Mercury MerCruiser 8.2 Horizon ECT Maintance Manual
8.2
H.O.
/
Horizon
ECT
OPERATION &
MAINTENANCE
MANUAL
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to
ensure operating ease and durability.
With proper care and maintenance, you will 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 and Maintenance 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 products. We sincerely hope your boating will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine
Read This Manual Thoroughly
IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a
demonstration of actual starting and operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the
8M0113925 1215 eng
International Hazard Symbol !, may be used to alert the installer and user 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
!
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.
NOTE: Indicates information that helps in the understanding of a particular step or action.
IMPORTANT: 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 and Maintenance
Manual and thoroughly understand the operational instructions for the power package and all related accessories before
the boat is used.
WARNING
!
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
8.2 H.O./Horizon ECT
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine
power package. When contacting Mercury Marine about service, always specify model and serial numbers.
Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury
Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
© 2015 Mercury Marine
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth
in the Warranty Manual included with the product. The Warranty Manual 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.
Copyright and Trademark Information
© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Identification Records
Please record the following applicable information:
MerCruiser
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number (Europe Only)
TABLE OF CONTENTS
Section 1 - Getting to Know Your Power Package
Identification............................................................................... 2
Information Decal................................................................ 2
Quick Response (QR) Code............................................... 2
Engine Serial Number ........................................................ 3
Lanyard Stop Switch.................................................................. 3
Keep the Lanyard Stop Switch and Lanyard Cord in Good
Operating Condition............................................................. 4
Instrumentation.......................................................................... 4
VesselView......................................................................... 4
Front Controls................................................................. 5
Troll Control Speed Range Specification............................ 5
Digital Gauges.................................................................... 5
Analog Gauges................................................................... 6
Remote Controls (DTS Models)................................................. 7
Remote Controls................................................................. 7
Panel Mount Features........................................................ 7
DTS Slim Binnacle Single Handle Console Features and
Operation............................................................................ 7
Special Digital Throttle and Shift (DTS) Features...........8
Dual‑Handle Electronic Remote Control (ERC)—Operation
and Adjustment................................................................... 9
Section 2 - On the Water
Safe Boating Recommendations............................................. 20
Carbon Monoxide Exposure.................................................... 21
Be Alert To Carbon Monoxide Poisoning........................... 21
Stay Clear of Exhaust Areas.............................................. 21
Good Ventilation ................................................................ 21
Poor Ventilation ................................................................. 22
Basic Boat Operation (DTS Models)........................................ 22
Launching and Boat Operation......................................... 22
Operation Chart............................................................ 22
Starting and Stopping the Engine..................................... 23
Starting the Engine....................................................... 23
Stopping the Engine..................................................... 23
Throttle Only Operation.................................................... 24
Freezing Temperature Operation..................................... 24
Drain Plug and Bilge Pump............................................... 24
Protecting People in the Water................................................ 24
While You Are Cruising...................................................... 24
While Boat Is Stationary..................................................... 25
Operation........................................................................ 9
Adjustment......................................................................9
Special Digital Throttle and Shift (DTS) Features............. 10
Dock............................................................................. 11
Throttle Only................................................................. 11
1 Lever..........................................................................12
Sync..............................................................................12
Transfer (Boats equipped with dual helms).................. 13
Helm Transfer................................................................... 13
Zero Effort Features.......................................................... 13
Electrical System Overload Protection..................................... 14
Visual and Audio Warning Systems......................................... 15
Service Engine Light and OBD‑M MIL Kit......................... 15
Testing the OBD‑M Malfunction Indicator Lamp (MIL). 16
Audio Warning System..................................................... 16
Caution......................................................................... 16
Critical...........................................................................16
Nonconfigured Alarm–DTS Only.................................. 16
Testing the Audio Warning System.............................. 17
Guardian Strategy............................................................. 17
Transmission Guardian Strategy............................................. 17
High‑Speed and High‑Performance Operation........................ 25
Passenger Safety in Pontoon Boats and Deck Boats.............. 25
Boats Having an Open Front Deck.....................................25
Boats With Front‑Mounted, Raised Pedestal Fishing Seats
