Steyr Motors Marine Engines Manual.pdf

www.steyr-motors.com

STEYR MOTORS GmbH Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA

STEYR MOTORS MARINE ENGINES

OPERATION,

MAINTENANCE AND

WARRANTY MANUAL

P/N Z001140-0 6th Edition November 2016

4 CYLINDERS

+ 6 CYLINDERS

4 CYLINDERS

+ 6 CYLINDERS

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WELCOME ABOARD

Congratulations on your decision of choosing a STEYR MOTORS GmbH 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 GmbH 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 GmbH marine engine to get sufficient infor-mation on its operation and handling and to permit an optimal use of the various built-in functions.

With kind regards, STEYR MOTORS GmbH

STEYR MOTORS GmbH After Sales Service

Im Stadtgut B1 4407 Steyr, Austria www.steyr-motors.com 6th Edition, November 2016 P/N Z001140-0

YOUR STEYR MOTORS GmbH

MARINE DEALER

How to use this manual

Table of Contents

GENERAL PART PAGE 10 - 21

This section contains user instructions and general notes on safety for STEYR MOTORS GmbH marine engines.

START-UP AND FUNCTIONS PAGE 22 - 49

This section contains brief instruction, function description and normal operation, as well as correct start-up and handling of STEYR MOTORS GmbH marine engines.

FUEL AND LUBRICANTS PAGE 50 - 53

This section defines the requirements as to fuel and lubricants for STEYR MOTORS GmbH marine engines.

TECHNICAL DATA PAGE 54 - 63

This section contains technical data and product description of STEYR MOTORS GmbH marine engines.

MAINTENANCE, TROUBLE SHOOTING PAGE 64 - 107

This section contains instructions for required maintenance and notes on the fault finding on your STEYR MOTORS GmbH marine engine.

DEALER´S RESPONSIBILITIES PAGE 108 - 121

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 122 - 134

This section contains warranty conditions (services and obligations) for owners and manufacturers of STEYR MOTORS GmbH marine engines.

full load speedrange

100%

90%

80%

70%

60%

50%

40%

30%

B

C D

RPM

A

O U T P U T

P O W E R

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SAFETY PRECAUTIONS

Safety Precautions

Introduction

Safety Precautions

Introduction This Operation, Maintenance and Warranty Manual contains the information you will need to operate the engine cor-rectly. Check that you have the correct Operation, Maintenance and Warranty 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 damaging the engine itself. If you do not understand or are uncertain on 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/break-ers) 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, some work, for example 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 rotat-ing parts and cause serious personal injury. If working in proximity of an engine which is operating, care-less 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 visible. Replace labels which have been damaged or painted over.

Engines with turbocharger: Never start the engine without installing the air cleaner 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 engines) 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 lubrication 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.

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 ventilation emissions.

Always use protective glasses or goggles when carrying out work where there is a risk of splinters, grind-ing 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 instructions on the product packaging carefully! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.). Make sure that other personnel are not exposed to hazardous chemicals, for example 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 penetrate 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 vicin-ity. 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 precautions before starting welding or grinding work. Always ensure that there are fire extinguishers at hand when work is being car-ried out.

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 danger-ous 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 proximity 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 connec-tions 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. Incorrect 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 sulfuric 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, immediately 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.

GENERAL PART

General

Marine 4 Cyl Engines Overview

Marine 6 Cyl Engines Overview

Product References, Illustrations and Specifications

Insurance

Stolen Unit

Warranty Registration Approval

Dealer Service - Maintenance

Illustration Symbols

Repair Service

Replacement Parts

Before Casting Off

Engine Submersion

Bottom Painting

Boat Bottom

Boating Responsibilities

Safety

WARNING

Symbols

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.

All 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 understandable?

–– 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 <3700 rpm whole page applies in principle for all en-gine types, but different data, e.g. techni-cal data, is marked.

