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Man E3262 LE202, Operating Instructions Manual

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Man E3262 LE202 Operating Instructions Manual Download Page 43

Installation and Commissioning

41

Carefully read these 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.

6

Installation and commissioning

6.1

Notes regarding installation and commissioning

6.1.1

Requirements

Before 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 injury and property
damage.

Personal Protective Equipment

The following protective equipment must be worn:

S

Protective Clothing

S

Safety Shoes

S

Safety Gloves

6.2

Safety instructions

Personnel

S

The installation and commissioning may only be performed by MAN employees or by MAN-trained quali­
fied personnel.

WARNING

Danger caused by faulty installation and commissioning!

Installation and commissioning require trained qualified personnel with sufficient experience. Faulty in­
stallation can cause life threatening situations and considerable property damage.

For this reason:

S

Installation and commissioning may only be performed by expert personnel trained by MAN.

Ground Rules

WARNING

Risk of injury due to improper installation and commissioning

Improper installation and commissioning can cause serious personal injury or considerable property
damage.

For this reason:

S

Ensure adequate work space before starting any work.

S

Be careful when working with exposed parts with sharp edges.

S

Make sure work space is kept clean and orderly!

S

Install components in a correct manner.

S

Observe the prescribed tightening torques.

S

Secure components so that they do not fall or tip over.

S

Before commissioning the engine, carefully read the Operating Instructions and familiarise yourself with
the “critical” subjects.

S

It is absolutely necessary to observe the “Assembly Instructions” for the installation and commissioning
of a new or reconditioned engine.

S

For safety reasons we recommend placing an off limits sign on the door to the engine room and to in­
struct the operating personnel that they are responsible for the safety of people who enter the engine
room.

Summary of Contents for E3262 LE202

Page 1: ...MAN Engines A Division of MAN Truck Bus Operating Instruction MAN Industrial Gas Engines E3268 LE212 222 E3262 LE202 212 ...

Page 2: ......

Page 3: ...Operating Instruction MAN Industrial Gas Engines E3268 LE212 E3268 LE222 E3262 LE202 E3262 LE212 51 99587 8006 Translation of the original instruction Version 05 ...

Page 4: ...hapters Subject to change without notice Reprinting copying or translation even of extracts is not allowed without written permission from MAN All rights under the copyright law are strictly reserved by MAN 2016 MAN Truck Bus AG Vogelweiherstrasse 33 90441 Nürnberg Germany Tel 49 911 420 1745 Fax 49 911 420 1932 email Engine Documentation man eu internet www man engines com Technical status 03 201...

Page 5: ...al 10 1 8 Warranty provisions 11 1 9 Product support 11 2 General Safety Instructions 13 2 1 Intended use 13 2 2 Content of the Installation and Operating Instructions 14 2 3 Engine modifications and conversions 14 2 4 Operator s responsibility 14 2 5 Personnel requirements 15 2 5 1 Qualifications 15 2 5 2 Unauthorised personnel 15 2 5 3 Instruction 15 2 6 Personal protective equipment 16 2 7 Part...

Page 6: ...llation and commissioning 41 6 1 1 Requirements 41 6 2 Safety instructions 41 6 3 Engine installation 42 6 3 1 Interfaces between engine and plant 42 6 3 2 Installation Instructions 44 6 3 3 Installation drawing 44 6 3 4 Screw and bolt connections 44 6 4 Completion of the engine and assembly of the drive system 45 6 4 1 Mounting an alternator on the flywheel housing 45 6 4 2 Checking crankshaft ax...

Page 7: ...stem 63 7 4 3 Emergency shutdown 63 7 4 4 Stopping 63 7 4 5 Data storage box 64 8 Maintenance and care 65 8 1 Requirements 65 8 2 Safety instructions 65 8 3 Maintenance schedule 66 8 3 1 Maintenance schedule for natural gas operation 67 8 3 2 Maintenance schedule for special gas operation 70 8 4 Maintenance work 75 8 4 1 Engine oil change 75 8 4 2 Changing the coolant 79 9 Faults 81 9 1 Requiremen...

Page 8: ...echnical data 91 11 1 Dimensions and weight 91 11 1 1 E3268 LE212 LE222 91 11 1 2 E3262 LE202 LE212 91 11 2 Installation location and space requirements 91 11 3 Engine data 92 11 3 1 E3268 LE212 LE222 92 11 3 2 E3262 LE202 LE212 94 12 Installation drawing 97 12 1 Installation drawing E3268 LE212 LE222 97 12 2 Installation drawing E3262 LE202 LE212 103 13 Indices 111 13 1 Abbreviations 112 13 2 Lis...

