Mercury 92-8M0069603, 92-8M0070979, MerCruiser Diesel Inboard 2.8L, MerCruiser Diesel Inboard 4.2L Maintance Manual
2.0L
Diesel Engine
Inboard Models
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
8M0113986 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.
2.0L Diesel Engine Inboard Models
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.
© 2016 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
Features and Controls............................................................... 2
Warning Horn Signals......................................................... 2
Instrumentation................................................................... 2
VesselView..................................................................... 2
SmartCraft Speedometer, Tachometer, and Digital
Gauges........................................................................... 2
System Link Digital Gauges........................................... 3
Switches............................................................................. 4
Emergency Stop Switch...................................................... 4
Lanyard Stop Switch........................................................... 5
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition.............................................. 6
Section 2 - On the Water
Safe Boating Recommendations............................................. 12
Carbon Monoxide Exposure.................................................... 13
Be Alert To Carbon Monoxide Poisoning........................... 13
Stay Clear of Exhaust Areas.............................................. 13
Good Ventilation ................................................................ 13
Poor Ventilation ................................................................. 14
Important Operation Information.............................................. 14
Launching......................................................................... 14
Duty Cycle Rating Requirements...................................... 14
High‑Output Rating........................................................... 14
Operation Chart................................................................ 15
Freezing Temperature and Cold Weather Operation....... 15
Drain Plug and Bilge Pump............................................... 16
Starting, Shifting, and Stopping............................................... 16
Before Starting the Engine................................................ 16
Important Information—SmartStart................................... 16
Starting a Cold Engine...................................................... 16
Engine Warm Up.............................................................. 17
Starting a Warm Engine ................................................... 17
Shifting.............................................................................. 17
Engine Shut Down (Stopping).......................................... 17
Protecting People in the Water................................................ 18
Digital Throttle and Shift..................................................... 6
Remote Controls................................................................. 6
Panel Mount Features.................................................... 6
Console Mount Features................................................ 7
Engine Electrical System Overload Protection................... 7
Vessel Integration Panel (VIP) Overload Protection........... 8
Engine Guardian System.................................................... 8
Identification............................................................................... 9
Specifications Label............................................................ 9
Data Label Location............................................................ 9
Engine Data Label.............................................................. 9
Technodrive Transmissions.............................................. 10
While Boat is in Operation.................................................. 18
While the Boat is Stationary............................................... 18
High‑Speed and High‑Performance......................................... 18
Passenger Safety In Pontoon Boats and Deck Boats.............. 18
Boats Having An Open Front Deck.................................... 18
Boats With Front‑Mounted, Raised Pedestal Fishing Seats
........................................................................................... 19
Wave and Wake Jumping........................................................ 19
Impact With Underwater Hazards............................................ 19
Conditions Affecting Operation................................................ 20
Weight Distribution (Passengers and Gear) Inside the
Boat.................................................................................. 20
Bottom of Boat.................................................................. 20
Elevation and Climate....................................................... 20
Propeller Selection............................................................ 21
Getting Started......................................................................... 21
Initial Break‑In Procedure................................................. 21
Engine Break‑In................................................................ 21
20‑Hour Break‑In Period...............................................21
After the 20‑Hour Break‑In Period................................ 21
End of First Season Checkup........................................... 22
Section 3 - Specifications
Fuel Requirements................................................................... 24
Diesel Fuel in Cold Weather.................................................... 24
Antifreeze/Coolant................................................................... 24
Engine Oil................................................................................ 25
Engine Specifications ‑ Inboard Models................................... 25
Fluid Specifications.................................................................. 26
Engine............................................................................... 26
Transmission.................................................................... 26
Approved Paints....................................................................... 26
Section 4 - Maintenance
Owner and Operator Responsibilities...................................... 28
Dealer Responsibilities............................................................ 28
Maintenance............................................................................ 28
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Do‑It‑Yourself Maintenance Suggestions................................ 28
General Inspection................................................................... 28
Engine Cover........................................................................... 29
Removal.......................................................................... 29
Cleaning.......................................................................... 29
Inspection........................................................................ 29
Installation....................................................................... 29
Maintenance Schedule........................................................... 29
Routine Maintenance...................................................... 29
Scheduled Maintenance.................................................. 30
Engine Oil............................................................................... 31
Specifications.................................................................. 31
Oil Level—Overfilled........................................................ 31
Checking......................................................................... 31
Filling............................................................................... 32
Changing Oil and Filter.................................................... 32
TM 345 Technodrive Transmission Fluid............................... 34
Checking......................................................................... 34
Filling............................................................................... 35
Changing......................................................................... 35
