Man E 2942 LE 302 Operating instructions

Instructions
2
Important instructions which concern technical safety and protection of persons are emphasised as shown
below.
Danger:
This refers to working and operating procedures which must be complied with in order to rule out
the risk to persons.
Caution:
This refers to working and operating procedures which must be complied with in order to prevent
damage to or destruction of material.
Note:
Explanatory descriptions which help in understanding the relevant work or operating procedure to
be carried out.
Assembly of pipes
Danger:
No pipes may be bent.
Risk of breakage!
Fitting flat seals / gaskets
Flat seals / gaskets are often inserted with sealing agents or adhesives to make fitting them easier or to
achieve better sealing. Flat seals may slip in operation due to the “sewing -machine” effect, in particular if
they are used between parts with different rates of linear expansion under heat (e.g. aluminium and cast
iron), and leaks may then occur.
Example:
The cap of the front crankshaft seal. If a sealing agent or an adhesive is used here the flat seal will move
inwards in the course of time as a result of the different expansion rates of the materials. Oil will be lost, for
which the shaft seal may be thought to be responsible.
Flat seals / gaskets can be fitted properly only if the following points are observed:
DUse only genuine MAN seals / gaskets
DThe sealing faces must be undamaged and clean
DDo not use any sealing agent or adhesive −as an aid to fitting the seals a little grease can be used if
necessary so that the seal will stick to the part to be fitted
DTighten bolts evenly to the specified torque
Fitting round sealing rings
DUse only genuine MAN round sealing rings
DThe sealing faces must be undamaged and clean
DAlways wet round sealing rings with engine oil before fitting them

Contents
3
Preface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type classification 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety regulations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault table 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General notes on engine overhaul 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrations of E 2842 LE 302 / E 2842 LE 312 engine 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubrication schedule 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system schedule 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine management schedule 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system
Replacing the spark plugs 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition control unit 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and setting the ignition point 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system
Draining and filling coolant 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication
Changing the oil filter 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the oil cooler 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the oil pump, servicing 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil injection nozzle 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel / Crankshaft seal
Removing and fitting vibration damper, replacing front crankshaft gasket 35. . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the flywheel, replacing the starter motor toothed wheel 39. . . . . . . . . . . . . . . . . . .
Removing and installing the crankshaft gasket on flywheel side 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the bearing race 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft gaskets 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake / exhaust system
Removing and installing the intake pipes 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the exhaust pipe 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger, troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking charging pressure 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the turbocharger 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the charge mixture cooler 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling the charge mixture cooler 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Removing and installing the cylinder head 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the valve clearance 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling the rocker arm mechanism 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valves 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check compression 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve timing
Removing and installing the gear case 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the camshaft, replacing camshaft bearings 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the valve timing 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
4
Crankgear, pistons
Removing and installing pistons with conrods 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing pistons from conrod and fitting, checking −replacing conrod 79. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing piston rings 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the cylinder liners 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring piston projection 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachments
Removing and installing the starter motor 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting impulse sensor 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Data 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liner 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel and starter motor toothed wheel 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conrods 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubrication 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition system 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition point 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque guide values 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque guide values 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special tools 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type classification
5
The type designation, consisting of a sequence of letters and numbers, indicates some characteristics of
each engine, provided you are familiar with the basic terminology.
The system is explained here using the type E 2842 LE 302 / E 2842 LE 312 as an example:
E The “E” at the start of the type designation stands for natural gas (German: Erdgas)
28 The numbers “28” indicate that this is a power unit with 128 mm bore
4 The “4” means 142 mm stroke
2 The “2” indicates the number of cylinders 12
L This letter stands for “charge-air cooling” (German: Ladeluftkühlung)
E The “E” stands for “fitted engine” (German: Einbaumotor) and is intended to distinguish MAN
vehicle engines
302 This is a factory-internal development number.

