2 - with
= 200
Nm
= 150
Nm
Modern connecting rods with

shank division have
no plug - 1 -.
2
Edition
12.02.1999
Service document of
Page
28
Engineers Handbook
M601 - M601C
Connecting rod
Big end bearing
Measurement of gap
1. Tighten big end bearing bolts
as prescribed.
2. Fasten dial gauge according
to sketch. Turn the scale
until the zero point coincides
with the pointer position.
3. Loosen both bolts on the
side with the dial gauge and
read off the gap size.
Gap
Gap for Miba-bearing var. -10
Correct mounting
of the dial gauge
After longer operation not below
Gap for BHW-bearing var. -03 / -07

Big end bearing
The reference dimension of the big end bearing shell after
correct tightening is
Piston pin bush
Insertion in supercooled condition
operating temperature
The reference dimension after insertion in supercooled
condition shall be
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
mm
+ 0.09
Dismounting
Only 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. The
groove for centering the bearing shells must always show to the camshaft side.
Edition
12.02.1999
Service document of
Page
29
Engineers Handbook
M601 - M601C
Main bearing
Tightening specification
Tighten nuts steadily by hand.
1st step tighten screws 1 + 4 with
= 340
bar
2nd step tighten screws 2 + 3 with
= 680
bar
3rd step tighten screws 1 + 4 with
= 1000
bar
4th step tighten screws 2 + 3 with
= 1000
bar
Check: After the last tightening step the tight support of the round nuts is to be checked at a
pressure 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.
Gap
1. 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 sizes
Main bearing
Located main bearing

Located main bearing
Axial clearance
Edition
12.02.1999
0.80 - 1.10
mm
0.70
mm
0.55 - 0.85
mm
0.45
mm
0.40 - 0.55
mm
Service document of
Page
30
Engineers Handbook
M601 - M601C
Counterweight
Mechanical tightening with tie bolt M56 x 4 length 408mm, SW 65
1. Pretighten tie bolts with
= 300
Nm
2. Transfer the 0-marking of the angle gauge 1.80.7-91.80.00-01 on the screw heads.
3. Pretighten tie bolts
Dw = 45
with
then
tighten with
Dw = 90 7.5
Hydraulic tightening with tie bolt

Thread M56 x 4, thread of nuts M48 x 3, length 520 mm SW 27
1. Screw tie bolts into the crankshaft with
= 200
Nm
2. Lengthen tie bolts simultaneously with

and tighten nuts.
= 960
bar
Piston area A = 78,5 cm2 - Both tightening variants are valid for Molykote.
Position a
Dismounting and
mounting counterweights.
1. Turn crankshaft into position a
and loosen both screws as
prescribed.
Should it not be possible during
hydraulic tightening to loosen
the nuts at the prescribed
pressure, increase the
pressure by 50 bar.
2. Remove round nut, washer

and tie bolt -1- from below.
Insert fitting bolts into the
free bore and tighten it
slightly.
Edition
12.02.1999
Service document of
Page
31
Engineers Handbook
M601 - M601C
Counterweight
3. Remove second tie bolt.
4. Turn crankshaft into postion b. Fasten device -1- at the intermediate stand on the
camshaft side, move it over the counterweight and insert the bolt in the counterweight
without tightening.
5. Turn the device until the fitting bolt can be removed, then turn it back into original
position. Tighten the bolt.
6. Lift counterweight (loosen stuck counterweights) and move it out of the crankcase.
7. Fitting proceeds in reverse order.
Position b
Edition
12.02.1999
Service document of
Page
32
Engineers Handbook
M601 - M601C
Gear drive
The gear wheels are marked with the corresponding drawing No.
1.80.7-25.30.00-02
The two halves are tightened with 4 hexagon screws M20 x 170 DIN 609
and the nuts M20 DIN 935.
M = 250
The tightening torque for the nuts is
Replacement for var. -02 is var. -05.
Nm
1.80.7-25.30.00-05 /-07
The 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 hexagon
screw M6 x 17.5 with pin, the two others with a threaded pin.
The castle nuts are tightened with
M = 100 + 20
Nm
Tooth 23
Tooth 24
Tooth 1
The gear wheels are fitted at the crankshaft with 4 reamed bolts M24 x 2 x 215 and 8 tie
bolts
M24 x 2 x 215.
The castle nuts for the above bolts are tightened as follows:
Tightening torque min.
= 450
Nm
Tightening torque max.
= 450
Nm
plus
Then tighten up to the next split pin hole.
Edition
12.02.1999
Dw = 30
Service document of
Page
33
Engineers Handbook
M601 - M601C
Gear drive
1.80.8-25.30.00-04
The engines No. 63051 and 63057 are equipped with this variant. The two gear wheel
halves are fitted on a centering ring which is screwed at the crankshaft. Tightening torques
see 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.
Fitting
The 4 fitting bores above and below the joint are rough-drilled with 23 mm. After
alignment they are reamed to 25 - 25.0021 mm (H7).
Step wheel
Pretighten tie bolts with
and tighten
with
Tightening check : min. 850 Nm
= 200
Dw = 60
Nm
- 10
Tie bolt - 1 - M27 x 101, SW41

