90 861179990 999 The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.
CA753 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.
CD539 Identification Record Please record the following information: 1. Engine Serial Number Engine Model and Horsepower 2. Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number Transmission Model (Inboard) Gear Ratio Transmission Serial Number 3. 4. Pitch Propeller Number Diameter 5. Hull Identification Number (HIN) Purchase Date 6. Boat Model Boat Manufacturer Length 7.
CD601 TABLE OF CONTENTS Page Warranty Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WELCOME! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Operation 32 Quicksilver Instruments and Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Electrical System Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 MerCathode System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remote Controls . . .
CD54 Warranty Information CD55 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.
CD56 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.
CE345 Mercury MerCruiser Diesel Limited Warranty I. We warrant each new production MerCruiser Diesel Sterndrive Power Package, Inboard Engine and Accessories attached thereto (hereafter referred to as “Product”), manufactured by MerCruiser (hereafter referred to as the “Company”), and sold to the consumer in a country to which distribution is authorized by the Company, to be free from defects in material and workmanship. II.
VI. Reasonable access must be provided to the Product for warranty service. This warranty will not apply to: 1) Haul-out, launch, towing and storage charges, telephone or rental charges of any type, inconvenience, or loss of time or income, or other consequential damages; or 2) Removal and/or replacement of boat partitions or material because of boat design for necessary access to the Product. VII.
CD622 Warranty Coverage and Exclusion The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The table explains some of the types of services that are not covered by warranty. 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.
CE350 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. DIRECT SALE BY OWNER • The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership.
CD594 THIS PAGE IS INTENTIONALLY BLANK 12
CE346 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.
CA619 GENERAL INFORMATION Lanyard Stop Switch 2 1 74608 The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed on the dashboard or side adjacent to the operator’s position.
Lanyard Stop Switch (Continued) While activation of the lanyard stop switch will stop the engine immediately, a 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.
CA641 1 Courtesy of ABYC CA642 2A 2B 3A 3B 16 Courtesy of ABYC
CA620 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
CD543 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water. The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to violently veer in a new direction.
CD604 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bottom. 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.
CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency.
• Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. • 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.
CD3 Conditions Affecting Operation CD4 Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. Shifting weight to rear (stern) will: • Generally increases speed and engine RPM. • At extremes, can cause boat to porpoise. • Causes bow to bounce in choppy water. • Increases danger of following wave splashing into boat when coming off plane. B. Shifting weight to front (bow) will: • Improves ease of planing on some boats. • Improves rough water ride.
CD605 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at the upper end of the specified throttle operating revolutions per minute (rpm) range, with a normal load aboard the boat. Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s).
CD476 How Elevation And Climate Affect Performance NOTE: Engines equipped with EDI (D-Tronic engines) reduce the effects of changes in elevation and climate by automatically adjusting fuel flow for weather conditions and elevation. EDI engines however, do not compensate for increased loading or hull conditions. Generally, elevation has a very noticeable effect on the wide-open-throttle power of an engine.
CD5 Important Information CD606 Operation and Maintenance RECOMMENDED OPERATION / DUTY CYCLE It is the operator’s responsibility to operate within the following recommended operational capability, or duty cycle, as applicable to engine and installation: D7.3L D-Tronic Models - PLEASURE DUTY RATING • Engine Specified Operating Rpm Range is 3600-3800 rpm. • Wide-Open-Throttle operation is limited to short periods of time. D7.
CE7 OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks, ensure that all lubrication and maintenance instructions are complied with for safe operation, and return the unit to an Authorized MerCruiser Dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
CE8 Freezing Temperature And Cold Weather Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Refer to the following and to “Cold Weather or Extended Storage” for related information and draining instructions. CAUTION Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing temperatures exist.
CA20 Launching and Boat Operation Care CAUTION During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders. The more weight on the transom, the more likely this is to occur.
CA772 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. • Present-day marine equipment, such as your MerCruiser 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.
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. EDI Electronic Control Module (ECM): The ECM requires a stable voltage source.
CE11 20-HOUR BREAK-IN PERIOD IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. During this break-in period, the following rules must be observed: • DO NOT operate engine below 1500 rpm for extended periods during the first 10 hours.
