- Ninguna Categoria
STEYR Marine Engine Service Manual: 4 & 6 Cylinders
Anuncio
STEYR MARINE ENGINES 4 CYLINDERS + 6 CYLINDERS SERVICE MANUAL P/N Z001019/0 6th Edition July 2008 www.steyr-motors.com STEYR MOTORS GmbH Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA Downloaded from www.Manualslib.com manuals search engine THIS PAGE IS INTENTIONALLY BLANK Downloaded from www.Manualslib.com manuals search engine PREFACE STEYR MOTORS GmbH has developed high-performance diesel engines with modulated highpressure 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: vom Inland: from home country STEYR MOTORS GmbH After Sales Service vom Ausland from foreign countries: 07252/222/52 +43/7252/222/52 Im Stadtgut B1 4407 STEYR AUSTRIA 07252/222/29 +43/7252/222/29 [email protected] http://www.steyr-motors.com Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 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 Service, 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 Downloaded from www.Manualslib.com manuals search engine 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 Downloaded from www.Manualslib.com manuals search engine Components 01 Engine 02 Coupling 03 Fuel system 04 Exhaust system 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 01.09 Auxiliary drive-PTO 01.13 Engine oil cooler, 01.14 Exhaust manifold, seals, heat exchanger 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 Downloaded from www.Manualslib.com manuals search engine 05 Cooling system 06 Electrical system 05.01 Cooler, heat exchanger, expansions tank 05.03 Pipes, thermostat 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 Downloaded from www.Manualslib.com manuals search engine 05.04 Coolant pump VERSIONS OF MANUAL Version Date Modification 1.0 2.0 3.0 4.0 5.0 6.0 01. 10. 2000 01. 06. 2002 01. 07. 2005 01. 07. 2007 01. 03. 2008 01. 07. 2008 new edition release typ 164, 246 release typ 256 modification modification modification Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine ToC SERVICE MANUAL MARINE ENGINES GENERAL GENERAL Table of Contents A A1 A2 A3 A 3.1 A 3.2 A4 A 4.1 A 4.2 General Remarks .................................................................................. 3 Model and Serial Numbers ..................................................................... 3 Documentation........................................................................................ 4 Model summary ...................................................................................... 5 Model summary 4 cylinder engines ........................................................ 5 Model summary 6 cylinder engines ........................................................ 8 Technical Data and Overview ................................................................. 12 Technical Data and Overview 4 cylinder engines.................................... 12 Technical Data and Overview 6 cylinder engines.................................... 16 B B1 B2 Specifications ....................................................................................... 20 Fuel Requirements ................................................................................. 20 Motor oil .................................................................................................. 21 C C1 C2 Maintenance and Service ..................................................................... 22 Trouble Check Chart ............................................................................... 22 Service- and Maintenance Schedule ...................................................... 24 D D1 D2 D3 D4 D5 General Information .............................................................................. 26 Electronic Engine Management System (ECU) ...................................... 26 Diagnostic System .................................................................................. 27 Extended Storage Preservation Procedure ............................................. 28 Engine Break-in procedure ...................................................................... 32 Operation after Break-in .......................................................................... 34 E E1 E2 E3 E4 E5 Quality Gudelines for Repair ................................................................ 36 Spare parts specification ......................................................................... 36 Workshop profile ..................................................................................... 36 Nomenclature .......................................................................................... 37 SI - System .............................................................................................. 38 Abbreviations .......................................................................................... 39 F F1 F2 Operating material and Information on Disposal ................................ 40 List of operating material ......................................................................... 40 Disposal of automotive waste products .................................................... 41 G G1 G2 G3 G4 Notes on Safety ..................................................................................... 42 General notes on safety ........................................................................... 42 Guidelines for damage prevention ........................................................... 42 Legal rules ............................................................................................... 42 Safety in the use of operating material ..................................................... 43 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-1 ToC SERVICE MANUAL MARINE ENGINES GENERAL G5 Measures in case of accidents ................................................................ 43 H H1 H2 H3 H4 H5 H6 Thightening Torques ............................................................................ 44 Listing of Thightening Torques .................................................................. 44 General Tightening torques ...................................................................... 49 Testing of torque wrench .......................................................................... 50 Non-destructive material testing ............................................................... 50 Use of adhesive and sealing materials ..................................................... 50 Solvent-free sealing materials .................................................................. 50 J J1 Wear Limits ............................................................................................ 52 Adjustment information for service and maintenance ................................ 53 Page GENERAL-2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES A GENERAL REMARKS A1 Model and Serial Numbers GENERAL 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. FOR ALL 4 CYL. MARINE ENGINES FOR ALL 6 CYL. MARINE ENGINES 1 1 08007 08006 01.01 ill.1 01.01 ill.2 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 01.01 ill.3 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-3 ToC SERVICE MANUAL MARINE ENGINES GENERAL A2 Documentation 4 and 6 cylinder 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 Page GENERAL-4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL A3 Modell summary A 3.1 Modell summary 4 cylinder engines Bobtail - Version 03.01 ill.1 Equipment: with side mounted raw water pump or, with side mounted raw water pump, power steering pump Inborder i.e. ZF 45 Marinegear Down angle 03.01 ill.2 Innenborder i.e. ZF 63 Marinegear 03.01 ill.3 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-5 ToC SERVICE MANUAL MARINE ENGINES GENERAL Lifeboat Engine Equipment Bobtail "B" 03.01 ill.4 Direkt gearbox 03.01 ill.5 A-down angle gear box 03.01 ill.6 Parallel offset gearbox 03.01 ill.7 Page GENERAL-6 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Jet Drive TYPE Alamarin Hamilton 03.01 ill.8 Castoldi 03.01 ill.9 03.01 ill.10 Stern Drive TYPE Mercury Alpha Bravo I, II & III Volvo DP 290 Volvo DP 290 Hydraulic 03.01 ill.11 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine SX - Stern Drive Page GENERAL-7 ToC GENERAL SERVICE MANUAL MARINE ENGINES A 3.2 Modell summary 6 cylinder engines Bobtail - Version with side mounted raw water pump or, with side mounted raw water pump, power steering pump and front mounted auxiliary drive-PTO 03.02 ill.1 Inborder i.e. ZF 63 Marine gear Down angle 03.02 ill.2 03.02 ill.3 Page GENERAL-8 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Transmission i = 2.5V, shaft angle 12° i = 2.0V, shaft angle 12° 03.02 ill.4 Lifeboat Engine Equipment Bobtail "B" 03.02 ill.5 Direkt gearbox 03.02 ill.6 A-down angle gear box 03.02 ill.7 Parallel offset gearbox 03.02 ill.8 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-9 ToC SERVICE MANUAL MARINE ENGINES GENERAL Jet drive 03.02 ill.9 Jet Drive TYPE Alamarin Hamilton 03.02 ill.10 Castoldi 03.02 ill.11 Stern drive Type Mercury Bravo II & III Volvo DP 290 Stern Power Drive 03.02 ill.12 Volvo DP 290 ZF Hydraulic Pump Volvo SX - Drive King Cobra Drive Page GENERAL-10 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-11 ToC SERVICE MANUAL MARINE ENGINES GENERAL A 4.1 Technical data and overview 4 cylinder engines MAKE STEYR M 14 TCM, TCAM type MO84K32 displacement 2133 cm³ piston displacement 85,0 x 94,0 mm rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive 53 / 71 52 / 70 number of cylinders 4-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order MO94K33 MO114K33 MO144V38 64 / 86 63 / 84 78 / 105 77 / 104 103 / 138 101 / 136 1-3-4-2 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 3000 - 3200 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 *) **) 3050 - 3800 3200 - 3800 3600 - 3800 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% Page GENERAL-12 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl. Marine Engines Item Designation 1 2 3 4 5 6 7 8 Zinc Anode (4 Units) Model and Serial Number Intercooler Fuel/Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation (only SOLAS) Oil Drain Plug Fuel Filter Oil Filter Hydraulic Pump Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug (2 Units) Engine Oilcooler Oil Suction Pipe Oil Dipstick Hydraulic Oil Tank Cooler Cap Potentiometer Accelerator Motor Oil Filler Cap Boost Pressure Sensor Rack Position Sensor *) Drive Belt Cover T-Belt, Lower Engine Mount Drive Belt Tensioner Vibration Damper Cover T-Belt, Upper Engine Lifting Eye Speed Sensor Valve Cover Heat Exchanger Coolant Expansion Tank Diagnostic Outlet Inversion Switch (only for SOLAS) Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Alternator Circuit Breakers Engine Management System/Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais (Backside E-Box Ground Plate) Starter Motor Flywheel Flywheel Housing Oil Pressure Sensor 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 19 18 17 1 2 3 4 5 6 1 16 15 14 13 12 11 7 8 10 9 06001 20 21 22 23 31 30 24 29 25 28 26 27 06002 1 32 33 34 35 36 37 38 39 15 44 40 43 41 42 06003 45 46 47 52 51 50 48 49 06004 *) This sensor is magnetism sensitive. All external magnets must be kept away. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine 1 Page GENERAL-13 ToC SERVICE MANUAL MARINE ENGINES GENERAL MAKE STEYR M 14 TCAM type MO144M38 displacement 2133 cm³ MO164M40 piston displacement 85,0 x 94,0 mm rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive 103 / 138 101 / 136 number of cylinders 4-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 116 / 156 114 / 154 1-3-4-2 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) 3700 - 3900 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 *) **) 3800 - 4000 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% Page GENERAL-14 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl. Marine Engines Item Designation 1 2 3 4 5 6 7 8 Zinc Anode (4 Units) Model and Serial Number Intercooler Fuel/Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation (only SOLAS) Oil Drain Plug Fuel Filter Oil Filter Hydraulic Pump Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug (2 Units) Engine Oilcooler Oil Suction Pipe Oil Dipstick Hydraulic Oil Tank Cooler Cap Potentiometer Accelerator Motor Oil Filler Cap Boost Pressure Sensor Rack Position Sensor *) Drive Belt Cover T-Belt, Lower Engine Mount Drive Belt Tensioner Vibration Damper Cover T-Belt, Upper Engine Lifting Eye Speed Sensor Valve Cover Heat Exchanger Coolant Expansion Tank Diagnostic Outlet Inversion Switch (only for SOLAS) Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Alternator Circuit Breakers Engine Management System/Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais (Backside E-Box Ground Plate) Starter Motor Flywheel Flywheel Housing Oil Pressure Sensor 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 19 18 1 2 3 4 5 6 1 17 16 15 7 8 14 13 12 11 10 9 06001 20 21 22 23 31 30 24 29 25 28 26 27 06002 1 32 33 34 35 36 37 38 39 15 44 40 43 41 42 06003 45 46 47 52 51 48 49 50 06004 *) This sensor is magnetism sensitive. All external magnets must be kept away. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine 1 Page GENERAL-15 ToC SERVICE MANUAL MARINE ENGINES GENERAL A 4.2 Technical data and overview 6 cylinder engines MAKE STEYR M 16 TCM, TCAM type MO126M28 displacement 3200 cm³ piston displacement 85,0 x 94,0 mm rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive 87 / 117 86 / 115 number of cylinders 6-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order MO166K28 MO196K35 MO236K42 116 / 156 115 / 154 136 / 182 134 / 179 165 / 221 162 / 218 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 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 *) **) 2600 - 2800 3300 - 3500 4000 - 4300 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% Page GENERAL-16 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO126M28, MO166K28, MO196K35, MO236K42 Item Designation 18 1 2 3 4 56 7 2 1 2 3 4 5 6 7 8 9 Boost Pressure Sensor 17 Zinc Anode (5 Units) 8 16 Intercooler 9 Fuel- / Hydr. Oil Cooler 15 Engine Oilcooler Model and Serial Number 10 Oil Seperator Raw Water Drain Plug 11 Valve Crankshaft Housing Ventilation 14 13 12 06032 (only SOLAS) 10 Fuel Filter 11 Fuel Pump 19 20 21 12 Oil Filter 13 Raw Water Inlet Fitting 14 Raw Water Pump 15 Coolant Drain Plug (2 Units) 29 16 Oil Suction Pipe 17 Oil Dipstick 18 Rack Position Sensor *) 22 28 19 Engine Lifting Eye 23 20 Motor Oil Filler Cap 21 Potentiometer Accelerator 24 27 22 Drive Belt, Raw Water Pump 26 25 23 Engine Mount 06033 24 Drive Belt Tensioner 25 Cover T-Belt, Lower 2 30 31 32 33 34 35 36 37 26 Vibration Damper 27 Drive Belt, Alternator & Hydr: Pump 2 28 Speed Sensor 15 29 Cover T-Belt, Upper 30 Valve Cover 38 46 31 Heat Exchanger 39 32 Coolant Expansion Tank 40 45 33 Cooler Cap 41 34 Diagnostic Outlet 44 35 Inversion Switch (only for SOLAS) 42 36 Connector Instrument Panel 37 Coolant Temperature Sensor 43 06034 38 Thermostat Housing 39 Hydraulic Oil Tank 40 Circuit Breakers 49 47 48 41 Alternator 42 Hydraulic Pump 43 Oil Drain Plug 2 53 44 Starter Motor 50 45 Engine Management System/Fuses 46 Exhaust Temperature Sensor 52 47 Air Filter 51 48 Turbo Charger 49 Exhaust Elbow 50 Starter Relais (Backside E-Box Ground Plate) 51 Flywheel 06035 52 Flywheel Housing 53 Oil Pressure Sensor *) This sensor is magnetism sensitive. All external magnets must be kept away. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-17 ToC SERVICE MANUAL MARINE ENGINES GENERAL MAKE STEYR M 16 TCAM type MO256K43 displacement 3200 cm³ piston displacement 85,0 x 94,0 mm rated power acc. EN ISO 8665:2006 (impeller **) KW / HP Jet - Drive / Inboard Z - Drive 178 / 239 176 / 236 number of cylinders 6-cylinder in-line engine (position of cyl. 1 at vibration damper side) ignition order 178 / 239 176 / 236 1 - 5 - 3 - 6 -2 - 4 sense of rotation, seen from front right compression ratio 17,5 : 1 full-load speed range (rpm) MO256H45 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 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 *) **) P/No.2178992/1 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% Page GENERAL-18 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO256K43, MO256H45 Item Designation 1 2 3 4 5 6 7 8 Boost Pressure Sensor Zinc Anode (5 Units) Intercooler Engine Oil / Fuel / Hydr. Oil Cooler Model and Serial Number Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation (only SOLAS) Fuel Filter Fuel Pump Oil Filter Raw Water Inlet Fitting Raw Water Pump Coolant Drain Plug (2 Units) Oil Suction Pipe Oil Dipstick Rack Position Sensor *) Engine Lifting Eye Motor Oil Filler Cap Potentiometer Accelerator Drive Belt, Raw Water Pump Engine Mount Drive Belt Tensioner Cover T-Belt, Lower Vibration Damper Drive Belt, Alternator & Hydr: Pump Speed Sensor Cover T-Belt, Upper Valve Cover Heat Exchanger Coolant Expansion Tank Cooler Cap Diagnostic Outlet Inversion Switch (only for SOLAS) Connector Instrument Panel Coolant Temperature Sensor Thermostat Housing Hydraulic Oil Tank Circuit Breakers Alternator Hydraulic Pump Oil Drain Plug Starter Motor Engine Management System/Fuses Exhaust Temperature Sensor Air Filter Turbo Charger Exhaust Elbow Starter Relais (Backside E-Box Ground Plate) Flywheel Flywheel Housing Oil Pressure Sensor 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 17 3 4 5 2 6 16 15 7 8 14 9 10 13 12 11 06028 18 19 20 28 27 21 22 26 23 25 2 29 24 30 31 32 33 34 35 Downloaded from www.Manualslib.com manuals search engine 36 2 14 37 45 38 39 40 44 43 41 42 46 06030 48 47 2 52 49 51 50 06031 *) This sensor is magnetism sensitive. All external magnets must be kept away. Z001019/0_8_Octobre 2011 06029 Page GENERAL-19 ToC SERVICE MANUAL MARINE ENGINES GENERAL B Specifications B1 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 General Fuel classification CEC RF-03-A-84 Limit value and units CEC RF-03-A-80 Limit value and units ASTM Test procedure Cetane number min. 49 - max. 53 min. 51 - max. 57 D 613 (D 976) min. 0,835 max. 0845 min. 0,835 max. 0845 D 1298 min. 245°C min. 320°C max. 340°C min. 245°C min. 320°C max. 340°C D86 End point max. 370°C max. 370°C Flash point min. 55°C min. 55°C D 93 CFPP (Cloud point) min. -- / max. -5°c max. -5°c EN 116 (CEN) Viscosity Kinematic 40°C min. 2,5 mm²/s max. 3,5 mm²/s min. 2,5 mm²/s max. 3,5 mm²/s D 445 Sulfur content max. 0,3 mass-% max. 0,50 mass-% D 1266/D 2622 D 2785 max. 1 max. 1 D 130 Carbon residue Conradson number (10% residue) max. 0,2 mass-% max. 0,2 mass-% D 189 Ash max. 0,01 mass-% max. 0,01 mass-% D 482 Water content max. 0,05 mass-% max. 0,05 mass-% D 95/D 1744 Acid content (strong acid) max. 0,20 mg KOH/g max. 0,20 mg KOH/g D 974 Oxidation stability max.2,5 mg/100ml max.2,5 mg/100ml D 2274 Gravity at 15°C (kg/l) Destillation 50% 90% Cupper corrosion Page GENERAL-20 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL 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 6 Cyl engines Oil quantity between MIN. and MAX. on dipstick 2,0 Litre Oil change quantity: 4 Cyl. engines 6 Cyl. engines Öil filter: ca. 1 Litre Oil - specification, Minimum: API: ACEA: Viscosity class: Recommended engine oil: 8,4 Litre (Oil filling, incl. 1l oil filter) 10,4 Litre (Oil filling, incl. 1l oil filter) 7,0 Liter (without oil filter) 9,0 Liter (without oil filter) CF or higher B4 - 02 or higher SYNTHETIC OIL 5W-50 SYNTHETIC OIL 10W-40 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. FOR HEAVY DUTY DIESEL ENGINES 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. ACEA E7 or B4-02 API CF 02.02 ill.1 ACEA E7 or B4 - 02 SAE 5 W-50 10 W-40 ill.1 Top of Can ill.2 Oil Identification Symbol API SERVICE CODE CF 02.02 ill.2 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-21 ToC SERVICE MANUAL MARINE ENGINES GENERAL C Maintenance and Service C1 Trouble Check Chart 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 Engine won’t start POSSIBLE CAUSE ACTION 1. No fuel in tank or shut-off valve closed. Fill tank or open valve. 2. Air leak in suction lines. Bleed fuel system and check for leaks. 3. Fuel line plugged or pump defective. Fuel pump may be 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. Only for SOLAS ==> 7. Battery output insufficient 8. Inversion switch actuated Charge or replace battery. Cancelled by ignition "OFF - ON" Starter won’t crank engine 1. Battery connections loose or corroded Check for loose connections 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. 5. Fuse blown on panel Check and replace if defect 6. Starter auxiliary relay Check terminal connection and function of relay. 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. Engine runs erratically Page GENERAL-22 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Trouble Check Chart - continued SYMPTOM Engine vibrates POSSIBLE CAUSE Propeller condition Unit injector Engine runs but boat makes little or no progress Fouled propeller etc. ACTION Check for bent, broken, or damaged propeller Check for weeds on propeller or sterndrive gearcase. Check for bent propeller shaft. Check. Check: 1. Propeller for weeds, remove as required. 2. Propeller for spun hub, repair or replace. 3. Hull for excessive marine growth, clean as required. 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 wheel Steering cable loose Adjust or replace. High shift effort 1. Remote control or transom bracket shift cable 2. Remote control binding Replace and adjust. Adjust. 3. Engine / drive mechanism sticks Center. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-23 ToC SERVICE MANUAL MARINE ENGINES GENERAL C2 Service- and Maintenance Schedule ENGINE LUBRICATION check change ENGINE COOLING SYSTEM check change RAW WATER SYSTEM check change preserve RAW WATER check COOLER (OIL-FUELAUX.LUBRICANT) for 246 / 256 change and 266 only AIR FILTER FUEL SYSTEM every 300 h. or 24 months *) notes - for leakage - oil level - oil filter - motor oil - for leakage - fluid level - hoses, hose clamps - antifreeze temperature condition - antifreeze*) every 24 month - hoses, hose clamps - zinc anodes - raw water pump V-belt - impeller - raw water pump V-belt*) - impeller*) - zinc anodes*) - raw water circuit*) if required if required if corroded > 50% after season - raw water passages*) clean out desposits in pipelines - zinc anodes*) check change preserve - contamination - air filter element check - for leakage - hoses - addtiional fuel filter - fuel filter - additional fuel filter - fuel system*) drain change check preserve daily after first every 50 hours 150 h. or 6 or 12 months months required if more than 50% material corroded after season after season BATTERY check - acid level - densitiy ELECTRONICS check - connections*) after season ELECTRICAL EQUIPMENT check - connections - insulation tighten loose connections. Renew cables, if required. INVERSION SWITCH check - switch*) (Solas only) every 50 hours or every 6 months DRIVING SYSTEM re-center - driving unit*) see manufacturer's specifications V-BELT check - generator & impeller pump - power-steering adjust tension adjust tension for all 6 cyl. models change - generator*) - power-steering*) if required if required POLY - V BELT check - belt, pulleys and tighteners for wear - Poly -V-belt change for all 4 cyl. models Page GENERAL-24 Downloaded from www.Manualslib.com manuals search engine every 1050 hours or every 48 months Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES Service- and Maintenance Schedule GENERAL daily after first every 50 hours 150 h. or 6 or 12 months months every 300 h. or 24 months *) notes POLY - V - BELT check TENSION lubricate GLOW PLUGS change - plugs*) TIMING BELT check change - belt tension - timing belt*) every 1500 h. or every 48 months - water pump, tensioner every 1500 h. or every 48 months every 3000 h. or every 48 months VALVES check - valve clearance*) every 750 hours ENGINE TIMING check - set timing every 750 hours check - set levers*) - set point - tighten torque every 750 hours every 750 hours every 750 hours UNIT INJECTOR SERVO PUMP check change GEARBOXSTERNDRIVE check change FRONT VIBRATION DAMPER check - oil level - for leakage - hydraulic oil (ATF) *) every 750 h. or every 24 months - oil level - for leakage - gear oil (ATF) *) - oil filter see manufacturer's specifications - torque ENGINE COMcheck for PARTMENT AND BILGE - leakage SHIFTING check - smooth action - adjustment If required, to be replaced by your STEYR Marine Dealer. STEERING check - lubrication - oil level see manufacturer´s specification SAFETY EQUIPMENT check - remote control - emergency cutout - completeness local rules and consultation of your STEYR - condition -water -fuel -exhaust gas repair or consult your STEYR Marine dealer Marine Dealer SHAFT BEARING check GLAND - lubrication - sealing consult STEYR Marine Dealer ENGINE MOUNT SCREWS check - torque*) every 750 hours WARNING DEVICE check - function Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-25 ToC SERVICE MANUAL MARINE ENGINES GENERAL D General Information D1 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 Effect noticed Panel Indication Additional Tool-Readings Action or possible reason High engine coolant temperature limit exceeded Reduction of engine speed Horn ON 2x p. sec. Gauge reading > 107 °C Steyr Diag Power limitation See table trouble shooting: Cooling system Defect - engine coolant sensor or sensor connection Reduction of engine speed Horn ON 2x p. sec. Gauge reading > 120 °C Steyr Diag Service code Sensor or connector failure; see service code table Exhaust temperature limit exceeded Reduction of engine speed Horn and indication light "CEL" ON 2x p. sec. Steyr Diag Power limitation See table trouble shooting: Raw water cooling system Defect - Exhaust temperature sensor or sensor connection Reduction of engine speed Horn and indication light "CEL" ON 2x p. sec. Steyr Diag Service code Sensor or connector failure; see service code table Oil pressure below limit Reduction of engine speed Horn continuous and Oil indication light continous switched ON Steyr Diag Power limitation See table trouble shooting: Engine oil system Defect - Oil pressure sensor or sensor connection Reduction of engine speed Oil pressure indication Steyr Diag light switched ON 1x Service code p. sec. Insufficient boost pressure or defective sensor Reduction of engine speed Engine speed sensor fault Higher or unstable idle speed, limited performance Engine speed remains at idle Governor position system Sensor or connector failure; see service code table Steyr Diag Power limitation See table trouble shooting: Air charge system Steyr Diag Service code See table trouble shooting: Speed sensor No increase of engine speed if throttle is moved to max. Steyr Diag Service code See table trouble shooting: Accelerator potentiometer failure Irregular engine speed or stalled engine Steyr Diag Service code See table trouble shooting: Governing system Page GENERAL-26 Downloaded from www.Manualslib.com manuals search engine No RPM indication on tachometer Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Operating Parameter Effect noticed Panel Indication Inverse position shut down (SOLAS) Engine shut down beyond 70° deg. angle After engine stop horn remains switched ON until ignition reset During break in phase Cel-ON at high accelerator position (more than 75%) Indication light "CEL" is switched ON Additional Tool-Readings Action or possible reason Reset through ignition OFF and then ON Steyr Diag Break-in phase See information break in procedure Optical and accustical warning signals are explained on the following tables. "Operating Status and Error Report" D2 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. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-27 ToC SERVICE MANUAL MARINE ENGINES GENERAL D3 Extended Storage Preservation Procedure: Use following kit-numbers to have the necessary equipment for an appropriate preservation: 1st Preservation- Service Kit art.nr.Z021003-0 (valid for all 4 and 6 cylinder Marine engine models) 2nd Preservation- Service Kit art.nr. Z021004-0 (valid for all 4 and 6 cylinder Marine engine models) 1. Remove the engine from storage and place on a suitable work shop area with access to all sides of the engine. Engine must not be removed from pallet. 2. check fluid levels: engine oil (min/max on oil dipstick) engine coolant water level (min/max) gear oil- level hydraulic oil- level or existing fluid levels of other system 3. Control valve clearance according SERVICE MANUAL MARINE ENGINES Z001019-0 (chapter 03 FUEL SYSTEM) and investigate free movement of all valves. 4. NOTE: Crank engine till oil pressure is inidicated/visible. Do not start engine before oil pressure is approved. Do not crank engine over max. 30 - 40 sec.! 5. Start the engine and let it run up to temperature. 6. Stop the engine and drain the old engine oil and store for future refill and usage. 7. Fill in preservation oil (art.nr. Z050323-0, 5liter canister, adequate quantity incl. in all Preservation Service Kits) up to the minimum mark on the dip stick. 8. Connect the fuel system to a canister Z010014-0 filled with preservation fuel (art.nr.Z010014-0, 5liter canister, incl. in all Preservation Service Kits). See ill.1 9. Restart the engine and allow to run in idle for 5 minutes. 10. 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. ill.1 ill.2 NOTE: 11. ill.3 Remove the main relay K27; this will stop fuel being injected and therefore the engine from starting. See ill.2 ill.4 Page GENERAL-28 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES 12. 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 13. Fill a spray bottle with the preservation oil (art.nr. Z050323-0, 5 liter canister, adequate quantity incl. in all Preservation Service Kits). 14. Whilst cranking the engine over, by turning the start key, spray the preservation oil into the turbo inlet. See ill.5 15. Continue this process for 20 to 30 seconds. 16. Refit the fuel feed line to the engine, ensure fuel supply 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. For corrosion protection of fuel system leave system filled with preservation fuel Z010014-0 till next preservation or engine is put into operation. NOTE: 17. *Only by 2nd Preservation: After two years engine storage replace engine coolant water (art. nr. Z011785-0, 5 liter canister, adequate quantity incl. in 2nd Preservation Service Kit) and fill between min/max-level in coolant expansion tank. 18. Replace all pipes and connections to original condition and restore engine. 19. Record carried out Storage Preservation Procedure in following documents: 1) STEYR MOTORS WARRANTY REGISTRATION CARD (to find under: Operation, Maintenance and Warranty Manual Z001022/ chapter WARRANTY) 2) COMMISSIONING REPORT (to find under: Installation Manual Z001007/0 / chapter 19. APPENDIX) Ensure notification in above documents for approval of extended STEYR MOTORS BASE ENGINE WARRANTY. Otherwise BASE ENGINE WARRANTY will end for PLEASURE /COMMERCIAL duty after 1 year starting from STEYR MOTORS manufacturing date. NOTE: For manufacturing date, see on engine carton! See ill.6 20. Note the date of preservation on: 1) sticker for engine-carton (sticker incl. in corresponding Preservation Service Kit) - see ill.6 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine GENERAL ill. 5 ill. 6 Page GENERAL-29 GENERAL 2) sticker for Maintenance Log of Operation, Maintenance and Warranty Manual Z001022-0 (sticker incl. in corresponding Preservation Service Kit) - see ill.7 NOTE: This preservation procedure must be done every year and ensures that all of the air ways systems, rawwater systems, oil system and the cylinders are protected against corrosion. This procedure is repeatable up to a maximum of two times, giving a shelf life of up to three years (36 months). After 3 years stocking, starting from STEYR MOTORS manufacturing date (see ill. 6), engine must be put into operation for BASE ENGINE WARRANTY approval. However preservation procedure can be continued every year after 3 years stocking without BASE ENGINE WARRANTY approval from STEYR MOTORS. SERVICE MANUAL MARINE ENGINES MAINTENANCE LOG Sticker of 1st preservation Sticker of 2nd preservation (refer to Installation Manual P/N Z001007-0/ Chapter 18/Installation and pre-delivery inspection report) STEYR MARINE ENGINES SERVICE MANUAL ToC Date: Date: Sticker of 3rd preservation reser Date: Date: 50 h Service 150 h Service ervice Made by: Made by: Date: Date: 300 h Service 450 h Service Made by: Ma Made by: Date: Date: 600 h Service rvice 750 h Service Made by: Made by: Date: Date: 900 h Service 1,050 h Service 1,05 Made by: Made by: Date: Date: 68 ill. 7 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. Page GENERAL-30 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-31 ToC SERVICE MANUAL MARINE ENGINES GENERAL D4 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. ON 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. Page GENERAL-32 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL 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" Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-33 ToC GENERAL D5 SERVICE MANUAL MARINE ENGINES 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: M084K32 3000 rpm. M094K33 3000 rpm. M0114K33 3000 rpm. M0144M38 + BUKH STEYR SOLAS 3200 rpm. M0144V38 + BUKH STEYR SOLAS 3200 rpm M0164M40 + BUKH STEYR SOLAS 3400 rmp M0126M28 2200 rpm M0166K28 2200 rpm M0236K42 + BUKH STEYR SOLAS 3300 rpm MO256K43 3600 rpm MO256H45 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. Page GENERAL-34 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-35 ToC SERVICE MANUAL MARINE ENGINES GENERAL E QUALITY GUIDELINES FOR REPAIR E1 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. E2 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 Page GENERAL-36 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES E3 GENERAL Nomenclature Term Description disassemble remove unscrew deflange dismantle Removal of an assembly of a main assembly or of a component of an assembly without other assemblies having been removed before assemble put on, place screw on flange mount disconnect connect pull off press on unscrew tighten disassemble assemble loosen remove secure Example Putting on of an assembly on a main assembly or a component of an assembly without further assemblies being put on for functional performance Separating of connections of lines, pipes and hoses, which are separable Putting together separable connections of lines, pipes and hoses Removal of a component with press fit from another Placement of a component with press fit to another Opening of turnable locks Closing of turnable locks Removal of an assembly from a main assembly or a component from an assembly, if other assemblies have been removed before Putting on an assembly to a main assembly or a component of an assembly, if further assemblies are put on for functional achievement Partial unlocking of fixing elements of a component or of an assembly Taking off a fixing element of a component or an assembly disassemble assemble adjust Putting on a fixing element of a component or an assembly and tightening Taking apart assemblies into individual components Putting together components to an assembly Elimination of a deviation by means of provided equipment or readjust refill renew Devices or tools Adding and replenishing of operating agents Replacing an auxiliary material by a new one gauge replace Reading in actual positions in programming memory Exchanging of a device, a main assembly, an assembly or a component by the same, new or repaired ones measure check Steps taken to determine the actual status by evaluating of physical entities Steps taken to compare the actual status with a determined clean maintain Removal of foreign and auxiliary material Steps taken to keep the respective determined planned status Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Valve clearance, start of feeding operation Corrosion protection agent, sealing material, paint Valve lift, piston diameter, valve clearance, close fit, V-belt tension Page GENERAL-37 ToC SERVICE MANUAL MARINE ENGINES GENERAL E4 SI- System The following measuring units are used. Linear km m mm " Pressure and Stress = = = = kilometer meter millimeter inch Area 2 m cm2 m cm3 dm3 mm3 l = = square meter square centimeter = = = = = cubic meter cubic centimeter cubic decimeter cubic millimeter litre metric ton kilogram gram K °C = = = newton kilonewton dekanewton h min s = = Joule kilowatt hour = kilowatt = = degrees Kelvin degrees Celsius = = = hour minute second = = kilometer per hour meter per second = r.p.m. Time Velocity = = = = ampere volt ohm microfarad Fuel consumption g/kWh kW = = = Electricity A V W µF J kW/h Temperature Energy N kN daN bar pascal Kilopascal newton per square millimeter Power Mass t kg g = = = = Energy Volume 3 bar Pa KPa N/mm2 km/h m/s Speed = gram per kilowatt hour Page GENERAL-38 Downloaded from www.Manualslib.com manuals search engine 1/min Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES E5 GENERAL 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 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-39 ToC SERVICE MANUAL MARINE ENGINES GENERAL F F1 OPERATING MATERIAL AND INFORMATION ON DISPOSAL List of operating material Order No. Qty. Designation VR00207/0 1 set of fuel and oil for engine service, consisting of: Z010058/0 3 - STEYR Turbo Diesel motor oil SAE 5W-50 (4l. can.) Z011785/0 3 - STEYR MOTORS engine coolant (5l. can.) 9000190/0 2 - hydraulic oil ATF (1l. bottle) Z012222/0 1 - grease, Never - Seez; NS-160 B (1 kg can.) Z909570/0 1 - caoutchouc sealing / electric contacts (148 ml can.) 9000059/1 1 - thread protection 243 (10 ml flask) 9000297/1 1 - surface sealing 509 (315 ml cartridge) 9000510/5 1 - surface sealing 5910 (50 ml cartridge) 9000019/1 1 - construction adhesive 620 (50 ml flask) 9000017/1 1 - construction adhesive 262 (50 ml flask) Z010207/0 1 - contact grease (100 ml tube) Z010226/0 1 - corrosion protection spray (400 ml can.) Z010227/0 1 - corrosion protection wax (120 ml can.) Z010084/0 1 - grease STABURAX NBU4 (1 kg can.) Z010205/0 1 - fuel rust protection additive (5 lt can.) 9000197/0 1 - electric contact spray Z011627/0 1 - silver varnish, RAL 9006 (1 lt can) Z010074/0 1 - hardener varnish (0,5 lt can) Z010075/0 1 - dilution for varnish (5 lt can) Page GENERAL-40 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES F2 GENERAL 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 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-41 ToC SERVICE MANUAL MARINE ENGINES GENERAL G NOTES ON SAFETY G1 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. G2 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. G3 Legal rules The following rules and guidelines are valid in Austria. For other countries, follow the local regulations. Maschinen - Sicherheitsverordnung - MSV (machine safety regulations) Page GENERAL-42 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES G4 GENERAL 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: G5 - 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. Measures in case of accidents Products First Aid Skin Eyes Diesel fuel and mineral oils Remove clothes and Rinse thoroughly with Lubricants clean skin thoroughly water for at least Anti-freeze agents with water and soap 10 minutes. Brake fluid SEE A Battery acid DOCTOR! Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Swallowing DO NOT VOMIT The biggest danger after an accidental intake is the fact that liquid could get into lungs by aspiration. DO NOT PROVOKE VOMITING AND IIMMEDIATELY SEE A DOCTOR Page GENERAL-43 ToC GENERAL H Tightening Torques H1 Listing of Tightening Torques SERVICE MANUAL MARINE ENGINES Camshaft Housing Screw joint to cylinder block 1. step: 15 Nm +/- 2 2. step: 25 Nm +/- 1 Tighten screws of camshaft housing in two steps in precedence of numbering on bearings (from the inside outwards). 