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Section 6 - Troubleshooting

90-8M0128975

eng

JUNE 2017

Page 63

Section 6 - Troubleshooting

Table of Contents

Diagnosing EFI Problems..................................................... 64

Engine Guardian System...................................................... 64

Troubleshooting Charts........................................................ 64

Starter Motor Will Not Crank Engine, or Cranks Slowly

....................................................................................... 64

Engine Will Not Start or Is Hard to Start........................ 64

Engine Runs Rough, Misses, or Backfires.................... 64

Poor Performance..........................................................65

Excessive Engine Temperature..................................... 65

Insufficient Engine Temperature.................................... 65

Low Engine Oil Pressure............................................... 65

Battery Will Not Recharge............................................. 65

Remote Control Is Difficult to Move or Makes Unusual

Sounds...........................................................................66

Steering Wheel Jerks or Is Difficult to Turn................... 66

Содержание 6.2 TowSport MPI

Страница 1: ...T6200 T6200 H O TowSport OPERATION AND MAINTENANCE MANUAL...

Страница 2: ......

Страница 3: ...ial instructions while performing the service plus common sense operation are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result in death or s...

Страница 4: ...the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Copyright and Trademark Information MERCURY MARINE All rights reserved Repr...

Страница 5: ...Operation 16 Operation Chart 16 Starting and Stopping the Engine 16 Starting the Engine 16 Stopping the Engine 17 Throttle Only Operation TowSport Panel Mount 17 Freezing Temperature Operation 18 Dra...

Страница 6: ...48 Section 5 Storage Cold Weather or Extended Storage 54 Reformulated Oxygenated Gasolines U S A Only 54 Fuel Containing Alcohol 54 Preparing Power Package for Storage MPI Models 54 Special Fuel Mix 5...

Страница 7: ...8M0128975 eng JUNE 2017 Page iii Section 8 Checklists Predelivery Inspection PDI 72 Customer Delivery Inspection CDI 73 Section 9 Maintenance Log Scheduled Maintenance Log 76 Vessel Maintenance Notes...

Страница 8: ...Page iv 90 8M0128975 eng JUNE 2017...

Страница 9: ...sselView 4 SmartCraft Digital Instruments 5 System Link Digital Instruments 5 Remote Controls Non DTS Models 6 Remote Control Features Non DTS 6 Gear Shifting 6 Remote Controls DTS Models 7 Remote Con...

Страница 10: ...can focus on the boating experience Identification The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting MerCruis...

Страница 11: ...tch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm as may happen in an accidental ejection The lanyard is connected to the operato...

Страница 12: ...a lanyard Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could...

Страница 13: ...fault codes associated with the engine audio warning system The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display For basic operation in...

Страница 14: ...ion While holding the throttle only button in move the throttle handle forward to assist in starting the engine Lanyard stop switch if equipped The purpose of a lanyard stop switch is to shut down the...

Страница 15: ...e use of this switch Control handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick firm motion to th...

Страница 16: ...control operation The hand throttle on and off switch kit with the foot throttle can also be used with the TowSport panel mount control Throttle only operation The throttle only operation allows engin...

Страница 17: ...engine wiring harness and the instrumentation power lead 63787 All of the engine protection fuses are located at the front of the engine To access the fuses disengage the fuse holders from the electr...

Страница 18: ...p relay fuse g Ignition coil fuse h Malfunction indicator lamp MIL fuse A 90 amp fuse located near the flame arrestor protects the engine power harness if an electrical overload occurs The fuse is tra...

Страница 19: ...ngine light and a special harness that connects to the engine harness may be purchased separately The service engine icon or MIL will provide a visual indication of a malfunction with the engine s emi...

Страница 20: ...ategy The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem Below are some examples of what Engine Guardian...

Страница 21: ...eezing Temperature Operation 18 Drain Plug and Bilge Pump 18 Protecting People in the Water 18 While You Are Cruising 18 While Boat Is Stationary 18 High Speed and High Performance Operation 18 Passen...

Страница 22: ...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...

Страница 23: ...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 combustion engines including the eng...

Страница 24: ...ing and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat Operation Chart Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Install bilge drain plug...

