MerCruiser QSD 2.0 Manual
  1. Manuals
  2. Brands
  3. MerCruiser Manuals
  4. Engine
  5. QSD 2.0
  6. Manual

MerCruiser QSD 2.0 Manual

Diesel engine sterndrive
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Declaration of Conformance—Cummins MerCruiser Diesel
This sterndrive or inboard engine when installed in accordance with Cummins MerCruiser Diesel instructions complies with
the requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement
Handling characteristics (A.4)
Inboard engine (A.5.1.1)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1) (sterndrive CE marked
products only)
Cummins MerCruiser Diesel declares that our sterndrive or inboard engines without integral exhaust, when installed in a
recreational craft in accordance with the manufacturer's supplied instructions will meet the exhaust emissions requirements
of the directive mentioned above. This engine must not be put into service until the recreational craft in which it is to be
installed has been declared in conformity, if so required, with the relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine driven
devices—radio disturbance characteristics
Electrostatic discharge testing
For specific information regarding exhaust or noise emissions and power declaration, please refer to the Declaration of
Conformity supplied with each Cummins MerCruiser Diesel engine.
This declaration is issued under the sole responsibility of Cummins MerCruiser Diesel.
Director of Engineering—Cummins MerCruiser Diesel, Charleston, South Carolina U.S.A.
Regulatory contact:
Engineering—Marine Emissions
Cummins MerCruiser Diesel
4500 Leeds Avenue
Charleston, South Carolina 29405
USA
(843) 745-1610
Identification Record
Please record the following information:
Engine Model and Horsepower
Transom Assembly Serial Number (Sterndrive)
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
Applicable portions of: ISO 10592, ISO 8848 and ABYC
P‑17
ISO 8178
ISO 8665
ISO 14509
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
Jim Kahlenbeck
Gear Ratio
Standards Applied
Engine Serial Number
Sterndrive Unit Serial Number

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the QSD 2.0 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for MerCruiser QSD 2.0

Summary of Contents for MerCruiser QSD 2.0

  • Page 1 ISO 14509 products only) Cummins MerCruiser Diesel declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft in accordance with the manufacturer's supplied instructions will meet the exhaust emissions requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive.
  • Page 2 Warranty Message The product you have purchased comes with a limited warranty from Cummins MerCruiser Diesel; the terms of the warranty are set forth in the Warranty Sections 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 DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Warranty Warranty Information..............2 High Output Recreational Use Worldwide Limited Warranty Registration—United States and Canada... 2 Warranty................3 Warranty Registration—Outside the United States and Limited Warranty Against Corrosion (Worldwide)....5 Canada................2 Transfer of Warranty............6 Warranty Policy................3 Section 2 - Getting to Know Your Power Package Identification................8...
  • Page 6 Section 4 - Specifications Fuel Requirements..............36 Engine................38 Recommended Fuels............. 36 QSD 2.0..............39 Diesel Fuel in Cold Weather........... 36 Alpha Sterndrive Fluid Specifications......39 Coolant (Antifreeze)..............37 Bravo Sterndrive Fluid Specifications—Diesel....39 Engine Oil................37 Approved Power‑assisted Steering Fluids...... 39 Engine Specifications.............
  • Page 7 Bravo Diesel Sterndrive Propeller Removal....102 Bravo Three..............108 Bravo One Models............103 Drive Belts................109 Bravo Two Models............104 QSD 2.0 Drive Belts............109 Bravo Three Models........... 104 Power‑Assisted Steering Pump Belt Inspection..... 109 Bravo Diesel Sterndrive Propeller Installation....106 Serpentine Belt Inspection..........110 Bravo One Models............106 Battery..................111...
  • Page 8 Page iv 90-8M0057081 MARCH 2011...

  • Page 9: Section 1 - Warranty

    Section 1 - Warranty Section 1 - Warranty Table of Contents Warranty Information.............. 2 High Output Recreational Use Worldwide Limited Warranty Registration—United States and Canada..2 Warranty................3 Warranty Registration—Outside the United States and Limited Warranty Against Corrosion (Worldwide).... 5 Canada................2 Transfer of Warranty............

  • Page 10: Warranty Information

    Federal Boat Safety Act be required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser's warranty registration department.

  • Page 11: Warranty Policy

    Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins MerCruiser Diesel to distribute the product in the country in which the sale occurred, and then only after the Cummins MerCruiser Diesel specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
  • Page 12 Additional service work requested by the customer other than that necessary to satisfy the warranty obligation • Damage to the Cummins MerCruiser Diesel product caused by the use of an accessory or part that was not manufactured or sold by Cummins MerCruiser Diesel or Mercury Marine •...

