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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
thrust pump 148mm 120 HP lb
thrust pump 148mm 85 HP lb
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Installation Weber Motor MPE 850 Marine Propulsion System
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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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Operation conditions:
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Engine compartment
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Engine compartment
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
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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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Fuel system: Layout
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
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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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Exhaust system (not in scope of supply):
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Exhaust system:
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Installation Weber Motor MPE 850 Marine Propulsion System
2. Boat system requirements
Exhaust system:
Note: Inner diameter AG2 65 mm
Inner diameter AG4 76 mm
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Installation Weber Motor MPE 850 Marine Propulsion System
3. Electric system
Chassis connector
(not in scope of supply)Delphi 13880240
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Installation Weber Motor MPE 850 Marine Propulsion System
3. Electric system
Wiring battery (not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
3. Electric system
Charge system: Wiring to voltage regulator (not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
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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Installation Weber Motor MPE 850 Marine Propulsion System
3. Electric system
Electric: Not in scope of supply
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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Installation Weber Motor MPE 850 Marine Propulsion System
3. Electric system
Electric: Not in scope of supply
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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Installation Weber Motor MPE 850 Marine Propulsion System
4. Engine control
TRU: throttle request unit
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Installation Weber Motor MPE 850 Marine Propulsion System
4. Engine control
TRU: throttle request unit
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Engine lift
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Drive shaft angle with weber Motor jet pump system
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Engine decoupling
(not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Engine mounting (not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Engine alignment
(shims not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Engine alignment
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Connect fuel system
(hoses not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
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)
Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Connect seawater out:
(hose between engine and jet not in scope of supply)
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Installation Weber Motor MPE 850 Marine Propulsion System
5. Engine installation
Connect seawater out:
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5. Engine installation
Flush system:
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Installation Weber Motor MPE 850 Marine Propulsion 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
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor 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
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Attach drill jig to jet intake with 4 fastener
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount Edding arbor on alignment shaft
Insert Edding in arbor
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Insert alignment shaft in jig
Mark position for hole for drive
shaft with Edding
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Dismount jig and machine hole for drive shaft
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount pump housing with liner with
4 pcs fastener M8
Length of fastener M8 dependinghull thickness
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount centering jig with 4 pcs fastener M 8
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount arbor for engine mount bore jig
Mount engine mount bore jig
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount vibration isolators to jig
Drill holes for vibration isolators
Mount vibration isolatorsto boat hull
Take off jig
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Mount alignement arbor
Slide back alignement bar to
give room for engine installation
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Engine alignment:
Align engine until arbor of alignment shaft fully and easy
slides into coupler
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Weber Motor jigs:
Jet pump and engine installation by using Weber Motor jigs
Connect seawater in and seawater out to jet pump
seawater in to engine
seawater out from engine
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Installation Weber Motor MPE 850 Marine Propulsion System
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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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Prototype installations without jigs:
Jet pump and engine installation WITHOUT Weber Motor jigs
Dimension 606,5 mm: Measured from pump housing with stainless steel liner to PTO
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Installation Weber Motor MPE 850 Marine Propulsion System
6. Installation Propulsion system: Prototype installations without jigs:
Jet pump and engine installation WITHOUT Weber Motor jigs
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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Installation Weber Motor MPE 850 Marine Propulsion System
7. Check ECU:
Before first engine start
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Installation Weber Motor MPE 850 Marine Propulsion System
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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Installation Weber Motor MPE 850 Marine Propulsion System
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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Installation Weber Motor MPE 850 Marine Propulsion System
9. Vendor controls (not in scope of supply):
Shift cable
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Installation Weber Motor MPE 850 Marine Propulsion System
9. Vendor controls (not in scope of supply):
Throttle cable
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Installation Weber Motor MPE 850 Marine Propulsion System
9. Vendor controls (not in scope of supply):
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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Installation Weber Motor MPE 850 Marine Propulsion System
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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