MaK M43 Engine Operating Instructions Manual – Engine 65265 PDF Download

Description

MaK M43 Engine Operating Instructions – Engine No. 65265

This MaK M43 Engine Operating Instructions manual is the full operating and maintenance document issued for engine number 65265, record number 281221, published by Caterpillar Motoren GmbH & Co. KG. It covers the MaK M43 four-stroke, direct-injection diesel engine in both distillate fuel and heavy fuel oil service, and it is written for the technical personnel responsible for running and caring for the plant. Everything needed to keep an M43 at its rated output – from daily supervision through to major component overhaul – is gathered into one indexed volume.

Because fuel quality directly influences component service life, the MaK M43 engine operating instructions deal in detail with both fuel regimes. The manual explains when the Caterpillar / MaK after-sales service has to be consulted before changing from distillate fuel operation to heavy fuel oil operation, and equally when returning from heavy fuel oil back to distillate, so that the plant is retrofitted correctly and the documentation with extended maintenance intervals can be supplied. That alone makes this a genuinely practical reference rather than a generic handbook.

File Details

• Manual type: Engine operating instructions / workshop and maintenance manual
• Brand: MaK (Caterpillar Motoren GmbH & Co. KG, Kiel)
• Engine type: MaK M43 (acceptance records list type 7M43)
• Engine number: 65265
• Record number: 281221
• Language: English, with German/English bilingual section headings and data sheets
• File format: PDF
• Page count: 517 pages
• Document structure: Chapters A0 through A6, with numbered job cards in the maintenance section

Chapters Covered

• A0 – Safety instructions, copyright notice, Proposition 65 warning
• A1 – Technical engine data
• A1 – Governor data: governor equipment, governor adjustment, speed reference signal table, start fuel limitation, ramps, notes
• A1 – Lubricating oil, cooling water, fuel and injection nozzle opening pressures, control air and starting air pressures
• A1 – Operating temperatures for lube oil, cooling water, charge air and fuel, plus the fuel preheating temperature / viscosity diagram
• A1 – Torsional vibration calculation: mass elastic system, coupling torque and power loss graphs, alternating stress graphs, speed diagrams, phase vector sums
• A1 – Acceptance test records for engine 65265
• A3 – Operating instructions: first startup, loading during warming up, cold starting, direct start and emergency start at the main engine
• A3 – Fuel system: storage, settling and day tanks, separators, fuel pressure pumps, regulating valve, self-cleaning filter, mixing tank, circulating pumps, final preheater, viscometer, fine filter
• A3 – Lubricating oil system: functions, by-pass separation, oil level control, prelubrication, engine-driven force pump, automatic filter, duplex filter, strainer filters
• A3 – Cooling water system, compressed air system and general performance testing
• A3 – Operational supervision: low intake air temperatures, exhaust temperatures, firing pressure indication, turbocharger compressor cleaning, charge air cooler
• A3 – Turbocharger turbine and nozzle ring cleaning procedures and parameters
• A3 – Changing over between distillate fuel and heavy fuel
• A3 – Partial load operation with heavy fuel and the cleaning-run load diagram
• A3 – Removal from operation, engine stop, emergency stop, aftercooling, resumption of operation
• A3 – Danger of frost and antifreeze protection
• A3 – Short term and long term preservation, plus depreservation measures
• A3 – Running-in after piston, piston ring and cylinder liner work
• A3 – Fault tracing: starting problems, poor starting, low power, unsteady speed, soot, blue and white exhaust gases
• A3 – Emergency operation with a defective turbocharger, operational misfire and flexible coupling protection
• A4 – Operating media: heavy fuels, CCAI limit curves, permissible heavy fuel limits, viscosity-temperature sheet, lubricating oil, cooling water treatment
• A5 – Maintenance: work interval schedule, job cards and maintenance schedule
• A5 – Running gear / engine timing, bearing shells, big end and main bearings, pistons, piston rings, small end bearing
• A5 – Engine housing, explosion relief valve, cylinder liner and engine fasteners
• A5 – Engine control: camshaft and camshaft bearings, timing gear train, governor drive, vibration damper
• A5 – Regulation: control shaft bearings, starting valve, control rod, compressed-air filter
• A5 – Exhaust gas system / supercharging: exhaust line, charge air cooler, exhaust gas turbocharger
• A5 – Fuel system: injection pump, deflector bolts, pressure valve, high-pressure injection pipe, fuel injector, duplex filter, fuel distributor line
• A5 – Lubricating oil system: oil pump, duplex filter, oil pressure control valve, prelubricating pump
• A5 – Starting system, engine control equipment, monitors and auxiliary units
• A6 – Tools

Read as a whole, the MaK M43 engine operating instructions give a technician a complete working picture of the engine. The technical chapter establishes what the plant is supposed to do – rated power, rated speed, firing order, injection timing, valve timing and governor characteristics – and the operating chapter explains how to get there safely, whether the engine is being commissioned for the first time, run on heavy fuel in pier-to-pier service, or brought back into service after a long shutdown. The maintenance job cards then take over, giving the interval, the tools, the personnel qualification, the auxiliary materials and the step-by-step disassembly and reassembly sequence for each component group.

