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Fuel Filter Maintenance

Remote‑Mounted Prefilter

!

 WARNING

Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot

start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated

and  avoid  prolonged  exposure  to  vapors.  Always  check  for  leaks  before  attempting  to  start  the  engine,  and  wipe  up  any

spilled fuel immediately.

NOTICE

Water entering the fuel injection system will cause corrosion and rusting of the injectors and other components, disabling the

fuel injection system. Check daily for water in the water‑separating fuel filter and have the engine inspected immediately if

there is evidence of water in the fuel system.

Draining Water from the Remote-Mounted Prefilter

The prefilter is equipped with a water‑in‑fuel (WIF) sensor that will alert the operator when water is present in the filter. This fuel

filter should be drained whenever water is detected, and replaced at specified intervals.
IMPORTANT: Use a suitable container to collect the draining water. Clean up any spills immediately and dispose of the water

and any residual fuel in a safe manner in accordance with all local, federal, and international regulations.
1. Fold the fire sleeve down, then slide the sleeve off of the fuel filter assembly to access the drain plug. Situate the sleeve

away from the drain plug.

2. Place a suitable container below the fuel filter assembly to collect the draining water.
3. Use a 9/16 in. wrench to loosen the drain plug at the bottom of the fuel filter assembly, and allow the water to drain. When

fuel is present, tighten the drain plug finger‑tight then rotate two to three turns.

4. Install the fire sleeve back into its original position, unfolding it up and over the metal bowl interface.

!

 CAUTION

When servicing the fuel filter, ensure that the factory‑installed fire sleeve is reinstalled and kept in its original position. This

sleeve protects the filter, cap, and water‑in‑fuel sensor.

a -

Fire sleeve

b -

Drain plug

Remote-Mounted Prefilter Replacement

IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe manner in

accordance with all local, federal, and international regulations.
IMPORTANT: The remote‑mounted prefilter cannot be cleaned; it must be replaced.
The prefilter is equipped with a water‑in‑fuel (WIF) sensor that will alert the operator when water is present in the filter. This fuel

filter should be drained whenever water is detected, and replaced at specified intervals.
1. Disconnect both battery cables from the battery.
2. Disconnect the WIF sensor at the 3‑pin connector.
3. Fold the fire sleeve down, then slide the sleeve off of the fuel filter assembly to access the drain plug. Situate the sleeve

away from the drain plug.

4. Place a suitable container below the fuel filter assembly to collect fuel.

66124

b

a

Section 5 - Maintenance 

Page  56

90-8M0117076   

eng

  FEBRUARY 2018

Содержание MerCruiser Series

Страница 1: ...eration are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not...

Страница 2: ...th Waves Logo K planes Mariner MerCathode MerCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGuide OptiMax Quicksilver SeaCore Sky...

Страница 3: ...nction Display 11 SmartCraft Digital Instruments 11 System Link Digital Instruments 12 Remote Controls 12 DTS Slim Binnacle Single Handle Console Features and Operation 12 Special Digital Throttle and...

Страница 4: ...lter 49 Engine Coolant 50 Checking the Engine Coolant Level 50 Inspect the Coolant Recovery Reservoir Fluid Level 51 Filling 51 Changing the Engine Coolant 51 Air Filter 53 Oil Vapor Filter 55 Fuel Fi...

Страница 5: ...Away From Home 86 Stolen Power Package 86 Attention Required After Submersion 86 Replacement Service Parts 86 Parts and Accessories Inquiries 86 Resolving a Problem 86 Contact Information for Mercury...

Страница 6: ...Page iv 90 8M0117076 eng FEBRUARY 2018...

Страница 7: ...tput Rating 3 Conditions That Must Be Met in Order to Obtain Warranty Coverage 3 Purchaser s Responsibility 3 What Mercury Will Do 3 How to Obtain Warranty Coverage 3 Termination of Coverage 4 What is...

Страница 8: ...r to Mercury Marine s warranty registration department In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054...

Страница 9: ...ion of Mercury Marine Purchaser s Responsibility Perform all regular maintenance in compliance with the schedule in the applicable Operation and Maintenance Manual Maintain records of service and main...

