FNM HPEP 225 Installation Manual
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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

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Summary of Contents for FNM HPEP 225

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

  • Page 2: Table Of Contents

    INSTALLATION MANUAL HPEP 225 / 250 DIESEL ENGINE & BRAVO STERN DRIVES Table of Contents General Information ........Notice Installer ......... Operation/Duty Cycle Rating Notice ..Transom Cutout ......... Bravo Three Notice: Increased Trim-In Range Cutting Transom …………………………… Capability ……………………………………...

  • Page 3: General Information

    GENERAL INFORMATION Notice to Boat Manufacturer/Installer Throughout this publication, Warnings and Cautions (accompanied by the International Hazard Symbol) are used to alert the installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. - Observe Them Carefully! These Safety Alerts, alone, cannot eliminate the hazards that they signal.

  • Page 4: Operation/Duty Cycle Rating Notice

    PLEASURE DUTY RATING Model Engine Specified Operating (RPM) HPEP 225 - 250 4200 Wide open throttle operation is limited to short periods of time. IMPORTANT: Damage caused by improper application or failure to operate within the operational capability or duty cycle, will not be covered by the CMD Limited Warranty.

  • Page 5: Multiple Sterndrive Steering Tie Bar

    MULTIPLE STERNDRIVE STEERING TIE BAR ARRANGEMENTS With multiple sterndrives it is important to consider which of several possible steering systems should be selected. CAUTION Failure to observe the recommended Tie Bar Arrangements as presented in this section could result in serious damage to the steering and/or trim system compo- nents.

  • Page 6: Propeller Rotation On Dual Installations

    EXTERNAL POWER STEERING When boat speeds move past 112 KMH (70 MPH) or if additional steering backlash reduction is desired, external power steering is recommended. This normally will include an external tie bar mounted at the same general location of the power steering cylinders which are generally attached at the top of the sterndrive's drive shaft housing.

  • Page 7: Quicksilver Products

    Quicksilver Products ORIGINAL PRODUCTS FOR STERN DRIVE INSTALLATION Description Part Number Engine Coupler Spline Grease 92-802869A1 2-4-C Marine Lubricant with Teflon 92-802859A1 U-Joint and Gimbal Bearing Grease 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 Locally...

  • Page 8: Torque Specifications

    TORQUE SPECIFICATIONS Description Torque Ib- in. Ib- ft Speedometer Pickup Barb Fitting Exhaust Pipe or Block-off Plate Power Steering Hose Fittings Power Trim Pump Hose Fittings Propeller Nut (Bravo 1 e 2) Propeller Nut Front Back (Bravo 3) Rear Engine Mounts Steering Cable Couplet Nut Steering System (Pivot Bolts) Stern Drive Fasteners...

  • Page 9: Corrosion Protection

    CORROSION PROTECTION This power package is equipped with various anodes and a MerCathode System. A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for part numbers.

  • Page 10: Antifouling Paint

    ANTIFOULING PAINT IMPORTANT: Corrosion damage that results from the improper application of anti- fouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

  • Page 11: Installation Requirements

    INSTALLATION REQUIREMENTS WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.

  • Page 12: Engine Bed

    Engine Bed Distance between starboard and port engine mount is 23-1/2 in. (600 mm). Engine bed must position engine so that a minimum of 1/4 in. (6 mm) up and down adjustment still exists on mounts after performing final engine alignment. This is necessary to allow for realigning engine in the future.

  • Page 13: Engine Compartment Ventilation

    Combustion Air Requirements (Per Engine) Model Engine Air Requirements at WOT HPEP 225 - 250 10 m / min. (353 ft / min.) IMPORTANT: Follow regulations and boating standards for engine compartment ventilation.
  • Page 14 COMPARTMENT TEMPERATURE - SPECIFICATIONS Too high an inlet air temperature lowers the engine performance. Therefore: Engine compartment temperature shall not exceed outside air temperature by more than 17 degrees C (30 degrees F). Since many factors influence engine compartment temperature, temperature measurements should always be carried out.

  • Page 15: Exhaust System

    Verify that the riser provides the required dimension "c," or a distance greater than "c," as indicated. Model "c" = "a" Minus "b" HPEP 225 - 250 "c" Must Be 280 mm (11 inches) or More Engine With Standard Riser a - From Waterline To Top Of Transom b - From Highest Point On Exhaust Riser To Top Of Transom c - From "a"...