Safety regulations
6
General
Important safety regulations are summarized in this quick-reference overview and arranged by topic to ef-
fectively convey the knowledge necessary to avoid accidents causing injury, damage or environmental haz-
ard. Additional information can be found in the operating instructions of the engine.
Important:
Should an accident occur despite all precautionary measures, particularly one involving contact with corros-
ive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc. you
must seek medical assistance immediately.
1. Regulations for the prevention of accidents with personal injury
Inspection, adjustment and repair work may only be performed by authorised and skilled person-
nel.
DThe engine may only be started and operated by authorised personnel.
DWhen the engine is running, do not get too close to the rotating parts.
Wear close-fitting clothing.
DDo not touch hot engine with bare hands: Risk of burns.
ËË
DKeep area surrounding engine, ladders and stairways free of oil and grease. Accidents
caused by slipping can have serious consequences.
DOnly work with tools which are in good condition. Worn spanners/wrenches slip: Danger
of injury.
DPersons must not stand under an engine suspended on a crane hook. Keep lifting gear
in order.
DOpen the coolant circuit only when the engine has cooled down. If it is unavoidable that
the circuit be opened with the engine at operating temperature, observe the instructions
in the chapter “Maintenance and care” in the operating instructions.
DDo not tighten or undo pipes and hoses under pressure (lubricating oil circuit, coolant
circuit and any downstream hydraulic oil circuits). The fluids which flow out can cause
injury.

Safety regulations
7
DWhen working on the electrical system, first disconnect the earth cable of the battery
and reconnect this last to prevent short circuits.
DFollow the manufacturer’s instructions for handling batteries.
Caution:
Accumulator acid is toxic and caustic. Battery gases are explosive.
DWhen performing welding work, observe the “Notes for welders”.

Safety regulations
8
2. Regulations for the prevention of engine damage and premature wear
DThe engine must be cleaned thoroughly prior to repair. Ensure that during repair work no dirt,
sand or foreign bodies enter the engine.
DIf engine operation is disrupted, immediately determine the cause and have it remedied to prevent addi-
tional damage.
DIn every case, use only original MAN spare parts. The installation of parts that are “just as good” but do
not originate from MAN can under certain circumstances cause severe damage −for which the work-
shop performing the repair must bear responsibility.
DNever allow the engine to run dry, i.e. without lubricant or coolant.
Appropriate notices must be attached to engines that are not ready for operation.
DOnly use lubricants, fluids and fuel approved by MAN (gas, engine oil, antifreeze and corrosion protec-
tion agents). Pay attention to cleanliness.
DDo not fill engine oil beyond the max. notch on the dipstick. Do not exceed the maximum per-
missible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered to.
DControl and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect
working order.
3. Safety instructions for handling the ignition system
DWhen the engine is in operation, the following parts of the ignition system must not be
touched or disconnected under any circumstances:
−Ignition coils and caps
−Cables of the high-voltage circuit
−Cables of the low-voltage circuit
−Plugs of the output and input wiring harness
DFor all work related to set-up, operation, conversion, customisation, maintenance and
repairs, the power must be disconnected from the ignition system and secured against
inadvertent reactivation.

Safety regulations
9
4. Regulations for the prevention of environmental damage
Engine oil and filter cartridges
DOld oil must be passed on for recycling.
DTake extreme care that no oil enters the waste water system or seeps into the ground.
Caution:The drinking water supply could be contaminated.
DFilter elements are classed as dangerous waste and must be treated as such.
Coolant
DTreat undiluted corrosion protection agents and / or antifreeze as hazardous waste.
DWhen disposing of used coolant, the regulations issued by the relevant local authorities must be ob-
served.
5. Instructions for handling used engine oil ∗
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, ir-
ritation or inflammation of the skin may therefore occur. Used engine oil also contains hazardous sub-
stances that have caused skin cancer in tests on animals. If the basic principles of work safety and hygiene
are observed, handling used engine oil does not represent a health hazard.
Precautionary measures to protect your health:
DAvoid prolonged or repeated skin contact with used engine oil.
DProtect your skin by means of suitable agents (creams etc.) or wear protective gloves.
DClean skin which has been in contact with engine oil.
−Wash thoroughly with soap and water. A nail brush provides effective assistance here.
−Special hand cleaning agents make it easier to clean dirty hands.
−Do not use petrol (gasoline), diesel fuel, gas oil or solvents as washing agents.
DAfter washing apply a fatty skin cream to the skin.
DChange clothing and shoes that are soaked in oil.
DDo no put oily cloths in you pockets.
Ensure that used engine oil is disposed of in the appropriate manner.
−Engine oil is a substance that endangers the water supply −
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are
punishable.
Carefully collect and dispose of used engine oil. Information on collection points can be obtained from sales
personnel, the supplier or the local authorities.
∗Based on “Information sheet for handling used engine oil”.

