RESCUE_BOAT_ENGINE_MANUAL.pdf

Z001019/0_6_July 2008 Page GENERAL-1

GENERALSERVICE MANUAL MARINE ENGINES

GENERAL

Table of Contents

A General Remarks A 1 Model and Serial Numbers A 2 Documentation A 3 Model summary A 3.1 Model summary 4 cylinder engines A 3.2 Model summary 6 cylinder engines A 4 Technical Data and Overview A 4.1 Technical Data and Overview 4 cylinder engines A 4.2 Technical Data and Overview 6 cylinder engines

B Specifications B 1 Fuel Requirements B 2 Motor oil

C Maintenance and Service C 1 Trouble Check Chart C 2 Service- and Maintenance Schedule

D General Information D 1 Electronic Engine Management System (ECU) D 2 Diagnostic System D 3 Extended Storage Preservation Procedure D 4 Engine Break-in procedure D 5 Operation after Break-in

E Quality Gudelines for Repair E 1 Spare parts specification E 2 Workshop profile E 3 Nomenclature E 4 SI - System E 5 Abbreviations

F Operating material and Information on Disposal F 1 List of operating material F 2 Disposal of automotive waste products

G Notes on Safety G 1 General notes on safety G 2 Guidelines for damage prevention G 3 Legal rules G 4 Safety in the use of operating material

GENERAL

Page GENERAL-2 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

G 5 Measures in case of accidents

H Thightening Torques H 1 Listing of Thightening Torques H 2 General Tightening torques H 3 Testing of torque wrench H 4 Non-destructive material testing H 5 Use of adhesive and sealing materials H 6 Solvent-free sealing materials

J Wear Limits J 1 Adjustment information for service and maintenance

ToC

Z001019/0_6_July 2008 Page GENERAL-3

A GENERAL REMARKS

A 1 Model and Serial Numbers

01.01 ���.1

01.01 ���.3

01.01 ���.2

FOR ALL

4 CYL. MARINE ENGINES

The primary model and serial number (ill.1 or ill.2) is located on the engine as illustrated.

These numbers are required for warranty claims and ordering parts.

The model and serial number of the marine gearbox is located on the marine gearbox housing as illustrated.

To obtain instructions regarding marine gearbox operation, refer to marine gearbox owners manual.

06014

08006

08007

FOR ALL

6 CYL. MARINE ENGINES

Page GENERAL-4 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

The following documentation is available in English language on our website:

http://www.steyr-motors.com/technical technical documentation on CD - ROM P/N Z 001009/0 operation-, maintenance & warranty manual for all marine engines P/N Z 001022/0 tool catalogue for all marine engines P/N Z 001002/1 spare parts catalogue STEYR 94 td diesel marine P/N Z 001023/0

STEYR 144 vti/td diesel marine P/N Z 001005/0

STEYR 164 td diesel marine P/N Z 001015/0

STEYR 174 vti diesel marine P/N Z 001011/0

STEYR 166 td diesel marine P/N Z 011796/1

STEYR 236 FDE P/N Z 011796/0

STEYR 236 td diesel marine P/N Z 011796/1 - Z011769/2

STEYR 246 td diesel marine P/N Z 011800/0

STEYR 256 td diesel marine P/N Z 011810/0

STEYR 266 td diesel marine P/N Z 011805/0 installation manual for marine engines P/N Z 001007/0 service manual for all marine engines P/N Z 001019/0 operator's manual marine gear ZF P/N Z 001003/0

Diagrams marine engine functions on CD P/N Z 001021/0

A 2 Documentation 4 and 6 cylinder

Z001019/0_6_July 2008 Page GENERAL-5

A 3 Modell summary

A 3.1 Modell summary 4 cylinder engines

03.01 ill.1

03.01 ill.2

03.01 ill.3

Inborder i.e. ZF 45 Marinegear

Down angle

Bobtail - Version

Innenborder i.e. ZF 63 Marinegear

Equipment:

with side mounted raw water pump or, with side mounted raw water pump, power steering pump

Page GENERAL-6 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

03.01 ill.4

03.01 ill.5

03.01 ill.6

Equipment

Bobtail "B"

Direkt gearbox

A-down angle gear box

Parallel offset gearbox

Lifeboat Engine

03.01 ill.7

Z001019/0_6_July 2008 Page GENERAL-7

Stern Drive

Jet Drive

03.01 ���.10

03.01 ���.11

TYPE

Mercury Alpha Bravo I, II & III

Volvo DP 290

Volvo DP 290 Hydraulic

SX - Stern Drive

TYPE

Alamarin

Hamilton

Castoldi03.01 ���.8

03.01 ���.9

Page GENERAL-8 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

A 3.2 Modell summary 6 cylinder engines

03.02 ���.1

03.02 ���.2

03.02 ���.3

Inborder i.e. ZF 63 Marine gear

Down angle with side mounted raw water pump or, with side mounted raw water pump, power steering pump and front mounted auxiliary drive-PTO

Bobtail - Version

Z001019/0_6_July 2008 Page GENERAL-9

03.02 ���.4

03.02 ���.5

03.02 ���.6

03.02 ���.7

03.02 ���.8

Transmission

Lifeboat Engine Equipment

Bobtail "B"

