Man E 2942 LE 302 Mode d'emploi

Instructions

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

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

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

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

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

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

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

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

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!

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