Safety regulations
10
6. Safety instructions for handling gaseous fuels
Gaseous fuels consist essentially of methane, propane and butane as well as traces of higher hy-
drocarbons and inert components such as carbon dioxide and nitrogen.
DThe regulations applicable to gas installations must be observed.
DExhaust gases are toxic. Comply with the regulations for the installation of MAN indus-
trial gas engines for operation in enclosed areas. Ensure adequate ventilation.
DSmoking and naked flames are prohibited.
DLeaks in the gas supply system mean danger of explosion and these must be remedied
immediately.
DFire extinguishers and other firefighting equipment must be on hand.
DDo not store combustible material in the engine room.
Conduct in the case of gas leaks
DClose the shutoff valve of the gas supply.
DSwitch off the main switch of the electric system.
DCordon off the danger zone. Ask persons who are not involved in the work to leave the danger zone.
DIf gas is leaking, inform the relevant authorities immediately and initiate repairs.
Conduct in the event of fire
DAlert the fire brigade.
DImmediately assist any injured persons, call paramedics if necessary.
DIn the case of a pure gas fire, do not extinguish the gas flame; if necessary, cool down the burning
object (e.g. by starving the fire of oxygen: close doors and windows).
Burning gas = controlled gas!
DPrevent the flames from spreading.
DIf the flames spread to the surroundings, use a fire extinguisher.
DStay calm!

Fault table
11
Operating faults and possible causes
We recommend
A repair is only complete when both the damage that occurred and the possible causes have been elimin-
ated. Finding out the cause of damage is often more difficult than repairing the damage that occurred. We
therefore recommend that you obtain a precise description of the operating fault before removing and dis-
mantling components. Then use a process elimination (questions) to pin-point the probable causes and
investigate and eliminate these successively on the basis of the table and your own experience. This
helps to reduce repairs to the required scale and to counteract claims regarding “over-eager” replacement
of parts and complaints about expensive work and down time.
Note:
The following list is conceived as an aid to memory for experts so that to causes of damage are overlooked
when dealing with faults. It is expected of experts that they are very familiar with the repair instructions for
the engine, but also with the engine operating instructions and “Fluids and lubricants for industrial gas en-
gines”.

