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MAN Engines

A Division of MAN Truck & Bus

Assembly Instruction

MAN Industrial Gas Engines

E0834 LE302

/312/322

/ E0836 LE202

/302

Содержание E0834 LE312

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

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Страница 3: ...Assembly Instructions MAN Industrial Gas Engines E0834 LE302 312 322 E0836 LE202 302 50 99496 8001 Translation of the original assembly instructions Version 08...

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Страница 5: ...rty rights Any misuse 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 T...

Страница 6: ...Instructions 12 2 3 Modifications and Conversions to the Engine 12 2 4 Responsibility of the Operator 12 2 5 Personnel Requirements 13 2 5 1 Qualifications 13 2 5 2 Unauthorised Persons 13 2 5 3 Instr...

Страница 7: ...Coolant Lines for Mixture Cooling 40 5 7 Installing Intake System 41 5 7 1 Installing Gas Mixer E0836LE202 41 5 7 2 Installing Gas Mixer E0836LE302 41 5 7 3 Installing Actuation Linkage for Throttle...

Страница 8: ...alled into the plant cogeneration power station power generator All open questions about the installation of the engine are to be clarified during planning project phase The scope of delivery will als...

Страница 9: ...hich 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 hazardou...

Страница 10: ...eviate 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...

Страница 11: ...hese parts have been established specifically for the engines We cannot assess and vouch for other non MAN products despite ongoing market observations WARNING Risk of injury from incorrect spare part...

Страница 12: ...ly Instructions and any accompanying supplier assembly 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...

Страница 13: ...erns the compliance with the applicable legal exhaust emission limits Furthermore the engine operating parameters according to the technical data sheets currently in effect must also be adhered to The...

Страница 14: ...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 regu...

Страница 15: ...ical systems due to his her technical education training knowledge and experiences as well as knowledge of the respective standards and regulations and can recognise and avoid any possible dangers The...

Страница 16: ...narrow sleeves and with no protruding 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 He...

Страница 17: ...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...

Страница 18: ...ammable 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 observed...

Страница 19: ...ts contain substances that are hazardous to your health Contact with these substances can lead to serious poisoning allergies skin irritations and damage to eyes For this reason S Observe the safety s...

Страница 20: ...r 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 fi...

Страница 21: ...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...

Страница 22: ...st 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 R...

Страница 23: ...legible 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 condition...

Страница 24: ...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...

Страница 25: ...y only be used in accordance with their use laid down in the planning stage also see chapter General Safety Instructions section 2 1 Therefore it is important for the plant manufacturer technician to...

Страница 26: ...o 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 Declaration Example E Fuel type...

Страница 27: ...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...

Страница 28: ...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...

Страница 29: ...on Check the delivery for missing 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 d...

Страница 30: ...instructions in each of the chapters 4 4 Transport Lifting Points There are 2 lifting lugs 1 and 2 installed on the engine WARNING Risk of death caused by the load falling During lifting operations l...

Страница 31: ...multipoint lifting 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...

Страница 32: ...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...

Страница 33: ...ed personnel WARNING Danger caused by faulty installation Installation requires trained qualified personnel with sufficient experience Faulty installation can cause life threatening situations and con...

Страница 34: ...d the Assembly 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 5 3 Interfaces between...

Страница 35: ...he engine and the plant when installing the engine 1 Connect starter electrical system see page 44 2 Connect coolant lines for mixture cooling see page 40 3 Connect oil pressure sensor see page 46 4 B...

Страница 36: ...d the Assembly 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 5 3 Interfaces between...

Страница 37: ...emperature sensor see page 46 9 Install generator see page 37 10 Install exhaust system see page 42 11 Install gas mixer see page 41 5 3 1 Installation drawing IMPORTANT The installation drawing forms...

Страница 38: ...ters 5 4 Completing the Engine and Assembling the Plant 5 4 1 Installing Ignition System NOTE The engines are delivered from the factory with no ignition system installed except for the spark plugs Th...

Страница 39: ...the installation instructions of the relevant manufacturer Flywheel The interface dimensions of the flywheel are indicated in the installation drawing Remove any oil grease or conservation agents from...

Страница 40: ...ng a dial indicator held by a magnetic stand The crankshaft axial play is to be measured before and after installing the generator or other assemblies onto the engine SRemove crankshaft cover S Place...

Страница 41: ...quipment is installed on the engine for safety reasons to prevent the touching of hot or rotating parts contact protection of exhaust manifold hot and on the front side of the engine rotating cranksha...

Страница 42: ...es the implementation of the coolant connections E0834 LE302 1 Connect coolant inlet 1 2 Connect coolant outlet 2 E0836 LE202 1 Connect coolant inlet 1 2 Connect coolant outlet 2 5 6 2 Connecting Cool...