Marine 4 Cyl Engines Overview

MO & SE 4-cylinder engine models engine type number of cylinders displacement [cm³] rated power [kW] rated speed (rpm)

Propeller selection range (rpm)

Jet selection range (rpm)

MO84K32 4 2100 55 3200 3000-3200 /

MO94K33 4 2100 66 3300 3100-3300 /

MO114K33 4 2100 81 3300 3100-3300 /

MO144M38 4 2100 106 3800 3500-3800 /

MO164M40 4 2100 120 4000 3700-4000 /

MO174V40 4 2100 125 4000 3700-4000 /

SE144E38 4 2133 106 3800 3700-3900 3300-3800

SE164E40 4 2133 118 4000 3900-4100 3550-4000

MO & SE 4-cylinder engine models engine type dry weight (kg)

Fuel cons @ rated power

(kg/h)

MAP

[mbar] compression ratio max. exhaust backpressure

(mbar)

MO84K32 243 14,2 1900 ε = 17,5 100 MO94K33 243 17,5 1900 ε = 17,5 100 MO114K33 255 18,6 1900 ε = 17,5 100 MO144M38 258 26,8 / ε = 17,5 100 MO164M40 258 31,6 2740 ε = 17,5 100 MO174V40 276 33,4 3100 ε = 17,0 150 SE144E38 263 27 2520 ε = 17,0 150 SE164E40 263 29,7 2650 ε = 17,0 150

MO & SE 4-cylinder engine models engine type backpressure tolerance (mbar) max. engine cooling water outlet temp

(°C) max. engine coolant outlet temperature

(°C)

Oil filling quantity

[lt.]

Coolant water quantity

[lt.]

MO84K32 +/-50 / / 8,4 9,0

MO94K33 +/-50 / / 8,4 9,0

MO114K33 +/-50 / / 8,4 9,0

MO144M38 +/-50 / / 8,4 9,0

MO164M40 +/-50 / / 8,4 9,0

MO174V40 +0/- 50 / / 8,4 9,0

SE144E38 +0/- 50 83 105 8,75 10,7

SE164E40 +0/- 50 83 105 8,75 10,7

Marine 6 Cyl Engines Overview

SE 6-cylinder engine models engine type number of cylinders displacement [cm³] rated power [kW] rated speed (rpm)

Propeller selection range (rpm)

Jet selection range (rpm)

SE126E25 6 3200 88 2500 2300-2550 /

SE156E26 6 3200 110 2600 2400-2650 /

SE156E32 6 3200 110 3200 3000-3250 /

SE156E34 6 3200 110 3400 3200-3500 /

SE196E35 6 3200 140 3500 3300-3550 /

SE236E40 6 3200 170 4000 3900-4100 /

SE236S36 6 3200 170 3600 3400-3650 /

SE266E40 6 3200 190 4000 3850-4050 /

SE266S36 6 3200 190 3600 3300-3650 /

SE286E40 6 3200 205 4000 3900-4150 /

SE306J38 6 3200 215 3800 3500-3850 /

SE 6-cylinder engine models engine type dry weight (kg)

Fuel cons @ rated power

(kg/h)

MAP

[mbar] compression ratio max. exhaust backpressure

(mbar)

SE126E25 340 20,1 2130 ε = 17,0 150 SE156E26 340 25,4 2200 ε = 17,0 150 SE156E32 340 25,8 2280 ε = 17,0 150 SE156E34 340 25,1 2240 ε = 17,0 150 SE196E35 340 33,7 2280 ε = 17,0 150 SE236E40 340 42,5 2790 ε = 17,0 150 SE236S36 340 40,9 2560 ε = 17,0 150 SE266E40 340 47,3 2840 ε = 17,0 150 SE266S36 340 46,1 2740 ε = 17,0 150 SE286E40 340 51 2990 ε = 17,0 150 SE306J38 340 52,2 3060 ε = 17,0 150

SE 6-cylinder engine models engine type backpressure tolerance (mbar) max. engine cooling water outlet temp

(°C) max. engine coolant outlet temperature

(°C)

Oil filling quantity

[lt.]

Coolant water quantity

[lt.]

