Home

4 cylinders + 6 cylinders 4 cylinders + 6 cylinders

1. 08021 This sensor is magnetism sensitive All external magnets must be kept away 61 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS 62 INNOVATION WITH LIGHTNESS 7 G Owner Log MR Rm o 65 FOREWORD 65 IMPORTANT NOTE 65 Service and Maintenance Schedule ecce 66 MAINTENANCE LOG 68 Table Error Indication on Instrument Panel 70 Table Error Indication on Instrument Panel for SOLAS only 72 Reading Service Codes 74 Indication and Cancellation of memorised sensor and circuit faults 75 Selection and clearing of stored service codes 75 Principle service code list 76 Trouble Check Mec 78 NVM cm 80 WIRING DIAGRAM MARINE BASE 4 6 CYLINDER 12 V 81 WIRING DIAGRAM MARINE 4 6 CYLINDER 2 POLE JP Ero gps 82 WIRING DIAGRAM MARINE 4 6 CYLINDER 24 V OPTION 83 WIRING DIAGRAM MARINE 4 6 CYLINDER 2 POLE 24 V COMPLETE SYS TEM ecc M 84 Description Wiring harness instrument
2. jo je Way QLVLE 391 0 c94 poys 10 enpe val 99 LAIH LOL uonoeuuoo ussu JO oys LO ZLOGL ZUld 129J9q Eid d L0 60v L LUld 10sues M2 Jo uiejqoud 024 uonisod uonisod peg 1 Dunes 0721 LOO guid oey 49 uoge4qieo sod Humes 10 6109 guid 0915 99 yueso jeubis peeds 1051 5 LO ELLO9 GLE GLX 99 Bunes prouejos jsisse 5 5 ON jsisse 5 92M Ed 18 8CM OSUld LIN ejspeg YS 95 4 LO ELLO9 19 8 yx 59 uonoeuuoo Bussu 10 0109 9 poys 00 jaaa 10 1109 guid Vig vix 504 407 GE uonoeuuoo 00 10721019992 10 91109
3. after season clean out desposits in pipelines OIL FUEL AUX LUBRICANT for 246 256 and 266 286 306 126 156 only check change zinc anodes check required if more than 50 96 material corroded change AIR FILTER preserve for leakage contamination air filter element after season check hoses drain addtiional fuel filter change fuel filter check additional fuel filter fuel system FUEL SYSTEM level after season ELECTRONICS connections connections tighten loose EQUIPMENT INVERSION check SWITCH Solas only DRIVING re center driving unit SYSTEM insulation ELECTRICAL connections check V BELT connections Renew cables if required Er 50 hours or Er 6 months see eg 5 eg adjust tension power steering adjust tension if required for 6 cyl models generator amp impeller check change power steering POLY V BELT SERPENTINE BELT belt pulleys and tighteners for wear if required for 4 and 286 306 126 156 models Poly V belt pump check change every 1 050 hours or every 48 months 66 INNOVATION WITH LIGHTNESS STEYRMOTORS Service and Maintenance Sc
4. C 2 4 o 50 3 300 rpm 0 rpm 200 rpm uoi 3 800 rpm 0 rpm 300 rpm 3 800 rpm 0 rpm 300 rpm scat Range RPM 174 40 4 000 0 300 126 25 2 500 0 200 2 800 rpm 0 rpm 200 rpm 2 500 rpm 0 rpm 200 rpm 2 800 rpm 0 rpm 200 rpm 4 300 rpm 0 rpm 300 rpm 4 500 rpm 0 rpm 300 rpm 4 300 rpm 0 rpm 300 rpm 97 10 11 12 13 14 15 16 T 18 STEYRMOTORS INNOVATION WITH LIGHTNESS STEYR MOTORS Dealer Check List NOTE If STEYR MOTORS HYBRID SYSTEM is in use check below mentioned points but also START UP OF HYBRID SYSTEM see HYBRID INSTALLATION MANUAL P N Z001044 0 chapter 5 before ignition is turned on or engine is started Remove carton from palette and check the separately packed components are complete and undamaged Visual inspection of engine for transit damage and finish Check coolant and oil level If required add operational fluids as specified in Operation Maintenance amp War ranty Manual and Service Manual Inform customer about important guidelines in the Installation Manuals and instruct him as to safety regulations Inform customer about break in procedure in the Operation Maintenance amp Warranty Manual Advise customer what to do when the engine s self diagnostic management system reduc
5. NV2 NYD IXSNOLWON vec NILON EZZ JO 5 LOS L BUISSIW JO 951 NOAON ce JO pijeAur 2 1senbses enbJo 08404 Ez LZZ eBesse N NVO m 022 Bunseoo peeds 5 5 voc ueeq peu 95 9 uBiu uonisod 4984 esnsi N pepeeoxe jur einsseJd 00 eJnssaJg asnsiy pepeeoxe jur uoneJedo 202 juejooo uj sem 95 pepeeoxe yur LOZ uonoeuuoosip ejeJ Bnid pejoejep ou 151556 10 9991 S8 92M 92M O Hd9 961 oys pepeeoxe fejaJ jsisse 10 9991 98 92 S 76 uonoeuuoo Jo 5 jndyno ur
6. NODA 91 peg NOA 9495 NALSAS 1 A vZ 3109 2 97 84 INNOVATION WITH LIGHTNESS lt Description Wiring harness instrument panels 4 6 cyl marine engines current version fuse 10A 23 pin plug switch switch switch switch lamp lamp lamp gauge gauge gauge warning horn lighting lighting lighting 1 pin plug 8 pin plug splice splice splice splice interm cable connection engine cable instrument cable ignition red start green emergency cut off orange key switch constant revolution optional charge control cel check engine lamp oil pressure preheating conrol engine coolant temperature oil pressure optional tachometer with running time meter engine coolant temperature gauge oil pressure gauge optional tachometer gauge connector illumination switch connector STEYR MOTORS display battery battery ignition key switch constant revolution charge indicator 85 LZ060 00 99 6 12 UJOO SJ0 OUJ J 9 S e a
7. a r 9 7 NYO 9NIHIM 87 STEYRMOTORS INNOVATION WITH LIGHTNESS 011160 LO 99 6 12 193 sues eDJeu MPO peg UJOO SJO OUJ J O S MMM NWO 80700609 woe 1 NWO 80710609 10 0109 MONS 10 01809 15 91 00018 Li Li Li LI Li LI Li Li Li 1 Li LI 1 20 00019 I Li 1 LI LO SLOLE i H 10 0001 SS 1 A H T T 1 20 21006 See i i 1000091 1 5 1 4 8 ty 5 Ci yy mn 0 8 AAA Zt We OL 6 8 1 9 V Lo i Lx Le Dm x Le i 2 2 L 15 n es f zs m 64 99 ae bird YOUMS v OL Jexeeuq ERE 19409 41 ied Es N i AN Sd Key 390
8. 2 34 56 iN PNA 10 9 1 32 33 34 35 36 37 38 39 This sensor is magnetism sensitive All external magnets must kept away 53 000 06001 06036 15 40 41 42 06003 46 47 48 49 06004 MO196K35 MO236K42 STEYRMOTORS INNOVATION WITH LIGHTNESS Technical Data and Overview MO196K35 MO236K42 MAKE STEYR MOTORS M 16 TCM TCAM 2 6 2 displacement 3 200 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 136 182 165 221 Z Drive 134 179 162 218 full load speed range rpm 4 200 rpm 0 rpm 300 rpm idle speed 630 rpm adjustable injection Plunger activated two stage high pressure with electronically controlled injection rate 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 refer to spare part catalogue fuel filter location suction sided oil pressure above 2 000 rpm 400 700 kPa 58 101 PSI microprocessor controlled filling capacity motor oil approx 12 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 5
9. L 7 zi ____ 5 OQ APZ om i jeuondo i 2 5210 ES EX Jepues SJ AU ES EX 10 52109 T mundo dew p fF ee zz 1005 m d ug zT pamnoge oe to 9 2202000108 1 Weg 0 ZLOOE 4 LL 1 p EZX z0 10608 OZ fg 18 T6 1 oz T5 Tt NYO G EZX 220700 Ji 10 10609 SM 5 1814 s do Sodi Dn 198 a m Z 2X gt a m uL 00 000 1 T SN O109099 os so 0 09 09 09 09 09 09 n w n EC oSI 10 80809 vl ama E CLINQ TOH NOO 3NION3 HOLO3NNOO oy PB a M 10 10 10 10 20 10 80 10 wore na S 919 08 o 607 999 20 855 000 vss gt 1 09 og 09 09 SL n S i oe 91 n ass dmi H 1 amwa 1nOM 789 780 udo 1V8A NOI gt un is Ur se il la Yer Gz LE ill V 0L 24 ome m JI 20 00609 ___ V 01 94 iur LL E E us 1 20 00015 1 bs win VS 74 I I gt ane
10. WS gv SSANLHOIT NOILVAONNI AG 8 HB 4 NOILdO A ZL 52108 97 NYO n Vif 1 s t W V a r VIV SeOLOWHAA215 88 STEYRMOTORS 2 INNOVATION WITH LIGHTNESS 4 AS Check motor oil level ccn tainen tune bekennen 91 Refill Rer 91 Oil level tor Power Steering 91 Oil Tevel TOF 1 alec deor bu 91 Check coolant closed cooling circuit peto on Eran netu 92 Drain the raw water circuit of the engine 92 Check raw water open circuit with pump 92 Cooling System Anodes PH 93 Anti Corrosion Anodes e 93 Maintainance Poly V belt resp Serpentine Belt 94 ziep X nle M 94 FIST o o E 94 Adj stment of belts e 95 Measuring device VR00515 0 for toothed and V belt 95 Alternator Delt eem 95 Servopump belt if SO cach 95
11. 9 Illustration SymDOlS scenice TIPO 9 PROP SC 10 Replacement Parts 10 Before Casting M 10 Engine Submersion ett 11 TOT 11 Boat BOON 11 Boating Responsibilities 12 E 12 gc 13 STEYRMOTORS 6 INNOVATION WITH LIGHTNESS General This MANUAL is published by STEYR MOTORS GmbH with the main intention to provide information in form of technical data and know how based on our experience in the marine diesel engine business which will enable you after thorough study to operate and check the engines on your boat ensuring their operating safety reliability and long service life CE conformity Under regular maintenance as described in the chapter Maintenance and Trouble Shooting the exhaust gas emis sion levels adhere to the limits stipulated for pleasure boat operation throughout the life time of the engine warranty claims to be addressed to your local STEYR MOTORS Marine Dealer We have to rely on your assistance however For continuous improvement with regard to form and contents of the information required Your comments on the following questions would be much appreciated Which descriptions or terms are not understand
12. zooo V 06 4 rive V 09 eJ 70 90709 1 4 4 V 09 EEG 96128 Tee ss 10 51909 10 71909 gt UTR Dame mtm za OSA ee 5 60 10019 Jepues 390 m 91 ZIRA Lr sueg ep 5 MT 10 00015 Ssy ss AG 5405 umm E Mer oo HEJS 20 00005 2 04409 E 10 91909 NODA sues siejay 1004809 pagans 06 80 21002 _ our 10 1008 neg 20 00051 vile lt 10 00091 gt SSANLHSIT HLIAA NOILVAONNI 4 315 A V 9 7 3SV8 81 22800 60 0 096 12 UJO9 SJOJOUJ J 9 S MMM sen ee eo 873992 OW 18 2 pz 10PAPLLON t s Paus T peg omaron 0 mE E Hop Had
13. Adjustment of belts FOR 6 CYL MARINE ENGINES WITH V BELT Measuring device VR00515 0 for toothed and V belt With engine stopped tension of the belt should be so that it yields for 6 13 mm 350 50 when pressing your finger on marked spots A and B If the belt is too slack it may slip through which results in higher wear and bad efficiency of generator or pump Belt tension is to be checked after first 10 operating hours and then every 50 operating hours NOTE Alternator belts and servo pump belts are special Marine belts DO NOT replace by traditional V belts Alternator belt Check tension of alternator belt on spot A in the center be tween crankshaft belt pulley 1 and alternator belt pulley 2 Retighten the belt Loosen the alternator holding down bolts 34 C and 34 D Turn the clamping bolt E clockwise turn away alternator from engine and increase belt tension 350 50 N Tighten screws C and D Check belt tension Servopump belt if so NOTE Servopump is jointly driven with alternator tension belt via alternator Belt for raw water pump Check tension of belt for raw water pump halfway B between crankshaft belt pulley 1 and belt pulley on raw water pump 3 95 FOR 6 CYL MARINE ENGINES WITH V BELT To tension the belt Loosen hexagon screw 35 F Turn the clamp ing bolt 36 G clockwise in order to increase the belt tension to 300
14. E Gi a E T o uondo fyoalenuo p gsx aren ears V dupl aur 1 5 uoneuluunyj 103 sues IoMhiIpiII I oDJeu5 peg Wisi 10 02109 sr UES 1 ae ae aac 60000067 O 22 1 P Seer arenes Sasson saad it 10 01809 i i i 1 1 5 91 00018 Wie i Todd Var 1 1 i 1 1 1 1 4 1 10 6191 HI 10 91909 i 1 1 1 1 1 Li LI i 2 Ss ee 1 i DL ee A H D 11 i11 10 24008 TE i dco oo te ee g 5 10 00091 VEM E M H 5 1 22 1 Y T TTT T T We OL 6 8 4 9 2 1 e 1 e L z L 9 V on dua e 15 1 za n E 5 64 Wd dwe7 dwe dwe YOUMS Aes YoUMS v OL Jayeauq JuejSUOD UIMS 9579 jjo1n9 380 To d J3 1299 190 KeoueBieur3 SSANLHOIT NOILVAONNI SADLOWAASLS A 21 H3QNl 1AO 9 7 TANVd NYO
15. 9 1 6 6 jn aj pasen 400Z E LI Amore 5805 5 7700018 lt Jepues gt 1 21002 gt A i amp ueo H 50 00018 ta 1 m esed 1 1 1 Aw H NYO 1 i H NVO 10 10609 SM ps 1914 RS pd T eu 9 00 10 80809 4 Hno 1000609 02 000 w s da Us 09 09 a szlvd 5 peg OSI L0 80809 Wo gt 1 ze HOLO3NNOO LO 20 ET H a 99 n 0 09 o 09 n FH 1 amwa 1noM 199 ise bi wos AIM gt nn L V 0L 24 Ac T 0 94 UM 0 94 TUN VS v3 10 12109 V 09 24 10 90 09 H V 06 Zd psp Tess psp EES v OS Ld 10 71909 Ae 0 10019 jepues 180 821 TER NVO EL 10 0001 ssy ues ssy _ NC Et suas ee
16. 300008 OW 62 ano 53441 3NION3 TV ae oee 1 Li LI 1 Li 1 Li 1 Li Li LI Li 1 ez dl Li 1 Re Tu Roe 16 o Te Re p SM 510 149 iay Wad 198 14 10 10609 o 10 10 Lo 10 La 0 to 10 Lo Lo 90 T 000 00 n 001 904 000 10 00609 gg 09 05 SL 09 09 09 09 09 09 09 09 be 09 Le 051 10 80809 SY HOLOANNOO w 16 10 10 10 10 10 zo 10 10 0 10 no 99 9 9 018 999 855 000 798 o9 0 09 09 i Si 06 ig LOM 789 130 0 udo NOI udi s lw ls hz ds g9 le m Um Yar n le lu zl EES ot TT CTS zi EE CAMEE cea OSA Jepues aunsseid 91 10 Jr SSW 1002 Buum peg peg A 9 5095
17. 2220 i L A 095 Ut a Men pes 10 91909 Ovid 217 70 01809 04 00 NODA 495 80721008 siejayy peiddng 2078008 vie 0 00091 10 0009 peg SSANLHOIT NOILVAONNI NOLLdO A 310d Z 9 3NISVW NVSOVIG 82 STEYRMOTORS INNOVATION WITH LIGHTNESS 6ZEOLL 00 0 80808 15 5 MMM Caan 09 ___ joo 82 1 ai ges ME BM P vem i 81 Herz OW 8 Bz OPAPLL OW ano i al op ee HUM SIAL g pko T TEE 4 _ 1002 BULIM e 01009 a T 1 zs 3 Z EX 20001 gens endo 8 8 SsJeAu 10 52109 TY assaig e p t5
18. agen Po Dra DI E a eid 34 Propellers 34 Propeller 35 Propeller CANS NER RE Emm 35 WaterdJet Me 35 Operating Procedure for Freezing Temperatures 35 Salt Water 35 F el PUMP SP 36 F el System GMS CRS 36 Fuel Contamination c 36 Cooling System Function Description 37 Electrical Equipment acxebdodeedit hat oeste ox dua 38 re MERE OR 38 BINOY eer eee eee ey eee ee 38 Circuit 0 P 39 Inversion SWiItCh Me 40 Interrupt crankshaft housing ventilation 2 40 Instrument Panel t Lom 40 Dry ooo S 40 STEYRMOTORS INNOVATION WITH LIGHTNESS 7 6 4 Before Starting Familiarize yourself with the handling of the boat in particular how to use transmission and then proceed as follows 1 Check the bilge for excessive water accumulation Always keep the bilge clean and dry Never allow the water level in the engine compartment to exceed the bottom of the oil pan If water accumulation is unavoidable install a bilge pump with an automatic control switch NOTE The water level in the boat s engine compartment
19. poys jana jeuBis 108694 1051958 LO VLLO9 12301 LZ uonoeuuoo jo 9 JojsiseM Josues 10 81109 218 11 9L 1045 00 jeuDis 1051894 Josu s dw 10 81109 ZL E ZLX HX301 41 uonoeuuoo Buissiw eBeyoA Josues aJnssaJd 15004 LO ZLLOO 218 21 vL poys Josues eunsseJd 15004 LO ZLLOO ZLG ZLX deno L ui j ym jo pue 9poo 0Jju02 e asnvo Q3A1OANI OSL 28003 76 INNOVATION WITH LIGHTNESS STEYRMOTORS 72940 NYO ulejs s NOH 722 umop 10 109 00 3 216 29490 10419 NYO pugAH 212 Aiddns NWO NVO 5 jo3u02 Jo
20. Stolen Unit The model and serial numbers on your engine are important for you As to the location of these important numbers refer to Model and Serial Numbers in the section Technical Data Record each of these numbers in the spaces provided at the end of this manual and on a separate sheet Store the separate sheet in a safe place other than your boat In case of theft report the model and serial numbers to your local authorities and your insurance agent Owner Identification Card When you purchases your boat your dealer was obliged to issue an owner identification card for your STEYR MOTORS Marine Engine This owner identification card gives proof and is to be submitted in case of warranty claims INNOVATION WITH LIGHTNESS STEYRMOTORS Q Installation and pre delivery inspection log Your STEYR MOTORS Marine dealer is also obliged to complete the installation and pre delivery inspection log Chapter DEALER S RESPONSIBILITIES Required tests and measurements are to be carried out accordingly A copy of the installation and pre delivery inspection log and engine registration card are to be forwarded to STEYR MOTORS GmbH Dealer Service Maintenance NOTE Please do not forget to have confirmed in your manual that the installation and maintenance have been carried out in accordance with the guidelines This is also an opportunity to clarify with your STEYR MOTORS marine dealer possible questions arisen during the
21. 115 STEYR OWNER IDENTIFICATION CARD _ 116 SERVICE NETWORIenterabe re st 117 107 WARRANTY pe cy STEYRMOTORS INNOVATION WITH LIGHTNESS 4 STEYR MOTORS Marine Engines LIMITED ENGINE WARRANTY STEYR MOTORS GmbH STEYR MOTORS warrants to the original retail purchaser of a product covered under this Warranty the Product and to any other person to whom the Product is transferred during the duration of this Warranty that in the event of a failure of the Product occurring during the applicable warranty period resulting from a defect in materials or factory workmanship STEYR MOTORS will at its option repair or replace the defective Prod uct according to the terms and conditions set forth herein Products Warranted This Limited Warranty applies to all new marine engines manufactured by STEYR MOTORS GmbH and sold by STEYR MOTORS or by a STEYR MOTORS approved distributor or dealer until such time as this Warranty may be subsequently updated or revised This Warranty also applies to the following engine accessories when approved and supplied by STEYR MOTORS and when installed by STEYR MOTORS or by a STEYR MOTORS approved distribu tor or dealer acc To enlisted distributor as stated in STEYR MOTORS Service Network refer to website at www steyr motors com This Warranty does not apply to any component manufactured by a third party and supplie
