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Section 5 - Maintenance

90-8M0069748

eng

APRIL 2012

Page 39

2. Check electrical connections and leads for damage or corrosion.
3. Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your Mercury Diesel authorized repair facility.
4. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel authorized repair

facility.

NOTE: A small panel in the engine cover allows access to the engine fuse panel, the engine oil fill cap, and the engine oil

dipstick without removing the entire engine cover.

Engine Cover

Removal

1. Remove the engine fuse panel cover.
2. Lift straight up and detach the engine cover from the ball stud mounts.

a -

Engine cover

b -

Fuse panel cover

c -

Engine access

3. Replace the fuse panel cover during storage.

Cleaning

1. Clean the engine cover with warm soapy water.
2. Air dry the cover.

Inspection

1. Inspect the engine cover for cracks or deterioration.
2. Inspect the rubber grommets for deterioration.
3. Inspect the hardware used with each grommet.
4. Replace damaged parts.

Installation

1. Remove the fuse panel cover.
2. Set the engine cover over the ball stud mounts.
3. Press the engine cover down above each mount to reattach the engine cover.
4. Replace the fuse panel cover.

Maintenance Schedule

Routine Maintenance

NOTE: Perform only the maintenance tasks that apply to your particular power package.

33467

a

b

c

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Содержание 92-813054A2

Страница 1: ...xhaust 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 Engine Type Fuel Type Comb...

Страница 2: ...rcury Diesel power package When contacting Mercury Marine about service always specify model and serial numbers Descriptions and specifications contained herein were in effect at the time this guide w...

Страница 3: ...ts alone cannot eliminate the hazards that they signal Strict compliance with these special instructions while performing the service plus common sense operation are major accident prevention measures...

Страница 4: ......

Страница 5: ...tch 13 Lanyard Stop Switch 14 Remote Controls 15 Panel Mount Features 15 Console Mount Features 15 Engine Electrical System Overload Protection 16 Vessel Integration Panel VIP Overload Protection 17 S...

Страница 6: ...spection 56 Installation 56 Water Separating Fuel Filter 57 Draining 57 Replacing 58 Filling 60 Fuel System 61 Priming 61 Filling Bleeding 61 Fuel Tank Cleaning and Flushing 62 Seawater System 62 Drai...

Страница 7: ...sistance Information Owner Service Assistance 86 Local Repair Service 86 Service Away From Home 86 Stolen Power Package 86 Attention Required After Submersion 86 Replacement Service Parts 86 Parts and...

Страница 8: ...Page iv 90 8M0069748 eng APRIL 2012...

Страница 9: ...What is Covered 2 Duration of Coverage 2 High Output Rating 3 Conditions That Must Be Met to Obtain Warranty Coverage 3 What Mercury Marine Will Do 3 How to Obtain Warranty Coverage 3 Termination of C...

Страница 10: ...or the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms 4 In some countries the Marine Power Service Center will issue y...

Страница 11: ...arine s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified re manufactured parts...

Страница 12: ...ND COUNTRY TO COUNTRY 3 Year Limited Warranty Against Corrosion Diesel Models Recreational Use Only What Is Covered Mercury Marine warrants that each new recreational use engine drive package Product...

Страница 13: ...or any use of the product which generates income for any part of warranty period even if the product is only occasionally used for such purposes DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF M...

Страница 14: ...Section 1 Warranty Notes Page 6 90 8M0069748 eng APRIL 2012...

Страница 15: ...es and Controls 10 Audio Warning System 10 Digital Throttle and Shift 10 Instrumentation 10 VesselView 10 SmartCraft Speedometer and Tachometer Digital Gauges 11 System Link Digital Gauges 11 System T...

Страница 16: ...xed to the engine at the time of manufacture It contains important information Note that the engine data label will not affect the fit function or performance of the engine and neither boatbuilders no...

Страница 17: ...ed on the front of the engine as shown below a Serial number and part number label with bar codes b Engine data label Technodrive Transmissions The transmission identification plate indicates gear rat...

Страница 18: ...malfunction has occurred Operating a power package with a critical fault can damage components If the audio warning horn emits a sound do not continue operations unless avoiding a hazardous situation...

Страница 19: ...tion information on the SmartCraft instrument package and for details on the warning functions monitored by the system refer to the manual provided with your gauge package System Link Digital Gauges S...

Страница 20: ...activate an audio warning Smart Tach Display Warning Indication LOW OIL PRESS The oil pressure has dropped below the critical engine protection limit OVERHEAT The engine coolant temperature has risen...

Страница 21: ...an emergency situation such as a person overboard or a tangled propeller When activated an E stop switch interrupts the power supply to the engine and transmission If the boat is equipped with an E s...

