GENERAL Table of Contents A General Remarks
Contents
1. 03 01 ill 7 SERVICE MANUAL MARINE ENGINES Equipment Bobtail B Direkt gearbox A down angle gear box Parallel offset gearbox Page GENERAL 6 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Jet Drive 0301 8 0301 9 79 I Stern Drive ma TYPE Alamarin Hamilton Castoldi TYPE Mercury Alpha Bravo amp III Volvo DP 290 Volvo DP 290 Hydraulic SX Stern Drive Z001019 0 6 July 2008 Page GENERAL 7 GENERAL SERVICE MANUAL MARINE ENGINES 3 2 Modell summary 6 cylinder engines Bobtail Version 0302 1 Inborder i e ZF 63 Marine gear Down angle with side mounted raw water pump or with side mounted raw water pump power steering pump and front mounted auxiliary drive2. number of cylinders 6 cylinder in line engine position of cyl 1 at vibration damper side ignition order 1 5 3 6 2 4 sense of rotation seen from front right compression ratio full load speed range rpm 17 5 1 2600 2800 2600 2800 3300 3500 4000 4300 idle speed 630 rpm adjustable injection pump nozzle with modelling needle control and electronic control fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel 2 D temperature above 7 C No 1 D temperature below 7 fuel filter P No 2177745 1 fuel filter location suction sided air filter MO126 P No 2178992 0 all other 6 Cyl P N 2178992 1 oil pressure above 2000 rpm 400 700 kPa 60 100 PSI microprocessor controlled filling capacity motor oil approx 10 0 engine housing incl approx 1 oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location suction sided electric charging system 14 V 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit thermostat controlled pressurized cooling circuit circulating pump with heat exchanger on engine governor pump external ra
3. Coolant Drain Plug 2 Units Oil Suction Pipe Oil Dipstick Rack Position Sensor Engine Lifting Eye Motor Oil Filler Cap Potentiometer Accelerator Drive Belt Raw Water Pump Engine Mount Drive Belt Tensioner Cover T Belt Lower Vibration Damper Drive Belt Alternator amp Hydr Pump Speed Sensor Cover T Belt Upper Valve Cover Heat Exchanger Coolant Expansion Tank Cooler Cap Diagnostic Outlet Inversion Switch only for SOLAS Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Hydraulic Oil Tank Circuit Breakers Alternator Hydraulic Pump Oil Drain Plug Starter Motor Engine Management System Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais Backside E Box Ground Plate Flywheel Flywheel Housing Oil Pressure Sensor 06029 2 _ 29 30 31 32 33 34 35 36 2 14 37 38 39 40 45 44 43 41 06030 06031 This sensor is magnetism sensitive All external magnets must be kept away Z001019 0_6 July 2008 Page GENERAL 19 GENERAL SERVICE MANUAL MARINE ENGINES B Specifications B1 Fuel Requirements The STEYR Marine Engines are designed for maximum fuel economy To maintain optimum performance use diesel fuel according to CEC RF 03 A 84 or equivalent to meet this specification When temperatures are below 7 C 20 F use diesel fuels with additives for low temperature operation H
4. 48 49 06004 GENERAL SERVICE MANUAL MARINE ENGINES moreamao O displacement 2133 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 103 138 116 156 Z Drive 101 136 114 154 number of cylinders 4 cylinder in line engine position of cyl 1 at vibration damper side ignition order 1 3 4 2 sense of rotation seen from front right compression ratio 17 5 1 full load speed range rpm 3700 3900 3800 4000 idle speed 650 rpm adjustable injection pump nozzle with modelling needle control and electronic control fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel No 2 D temperature above 7 C No 1 D temperature below 7 C fuel filter P No 2203710 0 fuel filter location intake sided air filter P No 2178992 0 oil pressure above 2000 rpm 400 700 kPa 60 100 PSI microprocessor controlled filling capacity motor oil approx 8 0 engine housing incl approx 1 oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P NO Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location pressure sided electric charging system 14 V 90 A alternator with transistorized voltage regulator
5. Check Engine Light if much power is demanded from the new engine ON In case the operator get alert when running the engine during break in phase by this Break In warning indication CEL light ON the throttle position must be reduced until this signals are extinguish Next Eight Hours For the next eight hours continue to run engine at approximately three fourth throttle or less minimum planing speed Occasionally reduce throttle to idle speed for cooling down During this eight hours of running it is permissible to run at full throttle for periods of less than two minutes NOTE DURING BREAK IN DO NOT RUN ENGINE AT A CONSTANT RPM FOR LONGER PERIODS Page GENERAL 30 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Final Ten Hours of Break in During the final ten hours of break in the engine may run at full speed for five to ten minutes After warming up the engine to operating temperature momentarily reduce the engine speed and then increase it again For cooling down the engine occasionally reduce the engine speed NOTE DURING THE BREAK IN PERIOD THE ENGINE MUST NOT BE OPERATED AT CONSTANT RPM FOR LONGER PERIODS During break in period be particularly observant of the following A Check motor oil level daily Always maintain oil level in the desired range between the MIN and MAX marks on dipstick When refilling motor oil refer to information Motor Oil B 2 B Check oil pr
6. E Quality Gudelines for Repair 34 E 1 specificato aseo eie Dog re rag t 34 E2 Workshop 4prolle is EE ER EHE DUI 34 E3 cae re ee 35 E4 ROSY SUSI M ET 36 E5 S 37 F Operating material and Information on Disposal 38 F 1 List of operating t treo d ette een ede RR E A ed 38 F2 Disposal of automotive waste 39 G Notes on Safety 40 G 1 General notes on sale o eiue RR um eee 40 G2 Guidelines for damage prevention 40 G3 e ee Ee 40 G4 Safety in the use of operating material 40 2001019 0 6 July 2008 Page GENERAL 1 lt lt GENERAL SERVICE MANUAL MARINE ENGINES G5 Measures in case of accidents 40 H Thightening Torques asse KAR KRAG ENE KAREN KG KEN EP am Pk EPIRI N EG eN EN ed Ke 42 H 1 Listing of Thightening Torques 42 H2 General Tightening torques GE echa EG 47 H3 Testing of torque Wrench 48 H4 Non destructiv
7. cooling system dual cooling circuit thermostat controlled pressurized cooling circuit circulating pump with heat exchanger on engine governor pump external raw water circuit to heat exchanger coolant capacity 11 5 liters coolant STEYR MOTORS engine coolant 36 C P No Z011785 0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH reserves the right to make changes without notice or obligations A Efficiency of gearbox 97 0 efficiency of Z drive 95 5 Page GENERAL 14 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl Marine Engines Zinc Anode 4 Units Model and Serial Number Intercooler Fuel Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation only SOLAS Oil Drain Plug Fuel Filter Oil Filter Hydraulic Pump Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug 2 Units Engine Oilcooler Oil Suction Pipe Oil Dipstick Hydraulic Oil Tank Cooler Cap Potentiometer Accelerator Motor Oil Filler Cap Boost Pressure Sensor Rack Position Sensor Drive Belt Cover T Belt Lower Engine Mount Drive Belt Tensioner Vibration Damper Cover T Belt Upper Engine Lifting Eye Speed Sensor Valve Cover Heat Exchanger Coolant Expansion Tank Diagnostic Outlet Inversion Switch only for SOLAS Connector In
