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4 cylinders + 6 cylinders 4 cylinders + 6 cylinders

1. U H U ill 15 1 1 instruments top control station 4 2 stearing top control station 5 3 control lever top control station 6 15 2 CONTROL SYSTEMS instruments lower control station stearing lower control station control lever lower control station For STEYR MOTORS Marine Engines a mechanically operated control is provided However other control systems may be used too 15 2 1 Mechanical Control With mechanical control movement of the lever is transmitted through a steel cable in a plastic sleeve onto the engine and reversing gear This cable is called pressure and tension cable Illustration shows the most current mechanical control with a combined lever for accelerator potentiometer acceleration and reversing gear forward or backward For special applications industrial use control of accelerator potentiometer and reversing gear may also be done by one separate lever each ill 15 2 Z001007 0 4 September 2007 Page CONTROL STATION 3 CONTROL STATION INSTALLATION INSTRUCTION 15 2 2 Hydraulic Control Hydraulic control is designed for ships where the distance between engine and control station is too large and pressure and tension cables often cause
2. Z001007 0 4 September 2007 Page DRILL TEMPLATES 9 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 10 Z001007 0 4 September 2007 DRILL TEMPLATES INSTALLATION INSTRUCTION Drill templates scale approx 1 10 Stern Drive VOLVO DP 290 Hydraulic 4 Cyl Marine Engine 847 Exhaust type TU R4 R6 ex V8 EN Qi e f A Page DRILL TEMPLATES 11 2001007 0 4 September 2007 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 12 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Stern Drive VOLVO DP 290 Exhaust type 847 8 xhaust type cer R4 R6 e pe E i j SERATE e nali 702 581 _ 140 7 z 5 ide Ui eem fin LI NL dA U U DA 551 Z001007 0_4 September 2007 Page DRILL TEMPLATES 13 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 14 Z001007 0 4 September 20
3. A aw 7 2 i H lt ill 6 2 Z001007 0_4_September 2007 Page COOLING SYSTEM 3 COOLING SYSTEM INSTALLATION INSTRUCTION 6 3 RAW WATER PIPES Raw Water Pipes 4 8 Cyl Dimensions in mm and inches Engine suction pipe inside diameter 32 1 1 4 suction pipe outside diameter 42 1 5 8 hose bottom valve sea water pump inside diameter 32 1 1 4 connection for bottom valve thread R 1 1 2 pressure pipe inside diameter 32 1 1 4 pressure pipe outside diameter 42 1 5 8 hose for pressure pipe inside diameter 32 1 1 4 connection for outgoing water and exhaust connection sprinkler 90 3 5 min rate of flow of raw water in l min and gal min gt 140 gt 30 6 4 RAW WATER PICK UP AND BOTTOM VALVE The raw water pick up isto be provided within appropriate distance to the raw water pump ofthe engine to avoid a suction of air when the boat rolls Max suction height of the raw water pump is approx 9 ft 3 m for standard installation If required the suction height may be increased by loop laying ofthe suction pipe so that the pump can start filled up with water On top ofthe loop an air cock is to be provided which is to be closed when the engine is stopped to avoid a rising effect Before starting the cock is to be opened On wooden boats the raw water inlet should preferably be made
4. Leakage oil fuel coolant checked ii Instruments adjusted of secondary drive if available Type of cabin heating if 2nd control station if available iii CEL extinguishes after 0 7 sec YES NO Test made Mon Name in block letters 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 APPENDIX INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX 6 Z001007 0 4 September 2007 STEYR MOTORS WARRANTY REGISTRATION CARD INSTALLATION INSTRUCTION APPENDIX STEYR OWNER IDENTIFICATION CARD Owner s Name Address City State Zip Date of commissioning MODEL SERIAL STEYRMOTORS DEALER RECORD CARD ENGINE MODEL REGISTRATION OUT DRIVE REGISTRATION TRANSOM MOUNT REGISTRATION SERIAL MODEL SERIAL MODEL SERIAL Owner s Name Address City State Zip Date of commissioning Ignition Key No Boat Mfgr Hull No Boat Model Boat Length Owners signature Important The Federal Boat Safety Act requires registration list to be maintained on product sales by manufacturer and DEAL
5. ill 15 3 1 microprocessor unit 2 tension and pressure cable accelerator 3 tension and pressure cable reversing gear A so called potentiometer on the control handle imparts the respective position of the handle to the microprocessor unit In the processor unit this signal is converted via servo motors into mechanical movements Depending on manufacturer and design of this processor unit several control levers may be connected For the control of twin engines two processor units are required Compared to mechanical control mechanical differential devices are not necessary Page CONTROL STATION 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CONTROL STATION scheme of an installation with one engine and one control station 1 2 3 4 ill 15 4 scheme of an installation with one engine and two control stations 1 2 3 4 ill 15 5 scheme of an installation with two engines 4 and two control stations 2 yY y y o CD 3 4 OE 4 il l ill 15 6 15 3 CONTROL LEVERS one single lever control microprocessor unit tension and pressure cable accelerator tension and pressure cable reversing gear two single lever controls microprocessor unit tension and pressure cable accelerator tension and pressure cable reversing gear four single
6. D Fe i 2 0V shaft angle 12 Lifeboat Engine Equipment Bobtail B Direkt gearbox A down angle gear box Parallel offset gearbox For exact installation dimensions see chapter 17 Drill templates Z001007 0_4_September 2007 Page VARIANTS ENGINE PROPULSION 7 VARIANTS ENGINE PROPULSION INSTALLATION INSTRUCTION KO U TT Jet drive Jet Drive KO TYPE 19 EM Alamarin U Hamilton Castoldi AO Mercury Bravo II amp SE ig H Volvo DP 290 A Stern Power Drive Volvo DP 290 ZF Hydraulic Pump Volvo SX Drive King Cobra Drive For
7. 778 ca 137 911 D T 2 l o STEYR hr m A AX H E N 1 140 2001007 0 4 September 2007 Page DRILL TEMPLATES 41 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 42 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Cyl Marine Engine Stern Drive STERN POWER 51000 Z001007 0 4 September 2007 Page DRILL TEMPLATES 43 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 44 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Cvl Marine Engine Stern Drive VOLVO DP 290 Hydraulic 1033 Exhaust type R4 R6 V8 LO 8 2 5 CH d o M 296 610 NU 3 na LO DI K i Hetz 2001007 0 4 September 2007 Page DRILL TEMPLATES 45 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 46 Z001007
8. 12 1 25 88 125 150 M 12x1 25 95 135 160 M 12x1 5 72 100 120 M12x1 5 83 115 140 M 12x1 5 90 125 150 M 14x1 5 120 165 200 14 1 5 140 195 235 M 14x1 5 150 210 250 M 16x1 5 180 250 300 16 1 5 210 295 350 M 16x1 5 225 315 380 M 18x1 5 260 365 435 M18x1 5 305 425 510 M 18x1 5 325 460 550 M 20x1 5 360 510 610 M20x1 5 425 600 720 M 20x1 5 460 640 770 M 22x1 5 480 680 810 M22x1 5 570 800 960 M 22x1 5 610 860 1050 24x2 610 860 1050 24 2 720 1000 1200 24x2 780 1100 1300 M27x2 900 1250 1500 M27x2 1050 1500 1800 M27x2 1150 1600 1950 M 30x2 1250 1750 2100 M30x2 1450 2050 2500 M 30x2 1600 2250 2700 If the tightening torque of a screw connection is not achieved the strength of the screw nut is insufficient or the ratio of friction does not correspond In any of these cases the screw nut is to be exchanged total 7 total friction coefficient Page QUALITY DIRECTIVES 8 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION QUALITY DIRECTIVES 3 5 CHECKING OF TORQUE WRENCH The torque wrench requires regular checking as to the values adjusted For signaling torque wrenches the release value is tested and for measuring torque wrenches the scale accuracy 3 6 NONDESTRUCTIVE TESTING OF MATERIALS To detect and locate surface cracks nondestructive testing based on the colour penetration testing process is recommended Inthis case the workpiec
9. 9 6 INLET CROSS SECTION AIR CONSUMPTION OF ENGINE Min requirement for proper ventilation and air supply for pleasure boats are 4 pipes with a diameter of 3 75 mm each two pipes for engine supply air one pipe for ventilation of engine compartment and one pipe equipped with a fan efficiency 440 ft min 11 m min for exhaust air of engine compartment The engine needs a certain quantity of air for the combustion process which requires a certain min flow area for the air stream Page AIR INTAKE AND VENTILATION 4 Z001007 0_4_September 2007 INSTALLATION INSTRUCTION AIR INTAKE AND VENTILATION This area may be calculated with the following formula 1 9 x engine power in KW Diesel engines cross section of area in cm For example 256 marine 164 marine 9 x 184 kW 54 2 inch 349 6 cm 8 1 4 210 mm diameter A21 1 9 x 120 kW 35 4 inch 228 0 cm 6 3 4 170 mm diameter Max possible combustion air consumption per engine unit at 20 990 mbar 256 marine 1190 yd h 910 m h 174 marine 798 yd h 610 m h The value is based on free influx and a pipe lenght up to 3 feet one meter with a max bend of 90 When using longer pipes or several pipe bends correct the cross section by multiplication with a coefficent See chart number length of pipe in meters yrd of pipe bends 1 2 3 4 5 1 1 1 04 1 09 1 13 1 20 2 1 39 1 41 1 43 1 45 1 49 3 1 70 1 72 1 74 1
10. 6 COOLING SYSTEM TABLE OF CONTENTS 6 1 SCHEME A RAW WATER COOLING WITH GEAR 3 6 2 SCHEME OF A RAW WATER COOLING WITH STERN DRIVE 3 6 3 RAW WATER PIPES Sanaa ass UMEN EU 4 6 4 RAW WATER INLET AND BOTTOM VALVE 4 6 5 RAW WATER FILTER ses nano issu 5 6 6 COOLING WATER PIPES EXHAUST CONNECTION 5 Z001007 0 4 September 2007 Page COOLING SYSTEM 1 COOLING SYSTEM INSTALLATION INSTRUCTION 6 COOLING SYSTEM NOTES Page COOLING SYSTEM 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION COOLING SYSTEM 6 COOLING SYSTEM 6 1 SCHEME OF RAW WATER COOLING WITH GEARBOX raw water inlet bottom valve raw water filter exhaust and raw water gate AUN ill 6 1
11. i 3 5 DOWN ANGLE 52 2 22 0H i 7 TUNNEEDRIVE e e 9 STERN DRIVE VO E 11 STERNIDRIVE 290000000 13 STERN DRIVE ae nana nue an ct at E EEs E EENEN 15 STE RNID RVE BRAVO 17 JET DRIVEGASTOLDI iii A 19 JBTDbRIVE GASTOLDI ne 21 JETDRIVEGASTOL DI assessment 23 Marine Engine 25 27 29 STRAIGTH SHAFT 31 DRIVE A 33 JET DRIVE CASTOLDI iii ina pu an pana a 35 EIERE 37 STERN DRIVE MERCURY BRAVO Il amp lll 39 STERNIDRIVE 200 ED 41 2001007 0 4 September 2007 Page DRILL TEMPLATES 1 DRILL TEMPLATES INSTALLATION INSTRUCTION 17 DRILL TEMPLATES TABLE OF CONTENTS 6 Marine Engine STERN DRIVE VOLVO DP 290 ZF m 45 STERN DRIVE SX DRIVE OMG he un 47 TUNNEEDRIVESARQ tet nu 49 Page DRILL TEMPLATES 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Front view without hydraulic pump with hydraulic pump Z001007 0 4 September 2007 Page DRILL TEMPLATES 3 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 4 Z001007 0 4 S
12. 0 4 September 2007 778 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine VOLVO SX Drive King Cobra Drive 1033 554 8 lt TU Bia ca 137 2001007 0 4 September 2007 Page DRILL TEMPLATES 47 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 48 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Tunnel Drive SARO STEYR ENGINE STP 320 ZF 63 A 8 1033 778 554 8 T iam A ES ca 90 110 Fort RO arce JO nag fl 196 109 112 153 57 di E 895 265 1156 296 711 286 669 286 En 012 2001007 0 4 September 2007 Page DRILL TEMPLATES 49 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 50 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION APPENDIX 18 APPENDIX TABLE OF CONTENTS PROPELLER CALCU
13. 5 QUALITY DIRECTIVES INSTALLATION INSTRUCTION 3 3 7 Tightening Torques cutting ring connections for steel tubes Tube Torque 6 10 12 Nm 18 65 80 Nm cutting ring connections for plastic tubes Tube Torque 6 16 20 Nm 8 25 30 Nm A ATTENTION ABSOLUTELY USE SLIP ON SLEEVES clamping ring connections for plastic tubes Tube Torque 12 30 50 Nm screwed pipe joints in aluminum housings Thread Torque M 10x1 20 Nm M 12x1 5 26 Nm M 14x1 5 28 Nm M 16x1 5 35 Nm M18x1 5 38 Nm 22 1 5 40 Nm M26x1 5 50 Nm Page QUALITY DIRECTIVES 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION QUALITY DIRECTIVES 3 3 8 Pipe Relaying During assembly of pipings take care of a non chafing and for plastic tubes even of a non twisting relaying Grooves or other damages of the tube surface are to be avoided Damaged tubes are to be exchanged If plastic tubes are clamped with cable bond it is to be ensured that the tubes are not constricted Relaying is to be done with sufficient safety distance to chafe marks In case of possible chafing use an edge protection or a spacer Z001007 0 4 September 2007 Page QUALITY DIRECTIVES 7 QUALITY DIRECTIVES INSTALLATION INSTRUCTION 3 4 TIGHTENING TORQUES The values in this table refer to ind
14. 78 9 7 INLET CROSS SECTIONS VENTILATION OF ENGINE COMPARTMENT To keep the temperature in the engine compartment at the admissible value a part of the radiation heat is to be conducted resp expelled from the engine compartment The supply and exhaust air pipe should be of the same size to achieve a low velocity of flow and thus a low sound level Pipe cross section for supply and exhaust air is computed with the following formula A 1 65 x engine power in kW 7 cross section of area cm For example 256 marine A lt 1 65 x 184 47 1 inch 303 6 cm 8 200 mm diameter 164 marine 1 65 x 120 32 0 inch 198 0 cm 6 1 4 160 mm diameter 9 8 FANS To permit an effective ventilation of the engine compartment which keeps the temperatures low a suction fan is to be installed in the exhaust air duct Attention Never install the fan in the supply air duct This would cause an excess pressure in the engine compartment with the risk of gas and air leakage in the other compartments of the boat Z001007 0 4 September 2007 Page AIR INTAKE AND VENTILATION 5 INSTALLATION INSTRUCTION 9 9 CHOICE OF BLAST The blast is to be provided for the following air volume flow air volume flow m min 0 07 x engine power in kW For example 256 marine 0 07 x 184 lt approx 17 yd min 13 m min 164 marine 0 07 x 120 lt approx 11 8 y
15. 9 filler socket 5 thermal lag switch 10 drain cock at lowest point opening temperature 70 74 In a Diesel engine 35 to 40 96 of the energy supplied by the fuel are used as motive power The rest fades as exhaust heat frictional losses radiation and through the cooling system The heat passing offthe cooling system may be usedto some extentto heatthe cabin In such case itis extremely important that not too much heat is taken which causes the engine to run at too low operating temperature A quick rise of the engine temperature to operating temperature is also important If the engine operates too cold below 65 C approx wear will increase considerably This means that too large heatings and too soon starting heatings i e heatings starting before the operating temperature of the engine is reached may cause severe damages on the engine Z001007 0 4 September 2007 Page CABIN HEATING 3 INSTALLATION INSTRUCTION It is recommended to install in the feed line to the radiator a thermostat with the same or about 2 lower opening temperature as the engine thermostat A circulating pump may also be required This maintains the operating temperature of the engine at normal speed and keeps it at the correct level At the same time the radiator gets maximum heat Never run the engine at idle motion just to keep the heat in the cabin To ease water circulation through the heating water pipes should be large eno
