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Section 5 - Maintenance

Page 84

90-8M0057081

eng

MARCH 2011

4. Move the fuel lines so they do not obstruct access to the engine coolant drain plug.

Port side of engine

a -

Throttle cable bracket

b -

14–pin electrical connector

c -

Water–separating fuel filter

d -

Fuel cooler with fuel lines moved to provide access

e -

General location of engine coolant drain plug

f -

Engine control module

5. Remove the engine coolant drain plug and drain the coolant into a suitable container.

NOTE: Allow the engine coolant system to drain completely.
NOTE: Dispose of old coolant properly.

Port side of block with

water–separating fuel

filter removed for access

a -

Engine coolant drain

plug

6. Ensure that the coolant has drained completely.
7. If required, clean the closed cooling system. See your local Cummins MerCruiser Diesel Authorized Repair Facility.
8. Install and tighten the engine coolant drain plug.
9. Reinstall the water–separating fuel filter. See

Water–Separating Fuel Filter, Replacing.

10. Fill the system with the specified coolant. See

Filling the Closed Cooling System

.

Filling the Closed Cooling System

1. Remove the pressure cap.

QSD 2.0L (engine cover removed)

a -

Pressure cap

b -

Coolant expansion tank

c -

Coolant fill neck

25571

a

b

c

d

e

f

a

25768

a

b

c

25356

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Summary of Contents for QSD 2.0

Page 1: ...ed above This engine must not be put into service until the recreational craft in which it is to be installed has been declared in conformity if so required with the relevant provision of the directive Electromagnetic Compatibility Directive 89 336 EC 92 31 EEC and 93 68 EEC Generic emission standard EN 50081 1 Generic immunity standard EN 50082 1 Vehicles boats and internal combustion engine driv...

Page 2: ... you will thoroughly enjoy using this product for many boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation Maintenance and Warranty Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purcha...

Page 3: ...he successful completion of the task NOTE Indicates information that helps in the understanding of a particular step or action WARNING The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the o...

Page 4: ......

Page 5: ...essel Integration Panel VIP Overload Protection 21 Power Trim and MerCathode Overload Protection 22 Section 3 On the Water Safe Boating Suggestions 24 Be Alert to Carbon Monoxide Poisoning 25 Good Ventilation 25 Poor Ventilation 25 Important Operation Information 25 Launching 25 Duty Cycle Rating Requirements 25 High Output Rating 26 Operation Chart 26 Starting Shifting and Stopping 27 Important I...

Page 6: ...ling 63 Changing 64 Power Assisted Steering Fluid 64 Checking 64 Filling 65 Changing 65 Engine Coolant 65 Checking 65 Filling 66 Changing 66 Air Filter 67 Removal 67 Inspection 67 Installation 67 Water Separating Fuel Filter 68 Draining 69 Replacing 69 Filling 71 Fuel System 72 Priming 72 Filling Bleeding 73 Fuel Tank Cleaning and Flushing 73 Seawater System 73 Draining the Seawater System 73 Ster...

Page 7: ...ow 120 Engine Will Not Start or Is Hard to Start 120 Engine Runs Rough Misses or Backfires 120 Poor Performance 121 Excessive Engine Temperature 121 Insufficient Engine Temperature 121 Low Engine Oil Pressure 121 Battery Will Not Charge 122 Remote Control Operates Hard Binds Has Excessive Free play or Makes Unusual Sounds 122 Steering Wheel Turns Hard or Jerky 122 Power Trim does not Operate Elect...

Page 8: ...Page iv 90 8M0057081 eng MARCH 2011 ...

Page 9: ...tents Warranty Information 2 Warranty Registration United States and Canada 2 Warranty Registration Outside the United States and Canada 2 Warranty Policy 3 High Output Recreational Use Worldwide Limited Warranty 3 Limited Warranty Against Corrosion Worldwide 5 Transfer of Warranty 6 1 ...

Page 10: ...ion Outside the United States and Canada 1 It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration and claim program for your area 2 The Warranty Registration Card identifies your name and address product model and serial numbers date of sale t...

Page 11: ...ariable load applications where full power is limited to one 1 hour out of every eight 8 hours of operation Reduced power operation must be at or below cruise speed Cruise speed RPM is dependant on the engine s maximum engine rated speed RPM Rated Speed RPM Cruise Speed RPM Reduction from Rated Speed RPM 2000 2800 RPM 200 RPM 2801 3500 RPM 300 RPM 3501 4500 RPM 400 RPM This rating is for pleasure ...

Page 12: ...s checking filters adjusting belts or controls lubrication and fluid level checks made in connection with normal service Oils lubricants or fluids unless loss or contamination of the same is caused by a product failure that would be eligible for warranty consideration Normal wear and tear Correction of an engine noise unless diagnosis indicates the condition responsible for the noise is a serious ...

Page 13: ...an those contained in this limited warranty and if made shall not be enforceable against Cummins MerCruiser Diesel DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENT...

Page 14: ...elated labor and material and any other expenses associated with that service Purchaser shall not unless requested by Cummins MerCruiser Diesel ship the product or parts of the product directly to Cummins MerCruiser Diesel Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage What Is Not Covered This limited warranty doe...

Page 15: ...tation QSD Sterndrive Models 12 Digital Gauges 12 Instruments Sterndrive models 12 VesselView if equipped 13 Switches 14 Start Stop Panel 14 Engine Monitoring Features 15 Audio Warning System 15 VesselView 15 System Tachometer or Speedometer 15 Features And Controls 16 Emergency Stop Switch If Equipped 16 Lanyard Stop Switch 17 Digital Throttle and Shift Applications 17 Remote Controls 18 Panel Mo...

