Steyer Motors 4 Cylinders Installation Instructions Manual
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Steyer Motors 4 Cylinders Installation Instructions Manual

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INSTALLATION
INSTRUCTION
P/N Z001007/0
www.steyr-motors.com
STEYR MARINE ENGINES
4 CYLINDERS
4 CYLINDERS
+ 6 CYLINDERS
+ 6 CYLINDERS
4
Edition
September 2007
th
STEYR MOTORS GmbH
Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA

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  • Page 1 STEYR MARINE ENGINES 4 CYLINDERS 4 CYLINDERS + 6 CYLINDERS + 6 CYLINDERS INSTALLATION INSTRUCTION P/N Z001007/0 Edition September 2007 www.steyr-motors.com STEYR MOTORS GmbH Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA...
  • Page 2 There are two main purposes in publishing this book: 4 & 6 Cyl. STEYR MARINE Product description, illustration and technical data Warranty: The illustrations in this manuel do not always come up to the actual equipments or components, and serve first of all as a reference. STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, as to technical data or models, and also to discontinue certain models.

  • Page 3: Table Of Contents

    1. GENERAL 2. GENERAL INFORMATION ON INSTALLATION 3. QUALITY DIRECTIVES FOR ASSEMBLY 4. VARIANTS ENGINE - PROPULSION 5. ENGINE INSTALLATION 6. COOLING SYSTEM 7. FUEL SYSTEM 8. EXHAUST SYSTEM 9. AIR INTAKE AND VENTILATION 10. AUXILIARY PROPULSION 11. SAFETY COVERS 12.
  • Page 4 VERSIONS OF MANUAL Version Date Modification 01. 11. 1998 First edition 01. 03. 1999 Modification 01. 04. 2006 Modification 01. 09. 2007 Modification Z001007/0_4_September 2007...
  • Page 5 INSTALLATION INSTRUCTION 1. GENERAL 1.1. REGULATIONS 1.2. RESPONSIBILITIES OF BOAT OWNERS STEYR MOTORS Z001007/0_4_September 2007 Page GENERAL-1...
  • Page 6 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page GENERAL-2 Z001007/0_4_September 2007...
  • Page 7 INSTALLATION INSTRUCTION 2. GENERAL INFORMATION ON INSTALLATION TABLE OF CONTENTS 2.1. WEIGHT-DISTRIBUTION BALANCE ..........3 2.2. ACCESSIBILITY .................3 2.3. DISPLACEMENT OF WATER ............4 2.3.1. Examples for Block Coefficient ..........4 2.4. SAFETY IN DEALING WITH FUEL AND OIL ........5 2.5.
  • Page 8 INSTALLATION INSTRUCTION 2. GENERAL INFORMATION ON INSTALLATION NOTES Page GENERAL INFORMATION-2 Z001007/0_4_September 2007...

  • Page 9: Weight-Distribution Balance

    INSTALLATION INSTRUCTION 2. GENERAL INFORMATION ON INSTALLATION 2. 1. WEIGHT-DISTRIBUTION BALANCE ATTENTION! ON ACCOUNT OF THE RISK OF EXPLOSION AND FIRE THE FUEL TANKS, BATTERIES AND ENGINES ARE TO BE PLACED IN WELL VENTILATED COMPARTMENTS SEPARATED FROM EACH OTHER. MORE DETAILS WILL FOLLOW. 2.

  • Page 10: Displacement Of Water

    INSTALLATION INSTRUCTION 2.3. DISPLACEMENT OF WATER 2.3.1. Examples for the Block Coefficient Page GENERAL INFORMATION-4 Z001007/0_4_September 2007...

  • Page 11: Safety In Dealing With Fuel And Oil

    INSTALLATION INSTRUCTION 2. 4. SAFETY IN DEALING WITH FUEL AND OIL Dangerous materials, fire In case of spilling Attention: - Avoid direct contact with dangerous materials. - Change clothing contaminated with dangerous materials as soon as possible. - Do not keep oily cloths in your overalls. - Clean oily parts of your body only with skin-care products (never use abrading sand or solvent).

  • Page 12: List Of Fuel And Oil

    INSTALLATION INSTRUCTION 2.5. LIST OF FUEL AND OIL Page GENERAL INFORMATION-6 Z001007/0_4_September 2007...

  • Page 13: Manuals

    INSTALLATION INSTRUCTION 2.5.1. Manuals http://www.steyr-motors.com/technical Z001007/0_4_September 2007 Page GENERAL INFORMATION-7...

  • Page 14: Si-System

    INSTALLATION INSTRUCTION 2.6. SI-SYSTEM units of length units of pressure and tension units of area units of energy units of volume units of energy units of measure units of temperature units of force units of time electric units speeds fuel consumption speeds Page GENERAL INFORMATION-8 Z001007/0_4_September 2007...

  • Page 15: Abbreviations

    INSTALLATION INSTRUCTION 2.7. ABBREVIATIONS Z001007/0_4_September 2007 Page GENERAL INFORMATION-9...

  • Page 16: General Information On Safety

    INSTALLATION INSTRUCTION 2.8. GENERAL INFORMATION ON SAFETY 2.9. GUIDELINES FOR DAMAGE PREVENTION 2.10. LEGAL RULES 2.11. DISPOSAL OF AUTOMOTIVE WASTE PRODUCTS THE DISPOSAL OF ANY FUEL AND OIL FOR THE ENGINE IS SUBJECT TO THE SPECIAL WASTE ACT. THE "SPECIAL WASTE CATALOGUE" ÖNORM S2100 REFERS TO THE NECESSARY DISPOSAL IN AUSTRIA.