16. INSTALLATION 5 9 1 Adjustment of Engine on flexible engine mounts The settings of the height adjusters should be equal right and left Between the front and rear of the engine a difference in adjustment is admissible and often unavoidable Before beginning the alignment the engine should rest on the mounts for about 48 hours Proper setting of the engine mounts can be done as follows Roughly align the engine with the propeller shaft on the mounts by means of adjusting nuts without connecting the propeller shaft to the flange on the reversing gear Lift the engine at the front to such an extent that both front supports are released from the lower nuts of the mounts Lower the engine and adjust the nuts so that both engine supports sit simultaneously Same procedure at the rear side of the engine The engine foundation must be rigid enough to absorb the concentrated load After correct adjustment of the engine mounts the engine can be balanced by front and rear adjustment ofthe two nuts right and left with exactly the same number of turns In longitudinal direction the vibration dampers are to be mounted free of tension Engine mounts being mounted with initial stress may transmit vibrations and sound into the hull The oblong holes in the vibration damper feet permit a lateral correction of the adjustment When the boat is in the water the alignment is to be checked once again Z001007 0 4 September 2007 Page ENGINE INSTALLA
17. TESS U J LZ XK sil d S cd us lt 2 24 7 without hvdraulic pump 2001007 0 4 September 2007 Page DRILL TEMPLATES 25 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 26 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Bobtail TR e IB A aii dj AI D O QF 06 T 2001007 0 4 September 2007 Page DRILL TEMPLATES 27 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 28 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Inboard with ZF 63A marine gear Down Angle 8 1033 296 711 a 0 WE SD OTS O O m LI AT I e 8 i i 9 6 Di AS e e Je Y b PEN Z001007 0 4 September 2007 Page DRILL TEMPLATES 29 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 30 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLAT
18. THIS PAGE IS INTENTIONALLY BLANK Page BILGE PUMPS 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CABIN HEATING 13 CABIN HEATING TABLE OF CONTENTS 13 T SEPARATE HEATING a ERRESA PASE 3 13 2 CABIN HEATING CONNECTED TO 3 Z001007 0 4 September 2007 Page CABIN HEATING 1 INSTALLATION INSTRUCTION 13 CABIN HEATING NOTES Page CABIN HEATING 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CABIN HEATING 13 CABIN HEATING 13 1 SEPARATE HEATING Heating for the ship s cabin or for passenger rooms may be connected to a separate generating set run by petroleum Diesel liquid gas etc Separate heating is always to be preferred for large heating installations anyway to prevent the engine from running at too low operating temperature Such an installation also guarantees a uniform heat input wether the engine runs or not Several products are available on the market For assembly current safety rules are to be considered However heat can also be taken from the engine s cooling system and be supplied to a small radiator But this heat is only available when the engines runs 13 2 CABIN HEATING CONNECTED TO ENGINE ill 13 1 1 hot water outlet from engine 6 hose with twin hose clips 2 water return to engine 7 cabin heating event with fan 3 heating pump STEYR option 8 venting screw 4 angle with stopcock
19. acc to ill 7 3 may be chosen Connect the tanks on top and on bottom with pipe lines equipped with stop cocks Min inside diameter of the lower connecting pipe should be 3 4 19 mm in orderto permit a filling of the tanks ifthey are installed alongside from both sides of the boat The fuel pipe from the engine has to depart from the lower connecting pipe of the tank only valid fortanks with bottom drain An additional fuel filter or water separator is to be installed in front of the feed pump on the injection pump In case of a daily tank it is recommended to connect the fuel return pipe to this tank which reduces the filling intervals ill 7 3 7 5 FUEL PIPES Min inside diameter of the fuel filler socket should be 1 1 2 38 mm Length of the socket should be chosen in such a way that the distance to the tank bottom is approx 2 50 mm Connect the filler socket from the tank to the deck union by means of a pipe joint to the tank socket On the deck lead in a sleeve made of fuel resistant rubber is to be provided If possible rubber hoses should be avoided When using a rubber hose it should be of fuel resistant reinforced quality Always connect tank and deck union by a grounding cable unless there is a metallic contact Z001007 0 4 September 2007 Page FUEL SYSTEM 5 FUEL SYSTEM INSTALLATION INSTRUCTION The air vent pipe is to be laid from the hightest point of each tank to a protected area on deck On
20. and belt drives being exposed are to be provided with safety covers Their construction and Size must prevent accidents e g if somebody slips and in falling comes close to a source of danger To permit an inspection of the engine control its protection isto be constructed as net orgrate Fixthe protection by means of screws and nuts to allow an easy removal for maintenance ill 11 1 example for a belt drive cover ill 11 2 example for a stem shaft cover Z001007 0 4 September 2007 Page SAFETY COVERS 3 SAFETY COVERS INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page SAFETY COVERS 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION BILGE PUMPS 12 BILGE PUMPS TABLE OF CONTENTS 12 L GENERAL li 3 Z001007 0 4 September 2007 Page BILGE PUMPS 1 BILGE PUMPS INSTALLATION INSTRUCTION 12 BILGE PUMPS NOTES Page BILGE PUMPS 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION BILGE PUMPS 12 BILGE PUMPES 12 1 GENERAL To achieve max Lenz power pumps and piping are to be chosen as follows length of hand bilge pumps power driven nominal width of bilge pipes boat volume flow bilge pumps main bilge branch bilge pipe m m3 h m3 h mm 8 3 5 32 10 5
21. ater pick up must be aligned to the rear aft therewith water can t be pressed into the external cooling system when the boat is undersailing conditions with stopped engine The bottom valve must be closed if the boat rides at ill 6 3 anchor Page COOLING SYSTEM 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION COOLING SYSTEM Apply a proper sealing agent e g Permatex on the screw passages Sheet boats should have a screwed pipe joint welded tothe ship bottom on which the bottom valve is fastened with screws On the bottom side a screen is to be fixed Apply a proper sealing agent between valve and screwing thread When fixing the floor valve there should be sufficient free space around the valve to permit an easy opening and closing ofthe valve If this space istoo small an intermediate piece can be fixed belowthe valve In many cases a remote control will be required 6 5 RAW WATER FILTER During coasting trade on the pier etc it cannot be avoided that small particles of mud sand and other dirt enter into the water inlet A filter in the suction pipe must be fitted so that these contaminations can be separated A raw water filter also helps to increase the pump life thus preventing engine defects due to insufficient cooling water supply III 6 4 shows one of the Sherewood filters which may be installed with easy acces in a bulkhead In case of severe contaminations it may be necessary to install
22. carburetor engines All engines also radiate a specific amount of radiation heat to the ambient e g to the engine compartment Therefore airinlet and air ducts are to be dimensioned spaciously in orderto achieve a very low velocity of airflow 9 4 PIPES FOR SUPPLY AIR AND EXHAUST AIR It is of great advantage to consider the supply and exhaust air ducts already during construction and to provide them in the hull or superstructure thus avoiding exposed pipes To supply the engine with sufficient combustion air is relatively easy but itis much more difficult to carry off the radiation heat The engine itself sucks in the air very effectively and takes it from everywhere If dimensions of the supply and exhaust airducts are too small the engine will suck inthe airfrom the exhaust airducts Due to missing ventilation high temperatures will arise in the engine compartment Most of the engine s radiation heat is to be conducted from the engine compartment This is an imperative requirement for keeping the engine temperature under the max limiting value 9 5 TEMPERATURE IN ENGINE COMPARTMENT Since the indicated engine power is based on atest temperature of 25 C itis important to keep the temperature of the intake air as low as possible Increased temperature will always cause a power loss Max temperature for areas where electric components are installed is 70 C for starter and generator special regulations are to be applied however
23. case the fuel flowing back from the engine is pumped into the daily tank ag Va A 6 ill 7 2 17 9 water separator rate of flow gt 65 Brit gl h gt 300 I h fuel stop cock fuel pipe outside diameter 3 8 10 mm for a length of 20 ft 6 m For longer lines use a 1 2 12 mm pipe inspection cover filler socket cover lead in sleeve made of fuel resistant rubber with drain possibility air vent pipe diameter at least 1 1 2 38 mm guide bulkhead ground connection return pipe suction pipe complete with screen distance to tank bottom 1 25 mm anti siphon valve NOTE If demanded by THE US COAST GUARD install a anti siphone valve which must be opened by fuel pump suction to withdraw fuel from the tank and which will remain closed without fuel pump suction preventing siphon action created by a break at any point in the fuel feed system The valve shall be designed and sized to provide the requiered fuel flow of 65 Brit gl h 300 I h to the engine Page FUEL SYSTEM 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION FUEL SYSTEM 7 3 MATERIALS If possible the fuel tanks should be made of stainless steel Nirosta Light metal steel plate or plastic may be used too Copper plate galvanized or pot galvanized plate are no suitable materials for fuel tanks 7 4 TWIN FUEL TANKS For a lateral arrangement of the tanks in the boat a construction
24. lever controls two microprocessor units tension and pressure cable accelerator tension and pressure cable reversing gear Speed and control levers should be of good quality to ensure a reliable control ofthe boat Forhydraulic reversing gears we recommend the combined lever control for single and twin engines This control is designed in such a way that control of engine speed and hydraulically actuated reversing gear can be done by one single lever If the engine is equipped with a clutch for mechanical operation the engine speed is to be controlled by means of a separate gearshift Z001007 0 4 September 2007 Page CONTROL STATION 5 CONTROL STATION INSTALLATION INSTRUCTION ATTENTION WHEN ENGAGING REVERSING GEARS OR CLUTCHES THE ENGINE SPEED NEVER SHOULD EXCEED 800 RPM 15 3 1 Kinds of Control Levers 1 single lever control for top asembly 2 single lever control for twin engine plant for top assembly 3 single lever control for lateral assembly 4 twin lever control for top assembly ill 15 7 15 3 2 Possible Functions of a Control Lever 1 safety key only by pressing key 1 control lever may be moved forward or backward 2 trimming switch 3 by pressing key 3 engine speed may be changed without putting in a gear ill 15 8 15 4 CONTROL CABLE Cables provided for the control devices described are designed for function in two operating directions push pull function and available in
25. made of 1 12 2 mm steel plate or 3 4 19 mm plywood A 3 8 10 mm rubber strip is used as cover sealing For ventilation of the engine two air intakes see chapter 7 for sufficient air supply are to be provided The air intakes are connected to the bottom edge of the engine compartment by means of rubber hoses which ensures sufficient noise reduction without any further measures Exhaust air of the engine compartment is conducted via two noise catchers with the some cross section as that ofthe airintakes These noise catchers must be insulated on both sides with the same material used forthe inner side of the engine protection In hot regions it may be necessary to install fans see chapter 7 8 for air exhaust Atmospheric temperature of the engine may rise to a max value of 40 45 C only However a temperature as low as possible should be the aim Page NOISE ATTENUATION 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION NOISE ATTENUATION 14 4 NOISE ABSORBING MATERIAL a D Bo ill 14 5 ill 14 6 noise absorbing material forengine hood made noise absorbing material forengine hood made of wood plywood 5 8 15 mm or 1 12 of 1 12 2 mm steel plate or wood plywood 2 mm steel plate 5 8 15 mm 1 engine hood 1 engine hood 2 lead sheet 0 5 line 1 mm 2 flame proof absorbing mat 3 mineral cotton 2 50 mm e g Porolon Revertex 4 plastics foil Acoustics or Baryfoil 5 perforated a
26. of red metal brass unsuited corrosion due to high zinc content On steel boats red metal is recommended too If the materials used for the hull and the raw water inlet are very different with regard to their galvanic characteristics the inlet isto be electrically insulated from the hull Flow area of raw water inlet and screen should be large enough to avoid a throttling and thus a smaller water supply to the pump The pipe should be laid in smooth curves to avoid unnecessary throttling and preferably be made of copper nickel tube To eliminate tensions lay it in a curve and terminate it with a reinforced rubber hose the raw water pump The hose should be designed with steel spiral otherwise the underpressure in the suction pipe may cause a collapse of the hose thus no more guaranteeing a sufficient natural water supply Inside diameter of the floor cock should at least be equal to the suction pipe diameter see dimensions raw water pipe Make sure that the cock does not cause a reduction in flow On wooden boats connect the bottom valve to the raw water pick up ship bottom through a board lead in with through screws stop cock Provide a proper sealing between valve and ship bottom hose NOTE On motor boat installation the grid of the water pick up must be alignedtothe front driving direction therewith on increasing boat speed the water will be pressed into the external cooling system On sailing boat installation the grid ofthe
27. propeller speed number of revolutions of engine divided through reduction of gear C speed of the boat is a wrong assumption that the propeller determines the speed but it is the combination of engine power with adapted hull and matching propeller The propeller diameter can be approximately computed based on the diagram enclosd but this only for water displacers Before using the diagram the max speed of the ship is to be computed Only use this diagram for an approximate computing of the diameter e g for determining the height of the propeller frame Computing of the correct diameter and of the pitch is to be done by a specialist MOTORENTECHNIK offers this service to their dealers and customers If required please fill in the enclosed form 5 15 2 Propeller pitch The pitch is the theoretical distance the boat runs at one rotation of the propeller which is being determined for 100 96 by the speed of the boat Every propeller rotating in water will have a slip Thus the advance of the boat will be approx 60 to 75 96 per rotation of the pitch Computation of pitch 5 speed m min pitch rotation of propeller wt 200 m 0 7 30 sli 2 eee pitch 0 357 A propeller the pitch of which is not exactly adapted to the speed of the boat will always show a lower efficiency To reduce the diameter and then increase the pitch for the same size which sometimes is required when the ac