Страница 22: ...tretched out with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as po...

Страница 23: ...ing the shift mechanism from the control handle The throttle only button can be pressed only when the remote control handle is in the neutral position and should only be used to assist in starting the...

Страница 24: ...uctions provided with the remote control for complete adjustment instructions Engine Electrical System Overload Protection If an electrical overload occurs a fuse will open blow Find and correct the c...

Страница 25: ...ed power to ECM Middle left c 10 amp Keyed power to ECM Upper left d 5 amp Power diagnostic connector Upper right e 15 amp ECM switched power to SIM Middle right f 15 amp Switched power to ECM Lower r...

Страница 26: ...Section 2 Getting to Know Your Power Package Notes Page 18 90 8M0069748 eng APRIL 2012...

Страница 27: ...ngine 24 Engine Warm Up 24 Starting a Warm Engine 24 Shifting 25 Engine Shut Down Stopping 25 Protecting People in the Water 25 While Boat is in Operation 25 While the Boat is Stationary 25 High Speed...

Страница 28: ...le in the boat Prepare other boat operators Instruct at least one person aboard in the basics of starting and operating the engine and handling the boat in case the driver becomes disabled or falls ov...

Страница 29: ...ile at rest or underway and avoid prolonged exposure to carbon monoxide Good Ventilation Ventilate the passenger area open the side curtains or forward hatches to remove fumes 1 Example of desired air...

Страница 30: ...rumentation to monitor the condition of the engine If not normal stop the engine Frequently review all instrumentation to monitor engine condition Shift the remote control lever to the neutral positio...

Страница 31: ...thorized repair facility for information about special cold weather equipment and precautions Refer to Section 6 for cold weather or extended storage related information Drain Plug and Bilge Pump The...

Страница 32: ...hin seconds of starting the engine Stop the engine if the engine oil pressure does not meet this specification Locate and correct the problem If you are unable to correct the problem see a Mercury Die...

Страница 33: ...he start stop button if equipped The engine will stop and the control system will remain active c Momentarily move the ignition key switch to the START position then release immediately The control sy...

Страница 34: ...on them to be run over Boats Having An Open Front Deck No one should ever be on the deck in front of the rail while the boat is in motion Keep all passengers behind the front rail or enclosure Persons...

Страница 35: ...in an infinite number of situations Some of these situations could result in the following The boat could move suddenly in a new direction Such a sharp change in direction or turn can throw occupants...

Страница 36: ...damage Choose a propeller that allows the engine to operate at the specified wide open throttle RPM The boat manufacturer and the selling dealer are responsible for equipping the power package with t...

Страница 37: ...tle above 1500 RPM if conditions permit safe operation Do not operate at one constant speed for extended periods Do not exceed 3 4 throttle during the first 10 hours During the next 10 hours occasiona...

Страница 38: ...Section 3 On the Water Notes Page 30 90 8M0069748 eng APRIL 2012...

Страница 39: ...Section 4 Specifications Table of Contents Fuel Requirements 32 Recommended Fuels 32 Diesel Fuel in Cold Weather 32 Coolant Antifreeze 33 Engine Oil 33 Engine Specifications 34 Fluid Specifications 3...

Страница 40: ...ise the cetane rating for low temperature or high altitude use A lower cetane number could cause hard starting and slower warm up and could increase engine noise and exhaust emissions NOTE If your eng...

Страница 41: ...to protect the engine and closed cooling system to the lowest temperature to which they will be exposed NOTE Generally we recommend using a 50 50 solution of coolant antifreeze and deionized purified...

Страница 42: ...dle 2 4 bar 240 kPa 35 psi Oil pressure at 4000 RPM 6 6 bar 660 kPa 95 psi Thermostats water 83 C 181 F Thermostats oil 95 C 203 F Coolant temperature 80 85 C 176 185 F Electrical system 12 volt negat...

Страница 43: ...tguard Part Number CC2825 Container size 3 75 L 1 00 US gal Obtain locally Transmission NOTE Capacities are for the transmission only and do not include the fluid cooler or fluid cooler hose capacitie...

Страница 44: ...Section 4 Specifications Notes Page 36 90 8M0069748 eng APRIL 2012...

Страница 45: ...51 Change Fluid 51 Engine Coolant 53 Checking 53 Filling 54 Changing 55 Air Filter 55 Removal 55 Inspection 56 Installation 56 Water Separating Fuel Filter 57 Draining 57 Replacing 58 Filling 60 Fuel...

Страница 46: ...nts WARNING Fuel vapors trapped in the engine compartment may be an irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before se...

Страница 47: ...fuse panel cover 2 Lift straight up and detach the engine cover from the ball stud mounts a Engine cover b Fuse panel cover c Engine access 3 Replace the fuse panel cover during storage Cleaning 1 Cle...

