Mercury 2.8 EI 200 User Manual

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Page 1

CMDĆ4081877 / 90Ć865861040 304

2.8 EI 200 Diesel Inboard Models

2004, Mercury Marine

Page 2

0001.

Identification Record

The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Cummins MerCruiser Diesel MerCruiser Diesel (CMD

 power package. When contacting Cummins

) about service, always specify model and serial numbers.

Please record the following information:

Engine Model and Horsepower

Transom Assembly Serial Number (Sterndrive)

Transmission Model (Inboard)

Propeller Number

79994

Engine Serial Number

Gear Ratio

Pitch Diameter

Sterndrive Unit Serial

Number

Transmission Serial

Number

Hull Identification Number (HIN)

Boat Manufacturer

Exhaust Gas Emissions Certificate Number (Europe Only)

The description and specifications contained herein were in effect at the time this guide was approved for printing. Cummins MerCruiser Diesel, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.

 2004, Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Marathon, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport–Jet, Cleaver, K–Planes, MerCathode, Quickleen, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.

Boat

Model

Purchase Date

Length

Page 3

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. We suggest that this manual remain with the product for ready reference whenever you are on the water.

Thank you for purchasing one of our Cummins MerCruiser Diesel products. We sincerely

hope your boating will be pleasant!

Cummins MerCruiser Diesel

0003 with CMD

Warranty Message

The product you have purchased comes with a limited warranty from Cummins MerCruiser Diesel; 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.

Page 4

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

to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.

WARNING - Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION - Hazards or unsafe practices which could result in minor personal injury or product or property damage.

WARNING

CAUTION

, may be used to alert the installer/user

0197 modified or CE461

IMPORTANT: - Indicates information or instructions that are necessary for proper operation and/or maintenance.

WARNING

The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an emergency.

WARNING

California Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

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.

Page 5

SECTION 1 - WARRANTY

Warranty Information 2. . . . . . . . . . . . . . . . . . . .

Owner Warranty Registration 2. . . . . . . . . . . .

United States And Canada Only 2. . . . . .

International Owner Registration 3. . . . . . . . .

Outside The United States And

Canada 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .

Recreational Use Diesel Limited

Warranty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What Is Covered 4. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 4. . . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 4. . . . . . . .

What Cummins Mercruiser Diesel Will

Do 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 5. . . .

What Is Not Covered 5. . . . . . . . . . . . . . . .

Disclaimers And Limitations 5. . . . . . . . . .

Warranty Coverage and Exclusion 6. . . . . . .

Warranty Does Not Apply To The

Following: 6. . . . . . . . . . . . . . . . . . . . . . . . .

Transferable Warranty 8. . . . . . . . . . . . . . . . . . .

Direct Sale By Owner 8. . . . . . . . . . . . . . . . . .

SECTION 2 - GETTING TO KNOW YOUR POWER

PACKAGE

Features And Controls 10. . . . . . . . . . . . . . . . .

Lanyard Stop Switch 10. . . . . . . . . . . . . . . . . .

Instrumentation 12. . . . . . . . . . . . . . . . . . . . . . .

Remote Controls 15. . . . . . . . . . . . . . . . . . . . .

Panel Mounted 15. . . . . . . . . . . . . . . . . . . .

Console Mounted 16. . . . . . . . . . . . . . . . . .

Electrical System Overload Protection 17. . .

Audio Warning System 18. . . . . . . . . . . . . . . .

Testing The Audio Warning System 18. . .

Emissions Information 19. . . . . . . . . . . . . . . . .

Exhaust Gas Emissions Certificate

(Europe Only) 19. . . . . . . . . . . . . . . . . . . . . . .

Owner Responsibility 19. . . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page i

Page 6

SECTION 3 - ON THE WATER

Safe Boating Suggestions 22. . . . . . . . . . . . . .

Be Alert To Carbon Monoxide

Poisoning 24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Good Ventilation 25. . . . . . . . . . . . . . . . . . .

Poor Ventilation 25. . . . . . . . . . . . . . . . . . . .

Basic Boat Operation 26. . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 26. . . .

Duty Cycle Rating 27. . . . . . . . . . . . . . . . . . . .

Pleasure Duty Rating 27. . . . . . . . . . . . . . .

Operation Chart - 2.8 EI 200 28. . . . . . . . . . .

Starting, Shifting and Stopping -

2.8 EI 200 29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting The Engine 29. . . . . . . . . .

Starting A Cold Engine 30. . . . . . . . . . . . . .

Engine Warm Up 30. . . . . . . . . . . . . . . . . . .

Engine Shut-Down (Stopping) 31. . . . . . .

Freezing Temperature And Cold

Weather Operation 32. . . . . . . . . . . . . . . . . . .

Drain Plug and Bilge Pump 32. . . . . . . . . . . .

Protecting People In The Water 33. . . . . . . . .

SECTION 4 - SPECIFICATIONS

Fuel Requirements 42. . . . . . . . . . . . . . . . . . . . .

Diesel Fuel In Cold Weather 43. . . . . . . . . . . . .

AntiFreeze/Coolant 43. . . . . . . . . . . . . . . . . . . . .

Engine Oil 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

While You Are Cruising 33. . . . . . . . . . . . . . . .

While Boat Is Stationary 33. . . . . . . . . . . . . . .

High-Speed And High-Performance

Boat Operation 33. . . . . . . . . . . . . . . . . . . . . . . .

Passenger Safety Message - Pontoon

And Deck Boats 34. . . . . . . . . . . . . . . . . . . . . . .

Wave And Wake Jumping 35. . . . . . . . . . . . . . .

Impact With Underwater Hazards 36. . . . . . . .

Conditions Affecting Operation 37. . . . . . . . .

Weight Distribution (Passengers And

Gear) Inside The Boat 37. . . . . . . . . . . . . . . .

Bottom Of Boat 37. . . . . . . . . . . . . . . . . . . . . . .

Elevation And Climate 37. . . . . . . . . . . . . . . . .

Propeller Selection 38. . . . . . . . . . . . . . . . . . . .

Getting Started 39. . . . . . . . . . . . . . . . . . . . . . . . .

Initial Break-In Procedure 39. . . . . . . . . . . . . .

20-Hour Break-In Period 39. . . . . . . . . . . . . . .

After Break-In Period 40. . . . . . . . . . . . . . . . . .

End of First Season Checkup 40. . . . . . . . . .

Engine Specifications 46. . . . . . . . . . . . . . . . . .

2.8 EI 200 46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Specifications 47. . . . . . . . . . . . . . . . . . . .

Page ii CMD-4081877 / 90-865861040 MARCH 2004

Page 7

SECTION 5 - MAINTENANCE

Owner/Operator Responsibilities 50. . . .

Dealer Responsibilities 50. . . . . . . . . . . . . . . . .

Maintenance 51. . . . . . . . . . . . . . . . . . . . . . . . . . .

Do-It-Yourself Maintenance

Suggestions 52. . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 52. . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedules 53. . . . . . . . . . . . . . .

Routine Maintenance 53. . . . . . . . . . . . . . . . . .

Scheduled Maintenance 54. . . . . . . . . . . . . . .

Maintenance Record 55. . . . . . . . . . . . . . . . . .

Engine Oil 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking 57. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Oil and Filter 59. . . . . . . . . . . . . . . .

2.8 ES 200 59. . . . . . . . . . . . . . . . . . . . . . . .

Transmission Fluid 61. . . . . . . . . . . . . . . . . . . . .

