2003, Mercury Marine 2.8 And 4.
0001. Identification Record The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Cummins MerCruiser Diesel power package. When contacting Cummins MerCruiser Diesel (CMD) about service, always specify model and serial numbers. 1 2 73929 1 71675 1 7 78445 75388 75298 Please record the following information: 1. Engine Model and Horsepower Engine Serial Number 2.
0002.1 and CE459 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product.
0004 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol ! , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
SECTION 1 - WARRANTY Warranty Information . . . . . . . . . . . . . . . . . . . . Owner Warranty Registration . . . . . . . . . . . . United States And Canada Only . . . . . . International Owner Registration . . . . . . . . . Outside The United States And Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Policies . . . . . . . . . . . . . . . . . . . . . . . Recreational Use Diesel Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What Is Covered . . . . . . . .
SECTION 3 - ON THE WATER Safe Boating Suggestions . . . . . . . . . . . . . . Be Alert To Carbon Monoxide Poisoning . Good Ventilation . . . . . . . . . . . . . . . . . . . Poor Ventilation . . . . . . . . . . . . . . . . . . . . Basic Boat Operation . . . . . . . . . . . . . . . . . . . Launching And Boat Operation Care . . . . Duty Cycle Rating . . . . . . . . . . . . . . . . . . . . Pleasure Duty Rating . . . . . . . . . . . . . . . Light Duty Rating . . . . . . . . . . . . . . . . . .
SECTION 5 - MAINTENANCE Owner/Operator Responsibilities . . . . . . . . 68 Dealer Responsibilities . . . . . . . . . . . . . . . . . 68 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Do-It-Yourself Maintenance Suggestions . 70 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Maintenance Schedules . . . . . . . . . . . . . . . 72 Routine Maintenance . . . . . . . . . . . . . . . . . . 72 Scheduled Maintenance . . . . . . . . . . . . . . . 73 Maintenance Record . . . .
SECTION 6 - STORAGE Cold Weather Or Extended Storage . . . . . 126 Preparing Your Power Package For Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Draining Instructions . . . . . . . . . . . . . . . . . 127 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Recommissioning . . . . . . . . . . . . . . . . . . . . . 134 SECTION 7 - TROUBLESHOOTING Diagnosing EDI Problems . . . . . . . . . . . . . . Troubleshooting Charts . . . . . . . . . . . . . . .
WARRANTY SECTION 1 SECTION 1 - WARRANTY 1 Table of Contents Warranty Information . . . . . . . . . . . . . . . . . . . . Owner Warranty Registration . . . . . . . . . . . . United States And Canada Only . . . . . . International Owner Registration . . . . . . . . . Outside The United States And Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Policies . . . . . . . . . . . . . . . . . . . . . . . Recreational Use Diesel Limited Warranty . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY SECTION 1 0005 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. • It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.
WARRANTY SECTION 1 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.
WARRANTY SECTION 1 0006 and CD854 Warranty Policies Recreational Use Diesel Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
WARRANTY SECTION 1 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
WARRANTY SECTION 1 000000 was CD687 Light Duty Commercial Use Diesel Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below DURATION / DESCRIPTION OF COVERAGE This Limited Warranty provides coverage from the date the product is first sold to a retail customer, or the date on which the product is first put into service, whichever occurs first.
WARRANTY SECTION 1 HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair.
WARRANTY SECTION 1 00000 was CD622 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents normal wear and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.
WARRANTY SECTION 1 • Use of other than Quicksilver replacement parts when making warranty repairs. • Oils, lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration. • Participating in or preparing for racing or other competitive activity. • Engine noise does not necessarily indicate a serious engine problem.
WARRANTY SECTION 1 0008 Transferable Warranty The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 SECTION 2 - GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls . . . . . . . . . . . . . Lanyard Stop Switch . . . . . . . . . . . . . . Instrumentation . . . . . . . . . . . . . . . . . . . Remote Controls . . . . . . . . . . . . . . . . . Panel Mounted . . . . . . . . . . . . . . . . Console Mounted . . . . . . . . . . . . . . Console Mounted . . . . . . . . . . . . . . Power Trim . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0010 Features And Controls 0011 Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator’s position (as in accidental ejection from the operator’s position).
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 00000 was 0012.2 Instrumentation INSTRUMENTS The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was part CD934 and CD860 SWITCHES b d a d a c 73547 79076 e d 71891 70522 Typical switches a - Key switch b - Engine stop switch - toggle, if equipped c - Engine stop switch - push button, if equipped d - Panel lights / audio test switch e - Bilge blower switch Key Switch - has three positions. 1. OFF - In the OFF position, all electrical circuits are off and engine cannot be started.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 00000 was CE479 and CD860 ENGINE MONITORING FEATURES n a a b c d e f b c d e 77359 f - Malfunction indicator lamp (D-Tronic engines) - Water-in-fuel warning lamp - Coolant temperature warning lamp - Oil pressure warning lamp - Charge indicator lamp - Preheat indicator lamp The appropriate light functions as follows: Malfunction Indicator Lamp (MIL), D2.8L D-Tronic, D4.2L D-Tronic and D4.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 0014 Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control. 0015.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0016.01 CONSOLE MOUNTED CAUTION Avoid possible boat and power package damage. Never shift unit into or out of gear unless throttle lever is at idle rpm. IMPORTANT: Boats equipped with dual power packages may have both shift levers on 1 control and both throttle levers on the other control. d b a c 70537 71339 a b c d - Shift lever - Throttle lever - Friction screw - Detent screw Shift Lever - shifts unit into gear with full lever movement.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 0017.02 CONSOLE MOUNTED c c d e d b b e a a 77971 a b c d e - Throttle only button - Control handle tension adjustment screw - Control handles - Power Trim switch - Trailer switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0169 Power Trim Power Trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system Trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching and low speed (below 1200 rpm engine speed), shallow water operation.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 Trimming sterndrive unit DOWN/IN can: • Help the boat accelerate and plane off quicker • Generally improve the ride in choppy water • In most cases, reduce boat speed • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 00000 was 0018.01 w / CMD change Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing the fuse or resetting the circuit breaker.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was 0172.01 4. The Power Trim System is protected from overload by a 110 amp fuse and a 20 amp in-line fuse on the power trim pump. a b 70526 a - 20 amp fuse b - 110 amp fuse 5. The Quicksilver Three-Button Power Trim Control Panel is further protected by a 20 amp in-line fuse. 70527 6. The Quicksilver MerCathode System has a 20 amp in-line fuse in the wire which connects to the positive (+) terminal on controller.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE 0020.03 w changes – CMD Audio Warning System Your Cummins MerCruiser Diesel power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
GETTING TO KNOW YOUR POWER PACKAGE SECTION 2 00000 was 0220.0 Emissions Information Exhaust Gas Emissions Certificate (Europe Only) A tamper-resistant label is affixed to the engine at time of manufacture by Cummins MerCruiser Diesel. In addition to the required exhaust gas emissions certificate number, the label lists the engine serial number, engine family, maximum rpm, engine power, and weight.