Direkt gearbox

A-down angle gear box

Parallel offset gearbox i = 2.5V, shaft angle 12° i = 2.0V, shaft angle 12°

Page GENERAL-10 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

03.02 ���.9

03.02 ���.10

03.02 ���.12

Stern drive

Mercury Bravo II & III

Volvo DP 290

Stern Power Drive

Volvo DP 290 ZF Hydraulic Pump

Volvo SX - Drive King Cobra Drive

Type

Jet Drive

TYPE

Alamarin

Hamilton

Castoldi

Jet drive

03.02 ���.11

Z001019/0_6_July 2008 Page GENERAL-11

THIS PAGE IS INTENTIONALLY BLANK

Page GENERAL-12 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

A 4.1 Technical data and overview 4 cylinder engines

MAKE STEYR M 14 TCM, TCAM

type MO84K32 MO94K33 MO114K33 MO144V38 displacement 2133 cm³ piston displacement 85,0 x 94,0 mm number of cylinders 4-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 1 - 3 - 4 - 2 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 3000 - 3200 3050 - 3800 3200 - 3800 3600 - 3800 idle speed 650 rpm. (adjustable) injection pump - nozzle with modelling needle control and electronic control fuel acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C fuel filter P/No. 2203710/0 fuel filter location intake-sided air filter P/No. 2178992/0 oil pressure above 2000 rpm. 400 - 700 kPa (60 - 100 PSI) microprocessor controlled filling capacity motor oil approx. 8,0 l engine housing (incl. approx. 1 l oil filter contents) specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7, API CF / P/N0. Z010058/0 oil and oil filter change intervals*) every 150 operating hours and/or once per season oil filter P/No. 2178582/1 oil filter location pressure-sided electric charging system 14 V / 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit; thermostat-controlled, pressurized cooling circuit; circulating pump with heat exchanger on engine; governor pump, external raw water circuit to heat exchanger coolant capacity 11,5 liters coolant STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0

*) extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations.

**) Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive

53 / 71 52 / 70

64 / 86 63 / 84

78 / 105 77 / 104

103 / 138 101 / 136

06001

1 5

2 3 6

10 9

06002

06003

1 36

3932 33 37

06004

Z001019/0_6_July 2008 Page GENERAL-13

GENERALSERVICE MANUAL MARINE ENGINES

Overview for all STEYR 4 Cyl. Marine Engines

Item Designation

1 Zinc Anode (4 Units) 2 Model and Serial Number 3 Intercooler 4 Fuel/Oil Cooler with Raw Water Drain Plug 5 Fuel Pump 6 Oil Seperator 7 Raw Water Drain Plug 8 Valve Crankshaft Housing Ventilation

(only SOLAS) 9 Oil Drain Plug 10 Fuel Filter 11 Oil Filter 12 Hydraulic Pump 13 Raw Water Inlet Fitting 14 Raw Water Pump 15 Coolant Drain Plug (2 Units) 16 Engine Oilcooler 17 Oil Suction Pipe 18 Oil Dipstick 19 Hydraulic Oil Tank 20 Cooler Cap 21 Potentiometer Accelerator 22 Motor Oil Filler Cap 23 Boost Pressure Sensor 24 Rack Position Sensor *) 25 Drive Belt 26 Cover T-Belt, Lower 27 Engine Mount 28 Drive Belt Tensioner 29 Vibration Damper 30 Cover T-Belt, Upper 31 Engine Lifting Eye 32 Speed Sensor 33 Valve Cover 34 Heat Exchanger 35 Coolant Expansion Tank 36 Diagnostic Outlet 37 Inversion Switch (only for SOLAS) 38 Connector Instrument Panel 39 Coolant Temperature Sensor 40 Thermostat Housing 41 Alternator 42 Circuit Breakers 43 Engine Management System/Fuses 44 Exhaust Temperature Sensor 45 Air Filter 46 Turbo Charger 47 Exhaust Elbow 48 Starter Relais (Backside E-Box Ground Plate) 49 Starter Motor 50 Flywheel 51 Flywheel Housing 52 Oil Pressure Sensor

*) This sensor is magnetism sensitive. All external magnets must be kept away.

Page GENERAL-14 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

MAKE STEYR M 14 TCAM

type MO144M38 MO164M40 displacement 2133 cm³ piston displacement 85,0 x 94,0 mm number of cylinders 4-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 1 - 3 - 4 - 2 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 3700 - 3900 3800 - 4000 idle speed 650 rpm. (adjustable) injection pump - nozzle with modelling needle control and electronic control fuel acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C fuel filter P/No. 2203710/0 fuel filter location intake-sided air filter P/No. 2178992/0 oil pressure above 2000 rpm. 400 - 700 kPa (60 - 100 PSI) microprocessor controlled filling capacity motor oil approx. 8,0 l engine housing (incl. approx. 1 l oil filter contents) specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7, API CF / P/N0. Z010058/0 oil and oil filter change intervals*) every 150 operating hours and/or once per season oil filter P/No. 2178582/1 oil filter location pressure-sided electric charging system 14 V / 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit; thermostat-controlled, pressurized cooling circuit; circulating pump with heat exchanger on engine; governor pump, external raw water circuit to heat exchanger coolant capacity 11,5 liters coolant STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0

*) extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations.

**) Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive

103 / 138 101 / 136

116 / 156 114 / 154

06001

1 5

2 3 6

10 9

06002

06003

1 36

3932 33 37

06004

Z001019/0_6_July 2008 Page GENERAL-15

GENERALSERVICE MANUAL MARINE ENGINES

Overview for all STEYR 4 Cyl. Marine Engines

Item Designation

1 Zinc Anode (4 Units) 2 Model and Serial Number 3 Intercooler 4 Fuel/Oil Cooler with Raw Water Drain Plug 5 Fuel Pump 6 Oil Seperator 7 Raw Water Drain Plug 8 Valve Crankshaft Housing Ventilation

(only SOLAS) 9 Oil Drain Plug 10 Fuel Filter 11 Oil Filter 12 Hydraulic Pump 13 Raw Water Inlet Fitting 14 Raw Water Pump 15 Coolant Drain Plug (2 Units) 16 Engine Oilcooler 17 Oil Suction Pipe 18 Oil Dipstick 19 Hydraulic Oil Tank 20 Cooler Cap 21 Potentiometer Accelerator 22 Motor Oil Filler Cap 23 Boost Pressure Sensor 24 Rack Position Sensor *) 25 Drive Belt 26 Cover T-Belt, Lower 27 Engine Mount 28 Drive Belt Tensioner 29 Vibration Damper 30 Cover T-Belt, Upper 31 Engine Lifting Eye 32 Speed Sensor 33 Valve Cover 34 Heat Exchanger 35 Coolant Expansion Tank 36 Diagnostic Outlet 37 Inversion Switch (only for SOLAS) 38 Connector Instrument Panel 39 Coolant Temperature Sensor 40 Thermostat Housing 41 Alternator 42 Circuit Breakers 43 Engine Management System/Fuses 44 Exhaust Temperature Sensor 45 Air Filter 46 Turbo Charger 47 Exhaust Elbow 48 Starter Relais (Backside E-Box Ground Plate) 49 Starter Motor 50 Flywheel 51 Flywheel Housing

