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Mercury MerCruiser 5.7 Horizon, User Manual

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Mercury MerCruiser 5.7 Horizon User Manual Download Page 29

Section 2 - Getting to Know Your Power Package

90-899883173   DECEMBER  2007

Page  21

On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate

indicates gear ratio, serial number and model.

7370

a

Velvet Drive 5000A ‑ 8 degree down‑angle transmission shown (5000V ‑ V‑drive similar)

a -

Transmission identification plate

ZF MARINE TRANSMISSIONS

On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission

identification plate indicates gear ratio, serial number, and model.

a

7449

Typical ZF Marine down‑angle transmission shown (V‑drive similar)

a -

Transmission identification plate

Summary of Contents for MerCruiser 5.7 Horizon

Page 1: ...t Annex II ISO 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with...

Page 2: ...rinting Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring ob...

Page 3: ...me in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the eng...

Page 4: ...er 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...

Page 5: ...Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Transmissions 20 Velvet Drive Transmissions 20 ZF Marine Transmissions 21 Walter V Drive Transmissions 22 L...

Page 6: ...Reformulated Oxygenated Gasoline USA Only 54 Gasoline Containing Alcohol 54 Engine Oil 55 Engine Specifications 56 Fluid Specifications 57 Engine 57 Transmission 57 Section 5 Maintenance Owner Operat...

Page 7: ...ooting Charts 98 Starter Motor Will Not Crank Engine or Cranks Slowly 98 Engine Will Not Start or Is Hard to Start 99 Engine Runs Rough Misses or Backfires 99 Poor Performance 99 Excessive Engine Temp...

Page 8: ...Page iv 90 899883173 DECEMBER 2007...

Page 9: ...Chart 7 Commercial Application Warranty Chart 8 Government Application Warranty Chart 9 Mercury Installation Quality Certification Program 9 California Emissions Limited Warranty 10 What Is Covered 1...

Page 10: ...rned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine pro...

Page 11: ...ng the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory...

Page 12: ...ied installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 yea...

Page 13: ...purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that c...

Page 14: ...t noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or...

Page 15: ...ands Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Cooli...

Page 16: ...year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Jap...

Page 17: ...r 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 50...

Page 18: ...ertification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com merc...

Page 19: ...lendar year As an example 2003 model year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems...

Page 20: ...sistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for...

Page 21: ...ation System a Oil pump and internal parts b Oil injector s c Oil meter 5 Positive Crankcase Ventilation PCV System a PCV Valve b Oil filler cap 6 Exhaust System a Exhaust manifold b Exhaust elbow c I...

Page 22: ...o included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your inboard or sterndrive engine at no cost to you inclu...

Page 23: ...e label or the part it is affixed to before sale If modifications are necessary contact Mercury MerCruiser about the availability of replacement decals before proceeding NOTE When the CE mark is prese...

Page 24: ...omy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer Emission Warranty Protects consumer for worry free operation Beginnin...

Page 25: ...marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star...

Page 26: ...Section 1 Warranty Notes Page 18 90 899883173 DECEMBER 2007...

Page 27: ...on DTS Models 25 Remote Controls 25 Panel Mount Features 26 Console Mount Features 27 Zero Effort Features 27 Remote Controls DTS Models 28 Remote Controls 28 Panel Mount Features 28 Console Mount Fea...

Page 28: ...al number is also stamped in the engine block Transmissions VELVET DRIVE TRANSMISSIONS On Velvet Drive In Line and V Drive Transmissions 71C 72C 72C V Drive with or without Walter transmissions the ge...

Page 29: ...model 7370 a Velvet Drive 5000A 8 degree down angle transmission shown 5000V V drive similar a Transmission identification plate ZF MARINE TRANSMISSIONS On the ZF Marine 8 Degree Down Angle and V Dri...

Page 30: ...e operator moves outside the operator s position as in accidental ejection from the operator s position 74608 RUN a b c a Stop switch b Lanyard c Clips to the operator Accidental ejections such as fal...

Page 31: ...oat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the...

Page 32: ...VesselView may also be connected to other vessel systems such as GPS generators and cabin environmental controls This comprehensive vessel integration allows the operator to monitor and control a wid...

Page 33: ...dings for your boat L H OIL C H TEMP 0 1 2 3 4 5 6 7 8 R P M X 1000 MPH KPH 10 20 30 40 50 60 70 80 30 40 50 60 70 80 90 100 120 110 10 16 BATT 0 4 4 4 FUEL CRUISELOG 0 0 0 0 0 a b c d e f g h i 17352...

Page 34: ...in starting the engine Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to...

Page 35: ...to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continu...

Page 36: ...system works with specialized helm components such as a command module kit and electronic remote control Consult your dealer for a description and or demonstration of your remote control Panel Mount F...

Page 37: ...ect key e Arrow trackpad f Throttle only station select key g Detent tension adjustment h Control handle friction adjustment screw Control Handle Operation of the shift and throttle are controlled by...