  • Page 17: Safety In Dealing With Fuel And Oil

    INSTALLATION INSTRUCTION 2.12. SAFETY IN DEALING WITH FUEL AND OIL ATTENTION: 2.13. MEASURES IN CASE OF ACCIDENTS Z001007/0_4_September 2007 Page GENERAL INFORMATION-11...
  • Page 18 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page GENERAL INFORMATION-12 Z001007/0_4_September 2007...
  • Page 19 INSTALLATION INSTRUCTION 3. QUALITY DIRECTIVES FOR ASSEMBLY TABLE OF CONTENTS 3.1. SPECIFICATION OF SPARE PARTS ..........3 3.2. WORKSHOP PROFILE ................ 3 3.3. ASSEMBLY OF PLUG CONNECTIONS ..........4 3.3.1. Plug connection for steel tube ..........4 3.3.2. Plug connection for plastic tube ..........4 3.3.4.
  • Page 20 INSTALLATION INSTRUCTION 3. QUALITY DIRECTIVES FOR ASSEMBLY NOTES Page QUALITY DIRECTIVES-2 Z001007/0_4_September 2007...

  • Page 21: Specification Of Spare Parts

    INSTALLATION INSTRUCTION 3. QUALITY DIRECTIVES FOR ASSEMBLY 3.1. SPECIFICATION OF SPARE PARTS STEYR GENUINE - STEYR - spare parts GENUINE - STEYR spare parts 3.2. WORKSHOP PROFILE Z001007/0_4_September 2007 Page QUALITY DIRECTIVES-3...

  • Page 22: Assembly Of Plug Connections

    INSTALLATION INSTRUCTION 3.3. ASSEMBLY OF PLUG CONNECTIONS 3.3.1. Plug connections for steel tube 3.3.2. Plug connection for plastic tube Page QUALITY DIRECTIVES-4 Z001007/0_4_September 2007...

  • Page 23: Checking Of Plug Connections

    INSTALLATION INSTRUCTION 3.3.4. Checking of Plug Connections 3.3.5. Assembly of Raufoss Plug Systems ATTENTION: FOR SAFETY REASONS, SOCKETS MUST NOT BE DISMANTLED. 3.3.6. Sealing of Screwed Pipe Joints ATTENTION: GREASE AND SEALING AGENTS MUST NOT ENTER INTO PIPING Z001007/0_4_September 2007 Page QUALITY DIRECTIVES-5...

  • Page 24: Tightening Torque

    INSTALLATION INSTRUCTION 3.3.7. Tightening Torques Tube Torque 10 - 12 Nm 65 - 80 Nm Tube Torque 16 - 20 Nm 25 - 30 Nm ATTENTION: ABSOLUTELY USE SLIP-ON SLEEVES! Tube Torque 30 - 50 Nm Thread Torque M 10x1 20 Nm M 12x1,5 26 Nm...

  • Page 25: Pipe Relaying

    INSTALLATION INSTRUCTION 3.3.8. Pipe Relaying Z001007/0_4_September 2007 Page QUALITY DIRECTIVES-7...

  • Page 26: Tightening Torques

    INSTALLATION INSTRUCTION 3.4. TIGHTENING TORQUES µ total *) 0,100 µ total 0,125 µ total 0,140 MA in Nm MA in NM MA in NM grade of grade of grade of strength strength strength 10,9 12,9 10,9 12,9 10,9 metric metric metric nominal Ø...

  • Page 27: Checking Of Torque Wrench

    INSTALLATION INSTRUCTION 3.5. CHECKING OF TORQUE WRENCH 3.6. NONDESTRUCTIVE TESTING OF MATERIALS 3.7. USE OF ADHESIVE AND SEALING MATERIALS Solvent free sealing material Sealing material containing solvent 3.8. SOLVENT FREE SEALING MATERIALS Silicon sealing materials Anaerobic sealing materials Z001007/0_4_September 2007 Page QUALITY DIRECTIVES-9...