Страница 48: ...any water from the fuel filters Check the seawater inlets for debris or marine growth Check and clean the seawater strainer Every Two Months Check the battery connections and fluid level Treat the eng...

Страница 49: ...nd tension of the engine accessory drive belts Inspect the cooling system and the exhaust system for damage or leaks Check both systems hose clamps for tightness Disassemble and inspect the engine sea...

Страница 50: ...Section 5 Maintenance Page 42 90 8M0069748 eng APRIL 2012 Date Maintenance Performed Engine Hours...

Страница 51: ...efore checking the oil level If the boat is in the water ensure that the boat is at rest If the boat is on a trailer raise or lower the bow until the boat is sitting as it does at rest in the water Al...

Страница 52: ...QSD 2 0L engine oil service a Engine cover with access panel removed b Engine oil fill cap c Engine oil dipstick 2 Add the specified oil to bring the oil level up to but not over the maximum mark on...

Страница 53: ...ating temperature 2 Stop the engine and allow some time for the oil to drain into the oil pan approximately five minutes 3 Remove the fitting from the end of crankcase oil drain hose 4 Install the cra...

Страница 54: ...cover 11 Remove the oil filter cover and cartridge type oil filter 12 Remove and discard the old filter element Discard the old cover O ring Engine coolant oil cooler Seawater oil cooler a Oil filter...

Страница 55: ...g the cover may cause an oil leak Engine Coolant Oil Cooler Description Nm lb in lb ft Engine oil filter housing cover 25 0 18 0 Seawater Oil Cooler Description Nm lb in lb ft Engine oil filter housin...

Страница 56: ...f the oil level is low add transmission oil to bring the level up to the maximum mark on the dipstick See Filling NOTE If the transmission oil level was extremely low see your local Mercury Diesel aut...

Страница 57: ...t Transmission oil drain plug 17 12 5 6 Clean the exterior of the transmission around the oil filter assembly 7 Loosen the retaining nut 27978 Transmission oil filter retaining nut 8 Remove the filter...

Страница 58: ...d hole NOTE The fluid level may be somewhat over the maximum mark as some of the fluid from the transmission fluid cooler and hoses may have drained back into the transmission 3 If the fluid level is...

Страница 59: ...l Refer to Check Fluid Change Fluid NOTICE Discharge of oil coolant or other engine drive fluids into the environment is restricted by law Use caution not to spill oil coolant or other fluids into the...

Страница 60: ...sen the assembly nut and rotate the securing tab in the direction shown a Assembly nut b Securing tab 8 Remove the filter element a Filter element 9 Clean the filter element with a mild cleaning solve...

Страница 61: ...it clockwise 13 Tighten the assembly nut to the specified torque a Assembly nut b Securing tab Description Nm lb in lb ft Assembly nut 5 8 48 72 14 Fill the transmission to the proper level with the...

Страница 62: ...cessary a Gasket c The pressure cap maintains pressure on the cooling system and may not be holding pressure properly To have the cap tested contact your Mercury Diesel authorized repair facility d Ad...

Страница 63: ...tguard Compleat with DCA4 Fleetguard Part Number CC2825 Obtain Locally IMPORTANT When installing the pressure cap be sure to tighten it securely to prevent coolant loss 4 Install the pressure cap Tigh...

Страница 64: ...lation IMPORTANT The foam cover is an integral component of the air filter element and must be clean and dry for proper filtration and engine performance Do not treat the foam filter cover with oil 1...

Страница 65: ...and dispose of fuel in a safe manner in accordance with all local federal and international regulations The engine mounted water separating fuel filter is equipped with a water in fuel WIF sensor that...

Страница 66: ...tery can cause 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 ser...

Страница 67: ...d filter and O ring seal as defined by local authorities 6 Install the O ring and drain cap on the new water separating fuel filter Typical a Drain cap b O ring seal 7 Lubricate the fuel filter seals...

Страница 68: ...lation If leaks continue stop the engine immediately and contact your Mercury Diesel authorized repair facility Filling A type of hand pump and primer plunger is located on the fuel filter bracket and...

Страница 69: ...ne if it has not been run for an extended period or if the engine will not start 1 Move the primer plunger up and down repeatedly a Fuel priming pump 2 Attempt to start the engine Filling Bleeding NOT...

Страница 70: ...e the engine with the drain system open IMPORTANT The engine must be as level as possible to ensure complete draining of the seawater system Drain the seawater system before flushing or prior to cold...

Страница 71: ...clear the seawater drain valve of any debris 7 Disconnect the seawater inlet hose from the connector on the seawater pump a Seawater pump inlet b Seawater pump c Seawater pump outlet d Fuel cooler if...

