Mi mr700 6_systems installation

MR700

SYSTEMS INSTALLATION
The systems which need to be interconnected in order for the engine to work, must be
implemented by the installer according to the technical data provided by VM Motori S.p.A.
and to the information contained in this manual.

• Electric system;
• Control panel wiring;
• Fuel system;
• Exhaust system;
• Sea water feeling and draining system;
• Throttle Cable Installation;
• Services.

ELECTRICAL SYSTEM
The installer shall carry out the electrical connection between:
Engine interface connector and control panel
ECU power supply connector and battery
Engine Starter motor and Battery
The electrical system must be planned and carried out with extreme care and designed
with an eye to simplicity.
The cables and connectors used in the electrical system must be of a type suited for
marine use. The cables must be enclosed in a protective sheath and must be laid
appropriately.
Ensure that the conductors are not installed near the hot parts of the engine or near heat
sources. Cables must not be subjected to mechanical stress. If necessary, they can be led
through protective conduits.

ENGLISH - 20/58- SYSTEMS INSTALLATION
THE PRESENT DOCUMENT IS PROPERTY OF VM MOTORI S.P.A.; IT IS PROTECTED ACCORDING TO THE LAWS IN FORCE ON COPYRIGHT AND INDUSTRIAL
PROPERTY; ITS REPRODUCTION, ITS DELIVERY TO A THIRD PARTY OR ANYWAY ITS CIRCULATION IS NOT ALLOWED WITHOUT PREVIOUS WRITTEN CONSENT OF
VM MOTORI S.P.A.; OFFENDERS WILL BE PROSECUTED ACCORDING TO THE LAWS. THE CONTENT OF THIS DOCUMENT IS STRICTLY CONFIDENTIAL AND NO
INFORMATION CAN BE DISCLOSED TO THIRD PARTIES WITHOUT VM MOTORI S.P.A. PRIOR AGREEMENT.

MR700

Power supply Interface
connector connector

Extension cable

Install the extension cable between the Interface connector and Control panel

Power supply cable

Install the Power supply cable between the power supply connector and Battery as
shown in the following electric diagram.

INFORMATION MAY BE DISCLOSED TO THIRD PARTIES WITHOUT VM MOTORI S.P.A. PRIOR AGREEMENT.

MR700

The ECU power supply cable must be connected directly to the engine battery to avoid
voltage drops during cranking phase.
A 30A fuse (not included in the supply), installed as close as possible to the battery is
recommended to protect the power supply line from the battery to the engine.


MR700

Positive battery cable Starter motor
Connection point

Install the Positive battery cable (not included in the supply) between the Starter motor
and the battery positive pole.

Negative battery cable
connection point

Install the Negative battery cable (not included in the supply) between the engine
negative connection point and the battery negative pole.


MR700

Neutral safety switch cable:
Install the neutral safety switch cable
between neutral safety switch and the
2 way connector on the engine wiring
harness instead of the bypass jumper
as shown below

Engine wiring harness with bypass
jumper installed (standard).
Warning! This by-pass allows the
engine to crank on even with gear
engaged

Remove the bypass-switch jumper

Connect the 2 way connector to the
engine wiring harness and the two
eyelets to the neutral safety switch.


MR700

Thermal Circuit Breakers

BREAKER CURRENT DESCRIPTION
F1 20 A UNSWITCHED +12V FOR KEY SWITCH AND CONTROL PANEL

F2 10 A +12V KEYSWITCH ECU INPUT SIGNAL

F3 10 A +12V POWER SUPPLY FROM MAIN RELAY TO ECU

F4 15 A +12V POWER SUPPLY FROM MAIN RELAY TO ECU

F5 15 A +12V POWER SUPPLY FROM MAIN RELAY TO ACTUATORS

F6 5A UNSWITCHED +12V FOR DIAGNOSTIC TOOL CONNECTOR


MR700

Diagnostic system
connection

On the engine, at the side of the electronic control unit, there is a connection for the
diagnostic system, which is to be used only for controlling the control unit during
maintenance.


