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FNM HPEP 225, Installation Manual

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INSTALLATION MANUAL   

                       HPEP 225

 - 

HPEP 250

 

       DIESEL ENGINE & BRAVO STERN DRIVES

 

 
 
 
 
 

 

 

 

 
 
 

First Release  

May 2006 

 
 
 
 
 
 
 
 
 
 
 

 

 

 

Summary of Contents for HPEP 225

Page 1: ...1 INSTALLATION MANUAL HPEP 225 HPEP 250 DIESEL ENGINE BRAVO STERN DRIVES First Release May 2006...

Page 2: ...nd Surface Engine Bed Engine Compartment Engine Compartment Ventilation Exhaust System Fuel Delivery System Battery Battery Cables Instrumentation Power Trim Control Power Trim Pump Location Propeller...

Page 3: ...eivable application or installation We have not undertaken any such wide evaluation Therefore any manufacturer which or person who applies or installs the product in a manner which does not fulfill th...

Page 4: ...are to be removed the boat must be water tested to ensure that the increased trim in range does not cause any undesired boat handling characteristics bow steer chine walk etc if the stern drive is tri...

Page 5: ...cts the slave sterndrive to the sterndrive that is directly connected to the factory power steering output This internal tie bar is available in a variety of lengths from the sterndrive manufacturer I...

Page 6: ...ernal power steering BUT where mechanically possible with the external tie bar mounted at the trim cylinder boss location as previously described in Internal and External Tie Bar This system does not...

Page 7: ...A1 U Joint and Gimbal Bearing Grease1 92 802870A1 Special Lubricant 101 92 802865A1 Liquid Neoprene 92 25711 3 Power Trim and Steering Fluid 92 802880A1 Dexron III Automatic Transmission Fluid Obtain...

Page 8: ...7 35 Steering System Pivot Bolts 34 25 Stern Drive Fasteners 68 50 Transom Assembly Fasteners 31 23 Seawater Pickup Fitting 5 45 Power Trim Cylinder Fasteners Keep tightening up to contact point 1 Amo...

Page 9: ...re power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire A Quicksilver Galvanic Isolator can be installed to block t...

Page 10: ...pper or tin base paints if not prohibited by law can be used If using copper or tin based anti fouling paints observe the following Avoid an electrical interconnection between the Mercury MerCruiser P...

Page 11: ...surface must conform to the following Transom Specifications Thickness Between 2 2 1 4 in 51 57 mm for 8 in 203 mm to either side of the vertical centerline1 1 Parallelism Inner and outer surfaces mus...

Page 12: ...ocation to the right rear mount location and another from right front to left rear The strings should touch where they cross ENGINE COMPARTMENT ENGINE COMPARTMENT WARNING Boating standards NMMA ABYC e...

Page 13: ...must be increased if any auxiliary equipment is located in the engine compartment The combustion air requirement per engine for the specified engines at wide open throttle are shown in the chart belo...

Page 14: ...opening the engine cover During the test in Step 1 engine compartments are to remain closed No outside air is to be forced into the engine compartment during the test and the bilge blower should not...

Page 15: ...amage the engine Damage caused by water in the engine will not be covered by C M D srl Warranty unless this damage is the result of defective part s Verify that the riser provides the required dimensi...

Page 16: ...ust be well secured The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets This prevents damage to the lines from abrasion FUEL CONNECTIO...

Page 17: ...fuel tank for the additional filter The position selected must be free from vibrations and allow for easy inspection and replacement It is also recommended that a diesel fuel additive be used to comba...

Page 18: ...Do not use acid flux solder as it may cause corrosion and a subsequent failure Battery Cable Length Minimum Cable Gauge Fino a 0 9m 3 ft 2 35mm2 0 9 1 1m 3 3 3 4 ft 1 50mm2 1 1 1 4m 3 3 4 4 3 4 ft 0...

Page 19: ...19 Notes...

