Man E 2842 LE 302 Operating Instructions Manual Download

Page: 40 / 50

Maintenance plan for operation with natural gas

E 2842 LE 312

Check for leaks

Check screw connections

Change engine oil / oil
analysis*)

Change oil filter *)

Record operating data

Check starting procedure

Set / check butterfly valve

Clean gas filter

Clean or change pulse pickup

Check coolant concentration

Check ignition point

Check coolant circuit / system
pressure

Measure crankcase pressure

Measure exhaust back pressure

Clean or change mixture cooler

Check emissions and lambda

Check for leaks

Check screw connections

Change engine oil / oil
analysis*)

Change oil filter *)

Record operating data

Check sparkplugs

Check starting procedure

Check intake vacuum

Check valve clearance, adjust if
necessary

Change sparkplugs

Measure compression

Set / check butterfly valve

Clean gas filter

Clean or change pulse pickup

Check coolant concentration

Check /change oil trap

Check ignition point

Check coolant circuit / system
pressure

Measure crankcase pressure

Measure exhaust back pressure

Clean or change mixture cooler

Check emissions and lambda

Check /calibrate sensors

Change coolant

Change turbocharger

Measure crankshaft axial play

Change cylinder liners

Change conrods

Change piston rings

Change cylinder heads

Change pistons

Overhaul engine generally

*) The engine oil change intervals must be determined on the basis of regular oil analy-

ses depending on the conditions of operation and the engine oil used in accordance
with MAN works standard M 3271-2.

−

The oil analysis must be carried out after the first 600 hours of operation

Summary of Contents for E 2842 LE 302

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Page 3: ...49 Operating Instructions MAN Industrial Gas Engines...

Page 4: ...50...

Page 5: ...ants are used Note Only use fuel coolants and lubricants in accordance with MAN s regulations otherwise the manufacturer s warranty will not apply For basic information on the fuels see the publicatio...

Page 6: ...operation due to the sew ing machine effect in particular if they are used between parts with different rates of lin ear expansion under heat e g aluminium and cast iron and leaks may then occur Exam...

Page 7: ...Cooling system 66 Commissioning 70 Starting 71 Operation monitoring system 72 Shutting down 72 Gas system 73 Maintenance and care 74 Lubrication system 74 Cooling system 77 Temporary decommissioning...

Page 8: ...number 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 related...

Page 9: ...nter them in the appropriate spaces The engine type plates are on the crankcase Model delivered on installed on Engine serial number Order number MAN Nutzfahrzeuge Aktiengesellschaft Typ Motor Nr Engi...

Page 10: ...ely 1 Regulations designed to prevent accidents with injury to persons During commissioning starting and operation D Before putting the engine into operation for the first time read the oper ating ins...

Page 11: ...o account 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 e...

Page 12: ...un when dry i e without lube oil or coolant D When starting do not use any additional starting aids D Use only MAN approved service products gas engine oil antifreeze and anti cor rosion agent Pay att...

Page 13: ...utions to ensure that no oil gets into the drains or the ground Caution The drinking water supply could be contaminated D Filter elements are classed as dangerous waste and must be treated as such Coo...

Page 14: ...c or wear protective gloves D Clean skin which has been in contact with engine oil Wash thoroughly with soap and water A nailbrush is an effective aid Certain products make it easier to clean your han...

Page 15: ...gine compartment Behaviour in the event of escaping gas D Close the cut off cock of the gas supply D Switch off the main switch of the electrical system D Block off the area at risk Instruct unauthori...

Page 16: ...Commissioning and operation 62 Engine views E 2842 LE 302 1 2 3 4 5 1 6 8 9 10 11 7...

Page 17: ...over for crankshaft vibration damper Exhaust manifold with Heat Protection Plate Breather housing for coolant Intake manifold Coolant inlet 1 1 Oil filter Note The gas line consisting of a ball valve...

Page 18: ...Commissioning and operation 64 Engine views E 2842 LE 312 1 2 3 4 1 8 9 10 7 5 6...

Page 19: ...vibration damper Coolant outlet Breather housing for coolant Intake manifold Coolant inlet Oil filter Exhaust manifold with Heat Protection Plate Note The gas line consisting of a ball valve gas filte...

Page 20: ...e specified maximum power Caution Use only approved fuels lubricants etc see brochure Fuels lubricants etc Otherwise the manufacturer s warranty will become null and void Cooling system Danger Drainin...

Page 21: ...3 0 bar D Observe the filling regulations of the manufacturer of the cogeneration power unit D For coolant filling quantity see Technical data D Fill up the cooling system with the filler device keep...

Page 22: ...rate 7 l min to max 10 l min Filler cap with over underpressure Expansion tank Connection line to the intake side of the coolant pump 25 mm Coolant inlet Coolant outlet D Valve 0 6 0 08 bar D Observe...

Page 23: ...n engine which is warm from operation Ensure that the ratio of water to anti freeze is correct D With the engine is next put into operation with the engine cold check the coolant level and top up is n...

Page 24: ...y approx 20 minutes after the unit has been switched off D Pull out dipstick arrow D wipe it with a clean lintfree cloth D and push it in again up to the stop D Pull out dipstick again The oil level s...

Page 25: ...er to the operating instructions for the ignition system and the guide to installation Switch on coolant pump before the start Switch the starter on and let it run for at least 3 seconds to ensure an...

