STEYR MO256K43 User manual

www.steyr-motors.com

STEYR MOTORS GmbH

Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA

4 CYLINDERS

+ 6 CYLINDERS

STEYR MARINE ENGINES

SERVICE MANUAL

P/N Z001019/0 6th Edition July 2008

4 CYLINDERS

+ 6 CYLINDERS

THIS PAGE IS INTENTIONALLY BLANK

PREFACE

STEYR MOTORS GmbH

After Sales Service

Im Stadtgut B1

4407 STEYR

AUSTRIA

07252/222/52

07252/222/29

vom Inland:

from home country

+43/7252/222/52

+43/7252/222/29

vom Ausland

from foreign

countries:

[email protected]

http://www.steyr-motors.com

STEYR MOTORS GmbH has developed high-performance diesel engines with modulated high-

pressure direct injection, especially for the marine environment. STEYR marine engines are designed to be

adapted to various propulsion systems.

This SERVICE MANUAL is published 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 in case of possible failure to operate, service and repair the engine

4 & 6 CYLINDER MARINE

ENGINES

to maintain their operating safety and reliability.

To achieve continuous improvement with regard to form and contents of the information required, we are

assigned to your aid.

We, therefore, would much appreciate your comment to the following questions -

- Which descriptions or terms are not understandable?

- Which supplements or completions do you propose ?

- Where did creep in contents-related mistakes ?

Please address your comment to:

Z001019/0_6_July 2008

Repair and maintenance works on engine

The descriptions and instructions in this technical documentation should support you in use and repair of our

product. They refer to a specific equipment status of engine componets and accessories. Your individual

engine may be equipped with other or less accessory.

For any component not covered in this manual, please contact STEYR MOTORS GmbH, After Sales Ser-

vice, as to respective documentation.

This manual also contains specific references to your personal safety as user, as well as that of your

customers, their passengers and other persons being close to the engine/boat.

Product specifications, illustrations and technical data

When reference is made in this manual to a brand name, product number, product or specific tool, an

equivalent product may be used in place of the product or tool referred to, unless stated otherwise. To exclude

possible danger, the operator has to provide for adequate safety precautions.

All information, illustrations and specifications in this manual are based on the latest product data available at

the time of printing. It cannot be guaranteed that this manual is constantly updated. Revised versions edited at

a later date will replace all preceding editions.

Illustrations in this manual may not always correspond to actual implements or components and are

mainly intended as reference.

STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, on technical

data or models and/or to discontinue models. The right is also reserved to change technical data or

components at any time, without incurring any obligation to retrofit new parts on models produced

prior to date of such change.

To guarantee proper function of the engine and its attached parts after a repair, correct assembly is of

utmost importance. Such works are to be carried out with greatest care, in accordance with repair

instructions.

WARRANTY: Warranty claims will expire if repair, service and operation of the engine do not

correspond to the guidelines defined by STEYR MOTORS GmbH Please

address your warranty claims, in accordance with warranty regulations, directly to

the After Sales Service of STEYR MOTORS GmbH, Steyr.

Every STEYR dealer is obliged to fill out the warranty registration card enclosed to every sold

STEYR marine engine or every sold boat with a built-in STEYR marine engine.

Part 1 (Warranty Registration Card) is to be handed over to the customer, part 2 (Dealer Record

Card) remains with the dealer and part 3 is to be sent to the After Sales Service of STEYR

MOTORS GmbH.

This warranty registration card serves as a proof of ownership and is to be submitted in case

of warranty claims.

Every STEYR dealer is also obliged to carry out the Installation and pre-delivery inspection log.

One copy (completely filled out) of this Installation and pre-delivery inspection log is to be sent

to the After Sales Service of STEYR MOTORS GmbH.

Z001019/0_6_July 2008

TABLE OF CONTENTS

(MAIN ASSEMBLY GROUP ENGINE)

