Man E3268 LE212, E3262 LE202, E3268 LE222, E3262 LE212 Operating Instructions Manual
Operating Instruction
MAN Industrial Gas Engines
E3268 LE212/222 / E3262 LE202/212
MAN Engines
A Division of MAN Truck & Bus
Operating Instruction
MAN Industrial Gas Engines
E3268 LE212, E3268 LE222
E3262 LE202, E3262 LE212
51.99587-8006
Version 05
Translation of the original instruction”
“
Information and Copyright
Subject to change without notice.
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.
2016
MAN Truck & Bus AG
Vogelweiherstrasse 33
90441 Nürnberg
Germany
Tel.: +49 911 / 420-1745
Fax: +49 911 / 420-1932
email: Engine-Documentation@man.eu
internet: www.man-engines.com
Technical status: 03.2016
51.99587-8006
Carefully read these Operating Instructions before starting any work!
2
This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
List of contents
Information and Copyright 2...............................................................
1 Foreword 7.........................................................................
1.1 Information about these instructions 7.............................................
1.1.1 Supplementary publications 7...............................................
1.1.2 Further publications 7......................................................
1.2 Symbol explanation 8...........................................................
1.3 Limitation of liability 9............................................................
1.4 Copyright protection 9...........................................................
1.5 Applicable documents 9.........................................................
1.6 Spare parts 10..................................................................
1.7 Disposal 10.....................................................................
1.8 Warranty provisions 11...........................................................
1.9 Product support 11...............................................................
2 General Safety Instructions 13........................................................
2.1 Intended use 13.................................................................
2.2 Content of the Installation and Operating Instructions 14..............................
2.3 Engine modifications and conversions 14...........................................
2.4 Operator's responsibility 14........................................................
2.5 Personnel requirements 15........................................................
2.5.1 Qualifications 15............................................................
2.5.2 Unauthorised personnel 15..................................................
2.5.3 Instruction 15..............................................................
2.6 Personal protective equipment 16..................................................
2.7 Particular dangers 17.............................................................
2.8 Safety equipment 20.............................................................
2.9 Response to danger and accidents 21..............................................
2.10 Signs 22........................................................................
2.11 Weight data E3268 LE212/LE222 23...............................................
2.12 Environmental protection 24.......................................................
3 Engine model plate 25................................................................
3.1 Explanation of Motor-Nr./Engine No. (engine identification number) 26..................
3.2 Explanation of model designation 26................................................
Carefully read these 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
List of contents
4 Design and function 27...............................................................
4.1 Engine application fields 27.......................................................
4.2 Engine design and engine equipment 27............................................
4.3 Engine views E3262 LE202 29.....................................................
4.3.1 Front left view 29...........................................................
4.3.2 Front right view 30..........................................................
4.4 Engine views E3268 LE212 31.....................................................
4.4.1 Front left view 31...........................................................
4.4.2 Front right view 32..........................................................
5 Transport, packaging and storage 33..................................................
5.1 Requirements 33................................................................
5.2 Safety instructions 33............................................................
5.3 Transport inspection 35...........................................................
5.4 Transport 36....................................................................
5.5 Packaging 40....................................................................
5.6 Storage 40......................................................................
6 Installation and commissioning 41....................................................
6.1 Notes regarding installation and commissioning 41...................................
6.1.1 Requirements 41...........................................................
6.2 Safety instructions 41............................................................
6.3 Engine installation 42.............................................................
6.3.1 Interfaces between engine and plant 42.......................................
6.3.2 Installation Instructions 44...................................................
6.3.3 Installation drawing 44......................................................
6.3.4 Screw and bolt connections 44...............................................
6.4 Completion of the engine and assembly of the drive system 45.........................
6.4.1 Mounting an alternator on the flywheel housing 45..............................
6.4.2 Checking crankshaft axial clearance 46........................................
6.5 Connecting the cooling system 47..................................................
6.5.1 Connecting the engine cooling 47.............................................
6.6 Mounting the gas inlet 48.........................................................
6.7 Mounting the exhaust system 49...................................................
6.7.1 Exhaust gas outlet on engine 49..............................................
6.7.2 Connecting the exhaust system to the engine 50................................
6.8 Connecting the electrical system 51................................................
6.8.1 Starter 51.................................................................
6.9 Torques for screw and bolt connections to Works Standard M 3059 52..................
6.10 First commissioning 53...........................................................
6.11 Commissioning 54...............................................................
6.11.1 Gas system 54.............................................................
6.11.2 Adding coolant 55..........................................................
6.11.3 Filling Engine Oil 56.........................................................
Carefully read these 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.
