Man E 0824 E 301, Operating Instructions Manual

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Page 3: ...erformance can only be achieved if the specified maintenance intervals are observed and only approved fuels lubricants and coolants are used It is imperative and in your own interest to entrust your M...

Page 4: ...system 24 Spark plugs 27 Air filter 28 Starter motor 28 Temporary decommissioning of engines 28 Checking and setting 29 Adjusting ignition timing 29 Adjusting the overspeed setting 31 Adjusting valve...

Page 5: ...r Rating speed Note The manufacturer of the complete ready to use machine in which this engine is to be installed must take the further action necessary in the context of indirect safety re lated engi...

Page 6: ...umber For this reason it is advisable to read off the data from the engine type plates before put ting the engine into operation and to enter them in the appropriate spaces The engine type plates are...

Page 7: ...at hand D Inflammable material must not be stored in the engine room What must be done in the event of a gas leak D Close the shut off tap for the gas supply D Turn off main switch for the electrical...

Page 8: ...ersons During commissioning starting and operation D Before putting the engine into operation for the first time read the oper ating instructions carefully and familiarize yourself with the critical p...

Page 9: ...ccount the amount of oil in the sump Use a vessel of suffi cient size to ensure that the oil will not overflow D Open the coolant circuit only when the engine has cooled down If opening while the engi...

Page 10: ...circuits D When welding comply with the Instructions for welders When working on the electronic ignition system The firing power of electronic ignition systems is significantly higher than that of co...

Page 11: ...ove note the following points D Never let the engine run when dry i e without lube oil or coolant D When starting do not use any additional starting aids e g injection with starting pilot D Use only M...

Page 12: ...oil decreases the skin Drying irritation or inflammation of the skin may therefore occur Used engine oil also contains dangerous substances which have caused skin cancer in animal experi ments If the...

Page 13: ...For this reason do not let engine oil get into the ground waterways the drains or the sewers Violations are punishable Collect and dispose of used engine oil carefully For information on collection po...

Page 14: ...Commissioning and operation 12 Engine views E 0824 E 301 302 1 2 3 4 5 6 7 8 9 10 11 12...

Page 15: ...icture it is closed up by a blind flange 6 Coolant temperature transmitter 7 Oil cooler 8 Oil filter 9 Intake pipe 10 Pulse recorder for ignition system accessory 11 Oil pressure transmitter 12 Starte...

Page 16: ...Commissioning and operation 14 Engine views E 0826 E 301 302 1 2 3 4 5 6 7 8 9 10 11 12...

Page 17: ...icture it is closed up by a blind flange 6 Coolant temperature transmitter 7 Oil cooler 8 Oil filter 9 Intake pipe 10 Pulse recorder for ignition system accessory 11 Oil pressure transmitter 12 Starte...

Page 18: ...up with coolant max 10 l min Filling with engine oil Caution Do not add so much engine oil that the oil level rises above the max marking on the dipstick Overfilling will result in damage to the engi...

Page 19: ...it in again up to the stop D Pull out dipstick again The oil level should be between the two notches in the dipstick and must never fall below the lower notch Top up oil as necessary Caution Do not a...

Page 20: ...t to the engine Danger Disconnect battery before doing any work on electric cables or making adjustments to the con trol unit as described here Adjusting ignition sequence and tim ing The same control...

Page 21: ...he input signals to the control unit D The cable harness for the output sig nals from the control unit The plugs 14 pin and 10 pin are de signed to prevent them from being in serted in the wrong socke...

Page 22: ...enerator load on id ling gas flow D The starting control will move the throttle valve into operating position Simultaneously the generator will be connected to the system Operation with synchronous ge...

Page 23: ...l combustion engines to increased wear through corrosion Letting the engine idle over prolonged periods is detrimental to the environment Switching off After operation at full load let engine idle for...

Page 24: ...n out completely To catch emerging oil use a container of sufficient capacity to prevent the oil from spilling over Loosen oil filter cartridge by means of a tape wrench and remove it The oil filter c...

Page 25: ...oil pressure and for leaks Switch off engine and check oil level after five minutes D Pull out dipstick D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick...

Page 26: ...sure the engine has cooled down Then drain the coolant as follows D Open filler cap of coolant reservoir not supplied by MAN to permit pressure equalisation D Unscrew drain plugs see pictures wrench...