22. INNOVATION WITH LIGHTNESS Preparations for Off Season Storage An adequate preservation of the engine will contribute to an efficient and troublefree operation in the long term Consult your STEYR MOTORS Marine Dealer to get professional assistance in performing a proper off season storage 0 ON NOTE If engine is stored above 1 year advise your STEYR MOTORS Marine Dealer to the Extended Preservation Procedure Service Manual P N Z001019 0 chapter GENERAL D3 Change motor oil and oil filter Change fuel filter Check air filter Check coolant closed circuit Add fuel stabilizer to fuel Drain engine s raw water system NOTE If the raw water is not completely removed from the engine expensive freeze damage may be the result Drain raw water system from boat and driving system consider manufacturer s instructions as to storage Change gear oil or lubricant Disconnect battery and store it Spray engine outside with corrosion prevention oil Ventilate engine compartment and bilge Start up after Storage An correct start up of the engine will contribute to an efficient and troublefree operation in the long term Your STEYR MOTORS Marine Dealer will gladly be available as consultant or for an expert performance 1 ONDA 10 Check condition of hoses and hose clamps Clean battery terminals ATTENTION Connect RED cable to positive terminal and then BLACK cable to negative terminal Wrong
23. To obtain the best engine performance and engine life STEYR MOTORS TURBO Diesel Engine Oil SAE 5 W 50 or 10 W 40 2010058 0 is recommended Motor oils are specified by ACEA service codes and SAE viscosity numbers If STEYR MOTORS TURBO Diesel Engine Oil is not available you are required to use a reputable brand of motor oil labelled for ACEA E7 or B4 02 API CF Service codes and SAE viscosity number 5 W 50 or 10 W 40 Refer to oil identification symbol on the container Initial factory fill is a full synthetic high quality break in oil specified ACEA CF SAE 10 W 40 During the break in period ini tial 20 hours frequently check the oil level Somewhat higher oil consumption is normal until piston rings are seated The oil level should be maintained between the minimum and maximum marks on the dipstick The space between the marks represents approxi mately 3 7 quarts 3 5 litres For oil level dipstick location refer to section Maintenance ACEA E7 or B4 02 API CF ACEA E7 or B4 02 After first 50 hours of operation change the motor oil and replace the oil filter Refer to Service and Maintenance Schedule Identification Symbol Motor oils are specified by ACEA API service codes and SAE viscosity numbers These may be found on label top of can 3 CE or oil identification symbol NOTE Some oils meet more then one ACEA or API service rating The recommended
24. 1002 e1ojeq BUI 2 WE T N oc 10 9 n gt I 2010608 97 1 NOS 2 560609 1 d cai I NVO 10 10609 Ts nay e ma gt M 10 80809 1 4 10 00609 92 my on aat 7499 9211 3 LINN 1OU LNOO OINOYNLOATA HOLOANNOO Wr oy i T m 10 10 10 1o 20 10 10 02109 919 018 607 896 o 09 09 Si n n st n Cope dom E qeu 139 Sid Ho Fi Hi 94 50 00509 T NIE Oe i 43 me 94 20 0001 1 UW gt 2 O 84 20 00019 H v4 OQ HP p 20 12109 D lI ag 4 24 TATE UU 1 eit spp Tess opis Tee ss CAMEE 1 ld 10 71909 Ph LIME Yom em eee zog 1 plousjog 21921 v E 2010049 i OLA _ p 10 00015 T 8095 10707109 weis H MILI Mec RAE amma AGSUSS 0000 ria 2200008 S 109790 10 91909 103009
25. Air Filter All STEYR MOTORS Marine Engine models are equipped with an air filter at the turbocharger inlet as to specifications see Specifica tions and Maintenance Loosen clamp to exchange air filter Remove air filter Place clamp on filter neck and mount air filter onto flange Tighten clamp 3 Nm Maintainance Poly V belt resp Serpentine Belt FOR 4 CYL MARINE ENGINES Occassionally check components for excessive wear and or clearance on tension bearing NOTE It is recommended to spray frequently some corrosion inhibiting spray into the spring housing of the belt tensioner FOR 6 CYL MARINE ENGINES and Occassionally check components for excessive wear and or clearance on tension bearing NOTE It is recommended to spray frequently some corrosion inhibiting spray into the spring housing of the belt tensioner Engine alignment Engine alignment requires special tools The output coupler must be disengaged from the take off shaft This should be rechecked during off season storage preparations Because of the special tools required engine alignment is to be performed by a STEYR MOTORS Marine dealer NOTE Failure to check the engine alignment could result in premature failure of engine coupler or universal joints 94 INNOVATION WITH LIGHTNESS
26. eserse onanie 43 Disposal of Automotive Waste Products 44 41 Fuel Requirements STEYRMOTORS INNOVATION WITH LIGHTNESS 7 The STEYR MOTORS Marine Engines are designed for maximum fuel economy To maintain optimum mance use diesel fuel according to CEC RF 03 A 84 or equivalent to meet this specification When tempera tures are below 7 20 F use diesel fuels with additives for low temperature operation How to Select Fuel 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 with 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 adequately define the fuel characteristics needed to guarantee the fuel quality The properties listed in the following fuel selection chart have provided optimum engine performance Fuel Selection Chart General Fuel classification Cetane number Gravity at 15 Destillation 50 90 End point Flash point CFPP Cloud point Viscosity Kinematic 40 Sulfur content Copper corrosion Carbon residue Conradson number 10 96 settling Ash Water content Acid content strong acid Oxidation stability CEC RF 03 A 84 Limit
27. lers To identify a right hand propeller note the angle A of the blade as seen from portside Left hand propellers rotate counterclockwise to propel a boat forward Left hand propellers are considered counter rotation propellers To identify a left hand propeller note the angle B of the blade as seen from portside NOTE Never interchange a right hand propeller with a left hand propeller This would result in the boat being propelled in reverse when propulsion units are operated in forward gear and forward when propulsion units are operated in reverse gear To help you better understand and show the difference between left hand and right hand propellers see illustrations After having the propellers serviced always shift into FORWARD or REVERSE at idle speed and determine wether the boat moves in the right direction If the boat moves in the OPPOSITE direction the pro pellers have not been installed properly ATTENTION Failure to perform above test could result in loss of control 34 STEYRMOTORS INNOVATION WITH LIGHTNESS INNOVATION WITH LIGHTNESS 7 Propeller Torque The torque of the propeller creates forces that are transmitted to the boat This can cause the boat to lean to one side list The forces created by the counter rotating propeller are opposite to the forces created by the standard rotating pro
28. 50 Nm Tighten hexagon screw 35 F with a Torque of 23 2 to secure idle pulley bracket Check belt tension 96 5 5 Q INNOVATION WITH LIGHTNESS pd Ss TES INNOVATION WITH LIGHTNESS STEYRMOTORS Q GENERAL Propeller Selection Your STEYR MOTORS Marine dealer has chosen a propeller designed to deliver top performance and econ omy under most conditions To obtain the maximum percentage of available output the engine RPM at Full Throttle should be in the specified Full Load Speed Range 8 gt As to specifications see Technical Data and Maintenance If engine s full throttle RPM with normal load is below the specified range use a propeller with less pitch to in crease the RPM Should the engine s full throttle RPM exceed the specified range the engine RPM and output is limited by the governor Use a propeller of higher pitch to achieve a RPM reduction in the specified range B NOTE Engine damage can result from incorrect propeller selection if The engine RPM does not attain the specified Full Load Speed Range The engine thus runs in RPM range gt Therefore use a propeller with a lower pitch The engine RPM exceeds the specified Full Load Speed Range Engine speed is therefore above the admissible range D Therefore use a propeller with a higher pitch
29. 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 103 138 116 156 121 165 Z Drive 101 136 114 154 119 162 full load speed range rpm rpm ge 0 rpm 300 rpm 0 300 rpm 0 rpm 300 rpm idle speed 700 rpm adjustable injection Plunger activated two stage high pressure with electronically controlled injection rate fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel 2 D temperature above 7 No 1 D temperature below 7 fuel filter refer to spare part catalogue fuel filter location intake sided oil pressure above 2 000 rpm 400 700 kPa 58 101 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 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 exchange coolant capacity 11 5 liters coolant STEYR MOTORS engine coolant 36 P No Z011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 52 STEYRM
30. An service code can only be deleted if no defect exists in this circuit In case of a present active failure the service code keeps reappearing until the problem has been repaired and the circuit is properly working again Disconnect Tool VR00135 1 from Diagnostic Outlet Plug X23 to exit from service code display NOTE Watch indication of the Check Engine Light and the Warning Horn after ignition contact If all ser vice codes are deleted from the Engine Management System the indication resumes to 0 7 sec function test of Check Engine Light and the Warning Horn For additional details see Chart Op erating Conditions Instrument panel 75 INNOVATION WITH LIGHTNESS STEYRMOTORS de list le serv Some codes may not apply due to different application 3104 eje jueuno ON 10 899 12 98 72 12M S 111 uonoeuuoosip ur jueuno ON ejeJ LO vSSLE 98 2 vey 891 poys ur pepeeoxe jui zuno ejeJ 2 98 2 vem S HdJ 49 umojq uonoeuuoo 10 01809 0199 GOL poys pepeeoxe ur 10 01809 5730 79
31. E4 E5 E7 API CF P NO 2010058 0 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 exchange coolant capacity 11 5 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 48 INNOVATION WITH LIGHTNESS AU 54 E STEYRMOTORS Overview for all STEYR MOTORS 4 Cyl Marine Engines Designation Zinc Anode 2 Units Model and Serial Number Intake Manifold 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 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 The
32. LNAWNYLSNI NVYSOVIC 86 STEYRMOTORS INNOVATION WITH LIGHTNESS Jj 6ZEOLL 00 0 6080812 uondo 4405 uoneutunj i 103 sues 777777777 peg AAA 8 4 9 8 2 NYO SSANLHOIT NOILVAONNI SADOLOWAASLS Zs ju amp jsuo2 uiMs 1 915 MMM eee mie ee ogre NVO 20 00609 MZ 078 dwe dwe dwe 72 50 20609 vci g 10 10019 H0 02L09 E E 0 4 Ave Joyeop ul eo ul 0 0000S 10 01809 5 punoJ 91 00018 10 90409 LO SLOLE 10 91909 10 00015 2 d LR J L 2 L Lb 40 21002 10 00051 5 uos 5 y oL 1exeeiq 33 9 Ie3noN uou 440 1ND 9 5 Jeoc 140 99 D n Vif SI
33. Preservation 1 2 ENGINE CHECK POINTS Installation checked according to the installation guide Following points are in compliance 01 12 13 14 15 06 07 08 09 010 5 HYBRID ELECTRICAL CONNECTIONS according schematic CONNECTION SCHEMATIC HYBRID see Hybrid Installation Manual schematic with art nr 2180526 0 Notes e g wiring extensions etc SYSTEM GROUNDS connected see Hybrid Installation Manual schematic with art nr 2180526 0 L PROTECTION COVERS mounted on O V B B O Generator U V W O Hybrid battery L END POSITON FREE MOVEMENT of Coupling Actuator D Mode E Mode ensured MAIN SWITCH capacity between Hybrid battery and HCU Amp min 400 Amp CONSUMERS mounted to Hybrid battery only to 48 V max 100 Amp 0 Hybrid Cooling 0 Raw water cooling 0 Dual circuit cooling 0 Keel cooling 100 INNOVATION WITH LIGHTNESS COMMISSIONING REPORT STEYRMOTORS BEFORE MEASURING DATA Correct level of operating fluids motor oil gear oil hydraulic oil cooling agent confirmed Leakage oil fuel coolant checked ok if not detail HYBRID 0 full filled STEYR MOTORS Dealer Check List find in Hybrid Operation Maintenance and Warranty Manual and send signed document to STEYR MOTORS GENERAL Max Voltage supply Hybrid battery bank to HCU s57 V V MEASURING DATA Max boat speed Fu
34. 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 1 2 3 4 56a 7 2 18 17 16 15 10 11 06032 06033 2 30 31 32 33 34 35 36 37 2 15 38 39 40 41 46 45 44 42 06034 06035 This sensor is magnetism sensitive All external magnets must kept away 55 MO256K43 2 Euer STEYRMOTORS 0 INNOVATION WITH LIGHTNESS Technical Data and Overview MO256K43 MO256H45 MAKE STEYR MOTORS M 16 TCAM displacement 3 200 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 injection Plunger activated two stage high pressure with electronically controlled injection rate fuel acc to CEC RF 03 A 84 DIN EN 590 Cetan gt 49 diesel fuel No 2 D temperature above 7 No 1 D temperature below 7 fuel filter refer to spare part catalogue fuel filter location suction sided oil pressure above 2 000 rpm 400 700 kPa 58 101 PSI microprocessor controlled filling capacity motor oil
35. approx 12 0 engine housing incl approx 1 oil filter contents specification motor oil SAE 5W 50 ACEA 4 02 CF or 10W 40 ACEA E4 E5 E7 API CF P NO 2010058 0 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 exchange coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 56 INNOVATION WITH LIGHTNESS 256 43 STEYRMOTORS MO256H45 Overview STEYR MOTORS MO256K43 MO256H45 12 3 4 52 6 2 Designation 17 Boost Pressure Sensor Zinc Anode 5 Units Intercooler 16 Engine Oil Fuel Hydr Oil Cooler 15 Model and Serial Number 14 Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation only SOLAS Fuel Filter Fuel Pump Oil Filter Mind 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
36. 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 speeds MO54NA33 3 000 rpm MO84K32 3 000 rpm MO94K33 3 000 rpm MO114K33 3 000 rpm MO144M38 3 200 rpm 164 40 3 400 MO174V40 3 400 rpm MO126M28 2 200 rpm MO126K25 2 200 rpm MO156K25 2 200 rpm MO196M28 2 200 rpm MO236K42 3 300 rpm MO256K43 3 600 rpm MO256H45 3 600 rpm MO286H43 3 600 rpm MO306H43W 3 600 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 22 5 6 Shifting 1 If the gear shift mechanism is disengaged move the control lever to neutral position The shift mechanism will automatically engage 2 To go FORWARD press the neutral lock button if fitted and move the control lever forward Throttle move ment will begin after forward gear engagement 3 To go in REVERSE press the neutral lock button if fitted and move the control lever backwards Throttle movement will begin after reverse gear engagement 4 To go from FORWARD to REVERSE or REVERSE to FORWARD always pause at NEUTRAL and allow engine speed to return to idle 5 After shifting is completed continue to move the control lever slowly in the desired
37. chapter 9 Appendix 28 Grease raw water pump impeller at BUKH STEYR MOTORS SOLAS engine with original grease of P N Z011753 2 29 Carry out Start Idle Test and check engine operation Check behavior of the boat when engine is in idle gear If there are unpleasant vibrations adjust the engine speed to a vibration free operation see Service Manual 30 Check correct function of gearshift 31 Stop engine and check again the levels of all operational fluids during test run a certain loss operation fluids may occur TUE uis cq DEALER UULTUS ADDRESS EET ENGINE TYPE SERIAL NUMBER tarte Ee e HERE equa HAE PER ENGINE RUNNING HOURS etse tr rre reete ead ever muc ede ever Ee eb eredi ee A copy of the installation and pre delivery inspection log is to be sent to STEYR MOTORS GmbH After Sales Service 99 TA COMMISSIONING REPORT STEYRMOTORS Q INNOVATION WITH LIGHTNESS Engine serial number Engine model Hybrid serial number Boat Owner Company Name Address Phone Dealer Company Address Phone Type of boat Dimension of propellers Model No Special Equipment from STEYR MOTORS Boat length SCC IFG Cabin Heating etc Boat weight Driving system Hybrid Battery specification Gear reduction Extended Storage Preservation Procedure acc SERVICE Manual GENERAL D3 Date of
38. charge battery in boat Fumes vented during battery charging can lead to an explosion Battery electrolyte is a corrosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible High resistance in the charging circuit can seriously affect the operation of the electrical system Unless there is definite malfunction in the electrical system high resistance is sometimes caused by corroded or loose connections Wherever practical the electrical connections on your engine have been sealed However we recommend that you make periodic inspections to ensure clean tight connections throughout the electrical system NOTE It is important that the battery connections are correct The negative battery cable must be attached to the negative terminal on the battery and the engine s positive cable must be attached to the positive terminal on the battery If these connections are reversed the regulating unit may be immediately damaged Inspect your battery at regular intervals for specific gravity state of charge individual cell water level cleanliness and clean tight connections If the battery has become discharged for no apparent reason check all electrical system components for malfunction or a switch left in ON position prior to installing recharged battery Circuit Breakers STEY
39. emergency cutout check completeness condition Marine Dealer consult lubrication check sealing ENGINE MOUNT ock onus SCREWS 3 WARNING STEYR MOTORS Marine Dealer every 750 hours 67 Sticker of 1 preservation refer to Installation Manual P N Z001007 0 Chapter 18 Installation and pre delivery inspection report Sticker of 3 preservation 50 h Service 300 h Service 600 h Service 900 h Service 68 INNOVATION WITH LIGHTNESS STEYRMOTORS Q Sticker of 2 preservation Commissioning 150 h Service 450 h Service 750 h Service 1 050 h Service Made by STEYRMOTORS INNOVATION WITH LIGHTNESS Made by Made by Made by 1 200 h Service 1 500 h Service 1 800 h Service 2 100 h Service 2 400 h Service 2 700 h Service Q 69 Made by Made by MAINTENANCE LOG 1 350 h Service 1 650 h Service 1 950 h Service 2 250 h Service 2 550 h Service 2 850 h Service STEYRMOTORS INNOVATION WITH LIGHTNESS Table Error Indication on Instrument Panel CLOCK 12 24 PM Fuel Level STEYR INNOVATION WITH LIGHTNESS A audible warning device combined light preheating control 4 warning light engine oil pressure B warning light battery charge D warning light check engine Operating condition During normale engine operation or indica
