Man E0834 LE302 User manual

MAN Engines
A Division of MAN Truck & Bus
Operating Instruction
MAN Industrial Gas Engines
E0834 LE302/312/322 / E0836 LE202/302

Operating Instructions
MAN Industrial Gas Engines
E0834 LE302 / 312/ 322
E0836 LE202/ 302
51.99493-8538 “Translation of the original operating instructions”
Version 07

Information and Copyright
MAN-Industrial Gas Engines E0834 LE302 ; E0836LE202/302
3
Carefully read the 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.
Subject to change.
The information, text, drawings, pictures and other illustrations that it contains are protected by copyright
and are subject to industrial property 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 Truck & Bus AG assumes no liability for any
damages arising from non-compliance with the above provisions.
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.
2018
MAN Truck & Bus AG
Vogelweiherstraße 33
90441 Nuremberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
Email: [email protected]
Internet: www.man-engines.com
Technical status: 08.2018
51.99493-8538

Table of Contents
4
Carefully read the 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.
1 Preface 8...........................................................................
1.1 Information about Operating Instructions 8.........................................
1.1.1 Publications belonging to the Operating Instructions 8..........................
1.1.2 Additional Publications for the Engines 8.....................................
1.2 Key to Symbols 9...............................................................
1.3 Limitation of Liability 10...........................................................
1.4 Copyright 10....................................................................
1.5 Other Applicable Documents 10...................................................
1.6 Spare Parts 11..................................................................
1.7 Disposal 11.....................................................................
1.8 Warranty Terms 12..............................................................
1.9 Service 12......................................................................
2 General Safety Instructions 13........................................................
2.1 Intended Use 13.................................................................
2.2 Contents of the Operating Instructions 14...........................................
2.3 Modifications and Conversions to the Engine 14.....................................
2.4 Responsibility of the Operator 14...................................................
2.5 Personnel Requirements 15.......................................................
2.5.1 Qualifications 15...........................................................
2.5.2 Unauthorised Persons 15....................................................
2.5.3 Instructions 15.............................................................
2.6 Personal Protective Equipment 16.................................................
2.7 Specific Dangers 17..............................................................
2.8 Safety Equipment 21.............................................................
2.9 Conduct in Dangerous Situations and When Accidents Occur 22.......................
2.10 Signs 23........................................................................
2.11 Environmental Protection 24.......................................................
3 Engine Model Plate 25................................................................
3.1 Explanation of the Motor-Nr./Engine-No. (Engine Identification Number) 26..............
3.2 Explanation of Model Designation 26...............................................
4 Design and Function 27..............................................................
4.1 Engine, General 27..............................................................
4.2 Engine Views E0834 LE302/ 312/ 322 28...........................................
4.2.1 Front Left View 28..........................................................
4.2.2 Front Right View 29........................................................
4.3 Engine Views E0836 LE202 30....................................................
4.3.1 Front Left View 30..........................................................
4.3.2 Front Right View 31........................................................
4.4 Engine Views E0836 LE302 32....................................................
4.4.1 Front Left View 32..........................................................
4.4.2 Front Right View 33........................................................

Table of Contents
5
Carefully read the 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.
5 Transport, Packaging and Storage 36..................................................
5.1 Prerequisite 36..................................................................
5.2 Safety Instructions 36............................................................
5.3 Transport Inspection 38...........................................................
5.4 Transport 39....................................................................
5.5 Packaging 41....................................................................
5.6 Storage 41......................................................................
6 Installation and Commissioning 42....................................................
6.1 Prerequisite 42..................................................................
6.2 Safety Instructions 42............................................................
6.3 Installation - Engine 43...........................................................
6.3.1 Safety Equipment 43.......................................................
6.3.2 Engine Model Plate Data 43.................................................
6.4 Commissioning 44...............................................................
6.4.1 Gas System 44............................................................
6.4.2 Filling Coolant 45...........................................................
6.4.3 Filling Engine Oil 46........................................................
7 Operation 48.........................................................................
7.1 Prerequisite 48..................................................................
7.2 Safety Instructions 48............................................................
7.3 Preparations before Operation 49..................................................
7.3.1 Check Gas Quality, Open Gas Supply 49......................................
7.3.2 Checking Coolant 49........................................................
7.3.3 Refilling Coolant 50.........................................................
7.3.4 Checking Engine Oil Level 51................................................
7.3.5 Refilling Engine Oil 52......................................................
7.4 Operation 53....................................................................
7.4.1 Starting Engine 53..........................................................
7.4.2 Monitoring Operation 54.....................................................
7.4.3 Stopping in an Emergency 54................................................
7.4.4 Engine Shut Off 54.........................................................
8 Maintenance and Care 55.............................................................
8.1 Maintenance instructions 55.......................................................
8.2 Maintenance Schedule 55.........................................................
8.3 Repair instructions 55............................................................

