Man E 2842 E Operating Instructions Manual
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Man E 2842 E Operating Instructions Manual

Man E 2842 E Operating Instructions Manual

Industrial gas engines
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Summary of Contents for Man E 2842 E

  • 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 repair work.

  • Page 4: Table Of Contents

    Technical information Engine views E 2842 E ........... .

  • 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

    ..............delivered on ..............installed on ..............2152 Enter 14-digit serial number (is used in the MAN Nutzfahrzeuge Aktiengesellschaft spare parts catalog to distinguish between spare parts). Motor-Nr. / Engine No. NI/II 49 R- In all your correspondence please always quote engine model, serial number and job number (Order number).

  • Page 7: Safety Regulations

    D Before putting the engine into operation for the first time, read the operating instruc- tions carefully and familiarize yourself with the ”critical” points. If you are unsure, ask your MAN representative. D For reasons of safety we recommend you attach a notice to the door of the engine...
  • Page 8 Safety regulations During maintenance and care D Always carry out maintenance work when the engine is switched off. D Change the oil when the engines is warm from operation. Caution: There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare hands.
  • Page 9 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 10 Safety regulations 3. Regulations designed to prevent pollution Engine oil, filter elements D Take old oil only to an old oil collection point. D Take strict precautions to ensure that oil does not get into the drains or into the ground.
  • Page 11 Safety regulations D After washing apply a fatty skin cream to the skin. D Change oil-soaked clothing and shoes. D Do not put oily rags into your pockets. 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.

  • Page 12: Technical Information

    Technical information Engine views E 2842 E 2149 2150...
  • Page 13 Technical information 1 Lifting eye, front 2 Oil filler neck 3 Oil separator for crankcase breather 4 Distributor 5 Starter motor 6 Exhaust manifold, liquid cooled 7 Oil dipstick 8 Pointer, TDC mark 9 Cranking device 10 Torsional vibration damper 11 Generator 12 Oil cooler 13 Oil filter...

  • Page 14: Engine

    Technical information Engine The E 2842 E is a liquid-cooled 12-cylinder Otto-Cycle-Gas engine. The cylinders are on a 90° V pattern. Combustion system The engine uses the Otto-Cycle-gas combustion system developed by MAN. The outstanding design features of this system are a truncated combustion chamber located at the centre of the piston crown and the special shape of the intake port in the cylinder head (swirl).
  • Page 15 Technical information Engine timing Camshaft, oil pump and distributor are driven by a gear train arranged at the flywheel end. 2330 1 Crankshaft gear 4 Camshaft drive gear 2 Oil pump drive gear 5 Idler gear 3 Oil pump impeller gears 6 Injection pump drive gear The crankshaft gear and camshaft gear are match-marked by the digit ”1”...

  • Page 16: Engine Lubrication

    Technical information Engine lubrication The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the flywheel end. The oil pump draws the oil from the sump and delivers it via the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and locker arms.
  • Page 17 Technical information 2337 1 Oil suction pipes 10 Ports for big-end bearing lube 2 Oil pumps 11 Small-end baring lube 3 Relief valve 12 Camshaft bearing lube 4 Oil cooler 13 Rocker arm lube 5 Oil filter 14 Oil jets for piston cooling and 6 Bypass valve cam lube 7 Main oil galleries...

  • Page 18: Cooling

    Technical information Cooling The engine has a liquid cooling system. The water pump is a maintenance-free impeller pump and is driven by V-belts from the crankshaft pulley. Depending on the agreed extent of delivery and the design of the engine, the coolant cir- cuit can be equipped with temperature and level monitors which, in the event of over- heating, will trigger an advance warning system or, in the event of loss of coolant, shut the engine down.

  • Page 19: Electrical Equipment

    Technical information Electrical equipment Alternator AC three-phase alternator with integral silicon rectifiers is installed. A transistorized regulator mounted on the alternator limits the alternator voltage. The alternator should not be operated except with the regulator and battery connected in cir- cuit to avoid damage to the rectifier and regulator.

  • Page 20: Ignition System

    Technical information Ignition system The engine is equipped with contactless transistorized ignition system (TSZ-i). The main components of the ignition systems are: 2 Distributor with induction transmitter, 2 Ignition coil, 2 Control unit, 2 Series resistor, 12 Spark plugs. The drive of the distributor is via a gear train from the timing idler gear. TD 31 3 15 16 2338...
  • Page 21 Technical information Distributor with induction transmitter In the contactless transistorized coil ignition system with inductive transmitter (TSZ-i), the mechanical control switch is replaced by a pulse transmitter. The inductive transmitter in the distributor casing consists of a moving part, the pulse transmitter wheel, and a fixed part, the disc with a permanent magnet, induction coil and core.
  • Page 22 Technical information Electronic speed governor (for use with synchronous generator) 1891 1 Pulse transducer 2 Starter ring gear 3 Control unit 4 Set point potentiometer 5 Indexer 6 Gas mixer Operation: A pulse transducer senses the engine speed on the starter ring gear and transmits the signal to the control unit.
  • Page 23 Technical information Note: Install the transducer so that the gap between it and the tip of the ring gear tooth is 0.5 to 0.8 mm. D Screw down the transducer until it contacts the tip of the tooth D Back off about one half turn D Lock in this position (For a description of the individual components and setting procedures, see publications E 80001 and E 80002 ”Heinzmann Electronic Speed Governors”).