40. first ten hours of operation accelerate to bring boat onto plane quickly After reaching planing reduce throttle to remain at minimum planing For displacement or semi displacement boats the throttle position of 75 must not be tran scended Occasionally reduce throttle to idle speed for cooling down ATTENTION Warning indication engine over load during break in via ECU Engine Control Unit The ECU monitors during the first two hours of engine operation the load on the engine If the engine is overloaded during the first 2 hours of running the Check Engine Light will automatically illuminate If the warning light illuminates CEL light ON the throttle position must be reduced until this signals are extinguish Final Ten Hours of Break in Maximum Short Term Speed 100 of rated speed Maximum Short Term Throttle Position 100 During the final ten hours of break in the engine may run at full speed for five to ten minutes The remaining hours should be operated up to 75 throttle position For displacement or semi displacement boats the throttle position of 75 must not be transcended Occasionally reduce the engine speed to cool is down NOTE During the break in period the engine must not be operated at high 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
41. off valve closed Air leak in suction lines Fuel line plugged or pump defective Poor fuel quality Water in fuel filter System error or failure Battery output insufficient Inversion switch actuated Battery connections loose or corroded Battery is dead Starter connections loose lgnition switch Fuse blown on panel Starter auxiliary relay Water air and or dirt in fuel filter Anti siphon valve stuck Fuel pump 78 Fill tank or open valve Bleed fuel system and check for leaks Fuel pump may be defective See your STEYR MOTORS Marine dealer Replace fuel Replace or drain water from fuel filter Check fuel supply for water contamination If water is present drain fuel tank and flush with fresh fuel Check Engine Management System display for service code Charge or replace battery Cancelled by ignition OFF ON Check for loose connections and corrosions Clean connections and thighten Check level of electrolyte and charge battery Check connections and tighten If solenoid clicks when attempting to start engine see your STEYR MOTORS Marine dealer If inoperative see your STEYR MOTORS Marine dealer Check and replace if defect Check terminal connection and function of relay Replace filter Inspect fuel supply line Clean and inspect or replace Tank Check operation of pump Replace fuel pump See your STEYR MOTORS Marine dealer STEY
42. panels 4 6 cyl marine engines current version 85 WIRING DIAGRAM INSTRUMENT CAN PANEL 4 6 CYLINDER js e 86 WIRING DIAGRAM INSTRUMENT CAN PANEL 4 6 CYLINDER 24 V 87 WIRING DIAGRAM INSTRUMENT CAN PANEL 4 6 CYLINDER Solas 88 63 64 E STEYRMOTORS A INNOVATION WITH LIGHTNESS INNOVATION WITH LIGHTNESS J G Owner Service Log FOREWORD On receipt of your new STEYR MOTORS Marine Engine the authorised dealer has signed the pre delivery inspec tion log thus confirming to have carried out a pre delivery service according to the manufacturers specifications Future service requirements are indicated in this OWNER SERVICE LOG When these services are carried out the STEYR MOTORS Marine dealer will stamp the respective stubs This servicing will assist in maintaining the value and satisfactory operation of your STEYR MOTORS Marine Engine lies in the 5 interest that for maintaining warranty and best performance of his STEYR MOTORS Marine Engine he always insists on the sole utilization of STEYR MOTORS ORIGINAL replacement parts operational fluids and lubricants as well as STEYR MOTORS proved service procedures It is important that you study this booklet carefully it will assist you in achieving satisfaction from your STEYR MOTORS Marine Engine Plea
43. peller When the vertical drives are trimmed equal these opposite forces balance each other Propeller care A damaged or unbalanced propeller will cause excessive vibration and a loss of boat speed Under these conditions stop the engine and check the propeller for damage If the propeller seems to be damaged have it checked and repaired by your local STEYR MOTORS Marine dealer Always carry a spare propeller and replace the damaged propeller as soon as possible NOTE Never run with a damaged propeller Running with a damaged propeller can result in damage to drive components and engine Water Jet When using water jet drives please contact your STEYR MOTORS Marine dealer As to information on function and application please refer to respective documents and documentation of the drive manufacturer Operating Procedure for Freezing Temperatures When freezing temperatures are forecast and the boat will be operated and left in the water the propeller must re main in the tilted down submerged position at all times to prevent water in the vertical drive from freezing Upon completion of engine operation drain the engine as described in Off Season Storage Preparations Salt Water Operation Fresh water to flush the raw water circuit is recommended after use in salt polluted or brackish water to prevent deposits from clogging and corroding the cooling passages Contact your STEYR MOTORS Marine dealer to obtain an Engine Flushing Kit that allows
44. warrant any product or component not specifically identified in the Products Warranted section of this document Please note in particular the following STEYR MOTORS does not warrant any product or component not manufactured by STEYR MOTORS except for those accessories specifically identified in the Products Warranted section of this document that are supplied by STEYR MOTORS and installed by STEYR MOTORS or by a STEYR MOTORS ap proved distributor or dealer Examples of items not warranted are stern drives sail drives gear boxes and water jets control lever etc STEYR MOTORS does not warrant maintenance components supplied by STEYR MOTORS after 90 days of the date on which warranty coverage commences Maintenance components include but are not limited to sea water pump impellers zinc plugs oil filters fuel filters air filters water filters fuel wa ter separator filters belts automatic belt tensioner timing belt and idler gaskets hoses fuses brushes and accommodator fuel injection nozzle valves expansion tank pressure caps and thermostats 112 INNOVATION WITH LIGHTNESS STEYR MOTORS will not warrant their product with the limited engine warranty if the provided product warranty registration card will not be submitted and received by STEYR MOTORS within 3 years from the date of product manufacturing STEYRMOTORS Q IN NO EVENT SHALL STEYR MOTORS BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGE
45. with a flow rate of at least 300 l h at a pressure difference of 200 mbar Fuel Contamination In the marine environment the most likely fuel contaminants are water and microbial growth black slime Gener ally this type of contamination is the result of poor fuel handling practices Black slime requires water in the fuel to form and grow the best prevention is to keep water content in storage tank to a minimum Treating fuel with microbial growth requires the use of fuel additive STEYR MOTORS does recommend the use of fuel additives such as Biobor JF or equivalent for treatment of mi crobiological fuel contamination Follow the manufacturers instructions for use If treating fuel frequent fuel filter changes will be necessary until fuel system is purged NOTE A galvanized steel tank should never be used for fuel storage because the fuel reacts chemically with the zinc coating forming powdery flakes which can quickly clog the fuel filters and damage the fuel pump and injectors 36 INNOVATION WITH LIGHTNESS Cooling System Function Description STEYR MOTORS Marine Engines are equipped with a closed internal and an open external cooling circuit Closed Cooling Circuit The closed cooling circuit includes monoblock as well as exhaust O manifold heat exchanger and expansion tank Temperature in the closed cooling circuit is precisely controlled by means of thermo stat The the
46. ACEA or API service codes must be among these service ratings Top of Can Oil Identification Symbol 43 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS 4 Disposal of Automotive Waste Products Used fuel and oil is to be collected in separate containers to permit an eventual subsequent treatment The disposal of any fuel and oil for the engine is subject to the special waste act The A special waste catalogue norm s2100 refers to the necessary disposal in austria Please follow the local regulations of your country The operating and maintenance personnel has to take care that fuel and oil as well as other material ranking as spe cial waste are deposited at the respective collecting points Code No Designation 31 423 oil contaminated ground or oil binder 54 102 waste oil 54 104 fuel 54 202 grease 54 207 vaseline 54 917 compact sealing material 54 927 oil contaminated scouring cloth 54 928 usel oil and air filters 55 510 colour or varnish containing waste 44 STEYRMOTORS INNOVATION WITH LIGHTNESS Model and Serial Numbers AT Technical Data and Overview ce E 48 Technical Data and Overview MO84K32 MO94K33 MO114K33 iesu aca 50 Technical Data and Overview MO144M38 164 40 MO174VAO 52 Technical Data and Overview MO196K35 MO236K42 eve ta
47. Belt for raw 95 Selection MT 97 STEYR MOTORS Dealer 98 Commissioning REPOR uon boda dienen 100 Preparations for Off Season Storage 102 Start up after Storage J H 102 ENGINE eae a e 103 89 INNOVATION WITH LIGHTNESS STEYRMOTORS cram 90 STEYRMOTORS INNOVATION WITH LIGHTNESS Check motor oil level ATTENTION Check with cooled down engine only or after a shut down period of app 3 to 5 min Then remove oil dipstick 19 A clean it and insert again into oil dipstick tube 19 A then remove again and check oil level on marker Refill motor oil Remove motor oil filler cap 19 B and add STEYR MOTORS TURBO DIESEL ENGINE OIL 5 W 50 10 W 40 or an equivalent marked ACEA B4 02 E7 E4 E5 or with API Code CF up to speci fied maximum marker on oil dipstick ATTENTION Motor oil must not exceed maximum marker An overfilling results in high operating temperatures foaming air in oil loss in efficiency and reduced engine life Put on the motor oil filler cap NOTE Remove possible oil contaminations The use motor oil with other quality than specified warranty canexpire level for Power Steering Whenever you check motor oil level
48. Connect temporarily Pin Pos 1 with Pin Pos 2 of Diagnostic Plug X23 before ignition is turned on at key switch Connect as above and turn the ignition on to enter error indica tion mode Code indication and indication sequence After entering the service code indication modus the Engine Management System will display a blink code at the Check Engine Light on the dash panel The blinking sequence will always begin and end with control code indication 12 Each service code will be re peated 3 times to assure your correct reading see below bar code illustration Example sequence check engine light Service code 14 3 time 1 time 2 time 3 time 1 time CODE 12 CODE 14 CODE 14 CODE 14 CODE 12 sec 4 0 3 sec 1 5 sec 3x 0 4 sec 3 0 sec Stroke Check Engine Light illuminated for 0 3 sec Light Off period within blink sequence 0 4 sec E Dashed Line interruption within code indication 1 5 sec Solid Line interval interruption between service code 3 0 sec If more then one service code is stored in the Engine Management System the indication sequence will be continued blinking additional stored error codes To delete a memorized service code see description Indication and Cancella tion of memorized sensor and circuit faults For a description of the possible service codes refer to enclosed Table Service Codes ATTENTION To exit from Service code indication Tool VR00135 1 must be r
49. E7 API CF P NO 2010058 0 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 exchange coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 54 STEYRMOTORS INNOVATION WITH LIGHTNESS 196 5 MO236K42 Overview STEYR MOTORS 196 35 MO236K42 Designation 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 Coolant Expansion Tank Cooler Cap Diagnostic Outlet Inversion Switch only for
50. LUld Ig erx 143 poys 00 10 91109 Ig e rx cpedoT 55 uonoeuuoo 00 10sues eJnssaud 20 11109 eLd grx poys Josues jueouqn 20 21109 818 8 54101 U91IAS 10 21109 2 1 Ajejes jeped o jejeg v LO LLLOQ Z rx SPed 6c poys Ajddns 1 uo ibn Jojoeuuoo 0 001S1 LZ SX 8c 103 20 Josues poys Ajddns 05 95 uo EA pes J0joeuuoo 0 00LS4 7 J3HAO1 LOHdA 0 1091 123 223194 9c 42M Ajddns ZO ZLOGL 123 2231 94 SC j euBis 1ejeuonuejod 10 11109 Ig E LX ve 00 jeuBls 10 1109 ELa eLx LP8d07 uonoeuuoo uBiu jeuBis 1015 59 4 10595 eJnjeJeduie 194E M LO VLLO9 9Lg 9Lx
51. NODA sues siejay perjddns 80 21008 S 20 0008 10 00081 8 SS3NLIHSIT NOILVAONNI SADOLOWAAALS 9 7 9NISIM 83 INNOVATION WITH LIGHTNESS STEYRMOTORS 62 6 12 pd moge 06 10 9 peg i qm jeuondo S X 11 0001 8 8 10 52109 9 2X 590 0001 v4 80 21008 9599 Na Md 20 10609 97 aH NYO 220200609 gt 10 80809 1 Li Li LI E 0 00609 Midi PEE T 20 0001 1 20 00019 31690108 H 10 71909 el 20 10019 10 00018 SI gt f O I 20 00008 1091909 10 01809 290721008 70 2008 20 0005 10 00091 MIM 10 52008 XI SSANLHOI HLIM NOILVAONNI SADOLOWAASLS UJOO SJO OUJ J 9 S MMM ee eee pe ey 80 0018 6952 ON 1 SPH9SZ ON au 99 ON
52. ORS INNOVATION WITH LIGHTNESS Indication status 80 90 C FLASHING 2x per ON sec 24 SS 2x per sec high approx 105 OFF ON 4 2x per sec 120 C OFF ON Z E OFF a BA 2x per sec 80 90 C OFF opo 80 90 C HI ON a EXT FF BUKH STEYR MOTORS SOLAS amp E9 Fault high exhaust temperature over 80 C or defect exhaust temperature sensor or bad connection engine coolant temperature too high defect engine coolant sensor or bad connection unstable idle speed no indication on tachometer MPN chock 12 24PM Fuel Level Trouble in governing loop involved components control solenoid rack control gear of unit injector rack position sensor 73 Remarks check raw water system strainer impeller pump contact authorized workshop after cooling down check engine coolant level contact authorized workshop after cooling down check engine coolant level contact authorized workshop defect speed sensor or sensor connection contact authorized workshop contact authorized workshop STEYRMOTORS INNOVATION WITH LIGHTNESS 4 Reading Service Codes Entering and reading of stored faults via Check Engine Lamp and Diagnostic Outlet Plug X23 Needed device Tool VR00135 1 normally closed push button switch connected to Diagnostic Outlet Plug X23 In case this tool is not available
53. OTORS INNOVATION WITH LIGHTNESS MO144M38 MO164M40 MO174V40 Overview for all STEYR MOTORS 4 Cyl Marine Engines Designation 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 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 44 43
54. R MOTORS Marine Engine models are protected against overload by circuit breakers On the base plate of the E box three thermical triggered 50 amp circuit breakers are installed F2 protects the electric circuit of the glow plugs of cylinder 1 amp 2 4 cyl and 1 3 6 cyl protects the electric circuit for the glow plugs of cylinder 3 4 4 4 cyl and 4 6 6 cyl F1 protects electric system and electronic management The ignition key and instruments are protected by a 10 amp Fuse located in the main wiring harness under the instru ment panel at height of ignition key 06011 F4 Fuse supply module F5 Fuse main circuit supply F6 Fusefuel pump circuit F7 Fuse glow plug circuit F9 Fuse ignition switch circuit instrument panel The installation of any additional electrical accessories requires the protection of individual circuits Consumption of current should occur directly at the battery NOTE Avoid sparks that will damage the alternator or ECU Do not attempt to connect or disconnect any part of the electrical system while the engine is running Fuses for fuel ECU supply glow plug relay are inside the E box cover 39 9 BUKH STEYR MOTORS SOLAS SB Inversion Switch The inversion switch is a mercury switch A which is actu ated in case of an inclination of the boat in any direction over 70 Via the main circuit relay the engine is shut down For safe guarding reasons th
55. RIAL STEYRMOTORS INNOVATION WITH LIGHTNESS DEALER RECORD CARD ENGINE REGISTRATION MODEL SERIAL OUT DRIVE REGISTRATION MODEL SERIAL TRANSOM MOUNT REGISTRATION MODEL SERIAL Owner s Name Address City State Zip Date of commissioning Ignition Key No Boat Mfgr Hull No Boat Model Boat length Owner s signature IMPORTANT The Federal Boat Safety Act requires registration list to be maintained on product sales by manufac turer and DEALER This is a standard card on which a dealer can keep his records 116 Name Address City State Zip Date of commissioning Type of Use Pleasure Comml Govt Extended Storage Preservation Procedure refer to Installation Manual Z001007 0 commissioning REPORT 1 preservation 2 preservation Dealer Name Address City State Zip Owner s e Mail Dealer Code Engine Registration Model Serial Boat Mfg Model Hull No Length Trailer Vin No Rate Overall Quality of Boat LJ L L Good Acceptable Poor Motor L INNOVATION WITH LIGHTNESS STEYRMOTORS SERVICE NETWORK AUSTRIA STEYR MOTORS GmbH Im Stadtgut B1 4407 STEYR AUSTRIA Phone 43 7252 222 52 Fax 43 7252 222 29 e mail service steyr motors com http www steyr motors com A full list of our worldwide Service network can you found on o