Technical Data and Governor Settings

The engine data section records the MaK M43 as a four-stroke, direct-injection, port engine with clockwise rotation viewed from the drive end. For engine 65265 the acceptance test records give a rated power of 6300 kW at 500 1/min, a bore of 430 mm and a stroke of 610 mm, with firing order 1-2-4-6-7-5-3 and a flywheel diameter of 1810 mm. Charging is by ABB TPL 73-A30 turbocharger with a maximum speed of 21600 1/min, fuel injection pump type FY 457706, fuel injector MaK J1/1 and an idle stroke X of 10.5 mm. Commencement of injection for cylinder 1 is 5.8 degrees crank angle before top dead centre, with the inlet valve opening 45 degrees before TDC, the exhaust valve opening 40 degrees before bottom dead centre and the exhaust valve closing 45 degrees after TDC.

Governor data is set out in its own numbered section, covering governor equipment – the 4-20 mA verstellmotor, 24 VDC synchronizing motor, shut-down solenoid, pilot valve plunger, terminal shaft, pilot valve bushing, drive shaft, power piston, speeder spring, compensation piston and laminated drive shaft assembly – together with the governor adjustment values. The governor speed is given as 1.928 x engine speed, with a compensating needle valve opening of one half turn, and the speed reference signal table maps 4 mA / 20 mA signals against lower idling, upper idling and full load speeds. Start fuel limitation, ramp rates for 4-20 mA raise and lower, clutch fuel setting and P-range droop values are all listed so that the settings can be restored after any governor oil change or repair.

Operating Pressures and Temperatures

The manual gives the working envelope for the engine in a compact reference section. Lubricating oil at the last camshaft bearing at rated engine speed should sit at 4.0 to 5.0 bar, with an engine inlet temperature of 60 to 65 degrees C and a temperature rise at rated output of 10 to 14 degrees C. Cooling water requires a minimum feed head at the pump inlet of 4 m water gauge, 2.5 to 5.0 bar pressure, an engine outlet temperature of 80 to 85 degrees C and a rise at rated output of 7 to 10 degrees C. Fuel pressure at the injection pump inlet is 3.0 to 5.0 bar for distillate fuel and 4.0 to 5.0 bar for heavy fuel. Control air is 7.5 bar and starting air is 12 to 30 bar. Charge air at engine inlet runs 45 to 60 degrees C and distillate fuel is preheated to 40 to 50 degrees C.

The fuel preheating temperature / viscosity diagram is central to the heavy fuel section. Permissible injection viscosity must be set on the viscometer so that a kinematic viscosity of 10 to 12 mm2/s (cSt) is reached before the injection pumps, corresponding to a dynamic viscosity of 9 to 11 mPa s. The heavy fuel specifications defined by MaK give the heavy fuel temperature before engine starting, but the maximum temperature at the injection pumps must not exceed 155 degrees C.

Heavy Fuel Treatment and Changeover

The MaK M43 engine operating instructions treat heavy fuel as a system, not just a fuel. Storage, settling tanks, separators, day tank, fuel pressure pump, pressure regulating valve, self-cleaning filter, mixing tank, circulating pump, final preheater, viscometer and fine filter are each covered with their own operating notes. Settling tank temperature runs 80 to 90 degrees C and separation temperature is 98 degrees C. The day tank is sized for a minimum of four hours of full load operation with daily de-sludging, and the final preheater is set to bring fuel viscosity down to the optimal injection range. Fuel temperature before engine intake is kept at or below 150 degrees C.

Changeover procedure is spelled out in both directions. The change from heavy fuel to distillate is done exclusively with the three-way selector cock, the three-way cock in the return line stays in its position so excess fuel is returned, and the circulating pump and final preheater are switched off no earlier than one hour after changeover. A different procedure can lead to sticking or scuffing of the injection pump plungers. Flushing a heavy-fuel-filled system with distillate to empty it more rapidly is only permitted when the engine has been shut down.

Partial Load, Running-In and Emergency Operation

Partial load running on heavy fuel is restricted. Continuous heavy fuel operation is permitted above 25 percent Pe; below that the heavy fuel operating time must be limited according to load stage, or the engine changed over to distillate fuel. The load-versus-hours diagram in the manual shows, for example, that at 15 percent Pe the engine runs about four hours on heavy fuel before changeover or a move to high load is required, after which a cleaning run of roughly 40 minutes burns the deposits away. A cleaning run after partial load operation is shown with a load increase period of approximately 15 minutes.

Running-in instructions apply after certain repairs – piston reconditioning, piston rings and cylinder liners. Once the engine is preheated, it is started at 20 percent rated power and brought to full power over a period defined per engine type; for the M43 the running-in time is 10 hours. No running-in instructions are needed after work on the main and big end bearings.