28. requires two checks vanishing check contact accuracy and angularity check no bends With two dial gauges both checks can be done simultaneously For each check the part at which the dial gauge is fixed is to be moved for at least one turn An exact alignment ofthe part to be mounted mostly requires several checks Because of that it is advisable to fix the dial gauge on that part which can be turned more easily Page ENGINE INSTALLATION 12 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 15 PROPELLER Too less attention is paid to the propeller and in particular to its efficiency even though it is responsible for transformation of engine energy into mouvement Sizing and selection of the propeller mean a positive or nega tive decision as to driving qualities as well as fuel consumption Voluminous books have been written about right sizing and computation of a propeller For this reason the following information shall serve for better understanding of the complexity and impart basic knowledge Of all driving possibilites developped so far the propeller shows the best efficiency Sizing of the propeller is determined by the boat type the engine power and speed 5 15 1 Dimensions A propeller is designated by diameter pitch number of blades blade surface sense of rotation and hole in the hub Diameter of the propeller is determined by 8 engine power in horsepower or kilowatt hours b
29. rubber as spring elements and for power transmission it is to be considered that the transferable alternating moment of oscillation decreases very fast with increasing temperature of the rubber Based on the information of a known manufacturer of elastic couplings the temperature factor at 60 C is 1 and at 80 C 0 5 only Therefore an effective aeration of the coupling is useful since the rubber expands or contracts with ambient temperature For assemby of the clutch and alignment of the coupling flanges the manufacturer s instructions are to be considered Z001007 0 4 September 2007 Page ENGINE INSTALLATION 3 ENGINE INSTALLATION INSTALLATION INSTRUCTION When assembling a coupling or a connecting shaft between engine and gear or when flanging a gear the end clearance of the engine s crankshaft must not be affected V belts gear couplings or similar connecting links thus should permit to be encaged easily Also when flanging a gear onto the engine make sure that after tightening of the fastening screws no axial load or tension is transmitted onto the crankshaft It is therefore necessary to check the end clearance of the crankshaft journal before and after assembly During both checks the clearance must be equal The crankshaft must not spring back after pressing it againstthe front and rear collar of the lapped bearing On boats destined for frequent reversing and maneuvring e g service boats the couplings are heavily stressed b
30. stop on the cutting ring Now press the tube against the stop in the threaded socket and tighten the union nut with the torque specified In the course of this the tube must not turn Page QUALITY DIRECTIVES 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION QUALITY DIRECTIVES 3 3 4 Checking of Plug Connections After having tightened the union nut unscrew it again and check if the cutting edge of the cutting ring has penetrated the outer skin of the tube and if the elevated collar in front of the edge is visible 3 3 5 Assembly of Raufoss Plug Systems visible collar e ATTENTION FOR SAFETY REASONS SOCKETS MUST NOT BE DISMANTLED Before insertion mark the plastic tube at gape x depending on its diameter and then push it into the socket upto this mark Afterwards check clamping of the plastic tube by a quick traction in direction B NOTE THE PLASTIC TUBE MUST NOT TURN IN THE SOCKET 3 3 6 Sealing of Screwed Pipe Joints Before assembly of the plug connections thinly coat the outer side of the cutting ring with a sealing agent for screwings A For screwed pipe joints of hydraulic piping coat the point of contact tube screwed pipe joint with standard grease B ATTENTION GREASE AND SEALING AGENTS MUST NOT ENTER INTO PIPING plastic tube gt 9 X tube marking socket Z001007 0 4 September 2007 Page QUALITY DIRECTIVES
31. 07 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine SX Stern Drive n 847 j 4 1 2 5 N O 114 593 128 37 758 2001007 0 4 September 2007 Page DRILL TEMPLATES 15 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 16 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine MERCURY ALPHA BRAVO II amp III Z001007 0 4 September 2007 Page DRILL TEMPLATES 17 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 18 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Jet Drive CASTOLDI 550 _ i m O gt o 79 286 O PY 2001007 0 4 September 2007 Page DRILL TEMPLATES 19 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENT
32. 1 elastic engine suspension 2 gland in rubber suspension 3 grease gun ill 5 11 Engine with elastic suspension and fixed stem bearing 1 elastic engine suspension 2 elastic shaft coupling 3 butt supported stem bearing Attention The stem bearing must not be elastic A max distance between supports 6 1 2 ft 2 m ill 5 12 Engine with elastic Suspension and elastically supported stem bearing 1 elastic engine suspension 2 elastically supported stem bearing Attention The shaft coupling must not be elastic A max distance between supports ill 5 13 6 1 2 ft 2 m Page ENGINE INSTALLATION 10 Z001007 0_4_September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 12 ADJUSTMENT OF ENGINE DRIVE UNIT As soon asthe base frame has been finished the propeller shaft mounted and the other preparation works done the engine and the reversing gear can be mounted For engines with double reversing gears the reversing gear is to be mounted first and exactly aligned to the propeller shaft Then the couplings are mounted and the engines are aligned towards the reversing gear First adjustment of the engine on the boat can be done either on land or on the seas Before final adjustment the boat should however be on the seas for some days so that the body can take its final shape When mounting a marine reversing gear it is reco
33. 1007 0 4 September 2007 Page CONTROL STATION 7 CONTROL STATION INSTALLATION INSTRUCTION 15 6 TWIN INSTRUMENT PANELS 15 6 1 Scheme for second instrument panel standard equipment instrument panel with cable 7m instrument panel with cable 1 5 m Y branch extension cable 6 3 m ill 15 10 NOTE Oil pressure sender for twin installation must be changed Page CONTROL STATION 8 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CONTROL STATION 15 6 2 Scheme for instrument panel and SCC standard equipment instrument panel with cable 7m SCC with cable 1m Y branch extension cable 6 3 m ill 15 11 NOTE Oil pressure sender for twin installation must be changed Z001007 0_4_September 2007 Page CONTROL STATION 9 ION CONTROL STATION WW 972 180 4 57 116 mm 15 10 UIMEJP no 67974 0 Se C0 LONWPAAIS ill 15 12 2007 Page CONTROL STATION INSTALLATION INSTRUCTION CONTROL STATION 15 6 4 Cut out drawing for SOLAS Instrument Panel STO TTT 5 63 143 mm N A o N E 2001007 0 4 September 2007 Page CONTROL STATION 11 CONTROL STATION INSTALLATION INSTRUCTION 15 6 5 Cut out drawing for SCC inch 5 63 143 mm inch 6 93 176 mm Page CONTROL STATION 12 Z001007 0 4 September 2007 INSTALLA
34. 1022 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 2 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 Z001007 0 4 September 2007 Page GENERAL INFORMATION 7 GENERAL INFORMATION INSTALLATION INSTRUCTION 2 6 SI SYSTEM The following units are used units of length km m mm ft yd le units of area m cm ft yd units of volume m cm dm mm ft yd units of measure t kg g units of force N kN daN electric units A V W uF fuel consumption g kWh kilometer meter millimeter inch foot yard line square meter square centimeter square foot square yard cubic meter cubic centimeter cubic decimeter cubic millimeter cubic foot cubic yard liter ton kilogram gram Newton kilo Newton deca Newton ampere volt ohm mikrofarad gram per kilowatt hour u
35. 286 0 zu pO 2001007 0 4 September 2007 Page DRILL TEMPLATES 35 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 36 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Jet Drive CASTOLDI 778 ca 137 Z001007 0 4 September 2007 Page DRILL TEMPLATES 37 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 38 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Stern Drive MERCURY BRAVO II amp 1033 Z001007 0 4 September 2007 Page DRILL TEMPLATES 39 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 40 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Stern Drive VOLVO DP 290 1033 Exhaust type R6 R4 V8
36. 4 September 2007 INSTALLATION INSTRUCTION VARIANTS ENGINE PROPULSION Jet Drive TYPE Alamarin Hamilton Castoldi Stern Drive TYPE TOUTES Mercury Alpha Bravo 18 III Volvo DP 290 DI Volvo DP 290 Hydraulic Seu SX Stern Drive For exact installation dimensions see chapter 17 Drill templates Z001007 0 4 September 2007 Page VARIANTS ENGINE PROPULSION 5 VARIANTS ENGINE PROPULSION INSTALLATION INSTRUCTION 4 2 VERSIONS FOR 6 CYL MARINE ENGINES Bobtail Version Equipment with side mounted raw water pump MC with side mounted raw water pump power steering pump and front mounted auxiliarv drive PTO Inborder i e ZF 63 Marine gear Down For exact installation dimensions see chapter 17 Drill templates Page VARIANTS ENGINE PROPULSION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION VARIANTS ENGINE PROPULSION E Transmission i 2 5V shaft angle 12
37. 6 32 lt 15 5 7 5 40 lt 20 6 9 50 40 lt 24 6 10 5 60 40 permanent pipe copper tube 3 8 outside diameter ill 12 1 From the suction side of the pump a copper tube or reinforced rubber hose is to be laid towards the keel Provide the suction pipe at its lower end with a relief valve and a screen the latter to permit easy cleaning The relief valve prevents a reflux of water of the permanent pipe in case of a damage on the pump wheel The bilge pump always should have constant water supply to avoid dry operation Connect the permanent pipe atthe delivery side of the pump Board lead in at the delivery side ofthe bilge pump should be at higher level as the permanent pipe connection Equipthe permanent pipe with a stop cock This cock must be closed with inactive engine Otherwise sea water may be pressed into the boat through the permanent pipe passing the bilge pump unless the suction pipe is provided with an effective relief valve At the lowest points of the pipes drain cocks are to be installed so that water can be drained in case of danger of frost To avoid pumping out of dirty water in the port or close to the beach install a cock on the suction pipe of the bilge pump If drainage is not required this cock should let pass the air onto the pum thus preventing that water is sucked in from the keel Z001007 0 4 September 2007 Page BILGE PUMPS 3 BILGE PUMPS INSTALLATION INSTRUCTION
38. Boat 15 515 9 Sediments a ee ce 15 5 15 10 Choice of Propeller 15 et 16 5 16 PROPELLER THRUST BEARING RESP STEP BEARING 16 Page ENGINE INSTALLATION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 ENGINE INSTALLATION After pre planning assembly of the engine usually begins with the engine base Then the stem bearings if available the step or thrust bearing and the propeller shaft are mounted After that the fuel tanks the water tanks with control device and the battery box are installed The engine is attached to the base and aligned in relation to the propeller shaft Then the exhaust pipes the air pipe to the engine the aeration pipes and the sound absorbing material for the engine compartment are mounted Manoeuvring apparatus instruments and electrical equipment are installed last After the final trial run a precise check with final inspection is to be carried out Test results to be noted 5 1 FOUNDATION The individual aggregates and parts ofthe marine propulsion unit must be aligned precisely to each other in order to guarantee a troublefree operation The distortion rigidity of the foundation should thus be to such an extent that ship distorsions due to motion of the sea or loading resp unloading ofthe ship are not transmitted onto the propulsion unit In addition the foundation mu
39. ER This is a standard card on which a dealer can keep his records Date of commissioning Type of Use O Govt O Pleasure Dealer Name Engine Model Serial Registration Trailer Vin No Rate Overall Quality of BOAT MOTOR Good n Acceptable 2179157 0 STEYRMOTORS WELCOME ABOARD YOUR GUARANTEE OF WARRANTY PROTECTION Present this card to your Authorized Dealer should you require warranty service It will assist you in obtaining service by verifying your ownership and date of purchase When in need of an Authorized Dealer to service your STEYR Product when away from home consult your Yellow Pages If no listing is available please call 0043 7435 501 0 or contact us on our e mail address office steyr motors com or through our homepage www steyr motors com lt gt U UJ 82 T 2 R 20 BD 5 m 9 So 53 ZI O m 70 2 2 gt o z a T p Q T E m mn e B B O N 4 lt D Di 2 A gt C D gt SSINISNE U S Q m 2 m C co g gt 2 lt Z001007 0 4 September 2007 Page APPENDIX 7 APPENDIX INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX 8 Z001007 0 4 September 2007
40. ES Drill templates scale approx 1 10 6 Cyl Marine Engine Inboard with ZF 63 marine gear Straight Shaft 1033 EL 5 8 n 1217 296 711 5 mm i DDT Q b rex ENSE i H 156 I 07 o ay svn IIA e i me P E 5 Z001007 0 4 September 2007 Page DRILL TEMPLATES 31 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 32 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Inboard with ZF IV marine gear V Drive 12 1033 WI m E N i TEC e AN 2001007 0 4 September 2007 Page DRILL TEMPLATES 33 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 34 Z001007 0 4 September 2007 669 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Marine Engine Jet Drive CASTOLDI 1033 296 568 286
41. FUEL SYSTEM 7 FUEL SYSTEM 7 1 GENERAL Assembly of the individual components of the fuel system must ensure an optimum sealing and fire resistance Before starting these works plan the location as well asthe type of fuel tanks Decide for a good quality in order to avoid a leakage of fuel on the cocks A leak fuel system always means the risk of trouble and fire The fuel quantity may be split upto several fueltanks thus keeping the center of gravity low and retaining certain trim potentials for the hull When installing the fuel tanks adequate room is to be provided with ventilation Connect filling fixture and tank with an impregnated cable unless being already connected electrically Also provide grounding of the tank When planning the assembly always try to store the tanks in a separate area in order to minimize as far as possible the risk of fire in case of an eventual fuel leakage For assembly of the fuel tanks proceed with greatest care to avoid leakage or water inlet STEYRMOTORS insistthat a water seperatoris fitted intothe fuel system beforethe fuel pump as drops of water in the fuel are ideal transporters of dirt and rust through narrow pipes One drop of water may cause a locking of the fuel pump thus cutting the fuel supply Particularly with diesel engines small deposits of dirt or rust may result in heavy damages on the injection pump and nozzles The water separator should be installed as close as possible to the
42. IONALLY BLANK Page DRILL TEMPLATES 20 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine 847 Jet Drive CASTOLDI 9 101 5 8 x M10 Klee 31 702 103 405 1210 Be 2001007 0 4 September 2007 Page DRILL TEMPLATES 21 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 22 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Jet Drive CASTOLDI 05 847 624 8 11 52 pe 24 ee r ii O 31 702 1210 780 Z001007 0_4_September 2007 Page DRILL TEMPLATES 23 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 24 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 6 Cvl Marine Engine Front view 55 8 with hydraulic pump 337 332 55 8 ET ORO Vi S SE Le 7 N ZA
