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PCM 2008 Catanium CES 6.0L ZR-409, Owner'S Operation And Maintenance Manual

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PCM 2008 Catanium CES 6.0L ZR-409 Owner'S Operation And Maintenance Manual Download Page 6

2

L510010-11

Electrical System Relay and Fuse Block 

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32

Electrical System Fuses 

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32

Boat’s Ignition Fuse 

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32

Electrical System Wiring and Connectors 

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32

Battery 

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32

Fresh Water Cooling System Sacri

fi

 cial Zinc Anode 

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33

Checking Coolant Level 

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34

Flushing Cooling System - Sea-Water Section 

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34

Testing Coolant For Alkalinity 

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34

Draining Fresh-Water Cooling System 

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35

Filling Fresh-Water Cooling System 

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36

Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) 

....................... 

39

Fuel System Description 

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40

Fuel Control Cell (FCC) Fuel System 

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40

Servicing the FCC 

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41

Primary Fuel Filter (FCC Clamp-on Canister) 

............................................................................. 

41-42

Servicing Fuel Pre-Filter 

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43

Priming Fuel System 

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43

Flame Arrestor 

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44

Accessory Drive Belt 

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44-45

Servicing Raw Water Pump Impeller 

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45

Changing Oils 

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46

Engine Alignment 

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47-50

Engine Maintenance Log 

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51

Maintenance Schedule 

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52-53

Visual Inspection 

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54

Engine Fluid Capacities 

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54

Transmission Fluid Capacities 

..................................................................................................... 

54

Filter and Accessory Requirements 

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55

ENGINE SPECIFICATIONS

 

................................................................................................... 

56-58

OUT-OF-SEASON STORAGE

 

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59-61

Engine Storage 

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59

Draining Instructions 

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60

Battery Storage 

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60

Recommissioning After Storage 

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61

TROUBLESHOOTING

 

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62-64

RAW WATER FLOW DIAGRAMS

 

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65-76

HEATER CONNECTIONS

 

..................................................................................................... 

77-78

INSTRUMENTATION WIRING DIAGRAM

 

..................................................................................... 

79

LITERATURE

 

.......................................................................................................................... 

80

FORMS

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81-84

NOTES

 

................................................................................................................................... 

85

WARRANTY/REGISTRATION CARD

 

.

TABLE OF CONTENTS

Summary of Contents for 2008 Catanium CES 6.0L ZR-409

Page 1: ...OWNER S OPERATION and MAINTENANCE MANUAL A Division of...

Page 2: ...This Page Was Intentionally Left Blank...

Page 3: ...n technology for added performance and durability READ THIS MANUAL THOROUGHLY Before starting your engine s READ THIS MANUAL CAREFULLY AND COMPLETELY If you do not understand any portion of the manual...

Page 4: ...t Number L510010 11 Printed 04 11 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm PROPOSITION...

Page 5: ...Advisory 14 ELECTRONIC FUEL INJECTION INFORMATION 15 Electronic Fuel Injection System 15 OPERATING INSTRUCTIONS 16 22 Engine Alarm System 16 Instrumentation 17 Electronic Speed Control 17 Starting Eng...

Page 6: ...ing the FCC 41 Primary Fuel Filter FCC Clamp on Canister 41 42 Servicing Fuel Pre Filter 43 Priming Fuel System 43 Flame Arrestor 44 Accessory Drive Belt 44 45 Servicing Raw Water Pump Impeller 45 Cha...

Page 7: ...Survey We appreciate your feedback and encourage you to fill 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 o...

Page 8: ...s O 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...

Page 9: ...nes manufactured after January 1 2008 for CARB and after January 1 2011 for EPA are warranted for 3 years or 480 hours whichever first occurs However warranty coverage based on the hourly period is on...

Page 10: ...the period of warranty coverage Pleasurecraft will repair or replace the defective part at any Pleasurecraft warranty station The repair or replacement will be performed at no charge to the owner Any...

Page 11: ...perly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part 11 Pleasurecraft original equipment parts are identical in a...

Page 12: ...8 L510010 11 This Page Was Intentionally Left Blank INTRODUCTION 1...

Page 13: ...oved could cause a fire 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 14: ...n reveals possible leaks DO NOT operate your engine s until it can be serviced by a qualified technician Proper and adequate air circulation around and throughout the boat is absolutely necessary to a...

Page 15: ...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 boat is...

Page 16: ...he 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 t...

Page 17: ...29075 SERIAL No MODEL MARINE POWER RATIO CHECK OIL LEVEL DAILY OIL CHANGE AFTER FIRST 25 HOURS OF OPERATION AND EVERY 100 HOURS OR 12 MONTHS WHICHEVER OCCURS FIRST IMPORTANT NOTE WARRANTY IS VOID IF M...