  • Page 16: Fuel Delivery System

    Fuel Delivery System WARNING Boating standards (CEE) and Coast Guard regulations must be adhered to when installing fuel delivery system. GENERAL The main concern of a boat's fuel system is safety; this must be achieved through a technically sound installation and constant inspection. The fuel system, from the filler pipe to the fuel pump is the same, in principle, for all boats.

  • Page 17: Battery

    DIESEL FUEL FILTERS AND FUEL ADDITIVES There is the possibility that contamination of diesel fuel and algae growth in the diesel fuel could block the lift pump resulting in poor performance. IMPORTANT: The engine is provided with an element type fuel filter, but to help eliminate water and dirt it is recommended to use an additional 10 micron, 40 lt/min (60 gpm) flow rated filter that has a water trap.

  • Page 18: Battery Cables

    Battery Cables Select proper size positive (+) and negative (-) battery cables, using chart. Battery should be located as close to engine as possible. IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder, as it may cause corrosion and a subsequent failure.
  • Page 19 Notes...
  • Page 20 Electrical connection of the batteries in case of twin installation Here below you will find the scheme for the electrical connection of the batteries in case of twin installation. If you look further below, you will find another scheme which is referred to the case when another battery (for onboard services such as TV, refrigerator, etc.) is used (suggested scheme).
  • Page 21 Alternator Selection Device Engine Battery Auxil. Battery Lo schema che segue si riferisce al caso di doppia installazione (due motori) con batteria per i servizi. In questo caso saranno installate tre batterie e lo schema prevede l’utilizzo di due scambiabatterie (interruttori di selezione manuali).
  • Page 22 IGNITION SYSTEM ENABLED BY THE REMOTE CONTROL LEVER IN IDLING POSITION The purpose is that of making sure that the start of the engine only takes place when the remote control lever is placed in the idling position. The operations that need to be done are as following: 1.
  • Page 23 Figure 2...

  • Page 24: Instrumentation

    Instrumentation GENERAL INFORMATION We recommend using CMD Instrumentation and Wiring Harnesses. Refer to CMD for selection. NOTE: If using other than CMD instrumentation and harnesses, refer to manufacturers' instructions. The six basic gauges that must be used with the engine are: •...
  • Page 25 EXTENSION HARNESS When routing any wiring extension harness back to the engine, make sure that the harness does not rub or get pinched. Be sure all extension harness connector collars are secure. Fasten harness to boat at least every 400 mm (17 inches) using appropriate fasteners.

  • Page 26: Power Trim Control

    Power Trim Control Any of the panel or in-handle type trim controls can be used with this Power Trim system. Install trim control in accordance with instructions that accompany it. Power Trim Pump Location Select an appropriate mounting location for the trim pump that meets the following requirements: •...

  • Page 27: Propeller Selection

    Propeller Selection IMPORTANT: Installed propeller must allow engine to run at the upper end of the specified wide open throttle operating revolutions per minute (rpm) range, with a normal load aboard the boat. Use an accurate service tachometer to verify engine operating rpm.
  • Page 28 Hot Water Heater Installation Recommendation IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met, including but not limited to the following: • Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in.
  • Page 29 Seawater Connections SEAWATER PICKUP HOSE Seawater inlet hose connections must be made with wire reinforced hose of adequate wall thickness to prevent it from collapsing from pump suction. Be sure to secure hose connections with hose clamps. Secure hose to prevent contact with any moving parts of the engine.

  • Page 30: Steering Helm And Cable

    Steering Helm and Cable Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with the standards used for each country. The steering cable coupler nut must also have 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.
  • Page 31 ATTENTION: If using a steering cable that does not have a self-locking coupler nut, an external locking device must be used. a - Steering Cable b - Grease Fitting c -Cotter Pin d - Locking Sleeve (If Required - Must Be Ordered Separately) e - Cable Coupler Nut f - Cable Guide Tube CAUTION...
  • Page 32 STEERING CABLE SPECIFICATIONS IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions. a - Coupler Nut - 7/8 -14 UNF - 28 Thread b -11-3/4 in.