Page GENERAL-16 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

A 4.2 Technical data and overview 6 cylinder engines

MAKE STEYR M 16 TCM, TCAM

type MO126M28 MO166K28 MO196K35 MO236K42 displacement 3200 cm³ piston displacement 85,0 x 94,0 mm number of cylinders 6-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 1 - 5 - 3 - 6 -2 - 4 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 2600 - 2800 2600 - 2800 3300 - 3500 4000 - 4300 idle speed 630 rpm. (adjustable) injection pump - nozzle with modelling needle control and electronic control fuel acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C fuel filter P/No. 2177745/1 fuel filter location suction-sided air filter MO126 - P/No. 2178992/0; all other 6 Cyl. - P/N 2178992/1 oil pressure above 2000 rpm. 400 - 700 kPa (60 - 100 PSI) microprocessor controlled filling capacity motor oil approx. 10,0 l engine housing (incl. approx. 1 l oil filter contents) specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7, API CF / P/N0. Z010058/0 oil and oil filter change intervals*) every 150 operating hours and/or once per season oil filter P/No. 2178582/1 oil filter location suction-sided electric charging system 14 V / 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit; thermostat-controlled, pressurized cooling circuit; circulating pump with heat exchanger on engine; governor pump, external raw water circuit to heat exchanger coolant capacity 13,2 liters coolant STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0

*) extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations.

**) Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive

87 / 117 86 / 115

116 / 156 115 / 154

136 / 182 134 / 179

165 / 221 162 / 218

06032

1 42 3 6 7 2

121314

06033

19 20 21

06034

2 30 31 32 33 34 35 36 37

06035

47 48 49

Z001019/0_6_July 2008 Page GENERAL-17

GENERALSERVICE MANUAL MARINE ENGINES

Overview STEYR MO126M28, MO166K28, MO196K35, MO236K42

Item Designation

1 Boost Pressure Sensor 2 Zinc Anode (5 Units) 3 Intercooler 4 Fuel- / Hydr. Oil Cooler 5 Engine Oilcooler 6 Model and Serial Number 7 Oil Seperator 8 Raw Water Drain Plug 9 Valve Crankshaft Housing Ventilation

(only SOLAS) 10 Fuel Filter 11 Fuel Pump 12 Oil Filter 13 Raw Water Inlet Fitting 14 Raw Water Pump 15 Coolant Drain Plug (2 Units) 16 Oil Suction Pipe 17 Oil Dipstick 18 Rack Position Sensor *) 19 Engine Lifting Eye 20 Motor Oil Filler Cap 21 Potentiometer Accelerator 22 Drive Belt, Raw Water Pump 23 Engine Mount 24 Drive Belt Tensioner 25 Cover T-Belt, Lower 26 Vibration Damper 27 Drive Belt, Alternator & Hydr: Pump 28 Speed Sensor 29 Cover T-Belt, Upper 30 Valve Cover 31 Heat Exchanger 32 Coolant Expansion Tank 33 Cooler Cap 34 Diagnostic Outlet 35 Inversion Switch (only for SOLAS) 36 Connector Instrument Panel 37 Coolant Temperature Sensor 38 Thermostat Housing 39 Hydraulic Oil Tank 40 Circuit Breakers 41 Alternator 42 Hydraulic Pump 43 Oil Drain Plug 44 Starter Motor 45 Engine Management System/Fuses 46 Exhaust Temperature Sensor 47 Air Filter 48 Turbo Charger 49 Exhaust Elbow 50 Starter Relais (Backside E-Box Ground Plate) 51 Flywheel 52 Flywheel Housing 53 Oil Pressure Sensor

Page GENERAL-18 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

MAKE STEYR M 16 TCAM

type MO256K43 MO256H45 displacement 3200 cm³ piston displacement 85,0 x 94,0 mm number of cylinders 6-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 1 - 5 - 3 - 6 -2 - 4 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 4000 - 4300 4000 - 4500 idle speed 630 rpm. (adjustable) injection pump - nozzle with modelling needle control and electronic control fuel acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C fuel filter P/No. 2178992/1 fuel filter location suction-sided air filter P/No. 2178992/0 P/No.2178992/1 oil pressure above 2000 rpm. 400 - 700 kPa (60 - 100 PSI) microprocessor controlled filling capacity motor oil approx. 10,0 l engine housing (incl. approx. 1 l oil filter contents) specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7, API CF / P/N0. Z010058/0 oil and oil filter change intervals*) every 150 operating hours and/or once per season oil filter P/No. 2178582/1 oil filter location suction-sided electric charging system 14 V / 90 A alternator with transistorized voltage regulator cooling system dual cooling circuit; thermostat-controlled, pressurized cooling circuit; circulating pump with heat exchanger on engine; governor pump, external raw water circuit to heat exchanger coolant capacity 13,2 liters coolant STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0

*) extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations.

**) Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive

178 / 239 176 / 236

178 / 239 176 / 236

06028

1 42 3 5 6 2

111213

06029

18 19 20

06030

2 29 30 31 32 33 34 35 36

06031

46 47 48

Z001019/0_6_July 2008 Page GENERAL-19

GENERALSERVICE MANUAL MARINE ENGINES

Overview STEYR MO256K43, MO256H45

Item Designation

1 Boost Pressure Sensor 2 Zinc Anode (5 Units) 3 Intercooler 4 Engine Oil / Fuel / Hydr. Oil Cooler 5 Model and Serial Number 6 Oil Seperator 7 Raw Water Drain Plug 8 Valve Crankshaft Housing Ventilation (only

SOLAS)