Page 18: ...ATES DECADE ENGINE WAS MANUFACTURED 3 1990 4 2000 5 2010 2nd DIGIT INDICATES CALENDAR YEAR ENGINE WAS MANUFACTURED 1st 2nd Space MANUFACTURING CODE 3rd 5th Space ENGINE CODE 502 HO303 570 EX343 602 ZR...

Page 19: ...e ECM monitors are Engine Coolant Temperature ECT Sensor Throttle Position TP Sensor Manifold Absolute Pressure MAP Sensor Knock Sensor KS System Crankshaft Positioning CKP Sensor Camshaft Positioning...

Page 20: ...ontinuously as an audible warning For emissions related faults MIL the buzzer will initially sound for 5 seconds then will sound for 1 2 second ON once per minute thereafter In the event of a MIL circ...

Page 21: ...eed control system for skiing wake boarding or cruise control When the boat is operated in a speed control mode the operator may not have full control of the throttle until the speed control system is...

Page 22: ...structions on throttle shift lever operation Battery connections and water level in battery cells Accessory drive belt s Cooling system for leaks If equipped with fresh water cooling check coolant lev...

Page 23: ...hin the normal temperature range If the temperature is abnormally high stop the engine immediately and determine the cause SHIFTING TRANSMISSION CAUTION Never shift the transmission into or out of gea...

Page 24: ...lose the fuel 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 sys...

Page 25: ...o ramp the speed up to throttle handle position and turn on the MIL Pull the throttle handle back and exit MPH Cruise Mode RPM Cruise Mode is not affected by the loss of the paddle wheel input With th...

Page 26: ...EXITING CRUISE MODE 1 Press the MPH RPM switch to OFF 2 The Cruise Lamp will go OFF Cruise mode will remain engaged until the operator pulls the throttle handle back below the set point IMPORTANT It...

Page 27: ...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 28: ...r factors to take into consideration are as follows Warmer weather and higher humidity will cause an RPM loss Operating the boat in a higher elevation will cause an RPM loss Operating the boat with an...

Page 29: ...mplete safety CAUTION DO NOT operate at full throttle in neutral at any time or at sustained full throttle during the first 5 hours of operation Thereafter use sustained wide open throttle in the even...

Page 30: ...ck the throttle 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 tightne...

Page 31: ...10 or less is used or if the presence of alcohol is uncertain more frequent inspections and service of the complete fuel system are required Any sign of fuel leakage or deterioration must be repaired...

Page 32: ...Classification Viscosity Above 50 F SAE 15W 40 GF 4 SM Below 50 F SAE 5W 30 GF 4 SM IMPORTANT The use of oils which contain solid additives non detergent oils or low quality oils specifically are not...

Page 33: ...nning Allow approximately 5 minutes for the oil to drain back into the oil pan 2 Remove the dipstick wipe it clean and reinstall it until it is within two 2 inches of being fully seated Slowly move th...

Page 34: ...e dipstick and check the fluid level The dipstick should read FULL 5 If the fluid level is low add in small increments until the FULL mark is reached 6 It is normal after the engine is turned OFF for...

Page 35: ...hanged if evidence of contamination is present Use Mobiltrans SHC 50 synthetic transmission lubricant PCM P N R190250 1 Remove the drain fill dipstick plug from the transmission Wipe the dipstick clea...

Page 36: ...SE If the engine will not crank when the ignition key is turned to the START position first check that the shift lever is in the neutral position and the safety lanyard if equipped is attached properl...

Page 37: ...electronics installed in your boat If you add other electrical components or accessories you could change the way the fuel injection controls your engine or the overall electrical system functions Bef...

Page 38: ...et hose CAUTION Do not operate the engine without sufficient amount of water being supplied to the sea water pump The sea water pump impeller may be damaged and subsequent overheating damage may resul...

Page 39: ...for proper locations Remove the following drain plugs hoses in order to drain the coolant from the fresh water portion of the cooling system HO303 EX343 Half System A Fresh Water drain plug from heat...

Page 40: ...ween coolants If contamination occurs the cooling system must be immediately drained and flushed and refilled with DEX COOL No short term damage will occur however the service interval will be reduced...

Page 41: ...valves and plug hoses to prevent leakage 2 First raise the degas bottle from the lower or running location to the upper or filling location of the bracket If the bottle can be held higher than that f...

Page 42: ...Note Make sure the drain hose is uncoiled and flowing freely Note A plug may have to be removed from the end of the drain hose 4 Add 50 50 mixture of Dexcool or equivalent to the degas bottle Keep ad...

Page 43: ...s on the end plates and the heat exchanger Apply PerfectSeal to both sides of the new gaskets Install the end plates and the new gaskets onto the heat exchanger Install the bolts and tighten securely...

Page 44: ...me much greater than the fuel flow rate required of the high pressure pump and engine demands The high pressure pump mounted inside the FCC bowl provides the necessary fuel pressure and volume to main...

