STEYR MOTORS Marine Engine 2012 Series User manual

General
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STEYR TURBO DIESEL ENGINES
Steyr Marine Engine Family 2012
SERVICE MANUAL
Z001138-0 1st Edition February 2013
STEYRMOTORSGmbH
www.steyr-motors.com ImStadtgutB1,
A-4407 Steyr-Gleink,
AUSTRIA

General Preliminary Service Manual MARINE 2012
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General
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PREFACE
STEYR MOTORS GmbH has developed high-performance diesel engines with modulated
high-pressure direct injection, especially for special vehicles. STEYR 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 diesel engine
business, which will enable you in case of possible failure to operate, service and repair
the engines
Steyr Marine Engine Family 2012
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 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 vom Ausland
from home from foreign
countries: countries:
STEYR MOTORS GmbH
07252/222/52 +43/07252/222/52
After Sales Service
Im Stadtgut B1 07252/222/29 +43/07252/222/29
4400 STEYR
AUSTRIA [email protected]
http://www.steyr-motors.com
1
st Edition
Feb. 2012
P/N Z001138-0

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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 components 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.
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 of such change.
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.
Every STEYR dealer is obliged to fill out the owner identification card enclosed to
every sold STEYR engine or every sold vehicle with a built-in STEYR engine.
Part 1 (Owner Identification 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 owner identification card serves as a proof of ownership and is to be submitted
in case of warranty claims.

General
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TABLE OF CONTENTS
(MAIN ASSEMBLY GROUP ENGINE)
GENERAL
01 ENGINE
02 COUPLING
03 FUEL SYSTEM
04 EXHAUST SYSTEM
05 COOLING SYSTEM
06 ELECTRICAL EQUIPMENT
14 HYDRAULIC PUMP
22 ENGINE PREHEATING

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Components
01
Engine
01.00
Mount Bracket,
Lifting Eye,
Gasket Set
01.01
Crankcase 01.02 Crankshaft, Bearing,
Damper
01.03
Flywheel 01.04 Piston,
Rings and Pin,
Connection Rod
01.05
Camshaft, Housing
01.06
Oil pump, Oil pipe,
Oilcan
01.08 (Page 1 & 2)
Intake Manifold
Exhaust Manifold
01.13
Oil cooler, Filter
02
Coupling
02.00
Fly Wheel housing 02.01 Ring Gear Carrier
and Flex Plate
03
Fuel System
03.02
Unit Injector,
Fuel Pump
03.05
Turbocharger 03.08 Contr. Solenoid,
Inj. Timing Device
03.09
Fuel Filter 03.11 Glow Plug

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04
Exhaust System
04.00
Connection to Turbo
Charger
05
Cooling System
05.03
Water pipe,
Thermostat
05.04
Water pump
05.05
Fan Assy.
05.06 (Page 1 & 2)
Drive Belt, Pulleys,
Tensioner-Belt 1 & 2
06
Electrical System
06.01
Alternator, Bracket
06.03
Starter 06.05 Engine Harness
06.06
Harness, ECU
14
Hydraulic pump
14.08
Hydraulic pump
52
Air Conditioning
52.00
A-C Compressor

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VERSIONS OF MANUAL
Version Date Modification
1.0 01.02.2013 New edition

General
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GENERAL
Table of Contents
AGENERAL REMARKS..................................................................................11
A 1 Model and Serial Number .......................................................................................11
A 2 Documentation........................................................................................................12
A 3 Technical Data and Overview .................................................................................13
A 3.2 Overview engine M16 TCA .....................................................................................22
BSpecification ................................................................................................23
B 1 Fuel Requirements..................................................................................................23
B 2 Motor oil ..................................................................................................................25
CMaintenance and Service............................................................................26
C 1 Trouble Check Chart...............................................................................................26
C1 Trouble Check Chart continued...............................................................................27
C2 Service- and Maintenance Schedule......................................................................30
DGeneral Information ....................................................................................33
D 1 Electronic Engine Management System .................................................................33
D 2 Diagnostic system...................................................................................................37
D 3 Operation after Break – In.......................................................................................42
D 4 Extended Storage Preservation Procedure.............................................................42
EQuality guidelines for repair.......................................................................44
E 1 Spare part specification...........................................................................................44
E 2 Workshop Profile.....................................................................................................44
E 3 Nomenclature..........................................................................................................45
E 4 SI – System.............................................................................................................47
E 5 Abbreviations ..........................................................................................................48
FOperating material and information on disposal......................................49
F 1 List of operating material.........................................................................................49
F 2 Disposal of automotive waste products...................................................................50
GNotes on safety............................................................................................51
G 1 General notes on safety ..........................................................................................52
G 2 Guidelines for damage prevention ..........................................................................52
G 3 Legal rules ..............................................................................................................52
G 4 Safety in the use of operating material....................................................................53
G 5 Measures in case of accidents................................................................................53
HTightening Torques.....................................................................................54
H 1 Listing of Tightening Torques..................................................................................54
H 2 General Tightening Torques ...................................................................................60