SECTION 2 GETTING TO KNOW YOUR POWER PACKAGE NOTES: Page 26 CMD-4081850 / 90-860094030 SEPTEMBER 2003
ON THE WATER SECTION 3 SECTION 3 - ON THE WATER Table of Contents Safe Boating Suggestions . . . . . . . . . . . . . . Be Alert To Carbon Monoxide Poisoning . Good Ventilation . . . . . . . . . . . . . . . . . . . Poor Ventilation . . . . . . . . . . . . . . . . . . . . Basic Boat Operation . . . . . . . . . . . . . . . . . . . Launching And Boat Operation Care . . . . Duty Cycle Rating . . . . . . . . . . . . . . . . . . . . Pleasure Duty Rating . . . . . . . . . . . . . . . Light Duty Rating . . . . . .
ON THE WATER SECTION 3 0022 w / CMD changes Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and also consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S.
ON THE WATER SECTION 3 • Watch for signs of weather change and avoid foul weather and rough-sea boating. • Tell someone where you are going and when you expect to return. • Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient. • Use personal flotation devices. Federal Law requires that there be a U. S.
ON THE WATER SECTION 3 • Know your boating area and avoid hazardous locations. • Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight and hearing.” The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when operating the boat above idle or planing transition speed. Watch out for others, the water and your wake.
ON THE WATER SECTION 3 0024 GOOD VENTILATION Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. Courtesy of ABYC 0025 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install 1 or more carbon monoxide detectors in your boat.
ON THE WATER SECTION 3 0026 Basic Boat Operation 0027.1 Launching And Boat Operation Care CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly. • Do not use the lanyard stop switch to shut off the engine above idle speed.
ON THE WATER SECTION 3 CD908 Duty Cycle Rating IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters, will not be covered by the Mercury MerCruiser Diesel Limited Warranty. It is the responsibility of the boat manufacturer and/or the installing dealer to ensure that the power package is properly applied.
ON THE WATER SECTION 3 LIGHT DUTY RATING It is the operator’s responsibility to operate within the following specified operational capability, or duty cycle, as applicable to the engine and installation: Description Rated Engine RPM Wide Open Throttle (WOT) Operation Continuous cruising rpm Annual operating time D4.2L LD 3600 Limited to less that 10% of total operating time. Limited to no greater than 90% of WOT rpm. Not to exceed 500 hours.
ON THE WATER SECTION 3 000000 was 0028.3 and CD694 – changed 4th row last column to be “Engage STOP switch and hold...” Operation Chart - D4.2L, D4.2L LD, and D4.2L 230 STARTING PROCEDURE Open engine hatch. Air out bilge completely. AFTER STARTING WHILE UNDERWAY Frequently observe all Observe all gauges and gauges and indicator warning lights to check lights to monitor engine condition of engine. If not condition. normal, stop engine. STOPPING & SHUT DOWN Shift remote control lever to neutral position.
ON THE WATER SECTION 3 00000 was 0029 and CD913 Starting, Shifting and Stopping - D4.2L, D4.2L LD and D4.2L 230 NOTE: Does not include engines equipped with D-Tronic fuel injection. WARNING Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
ON THE WATER SECTION 3 Mechanical Engine Stop Lever - located on the injection pump of all engines except D-Tronic Engines. It is used to manually shut off engine by cutting off the fuel supply. It can be engaged by moving the lever in the direction shown. 71386 D4.2L Models 76378 D4.2L LD and D4.
ON THE WATER SECTION 3 CD STARTING A COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. Refer to Maintenance Chart. 1. Turn on and run engine compartment bilge blower (if equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine(s). 2. On D4.2L only: set cold start lever if temperature is less than 10 degrees C (50 degrees F). Move lever in direction shown. Lever should be reset as soon as engine starts and idles smoothly. 71386 3.
ON THE WATER SECTION 3 CE ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. 1. After starting, ensure all instrumentation is functioning properly. NOTE: It is very important that any engine be warmed up before applying full load. 2. Operate engine for 1 or 2 minutes at fast IDLE (1000-1500 rpm) or until engine temperature reaches operating temperature before applying full load.
ON THE WATER SECTION 3 CE33 SHIFTING CAUTION Never attempt to shift unit unless engine is at idle rpm. Damage to drive unit could occur. 1. To shift unit, be sure remote control/throttle lever is in NEUTRAL. Move control/shift lever with a firm, quick motion forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting drive unit, advance throttle to desired setting. 2.
ON THE WATER SECTION 3 CD864 Operation Chart - D2.8L D-Tronic, D4.2L D-Tronic and D4.2L STARTING PROCEDURE AFTER STARTING WHILE UNDERWAY STOPPING & SHUT DOWN Open engine hatch. Air out bilge completely. Observe all gauges and warning lights to check condition of engine. If not normal, stop engine. Frequently observe all gauges and indicator lights to monitor engine condition. Shift remote control lever to neutral position. Turn battery switch ON, if so equipped.
ON THE WATER SECTION 3 CD863 with changes to Engine Oil one bullet point Starting, Shifting and Stopping - D2.8L D-Tronic, D4.2L D-Tronic and D4.2L 300 WARNING Do not use volatile starting aids, such as Ether, Propane, or Gasoline in the engine air intake system. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage.