MR700

Selecting The Battery

IMPORTANT: Boating industry standards (BIA, ABYC, etc.) federal standards and Coast
Guard regulations must be adhered to when installing battery. Be sure
battery cable installation meets the pull test requirements and that positive
battery terminal is properly insulated in accordance with regulations.

It is recommended (required in some states) that battery be installed in an
enclosed case. Refer to regulations for your area.
Engine electrical system is negative (-) ground.

Select a battery that meets all of the following specifications:
• 12-volt marine type.
• Tapered post connectors or side terminal connectors. Do not use a battery with wing
nut connectors.

Battery capacity rating of at least:

Engine Minimum Required Cranking Battery Size

MR704/MR706 120 Ah, cca 750 A EN


MR700

Battery Precautions For Multiple Engines With Electronic Control

Alternators: Alternators are designed to charge a single battery that supplies electrical
power to the individual engine that the alternator is mounted on.

Batteries: Boats with multi-engine Electronic Control power packages require each engine to be
connected to its own battery. This assures that the engine's Electronic Control Unit (ECU) has a
stable voltage source.

Battery Switches: Battery switches should always be positioned so each engine is running off its
own battery. Do not operate engines with switches in BOTH or ALL position. In an
emergency, another engine's battery can be used to start an engine with a dead battery.

Generators: The generator's battery should be considered in the same manner as another
engine's battery.


MR700

Selecting The Battery Cables
Select battery cables that meet the following specifications:
• Battery cables must comply with SAE J1127 or comparable standards.
• Battery cable terminals must be soldered to cable ends to assure good electrical
contact, using electrical grade (resin flux) solder only. Some form of mechanical
connection (such as swage or crimp) is also recommended, and is required if length of
solder connection is less than 1 -1 /2 times the diameter of the stranded area of the cable.
• Battery should be located as close to the engine as possible.
• Select proper cable gauge. Length in charts are for one way from battery to engine.
Refer to the longest cable length (positive or negative) selecting the cable size from the
table below.

In-Line Diesel Engines

Battery Cable Length Minimum Cable Gauge

0.9m (Up to 3 ft) 30mm2 (2)

0.9 -1.1m (3 -3-3/4 ft) 50mm2 (1)

1.1 - 1.4m {3-3/4 - 4-3/4 ft) 50mm2 (0)

1 .4 - 1 .8m (4-3/4 - 6 ft) 70mm2 (00)

1.8 -2.3m (6 -7-1 /2ft) 90mm2 (000)

2.3 -2.9m (7-1/2 -9-1 /2ft) 100mm2 (0000)

2.9 -3.7m (9-1/2 -12 ft) (*) 70mm2 (00)

3.7 -4.6m (12- 15ft) (*) 90mm2 (000)

4.6 -5.8m (15 -19 ft) (*) 100mm2 (0000)

(*) Two cables of specified gauge required for positive and two required for negative.


MR700

Battery Cable Installation Requirements

• Battery cables must be routed above normal bilge water levels throughout their length.

• Battery cables must be routed to avoid contact with metallic fuel system components.

• The positive battery cable must be routed to avoid contact with any portion of the
engine or drive train.

• Cables that are exposed to physical damage must be protected by conduit, raceways,
tape, etc.

• Cables that pass through bulkheads or other structural members must be protected
against chafing with grommets, etc.

• Connect the negative battery cable to the unpainted locations shown in Connections
information to ensure good electrical contact.


MR700

FUEL SYSTEM
General
The installation of the fuel system components: fuel tanks, shut-off valves, fuel line, filters
and extra filters, etc., must be carried out carefully to ensure sufficient supply of fuel to the
engine as well as to fulfil the requirements of perfect sealing and protection against fire.
Carefully plan the location of the tank before beginning work. Use good quality shutoff
valves to prevent the fuel from dripping. A fuel system that always drips implies a great risk
of operation.
The shutoff valves must be located preferably outside the engine room or must be
controlled from a remote position.
The amount of fuel can be subdivided between several tanks to maintain the center of
gravity as low as possible and also to give the hull certain possibilities of longitudinal
stability.
If the tanks are structural, then sufficient ventilation must be provided to the surrounding
space.

