4 HP THRU 60 HP 4-STROKE WARRANTY FLAT RATE MANUAL

Transcription

1 4 HP THRU 60 HP 4-STROKE WARRANTY FLAT RATE MANUAL This Manual includes all Mercury and Mariner Outboard ls and is your guide for completing warranty labor claims. The flat rate times are listed in hours and tenths-of-hours. Troubleshooting and test times are listed in appropriate sections. rate times were developed from studies using normal shop hand tools and special tools listed in the Special Tool Catalog and following published Service Manual procedures. This Manual supersedes all previous flat rate manuals. This manual also may serve as a guide for non-warranty repairs. Printed in U.S.A. Page

2 Explanation of Table Table Instructions - Four Stroke Outboards All Mercury Marine products have a flat rate table which is used to complete warranty claims for labor reimbursement. The times listed for each repair include all operations and procedures required to complete that job. The times are listed in hours and tenths of hours. Mercury Marine warranty labor reimbursement is computed at your approved warranty labor rate currently on record. The tables are arranged by engine sub-systems and related accessories, e.g. ignition systems, powerhead, remote control, etc. Each area has a diagnostic flat rate code in addition to the removal, and replacement flat rate code for failed parts. Diagnostic time needs to be listed along with the removal and replacement time to properly complete most warranty claims. For example: replacing an ignition coil on a four-stroke outboard will have two codes listed on the claim: CA coil/each and CA18 ignition system diagnostics/test. Repairs requiring an outside expense such as machining, welding, or painting will require the dollar amount to be entered as outside labor. If you have entered a sublet labor amount you must send/fax the receipt to the appropriate Warranty Department at Mercury Marine with a copy of the claim. When a repair requires the replacement of more than one part in a related procedure use the flat rate that covers the entire repair. For example: powerhead replacement on four-stroke outboards code CP51 includes removing and replacing the powerhead and its components. Do not use component codes in addition to OP51. This would result in overlapping of flat rate codes which is not allowed. When a repair requires more than one part in unrelated failures, file a separate warranty claim for each repair. To Use The Table Find the engine sub-system being repaired. Enter the appropriate diagnostic and the removal and replacement code on the claim. For repairs that are not specified in the table or to request additional time beyond the established flat rate, you may use the code NJC (no job code) and manually record the time in hours and tenths of an hour. All claims using an NJC code for labor will require a detailed explanation in the failure description area in order to support the claimed labor. All NJC coded claims will be reviewed. Page 2

3 805 CR CR CR CR CR CR CR CR CR CR CR CR CR Seized / Stuck 59 Bushing Failed Page 3

4 904 CC CC CC CC CC CS CS CS CS CS Paint / Finish Bad Page 4

5 399 CA CA CA CA CA CA CA CA CA CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF Contaminated (Water) Contaminated (Debris) Fuel Leak Brush Failed Burnt Page 5

6 731 CI CI CI CI CI CI CI CI CI CI CI CI CI CI CI CI CI Fuel Leak Shorted / Open Air Leak Contaminated (Debris) 31 Seized / Stuck Page 6

7 7 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE Brush Failed Burnt Contaminated (Water) Page 7

8 Page 8 2 CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP CP67 1 CP CP CP CP CP CP Air Leak 04 Bearing Spalled Casting Flaw Contaminated (Debris) Detonated / Scored Oil Leak Seized / Stuck Spun 38 Water Leak

9 509 CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD CD Bearing Spalled 31 Casting Flaw Seized / Stuck Page 9

10 205 CG CG CG CG CG CG CG CG CG CG CH CH CH CH CH CH CH CH *Diagnosis Not Allowed NOTE: R & R of Complete System included in all of the Above Bearing Spalled Blocked or Clogged Oil Leak Bushing Failed Vibration Casting Flaw Seized / Stuck Page 10

11 75 HP THRU 2 HP 4-STROKE WARRANTY FLAT RATE MANUAL This Manual includes all Mercury and Mariner Outboard ls and is your guide for completing warranty labor claims. The flat rate times are listed in hours and tenths-of-hours. Troubleshooting and test times are listed in appropriate sections. rate times were developed from studies using normal shop hand tools and special tools listed in the Special Tool Catalog and following published Service Manual procedures. This Manual supersedes all previous flat rate manuals. This manual also may serve as a guide for non-warranty repairs. Printed in U.S.A. Page

