Sea Ray 2001 540 SUNDANCER Owners Manual

540 Sundancer®
Welcome
Congratulations on becoming the new owner of the
world’s most prestigious yacht. We at Sea Ray®
Boats, Inc. welcome you into our world-wide and
ever-expanding family of boating enthusiasts.
Every journey lets you enjoy the excitement of a
new adventure. Your new yacht is more than a boat;
itis a way of living. Our organization is dedicated to
providing pleasure and fulfillment to your boating
experience.
Sea Ray's commitment — Excellence by Design —
has enabled us to create a superior craft providing
you with comfort, performance, safety and
dependability. All of our boats comply with safety
standards set by the United States Coast Guard and
are designed, engineered and manufactured in
accordance with applicable recommendations and
guidelines of the National Marine Manufacturers
Association (NMMA) and the American Boat and
Yacht Council (ABYC).
The Owners Manual Packet, to be kept on board
your Sea Ray, introduces you to all the features
which make our boats so incomparable. For years
of trouble-free boating, take the time now to carefully
review the information in your Owners Manual
Packet and really get to know your boat. Have
everyone who will operate your yacht read this
manual.
The Owner's Manual Packet contains the following:
e Sea Ray Warranty Statement
Read the Sea Ray Warranty Statement so you
will be familiar with the terms.
e Specification Sheet
The Specification Sheet lists standard
equipment for your boat as well as available
optional equipment and useful specifications
needed for safe boating.
* Parts Manual
The Parts Manual helps you locate items and
understand the layout of your Sea Ray.
* Sea Ray Yacht Owner’s Manual
The Sea Ray Yacht Owners Manual gives you
valuable operating and safety information about
your responsibilities as a Yacht owner/operator.
e Original Equipment Manufacturer (OEM)
Information
This section of your Owners Manual Packet
contains information from the manufacturer of
equipment installed on your boat. Examples
include the engine, steering and VHF radio.
Throughout the Owner's Manual Packet you will
be referred to information provided by
manufacturers of specific systems.
Because our Product Development and Engineering
Division is continually upgrading our products, some
descriptions in this manual may differ somewhat
from equipment on your boat. If this occurs, please
refer directly to the updated information in the
accompanying Owner's Manual Packet. If such
information is not included, consult your authorized
dealer for assistance.
Because your purchase represents a substantial
investment, we know you will want to take the
necessary measures to protect its value. We
suggest you plan a program for proper operation,
periodic maintenance and safety inspections. If you
have questions which are not fully covered by the
Owners Manual Packet or the manufacturer's
instructions, please consult your authorized dealer
for assistance.
Thank you for selecting a Sea Ray”!
Bon Voyage
Sea Riga E,
OWNER’S MANUAL PACKET CONTENTS
Sea Ray
Sea Ray Sea Ray Sea Ray Engine Owner’s
Owner’s Specification Parts Operator’s OEM Manual
Manual Sheet Manual Manual Manual Packet
Accident Reporting X
Alarms X X
AM/FM Cassette Stereo
XXXIX
Anchoring X
Auto-Pilot System X
x
x
Battery System
Bilge Layout Х*
* Bilge Blower
* Bilge Pump
Canvas
Capacity Plate
Carbon Monoxide
Certifications
X| XXX XXX
x
Cleaning
Cockpit
Communication Equipment
Compass
Console
Construction Standards
X| XXX Xx
x
Controls
Depth Finder X
Dimensions X
Drains
Education
Electrical System
Electrolysis
Emergency Engine Shutdown
Emergency Procedures
Engine
X| XXX IX XXX
Environmental Considerations
Equipment:
* Recommended
XX
x
* Required
* Standard X
Fire
XX
x
x
Fire Suppression Equipment
Flame Arrestor X X
Flooding, Swamping
Fuel System
Gauges
XXXIX
Gear Shitt
Global Positioning System (GPS) X
Graphics X
Head System
Homologations (International)
Hotlines (Safety)
Identification Numbers
Ignition
Ignition Protection
Impaired Operation
X| XX XX XXX
x
Instrument Use & Calibration
Sea Ray
Sea Ray SeaRay Sea Ray Engine Owner's
Owner's Specification Parts Operator's OEM Manual
Manual Sheet Manual Manual Manual Packet
Layout X X
Lifesaving Equipment X
Lifting
Lightning Protection
Lights
Load Capacity
Maintenance
Maneuvering
Monitors
Nautical Terms
Navigation
DE | DE | XXX IX XX XX XX
x
x
Operation
Optional Systems
Personal Flotation Devices
Power Capacity
Powertrain
X| XXX
Propeller
Propulsion
x
Required Equipment
Registration X
Safety X X
Seating
Seaworthiness Inspection X
Service Schedule X X
Spare Parts X
Specifications X
Stability
X
Start-In-Gear Protection X X
Steering X
Sump X
Symbols X
Switches
Tank Capacities X
Throttle
Through-Hull Fittings
Trim Tabs
Troubleshooting
Upholstery
Ventilation
XXX XX Xx
x
x
Warning Labels
Warranty X
x
x
Water System
Weight X
Winterizing X X
Wiring Schematics X
To replace any material from the Owner’s Manual Packet, contact your Sea Ray® dealer.
Information in this publication is based upon the latest product specifications available at printing. Sea Ray Boats,
Inc. reserves the right to make changes at any time, without notice, in the colors, equipment, specifications, materials
and prices of all models, or to discontinue models. Should changes in production models be made, Sea Ray® is not
obligated to make similar changes or modifications to models sold prior to the date of such changes.
* If available at the time of publication of the manual. |||
KEY TO SYMBOLS ON PRINTS
PROPULSION PROPULSION PROPULSION TRIM TAB SINGLE LEVER CONTROL LEVER
SYSTEM SYSTEM TRIM SYSTEM TRIM TRIMMING CONTROL OPERATING
TRIM BOW UP BOW DOWN OPERATION (THROTTLE & SHIFT) DIRECTION
LIFT POINT OR boa
PROPER LOCATION ENGINE ENGINE FUEL FUEL ENGINE
OF SLING START STOP LEVEL FILTER
SS GI -(0)- A A ès
ENGINE ENGINE (COOLANT) ENGINE OIL WARNING FIRE NO OPEN FLAME
COOLANT WATER JACKET ELECTRICAL RISK NO SMOKING
TEMPERATURE PRESSURE HAZARD
En ||
и AAA Е () AAA
ROTARY CONTROL
(QUANTITY INCREASES FRESH WATER LEADED UNLEADED OIL WASTE WATER/
WITH WIDTH OF BASED COOLANT FUEL FUEL SEWAGE
SYMBOL)
FUEL, GENERAL DIESEL LIFT ELAPSED ENGINE BILGE PUMP
FUEL POINT TIME ROTATIONAL
SPEED
Q x 1 N ,
® ZT -S- -(1)- NW
o o / ! N / | x / I “
BILGE BLOWER PROPELLER INTERIOR RUNNING LIGHTS ANCHOR WINDSHIELD
LIGHT UNDER POWER LIGHT WIPER
^^^“ “+”
D | © Y L be
WINDSHIELD WINDSHIELD COMPASS ANCHOR HORN BATTERY
WIPER AND
WASHER WASHER
Table of Contents
SECTION 1 — GENERAL INFORMATION
Certifications & Specifications.................... 1.1
Manufacturer’s Certifications .......................... 1.1
Manufacturer’s Specifications 1.1
Introduction ...........-. re 1.2
Warranty & Construction Standards ............... 1.2
Registration ...........oooiiiiii A 1.2
Education .........coooiii R KR K EEK EEK RER KERKEEG 1.2
Dealer ResponsibilitieS ae 1.2
Owner/Operator Responsibilities .................... 1.2
Parts & Equipment... 1.3
Nautical Terms .........ccoooiiiiiii i, 1.3
Safety coor eas 1.4
Explanation Of Safety Precautions ................. 1.4
CE 1.4
Fire Suppression Equipment ............................ 1.5
Flooding, Swamping.........ccccciiiiievviiiicn cece, 1.5
Lifesaving Equipment ................... eee 1.5
Impaired Operation ......................eeeeeeeeeeeeen 1.6
Load Capacity ....................eeeeeeeeeeeeeeeree ee. 1.6
Load Capacity (European Certified Vessels) .... 1.6
Power Capacity (European Certified Vessels) .. 1.6
Stability ..................ee2.rreeererrecccerereceee reee. 1.6
Boarding ................... R KR K REKEN 1.6
Maneuvering/Maintaining Control ................... 1.7
Weather... eee EEG 1.8
Float Plan... re R RER K EEG 1.9
Warning LabelS eK 1.9
Accident Report esse KERN 1.9
Safety Hotline ee 1.9
Additional Recommended Equipment .......... 1.10
Minimum Required Equipment ..................... 1.11
Environmental Considerations.................. 1.12
Fuel & Oil SpillaQE A 1.12
Waste DispoSal eek 1.12
Excessive Noise ae 1.12
Wake/Wash ...................e.eericiicreocieer eee. 1.12
Exhaust Emissions ..................e..exeeveresceeceeeees 1.12
(Gasoline engines produce CARBON MONOXIDE
GAS (CO). Please read this section and ask your
dealer for more information on CO.)
Paint, Cleaning Agents & Other Substances... 1.13
Emergency Procedures ..............==-..e==....e—... 1.14
Explosion € Fire ..............e.—.eeeeeeeereeeneeeee_.. 1.14
Flooding, Swamping or Capsizing................. 1.14
COlliSION eee, 1.14
GrouNdiNO er K KR K REKEN 1.15
LeaksS een ERK RK ER KR K EEK EHEN 1.15
TOWING cone eee 1.15
Person Overboard ...........ccccooeviiiiiiinii nce, 1.16
DrOWNING .….....….....…......rrcssscaesesea resserre are ner 1.16
Medical Emergency .……....….....…....……....……..….….….….….…. 1.16
Carbon Monoxide serres 1.16
Propulsion, Control Or Steering Failure ........ 1.16
540 DA
Radio Communication es 1.16
Distress SignalS ee 1.17
Specifications & Dimensions ..........c......... 1.18
Accommodation Plan 1.19
Location of Through-Hull Fittings ............. 1.20
(This section contains 20 pages)
SECTION 2 - BILGE & UNDERWATER GEAR
Bilge cco an 2.1
Fuel €: Oil Spillage .....................—....e..eiie 2.1
В1де Ритрз........нннкнннннененннннннннннннннннннннненннее) 2.1
Bilge Blowers & Bilge Ventilation Filters ......... 2.2
Engines ...........--..eeeesneneneennnenonnenennneonnnee nene... 2.3
Engine Gauge Package .....................=m.e...... 2.3
Bilge Heat Detector .........................22 e... 2.3
Engine Block Heater ............................ 2.3
Engine Mounts .......................=.eeeeeeiee 2.3
Marine Gears ....................mmiieeeenence eee 2.4
Engine Removal ...................... 0.002 2.4
Engine Exhaust System ...............ciei 2.4
Vibration á Causes ..................eeemeíxeeereeeeeenee 2.5
Fresh Water Cooling System ............................ 2.5
Underwater Gear ..............-==......neeneenonneneeneee—. 2.6
Propellers .......................eemereeeereeeneeer eee 2.6
SU encens 2.7
Shaft Log & Strong Seal” a 2.7
StrUt ….........……rrrrrereeccccaa se srrserr cree ec ananas n re eeee 2.7
Rudder & Rudder Stuffing Box .................—.——.—.. 2.7
Seacocks € Strainers ..............—w———......eeeeee..... 2.8
Accessory Room ............=-..ee=.neeeeneeeeneeeenneme—. 2.8
Bilge Layout (Port) ................. eee ee, 2.9
Bilge Layout (Stbd) .......................eeeeeeeee 2.10
Bilge Fwd Engine Room Bulkhead ................ 2.11
(This section contains 11 pages)
SECTION 3 — INSTRUMENTS 8: CONTROLS
Control Station Analog Dash Panel ................ 3.1
Slow Vessel Mode ..................e.=xreeeereeeeeeeeeeee 3.3
Trolling Valve and Low Idle Option .................. 3.4
Hydraulic Power Steering System .................. 3.5
Gear Shifts & Throttle Controls ....................... 3.5
Gear Shifts & Throttle Controls (Hydraulic) .... 3.
Gear Shifts & Throttle Controls (Electric Option) ....3.7
Engine Synchronizers eee 3.8
Instrument Gauges ................e==.....ee=eeeneneeenenees 3.8
Tachometer (with Hourmeter) ......................—...... 3.9
Oil Pressure Gauge .....................eeeiiieerieeeeee 3.9
Water Temperature Gauge «se 3.9
Voltmeter …….......…...……...…..rerserenserea rare anse casser nn 0e 3.9
Fuel Gauge .........covviiiiiii ener AA 3.9
Engine Monitoring System (EMS) ...................... 3.10
Main EMS Display er. EEE 3.10
V
Houmeters .......covvveiiiii ee, 3.10
Quad Gauge ……..….....…..…...…rererrrrrrerrerercrrnneuce 3.10
Oil Pressure Gauge 3.10
Water Temperature Gauge 3.11
Transmission Oil Temperature Gauge ............. 3.11
Transmission Oil Pressure Gauge .................. 3.11
Tachometer... E 3.11
Detroit Diesel Electronic
Display Module (EDM) 3.11
Console Dimmer ……………..............…..…......eees 3.12
Marine Compass ..................eeseeeeereceereceereceenos 3.12
Navigation Lights eee 3.12
Systems Monitor …………....…….…..…csserrercssneeee 3.12
Trim TADS oo, 3.15
(This section contains 15 pages)
SECTION 4 - FUELING & STARTING
Fuel Systems ............. ee. neeeeneenonnennooneneneeneme—. 4.1
Fuel Tanks ...............eeeeeeesceercenereneneneneeeenenemece. 4.1
Crossover Fuel System ....................ieeeeerereeecce 4.2
Fuel Recommendations .......................=.._..— 4.2
Fueling Precautions ................e=-.==-..e-..eeeneemn. 4.3
Starting Engines ...............--==...m.eeeeeeneneemneeeeem. 4.3
Stopping Engines ...............-=-...eeeeneeeeeneeee—.. 4.4
(This section contains 4 pages)
SECTION 5 - WATER SYSTEM
Water System... res 5.1
Filling The Water Tank ........................——— 5.1
WaterTanK ........cooooiiii K RER K EEK EEEG 5.1
Sanitizing The Water System............................ 5.1
Water Pumps á FiltersS................——.e ee. 5.2
Water System Accumulator Tank ...................... 5.2
WaterHeater.........ccoooo iii, 5.2
Shower System ….....…......……...rerceccasererc es rencnes 5.3
Fresh Water Washdown ................. e... 5.3
Cockpit Shower ...................r.reeeriieeereeeeee e. 5.3
Dockside Water Inlet ere 5.3
Washer & Dryer Water Valve ............................. 5.4
Fresh Water System Layout 5.5
Gray Water System Layout ee. 5.6
(This section contains 6 pages)
SECTION 6 — HEAD SYSTEM
Head System ...................eeeneeneennennneenoenneneeme—. 6.1
Requirements For Vessel Operators ................. 6.1
Vacu-Flush Head ....................eeeieeneereee e 6.1
Holding Tank Operation ee 6.1
Vent Filter ers errar 6.1
Head System Layout... 6.2
Macerator Discharge Pump ............................ 6.2
(This section contains 2 pages)
VI
SECTION 7 - ELECTRICAL SYSTEM
DC SyStEm reece 7.1
Batteries …..….…..……...…...…....sercrrerercsen see ne rene nneeee 7.1
12 Volt System cocci, 7.2
Electrical System Breakers 7.2
Battery Switches ee EEE 7.3
Emergency Start System ….….…....….……....…….…….…….…. 7.3
Crossover Charging System ……....…......………... 7.4
Halogen Lighting secs 7.4
Electronics Circuit With Ground Plate ............ 7.4
Main DC Breaker Panel
& Control Station Breaker Panel ................... 7.4
DC Distribution Panel
Controls € Functions ..............e=--..====-. se... 7.6
AC System... reece 7.9
Main Shore Power Breaker Box ..............c......... 7.9
Cablemaster With Remote .............................. 7.10
Shore Power Hookup (U.S.) ................—....._... 7.11
Shore Power Hookup (Int'l.) ...................—....—... 7.11
Maintenance For Shore Power Cable Set
& Shore Power Inlets....................—.....==...... 7.12
Servicing The Main Distribution Panel ............ 7.12
AC Main Distribution Panel
Controls 8% Functions (U.S)) .................... 7.13
AC Main Distribution Panel
Controls & Functions (Int'l.) .................... 7.16
Converters .....................eeeeneeeconaecacanenen enano. 7.18
Ground Fault Interrupter Receptacie ........... 7.19
Generator ............... e... .eeecenenenenaee nana nene. 7.20
Starting The Generator ......................eeeeeeeee... 7.20
Shifting From Shore Power To
Generator Power .....................=mereeeercric 7.21
Stopping The Generator .........................e........ 7.21
Electrolysis 8: Zinc Anodes ..................e...... 7.21
AC 8: DC Electrical Schematics ......... 7.21-7.48
(This section contains 48 pages)
SECTION 8 - ACCESSORIES
Air Conditioning 8: Heating...............-————--.— 8.1
Anchoring -..............-...eeeneeeeneeeennneennneeennene nene. 8.2
Anchoring Arrangement ....................... ee... 8.2
Retractable Sun Pad ................e==e==eeneenaeenaee 8.4
BowThruster eee 8.5
(0 1 |= TJ RR RRRRRRRRRRRRKRKRRRRRRRRRKRRERARRRRARAEG 8.5
Care é: Maintenance ee 8.5
Canvas Installation ve 8.6
Coffee Maker ..…..…...................….…..….….srecsennensensnenne 8.7
Entertainment Center.….….…........…..............…..….…..….. 8.7
Salon Entertainment Center ............................. 8.7
Master And Guest Stateroom
Entertainment Center es 8.7
Television Signal SeleCtOF a 8.7
Cable Television ConnecCtiON ee 8.7
Cockpit Entertainment Center ……………..………….……… 8.7
540 DA
Automatic Fire Extinguisher System ............ 8.8 Batteries .......c.oov viii, 9.3
HOP eeeeerr ernennen EPP REP EPP RER PRE PPPPR EEE PPPPPREE 8.8 Shaft Alignment... 9.3
Ice MaK@r are RRRRRRRKKRRRKREEERKRERERKAUEG 8.8 Miscellaneous RER nan nees 9.3
Oil Change System нинининнннннинининннннннинннннинининниние 8.9 (This section contains 3 pages)
Power Ventilation System e... eee... 8.9
Refrigerator/Freezer ARNET еененнеенененеенненеенненеее! 8.9 SECTION 10 — САВЕ & REFINISHING
Salon Sofa/Sleeper (Electric)....................... 8.10
Searchlight...................-————————.—— ==... 8.10 FIberglass -...........—..—..—..—e.eeneeene ens 10.1
Stove 8 Microwave PIN 8.10 Stains & Scratches KEREREERRRRERRRRRARERERRRARARERARARARARM 10.1
Electric StOVE are eee. 8.10 Special Care For Boats That Are Moored ....... 10.1
Microwave/Convection Oven SA 8.1 0 Саге Рог Bottom Paint EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE®E 10.1
Telephone .................11seceviarecienarr eee 8.10 Bilge/Engine Compartment.................——.—... 10.2
Washer 8 Dryer ....................em.neeneeneeneenenee..s 8.11 Topside Areas .......... энеенненненненненненнененнненнннее 10.2
Central Vacuum System EEE EEE a anus 8.11 Acrylic Plastic Sheeting EE EEEEEE EEE EEE EEE EEEEEEEEEEEEEE 10.2
WindlaSS ee R RE 8.11 Upholsteries .................—..eeeeemeeneceneeneenenenene. 10.2
Windshield Wipers ............................ 8.11 Vitracore® CabinetS ae 10.3
. . Cleaning Recommendations
Windshield Washer cocoon, 8.11 For Marine Fabrics 0 10.3
Windshield Vent ............................ ii eee 8.11
I (This section contains 3 pages)
Accessory Locations .............=-..==..==e.ee=enem... 8.12
(This section contains 12 pages)
SECTION 11 - SERVICE INFORMATION
SECTION 9 - STORAGE & LAUNCHING Useful Service Information 0000. 11.1
PROCEDURES Service Guide ....................esmenaeeceoenannaaoo ee. 11.2
Quick Reference Departure Checkdlist.......... 11.3
Laying-Up Instructions see 9.1 Before Departing .......................eiee 11.3
Lifting The Boat RE 9.1 Starting Engines TT 11.3
Supporting The Boat During Storage ................ 9.1 After Starting Engines .......................... 11.4
Draining TheBoat ......cocoovii ie, 9.1 Stopping Engines CL ae e aaa, 11.4
Winterization Checklist For Boats Operating Generator ........................e.ees 11.4
StoredOnLand ..............ccooiiii ER REEE 9.2 Thi я tains 4
Fitting Out After Storage ==... ...e=..... 9.3 (This section contains 4 pages)
Рие! Эуз!ет .........неенннннннненннненныннененненыйе 9.3
Exhaust System ..................eerrieeeceie 9.3 INDEX
Information in this publication is based upon the latest product specifications available at printing. Sea Ray” Boats,
Inc. reserves the right to make changes at any time, without notice, in the colors, equipment, specifications, materials
and prices of all models, or to discontinue models. Should changes in production models be made, Sea Ray® is not
obligated to make similar changes or modifications to models sold prior to the date of such changes.
540 Sundancer® Owner’s Manual
Printed in the U.S.A April 1997
Revised: July 1997, May 2000
O Sea Ray Boats, Inc. * A Brunswick Company
MRP #981944
The following are registered trademarks of the Brunswick Corporation: Sea Ray® & The SR Wave Logo
540 DA VII
Section 1 * General
CERTIFICATIONS & SPECIFICATIONS
CERTIFICATIONS & SPECIFICATIONS
MANUFACTURER'S CERTIFICATIONS
A CE mark means that your Sea Ray® Yacht has been certified with applicable International Organization for
Standardization directives.
NMMA certification means that your Sea Ray® Yacht has been judged by the National Marine Manufacturers
Association to be in compliance with applicable federal regulations and American Boat and Yacht Council
standards.
The following information is furnished in compliance with ISO directives and RSG guidelines in effect as of the
date of publication of this manual. Sea Ray® will provide additional information if standards are amended.
MANUFACTURER'S SPECIFICATIONS
Sea Ray® provides specific information about your boat in compliance with ISO 10240, American Boat and
Yacht Council (ABYC) Technical Report T-24 and other applicable standards and directives. The following is
included in the Owner’s Manual Packet supplied with the boat.
* Warranty Terms & Conditions * Lightning Protection System
e Hull identification Number e Tank Capacities — Gallons (Liters):
Engine/Transmission Serial Numbers — Fuel
* Type of Boat/Series Name — Fresh Water
* Dimensions — Feet (Meters): — Holding Tanks
System Diagrams:
— Length
— Beam — Water
— Vertical Clearance — Fuel
— Draft — Exhaust
* General Arrangements: - Ventilation |
— Deck Plan — Bilge Pumping
— Steering
— Interior Plan Enaine Cool
— Profile ngine Cooling
о Stability/Flotation Capability
Propulsion:
e Strong Points for Docking & Lifting
— Engine Type
— Propeller o Warning Labels, Part Numbers
& Ordering Procedure
— Shafting
e Electrical: o o Equipment
o ional Equi
— Rated Amperage ptiona! Equipment |
— Voltages — Frequency — Phases * Reference Manuals for Other Equipment
— Battery Capacity * Contacting Manufacturers of Other Systems
— Switches, Fuses, Circuit Breakers (Contacting Factory Service Department
(location, type) « Construction Features
— Wiring Diagrams e Construction Standards
540 DA 11
INTRODUCTION
This manual has been compiled to help you operate
your Sea Ray® Yacht with safety and pleasure. It
contains details of the craft, typical equipment
supplied or fitted, its systems and information on
operation and maintenance. Please read this
manual carefully, and familiarize yourself with all
systems before using your craft.
If you are not familiar with the Sea Ray® Yacht, for
your own comfort and safety, please ensure that you
obtain handling and operating experience before
taking command. Your dealer or yacht club can direct
you to sources of instruction.
PLEASE KEEP THIS MANUAL IN A SECURE
PLACE, AND GIVE IT TO THE NEW OWNER
WHEN YOU SELL THE CRAFT.
WARRANTY & CONSTRUCTION
STANDARDS
Sea Ray® provides a Warranty Statement describing
terms and conditions under which defects in your
boat will be repaired. Familiarize yourself with the
warranty and follow instructions regarding proper
operation and maintenance. Lack of attention to
instructions can void the warranty.
Sea Ray® also provides a Construction Standards
Statement detailing industry standards followed in
building your boat (see the Welcome page at the
beginning of the manual). Consult your marine
dealer for additional information.
REGISTRATION
Register your boat in the state where it is used most
frequently. Many states require additional
registration when an out-of-state boat is used within
their boundaries. Contact state boating authorities
or your marine dealer for registration requirements
and forms.
EDUCATION
Learn how to operate your boat safely. This book
cannot teach everything you need to know. We
strongly urge you to get training in proper boat
handling and navigation before taking command.
Some agencies which offer boating courses are:
* U.S. Coast Guard Auxiliary
United States Power Squadrons
Canadian Power and Sail Squadrons
1.2
* Red Cross
e State Boating Offices
e Yacht Clubs
Ask your marine dealer or check your telephone
directory for agencies near you. Information is also
available from the Boat U.S. Foundation by calling
1-800-336-BOAT. International owners/operators
should consult their marine dealer.
Many books provide information that is valuable to
you as a boat owner/operator. A book that is
considered to be the most well-rounded is Chapman
— Piloting, Seamanship and Small Boat Handling,
by Elbert S. Maloney, published by Hearst Marine
Books. In addition, there are many free pamphlets
available from your local Coast Guard Auxiliary. It
is highly recommended that you read additional
publications other than just this owner's manual to
become a well-informed boat owner/operator.
DEALER RESPONSIBILITIES
Although your boat has undergone a series of rigid
inspections throughout the manufacturing process,
the final factory check is not the last one before you
take delivery. Your dealer must perform additional
pre-delivery checks and service your Sea Ray” in
preparation for delivery. Dealer responsibilities
include providing:
* Anadequate orientation in the general operation
of your Sea Ray” boat.
e An “In Service Form” to be completed and
signed by both the dealer and the consumer
after inspection of boat by consumer.
* An explanation of safety considerations
regarding the use of containment systems and
components.
* Acomplete Owner's Manual Packet containing
literature and information regarding your Sea
Ray* boat andits separate warranted products,
warranty and registration cards, and operation,
installation and maintenance instructions.
* A review of all warranties, pointing out the
importance of mailing warranty and registration
to various manufacturers within the required
time limits, and assistance in accomplishing
same.
* [Instructions on obtaining local and out-of-area
service during and out of warranty periods.
OWNER/OPERATOR RESPONSIBILITIES
The owner/operator is responsible for examining the
boat before accepting delivery to ensure all systems
are working properly. In addition, the owner/operator
is responsible for understanding and complying with
540 DA
the following procedures and operational
requirements:
о State registration
Warranty registration
Warranty terms and conditions
* Rules of the road
Break-in procedure
* Return boat to dealer for inspection after 50
hours of operation in salt water, 100 hours fresh
water, or at the end of the first year, whichever
comes first
Proper maintenance of boat and its systems
Safety equipment
e Safety training of passengers and crew
Insurance
Knowledge of boat systems
о Seaworthiness/operational inspection
e Safe operating practices
Avoiding use of drugs/alcohol
Environmental regulations
Accident reports
Assistance to other boaters
PARTS & EQUIPMENT
Personal equipment and supplies accumulated on
a boat can amount to a great deal more weight than
the owner realizes, and may result in a loss of speed.
Keep such weight to a reasonable minimum. When
accessories or extra items are added, consider their
weight and select their location to maintain the
desired trim of the boat, fore, aft and athwartship. A
drop in RPM will be noted as weight is added, and it
may be advisable to change propeller size to
compensate. Because of these variables, Sea Ray®
cannot guarantee performance standards such as
speed. Consult your Sea Ray® dealer when
considering the addition of a major weight.
Replacement parts or additional equipment may be
purchased through your Sea Ray® dealer.
NAUTICAL TERMS
Abeam — object 90 degrees to center line on either
side of boat.
Abaft — a point on a boat that is aft of another.
Aft — toward the rear or stern of the boat.
Beam — the width of a boat.
540 DA
Bow — the fore part of a boat.
Bulkhead — vertical partition in a boat.
Chine — meeting juncture of side and bottom of boat.
Chock — deck fitting, used as guides for mooring or
anchor lines. Also, a wedge to stop wheels from
rolling.
Cleat — deck fitting with arms or horns on which
lines may be made fast.
Cockpit — an open space from which a boat is
operated.
Deck — upper structure which covers the hull
between gunwales.
Draft — depth of water required to float boat and its
propulsion system.
Fathom — six feet.
Fenders — rope or plastic pieces hung over the side
to protect the hull from chafing.
Freeboard — height of exposed hull from water line
to deck.
Ground tackle — general term referring to anchors,
anchor lines, etc.
Gunwale (pronounced gun’l) — meeting juncture of
hull and deck.
Hatch — an opening in deck to provide access below.
Head — toilet or toilet area in a boat.
Headroom — vertical distance between the deck and
cabin or canopy top.
Helm — steering console.
Hull — the basic part of a boat that provides
buoyancy to float the weight of the craft and its load.
Keel — the major longitudinal member of a hull; the
lowest external portion of a boat.
Knot — unit of speed in nautical miles per hour.
Lee — the side that is sheltered from the wind.
Port — term designating left side of the boat.
Scupper — hole permitting water to drain overboard
from deck or cockpit.
Sheer — curve or sweep of the deck as viewed from
the side.
Snub — to check or tighten a line suddenly.
Starboard — term designating right side of the boat.
Stern — the aft end of a boat.
Stern drive — outboard unit of an inboard/outboard
(I/O) engine installation.
Stringer — longitudinal members fastened inside the
hull for additional structural strength.
Transom — transverse part of stern.
Wake — disturbed water that a boat leaves behind
as a result of forward motion.
Windward — toward the direction from which the
wind is blowing.
1.3
SAFETY
The freedom of boating is a magnificent feeling.
However, fun can be overtaken by disaster if you
ignore safety precautions. This manual presents
basic guidelines, but it cannot describe every
possible risk you may encounter. You are strongly
urged to:
Take a boating safety course.
(Get hands-on training from your boat dealer.
Regularly review safety requirements.
Maintain your boat and its systems.
e Have your boat inspected at least annually by a
qualified mechanic or dealer.
EXPLANATION OF SAFETY
PRECAUTIONS
A DANGER
DANGER - Immediate hazards which WILL
result in severe personal injury or death if
the warning is ignored.
WARNING - Hazards or unsafe practices
which COULD result in severe personal injury
or death if the warning is ignored.
CAUTION - Hazards or unsafe practices which
could result in minor injury or product or prop-
erty damage if the warning is ignored.
NOTICE
| Information which is important to proper opera- |
tion or maintenance, but is not hazard-related.
This book contains safety precautions which must
be observed when operating or servicing your boat.
Review and understand these instructions.
1.4
A FIRE
Fire is always serious, but it usually can be brought
under control if you are prepared and act quickly.
Extinguishers required by the Coast Guard or other
boating law enforcement agency are only the
minimum needed. Install fire extinguishers where
they might be needed, and test equipment and
emergency plans regularly.
Prevention is the safest method of fighting fires.
Remember:
Use extreme caution while fueling.
Refrain from smoking while fueling.
Use only marine safety-approved cooking and
heating systems.
Open flames demand constant attention.
Run exhaust blowers at least 4 minutes before
starting engine.
Use “sniff test” to check for fumes in bilge and
engine compartment.
Store flammable material in safety-approved
containers.
Keep flammable material containers in a locker,
sealed from the interior of the boat and vented
overboard.
Ensure ventilation systems are unobstructed.
Remove canvas before starting engine.
Ensure fuel does not leak.
Extinguish smoking material carefully.
Use special care with flames or high
temperature near urethane foam.
Check cleaning products for flammability.
Ventilate when cleaning or painting.
Disconnect electrical system from its power
source before performing maintenance. (See
Section 7 — Electrical.)
Replace breaker or fuse with same amperage
device.
Electrical appliances must be within the rated
amperage of boat circuits.
Observe the boat carefully while the electrical
system is energized.
Only a qualified marine electrical technician may
service the boat’s electrical system.
540 DA
FIRE SUPPRESSION EQUIPMENT
General
Fire suppression equipment can be either fixed
or portable. Fixed systems are located in
machinery compartments. They should be
supplemented by portable extinguishers
mounted at key sites, for example, near the
engine compartment, galley and helm.
Coast Guard or other boating law enforcement
agency regulations govern the number and type
of devices on board. (See Safety — Minimum
Required Equipment.)
Fixed System
Fire extinguishant is installed permanently in
one or more machinery spaces. In the event of
a fire, a sensor releases fire-killing extinguishant
in the compartment.
e Fixed system is wired to the ignition and turns
on with the engine.
An indicator light on the dash is lit when the fire
suppression system is available. The light goes
out when the system discharges.
о See Section 8 — Automatic Fire Extinguisher
System.
Portable Extinguishers
Fire extinguishers are classified according to fire
type:
e “A” — Combustible solids (wood, plastic)
“B”— Flammable liquids (oil, gasoline)
e “C”— Electrical fires
Sizes are identified by Roman numerals — from |
(smallest) to V (largest). Small size provides only a
few seconds of firefighting capability.
Test fire extinguishers according to manufacturer’s
instructions. Do not test by squirting small amounts
of the agent; the extinguisher might not work when
needed.