Emergency operation with a defective turbocharger is covered in full. The manual explains how to determine the maximum permissible fuel rack position from the relation between fuel rack position and mean brake effective pressure, using the 100 percent and 50 percent values from the acceptance test records, and how to shut down the turbocharger, interrupt its oil supply and blank off the air outlet casing where two turbochargers feed one charge air manifold. Monitoring limits during emergency operation, including a maximum exhaust gas temperature after the turbine of 500 degrees C and a charge air temperature not lower than 30 degrees C, are given, as is the recommendation to change to distillate fuel. After an emergency run on heavy fuel, at least one cylinder head must be removed for safety and to assess whether a general valve overhaul is necessary.

Fault Tracing and Maintenance Job Cards

The fault tracing chapter works through the symptoms an engine room crew actually meets: the engine starts poorly or does not start at all, reaches ignition speed but does not fire, does not reach full speed or full power, runs at an unsteady speed, or emits soot, blue or white exhaust gas. Each symptom is followed by possible causes – starting air pressure too low, a defective air starter solenoid, jammed stop cylinders, low governor oil pressure, a seized linkage, a clogged fuel filter, a defective feed pump, air or water in the fuel, a seized pump plunger, a clogged nozzle – and the corresponding remedy with a cross-reference to the relevant job card.

The maintenance section is built around a work interval schedule running up to 90,000 operating hours and split into daily inspection and control work, initial inspection and maintenance after first commissioning or major repair, periodic maintenance work, and maintenance work carried out independent of deadlines. The interval tables list the job card document number for each task, so a valve clearance check at 1,500 hours, a fuel injector overhaul at 7,500 hours, a cylinder head overhaul at 15,000 hours and a main bearing exchange at 30,000 hours can all be traced to their full procedure. Job cards give the engine type, the operating hours and maintenance deadline, the personnel qualification, the time requirement, the spare parts list reference and the special tools with MaK tool numbers, then walk through the work in numbered steps with the necessary torque and pressure values – for example the 2250 bar hydraulic clamping pressure used for the rocker arm bracket bolts and the cylinder head bolts, or the 300 Nm nozzle sleeve tightening torque.

Operating Media and Cooling Water Treatment

Operating media guidance covers permissible heavy fuel grades with the CIMAC and ISO equivalents, the CCAI limit curves that define the unrestricted, predominantly acceptable and avoidable fuel ranges, and the permissible limits table showing which heavy fuel classes are admissible for the M43. Lubricating oil recommendations are split by fuel regime, with the SAE 40 viscosity class specified for all Caterpillar / MaK engines and base number limits given for heavy fuel operation – the total base number of the circulation oil must not fall below 18 mg KOH/g, or 15 mg KOH/g on engines with cylinder lubrication. Oil change intervals are quoted as guide values based on 1.36 l/kW circulation quantity: every 1,500 hours with pre- and main filter, every 3,500 hours with additional by-pass filter or oil centrifuge, and every 7,500 hours with a separator.

Cooling water treatment is dealt with in detail, since the manual is explicit that even a short period of operation with improperly prepared water can cause corrosion damage. Fresh water analysis limits are given for hardness, pH value, chloride ion content and total chloride plus sulphate ions, and both corrosion-inhibiting oil emulsions and chemical corrosion inhibitors are covered with dosing, checking intervals and cleaning procedures. Emulsion concentration is checked every 750 operating hours; chemical inhibitor concentration is checked every 150 hours against the relevant limit values. Anti-freeze protection, cooling water chamber cleaning and the cooling water change procedure are all documented.

Preservation, Depreservation and Storage

Short term preservation for shutdowns up to two months and long term preservation for shutdowns longer than two months but not longer than one year are both covered, with the required tools, preserving oils, cleaning agents and auxiliary materials listed. The preservation measures are given component by component: fuel system with a 1:1 mixture of distillate fuel and corrosion inhibiting oil at 75 percent nominal speed and low load; lubricating oil system; cooling water system drained after cooling to 30 degrees C; crankcase, running gear, camshaft, roller tappets and charge air manifold sprayed with preserving oil; upper valve rockers; and external preservation of unpainted bright parts. Long term preservation adds combustion chamber and cylinder liner treatment through the indicator passages, starting system and starting air distributor preservation, governor oil change and turbocharger oil filling. Depreservation measures reverse the process, with a note that the fuel system needs no depreservation because the engine can simply be restarted on the mixture remaining in the system.

What This Manual Lets You Do

With the MaK M43 engine operating instructions for engine 65265 in hand, a chief engineer or workshop technician can commission the engine correctly, set and restore governor values after repair, run the plant on distillate or heavy fuel with the right pressures and temperatures, carry out the full maintenance schedule on the correct interval, diagnose and correct the common starting, running and exhaust faults, and manage preservation for a lay-up or an emergency run with a failed turbocharger. The acceptance test records for engine 65265 mean the reference figures are the ones that belong to this specific engine rather than generic values.

IMAGES PREVIEW

Getting these procedures and specifications right is what protects bearings, pistons, cylinder liners and exhaust valves, and it is what keeps the engine within its thermal limits at full load and at part load. Delivered as an instant PDF download, the manual needs no shipping and can be opened on a laptop, tablet or phone in the engine room, or printed for the workshop bench – a working copy that stays with the plant for as long as the engine is in service.