ON THE WATER SECTION 3 CE w changes in all except list 1 and 2 STARTING A COLD ENGINE IMPORTANT: Always check fluid levels before starting the engine. Refer to Maintenance Chart. 1. Turn on and run engine compartment bilge blower (if so equipped) for five minutes. Or, open engine hatch to air out bilge before attempting to start engine(s). 2.
ON THE WATER SECTION 3 CE STARTING A WARM ENGINE 1. Turn on and run engine compartment bilge blower for five minutes (if so equipped). Or, open engine hatch to air out bilge before attempting to start engine(s). 2. Turn key switch to the RUN position. 3. Ensure charge indicator and oil pressure warning lamps are off. 4. Turn key switch to START position. Release the key and allow the switch to return to RUN position when the engine starts. 5.
ON THE WATER SECTION 3 0173 Starting Engine After Stopped While In Gear IMPORTANT: Avoid stopping the engine if the sterndrive unit is in gear. If the engine does stop, refer to the following procedure: 1. Push and pull repeatedly on the remote control handle until handle returns to the NEUTRAL/IDLE position. This may take several tries if the power package was operating above idle rpm when the engine stopped. 2. After the handle returns to the NEUTRAL/IDLE position, resume normal starting procedures.
ON THE WATER SECTION 3 0032 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. Whenever a boat is moving (coasting) in NEUTRAL/IDLE, there is sufficient force by the water on the propeller to cause the propeller to rotate.
ON THE WATER SECTION 3 0131 w/ changes to align text and graphics Passenger Safety Message - Pontoon And Deck Boats WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and coming in contact with the boat hull or propeller. Stay back from the front end of the deck and remain seated while the boat is in motion. Whenever the boat is in motion, observe the location of all the passengers.
ON THE WATER SECTION 3 0034 Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold. Operating recreational boats over waves and wakes is a natural part of boating.
ON THE WATER SECTION 3 0035.1 with CMD change Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom. IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed.
ON THE WATER SECTION 3 0132 Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.
ON THE WATER SECTION 3 0036 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): • Generally increases speed and engine rpm • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane • At extremes, can cause the boat to porpoise Shifting weight to front (bow): • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back an
ON THE WATER SECTION 3 0134 Ventilation Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speedup and a reduction in boat speed.
ON THE WATER SECTION 3 0040 and CE464 Propeller Selection CAUTION The installed propeller must allow the engine to run at the Rated Engine rpm at WOT to avoid engine damage. Using a propeller that causes the engine to operate below the Rated Engine rpm can cause piston and/or valve damage (even if the engine is not operated at WOT).
ON THE WATER SECTION 3 0042 Getting Started CD912 Initial Break-In Procedure It is especially important that the following procedure be used on new diesel engines. This break-in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems. IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed.
ON THE WATER SECTION 3 CD608 Sterndrive Unit 10-Hour Break-In Period It is especially important that the following procedure be used on new sterndrive units. This break-in procedure allows the proper seating of drive unit gears and related components, which greatly reduces the likelihood of problems. 1. Avoid full throttle starts. 2. Do not operate at any one constant speed for extended periods of time. 3. Do not exceed 75 percent of full throttle during the first 5 hours.
ON THE WATER SECTION 3 0043 w / changes – CMD and remove lasst bullet, see CE475 After Break-In Period To help extend the life of your Cummins MerCruiser Diesel power package, the following recommendations should be considered: • Use a propeller that allows the engine to operate at the Rated Engine rpm at WOT when at full throttle with a normal boat load. Refer to Specifications and Maintenance. • Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at WOT rpm.
SPECIFICATIONS SECTION 4 SECTION 4 - SPECIFICATIONS Table of Contents Fuel Requirements . . . . . . . . . . . . . . . . . . . . . Diesel Fuel In Cold Weather . . . . . . . . . . . . . Anti-Freeze/Coolant . . . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . D4.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 59 59 60 61 61 D4.2L LD And D4.2L 230 . . . . . . . . . . . . . .
SPECIFICATIONS SECTION 4 CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury.
SPECIFICATIONS SECTION 4 CE16 Diesel Fuel In Cold Weather Unaltered diesel fuels thicken and “gel” in cold temperatures, unless treated. Virtually all diesel fuels are “climatized” to allow their use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel, it is the owner/operator’s responsibility to add a commercial “standard brand” “anti-gel” diesel fuel additive, following that product’s directions.
SPECIFICATIONS SECTION 4 CD865 w changes in table Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do NOT spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. To help obtain optimum engine performance and to provide maximum protection, the engine requires engine oil with a rating of HD-SAE-API CG-4 and CH-4.
SPECIFICATIONS SECTION 4 00000 was CD731 Engine Specifications D4.2L Specification - Sterndrive Description D4.2L Crankshaft Horsepower (Kilowatts) 1 Propeller Shaft Horsepower (Kilowatts) 1 220 ( 164 ) 200 ( 149 ) Engine Type In-Line 6 Cylinder Diesel Displacement 254 cu. in. ( 4.2 L ) Firing Order 1-5-3-6-2-4 Bore 3.700 in. ( 94 mm ) Stroke 3.937 in. ( 100 mm ) Compression Ratio 21.
SPECIFICATIONS SECTION 4 00000 was CD936 D4.2L LD And D4.2L 230 Specification - Sterndrive Description Crankshaft Kilowatts (Horsepower) 1 Propeller Shaft Kilowatts (Horsepower) 1 D4.2L LD D4.2L 230 149 ( 200 ) 171 ( 230 ) 134 ( 180 ) 154 ( 207 ) Engine Type In-Line 6 Cylinder Diesel Displacement 4.2 L ( 254 cu. in. ) Firing Order 1-5-3-6-2-4 Bore 94 mm ( 3.700 in. ) Stroke 100 mm ( 3.937 in. ) Compression Ratio 16.
