How it Works
Mercury
Loading...
TDI 4.2L
User Manual
89 pgs5.79 Mb0
Table of contents
Loading...

Mercury TDI 4.2L User 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.
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
8M0114081 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.

TDI 4.2L Diesel Sterndrive 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
TDI 4.2L Engine Description............................................... 2
Identification........................................................................ 2
Audio Warning System....................................................... 2
Testing the Audio Warning System................................ 3
Digital Throttle and Shift..................................................... 3
Instrumentation................................................................... 3
VesselView..................................................................... 3
SmartCraft Speedometer, Tachometer, and Digital
Gauges........................................................................... 3
System Link Digital Gauges........................................... 4
Controls...................................................................................... 5
Switches............................................................................. 5
Emergency Stop Switch...................................................... 6
Lanyard Stop Switch........................................................... 6
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition.............................................. 7
Section 2 - On The Water
Safe Boating Recommendations............................................. 16
Carbon Monoxide Exposure.................................................... 17
Be Alert To Carbon Monoxide Poisoning........................... 17
Stay Clear of Exhaust Areas.............................................. 17
Good Ventilation ................................................................ 17
Poor Ventilation ................................................................. 18
Duty Cycle................................................................................ 18
Basic Boat Operation......................................................... 18
Duty Cycle Rating......................................................... 18
Pleasure Duty Rating....................................................18
Basic Boat Operation............................................................... 19
Operation Chart................................................................ 19
Freezing Temperature and Cold Weather Operation....... 19
Drain Plug and Bilge Pump............................................... 20
Starting, Shifting, and Stopping............................................... 20
Before Starting the Engine................................................ 20
Starting a Cold Engine...................................................... 21
Engine Warm‑Up.............................................................. 21
Starting a Warm Engine ................................................... 21
Shifting.............................................................................. 22
Engine Shutdown (Stopping)............................................ 22
Starting the Engine After Stopped While in Gear............. 22
Trailering the Boat.................................................................... 22
Protecting People In The Water............................................... 22
Protecting People in the Water......................................... 22
Digital Throttle and Shift..................................................... 7
Engine Electrical System Overload Protection.......................... 7
Fuses....................................................................................7
Vessel Adapter Assembly Fuse Replacement..................... 8
Lanyard Stop Switch.................................................................. 8
Keep the Lanyard Stop Switch and Lanyard Cord in Good
Operating Condition............................................................. 9
Power Trim............................................................................... 10
Single‑Engine Trim and Trailer...........................................10
Dual‑Engine Trim and Trailer............................................. 11
Power Trim and MerCathode Overload Protection.................. 11
Emissions Information.............................................................. 12
Exhaust Gas Emissions Certificate (Europe Only)............. 12
Owner Responsibility..........................................................12
Engine Components................................................................ 13
While Boat is in Operation............................................ 22
While the Boat is Stationary......................................... 23
High Speed and High Performance.................................. 23
Passenger Safety in Pontoon Boats and Deck Boats....... 23
Boats Having an Open Front Deck............................... 23
Boats with Front‑Mounted, Raised‑Pedestal Fishing
Seats............................................................................ 23
Wave and Wake Jumping........................................................ 24
Impact with Underwater Hazards............................................. 24
Conditions Affecting Operation................................................ 25
Weight Distribution (Passengers and Gear) Inside the
Boat.................................................................................. 25
Bottom of Boat.................................................................. 25
Cavitation.......................................................................... 25
Ventilation......................................................................... 25
Elevation and Climate....................................................... 25
Propeller Selection............................................................ 26
Break‑In................................................................................... 26
Initial Break‑In Procedure................................................. 26
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)......................................................... 26
Engine Break‑In................................................................ 26
20‑Hour Break‑In Period...............................................26
After the 20‑Hour Break‑In Period................................ 27
End of First Season Checkup........................................... 27
Section 3 - Specifications
Fuel Requirements................................................................... 30
Nonferrous Metals and the Fuel System............................ 30
Diesel Fuel in Cold Weather.................................................... 30
Antifreeze/Coolant................................................................... 30
Engine Oil ............................................................................... 31
90-8M0114081 eng DECEMBER 2015 Page i