08.01 ill.1 Plug screw for locking pin in engine housing 50 Nm +/- 5 08.01 ill.2 Connecting rod screws (apply oil to thread and screwhead support) 1. step: 10 Nm +/- 1 2. step: 30 Nm +/- 3 3. step: 75° +/- 4° 08.01 ill. 3 Main bearing screws (apply oil to thread and screwhead support) 1. step: 35 Nm +/- 3 2. step: 45° +/- 4° 3. step: 45° +/- 4° 08.01 ill.4 Page GENERAL-44 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Flywheel screws (use LOCTITE 243 on thread) 75 Nm +/- 4 08.01 ill.5 Vibration damper screws (apply oil to thread and screwhead support) 135 Nm (2x) +/- 7 08.01 ill.6 Screw, rear ring carrier (use LOCTITE 243 on thread) 1. step: 8 Nm +/- 1 2. step: 30 Nm +/- 3 08.01 ill.7 Nut, camshaft sprocket (taper degreased on camshaft, thread lubricated) 1. step: 80 Nm +/- 4 2. step: 240 Nm +/-12 08.01 ill.8 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-45 ToC GENERAL SERVICE MANUAL MARINE ENGINES Screw tooth, belt tensioner 45 Nm +/- 4 08.01 ill.9 Valve adjustment element 55 Nm +/- 3 08.01 ill.10 Screw, linkage lever CAUTION: left-hand thread 7 Nm +/- 0,5 08.01 ill.11 Stud, unit injector 21 Nm +/- 2 08.01 ill.12 Page GENERAL-46 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL Collar nut for unit injector 18 Nm - 2 08.01 ill.13 Nut, adjustment screw of unit injector 30 Nm +/- 3 08.01 ill.14 Plug screw for control rack in camshaft housing 50 Nm +/- 5 08.01 ill.15 Screw, exhaust manifold 23 Nm +/- 2 08.01 ill.16 Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-47 ToC GENERAL SERVICE MANUAL MARINE ENGINES Studs, turbocharger M8 - 23 Nm +/- 2 M10 - 35 Nm +/-2 Nut, turbocharger (greased with NEVER SEEZ ) M8 - 25 Nm +/-2 M10 - 45 Nm +/-2 08.01 ill.17 Screws, intercooler 28 Nm +/- 2 08.01 ill.18 Plug screws, zinc anode 50 Nm +/- 5 08.01 ill.19 Crown nut, oil cooler (use LOCTITE 243 on thread) 55 Nm +/- 5 NOTE: for all clamps 3,5 Nm 08.01 ill.20 Page GENERAL-48 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES H2 GENERAL General Tightening torques Values in this table refer to industrial standard and are applicable, if no specific torques are are indicated. For studs, tightening torques are to be reduced by 50%. µ tot. *) 0.100 µ tot. 0.125 MA in Nm MA in NM Property 8.8 10.9 12.9 Nominal Ø class 8.8 10.9 12.9 Metric standard thread Nominal Ø M4 2.4 3.3 4 M4 2.7 3.88 4.6 M5 4.9 7 8 M5 5.5 8 9.5 M6 8 12 14 M6 9.5 13 16 (M 7) 13 19 23 (M 7) 15 22 26 M8 20 28 34 M8 23 32 39 M 10 40 56 67 M 10 46 64 77 M 12 69 98 115 M 12 80 110 135 M 14 110 155 185 M 14 125 180 215 M 16 170 240 285 M 16 195 275 330 M 18 235 330 395 M 18 270 390 455 M 20 330 465 560 M 20 385 540 650 M 22 445 620 750 M 22 510 720 870 M 24 570 800 960 M 24 660 930 1100 M 27 840 1200 1400 M 27 980 1400 1650 M 30 1150 1600 1950 M 30 1350 1850 2250 Nominal Ø Nominal Ø Metric standard thread M 8x1 22 30 36 M 8x1 25 35 M 10x1.25 42 59 71 M 10x1.25 49 68 42 82 M 12x1.25 76 105 130 M 12x1.25 88 125 150 M 12x1.5 72 100 120 M 12x1.5 83 115 140 M 14x1.5 120 165 200 M 14x1.5 140 195 235 M 16x1.5 180 250 300 M 16x1.5 210 295 350 M 18x1.5 260 365 435 M 18x1.5 305 425 510 M 20x1.5 360 510 610 M 20x1.5 425 600 720 M 22x1.5 480 680 810 M 22x1.5 570 800 960 M 24x2 610 860 1050 M 24x2 720 1000 1200 M 27x2 900 1250 1500 M 27x2 1050 1500 1800 M 30x2 1250 1750 2100 M 30x2 1450 2050 2500 If the tightening torque of a screw connection is not reached, the tightness of the screw/nut is too low or the ratio of friction do not correspond. In any case, the screw/nut is to be replaced. *) µ tot. = total frictional value Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-49 ToC GENERAL H3 SERVICE MANUAL MARINE ENGINES Testing of torque wrenches The torque wrenches are subject to regular tests of the set values. By doing so, the tripping value of signalling torque wrenches and the scale accuracy of measuring torque wrenches are tested. H4 Non-destructive material testing For the detection of surface cracks, the non-destructive test according to colour penetration test procedure is recommended. The workpiece is sprayed or coated with a penetration agent, and after drying a developer is applied. After a development time of appr. 10 minutes, defects on the workpiece appear as dots or lines. H5 Use of adhesive and sealing materials In the workshop manual adhesive and sealing materials are specified for the repair of engines and aggregates, which are used at operating temperatures of up to 150° C and agents such as water, coolants and hydraulic fluids, engine and gear oils as well as fuels. Solvent-free sealing materials The hardening takes places without loss of volume, so that a retightening of screw connections is not necessary. Anaerobic sealing materials These are used for securing, fixing and sealing, and only harden under exclusion of air. Solvent containing sealing materials Due to their contents of volatile parts a loss of volume occurs during hardening. During repair, the hardening time is taken into consideration. If such sealing materials are used, special reference is made in the description of the workshop manual. H6 Solvent-free sealing materials Silicon sealing materials They consist of silicon and filling materials and are free of solvents. The product is applied to the cleaned sealing surface from the tube or cartridge in form of a string. Sealing material residues are removed with cleaning agent. Silicon sealing material is to be stored below 30° C. Anaerobic sealing materials They consist of a single component epoxy in liquid form. The product is applied as a liquid to the components and remains liquid, as long as it is in contact with ambient air (oxygen). Only when the parts are assembled, chemical reaction starts due to exclusion of air (oxygen) and metal contact, i.e. transformation of liquid state into an epoxy built up by molecular chains. Any residues remaining after assembly and/or are pressed out of the connection remain liquid and may be removed easily. Page GENERAL-50 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES GENERAL General guidelines of application for the of use of anaerobic sealing materials Cleanliness of components Non-metallic surface protection must be removed. In case of repair, soiled and oily components are to be cleaned and residues of adhesive plastic material are to be removed. Thread bores are recut with the appropriate thread bore and blown out with compressed air. If solvents or degreasing agents are used for cleaning, take care that they are completely volatilized before application of the epoxyl. Storage At temperatures below 28° C, 1 year minimum. Guidelines of application for securing (S) Designation: SM ....... Securing medium tight (the connection is to be loosened without problems) Designation: SF ........Securing tight (the connection is difficult to loosen) Application: Screw connections Fixing procedure In general, the application of the epoxy to the screw thread is sufficient. If screws are screwed into socket threads, only the thread bore is wet in order to let the air escape during screwing in. Screws or nuts which are tightened with a specified torque, are slightly oiled on their support surface or housing part. Guidelines for fixing (B) Designation: BM ....... Fixing medium tight Designation: BF ........ Fixing tight Application: Jointing connections, bushings, sprockets, belt pulleys, bearings etc. Jointing procedure In case of jointing connections both jointing parts are to be wetted. The wetting has to completely cover the jointing surfaces. The parts are shifted into each other by turning, in case of slide fits. No strength may be exerted to the connection until sturdiness is reached (for time, refer to Table 1). Guidelines of application for sealing (D) Designation: DR ....... Sealing of pipe connections Designation: DF ........Sealing of plane surfaces Application: Sealing of threads , screw connections, jointing connections and plane surfaces. Hardening time Use F ixing (B ) S ecuring S ealing C lass SM SF BF DR DF DF P roduct Loctite 243 Loctite 262 Loctite 620 Loctite 509 Loctite 510 Loctite 5900 Handtightness reached after 15 - 30 min 15 - 30 min 5 - 10 min 15 - 30 min immediately immediately F unctional tightness reached after 1h 1h 1h 0.5 h immediately immediately F inal tightness reached after 3h 3h 4h 12 - 24 h 24 h 12 - 24 h Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-51 ToC SERVICE MANUAL MARINE ENGINES GENERAL J Wear Limits New part tolerance Wear Limit 0,032 - 0,099 0,080 . 0,263 0,15 0,30 Connect.rod bearing clear. radial Connect.rod bearing clear. axial 0,024 - 0,073 0,10 0,064 - 0,217 0,50 Cylinder bore 85,00 - 85,01 0,20 Piston travel clearance 0,071 - 0,099 0,20 Piston diameter 84,911 - 84,929 0,10 0,25 - 0,40 0,50 - 0,75 1,50 0,25 0,30 - 0,60 1,00 0,077 - 0,127 0,07 - 0,102 0,25 0,25 0,03 - 0,065 0,15 Camshaft axial 0,034 - 0,075 0,096 - 0,230 0,20 0,50 Valve guide 7,000 - 7,015 0,15 Part resp. part union Main bearing clearance radial Main bearing clearance axial Gap 1. ring Gap 2. ring Gap 3. ring Axial play 1. ring Axial play 2. ring Axial play 3. ring Camshaft radial Remark deviation from initial dimension indicates gauging depth up to 3 mm before end of valve guide Oil pressure idle run Oil pressure rated speed 0,6 - 1,5 0,50 4,0 - 7,0 3,00 Backlash of teeth oil pump 0,2 - 0,3 0,2 0,80 0,40 Axial play gear wheel Page GENERAL-52 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES J1 Adjustment information for service and maintenance J 1.1 Engine timing (measured with dial indicator No. 2300899/0) Setting instruction: GENERAL 3,20 +/- 0,04 mm Maintenance instruction: In case the measurements are not within the specified limits of 3,14 to 3,26 mm - than the settings needs to be reset to the original specified value. J 1.2 Tension timing belt (measured with tool VR00515/0) Tension instruction: 600 +/- 30 N (new belt) Tension instruction: 520 +/- 30 N (used belt) Maintenance instruction: In case the measurements are not within the specified limits of 630 N to 490 N - than the settings needs to be reset to the original specified value. J 1.3 Start of fuel delivery on the unit injectors (measured with dial indicator No. 2300899/0) Setting instruction: For original settings on your engine please see table 03. 02. 06 Maintenance instruction: In case the measurements are not within the specified limits the settings needs to be reset to the original specified value. J 1.4 Valve clearance (measured with tool No. 2300712/3)) Setting instruction: 0,25 mm Maintenance instruction: In case the measurements are not within the specified limits less than 0,25 more than 0,30 mm - the settings needs to be reset to the original specified value. Z001019/0_8_Octobre 2011 Downloaded from www.Manualslib.com manuals search engine Page GENERAL-53 ToC SERVICE MANUAL MARINE ENGINES GENERAL THIS PAGE IS INTENTIONALLY BLANK Page GENERAL-54 Downloaded from www.Manualslib.com manuals search engine Z001019/0_8_Octobre 2011 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01 ENGINE Table of Contents 01.00 Engine timing, engine mount ......................................................................... 3 01.00.01 Lock crankshaft ................................................................................................. 3 01.00.02 Exchange camshaft housing cover sealing ........................................................ 6 01.00.03 Maintenance timing-belt exchange .................................................................... 7 01.00.04 Remove timing belt........................................................................................... 15 01.00.05 Timing adjustment procedure for dismantled engine ....................................... 16 01.00.06 Replace engine mount and engine bracket ...................................................... 26 01.01 Cylinder block ................................................................................................ 28 01.01.01 Replace valves ................................................................................................ 28 01.01.02 Adjust valve clearance .................................................................................... 30 01.01.03 Replace valve guide ........................................................................................ 30 01.01.04 Replace pressure regulating valve for oil cooling jet ....................................... 31 01.01.05 Replace stud bolt for unit injector .................................................................... 32 01.01.06 Replace dowel pin for positioning of unit injector ............................................ 33 01.01.07 Replace dowel pin for positioning of camshaft housing ................................... 34 01.01.08 Replace external screw adaptor for oil cooler ................................................. 35 01.01.09 Replace coolant supply pipe ........................................................................... 35 01.01.10 Mount frame seal ............................................................................................ 36 01.02 Crankshaft, bearing, vibration damper ......................................................... 38 01.02.01 Replace crankshaft.......................................................................................... 38 01.02.02 Replace gear for oil pump drive ...................................................................... 42 01.03 Flywheel, housing ......................................................................................... 43 01.03.01 Replace flywheel housing ................................................................................ 43 01.03.02 Replace flywheel .............................................................................................. 44 01.03.03 Replace adapter ring ....................................................................................... 45 01.04 Piston and connecting rod ........................................................................... 46 01.04.01 Dismantle piston and connecting rod .............................................................. 46 01.05 Camshaft, housing, valve gear ..................................................................... 48 01.05.01 Replace camshaft housing .............................................................................. 48 01.05.02 Replace valve stem gasket (on engine assembly) .......................................... 52 01.05.03 Replace control rack ........................................................................................ 54 01.05.04 Replace camshaft ........................................................................................... 56 01.05.05 Replace rocker arm shaft ................................................................................ 58 01.05.06 Replace radial shaft seal of camshaft ............................................................. 59 01.05.07 Replace cam follower ...................................................................................... 60 01.05.08 Replace retainer of cam follower ..................................................................... 61 01.05.09 Replace valve adjusting element ..................................................................... 62 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 1 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06 Engine housing, oil pump, oil suction pipe ................................................ 63 01.06.01 Replace engine housing .................................................................................. 63 01.06.02 Replace support ring rear ................................................................................. 70 01.06.03 Replace rear radialshaft sealing ring ................................................................ 71 01.06.04 Replace oil pump (front ring carrier) ................................................................ 72 01.06.05 Replace oil suction pipe .................................................................................. 73 01.08 Intercooler ...................................................................................................... 74 01.08.01 Remove intercooler ......................................................................................... 74 01.08.02 Assembly of intercooler .................................................................................... 78 01.08.03 Replace intercooler - element .......................................................................... 79 01.09 Auxiliary drive, in front (PTO) ....................................................................... 81 01.13 Engine oil cooler ........................................................................................... 82 01.13.01 Replace engine oil cooler ................................................................................ 82 01.13.02 Repair oil cooler .............................................................................................. 84 01.13.03 Change motor oil .............................................................................................. 85 01.13.04 Change oil filter ................................................................................................ 86 01.14 Exhaust manifold, seals, heat exchanger ................................................... 87 Page ENGINE- 2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.00 01 ENGINE ENGINE TIMING, ENGINE MOUNT 01.00.01 Lock crankshaft Preparation: Put engine out off operation Disconnect battery Remove camshaft housing cover, 01.00.02 Special tool: for vibration damper screws No. 2300767/0 Locking pin No. 2300551/2 00.01 ill.1 1 Unscrew allen head plug screw (ill.1) (SW 10). 2 Turn crankshaft by means of special tool 2300767/0 (ill.2) until roller of rocker arm cyl. 1 runs up the ramp of injection cam (ill.3). 00.01 ill.2 00.01 ill.3 3 Insert locking pin 2300551/2 into guide hole and slightly press it against crankshaft counter weight. 00.01 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 3 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 4 Continue to turn crankshaft slowly manually in direction of rotation until locking pin engages into slot of crankshaft. ATTENTION: Never actuate starter engine as long as locking pin is inserted. 00.01 ill.5 Removal of locking pin 1 Pull out locking pin 2300551/2. 2 Screw in plug screw with hexagon socket and tighten with 50 Nm +/- 5. NOTE: Use new copper sealing. ATTENTION: Prior to starting, make sure that locking pin has been removed. 3 Clean sealing surface of camshaft housing and camshaft housing cover. Check seal for hardening and damage. Exchange, if necessary. See 01.00.02 4 Remaining assembly is done in reserve order. Page ENGINE - 4 Downloaded from www.Manualslib.com manuals search engine 00.01 ill. 6 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Explanation: (for engine timing) If the crankshaft has been locked in position as described (piston; cylinder; in TDC), the following positions are to be found in case of correct adjustment. * The bearing roller of the rocker arm on cyl. 1 is located just before the injection cam cap. * The marked tooth of the camshaft timing belt sprocket stay´s in line with the upper edge (sealing surface) of the camshaft housing. 00.01 ill.8 00.01 ill.9 * The notch on the timing belt sprocket of crankshaft is opposite to the arrow marker on the oil pump housing. 00.01 ill.10 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 5 ToC 01 ENGINE SERVICE MANUAL MARINE ENGINES 01.00.02 Exchange camshaft housing cover sealing 1 Release hexagon nuts. 2 Remove camshaft housing cover. 3 For engines with plane sealing surface. Release camshaft housing cover sealing by means of screwdriver and remove. 4 For engines with bossed sealing surface. Remove seal with a scraper and dispose. 5 Clean sealing surface of camshaft housing cover and camshaft housing. 6 For engines with plane sealing surface. Position new seal on camshaft housing cover and press it into the groove, beginning at the half-moon (ill.2). 7 For engines with bossed sealing surface. Apply LOCTITE 5900 to sealing surface of camshaft housing cover; position the new sealing on and force against the cover. 00.02 ill.1 00.02 ill.2 8 Put camshaft housing cover onto camshaft housing. Tighten with hexagon nuts SW 10. Page ENGINE - 6 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.03 Maintenance timing belt exchange Preparation: put engine out of operation disconnect battery remove camshaft housing cover Special tool: for vibration damper screws No. 2300767/0 1 2 For 4 cyl. engines Remove Poly-V-belt. See exchange of Poly-V-belt (05.06) For 6 cyl. engines Remove all V-belts. See exchange of V-belts (05.07) 3 Unscrew 3 hexagon screws (SW10) of upper V-belt covering (ill.2/pos.1) and remove V-belt covering. 4 Unscrew hexagon screws (SW 10) of lower timing belt covering (ill.2/pos.2)) and remove timing belt cover. NOTE: Special tool: See for arrows markings on used timing belt; mark timing belt if necessary. Consider change intervals - see chart "maintenance". 00.03 ill.1 00.03 ill. 2 2306031/4 dial gauge rail 4 cyl. 2306031/1 dial gauge rail 6 cyl. with bossed seal surface 2306031/6 dial gauge rail 6 cyl. with plane seal surface 2300899/0 dial gauge 2300641/1 probe pin VR00515/0 V-belt tightener 2300711/0 open end wrench VR00113/0 remover 2300551/2 locking pin 5 Mount dial gauge rail with brackets 2306031/. (see list special tool) on studs at intake side of camshaft housing. 6 Insert dial gauge 2300899/0 with probe pin 2300641/1 in dial gauge rail and put probe pin onto unit injector-plunger guide cylinder 1. 7 Turn camshaft until the roller of rocker arm is located on base circle of injection cam. 00.03 ill. 3 00.03 ill. 4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 7 ToC 01 ENGINE 8 SERVICE MANUAL MARINE ENGINES Pre-set dial gauge to position 20 mm stroke (small pointer at 20 - inside scale, big pointer at 0 - outside scale) or press zero button an digital dial gauge. 00. 00 00.03 ill.5 9 Lock crankshaft, refer 01.00.01 00.03 ill.6 10 Loosen Allen head screw SW 8 of belt tensioner and remove tensioner. 00.03 ill. 7 11 Loosen 3 TORX screws for vibration damper by means of special tool 2300767/0 and remove vibration damper. 12 Remove timing belt. ATTENTION: With loose and/or removed timing belt, the camshaft or crankshaft must not be turned. This could result in a collision of pistons and valves. 00.03 ill. 8 Page ENGINE - 8 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 13 01 ENGINE Put new timing belt onto crankshaft sprocket and camshaft sprocket (marked tooth of camshaft sprocket points at upper edge of camshaft housing). 00.03 ill.9 ATTENTION: Pay attention to arrow marker (direction of rotation) on timing belt. 00.03 ill.10 14 Mount vibriation damper. Slightly grease thread and flange of 3 TORX screws (Grease P/N Z012222/0) and tighten with torque wrench to 135 Nm +/-7. NOTE: Recheck torque after first test run. 00.03 ill.11 15 Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket, and position camshaft sprocket with marked tooth towards upper sealing edge of camshaft housing. 00.03 ill.12 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 9 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 16 Clean and degrease contact surface of tensioner and camshaft housing. Then mount tensioner. 00.03 ill.13 17 Pre tension timing belt by turning tensioner on hexagon WS 32 counterclockwise. Tighten hexagon socket SW 8 with torque wrench to 20 Nm +/- 2. 00.03 ill.14 18 Put on tension gauge No. VR00515/0 (ill.15/pos.1) between camshaft sprocket and tensioner. Pre tension timing belt tension by further counterclockwise turning of tensioner hexagon SW 32 to read 600 N +/- 30 Nm for new timing belt indication on tension gauge between green and red marked field. 1 2 ATTENTION: When putting on tension gauge No. VR00515/0, consider the following: * The two stop trunnions (ill.15/pos.2) should rest on the forehead of timing belt and must not rest on the back of timing belt. * Put measuring bow onto tooth. * During measuring, completely push in measuring bow and relax quickly. 00.03 ill.15 When attaining the required timing belt tension, tighten the Allen head screw SW 8 with torque wrench to 45 Nm +/-4, and hold up at the same time with wrench SW32. 00.03 ill.16 Page ENGINE - 10 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 19 01 ENGINE Remove locking pin from crank shaft. 00.03 ill.17 20 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx. 3.32 mm (dial gauge reading). Then turn back crank shaft by a stroke measurement of 0.5 mm on the dial gauge. NOTE: 21 Put on tension gauge No. VR00515/0 between camshaft sprocket and tensioner, as described, and read measured value. Timing belt tension should be 600 N +/- 30 N for a new timing belt. NOTE: 4x During above mentioned operation the timing belt should run into place and a uniform tension shall result for measuring of timing belt tension. 00.03 ill.18 If timing belt tension does not correspond to specified tension, loosen the tensioner and repeat adjustment according to instructions under item 21 through 24. In this case, a re-positioning of the camshaft sprocket may be required. 00.03 ill.19 22 Turn crankshaft further 2 turns, and at second turn fix crankshaft with locking pin in TDC position (cylinder 1; in TDC). See chapter 01.00.01. With crank shaft in locked position, the plunger guide stroke of the unit injector at first cylinder should show the following value on the dial gauge: 00. 00 Index value of engine timing 3.20 mm +/- 0,04 mm (plunger guide stroke - unit injector) 00.03 ill.20 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 11 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should not correspond to the specifical value, follow the instructions as per item 26. Remove camshaft sprocket 23 Loosen hexagon nut of camshaft sprocket SW 30 by holding up with special tool No. 2300711/0 and turn nut by approx. 1/4 rotation. 00.03 ill.22 24 Mount extractor (ill.23/pos.1) camshaft sprocket VR00113/0 and screw in puller screw "LEFTHAND THREAD" by hand. Prestress puller screw with approx. 100 Nm +/-5. NOTE: 1 Do not remove camshaft sprocket from conical seat when screwing in the puller screw. 00.03 ill.23 25 Remove camshaft sprocket from concial seat by one hammer blow on puller screw. NOTE: To correct the setting of engine timing, follow further instructions as per item 26. 00.03 ill.24 Page ENGINE - 12 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Readjustment of camshaft position in case of correction of set engine timing This is to be carried out, if the index value of the engine timing is not within the allowed adjustment tolerance. 26 Check locking position of crankshaft or lock crank shaft, if necessary. (piston; cylinder 1; in TDC). Refer 01.00.01 27 Adjust camshaft to 3.27 mm on the dial gauge, by turning with special tool 2300711/0 (ill.26).(plunger guide at unit injector is moved down by 3,27 mm.) õ NOTE: 00.03 ill.25 NOTE: 28 1 During this operation, the camshaft sprocket must be released from the taper connection and should only slightly supported by the cone. Tension of timing belt remains adjusted, as described before. Remove locking pin from crankshaft. Refer 01.00.01 00.03 ill.26 29 Tighten hexagon nut SW 30 of camshaft sprocket to 80 +/-4 Nm by holding up with special tool 2300711/ 0 at hexagon on camshaft. ATTENTION: During this operation, camshaft sprocket and camshaft are connected positively. A positive connection is only achieved by tightening the hexagon nut with 240 +/-12 Nm. The previously set stroke on the unit plunger guide must not be changed when tightening the hexagon nut. 00.03 ill.27 30 Turn crankshaft by 2 further turns, and at the second turn fix crankshaft with locking pin in TDC position (cylinder 1; in TDC). See chapter 01.00.01. With locked crankshaft, the plunger guide stroke of unit injector at first cylinder should show the following dial gauge value: 00. 00 Index value of engine timing 3.20 mm +/- 0,04 mm (plunger guide stroke - unit injector) 00.03 ill.28 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 13 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should not correspond to the allowed value, follow the instructions as per item 24. 31 In case of correct index value of engine timing, tighten hexagon nut of camshaft sprocket SW 30 with 240 +/-12 Nm by holding up with special tool No. 2300711/0. 32 ATTENTION: The following torques are to be checked again: 1 Torque on hexagon nut of camshaft sprocket SW 30 240 +/-12 Nm. 2 Fillister socket head screw SW 8 of timing belt tensioner at 45 +/-4 Nm. 3 3 TORX screws on vibration damper with 135 +/-4 Nm. 33 Remove locking pin on crankshaft. Page ENGINE - 14 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.04 Remove timing belt Preparation: put engine out of operation disconnect battery remove camshaft housing cover Special tool: for vibration damper screws No. 2300767/0 1 2 For 4 cyl. engines Remove Poly-V-belt. See exchange of Poly-V-belt (05.06) For 6 cyl. engines Remove all V-belts. See exchange of V-belts (05.07) 3 Unscrew 3 hexagon screws (SW10) of upper V-belt covering (ill.2/pos.1) and remove V-belt covering. 4 Unscrew hexagon screws (SW 10) of lower timing belt covering (ill.2/pos.2)) and remove timing belt cover. NOTE: See for arrows markings on used timing belt; mark timing belt if necessary. Consider change intervals - see chart "maintenance". 5 Lock crankshaft, see 01.00.01 6 Loosen Allen head screw (SW 8) of belt tensioner and remove tensioner. 7 Loosen 3 TORX screws for vibration damper by means of special tool 2300767/0 and remove vibration damper. 8 Remove timing belt. 00.04 ill.1 00.04 ill. 2 00.04 ill. 3 ATTENTION: With loose and/or removed timing belt, the camshaft or crankshaft must not be turned. This could result in a collision of pistons and valves. MOUNT TIMING BELT - see adjust engine timing; 01.00.04 00.04 ill. 4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 15 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.05 Timing adjustment procedure for dismantled engine Function description: Time control of injection and valves are consistent due to the special camshaft design (3 cams per cylinder). During adjustment, pay attention to essential functional elements, such as unit injector, timing belt tension and sense of rotation of engine, in order to achieve the required setting accuracy of injection. A change of the timing belt tension or the sense of rotation during adjustment always causes wrong positioning of the injection control.For this reason it is to be ensured that the adjusting procedure follows the conditions of real operation. Status for job: * Camshaft housing cover dismantled. * Set up crankshaft to approx. 40° crank angle before TDC (piston; cylinder 1; in TDC) in order to set all pistons in the engine to approximately the same length of stroke, thus providinge open space for the valve movement (stroke). This ensures that the camshaft may be turned to the desired position (injection stroke - unit injector cylinder 1) without problems. * Crankshaft position with dismantled vibration damper. * Crankshaft position with mounted damper, if timing belt has not been removed. NOTE: Before disassembly, mark the vibration damper, with locked crankshaft. A corresponding marking must be made on the timing belt cover. * Unit injectors mounted and adjusted. See 03.02.02 and 03.02.06. * Valve clearance set. Special tool.: 00.05 ill.1 2306031/4 dial gauge rail 4 cyl. 2306031/1 dial gauge rail 6 cyl. with bossed seal surface 2306031/6 dial gauge rail 6 cyl. with plane seal surface 2300899/0 dial gauge 2300641/1 probe pin VR00515/0 V-belt tightener 2300711/0 open end wrench VR00113/0 remover 2300551/2 locking pin Page ENGINE - 16 Downloaded from www.Manualslib.com manuals search engine 00.05 ill.2 00.05 ill.3 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 1 Mount dial gauge rail with brackets 2306031/. (see list special tool) on studs at intake side of camshaft housing. 2 Insert dial gauge 2300731/0 with probe pin 2300641/1 in dial gauge rail and put probe pin onto unit injector-plunger guide cylinder 1. 01 ENGINE 00.05 ill.4 3 Turn camshaft until the roller of rocker arm is located on base circle of injection cam. 00.05 ill.5 4 Pre-set dial gauge to position 20 mm stroke (small pointer at 20 - inside scale, big pointer at 0 - outside scale). 00. 00 00.05 ill.6 5 Slowly turn camshaft in direction of rotation until dial gauge shows a stroke of 2 mm (injection stroke at unit injector). Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 17 ToC 01 ENGINE 6 Continue to turn crankshaft in direction of rotation and position it with locking pin on TDC (piston; cylinder 1; in TDC). See chapter 01.00.01. 7 Continue to turn camshaft slowly in direction of rotation until a total distance of 3.32 mm can be read on the dial gauge (plunger stroke at unit injector). Assembly of camshaft sprocket 8 SERVICE MANUAL MARINE ENGINES 00.05 ill.7 Clean and degrease cone on camshaft and in camshaft sprocket. ATTENTION: Very high for as are transmitted via this conical seat. Therefore, it is extremely important that the two cone surfaces are assembled absolutely clean and grease-free. 00.05 ill.8 9 Shift camshaft sprocket onto cone and slightly lubricate thread at front end of camshaft. Slightly turn hexagon nut and washer by hand. The camshaft sprocket should only slightly be supported by the cone, in this status on easily turning of the camshaft sprocket must be possible. 00.05 ill.9 Put timing belt onto pre-positioned crankshaft sprocket (Lock crank shaft - see 01.00.01) and camshaft sprocket (marked tooth of camshaft sprocket points at upper edge of camshaft housing). • õ 10 00.05 ill.10 Page ENGINE - 18 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE ATTENTION: Pay attention to arrow marker (direction of rotation) on timing belt. 00.05 ill.11 11 Mount vibriation damper. Slightly grease thread and flange of 3 TORX screws (Grease P/N Z012222/0) and tighten with torque wrench to 135 Nm +/-7. NOTE: Recheck torque after first test run. 00.05 ill.12 12 Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket, and position camshaft sprocket with marked tooth towards upper sealing edge of camshaft housing. 00.05 ill.13 13 Clean and degrease contact surface of tensioner and camshaft housing. Then mount tensioner. 00.05 ill.14 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 19 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 14 Prestress timing belt by turning tensioner on hexagon (WS 32) counterclockwise. Tighten hexagon socket (SW 8) with torque wrench to 20 Nm +/- 2. 15 Put on tension gauge No. VR00515/0 (ill.16/pos.1) between camshaft sprocket and tensioner. Prestress timing belt tension by further counterclockwise turning of tensioner hexagon (SW 32) to 710 N +/30 N for new timing belt. NOTE: 600 N +/- 30 N for used timing belt 00.05 ill.15 1 2 ATTENTION: When putting on tension gauge No. VR00515/0, consider the following: * The two stop trunnions (ill.16/pos.2) should rest on the forehead of timing belt and must not rest on the back of timing belt. * Put measuring bow onto tooth. * During measuring, completely push in measuring bow and relax quickly. 00.05 ill.16 When attaining the required timing belt tension, tighten the Allen head screw (SW 8) with torque wrench to 45 Nm +/-4, and hold up at the same time with wrench (SW32). 00.05 ill.17 16 Tighten hexagon nut (SW 30) of camshaft sprocket to 80 Nm +/- 4, by holding up with special tool 2300711/0 at hexagon on camshaft. ATTENTION: The preset stroke at the unit injector (3.32 mm) must not be changed when tightening the hexagon nut. During this operation step, camshaft sprocket and camshaft are connected measurement purpose. A positive connection is only achieved by finally tightening the hexagon nut with 240 Nm +/-12. 00.05 ill.18 Page ENGINE - 20 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 17 01 ENGINE Remove locking pin from crank shaft. 00.05 ill.19 18 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx. 3.30 mm (dial gauge reading). Then turn back crank shaft by a stroke measurement of 0.5 mm on the dial gauge. NOTE: 4x During above operation mentioned on the timing belt shall be positioned correctly and a uniform tension is set up for measuring of timing belt tension. 00.05 ill.20 19 Put on tension gauge No. VR00515/0 between camshaft sprocket and tensioner, as described under item 15, and read measured value. Timing belt tension should be 600 N +/- 15 N for a new timing belt. NOTE: for a used timing belt 520 N +/- 30 N NOTE: If timing belt tension does not correspond to desired value, loosen the tensioner and repeat adjustment according to instructions under item 14 to 19. In this case, a re-positioning of the camshaft sprocket may be required. 00.05 ill.21 20 Turn crankshaft further 2 turns, and at second turn fix crankshaft with locking pin in TDC position (cylinder 1; in TDC). See chapter 01.00.01. With crank shaft in locked position, the plunger guide stroke of the unit injector at first cylinder should show the following value on the dial gauge: 00. 00 Index value of engine timing 3.20 mm +/- 0,04 mm (plunger guide stroke - unit injector) 00.05 ill.22 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 21 ToC 01 ENGINE SERVICE MANUAL MARINE ENGINES NOTE: If the index value of engine timing should not correspond to the desired value, follow the instructions as per item 24. 21 In case of a correct index value of engine timing, tighten the hexagon nut of the camshaft sprocket (SW 30) with 240 Nm by holding up with special tool No. 2300711/0. 00.05 ill.23 ATTENTION: The following torques are to be checked again. õ 22 1 Torque on hexagon nut of camshaft sprocket (SW 30) 240 Nm +/- 12 2 Allen head screw (SW 8) of timing belt tensioner at 45 Nm +/- 4 3 3 TORX screws on vibration damper with 135 Nm +/- 7 23 Remove locking pin on crankshaft. 00.05 ill.24 Page ENGINE - 22 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Remove camshaft sprocket 24 Loosen hexagon nut of camshaft sprocket (SW 30) by holding up with special tool No. 2300711/0 and turn nut by approx. 1/4 rotation. 00.05 ill.25 25 Mount extractor (ill.26/pos.1) camshaft sprocket VR00113/0 and screw in puller screw "LEFTHAND THREAD" by hand. Prestress puller screw with approx. 100 Nm +/-5. NOTE: 1 Do not remove camshaft sprocket from conical seat when screwing in the puller screw. 00.05 ill.26 26 Remove camshaft sprocket from concial seat by one hammer blow on puller screw. NOTE: To correct the setting of engine timing, follow further instructions as per item 27. 00.05 ill.27 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 23 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Readjustment of camshaft position in case of correction of set engine timing This is to be carried out, if the index value of the engine timing is not within the allowed adjustment tolerance. 27 Check locking position of crankshaft or lock crank shaft, if necessary. (piston; cylinder 1; in TDC). See 01.00.01 28 Adjust camshaft to 3.27 mm on the dial gauge, by turning with special tool 2300711/0 (ill.29).(plunger guide at unit injector is moved down by 3,27 mm.) õ NOTE: 00.05 ill.28 NOTE: 29 1 During this operation, the camshaft sprocket must be released from the taper connection and should only slightly supported by the cone. Tension of timing belt remains adjusted, as described before. Remove locking pin from crankshaft. See 01.00.01 00.05 ill.29 30 Tighten hexagon nut (SW 30) of camshaft sprocket to 80 Nm +/-4 by holding up with special tool 2300711/ 0 at hexagon on camshaft. ATTENTION: During this operation, camshaft sprocket and camshaft are connected positively. A positive connection is only achieved by tightening the hexagon nut with 240 Nm +/-12. The previously set stroke on the unit plunger guide must not be changed when tightening the hexagon nut. 00.05 ill.30 31 Turn crankshaft by 2 further turns, and at the second turn fix crankshaft with locking pin in TDC position (cylinder 1; in TDC). See chapter 01.00.01. With locked crankshaft, the plunger guide stroke of unit injector at first cylinder should show the following dial gauge value: 00. 00 Index value of engine timing 3.20 mm +/- 0,04 mm (plunger guide stroke - unit injector) 00.05 ill.31 Page ENGINE - 24 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES NOTE: 01 ENGINE If the index value of engine timing should not correspond to the allowed value, follow the instructions as per item 24. 32 In case of correct index value of engine timing, tighten hexagon nut of camshaft sprocket (SW 30) with 240 Nm +/-12 by holding up with special tool No. 2300711/0. 33 ATTENTION: The following torques are to be checked again: 1 Torque on hexagon nut of camshaft sprocket (SW 30) 240 Nm +/-12. 2 Fillister socket head screw (SW 8) of timing belt tensioner at 45 Nm +/-4. 3 3 TORX screws on vibration damper with 135 Nm +/-4. 34 Remove locking pin on crankshaft. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 25 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.06 Replace engine mount and engine bracket ATTENTION: 1 Slightly lift the engine by means of suspension VR 00130/0 at lifting shackles (ill.1/pos.1) (approx. 