Installation and Service Manual:
Contents
1. FFERS FUEL SYSTEMS AND MO V4 Wana FUEL RAIL Vans 314 1934 3919 ISd 09 37 MMS Airboat Engine Manual v1 0 Appendix Mast Motorsports System Fault Codes System System Fault Description Fault Description Code Code 111 IAT High Voltage 411 Injector Driver 1 Open 112 IAT Low Voltage 412 Injector Driver 1 Shorted 113 IAT Higher than Expected 7 413 Injector Driver 2 Open 114 IAT Higher than Expected 2 414 Injector Driver 2 Shorted 115 Oil Pressure Low 415 Injector Driver 3 Open 121 ECT CHT High Voltage 416 Injector Driver 3 Shorted 122 ECT CHT Low Voltage 421 Injector Driver 4 Open 123 ECT Higher than Expected 1 422 Injector Driver 4 Shorted 124 ECT Higher than Expected 2 423 Injector Driver 5 Open 131 MAP High Pressure 424 Injector Driver 5 Shorted 132 MAP Low Voltage 425 Injector Driver 6 Open 134 BP High Pressure 426 Injector Driver 6 Shorted 135 Low Pressure 431 Injector Driver 7 Open 136 TIP Voltage High 432 Injector Driver 7 Shorted 137 TIP Voltage Low 433 Injector Driver 8 Open 142 Crank Sync Noise 434 Injector Driver 8 Shorted 143 Never Crank Synced at Start 511 Failure 144 Camshaft Sensor Loss 512 Invalid Interrupt 145 Camshaft Sensor Noise 513 A D Loss 212 HO2S Open Inactive 514 1 Loss 221 Closed Loop Multiplie2. Temperature Load Limit deg F 40 0 60 0 0 0 100 0 40 0 100 0 200 0 100 0 220 0 100 0 250 0 100 0 260 0 80 0 280 0 40 0 Table 3 Power Reduction Parameters MMS Airboat Engine Manual v1 0 26 Service Replacement Parts Use of replacement parts 1 e automotive after market etc in the electrical ignition and fuel systems which are not Mast Motorsports approved could cause fire or explosion hazard and void the warranty and should be avoided Always use Mast Motorsports approved replacement parts in any repairs or maintenance being performed on your engine s Accessory Drive Belt and Pulleys Inspect the drive belt for excessive wear shredding or missing sections Excessive dirt oil coolant or other substances on the belt and pulleys can cause abnormal belt noise and will affect the drive belt life and operation Figure 29 shows the proper belt routing If a problem is found replace the belt after inspecting the following items All pulleys and tensioners for signs of misalignment rust or other damage e Excessive debris embedded in pulleys e Tight or worn bearings in pulleys engine water circulation pump and alternator Figure 29 Proper Belt Routing OL MMS Airboat Engine Manual v1 0 27 Changing Refer to the MAINTENANCE SCHEDULE for oil change intervals engine oil should be changed prior to placing the engine into storage IMPORTANT Change the
3. RER MMS Airboat Engine Manual v1 0 40 VAA SS 330 NW Stallings Nacogdoches TX 75964 WARRANTY STATEMENT Congratulations on your purchase of Mast Motorsports Typhoon Cyclone Engine The industries finest Fuel Injected High Performance Airboat Engine The following Terms and Conditions of Sale protect the purchaser owner from defects in materials and workmanship It is important that the purchaser owner provide their Engine with a favorable break in and good maintenance in order to get the very best performance from this engine MAST MOTORSPORTS LLC CONSUMER TERMS AND CONDITIONS OF SALE GOVERNING PROVISIONS All sales of Airboat engines and engine parts Engines by Mast Motorsports LLC MMS to distributors or consumers are made subject to these MMS Consumer Terms and Conditions of Sale No additional or different terms shall apply If you do not agree to all of these Terms and Conditions of Sale do not place an order of any Mast Motorsports manufactured Engines Placing an order for Engines from MMS a MMS distributor or any entity that sells MMS Engines will confirm that you agree to be bound by all of these MMS Consumer Terms and Conditions of Sale LIMITED WARRANTY MMS warrants to the original consumer purchaser of each Airboat Engine the Engine will be free from defects in materials and workmanship for a period of 12 months or 300 hours whichever comes first from the date the Engine was purchased from M
4. Battery EGG Battery Ground Ignition Switch Valet Ground el teed 5 Electric Gauge WATE sj Tachometer Gauge Wining Oil Pressure Engine Coolant Temperature Gauge Wiring Malfunction Indicator Lamp Fit and Finish Electric Gauge Calibration 4 44 Oil Pressure and Engine Coolant Temperature Controller Area Network 2 Mast Motorsports Gauges tant Operating Engine Starting 8 Engine IE NS Power Reduction BSCE VICE A Replacement ai Accessory Driv Changing Oil Engine Storage EBen E MMS Airboat Engine Manual v1 0 1 COS 00 JO A BR Table of Contents Continued PTep ATLEE Stora Be Norm
5. MASE gt ea ee Morse Installation and Service Manual For use with Mast Motorsports Airboat engines It is advised to read this Installation and Service Manual THOROUGHLY before proceeding with installation Engine Serial Number ECM Serial Number VOLE MMS Airboat Engine Manual v1 0 Table of Contents Serial Number 8 A Fuel System 2 2 Gasoline Requirement is des nn Engine Installation Engine Onl Cooling System Cooling Systemes Fuel System Wiring Installation Preferred Wirmg Alternative Wiring 2 2 2 M 90 ECM and Wiring Harness item unten Harness re nes EE E E E E E tad Dash Harness Drive By Wire Getting System POWER
6. follow the gauge manufacturer s wiring instructions When hooking up the ECT signal wire use the Light Green and Dark Green L GN D GN wire in cavity C10 Figure 18 of the Dash Harness The process of calibrating the gauge is explained in the Electric Gauge Calibration section on page 19 Malfunction Indicator Lamp MIL Wiring The M 90 has the ability to power a MIL light so that the user can be notified of a potential engine problem Many lights can be used and in some cases an OEM light can be used The MIL wire is Orange OR and is located in cavity C12 Figure 18 of the Dash Harness This wire will provide a ground when the ECM sees a Diagnostic Trouble Code DTC When wiring the MIL light hook the wire up to the ground side of the MIL light The terminal on the light should have switched ignition power Fit and Finish of Installation During final installation make sure that all wires are away from heat sources sharp edges and moving parts This is especially true for the heat shielded wires that run to the Main Power on the Starter Post Ground Wires Knock Sensors and Crankshaft Position Sensor that run toward the bottom of the engine These wires should be fastened back away from the exhaust system using a P Clip or other reliable solution Figures 19 20 and 21 below show a great strategy for using P Clips to retain wires away from exhaust heat FAILURE TO KEEP WIRES AWAY FROM HEAT AND MOVING PARTS COULD RESULT IN C
7. 1000 1500 RPM Using an aerosol type fogging oil such as STA BIL Fogging Oil spray a sufficient amount into the throttle body assembly bore to treat internal surfaces of the engine Do not allow the engine to stop while spraying fogging oil Short bursts work best Refer to the instructions on the fogging oil canister Turn the ignition switch to the OFF position 4 Cover the throttle body assembly to prevent the possibility of water and debris entering the engine through the throttle body assembly during storage 5 Close the fuel shut off valve if equipped IU MMS Airboat Engine Manual v1 0 28 Engine after Storage When re commissioning the engine after storage the following items should be checked e Check the condition of all cooling system hoses sure they are properly connected and all clamps are tight Install a fully charged battery Be sure that all the connections are clean and free from corrosion Coat the battery terminal connections with an anti corrosion battery terminal spray Refer to the OPERATING INSTRUCTIONS on page 24 and perform all the safety checks before starting the engine Start the engine and closely observe all gauges for proper operating parameters Allow the engine to reach normal operating temperature Inspect the engine carefully for fuel exhaust oil and coolant leaks e Check the steering and throttle controls for proper operation Normal Operating Paramete
