Mercury MerCruiser Series Manual
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Mercury MerCruiser Series Manual

6.7l tier 3 diesel inboard
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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 experience 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 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.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
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.
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
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.
WARNING
!
CAUTION
!
NOTICE
WARNING
!

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Summary of Contents for Mercury MerCruiser Series

  • Page 1 The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. 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.
  • Page 2 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 section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.

  • Page 3: Table Of Contents

    Transfer of Warranty............2 What is Not Covered............4 United States and Canada..........2 Mercury Diesel 6.7L 480, 500, 550 Light Duty Commercial Use Outside the United States and Canada......2 Limited Warranty ............... 5 Mercury Diesel 6.7L 480, 500, 550 High‑Output Recreational What is Covered..............
  • Page 4 Starting, Shifting, and Stopping..........32 Impact with Underwater Hazards........... 34 Before Starting the Engine..........32 Conditions Affecting Operation..........35 Starting a Cold Engine............ 32 Weight Distribution (Passengers and Gear) Inside the Engine Warm‑Up............. 33 Boat................. 35 Shifting................33 Bottom of Boat..............35 Engine Shut Down (Stopping).........
  • Page 5 Engine Runs Rough, Misses, or Backfires....... 82 Battery Will Not Charge............ 83 Section 8 - Customer Assistance Information Owner Service Assistance............86 Contact Information for Mercury Marine Customer Service Local Repair Service............86 ................... 87 Service Away From Home..........86 Customer Service Literature............
  • Page 6 Page iv 90-8M0117076 FEBRUARY 2018...

  • Page 7: Section 1 - Warranty

    Transfer of Warranty ............2 What is Not Covered ............4 United States and Canada ........2 Mercury Diesel 6.7L 480, 500, 550 Light Duty Commercial Outside the United States and Canada ....2 Use Limited Warranty ............5 Mercury Diesel 6.7L 480, 500, 550 High‑Output Recreational What is Covered .............

  • Page 8: Warranty Registration And Transfer

    Outside United States and Canada, check with your local distributor. You may change your address on file with Mercury Marine at any time, including at the time of a warranty claim, by calling, mailing or faxing your name, old address, new address and engine serial number to Mercury Marine’s warranty registration department.

  • Page 9: Extended Major Components Limited Warranty

    Warranty coverage is available only to retail customers who purchase the Product from a dealer authorized by Mercury Marine to distribute the Product in the country in which the sale occurred, and then only after the Mercury Marine‑specified predelivery inspection process is complete and documented. Inaccurate warranty registration information regarding recreational use, or subsequent change of use from recreational to commercial (unless properly registered) may void the warranty at the sole discretion of Mercury Marine.

  • Page 10: Termination Of Coverage

    Use of the Product for racing or other competitive activity, even by a previous owner of the Product, voids the warranty. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the Product, other than those contained in this limited warranty.

  • Page 11: Mercury Diesel 6.7L 480, 500, 550 Light Duty Commercial Use Limited Warranty

    Warranty coverage is available only to retail customers who purchase the Product from a dealer authorized by Mercury Marine to distribute the Product in the country in which the sale occurred, and then only after the Mercury Marine‑specified predelivery inspection process is completed and documented. Routine maintenance must be performed according to the schedule in the Operation and Maintenance manual in order to obtain warranty coverage.

  • Page 12: What Is Not Covered

    Use of the Product for racing or other competitive activity, even by a previous owner of the Product, voids the warranty. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the Product, other than those contained in this limited warranty.

  • Page 13: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................8 1 Lever ..............16 Maintenance Schedule Decal.......... 8 Sync ..............17 Emission Control Information Label and Engine Data Transfer (Boats equipped with dual helms) ...

  • Page 14: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers. The engine serial number can be found on the maintenance schedule decal, the emission control information label, and the engine data label.

  • Page 15: Key Switch

    Section 2 - Getting to Know Your Power Package Key Switch The key switch provides switched power to the control system, and, on some applications, can be used to start or stop an engine—although most larger vessels use a start/stop panel. There will be one key switch for each engine. For larger vessels, the key switches are typically located on the main distribution panel (MDP), with a start/stop panel at each helm.