Checking 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing 63. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant 65. . . . . . . . . . . . . . . . . . . . . . . .

Checking 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Filter 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement 68. . . . . . . . . . . . . . . . . . . . . . . . .

Water Separating Fuel Filter 69. . . . . . . . . . . .

Draining 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 74. . . . . . . . . . . . . . . . . . . . . . .

Priming 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling (Bleeding) 74. . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Cleaning And Flushing 74. . . . . . .

Lubrication 75. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shift Cable 75. . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Cable 75. . . . . . . . . . . . . . . . . . . . . . . .

Drive Belts 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Serpentine Belt 76. . . . . . . . . . . . . .

Corrosion Protection 78. . . . . . . . . . . . . . . . . . .

Antifouling Paints 78. . . . . . . . . . . . . . . . . . . . .

Internal Components 78. . . . . . . . . . . . . . . . . .

Removal 78. . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 79. . . . . . . . . . . . . . . . . . . . . . . . .

Repair 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 80. . . . . . . . . . . . . . . . . . . . . . . .

Seawater System 80. . . . . . . . . . . . . . . . . . . . . . .

Draining The Seawater System 80. . . . . . . . .

Cleaning The Seawater Strainer, If

Equipped 83. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing The Seawater System 84. . . . . . . . .

Checking The Water Pickups 86. . . . . . . . . . .

Though The Hull Or Through The

Transom Pickups 86. . . . . . . . . . . . . . . . . .

Battery 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multiple Electronic Control Engine

Battery Precautions 87. . . . . . . . . . . . . . . . . .

Situation 87. . . . . . . . . . . . . . . . . . . . . . . . . .

Recommendations 87. . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page iii

Page 8

SECTION 6 - STORAGE AND RECOMMISSIONING

Cold Weather (Freezing Temperature),

Seasonal, And Extended Storage 90. . . . . . .

Cold Weather (Freezing Temperature)

Storage 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing Your Power Package For

Seasonal or Extended Storage 91. . . . . . . . .

Seasonal Storage Instructions 92. . . . . . . . . .

Extended Storage Instructions 93. . . . . . . . . .

Recommissioning 94. . . . . . . . . . . . . . . . . . . . . .

SECTION 7 - TROUBLESHOOTING

Diagnosing Electronically Controlled Fuel

System Problems 98. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Charts 98. . . . . . . . . . . . . . . .

Starter Motor Will Not Crank Engine,

Or Cranks Slow 98. . . . . . . . . . . . . . . . . . . . . .

Engine Will Not Start, Or Is Hard To

Start 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Runs Rough, Misses And/Or

Backfires 100. . . . . . . . . . . . . . . . . . . . . . . . . . .

Poor Performance 100. . . . . . . . . . . . . . . . . . .

Excessive Engine Temperature 101. . . . . . . .

Insufficient Engine Temperature 101. . . . . . .

Low Engine Oil Pressure 102. . . . . . . . . . . . .

Battery Will Not Charge 102. . . . . . . . . . . . . . .

Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes

Unusual Sounds 102. . . . . . . . . . . . . . . . . . . .

SECTION 8 - CUSTOMER ASSISTANCE INFORMATION

Owner Service Assistance 104. . . . . . . . . . . . .

Local Repair Service 104. . . . . . . . . . . . . . . . .

Service Away From Home 104. . . . . . . . . . . .

Stolen Power Package 104. . . . . . . . . . . . . . .

Attention Required After Submersion 104. . .

Replacement Service Parts 105. . . . . . . . . . .

Parts And Accessories Inquiries 105. . . . . . .

Resolving A Problem 106. . . . . . . . . . . . . . . . .

Customer Service Literature 107. . . . . . . . . . .

English Language 107. . . . . . . . . . . . . . . . . . .

Other Languages 107. . . . . . . . . . . . . . . . . . . .

Andre sprog 107. . . . . . . . . . . . . . . . . . . . . . . . .

Andere talen 107. . . . . . . . . . . . . . . . . . . . . . . .

Muut kielet 107. . . . . . . . . . . . . . . . . . . . . . . . . .

Autres langues 107. . . . . . . . . . . . . . . . . . . . . .

Andere Sprachen 108. . . . . . . . . . . . . . . . . . . .

Altre lingue 108. . . . . . . . . . . . . . . . . . . . . . . . .

Andre språk 108. . . . . . . . . . . . . . . . . . . . . . . . .

Outros Idiomas 108. . . . . . . . . . . . . . . . . . . . . .

Otros idiomas 108. . . . . . . . . . . . . . . . . . . . . . .

Andra språk 108. . . . . . . . . . . . . . . . . . . . . . . . .

Allej glþssej 108. . . . . . . . . . . . . . . . . . . . . .

Ordering Literature 109. . . . . . . . . . . . . . . . . . . .

United States and Canada 109. . . . . . . . . . . .

Outside The United States and

Canada 109. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page iv CMD-4081877 / 90-865861040 MARCH 2004

Page 9

SECTION 1SECTION 1

SECTION 1 - WARRANTY

Table of Contents

WARRANTY

Warranty Information 2. . . . . . . . . . . . . . . . . . . .

Owner Warranty Registration 2. . . . . . . . . . . .

United States And Canada Only 2. . . . . .

International Owner Registration 3. . . . . . . . .

Outside The United States And

Canada 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .

Recreational Use Diesel Limited

Warranty 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What Is Covered 4. . . . . . . . . . . . . . . . . . . .

Duration Of Coverage 4. . . . . . . . . . . . . . .

Conditions That Must Be Met In Order

To Obtain Warranty Coverage 4. . . . . . . .

What Cummins Mercruiser Diesel Will

Do 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How To Obtain Warranty Coverage 5. . . .

What Is Not Covered 5. . . . . . . . . . . . . . . .

DISCLAIMERS AND LIMITATIONS 5. . . .

Warranty Coverage and Exclusion 6. . . . . . .

Warranty Does Not Apply To The

Following: 6. . . . . . . . . . . . . . . . . . . . . . . . .

Transferable Warranty 8. . . . . . . . . . . . . . . . . . .

Direct Sale By Owner 8. . . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page 1

Page 10

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. The dealer also certifies that you are the original purchaser and user of the product.

• Upon receipt of the Warranty Registration Card at the factory, you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification. It must be presented to the servicing dealer should warranty service be required. Warranty claims will not be accepted without presentation of this card.

• A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed. Should your product need service during this period, present the temporary registration card to the dealer. He will attach it to your warranty claim form.

• Because of your selling dealer’s continuing personal interest in your satisfaction, the product should be returned to him for warranty service.

• If your plastic card is not received within 30 days from date of new product sale, please contact your selling dealer.

• The product warranty is not effective until the product is registered at the factory.

• NOTICE: Registration lists must be maintained by factory and dealer on marine

products sold in the United States, should notification under the Federal Boat Safety Act be required.

• You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser’s warranty registration department. Your dealer can also process this change of information.

Mercury Marine

Attn: Warranty Registration Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54935-1939

Phone: 920-929-5054

Fax: 920-929-5893

Page 2 CMD-4081877 / 90-865861040 MARCH 2004

Page 11

SECTION 1SECTION 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.

• The Warranty Registration Card identifies your name and address, product model

and serial number(s), date of sale, type of use and the selling distributor’s/dealer’s code number, name and address. The distributor/dealer also certifies that you are the original purchaser and user of the product.