Engine Specifications............................................................... 31
Fluid Specifications.................................................................. 32
Engine............................................................................... 32
Bravo Sterndrive Fluid Specifications—Diesel................. 32
Power Steering and Power Trim Fluids........................... 32
Approved Power Steering Fluids.................................32
Section 4 - Maintenance
Approved Power Trim Fluids....................................... 32
Approved Paints..................................................................... 32
Owner and Operator Responsibilities..................................... 34
Dealer Responsibilities........................................................... 34
Maintenance........................................................................... 34
Replacement Parts Warning................................................... 35
Inspection............................................................................... 35
Routine Maintenance.............................................................. 35
Start of Season................................................................. 35
Each Day Start.................................................................. 35
Each Day End................................................................... 35
Weekly.............................................................................. 35
End of Season.................................................................. 35
Scheduled Maintenance......................................................... 36
Once a Year or Every 200 Operating Hours (Whichever
Occurs First)..................................................................... 36
Maintenance Notice.......................................................... 36
Every 5 Years or 500 Hours (Whichever Occurs First)..... 36
Every 5 Years or 1,000 Operating Hours (Whichever
Occurs First)..................................................................... 36
Every 5 Years or 2,000 Operating Hours (Whichever
Occurs First)..................................................................... 36
Engine Oil............................................................................... 36
Checking........................................................................... 37
Filling................................................................................ 37
Draining Using the Easy Drain System, if Equipped......... 37
Changing Oil and Filter..................................................... 38
Sterndrive Gear Lube............................................................. 39
Checking........................................................................... 39
Filling................................................................................ 39
Changing.......................................................................... 40
Power Trim Fluid.................................................................... 43
Checking........................................................................... 43
Filling................................................................................ 44
Changing.......................................................................... 45
Power Steering Fluid.............................................................. 45
Checking........................................................................... 45
Filling................................................................................ 45
Changing.......................................................................... 46
Engine Coolant....................................................................... 46
Checking the Coolant Level.............................................. 47
Adding Coolant................................................................. 47
Air Filter.................................................................................. 47
Removal............................................................................ 47
Inspection and Cleaning................................................... 47
Installation......................................................................... 48
Fuel Filter................................................................................ 48
Draining Water from the Filter........................................... 48
Replacing the Filter........................................................... 48
Purging the Fuel System........................................................ 49
Fuel System............................................................................ 49
Priming.............................................................................. 49
Fuel Tank Cleaning and Flushing..................................... 49
Seawater System................................................................... 49
Seawater Pump Impeller Inspection................................ 49
Sterndrive Water Inlets Check......................................... 50
Flushing and Draining the Seawater System.................. 51
Checking the Seawater Pickups...................................... 52
Cleaning the Seawater Strainer, if Equipped.................. 52
Corrosion Protection............................................................... 53
General Information......................................................... 53
Sacrificial Anode.............................................................. 53
Antifouling Paint.............................................................. 54
Lubrication.............................................................................. 54
Steering System.............................................................. 54
Throttle Cable.................................................................. 55
Shift Cable....................................................................... 55
Transom Assembly.......................................................... 55
Propeller Shaft................................................................. 55
Engine Coupler................................................................ 56
Driveshaft Extension Models........................................... 57
Maintaining Torques............................................................... 57
Gimbal Ring U‑bolt Nuts.................................................. 57
Engine Mounts................................................................ 58
Propellers............................................................................... 58
Bravo Sterndrive Propeller Removal............................... 58
Bravo One Models...................................................... 58
Bravo Two Models...................................................... 59
Bravo Three Models.................................................... 60
Bravo Sterndrive Propeller Installation............................ 61
Bravo One Models...................................................... 61
Bravo Three................................................................ 62
