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MAINTENANCE

SECTION 5

Page 75

CMD-4081877 / 90-865861040 MARCH 2004

0078

Lubrication

Shift Cable

1. Lubricate the pivot points and the guide contact surfaces.

71374

Typical

a -

Pivot points

b -

Guide contact surfaces

Description

Where Used

Part Number

Engine Oil

Pivot points, guide contact

surfaces

Obtain Locally

00000 was 0079 with diesel graphics added

Throttle Cable

1. Lubricate the pivot points and the guide contact surfaces.

79934

Typical

a -

Pivot points

b -

Guide contact surfaces

Description

Where Used

Part Number

SAE 30W Engine Oil

Pivot points, guide contact

surfaces

Obtain Locally

Summary of Contents for 2.8 EI 200

Page 1: ...2004 Mercury Marine 2 8 EI 200 Diesel Inboard Models CMD 4081877 90 865861040 304...

Page 2: ...Number Europe Only The description and specifications contained herein were in effect at the time this guide was approved for printing Cummins MerCruiser Diesel whose policy is one of continuous impr...

Page 3: ...this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Cummins MerCruiser Diesel products We sincerely hope your boating will be plea...

Page 4: ...ecessary for proper operation and or maintenance 0197 modified or CE461 WARNING The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of...

Page 5: ...Mercruiser Diesel Will Do 4 How To Obtain Warranty Coverage 5 What Is Not Covered 5 Disclaimers And Limitations 5 Warranty Coverage and Exclusion 6 Warranty Does Not Apply To The Following 6 Transfer...

Page 6: ...ilge Pump 32 Protecting People In The Water 33 While You Are Cruising 33 While Boat Is Stationary 33 High Speed And High Performance Boat Operation 33 Passenger Safety Message Pontoon And Deck Boats 3...

Page 7: ...ing 68 Replacement 68 Water Separating Fuel Filter 69 Draining 70 Replacing 71 Filling 73 Fuel System 74 Priming 74 Filling Bleeding 74 Fuel Tank Cleaning And Flushing 74 Lubrication 75 Shift Cable 75...

Page 8: ...ine Temperature 101 Insufficient Engine Temperature 101 Low Engine Oil Pressure 102 Battery Will Not Charge 102 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 102 S...

Page 9: ...ted States And Canada 3 Warranty Policies 4 Recreational Use Diesel Limited Warranty 4 What Is Covered 4 Duration Of Coverage 4 Conditions That Must Be Met In Order To Obtain Warranty Coverage 4 What...

Page 10: ...date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will a...

Page 11: ...ty service on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some cou...

Page 12: ...T BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins MerCruiser Diesel to distribute the product in t...

Page 13: ...sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the product see the Operation Maintenance And Warranty Manual alteration or remova...

Page 14: ...ices Damage caused by neglect lack of maintenance accident abnormal operation improper installation or service or freezing temperatures Haul out launch towing charges removal and or replacement of boa...

Page 15: ...zard Water entering the engine via the air filter or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead...

Page 16: ...er Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road...

Page 17: ...ble of Contents Features And Controls 10 Lanyard Stop Switch 10 Instrumentation 12 Remote Controls 15 Panel Mounted 15 Console Mounted 16 Electrical System Overload Protection 17 Audio Warning System...

Page 18: ...aters releasing your grip on the steering wheel that is pulling in 1 direction consuming alcohol or drugs high speed boating maneuvers Some remote control units are equipped with a lanyard stop switch...

Page 19: ...ntact with the boat hull and propeller from accidental ejection Personal injury or death could occur Always properly connect both ends of the lanyard stop switch Accidental or unintended activation of...

Page 20: ...dings that will appear on your style gauges 70514 70518 70521 70519 71856 a b c d e f g h 71856 71856 71856 Typical a Speedometer b Tachometer c Oil pressure gauge d Battery meter e Coolant temperatur...

Page 21: ...on 2 RUN In the RUN position all electrical circuits indicator lamps automatic preheating if equipped and all instruments are operational 3 START In the START position the engine can be started NOTE K...

Page 22: ...re is too high Refer to the following note NOTE The audio warning alarms are wired in a parallel circuit If an alarm sounds while the engine is operating quickly observe the coolant temperature gauge...