  • Page 28: General Directions For Use

    INSTALLATION INSTRUCTION 3.8.1. General Directions for Use of Aanaerobic Sealing Materials Cleanliness of components Storage Directions for securing (S) Application: Fixing procedure Directions for fixing (B) Application: Jointing procedure Directions for sealing (D) Application: Hardening time Fixing Securing Sealing Class Product Loctite 243 Loctite 262...
  • Page 29 INSTALLATION INSTRUCTION 4. VARIANTS ENGINE - PROPULSION TABLE OF CONTENTS 4.1. VERSIONS FOR 6 CYL. MARINE ENGINES ........3 4.2. VERSIONS FOR 4 CYL. MARINE ENGINES ........6 Z001007/0_4_September 2007 Page VARIANTS ENGINE-PROPULSION-1...
  • Page 30 INSTALLATION INSTRUCTION 4. VARIANTS ENGINE - PROPULSION NOTES Page VARIANTS ENGINE-PROPULSION-2 Z001007/0_4_September 2007...
  • Page 31 INSTALLATION INSTRUCTION 4. VARIANTS ENGINE - PROPULSION 4.1. VERSIONS FOR 4 CYL. MARINE ENGINES Bobtail - Version Inborder i.e. ZF 45 Marinegear Down angle Innenborder i.e. ZF 63 Marinegear Z001007/0_4_September 2007 Page VARIANTS ENGINE-PROPULSION-3...
  • Page 32 INSTALLATION INSTRUCTION Lifeboat Engine Page VARIANTS ENGINE-PROPULSION-4 Z001007/0_4_September 2007...
  • Page 33 INSTALLATION INSTRUCTION Jet Drive Stern Drive Z001007/0_4_September 2007 Page VARIANTS ENGINE-PROPULSION-5...
  • Page 34 INSTALLATION INSTRUCTION 4.2. VERSIONS FOR 6 CYL. MARINE ENGINES Bobtail - Version Equipment Inborder i.e. ZF 63 Marine gear Down angle Page VARIANTS ENGINE-PROPULSION-6 Z001007/0_4_September 2007...
  • Page 35 INSTALLATION INSTRUCTION Transmission Lifeboat Engine Equipment Z001007/0_4_September 2007 Page VARIANTS ENGINE-PROPULSION-7...
  • Page 36 INSTALLATION INSTRUCTION Jet Drive Stern drive Type Page VARIANTS ENGINE-PROPULSION-8 Z001007/0_4_September 2007...
  • Page 37 INSTALLATION INSTRUCTION 5. ENGINE INSTALLATION TABLE OF CONTENTS 5.1. FOUNDATION ..................3 5.2. POWER TRANSMISSION ..............3 5.2.1. Coupling ................... 3 5.2.2. Universal-Joint Shafts ............. 4 5.3. ENGINE BASE ..................5 5.3.1. Engine Base on Synthetic Boats ..........5 5.4. SPACE FOR MAINTENANCE ............5 5.5.
  • Page 38 INSTALLATION INSTRUCTION 5. ENGINE INSTALLATION TABLE OF CONTENTS 5.15.1. Dimensions ................13 5.15.2. Propeller pitch ..............13 5.15.3. Blade Surface ............... 14 5.15.4. Sense of Rotation ..............14 5.15.5. Number of Blades ..............14 5.15.6. Axle Hub ................14 5.15.7. Adjustment of Propeller Pitch ..........14 5.15.8.

  • Page 39: Foundation

    INSTALLATION INSTRUCTION 5. ENGINE INSTALLATION 5.1. FOUNDATION 5.2. POWER TRANSMISSION 5.2.1. Coupling Z001007/0_4_September 2007 Page ENGINE INSTALLATION-3...

  • Page 40: Universal-Joint Shafts

    INSTALLATION INSTRUCTION 5.2.2. Universal-Joint Shafts forks of intermediate shaft marking IMPORTANT Page ENGINE INSTALLATION-4 Z001007/0_4_September 2007...

  • Page 41: Engine Base

    INSTALLATION INSTRUCTION 5.3. ENGINE BASE 5.3.1. Engine base on synthetic boats 5.4. SPACE FOR MAINTENANCE Z001007/0_4_September 2007 Page ENGINE INSTALLATION-5...

  • Page 42: Engine Inclination

    INSTALLATION INSTRUCTION IMPORTANT: 5.5. ENGINE INCLINATION 4 & 6 Cyl. max. inclination in ° 10° 10° 10° 5° Page ENGINE INSTALLATION-6 Z001007/0_4_September 2007...

  • Page 43: Lifting Eyes

    INSTALLATION INSTRUCTION 5.6. LIFTING EYES 6 Cyl. Engine 4 Cyl. Engine ATTENTION: NEVER PLACE THE ENGINE DIRECTLY ONTO THE FLOOR. THE OIL PAN AND OTHER PARTS COULD BE DAMAGED. JACK UP THE ENGINE ON THE ENGINE BEARERS SO THAT ITS LOWER PART IS TRAILING, OR KEEP THE ENGINE IN THE TRANSPORT BOX UNTIL IT IS LIFTED INTO THE BOAT.

  • Page 44: Propeller Shaft Flange

    INSTALLATION INSTRUCTION 5.8. PROPELLER SHAFT FLANGE 5.9. ENGINE MOUNTS For all STEYR Marine Engine Page ENGINE INSTALLATION-8 Z001007/0_4_September 2007...
  • Page 45 INSTALLATION INSTRUCTION 5. 9. 1. Adjustment of Engine on flexible engine mounts Z001007/0_4_September 2007 Page ENGINE INSTALLATION-9...

  • Page 46: Elastic Shaft Coupling

    INSTALLATION INSTRUCTION 5. 10. ELASTIC SHAFT COUPLING 5.11. STEP BEARING Examples: Attention: Attention: Page ENGINE INSTALLATION-10 Z001007/0_4_September 2007...

  • Page 47: Adjustment Of Engine Drive Unit

    INSTALLATION INSTRUCTION 5.12. ADJUSTMENT OF ENGINE DRIVE UNIT Z001007/0_4_September 2007 Page ENGINE INSTALLATION-11...

  • Page 48: Twin Installation

    INSTALLATION INSTRUCTION 5.13. TWIN INSTALLATION 5. 14. SHAFT AND STEM TUBE Page ENGINE INSTALLATION-12 Z001007/0_4_September 2007...