Drive Belts.............................................................................. 63
Drive Belt......................................................................... 63
Drive Belt Failure Identification........................................ 63
Battery.................................................................................... 64
Battery Precautions for Multiple Engines................................ 65
Alternators........................................................................ 65
Engine Control Unit (ECU)................................................ 65
Batteries............................................................................ 65
Battery Switches............................................................... 65
Battery Isolators................................................................ 65
Generators........................................................................ 65
Section 5 - Storage
Cold Weather (Freezing Temperature), Seasonal Storage, and
Extended Storage................................................................... 68
Preparing Your Power Package for Seasonal or Extended
Storage............................................................................ 68
Page ii 90-8M0114081 eng DECEMBER 2015
Seasonal Storage Instructions........................................ 68
Extended Storage Instructions........................................ 69
Battery Storage............................................................... 70
Recommissioning the Power Package................................... 70
Section 6 - Troubleshooting
Troubleshooting....................................................................... 72
Troubleshooting Charts............................................................ 72
Starter Motor Will Not Crank Engine, or Cranks Slow...... 72
Engine Will Not Start, or Is Hard to Start.......................... 72
Engine Runs Rough, Misses, or Backfires....................... 72
Poor Performance............................................................. 73
No Fuel or Faulty Fuel Supply.......................................... 73
Engine Will Not Start, Starter Does Not Turn................... 73
Excessive Engine Temperature........................................ 73
Insufficient Engine Temperature....................................... 74
Section 7 - Customer Assistance Information
Owner Service Assistance....................................................... 78
Local Repair Service.......................................................... 78
Service Away From Home..................................................78
Stolen Power Package....................................................... 78
Attention Required After Submersion................................. 78
Replacement Service Parts................................................ 78
Parts and Accessories Inquiries................................... 78
Resolving a Problem.......................................................... 78
Section 8 - Maintenance Log
Low Engine Oil Pressure.................................................. 74
Battery Will Not Charge.................................................... 74
Remote Control Operates Hard, Binds, Has Excessive
Free‑play, or Makes Unusual Sounds.............................. 74
Steering Wheel Turns Hard or Jerky................................ 74
Power Trim Does Not Operate (Electric Motor Operates but
Sterndrive Unit Does Not Move)....................................... 74
Power Trim Does Not Operate (Electric Motor Does Not
Operate)............................................................................ 75
Contact Information for Mercury Marine Customer Service
........................................................................................... 79
Customer Service Literature.................................................... 79
English Language.............................................................. 79
Other Languages................................................................80
Ordering Literature................................................................... 80
United States and Canada................................................. 80
Outside the United States and Canada.............................. 80
Scheduled Maintenance Log................................................... 82 Vessel Maintenance Notes...................................................... 83
90-8M0114081 eng DECEMBER 2015 Page iii
Page iv 90-8M0114081 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
Section 1 - Getting to Know Your Power Package
Table of Contents
Features and Controls............................................................ 2
TDI 4.2L Engine Description............................................ 2
Identification.....................................................................2
Audio Warning System.................................................... 2
Testing the Audio Warning System ......................... 3
Digital Throttle and Shift.................................................. 3
Instrumentation................................................................ 3
VesselView .............................................................. 3
SmartCraft Speedometer, Tachometer, and Digital
Gauges .................................................................... 3
System Link Digital Gauges .................................... 4
Controls.................................................................................. 5
Switches.......................................................................... 5
Emergency Stop Switch...................................................6
Lanyard Stop Switch........................................................ 6
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition ....................................... 7
1
Digital Throttle and Shift.................................................. 7
Engine Electrical System Overload Protection....................... 7
Fuses .............................................................................. 7
Vessel Adapter Assembly Fuse Replacement ............... 8
Lanyard Stop Switch............................................................... 8
Keep the Lanyard Stop Switch and Lanyard Cord in
Good Operating Condition .............................................. 9
Power Trim........................................................................... 10
Single‑Engine Trim and Trailer ..................................... 10
Dual‑Engine Trim and Trailer ....................................... 11
Power Trim and MerCathode Overload Protection............... 11
Emissions Information.......................................................... 12
Exhaust Gas Emissions Certificate (Europe Only) ....... 12
Owner Responsibility .................................................... 12
Engine Components............................................................. 13
90-8M0114081 eng DECEMBER 2015 Page 1
Section 1 - Getting to Know Your Power Package
52307

