Declrtion of Conformity for Recretionl Crft Propulsion Engines with the requirements of Directive 94/25/EC s mended y 2003/44/EC This inord engine, when instlled in ccordnce with Mercury Mrine s instructions, complies with the requirements of the following directives y meeting the ssocited stndrds s mended: Nme of engine mnufcturer: V M Motori, s.p.. Address: 29 Vi Ferrrese Town: Cento (FE) Post Code: 44042 Country: Itly Nme of Authorized Representtive: Brunswick Mrine in EMEA Inc. Address: Prc Industriel de Petit Rechin Town: Verviers Post Code:B 4800 Country: Belgium Nme of Notified Body for exhust emission ssessment (115/130 HP): T Ü V Product Service Gmh Address: 65 Ridlerstrsse Town: Münich Post Code: 80339 Country: Germny ID Numer: 0123 Nme of notified ody for exhust emission ssessment (150/170 HP): Interntionl Mrine Certifiction Institute (IMCI) Address: Rue Aé Cuypers 3 Town: Bruxelles Post Code: B 1040 Country: Belgium ID Numer: 0609 Conformity ssessment module used for exhust emissions: B+C B+D B+E B+F G H Other Community Directives pplied: Electromgnetic Comptiility Directive 2004/108/EC Description of Engines nd Essentil Requirements Engine Type: Fuel Type: Comustion Cycle: Inord engine Diesel 4 stroke Identifiction of Engines Covered y this Declrtion of Conformity Nme of engine model or engine fmily: Unique engine identifiction numer(s) or engine fmily code(s) EC Type exmintion certificte or type pprovl certificte numer 2.0L 115/130 MR504LB3/MR504LS3 SB5 13 11 57278 013 2.0L 150/170 MR504LH3/MR504LX3 EXVMMO001 Essentil requirements Annex I.B Exhust Emissions Stndrds Other normtive document/ method Technicl file B.1 Engine Identifiction B.2 Exhust Emission Requirements Plese specify in more detil (* = mndtory stndrd) * *EN ISO 8178 1:1996 B.3 Durility B.4 Owner s Mnul ISO 8665:2006 Annex I.C Noise Emissions see the Declrtion of Conformity for the crft in which the engine(s) hs (hve) een instlled 2014 Mercury Mrine 2.0L Diesel Engine Inord Models 90-8M0089579 314
This declrtion of conformity is issued under the sole responsiility of the mnufcturer. I declre on ehlf of the engine mnufcturer tht the engine(s) will meet the exhust emission requirements of Directive 94/25/EC s mended y Directive 2003/44/EC when instlled in recretionl crft, in ccordnce with the engine mnufcturer s supplied instructions, nd tht this (these) engine(s) must not e put into service until the recretionl crft into which it is (they re) to e instlled hs een declred in conformity with the relevnt provisions of the ove mentioned Directives. Nme / function: Mrk D. Schwero, President, Mercury Mrine Dte nd plce of issue: Novemer 5, 2013 Fond du Lc, Wisconsin, U.S.A. Regultory contct: Regultions nd Product Sfety Deprtment Mercury Mrine W6250 Pioneer Rod Fond du Lc, WI 54936 U.S.A. Identifiction Record Plese record the following informtion: Engine Model nd Horsepower Engine 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 The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Diesel 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 guide 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. 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, 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 Mercury Mrine products. We sincerely hope your oting will e plesnt! Mercury Mrine
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 sections of this mnul. The wrrnty sttement 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. Red This Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler, who cn nswer questions nd demonstrte ctul strting nd operting procedures. Notice Throughout this puliction, nd on your power pckge, dngers, 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.! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! 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.! WARNING 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, Mintennce nd Wrrnty 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. 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.
TABLE OF CONTENTS Section 1 - WARRANTY Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Mercury Product Protection Pln: United Sttes nd Cnd... 3 Emission Control Wrrnty Informtion... 3 Importnt Informtion... 3 Emission Control System Components... 3 Emission Control Informtion Lel... 4 Owner Responsiility... 4 Wrrnty Policy Diesel Models... 4 High Output Recretionl Use Limited Wrrnty... 4 Light Duty Commercil Use Limited Wrrnty... 6 3 Yer Limited Wrrnty Aginst Corrosion Diesel Models (Recretionl Use Only)... 7 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Trnsfer of Wrrnty Austrli nd New Zelnd Policy... 10 Glol Wrrnty Chrts... 11 United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel... 11 Outside United Sttes...11 Cnd Wrrnty Chrt MerCruiser Gs nd Diesel... 11 Outside Cnd...11 Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside Austrli nd New Zelnd... 12 South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside of the South Pcific... 12 Asi Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside of Asi... 12 Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel... 12 Outside Europe nd CIS...13 Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel... 13 Outside Middle Est nd Afric... 13 South Afric Wrrnty Chrts MerCruiser Gs nd Diesel... 13 Outside South Afric...13 Section 2 - Getting to Know Your Power Pckge Fetures nd Controls... 16 Wrning Horn Signls... 16 Instrumenttion... 16 VesselView... 16 SmrtCrft Speedometer, Tchometer, nd Digitl Guges... 16 System Link Digitl Guges... 17 Switches... 18 Emergency Stop Switch... 18 Lnyrd Stop Switch... 19 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 20 Digitl Throttle nd Shift... 20 Remote Controls... 20 Pnel Mount Fetures... 20 Console Mount Fetures... 21 Engine Electricl System Overlod Protection... 21 Vessel Integrtion Pnel (VIP) Overlod Protection... 22 Engine Gurdin System... 22 Identifiction... 23 Specifictions Lel... 23 Dt Lel Loction... 23 Engine Dt Lel... 23 Technodrive Trnsmissions... 24 Section 3 - On the Wter Sfe Boting Recommendtions... 26 Cron Monoxide Exposure... 27 Be Alert To Cron Monoxide Poisoning... 27 Sty Cler of Exhust Ares... 27 Good Ventiltion... 27 Poor Ventiltion... 28 Importnt Opertion Informtion... 28 Lunching... 28 Duty Cycle Rting Requirements... 28 High Output Rting... 28 Opertion Chrt... 29 Freezing Temperture nd Cold Wether Opertion... 29 Drin Plug nd Bilge Pump... 30 Strting, Shifting, nd Stopping... 30 Before Strting the Engine... 30 Importnt Informtion SmrtStrt... 30 Strting Cold Engine... 30 Engine Wrm Up... 31 Strting Wrm Engine... 31 Shifting... 31 Engine Shut Down (Stopping)... 31 Protecting People in the Wter... 32 While Bot is in Opertion... 32 While the Bot is Sttionry... 32 90-8M0089579 eng MARCH 2014 Pge i
High Speed nd High Performnce... 32 Pssenger Sfety In Pontoon Bots And Deck Bots... 32 Bots Hving An Open Front Deck... 32 Bots With Front Mounted, Rised Pedestl Fishing Sets... 33 Wve nd Wke Jumping... 33 Impct With Underwter Hzrds... 33 Conditions Affecting Opertion... 34 Weight Distriution (Pssengers nd Ger) Inside the Bot... 34 Bottom of Bot... 34 Elevtion nd Climte... 34 Propeller Selection... 35 Getting Strted... 35 Initil Brek In Procedure... 35 Engine Brek In... 35 20 Hour Brek In Period... 35 After the 20 Hour Brek In Period...35 End of First Seson Checkup... 36 Section 4 - Specifictions Fuel Requirements... 38 Nonferrous Metls nd the Fuel System... 38 Diesel Fuel in Cold Wether... 38 Antifreeze/Coolnt... 38 Engine Oil... 39 Engine Specifictions... 39 Fluid Specifictions... 40 Engine... 40 Trnsmission... 40 Approved Pints... 40 Section 5 - Mintennce Owner nd Opertor Responsiilities... 42 Deler Responsiilities... 42 Mintennce... 42 Do It Yourself Mintennce Suggestions... 42 Generl Inspection... 42 Engine Cover... 43 Removl... 43 Clening... 43 Inspection... 43 Instlltion... 43 Mintennce Schedule... 43 Routine Mintennce... 43 Scheduled Mintennce... 45 Engine Oil... 45 Specifictions... 45 Oil Level Overfilled... 45 Checking... 46 Filling... 46 Chnging Oil nd Filter... 47 TM 345 Technodrive Trnsmission Fluid... 49 Checking... 49 Filling... 50 Chnging... 50 TM 485 A Technodrive Trnsmission Fluid... 51 Check Fluid... 51 Add Fluid... 52 Chnge Fluid... 53 Engine Coolnt... 55 Checking nd Filling the Closed Cooling System... 55 Drining the Closed Cooling System... 56 Air Filter... 57 Removl... 57 Inspection... 58 Instlltion... 58 Wter Seprting Fuel Filter... 59 Drining... 59 Replcing... 60 Filling... 62 Fuel System... 63 Priming... 63 Filling (Bleeding)... 63 Fuel Tnk Clening nd Flushing... 64 Sewter System... 64 Drining the Sewter System... 64 Checking the Sewter Pickups... 65 Clening the Sewter Striner... 66 Engine Sewter Pump Inspection... 67 Corrosion Protection... 67 Generl Informtion... 67 Engine Corrosion Protection Components... 68 Removl... 68 Clening nd Inspection... 68 Instlltion... 69 Antifouling Pint... 69 Luriction... 69 Throttle Cle... 69 Shift Cle... 70 Drive Belts... 70 Serpentine Belt Inspection... 70 Bttery... 71 Bttery Precutions for Multiple Engines... 71 Section 6 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge... 74 Cold Wether (Freezing Temperture) Storge... 74 Prepring Your Power Pckge for Sesonl or Extended Storge... 74 Sesonl Storge... 75 Pge ii 90-8M0089579 eng MARCH 2014
Extended Storge Instructions... 76 Bttery... 76 Recommissioning... 76 Section 7 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems... 78 Trouleshooting Chrts... 78 Strter Motor Will Not Crnk Engine, or Crnks Slow... 78 Engine Will Not Strt, or Is Hrd to Strt... 78 Engine Runs Rough, Misses, or Bckfires... 78 Poor Performnce... 79 Incorrect Engine Temperture... 79 Low Engine Oil Pressure... 79 Bttery Will Not Chrge... 79 Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds... 80 Section 8 - Customer Assistnce Informtion Owner Service Assistnce... 82 Locl Repir Service... 82 Service Awy From Home...82 Stolen Power Pckge... 82 Attention Required After Sumersion... 82 Replcement Service Prts... 82 Prts nd Accessories Inquiries... 82 Resolving Prolem... 82 Contct Informtion for Mercury Mrine Customer Service... 83 Customer Service Literture... 83 English Lnguge... 83 Other Lnguges...84 Ordering Literture... 84 United Sttes nd Cnd... 84 Outside the United Sttes nd Cnd... 84 Section 9 - Mintennce Log Mintennce Log... 86 90-8M0089579 eng MARCH 2014 Pge iii
Pge iv 90-8M0089579 eng MARCH 2014
Tle of Contents Section 1 - WARRANTY Section 1 - WARRANTY 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Mercury Product Protection Pln: United Sttes nd Cnd... 3 Emission Control Wrrnty Informtion... 3 Importnt Informtion...3 Emission Control System Components... 3 Emission Control Informtion Lel... 4 Owner Responsiility... 4 Wrrnty Policy Diesel Models... 4 High Output Recretionl Use Limited Wrrnty...4 Light Duty Commercil Use Limited Wrrnty...6 3 Yer Limited Wrrnty Aginst Corrosion Diesel Models (Recretionl Use Only)... 7 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Trnsfer of Wrrnty Austrli nd New Zelnd Policy... 10 Glol Wrrnty Chrts... 11 United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel... 11 Outside United Sttes... 11 Cnd Wrrnty Chrt MerCruiser Gs nd Diesel... 11 Outside Cnd... 11 Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside Austrli nd New Zelnd... 12 South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside of the South Pcific... 12 Asi Wrrnty Chrt MerCruiser Gs nd Diesel... 12 Outside of Asi... 12 Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel... 12 Outside Europe nd CIS... 13 Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel... 13 Outside Middle Est nd Afric... 13 South Afric Wrrnty Chrts MerCruiser Gs nd Diesel... 13 Outside South Afric... 13 90-8M0089579 eng MARCH 2014 Pge 1
Section 1 - WARRANTY Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd Outside United Sttes nd Cnd Check with your locl distriutor. 1. You my chnge your ddress on file with Mercury Mrine t ny time, including t time of wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril numer to Mercury Mrine 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 54936-1939 920-929-5054 Fx +1 920 907 6663 NOTE: Registrtion lists must e mintined y Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act e required. 2. To e eligile for wrrnty coverge, the product must e registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely sumit it to Mercury Mrine vi MercNET, E mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 3. Upon processing the wrrnty registrtion, Mercury Mrine will send registrtion verifiction y mil to the purchser of the product. If this registrtion verifiction is not received within 30 dys, plese contct your selling deler immeditely. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. Wrrnty Registrtion Outside the United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the wrrnty registrtion crd completely nd mils it to the distriutor or Mrine Power Service Center responsile for dministering the wrrnty registrtion nd clim progrm for your re. 2. The wrrnty registrtion crd identifies your nme nd ddress, product model nd seril numers, dte of sle, type of use nd the selling distriutor's nd deler's code numer, nme nd ddress. The distriutor or deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the wrrnty registrtion crd, designted s the purchser's copy, must e given to you immeditely fter the crd hs een completely filled out y the selling distriutor or deler. This crd represents your fctory registrtion identifiction, nd should e retined y 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 forms. 4. 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 distriutor or deler. If you receive plstic wrrnty registrtion crd, you my discrd the purchser's copy tht you received from the distriutor or deler when you purchsed the product. Ask your distriutor or deler if this plstic crd progrm pplies to you. 5. For further informtion concerning the wrrnty registrtion crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. See Tle of Contents. IMPORTANT: Registrtion lists must e mintined y the fctory nd deler in some countries y lw. It is our desire to hve ALL products registered t the fctory should it ever e necessry to contct you. Mke sure your Mercury Mrine distriutor or Mercury Mrine uthorized deler fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. Trnsfer of Wrrnty The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd engine seril numer to Mercury Mrine s Wrrnty Registrtion Deprtment. 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 54936-1939 920-929-5054 Fx +1 920 907 6663 Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. Pge 2 90-8M0089579 eng MARCH 2014