TM 485‑A Technodrive Transmission Fluid............................ 37
Check Fluid..................................................................... 37
Add Fluid......................................................................... 38
Change Fluid................................................................... 38
Engine Coolant....................................................................... 40
Checking and Filling the Closed‑Cooling System........... 40
Draining the Closed‑Cooling System.............................. 42
Air Filter.................................................................................. 43
Removal.......................................................................... 43
Inspection........................................................................ 44
Installation....................................................................... 44
Water‑Separating Fuel Filter.................................................. 45
Draining........................................................................... 45
Replacing........................................................................ 46
Filling............................................................................... 48
Fuel System............................................................................ 49
Priming............................................................................ 49
Filling (Bleeding).............................................................. 49
Fuel Tank Cleaning and Flushing.................................... 49
Seawater System................................................................... 49
Draining the Seawater System........................................ 49
Checking the Seawater Pickups...................................... 51
Cleaning the Seawater Strainer...................................... 51
Engine Seawater Pump Inspection................................. 53
Corrosion Protection............................................................... 53
General Information......................................................... 53
Engine Corrosion Protection Components...................... 53
Removal...................................................................... 53
Cleaning and Inspection............................................. 54
Installation................................................................... 55
Antifouling Paint.............................................................. 55
Lubrication.............................................................................. 55
Throttle Cable.................................................................. 55
Shift Cable....................................................................... 56
Drive Belts.............................................................................. 56
Power‑Assisted Steering Pump Belt Inspection.............. 56
Serpentine Belt Inspection.............................................. 57
Battery.................................................................................... 58
Battery Precautions for Multiple Engines.......................... 58
Section 5 - Storage
Cold Weather (Freezing Temperature), Seasonal Storage, and
Extended Storage................................................................... 62
Cold Weather (Freezing Temperature) Storage.............. 62
Preparing Your Power Package for Seasonal or Extended
Storage............................................................................ 62
Section 6 - Troubleshooting
Diagnosing Electronically Controlled Fuel System
Problems................................................................................ 66
Troubleshooting Charts.......................................................... 66
Starter Motor Will Not Crank Engine, or Cranks Slow..... 66
Engine Will Not Start, or Is Hard to Start......................... 66
Engine Runs Rough, Misses, or Backfires...................... 66
Section 7 - Customer Assistance Information
Owner Service Assistance...................................................... 70
Local Repair Service......................................................... 70
Service Away From Home................................................ 70
Stolen Power Package..................................................... 70
Attention Required After Submersion............................... 70
Replacement Service Parts.............................................. 70
Parts and Accessories Inquiries.................................. 70
Resolving a Problem......................................................... 70
Seasonal Storage............................................................ 63
Extended Storage Instructions........................................ 64
Battery............................................................................. 64
Recommissioning................................................................... 64
Poor Performance........................................................... 66
Incorrect Engine Temperature......................................... 67
Low Engine Oil Pressure................................................. 67
Battery Will Not Charge................................................... 67
Remote Control Operates Hard, Binds, Has Excessive
Free‑play, or Makes Unusual Sounds............................. 67
Contact Information for Mercury Marine Customer Service
.......................................................................................... 71
Customer Service Literature................................................... 71
English Language............................................................. 71
Other Languages.............................................................. 72
Ordering Literature................................................................. 72
United States and Canada................................................ 72
Outside the United States and Canada............................ 72
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Section 8 - Maintenance Log
Scheduled Maintenance Log................................................... 74 Vessel Maintenance Notes...................................................... 75
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Section 1 - Getting to Know Your Power Package
Section 1 - Getting to Know Your Power Package
Table of Contents
Features and Controls............................................................ 2
Warning Horn Signals...................................................... 2
Instrumentation................................................................ 2
VesselView .............................................................. 2
SmartCraft Speedometer, Tachometer, and Digital
Gauges .................................................................... 2
System Link Digital Gauges .................................... 3
Switches.......................................................................... 4
Emergency Stop Switch...................................................4
Lanyard Stop Switch........................................................ 5
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition ....................................... 6
1
Digital Throttle and Shift.................................................. 6
Remote Controls.............................................................. 6
Panel Mount Features ............................................. 6
Console Mount Features ......................................... 7
Engine Electrical System Overload Protection................ 7
Vessel Integration Panel (VIP) Overload Protection........ 8
Engine Guardian System................................................. 8
Identification........................................................................... 9
Specifications Label......................................................... 9
Data Label Location......................................................... 9
Engine Data Label........................................................... 9
Technodrive Transmissions........................................... 10
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Features and Controls
Warning Horn Signals
When the key switch is turned to the on position, the horn will turn on for a moment as a test to indicate the horn is working.