  • Page 13: Limited Warranty Against Corrosion (Worldwide)

    Damage caused by engines that do not reach maximum rated RPM because of vessel overloading • Labor not performed by a Cummins MerCruiser Diesel Authorized Repair Facility except when such a facility is not available to perform the work required and prior factory approval has been given to have the work performed at an alternate repair facility on an emergency basis •...

  • Page 14: Transfer Of Warranty

    Cummins MerCruiser Diesel dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Cummins MerCruiser Diesel. We will then arrange for the inspection and any covered repair. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 15: 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 Engine Monitoring Features..........15 Serial Number Decal............8 Audio Warning System..........15 Dataplate location............8 VesselView..............15 Engine Data Plate............8 System Tachometer or Speedometer......

  • Page 16: Identification

    Engine Data Plate A tamper‑resistant engine data plate is affixed to the engine at the time of manufacture by Cummins MerCruiser Diesel. It contains important exhaust gas emissions information. Please note that the engine data plate will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may remove the engine data plate or the engine component it is affixed to before sale.

  • Page 17: Emissions Information

    A tamper‑resistant exhaust gas emission label is affixed to the engine's integrated exhaust manifold and expansion tank assembly at the time of manufacture by Cummins MerCruiser Diesel. Please note that the exhaust gas emissions certification will not affect the fit, function, or performance of the engine. Neither boatbuilders nor dealers may remove the exhaust gas emission label or the part it is affixed to before sale.

  • Page 18: Alpha Sterndrive Decal Identification

    Section 2 - Getting to Know Your Power Package Alpha Sterndrive Decal Identification The Drive Serial No. is located on the port side of the alpha sterndrive. The Drive Ratio is located on the starboard side of the alpha sterndrive. Alpha sterndrive Drive gear ratio decal (starboard) Serial number decal (port)

  • Page 19: Bravo Sterndrive Serial Number And Identification

    Section 2 - Getting to Know Your Power Package Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive. 33533 Bravo sterndrive information on ground plate The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover.

  • Page 20: Instrumentation-Qsd Sterndrive Models

    Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for Cummins MerCruiser Diesel Authorized Repair Facilities. Gimbal housing with serial number stamping Transom assembly serial...

  • Page 21: Vesselview (If Equipped)

    Section 2 - Getting to Know Your Power Package The following types of gauges may be included with your power package. 26019 Typical gauges Reference Gauge Function Oil pressure gauge Indicates engine oil pressure. Battery meter Indicates battery voltage. Coolant temperature gauge Indicates engine operating temperature.

  • Page 22: Switches

    Section 2 - Getting to Know Your Power Package Switches Key switch Bilge blower switch (if equipped) 24735 Reference Switch Function Key switch Has four positions. "OFF." In the "OFF" position, all electrical circuits are off and the engine cannot be started. The engine is stopped when the key switch is turned to the "OFF"...

  • Page 23: Engine Monitoring Features

    Audio Warning System Your Cummins MerCruiser Diesel power package is equipped with an audio warning system. The audio warning system monitors critical components and informs the operator when a malfunction has occurred. The warning system is not capable of protecting the power package from damage caused by a malfunction.

  • Page 24: Features And Controls

    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 Cummins MerCruiser Diesel Repair Facility. Page 16...

  • Page 25: Lanyard Stop Switch

    Digital Throttle and Shift Applications For Digital Throttle and Shift (DTS) applications and electronic remote control operation (ERC) refer to the Cummins MerCruiser Diesel SmartCraft and DTS Owner's Manual.

  • Page 26: Remote Controls

    Section 2 - Getting to Know Your Power Package Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote control. All controls may not have all features shown. Consult your dealer for a description or demonstration of your remote control. Panel Mount Features Neutral lock button Throttle–only button...

  • Page 27: Power Trim

    Section 2 - Getting to Know Your Power Package Throttle–Only Button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle–only button can be depressed only when the remote control handle is in the neutral position.

  • Page 28: Single Engine Trim And Trailer

    If the replacement fuse also blows then the electrical overload has not been eliminated. Further checks must be made on the electrical system. Do not circumvent the electrical overload protection provided on fused circuits by installing a higher Contact your Cummins MerCruiser Diesel Authorized Repair amperage fuse or shorting across the fuse block terminals.

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

    Section 2 - Getting to Know Your Power Package After finding and correcting the cause of the overload, replace any burned out (blown) fuses. 27000 2.0 fuse panel Location on fuse panel (From Front Reference Fuse Protection of Engine) 20‑amp Un‑switched power to helm Lower left 10‑amp...

