Man E 0824 E 301 User manual

1
Dear Customer,
these Operating Instructions are intended to familiarize you with your new MAN-Otto-
Cycle Gas engine and how it operates.
Note:
This publication applies to the engine and must always be kept to hand in its vicinity
in the engine room.
Comply in full with instructions relating to operation, prevention of accidents and en-
vironmental protection.
MAN MAN-Otto-Cycle Gas engines are developed and manufactured in line with the
latest state of the art. However, trouble-free operation and high performance can only be
achieved if the specified maintenance intervals are observed and only approved fuels,
lubricants and coolants are used.
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.
Yours faithfully,
MAN Nutzfahrzeuge Aktiengesellschaft
Werk Nürnberg
Subject to change to keep abreast with technological progress.
2000 MAN Nutzfahrzeuge Aktiengesellschaft
No parts of this publication may be reproduced or translated without prior written per-
mission of MAN. MAN explicitly reservs all rights according to copyright law.
MTDA Technical status: 05.1998 51.99493-8466

Contents
2
Page
Declaration 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplates 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions for handling gaseous fuels 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning and operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views E 0824 E 302 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine views E 0826 E 302 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First commissioning 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The control unit (option) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System monitoring 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching off 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and care 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication system 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plugs 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary decommissioning of engines 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and setting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting ignition timing 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the overspeed setting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting valve clearances 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance chart 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit diagrams 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable harness for the input signals to the control unit
for E 0824 E and E 0826 E engines 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable harness for the output signals from the control unit
for E 0824 E engines 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable harness for the output signals from the control unit
for E 0826 E engines 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For data see original declaration
If required this declaration is
enclosed with the delivery note.
3
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.
Engine model:
Design:
Engine number:
Rating / speed:
Note:
The manufacturer of the complete ready-to-use machine in which this engine is to be
installed must take the further action necessary in the context of indirect safety-re-
lated engineering and provision of instructions to ensure that the ready-to-use
machine complies with the requirements of the EC directive on machines.
The engine must not be put into operation until the complete machine satisfies the
conditions laid down in the EC directive on machines 89/392/EEC, most recently
amended by 93/44/EEC, or the latest amendment of said directive.
MAN Nutzfahrzeuge Aktiengesellschaft
Vogelweiherstraße 33
D-90441 Nürnberg

Nameplates
4
In all your correspondence please always quote engine model, serial number and job
number (Order number).
For this reason it is advisable to read off the data from the engine type plates before put-
ting the engine into operation and to enter them in the appropriate spaces.
The engine type plates are on the crankcase.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAN Nutzfahrzeuge Aktiengesellschaft
Typ
Motor-Nr. / Engine No. NI/II

Safety precautions for handling gaseous fuels
5
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:
DSmoking or the use of a naked flame are prohibited.
DLeaks in the gas supply system represent an explosion risk and must
be eliminated without delay.
DFire extinguishers and other fire-fighting equipment must be kept close
at hand.
DInflammable material must not be stored in the engine room.
What must be done in the event of a gas leak?
DClose the shut-off tap for the gas supply.
DTurn off main switch for the electrical system.
DCordon off danger area. Order unauthorised persons to leave the
danger area.
DIf gas is escaping, inform the relevant authorities without delay and
make arrangements for repair work.
What must be done if fire breaks out?
DAlert the fire brigade.
DAssist any persons who may be in danger.
DIf the fire is a pure gas fire, the escaping gas flame must not be extin-
guished.
Cool the burning object if necessary.
Burning gas = controlled gas!
DIf the flames spread to the surrounding area, fight the fire with extin-
guishers.

