Man E0834 LE302, E0834 LE312, E0834 LE322, E0836 LE202, E0836 LE302 Operating Instructions Manual
Operating Instruction
MAN Industrial Gas Engines
834 LE302/312/322 / E0836 LE202/302
E0
MAN Engines
A Division of MAN Truck & Bus
Operating Instructions
MAN Industrial Gas Engines
E0834 LE302 / 312/ 322
E0836 LE202/ 302
51.99493-8538 “Translation of the original operating instructions”
Version 07
MAN-Industrial Gas Engines E0834 LE302 ; E0836LE202/302
Information and Copyright
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: Engine-Documentation@man.eu
Internet: www.man-engines.com
Technical status: 08.2018
51.99493-8538
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.
3
Table of Contents
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........................................................
Carefully read the Operating Instructions before starting any work!
4
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
Table of Contents
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............................................................
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
Table of Contents
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...........................................................
Carefully read the Operating Instructions before starting any work!
6
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
Table of Contents
12 Indices 79..............................................................................
12.1 Abbreviations 80.................................................................
12.2 Technical Terms 81..............................................................
12.3 Index 82........................................................................
13 Notes 84.............................................................................
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.
7
Foreword
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
Carefully read the Operating Instructions before starting any work!
8
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
Foreword
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.
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
Foreword
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
S Improper use
S Use of untrained personnel
S Customer conversions
S Technical modifications
S Use 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.
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.
Foreword
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:
S Only 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:
S Sort metals before scrapping.
S Recycle the plastic parts.
S Dispose of all other parts according to their material composition.
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.
11
Foreword
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.
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.
General Safety Instructions
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:
S Use the engine for its intended purpose only.
S Use the engine outside of hazardous areas where there is a risk of explosion.
S Use the engine with an overspeed limiting device installed.
NOTE!
Observe the following information when operating the engine:
S The safety information in these Operating Instructions and in the supplier's operating in
structions.
S The “Technical Data" chapter in these Operating Instructions and in the supplier's operat
ing instructions.
S Country-specific regulations.
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.
13
General Safety Instructions
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:
S The 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.
S During 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.
S The operator must clearly define and regulate the responsibilities for installation, operation, maintenance
and cleaning of the product.
S The 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.
S The operator must provide the personnel with the necessary protective equipment.
S The operator must limit access to the operating room.
S The operator must ensure proper ventilation of the operating room.
S These 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:
S Maintenance 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.
S The operator must have all safety equipment checked regularly for function and integrity.
S The instructions in the Operating Instructions are to be followed completely and fully!
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.
General Safety Instructions
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:
S Specific 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.
S Instructed Persons
Have been instructed in a briefing about the possible dangers of improper handling in their tasks.
S Qualified Personnel
Due to their technical training, knowledge and experience and knowledge of the relevant regulations
they can properly perform the tasks assigned to them.
S Electric 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.
S When 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:
S Keep unauthorised persons out of the working area.
S In case of doubt, address the person and remove him/her from the working area if neces
sary.
S Interrupt 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.
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.
15
General Safety Instructions
2.6 Personal Protective Equipment
Wearing personal protective equipment is necessary to minimise the health risks when working.
S The required personal protective equipment for the relevant job must always be worn while working.
S All 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.
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.
General Safety Instructions
2.7 Specific Dangers
The following section describes residual risks which have been identified.
S Observe 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:
S If the insulation is damaged, immediately switch off the power supply and get the insula
tion repaired.
S Any work performed on the electrical system may only be made by a qualified electrician.
S When working on 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 supply must be
switched off and secured from being accidentally switched back on.
S Do not bridge or bypass any fuses. When replacing fuses, ensure to use the correct am
perage.
S Keep moisture clear of parts conducting electrical current. This could cause a short-cir
cuit.
Moving Parts
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:
S Ignition coils and caps
S Wires of the high voltage circuit
S Wires of the low voltage circuit
S Connectors of the output and input wires
WARNING!
Risk of injury caused by moving parts!
Rotating or linear moving parts can cause serious injuries.
For this reason:
S During operation do not reach into or tamper with moving parts.
S Do not open the covers during operation.
S Observe the run-on time: before opening any covers ensure that no parts are still moving.
S Wear close-fitting clothing in the hazard area.
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.
17
General Safety Instructions
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:
S Limit the time spent in the operating room to the absolute minimum.
S Set up protective partitions to isolate running engines.
S Access 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:
S Ensure sufficient ventilation.
S Immediately shut down engines with exhaust leaks.
Highly Flammable 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.
S Leaks in the gas supply system are an explosion hazard and are to be rectified
immediately.
Conduct when gas leaks
S Close shutoff valve for gas supply
S Switch off master switch for electrical system
S Block off the hazard area. Keep all uninvolved persons out of the hazard area
S If gas leaks, immediately notify those responsible and start repairs
Conduct in case of fires
S Alert fire department
S Administer first aid to the injured and, if necessary, notify the paramedics
S When 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!
S Prevent the flames from spreading to the surroundings
S If the flames spread to the surroundings, fight resulting fires using fire extinguishers
S Keep calm!
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.
WARNING!
Risk of fire caused by highly flammable substances!
Highly flammable materials (lubricating oils, greases) can catch fire and cause serious to
deadly injuries.
For this reason:
S Do not smoke in the hazard area or in the vicinity.
No open fires or sources of ignition.
S Keep fire extinguishers at hand.
S Immediately report any suspicious substances, fluids or gases to the person in charge.
S In the case of fire, immediately stop working. Leave hazard area until the danger is over.
Coolants - Antifreeze, Anticorrosion Agents
WARNING!