  • Page 49: Propeller

    INSTALLATION INSTRUCTION 5. 15. PROPELLER 5. 15. 1. Dimensions 5. 15. 2. Propeller pitch speed (m/min) pitch x slip (%) rotation of propeller pitch x 0,7 (30% slip) 1200 pitch = 0,357 m Z001007/0_4_September 2007 Page ENGINE INSTALLATION-13...

  • Page 50: Blade Surface

    INSTALLATION INSTRUCTION 5.15.3. Blade Surface 5.15.4. Sense of Rotation 5.15.5. Number of Blades 5.15.6. Axle hub D - d cone 5.15.7. Adjustment of Propeller Pitch Page ENGINE INSTALLATION-14 Z001007/0_4_September 2007...

  • Page 51: Space Between Propeller And Boat

    INSTALLATION INSTRUCTION 5.15.8. Space between Propeller and Boat D. C 5.15.9. Sediments 5.15.10. Choice of Propeller Z001007/0_4_September 2007 Page ENGINE INSTALLATION-15...

  • Page 52: Cavitation

    INSTALLATION INSTRUCTION 5.15.11. Cavitation 5. 16. PROPELLER - THRUST BEARING RESP. STEP BEARING Page ENGINE INSTALLATION-16 Z001007/0_4_September 2007...
  • Page 53 INSTALLATION INSTRUCTION 6. COOLING SYSTEM TABLE OF CONTENTS 6.1. SCHEME OF A RAW WATER COOLING WITH GEAR ....... 3 6.2. SCHEME OF A RAW WATER COOLING WITH STERN DRIVE ..3 6.3. RAW WATER PIPES ................4 6.4. RAW WATER INLET AND BOTTOM VALVE ........4 6.5.

  • Page 54: Cooling System

    INSTALLATION INSTRUCTION 6. COOLING SYSTEM NOTES Page COOLING SYSTEM-2 Z001007/0_4_September 2007...
  • Page 55 INSTALLATION INSTRUCTION 6. COOLING SYSTEM 6.1. SCHEME OF RAW WATER COOLING WITH GEARBOX 6.2. SCHEME OF RAW WATER COOLING WITH STERNDRIVE Z001007/0_4_September 2007 Page COOLING SYSTEM-3...
  • Page 56 INSTALLATION INSTRUCTION 6. 3. RAW WATER PIPES 4 + 6 Cyl. Engine 6. 4. RAW WATER PICK UP AND BOTTOM VALVE NOTE: Page COOLING SYSTEM-4 Z001007/0_4_September 2007...
  • Page 57 INSTALLATION INSTRUCTION 6. 5. RAW WATER FILTER 6. 6. COOLING WATER PIPES / EXHAUST CONNECTION Z001007/0_4_September 2007 Page COOLING SYSTEM-5...
  • Page 58 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page COOLING SYSTEM-6 Z001007/0_4_September 2007...
  • Page 59 INSTALLATION INSTRUCTION 7. FUEL SYSTEM TABLE OF CONTENTS 7. 1. GENERAL ................... 3 7. 2. FUEL TANKS ..................4 7. 3. MATERIALS ..................5 7. 4. TWIN FUEL TANKS ................5 7. 5. FUEL PIPES ..................5 Z001007/0_4_September 2007 Page FUEL SYSTEM-1...

  • Page 60: Fuel System

    INSTALLATION INSTRUCTION 7. FUEL SYSTEM NOTES Page FUEL SYSTEM-2 Z001007/0_4_September 2007...

  • Page 61: General

    INSTALLATION INSTRUCTION 7. FUEL SYSTEM 7. 1. GENERAL 300 l/h 65 gl/h Z001007/0_4_September 2007 Page FUEL SYSTEM-3...

  • Page 62: Fuel Tanks

    INSTALLATION INSTRUCTION 7. 2. FUEL TANKS NOTE: THE US COAST GUARD Page FUEL SYSTEM-4 Z001007/0_4_September 2007...

  • Page 63: Materials

    INSTALLATION INSTRUCTION 7. 3. MATERIALS 7. 4. TWIN FUEL TANKS 7. 5. FUEL PIPES Z001007/0_4_September 2007 Page FUEL SYSTEM-5...
  • Page 64 INSTALLATION INSTRUCTION Page FUEL SYSTEM-6 Z001007/0_4_September 2007...
  • Page 65 INSTALLATION INSTRUCTION 8. EXHAUST SYSTEM TABLE OF CONTENTS 8. 1. GENERAL .................... 3 8. 2. MATERIALS ..................3 8. 3. DRY EXHAUST PIPE................3 8. 4. WET EXHAUST PIPE ................4 8. 5. DIMENSIONS EXHAUST PIPE ............5 8. 6. CONDENSED-WATER COLLECTOR ..........5 8.

  • Page 66: Exhaust System

    INSTALLATION INSTRUCTION 8. EXHAUST SYSTEM NOTES Page EXHAUST SYSTEM-2 Z001007/0_4_September 2007...

  • Page 67: General

    INSTALLATION INSTRUCTION EXHAUST SYSTEM 8. 1. GENERAL Dry exhaust pipe, insulated Wet exhaust pipe (water flow in the pipe) Exhaust pipe with water jacket (double-walled, water-cooled) 8. 2. MATERIALS 8. 3. DRY EXHAUST PIPE Z001007/0_4_September 2007 Page EXHAUST SYSTEM-3...

