Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the

Transcription

1 Welcome You hve selected one of the finest mrine power pckges ville. It incorportes numerous design fetures to ensure operting ese nd durility. With proper cre nd mintennce, you will enjoy using this product for mny oting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion nd Mintennce Mnul contins specific instructions for using nd mintining your product. We suggest tht this mnul remin with the product for redy reference whenever you re on the wter. Thnk you for purchsing one of our products. We sincerely hope your oting will e plesnt! Mercury Mrine, Fond du Lc, Wisconsin, U.S.A. 8M eng Nme / function: John Pfeifer, President, Mercury Mrine Red This Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler. Your deler cn lso provide demonstrtion of ctul strting nd operting procedures. Notice Throughout this puliction, nd on your power pckge, wrnings, cutions, nd notices, ccompnied y the Interntionl Hzrd Symol!, my e used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. Oserve them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction. IMPORTANT: The opertor (driver) is responsile for the correct nd sfe opertion of the ot, the equipment ord, nd the sfety of ll occupnts ord. We strongly recommend tht the opertor red this Opertion nd Mintennce Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories efore the ot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, irth defects or other reproductive hrm. The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine out service, lwys specify model nd seril numers. Descriptions nd specifictions contined herein were in effect t the time this ws pproved for printing. Mercury Mrine, whose policies re sed on continuous improvement, reserves the right to discontinue models t ny time or to chnge specifictions or designs without notice nd without incurring oligtion Mercury Mrine TDI 4.2L Diesel Sterndrive Models

2 Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Mrine; the terms of the wrrnty re set forth in the Wrrnty Mnul included with the product. The Wrrnty Mnul contins description of wht is covered, wht is not covered, the durtion of coverge, how to est otin wrrnty coverge, importnt disclimers nd limittions of dmges, nd other relted informtion. Plese review this importnt informtion. Copyright nd Trdemrk Informtion MERCURY MARINE. All rights reserved. Reproduction in whole or in prt without permission is prohiited. Alph, Axius, Brvo One, Brvo Two, Brvo Three, Circle M with Wves Logo, K plnes, Mriner, MerCthode, MerCruiser, Mercury, Mercury with Wves Logo, Mercury Mrine, Mercury Precision Prts, Mercury Propellers, Mercury Rcing, MotorGuide, OptiMx, Quicksilver, SeCore, Skyhook, SmrtCrft, Sport Jet, Verdo, VesselView, Zero Effort, Zeus, #1 On the Wter nd We're Driven to Win re registered trdemrks of Brunswick Corportion. Pro XS is trdemrk of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion. Identifiction Records Plese record the following pplicle informtion: Engine Model nd Horsepower MerCruiser Engine Seril Numer Trnsom Assemly Seril Numer (Sterndrive) Ger Rtio Sterndrive Unit Seril Numer Trnsmission Model (Inord) Ger Rtio Trnsmission Seril Numer Propeller Numer Pitch Dimeter Hull Identifiction Numer (HIN) Purchse Dte Bot Mnufcturer Bot Model Length Exhust Gs Emissions Certifiction Numer (Europe Only)

3 TABLE OF CONTENTS Section 1 - Getting to Know Your Power Pckge Fetures nd Controls... 2 TDI 4.2L Engine Description... 2 Identifiction... 2 Audio Wrning System... 2 Testing the Audio Wrning System... 3 Digitl Throttle nd Shift... 3 Instrumenttion... 3 VesselView... 3 SmrtCrft Speedometer, Tchometer, nd Digitl Guges... 3 System Link Digitl Guges... 4 Controls... 5 Switches... 5 Emergency Stop Switch... 6 Lnyrd Stop Switch... 6 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 7 Digitl Throttle nd Shift... 7 Engine Electricl System Overlod Protection... 7 Fuses...7 Vessel Adpter Assemly Fuse Replcement... 8 Lnyrd Stop Switch... 8 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 9 Power Trim Single Engine Trim nd Triler...10 Dul Engine Trim nd Triler Power Trim nd MerCthode Overlod Protection Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsiility...12 Engine Components Section 2 - On The Wter Sfe Boting Recommendtions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Duty Cycle Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting...18 Bsic Bot Opertion Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump Strting, Shifting, nd Stopping Before Strting the Engine Strting Cold Engine Engine Wrm Up Strting Wrm Engine Shifting Engine Shutdown (Stopping) Strting the Engine After Stopped While in Ger Trilering the Bot Protecting People In The Wter Protecting People in the Wter While Bot is in Opertion While the Bot is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection Brek In Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) Engine Brek In Hour Brek In Period...26 After the 20 Hour Brek In Period End of First Seson Checkup Section 3 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine Brvo Sterndrive Fluid Specifictions Diesel M eng DECEMBER 2015 Pge i

4 Power Steering nd Power Trim Fluids Approved Power Steering Fluids...32 Approved Power Trim Fluids Approved Pints Section 4 - Mintennce Owner nd Opertor Responsiilities Deler Responsiilities Mintennce Replcement Prts Wrning Inspection Routine Mintennce Strt of Seson Ech Dy Strt Ech Dy End Weekly End of Seson Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Mintennce Notice Every 5 Yers or 500 Hours (Whichever Occurs First) Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) Engine Oil Checking Filling Drining Using the Esy Drin System, if Equipped Chnging Oil nd Filter Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Steering Fluid Checking Filling Chnging Engine Coolnt Checking the Coolnt Level Adding Coolnt Air Filter Removl Inspection nd Clening Instlltion Fuel Filter Drining Wter from the Filter Replcing the Filter Purging the Fuel System Fuel System Priming Fuel Tnk Clening nd Flushing Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing nd Drining the Sewter System Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Scrificil Anode Antifouling Pint Luriction Steering System Throttle Cle Shift Cle Trnsom Assemly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Giml Ring U olt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches Bttery Isoltors Genertors Section 5 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Prepring Your Power Pckge for Sesonl or Extended Storge Sesonl Storge Instructions Extended Storge Instructions Bttery Storge Recommissioning the Power Pckge Pge ii 90-8M eng DECEMBER 2015

5 Section 6 - Trouleshooting Trouleshooting Trouleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow Engine Will Not Strt, or Is Hrd to Strt Engine Runs Rough, Misses, or Bckfires Poor Performnce No Fuel or Fulty Fuel Supply Engine Will Not Strt, Strter Does Not Turn Excessive Engine Temperture Insufficient Engine Temperture Low Engine Oil Pressure Bttery Will Not Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Steering Wheel Turns Hrd or Jerky Power Trim Does Not Operte (Electric Motor Opertes ut Sterndrive Unit Does Not Move) Power Trim Does Not Operte (Electric Motor Does Not Operte) Section 7 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home...78 Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem Contct Informtion for Mercury Mrine Customer Service Customer Service Literture English Lnguge Other Lnguges...80 Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd Section 8 - Mintennce Log Scheduled Mintennce Log Vessel Mintennce Notes M eng DECEMBER 2015 Pge iii

6 Pge iv 90-8M eng DECEMBER 2015

7 Section 1 - Getting to Know Your Power Pckge Section 1 - Getting to Know Your Power Pckge Tle of Contents 1 Fetures nd Controls... 2 TDI 4.2L Engine Description... 2 Identifiction...2 Audio Wrning System... 2 Testing the Audio Wrning System... 3 Digitl Throttle nd Shift... 3 Instrumenttion... 3 VesselView... 3 SmrtCrft Speedometer, Tchometer, nd Digitl Guges... 3 System Link Digitl Guges... 4 Controls... 5 Switches... 5 Emergency Stop Switch...6 Lnyrd Stop Switch... 6 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 7 Digitl Throttle nd Shift... 7 Engine Electricl System Overlod Protection... 7 Fuses... 7 Vessel Adpter Assemly Fuse Replcement... 8 Lnyrd Stop Switch... 8 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 9 Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler Power Trim nd MerCthode Overlod Protection Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsiility Engine Components M eng DECEMBER 2015 Pge 1

8 Section 1 - Getting to Know Your Power Pckge Fetures nd Controls TDI 4.2L Engine Description Four stroke V8 diesel engine 4.2 liter displcement (252 cid) Common ril direct fuel injection Chin driven overhed cm hydrulic vlvetrin Pressurized engine luriction with replcele oil filter Dry ir filter Vrile geometry turochrgers Twin cooling circuits, utilizing sewter cooling nd closed circuit cooling Refer to Engine Specifictions for dditionl detils. Refer to Engine Components for the loctions of engine components referenced in this mnul. Identifiction The seril numers re the mnufcturer's keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine out service, lwys specify model nd seril numers. Audio Wrning System Your Mercury Diesel power pckge my e equipped with n udio wrning system. The udio wrning system will not protect the engine from dmge. It is designed to wrn the opertor tht prolem hs occurred. The udio wrning system will sound with continuous horn if one of the following occurs: The engine oil pressure is too low The coolnt temperture is too hot Wter in fuel Low coolnt level NOTICE A continuous horn indictes criticl fult. Operting the engine during criticl fult cn dmge components. If the wrning horn emits continuous eep, do not operte the engine unless voiding hzrdous sitution Pge M eng DECEMBER 2015

9 Section 1 - Getting to Know Your Power Pckge If the lrm sounds, stop the engine immeditely if you re not in hzrdous sitution. Investigte the cuse nd correct it, if possile. If you cnnot determine the cuse, consult your Mercury Diesel uthorized repir fcility. Testing the Audio Wrning System 1. Turn the ignition switch to the "RUN" or 1 position; do not strt the engine. 2. Push the udio test switch toggle lever down nd hold it. 3. Listen for the lrm. The lrm will sound if the system is functioning correctly. Digitl Throttle nd Shift Digitl Throttle nd Shift (DTS) operting instructions re provided in seprte mnul. Refer to Mercury Diesel's SmrtCrft nd DTS Opertor's Mnul. Instrumenttion VesselView Your power pckge my e connected to SmrtCrft VesselView disply. VesselView 7 is comprehensive ot informtion center tht cn disply informtion for up to four gsoline or diesel engines. It continuously monitors nd reports sic operting dt including detiled informtion such s sewter temperture nd depth, trim sttus, ot speed nd steering ngle, nd the sttus of fuel, oil, wter, nd wste tnks. VesselView cn e fully integrted with vessel s glol positioning system (GPS) or other NMEA comptile device to provide up to the minute nvigtion, speed, nd fuel to destintion informtion. VesselView 4 nd 7 re equipped with micro SD crd port tht llows n uthorized OEM or delership to import the personlity configurtion. It cn lso e use y the owner to import pictures or grphics. When more thn one VesselView is used, either s triple or qud engine ppliction for multiple helms, the sme mico SD crd cn e used to downlod those configurtions. VesselView Refer to your VesselView opertions mnul for detiled instructions on how to operte this disply. SmrtCrft Speedometer, Tchometer, nd Digitl Guges The SmrtCrft instrument pckge ugments the informtion provided y VesselView. The instrument pckge my disply: Engine RPM Bot speed Coolnt temperture Oil pressure Bttery voltge Fuel consumption Engine operting hours M eng DECEMBER 2015 Pge 3

10 Section 1 - Getting to Know Your Power Pckge SmrtCrft tchometer nd speedometer - Tchometer - Speedometer c - LCD disply c The SmrtCrft instrument pckge lso ids in identifying the fult codes ssocited with the engine udio wrning system. The SmrtCrft instrument pckge displys criticl engine lrm dt nd other potentil prolems on its LCD disply. For sic opertion informtion on the SmrtCrft instrument pckge nd for detils on the wrning functions monitored y the system, refer to the mnul provided with your guge pckge. System Link Digitl Guges Some instrumenttion pckges include guges tht ugment the informtion provided y VesselView nd the SmrtCrft tchometer nd speedometer. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Hve your ot deler explin the guges nd norml redings tht pper on your ot. The following types of digitl guges my e included with your power pckge. c d System Link digitl guges Item Guge Indictes Oil pressure guge Engine oil pressure Voltmeter Bttery voltge c Wter temperture guge Engine operting temperture d Fuel guge Quntity of fuel in tnk Pge M eng DECEMBER 2015