• A copy of the Warranty Registration Card, designated as the “Purchaser’s Copy”,

MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification, and should be retained by you for future use when required. Should you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form(s).

• In some countries, the Marine Power Service Center will issue you a permanent

(plastic) Warranty Registration Card within 30 days after receiving the “Factory Copy” of the Warranty Registration Card from your distributor / dealer. If you receive a plastic Warranty Registration Card, you may discard the “Purchaser’s Copy” that you received from the distributor / dealer when you purchased the product. Ask your distributor / dealer if this plastic card program applies to you.

WARRANTY

• For further information concerning the Warranty Registration Card and its

relationship to Warranty Claim processing, refer to the “International Warranty.” Refer to “Table of Contents.”

IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your dealer / distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.

CMD-4081877 / 90-865861040 MARCH 2004 Page 3

Page 12

WARRANTY SECTION 1

CE547

Warranty Policies

Recreational Use Diesel Limited Warranty

WHAT IS COVERED

Cummins MerCruiser Diesel 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. Commercial use of the product voids the warranty. Commercial use is defined as any work or employment related use of the product, or any use of the product which generates income, for any part of the warranty period, even if the product is only occasionally used for such purposes. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon proper re-registration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial use customer.

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE

Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins MerCruiser Diesel to distribute the product in the country in which the sale occurred, and then only after the Cummins MerCruiser Diesel specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless properly re-registered) may void the warranty at the sole discretion of Cummins MerCruiser Diesel. Routine maintenance outlined in the Operation, Maintenance, and Warranty Manual must be timely performed in order to obtain warranty coverage. Cummins MerCruiser Diesel reserves the right to make any warranty coverage contingent upon proof of proper maintenance.

WHAT CUMMINS MERCRUISER DIESEL WILL DO

Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Cummins MerCruiser Diesel product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

Page 4 CMD-4081877 / 90-865861040 MARCH 2004

Page 13

SECTION 1SECTION 1

HOW TO OBTAIN WARRANTY COVERAGE

The customer must provide Cummins MerCruiser Diesel 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 Cummins MerCruiser Diesel dealer / distributor authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Cummins MerCruiser Diesel. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Cummins MerCruiser Diesel, ship the product or parts of the product directly to Cummins MerCruiser Diesel. The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage.

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to operate at the recommended Engine Rated rpm, operation of the product in a manner inconsistent with the recommended operation / duty cycle section of the Operation, Maintenance, And Warranty Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part which damages the Cummins MerCruiser Diesel product and was not manufactured or sold by us, jet pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation, Maintenance, And Warranty Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. Use of the product for racing or other competitive activity, or operating with a racing type lower unit, at any point, even by a prior owner of the product, voids the warranty.

WARRANTY

Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty.

No individual or entity, including Cummins MerCruiser Diesel authorized dealers, has been given authority by Cummins MerCruiser Diesel to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Cummins MerCruiser Diesel.

DISCLAIMERS AND LIMITATIONS

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.

CMD-4081877 / 90-865861040 MARCH 2004 Page 5

Page 14

WARRANTY SECTION 1

CE552

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.

Should you have any questions concerning warranty coverage contact your authorized dealer. They will be pleased to answer any questions that you may have.

WARRANTY DOES NOT APPLY TO THE FOLLOWING:

• Minor adjustments or checks, including checking fuel injection pump timing, cleaning fuel injectors, filters, or adjusting belts, controls, and checking lubrication made in connection with normal services.

• Damage caused by neglect, lack of maintenance, accident, abnormal operation, improper installation or service, or freezing temperatures.

• Haul-out, launch, towing charges; removal and/or replacement of boat partitions or material because of boat design for necessary access to the product; all related transportation charges and/or travel time, etc. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an Authorized Dealer.

• Additional service work requested by customer other than that necessary to satisfy the warranty obligation.

• Labor performed by other than an Authorized Dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility).

• All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner’s responsibility.

Page 6 CMD-4081877 / 90-865861040 MARCH 2004

Page 15

SECTION 1SECTION 1

WARRANTY

• 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. If diagnosis

indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty.

• Lower unit and/or propeller damage caused by striking a submerged object is

considered a marine hazard.

• Water entering the engine via the air filter or exhaust system or submersion. Also,

water in the starter motor.

• Starter motors and/or armatures or field coil assembly, which are burned, or where

lead is thrown out of commutator because of excess cranking.

• Valve or valve seat grinding required because wear.

• Failure of any parts caused by lack of cooling water, which results from starting

power package out of water, foreign material blocking inlets or power package being mounted too high.

• Use of fuels and lubricants that are not suitable for use with or on the product. Refer

to your Operation, Maintenance, And Warranty Manual.

• Our limited warranty does not apply to any damage to our products caused by the

installation or use of parts and accessories that are not manufactured or sold by us. Failures that are not related to the use of those parts or accessories, are covered under warranty, if they otherwise meet the terms of the limited warranty for that product.

CMD-4081877 / 90-865861040 MARCH 2004 Page 7

Page 16

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.

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. In the United States and Canada, mail to:

Mercury Marine

Attn: Warranty Registration Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54935-1939

• A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration records will be changed on the factory computer registration file.

• There is no charge for this service.

Outside the United States and Canada, please contact the distributor in your country, or the Marine Power International Service Center closest to you, for the transferable warranty procedure that would apply to you.

Page 8 CMD-4081877 / 90-865861040 MARCH 2004

Page 17

SECTION 2

SECTION 2 - GETTING TO KNOW YOUR POWER

Table of Contents

Features And Controls 10. . . . . . . . . . . . . . . . .

Lanyard Stop Switch 10. . . . . . . . . . . . . . . . . .

Instrumentation 12. . . . . . . . . . . . . . . . . . . . . . .

Remote Controls 15. . . . . . . . . . . . . . . . . . . . .

Panel Mounted 15. . . . . . . . . . . . . . . . . . . .

Console Mounted 16. . . . . . . . . . . . . . . . . .

Electrical System Overload Protection 17. . .

GETTING TO KNOW YOUR POWER PACKAGE

PACKAGE

Audio Warning System 18. . . . . . . . . . . . . . . .

Testing The Audio Warning System 18. . .

Emissions Information 19. . . . . . . . . . . . . . . . .

Exhaust Gas Emissions Certificate

(Europe Only) 19. . . . . . . . . . . . . . . . . . . . . . .

Owner Responsibility 19. . . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page 9

Page 18

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).

SECTION 2

74608

a-Stop switch b-Lanyard c-Clips to the operator

Accidental ejections, such as falling overboard, are more likely to occur in:

• low sided sport boats

• bass boats

• high performance boats

Accidental ejections can also occur from:

• poor operating practices

• sitting on the seat or gunwale at planing speeds

• standing at planing speeds

• operating at planing speeds in shallow or obstacle infested waters

• releasing your grip on the steering wheel that is pulling in 1 direction

• consuming alcohol or drugs

• high speed boating maneuvers

Some remote control units are equipped with a lanyard stop switch, if your remote control is not equipped with a lanyard stop switch one can be installed on the dashboard or side adjacent to the operator’s position. The lanyard is a cord usually 1.2 - 1.5 m (4 - 5 ft) long when stretched out with an element on 1 end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make it as short as possible to minimize the likelihood of entanglement with nearby objects. It stretches to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator’s position. To shorten the lanyard, wrap it around the operator’s wrist or leg, or tie a knot in the lanyard.

