Table of Contents
1 Safety
1.1 Important requirements for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety requirements for startup and
operation 8
1.5 Safety requirements for maintenance and
repair work 9
1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12
1.7 Standards for safety notices in the text 14
2 General Information
2.1 Torque specifications for screws and nuts 15
2.2 Engine side and cylinder designations 26
2.3 Product description 27
2.4 Engine layout 33
2.5 Sensors and actuators – Overview 35
3 Technical Data
3.1 12V 2000 M86/M96/M96L engine data 40
3.2 16V 2000 M86/M86/M96L engine data 43
3.3 Firing order 46
3.4 Engine – Main dimensions 47
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 48
4.2 Engine – Putting into operation after
scheduled out-of-service-period 49
4.3 Operational checks 50
4.4 Starting the engine 51
4.5 Engine – Shutdown 52
4.6 Emergency engine stop 53
4.7 After stopping the engine 54
4.8 Plant – Cleaning 55
5 Maintenance
5.1 Maintenance task reference table [QL1] 56
6 Troubleshooting
6.1 Troubleshooting 57
7 Task Description
7.1 SOLAS 60
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 60
7.1.2 SOLAS shielding – Installation 61
7.1.3 Installation locations for SOLAS shielding 62
7.2 Engine 67
7.2.1 Engine – Barring manually 67
7.2.2 Engine – Cranking on starting system 68
7.3 Cylinder Liner 69
7.3.1 Instructions and comments on endoscopic and
visual examination of cylinder liners 69
7.3.2 Cylinder liner – Endoscopic examination 71
7.4 Crankcase Breather 73
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 73
7.4.2 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 74
7.5 Valve Drive 76
7.5.1 Cylinder head cover – Removal and
installation 76
7.5.2 Valve clearance – Check and adjustment 77
7.6 Injection Pump / HP Pump 79
7.6.1 HP fuel pump – Filling with engine oil 79
7.7 Injector 80
7.7.1 Injector – Replacement 80
7.7.2 Injector – Removal and installation 81
7.8 Fuel System 83
7.8.1 Fuel system – Venting 83
7.9 Fuel Filter 84
7.9.1 Fuel filter – Replacement 84
7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 85
7.9.3 Fuel prefilter – Draining 86
7.9.4 Fuel prefilter – Flushing 88
7.9.5 Fuel prefilter – Filter element replacement 90
7.10 Charge-Air Cooling 92
7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 92
7.11 Air Filter 93
7.11.1 Air filter – Replacement 93
7.11.2 Air filter – Removal and installation 94
7.12 Air Intake 95
7.12.1 Service indicator – Signal ring position check 95
7.13 Starting Equipment 96
7.13.1 Starter – Condition check 96
MS150119/00E 2014-08 | Table of Contents | 3
DCL-ID: 0000033801 - 001
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