CD9 Operation CD16 1 3 71856 2 4 6 32 71856 5 72753 71856 71856 7 71772 8 71856 71886
CD548 Quicksilver Instruments and Instrumentation Shown is the basic Quicksilver instrumentation and engine system monitor display for the Diesel Power Package. The instrumentation shown is required for safe operation of boat and engine. Operator should become familiar with all instrumentation before operating the engines. Gauges and engine system monitor panel may be individually mounted, or collectively mounted in the optional single panel available from Quicksilver.
CD549 AUDIO TEST E D C B A 71891 2 AUDIO TEST 71891 1 CD550 1 Engine System Monitor Features - The appropriate light functions as follows: A Preheat Indicator Lamp - lights up when the glow plugs are preheating the combustion chambers. The timed preheat period begins when the key switch is turned on. THE ENGINE SHOULD BE STARTED ONLY AFTER THE LAMP GOES OFF. B Charge Indicator Lamp - indicates a problem with charging system if lamp illuminates while engine is running.
CD551 3 71630 2 4 1 75955 22444 CD20 Electrical System Overload Protection lf an electrical overload occurs the circuit breaker will trip open. IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker. 1 One 30 amp circuit breaker provides protection for engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN (from outside).
CD197 1 7 3 2 8 11 5 6 4 10 12 9 8 11 12 10 9 13 36
CD195 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. NOTE: If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control. 1 Neutral Lock Bar - Prevents accidental shift and throttle engagement.
CD552 2 1 71339 4 3 70537 38
CD217 Remote Controls (Two Lever) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. NOTE: If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control. 1 Shift Lever - shifts unit into gear with full lever movement. Move lever forward to shift to FORWARD gear.
CD553 3-5° 1 2 3 40
CA35 Power Trim The Power Trim system allows operator to raise and lower drive unit for trailering, beaching, launching and shallow water operation. Power Trim also allows operator to adjust drive unit angle, while underway, to provide ideal boat angle for varying load and water conditions. 1 In most cases, best overall performance is obtained with drive unit adjusted so boat will run at a 3° to 5° angle to water. CA36 2 Trimming Drive Unit UP/OUT Will: • Lift bow of boat. • Generally increase top speed.
CD199 2 3 1 73976 5 6 4 73977 42
CB188 POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed. 1 Trailer Position: Press button until drive unit reaches desired height.
CD200 2A 1 2B 73979 4 1 73978 3 5 6 70540 44 7 70540 70540
CB191 POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed.
CE29 Starting, Shifting and Stopping BEFORE STARTING THE ENGINE 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. 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.
CE31 ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. 1 After starting, check to ensure all instrumentation is functioning properly. Run engine at idle rpm until engine temperature is within normal operating range. It is very important that any engine be warmed up before applying full load. The warm-up period provides time for the lubricating oil to establish a film between moving parts.
CE35 OPERATION CHART 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. Check for fuel, oil, water, fluid, and exhaust leaks, etc.
CD7 Specifications CD11 Seacock Seacock (water inlet valve) used, must have an internal cross-sectional area equal to or greater than hose to prevent restricting water flow. A 1-1/2 in. (38mm) brass ball or gate valve is minimum required. Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue.
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. WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death.
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.
CD557 Engine SPECIFICATION - MCM (Sterndrive) DESCRIPTION Crankshaft Horsepower (Kilowatts) 1 Propeller Shaft Horsepower (Kilowatts) 1 D7.3L D-Tronic D7.3L D-Tronic LD 300 (223) 260 (195) 270 (202) 230 (170) Engine Type V-8 Cylinder Diesel Displacement 444 cu. in. (7.3L) Firing Order 1-2-7-3-4-5-6-8 Bore 4.11 in. ( 104.39 mm ) Stroke 4.18 in. ( 106.20 mm ) Compression Ratio 15:1 Valve Clearance - Intake / Exhaust Non-Adjustable (Hydraulic) Maximum Pressure Difference Between Cyl.