8. 37 Flywheel Bolts 74 Engine Mounts Bolts 37 Bell Housing Bolts 37 Idler Pulley Bolt 37 Coolant Temperature Sensor 15 Crankshaft Position Sensor 18 Oil Pan Drain Plug 18 Oil Pressure Sensor 26 Throttle Body Bolts 7 Intake Manifold Bolts 7 Other M8 18 Other M10 Bolts 37 Coolant Thermostat Housing Bolts 11 MMS Airboat Engine Manual v1 0 Maintenance Schedule Location amp Service Check Daily After 1 25 Hours of Operation Every 50 Hours of Operation Every 100 Hours of Operation Once Each Year Check Coolant Level X Check Oil Level Engine Crankcase X Engine Assembly Check for obvious leaks water oil fuel and exhaust Throttle and Steering System Check for proper operation Cooling system Check condition and tightness of all hose clamps Exhaust System Check for leaks at manifold Ignition System and Spark plugs Clean and inspect condition Complete Engine Assembly Check for loose missing or damaged parts especially engine mounts starter and alternator mounting fasteners Change Engine Oil and Filter Drain PCV Breather Tank Engine Alignment Check and adjust if necessary Air Filter Clean or Replace Battery Check electrolyte level and specific gravity Inspect case for damage Check cables and connections Electrical System Check for loose or dirty connections
9. C6 Starter Activation Activates Starter Motor Wire Accessory 12V Output for Chassis Accessories if Power applicable Chassis Ground Valet Ground Table 1 Mast Motorsports Ignition Power Wire Connection Chart a TE ASON AN DA Sits NEN SNE INE UNE ERRAN EAA eee gt gt gt gt lt RER ER ER ZEA 12 Se Oe te 2 NA Figure 18 Wiring Cavity Location NE MMS Airboat Engine Manual v1 0 16 Valet Ground Wiring The White and Pink WH PK Valet Ground Wire is a safety feature integrated into the M 90 ECM Wiring Harness Package located in Cavity B8 Figure 18 This disables the user from activating the starter motor unless this wire is grounded This wire should be placed on a switch that grounds whenever activated If it is not possible to install a Valet Ground Wire switch in the vessel the wire may simply be attached to a permanent ground However Mast Motorsports highly recommends that a Valet Ground Wire switch be fitted to the vessel in the interest of safety Wire the WH PK Valet Ground wire to one side of the switch and the other side of the switch to a ground Now you are ready for safe vessel operation Fuel Pump Wiring The fuel pump wiring harness Figure 13 connects to an 8 pin connector on the main harness This connector is located on the driver s side re
10. Engine Manual v1 0 33 Troubleshooting Malfunction Possible Cause Corrective Action Engine Oil Pressure Low Continued Engine Overfilled Causing Aeration Diluted or Improper grade Viscosity of Oil Remove the required amount of oil Determine the cause of the overfilled condition Change the oil and filter with proper grade viscosity Determine the cause of the dilution Insufficient engine temperature excessive idling etc High Oil Temperature Incorrect Oil Temperature Gauge Calibration Oil Level Low Incorrect Oil Viscosity Oil Cooler Placement Sizing Recalibrate gauge Refer to Electric Gauge Calibration Check oil level Adjust as necessary Replace oil and filter Refer to Normal Operating Parameters and Requirements No air flow to oil cooler Refer to Oil Cooling System Incorrect size cooler Refer to Oil Cooling System Engine Enters Power Reduction Mode Oil Temperature Sensor and or ECT Sensor Not Connected High Engine Coolant Temperature High Oil Temperature Confirm connection of oil temperature sensor and or ECT Sensor Refer to Troubleshooting Engine Overheats Refer to Troubleshooting High Oil Temperature IU E MMS Airboat Engine Manual v1 0 34 Troubleshooting Malfunction Possible Cause Corrective Action Engine Enters Power Low ECT and or Oil Run e
11. LIMITATION OF LIABILITY In no event will MMS be liable to you for any incidental indirect or consequential damages including but not limited to any damage to your vessel engine or any fines or penalties arising from or out of the installation or use of an MMS product even if MMS has been advised of the possibility of such damages In no event will MMS s liability for any claim whether in contract tort including negligence and strict liability or under any other theory of liability exceed the amount paid by you for the product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you RECEIVING Please inspect the MMS Engine immediately after receiving your order Any damages or evidence of tampering on the outer packaging must be noted on the delivery receipt of the driver ANY DAMAGES MUST BE REPORTED TO MMS WITHIN 48 HOURS of your receiving the item no exceptions Incorrect shipments must be reported within 5 BUSINESS DAYS of receiving the Engine s as described in the Incorrect Products Section below no exceptions IU MMS Airboat Engine Manual v1 0 42 INCORRECT PRODUCTS MMS make every effort to ship the correct Engine However unusual mistakes can happen If we ship you a MMS Engine you did not order we will pay for return shipment and replace it with the correct Engine Please let us know within 5 business days after receipt if yo
12. sizing for a radiator varies depending on application installation and horse power Please refer to the radiator manufacturers recommendations for proper sizing Figure 5 below shows the proper connections and plumbing of the cooling system j lt J Water Pump Outlet Y lt Radiator Inlet Top s Water Pump inlet to Radiator Outlet Bottom Figure 5 Cooling System Plumbing Diagram Fuel System Mast Motorsports suggests using the Fuel System Plumbing Diagram located in Appendix B as a general outline The supplied Mast Motorsports Universal Fuel System Kit is designed to keep your engine running at the proper 58 5 psi of fuel pressure This fuel system kit closely models the configuration shown in Appendix B The fuel pump and filter regulator should be mounted to a rigid structure using the supplied mounting kit The fuel pump should be mounted below the lowest point of the fuel tank If this is not possible it is recommended to install a High Volume Low Pressure fuel pump between the fuel tank and the high pressure fuel pump Failure to install a high volume low pressure fuel pump will cause poor engine performance and or fuel system failure that could result in engine damage All fuel lines should be approved for fuel injected applications and be rated to a minimum working pressure of 100 psi Fuel lines to the pump filter regulator and fuel rail should be a minimum of 3 8 ID The return fuel line from the f
13. 8 Valve Cover Breather Location MMS Airboat Engine Manual v1 0 25 Power Reduction Mode The Mast Motorsports M 90 ECM monitors engine oil temperature and engine coolant temperature ECT whenever the engine is running When the ECT or oil temperature is out of the normal operating parameters the system will go into Power Reduction mode This is a feature that will help protect the engine during abnormal temperature conditions When operating in Power Reduction mode the ECM will default to a load limit condition Refer to Table 3 for Power Reduction Mode conditions While operating in power reduction mode the ECM will only allow limited engine performance Once the engine has returned to normal operating temperatures normal engine operation is restored until the engine exceeds the temperature parameters again This feature still allows maneuverability of the boat while removing the possibility of high engine speed operation until the problem is corrected NOTICE For continued reliability of your Mast Motorsports engine the cause of the Power Reduction Mode fault must be determined and corrected Please refer to the Troubleshooting Section of this manual Engine failure due to symptoms of Power Reduction Mode faults will not be covered under warranty ECT Load Limit degF 0 0 60 0 40 0 70 0 80 0 85 0 120 0 100 0 160 0 100 0 200 0 100 0 210 0 80 0 220 0 40 0
14. ATASTROPHIC ENGINE DAMAGE AND IS NOT COVERED BY WARRANTY Figure 19 Passenger Side P Clip Installation OU ae MMS Airboat Engine Manual v1 0 18 Figure 21 Driver s Side Rear P Clip Installation Electric Gauge Calibration Oil Pressure and Engine Coolant Temperature ECT Gauge Calibration The Mast Motorsports M 90 ECM contains the unique capability of fully calibratable Oil Pressure and ECT gauge drivers This allows customers to use virtually any electric gauge they choose without using a specific sending unit The ECM simply streams the information across the Oil Pressure and ECT signal wires To perform the following calibration a Mast Motorsports communication software package PN 302 102 and password are required These are available from Mast Motorsports Please have the ECM serial number available when contacting Mast Motorsports MMS Airboat Engine Manual v1 0 19 Step 1 To start the calibration process you must be in the Mast Display under Page gt GaugeDrive Figure 22 Verify that your Display shows connected in upper left hand corner of the software 2 Figure 22 Mast Gauge Driver Calibration Screen Step 2 To begin the calibration process start with the engine coolant temperature section Gauge Driver Calibration Figure 22 Enter 100 in the highlighted area under the Duty Cycle column shown in Figure 23 This area will be re
