Installation Guide MPE 750 Turbo Marine Closed Loop MPE 750 Turbo Marine - Closed Loop This Installation Guide is valid for the following engine variants: • 103666_I2 749 MAR TC-100 DS V4 2007 3.1 • 103730_I2 749 MAR TC-143 DS V1 2007 3.1 103666_EHB_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop Table of contents 1 Mechanical Installation 1 1.1 Engine lift 2 1.2 Engine fixation and decoupling 3 1.3 Power Take Off (PTO) 4 1.4 Throttle cable 5 2 Alignment engine to drive train 6 3 Fuel system 7 4 Cooling water 10 4.1 Supply sea water 12 4.2 Flush system 13 4.3 Boat tow 14 5 Exhaust system 15 6 Electric 17 6.1 Engine monitoring 18 6.2 Schema engine wire harness 19 6.
Installation Guide MPE 750 Turbo Marine Closed Loop 1 Mechanical Installation The following section describes the handling of the engine during installation and the assembly into the boat. In general a clearance of 50 mm between engine and boat hull is required. Vent openings of an area of 9000 m² is needed to give the engine enough air to operate. 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 1.1 Engine lift The engine has two lift eyes (1) at the cylinder head. Only use these eyes to raise the engine. 1 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 1.2 Engine fixation and decoupling The engine mounts are specific for marine applications, a decoupling to the boat is necessary. The picture shows the placement and proposed engine bearings (1) of the marine engine. 2 1 3 Pos. Part No Description QTY 1 100527 engine mount 2 102535 engine bracket front 1 3 100119 engine bracket rear 1 D62 H30 M12 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 1.3 Power Take Off (PTO) The connection to the drive train is by a thread M24x2 on the PTO of the engine 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 1.4 Throttle cable The engine has a mechanical throttle body which has to be activated by a marine throttle cable. The travel of 70 mm is designed to meet the function throttle levers like the Teleflex JBS system. maximum possible position of bowden cable The Teleflex JBS system is designated for jet boats and is available e.g. at Allpa Marine Equipment, part number CH2300 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 2 Alignment Engine to Drive Train The alignment of the engine to the drive train has to be in following limits Radial alignment: max. 0.8 mm [ 0.03 inch ] Angular alignment: max. 0.5° To check and adjust the alignment between the engine and the Weber Automotive Jet Propulsion System a Weber Automotive alignment tool was designed. This tool is using a laser to get the engine with drive system set up properly.
Installation Guide MPE 750 Turbo Marine Closed Loop 3 Fuel System The fuel pump (1) has to deliver 120 liters per hour at a pressure of 4.5 bar. A possible pump and filter configuration is shown in the following picture. To ensure a safe and adequate fuel delivery a minimum inner diameter of 8 mm is required for fuel hoses and fittings. This includes fittings on the gas tank including gas pick up in the tank.
Installation Guide MPE 750 Turbo Marine Closed Loop 3 Fuel System b The fuel rails fittings ars designed conform to SAE J2044. The use of quick connectors (1) (2) is strictly recommended. a (a) Fuel Feed Line from Fuel Pump: Fitting SAE J2044 diameter 7,89 mm for quick connector (b) Fuel Return Line to tank: Fitting SAE J2044 diameter 7,89 mm for quick connectors 1 2 3 fuelrail fuel tank 4 fuel pump 120liter/hour at 4.5bar Pos.
Installation Guide MPE 750 Turbo Marine Closed Loop 3 Fuel System The engine and the fuel components including recommended fuel filters and stainless steel fuel quick connectors are conform to: • USCG: Boatbilder handbook Subpart J - Fuel Systems: Title 33 CFR Sections 183.501-183.
Installation Guide MPE 750 Turbo Marine Closed Loop 4 Cooling Water The engine itself has no water pump to feed the open loop of the cooling system. In a combination with a jet pump the sea water for cooling is delivered by the jet pump propulsion system. By using different propulsion systems a water pump has to be integrated into the drive train. The tube for the sea water supply has to be mounted to the fitting at the charge air cooler 103666_I2 749 MAR TC-100 DS V4 2007 3.
Installation Guide MPE 750 Turbo Marine Closed Loop 4 Cooling Water 103730_I2 749 MAR TC-143 DS V1 2007 3.1 (2) Fitting at charge air cooler for sea water supply . Inner diameter of tube: 19mm 2 The water / water cooler has a fitting to drain the water out of the open loop. This drainage can be implemented into the sea water supply tube. water / water cooler drainage tube from jetpump 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 4.1 Supply Sea Water The delivery of sea water of the open loop cooling circuit has to meet the specification listed in the table. Engine: 98 - 105 kW Engine: 49 - 76 kW engine speed Fresh water pressure Waterflow Fresh water pressure Waterflow HO cooling system HO system SO cooling system SO system (at pump outlet Line) (at pump outlet Line) [ rpm] [ bar ] [ l/min ] [ bar ] [ l/min ] 1500 0.25 13.40 0.18 11.00 2000 0.26 17.50 0.22 12.