List of contents
7 Operation and use 57.................................................................
7.1 Requirements 57................................................................
7.2 Safety instructions 57............................................................
7.3 Preparations prior to operation 58..................................................
7.3.1 Checking the gas quality, opening the gas supply 58............................
7.3.2 Checking the coolant 59.....................................................
7.3.3 Topping up the coolant 59...................................................
7.3.4 Check Engine Oil Level 60...................................................
7.3.5 Topping up the engine oil 61.................................................
7.4 Operation 62....................................................................
7.4.1 Starting 62.................................................................
7.4.2 Operation monitoring system 63..............................................
7.4.3 Emergency shutdown 63....................................................
7.4.4 Stopping 63................................................................
7.4.5 Data storage box 64........................................................
8 Maintenance and care 65..............................................................
8.1 Requirements 65................................................................
8.2 Safety instructions 65............................................................
8.3 Maintenance schedule 66.........................................................
8.3.1 Maintenance schedule for natural-gas operation 67.............................
8.3.2 Maintenance schedule for special gas operation 70.............................
8.4 Maintenance work 75.............................................................
8.4.1 Engine oil change 75........................................................
8.4.2 Changing the coolant 79.....................................................
9 Faults 81............................................................................
9.1 Requirements 81................................................................
9.2 Safety instructions 81............................................................
9.3 Troubleshooting chart 82..........................................................
10 Decommissioning and recommissioning 87............................................
10.1 Requirements 87................................................................
10.2 Safety instructions 87............................................................
10.3 Temporary decommissioning of an engine 88........................................
10.4 Recommissioning of decommissioned engines 89....................................
10.4.1 Commissioning of preserved engines to MAN Works Standard M 3069 89..........
10.4.2 Commissioning of non-preserved engines 89...................................
Carefully read these 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
List of contents
11 Technical data 91....................................................................
11.1 Dimensions and weight 91........................................................
11.1.1 E3268 LE212/LE222 91.....................................................
11.1.2 E3262 LE202/LE212 91.....................................................
11.2 Installation location and space requirements 91......................................
11.3 Engine data 92..................................................................
11.3.1 E3268 LE212/LE222 92.....................................................
11.3.2 E3262 LE202/LE212 94.....................................................
12 Installation drawing 97...............................................................
12.1 Installation drawing E3268 LE212/LE222 97.........................................
12.2 Installation drawing E3262 LE202/LE212 103.........................................
13 Indices 111...........................................................................
13.1 Abbreviations 112.................................................................
13.2 List of keywords 113..............................................................
Carefully read these 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.
Foreword
1 Foreword
1.1 Information about these instructions
User tip
This provisional version of the instructions reflects the current development state of the engines.
These instructions therefore contain graphic representations of the MAN industrial gas engines on which
these instructions are based.
These instructions provide important information on handling engines. Safe working can only be assured if
all safety instructions and handling instructions are followed.
In addition to this, the local accident prevention regulations and general safety regulations applicable to the
engines' field of application must be followed.
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.
Only use genuine MAN spare parts and accessories or ones that have been approved by MAN.
Only the genuine spare parts approved by us have been tested by us and therefore meet the requirements
for use of the engine.
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 ha
zardous materials are used and, for example, that the emissions fulfil the highest requirements.
Economical operation helps to conserve our resources and our environment.
1.1.1 Supplementary publications
These instructions are supplemented by the following publications:
- Fuels, Lubricants and Coolants for MAN Industrial Gas Engines
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 Installation and 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 follow these instructions and any operating instructions provided by suppliers invalidates the war
ranty.