Page 45: ...vel of the fuel Replace the filter element at least once a year or when a loss of power is noticed whichever occurs first WARNING Improper use installation or servicing may cause an explosion or fire...

Page 46: ...one side in order to remove 6 Remove the fuel filter element from the suspended pump by gripping the fuel pump with one hand and pulling the filter element downward with the other hand 7 Visually ins...

Page 47: ...ng clamps securely 5 Start the engine and inspect for fuel leaks Correct any leaks prior to operating the engine any further 15 Reconnect the fuel supply line to the LPFP 16 Reconnect the two wire ele...

Page 48: ...causing damage to the tensioner 3 Slide the new belt onto the pulleys using the same routing as noted prior to removal 4 Compress the belt tensioner and slide the belt over the tensioner pulley Releas...

Page 49: ...occurs first See Maintenance Schedule Locations A Figures 11 17 11 19 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 f...

Page 50: ...and insert the discharge hose into a suitable container Allow the oil from the engine to drain until the crankcase is empty Reinstall the cap onto the quick drain hose and pull the hose back through t...

Page 51: ...nts to achieve alignment The Transmission mounts are for support only and are not used to achieve proper alignment PLEASURECRAFT ENGINEGROUP POWER PLUS RATIO 1 48 MADEINUSA V DRIVE ALIGNMENT The Trans...

Page 52: ...haft Mating Surface Check OFFSET MISALIGNMENT ANGULAR MISALIGNMENT PERFECT ALIGNMENT COUPLING FACES ARE PARALLEL WITH DISTANCE BETWEEN FACES EXACTLY THE SAME AT ALL POINTS Figure 11 27 Angular Alignme...

Page 53: ...sufficient amount of the trunnion must remain in the mount to be secured by the trunnion locking bolt Figure 11 31 Angular Alignment STRAIGHT EDGE TRANSMISSION OUTPUT FLANGE 003 INCH 0 07 mm FEELER G...

Page 54: ...ting 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 A quadrant Figure 11 3...

Page 55: ...51 L510010 11 ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Date Maintenance Repair Hours...

Page 56: ...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 elbow gaskets X Ignition...

Page 57: ...he owner operator O Denotes service to be performed by an authorized PCM Engines Premier dealer A Use SAE 30 engine oil B All PCM Velvet Drive and Hurth transmissions Use Dexron III automatic transmis...

Page 58: ...transmission cooler and oil lines Refer to the Checking Fluid Levels instructions page 29 and Changing Oils instructions page 46 of this manual for complete instructions important notes and Cautions f...

Page 59: ...ICANT Description Part No PCM Power Plus V Drive Lubricant 1 qt bottle R190250 PN R080024A IN OUT RP080026 Fuel Water Separating Filter Element Part Number R077019 Manufacture Date 10 03 09 Tested To...

Page 60: ...a 172 552 kPa Minimum Oil Pressure 5 psi 35 kPa 5 psi 35 kPa 5 psi 35 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 040 in Firing Order 1 8 4 3...

Page 61: ...Buzzer and Buzzer and Buzzer and Buzzer Engine Derates Engine Derates Engine Derates Engine Derates Engine Derates Engine Derates Exhaust Manifold 240 F 240 F 240 F Water Temperature Not Not Not DTC 1...

Page 62: ...3 FLYWHEEL END OF ENGINE ALL V 8 MODELS 1 7 c 6 4 2 8 3 5 Rotation TUNE UP SPECIFICATIONS Model ALL HO303 ALL ZR409 ALL EX343 ALL ZR450 Spark Plug Type R030010 R030011 Spark Plug Gap 0 060 in 0 040 in...

Page 63: ...ine compartment is well ventilated to prevent a potential fire hazard 2 Remove empty and clean the fuel filter assembly Reinstall with a new fuel filter and gasket seals Refer to Engine Maintenance fo...

Page 64: ...drain completely 2 Remove the raw water pump impeller See ENGINE MAINTENANCE If inspection proves the impeller to be in good condition store it in an accessible spot for re installation at the end of...

Page 65: ...vapors sparks or open flame 3 Install the fully charged battery Be sure that all the connections are clean and free from corrosion Coat the battery terminal connections with an anti corrosion battery...

Page 66: ...rcuit wiring Clean and tighten all connections Repair or replace the damaged wiring Dead Battery Recharge test and replace as necessary Engine Cranks will not Improper starting procedure Refer to STAR...

Page 67: ...ing system for leaks equipped with Fresh Water section of the cooling system Refill the system See Warning Cooling FWC systems before removing the fill cap Heat exchanger passages plugged Clean and fl...

Page 68: ...eplaced 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 necessary Flame arrestor...