There is no chrge for this service. Section 1 - WARRANTY For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Mercury Product Protection Pln: United Sttes nd Cnd IMPORTANT: Certin performnce products, triple engine instlltions, nd commercil pplictions re excluded from the Mercury Product Protection Pln progrm. The Mercury Product Protection Pln provides coverge ginst unexpected mechnicl nd electricl rekdowns tht my occur eyond the stndrd limited wrrnty. The pln my e purchsed up to twelve months fter the originl engine registrtion dte nd is ville with terms rnging from one to five yers. The optionl Mercury Product Protection Pln is the only fctory uthorized extended wrrnty pln ville for your engine. See your prticipting Mercury MerCruiser deler for complete progrm detils. Emission Control Wrrnty Informtion Importnt Informtion To identify the pplicle emission control wrrnty coverge for prticulr product, refer to the Emission Control Informtion lel ffixed to the engine. Engines designted s exempt from either Federl EPA or Cliforni emission control regultions re not covered y seprte emission control component wrrnty. The product's Mercury MerCruiser mnufcturer's wrrnty is not ffected y the engine's designtion under Federl EPA or Cliforni emission control regultions. For list of typicl emission control relted engine components, refer to Emission Control System Components in the wrrnty section of your owner's mnul. Emission Control System Components The emission relted wrrnty covers ll components whose filure would increse n engine's emission of ny regulted component including the following list of components: 1. Fuel metering system. Pressure regultor or fuel injection system. Cold strt enrichment system c. Intke vlves 2. Air induction system. Intke mnifold. Turochrger or superchrger systems c. Chrge ir cooler 3. Exhust system. Exhust mnifold. Exhust vlves 4. Miscellneous items used in ove systems. Hoses, clmps, fittings, tuing, seling gskets or devices, nd mounting hrdwre. Pulleys, elts, nd idlers c. Vcuum, temperture, check nd time sensitive vlves nd switches d. Sensors e. Electronic controls NOTE: The EPA emission relted wrrnty does not cover components whose filure would not increse n engine's emissions on ny regulted pollutnt. 90-8M0089579 eng MARCH 2014 Pge 3
Section 1 - WARRANTY Emission Control Informtion Lel A tmper resistnt emission control informtion (ECI) lel is ffixed to the engine in visile loction t the time of mnufcture. Plese note tht the emissions certifiction will not ffect the fit, function, or performnce of the engine. Botuilders nd delers my not remove the lel or the prt it is ffixed to efore sle. If modifictions re necessry, contct Mercury MerCruiser out the vilility of replcement decls efore proceeding. In ddition to the required emissions sttement, the lel lists the fmily, pplicle emission stndrd, nd dte (month, yer) of mnufcture. IMPORTANT: Engines designted s exempt from either Federl EPA or Cliforni emission control regultions re not covered y seprte emission control component wrrnty. The product's Mercury MerCruiser mnufcturer's wrrnty is not ffected y the engine's designtion under Federl EPA or Cliforni emission control regultions. Owner Responsiility The opertor must hve routine engine mintennce performed to mintin emission levels within prescried certifiction stndrds. The opertor my not modify the engine in ny mnner tht lters the horsepower or llows emissions levels to exceed fctory specifictions. Wrrnty Policy Diesel Models High Output Recretionl Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new engine/drive pckge (Product) to e free of defects in mteril nd workmnship during the period descried following. DURATION OF COVERAGE: The wrrnty period egins on 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. This Limited Wrrnty provides specific coverge in the regions stipulted in the Glol Wrrnty Chrts for plesure (noncommercil) pplictions, or the ccumultion of 1000 hours of opertion, whichever occurs first. Commercil use of product tht is registered s plesure voids the wrrnty. Commercil use includes ny work relted or employment relted use of the product, or ny use of the product which genertes income during 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 term of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper registrtion of the product. HIGH OUTPUT RATING: High output rting pplies to vrile lod pplictions where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion (the seven hours out of eight hours in which the engine is not operted t full power) must e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) 53309 Cruise Speed Reduction from Engine Rted Speed (RPM) 4000 RPM 400 RPM This rting is for plesure (noncommercil) pplictions tht operte 500 hours or fewer per yer. Pge 4 90-8M0089579 eng MARCH 2014
Section 1 - WARRANTY CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or susequent chnge of use from recretionl to commercil (unless properly registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my e terminted for used product otined in ny of the following wys: The product ws repossessed from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Registered with incorrect informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Dmge cused y norml use Dmge cused y the use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce nd Wrrnty mnul) Dmge cused y operting the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Dmge cused y neglect Dmge cused y n ccident Dmge cused y sumersion Dmge cused y improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Dmge cused y improper service Dmge cused y the use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine nd tht dmges the Mercury product Jet pump impellers nd liners Dmge cused y the use of fuels, oils, or luricnts tht re not suitle for use with the product Altertion or removl of prts Dmge cused y wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Dmge cused y running the engine out of wter Mounting the engine too high on the trnsom Dmge cused y operting the ot with the engine overtrimmed 90-8M0089579 eng MARCH 2014 Pge 5
Section 1 - WARRANTY Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y previous 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 y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele 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 MAY VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Light Duty Commercil Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new engine/drive pckge (Product) to e free of defects in mteril nd workmnship during the period descried following. DURATION OF COVERAGE: The wrrnty period egins on the dte the product is first sold to light duty commercil use retil purchser or the dte on tht the product is first put into service, whichever occurs first. This Limited Wrrnty provides coverge for one (1) yer or 500 hours of use, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of the wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cnnot e trnsferred. LIGHT DUTY COMMERCIAL RATING: Applies to vrile lod pplictions where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion (the seven hours out of eight hours in which the engine is not operted t full power) must e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) Cruise Speed Reduction from Engine Rted Speed (RPM) 4000 RPM 400 RPM COMMERCIAL USE: Is defined s ny work or employment relted use of this product, or ny use of the product tht genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. Opertion of the product in excess of the light duty commercil specifictions will void the wrrnty. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my e terminted for used product otined in ny of the following wys: The product ws repossessed from retil customer Purchsed t n uction Purchsed from slvge yrd Pge 6 90-8M0089579 eng MARCH 2014
Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Registered with incorrect informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Dmge cused y norml use Section 1 - WARRANTY Dmge cused y the use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce nd Wrrnty mnul) Dmge cused y operting the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Dmge cused y neglect Dmge cused y n ccident Dmge cused y sumersion Dmge cused y improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Dmge cused y improper service Dmge cused y the use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine nd tht dmges the Mercury product Jet pump impellers nd liners Dmge cused y the use of fuels, oils, or luricnts tht re not suitle for use with the product Altertion or removl of prts Dmge cused y wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Dmge cused y running the engine out of wter Mounting the engine too high on the trnsom Dmge cused y operting the ot with the engine overtrimmed Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y previous 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 y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele 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 MAY VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Yer Limited Wrrnty Aginst Corrosion Diesel Models (Recretionl Use Only) WHAT IS COVERED: Mercury Mrine wrrnts tht ech new recretionl use engine/drive pckge (Product) will not e rendered inopertive s direct result of corrosion for the period of time descried in the following. 90-8M0089579 eng MARCH 2014 Pge 7
Section 1 - WARRANTY DURATION OF COVERAGE: This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir nd replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred to susequent (noncommercil use) purchser upon proper reregistrtion of the product. Wrrnty coverge my e terminted for used product repossessed from retil customer, purchsed t n uction, from slvge yrd, or from n insurnce compny tht otined the product s result of n insurnce clim. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified predelivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce nd Wrrnty mnul must e in use on the ot, nd routine mintennce outlined in the Opertion, Mintennce nd Wrrnty mnul must e timely performed (including without limittion the replcement of scrificil nodes, use of specified luricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury's sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured 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 oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y 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 e 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 y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, use or improper service; corrosion to ccessories, instruments, steering systems; dmge due to mrine growth; product sold with less thn one yer limited product wrrnty; replcement prts (prts purchsed y the Customer); products used in commercil ppliction. 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 wrrnty period, even if the product is only occsionlly used for such purposes. 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. Wrrnty Policy Austrli nd New Zelnd MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy This Limited Wrrnty is given y Mrine Power Interntionl Pty Ltd ACN 003 100 007 of 41 71 Bessemer Drive, Dndenong South, Victori 3175 Austrli (telephone (61) (3) 9791 5822), e mil: merc_info@mercmrine.com. WHAT IS COVERED: Mercury Mrine wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. The enefits to the consumer given y the wrrnty re in ddition to other rights nd remedies of the consumer under lw in reltion to the goods or services to which the wrrnty reltes. GUARANTEES UNDER AUSTRALIAN CONSUMER LAW: Our goods come with gurntees tht cnnot e excluded under the Austrlin Consumer Lw. You re entitled to replcement or refund for mjor filure nd compenstion for ny other resonly foreseele loss or dmge. You re lso entitled to hve the goods repired or replced if the goods fil to e of cceptle qulity nd the filure does not mount to mjor filure. Pge 8 90-8M0089579 eng MARCH 2014
