OWNER’S OPERATION
and
MAINTENANCE MANUAL
A Division of
Page 1: ...OWNER S OPERATION and MAINTENANCE MANUAL A Division of...
Page 2: ...transmission computerized engine control and the Fuel Control Cell FCC are all PCM innovations No matter which PCM model you purchased you can be sure it is equipped with the latest in modern technolo...
Page 3: ...n Advisory 14 ELECTRONIC FUEL INJECTION INFORMATION 15 Electronic Fuel Injection System 15 Power Reduction Mode 15 OPERATING INSTRUCTIONS 16 20 Electronic Speed Control 16 Engine Alarm System 16 Instr...
Page 4: ...ystem 38 Servicing the FCC 39 Primary Fuel Filter FCC Screw on Canister 40 Primary Fuel Filter FCC Clamp on Canister 41 Servicing Fuel Pre Filter 42 Priming Fuel System 42 Flame Arrestor 42 Accessory...
Page 5: ...Survey We appreciate your feedback and encourage you to ll out the survey after you have had a chance to run your boat for several weeks We take this input very seriously and have implemented many of...
Page 6: ...rings and other material affected by time are not covered by this Warranty if their effectiveness is reduced by an extended storage period prior to sale or use OBTAINING PERFORMANCE UNDER WARRANTY PCM...
Page 7: ...diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Select emission control parts from Model Years 2003 2008 inboard engines are warranted for 2 years OWNER S WARRANTY RESPONSIBILITIES As the...
Page 8: ...asurecraft warranty station The repair or replacement will be per formed at no charge to the owner Any such part repaired or replaced under this Warranty will be warranted for the remainder of the two...
Page 9: ...gible for coverage under this Warranty may be excluded from such warranty coverage if Pleasurecraft demonstrates that the engine and or part has been abused neglected or improperly maintained and that...
Page 10: ...8 L510010 06 This Page Was Intentionally Left Blank INTRODUCTION 1...
Page 11: ...proved could cause a re or explosion hazard and should be avoided Always request that genuine PCM Engines replacement parts be used in any repairs or maintenance being performed on your engine s DANGE...
Page 12: ...on reveals possible leaks DO NOT operate your engine s until it can be serviced by a quali ed technician Proper and adequate air circulation around and throughout the boat is absolutely necessary to a...
Page 13: ...seas whenever possible Follow the Rules of the Road when boating Always be on the alert and watch out for the other guy Plan and chart your course Be aware of and avoid hazardous areas Be sure your bo...
Page 14: ...the boat that are designed for that purpose If water is rough carry fewer passengers Observe the Rules of the Road PORT Left Leaving the harbor with green buoys to your right STARBOARD Right Entering...
Page 15: ...LITTLE MOUNTAIN SC 29075 1 ENGINE SPECIFICATION DECAL 2 ENGINE IDENTIFICATION DECAL 3 TRANSMISSION IDENTIFICATION PLATE 3 2 2 1 OIL TYPE DEXRON III HIGHWAY 76 EAST LITTLE MOUNTAIN S C 29075 SERIAL No...
Page 16: ...pace MANUFACTURING CODE 3rd 5th Space ENGINE CODE 810 8 1L 496 CID MPI GM 811 8 1L 496 CID H O MPI GM 600 6 0L 364 CID MPI GM 570 5 7L 350 CID LH MPI GM 571 5 7L 350 CID RH MPI GM 572 5 7L 350 CID LH...
Page 17: ...sor Knock Sensor KS System Crankshaft Positioning CKP Sensor Camshaft Positioning CMP Sensor Intake Air Temperature IAT Sensor POWER REDUCTION MODE The ECM monitors engine oil pressure and engine cool...
Page 18: ...ivery OPERATING INSTRUCTIONS 5 ELECTRONIC SPEED CONTROL IF EQUIPPED This engine is equipped with a Digital Throttle Control DTC system The system uses a throttle cable connected between the throttle h...