11 Section 1 - Getting to Know Your Power Pckge Controls Switches Four Position Key Switch "OFF" In the "OFF" position, ll electricl circuits re off. The engine will not operte with the key switch in the "OFF" position. "ACC" In the "ACC" position, ny ccessories connected to the electricl circuits cn e operted. The engine will not operte with the key switch in the "ACC" position. "ON" In the "ON" position, ll electricl circuits nd instrumenttion receive power. The engine cn e strted with n optionl strt stop switch. "START" Turn the key to the strt position nd relese to strt the engine. NOTE: The key cn only e removed with the key switch in the "OFF" position Dul Engine Strt Stop Switch A strt stop switch is optionl equipment. The strt stop switch works in conjunction with the key switch. There is one strt stop switch for ech engine. Ech utton on multi engine strt stop switch functions independently. The key switch must e in the "ON" position to strt stopped engine with the strt stop switch. Pressing strt stop switch utton when n engine is running will shut down the corresponding engine Bilge Blower Toggle Switch Opertes the ilge lower, if equipped. ON OFF M eng DECEMBER 2015 Pge 5

12 Section 1 - Getting to Know Your Power Pckge Emergency Stop Switch An emergency stop (E stop) switch is used to turn off the engines in n emergency sitution, such s person overord or tngled propeller. When ctivted, n E stop switch interrupts the power supply to the engine nd trnsmission. If the ot is equipped with n E stop switch, the E stop switch turns off ll of the engines. Typicl E-stop switch Activtion of n E stop switch stops the engine, or engines, immeditely, ut the ot cn continue to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Accidentl or unintended ctivtion of the switch during norml opertion is lso possile, which cn cuse ny or ll of the following potentilly hzrdous situtions: Occupnts cn e thrown forwrd due to unexpected loss of forwrd motion, nd pssengers in the front of the ot could e ejected over the ow nd possily struck y the propulsion or steering components. The opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. The opertor cn lose control of the vessel when docking. Restrting n engine using the key switch or strt utton fter n E stop shutdown without first turning the key switch to the off position for t lest 30 seconds will restrt the engine ut cuse fult codes to e set. Unless you re in potentilly hzrdous sitution, turn the key switch off nd wit t lest 30 seconds efore restrting the engine or engines. If fter restrting, some fult codes re still eing displyed, contct your uthorized Mercury Diesel repir fcility. Lnyrd Stop Switch A lnyrd switch is designed to shut down the engine in the event the opertor unexpectedly moves wy from the helm, s my hppen in n ccidentl ejection. The lnyrd is connected to the opertor's personl flottion device or wrist. A decl ner the lnyrd stop switch reminds the opertor to ttch the lnyrd to his or her personl flottion device or wrist ATTACH LANYARD RUN OFF - Lnyrd cord clip - Lnyrd decl c - Lnyrd stop switch c Accidentl ejections, such s flling overord, re more likely to occur in: Low sided sport ots Bss ots High performnce ots Pge M eng DECEMBER 2015

13 Accidentl ejections cn lso occur from: Poor operting prctices Sitting on the set or gunwle t plning speeds Stnding t plning speeds Operting t plning speeds in shllow or ostcle infested wters Relesing your grip on the steering wheel Crelessness cused y consuming lcohol or drugs High speed oting mneuvers Section 1 - Getting to Know Your Power Pckge The lnyrd is cord usully etween 122 nd 152 cm (4 nd 5 ft) long when stretched out, with n element on one end mde to e inserted into the switch, nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the opertor's norml position. The opertor cn shorten the lnyrd y wrpping the lnyrd round his wrist, or y tying knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, ut the ot will continue to cost for some distnce, depending upon its velocity. While the ot is costing, it cn cuse injury to nyone in the ot's pth s it would under power. Instruct ll pssengers on the proper strting nd operting procedures should they e required to operte the ot in n emergency.! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Before ech use, ensure tht the lnyrd stop switch works properly. Strt the engine, nd then stop it y pulling the lnyrd cord. If the engine does not stop, hve the switch repired efore operting the ot. Before ech use, inspect the lnyrd cord to ensure tht it is in good working condition nd tht there re no reks, cuts, or wer to the cord. Check tht the clips on the ends of the cord re in good condition. Replce ny dmged or worn lnyrd cords. Digitl Throttle nd Shift Digitl Throttle nd Shift (DTS) operting instructions re provided in seprte mnul. Refer to Mercury Diesel's SmrtCrft nd DTS Opertor's Mnul. Engine Electricl System Overlod Protection Fuses! CAUTION Filure to protect wiring with n pproprite fuse cn dmge the wiring nd strt fire. When instlling ny ccessories, we recommend using Mercury ccessory kit. Alwys use the pproprite fuse to protect wiring. Individul circuits re protected y fuses. If n electricl overlod occurs, fuse will urn out. Find nd correct the cuse for the electricl overlod efore replcing the fuse. 90-8M eng DECEMBER 2015 Pge 7

14 Section 1 - Getting to Know Your Power Pckge Two fuses re locted on the top of the engine. Remove the engine cover to ccess these fuses. Be certin to replce n open fuse only with one of the sme rting mp fuse - 25 mp fuse The remining fuses re locted in the vessel dpter ssemly (refer to your ot owner's mnul for loction) nd on the rer side of the control unit of the individul instrumenttion. Vessel Adpter Assemly Fuse Replcement NOTE: Refer to your ot owner's mnul for the loction of the vessel dpter ssemly (VAA). The key for the VAA ws provided long with the ignition keys. 1. Turn the ignition switch to the "OFF" position Unlock nd open the cover of the vessel dpter ssemly. 3. Determine which fuse elongs to the filed circuit using the illustrtion elow. f e d c - Helm power 5 mp fuse - EFP 1 mp fuse c - Feture A 1 mp fuse d - T.15 5 mp fuse e - Feture B 1 mp fuse f - Min power 10 mp fuse 4. Replce the lown fuse with new fuse of the sme rting. 5. Close nd lock the cover of the VAA. Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves fr enough wy from the opertor's position (s in ccidentl ejection from the opertor's position) to ctivte the switch. Tiller hndle outords nd some remote control units re equipped with lnyrd stop switch. A lnyrd stop switch cn e instlled s n ccessory generlly on the dshord or side djcent to the opertor's position. A decl ner the lnyrd stop switch is visul reminder for the opertor to ttch the lnyrd to their personl flottion device (PFD) or wrist Pge M eng DECEMBER 2015

15 Section 1 - Getting to Know Your Power Pckge The lnyrd cord is usully cm (4 5 feet) in length when stretched out, with n element on one end mde to e inserted into the switch nd clip on the other end for ttching to the opertor's PFD or wrist. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. ATTACH LANYARD RUN OFF - Lnyrd cord clip - Lnyrd decl c - Lnyrd stop switch c Red the following Sfety Informtion efore proceeding. Importnt Sfety Informtion: The purpose of lnyrd stop switch is to stop the engine when the opertor moves fr enough wy from the opertor's position to ctivte the switch. This would occur if the opertor ccidentlly flls overord or moves within the ot sufficient distnce from the opertor's position. Flling overord nd ccidentl ejections re more likely to occur in certin types of ots such s low sided infltles, ss ots, high performnce ots, nd light, sensitive hndling fishing ots operted y hnd tiller. Flling overord nd ccidentl ejections re lso likely to occur s result of poor operting prctices such s sitting on the ck of the set or gunwle t plning speeds, stnding t plning speeds, sitting on elevted fishing ot decks, operting t plning speeds in shllow or ostcle infested wters, relesing your grip on steering wheel or tiller hndle tht is pulling in one direction, drinking lcohol or consuming drugs, or dring high speed ot mneuvers. While ctivtion of the lnyrd stop switch will stop the engine immeditely, ot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the ot will not complete full circle. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We strongly recommend tht other occupnts e instructed on proper strting nd operting procedures should they e required to operte the engine in n emergency (if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the gercse or propeller. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking. Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Before ech use, check to ensure the lnyrd stop switch works properly. Strt the engine nd stop it y pulling the lnyrd cord. If the engine does not stop, hve the switch repired efore operting the ot. Before ech use, visully inspect the lnyrd cord to ensure it is in good working condition nd tht there re no reks, cuts, or wer to the cord. Check tht the clips on the ends of the cord re in good condition. Replce ny dmged or worn lnyrd cords. 90-8M eng DECEMBER 2015 Pge 9

16 Section 1 - Getting to Know Your Power Pckge Power Trim Power trim llows the opertor to djust the sterndrive ngle while underwy to provide the idel ot ngle for vrying lod nd wter conditions. Also, the trilering feture llows the opertor to rise nd lower the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM engine speed), nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds, nd single rm trim systems do not provide trim out limiting device or trim indictor. Use cution when trimming with single rm trim system nd never trim out eyond the unit's side support flnges while the ot is underwy or t engine speeds ove 1200 RPM. For est performnce, trim the sterndrive so tht the ot ottom is t 3 5 ngle to the wter. 3-5 mc79528 Trimming the sterndrive up (out) cn: Generlly increse top speed Increse clernce over sumerged ojects or shllow ottom Cuse the ot to ccelerte nd plne off slower In excess, cuse ot porpoising (ouncing) or propeller ventiltion Cuse engine overheting if trimmed up (out) to point where ny cooling wter intke holes re ove the wter line mc78529 Trimming the sterndrive down (in) cn: Help the ot ccelerte nd plne off quicker Generlly improve the ride in choppy wter In most cses, reduce ot speed If in excess, lower the ow of some ots to point t which they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction clled ow steering or over steering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single Engine Trim nd Triler Single engine pplictions hve utton tht cn e pressed to trim the sterndrive unit up (out) or down (in). Pge M eng DECEMBER 2015

17 Section 1 - Getting to Know Your Power Pckge To rise the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM), nd shllow wter opertion push the trim utton to rise the sterndrive to the full up (out) position. Some controls lso hve triler utton tht trims the sterndrive to position suitle for triler purposes only. Dul Engine Trim nd Triler NOTICE If using externl tie rs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie r, rise nd lower ll drives together s unit. Dul engine pplictions my hve single integrl utton to operte oth sterndrives simultneously or my hve seprte uttons for ech sterndrive. Some controls lso hve triler utton tht trims the sterndrives to position suitle for triler purposes only. Power Trim nd MerCthode Overlod Protection If n electricl overlod on the electricl system occurs, fuse will open (low). Find nd correct the cuse efore replcing the fuse. NOTE: If you must operte the engine in n emergency, turn off nd disconnect ll ccessories from the engine nd instrumenttion wiring if you cnnot find nd correct the cuse for the electricl overlod or excessive current drw. Replce the fuse. If the fuse urns out, the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. 1. The power trim system is protected from overlod y 110 mp fuse nd 20 mp in line fuse on the power trim pump mp in line fuse holder mp fuse There re severl different Quicksilver MerCthode systems ville. Ech hs fuse connected to the positive (+) terminl on the controller. If the fuse is open (lown), the system will not operte, resulting in loss of corrosion protection. Replce the fuse with one of the sme mp rting. - MerCthode - Red/purple wire c - Fuse c M eng DECEMBER 2015 Pge 11