3500 N). Replace engine mount 00.06 ill.1 1 Loosen hexagon nut (SW24), remove washer. 2 Loosen two setscrews (SW17) of engine mount, remove engine mount. NOTE: After assembly of the engine mount, center the engine to correct axis geometry of drive unit. Replace engine bracket 1 00.06 ill.2 For 4 cyl. engines Loosen 7 allen head screws (SW6), remove bracket and 7 washers. NOTE: During assembly, secure allen head screws with LOCTITE 243 (9000059/1) and tighten with a torque of 23 +/- 2 Nm. 00.06 ill.3 1 For 6 cyl. engines Loosen 4 allen head screws (SW8), remove bracket and 4 washers. NOTE: During assembly, secure allen head screws with LOCTITE 243 (9000059/1) and tighten with a torque of 64 +/- 5 Nm. 00.06 ill.4 Page ENGINE - 26 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Exchange bracket on flywheel housing 1 Loosen 4 allen head screws (SW10) and remove support. NOTE: During assembly, secure allen head screws with LOCTITE 243 (9000059/1) and tighten with a trorque of 75 +/- 5 Nm. 00.06 ill.5 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 27 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01 01.01.01 CYLINDER BLOCK Replace valves Preparation: 1 Disassemble engine housing, 01.06.01, Disassemble crankshaft, 01.02.01, Disassemble pistons, 01.04.01. Insert special tool No. VR00104/00 in cylinder bore and tighten sturdily with two hexagon screws (SW19). 01.01 ill.1 2 Mount valve spring retainer No. VR00105/1 . 01.01 ill.2 3 Prestress valve spring with hexagon nut (SW28). 01.01 ill.3 4 Remove wedges. 5 Relax valve spring again, remove valve spring, spring plate and spring washer. 6 Remove special tool from cylinder bore, remove valves. 01.01 ill.4 Page ENGINE - 28 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 7 01 ENGINE Pull out valve stem gasket with special tool No. 2300758/0. 01.01 ill.5 NOTE: When inserting the valves, lubricate valve stem with motor oil. 8 Put special tool No. V000152/0 onto valve stem end and pull on new valve stem over sleeve. 9 Remove sleeve and press on valve stem gasket with special tool No. V000166/0 until valve stem gasket is supported on collar of valve guide. 10 Lubricate valve stem (motor oil). 11 Mount special tool No. VR00104/0 again. 01.01 ill.6 12 Put on spring washer, valve spring and spring plate and prestress valve spring with special tool No. VR00105/1. NOTE: 13 The progressively wound end of the valve spring is located on the cylinder block. Insert wedges, relax valve spring and check correct seat of wedges. 01.01 ill.7 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 29 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.02 Adjust valve clearance Preparation: Remove camshaft housing cover 1 2 3 Valve clearance is adjusted by means of special tool No. VR 00125/0 and adjusting gauge 2300712/3 (ill.1/pos.1) between camshaft base circle (ill.1/pos.2) and cam follower (ill.1/pos.3). NOTE: 01.01.03 index value outlet valve index value intake valve 0.25 mm 0.25 mm 01.02 ill.1 Replace valve guide Preparation: Disassemble valves, 01.01.01. 1 Press out valve guide with special tool VR00154/0. 2 Insert valve guide with special tool VR00109/0. 01.03 ill.1 Page ENGINE - 30 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.01.04 01 ENGINE Replace pressure regulating valve for oil cooling jet Preparation: Disassemble engine casing 01.06.01 Remove pressure regulating valve with open-end wrench (WS13). ATTENTION: Screw in pressure regulating valve until front collar is seated in bore. Screw in pressure regulating valve sturdily. 01.04 ill.1 NOTE: Secure thread with structural adhesive LOCTITE 262. ATTENTION: Only tested valves with an opening pressure of 1.6 bar (+/- 0,15 bar) to be used. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 31 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.05 Replace stud bolt for unit injector Preparation: Remove camshaft housing cover, 01.05.01 Remove unit injector, 03.02.02 1 Tighten threaded pin with a torque of 21 +/- 1 Nm. 01.05 ill.1 Page ENGINE - 32 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.01.06 Replace dowel pin for positioning of unit injector Preparation: 1 01 ENGINE Disassemble camshaft housing, 01.05.01. Insert new dowel pin by means of setter. 01.06 ill.1 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 33 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.07 Replace dowel pin for positioning of camshaft housing Preparation: Disassemble camshaft housing, 01.05.01. Insert new dowel pin by means of setter. 01.07 ill.1 ATTENTION: Do not close oil supply duct with dowel pin in front. (see illustration below) ENGINE DAMAGE! Cylinder 1 Oil supply duct Dowel pin 01.07 ill.2 Page ENGINE - 34 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July2008 ToC SERVICE MANUAL MARINE ENGINES 01.01.08 01 ENGINE Replace external screw adaptor for oil cooler Preparation: Disassemble oil cooler, 01.06.01. 2 1. Screw in external screw part (ill.1/pos.1) with a torque of 100 Nm +/-5. 2. Put on new O-ring. (ill.1/pos.2) 1 01.08 ill.1 01.08 ill.2 01.01.09 Replace coolant supply pipe 1 Preparation: Disassemble control solenoid, 03.08. 1 Loosen hose clamp (ill.1/pos.1), remove hose. 2 Loosen three allen head screws (SW5) (ill.1/pos.2), remove coolant supply pipe. NOTE: 2 Use new seal for assembly. 01.09 ill.1 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 35 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.10 Mount frame seal Preparation: 1 Disassemble engine housing, 01.06.01, Disassemble crankshaft, 01.02.01, Clean and degrease groove in cylinder block. 01.10 ill.1 2 For engines with rubber frame seal (slot-variant) (item 2-7) Apply construction adhesive LOCTITE 262 on both sides of first profile groove of frame seal. 01.10 ill.2 3 Apply activator 764 to groove in the cylinder block. 01.10 ill.3 4 Put frame seal from the bottom over the cylinder block. 5 Bourrelet of frame seal profile must be placed at the front (coolant pump) in the center of the side of cylinder block.. Important for later assembly of engine housing. 01.10 ill.4 Page ENGINE - 36 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 6 Press frame seal into cylinder block groove, beginning at the cylinder block corner and then along side of the block. NOTE: 7 01 ENGINE Only press in the rubber of the frame seal by hand. Do not stretch or displace. Pay attention do least curing time and curing temperature. Also see manufacturer's specifications. ATTENTION: Pay attention to safety notes/rules. For engines with frame seal with alu support (screwed variant) - (item 8-9) Special tool 4 cyl. V000307/0 6 cyl. V000306/0 Installation device 8 Slide frame seal using special tool into block-groove. NOTE: 9 10 For easier installation of frame seal apply alcohol on sealing profil. The alcohol will serve as a lubrication agent during installation process. Clean of the frame seal lip and the block slot using Acetone or a non oil based cleaner (pure alcohol) and give time for this dry before continuing. Place Loctite activator #7649 (see below) on the upper edge of the frame seal lip and in the slot of the block. After waiting 2 minutes for Activator to work, apply Loctite 620 (green) on the upper edge of the frame seal lip 01.10 ill.6 Press frame seal into cylinder block groove, beginning at the cylinder block corner and then along side of the block. NOTE: 11 01.10 ill.5 Only press in the rubber of the frame seal by hand. Do not stretch or displace. Secure the frame seal to the housing using the screws and Loctite 243 (blue), tighten to 10 Nm. 01.10 ill.7 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 37 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.02 01.02.01 CRANKSHAFT, BEARING, VIBRATION DAMPER Replace crankshaft Preparation: Disassemble flywheel housing and flywheel, 01.03.01 und 01.03.02, Disassemble timing belt and vibration damper, Dissamble engine housing, 01.06.01, Disassemble oil suction pipe, 01.06.03. Disassemble oil pump housing, 01.06.02, 02.01 ill.1 1 Turn crankshaft in such a way that first cylinder is located at TDC, and secure with locking pin No. 2300551/2. ATTENTION: While disassembling the connecting rod bearing caps and the main bearing caps, the crankshaft may not be turned. 02.01 ill.2 2 Loosen the two screws of each connecting rod with special tool 2300746/0, remove connecting rod bearing caps with bearing shell. Push down all pistons and connecting rods to TDC position. NOTE: 3 Remain with crank shaft in position during work operation to avaid damange the bearings. Never turn crank shaft. Remove rocking pin. 02.01 ill.3 4 Loosen two screws of each main bearing cap with special tool No. 2300747/0, remove main bearing shells and caps. 5 Lift out crankshaft. Remove thrust bearings from main bearing section. ATTENTION: When removing, take care that released connecting rods do not hit against cylinder liner! 02.01 ill.4 Page ENGINE - 38 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 6 Remove main bearing blocks. 7 Pull out oil nozzles for piston cooling. 01 ENGINE 02.01 ill.5 02.01 ill.6 8 Remove main bearing shells from bearing blocks. NOTE: 9 For assembly, lubricate all bearing with engine oil. All pistons with connecting rods are inserted in the cylinder bore. Mount injection oil nozzles with new Orings. When inserting the crankshaft, take care that the first connecting rod journal pin is positioned at TDC. Check, fot proper installation main bearing shells and connecting rod bearing shells. 02.01 ill.7 ATTENTION:Main bearing base and main bearing cap are marked with consequential numbers on one side of the bearing cast. Make sure this number between base and bearing cap match. 02.01 ill.8 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 39 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 10 Insert the two upper thrust bearing segments onto main bearing cap and mount main bearing cap. Install remaining main bearing caps with bearing shalls and tighten main bearing screws sturd. 11 Mount connecting rod cap with bearing shell. (pay attention to numbering). 02.01 ill.9 Tightening specification for connecting rod screws (thread and screw head support lubricated) 1st working step: all screws 2nd working step: all screws 3rd working step: all screws 10 Nm +/-1 30 Nm +/-3 75 ° +/-4° Special tool No. 2300706/0 ATTENTION: Use screws only twice. After tightening, mark with center punch. 02.01 ill.10 Tightening specification for main bearing screws (thread and screw head support lubricated): 1st working step: all screws 2nd working step: all screws 3rd working step: all screws 35 Nm +/-3 45 ° +/-4° 45 ° +/-4° Special tool No. 2300706/0 Tightening sequence 4 cyl. engines 02.01 ill.11 10 7 1 5 4 8 9 2 3 6 12 13 5 1 4 9 8 14 11 6 2 3 7 10 6 cyl. engines Page ENGINE - 40 Downloaded from www.Manualslib.com manuals search engine 02.01 ill.12 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Measuring of end clearance Put on magnetic holder with dial gauge, put dial gauge caliper onto crankshaft end. Move crankshaft in forward direction and set dial gauge to zero. Move crankshaft backwards and read measured value. Clearance should be between 0.07 and 0.25 mm. 02.01 ill.13 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 41 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.02.02 Replace gear for oil pump drive Preparation: Disassemble engine housing, 01.06.01, Disassemble timing belt, Disassemble oil pump, 01.06.02, Disassemble oil suction pipe, 01.06.03. 2 3 1 Remove woodruff key.(ill.1/pos.1) 2 Pull off gear (ill.1/pos.2) with sleeve ring (ill.1/pos.3). 1 NOTE: 3 Apply surface sealing agent 509 to contact surfaces of gear towards crankshaft and sleeve ring. 02.02 ill.1 Place oil pump drive gear with larger chamfer against crank shaft contact surface to clear machined shaft radius. (ill.2/pos.1) 1 02.02 ill.2 Page ENGINE - 42 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.03 01.03.01 01 ENGINE FLYWHEEL, HOUSING Replace flywheel housing Preparation: Dismantle engine mount of flywheel housing, 01.00.04. 1 Loosen 6 hexagon sockets (SW8 and 4) hexagon sockets (SW6). 2 Remove flywheel housing from adjusting sleeve (ill.1/ pos.1). 3 For SOLAS models only 1 03.01 ill.1 First loosen screw (ill.2/pos.1) and fix blow-by valve above flywheel housing. 4 Assembly is done in reverse order. 1 03.01 ill.2 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 43 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.03.02 Replace flywheel Preparation: disassemble torsion coupling, 02.01 disassemble intermediate ring, 01.03.03 1 Lock crankshaft, 01.00.01 2 Loosen eight hexagon head screws (SW17) and remove flywheel. NOTE: Apply thread protection LOCTITE 243 to hexagon head screws and tighten with a torque of 75 Nm +/-4. Page ENGINE - 44 Downloaded from www.Manualslib.com manuals search engine 03.02 ill.1 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.03.03 01 ENGINE Replace adapter ring Preparation: Dismantle flywheel housing, 01.03.01. For 6 cyl. engines 1 Loosen 9 hexagon head screws (SW13), remove adapter ring. NOTE: Screw tensile strength - 10.9 Tighten hexagon screws with a torque of 30 Nm +/-3. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 03.03 ill.1 Page ENGINE - 45 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.04 01.04.01 PISTON AND CONNECTING ROD Dismantle piston and connecting rod Preparation: dismantle engine housing, 01.06.01 disassemble crankshaft, 01.02.01. 1 Pull out piston with connecting rod. 2 Remove retainer ring of piston pin by means of a screwdriver. 04.01 ill.1 04.01 ill.2 3 Push out piston pin, remove piston from connecting rod. 04.01 ill.3 4 Remove piston rings by means of piston ring pliers. Special tool: piston ring pliers 2300906/0 ATTENTION: For assembly of piston rings, take care of marking "TOP". In case of a change of cylinder diameter, take care of respective repair steps. 04.01 ill.4 Page ENGINE - 46 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE ATTENTION: For assembly of piston and connecting rod, take care that positioning groove of connecting rod bearing is opposite to the clearance for injection oil nozzle. NOTE: For best result position rings with piston gap about one third of a turn a part from each other gap. NOTE: When inserting the piston into cylinder bore, with special tool No. 2300714/1, take care that arrow marking on piston bottom shows to the front. 04.01 ill.5 04.01 ill.6 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 47 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05 01.05.01 CAMSHAFT, HOUSING, VALVE GEAR Replace camshaft housing Preparation: Empty fuel system, 03.02.02 item 2. Disconnect battery. Disconnect crankshaft from TDC, 01.00.01. Dismantle all unit injectors, 03.02.02. 1 Loosen all control links and turn to the back (ill.1/ pos.1). ATTENTION: LEFTHAND THREAD (ill.1/pos.2) 1 2 05.01 ill.1 2 Release timing belt, dismantle tightener. 3 Remove timing belt from gear. 05.01 ill.2 4 For 4 cyl. engines Loosen 3 hexagon nuts (SW13) (ill.3/pos.1) and remove. Remove indexing plate. C1 C1 05.01 ill.3 Page ENGINE - 48 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE C3 For 6 cyl. engine (item 5-8) 5 Remove plug (ill.4/pos.1) for sensor of control rack. Remove control rack. 6 Loosen plug (ill.4/pos.2) for potentiometer accelerator. 7 C1 Loosen 3 hexagon screws (SW13) (ill.4/pos.3) and remove. Remove bracket with potentiometer. C2 OFF 05.01 ill.4 8 Remove plug (ill.5/pos.1) from control solenoid. C1 05.01 ill.5 For 4 cyl. engine (item 9-12) 9 Remove plug (ill.6/pos.1) from control solenoid. 10 Remove plug (ill.6/pos.3) for sensor of control rack. 11 Loosen plug (ill.6/pos.2) for potentiometer accelerator. C1 C3 C2 õ 05.01 ill.6 12 Dismantle supportig strap (ill.7/pos.1) between cam shaft housing and intercooler. C1 05.01 ill.7 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 49 ToC 01 ENGINE SERVICE MANUAL MARINE ENGINES For 6 cyl. engines (item 13-15) 13 Loosen setscrews (ill.8/pos.1) for support of raw water pipe. 14 Loosen hose clamp (ill.8/pos.2 and ill.9/pos.1) and dismantle raw water pipe and bend. 15 Dismantle cover (ill.8/pos.3) to intercooler by loosening 5 hexagon screws (SW10). C2 C3 C1 05.01 ill.8 C1 05.01 ill.9 16 Disconnect speed sensor (ill.10/pos.1). C1 05.01 ill.10 17 Loosen hexagon screws (SW13) (ill.11). 18 Remove camshaft housing upwards. Remove sealing. 05.01 ill.11 Page ENGINE - 50 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE Assembly of camshaft housing 1 2 Clean sealing surfaces of motorblock (ill.12/pos.1) and camshaft housing (ill.12/pos.2). 2 Put on camshaft housing sealing (ill.12/pos.3). 1 ATTENTION: Always use new sealing! 3 05.01 ill.12 3 Put on camshaft housing. Take care that all cam followers (ill.13/pos.1) rest on valve stems (ill.13/pos.2), are positioned and aligned accordingly. 1 2 05.01 ill.13 4 Crankshaft must be set up to approx. 40° before TDC, to avoid a collosion of valves with pistons. 5 Tighten screws of camshaft housing in two steps in precedence of numbering to be read at the bearings (from inside outwards). Torque: 1. step 2. step 15 Nm +/- 1 25 Nm +/- 2 05.01 ill.14 6 Assembly unit injectors; refer 03.02.02 7 Adjust unit injectors, refer to 03.02.06. 8 Adjust valves, refer to 01.01.02. 9 Adjust control links (mass equalization), refer to 03.02.04. 10 Adjust control, refer to 01.00.03. 11 Calibrate sensor for main rack position, refer to 06.10. 03 12 Assembly engine in reversed order. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 51 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.02 Replace valve stem gasket (on engine assembly) Preparation: Disassemble camshaft housing, 01.05.01. ATTENTION: Set piston of respective cylinder on TDC. 1 Mount valve spring retainer No. VR00105/1 (ill.1). 2 Presstress valve spring (ill.2) with hexagon socket (SW28). 05.02 ill.1 05.02 ill.2 3 Remove wedges. 4 Relax valve spring again, remove valve spring and spring washer. 05.02 ill.3 5 Remove valve stem gasket with special tool No. 2300758/0. 05.02 ill.4 Page ENGINE - 52 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 6 Put special tool No. V000152/0 onto valve stem end and push new valve stem gasket over sleeve. 7 Remove sleeve and press on valve stem gasket with special tool No. V000166/0 until valve stem is supported on collar of valve guide. 8 Lubricate valve stem (motor oil). 9 Put on valve spring and spring washer and prestress with special tool No. VR00105/1. NOTE: 10 01 ENGINE 05.02 ill.5 Progressively wound end of valve spring is located at cylinder block. Put in wedges, relax valve spring, check correct seat of wedges. NOTE: In case of replacing other valve stem gaskets, take care that respective piston is set to TDC. 05.02 ill.6 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 53 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.03 Replace control rack Preparation: Drain fuel system, 03.02.02 item 2. Disassemble camshaft housing cover, 01.05.01. Disassemble control solenoid, 03.08.01. Disassemble unit injector of 1st cylinder, 03.02.02. 05.03 ill.1 1 Disassemble handle to control solenoid by loosening two hexagon screws (SW8) (ill.2/pos.1). 1 05.03 ill.2 2 Disassemble all control links (ill.3/pos.1) by loosening hexagon socket (SW4) (ill.3/pos.2). 1 ATTENTION: LEFTHAND THREAD 2 05.03 ill.3 3 Remove setpin (ill.4/pos.1) from last bulkhead. 1 05.03 ill.4 Page ENGINE - 54 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 4 01 ENGINE Loosen locking screw (SW22) (ill.5), remove sealing ring, pull out control rod to the back. NOTE: Connection of lefthand thread screws and control links to be opened three times only. 05.03 ill.5 5 Adjust control link (mass equalization), refer to 03.02.04. 6 Adjust control, refer to 01.00.03. 7 Calibrate rack position, refer to 06.10.03 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 55 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.04 Replace camshaft Preparation: 1 disassemble camshaft housing, refer to 01.05.01. Loosen hexagon nut (SW30). (ill.1/pos.1) 2 1 05.04 ill.1 2 Disassemble camshaft wheel with special tool No. VR00113/0 (ill.2), remove washer. 05.04 ill.2 3 Remove axial holder of camshaft and rocker arm shaft. (ill.3) 05.04 ill.3 4 Disassemble all cam followers, refer to 01.05.07. 05.04 ill.4 Page ENGINE - 56 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 5 Push out camshaft (ill.5) with radial shaft seal to the front. 6 Pull out camshaft from the front of camshaft housing. 01 ENGINE ATTENTION: On all 4 cyl. and 6 cyl. engines before: 68224400 At the rear end of camshaft (ill.1/pos.2) the speed sensor wheel is located. When pulling out and pushing in the camshaft, take care that bearings of camshaft are not damaged. 05.04 ill.5 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 57 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.05 Replace rocker arm shaft Preparation: Disassemble camshaft housing cover, 01.05.01. Loosen setscrews of unit injector on rocker arm. 1 1 2 Remove half-moon rings (ill.1/pos.1) on both sides of rocker arms. 05.05 ill.1 Variant 1: Extract axial holder (ill.2) of camshaft and rocker arm shaft. 05.05 ill.2 3 Variant 2: Extract axial half-moon rings (ill.3) of rocker arm shaft (2x) (same as for rocker arms) 05.05 ill.3 4 Displace rocker arm, remove slide rings, remove rocker arms one by one and pull out rocker arm shaft towards cyl. 4 or 6. (ill.4). 05.05 ill.4 Page ENGINE - 58 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.05.06 01 ENGINE Replace radial shaft seal of camshaft Preparation: Lock crankshaft, 01.00.01. Remove timing belt. Disassemble camshaft wheel. 1 Disassemble radial shaft seal. 2 Mount new radial shaft seal with special tool No. VR00122/0. 05.06 ill.1 NOTE: Radial shaft seal is waxed; therefore needs not to be oiled. Do not use grease on radial shaft lip seal. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 59 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.07 Replace cam follower 1 4 Preparation: disassemble camshaft housing cover. 1 Loosen adjusting screw (ill.1/pos.1) with special tool No. VR00125/0. 2 Chuck cam follower spring (ill.1/pos.2) with special tool No. V000121/0. 3 Compress valve spring (ill.1/pos.3) with special tool No. VR00106/0. NOTE: 2 3 05.07 ill.1 05.07 ill.2 Crankshaft is first to be turned in a position which prevents collision between valve - piston bottom. ATTENTION: Before r elaxing the valve spring, check whether the valve wedges (ill.1/pos.4) are still positioned correctly. ENGINE DAMAGE! 05.07 ill.3 4 Lift cam follower from valve stem end and turn sidewards. 5 Lift cam follower from ball pin. 6 Lift cam follower by means of pointed pliers. NOTE: Adjust valves, refer to 01.01.02. 05.07 ill.4 Page ENGINE - 60 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.05.08 01 ENGINE Replace retainer of cam follower Preparation: disassemble cam follower, 01.05.07 1 1 Turn retainer spring (ill.1/pos.1) sidewards and remove by means of screwdriver from valve adjusting element towards center. 05.08 ill.1 NOTE: Adjust valves, refer to 01.01.02. 05.08 ill.2 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 61 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.09 Replace valve adjusting element Preparation: 1 Disassemble retainer spring of cam follower spring, 01.05.08 Unscrew valve adjusting element with hexagon socket (SW21). NOTE: NOTE: Apply thread protection LOCTITE 243 to valve adjusting element and tighten with a torque of 55 Nm +/-3. 05.09 ill.1 Adjust valves, refer to 01.01.02. 05.09 ill.2 Page ENGINE - 62 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.06 01.06.01 ENGINE HOUSING, OIL PUMP, OIL SUCTION PIPE Replace engine housing Preparation: 1 01 ENGINE disconnect battery close fuel feed- and return line, empty closed cooling circuit, refer to 05.00.02.01. suck off motor oil dismantle wiring harness, 06.05.02. dismantle E-box dismantle exhaust manifold - heat exchanger, refer to 05.01.02. 06.01 ill.1 Lock lifting chain special tool No. VR00103/0 onto the two lifting shackles (ill.2/1). 1 06.01 ill.2 2 Lift engine with special tool No. VR00130/0 and crane (min. 3500 N) and mount it on No.VR00102/0 and trestle No. VR00101/0 by means of four hexagon screws M8x30 (SW13). ATTENTION: thread screwing depth 1,5xD. 06.01 ill.3 3 Dismantle oil dipstick tube (ill.4/pos.1) and ventilation hose (ill.4/pos.2). 4 Dismantle tandem cooler, refer to 05.01.03. 1 2 06.01 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 63 ToC 01 ENGINE 5 SERVICE MANUAL MARINE ENGINES Dismantle oil hose on engine cooler (ill.5/pos.1). 1 06.01 ill.5 6 Disconnect oil hose on oil pump (ill.6/pos.1). 1 06.01 ill.6 7 Unscrew hollow screw (SW19) (ill.7/pos.1) to fuel feed pipe. 1 06.01 ill.7 For 4 cyl. engines 8 Remove oil filter bracket. 06.01 ill.8 Page ENGINE - 64 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE For 6 cyl. engines 9 Loosen two hexagon nuts and two hexagon screws (SW13). Remove filter plate. 10 Remove V-belt. For 4 cyl. engines 11 Remove Poly-V-belt. 12 Dismantle raw water pump laterally, refer to 05.10 13 Loosen 11 hexagon screws (SW10), remove lower timing belt covering. 06.01 ill.9 For 6 cyl. engines 14 Loosen 6 hexagon screws. Remove lower timing belt covering. 15 Dismantle flywheel housing, refer to 01.03. Dismantle torsion coupling, refer to 02. Remove flywheel, refer to 01.03. 16 Dismantle engine cooler, refer to 01.13. 06.01 ill.10 06.01 ill.11 For engines with screwed frame seal (alu support) 17 Unscrew frame sealing from housing halfs. 06.01 ill.12 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 65 ToC 01 ENGINE SERVICE MANUAL MARINE ENGINES For engines with rubber frame seal (slot variant) 18 Force out frame sealing from engine housing slot by means of broad screwdriver. NOTE: Do not puncture frame seal. 06.01 ill.13 19 Loosen one hexagon screw (SW10) (ill.14/pos.1). Remove protective sheet. 1 06.01 ill.14 For 4 cyl. engines 20 First loosen 11 Allen head screws (SW5) (ill.15/ pos.1), then 7 hexagon screws (SW17) (ill.15/pos.2). 1 2 For 6 cyl. engines 21 2 06.01 ill.15 First loosen 13 Allen head screws (SW5) (ill.17/ pos.1), then 3 hexagon screws (SW13) (ill.17/pos.2), and at last 4 hexagon screws (SW17) (ill.17/pos.3). 1 3 3 2 06.01 ill.17 Page ENGINE - 66 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 22 01 ENGINE Force apart housing halfs and remove. 06.01 ill.18 Assembly 1 Check membrans of frame sealing for damage, replace if necessary. 2 Clean and degrease all sealing surfaces. For 4 cyl. engines 3 Wet front and rear ring carrier with construction adhesive LOCTITE 620, in the area of the parting plane from the engine housing. Wet sealing surfaces of screws with surface sealing agent LOCTITE 509. 06.01 ill.20 For 6 cyl. engines (item 4 - 6) 4 Clean sealing profiles from adhesive residues. 5 Only for engines with rubber frame seal (slot variant) Wet sealing profile of frame sealing on both sides with construction adhesive LOCTITE 262. 6 Wet sealing ring on front ring carrier with surface sealing agent LOCTITE 5910. Wet rear ring carrier in the area of the parting plane from the engine housing with construction adhesive LOCTITE 620. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 67 ToC 01 ENGINE 7 First put suction-sides housing half onto dowel pin, then check for second housing half wether oil suction pipe and oil suction pipe horn do not collide with the housing. 8 Screw together the housing halfs. SERVICE MANUAL MARINE ENGINES 06.01 ill.21 9 For 4 cyl. engines ATTENTION: Tighten 7 hexagon screws (SW17) (ill.22/pos.2) with a torque of 50 Nm +/-5. Fasten 11 Allen head screws (SW5) (ill.22/pos.1) with a torque of 10 Nm +/-1. 10 For 6 cyl. engines 1 2 2 06.01 ill.22 ATTENTION: Tighten 4 hexagon screws (SW17) (ill.23/pos.3) with a torque of 50 Nm +/-5. Then fasten 3 hexagon screws with a torque of 23 Nm +/-2 (SW13) (ill. 23/ pos.2) and at last 13 Allen head screws with a torque of 10 Nm +/-1(SW5) (ill.23/pos.1). 1 3 3 2 06.01 ill.23 11 For engines with screwed frame seal (alu support) Screw together frame sealing with housing halfs. Tighten with a torque of 5,5 Nm +/-0,5. 06.01 ill.24 Page ENGINE - 68 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 12 01 ENGINE For engines with rubber frame seal (slot variant) Press frame sealing by hand into housing halfs. NOTE: To avoid an extension of the rubber, only push frame seal profil straight into groove of engine housing. 06.01 ill.25 13 Further assembly is done in reverse order of disassembly. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 69 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.02 Replace support ring rear Preparation: Replace engine housing, 01.06.01 1 Loosen 7 hexagon screws. Remove support ring. 2 Clean and degrease all sealing surfaces. 3 Wet sealing area of support ring with surface sealing agent LOCTITE 509. 4 Mount new support ring 06.02 ill.1 ATTENTION: Replace radial shaft sealing ring. (VR00107/0) 5 Tighten flange screws of rear ring carrier with a torque of 28 Nm +/-3. NOTE: Secure flange screws of rear ring carrier with thread protection LOCTITE 243. Page ENGINE - 70 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.06.03 Replace rear radialshaft sealing ring Preparation: 1 01 ENGINE Remove flywheel, refer 01.03 Remove radial shaft sealing ring Mount special tool No. VR00107/0 to press in the rear radial shaft sealing ring. 06.03 ill.1 2 Press radial shaft sealing into rear built-in ring carrier by means of special tool No. VR00107/0. Assembly engine in reverse order. 06.03 ill.2 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 71 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.04 Replace oil pump (front ring carrier) Preparation: 1 dismantle engine housing, 01.06.01. remove timing belt remove vibration damper Pull of timing belt sprocket by means of special tool No. 2300636/0 (ill.1). 06.04 ill.1 2 Loosen 6 hexagon screws (SW13) (ill.2), remove oil pump housing. õ 06.04 ill.2 ATTENTION: Replace radial shaft sealing ring (ill.3/ pos.1) in oil pump housing. Mount oil pump housing, and insert radial shaft sealing ring with special tool No. VR00118/0. NOTE: 2 1 Check sealing ring (ill.3/pos.2) on oil pump housing for damage; exchange if necessary. (wet new sealing ring with surface sealing agent LOCTITE 5910) Apply LOCTITE 509 to flange surface to front main bearing block and oil pump (front ring carrier) 06.04 ill.3 Secure the 6 hexagon screws (ill.2) with thread protection LOCTITE 243 and tighten with a torque of 23 Nm +/-2. Page ENGINE - 72 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.06.05 01 ENGINE Replace oil suction pipe Preparation: Exchange engine housing, 01.06.01. 06.05 ill.1 1 2 Unscrew 2 screws (ill.2/pos.1) on main bearing block. Remove plate (only possible at 4 cyl. engines) - (ill.2/ pos.2). 2 Pull of oil suction pipe. Check O-ring (ill.2/pos.3), replace if necessary. 1 3 ATTENTION: During assembly of oil suction pipe, take care that no bracings occur. 06.05 ill.2 Assembly is done in reverse order. 3 Grease O - ring during assembly. 4 Secure the screws with thread protection LOCTITE 243 and tighten with a torque of 10 Nm +/- 1. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 73 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.08 01.08.01 INTERCOOLER Remove intercooler Preparation: remove air filter, 03.04.01 C1 08.01 ill.1 1 Unscrew hexagon screw (ill.2/pos.1) (SW10) of clamp of oil dipstick tube, carefully turn away oil dipstick tube. 2 Remove tandem cooler, refer to 05.01.06 or remove triple cooler, refer to 05.01.08 or For M16 - 246 only: Remove additional oil cooler, refer to 05.01.07 For 4. cyl. engines (item 3-8) 3 C1 08.01 ill.2 Unscrew 3 hexagon nuts (ill.3/pos.1) of shift plate and remove. C1 C1 08.01 ill.3 4 Loosen plug connections of boost pressure sensor (ill.4/pos.1), loosen accelerator potentiometer (ill.4/ pos.2). 5 Loosen hose clamp (ill.4/pos.3). Take off hose and remove shift plate. 1 2 A 3 08.01 ill.4 Page ENGINE - 74 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 6 Unscrew hollow screw of boost pressure hose (ill.5) and remove. 7 Remove two supports-intercooler (ill.6/pos.1) 01 ENGINE 08.01 ill.5 1 08.01 ill.6 8 Loosen hose clamps of hose connection turbocharger - intercooler (ill.7/pos.1), and remove hose. 1 A For 6. cyl. engines (item 9-10) 08.01 ill.7 9 Unscrew setscrews (ill.8/pos.1) for pipe support of raw water pipe. 10 Remove cover (ill.8/pos.2) to intercooler by loosening 5 hexaong screws (SW10). C2 1 08.01 ill.8 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 75 ToC 01 ENGINE 11 For 4. cyl. engines Unscrew hexagon screw (SW10) (ill.9/pos.1) of raw water pipe clamp. 12 Open hose clamp (ill.9/pos.2) on intercooler. 13 Open hose clamp on heat exchanger (ill.10/pos.1) and remove raw water pipe. SERVICE MANUAL MARINE ENGINES 1 A 2 A 08.01 ill.9 C1 For 6 cyl. engines (item 14-19) 14 Loosen hose clamp (ill.11/pos.1). Loosen 2 hexagon screws (SW13) (ill.11/pos.2) and remove connecting bend. 08.01 ill.10 C2 C1 08.01 ill.11 15 Pull of plug (ill.12/pos.1) for sensor of control rack. 16 Loosen plug (ill.12/pos.2) for accelerator potentiometer. 17 Loosen 3 hexagon screws (SW13) (ill.12/pos.3) and remove. Remove bracket with potentiometer. 18 C3 C1 Loosen hollow screw of boost pressure hose (ill.12/ pos.4) on air collector and remove. C4 C2 08.01 ill.12 Page ENGINE - 76 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 19 Disconnect plug from control solenoid (ill.13/pos.1). 20 Remove mounts of wiring harness on the bottom of air collector and turn away wiring harness. 21 Only for 4 cyl. engines with hydraulic system 01 ENGINE C1 08.01 ill.13 Loosen 2 hexagon sockets (ill.14/pos.1), remove hydraulic tank and fix it laterally in such a way that no oil can leak. 1 A 08.01 ill.14 22 Unscrew hexagon sockets (SW6) from intercooler and remove. 08.01 ill.15 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 77 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.08.02 Assembly of intercooler Preparation: check intercooler 1 Clean sealing surfaces on motorblock (ill.1). 2 For 6 cyl. engines Fix 2 seals (ill.2/pos.1) with grease Staburax NB04 on marked surfaces of monoblock. 08.02 ill.1 C1 3 Clean sealing surfaces on intercooler (ill.3). 4 For 4 cyl. engines Apply a slight film of LOCTITE 5900 to the sealing surfaces (ill.3) of intercooler. 5 Fix intercooler on engine block by means of 2 hexagon sockets. For 4 cyl. engines, screw in remaining 6 hexagon sockets (SW8), and for 6 cyl. engines remaining 10 hexagon sockets, and tighten with a torque of 28 Nm +/-2. 6 Further assembly is done in reverse order of disassembly. 08.02 ill.2 08.02 ill.3 08.02 ill.4 Page ENGINE - 78 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.08.03 01 ENGINE Replace intercooler - element Preparation: remove air filter, refer to 03.04.01 drain raw water circuit, refer to 05.00.07 remove intercooler, refer to 01.08.01 C7 C8 C9 C4 C1 C2 C3 C6 C 10 08.03 ill.1 C5 1 For engines with hydraulic systems, loosen upper screw; for all other engines, loosen 3 screws (ill.1/ pos.1) from intercooler cover in front and 3 screws (ill.1/pos.2) from intercooler cover at the back from intercooler. Remove intercooler cover in front (ill.1/pos.4) and at the back (ill.1/pos.3). 2 Loosen the intercooler element by slightly knocking with a plastic hammer on the front end of the element, and remove it. Dispose the O-ring of the element as well as the O-rings in the intercooler covers. 3 Clean all sealing surfaces on intercooler, intercooler-element and intermediate flange. 4 Grease O-ring (ill.1/pos.5) with Molykote BR 2 PLUS and shift it up to the flange of the intercooler element (ill.1/pos.10). Insert intercooler element into intercooler. Grease O-ring (ill.1/pos.6) with Molykote BR 2 PLUS, insert it into intercooler cover (ill.1/pos.3), fix on intercooler and loosely mount on intercooler with 3 screws (ill.1/pos.2). 5 Push O-ring greased with Molykote BR 2 PLUS (ill.1/pos.7), intermediate flange (ill.1/pos.8) and Oring greased with Molykote BR 2 PLUS (ill.1/pos.9) onto exposed end of intercooler element. Mount intercooler cover in front (ill.1/pos.4) with upper screw (for all engines with hydraulic system) and all other engines onto intercooler with 3 screws (ill.1/pos.1) 6 Tighten screws (ill.1/pos.2) with standard torque of 23 Nm +/-2. NOTE: For engines with hydraulic system, tighten the screw (ill.1/pos.1) together with the two screws for fixation of the hydraulic tank, with a torque of 23 Nm +/-2. 7 Remaining assembly is done in reverse order. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 79 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE THIS PAGE IS INTENTIONALLY BLANK Page ENGINE - 80 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.09 01 ENGINE AUXILIARY DRIVE, IN FRONT (PTO) 1 Disconnect battery cables. 2 Remove protective cover. 2 For 4 cyl. engines (item 3-4) 3 Loosen 3 hexagon screws (SW13) (ill.1/pos.1) and remove drive shaft. 4 Loosen 3 hexagon screws (SW13) (ill.1/pos.2) and remove flange ring. 1 09.01 ill.1 For 6 cyl. engines (item 5-7) 5 Loosen 6 hexagon screws (SW10) (ill.2/pos.1) and remove elastic shaft with adapter plate. 6 Loosen 3 hexagon screws (SW13) and 3 hexagon nuts (SW13) (ill.2/pos.2). Remove adapter plate from elastic shaft. 7 Assembly is done in reverse order. 1 2 09.01 ill.2 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 81 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13 01.13.01 ENGINE OIL COOLER Replace engine oil cooler Preparation: Empty closed cooling circuit, 05.00.02 Remove tandem cooler 05.01.06 1 Loosen hose clamp (ill.1/pos.1) on oil cooler. C1 13.01 ill.1 6 Loosen fixing nut (ill.2) of oil line (SW22). 13.01 ill.2 7 Loosen 4 allen head screws (SW6), remove cooler. 13.01 ill.3 Page ENGINE - 82 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 4 01 ENGINE Clean marked sealing surface (ill.4) with scraper and remove O-Ring. Assembly oil cooler 13.01 ill.4 Replace O-ring on adaptor main oil duct and slightly grease with Staburax NB U4 before assembly. When putting on the engine oil cooler, immediately fix the water intake of the oil cooler on the hose albow of the water pump . Take care that the engine oil cooler is led parallel to the assembly surface (O-ring may be damaged in main oil duct ill.6/pos.1). Replace Orings of oil hoses and grease with Staburax NB04. Filling refer to 05.00.08 Filling - closed cooling system. 1 NOTE: Cover the three contact surfaces with surface sealing agent LOCTITE 5900 Tighten 4 allen head screws with a torque of 23 Nm +/- 2. Secure union nuts of oil hoses with LOCTITE 243 and tighten with a torque of 20 Nm +/-2. 13.01 ill.5 Further assembly is done in reverse order of disassembly. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 83 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13.02 Repair oil cooler 1 Preparation: remove oil cooler, 01.13.01 3 2 Disassembly: 1 Unscrew two slotted round nuts (ill.1/pos.1) by means of special tool 2300709/1. 2 Unscrew hexagon sockets (ill. 1/pos.2) (SW5), separate housing halfs, remove cooler element. 3 Assembly: NOTE: Prior to assembly, clean all sealing surfaces. Slightly grease the O-rings with Staburax NB04. 1 Cover sealing surfaces of the two housing halfs with surface sealing agent LOCTITE 5900, special tool No. 2300717/0. 2 Put together cooler insert and housing halfs with three new O-rings (ill.1/pos.3). 3 Loosely screw in hexagon sockets. (SW5) (ill.1/pos.2). 4 Screw in the two slotted round nuts with thread protection LOCTITE 243 and tighten with a torque of 55 Nm +/-3. 5 Tighten hexagon sockets with a torque of 10 Nm +/-1 (ill.1/pos.2). Page ENGINE - 84 Downloaded from www.Manualslib.com manuals search engine 13.02 ill.1 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.13.03 01 ENGINE Change motor oil 1 Bring engine to operating temperature and stop engine. 2 Remove oil dipstick (ill.1/pos.1). 3 Open oil filler cap (ill.2/pos.1), but do not remove because of possible contamination. 4 Suck off motor oil on oil dipstick tube by means of suction pump No. 0172473/0 (ill.2/pos.2), and pump it into a suitable receptacle. 1 NOTE: Pay attention to heat- (approx. 120°C) and oil resistance of receptacle for the used motor oil. Dispose the oil properly. 5 Remove oil filler cap (ill.2/pos.1). 6 Fill in STEYR turbo diesel engine oil SAE 10W-40 (No. Z010058/0) (ill.3) or equivalent motor oil with characteristics ACEA B4 - 02 or API code CF. 13.03 ill.1 1 2 13.03 ill.2 ATTENTION: Oil filling must not exceed the maximum marker. Overfilling results in high operating temperatures, foaming (air in oil), loss in efficiency and a reduced engine life. As the quantity for an oil change, refer to Specifications Motor Oil GENERAL B 2 As the quantity for first filling (e.g. after engine repair), refer to Specifications Motor Oil GENERAL B2 7 Put on oil filler cap and lock. ATTENTION: Remove possible oil contaminations from oil filler cap and environment. 