SE126E25 +0/- 50 81 105 17,0 15,5

SE156E26 +0/- 50 83 105 17,0 15,5

SE156E32 +0/- 50 83 105 17,0 15,5

SE156E34 +0/- 50 105

SE196E35 +0/- 50 83 105 17,0 15,5

SE236E40 +0/- 50 85 105 17,0 15,5

SE236S36 +0/- 50 86 105 17,0 15,5

SE266E40 +0/- 50 86 105 17,0 15,5

SE266S36 +0/- 50 86 105 17,0 15,5

SE286E40 +0/- 50 86 105 17,0 15,5

SE306J38 +0/- 50 87 105 17,0 15,5

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. Equivalent 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:

All 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 GmbH Marine Engine and boat should be obtained as soon as practical for protection against loss by fire, theft, etc. Consult your local insurance agent.

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.

Warranty Registration Approval

When you purchases your boat, your dealer was obliged to issue a Warranty Registration Approval for your STEYR MOTORS Marine Engine.

This Warranty Registration Approval gives proof and is to be submitted in case of warranty claims.

Your STEYR MOTORS Marine dealer is also obliged to complete the Warranty Registration Approval (Chapter “War-ranty”). Required tests and measurements are to be carried out from your STEYR MOTORS Marine dealer and sent to STEYR MOTORS GmbH for approval of warranty registration.

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 GmbH marine dealer possible questions arisen dur-ing the first running hours on your boat, and to establish a service- and maintenance routine.

Services will be performed by STEYR MOTORS GmbH 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.

Repair Service

All repair works on your STEYR MOTORS GmbH marine engine should be carried out by a licensed STEYR MO- TORS GmbH Marine Dealer with his professional knowledge, trained staff and special-purpose tools to solve all oc-curing problems. Preferably, all work on your STEYR MOTORS GmbH marine engine should be carried out by the STEYR MOTORS GmbH 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 GmbH Marine Dealer. Information on Dealers and Distributors can be found at the end of this manual.

Replacement Parts

Your STEYR MOTORS GmbH Marine Engine was designed to operate in a marine environment use STEYR MO- TORS GmbH 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.

Recommended Minimum On-Board Tools

Recommended Minimum On-Board Spare Parts

These lists represent a suggested MINIMUM, and are not intended to cover all boats or possible boating conditions.

Engine Submersion

Remove engine from water as quickly as possible and contact your local STEYR MOTORS GmbH 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 sacrificial 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.

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.

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 you 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 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

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.

Symbols

Certain symbols or combinations of symbols may appear on your STEYR MOTORS GmbH Marine Engine or on its accessories. It is very important that you understand their meaning or purpose. If any symbol is not clearly under-stood, see your DEALER.

"Safety Warning" Symbols Means risk of SERIOUS injury is present. Follow instructions in the Operation, Maintenance & Warranty Manual before using motor or accsessory.

Means place shift control in NEUTRAL before starting motor.

Follow instructions in Operation, Maintenance & Warranty Manual before starting motor.

Indicates that ELECTRICITY of more than 50 volts is present.

Indicates that contents are under pressure.

Identifies poisonous material. Indicates a potential fire hazard.

"Position Indicator" Symbols Indicates upward movement.

Example: While boat is at planing speed, activating trim switch to raise the bow of the boat.

Indicates downward movement.

Example: While boat is at planing speed, activating trim switch to lower the bow of the boat.

Indicates gear shift control positions:

FORWARD, NEUTRAL and

REVERSE

"Condition" Symbols Indentifies the meter which indicates accumulative running hours of engine.

Identifies the meter which indicates battery voltage or amperage.

Identifies the meter which indicates engine speed expressed in revolutions per minute.

Identifies battery or a meter wich indicates status of battery-generator charging system.

Indicates the amount of liquid in tank.

Indentifies the meter which indicates engine coolant pressure.

Identifies the meter which indicates engine coolant temperature.

FILTER: Identifies a device which removes contaminants from engine’s oil system.

Identifies the meter which indicates the pressure of engine’s lubricating system.

"Functional Description" Symbols FILTER: Identifies a device which removes contaminants from fuel.

Identifies the EMERGENCY

IGNITION CUT-OFF SWITCH.

Emergency engine stop.

FUSE: Identifies a device which protects the electrical system from overload.

Identifies the negative ground or negative voltage connection.

Identifies engine drain plugs and fittings.

Identifies the operating device for starting the motor.

Identifies the STOP SWITCH.

It may also identify STOP position of the throttle control.