  • Page 33: Transom Cutout

    Transom Cutout NOTICE TO INSTALLER Before Starting Installation Read "General Information" and "Installation Require- ments" Sections Completely. IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. Best mounting location for a particular boat, however, can be determined only by testing.
  • Page 34 SINGLE ENGINE Locate and mark boat vertical centerline on transom. a - Vertical Centerline DUAL ENGINE 1. Locate and mark boat vertical centerline on transom. a - Vertical Centerline 2. Locate 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 Vertical Centerlines Must Be An Equal Distance From Boat Vertical Centerline...
  • Page 35 Finding Crankshaft Horizontal Centerline ("X" Dimension) "X" Dimension can be measured by the "90 Degree Tool Method" or by the "Tape Measure Method." 90 DEGREE TOOL METHOD 1. Construct 90 degree tool. a – Horizontal Dimension b – Vertical Dimension: 4 ft. (1.2 m) To Lower Drive Unit - Subtract from dimension "a".
  • Page 36 TAPE MEASURE METHOD Transom angle must be known, then measure "X" Dimension with tape measure. 1. Select "X" Dimension from Tape Measure Method Chart that corresponds to transom angle. Tape Measure Method Chart Model All Alpha and Bravo This dimension should only be raised or lowered after proper Transom Angle testing.
  • Page 37 b. For Dual Engine Applications: (1.) Measure and layout two horizontal lines spaced 2 in. (51 mm) apart, as shown. (2.) Locate and mark center of both horizontal lines. (3.) Measure"!/2 the distance of desired crankshaft centerlines from centers of both horizontal lines.

  • Page 38: Cutting Transom

    Cutting Transom Transom cutout can be made by either using the Template (shipped with transom assembly) or the Quicksilver Transom Drilling Fixture Kit (purchased separately). Follow instructions indicated on template or provided with drilling fixture. IMPORTANT: Ensure that centerlines on either the template or transom drilling fixture align with lines previously marked on transom.

  • Page 39: Checking Transom Thickness

    CHECKING TRANSOM THICKNESS (TRANSOM) Ensure transom surface thickness and flatness conform to minimums specified in Installation Requirements listed previously. a – Measuring Thickness b – Measuring Flatness c – Suitable Mandrel To Check For Uniform Transom Thickness NOTE: Transom must be between 51-57 mm (2-2-1/4 in.) a distance 203 mm (8 in.) to either side of the vertical centerline.
  • Page 40 a - Exhaust Tube b -Clamp c -"SIDE" Marking d - Exhaust Tube e -Grounding Clip...

  • Page 41: Installing Inner Transom Plate

    Installing Inner Transom Plate 1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate. 2. Position gimbal housing on transom and hold in place. IMPORTANT: Tightening the transom assembly fasteners using an X-pattern torque sequence. Tighten in small increments and go around the pattern several times until the proper torque is achieved.

  • Page 42: Installing Power Trim Pump

    Installing Power Trim Pump 1. Mount pump in desired location. IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking out of system. Be careful not to cross-thread or overtighten hose fittings. 2. Connect hydraulic hoses to trim pump. Torque fittings to 125 Ib-in. (14 Nm). 3.

  • Page 43: Installing Steering System

    FNM-HPE200 Installing Steering System MANUAL STEERING 1. Inspect bushings for debris. Rubricate bushings with Special Lubricant 101. Manual Steering a - Bushings b – Special Lubricant 101 2. Remove shipping hardware. 3. Remove upper and lower pivot bolts and ensure threads are well lubricated with Special Lubricant 101.
  • Page 44 5. Torque pivot bolts to 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 Washers b –...
  • Page 45 CAUTION Steering cable outer casing must be free to move back and forth for steering system to function properly. Do not fasten any items to steering cable. L’involucro esterno del cavo della timoneria deve essere libero di muoversi avanti e dietro per un corretto funzionamento del sistema di timoneria.
  • Page 46 HYDRAULIC STEERING NOTE: For dual installations, power steering unit can be mounted on port or starboard transom assembly. Measure distance between power package centerlines. 1. Inspect bushings for debris. Lubricate bushings with Special Lubricant 101. 2. Remove shipping hardware. Power Steering a - Bushings b –...
  • Page 47 5. Torque pivot bolts to 34 Nm (25 Ib-ft). Bend washer 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 kasher. a – Tab Washer b –Ridge c –...
  • Page 48 7. Connect clevis to steering lever. Lubricate clevis pin with Special Lubricant 101. Be sure to spread both ends of the cotter pin. NOTE: Make sure to insert clevis pin from the top to censure that cotter pin hole is as shown in the diagram.
  • Page 49 8. Connect steering cable as follows: a. Remove shipping cap from both ends of steering cable guide tube. b. Coat steering cable end with a liberal amount of Special Lubricant 101. c. Install steering cable and secure with hardware as shown. NOTICE TO INSTALLER Refer to “Installation Requirements –...