  • Page 16: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    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. Page 10...

  • Page 17: Instrumentation

    Section 2 - Getting to Know Your Power Package Instrumentation Multifunction Display Your power package may be connected to a multifunction display (MFD), such as the SmartCraft VesselView display. Refer to your MFD owner's guide for detailed instructions on how to operate your vessel's display. There are several VesselView products available.

  • Page 18: System Link Digital Instruments

    Remote Controls IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

  • Page 19: Special Digital Throttle And Shift (Dts) Features

    Section 2 - Getting to Know Your Power Package Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn the screw clockwise to increase tension and counterclockwise to decrease tension.

  • Page 20: Dual-Handle Electronic Remote Control (Erc)-Operation And Adjustment

    Section 2 - Getting to Know Your Power Package Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment Operation The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop.

  • Page 21: Special Digital Throttle And Shift (Dts) Features-Dual Handle Erc

    Section 2 - Getting to Know Your Power Package Special Digital Throttle and Shift (DTS) Features—Dual Handle ERC The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously. 58650 Dual engine ERC Item...

  • Page 22: Throttle Only

    Section 2 - Getting to Know Your Power Package Throttle Only Placing the ERC in throttle only mode will avoid unintended gear engagement. The RPM of the engines can be increased while in throttle only mode, but the gear position will remain in neutral. 51855 THROTTLE ONLY button To engage throttle only mode:...

  • Page 23: Sync

    Section 2 - Getting to Know Your Power Package Sync Sync is an automatic engine synchronization feature that is always on unless it is manually turned off. Sync monitors the position of both ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM.

  • Page 24: Dual Handle Yacht Console Control-Operation And Adjustment

    Section 2 - Getting to Know Your Power Package Dual Handle Yacht Console Control—Operation and Adjustment Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.

  • Page 25: Troll And Throttle Response

    Section 2 - Getting to Know Your Power Package • Dual helm station transfer. ERC with DTS trackpad Neutral lights Troll mode Transfer function Dock mode Throttle only mode Single‑lever control Synchronization feature + (increase idle speed) and – (decrease idle speed) 28090 Control Function...

  • Page 26: Dock Mode

    Section 2 - Getting to Know Your Power Package Place both ERC levers in neutral. Press the troll button, located on the DTS trackpad attached to the ERC levers. Place either ERC lever into gear. The troll button lights when the lever or levers are moved out of neutral. The RPM of the engines do not change for the first 25% of ERC lever travel while the transmissions allow some slippage at lower speeds.

  • Page 27: Single-Lever Mode

    Section 2 - Getting to Know Your Power Package Press THROTTLE ONLY on the DTS trackpad. 31465 Throttle only button and light The throttle only light illuminates and the neutral lights blink. Place either ERC lever into gear. The RPM of the engines can be raised while the transmissions remain in neutral. To disengage throttle only mode: Bring both ERC levers to neutral.

  • Page 28: Synchronizing The Engines

    Some fault codes may appear on the Mercury‑approved multifunction display if other control or navigation functions are attempted after the helm transfer procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the helm transfer procedure.

  • Page 29: Vessel Interface Panel (Vip) Overload Protection

    If the circuit remains open, the electrical overload has not been eliminated. Contact your Mercury Diesel authorized repair facility to check the electrical system. Circuit breakers and fuses provide protection for the electrical system as indicated. The circuit breakers and fuses are located in various locations throughout the boat.

  • Page 30: Audio Warning System

    Section 2 - Getting to Know Your Power Package NOTE: For additional information about the on‑off switch for the DC voltage regulator, refer to the owner's literature included with your vessel. 37994 DC voltage regulator Wiring to DC voltage regulator 30‑amp fuse and holder To 24‑volt battery system positive ( +) To 24‑volt battery system negative (–)

  • Page 31: Nonconfigured Alarm-Dts Only

    Listen for the audio alarm. The alarm will sound if the system is functioning correctly. Guardian Strategy The Mercury Engine Guardian system reduces the potential for engine damage by restricting engine power when the control module detects a potential problem. Below are some examples of what Engine Guardian monitors: •...
  • Page 32 Section 2 - Getting to Know Your Power Package Notes: Page 26 90-8M0117076 FEBRUARY 2018...
  • Page 33 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Recommendations.......... 28 Engine Shut Down (Stopping)........33 Carbon Monoxide Exposure..........29 Protecting People in the Water..........33 Be Alert To Carbon Monoxide Poisoning ..... 29 While You Are Cruising .........