  • Page 68: Wet Exhaust Pipe

    INSTALLATION INSTRUCTION 8. 4. WET EXHAUST PIPE ATTENTION: ATTENTION: Page EXHAUST SYSTEM-4 Z001007/0_4_September 2007...
  • Page 69 INSTALLATION INSTRUCTION 8.4.1 Exhaust for Inboard Engines 12" (300 mm) 8.4.2. Exhaust for Stern Drive Engines 14" (350mm) Z001007/0_4_September 2007 Page EXHAUST SYSTEM-5...

  • Page 70: Condensed-Water Collector

    INSTALLATION INSTRUCTION 8. 5. DIMENSIONS OF EXHAUST PIPE 6 Cyl. Engine 4 Cyl. Engine 8. 6. CONDENSED-WATER COLLECTOR 8. 7. MEASURING OF BACKPRESSURE max. admissible exhaust backpressure 100 mbar < 100 mbar = > 200 mbar = > 300 mbar = Page EXHAUST SYSTEM-6 Z001007/0_4_September 2007...
  • Page 71 INSTALLATION INSTRUCTION 9. AIR INTAKE AND VENTILATION TABLE OF CONTENTS 9. 1. GENERAL ..................3 9. 2. ENGINE POWER AND AIR TEMPERATURE ........4 9.3. CALCULATION OF AIR AND DUCTS ..........4 9. 4. PIPES FOR SUPPLY AIR AND EXHAUST AIR .......4 9.
  • Page 72 INSTALLATION INSTRUCTION 9. AIR INTAKE AND VENTILATION NOTES Page AIR INTAKE AND VENTILATION-2 Z001007/0_4_September 2007...

  • Page 73: General

    INSTALLATION INSTRUCTION AIR INTAKE AND VENTILATION 9. 1. GENERAL ATTENTION: Z001007/0_4_September 2007 Page AIR INTAKE AND VENTILATION-3...

  • Page 74: Engine Power And Air Temperature

    INSTALLATION INSTRUCTION 9. 2. ENGINE POWER AND AIR TEMPERATURE 9.3. CALCULATION OF AIR INLETS AND DUCTS require a certain min. quantity of oxygen (air) for their combustion process. amount of radiation heat 9. 4. PIPES FOR SUPPLY AIR AND EXHAUST AIR This is an imperative requirement for keeping the engine temperature under the max.

  • Page 75: Cross Sections - Ventilation Of Engine Compartment

    INSTALLATION INSTRUCTION A = 1,9 x engine power in KW (Diesel engines) = cross section of area in cm² For example: 256 marine A = 1,9 x 184 kW = 54,2 inch² (349,6 cm²) = 8 1/4" (210 mm diameter) 164 marine A = 1,9 x 120 kW = 35,4 inch²...

  • Page 76: Choice Of Blast

    INSTALLATION INSTRUCTION 9. 9. CHOICE OF BLAST air volume flow (m³/min) = 0,07 x engine power in kW For example: 256 marine 0,07 x 184 = approx. 17 yd³/min (13 m³/min) 164 marine 0,07 x 120 = approx. 11,8 yd³/min (9 m³/min) 9.
  • Page 77 INSTALLATION INSTRUCTION 10. AUXILIARY PROPULSION - PTO TABLE OF CONTENTS 10. 1. GENERAL ..................3 Z001007/0_4_September 2007 Page AUXILIARY PROPULSION-1...

  • Page 78: Auxiliary Propulsion

    INSTALLATION INSTRUCTION 10. AUXILIARY PROPULSION NOTES Page AUXILIARY PROPULSION-2 Z001007/0_4_September 2007...
  • Page 79 INSTALLATION INSTRUCTION 10. AUXILIARY PROPULSION - PTO 10.1. GENERAL 4 Cyl. Engine 6 Cyl. Engine 4 Cyl. Engine 6 Cyl. Engine Z001007/0_4_September 2007 Page AUXILIARY PROPULSION-3...
  • Page 80 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page AUXILIARY PROPULSION-4 Z001007/0_4_September 2007...
  • Page 81 INSTALLATION INSTRUCTION 11. SAFETY COVERS TABLE OF CONTENTS 11. 1. GENERAL ..................3 Z001007/0_4_September 2007 Page SAFETY COVERS-1...
  • Page 82 INSTALLATION INSTRUCTION 11. SAFETY COVERS NOTES Page SAFETY COVERS-2 Z001007/0_4_September 2007...
  • Page 83 INSTALLATION INSTRUCTION 11. SAFETY COVERS 11.1. GENERAL Z001007/0_4_September 2007 Page SAFETY COVERS-3...
  • Page 84 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page SAFETY COVERS-4 Z001007/0_4_September 2007...
  • Page 85 INSTALLATION INSTRUCTION 12. BILGE PUMPS TABLE OF CONTENTS 12. 1. GENERAL ..................3 Z001007/0_4_September 2007 Page BILGE PUMPS-1...

  • Page 86: Bilge Pumps

    INSTALLATION INSTRUCTION 12. BILGE PUMPS NOTES Page BILGE PUMPS-2 Z001007/0_4_September 2007...
  • Page 87 INSTALLATION INSTRUCTION 12. BILGE PUMPES 12.1. GENERAL relief valve screen Z001007/0_4_September 2007 Page BILGE PUMPS-3...
  • Page 88 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page BILGE PUMPS-4 Z001007/0_4_September 2007...
  • Page 89 INSTALLATION INSTRUCTION 13. CABIN HEATING TABLE OF CONTENTS 13. 1. SEPARATE HEATING ...............3 13.2. CABIN HEATING, CONNECTED TO ENGINE ........3 Z001007/0_4_September 2007 Page CABIN HEATING-1...