  • Page 50: Connecting Speedometer Pickup

    Connecting Speedometer Pickup CAUTION Excess water in bilge can damage engine or cause boat to sink. Do not remove plug from speedometer pickup tube fitting unless connection is to be utilized. The connection for the speedometer pickup can be accessed through a hole and fitting in the inner transom plate.

  • Page 51: Connecting Gear Lube Monitor Hose And Installing Water Inlet Fitting

    FNM-HPE200 Connecting Gear Lube Monitor Hose And Installing Water Inlet Fitting 1. Connect the gear lube monitor hose to quick release 90° fitting. Secure with hose clamp. 2. Connect fitting to the gimbal housing. a – Hose b – 90° Hose Fitting c –...
  • Page 52 CAUTION Do not interfere with quick release button on gear lube monitor 90° 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 –...

  • Page 53: Engine Installation

    - Maximum Torque: 494 Nm at 2600 rpm for the HPEP 250, 416 Nm at 2500 rpm for the HPEP 225; - Max. Power: 184 kW at 4000 rpm for the HPEP 250, 165 kW (225 HP) at 4200 rpm for the HPEP 225;...

  • Page 54: Engine Identification

    Identification plate on the ECU box b- Identification plate on the intercooler cover On the identification plates you will find the engine type (commercial denomination, i.e. HPEP 225) and the serial number: SERIAL...
  • Page 55 Engine dimensions...
  • Page 56 Engine Preparations 1. Remove and read all tags attached to the engine. 2. Remove all hardware that secures engine to shipping container. 3. Connect battery cables to engine. Be sure to observe the following: a. Make sure that grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection.

  • Page 57: Transom Preparation

    Transom Preparation IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches, and O-ring must be properly seated in groove, or water and exhaust may leak into boat. a - Gimbal Housing Mating Surface b -O-Ring 1.
  • Page 58 FNM-HPE200 Installing Engine / Alignment 1. Attach a suitable chain sling to lifting eyes on engine and adjust so that engine is level when suspended. a – Rear Lifting Eye b – Front Lifting Eye 2. Lift engine into position (in boat) using an overhead hoist.
  • Page 59 READ CAREFULLY BEFORE PROCEEDING TO POINT 4 Upper mounting – All Models Avoid product damage resulting from incorrect aligning of the engine. Incorrect aligning (not centered) between the mounts of the coupling bell to the stern drive and the mounts of the inner plate of the transom may result in a wrong aligning for the engine.
  • 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 4. Install both rear engine mounting bolts using hardware as shown. Torque to 51 Nm (38 Ib-ft). a – Rear Engine Mount b – Inner Transom Plate Mount c - Bolt d – Washer e – Spacer f – Fiber Washer g –...
  • Page 62 8. Fold perforated area in bell housing dust cover. a – Dust Cover CAUTION DO NOT use an alignment tool from another manufacturer. Alignment tools from other manufacturers may cause improper alignment and damage to gimbal bearing and/or engine coupler. CAUTION To avoid damage to gimbal bearing, engine coupler, or alignment tool: DO NOT attempt to force alignment tool!
  • Page 63 10. If the alignment tool does not fit, remove it and carefully adjust engine mounts as necessary: a. To Adjust Engine Up or Down: Loosen locknut on mounts. Turn adjusting nuts as necessary. Retighten locknuts. b. To Move Engine Left or Right: Loosen trunion camping bolt on both front mounts and move engine as necessary.
  • Page 64 a. Repeat steps 10. and 11., until the alignment tool installs easily (SLIDES FREELY WITH TWO FINGERS) all the way into and out of engine coupler 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.
  • Page 65 13. Recheck alignment with alignment tool. Tool must enter coupler splines freely. If not, readjust front mounts. IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine. 14. When alignment is correct, tighten locknut securely. Recheck alignment. 15.