  • Page 24: Gas Supply System

    Technical information Gas supply system Note: The gas supply system is not included in our scope of supply. Metal hose and zero-pres- sure regulator, however, can be supplied at request. Always proceed according to Manufacturer’s Operating Instructions when commission- ing, operating and servicing the gas supply system. A typical gas supply system which meets all requirements for trouble-free operation of the engine is described below.
  • Page 25 Technical information Gas pressure regulator, zero pressure regulator, (3) Function Reducing the gas pressure (low pressure) fluctuating at the gas station inlet within acceptable limits to zero pressure. Negative-pressure-controlled gas metering for the venturi in the gas mixer as a function of engine load, i.e.
  • Page 26 Technical information Gas mixer (7) 2339 1 Setting screw for regulating A Air inlet from air cleaner bypass gas for idling B Outlet of gas/air mixture to 2 Gas annulus engine 3 Gas passage C Throttle valve casing 4 Metal hose D Venturi 5 Setting screw for regulating max E Gas inlet from gas...
  • Page 27 By no means must the maximum continuous engine rating permitted by the maker (see applicable engine performance characteristic of E 2842 E) be exceeded due to incorrect setting. Any necessary readjustment of the gas flow, e.g. especially when a different gas quality with a higher heat value is used, must only be entrusted to trained personnel.
  • Page 28 Technical information Notes on necessary gas plant components upstream of the zero pressure regula- 1888 1 Ball cock 2 Push button cock 3 Pressure gauge with push button cock 4 Gas filter 5 Pressure gauge with push button cock 6 Gas pressure monitor 7 Safety solenoid valve 8 Leak gas solenoid valve 9 Main gas solenoid valve...
  • Page 29 400 litres capacity is required for the E 2842 E in the gas supply line ahead of the gas station inlet, prefer- ably in the main flow. If connected in a bypass, the connecting pipe to the gas mains should be as short as possible and with at least 50 mm bore.

  • Page 30: Commissioning And Operation

    Diesel engines”) only, as have observed the ”Technical Information otherwise the manufacturer’s guaran- for the installation of MAN engines”. tee will be null and void. During operation During operation the oil pressure in the engine lubrication system must be moni- tored.

  • Page 31: Starting

    D Do not switch off ignition until the engine is at a standstill A.Operation with asynchronous generator (E 2842 E - A) B.Operation with synchronous Starting generator (E 2842 E - S) D Operate starter to crank engine with...

  • Page 32: Temporary Decommissioning Of Engines

    D Switch off ignition and electronic speed Temporary anti-corrosion protection ac- governor after about 5 seconds cording to MAN works norm M 3069 is re- quired for engines which are to be put out of service for fairly long periods.

  • Page 33: Maintenance And Care

    Maintenance and care Engine lubrication Caution: The oil is hot- risk of scalding. Do not Oil level touch the oil drain plug with bare fin- gers. Oil is an environmental hazard. Check the oil level in the engine sump Handle it with care! daily with a dipstick.
  • Page 34 Maintenance and care Lubricating oil filter Renewal of filter cartridges D Allow the filter content to run off along Cleaning of the lubricating oil is effected in drain plugs. Hold a suitable vessel un- a full-flow oil filter with paper cartridges. der hole A bypass valve ensures continuity of oil Caution:...

  • Page 35: Cooling

    HENKEL P3-begesol. This cleansing agent is avail- ture boiling occurs and coolant is lost. able from MAN in 10-kg cans under Part To prevent damage to the engine No. 09.21002-0164. open this cap only in exceptional cir- cumstances and fit a new one as soon as possible.
  • Page 36 Maintenance and care Procedure: flushed through immediately during D Mix P3-begesol with water, ratio 1:1 cleaning D Using a spray gun, spray the mixture in c) Fill coolant circuit with a mixture of hot as straight a jet as possible directly into water (min.
  • Page 37 Maintenance and care D Drain the pickling fluid and thoroughly Waste water treatment flush the system with tap water Drained and spent cleaning and pickling D If necessary, refill the circuit again with fluid should be brought up to a pH value fresh pickling fluid and pickle the en- of 7.5 to 8.5 with the aid of caustic soda.