Страница 72: ...er NOTE Visually inspect the seawater strainer through its clear cover NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat causi...

Страница 73: ...overtighten a Seawater inlet b Seawater outlet c Seawater strainer cover 8 If the boat is out of the water Perform an operational inspection of the seawater cooling system after cleaning the seawater...

Страница 74: ...te and contain and dispose of fluids as required NOTE For instructions on draining the seawater section refer to Draining the Seawater System in this section IMPORTANT Observe the following points Ens...

Страница 75: ...the specified coolant Refer to Filling the Closed Cooling System Filling the Closed Cooling System 1 Remove the pressure cap QSD 2 0L engine cover removed a Pressure cap b Coolant expansion tank c Co...

Страница 76: ...s such as those found on this power package are submerged in a conductive solution such as saltwater polluted water or water with a high mineral content a chemical reaction takes place causing electri...

Страница 77: ...ion 1 Remove the deposits 2 Inspect and measure the anode Compare the measurements to the specifications for a new sacrificial anode and replace the anode assembly when deteriorated 50 NOTE Sacrificia...

Страница 78: ...r pickup pumps are supplied cooling water 5 Start the engine and check for leaks Antifouling Paint IMPORTANT Corrosion damage that results from the improper application of anti fouling paint is not co...

Страница 79: ...drive belts must be periodically inspected for proper tension and condition Belts that show signs of wear such as cracking fraying or glazing of the belt surface should be replaced If the serpentine...

Страница 80: ...ite and explode spraying out sulfuric acid which can cause severe burns Ventilate the area around the battery and wear protective equipment when handling or servicing batteries Battery Precautions for...

Страница 81: ...tion In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary battery used for powering accessories in...

Страница 82: ...Section 5 Maintenance Notes Page 74 90 8M0069748 eng APRIL 2012...

Страница 83: ...Contents Cold Weather Freezing Temperature Seasonal Storage and Extended Storage 76 Cold Weather Freezing Temperature Storage 76 Preparing Your Power Package for Seasonal or Extended Storage 77 Seaso...

Страница 84: ...torage refers to whenever the boat is not being operated and the possibility of freezing temperatures exists In such cases the seawater section of the cooling system must be completely drained immedia...

Страница 85: ...rom the water to drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures IMPORTANT We recommend the use of propylene glyco...

Страница 86: ...for storage Recommissioning NOTE Discharge of propylene glycol into the environment may be restricted by law Contain and dispose of propylene glycol in accordance with federal state and local laws an...

Страница 87: ...de a sufficient supply of water to the water inlets during operation 10 Supply cooling water to the water inlet openings 11 Start the engine and closely observe instrumentation Ensure that all systems...

Страница 88: ...Section 6 Storage Notes Page 80 90 8M0069748 eng APRIL 2012...

Страница 89: ...82 Troubleshooting Charts 82 Starter Motor Will Not Crank Engine or Cranks Slow 82 Engine Will Not Start or Is Hard to Start 82 Engine Runs Rough Misses or Backfires 82 Poor Performance 83 Incorrect...

Страница 90: ...uel tank or fuel shut off valve closed Fill tank or open valve Throttle not operating properly Check the throttle for freedom of movement Faulty electrical stop circuit Have a Mercury Diesel authorize...

Страница 91: ...test pressure cap See a Mercury Diesel authorized repair facility Faulty seawater pickup pump Repair See a Mercury Diesel authorized repair facility Seawater discharge restricted or plugged Clean exh...

Страница 92: ...steners Lubricate Obstruction in the shift or throttle linkages Remove the obstruction Loose or missing shift and throttle linkages Check all throttle linkages If any are loose or missing see a Mercur...

Страница 93: ...red After Submersion 86 Replacement Service Parts 86 Parts and Accessories Inquiries 86 Resolving a Problem 86 Customer Service Literature 87 English Language 87 Other Languages 87 Andre sprog 87 Ande...

Страница 94: ...cycle of the engine They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Exercise caution when replacing marine engine parts Marin...

Страница 95: ...ie geleverd Muut kielet Saadaksesi K ytt ja huolto ohjekirjoja muilla kielill ota yhteys l himp n Mercury Marine tai Marine Power International huoltokeskukseen josta saat l hempi tietoja Moottorisi m...

Страница 96: ...saj sunode etai ap nan kat logo ariqm n paraggel aj gia llej gl ssej Ordering Literature Before ordering literature have the following information about your power package available Model Serial Numbe...

Страница 97: ...Section 8 Customer Assistance Information 90 8M0069748 eng APRIL 2012 Page 89 Quantity Item Stock Number Price Total Total Due...

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