13.03 ill.3 ATTENTION: Do not forget oil check after test run. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 85 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13.04 1 Change oil filter For 4 cyl. engines Waiting time 30 min. after having stopped the engine. NOTE: 2 First suck off the motor oil. This reduces the waiting time. For 6 cyl. engines Position (special tool No. VR 00132/0) oil collecting pan below oil filter (ill.2). 3 Loosen the oil filter with oil filter wrench No. 2300713/1 and unscrew by hand. Dispose the oil filter acc. EPA-regulation. 4 Clean sealing surface of oil filter head. 5 Oil the seal of new oil filter and screw it onto oil filter head until the seal easily rests against. Tighten the oil filter with a 3/4 turn. 13.04 ill.1 13.04 ill.2 ATTENTION: Remove possible oil contaminations from filter head and environment. Do not forget to check engine oil level! 13.04 ill.3 Page ENGINE - 86 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 01.14 01 ENGINE EXHAUST MANIFOLD, SEALS, HEAT EXCHANGER Refer to 05.01.02 Exhaust manifold, heat exchanger Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ENGINE - 87 ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE THIS PAGE IS INTENTIONALLY BLANK Page ENGINE - 88 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING 02 COUPLING Table of Contents Page 02.01 02.01.01 02.01.02 02.01.03 Replace torsion coupling ...................................................................... 2 For 6 cyl. engines ...................................................................................... 2 For 4 cyl. engines ...................................................................................... 4 Installation ................................................................................................. 6 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COUPLING - 1 ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING 02.01 REPLACE TORSION COUPLING Preparatory work: disassemble flywheel housing, refer to 01.03.01. 02. 01. 01 Remove coupling for 6 cyl. engines Remove coupling for gearbox, jet drive, VOLVO stern drive apllication: Variant 1: Loosen 9 screws. Remove coupling. Variant 2: Loosen 6 screws. Remove coupling. (Old version replaced by variant 2) 01.01 ill.1 (Current version replaced variant 1) 01.01 ill.2 Variant 3: Loosen 9 hexagon screws. Remove flywheel adaptor and coupling. 01.01 ill.3 Page COUPLING - 2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING Remove coupling for OMC/ VOLVO SX - stern drive apllication: Loosen 6 screws, remove washers. Remove coupling. Remove coupling for MERCURY - stern drive apllication: 01.01 ill.4 (Old version replaced by variant 2) Variant 1: Loosen 3 screws. Remove coupling. Loosen 9 screws. Remove flywheel adaptor, if necessary. 01.01 ill.5 Variant 2: Loosen 6 screws. Remove coupling. (Current version replaced variant 1) Loosen 9 screws. Remove flywheel adaptor, if necessary. Variant 3: Loosen 6 screws. Remove coupling. 01.01 ill.6 Loosen 9 screws. Remove flywheel adaptor, if necessary. 01.01 ill.7 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COUPLING - 3 ToC 02 COUPLING SERVICE MANUAL MARINE ENGINES 02. 01. 02 Remove coupling for 4 cyl. engines (Old version replaced by variant 2) Remove coupling for gearbox, jet drive, VOLVO stern drive apllication: Variant 1: Loosen 9 screws. Remove coupling. Variant 2: Loosen 6 screws. Remove coupling. 01.02 ill.1 (Current version replaced variant 1) Loosen 9 hexagon screws. Remove coupling. Remove coupling for OMC/ VOLVO SX - stern drive apllication: 01.02 ill.2 Loosen 6 screws, remove washers. Remove coupling. 01.02 ill.3 Page COUPLING - 4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING Remove coupling for MERCURY - stern drive apllication: (Old version replaced by variant 2) Variant 1: Loosen 3 screws. Remove coupling. Variant 2: Loosen 6 screws. Remove coupling. 01.02 ill.4 (Current version replaced variant 1) Loosen 9 screws. Remove flywheel adaptor, if necessary. 01.02 ill.5 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COUPLING - 5 ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING 02.01.03 Installation Description Nm Screw Coupling M8 x 1,25 - 8.8 23 Screw Coupling M8 x 1,25 - 10.9 32 Screw Coupling M10 x 1,5 45 Use locking compound LOCTITE 243 on threads. Page COUPLING - 6 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 FUEL SYSTEM Table of Contents Page 03.00 Fuel system / Functional description .................................................... 2 03.02 03.02.01 03.02.02 03.02.03 03.02.04 03.02.05 03.02.06 03.02.07 Fuel pump, unit injector, lines ............................................................... 4 Replace fuel pump ................................................................................. 4 Disassembly and assembly of unit injector ............................................... 7 Fix control rack......................................................................................... 14 Adjust control link (injection quantity)....................................................... 15 Loosen fixing of control rod ..................................................................... 16 Adjust start of injection............................................................................. 17 Exchange check valve for fuel pre-pressure to unit injector ................... 20 03.04 03.04.01 Air filter .................................................................................................. 21 Change air filter ....................................................................................... 21 03.05 03.05.01 03.05.02 Turbocharger ......................................................................................... 22 Replace turbocharger ............................................................................. 22 Check bearing clearance......................................................................... 25 03.08 03.08.01 03.08.02 03.08.03 Control solenoid.................................................................................... 26 Remove control solenoid......................................................................... 26 Install control solenoid.............................................................................. 28 Replace sensor, indication of control rack position.................................. 29 03.09 Change fuel filter .................................................................................. 30 03.11 Replace glow plug ................................................................................ 31 03.12 Measurement of Compression Pressure.............................................. 32 03.14 03.14.01 03.14.02 03.14.03 Fuel system check.................................................................................. 34 Manual injection test methode.................................................................. 34 Disengagement methode of injection........................................................ 36 Air bubble formation in fuel system........................................................... 37 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 1 Page FUEL SYSTEM - 2 Downloaded from www.Manualslib.com manuals search engine Rückschlagventil Check valve Kraftstoffzufuhr PD Fuel supply UI 5 6 Regelstangensensor Rack position sensor Kraftstoffpumpe Fuel pump 4 8 Kraftstoff Filter Fuel filter 3 Pumpedüse Unit Injector Absperrhahn Fuel stop cock 2 7 Saugventil Anti-siphon valve 1 13 9 7 10 6 11 8 12 3 14 1 4 15 5 15 Kraftstoffrücklauf Fuel return line 13 Druckhalteventil Fuel check valve 14 12 Aktuator Control solenoid Kraftstoffkühler Fuel cooler 11 10 Anlenkhebel Adjustment lever Regelstange Common rack 9 Kipphebel Rocker arm 2 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03.00 fuel system Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Functional Description When the ignition switch is turned, an electric fuel pump 1 is put into operation and sucks fuel from the fuel tank 2. This fuel is led via fuel filter 3 to the fuel pump. From the fuel pump, fuel is pumped to the engine block 4 and the unit injectors 5. Excess fuel not injected by the unit injectors is led via fuel cooler 6 back to the fuel tank. The operating pressure is controlled by pressure valve 7 (1,8 - 2,5 bar at idle). 8 anti-siphon valve; 9 baffles (depending on tank size) For fuel requirements, refer to chapter GENERAL 03.00 ill. 1 Specification for fuel pipes Minimum inside diameter: Recommended material: NOTE: 8 mm stainless steel or copper Min. inside diameter for hosepipes or PA-pipes is 10 mm. Rate of flow: > 240l/h +/-7 (in case of continuously operating pump) If additional filters are installed, the requirements of higher flow rates must to be considered. (filter dimension) NOTE: In case of pipe connections, pay special attention to the tightness of the suction pipe (all fittings and line before fuel pump)! Types of pipe connections 03.00 ill. 2 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 3 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03.02 FUEL PUMP, UNIT INJECTOR, LINES 03.02.01 Replace fuel pump Fuel pump operation is controlled by EMS. Disassembly 1 Ventilate drain fuel system.For this purpose, open fuel line between fuel filter and fuel pump (ill.4/pos.1) and let pump run for approx. 6 x 10 sec. Make sure that air is sucked into the line. 02.01 ill.3 1 ATTENTION: Close fuel cock on tank, if tank is higher. 2 ATTENTION: Prior to disassembly, disconnect battery cables from battery, to avoid damages to the electronic system. 3 Disconnect positive cable and negative cable (ill.6) by unscrewing hexagon nuts (SW7/8) with washer from terminals of fuel pump. 4 Unscrew hollow screw (ill.6/pos.1) of fuel feed line. Dispose Cu-sealing rings. 5 Unscrew hollow screw (ill.6/pos.2) of fuel line. Dispose Cu-sealing rings. 02.01 ill.4 2 + - ATTENTION: Hold up with second wrench on hexagon of pump housing, to avoid a a damage to the E-pump. 1 02.01 ill.6 Page FUEL SYSTEM - 4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 6 03 FUEL SYSTEM For 4 cyl. engines only Unscrew two hexagon screws of filter plate. Remove filter plate and holding strap. Remove fuel pump. For 6 cyl. engines only (item 7-8) 7 02.01 ill.7 Remove two hexagon screws (SW10) for fixing fuel pump on filter plate (ill.8/pos.1), as well as ground wire. 1 ATTENTION: Mark position of fuel pump on pump support. 8 Remove pump bracket. ATTENTION: Measure height for assembly of pump because of fitting position of fuel lines. Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine 02.01 ill.8 Page FUEL SYSTEM - 5 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES Assembly 2 + For 4 cyl. engines only (item 1-3) 1 Place new fuel pump. 2 Mount filter bracket with holding strap by means of 2 hexagon screws. 3 Attach fuel line between filter and pump (ill.9/pos.1) as well as pump and block (ill.9/pos.2). Tighten hollow screws with a torque of 30 Nm +/-3. - 1 02.01 ill.9 For 6. cyl. engines only (item 4-7) 4 Mount bracket in correct position onto new fuel pump. Tighten screws of bracket. 5 Mount pump and ground wire on filter plate and fix with two hexagon screws (ill.10/pos.1). Tighten screws with a standard torque of 10 Nm +/-1 . Torque wrench No. 2300704/0. Fix ground cable together with bracket. 6 Mount adaptor with Cu-sealing rings at top face of fuel pump. 7 Attach fuel lines between filter and pump, as well as pump and block. Tighten hollow screws with a torque of 30 Nm +/-3. 1 ATTENTION: Hold up with second wrench on hexagon of pump housing, to avoid a damage to the E-pump. Always use new Cu-sealing rings. 8 Connect two cables to negative terminal (-) and to positive terminal (+). Cover the two terminals with neoprene lacquer sealing No. P/N Z909570/0. 9 Connect battery cables. 10 Connect fuel lines and operate electric fuel pump 3 times for 10 sec., to bleed fuel system. 11 Check fuel system for leakage.ò (No. 2300719/1, mount fuel return line) Page FUEL SYSTEM - 6 Downloaded from www.Manualslib.com manuals search engine 02.01 ill.10 Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.02.02 03 FUEL SYSTEM Disassembly and assembly of unit injector Preparation: Remove camshaft housing cover. Clean sealing surface of rubber seal and check for hardening and damage. Replace seal, if required. 02.02 ill.1 1 Turn crankshaft until injector cam is at base circle as well intake and exhaust valve are open, in order to permit a lateral shifting of rocker arm. 02.02 ill.2 02.02 ill.3 2 Before loosening flange nuts of unit injectors, ventilate fuel system. For this purpose, open screw of banjo fitting just enaugh to let air through seal rings between fuel filter and fuel pump (ill.4/pos.1), and let pump run approx. 6 times for 10 sec. Make sure that air is sucked. 1 ATTENTION: Close fuel cock on tank, if tank is higher than fuel supply on filter head. 02.02 ill.4 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 7 03 FUEL SYSTEM 3 SERVICE MANUAL MARINE ENGINES Remove nuts on unit injector flange (2 hexagon nuts SW 13). 02.02 ill.5 4 Loosen left-handed hexagon socket securing the control link on the control rack by using a 4 mm hexagon socket wrench. Turn control link against bulk head. (1 hexagon socket SW 4 - ”LEFT-HAND THREAD” per unit injector). 02.02 ill.6 5 Loosen adjusting nut with 17 mm socket wrench (hexagon nut SW 17 and screwdriver). Turn adjusting screw to such an extent that the slide cup is loosely attached to the spring plate. Do not remove. 02.02 ill.7 6 Insert screwdriver with small blade into recess of retainer ring (half-moon ring) for rocker arm lock, push retainer ring upwards and remove. For disassembly of unit injector, always remove rocker arm retaining ring at timing belt side. 02.02 ill.8 Page FUEL SYSTEM - 8 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 7 03 FUEL SYSTEM Move the rocker arm towards timing belt side of engine and remove the tappet. NOTE: Adjusting screw and slide cup match exactly and thus have to be removed kept matched. 02.02 ill.9 8 Check position of control link(s) against bulkhead as illustrated. 02.02 ill.10 9 Insert the unit injector lever SMO No. VR00126/0 below the camshaft and push upwards against the body of unit injector. The unit injector is thus lifted out from the engine block and may be removed manually. NOTE: For disassembly of the unit injector from cylinder No. 1, the control rack is to be moved forward. 02.02 ill.11 10 Remove unit injector with mounting flange. 02.02 ill.12 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 9 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 11 Remove copper seal washer from bottom side of copper insert by means of hook- and lifting tool (No. VR 00116/0). NOTE: Avoid scratches on the sealing surface of the copper insert. 02.02 ill.13 Assembly 1 In order to secure an appropriate tight fit, recheck tighten stud bolt with a torque of 21 Nm +/- 2 02.02 ill.14 2 Drain possible fuel residues by means of suction device No. VR 00121/0 from the combustion chamber. Suction device must be equipped with a suction hose of at least 250 mm of length in order that possible fuel residues can be sucked from piston recess. NOTE: Fuel residues in the combustion chamber may cause severe damage to the engine. 02.02 ill.15 3 Check copper insert for possibly remaining seal washers; remove and dispose, if necessary. NOTE: Always use new copper seal washers! (ill.16/pos.1 ) 1 02.02 ill.16 Page FUEL SYSTEM - 10 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 4 Clean conical part of copper insert with cleaning mandrel No. 2300565/0. For this purpose,, turn cleaning mandrel several times in both directions and then clean copper insert with cleaning tissue. 5 ATTENTION: Insert new special copper seal washer (ill.19/pos.2), from seal kit Z002031/0, with a screwdriver into copper insert. 03 FUEL SYSTEM 02.02 ill.17 Make sure the copper seal washer is plane. 02.02 ill.18 6 Install new O-rings (ill. 19/pos.1), from seal kit Z002031/0, and cover O-rings with a thin coat of clean motor oil. 1 2 02.02 ill.19 7 Insert unit injector into bore and align unit injector recess to dowel pin (ill. 20/pos.1) for positioning. Avoid any contact with control link. ATTENTION: Risk of damage to control rack. 1 02.02 ill.20 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 11 03 FUEL SYSTEM 8 SERVICE MANUAL MARINE ENGINES Push unit injector firmly downwards in order to position it correctly with the O-rings. 02.02 ill.21 9 Lubricate slide cup with motor oil, put it onto adjustment screw, as shown, and shift it together with rocker arm onto unit injector. 02.02 ill.22 10 Install retainer ring to secure the rocker arm. 02.02 ill.23 11 Screw on flange nuts (hexagon nuts SW 13) and tighten evenly. Absolutely tighten nuts with a torque of 18 /-2 Nm. ATTENTION: Pay attention to horizontal installation of mounting flange. 02.02 ill.24 Page FUEL SYSTEM - 12 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 12 Fix control rack. 13 Attach control link to control rack and adjust. Refer to 03.02.04, Adjusting Control Link. 14 Adjust injection start. Refer to 03.02.06, Injection Start unit injector. 15 Connect fuel pipes and operate electric fuel pump 3 times for 10 seconds to vent fuel system. Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine 03 FUEL SYSTEM Page FUEL SYSTEM - 13 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.03 Fix control rack Preparation: Remove camshaft housing cover, refer to 01.00.02 1 1 2 Unscrew setpin of control rack (ill.1/pos.1) at the back of camshaft housing, as shown. 02.03 ill.1 Position bore (diameter 4 mm) in control rack(ill.2/ pos.1) over reference bore (ill.2/pos.2) in the bulkhead wall. 2 1 02.03 ill.2 3 Pull control rack manually to the front, against spring resistance, and hold. Insert setpin, as shown, and fasten sturdily. 02.03 ill.3 3 2 1 02.03 ill.4 Page FUEL SYSTEM - 14 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.04 Adjust Control Link (injection quantity) Prior to adjustment, unit injector must be tightened properly, and control rack must be fixed in position with set pin. NOTE: Readjust all control links even if only one link has been opened. STARTING POSITION: 02.04 ill.1 Loosen left-handed setscrew of control link. Turn control link against bulkhead on camshaft housing. 02.04 ill.2 1 Carefully position end of control link on front side of unit injector control rack (possibly use screwdriver). 2 Turn control link against unit injector control gear until control gear completely pushes against upper gauged stop and hold position with screwdriver. Hold in this position and tighten left-handed setscrew of control link with a torque of 7 Nm +/-0,5. Repeat steps 1 and 2 for the rest of unit injector control racks. 02.04 ill.3 3 Calibrate rack position, refer to 06.10.03 4 Loosen fixing of control rack, refer to 03.02.05 02.04 ill.4 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 15 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.05 1 Loosen fixing of control rod Unscrew setpin (ill.3/pos.2) from bulkhead wall with removing setpin and hold control rack. Reinstall setpin in rear camshaft housing bore.(ill.3/pos.1). 02.05 ill.1 2 Tighten setpin with a torque of 7 Nm. 02.05 ill.2 3 Check axial flexibility of control rack. Control rack is to be moved easily and should automatically return to reverse position due to spring load. 2 1 02.05 ill.3 Page FUEL SYSTEM - 16 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.02.06 03 FUEL SYSTEM Adjust start of injection Preparation: Remove camshaft housing cover NOTE: Special tool.: 1 The adjustment of start of injection is necessary: - if unit injector was removed - periodically according to maintenance (chart) - if set value has changed (see chart Set Values Unit Injector Stroke). 02.06 ill.1 Adjustment of injection start is to be done prior to adjustment of engine control. 2306031/4 dial gauge rail 4 cyl. 2306031/1 dial gauge rail 6 cyl. with bossed seal surface 2306031/6 dial gauge rail 6 cyl. with plane seal surface 2300899/0 dial gauge 2300641/1 probe pin Unit injector must be installed properly and fastened. Control rack and unit injector control gear must be free to move. 2 Put dial gauge rail with bracket, No. 2306031/. (see list special tool), onto stud bolt at intercooler side of camshaft housing and fasten with nuts. 3 Turn camshaft until bearing rollers of rocker arm for unit injector being adjusted is on the base circle of the cam. Unit injector spring should be in most relaxed position. 02.06 ill.2 02.06 ill.3 4 Mount dial gauge No. 2300899/0 with pointer No. 2300641/1 into dial gauge rail. 5 Put pointer onto unit injector plunger guide. 00. 00 . 02.06 ill.4 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 17 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 7 1 Insert unit injector extracting lever No. VR 00126/0 (ill.5/pos.1) in recess of rocker arm between rocker arm body and roller, as shown, and fully press down spring of unit injector. Set display to zero. NOTE: Slowly release unit injector spring. Read total indicating travel (ill.5/pos.2) on dial gauge. 2 02.06 ill.5 8 Turn adjusting screw (ill.6/pos.1) with screwdriver and set to the value as listed in below table. Hold adjusting screw in this position and tighten hexagon nut (ill.6/pos.2) by means of torque wrench No. 2300743/0 and tee-handled socket wrench (SW17) with a torque of 30 Nm +/-3. 1 2 02.06 ill.6 Engine setting values for engines with a build date before 2007 (<48226999/<68226999) TYPE Unit Injector Stroke Adjustment Engine Timing New Copper Ring / Control Value Valve Clerance Inlet &Outlet M094K32 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 M0114K33 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 M0144M38 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 M0144V38 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 M0164M40 2176557/0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO174V40 2176557/0 8,07 ±0,02 8,12 ±0,02 3,20 ±0,05 0,25/0,25 MO126K28 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO166K28 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO236K43 2176555/5 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO246M41 2176557/0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO256H45 2176557/0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO256K43 2176557/0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,05 0,25/0,25 MO266K43 2176557/0 8,07 ±0,02 8,12 ±0,02 3,20 ±0,05 0,25/0,25 Page FUEL SYSTEM - 18 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Engine setting values for engines with a build date from 2007 (>48227001/>68227001) Type Unit Injector Engine Timing New Copper Ring / Control Value Valve Clerance Inlet &Outlet MO54NA33 2176553-1 8,07 ±0,02 8,12 ±0,02 3,20 ±0,02 0,25 / 0,25 MO84K32 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 MO94K33 MO114K33 2176557-0 8,47 MO144V38 2176557-0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 MO144M38 2176557-0 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 2176557-0 8,37 ±0,02 8,42 ±0,02 3,20 ±0,02 0,25 / 0,25 ±0,02 8,82 ±0,02 3,20 ±0,02 0,25 / 0,25 MO164M40 MO174V40 2176552-1 8,77 MO126K25 2176552-1 9,29 ±0,02 9,34 ±0,02 3,20 ±0,02 0,25 / 0,25 MO156K25 2176552-1 9,15 ±0,02 9,20 ±0,02 3,20 ±0,02 0,25 / 0,25 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 8,37 ±0,02 8,42 ±0,02 3,20 ±0,02 0,25 / 0,25 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 MO196K35 MO236K42 2176557-0 MO256K43 2176557-0 8,27 MO256H45 2176557-0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 MO286H43 2176552-1 8,70 ±0,02 8,75 ±0,02 3,20 ±0,02 0,25 / 0,25 2176552-1 ±0,02 ±0,02 ±0,02 0,25 / 0,25 MO306H43WJ 9 Stroke Adjustment 8,55 8,60 3,20 Recheck stroke adjustment, recheck zero value and total stroke adjustment as described in steps 7 and 8. ATTENTION: In case of deviation, repeat setting process. Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 19 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.07 1. Exchange check valve for fuel pre- pressure to unit injector Unscrew valve SW 19 mm (ill.1/pos.1), remove 2 Cu-sealing rings. NOTE: Use new Cu-sealing rings for assembly. Tighten with a torque of 40 Nm+/-4. ATTENTION: On account of importance of this valve (proper function of fuel system), only use genuine STEYR spare part for possible exchange. Page FUEL SYSTEM - 20 Downloaded from www.Manualslib.com manuals search engine 1 02.07 ill.1 Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.04 03 FUEL SYSTEM CHANGE AIR FILTER 03.04.01 Change air filter Till engine serial no. 48219069 ( 4-cyl.) and 68219174 ( 6-cyl.) 1 Open retaining clip. 04.01 ill.1 2 Remove air filter and cover. 3 Put new air filter together with cover onto filter head and fix with retaining clip. From engine serial no. 48219070 ( 4-cyl.) and 68219175 ( 6-cyl.) 1 Remove hose clamp and air filter. 2 Mount new air filter together with hose clamp and tighten clamp solid. 04.01 ill.2 04.01 ill.3 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 21 03 FUEL SYSTEM 03.05 SERVICE MANUAL MARINE ENGINES TurboCHARGER 03.05.01 Replace turbocharger 1 Remove air filter, refer to 03.04.01 2 Remove high-riser, refer to 04.01 3 For 6 cyl. engines only Drain coolant from closed cooling circuit, refer to 05.00.07 05.01 ill.1 For 4 cyl. engines only (item 4-7) 4 Loosen fastenings of heat protection. Remove heat protection (ill.2/pos.1). 5 Loosen hose clamp (ill.2/pos.2) and remove hose for air charge pressure box. 6 Loosen screw (ill.2/pos.3) for raw-water pipe support (SW10). 1 2 3 05.01 ill.2 7 Loosen hollow screw (ill.3/pos.1) of oil feed line on turbocharger. 8 Remove plug of oil pressure switch (ill.3/pos.2). 9 Loosen hollow screw (ill.3/pos.3) of oil feed line on motorblock. Dispose Cu-sealing rings. 1 2 3 05.01 ill.3 10 Loosen two hexagon screws (ill.4) of oil return line. Dispose seal. 05.01 ill.4 Page FUEL SYSTEM - 22 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 11 03 FUEL SYSTEM For 6 cyl. engines only Loosen 2 hexagon screws on flange of oil feed line. 05.01 ill.5 12 For 4 cyl. engines only Loosen hose clamps of hose connection turbocharger-intercooler (ill.6/pos.1) and remove hose. 1 For 6 cyl. engines only (item 13-17) 13 Loosen support screw (ill.7/pos.1) for raw-water pipe. 14 Remove covering (ill.7/pos.3) to intercooler by loosening 5 hexagon screws (SW10) (ill.7/pos.2). 05.01 ill.6 2 3 1 05.01 ill.7 15 Loosen hose clamp (ill.8/pos.1) connection compression housing. 16 Loosen 2 hexagon screws (ill.8/pos.2) and remove connecting bend. 17 Loosen hollow screw (ill.8/pos.3) of cooling system - vent pipe (SW14) . Remove pipe. C2 C1 3 05.01 ill.8 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 23 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 18 Loosen hose clamp (ill.9/pos.1) of hose of oil separator and remove hose. 1 19 Loosen 4 hexagon nuts (ill.10+11/pos.1) of turbocharger flange. Remove turbocharger and seal, dispose seal. (if seal is used) 05.01 ill.9 1 1 05.01 ill.10 Assembly: ATTENTION: Check hose connection and hose between turbocharger return pipe and engine housing intake for crack and damage. Replace, if necessary. 1 05.01 ill.11 For 4 cyl. engines only Clean sealing surface of flange turbo charger and exhaust manifold and lubricate with grease Z012222/0. For 6 cyl. engines only: Clean sealing surfaces of flange turbo charger and exhaust manifold. Replace flange seal. Further assembly is done in reverse order. ATTENTION: Tigthen the two spring-clamps of hose turbocharger - intercooler with a torque of 3,5 Nm. Don´t strip! Page FUEL SYSTEM - 24 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM For 4 cyl. engines only (item 1-2) 1 Tighten 4 hexagon nuts of turbocharger flange with a torque of 25 Nm +/-2. 2 Tighten 2 screws for fixing the flange of oil return pipe with a torque of 10 Nm +/-1. Tighten hollow screw with 25 Nm +/-3. For 6 cyl. engines only (item 3-6) 3 Tighten 4 hexagon nuts of turbocharger flange by means of torque wrench No. 2300743/0 and treehandled socket wrench No. 2300744/0 with a torque of 40 Nm +/-4. 4 Tighten 2 screws for fixing the oil return pipe flange with a torque of 23 Nm +/-2. Tighten hollow screw with 40 Nm +/-4. 5 Tighten hollow screw of vent pipe (cooling circuit) with a torque of 20 Nm +/-2 . Maintain horizontal position of banjo fitting while tightning hollow screw. 6 Fill closed cooling circuit, refer to 05.00.08 03.05.02 Check bearing clearance measuring point Measure end clearance: 1 Put test prod of dial gauge onto face of turbine wheel hub. 2 Push cursor downwards and set dial gauge to "0". 3 Push cursor against dial gauge and note deflection of pointer. permissible end clearance: max. 0.16 mm +/-0,01 05.02 ill.1 Measure radial clearance: NOTE: location point of dial gauge prod Determination of radial clearance is only required turbine-sided. 1 Put test prod of dial gauge onto center of retainer cone of turbine wheel. 2 Pull turbine wheel hub upwards by means of spring balance. Measuring strength 50 N. 3 Note deflection of pointer. 4 Repeat measurement, by turning cursor by 90°. Permissible radial clearance: max. 0.42 mm +/-0,04 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine measuring strength 05.02 ill.2 Page FUEL SYSTEM - 25 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.08 CONTROL SOLENOID 03.08.01 Remove control solenoid Prepartion: 1 for 4 cyl. engines only remove intercooler, refer to 01.08.01. Disconnect battery. For 4 cyl. engines only (item 2-3) 2 Loosen plug connection (ill.2/pos.1) for control rack potentiometer. 3 Remove plug from control solenoid (ill.2/pos.2). For 6 cyl. engines only (item 4-11) 4 08.01 ill.1 1 2 08.01 ill.2 Unscrew 3 hexagon screws (SW10) (ill.3/pos.1) of upper timing belt covering. 1 08.01 ill.3 5 Unscrew 2 hexagon screws (SW10) (ill.4/pos.1) of front control solenoid covering. 1 08.01 ill.4 Page FUEL SYSTEM - 26 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 6 Loosen 2 hexagon nuts (SW10) (ill.5/pos.1). Remove boost pressure sensor. 7 Loosen plug (ill.5/pos.2) for potentiometer accelerator. 8 Loosen 3 hexagon nuts (SW10) (ill.5/pos.3). Remove bracket with potentiometer accelerator. 9 Remove plug (ill.5/pos.4) for sensor of control rod. 10 Remove plug (ill.6/pos.1) from control solenoid. 11 Loosen 4 hexagon screws (SW13) (ill.6/pos.2) on control solenoid housing; Remove control solenoid assembly. Remove seal and dispose. 03 FUEL SYSTEM C3 C1 C4 C2 08.01 ill.5 1 2 For 4 cyl. engines only 12 08.01 ill.6 Loosen 4 hexagon screws (SW13) (ill.7) on control solenoid housing, remove control solenoid assembly. Remove seal and dispose. 08.01 ill.7 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 27 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.08.02 Install control solenoid To install control solenoid assembly onto camshaft housing, proceed as follows: NOTE: Use new gasket for control solenoid if fitted. O-ring can be re-used. 1 Remove camshaft housing cover. 2 Move control rack by hand (ill.1) to front position and hold. 3 Insert control rack lever in to the solenoid as shown. (ill.2/pos.1) 08.02 ill.1 4Bring up control solenoid assembly parallel to sealing surface of camshaft housing, put it onto the dowel pin(s) (ill.3/pos.1) and hold. 5 Slowly release control rack and fasten control solenoid housing by means of 4 screws. 6 For 4 cyl. engines only Secure the 4 screws with LOCTITE 243 and tighten with a torque of 23 Nm +/-2. 7 1 08.02 ill.2 For 6 cyl. engines only (item 8-9) Cover the two lower screws with LOCTITE 243 and slightly tighen. 8 Cover the two upper screws with LOCTITE 243. Bring into position bracket with potentiometer accelerator and fix with upper screws. Tighten the 4 screws with a torque of 23 Nm+/-2. 9 Check whether the control rack can be moved over a distance of approx. 18 mm. ATTENTION: Pin of control rack position sensor is spring-loaded and might easily slip off from the face of control rack lever, during assembly. In such a case, the control rack is blocked and thus prevents resetting to zero delivery ===> ENGINE FAILURE. 10 2 1 08.02 ill.3 Remaining assembly is done in reverse order. NOTE: The rack position sensor is magnetism sensitive. All external magnets must be kept away as the may disturb the sensor. Page FUEL SYSTEM - 28 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.08.03 03 FUEL SYSTEM Replace sensor, indication of control rack position Preparation: For 4 cyl. engines only remove shift plate, refer to 01.08.01, ill.3. For 6 cyl. engines only remove bracket of potentiometer accelerator, refer to 03.08.01, ill. 5-6 1 Loosen 2 Allen head screws (ill.1/pos.1) (SW3). Remove rack position sensor. 08.03 ill.1 Assembly 1 Insert new sensor in such a way that rod of potentiometer (ill.2/pos.1) is positioned in front of solenoid rod (ill.2/pos.2). 2 Secure 2 Allen head screws 3 mm with Loctite 243 and tighten with a torque of 5 Nm +/-0,5. 3 Check whether control rack can be moved over a distance of approx. 18 mm. ATTENTION: Rod of rack rack position sensor is spring-loaded and might easily slip off from the face of solenoid rod (ill.2/pos.2), during assembly. In such a case the control rack is blocked, and thus prevents resetting to zero delivery ===> ENGINE FAILURE. 4 1 2 08.03 ill.2 Remaining assembly is done in reverse oder. NOTE: The rack position sensor is magnetism sensitive. All external magnets must be kept away as the may disturb the sensor. Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 29 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.09 Change fuel filter 1 Water or other fuel contaminations may form deposits which clog the fuel filter and may lead to a disturbance. Therefore, change the fuel filter every 300 operating hours and/or every 2 years at least. 1 Ventilate fuel system. For this purpose, open fuel pipe between fuel filter and fuel supply (from fuel tank or water separator) on filter head (ill.1/pos.1), and operate the pump approx 6 times each 10 sec. = 6 times 10 sec. ignition ON. Make sure that air is sucked. ATTENION: Close fuel cock on tank, if tank is higher than fuel filer. 2 Unscrew filter (ill.2) by means of filter wrench No. 2300713/1. Remove filter and dispose. Take care that original seal does not adhere to filter housing. If so, remove seal and dispose. 3 Clean sealing surface on filter head (ill.3). 4 Slightly oil seal of new fuel filter with clean motor oil (ill.4). 5 Screw on new fuel filter until seal slightly rests on sealing surface of filter head. Then tighten filter by hand with 3/4 turn. 6 Connect fuel pipe between fuel filter and fuel supply or water separator on filter head (ill.1/pos.1) again. 7 Ventilate fuel system. NOTE: 8 09.00 ill.1 09.00 ill.2 09.00 ill.3 Fuel system is ventilated via E-fuel pump. Turn ignition ON 6 times each 10 sec. Remove possibly spilled fuel residues. Start engine and check fuel system for leakage. 09.00 ill.4 Page FUEL SYSTEM - 30 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.11 03 FUEL SYSTEM Replace GlOW Plug Preparation: 03.08.01 For 4 cyl. engines only for glow plug of second to fourth cylinder, remove intercooler refer to 01.08.01 for glow plug of first cylinder, additionaly remove control solenoid - refer to For 6 cyl. engines only for glow plug of first cylinder, remove control solenoid - refer to 03.08.01 for glow plug of second to sixth cylinder, remove intercooler refer to 01.08.01 1 Remove glow plug. 2 Unscrew glow plug(s) with special tool No.VR00146/0. 3 Screw in new glow plug(s) by means of special tool No. VR00146/0 and tighten by means of special tool No. 2300703/0 with a torque of 15 Nm +/-1. 11.00 ill.1 NOTE: Exactly keep torque of 15 Nm +/-1 when fixing glow plugs! 11.00 ill.2 Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 31 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.12 MEASUREMENT OF COMPRESSION PRESSURE Preparation: remove glow plug, refer to 03.11 1 Screw special tool glow plug adaptor 230 0638/2 (ill.1) into cylinder to be checked (ill.2). 2 Connect pressure hose of compression pressure meter No. 2300750/0 to glow plug adaptor (ill.2). 3 Connect pressure hose to compression pressure meter No. 2300750/0 (ill.3). 4 Remove plug J1. Connect special tool No. VR00145/0 instead of plug J1. 5 Put into operation compression pressure meter according to operating instructions. 6 Start engine by pressing the button for 5 to 10 sec. of special tool No. VR00145/0 until compression pressure rises no more. ATTENTION: 12.00 ill.1 12.00 ill.2 Start with special tool VR00145/0 only. Engine may just turn, but not feed and inject fuel. 12.00 ill.3 Compression pressure for all STEYR MARINE DIESEL ENGINES NOM. VALUE 21,0 +/- 1,0 bar 7 LOWER BOUNDARY VALUE 18,0 +/- 1,0 bar Assembly is done in reverse order. Page FUEL SYSTEM - 32 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 33 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.14 03.14.01 FUEL SYSTEM CHECK Manual injection test methode Preparation: 1 Remove camshaft housing cover, refer to 01.00.02 1 Remove plug screw (ill.1/pos.1) with sealing ring. 14.01 ill.1 2 Mount special tool No. VR00148/0 (ill.2/pos.1) together with sealing ring (ill.2/pos.2). 2 1 14.01 ill.2 3 Move control rack by means of special tool No. VR00148/0 into idle injection position (approx.5-6 mm) (ill.3) and remain in this position. 14.01 ill.3 Page FUEL SYSTEM - 34 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 4 03 FUEL SYSTEM Put unit injector withdrawing lever No. VR00126/0 onto rocker arm of individual unit injectors (ill. 4) and move upper end of lever in direction of air intake manifold. As a result, unit injector is pressed down and injection process is simulated. NOTE: When moving the unit injectors, a creaky noise is to be heard during the injection process and/or a solide resistance is to be felt due to produced injection pressure (pressure point) . If no difference is detectable in the individual unit injectors, continue with item 5. 5 Adjust control rack by means of special tool No. VR00148/0 to partial load (approx. 10-12 mm in direction full delivery) (ill.3) and remain in this position. 6 Repeat item 4. 14.01 ill.4 NOTE: 7 Defective unit injectors which fail to produce a creaky noise in one or none of the two checks and/or where no resistance (pressure point) can be felt are to be exchanged. (Exchange unit injector, refer to 03.02.02). Assembly is done in reverse order. ATTENTION: Absolutely remove special tool No. VR 00148/0. Use new sealing ring. Manual check of unit injector without tool No. VR 00148/0 Fuel System Check: 1. Investigate condition of return fuel. There should be neither air bubbles nor discoloration (gray) in the fuel. 2. Check proper flow quantity (i.e. engine at idle - flow rate after engine block 180 to 240 l/hr; 47 to 63 gal.) Injector Check: To feel the injection activities, move the control rack (quantity delivery) in between its acceptable travel (5 to 14mm) while depressing the „plunger“ with the rocker arm. For safe and easier handling, use our special tool lever. While moving the rocker arm (and/or the plunger up and down), try to get the control rack into idle delivery position (approx. 4-5 mm). In this spot you will feel only a very slight/short pressure build up as the duration of injection is very short (~ 5mm³/stroke). Keep this position on the control rack (freeze there) and then move over with tool VR 00126/0 to the next unit injector/rocker arm to repeat the plunge movement and feel the resistance during injection. The test should give an equal pressure load/peak on each injector, while maintaining the same position on the control rack. If one injector fails to show any pressure or this pressure peak is found in a much higher position of the control rack, this is an indication for a possible deficiency on this injector. ATTENTION:Before removing this unit injector from the engine, check for proper adjustment of the linking lever and for correct fit/tightness and/or torque of the unit injector mounting nuts. Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 35 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.14.02 Disengagement methode of injection NOTE: Disengagement methode of injection is a simple and effective method to detect defective unit injectors with regard to formation of bubbles in both the fuel system and the engine cooling system or lack of power it related to deficiencies in injection equipment. Preparation: Remove camshaft housing cover refer 01.00.02 Special tool: 4 cyl. engines VR00133/1 6 cyl. engines with bossed seal surface VR00133/0 6 cyl. engines with plane seal surface VR00133/2 1 Mount special tool No. VR00133/.