Page 10 CMD-4081877 / 90-865861040 MARCH 2004

Page 19

SECTION 2

GETTING TO KNOW YOUR POWER PACKAGE

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.

We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).

WARNING

Avoid contact with the boat hull and propeller from accidental ejection. Personal injury or death could occur. Always properly connect both ends of the lanyard stop switch.

Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion, a

particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller.

• Loss of power and directional control in heavy seas, strong current or high winds.

• Loss of control when docking.

WARNING

Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat damage and personal injury or death could occur. NEVER leave the operator’s station with the engine operating and in gear.

CMD-4081877 / 90-865861040 MARCH 2004 Page 11

Page 20

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.

a b c d

SECTION 2

70514

71856

e f g h

70518

70519

71856

70521

Typical

a-Speedometer b-Tachometer c-Oil pressure gauge d-Battery meter

e-Coolant temperature gauge

f-Fuel gauge g-Hour meter h-Power trim gauge

Speedometer: Indicates boat speed.

Tachometer: Indicates engine rpm.

Oil Pressure Gauge: Indicates engine oil pressure.

Battery Meter: Indicates battery voltage.

71856

Coolant Temperature Gauge: Indicates engine operating temperature.

Fuel Gauge: Indicates quantity of fuel in tank.

Hour Meter: Records engine operating time.

Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in). Sterndrive

Models only.

Page 12 CMD-4081877 / 90-865861040 MARCH 2004

Page 21

SECTION 2

a modified CD934 and CD860

SWITCHES

GETTING TO KNOW YOUR POWER PACKAGE

73547

71891

70522

79996

Typical switches

a-Key switch b-Panel lights / audio test switch c-Bilge blower switch

Key Switch - has three positions.

1. OFF - In the OFF position, all electrical circuits are off and engine cannot be started. The engine is stopped when the key switch is turned to the OFF position.

2. RUN - In the RUN position, all electrical circuits, indicator lamps, automatic preheating (if equipped) and all instruments are operational.

3. START - In the START position the engine can be started.

NOTE: Key can only be removed in the OFF position.

Panel Lights / Audio Test Switch - has three positions; in the NORMAL position all electrical circuits operate in a standard fashion (as described above). With switch toggled UP the instrumentation lights are all illuminated. When the switch is toggled DOWN the audio warning horn will sound allowing the operator to perform a test of the audio warning horn.

Bilge Blower Switch: Operates bilge blower.

CMD-4081877 / 90-865861040 MARCH 2004 Page 13

Page 22

GETTING TO KNOW YOUR POWER PACKAGE

CE479 and CD860

ENGINE MONITORING FEATURES

a b c d e

Typical

a-Malfunction indicator lamp b-Water-in-fuel warning lamp, if equipped c-Coolant temperature warning lamp d-Oil pressure warning lamp e-Charge indicator lamp

f-Preheat indicator lamp

The appropriate lamp functions as follows:

Malfunction Indicator Lamp (MIL) - additional lamp indicates when a problem exists, or a malfunction has occurred, that requires service.

SECTION 2

77359

Water-In-Fuel Warning Lamp, if equipped - indicates water is present in fuel filter and that

fuel filter requires service.

Coolant Temperature Warning Lamp - indicates excessive engine coolant temperature if lamp illuminates while engine is running, or transmission fluid temperature is too high Refer to the following note.

NOTE: The audio warning alarms are wired in a parallel circuit. If an alarm sounds while the engine is operating, quickly observe the coolant temperature gauge. If coolant temperature gauge reading is normal this may be an indication of excessive transmission temperature. The cause should be determined and corrected.

Oil Pressure Warning Lamp - indicates low engine oil pressure if lamp illuminates while engine is operating.

Charge Indicator Lamp - indicates a problem with charging system if lamp illuminates while engine is operating. Lamp will be on when key switch is in RUN and engine is not operating. When engine starts, light should go off.

Preheat Indicator Lamp - indicates when the glow plugs, if equipped, are preheating the combustion chambers. When the engine is cold the timed preheat period begins when the key switch is turned to RUN. The light stays on until the preheat period is complete. The engine can be started only after the light goes out.

Page 14 CMD-4081877 / 90-865861040 MARCH 2004

Page 23

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.

0015.03

PANEL MOUNTED

GETTING TO KNOW YOUR POWER PACKAGE

a-Neutral lock button b-Throttle only button c-Lanyard stop switch d-Control handle throttle friction screw e-Control handle

77019

Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed IN to move the control handle out of NEUTRAL.

Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.

Lanyard Stop Switch - Turns the ignition OFF whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.

Control Handle Throttle Friction Screw - This screw (located behind the bezel cover) can be adjusted to increase or decrease the tension on the control handle. This will help prevent slipping of the remote control handle. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear. Continue pushing forward to increase speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear and continue pushing back to increase speed.

CMD-4081877 / 90-865861040 MARCH 2004 Page 15

Page 24

GETTING TO KNOW YOUR POWER PACKAGE

0242.01

CONSOLE MOUNTED

SECTION 2

79769

a-Throttle only button b-Control handles

Throttle Only Button - Allows engine throttle advancement without shifting the engine. This

is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position, and should only be used to assist in starting the engine.

Control Handle Tension Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed to adjust). This will help prevent slipping of the remote control handle. Turn screw clockwise to increase tension and counterclockwise to decrease tension. Adjust to tension desired.

Control Handles - Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear and continue pushing forward to increase speed. Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear and continue pushing back to increase speed.

79770

Page 16 CMD-4081877 / 90-865861040 MARCH 2004

Page 25

SECTION 2

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.

NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized Cummins MerCruiser Diesel dealer / distributor.

00000 was CD862

1. Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN (on outside of electrical box).

2. The Engine Control Module (ECM) is protected from overload by a 5 amp in-line fuse inside the electrical box. Additional fuses are located inside the electrical box.

GETTING TO KNOW YOUR POWER PACKAGE

79930

a-Electrical box b-Circuit breaker c-ECM fuse

3. A 20 amp. fuse located in-line on key switch power supply wire and protects the instrumentation and wiring should an electrical overload occur. If an overload occurs, the fuse will burn out. Check blown (burned) fuse if key is turned to RUN or START and instruments do not work and/or if switches do not function (and a circuit breaker is not tripped).

a-Key switch power supply wire b-20 amp. fuse holder

CMD-4081877 / 90-865861040 MARCH 2004 Page 17

77421

Page 26

GETTING TO KNOW YOUR POWER PACKAGE

CE480

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 or transmission from damage. It is designed to warn the operator that a problem has occurred.

The audio warning system will sound with a continuous alarm if one of the following occurs:

• Engine oil pressure too low

• Coolant temperature too hot

• Transmission fluid temperature too hot

SECTION 2

Typical oil pressure gauge Typical coolant temperature gauge

Typical transmission fluid temperature switch

Operation of the engine after the audio warning system alarm has sounded could result in damage to the power package. Do not operate engine once the alarm has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION.

If the alarm sounds, stop the engine immediately. Investigate the cause and correct it, if possible. If the cause cannot be determined, consult your authorized Cummins MerCruiser Diesel dealer / distributor.

00000 – a modified 0128 from CE480

TESTING THE AUDIO WARNING SYSTEM

70516

70518

79753

CAUTION

1. Turn the ignition switch to the ON position without cranking the engine.

2. Engage the audio test switch and hold.

3. Listen for the alarm to sound indicating that the system is functioning correctly.

Page 18 CMD-4081877 / 90-865861040 MARCH 2004

Page 27

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. Please note that the exhaust gas emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and Dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Cummins MerCruiser Diesel about the availability of replacement decals before proceeding.