15. M 90 ECM to operate other devices such as gauges and data loggers Mast Motorsports CAN Gauge Wiring Mast Motorsports offers a Livorsi CAN Gauge Package Figure 26 that allows the data transmission of multiple engine parameters across two wires There is a master tachometer gauge and multiple slave gauges in this setup The master tachometer contains all the major electronic circuitry The slave gauges are completely plug and play into the master gauge with the supplied 3 wire slave harness master gauge will come with a 12 wire master harness to operate the gauges Only six of these wires will need to be connected to the Mast Motorsports Dash Harness Table 2 shows the wire connections for Mast Motorsports CAN Gauges The remaining wires are connected to the supplied control pod to operate multiple functions of the master tachometer N E MMS Airboat Engine Manual v1 0 22 Figure 26 Livorsi Gauges With the master Gauge wired satellite gauges plug and play installation Plug them into the master gauge using the slave harnesses supplied with the gauge package Full instructions for connection of the CAN gauges are supplied with the Livorsi CAN Gauge Kit Mast Motorsports CAN Gauge Wiring Table Mast Motorsports Wire Mast Motorsports Dash Wire Function Wire Number Color Harness Cavity 6 LT BU RD AS Ground 2 BK C7 High 4 LT BU BK D1 Low 3 LT BU WH D2 Illuminati
16. OBLIGATIONS AND PROCEDURES Upon initial startup ultimate purchaser owner shall assure that a qualified mechanic inspects your engine The inspection should include but is not limited to a change of oil and oil filter after the first 25 hours Carefully monitor coolant and oil levels for the first 100 hours as oil consumption may be higher during this period The owner and or operator is responsible for checking and maintaining ALL fluid levels before and during operation and for regularly monitoring gauges during operation Change engine oil as specified in the Maintenance Schedule of this manual Maintain a documented maintenance schedule including the facility performing the services corresponding receipts and dates Use only approved motor oil stated above or equivalent Allow the engine s coolant and oil to reach operating temperatures before the engine is placed in a high load or high RPM operating condition DO NOT OPERATE THE ENGINE WITH ABNORMAL OIL PRESSURE OR WATER TEMPERATURE MMS does not recommend the use of full synthetic oils or non detergent oils the use of which shall void this Limited Warranty Due to the manufacturing techniques the quality products used in MMS Engines and the initial break in performed at MMS very few special requirements apply to break in Use only the recommended engine oil for the temperature for which the vessel will be operated The engine oil level and coolant level should be checked frequently during thi
17. Replace or repair as needed Fuel pump not functioning Confirm wiring Refer to Wiring Installation Section Confirm MAP IAT Sensors and pedal assembly are connected Confirm all wiring connectors are connected Refer to Wiring Installation Section MMS Airboat Engine Manual 1 0 Troubleshooting Malfunction Possible Cause Corrective Action Engine Cranks will not start or is hard starting continued Contaminated Fuel Ignition System Malfunction Check for water and other contaminates fuel Replace fuel and fuel filters Contact Mast Motorsports Engine overheats Improper Coolant Hose Routing Incorrect Coolant Gauge Calibration Coolant Level Low Loose or Worn Accessory Belt Collapsed Kinked or Leaking Hoses Faulty Thermostat Faulty Temperature Gauge or Sending Unit Confirm proper hose routing Refer to Figure 4 Recalibrate gauge Refer to Electric Gauge Calibration Refill the system Check cooling system for leaks Replace Belt Replace hoses Replace thermostat Test and replace as necessary Engine Oil Pressure Low Oil Level Low Incorrect Oil Pressure Gauge Calibration Faulty Oil Pressure Gauge or Sending Unit Check engine for leaks Add specified oil Recalibrate gauge Refer to Electric Gauge Calibration Test and replace as necessary MMS Airboat
18. SE INC DEC INICATOR GND START SWITCH LUTCH SWITCH AUX_ANA_PUD3 AUX_ANA_PDS SUX_DIG3 NSS VSS CRUISE REQUEST BRAKE INPUT A C COMPRESSOR GNITION SWITCH CAN GND GAUGE CT GAUGE TACH NAVAILTBLE NAWATLIBLE MMS Airboat Engine Manual v1 0 Appendix Mast Motorsports Suggested Fuel System Plumbing Diagram FUEL SUPPLIED FROM PU MIS FUEL FLOW gt le ANd lt FUEL FLOW FUEL RETURN FROM FILTER REGULATOR ENSURE APPROXIMATELY 60 PSI FUEL PRESSURE IS AVAILABLE AT FUEL RAIL BEFORE ENGINE OPERATION 1 ALL FITTINGS SHOULD BE CHECKED FOR LEAKS BEFORE OPERATION NOTES gt SYS lt EFI FUEL SYSTEM PLAMBING DIAGRAM PSD VE DRAWN BY LIDE 1 A D E 0 of Fi 0 0 8 THIS DRAWING IS THE PROPERTY i OF MAST MOTORSPORTS LLC AND IS THE SUBJECT TO RETURN Ly UPON REQUEST AND IS NOT 1 gt 1 F BE COPIED OR REPRODUCED WITHOUT WRITTEN PERMISSION ALL RIGHTS RESERVED REVISION 1 GM P N 10299146 FILTER REGULATOR REVISIONS AST MOTORSPORTS BOTH INTANK INE FUEL PUMP NFIGURATIONS 3 FUEL
19. al Operating Parameters 8 Service General Torque 2 Appendix Mast Motorsports Dash Harness Wiring Appendix Mast Motorsports Suggested Fuel System Plumbing Diagram Appendix Mast Motorsports System Fault Warranty State me Warranty Policy Procedures 0V Slope MMS Airboat Engine Manual v1 0 Serial Number Location Engine Serial Number Location ECM Serial Number located on Back of M 90 WBO2 ECM Please fill in the engine and ECM serial number on the cover page of this manual and on page 44 in the warranty section of this manual These numbers are required for any service or warranty work VER MMS Airboat Engine Manual v1 0 4 Overview Congratulations on the purchase of your Mast Motorsports Airboat Engine Now that you have the parts in hand it is time to begin the installation process so that you may enjoy your project The following information listed in this manual was in effect at the time of printing Due to continued improvements Mast Motorsports reserves the r
20. an anti wear agent However it is imperative that you choose engine oil with a significant amount of ZDDP For Mast Motorsports Typhoon and Cyclone engines we suggest an engine oil with a minimum ZDDP content of the following Approximate Percentage by Weight Zinc 0 120 Phosphorus 0 115 Suggested Oils Valvoline Racing Oil 20W 50 normal ambient operating temperatures above 32 F Valvoline Racing Oil 10W 30 normal ambient operating temperatures below 32 F Engine Installation Engine Mounting The engine stringer and bed system in a vessel is the single most important structural component It must be designed to withstand not only the weight of the engine but also the thrust of the propeller propeller torque reaction and the stresses caused by the pitching and rolling of the vessel in the harshest of environmental conditions Correctly constructed the engine stringers and engine bed should absorb all of the vessel strain and stress and not transfer it to the engine The mounting system must be constructed so VER MMS Airboat Engine Manual v1 0 6 supporting structure deflections do not overstress engine castings engine must have sufficient clearance to prevent damage from physical contact between the engine components and adjoining vessel structures Static installation angle of the engine in a vessel must be between 0 and 5 front up Steel or stainless steel bolts should be used for all fa
21. and damaged wiring Hoses Inspect for cracks swelling weather checking or other signs of deterioration Fuel Filters Service or replace X Engine Assembly Exterior Surfaces Spray with rust preventative oil WD 40 Penetration oil or equivalent Fresh water areas Every 60 Days Salt water areas Every 15 Days NE MMS Airboat Engine Manual v1 0 31 Troubleshooting Malfunction Possible Cause Corrective Action Engine will not crank with the starter motor or cranks slowly Note Battery voltage must be AT or ABOVE 10 volts while engine is cranking Engine Cranks will not start or is hard starting Improper Valet Ground Connection Blown Ignition Fuse Loose and or Dirty Wiring Connections Dead Battery Insufficient Fuel Low Fuel Pressure Improper Wiring Confirm Valet Ground is properly grounded Refer to Wiring Installation Section Confirm proper wiring Refer to Wiring Installation Section Replace the Fuse Check battery cables and starter circuit wiring Refer to Wiring Installation Section Clean and tighten all connections Recharge test and replace if necessary Verify fuel pressure of 58 5 psi at the fuel rail Open fuel shut off valve Check fuel level Verify fuel system plumbing Refer to Appendix B Plugged fuel filter plugged or kinked fuel lines or plugged fuel tank vent