Safety regulations
6
General notes
Day-to-day use of power engines and the service products necessary for running
them presents no problems if the persons occupied with their operation, mainten-
ance and care are given suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken down
into main sections which contain the information necessary for preventing injury to per-
sons, damage to property and pollution. In addition to these regulations those dictated by
the type of engine and its site are to be observed also.
Important:
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from hot oil, anti-freeze being splashed in the
eyes etc., consult a doctor immediately.
1. Regulations designed to prevent accidents with injury to persons
During commissioning, starting and operation
DBefore putting the engine into operation for the first time, read the oper-
ating instructions carefully and familiarize yourself with the “critical”
points. If you are unsure, ask your MAN representative.
DFor reasons of safety we recommend you attach a notice to the door of
the engine room prohibiting the access of unauthorized persons and
that you draw the attention of the operating personal to the fact that
they are responsible for the safety of persons who enter the engine
room.
DThe engine must be started and operated only by authorized personnel.
Ensure that the engine cannot be started by unauthorized persons.
DWhen the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.
DDo not touch the engine with bare hands when it is warm from opera-
tion – risk of burns.
ËË
DExhaust 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.

Safety regulations
7
DKeep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
During maintenance and care
DAlways 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. Do not get too close to rotating parts.
DChange 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.
ËËË
ËËË
DTake into account the amount of oil in the sump. Use a vessel of suffi-
cient size to ensure that the oil will not overflow.
DOpen the coolant circuit only when the engine has cooled down.
If opening while the engine is still warm is unavoidable, comply with the
instructions in the chapter entitled “Maintenance and Care”.
DNeither tighten up nor open pipes and hoses (lube oil circuit, coolant
circuit and any additional hydraulic oil circuit) during the operation.
The fluids which flow out can cause injury.
DWhen using compressed air, e.g. for cleaning the radiator, wear
goggles.
DKeep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
DComply with the manufacturer’s instructions when handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.

Safety regulations
8
When carrying out checking, setting and repair work
DChecking, setting and repair work must be carried out by authorized
personnel only.
DUse only tools which are in satisfactory condition. Worn open-end
wrench slip, which could lead to injury.
DWhen the engine is hanging on a crane, no-one must be allowed to
stand or pass under it. Keep lifting gear in good condition.
DWhen checking injectors do not put your hands under the jet of fuel.
Do not inhale atomised fuel.
DWhen working on the electrical system disconnect the battery earth
cable first. Connect it up again last in order to prevent short circuits.
DWhen welding comply with the “Instructions for welders”.
When working on the electronic ignition system
The firing power of electronic ignition systems is significantly higher than that of conven-
tional, mechanically controlled systems.
As a result, electronic ignition systems work in a voltage range which in the event of
physical contact with energised parts (of both primary and secondary circuits) may be ex-
tremely dangerous.
In this context we refer you to the relevant VDE instructions, particularly to VDE
0104/7.67, which must be complied with in all work on and checks of the ignition system.
DWhen working on the ignition system, always switch off the ignition.
Such work comprises the installation of cable harnesses in commis-
sioning procedures and the exchange of parts (spark plugs, ignition
cables etc).

Safety regulations
9
2. Regulations designed to prevent damage to engine and premature wear
Do not demand more from the engine than it is able to supply in its intended application.
Detailed information on this can be found in the sales literature. The injection pump must
not be adjusted without prior written permission of MAN Nürnberg.
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”.
In addition to the above, note the following points:
DNever let the engine run when dry, i.e. without lube oil or coolant.
DWhen starting do not use any additional starting aids (e.g. injection with starting pilot).
DUse only MAN-approved service products (engine oil, anti-freeze and anti-corrosion
agent). Pay attention to cleanliness.
DHave the engine maintained at the specified intervals.
DDo not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
DNever put cold coolant into an overheated engine. See “Maintenance and care”.
DDo not add so much engine oil that the oil level rises above the max. marking on
the dipstick.
DAlways ensure that the testing and monitoring equipment (for battery charge, oil pres-
sure, coolant temperature) function satisfactorily.

