Mercury MerCruiser 6.2 Inboard MPI DTS Manual Download

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Section 3 - On the Water

Page 44

90-8M0099741

eng

JUNE 2015

End of First Season Checkup

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 operated continuously, year‑round, you should contact

your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

Summary of Contents for MerCruiser 6.2 Inboard MPI DTS

Page 1: ...ssessment module used for exhaust emissions B C B D B E B F G H Other Community Directives applied Electromagnetic Compatibility Directive 2004 108 EC Description of Engines and Essential Requirements...

Page 2: ...tive 94 25 EC as amended by Directive 2003 44 EC when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that these engines must not be put into s...

Page 3: ...ns At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use In addition certain Mercury Marine products are tested in a cont...

Page 4: ...Bravo Two Bravo Three Circle M with Waves Logo K planes Mariner MerCathode MerCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGui...

Page 5: ...and Diesel 14 Outside Canada 14 Australia and New Zealand Warranty Chart MerCruiser Gas and Diesel 15 Outside Australia and New Zealand 15 South Pacific Warranty Chart MerCruiser Gas and Diesel 15 Out...

Page 6: ...Checkup 44 Section 4 Specifications Fuel Requirements 46 Fuel Ratings 46 Using Reformulated Oxygenated Gasoline USA Only 46 Gasoline Containing Alcohol 46 Engine Oil 46 6 2 MPI Inboard Engine Specifi...

Page 7: ...ne Runs Rough Misses or Backfires 79 Poor Performance 79 Excessive Engine Temperature 79 Insufficient Engine Temperature 79 Low Engine Oil Pressure 80 Battery Will Not Recharge 80 Remote Control Is Di...

Page 8: ...Page iv 90 8M0099741 eng JUNE 2015...

Page 9: ...nty 11 Warranty Period for Recreational Use 11 Warranty Period for Commercial Use 11 Transfer of Coverage 11 Termination of Coverage 11 Conditions That Must Be Met to Obtain Warranty Coverage 12 What...

Page 10: ...ty 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 re...

Page 11: ...ce overall product quality 2 To improve the boat ownership experience 3 To enhance overall customer satisfaction The certification process is designed to review all facets of manufacturing and engine...

Page 12: ...unused portion of the limited warranty This will not apply to products used for commercial applications CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available...

Page 13: ...LAIMERS 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...

Page 14: ...ion warranty and should be protected against by the use of a corrosion protection system such as the Mercury Precision Parts or Quicksilver MerCathode system and or Galvanic Isolator Corrosion damage...

Page 15: ...EMISSION CONTROLINFORMATION NOT FOR SALE IN CALIFORNIA THIS MARINE ENGINE COMPLIES WITH U S EPA EXHAUST REGULATIONS FOR XXXX XXXXXXXX SERIAL DOM MMM YYYY DISP X XL ECIEPA 0575 43518 CO FEL XXX g kWh P...

Page 16: ...components 1 Fuel metering system a Carburetor and internal parts or fuel pressure regulator or fuel injection system b Air fuel ratio feedback and control system c Cold start enrichment system d Inta...

Page 17: ...board or sterndrive engines are warranted for three years or 480 hours whichever occurs first from either the date the product is first sold or first put into service whichever occurs first Emission r...

Page 18: ...maintenance of your inboard or sterndrive engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also include...

Page 19: ...ccurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this limited warranty beyond its original expiration date The warranty peri...

Page 20: ...o Mercury Marine at the address shown above Mercury Marine will then arrange for the inspection and any covered repair This Limited Warranty will not cover the purchaser for all related transportation...

Page 21: ...SUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT B...

Page 22: ...For product purchased outside of United States contact the distributor in your country or the authorized Marine Power Service Center closest to you Canada Warranty Chart MerCruiser Gas and Diesel Pro...

Page 23: ...s 3 years Outside of the South Pacific For product purchased outside of the South Pacific contact the distributor in your country or the authorized Marine Power Service Center closest to you Asia Warr...

