MAK M43C User manual

Engine Operating Instructions
Type
M43C
68 280
68 281
Engine Operating Instructions
A0
M43C
en / 26.05.2009 AA000643 1/2
281717
Engine No.: Record No.:

Engine Operating Instructions
A0
M43C
en / 26.05.2009 AA000643 2/2
Please note the copyright notice pursuant to ISO 16016
"All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our
exclusive property. They are only handed over to the agreed purpose and must not be used for any other
purpose. Copies or other reproductions including storage, processing or distribution by using electronic
systems may only be made to the agreed purpose. Neither originals nor copies may be handed over to third
parties or be made available in any other form.
All rights (in case of registration of patent, utility patent, design patent) reserved.
Offenders will be liable for damages."
Caterpillar Motoren GmbH & Co. KG

Total Index
Book A, B and C
A0.01
-
en / 26.05.2009 AA020014 1/2
Engine Operating Instructions A0
Total Index Book A, B and C A0.01
Introduction A0.02
Safety instructions A0.03
Emergency Stop Safety System A0.04
Technical Engine Data A1
Governor Data A1.04
Working pressures of auxiliary equipment A1.05
Temperatures of operating media A1.06
Torsional Vibration Calculation A1.09
Acceptance Test Records A1.10
Operating Instructions A3
Table of Contents A3.01
Introduction A3.02
Safety Instructions A3.03
Instructions for Heavy Fuel Operation A3.04
Initial Operation Engine A3.05
Operational Supervision Engine A3.06
Removal from operation Engine A3.07
Danger of Frost Engine A3.08
Running-in Engine A3.10
Fault Tracing Engine A3.11
Emergency Operation Engine A3.12
Operating Media A4
Table of Contents A4.01
Introduction A4.02
Safety instructions A4.03
Regulations and Recommendations Engine A4.05
Maintenance A5
Table of Contents A5.01
Introduction A5.02
Safety instructions A5.03
Tools A6
Table of contents A6.01

Total Index
Book A, B and C
A0.01
-
en / 26.05.2009 AA020014 2/2
Spare Parts Catalogue B0
Total Index Book A, B and C B0.01
Introduction B0.02
Spare Parts B1
Table of contents B1.01
Safety instructions B1.03
Stand-by parts B2
External Documentation C0
Total Index Book A, B and C C0.01
Introduction Electrical Equipment C0.02
Table of contents C5.01

Introduction
A0.02
M20-M601C
en / 26.11.2008 AA000024 1/1
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is
matched with the equipment condition and the type of fuel sold.
Since the type of fuel used considerably influences the service life of the components, the Caterpillar / MaK
after-sales service has to be consulted when it is required to change from destillate fuel operation to heavy
fuel oil operation, in order to ensure an expert retrofit of the engine plant and to exchange the necessary
documentation. When changing over from heavy fuel oil operation to destillate operation, the Caterpillar /
MaK after-sales service should also be consulted for a longer period of time so that a documentation with
extended maintenance intervals can be made available.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the
operating instructions are subdivided into the following chapters:
A1 Technical engine data
A3 Operating instructions
A4 Fuels
A5 Maintenance
A6 Tools
With the respective information contained in the individual chapters, the technical personnel is able to
maintain the engine in such a manner that regarding its output, reliability, economy and service life opti-
mum operating results can be achieved.
If you need further information or if you have any other questions, we kindly ask you to contact our respon-
sible service organization.
The operating instructions do not release the personnel in charge of this engine plant from their duty to take
care. The recognized rules of technology are to be observed, taking into account overriding regulations,
observance of the general safety measures and locally applicable accident prevention regulations. Data or
explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not
contained.
Caterpillar / MaK is not responsible for damage caused by improper operation and maintenance.
These operating instructions are only intended for our customers. All rights reserved for this document. All
technical data contained in these operating instructions must neither be reproduced, distributed nor utilized for
competitive purposes or disclosed to third parties without our express approval.
Postal address: Caterpillar Motoren GmbH & Co. KG, P.O. Box 9009, D-24157 Kiel
Telephone: [phone] (chief operator)
Telefax: [phone] (after-sales service only)
http://www.marine.cat.com

Safety instructions
A0.03
M20-M601C
en / 15.12.2005 AA000370 1/2
Personnel entrusted with work on the engine/plant must have read the
operating instructions and in particular the pages on safety instructions
which precede the chapters before beginning work. In order to eliminate
danger which may constitute a risk of life and limb of the user or of third
parties, all safety regulations which are marked with the ~
~~
~ symbol have
to be observed in all cases.
Technical instructions and/or operations to be strictly observed are
marked in the documents with attention. They warn of possible damage to
the machinery or to other material property.
Note refers to special information on appropriate use and work to be
carried ou
California / USA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects, and other reproductive harm.

