Mercury 2.8 EI 200 User Manual

CMDĆ4081877 / 90Ć865861040 304

2.8 EI 200 Diesel Inboard Models

2004, Mercury Marine

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.

1

2

7

Please record the following information:

1.

Engine Model and Horsepower

2.

Transom Assembly Serial Number
(Sterndrive)

3.

Transmission Model (Inboard)

4.

Propeller Number

1

1

79994

Engine Serial Number

Gear
Ratio

Gear
Ratio

Pitch Diameter

Sterndrive Unit Serial

Number

Transmission Serial

Number

5.

Hull Identification Number (HIN)

6.

Boat Manufacturer

7.

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

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.

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.

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

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

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

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

SECTION 1SECTION 1

SECTION 1 - WARRANTY

Table of Contents

WARRANTY

1

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

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: [phone]

Fax: [phone]

Page 2 CMD-4081877 / 90-865861040 MARCH 2004

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

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

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

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

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

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

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

2

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

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

b

c

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

a

• 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

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

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

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

SECTION 2

a modified CD934 and CD860

SWITCHES

GETTING TO KNOW YOUR POWER PACKAGE

b

a

b

a

73547

c

b

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

GETTING TO KNOW YOUR POWER PACKAGE

CE479 and CD860

ENGINE MONITORING FEATURES

n

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

f

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

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

b

c

d

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

e

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

GETTING TO KNOW YOUR POWER PACKAGE

0242.01

CONSOLE MOUNTED

SECTION 2

b

b

a

a

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

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

a

c

b

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

a

b

77421

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

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

a

b

c

H

d

P
L
B

MARINE POWER

EUROPE INC

MADE IN ITALY

MAX

RPM

K
W
K
G

d

e

78445

CMD-4081877 / 90-865861040 MARCH 2004 Page 19

GETTING TO KNOW YOUR POWER PACKAGE

SECTION 2

NOTES:

Page 20 CMD-4081877 / 90-865861040 MARCH 2004

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. . . . . . . . . .

3

CMD-4081877 / 90-865861040 MARCH 2004 Page 21

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