Mercury 4.2 Diesel Manuals

Manuals and User Guides for Mercury 4.2 Diesel. We have 2 Mercury 4.2 Diesel manuals available for free PDF download: Operation & Maintenance Manual

Mercury 4.2 Diesel Operation & Maintenance Manual (123 pages)

Sterndrive Models

Brand: Mercury | Category: Engine | Size: 25 MB

Table of Contents

5
- Read this Manual Thoroughly
  3
- Identification
  10
- Section 1 - Getting to Know Your Power Package
  10
- Features and Controls
  12
- Seacore Equipped Drives
  22
  - Seacore Components and Castings
    22
  - Stainless Steel Fasteners
    22
- Safe Boating Recommendations
  26
- Carbon Monoxide Exposure
  27
  - Be Alert to Carbon Monoxide Poisoning
    27
  - Stay Clear of Exhaust Areas
    27
  - Good Ventilation
    27
  - Poor Ventilation
    28
- Important Operation Information
  28
  - Launching
    28
  - Duty Cycle Rating Requirements
    28
  - High-Output Rating
    28
  - Operation Chart
    29
  - Freezing Temperature and Cold Weather Operation
    29
  - Drain Plug and Bilge Pump
    30
  - Trailering the Boat
    30
- Starting, Shifting, and Stopping
  30
  - Before Starting the Engine
    30
  - Important Information - Smartstart
    30
  - Starting a Cold Engine
    30
  - Engine Warm-Up
    31
  - Starting a Warm Engine
    31
  - Shifting
    32
  - Engine Shut down (Stopping)
    32
  - Starting the Engine after Stopped While in Gear
    32
- Protecting People in the Water
  32
  - While You Are Cruising
    32
- Section 2 - on the Water
  32
Section 3 - Specifications

39
- Antifreeze/Coolant
  40
- Diesel Fuel in Cold Weather
  40
- Fuel Requirements
  40
- Engine Oil
  41
- Engine Specifications
  42
- Fluid Specifications
  42
- Approved Paints
  43
Section 4 - Maintenance

45
- Dealer Responsibilities
  46
- Do-It-Yourself Maintenance Suggestions
  46
- Inspection
  46
- Maintenance
  46
- Owner and Operator Responsibilities
  46
- Maintenance Schedules
  47
  - Routine Maintenance
    47
  - Scheduled Maintenance
    48
- Engine Oil
  49
  - Checking
    49
  - Filling
    49
  - Changing Oil and Filter
    50
- Sterndrive Gear Lube
  51
  - Checking
    52
  - Filling
    52
  - Changing
    53
- Power Trim Fluid
  55
  - Checking
    55
  - Filling
    56
  - Changing
    57
- Power-Assisted Steering Fluid
  57
  - Checking
    57
  - Filling
    58
  - Changing
    58
- Engine Coolant
  58
  - Check Coolant
    58
  - Changing
    59
- 2.8 Air Filter
  59
  - Removal
    59
  - Inspection
    60
  - Installation
    60
- 4.2 Air Filter
  61
  - Removal
    61
  - Inspection
    61
  - Installation
    62
- Water-Separating Fuel Filter
  62
  - Draining
    63
  - Replacing
    63
  - Filling
    65
- Fuel System
  66
  - Priming
    66
  - Filling (Bleeding)
    66
  - Fuel Tank Cleaning and Flushing
    67
- Seawater System
  67
  - Draining the Seawater System
    67
  - Sterndrive Water Inlets Check
    69
- Section 4 - Maintenance
  69
  - Checking the Seawater Pickups
    70
  - Cleaning the Seawater Strainer, if Equipped
    70
    
    Flushing the Seawater System-Sterndrive Models
    72
    
    With the Boat out of the Water
    72
    
    With the Boat in the Water
    74
    
    Engine Seawater Pump Inspection
    75
  - Replacing the Engine Coolant in the Closed-Cooling System
    75
  - System
    75
    