There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
1.
Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian
system may engage and protect the engine by limiting power. You should return to port immediately and contact your
servicing dealer.
2.
Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require
immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s
power may be limited by the Engine Guardian system to protect the engine. You should contact your servicing dealer at
your earliest convenience.
It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and
restart it, the horn will sound again, one time, if the fault is still present.
A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator.
These operator correctable conditions are as follows:
•
Water in the fuel filter. Refer to Maintenance – Water Separating Fuel Filter.
• Cooling system (water pressure or engine temperature) problem. Stop the engine and check the water intake holes in the
lower unit for obstruction.
•
Low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.
Instrumentation
VesselView
Your power package may be connected to a SmartCraft VesselView display. VesselView 7 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 including detailed information such as seawater temperature and depth, trim status, boat speed and
steering angle, and the status of fuel, oil, water, and waste tanks.
VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible device to provide
up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.
VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the
personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is
used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those
configurations.
VesselView
Refer to your VesselView operations manual for detailed instructions on how to operate this display.
SmartCraft Speedometer, Tachometer, and Digital Gauges
The SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:
• Engine RPM
• Boat speed
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• Coolant temperature
• Oil pressure
• Battery voltage
• Fuel consumption
• Engine operating hours
SmartCraft tachometer and speedometer
a - Tachometer
b - Speedometer
c - LCD display
The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system.
The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.
For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the
system, refer to the manual provided with your gauge package.
System Link Digital Gauges
Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft
tachometer and speedometer. The owner and operator should be familiar with all the instruments and their functions on the
boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.
The following types of digital gauges may be included with your power package.
System Link digital gauges
Item Gauge Indicates
a Oil pressure gauge Engine oil pressure
b Voltmeter Battery voltage
c Water temperature gauge Engine operating temperature
d Fuel gauge Quantity of fuel in tank
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a
b
Switches
Reference Switch Function
a Key switch Has four positions.
b
Bilge blower switch (if equipped) Operates the bilge blower, if equipped
a - Key switch
b - Bilge blower switch (if equipped)
1.
"OFF." In the "OFF" position, all electrical circuits are off and the
engine cannot be started. The engine is stopped when the key
switch is turned to the "OFF" position.
2.
"ACC." In the "ACC" position, any accessory connections to the
electrical circuits can be operated. The engine will not operate with
the key switch in the "ACC" position.
3.
"ON." In the "ON" position, all electrical circuits and instruments
are operational.
4.
"START." In the "START" position the engine can be started.
NOTE: The key can only be removed with the key switch in the "OFF"
position.
Emergency Stop Switch
An emergency stop (E‑stop) switch is used to turn off the engines in an emergency situation, such as a person overboard or a
tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is
equipped with an E‑stop switch, the E‑stop switch turns off all of the engines.
Typical E-stop switch
Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance
depending upon the velocity and degree of any turn at shutdown. 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.
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a
b
53910
OFF
RUN
ATTACH LANYARD
We recommend instructing other occupants on proper starting and operating procedures should they need to operate the
engine in an emergency.
Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the
following potentially hazardous situations:
• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could
be ejected over the bow and possibly struck by the propulsion or steering components.