Features and Controls

TDI 4.2L Engine Description

• Four‑stroke V8 diesel engine
• 4.2 liter displacement (252 cid)
• Common‑rail direct fuel injection
• Chain‑driven overhead‑cam hydraulic valvetrain
• Pressurized engine lubrication with replaceable oil filter
• Dry air filter
• Variable geometry turbochargers
• Twin cooling circuits, utilizing seawater cooling and closed‑circuit cooling Refer to Engine Specifications for additional details. Refer to Engine Components for the locations of engine components referenced in this manual.

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.

Audio Warning System

Your Mercury Diesel power package may be equipped with an audio warning system. The audio warning system will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
The audio warning system will sound with a continuous horn if one of the following occurs:
• The engine oil pressure is too low
• The coolant temperature is too hot
• Water in fuel
• Low coolant level
NOTICE
A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage components. If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation.
Page 2 90-8M0114081 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
52421
If the alarm sounds, stop the engine immediately if you are not in a hazardous situation. Investigate the cause and correct it, if possible. If you cannot determine the cause, consult your Mercury Diesel authorized repair facility.
Testing the Audio Warning System
1. Turn the ignition switch to the "RUN" or 1 position; do not start the engine.
2. Push the audio test switch toggle lever down and hold it.
3. Listen for the alarm. The alarm will sound if the system is functioning correctly.

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.

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
• Coolant temperature
• Oil pressure
• Battery voltage
• Fuel consumption
• Engine operating hours
90-8M0114081 eng DECEMBER 2015 Page 3
Section 1 - Getting to Know Your Power Package
abc
d
37925
a
b
c
c
50400
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
Page 4 90-8M0114081 eng DECEMBER 2015

Controls

38160
28082
OFF
ON
38277

Switches

Four‑Position Key Switch
NOTE: The key can only be removed with the key switch in the "OFF" position.
Dual‑Engine Start‑Stop Switch
Section 1 - Getting to Know Your Power Package
•
"OFF" ‑ In the "OFF" position, all electrical circuits are off. The engine will not operate with the key switch in the "OFF" position.
•
"ACC" ‑ In the "ACC" position, any accessories connected to the electrical circuits can be operated. The engine will not operate with the key switch in the "ACC" position.
•
"ON" ‑ In the "ON" position, all electrical circuits and instrumentation receive power. The engine can be started with an optional start‑stop switch.
•
"START" ‑ Turn the key to the start position and release to start the engine.
A start‑stop switch is optional equipment. The start‑stop switch works in conjunction with the key switch. There is one start‑stop switch for each engine. Each button on a multi‑engine start‑stop switch functions independently. The key switch must be in the "ON" position to start a stopped engine with the start‑stop switch. Pressing a start‑stop switch button when an engine is running will shut down the corresponding engine.
Bilge Blower Toggle Switch
Operates the bilge blower, if equipped.
90-8M0114081 eng DECEMBER 2015 Page 5
Section 1 - Getting to Know Your Power Package
35308
c
a
b
53910
OFF
RUN
ATTACH LANYARD

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.
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
Page 6 90-8M0114081 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
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.
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.

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.

Engine Electrical System Overload Protection

Fuses

!
CAUTION
Failure to protect wiring with an appropriate fuse can damage the wiring and start a fire. When installing any accessories, we recommend using a Mercury accessory kit. Always use the appropriate fuse to protect wiring.
Individual circuits are protected by fuses. If an electrical overload occurs, a fuse will burn out. Find and correct the cause for the electrical overload before replacing the fuse.
90-8M0114081 eng DECEMBER 2015 Page 7
Section 1 - Getting to Know Your Power Package
a
b
52201
a
b
c
d
e
f
52510
Two fuses are located on the top of the engine. Remove the engine cover to access these fuses. Be certain to replace an open fuse only with one of the same rating.
a - 15‑amp fuse b - 25‑amp fuse
The remaining fuses are located in the vessel adapter assembly (refer to your boat owner's manual for location) and on the rear side of the control unit of the individual instrumentation.

Vessel Adapter Assembly Fuse Replacement

NOTE: Refer to your boat owner's manual for the location of the vessel adapter assembly (VAA). The key for the VAA was provided along with the ignition keys.
1. Turn the ignition switch to the "OFF" position.
2. Unlock and open the cover of the vessel adapter assembly.
3. Determine which fuse belongs to the failed circuit using the illustration below.
a - Helm power 5‑amp fuse b - EFP 1‑amp fuse c - Feature A 1‑amp fuse d - T.15 5‑amp fuse e - Feature B 1‑amp fuse f - Main power 10‑amp fuse
4. Replace the blown fuse with a new fuse of the same rating.
5. Close and lock the cover of the VAA.

