Steyr Motor Marine Engines SE SERIES 4 Cylinders plus 6 Cylinders Operation Maintenance and Warranty Manual P_N 707245 1st Edition February 2021.pdf

Operation Manual

MARINE SE

4 Cylinder / 6 Cylinder

Edition Order number Language Date

707245

EN

February 2021

Preface

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PREFACE

Steyr Motors develops high-performance diesel engines with modulated high pressure direct injection, especially for marine applications. Steyr Motors engines are designed to be adapted to various propulsion systems.

This OPERATION MANUAL provides technical data and know-how based on our experi-ence in the diesel engine business. This manual intends to assist you in operating and maintaining the operational safety and reliability of the following engines:

MARINE SE

4 Cylinder 6 Cylinder

SE144E38 SE126E32 SE236E40 SE266S36

SE164E40 SE156E34 SE236S36 SE286E40

SE186E38 SE266E40 SE306J38

To achieve continuous improvement with regard to the format and content of the informa-tion provided, we would like to hear from you.

We, therefore, would much appreciate your comments to the following questions:

- What mistakes have you noticed?

- What information was not in the manual?

- Suggestions for improvement in general?

Please address your comment to:

from home country from foreign countries

ADR Steyr Motors Betriebs GmbH Customer Service TEL 07252/222/52 +43/7252/222/52

Im Stadtgut B1

4407 STEYR, AUSTRIA

technical@steyr-motors.com http://www.steyr-motors.com mailto:technical%40steyr-motors.com?subject= http://www.steyr-motors.com

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Welcome aboard

Fig. 1.

Congratulations on your decision of choosing a Steyr Motors marine engine for your boat, and we hope you will enjoy it.

Steyr Motors develops high-speed diesel engines with two stage high-pressure fuel injec-tion specifically for the marine environment. Steyr Motors marine engines are designed to be adapted to various propulsion systems.

To meet your expectations, please thoroughly study this manual for your new Steyr Mo-tors marine engine to obtain information on its operation and handling in order to optimize the use of the various built-in functions.

With kind regards, Steyr Motors Betriebs GmbH

Your Steyr Motors marine dealer

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TABLE OF CONTENTS

SAFETY

GENERAL

01 OPERATION

02 MAINTENANCE

03 DEALERS ACTIVITIES

04 TRANSPORT AND STORAGE

WARRANTY

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VERSIONS OF MANUAL

Version Date Modification

1.0 02.2021 new edition

Table of Contents

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Table of Contents

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1 Operation

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Safety

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S Safety

This manual contains certain information related to the personal safety of you as the op-erator, your passengers, bystanders and other persons.

Steyr Motors Betriebs GmbH is concerned about your safety and the condition of your engine. The safety instructions will alert you to potential hazards associated with installing Steyr Motors engines.

This chapter provides an overview of all important safety aspects for optimal protection of personnel as well as safe and trouble-free operation. Inappropriate behaviour and insuffi-cient knowledge of hazards during works may cause personal injury.

Non-observance of these safety instructions and safety regulations can result in consider-able danger. In the description of works, such sources of danger are marked with one of the three following symbols:

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury!

Possible consequences by non-observance.

► How to avoid injuries.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury!

Possible consequences by non-observance.

► How to avoid injuries.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury!

Possible consequences by non-observance.

► How to avoid injuries.

Property damage to the engine

NOTICE

NOTICE indicates a potentially hazardous situa-tion, if not avoided, could result in damage to the engine.

► How to avoid damages.

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S 1 Safety precautions

S 1.1 Introduction

This operation manual contains the information you will need to operate the engine cor-rectly. Check that you have the correct operation manual for your engine.

Read the book carefully before operating or servicing the engine. Incorrect operation or servicing of the engine could result in personal injury or material damage as well as dam-age to the engine itself. If you do not understand or are uncertain of any operation in this book, contact your dealer who can explain or demonstrate the procedure for you.