22. ar of the engine There are two wires in the fuel pump harness They are to be run directly to the fuel pump The Yellow Red Y RD wire goes to the positive side of the fuel pump and the Black BK wire goes the ground or negative side of the fuel pump The fuel pump fuse and relay are integrated into the Mast Motorsports Wiring Harness The fuel pump is programmed to prime the fuel system for 5 seconds at key on and is turned on continuously as soon as the starter relay is triggered by the end user s ignition switch The fuel pump will also stop whenever the engine is stopped for safety and convenience reasons The fuel system prime feature ensures easy starting and the convenience of not needing a separated switch for the fuel pump If the end user needs the ignition switch on for lights radio or accessories the fuel pump will not run continuously Gauge Wiring and Setup Electric Gauge Wiring Mast Motorsports M 90 ECM has the ability to drive duty cycle or resistance electric gauges It drives gauges using a Duty Cycle PWM signal This eliminates the need to have a separate sender to provide gauge signals In the absence of gauge manufacturer s calibration data a custom gauge calibration must be created This process consists of correlating the values on the Mast Motorsports Calibration Software to the value shown on the gauge This process is explained in detail below as well as in the Mast Motorsports Calibration Manual It should be not
23. as a general outline The supplied Mast Motorsports Universal Fuel System Kit is designed to keep your engine running at the proper 58 5 psi of fuel pressure This fuel system closely models the configuration shown in Appendix B After the fuel system installation ensure that the fuel system lines and components are away from excessive heat sharp edges and vibration Figure 1 Universal Fuel System Kit N E MMS Airboat Engine Manual v1 0 5 Gasoline Requirements WARRANTY NOTICE Damage caused to the engine through the use of improper gasoline gasoline with an octane rating below the minimum requirements listed below or low quality gasoline is considered misuse of the engine Such damage is not covered by the Mast Motorsports Engines warranty NOTICE Mast Motorsports Typhoon and Cyclone engines are calibrated to operate on 91 93 octane R M 2 fuel Maximum performance and reliability is obtained when using this fuel Ifa slight pinging is heard during acceleration and the proper octane fuel is being used it is considered normal If a constant heavy knock occurs the engine should be evaluated by Mast Motorsports The use of 87 octane fuel is permissible but only in an emergency The engine should never be operated at full throttle full load or high RPM while using 87 octane fuel Oil Requirements Motor oil has had several significant changes in the last ten years In 2004 a decision was made to reduce the sulfur and the zinc phos
24. ast Motorsports The limited warranty is not an unconditional warranty against all hazards or failures This limited warranty shall not apply to defects or conditions caused by misuse abuse misapplication incorrect installation modification or accident after you received the Engine The limited warranty shall not apply to any Engine that has been installed in any application that is used or could be used for competition purposes The limited warranty shall not cover damages resulting from lack of lubrication improper oil and or lube overheating oil starvation oil pressure loss engine over speed excessive oil temperature contamination from foreign elements environment or auxiliary components failures due to extreme weather conditions detonation or pre ignition including but not limited to melted or broken pistons broken or scored rings damaged cylinder heads or gaskets scoring on cylinder walls or piston heads The limited warranty shall not cover replacement oil antifreeze or other substances used in normal maintenance tune ups replacement of belts hoses or routine maintenance items The limited warranty shall not cover or provide payment or reimbursement for towing charges transportation charges lift dock or storage fees loss of use of vessel time or income MMS s entire liability and your exclusive remedy under this limited warranty in the event of a breach during the warranty period will be for MMS to either repair or r
25. cond cable with ring terminal from the vessel ground to the front driver s side of the engine e Secure both ring terminals to the side of the engine in the same location as the ECM and fuse block grounds Figure 17 Figure 17 90 Fuse Block Ground Terminal Installation NE MMS Airboat Engine Manual v1 0 15 NOTE ALL GROUND CONNECTIONS SHOULD CLEAN FREE PAINT AND SECURED SUFFICIENTLY This will eliminate potential hours of troubleshooting throughout the build process Now your ECM Wiring Harness is grounded to the engine and the engine is also grounded to the chassis On most installations this should make for a common ground for the entire vessel Ignition Switch Wiring There are many different configurations that may be used for wiring the ignition start switch The most commonly used configuration is a tumbler style ignition switch that is found on road cars These switches commonly have four posts connections The functions of these posts are 12V Power Ignition Power Starter Activation and Accessory Power Table 1 shown below describes the wire in the Mast Motorsports Dash Harness that corresponds to each of the posts connectors Mast Mast Motorsports Wire Function Motorsports Dash Harness Wire Color Cavity Figure 18 12V Power Supplies 12V to Ignition Switch RD BK A4 Ignition Switch Post Switched Supplies 12V to ECM and Other Ignition Power Connected Subsystems PK D BU
26. d on your screen and press enter while watching to see if your coolant gauge moves If your gauge moves you have a successful connection and can continue to step 3 If it does not move please verify wiring is connected correctly MMS Airboat Engine Manual v1 0 20 Figure 23 Entry Field Step 3 Notate the number in the highlighted area in Figure 24 below This is the number we want to start with Enter different values from 0 100 in the highlighted area in Figure 23 until your gauge reads the value Figure 24 Figure 24 Gauge Value OLE MMS Airboat Engine Manual v1 0 21 Step 4 After getting the correct value in the entry field Figure 23 enter this value in the highlighted area under the Duty Cycle column shown in Figure 25 Continue repeating steps 1 4 until you have entered values into each cell under Duty Cycle Figure 25 Result Field After you have entered values into each cell under Duty Cycle you have successfully calibrated your coolant gauge Follow these same steps to calibrate your Oil Pressure Gauge Controller Area Network CAN CAN is a means of data transfer that is commonly used in modern vehicle OEM marine and industrial applications This allows the transfer of large amounts of data over just two wires Taking advantage of this technology can greatly reduce the amount of wiring that is required to monitor certain parameters of an engine CAN also transmits data from the
27. derstood that every internal combustion engine will use a certain amount of oil during operation to act as a lubricating and cooling agent especially during the break in period Oil consumption should decrease and become stabilized after approximately 100 hours of operation IU MMS Airboat Engine Manual v1 0 24 Systems LS Series engines to excessive case pressure build up resulting oil blow by consumption and oil wetting of the intake manifold One of the first changes from GM to help resolve this issue was the bay to bay windows placed in the main webs of the blocks Any increase in cubic inch displacement over stock places more demand on the PCV system regardless of the engine type Operating the engine with the improper oil viscosity or below normal oil temperature will increase engine blow by and lead to abnormal oil consumption Use only the specified oil for the temperature range for which the engine will be operated See Normal Operating Parameters and Requirements Mast Motorsports Airboat Engines are supplied with a PCV Breather Tank Figure 27 This tank should be mounted to a rigid structure at a level higher than the breather fittings on the engine The fitting on the side should be plumbed directly to the valve cover breather located next to the oil fill cap Figure 28 The tank should be drained of any excess oil every 50 hours Mounting Points Figure 2