Страница 10: ...techniques are set forth in the installation instructions for the Product Improper service Use of an accessory or part that was not manufactured or sold by Mercury Marine Operation with oils or lubric...

Страница 11: ...mented Routine maintenance must be performed according to the schedule in the Operation and Maintenance manual in order to obtain warranty coverage Mercury Marine reserves the right to make any warran...

Страница 12: ...or part that was not manufactured or sold by Mercury Marine Operation with oils or lubricants that are not suitable for use with the Product Alteration or removal of parts Insufficient cooling water...

Страница 13: ...ment 14 Special Digital Throttle and Shift DTS Features Dual Handle ERC 15 Dock 15 Throttle Only 16 1 Lever 16 Sync 17 Transfer Boats equipped with dual helms 17 Dual Handle Yacht Console Control Oper...

Страница 14: ...ls or the engine component they are secured to before sale If modifications are necessary or the emission control information label or the engine data label are damaged contact Mercury Marine about th...

Страница 15: ...eeds in shallow or obstacle infested waters Releasing your grip on the steering wheel Carelessness caused by consuming alcohol or drugs High speed boating maneuvers The lanyard is a cord usually betwe...

Страница 16: ...in 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...

Страница 17: ...e VesselView operator s manual for more information 65075 VesselView 703 SmartCraft Digital Instruments The SmartCraft instrument package augments the VesselView display The instrument package may inc...

Страница 18: ...tal throttle and shift DTS system required to operate this engine package provides start and stop functions throttle control shift control start in gear protection and emergency lanyard stop functions...

Страница 19: ...Slim binnacle ERC Item Control Function a Stop Start Allows the operator to start or stop the engine without the use of the key switch The key switch must be in the run position for the start stop sw...

Страница 20: ...a Forward b Neutral c Reverse To help prevent unwanted motion the amount of force needed to move the levers is adjustable Adjustment NOTE The control handle tension and detent tension may require per...

Страница 21: ...l control lever throttle demand d Increases brightness settings for the CAN pad VesselView and SmartCraft gauges e Throttle only Allows the boat operator to increase engine RPM for warm up without shi...

Страница 22: ...ttle only mode You must place the ERC levers into the neutral position to disengage throttle only mode To disengage throttle only mode 1 Place both ERC levers into neutral Throttle only will not disen...

Страница 23: ...ttle and when the engines are not synchronized The light turns red when the engines are synchronized 51857 SYNC button The RPM display of VesselView also shows an orange icon under the RPM numbers if...

Страница 24: ...water Turn the screw clockwise to increase tension and counterclockwise to decrease tension Adjust to tension desired 2 Detent tension adjustment screw This screw can be adjusted to increase or decre...

Страница 25: ...out shifting the transmission into gear 1 LEVER Enables the throttle and shift functions of both engines to be controlled by the starboard lever SYNC Turns the auto synchronization feature off or on R...

Страница 26: ...0 This allows better control of engine power in close quarter situations 31464 Dock button and light To engage dock mode 1 Place both ERC levers in neutral 2 Press the dock button located on the DTS t...

Страница 27: ...ess THROTTLE ONLY The throttle only light turns off Notice that the neutral lights remain on Single Lever Mode DTS features the ability to command all engines with a single lever This feature simplifi...

Страница 28: ...helm is in control of the vessel Before a transfer can be initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position NOTE If you attempt to t...

Страница 29: ...ders from the electrical plate assembly a Fuse box cover b 25 amp electronic diesel control EDC power c 15 amp for optional fuel priming pump d 5 amp key switch e 5 amp wake to key 12 pin f 5 amp diag...

Страница 30: ...rotect the engine from damage Most faults cause the warning horn circuit to activate How the warning horn activates depends on the severity of the problem There are two warning horn states Caution Cri...

Страница 31: ...oolant level Seawater pressure sensor ECM malfunction Crankshaft speed sensor Camshaft sensor Boost pressure Fuel pressure Air temperature Oil temperature Fuel temperature Exhaust gas temperature IMPO...

Страница 32: ...Section 2 Getting to Know Your Power Package Notes Page 26 90 8M0117076 eng FEBRUARY 2018...