8. Check makes little or no 1 Propeller for weeds remove progress as required 2 Propeller for hub repair or replace 3 Hull for excessive marine growth clean as required Performance loss System error or failure Check Engine Management System display for service code Engine coolant temperature audible alarm Boat overloaded Reduce load Boat trim Distribute boat load evenly Adjust trim Excessive water in bilge Drain bilge Boat hull condition Cleaning Improper propeller selection Select proper propeller pitch and diameter Fuel incorrect Fill tank with correct fuel Check fuel filter and fuel flow condition Throttle not fully open Check throttle command lever for full travel Overheating Check cooling system Remove debris from water intake Check belt tension Check condition of impeller Check for clogged heat exchanger tubing in raw water circuit 10 Air intake troubles Check intake air filter Check ventilation of engine compartment Excessive free play in Steering cable loose Adjust or replace steering wheel High shift effort 1 Remote control or transom Replace and adjust bracket shift cable 2 Remote control binding Adjust 3 Engine drive mechanism sticks Center 2001019 0 6 July 2008 Page GENERAL 23 GENERAL C2 Service and Maintenance Schedule ENGINE LUBRICATION for leakage SERVICE MANUAL MARINE ENGINES oil level ENGINE
9. POLY V BELT generator if reguired power steering belt pulleys and tighteners for wear if reguired for all 4 cyl models Page GENERAL 24 Poly V belt every 1050 hours or every 48 months 2001019 0 6 2008 SERVICE MANUAL MARINE ENGINES GENERAL after first every 50 hours 150 h 300 h or 6 or 24 months months months Service and Maintenance Schedule POLY V BELT check TENSION lubricate GLOW PLUGS change plugs every 1500 h or every 48 months TIMING check belt tension BELT change timing belt every 1500 h or every 48 months water pump tensioner every 3000 h or every 48 months ENGINE TIMING check __ settiming ____ _ ____ every 750 hours every 750 hours every 750 hours UNIT INJECTOR set levers check set point tighten torque oil level every 750 hours for leakage hydraulic oil ATF GEARBOX oil level every 750 h or every 24 months STERNDRIVE for leakage gear oil ATF see manufacturer s oil filter ENGINE COM check for leakage water specifications repair or consult PARTMENT AND fuel your STEYR BILGE exhaust gas Marine dealer If required to be SHIFTING check smooth action A adjustment replaced by your STEYR Marine Dealer see manufacturer s STEERING check lubrication oil l
10. a component screw on of an assembly without further assemblies being put on flange for functional performance mount disconnect Separating of connections of lines pipes and hoses which are separable connect Putting together separable connections of lines pipes and hoses pull off Removal of a component with press fit from another press on Placement of a component with press fit to another unscrew Opening of turnable locks tighten Closing of turnable locks disassemble Removal of an assembly from a main assembly or a component from an assembly if other assemblies have been removed before assemble Putting on an assembly to a main assembly or a component of an assembly if further assemblies are put on for functional achievement loosen Partial unlocking of fixing elements of a component or of an assembly remove Taking off a fixing element of a component or an assembly secure Putting on a fixing element of a component or an assembly and tightening disassemble Taking apart assemblies into individual components assemble Putting together components to an assembly adjust Elimination of a deviation by means of provided equipment or Valve clearance start of feeding readjust Devices or tools operation refill Adding and replenishing of operating agents renew Replacing an auxiliary material by a new one Corrosion protection agent sealing material paint gauge Reading in actual positions in programming memory replace Exchanging of a device a main assem
11. i SEN E Stern Power Drive 0302 P ed Volvo DP 290 ZF Hydraulic Pump Volvo SX Drive King Cobra Drive Page GENERAL 10 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK 2001019 0 6 2008 GENERAL 11 GENERAL SERVICE MANUAL MARINE ENGINES 4 1 Technical data and overview 4 cylinder engines type MO84K32 MO94K33 MO114K33 MO144V38 displacement 2133 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 53 71 64 86 78 105 103 138 Z Drive 52 70 63 84 77 104 101 136 number of cylinders 4 cylinder in line engine position of cyl 1 at vibration damper side ignition order 1 3 4 2 sense of rotation seen from front right compression ratio 17 5 1 full load speed range rpm 3000 3200 3050 3800 3200 3800 3600 3800 idle speed 650 rpm adjustable injection pump nozzle with modelling needle control and electronic control fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel No 2 D temperature above 7 C No 1 D temperature below 7 C fuel filter P No 2203710 0 fuel filter location intake sided air filter P No 2178992 0 oil pressure above 2000 rpm 400 700 kPa 60 100 PSI microprocessor controlled filling capacity motor oil approx 8 0 engi
12. of hazard during repair works may cause injury to persons In the description of repair works such sources of danger are marked with A ATTENTION The personnel is to be trained accordingly and requested to follow the saftey rules G2 Guidelines for damage prevention The general knowledge and training of the workshop personnel and the contents of the general regulations of safety technology and machine safety regulations Maschinen Sicherheitsverordnung MSV are not subject of this chapter Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons In the description of repair works such sources of danger are marked with A ATTENTION While handling with operating materials take care that these are not applied to visible surfaces Lubricants should form a thin film on the surface surplus lubricants are to be wiped off G3 Legal rules The following rules and guidelines are valid in Austria For other countries follow the local regulations Maschinen Sicherheitsverordnung MSV machine safety regulations Page GENERAL 40 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL G4 Safety in the use of operating material Dangerous operating material in the sense of accident prevention are all operating materials potentially explosive fire provoking easily flammable poisonous injurious to health and corrosive Especially the following material belong t