"Instructional" Symbols Indicates FUEL is to be used or FUEL is present.

Means read your Operation, Maintenance & Warranty Manual before operating the product. It contains information or instructions vital for operation of product.

Indicates areas to be lubricated.

Indicates OIL is to be used or OIL is present.

ENGINE OIL FILL: Location for introduction of oil into the engine.

Indicates lubricating oil used in transmissions.

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START-UP AND FUNCTIONS

Before Starting

Starting the Engine (key switch version)

Stopping the Engine

Starting the Engine (push button version)

Stopping the Engine (push button version)

Run In Procedure After Major Overhaul

Definitions

Procedure, Work steps

Engine Break-In procedure

First Ten Hours

Final Ten Hours of Break-in

Operation after Break-In

Shifting

Remote Control Operating Instructions

How to Shift and Control Speed

Fuel Economy

Gear Box - Information

Instrument panel (key switch version)

Instrument panel, standard

Instrument indication during normal operation

Instrument panel (push button version)

Instrument indication during normal operation (push button version)

Emergency cut off switch (Lanyard)

Warning lights and audible alarm

START-UP AND FUNCTIONS

Electronic Engine Control Unit (ECU)

Diagnostic system

Twin Installations

Optional Propellers

Propellers

Propeller Torque

Propeller care

Water Jet

Operating Procedure for Freezing Temperatures

Salt Water Operation

High Altitude Operation

Fuel Pump

Fuel System Checks

Fuel Contamination

Cooling System

Electrical Equipment

Alternator

Battery

Circuit Breakers & Fuses 4 Cylinder Marine Engine

Circuit Breakers & Fuses 6 Cylinder SE Marine Engine

Inversion Switch (optional)

Interrupt crankshaft housing ventilation (optional)

Instrument Panel

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 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.

2. 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.

3. 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.

4. Check the operating levels of:

5. Control of electric system:

* Charge and charge state of battery.

Starting the Engine (key switch version)

Starting procedure for the STEYR MOTORS GmbH marine engine is the same for both cold and warm engines. The engine 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 func-tion of the audible and visual warning systems.

NOTE: � In case of a low temperature start wait until the combined oil pressure/glow plug pre-heating indication light is turned off, before you continue with the start procedure.

3. �Turn ignition key into position “START” 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, wait 30 seconds to cool down starter motor, re-peat starting procedure.

4. �As soon as engine starts, release ignition key.

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 GmbH 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.

OFF

ON

START

F

G

Starting the Engine (push button version)

Starting procedure for the STEYR MOTORS GmbH marine engine is the same for cold or warm operating condi-tion. The engine 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. �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 ignition key, wait 30 seconds to cool down starter motor, 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 GmbH Marine dealer.

Never push start button when engine is running.

Stopping the Engine (push button version)

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 engine.

ATTENTION: �Do not stop engine at speeds above idle or “accelerate” engine while turning off engine. This may result in engine failures.

Run In Procedure After Major Overhaul

The following run in procedure must be used on STEYR MOTORS GmbH 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

Procedure, Work steps

Preparation

Test method

contact STEYR MOTORS GmbH authorized Service-Partner for further decisions

occurred, contact STEYR MOTORS GmbH authorized Service-Partner for further decisions

e.g. 68225765_20080910.dat)

* �Check the service code list in the ECU. If errors occurred, contact STEYR MOTORS GmbH authorized Service-

Partner for further decisions

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 1500 RPM). For the remaining 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 max. 2 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 on dipstick. When refilling motor oil, refer to information “Engine Lubrication - Motor Oil”.

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 GmbH 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 75 °C - 95 °C (part heat up to full load, at idle speed the engine temperature will be between 68 °C and 80 °C depending on ambient temp. and raw water temperature). 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.