Страница 33: ...ting the Engine 32 Starting a Cold Engine 32 Engine Warm Up 33 Shifting 33 Engine Shut Down Stopping 33 Protecting People in the Water 33 While You Are Cruising 33 While Boat Is Stationary 34 High Spe...

Страница 34: ...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 Coast Guard approved life jacket personal flotation device co...

Страница 35: ...oxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal combustion engines including the engines that propel boats and the generators that power boat ac...

Страница 36: ...gle of the bow too high b Operating the boat with no forward hatches open station wagon effect Important Operation Information Launching IMPORTANT Install the bilge drain plug before launching the boa...

Страница 37: ...at is not fitted with a seacock leave the water inlet hose disconnected and plugged NOTE As a precautionary measure attach a tag to the key switch or steering wheel of the boat reminding the operator...

Страница 38: ...en the engine hatch to air out the bilge before attempting to start the engine 2 Place the control handle in neutral 3 Turn the ignition key to the on position a Preheat is activated at key on when th...

Страница 39: ...e oil filter oil lines oil line connectors and oil pan d Check for coolant leaks Check the coolant hoses and connection pipes of the heat exchanger fluid coolers aftercooler water pump and drain fitti...

Страница 40: ...of the jump In such cases the landing may cause the boat to violently veer in a new direction Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of th...

Страница 41: ...speed and engine RPM Causes bow to bounce in choppy water Increases danger of following wave splashing into the boat when coming off plane At extremes can cause the boat to porpoise Shifting weight t...

Страница 42: ...s 3 Operating with increased load additional passengers accessories etc Because of the many variables of boat design only testing will determine the best propeller for a particular application Refer t...

Страница 43: ...d Weather 38 Antifreeze Coolant 38 Engine Oil 39 Engine Specifications 40 Fluid Specifications 40 6 7L Diesel Engine 40 Approved Paints 40 ZF Marine Transmissions 40 ZF 85 IV 41 ZF 280 IV 42 ZF 280 1...

Страница 44: ...ll up you possibly received substandard fuel with a low cetane rating On engines that use high sulphur content diesel fuel this will greatly increase Corrosion on metal parts Deterioration of elastome...

Страница 45: ...ntaining special additives and deionized or purified water Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine Do not combine different types of...

Страница 46: ...ling systems heat exchanger and fluid lines Always use the dipstick to determine the exact quantity of oil or fluid required All models Capacity Fluid Type Part Number Engine oil with filter 19 L 20 1...

Страница 47: ...tio Hydraulic actuated multi disc clutches Suitable for twin engine installations same ratio and torque capacity in forward or reverse 12 reverse down angle Weight with fluids 92 kg 203 lbs System oil...

Страница 48: ...in engine installations same ratio and torque capacity in forward or reverse 14 reverse down angle Weight with fluids 111 kg 245 lbs System oil volume 6 L 6 3 US qt Oil type general applications 15W 4...

Страница 49: ...mperatures above 80 C 176 F 40W 4 Cycle Diesel Engine Oil ZF 280 1 A 59254 ZF 280 1 A ZF 280 1 A General Description and Specifications Several ratios available Refer to the identification plate for t...

Страница 50: ...Section 4 Specifications Notes Page 44 90 8M0117076 eng FEBRUARY 2018...

Страница 51: ...Engine Mounted Fuel Filter 59 Engine Mounted Fuel Filter Replacement 59 Transmission Maintenance 60 Checking the Fluid Level Before Operation 60 Checking the Fluid Level When Hot 61 Transmission Oil...

Страница 52: ...Do not attempt repairs unless qualified Special tools and equipment are required to perform certain repairs Failure to use the correct special tools and equipment can result in severe damage to the pr...

Страница 53: ...ect the oil vapor filters Clean or replace as necessary Clean the air filter Inspect and clean the seawater section of the closed cooling system Check the closed cooling fluid level and level of prote...

Страница 54: ...amount of oil during operation The amount of oil consumed depends upon engine speed Oil consumption is the highest at wide open throttle and decreases substantially as engine speed is reduced NOTICE...

