2.8 And 4.2 Diesel Sterndrive Models

Transcription

1 2.8 And 4.2 Diesel Sterndrive Models

2 0001. Identifiction Record The seril numbers re the mnufcturer s keys to numerous engineering detils which pply to your Cummins MerCruiser Diesel power pckge. When contcting Cummins MerCruiser Diesel (CMD ) bout service, lwys specify model nd seril numbers Plese record the following informtion: Engine Model nd Horsepower Trnsom Assembly Seril Number (Sterndrive) Trnsmission Model (Inbord) Ger Rtio Ger Rtio Engine Seril Number Sterndrive Unit Seril Number Trnsmission Seril Number Propeller Number Pitch Dimeter Hull Identifiction Number (HIN) Bot Mnufcturer Bot Model Exhust Gs Emissions Certificte Number (Europe Only) Purchse Dte Length The description nd specifictions contined herein were in effect t the time this guide ws pproved for printing. Cummins MerCruiser Diesel, whose policy is one of continuous improvement, reserves the right to discontinue models t ny time, or to chnge specifictions or designs, without notice nd without incurring obligtion. 2003, Mercury Mrine. The following re trdemrks / service mrks of Brunswick Corportion: Alph, Brvo, Flo-Torq, Merc, MerCthode, Mercury, Mercury Mrine, Mercury MerCruiser, Mercury Precision Prts, Mercury Propellers, Mercury Product Protection, Quicksilver, RideGuide, SmrtCrft nd Zero Effort. Mercury Mrine, Fond du Lc, Wisconsin, U.S.A. Printed in U.S.A.

3 nd CE459 WELCOME! 0003 with CMD Wrrnty Messge You hve selected one of the finest mrine power pckges vilble. It incorportes numerous design fetures to ssure operting ese nd durbility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny boting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion, Mintennce nd Wrrnty 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 Cummins MerCruiser Diesel products. We sincerely hope your boting will be plesnt! Cummins MerCruiser Diesel The product you hve purchsed comes with limited wrrnty from Cummins MerCruiser Diesel; the terms of the wrrnty re set forth in the Wrrnty Sections of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to best obtin wrrnty coverge, importnt disclimers nd limittions of dmges nd other relted informtion. Plese review this importnt informtion.

4 0004 Red This Mnul Thoroughly NOTICE 0197 modified or CE461 IF YOU DON T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. Throughout this publiction, nd on your power pckge, WARNINGS nd CAUTIONS, ccompnied by the Interntionl Hzrd Symbol!, my be used to lert the instller/user to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly. Observe them crefully. These Sfety Alerts 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 WARNING - Hzrds or unsfe prctices which could result in severe personl injury or deth. CAUTION CAUTION - Hzrds or unsfe prctices which could result in minor personl injury or product or property dmge. IMPORTANT: - Indictes informtion or instructions tht re necessry for proper opertion nd/or mintennce. WARNING The opertor (driver) is responsible for the correct nd sfe opertion of the bot, the equipment bord nd the sfety of ll occupnts bord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories before the bot is used. We strongly recommend tht other occupnts be instructed on proper strting nd opertion procedures so they will be prepred should they be required to operte the power pckge nd bot in n emergency. WARNING Cliforni Proposition 65 Wrning The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, birth defects or other reproductive hrm. WARNING Electricl system components on this engine re not externl ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Filure to comply could result in fire, explosion nd/or severe personl injury.

5 Wrrnty Informtion Owner Wrrnty Registrtion United Sttes And Cnd Only Interntionl Owner Registrtion Outside The United Sttes And Cnd Wrrnty Policies Recretionl Use Diesel Limited Wrrnty Wht Is Covered Durtion Of Coverge Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge Wht Mercury Will Do How To Obtin Wrrnty Coverge SECTION 1 - WARRANTY Wht Is Not Covered Disclimers And Limittions Light Duty Commercil Use Diesel Limited Wrrnty Wht Is Covered Durtion / Description Of Coverge Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge Wht Mercury Will Do How To Obtin Wrrnty Coverge Wht Is Not Covered Disclimers And Limittions Wrrnty Coverge nd Exclusion Trnsferble Wrrnty Direct Sle By Owner SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Fetures And Controls Lnyrd Stop Switch Instrumenttion Remote Controls Pnel Mounted Console Mounted Console Mounted Power Trim Single Engine Trim/Triler Dul Engine Trim/Triler Electricl System Overlod Protection 22 Audio Wrning System Testing The Audio Wrning System 24 Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsibility CMD / SEPTEMBER 2003 Pge i

