Man E 0824 E 301 Operating Instructions Manual
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Man E 0824 E 301 Operating Instructions Manual

Man E 0824 E 301 Operating Instructions Manual

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Summary of Contents for Man E 0824 E 301

  • Page 3 It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any disturbances and with the performance of checking, setting, and re- pair work.

  • Page 4: Table Of Contents

    Contents Page Declaration ..............Nameplates .

  • Page 5: Declaration

    In accordance with Article 4, paragraph 2, in conjunction with Appendix II, section B, of Directive 89/392/EEC, version 93/44/EEC MAN Nutzfahrzeuge Aktiengesellschaft, hereby declares that the engine described below is destined for installation in a machine as defined in the EC directive on machines.

  • Page 6: Nameplates

    ........MAN Nutzfahrzeuge Aktiengesellschaft Motor-Nr.

  • Page 7: Safety Precautions For Handling Gaseous Fuels

    Safety precautions for handling gaseous fuels Gaseous fuels consist basically of methane, propane, butane, traces of higher–order hy- drocarbons and of inert components such as carbon dioxide and nitrogen. When commissioning, starting and operating the gas engine, observe the following without fail: D Smoking or the use of a naked flame are prohibited.
  • Page 8 – risk of burns. Ë Ë D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.
  • Page 9 Safety regulations D Keep vicinity of engine, ladders and stairways free of oil and grease. Accidents caused by slipping can have serious consequences. During maintenance and care D Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scald- ing.
  • Page 10 Safety regulations When carrying out checking, setting and repair work D Checking, setting and repair work must be carried out by authorized personnel only. D Use only tools which are in satisfactory condition. Worn open-end wrench slip, which could lead to injury. D When the engine is hanging on a crane, no-one must be allowed to stand or pass under it.
  • Page 11 If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage. Use only genuine MAN spare parts. MAN will accept no responsibility for damage result- ing from the installation of other parts which are supposedly “just as good”.
  • Page 12 Safety regulations 3. Regulations designed to prevent pollution Engine oil and filter elements / cartridges, fuel / fuel filter D Take old oil only to an old oil collection point. D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.
  • Page 13 Safety regulations Ensure that used engine oil is disposed of properly – Engine oil can endanger the water supply – 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.

  • Page 14: Commissioning And Operation

    Commissioning and operation Engine views E 0824 E 301 / 302...
  • Page 15 10 Pulse recorder for ignition system (accessory) 11 Oil pressure transmitter 12 Starter Note: The gas tract, which consists of ball valve, gas filter, solenoid valve, gas pressure governor, gas mixer and air filter, is not part of MAN’s extent of delivery.

  • Page 16: Engine Views E 0826 E 302

    Commissioning and operation Engine views E 0826 E 301 / 302...
  • Page 17 10 Pulse recorder for ignition system (accessory) 11 Oil pressure transmitter 12 Starter Note: The gas tract, which consists of ball valve, gas filter, solenoid valve, gas pressure governor, gas mixer and air filter, is not part of MAN’s extent of delivery.

  • Page 18: First Commissioning

    For the quantity required see “Technical Data”. Note: Use approved service products only (see “Fuels, Lubricants and Coolants for MAN Industrial Gas Engines”); non-compliance renders warranty claims against manufac- turer null and void. Ensure outmost cleanliness when handling lubricants and coolants.
  • Page 19 Commissioning and operation Checking oil level Check the oil level at least 5 minutes have passed since the machine was 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 should be between the two notches in the dipstick and must never fall...

  • Page 20: The Control Unit (Option)

    Commissioning and operation The control unit (option) Purpose of the control unit The control unit records the respective crank angle of the engine at very short in- tervals and calculates from these data the time for triggering the ignition pulse for each and every cylinder.
  • Page 21 Commissioning and operation Connecting the control unit Two cable harnesses are supplied with the engine: D The cable harness for the 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 socket.

  • Page 22: Starting

    D Operate starter to crank engine with gas supply shut off and without ignition for a few seconds (air purge). D Starting control will close throttle valve in gas mixer (gas mixer is not part of MAN’s ex- tent of delivery).

  • Page 23: System Monitoring

    Commissioning and operation System monitoring Caution: In the event of faults have their cause immediately ascertained and rectified so that no major damage will occur. During operation the oil pressure of the engine lubrication and the coolant temperature are to be monitored. If the monitoring devices indicate a drop in lube oil pressure or coolant excess tempera- ture, the engine is to be switched off immediately.

  • Page 24: Maintenance And Care

    Maintenance and care Lubrication system Draining of engine oil and changing of filters Caution: Used oil and oil filter cartridges are dangerous waste. Observe safety regulations to prevent damage to the environment. When engine is at operating temperature, remove oil drain plug from oil pan and let old oil drain out completely.
  • Page 25 Maintenance and care Refilling with 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 engine. Fill up with fresh engine oil via oil filler neck on cylinder head cover.