Safety instructions
A0.03
M20-M601C
en / 15.12.2005 AA000370 2/2
Our engine is equipped with a monitoring system and an emergency stop
system to prevent damage caused to the operators' health as well as
damages to the engine.
Within the scope of commissioning all mechanical, electric and pneumatic
equipment and systems allowing the engine to be stopped for safety
reasons will be demonstrated and explained by our commissioning
personnel.
Participants in this acceptance procedure are the authorized personnel of
CATERPILLAR Motoren Kiel, the managing and operating personnel of the
operator and also representatives of the insurance companies.
This important system is subject to recurrent inspections and tests in
order to ensure proper function of its individual components.
In the section "Scheduled Maintenance" you will find the respective test
frequencies and related job instructions that should be followed to protect
the personnel from injuries and prevent material damages.

Emergency Stop
Safety System
A0.04
M20/M25/M32/M43
en / 20.02.2008 AA033984 1/5
Attention:
Do not perform further starting attempts for a while after the safety/emergency stop de-
vice has triggered!
Note and observe the following points and actions.
If these actions are not observed, severe personal injuries as well as damage to the engine
can occur, which may void the warranty.
*Note:
With some engine assemblies, in particular in marine applications, an alarm or a power reduction
may be triggered before a safety/emergency stop is performed. If there are no safety concerns,
the engine must also be shut down, if an alarm occurs or engine power is reduced and the causes
have to be eliminated.
Actions that must be performed after a safety/emergency stop* occurred:
- Identify the reason for emergency stop based on the points listed below.
- Work through list of corresponding sub-points.
- Contact your Caterpillar/ MaK Service.
Type of emergency stop:
1. Overspeed condition
2. Lubrication oil (pressure and temperature)
3. Engine room monitoring
4. Cooling water - fresh water - HT (pressure and temperature)
5. Exhaust gas
6. Check pneumatic emergency stop system on engine after every emergency stop
7. Fault messages and measuring points
Note:
The following checks may be of assistance during troubleshooting and permit identification of root
causes of an emergency stop. However, they cannot cover the entire spectrum of possible cau-
ses.

Emergency Stop
Safety System
A0.04
M20/M25/M32/M43
en / 20.02.2008 AA033984 2/5
1. Overspeed condition
Emergency stop due to excessive rpm.
1.1 How high was the maximum rpm before emergency stop was triggered?
1.2 Why did engine go into an overspeed condition?
Check:
• Check if emergency stop safety device is operational.
• Check free operation of adjustment shaft and joint
• Check every single regulator rack of fuel pumps in both directions for proper operation by
pulling and pressing.
• Checking governor drive.
• Verification of possible out of calibration of actuator (if fitted).
1.3 Contact your Caterpillar/ MaK Service.
2. Lube oil (lube oil pressure, lube oil temperature)
2.1 Emergency stop due to lack of lube oil
Checks:
• Visual inspection of engine.
• Lube oil pump drive:
- Check gears for damage or loss.
• Check lube oil pressure switch.
• Check lube oil filter for metal chips.
• Check oil sump and piping for leaks and cracks.
2.2 Contact the Caterpillar/ MaK-Service.

Emergency Stop
Safety System
A0.04
M20/M25/M32/M43
en / 20.02.2008 AA033984 3/5
2.3 Emergency stop due to high lube oil temperature
Checks:
• Check temperature sensor.
• Check oil cooler.
• Check cooling water circuit.
• Pressurize each cylinder through opened indexing valves with shop air.
If there is a rapid pressure drop or if no pressure builds up the cause must be investigated.
2.4 Contact the Caterpillar/ MaK Service.
3. Engine room monitoring
Emergency Stop due to excessive oil mist concentration (refer to A3.11.18.01.nn).
Checks:
• Check engine room monitoring device (operational test),
refer to C5.05.11.02.03. nn.
• Visual inspection of engine and gear train,
• of cam shaft trough,
• of combustion chamber,
• of turbo charger.
3.1 Contact your Caterpillar/ MaK Service.
4. Cooling water (fresh water - HT, pressure and temperature)
Emergency stop due to excessively high cooling water temperature
Checks:
• Visual inspection of engine
• Check temperature sensors

Emergency Stop
Safety System
A0.04
M20/M25/M32/M43
en / 20.02.2008 AA033984 4/5
• Check fresh water cooler
• Operational test of LT - Cooling water circuit with cooling water pump.
4.1 Contact your Caterpillar/ MaK Service.
5. Exhaust gas
Emergency stop due to excessively high exhaust temperature
Checks:
• Check exhaust gas temperature sensors.
• Aftercooler (differential pressure) (refer to A5.05.06.04.02.nn).
• Fuel pumps and fill level scale on each fuel pump.
• Injection valves (refer to A5.05.07.08.01.nn).
• Turbocharger
5.1 Contact your Caterpillar/ MaK Service.
6. Check pneumatic emergency stop system on engine after every emergency
stop
Attention:
In order for emergency stop safety device to operate properly, 7,5 bar pneumatic supply
has to be available continuously.
Checks:
• Check emergency stop pneumatic system on the engine for leaks.
• Stop valve to main start line upstream from start valve must constantly be open during
operation.(Refer to A3.05.11.nn).