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H 3 Testing of torque wrenches.....................................................................................61
H 4 Non-destructive material testing..............................................................................61
H 5 Use of adhesive and sealing materials....................................................................61
H 6 Solvent-free sealing materials.................................................................................61
IWear Limits ..................................................................................................64
I 1 Adjustment information for service and maintenance..............................................65
I.1.1 Engine timing (measured with dial indicator No. 2300899/0) ..................................65
I.1.2 Tension timing belt (measured with tool VR00515/0)..............................................65
I.1.3 Start of fuel delivery on the unit injectors
(measured with dial indicator No. 2300899/0).........................................................65
I.1.4 Valve clearance (measured with tool No. 2300712/3))............................................65

General
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A GENERAL REMARKS
A 1 Model and Serial Number
The primary model and serial number is located on the engine as illustrated.
These numbers are required for warranty claims and ordering parts.

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A 2 Documentation
The following documentation is available in English language on our website:
Installation manual 2012 P/N Z001139-0
operation-, maintenance & warranty manual
for MARINE 2012
P/N Z001140-0
service manual for MARINE 2012 P/N Z001138-0
spare parts catalogue SE126E25 P/N Z011841-0
spare parts catalogue SE156E26 P/N Z011842-0
spare parts catalogue SE196E35 P/N Z011843-0
spare parts catalogue SE236E40 P/N Z011844-0
spare parts catalogue SE236S36 P/N Z011845-0
spare parts catalogue SE266E40 P/N Z011846-0
spare parts catalogue SE266S36 P/N Z011847-0
spare parts catalogue SE286E40 P/N Z011848-0
spare parts catalogue SE306J38 P/N Z011849-0
Optional equipment (IFG, SCC) P/N xxxxxxxxxx
tool catalogue for STEYR MOTORS ENGINES P/N Z001125-0
general technical documentation CD – ROM P/N Z 001009/0

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A 3 Technical Data and Overview
engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
Number of
Cylinders 6 6 6 6 6 6 6 6 6
bore (mm) 85 85 85 85 85 85 85 85 85
stroke (mm) 94 94 94 94 94 94 94 94 94
displacement
(cm³) 3200 3200 3200 3200 3200 3200 3200 3200 3200
rated power
(kW) 88 110 140 170 170 190 190 205 215
rated speed
(rpm) 2500 2600 3500 4000 3600 4000 3600 4000 3800
full power
speed range
(rpm) 2175 - 2550 2350 – 2650 3050 - 3550 3550 - 4100 3350 - 3650 3550 - 4050 3350 - 3650 3500 - 4100 3600 - 3850
max. torque
(Nm) 390 450 445 470 540 530 600 570 588
max. torque
(lb-ft) 288 360 328 347 398 391 443 420 434
Speed at
Maximum
Torque (rpm) 1800 1800 2050 2550 1800 2300 1800 2550 3300
Maximum
test speed
(rpm) 2500 2600 3500 4000 3600 4000 3600 4000 3800
Torque at
maximum
test speed
(Nm)
336 404 382 406 451 454 504 489 540
Lower
tolerance of
maximum
power (%)
5 5 5 5 5 5 5 5 5

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
Upper
tolerance of
maximum
power (%)
5 5 5 5 5 5 5 5 5
Fuel rate at
rated speed
(mm³/stroke) 54,5 65,9 65,2 71,3 75,9 81,1 86,4 86,3 93,4
Fuel rate at
Maximum
Torque
(mm³/stroke)
58 66,8 65 72 78,9 80,5 89,8 85,9 96,3
mean
effective
Pressure
(bar)
13,2 15,9 15,0 15,9 17,7 17,8 19,8 19,2 21,2
specific
power
(lbs/HP) 6,26 5,01 3,94 3,24 3,24 2,90 2,90 2,69 2,56
dry weight
(kg) 340 340 340 340 340 340 340 340 340
specific
power
(kg/PS) 2,84 2,27 1,79 1,47 1,47 1,32 1,32 1,22 1,16
idle speed
(rpm) 630 630 630 630 630 630 630 630 630
aspiration TCA TCA TCA TCA TCA TCA TCA TCA TCA
turbo
system WG WG WG geom VTG WG VTG WG WG
Fuel Cons. at
idle speed
(kg/h) 0,52 0,52 0,52 0,52 0,52 0,52 0,52 0,52 0,52
air mass flow
@ rated
power (kg/h) 490 520 710 965 808 980 860 1040 1020