Before starting work on the engine, read the “Safety precautions” of this manual carefully.

Immobilize the engine by turning off the power supply to the engine at the main switch (switches/breakers) and lock it (them) in the OFF position before starting work. Set up a warning notice at the engine control point or helm.

As a general rule all service operations must be carried out with the engine stopped. However, certain adjustments require that the engine is running when they are carried out.

Approaching an engine which is operating is a safety risk. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If working in proximity of an engine which is operating, careless movements or a dropped tool can result in personal injury.

Take care to avoid contact with hot surfaces (exhaust pipes, turbocharger, air intake pipe, start element etc.) and hot liquids in lines and hoses on an engine which is running or which has just been stopped. Reinstall all protective parts removed during service operations before starting the engine.

Check that the warning or information labels on the engine are always clearly vis-ible. Replace labels which have been damaged or painted over.

Engines with turbocharger: Never start the engine without installing the air clean-er filter. The rotating compressor in the turbo can cause serious personal injury.

Foreign objects entering the intake ducts can also cause mechanical damage.

Never use start spray products or similar when starting the engine. They may cause an explosion in the inlet manifold. Danger of personal injury.

Avoid opening the filler cap for engine coolant system (freshwater cooled en-gines) when the engine is still hot. Steam or hot coolant can spray out. Open the filler cap slowly and release the pressure in the system. Take great care if a cock, plug or engine coolant line must be removed from a hot engine. Steam or hot coolant can spray out in any direction.

Hot oil can cause burns. Avoid getting hot oil on the skin. Ensure that the lubrica-tion system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected.

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Stop the engine and close the sea cock before carrying out operations on the engine cooling system.

Only start the engine in a well-ventilated area. If operating the engine in an enclosed area ensure that there is exhaust ventilation leading out of the engine compartment or workshop area to remove exhaust gases and crankcase ventila-tion emissions.

Always use protective glasses or goggles when carrying out work where there is a risk of splinters, grinding sparks, acid splashes or where other chemicals are used. The eyes are extremely sensitive, an injury could result in blindness!

Avoid getting oil on the skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry. Irritation, dryness and eczema and other skin problems can then occur. Used oil is more dangerous than fresh oil from a health aspect. Use protective gloves and avoid oil soaked clothes and shop rags. Wash regularly, especially before eating. There are special skin creams which counteract drying out of the skin and make it easier to clean off dirt after work is completed.

Many chemicals used on the product (for example engine and transmission oils, glycol, gasoline and diesel oil), or chemicals used in the workshop (for example degreasing agents, paint and solvents) are dangerous to health. Read the in-structions on the product packaging carefully! Always follow the safety precau-tions for the product (for example use of protective mask, glasses, gloves etc.).

Make sure that other personnel are not exposed to hazardous chemicals (for chemicals released in the air). Ensure good ventilation in the work place. Follow the instructions provided when disposing of used or leftover chemicals.

Exercise extreme care when leak detecting on the fuel system and testing the fuel injector jets. Use eye protection. The jet from a fuel injector nozzle is under extremely high pressure and has great penetrative energy, so the fuel can pen-etrate deep into the body tissue and cause serious personal injury. Danger of blood poisoning.

All fuels and many chemical substances are flammable. Do not allow naked flame or sparks in the vicinity. Fuel, certain thinner products and hydrogen from batteries can be extremely flammable and explosive when mixed with air.

Smoking is not to be permitted in the vicinity!

Ensure that the work area is well ventilated and take the necessary safety pre-cautions before starting welding or grinding work. Always ensure that there are fire extinguishers at hand when work is being carried out.

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Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely.

Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, solvent, degreasing agents and waste from washing parts.

Never expose a battery to naked flame or electrical sparks. Never smoke in prox-imity to the batteries. The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas -oxyhydrogen. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a single spark which is sufficient to cause an explosion with resulting damage. Do not shift the connections when attempting to start the engine (spark risk) and do not lean over any of the batteries.