13. oil in as this will lead to severe engine damage if run for extended periods 9 Remove the main relay K27 this will stop fuel being injected and therefore the engine from starting See ill 2 Page GENERAL 28 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL 10 11 12 13 14 15 16 Remove the air filter plug the exhaust elbow and remove the inlet pipe to the tandem triple cooler see photo See ill 3 and ill 4 Fill a spray bottle with the preservation oil Shell Ensis Engine Oil 30 part number 2050323 0 Whilst cranking the engine over by turning the start key spray the preservation oil into the turbo inlet See ill 5 Continue this process for 20 to 30 seconds Refit the fuel feed line to the engine and turn the ignition on the fuel pump runs for 10 sec automatically refilling the fuel system Repeat until fuel comes from the return line Replace all pipes andconnections to original condition and re store engine The engine is now preserved for one more year ill 5 This preservation procedure must be done every year and ensures that all of the air ways systems raw water systems oil system and the cylinders are protected against corrosion This procedure is repeatable up to a maximum of three times giving a shelf life of up to four years NOTE When commissioning or running an engine that has been preserved as stated above the engine will run roughly and smoke fo
14. play 3 ring Camshaft radial Camshaft axial Valve guide Oil pressure idle run Oil pressure rated speed Backlash of teeth oil pump Axial play gear wheel New part tolerance 0 032 0 099 0 080 0 263 0 024 0 073 0 064 0 217 85 00 85 01 0 071 0 099 84 911 84 929 0 25 0 40 0 50 0 75 0 30 0 60 0 077 0 127 0 07 0 102 0 03 0 065 0 034 0 075 0 096 0 230 7 000 7 015 0 6 1 5 4 0 7 0 0 2 0 3 0 2 SERVICE MANUAL MARINE ENGINES Remark deviation from initial dimension indicates gauging depth up to 3 mm before end of valve guide Page GENERAL 50 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL J1 Adjustment information for service and maintenance Engine timing measured with dial indicator No 2300899 0 Setting instruction 3 20 0 04 mm Maintenance instruction In case the measurements are not within the specified limits of 3 14 to 3 26 mm than the settings needs to be reset to the original specified value Tension timing belt measured with tool VR00515 0 Tension instruction 600 30 N new belt Tension instruction 520 30 N used belt Maintenance instruction In case the measurements are not within the specified limits of 630 N to 490 N than the settings needs to be reset to the original specified value Start of fuel delivery on the unit injectors measured with dial indicator No 2300899 0 Setting instru
15. 006 1 It can 2010074 0 1 hardener varnish 0 5 can 2010075 0 1 dilution for varnish 5 It can Page GENERAL 38 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL F2 Disposal of automotive waste products Used operating material is to be collected in special containers to enable possible subsequent treatment ATTENTION All operating materials for the engine are subject to the Special Waste Act for disposal The Special Waste Catalog ONORM 5 2100 refers to the required disposal in Austria A Respective legal local regulations are to be followed The maintenance and repair personnel has to take care that operating material and other material to be regarded as special waste product is always deposited at collection site Key No Description 31 423 Oil contaminated soil or oil bonding agent 54 102 Waste oil 54 104 Fuels 54 202 Lubricants 54 207 Vaseline 54 917 Solid sealing material 54 927 Cil soiled cleaning rags 54 928 Used oil and air filters 55 510 Paint and varnish containing waste material 2001019 0 6 July 2008 Page GENERAL 39 GENERAL SERVICE MANUAL MARINE ENGINES NOTES ON SAFETY G1 General notes on safety The general knowledge and training of the personnel and the contents of the general regulations of safety technology and machine safety regulations Maschinen Sicherheitsverordnung MSV are not subject of this chapter Inappropriate behaviour and insufficient knowledge
16. 1 max 0 2 mass max 0 01 mass max 0 05 mass max 0 20 mg KOH g max 2 5 mg 100ml max 0 50 mass max 1 max 0 2 mass max 0 01 mass max 0 05 mass max 0 20 mg KOH g max 2 5 mg 100ml D 1266 D 2622 D 2785 D 130 D 189 D 482 D 95 D 1744 D 974 D 2274 Page GENERAL 20 2001019 0 6 2008 SERVICE MANUAL MARINE ENGINES GENERAL B2 Motor oil To obtain the best engine performance and engine life only motor oils of know manufacturers are to be used with ACEA API service code and specified SAE viscosity Refer to oil identification symbol on the container Initial filling quantity 4 Cyl engines 8 4 Litre Oil filling incl 11 oil filter 6 Cyl engines 10 4 Litre Oil filling incl 11 oil filter Oil quantity between MIN and MAX on dipstick 2 0 Litre Oil change quantity 4 Cyl engines 7 0 Liter without oil filter 6 Cyl engines 9 0 Liter without oil filter Oil filter ca 1 Litre Oil specification Minimum API CF or higher ACEA B4 02 or higher Viscosity class SYNTHETIC OIL 5W 50 SYNTHETIC OIL 10W 40 Recommended engine oil STEYR TURBO DIESEL ENGINE OIL SAE 10W 40 SMO No Z010058 0 Initial factory fill is a high quality break in oil specified ACEA B4 02 SAE 5W 50 During the break in period 20 hours frequently check the oil level Somewhat higher oil consumption is normal until piston rings are seated The oil level should be maintained bet
17. 1 Nm 2 SERVICE MANUAL MARINE ENGINES 08 01 ill 9 08 01 ill 10 08 01 ill 11 Page GENERAL 44 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Collar nut for unit injector 18 Nm 2 Nut adjustment screw of unit injector 30 Nm 3 Plug screw for control rack in camshaft housing 50 Nm 5 Screw exhaust manifold 23 Nm 2 08 01 ill 14 08 01 ill 16 2001019 0 6 2008 GENERAL 45 GENERAL Studs turbocharger M8 23 Nm 2 M10 35 Nm 2 Nut turbocharger greased with NEVER SEEZ M8 25 Nm 2 M10 45 Nm 2 Screws intercooler 28 Nm 2 Plug screws zinc anode 50 Nm 5 Crown nut oil cooler use LOCTITE 243 on thread 55 Nm 5 NOTE for all clamps 3 5 Nm SERVICE MANUAL MARINE ENGINES 08 01 1 17 08 01 ill 19 08 01 ill 20 Page GENERAL 46 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL H2 General Tightening torques Values in this table refer to industrial standard and are applicable if no specific torques are are indicated For studs tightening torques are to be reduced by 50 p tot 0 125 MA in NM Property class 8 8 109 129 Metric Nominal standard thread M4 2 7 3 88 4 6 M5 5 5 8 9 5 M6 9 5 13 16 M7 15 22 26 M8 23 32 3
18. 9 M 10 46 64 77 M 12 80 110 135 M 14 125 180 215 M 16 195 275 330 M 18 270 390 455 M 20 385 540 650 M 22 510 720 870 M 24 660 930 1100 M27 980 1400 1650 M 30 1350 1850 2250 Nominal 8 1 25 35 42 10 1 25 49 68 82 12 1 25 88 125 150 12 1 5 83 115 140 14 1 5 140 195 235 16 1 5 210 295 350 18 1 5 305 425 510 20 1 5 425 600 720 22 1 5 570 800 960 24 2 720 1000 1200 27 2 1050 1500 1800 30 2 1450 2050 2500 If the tightening torque of a screw connection is not reached the tightness of the screw nut is too low or the ratio of friction do not correspond In any case the screw nut is to be replaced tot total frictional value 2001019 0 6 July 2008 Page GENERAL 47 GENERAL SERVICE MANUAL MARINE ENGINES H3 Testing of torque wrenches The torque wrenches are subject to regular tests of the set values By doing so the tripping value of signalling torque wrenches and the scale accuracy of measuring torque wrenches are tested H4 Non destructive material testing For the detection of surface cracks the non destructive test according to colour penetration test procedure is recommended The workpiece is sprayed or coated with a penetration agent and after drying a developer is applied After a development time of appr 10 minutes defects on the workpiece appear as dots or lines H5 Use of adhesive and sealing materials In the workshop manual adhesi