........................................................................................... 25
Wave and Wake Jumping........................................................ 26
Impact with Underwater Hazards............................................. 26
Conditions Affecting Operation................................................ 27
Weight Distribution (Passengers and Gear) Inside the
Boat.................................................................................. 27
The Bottom of the Boat..................................................... 27
Cavitation.......................................................................... 27
Elevation and Climate....................................................... 27
Getting Started......................................................................... 27
20‑Hour Break‑In Period................................................... 27
After the Break‑In Period.................................................. 28
End of First Season Checkup........................................... 28
Section 3 - Specifications
Cruising RPM........................................................................... 30
Fuel Requirements................................................................... 30
Fuel Ratings....................................................................... 30
Using Reformulated (Oxygenated) Gasoline (USA Only).. 30
Gasoline Containing Alcohol.............................................. 30
Bu16 Butanol Fuel Blends............................................ 30
Methanol and Ethanol Fuel Blends...............................30
90-8M0113925 eng DECEMBER 2015 Page i
Engine Oil................................................................................ 31
Engine Specifications............................................................... 31
Horizon 8.2 ECT and 8.2 H.O. ECT.................................. 31
Fluid Specifications.................................................................. 32
Engine............................................................................... 32
Transmission.................................................................... 32
Section 4 - Maintenance
Owner/Operator Responsibilities............................................ 34
Dealer Responsibilities........................................................... 34
Maintenance........................................................................... 34
Do‑It‑Yourself Maintenance Suggestions............................... 34
Inspection............................................................................... 35
MerCruiser Gas Inboard Inspection and Maintenance
Schedule................................................................................. 35
Daily Checks..................................................................... 35
After Each Use.................................................................. 35
Weekly Checks................................................................. 35
20 Hour Break In............................................................... 35
Annually or 100 Hours...................................................... 35
Three Years or 300 Hours................................................ 36
Five Years or 500 Hours................................................... 36
Engine Oil............................................................................... 36
Checking......................................................................... 36
Oil Level—Overfilled................................................... 37
Filling............................................................................... 37
Changing Oil and Filter.................................................... 38
Oil Removal with Drain Pump......................................... 38
Changing the Oil Filter..................................................... 38
Transmission Fluid................................................................. 39
Checking While Engine is Warm...................................... 39
Checking While Engine is Cold......................................... 39
Section 5 - Storage
Transmission Fluid............................................................ 39
Changing.......................................................................... 39
Closed Cooling System.......................................................... 40
Coolant Requirement...................................................... 40
Checking Coolant Level.................................................. 40
.................................................................................... 40
Filling the Closed Cooling System................................... 40
Draining........................................................................... 41
Cleaning.......................................................................... 41
Battery.................................................................................... 41
Multiple EFI Engine Battery Precautions......................... 41
Cleaning the Flame Arrestor................................................... 42
Changing the Positive Crankcase Ventilation Valve (PCV).... 43
Water‑Separating Fuel Filter.................................................. 43
Removal and Installation................................................. 44
Removal...................................................................... 44
Installation................................................................... 44
Serpentine Drive Belt.............................................................. 45
Inspection........................................................................ 45
Checking......................................................................... 45
Replacing........................................................................ 46
Flushing the Seawater System—Inboard Models.................. 47
The Boat Out of the Water—Inboard Models.................. 47
The Boat in the Water—Inboard Models......................... 48
Cold Weather or Extended Storage........................................ 50
Reformulated (Oxygenated) Gasolines (U.S.A. Only)..... 50
Fuel Containing Alcohol.................................................. 50
Preparing Power Package for Storage—MPI Models..... 50
Special Fuel Mix.......................................................... 51
Engine and Fuel System Preparation......................... 51
Draining the Seawater System............................................... 52
Drain System Identification.............................................. 52
Air‑Actuated Single‑Point Drain System..................... 52
Manual Drain System.................................................. 53
Section 6 - Troubleshooting
Diagnosing EFI Problems....................................................... 60
Diagnosing DTS Problems..................................................... 60