Page 9: ...at have been approved by MAN Only the genuine spare parts approved by us have been tested by us and therefore meet the requirements for use of the engine A particular concern of MAN is to improve environmental protection This begins with the development and design of our engines We make sure that no environmentally ha zardous materials are used and for example that the emissions fulfil the highest...

Page 10: ... or death if it is not avoided WARNING Describes a possibly dangerous situation that can lead to serious injury or death if it is not avoided CAUTION Describes a possibly dangerous situation that can lead to minor or moderate injury if it is not avoided NOTE Describes a possibly dangerous situation that can lead to damage if it is not avoided Tips and Recommendations User tip Tips and recommendati...

Page 11: ...modifications 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 applicable at the time of contracting arrangements 1 4 Copyright protection Treat the Installation and Operating Instructions confidentially They are aimed solely at persons who deal with the en...

Page 12: ...ablished specifically for the engines We cannot assess and vouch for other non MAN products despite ongoing market observations WARNING Risk of injury due to incorrect spare parts Incorrect or faulty spare parts can lead to damage malfunctions or total failures and interfere with safety For this reason S Only use MAN genuine spare parts User tip Quote the engine type engine number and order number...

Page 13: ...hese instructions and any operating instructions provided by suppliers invalidates the war ranty The use of non approved parts leads to the loss of warranty claims We recommend to use genuine parts even after the warranty period has expired This will ensure the conti nuous performance of the engine 1 9 Product support Our MAN product support is available for technical information User tip Quote th...

Page 14: ...oreword 12 Carefully read these 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 ...

Page 15: ...ating parameters according to 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 manufacturer of the complete machine to meet these criteria Intended use also includes compliance with the prescribed operating maintenance and repair work The engine may only be ...

Page 16: ...he valid occupational health 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 safety regulations in the form of operating instructions for the operation of the engine S During the entire period of operation of the engine the operator must check whether the...

Page 17: ...cal systems due to his her technical education training know ledge and experience as well as knowledge of the respective standards and regulations and can recog nise and avoid any possible dangers The electric specialist is trained for the specific operating site in which he she works and knows the rele vant standards and regulations Only those people who can perform their work reliably should be ...

Page 18: ...rength with 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 Helmet To protect against falling and flying parts Safety Shoes To protect against heavy falling parts and slipping on slippery surfaces Safety Gloves To protect the hands from friction scra...

Page 19: ...ly checked to ensure no electrical current is present S Before starting any maintenance cleaning or repair work the power supply must be switched off and secured from being accidentally switched back on S Do not bridge or bypass any fuses When replacing fuses ensure to use the correct amperage S Keep moisture clear of parts conducting electrical current This could cause a short circuit Moving Part...

Page 20: ...immediate sur roundings S Keep fire extinguishers at hand S Immediately report any suspicious substances fluids or gases to the person in charge S Repair any leaks S In the case of fire immediately stop working Leave hazard area until the danger is over Coolants Antifreeze Anticorrosion Agents WARNING Risk of injury caused by coolants that are hazardous to health Coolant contains substances that a...

Page 21: ... area can cause serious hearing damage For this reason S Always wear hearing protection when working S Do not unnecessarily remain in the hazard area Leave hazard area when work is finished Sharp Edges and Corners CAUTION Risk of injury on edges and corners Sharp edges and corners can cause skin grazes and cuts For this reason S Always work carefully and with caution in the vicinity of sharp edges...

Page 22: ...uipment and connect it into the safety chain of the system Connect the emergency off equipment so that dangerous situations to people 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 Danger to life due to non functioning safety equipment For this reason S Before comme...

Page 23: ...id 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 Remain calm S Immediately shut down engine using the emergency off button S Start first aid measures S Alert rescue services and or fire department S Move people out of the danger zone S Clear access lanes...

Page 24: ...rning and operational signs The following symbols should be installed in the immediate vicinity of the hazard area Access forbidden Areas displaying this sign must not be entered Electric Voltage Spaces marked with this symbol may only be accessed by qualified electricians Unauthorised persons may not enter these spaces Hot Surfaces Hot surfaces such as hot engines and hot fluids may not always be...

Page 25: ...ns and the safety instructions in each of the chapters 2 11 Weight data E3268 LE212 LE222 Ensure that suitable lifting gear is used for handling the engine and the engine parts listed in the table Part Weight kg Oil pan 95l 27 Crankcase 459 Crankshaft 131 Flywheel housing 30 Flywheel 66 Exhaust turbocharger 1500 rpm 38 Charge mixture cooler E3268 88 Engine carriage 107 ...

Page 26: ...S Take suitable measures immediately if environmentally hazardous substances escape into the envi ronment S Inform the relevant local authorities of the damage The following environmentally hazardous substances are used Lubricants Lubricants such as grease and oils contain poisons and environmentally hazardous substances They must not be allowed to be released into the environment Disposal must be...