Always ensure that the Plus [+ (positive)] and Minus [− (negative)] battery leads are correctly installed on the corresponding terminal posts on the batteries. Incor-rect installation can result in serious damage to the electrical equipment. Refer to the wiring diagrams.

Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulphuric acid which is highly corrosive. Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, immedi-ately flush with plenty of water and obtain medical assistance at once.

Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system.

Clutch adjustments must be carried out with the engine stopped.

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S 2 Customer’s responsibility

The engine is only to be used in the commercial field of usage. The owner of the engine is subject to the legal obligations for health and safety at work. In addition the operational safety instructions in this manual, the applicable safety, accident prevention and environ-mental regulations for the application must also be complied with. The following particularly apply:

● The owner must be informed about the applicable health and safety conditions and de-termine determine hazards arising from the special operating conditions at the usage location of the engine in a risk analysis. The owner must implement this in the form of operating instructions (e.g. service manual).

● The owner must check during the entire period of use of the engine whether the oper-ating instructions he has produced comply with the current state of the regulations and adapt them if necessary.

● The owner must clearly regulate and specify the responsibilities for installation, opera-tion, maintenance and cleaning.

● The owner must ensure that all employees involved with the engine have read and un-derstood the operating instructions. He must also train the personnel and inform them about the dangers at regular intervals.

● The owner must provide the necessary protective equipment for the personnel.

The owner is also responsible that the engine is always in proper working condition. There-fore, strictly observe the following:

● The owner must ensure that the maintenance intervals specified in this manual are complied with.

● The owner must arrange for all safety equipment to be checked regularly for functional-ity and completeness.

● Explosive and easily flammable substances must always be kept away from the engine as the engine can become very hot during operation.

flames or ignitable sparks, do not smoke and do not spill any fuel.

● This manual must be kept in the immediate vicinity of the engine and must be acces-sible at any time to all persons working on and with the engine.

● In the case of doubt, always contact Steyr Motors Betriebs GmbH before starting the engine.

● The engine must only be operated if it is in proper working condition. The engine must be checked for intactness before every start-up.

● Only regular maintenance in accordance with the information in this manual maintains the operational readiness of the engine - otherwise loss of warranty.

tive effect on functioning and/or safe operation as well as the service life.

● Any variations from the operating conditions that are defined in the technical data can result in premature failure of the engine or lead to major damage to property (e.g. by using the wrong fuel, etc).

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S 3 Intended (appropriate) use

The engine is designed and constructed exclusively for the intended purpose described here.

The engine is provided exclusively for the intended purpose which has been specified and tested by the manufacturer of the equipment in which the engine is installed:

Motors Betriebs GmbH

Any other use is considered to be improper.

Steyr Motors Betriebs GmbH accepts no liability for any dangers and damage resulting from this. The risk is born solely by the user.

The installation must be made so that all applicable safety regulations for the operation of diesel engines are complied with.

Proper use also includes compliance with all the information in this operation manual.

Any use beyond the intended use and/or other types of use is considered misuse and can result in dangerous situations.

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S 4 Personnel requirements

S 4.1 Qualification

WARNING

Danger of injury for unqualified personnel!

Improper handling can result in severe personal injuries and/or material damage.

► Have all jobs carried out by qualified person-nel only.

The following qualifications are specified for different areas of activity listed in the manual:

● Operator / User has been instructed by the owner about the tasks assigned to him and possible dan-gers in the case of improper behaviour.

● Service personnel are persons who on the basis of their professional training by Steyr Motors Betriebs GmbH, experience and knowledge of the relevant conditions can perform the work as-signed to them using the operating, service and repair instructions and can recognise and avoid possible dangers themselves.

● Only persons who perform their tasks reliably are permitted as personnel. Persons whose reaction capability is impaired (e.g. through drugs, alcohol or medication) are not permitted.

● When selecting personnel, observe the age and occupational regulations applicable at the place of employment.