GENERAL

01 ENGINE

02 COUPLING

03 FUEL SYSTEM

04 EXHAUST SYSTEM

05 COOLING SYSTEM

06 ELECTRICAL EQUIPMENT

Z001019/0_6_July 2008

Components

01

Engine 01.00

Engine timing,

engine mount

01.01

Cylinder block 01.02

Chrankshaft

bearing,

vibration damper

01.03

Flywheel,

housing

01.04

Piston,

connection rod

01.05

Chamshaft,

housing,

valve drive

01.06

Engine housing,

oil pump,

oil suction pipe

01.08

Intake manifold,

intercooler

01.13

Engine oil cooler,

01.09

Auxiliary drive-PTO

01.14

Exhaust manifold,

seals,

heat exchanger

02

Coupling

03

Fuel system

04

Exhaust system

02.01

Torsion coupling 02.02

Coupler 02.03

Torsion coupling

Centa

03.02

Fuel pump,

unit injector,

pipes

03.04

Air filter 03.05

Turbo charger

03.08

Control solenoid 03.09

Fuel filter 03.11

Glow plugs

04.01

Hi-riser

Z001019/0_6_July 2008

05

Cooling system

06

Electrical

system

05.01

Cooler,

heat exchanger,

expansions tank

05.03

Pipes,

thermostat

05.04

Coolant pump

05.10

Raw water pump,

side mounted

05.11

Raw water pump,

front mounted

06.01

Generator,

alternator

06.03

Starter motor 06.05

Engine harness

06.06

EMS, E-box,

diagnosis system,

fuses

06.07

Instrument panel,

connecting cable

06.10

Sender, sensor

06.12

Battery,

charge equalization

Z001019/0_6_July 2008

VERSIONS OF MANUAL

Version Date Modification

1.0 01. 10. 2000 new edition

2.0 01. 06. 2002 release typ 164, 246

3.0 01. 07. 2005 release typ 256

4.0 01. 07. 2007 modification

5.0 01. 03. 2008 modification

6.0 01. 07. 2008 modification

Z001019/0_8_Octobre 2011 Page GENERAL-1

GENERAL

SERVICE MANUAL MARINE ENGINES

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GENERAL

Table of Contents

A General Remarks .................................................................................. 3

A 1 Model and Serial Numbers ..................................................................... 3

A 2 Documentation........................................................................................ 4

A 3 Model summary ...................................................................................... 5

A 3.1 Model summary 4 cylinder engines ........................................................ 5

A 3.2 Model summary 6 cylinder engines ........................................................ 8

A 4 Technical Data and Overview ................................................................. 12

A 4.1 Technical Data and Overview 4 cylinder engines.................................... 12

A 4.2 Technical Data and Overview 6 cylinder engines.................................... 16

B Specifications ....................................................................................... 20

B 1 Fuel Requirements ................................................................................. 20

B 2 Motor oil.................................................................................................. 21

C Maintenance and Service ..................................................................... 22

C 1 Trouble Check Chart............................................................................... 22

C 2 Service- and Maintenance Schedule ...................................................... 24

D General Information.............................................................................. 26

D 1 Electronic Engine Management System (ECU)...................................... 26

D 2 Diagnostic System .................................................................................. 27

D 3 Extended Storage Preservation Procedure............................................. 28

D 4 Engine Break-in procedure ...................................................................... 32

D 5 Operation after Break-in .......................................................................... 34

E Quality Gudelines for Repair ................................................................ 36

E 1 Spare parts specification......................................................................... 36

E 2 Workshop profile ..................................................................................... 36

E 3 Nomenclature .......................................................................................... 37

E 4 SI - System .............................................................................................. 38

E 5 Abbreviations .......................................................................................... 39

F Operating material and Information on Disposal................................ 40

F 1 List of operating material ......................................................................... 40

F 2 Disposal of automotive waste products.................................................... 41

G Notes on Safety..................................................................................... 42

G 1 General notes on safety ........................................................................... 42

G 2 Guidelines for damage prevention ........................................................... 42

G 3 Legal rules............................................................................................... 42

G 4 Safety in the use of operating material ..................................................... 43

GENERAL

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SERVICE MANUAL MARINE ENGINES

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G 5 Measures in case of accidents ................................................................ 43

H Thightening Torques ............................................................................ 44

H 1 Listing of Thightening Torques.................................................................. 44

H 2 General Tightening torques ...................................................................... 49

H 3 Testing of torque wrench .......................................................................... 50

H 4 Non-destructive material testing ............................................................... 50

H 5 Use of adhesive and sealing materials..................................................... 50

H 6 Solvent-free sealing materials.................................................................. 50

J Wear Limits............................................................................................ 52

J 1 Adjustment information for service and maintenance ................................ 53

Z001019/0_8_Octobre 2011 Page GENERAL-3

GENERAL

SERVICE MANUAL MARINE ENGINES

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A GENERAL REMARKS

A 1 Model and Serial Numbers

01.01 ill.1

01.01 ill.3

01.01 ill.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.

17

06014

08006

1

08007

FOR ALL

6 CYL. MARINE ENGINES

GENERAL

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SERVICE MANUAL MARINE ENGINES

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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_8_Octobre 2011 Page GENERAL-5

GENERAL

SERVICE MANUAL MARINE ENGINES

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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

GENERAL

Page GENERAL-6 Z001019/0_8_Octobre 2011

SERVICE MANUAL MARINE ENGINES

ToC

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_8_Octobre 2011 Page GENERAL-7

GENERAL

SERVICE MANUAL MARINE ENGINES

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Stern Drive

Jet Drive

03.01 ill.10

03.01 ill.11

TYPE

Mercury Alpha Bravo I, II & III

Volvo DP 290

Volvo DP 290 Hydraulic

SX - Stern Drive

TYPE

Alamarin

Hamilton

Castoldi

03.01 ill.8

03.01 ill.9

GENERAL

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SERVICE MANUAL MARINE ENGINES

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A 3.2 Modell summary 6 cylinder engines

03.02 ill.1

03.02 ill.2

03.02 ill.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_8_Octobre 2011 Page GENERAL-9

GENERAL

SERVICE MANUAL MARINE ENGINES

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03.02 ill.4

03.02 ill.5

03.02 ill.6

03.02 ill.7

03.02 ill.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°

GENERAL

Page GENERAL-10 Z001019/0_8_Octobre 2011

SERVICE MANUAL MARINE ENGINES

ToC

03.02 ill.9

03.02 ill.10

03.02 ill.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 ill.11

Z001019/0_8_Octobre 2011 Page GENERAL-11

GENERAL

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GENERAL

Page GENERAL-12 Z001019/0_8_Octobre 2011

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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

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