Страница 43: ...specified in the installation drawing 5 7 2 Installing Gas Mixer E0836LE302 The location of the gas inlet at the engine 1 and the drilling pattern of the flange are both specified in the installation...

Страница 44: ...LE202 Install exhaust manifold at turbocharger 1 There is a counter flange weld flange at the exhaust outlet of the turbocharger 2 to connect the exhaust system The dimensions are specified in the ins...

Страница 45: ...he position of the guide pipe 4 determines the flow direction of the exhaust Install exhaust pipe bellows under tensile prestress 2 A tensile prestress means that before the bellows are bolted the dis...

Страница 46: ...Engine models E0834 LE302 E0836 LE202 Starter type Bosch Rated voltage V 24 Rated output kW 4 Permitted battery capacity1 Ah 66 88 110 Starter short circuit current A at 20_C with a feed cable of 1mW...

Страница 47: ...302 E0836 LE202 E0836 LE302 Starter type Mitsubishi Rated voltage V 24 Rated output kW 5 Permitted battery capacity1 Ah 66 88 110 Starter short circuit current A at 20_C with a feed cable of 1mW m 940...

Страница 48: ...safety instructions in each of the chapters 5 9 2 Connecting Sensors NOTE The location of sensors on the engine is shown in the installation drawing Each sensor s drawing gives information on the pin...

Страница 49: ...arameters Sensors that are not connected or are inoperative can lead to damage to the engine For this reason S Connect sensors to the engine monitoring system and check for proper operation 5 9 3 Safe...

Страница 50: ...2 5 4 0 4 5 M5 5 0 8 0 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 67 0 75 0 M10x1 50 0 70 0 85 0 M12 75 0 110 0 125 0 M12x1 5 75 0 11...

Страница 51: ...f injury caused by improper commissioning Improper commissioning can case serious injuries or considerable property damage For this reason S Before commissioning the engine carefully read the Operatin...

Страница 52: ...or this reason S Do not let engine oil spill while filling Do not let engine oil leak out onto the ground or into bodies of water The engines are as a rule supplied without oil Fill engine with lubric...

Страница 53: ...e safety instructions in each of the chapters 6 1 2 Checking Engine Oil Level Check engine oil level 30 minutes after filling engine with oil S Remove oil dipstick S Wipe off with lint free cloth S Re...

Страница 54: ...d Coolants for MAN Industrial Gas Engines The amount of coolant to be prepared is given by the total filling capacity of the cooling system For the design of the engine cooling system see the installa...

Страница 55: ...in the cooling circuit 0 4 0 5 bar static and is maintained after engine is turned off S The required coolant flow rate is achieved in the coolant circuit at max permissible coolant temperature and w...

Страница 56: ...ocharger will have distorted results by approx 20 mbar The static pressure is measured i e the measuring connection must be flush with the inner pipe walls Measurement of the head pressure and measure...

Страница 57: ...Installation Drawings of the Engine E0834 LE302 55 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 58: ...Installation Drawings of the Engine E0834 LE302 56 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 59: ...Installation Drawings of the Engine E0834 LE302 57 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 60: ...Installation Drawings of the Engine E0834 LE302 58 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 61: ...Installation Drawings of the Engine E0834 LE302 59 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 62: ...Installation Drawings of the Engine E0834 LE302 60 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 63: ...Installation Drawings of the Engine E0834 LE302 61 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 64: ...Installation Drawings of the Engine E0834 LE302 62 Identification no of installation drawing 51 00504 7109 drawn September 03 2012...

Страница 65: ...Installation Drawings of the Engine E0836 LE202 63 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 66: ...Installation Drawings of the Engine E0836 LE202 64 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 67: ...Installation Drawings of the Engine E0836 LE202 65 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 68: ...Installation Drawings of the Engine E0836 LE202 66 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 69: ...Installation Drawings of the Engine E0836 LE202 67 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 70: ...Installation Drawings of the Engine E0836 LE202 68 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 71: ...Installation Drawings of the Engine E0836 LE202 69 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 72: ...Installation Drawings of the Engine E0836 LE202 70 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 73: ...Installation Drawings of the Engine E0836 LE302 71 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 74: ...Installation Drawings of the Engine E0836 LE302 72 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 75: ...Installation Drawings of the Engine E0836 LE302 73 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 76: ...Installation Drawings of the Engine E0836 LE302 74 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 77: ...Installation Drawings of the Engine E0836 LE302 75 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 78: ...Installation Drawings of the Engine E0836 LE302 76 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 79: ...Installation Drawings of the Engine E0836 LE302 77 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 80: ...Installation Drawings of the Engine E0836 LE302 78 Identification no of installation drawing 51 00506 7817 B drawn November 3 2005...

Страница 81: ......

Страница 82: ...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...

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