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PCM DI Catanium CES Owner's Operation And Maintenance Manual

2017
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OWNER'S OPERATION
AND MAINTENANCE
MANUAL

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Summary of Contents for PCM DI Catanium CES

  • Page 1 OWNER’S OPERATION AND MAINTENANCE MANUAL...
  • Page 2 This Page Was Intentionally Left Blank...
  • Page 3 Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to Team PCM, which puts you in the company of tens of thousands of boaters who have relied on Pleasurecraft inboards as their power of choice for over 30 years.
  • Page 4 PROPOSITION 65 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Part Number - L510010D-17...

  • Page 5: Table Of Contents

    Registration Information (Warranty Registration Card is located at the back of this manual) ..................... 5-Year Transferable Limited Warranty ................. Federal/California Emission Control Warranty Statement ............PCM Inboard Marine Engine General Emissions Warranty Coverage ..........................Safety Information ..........................Replacement Parts ...........................
  • Page 6 TABLE OF CONTENTS ....................Electrical System Relay and Fuse Block ......................Electrical System Fuses ........................Boat’s Ignition Fuse ..................Electrical System Wiring and Connectors ............................ Battery ....................Cooling System Sacrificial Anode ......................Checking Coolant Level ....................... Testing Coolant For Alkalinity ................

  • Page 7: Introduction

    You may also visit our web site at www. pleasurecraft.com. Again, thanks for choosing PCM. We sincerely wish you happy days on the water. L510010D-17...

  • Page 8: 5-Year Transferable Limited Warranty

    The obligation of PCM set forth in the first paragraph of this warranty shall be the exclusive remedy for any breach of warranty hereunder, and any owner or user’s sole remedy in the event of breach of the warranty is repair or replacement of the product or any warranted part thereof as set forth in this warranty. With this sole exception, PCM shall not be liable for any direct or...

  • Page 9: Federal/California Emission Control Warranty Statement

    PCM recommends that you retain all receipts covering maintenance on your inboard engine, but PCM cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

  • Page 10: Pcm Inboard Marine Engine General Emissions Warranty Coverage

    PCM inboard marine engine manufactured after January 1, 2008 for CARB and after January 1, 2011 for EPA, that the emissions control devices on PCM inboard marine engines are free from defects in materials and workmanship when manufactured and will...
  • Page 11 11. PCM original equipment parts are “identical in all material respects to that part as described in the engine manufacturer’s application for certification”. The use of any replacement parts not supplied by PCM may not meet this requirement and will be grounds for disallowing a claim made under this warranty.
  • Page 12 INTRODUCTION - 1 This Page Was Intentionally Left Blank L510010D-17...

  • Page 13: Safety Information

    U.S. Coast Guard approved, could cause a fire operation, are major accident prevention measures. or explosion hazard and should be avoided. Always request that genuine PCM Engines replacement parts be used in any repairs or maintenance being performed on your engine(s).

  • Page 14: Boating Responsibilities

    BOATING RESPONSIBILITIES - 2 CARBON MONOXIDE HAZARD To find out more about making boating safer, including how you can prevent carbon monoxide poisoning on recreational boats, contact: DANGER National Marine Manufacturers Association Carbon Monoxide (CO) is a colorless, odorless 200 East Randolph Drive and tasteless gas.

  • Page 15: Safe Boating Suggestions

    Tools necessary for minor water safety enforcement repairs. • Spare propeller. PCM Engines highly recommends that all power boat • Anchor and anchor line. operators attend one of these courses. To help locate • First aid kit and first aid book.

  • Page 16: Rules Of The Road

    BOATING RESPONSIBILITIES - 2 RULES OF THE ROAD Boat Capacity • Load only to manufacturer’s specifications. Channel Buoy Guide • Distribute load evenly; keep it low. • Passengers should only ride on the parts of the The color of the paint is the only characteristic which boat that are designed for that purpose.

  • Page 17: Engine Identification

    ENGINE IDENTIFICATION - 3 ENGINE IDENTIFICATION 1. ENGINE SPECIFICATION DECAL - The engine specification decal is located on the inboard side of When ordering service parts or obtaining information, the right exhaust manifold. always give the engine model and the serial number. This information can be found on the following decal.