Page 20: ...teriesin the case that it is necessary to use an auxiliary battery As you will be able to see this scheme uses a device that makes sure that the alternator charges also the auxiliary battery without h...

Page 21: ...cambiabatterie interruttori di selezione manuali Lo scambiabatterie prevede la possibilit di utilizzare e caricare le varie batterie individualmente o in connessione parallela mediante selezione manua...

Page 22: ...hat need to be done are as following 1 when looking at the ignition key from behind figure 1 proceed to disconnecting the female fast on from the pin 50a as indicated by the arrow 2 connect the two el...

Page 23: ...23 Figure 2...

Page 24: ...ature Voltmeter Cruise Log Engine Hour Meter Trim Gauge In addition to basic gauges consideration should be given to providing indicator lamps for the following Preheat Glow Plugs If Equipped Charging...

Page 25: ...s are secure Fasten harness to boat at least every 400 mm 17 inches using appropriate fasteners NOTE It may be necessary to use an adapter harness on some models where the engine harness and instrumen...

Page 26: ...at meets the following requirements Within limits of black and gray hydraulic hoses coming from gimbal housing assembly Close to the battery so that trim pump battery leads can be connected Allow easy...

Page 27: ...peller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the specified operating rpm range will cause higher than normal wear and or...

Page 28: ...ge Engine coolant must flow continuously from the engine intake manifold to the engine water circulating pump NEVER close off or block the coolant flow to or from a heater All heater installations mus...

Page 29: ...e it will be easily accessible and supported adequately to prevent hose fatigue A brass ball or gate valve is required Select a proper seacock based on the following chart Seacock Size Internal Cross...

Page 30: ...a means of locking it to the guide tube WARNING Failure to use a steering cable locking device could cause loss of steering which could cause damage to the boat and or injury All current production st...

Page 31: ...er dimensions is installed severe damage to transom assembly and or steering system may result DO NOT attempt to adjust cable guide tube on power steering unit as guide tube and locknut have been torq...

Page 32: ...mm Min Flat f 7 64 in 3 1 mm Min Radius g 5 8 in 15 9 mm Max Diameter End Fitting h 3 8 in 9 5 mm i 3 8 in 9 8 mm Diameter Through Hole Chamfered Each Side j 1 3 8 in 34 9 mm Max k 5 8 in 15 9 mm Diam...

Page 33: ...owever pulling power for skiing will decrease During testing X Dimension should be increased 1 2 in 13 mm at a time until desired performance is achieved but in no case should it ever be increased by...

Page 34: ...and mark crankshaft vertical centerlines on transom a Crankshaft Vertical Centerline Drawn Through Desired Mounting Locations b Minimum Distance Between Crankshaft Vertical Center Lines c Crankshaft...

Page 35: ...e Unit Location Bravo One Two Three 13 9 16 in 345mm IMPORTANT This dimension should only be raised or lowered after proper testing 2 Determine X Dimension location of crankshaft centerline a Place 90...

Page 36: ...m 13 14 1 8 in 359 mm 12 14 1 16 in 357 mm 11 14 in 356 mm 10 13 15 16 354 mm 2 Follow instructions a or b a For Single Engine Applications 1 Measure and layout horizontal line as shown 2 Locate and m...

Page 37: ...ce Between Crankshaft Vertical Centerlines Chart for minimum measurement 4 Draw two vertical lines from the bottom of the transom to the crankshaft center line marks on horizontal lines 5 Measure upwa...

Page 38: ...with lines previously marked on transom If cutout is made incorrectly drive unit steering lever may contact transom thus limiting steering travel IMPORTANT Drill 1 4 in 6 mm pilot holes for hole saw g...

Page 39: ...engine and the thru propeller exhaust system With any application installation of an exhaust tube will increase exhaust noise With Bravo Three Drive Models the exhaust bellows must be removed and an...

Page 40: ...40 a Exhaust Tube b Clamp c SIDE Marking d Exhaust Tube e Grounding Clip...