18 Section 1 - Getting to Know Your Power Pckge Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) A tmper resistnt lel is ffixed to the engine t time of mnufcture. In ddition to the required exhust gs emissions certificte numer, the lel lists the engine seril numer, engine fmily, mximum RPM, engine power, nd weight. Note tht the exhust gs emissions certifiction will not ffect the fit, function, or performnce of the engines. Botuilders nd delers my not remove the lel or the prt it is ffixed to efore sle. If modifictions re necessry, contct Mercury Diesel out the vilility of replcement decls efore proceeding. xxxxxxxxx x.x xxxxxxxxx x x Owner Responsiility The owner or opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow exhust gs emission levels to exceed their predetermined fctory specifictions. Pge M eng DECEMBER 2015

19 Engine Components Section 1 - Getting to Know Your Power Pckge c d e f g h i Exhust outlet - Turochrger c - Oil filter d - Engine oil filler cp e - Scrificil node (hidden) f - Intercooler g - Sewter pump h - Het exchnger i - Strter 90-8M eng DECEMBER 2015 Pge 13

20 Section 1 - Getting to Know Your Power Pckge c d e f g h i Engine oil dipstick - Coolnt resevoir c - Coolnt reservoir cp d - Ried V elt e - Alterntor f - Fuses g - Air filter h - Fuel injection pump drive elt (hidden) NOTE: The fuel injection pump drive elt is locted t the rer of the engine nd is protected y cover. Refer to your Mercury Diesel uthorized repir fcility for servicing. i - Electronic control units Pge M eng DECEMBER 2015

21 Tle of Contents Sfe Boting Recommendtions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Duty Cycle Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting Bsic Bot Opertion Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump...20 Strting, Shifting, nd Stopping Before Strting the Engine...20 Strting Cold Engine Engine Wrm Up Strting Wrm Engine...21 Shifting Engine Shutdown (Stopping) Strting the Engine After Stopped While in Ger Trilering the Bot Protecting People In The Wter Protecting People in the Wter Section 2 - On The Wter Section 2 - On The Wter While Bot is in Opertion While the Bot is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection...26 Brek In Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...26 Engine Brek In Hour Brek In Period After the 20 Hour Brek In Period End of First Seson Checkup M eng DECEMBER 2015 Pge 15

22 Section 2 - On The Wter Sfe Boting Recommendtions To sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions nd consider the following suggestions. Know nd oey ll nuticl rules nd lws of the wterwys. We recommend tht ll powerot opertors complete oting sfety course. In the U.S., the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency provide courses. For more informtion in the U.S., cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment onord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Tools necessry for minor repirs Anchor nd extr nchor line Mnul ilge pump nd extr drin plugs Drinking wter Rdio Pddle or or Spre propeller, thrust hus, nd n pproprite wrench First id kit nd instructions Wterproof storge continers Spre operting equipment, tteries, uls, nd fuses Compss nd mp or chrt of the re Personl flottion device (one per person onord) Wtch for signs of wether chnge nd void foul wether nd rough se oting. Tell someone where you re going nd when you expect to return. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there e U.S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessile for every person onord, plus throwle cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the ot. Prepre other ot opertors. Instruct t lest one person onord in the sics of strting nd operting the engine nd ot hndling in cse the driver ecomes disled or flls overord. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot's cpcity plte). Know your ot's operting nd loding limittions. Know if your ot will flot if it is full of wter. When in dout, contct your uthorized Mercury Mrine deler or the ot mnufcturer. Ensure tht everyone in the ot is properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the cks of sets, gunwles, trnsom, ow, decks, rised fishing sets, nd ny rotting fishing set. Pssengers should not sit or ride nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of ot control, or sudden ot movement could cuse person to e thrown overord or into the ot. Ensure tht ll pssengers hve proper set nd re in it efore ny ot movement. Never operte ot while under the influence of lcohol or drugs. It is the lw. Alcohol or drugs cn impir your judgment nd gretly reduce your ility to rect quickly. Know your oting re nd void hzrdous loctions. Pge M eng DECEMBER 2015

23 Be lert. Section 2 - On The Wter The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertor's view when the ot is ove idle or plning trnsition speed. Wtch out for others, the wter, nd your wke. Never drive your ot directly ehind wter skier. Your ot trveling t 40 km/h (25 mph) will overtke fllen skier who is 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your ot for wterskiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the ot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required y lw to file oting ccident report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds $500.00, or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Cron monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl comustion engines, including the engines tht propel ots, nd the genertors tht power ot ccessories. By itself, CO is odorless, colorless, nd tsteless, ut if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of cron monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Inhling engine exhust gses cn result in cron monoxide poisoning, which cn led to unconsciousness, rin dmge, or deth. Avoid exposure to cron monoxide. Sty cler from exhust res when engine is running. Keep the ot well ventilted while t rest or underwy. Sty Cler of Exhust Ares Engine exhust gses contin hrmful cron monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the ot, nd do not sit, lie, or stnd on swim pltforms or ording ldders. While underwy, do not llow pssengers to e positioned immeditely ehind the ot (pltform drgging, tek/ody surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, ut lso sujects them to the possiility of injury from the ot propeller. Good Ventiltion Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the ot: M eng DECEMBER 2015 Pge 17

24 Section 2 - On The Wter Poor Ventiltion Under certin running or wind conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry ot tht contins or is ner running engine my e exposed to hzrdous level of cron monoxide. 1. Exmples of poor ventiltion while the ot is sttionry: - Operting the engine when the ot is moored in confined spce - Mooring close to nother ot tht hs its engine operting 2. Exmples of poor ventiltion while the ot is moving: Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Duty Cycle Bsic Bot Opertion IMPORTANT: Dmge cused y improper ppliction or filure to operte the power pckge within the specified operting prmeters will not e covered y the Mercury Diesel Limited Wrrnty. Duty Cycle Rting It is the responsiility of the ot mnufcturer or the instlling deler to ensure tht the power pckge is properly pplied. In ll cses, the power pckge must e equipped with the ger rtio tht llows the engine to operte t wide open throttle (WOT) t the rted engine RPM. The power pckge must lso e pplied in ccordnce with recommendtions indicted in the pproprite pplictions mnul. Use of Mercury Diesel engines in other thn the pplictions indicted y the following informtion nd in the pproprite pplictions mnul requires written pprovl from n uthorized Mercury Diesel ppliction engineer. Plesure Duty Rting The plesure duty rting pplies to recretionl plning crft used exclusively for plesure nd recretion. Typicl plesure crft include silots, ski ots, runouts, speedots, nd other plning hulls. Appliction must conform to the Plesure Crft/Recretionl duty cycle shown in the following tle. Pge M eng DECEMBER 2015

25 Section 2 - On The Wter EPA Mode Numer Cycle 5 Duty Cycle Modes Engine speed (percent of WOT) Idle Engine power (percent of totl) Time t given mode (percent of totl operting time) Chrt showing full power opertion is limited to mximum of 1 of 12 hours 1 - Mode 1: 1.0 hour (8%) 2 - Mode 2: 1.5 hours (13%) 3 - Mode 3: 2.0 hours (17%) 4 - Mode 4: 4.0 hours (32%) 5 - Mode 5: 3.5 hours (30%) Bsic Bot Opertion Opertion Chrt Strting Procedure After Strting While Underwy Stopping nd Shut Down Open the engine htch. Air out the ilge completely. Turn the ttery switch on, if equipped. Turn on nd run the engine comprtment ilge lower, if equipped, for five minutes. Check for leks: fuel, oil, wter, fluid, etc. Open the fuel shut off vlve, if equipped. Open the secock, if equipped. Prime the fuel injection system, if necessry. Turn the key switch to "START" position. Relese the key when the engine strts. Wrm up the engine t fst idle RPM for severl minutes. Oserve ll instrumenttion to monitor the condition of the engine. If not norml, stop the engine. Check for fuel, oil, wter, fluid, nd exhust leks, etc. Check shift nd throttle control opertion. Check steering opertion. Frequently review ll instrumenttion to monitor engine condition. Listen for the udio lrm. Shift the remote control lever to the neutrl position. Run the engine t idle RPM for severl minutes to llow the turochrger nd engine to cool. Turn the key switch to "OFF" position. Turn the ttery switch off, if equipped. Close the fuel shut off vlve, if equipped. Close the secock, if equipped. Flush the sewter cooling circuit, if operting in sltwter, rckish wter, or polluted wter. Freezing Temperture nd Cold Wether Opertion IMPORTANT: If the ot is operted during periods of freezing temperture, tke precutions to prevent freezing dmge to the power pckge. Dmge cused y freezing is not covered y the Mercury Mrine Limited Wrrnty. 90-8M eng DECEMBER 2015 Pge 19

26 Section 2 - On The Wter NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd connect the wter inlet hose efore strting the engine. In order to operte the engine in tempertures of 0 C (32 F) or lower, oserve the following instructions: At the end of ech dily opertion, completely drin the sewter section of the cooling system to protect ginst dmge y freezing. At the end of ech dily opertion, drin the wter from the wter seprtor, if equipped. Fill the fuel tnk t the end of dily opertion to prevent condenstion. Use the required permnent type ntifreeze solution to protect components ginst dmge y freezing. Use proper cold wether luriction oil; ensure tht the crnkcse contins sufficient mount. Mke certin tht the ttery is of sufficient size nd is fully chrged. Check tht ll other electricl equipment is in optimum condition. At tempertures of 20 C ( 4 F) nd elow, use coolnt heter nd mrine ppliction ilge ir heter to improve cold strting. If operting in rctic tempertures of 29 C ( 20 F) or lower, consult your Mercury Diesel uthorized repir fcility for informtion out specil cold wether equipment nd precutions. Refer to Section 6 for cold wether or extended storge relted informtion. Drin Plug nd Bilge Pump The engine comprtment in your ot is nturl plce for wter to collect. For this reson, ots re normlly equipped with drin plug or ilge pump. It is very importnt to check these items on regulr sis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will e dmged if sumerged. Dmge cused y sumersion is not covered y the wrrnty. Strting, Shifting, nd Stopping! WARNING Vpors cn ignite nd cuse n explosion, resulting in engine dmge or severe personl injury. Do not use voltile strting ids such s ether, propne, or gsoline in the engine ir intke system.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. Before Strting the Engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. IMPORTANT: Oserve the following efore strting: Verify sewter pickup is open. Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit one minute to llow the strter motor to cool; then, repet the strting procedure. Ensure tht the engine crnkcse is filled to the correct level with the proper grde of oil for the previling temperture. Refer to Specifictions Engine Oil. Ensure tht ll electricl connections re secure. Check ll items listed in the mintennce schedules nd Opertion Chrt. Perform ny other necessry checks s indicted y your Mercury Diesel uthorized repir fcility or specified in your ot owner s mnul. Pge M eng DECEMBER 2015