Page 16: ...engine dataplate is located on the side of the integrated exhaust manifold and expansion tank assembly QSD 2 0 engine dataplate a Engine dataplate and emissions information location on the integrated exhaust manifold and expansion tank assembly Engine Data Plate A tamper resistant engine data plate is affixed to the engine at the time of manufacture by Cummins MerCruiser Diesel It contains importa...

Page 17: ... tank assembly at the time of manufacture by Cummins MerCruiser Diesel Please note that the exhaust gas emissions certification will not affect the fit function or performance of the engine Neither boatbuilders nor dealers may remove the exhaust gas emission label or the part it is affixed to before sale If modifications require the removal or cause damage to the exhaust gas emission label contact...

Page 18: ...he port side of the alpha sterndrive The Drive Ratio is located on the starboard side of the alpha sterndrive Alpha sterndrive a Drive gear ratio decal starboard b Serial number decal port Alpha Transom Serial Number The Transom Serial No is located on the top of the transom assembly Alpha transom assembly a Transom assembly serial number b a 25681 25619 ...

Page 19: ... on the port side of the sterndrive 33533 Bravo sterndrive information on ground plate The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover 33534 Bravo sterndrive serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the U bolt plate of the Bravo transom assembly Bravo transom assembly U bolt plate a T...

Page 20: ...achometer b Speedometer c LCD system view display The SmartCraft instrument package will also aid in identifying the fault codes associated with the sounding of the engine audio warning system The SmartCraft instrument package will display critical engine alarm data and relate other potential problem areas on its LCD display Refer to the manual with your gauge package for the warning functions mon...

Page 21: ...ckage may be connected to a SmartCraft VesselView display The interactive VesselView display continuously reports real time information about speed and performance engine fault codes fuel status water temperature and depth and other operating data When VesselView detects a problem with any connected system it displays an alarm message to the boat operator 24797 Typical VesselView display VesselVie...

Page 22: ...ts are operational 4 START In the START position the engine can be started NOTE The key can only be removed with the key switch in the OFF position b Bilge blower switch if equipped Operates the bilge blower if equipped Start Stop Panel The start stop panel allows the operator to start or stop an engine with the press of a single button In dual engine applications each engine is controlled indepen...

Page 23: ...ports the warning system and can display fault codes The following instruments have screens that display fault codes VesselView SmartCraft System Tachometer SmartCraft System Speedometer NOTICE The sound from an audio warning horn indicates that a critical fault malfunction has occurred Operating a power package with a critical fault can damage components If the audio warning horn emits a sound do...

Page 24: ...s immediately but the boat can continue to coast for some distance depending upon the velocity and degree of any turn at shutdown While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We recommend instructing other occupants on proper starting and operating procedures should they need to operate the engine in an emergency Accide...

Page 25: ...ely but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures shou...

Page 26: ...ould only be used to assist in starting the engine Lanyard Stop Switch Provides an emergency engine shut down if the boat operator when attached to the lanyard moves far enough away from the operator s position to pull the lanyard key that activates the engine stop switch Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle...

Page 27: ...operation See Power Trim for detailed trailer switch operation Power Trim Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions Also the trailering feature allows the operator to raise and lower the sterndrive for trailering beaching launching low speed below 1200 RPM engine speed and shallow water operati...

Page 28: ...d lower all drives together as a unit Dual engine applications may have a single integral button to operate both sterndrives simultaneously or may have separate buttons for each sterndrive Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only Engine Electrical System Overload Protection If an electrical overload occurs a fuse will burn...

Page 29: ...CM Middle left c 10 amp Keyed power to ECM Upper left d 5 amp Power diagnostic connector Upper right e 15 amp ECM switched power to SIM Middle right f 15 amp Switched power to ECM Lower right Vessel Integration Panel VIP Overload Protection The Vessel Integration Panel VIP contains two circuit breakers that help protect the engine harness vessel sensor harness and helm harness 23742 a b Vessel Int...

Page 30: ...lectrical overload has not been eliminated Further checks must be made on the electrical system Contact your Cummins MerCruiser Diesel Authorized Repair Facility 1 The power trim system is protected from overload by a 110 amp fuse and a 20 amp in line fuse on the power trim pump a 20 amp holder b 110 amp fuse 2 The Quicksilver Three Button Power Trim Control Panel if equipped is protected from ove...

Page 31: ... and Cold Weather Operation 29 Drain Plug and Bilge Pump 29 Protecting People In The Water 30 While You Are Cruising 30 While Boat Is Stationary 30 High Speed and High Performance 30 Passenger Safety In Pontoon Boats And Deck Boats 30 Boats Having An Open Front Deck 30 Boats With Front Mounted Raised Pedestal Fishing Seats 30 Wave and Wake Jumping 31 Impact with Underwater Hazards 31 Sterndrive Im...

Page 32: ...t Prepare other boat operators Instruct at least one person aboard in the basics of starting and operating the engine and handling the boat in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate Know your boat s operating and loading limitations Know if your boat will f...

Page 33: ...at rest or underway and avoid prolonged exposure to carbon monoxide Good Ventilation Ventilate the passenger area open the side curtains or forward hatches to remove fumes 1 Example of desired air flow through the boat mc79553 1 Poor Ventilation Under certain conditions permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one ...

Page 34: ...ing Procedure After Starting While Underway Stopping and Shut Down Open the engine hatch and completely ventilate the bilge Monitor instrumentation to confirm normal engine operation If not normal stop the engine Monitor instrumentation to confirm normal engine operation Shift the remote control lever to the neutral position Turn the battery switch on if equipped Check for fuel oil water fluid and...