    Draining the Closed-Cooling System
    75
    
    Filling the Closed-Cooling System
    76
  - Corrosion Protection
    77
    
    Engine Corrosion Protection Components
    77
    
    General Information
    77
    
    Removal
    77
    
    Cleaning and Inspection
    78
    
    Installation
    79
    
    Sterndrive Corrosion Protection Components
    80
    
    Continuity Circuit-Bravo Sterndrive
    83
    
    Mercathode
    85
    
    Boat Bottom Care
    86
    
    Painting Your Power Package
    86
    
    Sterndrive Surface Care
    87
  - Lubrication
    87
    
    Steering System
    87
    
    Shift Cable
    89
    
    Throttle Cable
    89
    
    Driveshaft Extension Models
    90
    
    Engine Coupler
    90
    
    Transom Assembly
    90
    
    Sterndrive, Bellows, and Engine Alignment
    91
  - Maintaining Torques
    92
    
    Bravo Gimbal Ring U-Bolt Nuts
    92
    
    Engine Mounts
    93
  - Propellers
    93
    
    Bravo Sterndrive Propeller Removal
    93
    
    Bravo One Models
    94
    
    Bravo Two Models
    94
    
    Bravo Three Models
    95
    
    Bravo One Models
    96
    
    Bravo Sterndrive Propeller Installation
    96
    
    Bravo Three
    97
  - Drive Belts
    98
    
    Inspection
    98
    
    Serpentine Belt
    98
    
    Replacement
    99
    
    Adjustment
    100
    
    Inspection
    100
    
    Power-Assisted Steering Pump Belt
    100
    
    Replacement
    101
  - Battery
    102
    
    Battery Precautions for Multiple Engines
    102
Section 5 - Storage

105
- Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage
  106
  - Cold Weather (Freezing Temperature) Storage
    106
    
    Preparing Your Power Package for Seasonal or Extended Storage
    106
    
    Seasonal Storage Instructions
    107
    
    Battery
    108
    
    Extended Storage Instructions
    108
  - Recommissioning
    108
Section 6 - Troubleshooting

111
Section 7 - Customer Assistance Information

115
- Attention Required after Submersion
  116
- Local Repair Service
  116
- Owner Service Assistance
  116
- Parts and Accessories Inquiries
  116
- Replacement Service Parts
  116
- Resolving a Problem
  116
  - Contact Information for Mercury Marine Customer Service
    117
- Service Away from Home
  116
- Stolen Power Package
  116
- Customer Service Literature
  117
  - English Language
    117
  - Other Languages
    118
- Ordering Literature
  118
  - United States and Canada
    118
  - Outside the United States and Canada
    118
- Scheduled Maintenance Log
  120
- Vessel Maintenance Notes
  121

Mercury 4.2 Diesel Operation & Maintenance Manual (89 pages)