Page 24: ...ears 3 years Contact the Marine Power Service Center closest to you Horizon Scorpion SeaCore 2 years 3 years 4 years Mercury Diesel Sterndrive and Inboard 1 year Not available at time of printing 3 ye...

Page 25: ...nes Three Stars Ultra Low emission 42538 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or t...

Page 26: ...1 Warranty Page 18 90 8M0099741 eng JUNE 2015 If in California the dealer must place the hang tag in a visible location in the boat prior to displaying the boat 43291 Hang tag front side Hang tag bac...

Page 27: ...ote Controls 23 DTS Slim Binnacle Single Handle Console Features and Operation 24 Special Digital Throttle and Shift DTS Features 25 Dual Handle Electronic Remote Control ERC Operation and Adjustment...

Page 28: ...the steering wheel which is safer and the operator can focus on the boating experience Identification The serial numbers are the manufacturer s keys to numerous engineering details which apply to your...

Page 29: ...eds Standing at planing speeds Operating at planing speeds in shallow or obstacle infested waters Releasing your grip on the steering wheel Carelessness caused by consuming alcohol or drugs High speed...

Page 30: ...disconnecting the stop switch lanyard from the operator Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition Before each use ensure that the lanyard stop switch works properly St...

Page 31: ...t Have your boat dealer explain the gauges and normal readings that appear on your boat The following digital instruments may be included with your power package a b c d 37925 System Link digital gaug...

Page 32: ...djusted to increase or decrease the effort to move the control handle out of detent positions Turning the screw clockwise will increase tension Turning the screw counterclockwise will decrease tension...

Page 33: ...for the CAN pad VesselView and SmartCraft gauges e Decreases brightness settings for the CAN pad VesselView and SmartCraft gauges f Dock Reduces control lever operation throttle capacity to approxima...

Page 34: ...djustment NOTE The control handle tension and detent tension may require periodic maintenance using the adjustment screws To adjust the handle detent tension 1 Remove the side cover plugs of the handl...

Page 35: ...m Transfer c Dock Available with joystick operation and the control levers Joystick operation reduces throttle capacity to approximately 70 of normal joystick throttle demand Control lever operation r...

Page 36: ...will remain in neutral 51855 THROTTLE ONLY button To engage throttle only mode 1 Place both ERC levers in neutral 2 Press the THROTTLE ONLY button The button light will turn on and the neutral lights...

Page 37: ...automatic engine synchronization feature that is always on unless it is manually turned off Sync monitors the position of both ERC levers When both levers are within 10 of one another the port engine...

Page 38: ...e helm transfer will not succeed until the levers at the helms are moved to neutral and transfer is requested again Some fault codes may appear on VesselView if other control or navigation functions a...

Page 39: ...iring harness and the instrumentation power lead 55033 All of the engine protection fuses are located at the front of the engine To access the fuses disengage the fuse holders from the electrical plat...

Page 40: ...mizes an excessive voltage drop to the engine and drive digital control electrical system This harness is protected by a 5 amp fuse and is located near the engine starting battery a 5 amp fuse b Posit...

Page 41: ...faults cause the warning horn circuit to activate How the warning horn activates depends on the severity of the problem There are two warning horn states Caution Critical There is also an alarm that s...

Page 42: ...lem Below are some examples of what Engine Guardian monitors Oil pressure Engine overspeed Exhaust manifold temperature IMPORTANT Engine Guardian can reduce power anywhere from 100 to idle depending o...

Page 43: ...eezing Temperature Operation 40 Drain Plug and Bilge Pump 40 Protecting People in the Water 40 While You Are Cruising 40 While Boat Is Stationary 40 High Speed and High Performance Operation 40 Passen...

Page 44: ...assengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S C...

Page 45: ...ther assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal combus...