Page 23: ...trol handle is in the NEUTRAL position and should only be used to assist in starting the engine Lanyard Stop Switch Turns the ignition OFF whenever the operator when attached to the lanyard moves far...

Page 24: ...Adjustment Screw This screw can be adjusted to increase or decrease the tension on the control handle cover must be removed to adjust This will help prevent slipping of the remote control handle Turn...

Page 25: ...ectrical system Contact your authorized Cummins MerCruiser Diesel dealer distributor 00000 was CD862 1 Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation powe...

Page 26: ...gauge Typical coolant temperature gauge 79753 Typical transmission fluid temperature switch CAUTION Operation of the engine after the audio warning system alarm has sounded could result in damage to...

Page 27: ...l not affect the fit function or performance of the engines Boatbuilders and Dealers may not remove the label or the part it is affixed to before sale If modifications are necessary contact Cummins Me...

Page 28: ...GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 Page 20 CMD 4081877 90 865861040 MARCH 2004 NOTES...

Page 29: ...e Warm Up 30 Engine Shut Down Stopping 31 Freezing Temperature And Cold Weather Operation 32 Drain Plug and Bilge Pump 32 Protecting People In The Water 33 While You Are Cruising 33 While Boat Is Stat...

Page 30: ...w the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information Nationa...

Page 31: ...e 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 operatin...

Page 32: ...Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must b...

Page 33: ...detectors in your boat Although the occurrence is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a...

Page 34: ...above idle speed w When launching your boat from a steep ramp enter the water slowly Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large followi...

Page 35: ...asure Duty Rating applies to recreational planing craft used exclusively for pleasure and recreation Typical applications include pleasure craft such as sailboats ski boats runabouts speedboats and ot...

Page 36: ...to allow the turbocharger and engine to cool Check shift and throttle control operation Prime fuel injection system if necessary Turn key switch to OFF position Turn battery switch if so equipped to O...

Page 37: ...ckup pump as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result IMPORTANT Observe the following before starting Provide water to the seawater pickup pump...

Page 38: ...Cummins MerCruiser Diesel dealer or distributor if you are unable to determine the problem 6 Ensure charge indicator and oil pressure warning lamps are off CAUTION Do not increase the engine speed un...

Page 39: ...ft to REVERSE After shifting the transmission advance the throttle to the desired setting 2 Once underway engine oil pressure should be within the range listed in the engine specifications chart at ma...

Page 40: ...ifreeze solution to protect components against damage by freezing Be sure to use proper cold weather lubrication oil and be sure the crankcase contains a sufficient amount Make certain that the batter...

Page 41: ...ever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a gear case or any solid device rigidly attached to a...

Page 42: ...ow them over the front of boat Falling over the front of the boat between the two pontoons will position them to come into contact with the drive unit 1 Boats having an open front deck a No one should...

Page 43: ...of the water certain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such cases the landing may cause...

Page 44: ...even out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situa...

Page 45: ...d This growth must be removed before operation it may clog the water inlets and cause the engine to overheat 0039 w changes to fit these diesel engines Elevation And Climate NOTE Engines equipped with...

Page 46: ...mits engine rpm Be sure that propeller being used does not allow engine to run against the limiter as a significant loss in performance will result NOTE Use an accurate service tachometer to verify rp...

Page 47: ...400 rpm 4 Operate the engine in gear for 3 minutes at each of the following rpms 1800 rpm 3000 rpm and Maximum Rated Full Throttle rpm 0041 w change that added last bullet on 20 hour from CE11 20 Hour...

Page 48: ...ull boat load Refer to Specifications and Maintenance Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT rpm 0044 w changes to CMD or see CE476 End of Fi...

Page 49: ...081877 90 865861040 MARCH 2004 Page 41 SECTION 4 SPECIFICATIONS Table of Contents Fuel Requirements 42 Diesel Fuel In Cold Weather 43 AntiFreeze Coolant 43 Engine Oil 45 Engine Specifications 46 2 8 E...

Page 50: ...el is highly flammable and produces a significant risk to the user IMPORTANT Use of improper or water contaminated diesel fuel can damage your en gine seriously Use of improper fuel is considered misu...

Page 51: ...elated cooling passages must remain as clean as possible to provide adequate engine cooling This can only be assured by using the proper antifreeze water additives and inhibitors It is recommended tha...