  • Page 90: Cabin Heating

    INSTALLATION INSTRUCTION 13. CABIN HEATING NOTES Page CABIN HEATING-2 Z001007/0_4_September 2007...
  • Page 91 INSTALLATION INSTRUCTION 13. CABIN HEATING 13. 1. SEPARATE HEATING 13.2. CABIN HEATING, CONNECTED TO ENGINE Z001007/0_4_September 2007 Page CABIN HEATING-3...
  • Page 92 INSTALLATION INSTRUCTION Attention: Page CABIN HEATING-4 Z001007/0_4_September 2007...
  • Page 93 INSTALLATION INSTRUCTION 14. NOISE ATTENUATION TABLE OF CONTENTS 14. 1. GENERAL ..................3 14. 2. NOISE REDUCTION ................3 14. 3. NOISE-ABSORBING HOODS AS SUPERSTRUCTURE ....4 14. 4. NOISE-ABSORBING MATERIAL ............5 Z001007/0_4_September 2007 Page NOISE ATTENUATION-1...
  • Page 94 INSTALLATION INSTRUCTION 14. NOISE ATTENUATION NOTES Page NOISE ATTENUATION-2 Z001007/0_4_September 2007...

  • Page 95: General

    INSTALLATION INSTRUCTION 14. NOISE ATTENUATION 14. 1. GENERAL 14. 2. NOISE REDUCTION Z001007/0_4_September 2007 Page NOISE ATTENUATION-3...

  • Page 96: Noise-Absorbing Hoods As Superstructure

    INSTALLATION INSTRUCTION 14. 3. NOISE ABSORBING HOODS AS SUPERSTRUCTURE Attention: Page NOISE ATTENUATION-4 Z001007/0_4_September 2007...

  • Page 97: Noise-Absorbing Material

    INSTALLATION INSTRUCTION 14. 4. NOISE-ABSORBING MATERIAL Z001007/0_4_September 2007 Page NOISE ATTENUATION-5...
  • Page 98 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page NOISE ATTENUATION-6 Z001007/0_4_September 2007...
  • Page 99 INSTALLATION INSTRUCTION 15. CONTROL STATION TABLE OF CONTENTS 15. 1. CONTROL STATION, GENERAL ............3 15. 2. CONTROL SYSTEMS ............... 3 15.2.1. Mechanical Control ..............3 15.2.2. Hydraulic Control ..............4 15.2.3. Electronic Control ..............4 15.3. CONTROL LEVERS ................5 15.3.1.
  • Page 100 INSTALLATION INSTRUCTION 15. CONTROL STATION NOTES Page CONTROL STATION-2 Z001007/0_4_September 2007...

  • Page 101: Control Station, General

    INSTALLATION INSTRUCTION 15. CONTROL STATION 15. 1. CONTROL STATION, GENERAL 15. 2. CONTROL SYSTEMS STEYR MOTORS Marine Engines 15.2.1. Mechanical Control Z001007/0_4_September 2007 Page CONTROL STATION-3...

  • Page 102: Hydraulic Control

    INSTALLATION INSTRUCTION 15.2.2. Hydraulic Control 15.2.3. Electronic Control Page CONTROL STATION-4 Z001007/0_4_September 2007...

  • Page 103: Control Levers

    INSTALLATION INSTRUCTION 15.3. CONTROL LEVERS Z001007/0_4_September 2007 Page CONTROL STATION-5...

  • Page 104: Kinds Of Control Levers

    INSTALLATION INSTRUCTION ATTENTION: WHEN ENGAGING REVERSING GEARS OR CLUTCHES, THE ENGINE SPEED NEVER SHOULD EXCEED 800 RPM. 15.3.1. Kinds of Control Levers 15.3.2. Possible Functions of a Control Lever 15.4. CONTROL CABLE Page CONTROL STATION-6 Z001007/0_4_September 2007...

  • Page 105: Twin Control Stations

    INSTALLATION INSTRUCTION 15. 5. TWIN CONTROL STATIONS Z001007/0_4_September 2007 Page CONTROL STATION-7...

  • Page 106: Twin Instrument Panels

    INSTALLATION INSTRUCTION 15. 6. TWIN INSTRUMENT PANELS 15.6.1 Scheme for second instrument panel standard equipment instrument panel with cable 7m optional equipment instrument panel with cable 1,5 m Y-branch extension cable 6,3 m NOTE: Oil pressure sender for twin installation must be changed. Page CONTROL STATION-8 Z001007/0_4_September 2007...

  • Page 107: Scheme For Instrument Panel And Scc

    INSTALLATION INSTRUCTION 15.6.2 Scheme for instrument panel and SCC standard equipment instrument panel with cable 7m optional equipment SCC with cable 1 m Y-branch extension cable 6,3 m NOTE: Z001007/0_4_September 2007 Page CONTROL STATION-9...
  • Page 108 INSTALLATION INSTRUCTION Page CONTROL STATION-10 Z001007/0_4_September 2007...

  • Page 109: Cut Out Drawing For "Solas Instrument Panel

    INSTALLATION INSTRUCTION 15.6.4 Cut out drawing for "SOLAS Instrument Panel" 5,63” / 143 mm Z001007/0_4_September 2007 Page CONTROL STATION-11...