  • Page 34: Safe Boating Recommendations

    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.

  • Page 35: Carbon Monoxide Exposure

    Section 3 - On the Water 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.

  • Page 36: Poor Ventilation

    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.

  • Page 37: Operation Chart

    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.

  • Page 38: Starting, Shifting, And Stopping

    Check all items listed in Section 5 ‑ Maintenance Schedules. • Perform any other necessary procedures as indicated by your dealer or Mercury Diesel authorized repair facility. Starting a Cold Engine NOTE: Check the fluid levels before starting the engine. Refer to Section 5 ‑ Maintenance .

  • Page 39: Engine Warm-Up

    Check for coolant leaks. Check the coolant hoses and connection pipes of the heat exchanger, fluid coolers, aftercooler, water pump, and drain fittings. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.

  • Page 40: While Boat Is Stationary

    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.

  • Page 41: Conditions Affecting Operation

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

  • Page 42: Getting Started

    It is important to achieve the engine rated speed and appropriate load factor when selecting propellers. Mercury Marine desires a 92–95% load factor target at full throttle during the initial vessel sea trials. This load factor target provides allowance for vessel fouling and additional loads the customer may add which are greater than the sea trial weight.
  • Page 43 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 38 Approved Paints..............40 Diesel Fuel in Cold Weather..........38 ZF Marine Transmissions ............ 40 Antifreeze/Coolant..............38 ZF 85 IV ................ 41 Engine Oil................39 ZF 280 IV ..............42 Engine Specifications............

  • Page 44: Fuel Requirements

    IMPORTANT: Use of improper or water‑contaminated diesel fuel can seriously damage your engine. Use of improper fuel is considered misuse of the engine, and damage caused thereby will not be covered by the warranty. Mercury 6.7L diesel engines require ASTM #2 ULSD or ECE EN 590. Key points are: •...

  • Page 45: Engine Oil

    Shell Myrina Mopar Texaco Ursa Super TD Engine crankcase Obtain Locally Wintershall Multi‑Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W‑40 oil. 90-8M0117076 FEBRUARY 2018 Page 39...

  • Page 46: Engine Specifications

    NOTE: The system oil volumes specified are for the complete Mercury Diesel assembly; the transmission, transmission oil cooler, and transmission oil lines. Always use the dipstick to assure proper oil level when replenishing or filling oil.
  • Page 47 Section 4 - Specifications ZF 85 IV 65044 ZF 85 IV ZF 85 IV General Description and Specifications Several ratios available. Refer to the identification plate for the specific ratio. Hydraulic actuated multi‑disc clutches Suitable for twin engine installations (same ratio and torque capacity in forward or reverse) 12°...
  • Page 48 Section 4 - Specifications ZF 280 IV 59267 ZF 280 IV ZF 280 IV General Description and Specifications Several ratios available. Refer to the identification plate for the specific ratio. Hydraulic actuated multi‑disc clutches Suitable for twin engine installations (same ratio and torque capacity in forward or reverse) 14°...
  • Page 49 Section 4 - Specifications ZF 280‑1 59266 ZF 280-1 ZF 280‑1 General Description and Specifications Several ratios available. Refer to the identification plate for the specific ratio. Hydraulic actuated multi‑disc clutches Suitable for twin engine installations (same ratio and torque capacity in forward or reverse) Weight (with fluids) 77 kg (170 lbs) System oil volume...
  • Page 50 Section 4 - Specifications Notes: Page 44 90-8M0117076 FEBRUARY 2018...
  • Page 51 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner and Operator Responsibilities........46 Transmission Maintenance........... 60 Dealer Responsibilities............46 Checking the Fluid Level Before Operation ....60 Do‑It‑Yourself Maintenance Suggestions......46 Checking the Fluid Level When Hot......61 Inspection................