Page 35: ... section 5 of this manual for seawater pickup information Ensure that the drive is trimmed in to its Full Down trim position Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor If the engine does not start wait one minute to allow the starter motor to cool then repeat the starting procedure Ensure that the engine crankcase is filled to the correc...

Page 36: ...e blower if equipped for 5 minutes Or open the engine hatch and ventilate the bilge before starting the engine 2 Place the remote control handle in neutral 3 Turn the ignition key switch to RUN position 4 Turn the ignition key switch to START position and release or press and release the start stop switch if equipped 5 Ensure that all instrumentation is functioning properly and indicating normal e...

Page 37: ...water section of the cooling system immediately after operation or before any length of storage in freezing temperatures If the boat is in the water keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system If the boat is not fitted with a seacock leave the water inlet hose disconnected and plugged NOTE As a precautionary measure attach a tag to...

Page 38: ... information refer to the Hi Performance Boat Operation booklet 90 849250 R03 from your Cummins MerCruiser Diesel Authorized Repair Facility Passenger Safety In Pontoon Boats And Deck Boats Whenever the boat is in motion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boa...

Page 39: ...e bow of your boat pitches down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also veer sharply to one side Impact with Underwater Hazards Reduce speed and proceed with caution whenever you re driving a boat in shallow w...

Page 40: ...draulic system allows the sterndrive to return to its original operating position preventing loss of steering control and engine overspeed Use extreme caution when operating in shallow water or where underwater objects are known to be present No impact protection is provided in reverse use extreme care to prevent striking submerged objects while operating in reverse IMPORTANT Impact protection sys...

Page 41: ...ipping the power package with the correct propellers IMPORTANT The engines covered in this manual are equipped with an ECM that limits engine RPM Be sure that the propeller being used does not allow the engine to run against the limiter as a significant loss in performance will result NOTE Use an accurate service tachometer to verify RPM Select a propeller that will allow the engine power package ...

Page 42: ...first 10 hours Shift into gear as soon as possible after starting and advance the throttle above 1500 RPM if conditions permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during the first 10 hours During the next 10 hours occasional operation at full throttle is permissible 5 minutes at a time maximum Avoid full throttle acceleration from...

Page 43: ...nded Fuels 36 Diesel Fuel in Cold Weather 36 Coolant Antifreeze 37 Engine Oil 37 Engine Specifications 38 Fluid Specifications 38 Engine 38 QSD 2 0 39 Alpha Sterndrive Fluid Specifications 39 Bravo Sterndrive Fluid Specifications Diesel 39 Approved Power assisted Steering Fluids 39 Approved Power Trim Fluids 40 Approved Paints 40 4 ...

Page 44: ...aise the cetane rating for low temperature or high altitude use A lower cetane number could cause hard starting and slower warm up and could increase engine noise and exhaust emissions NOTE If your engine suddenly becomes noisy after a fill up you possibly received substandard fuel with a low cetane rating Sulphur content of the above fuel is rated at 0 50 by weight maximum ASTM Limits may vary in...

Page 45: ...ct the engine and closed cooling system to the lowest temperature to which they will be exposed NOTE Generally we recommend using a 50 50 solution of coolant antifreeze and deionized purified water When operating where seawater temperatures are greater than 32 C 90 F you can use a 25 75 solution of coolant antifreeze and deionized purified water for improved cooling performance IMPORTANT The coola...

Page 46: ...or additional information Refer to CMD s Marine Performance Curves And Data Sheet www Cummins com Idle RPM in neutral engine at normal operating temperature 700 RPM Oil pressure at idle 2 4 bar 240 kPa 35 PSI Oil pressure at 4000 RPM 6 6 bar 660 kPa 95 PSI Thermostats water 83 C 181 F Thermostats oil 95 C 203 F Coolant temperature 80 85 C 176 185 F Electrical system 12 volt negative ground Alterna...

Page 47: ...n Europe 92 813054A2 Fleetguard Compleat with DCA4 Fleetguard Part Number CC2825 Container size 3 75 liter 1 00 US gal Obtain locally Alpha Sterndrive Fluid Specifications NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Fluid Part Number Alpha One 1892 ml 64 oz High Performance Gear Lubricant 92 858064K01 Bravo Sterndrive Fluid Specifications Diesel Sterndrive Model Fluid Ca...

Page 48: ...ions Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain locally SAE Engine Oil 10W 40 Approved Paints Description Part Number Marine Cloud White CMD part number 40918660 Obtain locally Mercury Light Gray Primer 92 80287852 Mercury Phantom Black 92 802878Q1 ...

Page 49: ... the Seawater System 73 Sterndrive Water Inlets Check 75 Checking the Seawater Pickups 76 Cleaning the Seawater Strainer 76 Flushing the Seawater System Alpha Sterndrives 78 Flushing the Seawater System Bravo Sterndrives 80 Engine Seawater Pump Inspection 83 Alpha Sterndrive Seawater Pump Inspection 83 Replacing the Engine Coolant 83 Draining the Closed Cooling System 83 Filling the Closed Cooling...

Page 50: ...athing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before servicing the power package IMPORTANT See Maintenance Schedule for a complete listing of all scheduled maintenance to be performed Some listings can be done by the owner or operator while others should be performed by a Cummins MerCruiser Diesel Authorized Repair Facility Before attempting maintena...