Tie bolt - 2 - M27 x 114, SW41
Tooth 1
Tooth 2
Tooth 1
0,059
149,96 +
Tooth 2
2
1
Edition
12.02.1999
Service document of
Page
34
Engineers Handbook
M601 - M601C
Gear drive
Intermediate wheel mounting
Bearing bracket for intermediate wheel
Up to eng. No. 63123 tighten screws -1- with
From eng. No. 63124 tighten screws -1- with
= 450
Nm
= 500
Nm
Tie bolts M24 x 2 x 99 SW 36 with tension bush 40, - 24,5 height 19
b
a
Step bearing intermediate wheel

Tighten hexagon srews -2- with
= 230
+ 20
Nm
M20 x 80 DIN 931
Tighten grooved nut -3- with
Dw = 390 + 30
The thickness of the laminium shim is as follows:

x = a - b + 0,4
Edition
12.02.1999
+ 0,1
mm
Service document of
Page
35
Engineers Handbook
M601 - M601C
Gear drive
Mounting of camshaft gear with coupling piece
1. 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 on
the 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 full
blueing 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 160C
and move it on the camshaft cone into its final position (2nd marking 4.5 mm).
5. Fit thrust ring - 4 -, fasten nut
with a hook wrench and secure it.
1
2
3
Edition
12.02.1999
Service document of
Page
36
Engineers Handbook
M601 - M601C
Gear dive
Camshaft gear
Pretighten tension bolts - 1 - with
and tighten
with
Tightening check : min. 850 Nm
Tie bolt M27 x 101, SW 41
= 200
Dw = 60
Nm
- 10
Tooth1
Tooth space1
1
Coupling piece
Tooth1
Parallel key
groove
Tooth 1 and parallel

key groove must be
in alignment.
Edition
12.02.1999
Service document of
Page
37
Engineers Handbook
M601 - M601C
Gear drive
Gear wheels for gear drive
The engines up to engine No. 63146 as well as the engines No. 63150 and 63169 are
equipped as follows:
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 up
to engine No. 63168 and from engine No. 63170 are equipped as follows:
82 teeth
Twin wheel
52 and 104 teeth
Camshaft gear
82 teeth
Backlashes
Crankshaft gear - big intermediate wheel
Small intermediate wheel - camshaft gear -