12 Explanation of Table Table Instructions - Four Stroke Outboards All Mercury Marine products have a flat rate table which is used to complete warranty claims for labor reimbursement. The times listed for each repair include all operations and procedures required to complete that job. The times are listed in hours and tenths of hours. Mercury Marine warranty labor reimbursement is computed at your approved warranty labor rate currently on record. The tables are arranged by engine sub-systems and related accessories, e.g. ignition systems, powerhead, remote control, etc. Each area has a diagnostic flat rate code in addition to the removal, and replacement flat rate code for failed parts. Diagnostic time needs to be listed along with the removal and replacement time to properly complete most warranty claims. For example: replacing an ignition coil on a four-stroke outboard will have two codes listed on the claim: CA coil/each and CA18 ignition system diagnostics/test. Repairs requiring an outside expense such as machining, welding, or painting will require the dollar amount to be entered as outside labor. If you have entered a sublet labor amount you must send/fax the receipt to the appropriate Warranty Department at Mercury Marine with a copy of the claim. When a repair requires the replacement of more than one part in a related procedure use the flat rate that covers the entire repair. For example: powerhead replacement on four-stroke outboards code CP51 includes removing and replacing the powerhead and its components. Do not use component codes in addition to OP51. This would result in overlapping of flat rate codes which is not allowed. When a repair requires more than one part in unrelated failures, file a separate warranty claim for each repair. To Use The Table Find the engine sub-system being repaired. Enter the appropriate diagnostic and the removal and replacement code on the claim. For repairs that are not specified in the table or to request additional time beyond the established flat rate, you may use the code NJC (no job code) and manually record the time in hours and tenths of an hour. All claims using an NJC code for labor will require a detailed explanation in the failure description area in order to support the claimed labor. All NJC coded claims will be reviewed. Page 2

13 Part Remote Control/ Steering Cables Ride-Guide Cable - Rack CR Ride-Guide Cable - Rotary CR Remote Control R & R CR Remote Control Maj. Repair CR Remote Control Covers CR Lanyard Stop Switch CR Lock Bar CR Neutral Stop Switch CR Throttle Only Button CR Trim Switch CR Throttle & Shift Cables CR Control Diagnostic/Test CR Remote Control Harness and/or Key Switch CR Seized / Stuck 59 Bushing Failed Page 3

14 Part Covers Bottom Cowl CC Top Cowl CC Decals Remove & Replace CC Cowl Latch - Each CC Lower Cowl Bottom Seal CC Part Manual Starter Manual Starter Pinion Gear CS Manual Starter Replace CS Manual Starter Rope CS Manual Starter Rewind Spring CS Paint / Finish Bad Part Miscellaneous Install Heli-Coil CM Remove & Replace Broken/Seized Fasteners - Each CM Page 4

15 Part Ignition System Magneto Base CA Coil / Each CA Flywheel Cover CA Flywheel CA Stator CA C.D.I./Switchbox/ECM CA Trigger CA Ignition System Diagnostic/Test CA Crankshaft Position Sensor/Coil CA Part Fuel System Carburetor Replace (One) CF Carburetor Replace Ea. Add. CF Carburetor Repair (One) CF Carburetor Repair Ea. Add. CF Fuel Pump Replace - Each CF Fuel Pump Repair CF Primer Bulb CF Fuel System Diagnostic/Test CF Intake Manifold CF Air Funnel CF Breather/Oil Separator CF Fuel Filter CF Fuel Lines CF Oil Breather Line/Tube CF Throttle Control Linkage CF Contaminated (Water) Contaminated (Debris) Fuel Leak Brush Failed Burnt Page 5

16 Part Electronic Fuel Injection ECM - R & R CI Electric Fuel Pump Assy. - R&R CI Fuel Injectors CI Fuel Pressure Regulator CI Engine Coolant Temperature (ECT) Sensor CI Throttle Position Sender (TPS) CI Vapor Separator - R & R CI Manifold Air Temperature (MAT) Sensor CI Fuel Cooler CI Idle Air Control (IAC) CI Manifold Absolute Pressure (MAP) Sensor CI Throttle Body CI Induction Manifold Assembly CI Intake Silencer CI Diagnostics CI Main Power Relay CI Fuel Injectors - Each Bank CI Step Motor Idle Speed Control CI Injection Pump Relay CI Fuel Leak Shorted / Open Air Leak Contaminated (Debris) 31 Seized / Stuck Page 6

17 Part Electrical System Electric Choke CE Internal Harness CE Key Switch - Dash Mount CE Neutral Start Switch CE Regulator/Rectifier CE Starter Motor Repair CE Starter Motor Replace CE Starter Relay/Solenoid CE Start/Stop Switch - Tiller CE Gauges/Each CE Trim Sender CE Electrical System Diagnostic/Test CE Power Trim Relay/Each CE Ground Wire/Each CE Oil Pressure Sender Switch CE Lanyard Switch Tiller CE Lanyard Switch - Remote Control CE Trim Switch - Remote Control CE Trim Switch - Cowl CE Starter Pinion Gear CE Brush Failed Burnt Contaminated (Water) Page 7

