PCM DI Catanium CES Owner'S Operation And Maintenance Manual Download Page 6

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L510010D-17

Electrical System Relay and Fuse Block

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Electrical System Fuses

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Boat’s Ignition Fuse

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Electrical System Wiring and Connectors

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Battery

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Cooling System Sacrificial Anode

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Checking Coolant Level

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Testing Coolant For Alkalinity

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Flushing Cooling System - Sea-Water Section

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Draining Fresh-Water Cooling System

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Inspect and Clean Exhaust System Cooling Thermostat

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

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Fuel System Description

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Fuel Control Cell (FCC) Fuel System

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Servicing the FCC

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Primary Fuel Filter (FCC Clamp-on Canister)

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33-34

Servicing Fuel Pre-Filter

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Priming Fuel System

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Flame Arrestor

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Accessory Drive Belt

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Servicing Raw Water Pump Impeller

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Changing Oils

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Engine Alignment

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38-41

Engine Maintenance Log

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Maintenance Schedule

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43-44

Visual Inspection

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Engine Fluid Capacities

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Transmission Fluid Capacities

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Filter and Accessory Requirements

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ENGINE SPECIFICATIONS

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47-48

OUT-OF-SEASON STORAGE

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49-51

Engine Storage

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Draining Instructions

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Battery Storage

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Recommissioning After Storage

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TROUBLESHOOTING

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52-54

RAW WATER DRAINING LOCATIONS

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55-56

HEATER CONNECTIONS

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INSTRUMENTATION WIRING DIAGRAM

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LITERATURE

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FORMS

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

60-61

NOTES

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WARRANTY/REGISTRATION CARD

TABLE OF CONTENTS

Summary of Contents for DI Catanium CES

Page 1: ...OWNER S OPERATION AND MAINTENANCE MANUAL...

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

Page 3: ...latest in modern 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 porti...

Page 4: ...Part Number L510010D 17 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 65...

Page 5: ...14 Owner Identification and Registration Information 14 ELECTRONIC FUEL INJECTION INFORMATION 15 Electronic Fuel Injection System 15 Engine Alarm System 15 OPERATING INSTRUCTIONS 16 18 Instrumentatio...

Page 6: ...cing the FCC 32 Primary Fuel Filter FCC Clamp on Canister 33 34 Servicing Fuel Pre Filter 34 Priming Fuel System 34 Flame Arrestor 34 Accessory Drive Belt 35 Servicing Raw Water Pump Impeller 36 Chang...

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: ...ING 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 30 days after the date of your...

Page 9: ...inboard marine engines manufactured after January 1 2008 for CARB and after January 1 2011 for USEPA are warranted for 3 years or 480 hours of use whichever first occurs However warranty coverage base...

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

Page 11: ...neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part 11 PCM original equipment parts are identi...

Page 12: ...8 L510010D 17 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: ...ever 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 equ...

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: ...ECAL 2 ENGINE IDENTIFICATION DECAL 3 TRANSMISSION IDENTIFICATION PLATE 5 3L and 6 2L Direct Injection FUEL RECOMMENDATION Unleaded 87 Octane minimum ENGINE OIL 15W 40 above 50 degrees F See Owners Man...

Page 18: ...jection 625 6 2L Direct Injection 6th 8th Space DRIVE CONFIGURATION blank Direct Drive V V Drive C Catanium Clean Emissions System CES S Coastal Edition 9th 10th Space SPECIFICATION CODE Engine Model...

Page 19: ...f possible engine problems The Check Gauges Lamp CGL is used for notification of any non emissions related fault This is a red indicator lamp to warn the operator of possible engine problems such as l...

Page 20: ...operating the bilge blower for a minimum of five minutes to remove any gas fumes from the engine compartment If the boat is not equipped with a blower open the engine compartment hatches to ventilate...

Page 21: ...l automatically turn over and start The engine will turn over until the engine starts or a maximum of 5 seconds The key switch or stop button can always be utilized in order to cease the engine from c...

Page 22: ...Range 4 Move the transmission lever to the center detent position to shift into Neutral FREEZING TEMPERATURE OPERATION If the possibility of freezing exists the cooling system must be protected after...

Page 23: ...ture engine failure See NORMAL CRUISING SPEEDS in SPECIFICATIONS Problems caused by prolonged WOT operation are considered abuse and are not covered under the PCM Warranty PROPELLER SELECTION Best all...

Page 24: ...complete 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 e...

Page 25: ...ve belt s and check the tension Check all the fluid levels Check the throttle and the shift cable adjustments and check for freedom of movement Cooling System Inspect all the hoses for leaks damage an...

Page 26: ...ated E10 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 rep...

Page 27: ...r low quality oils specifically are not recommended IMPORTANT Dexron III should be used in all applications requiring Dexron III Dexron VI MUST NOT be mixed with Dexron III when servicing Damage cause...

Page 28: ...gine if running 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 Slow...

Page 29: ...dd the specified fluid in small increments through the dipstick hole in the transmission Repeat the checking procedures until the fluid level is at the FULL mark 5 Replace the dipstick and tighten sec...

Page 30: ...s instrumentation wiring and components Should an electrical overload occur the PANEL fuse will open and prevent electrical current flow When this fuse opens the cause for the high current draw must...

Page 31: ...attery care Do not operate the 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 cable...