Brand: Mercury | Category: Engine | Size: 21 MB

Table of Contents
4
Identification
9
Serial Number Decal
9
Engine Data Label
9
ZF Marine Transmissions
10
Technodrive Transmissions
10
Features and Controls
10
Audio Warning System
10
Switches
11
Lanyard Stop Switch
11
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
12
Instrumentation
13
Vesselview
13
Smartcraft Speedometer, Tachometer, and Digital Gauges
13
System Link Digital Gauges
14
Emergency Stop Switch
15
Remote Controls
15
Panel Mount Features
16
Console Mount Features
16
Overload Protection-Upper Engine Circuit Breaker Panel
17
Overload Protection-Port Side Power Distribution Box
18
Vessel Integration Panel (VIP) Overload Protection
19
Engine Guardian System
19
Safe Boating Recommendations
21
Carbon Monoxide Exposure
22
Be Alert to Carbon Monoxide Poisoning
22
Stay Clear of Exhaust Areas
22
Good Ventilation
22
Poor Ventilation
23
Important Operation Information
23
Launching
23
Duty Cycle Rating Requirements
23
High-Output Rating
23
Operation Chart
24
Freezing Temperature and Cold Weather Operation
24
Drain Plug and Bilge Pump
25
Trailering the Boat
25
Starting, Shifting, and Stopping
25
Before Starting the Engine
25
Important Information - Smartstart
25
Starting a Cold Engine
25
Engine Warm up
26
Starting a Warm Engine
26
Shifting
26
Trolling Valve Operation on Technodrive Transmissions
26
Section 2 - on the Water
26
Engine Shut down (Stopping)
27
Protecting People in the Water
27
While Boat Is in Operation
27
While the Boat Is Stationary
27
High-Speed and High-Performance
27
Passenger Safety in Pontoon Boats and Deck Boats
27
Boats Having an Open Front Deck
27
Boats with Front-Mounted, Raised Pedestal Fishing Seats
28
Wave and Wake Jumping
28
Impact with Underwater Hazards
29
Conditions Affecting Operation
29
Weight Distribution (Passengers and Gear) Inside the Boat
29
Bottom of Boat
29
Elevation and Climate
30
Propeller Selection
30
Getting Started
30
Initial Break-In Procedure
30
Engine Break-In
30
20-Hour Break-In Period
30
After the 20-Hour Break-In Period
31
End of First Season Checkup
31
Section 3 - Specifications
32
Fuel Requirements
33
Diesel Fuel in Cold Weather
33
Antifreeze/Coolant
33
Engine Oil
34
Engine Specifications
35
Fluid Specifications
35
Engine
35
Transmission
35
Approved Paints
35
Owner and Operator Responsibilities
39
Dealer Responsibilities
39
Maintenance
39
Do-It-Yourself Maintenance Suggestions
39
Inspection
39
Maintenance Schedule
40
Routine Maintenance
40
Scheduled Maintenance
41
Engine Oil
42
Checking
42
Filling
42
Changing Oil and Filter
43
ZF Marine Transmission Fluid
44
Check Fluid Level
44
Add Fluid
45
Change Fluid
45
Technodrive Transmission Fluid
47
Check Fluid
47
Add Fluid
48
Change Fluid
48
Engine Coolant
50
Check Coolant
50
Filling
51
Changing
52
2.8 Air Filter
52
Removal
52
Inspection
52
Installation
52
Inspection
53
Installation
54
Water-Separating Fuel Filter
54
Draining
55
Replacing
55
Filling
57
Fuel System
58
Priming
58
Filling (Bleeding)
58
Fuel Tank Cleaning and Flushing
59
Seawater System
59
Draining the Seawater System
59
Checking the Seawater Pickups
61
Cleaning the Seawater Strainer, if Equipped
61
Flushing the Seawater System-Inboard Models
63
With the Boat out of the Water
63
With the Boat in the Water
64
Engine Seawater Pump Inspection
65
Replacing the Engine Coolant in the Closed-Cooling System
65
Draining the Closed-Cooling System
65
Filling the Closed-Cooling System
66
Corrosion Protection
67
General Information
67
Engine Corrosion Protection Components
67
Removal
67
Cleaning and Inspection
68
Installation
69
Antifouling Paint
70
Lubrication
70
Throttle Cable
70
Shift Cable
70
Drive Belts
71
Drive Belt
71
Serpentine Belt
71
Inspection
71
Replacement
72
Battery
73
Battery Precautions for Multiple Engines
73
Section 5 - Storage
74
Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage
75
Cold Weather (Freezing Temperature) Storage
75
Preparing Your Power Package for Seasonal or Extended Storage
75
Seasonal Storage
76
Extended Storage Instructions
77
Battery
77
Recommissioning
77
Section 6 - Troubleshooting
78
Diagnosing Electronically Controlled Fuel System Problems
79
Troubleshooting Charts
79
Starter Motor will Not Crank Engine, or Cranks Slow
79
Engine will Not Start, or Is Hard to Start
79
Engine Runs Rough, Misses, or Backfires
79
Poor Performance
79
Incorrect Engine Temperature
80
Low Engine Oil Pressure
80
Battery will Not Charge
80
Remote Control Operates Hard, Binds, Has Excessive Free-Play, or Makes Unusual Sounds
80
Owner Service Assistance
83
Local Repair Service
83
Service Away from Home
83
Stolen Power Package
83
Attention Required after Submersion
83
Replacement Service Parts
83
Parts and Accessories Inquiries
83
Resolving a Problem
83
Contact Information for Mercury Marine Customer Service
84
Customer Service Literature
84
English Language
84
Other Languages
85
Ordering Literature
85
United States and Canada
85
Outside the United States and Canada
85
Section 8 - Maintenance Log
86
Scheduled Maintenance Log
87
Vessel Maintenance Notes
88

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Mercury 4.2 Diesel Manuals

Mercury 4.2 Diesel Operation & Maintenance Manual (123 pages)

Table of Contents

Table of Contents

Section 3 - Specifications

Section 4 - Maintenance

Section 5 - Storage

Section 6 - Troubleshooting

Section 7 - Customer Assistance Information

Mercury 4.2 Diesel Operation & Maintenance Manual (89 pages)

Table of Contents

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