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. Tiller handle outboards and some remote control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed as an accessory ‑ generally on the dashboard or side adjacent to the operator's position.
A decal near the lanyard stop switch is a visual reminder for the operator to attach the lanyard to their personal flotation device (PFD) or wrist.
Page 8 90-8M0114081 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
c
a
b
53910
OFF
RUN
ATTACH LANYARD
The lanyard cord is usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a clip on the other end for attaching to the operator's PFD or wrist. 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 normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard.
a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch
Read the following Safety Information before proceeding. Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far
enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position. Falling overboard and accidental ejections are more likely to occur in certain types of boats such as low sided inflatables, bass boats, high performance boats, and light, sensitive handling fishing boats operated by a hand tiller. Falling overboard and accidental ejections are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow or obstacle infested waters, releasing your grip on a steering wheel or tiller handle that is pulling in one direction, drinking alcohol or consuming drugs, or daring high speed boat maneuvers.
While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (if the operator is accidentally ejected).
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.
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.
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 gearcase or propeller.
• Loss of power and directional control in heavy seas, strong current, or high winds.
• Loss of control when docking.

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Before each use, check to ensure the lanyard stop switch works properly. Start the engine and stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, visually inspect the lanyard cord to ensure 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.
90-8M0114081 eng DECEMBER 2015 Page 9
Section 1 - Getting to Know Your Power Package

Power Trim

Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM engine speed), and shallow water operation.
WARNING
!
Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out limiting device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's side support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance, trim the sterndrive so that the boat bottom is at a 3–5° angle to the water.
3 - 5
mc79528
Trimming the sterndrive up (out) can:
• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Cause the boat to accelerate and plane off slower
• In excess, cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if trimmed up (out) to a point where any cooling water intake holes are above the water line
mc78529
Trimming the sterndrive down (in) can:
• Help the boat accelerate and plane off quicker
• Generally improve the ride in choppy water
• In most cases, reduce boat speed
• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
mc79530
Single‑Engine Trim and Trailer
Single engine applications have a button that can be pressed to trim the sterndrive unit up (out) or down (in).
Page 10 90-8M0114081 eng DECEMBER 2015
Section 1 - Getting to Know Your Power Package
a
c
50534
b
To raise the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM), and shallow water operation push the trim button to raise the sterndrive to the full up (out) position.
Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.
Dual‑Engine Trim and Trailer
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems. If using an external tie bar, raise and lower all drives together as a unit.
Dual‑engine applications may have a single integral button to operate both sterndrives simultaneously or may have separate buttons for each sterndrive.
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.

Power Trim and MerCathode Overload Protection

If an electrical overload on the electrical system occurs, a fuse will open (blow). Find and correct the cause before replacing the fuse.
NOTE: If you must operate the engine in an emergency, turn off and disconnect all accessories from the engine and instrumentation wiring if you cannot find and correct the cause for the electrical overload or excessive current draw. Replace the fuse. If the fuse burns out, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility.
1. The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump.
a - 20‑amp in‑line fuse holder b - 110‑amp fuse
a
b
2. There are several different Quicksilver MerCathode systems available. Each has a fuse connected to the positive (+)
terminal on the controller. If the fuse is open (blown), the system will not operate, resulting in a loss of corrosion protection. Replace the fuse with one of the same amp rating.
a - MerCathode b - Red/purple wire c - Fuse
9208
90-8M0114081 eng DECEMBER 2015 Page 11
Section 1 - Getting to Know Your Power Package
xxxxxxxxx
x.x
x x
52250
xxxxxxxxx

Emissions Information

Exhaust Gas Emissions Certificate (Europe Only)

A tamper‑resistant label is affixed to the engine at time of manufacture. In addition to the required exhaust gas emissions certificate number, the label lists the engine serial number, engine family, maximum RPM, engine power, and weight. Note that the exhaust gas emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury Diesel about the availability of replacement decals before proceeding.