9 Fuel Filter 10 Fuel Pump 11 Oil Filter 12 Raw Water Inlet Fitting 13 Raw Water Pump 14 Coolant Drain Plug (2 Units) 15 Oil Suction Pipe 16 Oil Dipstick 17 Rack Position Sensor *) 18 Engine Lifting Eye 19 Motor Oil Filler Cap 20 Potentiometer Accelerator 21 Drive Belt, Raw Water Pump 22 Engine Mount 23 Drive Belt Tensioner 24 Cover T-Belt, Lower 25 Vibration Damper 26 Drive Belt, Alternator & Hydr: Pump 27 Speed Sensor 28 Cover T-Belt, Upper 29 Valve Cover 30 Heat Exchanger 31 Coolant Expansion Tank 32 Cooler Cap 33 Diagnostic Outlet 34 Inversion Switch (only for SOLAS) 35 Connector Instrument Panel 36 Coolant Temperature Sensor 37 Thermostat Housing 38 Hydraulic Oil Tank 39 Circuit Breakers 40 Alternator 41 Hydraulic Pump 42 Oil Drain Plug 43 Starter Motor 44 Engine Management System/Fuses 45 Exhaust Temperature Sensor 46 Air Filter 47 Turbo Charger 48 Exhaust Elbow 49 Starter Relais (Backside E-Box Ground Plate) 50 Flywheel 51 Flywheel Housing

Page GENERAL-20 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

B Specifications

B 1 Fuel Requirements The STEYR Marine Engines are designed for maximum fuel economy. To maintain optimum performance use diesel fuel according to CEC RF-03-A-84 or equivalent to meet this specification. When temperatures are below -7° C (20° F), use diesel fuels with additives for low temperature operation.

How to Select Fuel Oil Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. Direct injected diesel engines are designed to operate on most diesel fuels marketed today. In general, fuels meeting the properties of CEC RF-03-A-84 have provided satisfactory performance.

The ASTM D 975 specification, however, does not in itself adequately define the fuel characteristics needed for assurance of fuel quality. The properties listed in the following fuel oil selection chart have provided optimum engine performance.

Fuel Oil Selection Chart

ASTM -

Test procedure

D 613 (D 976)

D 1298

D86

D 93

EN 116 (CEN)

D 445

D 1266/D 2622 D 2785

D 130

D 189

D 482

D 95/D 1744

D 974

D 2274

General Fuel classification

Cetane number

Gravity at 15°C (kg/l)

Destillation 50% 90%

End point

Flash point

CFPP (Cloud point)

Viscosity Kinematic 40°C

Sulfur content

Cupper corrosion

Carbon residue Conradson number (10% residue)

Ash

Water content

Acid content (strong acid)

Oxidation stability

CEC RF-03-A-84

Limit value and units min. 49 - max. 53 min. 0,835 max. 0845 min. 245°C min. 320°C max. 340°C max. 370°C min. 55°C min. -- / max. -5°c min. 2,5 mm²/s max. 3,5 mm²/s 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/100ml

CEC RF-03-A-80

Limit value and units min. 51 - max. 57 min. 0,835 max. 0845 min. 245°C min. 320°C max. 340°C max. 370°C min. 55°C max. -5°c min. 2,5 mm²/s max. 3,5 mm²/s max. 0,50 mass-% max. 1 max. 0,2 mass-% max. 0,01 mass-% max. 0,05 mass-% max. 0,20 mg KOH/g max.2,5 mg/100ml

Z001019/0_6_July 2008 Page GENERAL-21

B 2 Motor oil

To obtain the best engine performance and engine life, only motor oils of know manufacturers are to be used, with ACEA, API service code and specified SAE viscosity. Refer to oil identification symbol on the container.

Initial filling quantity: 4 Cyl. engines 8,4 Litre (Oil filling, incl. 1l oil filter) 6 Cyl engines 10,4 Litre (Oil filling, incl. 1l oil filter)

Oil quantity between MIN. and MAX.

on dipstick 2,0 Litre Oil change quantity: 4 Cyl. engines 7,0 Liter (without oil filter)

6 Cyl. engines 9,0 Liter (without oil filter) Öil filter: ca. 1 Litre Oil - specification, Minimum: API: CF or higher

ACEA: B4 - 02 or higher

Viscosity class: SYNTHETIC OIL 5W-50

SYNTHETIC OIL 10W-40

Recommended engine oil: STEYR TURBO DIESEL ENGINE OIL - SAE 10W-40

SMO No. Z010058/0

Initial factory fill is a high quality break-in oil specified ACEA B4 - 02, SAE 5W-50. During the break in period (20 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained between the minimum and maximum marks on the dipstick. The space between the marks represents approximately 2 quarts (2 litres). For oil dipstick location, refer to section Technical Data and Overview (A 4)

Refer to Service and Maintenance Chart (C 2) for recommended oil change intervals.

Oil Identification Symbol

Motor oils are specified by ACEA, API service code and SAE viscosity numbers.

These may be found on the label, top of can, or oil identification symbol.

NOTE: Some motor oils have several ACEA / API quality ratings.

The recommended ACEA /API service letter code must be among these quality ratings.

ill.1 Top of Can ill.2 Oil Identification Symbol

02.02 ill.2

SAE

5 W-50 10 W-40

API

SERVICE CODE

CF

ACEA E7 or B4 - 02

FOR HEAVY DUTY

DIESEL ENGINES

ACEA E7 or B4-02

API CF

Page GENERAL-22 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

C Maintenance and Service

ATTENTION:

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 vapours.

Failure to do so could result in fire.

SYMPTOM POSSIBLE CAUSE ACTION

Engine won’t start 1. No fuel in tank or shut-off valve Fill tank or open valve.

closed.

2. Air leak in suction lines. Bleed fuel system and check for leaks.

3. Fuel line plugged or pump Fuel pump may be defective.

defective.

4. Poor fuel quality. Replace fuel .

5. Water in fuel filter. 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.

6. System error or failure. Check Engine Management System display for service code.

7. Battery output insufficient Charge or replace battery.

Only for SOLAS ==> 8. Inversion switch actuated Cancelled by ignition "OFF - ON"

Starter won’t crank 1. Battery connections loose or Check for loose connections engine corroded and corrosions. Clean connections and thighten.

2. Battery is dead Check level of electrolyte and charge battery.

3. Starter connections loose Check connections and tighten.

If solenoid clicks when attempting to start engine, check starter.