SPECIFICATIONS SECTION 4 00000 was CD866 D2.8L D-Tronic and D4.2L D-Tronic Specification - Sterndrive Description D2.8L D-Tronic D4.2L D-Tronic 165 ( 123 ) 250 ( 186 ) 150 ( 112 ) 225 ( 168 ) Engine Type In-Line 4 Cylinder Diesel In-Line 6 Cylinder Diesel Displacement 169 cu. in. ( 2.8 L ) 254 cu. in. ( 4.2 L ) Firing Order 1-3-4-2 1-5-3-6-2-4 Crankshaft Horsepower (Kilowatts) 1 Propeller Shaft Horsepower (Kilowatts) 1 Bore 3.700 in. ( 94 mm ) Stroke 3.937 in.
SPECIFICATIONS SECTION 4 00000 was CD867 D4.2L 300 Specification - Sterndrive Description D4.2L 300 Crankshaft Horsepower (Kilowatts) 1 Propeller Shaft Horsepower (Kilowatts) 1 300 ( 224 ) 270 ( 202 ) Engine Type In-Line 6 Cylinder Diesel Displacement 254 cu. in. ( 4.2 L ) Firing Order 1-5-3-6-2-4 Bore 3.705 in. ( 94.1 mm ) Stroke 3.941 in. ( 100.1 mm ) Compression Ratio 17.
SPECIFICATIONS SECTION 4 0051.02 Fluid Specifications IMPORTANT: All capacities are approximate fluid measures. CD868 is same information but in table like in gas module Engine IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). D2.8L D-Tronic Capacity Liters (U.S.
SPECIFICATIONS SECTION 4 NOTES: Page 66 CMD-4081850 / 90-860094030 SEPTEMBER 2003
SECTION 5 MAINTENANCE SECTION 5 - MAINTENANCE Table of Contents Owner/Operator Responsibilities . . . . . . . . Dealer Responsibilities . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . Do-It-Yourself Maintenance Suggestions . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedules . . . . . . . . . . . . . . . Routine Maintenance . . . . . . . . . . . . . . . . . . Scheduled Maintenance . . . . . . . . . . . . . . .
MAINTENANCE SECTION 5 0054 W /CMD changes Owner/Operator Responsibilities It is the operator’s responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Cummins MerCruiser Diesel dealer / distributor for a periodic checkup.
SECTION 5 MAINTENANCE 0056.1 w/ CMD changes Maintenance WARNING Avoid injury or death and power package damage from an electrical shock, fire or explosion. Always disconnect both battery cables from the battery before servicing the power package. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.
MAINTENANCE SECTION 5 0057 W CMD changes Do-It-Yourself Maintenance Suggestions Present-day marine equipment, such as your Cummins MerCruiser Diesel power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.
SECTION 5 MAINTENANCE 0058 W / CMD changes Inspection Inspect your power package often, and at regular intervals, to help maintain its top operating performance and correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts. Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as necessary. Check plug leads and electrical leads for damage. Remove and inspect the propeller.
MAINTENANCE SECTION 5 00000 was CD937 Maintenance Schedules Routine Maintenance * Each Day Start Check the engine oil level (interval can be extended based on experience). Check the coolant level. Check the power steering fluid level. Each Day End Weekly Every Two Months D D D Check the drive unit oil level in the gear lube monitor. If operating in salt, brackish or polluted waters, flush the cooling system after each use.
SECTION 5 MAINTENANCE Maintenance Schedules (Continued) Scheduled Maintenance * Every After 100 First Annually hours or 20 Annually hours z Change the engine oil and filter. Touch-up paint the power package and spray with corrosion guard. Change the drive unit oil. Retorque the gimbal ring to steering shaft connection. Replace the fuel filter(s). D D D Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and linkages.
MAINTENANCE SECTION 5 Maintenance Schedules (Continued) Scheduled Maintenance * (Continued) Every 500 Every hours 2 or 5 years years z Replace the coolant. Every 1000 hours or 5 years z D Clean the aftercooler core. D Clean the fuel tank. D * Only perform maintenance which applies to your particular power package.
SECTION 5 MAINTENANCE 0166 Maintenance Record Date Hour Meter Reading CMD-4081850 / 90-860094030 SEPTEMBER 2003 Serviced By Maintenance Performed Page 75
MAINTENANCE SECTION 5 0062 Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do NOT spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. 00000 was CD917 Checking CAUTION Avoid possible injury or damage to oil dipstick and internal engine components. Do not remove crankcase oil dipstick when engine is running.
SECTION 5 MAINTENANCE CD917 Filling IMPORTANT: Do not overfill the engine with oil. 1. Remove oil filler cap. a b 73322 c 76394 75301 a - D4.2L b - D2.8L D-Tronic, D4.2L D-Tronic and D4.2L 300 c - D4.2L LD and D4.2L 230 2. Add specified oil to bring level up to, but not over, MAX mark on dipstick. D2.8L D-Tronic Engine Oil (With Filter) 1 1 Fluid Type 8 (8-1/2) 4-Cycle 25W-40 Marine Engine Oil Always use the dipstick to determine the exact quantity of oil or fluid required. D4.2L, D4.
MAINTENANCE SECTION 5 0065 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended engine oil (refer to Specifications). 00000 was CD940 D4.2L, D4.2L 230, D2.8L D-TRONIC, D4.2L D-TRONIC AND D4.2L300 1.
SECTION 5 MAINTENANCE 6. Remove and discard oil filter and sealing ring. 7. Coat sealing ring on new filter with oil and install filter. Hand tighten only, do not use a filter wrench. a 74725 Typical engine and oil filter, all similar a - Oil filter 8. Remove oil fill cap and refill engine with new oil. Refer to Filling. IMPORTANT: When refilling engine with oil always use dipstick to determine how much oil is required.
MAINTENANCE SECTION 5 00000 was CD919 D4.2L LD 1. Start engine and allow it to warm up to normal operating temperature. 2. Stop engine and allow some time for oil to drain into oil pan (approximately 5 minutes). 3. Remove fitting from end of crankcase oil pump. Attach a suitable hose for draining. 4. Pump oil out of crankcase into drain pan. When crankcase is empty, remove hose and reinstall crankcase oil pump fitting. Tighten securely. a b 76379 a - Threaded fitting b - Crankcase oil pump 5.
SECTION 5 MAINTENANCE 0139.2 / w changes or see CD939 Power Steering Pump Fluid Checking 1. Stop the engine and center the sterndrive unit. 2. Remove the fillcap/dipstick and observe the level. a. Proper fluid level with engine at normal operating temperature should be between the full hot and full cold marks. b. Proper fluid level with engine cold should be between the full cold mark and the end of the dipstick.