6 SECTION 3 - ON THE WATER Sfe Boting Suggestions While You Are Cruising Be Alert To Crbon Monoxide Poisoning. 30 While Bot Is Sttionry Good Ventiltion High-Speed And High-Performnce Bot Poor Ventiltion Opertion Bsic Bot Opertion Pssenger Sfety Messge - Pontoon Lunching And Bot Opertion Cre And Deck Bots Duty Cycle Rting Wve And Wke Jumping Plesure Duty Rting Impct With Underwter Hzrds Light Duty Rting Drive Unit Impct Protection Opertion Chrt - D4.2L, D4.2L LD, nd Conditions Affecting Opertion D4.2L Weight Distribution (Pssengers And Strting, Shifting nd Stopping - D4.2L, Ger) Inside The Bot D4.2L LD nd D4.2L Bottom Of Bot Opertion Chrt - D2.8L D-Tronic, Cvittion D4.2L D-Tronic nd D4.2L Ventiltion Strting, Shifting nd Stopping - D2.8L D- Elevtion And Climte Tronic, D4.2L D-Tronic nd D4.2L Propeller Selection Strting Engine After Stopped While In Getting Strted Ger Initil Brek-In Procedure Trilering The Bot Sterndrive Unit 10-Hour Brek-In Period. 55 Freezing Temperture Opertion Hour Brek-In Period Drin Plug nd Bilge Pump After Brek-In Period Protecting People In The Wter End of First Seson Checkup SECTION 4 - SPECIFICATIONS Fuel Requirements Diesel Fuel In Cold Wether Anti-Freeze/Coolnt Engine Oil Engine Specifictions D4.2L D4.2L LD And D4.2L D2.8L D-Tronic nd D4.2L D-Tronic D4.2L Fluid Specifictions Engine Sterndrives Pge ii CMD / SEPTEMBER 2003

7 SECTION 5 - MAINTENANCE Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do-It-Yourself Mintennce Suggestions. 70 Inspection Mintennce Schedules Routine Mintennce Scheduled Mintennce Mintennce Record Engine Oil Checking Filling Chnging Oil nd Filter D4.2L, D4.2L 230, D2.8L D-Tronic, D4.2L D-Tronic nd D4.2L D4.2L LD Power Steering Pump Fluid Checking Filling Chnging Engine Coolnt - Closed Cooled Models Only 82 Checking Filling Chnging Drive Unit Oil Checking Filling Chnging Power Trim Pump Fluid Checking Filling Chnging Bttery Multiple EDI Engine Bttery Precutions. 91 Sitution Recommendtions Air Filter Clening Replcement Wter Seprting Fuel Filter Drining Replcing Filling The Fuel Filter Fuel System Priming Fuel System Filling (Bleeding) Fuel System Fuel Tnk Clening And Flushing Lubriction Steering System Throttle Cble Shift Cble Sterndrive Unit nd Trnsom Assembly. 104 Engine Coupler Drive Shft Extension Models Propellers Brvo One nd Two Removl Repir Instlltion Brvo Three Removl Repir Instlltion Drive Belts - All Engines Alterntor Drive Belt nd Engine Wter Circulting Pump Belt, or Belts Power Steering Pump Belt Vcuum Pump Belt (If Equipped) Corrosion Protection Internl Components Removl Inspection Repir Instlltion Pinting Your Power Pckge Clening The Sewter Striner Flushing The Sewter System CMD / SEPTEMBER 2003 Pge iii

8 Cold Wether Or Extended Storge Prepring Your Power Pckge For Storge SECTION 6 - STORAGE Drining Instructions Bttery Recommissioning SECTION 7 - TROUBLESHOOTING Dignosing EDI Problems Troubleshooting Chrts Strter Motor Will Not Crnk Engine, Or Crnks Slow Engine Will Not Strt, Or Is Hrd To Strt Engine Runs Rough, Misses And/Or Bckfires Poor Performnce 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 (Motor Doesn t Operte) Power Trim Does Not Operte (Motor Opertes But Sterndrive Unit Does Not Move) SECTION 8 - CUSTOMER ASSISTANCE INFORMATION Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Submersion Replcement Service Prts Prts And Accessories Inquiries Resolving A Problem Customer Service Literture English Lnguge Other Lnguges Andre sprog Andere tlen Muut kielet Autres lngues Andere Sprchen Altre lingue Andre språk Outros Idioms Otros idioms Andr språk Ordering Literture United Sttes nd Cnd Outside The United Sttes nd Cnd. 151 Pge iv CMD / SEPTEMBER 2003