Page 19: ...ions per minute 2 Engine Synchronizer twin engines only 3 Water Temperature Gauge indicates the engine coolant temperature 4 Oil Pressure Gauge indicates the engine oil pressure 5 Voltmeter indicates...
Page 20: ...a 100 open position Figure 5 1 At this throttle position the ECM will command the injectors to deliver no fuel during engine cranking When the engine starts return the throttle lever back to the idle...
Page 21: ...the engine is operating within the normal temperature range If the temperature is abnormally high stop the engine immediately and determine the cause SHIFTING TRANSMISSION CAUTION Never shift the tra...
Page 22: ...valve 3 Close the seacock 4 Flush the cooling system if in a salt water area OPERATING INSTRUCTIONS 5 FREEZING TEMPERATURE OPERATION If the possibility of freezing exists the cooling system must be pr...
Page 23: ...cruising running against a choppy wave condition acceleration onto plane and operating at slow planing speeds Will improve rough water ride and handling In extreme may cause the boat to bow steer veer...
Page 24: ...iscellaneous gear is one of the major factors and should be one of the primary considerations when selecting a propeller Other factors to take into consideration are as follows Warmer weather and high...
Page 25: ...complete safety CAUTION DO NOT operate at full throttle in neutral at any time or at sustained full throttle during the rst 5 hours of operation Thereafter use sustained wide open throttle in the even...
Page 26: ...ottle and the shift cable adjustments and check for freedom of movement Cooling System Inspect all the hoses for leaks damage and deterioration Check all the hose clamps for adequate tightness Exhaust...
Page 27: ...recommended for use in your engine Gasoline containing alcohol will attract and hold moisture and may cause the following Hard starting and operating dif culties vapor lock low speed stalling Corrosio...
Page 28: ...rious ambient temperature ranges Prevailing Ambient Recommended A P I Temperature Classi cation Viscosity Above 50 F SAE 15W 40 SM Below 50 F SAE 5W 30 SM IMPORTANT The use of oils which contain solid...
Page 29: ...il pressure and may result in internal engine damage from lack of lubrication 1 Stop the engine if running Allow approximately 5 minutes for the oil to drain back into the oil pan 2 Remove the dipstic...
Page 30: ...Remove the dipstick and check the uid level The dipstick should read FULL 5 If the uid level is low add in small increments until the FULL mark is reached 6 It is normal after the engine is turned OF...
Page 31: ...e Maintenacne Free Inspect uid level after the rst 25 hours of use and annually thereafter Fluid should only be changed if evidence of contamination is present Use Mobiltrans SHC 50 synthetic transmis...
Page 32: ...ECM and fuel injectors The fuse block is mounted to a bracket near the exhaust elbow under a weather tight cover Figure 11 5 Typical Electrical System Circuit Breaker and Fuses IGNITION FUSE If the en...
Page 33: ...engine with an open in the battery circuit as this may cause damage to the alternator Make sure that all connections are clean and secure When removing the battery cables always remove the negative ca...
Page 34: ...gone replace with a new zinc anode Different geographic locations and water make up can result in either high or low sacri cial requirements A high rate of zinc anode consumption should also alert th...
Page 35: ...e severe burns Degas Bottle The see through degas bottle is connected to the heat exchanger by a small hose The degas bottle collects coolant that expands with rising temperature and would otherwise o...
Page 36: ...hose CAUTION Do not operate the engine without suf cient amount of water being supplied to the sea water pump The sea water pump impeller may be damaged and subsequent overheating damage may result F...
Page 37: ...ter cooling system Drain plug on oil cooler Drain plug on heat exchanger Drain plug on the bottom of each exhaust manifold 3 After system has drained completely coat all the drain plugs with PerfectSe...
Page 38: ...contamination occurs the cooling system must be immediately drained and ushed and re lled with DEX COOL No short term damage will occur however the service interval will be reduced from 5 years to 2 y...
Page 39: ...repair facility 1 Remove the bolts securing the heat exchanger end plates Remove the end plates and gaskets 2 Clean the water passages in the heat exchanger by inserting a suitable size wire brush in...