  • Page 110: Cut Out Drawing For Scc

    INSTALLATION INSTRUCTION 15.6.5 Cut out drawing for SCC inch 5,63 / 143 mm Page CONTROL STATION-12 Z001007/0_4_September 2007...
  • Page 111 INSTALLATION INSTRUCTION 16. ELECTRICAL EQUIPMENT TABLE OF CONTENTS 16.1. GENERAL ................... 3 16.2. BATTERIES ..................3 16. 3. BATTERY CABLE LENGTHS AND CROSS-SECTIONS ....4 16. 4. ADDITIONAL CURRENT UTILIZATION DEVICES ......5 16. 5. COMPUTATION OF CABLE-CROSS SECTION FOR ADDITIONAL EQUIPMENT .............6 16.

  • Page 112: Electrical Equipment

    INSTALLATION INSTRUCTION 16. ELECTRICAL EQUIPMENT NOTES Page ELECTRICAL EQUIPMENT-2 Z001007/0_4_September 2007...

  • Page 113: General

    INSTALLATION INSTRUCTION ELECTRICAL EQUIPMENT 16. 1. GENERAL Attention: 16. 2. BATTERIES Attention: 4 Cyl. Engine 6 Cyl. Engine Z001007/0_4_September 2007 Page ELECTRICAL EQUIPMENT-3...

  • Page 114: Battery Cable Lengths And Cross-Sections

    INSTALLATION INSTRUCTION 16. 3. BATTERY CABLE LENGTHS AND CROSS-SECTIONS For 4 cyl. engines only For 6 cyl. engines only Page ELECTRICAL EQUIPMENT-4 Z001007/0_4_September 2007...

  • Page 115: Additional Current Utilization Devices

    INSTALLATION INSTRUCTION 16. 4. ADDITIONAL CURRENT UTILIZATION DEVICES ELECTRICAL EQUIPMENT OF THE ENGINE PERMANENTLY REQUIRES APPROX. 15 A. Z001007/0_4_September 2007 Page ELECTRICAL EQUIPMENT-5...

  • Page 116: For Additional Equipment

    INSTALLATION INSTRUCTION 16. 5. CALCULATION OF CABLE CROSS-SECTION FOR ADDITIONAL EQUIPMENT length cross-section amp watt length cross-section amp watt in m in mm² in m in mm² 16. 6. CABLE-CROSS SECTION Page ELECTRICAL EQUIPMENT-6 Z001007/0_4_September 2007...
  • Page 117 INSTALLATION INSTRUCTION 17. DRILL TEMPLATES TABLE OF CONTENTS 4 Cyl. Marine Engine FRONT VIEW ....................3 BOBTAIL ..................... 5 DOWN ANGLE .................... 7 TUNNELDRIVE SARO .................9 STERN DRIVE VOLVO ................11 STERN DRIVE VOLVO DP 290 ..............13 STERN DRIVE ..................... 15 STERN DRIVE BRAVO ................17 JET-DRIVE CASTOLDI ................19 JETDRIVE CASTOLDI .................21...

  • Page 118: Cyl. Marine Engine

    INSTALLATION INSTRUCTION 17. DRILL TEMPLATES TABLE OF CONTENTS 6 Cyl. Marine Engine STERN DRIVE VOLVO DP 290 ZF ............. 45 STERN DRIVE SX-DRIVE OMC ..............47 TUNNELDRIVE SARO.................49 Page DRILL TEMPLATES-2 Z001007/0_4_September 2007...

  • Page 119: Front View

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Front view 337,4 without hydraulic pump 337,4 with hydraulic pump Z001007/0_4_September 2007 Page DRILL TEMPLATES-3...
  • Page 120 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-4 Z001007/0_4_September 2007...

  • Page 121: Bobtail

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Bobtail - without coupling Z001007/0_4_September 2007 Page DRILL TEMPLATES-5...
  • Page 122 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-6 Z001007/0_4_September 2007...

  • Page 123: Down Angle 8

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Inboard with ZF 45A marine gear Down angle 8° 1007 Z001007/0_4_September 2007 Page DRILL TEMPLATES-7...
  • Page 124 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-8 Z001007/0_4_September 2007...

  • Page 125: Tunneldrive Saro

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Tunnel Drive SARO (ca. 90 - 110) 1007 Z001007/0_4_September 2007 Page DRILL TEMPLATES-9...
  • Page 126 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-10 Z001007/0_4_September 2007...
  • Page 127 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Stern - Drive VOLVO DP 290 Hydraulic Z001007/0_4_September 2007 Page DRILL TEMPLATES-11...
  • Page 128 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-12 Z001007/0_4_September 2007...

  • Page 129: Stern Drive Volvo Dp 290

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Stern - Drive VOLVO DP 290 Z001007/0_4_September 2007 Page DRILL TEMPLATES-13...
  • Page 130 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-14 Z001007/0_4_September 2007...

  • Page 131: Stern Drive

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine SX Stern - Drive Z001007/0_4_September 2007 Page DRILL TEMPLATES-15...
  • Page 132 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-16 Z001007/0_4_September 2007...
  • Page 133 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine MERCURY ALPHA BRAVO II & III Z001007/0_4_September 2007 Page DRILL TEMPLATES-17...
  • Page 134 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-18 Z001007/0_4_September 2007...