  • Page 30: Power Trim And Mercathode Overload Protection

    Further checks must be made on the electrical system. Contact your Cummins MerCruiser Diesel Authorized Repair Facility. 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.
  • Page 31 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 24 High‑Speed and High‑Performance....... 30 Be Alert to Carbon Monoxide Poisoning....... 25 Passenger Safety In Pontoon Boats And Deck Boats... 30 Good Ventilation ............25 Boats Having An Open Front Deck .......

  • Page 32: Safe Boating Suggestions

    Know and obey all nautical rules and laws of the waterways. Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency.

  • Page 33: Be Alert To Carbon Monoxide Poisoning

    IMPORTANT: Install the bilge drain plug before launching the boat. Duty Cycle Rating Requirements IMPORTANT: Damage caused by incorrect application or failure to operate the power package within the specified operating parameters will not be covered by the Cummins MerCruiser Diesel Limited Warranty. 90-8M0057081 MARCH 2011...

  • Page 34: High Output Rating

    Cummins MerCruiser Diesel application manual. 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 Cummins MerCruiser Diesel engines in applications that do not meet specified operational parameters is not approved.

  • Page 35: Starting, Shifting, And Stopping

    IMPORTANT: Engine oil pressure should exceed 69 kPa (10 psi) a few seconds after the engine starts. If oil pressure does build adequatly, stop the engine then locate and correct the problem. See your Cummins MerCruiser Diesel Authorized Repair Facility if you are unable to identify and correct the problem.

  • Page 36: 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 Cummins MerCruiser Diesel Authorized Repair Facility if you are unable to determine the problem.

  • Page 37: Starting The Engine After Stopped While In Gear

    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 Cummins MerCruiser Diesel Authorized Repair Facility for information about special cold weather equipment and precautions.

  • Page 38: Protecting People In The Water

    For additional information, refer to the Hi-Performance Boat Operation booklet (90‑849250‑R03) from your Cummins MerCruiser Diesel Authorized Repair Facility. Passenger Safety In Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers.

  • Page 39: Wave And Wake Jumping

    Section 3 - On the Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

  • Page 40: Sterndrive Impact Protection

    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 Cummins MerCruiser Diesel repair facility for a thorough inspection and any necessary repair.

  • Page 41: Ventilation

    The following procedure is especially important on new diesel engines. This break‑in procedure allows the proper seating of the pistons and rings, which greatly reduces the likelihood of problems. IMPORTANT: Cummins MerCruiser Diesel recommends that the boat not be accelerated hard until this procedure has been completed.

  • Page 42: Sterndrive 10-Hour Break-In Period (New Or With Replacement Gears)

    End of First Season Checkup At the end of the first season of operation, contact a Cummins MerCruiser Diesel Authorized Repair Facility to discuss or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
  • Page 43 Section 4 - Specifications Table of Contents Fuel Requirements............... 36 Engine................38 Recommended Fuels............36 QSD 2.0 ..............39 Diesel Fuel in Cold Weather..........36 Alpha Sterndrive Fluid Specifications......39 Coolant (Antifreeze).............. 37 Bravo Sterndrive Fluid Specifications—Diesel....39 Engine Oil................37 Approved Power‑assisted Steering Fluids.....

  • Page 44: Fuel Requirements

    Section 4 - Specifications Fuel Requirements WARNING Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines, unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).

  • Page 45: Coolant (Antifreeze)

    Section 4 - Specifications Coolant (Antifreeze) NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed. Because diesel engines are high‑compression engines, they operate at higher operating temperatures.

  • Page 46: Engine Specifications

    Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W40 oil. Engine Specifications Specifications Description QSD 2.0 Engine type In‑line 4 cylinder diesel Induction Type Turbocharged and Aftercooled 16 Valve Displacement 2.0 liter (122 cu.

  • Page 47: Qsd 2.0

    Section 4 - Specifications QSD 2.0 Engines with Closed Cooling System Oil Cooler QSD 2.0 System Capacity Liters Fluid Type Part Number Engine oil (with filter) 5.85 liter (6.20 US qt) 15W40 4‑cycle Diesel Engine Oil 92‑877695K1 Marine Engine Coolant 92‑813054A2...

  • Page 48: Approved Power Trim Fluids

    Section 4 - Specifications Approved Power Trim Fluids All Applications Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 Approved Paints Description Part Number Marine Cloud White (CMD part number: 40918660) Obtain locally Mercury Light Gray Primer 92‑80287852...
  • Page 49 Removal................. 67 Bravo Two Models ..........107 Inspection..............67 Bravo Three ............108 Installation..............67 Drive Belts................109 Water‑Separating Fuel Filter..........68 QSD 2.0 Drive Belts............. 109 Draining.................69 Power‑Assisted Steering Pump Belt Inspection..109 Replacing...............69 Serpentine Belt Inspection........... 110 Filling................71 Battery................111 Fuel System................