Page 41: ...steners using an X pattern torque sequence Tighten in small increments and go around the pattern several times until the proper torque is achieved 3 Secure transom assembly with hardware as shown Torq...

Page 42: ...s to trim pump Torque fittings to 125 Ib in 14 Nm 3 Connect power trim pump control harness to trim pump 4 Connect trim limit switch wires and secure with wire retainer and sta strap a Black Hose Fitt...

Page 43: ...Installer Refer to Installation Requirements Steering Helm and Cable for steering selection and couplet nut locking requirements 4 Install steering assembly as follows a Position steering assembly so...

Page 44: ...o 34 Nm 25 Ib ft Bend kasher tabs against corresponding flats on bolt heads NOTE It may be necessary to tighten further to align flats on pivot bolt with tabs on tab washer Manual Steering a Tab Washe...

Page 45: ...a Remove shipping cap from both ends of steering cable guide tube or control valve spool b Coat steering cable end with a liberal amount of Special Lubricant 101 c Install steering cable and secure wi...

Page 46: ...01 c Shipping Hardware 3 Remove upper and lower pivot bolts and ensure threads are well lubricated with Special Lubricant 101 4 Install steering assembly as follows a Position steering assembly so tha...

Page 47: ...kasher a Tab Washer b Ridge c Pivot Bolts CAUTION MOVING THE CONTROL VALVE CABLE GUIDE TUBE with the hoses disconnected will expel fluid from the ports Wear eye protection 6 The cable guide tube may...

Page 48: ...otter pin hole is as shown in the diagram a Clevis b Steering Lever c Clevis Pin d Cotter Pin IMPORTANT Steering cable has a self locking couplet nut and does not requie an external locking sleeve or...

Page 49: ...flat surfaces on the cable guide tube in the vertical position Torque coupler nut to 47 Nm 35 lb ft Be certain the flat surfaces are still aligned vertically after torque is applied to coupler nut IMP...

Page 50: ...tall and torque to 13 Ib in 1 5 Nm a Barb Fitting NOTE Barb fitting is designed for 5 32 in 4 mm hose 3 Connect an appropriate hose not provided from speedometer to barb fitting Secure hose to fitting...

Page 51: ...Hose Clamp d Gimbal Housing Fitting e Gear Lube Monitor 3 Install water inlet fitting Install hose clip Torque bolts and star washers to 5 Nm 45 lb in 4 Route lube monitor hose to port side of engine...

Page 52: ...0 hose fitting 5 Position quick release button on hose fitting away from water inlet fitting Release button must not contact water fitting a Water Inlet Fitting b Star Washer And Screw c 90 Hose Fitti...

Page 53: ...cription of the engine Four stroke Diesel Engine 5 cylinders in line Displacement 2387 cc Bore x stroke 82 x 90 4 mm Compression Ratio 18 45 1 Maximum Torque 494 Nm at 2600 rpm for the HPEP 250 416 Nm...

Page 54: ...dentification plates which feature the identification data for the engine commercial denomination and serial number One plate is located on the upper side of the engine on the intercooler cover The ot...

Page 55: ...55 Engine dimensions...

Page 56: ...hat could cause a poor electrical connection b Ensure the positive battery cable is inserted through the protective rubber boot before attachment c After battery cables are connected apply a thin coat...

Page 57: ...ter and exhaust may leak into boat a Gimbal Housing Mating Surface b O Ring 1 Install exhaust pipe assembly as shown using four 4 bolts and thick lockwashers Torque bolts to 23 Ib ft 31 Nm 2 Position...

Page 58: ...s level when suspended a Rear Lifting Eye b Front Lifting Eye 2 Lift engine into position in boat using an overhead hoist 3 Align rear engine mounts with inner transom plate mounts while simultaneousl...

Page 59: ...for the engine Therefore before installing the engine make sure that the mounts of the coupling bell to the stern drive and the the mounts of the inner plate of the transom left and right are correct...

Page 60: ...c For the models with the new mounts knurled surface use only the fiber washer Do not use the double blade safety washer a New mount knurled surface b Fiber washer...

