Excalibur Water Systems 2.0" High Capacity Premium Flow Series Spécifications

OWNER’S OPERATIONandMAINTENANCE MANUALA Division of

8L510010-04This Page WasIntentionallyLeft BlankINTRODUCTION - 1

9L510010-04SAFETY INFORMATION“Safety Warnings” and additional information or instructions are used to alert the installer/operator of possible safety

10L510010-04BOATING RESPONSIBILITIES - 2CARBON MONOXIDE HAZARDCarbon monoxide is produced when anything that contains carbon, such as gasoline, natura

11L510010-04BOATING RESPONSIBILITIES - 2SAFE BOATING SUGGESTIONSThe nation’s waterways are becoming increasingly crowded and, in order to enjoy them s

12L510010-04RULES OF THE ROADChannel Buoy GuideThe color of the paint is the only characteristic which has the same meaning on all buoys. Red buoys a

13L510010-04ENGINE IDENTIFICATION - 3ENGINE IDENTIFICATIONWhen ordering service parts or obtaining information, always give the engine model and the s

14L510010-04ENGINE IDENTIFICATION - 3 PCM2004 MODEL IDENTIFICATION / ADVISORYMODEL P X L A P R R 123 M SERIAL 4400008th 9th 10th Spaces: DRIVE GEAR R

15L510010-04ELECTRONIC FUEL INJECTION INFORMATION - 4ELECTRONIC FUEL INJECTION SYSTEMThe PCM engines covered in this manual are equipped with an Elect

16L510010-04ENGINE ALARM SYSTEM (IF EQUIPPED)The PCM engine electronic system is programmed to control the engine alarm system. This system utilizes

17L510010-04INSTRUMENTATIONBoat manufacturers install many different types of instrumentation on boats. Become familiar with the instrumentation on y

Part Number - L510010-04 Printed 05/04Thank you for your selection of Pleasurecraft (PCM) Marine Power for your boating needs. We welcome you to T

18L510010-04STARTING ENGINE (FUEL INJECTED ENGINES)WARNINGBefore starting engine, ventilate the engine compartment by operating the bilge blower for a

19L510010-04Figure 5-1 Throttle Position SettingOPERATING INSTRUCTIONS - 5NOTICE: If engine still fails to start, contact your PCM Engines Dealer for

20L510010-04STOPPING ENGINEWhen returning to the dock, or whenever stopping the engine, bring the throttle back to the idle position. After the engin

21L510010-04TRIM AND WEIGHT DISTRIBUTIONTrimming of the boat and positioning of the weight (gear and passengers) inside the boat has the following eff

22L510010-04CONDITIONS AFFECTING OPERATION - 6CAUTIONProlonged WOT operation will shorten the life of your engine and could cause premature engine fai

23L510010-04ENGINE BREAK-IN PERIOD - 7The break-in period of your engine is the fi rst 25 hours of operation. Proper engine break-in is essential to a

24L510010-0425-HOUR ENGINE INSPECTION - 8After the fi rst 25 hours of operation, it is recommended that the engine be given an inspection. Your boat d

25L510010-04FUEL REQUIREMENTS - 9GASOLINE REQUIREMENTSWARRANTY NOTICE: Damage caused to the engine through the use of improper gasoline, low-quality

26L510010-04OIL REQUIREMENTS - 10ENGINE OIL RECOMMENDATIONSUse of Supplemental AdditivesEngine oils meeting PCM Engines’ recommendations already conta

27L510010-04ENGINE MAINTENANCE - 11ENGINE MAINTENANCERefer to the MAINTENANCE SCHEDULE for a complete listing of required maintenance and the frequenc

1L510010-04INTRODUCTION ... 3-5Regis

28L510010-04ENGINE MAINTENANCE - 11Figure 11-2 Transmission Dipstick and LocationFULL MARKDIPSTICKSHIFT LEVERPCM 1.23:1 TRANSMISSIONFigure 11-2A Trans

29L510010-04ENGINE MAINTENANCE - 11LUBRICATIONThrottle CableLubricate pivot points and exposed cable (Figure 11-3) with SAE 30W-30 engine oil. Figure

30L510010-04ENGINE MAINTENANCE - 11ELECTRICAL SYSTEM CIRCUIT BREAKERMain Circuit BreakerPCM engines are equipped with a circuit breaker which provides

31L510010-04ENGINE MAINTENANCE - 11BATTERYWARNINGBattery electrolyte is a corrosive acid and should be handled with care. If electrolyte is spilled o