  • Page 18: Engine Model Identification / Advisory

    ENGINE IDENTIFICATION - 3 ENGINE MODEL IDENTIFICATION / ADVISORY MODEL 0 2 - 535 VC - 0 1 SERIAL 575000 Space: MANUFACTURING CODE *SERIAL NUMBER I.D.* Space: ENGINE CODE rd - DIGIT INDICATES DECADE ENGINE WAS 535 = 5.3L Direct Injection MANUFACTURED ( 3 = 1990, 4 = 2000, 5 = 2010 ) 625 = 6.2L Direct Injection DIGIT INDICATES CALENDAR YEAR ENGINE WAS...

  • Page 19: Electronic Fuel Injection Information

    The Malfunction Indicator Lamp (MIL) is used for notification of any emissions-related fault. This is an The PCM Engines covered in this manual are equipped amber indicator lamp, that may be labeled ‘Service with an Electronic Fuel Injection (EFI) system, which Soon’...

  • Page 20: Operating Instructions

    OPERATING INSTRUCTIONS - 5 INSTRUMENTATION STARTING ENGINE (FUEL INJECTED ENGINES) Boat manufacturers install many different types of WARNING instrumentation on boats. Become familiar with the instrumentation on your boat and be aware of abnormal Before starting engine, ventilate the engine operating conditions.
  • Page 21 2 minutes for the starter motor to cool off normal temperature range. If the temperature before attempting to restart the engine. is abnormally high, stop the engine immediately and determine the cause. NOTICE: If engine still fails to start, contact your PCM Engines Dealer for service. L510010D-17...

  • Page 22: Electronic Speed Control

    OPERATING INSTRUCTIONS - 5 ELECTRONIC SPEED CONTROL (IF EQUIPPED) FREEZING TEMPERATURE OPERATION Refer to your Boat Manufacturers Owners/Operation If the possibility of freezing exists, the cooling system manual for specific operation and troubleshooting must be protected after the engine is shut off to prevent information for your speed control system.

  • Page 23: Conditions Affecting Operation

    WOT operation are considered abuse and are not to overheat. covered under the PCM Warranty. In most areas, it is advisable to coat the boat bottom with IMPORTANT NOTICE: antifouling paint to prevent the build-up of marine growth.

  • Page 24: Engine Break-In Period

    DO NOT EXCEED MAXIMUM RPM. (RPM contact your dealer and have the recommended 25-hour should cease climbing after 10 to 20 seconds). inspection done. NOTICE: PCM Engines assumes no responsibility for CAUTION the costs related to the 25-hour inspection. This is the owner’s responsibility.

  • Page 25: 25-Hour Engine Inspection

    After the first 25 hours of operation, it is recommended that the engine be given an inspection. Your boat dealer or a PCM Premier servicing dealer should be contacted to perform the necessary checks and adjustments to ensure the proper engine performance. The following maintenance should be performed: •...

  • Page 26: Fuel Requirements

    This information addresses the use of ethanol fuels in inspection of the entire fuel system including, but PCM ENGINES ONLY. It does not address the use of not limited to, fuel tanks, fuel lines, fuel filters and ethanol fuels in vessel related components such as boat all fittings is mandatory, especially after periods gas tanks, boat fuel lines, etc.

  • Page 27: Oil Requirements

    Viscosity use of supplemental additives which are added to the engine oil by the customer are unnecessary and may Dexron III Automatic be harmful. PCM Engines does not review, approve or Transmissions Transmission Fluid (ATF) recommend such products. or equivalent...

  • Page 28: Engine Maintenance

    PCM Engines Premier Dealer. Before performing any maintenance or repair procedure not covered in this manual, it is strongly recommended that a PCM Engines repair manual be purchased and read thoroughly. CHECKING FLUID LEVELS...
  • Page 29 NOTE: If the Dipstick Handle does not contain the “hole” by the transmission manufacturer before you identifier, consult PCM Customer Service for the proper attempt to perform maintenance on your own. If Checking Procedure.

  • Page 30: Engine Maintenance

    WARNING MAIN PANEL FUSE Do not attempt to remove the transmission drain/ PCM engines are equipped with a 40 Amp PANEL fuse fill plug while the engine is running or while the which provides electrical overload protection for the transmission is hot. Hot transmission fluid could be boat’s instrumentation wiring and components.

  • Page 31: Battery

    ENGINE MAINTENANCE - 11 WARNING Hydrogen gases that escape from the battery when charging are highly explosive. Do not use jumper cables and a booster battery to start the engine. Do not recharge a weak battery in the boat. Remove the battery from the boat and recharge in a well ventilated area away from fuel vapors, sparks and open flames.