Страница 25: ...to the ON position 7 Inspect the power package for fuel oil water and exhaust leaks 8 Move the control handle with a firm quick motion forward to shift to forward gear or backward to shift to reverse...

Страница 26: ...le in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction even at slow speeds 21604 Always slow down and exe...

Страница 27: ...ling over the front of the boat mc79557 1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake...

Страница 28: ...n forward or even out of the boat The underwater drive components rudder or boat could sustain impact damage After striking a submerged object stop the engine as soon as possible and inspect the drive...

Страница 29: ...ormance under changing 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 du...

Страница 30: ...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...

Страница 31: ...tents Fuel Requirements 24 Fuel Ratings 24 Using Reformulated Oxygenated Gasoline USA Only 24 Gasoline Containing Alcohol 24 Bu16 Butanol Fuel Blends 24 Methanol and Ethanol Fuel Blends 24 Engine Oil...

Страница 32: ...ct your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasoline containing methanol or ethanol may cause increase...

Страница 33: ...ting 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 Compa...

Страница 34: ...eries to different standards MCA CCA Ah and reserve capacity RC are the ratings recognized by Mercury Marine Manufacturers that use standards different than these such as equivalent MCA do not meet Me...

Страница 35: ...hecking 33 Filling 34 Changing 35 Transmission Fluid 35 Checking the Fluid Level Before Operation 35 Checking the Fluid Level When Hot 36 Changing 36 Transmission Anodes 45IV and 46IV 36 Transmission...

Страница 36: ...display lens while cleaning When water marks cannot be removed with a damp cloth mix a 50 50 solution of warm water and isopropyl alcohol to clean the display lens Do not use acetone mineral spirits t...

Страница 37: ...diately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to reques...

Страница 38: ...se clamps for tightness Inspect for damage or leaks dealer item Inspect and clean seawater side of closed cooling system if equipped dealer item Clean inspect and test the closed cooling pressure cap...

Страница 39: ...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...

Страница 40: ...Models 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 Remov...

Страница 41: ...he 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 top of the OK range All Models Capacity Fluid Type Eng...

Страница 42: ...d the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol antifreeze in...

Страница 43: ...the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed cooling system 92 877770K1 3 Check the antifreeze concentration for adequate freeze protect...

Страница 44: ...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 the fluid level before operation Changi...

Страница 45: ...r battery If this information is not available observe the following precautions when handling a battery WARNING Recharging a weak battery in the boat or using jumper cables and a booster battery to s...

Страница 46: ...is operating off of its own battery Do not operate engines with switches in both or all position In an emergency another engine s battery can be used to start an engine with a dead battery Battery iso...

Страница 47: ...arrestor 3 Cut the cable tie securing the crankcase vent hose to the flame arrestor and gently pull the vent hose off the flame arrestor 61330 4 Clean the flame arrestor with warm water and a mild det...

Страница 48: ...Water Separating Fuel Filter The water separating fuel filter is a low pressure filter that removes debris and water before the fuel reaches the high pressure fuel pump It is best to service the water...

Страница 49: ...and remove the filter cover to drain the fluid into an approved container Dispose of the fuel according to local regulations 61360 Fuel Filter Inspection The fuel filter is an important component in...

Страница 50: ...25W 40 Synthetic Blend 4 Stroke Engine Oil Shift cable pivot points 92 8M0078629 95 2 4 C with PTFE Shift cable guide 92 802859A 1 Serpentine Drive Belt Serpentine Drive Belt Routing WARNING Inspecti...

Страница 51: ...ion is a common cause of premature failure One of the outermost belt ribs is placed outside the pulley groove causing a belt rib to run without a supporting or aligning pulley groove The belt life has...

Страница 52: ...wear Cracks Fraying Glazed surfaces Proper tension Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys Description Deflection 13 mm 1 2 in NOTE Minor...

Страница 53: ...location that has the longest distance between two pulleys Description Deflection 13 mm in Flushing the Power Package Models without a Flushing Attachment The Boat Out of the Water IMPORTANT Flushing...