Table of Contents
6
Carefully read the 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.
9 Faults 57............................................................................
9.1 Prerequisite 57..................................................................
9.2 Safety Instructions 57............................................................
9.3 Fault Table 58...................................................................
10 Decommissioning and Recommissioning 63...........................................
10.1 Prerequisite 63..................................................................
10.2 Safety Instructions 63............................................................
10.3 Temporary Decommissioning of Engines 64.........................................
10.4 Recommissioning of Decommissioned Engines 65...................................
10.4.1Commissioning of Preserved Engines according to MAN-Werknorm M 3059 65.....
10.4.2Commissioning of Non-Preserved Engines 65..................................
11 Technical Data 67....................................................................
11.1 Dimensions and Weights 67.......................................................
11.1.1E0834 LE302 67...........................................................
11.1.2E0836 LE202 67...........................................................
11.1.2E0836 LE302 67...........................................................
11.2 Installation Location and Space Requirements 67....................................
11.3 Engine Data 68..................................................................
11.3.1E0834 LE302 68...........................................................
11.3.1E0834 LE312 70...........................................................
11.3.1E0834 LE322 72...........................................................
11.3.2E0836 LE202 74...........................................................
11.3.2E0836 LE202 76...........................................................

Table of Contents
7
Carefully read the 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 Indices 79..............................................................................
12.1 Abbreviations 80.................................................................
12.2 Technical Terms 81..............................................................
12.3 Index 82........................................................................
13 Notes 84.............................................................................

Foreword
8
Carefully read the 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.
1 Preface
1.1 Information about Operating Instructions
These Operating Instructions provide important information on dealing with engines. Prerequisite for safe
operation is the compliance with all safety and handling instructions.
Furthermore, the local accident prevention regulations valid for the engine's area of application and the
general safety regulations must be observed.
Timely and proper maintenance and care of the engines according to the set maintenance intervals ensure
and maintain the operational safety and the reliable application of these engines.
Use only genuine MAN spare parts and accessories or those approved by MAN.
Only MAN approved genuine spare parts have been tested by us and thus suitable for use in our engines.
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 hazardous materials are used and, for ex
ample, that the emissions fulfil the highest requirements.
Economical operation helps to conserve our resources and our environment.
1.1.1 Publications belonging to the Operating Instructions
The following publications belong to the Operating Instructions
- Fluids and Lubricants for MAN Gas Engines
- Assembly Instructions
Both publications are considered "parts of the product" and should always be kept in the immediate vicinity
of the engine for the personnel.
Carefully read the 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.
Failure to observe these Operating Instructions and any accompanying supplier operating instructions
leads to the loss of warranty claims.
1.1.2 Additional Publications for the Engines
The following instructions supplement the Operating Instructions for the engines:
For the operator, maintenance and service personnel
- Spare Parts Catalogue (included)
For the service personnel
- Repair Instructions

Foreword
9
Carefully read the 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.
1.2 Key to Symbols
Warnings
Warnings are identified in these Operating Instructions with symbols. These warnings are pre
ceded by signal words that express the magnitude of the risk.
Always heed these warnings and act prudently to prevent accidents, injuries and property damage.
DANGER!
... indicates an imminently hazardous situation, which 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 hazardous situation, which can lead to minor or light injuries if not
avoided.
IMPORTANT!
indicates a possible dangerous situation that can lead to property damage if it is not
avoided.
Tips and Recommendations
NOTE!
highlights useful tips and recommendations as well as information for efficient and smooth
operation.
General Information
• This symbol indicates a list at the first level.
- This symbol indicates a list at the second level.
1. This symbol indicates a sequence of actions.
(1) In the text, this symbol indicates a position in a graphic.