Page 69: ...or shape of the hoses may vary slightly depending on installation 1 1 1 2 2 3 3 3 4 4 Drain Locations Engine Block Drains Remove Knock Sensors Engine Circulating Water Pump Pipe Remove Drain Plug Exh...

Page 70: ...n PLEASURECRAFT ENGINE GROUP POWER PLUS RATIO 1 48 MADE IN USA Raw Water Drain Plug 1 2 Square PCM V Drive 1 1 1 2 3 3 3 4 4 5 5 5 Drain Locations Engine Block Drains Remove Knock Sensors Engine Circu...

Page 71: ...s diagram is for illustration purposes only The actual routing and or shape of the hoses may vary slightly depending on installation 1 1 2 2 2 3 3 Drain Locations Heat Exchanger Remove Drain Plug Exha...

Page 72: ...shape of the hoses may vary slightly depending on installation PLEASURECRAFT ENGINE GROUP POWER PLUS RATIO 1 48 MADE IN USA Raw Water Drain Plug 1 2 Square PCM V Drive 1 2 2 3 4 4 1 2 3 4 Drain Locati...

Page 73: ...and or shape of the hoses may vary slightly depending on installation 1 1 1 2 2 3 3 3 4 4 5 5 5 Drain Locations Engine Block Drains Remove Knock Sensors Engine Circulating Water Pump Pipe Remove Drai...

Page 74: ...n PLEASURECRAFT ENGINE GROUP POWER PLUS RATIO 1 48 MADE IN USA Raw Water Drain Plug 1 2 Square PCM V Drive 1 1 1 2 2 3 3 3 4 4 5 5 5 6 6 6 Drain Locations Engine Block Drains Remove Knock Sensors Engi...

Page 75: ...gram is for illustration purposes only The actual routing and or shape of the hoses may vary slightly depending on installation 1 1 2 2 3 4 4 4 3 Drain Locations Transmission Cooler Remove Inlet Hose...

Page 76: ...2 Square PCM V Drive Note This diagram is for illustration purposes only The actual routing and or shape of the hoses may vary slightly depending on installation 1 2 2 3 3 4 4 4 5 5 5 Drain Locations...

Page 77: ...purposes only The actual routing and or shape of the hoses may vary slightly depending on installation Raw Water Drain Zinc Anode Shaft Seal Fitting Fresh Water Drain 1 2 2 3 3 Drain Locations Transmi...

Page 78: ...Water Drain Plug 1 2 Square PCM V Drive Note This diagram is for illustration purposes only The actual routing and or shape of the hoses may vary slightly depending on installation 1 2 2 3 3 4 4 4 Dra...

Page 79: ...Water Pump Remove Outlet Hose Heat Exchanger Remove Drain Plug Zinc Anode Exhaust Manifolds Remove Hose Exhaust Corners Remove Drain Plugs Raw Water Drain Zinc Anode Fresh Water Drain Shaft Seal Fitt...

Page 80: ...c Anode Shaft Seal Fitting 4 4 5 5 1 2 3 4 5 6 Drain Locations Transmission Oil Cooler Remove Inlet Hose Raw Water Pump Remove Outlet Hose Heat Exchanger Remove Drain Plug Zinc Anode Exhaust Manifolds...

Page 81: ...ove plug from intake manifold and install proper barbed fitting The plug is located toward the front of the intake belt end on the even cylinder side WATER RETURN Remove plug from circulation pump and...

Page 82: ...fitting is located in the hose above the heat exchanger on both CES and non catalyst engines WATER RETURN Remove plug from supplied ball valve fitting and install proper barbed fitting The fitting is...

Page 83: ...EMP TAN 4 BUZZER TAN BLACK 5 IGNITION PURPLE 6 MIL GREEN YELLOW 7 STARTER YELLOW RED 8 OIL PRESSURE DARK BLUE 8 PIN WIRE HARNESS COLOR CHART CES ENGINES ONLY NOTE The MIL or Malfunction Indicator Lamp...

Page 84: ...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 85: ...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 at...

Page 86: ...ent purchaser provided the engine does not have in excess of 300 hours and is submitted to PCM within 30 days of the date of sale PCM OWNERSHIP CHANGE NOTICE If you are the new owner of a Pleasurecraf...

Page 87: ...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 88: ...is 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 Deale...

Page 89: ...85 L510010 11 NOTES 20...

Page 90: ...iod prior to sale or use OBTAINING PERFORMANCE UNDER WARRANTY PCM s warranty registration form should be prepared by your selling dealer executed by you and the dealer and mailed by you to PCM within...

Page 91: ...From MAIL TO WARRANTY DEPARTMENT PLEASURECRAFT ENGINE GROUP P O DRAWER 369 LITTLE MOUNTAIN SC 29075 FIRST CLASS POSTAGE...

Page 92: ...This Page Was Intentionally Left Blank...

Page 93: ...Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075...

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