Page 38: ...ard to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Active Light The active light...

Page 39: ...ion messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Throttle Only Station Select Key Allows engine throttle advancement witho...

Page 40: ...m transfer should only be performed while engine is in neutral NOTE Idle position is preferred when doing a station transfer If conditions do not allow the remote control to be placed at idle position...

Page 41: ...ift lever to its center position Shift into forward by moving the shift lever to its forward position Throttle Lever Throttle functions are controlled by the movement of the throttle lever Increase th...

Page 42: ...perly the yellow lever appears Push the yellow lever into the housing to reset the circuit breaker b a 22529 a Yellow lever shown tripped b Red test button A 90 amp fuse is located on the large post o...

Page 43: ...pin connector 33177 Oxygen sensor fuses A 15 amp accessory fuse protects the accessory circuits a b c 32206 a Fuse cover b 15 amp fuse c Power harness A power harness connected to the engine starting...

Page 44: ...power package may be equipped with an audio warning system Most faults cause the warning horn circuit to activate How the warning horn activates depends on the severity of the problem There are three...

Page 45: ...Warning System 1 Turn the ignition switch to the ON position without cranking the engine 2 Listen for the audio alarm The alarm will sound if the system is functioning correctly Guardian Strategy Engi...

Page 46: ...an monitors the clutch pack pressure in forward and reverse gears If the transmission fluid pressure drops below a predetermined level Transmission Guardian lowers the engine torque and speed to preve...

Page 47: ...opping the Engine 45 Starting the Engine 45 Stopping the Engine 46 Throttle Only Operation 46 Freezing Temperature Operation 47 Drain Plug and Bilge Pump 47 Protecting People in the Water 47 While You...

Page 48: ...instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for signs of...

Page 49: ...r similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight and never back...

Page 50: ...erating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon...

Page 51: ...engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes 3 Turn ignition...

Page 52: ...e reverse position without pressing the throttle only button will shift the unit into the chosen gear Freezing Temperature Operation IMPORTANT If the boat is operated during periods of freezing temper...

Page 53: ...fumes contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five...

Page 54: ...ignition key switch to the START position then release immediately The control system will recognize that the engine is running and will stop the engine The control system will remain active Moving t...

Page 55: ...freeze damage to the power package Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for...

Page 56: ...udden throttle reduction or a sharp change of boat direction could throw them over the front of boat Falling over the front of the boat between the two pontoons will position them to be run over Boats...

Page 57: ...e 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 Impa...

Page 58: ...inspect and repair the vessel or power package Conditions Affecting Operation Weight Distribution Passengers and Gear Inside the Boat Shifting weight to rear stern Generally increases speed and engine...

Page 59: ...eved by changing to a lower pitch propeller Getting Started 20 Hour Break In Period IMPORTANT The first 20 hours of operation is the engine break in period Correct break in is essential to obtain mini...

Page 60: ...kup At the end of the first season of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operate...

Page 61: ...ion 4 Specifications Table of Contents Cruising RPM 54 Fuel Requirements 54 Fuel Ratings 54 Using Reformulated Oxygenated Gasoline USA Only 54 Gasoline Containing Alcohol 54 Engine Oil 55 Engine Speci...

Page 62: ...imum Premium gasoline 92 R M 2 Octane is also acceptable Do not use leaded gasoline Outside USA and Canada A posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If u...

Page 63: ...ong enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal components Engine Oil To maintain op...

Page 64: ...All measurements are taken with the engine at normal operating temperature RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures Oil pressure mus...

Page 65: ...mixed 50 50 with purified water Transmission Model Capaci Fluid Type 5000A 2 84 L 3 00 US qt Dexron III Automatic Transmission Fluid 5000V 3 30 L 3 50 US qt 71C In Line 1 66 L 1 75 US qt Dexron III A...

Page 66: ...Section 4 Specifications Notes Page 58 90 899883173 DECEMBER 2007...

Page 67: ...g the Oil Filter 67 Transmission Fluid 67 Checking While the Engine is Warm 67 Checking While Engine is Cold 68 Changing 68 Engine Coolant 68 Checking 68 Filling 69 Changing 70 Battery 70 Multiple EFI...

Page 68: ...Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dea...

Page 69: ...e unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It m...

Page 70: ...Maintenance NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the initial 20 hour break in period Change the engine oil and fi...

Page 71: ...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...

Page 72: ...he oil pan for approximately five minutes with the boat at rest in the water 2 Remove the dipstick wipe clean and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NO...

Page 73: ...qt Mercury Full Synthetic MerCruiser Engine Oil 20W 40 Changing Oil and Filter See Maintenance Schedule for the change interval Engine oil should be changed before placing the boat in storage IMPORTA...

Page 74: ...tely install the drain plug in the oil drain hose 8 Push the hose through bilge drain and install the plug 9 Replace the engine oil filter See Changing the Oil Filter Engine Oil Drain Pump 1 Loosen th...