  • Page 32: Cooling System Sacrificial Anode

    DEGAS PRESSURE BOTTLE Figure 11-8 Sacrificial Anode SACRIFICIAL ANODE LOCATIONS PCM Raw Water Applications • One anode is in the rear of each exhaust manifold. PCM Fresh Water Applications • One anode is in the rear of each exhaust manifold.

  • Page 33: Flushing Cooling System - Sea-Water Section

    ENGINE MAINTENANCE - 11 NOTICE: In order to drain the raw-water portion of the WARNING systems, refer to WATER DRAIN DIAGRAMS section of this manual for proper locations. Do not remove cooling system filler cap when the engine is hot. Allow the engine to cool and then Remove the following drain plugs/hoses in order to drain remove the pressure cap slowly, allowing the the coolant from the fresh-water portion of the cooling...

  • Page 34: Inspect And Clean Exhaust System Cooling Thermostat

    ENGINE MAINTENANCE - 11 INSPECT and CLEAN EXHAUST COOLING Outlet SYSTEM THERMOSTATS - Partial Fresh System Housing There is a thermostat housing on the outlet side of each exhaust manifold. Remove each raw water exhaust thermostat housing and inspect. Clean as required. This O-Ring thermostat must be inspected and cleaned at the first 25 hour inspection.

  • Page 35: Fuel System Description

    The FCC system incorporates two (2) fuel pumps to pressures. Pressures can exceed 2000 psi in the provide an uninterrupted flow of fuel to your PCM marine fuel rail. Fuel system repairs should be performed engine. Fuel is fed into the FCC bowl by a low-pressure, only by trained and qualified technicians.

  • Page 36: Servicing The Fcc

    ENGINE MAINTENANCE - 11 FUEL SUPPLY LINE FUEL PRESSURE SENSOR RETURN FUEL TANK FUEL CONTROL CELL FROM FUEL TANK LOW-PRESSURE FUEL PUMP PRIMARY Fuel / Water Separating Filter FUEL Element Part Number R077019 Manufacture Date 10/03/09 Tested To ISO, SAE, and JIC Standards at 5 PSI WARNING-PRESSURIZED GASOLINE FUEL SYSTEM-FIRE HAZARD PRE-FILTER To Replace Filter Element:...

  • Page 37: Primary Fuel Filter (Fcc Clamp-On Canister)

    ENGINE MAINTENANCE - 11 Draining the FCC Bowl, ENGINE OFF 1. Disconnect the two-wire electrical connectors from the FCC and the Low Pressure Fuel Pump (LPFP). 2. Remove the 7/16” plug, and drain the bowl contents into an approved container. O-RINGS FUEL CAUTION: Both fuel and water will drain from the...

  • Page 38: Servicing Fuel Pre-Filter

    ENGINE MAINTENANCE - 11 15. Reconnect the fuel supply line to the LPFP. 16. Reconnect the two-wire electrical connectors to the FCC and the LPFP. 17. Cycle the ignition key several times to run the electric fuel pumps and fill the FCC bowl with fuel.

  • Page 39: Accessory Drive Belt

    Figure 11-16 Flame Arrestor over the tensioner pulley. Release the tension slowly to tension the belt. ACCESSORY DRIVE BELT Alternator PCM engines use a single serpentine belt to drive the Pulley engine water circulation pump, sea-water pump and the alternator. Idler...

  • Page 40: Servicing Raw Water Pump Impeller

    Idler The transmission oil change should be performed by an Idler authorized PCM Premier dealer, at specified intervals. Transmission fluids should be removed through a copper Circulation tube, that extends to the bottom of the transmission...
  • Page 41 ENGINE MAINTENANCE - 11 OIL QUICK-DRAIN HOSE CONTAINER Figure 11-21 Engine Oil Removal Figure 11-22 Engine Oil Fill 4. Fill the engine with the recommended oil and IF YOU ARE UNSURE OF THE CORRECT AMOUNT OF OIL TO USE DURING A SERVICE INTERVAL, quantity, through the oil fill location on the valve cover (Figure 11-22).