Emergency Stop
Safety System
A0.04
M20/M25/M32/M43
en / 20.02.2008 AA033984 5/5
7. Fault messages and measuring points
Attention:
The fault messages listed below do not directly lead to an emergency stop, but they consi-
derably affect reliable engine operation.
If such a fault message appears on the monitoring display of the alarm system, the engine
plant may only be operated for a short time and under permanent observation.
At any rate, the cause of the fault message must be remedied immediately.
7.1 General fault messages:
Fault message: Description:
(Measuring point number)
6105 * Low shutdown air pressure
9631 * Oil mist detector failure
9601 * Terminal set X1 voltage failure
9717 * Terminal set X3 voltage failure
* see also List of Measuring Points C5.05.02.01.nn.nn.
7.2 Plant-specific fault messages:
- Safety system failure
- RPM switch unit failure (overspeed)
7.3 Please contact the Caterpillar/ MaK Customer Service.

Technical Engine Data
A1
M20-M601C
en / 26.05.2009 AA000103 1/1
Technical Engine Data

Governor Data
A1.04
-
en / 20.02.2008 AA000097 1/1
Governor Data

Governor-data
-A1.04.30
.71
M43
en / 26.05.2009 AA045578 1/1

m
Reglerdatenblatt / Governor Data
(Woodward-Regler / Woodward Governor)
Motor-Type:
Engine type:
9 M43 C
Kostenträger-Nr.:
Record No.:
281717/1
Motor-Nr.:
Engine No.:
68280
Aussteller:
Abteilung:
VT3
Name:
Westphal
Datum:
29.05.2009
1. Motordaten / Engine Data
Leistung: Regelbereich:
Power: 8100 kW Control range: 300-500 1/min
Vollastdrehzahl: Gesamt-Massenträgheitsmoment:
Full load speed: 500 1/min Total moment of inertia: 7845,4 kg m²
2. Stellgerät / Actuator
Type: Designation: Serien-Nr.:
Type: UG40-ACT Designation: B 8251-772 Serial No.: 16460561
2.1 Bau-Beschreibung / Specification
Ausgangswelle: beidseitig-kerbverzahnt
Terminal shaft: 3/4" - 48 serrated both sides
Antriebswelle: kerbverzahnt
Drive shaft: 1 1/8" - 48 serrated
Basis:
Base: UG 40
2.2 Ölfüllung des Stellgerätes: Siehe Abschnitt "Betriebsstoffe"
Oil filling of the actuator: See section "Operating Media"
Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich, z. B. von Eismeerfahrt in Tropenfahrt, und nicht nur
vorübergehend, so ist bei evtl. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar
Motoren GmbH & Co. KG Auskunft einzuholen.
If the climatic conditions are considerably changed in the main district of operation (e. g. change from polar sea navigation to
tropical regions) eventually causing failures, Caterpillar Motoren GmbH & Co. KG should be asked with respect to change of the
grade of oil
2.3 Stellgerätdrehzahl: x Motordrehzahl
Actuator speed: 1,928 x engine speed
3. Digitaler Drehzahlregler / Digital Speed Governor
Reglertype: Reglerdesignation: Serien-Nr.:
Governor type: 723+ Governor designation: 9906-619 Serial No.: …
Abb. / Fig. 1
3.1 Reglereinstellung / Adjustment of governor Hebel am Regler
Lever on governor
siehe Programmierliste:
see program list: ..
Anlenkung zwischen Reglerausgangswelle Hebel an der Regulierwelle
und Regulierwelle siehe Abb. 1 Lever on injection pump control shaft
(entspricht einer Reglerhubausnutzung von:
Link between actuator terminal shaft and injection pump control shaft see Fig. 1
(corresponds to a governor stroke utilization of: ~ 75 (%)
3.2 Hinweise / Notes
Nach Ölwechsel oder Reparatur des Stellgerätes müssen diese Einstelldaten wieder angestrebt werden. Jede
Änderung der Stellgerätausrüstung (2.1) bzw. der Reglereinstellung (3.1) ist in diesem Fall zu vermerken.
After oil change or repair of the actuator the adjustment data must set again. Every change of the actuator (2.1) or
governor adjustment (3.1) must be recorded on this sheet.
Caterpillar: Confidential Green