9 SECTION 1 Tble of Contents SECTION 1 - WARRANTY WARRANTY 1 Wrrnty Informtion Owner Wrrnty Registrtion United Sttes And Cnd Only Interntionl Owner Registrtion Outside The United Sttes And Cnd Wrrnty Policies Recretionl Use Diesel Limited Wrrnty Wht Is Covered Durtion Of Coverge Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge Wht Mercury Will Do How To Obtin Wrrnty Coverge Wht Is Not Covered Disclimers And Limittions Light Duty Commercil Use Diesel Limited Wrrnty Wht Is Covered Durtion / Description Of Coverge Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge Wht Mercury Will Do How To Obtin Wrrnty Coverge Wht Is Not Covered Disclimers And Limittions Wrrnty Coverge nd Exclusion Trnsferble Wrrnty Direct Sle By Owner CMD / SEPTEMBER 2003 Pge 1

10 WARRANTY SECTION Wrrnty Informtion Owner Wrrnty Registrtion UNITED STATES AND CANADA ONLY It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the fctory immeditely upon sle of the new product. It identifies nme nd ddress of the originl purchser, product model nd seril number(s), dte of sle, type of use nd selling deler s code, nme nd ddress. The deler lso certifies tht you re the originl purchser nd user of the product. Upon receipt of the Wrrnty Registrtion Crd t the fctory, you will be issued plstic Owner Wrrnty Registrtion Crd which is your only vlid registrtion identifiction. It must be presented to the servicing deler should wrrnty service be required. Wrrnty clims will not be ccepted without presenttion of this crd. A temporry Owner Wrrnty Registrtion Crd will be presented to you when you purchse the product. It is vlid only for 30 dys from dte of sle while your plstic Owner Wrrnty Registrtion Crd is being processed. Should your product need service during this period, present the temporry registrtion crd to the deler. He will ttch it to your wrrnty clim form. Becuse of your selling deler s continuing personl interest in your stisfction, the product should be returned to him for wrrnty service. If your plstic crd is not received within 30 dys from dte of new product sle, plese contct your selling deler. The product wrrnty is not effective until the product is registered t the fctory. NOTICE: Registrtion lists must be mintined by fctory nd deler on mrine products sold in the United Sttes, should notifiction under the Federl Bot Sfety Act be required. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury MerCruiser or sending letter or fx with you nme, old ddress, new ddress, nd engine seril number to Mercury MerCruiser s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Phone: Fx: Pge 2 CMD / SEPTEMBER 2003

11 SECTION 1 Interntionl Owner Registrtion WARRANTY OUTSIDE THE UNITED STATES AND CANADA It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion/clim progrm for your re. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril number(s), dte of sle, type of use nd the selling distributor s/deler s code number, nme nd ddress. The distributor/deler lso certifies tht you re the originl purchser nd user of the product. A copy of the Wrrnty Registrtion Crd, designted s the Purchser s Copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor/deler. This crd represents your fctory registrtion identifiction, nd should be retined by you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim form(s). In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distributor / deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser s Copy tht you received from the distributor / deler when you purchsed the product. Ask your distributor / deler if this plstic crd progrm pplies to you. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. Refer to Tble of Contents. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your deler / distributor fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. CMD / SEPTEMBER 2003 Pge 3

12 WARRANTY SECTION nd CD854 Wrrnty Policies Recretionl Use Diesel Limited Wrrnty WHAT IS COVERED DURATION OF COVERAGE Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described below. This Limited Wrrnty provides coverge for one (1) yer from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil use of the product voids the wrrnty. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper re-registrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre-delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent chnge of use from recretionl to commercil (unless properly re-registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty Mnul must be timely performed in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re-mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. Pge 4 CMD / SEPTEMBER 2003

13 SECTION 1 HOW TO OBTAIN WARRANTY COVERAGE WHAT IS NOT COVERED WARRANTY The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce And Wrrnty Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion, Mintennce And Wrrnty Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt which dmges the Mercury product nd ws not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion, Mintennce And Wrrnty Mnul), ltertion or removl of prts, wter entering the engine through the fuel intke, ir intke or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul-out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. CMD / SEPTEMBER 2003 Pge 5

