Man E0834 LE302, Operating Instructions Manual

Page 1: ...MAN Engines A Division of MAN Truck Bus Operating Instruction MAN Industrial Gas Engines E0834 LE302 312 322 E0836 LE202 302...

Page 2: ......

Page 3: ...Operating Instructions MAN Industrial Gas Engines E0834 LE302 312 322 E0836 LE202 302 51 99493 8538 Translation of the original operating instructions Version 07...

Page 4: ......

Page 5: ...is punishable by law It is not permitted to change the contents of this document The same applies to changes to the context of individual chapters and or the whole document MAN Truck Bus AG assumes no...

Page 6: ...ctions 14 2 3 Modifications and Conversions to the Engine 14 2 4 Responsibility of the Operator 14 2 5 Personnel Requirements 15 2 5 1 Qualifications 15 2 5 2 Unauthorised Persons 15 2 5 3 Instruction...

Page 7: ...on Engine 43 6 3 1 Safety Equipment 43 6 3 2 Engine Model Plate Data 43 6 4 Commissioning 44 6 4 1 Gas System 44 6 4 2 Filling Coolant 45 6 4 3 Filling Engine Oil 46 7 Operation 48 7 1 Prerequisite 48...

Page 8: ...te 63 10 2 Safety Instructions 63 10 3 Temporary Decommissioning of Engines 64 10 4 Recommissioning of Decommissioned Engines 65 10 4 1Commissioning of Preserved Engines according to MAN Werknorm M 30...

Page 9: ...Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 12 Indices 79 12 1 Abbreviations 80 1...

Page 10: ...mental protection This begins with the development and design of our engines We make sure that no environmentally hazardous materials are used and for ex ample that the emissions fulfil the highest re...

Page 11: ...which leads to death or serious injuries if not avoided WARNING indicates a possible hazardous situation which can lead to death or serious injuries if not avoided CAUTION indicates a possible hazardo...

Page 12: ...ations may deviate from what is described and illustrated in these instructions Valid are the commitments agreed upon in the delivery contract and the General Terms and Conditions of MAN and the law a...

Page 13: ...the engines We cannot assess and vouch for other non MAN products despite ongoing market observa tions WARNING Risk of injury from incorrect spare parts Incorrect or faulty spare parts can lead to da...

Page 14: ...g Instructions and any accompanying supplier operating instructions leads to the loss of warranty claims The use of non approved parts leads to the loss of warranty claims We recommend to use genuine...

Page 15: ...the technical data sheets currently in effect must also be adhered to The mixture generating and control system as well as if needed the exhaust aftertreatment system must be prepared by the manufactu...

Page 16: ...lth and safety regulations and be able to assess in a risk analysis the dangers that are present in the specific working conditions at the operating site of the engine He must then implement these saf...

Page 17: ...cal systems due to his her technical education training know ledge and experiences as well as knowledge of the respective standards and regulations and can recog nise and avoid any possible dangers Th...

Page 18: ...narrow sleeves and with no pro truding parts It is used primarily to protect against injury weather and dirt No rings bracelets necklaces and other jewellery are to be worn while working Protective H...

Page 19: ...the electrical system the power supply must be switched off and then properly checked to ensure no electrical current is present S Before starting any maintenance cleaning or repair work the power sup...

Page 20: ...lammable Substances Gaseous Fuels Oils and Grease WARNING Fire hazard caused by gaseous fuels For this reason S No smoking and no open flames S The regulations for gas installations must to be observe...

Page 21: ...s contain substances that are hazardous to your health Contact with these sub stances can lead to serious poisoning allergies skin irritations and damage to eyes For this reason S Observe the safety s...

Page 22: ...or this reason S Always keep the work area clean S Remove any objects that are no longer necessary S Mark areas where there is a danger of tripping with yellow and black striped tape Strong magnetic f...

Page 23: ...and property are avoided in case the its power supply is interrupted or is turned back on after an interruption The emergency off equipment must always be freely accessible WARNING Risk of death caus...

Page 24: ...rst aid and rescue equipment S Instruct the personnel on safety on a regular basis S Always keep access lanes for rescue vehicles free of any obstructions In the case of an accident Act accordingly S...

Page 25: ...llegible symbols Stickers and symbols can become dirty or made otherwise illegible in the course of time For this reason S Always keep the safety warning and operational signs in good legible conditio...

Page 26: ...nformation below S If environmentally hazardous substances are accidentally released into the environment immediately take suitable measures to minimise this If in doubt inform the responsible local a...

Page 27: ...y Instructions and the safety instructions in each of the chapters 3 Engine Model Plate Always specify the engine typeand engine number when sending messages and making queries For this reason before...

Page 28: ...mber according to index of model codes 1234 Day of assembly plant internal 547 Assembly order sequence number on day of assembly 3 2 Explanation of Model Designation Model designation Explanation Exam...

Page 29: ...information received from the sensors and control the output signals which are sent to the actuators The actuators convert the signals into mechanical factors Engine Lubrication Pressure feed lubrica...