32L510010-04ENGINE MAINTENANCE - 11FRESH-WATER COOLING SYSTEM SACRIFICIAL ZINC ANODELocated in the raw water side of the heat exchanger is a zinc anod

33L510010-04ENGINE MAINTENANCE - 11CHECKING COOLANT LEVELWARNINGDo not remove cooling system fi ller cap when the engine is hot. Allow the engine to c

34L510010-04ENGINE MAINTENANCE - 11FLUSHING COOLING SYSTEM - SEA-WATER SECTIONTo prevent silt and/or salt build-up in the cooling system (fresh or raw

35L510010-04ENGINE MAINTENANCE - 11TESTING COOLANT FOR ALKALINITYIt is recommended that the coolant in the fresh-water section be tested each year for

36L510010-04ENGINE MAINTENANCE - 11FILLING FRESH-WATER COOLING SYSTEMA new extended life engine coolant known as DEX-COOL™ is used in your engine(s).

37L510010-04ENGINE MAINTENANCE - 11CLEANING SEA-WATER SECTION OF HEAT EXCHANGER - FRESH-WATER COOLED MODELS ONLYThe sea-water section of the heat exch

2L510010-04Checking Fluid Levels ... 27-28Lubr

38L510010-04WARNINGExtreme caution must be exercised when servicing the fuel system and/or replacing fuel fi lter. Gasoline is extremely fl ammable and

39L510010-04ENGINE MAINTENANCE - 11Figure 11-14 Fuel Control Cell (FCC) Fuel System (Typical)FUELRETURNLINE5.0/5.7/8.1LONLYFUELSUPPLYLINETOFUELTANKFUE

40L510010-04ENGINE MAINTENANCE - 11Figure 11-15 Fuel Control Cell (FCC) (6.0L)FUELDRAINFUELBOWLFUELFILTERFUELPUMPFUELPRESSUREREGULATOR"O"- R

41L510010-04ENGINE MAINTENANCE - 11 8. Lubricate the new O-ring with a light grease and install the new O-ring into the FCC bowl mounting head. 9. A

42L510010-04ENGINE MAINTENANCE - 11WARNINGMake sure there are no fuel leaks before closing the engine hatch.Priming Fuel SystemTo prime the fuel syste

43L510010-048.1L ACCESSORY DRIVE BELTThe PCM 8.1L engine uses a single serpentine belt to drive the engine water circulation pump and the alternator.

44L510010-04ENGINE MAINTENANCE - 11Figure 11-19 Belt Tensioner (8.1L) 5. Using a 15 mm box wrench or socket, turn the belt tensioner to relieve the t

45L510010-04ENGINE MAINTENANCE - 11DRIVE BELT REPLACEMENT (6.0L) 1. Note the routing of the belt before removing. 2. Using a 15 mm box wrench or so

46L510010-04WARNINGEngine must be shut OFF and the ignition key removed before inspecting the drive belt(s). The drive belt(s) should be checked peri

47L510010-04ENGINE MAINTENANCE - 11CHANGING OILSWARNINGIMPORTANT: The Federal Water Pollution Control Act prohibits the discharge of oil or oily wast

3L510010-04REGISTRATION INFORMATION(Warranty Registration Card is located at the back of this manual)Shortly after your purchase is registered with PC

48L510010-04ENGINE MAINTENANCE - 11ENGINE ALIGNMENTCAUTIONEngine must be properly aligned, or vibration, noise and damage to the transmission output s

49L510010-04ENGINE MAINTENANCE - 11Figure 11-29 Angular AlignmentSTRAIGHTEDGETRANSMISSIONOUTPUT FLANGE.003 INCH(0.07 mm)FEELER GAUGEPROPELLERSHAFTCOUP

50L510010-04ENGINE MAINTENANCE - 11 6. After the engine has been properly aligned, secure the engine mounts. 7. Connect the propeller shaft coupling

51L510010-04ENGINE MAINTENANCE - 11ENGINE MAINTENANCE LOG Operating Date Maintenance/Repair Hours

52L510010-04ENGINE MAINTENANCE - 11MAINTENANCE SCHEDULE After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Hours of H

53L510010-04ENGINE MAINTENANCE - 11MAINTENANCE SCHEDULE (cont’d) After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Ho

54L510010-04VISUAL INSPECTIONIt is important for the owner/operator to visually inspect the complete engine assembly at regular intervals. Most often

55L510010-04ENGINE MAINTENANCE - 11FILTER REQUIREMENTS Description Part No. Oil Filter (remote-mounted) R077001 Fuel Control Cell (FCC) Fuel Filt

56L510010-04ENGINE SPECIFICATIONS - 12 MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L (Horsepower) (275 HP) (330 HP) (385 HP) (42