CD558 Capacities NOTE: All measurements are given in US Quarts (Liters). SPECIFICATION - MCM (Sterndrive) D7.3L D-Tronic and D7.3L D-Tronic LD ITEM Total Oil-Filling Capacity1 Oil Drainage: Drive Unit Oil Capacity Ca acity (With Gear Lube Monitor)1 16.5 (15.6) from oil pan 13.5 (12.8) from oil filter 1 (1) from oil cooler 1 (1) Bravo Two 3.2 (3) Bravo Three 3 (2.9) Closed Cooling System 1 Always 26 (24-1/2) use dipstick to determine exact quantity of oil or fluid required.
CD10 Maintenance CD559 Power Package Views FRONT a b s d r q q p c f n o e m g l h k k i j a -Heat Exchanger/Coolant Tank Cap b -Engine Water Circulating Pump and Pulley c -Sacrificial Anode (On Heat Exchanger) d -Heat Exchanger/Coolant Tank e -Alternator f -Port Exhaust Manifold g -Seawater Pump and Pulley h -Engine Water Circulating Pump Belt i -Crankshaft Pulley j -Oil Pan k -Oil Pan Drain Plug l -Starter m-Starboard Front Engine Mount n -Water Separating Fuel Filter o -Power Steering Pum
CD560 PORT (LEFT) SIDE t r u v w x a s q b p c merCruiser o n m d k l j k i h g f e 76075 a -Steering System b -Transom Assembly c -Sterndrive Unit d -Antiventilation Plate e -Power Trim Cylinder f -Speedometer Pitot Tube g -MerCathode Electrode h -Rear Engine Mount i -Exhaust Manifold j -Oil Pan k -Oil Pan Drain Plug l -Front Engine Mount m-Seawater Pump and Pulley n -Crankshaft Pulley o -Alternator p -Sacrificial Anode (On Heat Exchanger) q -Heat Exchanger/Coolant Tank r -Heat Exchange
CD561 2 10 1 3 4 6 7 8 11 9 5 76075 CE348 General Maintenance Information WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire. This eliminates the engine wiring as a potential source of ignition.
CD609 Maintenance Schedules DIESEL STERNDRIVE Routine Maintenance Each Day Start Check crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush cooling system after each use. Each Day End Weekly Drain any water from fuel filter (After each use If operating in freezing temperatures). Check drive unit oil level, trim pump oil level and power steering pump fluid level. Check water pickups for debris or marine growth.
Maintenance Schedules DIESEL STERNDRIVE Scheduled Maintenance After After First First 20 100 hours hours Change crankcase oil and filter. Touch-up paint power package and spray with corrosion guard. Change crankcase oil and filter. Every Every Every 200 300 500 Every hours hours Every Every hours 100 Annu2 5 or 3 or 5 hours or or 3 ally years years years Annually years years Change drive unit oil and retorque connection of gimbal ring to steering shaft. Replace fuel filter(s).
Maintenance Schedules DIESEL STERNDRIVE Scheduled Maintenance (Continued) After After First First 20 100 hours hours Every Every Every 200 300 500 Every hours hours Every Every hours 100 Annu2 5 or 3 or 5 hours or or 3 ally years years years Annually years years Inspect condition and tension of belts. Check cooling system and exhaust system hose clamps for tightness Inspect both systems for damage or leaks. Disassemble and inspect seawater pump and replace worn components.
CD564 3A 3B 71380 2 76075 4 76126 5 75955 10A 76075 6 10B 71672 7 70979 70979 60 9 75955
CD565 Checking Fluids Levels CRANKCASE OIL 1 Check engine oil daily before first start-up. NOTE: If it becomes necessary to check oil level during operation, stop engine and allow 5 minutes for oil to drain into pan. 2 Remove dipstick. Wipe clean and reinstall into dipstick tube. 3 Remove dipstick and observe oil level. Oil must be between marks and on dipstick. A MAXIMUM Oil Level - top line. Fill to this level; do not overfill. B MINIMUM Oil Level - Do not allow oil level to drop below this line.