4. Ignition switch If inoperative, replace.

6. Starter auxiliary relay Check terminal connection and function of relay.

Engine runs erratically 1. Water, air and/or dirt in fuel filter Replace filter. Inspect fuel supply line.

2. Anti-siphon valve stuck Clean and inspect or replace. (Tank)

3. Fuel pump Check operation of pump.

Replace fuel pump.

C 1 Trouble Check Chart

5. Fuse blown on panel Check and replace if defect

Z001019/0_6_July 2008 Page GENERAL-23

Trouble Check Chart - continued

SYMPTOM POSSIBLE CAUSE ACTION

Engine vibrates Propeller condition Check for bent, broken, or damaged propeller Check for weeds on propeller or sterndrive gearcase. Check for bent propeller shaft.

Unit injector Check.

Engine runs but boat Fouled propeller etc. Check:

makes little or no 1. Propeller for weeds, remove progress as required.

2. Propeller for spun hub, repair or replace.

3. Hull for excessive marine growth, clean as required.

Performance loss 1. System error or failure. Check Engine Management System display for service code. Engine coolant temperature; audible alarm.

2. Boat overloaded Reduce load.

3. Boat trim Distribute boat load evenly. Adjust trim.

4. Excessive water in bilge Drain bilge.

5. Boat hull condition Cleaning

6. Improper propeller selection Select proper propeller pitch and diameter.

7. Fuel incorrect Fill tank with correct fuel.

Check fuel filter and fuel flow condition.

8. Throttle not fully open Check throttle command lever for full travel.

9. Overheating Check cooling system. Remove debris from water intake. Check belt tension.

Check condition of impeller.

Check for clogged heat exchanger tubing (in raw water circuit).

10. Air intake troubles Check intake air filter.

Check ventilation of engine compartment.

Excessive free play in Steering cable loose Adjust or replace.

steering wheel

High shift effort 1. Remote control or transom Replace and adjust.

bracket shift cable

2. Remote control binding Adjust.

3. Engine / drive mechanism sticks Center.

Page GENERAL-24 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

ENGINE check - for leakage LUBRICATION - oil level change - oil filter

- motor oil

ENGINE check - for leakage COOLING - fluid level SYSTEM - hoses, hose clamps

- antifreeze temperature condition change - antifreeze*) every 24 month

RAW WATER check - hoses, hose clamps SYSTEM - zinc anodes

- raw water pump V-belt

- impeller change - raw water pump V-belt*) if required

- impeller*) if required

- zinc anodes*) if corroded > 50% preserve - raw water circuit*) after season

RAW WATER check - raw water passages*) clean out desposits

COOLER

(OIL-FUEL- in pipelines

AUX.LUBRICANT)

for 246 / 256 change - zinc anodes*) required if more and 266 only than 50% material corroded

AIR check - contamination FILTER change - air filter element preserve after season

FUEL check - for leakage SYSTEM - hoses drain - addtiional fuel filter change - fuel filter check - additional fuel filter preserve - fuel system*) after season

BATTERY check - acid level

- densitiy

ELECTRONICS check - connections*) after season

ELECTRICAL check - connections tighten loose con- EQUIPMENT - insulation nections. Renew cables, if required.

INVERSION check - switch*) every 50 hours SWITCH (Solas only) or every 6 months

DRIVING re-center - driving unit*) see manufacturer's SYSTEM specifications

V-BELT check - generator & impeller pump adjust tension

- power-steering adjust tension for all 6 cyl. change - generator*) if required models - power-steering*) if required

POLY - V - check - belt, pulleys and tighteners BELT for wear change - Poly -V-belt every 1050 hours or for all 4 cyl. every 48 months models after first 50 hours or 6 months

*) notesdaily every 150 h.

or 12 months every 300 h.

or 24 months

C2 Service- and Maintenance Schedule

Z001019/0_6_July 2008 Page GENERAL-25

TIMING check - belt tension BELT change - timing belt*) every 1500 h. or every 48 months

- water pump, tensioner every 3000 h. or every 48 months

VALVES check - valve clearance*) every 750 hours

ENGINE TIMING check - set timing every 750 hours

UNIT INJECTOR - set levers*) every 750 hours check - set point every 750 hours

- tighten torque every 750 hours

SERVO check - oil level PUMP - for leakage change - hydraulic oil (ATF) *) every 750 h. or every 24 months after first 50 hours or 6 months

*) notesdaily every 150 h.

or 12 months every 300 h.

or 24 months

Service- and Maintenance Schedule

GEARBOX- check - oil level STERNDRIVE - for leakage change - gear oil (ATF) *) see manufacturer's

- oil filter specifications

FRONT VIBRA- check - torque

TION DAMPER

ENGINE COM- check for - leakage -water repair or consult PARTMENT AND -fuel your STEYR

BILGE -exhaust gas Marine dealer

SHIFTING check - smooth action If required, to be

- adjustment replaced by your

STEYR Marine Dealer.

STEERING check - lubrication see manufacturer´s

- oil level specification

SAFETY check - remote control local rules EQUIPMENT - emergency cutout and consultation

- completeness of your STEYR

- condition Marine Dealer

SHAFT BEARING check - lubrication consult STEYR GLAND - sealing Marine Dealer

ENGINE MOUNT check - torque*) every 750 hours

SCREWS

WARNING check - function

DEVICE

POLY - V - BELT check TENSION lubricate

GLOW PLUGS change - plugs*) every 1500 h. or every 48 months

Page GENERAL-26 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

D General Information

D 1 Electronic Engine Management System

The STEYR Marine engine is equipped with an Electronic Management System (EMS) that performs the following:

* controls engine functions to ensure maximum efficiency.

* self-diagnostic to protect the engine from damage if operating parameter are exceeded.

* stores diagnostic data of EMS server circuits for maintenance and service.

* stores abuse data

Engine power is reduced if:

Operating Parameter

High engine coolant temperature limit exceeded

Defect - engine coolant sensor or sensor connection

Exhaust temperature limit exceeded

Defect - Exhaust temperature sensor or sensor connection

Oil pressure below limit

Defect - Oil pressure sensor or sensor connection

Insufficient boost pressure or defective sensor

Additional Tool-Readings

Steyr Diag Power limitation

Steyr Diag Service code

Steyr Diag Power limitation

Steyr Diag Service code

Steyr Diag Power limitation

Steyr Diag Service code

Steyr Diag Power limitation

Panel Indication

Horn ON 2x p. sec.