Page 46: ...tion wagon effect Basic Boat Operation DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat Operation Chart Operation Chart BEFORE STARTING AFTER STARTING...

Page 47: ...f the engine does not start after step 5 a Move the remote control handle throttle lever to the full throttle position then return to 1 4 throttle b Turn the ignition key to START Release the key when...

Page 48: ...r 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 water to collect For this...

Page 49: ...cause serious injury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion Boats With Front Mounted Raised Pedestal Fishing Seats Eleva...

Page 50: ...the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed Boat speed should be kept to a minimum planing speed when driving in waters kn...

Page 51: ...g weather conditions it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boat...

Page 52: ...ason 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 operated continuously year round you...

Page 53: ...ion 4 Specifications Table of Contents Fuel Requirements 46 Fuel Ratings 46 Using Reformulated Oxygenated Gasoline USA Only 46 Gasoline Containing Alcohol 46 Engine Oil 46 6 2 MPI Inboard Engine Speci...

Page 54: ...nt in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fu...

Page 55: ...cting the type of oil according to the order of preference Mercury Quicksilver 25W 40 Synthetic Blend NMMA FC W Catalyst Compatible rated 4 cycle oil Other recognized brands of NMMA FC W Catalyst Comp...

Page 56: ...manufacturers may rate and test their batteries to different standards MCA CCA Ah and reserve capacity RC are the ratings recognized by Mercury Marine Manufacturers that use standards different than...

Page 57: ...the Fluid Level Before Operation 55 Checking the Fluid Level When Hot 56 Changing 56 Transmission Filter Inspection Replacement 56 Engine Coolant 56 Checking 56 Filling 57 Changing 58 Flame Arrestor...

Page 58: ...e product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing instal...

Page 59: ...including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as necessary Check plug leads and electrical leads for damage Remove and inspect the...

Page 60: ...n the flame arrestor Check the engine mounts for tightness and tighten to specifications if necessary Inspect the condition of the spark plugs spark plug wires Replace as necessary If the condition of...

Page 61: ...ase can cause a fluctuation or drop in oil pressure and rocker arm clatter and result in a loss of engine performance An overfilled crankcase oil level too high can cause a fluctuation or drop in oil...

Page 62: ...odels Capacity Fluid Type Engine oil with filter 4 7 L 5 US qt Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil NMMA FC W Engine Oil Drain Pump 1 Loosen the oil filter to vent the system 2 Remove...

Page 63: ...to the bottom of the OK range on the dipstick 7 With the boat at rest in the water repeat steps 5 and 6 if necessary NOTE Adding 0 95 L 1 US qt of engine oil raises the level from the ADD mark to the...

Page 64: ...do not overfill 4 Install the dipstick and tighten the T handle securely Do not overtighten Checking the Fluid Level When Hot The process for checking the fluid level when hot is the same as checking...

Page 65: ...Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage th...

Page 66: ...l the fill cap to the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Flame Arrestor WARNING Fuel is flammable and explosive Ensure that the key switch is off and th...

Page 67: ...ore fuel Wipe up spilled fuel immediately Material used to contain spilled fuel must be disposed of in an approved receptacle Before servicing any part of the fuel system 1 Stop engine and disconnect...

Page 68: ...lter Removal Installation Tool 91 896661 24896 Aids in the removal and installation of the fuel filter cap assembly 7 Slide the filter housing up to release it from the bracket The fuel hoses have eno...

Page 69: ...rom the boat and recharge in a ventilated area away from sparks or flames WARNING An operating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause s...

Page 70: ...ine running may cause serious injury or death Turn off the engine and remove the ignition key before adjusting tension or inspecting belts With a seawater pump a Alternator pulley b Water circulating...

Page 71: ...belt and verify the alignment of the pulley 40797 Chunk out Pieces or chunks of rubber material have broken off the belt When chunk out has occurred a belt can fail at any moment Chunk out can happen...