Page 61: ...ount c Bolt d Washer e Spacer f Fiber Washer g Double Wound Lockwasher IMPORTANT Finished boat stringer must position engine so that some mount adjustment remains after front mount is adjusted down to...

Page 62: ...oupler CAUTION To avoid damage to gimbal bearing engine coupler or alignment tool DO NOT attempt to force alignment tool DO NOT raise or lower engine with alignment tool inserted or partially inserted...

Page 63: ...bolt on both front mounts and move engine as necessary NOTE A small amount of side to side adjustment can be obtained from the slots on the engine mount pads We strongly advise that you also use a loc...

Page 64: ...er splines DO NOT check by turning NOTE This may require tapping the sides of the tool DO NOT check by turning By greasing the splines you can identify which side has interference a Alignment Tool b G...

Page 65: ...ing in a saltwater environment apply a seal to threads and nuts to help protect against corrosion This will allow for easier loosening in the future if readjustment becomes necessary We strongly advis...

Page 66: ...TION Ensure gear lube monitor hose is not kinked when connecting in the following step If hose is kinked gear lube monitor will not function properly and damage to stern drive could occur 2 Route gear...

Page 67: ...prevent fluid leaks IMPORTANT Be careful not to cross thread or overtighten fittings 6 Connect power steering hoses to control valve Torque both fittings to 23 lb ft 31 Nm a Rear Fitting Pressure Hose...

Page 68: ...AUTION Avoid exhaust hose failure Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned through exhaust...

Page 69: ...t recovery bottle and mounting bracket that meets all of the following a Within limits of clear plastic tubing b Accessible for observing coolant level and filling 3 Mount coolant recovery bottle and...

Page 70: ...ire supplied with engine package from engine to transom assembly Tighten inner transom plate screw securely IMPORTANT Do not attach any accessori round wires to transom plate round point a Flywheel Ho...

Page 71: ...en harness to the boat at least every 400 mm 17 in using appropriate fasteners 3 Connect extension harness to engine harness end Connector collars must be fully engaged and secure Tighten threaded con...

Page 72: ...lt and Nut a From Remote Control b From Instrument Harness c Rubber Sleeve MERCATHODE CONTROLLER IF EQUIPPED 1 Connect electrical leads to controller assembly 2 Apply a thin coat of liquid neoprene to...

Page 73: ...moves in direction B when control lever is placed in FORWARD remote control is setup for LEFT HAND LH propeller rotation A 0 All Bravo One Two c All Bravo Three Front propeller on drive unit is always...

Page 74: ...tape over the barrel retainer a Shift remote control to NEUTRAL b Push in on shift cable end with enough pressure to remove play and mark position a on tube c Pull out on shift cable end with enough p...

Page 75: ...de anchor pin from shift lever and removing cable Attempting to bend shift cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur c...

Page 76: ...orward slot in tool should fit over shift lever stud If slot does not fit over stud loosen shift lever stud and slide stud either direction until slot in tool fits over stud When adjustment is correct...

Page 77: ...back towards any fiberglass structure the cables will be interfered with this will cause very hard shifting NOTE The control box housing can be rotated in 30 increments to improve cable routing Prope...

Page 78: ...his will crush the inner cable tubing and cause improper and or stiff shifting 8 Do NOT fasten the shift cable with straps or clamps to any other cable within 5 ft 1524 mm of the shift plate 9 Do NOT...

Page 79: ...h flat kasher and split pin 3 Regulate the lenght of the cable with the cable clamp 4 Tighten locknut until it touches the adjustment clamp a Throttle Cable End anchored with flat kasher and split in...

Page 80: ...ve gear lube monitor bottle cap Fill with gear lubricant a Typical gear lube monitor bottle b Cap 3 Push dribble valve stern drive in until gear lube appears Release dribble valve a Dribble Valve Ster...