  • Page 50: 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 Cummins MerCruiser Diesel Authorized Repair Facility for a periodic checkup.

  • Page 51: General Inspection

    Do not telephone the dealer, service office, or the factory to attempt for them to diagnose a problem or to request the repair procedure. It is difficult for them to diagnose a problem over the telephone. Your local Cummins MerCruiser Diesel Authorized Repair Facility is there to service your power package. They have qualified factory‑trained mechanics.

  • Page 52: Maintenance Schedules-Alpha And Bravo Models

    IMPORTANT: See Maintenance Schedule for a complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner or operator, while others should be performed by an Cummins MerCruiser Diesel Authorized Repair Facility. Before attempting maintenance or repair procedures not covered in this manual we recommended that you purchase the appropriate Cummins MerCruiser Diesel or Mercury MerCruiser Alpha Sterndrive Service Manuals, and read thoroughly.

  • Page 53: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Change the engine oil and filter. • Change the sterndrive gear lube. • Torque the gimbal ring U‑bolt locknuts. • Replace the fuel filters. • Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate the cables and linkages.
  • Page 54 Section 5 - Maintenance Date Maintenance Performed Engine Hours Page 46 90-8M0057081 MARCH 2011...

  • Page 55: Maintenance Schedules-Axius Models

    Section 5 - Maintenance Maintenance Schedules—Axius Models Routine Maintenance—Axius Models NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...

  • Page 56: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Inspect the U‑joints, the splines, and the bellows. Check the clamps. • Check the engine alignment. Every 200 hours or 3 • Lubricate the U‑joint splines and cross bearing, if equipped with grease fittings. years •...
  • Page 57 Section 5 - Maintenance Date Maintenance Performed Engine Hours 90-8M0057081 MARCH 2011 Page 49...

  • Page 58: Engine Oil

    Part No. 15W40 4-cycle Diesel Engine crankcase 92-858042K01 Engine Oil Other recommended oils are listed in the following table. These oils are approved by Cummins MerCruiser Diesel and Marine Power Europe. Shell Myrina Texaco Ursa Super TD Veedol Turbostar Mopar Wintershall Multi‑Rekord...

  • Page 59: Filling

    Section 5 - Maintenance Remove the dipstick. Wipe clean and reinstall into the dipstick tube. QSD 2.0L engine oil service Engine cover with access panel removed Engine oil fill cap Engine oil dipstick 27986 Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil. See Filling.

  • Page 60: Changing Oil And Filter

    Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick. Coolant oil cooler Seawater oil cooler 33988 Engine Coolant Oil Cooler QSD 2.0 System Capacity Fluid Type Part Number Engine oil (with filter) 5.85 L (6.20 US qt)
  • Page 61 Section 5 - Maintenance Crankcase oil pump 91‑90265A 5 Aids in the removal of engine oil without draining the crankcase. 11591 Pump the oil out of the crankcase into a drain pan. Remove the oil filter housing drain plug and drain the oil into an appropriate container. 33987 Engine coolant oil cooler Seawater oil cooler...
  • Page 62 Section 5 - Maintenance 13. Apply sealant to the threads of the oil filter housing drain plug and install. 33987 Engine coolant oil cooler Seawater oil cooler Oil filter housing Drain plug Tube Ref No. Description Where Used Part No. Loctite 567 PST Pipe Drain plug 92-809822...

  • Page 63: Alpha Sterndrive Gear Lube

    Section 5 - Maintenance 16. Push the filter element into the cover until it is locked. Listen for a click. 33986 Engine coolant oil cooler Seawater oil cooler Oil filter cover O‑ring Filter element 17. Install the cover with the new filter element into the oil filter housing. Turn the oil filter cover until the sealing surface contacts the housing.

  • Page 64: Filling

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Cummins MerCruiser Diesel Authorized Repair Facility .

  • Page 65: Changing

    Section 5 - Maintenance Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten. Gear lube monitor cap 19962 NOTE: When filling the entire sterndrive, see Changing . Changing Remove the gear lube monitor from the bracket. Retaining bracket Gear lube monitor 25339...
  • Page 66 IMPORTANT: If any water drained from the gear lube fill and drain hole, or if the oil appears milky, the sterndrive is leaking and should be checked immediately by your Cummins MerCruiser Diesel Authorized Repair Facility. Lower the sterndrive so that the propeller shaft is level. Fill the sterndrive through the gear lube fill and drain hole, with the specified gear lubricant until an air‑free stream of lubricant flows from gear lube vent hole.