1.1.2 Further publications
The following publications supplement these instructions:
- Spare Parts Catalogue (included)
For the service personnel
- Repair Instructions
Carefully read these 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
1.2 Symbol explanation
Warnings
Warnings are indicated by symbols in these instructions. The warnings are preceded by signal
words which indicate the extent of the danger.
Always heed these warnings and act prudently to prevent accidents, injuries and property damage.
DANGER
Describes an immediately dangerous situation that will lead to serious injury or death if it is not avoided.
WARNING
Describes a possibly dangerous situation that can lead to serious injury or death if it is not avoided.
CAUTION
Describes a possibly dangerous situation that can lead to minor or moderate injury if it is not avoided.
NOTE
Describes a possibly dangerous situation that can lead to damage if it is not avoided.
Tips and Recommendations
User tip
Tips and recommendation as well as information for efficient and trouble-free operation.
ENVIRONMENTAL NOTE
Tips on how to deal with protection of the environment.
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
This symbol indicates a graphic item in the text.
Carefully read these 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
1.3 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:
S Failure 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 fuels, 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 protection
Treat the Installation and Operating Instructions confidentially. They are aimed solely at persons who deal
with the engine.
The instructions may not be passed to third parties without written approval from MAN.
User tip
The information, texts, drawings, illustrations and other depictions are all protected by copyright and are
subject to industrial property rights.
Any improper use is punishable by law.
1.5 Applicable documents
Supplier components are installed in the engine. Risk assessments have been carried out on these parts
by the suppliers.
The compliance of the design with the existing European and national legislation has been declared by the
respective suppliers of the components.
Carefully read these 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
1.6 Spare parts
Only use genuine MAN spare parts and accessories or ones that have been approved by MAN.
Only the spare replacement parts approved by us have been tested by us and therefore meet the require
ments for use of the engine.
Spare parts and accessories must either be MAN genuine parts or parts that have been specifically appro
ved 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 observations.
WARNING
Risk of injury due to incorrect spare parts
Incorrect or faulty spare parts can lead to damage, malfunctions or total failures and interfere with
safety.
For this reason:
S Only use MAN genuine spare parts
User tip
Quote the engine type, engine number and order number in all enquiries and communications,
see page 25.
Order spare parts through authorised dealers or directly from MAN.
For address, see page 2.
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.
10
Carefully read these 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
1.8 Warranty provisions
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 follow these instructions and any operating instructions provided by suppliers invalidates the war
ranty.
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 expired. This will ensure the conti
nuous performance of the engine.
1.9 Product support
Our MAN product support is available for technical information.
User tip
Quote the engine type, engine number and order number in all enquiries and communications,
see page 25.
Information about contact persons can always be called up by telephone, fax, email or over the Internet.
For addresses see page 2.
Carefully read these 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
12
Carefully read these 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 generally valid safety instructions to be observed are listed here. They provide optimum protection for
personnel 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 signifi
cant 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 "non-intended".
MAN is not liable for any damage resulting from non-intended use. The risk is entirely borne by the opera
tor.
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.
Similarly, tampering with the control system can affect engine performance and emission characteristics.
Compliance with statutory environmental protection requirements is therefore no longer guaranteed.
DANGER
Danger due to non-intended use
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.
User tip
Observe the following information when operating the engine:
S The safety instructions in these Operating Instructions and the suppliers' instructions.
S The “Technical data" section in these instructions and the suppliers' instructions.
S Country-specific regulations.
Carefully read these 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 Content of the Installation and 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.
Familiarity with these instructions is therefore essential.
2.3 Engine modifications and conversions
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
no 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 Operator's responsibility
The engine operator 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 and 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 Opera
ting 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 accessi
ble 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 Perform maintenance work as described in these instructions in full and at the
specified intervals or have it performed by a MAN Service workshop/authorised MAN partner.
S The operator must have all safety equipment checked regularly for function and integrity.
S The instructions must be followed in full and without restrictions!
14
Carefully read these 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 if personnel is not sufficiently qualified
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 respective chapters
in these Operating Instructions.
The following qualifications are specified for various areas of activity in the instructions:
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 experience 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 rele
vant 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 personnel
WARNING
Danger to unauthorised personnel
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 necessary.