MAINTENANCE SECTION 5 0071.2 Engine Coolant - Closed Cooled Models Only CD166 / CD918 Checking CAUTION Allow the engine to cool down before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off. 1. Remove the pressure cap from the heat exchanger and observe the coolant level.
SECTION 5 MAINTENANCE 4. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle. 5. The coolant level should be between the ADD and FULL marks. 72520 6. Add the specified coolant as necessary. Description Where Used Marine Engine Coolant Fleetguard Compleat (Product 91-50663 with DCA4 Additive) Part Number 92-813054A2 Closed cooling system Obtain Locally 7.
MAINTENANCE SECTION 5 00000 was 0072 / and CD166 Filling 1. If coolant is low in the heat exchanger, add specified coolant as necessary to bring the level up to the bottom of the filler neck. IMPORTANT: When installing the pressure cap, be sure to tighten until it contacts locking tabs on the filler neck. 2. Install the pressure cap. Tighten until it contacts locking tabs on the filler neck. 3. Remove the fill cap from the coolant recovery bottle. 4. Fill to the FULL line with the specified coolant.
SECTION 5 MAINTENANCE 00000 was 0142.01 w / CMD changes Drive Unit Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do NOT spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities. Checking NOTE: Oil level will fluctuate during operation. Oil level should be checked with the engine cold, before starting. 1. Check the gear lube oil level.
MAINTENANCE SECTION 5 0143 w / CMD changes Filling IMPORTANT: If more than 59 ml (2 fl. oz.) of Quicksilver High Performance Gear Lube is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Cummins MerCruiser Diesel dealer/distributor. 1. Remove the gear lube monitor cap. 2. Fill to full line with specified fluid. Where Used Part Number Gear lube monitor 92-802854A1 Description High Performance Gear Lube 3.
SECTION 5 MAINTENANCE 4. Bravo One Models: Remove the propeller, place the sterndrive unit in full trim limit IN position, remove the oil fill/drain screw and sealing washer and drain the oil. a 70568 b a - Oil fill/drain b - Sealing washer 5. All Other Models: Place the sterndrive unit in full trim limit OUT position, remove the oil fill/drain screw and sealing washer and drain the oil. b a 72522 a - Oil fill/drain b - Sealing washer 6. Remove the oil vent screw and sealing washer.
MAINTENANCE SECTION 5 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Cummins MerCruiser Diesel dealer/ distributor. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lube until an air-free stream of lubricant flows from oil vent hole.
SECTION 5 MAINTENANCE 0145 w / changes – see rev bars Power Trim Pump Fluid Checking 1. Place the sterndrive unit in full DOWN/IN position. 2. Remove the fill cap from the reservoir and verify that the cap plug has been removed. If not, remove and discard the cap plug. a 70979 a - Cap plug 3. Observe the oil level. Oil level should be maintained within the ADD and FILL or MINIMUM and MAXIMUM lines on the reservoir. a 77348 a - Oil level marks NOTE: Fill cap is vented. 4.
MAINTENANCE SECTION 5 00000 was 0146 see rev. bars Filling 1. Remove the fill cap from the reservoir. 2. Add lubricant to bring level to within the ADD and FILL or MINIMUM and MAXIMUM lines on the reservoir. a 77348 a - Oil level marks Description Power Trim And Steering Fluid Where Used Part Number Power trim pump 92-802880A1 3. Install the cap. 0147 w / CMD changes Changing Power Trim fluid does not require changing unless it becomes contaminated with water or debris.
SECTION 5 MAINTENANCE 00000 was CE335 Multiple EDI Engine Battery Precautions SITUATION Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current.
MAINTENANCE SECTION 5 00000 was CD648 Air Filter Cleaning 1. Disconnect crankcase vent hose from end of air cleaner. 2. Carefully remove air cleaner foam element from around air intake screen housing mounted on turbocharger inlet. CAUTION Avoid potential fire hazards and injury, or damage to polyester foam element. Do not clean foam element in petroleum based solvents or cleaners. 3. Wash foam element in warm water and detergent until clean.
SECTION 5 MAINTENANCE 00000 was CD884 with CMD changes Water Separating Fuel Filter WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do not allow sources of open flame in the area. Wipe up any spilled fuel immediately. Dispose of fuel soaked rags, paper, etc. in an appropriate air tight, fire retardant container.
MAINTENANCE SECTION 5 00000 was CD885 with step 1 f added, 2 E and ?CMD changes Replacing 1. On D4.2L, D2.8L D-Tronic, D4.2L D-Tronic and D4.2L 300 Models: a. Twist locking ring by hand. Remove water separating fuel filter and sealing ring from mounting bracket. Do not use a filter wrench. a c b 76114 a b 74731 a - Locking ring b - Water separating fuel filter c - Sealing ring b. Remove the drain cap and O-ring from bottom of the existing filter. Install on new filter. c.
SECTION 5 MAINTENANCE 2. On D4.2L LD and D4.2L 230 Models: a. Remove and discard water separating fuel filter and sealing ring from mounting bracket. a 76379 a - Filter b. Coat sealing ring on new filter with clean motor oil. a A 76379 a - Sealing ring Description A SAE 30W engine oil Where Used Part Number Water separating fuel filter sealing ring Obtain locally c. Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench. d.
MAINTENANCE SECTION 5 00000 was CD882 using subsub only from mod , and Filling CD880 same text in new arrangement and component style for use here, new graphics A plunger-type of hand pump/primer is located on the fuel filter bracket and is used to: • Refill fuel filter when changing filter • Refill fuel system if system was run dry • To prime the fuel system if engine has not been run for a while. To operate the hand pump/primer, move the plunger (upper portion) up and down as needed.
SECTION 5 MAINTENANCE 2. Move the plunger on the hand pump/primer up and down repeatedly, until an air free stream of fuel flows from the bleed screw. Filter is full when this occurs. b a b a 76390 74726 D4.2L, D2.8L D-Tronic, D4.2L D-Tronic and D4.2L 300 76379 D4.2L LD and D4.2L 230 a - Plunger b - Fuel from bleed screw 3. Tighten the bleed screw.