19. COOLING SYSTEM oil filter motor oil for leakage fluid level hoses hose clamps antifreeze temperature condition RAW WATER SYSTEM antifreeze hoses hose clamps every 24 month zinc anodes raw water pump V belt impeller change raw water pump V belt impeller zinc 5 preserve RAW WATER COOLER OIL FUEL raw water circuit raw water passages clean out desposits in pipelines AUX LUBRICANT for 246 256 and 266 only AIR check zinc anodes contamination required if more than 50 material corroded FILTER change air filter element preserve check for leakage after season hoses drain addtiional fuel filter change fuel filter check additional fuel filter preserve fuel system if reguired if reguired if corroded 50 after season after season BATTERY check acid level densitiy ELECTRICAL EQUIPMENT INVERSION check SWITCH Solas only DRIVING re center SYSTEM V BELT connections insulation driving unit generator amp impeller pump tighten loose con nections Renew cables if required Switch every 50 hours or every 6 months see manufacturer s specifications adjust tension power steering adjust tension for all 6 cyl models
20. ENERAL SERVICE MANUAL MARINE ENGINES H Tightening Torques H 1 Listing of Tightening Torques Camshaft Housing Screw joint to cylinder block 1 step 15 Nm 2 2 step 25 Nm 1 Tighten screws of camshaft housing in two steps in precedence of numbering on bearings from the inside outwards 08 01 ill 1 Plug screw for locking pin in engine housing 50 Nm 5 Connecting rod screws apply oil to thread and screwhead support 1 step 10Nm 1 2 step 30 Nm 3 3 step 75 4 08 01 ill 3 Main bearing screws apply oil to thread and screwhead support 1 step 35 Nm 2 step 45 4 3 step 45 4 08 01 1 4 Page GENERAL 42 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Flywheel screws use LOCTITE 243 on thread 75 Nm 4 Vibration damper screws apply oil to thread and screwhead support 135 Nm 2x 7 Screw rear ring carrier use LOCTITE 243 on thread 1 step 8 Nm 1 2 step 30 Nm 3 Nut camshaft sprocket taper degreased on camshaft thread lubricated 1 step 80 Nm 4 2 step 240 Nm 12 08 01 ill 6 08 01 ill 8 Z001019 0 6 July 2008 Page GENERAL 43 GENERAL Screw tooth belt tensioner 45 Nm 4 Valve adjustment element 55 Nm 3 Screw linkage lever CAUTION left hand thread 7 Nm 0 5 Stud unit injector 2
21. PTO Page GENERAL 8 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Transmission i 2 5V shaft angle 12 JL i 2 0V shaft angle 12 0302 4 Lifeboat Engine Equipment KE Bobtail Direkt gearbox 03 02 A down angle gear box 0302 7 H Parallel offset gearbox DEUT 0302 8 2001019 0 6 July 2008 Page GENERAL 9 GENERAL SERVICE MANUAL MARINE ENGINES aces HO Ke T Jet drive 0302 9 Jet Drive AKO TYPE C Alamarin Hamilton Castoldi T T 03 02 1 Stern drive Type Mercury Bravo amp 111 Volvo 290
22. Pipe Oil Dipstick Hydraulic Oil Tank Cooler Cap Potentiometer Accelerator Motor Oil Filler Cap Boost Pressure Sensor Rack Position Sensor Drive Belt Cover T Belt Lower Engine Mount Drive Belt Tensioner Vibration Damper Cover T Belt Upper Engine Lifting Eye Speed Sensor Valve Cover Heat Exchanger Coolant Expansion Tank Diagnostic Outlet Inversion Switch only for SOLAS Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Alternator Circuit Breakers Engine Management System Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais Backside E Box Ground Plate Starter Motor Flywheel Flywheel Housing Oil Pressure Sensor 19 18 17 16 15 14 13 12 11 20 31 30 29 28 44 43 1 1 32 33 34 35 36 37 38 39 This sensor is magnetism sensitive All external magnets must be kept away Z001019 0 6 July 2008 Page GENERAL 13 06001 06002 15 40 41 42 06003 46 47
23. SERVICE MANUAL MARINE ENGINES GENERAL GENERAL Table of Contents A General Remarks 3 1 Model and Serial Numbers Eee 3 A2 Doc m ntatio EES T 4 A3 Model EU E EE doch cee 5 A 3 1 Model summary 4 cylinder ee ee ee 5 3 2 Model summary 6 cylinder ee 8 A4 Technical Data and etc iat e taut ea eo 12 A 4 1 Technical Data and Overview 4 cylinder engines 12 A 4 2 Technical Data and Overview 6 cylinder engines 16 B DN c 20 B 1 Fuel 20 B2 pte 21 C Maintenance and Service 22 C 1 Trouble CHECK Gall EI 22 C2 Service and Maintenance Schedule 24 D General Information EKS eN Ee De GR EK eu be we 26 D 1 Electronic Engine Management System ECU 26 D2 Diagnostic 27 D3 Extended Storage Preservation Procedure 28 D4 Engine Break in procedure 30 D5 Operation after Break iss hee icon e EER 32
24. an dry and dustfree environment Lifting gear crane with a lifting capacity of 5 000 N 500 kg minimum Cleaning device wash basin for soiled components Commercial tools Appropriate test and measuring equipment Receptacles for operating agents Depending on the repair step to be carried out the tools indicated in the catalog TOOL KIT are to be provided Furthermore special care is to be taken in case of purchasing and stock of required operating material spare parts and wear parts e g seals filters anodes For appointed retailers and authorized workshops of STEYR MOTORS GmbH the following minimum standard is to be met basic training as soon as possible after conclusion of contract for trade and workshop biannual training reacurring tool kit service and maintenance tools tool kit III depending on repair to be carried out procurement and stock of required genuine spare parts as per proposed spare parts spare part catalogue for all STEYR MARINE ENGINES models technical literature PC diagnostics Page GENERAL 34 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL E3 Nomenclature Term Description Example disassemble Removal of an assembly of a main assembly or of a component remove of an assembly without other assemblies having been removed unscrew before deflange dismantle assemble put on place Putting on of an assembly on a main assembly or
25. bly an assembly or a component by the same new or repaired ones measure Steps taken to determine the actual status by evaluating of physical entities check Steps taken to compare the actual status with a determined Valve lift piston diameter valve clearance close fit V belt tension clean Removal of foreign and auxiliary material maintain Steps taken to keep the respective determined planned status 2001019 0 6 July 2008 Page GENERAL 35 GENERAL E4 SI System The following measuring units are used Linear km kilometer m meter mm millimeter inch Area m square meter cm Square centimeter Volume m cubic meter cm cubic centimeter dm cubic decimeter mm cubic millimeter litre Mass t metric ton kg kilogram g gram Energy N newton kN kilonewton daN dekanewton Electricity A ampere V volt ohm uF microfarad Fuel consumption g kWh gram per kilowatt hour SERVICE MANUAL MARINE ENGINES Pressure and Stress bar bar Pa pascal KPa Kilopascal N mm newton per square millimeter Energy J Joule kW h kilowatt hour Power kW kilowatt Temperature K degrees Kelvin C degrees Celsius Time h hour min minute 5 second Velocity km h kilometer per hour m s meter per second Speed 1 min GENERAL 36 2001019 0 6 July 2008 SERVICE MANUA L MARINE ENGINES GENERAL E5 Abbrev