Page 72: ...ry are correct If the tensioner contacts either of the cast stops during operation check the mounting brackets and the belt length Loose brackets bracket failure accessory drive component movement inc...

Page 73: ...equipped ensure that all alternative water inlet hoses are plugged at both ends 1 Close the seacock if equipped For visual clarity the seacock shown is not installed a Hose fitting to engine b Seacoc...

Page 74: ...ing the release button on the flush socket a Quick connect fitting water hose end b Flush socket release button 14 Remove the quick connect fitting from the water hose a Quick connect fitting water ho...

Page 75: ...sh socket a Dust cover b Flush socket 17 Remove the plugs from the water hose and connect to the fittings Tighten the hose clamps securely 18 Open the seacock if equipped IMPORTANT If the unit is to b...

Page 76: ...Section 5 Maintenance Notes Page 68 90 8M0099741 eng JUNE 2015...

Page 77: ...el Containing Alcohol 70 Preparing Power Package for Storage MPI Models 70 Special Fuel Mix 71 Engine and Fuel System Preparation 71 TowSport and Inboard Transmissions Extended Storage 72 Draining the...

Page 78: ...presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a Mercury Marine engine on gasoline containing alcohol storage of gasolin...

Page 79: ...irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before servicing the power package NOTICE Running out of fuel can damage cat...

Page 80: ...e 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 ope...

Page 81: ...s out of the distribution housing IMPORTANT If water does not drain from the distribution housing when both green indicators are extended remove the blue plug on the distribution housing a Distributio...

Page 82: ...ny water trapped in the seawater pump Do not allow the engine to start IMPORTANT This engine has an automatic start function controlled by the PCM The start function can be terminated by turning the k...

Page 83: ...ting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 2 Insta...

Page 84: ...Section 6 Storage Notes Page 76 90 8M0099741 eng JUNE 2015...

Page 85: ...rts 78 Starter Motor Will Not Crank Engine or Cranks Slowly 78 Engine Will Not Start or Is Hard to Start 78 Engine Runs Rough Misses or Backfires 79 Poor Performance 79 Excessive Engine Temperature 79...

Page 86: ...speed is within the allowable limit Consult an authorized Mercury MerCruiser dealer for assistance Troubleshooting Charts Starter Motor Will Not Crank Engine or Cranks Slowly Possible Cause Remedy Ba...

Page 87: ...edistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Clean or repair as necessary Ignition problem See Engine Runs Rough Misses or Backfires Engine...

Page 88: ...y condition Test battery replace if necessary Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten...

Page 89: ...ice Away From Home 82 Stolen Power Package 82 Attention Required After Submersion 82 Replacement Service Parts 82 Parts and Accessories Inquiries 82 Resolving a Problem 82 Contact Information for Merc...

Page 90: ...d 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 wh...

Page 91: ...iers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan Te...

Page 92: ...ercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Departm...

Page 93: ...Section 9 Checklists 90 8M0099741 eng JUNE 2015 Page 85 Section 9 Checklists Table of Contents Predelivery Inspection PDI 86 Customer Delivery Inspection CDI 87 9...

Page 94: ...s tight Battery of proper rating fully charged secured with protective covers in place All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct propeller se...

Page 95: ...sident of California CARB hang tag in boat CARB decal properly affixed to boat hull Customer Delivery Inspection CDI IMPORTANT This checklist is for packages that are not equipped with Axius For engin...

Page 96: ...martCraft accessories if applicable Off season storage and maintenance schedule Engine starting stopping shifting using throttle Boat lights battery switch location fuses breakers Trailer if applicabl...

Page 97: ...Section 10 Maintenance Log 90 8M0099741 eng JUNE 2015 Page 89 Section 10 Maintenance Log Table of Contents Scheduled Maintenance Log 90 Vessel Maintenance Notes 91 10...

Page 98: ...Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name Signatu...

Page 99: ...Log 90 8M0099741 eng JUNE 2015 Page 91 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Comp...

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