Engine Guardian System........................................................ 60
Troubleshooting Charts.......................................................... 60
Starter Motor Will Not Crank Engine, or Cranks Slowly.. 60
Engine Will Not Start or Is Hard to Start.......................... 60
Engine Runs Rough, Misses, or Backfires...................... 61
Poor Performance........................................................... 61
Air‑Actuated Single‑Point Drain System.......................... 53
Boat in the Water........................................................ 53
Boat Out of the Water................................................. 54
Manual Drain System...................................................... 56
Boat in the Water........................................................ 56
Boat Out of the Water................................................. 56
Draining Water from the Cool Fuel Module..................... 57
Battery Storage....................................................................... 57
Recommissioning the Power Package................................... 57
Excessive Engine Temperature...................................... 61
Insufficient Engine Temperature..................................... 61
Low Engine Oil Pressure................................................. 62
Battery Will Not Recharge............................................... 62
Remote Control Is Difficult to Move or Makes Unusual
Sounds............................................................................ 62
Steering Wheel Jerks or Is Difficult to Turn..................... 62
Page ii 90-8M0113925 eng DECEMBER 2015
Section 7 - Customer Assistance Information
Owner Service Assistance....................................................... 64
Local Repair Service.......................................................... 64
Service Away From Home..................................................64
Stolen Power Package....................................................... 64
Attention Required After Submersion................................. 64
Replacement Service Parts................................................ 64
Parts and Accessories Inquiries................................... 64
Resolving a Problem.......................................................... 64
Contact Information for Mercury Marine Customer Service
........................................................................................... 65
Customer Service Literature.................................................... 65
English Language.............................................................. 65
Other Languages................................................................66
Ordering Literature................................................................... 66
United States and Canada................................................. 66
Outside the United States and Canada.............................. 66
Section 8 - Checklists
Predelivery Inspection (PDI).................................................... 68 Customer Delivery Inspection (CDI)........................................ 69
Section 9 - Maintenance Log
Scheduled Maintenance Log................................................... 72 Vessel Maintenance Notes...................................................... 73
90-8M0113925 eng DECEMBER 2015 Page iii
Page iv 90-8M0113925 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
Section 1 - Getting to Know Your Power Package
Table of Contents
Identification........................................................................... 2
Information Decal.............................................................2
Quick Response (QR) Code............................................ 2
Engine Serial Number .....................................................3
Lanyard Stop Switch............................................................... 3
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition .............................................. 4
Instrumentation....................................................................... 4
VesselView...................................................................... 4
Front Controls .......................................................... 5
Troll Control Speed Range Specification......................... 5
Digital Gauges................................................................. 5
Analog Gauges................................................................ 6
Remote Controls (DTS Models)............................................. 7
Remote Controls.............................................................. 7
Panel Mount Features..................................................... 7
DTS Slim Binnacle Single Handle Console Features and
Operation......................................................................... 7
Special Digital Throttle and Shift (DTS) Features ... 8
Dual‑Handle Electronic Remote Control (ERC)—
Operation and Adjustment............................................... 9
Operation ................................................................. 9
1
Adjustment .............................................................. 9
Special Digital Throttle and Shift (DTS) Features.......... 10
Dock ...................................................................... 11
Throttle Only .......................................................... 11
1 Lever .................................................................. 12
Sync ...................................................................... 12
Transfer (Boats equipped with dual helms) ........... 13
Helm Transfer................................................................ 13
Zero Effort Features.......................................................13
Electrical System Overload Protection................................. 14
Visual and Audio Warning Systems..................................... 15
Service Engine Light and OBD‑M MIL Kit......................15
Testing the OBD‑M Malfunction Indicator Lamp (MIL)
.............................................................................. 16
Audio Warning System.................................................. 16
Caution .................................................................. 16
Critical ................................................................... 16
Nonconfigured Alarm–DTS Only ........................... 16
Testing the Audio Warning System ....................... 17
Guardian Strategy..........................................................17
Transmission Guardian Strategy.......................................... 17
90-8M0113925 eng DECEMBER 2015 Page 1
Section 1 - Getting to Know Your Power Package
50444
a
c
d
e
f
50314
b
Identification
The serial numbers are the manufacturer's key to numerous details which apply to your MerCruiser power package. When
contacting MerCruiser about service, always specify model and serial numbers.