26. ction For original settings on your engine please see table 03 02 06 Maintenance instruction In case the measurements are not within the specified limits the settings needs to be reset to the original specified value Valve clearance measured with tool No 2300712 3 Setting instruction 0 25 mm Maintenance instruction In case the measurements are not within the specified limits less than 0 25 more than 0 30 mm the settings needs to be reset to the original specified value 2001019 0 6 2008 GENERAL 51 GENERAL SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK Page GENERAL 52 2001019 0 6 July 2008
27. e transformation of liquid state into an epoxy built up by molecular chains Any residues remaining after assembly and or are pressed out of the connection remain liquid and may be removed easily Page GENERAL 48 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL General guidelines of application for the of use of anaerobic sealing materials Cleanliness of components Non metallic surface protection must be removed In case of repair soiled and oily components are to be cleaned and residues of adhesive plastic material are to be removed Thread bores are recut with the appropriate thread bore and blown out with compressed air If solvents or degreasing agents are used for cleaning take care that they are completely volatilized before application of the epoxyl Storage At temperatures below 28 C 1 year minimum Guidelines of application for securing S Designation SM Securing medium tight the connection is to be loosened without problems Designation SF Securing tight the connection is difficult to loosen Application Screw connections Fixing procedure In general the application of the epoxy to the screw thread is sufficient If screws screwed into socket threads only the thread bore is wet in order to let the air escape during screwing in Screws or nuts which are tightened with a specified torque are slightly oiled on their support surface or housing part Guidelines for
28. e material 2 22044 48 H5 Use of adhesive and sealing materials 48 H6 Solvent free sealing materials 48 J Wear 50 41 Adjustment information for service and maintenance 51 Page GENERAL 2 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL A GENERAL REMARKS A1 Model and Serial Numbers The primary model and serial number ill 1 or ill 2 is located on the engine as illustrated These numbers are required for warranty claims and ordering parts FOR ALL FOR ALL 4 CYL MARINE ENGINES 6 CYL MARINE ENGINES 08006 The model and serial number of the marine gearbox is located on the marine gearbox housing as illustrated To obtain instructions regarding marine gearbox operation refer to marine gearbox owners manual Z001019 0 6 July 2008 Page GENERAL 3 GENERAL SERVICE MANUAL MARINE ENGINES A2 Documentation 4 and 6 cylinder The following documentation is available in English language on our website http www steyr motors com technical technical documentation on CD ROM P N Z 001009 0 operation maintenance amp warranty manual for all marine engines P N Z 001022 0 tool catalogue for all marine engines P N Z 001002 1 spare parts ca
29. eds M084K32 3000 rpm M094K33 3000 rpm MO114K33 3000 rpm MO144M38 BUKH STEYR SOLAS 3200 rpm 0144 38 BUKH STEYR SOLAS 3200 rpm 0164 40 BUKH STEYR SOLAS 3400 rmp 126 28 2200 0166 28 2200 MO236K42 BUKH STEYR SOLAS 3300 rpm MO256K43 3600 rpm MO256H45 3600 rpm which will prolong engine life and reduce sound emissions When starting a cold engine always allow the engine to warm up slowly Never run the engine at full speed until operating temperature is reached During the first 50 running hours check the oil level frequently Page GENERAL 32 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK 2001019 0 6 2008 GENERAL 33 GENERAL SERVICE MANUAL MARINE ENGINES E E 1 E2 QUALITY GUIDELINES FOR REPAIR Spart part specification Your STEYR marine engine was designed for marine operation which means operating conditions such as Long time operation at high speed Operation in salt or brackish water Operation in very muddy water Only use genuine STEYR MARINE spare parts in order to avoid possible loss of performance For this reason you should insist on the famous quality of genuine STEYR MARINE spare parts and under no circumstances use spare parts of unknown quality Workshop profile Independently of the respective repair steps and the legal regulations the workshops have to meet the following requirements Cle
30. er Motor Engine Management System Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais Backside E Box Ground Plate Flywheel Flywheel Housing Oil Pressure Sensor This sensor is magnetism sensitive All external magnets must be kept away 12 3 456 7 2 06033 2 _ 30 31 32 33 34 35 36 37 15 38 39 40 41 42 06034 06035 Z001019 0 6 July 2008 Page GENERAL 17 GENERAL SERVICE MANUAL MARINE ENGINES type MO256K43 MO256H45 displacement 3200 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 178 239 178 239 Z Drive 176 236 176 236 number of cylinders 6 cylinder in line engine position of cyl 1 at vibration damper side ignition order 1 5 3 6 2 4 sense of rotation seen from front right compression ratio 17 5 1 full load speed range rpm 4000 4300 4000 4500 idle speed 630 rpm adjustable injection pump nozzle with modelling needle control and electronic control fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel No 2 D temperature above 7 C No 1 D temperature below 7 fuel filter P No 2178992 1 fuel filter location suction sided air filter P No 2178992 0 P No 2178992 1 oil pressure above 2000 rpm 400 700 kPa 60 100 PSI microprocessor co
31. essure control lamp If the lamp lights up as soon as the boat changes its position while turning raising the boat or planing check the oil level in the engine housing by means of dipstick If necessary add oil DO NOT OVERFILL In casethatthe oil pressure control lamp still illuminated with correctoil level have the engine checked by your STEYR Marine dealer as to malfunction of signal or oil pump NOTE During normal operation of engine oil pressure will rise as RPM increases and fall as RPM decreases In general oil pressure will be higher with cold motor oil and specific RPM than with hot motor oil C Check engine temperature indication Normal operation between 80 95 In case of audible alarm check coolant level in expansion tank only at cold engine D Deviations from normal operating conditions will be indicated by warning lights and audible alarm As to exact meanings see 06 07 02 amp 06 07 05 ATTENTION In case of nonobservance of break in instructions warranty will expire A Engine to be filled with recommended oil quality only See chapter Engine Lubrication 2001019 0 6 2008 GENERAL 31 GENERAL SERVICE MANUAL MARINE ENGINES D5 Operation after Break In The engines specified in this manual are intended to be operated at different speeds and loads but not allowing full load of the engine for more than one hour per 12 running hours Economic driving may be achieved at the following spe