• The operator can lose power and directional control in heavy seas, strong current, or high winds.
• The operator can lose control of the vessel when docking.
Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off
position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous
situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some
fault codes are still being displayed, contact your authorized Mercury Diesel repair facility.
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.
Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
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.
WARNING
!
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e
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.
Digital Throttle and Shift
Digital Throttle and Shift (DTS) operating instructions are provided in a separate manual. Refer to Mercury Diesel's SmartCraft
and DTS Operator's Manual.
Remote Controls
Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features
shown. Consult your dealer for a description or demonstration of your remote control.
Panel Mount Features
Neutral lock button. Prevents accidental shift and throttle engagement. The 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 pressed 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. Operation of the shift and throttle is 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.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
a - Neutral lock button
b - Throttle‑only button
c - Lanyard stop switch
d - Control handle tension adjustment screw
e - Control handle
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b
a
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Console Mount Features
a - Control handle
b - Throttle‑only button
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 pressed only when the remote control handle is in the
neutral position.
Control handles. Operation of the shift and throttle is 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.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
Engine Electrical System Overload Protection
If an electrical overload occurs, a fuse will open (blow). Find and correct the cause of the electrical overload before replacing
the fuse.
NOTE: In an emergency, when the engine must be operated and the cause of the electrical overload cannot be located and
corrected, turn off or disconnect all the accessories connected to the engine and instrumentation wiring. Replace the blown
fuse. If the replacement fuse also blows, then the electrical overload has not been eliminated. Further checks must be made on
the electrical system.
higher amperage fuse or shorting across the fuse block terminals.
Fuses provide protection for the engine electrical system as indicated. The fuse panel is located beneath an access panel in
the front of the engine cover.
Do not circumvent the electrical overload protection provided on fused circuits by installing a
Contact your Mercury Diesel authorized repair facility.
2.0 engine cover with access panel
a - Engine cover access panel
b - Fuse panel
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After finding and correcting the cause of the overload, replace any open (blown) fuses.
2.0 fuse panel
Reference Fuse Protection
a 20‑amp Unswitched power to helm Lower left
b 10‑amp Switched power to ECM Middle left
c 10‑amp Keyed power to ECM Upper left
d 5‑amp Power—diagnostic connector Upper right
e 15‑amp ECM switched power to SIM Middle right
f 15‑amp Switched power to ECM Lower right
Location on fuse panel
(From Front of Engine)
Vessel Integration Panel (VIP) Overload Protection
A vessel integration panel (VIP) is typically mounted in the engine compartment. The VIP contains three circuit breakers that
help protect system wiring.
a - Helm circuit breaker (10 A)
b - Gear circuit breaker (15 A)
c - SIM/Vessel circuit breaker (10 A)
Engine Guardian System
The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian
is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected.
The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to
provide engine protection.
If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The
system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will
reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem,
Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine
Guardian will allow the engine to reach a normal operating RPM.
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a
b
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a
53340
Identification
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.
Specifications Label
A specifications label on the top of the engine cover provides quick reference information for the engine and drive with color
codes that identify where to check specific types of fluids and the belt routing. A QR code can be scanned with a smartphone
for more engine information.
Data Label Location
The engine data label is located on the front of the engine as shown below.
a - Serial number and part
number label, with bar codes
b - Engine data label
Engine Data Label
A tamper‑resistant engine data label is affixed to the engine at the time of manufacture. It contains important information. Note
that the engine data label will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may
remove the engine data label or the engine component it is affixed to before sale. If modifications are necessary or the engine
data label is damaged, contact Mercury Marine about the availability of a replacement.
The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission
levels to exceed their predetermined factory specifications.
Engine data label example
a - Engine weight
b - Engine power rating
c - Maximum engine speed (RPM)
d - Engine serial number
e - Abbreviated engine description
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Technodrive Transmissions
The transmission identification plate indicates gear ratio, serial number, and model.