14 WARRANTY SECTION ws CD687 Light Duty Commercil Use Diesel Limited Wrrnty WHAT IS COVERED Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described below DURATION / DESCRIPTION OF COVERAGE This Limited Wrrnty provides coverge from the dte the product is first sold to retil customer, or the dte on which the product is first put into service, whichever occurs first. The wrrnty provides coverge for period of one yer, or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. Light duty commercil use is defined s nnul opertion not to exceed 500 hours, opertion of the product t full rted power t mximum rted rpm for less thn 10% of totl opertion time, nd continuous cruising rpm is limited to no greter thn 90% of wide open throttle rpm (see the Opertion, Mintennce nd Wrrnty Mnul for further discussion nd exmples, incorported by reference into this limited wrrnty sttement, of light duty commercil opertion). Opertion of the product in excess of the light duty commercil specifictions will void the wrrnty. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent purchser upon proper re-registrtion of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE WHAT MERCURY WILL DO Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent chnge of use from recretionl to commercil (unless properly re registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty Mnul must be timely performed in order to obtin wrrnty coverge. If this mintennce is performed by the retil customer Mercury Mrine reserves the right to mke future wrrnty coverge contingent on proof of proper mintennce. Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. Pge 6 CMD / SEPTEMBER 2003

15 SECTION 1 WARRANTY HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. WHAT IS NOT COVERED This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce, And Wrrnty Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion, Mintennce, And Wrrnty Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt which dmges the Mercury product nd ws not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion, Mintennce, And Wrrnty Mnul), ltertion or removl of prts, wter entering the engine through the fuel intke, ir intke or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul-out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. CMD / SEPTEMBER 2003 Pge 7

16 WARRANTY SECTION ws CD622 Wrrnty Coverge nd Exclusion Keep in mind tht wrrnty covers repirs tht re needed within the wrrnty period becuse of defects in mteril nd workmnship. Instlltion errors, ccidents norml wer nd vriety of other cuses tht ffect the product re not covered. Wrrnty is limited to defects in mteril or workmnship, but only when the consumer sle is mde in the country to which distribution is uthorized by us. Should you hve ny questions concerning wrrnty coverge contct your uthorized deler. They will be plesed to nswer ny questions tht you my hve. WARRANTY DOES NOT APPLY TO THE FOLLOWING: Minor djustments or checks, including checking fuel injection pump timing, clening fuel injectors, filters, or djusting belts, controls, nd checking lubriction mde in connection with norml services. Dmge cused by neglect, lck of mintennce, ccident, bnorml opertion, improper instlltion or service, or freezing tempertures. Hul-out, lunch, towing chrges; removl nd/or replcement of bot prtitions or mteril becuse of bot design for necessry ccess to the product; ll relted trnsporttion chrges nd/or trvel time, etc. Resonble ccess must be provided to the product for wrrnty service. Customer must deliver product to n Authorized Deler. Additionl service work requested by customer other thn tht necessry to stisfy the wrrnty obligtion. Lbor performed by other thn n Authorized Deler my be covered only under following circumstnces: When performed on emergency bsis (providing there re no Authorized Delers in re who cn perform the work required or hve no fcilities to hul out, etc., nd prior fctory pprovl hs been given to hve the work performed t this fcility). All incidentl nd/or consequentil dmges (storge chrges, telephone or rentl chrges of ny type, inconvenience or loss of time or income) re the owner s responsibility. Pge 8 CMD / SEPTEMBER 2003

17 SECTION 1 Use of other thn Quicksilver replcement prts when mking wrrnty repirs. WARRANTY Oils, lubricnts or fluids chnged s mtter of norml mintennce is customer s responsibility unless loss or contmintion of sme is cused by product filure tht would be eligible for wrrnty considertion. Prticipting in or prepring for rcing or other competitive ctivity. Engine noise does not necessrily indicte serious engine problem. If dignosis indictes serious internl engine condition which could result in filure, condition responsible for noise should be corrected under the wrrnty. Lower unit nd/or propeller dmge cused by striking submerged object is considered mrine hzrd. Wter entering the engine vi the ir filter or exhust system or submersion. Also, wter in the strter motor. Strter motors nd/or rmtures or field coil ssembly, which re burned, or where led is thrown out of commuttor becuse of excess crnking. Vlve or vlve set grinding required becuse wer. Filure of ny prts cused by lck of cooling wter, which results from strting power pckge out of wter, foreign mteril blocking inlets or power pckge being mounted too high. Use of fuels nd lubricnts which re not suitble for use with or on the product. Refer to your Opertion, Mintennce, And Wrrnty Mnul. Our limited wrrnty does not pply to ny dmge to our products cused by the instlltion or use of prts nd ccessories which re not mnufctured or sold by us. Filures which re not relted to the use of those prts or ccessories, re covered under wrrnty, if they otherwise meet the terms of the limited wrrnty for tht product. CMD / SEPTEMBER 2003 Pge 9