27 Section 2 - On The Wter Strting Cold Engine IMPORTANT: Check the fluid levels efore strting the engine. Refer to the Mintennce Schedule. Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit one minute to llow the strter motor to cool; then, repet the strting procedure. 1. Run the engine comprtment ilge lower for five minutes, or open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the sterndrive in the full down (in) position. 3. Plce the control hndle in neutrl. 4. If the engine hs not een run for long period of time nd will not redily strt with the stndrd strting procedure, proceed s follows. 5. Turn the ignition switch to the "ON" position nd the fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit for five seconds. repet this step six times. 6. Strt the engine. IMPORTANT: Within seconds fter strting the engine, the oil pressure should exceed minimum of 10 psi (69 kp). If the oil pressure is elow the minimum specifiction, stop the engine then locte nd correct the prolem. If you re unle to determine the prolem, see your Mercury Diesel uthorized repir fcility. NOTICE Engging the strter motor while the engine is operting cn dmge the strter motor or flywheel. Do not engge the strter motor continully for longer thn 15 seconds. Do not engge the strter motor when the engine is operting. 7. Verify tht the chrge indictor nd oil pressure wrning lmps re off. 8. Verify tht ll instrumenttion is functioning properly nd indicting norml redings. 9. Allow the engine to rech norml operting temperture efore demnding power from the engine. Engine Wrm Up 1. After strting the engine, verify tht ll instrumenttion is functioning properly. 2. Operte the engine t RPM until the engine temperture is within the norml operting rnge. It is importnt tht ny engine e wrmed up efore pplying full lod. The wrm up period provides time for the luricting oil to estlish film etween moving prts. NOTICE Engine wer cused y incresed friction nd limited oil flow is gretest when n engine is cold. Decrese engine wer y llowing the engine coolnt temperture to rech norml operting rnge efore hrd ccelertion or pplying full throttle. 3. After the engine hs reched operting temperture:. The oil pressure should e within the rnge specified. Refer to Specifictions Engine Specifictions. Stop the engine if the oil pressure is not within the rnge specified.. Check the fuel system for lekge from the injection pump, fuel pipes, fuel filter, or fuel lines. c. Check the engine nd drive system for oil lekge. Specificlly inspect the oil filter, oil lines, oil line connectors, nd oil pn. d. Check for coolnt leks. Check the coolnt hoses nd connection pipes of the het exchnger, fluid coolers, ftercooler, wter pump, nd drin fittings for leks. 4. Correct ny prolems found, or see your Mercury Diesel uthorized repir fcility if you re unle to determine the prolem. Strting Wrm Engine 1. Run the engine comprtment ilge lower for five minutes, or open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Move the remote control hndle to the "NEUTRAL" position. 3. Turn the key switch to the "ON" position. 4. Turn the key switch to the "START" position nd relese the key when the engine strts. Verify tht the chrge indictor nd oil pressure wrning lmps turn off. 5. Verify tht the instrumenttion functions properly nd norml redings re indicted. 90-8M eng DECEMBER 2015 Pge 21

28 Section 2 - On The Wter Shifting NOTICE Shifting into ger t engine speeds ove idle will dmge the gercse. Shifting into ger when the engine is not running cn mislign the clutch, preventing proper shifting. Alwys shift the gercse into ger when the engine is operting t idle. If you must shift while the engine is not operting, rotte the propeller shft in the pproprite direction during shifting. 1. Verify tht the remote control shift lever is in neutrl. 2. To shift the sterndrive, move the remote control shift lever with firm, quick motion forwrd to shift to forwrd ger, or ckwrd to shift into reverse. 3. After shifting the sterndrive, dvnce the throttle to the desired setting. IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, proceed to steps 4 nd 5: 4. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped. 5. After the hndle returns to the neutrl detent position, resume norml strting procedures. Engine Shutdown (Stopping) 1. Plce the remote control lever in neutrl. NOTICE Immeditely stopping the engine fter high lod opertion cn dmge the turochrger erings. Idle the engine for severl minutes efore shutdown. 2. Operte the engine t idle speed for severl minutes to llow the turochrger nd engine to cool. 3. Turn the key switch to the "OFF" position or press the strt stop switch utton if equipped. Strting the Engine After Stopped While in Ger IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 1. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped. 2. After the hndle returns to the neutrl detent position, resume norml strting procedures. Trilering the Bot Your ot cn e trilered with the sterndrive unit in the up or down position. Adequte clernce is required etween the rod nd sterndrive when trnsporting. If dequte rod clernce is prolem, plce the sterndrive unit in full triler position nd support it with n optionl triler kit, ville t your Mercury Diesel uthorized repir fcility. Protecting People In The Wter While Bot is in Opertion People in the wter cnnot tke quick ction to void ot heding in their direction Approch slowly nd exercise extreme cution when oting in res where people my e in the wter. When ot is moving nd the ger shift is in neutrl, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. Pge M eng DECEMBER 2015

29 Section 2 - On The Wter While the Bot is Sttionry! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Shift into neutrl nd shut down the engine efore llowing people in the wter ner the ot. High Speed nd High Performnce If your ot is high speed or high performnce ot with which you re unfmilir, we recommend tht you never operte it t its high speed cpility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your ot. For dditionl informtion, refer to the High Performnce Bot Opertion ooklet ( R2) from your uthorized Mercury Diesel repir fcility. Pssenger Sfety in Pontoon Bots nd Deck Bots Whenever the ot is in motion, oserve the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in ot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of ot direction, could throw them over the front of ot. Flling over the front of the ot etween the two pontoons will position them to e run over. Bots Hving n Open Front Deck No one should ever e on the deck in front of the ril while the ot is in motion. Keep ll pssengers ehind the front ril or enclosure. Persons on the front deck could esily e thrown overord or persons dngling their feet over the front edge could get their legs cught y wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the ot not designed for pssengers t speeds ove idle cn cuse serious injury or deth. Sty ck from the front end of deck ots or rised pltforms nd remin seted while the ot is in motion. Bots with Front-Mounted, Rised-Pedestl Fishing Sets Elevted fishing sets re not intended for use when the ot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in ot speed could result in the elevted pssenger flling over the front of the ot. mc M eng DECEMBER 2015 Pge 23

30 Section 2 - On The Wter Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. mc Operting recretionl ots over wves nd wkes is nturl prt of oting. However, when this ctivity is done with enough speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot reenters the wter. The primry concern is the ot chnging direction while in the midst of the jump. In such cses the lnding my cuse the ot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to e thrown out of their sets or out of the ot. There is nother less common hzrdous result from llowing your ot to lunch off of wve or wke. If the ow of your ot pitches down fr enough while irorne, upon wter contct it my penetrte under the wter surfce nd sumrine for n instnt. This will ring the ot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The ot my lso veer shrply to one side. Impct with Underwter Hzrds Reduce speed nd proceed with cution when operting in shllow wter or in res where the wters re suspected of hving underwter ostcles tht could e struck y the drive components, rudder, or the ot ottom. mc IMPORTANT: To help reduce injury or impct dmge from striking floting or underwter oject, control the ot speed. Under these conditions, ot speed should e kept to mximum of 24 to 40 km/h (15 to 25 mph). The following demonstrte some, ut not ll, exmples of wht cn hppen if the ot strikes n oject: The ot could move suddenly in new direction. A shrp chnge in direction or turn cn throw occupnts out of their sets or out of the ot. A rpid reduction in speed. This will cuse occupnts to e thrown forwrd, even out of the ot. Impct dmge to the underwter drive components, rudder, or ot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the ot speed. Bot speed should e kept to minimum plning speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect the drive system for ny roken or loose prts. If dmge is present or suspected, the power pckge should e tken to Mercury Diesel uthorized repir fcility for thorough inspection nd ny necessry repir. The ot should e checked for hull frctures, trnsom frctures, nd wter leks. Operting with dmged drive components, rudder, or ot ottom could cuse dmge to other prts of the power pckge, or could ffect control of the ot. If continued opertion is necessry, do so t gretly reduced speeds. Pge M eng DECEMBER 2015

31 ! WARNING Section 2 - On The Wter Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Shifting weight to the rer (stern): Generlly increses speed nd engine RPM Cuses ow to ounce in choppy wter Increses dnger of following wve splshing into the ot when coming off plne At extremes, cn cuse the ot to porpoise Shifting weight to the front (ow): Improves ese of plning Improves rough wter ride At extremes, cn cuse the ot to veer ck nd forth (ow steer) Bottom of Bot To mintin mximum speed, ensure tht the ot ottom is: Clen, free of rncles nd mrine growth Free of distortion, nerly flt where it contcts wter Stright nd smooth, fore nd ft Mrine vegettion my ccumulte when the ot is docked. This growth must e removed efore opertion; it my clog wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion increses propeller speed while reducing ot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other deris sngged on the propeller Bent propeller lde Rised urrs or shrp edges on the propeller Ventiltion Ventiltion is cused y surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in ot speed. Air ules strike the propeller lde nd cuse erosion of the lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Excessive ventiltion is usully cused y: The drive unit eing trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, tht llows exhust gses to escpe etween the propeller nd ger housing The drive unit instlled too high on trnsom Elevtion nd Climte Elevtion nd climte chnges ffect the performnce of your power pckge. Loss of performnce cn e cused y: High elevtions High tempertures Low rometric pressures High humidity For you to hve optimum engine performnce under chnging wether conditions, it is essentil tht the engine e propped to llow the engine to operte t or ner the top end of the specified mximum RPM rnge with norml ot lod during your norml oting wether conditions. In most cses, the recommended RPM cn e chieved y chnging to lower pitch propeller. 90-8M eng DECEMBER 2015 Pge 25

32 Section 2 - On The Wter Propeller Selection NOTICE Operting the engine with the wrong propeller instlled cn limit power, increse fuel consumption, overhet the engine, or cuse internl powerhed dmge. Choose propeller tht llows the engine to operte t the specified wide open throttle RPM. It is the responsiility of the ot mnufcturer nd the selling deler to equip the power pckge with the correct propellers. IMPORTANT: Be sure tht the propeller eing used does not llow the engine to run ginst the limiter, s significnt loss in performnce will result. NOTE: Use n ccurte service tchometer to verify RPM. Select propeller tht will llow the engine power pckge to operte t the rted engine RPM with full lod. If full throttle opertion is elow the rted engine RPM, the propeller must e chnged to prevent loss of performnce nd possile engine dmge. On the other hnd, operting n engine ove the rted engine RPM will cuse higher thn norml wer or dmge. After initil propeller selection, the following common prolems my require tht the propeller e chnged to lower pitch: Wrmer wether nd greter humidity cuse n RPM loss (not s significnt on these models). Operting in higher elevtion cuses n RPM loss (not s significnt on these models). Operting with dmged propeller or dirty ot ottom cuses n RPM loss. Operting with incresed lod (dditionl pssengers, pulling skiers). For etter ccelertion, such s is needed for wter skiing, use the next lower pitch propeller. Do not operte t full throttle when using the lower pitch propeller ut not pulling skiers. Brek In Initil Brek In Procedure It is especilly importnt tht the following procedure e used on new diesel engines. This rek in procedure llows the proper seting of the pistons nd rings, which gretly reduces the likelihood of prolems. IMPORTANT: It is recommended tht the ot not e ccelerted hrd until this procedure hs een completed. IMPORTANT: Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit pproximtely 60 seconds to llow the strter motor to cool; then, repet the strting procedure. 1. See the pproprite Strting, Shifting, nd Stopping section, nd strt the engine. Operte the engine t fst idle until it hs reched norml operting temperture. 2. Operte the engine in ger for three minutes t : 1200 RPM, 2400 RPM, nd 3000 RPM. 3. Operte the engine in ger for three minutes t: 1500 RPM, 2800 RPM, nd 3400 RPM. 4. Operte the engine in ger for three minutes t : 1800 RPM, 3000 RPM, nd mximum rted full throttle RPM. Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) It is importnt tht the following procedure e used on new sterndrives nd reuilt sterndrives with new replcement gers. This rek in procedure llows the proper seting of the sterndrive gers nd relted components, which gretly reduces the likelihood of prolems. Avoid full throttle strts. Do not operte t ny constnt speed for n extended period of time. Do not exceed 75% throttle during the first five hours. During the next five hours, operte t intermittent full throttle. The sterndrive should e shifted into forwrd ger minimum of 10 times during rek in, with run in time t moderte RPM fter ech shift. Engine Brek In 20-Hour Brek-In Period IMPORTANT: The first 20 hours of opertion is the engine rek in period. Correct rek in is essentil to otin minimum oil consumption nd mximum engine performnce. During this rek in period, the following rules must e oserved: Do not operte elow 1500 RPM for extended periods of time for the first 10 hours. Shift into ger s soon s possile fter strting, nd dvnce the throttle ove 1500 RPM if conditions permit sfe opertion. Do not operte t ny constnt speed for n extended period of time. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occsionl opertion t full throttle is permissile (in five minute intervls). Pge M eng DECEMBER 2015