  • Page 67: Bravo Sterndrive Gear Lube

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Cummins MerCruiser Diesel Authorized Repair Facility .

  • Page 68: Changing

    Section 5 - Maintenance Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten. Gear lube monitor cap 19962 NOTE: When filling the entire sterndrive, see Changing . Changing Remove the gear lube monitor from the bracket. Gear lube monitor bracket Gear lube monitor and cap Retaining strap...
  • Page 69 IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is leaking and should be checked immediately by your Cummins MerCruiser Diesel Authorized Repair Facility. Lower the sterndrive so that the propeller shaft is level.
  • Page 70 Section 5 - Maintenance 12. Fill the gear lube monitor so that the gear lube level is in the operating range. Do not overfill. Gear lube monitor Gear lube level at the "ADD" mark Gear lube level at the "OPERATING RANGE" mark Gear lube monitor cap 19947 Fluid Capacity includes the...

  • Page 71: Power Trim Fluid

    Section 5 - Maintenance Description lb–in. lb–ft Fill and drain plug – 16. Install the sterndrive propeller. See Propellers. 17. Recheck the gear lube level at the gear lube monitor after the first use. See Checking. IMPORTANT: The gear lube level in the gear lube monitor will rise and fall during sterndrive operation; always check the gear lube level when the sterndrive is cool and the engine is shut down.

  • Page 72: Changing

    Fluid Install the fill cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your Cummins MerCruiser Diesel Authorized Repair Facility. Power‑Assisted Steering Fluid IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid (ATF) in the power‑assisted steering system.

  • Page 73: Filling

    Section 5 - Maintenance IMPORTANT: If fluid is not visible in the fluid reservoir, see your Cummins MerCruiser Diesel Authorized Repair Facility. Filling Remove the fill cap and dipstick and observe the fluid level. Add the specified fluid to bring the fluid level up to the proper level.

  • Page 74: Filling

    14142 The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the cap tested, contact your Cummins MerCruiser Diesel Authorized Repair Facility. Add the specified coolant as necessary. See Filling. IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolant loss.

  • Page 75: Air Filter

    Section 5 - Maintenance Air Filter Removal Loosen the clamp and remove the oil separator vent hose. Loosen the clamp and remove the air filter housing from the turbocharger inlet. Air filter housing installed on engine Air filter housing Oil separator vent hose Air intake retaining clamp 25357 Remove the air filter element from the air filter housing...

  • Page 76: Water-Separating Fuel Filter

    Section 5 - Maintenance Slide the filter element into the air filter housing. Ensure that the element is seated fully into the air filter housing. Air filter housing Air filter element 25893 NOTE: The warning labels on the air filter housing must be visible after the air filter housing is installed. Install the air filter housing on to the turbocharger inlet.

  • Page 77: Draining

    Section 5 - Maintenance IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe manner in accordance with all local, federal, and international regulations. The engine‑mounted water‑separating fuel filter is equipped with a water‑in‑fuel (WIF) sensor that should alert the operator when water is present in the filter.
  • Page 78 Section 5 - Maintenance Remove the water‑separating fuel filter and sealing ring from the mounting bracket. Do not use a filter wrench. Typical Water‑separating fuel filter 23459 NOTE: It may be necessary to keep the existing drain cap and use it on the new filter. Be sure to replace the O‑ring on the drain cap.

  • Page 79: Filling

    13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck filter installation. If leaks continue, stop the engine immediately and contact your Cummins MerCruiser Diesel Authorized Repair Facility. Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to •...

  • Page 80: Fuel System

    Section 5 - Maintenance Loosen the air vent (bleed) screw on the fuel filter bracket. Typical Air vent screw 23469 Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw. Typical Air vent screw Primer plunger...

  • Page 81: Filling (Bleeding)

    Section 5 - Maintenance Move the primer plunger up and down repeatedly. Fuel priming pump 25985 Attempt to start the engine. Filling (Bleeding) NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function. See Water Separating Fuel Filter - Filling and fill the fuel filter.
  • Page 82 Section 5 - Maintenance If the boat is to remain in the water, turn on the bilge pump, close the seacock (if equipped), or disconnect and plug the seawater inlet hose. 25667 Typical seacock installation Make the engine as level as possible to ensure complete draining of the seawater system. Attach a temporary drain hose to the barbed fitting of the seawater drain valve.

  • Page 83: Sterndrive Water Inlets Check

    Section 5 - Maintenance On models equipped with a seawater strainer, remove the hoses at the seawater strainer and drain them completely. Drain and empty the seawater strainer. Reconnect the hoses and tighten the hose clamps securely. Typical Seawater inlet Seawater outlet Seawater strainer cover 25831...