Risk of injury caused by coolants that are hazardous to health
Coolants contain substances that are hazardous to your health. Contact with these sub
stances can lead to serious poisoning, allergies, skin irritations and damage to eyes.
For this reason:
S Observe the safety sheets from the manufacturer.
S Always wear protective clothing, chemical-resistant protective gloves and safety glasses.
S Avoid spilling or spraying these substances.
General Safety Instructions
Hot Fluids and Lubricants
WARNING!
Risk of burns caused by hot fluids and lubricants!
Fluids and lubricants can reach high temperature while in operation and cause burns when
coming into contact with them.
For this reason:
S Before handling any fluids and lubricants, check whether they are hot. If necessary, let
them cool down first.
Hot Surfaces
CAUTION!
Risk of burns caused by hot surfaces!
Contact with hot components can cause burns.
For this reason:
S When performing any work in the vicinity of hot components always wear protective cloth
ing and protective gloves.
S Before starting any work ensure that all components have cooled down to ambient tem
perature.
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.
19
General Safety Instructions
Noise
WARNING!
Risk of hearing damage caused by noise!
The level of noise occurring in the working area can cause serious damage to hearing.
For this reason:
S Always wear hearing protection when working.
S Do not unnecessarily remain in the hazard area. Leave hazard area when work is fin
ished.
Sharp Edges and Corners
CAUTION!
Risk of injury cause by sharp edges and corners!
Sharp edges and corners can cause cuts and scrapes to the skin.
For this reason:
S Always work carefully and with caution in the vicinity of sharp edges and corners.
S In cases of doubt, wear protective gloves.
Dirt and Objects
CAUTION!
Risk of tripping caused by dirt and objects!
Dirt and objects can cause a person to slip or trip which can cause considerable injuries.
For 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 fields
WARNING!
Risk of death caused by strong magnetic fields!
Strong magnetic fields can cause serious injuries and death as well as considerable prop
erty damage.
For this reason:
S Persons with cardiac pacemaker must not remain in the vicinity of the engine.
The operation of the cardiac pacemaker could be negatively affected.
S Persons with metal implants must not remain in the vicinity of the engine. Metal implants
could heat up or be attracted to the magnetic source.
S Keep ferromagnetic materials and electromagnets away from magnetic sources. These
materials can be magnetically attracted and can fly through the room and injure people or
cause death. Keep a minimum distance of 3 m.
S Take off all metal objects (jewellery, watches, pens, etc.) before starting any maintenance
work.
S Do not take any electronic devices near the magnetic source. They could be damaged.
S Dot not take any memory devices, credit cards, etc. near the magnetic source. Data could
be erased.
20
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.
General Safety Instructions
2.8 Safety Equipment
The operator must have the following safety equipment in place:
Before the engine is placed into operation, install the emergency-off equipment and connect it into the
safety chain of the system.
Connect the emergency-off equipment so that dangerous situations to people 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 caused by non-operational safety equipment!
Safety equipment ensures maximum safety during operation. Even if they may make work
ing more complicated, they must not be overridden. Safety can only be guaranteed if the
safety equipment is intact and operational.
For this reason:
S Before starting any work, check whether all of the safety equipment is correctly installed
and in good operating order.
S Before starting the engine, check whether all of the safety equipment is correctly installed
and in good operating order.
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.
21
General Safety Instructions
2.9 Conduct in Dangerous Situations and When Accidents Occur
Preventative Measures
S Always be prepared for an accident!
S Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers at hand.
S Check first aid equipment and fire extinguishers regularly for completeness and proper operation.
S Familiarise the personnel with the emergency, first 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 Remain calm.
S Immediately shut down engine using the emergency-off button.
S Start first aid measures.
S Alert rescue services and/or fire department.
S Move people out of the danger zone.
S Clear access lanes for rescue vehicles.
S Inform the person in charge.
CAUTION!
Accidents despite preventative measures
If an accident occurs, e.g. from one of the listed points below, despite all of the preventative
measures, contact a physician immediately.
S Contact with caustic acids.
S Penetration of fuel into the skin.
S Scalding by hot oil or coolant.
S Antifreeze sprayed into the eyes, etc..
22
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.
General Safety Instructions
2.10 Signs
The following symbols should be installed in the immediate vicinity of the hazard area.
WARNING!
Risk of injury caused by illegible 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.
S Clean or replace illegible safety, warning and operational signs.
Electric Voltage
Rooms marked with this symbol may only be accessed by qualified electricians.
Unauthorised persons may not enter these rooms.
Hot Surfaces
Hot surfaces such as hot engines and hot fluids may not always be recognisable. Do not
touch these surfaces without protective gloves.
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.
23
General Safety Instructions
2.11 Environmental Protection
CAUTION!
Environmental hazard caused by incorrect handling!
Incorrect handling of environmentally hazardous substances, especially when incorrectly
disposed of, can cause considerable damage to the environment.
For this reason:
S Always heed the information 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 authorities.
The following environmentally hazardous substances are used:
Lubricants
Lubricants such as grease and oils contain poisons and environmentally hazardous substances. They must
not be allowed to be released into the environment. Disposal must be performed by a qualified disposal
company.
Coolants
Coolants can contain poisons and environmentally hazardous substances. They must not be allowed to be
released into the environment. Disposal must be performed by a qualified disposal company.
24
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.
3 Engine Model Plate
Always specify the engine typeand engine number
when sending messages and making queries.
For this reason before the engine is commis
sioned, read off and enter in the data from the en
gine model plates below.
Engine model plate (1) is installed on the crankcase.
Engine Model Plate
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.
25
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