Page 51: ... engine parts 1 Check for loose damaged or missing parts hoses and clamps tighten or replace as necessary 2 Check electrical connections and leads for damage or corrosion 3 Remove and inspect the propeller If badly nicked bent or cracked contact your Cummins MerCruiser Diesel Authorized Repair Facility 4 Repair nicks and corrosion damage on power package exterior finish Contact your Cummins MerCru...

Page 52: ...of the cooling system after each use Drain any water from the primary fuel filter after each use Drain any water from both fuel filters if operating in freezing temperatures Weekly Drain any water from the fuel filters Check the trim pump fluid level Check the seawater inlets for debris or marine growth Check and clean the seawater strainer Inspect the sterndrive anodes and replace if 50 eroded Ev...

Page 53: ... terminals On driveshaft extension models lubricate the drive shaft U joints transom end tailstock bearings and engine end output bearings Inspect the condition and tension of the engine accessory drive belts Inspect the cooling system and the exhaust system for damage or leaks Check both systems hose clamps for tightness Disassemble and inspect the engine seawater pump and replace worn components...

Page 54: ...Section 5 Maintenance Page 46 90 8M0057081 eng MARCH 2011 Date Maintenance Performed Engine Hours ...

Page 55: ...l to 25 hours or 30 days whichever occurs first Scheduled Maintenance Axius Models NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the first 20 hours and not to exceed 25 hours Change the engine oil and filter Check and adjust the serpentine belt tension Every 100 hours or annually whichever occurs first Touch up the paint...

Page 56: ...necessary If the condition of these components is satisfactory at inspection repeat inspection every 100 hours or once a year whichever occurs first Check the electrical system for loose damaged or corroded fasteners Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn component...

Page 57: ...Section 5 Maintenance 90 8M0057081 eng MARCH 2011 Page 49 Date Maintenance Performed Engine Hours ...

Page 58: ...shaft splashing and agitating the oil causing it to become aerated The aerated oil causes a loss of engine performance and an increase in crankcase back pressure An extreme overfill condition could result in large amounts of oil being drawn into the intake Checking engine oil level must be done carefully The oil level must be maintained between the minimum and the maximum oil level mark on the dip...

Page 59: ...serve the oil level The oil level must be between the marks on the dipstick If necessary add oil See Filling Engine oil level markings a Dipstick b Minimum operating level c Full mark and maximum operating level 4 Install engine oil dipstick Filling IMPORTANT Do not overfill the engine with oil 1 Remove the oil fill cap QSD 2 0L engine oil service a Engine cover with access panel removed b Engine ...

Page 60: ...e oil fill cap Changing Oil and Filter See the Maintenance Schedule for the change interval You should change the engine oil before placing the boat in storage IMPORTANT Change the engine oil when the engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended engine oil See Specifications 1 Start the engine and allow it to warm up to normal operatin...

Page 61: ...oil and used filter element as directed by all applicable ordinances 8 Remove the crankcase oil pump and install the crankcase oil drain hose fitting when the crankcase is empty Tighten securely 9 Install the oil dipstick 10 Place a suitable container under the oil filter housing to contain any spilled oil Use an appropriate socket to loosen the oil filter cover 11 Remove the oil filter cover and ...

Page 62: ...ion Where Used Part No 9 Loctite 567 PST Pipe Sealant Drain plug 92 809822 14 Tighten the oil filter housing drain plug to specification Engine Coolant Oil Cooler Description Nm lb in lb ft Drain plug 19 168 Seawater Oil Cooler Description Nm lb in lb ft Drain plug 19 168 15 Lubricate and install a new cover O ring Tube Ref No Description Where Used Part No 121 15W40 4 cycle Diesel Engine Oil Oil ...

Page 63: ...lter housing cover 22 5 16 0 19 Remove the oil fill cap and refill the engine with new oil See Filling IMPORTANT When refilling the engine with oil always use the dipstick to determine how much oil is required 20 Replace and secure the oil fill cap 21 Start the engine and check for leaks Alpha Sterndrive Gear Lube Sterndrive Gear Lube NOTICE Discharge of oil coolant or other engine drive fluids in...

Page 64: ...drive Filling IMPORTANT If more than 59 ml 2 fl oz of High Performance Gear Lube is required to fill the gear lube monitor a seal may be leaking Damage to the sterndrive may occur due to lack of lubrication Contact your Cummins MerCruiser Diesel Authorized Repair Facility 1 If the gear lube level is below or near the ADD mark the specified gear lube must be added 2 Remove the gear lube monitor cap...

Page 65: ...ket a Retaining bracket b Gear lube monitor 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Place the sterndrive in full trim limit out position remove the gear lube fill and drain screw and sealing washer and drain the gear lube a Gear lube fill and drain screw b Sealing washer 5 Remove the gear lube vent screw and sealing washer Allow the gear lube...

Page 66: ...bricant into the drive through the gear lube fill and drain hose until the gear lubricant appears in the gear lube monitor 9 Fill the monitor so that the gear lube level is in the operating range Do not overfill Ensure that the rubber gasket is inside the cap and install Do not overtighten a Gear lube monitor b OPERATING RANGE line NOTE Gear lube capacity includes gear lube monitor Model Capacity ...

Page 67: ... OPERATING RANGE mark IMPORTANT If any water is visible at the bottom of the gear lube monitor or appears at the fill and drain plug hole or if the gear lube appears discolored contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately Both conditions may indicate a water leak in the sterndrive Filling IMPORTANT If more than 59 ml 2 fl oz of High Performance Gear Lube is require...