Page 30: ...ne Views E0834 LE302 312 322 4 2 1 Front Left View 1 Turbocharger 2 Intake manifold 3 Charge mixture cooler 4 Starter 5 Throttle valve 6 Oil drain screw 7 Oil filter 8 Coolant inlet low temperature st...

Page 31: ...and the safety instructions in each of the chapters 4 2 2 Front Right View 14 Coolant inlet 15 Coolant outlet 16 Oil dipstick 17 Oil filler neck 18 Exhaust pipe 19 Crankcase ventilation NOTE The gas...

Page 32: ...ety Instructions and the safety instructions in each of the chapters 4 3 Engine Views E0836 LE202 4 3 1 Front Left View 1 Turbocharger 2 Intake manifold 3 Charge mixture cooler 4 Starter 5 Throttle va...

Page 33: ...and the safety instructions in each of the chapters 4 3 2 Front Right View 5 Oil drain screw 11 Coolant outlet 12 Coolant inlet 13 Oil dipstick 14 Exhaust pipe 15 Crankcase ventilation NOTE The gas s...

Page 34: ...chapter on General Safety Instructions and the safety instructions in each of the chapters 4 4 Engine Views E0836 LE302 4 4 1 Front Left View 1 Turbocharger 2 Intake manifold 3 Charge mixture cooler...

Page 35: ...ions and the safety instructions in each of the chapters 4 4 2 Front Right View 11 Coolant inlet 12 Coolant outlet 13 Oil filler neck 14 Oil dipstick 15 Oil separator 16 Bleeder line NOTE The gas supp...

Page 36: ...and Function 34 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the ch...

Page 37: ...and Function 35 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the ch...

Page 38: ...fore starting any work read and observe the General Safety Instructions and the safety information in this chapter Strictly observe these instructions and act prudently to avoid accidents personal inj...

Page 39: ...an swing out and cause serious injuries and significant property damage For this reason S Ensure that during the transport of packages no persons objects or obstacles are in the swivel range of the pa...

Page 40: ...tems and for damage from transport If external signs of transport damage are apparent S Do not accept delivery or only accept under written protest S List scope of damage on the transport documents or...

Page 41: ...uctions in each of the chapters 5 4 Transport Lifting Points There are 2 lifting lugs 1 and 2 for the crane installed on the engine WARNING Risk of death caused by the load falling During lifting oper...

Page 42: ...re 2 Ensure that the package is hanging straight or compensate for the off centre point of gravity 3 Start the transport Transport with Forklift The engine can be transported with a forklift under the...

Page 43: ...ing materials are valuable raw materials and can in many cases continue to be used or can be processed and recycled Incorrect disposal of packaging materials may cause an environmental hazard For this...

Page 44: ...el with sufficient experi ence Faulty installation can cause life threatening situations and considerable property damage For this reason S Installation and commissioning are only to be performed by M...

Page 45: ...st be installed for each engine For this reason S Install an emergency stop button to shut down the system in an emergency S Check whether all of the safety equipment is correctly installed and in goo...

Page 46: ...e gas system are all to be per formed as described in the manufacturer s instructions Setting for commissioning For commissioning the engine is to be set for the use of a suitable gas air mixture Any...

Page 47: ...the filling specifications of the BHKW combined heat and power plant manufacturer For suitable antifreeze agents see approved Fuels Lubricants and Coolants according to MAN 324 NF and MAN 248 Coolant...

Page 48: ...n each of the chapters 6 4 3 Filling Engine Oil IMPORTANT Component damage caused by over filling Engine damage can occur if engine oil is filled to above the max mark on the oil dipstick For this rea...

Page 49: ...and Commissioning 47 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of...

Page 50: ...sonnel or bytrained qualified personnel Ground Rules WARNING Danger caused by faulty operation Improper operation can cause serious personal injury or considerable property damage For this reason S Pe...

Page 51: ...lubricants see Fluids and Lubricants publication 7 3 1 Check Gas Quality Open Gas Supply WARNING Risk of fire caused by highly flammable substances Highly flammable substances fluids or gases can cat...

Page 52: ...e this will cause damage to the environment IMPORTANT Engine damage caused by excessive temperature difference When refilling with cold coolant in an engine at operating temperature there is a risk of...

Page 53: ...s horizontal and only after at least 20 minutes have passed since the engine was switched off 1 Pull out oil dipstick 1 2 Wipe off oil dipstick 1 with a lint free clean cloth 3 Reinsert the oil dipsti...

Page 54: ...filling Engine Oil IMPORTANT Component damage caused by over filling Engine damage can occur if engine oil is filled to above the max mark on the oil dipstick For this reason S Do not fill engine oil...

Page 55: ...n system is a high voltage condensator ignition system based on crankshaft rotation with a microprocessor control The ignition system muss be parameterized before commissioning For further information...

Page 56: ...ne Shut Off Deceleration of the engine from 100 to 0 is made using a ramp in a time interval of at least 3 minutes This minimises the thermal load on the engine block DANGER Risk of fire caused by unb...

Page 57: ...engines are available to supplement these operating instructions It contains a discription of all due turnaround maintenace work Maintenance instruction see leaflet Maintenance Instruction MAN Industr...