Page 52: ...eater than 32 degrees C 90 degrees F then a 25 75 antifreeze water solution can be used for improved cooling performance IMPORTANT The antifreeze coolant used in these marine engines must be a low sil...

Page 53: ...ngine oil with a rating of HD SAE API CG 4 and CH 4 We strongly recommend the use of Description Where Used Part Number 15W40 4 cycle Diesel Engine Oil Engine crankcase 92 877695K1 This oil is a speci...

Page 54: ...re 94 1 mm 3 705 in Stroke 100 1 mm 3 941 in Rated Engine rpm 2 3800 Idle rpm in Neutral 3 600 Water 2 total 1 at 70 160 1 Thermostats 1 at 82 180 1 Oil 95 203 1 Coolant Temperature 80 85 176 185 1 El...

Page 55: ...ter 1 8 9 2 4 15W40 4 cycle Diesel Engine Oil 92 877695K1 Marine Engine Coolant 92 813054A2 Closed Cooling System 11 3 Fleetguard Compleat with DCA4 Obtain Locally Fleetguard Part Number CC2825 1 Alwa...

Page 56: ...SPECIFICATIONS SECTION 4 Page 48 CMD 4081877 90 865861040 MARCH 2004 NOTES...

Page 57: ...Air Filter 68 Cleaning 68 Replacement 68 Water Separating Fuel Filter 69 Draining 70 Replacing 71 Filling 73 Fuel System 74 Priming 74 Filling Bleeding 74 Fuel Tank Cleaning And Flushing 74 Lubricati...

Page 58: ...ptimum performance and dependability and will keep your overall operating expenses at a minimum See your authorized Cummins MerCruiser Diesel dealer distributor for service aids CE467 Dealer Responsib...

Page 59: ...an be done by owner operator while others should be performed by an authorized Cummins MerCruiser Diesel dealer distributor Before attempting maintenance or repair procedures not covered in this manua...

Page 60: ...the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office...

Page 61: ...heck the transmission fluid level D Check the water inlets for debris or marine growth Check the seawater strainer and clean D Check the battery connections and fluid level D Operating in Saltwater On...

Page 62: ...nsion of the belts D Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks D Disassemble and inspect the seawater pump and replace worn com...

Page 63: ...hours or 5 years z Every 1000 hours or 5 years z Per OEM Replace the coolant D Clean the aftercooler core D Clean the fuel tank D Check engine to propeller shaft alignment D Only perform maintenance...

Page 64: ...MAINTENANCE SECTION 5 Page 56 CMD 4081877 90 865861040 MARCH 2004 0166 Maintenance Record continued Date Hour Meter Reading Serviced By Maintenance Performed...

Page 65: ...oid possible injury or damage to oil dipstick and internal engine components Do not remove crankcase oil dipstick when engine is running Stop the engine com pletely before removing or inserting dipsti...

Page 66: ...e oil filler cap 79911 a Shown without engine cover a Oil filler cap 2 Add specified oil to bring the level up to but not over the maximum mark on the dipstick 2 8 ES 200 Capacity Liters U S gal Fluid...

Page 67: ...and allow it to warm up to normal operating temperature 2 Stop engine and allow some time for oil to drain into oil pan approximately 5 minutes 3 Remove fitting from end of crankcase oil drain hose l...

Page 68: ...12 Push the filter element onto the top piece until it is locked Listen for a click sound 13 Install the top piece with the new filter element into the oil filter housing IMPORTANT Over tightening th...

Page 69: ...Dipstick b Threaded hole c Maximum fluid level d Minimum fluid level IMPORTANT To accurately check the fluid level the engine must be operated at 1500 rpm for 2 minutes immediately prior to checking t...

Page 70: ...rt Number ZF Marine 63A 3 3 1 4 1 D III A t ti T Obt i ZF Marine 63IV 4 4 1 4 1 Dexron III Automatic Trans mission Fluid or Equivalent Obtain Locally ZF Marine 45A 4 4 1 4 1 mission Fluid or Equivalen...

Page 71: ...and remove the fluid filter assembly by turning the assembly nut counterclockwise and pulling at the same time a b 79799 a Fluid filter assembly b Assembly nut 3 Push the hose of a suction pump throu...