Gauge reading > 107 °C

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.

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

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

Steyr Diag Service code

Steyr Diag Service code

Steyr Diag Service code

No RPM indication on tachometer

Higher or unstable idle speed, limited performance

No increase of engine speed if throttle is moved to max.

Irregular engine speed or stalled engine

See table trouble shooting:

Speed sensor

See table trouble shooting:

Accelerator potentiometer failure

See table trouble shooting:

Governing system

Engine speed sensor fault

Engine speed remains at idle

Governor position system

Z001019/0_6_July 2008 Page GENERAL-27

Operating Parameter

Inverse position shut down (SOLAS)

During break in phase

Additional Tool-Readings

Steyr Diag Break-in phase

Panel Indication

After engine stop horn remains switched ON until ignition reset

Indication light "CEL" is switched

ON

Effect noticed

Engine shut down beyond 70° deg. angle

Cel-ON at high accelerator position (more than 75%)

Action or possible reason

Reset through ignition OFF and then ON

See information break in procedure

D 2 Diagnostic system

The electronic management system monitors the following engine parameters:

oil pressure, boost pressure, coolant temperature, exhaust pipe temperature (Hi-riser), sensor control rack, potentiometer accelerator, speed signal

The electronic management system carries 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 71)

Existing active failures remain stored until the problem has been solved and the code has been cleared from the memory.

To select stored error codes, a PC with diagnostic program (VR00134/0) or diagnostic tool (VR00135/1) is necessary.

Malfunction during operation is ranked in three different categories intermittent failure, non essential failure and essential failure.

Optical and accustical warning signals are explained on the following tables.

"Operating Status and Error Report"

Page GENERAL-28 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

D 3 Extended Storage Preservation Procedure

1 Remove the engine from storage and place on a suitable work shop floor with access to all side of the engine. Do not remove from the original packing pallet.

2 Start the engine and let it run up to temperature.

3 Stop the engine and drain the old engine oil and store for future refill and usage.

4 Fill in preservation oil Shell Ensis Engine Oil 30 (part number Z050323/0-5 litres) up to the minimum mark on the dip stick.

5 Connect the fuel system to a tank or canister filled with Shell oil V1404 (part number Z010014/0 - 5 litres). See ill. 1

6 Restart the engine and allow to run in idle for 5 minutes.

7 Disconnect the fuel feed line from the engine and turn the ignition on, the fuel pump runs for 10 sec automatically emptying the fuel system. Repeat until no more fuel comes from the return line.

8 Either drain the preservation oil from the engine and replace with normal oil (as per Service Bulletin AS_7004) and store for future use. Alternatively leave it in the engine for future preservation work.

The preservation oil has a shelf life of also 3 years and may be used any number of times within this period. It is important to note that an engine may never be sold on or installed with this oil in as this will lead to severe engine damage if run for extended periods

9 Remove the main relay K27; this will stop fuel being injected and therefore the engine from starting.

See ill. 2 ill.1 ill.2

Z001019/0_6_July 2008 Page GENERAL-29

10 Remove the air filter, plug the exhaust elbow and remove the inlet pipe to the tandem/triple cooler, see photo. See ill. 3 and ill. 4

11 Fill a spray bottle with the preservation oil Shell Ensis Engine Oil 30 part number Z050323/0.

12 Whilst cranking the engine over, by turning the start key, spray the preservation oil into the turbo inlet.

See ill. 5

13 Continue this process for 20 to 30 seconds.

14 Refit the fuel feed line to the engine and turn the ignition on, the fuel pump runs for 10 sec automatically refilling the fuel system. Repeat until fuel comes from the return line.

15 Replace all pipes and connections to original condition and re-store engine.

16 The engine is now preserved for one more year.

This preservation procedure must be done every year and ensures that all of the air ways systems, raw water systems, oil system and the cylinders are protected against corrosion. This procedure is repeatable up to a maximum of three times, giving a shelf life of up to four years.

NOTE: When commissioning or running an engine that has been preserved as stated above the engine will run roughly and smoke for the first few minutes. Do not be alarmed as this is normal until the deposits of the preservation materials have cleared.

ill. 5 ill.4 ill.3

Page GENERAL-30 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

D 4 Engine Break-In procedure

The following procedure must be used on new and rebuilt STEYR Diesel Engines. You must follow the Engine Break-In instructions during the first 20 running hours to ensure maximum performance and longest engine life.

NOTE: NONOBSERVANCE OF BREAK-IN INSTRUCTIONS MAY CAUSE SEVERE ENGINE FAILURE.

First Two Hours

For the first five to ten minutes of operation, run engine at a fast idle (below 1500 RPM). For the remaining first two hours of operation, accelerate to bring boat onto plane quickly and bring throttle back to maintain a planing attitude.

During this period, vary the engine speed frequently by accelerating to approximately three-fourth throttle for two to three minutes, then back to minimum planing speed.

When the engine has reached operating temperature, reduce engine speed, then increase engine speed again, to assist the break-in of rings and bearings. Maintain planing attitude to avoid excessive engine load.

NOTE: DO NOT RUN ENGINE AT A CONSTANT RPM FOR LONGER PERIODS

DURING THIS INITIAL TWO HOURS OF BREAK-IN.

ATTENTION: Warning indication engine over load during break - in via ECU The ECU controls during the first two hours of engine operation the load on the engine and alarms the drive by the "Check Engine Light", if much power is demanded from the new engine.

In case the operator get alert, when running the engine during break in phase, by this "Break - In" warning indication (CEL light - ON), the throttle position must be reduced until this signals are extinguish.

Next Eight Hours

For the next eight hours, continue to run engine at approximately three-fourth throttle or less (minimum planing speed).

Occasionally reduce throttle to idle speed for cooling down. During this eight hours of running it is permissible to run at full throttle for periods of less than two minutes.

NOTE: DURING BREAK-IN, DO NOT RUN ENGINE AT A CONSTANT RPM

FOR LONGER PERIODS.