Page 27: ...of the chapters 3 Engine model plate Always quote the engine type 3 engine num ber 4 and factory number order number 5 in all enquiries and communications Before the engine is first commissioned you should therefore check the relevant data on the engine model plates and enter it below The engine model plates 1 and 2 are attached to the crankcase Model 3 Engine number 4 Factory number order number ...

Page 28: ...XXX 1 Model number after model code 2 Day of assembly determined internally at factory 3 Assembly sequence consecutive number on day of assembly 4 Production and equipment specific data 3 2 Explanation of model designation Model designation Explanation Example E Fuel type Natural gas biogas 32 Figure 100 132 mm bore 6 Stroke figure rounded 157 mm stroke 8 2 Number of cylinders 8 12 cylinders L Cha...

Page 29: ...h rods and rocker arms OHV Charge mixture system The charge mixture system consists of the charge mixture cooler the charge mixture manifolds the throttle valve and the air distributor pipes Gas supply line The gas supply line consisting of ball cock gas filter solenoid valves gas pressure regulator gas mixer and air filter is not supplied by MAN Engine Lubrication Force feed lubrication with two ...

Page 30: ...fety Instructions and the safety instructions in each of the chapters Flywheel housing and flywheel The flywheel housing as a connection to SAE1 Different flywheel versions can be supplied depending on the type of application Starter The electric starter is of two pin insulated design The starter can be mounted on the left or right of the en gine ...

Page 31: ...r on General Safety Instructions and the safety instructions in each of the chapters 4 3 Engine views E3262 LE202 4 3 1 Front left view 1 Vent housing for coolant 2 Data acquisition 3 Throttle valve 4 Exhaust turbocharger 5 Oil pan 6 Oil drain plug 7 Protective cover for crankshaft and vibration damper 8 Oil filter 9 Oil separator ...

Page 32: ...ns and the safety instructions in each of the chapters 4 3 2 Front right view 1 Intake manifold 2 Charge mixture cooler 3 Coolant outlet 4 Coolant inlet 5 Oil drain plug 6 Heat protection cover 7 Oil filler neck User tip The gas supply line consisting of ball cock gas filter solenoid valves gas pressure regulator gas mi xer and air filter is not supplied by MAN ...

Page 33: ...r on General Safety Instructions and the safety instructions in each of the chapters 4 4 Engine views E3268 LE212 4 4 1 Front left view 1 Oil separator 2 Vent housing for coolant 3 Data acquisition 4 Throttle valve 5 Exhaust turbocharger 6 Oil pan 7 Oil drain plug 8 Protective cover for crankshaft and vibration damper 9 Oil filter ...

Page 34: ...ctions and the safety instructions in each of the chapters 4 4 2 Front right view 1 Intake manifold 2 Charge mixture cooler 3 Coolant outlet 4 Coolant inlet 5 Oil drain plug 6 Oil dipstick 7 Oil filler neck User tip The gas supply line consisting of ball cock gas filter solenoid valves gas pressure regulator gas mi xer and air filter is not supplied by MAN ...

Page 35: ...ion in this chapter Strictly observe these instructions and act prudently to avoid accidents personal injury and property damage Personal Protective Equipment The following protective equipment must be worn S Protective Clothing S Protective Helmet S Safety Shoes S Safety Gloves 5 2 Safety instructions Heavy Suspended Loads WARNING Danger to life due to suspended loads During lifting loads can swi...

Page 36: ...e symbols and instructions on the packaging S Use lifting gear Diagonal pull not permitted Swingout of Packages being Transported WARNING Risk of injury due to transported item swinging out Transported item can cause injury and damage For this reason S Ensure that during the transport of packages no persons objects or obstacles are in the swivel range of the packages being transported Unauthorised...

Page 37: ...ing items 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 on the transportation company s packaging slip S Initiate a claims process User tip Make sure to claim each damage case as soon as it is discovered Damage claims can only be claimed within the a...

Page 38: ...and chains must be in perfect condition WARNING Danger to life due to incorrect handling of transported item Transported item can swing out tilt and or drop For this reason S Use the crane hook lugs solely for transporting the engine with gearbox S Observe the information and markings on the package concerning centre of gravity S When transporting with a crane the hook must be placed so that it is...

Page 39: ...tructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters Attachment points E3262 LE202 E3262 LE212 For lifting the engine 3 crane hook lugs 1 are attached to the engine ...

Page 40: ...tructions before starting any work This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters Attachment points E3268 LE212 E3268 LE222 For lifting the engine 3 crane hook lugs 1 are attached to the engine ...