m
Reglerdatenblatt / Governor Data
(Woodward-Regler / Woodward Governor)
Motor-Type:
Engine type:
9 M43 C
Kostenträger-Nr.:
Record No.:
281717/2
Motor-Nr.:
Engine No.:
68281
Aussteller:
Abteilung:
VT3
Name:
Westphal
Datum:
29.05.2009
1. Motordaten / Engine Data
Leistung: Regelbereich:
Power: 8100 kW Control range: 300-500 1/min
Vollastdrehzahl: Gesamt-Massenträgheitsmoment:
Full load speed: 500 1/min Total moment of inertia: 7845,4 kg m²
2. Stellgerät / Actuator
Type: Designation: Serien-Nr.:
Type: UG40-ACT Designation: A 8251-772 Serial No.: 16469414
2.1 Bau-Beschreibung / Specification
Ausgangswelle: beidseitig-kerbverzahnt
Terminal shaft: 3/4" - 48 serrated both sides
Antriebswelle: kerbverzahnt
Drive shaft: 1 1/8" - 48 serrated
Basis:
Base: UG 40
2.2 Ölfüllung des Stellgerätes: Siehe Abschnitt "Betriebsstoffe"
Oil filling of the actuator: See section "Operating Media"
Ändert sich das Klimaniveau des Hauptfahrgebietes wesentlich, z. B. von Eismeerfahrt in Tropenfahrt, und nicht nur
vorübergehend, so ist bei evtl. auftretenden Reglerschwierigkeiten wegen eines Wechsels der Ölsorte bei der Caterpillar
Motoren GmbH & Co. KG Auskunft einzuholen.
If the climatic conditions are considerably changed in the main district of operation (e. g. change from polar sea navigation to
tropical regions) eventually causing failures, Caterpillar Motoren GmbH & Co. KG should be asked with respect to change of the
grade of oil
2.3 Stellgerätdrehzahl: x Motordrehzahl
Actuator speed: 1,928 x engine speed
3. Digitaler Drehzahlregler / Digital Speed Governor
Reglertype: Reglerdesignation: Serien-Nr.:
Governor type: 723+ Governor designation: 9906-619 Serial No.: …
Abb. / Fig. 1
3.1 Reglereinstellung / Adjustment of governor Hebel am Regler
Lever on governor
siehe Programmierliste:
see program list: ..
Anlenkung zwischen Reglerausgangswelle Hebel an der Regulierwelle
und Regulierwelle siehe Abb. 1 Lever on injection pump control shaft
(entspricht einer Reglerhubausnutzung von:
Link between actuator terminal shaft and injection pump control shaft see Fig. 1
(corresponds to a governor stroke utilization of: ~ 75 (%)
3.2 Hinweise / Notes
Nach Ölwechsel oder Reparatur des Stellgerätes müssen diese Einstelldaten wieder angestrebt werden. Jede
Änderung der Stellgerätausrüstung (2.1) bzw. der Reglereinstellung (3.1) ist in diesem Fall zu vermerken.
After oil change or repair of the actuator the adjustment data must set again. Every change of the actuator (2.1) or
governor adjustment (3.1) must be recorded on this sheet.
Caterpillar: Confidential Green

Working pressures of auxiliary equipment
A1.05
M43
en / 28.03.2000 TD000142 1/1
Lubricating oil
- at the last Camshaft bearing
at rated engine speed 4,0 - 5,0 bar
Cooling water
- min. feed head at pump inlet 4 m. water gauge 2,5 - 5,0 bar
Fuel at injection pump inlet
- Distillate fuel 3,0 - 5,0 bar
- Heavy fuel 4,0 - 5,0 bar
Injection nozzle opening pressure
- take the applicable figures from the acceptance test records (A1.10)
Control air 7,5 bar
Starting air 12* - 30 bar
* = minimum pressure for starting

Temperatures of operating media
A1.06
M43
en / 19.12.2005 TD000144 1/1
Lubricating oil
- engine inlet 60 - 65 °C
- temperature rise at rated output 10 - 14 °C
Cooling water
- engine outlet 80 - 90°C
- temperature rise at rated output 5 - 10 °C
Charge air see also A3.06.05.nn
- engine inlet 45 - 60 °C
Distillate fuel 40 - 50 °C *
Fuel before injection pumps
(see diagram) *
* Permissible injection viscosity must be set on the viscothermic device to enable a kinematic vis-
cosity of 10 - 12 mm
2
/s (cSt) to be reached before the injection pumps, corresponding to a dyna-
mic viscosity of 9 - 11 mPa s (distillate fuel below 10 mm
2
/s or 9 mPa s).
The heavy fuel specifications defined by MaK (e.g. RHM 35 (~ IF 380) give the heavy fuel tempe-
rature before engine starting.
However, the maximum temperature at injection pumps must not exceed 155 °C!

Torsional Vibration Calculation
A1.09
-
en / 20.02.2008 AA020354 1/1
Torsional Vibration Calculation