Page 32: ...ANT LEVEL WARNING Do not remove cooling system filler cap when the engine is hot Allow the engine to cool and then remove the pressure cap slowly allowing the pressure to vent Hot coolant under pressu...

Page 33: ...Plug Figure 11 11 Right Side Engine Block Drain Plug NOTICE In order to drain the raw water portion of the systems refer to WATER DRAIN DIAGRAMS section of this manual for proper locations Remove the...

Page 34: ...e the following procedure for cleaning or if the build up of scale and mineral deposits is heavy it is recommended that the heat exchanger be removed and taken to a repair facility to be boiled out su...

Page 35: ...ands The high pressure pump mounted inside the FCC bowl provides the necessary fuel pressure and volume to maintain proper engine performance The FCC constantly has an ample supply of fuel to meet the...

Page 36: ...tion or bowl O ring swelling may result FCC Fuel Filter FCC Clamp on Canister WARNING Extreme caution must be exercised when servicing the fuel system The fuel system operates under high pressure Use...

Page 37: ...e unit to 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 Vis...

Page 38: ...or to operating the engine any further DO NOT ATTEMPT TO SERVICE ANY OTHER PARTS ON THIS UNIT Filter Element Replacement ENGINE OFF PRIMARY FUEL PRE FILTER R077019 SPIN ON NOTE This filter may be loca...

Page 39: ...should be checked periodically for condition and tension If the belt s shows signs of cracking glazing or deterioration replace with new belt s ACCESSORY DRIVE BELT PCM engines use a single serpentine...

Page 40: ...hat extends to the bottom of the transmission case using a suction vacuum type fluid extractor IMPORTANT Change the engine oil when the engine is warm from operation Warm oil flows more freely and all...

Page 41: ...or remove oil as needed to bring the engine oil to the proper level See CHECKING FLUID LEVELS for Important Notes and Cautions to observe when checking the engine crankcase oil level IF YOU ARE UNSURE...

Page 42: ...middle of the shaft log align the engine to the shaft IMPORTANT For PCM Power Plus V Drive applications adjust the engine and V Drive mounts to achieve alignment The Transmission mounts are for suppor...

Page 43: ...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 44: ...a 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...

Page 45: ...sting 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...

Page 46: ...42 L510010D 17 ENGINE MAINTENANCE 11 ENGINE MAINTENANCE LOG Operating Date Maintenance Repair Hours...

Page 47: ...em Inspect Replace raw water pump impeller 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 wate...

Page 48: ...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 49: ...the Checking Fluid Levels instructions and Changing Oils instructions of this manual for complete instructions important notes and Cautions for checking engine oil levels Always use the dipstick to de...

Page 50: ...080026 Fuel Water Separating Filter Element Part Number R077019 Manufacture Date 10 03 09 Tested To ISO SAE and JIC Standards at 5 PSI WARNING PRESSURIZED GASOLINE FUEL SYSTEM FIRE HAZARD To Replace F...

Page 51: ...i 207 kPa 2000 RPM 30 psi 207 kPa 2000 RPM 33 psi 228 kPa 3000 RPM 33 psi 228 kPa 3000 RPM Spark Plug P N R030013 R030013 Spark Plug Gap 0 040 in 0 040 in Firing Order 1 8 7 2 6 5 4 3 1 8 7 2 6 5 4 3...

Page 52: ...Derates Exhaust Manifold Riser 250 F 258 F Causes engine to go into Power Derate Temperature Sensors DTC 1415 1416 Fresh Water Applications 1417 1418 MIL and Buzzer Engine Derates Low Engine Oil Pres...

Page 53: ...bilge blower and be sure no fuel vapors are present when treating the engine Be sure the engine compartment is well ventilated to prevent a potential fire hazard 2 Remove empty and clean the fuel filt...

Page 54: ...to 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...

Page 55: ...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 56: ...ircuit 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 STA...

Page 57: ...ling 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 f...

Page 58: ...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 necessary Flame arresto...

Page 59: ...ations with 1 spare plug DDrive Applications 8 plug locations with 2 spare plug RAW WATER DRAIN PLUGS A drain plug bracket holder is mounted above the alternator This holder is designed to keep your d...

Page 60: ...1 SPARE 1 RAW WATER DRAIN PLUGS A drain plug bracket holder is mounted above the alternator This holder is designed to keep your drain plugs organized and secure until they need to be reinstalled The...

Page 61: ...aw Water Engines 1 Remove the U shaped hose from the engine circulation pump 2 Connect the heater hose going out to the heater core to the fitting labeled Outlet below 3 Connect the heater hose return...

Page 62: ...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 may be...

Page 63: ...8 To obtain service and or parts information for your PCM Marine Engine contact your servicing or local dealer PCM distributes publications through a worldwide dealer network the same way parts and te...

Page 64: ...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 Por...

Page 65: ...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 66: ...62 L510010D 17 NOTES 20...

Page 67: ...ed by you to PCM within 30 days after the date of your purchase of the product Upon receipt of the warranty registration form PCM will issue to you a personalized owner s registration card which will...

Page 68: ...From MAIL TO WARRANTY DEPARTMENT PLEASURECRAFT ENGINE GROUP P O DRAWER 369 LITTLE MOUNTAIN SC 29075 FIRST CLASS POSTAGE...

Page 69: ...This Page Was Intentionally Left Blank...

Page 70: ...Pleasurecraft Engine Group 1737 Highway 76 East Little Mountain SC 29075...

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