18 WARRANTY SECTION Trnsferble Wrrnty Direct Sle By Owner The product wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. The second owner cn be registered s the new owner nd retin the unused portion of the limited wrrnty by sending the former owner s plstic Owner Wrrnty Registrtion Crd nd copy of the bill of sle to show proof of ownership. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI A new Owner Wrrnty Registrtion Crd will be issued with the new owner s nme nd ddress. Registrtion records will be chnged on the fctory computer registrtion file. There is no chrge for this service. Outside the United Sttes nd Cnd, plese contct the distributor in your country, or the Mrine Power Interntionl Service Center closest to you, for the trnsferble wrrnty procedure tht would pply to you. Pge 10 CMD / SEPTEMBER 2003

19 SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Tble of Contents Fetures And Controls Lnyrd Stop Switch Instrumenttion Remote Controls Pnel Mounted Console Mounted Console Mounted Power Trim Single Engine Trim/Triler Dul Engine Trim/Triler Electricl System Overlod Protection 22 Audio Wrning System Testing The Audio Wrning System 24 Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsibility CMD / SEPTEMBER 2003 Pge 11

20 GETTING TO KNOW YOUR POWER PACKAGE SECTION Fetures And Controls 0011 Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor s position (s in ccidentl ejection from the opertor s position). c b Stop switch b-lnyrd c -Clips to the opertor Accidentl ejections, such s flling overbord, re more likely to occur in: low sided sport bots bss bots high performnce bots 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 obstcle infested wters relesing your grip on the steering wheel tht is pulling in 1 direction consuming lcohol or drugs high speed boting mneuvers Some remote control units re equipped with lnyrd stop switch, if your remote control is not equipped with lnyrd stop switch one cn be instlled on the dshbord or side djcent to the opertor s position. The lnyrd is cord usully m (4-5 ft) long when stretched out with n element on 1 end mde to be inserted into the switch nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke it s short s possible to minimize the likelihood of entnglement with nerby objects. It stretches to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor s position. To shorten the lnyrd, wrp it round the opertor s wrist or leg, or tie knot in the lnyrd. Pge 12 CMD / SEPTEMBER 2003

21 SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE Activtion of the lnyrd stop switch will stop the engine immeditely, but the bot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the bot will not complete full circle. While the bot is costing, it cn cuse injury to nyone in the bot s pth s seriously s the bot would when under power. We strongly recommend tht other occupnts be instructed on proper strting nd operting procedures should they be required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected). WARNING Avoid contct with the bot hull nd propeller from ccidentl ejection. Personl injury or deth could occur. Alwys properly connect both ends of the lnyrd stop switch. Accidentl or unintended ctivtion of the switch during norml opertion is lso possibility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could be thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the bot who could be ejected over the bow nd possibly struck by the ger cse or propeller. Loss of power nd directionl control in hevy ses, strong current or high winds. Loss of control when docking. WARNING Avoid brupt decelertion of the bot from lnyrd stop switch ctivtion. Bot dmge nd personl injury or deth could occur. NEVER leve the opertor s sttion with the engine operting nd in ger. CMD / SEPTEMBER 2003 Pge 13

22 GETTING TO KNOW YOUR POWER PACKAGE SECTION ws Instrumenttion INSTRUMENTS The following is brief explntion of instrumenttion typiclly found on some bots. The owner/opertor should be fmilir with ll instruments nd their functions on the bot. Becuse of the lrge vriety of instrumenttion nd mnufcturers, you should hve your bot deler explin the prticulr guges nd norml redings tht will pper on your style guges. b c d e f g h Speedometer b-tchometer c -Oil pressure guge d-bttery meter e -Coolnt temperture guge f -Fuel guge g-hour meter h-power trim guge Speedometer: Indictes bot speed. Tchometer: Indictes engine rpm. Oil Pressure Guge: Indictes engine oil pressure. Bttery Meter: Indictes bttery voltge. Coolnt Temperture Guge: Indictes engine operting temperture. Fuel Guge: Indictes quntity of fuel in tnk. Hour Meter: Records engine operting time. Power Trim Guge: Indictes sterndrive unit ngle (trim up/out nd down/in). Sterndrive Models only. Pge 14 CMD / SEPTEMBER 2003