28. ed that custom calibration of the gauge drivers requires the purchase of a communications cable and software Mast Motorsports P N 302 102 Tachometer Gauge Tach Wiring Mast Motorsports ECM Wiring Harness Packages have an integrated tachometer signal eliminating the need to acquire a tachometer signal through other means This signal comes from the ECM and is transmitted through the Red and Dark Green RD D GN wire in cavity C11 Figure 18 of the dash harness This tachometer driver uses a 4 pulses per revolution signal and is not custom configurable A 4 pulse per revolution tachometer or a tachometer that has a selectable pulse per revolution must be used IU MMS Airboat Engine Manual v1 0 17 Pressure Gauge Wiring Most oil pressure gauges will have a three wire connection These wires are for switched ignition power oil pressure signal and ground In order to take advantage of the oil pressure gauge driver follow the gauge manufacturer s wiring instructions When hooking up the oil pressure signal wire use the Black and Dark Green BK D GN wire in cavity C9 Figure 18 of the Dash Harness The process of calibrating the gauge is explained in the Electric Gauge Calibration section on page 19 Engine Coolant Temperature ECT Gauge Wiring Most engine coolant temperature gauges will have a three wire connection These wires are for switched ignition power ECT signal and ground In order to take advantage of the ECT gauge driver
29. engine oil when the engine is warm from operation Warm oil flows more freely and allows more foreign material and impurities to be removed 1 With the engine at normal operating temperature place an oil drain pan beneath drain plug on the oil pan Remove drain plug and let the oil drain completely 2 Remove the oil filter by turning it counterclockwise Use an oil filter wrench if necessary Discard the old filter and sealing gasket 3 Coat the sealing gasket on the new filter with a light coating of clean engine oil Install the oil filter securely by hand DO NOT over tighten 4 Fill the engine with the recommended oil through the oil fill location on the valve cover Engine Storage 1 the fuel tanks with gasoline that does not contain alcohol and add a sufficient amount of gasoline stabilizer such as STA BIL Fuel Stabilizer Marine Formula to prevent the formation of fuel gum and varnish Follow the instructions on the container IMPORTANT If the engine is to be placed into storage with fuel containing alcohol in the fuel tanks the engine fuel system must be run dry at idle RPM A fuel conditioner such as STA BIL Fuel Stabilizer Marine Formula should be added to any fuel remaining in the tanks 2 Run the engine and allow it to reach normal operating temperature Shut down the engine and change the oil and oil filter See CHANGING OIL 3 Remove the air filter Operate the engine at a fast idle speed
30. eplace at MMS s option and expense the defective Engine or Engine Components provided you return the defective Engine or Engine Components to MMS at your expense To make a claim under this limited warranty please contact MMS directly for a numbered authorization Prior authorization is required from MMS before warranty work is begun You must then return the alleged defective Engine or Engine Components via insured freight carrier MMS will process your return and if there has been no violation of the warranty and the claim was made within the warranty period send a repaired or replacement Engine to you at MMS s expense THE LIMITED WARRANTY SET FORTH ABOVE IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES IN NO EVENT SHALL ANY IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT EXTEND BEYOND THE DURATION OF THIS EXPRESS LIMITED WARRANTY NO ORAL STATEMENTS BY ANY PERSON DISTRIBUTOR OR SALESMAN MAY MODIFY OR CHANGE THIS LIMITED WARRANTY NO IU MMS Airboat Engine Manual v1 0 41 TERMS PURCHASE ORDER OTHER FORM FROM THE PURCHASER DISTRIBUTOR SELLER SHALL MODIFY OR CHANGE THIS LIMITED WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state OWNER
31. he ECM through a 35 amp relay Figure 13 Fuel Harness MMS Airboat Engine Manual 1 0 12 Dash Harness dash harness Figure 14 connects to the main wiring harness using 38 connector The dash harness was built to allow the end user to use as many or as few of our ECM features as they wish In order to run the engine only three connections are needed ignition power start and valet ground The dash harness encompasses many other features that can be wired in at the end users wishes It is also pre wired for future features of our ECM The dash harness has pre installed connectors for the ECM serial interface Foot Pedal and Mast Motorsports CAN Dongle The dash harness has flying lead wires for all other features The harness will allow for up to 32 separate Mast Motorsports CAN gauges to be connected that pull information off the M 90 CAN network such as engine hours RPM battery voltage engine coolant temperature oil pressure fuel level intake air temperature throttle position road speed DTC s and odometer The dash harness also has connections for analog gauges These include Tachometer Engine Coolant Temperature Oil Pressure and configurable gauge driver The ECM actually uses the engine s existing sensors to provide gauge signals This eliminates buying mounting and plumbing bulky sending units that would normally have to be placed on the engine This is a great feature to use with Autometer o
32. hree Pin Weather Pack Connector Apart and Assembled Alternative Wiring Procedure If Weather Pack connectors are not an option a soldered splice can be made to work Mast Motorsports recommends using a butt splice if applicable that has been soldered to ensure connection integrity BE SURE NOT TO GET THE WIRE TOO HOT WHILE SOLDERING Excessive heat to the wire will lead to eventual brittle fracture After soldering is complete the splice should be covered with heat shrink tubing It is good practice to protect the splice connection from excessive movement and vibration to prevent fatigue fracturing After the wiring job has been completed secure the wiring in an area that is free of heat sharp objects and moving objects IU MMS Airboat Engine Manual v1 0 9 90 WBO2 Wiring Harness While the 90 ECM and wiring harness very robust it is good practice to protect electrical components from excessive heat vibration and the elements of weather This will ensure many years of a smooth running electrical system It is acceptable to mount the ECM and fuse block in the engine compartment however as stated earlier it should be mounted AWAY FROM EXCESSIVE HEAT SHARP EDGES VIBRATION AND THE ELEMENTS OF WEATHER Once the engine is mounted it is recommended to make certain that the harness and all of the connectors are away from excessive heat sharp edges vibration and the elements of weather The M 90 ECM Package wi
33. ight to change any specification or design without notice or obligation Before we begin Mast Motorsports suggests some practices that you may want to employ during the installation process In order to have your boat running reliably for years to come it is necessary to ensure that the quality of wiring craftsmanship not be compromised throughout the installation Spending extra time to ensure that a wiring job has the integrity enough to withstand years of service can potentially save great amounts of time down the road This is a situation where two minutes can literally save two days of troubleshooting Fuel System Requirements Your Mast Motorsports engine boasts the latest in fuel injection technology It is supplied with a complete Mast Motorsports Universal Fuel System Kit Figure 1 This kit contains a pump high pressure fuel filter regulator and multiple fittings for proper connection In order for your engine to operate properly it must have the appropriate fuel volume and pressure supplied to the fuel rail Mast Motorsports Engines are required to have 58 5 psi gauge pressure to the fuel rail at all times of operation Proper fuel pressure 58 5 psi must be verified at the fuel rail Schrader valve by a mechanical gauge SUPPLYING IMPROPER FUEL PRESSURE TO YOUR ENGINE CAN RESULT IN CATASTROPHIC ENGINE FAILURE AND WILL NOT BE COVERED UNDER WARRANTY Mast Motorsports suggests using the Fuel System Plumbing Diagram located in Appendix B