Camshaft gear - governor drive gear
Edition
12.02.1999
0.32 - 0.40
mm
0.20 - 0.28
mm
0.20 - 0.29
mm
Service document of
Page
38
Engineers Handbook
M601 - M601C
Gear drive
Adjustment of gear drive starboard
type Piston 1 in TDC.
Crankshaft gear = 84 teeth,
intermediate wheel = 74 and 111
teeth,camshaft gear = 112 teeth
Tooth1
2 2
2
Tooth 30
Tooth 42
Tooth 31
Tooth 2
Tooth 1
Tooth 1
Tooth 20
Tooth 21
Tooth 1
Tooth 84
Edition
12.02.1999
Service document of
Page
39
Engineers Handbook
M601 - M601C
Gear drive
Adjustment of gear drive port type
Piston 1 in TDC
intermediate wheel = 74 and 111 teeth,
camshaft gear = 112 teeth
Tooth1
2 2
2
Tooth 72
Tooth 46
Tooth 47
Tooth 2
Tooth 1
Tooth 1
Tooth 23
Tooth 24
Tooth 1
Tooth 84
Edition
12.02.1999
Service document of
Page
40
Engineers Handbook
M601 - M601C
Gear drive
Adjustment of gear drive port type
Piston 1 in TDC
intermediate wheel = 52 and 104 teeth,
camshaft gear = 82 teeth
Tooth1
2 2
2
Tooth53
Tooth32
Tooth33
Tooth2
Tooth1
Tooth1
Tooth22
Tooth23
Tooth1
Tooth82
Edition
12.02.1999
Service document of
Page
41
Engineers Handbook
M601 - M601C
Gear drive
Gear box
Tighen screws M16 with
= 140
Nm
= 230
Nm
= 400
Nm
= 700
Nm
Tighten tie bolt - 1 - with
= 650
Nm
Tie bolt M30 x 500 DIN 931 - 10.9
Edition
12.02.1999
Service document of
Page
42
Engineers Handbook
M601 - M601C
Governor drive
Tighten screws - 1 with
= 37
Nm
= 60
Nm
6 screws M10 x 35 DIN 912
Tighten nuts - 2 - with
4 hexagon nuts M12 DIN 934
Backlash at - 3 -
0.12 - 0.20
mm
Backlash at - 4 -
0.20 - 0.29
mm
4
3
Edition
12.02.1999
Service document of
Page
43
Engineers Handbook
M601 - M601C
Camshaft
Tighten camshaft bearing
without lug with
corresponding to 90
= 770
Nm
Pretighten camshaft bearing

with lug with
= 750
Nm
and tighten with

corresponding to 850 Nm
Dw = 30
Without lug
With lug
Gap
After mounting
0.30 - 0.25
mm
After longer operation not

below
0.20
mm
Reference dimension
After correct tightening
150.15
+ 0.065
mm
The gap of the bearing shells must be absolutely horizontal

to guarantee sufficient oil supply.
Edition
12.02.1999
Service document of
Page
44
Engineers Handbook
M601 - M601C
Camshaft
Vibration damper
Tighten screws -1- with
= 270
Nm
= 70
Nm
M20 x 80 SK DIN 931
Tighten screws -2- with

M12 x 180 10.9 DIN 912
Tighten screws for additional weight on camshaft

with
= 480
Nm
Starting cam
Old design
Pretighten tie bolt M20 with
= 250
Nm
and tighten with
Dw = 60
Tie bolt secured with spring dowel pin 6 x 32 DIN 1481.
Edition
12.02.1999
Service document of
Page
45
Engineers Handbook
M601 - M601C
Camshaft
New design
The tightening torque for inserting the tie bolts is
Pretighten castellated nut with
and tighten with
= 200
Nm
= 200
Nm
Dw = 60
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 delivered
after consultation with VK14.
Mounting instruction
1. Turn engine to position firing
TDC cyl. 1.
2. Remove starting air distributor.
4. Check position of the thrust ring for

camshaft gear. In firing TDC cyl.1
onescrew - M12 - must be exactly
on top.
Otherwise ascertain the
displacement angle,transfer it to the
repair cam and bore anew
6x13,5mm on pitch circle
18
142
3. Dismount starting cam, remove