Information Decal
The information decal is located on the coolant reservoir.
a - Quick response code
b - Service point information
c - Engine serial number
d - Transom serial number
e - Sterndrive serial number
f - Specifications
Quick Response (QR) Code
Scan the QR code link with a smartphone to access additional product information.
QR code
Page 2 90-8M0113925 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
43554
a
b
c
c
a
b
53910
OFF
RUN
ATTACH LANYARD
Engine Serial Number
The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing cover.
a - Flywheel housing cover
b - Engine serial number stamp
c - Engine block
Lanyard Stop Switch
A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as
may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.
A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.
a - Lanyard cord clip
b - Lanyard decal
c - Lanyard stop switch
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
• Carelessness caused by consuming alcohol or drugs
• High‑speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one 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 its at‑rest
condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the
operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in
the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance,
depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.
90-8M0113925 eng DECEMBER 2015 Page 3
Section 1 - Getting to Know Your Power Package
Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
WARNING
!
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
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 propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current, or high winds.
• Loss of control when docking.
WARNING
!
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard
cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard
cords.
Instrumentation
VesselView
Your power package may have a SmartCraft VesselView display. VesselView is a comprehensive boat information center that
can display information for up to four gasoline or diesel engines. It continuously monitors and reports basic operating data, such
as information on fuel, oil, water and waste tanks, and will alert the operator if certain problems arise.
VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible devices to
provide up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.
Page 4 90-8M0113925 eng DECEMBER 2015
Front Controls
a
b
c
d
e
f
g
h
i
52293
Section 1 - Getting to Know Your Power Package
a - Touch screen
b - Mark–Menu button
c - Standby–Auto button
d - Exit button
e - Rotary knob (press for enter function)
f - Goto–Pages button
g - In/out zoom, man overboard (MOB) button
h - Power/brightness
i - Card reader door
Troll Control Speed Range Specification
Troll Control Speed Range Specification
Engine Model RPM
Horizon 8.2 with Emissions Control 600–1000
8.2 H.O. with Emissions Control 650–1200
Digital Gauges
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument
package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery
voltage, fuel consumption, and engine operating hours.
90-8M0113925 eng DECEMBER 2015 Page 5
Section 1 - Getting to Know Your Power Package
L
H
OIL
C H
TEMP
0
1
2
3
4
5
6
7
8
R P M
X 1000
MPH
KPH
10
20
30
40
50
60
70
80
30
40
50
60
70
80
90
100
120
110
10 16
BATT
0
4
4
4
FUEL
CRUISELOG
0 0 0 0
0
a
b
c
d
e
f
g
h
i
17352
26238
c
a
b
SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed
between the specified RPM range.
SmartCraft gauges
a - Tachometer
b - Speedometer
c - LCD system view display
The SmartCraft instrument package also aids in Engine Guardian diagnostics. The SmartCraft instrument package displays
critical engine alarm data and potential problems.
Refer to the manual with your gauge package for the warning functions monitored by and basic operation of the SmartCraft
instrument package.
Analog Gauges
The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar
with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have
your boat dealer explain the particular gauges and normal readings for your boat.
Reference
Gauge Function
a Speedometer Indicates boat speed.
b Tachometer Indicates engine RPM.
c Oil pressure gauge Indicates engine oil pressure.
d Voltmeter Indicates battery voltage.
e Coolant temperature gauge Indicates engine operating temperature.
Page 6 90-8M0113925 eng DECEMBER 2015
f Fuel gauge Indicates quantity of fuel in tank.
g Hour meter Records engine operating time.
h Bilge blower switch Operates the bilge blower.
i Ignition switch Allows the operator to start and stop engine.