(see list special tool) to disconnect injection. 2 Start the engine, let it run in idle and check if bubbles form. NOTE: 1 2 14.02 ill.1 If there are no bubbles at idle speed of engine, continue with item 3. 3Bring engine to operating temperature and then test the boat under operating conditions and watch for bubbles to form. Keeping this operating condition, continue with item 4. 4 Loosen nut on cover (ill .1/pos.1), screw in, with fast turns, screw (ill.1/pos.2) until knocking noise disappears. Tighten nut (ill.1/pos.1) again. As a result, unit injector is pressed down to such an extent that injector cam can no more touch the rocker arm, thus preventing the injection of fuel. (respectively eliminating combustion) 5 Test the boat with disengaged unit injector under operating conditions and observe the returning fuel if bubbles still appear. 6 Continue to check all other injectors (cylinders) in order to detect the defective(s) unit injector(s). NOTE: Bubble formation will change and/or stop as soon as injection of defective unit injector(s) is disengaged. 7 Replace defective unit injector(s). (Replace unit injector, refer to 03.02.02) Page FUEL SYSTEM - 36 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 SERVICE MANUAL MARINE ENGINES 03.14.03 03 FUEL SYSTEM 1 Air bubble formation in fuel system 2 Preparation: Change fuel filter, if necessary refer to 03.09 (item 1, ventilate fuel system) Special tool: Testing device for fuel return 2300719/1 1 Disconnect hose from fuel return line on fuel cooler outlet to fuel tank. (ill.2/pos.1). 2 Connect hose (ill.1/pos.1) of testing device 2300719/1 to tandem cooler outlet. (ill.2/pos.1). 3 Connect hose (ill.2/pos.2) of testing device 2300719/1 with return hose to fuel tank. (ill.2/pos.2). 4 Hold testing device, glass bulb upwards (ill.2/pos.3), or fix it on the boat. 14.03 ill.1 3 1 2 Procedure: 14.03 ill.2 Check 1: Ventilate fuel system by 6 times ignition ON. Observe the sight glass as to complete ventilation of system (bubblefree fuel flow). Result: If a bubblefree fuel flow cannot be achieved, search for the problem at the suction side (from fuel tank to fuel pump). Check: 1. Fuel in tank. 2. Tank suction pipe and fitting 3. ANTI-SIPHON VALVE (if installed) leckage. 4. Water separator leaky or contaminated. 5. Check all fuel lines connections and fittings in the feed line (suction side) up to fuel pump intake. After a bubblefree fuel flow can be achieved, continue with check 2. Check2: Start the engine and let it run at idle speed. Observe the glass bulb. Result: If bubble formation starts, search for the problem in the unit injectors. Probable contamination , on one or several nozzle elements cause a problem. Due to compression/combustion pressure, gases into the are forced fuel system throug the unit nozzle(s). Z001019/0_7_July 2012 Downloaded from www.Manualslib.com manuals search engine Page FUEL SYSTEM - 37 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Check: Manual: Defective unit injector(s) is/are to be detected definitely by means of "manual injection test methode" (manual injection test methode, refer to 03.14.01) If during disengagement methode of injection of unit injectors a creaky noise is to be heard and a solide resistance (pressure point) can be felt, check the tightening torque of the unit injectors (03.02.02 - assembly item 11). Then repeat check 3. If a bubble formation appears during load operation, continue with check 3. Check 3: Start the engine, bring it to operating temperature, test the boat under operating conditions and observe the glass bulb. Result: If it comes to bubble formation, search for the problem in the area of unit injectors. Control: Defective unit injector(s) is/are to be detected definitely by means of "Disengagement methode of injection" (manual injection test methode, refer to 03.14.01) If there is still bubble formation, continue with check 4. Check 4: Test the engine in the operating state where bubble formation occurs, by disengagement of injection per cylinder one after the other. (Disengagement methode of injection, refer to 03.14.02). Assembly is done in reverse order. Page FUEL SYSTEM - 38 Downloaded from www.Manualslib.com manuals search engine Z001019/0_7_July 2012 ToC SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM 04 EXHAUST SYSTEM Table of Contents Page 04.01 04.01.01 04.01.02 Hi-Riser ................................................................................................... 3 Replace Hi-Riser ....................................................................................... 3 Measurement of Exhaust Backpressure ................................................... 4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page EXHAUST SYSTEM - 1 ToC SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM THIS PAGE IS INTENTIONALLY BLANK Page EXHAUST SYSTEM - 2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 04.01 04.01.01 HI-RISER Replace hi-riser Preparation: If necessary, remove heat shield turbocharger. 04 EXHAUST SYSTEM Disassembly: 1 Disconnect plug (ill.2/pos.1) for exhaust temperature switch. 01.00 ill.1 2 If bracket is used loosen hexagon screws (ill.2/pos.2) of bracket. 3 3 Loosen hose clamp (ill.3/pos.1) connecting hose; heat exchanger - hi-riser. 4 Loosen 2 hose clamp (ill.4/pos.2) from exhaust pipe elbow. 5 Variant 1 Loosen hexagon screws (ill.2/pos.3) of hi-riser. Remove hi-riser. 6 Variant 2 Loosen profiled clamp (ill.4/pos.1) of hi-riser. Remove hi-riser. 2 1 01.00 ill.2 1 Assembly: 01.00 ill.3 1 Prior to assembly, clean sealing surfaces of turbocharger - high-riser and lubricate with high-temperature grease.(SMO Z012222/0) 2 Replace seal (if used). Tighten screws (M8) with a torque of 23 Nm. (Lubricate threads with high temperature grease Z012222/0) Tighten profile clamp hand-screwed. 3 Remaining assembly is done in reverse order. 1 2 01.00 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page EXHAUST SYSTEM - 3 ToC SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM 04.01.02 Measurement of exhaust backpressure special tool No. VR00136/0 9 10 1 2 8 3 4 7 ill.1/pos.1 ill.1/pos.3 ill.1/pos.4 ill.1/pos.5 ill.1/pos.6 ill.1/pos.7 ill.1/pos.9 pressure gauge (0-1 bar) intermediate sealing ring pressure gauge connection pressure hose double union sealing ring screw-in adaptor 1 Disconnect plug for exhaust temperature switch (ill.2/ pos.5). 2 Dismantle high-riser temperature sensor, connect plug to sensor again, and fix it temporary on the engine. 3 Mount double union (ill.1/pos.6) with sealing ring (ill.1/pos.7) instead of hi-riser temperature sensor. 4 For 6 cyl. engines only (with FORD ECU) 6 5 01.02 ill.1 1 9 7 6 3 4 5 Screw in double union (ill.1/6) with sealing ring (ill.1/ 7) into screw-in adaptor (ill.1/9) and mount screw-in adaptor instead of hi-riser temperature sensor. 5 Mount seal ring (ill.1/pos.3) with pressure gauge connection (ill.1/pos.4) onto pressure gauge (ill.1/ pos.1) Connect pressure gauge to one end of pressure hose (ill.1/pos.5). 6 Connect the other end of pressure hose (ill.1/pos.5) to double union (ill.1/pos.6). 01.02 ill.2 MEASUREMENT: Drive the boat under operating conditions (rated output at rated speed) and read off pressure on pressure gauge. RESULT: With an exhaust pressure below 100 mbar at rated output of engine, the exhaust system is dimentional correctly and represents the ideal status. (up to max. 200 mbar acceptable) With an exhaust pressure exceeding 200 mbar at rated output of engine, tuning of exhaust system is no more ideal. To avoid losses in efficiency, changes in the exhaust system should be made (pipe diameter, pipe lengths, muffler etc.) An exhaust pressure of 300 mbar at rated output of engine is no more acceptable. ATTENTION: Changes in the exhaust system (pipe diameter, pipe lengths, muffler etc.) absolutely required. Considerable influence on output, fuel consumption and life of engine. 7 Assembly is done in reverse order: Page EXHAUST SYSTEM - 4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05 COOLING SYSTEM Table of Contents Page 05.00 05.00.01 05.00.02 05.00.03 05.00.04 05.00.05 05.00.06 05.00.07 05.00.08 Functional description cooling circuit ............................................... 2 Raw water circuit (external cooling circuit) ............................................. 2 Closed coolant from cooling circuit (internal engine cooling circuit) ....... 4 Error detection cooling system ............................................................... 6 Check points for problems in cooling system ......................................... 9 Component check raw water system ................................................... 10 Component check engine cooling system ................................................ 11 Drain the coolant system........................................................................ 13 Fill the cooling system ............................................................................. 15 05.01 05.01.01 05.01.02 05.01.03 05.01.04 05.01.05 05.01.06 05.01.07 05.01.08 Cooler, heat exchanger, expansion tank ............................................ 16 Coolant tank ........................................................................................... 16 Disassembly exhaust manifold - heat exchanger .................................. 17 Checks ................................................................................................... 21 Exchange heat exchanger element ........................................................ 23 Assembly of exhaust manifold ............................................................... 24 Exchange tandem cooler ........................................................................ 26 Exchange additional oil cooler (only type 246) ........................................ 26 Exchange triple cooler............................................................................. 27 05.03 05.03.01 05.03.02 05.03.03 Pipes, thermostat ................................................................................. 27 Coolant pipes and hoses ....................................................................... 27 Exchange thermostat ............................................................................. 28 Exchange sacrificial anodes ................................................................... 30 05.04 05.04.01 05.04.02 Coolant pump ........................................................................................ 31 Exchange coolant pump ........................................................................ 31 Install coolant pump ................................................................................ 32 05.06 05.06.01 Poly-V-Belt ............................................................................................. 33 Exchange Poly-V-belt .............................................................................. 33 05.07 05.07.01 05.07.02 V-belt ...................................................................................................... 34 Exchange V-belts .................................................................................... 34 Adjust V-belts .......................................................................................... 36 05.10 05.10.01 Raw water pump ................................................................................... 37 Exchange raw water pump ...................................................................... 37 05.12 05.12.01 Checks .................................................................................................. 38 Check closed engine cooling system for air ............................................ 38 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 1 ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES 05.00. FUNCTIONAL DESCRIPTION COOLING CIRCUIT 05.00.01 Raw water circuit (external cooling circuit) Raw water is fed to the engine via a vane-type pump in the secondary circuit. The raw water pump (ill.1/2) is a self-sucking pump and is driven for 4 cyl. engines via Poly-V-belts and for 6 cyl. engines via V-belt. The impeller is arranged eccentrically. At higher speeds, it acts as combinded centrifugal- and displacement pump. At slow speeds, the impeller acts as displacement pump. This causes a pump effect of the impeller wings during operation of the engine. At high engine speed, the resistance of water on its way through the pump is sufficient to avoid a contact of the impeller wing with the inner side of housing. The wings are only bent inside in direction of impeller center, thus acting as combined centrifugal- and displacement pump. Raw water is fed to the raw water pump via raw water pick-up (ill.1/1) and/or via drive unit (Z-drive, jetdrive) and/or raw water filter (ill.1/11) arranged between. From the raw water pump, water flows into the combined fuel- (ill.1/3) and steering- and/or transmission oil cooler (ill.1/4) where the raw water absorbs thermal energy from the fuel- and steering- and/or transmission oil system. Then water flows through the tube stake of intercooler (ill. 1/5) where the raw water absorbs thermal energy from air charge. Through the connecting line above the rear part of the camshaft case the raw water enters the tube stake of heat exchanger (ill.1/6) where the raw water still absorbs thermical energy from engine coolant. Then raw water flows through the high-riser (ill.1/7) where the raw water still absorbs thermal energy from exhaust gas, and finally leaves, mixed with exhaust gas, the raw water circuit via exhaust pipe (raw water outlet) (ill. 1/9) either through the drive or a muffler, and is blown in below water surface. The splash water flap (ill.1/12) avoids a possible raw water entry with stopped engine. The raw water circuit is equipped with 5 sacrificial anodes (ill.1/10) (for salt water made of zinc; for sea water magnesium anodes are recommended). Temperature of raw water, mixed with exhaust gas, is controlled by means of sensor (ill.1/8) on highriser and transmitted to the electronic management system. If during operation the limit of 60°C is exceeded, the electronic management system will reduce the engine power to a perceptible extent of up to 50%. This disturbance will be indicated on the instrument panel by means of signal lamp for engine check which blinks 2 times/sec. and an audible warner (2times/sec). ATTENTION: To exclude consecutive damages, occured trouble should be analyzed and eliminated as soon as possible. Page COOLING SYSTEM - 2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 00.01 ill.1 1 2 3 4 5 6 7 8 9 10 11 12 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Raw water intake Impeller pump Fuel cooler Hydraulic oil- and transmission oil cooler Tube stake - intercooler Tube stake - heat exchanger Hi-riser Sensor exhaust gas temperature Raw water outlet Sacrificial anodes Raw water filter Splash water flap Page COOLING SYSTEM - 3 ToC 05 COOLING SYSTEM 05.00.02 SERVICE MANUAL MARINE ENGINES Closed coolant from cooling circuit (internal engine cooling circuit) In the closed (primary) cooling circuit of the engine, the coolant circulates by centrifugal pump (circulating pump) mounted at the front of motorblock. The belt pulley of the pump is driven from the back of the timing belt. The pump is maintenance-free. The engine coolant in the closed circuit of the cooling system circulates as follows: The circulating pump (ill.2/1) of the engine feeds the coolant through the oil cooler (ill.2/2) where thermal energy is absorbed from motor oil. Then the coolant flows through the water jacket (ill.2/3) into the motorblock. Coolant circulates around the cylinders. Here, thermal energy of combustion is absorbed. Then coolant reaches the exhaust manifold (ill.2/4), flows through the exhaust manifold in a separate channel and absorbs thermal energy from exhaust gas. For most of 6 cyl. marine engines (excluded 256H), coolant additionally flows through the exhaust turbocharger (ill.2/5). Here, thermal energy is also absorbed from exhaust gas. Then the coolant reaches the thermostat housing. By means of thermostat, depending on the engine's operating temperature, the coolant is fed to the heat exchanger or directly to the engine coolant pump. If the engine has not yet achieved the operating temperature of 80°C, the thermostat remains closed and the coolant is fed via contact-channel directly to the intake side of coolant pump. This circulating circuit (ill.2/A) is continued until the coolant in the thermostat housing (ill.2/6a) has achieved the temperature (80°C). As soon as the temperature of 80°C in the thermostat housing is achieved, the thermostat opens and the coolant is partially (thermostat opens according to operating temperature) transmitted to the heat exchanger (ill.2/B). Via the contact-channel the coolant partially arrives directly at the intake-side of the coolant pump (ill.2/A). Only after the coolant in the thermostat housing has achieved a temperature of 90-93°C, the thermostat (ill.2/6b) is completely open. From this time, the whole coolant flows through the tube stake of heat exchanger (ill.2/7) in the exhaust manifold housing. Here, the warmed up coolant releases thermal energy to the raw water circuit, and the coolant is fed via engine water pipe to the centrifugal pump again. The heat exchanger is an integrated component of the aluminium exhaust manifold. This component also includes the expansion tank (ill.2/9) with coolant reservoir, required for the pressure system. Operating pressure is regulated via excess-pressure valve (opening pressure 0,9 bar) in the cooler cap (ill.2/10). Coolant temperature is measured by means of sensor (ill.2/11) on exhaust manifold next to drain cock (ill.2/12) of coolant, and transmitted to the electronic management system. If during operation the limit (107°C) is exceeded, the electronic management system will reduce the engine power to a perceptible extent of up to 50%. This disturbance is indicated on the instrument panel by an audible warner (2 times/sec.). ATTENTION: To avoid consecutive damages, occured trouble should be analyzed and eliminated as soon as possible. Page COOLING SYSTEM - 4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM B Circuit thermostat open 00.02 ill.2 A Circuit, thermostat closed 1 2 3 4 5 6a Circulating pump Oil cooler Water jacket, block/cylinder Water cooled exhaust manifold Turbocharger Thermostat (closed) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 6b 7 8 9 10 11 12 Thermostat (open) Tube stake - heat exchanger Water-intake pipe Expansion tank Filler cap Coolant temperature sensor Drain plug Page COOLING SYSTEM - 5 ToC 05 COOLING SYSTEM 05.00.03 1 SERVICE MANUAL MARINE ENGINES Error Detection Cooling System Ask for the following information: - How old is the device (engine number and model)? - How many operating hours (wear and corrosion)? - How long does the problem already exist (gradual or sudden occurence)? - Operating conditions prior to occurence of problem (interior waters, salt water, muddy or sandy water?) - What repair- or service works have already been carried out (exchange of impeller, etc.)? - At what engine speed does the problem occur? - At what engine load does the problem occur? 2 Raw water circuit (external) 2.1 At first, take into consideration the following possibilities: - Defective or faulty cooling water temperature sensor (high-riser) - Sufficient rate of flow for raw water - raw water pick-up damaged or clogged - wrongly mounted raw water pick-up - raw water filter clogged - stop valve (bottom valve) defective (only opens partially) - Raw water pump - impeller defective (broken or strong wear) - suction pipe from raw water filter to raw water pump clogged or deformed - shaft bearing defective - Sealing - O-ring of impeller housing defective - impeller plate seal - Tandem cooler contaminated (e.g. through a part of broken impeller) Tube stake - intercooler contaminatd Heat exchanger exhaust - contaminated - seal in heat exchanger cover defective. - Ventilation Alga vegetation on quill Deformations on hull, etc. 2.2 - Problems of raw water supply due to troubles in the drive unit - defective seals or water pipes in lower gear box - damaged rubber seal on water pipe - damaged seal on box inlet - leaky impeller plate seal - leaky O-ring on impeller housing - defective hose connection between pivot housing and Cardan housing - observe notes and instructions of manufacturer. 2.3 - Inspection wether air reaches raw water. Procedure: Replace water hose between raw water pump and tandem cooler (fuel/hydraulic cooler) by transparent plastic hose. Let the device run in a test tank or with the boat in water, at rotation speeds which cause an overheating, in order to detect a possible bubble formation in the transparent plastic hose. Page COOLING SYSTEM - 6 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES NOTE: 2.4 05 COOLING SYSTEM When testing the device in a test tank, let the engine run in idle gear. For some test tanks the water volume possibly may not be sufficient to let the engine run in a gear without creating considerable turbulences. These could take effect onto water suction and be interpreted by mistake as a cooling problem. Check rate of flow of raw water. 9 Special tool No. VR00136/0 (ill.1) 8 ill.1/pos.2pressure gauge (0-4bar) ill.1/pos.3intermediate sealing ring ill.1/pos.4pressure gauge connection ill.1/pos.5pressure hose ill.1/pos.10 pipe stub, measurement of pressure raw water 7 6 10 1 2 3 4 5 Measurement of pump feed pressure at the outlet of raw water pump (ill.2) 1 2 Disconnect hose from pressure side of raw water pump, connect pipe stub (ill.2/pos.10) and connect raw water hose to pipe stub again. Mount intermediate sealing ring (ill.2/pos.3) with pressure gauge connection (ill.2/pos.4) onto pressure gauge (ill.2/pos.2) and connect it at one end of pressure hose (ill.2/pos.5). 3 Connect the other end of pressure hose (ill.2/pos.5) to pipe stub (ill.2/pos.10). 4 Start the engine and check for leakages. 00.03 ill.1 2 3 4 10 5 00.03 ill.2 5 Put boat into operation and approach speed points according to diagram. Compare measured pressure with table below. Conclusion: - If the pump pressure is lower than the min. quantity in the table, the problem is at suction side of raw water system. - If the pump pressure is higher than the max. quantity in the diagram, the problem is at pressure side of raw water system. Raw water pump delivered pressure (standard impeller) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine RPM Bar 600 0,20 1300 0,60 1800 1,00 2300 1,50 2800 1.85 3300 1,80 3800 1,60 4300 1,45 Page COOLING SYSTEM - 7 ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES 3 Closed Cooling Circuit (internal) 3.1 At first, take into consideration the following possibilites: 3.2 - Defective or faulty coolant temperature sensor. Coolant level in expansion tank < as minimum. - Malfunction of thermostat - thermostat does not open or opens only partially - thermostat blocked in partially open state - thermostat blocked in completely open state - damaged thermostat sealing ring - Malfunction of water circulating pump of engine - pump bearing defective - defective impeller seal - excessive wear of impeller wings - Cooler cap (pressure loss) - Cooler cap sealing defective - vacuum valve defective - excess-pressure valve defective. Malfunction of thermostat - overheating or slow heating of coolant: - Procedure: Let the engine run until indicated temperature exceeds 80° C. Feel on hose of front engine water pipe between heat exchanger and water-intake pipe. - Result: - Conclusion: Thermostat got stuck in closed state. - Result: - Conclusion: Thermostat opens partially or completely. - Procedure: Let the engine run; temperature of coolant will rise very slowly (feel on hose of front engine water pipe between heat exchanger and water-intake pipe). - Result: - Conclusion: - Thermostat blocked in partially open or completely open state. - Sealing ring of thermostat defective. - Control: Hose cold. Hose warm or hot. Themperature on hose slowly rises simultaneously with temperature of coolant, but does not reach operating temperature (80°C opening temperature of thermostat). - Thermostat got stuck in open or closed position. - Defective thermostat sealing. - Wrong thermostat for this type of engine. Page COOLING SYSTEM - 8 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.00.04 1 2 05 COOLING SYSTEM Check points for problems in cooling system Raw water circuit 1.1 water intake - clogged 1.2 raw water filter - clogged - strongly contaminated - filter defective 1.3 hoses - fragile or leaky 1.4 hose clamps - loose or defective 1.5 raw water pump - impeller stronlgy worn - impeller broken - cover loose - shaft bearing defective 1.6 tandem cooler - clogged - leaky - broken 1.7 intercooler - pipes clogged - internal leakage 1.8 exhaust manifold - heat exchanger clogged - internal leakage 1.9 cooling water temperature sensor - defective 1.10 manifold, elbows, seals, hoses - wrongly mounted seals - sand or dross in manifold - burned out hoses 1.11 hull NOTE: Mountings protruding over the hull may produce cavitations during fast ride which cause air bubbles. These are possibly taken at the lower gear box by the drive and mixed with the inflowing cooling water. Due to bad refrigerating capacity of the external cooling system, an overheating in the internal cooling system (engine) may occur. - state of hull - marine vegetation - equipment attached to hull Internal Cooling Circuit 2.1 hoses - craked or leaky 2.2 hose clamps - loose or defective 2.3 thermostat - thermostat defective - wrong thermostat 2.4 cooler cap - defective excess-pressure valve - defective vacuum valve - damaged cover sealing 2.5 coolant circulating pump - defective casing sealing - damaged bearing - worn impeller - defective slide ring sealing 2.6 coolant guide on cylinder block Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine - leaky connectors Page COOLING SYSTEM - 9 ToC 05 COOLING SYSTEM 05.00.05 1 SERVICE MANUAL MARINE ENGINES Component Check Raw Water System Hoses and clamps, drain plug etc. For all models: no special tool required. Control works: Check all external components of cooling system for leakage, wear and damages. Check tightness of all connections. Check hoses for cracks, breaks or wear. Water-supply hoses must be in accordance with SAE 20R3 specifications, class D-2. Repair works: Repair or exchange, as required. 2 Manifold, heat exchanger and intercooler: No special tools required. Control works: Check components for leakage, in a pressure test. Disassembly and check for corrosion and material residues. Repair works: Remove residues of foreign material from pipes. If there are signs of spongy spots between water ducts and exhaust channel, the component is to be exchanged. Also check exchangeable elements for damages. For assembly, use new sealings and sealing rings. 3 Raw water pump No special tools required. Control works: With running engine, check rotation of pump belt pulley. If belt pulley runs out of true, this may cause excessive wear of the pulley and damages on the pump itself. If with running engine leakages on the pump are stated, the shaft sealing ring at the front of the pump is leaky or the spacer is defective. Repair works: Not provided; exchange pump. 4 Fuel- and oil cooler No special tools required. Control works: Check components for internal leakage, in a pressure test. If possible, dismantle and check for corrosion and residues of foreign material. Repair works: Remove residues of foreign material. If possible, exchange inserts or replace components. 5 Water pump in stern-drive No special tools required. Control works: Check water sucking filter at lower gear box for clogging. Check for sufficient water supply - as per section Cooling System - Error Detection. Repair works: Dismantle water pump and repair or exchange defective components. For assembly, take care of respective sealing of water pump. See notes and instructions of manufacturer. Page COOLING SYSTEM - 10 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.00.06 1 05 COOLING SYSTEM Component Checks of Engine Cooling System Hoses and clamps, drain plug etc. For all models: no special tool required. Control works: Check all external components of cooling system for leakage, wear and damages. Check all connections for tightness. Check hoses for cracks, breaks or wear. Repair works: Repair or exchange Water-supply hoses must be in accordance with SAE 20R3 specifications, class D-2. 2 Thermostat No special tools required. Control works: As a standard, an 80° C thermostat is used for the marine engine. Check thermostat for correct model and correct rated output, corrosion, limited mobility or broken spring. Repair works: No repair possible. Exchange thermostat. Test procedure: 00.06 ill.1 Dip the thermostat together with a thermometer into a water tank and heat up the water. At a temperature of 80-81° C the thermostat should begin to open, and should open for 3,8-4,0 mm at a temperature of 85-88° C (ill.1/A). At 90-93°C the thermostat should be open for 7 mm in order to lock the little cooling circuit (contact-channel), thus permitting a complete flow through the heat exchanger. Off 95 °C, the complete thermostat stroke of 8.0-8,2 mm is achieved. 3 Water pump (coolant circulating pump) No special tools required. Control works: If with running engine leakage on the pump is stated, the slide-ring sealing at the front of the pump is leaky. Repair works: Not provided; exchange pump. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 11 ToC 05 COOLING SYSTEM 4 SERVICE MANUAL MARINE ENGINES Cooler cap No special tools required. Control works: As a standard, a cooler cap with an opening pressure of 1,0 bar is used. Check cooler cap for correct rated output, defective sealing (ill.2/ pos.1), defective vacuum valve (ill.2/pos.2) or broken spring (ill.2/pos.3). 3 1 2 Repair works: Not provided; exchange cooler cap. 00.06 ill.2 5 Coolant loss in closed engine cooling system 5.1 Coolant loss: Control works: - (item 4) check cooler cap - defective exhaust manifold (exhaust gases reach the engine cooling circuit) - defective monoblock (due to combustion pressure, gases reach the engine cooling system). 5.2 Gas-air mixtures reach the cooling system. 5.2.1- Defective exhaust manifold Control works: 05.01.03 Check exhaust manifold heat exchanger. 5.2.2 - Defective (leaky) monoblock Control works: Use special tool SMO: VR00147/0 by using enclosed instruction. Conclusion: Gas entry (combustion pressure) in the engine cooling circuit. Control works: Assembly of unit injector, refer to 03.02.02 "ASSEMBLY" item 11; check specified tightening torque. Repeat check. If result remains unchanged, the monoblock is defective. Repair works: Not provided; exchange monoblock. Page COOLING SYSTEM - 12 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.00.07 05 COOLING SYSTEM Drain coolant system Raw water circuit 1 NOTE: 2 1 Remove drain plug (ill.1/pos.1). Drain plug (ill.1/pos.1) does not exist for all models. To drain the raw water ducts on the engine, remove cover rear of raw water pump (ill.2+3/pos.1). NOTE: 00.07 ill.1 For complete removal of water residues from pump housing and water ducts of raw water circuit, proceed as follows: 3 Lock exhaust pipe with special tool No. VR00144/0 (ill.4/pos.1) 4 Remove plug J 1. Connect special tool No. VR00145/0 instead of plug J1. 1 00.07 ill.2 5 Start the engine by pressing the button, until raw water system is completly emptied. ATTENTION: Only start with special tool No. VR00145/0. Engine only be cranked by starter motor, but not start. 6 After complete drainage, assembly is done in reverse order. ATTENTION: If the water is not drained in time before the winter season, this could result in frost damage on the engine as well as the drive. 1 00.07 ill.3 1 00.07 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 13 ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES Closed cooling circuit 1 To drain the closed cooling circuit, lift or lower the bow of the boat in such a way that the engine is in horizontal position, which permits an ideal drainage of motorblock and manifold. ATTENTION: Approx. 1 liter of coolant will remain in the motorblock which is to be considered for refilling. With hot engine, the closed cooling circuit is under pressure. Do not try to open the coolant tank cap or the drain plug when the engine is hot. This could lead to severe injuries by hot coolant under pressure. As soon as the engine has cooled down, the cap may be opened by 1/4 turn to the left, to release possibly remaining pressure. Then press down the cap, turn and remove. 7 8 There are two drain plugs on the engine through which the coolant from the internal cooling circuit can be drained. (Refer to ill.5/pos.1 and ill.6/pos.1) 00.07 ill.5 1 00.07 ill.6 Loosen the two drain plugs (ill.5/pos.1 and 6/pos.1), possibly stick a hose onto the drain plugs and collect the coolant in a bucket. ATTENTION: The closed cooling circuit must always be filled with coolant. If the circuit remains for a long time without coolant, corrosion damages may occur. Page COOLING SYSTEM - 14 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.00.08 05 COOLING SYSTEM Fill cooling system Closed cooling system 1 Fill cooling circuit with specified coolant only. Coolant level should reach the lower edge of the filler neck in the expansion tank. 2 For 4 cyl. & 6 cyl. engines with new exhaust (screwed cap) only NOTE: Cooling system deaerate automatically while filling. For 6 cyl. engines (old version) only (item 3-4) Remove venting screw (ill.2/pos.1) (SW6) at the front of heat exchanger. Fill cooling circuit with specified coolant only. Coolant level should reach the lower edge of the filler neck in the expansion tank. 4 Mount venting screw again and tighten. 00.08 ill.1 ATTENTION: For a new filling of the closed cooling circuit, make sure that the cooling system is deaerated completely. 5 1 Let the engine run, check coolant level and refill coolant if necessary. 00.08 ill.2 Raw water circuit After engine start, filling is done automatically via raw water pump. ATTENTION: Raw water intake valve must be open. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 15 ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES 05.01 COOLER, HEAT EXCHANGER, EXPANSION TANK 05.01.01 Coolant tank The coolant tank is an integrated part of the exhaust manifold - heat exchanger housing and may not be exchanged in single parts. 01.01 ill.1 Page COOLING SYSTEM - 16 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.01.02 Disassembly exhaust manifold heat exchanger Preparation: tip away E-box remove air filter, refer to 03.04 NOTE: 05 COOLING SYSTEM 1 Where appropriate, remove exhaust manifold for these works, while turbocharger and hi-riser remain. 1 Drain closed cooling circuit according to instructions in 05.00.07, drain coolant 2 Unscrew three screws (ill.1/pos.1) of upper timing belt covering. Remove covering. 3 Disconnect water hose (ill.2/pos.2) to thermostat housing. 4 Loosen hose clamp (ill.2/pos.1) and remove coolant pipe. 01.02 ill.1 1 2 01.02 ill.2 For 6 cyl. engines only (item 5-6) 5 6 Loosen hose clamp (ill.3/pos.1) and remove coolant pipe. 1 Loosen hose clamp (ill.3/pos.2) and remove hose. 2 01.02 ill.3 7 Disconnect coolant temperature sensor (ill.4/pos.1). 1 01.02 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 17 ToC 05 COOLING SYSTEM 8 SERVICE MANUAL MARINE ENGINES Cut cable tie for cable- and plug fixing of speed sensor (ill.5/pos.1) on relief hose. 1 01.02 ill.5 For 4 cyl. engines only (item 9-12) 9 Loosen fixing of heat protection. Remove heat protection (ill.6/pos.1). 10 Loosen hose clamp (ill.6/pos.2) and remove hose for air charge pressure box. 11 Loosen screw (SW10) (ill.6/pos.3) for raw-waterpipe support. 1 2 3 01.02 ill.6 12 Loosen hollow screw (SW14) (ill.7/pos.1) of oil feed line on turbocharger. 13 Remove plug of oil pressure switch (ill.7/pos.2). 14 Loosen hollow screw (ill.7/pos.3) of oil feed line on motorblock. Dispose Cu-sealing rings. 1 2 3 01.02 ill.7 15 Loosen 2 hexagon screws (ill.8/1) of oil return line. Dispose seal. 1 01.02 ill.8 Page COOLING SYSTEM - 18 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 16 For 6 cyl. engines only Loosen two hexagon screws on flange of oil feed line. 17 For 4 cyl. engines only Loosen hose clamps of hose connection turbocharger - intercooler (ill.10/pos.1) and remove hose. 05 COOLING SYSTEM 01.02 ill.9 õõ For 6 cyl. engines only (item 18-21) 18 Loosen setscrew (ill.11/pos.1) for support of sea water pipe. 19 Remove covering (ill.11/pos.3) to intercooler by loosening 5 hexagon screws (SW10) (ill.11/pos.2). 20 Loosen hose clamp (ill.12/pos.1) compressor housing connection. 21 Loosen 2 hexagon screws (SW13) (ill.12/pos.2) and remove connecting manifold. 1 01.02 ill.10 2 3 1 01.02 ill.11 C2 C1 01.02 ill.12 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 19 ToC 05 COOLING SYSTEM 22 SERVICE MANUAL MARINE ENGINES Loosen hose clamp (ill.13/pos.1) of oil separator and remove hose. 1 23 Unscrew 8 - 12 screws (SW13) (ill.14/pos.1) and 2 - 3 nuts (ill.14/pos.2) . 01.02 ill.13 1 CAUTION: 24 2 Remove exhaust manifold with turbocharger and high-riser. CAUTION: 25 If the exhaust manifold is not secured, it migth fall when loosening the screws. Heavy unit (approx. 40 kg). Disassembly ONLY with suitable lifting device or second person. 01.02 ill.14 Remove O-rings or gaskets from exhaust manifold or cyl. block, and dispose. 1 01.02 ill.15 Page COOLING SYSTEM - 20 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.01.03 05 COOLING SYSTEM Checks Check exhaust duct for cracks. Check raw water circuit of the heat exchanger in a pressure test with closed outlet nipple. Pressurize inlet nipple with a pressure gauge and immerse manifold into water. At a pressure of 22-25 kPa, the manifold should show no leaks. ATTENTION: Mostly, structural cracks are highly dependent on thermal influence. In order to achieve a more reliable result of the pressure test, the component should be heated up to approx. 80°C. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 21 ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK Page COOLING SYSTEM - 22 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.01.04 05 COOLING SYSTEM Exchange heat exchanger element 7 9 8 6 5 4 3 01.04 ill.1 2 1 Dismantle heat exchanger element: 1 Drain closed coolant circuit, refer to 05.00.07 2 Drain raw water circuit, refer to 05.00.07 (item 1 remove drain plug). 3 Loosen 3 screws (ill.1/pos.1) of heat exchanger cover in front (ill.1/pos.2) and 3 screws (ill.1/pos.8) of heat exchanger cover at the back (ill.1/pos.7). Remove heat exchanger cover in front and at the back. Loosen the element by slightly knocking with a plastic hammer on the rear end of the element, and remove it. Dispose O-ring and rear cover of heat exchanger element as well as seal of heat exchanger cover. 4 Clean all sealing surfaces. Assembly: 5 Grease O-Ring (ill.1/pos.5) with Molykote BR 2 PLUS and push it onto flange of heat exchanger element (ill.1/pos.4). Then insert heat exchanger element from front into exhaust manifold. Grease O-ring (ill.1/pos.6) with Molykote BR 2 PLUS and push it onto exposed rear end of heat exchanger element. 6 Grease seal (ill.1/pos.9) with Molykote BR 2 PLUS and insert it into heat exchanger cover at the back (ill.1/pos.7). Fix cover on exhaust manifold and loosely mount it with 3 screws (ill 1/pos.8) on exhaust manifold. 7 Fix seal (ill.1/pos.3) together with heat exchanger cover in front on exhaust manifold and loosely mount it with 3 screws (ill.1/pos.1). 8 First tighten 3 screws (ill.1/pos.1) of heat exchanger cover in front, with a torque of 23 Nm +/-2, then 3 screws (ill.1/pos.8) of heat exchanger cover at the back, with a torque of 23 Nm +/-2. 9 Remaining assembly is done in reverse order. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 23 ToC 05 COOLING SYSTEM 05.01.05 Assembly of exhaust manifold Preparation: 1 SERVICE MANUAL MARINE ENGINES Check heat exchanger, refer to 05.01.03 Clean sealing surfaces on motorblock. 01.05 ill.1 2 Clean sealing surfaces on exhaust manifold (ill.2/ pos.1). 1 01.05 ill.2 For 4 cyl. engines only (item 3-5) 3 Insert O-ring on cyl. bloc (ill.3/pos.1) by means of Molykote. 