Technodrive TM 345 identification plate
Technodrive TM 485-A identification plate
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Table of Contents
Section 2 - On the Water
Section 2 - On the Water
Safe Boating Recommendations.......................................... 12
Carbon Monoxide Exposure................................................. 13
Be Alert To Carbon Monoxide Poisoning ..................... 13
Stay Clear of Exhaust Areas ........................................ 13
Good Ventilation .......................................................... 13
Poor Ventilation ........................................................... 14
Important Operation Information........................................... 14
Launching...................................................................... 14
Duty Cycle Rating Requirements...................................14
High‑Output Rating........................................................ 14
Operation Chart............................................................. 15
Freezing Temperature and Cold Weather Operation.... 15
Drain Plug and Bilge Pump............................................16
Starting, Shifting, and Stopping............................................ 16
Before Starting the Engine.............................................16
Important Information—SmartStart................................ 16
Starting a Cold Engine................................................... 16
Engine Warm Up........................................................... 17
Starting a Warm Engine ................................................17
Shifting........................................................................... 17
Engine Shut Down (Stopping)....................................... 17
Protecting People in the Water............................................. 18
While Boat is in Operation ............................................ 18
While the Boat is Stationary ......................................... 18
High‑Speed and High‑Performance..................................... 18
Passenger Safety In Pontoon Boats and Deck Boats.......... 18
Boats Having An Open Front Deck .............................. 18
Boats With Front‑Mounted, Raised Pedestal Fishing
Seats ............................................................................ 19
Wave and Wake Jumping..................................................... 19
Impact With Underwater Hazards......................................... 19
Conditions Affecting Operation............................................. 20
Weight Distribution (Passengers and Gear) Inside the
Boat............................................................................... 20
Bottom of Boat............................................................... 20
Elevation and Climate.................................................... 20
Propeller Selection.........................................................21
Getting Started..................................................................... 21
Initial Break‑In Procedure.............................................. 21
Engine Break‑In............................................................. 21
20‑Hour Break‑In Period ....................................... 21
After the 20‑Hour Break‑In Period ......................... 21
End of First Season Checkup........................................ 22
2
90-8M0113986 eng DECEMBER 2015 Page 11
Section 2 - On the Water
Safe Boating Recommendations
To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and
readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life
jacket at all times while in the boat.
Prepare other boat operators.
• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver
becomes disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your
authorized Mercury Marine dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of
seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride
anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat
movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat
and are in it before any boat movement.
Never operate a boat while under the influence of alcohol or drugs. It is the law.
• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
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Section 2 - On the Water
43367
Be alert.
• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have
an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when
the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.
Never drive your boat directly behind a water skier.
• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the
boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to
the skier or anyone in the water.
Report accidents.
• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when
their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable
loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from
local law enforcement.
Carbon Monoxide Exposure
Be Alert To Carbon Monoxide Poisoning
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.
WARNING
!
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines
are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While
underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the
possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
Example of desired air flow through the boat:
90-8M0113986 eng DECEMBER 2015 Page 13
Section 2 - On the Water
21626
a
b
a
b
43368
Poor Ventilation
Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that
contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:
a - Operating the engine when the boat
is moored in a confined space
b - Mooring close to another boat that
has its engine operating
2. Examples of poor ventilation while the boat is moving:
a - Operating the boat with the
trim angle of the bow too
high
b - Operating the boat with no
forward hatches open
(station wagon effect)
Important Operation Information
Launching
IMPORTANT: Install the bilge drain plug before launching the boat.
Duty Cycle Rating Requirements
IMPORTANT: Damage caused by incorrect application or failure to operate the power package within the specified operating
parameters will not be covered by the Mercury Marine Limited Warranty.
Mercury Diesel engines must be used in applications that meet the operation specifications indicated by a Mercury Diesel
product application engineer. The power package must be equipped with a gear ratio and propeller that allows the engine to
operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do
not meet specified operational parameters is not approved.
High‑Output Rating
A High‑output rating applies to pleasure (nonrevenue generating) applications that operate 500 hours or less per year, where
full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced power operation must be at or below
cruise speed (RPM). Cruise speed is dependant on the engine's maximum rated speed (RPM).
Page 14 90-8M0113986 eng DECEMBER 2015
Section 2 - On the Water
Operation Chart
Starting Procedure After Starting While Underway Stopping and Shut Down
Open the engine hatch. Air
out the bilge completely.