MAINTENANCE SECTION 5 00000 was CE406 removed some subsubs to make usable here Fuel System 00000 was CD881 Priming Prime engine if it has not been run for a while or if engine will not start. Move the hand pump/primer plunger up and down several times as previously outlined. Attempt to start engine. CD725 new text in list 1 and 2 Filling (Bleeding) NOTE: Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function. 1.
SECTION 5 MAINTENANCE 00000 was CE406 removed some subsubs to make usable here Fuel Tank Cleaning And Flushing IMPORTANT: Diesel fuel should not be left in tank during winter storage, as an accumulation of rust, sludge and wax residue will form. Refer to boat manufacturer’s instructions and clean fuel tank at specified intervals. Unless specified otherwise, flush and clean diesel fuel tank every 1000 hours or 5 years, whichever occurs first.
MAINTENANCE SECTION 5 0078 Lubrication 0148 Steering System WARNING Do NOT grease steering cable while extended. Hydraulic lock could occur and cause loss of steering control. 1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand-operated grease gun. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased.
SECTION 5 MAINTENANCE 3. Lubricate the steering system pivot points. A a 71904 a - Steering system pivot points Description A SAE 30W Engine Oil Where Used Part Number Pivot points Obtain Locally 4. On dual engine boats: Lubricate the tie bar pivot points. Description SAE 30W Engine Oil Where Used Part Number Pivot points Obtain Locally 5.
MAINTENANCE SECTION 5 0079 with diesel graphics from mod cd920 Throttle Cable 1. Lubricate the pivot points and the guide contact surfaces. A b A a A b a 78438 A 75332 D4.2L 300 With Rear Mounted ECM D2.8L D-Tronic, D4.2L D-Tronic and D4.2L 300 With Front Mounted ECM b A a A 76405 D4.2L, D4.2L LD and D4.
SECTION 5 MAINTENANCE 0080 modified graphics Shift Cable 1. Lubricate the pivot points and the guide contact surfaces.
MAINTENANCE SECTION 5 0149.01 Sterndrive Unit and Transom Assembly 1. Lubricate the gimbal bearing through the grease fittings by applying approximately 8-10 pumps of grease from a typical hand-operated grease gun. a A 77068 a - Gimbal bearing grease fitting Description A U-joint And Gimbal Bearing Grease Where Used Part Number Gimbal bearing 92-802870A1 2. For propeller shaft lubrication, refer to Propeller. 0150 Engine Coupler 1.
SECTION 5 MAINTENANCE 0000 New from SM #28 section 1B Sterndrive U-joint Cross Bearings And Shaft Splines (Sterndrive Unit Removed) 1. Lubricate the sterndrive U-joint cross bearings through the grease fittings by applying approximately 3-6 pumps of grease from a typical hand-operated grease gun. 2. Lubricate the U-joint shaft splines and the O-rings.
MAINTENANCE SECTION 5 0151 modified to be consistent with other diesel statements Drive Shaft Extension Models 1. Lubricate the drive shaft at the transom end, by applying approximately 10 - 12 pumps of grease from a typical hand-operated grease gun through the grease fittings. A a 71346 a - Grease fittings Description A U-joint and Gimbal Bearing Grease Where Used Part Number Drive shaft U-joints 92-802870A1 2.
SECTION 5 MAINTENANCE 0152 Propellers 0157 Bravo One and Two REMOVAL WARNING Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut. 1. Place wood block between propeller blade and anti-ventilation plate to prevent rotation.
MAINTENANCE SECTION 5 IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. 1. Apply a liberal coat of one of the following lubricants to the propeller shaft. Where Used Description Part Number Anti-Corrosion Grease 92-802867A1 Special Lubricant 101 92-802865A1 Propeller p shaft 2-4-C with Teflon 92-802859A1 2. Slide thrust hub into propeller hub with stepped side toward propeller hub. 3.
SECTION 5 MAINTENANCE 0159.01 Bravo Three REMOVAL WARNING Avoid Injury: Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut. 1. Place wood block between propeller blades and anti-ventilation plate to prevent rotation. 2.
MAINTENANCE SECTION 5 0160.01 INSTALLATION e b c f d a 77107 a b c d e f - Rear propeller nut - Rear propeller - Rear propeller thrust hub - Front propeller nut - Front propeller - Front propeller thrust hub 1. Apply a liberal coat of one of the following lubricants to the propeller shaft. Description Where Used Part Number Anti-Corrosion Grease Special Lubricant 101 92-802867A1 92-802865A1 Propeller p shaft 2-4-C with Teflon 92-802859A1 2.
SECTION 5 MAINTENANCE 7. Install and torque the propeller nut. Check propeller at least every 20 hours of operation and retorque as needed. Description Aft Propeller 1 Nm Nut1 lb-in. 81 lb-ft 60 The propeller torque stated is the minimum torque value. 8. Install the propeller shaft anode over the propeller shaft nut. 9. Place the flat washer onto the propeller shaft anode screw. 10. Place the star washer onto the propeller shaft anode screw.
MAINTENANCE SECTION 5 Alternator Drive Belt and Engine Water Circulating Pump Belt, or Belts 1. Inspect drive belt, or belts, for excessive wear or damage. 2. Check belt tension by depressing upper strand of belt, with moderate hand pressure, at point shown. Belt should move no more than 5 mm (3/16 in.) either way. 71588 74301 Power Steering Pump Belt 1. Inspect drive belt for excessive wear or damage. 2.
SECTION 5 MAINTENANCE 0161.02 Corrosion Protection Whenever 2 or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode.
MAINTENANCE SECTION 5 Ventilation Plate Anode - Is mounted on the front of the gearcase and serves as a sacrificial anode. a All Bravo Models a - Anode Drive Mounted Anodic Block (if equipped) - Is mounted to underside of gimbal housing and serves as a sacrificial anode. 70576 MerCathode System (if equipped) - Electrode assembly replaces Anodic Block. System should be tested to ensure adequate output.
