Weber Automotive MPE 750 Turbo Marine User manual

MPE 750 Turbo Marine
Closed Loop
103666_EHB_Rev1.0_080215
MPE 750 Turbo Marine - Closed Loop
• 103666_I2 749 MAR TC-100 DS V4 2007 3.1
• 103730_I2 749 MAR TC-143 DS V1 2007 3.1
Installation Guide
This Installation Guide is valid for the following engine variants:

MPE 750 Turbo Marine
Closed Loop
103666_EHB_Rev1.0_080215
Installation Guide
Table of contents
1 Mechanical Installation 1
1.1 Engine lift 2
1.2 Enginexation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
6.3 Schema boat harness 20
6.4 Required connectors for boat harness 21
7 First run and brake in of engine 22
8 Maintenance 24
9 Serial release 25
10 Specicationforfuel,oilandcoolant 26
11 Basic dimensions 27
12 Reference addresses 28
13 Appendix 29

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 1
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_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 2
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_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 3
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.
1
2
3
Pos. Part No Description QTY
1 100527 engine mount D62 H30 M12 4
2 102535 engine bracket front 1
3 100119 engine bracket rear 1

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 4
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_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 5
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.
The Teleflex JBS system is designated for jet boats and is available e.g. at Allpa Marine Equipment, part
number CH2300
maximum possible
position of bowden cable

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 6
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. The use of this tool is described in the installation manual of the Weber Jet Propulsion
System.
To adjust the alingnment engine shims (1) are available at Weber Automotive
Part No Description Thickness
103708 engine shim 0,5 mm
103707 engine shim 1,0 mm
1

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 7
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.
Fuel filters (2) (3) have to be used to be avoid damages on the fuel pump and malfunction of the fuel
injectors:
Prefilter (3):
• 105 μm
• e.g. Pierburg 4.000.30.80.0
Mainfilter (2):
• 15 μm, filtergrade 95%
• e.g. Mann&Hummel WK512
3
1
from gastank
to engine
2
1) fuel pump
2) main filter
3) pre filter

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 8
The fuel rails fittings ars designed conform to
SAE J2044. The use of quick connectors (1) (2) is
strictly recommended.
(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
3 Fuel System
Pos. Order No Description Specification Manufacturer
1 104227 quick connector 7,89x90° Weber
2 104228 quick connector 7,89x180° Weber
3 103450 fuel filter, pressure side Mann & Hummel WK512
4 103397 fuel filter, intake side Pierburg 4.000.30.80.0
ba
2
1
fuel tank
4
fuel pump
120liter/hour at 4.5bar
3
fuelrail

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 9
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 183.501-183.590
• DIN EN ISO 10088 - Pemanently installed fuel systems and
fixed fuel tanks
Consult the specifications for gas tanks, fuel pump and fuel line
installation of USCG Boatbilders handbook and the Directive 94/25/EG
last amended by 2003/44/EG

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 10
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
1
103666_I2 749 MAR TC-100 DS V4 2007 3.1
(1) Fitting at charge air cooler for sea water
supply. Inner diameter of tube: 19mm
tube from jetpump
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

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 11
4 Cooling Water
tube from jetpump
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

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 12
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 speed
Engine: 98 - 105 kW Engine: 49 - 76 kW
Fresh water pressure
HO cooling system
(at pump outlet Line)
Waterflow
HO system
Fresh water pressure
SO cooling system
(at pump outlet Line)
Waterflow
SO system
[ rpm] [ bar ] [ l/min ] [ bar ] [ l/min ]
1500 0.25 13.40 0.18 11.00
2000 0.26 17.50 0.22 12.20
2500 0.38 21.40 0.20 13.00
3000 0.58 26.20 0.25 15.00
3500 0.77 32.00 0.35 19.00
4000 0.98 36.70 0.51 24.00
4500 1.22 40.70 0.69 29.50
5000 1.49 47.20 0.92 35.00
5500 1.85 54.60 1.19 41.00
6000 2.20 61.60 1.53 46.50
6500 2.62 67.80 1.84 53.00
7000 3.00 71.70 2.20 59.00
7500 3.39 74.00 2.51 63.50

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 13
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.
4.2 Flush System
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 of the engine. If the engine does not run there is
no mechanism to drain the exhaust system.
Flush procedure:
• Connect the Flush kit
• Start the engine and operate only in idle. Do not accelerate
• Ensure the water supply within 30 seconds
• Flush the open loop cooling circuit for one minute minimum
• Stop water supply
• Stop engine within 30 seconds
• Remove the flush kit
Never flush without a running engine otherwise there is
a high risk to fill the engine with water
The engine may only be operated at idle speed for
maximum of 30 seconds without flush water
ATTENTION
Jetpump

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 14
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. If the engine does not run
there is no mechanism to drain the exhaust system.
By towing the boat the jet pump system delivers sea water to the engine even without running engine. This
means water will be injected into the exhaust system. When the exhaust system is fully filled with water it will
fill the engine with water.
Don’t tow the boat with a high speed. If a high
tow speed is necessary the water feed tube
between jet pump and engine has to be closed
by a clamping device or a closure valve has to
be installed.
ATTENTION

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 15
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).
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
1

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 16
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
5 Exhaust System

103666_EBH_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 17
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_Rev1.0_080215
MPE 750 Turbo Marine
Closed Loop
Installation Guide
Page 18
6.1 Electric
The engine can give out following output / informations:
• MIL (Malfunktion Indicator Light): Will be activated when engine performance is limited
• Engine overtemperature lamp: Is activated when engine temperature exceed the limit
• Oil pressure lamp
• Engine speed signal
• Engine up to 98 kW: 2 pulses/rev
• Engine 105 kW: 6 pulses/rev
The wireing for the oil pressure lamp is not included in the engine wire
harness and has to be implemented in the boat harness.
The EMS / engine package includes sensors and control strategies for:
• Raw water supply: temperature sensor in exhaust manifold
• Altitude: air pressure sensor
• Temperature: air and coolant temperature
• RPM: Crank sensor
• Start: Phase sensor for cylinder 1 detection
• Turbo System: pressure sensor for boost control
• Oil System: oil pressure switch to warning lamp
• Emissions / Performance: closed loop lamda control
Specification
Malfunktion Indicator Light (MIL) max. 10 Watt
engine overtemperature lamp max. 10 Watt
oil pressure lamp max. 10 Watt
engine speed signal Engine up to 98 kW: 2 pulses/rev
Engine 105 kW: 6 pulses/rev
battery capacity 12 V / 10 Ah
starter solenoid 600 A steady state
internal generator with regulator Idle: 150 Watt > 3000rpm: Watt max. 340 Watt