33 Section 2 - On The Wter Avoid full throttle ccelertion from n idle. Do not operte t full throttle until the engine reches norml operting temperture. Check engine oil level frequently. Add oil s needed. High oil consumption is norml during the rek in period. At the end of the 20 hour rek in period, chnge the engine oil nd filter s specified. Refer to Specifictions nd Mintennce. After the 20-Hour Brek-In Period To help extend the life of the power pckge, Mercury Diesel recommends the following: Select propeller tht functions efficiently throughout the recommended engine powernd for fully loded ot. Refer to Specifictions nd Mintennce. Never operte t wide open throttle for prolonged periods. Opertion t 3/4 throttle nd elow is recommeneded. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized Mercury Diesel repir fcility regrding scheduled mintennce items. If the product is operted on continuous, or yer round sis, contct the deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. 90-8M eng DECEMBER 2015 Pge 27

34 Section 2 - On The Wter Notes: Pge M eng DECEMBER 2015

35 Tle of Contents Section 3 - Specifictions Section 3 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine...32 Brvo Sterndrive Fluid Specifictions Diesel Power Steering nd Power Trim Fluids Approved Power Steering Fluids Approved Power Trim Fluids Approved Pints M eng DECEMBER 2015 Pge 29

36 Section 3 - Specifictions Fuel Requirements! WARNING Filure to comply with regultions cn result in injury from fire or explosion. Electricl system components on this engine re not rted s externl ignition protected (EIP). Do not store or use gsoline on ots equipped with these engines, unless provisions hve een mde to exclude gsoline vpors from the engine comprtment (REF: 33 CFR).! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement efore further engine opertion.! WARNING This engine requires diesel fuel. Mixing gsoline, gsohol, or lcohol nd diesel fuel cn cuse serious injury or deth due to fire or explosion. Never mix gsoline, gsohol, or lcohol with diesel fuel. IMPORTANT: Use of improper or wter contminted diesel fuel cn seriously dmge your engine. Use of improper fuel is considered misuse of the engine, nd dmge cused therey will not e covered y the wrrnty. Mercury diesels re required to use Grde No. 2 D ULSD (ultr low sulphur diesel) fuel meeting ASTM Stndrds D975 (or fuel rted Diesel DIN EN 590), nd hving minimum cetne rting of 40. BIODIESEL: The lend of diesel fuel used my not contin more thn 7% iodiesel fuel. Use of LSD or lends of ULSD fuel contining more thn 7% iodiesel fuel my result in fuel system degrdtion, injection nozzle clogging, hrd strting, incresed oil chnge intervls, or excessive exhust smoke. The cetne numer is mesure of the ignition qulity of diesel fuel. Incresing the cetne numer will not improve overll engine performnce, ut it my e necessry to rise the cetne rting for low temperture or high ltitude use. A lower cetne numer could cuse hrd strting nd slower wrm up, nd could increse engine noise nd exhust emissions. NOTE: If your engine suddenly ecomes noisy fter fill up, you possily received sustndrd fuel with low cetne rting. On intermittent use engines, high sulphur content diesel fuel will gretly increse: Corrosion on metl prts Deteriortion of elstomer nd plstic prts Excessive wer of internl engine prts, prticulrly erings, nd corrosion nd extensive dmge to other engine prts Difficulty strting nd operting the engine Nonferrous Metls nd the Fuel System Nonferrous metls must not e used in the fuel system components. The use of items such s copper lines, rss nipples, or glvnized tnks my result in n engine power loss or filure of the injection nozzles. Diesel Fuel in Cold Wether Unltered diesel fuels thicken nd gel in cold tempertures unless treted. Virtully ll diesel fuels re climtized to llow their use in the prticulr region for tht time of the yer. If it ecomes necessry to further tret diesel fuel, it is the owner/opertor's responsiility to dd commercil stndrd rnd of ntigel diesel fuel dditive, following tht product's directions. Antifreeze/Coolnt NOTICE Using propylene glycol ntifreeze in the closed cooling system cn dmge the cooling system or the engine. Fill the closed cooling system with n ethylene glycol ntifreeze solution suitle to the lowest temperture to which the engine will e exposed. Diesel engines re high compression engines tht operte t higher tempertures thn typicl insternl comustion engines. Therefore, the closed cooling system nd engine, including relted cooling pssges, must remin s clen s possile to provide dequte engine cooling. To ensure proper cooling, we recommend filling the closed cooling section of the cooling system with low silicte formul of ethylene glycol ntifreeze in solution with deionized wter. Common tp wter or softened wter contins unwnted minerls tht cn leve lrge deposits in the system tht restrict the cooling system efficiency. A low silicte formul prevents the ntifreeze from seprting nd forming silicte geltin. This geltin cn lock pssges in the engine nd het exchnger, cusing the engine to overhet. Pge M eng DECEMBER 2015

37 Section 3 - Specifictions Only premixed, coolnt should e dded to the closed cooling system. Additives nd inhiitors introduced into cceptle coolnt solutions will form protective film on the internl pssges nd provide protection ginst internl cooling system erosion. Do not drin the closed cooling section for storge. The closed cooling section should e kept filled yer round with n cceptle ntifreeze/coolnt solution to void rust forming on the internl surfces. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with properly mixed ntifreeze/coolnt solution to protect the engine nd closed cooling system to the lowest temperture to which they will e exposed. NOTE: It is recommended tht 50/50 solution of coolnt (ntifreeze) nd deionized, purified wter e used. A 50/50 solution will provide freeze protection to 35 C ( 31 F). Decresing the solution to 40/60 will provide freeze protection to 25 C ( 13 F). Even in the wrmest climtes, never decrese the solution elow 40/60. Incresing the solution to 60/40 will provide freeze protection to 50 C ( 58 F). IMPORTANT: The ntifreeze/coolnt used in these mrine engines must e low silicte ethylene glycol, contining specil dditives, nd deionized, purified wter. Using other types of engine coolnt my cuse fouling of the het exchngers nd overheting of the engine. Do not comine different types of coolnts without knowing tht they re comptile. Refer to the coolnt mnufcturer's instructions. The cceptle ntifreeze/coolnts is listed in the following tle. Refer to Section 5 Mintennce for respective chnge intervls. Description Avilility Prt Numer Mrine Engine Coolnt Worldwide 8M Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Engine oil must e 5W 30 viscosity, nd meet VW Stndrd / We strongly recommend the use of: Description Where Used Prt Numer 5W 30 (1 L) Engine crnkcse 8M W 30 (4 L) Engine crnkcse 8M Engine Specifictions Engine type Displcement Description Specifiction V8 diesel 4.2 L (252 cid) Firing order Bore Stroke Rted engine RPM (refer to Conditions Affecting Opertion Propeller Selection for dditionl informtion) Idle RPM in neutrl (engine t norml operting temperture) Oil pressure t ny engine temperture 83.0 mm (3.27 in.) 95.5 mm (3.75 in.) Refer to Performnce Curve nd Dt Sheet TDI (ville t RPM 750 RPM kp (22 45 psi) 3800 RPM kp (50 80 psi) Thermostt Wter 70 C (158 F) Coolnt temperture C ( F) Electricl system Bttery* Alterntor 12 volt negtive ( ) ground 750 CCA, 950 MCA, or 180 mah *Bttery mnufcturers my rte nd test their tteries to different stndrds. MCA, CCA, Ah, nd Reserve Cpcity (RC) re the rtings recognized y Mercury Mrine. Mnufcturers tht use stndrds different thn these, such s equivlent MCA, do not meet Mercury Mrine ttery requirements. 120 A 90-8M eng DECEMBER 2015 Pge 31

38 Section 3 - Specifictions Fluid Specifictions IMPORTANT: All cpcities re pproximte fluid mesures. Engine IMPORTANT: It my e necessry to djust oil levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). All models Cpcity Fluid Type Prt Numer Engine oil (with filter) 9.5 L (10.0 US qt) 5W 30 4 cycle Diesel Engine Oil (1 L) 8M W 30 4 cycle Diesel Engine Oil (4 L) 8M Closed cooling system 15.0 L (15.8 US qt) Mrine Engine Coolnt 8M Hydrulic oil Hydrulic oil K01 Brvo Sterndrive Fluid Specifictions Diesel Sterndrive Model Fluid Cpcity includes the Sterndrive nd the Ger Lue Monitor Fluid Type Brvo One XR 2736 ml (92 1/2 oz) High Performnce Ger Brvo Three XR 2972 ml (100 1/2 oz) Luricnt Fluid Prt Numer A1 Power Steering nd Power Trim Fluids Approved Power Steering Fluids Description Prt Numer Power Trim nd Steering Fluid A1 Dextron III Automtic Trnsmission Fluid Otin Loclly Approved Power Trim Fluids Description Prt Numer Power Trim nd Steering Fluid A1 SAE Engine Oil 30W Otin loclly SAE Engine Oil 40W Otin loclly Approved Pints Description Prt Numer Mercury Light Gry Primer Mercury Phntom Blck Q 1 Diesel White 8M Pge M eng DECEMBER 2015

39 Tle of Contents Section 4 - Mintennce Section 4 - Mintennce Owner nd Opertor Responsiilities Deler Responsiilities Mintennce Replcement Prts Wrning Inspection Routine Mintennce Strt of Seson Ech Dy Strt Ech Dy End Weekly End of Seson Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Mintennce Notice Every 5 Yers or 500 Hours (Whichever Occurs First) Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) Engine Oil Checking Filling Drining Using the Esy Drin System, if Equipped Chnging Oil nd Filter Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Steering Fluid Checking Filling Chnging Engine Coolnt Checking the Coolnt Level Adding Coolnt Air Filter Removl Inspection nd Clening Instlltion Fuel Filter Drining Wter from the Filter Replcing the Filter Purging the Fuel System Fuel System Priming Fuel Tnk Clening nd Flushing Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing nd Drining the Sewter System...51 Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Scrificil Anode Antifouling Pint Luriction Steering System Throttle Cle Shift Cle Trnsom Assemly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Giml Ring U olt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches Bttery Isoltors Genertors M eng DECEMBER 2015 Pge 33