Page 68: ...taining strap 2 Empty the contents of the gear lube monitor into a suitable container 3 Install the gear lube monitor in the bracket 4 Remove the propeller See Propellers 5 Bravo One Models a Lower the sterndrive to the full down position b Remove the gear lube fill and drain plug and sealing washer c Drain the gear lube into a suitable container a Fill and drain plug b Sealing washer 6 Bravo Two ...

Page 69: ...s MerCruiser Diesel Authorized Repair Facility 8 Lower the sterndrive so that the propeller shaft is level 9 Fill the sterndrive through the fill and drain plug hole with the specified gear lube until an air free stream of lube flows from the vent plug hole Tube Ref No Description Where Used Part No 87 High Performance Gear Lube Sterndrive unit 92 858064K01 IMPORTANT Use only Mercury Quicksilver H...

Page 70: ... X Diesel Bravo One XR 2736 mL 92 1 2 oz High Performance Gear Lube 92 858064K01 Bravo Two X Diesel 3209 mL 108 1 2 oz Bravo Three X Diesel Bravo Three XR 2972 mL 100 1 2 oz Bravo Three Dual seawater pickup 2736 mL 92 1 2 oz 13 Ensure that the rubber gasket is inside the gear lube monitor cap and install Do not overtighten 14 Remove the pump from the sterndrive fill and drain plug hole 15 Quickly ...

Page 71: ...he fluid level with the sterndrive in the full down in position only 1 Place the sterndrive in full down in position 2 Observe the fluid level The fluid level must be between the MIN and MAX lines on the reservoir a Reservoir b MIN and MAX lines 3 Fill as necessary with the specified fluid See Filling Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 8...

Page 72: ...luid IMPORTANT Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF in the power assisted steering system IMPORTANT Running the pump dry will damage the pump Always check steering fluid levels before operating the boat Checking 1 Center the sterndrive and stop the engine 2 Remove the fill cap and dipstick from the fluid reservoir and observe the level a...

Page 73: ...luid does not require changing unless it becomes contaminated See your Cummins MerCruiser Diesel Authorized Repair Facility Engine Coolant CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns Allow the engine to cool down before removing the coolant pressure cap Checking IMPORTANT Check the engine coolant before starting the...

Page 74: ...essary Filling 1 Allow the engine to cool 2 Remove the pressure cap from the coolant expansion tank 3 If the coolant is low in the coolant expansion tank add the specified coolant as necessary to bring the level to within 25 mm 1 in of the bottom of the fill neck Engine coolant fill location engine cover removed a Coolant cap b Coolant expansion tank c Bottom of fill neck Description Where Used Pa...

Page 75: ...ter housing a Air filter housing b Air filter element Inspection 1 The air filter cannot be cleaned Replace the air filter if it is dirty or contaminated 2 Replace the air filter if the foam element is deteriorated or torn 3 Replace the air filter at the recommended interval See Maintenance Schedules for the replacement interval under normal conditions Installation IMPORTANT The foam cover is an i...

Page 76: ...ning clamp 5 Tighten the oil separator vent hose clamp to specification Description Nm lb in lb ft Oil separator vent hose clamp 5 6 50 Water Separating Fuel Filter WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area...

Page 77: ...TE To ensure complete draining in warm weather drain the filter before starting daily operations In cold weather where there is a possibility that the condensed water will freeze drain the filter shortly after the end of daily operations NOTE Place a suitable container under the fuel filter to catch contaminated fuel or water Dispose of properly 1 Place a container under the drain cap on the filte...

Page 78: ... drain cap and use it on the new filter Be sure to replace the O ring on the drain cap 4 Remove the drain cap and O ring seal from the bottom of the existing fuel filter Note the position of the O ring seal Typical a Drain cap b O ring seal 5 Discard the used filter and O ring seal as defined by local authorities 6 Install the O ring and drain cap on the new water separating fuel filter Typical a ...

Page 79: ...ct the battery cables 14 Start and operate the engine Check the filter connection for fuel leaks If leaks exist recheck filter installation If leaks continue stop the engine immediately and contact your Cummins MerCruiser Diesel Authorized Repair Facility Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to Refill the fuel filter when draining or chan...

Page 80: ...er plunger up and down repeatedly The filter is full when an air free stream of fuel flows from the air vent screw Typical a Air vent screw b Primer plunger 3 Securely tighten the air vent screw Typical a Air vent screw Fuel System Priming Prime the engine if it has not been run for an extended period or if the engine will not start 23469 a b 23468 a 23469 a ...

Page 81: ...ver occurs first Seawater System Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or close the seacock disconnect and plug the seawater inlet hose and ensure the bilge pump is operational before draining Do not operate the engine with the drain system open IMPORTANT The engine...

Page 82: ...r system 4 Attach a temporary drain hose to the barbed fitting of the seawater drain valve Coolant oil cooler Seawater oil cooler a Seawater drain valve b Oil filter housing 5 Open the seawater drain valve 6 A small diameter wire bore brush or stiff piece of ware can be used to clear the seawater drain valve of any debris 7 Disconnect the seawater inlet hose from the connector on the seawater pump...

Page 83: ...y drain hose and close the heat exchanger seawater drain valve 10 Reconnect all seawater hoses 11 Tighten all hose clamps to specification Description Nm lb in lb ft Hose clamp 5 6 50 Sterndrive Water Inlets Check 1 Obtain a piece of wire that will fit into the water inlets holes 2 Insert the wire in and out of the sterndrive water inlets to ensure that they are open and to remove debris or marine...

Page 84: ...ny seawater system disassembly 1 NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat causing damage or sinking the boat Always close the water supply from the seawater pump water inlet or seacock when performing service or maintenance on the cooling system NOTICE Disconnecting the seawater inlet hose will cause water to enter ...