Section 1 - WARRANTY DURATION OF COVERAGE FOR THIS LIMITED WARRANTY: You re only entitled to clim this Limited Wrrnty for defects which pper during the relevnt wrrnty period. Refer to Glol Wrrnty Chrts for the wrrnty period specific to the model nd region where the power pckge ws purchsed. Your clim must lso e received y us efore the wrrnty period expires. WARRANTY COVERAGE FOR RECREATIONAL USE: The wrrnty period egins on 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. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this limited wrrnty eyond its originl expirtion dte. The wrrnty period is specific to the model covered. Refer to your model for the se coverge period. WARRANTY COVERAGE FOR COMMERCIAL USE: The wrrnty period egins on the dte the product is first sold to commercil use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge for either one (1) yer from the dte of first retil sle or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work relted or employment relted use of the product, or ny use of the product tht 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 eyond its originl expirtion dte. TRANSFER OF COVERAGE: Unexpired wrrnty coverge cn e trnsferred to susequent recretionl use customer upon proper registrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from commercil use customer. TERMINATION OF COVERAGE: Wrrnty coverge under this Limited Wrrnty is terminted for used product otined in ny of the following wys: Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Purchsed from slvge yrd Repossession from retil customer Purchsed t n uction CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: Wrrnty coverge under this Limited Wrrnty is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the predelivery inspection process specified y Mercury Mrine is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use or susequent chnge of use from recretionl to commercil (unless properly registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce must e performed ccording to the mintennce schedule in the Opertion, Mintennce, nd Wrrnty mnul in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY WILL DO: Mercury Mrine's sole nd exclusive oligtion under this Limited Wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y delivering the product for inspection to Mercury Mrine deler uthorized to service the product. A list of delers nd their contct detils is ville t http://www.mercurymrine.com.u/home.spx. If the purchser cnnot deliver the product to such deler, written notice must e given to Mercury Mrine t the ddress shown ove. Mercury Mrine will then rrnge for the inspection nd ny covered repir. This Limited Wrrnty will not cover the purchser for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered y this limited wrrnty, the purchser shll py for ll relted lor nd mteril nd ny other expenses ssocited with tht service, provided tht consumer will not e oligted to py where the service hs een crried out to remedy filure of n cceptle qulity gurntee which is inding on Mercury Mrine under the Austrlin Consumer Lw. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge under this Limited Wrrnty. WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Operting the ot with the engine overtrimmed Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge. Refer to the Opertion, Mintennce, nd Wrrnty mnul. 90-8M0089579 eng MARCH 2014 Pge 9
Section 1 - WARRANTY Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce, nd Wrrnty mnul. Neglect Accident Sumersion 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 tht ws not mnufctured or sold y Mercury Mrine tht cuses dmge to the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or luricnts tht re not suitle for use with the product. Refer to the Opertion, Mintennce nd Wrrnty mnul. Altertion 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 y lockge of the cooling system y foreign ody Running the engine out of wter Mounting the engine too high on the trnsom Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y previous owner of the product, voids this limited 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 y this limited wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this limited wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not e enforcele ginst Mercury Mrine. EXPENSE OF CLAIMING THIS LIMITED WARRANTY: This Limited Wrrnty does not cover ny expenses you my incur climing the wrrnty. DISCLAIMERS AND LIMITATIONS: EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE, 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 LIMITED WARRANTY. Trnsfer of Wrrnty Austrli nd New Zelnd Policy The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd hull identifiction numer (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. In Austrli nd New Zelnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment Brunswick Asi Pcific Group Privte Bg 1420 Dndenong South, Victori 3164 Austrli Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. There is no chrge for this service. You my chnge your ddress t ny time, including t the time of the wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd hull identifiction numer (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. Pge 10 90-8M0089579 eng MARCH 2014
Section 1 - WARRANTY Glol Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord 5.7 6.2 MPI, 8.2 H.O. MerCruiser Inord 5.7 6.2 8.2 Horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside United Sttes For product purchsed outside of United Sttes, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord 5.7 6.2 MPI, 8.2 H.O. MerCruiser Inord 5.7 6.2 8.2 Horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Cnd For product purchsed outside of Cnd, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. 90-8M0089579 eng MARCH 2014 Pge 11
Section 1 - WARRANTY Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Stndrd Limited Wrrnty 2 yers 3 yers MerCruiser SeCore 3 yers 4 yers MerCruiser TowSport 3 yers 3 yers Mercury Diesel Sterndrive nd Inord 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Austrli nd New Zelnd For product purchsed outside of Austrli nd New Zelnd, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty 2 yers 3 yers 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of the South Pcific For product purchsed outside of the South Pcific, contct the distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Asi Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Gsoline Sterndrive nd Inord Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty 1 yer 3 yers 1 yer 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of Asi For product purchsed outside of the Asin region, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 2 yers 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Pge 12 90-8M0089579 eng MARCH 2014
Outside Europe nd CIS Section 1 - WARRANTY For products purchsed outside of Europe nd CIS regions, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Middle-Est nd Afric For products purchsed outside of Middle Est nd Afric regions, contct the distriutor in your country, or the Mrine Power Service Center closest to you. South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside South Afric For products purchsed outside of South Afric, contct the distriutor in your country, or the Mrine Power Service Center closest to you. 90-8M0089579 eng MARCH 2014 Pge 13
Section 1 - WARRANTY Notes: Pge 14 90-8M0089579 eng MARCH 2014
Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tle of Contents Fetures nd Controls... 16 Wrning Horn Signls... 16 Instrumenttion... 16 VesselView... 16 SmrtCrft Speedometer, Tchometer, nd Digitl Guges... 16 System Link Digitl Guges... 17 Switches... 18 Emergency Stop Switch...18 Lnyrd Stop Switch... 19 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 20 Digitl Throttle nd Shift... 20 Remote Controls... 20 Pnel Mount Fetures... 20 Console Mount Fetures... 21 Engine Electricl System Overlod Protection... 21 Vessel Integrtion Pnel (VIP) Overlod Protection... 22 Engine Gurdin System... 22 Identifiction... 23 Specifictions Lel... 23 Dt Lel Loction... 23 Engine Dt Lel... 23 Technodrive Trnsmissions... 24 2 90-8M0089579 eng MARCH 2014 Pge 15
Section 2 - Getting to Know Your Power Pckge Fetures nd Controls Wrning Horn Signls When the key switch is turned to the on position, the horn will turn on for moment s test to indicte the horn is working. There re two types of wrning horns to lert the opertor of n ctive prolem within the engine s operting system. 1. Continuous six second eep: Indictes criticl engine condition. Depending on the condition, the Engine Gurdin system my engge nd protect the engine y limiting power. You should return to port immeditely nd contct your servicing deler. 2. Intermittent short eeps for six seconds: Indictes noncriticl engine condition. This condition does not require immedite ttention. You my continue using your ot, however, depending on the nture of the prolem, the engine s power my e limited y the Engine Gurdin system to protect the engine. You should contct your servicing deler t your erliest convenience. It is importnt to note tht in either of the ove scenrios, the horn will only sound one time. If you key the engine off nd restrt it, the horn will sound gin, one time, if the fult is still present. A few of the noncriticl conditions indicted y the intermittent short eeps for six seconds cn e corrected y the opertor. These opertor correctle conditions re s follows: Wter in the fuel filter. Refer to Mintennce Wter Seprting Fuel Filter. Cooling system (wter pressure or engine temperture) prolem. Stop the engine nd check the wter intke holes in the lower unit for ostruction. Low engine oil level. Refer to Fuel nd Oil Checking nd Adding Engine Oil. 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 52421 Pge 16 90-8M0089579 eng MARCH 2014
Section 2 - Getting to Know Your Power Pckge Coolnt temperture Oil pressure Bttery voltge Fuel consumption Engine operting hours SmrtCrft tchometer nd speedometer - Tchometer - Speedometer c - LCD disply c 50400 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 37925 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 90-8M0089579 eng MARCH 2014 Pge 17
Section 2 - Getting to Know Your Power Pckge Switches - Key switch - Bilge lower switch (if equipped) 24735 Reference Switch Function Key switch Hs four positions. 1. "OFF." In the "OFF" position, ll electricl circuits re off nd the engine cnnot e strted. The engine is stopped when the key switch is turned to the "OFF" position. 2. "ACC." In the "ACC" position, ny ccessory connections to the electricl circuits cn e operted. The engine will not operte with the key switch in the "ACC" position. 3. "ON." In the "ON" position, ll electricl circuits nd instruments re opertionl. 4. "START." In the "START" position the engine cn e strted. NOTE: The key cn only e removed with the key switch in the "OFF" position. Bilge lower switch (if equipped) Opertes the ilge lower, if equipped 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. 35308 Pge 18 90-8M0089579 eng MARCH 2014
Section 2 - Getting to Know Your Power Pckge 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 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 53910 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. 90-8M0089579 eng MARCH 2014 Pge 19
Section 2 - Getting to Know Your Power Pckge 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. Remote Controls Your ot my e equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description or demonstrtion of your remote control. Pnel Mount Fetures e - Neutrl lock utton - Throttle only utton c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle c d 17355 Neutrl lock utton. Prevents ccidentl shift nd throttle enggement. The neutrl lock utton must e pushed in to move the control hndle out of neutrl. Throttle only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e pressed only when the remote control hndle is in the neutrl position, nd should only e 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. Opertion of the shift nd throttle is controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Pge 20 90-8M0089579 eng MARCH 2014
Section 2 - Getting to Know Your Power Pckge Console Mount Fetures - Control hndle - Throttle only utton Throttle only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e pressed only when the remote control hndle is in the neutrl position. Control hndles. Opertion of the shift nd throttle is controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger nd continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Engine Electricl System Overlod Protection If n electricl overlod occurs, fuse will open (low). Find nd correct the cuse of the electricl overlod efore replcing the fuse. NOTE: In n emergency, when the engine must e operted nd the cuse of the electricl overlod cnnot e locted nd corrected, turn off or disconnect ll the ccessories connected to the engine nd instrumenttion wiring. Replce the lown fuse. If the replcement fuse lso lows, then the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Do not circumvent the electricl overlod protection provided on fused circuits y instlling higher mperge fuse or shorting cross the fuse lock terminls. Contct your Mercury Diesel uthorized repir fcility. Fuses provide protection for the engine electricl system s indicted. The fuse pnel is locted eneth n ccess pnel in the front of the engine cover. 17356 2.0 engine cover with ccess pnel - Engine cover ccess pnel - Fuse pnel 26993 90-8M0089579 eng MARCH 2014 Pge 21
Section 2 - Getting to Know Your Power Pckge After finding nd correcting the cuse of the overlod, replce ny open (lown) fuses. c f e d 27000 2.0 fuse pnel Reference Fuse Protection Loction on fuse pnel (From Front of Engine) 20 mp Unswitched power to helm Lower left 10 mp Switched power to ECM Middle left c 10 mp Keyed power to ECM Upper left d 5 mp Power dignostic connector Upper right e 15 mp ECM switched power to SIM Middle right f 15 mp Switched power to ECM Lower right Vessel Integrtion Pnel (VIP) Overlod Protection A vessel integrtion pnel (VIP) is typiclly mounted in the engine comprtment. The VIP contins three circuit rekers tht help protect system wiring. c - Helm circuit reker (10 A) - Ger circuit reker (15 A) c - SIM/Vessel circuit reker (10 A) Engine Gurdin System 50465 The Engine Gurdin system monitors the criticl sensors on the engine for ny erly indictions of prolems. Engine Gurdin is functionl whenever your engine is operting, so you never hve to e concerned out whether or not you re protected. The system will respond to prolem y sounding the wrning horn for six seconds nd/or reducing engine power in order to provide engine protection. Pge 22 90-8M0089579 eng MARCH 2014