The local legislation can apply more strictly all the prescriptions
recommended and published in the literature of the engine manufacturers.

Make sure that the high pressure pipes between the injector pump and the injectors are
not bent and are not stopped on the engine because there is a risk of bending the high
pressure pipes.
Do not put anything under the high pressure pipes, and keep the original seals intact.
Otherwise, there will be a risk of breaking the pressure lines and of causing fire.
When working on the fuel system, it is important to keep it free from dirt.
The installer has to connect the fuel circuit inlet and prepare a fuel supply system in
compliance with the data reported in chapter “Installation data”.
The following diagram illustrates the fuel high pressure (red) and low pressure (blue)
circuits.

The interconnecting point to which the installer has to connect the fuel supply is indicated
as fuel inlet.


MR700

Schematic fuel circuit MR 704/706:


MR700

Fuel Cooler
Iniectors

High Pressure
Fuel Pump
Rail
Fuel Filter

Fuel Filter

High Pressure
Fuel Pump


MR700

Fuel tank
If possible, fuel tank have to be located on the same level or someway above the engine. If
it is installed in a lower position, then due attention must be paid to the maximum suction
head of the high pressure fuel pump, that must not exceed -250 mbar.
Note that the suction head must be calculated from the bottom end of the suction piping.
The fuel return piping must be installed submerged approximately 10 mm over the bottom
of the tank and distant from the suction pipe to prevent air from entering when the engine
is turned off.
If the tank is located under the level allowed by the suction head of the pump, then the fuel
has to be delivered into a tank by means of a pump.

Flexible connections
All pipes from and to the propulsion unit must be fitted with flexible connecting elements.
These flexible connecting elements are available in the VM scope of supply and their
purpose is to compensate for relative motions between the propulsion plant and the
onboard piping systems. If the hoses, bellows or rubber sleeves are not supplied by VM,
they must satisfy the minimum requirements for plant operation. If doubt arises, customers
should consult VM to ascertain the displacements occurring at the interfaces due to
movements of the resilient mounts and thermally induced expansion. The invariable rule is
that all flexible connecting elements must be connected directly with the on-engine
interface.

Notes on installation:
The installation characteristics for the hoses, bellows and rubber sleeves are stated in the
chapter installation data.
If welding is performed on the on-board piping system, it is important ensure that no
hoses, rubber bellows or rubber sleeves are installed in the line, as they could be
damaged by the welding operations. If already installed, these elements must be removed
for the duration of the welding operations and stored where they are safe from damage
such as could be caused by weld spatter, e.g.


MR700

General notes on system routing:
• Hoses must be installed such that they are not subjected to tensile or compressive
loads in operation.

• Hoses should follow the contour of the foundation as closely as allowed by the
specified minimum bending radii.

• Multiple hoses should always be routed together and kept parallel.

• Suitable fittings (e.g. pipe elbows) can be used to avoid additional stresses and strain
on the hoses.

• When installing hoses, care must be taken to ensure that the hoses are not twisted.

• For a curved run, the length of the hose must be such that the curve does not
commence less than approx. 1.5 d from the fitting.

• Flexible connecting elements should be arranged and/or secured in such a way as to
prevent exposure to external mechanical influences, for example rubbing.

• The attachments used to secure hoses must be of correct size for the hose diameters.

• Hose attachments should not be used at points where they would impede the natural
freedom of motion of the hose.

• High ambient temperatures significantly reduce the durability of flexible connecting
elements and may even lead to failure of the component. Always ensure adequate
clearance from components that radiate heat or provide suitable heat shielding.

Make sure to use the inner diameter size correct for the hose.
Secure the fuel line with clamps.