FLOODING, SWAMPING
Flooding or swamping can be caused by many
factors. Operator disregard for hazardous weather
and water conditions is one of the most common
causes, along with improper loading, handling and
anchoring. Be aware of the possible consequences
of your actions. Have everyone wear a personal
flotation device when boating.
540 DA
Remember:
Ensure proper bilge pump operation.
e Anchor from bow if using only one anchor.
* Match speed to sea conditions.
e Adjust trim and close openings in rough weather.
* Reverse engine only when headway slows to
prevent following sea from swamping boat.
* Operate boat within maneuvering speed
limitations.
LIFESAVING EQUIPMENT
Wear a personal flotation device (PFD) when
boating. Boat operators are required to carry one
wearable personal flotation device (Type I, Il, lll or
V) for every person on board. Boats must also have
at least one throwable device (Type IV).
Classifications of PFDs are:
e Off-Shore Life Jacket (Type |) — most buoyant, it
is designed to turn an unconscious person face
up; used in all types of waters where rescue
may be slow.
e Near-Shore Life Vest (Type Il) — “keyhole” vest
with flotation-filled head and neck support is also
designed to turn a person face up, but the
turning action is not as pronounced; used in
calm, inland waters or where quick rescue is
likely.
Flotation Aid (Type lll) — vest is designed so
conscious wearers can turn face up; often
designed for comfort while engaged in sports
such as skiing.
e Throwable Devices (Type IV) — horseshoe
buoys, ring buoys and buoyant cushions are
designed to be grasped, not worn.
о Special-Use Devices (Type V) — sailboat
harnesses, white-water vests, float coats, and
hybrid vests which have minimum inherent
buoyancy and an inflatable chamber.
When purchasing PFDs, look for an attached tag
saying they are approved by the U.S. Coast Guard
or by your national boating law enforcement agency.
Children and non-swimmers must wear PFDs at all
times when aboard. All passengers and crew should
wear them, since a loose PFD is often useless in an
emergency. The law requires that PFDs, if not worn,
must be readily accessible, that is, removed from
storage bags and unbuckled. Throwable devices
must be readily available, that is, right at hand. The
operator is responsible for instructing everyone
aboard on their location and use.
1.5
Size PFDs for the wearer. Children require special
attention.
Test PFD buoyancy at least once a year.
IMPAIRED OPERATION
Give special attention to the effects of alcohol and
drugs while boating. No other single factor is
involved in so many marine accidents and deaths.
Wind, waves and sun heighten the effects of alcohol
and drugs, so your reactions may be quickly
impaired. Laws are stricter today than in the past,
and enforcement is tougher on those who use
alcohol and drugs when boating.
CONTROL HAZARD - Federal laws prohibit oper-
ating a boat while under the influence of alcohol
or drugs. These laws are vigorously enforced.
LOAD CAPACITY
* The number of seats does not necessarily
indicate how many people a boat can carry
safely.
* When operating on-plane (above idle speed),
carry no more passengers than there are real
seats, and insist that passengers sit down in
those seats.
* Do not permit passengers to ride on parts of
your boat not designed for such use.
y DANGER
EXTREME HAZARD - Do not use sun pads (if
equipped) while craft is underway.
Overloading, improper loading and distribution
of weight are significant causes of accidents.
Give yourself an extra margin of safety in rough
water.
1.6
LOAD CAPACITY
(European Certified Vessels)
* The builder's plate, attached near the helm,
states the maximum number of persons and the
maximum weight the boat will handle safely
under normal conditions.
Overloading violates regulations. Do not carry
more weight or passengers than indicated on
the builder’s plate.
* The presence of the builder's plate does not
relieve the owner/operator from responsibility for
using common sense and sound judgement.
POWER CAPACITY
(European Certified Vessels)
Do not exceed the maximum engine power rating
stated on the builder’s plate attached to your boat.
STABILITY
e Stability may be substantially reduced if
equipment is added to the superstructure.
e Stability is substantially reduced by loose fluids
or weight within the hull. Keep bilge area as dry
as possible, and close openings in rough
weather.
BOARDING
Board only one person at a time.
Load gear after you are aboard. Carrying gear
while boarding can make you lose balance.
STABILITY HAZARD — Load boat properly. The
manufacturer’s load rating is the maximum al-
lowed under normal conditions. Adjust down-
ward if weather, water or other conditions are
adverse.
Allow passengers to ride only in areas that do
not pose a hazard to themselves or the boat.
Passengers should remain seated while boat
Is moving.
SLIPPING HAZARD - Wet decks are slippery.
Wear proper footwear and use extreme caution
on wet surfaces.
540 DA
e Distribute weight evenly.
* Instruct passengers where to sit during on-plane
operation to reduce possibility of falling PERSONAL INJURY HAZARD
overboard during high speed maneuvers. * When underway, keep passengers clear of areas
* If gear is not immediately needed, stow it in not designed for riding. Especially hazardous
areas include seat backs, bow, gunwale, transom
platform and fore and aft decks.
Safety gear must be immediately accessible at N J
all times.
secure area.
e Children and non-swimmers must wear PFDs
at all times when aboard. All passengers and
crew should wear them, since a loose PFD is
SPEED HAZARD
often useless in an emergency. The law requires * Operate boat at speeds within ability to
that PFDs, if not worn, must be readily maintain control and react if an emergency
accessible, that is, removed from storage bags occurs.
and unbuckled. Throwable devices must be * Reduce speed at night, in congested
readily available, that is, right at hand. The waterways and when weather and sea
operator is responsible for instructing everyone conditions warrant.
aboard on their location and use. e Watch your wake. It might capsize a small
craft. You are responsible for damage
caused by your wake.
MANEUVERING/MAINTAINING CONTROL
COLLISION HAZARD - Turn on navigation
EXTREME HAZARD - Ensure adequate lights at night and in other reduced visibility
ventilation. Gasoline powered engines situations, and cruise at reduced speed to
produce odorless, colorless carbon monoxide allow time to avoid dangerous situations.
gas (CO). Prolonged exposure can cause
serious injury or death. Symptoms include
dizziness, nausea, drowsiness. To reduce
General Considerations
accumulation of CO, increase air movement by * You are responsible for passengers’ actions. If
opening windows or adjusting canvas. The
following conditions require special attention:
* Operating at slow speed or dead in the water.
* Operating with the bow high.
* Operating engine in confined spaces. Be
aware of possible CO from nearby boats in
a confined docking area.
e Using canvas curtains.
* Blocking hull exhausts.
* Winds blowing exhaust toward boat
occupants.
\.
CONTROL HAZARD
* A qualified operator must be in control of the
boat at all times.
e Always operate boat within maneuvering
speed limitations.
* Exercise constant attention to the boat’s
direction when underway.
* Always keep a firm grip on the steering control.
540 DA
J
they place themselves or the boat in danger,
immediately correct them.
e Know how your boat handles under different
conditions. Recognize your limitations and the
boat’s limitations. Modify speed in keeping with
weather, sea and traffic conditions.
|nstruct passengers on the fundamentals of
operating your boat in case you are unable to
do so.
|nstruct passengers on location and use of
safety equipment and procedures.
Visibility
Law requires the operator to “maintain a proper
lookout by sight (and hearing).”
* Operator must insist on unobstructed vision,
particularly to the front. Move passengers or
load if they block the view when the boat is above
idle speed.
e Post a lookout to watch for obstacles when
visibility from the helm is limited due to operating
conditions.
1.7
VISIBILITY HAZARD
* Designate a lookout to watch for obstacles and
other vessels when the field of vision from the
helm is limited due to operating conditions.
» Keep visibility clear. Move passengers if they
obstruct operator’s view.
\. J
* Be sure that other boats or objects are not in
the way before making quick turns.
Trimming
Hydraulic tabs at the transom control trim. Use
short bursts of rocker switches to adjust trim
tabs. Pushing switches too far at once may
cause sudden steering problems. Adjusting one
trim tab more than the other will adjust list
caused by improper storage, too many people
on one side or a strong cross wind.
Swimming, Skiing, Diving
* Do not swim from a moving boat.
PERSONAL INJURY HAZARD
* Keep clear of areas designated for
swimming, skiing or diving. Recognize
markers used for such areas.
* When engine is running, close and lock
transom door and do not use boarding
ladder and swim platform.
„
* Many areas prohibit swimming from boats
except in designated areas.
* Make sure boat's engine is turned off before
allowing people to swim anywhere near your
boat. Shut the engine OFF and remove the key
from the ignition switch so that nobody will
accidentally start the engine while swimmers are
nearby.
* Turn off engine when taking swimmers or skiers
aboard or when putting them overboard. Never
permit use of the transom swim platform while
engine is running.
* Slow down and exercise extreme caution when
cruising in an area where there might be
swimmers or skiers in the water.
* Never drive the boat directly behind a water skier.
At 22 knots (25 m.p.h.), it takes only 5 seconds
to overtake a fallen skier who was 60 meters
(200 feet) in front.
1.8
* Keep a downed skier in sight and on the
operator's side of the boat when approaching
the skier. Never back up to anyone in the water.
Recognize and respect diving flags. Keep at
least 30 meters (100 feet) away.
Sport Divers Flag — Red flag with diagonal
white stripe marks a diver in the water.
Code Alpha Flag — Blue and white pennant
designates boat being used in dive operations.
AN 1
SPORT DIVERS CODE ALPHA
FLAG FLAG
(fig. 1.8.1)
COLLISION HAZARD - Use extra caution
when underwater/floating objects may be
present. Hitting an object at high speed or
severe angle can seriously injure people and
damage your boat. Use extreme care when
operating in shallow water or when operating
in reverse.
\. J
Operating In Shallow Water
e Shallow water presents obvious hazards. In
addition to insufficient draft, shallow means sand
bars, stumps, or other unmarked obstructions
in deep water.
Other hazards in shallow water include mud,
sand, weeds and debris, which can foul your
engine’s cooling water intakes.
* Know the area in which you are operating.
Consult charts and ask local boaters. If you
know or suspect shallow water, post a lookout
and proceed slowly.
WEATHER
Learn to understand weather patterns and signs of
change. Bad weather and sea conditions can cause
an uncomfortable and unsafe situation. Here are a
few basic weather-related rules:
540 DA
Learn storm signals and be guided accordingly.
e Check the forecast and sea conditions before
leaving and while underway.
A sudden change in wind direction or speed or
an increase in wave height indicates
deteriorating weather.
e Wear a personal flotation device.
e |fastorm approaches, immediately seek a safe
harbor.
e [fa storm hits, have everyone sit low in the boat.
Head the bow into the wind with enough power
to maintain slow headway.
|f you encounter fog, determine your position,
set a safe course, slow down and alert other
boats of your presence with a sound signal.
* The best lightning protection is a properly
grounded lightning rod that is high enough to
provide a protective umbrella over the hull.
Lightning will seek a ground when it strikes. Stay
clear of the lightning rod, all attached wiring and
all metal parts of the boat.
e [falightning storm approaches, the safest action
is to dock and disembark. If you cannot return
to shore, seek shelter inside the boat and
remain there until the storm passes.
о Stay out of the water during a lightning
storm. If caught swimming during a storm, get
back into the boat and remain there until the
storm passes.
2 RED FLAGS —GALE
(UP TO 47 KNOTS)
RED FLAG — SMALL CRAFT
(WINDS TO 33 KNOTS)
SQUARE RED FLAG — 2 SQUARE RED FLAGS -
BLACK BOX — BLACK BOXES —
(STORM) (HURRICANE)
(fig. 1.9.1)
540 DA
FLOAT PLAN
File a float plan with a friend or relative about
where you intend to cruise. Give a good
description of the boat. Advise of any changes
in cruise plans.
e These precautions will enable your friend or
relative to tell the Coast Guard or your national
boat agency where to search for you and what
type of boat to look for if you fail to return.
Advise the same person when you complete
your trip to prevent false alarms about your
safety.
WARNING LABELS
Warning labels are mounted at key locations to
advise you of safety precautions when operating or
servicing equipment. Do not remove or cover
warning labels. Replace when illegible. See the
Parts Manual for replacement part numbers and
ordering procedure.
ACCIDENT REPORT
The U.S. Coast Guard and state agencies require
a report to be filed by the operator of a boat involved
in an accident involving loss of life, disappearance,
injury requiring treatment beyond first aid, loss of
boat or property damage exceeding $500. Contact
the state boating agency where the accident occurs
for a copy of the state’s accident report form. In the
absence of a state enforcement agency, contact the
Coast Guard office nearest the accident site. Other
countries have other reporting requirements.
Consult your nation’s boating law enforcement
agency.
SAFETY HOTLINES
The Coast Guard offers many pamphlets on safety
and other information not covered in this book.
Contact your local Coast Guard unit or call these
toll-free safety hotlines:
* U.S. Coast Guard 1-800-368-5647
e (Canadian Coast Guard 1-800-267-6687
In other countries, ask your marine dealer how
to contact the national boating law enforcement
agency.
1.9
ADDITIONAL RECOMMENDED
EQUIPMENT
A wise boater will include many of the following
items:
Visual distress signals for day and night use
(required in some areas; consult local
regulations)
Marine radiotelephone
Charts of your intended cruising area
Spare keys
Emergency position-indicating radio beacon
Portable radio with weather band
Waterproof flashlight(s)
Extra batteries
Mooring lines
Fenders
Lead line
Ground tackle (at least 2 anchors, rode,
shackles)
Boat hook
Manual bilge pump
Spare parts kit (spark plugs, fuses, etc.)
Instruction manuals for engine and accessories
First aid kit
Tool kit:
— Assorted screwdrivers (Phillips and flat
blade)
— Pliers (regular, vise-grip, and water pump)
— Wrenches (box, open-end, allen, adjustable)
— Socket set (metric or U.S. standard as
appropriate)
— Electrical tape
540 DA
MINIMUM REQUIRED EQUIPMENT
Consult your national boating law enforcement agency.
EQUIPMENT
Bell, Whistle
Fire
Extinguisher
-Portable
(if no fixed fire
extinguishing
system is
installed in
machinery
spaces)
Fire
Extinguisher
-Portable
(if fixed fire
extinguishing
system is
installed in
machinery
spaces)
Lights
Muffling
Personal
Flotation
Devices (PFDs)
Ventilation
540 DA
CLASS A CLASS 1
(Less than (4.8 to less than
4.8 meters 7.9 meters
[16 feet]) [16 to less than
26 feet])
CLASS 2
(7.9 to less than
12.2 meters
[26 to less than
40 feet])
CLASS 3
(12.2 to less
than 19.8 meters
[40 to less than
65 feet])
Some means of making efficient sound signal, for example, whistle or air horn
and a bell audible for .5 nautical mile.
At least one (ABYC recommends
two for boats 4.8 to less than
7.9 meters [16 to 26 feet])
B-1 type Coast Guard
approved portable marine fire
extinguisher. (Not required on
outboard motor boats less than
than 7.9 meters [26 feet] in length
without permanently installed
fuel tanks and not carrying
passengers for hire, provided
construction of boat will not
permit entrapment of explosive
or flammable gases or vapors.)
None None
At least two
(ABYC recommends
at least three)
B-1 type approved
portable marine
fire extinguishers,
or at least one B-Il
type Coast Guard
approved portable
marine fire
extinguishers.
At least one B-I
type approved
portable marine
fire extinguisher.
Required between sunset and sunrise or in reduced visibility.
At least three
(ABYC recommends
at least four)
B-1 type approved
portable marine
fire extinguishers,
or at least one B-I
type plus one
В- type Coast
Guard approved
portable marine
fire extinguisher.
At least two B-I
type approved
portable marine
fire extinguishers,
or at least one B-II
type Coast Guard
approved portable
marine fire
extinguisher.
Efficient muffling device or system to prevent excessive or unusual engine noise.
One Coast Guard approved Type |, Il or Ill device for each person aboard, plus one
throwable Type IV device. Type V device is acceptable if worn for approved use.
Always wear a PFD when boating.
Boats with closed compartments or permanently installed fuel tanks must be equipped
with an efficient natural or mechanical bilge ventilator or meet applicable Coast Guard
construction standards for fuel and electrical systems.
ENVIRONMENTAL CONSIDERATIONS
FUEL & OIL SPILLAGE
Regulations prohibit discharging fuel or oily waste
in navigable waters. Discharge is defined as any
action which causes a film, sheen or discoloration
on the water surface, or causes a sludge or emulsion
beneath the water surface. A common violation is
bilge discharge. Use rags or sponges to soak up
fuel or oily waste, then dispose of it properly ashore.
If there is much fuel or oil in the bilge, contact a
knowledgeable marine service to remove it. Never
pump contaminated bilge overboard. Help protect
your waters.
Fill tank(s) less than rated capacity. Allow for fuel
expansion.
WASTE DISPOSAL
lace facial tissues, paper towels or
sanitary napkins in head. Such material can
damage the waste disposal system and the
environment.
NOTICE
* There is a possibility of being fined for
having an operable direct overboard
discharge of waste in some waters.
Removing seacock handle, in closed
position, or other means must be used to
avoid fine.
e |t is illegal for any vessel to dump plastic
trash anywhere in the ocean or navigable
waters of the United States.
\. J
Many areas prohibit overboard sewer discharge.
Close and disable flow-through waste systems
to prevent discharge in such areas.
Bag all refuse until it can be disposed of ashore.
Regulations prohibit disposal of plastic
anywhere in the marine environment and restrict
other garbage disposal within specified
distances from shore.
The Coast Guard is requiring any ocean-going boats
40 feet or larger to have a written “waste
management” plan on board. While the requirement
is aimed at commercial and passenger ships, there
is no exception for recreational boats. “Ocean-going”
means any boat going beyond the three-mile coastal
1.12
U.S. boundary. The written plan can be as simple
as:
“All vessel refuse is placed in trash bags which
are stored on board until they can be disposed
of in dumpsters on shore. This policy is reviewed
by all crew and passengers. The person in
charge of carrying out the plan is:
Name;
EXCESSIVE NOISE
Many areas regulate noise limits. Even if there are
no laws, courtesy demands that boats operate
quietly.
WAKE/WASH
SPEED HAZARD - Watch your wake. It might
capsize a small craft. You are responsible for
damage caused by your wake.
Power boat wakes can endanger people and
vessels. Each power boat operator is responsible
for injury or damage caused by the boat's wake. Be
especially careful in confined areas such as
channels or marinas. Observe “no wake” warnings.
EXHAUST EMISSIONS
You can be overcome by fumes from your own engine
or generator or from neighboring boats. Ensure
continuous movement of fresh air.
EXTREME HAZARD - Ensure adequate ventila-
tion. Gasoline engines produce carbon monox-
ide gas (CO). Prolonged exposure can cause
serious injury or death. To reduce CO accumula-
tion, increase air movement by opening windows
or adjusting canvas. The following conditions
require special attention:
* Operating at slow speed or dead in the water.
* Operating with the bow high.
* Operating engine and/or generator in
confined spaces.
* Using canvas curtains.
* Blocking hull exhausts.
* Winds blowing exhaust toward boat
occupants.
540 DA
EXAMPLES OF HOW HIGH LEVELS OF CARBON MONOXIDE MAY ACCUMULATE
Blocking hull exhausts. Operating at slow speed or
dead in the water. (fig 1.13.1)
Winds blowing exhaust toward boat occupants.
(fig 1.13.3)
PAINT, CLEANING AGENTS & OTHER
SUBSTANCES
EXPLOSION/FIRE HAZARD - Ventilate when
painting or cleaning. Ingredients may be flam-
mable/explosive.
NOTICE
| Refer to cleaning product manufacturers’ speci- |
fications and directions before use.
Consult your marine dealer about environmental
regulations before painting the hull.
540 DA
Operating engine and/or generator in confined
spaces. (fig 1.13.4)
— , 7 у
i | \ > — в у 4
MEL
о о О —
= — >
Operating with the bow high. (fig 1.13.5)
Good ventilation. (fig 1.13.6)
Common household cleaning agents may cause
hazardous reactions. Fumes can last for hours, and
chemical ingredients can attack people, property
and the environment. Avoid products containing
chlorine, phosphates, perfumes and non-degradable
ingredients.
EMERGENCY PROCEDURES
The time to think about emergencies is before they
happen. Plan ahead. Know what to do before you
encounter any of these situations. Wear a PFD
when boating.
EXPLOSION/FIRE/ASPHYXIATION
Open flame cooking appliances consume
oxygen. This can cause asphyxiation or
death.
* Maintain open ventilation.
* Liquid fuel may ignite, causing severe burns.
о Use fuel appropriate for type of stove.
* Turn off stove burner before filling.
* Do not use stove for comfort heating.
FIRE/ASPHYXIATION HAZARD - Use special
care with flames or high temperature near
urethane foam used in construction of your boat.
Burning, welding, lights, cigarettes, space
heaters and the like can ignite urethane foam.
Once ignited, it burns rapidly, producing extreme
heat, releasing hazardous gases and consuming
much oxygen
EXPLOSION & FIRE
Explosion
|f explosion is imminent, put on PFDs, grab
distress signals and survival gear, and
immediately abandon ship.
Fire
* Turn off engines, generators and blowers.
Extinguish smoking materials.
e Fixed fire suppression system has heat sensors
that automatically flood machinery space with
a fire extinguishant. Allow extinguishant to
“soak” compartment for at least 15 minutes to
cool hot metals or fuel before cautiously
inspecting fire area. Have portable fire
extinguishers ready. Do not breathe fumes or
vapors caused by the fire or extinguishant.
|f you have access to fire, direct contents of
extinguishers at base of flames, not at the top.
* Throw burning materials overboard if possible.
* Move anyone not needed for firefighting
operations away from the flames.
* Signal for help.
e Puton PFDs, grab distress signals and survival
gear, and prepare to abandon ship.
Abandoning Ship
BURN HAZARD - Swim against the current or
wind if you abandon ship. Leaking fuel will float
with the current and may ignite.
When clear of danger, account for all who were
on board, and help those in need.
Use distress signal.
* Keep everyone together to make rescue easier.
FLOODING, SWAMPING OR CAPSIZING
e STAY WITH THE BOAT! A boat will usually float
even if there is major hull damage. Rescuers
can spot a boat much easier than a head
bobbing in water.
e Signal for help.
COLLISION
Account for everyone on board.
Check for injuries.
e Inspect structural damage.
Reduce flooding.
e Signal for help.
e STAY WITH THE BOAT!
540 DA
GROUNDING
Action depends on how hard the boat hits bottom
and whether the boat remains stranded. If it is a
simple touch, you may need only to inspect the hull.
If you are aground, assess the situation before
reacting. In some cases, throwing the boat into
reverse can cause more damage.
Basic Guidelines
* Inspect damage to hull, propulsion and steering
systems.
Check forleaks. If water is coming in, stopping
the flow takes priority over getting free.
Determine water depth all around the boat and
type of bottom (sand, mud, rocks, etc.). This will
help you decide which way to move the boat.
* Determine if tide, wind or current will drive the
boat harder aground or will help free it.
LEAKS
Immediately switch on bilge pumps.
e Assign crew to operate manual pumps if
needed.
e Check extent of leaks.
If boat is taking on water, have someone take
the helm while you manage damage control.
e Slow or stop to minimize inflow. However, if you
can keep a hole above water by maintaining
speed, do so.
e If possible, patch the outside with whatever
material is available.
TOWING
PERSONAL INJURY HAZARD - Towing or
being towed stresses the boat’s hardware and
lines. Failure of any part can seriously injure
people or damage the boat.
PRODUCT DAMAGE - While being towed,
seacocks on non-operating engines and genera-
tor must be closed to prevent water from being
forced into the engine’s exhaust and causing
internal damage.
PRODUCT DAMAGE - While being towed and
engines are not being operated, propeller
shaft(s) should be prevented from turning by
locking the shaft(s) using a pipe wrench or other
suitable method. This will prevent damage to the
shaft seal and transmission bearing.
Na J
540 DA
A recreational boat towing another is usually a last
resort because of possible damage to one or both
boats. The Coast Guard or a private salvage
company is better equipped. A recreational boat
may assist by standing by, and possibly keeping the
disabled boat's bow at a proper angle until help
arrives. Only when conditions are ideal — that is,
seas are calm, disabled boat is small, and one or
both skippers know correct technique — should a
recreational boat tow another.
Towing Vessel
Be sure your boat will not run aground too.
* Because you are maneuverable and the
grounded boat is not, you should pass the
towline to the grounded boat.
* Use double-braided or braid-on-braid line. Never
use three-strand twisted nylon; it has too much
elasticity and can snap back dangerously.
Fasten the towline as far forward as possible on
the upwind or up-current side of the towing boat.
Fastening it to the stern will restrict
maneuverability of the towing boat.
If possible, use a bridle.
* Move slowly to prevent sudden strain on slack
line.
Beready to cast loose or cut the line if the towing
situation becomes hazardous.
Vessel Being Towed
e Attach the towline to the bow eye, or forward
bitt if the fitting can take the load.
|fitis necessary to be towed after being freed,
keep someone at the wheel to steer.
Both Vessels
e Ifyou secure the towline to a fitting, be sure the
fitting is fastened with a through bolt and is
reinforced on the underside.
Creating a bridle with a line around the hull or
superstructure will distribute the load over a wide
area; pad pressure points. This technique can
be used on both the towing and towed boat.
Keep lines clear of propellers on both boats.
* Keep hands and feet clear of the other boat.
* Never hold a towline after it is pulled taut.
PERSON OVERBOARD
* Immediately sound an alarm and keep pointing
to the person overboard.
* Throw a life preserver even if the person is
wearing a PFD. It will serve as a marker.
e Immediately stop or slow the boat, then circle
toward the victim.
* Keep person overboard on helm side so
operator has the person constantly in sight.
Approach from downwind and move alongside
into the wind for pickup.
о When almost alongside, stop the engine in gear
to prevent dangerous propeller “windmilling.”
As part of your emergency plan, consider what
to do if you were alone and fell overboard (e.g.,
wear PFD, keep signal device in PFD, attach
emergency engine stop switch lanyard to
yourself).
DROWNING
* Swim to rescue a drowning victim only as a last
resort.
e Immediate resuscitation is critical! At least two
people on board should be certified in CPR.
* Keep the victim warm.
Use care in handling. Spinal injury may exist if
the victim fell overboard.
e Signal for help.
MEDICAL EMERGENCY
In an emergency, you may be far from professional
medical assistance. Be prepared. Take a first aid
course, and carry a first aid kit. Be aware of special
conditions that may affect anyone on board.
CARBON MONOXIDE
Carbon monoxide is an odorless, colorless,
extremely toxic gas. Symptoms of carbon monoxide
poisoning are dizziness, ears ringing, headaches,
nausea and unconsciousness. A poisoning victim’s
skin often turns cherry red.
Have the victim breathe fresh air deeply. If breathing
stops, resuscitate. A victim often revives, then
relapses because organs are damaged by lack of
oxygen. Seek immediate medical attention.
PROPULSION, CONTROL OR STEERING
FAILURE
* Shut off engine.
Put out an anchor to prevent drifting.
Determine if you can fix the problem yourself.
See engine operator's manual if engine is
flooded.
* Signal for help.
RADIO COMMUNICATION
Radio is the boat operator's main method of
receiving safety information and summoning aid.
VHF-FM radio is the primary means of short-range
communication. Single sideband radio (SSB) is
used for longer range communication.
VHF-FM Channel 16 and SSB 282 kHz are
designated for emergency use. Such situations can
be categorized as:
* Emergency —
“MAYDAY, MAYDAY, MAYDAY” - Used
when a life or vessel is in imminent danger.
о Urgency —
“PAN-PAN, PAN-PAN, PAN-PAN”
(pronounced PAHN-PAHN) — Used when a
person or vessel is in some jeopardy less than
indicated by a Mayday call.
* Safety —
“SECURITY, SECURITY, SECURITY”
(pronounced SAY-CURE-IT-TAY) — Used for
navigational safety or weather warning.
An emergency situation will be hectic and there will
not be time to learn proper radio procedure. LEARN
WHAT TO DO BEFORE YOU NEED TO DO IT.
If you hear a distress call, stop all radio
transmissions. If you can directly assist, respond
on the emergency frequency. If you cannot assist,
do not transmit on that frequency. However, continue
to monitor until it is obvious that help is being
provided.
540 DA
DISTRESS SIGNALS
Consult your national boating law enforcement
agency.
Visual Distress Signals
U.S. Coast Guard regulations require boats in
coastal waters and the Great Lakes to carry
visual distress signals for day or night use, as
appropriate for the time of operation. Exempt
from the day signals requirement, but not night
signals, are boats less than 4.8 meters (16 feet),
open sailboats less than 7.9 meters (26 feet),
boats participating in organized events, and
manually propelled boats.
If you are required to have visual distress
signals, at least three safety-approved
pyrotechnic devices in serviceable condition
must be readily accessible. They must be
marked with a date showing the service life,
which must not be expired.
Carry three signals for day use and three signals
for night use. Some pyrotechnic signals, such
as red flares, meet both day and night use
requirements.
Store pyrotechnic signals in a cool, dry location.
An orange or red watertight container
prominently marked “Distress Signals” is
recommended.
Other recognized visual distress signals include:
Flames in a bucket
Code flags November and Charlie
Square flag and ball
Black square and ball on orange background
flag
Orange flag (certified)
Electric distress light (certified) — for night
use only
Dye marker (any color)
Person waving arms
U.S. ensign flown upside down
540 DA
Audible Distress Signals
U.S. Coast Guard regulations require one hand,
mouth or power-operated whistle or horn, audible
for at least a half mile.
Other recognized audible distress signals include:
Radio communication (see Emergency
Procedures — Radio Communication)
Radio-telegraph alarm
Position indicating radio beacon
Morse Code SOS (3 short, 3 long, 3 short)
sounded by any means
Fog horn sounded continuously
SPECIFICATIONS AND DIMENSIONS
Profile: Standard 540DA with Sport Spoiler shown.
(fig. 1.18.1)
57' 8" (17.6 m)
55' 11" (17 m)
54' 91/2" (16.7 m)
14 10" 177"
(4.52 m) (5.36 m)
11' 6" 14'4" 134" 15'8"
(3.51 m) (4.37 m) (4.06 m) (4.78 m)
=
Fer FO
WATERLINE
——
47"
O
(119.4 cm)
KEEL
211" Std.
(.89 cm) Optional hard top has same dimensions as above.
4'7" Opt.
(1.40 cm)
Overall Length .............————. eee... 54' 11" (16.74 m)
w/Standard Platform ............-w==—...—....-.... 57' 8" (17.6 m)
1-7: || TT 15' 11" (4.85 m)
Draft .........—..emeeeeeeeeneeeeeneeeen reee 47" (119.4 cm) (4. 55m)
Dry Weight* ................. ===... 39,000 Ibs. (17,690 kg)
Fuel Capacity .............. ee... ee... 600 gal. (2,271 liters)
Usable Fuel** ................. ===... 570 gal. (2,157 liters)
Water Capacity ............ e... ..eee....... 150 gal. (567 liters)
Holding Tank -............. e... ...eee—...... 68 gal. (257.3 liters)
Dead Rise .............--eee...nnecneeooennanenemenoenannneemmmeonnenmeme 17°
Waterline To Top Of Spoiler.................. 11' 6" (3.51 m)
Waterline To Top Of Radar ................... 13'4" (4.06 m)
Waterline To Top Of Mast Light ......... 14' 10" (4.52 m)
Keel To Top Of Spoiler .................——..—.—— 14' 4" (4.37 m)
Keel To Top Of Radar .................—ew........ 15' 8" (4.78 m)
Keel To Top Of Mast Light.................... 17' 7" (5.36 m)
*This is an approximation. Weight is variable due to
manufacturing and equipment variances. Each vessel
must be independently weighed.
** Allow 15% reserve fuel for running in heavy seas.
540 DA
ACCOMMODATION PLAN
GUEST
STATEROOM
GUEST HEAD
& SHOWER
GALLEY
MASTER
HEAD/SHOWER
MASTER
STATEROOM
COCKPIT
Й
С
(fig. 1.19.1)
540 DA
ACCESSORY
ROOM
HATCH
HELM
NA
TRANSOM
COCKPIT
ENGINE
ROOM —t—
HATCH
D
|
(fig. 1.19.2)
5
LOCATION OF THROUGH-HULL FITTINGS
Port Side
(fig. 1.20.1)
HEAD VENT
WASHER/ GALLEY VENT
DRYER VENT
BILGE VENT
COMMON DRAIN
=
>= 7 L££_ = = |
=
WASHER/
DRYER DRAIN
PORT ENGINE &
GENERATOR EXHAUST
Starboard Side
(fig. 1.20.2)
VACUUM
HEAD VENT EXHAUST
BILGE VENT WATER TANK
VENT
WASTE HOLDING
TANK VENT =
> ri
OPTIONAL MANUAL {ри
BILGE PUMP ZA 7 dl
- ©
~~ ROPE LOCKER
DRAIN
STBD ENGINE
EXHAUST
FUEL TANK VENTS
Bilge Hull Cutouts
(fig. 1.20.3)
TRANSDUCER TRANSDUCER
(OPTIONAL) (OPTIONAL)
PORT ENGINE STBD ENGINE
PICKUP PICKUP
SHAFT LOG SHAFT LOG
GENERATOR PICKUP
HEAD DISCHARGE
PORT RUDDER STBD RUDDER
1.20
540 DA
Section 2 ¢ Bilge & Underwater Gear
FUEL & OIL SPILLAGE
Regulations prohibit discharging fuel or oily waste
in navigable waters. Discharge is defined as any
action which causes a film, sheen or discoloration
on the water surface, or causes a sludge or emulsion
beneath the water surface. A common violation is
bilge discharge. Use rags or sponges to soak up
fuel or oily waste, then dispose of it properly ashore.
If there is much fuel or oil in the bilge, contact a
knowledgeable marine service to remove it. Never
pump contaminated bilge overboard. Help protect
your waters.
Fill tank(s) less than rated capacity. Allow for fuel
expansion.