Page 41: ...ing equipment according to the picture 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 following conditions S The forklift must be designed for the weight of the engine S The engine must be securely mounted on the pallet S The pallet must not be dama...

Page 42: ...atutory regulations ENVIRONMENTAL NOTE Incorrect disposal of packaging materials poses an environmental hazard Dispose of packing materials in an environmentally friendly manner Observe the valid local regulations If necessary contact a professional disposal company 5 6 Storage Storage of packages Store packages under the following conditions S Do not store in the open S Store in a dry and dust fr...

Page 43: ...ence Faulty in stallation can cause life threatening situations and considerable property damage For this reason S Installation and commissioning may only be performed by expert personnel trained by MAN Ground Rules WARNING Risk of injury due to improper installation and commissioning Improper installation and commissioning can cause serious personal injury or considerable property damage For this...

Page 44: ...safety instructions in each of the chapters 6 3 Engine installation 6 3 1 Interfaces between engine and plant 1 Coolant connections on charge mixture cooler 2 Exhaust turbocharger 3 Intake manifold 4 Exhaust turbocharger 5 Engine mounting 6 Coolant inlet 7 Coolant outlet 2 and 4 Mount exhaust system see page 49 3 Mount gas inlet see page 48 6 and 7 Connect cooling system see page 47 ...

Page 45: ... Instructions and the safety instructions in each of the chapters 1 Exhaust turbocharger 2 Exhaust turbocharger 3 Flywheel 4 Gas inlet When installing the engine perform the following assembly work on the interfaces between engine and plant 1 and 2 Mount exhaust system see Installation Instructions 3 Mount alternator see page 45 4 Connect gas inlet see page 48 ...

Page 46: ...tion dimensions Depending on the scope of delivery wiring diagrams layout diagrams for the resilient engine mounts etc may be required These can be obtained from MAN see page 2 for contact address NOTE Engine installation is based on the installation instructions and the installation drawing For this reason S Observe these sources of information for each of the assembly jobs listed hereafter 6 3 4...

Page 47: ...ugh space to perform the regular maintenance work specified in the maintenance schedule 6 4 1 Mounting an alternator on the flywheel housing Flywheel The connection dimensions of the flywheel 1 are indicated on the installation drawing S Remove oil grease and preservative from the flywheel Flywheel housing User tip For screw and bolt tightening torques see page 52 Information regarding the dimensi...

Page 48: ...a dial gauge held on a magnetic stand before and after flange mounting any attachments S Remove V belt protection S Position the dial gauge holder 1 with dial gauge 2 on the engine mounting so that the dial gauge tracer pin is resting on the vibration damper with a preload S Push the crankshaft towards the flywheel hou sing in axial direction until the stop is reached S Zero the dial gauge S Pull ...

Page 49: ...specially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 6 5 Connecting the cooling system 6 5 1 Connecting the engine cooling The installation drawing provides information about the connections S Connect the coolant outlet 1 S Connect the coolant inlet 2 ...

Page 50: ...pecially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters 6 6 Mounting the gas inlet Both cylinder banks merge into a central gas inlet The dimensions of the flange 1 for connecting the plant side gas inlet can be found on the installation drawing see page 97 ...

Page 51: ...eneral Safety Instructions and the safety instructions in each of the chapters 6 7 Mounting the exhaust system 6 7 1 Exhaust gas outlet on engine The dimensions of the flange 1 for connecting the plant side exhaust system can be found on the in stallation drawing see page 97 S Connect the exhaust system to the flange 1 on the exhaust turbocharger s ...

Page 52: ...e exhaust system to the engine Flexible connecting elements which allow engine movements due to the flexible engine mounting and decouple the engine from the exhaust system in terms of vibration must be installed between the engine and the exhaust system Example compensator 1 NOTE Component damage due to forces acting on the turbocharger For this reason S Exhaust gas lines must be fastened and sup...

Page 53: ...ngine and all pipe connections from and to the engine with the plant potential using ground cables In the case of dual engine plants independent wiring is required for each engine i e the engines circuits must not be linked together Batteries Separate batteries for the starter must be provided for each engine 6 8 1 Starter All MAN industrial gas engines have two pole starters The starter battery s...

Page 54: ...for 10 9 10 for 12 9 12 M4 2 5 4 0 4 5 M5 5 0 7 5 9 0 M6 9 0 13 0 15 0 M7 14 0 20 0 25 0 M8 22 0 30 0 35 0 M8x1 23 0 35 0 40 0 M10 45 0 65 0 75 0 M10x1 25 45 0 65 0 75 0 M10x1 50 0 70 0 85 0 M12 75 0 105 0 125 0 M12x1 5 75 0 110 0 130 0 M12x1 25 80 0 115 0 135 0 M14 115 0 170 0 200 0 M14x1 5 125 0 185 0 215 0 M16 180 0 260 0 310 0 M16x1 5 190 0 280 0 330 0 M18 260 0 370 0 430 0 M18x2 270 0 290 0 4...