Page 26: ...minutes The thermal load on the engine block is thus minimised D Switch off the release of the gas line D The engine slows down D Switch off the ignition and control after approx 5 seconds Note The co...

Page 27: ...Sheet Mini mum Gas Quality Requirement for MAN Gas Engines The operating pressure for natural gas must be at least 20 mbar The gas pressure should remain as constant as possible within this range To a...

Page 28: ...oil is hot risk of scalding Do not touch the oil drain plug with bare fingers The oil damages the environment Handle it with care With the engine at operating temperature remove the oil drain plugs ar...

Page 29: ...a few minutes at low speed Caution If no oil pressure builds up after approx 10 seconds switch off the engine immediately Check oil pressure and check for leaks Then shut down the engine After about...

Page 30: ...ronment Renewal of filter cartridges Danger Oil filter can and oil filter are filled with hot oil Risk of burns and scalds D Take off the filter housing after re moving the mounting bolt D Renew filte...

Page 31: ...into a suitable con tainer and dispose of it in accord ance with regulations Drain coolant as follows when cooling sys tem has cooled down D Provide a large enough reservoir un derneath D Briefly open...

Page 32: ...th the safety valve carefully to first catch let off pressure then carefully open and if necessary top up coolant D Do not put cold coolant into an engine which is warm from operation Ensure that the...

Page 33: ...f engines Temporary anti corrosion protection according to MAN works norm M 3069 is required for engines which are to be put out of service for fairly long periods The works norm can be obtained from...

Page 34: ...the event of a higher calorific value the engine adjustment is to be corrected so that the specified engine output is not ex ceeded In the event of lower calorific values the output will be reduced ac...

Page 35: ...flow filter with 2 paper filter car tridges Oil capacity in oil sump litres min max semi flat 22 l 30 l deep 40 l 90 l Oil change quantity with filter semi flat 33 l deep 93 l Engine cooling system Li...

Page 36: ...er 80 In the event of a higher calorific value the engine adjustment is to be corrected so that the specified engine output is not ex ceeded In the event of lower calorific values the output will be r...

Page 37: ...flow filter with 2 paper filter car tridges Oil capacity in oil sump litres min max semi flat 22 l 30 l deep 40 l 90 l Oil change quantity with filter semi flat 33 l deep 93 l Engine cooling system Li...

Page 38: ...x x 2700 x 3600 x x 4500 x 5400 x x 6300 x 7200 x x 8100 x 9000 x x 9900 x 10800 x x 11700 x 12600 x x 13500 x 14400 x x 15000 x 15300 x 16200 x x 17100 x 18000 x x 18900 x 19800 x x 20700 x 21600 x...

Page 39: ...of operation at 1500 rpm 1 E1 E2 E3 R1 R2 R3 completed Stamp signature 27000 x x 27900 x 28800 x x 29700 x 30000 x 30600 x x 31500 x 32400 x x 33300 x 34200 x x 35100 x 36000 x x 36900 x 37800 x x 387...

Page 40: ...lve clearance adjust if necessary E3 D Change sparkplugs D Measure compression D Set check butterfly valve D Clean gas filter D Clean or change pulse pickup D Check coolant concentration D Check chang...

Page 41: ...and R2 R3 x 400 x 2 800 x 1200 x 1600 x x 2000 x 2400 x 2800 x 3200 x x 3600 x 4000 x 4400 x 4800 x x 5200 x 5600 x 6000 x 6400 x x 6800 x 7200 x 7600 x 8000 x x 8400 x 8800 x 9200 x 9600 x x 10000 x...

Page 42: ...rpm 1 E1 E2 E3 R1 R2 R3 completed Stamp signature 12800 x x 13200 x 13600 x 14000 x 14400 x x 14800 x 15000 x 15200 x 15600 x 16000 x x 16400 x 16800 x 17200 x 17600 x x 18000 x 18400 x 18800 x 19200...

Page 43: ...rpm 1 E1 E2 E3 R1 R2 R3 completed Stamp signature 27600 x 28000 x 28400 x 28800 x x 29200 x 29600 x 30000 x x x 30400 x x 30800 x 31200 x 31600 x 32000 x x 32400 x 32800 x 33200 x 33600 x x 34000 x 34...

Page 44: ...0 rpm 1 E1 E2 E3 R1 R2 R3 completed Stamp signature 42800 x 43200 x x 43600 x 44000 x 44400 x 44800 x x 45000 x 45200 x 45600 x 46000 x 46400 x x 46800 x 47200 x 47600 x 48000 x x 48400 x 48800 x 4920...

Page 45: ...60 CH4 40 CO2 E 2842 LE 312 91 Interval by hours of operation Maintenance service Service completed of operation at 1500 rpm 1 E1 E2 E3 R1 R2 R3 completed Stamp signature 57600 x x 58000 x 58400 x 588...

Page 46: ...et check butterfly valve D Clean gas filter D Clean or change pulse pickup D Check coolant concentration D Check change oil trap D Check ignition point D Check coolant circuit system pressure D Measur...

Page 47: ...Notes 93...

Page 48: ...tem 73 General notes 56 62 I Instructions 52 L Lubrication system 74 76 M Maintenance and care 74 79 Maintenance plan Operation with biological gas 87 Operation with natural gas 84 N Nameplates 55 O O...

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