BILGE PUMPS 5
The 540 DA is equipped with four (4) bilge pumps
with float switches. Three (3) are located in the
engine room bilge, and the other bilge pump and
float switch is located behind the shower sump
located under the hatch in the master stateroom.
See figures 2.9.1, 2.10.1 and 5.6.1 for locations.
SINKING HAZARD - Ensure the bilge pumps
are operating properly.
Your yacht is equipped with a shower sump pump
and float switch (see “SHOWER SYSTEM?” in
Section 5).
The forward and aft bilge pumps are equipped with
switches on the control station switch panel (see
fig. 3.3.1). These switches have MANUAL and
AUTO positions. When the switch is in the MANUAL
position, the pump will run continuously. When the
switch is in the AUTO position, the pump is activated
when there is enough water in the bilge to raise the
float switch to its highest position; and deactivated
when the water recedes.
The other two (2) pumps are emergency high water
pumps and are wired directly to the battery banks.
Periodically check the operation of all pumps.
540 DA
Run bilge pumps in the manual position only as
long as necessary to remove water. Running bilge
pumps dry can damage the pump motor.
The bilge pumps and high water alarms are wired
to the systems monitor located on the dash at the
control station (see “SYSTEMS MONITOR?” in
Section 3).
Whenever a bilge pump turns ON, either manually
or automatically, the systems monitor will display
which pump is active. Should the high water
alarms become activated, immediate attention
to the area indicated on the systems monitor
panel is required.
Each pump is protected by a breaker on the main
DC breaker panel located in the aft starboard bilge
(see Section 7 fig. 7.5.1).
Bilge Pump & Float Switch
(fig. 2.1.1)
BILGE PUMP
FLOAT SWITCH
Maintenance:
Frequently inspect the area under the float
switches to ensure they are free from debris
and gummy bilge oil. To clean, soak in heavy
duty bilge cleaner for 10 minutes, agitating several
times. Check for unrestricted operation of the float.
Repeat the cleaning procedure if necessary.
Inspect the bilge pump intakes and keep them
free of dirt or material which may impede the
flow of water through the pump. To clean the
pump strainer, depress the lock tabs on both sides
of the pump and lift the pump motor.
2.1
Troubleshooting:
If water does not come out of discharge hose:
1. Depress the breaker on the Main DC Breaker
Panel to ensure it has not tripped.
2. Remove the motor module to see if the impeller
rotates with the power on.
3. Remove any debris that may have accumulated
in the nozzle section or strainer base.
4. Check hose and connection on hull side for
debris and proper connections.
BILGE BLOWERS &
BILGE VENTILATION FILTERS 3%
BLOWER
HOSE
E 7%
on
ir Q e </
| / BILGE VENTILATION FILTERS or mn
BILGE oN
BLOWER
PORT SIDE ILLUSTRATED (STARBOARD SIDE TYPICAL)
Bilge Blower & Bilge Ventilation Filters (fig. 2.2.1)
The two bilge blowers remove fumes from the
engine compartment and provide ventilation through
the deck vents. The blowers are wired through
individual circuit breakers on the main DC breaker
panel (see fig. 7.4.1) with a switch on the control
station switch panel (see fig. 3.3.1) and on the DC
distribution panel located in the salon (see fig. 7.6.1).
Blower switches can be turned ON at one location
and turned OFF at the other location.
Blower Switch Light:
Light On: When a blower is turned ON, the light in
the switch will come on and stay on, indicating that
there is power to the blower.
Light Blinking: If the light is blinking, it is an
indication that the blower breaker has tripped.
Correct the problem and reset the breaker.
Light Not On: If you try to turn ON the blower and
no light comes on, then the breaker is tripped and
the blower is not receiving power. Correct the
problem and reset the breaker.
2.2
Blower switch lights do not indicate that the blower
motors are operating. To ensure blower motors are
operating, listen for blower motor noise and confirm
air flow at bilge vent (see page 1.20 for bilge vent
location).
EXPLOSION/FIRE HAZARD -- Вип blower at least
4 minutes before starting engine or generator.
Check bilge and engine compartment for fumes.
Run the blowers when operating below cruising
speed to dissipate bilge heat buildup, when idling,
and at all times when vessel is at rest with the
generator running.
о No ventilation system can remove the vapors
of liquid fuel in the bilge. (See Section 1 —
Environmental Considerations — Fuel & Oil
Spillage.)
* Store flammables only in approved, vented
containers securely fastened in a locker sealed
from the interior of the yacht and vented
overboard. Storing flammables in areas not
designed for vapor removal creates a hazard.
Be aware of carbon monoxide from your own
or other boats. Allow air movement to dissipate
fumes. (See Section 1 — Environmental
Considerations — Exhaust Emissions.)
Maintenance:
The bilge blowers should be checked periodically
to ensure that the hoses are securely fastened to
blowers. Check and make sure electrical wires are
secured in place.
Troubleshooting:
If your bilge blower fails to operate:
1. Depress the breakers on the main DC breaker
panel to ensure they have not tripped.
2. Check to see if the blower hose is fastened to
the blower.
The bilge ventilation filter intake ports are fitted with
foam air filters in the bilge. These filters are installed
to remove the salt mist from the air coming into the
bilge through the hull vents (see fig. 2.2.1). Keep
vents free from obstructions.
Location:
On the port and starboard sides of the bilge.
Maintenance:
Clean filters after every 100 hours of boat use.
Remove the filters, hose them down with fresh water,
shake off remaining water and reinstall.
540 DA
f A
NOTICE
М. A
The filters are directional. Note direction of filter
installation before removal. Filter must be
reinstalled facing the proper direction.
N J
The engines are the heart of your Sea Ray® boat.
Proper attention to and maintenance of your engines
will assure you of many hours of pleasurable, safe
boating and will prevent unnecessary engine
problems. You must therefore become thoroughly
familiar with all aspects of the engine’s proper
operation outlined in the Engine Operator’s Manual.
A general maintenance program consists of proper
lubrication, cleaning of fuel filters, fuel lines and air
filters. When washing down, or at any other time,
take care that water does not enter the air inlets.
Water entering the air inlets when the engines are
not operating may go directly into the cylinders,
resulting in rust and possibly internal engine
damage.
The engines are warranted directly by the engine
manufacturer, not Sea Ray”.
Sea Ray” strongly urges you to fully comply with
the manual provided by the engine manufacturer.
Follow the recommended maintenance and
warranty schedule in your Engine Operators Manual
included in the owner's packet. Engine abuse or
improper maintenance may adversely affect the
claims made under the independent warranty
provided by the engine manufacturer.
ENGINE GAUGE PACKAGE
Each of your engines have been equipped with an
engine gauge package. This package is provided
as a safety feature in the event of an electrical
malfunction and the helm gauges becoming
inoperative.
Detroit Engine Gauges Include:
Engine Oil Pressure
Engine Oil Temperature
Jacket Water Temperature
Location:
The engine gauge package is located on the inboard
side of each engine.
540 DA
Gauge package may differ with different engine
options.
Refer to your Engine Operators Manual for proper
gauge readings.
BILGE HEAT DETECTOR
The 540 DA is equipped with a forward bilge heat
detection device located in the forward engine bilge,
mounted above the engine area.
The bilge heat detector detects heat buildup in the
engine room bilge area. The heat detector alarm is
connected to the systems monitor panel on the
control station dash (see fig. 3.13.1). Never ignore
an alarm.
ENGINE BLOCK HEATER
The 540 DA is equipped with engine block heaters
for each engine. The block heaters, if applied for 8
hours continuously, should raise the engine jacket
water temperature by 50° F (28° C) over ambient. If
the engine temperature is maintained at 90° F (32° C)
or above, start-up smoke should be nonexistent.
Energize the block heaters by turning ON the “PORT
BLOCK HEATER” and “STARBOARD BLOCK
HEATER” breakers on the AC main distribution panel
(see fig. 7.13.1).
The engine block heaters are designed to be left
on. The block heaters are thermostatically set to
turn themselves on and off as needed. It takes about
8 — 12 hours for the engine blocks to heat up. Keep
in mind that with the block heaters turned on, the
engine room will be warmer than it would be
otherwise.
Note: It is not necessary for the block heaters to
be on to start the engines.
ENGINE MOUNTS
The adjustable type engine mounts permit
adjustment sideways as well as vertically. Vertical
adjustment nuts lock up or down on the threaded
vertical stud, with a slot provided to allow side to
side adjustment on the engine.
Important: The large adjustment locknuts on
these mounts must be tightened properly to
retain alignment. It is also advisable to spray a
protective coating on the studs and nuts to
prevent corrosion.
2.3
| Engine Mount
(fig. 2.4.1)
TORQUE ESNA NUT 300-320 FT. LBS.
SLOT FOR
SIDE TO SIDE
ADJUSTMENT
VERTICAL
ADJUSTMENT
NUT
TORQUE ESNA NUT
ENGINE MOUNT 100-120 FT. LBS.
BACKING PLATE
STRINGER
CAP
TORQUE ESNA NUT ñ STRINGER
95-110 FT. LBS.
MARINE GEARS
Reduction Gears
A reduction gear reduces the rotating speed of the
propeller shaft in relation to the engine RPM. This
permits the use of a larger propeller while allowing
the engine to attain its rated RPM, thereby
increasing efficiency.
Reverse Gears
The reverse gear incorporates the clutch and
controls the rotation of the propeller. The position
of the clutch control or shifting lever indicates the
motion which the clutch and reverse gear are
transmitting. The center position of the lever
indicates neutral. Engine RPM should never
exceed 1000 when engaging or disengaging the
clutch. Higher RPM will result in unnecessary
wear and shortened life of the unit, and perhaps
breakage.
Marine reverse gears are hydraulically operated,
thereby making it imperative to periodically maintain
and check oil level. If the correct oil level is not
maintained, slippage occurs, causing damage to the
clutch plates. Too much oil will cause foaming and
erratic clutch operation. For additional information
see the Engine Operator’s Manual.
2.4
ENGINE REMOVAL
Should the removal of an engine become necessary,
see your Sea Ray® dealer or an authorized
service representative of the engine
manufacturer. The following is only a generalized
procedure to follow.
Shut off the fuel lines and close the engine seacocks.
Remove all electrical wires, fuel lines and raw water
intake hoses from the engine. Unbolt the engine
coupling from the shaft coupling and slide the shaft
and coupling back from the engine. Detach both
throttle and shift connections. Cap off hoses to avoid
hydraulic fluid loss. Do not bend or twist the
hoses, as damage may result. Remove the
mounting bolts for the engine and lift the engine out,
leaving the mounts bolted to the stringer caps.
To reinstall, reverse the above procedure. Check
the coupling and shaft alignments, as well as water
hoses and wiring connections. Also check for fuel
and exhaust leaks and make sure seacocks are
open before starting engines.
ENGINE EXHAUST SYSTEM (™
The exhaust system used on Sea Ray® boats with
inboard engines is designed so that water from the
raw water cooling system enters the exhaust system
through the stainless steel elbows where water and
exhaust are mixed. Water and exhaust is then pumped
through the mufflers then overboard through the
exhaust outlet through-hull fitting. Make sure water is
flowing from the exhaust outlets while the engines are
operating. Prior to every boat use, examine the exhaust
system fittings to ensure tightness.
A plug is located on the aft section of each muffler
(see fig. 2.5.1). When servicing or winterizing,
remove the plug to drain the water out of each muffler.
Replace the plug after all water has drained from
the muffler.
CARBON MONOXIDE HAZARD - Ensure engine
exhaust system is working properly. Carbon
monoxide poison is extremely toxic.
Hose clamps must be tight at all times to avoid
exhaust leaks.
540 DA
540 DA Engine Exhaust
(fig. 2.5.1)
PORT FWD
AFT STBD
PORT ENGINE
MUFFLER
TO
ENGINE
GENERATOR
EXHAUST D
EXHAUST HOSE
|) EXHAUST
HOSE
DRAIN PLUG
TO GENERATOR
DRAIN PLUG
GENERATOR MUFFLER
ENGINE EXHAUST PORT
HULL
PORT ENGINE EXHAUST SHOWN. STARBOARD SIDE TYPICAL
(EXCEPT FOR GENERATOR EXHAUST).
Na
VIBRATION 8: CAUSES
Some vibration is to be expected in your boat
because of the action of the engines and the
propeller. But excessive vibration indicates
conditions which must be promptly corrected to
avoid damage. Contact your Sea Ray” dealer
immediately if you are experiencing severe vibration.
The following are some conditions which may
cause vibrations.
Foreign Object Interfering With Propeller
Action
Weeds, ropes, fishing lines or nets can become
wrapped around the propeller and/or shaft, causing
vibration and loss of speed. Always stop and then
reverse the propeller after going through a weedy
area to unwrap and clear away any weeds which
may have accumulated. Although reversing will
sometimes help to unwrap lines and nets, they are
difficult to remove without hauling boat.
Always check for loose or trailing dock lines before
getting underway. When towing a dinghy, remember
that a long line may easily become entangled with
the propeller when backing down.
Bent Propeller and/or Shaft
A badly damaged or distorted propeller or shaft is
an obvious cause of vibration. Even when the
propeller appears to be perfect, make sure it has
not been pulled off-center by the propeller key.
Engine and Shaft Out of Alignment
Although the shaft is properly aligned when it leaves
the factory, after transit and after the boat has been
in the water a few days, the alignment should be
540 DA
f в
rechecked. The shaft coupling is the connecting
point between the shaft and the engine and the
alignment should be set at .003" to .005." Refer to
“SHAFTS” in this section of the Owner’s Manual.
Coupling Out of True
Although an extremely unlikely condition, check the
couplings if other efforts to correct the vibration fail.
Check the engine half of the coupling (with dial
indicator on the face) to see that it runs true with
the shaft coupling. Also check the coupling keys.
They must fit correctly to prevent forcing the
couplings off center.
Engine Part Hitting Boat Structure
Engines are flexibly mounted to reduce transmission
of vibration to the hull structure. If some part of the
engine, such as the oil pan, reverse gear or
reduction gear housing, contacts a stringer, brace
or part of the hull, vibration will result. The flexible
shaft log allows a limited side motion of the shaft,
but an excessive “whip” can cause the shaft to strike
the sides of the shaft hole or the shaft log with
resultant vibration.
Other Causes
Other causes of vibration include the following:
engine out of tune, a bent rudder, a worn strut
bearing, a component of the exhaust system
vibrating against the hull or improper contact
between shaft taper and the propeller hub bore.
FRESH WATER COOLING SYSTEM ©)
The fresh water cooling system is a closed system
which helps protect engines from internal corrosion
and provides more even distribution of engine
temperature. The tank is located forward on the
engine with an overflow bottle. Change the coolant
annually.
Coolant Recommendations
The standard mixture of water and coolant is a
mixture of 30% antifreeze and 70% water, which
protects to 0°F (-18°C). This will allow the coolant
to expand properly and maintain normal operating
engine temperature. In colder climates, the coolant
level should be increased to 50/50, which protects
to -34°F (-37°C), for proper coverage. To find
engine coolant requirements, refer to your
Engine Owner’s Manual in the Owner’s Manual
Packet.
2.5
Underwater Gear
PROPELLERS 3,
Propellers should be free of nicks, excessive pitting
and any distortions that alter them from their original
design. Badly damaged propellers should be
replaced, but those that are chipped, bent or merely
knocked out of shape can be reconditioned by your
marine dealer.
When doing extensive cruising, it is advisable to
carry extra propellers aboard.
Propeller Installation:
For proper rotation, the installation of propellers on
inboard engine boats requires the right hand
propeller to be installed on the starboard side and
the left hand propeller to be installed on the port
side. Install in the following manner:
1. Inspect the key. It must be chamfered so that
the corners of the key do not touch the keyway
fillets (see illustration #2).
2. Install the propeller on the shaft without the key
in the keyway. Slide the propeller all the way
on the shaft until it seats. Mark the shaft on the
leading edge of the hub with a felt tip marker
and remove the propeller.
3. Install the key in the keyway and slide the
propeller on the shaft. If the key is not pinned,
tap the key back slightly as the propeller slides
up the taper. This will ensure that the propeller
does not ride the key up the keyway end radius,
thus forcing the propeller off-center. The
propeller is properly seated if the hub is in the
same position as previously marked.
Install a board (2 x 4) against the hub
perpendicular to the keel and rotate the
propeller clockwise until one blade rotates
against the board. Do not put a board between
the strut and the rudder. (See illustration #4.)
Install the large bronze nut on the propeller
shaft and seat the propeller with the correct
torque as listed on the following table.
Install the small nut to 100 ft. Ibs.
Install the cotter pin.
NOTICE
If the jam nut and prop nut are installed properly,
the propeller should not loosen. If you tighten
both nuts holding only the propeller blade, the
nuts could possibly thread back on the shaft to
the cotter pin. It is important that the above
procedure be followed.
J
Propeller Nut Torque Specifications (fig. 2.6.1)
Shaft Thread Torque |
| Diameter Size Nut Ft. Lbs.
1" 3/4" Bronze 100-125
11/4" 7/8" Bronze 150-175
11/2" 11/8" Bronze 250-275
1 3/4" 11/4" Bronze 275-300
2" 11/2" Bronze 325-350
21/2" 1 3/4" Bronze 400-425 |
1
Propeller Installation
: TOP RADIUS IN
(fig. 2.6.2) KEYWAY SHOULD
BE 1/2 THE FILLET
IMPROPER CHAMFER RADIUS WITH NO
ON KEY WILL RESULT CHAMFER ON KEY SHARP EDGES
IN KEY RIDING UP IN SHOULD BE LARGER
KEYWAY THAN FILLET IN
KEYWAY
KEY SHOULD SEAT IN
KEYWAY
CORRECT FIT
KEY RIDING UP IN KEYWAY
INCORRECT FIT
PROP NUT
KEYWAY
C
О
TTER PIN
PROP
2.6
JAM NUT
ILLUSTRATION #1 ILLUSTRATION #3
2 X 4 WEDGE
BLOCK
ALL CORNERS OF KEY SHOULD BE CHAMFERED
ILLUSTRATION #2 ILLUSTRATION #4
540 DA
SHAFTS
The shaft coupling is the connecting point between
the shaft and the engine. The alignment should be set
at .003" to .005" (0.08-0.13mm). Misalignment is much
exaggerated in Figure 2.7.1, but a slight misalignment
will cause loss of power, excessive wear, noise and
vibration. It should not be tolerated. When checking
for parallel coupling faces (the proof of proper
alignment), use a feeler gauge not more than .003 to
.005 of an inch thick (0.08 - 0.13mm).
With coupling faces brought together by hand — not
bolted — the feeler gauge should be tightly gripped at
all points around the edges of the couplings. Next,
hold the engine coupling flange stationary and rotate
the shaft coupling flange 90 degrees in either direction.
The feeler gauge should still be tightly gripped at all
points around the edges of the couplings.
SHAFT LOG & STRONG SEAL"
The shaft log is a fiberglass tube which provides an
opening through the bottom of the boat for the
propeller shaft. The Strong Seal™ is connected to it
by a short length of special flexible hose which
serves to absorb normal shaft vibration. The Strong
Seal™ prevents water from leaking around the shaft
and into the boat. Shaft alignment and straightness
must be correct to assure proper operation of the
Strong Seal”. Refer to the Strong Seal” information
for the seal carrier kit in the Owner's Manual packet.
=
| Shaft Misalignment (fig. 2.7.1)
TRANSMISSION
\. J
STRUT
The strut is the bronze casting fastened to the
bottom of the hull to support and form a bearing for
the propeller shaft. A replaceable rubber bearing is
inserted to minimize wear and protect the shaft
where it passes through the strut hub. During lay
up periods, squirt castor oil into this bearing to keep
it from freezing to the shaft. Never use machine
oil or grease on rubber bearing. Periodically check
all strut fastenings to assure that they are secure.
RUDDER & RUDDER STUFFING BOX
The rudder is the vertical flat surface aft of the
propeller that pivots about a vertical axis and
changes the direction of the boat through the water.
The rudder stuffing box prevents water from leaking
into the boat where the rudder post enters the hull.
N
Rudder 8: Rudder Stuffing Box
(fig. 2.7.3)
RUDDER POST
DD
NS
JAM NUT
PACKING
HULL
RUDDER
STUFFING
BOX
RUDDER
Shaft Log & Strong Seal”
(fig. 2.7.2)
SHAFT LOG
HOSE CLAMPS
STAINLESS STEEL
INJECTION FITTING
SEAL CARRIER KIT
HULL
FLEXIBLE HOSE
540 DA
STAINLESS STEEL
BANDS
STRONG SEAL”
2.7
Seacocks & Strainers
Seacocks and strainers are located in the bilge area.
To open the seacock, turn the handle in line with
water flow (vertically). To close, turn the handle
against water flow (horizontally). Some seacocks
are equipped with locking tee handles and must be
loosened before operating the handle. The seacock
body should be inspected and lubricated
annually. Sea water strainers should be inspected
frequently and cleaned out when plugged. To clean
the strainer, close the seacock and unscrew the cap,
or wingnuts, on top of the strainer housing. Remove
and wash the stainless steel screen. After replacing
the screen, replace and tighten the cap, open the
seacock and check for leaks.
NOTE: Engine seacock on the port side is for the
starboard engine, and the seacock on the starboard
side is for the port engine.
As a safety measure, close all seacocks when
leaving boat for any length of time to impede
water ingress in the event of water hose failure.
Accessory Room
The Accessory Room is located under a cockpit
hatch aft of the salon door (see fig. 2.8.2). Located
in the Accessory Room are 3 A/C compressor units,
an air conditioner relay, and a galley refrigerator/
freezer ice maker water shutoff valve.
2.8
1
Seacock & Strainer
(fig. 2.8.1)
SEACOCK
Na
CAP
O-RING
SCREEN
STRAINER
HANDLE
540 DA Accessory Room
(fig. 2.8.2)
ACCESSORY ==
ROOM ||
/
|
a)
FWD
PORT + STBD
AFT
ENGINE
ROOM
HATCH
540 DA
540 DA Bilge Layout (Port)
(fig. 2.9.1)
Port Fuel Tank
Emergency Start Solenoid
DC Main Breaker Panel
Head System Vacuum Generator
Oil Containers
Bilge Blower
Common Drain
Generator Battery
Hydraulic Swim Platform Lift
Generator Muffler
A
B
С
D
E
F
G
H
|
J
K
540 DA
< CC 4 nw VO To =z
Accumulator Tank
Water Heater
Waste Holding Tank
Buss Bar, Main DC
Aft Emergency Bilge Pump
Aft Emergency Bilge Pump Switch
Generator Seacock
Aft Bilge Pump Switch
Aft Bilge Pump
Waste Discharger Seacock
Maserator Pump
Batteries, Optional Bow Thruster
PORT FWD
AFT STBD
OPTIONAL BOW THRUSTER
COMPONENTS
Starboard Bilge Component Board
W
X Oil Exchange Pump
Y A/C Pump
Z Battery Isolator
A1 Battery Switch Solenoid
A2 12 Volt Converter
A3 24V Bow Thruster Converter
A4 Bow Thruster Disconnect Solenoid
A5 Fuse
A6 Control Box
2.9
(fig. 2.10.1)
FWD
><
PORT AFT
SEE PAGE 2.11 FOR
FWD ENGINE ROOM
BULKHEAD
540 DA Bilge Layout (Starboard)
Stbd. Head
System Vacuum
Generator
Located Forward
of Stbd. Bilge
Component
Board
A Fwd Component Board | Starboard Bilge Blower Q Vanner Equalizers
B A/C Seacock J Cable Master Tub R Converter
C Starboard Fuel Tank K Waste Tank Vent Filter S Starboard Bilge Component Board
D Steering Reservoir L Trim Pump T Engine Strainer
E Steering Filter M AC Main Shore Power Breaker Box U Seacock
F Head System Vacuum Generator N Cable Master Tub (Optional) V Bilge Pump Switch
G Autopilot Pump O Generator W Bilge Pump
H Batteries P Starboard Ventilation Filters X A/C Strainer
2.10 540 DA
540 DA Standard Detroit Fwd. Engine Room Bulkhead
(fig. 2.11.1)
STARBOARD ENGINE
RACOR FUEL FILTERS
RECOVERY BOTTLE
AUTOMATIC со 9
FIRE EXTINGUISHER
FWD
><
PORT AFT
DUPLEX OUTLET
EN
DD
RECOVERY BOTTLE
e
BUS BAR (DC) DE =
сл > D
FWD GND ZN [© Tn ©
BUSS BAR > EN y le Ae
= > a
PORT ENGINE NAN \ 9 Y
= ZI 7
RACOR FUEL FILTERS Se ZX В < = -
En |
Ce
> DEN A LA LA
= A TL
u 7 f Г [ A/C SEACOCK
A Es (
“
ЛЕТ
ЕТ
NA Г
FRESH WATER
PUMPS WITH
FRESH WATER
SYSTEM FILTER FILTERS
A/C STRAINER
AC PUMP STARBOARD ENGINE
SEACOCK
SYSTEMS MONITOR
BILGE INTEGRATED MODULE
(BIM)
STARBOARD ENGINE
STRAINER
PORT ENGINE
SEACOCK
FWD BILGE PUMP
PORT ENGINE STRAINER
540 DA Optional Caterpillar® Fwd. Engine Room Bulkhead
(fig. 2.11.2)
SYSTEMS MONITOR
BILGE INTEGRATED MODULE
AUTOMATIC FIRE EXTINGUISHER (BIM)
FWD
>
PORT AFT
RECOVERY BOTTLE
BUS BAR (DC)
FWD GND
BUSS BAR
A/C SEACOCK
FRESH WATER Hh
FRESH WATER PUES TT > :
SYSTEM FILTER 23
A
7
A/C STRAINER
STARBOARD ENGINE
AC PUMP SEACOCK
DUPLEX OUTLET
RECOVERY BOTTLE
STARBOARD ENGINE
STRAINER
PORT ENGINE
SEACOCK
FWD BILGE PUMP
PORT ENGINE STRAINER
540 DA
2.11
Section 3 * Instruments 6 Controls
f A
Control Station
Analog Dash Panel
(fig. 3.1.1)
COMPASS
TACHOMETER TACHOMETER
OIL PRESSURE OIL PRESSURE
WATER TEMPERATURE
VOLTMETER VOLTMETER
WATER TEMPERATURE FUEL GAUGE
FUEL GAUGE SYSTEMS MONITOR
DISPLAY CONTROL MODULE
IT
NN <> A (DCM)
OD ENGINE THROTTLE
OPTIONAL
ELECTRONICS MULTIFUNCTION << CONTROLS
BOW THRUSTER
BATTERY SWITCH
(OPTIONAL)
BOW THRUSTER
CONTROL PANEL
(OPTIONAL)
CONTROL STATION
ACCESSORY
PANEL SWITCH
VHF REMOTE
SPEAKER
VHF MARINE
RADIO
SEARCH LM
CONTROL AUTOMATIC FIRE
PANEL EXTINGUISHER
INDICATOR
TRIM TAB
CONTROLS
ENGINE
GEARSHIFT
CONTROLS
TRIM — \МРЕВ5 — — WINDSHIELD NAVIGATION ~~ TROLLING
TABS PORT STBD VENT LIGHTS VALVES ACCESSORY
o ©
SPOT ENGINE
LIGHT SYNC. HORN LIGHTS ACCESSORY ACCESSORY ACCESSORY
o о о ©
EMERGENCY
24VD FIRE EXTINGUISHER
e © O, RELEASE
CONTROL STATION 24 VOLT CIRCUIT BREAKER PANEL
(BEHIND FOLD-OUT DOOR) CONTROL STATION
SWITCH PANEL
\. J
540 DA 3.1
Optional Caterpillar® Engine
Monitoring System (EMS) (fig. 3.2.1)
TACHOMETER TACHOMETER
CATERPILLAR® W/HOURMETER W/HOURMETER
EMS GACGES CATERPILLAR® QUAD CATERPILLAR® QUAD
CAUCE PANEL GAUGE PANEL
VOLTMETER
FUEL GAUGE EES CATERPILLAR®
[TT EMS GAUGES
VOLTMETER
FUEL GAUGE
AUTOMATIC FIRE
EXTINGUISHER
INDICATOR
EMS
SCROLL
X A SWITCHES
TWIN DISC®
ELECTRIC SHIFT
AND THROTTLE
CONTROL A
CATERPILLAR
DIAGNOSTIC
OUTLETS
EMERGENCY
FIRE EXTINGUISHER
RELEASE
OPTIONAL TWIN DISC® ELECTRIC SHIFT AND THROTTLE CONTROLS
\.
1
Optional Detroit Electronic Display Module (EDM)
DDEC Dash Panel (fig. 3.2.2)
ELECTRONIC DISPLAY MODULE (EDM)
(PORT & STARBOARD ENGINES)
DDEC ENGINE
GEARSHIFT
CONTROLS DDEC ENGINE
THROTTLE
CONTROLS
4 BUTTON STATION
CONTROL PANEL
EMERGENCY
CONTROL PANEL
3.2 540 DA
(See fig. 3.1.1 for location)
Control Station Switch Panel (fig. 3.3.1)
ae
——— PORTIGNITION —— —— STBD IGNITION ——
EMERGENCY
TART
_
SCROLL
EMERG STOP/ START/RUN RUNNING
STOP
©
START/RUN EMERG STOP/
STO
PORT IGNITION STBD IGNITION
SLOW
VESSEL
US/METRIC TROLLING ENGINE SLOW
VALVE SYNC. VESSEL
SCROLL
NAVIGATION LIGHTS
ANCHOR
5 UL
O
US/METRIC
A
nu
ONO
CAM
The following switches are for Caterpillar® Electronic
Engines. If your engine choice is a Caterpillar®
Mechanical Engine, or any Detroit Engine, these
switches will be plugged.
1. U.S./Metric
Changes port EMS gauge readout to U.S. or
metric measurements.
2. Slow Vessel
Allows port engine RPM to drop (only at idle
throttle position). See information below for slow
vessel mode operation.
3. Scroll
Allows operator to scroll through the port EMS
gauge (see page 3.10 — main EMS display).
4. Scroll
Allows operator to scroll through the starboard
EMS gauge (see page 3.10 — main EMS
display).
5. Slow Vessel
Allows starboard engine RPM to drop (only at
idle throttle position). See information below for
slow vessel mode operation.
6. U.S./Metric
Changes starboard EMS gauge readout to U.S.
or metric measurements.
AC
SLOW VESSEL MODE
If your 540 DA engine option is one of the Caterpillar®
electronic engines, a Slow Vessel Mode may be
available. The Slow Vessel Mode enables the
operator to reduce engine idle RPM by the push of a
540 DA
DIMMER
BILGE
BLOWERS FWD AFT
о
LIGHTS
COCKPIT
WINDLASS
MAIN CONTROL
©
SPOILER SPOT
BILGE PUMPS
ELECTRONICS ~~ AUTOPILOT ACCY. ACCY.
_
JUL
LLL
о
rocker switch located on the control station switch
panel (see above panel). This reduction in RPM at
idle helps reduce the yachts wake in a Slow Speed
or No Wake zone.
With the Slow Vessel Mode turned ON your yacht
may produce a wake that violates a NO Wake zone
or cause a nuisance to other boat traffic. To correct
this, the operator should shift one of the engines to
N
EUTRAL, remembering to adjust your steering to
maintain your heading.
Pushing the rocker switch activates the Electronic
Control Module (ECM) to reduce the engine RPM
by 100 RPM's. Example: Programmed engine idle
IS
R
700 RPM’s. When Slow Vessel Mode is ON engine
PM will drop to 600 RPM's.
Slow Vessel Mode Should NOT be used during any
type of maneuvering such as docking at a slip or
rafting to other boats. Slow Vessel Mode reduces
engine RPM and could cause engine(s) to stall
during maneuvering.
NOTICE
Slow Vessel Mode should be used at engine idle
speed. Using Slow Vessel Mode at higher than
engine idle speed may limit top end performance.
3.3
To Engage Slow Vessel Mode:
Bring engines’ throttle controls to IDLE
e Push the Slow Vessel Mode switch to ON,
engine RPM's will drop by 100 RPM's
* Remember, shift one of the engines to
NEUTRAL if your yacht's wake is not reduced
enough with Slow Vessel Mode
To Disengage Slow Vessel Mode:
* Ensure engines are at idle speed
Push Slow Vessel Mode switch to OFF, engines’
RPM will increase to programmed engine idle
RPM
TROLLING VALVE AND LOW IDLE OPTION
(Only Available With Some Engine Options)
The TROLLING VALVE switch controls a valve on
both engine transmissions. When turned on, this
allows the shafts to turn slower when slow speeds
are required, such as when docking, trolling or
passing through no wake areas.
Trolling valve and Detroit DDEC low idle should
NOT be used at the same time. DDEC low idle
reduces engine RPM and could cause engine(s)
to stall during maneuvering.
The LOW IDLE switch (DDEC option only) activates
the engines to IDLE at a lower RPM, enabling slower
vessel speed for maneuvering and a reduction in
wake.
Refer to your Owner’s Manual Packet for your yacht's
Trolling Valve or Low Idle option for operating
instructions.
fr
(See fig. 3.1.1 for location)
Control Station Accessory Switch Panel (fig. 3.4.1)
3.4
(o
_ J
\. J
1
Control Station Breaker Panel (fig. 3.4.2)
(See fig. 3.1.1 for location)
O O)
о ©
о о о ©
24VDC
O O
540 DA
HYDRAULIC POWER STEERING SYSTEM
The hydraulic power steering system uses the boat's
engines to provide the “power” for the steering
system, via a mechanical or electrical motor driven
hydraulic pump.
A manual hydraulic steering system, consisting of a
helm and a hydraulic cylinder (fitted with an integral
servo cylinder and a power steering valve), supplies
the “control” portion of the steering system.