1 01.05 ill.3 4 Insert two O-rings (ill.4/pos.1) into exhaust manifold by means of Molykote. ATTENTION: different sizes 1 5 Thinly cover sealing surfaces (ill.4/pos.2) of exhaust manifold with surface sealing agent LOCTITE 5900. 2 01.05 ill.4 Page COOLING SYSTEM - 24 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM For 6 cyl. engines only (item 6-9) 1 Variant with gaskets: 6 Screw 3 assembly bolts for exhaust manifold No. P/N V000229/0 into respective left tapped hole of each seal. Put on new manifold seals. 7 Put exhaust manifold onto 3 assembly bolts (ill.5/ pos.1) Mount manifold screws with washers and tighten sturdily. Remove assembly bolts and screw in remaining 3 screws and 3 nuts with washers, and tighten with a torque of 23 Nm +/-2. 01.05 ill.5 Variant with O-rings: 8 Insert all O-rings into exhaust manifold by means of Molykote. 9 Put exhaust manifold onto 3 assembly bolts (ill.5/ pos.1). Mount manifold screws and tighten sturdily. Remove assembly bolts and screw in remaining 3 screw and 3 nuts. Tighten screws with a torque of 23 NM +/-2, nuts with 10 Nm. 1 For 4 cyl. engines only (item 10-11) 01.05 ill.6 10 Put exhaust manifold onto the two threaded bolts (ill.6/pos.1). 11 Tighten 8 hexagon screws (SW13) (ill.7/pos.1) with a torque of 23 Nm +/-2. Tighten 2 hexagon nuts 10 Nm (SW 10) (ill.7/pos.2). 12 Further assembly is done in reverse order of disassembly. 1 ATTENTION: Plug and cable of speed sensor to be tied up again with 2 cable ties on venting hose. 13 Mount E-box properly. 14 Fill heat exchanger and motorblock with coolant, according to instructions in this paragraph. 2 01.05 ill.7 õ Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 25 ToC 05 COOLING SYSTEM 05.01.06 SERVICE MANUAL MARINE ENGINES Exchange tandem cooler Disassembly 5 Preparation: 3 vent fuel system, refer to 03.09/1 1. Remove drain plug (ill.1/pos.1) to drain the raw water system. 2. Loosen hose clamp (ill.1/pos.2) of hose to raw water pump, and remove hose. 3. Loosen hose clamp of hose bend (ill.1/pos.3) to intercooler, and remove hose bend. 4 Loosen fuel return line (ill.1/pos.4) (SW19) mm and hydraulic lines. 5. Unscrew two Allen head screws (SW6) (ill.1/pos.5) of clamps, and remove tandem cooler (ill.1/pos.6). 1 6 4 2 01.06 ill.1 Assembly Assembly is done in reverse order. ATTENTION: Use new sealing rings. 05.01.07 Exchange additional oil cooler 5 (used only at type 246) 3 Disassembly Preparation: 1. loosen clamp oil dipstick (SW10) 6 Remove drain plug at tandem cooler to drain the raw water system. 2. Loosen union nuts of oil hoses (ill.1/pos.1) (SW 21) at the additional oil cooler. 3. Loosen hose clamp (ill.1/pos.2) of hose to raw water pump. 4. Loosen hose clamp of hose (ill.1/pos.3) to tandem cooler. 5. Unscrew two Allen head screws (SW6) (ill.1/pos.5) of clamps, and remove additional cooler (ill.1/pos.6). 1 1 2 01.07 ill.1 Assembly Assembly is done in reverse order. ATTENTION: Use new sealing rings for oil hoses. Secure union nuts of oil hoses with LOCTITE 243 and tighten with a torque of 20 NM +/-2 Page COOLING SYSTEM - 26 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.01.08 05 COOLING SYSTEM Exchange triple cooler 5 Disassembly Preparation: 1. 3 3 vent fuel system, refer to 03.09, item 1 Remove drain plug at triple cooler to drain the raw water system.(ill.1/pos.1) 2. Loosen union nuts of oil hoses (ill.1/pos.2) (SW 32) at the triple oil cooler. 3. Loosen hose clamps (ill.1/pos.3) of hose to raw water hoses. 4. Loosen fuel lines (ill.1/pos.4) (SW 19) and hydraulik lines (SW 22) 5. Unscrew three Allen head screws (SW6) (ill.1/pos.5) of clamps, and remove triple cooler (ill.1/pos.6). 1 2 4 6 01.08 ill.1 Assembly Assembly is done in reverse order. ATTENTION: Use new sealing rings for oil hoses. Secure union nuts of oil hoses with LOCTITE 243 and tighten with a torque of 45 NM +/-2 05.03 PIPES, THERMOSTAT 05.03.01 Coolant pipes and hoses Remove defective hoses by loosening the respective hose clamps and replace. ATTENTION: Tightning toose clamps with a torque of 3,5 Nm. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 27 ToC 05 COOLING SYSTEM 05.03.02 SERVICE MANUAL MARINE ENGINES Exchange thermostat Preparation: Drain closed cooling circuit refer to 05.00.07, item 7 DISASSEMBLY: 03.02 ill.1 1 Loosen 4 hexagon sockets fixing the covering of thermostat housing. Remove covering and seal. Dispose seal. 03.02 ill.2 Only for 6 cyl. engines with hydraulic system (item 2-3) 2 Loosen hexagon screw (SW10) fixing the oil tank of hydraulic system (ill.3/pos.1). Remove oil tank from mount and fix it laterally to avoid any leaking of hydraulic oil. 3 Loosen the two lower hexagon sockets (SW5) (ill.3/ pos.2) fixing the covering of thermostat housing. Remove covering of thermostat housing and seal together with mount for hydraulic tank. Dispose seal. 2 1 03.02 ill.3 4 Remove spacer (ill.4/pos.1) and thermostat (ill.4/ pos.2) with seal. 1 2 03.02 ill.4 Page COOLING SYSTEM - 28 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM ASSEMBLY: 1 Clean sealing surfaces on thermostat housing and on sealing surface of cover. . 03.02 ill.5 2 Put seal (ill.6/pos.1) onto thermostat. 1 03.02 ill.6 4 Insert thermostat into housing, ventilation mark (ill.7/ pos.1) showing upwards. 1 ATTENTION: Put on new seal. 5 Insert spacer. 6 Remaing assembly is done in reverse order. 7 Tighten screws of thermostat housing cover with a torque of 10 Nm +/-1. 8 Filling of closed cooling circuit, refer to 05.00.08 03.02 ill.7 03.02 ill.8 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 29 ToC 05 COOLING SYSTEM 05.03.03 SERVICE MANUAL MARINE ENGINES Exchange sacrificial anodes The raw water circuit of the cooling system is equipped with five sacrificial anodes. These anodes are to be removed once a year and checked for galvanic erosion. In case of a material loss of 50 %, the anode needs to be exchanged (SW23) . 1 Anodes 1 and 2 (ill.2/pos.1-2) are on the intercooler. 2 Anodes 3 is in the high riser (elbow). 3 Anodes 4 and 5 (ill.2/pos.4-5) are on the heat exchanger. 4 Illustration 1 shows a new anode. NOTE: 03.03 ill.1 For operation with fresh water, magnesium anode sticks are recommended. 03.03 ill.2 Page COOLING SYSTEM - 30 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.04 05.04.01 Preparation : 05 COOLING SYSTEM COOLANT PUMP Exchange coolant pump remove timing belt, see 01.00.04 drain closed cooling system, refer to 05.00.07, item 7 1 For 6 cyl. engines only 04.01 ill.1 Loosen hose clamp (ill.2/pos.1) and remove hose. 1 04.01 ill.2 2 Loosen hose clamps (SW6) and remove hose between thermostat housing and water pump (ill.3/ pos.1) 3 Loosen hose clamp of hose elbow (ill.3/pos.2) at oil cooler side. 1 2 04.01 ill.3 4 Loosen all screws (ill.4) and hexagon nut of water pump (ill.4/pos.3). 5 Loosen water pump by slight knocking with plastic hammer and remove hose elbow. 1 2 1 3 04.01 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 31 ToC 05 COOLING SYSTEM 05.04.02 1 SERVICE MANUAL MARINE ENGINES Install coolant pump Clean all sealing surfaces on water pump and on motorblock. 04.02 ill.1 2 Put on new sealing (ill.2/pos.1). 3 Align water pump on motorblock. Mount screws and nuts and tighen with standard torque for these size. 4 Further assembly is done in reverse order, in accordance with 01.00.04 remove timing belt. 5 Adjust control according to instructions in paragraph 01.00.05 engine timing adjustment procedure. 1 04.02 ill.2 Page COOLING SYSTEM - 32 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.06 05.06.01 05 COOLING SYSTEM POLY-V BELT Exchange Poly-V-belt For M 4 cyl. engines only Belt guide without hydraulic pump (ill.1). *) 04.06 ill.1 Belt guide with hydraulic pump (ill.2). NOTE*): It is recommended to spray frequently some corrosion inhibiting spray into the spring housing of the belt tensioner. *) 04.06 ill.2 1 Release belt tension by pulling tensioner from V-belt of torque wrench No. 2300704/0 (ill.3/pos.1). Remove Poly-V belt. 2 Pull the belt tightener counterclockwise by means of torque wrench No. 2300704/0 into position as show (ill.3/pos.1). Apply the Poly-V belt acc. to ill.1 for engine with hydraulic pump or ill.2 for engine without hydraulic pump. Tighten the belt by releasing the belt tightener. 1 04.06 ill.3 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 33 ToC 05 COOLING SYSTEM 05.07 05.07.01 V-BELT Exchange V-belts SERVICE MANUAL MARINE ENGINES 3 1 For 6 cyl. engines only 2 Alternator: (for example - different versions possible) 1 Loosen setscrews (ill.1+2/pos.1+2) 2 Release V-belts by turning clamping bolt (ill.1+2/ pos.3) counterclockwise and by turning alternator towards engine. Remove pair of V-belts. 07.02 ill.1 1 3 Assembly is done in reverse order. (According 05.07.02) 4 Adjust belt tension to 350 +/- 50 N. 5 Check tension of alternator V-belt on spot (ill.4/A) in the middle between crankshaft (ill.4/pos.1) and alternator (ill.4/pos.2). 3 2 NOTE: Always change V-belts in pairs only. 07.02 ill.2 Servopump NOTE: The servopump is driven together with the alternator. Tension of V-belt is done via alternator. 4 Raw water pump: (old version) Preparation: Remove alternator V-belts. 1 Loosen setscrews (ill.3/pos.1). 2 Loosen hexagon nut of clamping bolt (ill.3/pos.2). Release V-belt by turning the clamping bolt (ill.3/ pos.3) counterclockwise and turning the pump towards engine. Remove V-belt (ill.3/pos.4). 3 Assembly is done in reverse order. 4 Check tension of raw water pump V-belt on spot (ill.4/ B) in the middle between crankshaft (ill.4/pos.1) and raw water pump (ill.4/pos.3). 5 1 2 3 07.02 ill.3 2 A B 3 Adjust belt tension to 350 +/- 50 N. (According 05.07.02) 1 07.02 ill.4 Page COOLING SYSTEM - 34 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Raw water pump: (current version) Preparation: Remove alternator V-belts. 1 Loosen screw (ill.5/pos.1). Turn screw counter (ill.6/pos.1) clockwise to reduce of tension V-belt. 2 Remove V-belt. 3 Assembly is done in reverse order. 4 Adjust V-belt tension; according 05.07.02 5 Tighten screw (ill.5/pos.1) with a Torque of 23 N +/-2 to secure idler pulley bracket. 1 07.02 ill.5 1 07.02 ill.6 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 35 ToC 05 COOLING SYSTEM 05.07.02 SERVICE MANUAL MARINE ENGINES Adjust V-belts Measuring device No. VR00515/0 for timing- and V-belt For 6 cyl. engines only With engine stopped, belts should be stretched to such an extent that they yield for 10-13 mm when pressing your finger on marked spots (07.01 ill.4/ A + B). This corresponds to a belt tension of 350 Nm +/- 50. If the belt is too loose, it may slip through which results in higher wear and bad efficiency of alternator or servo pump. Belt tension is to be checked after first 10 operating hours and than every 50 operating hours. 07.02 ill.1 07.02 ill.2 Page COOLING SYSTEM - 36 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.10 05.10.01 05 COOLING SYSTEM RAW WATER PUMP Exchange raw water pump 1 Loosen 3 hexagon screws (ill.1/pos.1) of belt pulley. 3 2 Remove poly-V-belt or V-belt (05.06 or 05.07) 5 3 Unscrew 3 screws (ill.1/pos.1) of belt pulley and remove belt pulley (ill.1/pos.2). 4 Loosen hose clamp (ill.1/pos.3) and remove hose. 5 Loosen 4 screws (ill.1/pos.4), remove raw water pump (ill.1/pos.5). 6 Assembly is done in reverse order. 7 Torque screws M6 (pos.4) with 9,5 Nm; screws M8 (pos.1) with 23 Nm. Secure all threads with LOCTITE 243. 4 2 1 10.01 ill.1 For 6 cyl. engines only (old version) 1 Loosen two setscrews (SW17) (ill.2/pos.1) 2 Loosen hexagon nut of clamp bolt (ill.2/pos.2), relieve V-belt by turning clamp bolt (ill.2/pos.3) counterclockwise. 3 Remove V-belt (ill.2/pos.4). 4 Loosen hose clamps (ill.2/pos.5) and remove hoses. 5 Unscrew two setscrews (SW17) (ill.2/pos.1+2). Remove raw water pump with tightener. 5 4 1 2 3 10.01 ill.2 5 Loosen 4 hexagon screws (SW13), remove raw water pump. 6 Assembly is done in reverse order. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page COOLING SYSTEM - 37 ToC 05 COOLING SYSTEM 05.12 05.12.01 SERVICE MANUAL MARINE ENGINES CHECKS Check closed engine cooling system for air This check is for determination and retrieval of an inexplicable coolant loss. Procedure: Use special tool SMO: VR00147/0 by using enclosed instruction. Conclusion: Gas entry (combustion pressure) in the cooling system. Control works: Check tightening torque of unit injectors (03.02.02 "ASSEMBLY", item 11) and repeat check. NOTE: If there is no gas entry, coolant loss is eliminated. If there is still gas entry, refer to 03.14.02, to "disengagement methode of injection" this methode can help to detect a possible transfer of combustion gases into the water jacket. NOTE: If the defective cylinder is detected through the disconnection method and bubble formation and/ or coolant loss stops, the monoblock is to be replaced. Page COOLING SYSTEM - 38 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 ELECTRICAL SYSTEM Table of Contents 06.00 06.00.01 General ......................................................................................................... 3 Cable numbers and principal functions .......................................................... 3 06.01 06.01.01 06.01.02 06.01.03 06.01.04 Alternator ..................................................................................................... 4 Adjust poly-V-belt tension ............................................................................. 4 Replace generator......................................................................................... 5 Technical data of alternator .......................................................................... 6 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) .... 14 06.03 06.03.01 Replace starter motor ............................................................................... 16 Check starter ................................................................................................ 17 06.05 Cables, wiring harness - general ............................................................. 19 06.05.01 Battery cable lengths and cross-sections .................................................... 19 06.05.02 E - box base plate; to eng.no.: 482 17 000 ................................................. 20 06.05.02.01 Components of E - box ................................................................................ 21 06.05.02.02 Connection start assist relay K28 ................................................................. 21 06.05.02.03 Connection relay socket for K24, K26-1, K26-2, and K27 ............................ 21 06.05.02.04 Wiring harness; to eng.no.: 482 17 000 ...................................................... 22 06.05.03 E - box base plate; from eng.no.: 482 18 000/682 18 000 + SOLAS ......... 28 06.05.03.01 Components of E - box ................................................................................ 29 06.05.03.02 Connection start assist relay K28 and K26-2 ............................................... 29 06.05.03.03 Connection relay socket for K24, K26-1, and K27 ....................................... 29 06.05.03.04 Wiring harness; from eng.no.: 482 18 000/682 18 000 + SOLAS .............. 30 06.06 06.06.01 06.06.02 06.06.03 06.06.04 06.06.05 Electronics - general .................................................................................. 36 Electronic Engine Management System ..................................................... 36 Diagnostic system ....................................................................................... 37 Reading error codes .................................................................................... 38 Idication & cancellation of memorized sensor and circuit faults .................. 39 Principle failure code list ............................................................................. 40 06.06.06 Replace fuses ............................................................................................. 42 06.06.07 06.06.08 06.06.09 Connection J 1 ............................................................................................. 43 Connection A 5 and X5 ................................................................................ 44 Fitting main connector "J1" properly ............................................................ 45 06.07 06.07.01 06.07.02 06.07.03 06.07.04 06.07.05 Instrument panel ....................................................................................... 46 Chart - operating status normal operation ................................................... 47 Chart - error indication on instrument panel ................................................ 48 Instrument panel (for SOLAS only) ............................................................. 52 Chart - operating status normal operation (for SOLAS only) ...................... 53 Chart - error indication on instrument panel (for SOLAS only) .................... 54 06.07.10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) ........................................................................................ 58 Description - Wiring harness instrument panels 4/6 cyl. marine engines (current version) ........................................................................................... 62 06.07.11 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 1 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06.07.13 Adjust instruments ....................................................................................... 68 06.07.13.01 Tachometer with running-time meter ........................................................... 68 06.07.14 Replace instruments .................................................................................... 70 06.07.14.01 General notes on safety ............................................................................... 70 06.07.14.02 Audible warner, H22 ..................................................................................... 72 06.07.14.03 Circuit diagram voltmeter (optional) ............................................................. 73 06.07.14.04 Circuit diagram oil pressure gauge (optional, sensor B19-gauge P2) .......... 73 06.08.01 06.08.02 06.08.03 Potentiometer accelerator, B13 ................................................................ 74 Voltage regulator 24V - 12V equalizer ......................................................... 75 DC - DC converter ........................................................................................ 76 06.10 06.10.01 06.10.02 06.10.03 Sender, sensor .......................................................................................... 78 Component configuration 4 cyl. engine ........................................................ 78 Component configuration 6 cyl. engine ........................................................ 80 Calibration of rack position ........................................................................... 82 06.10.04 Replace sender, sensor ............................................................................... 83 06.10.04.01 Sensor exhaust gas temperature B17 .......................................................... 83 06.10.04.02 Sensor engine temperature B16 .................................................................. 83 06.10.04.03 Sensor engine speed B15 ............................................................................ 83 06.10.04.04 Sensor boost pressure B12 .......................................................................... 83 06.10.04.05 Sensor rack position feedback B14.............................................................. 84 06.10.04.06 Sensor oil pressure B18 ............................................................................... 84 06.10.04.07 Potentiometer accelerator B13 ..................................................................... 84 06.10.05 Check sensors and switches ........................................................................ 85 06.10.05.01 Check rack position feedback sensor B14 (= connector X14) ..................... 85 06.10.05.02 Check throttle potentiometer B13 (accelerator) (= connector X13) .............. 87 06.10.05.03 Check boost pressure sensor, B12 .............................................................. 88 06.10.05.04 Check speed sensor B15 and/or wiring ....................................................... 89 06.10.05.05 Check oil pressure sensor B18 and/or wiring ............................................... 90 06.10.05.06 Check oil pressure sensor "VDO-instrument" (option B19) .......................... 91 06.10.05.07 Check coolant temperature sensor, B16 ...................................................... 92 06.10.05.08 Check audible warner .................................................................................. 93 06.12 06.12.01 Battery ........................................................................................................ 94 Battery ......................................................................................................... 94 Page ELECTRICAL SYSTEM - 2 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06.00 06 ELECTRICAL SYSTEM GENERAL Wiring For the STEYR Marine Engines wiring and plug connections have been defined according to standard DIN 72 552. In case of necessary repair of a cable connection, take special care that cable quality, isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation and/or connector locks meet the respective requirements. Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4". 06.00.01 Cable numbers / principal functions: 15000-xx ignition - positive (from ignition switch) 31100-xx Do not connect earth for sensors with battery-negative! 15012-xx +12 volt via main relay and control unit A5 601xx-01 Sensor signal to control unit A5 and/or instruments. 15100-xx +5 volt supply voltage for sensors 606xx-01 30000-xx battery-positive (not secured) Output from control unit A5 to display system (tachometer, temperature display, ...) 30012-xx battery-positive (secured) 31000-xx battery-negative (GND) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 3 ToC 06 ELECTRICAL SYSTEM 06.01 SERVICE MANUAL MARINE ENGINES ALTERNATOR 06.01.01 Adjust poly-V-belt tension For 4 cyl. engines only Automatic initial tension of belt tension through spring-loaded tightener. (ill.1 and ill.2) 1 01.01 ill.1 1 01.01 ill.2 For 6 cyl. engines only As to tension of V-belt for alternator, refer to chapter 05.07.01 - 02 Page ELECTRICAL SYSTEM - 4 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01.02 Replace alternator Preparatory work: turn off engine, disconnect battery 1 Disconnect two cables (ill. 1/pos.1+2). 2 2 1 Remove belt. 01.02 ill.1 3 Loosen screws (ill.2/pos.1+2), remove alternator. NOTE: Assembly is done in reverse order. 1 2 For 4 cyl. engines only Connections acc. illustration 3: 01.02 ill.2 ill.3/1 B+ battery ill.3/2 D+ charging control (L1) ill.3/3 DF D-field (rotor winding) ill.3/4 D+ on governor 3 4 2 1 For 4 cyl engines only Governor acc. illustration 4: ill.4/1 B- ill.4/2 DF ill.4/3 D+ ill.4/4 D+ 01.02 ill.3 1 2 3 4 01.02 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 5 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06.01.03 Technical data of alternator For 6 cyl. engines only (old version till eng. no. 68224418) Model .................................................................................................... PRESTOLITE LEECE-Neville .............................................................................................................. 8RG2043 Minimum speed for voltage generation ................................................. 580 1/min Controlled voltage range ....................................................................... 13,9 - 14,2 V Output current ....................................................................................... 90 A Governor ............................................................................................... integrated base governor Charge capacity at 750 r.p.m. .......................................................................................... approx. 34 A at 2500 r.p.m ......................................................................................... maximum charge capacity Condensor capacity .............................................................................. 2,2 µF 01.03 ill.1 Charging circuit - scheme 1 ...... battery 2 ..... Z2, ground connection on engine 3 ..... red 4 ..... fuse 50 A 5 ..... starter engine 6 ..... red 7 ..... plug (engine electrics/instrument cable) 8 ..... fuse 10 A 9 ..... starter key lock 10 ..... 15000-xx 11 ..... red 16 mm² 12 ..... generator 13 ..... charging controll (L1) 14 ..... 61000-02 (18-pole connecting cable No.: 11) 15 ..... relay K10 16 ..... blocking diode (1N4007) Page ELECTRICAL SYSTEM - 6 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl. engines only (old version till eng. no. 68224418) circuit diagr.: Governor 01.03 ill.3 01.03 ill.2 Check of alternator and connections: With engine stopped, measure voltage on alternator (+output and -output). Measured voltage may be lower than the battery voltage by (up to) 1 volt only. Where appropriate, test wiring of cables and connections. Check of control voltage and/or alternator voltage: NOTE: For these works, the battery's state of charge should be 95% at least. Check tension of belt on alternator drive and make sure that cables are perfectly connected. 1. Disconnect all electrical consuming devices and adjust engine to a speed of approx. 1000 rpm. 2. Connect voltmeter to alternator output "B +". 3. Remove plastic screw on governor and apply screw driver with fine blade on adjusting screw. ATTENTION: The adjusting screw has a min./max. stop. There is danger to damage the governor when turning by force the adjusting screw so far that it overtravels the specified control range. 4. Turn screwdriver clockwise to increase the operating voltage and/or anticlockwise to lower the operating voltage. Adjust voltage range between 14,0 and 14,2 volt (28,0 to 28,4 volt for 24-volt plants). ATTENTION: Do not turn adjusting screw so far that it overtravels the stop, to prevent damages to the governor. 5. After adjustment, remove screwdriver and voltmeter and lock the governor by means of removed plastic screw. If voltage cannot be set to specified value, replace governor and/or alternator. Check of slip pistons: Disconnect battery and/or main switch. Unscrew governor. Clean slip ring and wipers; where appropriate, replace wipers. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 7 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES For 6 cyl.engines / Technical data of alternator 14V / 90A (current version from eng. no. 68224419) Model .................................................................................................... ISKRA-AAK5550-11.203.329 Minimum engine speed for voltage generation ..................................... 550 1/min Controlled voltage range ....................................................................... 14,1 - 14,5 V Output current ....................................................................................... 90 A Governor ............................................................................................... integratedl base governor Excitation winding resistance ................................................................ 2,7 / +0,27 01.03 ill.4 Error Detection Check battery: - All connections (terminals) - Acid concentration - Filling level (check, refill if necessary) - Carry out load test Excessive voltage: - Governor - Loose connections - Battery Page ELECTRICAL SYSTEM - 8 Downloaded from www.Manualslib.com manuals search engine Charging voltage too low: - Belt tension - Output - Governor - Slip ring - Internal components of alternator No charging voltage: - Belt tension - Charging control lamp defective (12V/2W) - Output - Cables and connections - Governor - Slip ring - Internal components of alternator Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl. engines / Technical data of alternator 28V / 80A (Option) Model .................................................................................................... ISKRA-AAN5161- 11.203.220 Minimum engine speed for voltage generation ..................................... 550 1/min Controlled voltage range ....................................................................... 28,1 - 28,7 V Output current ....................................................................................... 80 A Governor ............................................................................................... integratedl base governor Excitation winding resistance ................................................................ 7,9 / +0,79 01.03 ill.5 Error Detection Check battery: - All connections (terminals) - Acid concentration - Filling level (check, refill if necessary) - Carry out load test Excessive voltage: - Governor - Loose connections - Battery Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Charging voltage too low: - Belt tension - Output - Governor - Slip ring - Internal components of alternator No charging voltage: - Belt tension - Charging control lamp defective (24V/3W) - Output - Cables and connections - Governor - Slip ring - Internal components of alternator Page ELECTRICAL SYSTEM - 9 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES For 6 cyl. engines / Technical data of alternator 28V / 55A (Option) Model .................................................................................................... ISKRA-AAK5170- 11.201.894 Minimum engine speed for voltage generation ..................................... 550 1/min Controlled voltage range ....................................................................... 28,0 - 28,4 V Output current ....................................................................................... 55 A Governor ............................................................................................... integratedl base governor Excitation winding resistance ................................................................ 7,9 / +0,79 01.03 ill.6 Error Detection Check battery: - All connections (terminals) - Acid concentration - Filling level (check, refill if necessary) - Carry out load test Excessive voltage: - Governor - Loose connections - Battery Page ELECTRICAL SYSTEM - 10 Downloaded from www.Manualslib.com manuals search engine Charging voltage too low: - Belt tension - Output - Governor - Slip ring - Internal components of alternator No charging voltage: - Belt tension - Charging control lamp defective (24V/3W) - Output - Cables and connections - Governor - Slip ring - Internal components of alternator Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 11 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES For 4 cyl. engines only / Technical data of alternator Model .................................................................................................... BOSCH No. 6 033GB3 046 Minimum speed for voltage generation ................................................. 550 1/min Controlled voltage range ....................................................................... 13,9 - 14,7 V Output current ....................................................................................... 90 A Governor ............................................................................................... integratedl base governor Charge capacity at 750 r.p.m. .......................................................................................... ca. 34 A at 3000 r.p.m. ........................................................................................ maximum charge capacity Condensor capacity .............................................................................. 2,2 µF 01.03 ill.7 Charging circuit - scheme 1 ...... battery 2 ..... Z2, ground connection on engine 3 ..... red 4 ..... fuse 50 A 5 ..... starter engine 6 ..... red 7 ..... plug (engine electrics/instrument cable) 8 ..... fuse 10 A 9 ..... starter key lock 10 ..... 15000-xx 11 ..... red 16 mm² 12 ..... generator 13 ..... charging control (L1) 14 ..... 61000-02 (18-pole connecting cable Nr.: 11) 15 ..... blocking diode (1N4007) Page ELECTRICAL SYSTEM - 12 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 4 cyl. engines only Error Detection Check battery: - All connections (terminals) - Acid concentration - Filling level (check, refill if necessary) - Carry out load test Excessive voltage: - Governor - Loose connections - Battery Charging voltage too low: - Belt tension - Output - Governor - Slip ring - Internal components of alternator No charging voltage: - Belt tension - Charging control lamp defective (12V/2W) - Output - Cables and connections - Governor - Slip ring - Internal components of alternator Governor Alternator - scheme 01.03 ill.8 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 13 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) Trouble features Test procedure Error and/or Relief With engine stopped and ignition on, generator control lamp (L1) not shining or only slightly. Tester lamp connected between B+ and D+ on generator ; shining brightly. Generator control lamp (L1) burned out and/or disconnection in electric circuit of generator control lamp (L1) between term. 15 (No. 15000-xx) and term. D+ (No. 61000-02) on generator. Tester lamp connected between B+ and D+ on generator ; not shining, but shining brightly when connected between D+ and ground. Generator control lamp (L1) does not shine in both cases. Short circuit of a positive diode. Immediately disconnect starter battery from generator, otherwise battery may be discharged on state > replace generator. Tester lamp connected between D+ and ground; tester lamp and generator control lamp (L1) glowing. Error, wipers of governor worn out, oxid film on slip rings, disconnection of rotor winding -> replace governor and/or generator. With both engine stopped and running, generator lamp (L1) constantly shines brightly. With engine stopped, disassemble attached governor. Generator control lamp (L1) still shining brightly. Generator control lamp (L1) extinguishes. Install governor again. Connect ammeter between B+ and D+ (on generator). Exciting current is lower than specified (4 amp +/- 0,4). Exciting current is higher than specified (4 amp +/- 0,4). With engine stopped, generator control lamp (L1) shines brightly, with engine running only shines slightly. With engine running, tester lamp extinguishes. With engine stopped, install new governor and start engine again. Tester lamp between B+ und D+ Tester lamp extinguishes Tester lamp still glows Downloaded from www.Manualslib.com manuals search engine Governor is defective -> replace governor. Earth short circuit in the field of governor and connection DF (see ill.) of generator, earth short circuit in rotor winding -> replace generator. Connect tester lamp between B+ and D+ of generator. With engine running, tester lamp glows. Page ELECTRICAL SYSTEM - 14 Earth short circuit in lead betweeen generator control lamp and terminal D+ on generator. Contact resistance in charging circuit or in conductor to generator control lamp (L1) Governor or generator defective. Disassembled governor was defective. Generator is defective -> replace. Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Check rectifier diode Measuring devices with diode test function will show the following results: - 12-V-Lampe in forward direction: voltage drop from 0.4 to 0.6 volt in backward direction: reading is "OL". + 12V - a) by means of control lamp 01.04 ill.1 Diode and control lamp are connected in series in both forward and backward direction in an electric circuit. Diodes permitting passage in both directions were mostly exposed to excessive voltages. On the other hand, diodes with an interruption in forward direction were mostly destroyed by excessive current or excessive heating. ill. 04.1 Lamp burning: diode functional. Lamp not burning: diode interrupted. ill. 04.2 Lamp not burning: diode functional, Lamp burning: diode had short circuit. 12-V-Lampe + 12V - 01.04 ill.2 b) by means of ohmmeter For diode testing, only a simple, battery-powered ohmmeter may be used. Measuring bridges are unsuitable, as they indicate wrong values. Under no circumstances, hand generators may be used. Their high voltage would destroy the diodes. A perfect diode shows a resistance of only a few ohms (0,5 ...10 Ohm) in forward direction, but several kiloohms (almost) in backward direction. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 15 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.03 REPLACE STARTER MOTOR 1 Disconnect battery. 2 Remove cover of E-box. Remove E-box. 3 Loosen terminal +30 (ill.2/pos.1) on magnetic switch by means of (SW13). 4 Loosen start signal wiring (terminal 50) (ill.2/pos.2) by means of (SW10). 03.00 ill.1 5 Loosen two hexagon screws (ill.2/pos.3) (SW13) of starter bracket. 2 6 Loosen two screws (SW8) (ill.2/pos.4), remove starter. 1 4 3 03.00 ill.2 NOTE: Have starter motor repaired in an authorized STEYR workshop. After assembly, coat all electric supplies with rubber sealing Z909570/0. Page ELECTRICAL SYSTEM - 16 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.03.01 Check starter Trouble features Cause Relief When switching on the starter (acutation of starter key), starter shaft not turning or only slowly; starter pinion not engaging battery discharged and/or defective charge battery and/or replace terminals of starter battery are loose and/or oxidized, bad ground connection clean terminals and tighten, treat with pole grease, provide ground connection earth short circuit of terminals of starter or carbon brushes eliminate earth short circuit carbon brushes not resting on collector (sticking in guide, are broken, oily or worn out) depending on failure, make work carbon brushes, clean or replace --> in case of very strong wear, replace various parts and/or starter starter key or starter relay K28 and/or actuating relay on starter defective replace starter key or relay voltage drop in lines too large, lines damaged, line connections loose, links oxidized check starter line, eventually replace, clean links and tighten starter does not interrupt; starter key, starter relay (K28), actuating relay (on starter) defective short-circuit in wiring (cable No.: 50000-xx connected to +12V) immediately turn off ignition, immediately disconnect battery; check key and/or relay, evenutally replace; check wiring in case of longer running time --> replace starter starter keeps on running after starter key was released Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 17 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Page ELECTRICAL SYSTEM - 18 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06.05 06 ELECTRICAL SYSTEM CABLES, WIRING HARNESS - GENERAL Cable / wiring In case of necessary repair of a cable connection, take special care that cable quality, isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation and/or connector locks meet the respective requirements. Tools for crimp connections to be found in tool catalog P/N Z001002/0 "KIT 3". 06. 05. 01. Battery cable lengths and cross-sections Determine the lenght of the positive cable from the positive pole (+) of the battery to connection No. 30 at the starter. Total lenght is the sum of cable length of positive cable (+) and earth cable (-). For example: positive cable = 3,0 m ground cable = 2,0 m ----------------------------Total length = 5,0 m ===> cable cross section = 70 mm² For ground connection, determine corresponding cross-sections as per chart. For 4 cyl. engines only starter engine: 2 kW - 12 volt battery size: 92 AH length in m cable cross-section in mm² AWG 0,0 - 4,0 4,1 - 5,0 5,1 - 6,0 50 70 95 0 00 0000 length in m cable cross-section in mm² AWG 0,0 - 3,0 3,1 - 4,5 4,6 - 5,5 50 70 95 0 00 0000 For 6 cyl. engines only starter engine: 3 kW - 12 Volt battery size: 110 AH In general, take care that battery cable lengths are kept as short as possible. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 19 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06.05.02 E - box base plate; to eng.no.: 482 17 000 05.02 ill.1 Page ELECTRICAL SYSTEM - 20 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.02.01 Components of E - box; to eng.no.: 482 17 000 Designat. Component Description A5 E - box control unit F1 F2 fuse 50 A fuse 50 A main fuse glow plugs F3 F4 fuse 50 A fuse 5 A glow plugs permanent current module F5 F6 fuse 10 A fuse 10 A switched current for module (K27) fuel pump (K24) J1 K24 plug 23-pole relay connection engine cable - instrument cable fuel pump K26-1 K26-2 relay realy preheating preheating K27 K28 relay relay main circuit start assist relay X5 plug 35-pole module 06.05.02.02 Connection start assist relay K28 05.02 ill.2 06.05.02.03 Connection relay socket for K24, K26-1, K26-2 and K27 05.02 ill.3 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 21 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.02.04 Wiring harness; to eng.no.: 482 17 000 Designation Component Description A5 F1 F2 F3 F4 F5 F6 E-box fuse 50 A fuse 50 A fuse 50 A fuse 5 A fuse 10 A fuse 10 A control unit main fuse glow plugs glow plugs permanent current modul and K27 switched current for module (K27) fuel pump (K24) G1 G2 J1 K24 K26-1 K26-2 K27 K28 M1 M2 R10 X2 (S2) alternator battery 23-pole plug relay relay relay relay relay starter fuel pump glow pins 2-pole plug gear switch X5 (A5) X12 (B12) X13 (B13) X14 (B14) X15(B15) X16 B(16) X17 (B17) X18 (B18) X19 (B19) X20 (Y20) X22 (B22) X23 35-pole plug 3-pole plug 5-pole plug 3-pole plug 3-pole plug 2-pole plug 2-pole plug 3-pole plug 1-pole plug 2-pole plug without stop 6-pole plug module boost-pressure sensor pot. accelerator pot. rack position engine speed sensor engine temperature sensor exhaust gas temperature sensor oil pressure sensor oil pressure gauge (optional) control solenoid trim sensor (optional) diagnosis Z1 Z2 Z3 Z4 splice spot splice spot splice spot splice spot earth connection sensor earth connection (31) on engine sensor supply +5V earth connection (31) on E-box plate to be provided by customer connection engine cable - instrument cable fuel pump preheating - load circuit preheating - load circuit main circuit start Cable numbers / principal functions: 15000-xx 15012-xx 15100-xx 30000-xx 30012-xx 31000-xx ignition - positive (from ignition switch) +12 volt via main relay and control unit A5 +5 volt supply voltage for sensors battery-positive (not secured) battery-positive (secured) battery-negative (GND) Page ELECTRICAL SYSTEM - 22 Downloaded from www.Manualslib.com manuals search engine 31100-xx 601xx-01 606xx-01 Do not connect earth for sensors with battery-negative! Sensor signal to control unit A5 and/or instruments. Output from control unit A5 to display system (tachometer, temperature display, ...) Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 05.02 ill.4 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 06 ELECTRICAL SYSTEM Wiring harness; to eng.no.: 482 17 000 Page ELECTRICAL SYSTEM - 23 ToC 06 ELECTRICAL SYSTEM Circuit diagram; to eng.no.: 482 17 000 Page ELECTRICAL SYSTEM - 24 Downloaded from www.Manualslib.com manuals search engine SERVICE MANUAL MARINE ENGINES 05.02 ill.5 Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> 15000-01 J1 plug engine / instruments A K24 relay fuel pump 86 15000-02 J1 plug engine / instruments B K24 relay fuel pump 86 15000-03 X5 control unit (A5) 19 K24 relay fuel pump 86 15012-01 X20 control solenoid(Y20) 1 X5 control unit (A5) 17 15012-02 X5 control unit (A5) 18 K27 main circuit relay 87 15012-03 K27 main circuit relay 87 K26/1 relay preheating 86 15012-04 K26/1 relay preheating 86 K26/2 relay preheating 86 15012-06 X15 speed sensor (B15) C K26/2 relay preheating 86 15100-01 X5 control unit (A5) 3 Z3 link (splice) 15100-02 X13 pot. accelerator (B13) 5 Z3 link (splice) 15100-05 X12 boost press. sensor(B12) 3 Z3 link (splice) 15100-06 X14 pot. rack position (B14) C Z3 link (splice) 15100-07 X18 oil pressure sensor (B18) B Z3 link (splice) 17415-01 F2 50A fuse glow plugs IN K26/1 relay preheating 87 17415-02 F3 50A fuse glow plugs IN K26/2 relay preheating 87 30000-03 K26/1 relay preheating 30 K28 starter relay 30 30000-04 K26/2 relay preheating 30 K28 starter relay 30 30000-05 F1 50A main fuse IN starter solenoid 30 30012-01 X5 control unit (A5) 1 F4 fuse control unit 2 30012-02 K27 main circuit relay 86 F4 fuse control unit 2 30012-03 X23 diag 6 K27 main circuit relay 86 30012-04 K27 main circuit relay 30 F5 fuse control unit 2 30012-05 F1 50A main fuse OUT F5 fuse control unit 1 30012-06 F1 50A main fuse OUT F6 fuse fuel pump 1 30012-07 F1 50A main fuse OUT J1 plug engine / instruments C 30012-08 F1 50A main fuse OUT J1 plug engine / instruments D 30012-09 F5 fuse control unit 1 F4 fuse control unit Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine pin No. end point --> to pin No. 1 Page ELECTRICAL SYSTEM - 25 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> pin No. end point --> to pin No. 30055-01 K24 relay fuel pump 30 F6 fuse fuel pump 31000-01 J1 plug engine / instruments E Z2 - mass point 31000-02 J1 plug engine / insruments F Z2 - mass point 32 31000-03 Z4 earth connection in box X15 speed sensor (B15) 3 31000-04 fuel pump (M2) (M5)negat. Z2 link (splice) 31000-05 X23 diag 1 Z2 link (splice) 31000-06 S4 earth connection in box 31000-07 X2 gear switch(S2) 31000-08 S4 earth connection in box 31100-01 X5 control unit (A5) 20 Z1 link (splice) 31100-02 X13 pot. accelerator (B13) 3 Z1 link (splice) 31100-03 X13 pot. accelerator (B13) 4 Z1 link (splice) 31100-07 X16 ECT (B16) 2 Z1 link (splice) 31100-08 X12 MAP (B12) 2 Z1 link (splice) 31100-09 X14 RACK (B14) A Z1 link (splice) 31100-10 X18 oil pressure sensor (B18) A Z1 link (splice) 31100-11 X17 sensor exh.gas temp.(B17) 2 Z1 link (splice) 31409-01 X20 control solenoid (Y20) 2 X5 control unit (A5) 35 31554-01 K24 relay fuel pump 85 X5 control unit (A5) 22 31555-01 K26/1 relay preheating 85 X5 control unit (A5) 7 31555-02 K26/1 relay preheating 85 K26/2 relay preheating 86 31558-01 K27 main circuit relay 85 X5 control unit (A5) 24 31615-01 J1 plug engine / instruments H X5 control unit (A5) 6 50000-01 K28 starter relay 87 X5 control unit (A5) 13 50000-02 K28 starter relay 86 J1 plug engine / instruments S 50000-03 K28 starter relay Kl.86 J1 plug engine / instruments T 60110-01 X12 MAP (B12) 1 X5 control unit (A5) 28 Page ELECTRICAL SYSTEM - 26 Downloaded from www.Manualslib.com manuals search engine 2 X5 control unit (A5) 2 2 S2 link (splice) Z2 earth connection engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> pin No. end point --> to pin No. 60111-01 pot. accelerator B13 2 X5 control unit (A5) 12 60112-01 X14 RACK (B14) B X5 control unit (A5) 11 60113-01 X15 speed sensor (B15) 2 X5 control unit (A5) 33 60114-01 X16 ECT (B16) 1 X5 control unit (A5) 9 60116-01 X13 pot. accelerator (B13) 1 X5 control unit (A5) 30 60117-01 X18 oil pressure sensor (B18) C X5 control unit (A5) 10 60118-01 X17 sensor exh.gas temp.(B17) 1 X5 control unit (A5) 27 60121-01 J1 plug engine / instruments P oil pressure gauge optional 60122-01 X2 gear switch(S2) 1 X5 control unit (A5) 14 60412-01 M2 fuel pump (M4)posit. K24 relay fuel pump 87 60613-01 J1 plug engine / instruments N X5 control unit (A5) 8 60614-01 J1 plug engine / instruments K X5 control unit (A5) 26 60616-01 J1 plug engine / instruments G X5 control unit (A5) 25 60706-01 J1 plug engine / instruments J X5 fixed rotation speed (A5) 29 60808-01 Z 5 60808 X5 control unit (A5) 32 60808-02 Z 5 60808 J1 plug engine / instruments M 60808-03 Z 5 60808 X23 diag 2 60810-01 J1 plug engine / instruments R X5 control unit (A5) 23 60900-01 X23 diag 5 X5 control unit (A5) 15 60901-01 X23 diag 4 X5 control unit (A5) 16 61000-02 alternator D+ D+ J1 plug engine / instruments L network shield B15 S4 earth connection E-box Z5 was only built up for wiring harnesses up to engine No. 48217020 (no function), J1 / M on panel wiring harness „ free „. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 27 ToC 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06.05.03 E - box base plate; from eng. no.: 482 18 000 / 682 18 000 + SOLAS 05.03 ill.1 Page ELECTRICAL SYSTEM - 28 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06.05.03.01 06 ELECTRICAL SYSTEM Components of E-box; from eng. no.: 482 18 000 / 682 18 000 + SOLAS Designat. Component Description A5 E - box control unit F1 F2 fuse 50 A fuse 50 A main fuse glow plugs F3 F4 fuse 50 A fuse 5 A glow plugs permanent current module F5 F6 fuse 10 A fuse 10 A switched current for module (K27) fuel pump J1 K24 plug 23-pole relay connection engine cable - instrument cable fuel pump K26-1 K26-2 relay realy preheating preheating K27 K28 relay relay main circuit start X3 S3 plug 2-pole inversion switch inversion switch (for SOLAS only) (for SOLAS only) X5 plug 35-pole module 06.05.03.02 Connection relay K28 and K26/2 05.03 ill.2 06.05.03.03 Connection relay socket for K24, K26-1 and K27 05.03 ill.3 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 29 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.03.04 Wiring harness; from eng.no.: 482 18 000 / 682 18 000 + SOLAS Designation Component Description A5 F1 F2 F3 F4 F5 F6 F7 G1 G2 J1 K24 K26-1 K26-2 K27 K28 M1 M2 R10 X2 (S2) X3 (S3) X5 (A5) X12 (B12) X13 (B13) X14 (B14) X15(B15) X16 B(16) X17 (B17) X18 (B18) X19 (B19) X20 (Y20) X22 (B22) X23 X26 (Y26) Z1 Z2 Z3 Z4 Z6 E-Box fuse 50 A fuse 50 A fuse 50 A fuse 5 A fuse 10 A fuse 10 A fuse 10 A alternator battery plug 23--pole relay relay relay relay relay starter fuel pump glow pins plug 2-pole plug 2-pole plug 35-pole plug 3-pole plug 5-pole plug 3-pole plug 3-pole plug 2-pole plug 2-pole plug 3-pole plug 1-pole plug 2-pole without stop plug 6-pole plug 2-pole splice spot splice spot splice spot splice spot splice spot control unit main fuse glow plugs glow plugs permanent current modul and K27 switched current for module (K27) fuel pump (K24) preheating - control circuit to be provided by customer connection engine cable - instrument cable fuel pump preheating - control circuit preheating - load circuit main circuit start gears switch inversion switch ( only SOLAS) module boost-pressure sensor potentiometer accelerator pot. rack position engine speed sensor engine temperature sensor exhaust gas temperature sensor oil pressure sensor oil pressure gauge (optional) control solenoid trim sensor (optional) diagnosis disconnection blow-by (only SOLAS) earth connection sensor earth connection (31) on engine sensor supply +5V earth connection (31) on E-box plate shield speed sensor line Cable numbers / principal functions: 15000-xx 15012-xx 15100-xx 30000-xx 30012-xx 31000-xx ignition - positive (from ignition switch) +12 volt via main relay and modulator unit A5 +5 volt supply voltage for sensors battery-positive (not secured) battery-positive (secured) battery negative (GND) Page ELECTRICAL SYSTEM - 30 Downloaded from www.Manualslib.com manuals search engine 31100-xx 601xx-01 606xx-01 Do not connect mass for sensors with battery negative! Sensor signal to modulator unit A5 and/or instruments. Exit from modulator unit A5 to display system (tachometer, temperature display, ...) Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES Wiring harness; from eng.no.: 482 18 000 + SOLAS 682 18 000 + SOLAS Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 06 ELECTRICAL SYSTEM 05.03 ill.4 Page ELECTRICAL SYSTEM - 31 ALL ENGINE TYPES WITH FOLLOWING EXCEPTIONS 31100-10 60117-01 A EXCEPTIONS: ONLY FOR TYP: MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 Wiring MAP / All engines before 2007 60110-01 31100-08 Downloaded from www.Manualslib.com manuals search engine 15100-07 Page ELECTRICAL SYSTEM - 32 15100-05 60110-01 A EXT www.steyr-motors.com CONNECTOR "A5" (ENGINE-CONTROL-UNIT) STARTER 60 60900-01 CAN-H 123 -01 60901-01 CAN-L WS 60808-01 ISO D+ 6 CYL. 4 CAN "L" 5 CAN "H" 6 CYL. 4 CYL. 4 CYL. B+ Optional 24V DC Invers 31000-11 X3/S3 Solas R10/6 R10/4 R10/3 R10/2 R10/1 R10/5 J1 / V J1 / U 60123-01 X3/S3 Z6 60901-02 60900-02 Z5 60900-03 60901-03 61001-02 1 2 3 X3 4 5 6 3 2 1 K X W B J H V N C A G U O D E F T P Q R S L M 2179349/0-02-070118_tedoc 6 5 4 X23 J1 06 ELECTRICAL SYSTEM Wiring LPS / All engines before 2007 Batt + Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D+ Sens 5V Sens B+ 24V CAN 31100-08 WIRING DIAGRAM / MARINE BASE - 4/6 CYLINDER - 12V 15100-05 ToC SERVICE MANUAL MARINE ENGINES 05.03 ill.5 Z001019/0_6_July 2008 G2 ALL ENGINE TYPES WITH FOLLOWING EXCEPTIONS 60117-01 A Wiring LPS / All engines before 2007 31100-10 60110-01 EXCEPTIONS: ONLY FOR TYP: MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 Wiring MAP / All engines before 2007 Fuel Pump M2 31100-08 60110-01 A AUX LPS K27 K24 K26/1 K26/2 Preheating Load Relay Y20 Control Solenoid K28 Start Relay EXT B17 B16 PED RPOS B14 B15 RPM STARTER B22 Trim-Sensor (Option) www.steyr-motors.com B13 B12 ECT Map B18 EXT LPS ECT CONNECTOR "A5" (ELECTRONIC-CONTROL-UNIT) Main Relay Fuel Pump Relay Preheating Control Relay 60808-01 ISO Sensor Oil Pressure Gauge (Option) B19 S2 60 60900-01 CAN-H 123 -01 60901-01 CAN-L WS Gear Switch WIRING DIAGRAM / MARINE - 6 CYLINDER - 24V (OPTION) Batt + Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D+ Sens 5V Sens B+ 24V F8 - 5 A 31100-08 15100-07 Downloaded from www.Manualslib.com manuals search engine 15100-05 Z001019/0_6_July 2008 15100-05 D+ J1 / V J1 / U B- F8 B+ 61001-01 31000-11 X3/2 60123-01 X3/1 Z6 60901-02 60900-02 Z5 60900-03 60901-03 61001-02 60120-01 Batt - / 24 V Batt + / 24V Invers Solas 4 CAN "L" 5 CAN "H" 60120-01 1 2 3 G1 S3 4 5 6 3 2 1 K X W B J H V N C A G U O D E F T P Q R S L M 2179345/0-02-070118_tedoc 6 5 4 X23 R10 J1 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.6 Page ELECTRICAL SYSTEM - 33 ALL ENGINE TYPES WITH FOLLOWING EXCEPTIONS 31100-10 60117-01 A EXCEPTIONS: ONLY FOR TYP: MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 Wiring MAP / All engines before 2007 60110-01 31100-08 Downloaded from www.Manualslib.com manuals search engine 15100-07 Page ELECTRICAL SYSTEM - 34 15100-05 60110-01 A www.steyr-motors.com 60 60900-01 CAN-H 123 -01 60901-01 CAN-L WS 60808-01 ISO Z6 60901-02 60900-02 Z5 R10/6 R10/4 R10/3 R10/2 R10/1 R10/5 6 CYL. 6 CYL. 4 CYL. 4 CYL. 2179350/0-02-070118_tedoc 06 ELECTRICAL SYSTEM Wiring LPS / All engines before 2007 Batt + Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D+ Sens 5V Sens B+ 24V CAN 31100-08 WIRING DIAGRAM / MARINE - 4/6 CYLINDER - 2-POLE - 12V (OPTION) 15100-05 ToC SERVICE MANUAL MARINE ENGINES 05.03 ill.7 Z001019/0_6_July 2008 ALL ENGINE TYPES WITH FOLLOWING EXCEPTIONS A 60117-01 31100-10 Batt + Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D+ Sens 5V Sens B+ 24V CAN Wiring LPS / All engines before 2007 EXCEPTIONS: ONLY FOR TYP: MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 Wiring MAP / All engines before 2007 60110-01 31100-08 Downloaded from www.Manualslib.com manuals search engine 15100-07 Z001019/0_6_July 2008 15100-05 60110-01 A www.steyr-motors.com 60 60900-01 CAN-H 123 -01 60901-01 CAN-L WS 60808-01 ISO Z6 60901-02 60900-02 Z5 R10/6 R10/4 R10/3 R10/2 R10/1 R10/5 2179351/0-02-070118_tedoc ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.8 Page ELECTRICAL SYSTEM - 35 15100-05 31100-08 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06 ELECTRONICS - GENERAL Wiring In case of necessary repair of a cable connection, take special care that cable quality, isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation and/or connector locks meet the respective requirements. Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4". 06.06.01 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. Engine power is reduced if: Operating Parameter Effect noticed Panel Indication Additional Tool-Readings Action or possible reason High engine coolant temperature limit exceeded Reduction of engine speed Horn ON 2x p. sec. Gauge reading > 107 °C Steyr Diag Power limitation See table trouble shooting: Cooling system Defect - engine coolant sensor or sensor connection Reduction of engine speed Horn ON 2x p. sec. Gauge reading > 120 °C Steyr Diag Service code Sensor or connector failure; see service code table Exhaust temperature limit exceeded Reduction of engine speed Horn and indication light "CEL" ON 2x p. sec. Steyr Diag Power limitation See table trouble shooting: Raw water cooling system Defect - Exhaust temperature sensor or sensor connection Reduction of engine speed Horn and indication light "CEL" ON 2x p. sec. Steyr Diag Service code Sensor or connector failure; see service code table Oil pressure below limit Reduction of engine speed Horn continuos and Oil indication light continuos switched ON Steyr Diag Power limitation See table trouble shooting: Engine oil system Defect - Oil pressure sensor or sensor connection Reduction of engine speed Oil pressure indication Steyr Diag light switched ON 1x Service code p. sec. Insufficient boost pressure or defictive sensor Reduction of engine speed Page ELECTRICAL SYSTEM - 36 Downloaded from www.Manualslib.com manuals search engine Steyr Diag Power limitation Sensor or connector failure; see service code table See table trouble shooting: Air charge system Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Operating Parameter Effect noticed Panel Indication Additional Tool-Readings Action or possible reason Engine speed sensor fault Higher or unstable idle speed, limited performance No RPM inication on tachometer Steyr Diag Service code See table trouble shooting: Speed sensor Engine speed remains at idle No increase of engine speed if throttle is moved to max. Steyr Diag Service code See table trouble shooting: Accelerator potentiometer failure Governor position system Irregular engine speed or stalled engine Steyr Diag Service code See table trouble shooting: Governing system Inverse position shut down (SOLAS) Engine shut down beyond 70° deg. angle After engine stop horn remains switched ON until ignition reset During break in phase Cel-ON at high accelerator position (more than 75%) Indication light "CEL" is switched ON Reset through ignition OFF and then ON Steyr Diag Break-in phase See information break in procedure Optical and audible warning signals as shown on the dash board, are illustrated in chapter "Operating Status and Error Report" 06.06.02 Diagnostic system The electronic engine management system controls the following parameters: Oil pressure, boost pressure, coolant temperature, hi-riser (bend) temperature. The electronic engine management system has an automatic self-test program checking all data of electronic sensors. As soon as a fault is found, there is an optical or audible signal (refer to chart "Error Codes"). Occurred faults remain stored until cancellation. Stored faults may be selected, analyzed and cancelled by means of PC via diagnostic outlet. A reference to one or several stored faults is the 5 second "TESTING" of the "CHECK-ENGINE LAMP" and the "WARNING HORN" after ignition ON, instead of usual 0,7 seconds. (refer to chart "Operating Status") On the CHECK-ENGINE lamp (E) stored faults may be indicated by flashing codes. (With a special procedure, (06.06.04) individual cancellation is possible.) Error codes are regarded both as flashing codes as will as display by diagnostic instrument. There are three fault categories: temporary faults, non essential faults and essential faults. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 37 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.03 Reading Error Codes Entering and reading of stored faults via Check Engine Lamp and Diagnostic Outlet Plug ( X 23 ): Needed device: Tool No. VR00135/1 ( normally closed push button switch ) connected to Diagnostic Outlet Plug X23. In case this tool is not available: Connect temporarily Pin - Pos. 1 with Pin - Pos. 2 of Diagnostic Plug X 23 ( before ignition is turned on at key switch ) Code indication and indication sequence: 06.03 ill.1 After entering the error code indication modus the Engine Management System will display a blink code at the Check Engine Light on the dash panel. The blinking sequence will always begin and end with control code indication # 12. Each ERROR CODE will be repeated 3 times to reassure your correct reading – see below bar code illustration. Example sequence check engine light (ill.2/pos.1): Error code # 14 1 06.03 ill.2 06.03 ill.3 Stroke = Check Engine Light illuminated for 0,3 sec. (Light Off - period within blink sequence 0,4 sec.) Dashed Line = interruption within code indication 1,5 sec. Solid Line = interval interruption between error code 3,0 sec. Page ELECTRICAL SYSTEM - 38 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM If more then one error code is stored in the Engine Management System the indication sequence will be continued blinking additional stored error codes. To delete a memorized error code see description Indication and Cancellation of memorized sensor and circuit faults. For a description of the possible error codes refer to enclosed Table – Error Codes ATTENTION: To exit from Error code indication. Tool VR00135/1 must be removed ( connection between Pin 1 to Pin 2 opened ) before ignition is turned ON again. 06.06.04 Indication and Cancellation of memorized sensor and circuit faults Selection and clearing of stored error codes: Procedure: * Ignition — OFF * Connect Tool VR00135/1 to Diagnostic Outlet Plug ( X 23 ) – see 06.03 ill.1 * Ignition — ON Note: The program changes automatically to indication of error codes. If no error code is stored, only repeating control code reading “ CODE # 12 “ will be displayed. Possible memorized codes are indicated as shown in the previous illustrated example ( blinking 3x CODE # 12 i. e. 3x ERROR CODE # 14 etc. ) The sequence will be prolonged with additional codes if more then one ERROR CODE is stored. See Table – ERROR CODES for description * To delete a determined ERROR CODE from the Engine Management System concentrate for the 3rd times flashing the desired ERROR CODE. While this ERROR CODE is displayed the third time the button ( Tool VR00135/1 ) must be pushed and kept in this position ( contact open ). * The indication on the Check Engine Light changes to a fast blinking of the lamp ( app. 4 times per sec. ). During this rapid flashing light the push button must be released ( close contact after app. 2 sec.) to delete this ERROR CODE. Note: Any other ERROR CODE have to be selected and cleared individually following the above mentioned procedure to delete a determined ERROR CODE. Note: An ERROR CODE can only be deleted if no defect exists in this circuit. In case of a present active failure, the ERROR CODE keeps reappearing until the problem has been repaired and the circuit is properly working again. * Disconnect Tool VR00135/1 from Diagnostic Outlet Plug ( X 23 ) to exit from error code display. Note: Watch indication of the Check Engine Light and the Warning Horn after ignition contact. If all ERROR CODES are deleted from the Engine Management System the indication resumes to 0.7 sec. function test of Check Engine Light and the Warning Horn. For more details see Chart – Operating Conditions - Instrument panel. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 39 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.05 Principle failure code list NOTE: CODE Some codes may not apply due to different application! REFER TO ABBREV. CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE this code is designated for beginning or end of loop 12 Control code 13 LoMap X12/B12 boost pressure sensor signal level too low (short circuit or missing contact) 14 HiMap X12/B12 boost pressure sensor signal level too high (missing connection) 17 LoEXH X17/B17 air charge temp. sensor signal level too low (short circuit or missing contact) 18 HiEXH X17/B17 air charge temp. sensor signal level too high (missing connection) 21 LoECT X16/B16 water temp. sensor signal level too low (short circuit or missing contact) 22 HiECT X16/B16 water temp. sensor signal level too high (missing connection) 23 LoPed1 X13/B13 potentiometer accelerator signal level entry too low 24 HiPed1 X13/B13 potentiometer accelerator signal level entry too high 25 LoVPWR F5/K27 main relay low voltage supply to ECU, F5, K27 26 HiVPWR F5/K27 main relay too high voltage on VPROT input 27 LoVREF X5/Z3 module, connector too low voltage on sensor supply, possible short circuit 28 HiVREF X5/Z1 module, connector too high voltage on sensor supply 29 PedS X13/B13 accelerator potentiometer defect on pedal safety switch, pin 1-2 31 LoLPS X18/B18 lubricant pressure sensor signal level too low (short circuit or missing contact) 32 HiLPS X18/B18 lubricant pressure sensor signal level too high (missing connection) 33 LoPed2 X13/B13 potentiometer accelerator signal level too low 34 HiPed2 X13/B13 potentiometer accelerator signal level too high (missing connection) 35 LoRPos X14/B14 rack position sensor signal level too low (short circuit or missing contact) 36 HiRPos X14/B14 rack position sensor signal level too high (missing connection) 37 LoLOP X18/B18 lubricant pressure sensor signal level too low (short circuit) 38 HiLOP X18/B18 lubricant pressure sensor signal level too high (missing connection) 53 N_RFI X15/B15 RPM-sensor radio interference / sensor input 54 BadSta M1-Pin50 K28 start assist relay no start signal from assist solenoid 55 NoPuls X15/B15 RPM-sensor no speed signal during crank 56 Srpos Y14(B14) refer to setting rack pos. rack calibration bad/rack position outside tolerance field Page ELECTRICAL SYSTEM - 40 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM CODE ABBREV. REFER TO CIRCUIT 57 Rack0 Y14(B14) refer to setting rack pos. 99 FMSpwm X20/Y20 actuator / solenoid 161 HiVTGc Y28 REA unit at turbo charger defect in governor solenoid wire circuit (Y20, main relay K27-no frequency sent or govenor solenoid circuit connected) defect in circuit of actuator turbo charger (short circuit) 162 LoVTGc Y28 REA unit at turbo charger defect in circuit of actuator turbo charger (missing connection) 164 CELs L2 check engine lamp Current limit exceeded (short circuit) 165 CELo L2 check engine lamp missing connection or bulb blown 167 FPR_s K24 fuel pump relay Current limit exceeded in relay circuit (short circuit) 168 FPR_o K24 fuel pump relay no current detected in relay circuit (disconnection) 177 MR_s K27 main relay no current detected in main relay circuit (short circuit) 178 MR_o K27 main relay no current detected in main relay circuit (disconnection) 181 WarnLs L3 oil pressure lamp Current limit exceeded (short circuit) 182 WarnLo L3 oil pressure lamp no current in circuit of oil pressure lamp 186 BadPos Y20 governor solenoid Nominal-actual value difference (rack pos. error, rack jammed) 187 HiFMSC X20/X20 governor solenoid defect in governor wire circuit (resistance too high) (bulb blown or missing connection) 188 LoFMSc X20 governor solenoid defect in governor wire circuit (resistance too low) 193 VTG_Bad Y28 REA unit at turbo charger defect in output circuit (short circuit or missing connection) 194 GPR_s K26 glow assist relay current limit exceeded in glow plug relay circuit (short circuit) 195 GPR_o K26 glow assist relay no current detected in glow plug relay circuit (disconnection) 201 HiTEMP -- operation limit exceeded engine overheated engine was operated with too high coolant temperature 202 Lop -- operation limit exceeded - engine was operated with too low lubricant pressure lubricant pressure too low 203 Manop -- operation limit exceeded rack position too high engine operated with manual movement of rack 251 ITSL_Bad B30 position sensor - ITD signal level too low (short circuit) on injection timing sensor 252 ITV_LoCur Y29 proportional valve - ITD defect in circuit of valve (no current flow) 253 ITV_HiCur Y29 proportional valve - ITD defect in circuit of valve (current value too high) 254 SpvP_Bad B30 position sensor or ITD commanded timing position can not be achieved (sensor or injection timing device defect, eccenter shaft jammed) 255 Spv_INI B30 reference-position sensor ITD timing position calibration bad (position out of tolercance) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine INVOLVED DEVICE POSSIBLE CAUSE bad rack zero position Page ELECTRICAL SYSTEM - 41 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.06 REPLACE FUSES Preparatory works: Engine out of operation, disconnect battery. Replace automatic circuit breaker 1 Swing off E-box base plate. 2 Disconnect cable from automatic circuit breaker. 3 Loosen 2 hexagon screws (ill.1/pos.1) (SW1/4") and take off thermal circuit breaker (ill.1/pos.2). 3 2 1 NOTE: For assembly, seal cable screw connections with rubber varnish. 06.06 ill.1 Replace fuses 1 Remove E-box cover. 2 Remove fuse protection cap. Pull out fuses (ill.1/pos.3) Replace defect fuse. Page ELECTRICAL SYSTEM - 42 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.07 Connection J1 06.07 ill.1 Pin Cable - no. Explication A B 15000-01 15000-02 ignition 15 ignition 15 C D 30012-07 30012-08 terminal 30 terminal 30 E F 31000-01 31000-02 ground connection ground connection G H 60616-01 31615-01 lamp - oil pressure L3 warning horn J K 60706-01 60614-01 const. speed switch temperature display L M 61000-02 alternator D+ blind plug N O 60613-01 60121-01 tachometer (speed) oil pressure gauge (optional) P Q 60810-01 50000-02 check engine lamp ignition lock start R S 50000-03 60120-01 ignition lock start trim (optional) T U 61001-02 60901-03 alternator B+ 24V DC (ifused) CAN-low V W 60900-03 CAN-high blind plug X Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine blind plug Page ELECTRICAL SYSTEM - 43 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.08 Connection A5 and X5 06.08 ill.1 Pin Cable no. Designation Explication 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 30012 / 01 31000 / 06 15100 / 01 free free 60616 / 01 31555 / 01 60613 / 01 60114 / 01 60117 / 01 60112 / 01 60111 / 01 50000 / 01 60122 / 01 60900 / 01 60901 / 01 15012 / 01 15012 / 02 Vbat GND Vref free free GPL GPR Tacho ECT LPS RPOS PED1 CRI CLS CANH CANL VPROT2 VPROT 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 15000 / 03 31100 / 01 free 31554 / 01 60810 / 01 31558 / 01 31615 / 01 60614 / 01 60118 / 01 60110 / 01 60706 / 01 60116 / 01 60123 / 01 60808 / 01 60113 / 01 free 31409 / 01 IGN Gnd Vref free FPR CEL MR WOUT TEMP EXT MAP AUX PED2 WS ISO RPM free FMS terminal 30 terminal 31 + 5V not busy not busy oil pressure lamp L3 preheating relay speed instrument engine coolant temperature sensor oil pressure sensor pot. rack position pedal 1 start signal identification gear switch canbus high canbus low direct supply line to control solenoid protected 12V (after K27 and protective wiring in governor) ignition terminal 15 sensor ground connection not busy fuel pump relay check engine lamp main relay (K27) warning horn temperature display exhaust gas water temperature boost pressure sensor fixed speed pedal 2 warning switch / Solas inversion switch ISO 9141 (diag. cable) engine speed sensor not busy approach line for control solenoid Page ELECTRICAL SYSTEM - 44 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM " J1" Fitting Main Connector - M1 / 01 06.06.09 Fitting main connector "J1" properly Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 45 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. INSTRUMENT PANEL B A H C D E G I F 07.00 ill.1 Instrument panel, standard A B C D E F tachometer engine temperature warning light - battery charge combined light preheating control & warning light engine oil pressure warning light check engine ignition key lock Page ELECTRICAL SYSTEM - 46 Downloaded from www.Manualslib.com manuals search engine G H I blind plug - installation option for key switch constant revolution blind plug - installation option for oil pressure gauge or voltmeter 12V audible warner (installed to rear side of paneel) Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. 01 Chart - Operating Status Instrument indication during normal operation 1. ignition ON (... until engine start) light indication ON ON (0,7 sec.) ON (0,7 sec.) 07.01 ill.1 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. ON (0,7 sec.) 2. ignition ON (... until engine start) light indication Indication active error ON ON (0,7 sec.) ON (5 sec.) 07.01 ill.2 ON (5 sec.) 3. engine running after start Normal condition OFF OFF OFF 07.01 ill.3 OFF NOTE: Further information see: "Table - Error indication on Instrument Panel" Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 47 ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. 02 Chart - Error indication on Instrument Panel A C D E B A B C temperature gauge - coolant audible warner warning light - battery charge 07.02 ill.1 D E combined light preheating control & warning light engine oil pressure warning light check engine Operating condition: During normale engine operation, or indication in case of sensor defect while ignition is switched ON. Speed resp. performance limitation during engine operation Event: Indication status Fault Remarks oil pressure below min. limit check oil level 80° - 90°C OFF ON ON OFF 07.02 ill.2 80° - 90°C OFF OFF fault oil pressure sensor or sensor connection check oil pressure sensor (B18) and connection engine overload during break-in period reduce throttle position until light goes OFF (indication during first 2 hours of operation) FLASHING (1x per sec.) OFF 07.02 ill.3 NOTE: (see cap. general, D3) ON ON Page ELECTRICAL SYSTEM - 48 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Fault Indication status Remarks 80° - 90°C OFF ON (2x per sec.) high exhaust temperature (off 80° C) check raw water system, strainer, impeller pump engine coolant temperature to high after cooling down, check engine coolant level defect engine coolant sensor or sensor connection after cooling down, check engine coolant level, sensor (B16) and connection OFF FLASHING (2x per sec.) 07.02 ill.4 high approx 105°C OFF ON OFF OFF (2x per sec.) 07.02 ill.5 120°C OFF ON OFF OFF (2x per sec.) 07.02 ill.6 80° - 90°C OFF OFF instable idle speed, no indication on tachometer defect speed sensor (B15) or sensor connection OFF OFF 07.02 ill.7 80° - 90°C OFF ON OFF ON Trouble in governing loop, involved components: control solenoid, rack, control gear of unit injector, rack position sensor Failure in governing loop: time limit exceed for rack positioning. Restriction or high friction in control devices.Stored failure code must be cleared memory. Tool: PC-service program 07.02 ill.8 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 49 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Fault Indication status Remarks During start attempt ON ON OFF ON Engine will not start. Failure in governing circuit Failure in governing circuit. Positioning of rack not possible. Trouble shooting of control solenoid, rack, control gear of unit injection, rack position sensor 07.02 ill.9 Page ELECTRICAL SYSTEM - 50 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 51 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.03 Instrument panel (for SOLAS only) A B F G I J C D E H 07.03 ill.1 A G push button START (green) H blind plug - installation option for oil pressure gauge or voltmeter 12V E tachometer with service hour meter temperature gauge - coolant warning light - battery charge combined light preheating control & warning light engine oil pressure warning light - check engine light I emergency cut off switch F push button - ignition ON/OFF (red) J audible warning device (installed to rear side of panel) NOTE: Instrument gauges are automatically illuminated if ignition is turned ON. NOTE: In case an inversion occured, the engine gets shut down automatically to re-establish regular running and operation the push button Ignition (F) must be switched OFF and then ON again and engine must be restarted with push button START (G). B C D Page ELECTRICAL SYSTEM - 52 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.04 Chart - Operating Status (for SOLAS only) Instrument indication during normal operation 1. ignition ON (... until engine start) System check - see light indication 07.04 ill.1 ON (0,7 sec.) ON (0,7 sec.) ON 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. ON (0,7 sec.) 2. ignition ON (... until engine start) ON (5 sec.) Indication active error ON (0,7 sec.) ON 07.04 ill.2 ON (5 sec.) 3. engine running after start 07.04 ill.3 Normal condition NOTE: Further information see: "Table - Error indication on Instrument Panel" OFF Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 53 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.05 Error Indication - Error indication on instrument panel A (for SOLAS only) B A B C C D temperature gauge - coolant audible warning device warning light - battery charge E 07.05 ill.1 D E combined light preheating control & warning light engine oil pressure warning light - check engine light Operating condition: During normal engine operation, or indication in case of sensor defect while ignition is switched ON. Event: Speed resp. performance limitation during engine operation Indication status ON Remarks oil pressure below min. limit check oil level 80° - 90°C ON OFF 07.05 ill.2 OFF OFF 07.05 ill.3 Fault OFF 80° - 90°C FLASHING (1x per sec.) fault oil pressure sensor or sensor connection check oil pressure sensor (B18) and connection engine overload during break-in period reduce throttle position until light goes OFF (indication during first 2 hours of operation) OFF NOTE: (see cap. general, D3) ON ON Page ELECTRICAL SYSTEM - 54 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Fault Indication status Remarks 80° - 90°C ON high exhaust temperature (off 80° C) check raw water system, strainer, impeller pump engine coolant temperature to high after cooling down, check engine coolant level defect engine coolant sensor or sensor connection after cooling down, check engine coolant level, sensor (B16) and connection instable idle speed, no indication on tachometer defect speed sensor (B15) or sensor connection Trouble in governing loop, involved components: control solenoid, rack, control gear of unit injector, rack position sensor Failure in governing loop: time limit exceed for rack positioning. Restriction or high friction in control devices.Stored failure code must be cleared memory. Tools: PC-service program (2x per sec.) OFF OFF 07.05 ill.4 ON FLASHING (2x per sec.) high approx 105°C (2x per sec.) OFF 07.05 ill.5 OFF OFF ON 120°C (2x per sec.) OFF 07.05 ill.6 OFF OFF OFF 07.05 ill.7 80° - 90°C OFF OFF 80° - 90°C ON OFF 07.05 ill.8 OFF OFF Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine ON Page ELECTRICAL SYSTEM - 55 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Indication status Fault During start attempt ON ON 07.05 ill.9 OFF Engine will not start. Failure in governing circuit Remarks Failure in governing circuit. Positioning of rack not possible. Trouble shooting of control solenoid, rack, control gear of unit injection, rack position sensor ON Page ELECTRICAL SYSTEM - 56 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 57 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) Designat. Component F9 fuse J1 23-pin plug connection engine cable - instrument cable S1 switch ignition S7 switch fix-n (speed-selector switch optional) K10 relay charge control (90A PRESTOLITE) L1 lamp charge control L2 lamp cel - check engine lamp L3 lamp oil pressure / pre-heating control P1 gauge coolant P2 gauge oil pressure (optional) P3 gauge tachometer with running-time meter P4 gauge trim (optional) H22 warning horn XS8 1-pin plug to lighting switch - instrument panel XS9 2-pin plug charging control/relay charging control (wiring harness side) XS10 2-pin plug charging control/relay charging control (instrument side) X1/S1 4-pin plug ignition X2/L1 10-pin plug charge control lamp X3/L2 10-pin plug cel - check engine lamp X4/L3 10-pin plug oil pressure warning lamp X5/E10 2-pin plug lighting coolant display X6/P1 3-pin plug coolant temperature gauge X7/E11 2-pin plug lighting oil pressure X8/P2 3-pin plug oil pressure gauge X9/S7 10-pin plug speed-selector switch (optional) X11/P3/E12 8-pin plug speed instrument / lighting speed instrument X12/E13 2-pin plug lighting trim (optional) X22/P4 3-pin plug trim (optional) Page ELECTRICAL SYSTEM - 58 Downloaded from www.Manualslib.com manuals search engine Description Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) 07.10 ill.1 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 59 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) Designat. Component F9 fuse J1 23-pin plug connection engine cable - instrument cable S1 switch ignition S7 switch fix-n (speed-selector switch optional) K10 relay charge control (90A PRESTOLITE) L1 lamp charge control L2 lamp cel - check engine lamp L3 lamp oil pressure / pre-heating control P1 gauge coolant P2 gauge oil pressure (optional) P3 gauge tachometer with running-time meter P4 gauge trim (optional) H22 warning horn XS8 1-pin plug to lighting switch - instrument panel XS9 2-pin plug charging control/relay charging control (wiring harness side) XS10 