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S 5 Safety at work

Follow safety instructions Read carefully all safety instructions in this man-ual as well as all warning labels on the engine.

the currently valid warning labels.

► Replacement warning labels are available from the Steyr Motors dealer.

Familiarize yourself with the operation of the engine and the controls.

If you do not understand parts of this manual and need help, please contact your Steyr Motors dealer.

Risk of fire due to fuel and operating materi-als Handle fuel with care: it is highly flammable.

when near open flames, sparks or other fire hazards.

ards.

► Prevent fires by keeping engine clean of ac-cumulated trash, grease and debris.

► Do not store oily rags; they can ignite and burn spontaneously.

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Cutting injuries by fan Rotating cooling system fans can cause serious injury.

fore making adjustments or connections, or cleaning near the front of the engine.

Avoid high-pressure fluids Escaping fluid under pressure from high-pressure nozzles can penetrate the skin causing serious injury.

► Avoid the hazard by relieving pressure before disconnecting lines.

► Tighten all connections before applying pres-sure.

fluids.

ately.

► Any fluid injected into the skin must be surgi-cally removed within a few hours or gangrene may result.

Use proper lifting equipment Lifting heavy components incorrectly can cause severe injury.

► Use only approved, inspected and adequately rated lifting equipment.

► Follow recommended procedure for removal and installation of components in the manual.

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Use only approved tools Faulty or broken tools can result in serious injury.

Makeshift tools and procedures can create safety hazards. Avoid bodily injury caused by slipping wrenches.

► When constructing tools, use proper quality materials and good workmanship.

the correct size tools.

► Only use spare parts according to specifica-tion.

S 6 Personal protective equipment

The personal protective equipment must comply with the national employee protection regulations.

The operator must make the appropriate personal protective equipment available for any person who performs work on the engine and instruct them to wear it. Wearing of personal protective equipment is required when working to minimize the health hazards.

● Always wear the protective equipment that is necessary for the respective task when working.

● Follow the instructions on personal protective equipment that are posted in the work area.

Generally wear for all kind of work:

Protective clothing is close fitting, with low resistance to tearing, with narrow sleeves and without protruding parts. It mainly provides protection against being entangled by moving engine parts.

Do not wear any rings and other jewellery.

Safety boots to protect against heavy parts falling down or slipping on slippery ground.

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Personal protective equipment for special tasks. When performing special tasks it is nec-essary to wear personal protective equipment. This personal protective equipment will be separately specified in the chapters of this Manual. This special protective equipment is explained below.

Ear defenders to protect against hearing damage.

Hard hat, helmet to protect against parts and materials falling down and flying around.

Protective gloves to protect the hands against friction, graze, punctures or deep cuts as well as contact with hot surfaces.

Safety goggles to protect the eyes against parts flying around or squirts of fluids.

Fine dust mask to protect the airways against harmful dust.

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S 7 Noise

Noise can lead to an increased risk of accidents if the perception of acoustic signals, warn-ing cries or danger announcing noise is affected by it.

Wear hearing protection (e.g. earmuffs or earplugs) at all workplaces with a sound pres-sure level of 85 dB(A).

Safe operation of the vessel requires the driver’s full attention.

No headphones for listening to radio or music during operation.

Noise protection Prolonged exposure to loud noise can cause impairment or loss of hearing.

In the case of loud noises, wear suitable noise protection (e.g. ear protectors or ear plugs).

S 8 Exhaust gas

Risk due to exhaust gases! Engine exhaust fumes can result in sickness or death!

► The exhaust emissions need to be deflected from the control station of the engine. En-sure adequate ventilation.

Follow the law applicable to the site regulations!

Only carry out welding or grinding work on the engine, if it is expressly authorized. There is risk of fire or explosion!

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S 9 Operating and auxiliary material

Operating materials are

Auxiliary materials are those substances which are required for maintenance and repair work (e.g. glue, paste, etc.)

Warning - Danger of poisoning and danger of skin rashes and allergies!