Page 81: ...shaft splines with Engine Couplet Spline Grease Typical a Shaft splines b Shaft O Rings 9 Inspect drive shaft bellows for cleanliness and absence of debris a Drive Shaft Bellows 10 Lubricate O ring s...

Page 82: ...sembly in the sterndrive 12 Place remote control in neutral position NOTE As bell housing shift cable enters the shift linkage assembly it pushes the assembly back into the sterndrive housing and the...

Page 83: ...housing and into engine coupler Make sure that shift linkage jaws engage the bell housing shift cable assembly d If necessary rotate propeller shaft counterclockwise slightly using a propeller to alig...

Page 84: ...changed after the boat has been properly tested Refer to statement at the front of this manual entitled Bravo Three Notice Trim In Limit Insert IMPORTANT To aid in installing bushings use a water and...

Page 85: ...iately atop the transom end of the anti ventilation plate 19 Insert speedometer tube fitting into opening on topside of anti ventilation plate in position shown a Speedometer Tube Fitting b Opening 20...

Page 86: ...very read General Information and Installation Require ments completely 2 Connect engine negative battery cable usually BLACK to negative battery terminal 3 Connect power trim pump BLACK battery cable...

Page 87: ...discard cap plug from fill neck Replace fill cap a Cap Plug b Fill Cap 2 Fully raise and completely lower drive unit 6 to 10 times to purge air from system 3 Position drive unit in the full DOWN IN p...

Page 88: ...it and engine could result from lack of cooling water 2 Turn ignition key to the RUN position 3 Trim drive unit to the full DOWN IN position 4 Rotate trim position sender as required to show full DOWN...

Page 89: ...teering system CAUTION DO NOT run power steering dry or pump will be damaged 1 Position drive unit so that it is straight back 2 Remove fill cap from power steering fluid reservoir and check fluid lev...

Page 90: ...Gear lube monitor only MAINTAINS drive oil level and will not correct an improperly filled drive unit 2 Fill gear lube monitor with High Performance Gear Lube When oil starts to run out the oil vent h...

Page 91: ...future removal of the propeller liberally coat propeller shaft splines with one of the following Quicksilver lubricants Special Lubricant 101 2 4 C Marine Lubricant with Teflon IMPORTANT Installation...

Page 92: ...o aid in future removal of the propeller liberally coat propeller shaft splines with one of the following Quicksilver lubricants Special Lubricant 101 2 4 C Marine Lubricant with Teflon IMPORTANT Inst...

Page 93: ...the propeller shaft splines with one of the following Quicksilver lubricants Special Lubricant 101 2 4 C Marine Lubricant with Teflon 2 Install propellers with attaching hardware as follows a Slide fo...

Page 94: ...removed to avoid injury CAUTION Overheating from insufficient cooling water will cause engine and drive damage Ensure that there is sufficient water always available at the water inlet holes during op...

Page 95: ...is will rotate the starter motor and engine oil pump During this process the engine will not run because no fuel is injected Allow the starter motor to cool down for one minute and repeat the above de...

Page 96: ...is not contacting cutout in transom If contact is being made modify cutout 3 Check steering cable end dimension with cable FULLY EXTENDED Refer to Installation Requirements for proper steering cable d...

Page 97: ...sterndrive unit so that it is straight back 17 Remove dipstick from power steering fluid reservoir and observe fluid level 18 Level should be between the marks on dipstick a Power Steering Fluid Reser...

Page 98: ...y switch to START position for 15 seconds This will rotate the starter motor and engine oil pump During this process the engine will not run because no fuel is injected Allow the starter motor to cool...

Page 99: ...ming out High rpm caused by excessive trimming should not be used when checking for correct propeller The rpm should be near the top of specified range so that under a heavy load engine speed will not...

Page 100: ...d to prevent corrosion and freeze damage to engine 1 Drain water from seawater cooling system if Power Package will not be used for an extended period of time or will be exposed to freezing temperatur...