Page 40: ...o provide an uninterrupted ow of fuel to your PCM marine engine Fuel is fed into the FCC bowl by a low pressure high volume electric fuel pump This pump ows fuel at a volume much greater than the fuel...
Page 41: ...the fuel Replace the lter element at least once a year or when a loss of power is noticed whichever occurs rst WARNING Improper use installation or servicing may cause an explosion or re resulting in...
Page 42: ...the fuel pump with one hand and pulling the lter element downward with the other hand 6 Push on new lter element part number RP080026 over the electric fuel pump 7 Using a pick made of soft material s...
Page 43: ...nternal components i e hoses wires etc 7 Push on new lter element part number RP080026 over the electric fuel pump 8 Using a pick made of soft material such as a toothpick remove the old O rings from...
Page 44: ...ncy of replacing the lter element is determined by the contamination level of the fuel Replace the lter element at least once a year or when a loss of power is noticed whichever occurs rst WARNING Imp...
Page 45: ...0 are access holes in order to loosen the raw water pump attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal Torque the raw water pump housing attaching b...
Page 46: ...al 4 Compress the belt tensioner and slide the belt over the tensioner pulley Release the tension slowly to tension the belt SERVICING RAW WATER PUMP IMPELLER 5 0 5 7L 5 0 5 7L IMPELLER KIT RP061022 T...
Page 47: ...adapter DO NOT remove this adapter when changing the oil 1 With the engine at normal operating temperature locate the oil pan quick drain hose and thread the hose through the boat s drain plug hole Fi...
Page 48: ...ft in the middle of the shaft log align the engine to the shaft ENGINE MAINTENANCE 11 IMPORTANT For PCM Power Plus and Walters V Drive applications adjust the engine and transmission mounts to achieve...
Page 49: ...e 11 26 Figure 11 25 Shaft Mating Surface Check OFFSET MISALIGNMENT ANGULAR MISALIGNMENT PERFECT ALIGNMENT COUPLING FACES ARE PARALLEL WITH DISTANCE BETWEEN FACES EXACTLY THE SAME AT ALL POINTS Figure...
Page 50: ...a suf cient amount of the trunnion must remain in the mount to be secured by the trunnion locking bolt Figure 11 30 Angular Alignment STRAIGHT EDGE TRANSMISSION OUTPUT FLANGE 003 INCH 0 07 mm FEELER G...
Page 51: ...ing nut Turn the adjusting nut or the adjusting bolt in the direction required to raise or lower the engine After the adjustment is complete tighten the locking nut IMPORTANT If a pinch occurs in the...
Page 52: ...50 L510010 06 ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Date Maintenance Repair Hours...
Page 53: ...mpeller X X Drive Belt Inspect condition and check tension X X X Exhaust System Check condition and tightness of all hose clamps X X1 X Exhaust System Check for water leaks at the manifold riser and e...
Page 54: ...a water section After use each day X Notes X Denotes service to be performed by the owner operator O Denotes service to be performed by an authorized PCM Engines dealer A Use SAE 30 engine oil B All P...
Page 55: ...PCM Power Plus V Drive All Ratios 1 2 1 5 Quarts 1 42 L SHC 50 synthetic Walters RV 36D V Drive 1 5 Quarts 1 42 L SAE 30 1 Capacities are dependent on installation angle Oil capacities are approximate...
Page 56: ...54 L510010 06 ENGINE MAINTENANCE 11 FILTER REQUIREMENTS Description Part No Oil Filter remote mounted R077001 Fuel Pre Filter Element RP077014 Fuel Control Cell FCC Fuel Filter Element RP080026...
Page 57: ...72 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1 8 4 3...
Page 58: ...Over Temperature Gen Warning 1 Gen Warning 1 Gen Warning 1 Switch Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp Optional Power Reduction Power Reduction Power Reduction Low Oil 10 psi 10 psi 10 psi...