SECTION 5 MAINTENANCE Anode Kit (if equipped) - Mounted to boat transom. Acts as a sacrificial anode. Trim Cylinder Anodes - are mounted on each trim cylinder. a 71966 a - Trim cylinder anodes Bearing Carrier Anode (Bravo One Models) - is located in front of the propeller, between the front side of the propeller and the gear housing.
MAINTENANCE SECTION 5 Propshaft Anode (Bravo Three Only) - is located in front of the propeller, between the front side of the propeller and the gear housing. a 79161 a - Propshaft anode In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: 1. Paint your power package, refer to Painting Your Power Package. 2. Spray power package components on inside of boat annually with Corrosion Guard to protect finish from dulling and corrosion.
SECTION 5 MAINTENANCE Internal Components Sacrificial anode locations: • Starboard, aft-side of the heat exchanger. • Top of the intercooler end cover. REMOVAL 1. Allow the engine to cool. 2. Remove anode plugs and sacrificial anodes.
MAINTENANCE SECTION 5 INSPECTION NOTE: Remove deposits from surface of anode before trying to determine amount of erosion. 1. Replace anode assembly when deteriorated 50%. • Length When New - 19 mm (3/4 in.) • Diameter When New - 16 mm (5/8 in.) 2. Discard sealing washer. c e a b c d e d b a 71368 - Anode Plug - Sacrificial Anode - Length - Diameter - Sealing Washer REPAIR NOTE: Sacrificial anodes are available as an assembly. Replace both the plug and anode, if so desired. 1.
SECTION 5 MAINTENANCE 3. Apply sealant to threads of new sacrificial anode and install into anode plug. Tighten securely. A a b 71367 a - Plug b - Anode Description A Loctite 567 PST Pipe Sealant Where Used Part Number Threads of anode plug 92-809822 INSTALLATION 1. Install new sealing washer. 2. Install anode plug, with sacrificial anode and washer into heat exchanger or intercooler end cover. Tighten securely.
MAINTENANCE SECTION 5 0162 modified in step 2 to have the word tim removec Painting Your Power Package IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty. 1.
SECTION 5 MAINTENANCE CE376 modified Cleaning The Seawater Strainer 1. Visually inspect seawater strainer through glass top. CAUTION When cleaning seawater strainer, close seacock, if equipped. If boat is not equipped with a seacock, remove and plug seawater inlet hose to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. CAUTION Do not overtighten cover screws or cover will warp and leak. 2.
MAINTENANCE SECTION 5 Flushing The Seawater System Seawater section must be flushed after each operation in saltwater. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit and to the engine during operation. On Engines With Through The Hull Water Inlet: Supply sufficient cooling water to the seawater pump. Attach a hose between the sea pump and a water source.
SECTION 5 MAINTENANCE 1. Ensure the area around propeller is clear and no one is standing nearby. To avoid possible injury, remove the propeller. 2. Install Flushing Attachment (or equivalent) over water pickup openings in gear housing. CAUTION If using flush test device (attachment), install over water intake holes and connect a water hose. Do not use full water tap pressure.
MAINTENANCE SECTION 5 3. Attach a hose between the flushing attachment and a water source. a b 72012 Typical a - Flushing Attachment b - Hose 4. Lower sterndrive unit to full DOWN/IN position. 5. Partially open water tap (approximately 1/2 maximum capacity). Do not use full water pressure. 6. Place remote control in NEUTRAL, IDLE speed position and start engine. CAUTION Do NOT run engine above 1500 rpm when flushing.
STORAGE SECTION 6 SECTION 6 - STORAGE Table of Contents Cold Weather Or Extended Storage . . . . . 126 Preparing Your Power Package For Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Draining Instructions . . . . . . . . . . . . . . . . . . 127 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Recommissioning . . . . . . . . . . . . . . . . . . . . .
STORAGE SECTION 6 0084 w / CMD Cold Weather Or Extended Storage IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service should be performed by an authorized Cummins MerCruiser Diesel dealer / distributor. Damage caused by freezing IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist.
STORAGE SECTION 6 CD665 w / changes Draining Instructions IMPORTANT: Observe the following information to ensure complete draining of cooling system: • Engine must be as level as possible. • A wire should be repeatedly inserted into all drain holes to ensure there are no obstructions in passages. IMPORTANT: Drain seawater section of closed cooling system only. 1. Close seacock, if equipped, or disconnect and plug seawater inlet hose, if boat is to remain in the water.
STORAGE SECTION 6 5. Disconnect seawater outlet hose at aft end of power steering cooler. Lower hose and drain completely. a 861076 Typical a - Seawater outlet hose 6. Remove the drain plug from the aft end cover of the intercooler.
STORAGE SECTION 6 7. Remove the seawater pump outlet hose from top of seawater pump. Drain the hose. a 75301 D4.2L D-Tronic Engine (All Similar) a - Seawater pump outlet hose 8. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. CAUTION Avoid water entering boat. Do not unplug seawater inlet hose unless a seacock is present and it is closed. 9. Remove hose at seawater strainer and drain hose completely. Drain and empty seawater strainer.
STORAGE SECTION 6 10. Using a piece of wire, check water drain holes in sterndrive unit to ensure that they are open.
STORAGE SECTION 6 11. After seawater section of cooling system has been drained completely, coat threads of intercooler drain plug with sealant and install. Tighten plug securely. Description Where Used Part Number Perfect Seal Intercooler drain plug threads 92-34227-1 12. Reconnect hoses. Tighten hose clamps securely. 13. Replace end cover gaskets and seals if worn or deteriorated. Install all four end cover assemblies on the heat exchanger. 14.
STORAGE SECTION 6 00000 was CD927 w / changes IMPORTANT: Cummins MerCruiser Diesel recommends that propylene glycol antifreeze (nontoxic and biodegradable, which makes it friendly to lakes and rivers) be used in seawater section of the cooling system for cold weather or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer’s recommendations. 16.
STORAGE SECTION 6 24. Remove the seawater pump impeller for storage: a. Remove the seawater pump cover mounting screws, and remove the cover and gasket. b. Ease the impeller off the pump shaft with two screwdrivers. c. Reinstall the cover for storage. NOTE: Pump shown removed for visual clarity only. b e c a d 71366 Typical a - Seawater Pump Housing b - Cover Screws c - Cover d - Gasket e - Impeller IMPORTANT: It is recommended that others be informed to NOT operate the engine. 25.