ON

Z001019/0_6_July 2008 Page GENERAL-31

Final Ten Hours of Break-in

During the final ten hours of break-in, the engine may run at full speed for five to ten minutes. After warming up the engine to operating temperature, momentarily reduce the engine speed and then increase it again. For cooling down the engine, occasionally reduce the engine speed.

NOTE: DURING THE BREAK-IN PERIOD, THE ENGINE MUST NOT BE OPERATED AT CONSTANT

RPM FOR LONGER PERIODS.

During break-in period, be particularly observant of the following:

A. Check motor oil level daily. Always maintain oil level in the desired range between the "MIN" and "MAX" marks on dipstick.

When refilling motor oil, refer to information "Motor Oil" (B 2).

B. Check oil pressure control lamp. If the lamp lights up as soon as the boat changes its position (while turning, raising the boat or planing), check the oil level in the engine housing by means of dipstick. If necessary, add oil (DO NOT OVERFILL). In case that the oil pressure control lamp still illuminated with correct oil level, have the engine checked by your STEYR Marine dealer as to malfunction of signal or oil pump.

NOTE: During normal operation of engine, oil pressure will rise as RPM increases and fall as RPM decreases. In general, oil pressure will be higher with cold motor oil and specific RPM than with hot motor oil.

C. Check engine temperature indication. Normal operation between 80° - 95°. In case of audible alarm, check coolant level in expansion tank (only at cold engine).

D. Deviations from normal operating conditions will be indicated by warning lights and audible alarm. As to exact meanings see 06.07.02 & 06.07.05.

ATTENTION: In case of nonobservance of break-in instructions, warranty will expire.

Engine to be filled with recommended oil quality only. See chapter "Engine Lubrication"

Page GENERAL-32 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

D 5 Operation after Break - In

The engines specified in this manual are intended to be operated at different speeds and loads, but not allowing full load of the engine for more than one hour per 12 running hours. Economic driving may be achieved at the following speeds:

3000 rpm.

3000 rpm.

3000 rpm.

3200 rpm.

3200 rpm

3400 rmp

2200 rpm

2200 rpm

3300 rpm

3600 rpm

3600 rpm which will prolong engine life and reduce sound emissions.

When starting a cold engine, always allow the engine to warm up slowly. Never run the engine at full speed until operating temperature is reached. During the first 50 running hours, check the oil level frequently.

M084K32

M094K33

M0114K33

M0144M38 + BUKH STEYR SOLAS

M0144V38 + BUKH STEYR SOLAS

M0164M40 + BUKH STEYR SOLAS

M0126M28

M0166K28

M0236K42 + BUKH STEYR SOLAS

MO256K43

MO256H45

Z001019/0_6_July 2008 Page GENERAL-33

Page GENERAL-34 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

E QUALITY GUIDELINES FOR REPAIR

E 1 Spart part specification

Your STEYR marine engine was designed for marine operation which means operating conditions such as:

* Long-time operation at high speed

* Operation in salt or brackish water

* Operation in very muddy water

Only use genuine STEYR MARINE spare parts in order to avoid possible loss of performance. For this reason you should insist on the famous quality of genuine STEYR MARINE spare parts and under no circumstances use spare parts of unknown quality.

E 2 Workshop profile

Independently of the respective repair steps and the legal regulations the workshops have to meet the following requirements:

- Clean, dry, and dustfree environment

- Lifting gear (crane) with a lifting capacity of 5 000 N (500 kg) minimum

- Cleaning device (wash basin) for soiled components

- Commercial tools

- Appropriate test and measuring equipment

- Receptacles for operating agents.

Depending on the repair step to be carried out, the tools indicated in the catalog TOOL KIT are to be provided.

Furthermore special care is to be taken in case of purchasing and stock of required operating material, spare parts and wear parts (e.g. seals, filters, anodes,...).

For appointed retailers and authorized workshops of STEYR MOTORS GmbH, the following minimum standard is to be met:

- basic training (as soon as possible, after conclusion of contract, for trade and workshop)

- biannual training (reacurring)

- tool kit I (service and maintenance tools)

- tool kit II - III (depending on repair to be carried out)

- procurement and stock of required genuine spare parts (as per proposed spare parts)

- spare part catalogue for all STEYR MARINE ENGINES models

- technical literature

- PC diagnostics

Z001019/0_6_July 2008 Page GENERAL-35

E 3 Nomenclature

Term Description Example disassemble Removal of an assembly of a main assembly or of a component remove of an assembly without other assemblies having been removed unscrew before deflange dismantle assemble put on, place Putting on of an assembly on a main assembly or a component screw on of an assembly without further assemblies being put on flange for functional performance mount disconnect Separating of connections of lines, pipes and hoses, which are separable connect Putting together separable connections of lines, pipes and hoses pull off Removal of a component with press fit from another press on Placement of a component with press fit to another unscrew Opening of turnable locks tighten Closing of turnable locks disassemble Removal of an assembly from a main assembly or a component from an assembly, if other assemblies have been removed before assemble Putting on an assembly to a main assembly or a component of an assembly, if further assemblies are put on for functional achievement loosen Partial unlocking of fixing elements of a component or of an assembly remove Taking off a fixing element of a component or an assembly secure Putting on a fixing element of a component or an assembly and tightening disassemble Taking apart assemblies into individual components assemble Putting together components to an assembly adjust Elimination of a deviation by means of provided equipment or Valve clearance, start of feeding readjust Devices or tools operation refill Adding and replenishing of operating agents renew Replacing an auxiliary material by a new one Corrosion protection agent, sealing material, paint gauge Reading in actual positions in programming memory replace Exchanging of a device, a main assembly, an assembly or a component by the same, new or repaired ones measure Steps taken to determine the actual status by evaluating of physical entities check Steps taken to compare the actual status with a determined Valve lift, piston diameter, valve clearance, close fit, V-belt tension clean Removal of foreign and auxiliary material maintain Steps taken to keep the respective determined planned status

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SERVICE MANUAL MARINE ENGINES

E 4 SI- System

The following measuring units are used.