CD566 1 70548 2 3 76110 62 72714
CE45 ENGINE COOLANT 1 Check coolant level in coolant recovery bottle. Add specified coolant as required. NOTE: Coolant recovery system is considered to be functioning properly when coolant level in heat exchanger/ coolant tank remains at bottom edge of its filler neck. WARNING Do not remove coolant tank cap when engine is hot. Coolant may discharge violently, causing severe burns.
CD567 3 70571 5 75954 9 70121 7 6 64 8 76126 72522 12 75955
CD568 Changing Fluids See MAINTENANCE CHART for lubricant change interval. Lubricant should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Coolant in closed cooling system should be changed at specified intervals by your Authorized MerCruiser Dealer. CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use only recommended motor oil (see SPECIFICATIONS).
CD569 4 2 1 73190 76107 3 3 76116 66 76117
CE50 Drive Belts If any drive belts or pulleys need replacement or drive belt tension needs adjustment, see your Authorized MerCruiser Dealer. INSPECTION WARNING Make sure engine is shut off and ignition key is removed before inspecting belts or pulleys. IMPORTANT: Observe the following drive belt and pulley guidelines: • Do not use belt dressing. • Replace a belt if worn, cracked, grease or oil soaked. Always check condition of remaining belts.
CD611 1A 1C 1B 7 1 70556 75953 3 2 71903 7 71901 8 68 70558 10 73346 4 71904
CD572 Air Filter - Cleaning and Replacement 1 Disconnect and remove wire retainer. Carefully remove air cleaner element from air intake housing. Wash element in warm water and detergent until clean. CAUTION Avoid potential fire hazards and personal injury, do not clean elements in petroleum based solvents or cleaners. IMPORTANT: No treatment (such as partial oil saturation) is required or recommended on air cleaner element prior to use. Use element clean and dry for proper filtration.
CD573 1A 1E 1B 1C 1 1 70355 70062 1D 1 71362 CD603 Cleaning Quicksilver Seawater Strainer NOTE: Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer. CAUTION When cleaning seawater strainer, close seacock, if so 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.
CD575 10 2 73254 76107 CD576 Flushing Seawater Cooling System WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine to overheat. CAUTION Watch temperature gauge on dash to ensure that engine does not overheat.
CD577 1 71873 2 3 5 4 76116 76105 72
CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. 1 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range). CD625 Fuel System CAUTION Absolute cleanliness is required for work on the fuel system, fuel injection components have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system.
CD579 76114 76105 74731 1 f 2 71870 2B 2 2A 2C 73192 76108 74
CD580 REPLACING WATER SEPARATING FUEL FILTER CAUTION Any water entering the fuel injection system will disable the system. Check for water in water separating fuel filter before startup, daily. CAUTION If water should enter the fuel injection system, take unit to an Authorized MerCruiser Dealer IMMEDIATELY, so that corrosion and rusting of the injectors and other components can be avoided. WARNING Be careful when changing water separating fuel filter. Diesel fuel is flammable.
CD231 5A 1 73919 6 72032 5B 71966 71176 3 76 70578 4 70577 2 70055
CD205 EXTERNAL COMPONENTS Whenever two 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.
CD362 4 5 6 3 1 71176 2 78
CA168 In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty.
CD207 2 70561 5 7 72239 80
CA77 Propeller WARNING Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller. WARNING 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. CAUTION Periodically check propeller nut for tightness during boating season. A minimum of 55 lbs. ft. (75 N·m) torque is required.
CD204 3 1 2 4 5 70561 6 7 12 8 9 10 11 82 72239
CA79 REPAIR Some damaged propellers can be repaired. See your dealer. CD583 INSTALLATION (BRAVO TWO) 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 Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant. 2 Slide thrust hub into propeller hub, with stepped side toward propeller hub.
CD15 Miscellaneous Maintenance CD612 1 71088 3 2 76075 84
CA103 Battery 1 All lead acid batteries discharge when not in use. Recharge every 30 to 45 days. or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the boat.
CD585 Cold Weather Or Extended Storage CD586 1 75954 76075 86
CD587 Power Package Layup IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer. CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage. IMPORTANT: If boat has already been removed from water, before starting engine a source of water must be supplied to water intake (inlet) openings. Follow all warnings and flushing attachment procedures stated in “FLUSHING COOLING SYSTEM”.