centering piece - 2x M6 -.
142mm (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 after
TDC acc. to job card.
Edition
12.02.1999
Service document of
Page
46
Engineers Handbook
M601 - M601C
Camshaft
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 - . Turn
starting cam in the opposite direction to the rotation of
camshaft until the light gap is still just visible. Now the
starting cam has reached the position starting valve
opens"
1
2
3
Position at start
of setting
Position "starting
valve opens"
Repair cams
Fuel cams - non-reversible engines
engine
stroke
series design
on cam holder split
M601
40
1.80.7-32.30.01-04
M601 + M601C
M601
45
45
1.80.7-32.30.01-05
1.80.7-32.30.01-06
M601C
45
1.80.7-32.30.01-09
*
**
repair cam
1.80.7-32.35.00-03
1.80.7-32.35.00-07
1.80.7-32.35.00-10
1.80.7-32.35.00-04
1.80.7-32.35.00-10
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.
Edition
12.02.1999
Service document of
Page
47
Engineers Handbook
M601 - M601C
Camshaft
Fuel cams - reversible engines
engine
stroke
M601
M601
40
40
M601 + M601C
45
series design
on cam holder
1.80.7-32.30.01-01
1.80.7-32.30.01-02
Ers.
-03
1.80.7-32.30.01-07
repair cam
split
1.80.7-32.35.00-01 *
1.80.7-32.35.00-03 *
1.80.7-32.35.00-05 *
Cams are mounted on cam holder.
Tightening torque for fuel repair cams

Cams 1.80.7-32.35.00-01 / 03 / 04 / 05 (Cam holder)
M
Tighten screws alternately and steadily with
Molykote
Cam 1.80.7-32.35.00-06 / 07 (On camshaft)
Pretighten screws manually and
tighten alternately in small steps with
M
Molykote
Cams 1.80.7-32.35.00-09 / 10 / 11 / 12 / 13 / 14 (On camshaft)
Pretighten screws manually and
tighten alternately in small steps with
M
Molykote
= 90
Nm
= 800
Nm
= 900
Nm
Mounting
Mounting instruction for split fuel cams on non-reversible engines:
1.80.7-32.35.00-07 / -09 / 10 / 13 / 14
Spring dowel pin 4x28 DIN 1481
Fitting depth 20
Depth of bore 23
Parallel pin 20m6x50 DIN 7

Parallel pin 16m6x50 DIN 7
Exhaust cam
127
94,5
232
Edition
12.02.1999
Service document of
Page
48
Engineers Handbook
M601 - M601C
Camshaft
The dimensions for the distance between fuel cam and exhaust cam apply to the
cams 1.80.7-32.35.00-06 -10
For 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 19,8 mm or 15,5 and 23 mm deep, then ream jointly with the cam to
20 H7 or 16 H7 The fitting depth is 20 mm, the boreholes in the camshaft are to be
rounded off with R = 2. Mount the cam, pin and secure it with a spring dowel pin.
Pin 20m6 for the variants. - 06 to -10
Pin 16m6 for the variants -11 to -14
Are the variants -11 to -14 delivered in exchange for the variants -06 / -08 to -10, pin 20m6 must
be used.
Cams -11 to -14 are delivered with both pins.
Exhaust cams - non-reversible engines

engine
stroke
series design
M601
34
1.80.7-32.22.01-01
repl.
-02
M601 + M601C
34
1.80.7-32.22.01-03
M601C
34
1.80.7-32.22.01-04
M601C
34
1.80.7-32.22.01-05
repair cams, split

1.80.7-32.23.00-04
1.80.7-32.23.00-05
1.80.7-32.23.00-06
Mounting
Mounting instruction for split exhaust cams on non-reversible engines:
1.80.7-32.23.00-04 / -05 / 06
109
Edition
12.02.1999
Depth of bore
16H7
Service document of
17
1x45
Inlet cam
14
Exhaust repair cam
Depth of fit
94
Page
49
Engineers Handbook
M601 - M601C
Camshaft
Exhaust cams - reversible engines
engine
stroke
series design
repair cams, split
M601
34
1.80.7-32.20.01-06
repl.
-07
1.80.7-32.23.00-01
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
Exhaust repair cam
11
Depth of bore
14
Depth of fit
Inlet cam
16H7
44
124
Inlet cams - non-reversible engines

engine
stroke
series design
M601
30
1.80.7-32.12.01-01
repl.
-03
M601
30
1.80.7-32.12.01-04
M601
34
1.80.7-32.12.01-05
repl.
-06
M601 + M601C
34
1.80.7-32.12.01-07
M601C
34
1.80.7-32.12.01-09
Edition
12.02.1999
repair cams, split