32. evel SAFETY check remote control specification local rules EQUIPMENT emergency cutout and consultation of your STEYR A completeness condition SHAFT BEARING check lubrication consult STEYR sealing ENGINE MOUNT check SCREWS WARNING function DEVICE Marine Dealer every 750 hours 2001019 0 6 2008 GENERAL 25 GENERAL D General Information D1 Electronic Engine Management System SERVICE MANUAL MARINE ENGINES The STEYR Marine engine is equipped with an Electronic Management System EMS that performs the following controls engine functions to ensure maximum efficiency self diagnostic to protect the engine from damage if operating parameter are exceeded stores diagnostic data of EMS server circuits for maintenance and service stores abuse data Engine power is reduced if Operating Parameter High engine coolant temperature limit exceeded Defect engine coolant sensor or sensor connection Exhaust temperature limit exceeded Defect Exhaust temperature sensor or sensor connection Oil pressure below limit Defect Oil pressure sensor or sensor connection Insufficient boost pressure or defective sensor Engine speed sensor fault Engine speed remains at idle Governor position system Effect noticed Reduction of engine speed Reduction of engine speed Reduction of engine speed Red
33. fixing B Designation BM Fixing medium tight Designation BF Fixing tight Application Jointing connections bushings sprockets belt pulleys bearings etc Jointing procedure In case of jointing connections both jointing parts are to be wetted The wetting has to completely cover the jointing surfaces The parts are shifted into each other by turning in case of slide fits No strength may be exerted to the connection until sturdiness is reached for time refer to Table 1 Guidelines of application for sealing D Designation DR Sealing of pipe connections Designation DF Sealing of plane surfaces Application Sealing of threads screw connections jointing connections and plane surfaces Hardening time m Product Loctite 243 Loctite 262 Loctite 620 Loctite 509 Loctite 510 Loctite 5900 D 15 30 min 15 30 min 5 10 min 15 30 min immediately immediately reached after Functional tightness immediately immediatel reached after 4 d Final tightness 12 24h 12 24h reached after 2001019 0 6 2008 GENERAL 49 GENERAL J Wear Limits Part resp part union Main bearing clearance radial Main bearing clearance axial Connect rod bearing clear radial Connect rod bearing clear axial Cylinder bore Piston travel clearance Piston diameter Gap 1 ring Gap 2 ring Gap 3 ring Axial play 1 ring Axial play 2 ring Axial
34. fuel supply for water contamination If water is present drain fuel tank and flush with fresh fuel System error or failure Check Engine Management System display for service code Battery output insufficient Charge or replace battery Only for SOLAS gt 8 Inversion switch actuated Cancelled by ignition OFF ON Starter won t crank Battery connections loose or Check for loose connections engine corroded and corrosions Clean connections and thighten Battery is dead Check level of electrolyte and charge battery Starter connections loose Check connections and tighten If solenoid clicks when attempting to start engine check starter Ignition switch If inoperative replace 5 Fuse blown on panel Check and replace if defect Starter auxiliary relay Check terminal connection and function of relay Engine runs erratically 1 Water air and or dirt in fuel filter Replace filter Inspect fuel supply line Anti siphon valve stuck Clean and inspect or replace Tank Fuel pump Check operation of pump Replace fuel pump Page GENERAL 22 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Trouble Check Chart continued SYMPTOM POSSIBLE CAUSE ACTION Engine vibrates Propeller condition Check for bent broken or damaged propeller Check for weeds on propeller or sterndrive gearcase Check for bent propeller shaft Unit injector Check Engine runs but boat Fouled propeller etc
35. g operation is ranked in three different categories intermittent failure non essential failure and essential failure 2001019 0 6 July 2008 Page GENERAL 27 GENERAL SERVICE MANUAL MARINE ENGINES D3 Extended Storage Preservation Procedure 1 Remove the engine from storage and place on a suitable work shop floor with access to all side of the engine Do not remove from the original packing pallet 2 Start the engine and let it run up to temperature 3 Stopthe engine and drain the old engine oil and store for future refill and usage 4 Fill in preservation oil Shell Ensis Engine Oil 30 part number Z050323 0 5 litres up to the minimum mark on the dip stick 5 Connect the fuel system to a tank or canister filled with Shell oil V1404 part number Z010014 0 5 litres See ill 1 6 Restart the engine and allow to run in idle for 5 minutes 7 Disconnectthe fuel feed line from the engine andturn the ignition on the fuel pump runs for 10 sec automatically emptying the fuel system Repeat until no more fuel comes from the return line 8 Either drain the preservation oil from the engine and replace with normal oil as per Service Bulletin 5 7004 and store for future use Alternatively leave it in the engine for future preservation work The preservation oil has a shelf life of also 3 years and may be used any number of times within this period It is important to note that an engine may never be sold on or installed with this
36. iations ill Cu MAssy max TDC PTO WS EMS ECU illustration copper main assembly maximum top dead center POWER TAKE OFF power transmission at front crankshaft end wrench size Electronic Management System Electronic Control Unit 2001019 0 6 2008 GENERAL 37 GENERAL SERVICE MANUAL MARINE ENGINES F OPERATING MATERIAL AND INFORMATION ON DISPOSAL F 1 List of operating material Order No Qty Designation VR00207 0 1 set of fuel and oil for engine service consisting of 2010058 0 3 STEYR Turbo Diesel motor oil SAE 5W 50 41 can 2011785 0 3 STEYR MOTORS engine coolant 5l can 9000190 0 2 hydraulic oil ATF 11 bottle Z012222 0 1 grease Never Seez NS 160 B 1 kg can Z909570 0 1 caoutchouc sealing electric contacts 148 ml can 9000059 1 1 thread protection 243 10 ml flask 9000297 1 1 surface sealing 509 315 ml cartridge 9000510 5 1 surface sealing 5910 50 ml cartridge 9000019 1 1 construction adhesive 620 50 flask 900001 7 1 1 construction adhesive 262 50 ml flask Z010207 0 1 contact grease 100 ml tube 2010226 0 1 corrosion protection spray 400 ml can 2010227 0 1 corrosion protection wax 120 ml can 2010084 0 1 grease STABURAX NBU4 1 kg can 2010205 0 1 fuel rust protection additive 5 It can 9000197 0 1 electric contact spray Z011627 0 1 silver varnish RAL 9