  • Page 66: Engine Connections

    Engine Connections IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts. 1. Connect seawater inlet hose (provided in transom parts bag) to water tube. Secure with hose clamp.
  • Page 67 CAUTION Route hydraulic hoses exactly as shown below. This will help avoid stress on the hose fittings and kinks in the hose. ATTENTION: Make hydraulic connections as quickly as possibile to prevent fluid leaks. IMPORTANT: Be careful not to cross-thread or overtighten fittings. Connect power steering hoses to control valve.
  • Page 68 FNM-HPE200 8. Connect fuel return line to injection pump return fitting. Secure with hose clamp. a – Fuel Return Line b – Return Fitting 9. Tighten all exhaust hose clamps securely. CAUTION 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 hoses.
  • Page 69 Closed Cooling Recovery Bottle 1. Connect plastic tubing (from kit) from water pump to cooling recovery bottle lower fitting . Connect tubing that comes from the engine to the cooling recovery bottle upper fitting (return). Secure with tubing clamp provided. 2.

  • Page 70: Electrical Connections

    Electrical connections CONTINUITY CIRCUIT 1. Connect continuity circuit wire (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 –...
  • Page 71 INSTRUMENT AND EXTENSION HARNESS 1. Connect instrument extension harness to instrument harness ends. Connector collars must be fully engaged and secure. Tighten threaded connector collar of extension harness onto instrument harness connector. IMPORTANT: When routine any wiring extension harness back to the engine, make sure that the harness does not rub or get pinched.
  • Page 72 NEUTRAL SAFETY SWITCH 1. Connect neutral safety switch wires at instrument panel and remote control. Refer to appropriate wiring diagram. Secure connections. If using bolt and nut, coat with liquid neoprene. Slide rubber sleeve over connections. Neutral Safety Switch Wiring With Bullet Connectors Neutral Safety Switch Wiring Using Bolt and Nut a –...

  • Page 73: Shift Cable Installation

    Shift Cable Installation and Adjustment NOTE: Shift Cable Adjustment Tool (91-12427) allows the shift cables to be installed and adjusted, with or without the sterndrive attached. IMPORTANT: The direction of propeller rotation (RH or LH) for this drive unit is determined by the following method.
  • Page 74 4. Install drive unit shift cable. Tighten locknut until it contacts end guide, then loosen 1/2 turn. Insert cotter pin from the top and spread both ends. a - Washers (2) b -Locknut c - Cotter Pin 5. Place adjustment tool over drive unit shift cable. Hold tool in place, using a piece of tape over the barrel retainer.
  • Page 75 6. Adjust remote control shift cable as follows: a. Temporarily install shift cable end guide into shift lever and insert anchor pin. b. Adjust shift cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide. CAUTION DO NOT attempt to install or remove remote control shift cable barrel from stud, without first removing end guide anchor pin from shift lever, and removing cable.
  • Page 76 9. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer. Rh Rotation - All Bravo One, Two, And Three Models: Rear slot in tool should fit over shift lever stud. Lh Rotation - All Bravo One And Two Models: Forward slot in tool should fit over shift lever stud.

  • Page 77: Troubleshooting Shift Problems

    Troubleshooting Shift Problems NOTE: The following information is provide to assist an installer in troubleshooting, if hard shifting or chucking/racheting is encountered when shifting into forward gear. 1. When installing the control box in the side panel of the boat, ensure that the cables have enough clearance to operate.
  • Page 78 Do not strap or clamp the control cables to any other cables or rigid structure within 3 feet (914 mm) of the control box. 5. Ensure that the cable is not permanently kinked.Make sure there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either forward or reverse.

  • Page 79: Throttle Cable Installation And Adjustment

    Throttle Cable Installation and Adjustment IMPORTANT: Be sure that 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 throttle cables. 1. Place remote control lever in neutral / idle position. 2.