56. RMOTORS Q INNOVATION WITH LIGHTNESS Trouble Check Chart Continued SYMPTOM POSSIBLE CAUSE ACTION Engine vibrates Propeller condition Unit injector Engine runs but boat makes Fouled propeller etc little or no progress Performance loss System error or failure Boat overloaded Boat trim Excessive water in bilge Boat hull condition Improper propeller selection Fuel incorrect Throttle not fully open Overheating 10 Air intake troubles Check for bent broken or damaged propeller Check for weeds on propeller or sterndrive gearcase Check for bent propeller shaft See your STEYR MOTORS Marine dealer Check 1 Propeller for weeds remove as required 2 Propeller for spun hub repair or replace 3 Hull for excessive marine growth clean as required Check using diagnostics for errors or limitations Engine coolant temperature audible and or visual alarms Reduce load Distribute boat load evenly Adjust trim Drain bilge See your STEYR MOTORS Marine dealer Select proper propeller pitch and diameter Fill tank with correct fuel Check fuel filter and fuel flow condition Check throttle command lever for full travel 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 Check intake air filter Check ventilation of engine compartment Excess
57. S Such excluded damages include but are not limited to loss of use including down time loss of income or business revenue costs of travel costs of transport extra costs required to make the Product accessible as a result of particular vessel designs and or installations including the removal and or replacement of partitions or material personal injury loss of property cargo damage fines taxes damages to parts or goods other than products specifi cally covered by this Warranty and any other indirect or consequential loss resulting from a Warrantable Failure Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you THE WARRANTIES SET FORTH HEREIN ARE THE ONLY WARRANTIES MADE BY STEYR MOTORS WITH RE SPECT TO THE PRODUCT NO DEALER OR DISTRIBUTOR OF STEYR MOTORS IS AUTHORIZED TO MAKE ANY ADDITIONAL WARRANTY PROMISE OR REPRESENTATION ON BEHALF OF STEYR MOTORS OR TO MODIFY OR EXTEND THE TERMS OR DURATION OF THIS WARRANTY ANY WARRANTY IMPLIED BY LAW INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PUR POSE SHALL BE LIMITED IN DURATION TO THE TERM OF THIS WARRANTY Procedure for Making a Warranty Claim Warranty service may be obtained from any approved STEYR MOTORS distributor or dealer For a list of approved service locations please refer to Steyr Motors website at www steyr motors com or contact STEYR MOTORS After sales Divisio
58. S only 19 Run In Procedure After Major Overhaul 20 fec E Pm 20 Procedure Work SIBDS 20 Engine Break In DEODOUUB o ho bdo comen dte eeepc 21 EI EIU NR ooo 21 Final Ten Hours of 1 Lucan ruri 21 Operation after 22 23 Remote Control Operating Instructions Serin n eder ebat 24 How to Shift and Control Speed 25 Fuel 5 25 Gear Box Information EP 25 High Altitude Op ratiOn ano aai 25 Instrument pan l pub pa 26 Instrument panel standard 26 Instrument indication during normal operation 27 Instrument panel for SOLAS 28 Instrument indication during normal operation for SOLAS only 29 Emergency cut off switch Lanyard 95 00 30 Warning lights and audible alarm 31 Electronic Engine Control Unit ECU 32 15 STEYRMOTORS INNOVATION WITH LIGHTNESS START UP AND FUNCTIONS SU Ro ooo ooo T 33 Twin Pe 34 Optional Propellers
59. STEYRMOTORS INNOVATION WITH LIGHTNESS STEYR MOTORS MARINE ENGINES OPERATION MAINTENANCE AND WARRANTY MANUAL P N 2001022 0 10 Edition July 2011 www steyr motors com STEYR MOTORS GmbH After Sales Service Im Stadtgut B1 4407 Steyr Austria www steyr motors com STEYRMOTORS INNOVATION WITH LIGHTNESS WELCOME ABOARD Congratulations on your decision of choosing a STEYR MOTORS marine engine for your boat and we hope you will enjoy it STEYR MOTORS GmbH has developed a high speed diesel engine with two stage high pressure fuel injection specifically for the marine environ ment STEYR MOTORS marine engines are designed to be adapted to various propulsion systems To come up to your expectations please study thoroughly this manual for your new STEYR MOTORS marine engine to get sufficient information on its operation and handling and to permit an optimal use of the various built in functions With kind regards STEYR MOTORS GmbH YOUR STEYR MOTORS MARINE DEALER 10 Edition July 2011 P N 2001022 0 STEYRMOTORS How to use this manual Table of Contents GENERAL PART PAGE 5 12 This section contains user instructions and general notes on safety for STEYR MOTORS marine engines START UP AND FUNCTIONS PAGE 15 40 This section contains brief instruction function description and normal operation as well as correct start up and handling of STEYR MOTORS marine engines FUEL AND LUBRICAN
60. TS PAGE 41 44 This section defines the requirements as to fuel and lubricants for STEYR MOTORS marine engines TECHNICAL DATA PAGE 45 62 This section contains technical data and product description of STEYR MOTORS marine engines MAINTENANCE TROUBLE SHOOTING PAGE 63 88 This section contains instructions for required maintenance and notes on the fault finding on your STEYR MOTORS marine engine DEALER S RESPONSIBILITIES PAGE 89 106 This section contains instructions for installation acceptance tests propeller selection removal from service start up after storage adequate disposal and dealer s test list WARRANTY DISTRIBUTORS PAGE 107 118 This section contains warranty conditions services and obligations for owners and manufacturers of STEYR MOTORS marine engines INNOVATION WITH LIGHTNESS STEYRMOTORS INNOVATION WITH LIGHTNESS Cnr m 6 Marine Engine Overview 7 Product References Illustrations and Specifications 8 8 Stolen UNIN TE Oc 8 Owner identification Card e 8 Installation and pre delivery inspection log 9 Dealer Service
61. able Which enlargements or complements do you suggest Where did content related mistakes slip in Please address your comments and ideas to your STEYR MOTORS Marine Dealer Since this manual covers the whole family of STEYR MOTORS marine engines differing sections are marked as follows 1 whole page applies to all engines 2 MO144K33 whole page applies to specified engine types only 3 GENERAL MO114K33 3 700 rpm whole page applies in principle for MO166K28 2 600 rpm all engine types but different data e g technical data is marked MO236K42 4 000 rpm STEYRMOTORS INNOVATION WITH LIGHTNESS MARINE ENGINE OVERVIEW STEYR MOTORS M 16 MO156K25 50 100 126 25 100 MO196K35 100 MO236K42 100 256 43 100 256 45 100 286 43 100 MOS306H43WJ 100 MO114K33 MO144V38 MO144M38 MO164M40 MO174V40 MO84K32 2 100 MO94K33 2 100 STEYR MOTORS 14 NAM at standard reference conditions according to ISO 15550 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS Product References Illustrations and Specifications When reference is made in this manual to a brand name number product or specific tool an equivalent product may be used in place of the product referred to unless specifically stated otherwise Equ
62. actory warranty service from a STEYR MOTORS distributor or dealer please contact STEYR MOTORS after sales division directly Its contact information is as follows STEYR MOTORS GmbH Im Stadtgut B1 4407 Steyr Austria Phone 43 7252 222 52 Fax 43 7252 222 29 e mail service steyr motors com Erstellt Issued 04 02 2011 Gepr ft und freigegeben Approved Kundendienst After Sales Service 04 02 2011 Ing Rudolf Mandorfer 114 a WARRANTY STEYRMOTORS cy INNOVATION WITH LIGHTNESS 4 Engine Gearbox Boat Model and Hull Identification Numbers Record your engine and gearbox model and serial numbers immediately after purchase This will enable you to have them available for quick reference when ordering parts or literature Engine Model No Engine Serial No Gearbox or Stern Drive Model No Gearbox or Stern Drive Serial No Ignition Key No Boat Model Hull Identification No HIN Recommended Propeller Size Replacement Parts Never use parts of unknown quality on your STEYR MOTORS Marine Engine Insist on GENUINE STEYR MOTORS Marine parts See your local STEYR MOTORS Marine dealer STEYR MOTORS GMBH 2007 All rights reserved to changes or modifications 115 WARRANTY STEYRMOTORS INNOVATION WITH LIGHTNESS STEYR OWNER IDENTIFICATION CARD e Owner s Name Address City State Zip Date of commissioning MODEL SE
63. ailable coverage under the Warranty and so that STEYR MOTORS has a means of identifying and contacting you in the event of product updates or service notifications 108 ae INNOVATION WITH LIGHTNESS 7 Commissioning Report Your new Steyr engines have been shipped together with a form entitled Commissioning Report a copy of which is included in the installation manual that accompanies your engines It is your responsibility to insure that this form is completed by the seller distributor dealer or boat builder at the time of installation and that it is immediately re turned to STEYR MOTORS Keep a copy of the completed form for your records as you will be required to present it in the event you ever require warranty service Failure to complete and immediately return the Commissioning Report to STEYR MOTORS will cause your warranty to be voided Base Engine Warranty The Base Engine Warranty covers any failure of the Product under normal use and service that occurs during the applicable period of coverage and that results from a defect in STEYR MOTORS material or factory workmanship a Warrantable Failure STEYR MOTORS Responsibilities under the Base Engine Warranty During the applicable period of coverage under the Base Engine Warranty and subject to all conditions limitations and exclusions herein STEYR MOTORS will at its option either repair or replace the defective Product In the event that STEYR MOTORS elect
64. also check oil level of power steering If required add automatic transmission oil available with your STEYR MOTORS dealer Other approved oils such as GM Servo or Dexron may also be used Do not overfill pump reservoir level for Transmission Whenever you check motor oil level also check oil level of transmission required add automatic transmission oil available with your STEYR MOTORS dealer Other approved oils such as GM Servo or Dexron II may also be used Do not overfill transmission NOTE Consider specifications of respective transmission manufacturer 91 Y STEYR TURBO DIESEL STEYRMOTORS INNOVATION WITH LIGHTNESS Check coolant closed cooling circuit ATTENTION With hot engine the closed cooling circuit is under pressure Do not try to open the radiator cap or the drain plugs when engine is hot This may cause severe injuries by hot coolant As soon as the engine has cooled down the cap may be opened Remove radiator cap 23 A Coolant level should reach the MAX marking 23 B in the expansion tank ATTENTION Only add STEYR MOTORS engine coolant NOTE When not using the original STEYR MOTORS coolant severe damage to the cooling system of your engine may occur Drain the raw water circuit of the engine Check raw water open circuit with pump Filling is done automat
65. amp Hydr Pump Speed Sensor Cover T Belt Upper Valve Cover Heat Exchanger Coolant Expansion Tank Cooler Cap 45 Diagnostic Outlet Inversion Switch only for SOLAS 44 Connector Instrument Panel Coolant Temperature Sensor 43 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 41 06030 06031 This sensor is magnetism sensitive All external magnets must kept away 57 MO286H43 MO156K25 oe STEYRMOTORS 0 Technical Data and overview MO286H43 MO156K25 MO126K25 MAKE STEYR MOTORS M 16 TCAM displacement 3 200 cm piston displacement 85 0 x 94 0 mm rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 199 270 107 145 85 116 Z Drive 196 266 105 143 84 114 4 300 rpm 2 500 rpm 2 500 rpm 0 rpm 300 rpm Orpm 200 rpm 0 rpm 200 rpm idle speed 630 rpm adjustable injection Plunger activated two stage high pressure with electronically controlled injection rate fuel acc to CEC RF 03 A 84 DIN 51601 Cetan gt 45 diesel fuel No 2 D temperature above 7 No 1 D tempe
66. art catalogue fuel filter location intake sided oil pressure above 2 000 rpm 400 700 kPa 58 101 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 4 02 CF or 10W 40 ACEA E4 E5 E7 API P NO 2010058 0 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 exchange coolant capacity 11 5 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 50 MO84K32 ZEN MO94K33 Overview for all STEYR MOTORS 4 Cyl Marine Engines 1 2 34 5 6 Item Designation 19 A 1 Zinc Anode 4 Units 18 S Tem 2 Model and Serial Number 4 jr 1 3 Intercooler 17 i4 4 Fuel Oil Cooler with Raw Water Drain Plug 16 7 5 Fuel Pump 15 8 6 Oil Seperator 14 b 7 Raw Water Drain Plug 13 1 8 Valve Crankshaft Housing Ventilation only SOLAS En 9 Oi
67. ater system strainer impeller pump contact authorized workshop after cooling down check engine coolant level contact authorized workshop after cooling down check engine coolant level contact authorized workshop defect speed sensor or sensor connection contact authorized workshop contact authorized workshop BUKH STEYR MOTORS SOLAS STEYRMOTORS INNOVATION WITH LIGHTNESS Table Error Indication on Instrument Panel for SOLAS only py CLOCK 12 24 j Fuel Level STEYR INNOVATION WITH LIGHTNES combined light control amp warning light engine oil pressure B warning light battery charge D warning light check engine A audible warning device C x Operating condition During normale engine operation or indication in case of sensor defect while ignition is switched ON A Speed resp performance limitation during engine Event operation Indication status Fault Remarks 80 90 C OFF oil pressure below check oil level min limit contact authorized ON ON workshop a OFF fault oil pressure check oil level FLASH sensor or contact authorized OFF ING 1x sensor connection workshop qm per sec OFF ON A ON engine overload during reduce throttle position until light a break in period goes OFF indication during SS first 2 hours of operation see engine break in procedure 72 STEYRMOT
68. atio 17 0 1 full load speed range rpm 4 300 rpm 0 rpm 300 rpm idle speed 630 rpm adjustable injection Plunger activated two stage high pressure with electronically controlled injection rate fuel acc to CEC RF 03 A 84 DIN 51601 Cetan gt 45 diesel fuel 2 D temperature above 7 C No 1 D temperature below 7 fuel filter refer to spare part catalogue fuel filter location intake sided oil pressure above 2 000 rpm 400 700 kPa 58 101 PSI microprocessor controlled filling capacity motor oil approx 12 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 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 exchange coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 60 INNOVATION WITH LIGHTNESS 7 Overview STEYR MOTORS MO306H43WJ Designation N 4 Boost Pressure Sensor Zinc Anode 17 Intercooler 16 Fuel Hydr Oil Cooler Mod
69. connection of battery terminals may damage the electronic system Grease outer sides of terminals Open fuel stop valve and check all fuel lines for leakage Thoroughly check the boat and engine for slack or missing screws or nuts Pump the bilge dry and clean the engine compartment Complete the raw water system Open the raw water inlet ATTENTION Insufficient raw water supply may damage the engine and the raw water pump Test run Start engine Check voltmeter oil pressure and water temperature gauge Make sure that all sys tems function properly Check all parts for oil fuel or water leakage 102 INNOVATION WITH LIGHTNESS STEYRMOTORS ENGINE LOG a Number Engine Engine Service Record Destination Abord Started Stopped Inspection Tune up Lubrication 103 INNOVATION WITH LIGHTNESS STEYRMOTORS NS Number Engine Engine Service Record Destination Started Stopped Inspection Tune up Lubrication 104 INNOVATION WITH LIGHTNESS STEYRMOTORS ENGINE LOG a Number Engine Engine Service Record Destination Abord Started Stopped Inspection Tune up Lubrication 105 INNOVATION WITH LIGHTNESS STEYRMOTORS cram 106 f STEYRMOTORS INNOVATION WITH LIGHTNESS 1 4 LIMITED ENGINE WARRANTY dcus 108 Engine Gearbox Boat Model and Hull Identification Numbers
70. ct ono ae 54 Technical Data and Overview MO256K43 MO256H45 Ca Gra dae ca 56 Technical Data and overview MO286H43 MO126K25 MO156K25 58 Technical data and overview 2 60 45 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS 46 INNOVATION WITH LIGHTNESS AN GENERAL STEYRMOTORS Model and Serial Numbers The model and serial number see ill 15 16 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 The model and serial number of the marine gearbox is located on the marine gearbox housing as illustrated To obtain instructions regarding marine gearbox opera tion refer to marine gearbox owners manual 47 INNOVATION WITH LIGHTNESS STEYRMOTORS Q Technical Data and Overview MO54NA33 rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 39 52 Z Drive 38 52 ignition order 1 3 4 2 injection Plunger activated two stage high pressure with electronically controlled injection rate fuel acc to CEC RF 03 A 84 DIN 51601 Cetan gt 45 diesel fuel 2 D temperature above 7 C No 1 D temperature below 7 400 700 kPa 58 101 PSI microprocessor controlled specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA
71. d by STEYR MOTORS as part of a package Such non covered components include but are not limited to any MerCruiser Bravo Series stern drive ZF Marine transmissions sail drives water jet control lever and commander systems etc that may be sold together with a Steyr engine Buyers of a package that includes a MerCruiser Bravo Series stern drive should consult the product literature accompanying the stern drive for details on the warranty provided by its manufacturer Mercury Marine The provided warranty registration card with the Mercury Marine MerCruiser product needs to be returned to STEYR MOTORS for registration in their system What You Must Do to Activate the Warranty Owner Registration IMPORTANT In order to obtain the full benefit of this Warranty your new Steyr engines must be timely reg istered at the factory latest within 3 years from the date of sales document The engines you have purchased have been shipped from the factory together with a Warranty Registration Card a copy of which is included in your Operation Maintenance and Warranty Manual It is your responsibility to insure that the distributor or dealer from whom you purchased the engines fills out the Warranty Registration Card in its entirety and that it is immediately forwarded to STEYR MOTORS The Registration Card must include your name and address the product number and serial number s date of sale and type of use as well as the seller s name address code numbe
72. direction to increase speed NOTE A sudden increase in shifting torque on the remote control lever indicates a possible problem in the shifting system If so see your STEYR MOTORS dealer as soon as possible for proper diagnosis and and necessary service adjustment Continued operation under this condition could result in damage to the shifting mechanism 23 INNOVATION WITH LIGHTNESS Remote Control Operating Instructions 1 Your boat may be equipped with one of the following remote controls Single lever control Dual lever control for twin engines NOTE If other than STEYR MOTORS matched remote controls are used follow the manufacturer s recommendation Remote controls have the following important features Asingle lever which allows to select forward or reverse gear regulate engine speed and ensure shifting is done at low engine speed A start in neutral only feature which will protect you from starting your STEYR MOTORS Marine Engine with engaged gears The side mount control has a neutral lock button C located in the control lever which must be pressed to permit shifting from neutral to forward or reverse The top mount controls do not have a neutral lock but there is a neutral ratchet position Side Mount Control To disengage shift mechanism 1 Place control lever into neutral position D 2 Press both neutral lock button C and shift disengage button E 3 Move control lever forward to increase
73. e 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 potentiometer failure See table trouble shooting Governing system STEYRMOTORS INNOVATION WITH LIGHTNESS Diagnostic system The electronic engine control unit monitors the following engine parameters oil pressure boost pressure coolant temperature exhaust pipe temperature Hi riser sensor control rack potenti ometer accelerator speed signal The ECU carries out 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 77 Existing active failures remain stored until the problem has been solved and the code has been cleared from the memory To select stored service codes a with diagnostic program VR00134 0 or diagnostic tool VR00135 1 is necessa
74. e inversion switch is to be checked every 50 hrs or 6 months See service and maintenance chart page 64 ATTENTION After such an event this temporarily stored operating condition is to be cancelled from the engine management system by ignition OFF Reset Without Reset a new start of the engine is not possible Interrupt crankshaft housing ventilation During an activation of the mercury switch inversion the by pass valve B for crankshaft housing ventilation is closed too This avoids a possible oil outlet via suction through the air filter Instrument Panel The engines are supplied with the standard instrument panel The respective customer may use a self adapted STEYR MOTORS instrument panel or one which corresponds to his own ideas and requirements STEYRMOTORS INNOVATION WITH LIGHTNESS 06012 06010 ATTENTION For not approved alterations which lead to engine failure no liability can be undertaken Dry Operation After a dry operation of the engine without raw water cooling check the impeller of the raw water pump for dama ges Replace if necessary Grease the impeller use grease from special impeller kit 2011753 2 40 INNOVATION WITH LIGHTNESS STEYRMOTORS 42 How to Select Fuel e 42 Fuel Selection Chart EN E 42 Engine Lubrication Mcr Cm 43 Motor UST 43 Oil Identification Symbol
75. ecommended Minimum On Board Tools Screwdriver Set lubrication oil spray Metric Socket Set 12 volt pilot lamp Metric Allen Key Set flashlight Metric Spanner Set insulating tape long nose pliers sharp knife Recommended Minimum On Board Spare Parts propeller and small parts for propeller mounting fuses fuel filter bulbs impeller for raw water pump sealing compound These lists represent a suggested MINIMUM and are not intended to cover all boats or possible boating conditions 10 STEYRMOTORS Q INNOVATION WITH LIGHTNESS Engine Submersion Remove engine from water as quickly as possible and contact your local STEYR MOTORS Marine dealer for service It is imperative that your dealer removes all water from the engine and immediately relubricates all internal parts Electrical devices must be replaced Delay in completing these actions may allow extensive engine damage Frequently check engine compartment for excessive water accumulation water depth in bilge should be kept well below flywheel housing Engine compartment must enable proper venting to avoid condensation to build up on inner surfaces Bottom Painting If your boat is in water where marine growth is a problem the use of an antifouling paint will reduce the growth rate Tin base antifouling paint TBTA or TBTF is recommended where its use is permitted Copper base antifouling paint may be used but will require more frequent inspection and replacement of sacrific
76. el and Serial Number 15 8 Oil Seperator 12 10 Raw Water Drain Plug 13 9 Valve Crankshaft Housing Ventilation only SOLAS Fuel Filter and water seperator Fuel Pump Oil Filter Raw Water Inlet Fitting Raw Water Pump 18 29 19 20 Coolant Drain Plug 2 Units Oil Suction Pipe Oil Dipstick Rack Position Sensor Engine Lifting Eye 23 Motor Oil Filler Cap 22 Potentiometer Accelerator 9 Drive Belt Raw Water Pump Alternator Hydr Pump Engine Mount Drive Belt Tensioner Cover T Belt Lower Vibration Damper Speed Sensor Cover T Belt Upper 2 27 30 44 33 34 32 35 3931 36 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 46 48 Engine Management System Fuses 52 47 Exhaust Temperature Sensor Air Filter Turbo Charger 51 Exhaust Elbow 50 n9 28 21 25 24 22 08019 08020 49 Starter Relais Backside Ground Plate Flywheel Flywheel Housing Oil Pressure Sensor Water drain point
77. el flow amount on return line in idle Max engine rpm WOT CMD 5 Motor oil pressure SMO EDT Idle speed Engine coolant temp SMO EDT Temperature engine compartment C Exhaust raw water temp SMO EDT Exhaust backpressure mbar Boost pressure at max rom SMO EDT Active engine warnings YES NO if YES which Instruments adjusted YES LOG FILE Idle Full Load Idle name HYBRID Max boat speed in E Mode knots with Speed Mode UO low Omid Omid2 high max engine rpm achieved in E Mode rpm D Mode status on SCC E Mode ready red D Mode ready green HCU Mode ready green GENERATOR see SCC User Manual Z001071 0 chapter Hybrid menu NOTES E Mode status on SCC E Mode ready green D Mode ready red HCU Mode ready green E Drive see SCC User Manual Z001071 0 chapter Hybrid menu NOTES Flow rate through Hybrid cooling system l min see in Hybrid cooling schematics mentioned above Max HCU temperature on SCC see SCC User Manual Z001071 0 chapter Hybrid menu Max E MOTOR temperature on SCC see SCC User Manual Z001071 0 chapter Hybrid menu Safeguarding instruction carried out Manual warranty and operation explained Test made on by Name in block letters Please immediately return a copy of this report and the Warranty registration card to your STEYR MOTORS GENERAL DISTRIBUTOR Failure to do say may affect factory warranty 101 STEYRMOTORS
78. emoved connection between Pin 1 to Pin 2 opened before ignition is turned ON again 74 INNOVATION WITH LIGHTNESS 7 L Indication and Cancellation of memorised sensor and circuit faults Selection and clearing of stored service codes Procedure Ignition OFF Connect Tool VR00135 1 to Diagnostic Outlet Plug X23 Ignition ON NOTE The program changes automatically to indication of service codes If no service code is stored only repeating control code reading Code 12 will be displayed Possible memorized codes are indicated as shown in the previous illustrated example blinking 3x Code 12 i e 3x service code 14 etc The sequence will be prolonged with additional codes if more then one service code is stored See Table Service codes for description To delete a determined service code from the Engine Management System concentrate for the 3 times flashing the desired service code While this service code is displayed the third time the button Tool VR00135 1 must be pushed and kept in this position contact open The indication on the Check Engine Light changes to a fast blinking of the lamp app 4 times per sec During this rapid flashing light the push button must be released close contact after app 2 sec to delete this service code NOTE Any other service code have to be selected and cleared individually following the above men tioned procedure to delete a determined service code NOTE
79. er and or service facility undertaking the work Upon approval of a warranty claim you are responsible for making the Product available for repair at the place designated by STEYR MOTORS within a reasonable period of time IMPORTANT The foregoing procedures for making a warranty claim are mandatory Failure to comply with the requirements for submitting a warranty claim shall be presumed to have deprived STEYR MOTORS of adequate and timely notice of a defect and shall relieve STEYR MOTORS of any duty of performance under this Warranty 113 WARRANTY cy STEYRMOTORS Q INNOVATION WITH LIGHTNESS Venue and Applicable Law This Limited Warranty and the rights and obligations of STEYR MOTORS and of the Owner as they relate to any product supplied by Steyr Motors shall be governed by and construed in accordance with Austrian law and any legal action instituted against STEYR MOTORS as a result of this Warranty shall be brought in Vienna Austria In the event of a legal action commenced against Steyr Motors in the United States Steyr Motors shall have the option to consent to jurisdiction and to require that the action be submitted to binding arbitration according to the commercial rules of the American Arbitration Association Miscellaneous This Warranty document consists of the complete and final expression of the intent of the parties with respect to the warranty obligations of STEYR MOTORS The terms of this Warranty may not be modified
80. es the power See Electronic Engine Control Unit ECU in section Start up and Operation of Operation Maintenance amp Warranty Manual Check tightness of all cooling water hose clamps Check fuel hoses for correct size and safe routing to and from engine Check battery units for correct polarity and battery for correct capacity Check all electrical connections engine harness main connector accessories instrument panel Check level of all operational fluids Motor oil Coolant Power steering fluid Drive or gear Reservoir of trim pump Fill fuel tank for engine test run Check function of displays on instrument panel Check function of bilge pump and blower Check fuel system for free flow and leaks Check function of trim installation Check function of anchor light navigation lights and instrument panel lights Install drain plug of bilge 98 INNOVATION WITH LIGHTNESS 7 19 Steering Lubricate 20 Check condition and tension of all drive belts 21 Check engine mount screws for tight seat 22 Check for any leaks deficiencies signs of wrong use etc 23 Check function of all warning devices installed 24 Read out memorized service codes and make necessary corrective actions 25 Start engine and check for normal instrument display and normal operating noise 26 Obtain propeller load absorption 27 Check installation and fill in commissioning report Installation Manual P N Z001007 0
81. ever occurs first The period of coverage commences on the date on which the Product is delivered to the first retail purchaser or the date on which the unit is first leased rented or loaned or when the Product has been operated for 30 hours which ever occurs first 109 WARRANTY gt P STEYRMOTORS INNOVATION WITH LIGHTNESS Extended Major Components Warranty The Extended Major Components Warranty covers any failure under normal use and service of any of the below listed parts or castings that occurs during the extended warranty period and that is caused by a defect in material or factory workmanship Engine Monoblock Casting Engine Camshaft Engine Crankshaft Engine Connecting Rods Crankshaft Sprocket Camshaft Sprocket Engine Housing Flywheel Housing STEYR MOTORS Responsibilities under the Extended Major Components Warranty During the applicable period of coverage under the Extended Major Components Warranty and subject to the con ditions limitations and exclusions herein STEYR MOTORS will at its option either repair or replace the defective component STEYR MOTORS responsibilities in the event of a repair shall be the same as provided with respect to the Base Engine Warranty except that the cost of labor for removal and reinstallation is not covered under the Extended Major Components Warranty Duration of Coverage The Extended Major Components Warranty extends for a period of 60 months or until the en
82. except by a writing signed by an authorized representative of STEYR MOTORS Dealers and distributors of Steyr Motors engines whether or not approved by Steyr Motors are not agents of STEYR MOTORS and have no authority to alter the terms of this Warranty or to waive any condition or requirement stated herein Should any portion of this Warranty be determined unenforceable in a court of law the validity and legal effect of the remainder of the document shall not be affected STEYR MOTORS may in certain circumstances and at its sole discretion provide for service outside the scope of this Warranty to update modify or repair a product In that event Steyr Motors shall not be deemed to have assumed any additional obligation to the owner or to have modified or waived any of the provisions of this Warranty The owner shall be responsible for the cost of investigating complaints found not to be attributable to a defect in STEYR MOTORS material or factory workmanship Any STEYR MOTORS product or part replaced under warranty will automatically become the property of STEYR MOTORS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If You Do Not Receive Satisfactory Warranty Service STEYR MOTORS strives through an extensive network of independent distributors and dealers to provide prompt courteous and competent warranty service to owners of Steyr engines If you fail to receive satisf
83. f the following documentation and records which must be made available to STEYR MOTORS in the event that warranty service is required Whichever occurs first 111 WARRANTY cy STEYRMOTORS INNOVATION WITH LIGHTNESS You are responsible for keeping complete and accurate records of all service performed on the engines and for maintaining a log of all regularly scheduled maintenance in the Owner Service Log included in your Operations Maintenance and Warranty Manual You are responsible for assuring that at all times the engine hour meter on your Steyr engines is in good working order and in a condition that accurately reflects the total hours that the engines have been operated You are responsible for keeping copies of the completed Warranty Registration Form and of the Com missioning Report Limitations and Exclusions STEYR MOTORS is not responsible for any engine failure or other problem attributable in whole or in part to any of the following Any application or installation inconsistent with STEYR MOTORS published application and installation guidelines Abuse or neglect including but not limited to operation without adequate coolants or lubricants over fueling over speeding lack of maintenance of cooling lubricating or intake systems improper storage preservation rust or corrosion improper starting warm up run in or shutdown practices or failures caused by incorrect oil or by water dirt or other contaminan
84. first running hours on your boat and to establish a service and maintenance routine Services will be performed by STEYR MOTORS Marine Dealers at local rates Costs for service material to be paid by the owner Illustration Symbols Refer to the photograph or drawing described in that paragraph Refer to specific items or features described in the text and illustrated on the photograph Refer to the general subject of the text Refer to an item or feature not clearly visible on the photograph STEYRMOTORS INNOVATION WITH LIGHTNESS Repair Service All repair works on your STEYR MOTORS marine engine should be carried out by a licensed STEYR MOTORS Marine Dealer with his professional knowledge trained staff and special purpose tools to solve all occuring problems Preferably all work on your STEYR MOTORS marine engine should be carried out by the STEYR MOTORS Marine Dealer that sold the equipment to you he knows you and the equipment If problems occur during a trip bring your engine to the next STEYR MOTORS Marine Dealer Information on Deal ers and Distributors can be found at the end of this manual Replacement Parts Your STEYR MOTORS Marine Engine was designed to operate in a marine environment use STEYR MOTORS original replacement parts Before Casting Off Check the weather report wind and water conditions Tell someone where you are going to and when you expect to arrive or return R