Page 72: ...properly seated to avoid fluid foaming and or loss of fluid resulting in decreased efficiency and or damage to transmission 8 Install the fluid filter assembly in the transmission cavity by turning c...

Page 73: ...w the engine to cool 2 Remove the pressure cap from the coolant expansion tank 3 The coolant level in the coolant expansion tank should be within 25 mm 1 in of the bottom of the filler neck or between...

Page 74: ...of filler neck 7 Add the specified coolant as required Description Where Used Part Number Marine Engine Coolant 92 813054A2 Fleetguard Compleat with DCA4 Closed cooling system Obtain Locally Fleetgua...

Page 75: ...mpleat with DCA4 Closed cooling system Obtain Locally Fleetguard Part Number CC2825 IMPORTANT When installing the pressure cap be sure to tighten it securely to prevent coolant loss 2 Install the pres...

Page 76: ...um based solvents or cleaners 3 Wash the foam element in warm water and detergent until clean 4 Allow the foam element to completely dry before use IMPORTANT No treatment such as partial oil saturatio...

Page 77: ...nd rusting of the injectors and other components can be avoided 00000 wasCD880 A plunger type of hand pump primer is located on the engine mounted water separating fuel filter bracket and is used to R...

Page 78: ...eeze drain the filter shortly after the end of daily operations NOTE Place a suitable container under fuel filter to catch contaminated fuel and or water Dispose of properly 1 Place a container under...

Page 79: ...b Typical a Drain cap b WIF sensor wire 2 Twist locking ring by hand Remove water separating fuel filter and sealing ring from mounting bracket Do not use a filter wrench 76114 a c a b b 74726 Typica...

Page 80: ...lter to bracket Do not use a filter wrench 7 Ensure drain cap is securely tightened a b c 74726 Typical a Locking ring b Filter c Drain cap 8 Plug the WIF sensor wire onto the drain cap 9 Refer to Fil...

Page 81: ...has been drained from filter checking for water 1 Loosen the bleed screw on fuel filter bracket a 80015 80015 Typical a Bleed screw b Bleed screw 2 Move the plunger on the hand pump primer up and dow...

Page 82: ...or if part of fuel system was drained for a service function 1 Refer to Water Separating Fuel Filter Filling and fill the fuel filter 2 Check filter and drain cap for fuel leaks Ensure that bleed scr...

Page 83: ...ontact surfaces Description Where Used Part Number A Engine Oil Pivot points guide contact surfaces Obtain Locally 00000 was 0079 with diesel graphics added Throttle Cable 1 Lubricate the pivot points...

Page 84: ...ying or glazed surfaces If any drive belts need replacement or tension needs adjustment see your authorized Cummins MerCruiser Diesel dealer distributor WARNING Avoid possible serious injury Make sure...

Page 85: ...that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 75130 a b c a Transverse crack b Longitudinal crack c Fraying 3 Check operation of the automatic tensioner and ass...

Page 86: ...will in time cause the need for replacement of power package components exposed to water Refer to the Marine Corrosion Protection Guide 90 88181301 CE550 Antifouling Paints In some areas it may be adv...

Page 87: ...rificial Anode c Length d Diameter e Sealing Washer REPAIR NOTE Sacrificial anodes are available as an assembly Replace both the plug and anode if so desired 1 Unscrew sacrificial anode from anode plu...

Page 88: ...or cause the boat to sink When the drain system is open excess water can enter the bilge Do not operate the engine with the drain system open IMPORTANT Engine must be as level as possible to ensure c...

Page 89: ...e to heat exchanger water passage tubes 4 Remove the anode plug and drain the heat exchanger a b a 80057 b a Heat exchanger b Anode plug 5 Remove the drain plug or fitting if equipped from the aft end...

Page 90: ...e seawater inlet hose unless a seacock is present and it is closed 9 On models equipped with a seawater strainer remove the hose at the seawater strainer and drain the hose completely Drain and empty...

Page 91: ...move and plug the seawater inlet hose if no seacock exists 3 Remove the screws washers and cover 4 Remove the strainer drain plug and washer 5 Clean all debris from the strainer housing flush both the...

Page 92: ...ion in saltwater and prior to storage CAUTION When flushing the seawater cooling system close the seacock if so equipped If the boat is not equipped with a seacock remove and plug seawater inlet hose...