  • Page 42: Engine Alignment

    2. Center the propeller shaft in the shaft log as before performing the engine alignment. Alignment is follows: (Figure 11-25) achieved using the Engine front mounts and the PCM V-Drive rear mounts. • Push down and then lift the propeller shaft as far as it will move, then place the shaft in the •...
  • Page 43 ENGINE MAINTENANCE - 11 .003 INCH (0.07 mm) TRANSMISSION FEELER GAUGE OUTPUT FLANGE PROPELLER SHAFT COUPLING FLANGE STRAIGHT EDGE Figure 11-27 Angular Alignment Figure 11-25 Centering Prop Shaft OFFSET ALIGNMENT: 3. Check that the coupling center lines align by butting the propeller shaft coupling against 4.
  • Page 44 ENGINE MAINTENANCE - 11 • LEFT or RIGHT ADJUSTMENT: Loosen .003 INCH the trunnion clamping bolt and the nut on all (0.07 mm) four mounting brackets. Move the engine TRANSMISSION FEELER GAUGE to the left or right, as necessary, to obtain OUTPUT FLANGE the proper alignment.
  • Page 45 ENGINE MAINTENANCE - 11 Angular Misalignment Front Mount Adjusted Both Trunnion • To adjust a corner of the engine up or down, loosen the locking nut. Turn the adjusting nut or the adjusting bolt in the direction required to raise or lower the engine. After the adjustment is complete, tighten the locking nut.

  • Page 46: Engine Maintenance Log

    ENGINE MAINTENANCE - 11 ENGINE MAINTENANCE LOG Operating Date Maintenance/Repair Hours L510010D-17...

  • Page 47: Maintenance Schedule

    ENGINE MAINTENANCE - 11 MAINTENANCE SCHEDULE After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Hours of Hours of Once Daily Operation Operation Operation Each Year Check coolant level - Fresh-water cooled models only Check oil level - Engine crankcase Check oil level - Transmission Engine Assembly (complete - Check for obvious leaks (water, oil, fuel and exhaust)
  • Page 48 (A) Use SAE 30 engine oil In fresh-water areas, every 50 hours of operation or (B) All PCM, Velvet Drive and Hurth transmissions - Use 60 days (whichever occurs first). In salt-water areas, Dexron III automatic transmission fluid every 25 hours of operation or 30 days (whichever occurs first).

  • Page 49: Visual Inspection

    2 - Refer to the Checking Fluid Levels instructions of this manual for complete instructions for checking transmission fluid levels. IMPORTANT: 80 Series PCM 1:1, 1.23:1 and all other transmission fluid levels are checked at operating temperature and immediately after shutdown of the engine.

  • Page 50: Filter And Accessory Requirements

    Lubricate the O-ring of the new filter with a small amount of lubricating oil. Install filter turning it clockwise until hand tight plus 2/3 to 1 turn. P/N R143213 R077019 PCM POWER-PLUS V-DRIVE LUBRICANT Description Part No. PCM Power-Plus V-Drive Lubricant (1 qt. bottle) R190250 L510010D-17...

  • Page 51: Engine Specifications

    ENGINE SPECIFICATIONS - 12 MASTER ENGINE SPECIFICATIONS - 2017 MODEL 5.3L DI 6.2L DI Displacement 5.3L (327 CID) 6.2L (383 CID) Bore 3.78 in. (96.01 mm) 4.06 in. (103.25 mm) Stroke 3.62 in. (92.0 mm) 3.62 in. (92.0 mm) Compression Ratio 11:1 11.5:1 Compression...
  • Page 52 LH ROTATION FRONT DISTRIBUTOR FLYWHEEL END OF ENGINE ALL V-8 MODELS FIRING ORDER: 1-8-7-2-6-5-4-3 PCM FUEL PRESSURE and ALARM WARNING SPECIFICATIONS - 2017 MODEL NOTES FCC Fuel Pressure 57-62 psi @ WOT Monitored with sensor and displayed on Diacom Diagnostic Tool.

  • Page 53: Out-Of-Season Storage

    WARNING IMPORTANT: This service should be performed by Operate the bilge blower and be sure no fuel vapors an Authorized PCM Premier dealer. are present when treating the engine. Be sure the engine compartment is well-ventilated to prevent a CAUTION potential fire hazard.

  • Page 54: Draining Instructions

    BATTERY STORAGE IMPORTANT: These services should be performed Follow the battery manufacturer’s instructions for storage. If not available, use the following instructions: by an Authorized PCM Premier dealer. • Remove the battery from the boat and clean, CAUTION removing dirt and grease from the top of the battery.