Page 55: ... system S Starting of the engine S A test run with measurement and archiving of important data In order to perform first commissioning personnel require specific knowledge and skills as well as special equipment First commissioning may therefore only be performed by persons or workshops authorised and certified by MAN Nuremberg NOTE Incorrectly performed first commissioning results in operating fa...

Page 56: ...he gas system are all to be performed 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 deviations from this will negatively influence the output power the engine efficiency and the exhaust emissions The requirements on the quality of gas are specified in MAN data sheet Minimum requireme...

Page 57: ...is to be filled with a mixture of tap water and antifreeze ethylene glycol or an ticorrosion agent Coolant must be filled according to 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 may only be filled at the filler neck S Remove cap S Slowly fill ...

Page 58: ...h of the chapters 6 11 3 Filling Engine Oil NOTE Risk of damage due to incorrect oil quantity Engine damage For this reason S Never add more than the indicated oil quantity S Ensure that the oil level is correct S Observe the min max mark on the oil dipstick 1 Unscrew the cap 1 2 Slowly fill engine oil into the filler neck For oil filling capacity see Technical Data page 92 3 Screw the cap 1 back ...

Page 59: ...nal Protective Equipment The following protective equipment must be worn S Protective Clothing S Safety Shoes S Safety Gloves 7 2 Safety instructions Personnel S Operation of the engine may only be performed by instructed personnel or by trained qualified per sonnel Ground Rules WARNING Danger due to incorrect operation Incorrect operation can lead to serious injury and damage For this reason S Pe...

Page 60: ... checks regularly S Remedy minor faults or malfunctions immediately A basic requirement for trouble free operation is the provision of service products that have been approved by MAN Prior to each operation check the fuel level coolant level and oil level Top up the diesel fuel coolant and oil as necessary NOTE The liability for material defects no longer applies if non approved fuels lubricants a...

Page 61: ...heck the coolant level as indicated in the manufacturer s operating instructions 7 3 3 Topping up the coolant WARNING Risk of damage due to excessive temperature difference Engine damage For this reason S Do not fill with cold coolant S Allow the engine to cool down User tip The cooling system is not included in MAN s scope of delivery Add coolant according to the manufacturer s operating manual E...

Page 62: ... S Perform the oil level check with the engine in a horizontal position having waited around 5 minutes after stopping the machine Stop the engine Perform the oil level check after around 5 minutes S Pull out the oil dipstick 1 S Wipe the oil dipstick 1 with a clean lint free cloth S Reinsert the oil dipstick 1 as far as the stop S Pull the oil dipstick 1 back out The oil level should be between bo...

Page 63: ... Engine damage For this reason S Never add more than the indicated oil quantity S Ensure that the oil level is correct S Observe the min max mark on the oil dipstick ENVIRONMENTAL NOTE Take care not to spill engine oil when adding it Engine oil is not allowed to enter the ground or bodies of water S Unscrew the cap 1 S Add fresh engine oil at the oil filler neck 1 The oil level should be between b...

Page 64: ... serious or fatal injuries For this reason S Before starting engine check whether all protective equipment has been properly installed S Remove tools and aids out of the hazard area S Before starting make sure that no one is in the engine s danger area User tip A starting sequence may consist of max 3 successive starting attempts each lasting 12 seconds If no engine speed signal is detected within...

Page 65: ...mits are exceeded or not reached the engine will be automatically shut off 7 4 3 Emergency shutdown An emergency off button for shutting down the system in an emergency must be installed for each engine 7 4 4 Stopping The load is reduced by means of ramp control from 100 to 0 over a period of at least 3 minutes thus minimising the thermal load on the engine block WARNING Risk of injury due to high...

Page 66: ...n be visualised on display devices via a CAN interface The display devices are not included in the scope of delivery The engine operating parame ters can be saved in an Excel file The following engine parameters can be called up via the CAN interface S Engine oil temperature left and right S Engine oil pressure left and right S Exhaust temperature upstream of turbine left and right S Coolant inlet...

Page 67: ... WARNING Risk of injury due to improperly performed maintenance Improper maintenance can case serious injuries or considerable property damage For this reason S Ensure that the engine cannot be started by unauthorised persons S Perform all maintenance steps as indicated in these instructions S Ensure adequate work space before starting any work S Make sure work space is kept clean and orderly NOTE...

Page 68: ...ction precautions when handling used engine oil Filter inserts and filter cartridges S Filter inserts and filter cartridges e g oil and fuel filters are hazardous waste and must be disposed of properly Observe the regulations issued by the responsible local authorities Batteries S Used batteries contain hazardous substances Batteries must be taken back by the distributor and properly disposed of o...