Safety regulations
10
3. Regulations designed to prevent pollution
Engine oil and filter elements / cartridges, fuel / fuel filter
DTake old oil only to an old oil collection point.
DTake strict precautions to ensure that no oil or Diesel fuel gets into the drains or the
ground.
The drinking water supply could be contaminated.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolant
DTreat undiluted anti-corrosion agent and / or anti-freeze as dangerous waste.
DWhen disposing of spent coolant comply with the regulations of the relevant local au-
thorities.
4. Notes on safety in handling used engine oil ∗
Prolonged or repeated contact between the skin and any kind of engine oil decreases the
skin. Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal experi-
ments. If the basic rules of hygiene and health and safety at work are observed, health
risks are not to the expected as a result of handling used engine oil.
Health precautions:
DAvoid prolonged or repeated skin contact with used engine oil.
DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.
DClean skin which has been in contact with engine oil.
– Wash thoroughly with soap and water. A nailbrush is an effective aid.
– Certain products make it easier to clean your hands.
– Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
DAfter washing apply a fatty skin cream to the skin.
DChange oil-soaked clothing and shoes.
DDo not put oily rags into your pockets.

Safety regulations
11
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. For information on collection points
please contact the seller, the supplier or the local authorities.
∗Adapted from ”Notes on handling used engine oil”.

Commissioning and operation
12
Engine views E 0824 E 301 / 302
1
2
3
4
5
6
7
8
9
10
11
12

Commissioning and operation
13
1 Crankcase breather
2 Fluid-cooled exhaust-gas collector pipe
3 Coolant inlet
4 Ignition coils (accessory)
5 Coolant outlet (In the picture it is closed up by a blind flange)
6 Coolant temperature transmitter
7 Oil cooler
8 Oil filter
9 Intake pipe
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.

Commissioning and operation
14
Engine views E 0826 E 301 / 302
1
2
3
4
5
6
7
8
9
10
11
12

Commissioning and operation
15
1 Crankcase breather
2 Fluid-cooled exhaust-gas collector pipe
3 Coolant inlet
4 Ignition coils (accessory)
5 Coolant outlet (In the picture it is closed up by a blind flange)
6 Coolant temperature transmitter
7 Oil cooler
8 Oil filter
9 Intake pipe
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.

Commissioning and operation
16
First commissioning
Filling-in of coolant
Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze
agent on ethylene glycole basis or anti-corrosion agent (see “Fuels, Lubricants and Cool-
ants for MAN Industrial Gas Engines”).
DComply with the filling instructions of the cogeneration–plant manufacturer
DSlowly fill up with coolant (max. 10 l/min.)
Filling with engine 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.
The engines are as a rule supplied with-
out oil.
Pour oil into engine via filler neck.
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.

Commissioning and operation
17
Checking oil level
Check the oil level at least 5 minutes have
passed since the machine was switched
off.
DPull out dipstick (arrow)
Dwipe it with a clean, lintfree cloth
Dand push it in again up to the stop
DPull out dipstick again
The oil level should be between the two
notches in the dipstick and must never fall
below the lower notch. Top up oil as
necessary.
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.
Ensure outmost cleanliness when han-
dling lubricants and coolants.
Oil
?
MIN
MAX

Commissioning and operation
18
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.
Positioning of the control unit
The control unit is arranged close to the
engine so that the following conditions are
met:
DMounted on a stable support, with
vibration damping by rubber elements if
necessary
DMax. ambient temperature 70_C
DEarthing strip run from housing of con-
trol unit to the engine
Danger:
Disconnect battery before doing
any work on electric cables or
making adjustments to the con-
trol unit as described here!
Adjusting ignition sequence and tim-
ing
The same control unit is used for the
4-cylinder and the 6-cylinder engine.
The ignition sequence and timing must
therefore be set before the unit is used for
the first time. To do this, unscrew the
cover (see arrow in upper figure). You will
now see 2 potentiometers and a switch
panel with a total of 8 switches.
The first 5 switches are set to the posi-
tions shown on the right using a small
screwdriver.
Switches 6, 7 and 8 are not required.
1
2
3
4
5
6
7
8
Control unit setting for
the 4-cylinder
E 0824 E engine
1
2
3
4
5
6
7
8
Control unit setting for
the 6-cylinder
E 0826 E engine