Страница 55: ...ten securely Changing Oil and Filter Refer to the Maintenance Schedules for the change interval NOTE Change the engine oil before placing the boat in storage IMPORTANT Change the engine oil when the e...

Страница 56: ...pter 11 Lubricate the O ring on the new oil filter with engine oil Do not use grease Tube Ref No Description Where Used Part No 121 15W 40 4 Cycle Diesel Engine Oil Oil filter O ring 92 858042K01 12 I...

Страница 57: ...cap and tighten securely Changing the Engine Coolant CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns Allow the engine to...

Страница 58: ...ty drain pan below the engine coolant drain plug 6 Remove the drain plug and allow the fluid to drain into the drain pan 7 Remove any spilled engine coolant with a shop towel and dispose the towel acc...

Страница 59: ...lace the top cover and secure with the ten screws removed in step 2 Tighten the screws to the specified torque Description Nm lb in lb ft Top cover screws 10 10 1 88 5 8 8 14 Check the coolant level i...

Страница 60: ...water and allow it to air dry naturally or in the sun Do not use compressed air 8 Reoil the air filter element after cleaning Apply air filter oil included with Air Filter Cleaning Kit down each plea...

Страница 61: ...cover b Screws 6 2 Remove the two oil vapor filters and inspect for deposits or damage to the filter elements Replace the oil vapor filters if necessary a Oil vapor filter housing b Oil vapor filters...

Страница 62: ...way from the drain plug 2 Place a suitable container below the fuel filter assembly to collect the draining water 3 Use a 9 16 in wrench to loosen the drain plug at the bottom of the fuel filter assem...

Страница 63: ...to remove it from the mounting head Verify the gasket is not adhered to the mounting head b Remove the metal bowl assembly from the bottom of the fuel filter by turning counterclockwise Retain the me...

Страница 64: ...filter assembly clockwise until the gasket contacts the head Tighten the filter assembly an additional 3 4 of a turn Do not use tools when installing the new filter IMPORTANT Do not fill up the new fi...

Страница 65: ...iately IMPORTANT Use a suitable container to collect fuel Clean up any spills immediately and dispose of fuel in a safe manner in accordance with all local federal and international regulations IMPORT...

Страница 66: ...ied torque Description Nm lb in lb ft Vent plug 24 17 7 e Once the plug is installed press the button on the hand primer pump a few more times until it is hard to pump This will ensure air is purged f...

Страница 67: ...he suction device Use a back up wrench to support the evacuation hose 5 Install the oil evacuation hose plug Use a back up wrench to support the evacuation hose when tightening the connection Descript...

Страница 68: ...flushing of the seawater cooling system 1 Remove the boat from the water if possible 2 If the boat is to remain in the water close the seacock 3 Level the engine if possible to ensure complete draini...

Страница 69: ...y drained install the two drain plugs and tighten to the specified torque Close the heat exchanger drain petcock Description Nm lb in lb ft Aftercooler discharge pipe seawater drain plug and oil coole...

Страница 70: ...into the engine seawater cooling system 15 Stop the engine 16 Remove the temporary hose from the seawater pump 17 Install the seawater inlet hose onto the seawater pump housing and secure the hose wi...

Страница 71: ...ch operation in saltwater and before storage the seawater cooling system must be flushed NOTE An engine flushing attachment accessory kit P N 8M0117941 is available to provide easy and convenient flus...

Страница 72: ...r until the discharge water is clear 7 Observe the water temperature gauge to ensure that the engine is operating in the normal range 8 Stop the engine 9 Shut off the water tap 10 Remove the adapter f...

Страница 73: ...mp at the interval specified in the Maintenance Schedule See your Mercury Diesel authorized repair facility Corrosion Protection General Information Whenever two or more dissimilar metals such as thos...

Страница 74: ...to determine the amount of erosion Do not use a mild steel brush which might leave deposits that could accelerate corrosion 1 Remove the deposits from each anode 2 Inspect and measure the anodes Repla...

Страница 75: ...rs shiny or glazed Severe condition Fabric is exposed Belt is in contact with an object Can be caused by improper belt tension or tensioner failure Replace the belt and inspect for contact with an obj...