Fault table
12
x = likely to apply
o = might apply
1. Starter motor does not turn engine or only slowly (solenoid switch energises (“click” is audible)
2. Starter motor turns, engine does not turn
3. Starter motor turns engine, engine does not start / starts poorly
4. Ignition failure
5. Irregular engine running
6. Engine stalls during operation, no longer starts
7. Engine “shakes”
8. Engine only runs at idle speed
9. Idle speed unstable
10. Engine does not reach its nominal speed
11. Engine does not reach its nominal power
12. Fuel consumption too high
13. Oil consumption too high
14. Engine too “loud” / mechanical noise
15. Heavy blue smoke formation
16. Heavy white smoke formation
17. Exhaust temperature / exhaust back pressure too high (thermal overload)
18. Lubrication oil pressure too low
19. Temperature difference engine exit / engine entry too great
20. Coolant temperature too high
Possible causes
xBatteries discharged, battery cable connections loose or corroded, power circuit inter-
rupted
xStarter motor defective (carbon brushes loosened / worn, coil damaged, ground fault)
xEngaging lever / bearing bolt of the engaging lever broken
xCrankshaft drive blocked
x x Engine oil viscosity unsuitable, not suited to ambient temperature
xIgnition control unit defective
xImpulse sensor defective / gap incorrectly set
x x x Spark plug defective
x x x Ignition cable defective
x x x Ignition coil defective
o o x x x x Ignition point incorrectly set
x Throttle valve does not open / actuating rod jammed / setting unit de-energized or defec-
tive
x x Throttle valve not in full-load position / actuating rod jammed / throttle valve incorrectly
adjusted
x x Shut-off solenoid valve of gas supply closed / does not open
x x Zero pressure regulator of gas supply not correctly set or defective
x x x Gas metering valve defective
x x x Gas / air mixture too rich or too lean
x x Lack of compression, or more than 3 bar pressure difference between the individual cylin-
ders
x x x x Valve clearance not correct
x x Valve guides heavily worn
x x x x Valve seats leaking
x x x x x Piston rings heavily worn, broken (overpressure in the crankcase)
x x x x Air filter heavily soiled
x x x Charge mixture cooler soiled / leaking
x x x Charge mixture piping leaking
x x Turbine and compressor wheel in the turbocharger soiled (running off balance)
xCoolant entering combustion chamber (cylinder head gasket leaking)
xEngine in cold running phase
x x Crankcase breather blocked
xOil level in oil pan too high
xSafety valve in the oil circuit defective (does not close, spring fatigued or broken)
xHeavy bearing wear
xOil pump heavily worn
xSafety valve in the oil circuit defective (does not open), oil lines / oil ducts blocked
x Unsuitable exhaust-gas piping, heat exchanger and catalytic converters with excessive
resistance
xFlow resistance of cooling system too great
x x Soiling of cooling system

Fault table
13
x = likely to apply
o = might apply
1. Starter motor does not turn engine or only slowly (solenoid switch energises (“click” is audible)
2. Starter motor turns, engine does not turn
3. Starter motor turns engine, engine does not start / starts poorly
4. Ignition failure
5. Irregular engine running
6. Engine stalls during operation, no longer starts
7. Engine “shakes”
8. Engine only runs at idle speed
9. Idle speed unstable
10. Engine does not reach its nominal speed
11. Engine does not reach its nominal power
12. Fuel consumption too high
13. Oil consumption too high
14. Engine too “loud” / mechanical noise
15. Heavy blue smoke formation
16. Heavy white smoke formation
17. Exhaust temperature / exhaust back pressure too high (thermal overload)
18. Lubrication oil pressure too low
19. Temperature difference engine exit / engine entry too great
20. Coolant temperature too high
Possible causes
xCoolant level too low, air in the coolant circuit
xWater pump configured too small
x x Coolant lines leaking, blocked or twisted
xEngine mounting unsuitable / worn

General notes on engine overhaul
14
The service life of an engine is influenced by very different factors. It is therefore not possible to specify
certain fixed numbers of operating hours for general overhauls.
In our view, it is not necessary to open up and engine or perform a general overhaul
as long as the engine has good compression values and the following operating values have not changed
significantly in relation to the values measured on commissioning the engine:
DCharging pressure
DExhaust temperature
DCoolant and lubricant temperature
DOil pressure and oil consumption
The following criteria greatly influence the length of the engine service life:
DCorrect power setting in accordance with conditions of use
DTechnically correct installation
DInspection if installation by authorised personnel
DSelection and quality of lubricants, fuel and coolant
according to publication “Fluids and lubricants for industrial gas engines”

Illustrations of E 2842 LE 302 / E 2842 LE 312 engine
15
Illustrations of engine E 2842 LE 302 / E 2842 LE 312

Engine lubrication schedule
16
1
2
3
4
678
9
10
5
1 Rocker arm lubrication 6 Oil overpressure valve
2 Piston bolt lubrication 7 Oil cooler
3 Spray nozzles for piston cooling 8 Bypass valve
4 Camshaft bearing lubrication 9 Oil filter
5 Oil intake pipe 10 Main oil channels

Engine lubrication schedule
17
123
4
56
4
67
1 Lubrication oil lines to the exhaust turbochargers 5 Oil pump with oil-pressure relief valve
2 Oil return from exhaust turbochargers 6 Bore holes for conrod bearing lubrication
3 Oil line to crankshaft 7 Oil intake pipe
4 Bore holes to main bearing lubrication

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