Foreword
10
Carefully read the 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.
1.3 Limitation of Liability
All of the information in these instructions have been prepared while taking into account the valid standards
and regulations, the state of the art, as well as our many years of experience and knowledge.
MAN is not liable for damages resulting from:
SFailure to follow these instructions
SImproper use
SUse of untrained personnel
SCustomer conversions
STechnical modifications
SUse of non-approved spare parts and fluids and lubricants
The actual scope of delivery for special versions, additional ordering options or technical 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
Please handle these Operating Instructions as confidential. They are only to be used by the persons work
ing with the engine. Transfer to a third party without explicit written permission from MAN is strictly prohib
ited.
NOTE!
The information, texts, drawings, illustrations and other depictions are all protected by copy
right and are subject to industrial property rights. Any improper use is punishable by law.
1.5 Other Applicable Documents
Supplier components are installed in the engine. Risk assessments have been carried out on these parts
by the suppliers.
The compliance of construction with the existing European and national legislation has been declared by
the respective suppliers of the components.

Foreword
11
Carefully read the 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.
1.6 Spare Parts
Use only genuine MAN spare parts and accessories or those approved by MAN.
Only MAN approved genuine spare parts have been tested by us and thus suitable for use in our engines.
Spare parts and accessories must either be MAN genuine parts or parts that have been specifically ap
proved by MAN. The reliability, safety and suitability of these parts have been established specifically for
the engines. We cannot assess and vouch for other non-MAN products, despite ongoing market observa
tions.
WARNING!
Risk of injury from incorrect spare parts!
Incorrect or faulty spare parts can lead to damage, malfunctions or total failures and inter
fere with safety.
For this reason:
SOnly use MAN genuine parts
NOTE!
Please always specify the engine model, engine number and order number when corres
ponding with MAN, see page 25.
Order spare parts through an authorised dealer or directly from MAN.
For addresses, see page 3.
1.7 Disposal
Dispose in accordance with national regulations.
If no return or disposal agreement has been made, recycle the disassembled components as follows:
SSort metals before scrapping.
SRecycle the plastic parts.
SDispose of all other parts according to their material composition.

Foreword
12
Carefully read the 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.
1.8 Warranty Terms
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.
Failure to observe these Operating Instructions and any accompanying supplier operating 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 parts even after the warranty period has passed. This will ensure the con
tinuous performance of the engine.
1.9 Service
Our MAN product support is available for technical information.
NOTE!
Please always specify the engine model, engine number and order number when corres
ponding with MAN, see page 25.
Information about contact persons can always be called up by telephone, fax, email or over the Internet.
For addresses see page 3.

General Safety Instructions
13
Carefully read the 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.
2 General Safety Instructions
This chapter provides information on residual risks and hazards during proper use of the engine. The gen
erally valid safety instructions to be observed are listed here. They provide optimum protection for person
nel and for the safe and smooth operation of the engine.
In the following, specific, action and situation-related safety information is placed before the corresponding
step, or in the chapter described.
Failure to observe the Operating Instructions and Safety Instructions in this document can result in signific
ant hazards.
2.1 Intended Use
The engine is built exclusively to drive generators or for the coupling of heat exchangers within the limits of
technical data
Any other use is considered as "not intended".
MAN is not liable for any damage resulting from use that is not intended. The risk is entirely borne by the
operator.
Intended use also includes compliance with the country-specific, local environmental regulations.
This in particular concerns 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 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 used, maintained and repaired by persons who are familiar with the engine and
have been informed of the hazards.
Unauthorised modifications to the engine shall void any liability for any resulting property damage and per
sonal injury.
Likewise, the manipulation of the control system could affect the performance and emission characteristics
of the engine. Compliance with the statutory environmental requirements can therefore no longer be guar
anteed.
DANGER!
Danger from not using the product as intended!
Any use that exceeds the intended use and/or any different use of the engine can lead to
dangerous situations which will invalidate the operating permit.
For this reason:
SUse the engine for its intended purpose only.
SUse the engine outside of hazardous areas where there is a risk of explosion.
SUse the engine with an overspeed limiting device installed.
NOTE!
Observe the following information when operating the engine:
SThe safety information in these Operating Instructions and in the supplier's operating in
structions.
SThe “Technical Data" chapter in these Operating Instructions and in the supplier's operat
ing instructions.
SCountry-specific regulations.