34. ilter regulator to the tank should be a minimum of 5 16 ID After the fuel system installation ensure that the fuel system lines and components are away from excessive heat sharp edges and vibration and that all of the fittings and clamps are tight It is imperative that you make every effort to have your fuel system in proper working order prior to engine start up Inspection of the supply lines return lines filters regulators and fuel pressure are the responsibility of the boat owner and or installer Improper fuel plumbing can lead to an over rich or over lean condition which will result in engine failure and void the warranty It is extremely crucial that you only use the ECM delivered with the engine as it is calibrated specifically for that engine VU Se MMS Airboat Engine Manual v1 0 8 Wiring Installation Preferred Wiring Procedure The best way to ensure trouble free wire connections is with the purchase of a Weather Pack wiring kit and their corresponding crimpers When used correctly with the appropriate crimpers Weather Pack connectors can make OEM quality wire connections that will last the life of the installation They are available in multi pin configurations and their quick connect nature makes for easy disassembly should it ever be required A 1 pin as well as a 3 pin Weather Pack connector is shown in Figures 6 and 7 below Figure 6 One Pin Weather Pack Connector Apart and Assembled Figure 7 T
35. ir power from the large red RD battery cable ring terminal located near the starter motor Positive Battery Power Ensure the large ring terminal on the wiring harness is connected to the starter post Figure 16 Run a battery cable from the battery location to the starter post Do not connect this cable to the battery You should only connect the cable to the starter post at this time If running your alternator wire directly to the battery you can connect this cable now If you are running your alternator wire directly from the alternator to the starter post connect the terminal to the starter post at this point NOTE Connecting the alternator directly to the starter VER MMS Airboat Engine Manual v1 0 14 post will cause the engine to run off of the alternator independent of the battery For safety the alternator cable should be run to a battery cutoff switch first and then to the starter e Secure all cables to the starter post Figure 16 using the supplied nut Figure 16 M 90 Power Terminal Installation Battery Ground The ECM and fuse block grounds are the two large ring terminals with black BK cables that run to the front driver s side of the engine They are secured with an 10 1 5 bolt on the side of the engine located directly behind the alternator See Figure 17 a cable with ring terminal from the negative side of the battery to the front driver s side of the engine e Run a se
36. ll warranties Mast Motorsports reserves the right to waive or not waive the labor charge s involved with any and all warranty claims Any and all warranties will be issued at the sole discretion of Mast Motorsports I hereby agree to accept the responsibility of not altering or repairing my Mast Motorsports Engine without the authorization of Mast Motorsports Initials The limited warranty is not an unconditional warranty against all hazards or failures This limited warranty shall not apply to defects or conditions caused by misuse abuse misapplication incorrect installation modification or accident after you received the Engine The limited warranty shall not cover damages resulting from lack of lubrication improper oil and or lube overheating oil starvation oil pressure loss engine over speed excessive oil temperature contamination from foreign elements environment or auxiliary components failures due to extreme weather conditions detonation or pre ignition including but not limited to melted or broken pistons broken or scored rings damaged cylinder heads or gaskets scoring on cylinder walls or piston heads Initials All of the aforementioned items are at the sole discretion of Mast Motorsports Mast Motorsports may deem that neglect was the cause of the component failure In the event of a failure due to negligence the engine owner assumes responsibility of the failure If Mast Motorsports deems it necessary to warranty a com
37. ngine at high idle Reduction Mode Temperature speed 1500 RPM until Continued normal operating temperature is achieved Engine Misses Runs Rough and or Backfires Low Fuel Pressure Faulty Wiring Plugged fuel filters Faulty Fuel Pump Plugged or Kinked Fuel Lines or Fuel Tank Vent Ignition System Malfunction Confirm fuel pressure at fuel rail is 58 5 psi Confirm all wiring including MAP Sensor IAT Sensor and Pedal Assembly is connected Replace the fuel filters Replace the fuel pump Repair or replace the fuel lines Contact Mast Motorsports MMS Airboat Engine Manual v1 0 35 iagram D 9 1 18 16 STARTING 18 POWER DASH GROUP CAN GROUP iring OR D GH 18 AUXILLARY A GROUP DRZL GN 18 Wi AUXILLARY B GROUP Appendix A Mast Motorsports Dash Harness EE g IS DSTART SWIT CH SIGNAL l2 V H STAL 02 08 OF CONFIGURABLE OUTPUT SWITCH GND CORVETTE FPP CONNECTOR namon gt SIGNAL COMI N FIST FT FULL LENGTH OUT OF THE HAR 1 3 4 5 6 7 8 SIGNAL THAT YOU NEED TO APPLY TO THE WIRE ESS TO BE USED BY DIAGNOSTICS CONNECTOR YOU TASH HARNESS RTN V EXTI AN 12V PP SIGNAL 1 PP SIGNAL 2 DLE VALIDATION AUX_ANA_PU2 RUISE SET CLEAR RUI
38. on 5 Connect to Light Switch Power Source Ignition 1 PK D BU C6 Table 2 Mast Motorsports CAN Gauge Wire Connection Chart VER MMS Airboat Engine Manual v1 0 23 Operating Instructions Engine Starting Checklist Before your engine is started it is essential that the following checklist be completed Proper engine oil added to correct level Engine cooling system filled and bled of air plumbed correctly hose clamps tightened Fuel system provides 58 5 psi and checked to ensure no leakage Air filter installed secured and sensor connected Starter connections correct and tight Accessory drive belt installed and secured Exhaust system installed and secured Wires connected secured and placed away from heat sharp edges and moving parts Ensure flying lead wires not being used are insulated to prevent electrical shorting Battery cables properly connected to battery Engine Break in Your engine is a high performance engine and requires special care during the break in period and beyond Every airboat engine at Mast Motorsports goes through a thorough start up procedure and dyno run before the engine is shipped Special care was taken during the initial start up and dyno run to ensure the engine is performing properly Use only the recommended engine oil for the temperature for which the vessel will be operated The engine oil level and coolant level should be checked frequently during this period It is impo
39. phorus compounds ZDDP The ZDDP is used as the primary anti wear agent for internal engine components Beginning with the 2004 model of new vehicles the Federal Government has asked auto manufacturers to warranty catalytic converters for 120 000 miles Most catalytic converters eventually fail from harmful gases emitted thru the exhaust and two of these are the phosphorous and sulfur which were a prevalent make up of our older motor oils All engines will consume some oil thru the exhaust While in most cases this is only a very small amount the automakers decided it was time to change the chemistry of motor oil rather than adding to the cost of catalytic converters This change in engine oil has had a significant impact on the performance engine world specifically engines with forged pistons and or flat tappet camshafts The lack of the zinc phosphorus compounds has been a primary cause of premature failure in flat tappet camshafts and lifters Current oils for gasoline engines have the ZDDP compounds reduced by 20 or more We have seen an overwhelming increase in piston scuff and premature ring wear We have torn down performance engines with less than 1500 miles and seen piston scuff and ring wear that looked as if the engine had 100 000 miles This caused by super low viscosity oils with poor anti wear characteristics and a lack of following proper break in procedures We have taken every precaution to coat the cylinder walls pistons and rings with
