installtion manual 850 marine.pdf

7/25/2019 Installtion manual 850 Marine.pdf

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Weber Motor MPE 850 Marine

System installation


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Agenda of Presentation

Engineering and engine Supply

1 Application feasibility

2 Boat System requirements

3 Electric system

4 Engine control5 Engine installation

6

Content

Installation propulsion system

7 Check ECU

8 First start engine

9 Vendor controls10 Related documents


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Installation Weber Motor MPE 850 Marine Propulsion System

1. Application feasibility

General:

Max. thrust jet pump up to 490 kg depending water intake system for jet

0

200

400

600

800

1000

1200

0 10 20 30 40 50 60

thrustlb

boat speed mph

Thrustcurves Weber Motor jetpump solutions

thrust pump 148mm 150 HP lb




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1. Application feasibility

General:

Weber Motor MPE 850 Marine propulsion system feasible for:

Max. dry weight boat 800 kg

Max recommended length 6 m

Max recommended width 2,0 - 2,5 m

Deadrise approx. 20

Any other values above will result in lower boat performance

For application feasibility: Send application chart to Weber Motor for feasibility

check


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2. Boat system requirements

Operation conditions:


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Engine compartment


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Engine compartment


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Fuel system (not in scope of supply):

Fuel pump 12 V, flow rate > 100 liter/hour @ 4 bar

Fuel pressure 4 bar

Pre filter before fuel pump e.g. Pierburg

Main filter after fuel pump e.g. Mann Filter WK 69/2 or Mahle KL 156-3 WITHintegrated

pressure regulator 4 bar

Filter specification:

mesh area 50 cm2

mesh size 15 m

filter grade 95 %

Max. fuel temperature 55


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Fuel system: Layout


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Fuel system: Fuel pump:

First choice: In tank module

Not available at Weber Motor due to different fuel tank layouts

Second choice:

External fuel pump

Gravity feed of pump

Pressure relief valve

E.g. Walbro GSL 393


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Exhaust system (not in scope of supply):


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Exhaust system:


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Exhaust system:

Note: Inner diameter AG2 65 mm

Inner diameter AG4 76 mm


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3. Electric system

Chassis connector

(not in scope of supply)Delphi 13880240


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3. Electric system

Wiring battery (not in scope of supply)


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3. Electric system

Charge system: Wiring to voltage regulator (not in scope of supply)


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3. Electric system

Electric: Not in scope of supply

Battery 12 V min 20 Ah (40 Ah low ambient temperatures)

Ignition key switch:

Terminal 30 is protected by a 15 A fuse in engine wire harness

Additional connected electrical components may not exceed a total load of 15 A

It is absolutely necessary that there is no interruption on terminal 15 when key is on

and turned for cranking engine

Engine speed signal: 2 pulses / revolution

Indicator lights: MIL, temperature and oil pressure

Max. load 5 W per indicator light

LED lights need a 10kOhm parallel resistor


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3. Electric system


MIL (malfunction indicator light):

Illuminated during operation: Fault

Flashing during operation: Emission related fault

Temperature warning light:

Coolant temperature > 102 C: Engine speed is limited, light turns on

Coolant temperature < 100 C: Limit is reset, light turns off

Oil pressure warning light:

Illuminated during operation: Low oil pressure, shut off engine by operator


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3. Electric system


Service light:

Yearly service hours are counted in ECU

Illuminated service hour light: Engine to be serviced

Engine hour counter can be reset by diagnostic tool


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4. Engine control

TRU: throttle request unit


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4. Engine control

TRU: throttle request unit


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5. Engine installation

Engine lift


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Drive shaft angle with weber Motor jet pump system


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Engine decoupling

(not in scope of supply)


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Engine mounting (not in scope of supply)


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Engine alignment

(shims not in scope of supply)


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Engine alignment


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Connect fuel system

(hoses not in scope of supply)


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Connect seawater in

(hose between engine and jet not in scope of supply)


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Connect seawater in: Towing valve:

(hoses and tow valve not in scope of supply)




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Connect seawater out:

(hose between engine and jet not in scope of supply)


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Connect seawater out:


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Flush system:


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6. Installation Propulsion system: Weber Motor jigs:

Jet pump and engine installation by using Weber Motor jigs

Step 1: Install jet pump

Step 2: Install engine:

Distance to jet

Alignment engine to jet

NOTE: Weber Motor installation jigs will be available July 2014

Please see slides 55 - 57 for prototype installation without jigs


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Axial distance engine to jet has to meet spec:

Too small: Risk of engine failure axial bearing engine

Too big: Risk of spline failure of drive shaft

Axial play drive shaft: 6 +/- 2 mmm


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Alignment engine to jet pump:

Out of spec:

Risk of bearing failure jet pump

Vibration

Risk of failure through hull seal


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Place drill jig in jet intake and drill 6 mm holes for:

4 x fastener for pump housing 2 x holes seawater fitting

2 x holes for control cables


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Attach drill jig to jet intake with 4 fastener


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Mount Edding arbor on alignment shaft

Insert Edding in arbor


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Insert alignment shaft in jig

Mark position for hole for drive

shaft with Edding


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Dismount jig and machine hole for drive shaft


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Drill holes:

4 x holes for fastener pump housing dia. 8,5 mm

2 x holes for seawater fitting dia. 24 mm 2 x holes for control cables

(diameter depending control cables)


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Mount pump housing with liner with

4 pcs fastener M8

Length of fastener M8 dependinghull thickness


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Mount centering jig with 4 pcs fastener M 8


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Dismount Edding arbor from alignment shaft

Insert alignment shaft in centering jig

Alignment shaft can be used as jig to laminate through hull tube OD through hull tube 45 mm


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Mount arbor for engine mount bore jig

Mount engine mount bore jig


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Mount vibration isolators to jig

Drill holes for vibration isolators

Mount vibration isolatorsto boat hull

Take off jig


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Mount alignement arbor

Slide back alignement bar to

give room for engine installation


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Place engine with decoupling element into boat on

vibration isolator

Place 4 bolts with washer Dont tighten bolts,

give enough play to align

engine


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Engine alignment:

Align engine until arbor of alignment shaft fully and easy

slides into coupler


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Distance engine to jet is correct when:

Alignement pin is fully in centering jig

Shoulder alignment pin in contact with decoupling element


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Connect seawater in and seawater out to jet pump

seawater in to engine

seawater out from engine


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6. Installation Propulsion system: Prototype installations without jigs:

Jet pump and engine installation WITHOUT Weber Motor jigs

ENGINE MOUNT:

Mount rubber isolator mounts to engine

Place engine into boat hull to meet a dimension of 606,5 mm between PTO and pumphousing


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Dimension 606,5 mm: Measured from pump housing with stainless steel liner to PTO


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Mount drive shaft without through hull seal, bumper and O-Ring

Mount complete jet pump

Align engine to jet pump until drive shaft can be easily slided between engine and jetpump

Fasten engine to boat

Dismount jet pump

Control dimension 606,5 mm

Mount through hull seal, drive shaft with bumper and O-Ring Mount jet pump


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7. Check ECU:

Before first engine start


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8. First start engine:

Prime fuel system

Run engine max. 30 seconds without cooling

Extended engine run only with sufficient coling:

In the water

By using flush system: Connect flush system

Start engine

Open water tap

Run engine

Close water tap

Stop engine Remove flush system


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9. Vendor controls (not in scope of supply):

Steering unit Teleflex SH 5088

Mounting kit stering unit Teleflex SB 39452

Steering cable: RCS, Teleflex and Ultraflex

Steering wheel Various

Shift cable RCS, BTech and Ultraflex

Throttle lever Teleflex JBS CH 2300

Throttle cable to TRU RCS, BTech and Ultraflex

Tachometer VDO A2C59512395

Wema 110386

BTech

Fuel gauge VDO A2C59512497

Wema 110620

BTech Speedometer VDO A2C59512405

Wema 110388

BTech


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Shift cable


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Throttle cable


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Additional Weber Motor parts:

Fuel pre filter

Fuel filter with integrated pressure valve 4 bar

Quick connectors for fuel filter 4 bar

External fuel pump with fittings

Engine vibration isolator

Engine shims 0.5 mm and 1 mm


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10. Related documents:

Weber Motor diagnostic handbook

Weber Motor installation handbook engine

Weber Motor service handbook

USA: USCG boatbuilders handbook

Europe: Directive 94/25/EG


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installtion manual 850 marine.pdf

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