  • Page 52: Owner And Operator Responsibilities

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel authorized repair facility for a periodic checkup.

  • Page 53: Scheduled Maintenance

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Drain any water from the fuel filters. Weekly • Check the seawater inlets for debris or marine growth. • Check and clean the seawater strainer. • Check the battery connections and fluid level. •...

  • Page 54: Engine Oil

    Section 5 - Maintenance Task Interval Maintenance to Be Performed Every 2500 hours or 5 years (whichever occurs • Adjust the valve to rocker arm lash (clearance)—dealer service. first) Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.

  • Page 55: Filling

    Section 5 - Maintenance Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil. Refer to Filling. Starboard side dipstick marks Port side dipstick marks 65900 Filling IMPORTANT: Do not overfill the engine with oil.

  • Page 56: Engine Coolant

    Section 5 - Maintenance Use suction to draw the oil out of the sump, and into an appropriate container. Continue until oil flow ceases. Oil evacuation hose plug Oil evacuation hose Back‑up wrench 64941 Remove the pump from the hose and install the oil evacuation hose plug. Use a back‑up wrench to support the evacuation hose.

  • Page 57: Inspect The Coolant Recovery Reservoir Fluid Level

    IMPORTANT: The following engine coolant service replacement procedure does not completely drain the engine coolant. It is recommended that a Mercury Diesel service technician replace the engine coolant to ensure that the engine coolant is properly replaced. A Mercury Diesel service technician has the proper training and tools to completely drain the coolant.
  • Page 58 Section 5 - Maintenance Remove the ten screws securing the top cover, and remove the top cover from the engine. 65498 Remove the pressure cap from the coolant tank. 65497 Pressure cap Locate the engine coolant drain plug on the port side of the engine. 64945 Engine coolant drain plug Place a large capacity drain pan below the engine coolant drain plug.

  • Page 59: Air Filter

    Section 5 - Maintenance Antifreeze Specification ASTM D4985 or ASTM D6210 Tube Ref No. Description Where Used Part No. Heavy Duty Diesel Engine Cooling system 8M0124421 Coolant Antifreeze 10. Install the pressure cap at the top of the engine. 11. Verify the engine is supplied with water and start the engine. Run the engine for ten minutes to purge the system of trapped air.
  • Page 60 Section 5 - Maintenance Spray a liberal amount of air filter cleaner onto the entire air filter element, and allow it to soak for ten minutes. Do not use other detergents or diesel. Tube Ref No. Description Where Used Part No. Air Filter Cleaning Kit Air filter element 8M0140465...

  • Page 61: Oil Vapor Filter

    Section 5 - Maintenance 12. If necessary, reset the air filter restriction indicator by pressing down on the button. Air filter restriction indicator location Press down to reset 65116 Oil Vapor Filter Remove the screws securing the oil vapor filter cover and remove the cover. Oil vapor filter cover Screws (6) 64993...

  • Page 62: Fuel Filter Maintenance

    Section 5 - Maintenance Fuel Filter Maintenance Remote‑Mounted Prefilter WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.
  • Page 63 Section 5 - Maintenance Use a 9/16 in. wrench to remove the drain plug from the bottom of the fuel filter assembly, and allow the fuel to drain. Apply Loctite 567 PST Pipe Sealant to the threads of the drain plug. Tube Ref No.
  • Page 64 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. 15W-40 4-Cycle Diesel Engine Bowl O-ring 92-858042K01 Install the new O‑ring and retained bowl assembly onto the new fuel filter by turning clockwise until snug. Install the fire sleeve into its original position, unfolding it up and over the bowl interface. CAUTION When servicing the fuel filter, ensure that the factory‑installed fire sleeve is reinstalled and kept in its original position.

  • Page 65: Engine-Mounted Fuel Filter

    Section 5 - Maintenance Description lb‑in. lb‑ft Vent plug 132.7 – Vent plug Hand primer pump button 65933 12. Use a rag to clean any fuel from the exterior of the parts and bilge. Dispose of the rag in accordance with local, federal, and international regulations.