Page 69: ...E2 E3 R1 R2 R3 20 50 or after commissioning and R2 R3 x 400 2 800 x 1600 x x 2400 x 3200 x x 4000 x 4800 x x 5600 x 6400 x x 7200 x 8000 x x 8800 x 9600 x x 10 400 x 11 200 x x 12 000 x 12 800 x x 13 600 x 14 400 x x 15 000 x 15 200 x 16 000 x x 16 800 x 17 600 x x 18 400 x 19 200 x x 20 000 x 20 800 x x 21 600 x 22 400 x x 23 200 x 24 000 x x 24 800 x 25 000 x 25 600 x x 26 400 x 1 The maintenanc...

Page 70: ...hours at 1500 rpm 1 Scope of maintenance operations Service performed Stamp Signature E1 E2 E3 R1 R2 R3 27 200 x x 28 000 x 28 800 x x 29 600 x 30 000 x 30 400 x x 31 200 x 32 000 x x 32 800 x 33 600 x x 34 400 x 35 200 x x 36 000 x 36 800 x x 37 600 x 38 400 x x 39 200 x 40 000 x x 40 800 x 41 600 x x 42 400 x 43 200 x x 44 000 x 44 800 x x 45 000 x 45 600 x 46 400 x x 47 200 x 48 000 x x 48 800 ...

Page 71: ... spark plugs S Measure compression S Check set throttle valve S Clean check gas filter S Clean check air filter S Clean check impulse sensor S Check coolant concentration S Check change oil separator S Check ignition timing S Check cooling circuit system pressure S Measure crankcase pressure S Measure exhaust back pressure inclu ding catalytic converter S Check clean mixture cooler S Check emissio...

Page 72: ...terval after operating hours at 1500 rpm 1 Scope of maintenance operations Service performed Stamp Signature E1 E2 E3 R1 R2 R3 20 50 or after commissioning and R2 R3 x 400 2 x 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 10400 x 10800 x 11200 x x 11600 x 12000 x 12...

Page 73: ...e performed Stamp Signature E1 E2 E3 R1 R2 R3 15600 x 16000 x x 16400 x 16800 x 17200 x 17600 x x 18000 x 18400 x 18800 x 19200 x x 19600 x 20000 x 20400 x 20800 x x 21200 x 21600 x 22000 x 22400 x x 22800 x 23200 x 23600 x 24000 x x 24400 x 24800 x 25000 x 25200 x 25600 x x 26000 x 26400 x 26800 x 1 The maintenance intervals depend on the operating conditions and the quality of the gas For scope ...

Page 74: ...1 Scope of maintenance operations Service performed Stamp Signature E1 E2 E3 R1 R2 R3 27200 x x 27600 x 28000 x 28400 x 28800 x x 29200 x 29600 x 30000 x 30400 x x 30800 x 31200 x 31600 x 32000 x x 32400 x 32800 x 33600 x x 34000 x 34400 x 35200 x x 35600 x 36000 x 36800 x x 37600 x 38000 x 38400 x x 38800 x 39200 x 39600 x 40000 x x 40400 x 40800 x 41200 x 41600 x 41600 x x 42000 x 42400 x 42800 ...

Page 75: ...s at 1500 rpm 1 Scope of maintenance operations Service performed Stamp Signature E1 E2 E3 R1 R2 R3 45600 x 46000 x 46400 x x 46800 x 47200 x 47600 x 48000 x x 48400 x 48800 x 49200 x 49600 x x 50000 x x 50400 x 50800 x 51200 x x 51600 x 52000 x 52400 x 52600 x x 53000 x 53400 x 53800 x 53200 x x 53600 x 54000 x 54400 x 54800 x x 55200 x 55600 x 56000 x 56400 x x 56800 x 57200 x 57600 x 58000 x x ...

Page 76: ...an check gas filter S Clean check air filter S Clean check impulse sensor S Check coolant concentration S Check change oil separator S Check ignition timing S Check cooling circuit system pressure S Measure crankcase pressure S Measure exhaust back pressure inclu ding catalytic converter S Check clean mixture cooler S Check emissions and oxygen sensor S Check calibrate sensors S Check exhaust syst...

Page 77: ... screws using protective gloves User tip Use a container with a capacity of at least 100 litres for the oil change User tip Replace the oil filter inserts each time the engine oil is changed Drain engine oil Drain engine oil with engine at operating temperature 1 Loosen the oil filter cover 1 and unscrew by 2 3 turns The engine oil then flows out of the oil module into the oil pan 3 Position the c...