Page 75: ...L 4 50 US qt Mercury Full Synthetic MerCruiser Engine Oil 20W 40 8 Start the engine and operate for three minutes checking for leaks 9 Stop the engine and allow the oil to drain into the oil pan for...

Page 76: ...ertighten Changing Contact your authorized Mercury MerCruiser dealer Engine Coolant Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in seriou...

Page 77: ...can cause the engine to overheat resulting in engine damage Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the...

Page 78: ...ic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s battery The voltage may...

Page 79: ...restor a b c d e f 33180 a Engine cover knob b Engine cover c Nuts flame arrestor d Cover mount bracket e Flame arrestor f Crankcase ventilation hose 4 Clean the flame arrestor with warm water and a m...

Page 80: ...e hose 4 Ensure that the PCV valve is tightly seated in the valve cover Cleaning The IAC Muffler WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so t...

Page 81: ...ter WARNING Fuel is flammable and explosive Ensure 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...

Page 82: ...ff position 6 Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module Do not remove the filter assembly retaining screws from the filter cap 7 Unseat the fi...

Page 83: ...el Module and torque each filter assembly retaining screw Description Nm lb in lb ft Filter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness...

Page 84: ...tered in the detent hole for each F N R position 1 Lubricate the detent ball and the holes in the shift lever a 5934 In Line Transmission Tube Ref No Description Where Used Part No Synthetic Blend Mer...

Page 85: ...n of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the lon...

Page 86: ...the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 8 mm 1 16 in adjusting stud b 16 mm 5 8 in locking nut 8 Operate the engine for a short period of time and recheck the belt adj...

Page 87: ...clear 10 Shut off the engine NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more than 15 s...

Page 88: ...lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate 1 Models with Walter V Drive Transmissions a Close the seacock...

Page 89: ...nce the throttle until the engine reaches 1300 RPM 100 RPM 7 Observe the water temperature gauge to ensure that the engine is operating in the normal range 8 Operate the engine with the transmission i...

Page 90: ...er inlet hose will cause water to enter the bilge resulting in engine damage Close the seacock before disconnecting the seawater inlet hose Plug the seawater inlet hose immediately after disconnecting...

Page 91: ...ds creates suction which can collapse the water supply hose and overheat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply 6 Depress the...

Page 92: ...3 DECEMBER 2007 14 Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine 15 Repeat the flushing...

Page 93: ...stem Preparation 87 Draining the Seawater System 88 Drain System Identification 88 Air Actuated Single Point Drain System 88 Three Point Manual Drain System 89 Air Actuated Single Point Drain System 8...

Page 94: ...e for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instruc...

Page 95: ...out of fuel can damage catalyst components Do not allow the fuel tanks to become empty during operation 1 In a 23 liter 6 US gal remote fuel tank mix a 19 liter 5 US gal regular unleaded 87 octane 90...

Page 96: ...ystem Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure IMPORTANT Mercury MerCruiser requ...

Page 97: ...plug the water inlet hose 2 Remove the blue air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pul...

Page 98: ...m instructions a b 6133 a Port side drain location b Starboard side drain location 9 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended...

Page 99: ...NOTE This procedure is written for the blue air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remo...

Page 100: ...use the Three Point Manual Drain System instructions a b 6133 a Port side drain location b Starboard side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessar...

Page 101: ...re if your engine is not equipped with an air actuated single point drain system or if the air actuated single point drain system fails 1 Close the seacock if equipped or remove and plug the water inl...

Page 102: ...r to operating the engine BOAT OUT OF THE WATER NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails 1 Place...

Page 103: ...nnect the negative battery cable first and connect it last 2 Install a fully charged battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when co...

Page 104: ...Section 6 Storage Notes Page 96 90 899883173 DECEMBER 2007...

Page 105: ...er Motor Will Not Crank Engine or Cranks Slowly 98 Engine Will Not Start or Is Hard to Start 99 Engine Runs Rough Misses or Backfires 99 Poor Performance 99 Excessive Engine Temperature 99 Insufficien...

Page 106: ...ngine Guardian System monitors the critical sensors on the engine for any early indications of problems The system will respond to a problem by emitting a continuous beep and or reducing engine power...

Page 107: ...ent line Replace kinked lines or blow out lines with compressed air to remove obstruction Flame Arrestor dirty Clean Flame Arrestor Faulty ignition system component Service ignition system Idle speed...

Page 108: ...improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling Battery Will Not Recharge Possible Cause Remedy Excessive current...

Page 109: ...ak Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all...

Page 110: ...Section 7 Troubleshooting Notes Page 102 90 899883173 DECEMBER 2007...

Page 111: ...Assistance 104 Local Repair Service 104 Service Away From Home 104 Stolen Power Package 104 Attention Required after Submersion 104 Replacement Service Parts 104 Parts and Accessories Inquiries 105 Re...

Page 112: ...ct an authorized Mercury MerCruiser dealer 2 After recovery immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage Replacement Serv...

Page 113: ...t the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contac...

Page 114: ...ted States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or co...

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