43. LATION FORM INSTALLATION AND PRE DELIVERY INSPECTION LOG OWNER IDENDIFICATION CARD Z001007 0 4 September 2007 Page APPENDIX 1 APPENDIX INSTALLATION INSTRUCTION 18 APPENDIX NOTES Page APPENDIX 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION APPENDIX PROPPELER CALCULATION FORM B max LOA e LCG DNE Manufacturer of boat ss Own weight W MIN oaae aee eee kg Total weight W MaR e kg Over all length of boat COA aa m Length of boat over waterline Br C m Load centre of gravity endwise from transom LCG m Over all width of boat cep nee aus m Width of boat at water line led qM m Width of boat at transom 522 T Over all height of boat n m V angle boat centre E AU i V angle at transom ECC Engine models Nc ccm Gear Propeller Data Geartype RL Diameter inch Reduction of speed 1 P ch inch Shaft diameter _ mm Number of blades Slope of shaft Sense of rotation Cone Materia Costs contribution to propeller computation Euro 62 excl Z001007 0 4 September 2007 Page APPENDIX 3 APPENDIX INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page APPENDIX 4
44. NTS The flexible engine mounts provide proper insulation between engine and base frame thus reducing the noise conveyed to the hull This engine suspension may also absorb the thrust and shearing forces of the propeller A For all STEYR Marine Engine ill 5 10 bore dim bearing flange position of adjustment nut 5 mm adjustment space 5 mm spacer plate if required DOD Install the engine mounts directly onto the member of the base frame see ill 5 3 For an assembly with flexible engine mounts the overall height of the engine mounts is to be considered to achieve the proper installation height of the engine Height Adjustment recommended to achieve accurate alignment of the suspended unit When fitting mounts with height adjusters care must be taken to ensure that excessive bending forces are not imposed on the center spindle screw Mountings fitted with height adjusters are designed to allow a variation of 5 mm nominal mean height see illustration 5 mm distance between adjustment nuts Any larger variations need to be accommodated by fitting shims or packers under the mounting base Vertical and horizontal alignment should then be effected using the height adjusters and slotted holes in the mounting base Recheck alignment after fixings are tightened to the specified torque values nut center spindle screw 110 120 Nm Page ENGINE INSTALLATION 8 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE
45. RINE ENGINES 3 4 2 VERSIONS FOR 4 CYL MARINE ENGINES 6 Z001007 0 4 September 2007 Page VARIANTS ENGINE PROPULSION 1 VARIANTS ENGINE PROPULSION INSTALLATION INSTRUCTION 4 VARIANTS ENGINE PROPULSION NOTES Page VARIANTS ENGINE PROPULSION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION VARIANTS ENGINE PROPULSION 4 VARIANTS ENGINE PROPULSION 4 1 VERSIONS FOR 4 CYL MARINE ENGINES Bobtail Version Equipment with side mounted raw water pump with side mounted raw water pump power steering pump Inborder i e ZF 45 Marinegear Down angle Innenborder i e ZF 63 Marinegear AJ For exact installation dimensions see chapter 17 Drill templates Z001007 0 4 September 2007 Page VARIANTS ENGINE PROPULSION 3 VARIANTS ENGINE PROPULSION INSTALLATION INSTRUCTION Lifeboat Engine Equipment es Bobtail B Direkt gearbox c A down angle gear box Parallel offset gearbox For exact installation dimensions see chapter 17 Drill templates Page VARIANTS ENGINE PROPULSION 4 Z001007 0
46. RMATION INSTALLATION INSTRUCTION 2 GENERAL INFORMATION ON INSTALLATION NOTES Page GENERAL INFORMATION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 GENERAL INFORMATION ON INSTALLATION 2 1 WEIGHT DISTRIBUTION BALANCE It is important that the heavy components such as fuel tanks water tanks and batteries are installed in such a way that the best possible planing position of the boat will be kept Of course the optimum gliding position differs from boat to boat but the best possible weight distribution balance should always be the aim ATTENTION ON ACCOUNT OF THE RISK OF EXPLOSION AND FIRE THE FUEL TANKS A BATTERIES AND ENGINES ARE TO BE PLACED IN WELL VENTILATED COMPARTMENTS SEPARATED FROM EACH OTHER MORE DETAILS WILL FOLLOW 2 2 ACCESSIBILITY During assembly of the engine take greatest care as to accessibility for service works An easy exchange of pump wheels oil filters air filters water filters fuel filters V belts etc must be guaranteed ATTENTION THERE SHOULD ALSO BE ADEQUATE SPACE FOR SOUND ABSORBING A MATERIAL DIMENSIONAL DRAWINGS OF THE RELEVANT ENGINE MAY BE FOUND IN THE FOLLOWING CONTENTS Z001007 0 4 September 2007 Page GENERAL INFORMATION 3 GENERAL INFORMATION INSTALLATION INSTRUCTION 2 3 DISPLACEMENT OF WATER In orderto determin
47. STEYRMOTORS INNOVATION WITH LIGHTNESS STEYR MARINE ENGINES 4AGX LINDEI wu Ri 6 f INSTALLATION INSTRUCTION P N Z001007 0 4 Edition September 2007 WWW steyr motors com STEYRMOTORS PREFACE INNOVATION WITH LIGHTNESS 4 There two main purposes in publishing this book a To assist in the selection of suitable engines and auxiliary equipment for marine craft b The provide information in the form of technical data and installation know how built up from our marine diesel engine business enabling 4 amp 6 Cyl STEYR MARINE engines of series to be installed in a manner which will ensure safety reliability and ease of servicing Make sure to comply with all laws and regulations valid in the country of operation and for the respective type of boat It is particularly important too to ensure that the engine installation complies with the Health and Safety Legalisation of the country of intendad operation Before starting work make a detailled planning use true scale drawings and consider all assembly data available To guarantee a proper function of the engine and its built on parts the correct installation is of utmost importance These works are to be carried out with greatest care Make sure prior to assembly that true scale drawings and installation data are available which will enable you to realize a satisfactory technical pre planning and installation The en
48. T GENERAL de aun Oa UD err 3 Z001007 0 4 September 2007 Page AUXILIARY PROPULSION 1 AUXILIARY PROPULSION INSTALLATION INSTRUCTION 10 AUXILIARY PROPULSION NOTES Page AUXILIARY PROPULSION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION AUXILIARY PROPULSION 10 AUXILIARY PROPULSION PTO 10 1 GENERAL STEYR Marine engines optionally may be equipped with an auxiliary propulsion atthe front end ofthe crankshaft See ill 10 1 and 10 2 Max decline of output of the auxiliary propulsion is limited however See chart engine outside diameter propulsion of belt pulley max output on crankshaft 4 i 5 3 135 mm 100Nm 28 3kW Engine at 2700 rpm 6 6 5 165 mm 100Nm 28 3kW Engine at 2700 rpm 4 Cyl Engine 6 Oyl Engine ill 10 1 ill 10 2 Z001007 0 4 September 2007 Page AUXILIARY PROPULSION 3 AUXILIARY PROPULSION INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page AUXILIARY PROPULSION 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION SAFETY COVERS 11 SAFETY COVERS TABLE OF CONTENTS 1 14 la GENERAL a 3 2001007 0 4 September 2007 Page SAFETV COVERS 1 SAFETY COVERS INSTALLATION INSTRUCTION 11 SAFETY COVERS NOTES Page SAFETY COVERS 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION SAFETY COVERS 11 SAFETY COVERS 11 1 GENERAL All rotating shafts
49. TION 9 ENGINE INSTALLATION INSTALLATION INSTRUCTION 5 10 ELASTIC SHAFT COUPLING For engines with elastic suspension and a rigid stem bushing an elastic shaft coupling is always to be mounted Even for a rigid engine suspension an elastic propeller shaft coupling should be mounted if there is any risk that the engine may change its position with regard to the propeller shaft e g with different load of the boat Never use the elastic shaft coupling together with the elastically supported stem bushing This may result in heavy vibrations Elastic engine suspension and elastically supported shaft bushing may however be used without elastic coupling Engines provided for operation under heavy conditions e g way through ice are always to be equipped with elastic propeller shaft coupling A special thrust bearing for the propeller shaft is also to be mounted The elastic coupling should be situated between reversing gear and thrust bearing to avoid tensions between the parts 5 11 STEP BEARING If the distance between the supports a in ill 12 and 13 exceeds 6 1 2 ft 2 step bearing is to be mounted The correct distance between the step bearing and the engine is of utmost importance which requires a computation of vibrations Examples Elastic engine suspension elastic stem tube and bearing at 8 for reversing gear
50. TION CONTROL STATION 15 CONTROL STATION TABLE OF CONTENTS 15 1 CONTROL STATION 24 2 224 2 3 15 2 CONTROL SYSTEMS rame 3 15 2 1 Mechanical Controlla 3 15 2 2 Hydraulic Control 4 15 2 3 Electronic Control ee 4 15 3 CONTROL LEVERS ii 5 15 3 1 Kinds of Control Levers ss 6 15 3 2 Possible Functions of Control Lever 6 15 4 CONTROL CABLE er 6 15 5 TIWIN CONTROLS TATIONS dl 7 15 6 TWIN INSTRUMENT PANELS 2 4 22242222 8 15 6 1 Scheme for second instrument 2 2 4 2 8 15 6 2 Scheme for instrument panel and SCC 9 15 6 3 Cut out drawing for STANDARD Instrument panel 10 15 6 4 Cut out drawing for SOLAS Instrument panel 11 15 6 5 Cut out drawing for SCC eese 12 Z001007 0 4 September 2007 Page CONTROL STATION 1 CONTROL STATION INSTALLATION INSTRUCTION 15 CONTROL STATION NOTES Page CONTROL STATION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CONTROL STATION 15 CONTROL STATION 15 1 CONTROL STATION GENERAL The design of the control station should enable a functional placement of operating elements boat control instruments navigation equipment and alarm system That applies for both single and twin control stations
51. TION INSTRUCTION ELECTRICAL EQUIPMENT 16 ELECTRICAL EQUIPMENT TABLE OF CONTENTS 10 GENERAL ll 3 16 2 aan 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 eere 6 16 6 CABLE CROSS SECTION eene 6 Z001007 0 4 September 2007 Page ELECTRICAL EQUIPMENT 1 ELECTRICAL EQUIPMENT INSTALLATION INSTRUCTION 16 ELECTRICAL EQUIPMENT NOTES Page ELECTRICAL EQUIPMENT 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ELECTRICAL EQUIPMENT 16 ELECTRICAL EQUIPMENT 16 1 GENERAL Cable laying is to be planned and carried out precisely and carefully Cables must be approved for marine operation Pull the cables through appropriate protective sleeves to be fixed properly Make sure that cables are not too close to hot parts of the engine Cables must not be exposed to mechanical wear and mechanical abrasion If necessary pull the cables through protection tubes Attention Never fix a cable in such a way that it could lay in bilge water 16 2 BATTERIES Install the batteries in a battery box situated low in the boat to avoid leaking of battery acid due to motion of the sea Provide easy access to the box for servicing the batteries as well as proper ventilation as the batteries generate small amo
52. TION OF AIR E 6 Z001007 0 4 September 2007 Page AIR INTAKE AND VENTILATION 1 INSTALLATION INSTRUCTION 9 AIR INTAKE AND VENTILATION NOTES Page AIR INTAKE AND VENTILATION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION AIR INTAKE AND VENTILATION 9 AIRINTAKE AND VENTILATION 9 1 GENERAL Power of the engine is influenced by a number of different factors The most important ones are air pressure air temperature and exhaust gas counterpressure In case of large deviations from the standard values the diesel engine also loses power This loss can even be to such an extent that a planing boat cannot plane To guarantee a proper function of the engine and its full power it is vital that the supply and exhaust air ducts are designed large enough and functionally Two main demands are to be fulfilled 1 Sufficient supply of air oxygen to the engines in order to ensure a fuel combustion without residues 2 Ventilation of the engine compartment to keep the temperature level in the compartment low An adequate ventilation also improves the operating conditions for the whole eletrical equipment of the engine ATTENTION If people are in the engine compartment the ventilation is to be adapted Local safety rules and legal regulations are to be followed 9 1 Example for air inlet and ventilation of engine on sport boats and similar applications 1
53. TY DIRECTIVES INSTALLATION INSTRUCTION 3 QUALITY DIRECTIVES FOR ASSEMBLY NOTES Page QUALITY DIRECTIVES 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION QUALITY DIRECTIVES 3 QUALITY DIRECTIVES FOR ASSEMBLY For the assembly of spare parts the manufacter s instructions as well as legal regulations are to be considered If repaired components or units are used as spare parts the machining directives of the manufacturer are to be kept Safety components are components which due to a change of their initial form their surface and material resistance will no more guarantee operating reliability and traffic safety and may cause considerable material damage or even personal damage Such components may only be repaired or assembled if all testing and measuring instruments required for determination of component quality resp proper conditions of installation are guaranteed Model depending units and parts are components which are subjectto approval in the course of standardization of the boat Their failure means a risk for traffic safety Parts subject to design approval are components which are of particular importance for traffic safety and operating reliability and which are approved with regard to their effectiveness irrespective ofthe vehicle In case of an exchange such components may be replaced by design approved parts only 3 1 SPECIFICATION OF SPARE PARTS Your STEYR diesel engine with direct fuel injection has
54. Z001007 0 4 September 2007 INSTALLATION INSTRUCTION APPENDIX INSTALLATION AND PRE DELIVERY INSPECTION LOG ENGINE NO Boat Owner mE 5 C c Dealer E rie EI GE ele e EE Manual warranty and operation explaine yes Safeguarding instruction carried out vesl DOSES E Model No seen Dimension of propellers Boat length ___ m Transmission Boatweight kg Gear reduction _ Enginetype Driving uni Engine model Serial number Level of operating fluids motor gear hydraulic cooling agent checked yes Measuring data with rated power Motor oil pressure _ bar Max boat speed Engine coolant temperature C Max engine Exhaust gas raw water temperature Cross sect air intake duct eng comp cm Fuel rate of flow idle run Temperature engine compartment C measured from return line l min Boost pressure at max rpm mbar Idle speed rpm Exhaust backpressure mbar Name
55. a filter of special size The minimum flow of the filter is 140 l min 6 6 COOLING WATER PIPES EXHAUST CONNECTION All STEYR MOTORS MARINE Diesels are equipped with a water cooled exhaust gas elbow as shown on ill 6 5 At the exhaust gas muzzle the raw water is injected into the tail pipe for cooling of the exhaust gases When designing the exhaust elbow particular importance was attached to a relatively high exhaust duct in orderto avoid the entering of back wash In the adjoining exhaust pipe a splash flap is to be installed in addition In case of insufficient difference in level between exhaust gas outlet and sea water surface boad loaded a high riser exhaust elbow optional is to be installed See section 8 Exhaust System exhaust gas elbow connecting piece splash flap tail pipe with flange DAWN ill 6 4 ill 6 5 Z001007 0_4_September 2007 Page COOLING SYSTEM 5 COOLING SYSTEM INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page COOLING SYSTEM 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION FUEL SYSTEM 7 FUEL SYSTEM TABLE OF CONTENTS T GENERAL aan aan 3 1 2 FUEL TANI Siria 4 1 2 MATERIALS 5 7 4 TWIN FUEL TANKS a eege EES 5 7 5 FUEL PIPES D ae 5 Z001007 0 4 September 2007 Page FUEL SYSTEM 1 FUEL SYSTEM INSTALLATION INSTRUCTION 7 FUEL SYSTEM NOTES Page FUEL SYSTEM 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION
56. air inlet water separator 4 sound absorbing engine compartment effective surface see chart see section insulation 2 air pipes dimensions see chart 5 outlet for exhaust air with inactive engines 3 sound absorber see section insulation For running engines air will be sucked in at In the sound absorber no restriction may 1 and 5 Cross section as for 1 occur Inner distance between walls 6 sound absorbing hatches pipe diameter Z001007 0 4 September 2007 Page AIR INTAKE AND VENTILATION 3 AIR INTAKE AND VENTILATION INSTALLATION INSTRUCTION 9 2 ENGINE POWER AND AIR TEMPERATURE Indicated engine power is based on an air temperature of 25 C an atmospheric pressure of 997 mbar relative atmospheric moisture of 30 a fuel temperature of 20 C and a sea water temperature of 25 C acc to test standards Pay particular attention to good air supply and ventilation to achieve engine power and life as high as possible If the intake air of the engine cannot be kept below 40 C the power of turbo engines with boost intercooling will drop for up to one percent per 10 C rising engine temperature 9 3 CALCULATION OF AIR INLETS AND DUCTS Planning of an engine system should consider the following basic facts All internal combustion engines irrespective of trade mark ortype require a certain min quantity of oxygen air for their combustion process However Diesel engines operate with a little more excess air than
57. arers are parallel to the centre line ofthe propeller shafts and are not swung For assistance during assembly and checking ofthe engine base a short traversing slide with the same diameter as the propeller shaft may be used stern sided see ill 5 8 Through a bore 1 12 2mm diameter in the slide a 1 12 2 mm copper wire is strained to a holder Then adjust the holder in such a way that the wire is in the centre of the front end of the propeller shaft sleeve Then measure the base bearers and check their correct height and that they are not swung ill 5 8 checking of engine base 2 1 steel rulers 4 copper wire 2 5 holder with chuck 6 stem tube 3 traversing slide dimensions distance engine base surface propeller shaft centre correspond to respective shaft depending on type of engine and reversing gear Size Z001007 0 4 September 2007 Page ENGINE INSTALLATION 7 ENGINE INSTALLATION INSTALLATION INSTRUCTION 5 8 PROPELLER SHAFT FLANGE At delivery the flange to the reversing gear is rough drilled only The bores are to be made with utmost accuracy and have to correspond to the guiding edge on the flange Max admissible radial stop 0 05 mm ill 5 9 In many cases it is recommended to bore the coupling flange to the reversing gear with the same conicity as for the propeller Thus the shaft will be equal on both ends and can therefore be turned in case of being worn out in the stem bearing 5 9 ENGINE MOU
58. been designed for high output Only use GENUINE STEYR spare parts to avoid any loss of efficiency You therefore should insist on the known quality of GENUINE STEYR spare parts and should never use parts of unknown quality Chapter 17 appendix contains a proposal on spare parts 3 2 WORKSHOP PROFILE Irrespective of the individual repair steps and legal regulations the workshop should meet the following requirements clean dry and dust free ambiency lifting device crane with a carrying capacity of at least 5 000 N cleaning accomodation washbasin for contaminated components tool pertaining to commercial customs proper testing and measuring appliances collecting trays for fuel and oil Depending on the repair step to be carried out tools according to the TOOL catalogue are to be procured In addition procurement and stock of required fuel and oil spare and wear parts e g seals filters anodes is to be considered For authorized dealers and workshops a minimum standard as to tools of stage service tools is required Z001007 0 4 September 2007 Page QUALITY DIRECTIVES 3 QUALITY DIRECTIVES INSTALLATION INSTRUCTION 3 3 ASSEMBLY OF PLUG CONNECTIONS 3 3 1 Plug connections for steel tube For tubes with an outside diameter up to 10 mm it is recommended to screw the relevant sockets of the plug connections into the respective devices and to carry out assembly of the piping on the ins
59. bv brazing The best solution is however a flanging of pipes Well tighten the fuel pipes on planks or rigid supports to avoid vibrations or pipe fracture Page FUEL SVSTEM 6 2001007 0 4 September 2007 INSTALLATION INSTRUCTION EXHAUST SYSTEM 8 EXHAUST SYSTEM TABLE OF CONTENTS DR GENERAL lai 3 B MA TERRES REESE AAEE EAE EE 3 8 3 DRY EXHAUST PIPE eege 3 8 4 WET EXHAUST PIPE ii EEE EEEE SERE 4 8 5 DIMENSIONS EXHAUST PIPE iii cx 5 8 6 CONDENSED WATER COLLECTOR 5 8 7 MEASUREMENT OF COUNTERPRESSURE ne 6 Z001007 0 4 September 2007 Page EXHAUST SYSTEM 1 EXHAUST SYSTEM INSTALLATION INSTRUCTION 8 EXHAUST SYSTEM NOTES Page EXHAUST SYSTEM 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION EXHAUST SYSTEM 8 EXHAUST SYSTEM 8 1 GENERAL Install the exhaust line with as few as possible bends and as high as possible curve radius Provide sufficient pipe diameter to keep the backpressure within admissible values see 8 7 The exhaust system may be designed in 3 different ways 1 Dry exhaust pipe insulated 2 Wet exhaust pipe water flow in the pipe 3 Exhaust pipe with water jacket double walled water cooled The dry exhaust pipe releases large amounts of heat into the engine compartment thus requiring good insulation The wet exhaust pipe and the exhaustpipe with a water jacket are cooled and therefore mostly
60. d min 9 m min Total pressure rise by the blast should be 3 8 wc 10 mm WS 100 Pa Based on these two values air volume flow and total pressure rise the blast may be chosen 9 10 FUNCTION OF AIR INLETS Satisfactory function of air inlets and air outlets must also be guaranteed with bad weather conditions They should have water guards and normally sound insulation too Distances between air inlets and air outlets should be as long as possible Provide for a good air flow Attention If the distance between inlet and outlet is too short the air may circulate which results in a bad ventilation effect 9 11 POSITION OF AIR PIPES Lay the pipes for air supply of the engine up to the air filter s side but with a lateral distance of 8 12 20 30 cm to absolutely avoid any entering of water into the engine Airinlets and air outlets must never be installed in the stern transom In this area the air is mixed with water and exhaust gases and therefore never may be conducted into the boat For Diesel engines the air supply pipes should end at low level in the engine compartment but not too low to cause a fluidity stop brackish water which chokes the air supply Exhaust air pipes are to be provided diagonally on the opposite side of the engine Page AIR INTAKE AND VENTILATION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION AUXILIARY PROPULSION 10 AUXILIARY PROPULSION PTO TABLE OF CONTENTS
61. do not need insulation The water flow in the exhaust pipe also has a noise absorbing effect 8 2 MATERIALS Exhaust gases from a Diesel engine also contain sulfur compounds which mixed with water may corrode the metals For this reason copper tubes are unsuited for exhaust pipes Exhaust pipes with cooling jackets are to be made of acidproof steel tubes to guarantee satisfactory service life In case of water inlets into the exhaust pipe the line may be made completely or partially of special exhaust rubber hose Dry exhaust pipes are preferably made of acidproof steel tubes Pipess made of stainless or galvanized steel tube also guarantee a relatively satisfactory service life 8 3 DRY EXHAUST PIPE Scheme of a dry exhaust pipe for 2 engines ill 8 1 2001007 0 4 September 2007 Page EXHAUST SVSTEM 3 EXHAUST SYSTEM INSTALLATION INSTRUCTION 8 4 WET EXHAUST PIPE Wet exhaust pipes for turbo engines are designed according to III 8 2 All rubber hoses are to be connected at each end by 2 corrosion resistant hose clamps ill 8 2 wet exhaust pipe with muffler TWIN MI 236 TD example 1 wet exhaust elbow 5 board lead in with rubber expansion 2 exhaust rubber hose piece sealing the bore in the boat 3 water cooled muffler transom 4 exhaust pipe bend over water line 6 bore diameter in boat transom 5 0 5 line 127 1 mm With all kinds of exhaust pipes assembly is always to be done avoiding the enteri
62. e assembly parts and remains fluid as long as it is intouch with the ambient air oxygen Only as soon asthe parts are assembled the chemical reaction the transformation of fluid into a synthetic built up by molecular chains begins through exclusion of atmospheric oxygen and through metal contact Any surplus remaining after assembly or being forced out of the connection remains fluid and can be removed easily Z001007 0 4 September 2007 Page QUALITY DIRECTIVES 9 QUALITY DIRECTIVES INSTALLATION INSTRUCTION 3 8 1 General Directions for Use of Aanaerobic Sealing Materials Cleanliness of components Non metallic surface protection must be removed In case of repair works soiled and oily components are to be cleaned and residues of adhesive synthetic are to be removed Tapholes are recut with an appropriate tap and blown off with compressed air If solvents or degreasing agents are used for cleaning make sure that they have volatilized before application of the synthetic Storage At temperatures below 28 C 1 year minimum Directions for securing S Indication SM Medium tight Securing the connection can be loosened without problems Indication SF Tight Securing the connection is difficult to loosen Application Screw joints Fixing procedure In general it is sufficient to apply the synthetic on the screw thread If screws are screwed into socket threads only wet the taphole in order to let the air
63. e is sprayed or coated with a penetrating agent and after drying a developer is sprayed on After a development period of approx 10 min defects on the workpiece appear as points or lines 3 7 USE OF ADHESIVE AND SEALING MATERIALS The workshop manuel names adhesive and sealing materials for the repair of engines and aggregates which may be used at operating temperatures up to 150 and with mediums such as water cooling and hydraulic liquids engine and transmission lubricants as well as fuels Solvent free sealing material Hardening without loss in volume tightening of screw joints hence not required Anaerobic sealing materials are used for securing fixing and sealing and will only harden with exclusion of air Sealing material containing solvent Their volatile ingredients will cause loss of volume during hardening For repair works their exhaust period is to be considered If such sealing material is used the workshop manual will contain a particular reference 3 8 SOLVENT FREE SEALING MATERIALS Silicon sealing materials consist of silicon and fillers and are solvent free From the tube or cartridge the product is applied in a straight line on the cleaned surface Residues of sealing material are removed by means of cleaning agent Silicon sealing material is to be stored at temperatures below 30 C Anaerobic sealing materials consist of single component synthetic in fluid form The product is applied on th
64. e the displacement of water of a boat the weight of the boat should if possible be measured If this is not possible and if there is also no model of the hull with the boatbuilder a computation is to be made Before beginning computing the position of the water line should be checked on different points of the hull and this with normal boat loading since every change in weight has a strong effect on the speed of the boat At first subdivide the hull into different sectors Overlapping of the individual sectors with the actual waterline will result in different fields with different volumes and by adding these volumes the displacement of water can be calculated For the accuracy of calculation the number of subdivisions is determining e g Simpson s First Rule Murphys Law The displacement of water can also be determined by the BLOCK COEFFICIENT which however is more inaccurate In this case the difference between the volume ofthe keel andthat of a body which intersects the outer edges of the boat is determined But in practice it is very difficult to compute the volume of the keel 2 3 1 Examples for the Block Coefficient By means of the BLOCK COEFFICIENT the displacement of water can be estimated for every type of boat The value in ill 14 refers to a section of the hull at the widest spot Block Coefficient Cb 0 35 bis 0 40 Block Coefficient Cb 0 4 bis 0 45 Block Co
65. ed in a separate pamphlet Computation and determination ofthe propellersize may also be done by STEYR Motorentechnik claim in time together with drawing Consider a sufficient distance between propeller hull keel stem tube and oar To permit a dismantling of the reversing gearorthe coupling a sternward displacement of the propeller shaft for at least 8 200 mm should be possible Also take care that no transept bulkheads do interfire with dismantling Between propeller and stem bearing a min distance of 1 25 mm isto be kept in orderto preventthe propeller from bucking against the stem bearing Before mounting the shaft its straightness is to be controlled Check by means of a dial gauge that the shaft flanges do not twist Max admissible axial fault 0 1 mm Before launching the boat make sure that a propeller with correct pitch and diameter has been mounted Also check that the propeller shows the correct thread R or L for the provided sense of rotation The exact alignment ofthe whole drive unit onthe foundation is a condition fortroublefree operation On principle assembly and alignment is done in the order driving shaft engine Flange connections and couplings even elastic ones must be released when aligning the parts connected For elastic couplings followthe manufacturer s instructions For alignment of the parts to be mounted a dial gauge with suitable holder and eventually a thickness gauge will be necessary Alignment always
66. efficient Cb 0 45 bis 0 55 Block Coefficient Cb 0 55 bis 0 65 um Block Coefficient Cb 0 75 bis 0 95 Page GENERAL INFORMATION 4 Z001007 0_4_September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 4 SAFETY IN DEALING WITH FUEL AND OIL Dangerous materials according to accident prevention are all explosive fire provoking easy flammable poisonous injurious to health and corrosive materials In particular cleaning gasoline mineral oil battery acid antifreeze varnish and dilutions solvent In case of fire of such materials do not extinguish with water Use carbon dioxide extinguishers or powder extinguishers Notify the fire department In case of spilling such materials e g while refueling these are to be absorbed with sand earth or suitable binding agents and to be eliminated A Attention To avoid health troubles the following items are to be considered 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 Never put such materials into drinks bottles Z001007 0 4 September 2007 Page GENERAL INFORMATION 5 GENERAL INFORMATION INSTALLATION INSTRUCTION 2 5 LIST OF FUEL AND OIL Ord
67. eptember 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Bobtail without coupling 847 624 8 24 20 759 31 702 550 0 i WI H 3 ___ STEYR o ell 8 dA U 0 520 1407 2001007 0 4 2007 Page DRILL TEMPLATES 5 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine Inboard with ZF 45A marine gear Down angle 8 759 650 3 D re wa 9 L 149 di 8 1 STEYR ei id 9 dA Uj 2 2001007 0 4 September 2007 Page DRILL TEMPLATES 7 DRILL TEMPLATES INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page DRILL TEMPLATES 8 Z001007 0 4 September 2007 759 INSTALLATION INSTRUCTION DRILL TEMPLATES Drill templates scale approx 1 10 4 Cyl Marine Engine 847 62 8 24 26 e O O Tunnel Drive SARO E 1 li 2 i c ca 90 110