Under normal conditions, with engines running, a
hydraulic oil supply is in a standby mode, ready to
be directed to the steering cylinder as dictated by
the steering wheel, servo cylinder and power
steering valve. Turning the steering wheel left or right
makes the system go from “standby” into “operating”
mode and move the steering cylinder accordingly.
In the event of a power source failure, hydraulic oil
from the steering helm is automatically diverted into
the servo and steering cylinder, providing the
helmsman with manual backup steering.
An engine room mounted oil reservoir allows easy
fill and assists the in-line cooler in cooling the
hydraulic oil. An in-line oil filter helps to protect the
steering system components against contaminants.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
GEAR SHIFTS & THROTTLE CONTROLS
Your yacht may be equipped with hydraulic or
electric throttle control(s). There are different
functions, operating and maintenance instructions
which must be followed to prevent improper operation
and maintenance. Read and understand the
information in the Owner’s Manual Packet for your
yacht model's gear and throttle controls.
Your yacht has start in-gear protection. For safety’s
sake and as a good habit to get into, always put the
gear selector in the “NEUTRAL” position and the
throttle selector in the “IDLE” position before starting
the engines.
* Shift selector(s) to “NEUTRAL” before starting
engines.
* Shift only when engine is at idle.
* Reversing at high speeds can cause flooding/
swamping due to water being pushed over
the transom (stern).
* Shift quickly; easing into gear can damage the
transmission.
* Hydraulic controls “FORWARD” and “REVERSE”
positions should always be in the full travel
extremes in either direction for positive
engagement and minimum wear.
fr A
Typical Hydraulic Power Steering Assembly
. POWER STEERING HELM A)
(fig. 3.5.1 ) (OPTIONAL TILT VERSION NN NY
SHOWN) A
OIL UN
RESERVOIR
do
STEERING CYLINDER
COMPLETE WITH INTEGRAL
SERVO, CYLINDER & POWER
STEERING VALVE
MECHANICAL OR
ELECTRIC MOTOR
DRIVEN PUMP
e
OIL COOLER
\. J
540 DA 3.5
Maneuvering
Operating your yacht in reverse comfortably requires
practice. Find open water and practice reversing
techniques. Here are a few things to remember:
Bring engine to “IDLE” before shifting.
Pause in “NEUTRAL” while shifting to allow the
boat to lose headway, then shift quickly.
Reversing the shift lever will cause a “braking action”
when maneuvering the boat at low speeds. Care
should be exercised in using the reverse throttle for
“braking action” as the sudden slowing of the boat's
forward motion will create a following wake which
may rise above the transom and flood/swamp the
boat if the boat is moving at too great a speed. All
propellers are designed to give maximum forward
thrust, so the reverse thrust of the propeller will not
be as efficient.
Each gear shift lever can be used independently
from the other. For example, while idling you can
shift one forward and the other in reverse. This is
called differential power, and it will increase your
boat's maneuverability. We suggest that you go to
open water and practice, practice, practice.
GEAR SHIFTS & THROTTLE CONTROLS
(Hydraulic)
Your yacht is equipped with hydraulic gear shifts and
throttle controls as standard equipment.
Examples of Differential Power
(fig. 3.6.1)
PRACTICE, PRACTICE,
PRACTICE!
FORWARD FORWARD
Le J
The gear shift lever for each engine, twin lever
controls on port side of control station, has three
positions: forward, neutral, and reverse. The control
lever must be in the neutral (center) position when
starting the engine(s). À positioning indent can be
felt when the control is in exact neutral. Forward and
reverse positions should always be in full travel
extremes in either direction for a positive
engagement and minimum wear.
The throttle controls, twin lever controls on starboard
side of control station, regulate the RPM of the
engines. Periodically check and seasonally lubricate
the linkage with medium weight oil.
NOTE: Prior to starting engines, put throttles at idle
and clutches in neutral.
(fig. 3.6.2) PORT STBD
FORWARD
NEUTRAL
REVERSE
ENGINE GEARSHIFTS
3.6
Engine Shift & Throttle Functions (Hydraulic)
FULL THROTTLE
PORT STBD
VARIABLE
IDLE
ENGINE THROTTLES
540 DA
Operation (Hydraulic) (See fig. 3.6.2)
1. Throttle Levers:
Forward Motion — Increases Throttle
Aft Motion — Decreases Throttle
2. Gearshift Levers:
Forward Position — Forward Direction
Center Position — Neutral
Aft Position — Reverse Direction
Maintenance
The clutch and throttle lever bodies are made of
anodized aluminum. To clean them, a warm soapy
water solution should be used. Do not use an
abrasive compound.
NOTE: Refer to your Engine Owner’s Manual to
operate the throttle arm by hand for maintenance.
REFER TO OWNERS MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
GEAR SHIFTS & THROTTLE CONTROLS
(Electric Option — DDEC or Twin Disc®)
Your yacht may be equipped with either DDEC or
Twin Disc® electric gear shifts and throttle controls
as optional equipment. They are located on the
control station (see fig. 3.2.1 & 3.2.2). Electric
controls offer many advantages, including ease of
shifting, no mechanical linkages, and much more.
Sea Ray® recommends that you read the Owner’s
Manual for electric control options on your 540
DA to take full advantage of this option. Enjoy!
NOTE: Prior to starting engines (diesel):
e Shift throttle and gear levers into the NEUTRAL
position.
e Ensure that the boat's DC power is ON.
e DDEC only - Turn system activation switch ON.
Follow the engine START sequence according to
the Engine Owner's Manual. Also see Section 4
— Fueling é Starting.
Operation (DDEC) (See fig. 3.7.1)
1. Throttle Senders:
Forward Motion — Increases Throttle
Aft Motion — Decreases Throttle
2. Clutch Senders:
Forward Position — Forward Direction
Center Position — Neutral
Aft Position — Reverse Direction
Operation (Twin Disc®) (See fig. 3.8.1)
1. The port lever operates the gear and throttle for
the port engine and the starboard lever operates
the starboard engine gear and throttle.
1
(fig. 3.7.1)
PORT ENGINE STBD ENGINE
FULL
THROTTLE
|
VARIABLE
FULL
THROTTLE
|
VARIABLE
PORT ENGINE STBD ENGINE
ENGINE GEARSHIFTS
540 DA
Engine Shift & Throttle Functions (DDEC Electric Option)
PORT ENGINE STBD ENGINE
FORWARD
|
NEUTRAL
FORWARD
NEUTRAL
REVERSE REVERSE
PORT ENGINE STBD ENGINE
ENGINE THROTTLES
3.7
Engine Shift & Throttle Functions
(Twin Disc? Electric Option)
(fig. 3.8.1)
PORT STBD
ENGINE ENGINE
FULL
THROTTLE
FULL
THROTTLE
FORWARD GEAR | 1. FORWARD GEAR
NEUTRAL (IDLE)
REVERSE GEAR:
|
FULL
THROTTLE
NEUTRAL (IDLE)
© © REVERSE GEAR
FULL
THROTTLE
PORT STBD
ENGINE ENGINE
\. J
2. Moving the lever forward to the first indent
engages the forward gear. Moving the lever
backwards to the first indent engages the
reverse gear.
3. Moving the levers further forward or backwards
increases throttle and boat speed.
REFER TO OWNERS MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
ENGINE SYNCHRONIZERS
When the engine synchronizers are in operation,
any engine speed differential is immediately sensed
and automatically corrected. A single throttle
movement is all that is necessary to ensure that both
engines maintain identical RPM.
The standard helm for the 540 DA is equipped with
Glendinning synchronizers and hydraulic gearshift
and throttle controls. The optional helms offer
synchronizers that accompany the electronic gauge
and electric gearshift and throttle control package
(i.e. Twin Disc® or DDEC). If you have either of these
options, refer to your Owner's Manual Packet for the
correct operating instructions for your 540 DA engine
synchronizers.
Glendinning Synchronizers:
1. Have both engines running and advance speed
slightly above idle.
2. Turn ÓN synchronizer switch located on the
control station switch panel.
3.8
3. MOVE SLAVE (STARBOARD) ENGINE
THROTTLE LEVER TO “MAXIMUM” SPEED
POSITION since the synchronizer is now
controlling the slave engine, the lever is “limp”
or non-effective. Advancing the slave engine
lever eliminates the synchronizer of undue
strain in moving the entire control system.
4. Both engines are now under the control of a
single movement of the lead (port) engine
throttle control and may be advanced or
retarded through the entire cruising range.
ADVANCE LEAD (PORT) ENGINE CONTROL
SLOWLY. The indicator light next to the
synchronizer switch will illuminate when
engines are synchronized.
5. Todisengage - switch OFF synchronizer - move
slave engine lever back towards idle. It will
automatically reengage with the engine control.
A safety collar assures positive return to idle
when switching OFF and moving lever back.
Use of the automatic synchronizer at minimum and
maximum engine speeds call for engine speed
settings to be as follows:
о SLAVE engine at “IDLE.” Set SLAVE throttle
LOWER than LEAD engine.
e SLAVE engine at “MAXIMUM:” Set SLAVE
throttle HIGHER than LEAD engine.
Automatic deactivation of the Automatic
Synchronizer will result from conditions contrary to
the above settings. The power light will go OFF and
the automatic synchronizer will be deactivated. To
re-engage, switch OFF and ON again.
REFER TO OWNER’S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Instrument Gauges
Your 540 DA is equipped with analog gauges as
standard equipment (see fig. 3.1.1). There are two
optional electronic gauge packages available. They
are the Caterpillar® Engine Monitoring System (EMS)
and the Detroit Diesel® Electronic Display Module
(EDM) (referto fig. 3.2.1 or 3.2.2 for the display installed
on your yacht).
The following information is a brief description of the
standard and optional gauge packages. Refer to the
Owner’s Manual Packet and/or consult the dealer for
complete instructions regarding your 540 DA gauge
package.
540 DA
TACHOMETER (With Hourmeter)
f Y The tachometer
indicates the revolu-
tions per minute
(RPM) of the en-
gine. It does not in-
dicate the speed of
the boat through the
water or over the
bottom. Your Engine
q J Operators Manual
(fig. 3.9.1) states the maximum
full throttle RPM at
which your engine should operate. This should not
be exceeded. The tachometer should also be used
to determine the most comfortable and economical
cruising RPM.
Hourmeter
Hourmeters measure cumulative hours of operating
time and are available for both engines and the
generator. They should be used to keep a careful
log of engine maintenance as well as performance
data and fuel consumption. Do not leave ignition
key on with the engines off, as this will increase the
engine hours on the hourmeter. A generator hour
meter is located on the generator gauge panel
(see fig. 7.19.3).
OIL PRESSURE GAUGE <0)-
f Y Very little serious
trouble can occur in
an engine which will
not be reflected on
the oil pressure
indicator. Maximum
pressure is con-
trolled by a preset
\ J valve in the oil
(fig. 3.9.2) pump. Note the
reading which this
gauge records when the engine is new, as it is the
“norm” which can be used as reference during the
life of the engine. IF ACOMPLETE LOSS OF OIL
PRESSURE OCCURS, TURN ENGINE OFF AT
ONCE. Continued running after loss of pressure will
cause engine damage. First, manually check the oll
level. If low oil level is not the cause, consult your
Sea Ray® dealer. DO NOT RESTART THE ENGINE
UNTIL THE PROBLEM HAS BEEN CORRECTED.
Slight fluctuations in gauge readings are not
uncommon during operation and may be due to the
characteristics of the lubricating oil. Greater
fluctuations should be investigated. The cause may
PS/kPa
540 DA
be a clogged oil filter element which should be
replaced with every oil change.
WATER TEMPERATURE GAUGE El
Г |) The watertempera-
ture gauge indicates
temperature of the
cooling water circu-
lating inside the
engine. Your engine
is equipped with a
thermostat so a pre-
` J determined engine
(fig. 3.9.3) temperature should
be reached soon
after starting the engine and maintained thereafter
while the engine is running.
Refer to your Engine Operator's Manual for proper
gauge readings. If the temperature approaches
above normal on your gauge, shut down engine
at once.
VOLTMETER
The voltmeter indi-
cates battery bank
voltage. Normal en-
gine operating volt-
24 20123 age will range
between 24.0 to
28.5 volts when the
VDC alternator is charging.
Significantly higher
я 204 / or lower readings
(fig. 3.9.4) indicate a battery
problem, alternator malfunction or heavy battery drain.
FUEL GAUGE В
The fuel gauge indicates the amount of fuel in the
fuel tank. The most accurate reading of the fuel
f Y gauge is at idle
speeds when your
boat is in an approxi-
mately level posi-
tion. At slow plane,
when your boat is in
a bow up position,
the gauge will read
q J inaccurately be-
(fig. 3.9.5) cause the fuel in the
tank travels to the
rear of the tank and away from the fuel sending unit.
3.9
Because gauge readings are approximate, they
should be compared to the hours of use versus
known fuel consumption (GPH).
ENGINE MONITORING SYSTEM (EMS)
(OPTIONAL)
The optional Caterpillar® Engine Monitoring System
(EMS) incorporates three individual gauge units per
engine (see figure 3.2.1). They are:
Main EMS Gauge
Quad Gauge
Tachometer
Refer to the Owner’s Manual Packet for more
information about your gauge display operation
and instructions.
MAIN EMS DISPLAY
| Main EMS Gauge Unit (fig. 3.10.1)
© ©
7 NN
DONES
AN Jo
EMS is an electronic monitoring system designed
to display various engine/transmission parameters.
The main EMS gauge has ten (two rows of five)
indicators to display system related diagnostics. A
digital LCD is functional to scroll through the different
engine/transmission parameters monitored. A port
and starboard scroll switch is located on the
control station switch panel (see fig. 3.3.1).
The parameters monitored include the following
functions:
Engine Overspeed (Main and Back-up Speed
Sensors)
Engine Oil Pressure
Engine Coolant Temperature and Coolant Level
Transmission Oil Pressure and Oil Temperature
Percent Load (Actuator)
3.10
Fuel Rate (Throttle)
Engine Hours
HOURMETERS |
The hourmeters measure cumulative hours of
operating time. There are hourmeters on top of each
Caterpillar? engine and an hourmeter readout on the
Main EMS display by method of scrolling. They should
be used to keep a careful log of engine maintenance
as well as performance data and fuel consumption.
Do not leave ignition key on with the engines off, as
this will increase the engine hours on the hourmeter.
The generator hourmeter is located on the generator
gauge panel (see fig. 7.19.3).
QUAD GAUGE
| Quad Gauge Unit (fig. 3.10.2) |
ADN
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Noa Ng Ol
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The quad gauge unit displays in analog format
engine oil pressure, engine coolant temperature,
transmission oil pressure and transmission oil
temperature.
OIL PRESSURE GAUGE -(0)-
N
The oil pressure
gauge is often the
best indicator of
engine problems or
difficulties. Maximum
pressure is con-
trolled by a preset
Valve in the oil pump.
a 3103) / Note the reading
TT which this gauge
records after the break-in period, as it is the “norm”
which can be used as reference during the life of
the engine.
IF A COMPLETE LOSS OF OIL PRESSURE
OCCURS, TURN ENGINE OFF AT ONCE.
540 DA
Continued running after loss of pressure will cause
engine damage. First, manually check the oil level.
If low oil level is not the cause, consult your
Sea Ray® dealer. DO NOT RESTART THE ENGINE
UNTIL THE PROBLEM HAS BEEN CORRECTED.
Slight fluctuations in gauge readings are not
uncommon during operation and may be due to the
characteristics of the lubricating oil. Greater
fluctuations should be investigated. The cause may
be a clogged oil filter element which should be
replaced with every oil change.
WATER TEMPERATURE GAUGE OI
f YY The water
temperature gauge
indicates temperature
of the cooling water
circulating inside the
engine. Your engine is
equipped with a
thermostat so a
\ J predetermined
(fig. 3.11.1) engine temperature
should be reached soon after starting the engine and
maintained thereafter while the engine is running. Refer
to your Engine Operator's Manual for proper gauge
readings. If the temperature approaches above
normal on your gauge, shut down engine at once.
TRANSMISSION OIL TEMPERATURE |
Г GAUGE
The transmission oil
temperature gauge
indicates
temperature of the
transmission fluid
inside the engine
transmission. If the
temperature
approaches above
normal on your gauge, shut down engine at
once. Refer to Engine Owner’s Manual for
normal operating range.
<
(fig. 3.11.2)
TRANSMISSION OIL PRESSURE >48%<
GAUGE
The transmission oil pressure gauge indicates pressure
of the transmission fluid inside the engine transmission.
If the pressure approaches above or below
normal on your gauge, shut down engine at
once. Refer to Engine Owner’s Manual for normal
operating range.
540 DA
(О \ Мо!е: It is normal
for the oil pressure
to fluctuate when
the engines are
throttled up.
\ J
(fig. 3.11.3)
TACHOMETER
| The tachometer
indicates the
revolutions per
minute (RPM) of
the engine on an
analog gauge. |!
does not indicate
the speed of the
boat through the
water or over the
bottom. Your
Engine Operator's Manual states the maximum full
throttle RPM at which your engine should operate.
This should not be exceeded. The tachometer should
also be used to determine the most comfortable and
economical cruising RPM.
Na A
(fig. 3.11.4)
A three-digit LCD indicator displays vessel speed
and a two-digit indicator displays trolling mode status
or synchronization mode status.
DETROIT DIESEL ELECTRONIC DISPLAY
MODULE (EDM) (OPTIONAL)
Detroit Diesel? EDM (fig. 3.11.5)
r в
\ 066 2075100
19437
0 00 æ
000 1068 1788
N J
The Electronic Display Module (EDM) automatically
turns on with the ignition key. The module briefly
sounds its audible alarm and runs through checks
of the display and internal circuits. Following the
checks, it receives and displays engine and
transmission data. It always shows engine speed,
3.11
coolant temperature, oil pressure, fuel consumption
rate, battery voltage, transmission oil temperature,
transmission oil pressure, gear direction, and the
active control station number.
The six pushbuttons on the keypad allow you to
access information and features, displaying it in the
text window.
CONSOLE DIMMER
There is a “DIMMER?” control switch located on the
control station switch panel which controls the
intensity of the gauge and switch panel lights. The
gauge and switch panel lights are energized when
the navigation running lights are turned on.
MARINE COMPASS -4-
A marine compass is deflected and its usefulness
impaired when other instruments or objects
containing iron, magnets, or electric current carrying
wires are in its vicinity. A newly installed compass
must be adjusted to compensate for these influences
if they must remain in proximity to it.
The compensating or adjusting should be done by a
qualified compass adjuster. A compass can seldom
be corrected to zero deviation on all headings, so
you will be provided with a deviation card or chart
showing the correction to be applied when laying out
a compass course or making your navigational
calculations. Keep this card at the control station
at all times.
After your compass is adjusted, do not permit items
such as iron or steel to be placed near it, even
temporarily, as they will affect its accuracy. The
compass must be readjusted if any items which affect
it are removed, relocated or added in its vicinity.
When not in use, the compass should be protected
from excessive and prolonged sunlight. If your
compass becomes sluggish or erratic, it should be
serviced by an authorized repair station.
To keep the plexiglass dome free from scratches,
remove salt deposits and dust with a damp cloth. An
occasional treatment with paste wax will help
preserve the dome surface.
REFER TO OWNER’S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
3.12
NAVIGATION LIGHTS -&-&-
Navigation lights must be displayed while underway
from sunset to sunrise. The term “underway” denotes
not anchored or docked. Trolling or drifting with power
off is considered underway and normal running lights
must be displayed. At anchor, in open water, a 360°
white anchor light must be displayed.
To operate the RUNNING lights: -&-
Push “NAVIGATION” switch on control station switch
panel to the RUNNING position.
To operate the ANCHOR lights: &-
Push “NAVIGATION” switch on control station switch
panel to the ANCHOR position.
Your boat is equipped with a sport spoiler. If you opt
to install a radar, it then becomes your responsibility
to reevaluate your lighting situation to make certain
the navigation lights on your boat meet government
navigational lighting requirements. You will most likely
have to raise the mast light. Consider the weight of
the radar you install; be certain it is not too heavy for
your sport spoiler.
SYSTEMS MONITOR
The Systems Monitor consists of a Display Control
Module (DCM) located at the control station and a
Bilge Interface Module (BIM) located on the fwd bilge
bulkhead component board (see fig. 2.10.1 and
2.10.2). The DCM and BIM are connected to each
other by a coax cable and the BIM is continuously
looking at all inputs for an alarm condition.
The Systems Monitor is connected directly to the 24
volt battery bank through a circuit breaker and
continuously monitors two emergency high water
pumps, two bilge pumps and the bilge heat detector.
The engine and generator functions are only active
when ignition voltage is turned on. The circuit breaker
is on the main DC breaker panel located on the port
bilge component board (see fig. 7.5.1 and 2.9.1).
The BIM collects signals from critical engine
functions, generator oil pressure, bilge pumps, high
water emergency bilge pumps and bilge heat
detection and transmits that information to be
displayed on the DCM.
The features of the DCM include a two line LCD
display with backlighting of the display, audible alarm
and an Audible Reset/Alarm Select pushbutton
switch.
540 DA
Systems Monitor
Display Control Monitor (DCM)
(fig. 3.13.1)
f в
SEA RAY BOATS
ALL SYSTEMS NORMAL
SYSTEMS MONITOR
O
Sea Rage
AUDIBLE RESET 7
ALARM SELECT ®
J
Na J
The LCD display will read in two lines. For example,
at normal operation will read:
SEA RAY BOATS
ALL SYSTEMS NORMAL
Note: Some functions only read on one line. See
page 3.14 (DCM functions) for all DCM display
readouts.
Backlighting of the LCD is achieved by turning ON
the navigation lights switch. Intensity is controlled
by the electronic dimmer control. Both are located
on the control station switch panel.
Audible Alarms
An audible alarm will sound to alert the operator to
look at the DCM and determine the high level fault.
Only high level faults such as critical engine functions,
generator, emergency pumps and bilge heat detector
will have an audible alarm. The forward and aft bilge
pumps do not have an audible alarm, instead the
DCM will display those functions.
Audible Reset/Alarm Select
The Audible Reset/Alarm Select pushbutton switch
on the DCM is a dual purpose switch. It enables the
operator to reset an audible alarm or to manually
scroll the display during multiple alarms.
The Audible Reset is used to temporarily quiet an
alarm that is displayed on the LCD. If that function is
not corrected within 30 seconds, the audible alarm
will sound again. Pushing the switch again will
permanently quiet (turn off) the audible alarm for that
function. The LCD will still display that fault until it is
corrected.
540 DA
The Alarm Select is active only during multiple
alarms. For example, if the engine oil pressure,
forward emergency pump and transmission
temperature had faults at the same time the systems
monitor would sound an audible alarm and would
display the alarm with the highest priority. Each push
of the switch will show the new alarm and then the
LCD will automatically scroll through the multiple
alarm functions approximately every three (3)
seconds. By pushing on the switch, the operator will
be able to manually scroll the LCD for faulting
functions.
To monitor critical engine functions and generator
oil pressure:
1. The 24 volt main battery solenoid switches must
be energized either at the main DC breaker
panel on the port bilge component board or the
DC distribution panel on the port side just aft of
the galley.
2. At the DC distribution panel turn the port and
starboard master ignition key switch to the ON
position.
3. At the control station, locate the port and
starboard START/RUN switches. Without
starting the engines, push the START/RUN
switch(es) to the RUN position. The Display
Control Monitor (DCM) will display:
SEA RAY BOATS
ALL SYSTEMS NORMAL
Note: The generator and Detroit diesel engines will
have an alarm as soon as ignition is turned on.
4. Start the engines per the engine start
instructions in Section 4 pages 4.3 and 4.4.
5. Start the generator per the generator start
instructions in Section 7 page 7.19.
With the main engines and generator engine
running, the yacht's Systems Monitor is fully
activated. When the engine and generator engine
ignition is turned OFF, approximately five (5) minutes
later the LCD will go into a “Sleep Mode” and the
display will be blank. Engine and generator functions
are disabled because they are unnecessary,
however, the bilge heat detector and all pumps are
still being monitored.
The following DCM Function table will name each
function, describe the function and show how it is
displayed on the DCM. An * by the function indicates
that function has an audible alarm.
3.13
TRIM TABS
Ч
Function
Description
DCM
\.
Normal Operation
BIM Coax Cable to DCM
Bilge Heat Detector *
Forward Emergency *
Aft Emergency *
Forward Bilge
Aft Bilge
Oil Pressure *
Water Temperature *
Transmission Temperature *
Exhaust Temperature *
Fuel Filter Condition *
Generator Alarm *
CAT Diagnostics *
Caterpillar Electric
Engines Only
No Alarms
Cable Connection Fault
Sense Extreme (190°) Heat in the
Bilge or a 15° Increase in
Temperature
Forward Emergency Pump Under the
Master Stateroom Hatch is Running
Aft Emergency Pump in the Engine
Room is Running
Forward Bilge Pump in the Engine
Room is Running
Aft Bilge Pump in the Engine Room
is Running
Engine Oil Pressure Too Low
Engine Cooling System Too Hot
Transmission Cooling System is Hot
Engine Malfunction, Exhaust Too Hot
Fuel Filter Needs Cleaning
Generator Oil Pressure is Low
Generator Stopped Running
For CAT Diagnostic Engines
SEA RAY BOATS
ALL SYSTEMS NORMAL
DATA LINK FAILURE
ALARM SYSTEM OFF-LINE
HEAT DETECTOR
(NO SECOND LINE READING)
PUMP ALARM
FORWARD EMERGENCY
PUMP ALARM
AFT EMERGENCY
PUMP ALARM
FORWARD BILGE
PUMP ALARM
AFT BILGE
PORT (OR STBD) ENGINE ALARM
OIL PRESSURE
PORT (OR STBD) ENGINE ALARM
WATER TEMPERATURE
PORT (OR STBD) ENGINE ALARM
TRANSMISSION TEMPERATURE
PORT (OR STBD) ENGINE ALARM
EXHAUST TEMPERATURE
PORT (OR STBD) ENGINE ALARM
FUEL FILTER CONDITIÓN
GENERATOR ALARM
(No Second Line Reading)
PORT (OR STBD) ENGINE ALARM
CAT DIAGNOSTIC
The CAT Diagnostic feature is for Caterpillar electronic engines and will refer the operator to look at the port
or starboard Caterpillar Engine Monitoring System (EMS) on the gauge panel at the helm. See fig. 3.2.1 for
EMS gauge location and fig. 3.10.1 and text for more information on the EMS gauge unit.
J
If your Systems Monitor does not operate or display functions correctly per the instructions provided, recycle the
circuit breaker by pushing the circuit breaker to the OFF position and then pushing it to the ON position. Use a
small tool that will fit through the hole to push the breaker to the OFF position.
3.14
540 DA
The trim tabs on your Sea Ray® are operated with a
rocker type momentary switch at the control station.
They are protected by a circuit breaker on the control
station breaker panel which must be ON to use the
trim tabs (see fig. 3.4.2).
To trim the bow of your boat down, push the top
halves of both rockers down in half second bursts. If
you hold the rockers down, you will over trim the
boat and the bow will dig in. To correct over-trimming,
push bottom halves of both rockers to obtain desired
planing angle.
The two trim tabs on the transom of your boat can
also be used to trim the list of your boat that may be
caused by improper storage of gear, too many
people on one side or a strong cross wind. Operation
of the rocker switch should be momentary short
bursts to achieve proper attitude of the hull.
When running wide open, most boats do not require
any trim unless heavily loaded.
In heavy following seas or when running in an inlet,
best maneuverability is obtained with a bow high
attitude. To be sure the tabs are full up in the zero
position, push the bottom halves of the rockers for
several seconds.
The trim tab pump is located on the starboard aft
bilge bulkhead, mounted on the inside of the
transom. To service the unit, remove the tinted plastic
cover to gain access to reservoir fill plug and motor
parts. Hydraulic trim tabs use Type A Dexron ll
automatic transmission fluid, which should be filled
up to the “FULL” mark on the pump base. Add fluid
with the trim tabs in the up position only.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
PUMP FOR STARBOARD
TRIM TAB
RESERVOIR FILL
HYDRAULIC RAMS
TRIM TAB ZINC
540 DA
| RUNNING ATTITUDE LIST PUSH |
BOW UP ---- TOP OF BOTH ROCKERS
BOW UP PORT TOP OF STARBOARD ROCKER
BOW UP STARBOARD TOP OF PORT ROCKER
BOW DOWN PORT BOTTOM OF STARBOARD ROCKER
| BOWDOWN STARBOARD BOTTOM OF PORT ROCKER |
Trim Tab Pumps & Switch & TRIM TAB SWITCH |
(fig. 3.15.1) P—
STARBOARD
TRIM TAB
PORT TRIM TAB
3.15
Section 4 e Fueling & Starting
Fuel Systems
Fuel lines, filters and all fuel system components
should be checked at the start of each season and
periodically thereafter, particularly after any work
has been done aboard the boat which might have
affected any part of the system. Be certain that all
are in proper condition and that the entire system is
fuel tight. Each fuel tank has a manual shut-off valve
on the crossover fuel board to close off the fuel
system in case of leakage or line failure.
FUEL TANKS
The 540 DA has two (2) aluminum fuel tanks
mounted port and starboard (see figure 4.1.2 and
4.1.3). The fuel tanks each have a capacity of 300
gallons (1,135.5 liters). Fuel fills are located on the
starboard deck walkway. The port fuel fill fills the
port tank, the starboard fuel fill fills the starboard
fuel tank. The generator draws from the starboard
fuel tank only.
Your Sea Ray® is equipped with a fuel tank vent for
each tank which serves as a pressure/vacuum
release and safety overflow. The through-hull fitting
has a flame arrester, making it imperative that you
keep the screen clean and in excellent repair.
Catepillar Fuel System Layout
(fig. 4.1 2) FUEL TANK FILL SCC
AFT STBD
TO CROSSOVER BOARD
FUEL TANK
VENTS
PORT FUEL
TANK
7 GENERATOR A
(DRAWS FROM AS
(22 STARBOARD TAN
7) ONLY) A A
7
a < A
(a) 6 à
a STARBOARD
D FUEL TANK
=> a
PORT RACOR/FUEL STARBOARD
RACOR/FUEL
FILTERS
FILTERS
GENERATOR FUEL FILTER
N J
540 DA
Replace the screen immediately if it becomes
damaged or displaced. Periodically check the vent
to assure that it is not clogged.
Fuel Vent With Screen/Flame Arrestor (fig. 4.1.1)
DO NOT store fuel or flammable liquids in closed
storage areas. Ventilation has not been provided
for explosive vapors.
Leaking fuel is a fire and explosion hazard.
Inspect system at least annually. Examine fuel
tanks for leaks or corrosion at least annually.
4 N
Detroit Fuel System Layout
(fig. 4.1.3) FUEL TANK FILL >
TO CROSSOVER BOARD
PORT FUEL FUEL TANK
TANK VENTS
STARBOARD
RACOR/FUEL
FILTERS
GENERATOR STARBOARD
(DRAWS FROM FUEL TANK
STARBOARD TANK
ONLY) GENERATOR FUEL FILTER
N J
4.1
CROSSOVER FUEL SYSTEM
The crossover fuel system allows the engines to
draw fuel from either tank. This allows switching to
an alternate tank in case of fuel contamination or
for even fuel weight distribution. Each engine and
the generator are equipped with valves on the
crossover fuel board. The generator only draws fuel
from the starboard fuel tank utilizing valves offering
OPEN, CLOSED and RETURN settings only.
The crossover fuel board is located under the cockpit
seat cushion (see figure 4.2.1). For access to the
fuel board, lift the cushion on top of the starboard
seating area.
Crossover Fuel Board (fig. 4.2.1)
a a a
PORT STBD
TANK TANK
STBD PORT
TANK 1 OFF TANK 1 ОРЕ
e
GEN FEED GEN RETURN
OFF OFF
= ON ==») о
FUEL RECOMMENDATIONS fl
The quality of the fuel is very important for
satisfactory engine performance and long engine
life. Fuel should be clean and free of contamination.
Your fuel tanks should be kept full of fuel whenever
possible. This will reduce the amount of water
condensation and reduce the possibility of
contamination.
Recommended Fuel: #2 Diesel fuel
4.2
Я ÓN
Fuel Filters: (Diesel) [EN
Primary and secondary fuel filters are located on
your Sea Ray” to help keep the fuel as clean as
possible. Primary fuel filters are the Racor® water
separating fuel filters installed in the engine room
(see figs. 4.1.2 and 4.1.3). The secondary fuel filters
are located on the engines and should be replaced
in accordance with the Engine Owner’s Manual.
Use of any methanol, gasohol or alcohol based
fuel additive will damage the fuel filter.
Primary Fuel Filter Selection Valve:
Arrow Up: ALL OFF
Arrow Right: RIGHT ON
Arrow Down: ALL ON
Arrow Left: LEFT ON
i Diesel Racor® Fuel Filters
(fig. 4.2.2)
Filter Selection
Valve \
NOTE: INROUGH SEAS, ALLOW APPROXIMATELY
15% RESERVE WHEN PLANNING FUEL
CONSUMPTION.
REFER TO THE ENGINE OPERATOR’S MANUAL
FOR MORE DETAILED INFORMATION.
540 DA
Fueling Precautions
Certain precautions must be carefully and
completely observed every time a boat is fueled,
even with diesel fuel. Diesel fuel is nonexplosive
but it will burn.
General:
Fuel during daylight.
* Check fill plate label to ensure fuel is placed
only in fuel tank. Fuel fill plates are located on
the starboard deck.
Avoid spills.
e Know your fuel capacity and consumption.
Record the amount of fuel used since your last
fill up, and compute the engine’s hourly fuel
usage. As a backup check to your fuel gauge,
deduct the average hourly fuel usage from fuel
tank capacity.
* Observe the “Rule of Thirds”: one-third fuel for
trip out, one-third for return and one-third for
reserve.
Allow an additional 15 percent fuel reserve when
operating in rough seas.
Before and During Fueling — Checklist:
* Fire extinguisher — close at hand.