General Safety Instructions
14
Carefully read the 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.
2.2 Contents of the Operating Instructions
Any person who is instructed to perform work on or with the engine, must have read and understood these
Operating Instructions before starting any work. This also applies if the person has worked with such an
engine or a similar engine, or has already been trained by MAN.
Reading and understanding the Operating Instructions is thus mandatory.
2.3 Modifications and Conversions to the Engine
In order to avoid hazards and to ensure optimum performance, no modifications or conversions to the en
gine may be made which are not expressly approved by MAN.
If changes are made without the written consent of MAN, the guarantee or warranty obligation for MAN is
not longer valid for damage and defects, which are based on these unauthorised changes. Furthermore
MAN assumes no liability for any damage caused as a result of unauthorised changes.
2.4 Responsibility of the Operator
The operator of the motor is subject to the statutory requirements for workplace safety.
In addition to the Safety Instructions in these Operating Instructions, the safety regulations, accident pre
vention regulations and environmental protection regulations valid for the application area of this engine
must also be observed.
In particular:
SThe operator must be knowledgeable about the 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.
SDuring the entire period of operation of the engine the operator must check whether the operating in
structions he created meet the most current standards for regulations and revise them if necessary.
SThe operator must clearly define and regulate the responsibilities for installation, operation, maintenance
and cleaning of the product.
SThe operator must ensure that all staff who deal with the engine have read and understood the Operat
ing Instructions.
In addition, the operator must periodically train the staff and inform them about hazards.
SThe operator must provide the personnel with the necessary protective equipment.
SThe operator must limit access to the operating room.
SThe operator must ensure proper ventilation of the operating room.
SThese operating instructions must be kept in the immediate vicinity of the engine and be readily access
ible at any time to those persons working on and with the engine.
The operator is responsible for ensuring that the engine is always operated in perfect working condition and
working order.
In particular:
SMaintenance work such as that described in the Maintenance Instructions are to be completely per
formed within the prescribed time intervals or are to be performed by a MAN service workshop/MAN
contract partner.
SThe operator must have all safety equipment checked regularly for function and integrity.
SThe instructions in the Operating Instructions are to be followed completely and fully!

General Safety Instructions
15
Carefully read the 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.
2.5 Personnel Requirements
2.5.1 Qualifications
WARNING!
Risk of injury caused by insufficient qualifications!
Improper handling can result in significant personal injury and property damage
For this reason:
SSpecific activities must only be performed by those persons who are named in the re
spective chapters in these Operating Instructions.
The following qualifications will be designated in the Operating Instructions for various task areas.
SInstructed Persons
Have been instructed in a briefing about the possible dangers of improper handling in their tasks.
SQualified Personnel
Due to their technical training, knowledge and experience and knowledge of the relevant regulations
they can properly perform the tasks assigned to them.
SElectric Specialist
Is capable of performing work on electrical systems due to his/her technical education/training, know
ledge and experiences 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 rel
evant standards and regulations.
Only those people who can perform their work reliably should be considered as authorised personnel. Indi
viduals whose responsiveness is influenced, for example, by alcohol or drugs, are not permitted.
SWhen selecting personnel, observe the regulations regarding age and profession valid at the operating
site.
2.5.2 Unauthorised Persons
WARNING!
Danger for unauthorised persons!
Unauthorised persons who do not fulfil the requirements described here do not realise the
dangers that exist in the working area.
For this reason:
SKeep unauthorised persons out of the working area.
SIn case of doubt, address the person and remove him/her from the working area if neces
sary.
SInterrupt the work until all unauthorised persons are out of the working area.
2.5.3 Instructions
Personnel must be instructed on regular basis and this should be documented in a log to keep better track
of who and when.