40. ponent proof of oiling system flush procedure and or oiling system replacement must be presented to Mast Motorsports The thoroughness and validity of the flush procedure and or replacement is at the sole discretion of Mast Motorsports NE MMS Airboat Engine Manual v1 0 The owner and or operator is responsible for checking and maintaining ALL fluid levels before and during operation for regularly monitoring gauges during operation and following the maintenance schedule listed below The owner operator of a Mast Motorsports Engine must under all conditions abide by the following maintenance schedule and procedures Check and monitor engine coolant level and temperature before and during operation Check and monitor engine oil level and temperature before and during operation Change engine oil as outlined in the Maintenance Schedule Change fuel filter pressure regulator as outlined in the Maintenance Schedule Use only the oil specified in the Normal Operating Parameters and Requirements and Oil Requirements sections e Allow engine to come up to operating temperature as listed in the Normal Operating Parameters and Requirements before operation Allow engine to idle for 30 seconds before shut down Retighten header bolts to 15 Ft Lbs following the first 25 hours of operation Check that all nuts and bolts are tight and that all engine components are securely fastened to the engine e Check that all wiring is not subjec
41. r similar aftermarket gauges The Malfunction Indicator Lamp MIL output and the A C switch input are also on the dash harness The dash harness also contains wiring for the future option of Cruise Control with Engage Resume and Increase Decrease buttons ALL FLYING LEAD WIRE ENDS NOT BEING USED SHOULD BE PROPERLY TERMINATED AND INSULATED BY THE INSTALLER TO AVOID A POTENTIAL SHORT CIRCUIT Figure 14 Dash Harness VER MMS Airboat Engine Manual v1 0 13 Drive By Wire Foot Installation Drive By Wire DBW throttle actuation requires that a DBW foot pedal be installed The foot pedal should be rigidly mounted to a sufficient structure This will ensure that the driver has reliable and predictable control of the throttle at all times The connector simply plugs into the Dash Harness Failure to properly connect the pedal to the Dash Harness will cause poor engine performance Figure 15 below shows the DBW foot pedal securely attached to solid floor structure Figure 15 DBW Foot Pedal Installed Getting System Power Getting system power on a Mast Motorsports Airboat Engine and ECM Package is very straightforward Below is the procedure for connecting your package to your boat s 12V DC battery power DO NOT APPLY BATTERY POWER TO THE SYSTEM UNTIL THE INSTALLATION IS COMPLETE Applying battery power before installation is complete could potentially cause damage to components and void the warranty The ECM and fuse block get the
42. r High 515 Flash Checksum Invalid 222 Closed Loop Multiplier Low 516 RAM Failure 241 Adaptive Lean Fault 521 Shutdown Request 242 Adaptive Rich Fault 531 External 5 Reference Lower than Expected 261 System Voltage High 532 External 5v Reference Higher than Expected 262 System Voltage Low 555 2 Loss 311 Coil Driver 1 Open 556 RTI 3 Loss 312 Coil Driver 1 Shorted 611 FPP High Voltage 313 Coil Driver 2 Open 612 FPP Low Voltage 314 Coil Driver 2 Shorted 613 FPP Higher than IVS Limit 315 Coil Driver 3 Open 614 FPP Lower than IVS Limit 316 Coil Driver 3 Shorted 631 TPS1 signal voltage High 321 Coil Driver 4 Open 632 TPS1 signal voltage Low 322 Coil Driver 4 Shorted 633 TPS2 signal voltage High 323 Coil Driver 5 Open 634 TPS2 signal voltage Low 324 Coil Driver 5 Shorted 635 TPS1 Higher than TPS2 325 Coil Driver 6 Open 636 TPS2 Higher than TPS1 326 Coil Driver 6 Shorted 637 Throttle Unable to Open 331 Coil Driver 7 Open 638 Throttle Unable to Close 332 Coil Driver 7 Shorted 651 Max Govern Speed Override 333 Coil Driver 8 Open 652 Fuel Rev Limit 334 Coil Driver 8 Shorted 653 Spark Rev Limit MMS Airboat Engine Manual v1 0 38 Engine Maintenance Log Date Maintenance Repair Engine Hours MMS Airboat Engine Manual v1 0 39 Notes
43. ring harness and components can be seen below in Figure 8 OOF LN Figure 8 M 90 ECM Wiring Harness Package It can be seen that the ECM and fuse block run out of the harness on the port left side of the engine Other than the Injector Ignition banks Knock Sensors and engine start wire the connectors on this harness will not fit the wrong sensor The main wiring harness is the nervous system of the engine which sends and receives signals from various locations on the engine Our main wiring harness uses only marine grade TXL wire and ultrasonic welds for OEM quality connections The main wiring harness connects our 90 pin M 90 ECM to all the various engine sensors fuse relay box and auxiliary wiring harnesses The Mast Motorsports main wiring harness comes with a complete fuse relay box Figure 9 This is not the three relays and four fuses that most aftermarket fuel injection systems supply with their wiring harnesses The fuse relay box is populated with nine mini fuses three maxi fuses four 35 amp relays and two 50 amp relays for complete circuit control and protection The relays control the fuel pump starter electric fan ignition power AC compressor not used in airboat applications and Variable Valve Timing VVT camshaft phaser This makes for a full stand alone engine wiring system that allows less wiring than normally necessary 0V Slope MMS Airboat Engine Manual v1 0 10 Figure 9 Fuse Rela
44. rs and Requirements Engine oil Fuel Requirement Coolant Temperatures above 32 F Valvoline Racing SAE 20 50 Temperatures below 32 F Valvoline Racing SAE 10W 30 91 93 Octane R M 2 Extended Life Antifreeze Coolant 50 50 mix Oil Pressure 2500 RPM 25 50 psi with oil at operating temperature Minimum Oil Pressure 10 psi idle with oil at operating temperature Oil quantity 6 Quarts Normal Oil Temperature 180 230 Normal Engine Coolant 155 200 Temperature Voltage 13 0 14 8 volts Maximum RPM 6200 RPM Alternator 105 amp Battery CCA 650 CCA Minimum Spark plug gap 045 Capacities are dependent on installation angle capacities are approximate Always verify the correct amount by using the dipstick VV Sikes MMS Airboat Engine Manual v1 0 29 Service List Component Mast Motorsports Part Oil Filter 89017524 Spark Plugs AC 12621258 or NGK 4091 High Pressure Fuel Filter Regulator 105 006 Fuel Pump WAL GSL392 Air Filter 115 001 Inlet Air Temperature Sensor 12160244 B Spark Plug Wires 402 002 Accessory Drive Belt GATK060532 Diagnostic Software and USB Cable 302 102 Engine Coolant Extended Life Antifreeze Coolant 50 50 mix General Torque Specifications Component Torque _ft lb Spark Plug 11 Header Bolts 15 Alternator Bolts
45. rtant to watch all gauges while performing this break in If at any time the temperatures or pressures deviate from the normal operating parameters the engine must be stopped to determine the cause of the problem Refer to the Troubleshooting section of this manual if a problem occurs Mast Motorsports recommends a two hour break in period during which maximum RPM should never be sustained for more than two minutes During this break in period it is recommended to operate the engine at varied RPM levels between 2200 RPM and 5800 RPM Avoid operating the engine at a constant RPM including idling for extended periods of time during this period This procedure will help promote piston ring sealing Mast Motorsports Typhoon and Cyclone engines have forged pistons It is imperative that you always use the oil recommended by Mast Motorsports or oil with sufficient ZDDP for the entire life of the engine Mast Motorsports does not recommend the use of synthetic oil This will ensure proper ring seating Mast Motorsports does not warranty any application with the use of power adders such as turbochargers superchargers or nitrous If it is determined that premature ring wear ring sealing piston scuffing and or engine failure is the result of improper tuning incorrect oil improper installation and or the use of power adders all repairs parts materials shipping expenses and labor will be the sole responsibility of the purchaser NOTE It must be un