Mooring — boat tied securely to fueling pier.
e Crew — at least one knowledgeable person
present.
Passengers — unnecessary people off the boat.
* Engines — stopped.
о Electrical equipment, including blowers — power
off.
e Windows, doors, hatches — closed.
Smoking material — extinguished.
Inboard tanks — grounded.
Portable cans — placed on pier during filling.
Filler pipe — marked “FUEL.”
Fuel nozzle — in contact with can or filler pipe to
prevent static sparks.
Fill level — fill less than rated capacity of tank;
allow for fuel expansion.
Trim — fuel weight distributed equally if more
540 DA
than one tank.
After Fueling — Checklist:
e Windows, doors, hatches — open.
e Blowers — operate at least four (4) minutes
before starting engines.
e Sniff test — if fuel fumes remain, operate blowers
until fumes are gone.
Fuel tank — secure filler cap.
Spills — wipe; dispose of rags ashore.
Starting Engines
The engine operation and maintenance manual
furnished with your boat describes pre-start and
starting procedures. The following notes are basic
reminders and not intended to cover every detail of
starting. We urge you to thoroughly read and
understand your engine manual.
1. Check battery switches for ON position.
2. Check the fuel tank levels.
3. Check the oil and coolant levels. See your
Engine Operator’s Manual for proper readings.
4. Check engines for coolant drain plug
installations.
Check seacocks for open position.
Make sure strainers are clean and water tight.
Check fuel filters for tightness.
Turn on fuel valves on crossover fuel board.
© © N SO ©
Check the bilge for fuel fumes or liquid. Do not
start the engines until the source of fumes
GASOLINE VAPORS CAN EXPLODE.
Before Starting Engine:
Check engine compartment for fuel vapors.
e Operate blower for four (4) minutes.
* Run blowers below cruising speed.
\. J
15 determined and corrected and the bilge
area is safely ventilated.
10. Turn on the master key switches located on
the DC distribution panel. Listen for alarms
which indicate ignition power.
4.3
11.
4.4
NOTE: Ignition switches on the control station
must be in the RUN position.
NOTE: If your yacht is equipped with the
Caterpillar® EMS (Engine Monitoring System),
the Caterpillar® gauges on the control station
gauge panel will undergo an automatic self-test
on power-up. While executing this internal test,
the display will also provide a visual indication
by ramping gauges and displaying all digits to
the operator that the panel is (or is not)
functioning properly. Refer to your Engine
Owner's Manual in the Owner's Manual Packet.
NOTE: Electric Twin Disc? shift and throttle
controls require that the “STATION SELECT”
button be pushed twice: once before the start
of the port engine and again before the start of
the starboard engine, or vice versa (refer to the
Original Equipment Manual in the Owner's
Manual Packet).
After ignition power is verified, check the
gearshift lever(s) in the “NEUTRAL” position
and the throttle lever(s) at “IDLE,” then push
on the top of the ignition switch(es) until the
engine(s) start.
Do not operate starter for more than 10 seconds
without allowing starter to cool for two (2)
minutes. This will also allow the batteries to
recover between starting attempts. Once
engine has started and sufficient oil pressure
is achieved, alarm buzzer will stop.
Important: Check engine RPM on tachometer
as soon as engine starts. Do not allow RPM
to exceed 1,500. Move throttle lever down to
decrease RPM.
Alarm will sound when:
* Engine oil pressure is too low.
Engine temperature is too hot.
Transmission oil is too low.
Transmission temperature is too hot.
Engine stalls.
12.
13.
14.
* Fuel filter condition
Exhaust temperature too high.
Check the oil pressure and look at exhaust port
to assure that engine is pumping water.
Let the engines warm up at idle and check for
leaks. If engine is cold, run for a short period of
time at fast idle speed that does not exceed
1500 RPM.
Shut down the engines and recheck fluid levels;
top off if necessary.
NOTE: For general operation of the boat, its
instruments and the engine, follow detailed
instructions on “Engine Break-in” in the Engine
Operators Manual.
Stopping Engines
a SS © № =
©
Bring throttle controls to “IDLE” position.
Bring gear shift controls to “NEUTRAL” position.
Secure mooring lines.
Idle for five (5) minutes to cool the engines.
Switch momentary start switch or ignition key
to OFF position.
Turn battery switches OFF.
Turn fuel valves OFF.
540 DA
Section a * Water System
Water System
The fresh water system consists of two 24 volt water
pumps with filters, water system filter and pneumatic
accumulator tank (see fig. 5.5.1 for water system
layout).
The fresh water system is activated by the water
pump breakers on the DC distribution panel. The
breakers must be ON to operate the head, shower,
ice maker, fresh water wash down or faucets.
(fig. 5.1.1)
FWD #2 FRESH
STBD
> WATER PUMP
PORT per ANDFILTER ~~~
FRESHWATER CN |
SYSTEMFILTER NE
#1 FRESH
WATER PUMP
AND FILTER
AFT step eN EAS WATER
Ш a > HEATER
STARBOARD
EXHAUST
WASTE HOLDING
TANK
ACCUMULATOR
TANK
To begin initial operation:
1. Fill the water tank with potable water.
2. Switch the water pump breakers to the ON
position.
3. One at atime, open all hot and cold faucets to
bleed air from the water lines.
4. Once air has been eliminated from water lines,
close faucets.
5. Shutting off the last faucet should cause the
pump to shut off.
Make certain the hot water lines are air free,
indicating the water heater is full. Damage will occur
to water heater if it is not full when turned on.
540 DA
FILLING THE WATER TANK AAA
To fill your water tank you should use a plastic hose.
Do not use a rubber hose; it can give the water a
disagreeable flavor. The hose should be kept for
filling use only. After using the hose it should be
emptied. Start at one end and raise the hose to
shoulder level and walk to the opposite end of the
hose, allowing the remaining water to flow out. You
should store your water tank filling hose in a clean
dry place. ltis also a good practice to cover the ends
of the hose to keep the inside clean.
WATER TANK AAA
The 540 DA has a 150 gallon water tank. Access to
the tank fittings is gained through a hatch in the salon.
The tank is filled through a fill plate located on the
starboard deck walkway. Fill the water tanks only
from a source known to provide safe, pure drinking
water.
To check the water level in the tank, press the water
level switch on the 24V DC distribution panel. The
lights will indicate the amount of water in the tank.
SANITIZING THE WATER SYSTEM
Although your dealer initially sanitizes the water
system, if the system has not been used for a long
period of time, or you suspect it may be
contaminated, use a water treatment additive to
sanitize the potable water system. Water treatment
additives are available at marine/RV supply stores.
If water treatment additives are not available, adhere
to the following procedure for complete sanitation
of your potable water system.
1. Prepare a chlorine solution using one gallon of
water and 1 cup Clorox or Purex household
bleach (5% Hypochlorite solution). With tank
empty, pour chlorine solution into tank, using
one gallon solution for each 60 gallons of tank
capacity.
2. Complete filling of tank with fresh water. Open
each faucet until air has been released and the
entire system is filled.
3. Allow to stand for three (3) hours.
4. Drain and flush with potable fresh water.
5.1
5. To remove excessive chlorine taste or odor
which might remain, prepare a solution of
4 quarts of vinegar to 20 gallons of water and
allow this solution to agitate in the tank for
several days by vehicle motion.
6. Drain tank and again flush with potable water.
7. Replace water filter.
WATER PUMPS & FILTERS
Pumps
The 24 volt water pumps for the fresh water system
are located on the forward engine room bulkhead
(see fig. 2.11.1).
The pumps are turned on by the “FRESH WATER
PUMP” breakers on the DC main distribution panel.
Filters
Each of the water pumps have a filter on the suction
side of the pump to prevent particles from entering
the pump head. The filters should be checked and
cleaned periodically (see fig. 5.2.2).
There is also a water system filter on the supply side
of the pumps to filter any particles that the pump
filters did not trap. The filter should be checked and
cleaned periodically (see fig. 5.2.1).
Before servicing the system, turn the “WATER
SYSTEM” breakers OFF and release pressure on
the system by opening a faucet. To clean the filter,
remove the screen and rinse with clean water.
Replace, making sure the O-ring is in place when
replacing the cover.
f A
Water System Filter (fig. 5.2.1)
=
FILTER >
FILTER
CARTRIDGE
COVER
5.2
Water Pump Filter (fig. 5.2.2)
COVER
\. J
REFER TO OWNER’S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
WATER SYSTEM ACCUMULATOR TANK
The water system pneumatic accumulator tank is
located on the starboard side of the transom (see
fig. 2.9.1).
The Accumulator Tank smoothes water flow and
reduces on/off cycling of the pump by lessening the
variation in pressure and flow between the pump
and the outlets in the system.
The even flow of water gives better control of hot
water temperature especially noticeable with
instantaneous gas water heaters and with showers.
The reduced on/off cycling reduces noise from the
pump motor, and from shock pressures (pipe
hammer). It also reduces battery drain, and gives
longer pump life.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
WATER HEATER
The 20 gallon water heater is located in the engine
room behind the generator. It runs on the 240 volt
dockside system or generator and has a circuit
breaker on the main distribution panel.
The water heater has a check valve to prevent hot
water from back-washing into the cold water source
and a pressure relief valve to avoid damage to the
heater from over pressure or too high a temperature.
Initial Start-Up Or After Winterization:
1. Make sure the “WATER HEATER” breaker is
OFF.
2. Fill the heater with water.
540 DA
3. Open the hot water faucets until all air is
eliminated from the system.
4. Make certain the heater is full of water.
COMPLETE FAILURE OF THE HEATING
ELEMENTS WILL RESULT IF THEY ARE
NOT COMPLETELY IMMERSED IN WATER
AT ALL TIMES.
5. Turnthe “WATER HEATER” breaker ON.
To maintain water heater properly, drain whenever
the possibility of freezing occurs and frequently
inspect lines and connections for leaks.
REFER TO OWNER’S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
SHOWER SYSTEM
The 540 DA is equipped with a shower sump. Grey
water from the shower system drains into the shower
sump to be pumped overboard.
The shower sump is located under a hatch in the
master stateroom. The sump contains a pump and
float switch. Also draining into this sump are all of
the cabin air conditioner condensation drains, galley
sink and both cabin head sinks.
The sump pump is fully automatic and protected by
a breaker on the main DC breaker panel in the port
engine room. Periodically remove the clear cover;
check and clean the pump and float switch. Check
the pump and float switch for obstructions and proper
working order. The shower sump pump comes on
when there is enough water in the sump to raise the
float switch and start the pump. If it does not come
on after one or two gallons of water drain from the
shower, turn the water off and check the pump and
float switch for proper operation.
After using the shower, it is recommended that you
run a gallon of clean water through the shower drain
to clean out soap residue.
Shower Sump (fig. 5.3.1)
540 DA
FRESH WATER WASHDOWN
The 540 DA is equipped with three fresh water
spigots; one in the bilge, one at the transom and
one in the bow rope/chain locker. The bilge spigot
comes with a 12-foot hose and a strap for storage
when not in use. The transom spigot is located on
the starboard transom. The rope/chain locker spigot
is accessible through the bow deck hatch. The
system uses water from the fresh water tank. The
“FRESH WATER PUMP” breakers on the DC main
distribution panel must be ON to operate the system.
COCKPIT SHOWER AAA
(See fig. 7.10.1 for location)
The cockpit shower has a hot and cold control and
shower wand which are located in the starboard
transom. Squeeze the button on the shower wand
to dispense water and turn the knob to adjust water
temperature. The “FRESH WATER PUMP” breakers
on the main distribution panel must be ON to operate
the shower.
Cockpit Shower (fig. 5.3.2)
DOCKSIDE WATER INLET AAA
(See fig. 7.10.1 for location)
The dockside water inlet, located at the starboard
transom, allows use of a dockside water source to
provide water for the boat's fresh water system.
To use the system:
1. Make sure the “FRESH WATER PUMP”
breakers are OFF.
2. Remove the watertight plug from the face of
the dockside water inlet.
3. Connect a drinking water hose to the water
outlet on the dock, then to the dockside water
inlet on the boat and turn on the water at the
dock.
5.3
All fresh water faucets and showers are now usable.
To disconnect the system, reverse the procedure,
making sure the watertight plug is reinstalled tightly.
Remove the dockside water hose when leaving the
boat. This is a safety precaution to prevent the unlikely
event of a water system failure and the intake of
extreme amounts of water to the vessel.
(a) Fresh Water Washdown, (b) Dockside Water Inlet
(fig. 5.3.3)
Before connecting dockside water hose to
the yacht’s dockside water inlet, ensure that
dockside water pressure does not exceed
your yacht’s water system pressure limit.
e DO NOT leave boat unattended with the
dockside water hose connected.
* Dockside water should be connected during
periods of heavy water usage only.
5.4
WASHER & DRYER WATER VALVE
(OPTION)
The washer/dryer unit is located in the guest
stateroom. Hot and cold water lines are connected
to the back of the unit. The valves on the back of
the unit should be turned OFF when not in use. An
access hatch is provided in the botton of the cabinet
above the washer/dryer.
Washer & Dryer Water Valve (fig. 5.4.1)
5 EH
OPEN CLOSED
For information on the optional washer/dryer, see
page 8.11 and owner’s manual packet.
540 DA
540 DA
DISHWASHER (OPT)
WATER SYSTEM FILTER
COCKPIT ICE MAKER
Fresh Water System (fig. 5.5.1)
ROPE LOCKER WASH DOWN
WASHER/DRYER HOOK-UP
GUEST TOILET
GUEST HEAD FAUCETS
GUEST HEAD SHOWER
GALLEY FAUCETS
TO WINDSHIELD
WIPERS
ICE MAKER
= = = = = = = = = = = = = =!
77
Fwd
Port Stbd
Alt
= = = = HOTWATER
meses COLD WATER
FRESH WATER TANK
MASTER HEAD SHOWER
MASTER HEAD TOILET
MASTER HEAD FAUCETS
WET BAR
ALL Y
BILGE WASHDOWN
PRESSURIZED ACCUMULATOR
RE
=
WATER HEATER
/
//
|
FORWARD BILGE
BULKHEAD
24V WATER PUMPS
WITH FILTERS
TRANSOM SHOWER
CITY WATER
STERN
WASHDOWN
HOOK-UP
Port Stbd
Alt
GUEST HEAD SINK DRAIN
GUEST HEAD SHOWER
& FLOOR DRAIN
—
DISAWASHER DRAIN (OPT.) —
A/C UNIT DRAIN Da
ACCESSORY HATCH DRAIN =|
Gray Water System (fig. 5.6.1)
| MM MM MM MM mm
GALLEY DRAIN — | 0 I
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SUMP DISCHARGE
ob == mm =m ны
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GUEST STATEROOM A/C DRAIN
SALON A/C DRAIN
| MASTER HEAD SINK DRAIN
MASTER HEAD SHOWER
& FLOOR DRAIN
|
| MASTER STATEROOM A/C DRAIN
— SUMP BILGE PUMP
— FORWARD EMERGENCY BILGE PUMP
Mi.
— AC COMPRESSOR UNITS
COCKPIT SINK DRAIN
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COMMON DRAIN
Г FORWARD BILGE PUMP
AFT BILGE PUMP
—— AFT EMERGENCY BILGE PUMP
|
|
REFER TO PARTS MANUAL FOR GRAY WATER LINE ROUTING, HOSE LENGTHS AND FITTINGS
5.6
540 DA
Section 6 ® Head System
Head System
The head system on your Sea Ray® is available with
a variety of options. Below is a description of each
option. You should be aware of which option your
boat is equipped with and read the section pertaining
to it. The owner’s packet in your boat contains
information pertaining to your head system that
should be read carefully.
Do not flush facial tissue, paper towels or
sanitary napkins in head.
REQUIREMENTS FOR VESSEL
OPERATORS
The Environmental Protection Agency (EPA)
standards state that in freshwater lakes, freshwater
reservoirs or other freshwater impoundments whose
inlets or outlets are such as to prevent the ingress
or egress by vessel traffic subject to this regulation,
or in rivers not capable of navigation by interstate
vessel traffic subject to this regulation, marine
sanitation devices certified by the U.S. Coast Guard
installed on all vessels shall be designed and
operated to prevent the overboard discharge of
sewage, treated or untreated, or of any waste
derived from sewage. The EPA standards further
state that this shall not be construed to prohibit the
carriage of Coast Guard-certified flow through
treatment devices which have been secured so as
to prevent such discharges. They also state that
waters where a Coast Guard certified marine
sanitation device permitting discharge is allowed
include coastal waters and estuaries, the Great
Lakes and interconnecting waterways, freshwater
lakes and impoundments accessible through locks,
and other flowing waters that are navigable interstate
by vessels subject to this regulation (40 CFR 140.3).
VACU-FLUSH HEAD
The Vacu-Flush head utilizes the “HEAD SYSTEM”
breaker on the main distribution panel. The foot pedal
at the base of the toilet opens a mechanical seal
540 DA
and vacuum forces waste through the opening in the
bowl to the vacuum bottle, through the vacuum pump
and then to the holding tank.
To Operate:
1. Turn ON the “FRESH WATER PUMP” breaker.
2. Turn ON the “HEAD SYSTEM?” breaker.
HOLDING TANK OPERATION
Waste from the head is directed into the holding tank
located under the generator (see fig. 2.9.1). The
holding tank fluid level indicator is located on the
main distribution panel and in each head which
indicates “POWER,” “1/2” and “FULL-DO NOT
FLUSH. When the “FULL-DO NOT FLUSH? light is
on, the holding tank must be emptied before the head
can be reused. However it would be a good practice
to empty the holding tank when the “1/2” light is on
to avoid overflowing the holding tank and ruining the
vent filter.
To empty the holding tank, the services of a dockside
pump out station will be needed. Follow instructions
at the station and make sure pump out station hose
is inserted into the deck plate marked “WASTE,”
located on the starboard transom.
The holding tank can also be emptied by the optional
macerator (see page 6.2 for instructions).
VENT FILTER
The vent filter is designed to control odors
associated with the head system operations. The
vent filter is located on the aft starboard bilge wall
above the engine exhaust (see fig. 2.10.1). The filter
must be changed at the beginning of each boating
season to be effective. The vent filter is installed in-
line on the holding tank ventilation hose (see fig.
6.2.1).
NOTE: Do not overfill the holding tank as this will
flood the vent filter and render it useless. Filter
replacement will then be required. See Parts Manual
for correct replacement filter.
6.1
VACUUM
DOCKSIDE
PUMP-OUT
WASTE
LEVEL
INDICATOR
MACERATOR
DISCHARGE
HOLDING a] SEACOCK
TANK B > Я ~~
4
DA р
HOLDING TANK THRU-HULL
VENT FILTER VENT
MACERATOR DISCHARGE PUMP
The macerator gives the boat operator the means of
discharging the holding tank contents directly
overboard through a seacock in the bottom of the
hull. This is available in conjunction with the dockside
pump out. DISCHARGE OF SEWAGE DIRECTLY
OVERBOARD IS FOR USE ONLY WHERE
APPROVED.
To Operate The Macerator:
1.
6.2
Turn ON the “DISCHARGE PUMP” breaker on
the DC distribution panel and open the waste
discharge seacock located on the bilge floor (see
fig. 2.9.1 for seacock location).
Operate “DISCHARGE” switch under the
WASTE SYSTEM CONTROL area on the main
distribution panel.
When tank is empty, release the switch and close
waste discharge seacock.
GENERATOR
HEAD
VACUUM
GENERATOR
Vacu-Flush Head System With Holding Tank & Overboard Discharge Pump
(fig. 6.2.1)
PORT
STBD
TOILET
WATERLINE
TOILET
Rh
WATERLINE
NOTICE
This boat is equipped with an optional overboard
discharge valve.
Discharging of sewage directly overboard is for
use where approved only.
NOTICE
There is the possibility of being fined for having an
operable overboard discharge in U.S. waters.
Removing handle of seacock, in closed position,
or other means must be utilized to avoid fine.
540 DA
Section 7 * Electrical System
DC System
The 24/12 volt direct current (DC) electrical system
derives its power from the batteries, which are kept
charged by alternators and/or AC to DC converter.
The battery voltage is indicated by a digital voltmeter
on the 24 volt DC distribution panel located to port
as you descend the companionway to the salon, and
the voltmeter on the control station instrument panel.
Each battery bank’s voltage can be checked at the
24 volt distribution panel by using the Battery Bank
Selector and voltmeter. The batteries supply power
to the main DC breaker panel, the control station
and DC distribution panel breakers. The 12 volt
control station circuits are protected by the
“ACCESSORY (12V),” “ELECTRONICS (12V)” and
fuse blocks. The 24 volt functions on the control
station breaker panel are protected by the control
station main breaker in the main DC breaker panel.
The 24 volt functions on the DC distribution panel
are protected by the cabin main breaker in the main
DC breaker panel.
All main grounds are connected at the main DC
ground buss located on the port side of the engine
room (see fig. 7.1.1). The negative terminal of each
bank of batteries is connected to the ground buss,
and then on to ground the engines. This negative
ground system is the approved system for marine
DC electrical systems.
BATTERIES
The batteries in your boat have been selected for
their ability to furnish starting power based on engine
and generator starting requirements as well as their
ability to supply power to the DC system.
The main engine cranking batteries consist of two
(2) banks (port and starboard). Each bank consists
of two (2) 12 volt batteries connected in series to
create the 24 volts required for engine start, as well
as to supply the electrical system loads.
The recommended main engine battery to install in
your boat is a Group 8D, 12 volt marine battery with
a minimum of 1400 cold cranking amps and 435
minutes reserve capacity.
Battery Cable Routing
(fig. 7.1.1 ) STED BATTERY pd
PORT BATTERY > |
SOLENOID ;
EMERGENCY START
SOLENOID
AZ
MAIN DC
DISTRIBUTION PANEL
\
MAIN DC
GROUND
BUSS
TO PORT ENGINE —— —
PANDUIT TYP
POSITIVE
NEGATIVE
540 DA
|
ENGINE BLKHD
PORT OUTBD
STRINGER
7.1
The generator has its own battery for starting. The
recommended battery is a Group 27, 12 volt marine
battery with a minimum of 575 cold cranking amps
and 165 minutes reserve capacity. The generator
battery has its own dedicated converter.
Sea Ray® recommended batteries are available
through your local Sea Ray® dealer.
Always disconnect battery cables before doing
any work on the engine's electrical system or
alternator wiring to prevent arcing or damage to
the alternator.
To remove the battery cables:
1. Turn OFF all items drawing power from the
batteries.
Turn OFF the “CONVERTER?” breaker.
3. Turn OFF battery switches.
4. Remove the negative cable first, then the
positive cable. To replace the cables, reverse
the procedure.
Battery maintenance:
Check the fluid level in the cells approximately every
four (4) weeks, and more often in summer and hot
Zones.
The fluid level must be between the lower and the
upper markings.
Only replenish with distilled water. Do not use metal
funnels.
Coat battery terminal clamps with dielectric silicone
grease. Keep batteries clean and dry.
Only use a battery charger designed to charge
automotive/marine type batteries when batteries are
disconnected from the boat's electrical circuit.
While the engine is running the battery terminal
clamps must not be loosened or detached nor
should the battery switch(es) be turned off,
otherwise the alternator and other electronic
units will be damaged.
\ J
Never use an open flame in the battery storage area.
Avoid striking sparks near the batteries.
A battery will explode if a flame or spark ignites
the free hydrogen given off during charging.
7.2
12 VOLT SYSTEM
Although the boat’s DC system is primarily a 24 volt
system, the control station electronics require 12
volts to operate and has a dedicated fuse block. Also
operating on the 12 volt system is the cockpit stereo,
cablemaster remote, and 12 volt receptacle.
The 12 volt system derives its power from the 12
volt side of the 24 volt battery banks. The boat is
equipped with two (2) battery equalizers that allow a
differential amp draw between the 24 volt side and
the 12 volt side. The equalizers electronically balance
an equivalent voltage at each battery within tenths
of a volt of each other. Without equalizers, an over
or under charge of the individual batteries could
occur. The 12 volts are fed to the main DC breaker
panel, then distributed to the areas listed on the 12
volt side of the panel, i.e., electronics and
accessories (see fig. 7.5.1). The 12 volt system
power can be turned off by the 12 volt battery
switches.
ELECTRICAL SYSTEM BREAKERS
In the event it becomes necessary to replace an
electrical breaker, REPLACE THE BREAKER ONLY
WITH A BREAKER OF THE SAME RATING. The
breaker’s amperage is marked on the breaker.
@ A
BREAKER
SPECIFICATIONS
N J
Main Distribution Panel Breaker
(fig. 7.2.1)
If a breaker is replaced with a breaker of lower
amperage, it will be insufficient to carry the electrical
load of the equipment it is connected to and cause
nuisance tripping.
If a breaker is replaced with a breaker of higher
amperage, it will not provide adequate protection
against an electrical malfunction and could create
a possible fire hazard.
540 DA
BATTERY SWITCHES
There are four (4) main battery solenoid switches,
two (2) for 24 volt and two (2) for 12 volt, located on
the DC distribution panel in the salon and a duplicate
set on the main DC breaker panel in the engine
room. Your yacht's battery 24/12 volt power can be
turned ON or OFF at either location or ON at one
location and OFF at the other locationa. You do not
have to use the same battery switch location to turn
ON or OFF battery power. The indicator lights on
each switch are illuminated when the system is
energized. When the switches are in the “OFF”
position all 24/12 volt power to engines and
accessories are turned off, except power to the bilge
pumps, emergency bilge pumps, shower sump and
stereo memory circuits.
Always stop engines and/or generator before
switching to “OFF" position. This will help
prevent damage to your alternator and electrical
system.
NOTE: The bilge pumps, emergency bilge pump and
stereo memory CANNOT be turned OFF with the
battery switches. The entire remaining DC system
can be turned OFF with the battery switches.
24 Volt Battery Switch Solenoids
(Control Station Circuits, Cabin Circuits,
Lighting, Head System, etc.)
The two (2) 24 volt battery switch solenoids are
located at the port engine room component board
(see fig. 2.9.1). When turned on, the 24 volt system
becomes energized. The port and starboard sides
can be turned on and off independently. (Refer to
figure 7.3.1)
Each solenoid is equipped with two (2) fuses, one
on the line side to power the solenoid and the other
on the load side to power the rocker switch indicator
light.
12 Volt Battery Switch Solenoids
(Accessories, Electronics)
The two (2) 12 volt battery switch solenoids are
located on the port engine room component board
(see fig. 2.9.1). When turned on, the 12 volt system
becomes energized. The port (accessories) and
starboard (electronics) sides can be turned on and
off independently. (Refer to figure 7.3.1)
540 DA
MAIN BATTERY SOLENOIDS
ENERGIZE
- - -
DE-ENERGIZE
ENERGIZE
a - a
DE-ENERGIZE
„
24 & 12 Volt Battery Switches (fig. 7.3.1)
Each solenoid is equipped with two (2) fuses, one
on the line side to power the solenoid and the other
on the load side to power the rocker switch indicator
light.
EMERGENCY START SYSTEM
The emergency start system utilizes a momentary
switch, located on the control station switch panel
and an emergency start solenoid, located on the port
engine room component board (see fig. 2.9.1).
Holding the switch energizes the solenoid which
parallels the batteries to assist in starting. Use
emergency start when the charge of one bank of
batteries is insufficient to start its corresponding
engine. To engage the emergency start system, start
whichever engine has sufficient battery power, then
hold emergency start switch while starting the other
engine.
( ÓN
J
Emergency Start Solenoid (fig. 7.3.2)
7.3
CROSSOVER CHARGING SYSTEM
The crossover charging system utilizes a battery
isolator with blocking diodes and passes current to
the batteries from the engine alternators. It is an
automatic system with no switches, and designed to
charge each bank of batteries from both engine
alternators when necessary, while the diodes prevent
the discharge from one bank to the other bank. The
battery isolator is located in the engine room on the
port component board (see fig. 2.9.1).
REFER TO OWNERS MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
N
1
Battery Isolator (fig. 7.4.1)
HALOGEN LIGHTING
Use appropriate protection, such as
clean cloth gloves, when handling or
disposing of all halogen-cycle bulbs.
Wear eye protection. Turn power off
when installing or before removing
lamp. Allow lamp to cool before
removal.
Remove grease or fingerprints from
quartz halogen-cycle bulbs with a
grease-free solvent before use.
The filament bulbs used in all halogen-cycle
lamps generate intense heat. To avoid the
possibility of fire, do not use lamp at close range
to materials that are combustible or affected by
heat or drying. Halogen-cycle bulbs are
pressurized and could shatter if scratched or
damaged. Glass halogen-cycle bulbs should be
protected against contact with liquids when
operating.
7.4
ELECTRONICS CIRCUIT WITH
GROUND PLATE
The 50 amp electronics circuit utilizes a circuit
breaker in the main DC breaker panel to feed the
fuse block at the control station. The fuse block is
to be used for electronic equipment only. There is a
static ground buss located at the control station for
mounting of electronic equipment static grounds
only, not for current carrying grounds. It is grounded
via a ground plate mounted on the bottom of the
hull. Do not use bottom paint on the ground plate
as it will destroy the effective area of grounding.
MAIN DC BREAKER PANEL & CONTROL
STATION BREAKER PANEL
The main DC breaker panel is located on the port
engine room component board (see fig. 2.9.1). It
has breakers for both 24 and 12 volt electrical loads.
The control station breaker panel is located in a fold-
out door at the starboard helm and only has 24 volt
breakers (see Control Station Layout, page 3.1).
On the main DC breaker panel, notice that the
breakers are locked in the “ON” position. This
prevents all circuits from being inadvertently turned
off. The bilge pumps are connected directly to the
battery banks and CANNOT be turned off with the
battery switches. If maintenance is to be performed
on the pumps, use a small tool that will fit through
the hole to push the breaker to the “OFF” position.
When maintenance is complete, push the breaker
to the “ON” position.
FLOODING AND SWAMPING HAZARD -
Always check the operation of bilge pumps,
emergency bilge pumps and float switches
after performing maintenance.
540 DA
540 DA
540 Sundancer Main DC Breaker Panel (fig. 7.5.1)
Note: Panel layout and labeling are subject to variance due to customizing optional accessories and equipment updates.
fo
O
O
MAIN DC BREAKER PANEL
24 VDC
STBD
MAIN BATTERY SOLENOIDS
ENERGIZE
DE-ENERGIZE
A
A
A
A
A
A
A.
A
PORT
CABIN — |
MAIN о о
\ —
fr |
IGNITION o o
\ —
fr |
CABLEMASTER #1 O o
\ —
fr |
RETRACTABLE © o
нЕ
ACCESSORY о o
ACCESSORY © o
т
FWD
BILGE PUMP o о
Le —
{ |
WD
EMERGENCY PUMP © o
v —
и | ——— 7 \
O O
EMERGENCY PUMP
N —
f |
BLOWER #1 о о
N —
(7 |
CONTROL о о
STATION 12VDC
\ Ps
fr |
ELECTRONIC
CONTROL O O
\ —
fr |
SALON o o
STEREO MEMORY
\ ——
{ | О
COCKPIT
STEREO MEMORY © o
\_ — —
WINDLASS
SWIM PLATFORM LIFT
O
12 VDC
MAIN BATTERY SOLENOIDS
ENERGIZE
DE-ENERGIZE
A
CONTROL
о STATION
O IGNITIÓN
O CABLEMASTER #2
o OIL CHANGE
PUMP
© ACCESSORY
© ACCESSORY
o SYSTEMS
MONITOR
о АЕТ
BILGE PUMP
о SUMP
PUMP
© BLOWER #2
ELECTRONICS
O ELECTRONIC
CONTROL
o CABLE MASTER
O ACCESSORY
0)
O
7.5
DC Distribution Panel
Controls & Functions
24 Volt DC Distribution Panel (fig. 7.6.1)
Note: Panel layout and labeling are subject to variance due to customizing optional accessories and equipment updates.
fo о O)
QT RIBUTION PANEL
MAIN BATTERY SOLENOIDS
_ i J ENERGIZE
a 1
PC VOLTS DC AMPS
M BATTERY
> BANK ~
MONITOR DE-ENERGIZE
О О ENERGIZE
LAL POWER VENTS
FRESH WATER GUEST HEAD O EE DE-ENERGIZE
LIGHTING MASTER HEAD O LI de
LIGHTING Mp OS O Leo BLOWERS O
CU PE of | Jo
ACCESSORY ACCESSORY (O) O
o o CEN ternero
WASTE
WATER LEVEL SYSTEM CONTROL
MASTER IGNITION
FULL FULL
DO NOT FLUSH PORT
3/4
1/2 12
1 ЕМРТУ
EMPTY\ POWER N
DISCHARGE OF SEWAGE DIRECTLY
OVERBOARD IS FOR USE WHERE
D ONLY.
(25) SEE OWNER'S MANUAL 24 es)
FOR OPERATING INSTRUCTIONS
OF OVERBOARD DISCHARGE VALVES
© o ©
N 7
1. VOLTMETER DC
Indicates the amount of DC volts
being produced by the selected bank.
7.6
2. BATTERY BANK SELECTOR
PORT
STBD 12V STBD
24V 12V
POR GEN
24V 12V
BATTERY
BANK
SELECTOR
Selects which bank of batteries is
indicated on the voltmeter and
ammeter.
540 DA
3. AMMETERDC
DC AMPS
Indicates the amount of DC amps
being used from the selected bank.
4. FRESH WATER PUMP #1 24V BREAKER
of ]е
FRESH
WATER
PUMP #1
Supplies 24 volt DC power to the port
fresh water pump.
5. FRESH WATER PUMP #2 24V BREAKER
of ]е
FRESH
WATER
PUMP #1
Supplies 24 volt DC power to the
starboard fresh water pump.
6. FWD. LIGHTING 24V BREAKER
of To
FWD
LIGHTING
Supplies 24 volt DC power to guest
stateroom and guest head light
switches.