68. er 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 2011785 0 3 STEYR MOTORS engine coolant 5l can 9000190 0 2 hydraulic oil ATF 11 bottle 2012222 0 1 grease Never Seez 5 160 B 1 kg can 2909570 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 9000298 1 1 surface sealing 5900 300 ml cartridge 9000019 1 1 construction adhesive 620 50 ml flask 9000017 1 1 construction adhesive 262 50 ml flask 2010207 0 1 contact grease 100 ml tube 2010226 0 1 corrosion protection spray 400 ml can 2010227 0 1 corrosion protection wax 120 ml can Z010084 0 1 grease STABURAX NBUA 1 kg can 2010205 0 1 fuel rust protection additive 5 It can 9000197 0 1 electric contact spray 2011627 0 1 silver varnish RAL 9006 1 It can 2010074 0 1 hardener varnish 0 5 It can 2010075 0 1 dilution for varnish 5 It can Page GENERAL INFORMATION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 5 1 Manuals 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 amp warranty manual for all marine engines P N Z 00
69. escape during screwing Screws or nuts to be tightened with a specified torque are slightly oiled on their contact surface or housing section Directions for fixing B Indication BM Medium tight Fixing Indication BF Tight Fixing Application Joint connections sleeves gear wheels pulleys bearings etc Jointing procedure For jointing connections both jointing parts are to be wetted Wetting should completely cover the jointing surfaces In case of sliding fits the parts are encased by turning No strength may be exerted to the connection until sturdiness is reached for duration see table 1 Directions for sealing D Indication DR Sealing of pipe joint connections Indication DF Sealing of plane surfaces Application Sealing of threads screwings joint connections and plane surfaces Hardening time Use Securing Sealing Class SM SF BF DR DF DF Product Loctite 243 Loctite 262 Loctite 648 Loctite 572 Loctite 510 Loctite 620 Handtightness 15 30 min 15 30 min 5 10 min 15 30 min immediately immediately reached after Functional tightness reached after 1h 1h 1h 0 5 h immediately immediately Final tightness 3h 3h 4h 12 24h 24 h 12 24h reached after Page QUALITY DIRECTIVES 10 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION VARIANTS ENGINE PROPULSION 4 VARIANTS ENGINE PROPULSION TABLE OF CONTENTS 4 1 VERSIONS FOR 6 CYL MA
70. exact installation dimensions see chapter 17 Drill templates Page VARIANTS ENGINE PROPULSION 8 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 ENGINE INSTALLATION TABLE OF CONTENTS 5 1 FOUNDATION i m 3 5 2 POWER TRANSMISSION sn 3 02 3 5 2 2 Universal Joint Shafts rr 4 5 3 ee 5 5 3 1 Engine Base on Synthetic Boats 5 5 4 SPACE FOR MAINTENANCE ci 5 5 5 ENGINE INGLINATIO Mini 6 5 5 LIFTING EYES i i 7 5 7 CHECKING OF ENGINE kimiki kinetika 7 5 8 PROPELLER SHAFT FLANGE ina 8 5 9 ENGINE SUSPENSION E 8 5 9 1 Adjustment of Engine on flexible engine supports 9 5 10 ELASTIC SHAFT COUPLING ii 10 S IIL SIEP BEARING EE 10 5 12 ADJUSTMENT OF ENGINE DRIVE 11 5 18 IWININSTALLATION ammi 12 5 14 SHAFT AND STEM TUBE iii ek ji ei i 12 M PROPELLER ln 13 Z001007 0_4_September 2007 Page ENGINE INSTALLATION 1 ENGINE INSTALLATION INSTALLATION INSTRUCTION 5 ENGINE INSTALLATION TABLE OF CONTENTS 515 1 DIMENSIONS lla 13 5 15 2 Propeller pitch 13 5 15 3 Blade Surface 14 5 15 4 Sense of ROTATION esse ee 14 5 15 5 Of leese 14 5 15 6 Axle A0 14 5 15 7 Adjustment of Propeller Pitch 14 5 15 8 Space between Propeller and
71. gine compartment is to be designed in such a way that maintenance work on the engine will not be impeded Consult the Operating Manual of the engine and the drawings There should also be enough space to permit an inward and outward lifting of the engine The installation is to be done in such a way that the engine is easily accessible for regular routine and maintenance works in order to avoid unnecessary maintenance costs for the owner Product description illustration and technical data When reference is made in this manual to a brand name a product number a product or specific tool an equivalent product may be used in place of the product or tool referred to unless specifically stated otherwise To exclude any possible danger the operator has to provide for respective safety precautions data illustrations and specifications in this manuel are based on the latest product data available at the time of printing But it cannot be guaranteed that this manual will always be up to date Revised versions with a later date of edition will replace all previous editions Warranty This may be invalidated if the engine is not installed or operated maintained according to STEYR MOTORS instructions 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 mode
72. h aspiration liquid reaches the lung VOMIT SHOULD NOT BE STIMULATED IMMEDIATELY SEE THE NEAREST DOCTOR Z001007 0_4 September 2007 Page GENERAL INFORMATION 11 GENERAL INFORMATION INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page GENERAL INFORMATION 12 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION QUALITY DIRECTIVES 3 QUALITY DIRECTIVES FOR ASSEMBLY TABLE OF 5 3 1 SPECIFICATION OF SPARE PARTS eene 3 3 2 WORKSHOP PROFILE E 3 3 3 ASSEMBLY OF PLUG CONNECTIONS is 4 3 3 1 Plug connection for steel tube 4 3 3 2 Plug connection for plastic tube 4 3 3 4 Checking of plug connections eese 5 3 3 5 Assembly of Raufoss plug systems 5 3 3 6 Sealing of screwed pipe joints 5 3 3 7 Tightening te UE 6 2 28 IPiperelavin 7 3 4 TIGHTENING TORQUES me mme 8 3 5 CHECKING OF TORQUE WRENCH cca 9 3 6 NONDESTRUCTIVE TESTING OF MATERIALS 9 3 7 USE OF ADHESIVE AND SEALING MATERIALS 9 3 8 SOLVENT FREE SEALING MATERIALS 9 3 8 1 General directions for use 10 Z001007 0 4 September 2007 Page QUALITY DIRECTIVES 1 QUALI
73. ion ofthe flywheel should be 3 at least Such an installation with inverted engine occurs with a miter gear During course A may be upto 3 larger and B up to 3 smaller the stern is lower Maximum engine inclination for assembly ill 5 5 max inclination 4 amp 6 Cyl in A 102 10 C 10 GR Page ENGINE INSTALLATION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 6 LIFTING EYES To permit an easy lifting of the engine strong lifting eyes are provided bow and stern sided See ill 5 6 u 5 7 4 Oyl Engine 6 Cyl Engine ill 5 7 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 Do not lift the engine from any single lifting point damage to the engine or personnel injury could accrue When having to tilt the engines for installation use an adjustable load leveler to aid in installation 5 7 CHECKING OF ENGINE BASE When preparing the engine base make sure that the upper contact surfaces of the be
74. llector with a cock or a drain plug at its bottom Min diameter of the condensed water collector should be 1 25 mm and its length 12 300 mm 8 7 MEASURING OF BACKPRESSURE After assembly of the exhaust system always check the backpressure most simply by a pressure gauge connected by means of an adaptor instead of the temperature sensor for exhaust raw water Measuring is then to be done with nominal capacity of the engine The max admissible exhaust backpressure for STEYR Marine Engines 15 100 mm WS lt 100 mbar WS 7 water column Exhaust backpressure lt 100 mbar no loss in efficiency gt 200 mbar loss in efficiency gt 300 mbar not acceptable Page EXHAUST SYSTEM 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION AIR INTAKE AND VENTILATION 9 AIR INTAKE AND VENTILATION TABLE OF CONTENTS Sl IENERAL li 3 9 2 ENGINE POWER AND AIR TEMPERATURE 4 9 3 CALCULATION OF AIR AND DUCTS nem 4 9 4 PIPES FOR SUPPLY AIR AND EXHAUST 4 9 5 TEMPERATURE IN ENGINE COMPARTMENT 4 9 6 CROSS SECTION AIR CONSUMPTION OF ENGINE 4 9 7 CROSS SECTIONS VENTILATION OF ENGINE COMPARTMENT scissa sancta 5 9 8 FANS e 5 9 9 CHOICE OF BLAS i A 6 9 10 FUNCTION OF AIR INLETS nennen nnn 6 9 11 POSI
75. ls and also to discontinue certain models STEYR MOTORS GmbH also reserves the right to change any technical data or components at any time without incurring any obligation to equip same on models manufactured prior to the date of such change Z001007 0 4 September 2007 STEYRMOTORS INNOVATION WITH LIGHTNESS PREFACE 10 11 12 13 14 15 16 17 18 GENERAL GENERAL INFORMATION ON INSTALLATION QUALITY DIRECTIVES FOR ASSEMBLY VARIANTS ENGINE PROPULSION ENGINE INSTALLATION COOLING SYSTEM FUEL SYSTEM EXHAUST SYSTEM AIR INTAKE AND VENTILATION AUXILIARY PROPULSION SAFETY COVERS BILGE PUMPS CABIN HEATING NOISE ATTENUATION CONTROL STATION ELECTRICAL EQUIPMENT AND INSTRUMENTS DRILL TEMPLATES APPENDIX Z001007 0 4 September 2007 STEYRMOTORS INNOVATION WITH LIGHTNESS VERSIONS OF MANUAL Version Date Modification 1 0 01 11 1998 First edition 2 0 01 03 1999 Modification 3 0 01 04 2006 Modification 4 0 01 09 2007 Modification Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL 1 GENERAL The installation of a marine engine is a very comprehensive task to be carried out with greatest care and attention Before beginning plan the execution and the works very carefully There should be space for the following components Control manoeuvring apparatus instrument panel with laced wiring harne
76. luminum sheet 0 5 line 3 flame proof reflecting sound 1mm perforation 2096 absorbing foil ferruginous PVC thickness 1 10 2 5 mm 1596 of the engine sided surface to be provided with absorbing mat Noise absorbing material on ill 14 5 shows a construction for extremely high insulation requirements also containing a lead sheet layer This construction is very stable and is also recommended for engine compartments the walls of which are for different reasons weaker than recommended Under the same conditions as shown on ill 14 5 one single layer of a flame proof insulating mat e g Porolon Revertex Acoustics or Barifoil may be glued directly onto the inner side of the engine protection This noise absorbing material will in many cases be sufficient Use contact glue Such material requires little space and is easy to handle All surfaces to be glued must be completely grease and moisture free to achieve and maintain good adherence Many different noise absorbing materials are available on the market but only materials meeting the current requirements as to fire protection and noise reduction may be used Finished noise absorbing mats with absorbing layers for soundproofing are also available on the market Z001007 0 4 September 2007 Page NOISE ATTENUATION 5 NOISE ATTENUATION INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page NOISE ATTENUATION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUC
77. many different lengths Cables should not be shortened or extended respectively connected piece by piece Cables for reversing gear and engine normally have different lengths These lengths are to be considered and or measured exactly when planning the cable run The cables must be laid unrestrictedly and only be clipped at the spots provided If necessary cables may be laid in cable protection pipes The speed cable must not be clipped closerthan 0 9 mto the control since this cable moves a slightly back and forth during operation The speed and reversing gear cables are to be laid in as few as possible smooth curves to avoid unnecessary friction and clearance losses Min curve radius is 150mm Page CONTROL STATION 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION CONTROL STATION 15 5 TWIN CONTROL STATIONS For boats with a top control station fly bridge the control of engine and gear may be done an electrically controlled servo unit or a mechanical shift unit Manoeuvring and control apparatus are installed twice Conversion ofthe control levers between the individual control stations may be done automatically if an omnibus implement is provided The speed cables of the two controls are connected to the actuator solenoid unit Automatic commutation of the connecting cables between the control stations one for every engine should be placed as close as possible to the reversing gear ill 15 9 Z00
78. mmended to check the parallelism of the flanges by means of a dial gauge In this case the propeller shaft is to be moved sternwards for approx 3 8 10 mm and be well supported so that the clearance in the stem tube is uniformly distributed exactly center the shaft Rotate the reversing gear shaft and measure at first the radial off size Correctthe position ofthe reversing gear Then check the axial off size by a hinge dial gauge on the contact surfaces of the flange In both cases max possible off size is 0 1mm ill 5 14 B A checking of radial off size A checking of axial off size hinge dial gauge dial gauge flange on reversing gear propeller shaft support of propeller shaft dial gauge flange on reversing gear propeller shaft support of propeller shaft OND AUN After having finished the adjustment prepare supporting disks fitting between the engine reversing gear bearers andthe rests on the engine Measure the distances and prepare steel disks to be ground to the dimensions found Make all bores for the bearers and screw on the engine and the reversing gear Take care that all setscrews for the high position are unscrewed so that the bearers do not rest on the screws but on the supporting disks After alignment remove the setscrews for high position After launching the boat check the adjustment once again The boat with filled tanks and the required equipment should ha
79. mounts nuts 2 can also be cast ill 5 3 5 4 SPACE FOR MAINTENANCE The engine compartment is to be designed in such a way that maintenance work will not be impaired by bottom plates or other equipments Compare these requirements to the maintenance chart in the operating manual Also take care that there is enough space for lifting and lowering the engine Before beginning the assembly make sure that scale drawings for the engine and its equipment are available see appendix All necessary dimensions for assembly follow from the scale drawings e g the distance from the crankshaft centre to the engine bearers reversing gear bearers and to the centre line ofthe propeller shaft Z001007 0 4 September 2007 Page ENGINE INSTALLATION 5 ENGINE INSTALLATION INSTALLATION INSTRUCTION ill 5 4 IMPORTANT Keep sufficient distance between base frame oil pan and starter motor 3 4 20 mm 5 5 ENGINE INCLINATION Max permissible engine inclination backwards in direction of flywheel corresponds to angle A see table The engine must not be inclined downward in direction of the heat exchanger since such an installation could affect the cooling due to remaining air pockets Wheninstalling the engine with the flywheel side in direction of the bow the inclination in direct
80. nderthe direct control of STEYR MOTORS and Steyr cannot be held liable for any loss or damange where the installer or user has not followed advise given by the Company Z001007 0 4 September 2007 Page GENERAL 1 INSTALLATION INSTRUCTION THIS PAGE IS INTENTIONALLY BLANK Page GENERAL 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 GENERAL INFORMATION ON INSTALLATION TABLE OF 5 2 1 WEIGHT DISTRIBUTION BALANCE 3 222 ACCESSIBILITY i 3 2 3 DISPLACEMENT OF WATER sennunnnnnnnnnzznnznnannznznnnnnnzznmnnnannzmzenn 4 2 3 1 Examples for Block Coefficient 4 2 4 SAFETY IN DEALING WITH FUEL AND OIL 5 2 9 LIST OF FUEL AND OIL sand ne n UTR 6 2 9 1 7 2 6 Sl SYSTEM MDDHNM NOU 8 2 1 ABBREVIATIONS al lm 9 2 8 GENERAL INFORMATION ON SAFETY 10 2 9 GUIDELINES FOR DAMAGE PREVENTION 10 2 10 LEGAL RULES cm 10 2 11 DISPOSAL OF AUTOMOTIVE WASTE PRODUCTS 10 2 12 SAFETY IN DEALING WITH FUEL AND OIL 11 2 13 MEASURES IN CASE OF 11 Z001007 0 4 September 2007 Page GENERAL INFORMATION 1 GENERAL INFO
81. ng of water from the exhaust pipe into the engine otherwise severe damage to the engine due to hydro lock and corrosion of cylinders may occur ATTENTION When laying the exhaust pipe through bulkheads and similar make sure that the pipe does not touch material which transmit vibrations onto the hull thus causing resonance noise In case of lead in pipes take special care that the exhaust pipe will not cause a combustible heating of the surrounding material ATTENTION For the assembly of exhaust pipes to turbo charged engines The turbo charger must never have to support the weight of the exhaust system Page EXHAUST SYSTEM 4 Z001007 0_4_September 2007 INSTALLATION INSTRUCTION EXHAUST SYSTEM 8 4 1 Exhaust for Inboard Engines The exhaust outlet in the hull should be 12 300 mm below the exhaust elbow For correct installation the highest part of the exhaust system must be at least 12 300 mm above the water line with a loaded boat see ill 8 3 Install the drain cocks at the lowest points of the exhaust pipe Lo M Serge 300 mm d N 300 mm ill 8 3 8 4 2 Exhaust for Stern Drive Engines Precondition fora correct installation is compliance with the min height of 14 350mm fromthe exhaust system highest p