GETTING TO KNOW YOUR POWER PACKAGE

a-Engine serial number b-Engine family c-Maximum rpm d-Power and weight e-“IMO” - Exhaust Gas Emissions Certificate Number

Owner Responsibility

The owner/operator is not to modify the engine in any matter that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications.

SERIAL NUMBER

P L B

MARINE POWER

EUROPE INC

MADE IN ITALY

MAX

RPM

K W K G

78445

CMD-4081877 / 90-865861040 MARCH 2004 Page 19

Page 28

GETTING TO KNOW YOUR POWER PACKAGE

SECTION 2

NOTES:

Page 20 CMD-4081877 / 90-865861040 MARCH 2004

Page 29

SECTION 3

SECTION 3 - ON THE WATER

Table of Contents

ON THE WATER

Safe Boating Suggestions 22. . . . . . . . . . . . . .

Be Alert To Carbon Monoxide

Poisoning 24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Good Ventilation 25. . . . . . . . . . . . . . . . . . .

Poor Ventilation 25. . . . . . . . . . . . . . . . . . . .

Basic Boat Operation 26. . . . . . . . . . . . . . . . . . .

Launching And Boat Operation Care 26. . . .

Duty Cycle Rating 27. . . . . . . . . . . . . . . . . . . .

Pleasure Duty Rating 27. . . . . . . . . . . . . . .

Operation Chart - 2.8 EI 200 28. . . . . . . . . . .

Starting, Shifting and Stopping -

2.8 EI 200 29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting The Engine 29. . . . . . . . . .

Starting A Cold Engine 30. . . . . . . . . . . . . .

Engine Warm Up 30. . . . . . . . . . . . . . . . . . .

Engine Shut-Down (Stopping) 31. . . . . . .

Freezing Temperature And Cold

Weather Operation 32. . . . . . . . . . . . . . . . . . .

Drain Plug and Bilge Pump 32. . . . . . . . . . . .

Protecting People In The Water 33. . . . . . . . .

While You Are Cruising 33. . . . . . . . . . . . . . . .

While Boat Is Stationary 33. . . . . . . . . . . . . . .

High-Speed And High-Performance

Boat Operation 33. . . . . . . . . . . . . . . . . . . . . . . .

Passenger Safety Message - Pontoon

And Deck Boats 34. . . . . . . . . . . . . . . . . . . . . . .

Wave And Wake Jumping 35. . . . . . . . . . . . . . .

Impact With Underwater Hazards 36. . . . . . . .

Conditions Affecting Operation 37. . . . . . . . .

Weight Distribution (Passengers And

Gear) Inside The Boat 37. . . . . . . . . . . . . . . .

Bottom Of Boat 37. . . . . . . . . . . . . . . . . . . . . . .

Elevation And Climate 37. . . . . . . . . . . . . . . . .

Propeller Selection 38. . . . . . . . . . . . . . . . . . . .

Getting Started 39. . . . . . . . . . . . . . . . . . . . . . . . .

Initial Break-In Procedure 39. . . . . . . . . . . . . .

20-Hour Break-In Period 39. . . . . . . . . . . . . . .

After Break-In Period 40. . . . . . . . . . . . . . . . . .

End of First Season Checkup 40. . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page 21

Page 30

ON THE WATER

00000 was 0022 w / CMD changes orCE554

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. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline at 1-800-368-5647 or the Boat U.S. Foundation at 1-800-336-BOAT.

You should also review the NMMA Sources of Waterway Information booklet. It lists regional sources of safety, cruising and local navigation and is available at no charge by writing to:

Sources of Waterway Information National Marine Manufacturers Association 410 N. Michigan Avenue Chicago, IL 60611 U.S.A.

SECTION 3

• Perform safety checks and required maintenance. Follow a regular schedule and

ensure that all repairs are properly made.

• Check safety equipment on board. Here are some suggestions of the types of

safety equipment to carry when boating:

Approved fire extinguishers Paddle or oar

Signal devices: flashlight, rockets or flares, flag and whistle or horn

Spare propeller, thrust hubs, and an appropriate wrench

Tools necessary for minor repairs First aid kit and instructions

Anchor and extra anchor line Water-proof storage containers

Manual bilge pump and extra drain plugs

Spare operating equipment, batteries, bulbs and fuses

Drinking water Compass and map or chart of the area

Transistor radio

Page 22 CMD-4081877 / 90-865861040 MARCH 2004

Page 31

SECTION 3

ON THE WATER

• 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. Coast Guard approved, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for every person on board, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

• Prepare other boat operators. Instruct at least 1 person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

• Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Cummins MerCruiser Diesel dealer / distributor or the boat manufacturer.

• Ensure that everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

• 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.

CMD-4081877 / 90-865861040 MARCH 2004 Page 23

Page 32

ON THE WATER

• 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.

• Never drive your boat directly behind a water skier in case the skier falls. As an

example, your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who was 61 m (200 ft) in front of you in 5 seconds.

• Watch fallen skiers. When using your boat for water skiing or similar activities,

always keep a fallen or down skier on the operator’s side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

• Report accidents. Boat operators are required by law to file a Boating Accident

Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if (1) there is loss of life or probable loss of life, (2) there is personal injury requiring medical treatment beyond first aid, (3) there is damage to boats or other property where the damage value exceeds $500.00 or (4) there is complete loss of the boat. Seek further assistance from local law enforcement.

0023

Be Alert To Carbon Monoxide Poisoning

SECTION 3

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.

Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness and nausea.

WARNING

Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to unconsciousness, brain damage or death. Ensure that the boat, while at rest or underway, is well ventilated.

Page 24 CMD-4081877 / 90-865861040 MARCH 2004

Page 33

SECTION 3

0024.01

GOOD VENTILATION

Ventilate the passenger area by opening the side curtains or forward hatches to remove fumes.

ON THE WATER

0025.01

POOR VENTILATION

Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide.

mc79553

Courtesy of ABYC

Example of desired air flow through the boat

mc79554

Example of poor ventilation while a boat is stationary:

a-Operating the engine when the boat is moored in a confined space. b-Mooring close to another boat with its engine operating.

Courtesy of ABYC

Example of poor ventilation while a boat is moving:

a-Operating the boat with the trim angle of the bow too high. b-Operating the boat with no forward hatches open (station wagon effect).

CMD-4081877 / 90-865861040 MARCH 2004 Page 25

mc79556

Courtesy of ABYC

Page 34

ON THE WATER

0026

Basic Boat Operation

0027.1

Launching And Boat Operation Care

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.

• When coming off plane, if a large following wave may roll over the boat’s

transom, apply a short, light burst of throttle to minimize the wave action against the stern of the boat.

• Do not come off plane quickly, shift into reverse and shut off engine.

IMPORTANT: Install bilge drain plug prior to launching boat.

SECTION 3

CAUTION

Page 26 CMD-4081877 / 90-865861040 MARCH 2004

Page 35

SECTION 3

Cycle 5 / ICOMIA 83-28

CE465 or similar to 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 Cummins 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. In all cases, the power package must be equipped with a propeller that will allow the engine to operate at wide open throttle (WOT) at the Rated Engine rpm.