Page 27: ...e Ensure that the water anti freeze ratio is the same as before addition of the coolant D Unscrew cover D Add coolant slowly D Screw the cover back on D Run the engine for a short time and then check...

Page 28: ...at least 40 by volume see Fuels Lubricants and Coolants for MAN Industrial Gas Engines Note The surge tank should be filled only up to the bottom edge as otherwise foaming will cause the pickling flu...

Page 29: ...plugs see Technical Data Fit new spark plugs every 2 000 hours of operation Danger High voltage Do not remove spark plug connectors while en gine is running Fitting plugs when the engine is cold Tight...

Page 30: ...s and plug connec tions are secure Caution Always disconnect the battery earth cable before starting work on the electrical sys tem Connect up the earth cable last as there is otherwise a risk of shor...

Page 31: ...inder 1 takes place at 16 before TDC for 1 or 8 before TDC for 1 5 Check and set the ignition point with a stroboscopic lamp This must be done with the engine running Connect up the stroboscopic lamp...

Page 32: ...eter screwdriver point in the upper figure until the 12_ marking on the fly wheel and the edge in the inspection hole of the flywheel housing coincide The timing adjustment range is limited by the lef...

Page 33: ...um speed is 2 800 rpm A safety speed of 2 000 rpm can therefore be set for example Setting an overspeed of 2 000 rpm D Open cover on flywheel housing D Turn lower potentiometer arrow clock wise with a...

Page 34: ...on overlap E 0824 E 301 302 Valves rocking on cylinder 1 3 4 2 4 2 1 3 Adjust valves on cylinder E 0826 E 301 302 Valves rocking on cylinder 1 5 3 6 2 4 6 2 4 1 5 3 Adjust valves on cylinder The valv...

Page 35: ...Notes 33...

Page 36: ...80 Firing order 1 3 4 2 Valve clearance cold engine Intake 0 50 mm Exhaust 0 50 mm Valve timing Intake opens 6 before TDC Intake closes 38 after BDC Exhaust opens 56 before BDC Exhaust closes 12 after...

Page 37: ...System Elektronic ignition system with static igni tion timing Make Fairbanks Morse Type IQ 250 A Ignition time at l 1 Crank angle 16 before TDC at l 1 5 Crank angle 8 before TDC Spark plugs GE 3 1 El...

Page 38: ...Firing order 1 5 3 6 2 4 Valve clearance cold engine Intake 0 50 mm Exhaust 0 50 mm Valve timing Intake opens 6 before TDC Intake closes 38 after BDC Exhaust opens 56 before BDC Exhaust closes 12 aft...

Page 39: ...System Elektronic ignition system with static igni tion timing Make Fairbanks Morse Type IQ 250 A Ignition time at l 1 Crank angle 16 before TDC at l 1 5 Crank angle 8 before TDC Spark plugs GE 3 1 El...

Page 40: ...aner earlier if severe operating conditions demand it D Check and if neccessary adjust valve clearance D D D Change spark plugs D Check ignition timing D Check comprssion pressure D Check anti freeze...

Page 41: ...39 Circuit diagrams...

Page 42: ...V I A B 10 30 V E F G H J K L 2 3 4 1 5V 0 5V Ignition timer 5 6 7 5A 1 Plug 14 polig 2 Speed governor 5 Ignition ON OFF 3 Camshaft gear unit in picture 4 cylinder engine 6 Self test ON OFF 4 Interfe...

Page 43: ...nition coils of the respective cylinders D brown cylinder 2 the 1st cylinder is located at the non flywheel end E blue not required in 4 cyl engine F orange not required in 4 cyl engine 7 Plug G white...

Page 44: ...H I J 7 1 2 3 4 5 6 Ignition coils of the respective cylinders D brown cylinder 6 the 1st cylinder is located at the non flywheel end E blue cylinder 2 F orange cylinder 4 7 Plug G white green not use...

Page 45: ...Notes 43...

Page 46: ...2 13 E 0826 E 14 15 I Ignition sequence Adjusting 18 Ignition timing Adjusting 30 Checking 29 L Lubrication system 22 25 M Mainenance chart 38 39 Maintenance and care 22 42 N Nameplates 4 O Overspeed...

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