1.80.7-32.13.00-06
1.80.7-32.13.00-07
1.80.7-32.13.00-08
1.80.7-32.13.00-08
1.80.7-32.13.00-09
Service document of
Page
50
Engineers Handbook
M601 - M601C
Camshaft
Mounting
Mounting instruction for split inlet cams on non-reversible engines:
1.80.7-32.13.00-06/-07-08/-09
Attention !
After reaming the bore 16 H7, but before mounting the cam remove the positioning
pin 8 from the camshaft. Otherwise the cam cannot be fitted.
16 H7 = 16.000 - 16.018
Inlet cam, split
1 x 45
Depth of bore 17
94
Fitting depth 14
Exhaust cam
16 H7
109
Inlet cams - reversible engines

engine
stroke
series design
M601
30
1.80.7-32.10.01-05
repl.
-08
M601
30
1.80.7-32.10.01-07
repl.
-09
M601
34
1.80.7-32.10.01-10
repl.
-11
M601 + M601C
34
1.80.7-32.10.01-12
Edition
12.02.1999
repair cams, split

1.80.7-32.13.00-02
repl.
-03
1.80.7-32.13.00-01
repl.
-04
1.80.7-32.13.00-05
1.80.7-32.13.00-05
Service document of
Page
51
Engineers Handbook
M601 - M601C
Exhaust cam
Inlet repair cam
Depth of
bore
Depth of fit
Camshaft
14
16H7
124
11
44
Tightening torque for inlet and exhaust cams - reversible - non-reversible

Pretighten screws by hand and tighten alternately in
small steps with
M = 180
Nm
For all cam mountings treat contact surfaces and threads with Molykote.
Lower valve drive

Tighten screws for roller tappet housing with
= 210
Nm
M20 x 60 DIN 912

ATTENTION! The set screws for lifting the roller tappet bodies may only be used in the area of the
inlet and exhaust valves if at the same time the valve rocker bracket is removed. Otherwise, the
valves touch in TDC on the piston, shearing off the screws.
Fuel injection pump with drive

Tightening torque for inserting the tie bolts
= 300
Nm
= 50
Nm
Pretighten nuts with

and tighten
with
Edition
12.02.1999
Service document of
Dw = 90
Page
52
Engineers Handbook
M601 - M601C
Camshaft
Camshaft with additional masses
1100 KW/cyl. engines
The camshaft of the 1100 KW engines is provided with additional masses at the cylinders
5, 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 the
respective additional mass must be removed because the space for a repair cam is not
sufficient. This proceeds as follows:
1.
In case only one fuel cam is changed, the removed mass is to be mounted at
cylinder 4. Drilling of a new pin hole is not necessary.
2.
In case two fuel cams must be changed, all additional masses are to be
removed and a vibration damper assembly for the camshaft must be mounted
according 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.
Edition
12.02.1999
Service document of
Page
53
Engineers Handbook
M601 - M601C
Fuel injection pumps

Tighten nuts - 1 crosswise with
= 240
Nm
Tighten screws - 2 crosswise with
= 50
Nm
= 240
Nm
= 900 + 30
Nm
Tighten screws - 1 - with
Tighten connecting piece - 2 - with
2
1
Edition
12.02.1999
Service document of
Page
54
Engineers Handbook
M601 - M601C

Fuel injection pump M601C
Pretighten fixing nuts with
and tighten with

The following fuel injection pumps are used:
PGO - G006 a
PGO - G008
PGO - G008 a
PGO - G008 b
PGO - G015
= 100
Nm
= 210
Nm
= 240
Nm
Dw = 90
Mounting
During assembly of the fuel injection pumps particular attention must be paid to the
coincidence of marks. After correct fitting you can look through from the inlet to the outlet
opening.
Basic setting
The 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 spring
cup coincides with line mark - 2 - on the pump casing. In case of deviations: Unscrew
clamping screws - 4 - and adjust thrust bolt - 5 - until coincidence of line marks is
reached. Tighten clamping screws again.
After flywheel marking
turn engine into
position
5
2
1
commencement of
2
3
fuel delivery,
4
check if line mark
- 3 - on the spring
cup coincides with
line mark - 2 -.
Only in case of major deviations readjust cam.
Edition
12.02.1999
Service document of
Page
55
Engineers Handbook
M601 - M601C