General Safety Instructions
16
Carefully read the 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.
2.6 Personal Protective Equipment
Wearing personal protective equipment is necessary to minimise the health risks when working.
SThe required personal protective equipment for the relevant job must always be worn while working.
SAll signs pertaining to personal protective equipment in the working area must be followed.
Protective Clothing
Close-fitting clothing with low initial tear strength, 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 the head from falling or flying objects.
Safety Shoes
To protect the feet from heavy falling objects and from slipping on slick surfaces.
Safety Gloves
To protect the hands from friction, scraping, punctures or deep injuries and to protect
from hot or caustic parts or fluids
To be worn when performing specific types of work
When performing certain types of work, special protective equipment is required. These will be specifically
mentioned in the relevant chapters.
Safety Glasses
To protect the eyes from flying objects and spraying fluids.
Hearing Protection
To protect the ears from damage by loud noises.

General Safety Instructions
17
Carefully read the 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.
2.7 Specific Dangers
The following section describes residual risks which have been identified.
SObserve the safety instructions listed here and the warnings in the other chapters of these instructions
in order to reduce health hazards and avoid dangerous situations.
Electrical Current
DANGER!
Risk of death caused by electrical current!
There is a risk of death when coming into contact with parts conducting electrical currents.
Damaged insulation or components can be life threatening.
For this reason:
SIf the insulation is damaged, immediately switch off the power supply and get the insula
tion repaired.
SAny work performed on the electrical system may only be made by a qualified electrician.
SWhen working on the electrical system the power supply must be switched off and then
properly checked to ensure no electrical current is present.
SBefore starting any maintenance, cleaning or repair work the power supply must be
switched off and secured from being accidentally switched back on.
SDo not bridge or bypass any fuses. When replacing fuses, ensure to use the correct am
perage.
SKeep moisture clear of parts conducting electrical current. This could cause a short-cir
cuit.
DANGER!
Risk of death caused by electrical current!
Do not touch or pull on the following parts of the ignition system when the engine is in oper
ation:
SIgnition coils and caps
SWires of the high voltage circuit
SWires of the low voltage circuit
SConnectors of the output and input wires
Moving Parts
WARNING!
Risk of injury caused by moving parts!
Rotating or linear moving parts can cause serious injuries.
For this reason:
SDuring operation do not reach into or tamper with moving parts.
SDo not open the covers during operation.
SObserve the run-on time: before opening any covers ensure that no parts are still moving.
SWear close-fitting clothing in the hazard area.

General Safety Instructions
18
Carefully read the 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.
Multi-engine plants
WARNING!
Risk of injury caused by engines!
Persons in the operating room are at a risk if engine damage occurs.
For this reason:
SLimit the time spent in the operating room to the absolute minimum.
SSet up protective partitions to isolate running engines.
SAccess to the operating room may only be made when engine is running at a light load.
Exhaust gases
WARNING!
Risk of health hazard caused by exhaust gases!
Leaks in the exhaust system can cause dangerous exhaust gases to leak into the engine
room.
For this reason:
SEnsure sufficient ventilation.
SImmediately shut down engines with exhaust leaks.
Highly Flammable Substances - Gaseous Fuels, Oils and Grease
WARNING!
Fire hazard caused by gaseous fuels!
For this reason:
SNo smoking and no open flames.
SThe regulations for gas installations must to be observed.
SLeaks in the gas supply system are an explosion hazard and are to be rectified
immediately.
Conduct when gas leaks
SClose shutoff valve for gas supply
SSwitch off master switch for electrical system
SBlock off the hazard area. Keep all uninvolved persons out of the hazard area
SIf gas leaks, immediately notify those responsible and start repairs
Conduct in case of fires
SAlert fire department
SAdminister first aid to the injured and, if necessary, notify the paramedics
SWhen gas leaks from a system and catches fire, the flames cannot be easily
extinguished. Try to cool the burning object (e.g. by reducing the surrounding oxygen:
close doors and windows).
Burning gas = Controlled gas!
SPrevent the flames from spreading to the surroundings
SIf the flames spread to the surroundings, fight resulting fires using fire extinguishers
SKeep calm!