S Interrupt the work until all unauthorised persons are out of the working area.
2.5.3 Instruction
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 these 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 against falling and flying parts.
Safety Shoes
To protect against heavy falling parts and slipping on slippery 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. This will be specifically
mentioned in the relevant chapters.
Safety Glasses
To protect the eyes against flying parts and sprayed fluids.
Hearing Protection
To protect the ears from damage by loud noises.
16
Carefully read these 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 Particular 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
Danger to life due to electrical voltage
Touching live parts endangers life.
Damaged insulation of components endanger life.
For this reason:
S If the insulation is damaged, immediately switch off the power supply and get the insulation 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 amperage.
S Keep moisture clear of parts conducting electrical current. This could cause a short-circuit.
Moving Parts
WARNING
Risk of injury due to moving parts
Rotating and/or linear-moving components can cause injuries.
For this reason:
S Do not touch or handle moving parts during operation.
S Do not open the covers during operation.
S Only perform checking and maintenance jobs when the engine is at a standstill.
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.
Flying components in the event of sudden engine damage
WARNING
Risk of injury due to running engines
In the event of engine damage, components can fly through the engine room at high speed and injure
people in the immediate vicinity.
For this reason:
S Do not remain in the engine room when the engine is running.
Carefully read these 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
Exhaust gases
WARNING
Health risk due to leaking exhaust system
Exhaust gases can damage health.
For this reason:
S Immediately stop and repair machines with leaking exhaust systems.
S Ensure sufficient ventilation.
Highly Flammable Substances - Gaseous Fuels, Oils and Grease
WARNING
Risk of injury due to highly inflammable materials
Highly inflammable materials, liquids or gases catch fire easily.
For this reason:
S Smoking, naked flames and sources of ignition are prohibited in the danger zone and immediate sur
roundings.
S Keep fire extinguishers at hand.
S Immediately report any suspicious substances, fluids or gases to the person in charge.
S Repair any leaks.
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
Coolant contains substances that are hazardous to health.
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.
Hot Fluids and Lubricants
WARNING
Risk of burns due to hot fuels, lubricants and coolants
Fuels, lubricants and coolants get hot during operation and cause burns if touched.
For this reason:
S Before handling any fluids and lubricants, check whether they are hot. If necessary, let them cool
down first.
18
Carefully read these 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
Hot Surfaces
CAUTION
Risk of burns due to hot surfaces
Touching hot components causes burns.
For this reason:
S When performing any work in the vicinity of hot components always wear protective clothing and
protective gloves.
S Before starting any work ensure that all components have cooled down to ambient temperature.
Noise
WARNING
Hearing damage due to noise
The noise level in the working area can cause serious hearing damage.
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 finished.
Sharp Edges and Corners
CAUTION
Risk of injury on edges and corners
Sharp edges and corners can cause skin grazes and cuts.
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 due to dirt and discarded objects
Dirt and discarded objects represent a tripping and slipping hazard and can cause serious 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.
Carefully read these 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
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
Danger to life due to non-functioning safety equipment
For this reason:
S Before commencing work, check that all safety equipment is functioning and correctly installed.
S Before starting the engine, check that all safety equipment is functioning and correctly installed.
20
Carefully read these 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
2.9 Response to danger and accidents
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 Regularly check first-aid equipment and fire extinguishers for completeness and correct functioning.
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
Should an accident occur despite all preventative measures, e.g. due to one of the reasons listed below,
call a doctor 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..
Carefully read these 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
2.10 Signs
WARNING
Risk of injury due to illegible symbols
Labels and symbols get dirty over time, rendering them illegible.
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.
The following symbols should be installed in the immediate vicinity of the hazard area.
Access forbidden
Areas displaying this sign must not be entered.
Electric Voltage
Spaces marked with this symbol may only be accessed by qualified electricians.
Unauthorised persons may not enter these spaces.
Hot Surfaces
Hot surfaces such as hot engines and hot fluids may not always be recognisable. Do not
touch these surfaces without protective gloves.
Danger to life due to suspended loads
During lifting operations, loads can swing out and fall down. This can cause serious in
jury and even death.
Risk of injury
Failure to follow the instructions poses a risk of injury.