40 Section 4 - Mintennce Owner nd Opertor Responsiilities It is the opertor's responsiility to perform ll sfety checks, to ensure tht ll luriction nd mintennce instructions re complied with for sfe opertion, nd to return the unit to Mercury Diesel uthorized repir fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsiility of the owner or opertor nd re not covered y the terms of the wrrnty. Individul operting hits nd usge contriute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependility nd will keep your overll operting expenses t minimum. See your Mercury Diesel uthorized repir fcility for service ids. Deler Responsiilities Below is list of Mercury Diesel deler predelivery inspection nd preprtion responsiilities: Verify tht the power pckge is in proper operting condition. Mke ny necessry djustments for mximum efficiency. Explin nd demonstrte the opertion of the power pckge nd the ot. Provide copy of the Predelivery Inspection Checklist. Fill out the wrrnty registrtion crd completely nd mil it to the fctory immeditely upon sle of the new product. All power pckges must e registered for wrrnty purposes. Mintennce! WARNING Neglect or improper mintennce, repirs, or inspections of the power pckge cn result in product dmge or serious injury or deth. Perform ll procedures s descried in this mnul. If you re not fmilir with proper mintennce or service procedures, consign the work to n uthorized Mercury Mrine deler.! WARNING Accidentl engine strting cn cuse serious injury or deth. Remove the key from the ignition switch nd engge the lnyrd stop or E stop switch to prevent the engine from strting when performing service or mintennce on the power pckge.! WARNING Engine components nd fluids re hot nd cn cuse serious injury or deth. Allow the engine to cool efore removing ny components or opening ny fluid hoses.! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. IMPORTANT: Refer to Mintennce Schedule for complete listing of ll scheduled mintennce to e performed. Some tsks cn e done y the owner or opertor, while others should e performed y n uthorized Mercury Diesel repir fcility. Before ttempting mintennce or repir procedures not covered in this mnul, we recommended tht you purchse the pproprite Mercury Diesel service mnul nd red it thoroughly. Before performing ny mintennce on your Mercury Diesel engine: Protect yourself with suitle work clothing nd personl protection equipment. Stop the engine, remove the ignition key, nd press the emergency stop switch. Move the throttle to the neutrl position. Allow the engine to cool. Ventilte the engine comprtment for t lest five minutes efore eginning work. Disconnect the ttery, if servicing ny electricl components. Alwys disconnect the negtive ( ) led first nd reconnect it lst. Pge M eng DECEMBER 2015

41 Section 4 - Mintennce Replcement Prts Wrning! WARNING Avoid fire or explosion hzrd. Electricl, ignition, nd fuel system components on Mercury Mrine products comply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replcement electricl or fuel system components tht do not comply with these stndrds. When servicing the electricl nd fuel systems, properly instll nd tighten ll components. Inspection Inspect your power pckge often nd t regulr intervls to help mintin operting performnce nd to identify potentil prolems efore they occur. The entire power pckge should e checked crefully, including ll ccessile engine prts. 1. Check for loose, dmged, or missing prts, hoses, nd clmps; tighten or replce s necessry. 2. Check electricl connections nd leds for dmge. 3. Remove nd inspect the propeller. If it is dly nicked, ent, or crcked, contct your Mercury Diesel uthorized repir fcility. 4. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your Mercury Diesel uthorized repir fcility. Routine Mintennce Strt of Seson Inspect the power pckge for leks nd dmge. Inspect the ccessory drive elts, hoses, nd power steering pump (if pplicle). Inspect the fuel injection pump drive elt condition. Verify tht the secock opertes properly. Check the chrge, connections, nd condition of the ttery. Chrge or replce the ttery s necessry. Check ll fluid nd luricnt levels, nd djust them s necessry. Inspect the nodes nd replce them if they re 50% eroded. Ech Dy Strt Inspect the power pckge for leks nd dmge. Check the engine oil level nd djust it s necessry. Check the engine coolnt level nd djust it s necessry. Check the condition of the fuel filter. Drin wter from the filter s necessry. Check the sewter striner nd clen it s necessry. Check the drive luricnt level (if pplicle), nd djust it s necessry. Check the reverse gerox luricnt level nd djust it s necessry, where pplicle. Clen the guges. Inspect the ir filter for discolortion nd contminnts. Ech Dy End If operting in sltwter, rckish wter, or polluted wter, flush the sewter section of the cooling system. Drin ny wter from the fuel filter, if operting in freezing tempertures. Weekly Inspect the power pckge for leks nd dmge. Drin ny wter from the fuel filter. Check the trim pump fluid level, if pplicle. Check the sewter inlets for deris or mrine growth. Check nd clen the sewter striner. Inspect the nodes, nd replce them if they re 50% eroded. Inspect the ir filter for discolortion nd contminnts. End of Seson Inspect the power pckge for leks or dmge. 90-8M eng DECEMBER 2015 Pge 35

42 Section 4 - Mintennce Chnge the engine oil nd filter. Check the coolnt level nd djust it s necessry. Check the sewter pump impeller nd replce it s necessry. Check the ir filter element nd clen it s necessry. Check nd clen the sewter striner. Inspect the nodes nd replce them if they re 50% eroded. Clen the engine nd replce worn or dmged components. Flush, drin, nd winterize the sewter cooling system, if the climte requires it. Fill the fuel tnk with fresh fuel. Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Inspect the power pckge for leks nd dmge. Check the chrge, connections, nd condition of the ttery. Chrge or replce the ttery s necessry. Chnge the engine oil nd filter element. Drin ny wter nd chnge the fuel filter. Check the power steering hydrulic oil level (if pplicle), nd djust it s necessry. Inspect the coolnt level nd djust it s necessry. Inspect the ir filter element nd clen it s necessry. Inspect the ccessory drive elts, hoses, nd power steering pump, where pplicle. Inspect the fuel injection pump drive elt condition. Inspect nd clen the sewter striner. Inspect the sewter pump nd chnge the impeller s necessry. Inspect the nodes nd replce them if they re 50% eroded. Verify tht the guges nd the wiring connections re secure. Mintennce Notice IMPORTANT: Due to the risk of dmging equipment if they re performed incorrectly, we highly recommended tht the following scheduled mintennce items e performed only y Mercury Diesel uthorized repir fcility. Every 5 Yers or 500 Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours intervl: Clen the intercooler core. Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours intervl: Clen the fuel tnk. Check the het exchnger pipe undles. Remove nd clen them s necessry: Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours nd Every 5 Yers or 1,000 Operting Hours intervls: Replce the fuel injection pump drive elt. Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Pge M eng DECEMBER 2015

43 Section 4 - Mintennce Checking NOTICE With the engine running, the crnkshft journls or rod journls my strike nd rek the dipstick, resulting in dmge to internl engine components. Stop the engine completely efore removing or inserting the dipstick. 1. If it ecomes necessry to check the engine oil level during opertion, stop the engine nd llow five minutes for the oil to drin into the pn. 2. Remove the dipstick, wipe it clen, nd insert the dipstick ck into the dipstick tue. 3. Remove the dipstick nd check the oil level. The oil level must e etween the indictor mrks on the dipstick. If necessry, dd oil s follows. Dipstick indictor mrks - Do not dd oil - Sfe operting rnge c - Add oil c Filling IMPORTANT: Do not overfill the engine with oil. When filling the engine with oil lwys use the dipstick to determine how much oil is required. 1. Remove the oil fill cp. c Oil fill cp 2. Add oil to ring the level up to, ut not over, the mximum mrk on the dipstick. Description Cpcity Fluid Type Engine oil (with filter) 9.5 L (10.0 US qt) SAE 5W 30 meeting VW Spec Instll the oil fill cp. Drining Using the Esy Drin System, if Equipped NOTE: The ot must e out of the wter to perform this procedure. 1. Remove the ot from the wter M eng DECEMBER 2015 Pge 37

44 Section 4 - Mintennce 2. Loosen the oil filter to vent the oil system. c f d e Bilge drin plug - Tether c - Clip d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge 3. Remove the ilge drin plug. 4. Pull the tether through the ilge drin. 5. Plce the oil drin hose in suitle continer. 6. Remove the drin plug from the oil drin hose. 7. After the oil hs drined completely, instll the drin plug in the oil drin hose. 8. Push the oil drin hose through ilge drin nd instll the ilge drin plug. Chnging Oil nd Filter Refer to the Mintennce Schedule for the chnge intervl. You should chnge the engine oil efore plcing the ot in storge. IMPORTANT: Chnge the engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only the recommended engine oil. Refer to Specifictions. 1. Strt nd run the engine until norml operting temperture is chieved. 2. Stop the engine nd wit pproximtely five minutes for the oil to drin into the oil pn. 3. Drin the oil from the engine into suitle continer. Dispose of ll wste oil s directed y locl uthorities. 4. Plce suitle continer under the oil filter housing to contin ny oil lekge tht my occur. Use n pproprite socket to loosen the oil filter protective cp. 5. Remove the protective cp nd filter element. e c d Oil filter nd housing - Protective cp - O ring (lrge) c - Filter element d - Trnsfer tue O ring (smll) e - Oil filter housing Disconnect nd discrd the old filter element. 7. Discrd the old O ring from the protective cp. 8. Apply smll mount of engine oil to the lrge O ring nd instll the O ring in the protective cp. 9. Apply smll mount of engine oil to the smll O ring nd instll it onto the filter element trnsfer tue. Pge M eng DECEMBER 2015

45 Section 4 - Mintennce 10. Push the filter element onto the protective cp until it is locked. Listen for click. 11. Instll the protective cp with the new filter element into the oil filter housing. IMPORTANT: When instlling the filter element into the oil filter housing, e sure to lign the trnsfer tue on the filter element with the orifice in the ottom of the filter housing to void dmging the filter element. IMPORTANT: Overtightening the protective cp will cuse deformtion resulting in oil lekge. 12. Thred the protective cp into the filter housing until the seling surfce contcts the housing. Tighten the protective cp to the specified torque. Description Nm l in. l ft Protective cp Remove the oil fill cp nd fill the engine with new oil. Refer to Filling. IMPORTANT: When filling the engine with oil, lwys use the dipstick to determine how much oil is required. 14. Strt the engine nd check for leks. Sterndrive Ger Lue NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking NOTE: The ger lue level will fluctute during opertion. The ger lue level should e checked with the engine cold, efore strting. Check the ger lue monitor to determine the ger lue level. Keep the ger lue level within the recommended operting rnge. Refer to Filling. Ger lue level shown is t the correct operting rnge - "ADD" mrk - "OPERATING RANGE" mrk Filling IMPORTANT: If more thn 59 ml (2 fl oz) of High Performnce Ger Lue is required to fill the ger lue monitor, sel my e leking. Dmge to the sterndrive my occur due to lck of luriction. Contct your Mercury Diesel uthorized repir fcility. 1. If the ger lue level is elow or ner the "ADD" mrk, the specified ger lue must e dded. 2. Remove the ger lue monitor cp. 90-8M eng DECEMBER 2015 Pge 39

46 Section 4 - Mintennce 3. Fill the ger lue monitor with the specified ger lue so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Ger lue monitor K01 4. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll the cp. Do not overtighten. - Ger lue monitor cp NOTE: When filling the entire sterndrive, refer to Chnging. Chnging Remove the ger lue monitor from the rcket. - Ger lue monitor rcket - Ger lue monitor nd cp c - Retining strp c Empty the contents of the ger lue monitor into suitle continer. 3. Instll the ger lue monitor in the rcket. 4. Brvo One X Models:. Remove the propeller.. Lower the sterndrive to the full down (in) position. c. Remove the ger lue fill nd drin plug nd seling wsher. Pge M eng DECEMBER 2015

47 Section 4 - Mintennce d. Drin the ger lue into suitle continer. - Fill nd drin plug - Seling wsher mc Brvo Three X Models:. Plce the sterndrive in full trim limit out position.. Remove the fill nd drin plug nd seling wsher. c. Drin the ger lue into suitle continer Brvo Two X - Fill nd drin plug - Seling wsher Brvo Three X 6. Remove the vent plug nd seling wsher. Allow the ger lue to drin completely. - Vent plug - Seling wsher IMPORTANT: If ny wter drins from the fill nd drin plug hole, or if the ger lue ppers milky, the sterndrive is leking nd should e checked immeditely y your Mercury Diesel uthorized repir fcility. 7. Lower the sterndrive so tht the propeller shft is level. 8. Fill the sterndrive through the fill nd drin plug hole with the specified ger lue until n ir free strem of lue flows from the vent plug hole. IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lue in the sterndrive. Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Sterndrive unit K M eng DECEMBER 2015 Pge 41