  • Page 84: Checking The Seawater Pickups

    Section 5 - Maintenance Bravo sterndrive dual pickup water inlet locations Dual water pickup water inlets Side pickup water inlets 22495 Checking the Seawater Pickups Ensure that the water inlet holes for the seawater pickup are clean and not obstructed. 16776 Typical through-hull seawater pickup Typical through-transom seawater pickup...
  • Page 85 Section 5 - Maintenance Remove the the seawater strainer cover by turning it counterclockwise by hand. Seawater inlet Seawater outlet Seawater strainer cover 25831 Remove the strainer from the strainer housing and clean out any debris. Flush the strainer with clean water. Clean out any debris from the strainer housing and flush with clean water.

  • Page 86: Flushing The Seawater System-Alpha Sterndrives

    Section 5 - Maintenance Start the engine and allow the seawater system to be filled and the engine to reach normal operating temperature. Check the seawater cooling system for leaks within an RPM range of 600 to 1400 RPM. Carefully monitor the engine's operating temperature to ensure that it remains in normal operational range and that the seawater cooling system is functioning properly.
  • Page 87 Section 5 - Maintenance Install the appropriate flushing attachment over the water inlet holes in the gear housing. 5773 Alpha Sterndrive Side Pickup Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Lower the sterndrive to full down position.

  • Page 88: Flushing The Seawater System-Bravo Sterndrives

    Section 5 - Maintenance Connect a second flushing hose from a water tap to the seawater inlet hose connector or to the seawater pump inlet using an appropriate adapter. Seawater pump inlet Seawater pump Seawater pump outlet Fuel cooler (if equipped) 25668 With the sterndrive in the normal operating position, partially open both the sterndrive and engine flushing water supplies (about 1/2 maximum flow).
  • Page 89 Section 5 - Maintenance Close the seacock, if equipped, or disconnect and plug the seawater inlet hose. 13171 Seacock Seawater inlet hose Plug Raise the sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 21514 21515 Flushing attachments for dual water pickup...
  • Page 90 Section 5 - Maintenance Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Lower the sterndrive to full down position. If flushing the seawater system with the boat out of the water: Lower sterndrive to full down position.

  • Page 91: Engine Seawater Pump Inspection

    Cummins MerCruiser Diesel Authorized Repair Facility. Replacing the Engine Coolant Draining the Closed Cooling System IMPORTANT: Due to the complex nature of this service Cummins MerCruiser Diesel strongly recommends that this service be performed by a Cummins MerCruiser Diesel Authorized Repair Facility. NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.

  • Page 92: Filling The Closed Cooling System

    25768 Ensure that the coolant has drained completely. If required, clean the closed cooling system. See your local Cummins MerCruiser Diesel Authorized Repair Facility. Install and tighten the engine coolant drain plug. Reinstall the water–separating fuel filter. See Water–Separating Fuel Filter, Replacing.

  • Page 93: Corrosion Protection

    To help control the effects of galvanic corrosion, Cummins MerCruiser Diesel power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide (90‑88181301).

  • Page 94: 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. With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.

  • Page 95: Installation

    Section 5 - Maintenance Installation Install a new sealing washer on the anode assembly (anode plug with the sacrificial anode). Anode assembly Sealing washer 19227 Install the anode assembly and washer into the aftercooler end cover. Tighten securely. 25583 Seawater system anode assembly location Unplug and connect the seawater inlet hose, or open the seacock if equipped.

  • Page 96: Sterndrive Corrosion Protection Components

    Section 5 - Maintenance Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, Cummins MerCruiser Diesel sterndrives come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection, refer to the Marine Corrosion Protection Guide 90‑88181301.
  • Page 97 MerCathode System—The electrode assembly, if equipped, replaces Anodic block. The system should be tested to ensure adequate output. Perform the test when the boat is moored, using a Quicksilver Reference Electrode and Test Meter. Contact your Cummins MerCruiser Diesel Authorized Repair Facility. 90-8M0057081...
  • Page 98 Section 5 - Maintenance Description Location Figure Alpha Sterndrive Mounted on the underside of the lower gearcase. Gearcase anodic plate 22405 Bravo Sterndrive Mounted on the underside of the lower gearcase. Gearcase anode plate 20336 Alpha and Bravo Sterndrive Mounted on the front of the gearcase. Ventilation plate anode 20338 Alpha and Bravo Sterndrive...