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
Fuel cons. @
rated power
(kg/h) 20,1 25,4 33,7 42,5 40,9 47,3 46,1 51 52,2
exhaust
mass flow @
rated power
(kg/h)
510,1 545,4 743,7 1007,5 848,9 1027,3 906,1 1091 1072,2
max. inlet
depression
at rated
Power (mbar)
30/50 30/50 30/50 30/50 30/50 30/50 30/50 30/50 30/50
spec. fuel
consumption
at rated
power
(g/kWh)
228 230 240 249 240 249 243 248 243
min spec.
fuel
consumption
(g/kWh)
205 205 205 210 202 205 205 210 210
compressor
outlet
temperature
at rated
power (°C)
130 140 145 200 160 165 175 180 180
boost
pressure
adjustment
value 1mm
deflection
(mbar)
1680 1680 1880
geometrical
turbocharger
electronic
controlled 1920 electronic controlled 2040 2040
boost
pressure
adjustment
value 3mm
deflection
(mbar)
1880 1880 2020
geometrical
turbocharger
electronic
controlled 2100 electronic
controlled 2240 2240

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
MAP at rated
power (mbar) 2130 2200 2280 2790 2560 2840 2740 2990 3060
Map Toleranz
(+/-) [mbar] 75 75 75 100 50 75 50 75 75
MAP (mbar) 2180 2240 2440 2900 2690 2840 2800 3000 3060
speed @
max. MAP
(1/min) 2200 2350 2800 3550 3050 4000 3300 3800 3800
compression
ratio ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0 ε= 17,0
max. exhaust
backpressur
e (mbar) 150 150 150 150 150 150 150 150 150
backpressur
e tolerance
(mbar) +0/- 50 +0/- 50 +0/- 50 +0/- 50 +0/- 50 +0/- 50 +0/- 50 +0/- 50 +0/- 50
max. engine
cooling water
outlet temp.
(°C)
81 83 83 85 86 86 86 86 87
exhaust gas
temperature
(°C) 375 445 480 415 506 510 535 510 525
oil sump
temperature
(°C) 88 88 95 96 96 97 98 98 98
governed
speed (rpm) 2550 2650 3550 4100 3650 4100 3650 4150 3850
min. engine
compart-
ment
pressure
(mbar)
10 10 10 10 10 10 10 10 10

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
min. fuel
supply
pressure
block inlet
[mbar] - rel.
3500 3500 3500 3500 3500 3500 3500 3500 3500
max. engine
coolant
outlet
temperature
[°C]
105 105 105 105 105 105 105 105 105
raw water
flow (l/min) 105 105 135 150 150 150 150 150 140
raw water
supply
pressure
(bar)
0,37 0,37 0,67 0,8 0,8 0,8 0,8 0,8 0,75
Tension
timing belt
[N] 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30 600 +/- 30
unit injector
opening
pressure
(kPa)
26000 /
36000 kPa
26001 /
36000 kPa
26002 / 36000
kPa
26003 / 36000
kPa
26004 / 36000
kPa
26005 / 36000
kPa
26006 / 36000
kPa
26007 / 36000
kPa
26008 / 36000
kPa
UI
adjustment
(mm) 9,20 9,10 8,85 8,85 8,74 8,65 8,74 8,70 8,65
UI
adjustment
tolerance ±0,02 ±0,02 ±0,02 ±0,02 ±0,02 ±0,02 ±0,02 ±0,02 ±0,02
UI
adjustment
check value
after engine
braking-in
9,25 9,15 8,90 8,90 8,79 8,70 8,79 8,75 8,70
UI base
adjustment
value (mm) 9,30 9,20 8,95 8,95 8,84 8,75 8,84 8,80 8,75