48 Section 4 - Mintennce 9. Instll the vent plug nd seling wsher. 10. Continue to pump ger lue into the drive through the fill nd drin plug hole until the ger lue ppers in the ger lue monitor. 11. Fill the ger lue monitor so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Sterndrive Model Brvo One X Diesel Brvo One XR Brvo Three X Diesel Brvo Three XR Fluid Cpcity includes the Sterndrive nd the Ger Lue Monitor 2736 ml (92 1/2 oz) 2972 ml (100 1/2 oz) Fluid Type High Performnce Ger Lue 12. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll. Do not overtighten. - Ger lue monitor cp Fluid Prt Numer A Remove the pump from the sterndrive fill nd drin plug hole. Pge M eng DECEMBER 2015

49 Section 4 - Mintennce 14. Quickly instll the seling wsher nd the fill nd drin plug. Tighten the plug to the specified torque. mc All Brvo models shown - Fill nd drin plug - Seling wsher Description Nm l in l ft Fill nd drin plug Instll the sterndrive propeller. Refer to Propellers. 16. Check the level of the ger lue monitor fter the first use. Refer to Mintining Fluid Levels. IMPORTANT: The ger lue monitor level will chnge while the product is in use. Alwys check the ger lue level when the sterndrive is cool nd the engine is not running. Power Trim Fluid Checking IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only. 1. Plce the sterndrive in full down (in) position. 90-8M eng DECEMBER 2015 Pge 43

50 Section 4 - Mintennce 2. Oserve the fluid level. The fluid level must e etween the "MIN" nd "MAX" lines on the reservoir Reservoir - "MIN" nd "MAX" lines 3. Fill s necessry with the specified fluid. Refer to Filling. Filling Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 1. If the fluid level is elow the "MIN" line, the specified fluid must e dded. 2. Remove the fill cp from the reservoir. NOTE: The fill cp is vented. Power trim pump reservoir shows the fluid level is elow "MIN" line - Fill cp ssemly - Fill cp instlled 7701 Pge M eng DECEMBER 2015

51 3. Add the specified fluid to ring the fluid level to within the "MIN" nd "MAX" lines on the reservoir. Section 4 - Mintennce Reservoir - "MIN" nd "MAX" lines Tue Ref No. Description Where Used Prt No. 4. Instll the fill cp. Chnging 114 Power Trim nd Steering Fluid Power trim pump K01 Power trim fluid does not require chnging unless it ecomes contminted with wter or deris. Contct your Mercury Diesel uthorized repir fcility. Power Steering Fluid The power steering fluid level should e checked t regulr intervls. IMPORTANT: Do not leve the steering wheel t full lock longer thn 15 seconds with the engine running. The power steering fluid will het up considerly when the steering wheel is t full lock nd could dmge the power steering system. When the steering wheel is t full lock, power steering pump noise will increse s the pump is under full lod nd the engine idle RPM will e reduced momentrily. Checking 1. Center the sterndrive nd stop the engine. 2. Remove the fill cp nd dipstick from the fluid reservoir nd oserve the level. - Fill cp - Power steering fluid reservoir IMPORTANT: If fluid is not visile in the fluid reservoir, see your Mercury Diesel uthorized repir fcility. Filling Remove the fill cp/dipstick nd wipe it with clen cloth. 90-8M eng DECEMBER 2015 Pge 45

52 Section 4 - Mintennce 2. Screw the fill cp/dipstick completely into the power steering fluid reservoir. 3. Remove the fill cp/dipstick from the reservoir nd oserve the fluid level. If the fluid level is within rnge, no fluid should e dded. If the fluid level is within rnge, fluid my e dded ut should not exceed the mximum level in rnge. If the oil level is within rnge c, fluid must e dded. There is sufficient fluid when the fluid level is within rnge. NOTE: If high steering lods re going to e encountered for prolonged period of opertion (10 12 hours), the fluid level should e t lest in the middle of the min/mx mrkings of the dipstick. - No fluid required - Oil my e dded, ut do not exceed ove rnge c - Oil must e dded, ut do not exceed ove rnge c Add the specified fluid to ring the fluid level up to the proper level. Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power-ssisted steering system K01 28 Dexron III Automtic Trnsmission Fluid 5. Instll the fill cp/dipstick. Chnging Power-ssisted steering system Otin Loclly Power ssisted steering fluid does not require chnging unless it ecomes contminted. See your Mercury Diesel uthorized repir fcility. Engine Coolnt! CAUTION A sudden loss of pressure cn cuse hot coolnt to oil nd dischrge violently resulting in serious injury from urns. Allow the engine to cool down efore removing the coolnt pressure cp. - Coolnt minimum level ("min" mrk) - Coolnt mximum level For proper engine opertion, the coolnt must lwys e mintined t the correct level within the closed cooling system. With the engine cold, the level should lwys e etween the minimum nd mximum level mrks on the coolnt expnsion tnk. The coolnt level is monitored y sensor. The disply window on the tchometer will wrn the user of low coolnt level condition. An udile wrning will lso sound. A visul inspection of the coolnt level within the coolnt expnsion tnk should e performed regulrly. Pge M eng DECEMBER 2015

53 Checking the Coolnt Level IMPORTANT: Check the engine coolnt efore strting the engine. 1. Allow the engine to cool. 2. Verify tht the coolnt level is ove the "min" mrk on the coolnt expnsion tnk. 3. If the coolnt level is elow the "min" mrk: Section 4 - Mintennce. Inspect the closed cooling system for leks. If ny leks re found, contct your Mercury Diesel uthorized repir fcility for further dignosis nd repir.. Refer to Adding Coolnt nd dd the specified coolnt s necessry. Adding Coolnt 1. Allow the engine to cool. 2. Cover the cp on the coolnt expnsion tnk with cloth nd crefully remove the cp (counterclockwise). IMPORTANT: If the specified coolnt is not immeditely ville, dd only wter nd restore the proper coolnt/wter rtio with the specified coolnt s soon s possile. Do not dd ny coolnt other thn the specified coolnt. 3. Add the specified coolnt s necessry to ring the level to the minimum level ("min" mrk) ut no higher thn the coolnt mximum level. Description Where Used Prt Numer Mrine Engine Coolnt Closed cooling system 8M Instll the cp nd tighten securely to prevent coolnt loss. Air Filter Removl 1. Remove the crnkcse ventiltion hoses. 2. Remove the smll clmps from the turochrger inlets. 3. Remove the lrge clmps from the ir filter. 4. Remove the tension springs from the ir filter ssemly. 5. Remove the ruer side covers from the ir filter element. c 5 d Air filter mounting - Crnkcse ventiltion hoses - Smll clmps c - Lrge clmps d - Tension springs e - Ruer side covers e d e c Inspection nd Clening NOTICE Do not use fuel, thinner, or other clening gents for clening the ir filter element. Use only the recommended products in the clening kit. Filure to use the correct products cn dmge the ir filter element. 1. Inspect the ir filter for dmge. 2. Using compressed ir, not exceeding 2.0 r (29 psi), low deris from the ir filter from the inside, towrd the outside of the filter. 3. For clening the ir filter, purchse K&N filter rechrging kit Follow the procedures contined in rechrging kit. 4. Replce the ir filter s needed. 90-8M eng DECEMBER 2015 Pge 47

54 Section 4 - Mintennce Instlltion 1. Instll the ruer side covers onto the ir filter element. 2. Align the mrks s shown y the rrows in the ir filter mounting illustrtion. 3. Instll the tension springs. 4. Instll the lrge clmps onto the ruer side covers. Tighten the fsteners to retin the oots. 5. Plce the smll clmps onto the smll openings on the ruer side covers. 6. Gently compress the ruer side covers towrd the center of the ir filter element nd instll the filter ssemly onto the turochrger inlets. 7. Tighten the smll clmps to retin the filter ssemly. 8. Instll the crnkcse ventiltion hoses. Fuel Filter NOTICE Wter entering the fuel injection system will cuse corrosion nd rusting of the injectors nd other components, disling the fuel injection system. Check dily for wter in the wter seprting fuel filter nd hve the engine inspected immeditely if there is evidence of wter in the fuel system. IMPORTANT: Use suitle continer to collect fuel. Clen up ny spills immeditely nd dispose of fuel nd old filters in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. This remote mounted fuel filter nd lift pump ssemly is equipped with wter in fuel sensor to lert the opertor when wter is present in the filter. This filter needs to e replced t specified intervls, refer to Routine Mintennce, or whenever wter is detected in the fuel, whichever occurs first. d c e d - Wter in fuel sensor - Cnnister nut (hidden) c - Cnnister d - Fuel line fittings e - Power connector Drining Wter from the Filter 1. Plce suitle continer under the fuel filter ssemly. 2. Remove the drin plug from the ottom of the ssemly. 3. Drin the filter until the fuel is clen in ppernce. 4. Instll the drin plug nd tighten securely. Replcing the Filter! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components. IMPORTANT: The fuel filter cnnot e clened nd reused. It must e replced. Be sure to replce the filter with filter of the sme specifictions to eliminte possile dmge to the fuel system components. 1. Disconnect oth ttery cles from the ttery. 2. Disconnect the wter in fuel sensor from the wiring hrness. 3. Plce suitle continer under the fuel filter ssemly. 4. Remove the cnnister from the ssemly. 5. Pull up on the fuel filter to remove it from the cnnister Pge M eng DECEMBER 2015

55 Section 4 - Mintennce 6. Replce the O ring. 7. Insert the new fuel filter into the cnnister. The filter will snp into plce. 8. Luricte the new O ring round the cnnister with clen diesel fuel. NOTE: Do not fill the cnister with fuel. 9. Instll the cnnister onto the upper portion of the fuel filter ssemly nd hnd tighten it. 10. Connect the wter in fuel sensor to the wiring hrness. 11. Connect the ttery cles to the ttery, connecting the negtive ( ) cle lst. 12. Ensure the fuel tnk is filled with fuel. 13. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 14. Strt the engine nd let it idle for pproximtely seconds then shut the engine off. 15. Wit few seconds nd repet step 13 two more times. 16. Check fuel filter nd connections for leks. IMPORTANT: If leks exist, check the connections nd verify tht ll connections nd the cnnister re properly seted. If leks continue, stop the engine immeditely nd contct your Mercury Diesel uthorized repir fcility. Purging the Fuel System! WARNING The fuel injection pump genertes pressure in excess of kp (2000 psi), which is high enough to penetrte or cut the skin. Do not use your fingers to feel for fuel leks nd wer personl protective equipment when servicing the fuel system. NOTE: It is possile tht the engine will not strt if the fuel system hs not een completely purged of ir. 1. Ensure tht the fuel tnk is filled with fuel. 2. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 3. Strt the engine nd let it idle for pproximtely seconds, then shut the engine off. 4. Wit few seconds nd repet step 3 two more times. Fuel System Priming NOTE: Follow this procedure if the fuel system ws run dry or if prt of the fuel system ws drined for service function. 1. Turn the ignition switch to the "ON" position nd the fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 2. Strt the engine. Fuel Tnk Clening nd Flushing IMPORTANT: Diesel fuel should not e left in the tnk during winter storge, s n ccumultion of rust, sludge nd wx residue will form. Refer to the ot mnufcturer's instructions nd clen the fuel tnk t specified intervls. Unless specified otherwise, flush nd clen the diesel fuel tnk every 1000 hours or five yers, whichever occurs first. Sewter System Sewter Pump Impeller Inspection The sewter pump impeller must e inspected (nd replced, if necessry) t the intervl specified y the mintennce schedule. It is recommended this tsk e performed t Mercury Diesel uthorized repir fcility. 1. Close the secock. 90-8M eng DECEMBER 2015 Pge 49