PLEASURE DUTY RATING

The Pleasure Duty Rating applies to recreational planing craft used exclusively for pleasure and recreation. Typical applications include pleasure craft such as sailboats, ski boats, runabouts, speedboats, and other planing hulls. Application must conform to the Pleasure Craft / Recreational duty cycle shown (EPA Mode Number Cycle 5 / ICOMIA 83-28 Duty Cycle).

ON THE WATER

EPA Mode Number

Modes

Duty Cycle

1 2 3 4 5

Engine Speed (Percent of WOT) 100 91 80 63 Idle

Engine Power (Percent of Total) 100 75 50 25 0

Time At Given Mode

8 13 17 32 30

(Percent Of Total Operating Time)

Chart showing full power operation is limited to a maximum of 1 of 12 hours

a-Mode 1: 1.0 hour (8 percent) b-Mode 2: 1.5 hours (13 percent) c-Mode 3: 2.0 hours (17 percent) d-Mode 4: 4.0 hours (32 percent) e-Mode 5: 3.5 hours (30 percent)

79175

CMD-4081877 / 90-865861040 MARCH 2004 Page 27

Page 36

ON THE WATER

00000 was CD864 with header change

Operation Chart - 2.8 EI 200

SECTION 3

STARTING

PROCEDURE

Open engine hatch. Air out bilge completely.

Turn battery switch ON, if so equipped.

Turn on and run engine compartment bilge blower, if so equipped, for five minutes.

Check for leaks - fuel, oil, water, fluid, etc.

Open fuel shutoff valve, if so equipped.

Open seacock, if so equipped.

AFTER

STARTING

Observe all gauges and warning lights to check condition of engine. If not normal, stop engine.

Check for fuel, oil, water, fluid, and exhaust leaks, etc.

Check shift and throttle control operation.

Check steering operation.

WHILE

UNDERWAY

Frequently observe all gauges and indicator lights to monitor engine condition.

STOPPING & SHUT DOWN

Shift remote control lever to neutral position.

Operate engine at idle speed several minutes to allow the turbocharger and engine to cool.

Turn key switch to OFF position.

Turn battery switch, if so equipped, to OFF.

Close fuel shutoff valve, if so equipped.

Close seacock, if so equipped.

Prime fuel injection system, if necessary.

Turn key switch to RUN and check that lights and indicator lamps come on.

Turn key switch to START, after indicator lamp for the glow plugs (if so equipped) ceases. Release key when the engine starts.

Check that charge indicator and oil pressure indicator lamps cease AFTER engine starts.

Warm-up engine at idle rpm for several minutes.

Flush seawater cooling circuit, if operating in saltwater area.

Page 28 CMD-4081877 / 90-865861040 MARCH 2004

Page 37

SECTION 3

00000 was CD863 with changes to Engine Oil bullet point

Starting, Shifting and Stopping - 2.8 EI 200

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.

BEFORE STARTING THE ENGINE

CAUTION

Do not operate engine without water flowing thru seawater pickup pump, as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result.

IMPORTANT: Observe the following before starting:

• Provide water to the seawater pickup pump.

ON THE WATER

• Never operate the starter motor longer than 15 seconds at a time, to avoid overheating the starter motor. If engine does not start, wait 1 minute to allow the starter motor to cool; then, repeat starting procedure.

• Ensure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. Refer to Specifications - Engine Oil.

• Ensure all electrical connections are secure.

• Check the air cleaner for proper installation of filter element.

1. Check all items listed in the Maintenance Schedules and Operation Chart. Refer to Table Of Contents.

2. Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner’s manual.

CMD-4081877 / 90-865861040 MARCH 2004 Page 29

Page 38

ON THE WATER

00000 was CE298 w changes in all with revision bars

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.

2. Place control handle in NEUTRAL.

3. If engine has not been run for a period of time and will not readily start with the standard starting procedure, there is a hand pump/primer knob located on the fuel filter header. Move knob up and down four or five strokes. Attempt to start engine following normal procedure.

4. Turn key switch to the RUN position. Observe indicator lamp for glow plugs, if so equipped. When cylinder temperature is great enough to sustain combustion, the indicator lamp will go off and the engine can be started.

5. Turn key switch to START position. Release the key and allow the switch to return to RUN position when the engine starts.

IMPORTANT: Within seconds after starting the engine, the oil pressure should exceed 10 psi (69 kPa) minimum. If the oil pressure does not meet these minimum limits, stop the engine, locate and correct the problem, or see your authorized Cummins MerCruiser Diesel dealer or distributor if you are unable to determine the problem.

SECTION 3

6. Ensure charge indicator and oil pressure warning lamps are off.

Do not increase the engine speed until the oil pressure gauge indicates normal. Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start.

00000 wasCE31 with changes to all

ENGINE WARM UP

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. The warm-up period provides time for the lubricating oil to establish a film between moving parts.

NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed. Commence normal vessel operation when systems reach operating temperatures.

CAUTION

3. Inspect the power package for fuel, oil, water and exhaust leaks.

4. After the engine has reached operating temperature, oil pressure should be within range listed in the engine specifications chart. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your authorized Cummins MerCruiser Diesel dealer or distributor if you are unable to determine the problem.

Page 30 CMD-4081877 / 90-865861040 MARCH 2004

Page 39

SECTION 3

CE526

STARTING A WARM ENGINE

1. Place control handle in NEUTRAL.

2. Turn key switch to the RUN position.

3. Turn key switch to START position and release when engine starts. Ensure charge indicator and oil pressure warning lamps go off.

4. Check to ensure all instrumentation is functioning properly and indicating normal readings

CE483

SHIFTING

Never attempt to shift the transmission unless the engine is at IDLE rpm. Damage to the transmission could occur.

1. To shift unit, ensure remote control/throttle lever is in NEUTRAL. Move control/shift lever

forward to shift to FORWARD gear, or backward to shift to REVERSE. After shifting the transmission, advance the throttle to the desired setting.

2. Once underway, engine oil pressure should be within the range listed in the engine

specifications chart at maximum rpm, or wide-open-throttle. Stop the engine if oil pressure is not within this range. Locate and correct the problem, or see your authorized Cummins MerCruiser Diesel dealer / distributor if you are unable to determine the problem.

ON THE WATER

CAUTION

CD366

ENGINE SHUT-DOWN (STOPPING)

1. Place remote control lever in NEUTRAL.

Avoid damaging the turbocharger and engine. Immediate engine shutdown (stopping) after high load operation may result in permanent turbocharger bearing damage. Operate the engine at IDLE for several minutes before shut-down.

2. Operate the engine at idle speed for several minutes to allow the turbocharger and

engine to cool.

3. Turn key switch to the OFF position.

CAUTION

CMD-4081877 / 90-865861040 MARCH 2004 Page 31

Page 40

ON THE WATER

CE468

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. Damage caused by freezing IS NOT

covered by Cummins MerCruiser Diesel Limited Warranty.

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. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine.

In order to operate the engine in temperatures of 0 degrees C (32 degrees F) or lower, observe the following instructions:

• At the end of each daily operation, COMPLETELY drain seawater section of cooling system to protect against damage by freezing.

• At the end of each daily operation, drain water from water separator, if equipped. Fill fuel tank at end of daily operation to prevent condensation.

• Use required permanent-type antifreeze solution to protect components against damage by freezing.

SECTION 3

• Be sure to use proper cold weather lubrication oil, and be sure the crankcase contains a sufficient amount.

• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in optimum condition.