37. ne housing incl approx 1 oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P NO Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location pressure sided electric charging system 14 V 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit thermostat controlled pressurized cooling circuit circulating pump with heat exchanger on engine governor pump external raw water circuit to heat exchanger coolant capacity 11 5 liters coolant STEYR MOTORS engine coolant 36 C P No Z011785 0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH reserves the right to make changes without notice or obligations Efficiency of gearbox 97 0 efficiency of Z drive 95 5 Page GENERAL 12 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl Marine Engines Zinc Anode 4 Units Model and Serial Number Intercooler Fuel Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation only SOLAS Oil Drain Plug Fuel Filter Oil Filter Hydraulic Pump Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug 2 Units Engine Oilcooler Oil Suction
38. ntrolled filling capacity motor oil approx 10 0 1 engine housing incl approx 1 oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P NO Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location suction sided electric charging system 14 V 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit thermostat controlled pressurized cooling circuit circulating pump with heat exchanger on engine governor pump external raw water circuit to heat exchanger coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No Z011785 0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH reserves the right to make changes without notice or obligations 5 Efficiency of gearbox 97 0 efficiency of Z drive 95 5 Page GENERAL 18 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO256K43 MO256H45 ie eem _ 12 3 4 52 6 2 Boost Pressure Sensor Zinc Anode 5 Units Intercooler Engine Oil Fuel Hydr Oil Cooler Model and Serial Number Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation only SOLAS Fuel Filter Fuel Pump Oil Filter Raw Water Inlet Fitting Raw Water Pump
39. o this group Spirit Mineral oils Battery acid Anti freeze agent Varnishes and diluents Solvents Fluid seals and nut locks In case of fire of operating material do not try to extinguish the fire with water Use carbon dioxide extinguisher or powder extinguisher Contact fire brigade When operating material is spilled e g in case of refueling it is to be absorbed by sand soil or an appropriate bonding agent and to be disposed ATTENTION In order to prevent health hazards take care of the following A Avoid direct contact with dangerous operating material as far as possible Change clothes as quickly as possible if they are soiled with dangerous operating material Do not keep oily rags in work clothes Clean oil soiled body parts only with products friendly to skin never use rubbing sand or solvents Never fill operating agents in beverage bottles G5 Measures in case of accidents Products First Aid Skin Eyes Swallowing Diesel fuel DO NOT VOMIT and mineral oils Remove clothes and Rinse thoroughly with The biggest danger after an accidental intake is the fact that Lubricants clean skin thoroughly water for at least liquid could get into lungs by aspiration Anti freeze agents with water and soap 10 minutes DO NOT PROVOKE VOMITING Brake fluid SEE AND IIMMEDIATELY SEE A DOCTOR Battery acid DOCTOR 2001019 0 6 2008 Page GENERAL 41 G
40. otentiometer failure See table trouble shooting Governing system Page GENERAL 26 2001019 0 6 2008 SERVICE MANUAL MARINE ENGINES GENERAL Operating Parameter Effect Panel Additional Action or noticed Indication Tool Readings possible reason Inverse position shut Engine shut After engine stop Reset through ignition down SOLAS down beyond horn remains OFF and then ON 70 deg angle switched ON until ignition reset During break in phase Cel ON at high Indication light Steyr Diag See information break accelerator CEL is switched Break in in procedure position more ON phase than 75 Optical and accustical warning signals are explained on the following tables Operating Status and Error Report D2 Diagnostic system The electronic management system monitors the following engine parameters oil pressure boost pressure coolant temperature exhaust pipe temperature Hi riser sensor control rack potentiometer accelerator speed signal The electronic management system carries self diagnostic and or plausibility checks for all input values and sensor connections In case of irregularities there is an optical or audible warning signal see page 71 Existing active failures remain stored until the problem has been solved and the code has been cleared from the memory To select stored error codes a PC with diagnostic program VR00134 0 or diagnostic tool VR00135 1 is necessary Malfunction durin
41. ow to Select Fuel Oil Fuel quality is an important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels Direct injected diesel engines are designed to operate on most diesel fuels marketed today In general fuels meeting the properties of CEC RF 03 A 84 have provided satisfactory performance The ASTM D 975 specification however does not in itself adequately define the fuel characteristics needed for assurance of fuel quality The properties listed in the following fuel oil selection chart have provided optimum engine performance Fuel Oil Selection Chart General Fuel classification Cetane number Gravity at 15 C Destillation 50 90 End point Flash point CFPP Cloud point Viscosity Kinematic 40 C CEC RF 03 A 84 Limit value and units min 49 max 53 min 0 835 max 0845 min 245 C min 320 C max 340 C max 370 C min 55 C min max 5 min 2 5 mm s CEC RF 03 A 80 Limit value and units min 51 max 57 min 0 835 max 0845 min 245 C min 320 C max 340 C max 370 C min 55 C max 5 min 2 5 mm s max 3 5 mm s ASTM Test procedure D 613 D 976 D 1298 D86 D 93 EN 116 CEN D 445 max 3 5 mm s Sulfur content Cupper corrosion Carbon residue Conradson number 10 residue Ash Water content Acid content strong acid Oxidation stability max 0 3 mass max
42. r the first few minutes Do not be alarmed as this is normal until the deposits of the preservation materials have cleared Z001019 0 6 July 2008 Page GENERAL 29 GENERAL SERVICE MANUAL MARINE ENGINES D4 Engine Break In procedure The following procedure must be used on new and rebuilt STEYR Diesel Engines You must follow the Engine Break In instructions during the first 20 running hours to ensure maximum performance and longest engine life NOTE NONOBSERVANCE OF BREAK IN INSTRUCTIONS MAY CAUSE SEVERE ENGINE FAILURE First Two Hours For the first five to ten minutes of operation run engine at a fast idle below 1500 RPM For the remaining first two hours of operation accelerate to bring boat onto plane quickly and bring throttle back to maintain a planing attitude During this period vary the engine speed frequently by accelerating to approximately three fourth throttle for two to three minutes then back to minimum planing speed When the engine has reached operating temperature reduce engine speed then increase engine speed again to assist the break in of rings and bearings Maintain planing attitude to avoid excessive engine load NOTE DO NOT RUN ENGINE A CONSTANT RPM FOR LONGER PERIODS DURING THIS INITIAL TWO HOURS OF BREAK IN ATTENTION Warning indication engine over load during break in via ECU The ECU controls during the first two hours of engine operation the load on the engine and alarms the drive by the