CD588 2A 2A 76186 2C 76122 2 2B 71870 7 76107 88 6 5 4 71930 76106 71362
CD589 Power Package Layup (Continued) Drain seawater section of cooling system and prepare for cold weather or extended storage following these procedures: DRAINING INSTRUCTIONS CAUTION If boat is to remain in the water, seacock, if so equipped, must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system.
CD590 76186 10 76107 10 90 71873
CE76 Power Package Layup (Continued) Dealer should perform these remaining tasks prior to layup: 1 After draining, perform all checks, inspections, lubrication and fluid changes outlined in MAINTENANCE CHART. 2 Clean seawater strainer (refer to MAINTENANCE SECTION). IMPORTANT: MerCruiser 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.
CD591 71871 71873 1 76186 1 76107 92
CE78 Power Package Recommissioning IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer. WARNING To prevent possible injury or damage to equipment, do not install battery until all maintenance has been performed on engine. 1 Reinstall seawater pump components and pump as follows: NOTE: Use new gasket and O-ring. Install in correct position. A Place impeller in pump housing. B Install new O-ring in groove on housing. C Install pump plate, with new gasket in position as shown.
CD49 Troubleshooting CD623 Starter Motor Will Not Crank Engine, Or Cranks It Very Slowly Possible Cause • Battery switch turned off Remedy • Turn switch on. • Remote control not in neutral position • Position control lever in neutral. • Open circuit breaker or blown fuse • Check and reset circuit breaker or replace fuse. • Loose or dirty electrical connections or dam- • Check all electrical connections and wires (especially aged wiring battery cables). Clean and tighten faulty connection.
Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy • 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 • Replace kinked line or blow out line with com- vent line • Air in fuel injection system • Engine Oil - Level over full or wrong viscosity pressed air to remove obstruction. • Purge fuel injection system. • Correct engine oil level or viscosity problem.
Excessive Engine Temperature Possible Cause Remedy • Seacock closed, if so equipped • Open. • Drive belt loose or in poor condition • Replace and/or adjust belt. • Seawater pickups obstructed • Remove obstruction. • Faulty thermostat • Replace. • Coolant level low in closed cooling • Check for cause of low coolant level and repair. section • Heat exchanger cores plugged with foreign material • Loss of pressure in closed cooling section Fill system with proper coolant solution.
Low Engine Oil Pressure Possible Cause Remedy • Insufficient oil in crankcase • Check and add oil. • Excessive oil in crankcase (causing it to • Check and remove required amount of oil. become aerated) Check for cause of excessive oil (improper filling, bad fuel pump, etc.). • Diluted or improper viscosity oil • Change oil and oil filter, using correct grade and viscosity oil. Determine cause for dilution (excessive idling, faulty fuel pump, etc.).
CD624 Steering Wheel Turns Hard Or Jerky Possible Cause Remedy • Low power steering pump fluid level • Refill system with fluid. • Drive belt loose or in poor condition • Replace and/or adjust. • Insufficient lubrication on steering system • Lubricate. components • Loose or missing steering fasteners or parts • Check all parts and fasteners. If any are loose • Contaminated power steering fluid or missing, see Authorized MerCruiser Dealer immediately. • Drain and replace.
CA461 Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local 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.
CA785 Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. Telephone Fax Mail United States (405) 743-6566 (405) 743-6570 (905) 567-MERC (6372) (905) 567-8515 MerCruiser 3003 N. Perkins Rd. Stillwater, OK 74075 Canada Mercury Marine Ltd. 2395 Meadowpine Blvd.
CA463 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 54936-1939 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: 1. List your product, model, year and serial number(s). 2. Check the literature and quantities you want. 3.
cae781 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. caf781 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.
CA752 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 MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone (920) 929-5110 Fax (920) 929-4894 Mail Mercury Marine Attn: Publications
CD68 Owner’s Logbook Date 104 Maintenance and Repair Operating Hours
CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 105
CD68 Owner’s Logbook Date 106 Maintenance and Repair Operating Hours