Section 2 - Getting to Know Your Power Pckge If Engine Gurdin hs een ctivted, reduce the engine speed. The prolem will need to e identified nd corrected. The system must e reset efore the engine will operte t higher speeds. Moving the throttle lever ck to the idle position will reset the Engine Gurdin system. If the Engine Gurdin system hs determined the reset hs not corrected the prolem, Engine Gurdin will remin ctivted, limiting the throttle. The prolem must e identified nd corrected efore Engine Gurdin will llow the engine to rech norml operting RPM. 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. Specifictions Lel A specifictions lel on the top of the engine cover provides quick reference informtion for the engine nd drive with color codes tht identify where to check specific types of fluids nd the elt routing. A QR code cn e scnned with smrtphone for more engine informtion. 53033 Dt Lel Loction The engine dt lel is locted on the front of the engine, s shown elow. - Seril numer nd prt numer lel, with r codes - Engine dt lel Engine Dt Lel A tmper resistnt engine dt lel is ffixed to the engine t the time of mnufcture. It contins importnt informtion. Note tht the engine dt lel will not ffect the fit, function, or performnce of the engine nd neither otuilders nor delers my remove the engine dt lel or the engine component it is ffixed to efore sle. If modifictions re necessry or the engine dt lel is dmged, contct Mercury Mrine out the vilility of replcement. 50480 90-8M0089579 eng MARCH 2014 Pge 23
Section 2 - Getting to Know Your Power Pckge 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. d c e Engine dt lel exmple - Engine weight - Engine power rting c - Mximum engine speed (RPM) d - Engine seril numer e - Arevited engine description 53340 Technodrive Trnsmissions The trnsmission identifiction plte indictes ger rtio, seril numer, nd model. 27943 Technodrive TM 345 identifiction plte 24657 Technodrive TM 485-A identifiction plte Pge 24 90-8M0089579 eng MARCH 2014
Tle of Contents Section 3 - On the Wter Section 3 - On the Wter Sfe Boting Recommendtions... 26 Cron Monoxide Exposure... 27 Be Alert To Cron Monoxide Poisoning... 27 Sty Cler of Exhust Ares... 27 Good Ventiltion... 27 Poor Ventiltion... 28 Importnt Opertion Informtion... 28 Lunching... 28 Duty Cycle Rting Requirements...28 High Output Rting... 28 Opertion Chrt... 29 Freezing Temperture nd Cold Wether Opertion... 29 Drin Plug nd Bilge Pump...30 Strting, Shifting, nd Stopping... 30 Before Strting the Engine...30 Importnt Informtion SmrtStrt... 30 Strting Cold Engine... 30 Engine Wrm Up... 31 Strting Wrm Engine...31 Shifting... 31 Engine Shut Down (Stopping)... 31 Protecting People in the Wter... 32 While Bot is in Opertion... 32 While the Bot is Sttionry... 32 High Speed nd High Performnce... 32 Pssenger Sfety In Pontoon Bots And Deck Bots... 32 Bots Hving An Open Front Deck... 32 Bots With Front Mounted, Rised Pedestl Fishing Sets... 33 Wve nd Wke Jumping... 33 Impct With Underwter Hzrds... 33 Conditions Affecting Opertion... 34 Weight Distriution (Pssengers nd Ger) Inside the Bot... 34 Bottom of Bot... 34 Elevtion nd Climte... 34 Propeller Selection...35 Getting Strted... 35 Initil Brek In Procedure... 35 Engine Brek In... 35 20 Hour Brek In Period... 35 After the 20 Hour Brek In Period... 35 End of First Seson Checkup... 36 3 90-8M0089579 eng MARCH 2014 Pge 25
Section 3 - 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 1 800 336 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 26 90-8M0089579 eng MARCH 2014
Be lert. Section 3 - 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 41127 Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the ot: 43367 90-8M0089579 eng MARCH 2014 Pge 27
Section 3 - 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: 21626 43368 - Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Importnt Opertion Informtion Lunching IMPORTANT: Instll the ilge drin plug efore lunching the ot. Duty Cycle Rting Requirements IMPORTANT: Dmge cused y incorrect ppliction or filure to operte the power pckge within the specified operting prmeters will not e covered y the Mercury Mrine Limited Wrrnty. Mercury Diesel engines must e used in pplictions tht meet the opertion specifictions indicted y Mercury Diesel product ppliction engineer. The power pckge must e equipped with ger rtio nd propeller tht llows the engine to operte t wide open throttle (WOT) t the engine's rted speed (RPM). Use of Mercury Diesel engines in pplictions tht do not meet specified opertionl prmeters is not pproved. High Output Rting A High output rting pplies to plesure (nonrevenue generting) pplictions tht operte 500 hours or less per yer, where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion must e t or elow cruise speed (RPM). Cruise speed is dependnt on the engine's mximum rted speed (RPM). Pge 28 90-8M0089579 eng MARCH 2014
Section 3 - On the Wter Opertion Chrt Strting Procedure After Strting While Underwy Stopping nd Shut Down Open the engine htch. Air out the ilge completely. Oserve ll instrumenttion to monitor the condition of the engine. If not norml, stop the engine. Frequently review ll instrumenttion to monitor engine condition. Shift the remote control lever to the neutrl position. Turn the ttery switch on, if equipped. Check for fuel, oil, wter, fluid, nd exhust leks, etc. Listen for the udio lrm. Run the engine t idle RPM for severl minutes to llow the turochrger nd engine to cool. Turn on nd run the engine comprtment ilge lower, if equipped, for five minutes. Check shift nd throttle control opertion. Turn the key switch to "OFF" position. Check for leks: fuel, oil, wter, fluid, etc. Check steering opertion. Turn the ttery switch off, if equipped. Open the fuel shut off vlve, if equipped. Close the fuel shut off vlve, if equipped. Open the secock, if equipped. Close the secock, if equipped. Prime the fuel injection system, if necessry. Flush the sewter cooling circuit, if operting in sltwter, rckish wter, or polluted wter. 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. 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. 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 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. 90-8M0089579 eng MARCH 2014 Pge 29
Section 3 - On the Wter 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 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 Mercury Mrine Limited 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 the engine: Provide wter to the sewter pickup pump. Ensure tht the engine crnkcse is filled to the correct level with the proper grde of oil for the previling temperture. Refer to Section 4 Specifictions. Ensure tht ll electricl connections re secure. Check ll pplicle items 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 nd opertion mnul. Importnt Informtion SmrtStrt IMPORTANT: This Mercury Diesel model is equipped with SmrtStrt. SmrtStrt performs ll pproprite strting opertions upon initil strt switch ctivtion. To egin the SmrtStrt sequence, turn the ignition key switch to the "START" position nd relese, or turn the ignition key switch to the run position nd press nd relese the strt/stop switch. Rther thn holding the strt utton or key switch in position until the engine strts, SmrtStrt controls the strting process utomticlly. When the strt switch is ctivted, the system signls the engine ECM to strt the engine. The strter will receive power until the engine strts, the strting process times out fter few seconds, or when the engine reches 400 RPM. Attempting to strt the engine with the engine running will turn the engine off. Strting Cold Engine! 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. NOTE: Check the fluid levels efore strting the engine. Refer to Section 5 Mintennce Schedule. 1. Turn on nd run the engine comprtment ilge lower (if equipped) for five minutes. Alterntely, open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the control hndle in neutrl. NOTE: If the engine hs not een run for period of time nd will not redily strt with the stndrd strting procedure, use the fuel primer locted on the fuel filter heder. Cycle the primer plunger up nd down four or five strokes efore ttempting to strt the engine. 3. Turn the ignition key to the "RUN" position. 4. Turn the ignition key switch to the "START" position then relese, or press the strt/stop utton nd relese. If the engine is cold, llow the engine to operte t idle for 6 10 minutes or until the engine reches norml operting temperture. IMPORTANT: Engine oil pressure should exceed 69 kp (10 psi) within seconds of strting the engine. Stop the engine if the engine oil pressure does not meet this specifiction. Locte nd correct the prolem. If you re unle to correct the prolem, see Mercury Diesel uthorized repir fcility. Pge 30 90-8M0089579 eng MARCH 2014
Section 3 - On the Wter 5. Verify tht ll instrumenttion is functioning properly nd indicting norml redings. Engine Wrm Up 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. 1. After strting, ensure tht ll instrumenttion is functioning properly. 2. Operte the engine t 1,000 to 1,200 RPM until the engine temperture is within the norml operting rnge. It is crucil 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. NOTE: Engine wrm up time during cold wether cn e reduced y operting the vessel t reduced engine speed. Begin norml vessel opertion when systems rech operting tempertures. 3. After the engine hs reched operting temperture:. The oil pressure should e within the rnge specified. Refer to Section 4 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 the trnsmission, oil filter, oil lines, oil line connectors, nd oil pn for leks. d. Check the coolnt hoses, het exchnger connections, ftercooler, wter pump, nd drin fittings for leks. 4. Locte nd correct ny prolems, or see your Mercury Diesel uthorized repir fcility if you re unle to determine the prolem. Strting Wrm Engine 1. Turn on nd run the engine comprtment ilge lower (if equipped) for 5 minutes. Or, open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the remote control hndle in neutrl. 3. Turn the key switch to "START" position nd relese the key when the engine strts. 4. Ensure tht ll the instrumenttion is functioning properly nd indictes norml redings. Shifting NOTICE Shifting into ger t engine speeds ove idle will dmge the trnsmission. Shift into ger only when the engine is operting t idle. NOTICE Filure to rotte the propeller shft when shifting gers or forcing the shift mechnism while the engine is not operting cn result in product dmge. If you must shift gers with the engine off, mnully rotte the propeller shft in the pproprite direction. To shift the unit, verify the remote control throttle lever is in neutrl. Move the remote control shift lever forwrd to shift into forwrd ger or ckwrd to shift into reverse. After shifting the trnsmission, dvnce the throttle to the desired setting. Engine Shut Down (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. The engine cn e stopped y ny one of the following four methods:. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop nd the control system will e dectivted.. Depress the strt/stop utton, if equipped. The engine will stop nd the control system will remin ctive. 90-8M0089579 eng MARCH 2014 Pge 31
Section 3 - On the Wter c. Momentrily move the ignition key switch to the "START" position, then relese immeditely. The control system will recognize tht the engine is running nd will stop the engine. The control system will remin ctive. Moving the ignition key switch to the "START" position gin will issue strt request to the control system nd the control system will strt the engine, if pproprite. d. Activte the lnyrd stop switch, if equipped. The engine will stop, ut the control system will remin ctive. The control system will not llow the engine to strt if the lnyrd stop switch is ctivted. 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. 21604 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. 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 considered high speed or high performnce ot, 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 Hi Performnce Bot Opertion ooklet from your Mercury Diesel uthorized repir fcility. Pssenger Sfety In Pontoon Bots And 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 An 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. mc79555-1! 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. Pge 32 90-8M0089579 eng MARCH 2014
Bots With Front Mounted, Rised Pedestl Fishing Sets Section 3 - On the Wter 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. mc79557-1 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. mc79680-1 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 17269 Reduce speed nd proceed with cution whenever you're driving ot in shllow wter res or in res where the wters re suspected of hving underwter ostcles tht could e struck y the underwter drive components, rudder, or the ot ottom. The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter oject is control the ot speed. Under these conditions, ot speed should e kept to minimum plning speed of 24 to 40 km/h (15 to 25 MPH). Striking floting or underwter oject my result in n infinite numer of situtions. Some of these situtions could result in the following: 90-8M0089579 eng MARCH 2014 Pge 33
Section 3 - On the Wter The ot could move suddenly in new direction. Such 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 throw occupnts forwrd, even out of the ot. Impct dmge to the underwter drive components, rudder, or ot. Keep in mind, 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, tke the power pckge to n uthorized deler for thorough inspection nd necessry repir. The ot should lso e checked for ny hull frctures, trnsom frctures, nd wter leks. Operting with dmged underwter drive components, rudder, or ot ottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the ot. If continued running is necessry, do so t gretly reduced speeds.! WARNING 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 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 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. Elevtion nd Climte NOTE: Engines equipped with n Engine Control Module (ECM) reduce the effects of chnges in elevtion nd climte y utomticlly djusting fuel flow for wether conditions nd elevtion. ECM controlled engines, however, do not compenste for incresed loding or hull conditions. 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 optimum engine performnce under chnging wether conditions nd high elevtion, use propeller tht llows the engine to operte t rted RPM t wide open throttle (WOT) with mximum ot lod during your norml oting. In most cses, the rted RPM t WOT cn e chieved y chnging to lower pitch propeller. Pge 34 90-8M0089579 eng MARCH 2014