46. s period It is important to watch all gauges while performing this break in If at any time the temperatures or pressures deviate from the normal operating parameters the engine must be stopped to determine the cause of the problem Refer to the Troubleshooting section of this manual if a problem occurs Mast Motorsports recommends a two hour break in period during which maximum RPM should never be sustained for more than two minutes During this break in period it is recommended to operate the engine at varied RPM levels between 2200 RPM and 5800 RPM Avoid operating the engine at a constant RPM including idling for extended periods of time during this period This procedure will help promote piston ring sealing All engines should be equipped with gauges or lights to indicate engine RPM engine coolant temperature and engine oil pressure Mast Motorsports recommends using 91 93 Premium octane fuel only In the event that 91 93 octane fuel is not available a minimum of 87 octane fuel is permitted However the engine should not be operated and full throttle full load or high RPM while using 87 octane fuel IMPORTANT NOTICE EFFECT ON OTHER WARRANTIES Installation of MMS s Engine to a vessel may void reduce or otherwise adversely affect any warranties given by the manufacturer or seller of the vessel engine or other component parts MMS shall not be liable for any such adverse effect on such other manufacturers or warranties
47. steners relating to the mounting system Mast Motorsports recommends the use of fasteners that are SAE Grade 8 or equivalent CAUTION Failure to use proper mounts support brackets and hardware could result in premature failure of the mounts which could result in damage to the engine Figure 2 below shows motor mount attaching locations Figure 2 Engine Mounting Locations Oil Cooling System Mast Motorsports engines require an air to engine oil cooler A sample air to oil cooler is shown in Figure 3 This is mandatory for proper engine operation and reliability The air to engine oil cooler should be mounted to a solid structure and in an area that will allow proper air flow through the cooler It is recommended that the cooler installation be in front of the engine coolant radiator and positioned so that the length of oil lines will be as short as possible Proper sizing for the cooler should be based on the horse power of the engine Please refer to the oil cooler manufacturer s recommendations Figure 4 below shows the oil line connections Oikto Cooler Oil From Cooler e Figure 3 Oil Cooler Example Figure 4 Oil Line Connections Parsons MMS Airboat Engine Manual v1 0 7 Cooling System Mast Motorsports engines require the addition of a radiator Mast Motorsports airboat engines require the engine coolant system to be plumbed as a closed loop system This will enable proper engine performance and reliability Proper
48. t to the elements as well as securely fastened away from heat vibration sharp edges and moving parts Run fuel that is minimum 91 93 octane e Maintain a documented maintenance schedule including the facility performing the services corresponding receipts and dates I hereby agree to accept the responsibility of operating and maintaining my Mast Motorsports Engine to the specifications and procedures stated above Initials The customer will not be entitled to any special or consequential damages including but not limited to freight charges to and from our facility trip expense legal expense or loss of time as a result of the engine failure I hereby agree that any litigation which may be deemed necessary on behalf of either party involved must and will be filed in Nacogdoches Nacogdoches County Texas Initials THIS IS A LIMITED WARRANTY MAST MOTORSPORTS MAKES NO WARRANTIES EXPRESSED OR IMPLIED OTHER THAN WHAT IS STATED ABOVE STATEMENT MUST BE SIGNED DATED AND RETURNED TO MAST MOTORSPORTS TO VALIDATE THIS WARRANTY 1 printed name have read the above warranty statement I understand and accept the terms and conditions of this warranty statement Signature Date Start Date Date of engine purchase from Mast Motorsports End Date One year from date of engine purchase from Mast Motorsports NE MMS Airboat Engine Manual v1 0 45
49. ty By following the procedures and precautions stated below you greatly reduce the chances of an engine failure MMS warrants to the original consumer purchaser of each airboat engine the engine will be free from defects in materials and workmanship for a period of 12 months or 300 hours whichever comes first from the date the engine was purchased from Mast Motorsports Mast Motorsports Typhoon and Cyclone engines are calibrated to operate on 91 93 octane R M 2 fuel Maximum performance and reliability is obtained when using this fuel If a slight pinging is heard during acceleration and the proper octane fuel is being used it is considered normal constant heavy knock occurs the engine should be evaluated by Mast Motorsports The use of 87 octane fuel is permissible but only in an emergency The engine should never be operated at full throttle full load or high RPM while using 87 octane fuel I hereby agree to accept the responsibility of operating my Mast Motorsports Engine with the proper fuel octane requirement Initials This warranty is only for repair or replacement of failed components In the event that Mast Motorsports deems it necessary to replace or repair a component the component must be supplied by ONLY Mast Motorsports No other component supplier may be used under the terms of the warranty Any alteration repairs or services performed to a component that is not authorized by Mast Motorsports will void any and a
50. u receive a MMS Engine you did not order The replacement Engine will not be shipped until the incorrect Engine has been received by MMS Replacements can only be shipped in the same manner and to the same address as the original order was sent RETURNING A PRODUCT MMS does not accept any returns for any Engine All Product sales are final after receipt of payment GOVERNING LAW These MMS Consumer Terms and Conditions of Sale and all sales of Products by MMS to consumers shall be governed by the laws of the State of Texas The customer will not be entitled to any special or consequential damages including but not limited to freight charges to and from our facility trip expense legal expense or lost time as a result of the engine failure THIS IS A LIMITED WARRANTY MAST MOTORSPORTS MAKES NO WARRANTIES EXPRESSED OR IMPLED OTHER THAN WHAT IS STATED ABOVE STATEMENT MUST BE SIGNED DATED AND RETURNED TO MAST MOTORSPORTS TO VALIDATE THIS WARRANTY IU MMS Airboat Engine Manual v1 0 43 OS ee 330 NW Stallings Nacogdoches TX 75964 WARRANTY POLICY AND PROCEDURES Customer Name Date Engine Type Engine Serial Number ECM Serial Number Mast Motorsports strives to ensure that your Engine performs as intended for its entire life expectancy In order to achieve this it is important that certain procedures be followed These procedures are also required to validate the Mast Motorsports engine package warran
51. y Panel Figure 10 below shows the 90 90 is mounted on vibration damping mounts In order to ensure that these mounts achieve their intended purpose it is imperative that the M 90 be mounted rigidly to a solid structure This will help avoid problems and or damage to the ECM Figure 10 M 90 WBO2 ECM 0U Slope MMS Airboat Engine Manual v1 0 11 Harness harness Figure 12 allows for various means of calculating the fuel flow into the engine The method used on our engines is Speed Density The ECM uses engine speed intake air temperature and manifold air pressure to calculate the amount of fuel going into the engine The connection for this harness is at the rear of the engine in the main wiring harness The IAT sensor is mounted in the air filter Figure 11 The MAP sensor is located on top of the intake manifold Figure 11 Failure to have IAT and or MAP sensor connected will lead to poor engine performance 55 Figure 11 Sensor Location Figure 12 Harness Fuel Pump Harness The fuel pump harness Figure 13 utilizes 14 gauge yellow red and a black wire going to a six terminal connector The connection is made between the fuel pump harness and the main wiring harness on the driver side of the engine at the rear of the engine The yellow red and black wires are simply connected to the fuel pump and the circuit is controlled by t
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