Page 58: ...ance and Care 56 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the c...

Page 59: ...ctions and act prudently to avoid accidents personal injury and property damage 9 2 Safety Instructions Personnel S Engine faults may only be rectified by specially trained qualified personnel or by t...

Page 60: ...er broken D Internal engine damage piston seizure maybe due to incorrect oil type D Set main switch to on D Replace faulty fuses D Repair any loose corroded and broken wires and contacts D See informa...

Page 61: ...ctua tions during operation D Spark plug faulty D Ignition cable faulty D Ignition coil faulty D Ignition timing incorrectly set D Shutoff solenoid valve of gas supply closed does not open D Tachomete...

Page 62: ...xpansion reservoir radiator is faulty or leaks D Temperature display faulty D Coolant pump leaks defective bearing damage D Thermostat faulty does not open D Coolant lines leak clogged or twisted D Re...

Page 63: ...xhaust gas recirculation cooler dirty D See Fluids and Lubricants D Check intake vacuum D Remedy from manufacturer ser vice D Check exhaust back pressure Blue smoke D Lube oil penetrates into combusti...

Page 64: ...o turn after starter switch is re leased D Pinion gear does not disengage after en gine starts D Battery has insufficient charge D Terminal is loose oxidised poor connection to ground D Starter termin...

Page 65: ...pment The following protective equipment must be worn S Protective Clothing S Safety Shoes S Safety Gloves 10 2 Safety Instructions Personnel S Decommissioning and recommissioning of the engine may on...

Page 66: ...obtained from our After Sales Service department Nuremberg works NOTE A proper and careful recommissioning of new or operated engines has a great impact on the operating safety and remaining life of...

Page 67: ...above idle speed to avoid insufficient lubrication of the cylinder liners 9 Check engine for leaks unusual noises and observe the oil pressure and all temperatures Increase en gine speed in steps 10...

Page 68: ...and Recommissioning 66 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each o...

Page 69: ...imensions and Weights 11 1 1 E0834 LE302 Specification Value Unit Weight dry E0834 LE302 495 kg A 1055 mm B 809 mm C 866 mm 11 1 2 E0836 LE202 Specification Value Unit Weight dry E0836 LE202 605 kg A...

Page 70: ...calorific values a correspondingly lower engine power will be the result A new engine setup will be needed to achieve the rated output Rating for biogas operation 66 kW 90 HP at 1500 rpm The power out...

Page 71: ...il temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter Single use main flow filter easy change filter Oil capacity in oil sump litres min max half...

Page 72: ...re valid for operation with natural gas with a calorific value of 36 350 kJ m3 and a methane number 80 For higher calorific values the engine is to be set so that the specified engine power is not exc...

Page 73: ...il temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter Single use main flow filter easy change filter Oil capacity in oil sump litres min max half...

Page 74: ...re valid for operation with natural gas with a calorific value of 36 350 kJ m3 and a methane number 80 For higher calorific values the engine is to be set so that the specified engine power is not exc...

Page 75: ...il temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter Single use main flow filter easy change filter Oil capacity in oil sump litres min max half...

Page 76: ...wer will be the result A new engine setup will be needed to achieve the rated output Rating for biogas operation 110 kW 150 HP at 1500 rpm The power output specifications are valid for operation with...

Page 77: ...temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter Single use main flow filter easy change filter Oil capacity in oil sump litres min max half de...

Page 78: ...wer will be the result A new engine setup will be needed to achieve the rated output Rating for biogas operation 110 kW 150 HP at 1500 rpm The power output specifications are valid for operation with...

Page 79: ...temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter Single use main flow filter easy change filter Oil capacity in oil sump litres min max half de...

Page 80: ...nical Data 78 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chap...

Page 81: ...s 79 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 12 I...

Page 82: ...A Amps Ah Amp hours bzw Respectively C Celsius cm3 Cubic centimetre evtl Possibly Fa Company ggf If necessary h Hours Chap Chapter kg Kilogram kW Kilowatt m Metre MAX Maximum min Minutes MIN Minimum...

Page 83: ...Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 12 2 Tech...

Page 84: ...e Model Plate Data 43 Engine Monitoring 27 Engine Shut Off 54 Engine Views Engine General 27 Environmental Protection 24 F Fault Table 58 Faults 57 Filling Coolant 45 Filling Engine Oil 46 G Gas filte...

Page 85: ...Recommissioning of Decommissioned Engines 65 Refilling Coolant 50 Refilling Engine Oil 52 Responsibility of the Operator 14 S Safety Equipment 21 43 Service 12 Signs 23 Spare Parts 11 Specific Danger...

Page 86: ...s 84 Carefully read the Operating Instructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 13 N...

Page 87: ......

Page 88: ...MAN Truck Bus AG Vogelweiherstra e 33 90441 N rnberg Germany A member of the MAN Group Printed in Germany 51 99493 8538...

Page 89: ......

Page 90: ...MAN Truck Bus a member of the MAN Group MAN Truck Bus AG Vogelweiherstra e 33 90441 Nuremberg Germany man engines man eu www man engines com...