The classification societies and some registration authorities (that is to
say, river authorities) do not allow rubber hoses for fuel lines, or prescribe
hoses with concrete specifications. check in case the boat were used in
these zones.


MR700

Fuel pre-filters
The use of fuel pre-filter/water separator is mandatory.
The pre-filter has to be installed in the suction side, between the fuel inlet and the fuel tank,
and must be positioned at a height between the tank base and the suction pump, to
reduce resistance in the supply pipe.
Install the filter vertically in a support on a bulkhead, in a position not affected by engine
vibration and protected as much as possible from fire in the engine room.
The filter location must be easily accessible for inspection and replacement of the filter
elements.
Fire-resistant material in fuel filters is prescribed for classified installations and in some
cases by local authorities.
Three progressive levels of filtration are recommended: water separation, coagulation and
filtration ensure that fuel reaches the engine free of contamination.
Water and other impurities are collected in bottom containers, from where they can be
drained by means of a drain valve.

Maximum suction head to high pressure fuel pump must below 250 mbar
at any running condition


MR700

SEA WATER COOLING SYSTEMS
A standard characteristic of diesel engines made by VM Motori S.p.A is a closed cooling
system, with fresh water circulating through the cooling circuits and the heat exchanger of
the engine. In the heat exchanger, the engine coolant is cooled by sea water.
In order to reduce corrosion to a minimum, the correct combinations of materials must be
used for pipes, valves etc.
Electrolytic corrosion can result when two different materials are connected via water or
humidity inside metal surfaces.


MR700

Sea water cooling circuit
Sea water is circulated through the system by the rubber impeller of the water pump.
The pump is mounted in the engine and is impelled via belt.
The water intake must be positioned so that the water line to the pump be as short as
possible. In addition, it must be positioned so that no air can be dragged into the system
when the boat is planing or rolling in the sea.

Sea water pump

Sea water pump
connection ENGINE TYPE
MR704

Before connecting the MR704 Engine with the sea water pump, remove
the yellow protective cap.

Sea water pump
connection

Sea water pump
ENGINE TYPE
MR706

The water intake, the valve and filter must have a flow area sufficient to prevent volume
restrictions. For planing boats, fluted water intakes are recommended.


MR700

In very contaminated water and in presence of sand and mud in the water, these elements
are dragged into the water pump; this will reduce the useful life of the pump and the
impeller.
Fouling and obstructions of the sea water cooling system contribute to reduce the
performance of the cooling system and to cause damage to the engine.

A sea water filter helps extend the life of the pump and reduces fouling of the heat
exchanger, of the oil cooler and after cooler.

The following pressure conditions must be fulfilled:
• The pressure in the suction side of the pump (PA), measured immediately upstream of
the pump, with the engine running at maximum rpm and at the cruise speed, must be
between 0 and –200 mbar (NPSHr = 10 m H2O )

• The differential pressure between the suction side of the pump and the pressure side
does not have to exceed 1.7 bar.

• The sea water inlet, the valve, the filter hoses and the pipes must have a flow area
sufficient to prevent unnecessary pressure drops. To prevent pressure drops, any bend
in the line must be avoided. We recommend the use of copper pipes. If a bend is
installed to reduce tensions, it must be connected with a reinforced rubber hose. In
order to prevent breakage, the hose must have several layers.

• The increased temperature of the sea water and the pressure give a good
understanding of the function of the system.

• When an original sea water pump supplied by VM Motori S.p.A is replaced with a
different type of pump, the flow must be measured.

The following scheme shows the main component parts of this system, the circulating
direction of the various fluids and the interconnections for closing the sea water circuit.
The installer has to prepare the interconnection with itmes 1 and 9-10, taking into account
the data provided in charter “Installation data”.