  • Page 26: Cooling System

    Make 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 fitted to drain plug) and take off caps.
  • Page 27 (see “Fuel, Lu- bricants and Coolants for MAN Industrial Gas Engines”). Coolant must be added in accordance with the filling instructions issued by the manufacturer of the block-type thermal power plant.
  • Page 28 5 minutes, and flush with tap water until the discharging water is clear D Fill cooling circuit with a mixture of potable tap water and anti-freeze with 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 fluid to spill over.

  • Page 29: Spark Plugs

    Maintenance and care Spark plugs Special spark plugs have been developed for industrial gas engines in continuous operation. Use only the plugs specified in the ”Technical Data”. We recommend that you do not adjust the spark gap on these special plugs (see “Technical Data”).

  • Page 30: Air Filter

    Maintenance and care Air filter The air filter is not part and parcel of MAN’s extent of delivery. Concerning maintenance and cleaning work, the regulations of the cogeneration-plant manufacturer are to be heeded. Starter motor Check that the electric cables are properly fastened and that contacts and plug connec- tions are secure.

  • Page 31: Checking And Setting

    Checking and setting Adjusting ignition timing Checking ignition timing Ignition timing should be checked every 2,000 hours of operation. Open cover on flywheel housing (arrow). Before the first cylinder reaches TDC, you will see angle markings on the flywheel. These range from 40° before TDC to 0°. There is a reference edge on the flywheel housing to act as a corresponding marker.
  • Page 32 Checking and setting Adjusting the ignition timing The ignition point is adjusted at the control unit (accessories). D Unscrew the cover from the control unit. D Start engine. D Point stroboscopic lamp at scale on fly- wheel and the corresponding marker. D Adjust the control unit’s upper potentio- meter (screwdriver point in the upper figure) until the 12_ marking on the fly-...

  • Page 33: Adjusting The Overspeed Setting

    Checking and setting Adjusting the overspeed setting To protect the engine from mechanical damage if the governor fails – which would allow an uncontrolled increase in engine speed – there is a facility for set- ting a maximum speed which cannot be exceeded.

  • Page 34: Adjusting Valve Clearances

    TDC and the rockers are relieved of load. The valves of the synchronous cylinder are then on overlap. E 0824 E 301 / 302 Valves rocking on cylinder Adjust valves on cylinder E 0826 E 301 / 302...
  • Page 35 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 36: Technical Data

    Technical Data Model E 0824 E 301 / 302 Design in-line, vertical Cycle 4-stroke Otto-cycle Number of cylinders Bore 108 mm Stroke 125 mm Swept volume 4,580 cm Compression ratio 12,5 : 1 Speed 1,500 rpm Rating 45 kW Blocked ISO standard output as per ISO 3046 / part 7...
  • Page 37 Technical Data Ignition system 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 Electrode gap (when new)
  • Page 38 Technical Data Model E 0826 E 301 / 302 Design in-line, vertical Cycle 4-stroke Otto-cycle Number of cylinders Bore 108 mm Stroke 125 mm Swept volume 6,870 cm Compression ratio 12,5 : 1 Speed 1,500 rpm Rating 70 kW Blocked ISO standard output as per ISO 3046 / part 7 Standard reference conditions: air temperature 298 K, air pressure 1,000 mbar, humidity 30% for operation with natural gas (group H) with calorific value H methane number  80...
  • Page 39 Technical Data Ignition system 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 Electrode gap (when new)

  • Page 40: Maintenance Chart

    Maintenance chart ALWAYS COMPLY WITH SAFETY REGULATIONS! Maintenance cycles * Maintenance jobs Maintenance jobs 1 2 3 4 5 6 7 8 Check coolant level and oil level in engine Change engine oil in sump Change oil filter cartridge Check that removable unions (bolts, hose clips, pipe fittings) are firmly in position and, if necessary, retighten Service the air cleaner (earlier if severe operating conditions demand it)

  • Page 41: Circuit Diagrams

    Circuit diagrams...

  • Page 42: Cable Harness For The Input Signals To The Control Unit

    Cable harness for the input signals to the control unit for E 0824 E and E 0826 E engines 24 V – 0-5V (Ignition timer) 10-30 V – 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 Interference relay (eg for switching off gas tract)

  • Page 43: Cable Harness For The Output Signals From The Control Unit

    Cable harness for the output signals from the control unit for E 0824 E engines Cylinder – – – – 1, 2, 3, 4 Ignition coils of the respective cylinders D brown (cylinder 2) (the 1 cylinder is located at the non-flywheel end) E blue (not required in 4-cyl.

  • Page 44: Cable Harness For The Output Signals From The Control Unit

    Cable harness for the output signals from the control unit for E 0826 E engines cylinder – – – – – – 1, 2, 3, 4, 5, 6 Ignition coils of the respective cylinders D brown (cylinder 6) (the 1 cylinder is located at the non-flywheel end) E blue (cylinder 2) F orange (cylinder 4)
  • Page 45 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 46 ......Technical Data Engine views E 0824 E 301 ....34–35 E 0824 E .

This manual is also suitable for:

E 0824 e 302E 0826 e 301E 0826 e 302

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