Page 78: ... Change Oil Filter Element 1 Unscrew oil filter cover 1 with O ring 2 and oil filter insert 3 and then remove 2 Remove oil filter insert 3 and O ring 2 from oil filter cover 1 3 Clean oil filter cover 1 4 Fit new O ring 2 on oil filter cover 1 5 Insert new oil filter insert 3 into oil filter cover 1 6 Insert oil filter cover 1 with oil filter insert 3 into the oil module and then tighten Tightenin...

Page 79: ...Risk of damage due to lack of oil pressure Engine damage For this reason S If the engine has been running for around 10 seconds and the oil is not pressurised stop the engine immediately S Determine the cause of the problem ENVIRONMENTAL NOTE Take care not to spill engine oil when adding it Engine oil is not allowed to enter the ground or bodies of water 1 Unscrew cap 1 2 Add fresh engine oil at t...

Page 80: ...son S Perform the oil level check with the engine in a horizontal position having waited around 5 minutes after stopping the machine Stop the engine Perform the oil level check after around 5 minutes S Pull the oil dipstick 1 out S Wipe the oil dipstick 1 with a clean lint free cloth S Reinsert the oil dipstick 1 as far as the stop S Pull the oil dipstick 1 back out The oil level should be between...

Page 81: ... change ENVIRONMENTAL NOTE Risk of environmental pollution due to incorrect handling of service products Coolant gets hot during operation and causes scalding if touched For this reason S Take suitable measures immediately if environmentally hazardous fuels lubricants or coolants escape into the environment S Inform the relevant local authorities of the damage Drain coolant 1 Briefly open and clos...

Page 82: ...form the relevant local authorities of the damage Fill the cooling system of the engine with a mixture of tap water and ethylene glycol antifreeze agent or an ticorrosion agent For suitable antifreeze agents see approved Fuels Lubricants and Coolants according to MAN 324 NF and MAN 248 Coolant may only be filled at the filler neck 1 Remove cap 2 Slowly fill coolant 3 Close expansion tank 4 Run eng...

Page 83: ...ety information in this chapter Strictly observe these instructions and act prudently to avoid accidents personal injury and property damage 9 2 Safety instructions Personnel Engine faults may only be rectified by specially trained qualified personnel or by the manufacturer of the entire system Personal Protective Equipment The following protective equipment must be worn S Protective Clothing S Sa...

Page 84: ...lever 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 information at Starter D Clearance incorrectly set D A faulty tank system can cause oil to get into the pressure gas system Clean entire system D Remove objects that interfere with the movement of the fan...

Page 85: ...fluctua 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 Tachometer faulty D Gas pressure regulator faulty D Oxygen sensor faulty D Remedy from manufacturer ser vice Poor performance D Spark plug faulty D Ignition cable faulty D Ignition coil faulty D Ignition ti...

Page 86: ...sion tank 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 Remedy from manufacturer ser vice Lube oil pressure too low D Oil level in oil pan too low D Engine temperature to high D Oil pressure indicator faulty D Selected oil viscosity is inappropriate for ambient tempe...

Page 87: ... Exhaust gas recirculation cooler dirty D See Fuels Lubricants and Coo lants D Check intake vacuum D Remedy from manufacturer ser vice D Check exhaust back pressure Blue smoke D Lube oil penetrates into combustion chamber pistons piston rings worn or piston rings broken D Turbine and compressor impeller in tur bocharger dirty rough running out of balance D Valve stem guide worn D Remedy from manuf...

Page 88: ... to 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 terminal or carbon brushes are short circuited to ground D Carbon brushes stick or have poor con tact D Pinion gear or starter ring gear are very dirty or damaged D Solenoid switch faulty D Overrunning cl...

Page 89: ...e equipment must be worn S Protective Clothing S Safety Shoes S Safety Gloves 10 2 Safety instructions Personnel Decommissioning and recommissioning of the engine may only be performed by trained and qualified per sonnel Ground Rules WARNING Risk of injury and damage due to untrained personnel For this reason S Ensure that the engine cannot be started by unauthorised persons S Perform all work ste...

Page 90: ...tained from our After Sales Service department at the Nuremberg plant User tip A proper and careful recommissioning of new or operated engines has a great impact on the operating safety and remaining life of the engines In general the goal is to preserve the decommissioned engines or new engines after the factory tests If the engine is not preserved before decommissioning there is a risk of corros...

Page 91: ...unning operate engine 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 After a max of 25 operating hours drain preservation oil from engine and change oil filter fill engine with fresh approve engine oil 10 4 2 Commissioning of non preserved engines ...

Page 92: ... and recommissioning 90 Carefully read these 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 ...