18 Part Powerhead Cylinder Head - Each CP Cylinder Head Gasket - Each CP Outer Exhaust Cover/Gasket CP Lower Oil Seal CP Oil Pump Assembly CP Cylinder Head Cover/Gasket - Each CP Crankshaft CP Piston/Rings/Bearings - One CP Piston/Rings/Bearings Ea. Add. CP Crankshaft Lower Bearing CP Crankshaft Upper Bearing CP Oil Filter CP Powerhead Replaced CP Powerhead Rebuild CP Thermostat CP Upper Oil Seal CP Analysis/Test CP Camshaft/Oil Seal - Each CP Valve Spring - One CP Valve Spring Each Additional CP Valve/Valve Guide (One) CP Valve/Valve Guide Ea. Add. CP Rocker Arm/Shaft CP Timing Gear Belt CP Timing Drive Gear CP Timing Driven Gear CP Tensioner Assy. CP Valve Adjustment CP Fuel Pump Cam Follower CP Camshaft/Oil Seal Add. CP Valve Pad - One CP Valve Pad Eadh Add. CP Valve Pad Opp. Bank - One CP Oil Sump Clean-Up CP Valve Spring One - Port Head CP Valve Spring Each Additional - Port Head CP Air Leak 04 Bearing Spalled Casting Flaw Contaminated (Debris) Detonated / Scored Oil Leak Seized / Stuck Spun 38 Water Leak Page 8

19 Part 2 Powerhead 75 1 (continued) Valve Spring One - Starboard Head CP Valve Spring Each Additional - Starboard Head CP Valve/Valve Guide One - Port Head CP Valve/Valve Guide Each Additional - Port Head CP Valve/Valve Guide One - Starboard Head CP Valve/Valve Guide Each Additional - Starboard Head CP Valve Pad One - Port Head CP Valve Pad Each Additional - Port Head CP Valve Pad One - Starboard Head CP Valve Pad Each Additional - Starboard Head CP Air Leak 04 Bearing Spalled Casting Flaw Contaminated (Debris) Detonated / Scored Oil Leak Seized / Stuck Spun 38 Water Leak Page 9

20 Part Mid Section Adaptor Plate/Exhaust Manifold CD Clamp Bracket CD Driveshaft Housing CD Top Mount CD Lower Mounts / Each CD Swivel Bracket CD Swivel Pin/Tube CD Upper Shift Shaft CD Tiller Arm Repair/Replace CD Steering Tube CD Oil Reservoir/Pan/Sump CD Oil Strainer/Pickup CD Exhaust Pipe CD Mid-Section Diagnostic/Test CD Water Tube CD Tilt Stopper CD ShiftRodBracket/Each CD Bearing Spalled 31 Casting Flaw Seized / Stuck Page 10

21 Part Gear Housing Driveshaft CG Gear Housing Assy. - R & R CG Gear Housing Major Repair CG Gear Housing Reseal CG Propshaft or Brg. Carrier CG Shift Shaft - Lower CG Shift Shaft Bushing CG Water Pump CG Gear Housing Diagnostic/Test CG Gear Set - R & R CG Anode / Trim Tab CG Speedometer Hose CG Cover - Water Inlet Plate CG Plate Assy Seal - Rubber Guide CG Bearing Spalled Blocked or Clogged Oil Leak Bushing Failed Vibration Page 11

22 Part Single Ram Power Trim System Manual Release Valve CH **Rebuild Pump/Manifold CH **Replace Trim Motor CH **Rebuild Cylinder CH **Rebuild Pump/Manifold and Trim Motor CH **R & R Rocker Arm CH *R & R Complete Trim System CH Trim System Diagnostic/Test CH *Diagnosis Not Allowed **R & R of Complete System included Part Triple Ram Power Trim System *R & R Complete Trim System CH / 111 **Motor & Pump CH **Pump Motor Armature CH **Tilt Cylinder (Center) - Replace CH **Tilt Cylinder (Center) - Rebuild CH Trim Ram (Side) - Replace Each CH **Trim Manifold CH **Pump & Valve Body Assembly CH Manual Release Valve CH Diagnosis & Bleeding System CH Hydraulic Line - Each CH Casting Flaw Seized / Stuck *Diagnosis Not Allowed **R & R of Complete System included Page

23 Part Gear Housing Bigfoot Bigfoot cyl 747cc 50 Bigfoot cc cc 205 Driveshaft CG Gear Housing Assy. - R & R CG Gear Housing Major Repair CG Gear Housing Reseal CG Propshaft or Brg. Carrier CG Shift Shaft - Lower CG Shift Shaft Bushing CG Water Pump CG Gear Housing Diagnostic/Test CG Gear Set - R & R CG Part Single Ram Power Trim System cc cc 30 3 cyl 30 3 cyl 747cc cc cc Bigfoot 3 Manual Release Valve CH Rebuild Pump/Manifold CH Replace Trim Motor CH Rebuild Cylinder CH Rebuild Pump/Manifold and Trim Motor cc CH R&RRockerArm CH *R & R Complete Trim System CH Trim System Diagnostic/Test CH *Diagnosis Not Allowed NOTE: R & R of Complete System included in all of the Above cc Bigfoot Bearing Spalled Blocked or Clogged Oil Leak Bushing Failed Vibration Casting Flaw Seized / Stuck Page 10