Owner Responsibility

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.
Page 12 90-8M0114081 eng DECEMBER 2015

Engine Components

52199
a
b
c
d
e
f
g
h
i
Section 1 - Getting to Know Your Power Package
a - Exhaust outlet b - Turbocharger c - Oil filter d - Engine oil filler cap e - Sacrificial anode (hidden) f - Intercooler g - Seawater pump h - Heat exchanger i - Starter
90-8M0114081 eng DECEMBER 2015 Page 13
Section 1 - Getting to Know Your Power Package
a
c
b
d
e
f
g
h
i
52200
a - Engine oil dipstick b - Coolant resevoir c - Coolant reservoir cap d - Ribbed V‑belt e - Alternator f - Fuses g - Air filter h - Fuel injection pump drive belt (hidden)
NOTE: The fuel injection pump drive belt is located at the rear of the engine and is protected by a cover. Refer to your Mercury Diesel–authorized repair facility for servicing.
i - Electronic control units
Page 14 90-8M0114081 eng DECEMBER 2015
Table of Contents
Section 2 - On The Water
Section 2 - On The Water
Safe Boating Recommendations.......................................... 16
Carbon Monoxide Exposure................................................. 17
Be Alert To Carbon Monoxide Poisoning ..................... 17
Stay Clear of Exhaust Areas ........................................ 17
Good Ventilation .......................................................... 17
Poor Ventilation ........................................................... 18
Duty Cycle............................................................................ 18
Basic Boat Operation .................................................... 18
Duty Cycle Rating .................................................. 18
Pleasure Duty Rating ............................................ 18
Basic Boat Operation............................................................ 19
Operation Chart............................................................. 19
Freezing Temperature and Cold Weather Operation.... 19
Drain Plug and Bilge Pump............................................20
Starting, Shifting, and Stopping............................................ 20
Before Starting the Engine.............................................20
Starting a Cold Engine................................................... 21
Engine Warm‑Up........................................................... 21
Starting a Warm Engine ................................................21
Shifting........................................................................... 22
Engine Shutdown (Stopping)......................................... 22
Starting the Engine After Stopped While in Gear.......... 22
Trailering the Boat................................................................ 22
Protecting People In The Water........................................... 22
Protecting People in the Water...................................... 22
While Boat is in Operation ..................................... 22
While the Boat is Stationary .................................. 23
High Speed and High Performance............................... 23
Passenger Safety in Pontoon Boats and Deck Boats....23
Boats Having an Open Front Deck ........................ 23
Boats with Front‑Mounted, Raised‑Pedestal Fishing
Seats ..................................................................... 23
Wave and Wake Jumping..................................................... 24
Impact with Underwater Hazards......................................... 24
Conditions Affecting Operation............................................. 25
Weight Distribution (Passengers and Gear) Inside the
Boat............................................................................... 25
Bottom of Boat............................................................... 25
Cavitation....................................................................... 25
Ventilation...................................................................... 25
Elevation and Climate.................................................... 25
Propeller Selection.........................................................26
Break‑In................................................................................ 26
Initial Break‑In Procedure.............................................. 26
Sterndrive 10‑Hour Break‑In Period (New or With
Replacement Gears)......................................................26
Engine Break‑In............................................................. 26
20‑Hour Break‑In Period ....................................... 26
After the 20‑Hour Break‑In Period ......................... 27
End of First Season Checkup........................................ 27
2
90-8M0114081 eng DECEMBER 2015 Page 15
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.
Page 16 90-8M0114081 eng DECEMBER 2015
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:
90-8M0114081 eng DECEMBER 2015 Page 17
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)

Duty Cycle

Basic Boat Operation

IMPORTANT: Damage caused by improper application or failure to operate the power package within the specified operating parameters will not be covered by the Mercury Diesel Limited Warranty.
Duty Cycle Rating
It is the responsibility of the boat manufacturer or the installing dealer to ensure that the power package is properly applied. In all cases, the power package must be equipped with the gear ratio that allows the engine to operate at wide‑open throttle (WOT) at the rated engine RPM. The power package must also be applied in accordance with recommendations indicated in the appropriate applications manual. Use of Mercury Diesel engines in other than the applications indicated by the following information and in the appropriate applications manual requires written approval from an authorized Mercury Diesel application engineer.
Pleasure Duty Rating
The pleasure duty rating applies to recreational planing craft used exclusively for pleasure and recreation. Typical pleasure craft include sailboats, ski boats, runabouts, speedboats, and other planing hulls. Application must conform to the Pleasure Craft/Recreational duty cycle shown in the following table.
Page 18 90-8M0114081 eng DECEMBER 2015
Section 2 - On The Water
Engine speed (percent of WOT) 100 91 80 63 Idle
Engine power (percent of total) 100 75 50 25 0
(percent of total operating time)
1
5
4