MR700


MR700

Pos. Description

a) Fresh water pump

b) Base

c) Heads

d) Pipe for collecting water from the heads

e) Turbocharger (air inlet)

f) Freshwater outlet from suction / exhaust header

g) Fresh water thermostatic valve body

h) Fresh water thermostatic connection

i) Expansion vessel

1) Sea water inlet

2) Sea water pump

3) Water/diesel oil exchanger

4) Sea water / air exchanger

5) Water/oil exchanger

6) Fresh water / sea water exchanger

7) Sea water / inverter oil exchanger

8) Elbow

9) Elbow sleeve / stern foot connection

10) Sea water / exhaust gas outlet


MR700

EXHAUST SYSTEMS

Data such as:
• Exhaust gas volume flow
• Exhaust gas temperature
• Permissible exhaust backpressure

required for the design of the exhaust system is stated in the installation data chapter.
The design / dimensions of the exhaust gas system must be such as to ensure that the
datum exhaust backpressure as stated in the installation data is not exceeded when the
diesel engine is in operation.
If the engine operates at an exhaust backpressure higher than this datum, efficiency is
impaired.
Fuel consumption, for example, is higher as well as the exhaust gas temperature.
Operation at exhaust backpressure, higher than this upper limit, results in a loss of engine
power.


MR700

Exhaust line

VM engines are supplied with a “wet exhaust line”.
The expression " wet exhaust line " implies that cooling water enters the exhaust for
purposes of refrigeration and sound absorption.
A wet exhaust line is particularly advisable for use with flexible mount engines and can be
made of oil and heat resistant rubber. Also, it would be the most comfortable noise
reduction system.
Normally, manufacturers of marine engines do not commercialize complete wet exhaust
systems. OEM, shipyards, and boat builders, select the components and experiment the
final exhaust system that complies with all requirements of the suppliers.

Sea water circuit
connection

Wet exhaust line
(Elbow)

30°

The Elbow exhaust device is correctly installed prior to shipment. It is
forbidden to remove the above-mentioned device.


MR700

Installation Requirements
The Exhaust Hose must have a minimum slope to avoid low spot at any point in the line.
The Exhaust outlet must be slightly above the water line with boat at rest in the water and
full load.
It is required an exhaust flapper at each outlet.
Minimum exhaust hose is Ø 90 mm (3½ in.).
Back pressure at exhaust outlet must not exceed 200 mbar.

Wrong installations may damage the engine allowing water to enter
exhaust system and combustion chambers. Boat manufacturer or
installing dealer are responsible for a correct installation of exhaust
system and engine location.


MR700

THROTTLE CABLE INSTALLATION AND ADJUSTMENT

When installing the throttle cables, be sure that the cables are routed in
such a way as to avoid sharp bends and/or avoid contact with moving
parts.
Do not fasten any items to the throttle cables.

1. Install throttle cable end guide anchor stud in middle hole of throttle position sensor
lever.
2. Place remote control lever in NEUTRAL / IDLE position.
3. Measure between the center of the Throttle Position sensor anchor stud to the holes
on the cable barrel end bracket. Select the hole in the cable barrel end bracket that is
closest to the distance of 181 mm (7-1/8 in.) between studs.
4. Unless previously installed, install the throttle cable barrel end guide anchor stud
according to Step 1.
5. Install the cable end guide on the throttle lever, then push the cable barrel end lightly
toward the throttle lever end. Adjust the barrel on the throttle cable to align with the
stud in the anchor bracket. Ensure that the hole in the barrel positions cable as
shown. Install the cable and secure with the hardware as shown.
6. Tighten locknuts until they contact and loosen 1/2 turn.

Throttle lever

7. Place the remote control lever fully in the FORWARD WOT (wide open throttle)
position.
8. Ensure that the throttle position sensor lever is contacting the internal override spring.
Be certain that the cable is not causing the throttle position sensor to be over-pulled.
9. Place the remote control lever in the NEUTRAL / IDLE position and, if necessary,
readjust the throttle cable barrel.
10. Recheck that when operated the throttle position sensor lever contacts the internal
override spring, indicating WOT or 100% throttle position.


MR700

SERVICES

Connect the sea water tap with the user device.

INLET water tap OUTLET water tap
connection for boiler connection for boiler


Mi mr700 6_systems installation

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