56 Section 4 - Mintennce 2. Remove the four screws on the front side of the sewter pump nd remove the cover. Discrd the O ring. Sewter pump cover screws 3. Mrk the direction of rottion of the impeller nd remove the protective cp from the middle of the impeller c d e f - Sewter pump - Impeller c - Protective cp d - O ring e - Cover f - Screw (4) 4. Use suitle puller to remove the impeller from the impeller shft. 5. Inspect the impeller for dmge. The impeller must e replced if there re ny signs of dmge. NOTE: Keep n extr impeller onord the ot t ll times. 6. Luricte the impeller with silicone spry or glycerine. 7. Push the impeller onto the shft nd press the protective cp into the impeller. 8. Insert new O ring into its groove. 9. Instll the cover onto the housing nd secure the cover with the four screws. Tighten the screws to the specified torque. Description Nm l in. l ft Sewter pump cover screws Open the secock. 11. Strt the engine nd check the cooling system for leks. Sterndrive Wter Inlets Check Otin piece of wire the pproprite size to insert into the wter inlets holes. 2. Insert the wire in nd out of the sterndrive wter inlets to ensure tht they re open nd to remove deris or mrine growth. Do not scrpe the sterndrive pint. Pge M eng DECEMBER 2015

57 Section 4 - Mintennce 3. Remove the wire from the sterndrive nd retin for periodic wter inlet checks. - Dul wter pickup wter inlets - Side pickup wter inlets Flushing nd Drining the Sewter System 1. Close the secock. 2. Open nd clen the sewter filter. 3. Fill the sewter filter with fresh wter nd operte the engine t idle. IMPORTANT: Keep the sewter filter filled with fresh wter while the engine is running. 4. Operte the engine until the wter drining from the engine runs cler to ensure tht ll sludge nd slt residues re flushed wy. 5. Switch off the engine. 6. Replce the cover on the sewter filter. 7. Attch suitle hose to the sewter cooling system drin screw Het exchnger drin screws - Closed cooling system drin screw - Sewter cooling system drin screw Open the drin screw nd llow the wter to drin into suitle continer. 9. When the drining is complete, remove the hose nd close the drin screw. 10. Be certin to open the secock prior to ot opertion. 90-8M eng DECEMBER 2015 Pge 51

58 Section 4 - Mintennce Checking the Sewter Pickups Verify tht the wter inlet holes for the sewter pickup re clen nd unostructed Typicl through-the-hull sewter pickup - Wter inlet holes Typicl through-the-trnsom sewter pickup Clening the Sewter Striner, if Equipped NOTICE An open sewter striner or secock during some service or mintennce procedures cn introduce wter into the ot, cusing dmge or sinking the ot. Alwys close the wter supply from the sewter pump, wter inlet, or secock when performing service or mintennce on the cooling system. 1. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the screws, wshers, nd cover. 3. Remove the striner, drin plug, nd seling wsher. 4. Clen ll the deris from the striner housing. Flush oth the striner nd housing with clen wter. 5. Check the cover gsket nd replce when dmged or if it leks. 6. Reinstll the striner, drin plug, nd seling wsher.! CAUTION Sewter leking from the sewter striner could cuse excess wter in the ilge, dmging the engine or cusing the ot to sink. Do not overtighten the cover screws, or the cover my wrp nd introduce sewter into the ilge. Pge M eng DECEMBER 2015

59 Section 4 - Mintennce 7. Instll the sel nd cover using the screws nd wshers. Do not overtighten the cover screws. f - Screws nd wshers - Cover with glss c - Striner d - Housing e - Drin plug nd seling wsher f - Sel c d e 8. Open the secock, if equipped, or remove the plug nd reconnect the sewter inlet hose. 9. Upon first strting the engine, check for leks or ir in the system tht would indicte n externl lek. Corrosion Protection Generl Informtion When two or more dissimilr metls re sumerged in conductive solution of sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow etween metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This erosion is known s glvnic corrosion nd, if it is not controlled, it will eventully cuse the need for replcement of power pckge components exposed to wter. To help control the effects of glvnic corrosion, Mercury Diesel power pckges come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection refer to the Mrine Corrosion Protection Guide. IMPORTANT: Replce scrificil nodes if they re eroded 50% or more. Mercury Diesel strongly recommends voiding the use of nodes from other mnufcturers. Refer to your Mercury Diesel uthorized repir fcility for dditionl informtion. Scrificil Anode The scrificil node in the cooling system must e checked s specified y the mintennce schedule. The node is locted t the ck of the chrge ir cooler. - Scrificil node - Length of new node = 20 mm (0.79 in.) c - Bck of the chrge ir cooler c 1. Close the secock. 2. Plce suitle continer cple of holding pproximtely L ( US qt) of liquid in position to cpture the escping sewter. 3. Remove the scrificil node. 4. Inspect the node. If the node is less thn 10 mm (0.39 in.), it hs eroded more thn 50% nd must e replced M eng DECEMBER 2015 Pge 53

60 Section 4 - Mintennce 5. Instll the node into the ck of the chrge ir cooler. 6. Open the secock. 7. Strt the engine nd check for leks. Antifouling Pint IMPORTANT: Corrosion dmge tht results from the improper ppliction of nti fouling pint is not covered y the limited wrrnty. In some res it my e dvisle to pint the ottom of the ot to help prevent mrine growth. Contct Mercury Diesel uthorized repir fcility for recommendtions for your ot. Luriction Steering System! WARNING Incorrect cle luriction cn cuse hydrulic lock, leding to serious injury or deth from loss of ot control. Completely retrct the end of the steering cle efore pplying luricnt. NOTE: If the steering cle does not hve grese fitting, the inner wire of the cle cnnot e gresed. 1. If the steering cle hs grese fittings, turn the steering wheel until the steering cle is fully retrcted into the cle housing. Apply pproximtely three pumps of grese from typicl hnd operted grese gun. - Steering cle grese fitting 6221 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle grese fitting A 1 2. Turn the steering wheel until the steering cle is fully extended. Lightly luricte the exposed prt of the cle. - Extended steering cle 6222 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle A 1 Pge M eng DECEMBER 2015

61 Section 4 - Mintennce 3. Luricte the steering pin. - Steering pin Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W On dul engine ots: Luricte the tie r pivot points. Steering pin 8M Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie r pivot points 8M Upon first strting the engine, turn the steering wheel severl times to strord nd then port to ensure tht the steering system opertes properly efore getting underwy. Throttle Cle The throttle control system for the TDI 4.2L engine is electronic nd requires no mintennce. See your Mercury Diesel uthorized repir fcility for dignosis or repir. Shift Cle The shift control system for the TDI 4.2L engine is electronic nd requires no mintennce. See your Mercury Diesel uthorized repir fcility for dignosis or repir. Trnsom Assemly mc Luricte the giml ering y pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. - Giml ering grese insert Tue Ref No. Description Where Used Prt No. Extreme Grese Gimel ering grese insert 8M Propeller Shft NOTE: Refer to Propeller Removl. Luricte the sterndrive propeller shft y pplying coting of one of the following luricnts to the propeller shft. 90-8M eng DECEMBER 2015 Pge 55

62 Section 4 - Mintennce Apply generous coting of one of the following luricnts to the propeller shft Propeller shft Tue Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 Engine Coupler IMPORTANT: These engines re equipped with seled engine coupler. The seled coupler nd the shft splines cn e luricted without removing the sterndrive unit. Luricte the engine coupler splines through the grese fitting on the coupler y pplying pproximtely 8 10 pumps of Extreme Grese from typicl hnd operted grese gun. NOTE: On Brvo equipped models, if the ot is operted t idle for prolonged periods, the coupler should e luricted every 50 hours. Coupler shown seprted for clrity Tue Ref No. Description Where Used Prt No. Extreme Grese Engine coupler nd shft splines 8M Pge M eng DECEMBER 2015

63 Driveshft Extension Models Section 4 - Mintennce 1. Luricte the trnsom end grese fitting nd engine end grese fitting y pplying pproximtely pumps of grese from typicl hnd operted grese gun. 2. Luricte the driveshft grese fittings y pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c Driveshft grese fittings - Trnsom end grese fitting c - Engine end grese fitting Tue Ref No. Description Where Used Prt No. Mintining Torques Extreme Grese Giml Ring U olt Nuts NOTE: The giml ring is component of the trnsom ssemly. Tighten the giml ring U olt nuts to the specified torque. Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings 8M Trnsom ssemly - Giml ring U olt nuts Description Nm l in. l ft Giml ring U olt nuts for 3/8 in. U olt Giml ring U olt nuts for 7/16 in. U olt M eng DECEMBER 2015 Pge 57

64 Section 4 - Mintennce Engine Mounts Loosen the rer engine mount olts 1 to 1 1/2 turns. Tighten the rer engine mount olts to the specified torque. - Rer engine mount - Trnsom plte mount c - Rer engine mount olt c Description Nm l in. l ft Rer engine mount olts Propellers Brvo Sterndrive Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. Brvo One Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Pge M eng DECEMBER 2015

65 Section 4 - Mintennce 2. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise nd remove the nut. 4. Slide the propeller nd the ttching hrdwre from the propeller shft. c d e f g Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut 5301 Brvo Two Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise to remove the nut. 90-8M eng DECEMBER 2015 Pge 59

66 Section 4 - Mintennce 4. Slide the propeller nd ttching hrdwre from the propeller shft. c d f Brvo Two - Propeller shft splines - Forwrd thrust hu c - Propeller d - Spline wsher e - T wsher f - Propeller nut e 8566 Brvo Three Models 1. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. 2. Remove the olt nd wshers securing the propeller shft node. 3. Remove the propeller shft node. c - Propeller - Propeller shft nut c - Propeller shft node d - Propeller shft node screw e - Flt wsher f - Str wsher d f e Turn the ft propeller shft nut counterclockwise to remove the nut. 5. Slide the propeller nd thrust hu off of the propeller shft. 6. Using the propeller nut tool, turn the front propeller shft nut counterclockwise nd remove the nut. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Slide the propeller nd the thrust hu off the propeller shft. g i h j c d e f 5304 Brvo Three - Aft propeller nut - Aft propeller c - Aft propeller thrust hu d - Front propeller nut e - Front propeller f - Front propeller thrust hu g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node Pge M eng DECEMBER 2015

67 Section 4 - Mintennce Brvo Sterndrive Propeller Instlltion! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket Brvo One Models IMPORTANT: Use the correct rottion propeller. The propeller rottion must mtch the direction of rottion of the propeller shft. 1. Lierlly cot the propeller shft spline with one of the following luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Instll the propeller with the ttching hrdwre s shown. 3. Tighten the propeller nut to the specified torque. c d e f g Typicl Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut NOTE: The propeller torque stted is minimum torque vlue. Description Nm l in. l ft Brvo One propeller nut Then lign ts with grooves 4. Models equipped with the t wsher: Continue to tighten the propeller nut until the three ts on the t wsher lign with the grooves on the spline wsher M eng DECEMBER 2015 Pge 61

68 Section 4 - Mintennce 5. Bend the three ts down into the grooves. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Brvo Three 1. Lierlly cot the propeller shft spline with one of the following luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Slide the forwrd thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 3. Align splines nd plce front propeller on propeller shft. 4. Instll the front propeller locknut nd tighten to the specified torque using the propeller nut tool. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Description Nm l in. l ft Brvo Three front propeller nut Slide the ft thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 6. Align the splines nd instll the ft propeller. 7. Instll the propeller nut nd torque. NOTE: The propeller torque stted is minimum torque vlue. Description Nm l in. l ft Brvo Three rer propeller nut Pge M eng DECEMBER 2015