Page 85: ...ag the boats keys record the service in the maintenance log or otherwise make note that a proper operational inspection of the seawater system must be performed before returning the boat to use on the water 9 Boat out of the water Perform an operational inspection of the seawater cooling system after cleaning the seawater strainer a Cooling water must be supplied to both the engine and the sterndr...

Page 86: ...ith fresh water periodically when operating in saltwater brackish water polluted water or water with a high mineral content We recommend flushing the seawater system after each outing when operating under these conditions Always flush the seawater system after operating in saltwater and prior to placing the boat in storage See Routine and Schedule Maintenance section of this manual WARNING Rotatin...

Page 87: ...position 3 If flushing the seawater system with the boat out of the water a Lower sterndrive to full down position b Remove the propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 4 Connect a hose from a water tap to the flushing attachment Typical a Flushing attachment b Hose IMPORTANT Engines with the sterndrive water inlet blocked off at the gi...

Page 88: ...or the water temperature gauge to ensure that the engine is operating normally 10 Slowly return the throttle to the idle speed position 11 Stop the engine 12 Shut off the water supplies 13 Remove the sterndrive flushing attachment 14 Remove any adaptors used and reconnect the seawater hoses Flushing the Seawater System Bravo Sterndrives You must flush the seawater system with fresh water periodica...

Page 89: ... appropriate flushing attachment over the water inlet holes in the gear housing Flushing attachments for dual water pickup Flushing attachments for side water pickup a Flushing device b Hose attachment c Dual water pickup flush gearcase seal kit Flushing Device 91 44357Q 2 9192 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine ...

Page 90: ...off at the gimbal housing and using a through hull or through transom water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation 5 Connect a second flushing hose from a water tap to the seawater inlet hose connector or to the seawater pump inlet using an appropriate adapter a Seawater pump inlet b Seawater pump c Seawater pump outlet d Fuel coole...

Page 91: ...ngine Coolant Draining the Closed Cooling System IMPORTANT Due to the complex nature of this service Cummins MerCruiser Diesel strongly recommends that this service be performed by a Cummins MerCruiser Diesel Authorized Repair Facility NOTICE Discharge of oil coolant or other engine drive fluids into the environment is restricted by law Use caution not to spill oil coolant or other fluids into the...

Page 92: ...tely NOTE Dispose of old coolant properly Port side of block with water separating fuel filter removed for access a Engine coolant drain plug 6 Ensure that the coolant has drained completely 7 If required clean the closed cooling system See your local Cummins MerCruiser Diesel Authorized Repair Facility 8 Install and tighten the engine coolant drain plug 9 Reinstall the water separating fuel filte...

Page 93: ...eaking stop the engine immediately and inspect for the cause 7 After the first operation allow the engine to cool 8 Remove the pressure cap and add the specified coolant to the level indicated in the table Coolant level in expansion tank 2 0 Within 25 mm 1 in of the top of the filler neck 9 Install and securely tighten the pressure cap Corrosion Protection General Information Whenever two or more ...

Page 94: ...ystem anode assembly location Cleaning and Inspection NOTE Using sandpaper fiber brush or cleaning pad remove the deposits from the surface of the anode before trying to determine the amount of erosion Do not use a mild steel brush which might leave deposits that could accelerate corrosion 1 Remove the deposits 2 Inspect and measure the anode Compare the measurements to the specifications for a ne...

Page 95: ...ecurely 25583 Seawater system anode assembly location 3 Unplug and connect the seawater inlet hose or open the seacock if equipped NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 4 Ensure that both the sterndrive and engine seawater pickup pumps are suppl...

Page 96: ...1 Typical single sterndrive a MerCathode System if equipped b Ventilation plate anode c Trim cylinder anodes d Bearing carrier anodes e Gearcase anodic plate f Anode kit on lower hull Dual sterndrive a MerCathode System if equipped b Ventilation plate anode c Trim cylinder anodes d Bearing carrier anodes e Gearcase anodic plate f Anode kit on lower hull NOTICE Washing the MerCathode assembly can d...

Page 97: ...ce sacrificial anodes if eroded 50 or more The following sacrificial anodes are installed at different locations on your power package These anodes help protect against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package MerCathode System The electrode assembly if equipped replaces Anodic block The system should be tested to ensure a...

Page 98: ...athode System The MerCathode electrode if equipped is mounted to the underside of the gimbal housing The MerCathode controller is mounted on the engine or on the boat transom The controller harness connects to the electrode harness 20340 Anode kit if equipped Mounted to the boat transom 20341 In addition to the corrosion protection devices take the following steps to inhibit corrosion 1 Paint the ...

Page 99: ...the flywheel housing grounding stud ground wire and the inner transom plate grounding screw for loose connections broken connectors or frayed wiring Continuity Circuit Bravo Sterndrive The transom assembly and sterndrive unit are equipped with ground circuit wires to ensure good electrical continuity between the engine transom assembly and sterndrive components Good continuity to a ground is essen...

Page 100: ...ng stud ground wire and the inner transom plate grounding screw for loose connections broken connectors or frayed wiring Typical a Flywheel housing screw or grounding stud b Continuity circuit ground wire c Inner transom plate grounding screw 6 Inspect the gimbal ring ground wire and the sterndrive ground plate for loose connections broken connectors or frayed wiring a Gimbal ring to bell housing ...

Page 101: ...de and Test Meter Reference Electrode 91 76675T 1 9188 Senses and electrical current in the water when testing the MerCathode system Use to check hull potential Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures Painting Your Power Package IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the...