  • Page 55: Recommissioning After Storage

    9. Refer to the OPERATING INSTRUCTIONS IMPORTANT: These services should be performed section and perform all the safety checks by an Authorized PCM Premier dealer. before starting the engine. When recommissioning the engine after storage, the 10. Refer to the Engine Maintenance section...

  • Page 56: Troubleshooting

    TROUBLESHOOTING - 14 Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. When a problem cannot be easily diagnosed, consult a PCM Engines Servicing Dealer for assistance. Malfunction Possible Cause Corrective Action Engine will not crank with the...
  • Page 57 TROUBLESHOOTING - 14 Malfunction Possible Cause Corrective Action Engine Overheats Loose or worn drive belt(s) Adjust or replace the belts as necessary. Collapsed, kinked or leaking Replace the hoses. hoses. Transmission/engine oil cooler Remove the water hoses and flush plugged in opposite direction of the normal flow.
  • Page 58 Contaminated fluid Determine and correct the contamination source and change the fluid. Engine misses, runs rough Ignition system malfunction Contact PCM Engines Dealer. and/or backfires Plugged fuel filters Replace the fuel filters. Faulty fuel pump. Have fuel pump replaced by a...

  • Page 59: Raw Water Draining Locations

    RAW WATER DRAINING LOCATIONS - 15 Figure 15-1 Raw Water CES 5.3L DI / 6.2L DI 1 - Raw Water Inlet Manifold Hose Plug (1) 2 - Circulation Pump Hose Plug (1) BLOCK EXHAUST EXHAUST V-DRIVE 3 - Exhaust Manifold Plugs (2) MANIFOLD CORNERS SPARE...
  • Page 60 RAW WATER DRAINING LOCATIONS - 15 EXHAUST EXHAUST V-DRIVE MANIFOLD CORNERS SPARE Figure 15-2 Fresh Water CES 5.3L DI / 6.2L DI 1 - Raw Water Inlet Manifold Hose Plug (1) 2 - Exhaust Manifold Plugs (2) 3 - Exhaust Corners - Remove / Inspect Anodes (2) EXHAUST EXHAUST V-DRIVE...

  • Page 61: Heater Connections

    HEATER CONNECTIONS - 16 Connecting a Heater Raw Water Engines 1. Remove the “U” shaped hose from the engine circulation pump. 2. Connect the heater hose going out to the heater core to the fitting labeled “Outlet” below. 3. Connect the heater hose returning from the heater core to the fitting labeled “Return”...

  • Page 62: Instrumentation Wiring Diagram

    INSTRUMENTATION WIRING DIAGRAMS - 17 NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY. NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS. ENGINE 2-PIN WIRE HARNESS COLOR CHART HARNESS CIRCUIT CIRCUIT...

  • Page 63: Literature

    LITERATURE - 18 To obtain service and/or parts information for your PCM Marine Engine, contact your servicing or local dealer. PCM distributes publications through a worldwide dealer network the same way parts and technical support are handled. L510010D-17...

  • Page 64: Forms

    FORMS - 19 OPERATION AND MAINTENANCE LOG Engine Port Drive Port Ignition Key Port Model and Serial # Stbd. Serial # Stbd. Number Stbd. Fire Extinguisher Checked Batteries Tested Gal of Qts of Oil Check Lay Up Launch Runs Made Date Fuel Port...
  • Page 65 FORMS - 19 PROBLEM NOTIFICATION OR INFORMATION REQUEST FORM IMPORTANT: All blanks MUST be completed to insure proper identification of your engine which is necessary to properly understand your request. When completed, mail this form to: Pleasurecraft Marine PO Drawer 369 Little Mountain, SC 29075 Engine Model Engine Serial Number...

  • Page 66: Notes

    NOTES - 20 L510010D-17...
  • Page 67 The obligation of PCM set forth in the first paragraph of this warranty shall be the exclusive remedy for any breach of warranty hereunder, and any owner or user’s sole remedy in the event of breach of the warranty is repair or replacement of the product or any warranted part thereof as set forth in this warranty. With this sole exception, PCM shall not be liable for any direct or indirect, incidental or consequential damages, including without limitation, any damages for property damage, loss of use or loss of profits, loss of income, inconvenience, Owner’s Primary Email Address...
  • Page 69 This Page Was Intentionally Left Blank...
  • Page 70 Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075...

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