  • Page 66: Transmission Maintenance

    Connect the battery cables. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, check the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. Transmission Maintenance Checking the Fluid Level Before Operation IMPORTANT: Always check the fluid level before starting and operating.

  • Page 67: Checking The Fluid Level When Hot

    47.9 Oil evacuation hose plug Oil evacuation hose Back‑up wrench 66258 NOTE: If your system does not include transmission oil evacuation, a kit may be ordered from Mercury Marine and installed. Transmission Models Part Number 280‑1, 280‑1A 8M0138036 280 IV...
  • Page 68 Section 5 - Maintenance IMPORTANT: Mercury recommends that propylene glycol antifreeze be used in the seawater section of the cooling system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.
  • Page 69 Section 5 - Maintenance Loosen or remove the drain petcock on the front of the heat exchanger. This is located behind the starboard side engine oil dipstick. Heat exchanger drain petcock Engine oil dipstick (starboard side) 64801 Allow the seawater system to drain. Ensure debris is not clogging any of the drain points. Ensure each drain plug sealing washer is installed, and intact.

  • Page 70: Checking The Seawater Pickups

    Section 5 - Maintenance 12. Fill a container with a sufficient amount of propylene glycol antifreeze and tap water, mixed to manufacturer's recommendation to protect the engine to the lowest temperature to which it will be exposed during cold weather or extended storage.

  • Page 71: Flushing The Seawater System

    Section 5 - Maintenance Remove the strainer, drain plug, and sealing washer. Clean any debris from the strainer housing. Flush both the strainer and housing with clean water. Inspect the cover gasket and replace if damaged. Typical seawater strainer Screws and washers Cover with glass Strainer Housing...

  • Page 72: With The Boat In The Water

    Section 5 - Maintenance Use a suitable adapter to connect a flushing hose from a water tap source to the seawater inlet hose connected to the seawater pump inlet. Seawater pump Seawater inlet hose 64999 Partially open the water source to about 1/2 maximum. Do not use full water pressure. Place the remote control in the neutral, idle speed position and start the engine.

  • Page 73: Engine Seawater Pump Inspection

    Section 5 - Maintenance Utilize Mercury Marine's 8M0117941 kit to connect a flushing hose from a water tap to the seawater inlet hose connected to the seawater pump inlet. Seawater pump Seawater inlet hose 64999 Partially open the water source to about 1/2 maximum. Do not use full water pressure.

  • Page 74: Cleaning And Inspection

    Section 5 - Maintenance NOTICE Failure to close the seawater inlet or seacock when removing or replacing the anode plugs can lead to water damage. Close the seacock or remove and plug the seawater inlet hose to prevent water from entering the anode plug holes. Close the seacock.

  • Page 75: Boat Bottom Care

    Section 5 - Maintenance Description lb‑in. lb‑ft Anodes – 22.1 Open the seacock. 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. Verify that the seawater pickup pump is supplied cooling water.
  • Page 76 Section 5 - Maintenance Appearance Description Cause Solution Misalignment Sidewalls of the belt may appear glazed or the edge‑cord may Pulley misalignment. Misalignment Replace the belt and verify become frayed and the ribs are forces the belt to kink or twist while the alignment of the pulley.

  • Page 77: Serpentine Belt

    Section 5 - Maintenance Serpentine Belt Inspection Remove the five nuts securing the belt cover and remove the belt cover. Belt cover Belt cover nuts 66057 Inspect the belt for proper tension and for the following: • Excessive wear • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable.

  • Page 78: Replacement

    Section 5 - Maintenance Description lb‑in. lb‑ft Belt cover nuts (5) 97.3 – If the belt condition is poor, proceed to Replacement. Replacement IMPORTANT: If the belt condition is acceptable for use, it must be installed in the same direction of rotation as when first used. Remove the five nuts securing the belt cover and remove the belt cover.