Linear Pressure and Stress km = kilometer bar = bar m = meter Pa = pascal mm = millimeter KPa = Kilopascal " = inch N/mm2 = newton per square millimeter

Area Energy m2 = square meter J = Joule cm2 = square centimeter kW/h = kilowatt hour

Volume Power m3 = cubic meter kW = kilowatt cm3 = cubic centimeter dm3 = cubic decimeter mm3 = cubic millimeter l = litre

Mass Temperature t = metric ton K = degrees Kelvin kg = kilogram ° C = degrees Celsius g = gram

Energy Time

N = newton h = hour kN = kilonewton min = minute daN = dekanewton s = second

Electricity Velocity

A = ampere km/h = kilometer per hour V = volt m/s = meter per second W = ohm µF = microfarad

Fuel consumption Speed g/kWh = gram per kilowatt hour 1/min = r.p.m.

Z001019/0_6_July 2008 Page GENERAL-37

E 5 Abbreviations ill. illustration

Cu copper

MAssy main assembly max. maximum

TDC top dead center

PTO (POWER TAKE OFF) power transmission at front crankshaft end

WS wrench size

EMS Electronic Management System

ECU Electronic Control Unit

Page GENERAL-38 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

F OPERATING MATERIAL AND INFORMATION ON

DISPOSAL

F 1 List of operating material

Designation set of fuel and oil for engine service, consisting of:

- STEYR Turbo Diesel motor oil SAE 5W-50 (4l. can.)

- STEYR MOTORS engine coolant (5l. can.)

- hydraulic oil ATF (1l. bottle)

- grease, Never - Seez; NS-160 B (1 kg can.)

- caoutchouc sealing / electric contacts (148 ml can.)

- thread protection 243 (10 ml flask)

- surface sealing 509 (315 ml cartridge)

- surface sealing 5910 (50 ml cartridge)

- construction adhesive 620 (50 ml flask)

- construction adhesive 262 (50 ml flask)

- contact grease (100 ml tube)

- corrosion protection spray (400 ml can.)

- corrosion protection wax (120 ml can.)

- grease STABURAX NBU4 (1 kg can.)

- fuel rust protection additive (5 lt can.)

- electric contact spray

- silver varnish, RAL 9006 (1 lt can)

- hardener varnish (0,5 lt can)

- dilution for varnish (5 lt can)

Qty.

Order No.

VR00207/0

Z010058/0

Z011785/0

9000190/0

Z012222/0

Z909570/0

9000059/1

9000297/1

9000510/5

9000019/1

9000017/1

Z010207/0

Z010226/0

Z010227/0

Z010084/0

Z010205/0

9000197/0

Z011627/0

Z010074/0

Z010075/0

Z001019/0_6_July 2008 Page GENERAL-39

F 2 Disposal of automotive waste products

Used operating material is to be collected in special containers to enable possible subsequent treatment.

ATTENTION: All operating materials for the engine are subject to the Special Waste Act for disposal.

The "Special Waste Catalog" ÖNORM S 2100 refers to the required disposal in Austria.

Respective legal local regulations are to be followed.

The maintenance and repair personnel has to take care that operating material and other material to be regarded as special waste product, is always deposited at collection site.

Key-No.: Description

31 423 Oil contaminated soil or oil bonding agent

54 102 Waste oil

54 104 Fuels

54 202 Lubricants

54 207 Vaseline

54 917 Solid sealing material

54 927 Oil soiled cleaning rags

54 928 Used oil and air filters

55 510 Paint and varnish containing waste material

Page GENERAL-40 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES

G NOTES ON SAFETY

G 1 General notes on safety

The general knowledge and training of the personnel and the contents of the "general regulations of safety technology" and machine safety regulations (Maschinen-Sicherheitsverordnung - MSV) are not subject of this chapter.

Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons.

In the description of repair works, such sources of danger are marked with

ATTENTION

The personnel is to be trained accordingly and requested to follow the saftey rules.

G 2 Guidelines for damage prevention

The general knowledge and training of the workshop personnel and the contents of the "general regulations of safety technology" and machine safety regulations (Maschinen-Sicherheitsverordnung

- MSV) are not subject of this chapter.

Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons.

In the description of repair works, such sources of danger are marked with

ATTENTION

While handling with operating materials, take care that these are not applied to visible surfaces.

Lubricants should form a thin film on the surface, surplus lubricants are to be wiped off.

G 3 Legal rules

The following rules and guidelines are valid in Austria. For other countries, follow the local regulations.

Maschinen - Sicherheitsverordnung - MSV (machine safety regulations)

Z001019/0_6_July 2008 Page GENERAL-41

G 4 Safety in the use of operating material

Dangerous operating material, in the sense of accident prevention, are all operating materials potentially explosive, fire-provoking, easily flammable, poisonous, injurious to health and corrosive.

Especially the following material belong to this group:

- Spirit

- Mineral oils

- Battery acid

- Anti-freeze agent

- Varnishes and diluents

- Solvents

- Fluid seals and nut locks

In case of fire of operating material do not try to extinguish the fire with water. Use carbon dioxide extinguisher or powder extinguisher. Contact fire brigade.

When operating material is spilled, e.g. in case of refueling, it is to be absorbed by sand, soil or an appropriate bonding agent and to be disposed.

ATTENTION: In order to prevent health hazards, take care of the following:

- Avoid direct contact with dangerous operating material, as far as possible.

- Change clothes as quickly as possible, if they are soiled with dangerous operating material.

- Do not keep oily rags in work clothes.

- Clean oil soiled body parts only with products friendly to skin (never use rubbing sand or solvents).

- Never fill operating agents in beverage bottles.

G 5 Measures in case of accidents

Products First Aid

Skin Eyes Swallowing

Diesel fuel DO NOT VOMIT and mineral oils Remove clothes and Rinse thoroughly with The biggest danger after an accidental intake is the fact that Lubricants clean skin thoroughly water for at least liquid could get into lungs by aspiration.

Anti-freeze agents with water and soap 10 minutes.

DO NOT PROVOKE VOMITING

Brake fluid SEE A AND IIMMEDIATELY SEE A

DOCTOR

Battery acid DOCTOR!

Page GENERAL-42 Z001019/0_6_July 2008

SERV…