Page 102: ...Do not paint drain holes anodes MerCathode system or items specified by the boat manufacturer Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the steering cable before applying lubricant NOTE If the steering cable does not have a grease fitting the inner wire of the c...

Page 103: ...ering pin a Steering pin Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin 92 883725K01 4 On dual engine boats Lubricate the tie bar pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting the engine turn the steering wheel several times to s...

Page 104: ...d Part No 80 SAE Engine Oil 30W Throttle cable pivot points and guide contact surfaces Obtain Locally Shift Cable 1 Lubricate the pivot points and guide contact surfaces Typical sterndrive model shift cable a Pivot points b Guide contact surface Tube Ref No Description Where Used Part No 80 SAE Engine Oil 30W Shift cable pivot points and guide contact surfaces Obtain Locally a a b 23643 a a a b 20...

Page 105: ...ng the sterndrive 1 Lubricate the engine coupler splines through the grease fitting on the coupler by applying approximately 8 10 pumps of Engine Coupler Spline Grease from a typical hand operated grease gun NOTE If the boat is operated at idle for prolonged periods of time the coupler should be lubricated on Bravo models every 50 hours a Grease fitting b Coupler splines Tube Ref No Description Wh...

Page 106: ...rease Transom end grease fitting engine end grease fitting driveshaft grease fittings 92 802870A1 Sterndrive Bellows and Engine Alignment NOTE Have your Cummins MerCruiser Diesel Authorized Repair Facility perform the maintenance procedures listed or refer to the appropriate Mercury MerCruiser Alpha Sterndrive Service Manual 1 Lubricate the sterndrive U joint O rings and driveshaft splines Alpha S...

Page 107: ... or other signs of deterioration Ensure that the bellows clamps are tight 4 Rotate the bell housing in the upward and side to side directions to inspect the exhaust bellows shift cable bellows and clamps Alpha Sterndrive a U joint bellow b Exhaust bellow c Bell housing d Gimbal ring e Gimbal housing f Shift cable bellows Bravo Sterndrive a U joint bellow b Exhaust tube c Bell housing d Gimbal ring...

Page 108: ...aring d Engine coupler Maintaining Torques Alpha Gimbal Ring Clamp Bolt NOTE The gimbal ring is a component of the transom assembly Torque the gimbal ring clamp bolts a Transom assembly b Gimbal ring clamp bolts Description Nm lb in lb ft Gimbal ring clamp bolts 74 55 Bravo Gimbal Ring U bolt Nuts NOTE The gimbal ring is a component of the transom assembly b a 7936 c d a 19624 a b ...

Page 109: ...lt Description Nm lb in lb ft Rear engine mounts 47 35 Propellers Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the pr...

Page 110: ...802859A 1 2 Slide thrust hub onto propeller shaft with stepped side toward propeller hub 3 Install Flo Torq II Drive Hub into propeller NOTE The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued 4 Align splines and place propeller on propeller shaft 5 Install drive sleeve and locking tab washer 6 Install and torque the propeller nut Descri...

Page 111: ...e propeller blade and the sterndrive s anti ventilation plate a Wood block b Propeller c Propeller nut under socket 3 Turn the propeller shaft nut counterclockwise and remove the nut 4 Slide the propeller and the attaching hardware from the propeller shaft Bravo One models a Propeller shaft splines b Forward thrust hub c Flo Torque II drive hub d Propeller e Drive sleeve adapter f Tab washer g Pro...

Page 112: ...d block b Propeller c Propeller nut under socket 3 Turn the propeller shaft nut counterclockwise to remove the nut 4 Slide the propeller and attaching hardware from the propeller shaft Bravo Two a Propeller shaft splines b Forward thrust hub c Propeller d Spline washer e Tab washer f Propeller nut Bravo Three Models 1 Place a block of wood between the propeller blade and the sterndrive s anti vent...

Page 113: ...aft 6 Using the Propeller Nut Tool turn the front propeller shaft nut counterclockwise and remove the nut Propeller Nut Tool 91 805457T 1 10677 Aids in the removal and installation of the front propeller nut 7 Slide the propeller and the thrust hub off the propeller shaft Bravo Three a Aft propeller nut b Aft propeller c Aft propeller thrust hub d Front propeller nut e Front propeller f Front prop...

Page 114: ... following Quicksilver lubricants Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft splines 92 802865Q02 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A 1 94 Anti Corrosion Grease Propeller shaft splines 92 802867Q 1 NOTE Anti corrosion grease is for saltwater applications only 2 Install the propeller with the attaching hardware as shown 3...

Page 115: ...2 802865Q02 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A 1 94 Anti Corrosion Grease Propeller shaft splines 92 802867Q 1 NOTE Anti corrosion grease is for saltwater applications only 2 Install the propeller with the attaching hardware as shown 3 Torque the propeller nut Bravo Two a Propeller shaft splines b Forward thrust hub c Propeller d Spline washer e Tab washer f P...

Page 116: ... for saltwater applications only 2 Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub 3 Align splines and place front propeller on propeller shaft 4 Install the front propeller locknut and torque using the Propeller Nut Tool Propeller Nut Tool 91 805457T 1 10677 Aids in the removal and installation of the front propeller nut Description Nm lb in lb...

Page 117: ...the engine and remove the ignition key before adjusting tension or inspecting belts QSD 2 0L front cover removed a Serpentine belt b Power assisted steering belt Power Assisted Steering Pump Belt Inspection The 2 0 diesel engine uses a stretch belt to drive the power assisted steering pump The stretch belt is engineered to have a certain amount of elasticity and designed to have self tensioning an...