Page 93: ...flushing hose causing the engine to overheat Do not run engine above 1500 rpm when flushing 6 Operate the engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear 7 Stop...

Page 94: ...lowing precautions when handling a battery WARNING Avoid serious injury from fire or explosion Do NOT use jumper cables and a booster battery to start engine Do NOT recharge a weak battery in the boat...

Page 95: ...e voltage returns to the range that the ECM requires the ECM will reset itself The engine will now run normally This ECM shut down usually happens so fast that the engine just appears to have an ignit...

Page 96: ...MAINTENANCE SECTION 5 Page 88 CMD 4081877 90 865861040 MARCH 2004 NOTES...

Page 97: ...AND RECOMMISSIONING Table of Contents Cold Weather Freezing Temperature Seasonal And Extended Storage 90 Cold Weather Freezing Temperature Storage 91 Preparing Your Power Package For Seasonal or Exte...

Page 98: ...ratures for even a brief period of time could result in freeze damage Corrosion damage is the result of saltwater polluted water or water with a high mineral content trapped in the seawater cooling sy...

Page 99: ...r cooling system with a mixture of propylene glycol antifreeze and tap water Refer to Seasonal Storage Instructions in this section CD665 or CE500 w changes 0085 w changes used diesel information here...

Page 100: ...ufacturer s recommendations 3 Fill a container with approximately 5 6 liter 6 U S quarts of propylene glycol antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lo...

Page 101: ...hanges outlined in Section 5 Maintenance Schedules 10 Follow the battery manufacturer s instructions for storage and store the battery Extended Storage Instructions IMPORTANT Cummins MerCruiser Diesel...

Page 102: ...al laws and guidelines 3 Ensure that all cooling system hoses are in good condition connected properly and hose clamps are tight Verify that all drain valves and drain plugs are installed and tight 4...

Page 103: ...insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes during operation 10 Supply cooling water to the water...

Page 104: ...STORAGE AND RECOMMISSIONING SECTION 6 Page 96 CMD 4081877 90 865861040 MARCH 2004 NOTES...

Page 105: ...ng Charts 98 Starter Motor Will Not Crank Engine Or Cranks Slow 98 Engine Will Not Start Or Is Hard To Start 99 Engine Runs Rough Misses And Or Backfires 100 Poor Performance 100 Excessive Engine Temp...

Page 106: ...occur and store a Trouble Code in the ECM s memory This code can then be read later by a service technician using a special diagnostic tool CE516 Troubleshooting Charts Starter Motor Will Not Crank E...

Page 107: ...ctrical stop circuit Have an authorized Cummins MerCruiser Diesel dealer distributor service the electrical stop circuit Clogged fuel filters Replace filters Stale or contaminated fuel Drain tank Fill...

Page 108: ...in fuel system Purge fuel injection system Electronic fuel system fault Have electronic fuel system checked by an authorized Cummins MerCruiser Diesel dealer distributor 0106 w changes EDI and CMD Poo...

Page 109: ...orized Cummins MerCruiser Diesel dealer distributor Loss of pressure in closed cooling section Check for leaks Clean inspect and test pressure cap See an authorized Cummins MerCruiser Diesel dealer di...

Page 110: ...ery cables Clean and tighten faulty connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition Replace and or adjust Unacceptable battery condition Test battery 0112...

Page 111: ...d After Submersion 104 Replacement Service Parts 105 Parts And Accessories Inquiries 105 Resolving A Problem 106 Customer Service Literature 107 English Language 107 Other Languages 107 Andre sprog 10...

Page 112: ...thorized dealer Refer to the Yellow Pages of the telephone directory or by using the service locator on the Cummins website www Cummins com If for any reason you cannot obtain service contact the near...

Page 113: ...environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive en...

Page 114: ...ould you have a question concern or problem that cannot be resolved by your dealership please contact your local distributor of Cummins MerCruiser Diesel products for assistance The distributor will w...

Page 115: ...este Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedelsnumre for...

Page 116: ...bter um Manual de Opera o e Manuten o em outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n m...

Page 117: ...for your particular Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Diesel dealer distributor or contact Mercury Marine Telephone Fax...

Page 118: ...75308 CUSTOMER ASSISTANCE INFORMATION SECTION 8 Page 110 CMD 4081877 90 865861040 MARCH 2004 00000 was CD851...

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