Страница 76: ...the belt immediately 40799 Uneven rib wear Belt shows damage to the side with the possibility of breaks in the tensile cord or jagged edged ribs A foreign object in the pulley can cause uneven wear an...

Страница 77: ...cceptable Fraying Glazed surfaces 21062 3 Check the operation of the automatic tensioner and associated components a Use a suitable tool to rotate the automatic tensioner in the direction of the arrow...

Страница 78: ...ing the belt cover and remove the belt cover a Belt cover b Belt cover nuts 2 Remove the two nuts securing the belt cover attachment bracket to the studs Remove the bracket a Belt cover attachment bra...

Страница 79: ...cover nuts 5 11 97 3 10 Run the engine and check that the belt is correctly positioned Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity...

Страница 80: ...Section 5 Maintenance Notes Page 74 90 8M0117076 eng FEBRUARY 2018...

Страница 81: ...zing Temperature Seasonal Storage and Extended Storage 76 Seasonal Storage Instructions Six Months or Less 76 Extended Storage Instructions Exceeding Six Months 77 Battery 78 Recommissioning 78 6 Sect...

Страница 82: ...h the seawater cooling system after each outing NOTE An engine flushing attachment accessory kit P N 8M0117941 is available to provide easy and convenient flushing of the seawater cooling system Cold...

Страница 83: ...p the engine when the propylene glycol antifreeze has been drawn into the engine 10 Install the air filter 11 Clean the outside of the engine and paint damaged areas with primer and spray paint After...

Страница 84: ...glycol into the environment may be restricted by law Contain and dispose of propylene glycol in accordance with federal state and local laws and guidelines 1 On engines prepared for extended storage...

Страница 85: ...ng operation 12 Supply cooling water to the water inlet openings 13 Start the engine and closely observe instrumentation Ensure that all systems are functioning correctly 14 Carefully inspect the engi...

Страница 86: ...Section 6 Storage Notes Page 80 90 8M0117076 eng FEBRUARY 2018...

Страница 87: ...t 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 82 Incorrect Engine Temperature 82 Low Engine Oil Pressure 83 Ba...

Страница 88: ...r air filters Replace fuel or air filters Stale or contaminated fuel If fuel is contaminated drain tank Fill with fresh fuel Fuel line or tank vent line kinked or clogged Remove obstructions from line...

Страница 89: ...eck and add oil Excessive oil in crankcase causing it to become aerated Check and remove required amount of oil Check for cause of excessive oil improper filling Diluted or improper viscosity oil Chan...

Страница 90: ...Section 7 Troubleshooting Notes Page 84 90 8M0117076 eng FEBRUARY 2018...

Страница 91: ...on 86 Replacement Service Parts 86 Parts and Accessories Inquiries 86 Resolving a Problem 86 Contact Information for Mercury Marine Customer Service 87 Customer Service Literature 87 English Language...

Страница 92: ...n both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standard...

Страница 93: ...954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai shi Sakai ku 5900984 Osaka Japan...

Страница 94: ...ct Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada...

Страница 95: ...Section 9 Checklists Table of Contents Predelivery Inspection Checklist 90 Customer Delivery Inspection 90 9 Section 9 Checklists 90 8M0117076 eng FEBRUARY 2018 Page 89...

Страница 96: ...battery controller light is illuminated verifying it is connected to power Oil and fluid levels Apply Mercury Corrosion Guard to engine package Customer Delivery Inspection IMPORTANT This checklist is...

Страница 97: ...ttery switch location fuses breakers Trailer if applicable Customer is aware of the MerCathode location and controller light function Registration Complete and submit warranty registration provide the...

Страница 98: ...Section 9 Checklists Notes Page 92 90 8M0117076 eng FEBRUARY 2018...

Страница 99: ...Section 10 Maintenance Log Table of Contents Scheduled Maintenance Log 94 Vessel Maintenance Notes 95 10 Section 10 Maintenance Log 90 8M0117076 eng FEBRUARY 2018 Page 93...

Страница 100: ...Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name Signature Date 500 Hours Actual Hours Service Notes Dealer Name Signatu...

Страница 101: ...Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Completed Servicing Dealer Section 10 Maintenance Log 90 8M0117076 e...

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