Installation Guide MPE 750 Turbo Marine Closed Loop 4.2 Flush System Especially for the use of the boat in salt water a flush system to rinse the open loop cooling circuit is recommended. Therefore a flush system has to be implemented by the boat builder. The following picture shows an example how to implement this kind of system. Jetpump The engine has a wet exhaust system. This means sea water is injected into the exhaust out of the open loop cooling circuit.
Installation Guide MPE 750 Turbo Marine Closed Loop 4.3 Boat tow In combination with a jet propulsion system there is a risk to fill the engine with water by towing the boat. The engine has a wet exhaust system. This means sea water is injected into the exhaust out of the open loop cooling circuit. Due to this water injection the exhaust temperature and also noise is reduced. This water is pressed out of the exhaust system by the exhaust pressure / stream of the engine.
Installation Guide MPE 750 Turbo Marine Closed Loop 5 Exhaust System The exhaust system of the spark ignition marine engine is water cooled. A part of the sea water is injected into the manifold to reduce the exhaust temperature and the noise in the system. This injected water will leave the boat through the exhaust system (1). 1 The rest of the sea water leaves the engine through a fitting (2) at the bottom of the exhaust manifold. This water has to be drained out of the boat. 2 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 5 Exhaust System Engine exhaust manifold and muffler can be connected by a rubber tube, e.g. Marine exhaust tube by VETUS. The muffler should have a volume of approximately 17 Liter and the back pressure of the whole exhaust system has to be: max. 200 mbar - 143 hp max. 180 mbar - 104 hp To avoid a filling of the exhaust system e.g. by the stern wave or during boat slip, the layout should look like shown in the following picture 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 6 Electric The engine will be delivered including an engine wire harness and Engine ECU. All necessary connectors for the vehicle wire hardness are listed in section 6.4. Also diameters of the wires in the vehicle harness have to match the diameters of the engine harness. 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 6.
Installation Guide MPE 750 Turbo Marine Closed Loop 6.2 Schema engine wire harness 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 6.3 Schema boat wire harness 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 6.
Installation Guide MPE 750 Turbo Marine Closed Loop 7 First engine run and brake in After the engine installation is finished a first run with the boat out of the water is recommended. Therefor use the flush system to avoid any damage of the engine due to overheat. The use of the flush system is described in section 4.2. Engine is delivered filled with engine oil by the factory ATTENTION Procedure: Check at first the connection to the drive train.
Installation Guide MPE 750 Turbo Marine Closed Loop 7 First engine run and brake in • Prime the fuel system: Activate the fuel pump by turning on the key switch (not in start position). • Connect the flush system as described in section 4.2 • Start engine. Do not accelerate. The engine may only be operated at idle speed for a maximum of 30 seconds without sea water • Ensure the water supply within 30 seconds • Check if the water out of the outer cooling loop is leaving the boat.
Installation Guide MPE 750 Turbo Marine Closed Loop 8 Maintenance every 50 ■ 2) after 25 Motor oil and oil filter Change 14 ■ 2) Coolant Change 20 Check / clean 23 Change 23 Valve play Check / set 26 Fuel filter Change 32 Activity see page Maintenance interval h 1) Procedure 1st maintenance h 1) Spark plugs every 100 At end of season Following table shows the maintenance intervals for the marine engine.
Installation Guide MPE 750 Turbo Marine Closed Loop 9 Engine Serial Release The engine installation and function has to be released by Weber Automotive before warranty will cover the product.
Installation Guide MPE 750 Turbo Marine Closed Loop 10 Specification for fuel, oil and coolant Fuel: Fuel quality Unleaded gasoline according to DIN 51607 („super unleaded“), with an octane rating of at least 95 ROZ [RON] or 85 MOZ [MON] Oil: Recommendiation: 15W 50 completely synthetic, API SH, JASO MA Alternative 0W 50 Fill quantity Initial filling 4.2 liters [4.4 qt (US)] Oil change with filter 3.3 - 3.5 liters [3.5 - 3.
Installation Guide MPE 750 Turbo Marine Closed Loop 11 Basic dimensions [mm] 117,5 424 547 Please contact Weber Automotive for detailed drawings or CAD models. 214 332 52,5 720 609 140° 140° 295 400 103666_EBH_Rev1.
Installation Guide MPE 750 Turbo Marine Closed Loop 12 Reference Adresses Throttle cable: RCS: Remote Control Systems GmbH www.r-c-s-online.de Contact Mr. Frank Schneider Frank.Schneider@r-c-s-online.de Helm Throttle Level: Teleflex www.teleflexmorse.com Allpa Marine Equipment www.allpa.nl www.allpa.de www.allpa.eu Exhaust Tube: Vetus Allpa Marine Equipment www.allpa.nl www.allpa.de www.allpa.eu Engine Monitoring: VDO Marine www.vdo-marine.com Contact Mr. Joachim Smolka smolka@kienzle.
Installation Guide MPE 750 Turbo Marine Closed Loop 103666_EBH_Rev1.