Page 59: ...G ORDER 1 8 7 2 6 5 4 3 FLYWHEEL END OF ENGINE ALL V 8 MODELS 1 7 c 6 4 2 8 3 5 Rotation TUNE UP SPECIFICATIONS Model MP 5 0L 275 HP MP 5 7L 330 HP MP 6 0L 375 HP Spark Plug Type R030010 R030011 Spark...
Page 60: ...solution and spray a suf cient amount into each cylinder Spray 5 seconds per cylinder minimum Turn the crankshaft several revolutions by hand to spread the oil evenly throughout the cylinders NOTE If...
Page 61: ...NANCE If inspection proves the impeller to be in good condition store it in an accessible spot for re installation at the end of the storage period A damaged or badly worn impeller should be discarded...
Page 62: ...e drain plug 2 Remove the hose from the inlet side of the sea water pump 3 Remove the hose from the outlet side of the sea water pump NOTICE It may be necessary to bend or lift the hoses to allow wate...
Page 63: ...CAUTION If the engine s is are to be started prior to launching use the procedure FLUSHING COOLING SYSTEM before proceeding to start the engine s 14 Open the seacock before starting the engine 15 Star...
Page 64: ...he battery cables and connections starter circuit wiring Clean and tighten all connections Repair or replace the damaged wiring Dead Battery Recharge test and replace as necessary Engine Cranks will n...
Page 65: ...cooling system for leaks equipped with Fresh Water section of the cooling system Re ll the system See Warning Cooling FWC systems before removing the ll cap Heat exchanger passages plugged Clean and...
Page 66: ...Have fuel pump replaced by a PCM Engines Dealer Plugged or kinked fuel lines or Repair or replace the fuel lines fuel tank vent Remove obstruction Anti siphon valve faulty Clean or replace as necessa...
Page 67: ...t IMPORTANT Accessory i e heater hot water tank Hook Up Location 1 Water OUT to heater or hot water tank T Fitting required at temp sender location Location 2 Water RETURN from heater or hot water tan...
Page 68: ...FLOW FRESH WATER FLOW Drain Locations 1 2 2 IMPORTANT Accessory i e heater hot water tank Hook Up Location 1 Water OUT to heater or hot water tank T Fitting required at temp sender location Location...
Page 69: ...accessories i e heaters hot water tanks at this location IMPORTANT Accessory i e heater hot water tank Hook Up A tee may be inserted anywhere in the specified hose for most appropriate routing Locatio...
Page 70: ...in kit does not ensure that all of the water will drain out of the system Engine angle routing of drain hose and restricted drain fittings are some things that could prevent all of the water from drai...
Page 71: ...CUIT ENGINE HARNESS NUMBER NAME WIRE COLOR A TACHOMETER GRAY B VAR GOVERNOR YELLOW C STATUS LAMP WHITE RED D CRUISE REQUEST WHITE ORANGE E F TCP SENSOR BLACK GRAY G H J K PERFECT PASS GROUND BLACK A B...
Page 72: ...reassembly instructions Troubleshooting and maintenance charts are also included 2 PARTS Parts manuals with exploded views for service parts are available for all current engine models IMPORTANT When...
Page 73: ...re designed to insure safety and satisfaction A step by step procedure for pre delivery can be found in Course 1 of the PCM E Train Program Therefore we require the following inspection be performed a...
Page 74: ...ed by Ford Power Products PCM OWNERSHIP CHANGE NOTICE If you are the new owner of a Pleasurecraft Marine Engine on which the warranty has expired and would like to inform Pleasurecraft of your ownersh...
Page 75: ...LOG Engine Port Drive Port Ignition Key Port Model and Serial Stbd Serial Stbd Number Stbd Fire Extinguisher Checked Batteries Tested Gal of Qts of Oil Oil Check Lay Up Launch Runs Made Date Fuel Port...
Page 76: ...s form to Pleasurecraft Marine PO Drawer 369 Little Mountain SC 29075 Engine Model Engine Serial Number Gear Serial Number Owner Information Name Telephone Address City State Zip Selling Dealer Dealer...
Page 77: ...75 L510010 06 NOTES 19...
Page 78: ...Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075...