STORAGE SECTION 6 CD928 w / changes Recommissioning NOTICE Refer to Cold Weather Extended Storage - Precautions, BEFORE proceeding. 1. Reinstall seawater pump components as follows: a. Place impeller in pump housing, turning clockwise while simultaneously pushing firmly inward onto pump shaft. NOTE: Use new gasket. Install in correct position - wide surface on side of cam. b. Install pump cover with new gasket in noted position. c. Install the seawater pump cover mounting screws. Tighten securely.
STORAGE SECTION 6 2. Ensure that all cooling system hoses are in good condition, connected properly, and hose clamps are tight. Verify that all drain valves and drain plugs are installed and tight. 3. Inspect all drive belts. 4. Perform all lubrication and maintenance specified for completion Annually in Maintenance Schedule, except items that were performed at time of engine layup. 5. Fill fuel tanks with fresh diesel fuel. Old fuel should not be used.
TROUBLESHOOTING SECTION 7 SECTION 7 - TROUBLESHOOTING Table of Contents Diagnosing EDI Problems . . . . . . . . . . . . . . Troubleshooting Charts . . . . . . . . . . . . . . . Starter Motor Will Not Crank Engine, Or Cranks Slow . . . . . . . . . . . . . . . . . . . . . Engine Will Not Start, Or Is Hard To Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Runs Rough, Misses And/Or Backfires . . . . . . . . . . . . . . . . . . . . . . . . . . . Poor Performance . . . . . . . . . .
TROUBLESHOOTING SECTION 7 0102 changed to CMD and EDI not EFI Diagnosing EDI Problems Your authorized Cummins MerCruiser Diesel dealer / distributor has the proper service tools for diagnosing problems on Electronic Diesel Injection (EDI) systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM’s memory. This code can then be read later by a service technician using a special diagnostic tool.
TROUBLESHOOTING SECTION 7 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Lanyard stop switch activated. Check lanyard stop switch. Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shut off valve closed. Fill tank or open valve. Faulty mechanical fuel delivery pump. Have pump replaced by an authorized Cummins MerCruiser Diesel dealer / distributor, if fuel is present. Throttle not operating properly. Check throttle for freedom of movement.
TROUBLESHOOTING SECTION 7 0105 w / changes – EDI and CMD Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Throttle not operating properly. Check throttle linkages for binding or an obstruction. Idle speed too low. Check idle speed and adjust, if necessary. Clogged fuel or air filters. Replace filters. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel. Kinked or clogged fuel line or fuel tank vent line.
TROUBLESHOOTING SECTION 7 0107.2 with CMD changes Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer obstructed. Remove obstruction. Faulty thermostat. Replace. See an authorized Cummins MerCruiser Diesel dealer / distributor. Coolant level low in closed cooling section.
TROUBLESHOOTING SECTION 7 0109 with CMD changes Low Engine Oil Pressure Possible Cause Remedy Faulty senders. Have system checked by an authorized Cummins MerCruiser Diesel dealer / distributor. Insufficient oil in crankcase. Check and add oil. Excessive oil in crankcase (causing it to become aerated). Check and remove required amount of oil. Check for cause of excessive oil (improper filling). Diluted or improper viscosity oil. Change oil and oil filter, using correct grade and viscosity oil.
TROUBLESHOOTING SECTION 7 0175 w / changes – CMD Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level. Check for leak. Refill system with fluid. Drive belt loose or in poor condition. Replace and/or adjust. Insufficient lubrication on steering components. Lubricate. Loose or missing steering fasteners or parts. Check all parts and fasteners if any are loose or missing, see an authorized Cummins MerCruiser Diesel dealer / distributor.
TROUBLESHOOTING SECTION 7 NOTES: Page 144 CMD-4081850 / 90-860094030 SEPTEMBER 2003
CUSTOMER ASSISTANCE INFORMATION SECTION 8 SECTION 8 - CUSTOMER ASSISTANCE INFORMATION Table of Contents Owner Service Assistance . . . . . . . . . . . . . Local Repair Service . . . . . . . . . . . . . . . . . Service Away From Home . . . . . . . . . . . . Stolen Power Package . . . . . . . . . . . . . . . Attention Required After Submersion . . . Replacement Service Parts . . . . . . . . . . . Parts And Accessories Inquiries . . . . . Resolving A Problem . . . . . . . . . . . . . . . . .
CUSTOMER ASSISTANCE INFORMATION SECTION 8 CD944 w/ CMD changes Owner Service Assistance Local Repair Service Always return your Cummins MerCruiser Diesel (CMD) powered boat to your authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur. He knows your engine best.
CUSTOMER ASSISTANCE INFORMATION SECTION 8 0117 – precaution only then CE472 Replacement Service Parts WARNING Electrical, ignition and fuel system components on Cummins MerCruiser Diesel engines and sterndrives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion.
CUSTOMER ASSISTANCE INFORMATION SECTION 8 0119 w / changes – see rev. bars or CD945 Resolving A Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your Cummins MerCruiser Diesel dealer / distributor. If additional assistance is required, take these steps. 1. Talk with the dealership’s sales manager or service manager.
CUSTOMER ASSISTANCE INFORMATION SECTION 8 0121 Customer Service Literature English Language English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: • List your product, model, year and serial numbers.
CUSTOMER ASSISTANCE INFORMATION SECTION 8 Andere Sprachen Um eine Betriebs– und Wartungsanleitung in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power International Service Center. Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors enthalten. Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza internazionale Mercury Marine o Marine Power più vicino.
CUSTOMER ASSISTANCE INFORMATION SECTION 8 0122 w / changes – or see CD946 or see rev bars Ordering Literature Before ordering literature, please have the following information about your power package available: Model __________ Horsepower__________ Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular Cummins MerCruiser Diesel power package and how to order that literature contact your nearest Cummins MerCruiser Die
CUSTOMER ASSISTANCE INFORMATION SECTION 8 00000 was CD851 75308 Page 152 CMD-4081850 / 90-860094030 SEPTEMBER 2003