23 SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE ws prt CD934 nd CD860 SWITCHES b d d c e d Typicl switches -Key switch b-engine stop switch - toggle, if equipped c -Engine stop switch - push button, if equipped d-pnel lights / udio test switch e -Bilge blower switch Key Switch - hs three positions. 1. OFF - In the OFF position, ll electricl circuits re off nd engine cnnot be strted. If the engine is operting the Key Switch CANNOT be used to stop the engine, except on D-Tronic engines. On ll engines except D-Tronic engines, the engine cn only be stopped by using the engine Stop Switch, while the Key Switch is in the RUN position. No electricl circuit is opertionl when the Key Switch is turned to the OFF position. 2. RUN - In the RUN position, ll electricl circuits, indictor lmps, utomtic preheting (if equipped) nd ll instruments re opertionl. 3. START - In the START position the engine cn be strted. NOTE: Key cn only be removed in the OFF position. Engine Stop Switch (not present on D-Tronic engines) - is used to stop the engine. This is done by electriclly shutting off the fuel delivery system. The switch, toggle or push-button, is either toggled DOWN or pressed IN. Engge nd hold the stop switch until the engine stops completely. Then, turn the key switch to the OFF position. 1. Toggle Switch 2. Push-Button Switch Pnel Lights / Audio Test Switch - hs three positions; in the NORMAL position ll electricl circuits operte in stndrd fshion (s described bove). With switch toggled UP the instrumenttion lights re ll illuminted. When the switch is toggled DOWN the udio wrning horn will sound llowing the opertor to perform test of the udio wrning horn. Bilge Blower Switch: Opertes bilge blower. CMD / SEPTEMBER 2003 Pge 15

24 GETTING TO KNOW YOUR POWER PACKAGE SECTION ws CE479 nd CD860 ENGINE MONITORING FEATURES b c d e f Mlfunction indictor lmp (D-Tronic engines) b-wter-in-fuel wrning lmp c -Coolnt temperture wrning lmp d-oil pressure wrning lmp e -Chrge indictor lmp f -Prehet indictor lmp The pproprite light functions s follows: Mlfunction Indictor Lmp (MIL), D2.8L D-Tronic, D4.2L D-Tronic nd D4.2L 300 Only - dditionl lmp indictes when problem exists, or mlfunction hs occurred, tht requires service. Wter-In-Fuel Wrning Lmp - indictes wter is present in fuel filter nd tht fuel filter requires service. Coolnt Temperture Wrning Lmp - indictes excessive engine coolnt temperture if lmp illumintes while engine is running. Oil Pressure Wrning Lmp - indictes low engine oil pressure if lmp illumintes while engine is running, or low oil level in the ger lube monitor bottle. (See the following note). NOTE: The oil pressure wrning lmp is wired in prllel circuit with the ger lube monitor bottle switch. If lmp illumintes while engine is running nd oil pressure nd oil level re norml, this my be n indiction of low oil level in the ger lube monitor bottle. The cuse should be determined nd corrected. Chrge Indictor Lmp - indictes problem with chrging system if lmp illumintes while engine is operting. Lmp will be on when key switch is in RUN nd engine is not operting. When engine strts, light should go off. Prehet Indictor Lmp - indictes when the glow plugs, if equipped, re preheting the combustion chmbers. When the engine is cold the timed prehet period begins when the key switch is turned to RUN. The light stys on until the prehet period is complete. The engine cn be strted only fter the light goes out. Pge 16 CMD / SEPTEMBER 2003