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
valve timing
adjustment +
tolerance
(mm)
3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02
valve
clearancy
(mm) 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25
RCD EU
94/25/EC (2003/44/EC)
without integral
exhaust
X X X X X X X X X
Bode
nsee
BSO II
Bodensee
BSO II
Doppelinst
.
Commercial
EU
97/68/EG
(2004/26/EG)
X X X X X X X X X
EPA
Tier
III US
IMO Nox
Cert. Nr.
MED-B-5675 X X X X X X X X X
Performance
Rating PR, INT,
MCD
PR, INT,
MCD PR, INT, MCD PR, INT, MCD PR, HO PR, INT PR, HO PR, INT PR, INT
Prope
ller
Shaft
X X X X X X X X

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
Jet-
Powe
rtrain
X X X X X X
Z-
Powe
rtrain
X X X X X
RCD 85,36 106,7 135,8 164,9 164,9 184,3 184,3 198,85 208,55
RCD 86,68 108,35 137,9 167,45 167,45 187,15 187,15 201,925 211,775
Unit Injector 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0
Engine Block 2180996-0 2180996-0 2180996-0 2180996-0 2180996-0 2180996-0 2180996-0 2180996-0 2180996-0
Camshaft 2177843-0
or 2177843-
B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
2177843-0 or
2177843-B
charge air
Cooler 2180876-0 2180876-0 2180876-0 2180876-0 2180876-0 2180876-0 2180876-0 2180876-0 2180876-0
Piston
2181120-0
König
2181146-0
König
2181120-0 König
2181146-0 König
2181120-0 König
2181146-0 König
2181025-0 Tarabusi
2181146-0 König
2181120-0 König
2181146-0 König
2181025-0 Tarabusi
2181146-0 König
2181025-0 Tarabusi
2181146-0 König
2181025-0 Tarabusi
2181146-0 König
2181025-0 Tarabusi
2181146-0 König
piston bowl 2179531-3 2179531-3 2179531-3 2179531-3 2179531-3 2179531-3 2179531-3 2179531-3 2179531-3
Fuel delivery
pump 2173396-6 2173396-6 2173396-6 2173396-6 2173396-6 2173396-6 2173396-6 2173396-6 2173396-6
fuel delivery
pump name 12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
12V, TI
Automotive
fuel filter 2180831-0 2180831-0 2180831-0 2180831-0 2180831-0 2180831-0 2180831-0 2180831-0 2180831-0
Water Pump,
ratio 2180867-1 2180867-1 2180867-1 2180867-1 2180867-1 2180867-1 2180867-1 2180867-1 2180867-1
Heat-
exchanger WT-Einsatz
2180883-0
WT-Einsatz
2180883-1
WT-Einsatz
2180883-2
WT-Einsatz
2180883-3
WT-Einsatz
2180883-0
WT-Einsatz
2180883-3
WT-Einsatz
2180883-0
WT-Einsatz
2180883-3
WT-Einsatz
2180883-3
Oil cooler 2180824-0 2180824-0 2180824-0 2180824-0 2180824-0 2180824-0 2180824-0 2180824-0 2180824-0
lubricant
reservoir 2180643-0 2180643-0 2180643-0 2180643-0 2180643-0 2180643-0 2180643-0 2180643-0 2180643-0
charge air
cooler
module
2180768-0
Heat
exchanger
2180768-0
Heat
exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger
2180768-0
Heat exchanger

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engine
type SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38
air filter /
mark / type 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0
electric
system
voltage (V) 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V
alternator 2180569-0 2180569-0 2180569-0 2180569-0 2180569-0 2180569-0 2180569-0 2180569-0 2180569-0
starter 2040077-1 2040077-1 2040077-1 2040077-1 2040077-1 2040077-1 2040077-1 2040077-1 2040077-1
Max. Amp-
consumption
@20°C 240 240 240 240 240 240 240 240 240
Min. Starting
RPM
flywheel
/description 2180676-0 2180676-0 2180676-0 2180676-0 2180676-0 2180676-0 2180676-0 2180676-0 2180676-0
flywheel
torque of
inertia (kgm²) 0,1446 0,1446 0,1446 0,1446 0,1446 0,1446 0,1446 0,1446 0,1446
clutch 2179164-0 2179164-0 2179164-0 2179164-0 2179164-0 2179164-0 2179164-0 2179164-0 2179164-0
clutch torque
of inertia
(kgm²) 0,032 0,032 0,032 0,032 0,032 0,032 0,032 0,032 0,032