Summary of Contents for Mercury 6.2 Inboard MPI DTS
Page 1
6.2 Inboard MPI DTS O P E RAT I O N & MAI N T EN AN C E MAN UAL...
Page 3
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 4
Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Adaptive Speed Control (ASC)..........2 Adjustment..............8 Identification................2 Special Digital Throttle and Shift (DTS) Features....8 Engine Serial Number............2 Dock................9 Transmissions..............3 Throttle Only..............9 ZF Marine Transmissions..........
Page 6
Local Repair Service............64 Parts and Accessories Inquiries........64 Service Away From Home..........64 Resolving a Problem............64 Stolen Power Package............. 64 Contact Information for Mercury Marine Customer Service Attention Required After Submersion....... 64 ..................65 Page ii 90-8M0119292 MAY 2016...
Page 7
Customer Service Literature............ 65 Ordering Literature..............66 English Language.............. 65 United States and Canada..........66 Other Languages..............66 Outside the United States and Canada......66 Section 8 - Checklists Predelivery Inspection (PDI)............ 68 Customer Delivery Inspection (CDI)........69 Section 9 - Maintenance Log Scheduled Maintenance Log...........
Page 9
Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Adaptive Speed Control (ASC)..........2 Operation ..............7 Identification................2 Adjustment .............. 8 Engine Serial Number............2 Special Digital Throttle and Shift (DTS) Features.... 8 Transmissions..............
Section 1 - Getting to Know Your Power Package Adaptive Speed Control (ASC) This power package utilizes Adaptive Speed Control (ASC) to maintain the engine RPM that is demanded at the remote control, regardless of the load change. As an example of how ASC functions, when the operator steers the boat into a hard turn or is navigating at a slow on‑plane speed in following seas when boat control is needed without a lot of speed, the propulsion control module will automatically adjust the engine to maintain the RPM without the operator changing the position of the remote control throttle handle.
Section 1 - Getting to Know Your Power Package Transmissions ZF Marine Transmissions On the ZF Marine 63 series transmissions, the identification plate lists the gear ratio, serial number, and model. 58645 61400 Model 63A Model 63IV Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection.
Section 1 - Getting to Know Your Power Package Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency. WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat.
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.
Section 1 - Getting to Know Your Power Package DTS Slim Binnacle Single Handle Console Features and 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 forward to increase speed. Pull the control handle back from neutral to the first detent for reverse gear.
Section 1 - Getting to Know Your Power Package Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. STOP/ START DOCK TRANSFER THROTTLE - ONLY 58648 Slim binnacle ERC Item Control Function...
Section 1 - Getting to Know Your Power Package The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent unwanted motion. Adjustment NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws. To adjust the handle detent tension: Remove the side cover plugs of the handle that needs adjustment.
Section 1 - Getting to Know Your Power Package Item Control Function Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in throttle only Neutral lights mode. Transfer Allows boat control to be transferred to a different helm. Refer to Helm Transfer. Available with joystick operation and the control levers.
Section 1 - Getting to Know Your Power Package Throttle only mode also affects the joystick. The engines will move and the RPM can be increased, but will remain in neutral. NOTE: Pressing the THROTTLE ONLY button while the ERC levers are not in the neutral position turns the button light off and remains in throttle only mode.
Section 1 - Getting to Know Your Power Package Press the SYNC button. The button light turns off. To engage Sync mode, press the SYNC button at any time. Transfer (Boats equipped with dual helms) The TRANSFER button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms.
Page 20
Section 1 - Getting to Know Your Power Package To access the circuit breaker and fuses, remove the outside engine cover. Pull the outside engine cover up to remove it from the four rubber mount grommets. 58358 The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. 55033 All of the engine protection fuses are located at the front of the engine.
Page 21
Section 1 - Getting to Know Your Power Package DTS engine, freshwater cooled shown, others similar Oxygen sensor fuses (4) Spare fuse Engine and trim relays DTS helm power Fuel injectors Alternator and fuel pump relay Ignition coils Malfunction indicator lamp (MIL) 61448 A 90‑amp fuse located near the flame arrestor, protects the engine power harness if an electrical overload occurs.
Section 1 - Getting to Know Your Power Package This power package uses a clean power harness that is connected to the engine starting battery. This clean power harness minimizes an excessive voltage drop to the engine and drive digital control electrical system. This harness is protected by a 5‑amp fuse and is located near the engine starting battery.
Section 1 - Getting to Know Your Power Package Caution If a caution state is detected, the audio warning system will sound for six one‑second intervals. Horn (on or off) Time (in seconds) 33402 Critical If a critical state is detected, the audio warning system sounds for six seconds and then turns off. Horn (on or off) Time (in seconds) 53403...
Page 24
Section 1 - Getting to Know Your Power Package Notes: Page 16 90-8M0119292 MAY 2016...
Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 18 High‑Speed and High‑Performance Operation..... 22 Carbon Monoxide Exposure..........19 Passenger Safety in Pontoon Boats and Deck Boats..22 Be Alert To Carbon Monoxide Poisoning ..... 19 Boats Having an Open Front Deck .......