43. strument Panel Coolant Temperature Sensor Thermostat Housing Alternator Circuit Breakers Engine Management System Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais Backside E Box Ground Plate Starter Motor Flywheel Flywheel Housing Oil Pressure Sensor 19 18 17 16 15 14 13 12 11 20 31 30 29 28 44 43 1 1 32 33 34 35 36 37 38 39 This sensor is magnetism sensitive All external magnets must be kept away Z001019 0 6 July 2008 Page GENERAL 15 06001 06002 15 40 41 42 06003 46 47 48 49 06004 GENERAL SERVICE MANUAL MARINE ENGINES A 4 2 Technical data and overview 6 cylinder engines type MO126M28 MO166K28 MO196K35 MO236K42 displacement 3200 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard Z Drive 87 117 86 115 136 182 134 179 116 156 115 154 165 221 162 218
44. talogue STEYR 94 td diesel marine P N Z 001023 0 STEYR 144 vti td diesel marine P N Z 001005 0 STEYR 164 td diesel marine P N Z 001015 0 STEYR 174 vti diesel marine P N Z 001011 0 STEYR 166 td diesel marine P N Z 011796 1 STEYR 236 FDE P N Z 011796 0 STEYR 236 td diesel marine P N Z 011796 1 Z011769 2 STEYR 246 td diesel marine P N Z 011800 0 STEYR 256 td diesel marine P N Z 011810 0 STEYR 266 td diesel marine P N Z 011805 0 installation manual for marine engines P N 2 001007 0 service manual for all marine engines P N Z 001019 0 operator s manual marine gear ZF P N Z 001003 0 Diagrams marine engine functions on CD P N Z 001021 0 Page GENERAL 4 2001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES GENERAL Modell summary A3 1 Modell summary 4 cylinder engines Bobtail Version Equipment with side mounted raw water pump or with side mounted raw water 03 01 ill 1 pump power steering pump Inborder i e ZF 45 Marinegear Down angle 03 01 ill 2 Innenborder i e ZF 63 Marinegear 03 01 ill 3 2001019 0 6 July 2008 Page GENERAL 5 GENERAL Lifeboat Engine 03 01 1 4 03 01 ill 5 03 01 ill 6
45. uction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed Higher or unstable idle speed limited performance No increase of engine speed if throttle is moved to max Irregular engine speed or stalled engine Panel Indication Horn ON 2x p sec Gauge reading gt 107 Horn ON 2x p sec Gauge reading gt 120 Horn and indication light CEL ON 2x p sec Horn and indication light CEL ON 2x p sec Horn continuous and Oil indication light continous switched ON Oil pressure indication light switched ON 1x p sec No RPM indication on tachometer Additional Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Service code Steyr Diag Service code Action or possible reason See table trouble shooting Cooling system Sensor or connector failure see service code table See table trouble shooting Raw water cooling system Sensor or connector failure see service code table See table trouble shooting Engine oil system Sensor or connector failure see service code table See table trouble shooting Air charge system See table trouble shooting Speed sensor See table trouble shooting Accelerator p
46. ve and sealing materials are specified for the repair of engines and aggregates which are used at operating temperatures of up to 150 C and agents such as water coolants and hydraulic fluids engine and gear oils as well as fuels Solvent free sealing materials The hardening takes places without loss of volume so that a retightening of screw connections is not necessary Anaerobic sealing materials These are used for securing fixing and sealing and only harden under exclusion of air Solvent containing sealing materials Due to their contents of volatile parts a loss of volume occurs during hardening During repair the hardening time is taken into consideration If such sealing materials are used special reference is made in the description of the workshop manual H6 Solvent free sealing materials Silicon sealing materials They consist of silicon and filling materials and are free of solvents The product is applied to the cleaned sealing surface from the tube or cartridge in form of a string Sealing material residues are removed with cleaning agent Silicon sealing material is to be stored below 30 C Anaerobic sealing materials They consist of a single component epoxy in liquid form The product is applied as a liquid to the components and remains liquid as long as it is in contact with ambient air oxygen Only when the parts are assembled chemical reaction starts due to exclusion of air oxygen and metal contact i
47. w water circuit to heat exchanger coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No Z011785 0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH reserves the right to make changes without notice or obligations Efficiency of gearbox 97 0 efficiency of Z drive 95 5 Page GENERAL 16 2001019 0 6 2008 SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO126M28 MO166K28 MO196K35 MO236K42 mo emma O O O O Boost Pressure Sensor Zinc Anode 5 Units Intercooler Fuel Hydr Oil Cooler Engine Oilcooler Model and Serial Number Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation only SOLAS Fuel Filter Fuel Pump Oil Filter Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug 2 Units Oil Suction Pipe Oil Dipstick Rack Position Sensor Engine Lifting Eye Motor Oil Filler Cap Potentiometer Accelerator Drive Belt Raw Water Pump Engine Mount Drive Belt Tensioner Cover T Belt Lower Vibration Damper Drive Belt Alternator amp Hydr Pump Speed Sensor Cover T Belt Upper Valve Cover Heat Exchanger 46 Coolant Expansion Tank 45 Cooler Cap Diagnostic Outlet Inversion Switch only for SOLAS 44 Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Hydraulic Oil Tank Circuit Breakers Alternator Hydraulic Pump Oil Drain Plug Start
48. ween the minimum and maximum marks on the dipstick The space between the marks represents approximately 2 quarts 2 litres For oil dipstick location refer to section Technical Data and Overview A 4 Refer to Service and Maintenance Chart C 2 for recommended oil change intervals FOR HEAVY DUTY DIESEL ENGINES Oil Identification Symbol Motor oils are specified by ACEA API service code and SAE viscosity numbers These may be found on the label top of can or oil identification symbol NOTE Some motor oils have several ACEA API quality ratings A The recommended ACEA API service letter code must be among these quality ratings ill 1 Top of Can 1 2 Oil Identification Symbol 02 02 ill 2 Z001019 0 6 July 2008 Page GENERAL 21 GENERAL SERVICE MANUAL MARINE ENGINES Maintenance and Service C1 Trouble Check Chart ATTENTION After following the Action described in chart and before cranking the engine make sure A there are no loose fuel connections Make sure engine compartment is free of fuel vapours Failure to do so could result in fire SYMPTOM POSSIBLE CAUSE ACTION Engine won t start No fuel in tank or shut off valve Fill tank or open valve closed Air leak in suction lines Bleed fuel system and check for leaks Fuel line plugged or pump Fuel pump may be defective defective Poor fuel quality Replace fuel Water in fuel filter Replace or drain water from fuel filter Check
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