Section 3 - 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. The ot mnufcturer nd the selling deler re responsile for equipping the power pckge with the correct propellers. IMPORTANT: The engines covered in this mnul re equipped with n ECM tht limits engine RPM. 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 mximum lod. If full throttle opertion is elow the engine rted 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. Getting Strted Initil Brek In Procedure It is importnt to follow this procedure to properly rek in the engine. IMPORTANT: Mercury Mrine recommends 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 one minute to llow the strter motor to cool; then, repet the strting procedure. 1. Refer to the pproprite Strting, Shifting, nd Stopping section nd strt the engine. 2. Operte the engine t fst idle until it hs reched norml operting temperture. 3. Operte the engine in ger for three minutes t ech of the following: 1200 RPM, 2400 RPM, nd 3000 RPM. 4. Operte the engine in ger for three minutes t ech of the following: 1500 RPM, 2800 RPM, nd 3400 RPM. 5. Operte the engine in ger for three minutes t ech of the following: 1800 RPM, 3000 RPM, nd mximum rted full throttle RPM. Engine Brek In 20-Hour Brek-In Period IMPORTANT: The first 20 hours of opertion re considered to e the engine rek in period. Correct rek in is essentil to otin minimum oil consumption nd mximum engine performnce. During this rek in period, oserve the following rules: 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 one constnt speed for extended periods. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occsionl opertion t full throttle is permissile (five minutes t time mximum). Avoid full throttle ccelertion from idle speed. Do not operte t full throttle until the engine reches norml operting temperture. Check the engine oil level frequently. Add oil s needed. High oil consumption is norml during the rek in period. After the 20-Hour Brek-In Period To help extend the life of your power pckge, Mercury Mrine recommends the following: Chnge the engine oil nd filter nd the trnsmission fluid t the intervl indicted in the Mintennce Schedule. Refer to Specifictions nd Mintennce. Use propeller tht llows the engine to operte t the rted engine RPM when t full throttle with fully loded ot. Refer to Specifictions nd Mintennce. 90-8M0089579 eng MARCH 2014 Pge 35
Section 3 - On the Wter Opertion t 3/4 throttle setting or lower is recommended. Refrin from prolonged opertion t wide open throttle RPM. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized repir fcility to discuss or perform scheduled mintennce items. If you re in n re where the product is operted continuously, yer round, you should contct your deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. Pge 36 90-8M0089579 eng MARCH 2014
Tle of Contents Section 4 - Specifictions Section 4 - Specifictions Fuel Requirements... 38 Nonferrous Metls nd the Fuel System... 38 Diesel Fuel in Cold Wether... 38 Antifreeze/Coolnt... 38 Engine Oil... 39 Engine Specifictions... 39 Fluid Specifictions... 40 Engine...40 Trnsmission... 40 Approved Pints... 40 4 90-8M0089579 eng MARCH 2014 Pge 37
Section 4 - 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 nti gel diesel fuel dditive, following tht product's directions. Antifreeze/Coolnt NOTICE Avoid dmge to the cooling system nd engine from propylene glycol ntifreeze. Fill the closed cooling system only with n ethylene glycol orgnic cid technology ntifreeze solution suitle for the lowest temperture to which the engine will e exposed. Diesel engines re high compression engines tht operte t higher tempertures thn typicl internl 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 formul of ethylene glycol orgnic cid technology ntifreeze tht does not contin silicte nd 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. 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. Pge 38 90-8M0089579 eng MARCH 2014
Section 4 - Specifictions 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 not contin silicte ethylene glycol. The use of other types of engine coolnt tht is not pproved, 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. Tue Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/Coolnt Closed-cooling system 92-877770K1 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. To optimize the performnce of this engine in mrine pplictions, Mercury strongly recommends the use of Quicksilver 5W 30 Full Synthetic TDI Engine Oil. This oil meets interntionl ACEA C3 specifictions. Engine Oil 2.0L System Cpcity Fluid Type Prt Numer Engine oil (with filter) 5.2 L (5.5 US qt) 5W 30 Full Synthetic TDI Engine Oil 92 8M0069603 Engine Specifictions Description Engine type Induction type Displcement Specifictions In line 4 cylinder diesel Turochrged nd ftercooled 16 vlve 2.0L (122 cid) Firing order 1 3 4 2 Bore Stroke Rted engine RPM (refer to Section 3 Conditions Affecting Opertion Propeller Selection for dditionl informtion) Idle RPM in neutrl (engine t norml operting temperture) Oil pressure t idle Oil pressure t 4000 RPM 83 mm (3.27 in.) 92 mm (3.62 in.) 4000 RPM 700 RPM 2.4 r (240 kp [35 psi]) 6.6 r (660 kp [95 psi]) Thermostts (wter) 83 C (181 F) Thermostts (oil) 95 C (203 F) Coolnt temperture 80 85 C (176 185 F) Electricl system Alterntor rting 12 volt negtive ( ) ground 14 V, 110 A 90-8M0089579 eng MARCH 2014 Pge 39
Section 4 - Specifictions Description Recommended ttery rting* Specifictions 750 CCA, 950 MCA, or 180 Ah *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. Fluid Specifictions IMPORTANT: All cpcities re pproximte fluid mesures. Engine IMPORTANT: Fluid level indictors re clirted to provide ccurte redings with the engine level nd instlled ccording to the mnufcturer's instructions. Modifictions my ffect fluid level redings. Alwys use the proper fluid level indictor to determine the exct quntity of oil or fluid required. Engines with Closed Cooling System Oil Cooler 2.0L System Cpcity Fluid Type Prt Numer Engine oil (with filter) 5.2 L (5.5 US qt) 5W 30 Full Synthetic TDI Engine Oil 92 8M0069603 Closed cooling system 7.7 L (8.1 US qt) Extended Life Coolnt/Antifreeze concentrted 92 8M0070979 Trnsmission NOTE: Cpcities re for the trnsmission only nd do not include the fluid cooler or fluid cooler hose cpcities. Model Cpcity Fluid type Prt Numer Technodrive TM 345 1.6 L (1.7 US qt) Clss CD SAE 20 or Clss CD SAE 30 engine oil Otin loclly Technodrive TM 485 A 2.6 L (2.75 US qt) SAE 20W 40 or SAE 15W 40 engine oil Otin loclly Approved Pints Description Prt Numer Mrine Cloud White 8M0071082 Mercury Light Gry Primer 92 80287852 Mercury Phntom Blck 92 802878Q1 Pge 40 90-8M0089579 eng MARCH 2014
Tle of Contents Section 5 - Mintennce Section 5 - Mintennce Owner nd Opertor Responsiilities... 42 Deler Responsiilities... 42 Mintennce... 42 Do It Yourself Mintennce Suggestions... 42 Generl Inspection... 42 Engine Cover... 43 Removl...43 Clening...43 Inspection... 43 Instlltion...43 Mintennce Schedule... 43 Routine Mintennce... 43 Scheduled Mintennce... 45 Engine Oil... 45 Specifictions...45 Oil Level Overfilled... 45 Checking... 46 Filling... 46 Chnging Oil nd Filter... 47 TM 345 Technodrive Trnsmission Fluid... 49 Checking... 49 Filling... 50 Chnging... 50 TM 485 A Technodrive Trnsmission Fluid... 51 Check Fluid... 51 Add Fluid...52 Chnge Fluid... 53 Engine Coolnt... 55 Checking nd Filling the Closed Cooling System... 55 Drining the Closed Cooling System... 56 Air Filter... 57 Removl...57 Inspection... 58 Instlltion...58 Wter Seprting Fuel Filter... 59 Drining... 59 Replcing... 60 Filling... 62 Fuel System... 63 Priming...63 Filling (Bleeding)... 63 Fuel Tnk Clening nd Flushing... 64 Sewter System... 64 Drining the Sewter System... 64 Checking the Sewter Pickups... 65 Clening the Sewter Striner... 66 Engine Sewter Pump Inspection...67 Corrosion Protection... 67 Generl Informtion... 67 Engine Corrosion Protection Components... 68 Removl... 68 Clening nd Inspection... 68 Instlltion... 69 Antifouling Pint... 69 Luriction... 69 Throttle Cle... 69 Shift Cle... 70 Drive Belts... 70 Serpentine Belt Inspection... 70 Bttery... 71 Bttery Precutions for Multiple Engines... 71 5 90-8M0089579 eng MARCH 2014 Pge 41
Section 5 - 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, s such, re not considered defects in workmnship or mteril within 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 It is the deler's responsiility to provide predelivery inspection nd preprtion: Before delivery, mking certin tht the Mercury power pckge is in proper operting condition. Mking ll necessry djustments for mximum efficiency. Explining nd demonstrting the opertion of the power pckge nd the ot. Providing copy of the Predelivery Inspection Checklist. Completing the wrrnty registrtion nd immeditely sumitting it to Mercury Mrine vi MercNET, e mil, or mil. All power pckges must e registered for wrrnty purposes. Mintennce! 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 listings cn e done y the owner or opertor, while others should e performed y Mercury Diesel uthorized repir fcility. Before ttempting mintennce or repir procedures not covered in this mnul, we recommended tht you purchse the pproprite Mercury or Mercury MerCruiser Service Mnul nd red thoroughly. NOTE: Mintennce points re color coded for ese of identifiction. Refer to the decl on the engine for identifiction. Blue Coolnt Yellow Engine oil Ornge Trnsmission fluid Blck Ger lue oil Do It Yourself Mintennce Suggestions Mercury power pckges re highly technicl, complex pieces of mchinery. Only qulified personnel using the proper tools should ttempt mjor repir. Your sfety is our concern. Alwys red nd understnd the Cutions, Wrnings, Importnt Notices, nd Notes. Do not ttempt repirs unless specificlly trined in tht procedure. Reference the correct service mnul for the product. Do not ttempt repirs unless qulified. Specil tools nd equipment re required to perform certin repirs. Filure to use the correct specil tools nd equipment cn result in severe dmge to the product. Alwys hve Mercury Diesel uthorized repir fcility service your power pckge nd do periodic mintennce inspections to help provide sfe nd troule free oting. Generl Inspection Inspect your power pckge often nd t regulr intervls to help mintin its top operting performnce nd to correct 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 or corrosion. Pge 42 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 3. Remove nd inspect the propeller. If 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. NOTE: A smll pnel in the engine cover llows ccess to the engine fuse pnel, the engine oil fill cp, nd the engine oil dipstick without removing the entire engine cover. Engine Cover Removl 1. Remove the engine fuse pnel cover. 2. Lift stright up nd detch the engine cover from the ll stud mounts. 53354 3. Instll the fuse pnel cover to prevent loss. Clening 1. Clen the engine cover with wrm sopy wter. 2. Air dry the cover. Inspection 1. Inspect the engine cover for crcks or deteriortion. 2. Inspect the ruer grommets for deteriortion. 3. Inspect the hrdwre used with ech grommet. 4. Replce dmged prts. Instlltion 1. Remove the fuse pnel cover. 2. Set the engine cover over the ll stud mounts. 3. Press the engine cover down ove ech mount to rettch the engine cover. 4. Replce the fuse pnel cover. Mintennce Schedule Routine Mintennce NOTE: Perform only the mintennce tsks tht pply to your prticulr power pckge. 90-8M0089579 eng MARCH 2014 Pge 43
Section 5 - Mintennce Ech dy strt Ech dy end Weekly Every Two Months Check the engine oil level. (This intervl cn e extended sed on opertor experience with the product.) Check the engine coolnt level. Check the trnsmission oil level. If operting in sltwter, rckish wter, or polluted wter, flush the sewter section of the cooling system fter ech use. Drin ny wter from the primry fuel filter fter ech use. (Drin ny wter from oth fuel filters if operting in freezing tempertures.) Drin ny wter from the fuel filters. Check the sewter inlets for deris or mrine growth. Check nd clen the sewter striner. Check the ttery connections nd fluid level. Tret the engine surfces with Corrosion Gurd if operting in sltwter, rckish wter, or polluted wters. Inspect the ir filter. (Inspect every two months or every 50 hours, whichever occurs first.) Inspect the engine nodes nd replce if eroded y 50% or more. Ensure tht the guges nd ll wiring connections re secure. Clen the guges. (If operting in sltwter reduce the intervl to every 25 hours or 30 dys, whichever occurs first.) Pge 44 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce Scheduled Mintennce After first 50 hours Clen the trnsmission oil filter nd chnge the trnsmission oil. Annully Every 100 hours or nnully (whichever occurs first) Every 200 hours or nnully (whichever occurs first) Touch up the power pckge with pint nd spry with Corrosion Gurd. Clen the trnsmission oil filter nd chnge the trnsmission oil. Check the steering system nd the remote control for loose, missing, or dmged prts. Luricte the cles nd linkges. Check the engine lignment. Torque the engine mounts. Check the electricl system for loose, dmged, or corroded terminls. Inspect the cooling system nd the exhust system for dmge or leks. Check oth systems hose clmps for tightness. Clen the trnsmission oil filter nd chnge the trnsmission oil. Chnge the engine oil nd filter. Replce the fuel filters. Replce the ir filter. Inspect the condition nd tension of the engine ccessory drive elts. Disssemle nd inspect the engine sewter pump nd replce worn components. Check the sewter pump drive elt. Clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Check the nodes nd replce if eroded y 50% or more. Clen the sewter striner. Check the closed cooling fluid level nd level of protection. Check the run history for fults. Check the engine timing elt. Every 2 yers Replce the engine coolnt. Every 1000 hours or 5 yers (whichever occurs first) Replce the engine timing elt. Clen the fuel tnk. Clen the ftercooler core. According to OEM Schedule Check the engine to propeller shft lignment. Engine Oil Specifictions To optimize the performnce of this engine in mrine pplictions, Mercury strongly recommends the use of Quicksilver 5W 30 Full Synthetic TDI Engine Oil. This oil meets interntionl ACEA C3 specifictions. Engine Oil 2.0L System Cpcity Fluid Type Prt Numer Engine oil (with filter) 5.2 L (5.5 US qt) 5W 30 Full Synthetic TDI Engine Oil 92 8M0069603 Oil Level Overfilled 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. An overfilled engine crnkcse or lock cn cuse fluctution or drop in oil pressure. The overfull condition results in the engine crnkshft splshing nd gitting the oil, cusing it to ecome erted. The erted oil cuses loss of engine performnce nd n increse in crnkcse ck pressure. An extreme overfill condition could result in lrge mounts of oil eing drwn into the intke. 90-8M0089579 eng MARCH 2014 Pge 45