  • Page 38: Air Cleaner

    Maintenance and care Air cleaner Fouling Indicator As the degree of clogging increases the Dry air cleaner red indicator becomes more and more vis- ible in the transparent section of the air cleaner. If the fouling indicator remains engaged, i.e. it still shows completely red even with the engine shut down, the filter cartridge must be cleaned or replaced.
  • Page 39 Maintenance and care Changing the filter cartridge Blowing out (wear goggles) To do this fit a pipe to the compressed air Caution: gun. The end of the pipe should be bent No dust must get to the clear air end. by approx.
  • Page 40 Maintenance and care Checking the cartridge Safety cartridge When a cartridge has been cleaned it When the main cartridge is being serviced must be examined for damage before it is the safety cartridge remains in the filter refitted, e.g. damage to the paper bag and housing.

  • Page 41: Checking And Setting

    Checking and setting Ignition system The danger of accidents therefore exists on the individual components of the igni- tion system (such as distributors, ignition coil, control unit, ignition cables) as well Danger of electronic ignition systems as on the cable harness (such as tachom- Safety rules eter connection, diagnosis plug), at con- nectors and the test devices.
  • Page 42 Checking and setting D Insert ignition cables. The paint mark applied earlier will point to the cable connection for cylinder No. 1 (cylinder No. 12). Insert the other cables in the sequence of the firing order shown in the diagram 2340 1884 Set ignition timing by means of the strobo-...
  • Page 43 Checking and setting Synchronous flashing of the stroboscope is effected with the spark in the No. 1 cyl- inder or respectively No 12 cylinder. The inductive prongs are clamped on to the ignition cable to the No. 1 or No. 12 cylin- der near the distributor.

  • Page 44: Spark Plugs

    Checking and setting Spark plugs 1 12 5 8 3 10 6 7 2 11 4 9 6 7 2 11 4 9 1 12 5 8 3 10 The spark plugs should be renewed after Adjust valves on cylinder every 2000 hours operation.
  • Page 45 Checking and setting Bolts to be used in event of repairs: Remove the sticker ”First retightening of cylinder head bolts ...” and attach the Bolts with hex head may be replaced by sticker ”Second retightening of cylinder bolts with Torx head if all the bolts on the head bolts ...”...
  • Page 46 Checking and setting Tightening cylinder head bolts af- Retightening cylinder head bolts ter a repair after repairs (engine cold) (engine cold or warm) by authorized specialist personnel by authorized specialist personnel Before inserting the cylinder head bolts oil After the first 10 to 20 hours of operation them with engine oil on the thread (not to after a repair turn the cylinder head bolts the bore) and coat the contact face of the...

  • Page 47: V-Belts

    Checking and setting Re-using old cylinder head bolts V-belts The tension of the V-belts should be Checking checked after every 200 hours of opera- Before re-using old cylinder head bolts tion. check them as follows: Change the V-belts if necessary Length During tightening the bolts are intention- If, in the case of a multiple belt drive, wear...
  • Page 48 Checking and setting Tension and / or replace V-belts 1900 D Slowly depress pad (3) until the spring can be heard to disengage. This will cause the indicator to move upwards If pressure is maintained after the spring 2155 has disengaged a false reading will be obtained! Alternator D Remove fixing bolts (1)
  • Page 49 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 50: Technical Data

    Technical data Model E 2842 E Design V-90° Cycle 4-stroke Otto-cycle Number of cylinders Bore 128 mm Stroke 142 mm Swept volume 21 930 cm Compression ratio 12.5 : 1 Rating see engine nameplate The performance data are for operation on natural gas having a heat value of not less than 36.350 kJ/m...
  • Page 51 Technical data Engine lubrication Force feed lubrication Oil pressure at rated speed 3.5 ... 5.0 bar at 1500 rpm 2.5 ... 3.5 bar at no load 1.2 ... 1.5 bar Lube oil filter full-flow type with paper element Oil capacity in oil sump (litres) min.

  • Page 52: Maintenance Chart

    Maintenance chart ALWAYS COMPLY WITH SAFETY REGULATIONS ! Maintenance cycles * Maintenance jobs Maintenance jobs 1 2 3 4 5 6 7 8 9 Check coolant level and oil level in engine Change engine oil in oil sump (see also page 51) Change oil filter cartridge (see also page 51) Check and if necessary correct V-belt tension 1st retightening of cylinder head bolts (with overhauled engine)
  • Page 53 Maintenance chart Approved Engine Oils Oil quality The following brands of engine oils should be used 1. Special gas engine oils AVIA AG AVILUB Gasmotorenöl E 30 SAE 30 AVILUP Gasmotorenöl E 40 SAE 40 Deutsche Shell AG SHELL V-OEL 7078 SAE 30 SHELL V-OEL 7107 SAE 40...

  • Page 54: Index

    Index Adjusting the ignition timing ....Nameplates ....... Air cleaner .

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