7. AFT LIGHTING 24V BREAKER
o | Ab
LIGHTING
Supplies 24 volt DC power to master
stateroom light switches.
8. BILGE LIGHTING 24V BREAKER
of ]е
BILGE
LIGHTING
Supplies 24 volt DC power to “BILGE
LIGHTS” light switches on salon
entrance way switch panel above AC
main distribution panel.
9. ACCESSORY 24V BREAKER
ACCESSORY
of ]е
For future use.
10. POWER VENTS 24V BREAKER
POWER
VENTS
of To
Supplies 24 volt DC power to power
vent switches in galley and heads.
11. GUEST HEAD
GUEST
HEAD
of ]е
Supplies 24 volt DC power to fwd/
guest head system.
12. MASTER HEAD
MASTER
HEAD
of ]е
540 DA
Supplies 24 volt DC power to master
head system and waste level indicator.
13. DISCHARGE PUMP 24V BREAKER
DISCHARGE of To
Supplies power to holding tank
discharge pump or macerator.
14. INTERCOM/PHONE SYSTEM
INTERCOM/ —
PHONE of To
SYSTEM —
Supplies 24 volt DC power to
intercom/phone.
15. ACCESSORY 24V BREAKER
ACCESSORY of ]е
For future use.
16. MAIN BATTERY SOLENOIDS: 24V Port
Battery Bank Switch
MAIN BATTERY
ENERGIZE
DE-ENERGIZE
Energizes and de-energizes the 24
volt port battery bank. The 24 volt
port battery bank is used to start the
port engine.
17. MAIN BATTERY SOLENOIDS: 24V Starboard
Battery Bank Switch
MAIN BATTERY
ENERGIZE
DE-ENERGIZE
Energizes and de-energizes the 24
volt starboard battery bank. The 24
volt starboard battery bank is used
to start the starboard engine.
18. MAIN BATTERY SOLENOIDS: 12V Port
Battery Bank Switch
MAIN BATTERY
ENERGIZE
DE-ENERGIZE
Energizes and de-energizes the 12
volt port battery bank.
19. MAIN BATTERY SOLENOIDS: 12V Starboard
Battery Bank Switch
MAIN BATTERY
ENERGIZE
a |
DE-ENERGIZE
Energizes and de-energizes the 12
volt starboard battery bank.
20. BILGE BLOWER ON/OFF SWITCH
BLOWERS
BILGE Turns the bilge blowers ON and OFF.
7.7
21. GENERATOR START/STOP SWITCH
GENERATOR
START/STOP
Starts and stops generator.
22. STARBOARD IGNITION KEY SWITCH
STBD
Master key switch for providing ignition
ower to control station ignition switch.
p g
23. PORT IGNITION KEY SWITCH
PORT
—
Master key switch for providing ignition
power to control station ignition switch.
24. WASTE SYSTEM CONTROL SWITCH
WASTE
SYSTEM CONTROL
“DISCHARGE” switch operates
macerator with holding tank
macerator option. The level indicator
indicates power to head system and
amount of waste in holding tank when
head system breaker is ON.
25. WATER LEVEL INDICATOR & SWITCH
WATER LEVEL
FULL
Displays level of water in water tank.
Pressing momentary switch supplies
power to tank indicators.
7.8
540 DA
AC System /A
A\ DANGER
EXTREME HAZARD - Swimming near a boat
operating on AC electrical system can lead to
severe shock and death. Never swim or allow
swimming when AC system is in use.
The 540 DA AC standard electrical system operates
on a 240 volt/50 amp shore power system and/or
generator with one (1) shore power cable located at
the starboard transom. An optional 240/120 volt/50
amp electrical system is available with two (2) shore
power cables located at the starboard transom (see
fig. 7.10.1 for shore power cable(s) location).
The standard and optional AC electrical system Main
Distribution Panels (MDP) are different only in the
way shore and/or generator power is supplied to the
yacht’s electrical system. Take time to look at your
yacht’s MDP and read the MDP breaker descriptions
on pages 7.13-7.15.
NOTE: ACTUAL USAGE OF EQUIPMENT WILL
DEPEND ON THE AMPERAGE OUTPUT OF THE
POWER SOURCE AVAILABLE.
Line voltage from the generator or shore power is
shown by the voltmeters on the main distribution
panel. The ammeters indicate amperes being drawn
through the selected power source’s circuit breakers
on the main distribution panel.
The main distribution panel main breakers are
equipped with a source selector slide to prevent the
generator and shore power from being energized at
the same time and damaging the electrical system.
Both breakers must be in the OFF position before
switching to an alternate power source.
Under no circumstances override the source
select system.
The 240 volt system wiring consists of four (4) color-
coded wires. The black and black/red wires are the
“hot” feeds, the white is the common, or neutral, and
the green wire is the safety ground. The shore main
circuit breakers protect the white neutral feed and
the black hot feed wires. All branch breakers and
switches for AC equipment are installed on the “hot”
wires. The green conductor of the shore power is
connected through the galvanic isolator, and then
connected to the AC grounding buss bar behind the
main distribution panel.
540 DA
Never operate 240 volt shore power at less than
205 volts.
The 120 volt wiring installed on Sea Ray® boats
consists of three (3) color-coded wires. The black
wire is the “hot” feed, white is the common, or neutral,
and the green wire is the ground. All branch breakers
and switches for AC equipment are installed on the
“hot” wire. The green conductor of the shore power
is connected through the galvanic isolator and then
connected to the AC grounding buss bar behind the
main distribution panel.
Never operate shore power at less than 105 volts.
The main breakers may trip if there is a surge in line
voltage, an electrical storm or an onboard system
overload. The main breaker interrupts both the
neutral and hot feeds in the AC circuit to prevent
equipment damage due to internal overloads and
external surges.
MAIN SHORE POWER BREAKER BOX
The 540 DA is equipped with an AC Main Shore
Power Breaker Box mounted on the inside transom
above the starboard rudder shaft. The breaker(s)
must be “ON” at all times to operate the shore AC
power system.
© 'O
AC MAIN BREAKERS
\. J
Main Shore Power Breaker Box (fig. 7.9.1)
(see fig. 2.10.1 for location)
7.9
CABLEMASTER WITH REMOTE
(Automatic Shore Power Cord
Advance/Retrieve System)
Your Sea Ray” is equipped with the Cablemaster
shore power cord system located at the starboard
transom (see fig. 7.10.1). The system will advance
and retrieve the shore power cord(s) as needed to
hook up the shore power system. The circuit breaker
is located on the DC breaker panel (see fig. 7.5.1).
To Operate:
1.
2.
Remove shore power cord cover.
Press the switch on the aft starboard transom
to the “OUT” position to advance cable to the
shore power hookup, or the “IN” position to
rewind cable for storage. This is a momentary
switch which returns automatically to the center
OFF position.
For Remote operation, leave the regular
Cablemaster switch in the center (OFF)
position.
a. By pressing the buttons on the remote unit,
you will be able to advance and retrieve the
cable. Two (2) points should be observed
when using the Cable-Control system:
There is a slight delay (approximately
700 milliseconds) between pressing
the transmitter button and operation of
the Cablemaster system. This gives
the radio transmitter and receiver time
to establish communications and for
the transmitter to provide the receiver
with the appropriate instructions.
When using the Cable-Control Radio
Control system, the regular
Cablemaster switch should be left in the
center (OFF) position. The regular
switch is still fully operational when the
Cable-Control system is not used.
REFER TO OWNERS MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
7.10
(7
Cablemaster (fig. 7.10.1)
LINE 1 LINE 1
OUT | | IN FWD STBD
== | Не РОВТ АЕТ
Е
CABLEMASTER REMOTE UNIT
LINE 2
OUT
CABLEMASTER CONTROL
SWITCH (IN/OUT)
TV AND
TELEPHONE
HOOK-UP
FRESH WATER
DOCKSIDE WATER INLET
WASHDOWN
COCKPIT
SHOWER
OPTIONAL 120 VOLT
SHORE POWER CORD
(U.S.) OR 220 VOLT
LINE 2 SHORE POWER
CORD (INT'L)
À
STANDARD 240 VOLT
(U.S.) OR 220 VOLT
LINE 1 SHORE POWER
CORD (INT'L)
540 DA
SHORE POWER HOOKUP (U.S.)
Your 540 DA 240/120 volt main distribution panel
distributes the required voltage for all the boat's AC
equipment and accessories. It is very important to
know and understand where the power originates
and how the power is distributed to the different
voltage equipment and accessories.
To access the shore power cable(s), read the
instructions on page 7.10 for “CABLE-MASTER
WITH REMOTE,” then follow these steps:
Shore power cord should be secured or routed
to avoid laying or falling into water and to avoid
stress on shore power plug and inlet.
1. Make sure the shore power breaker(s) and all
“AC” branch breakers on the AC main
distribution panel are OFF.
2. Advance shore power cord(s) to dockside power
box. Ensure dockside breaker is OFF, then plug
the dockside cord(s) into the shore power outlet
box on the dock. Turn the circuit breaker on the
dock to the ON position.
3. Check the polarity lights on the main distribution
panel. The “POWER” lights should be on. If the
“REVERSED” lights are on, have the
dockmaster check the dockside power for a
reversed connection.
Do not energize main breaker under reversed
polarity conditions.
For using the GENERATOR:
Start the generator by following the generator start-
up procedures on pages 7.19 and 7.20 or in your
generator owner's manual.
Make sure the shore power breaker(s) and all “AC”
branch breakers on the AC main distribution panel
are OFF.
Slide the source selector to the right to expose the
three (3) breakers marked “GENERATOR.” Push up
on the three breakers to energize the 240 volt side
of the AC MDP.
540 DA
SHORE POWER HOOKUP (INT’L.)
The 220 volt main distribution panel distributes the
required voltage for all the boat's AC equipment and
accessories. lt is very important to know and
understand where the power originates and how the
power is distributed to the LINE 1 and LINE 2
equipment and accessories.
Your 540 DA is equipped with 220 volt AC service.
There are two (2) shore power cables. Both are for
220 volt AC power.
By looking at the AC main distribution panel (AC
MDP), notice there is a LINE 1 and LINE 2 side for
equipment and accessories. There are two (2) ways
to supply shore power to both lines.
1. Make sure the “MAIN” shore power breaker and
all “AC” branch breakers on the main AC
distribution panel are OFF.
2. Advance shore power cord(s) to dockside power
box. Ensure dockside breaker is OFF, then plug
the dockside cord into the shore power outlet
box on the dock. Turn the circuit breaker on the
dock to the ON position.
Shore power cord should be secured or routed
to avoid laying or falling into water and to avoid
stress on shore power plug and inlet.
3. Check the polarity lights on the main distribution
panel. The “POWER?” lights should be on. If the
“REVERSED” lights are on, have the
dockmaster check the dockside power for a
reversed connection.
Do not energize main breaker under reversed
polarity conditions.
For using only one (1) of the 220 volt shore
power cables:
Follow the shore power hookup sequence above.
7.11
Take the LINE 1 220 volt cable and plug into the
proper dockside outlet. Ensure proper polarity and
slide upper source selector to the left to expose the
two (2) breakers marked “SHORE.” By pushing the
two (2) breakers up you will be supplying 220 volts
of AC power through the AC MDP to only the LINE
1 side.
To supply power to the LINE 2 side of the AC MDP,
slide the lower source selector to the right to expose
the two (2) breakers marked “TRANSFER.” Push
up on the two (2) breakers. This will take the 220
volts supplied by the LINE 1 shore power cable and
transfers 220 volts to the LINE 2 side of the AC MDP.
NOTE: KEEP IN MIND THAT UTILIZING ONLY ONE
POWER CORD WILL SEVERELY LIMIT THE
AMOUNT OF EQUIPMENT THAT CAN BE USED.
For using the two (2) 220 volt shore power
cords:
Take both 220 volt cables and plug into the proper
dockside outlets. Ensure proper polarity and slide
the upper and lower source selectors to the left to
expose the two (2) breakers marked “SHORE.” Push
up on the two (2) breakers to energize the 220 volt
LINE 1 and LINE 2 sides of the AC MDP.
For using the GENERATOR:
Start the generator by following the generator start-
up procedures on pages 7.19 and 7.20 or in your
generator owner’s manual.
Once the generator is started, slide upper source
selector to the right to expose the two (2) breakers
marked “GENERATOR” and push the two (2)
breakers up to energize LINE 1.
Slide lower source selector to the right to expose
the two (2) breakers marked “TRANSFER” and push
the two (2) breakers up to energize LINE 2.
7.12
MAINTENANCE FOR SHORE POWER
CABLE SET 8: SHORE POWER INLETS
Disconnect the power cable from power source
before performing maintenance.
The metallic parts of your cable set and inlet are
made to resist corrosion. In salt water environment,
life of the product can be increased by periodically
wiping the exposed parts with fresh water, drying
and spraying with a moisture repellent.
A soiled cable can be cleaned with grease-cutting
household detergent. A periodic application of vinyl
protector will help both ends and cable maintain their
original appearance.
In case of salt water spray or immersion: Rinse plug
end and/or connector end thoroughly in fresh water,
shake or blow out excess water and allow to dry.
Spray with a moisture repellent before reuse.
SERVICING THE
MAIN DISTRIBUTION PANEL
(Servicing should be referred to a qualified
electrician)
To replace a faulty component on the main
distribution panel:
1. Turn all breakers OFF.
2. Make sure the generator is OFF.
3. Unplug the shore power.
4
Remove screws from all sides except the hinged
side of panel. The main distribution panel is
hinged to swing open for servicing.
Reverse the procedure for closing the panel.
540 DA
AC Main Distribution Panel
Controls & Functions (U.S.)
The following main distribution panels descriptions electrical system, pay attention to descriptions #4,
are based on standard construction with the 240 volt/ 5, 6 and 21 as these are different than the standard
50 amp AC electrical system. If your 540 DA is main distribution panel.
equipped with the optional 240/120 volt/50 amp AC
Standard 240 Volt/50 Amp Main Distribution Panel (U.S. Version) (fig. 7.13.1)
Note: Panel layout and labeling are subject to variance due to customizing optional accessories and equipment updates.
fo o 0)
REVERSED
POWE OLARITY
L | Г ||
ON FOR ON FOR 240V
GENERATOR SHORE
CONNECTION CONNECTION ,
= В
о o 240V o o 120V o
A/C WATER MASTER
o STOVE e E GALLEY STATEROOM
RELAY
MICROWAVE
GUEST
STATEROOM
REFRIGERATOR SALON
WATER
(2— ET]; HEATER A/C UNIT #1
PORT
O Block Heater AC UNIT #2
WASHER/ BILGE/
DRYER COCKPIT
о о
ME | 1 STBD
o 14) a O block Heater AC UNIT #3
ga EDS ACCESSORY ACCESSORY
С | |] O | ACCESSORY ACCESSORY
© A
o 120V o
CONVERTER COCKPIT
(24V) ICE MAKER
GENERATOR INDIRECT
CONVERTER LIGHTING
(12V)
BOW THRUSTER
CONVERTER ACCESSORY
GANG PLANK ACCESSORY
о о
о
\© o o
Optional 240/120 Volt/50 Amp Main Distribution Panel (U.S. Version) (fig. 7.13.2)
Note: Panel layout and labeling are subject to variance due to customizing optional accessories and equipment updates.
Го о о о о 0)
REVERSED
POWER POLARITY pr po PR Leon,
I à 1 À masi
| | | | и dt af И м) 3
ON FOR ON FOR 240V AC AMPS 120VAC AC AMPS
GENERATOR SHORE
CONNECTION CONNECTION
o 20 > o 120 o
Y TY | MASTER
o of [Ye | ee fees lo | Yo of | || sme siti o
—— RELAY = —_—
GUEST
e] HB © | microwave STE
о [Ie des AUNT#H | © [Ie о [|] O |REFRIGERATOR SALON
Y WASHER/ BILGE/
MAIN DISTRIBUTION PANEL oll | o| E acen
REVERSED FT E
POWER POLARITY o [|] o) Lock HEATER мс умт 2 | © [|] o o o
| | |
4 ON FOR GENERATOR OR ON FOR 120V 6
240V (ONLY SHORE SHORE — ство —
о CONNECTION) CONNECTION o [|] о bros Borg Аб МТ в | © [|] о о 120V о о
Be — = "ann =
CONVERTER COCKPIT
(24V) ICE MAKER
GENERATOR INDIRECT
ee о [Ie ACCESSORY A/CUNIT# | O EE CONVERTER LIGHTING
BOW THRUSTER
| CONVERTER ACCESSORY,
OFF FOR: ——Ñ == 24V
120V SINGLE SHORE, 120V/240V DUAL O [|] © | ACCESSORY ACCESSORY о [|] O GANG PLANK ACCESSORY
SHORE CONNECTION OR GENERATOR —— ———
WITH 120 SINGLE SHORE CONNECTION o o o o
\© o o o o o)
540 DA 7.13
1. (U.S.) GENERATOR MAIN BREAKER
ON FOR GENERATOR
CONNECTION
==
E)
E)
EJ
w/15KW GENERATOR: 240V/70
amp BREAKER
Power source selection. Supplies
power to 240 volt branch breakers
on main distribution panel from
generator.
2. (U.S.) POWER/REVERSEDPOLARITY
REVERSED
POWER POLARITY
— C1
INDICATOR LIGHTS
Indicates wiring connections condition
for 240 volt main shore power system.
When shore power connection is
correct, the “POWER?” light will be lit.
3. (U.S.) SHORE POWER MAIN BREAKER
ON FOR 240V
SHORE CONNECTION
Е
240V BREAKER
Power source selection. Supplies
power to 240 volt branch breakers
on main distribution panel from shore
power.
4. OPTIONAL (U.S.) TRANSFER BREAKER
ON FOR GENERATOR OR
240V (ONLY SHORE
CONNECTION)
Ë
Power source selection. Supplies
power to120 volt branch breakers on
main distribution panel from either
240 volt shore power or generator.
5. OPTIONAL (U.S.) POWER REVERSED
REVERSED
POWER POLARITY
E a
POLARITY INDICATOR LIGHTS
Indicates wiring connections condition
for120 volt main shore power system.
When shore power connection is
correct, the “POWER” light will be lit.
6. OPTIONAL (U.S.) 120 VOLT MAIN BREAKER
ON FOR 120V
SHORE CONNECTION
Е
120V breaker
Power source selection. Supplies
power to120 volt branch breakers on
main distribution panel from shore
power.
7. (U.S. AC VOLTMETER
Indicates the 240 volt AC power
source voltage.
8. (U.S.) AC AMMETER
AC AMPS
7.14
Indicates the amount of 240 volt
amperage being used by the
equipment that is energized on 240
volt branch breakers and 120 volt
branch breakers if transfer breaker is
energized.
9. (U.S.)AC VOLTMETER
120VAC
Indicates the 120 volt AC power source
voltage.
10. (U.S.) AC AMMETER
AC AMPS
Indicates the amount of 120 volt
amperage being used by the
equipment that is energized for 120
volt shore power.
11. (U.S.) STOVE 240V BREAKER
oT J
STOVE
Supplies 240 volt AC power to the
stove.
12. (U.S.) WATER HEATER 240V BREAKER
oT J
WATER
HEATER
Turns on hot water heater. WATER
HEATER MUST BE FULL OF
WATER.
13. (U.S.) PORT BLOCK HEATER
of ]е
PORT
BLOCK
HEATER
Supplies 240 volt AC power to the port
engine block heater.
14. (U.S.) STARBOARD BLOCK HEATER
of Je
STBD
BLOCK
HEATER
Supplies 240 volt AC power to the
starboard engine block heater.
15. (U.S.) ACCESSORY 240V BREAKER
of To
ACCESSORY
For future use.
16. (U.S.) ACCESSORY 240V BREAKER
of o
ACCESSORY
For future use.
17. (U.S.) A/C WATER PUMP & RELAY
A/C WATER
PUMP & RELAY
of ]е
240V BREAKER
Turns on air conditioner raw water
cooling pump and relay to cycle water
pump on and off with air conditioner
compressors. It must be ON when any
A/C unit is on.
18. (U.S.) A/C UNIT #1
A/CUNIT #1
oT J
Supplies 240 volt AC power to the
guest stateroom A/C unit.
19. (U.S.) A/C UNIT #2
A/C UNIT #2
oT J
Supplies 240 volt AC power to the
salon A/C unit.
20. (U.S.) A/C UNIT #3
A/CUNIT #3
oT J
Supplies 240 volt AC power to the
master stateroom A/C unit.
540 DA
21. (U.S.) ACCESSORY 240V BREAKER
ACCESSORY
of To
Standard MDP accessory. Optional
cockpit A/C unit.
22. (U.S.) ACCESSORY 240V BREAKER
ACCESSORY
oT J
For future use.
23. (U.S.) GALLEY 120V BREAKER
of ]е
GALLEY
Supplies power to 120 volt galley
equipment and light switch.
24. (U.S.) MICROWAVE 120V BREAKER
of To
MICROWAVE
Supplies 120 volt AC power to
microwave.
25. (U.S.) REFRIGERATOR 120V BREAKER
oT J
REFRIGERATOR
Supplies 120 volt AC power to the
galley refrigerator/freezer.
26. (U.S.) WASHER/DRYER 120V BREAKER
oT J
WASHER/
DRYER
(Optional)
Supplies 120 volt AC power to clothes
washer and dryer unit.
27. (U.S.) CONVERTER (24V) 120V BREAKER
of ]е
CONVERTER
(24V)
Turns on the main batteries 120V AC
to 24V DC converter.
28. (U.S.) GENERATOR CONVERTER
of TJ
GENERATOR
CONVERTER
(12v)
(12V) 120V breaker
Turns on the generator battery 120V
AC to 12V DC converter.
29. (U.S.) BOW THRUSTER CONVERTER (24V)
of ]е
BOW
THRUSTER
CONVERTER
(24V)
120V BREAKER (Optional)
Supplies 120 volt AC power to the bow
thruster converter.
30. (U.S.) GANG PLANK120V BREAKER
of ]е
GANG PLANK
(Optional)
Supplies power to gang plank switch.
31. (U.S.) MSTR STATEROOM 120V BREAKER
MASTER
STATEROOM
oT J
Supplies 120 volt AC power to master
stateroom, TV, light switch,
receptacle, head light switch, and
receptacle.
32. (U.S.) GUEST STATEROOM 120V
GUEST/
DINETTE
of ]е
540 DA
BREAKER
Supplies 120 volt AC power to guest
stateroom, TV, light switch,
receptacle, and head receptacle.
33. (U.S.) SALON 120V BREAKER
SALON
of To
Supplies 120 volt AC power to
receptacie on entertainment center,
120 volt salon lights and receptacles
above sofa.
34. (U.S.) BILGE/COCKPIT 120V BREAKER
BILGE/
COCKPIT
of ]е
Supplies 120 volt AC power to the
cockpit and bilge receptacles.
35. (U.S.) COCKPIT ICE MAKER 120V
COCKPIT
ICE MAKER
of ]е
BREAKER
Supplies 120 volt AC power to the
cockpit ice maker and optional
refrigerator.
36. (U.S.) INDIRECT LIGHTING 120V
INDIRECT
LIGHTING
o
[ Je
BREAKER
Plugged.
37. (U.S.) ACCESSORY 120V BREAKER
ACCESSORY
of To
For future use.
38. (U.S.) ACCESSORY 120V BREAKER
ACCESSORY
of To
For future use.
7.15
AC Main Distribution
Controls & Functions (Int’l.)
NOTE: The following main distribution panel
descriptions are based on standard construction with
the 220 volt AC system. The main distribution panel
in your yacht will be equipped with the appropriate
AC voltage breakers and meters.
220 Volt Main Distribution Panel (International Version) (fig. 7.16.1)
Note: Panel layout and labeling are subject to variance due to customizing optional accessories and equipment updates.
(o о о
REVERSED
ON FOR
ON FOR SHORE #1
DMA GENERATOR (3)
CONNECTION
o
LINE 1
o
GALLEY
KR
|
|
REFRIG.
MICROWAVE
PORT
BLOCK
HEATER
STBD
BLOCK
HEATER
ON FOR GENERATOR ON FOR
OR SHORE #1 SHORE #2
ONLY
—
Ho
HEE
о CONNECTION [
SALON
MASTER
STATEROOM
A/C WATER
PUMP & RELAY
A/C UNIT #1
A/C UNIT #2
LINE 2 — ~
ACCESSORY ACCESSORY | | CONVERTER ACCESSORY
| À (24V)
| ACCESSORY ACCESSORY | ||| À ME ACCESSORY ACCESSORY [ | ©
M LU LL Y
OFF FOR: o o o o
SINGLE SHORE, DUAL SHORE
CONNECTION OR GENERATOR
WITH 1SHORE CONNECTION
e o o 9,
LINE 2
о о
7
\
[
B
FWD
STOVE STATEROOM
N
Wu
|
|
WASHER/ BILGE/COCKPIT
DRYER
A/C UNIT:3 GANG PLANK
WATER CONVERTER
GENERATOR
CONVERTER OT
(12V)
BOW THRUSTER
AH
| || N
co
HEE
LA
“E
Le
LL
LL
1. (Int) LINE 1 / GENERATOR MAIN BREAKER
w/15KW GENERATOR: 220V/70
amp BREAKER
0 Power source selection. Supplies
— power to 220 volt branch breakers on
main distribution panel from generator.
ON FOR GENERATOR
CONNECTION
2. LINE 1 POWER/REVERSED POLARITY
——— INDICATOR LIGHTS
Г г Indicates wiring connections condition
for 220 volt main shore power
system. When shore power connection is
correct, the “POWER” light will be lit.
3. (Intl) LINE 1 / SHORE POWER MAIN BREAKER
ON FOR 220V BREAKER
— Power source selection. Supplies
DO power to line 1 220 volt branch
breakers on main distribution panel
from shore power.
7.16
4.
5.
(Int'l) TRANSFER BREAKER 2
ON FOR GENERATOR POLE BREAKER
OR SHORE #1
ONLY
Power source selection. Supplies
power to 220 volt branch breakers on
main distribution panel from either
line 1 220 volt shore power or
generator.
LINE 2 POWER/REVERSED
me] POLARITY INDICATOR LIGHTS
POWER POLARITY
es cc | Indicates wiring connections condition
for 220 volt main shore power system.
When shore power connection is correct, the
“POWER” light will be lit.
(Int!) LINE 2 / SHORE POWER MAIN
Ton BREAKER 220V BREAKER
— Power source selection. Supplies
LL powerto 220 volt branch breakers on
main distribution panel from line 2
shore power.
540 DA
7. (Intl) AC VOLTMETER
Indicates the 220 volt AC power
source voltage on line 1.
8. (Intl) AC AMMETER
Indicates the amount of 220 volt
amperage being used by the
equipment that is energized on line 1.
9. (Intl) AC VOLTMETER
Indicates the 220 volt AC power
source voltage on line 2.
10. (Intl) AC AMMETER
Indicates the amount of 220 volt
amperage being used by the
equipment that is energized on line 2.
11. (Intl) GALLEY 220V BREAKER
a. Supplies power to 220 volt galley
o LL Jo | сигн equipment and light switch.
12. (Int'l) REFRIGERATOR 220V BREAKER
Supplies power to the refrigerator.
o ET REFRIGERATOR
13. (Int) MICROWAVE 220V BREAKER
Supplies power to the microwave.
oT J MICROWAVE
14. (Intl) PORT BLOCK HEATER 220V
BREAKER
EL | ss Supplies power to the port engine
block heater.
15. (Intl) STARBOARD BLOCK HEATER
220V BREAKER
Le | e Supplies power to the starboard
engine block heater.
16. (Intl) ACCESSORY 220V BREAKER
o LJ ACCESSORY For future use.
17. (Int'l) ACCESSORY 220V BREAKER
ST | sessson For future use.
540 DA
18. (Intl) SALON 220V BREAKER
— | Supplies 220 volt AC power to
savon | o Lo receptacle on entertainment center,
220 volt salon lights, and outlets
above aft sofa.
19. (Int'l) MASTER STATEROOM 220V BREAKER
Supplies 220 volt AC power to master
satéteoml E L| stateroom, TV, light switch, receptacle,
head light switch, and receptacie.
20. (Intl) A/C WATER PUMP & RELAY
220V BREAKER
A/CWATER nn . ia
FRELAY EL Turns on air conditioner raw water
cooling pump and relay to cycle water
pump on and off with air conditioner
compressors. It must be ON when any A/C unit
is on.
21. (Int’l) A/C UNIT #1 220V BREAKER
—— | Supplies 220 volt AC power to the
коня | [СТ guest stateroom A/C unit.
22. (Intl) A/C UNIT #2 220V BREAKER
Supplies 220 volt AC power to the
A/C UNIT #2 oT J salon A/C unit.
23. (Intl) ACCESSORY 220V BREAKER
For future use.
ACCESSORY | © ET
24. (Intl) ACCESSORY 220V BREAKER
For future use.
ACCESSORY | o СТ
25. (Intl) STOVE 220V BREAKER
Supplies power to the stove.
o СТ STOVE
26. (Int'l) WASHER DRYER 220V BREAKER
— кн | SUPPlies 220 volt AC power to
¿CLP (vs washing machine/dryer unit.
27. (Intl) A/C UNIT #3 220V BREAKER
_ Supplies 220 volt AC power to the
[СТ | «сочтя master stateroom A/C unit.
28. (Intl) WATER HEATER 220V BREAKER
> | wma | [ums on hot water heater. WATER
LL) 2% |HEATER MUST BE FULL OF
WATER.
7.17
29. (Int'l) GENERATOR CONVERTER (12V) 220V
о O | CONVERTER
= = (12V)
BREAKER
Turns on the main batteries 220V AC to
12V DC converter.
30. (Intl) BOW THRUSTER CONVERTER (24V)
=== BOW
THRUSTER
off | e CONVERTER
(24V)
220V BREAKER (Optional)
Supplies 220 volt AC power to the bow
thruster converter.
31. (Int'l) ACCESSORY 220V BREAKER
o [| e ACCESSORY
For future use.
32. (Intl) FWD STATEROOM 220V BREAKER
INDIRECT
LIGHTING
LJ
Supplies 220 volt AC power to fwd
stateroom, TV, light switch,
receptacle, and head receptacle.
33. (Intl) BILGE/COCKPIT 220V BREAKER
GUES
STATEROOM
Supplies 220 volt AC power to cockpit
and bilge receptacles.
34. (Int'l) GANG PLANK 220V BREAKER
COCKPIT/
BILGE
LI
Supplies power to gang plank switch.
35. (Intl) CONVERTER (24V) 220V BREAKER
CREWS
QUARTERS
LI
Turns on the main batteries 220V AC to
24V DC converter.
36. (Int'l) COCKPIT ICE MAKER 220V BREAKER
DAVIT
LLP
Supplies 220V AC power to the cockpit
ice maker and optional refrigerator.
37. (Int'l) ACCESSORY 220V BREAKER
ACCESSORY
LLP
For future use.
38. (Intl) ACCESSORY 220V BREAKER
ACCESSORY
off | Je
7.18
For future use.
Converters
The battery charging unit installed on your yacht is
fully automatic and is designed specifically for the
marine environment. The high frequency characteristic
has allowed these chargers to achieve a huge size
and weight reduction over their previously used
equipment. Commonly called high frequency or smart
chargers, these units bring a new sophistication to
the battery charger field. These units feature a built-
in amperage indicator located on the front panel. This
gives an accurate reading of the combined battery
current and load current. If the batteries are fully
charged and no load is present, the ammeter will
read near zero. To verify that the charger is functioning
properly, turn on lights or other load. The ammeter
should register an increase.
Converter (fig. 7.18.1)
Never block air circulation through the unit.
Never store any gear on top of the units.
NOTICE
| Leave the converter running at all times to |
maintain the 12 volt system voltage.
Charging characteristics contain three (3) elements:
* Bulk Charge - this is initiated at power up and
provides the chargers full-rated current to the battery
bank until a predetermined voltage level of 14.2V to
14.4V is achieved and/or a certain time has passed.
540 DA
Absorption Charge - this stage immediately
follows the bulk charge mode. It maintains the battery
voltage at the bulk charge voltage level, but gradually
decreases the current as the battery accepts the
charge until it reaches a predetermined current level.
* Float Charge - this stage is designed to hold the
battery at a safe, low voltage (typically 13.3V)
providing up to the chargers full rated amperage to
accommodate DC load requirements. The charge will
remain in this mode until the AC power is cycled off
and then on again.
Location - The converter is located on the starboard
aft side of the aft engineroom bulkhead.
REFER TO OWNERS MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Ground Fault Interrupter
Receptacle
The ground fault interrupter receptacles (GFI) are
located in the aft galley inside the upper cabinet, master
head lower storage cabinet under the sink, guest head
upper cabinet, and mid salon upper cabinet. The GF
receptacles are out of sight and wired in-line with the
exposed Vmar receptacles throughout the yacht. This
allows your yacht to have an elegant exposed receptacle
while still providing some protection from shock hazards.
Please read and understand the CAUTION block for
GF receptacles.
The GF receptacle is designed to protect people from
the line-to-ground shock hazards which could occur from
defective power tools or appliances operating from this
device, or from down-line outlets protected by it. It
does not prevent line to ground electric shock, but does
limit the time of exposure to a period considered safe
for normally healthy persons. It does not protect persons
against line-to-line or line-to-neutral faults.
The GFI receptacle does not protect against short
circuits or overloads. This is the function of the circuit
breaker.
540 DA
Persons with heart problems or other conditions
which make them susceptible to electric shock
may still be injured by ground faults on circuits
protected by the GFI receptacle. No safety
devices yet designed will protect against all
hazards or carelessly handled or misused
electrical equipment or wiring.
GFI Outlet (fig. 7.19.1)
7.19
Generator
Sea Ray® strongly urges you to fully comply with
the manual provided by the generator manufacturer.