  • Page 79: Battery

    Section 5 - Maintenance Replace the serpentine belt and ensure that the belt is inserted correctly inside the alternator pulley, the water pump pulley, the crankshaft pulley, and the guide pulleys. Belt routing Alternator pulley Water pump pulley Crankshaft pulley Guide pulleys Automatic tensioner 66059...
  • Page 80 Section 5 - Maintenance Notes: Page 74 90-8M0117076 FEBRUARY 2018...
  • Page 81 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather (Freezing Temperature), Seasonal Storage, Battery................78 and Extended Storage............76 Recommissioning..............78 Seasonal Storage Instructions (Six Months or Less)..76 Extended Storage Instructions (Exceeding Six Months) ..................77 90-8M0117076 FEBRUARY 2018 Page 75...

  • Page 82: Cold Weather (Freezing Temperature), Seasonal Storage, And Extended Storage

    Section 6 - Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury Marine strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

  • Page 83: Extended Storage Instructions (Exceeding Six Months)

    8M0094988 Mercury Phantom Black 92‑802878Q1 12. Your Mercury Diesel authorized repair facility should now perform all checks, inspections, lubrications, and fluid changes outlined in Section 5 ‑ Maintenance Schedules. Extended Storage Instructions (Exceeding Six Months) IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility.

  • Page 84: Battery

    NOTE: Discharge of propylene glycol into the environment may be restricted by law. Contain and dispose of propylene glycol in accordance with federal, state, and local laws and guidelines. On engines prepared for extended storage, have a Mercury Diesel authorized repair facility install the seawater pump impeller, if it was removed for storage.
  • Page 85 Section 6 - Storage 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. 12. Supply cooling water to the water inlet openings. 13.
  • Page 86 Section 6 - Storage Notes: Page 80 90-8M0117076 FEBRUARY 2018...
  • Page 87 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Troubleshooting Charts............82 Poor Performance............82 Starter Motor Will Not Crank Engine, or Cranks Slow... 82 Incorrect Engine Temperature........82 Engine Will Not Start, or Is Hard to Start....... 82 Low Engine Oil Pressure..........

  • Page 88: Troubleshooting Charts

    Fuel line or tank vent line kinked or clogged Remove obstructions from lines. Air in fuel system Prime fuel system. Faulty wire connections Check wire connections. Have the electronic fuel system checked by a Mercury Diesel authorized repair Electronic fuel system fault facility. Engine Runs Rough, Misses, or Backfires Possible Cause...

  • Page 89: Low Engine Oil Pressure

    Alternator drive belt loose or in poor condition Replace or adjust. Unacceptable battery condition Test battery. NOTE: Check for faults on the MFD and contact a Mercury Diesel authorized repair facility for assistance. 90-8M0117076 FEBRUARY 2018 Page 83...
  • Page 90 Section 7 - Troubleshooting Notes: Page 84 90-8M0117076 FEBRUARY 2018...
  • Page 91 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 86 Contact Information for Mercury Marine Customer Local Repair Service ............ 86 Service ................. 87 Service Away From Home ..........86 Customer Service Literature..........87 Stolen Power Package ..........

  • Page 92: Owner Service Assistance

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 93: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 94: Other Languages

    Section 8 - Customer Assistance Information Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 95 Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection Checklist........... 90 Customer Delivery Inspection..........90 90-8M0117076 FEBRUARY 2018 Page 89...
  • Page 96 Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 97 Section 9 - Checklists Completed Item ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) ⃞ ⃞ Customer is aware of the MerCathode location and controller light function. Registration: ⃞ Complete and submit warranty registration—provide the customer with a copy 90-8M0117076 FEBRUARY 2018...
  • Page 98 Section 9 - Checklists Notes: Page 92 90-8M0117076 FEBRUARY 2018...
  • Page 99 Section 10 - Maintenance Log Section 10 - Maintenance Log Table of Contents Scheduled Maintenance Log..........94 Vessel Maintenance Notes........... 95 90-8M0117076 FEBRUARY 2018 Page 93...
  • Page 100 Section 10 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...
  • Page 101 Section 10 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0117076 FEBRUARY 2018 Page 95...

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