Check of commencement of fuel delivery
See commencement of fuel
Commencement of
delivery from the acceptance
Firing TDC
fuel delivery
test record and enter the
2
relevant arc on the measuring
groove of the flywheel and mark Position of
1
commencement of fuel delivery. commencement
Turn engine in direction of
of delivery
rotation until line mark - 1 - on
the 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 center
indicator.
Fuel injection pump M 601 C - Basic setting
1
2
Turn roller on the base circle of cam, check if the line mark - 1 - on the
spring cup coincides with the line mark - 2 - on the pump casing.(for this
purpose 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 thrust
bolt.
The nominal dimension is : 10 0.1 mm
In case of deviations insert corresponding shims - 1 - between thrust bolt - 2 - and thrust
piece - 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.
a
3
Edition
12.02.1999
Service document of
Page
56
Engineers Handbook
M601 - M601C

1.80.7-63.45.00-01 6 + 8 cyl. engines
Tighten hexagon screws M12x40 SK DIN 933
with
= 40
Nm
= 1150
Nm
1.80.7-63.45.00-02 6 cyl. engines without power take-off

1.80.7-63.40.00-01 6 cyl. engines with power take-off
Tighten hexagon srews M12x40 SK DIN 933
with
= 40
Nm
Tighten castellated nut M36x3 DIN 935 and M42x3 DIN 935
with
= 900
Nm
1.80.7-63.45.00-03 8 + 9 cyl. engines without power take-off

1.80.7-63.40.00-03 8 + 9 cyl. engines with power take-off
with
M
= 40
Nm
Tighten castellated nut M36x3 DIN 935 and M42x3 DIN 935
with
= 900
Nm
Tighten castellated nut M36x3 DIN 935 with
16 pcs. threaded bolts M36x3, length 286 mm
4 pcs. reamed bolts M42x3, length 438 mm

Bore of reamed bolt 44 H 7 H7 = 44,000 - 44,025
One reamed bolt every 90

1.80.7-63.45.00-04 with additional weight without vibration damper

M = 40
with
Tighten castellated nut M36x3 DIN 935 with
= 1150
Nm
Nm
Edition
12.02.1999
Service document of
Page
57
Engineers Handbook
M601 - M601C

1.80.7-63.45.00-05 8+9 cyl. engines without power take-off
1.80.7-63.40.00-04 8+9 cyl. engines with power take-off
M
with
= 40
Nm
Tighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935
with
= 900
Nm

1.80.7-63.45.00-06 6 cyl. engines - marine - without power take-off

1.80.7-63.40.00-05 6 cyl. engines - marine - with power take-off
with
M = 40
Pretighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935
with
M = 1000
and tighten
with
Dw = 30
Tighten up to the next split pin hole.
Nm
Nm

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
with
with
and tighten
with
= 40
Nm
= 1000
Nm
Dw = 30

Edition
12.02.1999
Service document of
Page
58
Engineers Handbook
M601 - M601C

1.80.7-63.45.00-08 8 cyl. engines - generator
with
Pretighten castellated nut M36x3 DIN 935 and M42x3 DIN 935
with
and tighten
with
= 40
Nm
= 1000
Nm
Dw = 30

1.80.7-63.45.00-09
with
= 40
Nm
Tighten castellated nut M36x3 DIN 935

with
= 1150
Nm

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
with
= 40
Nm
Tighten hexagon socket head cap screws M20x140 DIN 912

with
= 310
Nm
= 1000
Nm
with
and tighten
with
Tighten up to next split pin hole.
Dw = 30

Flange shaft side: Coat thread and contact surface of nut with Molykote.
The crankshaft side remains dry.
Edition
12.02.1999
Service document of
Page
59
Engineers Handbook
M601 - M601C

1.80.7-63.40.00-02 6 cyl. engines with power take-off
with
= 40
Nm
Tighten castellated nuts M36x3 DIN 935 and M42x3 DIN 935
with
= 900
Nm