85. flushing of the engine when in or out of the water NOTE Use in salt or brackish water may require additional anti corrosion protection 35 STEYRMOTORS INNOVATION WITH LIGHTNESS Fuel Pump The STEYR MOTORS Marine Engine is equipped with an electric fuel pump It is turned ON and OFF with the key switch If the engine is not started within 10 seconds after turning the key switch ON the fuel pump is automati cally turned off Fuel System Checks Fill the tank with the recommended fuel Keeping tanks full reduces water condensation and helps keep fuel cool which is important to engine performance Make sure that fuel supply valves if used are open and valve cock seals are absolutely gas tight To insure a prompt start and an even run of the engine the fuel system is to be rinsed by means of the electric fuel pump ignition ON several times for app 10 sec before starting the engine the first time and or after every replace ment of a fuel filter Refill at the end of each day s operation to prevent condensation from contaminating the fuel Condensation formed in a partially filled tank promotes the growth of microbial organisms that can clog fuel filters and restrict fuel flow If the engine is equipped with a fuel water separator drain off any water that has accumulated Water in fuel can seriously affect engine performance and may cause engine damage STEYR MOTORS recommends to install a fuel water filter
86. gine ATTENTION Do not stop engine at speeds above idle or accelerate engine while turning off engine This N may result in engine failures 19 STEYRMOTORS INNOVATION WITH LIGHTNESS Run In Procedure After Major Overhaul The following run in procedure must be used on STEYR MOTORS engines following a major overhaul where a major overhaul is defined as a replacement of any or all of the following Crank Shaft Piston s Con rod s Monoblock Definitions Rated speed Engine speed with maximum power Half engine speed Half of rated speed Procedure Work steps Preparation Engine filled with oil and coolant to max levels Shell RIMULA ULTRA 10 W 40 Coolant GLYCOSHELL 50 50 water coolant STEYR MOTORS engine diagnostic tool connected to the ECU Test method Remove the expansion tank pressure cap for degassing the system Start the engine Run at idle speed for 20 min Stop the engine Check coolant and oil level top up to max level if necessary Close the expansion tank with the pressure cap Start the engine Warm up the engine 715 mins Run the boat minimum for 4 hrs at no more than half engine speed Check oil level top up to max level Check the error list in the ECU using the diagnostic programme if no errors continue run in If errors occurred contact STEYR MOTORS After Sales department for further decisions Warm up the engine 7 15 mins Run the boat minimum for 2
87. gine In case of overheating problems contact your STEYR MOTORS Marine dealer 37 INNOVATION WITH LIGHTNESS STEYRMOTORS Q Electrical Equipment The electrical equipment of your STEYR MOTORS Marine engine primarily consists of an alternator with transistor ized voltage regulator battery and all necessary connecting cables and leads Alternator The alternator is driven a poly V belt resp serpentine belt from the 4 cyl engines and via a V belt from the engines and charges the battery at all engine speeds Output at idle speed is 30 A 12 V and will rise with an engine speed of 3 000 rpm to maximum output of 90 A 12 V Optional The 6 cylinder marine engines may be equipped with an optional 80 A 24 V alternator and DC DC charger system kit Battery FOR ALL 4 CYL MARINE ENGINES Use a 12 volt battery with a cold testing circuit of 450 A at 18 and a capacity of 92 Ah at 27 to ensure the supply of the electric and electronic components at all operating conditions FOR ALL 6 CYL MARINE ENGINES Use 12 volt battery with a cold testing circuit of 650 A at 18 and a capacity of 115 Ah at 27 C to ensure the supply of all electric and electronic components 38 INNOVATION WITH LIGHTNESS 7 ATTENTION Do not use jumper cables and a booster battery to start engine Remove battery from boat and recharge WRONG CONNECTION WILL DESTROY ELECTRONIC SYSTEM Do not
88. gine has been operated for 1 800 hours whichever occurs first As with the Base Engine Warranty the period of coverage commences on the date on which the Product is delivered to the first retail purchaser or on the date on which the unit is first leased rented or loaned or when the Product has been operated for 30 hours whichever occurs first Bushing and bearing failures are not covered 110 STEYRMOTORS Q INNOVATION WITH LIGHTNESS Repair Costs Paid STEYR MOTORS NNNM of Coverage Parts Labor Labor for Months Hours Removal amp Reinstallation Base Engine Warranty 1 000 PLEASURE Summary of Warranty Coverage Base Engine Warranty 1 000 COMMERCIAL Extended Major 1 000 Yes Yes No Components Warranty Additional Coverage for Parts Replaced or Repaired Under Warranty Any STEYR MOTORS product or part replaced or repaired under the Base Engine Warranty will be covered under the Base Engine Warranty for the remainder of the warranty period Warranty Coverage for genuine Spare Parts STEYR MOTORS warrants genuine spare parts for extent of 6 month from the date of sales Conditions of Warranty Coverage This Warranty is expressly conditioned upon proper application installation commissioning operation and mainte nance of the Product in accordance with the specifications and guidelines set forth by STEYR MOTORS in its Opera tions Maintenance and Warranty Manual and in its instal
89. haust 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 Reduction 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 controls engine functions to ensure maximum efficiency Panel Indication Horn ON 2x p sec Gauge reading 2107 Horn ON 2x p sec Gauge reading 120 C 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 32 self diagnostic to protect the engine from damage if operating parameter are exceeded stores diagnostic data of ECU server circuits for maintenance and service Additional Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service cod
90. hedule after first every every 50 hours 150 h 300 h or 6 or 12 or 24 months months months notes POLY V BELT check TENSION change PLUGS plugs every 1 500 h or every 48 months every 1 500 h or every 48 months belt tension TIMING BELT timing change water pump tensioner ENGINE TIMING settimng every 1 500 h every 48 months every 750 hours every 750 hours every 750 hours every 750 hours set levers UNIT INJECTOR check set point tighten torque every 750 hours SENSING HYDR PUMP oil ATF oil level POWER oil level STEERING chec PUMP OR ime Stel NU every 750 h or every 24 months check GEARBOX for leakage STERNDRIVE gear oil see manufacturer s h FUMUS oil filter FRONT VIBRATION check torque DAMPER specifications repair or consult your STEYR MOTORS leakage water ENGINE COMPARTMENT check for fuel AND BILGE exhaust gas Marine dealer If required to be SHIFTING smooth action check A adjustment replaced by your STEYR MOTORS Marine Dealer lubrication check oil level see manufacturer s specifications local rules and consultation of your STEYR MOTORS SAFETY remote control EQUIPMENT
91. hrs at no more than 75 engine speed Check the service code list in the ECU using the diagnostic program if no errors continue run in If errors occurred contact STEYR MOTORS After Sales department for further decisions Warm up the engine 7 15 mins Start the STEYR MOTORS diagnostic tool data logger Run the boat minimum for 20 mins at full rated speed Stop diagnostic tool data logger and save the file filename engine number and date e g 68225765 20080910 dat Check the service code list in the ECU If errors occurred contact STEYR MOTORS After Sales department for further decisions Send data Log file to STEYR MOTORS After Sales department Check coolant and oil level at cold engine top up to max level if necessary Continue using the engine acc to STEYR MOTORS Operator Manual 20 INNOVATION WITH LIGHTNESS STEYRMOTORS GENERAL Engine Break In procedure All STEYR MOTORS Marine engines have been run for a short period as a final test at the factory You must fol low the Engine Break In instructions during the first 20 running hours to ensure maximum performance and longest engine life NOTE Non observance of break in instructions may cause severe engine failure First Ten Hours Maximum Engine Speed 75 of rated speed Maximum Throttle Position 75 For the first five to ten minutes of operation run the engine at low speed below 1 500 RPM For the remaining
92. ial anodes DO NOT PAINT any part of the drive unit with copper base antifouling paint NOTE Painting the drive unit with copper base paint will accelerate galvanic corrosion Vinyl butyl base antifouling paint is a recommended alternative DO NOT USE any graphite base antifouling paint NOTE Never paint anti corrosion anodes or their effectiveness will be lost See your STEYR MOTORS Marine contract partner for an antifouling paint that is suitable for your area Boat Bottom The condition of the boat bottom can affect your boat s performance Marine growth present in fresh water as well as salt water will reduce boat speed A boat bottom with evidence of marine growth causes a reduction in top speed of 20 percent or more Periodically clean the bottom of your boat following the manufacturer s recommendations 11 STEYRMOTORS INNOVATION WITH LIGHTNESS Boating Responsibilities As a boat owner you have certain responsibilities to others Be sure that all operators read this manual You are legally responsible for all occupants of your boat Instruct at least one of your passengers in the basic fun damentals of handling your boat in case of an emergency Show all hands the location of emergency equipment and how to use it You are required by law to have one locally approved life jacket for each person aboard plus one ap proved throwable device for man overboard protection Learn the waterway rules of the location in which yo
93. ically via raw water pump after having star ATTENTION draining the raw water circuit in time before the winter season and or daily when running the engine during the winter season may lead to freeze demage on the engine Remove drain plug 24 Engine empties itself exhaust system e Drain plug 24 A is not availabe for types in that case remove the hose Li 06015 Loosen 2 hose clamps 25 A and remove raw water hoses Bra t iq quickly start the engine so that raw water pump empties 6 itself NOTE As to procedure for draining the remaining equipment on your boat see your STEYR MOTORS Marine dealer A FA 96 ted the engine 92 STEYRMOTORS GENERAE INNOVATION WITH LIGHTNESS Cooling System Anodes 2 FOR ALL 4 CYL MARINE ENGINES p TY i pan E E FOR ALL 6 CYL MARINE ENGINES i e There are 4 sacrificial zinc anodes in the raw water cooling system normally although if an exhaust high riser is used there
94. is one extra fit in it Which are installed as per ill 26 and 27 Remove and inspect anodes for galvanic erosion according to the maintenance schedule Replace anode when material loss is 50 75 Anti Corrosion Anodes If additional electronic equipment is installed each should have an individual anode or grounding device and all grounding devices must be interconnected Follow recommandations of manufacturers of equipment NOTE Inspect anodes every 30 days or more frequently if used in extremely salty water Anode is to be replaced according to the 2 1 maintenance schedule Boats that connect to an AC power source shore power require protection against increased potential of galvanic and spray cur rent corrosion For protection a galvanic isolator can be installed in series with the grounding green wire in the shore power cable between the boat and the shore power outlet on the dock The isola tor blocks direct current DC flow but permits the passage of alter nating current AC thus providing a path for ground fault currents 106021 NOTE If a boat is connected to an AC power source shore power and it is not equipped with a galvanic isolator the zinc anti corrosion anodes may be unable to handle the added corrosion potential 93 STEYRMOTORS INNOVATION WITH LIGHTNESS
95. ivalent products which are used must meet all current local regulations and standards to avoid hazards Some countries may apply additional internal regulation Please follow their advices appropriately example Austria Bundesamt f r Schiffahrt Sweden Navigation Office Finland Navigation Office Norway DNV Det Norske Veritas USA USCG United States Coast Guard USA ABYC American Boat Yacht Council USA NMMA National Marine Manufacturers Association England LR Lloyds Register of Shipping France BV Bureau Veritas Germany GL GERMANISCHER Lloyd Italy RINA Registro Italiano Navale information illustrations and specifications contained in this manual are based on the latest product informa tion available at the time of printing STEYR MOTORS GmbH reserves the right to make changes at any time without notice to specifications and models and also to discontinue models as well as the right to change specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change Continual accuracy of this manual cannot be guaranteed All illustrations used in this manual may not depict actual models or equipment and are intended as representative views for reference only Insurance Insurance on your STEYR MOTORS Marine Engine and boat should be obtained as soon as practical for protection against loss by fire theft etc Consult your local insurance agent
96. ive free play in steering Steering cable loose See your STEYR MOTORS Marine wheel dealer High shift effort shift cable 2 Remote control binding 3 Engine drive mechanism binding 79 1 Remote control or transom bracket Replace and adjust See your STEYR MOTORS Marine dealer See your STEYR MOTORS Marine dealer See your STEYR MOTORS Marine dealer Wiring harness STEYRMOTORS 0 INNOVATION WITH LIGHTNESS A5 F1 F2 F3 F4 F5 F6 F7 G1 G2 J1 K24 K26 1 K26 2 K27 K28 M1 M2 R10 X2 52 X3 53 5 5 12 12 X13 B13 X14 B14 X15 B15 X16 B16 X17 B17 X18 B18 X19 B19 X20 Y20 X22 B22 X23 X26 Y26 71 72 73 74 76 fuse 50A fuse 50A fuse 50A fuse5A fuse 10A fuse 10A fuse 10A alternator battery plug 23 pole relay relay relay relay relay starter fuel pump glow pins plug 2 pole plug 2 pole plug 35 pole plug 3 pole plug 5 pole plug 3 pole plug 3 pole plug 2 pole plug 2 pole plug 3 pole plug 1 pole plug 2 pole without stop plug 6 pole plug 2 pole splice spot splice spot splice spot splice spot splice spot control unit main fuse glow plugs glow plugs permanent current modul and K27 Switched current for module K27 fuel pump K24 preheating control circuit to be provided by customer connection engine cable instrument cable fuel pump preheating control circuit preheating l
97. l Drain Plug 12 Sw Nm Fuel Filter 11 Oil Filter 10 9 06001 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 06002 Cover T Belt Lower Engine Mount 1 32 33 34 35 36 37 38 39 1 Vibration Damper Cover T Belt Upper 8 15 Engine Lifting Eye Speed Sensor Valve Cover 43 41 Heat Exchanger 42 Coolant Expansion Tank E Diagnostic Outlet Inversion Switch only for SOLAS NI Connector Instrument Panel Coolant Temperature Sensor 06003 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 44 40 000 46 47 48 49 06004 This sensor is magnetism sensitive All external magnets must be kept away 51 144 38 164 40 5 0 Technical Data and Overview MO144M38 MO164M40 174 40 MAKE STEYR MOTORS M 14 TCM TCAM displacement 2 133 cm piston displacement 85 0 x
98. lation and service manuals Proper use and operation of the Product entails among other things use of the Product in strict compliance with the following power ratings Pleasure Duty This power rating is intended for use in variable load applications where full power is limited to one 1 hour out of every eight 8 hours of operation Reduced power operations must be at or below 200 RPM of the maximum rated RPM This rating is an ISO 3046 ISO 8665 fuel stop power rating and is intended exclusively for pleasure non revenue generating applications Engines rated Pleasure Duty may not be used for any commercial application without voiding the product warranty A commercial application includes any work or employment related use of the Product or any use of the Product that creates income even if the Product is only occasionally used for such purpose A commercial application also includes charter naval police and other similar applications Commercial Duty This power rating is intended for intermittent use in variable load applications where full power is limited to two 2 hours of every eight 8 hours of operation Reduced power operations must be at or below 400 RPM of the maximum rated RPM This rating is an ISO 3046 fuel stop power rating and is intended for applications that operate less than 1 500 hours per year STEYR MOTORS duty of performance under this Warranty is expressly conditioned upon the purchaser s mainte nance o