Section 1 - Getting to Know Your Power Package
Remote Controls (DTS Models)
Remote Controls
IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided
by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the
Mercury Precision Parts/Quicksilver Accessories Guide.
The digital throttle and shift (DTS) system required to operate this engine package provides start and stop functions, throttle
control, shift control, start in gear protection, and emergency lanyard stop functions. The DTS system works with specialized
helm components such as a command module kit and electronic remote control. Consult your dealer for a description and/or
demonstration of your remote control.
Panel Mount Features
d
c
b
e
-
+
f
a
g
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 ‑ 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.
Shift lock ‑ Pressing the shift lock allows the engine to shift. The shift lock must always be pressed when moving the control
handle out of the neutral position.
Trim/tilt switch (if equipped) ‑ Refer to Power Trim.
Throttle only button ‑ Allows engine throttle advancement without shifting the engine. The throttle only button can be
depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up
the engine.
Start/stop button ‑ Allows the boat operator to start or stop the engine without using the ignition key.
Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort required to move the control
handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension.
Control handle friction adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control
handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw
clockwise to increase tension and counterclockwise to decrease tension.
3409
a - Lanyard stop switch
b - Control handle
c - Shift lock
d - Trim/tilt switch
e - Throttle only button
h
f - Start/stop button
g - Detent tension adjustment screw
h - Control handle friction adjustment screw
DTS Slim Binnacle Single Handle Console Features and Operation
1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from
neutral to the first detent for reverse gear. Continue pushing back to increase speed.
90-8M0113925 eng DECEMBER 2015 Page 7
Section 1 - Getting to Know Your Power Package
a
STOP/
START
THROTTLE - ONLY
DOCK TRANSFER
N
bcd
e
f
g
52365
h
abc
d
52360
abc
52313
2. Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses
a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The
PCM closes the ground circuit to the up or down trim relay.
a - Forward
b - Neutral
c - Reverse
d - Trim switch
3. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle
out of detent positions. Turning screw clockwise will increase tension. Adjust to tension desired.
4. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control
handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn screw clockwise to
increase tension and counterclockwise to decrease tension. Adjust to tension desired.
a - Caps (2)
b - Detent tension adjustment
c - Control handle tension adjustment
NOTE: The control handle tension and detent tension screws may require periodic maintenance adjustment.
Special Digital Throttle and Shift (DTS) Features
The DTS system features several alternate operational modes for the electronic remote control (ERC) levers.
Slim binnacle ERC
Page 8 90-8M0113925 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
abc
51902
Item Control Function
a Trim control (handle)
b "Stop/Start"
c "Transfer" Allows boat control to be transferred to a different helm.
d "Throttle‑only"
e "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.
f "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.
g "Dock"
h Neutral light
Raises and lowers the engine for best efficiency, or for conditions such as shallow water,
trailering, etc.
Allows the operator to start or stop the engine without the use of the key switch. The key switch
must be in the run position for the start/stop switch to function.
Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission
into gear.
Reduces control lever operation throttle capacity to approximately 50% of normal control lever
throttle demand.
Illuminates when the drive is in the neutral gear position. The lights flash when the engine is in
throttle only mode.
Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment
Operation
The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from
the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to
the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.
NOTE: In certain modes, the gear position is determined by the electronic shift control (ESC), not the position of the ERC
levers. When using the joystick or while in Skyhook, the computer controls the shifting in and out of gears even though the
handles are in neutral.
a - Forward
b - Neutral
c - Reverse
The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent
unwanted motion.
Adjustment
NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws.
To adjust the handle detent tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
3. Adjust to the tension desired.
To adjust handle tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
90-8M0113925 eng DECEMBER 2015 Page 9
Section 1 - Getting to Know Your Power Package
a
b
c
d
e
f
g
h
i
j
51853
a
b
51901
3. Adjust to the tension desired.
a - Detent tension adjustment screw
b - Handle tension adjustment screw
Special Digital Throttle and Shift (DTS) Features
The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed
features can operate simultaneously.