Bore of reamed bolt 44 H 7 H7 = 44.000 - 44.025
All before mentioned tightening torques are valid when using Molykote.
Edition
12.02.1999
Service document of
Page
60
Engineers Handbook
M601 - M601C
Flywheel mounting
Mechanic tightening
The castellated nuts M56x4 for the flywheel mounting
are tightened with
Lubricant: Molykote
= 4000
Nm
Hydraulic tightening
Tighten round nuts continuously with a pin by hand paying attention to the dimension of 64
mm (sketch).
Apply two tightening devices crosswise opposite,
P
= 2420
bar
lengthen the screws with
and tighten the round nuts continuously with a pin.
Edition
12.02.1999
Service document of
Page
61
Engineers Handbook
M601 - M601C
Turbocharger mounting
The following screws are fitted on the turbocharger mounting:
Tie bolt M20x88 mm SW 30
M
Tightening torque
= 320
Nm

Tightening torque
= 330
Nm
= 660
Nm
= 50
Nm

Tightening torque
corresponding to
a pretightening torque of
and a
Dw = 45
Tie bolt M24x99 mm SW36

Tightening torque
corresponding to
and a
Edition
12.02.1999
Nm
= 50
Nm
= 1700
Nm
= 100
Nm
Dw = 90
Hexagon screw M30x140 DIN 931 10.9

Tightening torque
corresponding to manual tightening,
then tighten with
= 600
Dw = 55
Tie bolt M36xx2x203 mm SW50

Tightening torque
corresponding to
and a
* 20
= 1000
Dw = 30
Nm
+ 5
Service document of
Page
62
Engineers Handbook
M601 - M601C
Charge air cooler mounting

On the charge air cooler mounting the following screws are inserted:
Tie bolt M20x2x125 mm SW 30
Tightening torque
M = 230
Nm
Tie bolt M24x153 SW 36

Tightening torque
= 300
Nm
Tie bolt M16x95 SW 24

Tightening torque
= 150
Nm
Hexagon screw M16x90 DIN 931 12.9

Tightening torque
= 150
Nm
= 1150
Nm
= 1300
Nm
Connecting screws
Bedplate - intermediate frame
Tighten screws with
Screws M36 x 150 mm DIN 931
Intermediate frame - cylinder block

Tighten screws with
Screws M36 x 150 mm DIN 931
Edition
12.02.1999
Service document of
Page
63
Engineers Handbook
M601 - M601C
Tie rod
Tightening sequence
1.80.7-16.20.00-02
1st step
= 300
bar
2nd
step
= 600
bar
3rd
step
= 820
bar
= 370
bar
1.80.7-16.20.00-03
1st step
2nd
step
= 740
bar
3rd
step
= 960
bar
= 370
bar
1.80.7-16.20.00-04
1st step
2nd
step
= 740
bar
3rd
step
= 1030
bar
Tightening sequence
6 cylinders
step
2nd step
10
11
12
13
14
15
16
17
18
19
20
21
1st
3rd
step
Edition
12.02.1999
Service document of
Page
64
Engineers Handbook
M601 - M601C
Tie rod
Tightening sequence
8 cylinders
1st
step
2nd step
3rd
10
11
12
13
14
15
16
16
18
19
20
21
22
23
24
25
26
27
step
Tightening sequence
9 cylinders
1st
step
2nd step
3rd
step
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
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, the
final 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 applicable
to 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.
Edition
12.02.1999
Service document of
Page
65
Engineers Handbook
M601 - M601C
Tie rod
Application of the tightening
device
Tightening of tie rods
1. 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 mark
coincides with bottom edge guard
ring.
4. Lengthen tie rods according to
instructions.
5. Tighten round nuts with pin by
hand.
6. Make the hydraulic device stressfree.
Loosening of tie rods
1. 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.
S=5
Max. stroke = 10 mm red ring