99. ly regulates the fuel supply and the preheating period for any given temperature Therefore the throttle lever should remain in neutral position 1 To start the engine move throttle lever into idle position and gear into neutral position 2 Press the push button for ignition ill F red push button lock in place An audible alarm will sound and the warning lights are illumiated temporary indicating the correct function of the audible and visual warning system NOTE In case of a low temperature start wait until the combined oil pressure glow plug pre heating indication light is turned off then continue with the start procedure 3 Press the button START ill G green and hold in this position until starting of engine but under no circumstances hold in this position for more than ten seconds If engine does not start release start push 7 button momentarily and repeat starting procedure 4 As soon as engine starts release start button The audible alarm will stop when normal oil pressure has been reached ATTENTION If engine fails to start within one minute and or repeated attempts contact your STEYR MOTORS Marine dealer Never push start button when engine is running Stopping the Engine for SOLAS only 1 Move throttle lever into idle position and gear in neutral position 2 Cool down the engine 3 Press push button ignition ON OFF ill F to disengage from locking position and to shut OFF the en
100. me single side mount control and move the control lever to shift into forward or reverse The throttle will begin to advance after gear engagement Continue to move the control lever slowly in the de sired direction to increase speed H Reverse Shift Range 1 Reverse Throttle Range D Neutral position J Forward Throttle Range K Forward Shift Range Fuel Economy Using the fuel economy throttle range M can save fuel depending on boat load and hull design When the boat reaches top speed reduce engine speed slightly Make sure the boat maintains to plane when reducing engine speed Continue to reduce engine speed slightly while maintaining to plane Do not allow boat to fall off plane This will give a comfortable ride and help to save fuel at the same time Gear Box Information NOTE You are requested to follow the instructions and recommendations provided by the marine gear box manufacturer High Altitude Operation Your STEYR MOTORS Marine Engine is turbocharged and there should not be any noticeable performance loss at high altitudes 25 STEYRMOTORS INNOVATION WITH LIGHTNESS Instrument panel Fuel Level Instrument panel standard 7 A tachometer F ignition key A1 function buttons blind plug installation option for B engine parameter display key switch constant revolution C warning light battery charge H audible warning device D combined light preheating cont
101. meter Accelerator Drive Belt Raw Water Pump Alternator Hydr Pump Engine Mount Drive Belt Tensioner Cover T Belt Lower Vibration Damper 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 Water drain point Valve Crankshaft Housing Ventilation only SOLAS 34 52 Y 18 29 19 20 23 22 46 52 51 50 n 08015 2 27 30 44 33 34 32 35 393136 08016 48 47 49 This sensor is magnetism sensitive All external magnets must be kept away 59 08017 INNOVATION WITH LIGHTNESS STEYRMOTORS Q Technical data and overview MO306H43WJ rated power acc EN ISO 8665 2006 impeller KW HP Jet Drive Inboard 209 284 number of cylinders 6 oylinder in line engine position of cyl 1 at vibration damper side sense of rotation seen from front right compression r
102. meter limit has been exceeded Indication Pre warming Phase combined indication through oil pressure light Becomes affective if ambient engine coolant temperature is below 20 C 68 F Break In over load warning Engine oil pressure too low High coolant temperature Sensors or sensor circuit defect After ignition is turned ON the indication warning lights are illuminated and the warning horn will sound for less then a second 0 7 sec this serves as a functional check for the optical audible warning system The indication light and the warning horn remain switched on for 5 sec after ignition ON if a sensor or sensor circuit defect have been detected and stored in the Engine Control Unit ECU see section Instrument Panel Please contact your nearest STEYR MOTORS Marine Dealer to get proffesional assistance to verify the deficiency and to correct any possible failure If the engine oil pressure is too low the warning light engine oil pressure lights and the audible alarm sounds The engine power will be limited In this case proceed as follows Check engine oil level respectively add engine oil if necessary refer to chapter Fuel and Lubricants Restart engine and watch the oil pressure light The warning light has to extinguish within 3 or 4 second after the start If this does not happen the engine must be stopped immediately Ignition OFF In case of an overheating of the exhaust gas cooling sys
103. n the contact information for which is provided on the final page of this document In the event of a Warrantable Failure arising during the applicable warranty period a warranty claim must be submit ted promptly IN WRITING A warranty claim must be made immediately upon discovery of facts that would lead a reasonably prudent owner to believe that the Product is defective in materials or factory workmanship but in no event more than 30 days after such discovery To make a warranty claim contact any approved STEYR MOTORS distributor or dealer and present your STEYR MOTORS identification card and your copy of the Warranty Registration Form and Owner Service Log You may also be required to present your copy of the Commissioning Report all maintenance and service records A STEYR MOTORS Warranty Claim Form a sample copy of which is available from STEYR MOTORS website at www steyr motors com must be completed by the dealer or distributor and returned to STEYR MOTORS in Austria It is your responsibility to insure that the Warranty Form is properly completed and to retain a copy for your records as proof of the making of a timely warranty claim All warranty claims MUST be approved by STEYR MOTORS before any warranty work is undertaken No distribu tor or dealer of STEYR MOTORS is authorized to approve or to guarantee approval of a warranty claim Any work performed prior to obtaining authorization from STEYR MOTORS will be at the risk of the own
104. oad circuit main circuit start gears switch inversion switch only SOLAS module boost pressure senso potentiometer accelerator rack position sensor engine speed sensor engine temperature senso exhaust gas temperature senso oil pressure sensor oil pressure gauge optional control solenoid trim sensor optional diagnosis disconnection blow by only SOLAS earth connection sensor earth connection 31 on engine ensor supply 5 V earth connection 31 on E box plate shield speed sensor line Cable numbers principal functions 15000 xx ignition positive 31100 xx Do not connect mass for sensors with from ignition switch battery negative 15012 xx 12 volt main relay and modulator 601 01 Sensor signal to modulator unit A5 and unit A5 or instruments 15100 xx 5 volt supply voltage for sensors 606xx 01 Exit from modulator unit A5 to display System tachometer temperature display 30000 xx battery positive not secured 30012 xx battery positive secured 31000 xx battery negative GND 80 ZZZOOL 0 0 6 6 1 UJOO SJO OUJ J O S MMM T ano SNOLLd32X3 T ppm rt E Lo RE 28 48
105. on dipstick When refilling motor oil refer to information Engine Lubrication Motor Oil page 41 B Check oil pressure control lamp If the lamp lights up as soon as the boat changes its position while turning straightening up the boat or planing check the oil level in the engine housing by means of dipstick If neces sary add oil DO NOT OVERFILL In case that the oil pressure control lamp is still illuminated with correct oil level have the engine checked by your STEYR MOTORS 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 engine 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 with cold engine D Deviations from normal operating conditions will be indicated by warning lights and audible alarm As to exact meanings see section Error Indication on Instrument Panel 21 sTEYRMOTORS Q INNOVATION WITH LIGHTNESS ATTENTION In case of non observance of break in instructions warranty may expire Engine to be filled with recommended oil quality only See chapter Engine Lubrication Operation after Break In The engines specified in this manual are intended to be operated at different speeds and loads
106. ons in the Operation Maintenance amp Warranty Manual before using motor or accsessory Indicates that contents are under pressure A Means place shift control in NEUTRAL before starting motor Follow instructions in Operation Maintenance amp Warranty Manual before starting motor Identifies poisonous material Position Indicator Symbols Indicates upward movement Example While boat is at planing speed activating trim switch to raise the bow of the boat Indentifies the meter which indicates accumulative running hours of engine 1 1 2 Identifies battery or a meter wich indicates status of battery generator charging system Identifies the meter which indicates engine coolant temperature Functional Description Symbols FILTER Identifies a device which removes contaminants from fuel Identifies the negative ground or negative voltage connection Identifies the STOP SWITCH It may also identify STOP position of the throttle control 4 0 Indicates the amount of liquid in tank Indicates downward movement Example While boat is at planing speed activating trim switch to lower the bow of the boat Condition Symbols Identifies the meter which indicates battery voltage or amperage FILTER Identifies a device which removes contaminants from engine s oil system Identifies the EMERGENCY IGNITION CUT OFF SWITCH Emergency engine stop Identifie
107. r and a prop erly obtained commissioning report It must also contain the selling distributor dealer s certification that you are the original purchaser and user of the Product In case of an engine doesn t get put into operation within the first year from production the STEYR MOTORS long term preservation and conservation procedure must be followed and documented as described in this procedure to prove proper storage handling and re commissioning of the product A copy of the Warranty Registration Card designated Purchaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer Your copy of the Warranty Registration Card should be retained together with your Owner Identification Card and kept in a safe place In the event that you ever require warranty service you will be required to present your copy of the Warranty Registration Card along with your Owner Identification Card so that the date of purchase and delivery may be verified and so that the Warranty Claim Form can be properly completed Failure to register the Product with the factory within 60 days of the date on which you take delivery of the Product will cause the warranty period to begin running from the date on which the Product is shipped from STEYR MOTORS in Austria rather than on the date of delivery to you It is to your benefit to have all Products timely registered at the factory so that you receive the maximum av
108. rature below 7 fuel filter refer to spare part catalogue fuel filter location intake sided oil pressure above 2 000 rpm 400 700 kPa 58 101 PSI microprocessor controlled filling capacity motor oil approx 12 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 2010058 0 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 exchange coolant capacity 13 2 liters coolant STEYR MOTORS engine coolant 36 C P No 2011785 0 Efficiency of gearbox 97 0 95 efficiency of Z Drive 95 5 9 Extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH Reserves the right to make changes without notice or obligations 58 INNOVATION WITH LIGHTNESS STEYRMOTORS MO286H43 MO156K25 MO126K25 Overview STEYR MOTORS MO286H43 MO156K25 MO126K25 Item Designation Boost Pressure Sensor Zinc Anode Intercooler Fuel Hydr Oil Cooler Model and Serial Number Oil Seperator Raw Water Drain Plug n9 Fuel Filter and water seperator 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 Potentio
109. rmostat Housing Alternator Circuit Breakers Engine Management System Fuses Exhaust Temperature Sensor Air Filter Exhaust Elbow Starter Relais Backside E Box Ground Plate Starter Motor Flywheel Flywheel Housing Oil Pressure Sensor This sensor is magnetism sensitive All external magnets must be kept away 49 MO84K32 MO94K33 Technical Data and Overview MO84K32 MO94K33 MO114K33 MAKE STEYR MOTORS M 14 TCM TCAM displacement 2 133 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 Z Drive 52 70 63 84 77 104 number of cylinders 4 cylinder in line engine position of cyl 1 at vibration damper side compression ratio 17 5 1 T 3 200 rpm 3 300 rpm 3 800 rpm 0 rpm 200 rpm 0 rpm 200 rpm 0 rpm 200 rpm idle speed 700 rpm adjustable injection Plunger activated two stage high pressure with electronically controlled injection rate 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 refer to spare p
110. rmostat determines the amount of coolant circulating through the heat exchanger thus controlling the operating tem perature of the engine SLA 4264 CC A temperature sensor 8 A controls the cooling temperature An excessive temperature rise of the coolant will cause an optical Lal and audible alarm see chart Error indication on Panel Section In this case engine power will be reduced s TT T T 06008 The temperature gauge on the instrument panel indicates the coolant temperature of the engine 9 Open Cooling Circuit Raw Water Circuit Thermal energy transfered by the engine and absorbed by the engine coolant is drained via the external raw water circuit Raw water is sucked by the pump via the raw water intake constantly pumped through supercharger intercooler and heat exchanger and discharged together with the exhaust gas via the sprinkler During discharching the raw water entering the exhaust pipe adi tionally cools the exhaust gas A temperature sensor 9 A monitors the raw water and exhaust gas temperature An excessive rise will cause an optical and au dible alarm see chart Error indication on Panel Section In this case the engine power will be reduced too NOTE Should engine overheat at high speeds slowly reduce RPM to idling to prevent damages to the en
111. rol amp installed on rear side of panel warning light engine oil pressure emergency cut off switch lanyard E warning light check engine J circuit breaker 10 amp If you should need additional instruments or accessories please contact your STEYR MOTORS Marine dealer 26 STEYRMOTORS INNOVATION WITH LIGHTNESS Instrument indication during normal operation 1 ignition ON before starting System check see light indication ON 0 7 sec At low temperature condition cold weather the ON 0 7 sec combined light for glow plug preheating amp engine oil E pressure will not extinguish after 0 7 sec glow plug ON D preheating phase In this case start engine immediately after the light extinguishes Indication active error 1 5 5 4 0 7 5 Normal condition NOTE For further information see Table Error indication on Instrument Panel 27 STEYRMOTORS INNOVATION WITH LIGHTNESS CLOCK 12 24 PM Fuel Level nui TEYIS WITH LIGHTNESS 0 tachometer F push button ignition ON OFF red A1 function buttons G push button START green B engine parameter display H audible warning device C warning light battery charge installed on rear side of panel D combined light preheating control amp emergency cut off switch lanyard warning light engine oil pressure J circuit breaker 10 amp E
112. rom switch to stop the engine Using this switch is simple and should not interfere with normal operation of the boat Care must be taken to avoid accidental pulling of lanyard during normal operation Unexpected loss of forward motion will occur This could allow occupants to be thrown forward In case the emer gency cut off switch had been activated lanyard pulled the engine can be restarted by a person if the pull knob ill pos 1 of the emergency switch is being pulled and held in this position While holding the pull knob proceed with the normal start procedure and start engine The engine will immediately stop if the pull knob is released under this circumstances Fuel Level INNOVATION WITH LIGHTNESS S ATTENTION The emergency cut off switch can only be effective when in good working condition Observe the following Lanyard must always be free of entaglements that could hinder its operation Once a month check switch for proper operation With engine running pull lanyard If engine does not stop see your STEYR MOTORS DEALER for replacement of switch 30 INNOVATION WITH LIGHTNESS J Warning lights and audible alarm Your boat with the STEYR MOTORS Marine Engine engine is equipped with three warning lights and one audible alarm mounted behind the instrument panel to indicate the following operation condition or system deficiencies The ECU will also reduce the engine power in case an important operating para