82. nits of pressure and tension bar Pascal N mm Newton per square millimeter units of energy J kW h joule kilowatt hour units of energy kW PS kilowatt horsepower units of temperature K degree centigrade units of time h hour min minute S second speeds km h kilometer per hour m s meter per second speeds rpm revolutions per minute Page GENERAL INFORMATION 8 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 7 ABBREVIATIONS ill illustration Cu copper HGrp master unit Max maximum OT top dead center PTO POWER TAKE OFF on crankshaft SW head width WC water column Z001007 0 4 September 2007 Page GENERAL INFORMATION 9 GENERAL INFORMATION INSTALLATION INSTRUCTION 2 8 GENERAL INFORMATION ON SAFETY This section does not include the scope of general knowledge andthe training of personnel as well asthe general rules of safety technics and machine safety regulations MSV Inappropriate behaviour and the ignorance of hazards during repair works may result in injuries to persons The personnel on duty is to be trained accordingly and to be urged to respect the safety regulations 2 9 GUIDELINES FOR DAMAGE PREVENTION This section does not include the scope of general knowledge and the training of material maintenance personnel as well as the general rules of safety technics and machine
83. oint to the water line A ill 8 4 If required launch the boat with its real load resp load distribution weight of drive unit plus working load in order to determine the water line E A i deeg UY gt DE KI H SI n U D 3 see p ill 8 4 Z001007 0 4 September 2007 Page EXHAUST SYSTEM 5 EXHAUST SYSTEM INSTALLATION INSTRUCTION 8 5 DIMENSIONS OF EXHAUST PIPE SE 6 Cyl Engine 4 Cyl Engine dry exhaust pipe acidproof steel tube mm inch mm mm inside diameter 84 3 3 84 3 3 outside diameter 90 3 5 90 35 wet exhaust pipe industrial rubber hose inside diameter 127 5 110 4 3 outside diameter 140 5 5 127 5 8 6 CONDENSED WATER COLLECTOR Exhaust gases of an internal combustion engine contain water vapor which may condense and be converted into water which in the worst case flows back into the engine With an exhaust pipe inclined in direction of the engine therefore always install a condensed watet collector behind the water cooled standbend Provide the condensed water co
84. peller for commerical use to be applied in regions with strong alga and algae vegetation 2001007 0 4 September 2007 Page ENGINE INSTALLATION 15 ENGINE INSTALLATION INSTALLATION INSTRUCTION ill 5 21 ill 5 22 2 blade propeller to be applied 2 blade folding propellerto be aplied on sailing boats on sailing boats 5 15 11 Cavitation Propellers which have not been computed correctly e g a propeller with a too large pitch may cause cavitation formation of steam bubbles Cavitation may damage the propeller and occurs in case of a too high underpressure on the suction side of the propeller 5 16 PROPELLER THRUST BEARING RESP STEP BEARING All reversing gears covered by our product offer are provided with attached axial bearings for the traction and shearing forces of the propeller shafts In case of normal load conditions no other thrust bearings are required For very strong loads e g industrial operation on ice separate thrust bearings may be required In such cases an elastic coupling between reversing gear and thrust bearing is always to be installed in order to avoid axial tensions between the two thrust bearings With a shaft length exceeding the standard size a separate step bearing is to be installed The step bearing cannot take axial forces ill 5 23 1 thrust bearing 2 elastic coupling Page ENGINE INSTALLATION 16 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION COOLING SYSTEM
85. quirements are admissible under certain conditions to what extent depends on the application the speed the diffraction angle etc Depending on the diffraction angle of the two universal joints of a shaft the intermediate shaft will be more or less accelerated or retarded with every rotation This causes a stimulation of oscillation which isto be considered for the location ofthe universal joint shaft between engine and gear Overhanging mass on the shaft end atthe flywheel side such as e g couplings may be critical Considering the additionally occuring bending moment which depends on the initiated torque the length of individual universal joint shafts cannot be chosen at random If necessary several universal joints shafts are to be arranged 5 3 ENGINE BASE The engine base should be of a very rigid design Its suspension is to be distributed on the maximum surface overthe ship bottom The engine base should be strong enough to absorb with free play the compressive and shearing forces of the propeller Strains through heavy sea and dynamic load are also to be considered 5 3 1 Engine base on synthetic boats On synthetic boats the engine base may be made of flat irons see ill 3 casted in the boat The base 3 should be constructed as a box and filled with damp proof material 4 The flat irons 1 should be long enough to distribute the load of the engine overa surface as large as possible To facilitate screwing of the engine
86. rking materials according to accident prevention are all explosive fire provoking easy flammable poisonous injurious to health and corrosive materials In particular Spirit mineral oil battery acid antifreeze varnish and dilutions solvents In case of fire of such materials do not extinguish with water Use carbon dioxide extinguishers or powder extinguishers Notify the fire department In case of spilling such materials e g while refueling these are to be absorbed with sand earth or suitable binding agents and to be eliminated ATTENTION To avoid health troubles the following items are to be considered A 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 Never put working materials into drinks bottles 2 13 MEASURES IN CASE OF ACCIDENTS Products First Aid Skin Eyes Swallowing Diesel fuel and mineral oil lubricating grease antifreeze brake fluid battery acid remove contaminated clothing and thorough ly clean the skin with water and soap rinse extensively with water for at least 10 min SEE THE DOCTOR DO NOT VOMIT The greatest hazard after inadvertent taking consists in the fact that throug
87. rmined by specialists For the same boat and the same engine the diameter of a four blade propeller may be by 10 less than that of a three blade propeller On sailing boats often a two blade propeller is used which lessens the resistance and reduces the efficiency for an aliquot part only 5 15 6 Axle hub To permit a proper and centric mounting of the propeller on the propeller shaft the propeller should be provided with a well fitting conical hub and a spline Mostly the cone s pitch will be 1 10 In the United States and in England one may also find cones with 1 12 and 1 16 Conicity of a hub is told by the difference between the largest and the smalles diameter divided through the hub length ill 5 16 L 5 15 7 Adjustment of Propeller Pitch In case of a too high or too low propeller pitch a specialist may adjust the blades within a certain limit which however should be avoided as far as possible It is a difficult task and moreover it is almost impossible to modify the pitch close to the hub and to obtain a uniform pitch in every diameter of the propeller chosen at random On principle the pitch never should be modified for more than some cm and this only in case of no other solution Page ENGINE INSTALLATION 14 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION 5 15 8 Space between Propeller and Boat The maximum propeller diameter results from the shape of the hull The illustra
88. s Required cabel length is 8 meters since cable length back and forth is to considered Inthe table a straight line is drawn from 8 inthe length m column sloping downwardsto 300 in the power column This straight line crosses the cross sectional column at 4 5 Therefore a cable with a cross section of 4 5 mm min is to be used This value is rounded up to the next cable size available 12 Volt 24 Volt length cross section amp watt length cross section amp watt in m in mme inm in mme 25 pes 700 25 ille L 70 50 l 600 120 150 4000 20 50 20 95 E 40 500 an 3000 35 15 am 1 400 15 50 100 25 35 80 2000 16 r 300 Eat 10 10 8 10 8 16 50 ER 6 45 200 EAS he e T 6 10 40 1000 4 150 Nep Bon SET mE Sy 2 5 10 EL a 8 100 4 plis 600 3 T ali 25 20 500 1 e 80 e E 0 75 s 1 5 is 400 1 kd 2 2 E 4 50 0 75 300 15 370 1 54 104 8 200 0 5 30 0 5 ene 2 1 e 150 0 8 20 0 8 5 16 6 CABLE CROSS SECTION The cable cross section is determined by the rated current of the fuse Rule of thumb for dimensioning a maximum of 10 A per mm2 Page ELECTRICAL EQUIPMENT 6 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION DRILL TEMPLATES 4 6 Cyl 17 DRILL TEMPLATES TABLE OF CONTENTS Marine Engine FRONT VIEW
89. safety regulations MSV Inappropriate behaviour and the ignorance of material maintenance may result in considerable material damages While operating with fuel and oil take care not to apply them on the surface of optical systems Lubricants should form a thin film on the surface surplus lubricants must be removed 2 10 LEGAL RULES The following rules and guidelines are valid in Austria For other countries follow the local regulations 2 11 DISPOSAL OF AUTOMOTIVE WASTE PRODUCTS Used fuel and oil is to be collected in separate containers to permit an eventual subsequent treatment THE DISPOSAL OF ANY FUEL AND OIL FOR THE ENGINE IS SUBJECT TO THE SPECIAL 4 WASTE ACT THE SPECIAL WASTE CATALOGUE 52100 REFERS THE NECESSARY DISPOSAL IN AUSTRIA PLEASE FOLLOW THE LOCAL REGULATIONS OF YOUR COUNTRY The operating and maintenance personnel has to take care that fuel and oil as well as other material ranking as special waste are deposited at the respective collecting points Code No Designation 31 423 oil contaminated ground or oil binder 54 102 waste oil 54 104 fuel 54 202 grease 54 207 vaseline 54 917 compact sealing material 54 927 oil contaminated scouring cloth 54 928 usel oil and air filters 55 510 colour or varnish containing waste Page GENERAL INFORMATION 10 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION GENERAL INFORMATION 2 12 SAFETY IN DEALING WITH FUEL AND OIL Dangerous wo
90. ses a low noise level is required which implies an insulation of the machine unit The disturbing engine noise is transmitted through the hull i e engine base and and the air To avoid a propagation of the engine noise through the hull as first step engine and reversing gear are to be provided with elastic suspensions and elastic propeller shaft coupling see chapter 3 which results in a reduction of the hull latent noise In addition the acoustic source is to be shielded as far as possible to reduce the air latent noise This measure above all is a very simple way to reduce the high frequency noise However a small opening in the shielding may already cause a considerable noise leakage Therefore insulating material should also be provided below the engine bed down to the hull and all inlets are to be sealed with rubber bellows 14 2 NOISE REDUCTION 2 ill 14 1 ill 14 2 Equip the unit with a noise insulation to keep the sound level as low as possible Provide noise catchers in the engine compartment Various type are available 14 1 shows a construction with a water drain If a water drain is not possible the air tubes may be bent like a swanneck ill 14 2 to avoid the entering of water Design of the engine compartment should consider enough space for maintenance of the engine In addition thickness of the noise absorbing material is to be considered Carefully shield
91. ss fuel tanks pipings batteries engine compartment blower air vent conduits Don t forget that the engine compartment the tank compartment and the battery box must be separated from each other to reduce the danger of fire In addition separate fire extinguishers must be available e g in the pantry depending on boat size and type 1 1 REGULATIONS Note that each country has its own safety regulations as to installation It is necessary therefore that the boatbuilder engine fitter is aware of the safety regulations in his country before beginning works 1 2 RESPONSIBILITIES OF BOAT OWNERS As a boat owner you have certain responsibilites to others You are legally responsible for all occupants of your boat Show all assistants the location of the emergency equipment and how to use it Your are required by lawto have aboard one proper life jacket for each person plus one approved throwable device for man overboard protection Learn the local waterway rules for boats and ships Navigable waterways are controlled by Federal regulations Obey these regulations to protect yourself your passengers and your fellow boating enthusiasts Thoroughly familiarize yourself with weather station warning systems and waterway nautical signals Contact your local Coast Guard station and take advantage of their seasonal boat inspections and training courses The mannerand circumstances ofthe application installation and use ofthe engine is notu
92. st absorb the propeller thrust of the thrust bearing and transmit it onto the hull The foundation s supporting surface for the propulsion unit should be for approx 3 8 13 16 10 20 mm under the nominal size in orderto permit during asssembly and alignment ofthe unit the balancing of unevenness and differences by means of fitting pieces All fitting pieces should be of the same material e g steel or cast steel Soft material e g copper must not be used for fitting pieces and shims For boats made of wood or synthetics as well as for ships not built for a self contained propulsion or where a considerably stronger unit should be installed it may be useful to attach a subframe for reinforcement of the foundation 5 2 POWER TRANSMISSION 5 2 1 Coupling For power transmission from the engine to the gear we recommend a turn elastic coupling In all other cases of suspension of engine and gear a turn and radial elastic or an articulated coupling with torsion spring plate is required between engine and gear Coupling size depends on the maximum engine torque to be transmitted thetorque peaks due tothe degree of irregularity ofthe engine andthe alternating moments oftorsional vibration at critical speeds ofthe boat Based on atorsional vibration computation it must be checked whether the chosen coupling as well as dimensioning and arrangement of the unit could lead to undue torsional vibrations causing severe damages For couplings using
93. starter engine 2 kW 12 volt battery size 92 AH length cable cross section AWG inm For 6 cyl engines only length inm In general take care that battery cable lengths are kept as short as possible Page ELECTRICAL EQUIPMENT 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ELECTRICAL EQUIPMENT 16 4 ADDITIONAL CURRENT UTILIZATION DEVICES Before connecting an additional current utilization device such as lighting radio echo sounder etc first calculate the total power consumption of all these components to guarantee sufficient capacity of the dynamos Example When using a 50A dynamo you may connect current utilization devices consuming all together 50A simultaneously In case of atoo small capacity of the dynamo a larger or an additional dynamo may be installed Since the starting quality of the battery must be guaranteed max 90 45A of the rated capacity may consumed simultaneously and permanently A ELECTRICAL EQUIPMENT OF THE ENGINE PERMANENTLY REQUIRES APPROX 15 A Z001007 0 4 September 2007 Page ELECTRICAL EQUIPMENT 5 ELECTRICAL EQUIPMENT INSTALLATION INSTRUCTION 16 5 CALCULATION OF CABLE CROSS SECTION FOR ADDITIONAL EQUIPMENT Use this table to find the cable cross section required for a specific power requirement Example A current utilization device 24V of 300 watt is to be installed In this case distance from the current utilization device to the battery is four meter