Turn the battery switch on, if
equipped.
Turn on and run the engine
compartment bilge blower, if
equipped, for five minutes.
Check for leaks: fuel, oil,
water, fluid, etc.
Open the fuel shut‑off valve,
if equipped.
Open the seacock, if
equipped.
Prime the fuel injection
system, if necessary.
Turn the key switch to
"START" position. Release
the key when the engine
starts.
Warm‑up the engine at a
fast idle‑RPM for several
minutes.
Observe all instrumentation to
monitor the condition of the
engine. If not normal, stop the
engine.
Check for fuel, oil, water, fluid,
and exhaust leaks, etc.
Check shift and throttle control
operation.
Check steering operation.
Frequently review all
instrumentation to monitor
engine condition.
Listen for the audio alarm.
Shift the remote control lever
to the neutral position.
Run the engine at idle‑RPM
for several minutes to allow
the turbocharger and engine
to cool.
Turn the key switch to "OFF"
position.
Turn the battery switch off, if
equipped.
Close the fuel shut‑off valve, if
equipped.
Close the seacock, if
equipped.
Flush the seawater cooling
circuit, if operating in
saltwater, brackish water, or
polluted water.
Freezing Temperature and Cold Weather Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to
the power package. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE:
As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and connect the water inlet hose before starting the engine.
In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:
• At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage
by freezing.
• At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at the end of daily
operation to prevent condensation.
• Use the required permanent‑type antifreeze solution to protect components against damage by freezing.
• Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.
• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in
optimum condition.
• At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting.
• If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for
information about special cold weather equipment and precautions.
Refer to Section 6 for cold weather or extended storage related information.
90-8M0113986 eng DECEMBER 2015 Page 15
Section 2 - On the Water
Drain Plug and Bilge Pump
The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a
drain plug or a bilge pump. It is important to check these items on a regular basis to ensure that the water level does not come
into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by
submersion is not covered by the Mercury Marine Limited Warranty.
Starting, Shifting, and Stopping
WARNING
!
Vapors can ignite and cause an explosion, resulting in engine damage or severe personal injury. Do not use volatile starting
aids such as ether, propane, or gasoline in the engine air intake system.
WARNING
!
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
Before Starting the Engine
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: Observe the following before starting the engine:
• Provide water to the seawater pickup pump.
• Ensure that the engine crankcase is filled to the correct level with the proper grade of oil for the prevailing temperature.
Refer to Section 4 ‑ Specifications.
• Ensure that all electrical connections are secure.
• Check all applicable items in the maintenance schedules and operation chart.
• Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat
owner's and operation manual.
Important Information—SmartStart
IMPORTANT: This Mercury Diesel model is equipped with SmartStart. SmartStart performs all appropriate starting operations
upon initial start switch activation. To begin the SmartStart sequence, turn the ignition key switch to the "START" position and
release, or turn the ignition key switch to the run position and press and release the start/stop switch.
Rather than holding the start button or key switch in position until the engine starts, SmartStart controls the starting process
automatically. When the start switch is activated, the system signals the engine ECM to start the engine. The starter will receive
power until the engine starts, the starting process times out after a few seconds, or when the engine reaches 400 RPM.
Attempting to start the engine with the engine running will turn the engine off.
Starting a Cold Engine
WARNING
!
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
NOTE: Check the fluid levels before starting the engine. Refer to
1. Turn on and run the engine compartment bilge blower (if equipped) for five minutes. Alternately, open the engine hatch to
air out the bilge before attempting to start the engine.
2. Place the control handle in neutral.
NOTE: If the engine has not been run for a period of time and will not readily start with the standard starting procedure, use
the fuel primer located on the fuel filter header. Cycle the primer plunger up and down four or five strokes before
attempting to start the engine.
3. Turn the ignition key to the "RUN" position.
4. Turn the ignition key switch to the "START" position then release, or press the start/stop button and release. If the engine
is cold, allow the engine to operate at idle for 6–10 minutes or until the engine reaches normal operating temperature.
IMPORTANT: Engine oil pressure should exceed 69 kPa (10 psi) within seconds of starting the engine. Stop the engine if
the engine oil pressure does not meet this specification. Locate and correct the problem. If you are unable to correct the
problem, see a Mercury Diesel authorized repair facility.