Page 93: ... each of the chapters 11 Technical data 11 1 Dimensions and weight 11 1 1 E3268 LE212 LE222 Specification Value Unit Weight dry E3268 LE212 LE222 1432 kg A 1372 mm B 1245 mm C 1470 mm 11 1 2 E3262 LE202 LE212 Specification Value Unit Weight dry E3262 LE202 LE212 1849 kg A 1748 mm B 1243 mm C 1500 mm 11 2 Installation location and space requirements Observe these installation instructions ...

Page 94: ...Control comply with natural gas mode E3268LE212 370 kW bei 1500 1 min The output figures apply to operation with natural gas with a calorific value of 10 kWh m3 and a me thane number 80 If the calorific value is lower the output will be reduced accordingly Consultation with MAN required Output if German Technical In structions on Air Quality Control comply with biogas mode E3268 LE222 370 kW bei 1...

Page 95: ...268 LE 222 1800 rpm German Technical Instructions on Air Quality Con trol 20 1 Engine lubrication Force feed lubrication Lubrication oil pressure during ope ration depends on engine speed oil temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter 2 oil filters Full flow filters each with 1paper filter cartridge Oil capacity in oil sump litres max 9...

Page 96: ... 1 min 580 kW bei 1800 1 min The output figures apply to operation with natural gas with a calorific value of 10 kWh m3 and a me thane number 80 If the calorific value is lower the output will be reduced accordingly Consultation with MAN required Output if German Technical In structions on Air Quality Control comply with biogas mode E3262 LE202 550 kW bei 1500 1 min 580 kW bei 1800 1 min E3262 LE2...

Page 97: ...3262 LE 212 1500 rpm German Technical Instructions on Air Quality Con trol 16 1 20 1 1800 rpm German Technical Instructions on Air Quality Con trol 20 1 20 1 Engine lubrication Force feed lubrication Lubrication oil pressure during ope ration depends on engine speed oil temperature and engine load must be monitored via an oil pressure monitor or a display device Oil filter 2 oil filters Full flow ...

Page 98: ...nical Data 96 Carefully read these 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 ...

Page 99: ...E202 LE212 97 Carefully read these 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 Installation drawing 12 1 Installation drawing E3268 LE212 LE222 ...

Page 100: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 98 Carefully read these 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 ...

Page 101: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 99 Carefully read these 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 ...

Page 102: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 100 Carefully read these 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 ...

Page 103: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 101 Carefully read these 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 ...

Page 104: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 102 Carefully read these 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 ...

Page 105: ...E222 E3262 LE202 LE212 103 Carefully read these 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 Installation drawing E3262 LE202 LE212 ...

Page 106: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 104 Carefully read these 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 ...

Page 107: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 105 Carefully read these 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 ...

Page 108: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 106 Carefully read these 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 ...

Page 109: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 107 Carefully read these 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 ...

Page 110: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 108 Carefully read these 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 ...

Page 111: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 109 Carefully read these 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 ...

Page 112: ... Engines E3268 LE212 LE222 E3262 LE202 LE212 110 Carefully read these 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 ...

Page 113: ...s 111 Carefully read these 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 13Indices ...

Page 114: ...network for control units data bus system in vehicle Controller Area Network cm3 Cubic centimetre evtl Possibly Fa Company ggf If necessary h Hours kg Kilogram Tl Terminal kW Kilowatt LCD Liquid Crystal Display LED Light Emitting Diode m Metre MAX Maximum min Minutes MIN Minimum mm Millimetre Nm Newton meter TDC Top dead centre UBat Battery voltage usw etc BDC Bottom dead centre V Volt W Watt e g ...

Page 115: ... 62 Engine room Engine accessibility 46 Engine views 29 31 Environmental protection 24 Exhaust system exhaust gas outlet on engine 50 Exhaust system mounting 50 F Faults 82 Filling Engine Oil 57 78 Flywheel 28 Flywheel housing 28 Foreword 7 G Gas filter 55 Gas inlet mounting 49 Gas quality checking 59 Gas supply opening 59 Gas system 55 Gearbox Mounting 46 I Information about the Operating Instruc...

Page 116: ...apters R Recommissioning of decommissioned engines 90 Response to danger 21 S Safety equipment 20 Screw and bolt connections 45 Signs 22 Spare parts 10 Starter 52 Starting 63 Stopping 64 Storage 41 Symbol explanation 8 T Technical data 92 Temporary decommissioning 89 Transport 37 Transport inspection 36 Transport packaging and storage 34 Troubleshooting chart 83 W Warranty provisions 11 Weights 23...

Page 117: ......

Page 118: ...MAN Truck Bus a member of the MAN Group MAN Truck Bus AG Vogelweiherstraße 33 90441 Nuremberg Germany man engines man eu www man engines com ...

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