Section 5 - Mintennce Checking engine oil level must e done crefully. The oil level must e mintined etween the minimum nd the mximum oil level mrk on the dipstick. To ensure tht you re not getting flse reding, oserve the following efore checking the oil level. If the ot is in the wter, ensure tht the ot is t rest. If the ot is on triler, rise or lower the ow until the ot is sitting s it does t rest in the wter. Allow five minutes for the oil to drin into the oil pn if the engine hs just een operted or oil hs just een dded. Checking IMPORTANT: Engine crnkcse oil must e checked t intervls specified in Mintennce Schedules. It is norml for n engine to use certin mount of oil in the process of luricting nd cooling the engine. The mount of oil consumed depends gretly upon engine speed, with consumption eing highest t wide open throttle nd decresing sustntilly s engine speed is reduced. 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. 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 clen nd instll into the dipstick tue. c 2.0L engine oil service - Engine cover with ccess pnel removed - Engine oil fill cp c - Engine oil dipstick 27986 3. Remove the dipstick nd oserve the oil level. The oil level must e etween the mrks on the dipstick. If necessry, dd oil. Refer to Filling. Engine oil level mrkings - Dipstick - Minimum operting level c - Full mrk nd mximum operting level c 4. Instll engine oil dipstick. Filling IMPORTANT: Do not overfill the engine with oil. 14624 Pge 46 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 1. Remove the oil fill cp. c 2.0L engine oil service - Engine cover with ccess pnel removed - Engine oil fill cp c - Engine oil dipstick 2. Add the specified oil to ring the oil level up to, ut not over, the mximum mrk on the dipstick. Engine Oil 2.0L System Cpcity Fluid Type Prt Numer Engine oil (with filter) 5.2 L (5.5 US qt) 5W 30 Full Synthetic TDI Engine Oil 92 8M0069603 IMPORTANT: When filling the engine with oil, lwys use the dipstick to confirm the oil level. 3. Instll the oil fill cp. Chnging Oil nd Filter Refer to the Mintennce Schedule for the chnge intervl. 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 recommended engine oil. Engine Oil 2.0L System Cpcity Fluid Type Prt Numer Engine oil (with filter) 5.2 L (5.5 US qt) 5W 30 Full Synthetic TDI Engine Oil 92 8M0069603 1. Strt the engine nd llow it to wrm up to norml operting temperture. 2. Stop the engine nd llow the oil to drin into the oil pn for pproximtely five minutes. 3. Plce suitle continer under the oil filter housing to cpture ny spilled oil. Use n pproprite socket to loosen the oil filter cover. 4. Remove the drin plug on the oil filter housing nd llow to drin into suitle continer. 5. Remove the oil filter cover nd oil filter. 6. Discrd the oil filter nd O ring. 27986 c d - Drin plug - Oil filter cover c - O ring d - Oil filter 53087 7. Apply selnt to the threds of the oil filter housing drin plug nd instll. 90-8M0089579 eng MARCH 2014 Pge 47
Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. 9 Loctite 567 PST Pipe Selnt Drin plug threds 92-809822 8. Tighten the oil filter housing drin plug to the specified torque. Engine Coolnt Oil Cooler Description Nm l in. l ft Drin plug 19 168 9. Instll new O ring onto the oil filter cover nd luricte with engine oil. 10. Push the filter element into the cover until it is locked. Listen for click. 11. Instll the oil filter housing cover onto the oil filter housing nd tighten to the specified torque. IMPORTANT: Overtightening the cover my cuse n oil lek. Engine Coolnt Oil Cooler Description Nm l in. l ft Engine oil filter housing cover 25 18 12. Remove the dipstick. - Oil fill cp - Dipstick 13. Locte the crnkcse oil drin hose nd remove the cp. 53363 53365 14. Instll the crnkcse oil pump (order seprtely) onto the crnkcse oil drin hose. Pge 48 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce Crnkcse Oil Pump 91 802889Q 1 Aids in the removl of engine oil without drining the crnkcse. 11591 15. Pump the oil out of the crnkcse into n pproprite continer. 16. Remove the crnkcse oil pump nd instll the cp onto the crnkcse oil drin hose nd tighten securely. 17. Instll the oil dipstick. 18. Remove the oil fill cp nd fill the engine with oil. Refer to Filling. IMPORTANT: When filling the engine with oil, lwys use the dipstick to determine how much oil is required. 19. Replce nd secure the oil fill cp. 20. Strt the engine nd check for leks. 21. Dispose of the wste oil, filter, nd O ring s directed y locl ordinnces. TM 345 Technodrive Trnsmission Fluid Checking 1. Remove the dipstick. 2. Perform preliminry check the oil level s indicted on the dipstick with the dipstick fully inserted into the dipstick receptcle. NOTE: The oil level my e somewht over the mximum mrk, s some of the oil from the trnsmission oil cooler nd hoses my hve drined ck into the trnsmission. 3. If the oil level is elow the minimum mrk on the dipstick, dd trnsmission oil. See Filling. c - Minimum oil level - Mximum oil level c - Dipstick MIN MAX 4. Clen nd instll the dipstick. IMPORTANT: To ensure n ccurte indiction of the oil level, operte the engine t 1500 RPM for two minutes immeditely efore checking the oil level. 5. Strt the engine nd operte t 1500 RPM for two minutes to rech operting temperture nd fill ll of the trnsmission's hydrulic circuits. 6. Stop the engine nd quickly check the oil level with the dipstick. 7. If the oil level is low, dd trnsmission oil to ring the level up to the mximum mrk on the dipstick. See Filling. NOTE: If the trnsmission oil level ws extremely low, see your locl Mercury Diesel uthorized repir fcility. 8. Clen nd instll the dipstick. 27922 90-8M0089579 eng MARCH 2014 Pge 49
Section 5 - Mintennce Filling 1. If necessry, dd the specified trnsmission oil through the dipstick receptcle to ring the level up to the mximum mrk on the dipstick. c - Minimum oil level - Mximum oil level c - Dipstick MIN MAX NOTE: Alwys use the dipstick to determine the quntity of oil required. Model Cpcity Fluid type Prt Numer Technodrive 345 A 2. Clen nd instll the dipstick. 3. Check the oil level. Refer to Checking. Chnging 1. Remove the dipstick. 1.6 L (1.7 US qt) 27922 API Clss CD SAE 20 or API Clss CD SAE 30 engine oil 2. Remove the trnsmission oil drin plug nd drin the trnsmission into suitle continer. Otin Loclly Trnsmission drin plug 3. Contin nd dispose of the oil nd oil wste ccording to pplicle regultions. 4. Reinstll the trnsmission oil drin plug. 5. Tighten the drin plug to the specified torque. Description Nm l in. l ft Trnsmission oil drin plug 17 150 6. Clen the exterior of the trnsmission round the oil filter ssemly. 27977 Pge 50 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 7. Loosen the retining nut. 27978 8. Remove the filter element. 9. Clen the oil filter element using the clening solvent. Trnsmission oil filter retining nut Tue Ref No. Description Where Used Prt No. 10. Luricte the oil filter O rings. Clening solvent Trnsmission filter element Otin Loclly Tue Ref No. Description Where Used Prt No. 80 SAE engine oil 30W Trnsmission filter element O-ring Otin Loclly 11. Reinstll the filter element. NOTICE Improper instlltion of the trnsmission fluid filter ssemly my cuse the fluid to fom or lek out, resulting in decresed efficiency nd dmge to the trnsmission. Properly set the trnsmission fluid filter during instlltion. 12. Tighten the retining nut. 13. Fill the trnsmission to the proper level with the specified oil. See Filling. TM 485 A Technodrive Trnsmission Fluid Check Fluid 1. Remove the dipstick. IMPORTANT: When checking the fluid level, rest the dipstick on top of the threded housing hole. Do not screw the dipstick onto the threded housing hole. 2. Check the fluid level s indicted on the dipstick with the dipstick resting on the top of the threded hole. NOTE: The fluid level my e somewht over the mximum mrk, s some of the fluid from the trnsmission fluid cooler nd hoses my hve drined ck into the trnsmission. 90-8M0089579 eng MARCH 2014 Pge 51
Section 5 - Mintennce 3. If the fluid level is elow the minimum mrk on the dipstick, dd trnsmission fluid. See Add Fluid. - Dipstick - Mximum fluid level c - Minimum fluid level c IMPORTANT: To ccurtely check the fluid level, operte the engine t 1500 RPM for two minutes immeditely efore checking the level. 4. Strt the engine nd operte t 1500 RPM for two minutes to fill ll the hydrulic circuits. 5. Stop the engine nd quickly check the fluid level with the dipstick resting on the top of the threded hole. 6. If the fluid level is low, dd trnsmission fluid to ring the level up to the mximum mrk on the dipstick. See Add Fluid. NOTE: If the trnsmission fluid level ws extremely low, see your locl Mercury Diesel uthorized repir fcility. 7. Instll the dipstick. Add Fluid 24604 1. If necessry, dd specified trnsmission fluid through the dipstick threded hole to ring the level up to the mximum mrk on the dipstick. - Dipstick - Mximum fluid level c - Minimum fluid level c NOTE: Alwys use the dipstick to determine the quntity of oil or fluid required. Model Cpcity Fluid type Prt Numer Technodrive 485A 2. Instll the dipstick. 3. Check the fluid level. Refer to Check Fluid. 2.6 L (2.7 US qt) 24604 SAE 20W 40 or SAE 15W 40 engine oil Otin Loclly Pge 52 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce Chnge Fluid 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. 1. Remove the fill cp nd dipstick. 2. Remove the trnsmission fluid drin plug nd drin the trnsmission into suitle continer. - Fill cp nd dipstick - Drin plug 3. Dispose of the wste ccording to locl regultions. 4. Reinstll the trnsmission fluid drin plug. 5. Tighten the drin plug to the specified torque. 24623 Description Nm l in. l ft Trnsmission fluid drin plug 17 150 6. Clen the exterior of the trnsmission round the fluid filter ssemly. 7. Loosen the ssemly nut, nd rotte the securing t in the direction shown. - Assemly nut - Securing t 24608 90-8M0089579 eng MARCH 2014 Pge 53
Section 5 - Mintennce 8. Remove the filter element. - Filter element 24618 9. Clen the filter element with mild clening solvent, otined loclly. 10. Luricte the O rings with SAE Engine Oil 30W. Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Trnsmission filter element O-ring Otin Loclly 11. Reinstll the filter element. - Filter element - O ring 24620 NOTICE Improper instlltion of the trnsmission fluid filter ssemly my cuse the fluid to fom or lek out, resulting in decresed efficiency nd dmge to the trnsmission. Properly set the trnsmission fluid filter during instlltion. 12. Replce the securing t over the filter ssemly y turning it clockwise. Pge 54 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 13. Tighten the ssemly nut to the specified torque. - Assemly nut - Securing t Description Nm l in. l ft Assemly nut 5 8 48 72 14. Fill the trnsmission to the proper level with the specified fluid. See Add Fluid. 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. Checking nd Filling the Closed Cooling System 1. Allow the engine to cool. 2. Remove the pressure cp from the coolnt expnsion tnk. 3. The coolnt level in the coolnt expnsion tnk should e within 25 mm (1 in.) of the top of the fill neck. 24621 2.0L (engine cover removed) - Pressure cp - Coolnt expnsion tnk c - Coolnt fill neck c 25356 IMPORTANT: Use only the specified coolnt. The coolnt must e mixed with wter t the rtio specified in Section 4 Antifreeze/Coolnt. Tue Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/Coolnt Closed-cooling system 92-877770K1 4. If the coolnt level is low:. Inspect the coolnt recovery system for leks. 90-8M0089579 eng MARCH 2014 Pge 55