  • Page 80: Sterndrive Installation

    Sterndrive Installation 1. Remove trim cylinders support and dust cover from bell housing studs. (Retain locknuts and flat washers.) 2. Remove 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 –...
  • Page 81 8. Coat sterndrive pilot, U-joint shaft O-rings, and U-joint 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.
  • Page 82 11. Pull out shift linkage as far as it moves. "Jaws" will open, as shown. a - Shift Linkage IMPORTANT: As sterndrive is inserted into drive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the jaws of shift linkage assembly in the sterndrive.
  • Page 83 13. Place drive shaft housing in position on bell housing and install drive unit, as follows: a. Position trim cylinders so they point straight backwards. b. Position drive unit so that the U-joint shaft aligns with bell housing bore. c. Guide U-joint shaft through bearing in gimbal housing and into engine coupler. Make sure that shift linkage jaws engage the bell housing shift cable assembly.
  • Page 84 IMPORTANT: On Bravo One. Two and Three Models, the Trim-In Limit Insert must be properly positioned before installing the trim cylinder anchor pin in the following steps. 15. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model.
  • Page 85 18. Raise drive to gain access to area between gimbal housing and sterndrive, immediately 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: Predelivery Preparation

    Predelivery Preparation Battery Connection IMPORTANT: Engine electrical system is negative (-) ground. 1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal. NOTICE to INSTALLER Before starting Predelivery read "General Information" and "Installation Require- ments" completely. 2.

  • Page 87: Power Trim Pump

    Power Trim Pump IMPORTANT: Check oil level with sterndrive unit in the full DOWN / IN position. IMPORTANT: Use Quicksilver Power Trim and Steering Fluid, or SAE 10W-30 or 10W-40 engine oil in trim system. 1. Unscrew fill cap and remove and discard cap plug from fill neck. Replace fill cap. a - Cap Plug b - Fill Cap 2.

  • Page 88: Trim Position Sender Adjustment

    Trim Position Sender Adjustment 1. Loosen both trim position sender retaining screws. a - Retaining Screws (2) b - Trim Position Sender CAUTION DO NOT start engine in the following step or damage to drive unit and engine could result from lack of cooling water. 2.

  • Page 89: Power Steering Fluid

    Power Steering Fluid IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid, or Dexron automatic transmission fluid (ATF), in power steering system. CAUTION DO NOT run power steering dry, or pump will be damaged. 1. Position drive unit so that it is straight back. 2.
  • Page 90 Drive Unit Gear Lube Monitor IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always check oil level when drive is cool and engine is shut down. 1. With drive in full DOWN / IN position, remove oil vent screw. CAUTION Failure to fill drive unit to level of vent hole will result in a low drive oil level.
  • Page 91 Propeller Installation - All Bravo One IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. WARNING Avoid Injury: Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller. WARNING Avoid Injury: Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when...
  • Page 92 Propeller Installation - All Bravo Two IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. WARNING Avoid Injury: Be sure that remote control is in NEUTRAL position and ignition key is removed from switch prior to installing propeller. WARNING Avoid Injury: Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when...
  • Page 93 Propeller Installation - All Bravo Three IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft. WARNING Avoid Injury: Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller. WARNING Avoid Injury: Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades, and to prevent propeller from turning when tightening propeller nut.

  • Page 94: Test Running Engine

    Test Running Engine WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR).
  • Page 95 TESTING WARNING Do not leave helm unattended when making test with boat in the water. 1. Ensure that cooling system drain plugs, petcocks, and hoses are installed and tight. NOTE: Refer to the appropriate Mercury MerCruiser Operation, Maintenance and Warranty Manual for operating specifications and fluid capacities.
  • Page 96 b. Turn steering wheel RIGHT until it stops, and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes), check the fol- lowing: (1.) Inspect for an obstruction between gimbal ring and gimbal housing and all mov- ing steering components.
  • Page 97 15. Check power steering fluid level. 16. Stop engine and position 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 Reservoir b - Cap / Dipstick c - Full Hot Mark...
  • Page 98 Boat-In-The-Water Tests IMPORTANT: DO NOT perform the following with boat in a test tank or tied to dock. ENGINE INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of low hour problems.
  • Page 99 Engine Recommended Operating RPM Range Governor or Limiter rpm Setting (Begins At:) HPEP 225-250 4200 4400 To check that the correct propeller has been installed, operate the boat with a light load (one person, fuel tank half full) at wide open throttle and optimal trim. (Optimal trim is the point where boat speed no longer increases when trimming-out.
  • Page 100 After Running Engine CAUTION If power package will not be used for an extended period of time, or will be exposed to freezing temperatures, drain water from seawater cooling system. Refer to Cold Weather or Extended Storage Draining Instructions. Water MUST BE drained to prevent corrosion and freeze damage to engine. 1.