Fuels (carcinogenic) and lubricants contain substances harmful to health and can result in severe poisoning and skin rashes or allergies.

doctor.

► Contact doctor immediately in the case of swallowing. Rinse mouth thoroughly with water.

tact a doctor.

► Dispose of contamination in the working area properly and in accordance with environ-mental regulations.

Safe handling of auxiliary and operating ma-terials.

Direct contact with hazardous materials can cause serious injuries. Material Safety Data Sheets (MSDS) provide specific information about chemicals: physical and health hazards, safety precautions, and emergency procedures.

► Read Material Safety Data Sheets before starting work with hazardous chemicals (consult your dealer for safety data sheets for chemical products used with your engine).

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S 10 Electrical energy

Work on electrical equipment may only be carried out by a qualified electrician or by in-structed persons under the direction and supervision of a qualified electrician in accord-ance with electrotechnical regulations.

Check cable (hoses) and screw connections regularly for leaks and externally visible dam-ages. Repair damages immediately.

In addition to the general safety instructions, local safety instructions and guidelines must be observed and respected.

S 11 Maintenance

Service engine safely Loose clothing (e.g. necktie, scarf) or jewellery (e.g. necklace) can cause serious injury if these items were to get caught by moving parts.

necklace.

► Remove rings and other jewellery to prevent electrical shorts and entanglement in moving parts.

Service cooling system safely Explosive release of fluids from pressurized cool-ing system can cause serious burns.

touch with bare hands.

► Slowly loosen cap to first stop to relieve pres-sure before removing components.

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Practice safe maintenance ► All work may only be carried out by trained personnel.

► Understand service procedure before doing work.

it is moving.

► Keep hands, feet and clothing from power-driven parts.

► Securely support any engine elements that must be raised for service work.

► Keep all parts in good condition and properly installed.

S 12 Behaviour in case of danger and accidents

Prepare for emergencies Preventive measures:

etc.) and fire extinguishers ready at hand.

► Keep emergency numbers for doctors, ambu-lance service, hospital, and fire department near your telephone.

► Familiarise personnel with accident reporting, first aid and rescue equipment.

► Keep access routes clear for rescue vehicles.

Actions in case of accidents

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S 13 Cleanliness at the workplace

Keep workplace and engine clean.

Before starting a job:

your job.

tempt shortcuts. Unauthorized reconstruction and modification are not allowed.

S 14 Environmental protection

Environment Significant environmental damage can occur, par-ticularly from incorrect disposal, if environmentally hazardous operating materials are mishandled.

► Observe the safety data sheet from the manu-facturer.

hazardous materials reach the environment.

Inform the responsible local authorities about the damage in the case of doubt.

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Dispose of waste properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment includes such items as oil, fuel, coolant, brake fluid, filters and batter-ies.

mislead people into drinking from them.

► Do not pour waste onto the ground, down a drain, or into any water source.

► Inquire on the proper way to recycle or dis-pose of waste from your local environmental or recycling centre, or from your dealer / Steyr Motors Betriebs GmbH.

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General

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A General remarks

A 1 General

This manual is published by Steyr Motors 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 2 Maintenance and service, the exhaust gas emission levels adhere to the limits stipulated, for pleasure boat opera-tion, throughout the lifetime of the engine.

Limited Application (US only):

Ship-owners or boat builders intending to purchase and install a Steyr Motors marine engine in a vessel which will be used in ECA (Emission Control Areas) and which are not excluded from IMO Tier III in accordance with Annex VI regulation 13.1.2, must contact the EPA and the US Coast Guard to request an exception from IMO Tier III in accordance with Annex VI Regulation 13.5.2.2 using engines with an EPA Tier 3 / IMO MARPOL 73/78 Tier II approval.

Regarding the Steyr Motors Limited Engine Warranty please refer to the Steyr Motors website:

http://www.steyr-motors.com/.

All warranty claims to be addressed to your local Steyr Motors marine dealer.

(We have to rely on your assistance however.) For a continuous improvement with…