Section 5 - Mintennce. Inspect the gsket in the pressure cp for dmge nd replce if necessry. - Gsket 14142 c. The pressure cp mintins pressure on the cooling system nd my not e holding pressure properly. To hve the cp tested, contct your Mercury Diesel uthorized repir fcility. 5. Slowly dd the coolnt within 25 mm (1 in.) of the top of the expnsion tnk filler neck. 6. If the ot is out of the wter, oth the engine nd sterndrive must e supplied with cooling wter. Refer to Flushing the Sewter System section of this mnul. 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. 7. Do not instll the pressure cp. Strt nd operte the engine t fst idle speed etween 600 1400 RPM. Add coolnt s necessry to mintin the coolnt t the level specified previously. 8. Instll the pressure cp fter the engine hs reched norml operting temperture (with the thermostt fully open) nd the coolnt level remins constnt. IMPORTANT: When instlling the pressure cp, e sure to tighten it securely to void coolnt loss. 9. Test the engine opertion. Oserve the temperture guge nd check the engine for coolnt leks. If the temperture guge indictes the presence of excessive temperture or coolnt is leking, stop the engine immeditely nd inspect for the cuse. 10. After the first opertion, llow the engine to cool. 11. Remove the pressure cp nd dd coolnt to the specified level. 12. Instll nd securely tighten the pressure cp. Drining the Closed Cooling System IMPORTANT: Due to the complex nture of this service Mercury Diesel strongly recommends tht this service e performed y Mercury Diesel uthorized repir fcility. 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. NOTE: For instructions on drining the sewter section, refer to Drining the Sewter System in this section. IMPORTANT: Oserve the following points: Ensure tht the engine is s level s possile to promote complete drining of the cooling system. The closed cooling section must e filled yer round with the required coolnt. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with formul of ethylene glycol orgnic cid technology ntifreeze tht does not contin silicte nd deionized wter properly mixed to protect the engine to the lowest temperture to which it will e exposed. Do not use propylene glycol ntifreeze in the closed cooling section of the engine.! 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. Pge 56 90-8M0089579 eng MARCH 2014
1. Allow the engine to cool. 2. Remove the pressure cp from the expnsion tnk nd coolnt reservoir. 3. Remove the fuel filter for ccess to the engine coolnt drin plug. Refer to Wter Seprting Fuel Filter. Section 5 - Mintennce 4. If the engine hs the optionl fuel cooler instlled, move the fuel lines so they do not ostruct ccess to the engine coolnt drin plug. d e c f Port side of engine - Throttle cle rcket - 14 pin electricl connector c - Wter seprting fuel filter d - Fuel cooler with fuel lines moved to provide ccess (if equipped) e - Generl loction of engine coolnt drin plug f - Engine control module 25571 5. Remove the engine coolnt drin plug nd drin the coolnt into suitle continer. Allow the engine coolnt system to drin completely. Dispose of the coolnt ccording to locl lws. Port side of lock with wter-seprting fuel filter removed for ccess - Engine coolnt drin plug 6. Ensure tht the coolnt hs drined completely. 7. If required, clen the closed cooling system. See your locl Mercury Diesel uthorized repir fcility. 8. Instll nd tighten the engine coolnt drin plug. 9. Instll the wter seprting fuel filter. Refer to Wter Seprting Fuel Filter Replcing. 10. Fill the system with the specified coolnt. Refer to Checking nd Filling the Closed Cooling System. Air Filter Removl 1. Loosen the clmp nd remove the oil seprtor vent hose. 25768 90-8M0089579 eng MARCH 2014 Pge 57
Section 5 - Mintennce 2. Loosen the clmp nd remove the ir filter housing from the turochrger inlet. Air filter housing on engine - Oil seprtor vent hose clmp - Air filter element c - Air filter housing clmp c 3. Remove the ir filter element from the ir filter housing. 53217 - Air filter element - Air filter housing Inspection 1. The ir filter cnnot e clened. Replce the ir filter if it is dirty or contminted. 2. Replce the ir filter if the fom element is deteriorted or torn. 3. Replce the ir filter t the recommended intervl. See Mintennce Schedules for the replcement intervl under norml conditions. Instlltion IMPORTANT: The ir filter element is n integrl component nd must e clen nd dry for proper filtrtion nd engine performnce. Do not pply oil to the ir filter element. 53215 1. Slide the ir filter element onto the ir filter housing. Ensure tht the element covers ll of the holes on the ir filter housing. - Air filter element - Air filter housing 2. Instll the ir filter housing onto the turochrger inlet. 3. Tighten the ir filter housing clmp to the specified torque. Description Nm l in. l ft Air filter housing clmp 5.6 50 53215 Pge 58 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 4. Instll the oil seprtor vent hose. - Oil seprtor vent hose clmp - Air filter element c - Air filter housing clmp c 5. Tighten the oil seprtor vent hose clmp to the specified torque. 53217 Description Nm l in. l ft Oil seprtor vent hose clmp 5.6 50 Wter Seprting Fuel Filter! WARNING Fuel is flmmle nd explosive. Ensure tht the key switch is off nd the lnyrd is positioned so tht the engine cnnot strt. Do not smoke or llow sources of sprk or open flme in the re while servicing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys check for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. 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 in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. The engine mounted wter seprting fuel filter is equipped with wter in fuel (WIF) sensor tht should lert the opertor when wter is present in the filter. This fuel filter needs to e replced t specified intervls or whenever wter is detected in the fuel, whichever comes first. The opertor my e lerted tht the WIF sensor hs detected wter in the fuel, depending upon the ot instrumenttion pckge nd if equipped: A fult code my e displyed on system viewer. The udio wrning system my sound. See Fetures nd Controls. Drin or replce the remote mounted primry filter (such s Rcor filter) t specified intervls, or whenever wter is detected in the engine mounted fuel filter. Drining The engine mounted wter seprting fuel filter cn e drined of wter nd smll dirt prticles y opening the drin cp on the ottom of the filter. NOTE: To ensure complete drining in wrm wether, drin the filter efore strting dily opertions. In cold wether, where there is possiility tht the condensed wter will freeze, drin the filter shortly fter the end of dily opertions. NOTE: Plce suitle continer under the fuel filter to ctch contminted fuel or wter. Dispose of properly. 1. Plce continer under the drin cp on the filter. 90-8M0089579 eng MARCH 2014 Pge 59
Section 5 - Mintennce 2. Open the drin y turning the drin cp counterclockwise (s viewed from the ottom of the filter) until fuel strts drining. Do not remove the drin cp. Typicl wter-seprting fuel filter - WIF sensor wire connection - Filter c - Drin cp c 3. Drin until the fuel is cler in ppernce. 4. Close the drin cp y turning clockwise. Tighten securely. 5. Fill the fuel filter. See Filling. Replcing! 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 element cnnot e clened nd reused. It must e replced. 1. Disconnect oth ttery cles from the ttery. 2. Disconnect the WIF sensor wires, if equipped. 23318 3. Remove the wter seprting fuel filter nd seling ring from the mounting rcket. Do not use filter wrench. Typicl - Wter seprting fuel filter 23459 NOTE: It my e necessry to keep the existing drin cp nd use it on the new filter. Be sure to replce the O ring on the drin cp. Pge 60 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 4. Remove the drin cp nd O ring sel from the ottom of the existing fuel filter. Note the position of the O ring sel. Typicl - Drin cp - O ring sel 24566 5. Discrd the used filter nd O ring sel s defined y locl uthorities. 6. Instll the O ring nd drin cp on the new wter seprting fuel filter. Typicl - Drin cp - O ring sel 24568 7. Luricte the fuel filter sels with SAE engine oil 30W. Typicl - Wter seprting fuel filter - Sels 24569 Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Wter-seprting fuel filter seling ring Otin Loclly 90-8M0089579 eng MARCH 2014 Pge 61
Section 5 - Mintennce 8. Align the filter to the rcket. Twist the filter y hnd to secure the filter to the rcket. Do not use filter wrench. Typicl - Wter seprting fuel filter 9. Ensure tht the drin cp is securely tightened. 10. Connect the WIF sensor wires, if equipped. 11. Fill the wter seprting fuel filter with fuel. Refer to Filling. 12. Check the filter nd drin cp for fuel leks. 13. Connect the ttery cles. 14. Strt nd operte the engine. Check the filter connection for fuel leks. If leks exist, recheck the filter instlltion. If leks continue, stop the engine immeditely nd contct your Mercury Diesel uthorized repir fcility. Filling 23460 A type of hnd pump nd primer plunger is locted on the fuel filter rcket nd is used to Refill the fuel filter when drining or chnging the filter. Refill the fuel system on the engine if the system ws run dry. Prime the fuel system if the engine hs not een run for n extended period. IMPORTANT: Only fill the fuel filter with the hnd pump nd primer plunger to ensure tht unfiltered fuel does not get into the fuel system. NOTE: Follow this procedure fter instlling new filter or if the fuel hs een drined from the filter checking for wter. 1. Loosen the ir vent (leed) screw on the fuel filter rcket. Typicl - Air vent screw 23469 Pge 62 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 2. Move the primer plunger up nd down repetedly. The filter is full when n ir free strem of fuel flows from the ir vent screw. Typicl - Air vent screw - Primer plunger 3. Securely tighten the ir vent screw. 23468 Typicl - Air vent screw Fuel System Priming 23469 Prime the engine if it hs not een run for n extended period or if the engine will not strt. 1. Move the primer plunger up nd down repetedly. - Fuel priming pump 2. Attempt to strt the engine. Filling (Bleeding) 25985 NOTE: Follow this procedure if the fuel system ws run dry or if prt of the fuel system ws drined for service function. 1. See Wter Seprting Fuel Filter Filling nd fill the fuel filter. 2. Check the filter nd drin cp for fuel leks. Ensure tht the leed screw on the fuel filter rcket is closed. 90-8M0089579 eng MARCH 2014 Pge 63
Section 5 - Mintennce 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 Drining the Sewter System! CAUTION Wter cn enter the ilge when the drin system is open, dmging the engine or cusing the ot to sink. Remove the ot from the wter or close the secock, disconnect nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open. IMPORTANT: The engine must e s level s possile to ensure complete drining of the sewter system. Drin the sewter system efore flushing or prior to cold wether (freezing temperture), sesonl storge, or extended storge. IMPORTANT: The engine must not e operting during this procedure.! CAUTION Wter cn enter the ilge when the drin system is open, dmging the engine or cusing the ot to sink. Remove the ot from the wter or close the secock, disconnect nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open. 1. Remove the ot from the wter if possile. 2. If the ot is to remin in the wter, turn on the ilge pump, close the secock (if equipped), or disconnect nd plug the sewter inlet hose. 25667 Typicl secock instlltion 3. Mke the engine s level s possile to ensure complete drining of the sewter system. 4. Attch temporry drin hose to the red fitting of the sewter drin vlve. Coolnt oil cooler - Sewter drin vlve - Oil filter housing 53366 5. Open the sewter drin vlve. Pge 64 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 6. A smll dimeter wire ore rush or stiff piece of wire cn e used to cler the sewter drin vlve of ny deris. 7. Disconnect the sewter inlet hose from the connector on the sewter pump. d c - Sewter pump inlet - Sewter pump c - Sewter pump outlet d - Fuel cooler (if equipped) 25668 8. On models equipped with sewter striner, remove the hoses t the sewter striner nd drin them completely. Drin nd empty the sewter striner. Connect the hoses nd tighten the hose clmps securely. c Typicl - Sewter inlet - Sewter outlet c - Sewter striner cover 25831 9. After the sewter hs completely drined, remove the temporry drin hose nd close the het exchnger sewter drin vlve. 10. Connect ll sewter hoses. 11. Tighten ll hose clmps to the specified torque. Description Nm l in. l ft Hose clmp 5.6 50 Checking the Sewter Pickups Verify tht the wter inlet holes for the sewter pickup re clen nd not ostructed. 54902 Typicl through-the-hull sewter pickup 90-8M0089579 eng MARCH 2014 Pge 65
Section 5 - Mintennce Clening the Sewter Striner NOTE: Visully inspect the sewter striner through its cler cover. 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. NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the ilge resulting in engine dmge. Close the secock efore disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it. 1. If the ot is in the wter, ensure tht the engine is off nd close the secock, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the sewter striner cover y turning it counterclockwise y hnd. c - Sewter inlet - Sewter outlet c - Sewter striner cover 25831 3. Remove the striner from the striner housing nd clen out ny deris. Flush the striner with clen wter. 4. Clen out ny deris from the striner housing nd flush with clen wter. 5. Plce the striner ck into striner housing. Ensure tht it is fully nd evenly seted into the ottom of the striner housing. 6. Inspect the striner cover's O ring sel nd replce if dmged or leking. Pge 66 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce 7. Instll the striner cover y turning it clockwise y hnd. Ensure tht the striner cover O ring is properly locted nd modertely compressed when the cover is instlled. Do not overtighten. - Sewter inlet - Sewter outlet c - Sewter striner cover c 25832 8. If the ot is out of the wter. Perform n opertionl inspection of the sewter cooling system fter clening the sewter striner.. Cooling wter must e supplied to the engine sewter pump. Refer to Flushing the Sewter System regrding cooling wter supply when this service is performed with the ot out of the wter.. Strt the engine nd llow the sewter system to fill nd the engine to rech norml operting temperture. c. Run the engine t fst idle etween 600 nd 1400 RPM. Monitor engine temperture to confirm proper opertion of the cooling system. d. Inspect the sewter system for leks mintining fst idle engine speed etween 600 nd 1400 RPM. e. Tg the keys, record the service in the mintennce log, or otherwise mke note tht proper opertionl inspection of the sewter system must e performed efore returning the ot to service. 9. If the ot is in the wter, perform n opertionl inspection of the sewter cooling system.. Open the secock, if equipped, or remove the plug nd reconnect the sewter inlet hose.. Strt the engine nd llow the sewter system to e filled nd the engine to rech norml operting temperture. c. Check the sewter cooling system for leks within n RPM rnge of 600 to 1400 RPM. d. Crefully monitor the engine operting temperture to ensure tht it remins in norml opertionl rnge nd tht the sewter cooling system is functioning properly. Engine Sewter Pump Inspection IMPORTANT: Mercury strongly recommends tht this service e performed y Mercury Diesel uthorized repir fcility. Remove nd inspect the engine sewter pump t the intervl specified in the Mintennce Schedule. See your Mercury Diesel uthorized repir fcility. Corrosion Protection Generl Informtion Whenever two or more dissimilr metls (such s those found on this power pckge) re sumerged in conductive solution such s 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 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. 90-8M0089579 eng MARCH 2014 Pge 67