2-pin plug charging control/relay charging control (instrument side) X1/S1 4-pin plug ignition X2/L1 10-pin plug charge control lamp X3/L2 10-pin plug cel - check engine lamp X4/L3 10-pin plug oil pressure warning lamp X5/E10 2-pin plug lighting coolant display X6/P1 3-pin plug coolant temperature gauge X7/E11 2-pin plug lighting oil pressure X8/P2 3-pin plug oil pressure gauge X9/S7 10-pin plug speed-selector switch (optional) X11/P3/E12 8-pin plug speed instrument / lighting speed instrument X12/E13 2-pin plug lighting trim (optional) X22/P4 3-pin plug trim (optional) Page ELECTRICAL SYSTEM - 60 Downloaded from www.Manualslib.com manuals search engine Description Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) 07.10 ill.2 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 61 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 11 Description - Wiring harness instrument panels 4/6 cyl. marine engines (current version) Designat. Component F9 fuse 10 A J1 23-pin plug connection engine cable - instrument cable S1 switch ignition (red) S2 switch start (green) S3 switch emergency cut off (orange) S7 switch key switch constant revolution (optional) L1 lamp charge control L2 lamp cel - check engine lamp L3 lamp oil pressure / preheating conrol P1 gauge engine coolant temperature P2 gauge oil pressure (optional) P3 gauge tachometer with running-time meter H22 warning horn E10 lighting engine coolant temperature gauge E11 lighting oil pressure gauge (optional) E12 lighting tachometer gauge X8 1-pin plug connector illumination switch X24 8-pin plug connector STEYR - display Z1 splice battery + Z2 splice battery - Z3 splice ignition (+) Z4 splice key switch constant revolution 24 V interm. cable charge indicator Page ELECTRICAL SYSTEM - 62 Downloaded from www.Manualslib.com manuals search engine Description Z001019/0_6_July 2008 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 15000-02 30012-07 30012-08 31000-01 3100-02 60616-01 31615-01 60706-01 60614-01 61000-02 1 2 3 4 5 6 7 8 9 J1 / B J1 / C J1 / D J1 / E J1 / F J1 / G J1 / H J1 / J J1 / K 10 11 J1 / A Trim (Option) Ground shield (no connection) (no connection) J1 / W 19 J1 / X 20 60900-03 J1 / V 22 61001-01 B+ / 24V 60901-03 12 J1 / U 21 J1 / T 60120-01 J1 / S 18 J1 / P 15 50000-03 60810-01 J1 / O 14 J1 / R 17 60121-01 J1 / N 13 50000-02 60613-01 J1 / Q 16 31000-16 J1 / M J1 / L 15000-01 No./colours of shielded wire correspond to individual cable No. (15000-01) J1 K X L W M B J H V N C A G U O D E F T P Q R S Z1 Fuse 10A F9 1 5 6 Ignition Switch S1 7 2 - Start Z3 1 Charge Control Lamp L1 1 2 Check Engine Lamp L2 2 80 12 0 250 10 0 °F 210 °C + G _ Engine Coolant Temperature Gauge P1 105 175 58000-01 Connector Illumination X8 switch Z2 22 Z4 13 21 14 1 2 Opt. Key Switch-Constant Revolution S7 Lighting ECTGauge E10 www.steyr-motors.com 1 OILPreheating control Lamp L3 40 WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 12 V G _ 1 2 Lighting Opt. Gauge Oil-Pressure E11 Batt + Batt Sens ECU Control ECU 61 +24V + Opt. Gauge OilPressure P2 0 20 30 40 2 4 3 RPMGauge P3 10 1 5 Lighting RPMGauge E12 _ 0 1 4 bar 3 4 1 0 2 3 rpm x 1000 °C 3 85 4 73 77.8 RPM 120 6 5 1500 2650 TEMP TEMP/°C 50 1 2 5 4 X 24 8 6 65 1 2 3 4 2,8 6.3 OIL OIL/BAR 22 34 10.0 SPEED/KN MAIN SWITCH 2179338/D-02-070627_tedoc Start Charge Illumination Option 15 60 CAN + Warning Horn H22 SCC 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 49.16.45N 22:57 STEYR-CONTROL-CENTER ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM - 63 K X W B J H V N C A G U O D E F T P Q R S L M Page ELECTRICAL SYSTEM - 64 Downloaded from www.Manualslib.com manuals search engine 30012-07 30012-08 31000-01 3100-02 60616-01 31615-01 60706-01 2 3 4 5 6 7 8 9 J1 / B J1 / C J1 / D J1 / E J1 / F J1 / G J1 / H J1 / J Trim (Option) Ground shield (no connection) (no connection) J1 / W 19 J1 / X 20 60900-03 J1 / V 22 61001-01 B+ / 24V 60901-03 12 60120-01 50000-03 50000-02 60810-01 60121-01 60613-01 31000-16 J1 / U 21 J1 / T J1 / S 18 J1 / R 17 J1 / Q 16 J1 / P 15 J1 / O 14 J1 / N 13 11 Z1 Fuse 10A F9 1 5 6 Ignition Switch S1 7 2 30 Intermediate Cable Charge Indicator 24 V 85 86 87a 87 - Start Z3 1 Charge Control Lamp L1 1 12 0 1 2 + G _ OILEngine Preheating Coolant control Temperature Lamp Gauge L3 P1 250 10 0 °F 210 °C 58000-01 X8 1 14 Z2 22 Z4 13 21 G _ 1 2 Batt + Batt Sens ECU Control ECU 61 +24V + Opt. Gauge Lighting Opt. Key OilOpt. Gauge Switch-Constant Pressure Oil-Pressure Revolution P2 E11 S7 Connector Illumination switch 2 Lighting ECTGauge E10 www.steyr-motors.com 2 Check Engine Lamp L2 80 105 175 0 30 40 2 4 3 RPMGauge P3 10 20 1 5 Lighting RPMGauge E12 0 1 1 0 2 3 rpm x 1000 73 77.8 °C 3 85 4 RPM 120 6 5 1500 2650 TEMP TEMP/°C 50 1 2 5 4 X 24 8 6 65 1 2 3 4 2,8 6.3 4 bar 3 4 OIL OIL/BAR 22 34 10.0 SPEED/KN MAIN SWITCH 2179339/D-02-070627_tedoc Start Charge Illumination Option 15 60 CAN + _ Warning Horn H22 SCC 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 49.16.45N 22:57 STEYR-CONTROL-CENTER ELECTRICAL SYSTEM J1 / M J1 / L 61000-02 60614-01 15000-02 1 J1 / A J1 / K 10 15000-01 No./colours of shielded wire correspond to individual cable No. (15000-01) J1 40 WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 24V (OPTION) ToC SERVICE MANUAL MARINE ENGINES Z001019/0_6_July 2008 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine W B J H V N C A G U O D E F T P Q R S K X 60706-01 60614-01 61000-02 3 4 5 6 7 8 9 J1 / D J1 / E J1 / F J1 / G J1 / H J1 / J J1 / K 10 11 J1 / C 50000-03 60120-01 J1 / Q 16 J1 / R 17 J1 / S 18 ohne Anschlag (no connection) ohne Anschlag (no connection) J1 / V 22 J1 / X 20 60900-03 J1 / U 21 3 4 3 M M - Start 4 1 Z3 2 Emergency Charge IGN (red) START CUT OFF Control Switch Lamp ON/OFF (green) S3 S2 L1 S1 J1 / W 19 60901-03 Z1 Fuse 10A F9 Optional 24 V Trim (Option) Ground shield 61001-01 B+ / 24V 50000-02 J1 / P 15 12 60810-01 J1 / O 14 J1 / T 60121-01 J1 / N 13 31000-16 60616-01 3100-02 31000-01 30012-08 30012-07 60613-01 J1 / M J1 / L 31615-01 2 J1 / B 15000-02 1 J1 / A 15000-01 No./colours of shielded wire correspond to individual cable No. (15000-01) J1 L M 1 1 2 OILPreheating control Lamp L3 80 12 0 250 10 0 °F 210 °C + G _ Engine Coolant Temperature Gauge P1 105 175 58000-01 Connector Illumination X8 switch Z2 22 Z4 13 + G _ 1 2 Opt. Gauge Lighting OilOpt. Gauge Pressure Oil-Pressure P2 E11 Batt + Batt Sens ECU Control ECU 61 +24V 21 14 1 2 Opt. Key Switch-Constant Revolution S7 Lighting ECTGauge E10 www.steyr-motors.com 2 Check Engine Lamp L2 40 WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 12V (OPTION) 0 20 30 40 2 4 3 RPMGauge P3 10 1 5 Lighting RPMGauge E12 _ 0 1 1 0 2 3 rpm x 1000 73 77.8 °C 3 85 4 RPM 120 6 5 1500 2650 TEMP TEMP/°C 50 1 2 5 4 X 24 8 6 65 1 2 3 4 2,8 6.3 4 bar 3 4 OIL OIL/BAR 22 34 10.0 SPEED/KN MAIN SWITCH 2179340/D-02-070627_tedoc Start Charge Illumination Option 15 60 CAN + Warning Horn H22 SCC 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 49.16.45N 22:57 STEYR-CONTROL-CENTER ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM - 65 K X W B J H V N C A G U O D E F T P Q R S L M Page ELECTRICAL SYSTEM - 66 Downloaded from www.Manualslib.com manuals search engine 15000-02 30012-07 30012-08 31000-01 3100-02 60616-01 31615-01 60706-01 60614-01 61000-02 2 3 4 5 6 7 8 9 J1 / C J1 / D J1 / E J1 / F J1 / G J1 / H J1 / J J1 / K 10 11 J1 / B 60810-01 50000-02 50000-03 60120-01 J1 / O 14 J1 / P 15 J1 / Q 16 J1 / R 17 J1 / S 18 Trim (Option) Ground shield (no connection) (no connection) J1 / X 20 60900-03 J1 / V 22 J1 / W 19 60901-03 J1 / U 21 61001-01 B+ / 24V 60121-01 J1 / N 13 12 60613-01 J1 / T 31000-16 Z1 Fuse 10A F9 3 4 3 M M - Start 4 Z3 1 2 Emergency Charge IGN (red) START CUT OFF Control Switch Lamp ON/OFF (green) S3 S2 L1 S1 85 86 87a 87 1 2 Check Engine Lamp L2 12 0 1 2 + G _ Engine OILCoolant Preheating Temperature control Gauge Lamp P1 L3 250 10 0 °F 210 °C 58000-01 www.steyr-motors.com 30 Intermediate Cable Charge Indicator 24 V 80 105 175 2 Connector Illumination X8 switch 1 Lighting ECTGauge E10 14 Z2 22 21 + G _ 1 Batt + Batt Sens ECU Control ECU 61 +24V Z4 13 2 Opt. Gauge Lighting Opt. Key OilOpt. Gauge Switch-Constant Pressure Oil-Pressure Revolution P2 E11 S7 0 20 30 40 2 4 3 RPMGauge P3 10 1 5 Lighting RPMGauge E12 _ 0 1 4 bar 3 4 1 0 2 3 rpm x 1000 °C 3 85 4 73 77.8 RPM 120 6 5 1500 2650 TEMP TEMP/°C 50 1 2 5 4 X 24 8 6 65 1 2 3 4 2,8 6.3 OIL OIL/BAR 22 34 10.0 SPEED/KN MAIN SWITCH 2179341/D-03-070627-tedoc Start Charge Illumination Option 15 60 CAN + Warning Horn H22 SCC 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 49.16.45N 22:57 STEYR-CONTROL-CENTER ELECTRICAL SYSTEM J1 / M J1 / L 15000-01 1 J1 / A No./colours of shielded wire correspond to individual cable No. (15000-01) J1 40 WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 24V (OPTION) ToC SERVICE MANUAL MARINE ENGINES Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 67 ToC ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06. 07. 13 ADJUST INSTRUMENTS 06. 07. 13. 01 Tachometer with running-time meter There are 2 possible settings Function "PULSE": - Entry of pulse rate 12,18 per revolution - inductive sender Function "ADJUST": - Using a reference rpm meter (manual rpm meter), the rpm is compared and calibrated accordingly. 07.13 ill.1 Selection of function Operating voltage off. Press and hold down key on back of housing. Operating voltage (ignition) on. The display shows "PULSE" and "ADJUST" every 2 seconds in alternation. To select shown function, release the key for respective indication. Function "PULSE" When the function PULSE is selected, "P12.18" (12.18 pulses per revolution) appears for example on the display after approx. 3 seconds, with a flashing last digit. Immediately start entry of known pulse rate by repeated pressing of key. 07.13 ill.2 The flashing digit may be adjusted by activating the key (possible pulse settings: 0.50 to 399.99). After having adjusted the flashing digit, wait for approx. 3 sec. Then the next digit begins to flash. At completion of pulse rate setting, activate the key no more. The display then changes over to counting of runningtime. Thus the setting procedure is completed. By repeated selection of function PULSE the selected pulse rate may be checked. The pulse rate appears on the display and the individual digits begin to flash in sequence, starting with the last digit. 07.13 ill.3 P-12,18 Page ELECTRICAL SYSTEM - 68 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Function "ADJUSt" When selecting the function "ADJUST", the rpm. display may be adjusted between 30 and 100 % of the measuring range. Using a reference rpm meter (manual rpm meter), the rpm indicator is compared. Fine adjustment requires two persons, one to operate the instrument and the other one to operate the manual rpm meter on the axis of the engine's crankshaft. Extreme caution is required! Do not wear loose clothing! When the function ADJUSt is selected, UP or dn (UP or DOWN) appears in alternation on the display after approx. 3 seconds. If, for example, the key is pressed and held down when UP is displayed, the pointer deflection changes upwards (for "dn" analogously downwards). If you release the key for 2 seconds and then press it again, the pointer deflection changes downwards. At the beginning, the pointer deflection changes very slowly which permits a very precise fine adjustment. With a short release of the key, the procedure is repeated. With a longer pressing of the key, the pointer deflection will change faster. Release the key as soon as the fine adjustment corresponds to the reference rpm. The display then changes to counting of running-time. Fine adjustment is completed. 07.13 ill.4 Fine Adjustment: During normal operation of the indicator, a fine adjustment is possible by using the key. The adjustment range is +/- 20 % of the actual reading. Press the key, with voltage supply on. On the display appears A 0.0 By pressing and holding the key, the adjustment factor increases in steps of 0,5%. If you release the key for 2 seconds and then press it again, the adjustment factor decreases in steps of 0,5%. If the key is not pressed for more than 5 seconds, the adjustment factor will be stored and the indicator switches back to the normal running-time display. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 07.13 ill.5 Page ELECTRICAL SYSTEM - 69 ToC ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06. 07. 14 REPLACE INSTRUMENTS 06. 07. 14. 01. General notes on safety Safety instructions No smoking! No open fire lights! This product has been developed, produced and tested in compliance with the basic safety requirements of EC directives and in accordance with the established state of the art. Use our product for the intended purpose only. The consequences of use of the product for other than the intended purpose may be personal injury and damage to property as well as environmental damage. The unit is designed for use in sports boats. Record data of other instruments with transient electronic memories. Please note during installation: The product should be installed by your boatyard or by a person specialised in the installation of such devices. If you wish to carry out installation yourself, wear suitable working clothing. Do not wear loosefitting clothing. This may be caught by moving parts. If you have long hair, wear a hair net. When working on electric equipment, do not wear any metallic or conductive jewellery such as chains, bracelets, rings etc. Before beginning work, disconnect the negative pole of the battery, since otherwise there is a risk of a short ciruit. Short circuits can cause cable fires, battery explosions and damage to other electronic storage systems. Please note that when the battery is disconnected, all transient electronic memories lose the values entered and have to be reprogrammed. With petrol engines, allow the engine compartment fan to run before beginning work in the engine compartment. At the installation site, make sure there is sufficient space behind drilled holes or the installation aperture. First drill small holes at the installation apertures, and enlarge if necessary using tapered drills, compass saws, fretsaws of files. Deburr edges.The safety instructions of the hand tool manufacturer must be observed. If work has to be carried out without interruptions in voltage, only insulated tools may be used. The electrical outputs of the display unit and the connected cables must be protected from direct contact and damage. To this end, the cables used must have adequate insulation and/or dielectric strenght, and the contacts must be shockproof. The electrical conductive parts of the connected consumers must also be protected from direct contact by suitable means. The installation of bare metal cables and contacts is forbidden. After installation, please note: Clamp the earthing cable firmly to the negative pole of the battery. Enter/program the values of the transient electronic memories again. Test all functions. Page ELECTRICAL SYSTEM - 70 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Safety Instructions (electrical connection): To install the electric cables, use existing cable ducts and looms, but do not run the cables paralle to ignition cables or parallel to cables leading powerful consumers. Secure the cables using cable binders or adhesive tape. Do not run the cables over moving parts. Ensure that the cables are not exposed to any tensile, compressive or shear forces. If the cables have to be run through drilled holes, protect the cables using grommets or rubber bushings etc. Use only a cable stripper to strip the cables. Adjust the cable stripper so that the individual strands are not damaged or cut off. New connections should only be made using soft solder, or with commercial crimp connectors. Crimped connections should only be made using cable crimping pliers. The safety instructions of the hand tool manufacturer must be observed. Insulate exposed leads in such a way that short circuits cannot occur. Caution: Risk of short circuit through faulty junctions or damaged cables. Short circuits in the electrical system can cause cable fires, battery explosions and damage to other electronic systems. For this reason, all connections in the voltage supply system must be either soldered or fitted with weldable connectors and adequately insulated. Pay particular attention to correct earth connections. Incorrect connections can lead to short circuits. The cables must only be connected in accordance with the electrical terminal connection diagram. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 71 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 14. 02 Audible warner, H22 control unit 07.14 ill.1 sensor exhaust gas temperature Page ELECTRICAL SYSTEM - 72 Downloaded from www.Manualslib.com manuals search engine sensor engine coolant sensor oil pressure Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 14. 03 Circuit diagram voltmeter (optional) 07.14 ill.2 06. 07. 14. 04 Circuit diagram oil pressure gauge (optional, sensor B19 - gauge P2) single instruments 07.14 ill.3 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine double instruments (requires special sensor) sensor marking "G" one sensor for two two displays displays Page ELECTRICAL SYSTEM - 73 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.01 Potentiometer Accelerator, B13 1 Remove plug housing. 2 Unscrew hexagon nut of accelerator lever, remove lever. 3 Loosen 2 hexagon screws. Remove accelerator. Throttle potentiometer B13 (accelerator) (= connector X13) In case of defective potentiometer accelerator B13, service codes 23, 24 or 29 will flash. NOTE: R1 08.01 ill.1 First check cables and connections. Resistance between terminals 3 and 1; approximately 1,2 kOhm resistance value switch to infinetely after moving throttle lever from idle position. Switch contact should open within the first 10% of throttle lever (pedal) movement. R2 Resistance between terminals 5 and 4; 1,2 kOhm R3 Resistance between terminals 5 and 2; 2,2 kOhm for normal position of potentiometer accelerator ; 1,4 kOhm at "full speed " max. throttle position. 1 2 3 4 5 08.01 ill.2 Wiring Circuit - Potentiometer P/N 2176860/0 ~ 1k 1 R1 ~9 3 5 ~ 1k + ~ 1k 2 - R3 R2 4 08.01 ill.3 Page ELECTRICAL SYSTEM - 74 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.02 Voltage regulator 24V-12V equalizer Powersupply to equalizer recomandet wire gauge size. Starter must be connecting by customer use a wire min. AWG 0 (50 mm²) connect a red wire AWG 8 (6 mm²) at battery "A" positiv terminal +12V connect a red wire AWG 6 (10 mm²) at battery "B" positiv terminal +24V connect a black wire AWG 6 (10 mm²) directly at battery "A" negativ terminal. Battery equalizer 25A BLACK AWG 6 +24V 20A GND 30A 12V Protected Output RED AWG 6 24V LOAD (STARTER , ALTERNATOR, power supply glow , .....) OUT 12V RED AWG 8 (*) “A” “B” 08.02 ill.1 * Note:......Mainswitsches are mechanically interlinked. X21 ARMATUREN PLUG 6-POLE: --> USE ONLY 12 VOLT INSTRUMENTS pin1 pin2 pin3 pin4 pin5 pin6 60810--> check engine lampe (12V/2W) 60616--> glow lamp (12V/2W) 60614--> temperature instruments (12V) 60613--> engine speed instruments (12V) 50000--> starter terminal 50 (detection of start) 15000--> ignition connect it to the ignition-switch of the vehicle (protect with 5 Amp fuse) Note: The glow lamp has 2 functions --> at first it works as glow lamp after start it works as oil pressure lamp. ALTERNATOR B+ must be connection by customer --> use a wire AWG 6 (10 mm²) charging control --> must be connecting by customer. ATTENTION: Please observer and follow Original inclosed manufactures recommentation! Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 08.02 ill.2 Page ELECTRICAL SYSTEM - 75 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.03 DC - DC converter DC-DC Converter IVO 8770 CIRCUIT DIAGRAM IE Batt "A" IA 16A 25A 24VDC U1 Engine U2 G 12VDC Batt "B" Batt "C" Page ELECTRICAL SYSTEM - 76 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 77 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM to engine number 48226999 06.10 SENDER AND SENSOR OVERVIEW 06.10.01 Component configuration 4 cyl. engine 164/174 94/114/144 10.01 ill.1 CODE CODE KURZNAME ABBREVIATION KURZNAME ABBREVIATION BESCHREIBUNG DESCRIPTION BESCHREIBUNG DESCRIPTION Stecker Ölmanometer (Option) Connector oil pressure gauge (optional) Stecker Trimmanzeige (Option) Connector trim (optional) MAP Ladedrucksensor Boost-pressure sensor PED Gaspedal Potentiometer accelerator J1 Verbindungsstecker Motor - EMS Connector engine cable - EMS RPOS Regelstangensensor Rack position sensor DIAG Diagnose - Stecker Diagnosis - plug RPM Motordrehzahlsensor Sensor engine speed FMS Steuermagnet Control solenoid ECT ECT Kühlflüssigkeitstemperatursensor Sensor engine coolant temperature Stecker Getriebeschalter (Option) Connector gear switch (optional) EXT Abgastemperatursensor Sensor exhaust gas temperature Inversionsschalter (Nur bei SOLAS) Inversion switch (only for SOLAS) LPS Öldrucksensor Lubricant pressure sensor Abschaltventil (Nur bei SOLAS) Blow - by (only for SOLAS) Page ELECTRICAL SYSTEM - 78 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 48227000 07002 CODE BESCHREIBUNG DESCRIPTION CODE B12 Ladedrucksensor Boost-pressure sensor X19 Stecker Ölmanometer (Option) Connector oil pressure gauge (optional) B13 Gaspedal Potentiometer accelerator X22 Stecker Trimmanzeige (Option) Connector trim (optional) B14 Regelstangensensor Rack position sensor J1 Haupt-Verbindungsstecker Main connector B15 Motordrehzahlsensor Sensor engine speed X23 Diagnose - Stecker Diagnosis - plug B16 Kühlflüssigkeittemperatursensor Sensor engine coolant temperature Y20 Steuermagnet Control solenoid B17 Abgastemperatursensor Sensor exhaust gas temperature X2 Stecker Getriebeschalter (Option) Connector gear switch (optional) B18 Öldrucksensor Lubricant pressure sensor S3 Inversionsschalter (nur bei SOLAS) Inversion switch (only for SOLAS) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine BESCHREIBUNG DESCRIPTION Page ELECTRICAL SYSTEM - 79 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.02 Component configuration 6 cyl. engine to engine number 68226999 246/256/ 266 126/166/ 236 10.02 ill.1 CODE CODE KURZNAME ABBREVIATION KURZNAME ABBREVIATION BESCHREIBUNG DESCRIPTION BESCHREIBUNG DESCRIPTION Stecker Ölmanometer (Option) Connector oil pressure gauge (optional) Stecker Trimmanzeige (Option) Connector trim (optional) MAP Ladedrucksensor Boost-pressure sensor PED Gaspedal Potentiometer accelerator J1 Verbindungsstecker Motor - EMS Connector engine cable - EMS RPOS Regelstangensensor Rack position sensor DIAG Diagnose - Stecker Diagnosis - plug RPM Motordrehzahlsensor Sensor engine speed FMS Steuermagnet Control solenoid ECT ECT Kühlflüssigkeitstemperatursensor Sensor engine coolant temperature Stecker Getriebeschalter (Option) Connector gear switch (optional) EXT Abgastemperatursensor Sensor exhaust gas temperature Inversionsschalter (Nur bei SOLAS) Inversion switch (only for SOLAS) LPS Öldrucksensor Lubricant pressure sensor Abschaltventil (Nur bei SOLAS) Blow - by (only for SOLAS) Page ELECTRICAL SYSTEM - 80 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 68227000 07003 CODE BESCHREIBUNG DESCRIPTION B12 Ladedrucksensor Boost-pressure sensor X19 Stecker Ölmanometer (Option) Connector oil pressure gauge (optional) B13 Gaspedal Potentiometer accelerator X22 Stecker Trimmanzeige (Option) Connector trim (optional) B14 Regelstangensensor Rack position sensor J1 Haupt-Verbindungsstecker Main connector B15 Motordrehzahlsensor Sensor engine speed X23 Diagnose - Stecker Diagnosis - plug B16 Kühlflüssigkeittemperatursensor Sensor engine coolant temperature Y20 Steuermagnet Control solenoid B17 Abgastemperatursensor Sensor exhaust gas temperature X2 Stecker Getriebeschalter (Option) Connector gear switch (optional) B18 Öldrucksensor Lubricant pressure sensor S3 Inversionsschalter (nur bei SOLAS) Inversion switch (only for SOLAS) Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine CODE BESCHREIBUNG DESCRIPTION Page ELECTRICAL SYSTEM - 81 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.03 Calibration of rack position This procedure must be carried out if any of the following has been done: - Control solenoid has been disassembled or replaced, refer to 03. 08. 01. - Rack position sensor has been disassembled or replaced, refer to 03. 08. 03. - Engine control unit has been replaced. - Rack or linkage lever have been replaced or loosened. E F 1 D C B A 10.03 ill.2 10.03 ill.1 NOTE: Ensure that the ignition is turned off. 1 Remove threaded pin from position A (ill. 1). 2 Manually move rack (ill.1/B) forward until borehole (ill.1/C) is over tapped hole (ill.1/D) and fix with threaded pin. The pin must be fastened hand tight and sit correctly in the rack, see ill. 2. above. 3 Turn on ignition,rack position will be automatically stored in the ECU A5. Storage process will take approx. 20 sec. 4 Turn off ignition. 5 Loosen threaded pin and screw it into rear bulkhead wall (ill.1/A). NOTE: If storage in ECU A5 was unsuccessful, error code 56 will be detected. Refer to Error Codes. NOTE: The rack position sensor is magnetism sensitive. All external magnets must be kept away as the may disturb the sensor. Page ELECTRICAL SYSTEM - 82 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.04 Replace Senders, Sensors 06.10.04.01 Exhaust gas temperature sensor, B17 1 Unlock plug (ill.1/pos.1) and remove. 2 Unscrew temperature sensor (ill.1/pos.2) (SW19) 2 1 10.04 ill.1 06.10.04.02 Engine temperature sensor, B16 1 Remove plug housing (ill.2/pos.1). 2 Unscrew engine temperature sensor. 1 10.04 ill.2 06.10.04.03 Speed sensor, B15 1 Press catch spring and remove plug. 2 Loosen hexagon screw (SW10), pull out sensor. ATTENTION: For assembly, use new 0-ring. Grease O-ring and put it on. 06.10.04.04 Boost pressure sensor, B12 for engines 94 / 114 / 144 / 126 / 166 / 236 only 1 10.04 ill.3 Remove hose from exhaust manifold. 2 2 ATTENTION: Do not remove hose from boost pressure sensor. 2 Press retaining clip against plug housing (ill.4/pos.1), remove plug. 3 Loosen two hexagon screws (SW10), remove boost pressure sensor (ill.4/pos.2). NOTE: For assembly, take care of the 2 sealing cushions of plug housing. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine 1 10.04 ill.4 Page ELECTRICAL SYSTEM - 83 ToC ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES Boost pressure sensor, B12 for engines 164 / 174 / 246 / 256 / 266 only 1 Remove cable strap, lift shackle at plug and pull off plug. 2 Loosen clamp (SW6) and pull off hose. 3 Loosen union nut (SW17) by holding up at sensor (SW32). Remove sensor Assembly is done in reverse order off disassembly. NOTE: Wetten the thread from the new sensor with LOCTITE 243. Thigthen union nut solid. 10.04 ill.5 06.10.04.05 Rack position feedback sensor, B14 1 Remove retaining clip, remove plug housing (ill.6/pos.1). 2 Disassemble control solenoid, refer to 03.08.01 3 Loosen 2 cylinder screws with hexagon socket (SW 3), remove sensor (ill.6/pos.2). 1 2 Assembly is done according to assembly of control solenoid, refer to 03.08. 10.04 ill.6 06.10.04.06 Oil pressure sensor, B18 1 Remove plug housing. 2 Unscrew oil pressure sensor (ill.7/pos.1) from mount (ill.7/pos.2). ATTENTION: Collect running out motor oil in a suitable vessel. 1 2 10.04 ill.7 06.10.04.07 Potentiometer Accelerator, B13 1 Disassemble indexing plate (ill.8+9/pos.1). 2 Remove plug housing (ill.8+9/pos.2). 3 Unscrew hexagon nut of accelerator lever (ill.8+9/ pos.3), remove lever. 4 Loosen 2 hexagon screws. Remove accelerator (ill.8+9/pos.4). 3 1 4 2 10.04 ill.8 Page ELECTRICAL SYSTEM - 84 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 3 1 4 2 10.04 ill. 9 06.10.05 Check Sensors and Switches 06.10.05.01 A Check rack position feedback sensor B14 (= connector X14) In case of defective rack position feedback sensor B14, service codes (35) and (36) will flash. NOTE: First always check cables and connections. 10.05 A ill.1 Final check: C Disassemble rack position feedback sensor from control solenoid. 1 Check resistance between terminals A and C with a digital ohmmeter. Resistance must be between 2,2 kOhm ± 10 %. 2 Measure resistance between terminals B and C with extended shaft. Resistance must be 0,5 kOhm ± 10 %. A 10.05 A ill.2 C B 10.05 A ill.3 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 85 ToC ELECTRICAL SYSTEM 3 SERVICE MANUAL MARINE ENGINES Measure resistance between terminals B and C with inserted shaft. Resistance must be 2,4 kOhm ± 10 %. C B When a failure was found during one of above checks, replace rack position feedback sensor B14. 10.05 A ill.4 06.10.05.01 B Check rack position feedback sensor B14 (= connector X14) In case of defective rack position feedback sensor B14, service codes 35 and 36 or 186 will flash. NOTE: First always check cables and connections. 10.05 B ill.1 Final check: C Disassemble rack position feedback sensor from control solenoid. A 1 Supply terminals A ("-"; minus) and C ("+"; plus) with 5,0V DC +/- 1%. - 5V DC + 10.05 B ill.2 2 Sensor extended! Measure between terminal A (minus) and B (signal out). Measured voltage must be 4,8V DC +/- 5%. B A 10.05 B ill.3 Page ELECTRICAL SYSTEM - 86 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 3 ELECTRICAL SYSTEM Sensor retracted! Measure between terminal A (minus) and B (signal out). Measured votage must be 0,12V DC +/- 5%. A B When a failure was found during one of above checks, replace rack position feedback sensor B14. 10.05 B ill.4 06.10.05.02 Check throttle potentiometer B13 (accelerator) (= connector X13) In case of defective potentiometer accelerator B13, service codes 23, 24 or 29 will flash. NOTE: First check cables and connections. 10.05 ill.5 * Resistance between terminals 5 and 4; 1,2 kOhm * Resistance between terminals 5 and 2; 2,2 kOhm for normal position of potentiometer accelerator ; 1,4 kOhm at "full speed " max. impact. * Resistance between terminals 3 and 1; 1,2 kOhm With approx. 10% of max. first route, resistance value must increase infinetely high ==> (disconnection). 1 2 3 4 5 10.05 ill.6 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 87 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 100 microbar (absolute) 06.10.05.03 Check boost pressure sensor, B12, for engine models: 94 / 114 / 144 / 126 / 166 / 236 Athmospheric pressure PSI 10.05 ill.7 For engine models: 164 / 174 / 246 / 256 / 266 5,0 4,5 Supply voltage 5V +/- 0,2V Output - voltage (Volt) 4,0 3,5 Connector position A = +5V B = GND C = Signal 3,0 2,5 2,0 1,5 Max. pressure with 3 bar (3,5 absolut) 1,0 0,5 0,0 0,0 0,5 10.05 ill.8 NOTE: 1,0 1,5 2,0 2,5 3,0 3,5 4,0 Absolut - air pressure (bar) Before checking the boost pressure sensor, check air filter, sensor hose and connector. Pressure test: For a pressure test of the sensor, disconnect the sensor hose and connect a pressure gauge with a short piece of hose to the sensor. Carefully pressurize the sensor. Read and record the values on the gauge (input pressure) and on the display (output pressure) for 5 spots between 0 and 1.5 bar. Compare recorded input and output values with the chart. - If values are not within tolerance limits, replace the boost pressure sensor. - If values are within tolerance limits, the boost pressure sensor is functional and the turbocharger must be checked. Page ELECTRICAL SYSTEM - 88 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.04 Check speed sensor B15 and/or wiring X15 X 15/1 X15/2 X15/3 1 2 3 15012-06 60113-01 31000-03 10.05 ill.9 On account of the sensor's integrated electronic system, only the supply voltage and/or the output signal and the continuity to control unit A5 can be measured. Make sure that with disconnected plug X15 and ignition "ON" an error code can be stored --> At completion of checking, cancel the error code; refer to 06.06.04 Use a standard voltmeter / multimeter to measure the supply voltage and/or the resistance. Supply voltage Ubat (12V +/- 2V) ignition ON main relay K27 active measurement point GND on X15/3 against +supply voltage on X15/1 Continuity from X15/2 to control unit X5/33 max. resistance 2 ohms If supply voltage and transition from X15/2 to X5/33 are connect, replace the speed sensor. In case an error was detected during preceding measurements, check wiring according to circuit diagram and wiring harness diagram. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 89 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.05 Check oil pressure sensor B18 and/or wiring X18 X18/A X18/B X18/C 31100-10 15100-07 60117-01 10.05 ill.10 On account of the sensor's integrated electronic system,only the supply voltage and/or the output signal can be measured. Make sure that with disconnected plug X15 and ignition "ON" the error code 32 HiLPS is stored --> At completion of check, cancel the error code; refer to 06.06.04 Use a standard voltmeter / multimeter to mesure the supply voltage and/or the resistance. Supply voltage + 5V +/- 0,4V ignition ON main relay K27 active measuring point GND on X18/A against + 5V on X18/B Continuity from X18/C to control unit X5/10 max. resistance 2 ohms Output signal depending on pressure; see diagram Remove B18 and admit pressure when X18 is connected; max. 5 bars measuring point X18/C --> X18/B voltage via pressure voltage (V) voltage pressure (bar) 10.05 ill.11 Page ELECTRICAL SYSTEM - 90 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.06 Check oil pressure sensor "VDO-instrument" (option B19) NOTE: If oil pressure is questionable, - check oil level before starting the engine. - check minimum oil pressure. Minimum oil pressure Idle 1 bar 1000 2 bar 2500 and above 4 bar Check minimum oil pressure: Start engine and let engine run at idle speed, 1000 and 2500 r.p.m. Check tachometer and and oil pressure gauge. Record oil pressure value for idle speed, 1000 and 2500 r.p.m. If values are not appropriate, check the oil pressure gauge before checking the oil pressure sensor. To check the oil pressure gauge, disconnect cable from sensor, turn on ignition key and shortly put the sensor cable to ground connection. If gauge functions properly, the pointer will shortly deflect to high values. If there is no malfunction of the gauge, replace the oil pressure sensor. Check of oil pressure sensor: To check the oil pressure sensor, disconnect the sensor cable and connect an ohmmeter to sensor terminal and sensor. 2. Check resistance at zero pressure; resistance should be 240 Ohm ± 10 %. - If resistance is out of tolerance limits, replace the oil pressure sensor. - If resistance is within the tolerance range but function of oil pressure sensor is still questionable, measure the resistance over the entire field. PRESSURE 1. RESISTANCE (OHM) 10.05 ill.12 Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 91 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Check oil pressure sensor over entire pressure range: 1. Disassemble sensor and connect it to a gauged pressure source. 2. Connect ohmmeter and pressurize sensor. Read and record pressure and resistance at different spots over the entire pressure range. 3. Compare pressure and resistance values with chart. If values are not within tolerance range at one spot, replace sensor. 06.10.05.07 Check coolant temperature sensor, B16 To check the coolant temperature sensor, make the following test with connected ohmmeter. In case of failure, replace the sender. 1. Compare resistance value and ambient temperature to curve of diagram. Range of tolerance is ± 10 %. kOhm 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 TEMP °C 10.05 ill.13 Page ELECTRICAL SYSTEM - 92 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 2. ELECTRICAL SYSTEM If this check brings no information, drain the coolant and remove the sensor. Immerse sensor together with thermometer into a canister with coolant. Connect a digital ohmmeter to the sensor and heat the fluid on a heater. Monitor ohmmeter und thermometer. The ohmmeter should show values corresponding to the values of the resistance curve with a tolerance range of ± 10%. 06.10.05.08 Check audible warner 0,7 sec. with ignition "ON" ==> function check and message "no error stored" Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 93 ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.12. BATTERY 06.12.01 Battery Battery - Acid Test The battery provides the starter engine with energy and supplies the required voltage for lighting and other electrical equipment when the engine is not running. During the starting procedure and when the generator does not generate any current, the battery provides the electronic engine management system with voltage. For 4 cyl. engines only Use a 12 V battery with a cold test circuit of 450 ampere at -18°C and a capacity of 92 Ah at 27°C, to guarantee the supply of the electric and electronic components for all operating conditions. For 24 V - installation only Use two 12V batteries with a cold test circuit of 650 ampere each at -18°C and a capacity of 115 Ah at 27°C, to guarantee the supply of the electric and electronic components for all operating conditions. The batteries are connected in series and provide a capacity of 115 Ah / 24 V for the external supply of all electric components on the boat. 12V supply of all electric and electronic components on the engine (including instrument panel) by center tapping. Additional charge is guaranteed by charging equalization. For 6 cyl. engines only Use a 12 V battery with a cold test circuit of 650 ampere at -18°C and a capacity of 115 Ah at 27°C, to guarantee the supply of the electric and electronic components. Explanation: Cold current test: Capacity: The cold current test is a specified load test of a battery.The charge of battery with specified current (e.g. 450A). After discharge for 30 sec., the voltage should not drop bellow ³9V. With a current consumption of 1/20 of specified capacity (e.g. 92Ah) the battery voltage must not fall below 10 V after 20 hours, to guarantee the engine's starting ability. Maintenance To guarantee long battery life, the following tests should be carried out periodically. 1 The level of battery acid must always be above plates and separators. The acid level should reach the marking on the battery. Acid may only be refilled by an expert when it was definitely stated that some of it has been spilled. ATTENTION: Battery fluid is an aggressive acid and must be handled with care. In case of skin contact rinse thoroughly with water and consult a doctor - physician. Page ELECTRICAL SYSTEM - 94 Downloaded from www.Manualslib.com manuals search engine Z001019/0_6_July 2008 ToC SERVICE MANUAL MARINE ENGINES 2 ELECTRICAL SYSTEM The battery should always be charged as full as possible. Regularly check the state of charge with the battery acid tester. We recommend to check the acid density and acid level periodically every two weeks. If the density is 0.04 kg/dm³ below the value of full charge, the battery is to be removed and recharged. DENSITY WITH FULL CHARGE: 1.260 kg/dm3 (at 27°C). ATTENTION: Never charge the battery on the boat. The vapors resulting from charging could cause an explosion! 12.01 ill.1 For a periodical check of the battery, the following items are to be considered: 1 Protect the boat against acid leakage. 2 Clean battery. 3 Check connections and cables. 4 Clean battery contacts. (neg./pos.) 5 Check holding device of battery. 6 Check housing for damages (acid leakage). 7 Check acid density. 8 Disassemble battery for test. In case of less than 3/4 charge, charge it by means of battery charger, carry out charge test. 9 Check acid level. In case of a bad state of charge or excessive loss of water, check charge circuit. Clean battery, contacts and terminals with a solution of soda and water. This neutralizes the battery acid. After cleaning with the solution, rinse the surface with water by taking care that the solution does not penetrate into the battery ATTENTION: When connecting the battery cables, take special care of correct polarity. Incorrect polarity destroys electronic components. Z001019/0_6_July 2008 Downloaded from www.Manualslib.com manuals search engine Page ELECTRICAL SYSTEM - 95
0
Anuncio
![MTU SERIES 60 MARINE[1]](http://s2.studylib.es/store/data/009437511_1-a3e64a9d50ce320d33d006c4e06868c4-300x300.png)
Descargar
Anuncio
Añadir este documento a la recogida (s)
Puede agregar este documento a su colección de estudio (s)
Iniciar sesión Disponible sólo para usuarios autorizadosAñadir a este documento guardado
Puede agregar este documento a su lista guardada
Iniciar sesión Disponible sólo para usuarios autorizados