Page 101: ...Mount c UP Solenoid d 110 Amp Fuse e DOWN Solenoid f Trim Trailer Switch g Neutral Switch To Instrument Wiring Harness h Trim Limit Switch BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN PNK PINK...

Page 102: ...102 MerCathode System BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LT OR LIT LIGHT DRK DARK...

Page 103: ...FNM HPEP 225 250 a Controller b 20 Amp Fuse c Electrode d Black Wire With Engine Harness or Separate Model Dependent...

Page 104: ...em of the electronic control of the FNM engine HPE 225 250 The parts that constitute the electric system of the engine are as following Waterproof box in steel featuring the ECU Engine harness Instrum...

Page 105: ...lectronic Control Unit 2 Stamped circuit with fuses and relays whose main purpose is that of protecting the system from overcurrents On the outside of the box you will see a series of connectors that...

Page 106: ...ed on the box The connectors are waterproof and they are made of a material that is highly resistant to sea water salt All the connectors on the harness are waterproof and they features steel contacts...

Page 107: ...h bayonet locks that are meant to block and lock the wire connector male connector carrier in a very effective and rapid way The engine harness is made of the following connectors 1 Main 64 pin connec...

Page 108: ...FNM HPEP 225 250 2 5 pin Connector This is a 5 pin connector that is used for the sensor whose main task is that of taking the air intake capacity and air intake temperature...

Page 109: ...and the dashboard 4 Connector for the rpm sensor This is a 2 pin connector that is supposed to be connected to the Hall Effect RPM sensor featured on the engine The cable that carries the signal in th...

Page 110: ...ming sensor and the turbocharging pressure sensor with the main difference being the different polarization which makes it not possible to hook up this connector on either the timing sensor or the tur...

Page 111: ...ent where the five injector connectors are placed 10 Connector for throttle potentiometer This is a 6 pin connector that is connected to the wiring of the throttle potentiometer see Figure 4 Figure 3...

Page 112: ...12 Connector for the fuel pre heating resistor placed in the fuel filter This is a 2 pin connector aimed at pre heating the resistor that is responsible for the fuel pre heating The counterpart is pla...

Page 113: ...re 15 Connector for glow plugs This is a 1 pin female connector that is inserted on the glow plug 16 Connectors for the glow plug modulus These are two connectors that need to be connected to the glow...

Page 114: ...eyelet connector with a 6 mm hole is to be connected to the glow plug modulus while the eyelet connector with an 8 mm hole is to be connected to the direct 12 V of the battery which can be drawn from...

Page 115: ...g for the connection to the diagnosis instrument Reflex unit This is a wiring that is used to connect the diagnosis instrument to the ECU box in order to find out whether there is any malfunctions in...

Page 116: ...is to be connected to the negative of the fuel pump sign on the pump in order to secure and fasten this connector you need to use a wrench N 8 21 Connector for the VDO temperature sensor These are co...

Page 117: ...starter This cable carries the 12 V that are directed to the ECU box 24 Connector that takes the engine ground signal This eyelet connector with a hole of 8 mm is to be connected to the engine ground...

Page 118: ...ight placed on the instrument panel This is an eyelet connector with a hole of 5 mm that takes the signal from the alternator to the panel instrument It provides the panel with a signal that shows tha...

Page 119: ...Red 10 CODE 12V after ignition key F2 Red 10 CODE 12V direct F3 Red 10 OBD F4 Red 10 After ignition key KEYON pin 58 F5 Brown 7 5 Main relay F6 Blue 15 Fuel pump F7 Transparent 25 Fuel Heating F9 Blue...

Page 120: ...y Quaff Research Therefore please avoid using other types of cables In order to avoid bad connections you will see that there is stickers featuring the symbols for the oil pressure and water temperatu...

Page 121: ...FNM HPEP 225 250...

Page 122: ...FNM HPEP 225 250...

Page 123: ...at is feeded into the engine 1 intercooler then it cools power steering oil and the fuel feed circuit 2 double exchanger with pipes then it cools the internal cooling ciruit water 3 exchanger with pla...

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