25 SECTION Remote Controls GETTING TO KNOW YOUR POWER PACKAGE Your bot my be equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description nd/or demonstrtion of your remote control PANEL MOUNTED e f b c d Neutrl lock button b-throttle only button c -Lnyrd stop switch d-control hndle throttle friction screw e -Control hndle f -Trim / tilt button Neutrl Lock Button - Prevents ccidentl shift nd throttle enggement. Neutrl lock button must be pushed IN to move the control hndle out of NEUTRAL. Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the NEUTRAL position, nd should only be used to ssist in strting the engine. Lnyrd Stop Switch - Turns the ignition OFF whenever the opertor (when ttched to the lnyrd) moves fr enough wy from the opertor s position to ctivte the switch. Refer to Lnyrd Stop Switch for informtion on the use of this switch. Control Hndle Throttle Friction Screw - This screw (locted behind the bezel cover) cn be djusted to increse or decrese the tension on the control hndle. This will help prevent slipping of the remote control hndle. Turn screw clockwise to increse tension nd counterclockwise to decrese tension. Adjust to tension desired. Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from NEUTRAL with quick firm motion to the first detent for FORWARD ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from NEUTRAL with quick firm motion to the first detent for REVERSE ger nd continue pushing bck to increse speed. Trim/Tilt Button - Refer to Power Trim. CMD / SEPTEMBER 2003 Pge 17

26 GETTING TO KNOW YOUR POWER PACKAGE SECTION CONSOLE MOUNTED CAUTION Avoid possible bot nd power pckge dmge. Never shift unit into or out of ger unless throttle lever is t idle rpm. IMPORTANT: Bots equipped with dul power pckges my hve both shift levers on 1 control nd both throttle levers on the other control. d b c Shift lever b-throttle lever c -Friction screw d-detent screw Shift Lever - shifts unit into ger with full lever movement. Move lever forwrd to shift to FORWARD ger. Move lever bckwrd to shift to REVERSE ger. Lever in full verticl position shifts to NEUTRAL. Throttle Lever - llows engine rpm to be incresed or decresed. Friction Screw - djusts control hndle friction so motor speed cn be set nd driver does not hve to hold hndle. Turn screw clockwise to increse friction. Do NOT thred screw ll the wy out. Detent Screw - controls the effort needed to move control hndle out of NEUTRAL. To increse tension, turn screw clockwise; to decrese, turn screw counterclockwise. Do NOT thred screw ll the wy out. Pge 18 CMD / SEPTEMBER 2003

27 SECTION CONSOLE MOUNTED GETTING TO KNOW YOUR POWER PACKAGE d b c e d b c e -Throttle only button b-control hndle tension djustment screw c -Control hndles d-power Trim switch e -Triler switch Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the NEUTRAL position, nd should only be used to ssist in strting the engine. Control Hndle Tension Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed to djust). This will help prevent slipping of the remote control hndle. Turn screw clockwise to increse tension nd counterclockwise to decrese tension. Adjust to tension desired. Control Hndles - Opertion of the the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from NEUTRAL with quick firm motion to the first detent for FORWARD ger nd continue pushing forwrd to increse speed. Pull the control hndle bck from NEUTRAL with quick firm motion to the first detent for REVERSE ger nd continue pushing bck to increse speed. Power Trim Switch - See Power Trim section for detiled power trim operting procedures. Triler Switch - Used to rise drive unit for trilering, lunching, beching or shllow wter opertion. See Power Trim for detiled triler switch opertion. CMD / SEPTEMBER 2003 Pge 19

28 GETTING TO KNOW YOUR POWER PACKAGE SECTION Power Trim Power Trim llows the opertor to djust the sterndrive ngle while underwy, to provide the idel bot ngle for vrying lod nd wter conditions. Also, the Power Trim system Trilering feture llows the opertor to rise nd lower the sterndrive unit for trilering, beching, lunching nd low speed (below 1200 rpm engine speed), shllow wter opertion. CAUTION Never trim the sterndrive unit UP/OUT using TRAILER switch while bot is underwy t engine speeds bove 1200 rpm. Use extreme cution when operting with sterndrive unit rised. Severe dmge to the sterndrive unit my result if unit is rised beyond the gimbl ring support flnges t engine speeds bove 1200 rpm. For best performnce trim the sterndrive unit so tht the bot bottom is t 3-5 degree ngle to the wter. 3-5 Trimming sterndrive unit UP/OUT cn: Generlly increse top speed Increse clernce over submerged objects or shllow bottom Cuse bot to ccelerte nd plne off slower In excess, cuse bot porpoising (bouncing) or propeller ventiltion Cuse engine overheting if trimmed UP/OUT to point where ny cooling wter intke holes re bove the wter line Pge 20 CMD / SEPTEMBER 2003