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, 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:

4 Cylinder MO Marine Engines MO54NA33 3000 rpm MO84K32 3000 rpm MO94K33 3000 rpm MO114K33 3000 rpm MO144M38 3200 rpm MO164M40 3400 rpm MO174V40 3400 rpm

4 Cylinder SE Marine Engines 6 Cylinder SE Marine Engines SE144E38 3400 rpm SE126E25 2300 rpm SE164E40 3600 rpm SE156E26 2400 rpm

SE156E32 3000 rpm SE156E34 3200 rpm SE196E35 3200 rpm SE236E40 3800 rpm SE236S36 3400 rpm SE266E40 3800 rpm SE266S36 3400 rpm SE286E40 3800 rpm SE306J38 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 op-erating temperature is reached. During the first 50 running hours, check the oil level frequently.

Shifting

Example: single lever shift control system

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 en-gine speed to return to idle and vessel speed below 1 kn.

5. After shifting is completed, continue to move the control lever slowly in the desired 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 GmbH 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.

Remote Control Operating Instructions 1 Your boat may be equipped with one of the following remote controls:

NOTE: � If other than STEYR MOTORS GmbH matched remote controls are used, follow the manufacturer’s recommendation.

Remote controls have the following important features:

* �A single 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 GmbH 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 throttle

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:

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 GmbH 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 GmbH 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 prevent injury resulting from unexpected turning of the propeller and sudden movement of the boat.

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.

2 � Move the control lever to neutral position (D). The shift mechanism will automatically engage. Press neutral lock button (C) on some 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 desired direction to increase speed.

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.

B

A E D

F

H

G

J

A1

I

CA1

Instrument panel (key switch version)

Instrument panel, standard

A tachometer F ignition key A1 function buttons G blind plug - installation option for key switch constant revolutionB engine parameter display C warning light - battery charge H audible warning device

(installed on rear side of panel)D combined light preheating control & warning light - engine oil pressure I 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 GmbH Marine dealer.

Instrument indication during normal operation

NOTE:

�At low temperature condition (cold weather) the combined light for glow plug preheating & engine oil pressure will not extinguish after 0,7 sec. (glow plug preheating phase).

�In this case start engine immediately after the light extinguishes.

2. ignition ON (… before starting) Indication active error

3. engine running (after start) Normal condition

ON (0,7 sec.)

ON (5 sec.)

OFF

ON

ON

(0.7 sec.)

ON

(0.7 sec.)

OFF

OFF

OFF

ON

(0.7 sec.)

ON

(5 sec.)

ON

I

H

A

GB A1A1 E

H

J

C DF

Instrument panel (push button version)

A tachometer F push button - ignition ON/OFF (red) A1 function buttons G push button - START (green) B engine parameter display H audible warning device

(installed on rear side of panel)C warning light - battery charge D combined light preheating control & warning light - engine oil pressure I emergency cut off switch (lanyard) J circuit breaker (10 amp)

E warning light - check engine

NOTE: Instrument gauges are automatically illuminated if ignition is turned ON.

the push button START (G).

OFF

Instrument indication during normal operation (push button version)

1. ignition ON (… before starting) System check - see light indication

NOTE:

�At low temperature condition (cold weather) the combined light for glow plug preheating & warning light engine oil pressure will not extinguish after 0,7 sec.

(glow plug preheating phase).

�In this case start engine immediately after the light extinguishes.

2. ignition ON (… before starting) Indication active error

3. engine running (after start) Normal condition

NOTE:

�For further information see:

“Table - Error indication on Instrument Panel”

ON (0,7 sec.)

ON

(0.7 sec.)

ON

(0.7 sec.)

ON

ON

(0.7 sec.)

ON

(5 sec.)

ON

OFF

OFF

OFF

ON (5 sec.)

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 from 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.

ATTENTION: �The emergency cut off switch can only be effective when in good working condition.

Observe the following:

engine does not stop, see your STEYR MOTORS GmbH DEALER for replacement of switch.

Do not use the Emergency cut off switch as a "Stop"-switch. This will reduce the life time of the Emergency cut off switch!

Warning lights and audible alarm

Your boat with the STEYR MOTORS Marine 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 parameter 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 GmbH Marine Dealer to get proffesional assistance to verify the de-ficiency 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 seconds 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 system, 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 GmbH Marine dealer.

Electronic Engine Control Unit (ECU)

The STEYR MOTORS GmbH Marine engine is equipped with an Electronic Engine Control Unit (ECU) that per-forms the following:

* controls engine functions to ensure maximum efficiency.

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

* stores…