Basic Boat Operation

Operation Chart

Starting Procedure
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.
EPA Mode Number
Cycle 5
Duty Cycle
Time at given mode
Chart showing full power operation is limited to a maximum of 1 of 12 hours
2
3
14584
After Starting While Underway Stopping and Shut Down 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.
1 - Mode 1: 1.0 hour (8%) 2 - Mode 2: 1.5 hours (13%) 3 - Mode 3: 2.0 hours (17%) 4 - Mode 4: 4.0 hours (32%) 5 - Mode 5: 3.5 hours (30%)
Frequently review all instrumentation to monitor engine condition.
Listen for the audio alarm.
1 2 3 4 5
8 13 17 32 30
Modes
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.
90-8M0114081 eng DECEMBER 2015 Page 19
Section 2 - On The Water
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 and a marine application bilge air 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.

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 very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the 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:
• Verify seawater pickup is open.
• Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.
• Ensure that the engine crankcase is filled to the correct level with the proper grade of oil for the prevailing temperature. Refer to Specifications—Engine Oil.
• Ensure that all electrical connections are secure.
•
Check all items listed 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 manual.
Page 20 90-8M0114081 eng DECEMBER 2015
Section 2 - On The Water

Starting a Cold Engine

IMPORTANT: Check the fluid levels before starting the engine. Refer to the Maintenance Schedule. Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.
1. Run the engine compartment bilge blower for five minutes, or open the engine hatch to air out the bilge before attempting
to start the engine.
2. Place the sterndrive in the full down (in) position.
3. Place the control handle in neutral.
4. If the engine has not been run for a long period of time and will not readily start with the standard starting procedure,
proceed as follows.
5. Turn the ignition switch to the "ON" position and the fuel pump will run for five seconds. Turn the ignition switch to the
"OFF" position and wait for five seconds. repeat this step six times.
6. Start the engine.
IMPORTANT: Within seconds after starting the engine, the oil pressure should exceed a minimum of 10 psi (69 kPa). If the oil pressure is below the minimum specification, stop the engine then locate and correct the problem. If you are unable to determine the problem, see your Mercury Diesel‑authorized repair facility.
NOTICE
Engaging the starter motor while the engine is operating can damage the starter motor or flywheel. Do not engage the starter motor continually for longer than 15 seconds. Do not engage the starter motor when the engine is operating.
7. Verify that the charge indicator and oil pressure warning lamps are off.
8. Verify that all instrumentation is functioning properly and indicating normal readings.
9. Allow the engine to reach a normal operating temperature before demanding power from the engine.
Engine Warm‑Up
1. After starting the engine, verify that all instrumentation is functioning properly.
2. Operate the engine at 1000–1200 RPM until the engine temperature is within the normal operating range. It is important
that any engine be warmed up before applying full load. The warm‑up period provides time for the lubricating oil to establish a film between moving parts.
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.
3. After the engine has reached operating temperature:
a.
The oil pressure should be within the range specified. Refer to Specifications—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 drive system for oil leakage. Specifically inspect the oil filter, oil lines, oil line connectors, and
oil pan. d. Check for coolant leaks. Check the coolant hoses and connection pipes of the heat exchanger, fluid coolers,
aftercooler, water pump, and drain fittings for leaks.
4. Correct any problems found, or see your Mercury Diesel‑authorized repair facility if you are unable to determine the problem.

Starting a Warm Engine

1. Run the engine compartment bilge blower for five minutes, or open the engine hatch to air out the bilge before attempting to start the engine.
2. Move the remote control handle to the "NEUTRAL" position.
3. Turn the key switch to the "ON" position.
4. Turn the key switch to the "START" position and release the key when the engine starts. Verify that the charge indicator and oil pressure warning lamps turn off.
5. Verify that the instrumentation functions properly and normal readings are indicated.
90-8M0114081 eng DECEMBER 2015 Page 21
Loading...
+ 62 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use