  • Page 101: Wiring Diagrams

    Wiring Diagrams Power Trim System BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LT OR = LIGHT DRK = DARK...
  • Page 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 = LIGHT DRK = DARK...
  • Page 103 FNM-HPEP 225/250 a - Controller b - 20 Amp Fuse c - Electrode Black Wire – With Engine Harness or Separate, Model Dependent d –...
  • Page 104 Elements that costitute the Electric System for the electronic management of the FNM engine models HPEP 225 – HPEP 250 Elements that constitute the Electric System 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;...
  • Page 105 FNM-HPEP 225/250 This element of the system features the following parts: ECU, Electronic Control Unit; 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 exchange signals with the engine...
  • Page 106 In Figure 1 you see a photo of the engine harness for the models HPEP 225 and HPEP 250. Figure 1 – HPE225 - 250 – Engine wiring...
  • Page 107 FNM-HPEP 225/250 The 64-pin (female-connector carrier) panel connector is equipped with 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: Main 64-pin connector.
  • Page 108 FNM-HPEP 225/250 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 FNM-HPEP 225/250 Connector for the water temperature sensor This is a 4-pin connector for the sensor that takes the engine water temperature and then sends the acquired information to both the ECU and the dashboard. 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.
  • Page 110 FNM-HPEP 225/250 Connector for turbocharging pressure sensor This is a 3-pin connector that is to be connected to the sensor that measures the air pressure in the intake system of the engine. Connector for the rail pressure sensor This is a 3-pin connector that is connected to the sensor that measures the fuel pressure in the rail.
  • Page 111 FNM-HPEP 225/250 the signal for the opening of the electroinjectors. Here below you will find a picture that shows the wiring segment where the five injector connectors are placed. Connector for throttle potentiometer This is a 6-pin connector that is connected to the wiring of the throttle potentiometer (see Figure 4).
  • Page 112 FNM-HPEP 225/250 Connector for the engine oil pressure switch This is a 1-pin connector that is connected to the sensor switch, which takes the pressure in the engine oil circuit 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.
  • Page 113 FNM-HPEP 225/250 Connector for the sensor that signals the presence of water in the fuel This is a 3-pin connector that takes the signal for the fuel temperature. Connector for glow plugs This is a 1-pin female connector that is inserted on the glow plug.
  • Page 114 FNM-HPEP 225/250 Fuse for the glow plug modulus This is an 80A fuse used to protect the glow plug modulus. The 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 the engine starter.
  • Page 115 FNM-HPEP 225/250 Adapting wiring 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 the electric system of the engine.
  • Page 116 FNM-HPEP 225/250 Eyelet connector for fuel pump These are two eyelet connectors that are supposed to feed the fuel pump. The feeding is protected by a fuse. The red eyelet connector is to be connected to the positive of the fuel pump (+ sign on the •...
  • Page 117 FNM-HPEP 225/250 Connector that takes the battery voltage signal from the engine starter This eyelet connector with a hole of 8 mm is connected to the engine starter. This cable carries the 12 V that are directed to the ECU box.
  • Page 118 FNM-HPEP 225/250 Connector that takes the signal from the alternator to the battery light 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.
  • Page 119 FNM-HPEP 225/250 1.2 Indications for the replacement of the fuses The fuses on the stamped circuit have been inserted on eyelet connectors on the stamped circuit in order to make the replacement procedure easier. In order to replace the fuses, please refer to the following table:...
  • Page 120 FNM-HPEP 225/250 Panel instrument with VDO gauges and cables Il quadro strumenti sciolto è costituito dai seguenti 4 elementi: 1. Rpm indicator; 2. Engine oil pressure indicator; Engine water temperature indicator; Voltmeter. The cable that is used to connect the box to the VDO instruments is modified by Quaff Research.
  • Page 121 FNM-HPEP 225/250...
  • Page 122 FNM-HPEP 225/250...
  • Page 123 FNM-HPEP 225/250 The scheme above displayed represents the sea water flow (external circuit) which cools the various parts of the marine engine. The sequence is as following: the sea water cools the air that is feeded into the engine (1: intercooler); then it cools power steering oil and the fuel feed circuit (2: double exchanger with pipes);...

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Hpep 250

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