  • Page 99: Alpha Sterndrive Continuity Circuit Inspection

    Section 5 - Maintenance Alpha Sterndrive Continuity Circuit Inspection The transom assembly and sterndrive unit are equipped with ground‑circuit wires to ensure good electrical continuity between the engine, transom assembly, and sterndrive components. Good continuity to a ground is essential for the anode and MerCathode system to function most effectively.
  • Page 100 Section 5 - Maintenance Inspect the gimbal housing ground wires for loose connections, broken connectors, or frayed wiring. Gimbal housing–to–gimbal ring ground wire Gimbal housing–to–trim cylinder ground wires 7006 Inspect the flywheel housing grounding stud, ground wire, and the inner transom plate grounding screw for loose connections, broken connectors, or frayed wiring.

  • Page 101: Mercathode

    Use to check hull potential. 9188 Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures. Painting Your Power Package IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited warranty.

  • Page 102: Lubrication

    Section 5 - Maintenance • Avoid any electrical interconnection between the paint and the Mercury MerCruiser product, anodic blocks, or MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on the transom of the boat around these items.
  • Page 103 Lubricate the steering pin. Steering pin mc71904-1 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Steering pin 92‑883725K01 SAE25W‑40 On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.

  • Page 104: Throttle Cable

    Section 5 - Maintenance Throttle Cable Lubricate the pivot points and guide contact surfaces. Pivot points Guide contact surfaces 23643 Tube Ref No. Description Where Used Part No. SAE Engine Oil 30W Throttle cable pivot points and guide contact surfaces Obtain Locally Shift Cable Lubricate the pivot points and guide contact surfaces.

  • Page 105: Transom Assembly

    Section 5 - Maintenance Transom Assembly Lubricate the gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. Gimbal bearing grease insert 19979 Tube Ref No. Description Where Used Part No. U-joint and Gimbal Gimbal bearing grease insert 92-802870A1 Bearing Grease Engine Coupler...

  • Page 106: Sterndrive, Bellows, And Engine Alignment

    Sterndrive, Bellows, and Engine Alignment NOTE: Have your Cummins MerCruiser Diesel Authorized Repair Facility perform the maintenance procedures listed, or refer to the appropriate Mercury MerCruiser Alpha Sterndrive Service Manual . Lubricate the sterndrive U‑joint O‑rings and driveshaft splines.
  • Page 107 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Engine Coupler Spline Driveshaft splines and U-joint O-rings 92-802869A 1 Grease For propeller shaft lubrication, See Propellers. Inspect the U‑joint bellows for cracks or other signs of deterioration. Ensure that the bellows clamps are tight. Rotate the bell housing in the upward and side‑to‑side directions to inspect the exhaust bellows, shift cable bellows, and clamps.

  • Page 108: Maintaining Torques

    Section 5 - Maintenance Check the engine alignment. 7936 Alignment tool End of alignment tool to insert through gimbal housing assembly Gimbal bearing Engine coupler Maintaining Torques Alpha Gimbal Ring Clamp Bolt NOTE: The gimbal ring is a component of the transom assembly. Torque the gimbal ring clamp bolts.

  • Page 109: Engine Mounts

    Section 5 - Maintenance Tighten the gimbal ring U‑bolt nuts to specification. Transom assembly Gimbal ring U‑bolt nuts 19624 Description lb–in. lb–ft Gimbal ring U‑bolt nuts for 3/8 in. U‑bolt – Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt – Engine Mounts Loosen the rear engine mount bolts 1 to 1‑1/2 turns.

  • Page 110: Alpha Propeller Installation

    Section 5 - Maintenance Slide tab washer, drive sleeve, propeller and thrust hub off propeller shaft. Alpha Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage.

  • Page 111: Bravo One Models

    Section 5 - Maintenance Bravo One Models Straighten the bent tabs of the tab washer on the propeller shaft. Prop Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket...

  • Page 112: Bravo Two Models

    Section 5 - Maintenance Bravo Two Models Straighten the bent tabs of the tab washer on the propeller shaft. Prop Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket...
  • Page 113 Section 5 - Maintenance Remove the propeller shaft anode. Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 19058 Turn the aft propeller shaft nut counterclockwise to remove the nut. Slide the propeller and thrust hub off of the propeller shaft. Using the Propeller Nut Tool, turn the front propeller shaft nut counterclockwise and remove the nut.

  • Page 114: Bravo Diesel Sterndrive Propeller Installation

    Section 5 - Maintenance Bravo Diesel Sterndrive Propeller Installation WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 115: Bravo Two Models

    Section 5 - Maintenance Bend the three tabs down into the grooves. Prop Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Bravo Two Models IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction of rotation of the propeller shaft. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.

  • Page 116: Bravo Three

    Section 5 - Maintenance Bend the three tabs down into the grooves. Prop Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Bravo Three Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants. Tube Ref No. Description Where Used Part No.