mark must not be exceeded.
Edition
12.02.1999
Service document of
Page
66
Engineers Handbook
M601 - M601C
Firing sequences - valve timings
Firing sequences
6 cyl.
8 cyl.
9 cyl.
clockwise:
1-3-5-6-4-2
counterclockwise:
1-2-4-6-5-3
clockwise:
1-4-7-6-8-5-2-3
counterclockwise:
1-3-2-5-8-6-7-4
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
Edition
12.02.1999
Service document of
Page
67
Designation
Engineers Handbook
M601 - M601C
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
6 cyl. engines
5500
1730
978
10700
8 cyl. engines
7220
1730
978
13900
9 cyl. engines
8080
1730
978
15600
Intermediate frame
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
Edition
12.02.1999
Service document of
Page
68
Designation
Engineers Handbook
M601 - M601C
Length mm
Width mm
Tie rod
3166
Camshaft (with cams) non-reversible
6 cyl. engine
6029
Height mm
Weight kg
70
110
2117
8 cyl. engine
7744
2590
9 cyl. engine
8609
2825
6 cyl. engine
6029
2320
8 cyl. engine
7744
2860
9 cyl. engine
8609
2952
Reversible
Camshaft bearing
100
150/162
2,7
Piston
940
580
408
Piston pin
490
240
156
175/180
480
Connecting rod
(compl.)
2087
615
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
Turbocharger
VTR 454
2221
1427
1286
3250
VTR 501
2235
1320
3310
Edition
12.02.1999
Service document of
Page
69
Engineers Handbook
M601 - M601C
Designation
Length mm
Width mm
Height mm
Weight kg
VTR 564
2591
1656
1712
6500
VTR 631
2660
1732
5960
1620
1864
1005
Exhaust valve (compl.)
200
787
124
Injection valve
110
774
25
1280
1090
1690
757
1524
1146
615
2418
1357
Charge air cooler

(two-circuit)
782
Cyl. head (compl.)

Liner
Piston with connecting rod
Injection pum
78
120
695
176
Twin wheel
270
913
765
Camshaft gear
215
921
462
Located main bearing shell

Main bearing shell
Edition
12.02.1999
42
22,2
Service document of
Page
70

M601-M601C Engineer S Handbook

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Charge air cooler mounting

Engine operating data

Flange shaft mounting

Fuel injection pump

Fuel injection pump with drive

Lower valve drive

Sizes and weights

Engine operating data

Lub. oil, inlet

Fresh water circulation cooling

Charge air, inlet:

Nozzle cooling, inlet

Lub. oil, at the last

Fresh water circulation cooling:

1.5 - 3.0 bar

Fuel pressure before

*1 = at rated engine output

*2 = at rated engine speed

Instruction for tightening with 4 hydraulic jacks :

Old nut, height 46 mm

Valid for the cylinder head variants: 1.80.7-21.41.00-08 / 10

Instruction for tightening with 4 hydraulic jacks:

Tightening specification for the new hydraulic jack:

New nut, height 56 mm

New hydraulic jack

Inlet valve rocker

Both bushes shall recede

Exhaust valve rocker

Exhaust MDO operation

Inlet HFO + MDO operation

Tighten hexagon nut M16 DIN 934 with

The tightening torque for the

this corresponds to an arc

New nozzle nut, that means

Fuel injection valve M 601 C

Exhaust gas manifold

Old type of exhaust valve cage with

Tighten nuts steadily with

New type of exhaust valve cage with

Tighten nuts steadily with

Refinishing on the valve cage seat and / or in the bore

Attention: From engine No. 63156 on the exhaust valve

Exhaust valve seat

Inlet valve stem

Exhaust valve stem

Grinding of inlet and exhaust valves

Inlet valve stem

Gas oil and heavy fuel

Inlet valve stem

Exhaust valve stem

Exhaust valve stem

The tightening torque for inserting the studs is

Pretighten nuts crosswise with

The tightening torque for inserting the studs is

Pretighten nuts crosswise with

1.80.6-26.70.00-03 Mahle - M601 M601 C

Tighten nuts crosswise with

The tightening torque for inserting the studs is

Pretighten nuts crosswise with

Spacer rings for the piston -05 and -09

Check the tightening torque of the studs with

Pretighten nuts crosswise with