  • Page 135: Jet-Drive Castoldi

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Jet - Drive CASTOLDI ø 108 (6 x M12) 1017 Z001007/0_4_September 2007 Page DRILL TEMPLATES-19...
  • Page 136 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-20 Z001007/0_4_September 2007...
  • Page 137 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Jet - Drive CASTOLDI ø 101,5 (8 x M10) 1210 Z001007/0_4_September 2007 Page DRILL TEMPLATES-21...
  • Page 138 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-22 Z001007/0_4_September 2007...

  • Page 139: Jet - Drive Castoldi 05

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 4 Cyl. Marine Engine Jet - Drive CASTOLDI 05 1210 Z001007/0_4_September 2007 Page DRILL TEMPLATES-23...
  • Page 140 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-24 Z001007/0_4_September 2007...

  • Page 141: Front View

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Front view with hydraulic pump without hydraulic pump Z001007/0_4_September 2007 Page DRILL TEMPLATES-25...
  • Page 142 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-26 Z001007/0_4_September 2007...

  • Page 143: Bobtail

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Bobtail 1033 Z001007/0_4_September 2007 Page DRILL TEMPLATES-27...
  • Page 144 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-28 Z001007/0_4_September 2007...

  • Page 145: Down Angle 8

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Inboard with ZF 63A marine gear Down Angle 8° 1033 1156 Z001007/0_4_September 2007 Page DRILL TEMPLATES-29...
  • Page 146 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-30 Z001007/0_4_September 2007...
  • Page 147 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Inboard with ZF 63 marine gear Straight Shaft 1033 1217 Z001007/0_4_September 2007 Page DRILL TEMPLATES-31...
  • Page 148 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-32 Z001007/0_4_September 2007...

  • Page 149: Drive

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Inboard with ZF IV marine gear V - Drive 12° 1033 1221 Z001007/0_4_September 2007 Page DRILL TEMPLATES-33...
  • Page 150 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-34 Z001007/0_4_September 2007...
  • Page 151 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Jet - Drive CASTOLDI 1033 ø 108 (6 x M12) Z001007/0_4_September 2007 Page DRILL TEMPLATES-35...
  • Page 152 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-36 Z001007/0_4_September 2007...

  • Page 153: Jet-Drive Castoldi

    INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Jet - Drive CASTOLDI 1033 ø 101,5 (8 x M10) Z001007/0_4_September 2007 Page DRILL TEMPLATES-37...
  • Page 154 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-38 Z001007/0_4_September 2007...
  • Page 155 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Stern - Drive MERCURY BRAVO II & III 1033 Z001007/0_4_September 2007 Page DRILL TEMPLATES-39...
  • Page 156 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-40 Z001007/0_4_September 2007...
  • Page 157 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Stern - Drive VOLVO DP 290 1033 Z001007/0_4_September 2007 Page DRILL TEMPLATES-41...
  • Page 158 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-42 Z001007/0_4_September 2007...
  • Page 159 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Stern - Drive STERN POWER S1000 1205 Z001007/0_4_September 2007 Page DRILL TEMPLATES-43...
  • Page 160 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-44 Z001007/0_4_September 2007...
  • Page 161 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Stern - Drive VOLVO DP 290 Hydraulic 1033 Z001007/0_4_September 2007 Page DRILL TEMPLATES-45...
  • Page 162 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-46 Z001007/0_4_September 2007...
  • Page 163 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine VOLVO SX Drive, King Cobra Drive 1033 610,4 Z001007/0_4_September 2007 Page DRILL TEMPLATES-47...
  • Page 164 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-48 Z001007/0_4_September 2007...
  • Page 165 INSTALLATION INSTRUCTION Drill templates (scale approx. 1:10) 6 Cyl. Marine Engine Tunnel Drive SARO STEYR ENGINE + STP 320 - ZF 63 A (8°) 1033 (ca. 90 - 110) 1156 Z001007/0_4_September 2007 Page DRILL TEMPLATES-49...
  • Page 166 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES-50 Z001007/0_4_September 2007...
  • Page 167 INSTALLATION INSTRUCTION 18. APPENDIX TABLE OF CONTENTS PROPELLER CALCULATION FORM INSTALLATION AND PRE-DELIVERY INSPECTION LOG OWNER IDENDIFICATION CARD Z001007/0_4_September 2007 Page APPENDIX-1...
  • Page 168 INSTALLATION INSTRUCTION 18. APPENDIX NOTES Page APPENDIX-2 Z001007/0_4_September 2007...
  • Page 169 INSTALLATION INSTRUCTION PROPPELER CALCULATION FORM Gear Propeller Data: Euro 62,-- Z001007/0_4_September 2007 Page APPENDIX-3...
  • Page 170 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX-4 Z001007/0_4_September 2007...
  • Page 171 INSTALLATION INSTRUCTION INSTALLATION AND PRE-DELIVERY INSPECTION LOG: ENGINE NO:....... Manual, warranty and operation explaine Safeguarding instruction carried out Please immediately return a copy of this report and the Warranty registration card to your STEYR MOTORS GENERAL DISTRIBUTOR. If not doing so, guarantee will expire!! Z001007/0_4_September 2007 Page APPENDIX-5...
  • Page 172 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX-6 Z001007/0_4_September 2007...
  • Page 173 INSTALLATION INSTRUCTION Z001007/0_4_September 2007 Page APPENDIX-7...
  • Page 174 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX-8 Z001007/0_4_September 2007...

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