Dual-engine ERC
Item Control Function
a Trim control (handle)
Trim control (CAN
b
pad)
c "NEUTRAL" lights
d "TRANSFER"
e "DOCK"
Page 10 90-8M0113925 eng DECEMBER 2015
Raises and lowers the engines for best efficiency, or for conditions such as shallow water,
trailering, etc.
Raises and lowers all the engines.
Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in
throttle only mode.
Allows boat control to be transferred to a different helm. Refer to Helm Transfer.
Available with joystick operation and the control levers.
Joystick operation reduces throttle capacity to approximately 70% of normal joystick throttle
demand.
Control lever operation reduces throttle capacity to approximately 50% of normal control lever
throttle demand.
Section 1 - Getting to Know Your Power Package
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51855
Item Control Function
f "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.
g "THROTTLE ONLY"
h "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.
i "1 LEVER" Enables the throttle and shift functions of both engines to be controlled by the port lever.
j "SYNC" Turns off or on the auto‑synchronization feature.
Allows the boat operator to increase engine RPM for warm‑up without shifting the
transmission into gear.
NOTE: Not all functions may be active.
Dock
Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to
approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more
power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control
levers.
"DOCK" button
Throttle Only
NOTE: The joystick can become active when it is moved any time the engines are running and the ERC levers are in the
neutral position. Throttle only mode should be used to disable the joystick if the captain is not in command at the helm. Placing
the ERC in throttle only will avoid unintended gear engagement. The engines will turn using the steering wheel or the joystick
and the RPM of the engines can be increased while in the throttle only mode, but the gear position will remain in neutral.
"THROTTLE ONLY" button
To engage throttle only mode:
1. Place both ERC levers in neutral.
2. Press the "THROTTLE ONLY" button. The button light will turn on and the neutral lights will blink.
3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in
throttle only, but will remain in neutral.
4. The RPM of the engines can be increased.
5. Throttle only mode also affects the joystick. The engines will move and the RPM can be increased, but will remain in
neutral.
NOTE: Pressing the "THROTTLE ONLY" button while the ERC levers are not in the neutral position, turns the button light off
and remains in throttle only mode. You must place the ERC levers into the neutral position to disengage throttle only mode.
To disengage throttle only mode:
1. Place both ERC levers into neutral. Throttle only will not disengage unless the ERC levers are in neutral.
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51857
2. Press the "THROTTLE ONLY" button. The button light will turn off.
3. The neutral lights stop flashing and remain illuminated. The joystick can now be used.
1 Lever
The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application.
This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both
engines simultaneously. It has no affect on the joystick function. It is not the same as the system feature called Sync.
"1 LEVER" button
To engage 1 Lever mode:
1. Place both ERC levers in neutral.
2. Press the "1 LEVER" button. The button light will turn on.
3. Place the starboard ERC lever into gear.
4. When the handle is moved, the engines RPM and gear position is synchronized.
To disengage 1 lever mode:
1. Place both ERC levers in neutral.
2. Press the "1 LEVER" button. The button light turns off.
Sync
Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both
ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM. The
SmartCraft system will automatically disengage sync after 95% of throttle position range to allow each engine the ability to
reach maximum available RPM. Sync cannot engage until the engines are at a minimum speed.
The indicator light on the "SYNC" button is on when both engines are on. The light is yellow at idle and 95% of throttle and
when the engines are not synchronized. The light turns red when the engines are synchronized.
"SYNC" button
The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more than 10%
of each other, and the icon turns red when they are synchronize.
To disengage sync mode:
1. Place the ERC levers in any detent.
2. Press the "SYNC" button. The button light turns off.
To engage Sync mode, press the "SYNC" button at any time.
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Transfer (Boats equipped with dual helms)
The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on
boats equipped with dual helms. Refer to Helm Transfer.
"TRANSFER" button
Helm Transfer
Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to
as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to
another helm.
WARNING
!
Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is
in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be
performed while engine is in neutral.
The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be
initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.
NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer
will not succeed until the levers at the helms are moved to neutral and transfer is requested again.
Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer
procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the
helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid
setting fault codes.
NOTICE
The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects
nearby resulting in damage. Keep an adequate look out while performing the helm transfer.
To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items
or when near other vessels.
Zero Effort Features
c
a
b
a - Shift lever
b - Throttle lever
c - Trim/tilt switch
5656
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51332
a
b
c
d
43693
Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its
aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its
forward position.
Throttle lever ‑ Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle
lever forward. Achieve wide‑open throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by
moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.
Trim/tilt switch ‑ Refer to Power Trim.
Electrical System Overload Protection
If an electrical overload occurs, a fuse will open or the circuit breaker will open. The cause must be found and corrected before
replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when you must operate the engine and cannot locate the cause for the high current draw, 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. Contact your authorized dealer as soon as possible.
The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. To reset the circuit
breaker, push the red button. The circuit breaker is located at the starboard rear of the engine.
A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload
occurs.
a - Starter
b - Starter solenoid
c - 90‑amp fuse—do not remove
d - Positive (+) starter stud
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a
b
c
32206
43608
a
b
c
Four fuses protect the main power, fuel pump, ignition, and accessory circuits. These are located on the top of the engine near
the PCM. Fuses protect the O2 sensors. These are located near the 14‑pin harness connector.
A 15‑amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine.
a - Fuse cover
b - 15‑amp fuse
c - Accessory harness
The DTS control system is protected by a 5‑amp fuse located near the battery.
a - 5‑amp fuse
b - Positive battery terminal (harness lead with fuse)
c - Negative battery terminal
Visual and Audio Warning Systems
Service Engine Light and OBD‑M MIL Kit
Boats powered by emissions control technology (ECT) catalyzed engines must be equipped with a SmartCraft‑enabled gauge
capable of displaying the service engine icon, or a dash‑mounted service engine light. Malfunction indicator lamp (MIL) kits
containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased
separately.
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47594
ON ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
1
1
1
1
1
1
1
1
1
1
1
OFF
33402
a
b
53403
a
b
ON
6
OFF
ON ON
OFF
ON
OFF
ON
OFF
ON
OFF
1
1
1
1
1
1
1
1
1
OFF
53402
a
b
The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and
will remain illuminated while the OBD‑M fault is active.
SC 1000 gauge and service engine light
Testing the OBD-M Malfunction Indicator Lamp (MIL)
1. Turn the ignition switch to the on position without cranking the engine.
2. The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning
correctly.
Audio Warning System
IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from
damage.
Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
There are two warning horn states:
• Caution
• Critical
There is also an alarm that sounds if the helm has not been properly configured using the G3 service tool.
Caution
If a caution state is detected, the audio warning system will sound for six one‑second intervals.
a - Horn (on or off)
b - Time (in seconds)
Critical
If a critical state is detected, the audio warning system sounds for six seconds and then turns off.
a - Horn (on or off)
b - Time (in seconds)
Nonconfigured Alarm–DTS Only
If the helm has not been properly configured using the G3 service tool, the audio warning system will sound for five one‑second
intervals.
Horn (on or off)
a b - Time (in seconds)
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Testing the Audio Warning System
1. Turn the key switch to the on position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Guardian Strategy
The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM
detects a potential problem. Below are some examples of what Engine Guardian monitors:
• Oil pressure
• Engine overspeed
• Exhaust manifold temperature
IMPORTANT: Engine Guardian can reduce power anywhere from 100% to idle, depending on the severity of the problem. If
forced to idle, boat speed might not respond to throttle operation.
The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially blocked, Engine Guardian reduces
the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes
through, and full water flow is restored, Engine Guardian restores engine power to normal.
Transmission Guardian Strategy
IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle.
Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian
monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined
level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.
The ECM stores the fault and with this information the technician will be able to rapidly diagnose problems.
90-8M0113925 eng DECEMBER 2015 Page 17
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