113. ry Malfunction during operation is ranked in three different categories intermittent failure non essential failure and es sential failure 33 Twin Installations STEYR MOTORS Marine Engine inboard models can also be set up for counter rotation for twin installation This is done by inversing direction of cable lines on shift lever in order to achieve a counter rotation of propeller Counter rotation is accomplished in the gearbox The propeller propel ler shaft and output gear are the only parts that counter rotate The engine always has standard rotation 4 It is customary to operate your propeller as shown on this illus tration for twin installation Some boat manufacturers may set up twin installations the op posite way When propellers and or cable lines are removed care must be taken to attach them at the same position as be fore and that the propellers are not exchanged Optional Propellers 5 Propellers are available in all regular sizes for both right and left hand rotation Stainless steel has greater strength and du rability than aluminium This allows the stainless steel propeller blades to be thinner and still maintain more beam strength than aluminium propellers The result is a more efficient propeller that gives better performance and more fuel economy Propellers 6 Right hand propellers rotate clockwise to propel a boat forward Right hand propellers are considered standard rotation propel
114. s engine drain plugs and fittings Instructional Symbols Indicates FUEL is to be used or FUEL is present Indicates OIL is to be used or OIL is present Means read your Operation Maintenance amp Warranty Manual before operating the product It contains information or instructions vital for operation of product ENGINE OIL FILL Location for introduction of oil into the engine 13 eum Q ES Indicates that ELECTRICITY of more than 50 volts is present Indicates a potential fire hazard Indicates gear shift control positions FORWARD NEUTRAL and REVERSE Identifies the meter which indicates engine speed expressed in revolutions per minute Indentifies the meter which indicates engine coolant pressure Identifies the meter which indicates the pressure of engine s lubricating system FUSE Identifies a device which protects the electrical system from overload Identifies the operating device for starting the motor a Indicates areas to be lubricated Indicates lubricating oil used in transmissions STEYRMOTORS 0 INNOVATION WITH LIGHTNESS x INNOVATION WITH LIGHTNESS semwmmso O Z START UP AND FUNCTIONS Before SAWING MN 17 Starting the ea 18 Stopping th 18 Starting the Engine for SOLAS 19 Stopping the Engine for SOLA
115. s to repair the Product STEYR MOTORS will do the following STEYR MOTORS will pay for all parts and labor reasonably required to repair the defect responsible for the Warrantable Failure STEYR MOTORS will pay for all lubricating oil antifreeze filter elements and other similar mainte nance items replaced during a warranty repair when such items are not reusable due to a Warrantable Failure STEYR MOTORS will pay for the usual and customary labor costs for engine removal and reinstalla tion when necessary to repair a Warrantable Failure Labor costs will be paid by STEYR MOTORS only for work pre authorized by STEYR MOTORS and performed by an approved service facility during normal business hours Labor costs will be paid in accordance with STEYR MOTORS published standard repair time guidelines Parts used in warranty repairs may be new STEYR MOTORS parts STEYR MOTORS approved rebuilt parts or repaired parts Duration of Coverage The duration of coverage under the Base Engine Warranty depends upon whether your engine application and use are rated for Pleasure Duty or for Commercial Duty Forengines rated Pleasure Duty the Base Engine Warranty extends for a period of 24 months or until the engines have been operated for 1 000 hours whichever occurs first Forengines rated Commercial Duty the Base Engine Warranty extends for a period of 12 months or until the engines have been operated for 1 000 hours which
116. se retain this manual in the boat as it MUST be presented to the STEYR MOTORS Marine dealer whenever you require WARRANTY and or SERVICE IMPORTANT NOTE This manual contains all service activities required for your engine Checks and maintenance for the other parts of a complete drive system still need to be completed Any such procedures are to be found in sepa rate attached booklet s of the individual manufacturer s literature provided with the gearbox or similar drive components Whenever this manual refers to components like Manual Operation Hydraulic Pump etc such instructions only apply where applicable since they are not used on every engine model 65 Service and Maintenance Schedule for leakage INNOVATION WITH LIGHTNESS STEYRMOTORS Q after first 50 hours or 6 months every 150 h or 12 months every 300 h or 24 months ENGINE oil level LUBRICATION oil filter motor oil for leakage check change fluid level ENGINE hoses hose clamps COOLING SYSTEM antifreeze temperature condition check change antifreeze hoses hose clamps every 24 month zinc anodes raw water pump V belt RAW WATER impeller SYSTEM raw water pump V belt if required change impeller if required zinc anodes if corroded gt 50 96 raw water circuit raw water
117. tem the warning light engine control flashes and the au dible alarm sounds 2 times per second the engine power is reduced In this case proceed as follows IMMEDIATELY reduce the engine to idle speed Check an clean the raw water filter Check the coolant temperature gauge for overheating of engine coolant If the coolant temperature gauge indicates overheating of engine coolant switch for a short time to REVERSE to remove a possible clogging of the raw water inlet through large plastic parts etc and then to FORWARD Let the engine run at idle speed for some minutes If the temperature gauge still indicates an overheating of the engine the engine is to be stopped Restart the engine only after having found and eliminated the cause for alarm See loss of power in Trouble Shooting Chart Technical Data and in section Maintenance Check coolant level and if necessary refill coolant until an adequate coolant level is achieved If the cause for optical audible alarm cannot be found consult your STEYR MOTORS Marine dealer 31 Electronic Engine Control Unit STEYRMOTORS Q INNOVATION WITH LIGHTNESS The STEYR MOTORS Marine engine is equipped with an Electronic Engine Control Unit ECU that performs the following stores abuse data Engine power is reduced if Operating Parameter High engine coolant temperature limit exceeded Defect engine coolant sensor or sensor connection Ex
118. throttle F Shift Mechanism Engaged G Shift Mechanism Disengaged The neutral lock and shift mechanism will automatically engage when the control lever is returned to neutral position Top Mount Control To disengage shift mechanism 1 Grasp the control lever hub and pull straight in for approximately 1 4 6 mm 2 Move control lever forward to increase throttle The shift mechanism will automatically engage when control lever is returned to neutral Your boat may be equipped with remote controls other than those described above When not using STEYR MOTORS marine engine matched controls ask your DEALER for operating instructions for the remote control used in your boat since operation and function may differ from STEYR MOTORS marine engine matched remote controls ATTENTION Your boat should be equipped by manufacturer with a remote control with protection against starting in gear Only use a remote control with start in neutral only feature This feature can A prevent injury resulting from unexpected turning of the propeller and sudden movement of the boat 24 STEYRMOTORS INNOVATION WITH LIGHTNESS How to Shift and Control Speed NOTE Do not shift into FORWARD or REVERSE unless engine is running Damage to the shift mechanism could result from trying to shift without the engine running Move the control lever to neutral position D The shift mechanism will automatically engage Press neutral lock button C on so
119. tion in case of sensor defect while ignition is switched ON A Speed resp performance limitation during engine Event operation Indication status Fault Remarks 80 90 C oil pressure below check oil level min limit contact authorized ON ON workshop m SM OFF R 80 90 C OFF fault oil pressure check oil level FLASH sensor or contact authorized ING 1x sensor connection workshop OFF per sec ON A ON engine overload during reduce throttle position until light al break in period goes OFF indication during SS first 2 hours of operation see engine break in procedure 70 STEYRMOTORS INNOVATION WITH LIGHTNESS Indication status 80 90 C 2x per sec high approx 2x per sec 120 C 2x per sec 80 90 C 80 90 C AW 2x per sec FLASHING 2x per sec OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF Fault high exhaust temperature over 80 or defect exhaust temperature sensor or bad connection engine coolant temperature too high defect engine coolant sensor or bad connection unstable idle speed no indication on tachometer GN chock 12 24PM Fuel Level Trouble in governing loop involved components control solenoid rack control gear of unit injector rack position sensor 71 2 ES I Remarks check raw w
120. ts in the fuel or oil Unauthorized modifications of the engine Use of a service facility not approved by STEYR MOTORS or use of parts not supplied or approved by Steyr Motors For information on approved service partner in your area please contact STEYR MOTORS or refer to the list of approved service facilities posted on STEYR MOTORS website at www steyr motors com Prolonged or incorrect storage Prolonged storage for purposes of this Warranty is storage for a period of over one 1 year from the date of shipment from the STEYR MOTORS factory Normal wear or wearout of parts Faulty workmanship whether or not performed by an approved dealer or distributor of STEYR MOTORS and whether or not occurring in conjunction with a warranty repair STEYR MOTORS will not pay for any of the following costs which shall be the sole responsibility of the Owner The cost of transporting any STEYR MOTORS engine or product to or from the place of warranty service The cost of haulage launch docking or cranes The cost of lubricating oil antifreeze filter elements and other maintenance items replaced during war ranty repairs unless such items are not reusable because of the Warrantable Failure The cost of any part supplied or labor performed by a service facility not approved by STEYR MOTORS The cost of any part supplied or labor performed by a service facility without the prior authorization of STEYR MOTORS STEYR MOTORS does not
121. u are going to operate your boat Navigable waterways are con trolled by Federal regulations while inland lakes are controlled by local jurisdictions Obey these regulations to protect yourself your passengers and fellow boating enthusiasts Thoroughly familiarize yourself with weather station warning system signals and waterway traffic signs Contact your local Coast Guard station and take advantage of their seasonal boat inspections and training courses Safety This manual contains certain information related to the personal safety of you the operator your passengers and bystanders The Safety symbol A ATTENTION appears next to important information to prevent you and others from being hurt The symbol NOTE appears next to important information to keep machinery from being damaged Observe all notes and safety warnings contained in this manual WARNING A CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm 12 STEYRMOTORS Q INNOVATION WITH LIGHTNESS Symbols Certain symbols or combinations of symbols may appear on your STEYR MOTORS Marine Engine or on its acces Sories It is very important that you understand their meaning or purpose If any symbol is not clearly understood see your DEALER Safety Warning Symbols Means risk of SERIOUS injury is present Follow instructi
122. unc tion of the audible and visual warning systems NOTE In case of a low temperature em start wait until the combined oil pressure glow plug ENG indication light is turned off before you continue with the start procedure 3 Turn ignition key into position and hold in this position until starting of engine but under no circumstances hold in this position for more than ten seconds If engine does not start release ignition key mo mentarily and repeat starting procedure START 4 As soon as engine starts release ignition key The audible alarm will stop when normal oil pres sure has been reached ATTENTION If engine fails to start within one minute and or repeated attempts contact your STEYR MOTORS Marine dealer Never turn ignition key to position START when engine is running Stopping the Engine 1 Move throttle lever into idle position and gear in neutral position 2 Cool down the engine 3 Turn ignition key to OFF position ATTENTION Do not stop engine at speeds above idle or accelerate engine while turning off ignition This may result in engine failures 18 STEYRMOTORS INNOVATION WITH LIGHTNESS BUKH STEYR MOTORS SOLAS Starting the Engine for SOLAS only Starting procedure for the STEYR MOTORS marine engine is the same for cold or warm operating condition The engine control unit automatical
123. ur homepage under http www steyr motors com network 117 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS 118
124. v3 OLA 561 00 eouejsiseJ joejeg 5 JOUJOAOC 10 21091 L0 60v1 OCA OCX 2810501 88 00 eoueisiseJ 5 10 21091 L0 60v1 OCA OCX 181 piouejos OZA sodpeg 981 yore Buruonisod uonoeuuoo 5 JO Jo ON 10 91909 1 281 poys pepeeoxe uano eJnsseJd IO 10 91909 51 181 JUANI ON 10 99 12 98 72 YN 811 asnvo Q3A10OANI OSL 2003 77 5 Trouble Check Chart ATTENTION STEYRMOTORS INNOVATION WITH LIGHTNESS After following the Action described in chart and before cranking the engine make sure there are no loose fuel connections Make sure engine compartment is free of fuel A vapours Failure to do so could result in fire SYMPTOM POSSIBLE CAUSE ACTION Engine won t start Only for SOLAS gt Starter won t crank engine Engine runs erratically No fuel in tank or shut
125. 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 max 5 C min 2 5 mm s max 3 5 mm s min 0 2 mass max 0 3 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 100 ml Limit value and units 42 CEC RF 03 A 80 min 51 max 57 min 0 835 max 0845 min 245 C min 320 C max 340 C max 370 C min 55 C 5 C min 2 5 mm s max 3 5 mm s min 0 2 mass max 0 5 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 100 ml ASTM Test procedure D 613 D 976 D 1298 D 86 D 93 EN 116 CEN D 445 D 1266 D 2622 D 2785 D 130 D 189 D 482 D 95 0 1744 D 974 D 2274 STEYRMOTORS 0 INNOVATION WITH LIGHTNESS Engine Lubrication If you choose to lubricate your STEYR MOTORS Marine Engine yourself refer to the Lubrication and Inspection Chart for lu brication points and recommended lubricants Use only STEYR MOTORS recommended lubricants or lubricants of equivalent SAE VU quality and viscosity See your STEYR MOTORS dealer for ommended lubricants If you choose to have your STEYR MOTORS Marine Engine lu bricated see your local dealer He will gladly lubricate it at the required intervals STEYRTURBO DIESEL ENGINE OIL Motor Oil
126. warning light check engine NOTE Instrument gauges are automatically illuminated if ignition is turned ON NOTE n the case of inversion the engine will be automatically shut off in order to allow normal operation later The ignition push button F must be switched OFF and ON again then the engine can be restarted via the push button START 28 STEYRMOTORS INNOVATION WITH LIGHTNESS BUKH STEYR MOTORS SOLAS Instrument indication during normal operation for SOLAS only 1 ignition ON before starting System check see light indication ON 0 7 sec NOTE ON At low temperature condition cold weather the 0 7 combined light for glow plug preheating amp warning light engine oil pressure will not extinguish after 0 7 sec glow plug preheating phase x In this case start engine immediately after the light extinguishes Indication active error e 5 Sec ON 0 7 sec Normal condition NOTE For further information see Table Error indication on Instrument Panel 29 STEYRMOTORS INNOVATION WITH LIGHTNESS BUKH STEYR MOTORS SOLAS Emergency cut off switch Lanyard An emergency cut off switch is a feature on the instrument panel Use of this switch is highly recommended To prop erly use this feature attach the lanyard securely to your clothing Do not attach the lanyard to clothing that will tear away before the lanyard is pulled f
127. will increase when the boat is operated at a high incline before planing speed is reached Excessive water accumulation in the engine compartment bilge may cause engine failures Open the raw water intake valve NOTE Operate the engine only while the raw water supply is assured or the cooling system is equipped with a flushing device The raw water pump will be damaged and or the engine will overheat if operated without cooling water Open the fuel stop valve NOTE Only start the engine when a bubble free fuel supply is guaranteed Prior to first start up of the engine after installation after storage etc purge the fuel system by ignition ON for 6 x 10 sec Check the operating levels of coolant oil hydraulic oil transmission oil fuel Control of electric system Charge and charge state of battery 17 STEYRMOTORS INNOVATION WITH LIGHTNESS Starting the Engine Starting procedure for the STEYR MOTORS marine engine is the same for both cold and warm engines The en gine control unit automatically regulates the fuel supply and the preheating period for any given temperature Therefore the throttle lever should remain in neutral position 1 To start the engine move throttle lever into idle position and gear into neutral position 2 Turn ignition key into position ignition ON An au dible alarm will sound and the warning lights are illumiated temporary indicating the correct f

4 cylinders + 6 cylinders 4 cylinders + 6 cylinders

Contents

Download Pdf Manuals

Related Search

Related Contents