94. tallation site The prepared end of tube with union nut and cutting ring is plugged directly into the threaded socket and the union nut is done up by hand to the tangible stop on the cutting ring before tightening of union nut Now press the tube against the stop in the threaded socket and tighten the union nut for approx one 3 4 turn after tightening of union nut In the course of this the tube must not turn Since the cutting ring has now picked up the tube a further pressing of the tube is unnecessary Final tightening is done by repeated screwing down of the union nut for approx 1 turn After this disengage the union nut and check if the cutting ring s edge has penetrated the outer skin of the tube and if the collar in front of the edge is visible If necessary the union nut is to be tightened once again It is insignificant if the cutting ring at the end of tube can be turned After completion of the connection as well as after any loosening tighten the union nut by means of a standard wrench without increased expenditure of energy 3 3 2 Plug connection for plastic tube For tubes with an outside diameter up to 10 mm it is recommended to screw the relevant sockets of the plug connections into the respective devices and to carry out assembly of the piping on the installation site The end of tube with socket and union nut is done up by hand to the tangible
95. tank but with enough space for water drain and exchange of filter inserts For selection and dimensioning additional filters and water seperator must have flow of min 300 or 65 gl h as the rate of flow of the electric fuel pump must not be reduced fuel pump 2 fuel return fuel filter feed line coarse filter water separator anti syphon valve NOOR WD ill 7 1 Z001007 0 4 September 2007 Page FUEL SYSTEM 3 FUEL SYSTEM INSTALLATION INSTRUCTION 7 2 FUEL TANKS If possible arrange the fuel tanks at engine level or higher In case of a lower arrangement max suction height of the feed pump is to be considered which is 1 m for all kinds of engines Please consider that the suction head is calculated from the lower end ofthe suction pipe i e approx 1 2 5 cm overthe tank bottom The return pipe should lead into the tank at the level of the screen but with some distance to it to avoid a foam formation of fuel In case of arrangement ofthe tanks at a level lowerthan the admissible suction height of the feed pump the fuel is to pumped up to a daily tank by a manually operated pump or motor pump In this
96. the acoustic source Shielding should go down to the hull Gaps on hatches and bench covers to be sealed with insulating material see ill 14 3 If the engine isunderthe bottom plate cover all bulkheads and sheets ill 14 3 Z001007 0 4 September 2007 Page NOISE ATTENUATION 3 NOISE ATTENUATION INSTALLATION INSTRUCTION 180 mm ill 14 4 Before attaching the noise absorbing material make sure that there is sufficient space for movements of the engine during operation Noise absorbing material is available in different types and thickness Provide a free space of 8 180 mm ill 14 4 in front of the engine to permit its dismantling 14 3 NOISE ABSORBING HOODS AS SUPERSTRUCTURE On small commodity boats and normally on all sport boats at first engine and reversing gear are provided with an elastic suspension see chapter 3 However in case of an elastic stem tube no elastic coupling may be mounted Then the engine compartment preferably is built as self containted construction with a hinged cover as top ill 14 3 Attention Always consider enough space for maintenance ofthe engine see respective operating instructions The engine protection is
97. the upper end of these pipes a curve of 180 is to be provided which avoids the entering of water into the tanks The air vent pipes should also be arranged in such a way that e g flowing out gas cannot be ignited or enter into the rooms aboard The fuel pipes for the engine can be made of seamless tempered copper tubes or of steel tubes type Bundy tube Steel tubes are much stronger than copper tubes and should therefore be used as far as possible The hose pipes have to comply with specific conditions of use and respective local waterway regulations see hints in the preface Specific data for fuel hoses synthetic rubber hose with plies of fabric size DN 8 resistant to Diesel fuel fire proof temperature range 30 bis 30 C operating pressure 145 psi 10 bar Up to lengths of 2 ft 6 m outside diameter of the fuel suction pipe should be 3 8 10mm A longer suction pipe will require a larger diameter e g 1 2 12mm From the overflow valve on the engine a fuel return pipe to the tank or to the daily tank if available is to be laid Min outside diameter of the fuel return pipe should be 3 8 10mm On the engine side fuel pipes are always to be installed ill 7 4 ill 7 5 fuel pipe with brazed tapered piece flanged fuel pipe The connections of the fuel pipes are to be flanged with a special tool Loose or soft soldered tapered pieces must not be used When using tapered pieces these are to be fixed on the pipes
98. tion shows a displacer but even for a glider the conditions are similar The most important Size A space between propeller and hull should be at least 2 50 mm resp 10 96 of the propeller diameter noise malicious vibrations Size B should be approx 30 of size D C 2 3 4 20 mm more than the propeller hub length in order to avoid a dismantling of the oar in case of a propeller change X 7 space propeller stem bearing 1 25 mm ill 5 17 5 15 9 Sediments When removing sediments from the hull pay special attention to the propeller Salt water in particular but also sediments and vegetation cause additional resistance and thus a smaller efficiency resulting in a lower speed In general lower propeller speeds bring about higher efficiency and less vibrations compared to high speeds 5 15 10 Choice of Propeller There are a couple of coarse rules In general for a water displacer a 3 blade propeller with Fa F of approx 0 51 will be sufficient More or larger blades do not make sense For semi gliders we generally recommend 3 or 4 blade propellers with Fa F of 0 54 to 0 74 For gliding boats 4 blade propellers with Fa F of 0 54 to 0 74 may be considered Most propellers are made of bronze but propellers made of metal or aluminum are also available Various propellers with examples of application AO jix ill 5 18 ill 5 19 ill 5 20 3 blade 3 blade propeller 3 blade propeller high speed pro
99. tual diameter cannot be housed will thus reduce the efficiency Z001007 0 4 September 2007 Page ENGINE INSTALLATION 13 ENGINE INSTALLATION INSTALLATION INSTRUCTION 5 15 3 Blade Surface Correct determination of the blade surface is also to be done by specialists It depens on the speed and the type of boat and is always indicated in relation Fa F F being the total area of the propeller circle and Fa the surface of all blades or wings together Every propeller type has a fixed Fa F relation 5 15 4 Sense of Rotation To determine the sense of rotation of a propeller always stand behind the boat and look forward If the propeller rotates counterclockwise then it is a left hand propeller and if rotates clockwise then it is a right hand propeller It is the engine which always determines the sense of rotation of the propeller which can however be reversed by using a reversing gear 5 15 5 Number of Blades The number of blades is determined by the speed of the boat the number of rotations of the propeller and the type of boat dumb barge fisher boat glider and is first of all a matter of experience In general for standard boats up to a length of approx 70 ft 20 m with an engine speed of more than 800 rpm propellers with more than three blades are being used If much speed at low revolutions is required in particular on larger boats even propellers with more than three blades are used This should also be dete
100. ugh If one of the radiators is situated higherthanthe engine separate compensating tanks are to be installed The compensating tank should be higher than the radiator but max height over the engine must not exceed 2 m Attention When installing a separate compensating tank for the engine s cooling system this tank should be the the highest part of the cooling system The heating s inlet and outlet connections on the engine must be provided with stop cocks in order to permit a disconnection of the heating if required Provide the heating installation with drain cocks at the lowest points and with relief cocks at the highest points For connecting the water pipes to the engines bores are provided ex works equipped with paddings The arrows on the illustrations show the direction of the water stream Page CABIN HEATING 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION NOISE ATTENUATION 14 NOISE ATTENUATION TABLE OF CONTENTS 14 T GENERAL EN NE MM ND E RUE 3 14 2 NOISE REDUGTION ic 3 14 3 NOISE ABSORBING HOODS AS SUPERSTRUCTURE 4 14 4 NOISE ABSORBING MATERIAL rie 5 Z001007 0_4_September 2007 Page NOISE ATTENUATION 1 NOISE ATTENUATION INSTALLATION INSTRUCTION 14 NOISE ATTENUATION NOTES Page NOISE ATTENUATION 2 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION NOISE ATTENUATION 14 NOISE ATTENUATION 14 1 GENERAL In most ca
101. undesired play In this case control is done by means of hydraulic cylinders triggered by individual control valves These control valves receive the control commands via the hydraulic liquid of the control levers A separate hydraulic tank is to be installed Quality of the hydraulic liquid requires special attention since liquids with a low modulus of extension and a very low viscosity may be used only In no case may the hydraulic liquid be merged with different qualities 15 2 3 Electronic Control With electronic control movement of the control lever are converted into electric signals In this case the microprocessor unit plays a central role It is attached as close as possible to the engine and controls via short tension and pressure cables the engine and the reversing gear ELECTRONIC ene 05 O 3 Ra DEDE
102. unts of explosive gas Install main switches at the positive and negative side In case of one single switch install it easily accessible at the positive side Required capacity of main switches min 1000A short circuit current Attention Only bipolarsystems may be installed otherwise galvanic streams may occur which cause corrosion 1 air tube at least 25mm 1 conducted outwards 2 cover same material as box 3 clamping bar which fixes the battery by securing the nuts L iron or flat bar studs box made of steel plate min 3mm acid proof clamps with tightening screws use pole grease rubber sleeves for cable passage o 4 Engine 6 Cyl Engine rated capacity 12V 92 rated capacity 12V 115 Ah for 24V installation 2 x 12V 115 AH cold test current 450 A cold test current 650 A Z001007 0 4 September 2007 Page ELECTRICAL EQUIPMENT 3 ELECTRICAL EQUIPMENT INSTALLATION INSTRUCTION 16 3 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 lt 3 0 m ground cable 22 0 m Total length 25 0 m gt cable cross section 70 mm For ground connection determine corresponding cross sections as per chart For 4 cyl engines only
103. ustrial standards and are to be applied in case of no indication of specific tightening torques For studs the tightening torques are to be reduced for 50 96 p total 0 100 p total 0 125 p total 0 140 gradini MA in Nm grade of MA in NM grade of MA in NM iid 8 8 109 129 Strength 8 8 109 129 strength 88 109 129 metric metric metric nominal control thread nominal control thread nominal control thread M4 2 4 3 3 4 M4 Dal 3 88 46 M4 2 9 41 49 M5 4 9 7 8 5 5 5 8 9 5 M5 6 8 5 10 M6 8 12 14 M6 9 5 13 16 M6 10 14 17 M 7 13 19 23 7 15 22 26 7 16 23 28 M8 20 28 34 M8 23 32 39 M8 25 35 41 M 10 40 56 67 M10 46 64 77 M 10 49 69 83 M 12 69 98 115 M12 80 110 135 M 12 86 120 145 M 14 110 155 185 M14 125 180 215 M 14 135 190 230 M 16 170 240 285 M16 195 275 330 16 210 295 355 18 235 330 395 18 270 390 455 18 290 405 485 M 20 330 465 560 M20 385 540 650 M 20 410 580 690 M22 445 620 750 M22 510 720 870 M22 550 780 930 M24 570 800 960 M24 660 930 1100 M 24 710 1000 1200 M 27 840 1200 1400 M27 980 1400 1650 M27 1050 1500 1800 M 30 1150 1600 1950 M30 1350 1850 2250 M 30 1450 2000 2400 metric nominal control thread nominal control thread nominal control thread M 8x1 22 30 36 M8x1 25 35 42 M 8x1 27 38 45 M 10x1 25 42 59 71 M 10 x 1 25 49 68 82 M 10x1 25 52 73 88 M 12x1 25 76 105 130
104. ve been on the seas for some days Ship bodies are elastic and do not have the same shape when they are propped up In case of a necessary readjustment distance plates can be mounted under the bearers After start up of the boat verify at regular intervals that the adjustment of the machine unit has not changed due to deformations of the body A bad alignment of engine and propeller shaft may cause a lot of disturbances and operating troubles Such troubles may also result in vibrations in the hull in the reversing gear and in a quick wear of the propeller shaft bearings the shaft and the stem tube supports Z001007 0_4_September 2007 Page ENGINE INSTALLATION 11 ENGINE INSTALLATION INSTALLATION INSTRUCTION 5 13 TWIN INSTALLATION When mounting engines with one propeller each choose the reversing gears in such a way that the starboard propeller rotates clockwise and the port side propeller counterclockwise seen in the direction of the bow ill 5 15 centre distance of shafts A min dimension approx gt 31 gt 787 mm 5 14 SHAFT AND STEM TUBE To choose the right components of engine reversing gear and propeller with regard to the respective ratio of load follow the recommendations as to power and speed of various engines to be found in the product information marine engines The combination of reduction of speed shaft diameter and propeller size may be computed based on ourrecommendations on propellers includ
105. y start up impacts and acceleration Forthis reason a larger coupling should be chosen In addition it should be considered not to drive too long at the critical speed range If a disconnectable coupling is used the admissible axial load of the crankshaft must not be exceeded 5 2 2 Universal Joint Shafts Principles A universal joint produces a more or less strong irregularity on the driving axle depending on the diffraction angle This irregularity is compensated by providing a second universal joint under the following conditions 1 The two forks of the intermediate part must be coplanar 2 The diffraction angle of the second joint must be of the same size as that of the first one both joints must be coplanar ill 5 1 forks of intermediate shaft marking The illustration shows how the two forks of the intermediate shaft should be positioned to each other acc to 1 coplanar The splined shaft ends mostly show index arrows which should be opposite when connecting the shaft The following illustration shows the Z layout of a universal joint shaft The two angles 61 and 32 must be equal This means that with Z design the contact faces of the shaft ends for drive and drift must be parallel to each other IMPORTANT diffraction angle B min 1 max 6 ill 5 2 Page ENGINE INSTALLATION 4 Z001007 0 4 September 2007 INSTALLATION INSTRUCTION ENGINE INSTALLATION Slight deviations from these re

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