• At temperatures of – 20 degrees C (–4 degrees F) and below, it is recommended that you use a coolant heater to improve cold starting.

• If operating in arctic temperatures of – 29 degrees C (–20 degrees F) or lower, consult your Cummins MerCruiser Diesel dealer / distributor for information about special cold weather equipment and precautions.

Refer to Section 6 for Cold Weather or Extended Storage related information and draining instructions.

00000 was CE548 or 0031 with CMD

Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug and/or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Cummins MerCruiser Diesel Limited Warranty.

Page 32 CMD-4081877 / 90-865861040 MARCH 2004

Page 41

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. This neutral propeller rotation can cause serious injury.

While Boat Is Stationary

Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a gear case or any solid device rigidly attached to a moving boat or gear case.

ON THE WATER

WARNING

Shift into the NEUTRAL/IDLE position and shut off the engine before allowing people to swim or be in the water near your boat.

0033 w CMD changes

High-Speed And High-Performance Boat Operation

If your boat is considered a high-speed or high-performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to Hi-Performance Boat Operation booklet (90-849250-R2) from your authorized Cummins MerCruiser Diesel dealer or distributor.

CMD-4081877 / 90-865861040 MARCH 2004 Page 33

Page 42

ON THE WATER

0131.02

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. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as the result of plunging into a large wave or wake, a sudden throttle reduction or a sharp change of boat direction, could throw them over the front of boat. Falling over the front of the boat between the two pontoons will position them to come into contact with the drive unit.

1. Boats having an open front deck:

a. No one should ever be on the deck in front of the fence while the boat is in motion. Keep

all passengers behind the front fence or enclosure.

b. Persons on the front deck could easily be thrown overboard or persons dangling

their feet over the front edge could get their legs caught by a wave and pulled into the water.

SECTION 3

mc79555

Incorrect Correct

2. Boats with front-mounted, raised pedestal fishing seats:

a. These elevated fishing seats are not intended for use when the boat is traveling

faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

b. Any unexpected sudden reduction in boat speed could result in the elevated

passenger falling over the front of the boat.

mc79557

Incorrect Correct

Page 34 CMD-4081877 / 90-865861040 MARCH 2004

Page 43

SECTION 3

0034.01

Wave And Wake Jumping

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. However, when this activity is done with enough 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 cases the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

ON THE WATER

mc79675

WARNING

There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer sharply to one side.

CMD-4081877 / 90-865861040 MARCH 2004 Page 35

Page 44

ON THE WATER

0035.02

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 underwater drive components, rudder 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. Under these conditions, boat speed should be kept to a minimum planing speed of 24 to 40 km/h (15 to 25 MPH).

Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the following:

• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

SECTION 3

mc79680

• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.

• Impact damage to the underwater drive components, rudder and/or boat.

Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.

After striking a submerged object, stop engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized dealer for a thorough inspection and necessary repair.

The boat should also be checked for any hull fractures, transom fractures, water leaks.

Operating with damaged underwater drive components, rudder or boat bottom could cause additional damage to other parts of the power package, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

WARNING

Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts. Have the power package thoroughly inspected and any necessary repairs made.

Page 36 CMD-4081877 / 90-865861040 MARCH 2004

Page 45

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 and forth (bow steer)

0037

Bottom Of Boat

ON THE WATER

To maintain maximum speed, the boat bottom should be:

• Clean, free of barnacles and marine growth

• Free of distortion; nearly flat where it contacts the water

• Straight and smooth, fore and aft

Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the water inlets and cause the engine to overheat.

0039 w changes to fit these diesel engines

Elevation And Climate

NOTE: Engines equipped with an Electronic Control Module (ECM) reduce the effects of changes in elevation and climate by automatically adjusting fuel flow for weather conditions and elevation. ECM controlled engines however, do not compensate for increased loading or hull conditions.

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:

• Higher elevations

• Higher temperatures

• Low barometric pressures

• High humidity

For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the Rated Engine rpm with a normal boat load during your normal boating weather conditions.

In most cases, performance can be regained by changing to a lower pitch propeller.

CMD-4081877 / 90-865861040 MARCH 2004 Page 37

Page 46

ON THE WATER

00000 was 0040 or CE464 w rev bar indicated changes

Propeller Selection

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). Conversely, using a propeller that allows engine to operate above the specified Rated Engine rpm can increase fuel consumption and wear and will not allow engine to produce its rated horsepower.

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propellers.

IMPORTANT: The engines covered in this manual are equipped with an ECM that limits engine rpm. Be sure that propeller being used does not allow engine to run against the limiter, as a significant loss in performance will result.

NOTE: Use an accurate service tachometer to verify rpm.

Select a propeller that will allow the engine power package to operate at the Rated Engine rpm with a full load.

If full throttle operation is below the Engine Rated rpm, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the Rated Engine rpm will cause higher than normal wear and/or damage.

SECTION 3

CAUTION

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:

• Warmer weather and greater humidity cause an rpm loss (not as significant on these models).

• Operating in a higher elevation causes an rpm loss (not as significant on these models).

• Operating with a damaged propeller or dirty boat bottom causes an rpm loss.

• Operating with increased load (additional passengers, pulling skiers).

Page 38 CMD-4081877 / 90-865861040 MARCH 2004

Page 47

SECTION 3

0042

Getting Started

00000 was CD912 or CE555 with different rpms in lists

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.

IMPORTANT: Never operate the starter motor longer than 15 seconds at a time, to avoid overheating the starter motor. If engine does not start, wait 1 minute to allow the starter motor to cool; then, repeat starting procedure.

1. Refer to appropriate Starting, Shifting and Stopping section and start the engine.

Operate the engine at a fast idle until it has reached normal operating temperature.

2. Operate the engine in gear for 3 minutes at each of the following rpms: 1200 rpm, 2400

rpm and 3000 rpm.

3. Operate the engine in gear for 3 minutes at each of the following rpms: 1500 rpm, 2800

rpm and 3400 rpm.

ON THE WATER

4. Operate the engine in gear for 3 minutes at each of the following rpms: 1800 rpm, 3000

rpm and Maximum Rated Full Throttle rpm.

0041 w / change that added last bullet on 20 hour from 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 below 1500 rpm for extended periods of time for the first 10 hours.

Shift into gear as soon as possible after starting and advance the throttle above 1500 rpm if conditions permit safe operation.

• Do not operate at one speed consistently for extended periods.

• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours,

occasional operation at full throttle is permissible (5 minutes at a time maximum).

• Avoid full throttle acceleration from IDLE speed.

• Do not operate at full throttle until the engine reaches normal operating temperature.

• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption

to be high during the break-in period.

• AT END OF 20-HOUR break-in period, remove break-in oil and replace oil filter. Fill

the engine with the correct grade and viscosity oil.

CMD-4081877 / 90-865861040 MARCH 2004 Page 39

Page 48

ON THE WATER

0043 w / changes – CMD and remove last 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 full boat load. Refer to Specifications and Maintenance.

• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at WOT rpm.

0044 w / changes to CMD, or see CE476

End of First Season Checkup

At the end of the first season of operation, contact an authorized Cumins MerCruiser Diesel dealer / distributor to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year-round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

SECTION 3

Page 40 CMD-4081877 / 90-865861040 MARCH 2004

Page 49

SECTION 4

SECTION 4 - SPECIFICATIONS

Table of Contents

SPECIFICATIONS

Fuel Requirements 42. . . . . . . . . . . . . . . . . . . . .