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.
Section 2 - 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.
Section 2 - On the Water Poor Ventilation Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
Section 2 - On the Water Place the remote control handle in neutral. 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. WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion.
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.
Section 2 - On the Water Boats Having an Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.
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.
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/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 34
Section 2 - On the Water Notes: Page 26 90-8M0119292 MAY 2016...
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Section 3 - Specifications If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation. 1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible. IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.
*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.
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 an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.
Section 4 - Maintenance • Inspect anodes, if equipped Three Years or 300 Hours • Inspect the spark plugs and spark plug wires • Clean the flame arrestor and crankcase vent hoses • Check the engine mount fasteners for tightness and tighten to the specified torque—dealer item •...
Section 4 - Maintenance 58402 In-line drive model shown Inspect the dipstick for the oil level reading. The oil should be between the ADD mark and the FULL or OK range mark on the dipstick. Install the dipstick into the dipstick tube. If the oil level is low, refer to Filling. Oil Level—Overfilled IMPORTANT: Do not overfill the engine with oil.
Capacity Fluid Type Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Engine Oil Drain Pump Loosen the oil filter to vent the system. Remove the dipstick. Install the oil pump onto the dipstick tube.
Engine oil (with filter) 4.7 L (5 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Start the engine and operate for three minutes while checking for leaks. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, verify that there is fluid in the coolant recovery bottle. If the recovery bottle is empty, contact your authorized Mercury MerCruiser dealer.
Closed cooling system 92-877770K1 Check the antifreeze concentration for adequate freeze protection and correct if necessary. Refer to the Specifications section. Install the fill cap to the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 90-8M0119292 MAY 2016 Page 39...
Section 4 - Maintenance Flame Arrestor 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.
Section 4 - Maintenance Cut the cable tie securing the crankcase vent hose to the flame arrestor and gently pull the vent hose off the flame arrestor. 61330 Crankcase vent hose Clean the flame arrestor with warm water and a mild detergent. Inspect the flame arrestor for holes, cracks, or deterioration.
Section 4 - Maintenance Place a rag or towel around the fuel filter housing to prevent the fuel from leaking or spraying. Use the fuel filter removal/installation tool or the shaft of a screwdriver between the lugs on the filter cover and turn the fuel filter cover counterclockwise to loosen it.
Section 4 - Maintenance Fuel Filter Inspection The fuel filter is an important component in the fuel delivery system and should be inspected for debris or degradation every 100 hours of operation. Replace the fuel filter when necessary. Filter Housing Installation Place the filter housing mounting tabs into the slots on the bracket and push down on the filter housing to slide the mounting tabs into the lock position.
Section 4 - Maintenance Serpentine Drive Belt Serpentine Drive Belt Routing WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. With a seawater pump Alternator pulley Water circulating pump pulley...
Section 4 - 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.
Section 4 - Maintenance NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. 21062 Replacing IMPORTANT: If the belt is removed and is found to be in acceptable condition to use, you must install it in the same direction of rotation as before.
Page 55
Section 4 - Maintenance IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends. Close the seacock, if equipped. For visual clarity, the seacock shown is not installed Hose fitting to engine Seacock...
Page 56
IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 57
Section 4 - Maintenance 17. Remove the plugs from the water hose and connect to the fittings. Tighten the hose clamps securely. 18. Open the seacock, if equipped. IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If the unit is to be stored out of the water, open the seacock.
(phase) of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...
IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the raw water section of the cooling system during freezing temperatures or for extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 63
Section 5 - Storage Pull the lever on the air pump (vertical) to lock the pump onto the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 Pump air into the system until both green indicators extend out of the actuator assembly. Check to ensure water drains out of the distribution housing.
Page 64
Section 5 - Storage 10. There are power packages that require specific drain plugs removed because the engine angle is greater than the air actuated drain system allows for proper draining of the system. Remove the blue plugs shown in the following illustrations. 58423 Port side view 58765...
Section 5 - Storage 17. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 18. Open the seacock, if equipped, or unplug and connect the water inlet hose prior to operating the engine. Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition.
Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.
Clean the flame arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer. Poor Performance...
Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners if any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Page 62 90-8M0119292 MAY 2016...
Page 71
Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 64 Contact Information for Mercury Marine Customer Local Repair Service ............ 64 Service ................. 65 Service Away From Home ..........64 Customer Service Literature..........65 Stolen Power Package ..........
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.
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: •...
Section 7 - 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 76
Section 8 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...
Page 77
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 78
Section 8 - Checklists N/A Completed Item Registration: ⃞ Complete and submit warranty registration—provide the customer with a copy Page 70 90-8M0119292 MAY 2016...
Page 80
Section 9 - 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 81
Section 9 - 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 90-8M0119292 MAY 2016 Page 73...
Need help?
Do you have a question about the 6.2 Inboard MPI DTS and is the answer not in the manual?
Questions and answers