22
Carefully read these 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
2.11 Weight data E3268 LE212/LE222
Ensure that suitable lifting gear is used for handling the engine and the engine parts listed in the table.
Part Weight (kg)
Oil pan 95l 27
Crankcase 459
Crankshaft 131
Flywheel housing 30
Flywheel 66
Exhaust turbocharger 1500 rpm 38
Charge mixture cooler E3268 88
Engine carriage 107
Carefully read these 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
2.12 Environmental protection
ENVIRONMENTAL NOTE
Risk of environmental pollution due to incorrect handling of service products
Serious environmental damage can result.
For this reason:
S Follow the safety instructions.
S Take suitable measures immediately if environmentally hazardous substances escape into the envi
ronment.
S Inform the relevant local authorities of the damage.
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 these 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 quote the engine type 3, engine num
4
ber
and factory number/order number 5 in all
enquiries and communications.
Before the engine is first commissioned, you
should therefore check the relevant data on the
engine model plates and enter it below.
1
The engine model plates
the crankcase.
and 2 are attached to
Engine Model Plate
Model
......................................................................
Engine number
......................................................................
Factory number/order number
......................................................................
3
4
5
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This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
25
Engine Model Plate
3.1 Explanation of Motor-Nr./Engine No. (engine identification number)
Class identifier (assignment) 1 2 3 4
Motor-Nr./Engine No. XXX XXXX XXX XXXX
1 Model number after model code
2 Day of assembly (determined internally at factory)
3 Assembly sequence (consecutive number on day of assembly)
4 Production- and equipment-specific data
3.2 Explanation of model designation
Model designation Explanation Example
E Fuel type Natural gas/biogas
32 Figure + 100 132 mm bore
6 Stroke figure (rounded) 157 mm stroke
8 / 2 Number of cylinders 8, 12 cylinders
L Charging with charging and
charge mixture cooling
E Engine installation Installation engine
202/212/222 Model designation identification Development number
26
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This is especially valid for the chapter on General Safety Instructions
and the safety instructions in each of the chapters.
Design and Function
4 Design and function
4.1 Engine application fields
The 8- and 12-cylinder engines described here are liquid-cooled 4-stroke petrol engines with exhaust gas
turbocharger and mixture cooling.
4.2 Engine design and engine equipment
Engines E3268 LE212, E3268LE222 and E3262 LE202, E3262 LE212 are 8- or 12-cylinder gas engines
with turbocharger and mixture cooling.
Split crankcase, wet cylinder liners made of highly wear-resistant special centrifugal casting, aluminium
piston with cooling duct for piston cooling. Single cylinder heads with shrink-fitted valve seats and pressedin valve guides. 4 valves per cylinder. Valve control via central camshaft, roller tappets, tappet push rods
and rocker arms (OHV).
Charge mixture system
The charge mixture system consists of the charge mixture cooler, the charge mixture manifolds, the throttle
valve and the air distributor pipes.
Gas supply line
The gas supply line - consisting of ball cock, gas filter, solenoid valves, gas pressure regulator, gas mixer
and air filter - is not supplied by MAN.
Engine Lubrication
Force-feed lubrication with two lubrication oil pumps for crankshaft, conrod and camshaft bearings as well
as piston pin sockets, roller tappet and rocker arm.
Oil filtration through oil modules with integrated oil cooler and crankcase breather in main flow. Auxiliary
units such as turbocharger are connected to the engine lubrication oil circuit.
Intake and Exhaust System
Dry exhaust pipes.
For E3268, one exhaust turbocharger; for E3262, two exhaust turbochargers.
The exhaust turbochargers are lubricated via the engine's main flow oil circuit.
The intake air flows through the air filter to the gas mixer and then to the turbocharger(s). The now precom
pressed air/gas mixtures are supplied to the engine after mixture cooling.
Carefully read these 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.
27
Design and Function
Flywheel housing and flywheel
The flywheel housing as a connection to SAE1.
Different flywheel versions can be supplied, depending on the type of application.
Starter
The electric starter is of two-pin, insulated design. The starter can be mounted on the left or right of the en
gine.
28
Carefully read these 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.
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