The generator is warranted separately by the
generator manufacturer, not Sea Ray®. Follow the
recommended maintenance and warranty schedule
in your Generator Operator's Manual included in the
Owner's Manual Packet. Generator abuse or improper
maintenance may adversely affect claims made
under generator manufacturer separate warranty.
Do not run the generator or engines in an enclosed
area, such as a closed boat house, as there is
the possibility of inhaling exhaust fumes and the
build up of carbon monoxide (see Exhaust
Emissions pgs. 1.12 and 1.13).
f NN
Generator Controls On Main
Distribution Panel (fig. 7.20.1)
CE СЕМЕВАТОВ
START/STOP
\_ J
a NN
Generator Cockpit Instrument Panel
(fig. 7.20.2)
7.20
STARTING THE GENERATOR
NOTE: PRE-START GENERATOR PRIOR TO
GETTING UNDERWAY AS THERE IS A
POSSIBILITY THAT IT WILL NOT PICK UP
WATER IF STARTED UNDERWAY. MAKE SURE
THE “MAIN GENERATOR” BREAKERS ARE
“OFF” AND THERE IS NO LOAD ON THE
GENERATOR BEFORE STARTING IT.
To start the generator: (Switches located on the
24 volt distribution panel or on the generator set.)
1. Check the fuel tank levels. The generator draws
from the starboard fuel tank.
2. Check the oil and coolant levels. See your
Generator Operator's Manual for proper readings.
3. Check generator for coolant drain plug
installations.
4. Open the generator seacock.
5. Press and release the “GENERATOR” switch on
the main distribution panel. This puts the
generator into the preheat mode and the light in
the switch will begin to flash for approximately
30 seconds. The generator can be started at
any time during this period.
At the end of the 30 second period, the light
begins to flash rapidly, indicating that the
generator must be started in the next few
seconds or the cycle must be repeated.
6. When the light on the switch begins to flash
rapidly, the generator is ready to start. Push
and hold the “GENERATOR” switch until the unit
starts, then release the switch.
7. Once the generator is started, the light will stay
on continuously.
Bypass Switch
To start the Westerbeke® generator from the generator
mounted controls, a bypass switch, located on the
side of the generator mounted control box, must be
turned ON. The bypass switch must be OFF to start
and stop the generator from the DC main distribution
panel.
540 DA
SHIFTING FROM SHORE POWER TO
GENERATOR POWER
1. Turn all AC systems and branch circuit breakers
OFF. Turn main breaker on the main distribution
panel to the OFF position.
2. Startthe generator.
3. Slide the source select shuttle mechanisms on
the main distribution panel to expose the
“GENERATOR” breakers and turn them ON, (see
fig. 7.13.1, #1 on the main AC distribution panel).
4. Turn the individual system breakers ON.
STOPPING THE GENERATOR
1. Press the “GENERATOR” switch until the unit
stops.
After stopping the generator, the module will need
a few seconds to reset before restarting is
possible.
Electrolysis & Zinc Anodes
Electrolysis corrosion of metals on power boats can
result in serious deterioration. The boat owner must be
aware of the possibilities of galvanic action (the
deterioration of metals due to dissimilar characteristics
when placed in salt water), and/or electrolysis. It is the
owners responsibility to check for and replace damaged
parts due to galvanic deterioration. Refer to your Sea
Ray* dealer to investigate the source of stray corrosive
currents.
Zinc plates are installed on the transom and trim tabs
to protect underwater hardware. Zinc, being much less
“noble” than copper based alloys and aluminum usedin
Sea Ray® underwater fittings, will deteriorate first and
protect the more noble parts.
Zinc anodes generally require replacement about
once a year. (In salt water areas, replace every six
(6) months). The need to replace anodes more
frequently may indicate a stray current problem within
the boat or at the slip or mooring. If zinc anodes do not
need replacing after one year, they may not be providing
proper protection. Loose anodes or low-grade zinc may
be the problem.
DO NOT PAINT BETWEEN THE ZINC AND THE
METAL IT CONTACTS, AND DO NOT PAINT OVER
THE ZINC.
540 DA
When an AC shore power system is connected to the
boat, the underwater metal fittings will, in effect, be
connected through the water to grounded metals ashore.
The zincs will be consumed at a faster rate unless the
marina maintains a protective system to prevent this.
In this case, hanging a zinc in the water bonded to the
metal outlet box on the dock will reduce zinc loss on
the boat. Do not connect this zinc to the boat’s ground
system.
It is extremely important that all electrically operated
DC equipment and accessories be wired so that the
Never disconnect AC green wire (safety ground)
from the main DC ground buss. Removing safety
ground wire would create the possibility for
electrical shock hazard.
ground polarity of each device is the same as that of
the battery. Sea Ray® boats have a negative ground
system, which is the recommended practice throughout
the marine industry. All metal items (fuel tanks,
underwater gear, etc.) in the boat are connected to the
zinc anode by the green bonding wire.
Electrolysis can also be caused by “stray currents” due
to a fault in an electrical item, even though correctly
grounded. A galvanic current blocker (zinc saver) is
standard on all Sea Ray® boats. It is installed between
the shore power ground and the boat's AC ground
connection to the DC bonding system. This connection
maintains the safety ground from dockside power while
stopping the back-flow of DC corrosive currents.
AC & DC Electrical Schematics
This owner's manual contains electrical schematics
for your boat. These electrical schematics were
generated by technicians at the engineering division
for technical reference and service technicians. Sea
Ray® does not recommend that you attempt to work
on the boat's electrical system yourself. Instead we
recommend that you take your boat to your authorized
Sea Ray” dealer for service. Sea Ray* reserves the
right to change or update the electrical system on
any model at any time without notice to the consumer
and is NOT obligated to make any updates to units
built prior to changes.
7.21
540 Sundancer: DC Wiring Schematic 09-601 (1 of 6)
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
BUSS BAR
| fo PLUG 47
| REF SHEET 2
( D TRIM TABS <10— 14 RED/VIO ——t>|1 | [A A A] PLUG 49
INSTRUMENT PANEL 14 RED/VIO ——>|2 Г REF SHEET 2
ENG SYNC | K7> | 14 GRY > 13
REFERENCE 14-809 | 4 RED/VIO — Sa Sd
NAV LIGHTS | K10> 14 RED/VIO ——> 15 O O
14 RED/VIO ——->|6
> 18D PORT LIGHTS | 75 14 RED/VIO—>| 7 | | |
7 NU la RED/VIO—>|8 4 | | N |
VOLT FUEL voLT FUEL ACCY IE xx М4 ВЕО/МЮ — — > | 9 EL | .
NN (DO _ LAMPS CAP 16
! +“ |
TT SPOT LIGHT |[“7 CAP 48 | REF SHEET 4
e | HORN |
| HORN = 10 RED/VIO | 10 RED/VIO NL... | | 16 ORN/BLK 213—<!
Ne - 14 ORN/RED 2 14 ORN/RED Low — 6 ORN/RED 239 —<|2
PORT WIPER | F5 > 14 ORN/GRN 3 14 ORN/GRN — |
| 4 14 RED/VIO 312, 1 PARK | 16 ORN 240 —<|3
| TED WIPER IZ 14 RED7 VIO a PORT WIPER | 16 RED/VIO 241 —<|*
ВЕ > PLUG 48 | 6] 5] 4 |6 ORN/GRN 242 —<[5
VENT Low 16 RED/VIO 244 —<|
TROLLING | Leis PARK — 16 RED/VIO 243 —<|$
| STBD WIPE > 2 | 6 BLK/RED 245 —<| 3
м Эээ ACCY | 00 | | ts — 16 BLK/RED 246 —+ 10
som м 61 S] 4 i
D DO >= — 10 RED/VIO 214 |
9 we а ACCY | Xx» HIGH | —<| 2
DX
vos — wNDSHELO | 7 |
| 6 © © © TT ACCY | xy > CONTROL STATION MAIN WASHER —
TM TESTO y
сч BREAKER PANEL | WINDSHIELD VENT u
n € cIAAAAAA] O REF DWG 14-804 DD | 6” 5[ 7
VO PR OH NOs CO |
= тот ACCESSORY
ОО Ван, ~ BUSS BAR SWITCH PANEL
= | |
un
>
un
09-601, 1 of 6, Revision 01
Na J
540 DA 7.23
То 4
G0 uoIsiney ‘9 JO ¢ ‘109-60
o LS WE WY ew es твоею ся чвотз мрочв отр WP TM чи чт очи MN ED HR TP AR че UE чо чи чо мо окт отв WR EW YP YW EW WR Er We WR A ото We We Ne E
109uepuns 0vS
va 07S
1 4
' 6
i 1
1 |
4 6
| ( > ‘4
' PORT SLOW — ;
1 i
E
I '
VESSEL A0
1
t '
t САР РТ !
16 VIO 1
meras [Е 6ем 200 6 8LK —7<|2 HARNESS. |
2 | €4—16 PNK/BLK 202 16 BLU 3 |
4 J
1 PANEL PLUGIO y ¿| py 4 EF SHEETS
\ REF SHEET I OR 3 NOTE |
4 |<7— 16 8LK + —— 16 YEL/RED 5
' 5|<+— 16 VIO PNL GND 16 BLK/RED 6
6 | <— 16 VIO 16 BLK/ 16 BRN IPI 7
‘ JUMPER 16 YEL IP2 8 ;
PORT IGN STOP 6
EMER Peas | — 16 ORN/BLK q 16 YEL/RED!
PLUG | 1 16 PINK 200 STOP Î CUT AND |
pots HARNESS 2 PINK/BLK 202 PORT ‚см САР 52 PLUG 52 EXTEND
REF SHEET 4 RED/VIO 207 | | A 16 YEL/RED IE — 1) ТО МЕЦ *
4 BRN 322 | EMERGENCY я — 16 YEL/RED 21€ T SAFTEY ©
' 5 BRN 328 ———— | START | 16 YEL/RED 3|<T—— „SWITCH |
' 6 RED/VIO 223 | — 16 YEL/RED 4|< W/BV32TA |
STBD IGN /% — OPTION |
7 RED/VIO 224 + 16 BLK/RED
| 8 VIO 239 STBD IGN STOP__} + JUMPER CAP P8 |
q VIO 240 EMER STOP| 7% STOP 16 BLK US/METRIC 1 PORT ENG |!
' è 16 GRY SCROLL FWD 2 HARNESS |
| 14 BLK + 16 GRY/RED SCROLL BKWD 3 REF SHEET 5!
] 2 14 BLU 2022 NOTE |
' PLUGS 3 14 VIO 2023 — \
| REF 09-610 4 14 RED/VIO 20255 — ENGINE. SYNCH CAPP8 |
| 5 14 VIO 2024 I 16 BLK US/METRIC l STBDENG |
6 14 RED/VIO 20259 ——— 3 < 16 GRY SCROLL FWD —1<|2 HARNESS — |
— |] 16 GRY/RED SCROLL BKWD 3 REF SHEET 5,
! L 4 NOTE | |
\ — 2 16 VIO ! CAPPT
| 14 СВУ 255 psc qu 16 BLK 2 STBD ENG
1 2 14 GRY 256 2 | 16 BLU 3 HARNESS rs
|
CAP 2 3 MBLUSIE —— — —— S SCROLL L_—— 16 YEL/RED 5 NOTE |
ı REF SHEET 4 4 14 GRN 519 — Е 2 16 BLK/RED 6
1
5 10 RED/ VIO 520 — J > 16 BRN IP} 7 |
6 PUS/METRIC 16 YEL IP2 8
S US/METRIC 16 ORN/BLK q
i 1
FWD LA | !
' + — '
SEE DETAIL A BILGE PUMPS aD 52 Te > CAP 22
FOR OPTIONAL | |
TWN DISC TROLL “Ta | € RED 40с — [< hañness |
| BLOWERS —
E SWITCH WIRING В N — L 16 BLK/RED 232—]<|5 MEF SHEET 4
—— 16 BLK/RED 233—<l6
16 BLK 234—<| 7
16 BLK 235—1<|8
CAP 47 Ш PANEL GROUND € 14 BLK 137—<[9 !
REF SHEET | enano ono, - —— |6 ВК 42С e 18 '
- = ] 7 = чот тот тот тот ож = = от он = = = = = = = = = = serpent cern 1 i 1
1 [> 14 RED/vio < E и
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т 16 VIO 349 <l13
3|>4— 14 GRY 1 LA 16 Vio 350 —]<|14 '
4| >1—14 RED/VIO RUNNING | ! Klis
| NAVIGATION ti sss seme 3
: <I = vo LIGHTS | lL 14 RED/VIO 5010 1
21ST ia nen, ANCHOR [—_ 14 GRY/WHT 261 2 Mei
ED/ VIO SPOILER 14 GRY/RED 262 3 COCKPIT
8|>+ 14 RED/VIO PLZ 4 y ARNESS
9127 14 RED/vIO | 16 BLU 646 5 REF SHEET 4
COCKPIT ~~ | — 14 RED/VIO 648 6
SPOT LIGHT 7 16 BLU 664 7
1 16 GRN 6012 8
| 16 WHT 6013 q
PLEASURE LOK
10 RED/VIO 596 —€—— SYSTEM
14 WHT /BLU 585 —<| 1
14 WHT/BLU 586—<l2 Lass
14 RED 588 Зи ARNESE
14 RED/VIO 587 4 REF SHEET 4
5
6
CAP 50 PLUG 50
<|1[<-—16 reo/vi0 ELECTRONICS _ T-—
< | 2] €4—16 RED/VIO e 14 WHT/BLU 288GP 1
< |3|<+ 10 RED/VIO AUTOPILOT 7. MEN EILANE CT Gé 14 WHT/BLU 289GP 2 CAP1O7
<la| < +—16 REO/VIO SWITCH 8 14 RED 290GP—4<|3 GANGPLANK
< |5| €t+—16 RED/VIO 14 RED/VIO 291GP —<|a HARNESS
< | 6] €H—10 RED/vIO 14 BLK 2996P—|<|5 REF 09-623
ACCESSORY ~_ 6
c ce AECESSORY 7 TRIM TAB | AL ori se
5 F se « SWITCH 14 RED 546 >|1 PLUG 26
Za В 538 T 14 YEL 548 >|3 HARNESS
8 8 В 8 5 CONSOLE yp DOWN 14 BLU 549 >|4 REF SHEET 4
3 3 3 SER DIMMER a. TRIM TAB SW HARNESS REF 09-884
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333 _f
1 | a DIMMER [—I6ORN
TO 12VDC CONTROL|—16 WHT
ELECTRONICS
FUSE BLOCK —16 GRN
|
— NTROL STATION
| RED Lt BLU EROUR BOSS
——— er x re — = = = — — U—+16 GRY TO I2VDC ACCESSORY
Г DETAIL A |] hieBLK POSE BLOCK 14 RÉD/VIO
OPT TWIN DISC TROLL >
SYSTEM HARNESS IS | INVERTOR [ RECebT ef
| SUPPLIED BY TWIN |
| DISC W/CONTROL pop, | 14
| jou | cRuisE | EL LAMPS
TROLL
| WHT | . PLUG
| RED | SEE || REP Dee PANEL BON THRUSTER 14 WHT/ELU 284 2 once
| | \, 14-802 SWITCH 14 RED 285 3 HARNESS
ha = == = == = — = = = — = — = — 14 REO/VIO 286 4 REF SHEET 4
NOTES: 14 BLK 287 5
1) PORT ENG HRNS CONNECTORS TO BE IDENTIFIED WITH RED HEATSHRINK, AVAVAN [URL 6
STBD ENG HRNS CONNECTORS TO BE IDENTIFIED WITH GREEN HEATSHRINK. 341
2) SWITCH INDICATOR GROUNDS ARE TO BE WIRED TO THE PANEL GROUND CIRCUIT, REE
3) REF SHEET 6 FOR DETROIT 8V92TA ,THIS SECTION OF PANEL WIRING CHANGES. (CAT ENGINES)
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540 Sundancer: DC Wiring Schematic 09-601 (3 of 6)
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
= 16 BLU —< | 4
IL PR R — — CAP 54
OIL PRESSURE | 16 TAN — (2 REF pc
| - 16 GRY —< {3 09-864
WATER TEMP + * - 10 BLK —1< | 4
PORT
TACHOMETER \_}
FUEL UE
VOLT GE — — 16 BLU — COMPA
le BLK ОАО
14 BLU —SYSTEMS MONITOR
REF DWG 09-606
— \6 BLU —1< | CAP E3
OIL PRESSURE — 16 TAN—<|2 REF DWG
STBD | — 6 GRY —< |3 09-864
WATER TEMP + | | 10 В.К — < | 4
TACHOMETER U ES
FUEL \ |
| - x XxX XX
VOLT D а @
N uo
=> 5 = 88
INSTRUMENT PANEL a ad € x
Lu. ww
REFERENCE 14-800 HEE CAPI
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1234586
09-601, 3 of 6, Revision 01
540 DA 7.25
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PLUGIT
BILGE HARNESS
R A owe КЁ око REF 09-604
PLUG 18
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NOID REF 09-604
90:5 078 pi
034
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265 NU9 Y
65 Di Y
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PLUG 38 566 10 YEL COCKPIT STEREO MEMORY
7
mcr ved {= noo
REF 09-604
PLUG 60 54 14 BLK
EXTINGUISHER | 16 RED
2 16 YEL 227 MAIN DC GROUND BUSS
OVERRIDE 3 16 BLK CHANGE PUMP
CAP | BULGE
HARNESS ! 6 PK FVD OC
REF SHEET 2 2 16 PNK/BLK PUMP
3 10 RED/VIO 207 sux—
4 10 BAN 322 GROUND BUSS
: lO BAN 128 MAIN OC GROUND BUSS
6 10 RED/VIO MAIN OC
’ 10 RED/VIO GROUND BUSS GROUND BUSS
8 14 VIO 239
q 14 VIO 240
PLUG 27 1 10 RED/VIO 215
REF DWG 2 10 RED/VIO 223
09-603 3 10 RED/VIO 216
4 RED/VIO 224 ORT
CE 09-064
SHEET §
CAP 6! 16 RED 344 zu к
SYS MON 2 6 BLK 345
REF ONG 3 3346 BRN
09-606
30 16 BRN
345 16
3316 BLK/WHT
3326
33316 WHT
33916
35116 PA 2
3414 BLK 39
330 6 n
376 12
39 16 BRN/ORN 25
8
— i
4-10 BAN/RED 321
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HARNESS 2 < 10 BRN/RED 17
REFSHEET 2 3|€7——16 BLU 410€ 18
OR SHEET 6 al 16 YEL 4aC 19
“|< и BLK/RED 232 BLK 205 334 16 BLK/WHT 14
6[€ BLK/RED 233 CRN/WHT 204 335 16 GRY/WHT 15
71€ 14 BLK 234 336 16 WHT 2
в|< и op 25 340 6 GAN 22
Y Lal 352 к PNK 13
< % BLK 4i2C 33816 VIO 36
n/€ “ 33716 VIO 26
12]€ KEBLE WHT 32916 vIO 37
< % 20
< 16 VIO 350 23
|<] 24
PAra
PLUG 12 BLCE 1
HARNESS
REF ONG
09-603
(1 OF 2)
PLUG 2 STUD $180 vor RUNNING LIGHTS
1 12 GRY 255 — |
STBD CABIN HARNESS 10 GRY 256 eaux hi CONTROL STATION
14 BLU SIB TO WINDLASS SOLENOIDS GROUND BUSS
14 сям 519 REF 09-614
L
10 RED/VIO 520 con moof 10 BLK 521 — |
16 BLK 647
FWD MAST LT
PLUG 42 STBO DECK/ rie ANCHOR LT
COCKPIT HARNESS GRY/WHT 261 14 GRY/WHT 1 |< 14 GRY/WHT 2615
REF SHEET 2 GRY/RED 262 14 CAY/RED 262 21€ 14 GRY/RED 2625
RED/VIO 6485 bn 4 BLK 265 3 (€ 14 6LK 265$
WHT 646 | “4 14 GRY 263
RED/VIO 648 14 BLU 644 <| 5 |<}— 14 61) 6446 14 BLK 264— SE STERNLT
ORN 6811 MBLK 659 —— —— —<] 86 |€— 14 BLK 6595
GRN 6912 SPLICE LOCATION 16 WHT 646P ————t<| 7 |€1— 16 BLU 646P $160 SPORLER LY
WHT 6913 14 BLK §47P A} § [€d—— 18 6LK 6477 ————a 14 BLU 653-9 pont SPOLENLE
44 а ld 14 BLK 654 +
au” Vayas
PLUG 43
16 WHT 646M 16 BLK 647u \
DIGITAL SPOLER
| LICHTS DIMMER | CS GROUND BUSS
STBO CKPT 500 +)— 2
SPEAKER SOHN -) —, COCKPIT LIGHTS
sue some) — CONTROL MODULE
WOOFER SOM +) 14 BLU 649
J
PORT SPOLER[™- 7] PORT CKPT
PLUG TIA САР 45 _ SPEAKER PLUG 46 SPEATER
и< S009A(+) 1 SOOYAL+) 5009P(#) >| > 16 RED(+) SOO9P
24€ SOOYAC-) 2 S009A(-) 5009Р(-} >| 2 > 16 RED(-5009P
€ pm 14 BLU 654 з |< 4 BLU 6% NES 14 BLU ESF 16 BLU ESIA
< mt 4 BLK 652 4 |€ : 14 BLK 652 > > 1 BLK 6S2F . 16 BLK 6524
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6/€ SOI0AL-) 6 |Ef— 5001-1 SPEAKER 6 BLK 64TP >| 6 > 16 BLK 647 _
ne 19 RED/VIO 5069 ——-12\ ACCY FUSE BLOCK pLUG 45 — CAP 46 - 16 BLU 646A PORT AFT CKPT LT SW
8l€ 10 BLK 5070 12V ACCY FUSE BLOCK GROUND 916 BLK 647A
Y 14 BLU 5073 -— COCKPIT del 14 BLK 650 ——y cs GRNO
ee ema BLK 641 Buss SPLICE LOCATION — 1 OL GIE — o
14 BLU sao EAT CKPTLY 16 BLU 646F ” ] CABN ENTRY SW
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PLUGIG 11€ 16 ORN/BLK 213 —
WINDSHIELD 21€ 16 ORN/REO 239 Toh PORT WIPER |
HARNESS 3|< 16 ORN 248 fow BLK 251,
REF SHEET 2 4|€ 16 REO/VIO 241 PAR ,;
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< 14 BLK/RED 245 ` 248 19 BLK
18 < 14 BLK/RED 248 9 Y 15 = BLK 250 MDP
" “| 18 REO/VIO 214 vis SHIFLO uss
PLUG 25
PLUG 24 1 4 WHT/BLU 585 6:
NINDLASS 2) 4 WHT/BLU 586 >|2 HAN
HARNESS 3 4 RED 568 RE Bal hEr
REF SHEET 2 4 14 RED/VIO 587 Sis
CAP 38
CAP 26 BLGE | [> 14 RED 546 <! 12 Вск 584
HARNESS 2 deren 4 GRN 547 < 2 г —
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CAP MATCHES STANDARD BENNETT CONNECTOR |
14 WHT/BLU 283
PLUG 65 14 WHT/BLU 284
BOW THRUSTER 14 REO 285
HARNESS la REO/VIO 286
14 BLK 287 + Bou THRUSTER
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NOTES:
1) PORT ENG HRNS CONNECTORS TO BE IDENTIFIED WITH RED HEATSHRINK,
STBD ENG HRNS CONNECTORS TO BE IDENTIFIED WITH GREEN HEA TSHRINK.
2) SWITCH INDICATOR GROUNDS ARE TO BE WIRED TO THE PANEL GROUND CIRCUIT,
—
OPT TWIN DISC TROLL
SYSTEM HARNESS IS
SUPPLIED BY TWIN
BLK
|
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PANEL PLUGI9 | ¿Leg
REF SHEET | OR 3
ale PORT IGN STOP
5 |<++ 14 RED/BLK EMER STOP
6 — 14 R STOP —
< 4 REO/BLK CAP PT
16 YEL/RED | PORT ENG
— : — L/ 2 HARN
PLUG! 1 <f—16 PINK 200 3 ESS
pce HARNESS A| ST 1S PK 200 — | à 14 VIO REF SHEET 5
— | 10 BLU/RED 4 AND NOTE |
REF SHEET 4 31d 42 RED/VIO 207 | PORT IGN —_ L
4|<+— 10 BRN 322 EMERGENCY | |
5|<|-—10 BAN 328 START 16 YEL/RED ¡ CAPS?
6|<|—10 RED/BLK 223 L— 16 YEL/RED 2
7|<t— 10 RED/BLK 224 16 YEL/RED 3
8 |<+— 10 RED/BLK 239 | | — 16 YEL/REO 4
9| <A—10 RED/BLK 240 |, e
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| |< М ВСК + EMER STOP STOP | САР РТ
2|<+— 14 BLU 2022 — 16 YEL/RED 2 STBD ENG
5| <—14 vIO 2024 AND NOTE |
6 van
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| 14 GRY 255 1
2 14 GRY 256
REF SHEET 4 3 14 BLU 518 = ———— по | <|
H 4 4 14 CAN 519 BILGE PUMPS 14 BRN/RED 321 —+<| 1 CAP 22
5 Ю RED/VIO 520 — AFT 14 BRN/RED 327 —]<|2 BILGE
- 16 BLU 410C —<|3
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BLOWERS | I6 YEL 4IC_—T<|* REF SHEET 4
SEE DETAIL A —— 16 BLK/RED 232-—<|5
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CAP 47 PANEL GROUND € 14 BLK 137—]<[9
REF SHEET | 16 BLK 412¢ —1<]10
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TROLL VALVES 16 BLK/WHT 256—K<l12
2| >t—14 RED/VIO —. 16 VIO 349 —+<|13
3| >+—14 GRY 16 VIO 350 —j<[14
4 | >+ 6008 14 RED/VIO RUNNING +15
5|>4— 14 RED/VIO aro _—
6|>1— 10 RED/VIO LIGHTS 14 RED/VIO SOIO 1
ANCHOR 14 GRY /WHT 26 CAP 42
7 | >— 16 RED/VIO SPOILER 1 261 2 oecK/
| SH 14 RED/vIO A 14 GRY/RED 262 3 COCKPIT
273 —[ |4 BLU 644 4
9 | >+— 14 RED/VIO HARNESS
|] | 16 BLU 646 <IS REF SHEET 4
| > 14 RED/VIO 648 6 |
COCKPIT 16 ORN 601 7
SPOT LIGHT „и 16 GRN 6012 8
16 WHT 6013 q
PLEASURE LOK
10 RED/VIO 91 —<—— SYSTEM
(6 WHT/BLU ! PLUG 106
16 WHT/BLU 2 SWIM PLATFORM
v 16 RED 3 (ОРТ)
16 RED/VIO—<|4 REF 09-922 &
16 BLK 5 14-802
6
14 WHT /BLU 585 1 |
14 WHT/BLU 586 2 CAP 24
14 RED 588 3 ma
14 RED/VIO 587 4 REF SHEET 4
CAP 50 PLUG 50 5
6
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3 В 3 3 8 DIMMER * TRIM TAB SW HARNESS REF 09-884
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EL LAMPS
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BOW THRUSTER e BILG
MAIN DISCONNETT | 14 wn ; oto 28 2 HARNESS
| 14 RED/VIO 286 4 REF SHEET 4
(AA A] cap 49 14 BLK 287 5
| 6
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|
[AAA]
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19 RED/VIO 216 —
10 RED/VIO 224
14 WHT/BLU 267
14 RED 268
14 RED/VIO 269
|
14 WHT/BLU 278
14 WHT/BLU 271
14 RED 272
14 RED/VIO 273 —
|
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14 WHT/BLU 275 =e
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2
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14 RED/VIO 277
14 WHT/BLU 278
14 WHT/BLU 279
14 RED 280
14 RED/VIO 281 -———
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FWD CABIN LIGHTING Vio Y —14 BO 14 BLU EST ——[——
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BILCE LIGHTING P15>—4 BLU 14 BLU 659 ——————
Г АР
16 BRN 300 < 1 RÉF 3 ET 2
14 YEL 14 YEL 402 ——<|12
POWER VENTS il 14 YEL 16 RED 526 <|3
14 YEL 16 BLK 525 <|4
GUEST HEAD SYSTEM Y 5>—4 RED/VIO 16 WHT 524 <IS
DISCHARGE PUMP JS ——14 RED/VIO. — 16 GRN 523 <|6
14 YEL 407 <|7
2avoc | IO BLK 138. ——<|8
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ACCESSORY Ey —
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14 RED/VIO
MASTER HEAD SYSTEM nL 14 RED/VIO 16 RED 526 <]: REF Beer 2
16 BLK 525 <|2
INTERCOM/PHONE SYSTEM [5 x— 16 WHT 524 <|3
5 14 RED/VIO 16 GRN 523 < 4
16 RED 14 YEL 400 < 5
16 BRN 300 ———<|6
14 RED/VIO 514 ————<|7
+< 8
Ta
16 ORN UNUSED ————t 1 RÉF SPEET 2
UNUSED <|2
16 RED/VIO 226 <I13
6 CRY 16 BLK 227 <la
AP 36
POST | PORT SHUNT 24V (+) 14 RED 217 1 КЕ Meer 2
AE POST 2 PORT SHUNT 24V (-) 14 REO/BLK 218 2
x — POST 3 STBD 24V SHUNT (+) 14 RED 219 3
| ee POST 4 | STBD SHUNT 24V (-) 14 RED/BLK 220 4
| —— POST 5 — PORT 12V SHUNT (+) 14 RED 221 —K|5
| POST 7 PORT 12V SHUNT (-) 14 RED/BLK 222 6
LE POST 8 STBD 12V SHUNT (+) 14 RED 229—<|5
= —— POST 9 STBD 12V SHUNT (-) 14 RED/BLK 230 8
| — POST 10 UNUSED 9
— POST U
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< — Fu 14 ORN 535 E
WATERLEVEL| y, -16 GRN 536 >
Ya 16 YEL 537 ———Is > |3
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EMPTY 16 BLK 539 =———————[
16 BRN 300 >
14 RED/VIO —
DISCHARGE [_~ |
2 3
7
Г {6 RED
14 ORN 540 >|1 RENO cer 2
FULL 16 GRN 523 . >
y, 16 WHT 524 >
EMPTY 16 YEL 545 >
POWER 16 BLK 525 >
WASTE LEVEL 14 REO/VIO 562 >
UNUSED >
14 BRN/WHT 576 ===>
14 BRN/WHT 578 ———— >
М RED/VIO 582 ————> ha
16 BLK/YEL 542 ——>l
he
16 BLK 4125 нс
8 | fer Heer 2
eLOWERS| (5 16 BLU 410 <
16 УЕ. 41 ——o5seea<
уМ$Е0 ———————-<
UNUSED -< |5
UNUSED ———————— | 6
556-14 WHT/RED alll
ALL JUMPERS 14 RED/ VIO я 5515-14 BLK +<|2 CAP 90
PREHEAT 552-14 WT ——<|3 GENERATOR
553-14 RE/WHT ———<|4 HARN
WESTER -
GÉN RBEKE 550-14 RED/VIO <|s REF 09-617
REMOTE 5566-14 YEL/RED —————+<|I6
SYSTEM
RÈF Sheet 2
REFSRÉET 2
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PLUG 100 CAP 100 PLUNGER SW X BLK 656
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5 GLASS STORAGE LT
BER BLK 696 ocop STBD TASK LT PORT TASK LT
151515 | FWD STRM SW 14 BLU 6003 —— — 14 BLU 6005 y
DCOP 213 12 BLK 625 14 BLK 6004 14 BLK 6006
21%] DD 14 BLK 698 14 BLK 6000
FWD STRM SW I~ —— 14 BLU 695 14 BLU 697 14 BLU 699
ST8D VAL LT STBD CEN VAL LT PORT CNT VAL LT
¥ aux 660 SALON OC LT
— De SES A BLK 6008 < М ВСК 6000 14 BLK 6002
12BLU 626 x. =
FWD STRM SW 14 BLU 6007 14 BLU 6009
14 BLU 657-BULB SAVEN— ———— 12 BLU 657 — Ll — 1 BL 633 т 12 BLU 627 E ENTRY SW PNL SALON DC LT
4 BLU 604 —=L_FWD CABIN=—Ii2 BLU - 14 BLU 6001
BLU 600 a | — 8H 86 STEP LT 16 BLK 621
——>3 AFT CABIN< — | + --16 BLK 617 16 BLK 619
14 В — ~—16 BLU 6% —— OCOP
BLU 658 12 BLU 658 4 ENTR WAY Sy 6 BLU 616 16 BLU as Ÿ PORT VAL LT
[5 BILGE —+— 12 BLU 659
e _ 3 SALON BAR LIGHT BLU 6207
SENDA [16 BLK 629 ETE
TERM. STRIP 16 BLU 683 J6 BLK 684
* DCDP 14 BLK ul
DCOP MRL
MSTR STRM 16 BLK Re 16 BLK 665
ENTRY SW
16 BLU 6622 16 BLU 4
6 BLU 667 LLTI SEL LT2
| pos
16 BLK 670 — 53—16 В|К 60123 \ ANTY LT
.———— 6 BLU ces 16 BLU 600 77 VA L
Wa LT SW
J FwD Buss 14 BLK 623 CAP 62 PLUG 62 BLGLT *2
ACCY » 16 BLK 686 14 BLK 688 y 16 BLK 688 — \6 BLK 690
MAIN DC RÓOM (E 6 BLU 685 — 14 BLU 687 16 BLU ear те BLU 689
——o—[]—— 14 BLU 622 | 16 BLUES
ENTRY SW PNL SPLICE LOCATION
BLG LTS 16 BLK 692
CAP 28 PLUG 28
PLUG 15 | | — < 4B GUEST HEAD 16 BLK 613 — BLG LT "3
BRN 300 < | 1| H 14 Blu 604 a
La
SHEET 12|E+- 14YEL402 Da 4<|2| 14 YEL 402 emy TOR 16 BLU 693
3 RED 526 < 3 <+—16 RED 526 16 BLK 694
4 BLK 525 <|4 | <+— 16 BLK 525
5 WHT 524 <|5|<+—16 WHT 524
6 GRN 523 <|6| <]—I6 CRN 523 BLG LT *4
7 YEL 407 — 16 YEL 419 7| <1 16 BRN 300
8 BLK 138 POR —— 14 В|К 403 — |< |8 | <1— м ВК 403
9 || 6 ри BLK 605 —|9| +14 BLK 605
Ly De 16 BLU 606—< 101 + i6 BLU 606 | 610-16 BLU ——
GALLEY 16 BLK 607—K |11[ + i6 BLK 607
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BLK 406 WD STATEROOM —A— 16 BLK 612 —E— 16 BLK 649 —*
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eme er 14 BLK 515 + ocop GROUND
CAP 32 PLUG 32 U
1 CU
<|1| 14 ELU 600 MASTER HEAD
+<l2|€+--14 EL 400 —
PLUG 13 | RED 526 <|3| A-16 RED 526 — =
SHEET 1 2 BLK 525 <|4 1 SHI6 BLK 525 —
3 WHT 524 <15|<+—16 WHT 524 —
4 GRN 523 - <|6| HI6 CAN 523 —
5 14 YEL 400 —— | POWER VENT 1<]7| €1~16 BRN 300 ~~~
6 BRN 300-— 4 | 5401-14 НАТ YEL —<|8|<H14 YEL 4i7
7 RED/VIO 514 —- DCDR- 601-14 BLK —<|lal<t—14 BLK 601 HEAD LIGHT SWITCH
8 - 603-16 BLK—+< 10) <+—16 BLK 603 671-14 BLU
RM HANG LT
q MSTR ST CLINE 602-16 BLU—}< [11] €}—16 BLU 602 |
i SHOWER LT
ELS 16 BLU 673 ——* BLU 675 316 BLU 677 16 BLU 679 516 BLU 681 —3¢
CAP 33 16 BLK 674 16 BLK 676 E e BLK 678 16 BLK 680—16 BLK 682
HEAD LT #1 HEAD LT "2 HEAD LT *3 HEAD LT *4 HEAD LT *5
PLUG 35 1 [E-— unusED unuseo Ki [€&+ unuseo |
SHEET 1 2|<+-—-UNUSED UNUSED +<|12 UNUSED
3|<- - 16 RED/VIO 226 . <|3
4|<}— 16 eux 227 la BREAKER TEXT LIGHTING
PLUG 33 REF DWGS
PLUG 34 09-630.09-631 OR 09-634
PLUG 36 1 [<|-— port 2 T RED 217
REF ORT 24V SHUNT (+) 14 RED 21 1
SHEET 1 2|<} PORT 24V SHUNT (-) 14 RED/BLK 218 PORT 24VDC SHUNT
3 | &1— STBD 24V SHUNT (+) 14 RED 219 3
4|<l— STBD 24V SHUNT (-) 14 RED/BLK 220 STBD 24VDC SHUNT NOTE |
5 | El PORT 12V SHUNT (+) 14 RED 221 -——--———————+>|5 IP B| Sor
6 | € PORT 12V SHUNT (-) 14 RED/BLK 222 “Y |PORT 12VOC SHUNT
7|<+— STBD 12V SHUNT (+) 14 RED 229
8 |<+— STBD 12V SHUNT (-) 14 RED/BLK 230 STBO 12VDC SHUNT
9 | €+—
[ST UNUSED CAP 34 SHUNT HARNESS
— EF 09-904
GRÉ14 1 [>+—16 ORN 535
SHEET 1 2 |>+—16 GRN 536 —
3 |>+——16 YEL 537
4 |>+—6 BLU 538
5 |>+—16 BLK 539
6 |>— 6 BRN 300 |
307-14 BLK 326 14 BRN/ORN
SUMP PUMP DCDP | REF 09-604
324 16 BRN 323 14 BRN/YEL
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SHEET 1 2 16 GRN 523 0 10 Na _
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4 16 YEL 545 VACUUM
5 16 BLK 525 _ SWITCH
6 14 RED/VIO 562 <| 1 ++
7 14 RED/VIO 254 12VDC ACCESSORY FUSE BLOCK 563 14 BLK г: O
8 4 BRN/WHT 576 S77-14 BLK 3, MAIN OC MF MASTER HEAD
9 14 BRN/WHT 578 ") FRESH cop 12 12 JACOUM
19 14 RED/VIO 582 uu 579-14 BLK q WATER PUMP GENERATOR
VACUUM *2 FRESH
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MAIN DC MF GUEST HEAD NOTES:
Mon GENERA YOR I REF 09-601 FOR MAIN SHUNT WIRING.