57L510010-04ENGINE SPECIFICATIONS - 12 MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L (Horsepower) (275 HP) (330 HP) (385 HP) (42

INTRODUCTION - 13 Year Transferable Limited Warranty Pleasurecraft Marine Engine Co. (PCM) warrants its new products to be free from defects in mater

58L510010-04ENGINE SPECIFICATIONS - 12Figure 12-1 V-8 Firing Orders17c64283513572468135724685.0 / 5.7 LiterLH ROTATIONFRONT6.0 / 8.1 LiterLH ROTATIONF

59L510010-04OUT-OF-SEASON STORAGE - 13ENGINE STORAGEIMPORTANT: These services should be performed by an Authorized PCM Dealer.CAUTIONRefer to FLUSHIN

60L510010-04OUT-OF-SEASON STORAGE - 13DRAINING INSTRUCTIONSCAUTIONIf the boat is to remain in the water during or after draining, close the seacock to

61L510010-04OUT-OF-SEASON STORAGE - 13 9. Reinstall the hoses into the thermostat housing and tighten the hose clamps securely.After draining is comp

62L510010-04OUT-OF-SEASON STORAGE - 13CAUTIONWhen installing the battery, make certain that you connect the POSITIVE (+) BATTERY CABLE to the POSITIVE

63L510010-04TROUBLESHOOTING - 14Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. When

64L510010-04TROUBLESHOOTING - 14 Malfunction Possible Cause Corrective Action Engine Overheats Loose or worn drive belt(s) Adjust or replace the

65L510010-04TROUBLESHOOTING - 14 Malfunction Possible Cause Corrective Action Transmission slipping - Low oil level Add specifi ed oil. Check th

66L510010-04WATER FLOW DIAGRAMS - 15=RAWWATERFLOW= Drain LocationsKnock SensorTorque 20 N.m (15 lb ft)Figure 15-1 Raw-Water Cooling System (5.0/5.7L M

67L510010-04WATER FLOW DIAGRAMS - 15Figure 15-2 Fresh-Water Cooling System (5.0/5.7L)= RAW WATER FLOW= FRESH WATER FLOW= Drain Locations

5L510010-04CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONSThe California Air Resources Board and Pleasurecraft Mari

68L510010-04Figure 15-3 Fresh-Water Cooling System (6.0L)WATER FLOW DIAGRAMS - 15=RAWWATERFLOWNOTE: Location is the cooling system bypass. This bypass

69L510010-04WATER FLOW DIAGRAMS - 15= Optional Drain KitThe drain kit does not ensure that all of thewater will drain out of the system. Engineangle,

70L510010-04Figure 15-5 Raw-Water Cooling System (8.1L)= RAW WATER FLOW= Drain LocationsWATER FLOW DIAGRAMS - 15

71L510010-04Figure 15-5 Fresh-Water Cooling System (8.1L)To EngineBlockTo EngineBlock= RAW WATER FLOW= FRESH WATER FLOW= Drain LocationsWATER FLOW DIA

72L510010-04INSTRUMENTATION WIRING DIAGRAMS - 16Figure 16-1 Typical Instrumentation WiringCIRCUIT CIRCUIT ENGINE HARNESSNUMBER NAME WIRE COLOR1. GROUN

73L510010-04LITERATURE - 17To obtain service and/or parts literature for your PCM Marine Engine, contact the following: 1. SERVICE: For more detaile

74L510010-04FORMS - 18PCM WARRANTY TRANSFER APPLICATIONThe remainder of the original PCM limited warranty is transferable within thirty (30) days of d

75L510010-04FORMS - 18PCMSUMMARY OF WARRANTY TERM LIMITSThis list does not, in any way, modify the offi cial Limited Warranty Statement of PCM. This l

76L510010-04FORMS - 18OPERATION AND MAINTENANCE LOG Engine Port Drive Port Ignition Key Port Model and Serial # Stbd. Serial # Stbd. Number

77L510010-04FORMS - 18PROBLEM NOTIFICATION OR INFORMATION REQUEST FORMIMPORTANT: All blanks MUST be completed to insure proper identifi cation of your

6L510010-04PLEASURECRAFT MARINE ENGINE CO. MODEL YEARS 2003-2008 GENERAL EMISSIONS WARRANTY COVERAGE1. Pleasurecraft Marine Engine Co. (hereinafter r

78L510010-04NOTES - 19

7L510010-04INTRODUCTION - 18. To insure prompt repair under this Warranty, Pleasurecraft will maintain a supply of warranted parts suf-fi cient to mee