Installtion Manual 850 Marine PDF

Weber Motor MPE 850 Marine
System installation
Content
Agenda of Presentation
Engineering and engine Supply
1
Application feasibility
Boat System requirements
Electric system
Engine control
Engine installation
Installation propulsion system
Check ECU
First start engine
Vendor controls
10
Related documents
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
Thrustcurves Weber Motor jetpump solutions
1200
thrust pump 148mm 150 HP lb

1000
thrust lb
800
600
400
200
boat speed mph
0
0
10
20
30
40
50
60

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

2. Boat system requirements
Operation conditions:

Engine compartment

Engine compartment

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 WITH integrated
pressure regulator 4 bar
Filter specification:
mesh area 50 cm2
mesh size 15 m
filter grade 95 %
Max. fuel temperature 55

Fuel system: Layout

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

Exhaust system (not in scope of supply):

Exhaust system:

Exhaust system:
Note:
Inner diameter AG2 65 mm

Inner diameter AG4 76 mm

3. Electric system
Chassis connector
(not in scope of supply)
Delphi 13880240

3. Electric system
Wiring battery (not in scope of supply)

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

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

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

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

4. Engine control
TRU: throttle request unit

4. Engine control
TRU: throttle request unit

5. Engine installation
Engine lift

Drive shaft angle with weber Motor jet pump system

Engine decoupling
(not in scope of supply)

Engine mounting (not in scope of supply)

Engine alignment
(shims not in scope of supply)

Engine alignment

Connect fuel system
(hoses not in scope of supply)

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

Connect seawater in: Towing valve:
(hoses and tow valve not in scope of supply)

Connect seawater out:
(hose between engine and jet not in scope of supply)

Connect seawater out:

Flush system:

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

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

Alignment engine to jet pump:
Out of spec:
Risk of bearing failure jet pump
Vibration
Risk of failure through hull seal


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

Attach drill jig to jet intake with 4 fastener

Mount Edding arbor on alignment shaft

Insert Edding in arbor

Insert alignment shaft in jig
Mark position for hole for drive

shaft with Edding

Dismount jig and machine hole for drive shaft

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)

Mount pump housing with liner with

4 pcs fastener M8
Length of fastener M8 depending
hull thickness

Mount centering jig with 4 pcs fastener M 8

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

Mount arbor for engine mount bore jig

Mount engine mount bore jig

Mount vibration isolators to jig

Drill holes for vibration isolators
Mount vibration isolators
to boat hull
Take off jig

Mount alignement arbor

Slide back alignement bar to
give room for engine installation

Place engine with decoupling element into boat on

vibration isolator
Place 4 bolts with washer
Dont tighten bolts,
give enough play to align
engine

Engine alignment:
Align engine until arbor of alignment shaft fully and easy
slides into coupler

Distance engine to jet is correct when:

Alignement pin is fully in centering jig
Shoulder alignment pin in contact with decoupling element


Connect seawater in and seawater out to jet pump
seawater out from engine
seawater in to engine

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 pump
housing


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

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 jet
pump
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

7. Check ECU:
Before first engine start

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

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

Mounting kit stering unit Teleflex
Steering cable:
Steering wheel
Shift cable
Throttle lever
Throttle cable to TRU
Tachometer
Fuel gauge
Speedometer
SH 5088
SB 39452
RCS, Teleflex and Ultraflex
Various
RCS, BTech and Ultraflex
Teleflex JBS CH 2300
RCS, BTech and Ultraflex
VDO A2C59512395
Wema 110386
BTech
VDO A2C59512497
Wema 110620
BTech
VDO A2C59512405
Wema 110388
BTech

Shift cable

Throttle cable

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

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

Installtion Manual 850 Marine PDF

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Weber Motor MPE 850 Marine

Boat System requirements

Installation propulsion system

First start engine

Installation Weber Motor MPE 850 Marine Propulsion System

thrust pump 148mm 150 HP lb

thrust pump 148mm 85 HP lb

boat speed mph

Installation Weber Motor MPE 850 Marine Propulsion System

Max. dry weight boat 800 kg

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

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

Fuel pressure 4 bar

Pre filter before fuel pump e.g. Pierburg

mesh area 50 cm2

Max. fuel temperature 55

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

First choice: In tank module

Not available at Weber Motor due to different fuel tank layouts

External fuel pump

Gravity feed of pump

Pressure relief valve

E.g. Walbro GSL 393

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Inner diameter AG2 65 mm

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

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

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

Installation Weber Motor MPE 850 Marine Propulsion 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:

Installation Weber Motor MPE 850 Marine Propulsion System

Yearly service hours are counted in ECU

Illuminated service hour light: Engine to be serviced

Engine hour counter can be reset by diagnostic tool

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System

Installation Weber Motor MPE 850 Marine Propulsion System