Page 118: ... is used to drive the power assisted steering pump This belt must be removed to service the serpentine belt Stretch belt service and maintenance procedures differ significantly from those that apply to standard accessory drive belts Should the serpentine belt need replacement consult your Cummins MerCruiser Authorized Repair Facility 1 Inspect the belt for proper tension and for the following Exce...

Page 119: ...erating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause severe burns Ventilate the area around the battery and wear protective equipment when handling or servicing batteries Battery Precautions for Multiple Engines Alternators Alternators are designed to charge a single battery that supplies electrical power to the individual engine on which ...

Page 120: ...ition In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary battery used for powering accessories in the boat They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose Generators The generator s battery should b...

Page 121: ...and Extended Storage 114 Cold Weather Freezing Temperature Seasonal Storage and Extended Storage 114 Cold Weather Freezing Temperature Storage 114 Preparing Your Power Package for Seasonal or Extended Storage 114 Seasonal Storage Instructions 115 Extended Storage Instructions 116 Battery 116 Recommissioning 116 6 ...

Page 122: ...zing temperatures exists In such cases the seawater section of the cooling system must be completely drained immediately after operation Seasonal storage refers to when the boat is not being operated for one month or more The length of time varies depending on the geographic location of the boat in storage Seasonal storage precautions and procedures include all of the steps for cold weather freezi...

Page 123: ...the cooling system for cold weather freezing temperature seasonal storage or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 3 Fill a container with approximately 5 6 liters 6 U S quarts of propylene glycol antifreeze and tap water mixed to...

Page 124: ...attery manufacturer s instructions for storage Recommissioning NOTE Discharge of propylene glycol into the environment may be restricted by law Contain and dispose of propylene glycol in accordance with federal state and local laws and guidelines 1 On engines that were prepared for extended storage refer to a Cummins MerCruiser Diesel Authorized Repair Facility and have the seawater pump impeller ...

Page 125: ...cient supply of water to the water inlets during operation 10 Supply cooling water to the engine and sterndrive water inlet openings 11 Start the engine and closely observe instrumentation Ensure that all systems are functioning correctly 12 Carefully inspect the engine for fuel oil fluid water and exhaust leaks 13 Check the steering system shift and throttle control for proper operation ...

Page 126: ...Section 6 Storage Notes Page 118 90 8M0057081 eng MARCH 2011 ...

Page 127: ...ard to Start 120 Engine Runs Rough Misses or Backfires 120 Poor Performance 121 Excessive Engine Temperature 121 Insufficient Engine Temperature 121 Low Engine Oil Pressure 121 Battery Will Not Charge 122 Remote Control Operates Hard Binds Has Excessive Free play or Makes Unusual Sounds 122 Steering Wheel Turns Hard or Jerky 122 Power Trim does not Operate Electric Motor Operates but Sterndrive do...

Page 128: ... tank or fuel shut off valve closed Fill tank or open valve Throttle not operating properly Check the throttle for freedom of movement Faulty electrical stop circuit Have a Cummins MerCruiser Diesel Authorized Repair Facility service the electrical stop circuit Clogged fuel filters Replace fuel filters Stale or contaminated fuel Drain tank Fill with fresh fuel Fuel line or tank vent line kinked or...

Page 129: ...ores plugged with foreign material Clean heat exchanger See a Cummins MerCruiser Diesel Authorized Repair Facility Loss of pressure in closed cooling section Check for leaks Clean inspect and test pressure cap See a Cummins MerCruiser Diesel Authorized Repair Facility Faulty seawater pickup pump Repair See a Cummins MerCruiser Diesel Authorized Repair Facility Seawater discharge restricted or plug...

Page 130: ...nd repair Improper shift cable adjustment Have adjustment checked by a Cummins MerCruiser Diesel Authorized Repair Facility Steering Wheel Turns Hard or Jerky Possible Cause Remedy Low power steering pump fluid level Check for leak Refill the system with fluid Drive belt loose or in poor condition Replace or adjust Insufficient lubrication on the steering components Lubricate Loose or missing stee...

Page 131: ...er Submersion 124 Replacement Service Parts 124 Parts and Accessories Inquiries 124 Resolving a Problem 124 Customer Service Literature 125 English Language 125 Other Languages 125 Andre sprog 125 Andere talen 125 Muut kielet 125 Autres langues 125 Andere Sprachen 125 Altre lingue 125 Andre språk 126 Outros Idiomas 126 Otros idiomas 126 Andra språk 126 Allej glþssej 126 Ordering Literature 126 Uni...

Page 132: ...n servicing the electrical and fuel systems properly install and tighten all components Marine engines are expected to operate at or near full throttle for most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts as specifications are quite different from those of t...

Page 133: ... anskaffe en Betjenings og vedligeholdelsesmanual på et andet sprog En liste med reservedelsnumre for andre sprog leveres sammen med din power pakke Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover Een lijst met...

Page 134: ...åk medföljer ditt kraftpaket Allej glþssej Gia na apoktÞsete Ýna Egxeirßdio Leitourgßaj kai SuntÞrhshj se Üllh glþssa epikoinwnÞste me to plhsiÝstero DieqnÝj KÝntro SÝrbij thj Mercury Marine Þ thj Marine Power gia plhroforßej To pakÝto isxýoj saj sunodeýetai apü Ýnan katÜlogo ariqmþn paraggelßaj gia Üllej glþssej Ordering Literature Before ordering literature please have the following information ...

Page 135: ...Section 8 Customer Assistance Information 90 8M0057081 eng MARCH 2011 Page 127 Country Quantity Item Stock Number Price Total Total Due ...

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