Diesel Fuel In Cold Weather 43. . . . . . . . . . . . .

AntiFreeze/Coolant 43. . . . . . . . . . . . . . . . . . . . .

Engine Oil 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications 46. . . . . . . . . . . . . . . . . .

2.8 EI 200 46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Specifications 47. . . . . . . . . . . . . . . . . . . .

CMD-4081877 / 90-865861040 MARCH 2004 Page 41

Page 50

SPECIFICATIONS

CD164

Fuel Requirements

FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components including fuel tanks, whether plastic, metal or fiberglass, fuel lines, primers, fittings, and fuel filters should be inspected for leakage, soften, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation.

SECTION 4

WARNING

Under no circumstances should gasoline, gasohol and/or alcohol be mixed with diesel fuel for any reason. This mixture of gasoline, gasohol and/or alcohol with diesel fuel is highly flammable and produces a significant risk to the user.

IMPORTANT: Use of improper or water contaminated diesel fuel can damage your engine seriously. Use of improper fuel is considered misuse of engine, and damage caused thereby will not be covered by warranty.

Grade 2-D diesel fuel is required, meeting ASTM Standards D975 (or fuel rated Diesel DIN

51601), and having a minimum cetane rating of 45.

The Cetane number is a measure of the ignition quality of diesel fuel. Increasing the cetane number will not improve overall engine performance, but it may be necessary to raise the cetane rating for low temperature, or high altitude use. A lower cetane number could cause hard starting and slower warm-up, and could increase engine noise and exhaust emissions.

NOTE: If your engine suddenly becomes noisy after a fuel fill, you possibly received substandard fuel with a low cetane rating.

Sulphur content of the above fuel is rated at 0.50% by weight, maximum (ASTM). Limits may vary in countries outside of the United States.

On intermittent use engines, high sulphur content diesel fuel will greatly increase:

• Corrosion on metal parts.

• Deterioration of elastomer and plastic parts.

• Corrosion and extensive damage, and excessive wear of internal engine parts, par-

ticularly bearings.

• Starting and operating difficulties.

Page 42 CMD-4081877 / 90-865861040 MARCH 2004

Page 51

SECTION 4

00000 was 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.

CE528

AntiFreeze/Coolant

Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time.

Because diesel engines are high compression engines and related higher engine operating temperatures are created, the closed cooling system and engine, including related cooling passages must remain as clean as possible to provide adequate engine cooling. This can only be assured by using the proper antifreeze, water, additives and inhibitors. It is recommended that the closed cooled section of the cooling system be filled with a low silicate formula of ethylene glycol antifreeze in solution with deionized water. A low silicate formula prevents antifreeze separation which causes a silicate gelatin to form. This gelatin will block engine and heat exchanger passages causing engine overheating.

SPECIFICATIONS

CAUTION

The coolant, if not premixed, should be mixed before being added to the closed cooling system using a proper antifreeze together with deionized water. Common tap water or softened water contains unwanted minerals which can leave large deposits in the system that restrict the cooling system efficiency. In addition, additives and inhibitors introduced into acceptable coolant solutions will form a protective film on internal passages and provide protection against internal cooling system erosion.

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SPECIFICATIONS

SECTION 4

The closed cooling section should be kept filled year-round with an acceptable antifreeze/coolant solution. Do not drain closed cooled section for storage, as this will promote rusting of internal surfaces. If engine will be exposed to freezing temperatures, ensure that the closed cooled section is filled with a properly mixed antifreeze/coolant solution, to protect engine and closed cooling system to lowest temperature to which they will be exposed.

NOTE: A 50/50 antifreeze/coolant solution should be used except when operating where seawater temperatures are greater than 32 degrees C (90 degrees F), then a 25 / 75 (antifreeze / water) solution can be used for improved cooling performance.

IMPORTANT: The antifreeze/coolant used in these marine engines must be a low silicate ethylene glycol, containing special additives, and deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers, and overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer to the coolant manufacturer’s instructions.

Some acceptable types of antifreeze/coolants are listed in the following table. Refer to Maintenance Schedules for respective change intervals.

Description

Part Number

Marine Engine Coolant 92-813054A2

Fleetguard Compleat with DCA4 Fleetguard Part Number: CC2825

Obtain Locally

Quantity: 3-3/4 liters, 1 U. S. Gallon

Page 44 CMD-4081877 / 90-865861040 MARCH 2004

Page 53

SECTION 4

Engine

Obtain L

0000 0 was CD865 w changes in table

Engine Oil

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.

We strongly recommend the use of:

Description Where Used Part Number

SPECIFICATIONS

CAUTION

15W40 4-cycle Diesel Engine Oil

Engine crankcase 92-877695K1

This oil is a specially blended 15W-40 oil with Marine Additives, for all temperature operation. It exceeds requirements for API CF-2, CF-4, CG-4 and CH-4 oils.

Other recommended oils:

Description Where Used Part Number

Shell Myrina

Mopar

Texaco Ursa Super TD

Wintershall Multi-Rekord

crankcase

ocally

Veedol Turbostar

Wintershall VIiva 1

These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W-40 oil.

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SPECIFICATIONS

00000 was CD731

Engine Specifications

2.8 EI 200

SECTION 4

escription

2.8 EI 200

Engine Type In-Line 4 Cylinder Diesel

Displacement 2.8 liters ( 169 cu. in. )

Firing Order 1 - 3 - 4 - 2

Bore 94.1 mm ( 3.705 in. )

Stroke 100.1 mm ( 3.941 in. )

Specification - Inboard

Rated Engine rpm

Idle rpm in Neutral

Thermostats:

Coolant Temperature 80 - 85 ( 176 - 185 )

3800

600

Water: (2 total)1 at: 70 ( 160 )

1 at:

82 ( 180 )

Oil: 95 ( 203 )

Electrical System 12-volt Negative ( – ) Ground

Recommended Battery Rating 750 cca, 950 mca, or 180 Ah

Unit of measure shown in degrees C (degrees F).

Refer to “Conditions Affecting Operation - Propeller Selection” for additional information.

Engine at normal operating temperature.

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SECTION 4

Dexron III Automatic

Locally

0051.02

Fluid Specifications

IMPORTANT: All capacities are approximate fluid measures.

00000 was CE487 CD868 information but in table like in gas and new CMD information

ENGINE

IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines).

Capacity

All models

Engine Oil (With Filter)

Closed Cooling System

Always use the dipstick to determine the exact quantity of oil or fluid required.

00000 was CE488 w added information from CE509

TRANSMISSION

liters

(U.S. gal.)

8.9

(2.4)

11 (3)

SPECIFICATIONS

Fluid type Part Number

15W40 4-cycle Diesel

Engine Oil

92-877695K1

Marine Engine Coolant 92-813054A2

Obtain

Fleetguard Compleat

with DCA4

Locally–

Fleetguard

Part Number:

CC2825

Capacity

Model

liters

Fluid type Part Number

(U.S. qts)

ZF Marine 63A 3 (3-1/4) ZF Marine 63IV 4 (4-1/4) ZF Marine 45A 4 (4-1/4)

Always use the dipstick to determine the exact quantity of oil or fluid required.

Transmission Fluid or

Equivalent

Obtain

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SPECIFICATIONS

SECTION 4

NOTES:

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SECTION 5

SECTION 5 - MAINTENANCE

Table of Contents

MAINTENANCE

Owner/Operator Responsibilities 50. . . . . . . .