Страница 54: ...onto the flushing water supply hose and install onto the water inlet of the seawater pump d Proceed to step 3 NOTICE Flushing the engine when it is not operating will result in water collecting in the...

Страница 55: ...ting it 1 Models with 45IV or 46IV transmissions a Close the seacock if equipped and then disconnect the seawater inlet hose from the transmission seawater inlet fitting NOTICE Disconnecting the seawa...

Страница 56: ...ine above 1400 RPM out of the water and without sufficient cooling water supply 6 Press the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM 100 RPM 7 Observe the...

Страница 57: ...e a Quick connect fitting water hose end b Water hose 5 Snap the quick connect fitting with the water hose into the flush socket on the engine a Water hose b Quick connect fitting water hose end c Flu...

Страница 58: ...g with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the eng...

Страница 59: ...rom 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 be stored in the water the seacock should remain closed unti...

Страница 60: ...Section 4 Maintenance Notes Page 52 90 8M0128975 eng JUNE 2017...

Страница 61: ...54 Preparing Power Package for Storage MPI Models 54 Special Fuel Mix 55 Engine and Fuel System Preparation 55 TowSport and Inboard Transmissions Extended Storage 56 Draining the Seawater System 56 Dr...

Страница 62: ...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...

Страница 63: ...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...

Страница 64: ...er the bilge when the drain system is open damaging the 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 th...

Страница 65: ...g a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 8 Pump air into the system until both green indicators extend out of the actuator assembly 9 Water should begi...

Страница 66: ...e system to drain for a minimum of ten minutes Pump air as necessary to keep the green indicators extended 13 Crank the engine over slightly with the starter motor to purge any water trapped in the se...

Страница 67: ...n System Closed Cooling The following instructions apply to draining procedures performed on engines in vessels that are in the water For vessels that are not in the water you do not need to close the...

Страница 68: ...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...

Страница 69: ...er slightly with the starter motor to purge any 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 star...

Страница 70: ...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...

Страница 71: ...Motor Will Not Crank Engine or Cranks Slowly 64 Engine Will Not Start or Is Hard to Start 64 Engine Runs Rough Misses or Backfires 64 Poor Performance 65 Excessive Engine Temperature 65 Insufficient...

Страница 72: ...ry Loose or dirty electrical connections or damaged wiring Check all electrical connections and wires especially battery cables Clean and tighten all faulty connections Bad battery or low battery volt...

Страница 73: ...ooler plugged with foreign material Clean heat exchanger engine oil cooler and transmission oil cooler if equipped Loss of pressure in closed cooling section Check for leaks Clean inspect and test pre...

Страница 74: ...Incorrect detent adjustment Change detent adjustment Friction pad in the remote control worn Replace the remote control Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Insufficient...

Страница 75: ...ice Away From Home 68 Stolen Power Package 68 Attention Required After Submersion 68 Replacement Service Parts 68 Parts and Accessories Inquiries 68 Resolving a Problem 68 Contact Information for Merc...

Страница 76: ...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...

Страница 77: ...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...

Страница 78: ...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...

Страница 79: ...Section 8 Checklists 90 8M0128975 eng JUNE 2017 Page 71 Section 8 Checklists Table of Contents Predelivery Inspection PDI 72 Customer Delivery Inspection CDI 73 8...

Страница 80: ...steners 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 propel...

Страница 81: ...NT This checklist is for packages that are not equipped with joystick piloting For engine packages equipped with joystick piloting use the checklist included with the joystick piloting operation manua...

Страница 82: ...ts Page 74 90 8M0128975 eng JUNE 2017 N A Completed Item Boat lights battery switch location fuses breakers Trailer if applicable Registration Complete and submit warranty registration provide the cus...

Страница 83: ...Section 9 Maintenance Log 90 8M0128975 eng JUNE 2017 Page 75 Section 9 Maintenance Log Table of Contents Scheduled Maintenance Log 76 Vessel Maintenance Notes 77 9...

Страница 84: ...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...

Страница 85: ...Log 90 8M0128975 eng JUNE 2017 Page 77 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Comp...

Страница 86: ......

Страница 87: ...g South Victoria 3175 Australia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All ri...

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