  • Page 117: Drive Belts

    Stretch‑belt service and maintenance procedures differ from standard accessory drive belts. Should the power‑assisted steering pump stretch‑belt need replacement consult your Cummins MerCruiser Authorized Repair Facility.

  • Page 118: Serpentine Belt Inspection

    Section 5 - Maintenance Replace the belt if worn or damaged it must be replaced. See your Cummins MerCruiser Authorized Repair Facility. Power–assisted steering stretch belt Power–assisted steering pump pulley Crankshaft pulley 25604 There is no adjustment available for the power‑assisted steering pump stretch‑belt. If the belt becomes loose or noisy it has worn out and must be replaced.

  • Page 119: Battery

    See your Cummins MerCruiser authorized dealer for all of your repair needs. There is no adjustment available for the serpentine belt. If the belt becomes loose or noisy it has worn out and must be replaced.
  • Page 120 Section 5 - Maintenance Battery Switches. Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.
  • Page 121 Section 6 - Storage Section 6 - Storage Table of Contents Cold‑Weather, Seasonal, and Extended Storage....114 Seasonal Storage Instructions........115 Cold Weather (Freezing Temperature), Seasonal Storage, Extended Storage Instructions........116 and Extended Storage..........114 Battery.................116 Cold Weather (Freezing Temperature) Storage..114 Recommissioning...............

  • Page 122: Cold-Weather, Seasonal, And Extended Storage

    Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service be performed by a Cummins MerCruiser Diesel Authorized Repair Facility. Damage caused by freezing IS NOT covered by the Cummins MerCruiser Diesel Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.

  • Page 123: Seasonal Storage Instructions

    IMPORTANT: Cummins MerCruiser Diesel recommends the use of propylene glycol antifreeze 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.

  • Page 124: Extended Storage Instructions

    IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Cummins MerCruiser Diesel Authorized Repair Facility for additional information and service.
  • Page 125 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. 10. Supply cooling water to the engine and sterndrive water inlet openings. 11.
  • Page 126 Section 6 - Storage Notes: Page 118 90-8M0057081 MARCH 2011...
  • Page 127 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Low Engine Oil Pressure..........121 .................... 120 Battery Will Not Charge..........122 Troubleshooting Charts............120 Remote Control Operates Hard, Binds, Has Excessive Starter Motor Will Not Crank Engine, or Cranks Slow. 120 Free‑play, or Makes Unusual Sounds......

  • Page 128: Diagnosing Electronically Controlled Fuel System Problems

    Diagnosing Electronically Controlled Fuel System Problems Your Cummins MerCruiser Diesel Authorized Repair Facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The Engine Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a trouble code in the ECM's memory.

  • Page 129: Poor Performance

    Boat overloaded or improperly distributed. Reduce load or redistribute more evenly. Boat bottom fouled or damaged. Clean or repair as necessary. Have electronic fuel system checked by a Cummins MerCruiser Diesel Authorized Electronic fuel system fault. Repair Facility. Excessive Engine Temperature...

  • Page 130: Battery Will Not Charge

    Check all throttle linkages. If any are loose or missing, see a Cummins Loose or missing shift and throttle linkages. MerCruiser Diesel Authorized Repair Facility immediately. Straighten cable or have a Cummins MerCruiser Diesel Authorized Repair Shift or throttle cable kinked. Facility replace cable if damaged beyond repair.
  • Page 131 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........124 Muut kielet ..............125 Local Repair Service ..........124 Autres langues ............125 Service Away From Home .......... 124 Andere Sprachen ............125 Stolen Power Package ..........

  • Page 132: Owner Service Assistance

    Resolving a Problem Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem, question, or concern about your power package, contact your Cummins MerCruiser Diesel Authorized Repair Facility. If additional assistance is required, take these steps: Talk with the dealership’s sales manager or service manager.

  • Page 133: Customer Service Literature

    The nature of the problem To find the distributor for your area, use the service locator on the Cummins MerCruiser Diesel website (www.cmdmarine.com) or contact CMD sales or service listed in the yellow pages of the telephone directory. Contact 1‑800‑DIESELS to locate your closest distributor.

  • Page 134: Andre Språk

    Before ordering literature, please have the following information about your power package available: Serial Model Number Horsepower Year United States and Canada For additional literature about for your particular Cummins MerCruiser Diesel power package, contact your nearest Cummins MerCruiser Diesel dealer/distributor or contact: Mercury Marine Telephone Mail Mercury Marine (920) 929–5110 (920) 929‑4894...
  • Page 135 Section 8 - Customer Assistance Information Country Quantity Item Stock Number Price Total Total Due 90-8M0057081 MARCH 2011 Page 127...

Table of Contents

Save PDF