Section 5 ‑ Maintenance Schedule
.
Page 16 90-8M0113986 eng DECEMBER 2015
Section 2 - On the Water
5. Verify that all instrumentation is functioning properly and indicating normal readings.
Engine Warm Up
NOTICE
Engine wear caused by increased friction and limited oil flow is greatest when an engine is cold. Decrease engine wear by
allowing the engine coolant temperature to reach normal operating range before hard acceleration or applying full throttle.
1. After starting, ensure that all instrumentation is functioning properly.
2. Operate the engine at 1,000 to 1,200 RPM until the engine temperature is within the normal operating range. It is crucial
that any engine be warmed up before applying full load. The warm‑up period provides time for the lubricating oil to
establish a film between moving parts.
NOTE: Engine warm‑up time during cold weather can be reduced by operating the vessel at a reduced engine speed.
Begin normal vessel operation when systems reach operating temperatures.
3. After the engine has reached operating temperature:
a.
The oil pressure should be within the range specified. Refer to Section 4 ‑ Engine Specifications. Stop the engine if
the oil pressure is not within the range specified.
b. Check the fuel system for leakage from the injection pump, fuel pipes, fuel filter, or fuel lines.
c. Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks.
d. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks.
4. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the
problem.
Starting a Warm Engine
1. Turn on and run the engine compartment bilge blower (if equipped) for 5 minutes. Or, open the engine hatch to air out the
bilge before attempting to start the engine.
2. Place the remote control handle in neutral.
3. Turn the key switch to "START" position and release the key when the engine starts.
4. Ensure that all the instrumentation is functioning properly and indicates normal readings.
Shifting
NOTICE
Shifting into gear at engine speeds above idle will damage the transmission. Shift into gear only when the engine is operating
at idle.
NOTICE
Failure to rotate the propeller shaft when shifting gears or forcing the shift mechanism while the engine is not operating can
result in product damage. If you must shift gears with the engine off, manually rotate the propeller shaft in the appropriate
direction.
To shift the unit, verify the remote control throttle lever is in neutral. Move the remote control shift lever forward to shift into
forward gear or backward to shift into reverse. After shifting the transmission, advance the throttle to the desired setting.
Engine Shut Down (Stopping)
1. Place the remote control lever in neutral.
NOTICE
Immediately stopping the engine after high load operation can damage the turbocharger bearings. Idle the engine for several
minutes before shutdown.
2. Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.
3. The engine can be stopped by any one of the following four methods:
a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop and the control system will
be deactivated.
b. Depress the start/stop button, if equipped. The engine will stop and the control system will remain active.
90-8M0113986 eng DECEMBER 2015 Page 17
Section 2 - On the Water
21604
c. Momentarily move the ignition key switch to the "START" position, then release immediately. The control system will
recognize that the engine is running and will stop the engine. The control system will remain active. Moving the
ignition key switch to the "START" position again will issue a start request to the control system and the control
system will start the engine, if appropriate.
d. Activate the lanyard stop switch, if equipped. The engine will stop, but the control system will remain active. The
control system will not allow the engine to start if the lanyard stop switch is activated.
Protecting People in the Water
While Boat is in Operation
People in the water cannot take quick action to avoid a boat heading in their direction.
Approach slowly and exercise extreme caution when boating in areas where people may be in the water.
When a boat is moving and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the
propeller to rotate. This neutral propeller rotation can cause serious injury.
While the Boat is Stationary
WARNING
!
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
Shift into neutral and shut down the engine before allowing people in the water near the boat.
High‑Speed and High‑Performance
If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed
capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with
your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel
authorized repair facility.
Passenger Safety In Pontoon Boats and Deck Boats
Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a
large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat.
Falling over the front of the boat between the two pontoons will position them to be run over.
Boats Having An Open Front Deck
No one should ever be on the deck in front of the rail while the boat is in motion. Keep all passengers behind the front rail or
enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their
legs caught by a wave and pulled into the water.
mc79555-1
WARNING
!
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
Page 18 90-8M0113986 eng DECEMBER 2015
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