Section 5 - Mintennce IMPORTANT: Replce scrificil nodes if eroded 50% or more. Mercury strongly recommends voiding the use of nodes from other mnufcturers. Refer to your Mercury Diesel uthorized repir fcility for dditionl informtion. Engine Corrosion Protection Components The engine is equipped with scrificil node locted in the end cover of the engine ftercooler to ssist in protecting the engine nd the sewter cooling system from corrosion. Removl 1. Allow the engine to cool. NOTICE Filure to close the sewter inlet or secock when removing or replcing the node plugs cn led to wter dmge. Close the secock or remove nd plug the sewter inlet hose to prevent wter from entering the node plug holes. 2. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 3. Drin the sewter system. Refer to Drining the Sewter System. 4. Remove the node ssemly (node plug, seling wsher, nd the scrificil node) from the ftercooler end cover. Clening nd Inspection Sewter system node ssemly loction NOTE: Use sndpper, fier rush, or clening pd to remove the deposits from the surfce of the node efore trying to determine the mount of erosion. Do not use steel rush which might leve deposits tht could ccelerte corrosion. 1. Remove the deposits. 2. Inspect nd mesure the node. Compre the mesurements to the specifictions for new scrificil node nd replce the node ssemly when deteriorted 50%. NOTE: Scrificil nodes re ville only s n ssemly. Replce oth the plug nd node s unit. d e Anode ssemly - Anode plug - Scrificil node c - Length d - Dimeter e - Seling wsher 53216 c 19226 Scrificil node mesurements (new) Length 19 mm (3/4 in.) Pge 68 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce Scrificil node mesurements (new) Dimeter 16 mm (5/8 in.) 3. Discrd the seling wsher. Instlltion 1. Instll new seling wsher on the node ssemly (node plug with the scrificil node). - Anode ssemly - Seling wsher 2. Instll the node ssemly nd wsher into the ftercooler end cover. Tighten securely. 3. Unplug nd connect the sewter inlet hose, or open the secock if equipped. 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. 4. Ensure tht oth the sterndrive nd engine sewter pickup pumps re supplied sufficient cooling wter. 5. 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 Throttle Cle 19227 Luricte the pivot points nd guide contct surfces. - Pivot points - Guide contct surfces 23643 Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Throttle cle pivot points nd guide contct surfces Otin Loclly 90-8M0089579 eng MARCH 2014 Pge 69
Section 5 - Mintennce Shift Cle Luricte the pivot points nd guide contct surfces. Typicl inord model shift cle nd trnsmission linkge - Pivot points - Guide contct surfce 13347 Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Shift cle pivot points nd guide contct surfces Otin Loclly Drive Belts All drive elts must e periodiclly inspected for tension nd condition, such s excessive wer, crcks, frying, or glzed surfces.! WARNING Inspecting the elts with the engine running my cuse serious injury or deth. Turn off the engine nd remove the ignition key efore djusting tension or inspecting elts. 2.0L front cover removed - Serpentine elt - Power ssisted steering elt (sterndrive only) Serpentine Belt Inspection Should the serpentine elt need replcement, consult your Mercury Diesel uthorized repir fcility. 1. Inspect the serpentine elt for proper tension nd for the following: Excessive wer Crcks NOTE: Minor, trnsverse crcks (cross the elt width) my e cceptle. Longitudinl crcks (in the direction of elt length) tht join trnsverse crcks re not cceptle. Frying 25603 Pge 70 90-8M0089579 eng MARCH 2014
Section 5 - Mintennce Glzed surfces 21062 2. Check the opertion of the utomtic tensioner nd ssocited components.. Position suitle tool on the utomtic tensioner pulley olt.. Rotte the utomtic tensioner clockwise. c d e - Serpentine elt - Automtic tensioner c - Idler pulley d - Alterntor e - Idler pulley f - Sewter pump pulley f c. Relese the utomtic tensioner llowing it to return to lod position on the serpentine elt. d. The utomtic tensioner must return to the initil position nd hold tension on the serpentine elt. If the utomtic tensioner does not operte smoothly or does not return to loded position providing tension on the elt, it must e replced. See your Mercury Diesel uthorized deler for ll of your repir needs. 3. There is no djustment ville for the serpentine elt. If the elt ecomes loose or noisy, it hs worn out nd must e replced. See your Mercury Diesel uthorized repir fcility. 4. Should the serpentine elt need replcement consult your Mercury Diesel uthorized repir fcility. Bttery Refer to the specific instructions nd wrnings ccompnying your ttery. If this informtion is not ville, oserve the following precutions when hndling ttery.! WARNING Rechrging wek ttery in the ot, or using jumper cles nd ooster ttery to strt the engine, cn cuse serious injury or product dmge from fire or explosion. Remove the ttery from the ot nd rechrge in ventilted re wy from sprks or flmes.! WARNING An operting or chrging ttery produces gs tht cn ignite nd explode, sprying out sulfuric cid, which cn cuse severe urns. Ventilte the re round the ttery nd wer protective equipment when hndling or servicing tteries. Bttery Precutions for Multiple Engines 25415 Alterntors: Alterntors re designed to chrge single ttery tht supplies electricl power to the individul engine on which the lterntor is mounted. Connect only one ttery to one lterntor. Do not connect two tteries to the sme lterntor unless ttery isoltor is used. 90-8M0089579 eng MARCH 2014 Pge 71
Section 5 - Mintennce Engine Control Module (ECM) nd Vessel Integrtion Pnel (VIP). The ECM nd VIP require stle voltge source. During multiple engine opertion, n onord electricl device my cuse sudden drin of voltge t the engine's ttery. The voltge my drop elow the ECM or VIP minimum voltge requirements. The lterntor on the second engine my lso strt chrging, cusing voltge spike in the engine's electricl system. In either cse, the ECM could shut off. When the voltge returns to the rnge tht the ECM requires, the ECM will reset itself. The engine will now run normlly. This ECM shut down usully hppens so fst tht the engine just ppers to hve n ignition miss. Intermittent or temporry VIP shutdown cn cuse loss of instrumenttion, engine misfire nd cn dversely effect power pckge performnce nd ot sfety. Btteries. Bots with multi engine electronic control power pckges require ech engine e connected to its own ttery, ensuring tht the engine's ECM hs stle voltge source. Bttery Switches. Bttery switches should lwys e positioned so tht ech engine is operting off of its own ttery. Do not operte engines with switches in the oth or ll position. In n emergency, nother engine's ttery cn e used to strt n engine with ded ttery. Bttery Isoltors. Isoltors cn e used to chrge n uxiliry ttery used for powering ccessories in the ot. They should not e used to chrge the ttery of nother engine in the ot unless the type of isoltor is specificlly designed for this purpose. Genertors. The genertor's ttery should e considered nother engine's ttery. Pge 72 90-8M0089579 eng MARCH 2014
Tle of Contents Section 6 - Storge Section 6 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge... 74 Cold Wether (Freezing Temperture) Storge... 74 Prepring Your Power Pckge for Sesonl or Extended Storge... 74 Sesonl Storge... 75 Extended Storge Instructions...76 Bttery... 76 Recommissioning... 76 6 90-8M0089579 eng MARCH 2014 Pge 73
Section 6 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge IMPORTANT: Mercury Mrine strongly recommends tht this service e performed y Mercury Diesel uthorized repir fcility. Dmge cused y freezing is not covered y the Mercury Mrine Limited Wrrnty. 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 reconnect the wter inlet hose efore strting the engine. A ot is considered to e in storge whenever it is not in opertion. The mount of time tht the power pckge is not operted my e for rief period, such s during dy, overnight, for seson, or for n extended period of time. Certin precutions nd procedures must e oserved to protect the power pckge from freeze dmge, corrosion dmge, or oth types of dmge during storge. Freeze dmge cn hppen when wter trpped in the sewter cooling system freezes. For exmple, fter operting the ot, exposure to freezing tempertures for even rief period of time could result in freeze dmge. Corrosion dmge is the result of sltwter, polluted wter, or wter with high minerl content trpped in the sewter cooling system. Sltwter should not sty in n engine's cooling system for even rief storge time; drin nd flush the sewter cooling system fter ech outing. Cold wether opertion refers to operting the ot whenever the possiility of freezing tempertures exists. Likewise, cold wether (freezing temperture) storge refers to whenever the ot is not eing operted nd the possiility of freezing tempertures exists. In such cses, the sewter section of the cooling system must e completely drined immeditely fter opertion. Sesonl storge refers to when the ot is not eing operted for one month or more. The length of time vries depending on the geogrphic loction of the ot in storge. Sesonl storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd some dditionl steps tht must e tken when storge will lst longer thn the short time of cold wether (freezing temperture) storge. Extended storge mens storge for period of time tht my lst for severl sesons or longer. Extended storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd sesonl storge plus some dditionl steps. Refer to the specific procedures in this section relted to the conditions nd the length of storge for your ppliction. Cold Wether (Freezing Temperture) Storge 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 reconnect the wter inlet hose efore strting the engine. 1. Red ll precutions nd perform ll procedures found in Drining the Sewter System nd drin the sewter section of the cooling system. 2. Plce cution tg t the helm dvising the opertor to unplug nd connect the wter inlet hose or open the secock, if equipped, efore operting the ot. 3. For dditionl ssurnce ginst freezing nd corrosion fill the sewter cooling system with mixture of propylene glycol ntifreeze nd tp wter. See Sesonl Storge in this section. Prepring Your Power Pckge for Sesonl or Extended Storge 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: If the ot hs lredy een removed from the wter, supply wter to the wter inlet holes efore strting the engine. 1. Supply cooling wter to the wter inlet holes or sewter pump inlet. Pge 74 90-8M0089579 eng MARCH 2014
2. Strt the engine nd operte until it reches norml operting temperture. 3. Stop the engine. 4. Chnge the engine oil nd filter. 5. Strt the engine nd run for out 15 minutes. Check for oil leks. Sesonl Storge Section 6 - Storge 1. Red ll precutions nd perform ll procedures found in Prepring Your Power Pckge for Sesonl or Extended Storge. 2. Red ll precutions nd perform ll procedures found in Drining the Sewter System nd drin the sewter section of the cooling system. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Remove the ot from the wter to drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. IMPORTANT: We recommend the use of propylene glycol ntifreeze in the sewter section of the cooling system for cold wether (freezing temperture), sesonl storge, or extended storge. Mke sure tht the propylene glycol ntifreeze contins rust inhiitor nd is recommended for use in mrine engines. Be certin to follow the propylene glycol mnufcturer's recommendtions. 3. Fill continer with pproximtely 5.6 L (6.0 US qt) of propylene glycol ntifreeze nd tp wter mixed to mnufcturer's recommendtion to protect the engine to the lowest temperture to which it will e exposed during cold wether or extended storge. 4. Disconnect the sewter inlet hose from the sewter pump. Using n dpter, if required, temporrily connect n pproprite length piece of hose to sewter pump nd plce the other end of the hose into the continer of propylene glycol ntifreeze nd tp wter. Typicl - Sewter pump - Temporry hose c - Continer of propylene glycol ntifreeze nd tp wter IMPORTANT: Dischrge of propylene glycol into the environment my e restricted y lw. Dispose of propylene glycol in ccordnce with federl, stte, nd locl requirements. 5. Strt the engine nd operte t idle speed until the ntifreeze mixture hs een pumped into the engine sewter cooling system. 6. Stop the engine. 7. Remove the temporry hose from the sewter pump. 8. Clen the outside of the engine nd repint ny res required with primer nd spry pint. After the pint hs dried, cot the engine with the specified corrosion inhiiting oil or equivlent. Description Where Used Prt Numer Corrosion Gurd 92 802878 55 Light gry primer Outside of engine 92 802878 52 Mrine Cloud White pint c 8M0071082 Mercury Phntom Blck Shift plte nd ir filter housing 92 802878Q1 23452 90-8M0089579 eng MARCH 2014 Pge 75