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PANEL WIRING.
/ PORT 24 VDC
PORT 24V. 140 MAIN 70
LOAD SIDE g ReD/VIO 50 2
ION 215 14 RED/VI0 —<| CAP 38
15 216 14 RED/VIO —E 2056010
TER
BUSS BAR 5939 14 RED/VIO <A BG
SUN PAD RECLINER 5048 14 RED/VIO——1<] 05-601
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FWD EMERGENCY
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PORT 12 VDC | — NOTE 3 AT CONTROL STATION
PORTIZV — — as CONTROL STATION 114 8 RED/VIO — 6-0 114 4 RED/VIO —61—s RED/VIO
LOAD SIDE RED 12V0C ose | o | ACCESSORY
SSORY LINES OAD NOTE 3 FUSE BLOCK (+
CS o
104 8 RED/VIO ——|IKA KK Hi94 2 RED/VIO —e = BRED/VIO_
ACCESSORY 5760 FUSE BLOCK (+
TOFORIIZY 134 COCKPIT STEREO MEMORY SHUNT
19 RED NOTE 3
STBD 24V.—.. — 5002 SWIM NOTE 3
LOAD SIDE 2 ReD/VID PLATFORM LIFT
$3-00e NOTE 3
` WINDLASS SOLENOID
6 RED CAP 25
585 14 WHT/BLU 1 REF DWG
586 14 WHT/BLU > 99-601
588 14 RED 3
587 14 RED/VIO 4
STBD 24V _ 142 STBD 24 VDE 100 8 RED/VIO 100 2 RED/VIO 2 ONPAGEO
LOAD SIDE gReD/vIO 5p CONTROL STATION MAIN ~ ATION BRK PNL
STBD SINGLE TERMINAL
BUSS IGNITION LINE Swoc 080 Post AT CONTROL
SHUNT STATION
CABLEMASTER 2 NOTE 3 NOTE 3
OIL CHANGE PUMP
ELECTRONIC CONTROL
CAP 18
ACCESSORY 558 14 ORN | REF DWG
409 14 YEL <| > 09-601
408 14 YEL <| 3
LINE SIDE — eb SYSTEMS MONITOR 312 14 BRN/RED —<|5
566 14 YEL 6
BUSS BAR BILGE PUMP ‹
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2
STBO 12 STBD 12 vDC
12V - ELECTRONICS
LOAD SIDE REED
MONITOR
BUSS BAR ACCESSORY
- CAP 17
ACCESSORY 325-16 RED/VIO 1 REF DWG
321-14 BRN/RED 2 09-601
321-14 BRN/RED 3
306-14 BRN/RED 4
326-14 BRN/ORN 5
327-14 BRN/RED 6
309-14 BRN/RED 7
323-14 BRN/ YEL 8
567-14 RED/VIO q
10
1
326A 14 BRN/RED 12
106 10 RED/VIO ————E— 10 RED/VIO
— CO MONITOR
16 WHT /BLU 2668 —4< |! FUSE BOX
lo WHT/BLU 2678 —< b
16 RED 2688 —*< |
16 RED/VIO 2698 ~—4< Ц PLUG 68
16 WHT/BLU 2708 -+< |; B&F OC
l6 WHT/BLU 2718 —< k
6 ВЕ 2728 — << [>
16 RED/VIO 2738 —+< ls
14 BLK 282 ————<< |g
As CAP 67
16 WHT/BLU 274B —+> REF DWG
16 WHT/BLU 2758—> 09-601
16 RED 2768 ———t> [3
16 RED/VIO 2778 —t> a
16 WHT/BLU 2788 => |5
16 WHT/BLU 2798 >
16 RED 2808 ————+>|-
16 RED/VIO 281B-—t> lg
Js
MAIN DC BREAKER PANEL
REF DWG 14-850
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GND
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4 X BILGE HEAT DETECTOR 51 /[>—365 16 eL >)
PORT CAT DIAGNOSTIC (-) >| 2|>1—351 16 PNK
PORT OIL PSI > 3|>— 3316 BLK/WHT
PORT WATER TEMP > 4 332 16 GRY /WHT
PORT TRANSMISSION TEMP 5 333 16 WHT
TWO LINE EMERGENCY BILGE PUMP {6 |>+—313 16 BRN
LCD DISPLAY FWD EMERGENCY PUMP м 7 324 16 BRN
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FWD BILGE PUMP >{a|>— 353 16 BRN
SYSTEMS MONLTOR > LE,
STBD CAT DIAGNOSTIC (+ >is 352% Pb
RG6/U COAX FROM BILGE TO DISPLAY STBD O PSI 211421 — 334 16 BLK/MHT
O — —] mao Em
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AUDIBLE ALARM 2 w REF DWG
ARS > fr Be ra TE
STBD EXHAUST TEMP >22 340 16 GRN
| BÉ
STBD FUEL FILTER CONO >26 319 16 BRN/ORN
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STBD SERVICE ENG SOON >85 — 356 16 ORN/GRN
SYSTEMS MONITOR INDICATOR PANEL à Save <A
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GEN IGN >37 329 16 VIO
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344 16 RED
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STOVE BREAKER — O— 12 BLK | e— 12 BLK
REF DWG 09-63Q/09-63I AT |
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REF DWG 09-634 — |
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| | A INPUT | |
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| |
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| START | | |
| || + [1 POSITIVE OUTPUT — | |
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| ALARM e | |
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ALARM SW
| a LARM SW [a+ pos INPUT
THRUSTER CONTROL STATION
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3)
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=> El Г. BATTERY SOLENOID MAIN SWITCH
NOTES: Ze Al el VARISTOR т |
D INSTALL VARISTOR AS SHOWN.
2) VARISTOR IS NOT POLARITY SENSITIVE. MOTOR >| > à |
3) VARISTOR COMES WITH "BIG BOY" SOLENOID. THERMAL | | > |
4) THE CABLE LENGTH FROM THE CONVERTER ALARM 5 S 8 |1
TO THE FUSE MUST BE NO MORE THAN 40" SWITCH | | 3 |
IN LENGTH AND CONTAINED IN A SHEATH Oo T5 2 4 |
THROUGHOUT ITS ENTIRE LENGTH. (N.C) | 470 RED 2|5> 1 |
5) THE CABLE LENGTH FROM THE BATTERY TO | PDC nn _ ;
THE FUSE MUST BE NO MORE THAN 72“ IN NOTE 4
LENGTH & CONTAINED IN A SHEATH IT’S NOTE 5 OA PLUG 65 CAP 65
| -BLK—
4/0 RE A A | i
PER | 12vDC || 12vDC
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Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Г - ]
MAIN DC PORT 8D BATTERY *| | MAIN DC
GROUND) 80 BATTERY #I GROUND
BUSS Cl N BUSS
24 12 + TO MAIN + 12 24
[= > oc Frere N
< — —— > ©
N -134— | A
PORT 36 STBD
8D BATTERY #2 PORT PORT STBD STBD 8D BATTERY *2
BATTERY Ру 135 12V BATTERY
EQUALIZER] | SIOLENOID SOLENOID |EQUALIZER
z = > I 5
MAHA AHF RAT
14 BLK > FOIX 14 BLk ——
MAIN DC 7 45/48 14 WHT/BLU 274B < Sis|>— — 658 |
BRK PNL Y 6 — 14 WHT/BLU 2758 2|< 2181 CU 2798 32 1 |s BRK PAL
14 RED 2768 <|3|€ >|r{> ED 2808
14 RED/VIO 2778B—K|:l<- >|в|> VIO 2818
feb BLK 282
MAIN DC GROUND BUSS
14 BLK
P 64 C 64 C78 P78 P78 C70 64 P64
= YX LIT
DC DIST PNL 7| 4 ss < > SS DC DIST PNL
SWITCH 8 < > <|6|<
' < Us 280——<lrle SWITCH
Sr TA AN
2
DC DIST PNL GROUND
VARISTOR VARISTOR
EMER
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| PORT STBD TI
> E 24V 24V = RR
НМ NO Не ® Е <Q SN)
> < 4BLK——
css P
| || NT CE
| | < |5, 14 WHT /BLU 270B MAIN DC
SA PAL | a * Id WHT/BLU 08 772 + BRK PNL
al | B |
14 BLK
_ 7.5 7.5 N Y Y 6 7
IST PNL? >| —<|s|<-14 WHT/BLU 270 31
DST CHE Sle e leléL ja WHT/BLU 27] SA PE
S35 < |7|€ 14 RED 272 D272 |
Kp ISla|é—14 RED/VIÓ 273 0273
69 69 C69 P69 P63 C63
— STBD LINE IQ RED 141
PORT LINE 10 RED 139 MAN DC
NOTES: PORT LOAD 6 RED 140 PANEL
1) INSTALL VARISTOR AS SHOWN. ST8D LOAD 2/0 RED 8 REDI36 cpm
2) VARISTOR IS NOT POLARITY SENSITIVE. PLATFORM
3) VARISTOR COMES WITH "BIG BOY" SOLENOID. 2 RED 5002} LIFT/
| LOCATED BEHIND MAIN WINDLASS
DC BREAKER PANEL BREAKERS
09-609, 1 of 1, Revision 04
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7.34 540 DA
540 Sundancer: Engine/KYSOR Medallion Interface Schematic 09-610
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
f A
123456
САР 9! | Y Y Y Y Y Y] TO CONTROL STATION SW PANEL
REF DWG 09-601 SH 2
У оо
ааа = ===
OOOO O OO
COSC U TOA
NINO LOL
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MONITOR >
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PLUG 87 TO
24 VDC LIGHTING £2
CONVERTOR DI>+BACKLIGHTING 20228 16 GRN—
CI>
BD
A|>
CAP 80
BILGE HARNESS
— REF DWG 09-601
MMDC 21331 UNVRES 3
RUDDER ANGLE 3P>{>+255 18 WHT 200 18 WHT |
41+>| >-UNUSED UNUSED >
STBD FUEL 5+>|>+202 18 WHT | 202 18 WHT. 3
PLUG 85 6+>| >> UNUSED 255 18 WHT. 4
2027 16 REDK<f<I A ANALOG INST 7V REGULATED PORT FUEL IM y HT | - 256 16 BLK—<5
— UNUSED В PORT SWITCHED IGNITION 91> >+ 2024 18 WHT Ll UNUSE 6
LJ x UNUSED сет О PORE Re CRE VOL EI 50528 FWD DC
= — UNUSED Е STBD UNSWITCHEO 24VDC I25>|>+20255 18 WHT ———— GROUND
< UNU 13> >F UNUSED
; UNUSED G 14151 + BUSS
a UNUSED H 5H STUNUSED <
2028 16 WHT J ANALOG INST DATA 61> SH UNUSED ©
Ld 2026 16 BLK K ANALOG INST GND "E > UNUSED 5
O 19> >+ UNUSED PLUG 31 =
= PORT ATA(+)20+>| 257 16/2 RED 257 16/2 RED >|| =
= PORT ATA(-) 215>| >-258 16/2 BLK 258 16/2 BLK >TO PORT ENGINE 2]
STBD ATA(+) 22>1 >+259 16/2 RED =
O SUS UNUSED STBD ATA() 2312] 21260 16/2 BLK HARNESS =
> GROUND 241>{ >1-2030 18 BLK REF DWG 09-810 и
© PLUG 70 Й
=
Li CAP 82 x
= 259 16/2 RED-K! 5 I
о ED DC 260 16/2 BLK{<2TQ STBD ENGINE 50
GROUND CARNES 2
BUSS REF DWG 09-810 = a
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09-610, 1 of 1, Revision 00
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7 1) WITHOUT D.S.S. OPTION. CABLE 504
Q RUNS DIRECTLY TO SPLITTER.
2 HELM COAX BOAT TV 2) REF DWG 09-615 FOR OPTIONAL D.S.S.
S (ON CONNECTION LOCATION О ANTENNA SYSTEM OVERVIEW.
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ANTENNA
SHORE INLET SNJ
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RF ANTENNA
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RECE I VER out O SPOILER COAX
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POWER FROM 120VAC RECEPT. CONNECT IONS
ENTERTAINMENT LOCAT [ON
CENTER CIRCUIT 505 — 506
(SALON BREAKER) COM
5012
COUPLER
5048
4-WAY SPLITTER Tv
IN
| OUT OUT
OUT OUT 200
OUT OUT LOCATED AT
ENTERTAINMENT 507| CONTROL STATION
CENTER SALON VCR
501
BARREL CONNECTOR SALON STEREO
527 503 5038 AT MDP
531 5007
FWD MASTER CONTROL STATION
STATEROOM STATEROOM cori SALON STEREO
TV TV
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©
о,
3 ..... *178026 30° 5 PIN TO 8 PIN MINI INCLUDED W/STEREO
5 ——- *183IT4 ZONE 2 ADAPTOR ( 8 PIN TO FEMALE RCA )
9 — 16/2 105 STRAND, OXYGEN FREE HIGH CONDUCTIVITY
> 90~C CLEAR INSULATED WIRE MI Iv
o
VCR |
| M
MH— — SALON TV A
SUB MM
WOOFER MM —
- - - < = = = = = “1
|
|
AFT CUBE FWD CUBE
SPEAKER SPEAKER
НМ |
MASTER STRM
SPEAKER '
'
! STEREO
| RECEIVER
|
ne BIN NI
| |
MASTER STRM ml[e}---—
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'sejepdn juewudinba pue selosseje ¡euaINdo BuizivuajsNa 0) enp edueLNEA 0) J2elgns si 1eLUSYOS Siy| :810N
540 Sundancer: Lofrans® Progress Il Windlass Wiring Schematic 09-614
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
-
WINDLASS BREAKER SOLENOID
LOAD SIDE OF Lan L
BATTERY SWITCH” 80 —— 7 о
5 AMP 5 AMP
d e S
E
E
BREAKER |
PANEL REF — 14 RED |
DWG 09-604
PLUG 25 CAP 25
14 RED/VIO
14 WHT/BLU
14 WHT/BLU 527 +>
—— 14 WHT/BLU 528 +>
—— 14 RED 530 +>
— 14 R/V 52915
E QQ NN —
Y Y Y Y
14 BLU 572
RED 6
REDO RED 6 RED 6
|
RED 2
WINDLASS SOLENOID
MOTOR
BLACK 2
14 GRN 573
/ V PLUG 24
YY ——— WINDLASS HARNESS
| 3456 |
AT
e
N
<
>
<
N
E
N
<Ó
09-614, 1 of 1, Revision 00
Na
540 DA
MAIN DC GROUND BUSS
GROUNDING TO STBD ENGINE
BLACK 14
RED 6
MOUNTING
BOLT
GREEN 4
7.37
EZ
va 07S
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о
o
N
10
D
<
7)
oO
=
q SALON VCR
+ NN
KVH
ANT
2ND RECEIVER
ANTENNA
OPTION CABLE
30K OHM COAX
/ RF2
— A —
/ fi ZA
P — TA
| SES | Ми”
© |} ©
| 055 dd ‘ ]
O) 7 / RECEIVER +, ,
+1 5K OHM COAX
ARCH BREAKDOWN RF1
LOCATION
D ON/OFF
SWITCH
COAX IN FROM A/B SWITCH (REF DWG. 09-612)
COAX OUT FROM TV SPLITTER SYSTEM (REF DWG. 09-612)
DATA 5 AMP DSS HAS TWO (2) OUTPUTS; ONE (1) TO VCR INPUT &
PORT ONE (1) TO TV INPUT. THESE ARE AUDIO LEFT AND AUDIO
RIGHT AND VIDEO INPUTS.
SALON TV (4 POWER FROM 12VDC ELECTRONIC FUSE BLOCK AT HELM
FUSE AT 5 AMPS.
(5) RF ANTENNA
(6) WIRE SIZE FOR POWER CABLE : O TO 50° 14 AWG
(9) 12vDC 50° TO 80° 12 AWG
80° PLUS 10 AWG
(@ PHONE LINE ROUTE TO C-PHONE MODULE
PARALLEL W/SHORE CONNECTION
SK OHM RF1 IS FOR PRIMARY RECEIVER
©
©
©
о
N
o
N
Py Baseplate Connector Assignments
<
= Single IRD
5 Installation
o
o
PQ J13 (power)
- Second IRD
Installation
8
Power
E
+
——T0 RECEIVER
—
J14 (data)
TO SWITCH PLATE
SWITCH PLATE
+12 Vdc — Ship's Power
Ground — Ship's Power
DC In
MULTIRECEIVER OVERVIEW
oo om View) | Data Cable Wiring Arrangement
Buurtosrá J13 (power) [mm
то ©
=0 >
J14 (data) =>
= 9
Г г Mm 5 ® BLU/WHT // Not Used
| WHT/BLU // Not Used
@ NT ei To
NL > WHT/ORG | — PC GND
O GRYWHT || FPCTXD Des
S WHT/GRY /! . PCRXD
GRNWHT Not Used
WHT/GRN Not Used
'sejepdn juewdinbe pue seuossecoe jeuoIrdo BuIziwoIsno 0; onp s0ueuBA 0} 108lgns SI OINEWBUIS SIY | :910N
‘sorepdn juewdinbe pue seiosseooe [euolido Buiziwolsnd 0] anp adueleA 0] }o8lgns si d1ewayds Siy| :810N
(210 1) S19-60 maIAIBAQ AI QVHL SSA :492uepuns OFS
(210 2) 519-60 MmaIAIBAQ AI QVHL SS( :492uepuns OFS
540 Sundancer: Westerbeke® Diesel Generator Remote Wiring 09-617
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
“TO BATTERY SELECTOR SWITCH
PART OF DC DISTRIBUTION PANEL
ON DC DP REF DWG 09-603
see eee a
1
4
0
| CAP,
' 90
! = =»
8 7 "a
и
' u
|
A
‘ — ==> «—
2 5 2 JUMPER 5 <
5 Ра
' NS
; > = — e J
' 3 6 3 6 N
; 1
' START/STOP PREHEAT
!
t
| 14 RED/VIO 4 RED/ VIO
I IRCUIT | CIRCUIT 2
!
+
|
'
NOTE:
O an > u mn
AAA
0
W
ler
5
- 556 14 WHT/RED
- SSIS 14 BLK
Yoo.
- 552 14 WHT
r 953 14 RED/WHT
- 550 14 RED/VIO
+ 5656 14 YEL/RED
I) CONNECTORS ARE AMP MATE-N-LOK II, USE PINS IN PLUGS
AND SOCKETS IN CAPS.
09-617, 1 of 1, Revision 04
540 DA
1 4 e
[AAAAIE
| 2 3 4
ГЛ)"
GENERATOR REMOTE
INSTRUMENTS
330 16 BLK/WHT
329 16 WHT/RED
PART OF EXTINGUISHER MODULE
er Y 5 Or AR AR Ws Wh WR AE Gp GE GR ED EF ED ES UE WE WS ово тво че WE WE TE de Oe 18 Se we
> de de db ue d= em eu qu e a
PART OF SYSTEMS MONITOR |
- > <> > de ae
IT
|<t-
1
4
1
|
!
i
|
à
i
|
i
i
‘
'
|
'
PLUG | CAP
0 1! 40
-
557 14 WHT/RED-> ai > 14 WHT/RED ©
556 14 WHT/REDH3| 51| > 14 WHT/RED a
or i и
„” i
1 @— ®
| |
Laa = = = = = = = = = = = = = = = = = = = = = = = = ===
TE нано.
GENERIC WES TERBEKE DIES
15 POSITION CAPO ESEL
i
Р | CAP
51° YN
о
|
550 14 RED/VIO +> | 11] >—- 14 RED/VIO
—— 557 14 WHT/RED +> | 21 >—1- 14 WHT/RED В
| ' ото
5656 14 YEL/RED 4> | 31| >4 14 YEL/RED O 2 0-++ 12vDC
>0 3
5515 14 BLK + | 41| > 14 BLK 04 a
| x 050 [START
553 14 RED/WHT +> | S| >—1- 14 RED/WHT об 9
. ' 7
552 14 WHT + | 611 >—- 14 WHT 280
6028 16 УЕ! -+>> | 711 > 16 YEL — pe —qzy
4
5029 16 ORN > f 811 *>—+- 16 ORN ое GROUND
1
5030 16 RED/WHT — -
> 9 >} 16 RED/WHT
5031 16 BLK => [101] > 16 BLK 18:2
i
329 16 WHT/RED +> N >—{- 16 WHT/RED — e ! Sere AT
330 (6 BLK/WHT — | 3
> [121] D1 16 BLK/WHT -© à ©—— OÙ. PRESSURE
UNUSED <> | 13| >—- UNUSED 9 5 9-1—WATER TEMP
UNUSED > | tai] > UNUSED are
UNUSED +> [15] > UNUSED one
ho Y Ena
© ©
GENERATOR OIL
RESSURE SWITCH
7.39
540 Sundancer: Westerbeke® Generator High Voltage Wiring 09-618
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
540 Sundancer: Generator Remote Bypass Switch Location 09-619
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
09-618, 1 of 1, Revision 00
220V 50HZ 120V 6OHZ 120/240V 60HZ
HOV 50HZz
6
x
J
WESTERBEKE 12.5 BTDA 15.0 KW DIESEL
09-619, 1 of 1, Revision 00
NOTES: |
D INSTALL SWITCH AND LABEL AS SHOWN.
2) REF DWG 09-617 FOR WIRING.
SWITCH SPST
W/1>" DIA
REMOTE BYPASS
ON LABEL
GENERATOR
Na
7.40
540 DA
540 Sundancer: Halon System Wiring 09-624 (1 of 2)
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
540 Sundancer: Halon System Wiring 09-624 (2 of 2)
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
16 BLK 228
16 YEL 227
16 RED 226
— NNAPDÁ IT ROARON- CONO
ONNOHI(—
1H9I1 ONI(O
HILIMS (un
Z# 3NI
au H3IMO
Ta INI ev
1: #3M018(—
<r
m
Эл $
BLOWER MODULE
ЭЛ $1
09-624, 1 of 2, Revision 00
Na
© Oo
(e De
OBS 00D
au? - NO + — N МС ~— NOT O OND] ND FTW
Iwao Wo | |
УХУ YEE | YY YYYYYYYYYYY
m DD N < e o QT TT DON с © © > с
N N Су Neo ALP NNN юн нон Я т О о
0305 Q = «шо - ух хо р" У Ч ` У | обес
a > > OXS I Ш UILHDU LU — =
ac ma o < ~~ J J Lu > > >
М © $ © + X = о о 0 oo НЫ > >
Y Y — > > Mm > m o
- = > wo > > ++ À DO
с oc II Lama To
o с с = =
O S o
— —
CATERPILLAR
16 BLK 228
16 YEL 227
16 RED 226
— \ СУД ST LO NON NOD
ANNOY (—
1HOIT ONI(
HILIMS (un
¿a INTI
¿sx HIMOTS(M)I3A YI
la INT TN
le YUIMO 19G(—J13A t1
BLOWER MODULE
09-624, 2 of 2, Revision 01
=
т
+095
“NO + N ou ® +HNO$VONOo6oS15- NC EL
TUJO | |
o YY YY) у LYYYYYYYYYYYYYYY
св
MDN o O oc © 0 |.
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x mo © mo > TITUS TT J Jw Hd dx ows oo
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моно Хо — SOSSE DD FLO
o © O = =
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— —
a
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=
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<TC” =
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540 DA
7.41
540 Sundancer: AC Wiring Schematic (240VAC) 09-630
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
7.42
UG 33
UNUSED
UNUSED
<[-226-16 RED/VIO
SHORE POWER PLUG *I
TO MAIN DC GROUND
227-16 BLK
-F DWG
9-603
09-630, 1 of 1, Revision 05
240VAC/50A BOAT CABLE
[Los 6/4 | BUSS BAR
==
| <N | +
| <L2 | | GALVANIC
Li = ; ISOLATOR
GENERATOR ENT BOAT CABLE 8 IN 8 GRN
por 6 BREAKER 6/4
2.5 KW or
| 240 vace N
| 60Hh7 **L? AC GROUNDING BUSS
LoL |
|
— | GROUNDING STUD
NOTE | $
REVERSED POLARITY
4 |
À
GENERATO | SHORE 240VAC
|
|
[240] —— 16 WHT [70
24VDC 6 GA WHT
BLOCK VOLTS . VOLTS
UT 6 GA BLK ‹ 6 BLK
LIGHTING a 6 GA RED
AMPS
MDP > -
; AMPS
240VAC LOAD 7
12/3 STOVE 2 | | 8 BLK
20 9 8 RED I20VAC LOAD
14/3 WATER HEATER An | | и ‘20 GALLEY 14/3
TP — $—— 715 — MASTER STATEROOM— 14/3
14/3
— FORT BLOCK TEATER- 5 3 $ {15 >— MICROWAVE —————— 14/3
| - — Y LN
14/3_STBD BLOCK HEATER In J | ÿT 15 *— FWD STATEROOM—— 14/73
NOTE) > NEUTRAL BUSS Î {15 — REFRIGERATOR — 14/3
12/3 CONVERTER 10° 4 ‘ 5 SALON 14/3
| oN _
XX ACCESSORY SL | $ 20 >—WASHER/DRYER 12/3
> | | NOTE: $—— 90° — BILGE/COCKPIT — 14/3
— ) DENOTES SLIDE SHUTTLE, ONLY ONE SOURCE | AN |
2/3 A/C UNIT * 9 TO THE GROUNDING BUSS BAR. 15 >— COCKPIT ICE MAKER— 14/3
4 3) ALL I20VAC EQUIPMENT NEUTRALS RETURN ó LD GENERATOR 15/3
A ) TO THE NEUTRAL BUSS BAR. — CONVERTER (av)
12/3 A/C UNIT *2 | 4) VALUES LISTED FOR CAT 3406E OPT USE 10 AMP +15 — GANG PLAK ———— 12/3
| FOR DDEC OPT, | > BOW THRUSTER диз
2/3 176 UNIT 53 DK CONVERTER (24V)
$ ó—— 5 Ze >—DISWASHER ———— 14/3
(OPT)
| Uy >— ACCESSORY ———— XX
XX ACCY DD
XX *
540 DA
540 Sundancer: AC Wiring Schematic (240VAC/120VAC) 09-631
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
PLUG 33
SET
3|<—226-16 RED/ VIO
SHORE POWER PLUG *I
TO MAIN DC GROUND
4 227-16 BLK
REF DWG
09-603
09-631, 1 of 1, Revision 06
540 DA
240VAC/50A BOAT CABLE BOAT CABLE
| «12 | | GALVANIC GALVANIC | de |
x | | ISOLATOR ISOLATOR (55 AMP] NL)
_. $ 155 AMP) T i MAIN SHORE POWER PLUG #2
GENERATOR MAÍN BOAT CABLE 8 GRN 8 GRN а СРМ BREAKER I20VAC/50A
——— BREAKER 6/4
[15 kW Te - au |
| 240 vace N |
| 60H7 *—L2 AC GROUNDING BUSS
LoL] |
|
POWER POWER
+ 8 GRN +74 0
| | 8 GA A 0)
| GROUNDING STUD N
NOTE | | © Xx
ИИ |REVERSED POLARITY NOTE — | REVERSED POLARITY
EE x=] RISA %
GENERATOR SHORE 240VAC TRANSFER | 50A | 504 || [SHORE I20VAC
= LI MA
24VDC [240] 6 GA | 16 WHT + [20
6 GA _ 6 BLK -
BLOCK VOLTS — 8 WHT | VOLTS
LIGHTING 6 GA
6 GA — 8 WHT NX 8 Ga
[ 100] |
AMPS
in MDP (D =
u AMPS
240VAC LOAD |
12/3 STOVE 1 | | 8 BLK
20 + 8 RED IZOVAC LOAD
14/3 WATER HEATER > | | $ £50 — GALLEY 14/3
RD 4 ——£15 >— MASTER STATEROOM — [4/3
14/3 PORT BLOCK HEATER |
— NOTE oF NE 15 ? 6 “15 — MICROWAVE 14/3
14/3 STBD BLOCK HEATER = 1 | a $—— 15 >— FWD STATEROOM—— 14/3
(NOTE 4) | | NEUTRAL BUS с $ <5 >— REFRIGERATOR ——— 14/3
12/3 CONVERTER 10° | d 5 — SALON 14/3
XX ACCESSORY + ® ‘20 WASHER/DRYER —— 12/3
ХХ * p NOTES: AN
> | ) DENOTES SLIDE SHUTTLE, ONLY ONE SOURCE у 207 BILGE/COCKPIT —— 14/3
14/3 A/C WATER PUMP & RELAY CAN BE ENERGIZED AT A TIME. | TN
5 à + 2) ALL EQUPMENT SAFTEY GROUNDS RETURN XX ACCESSORY XX
I > TO THE GROUNDING BUSS BAR. +——< 15 >— COCKPIT REFER——— 14/3
12/3 A/C UNIT *i \ | 3) ALL IZOVAC EQUIPMENT NEUTRALS RETURN TO AN GENERATOR
я 1 THE NEUTRAL BUSS BAR. ? — 5 CONVERTER (12V) 12/3
; $ 4) VALUES LISTED FOR CAT 3406E OPT USE I0 AMP IN
12/3 A/C UNIT #2 20 4 FOR DDEC OPT. ¢—=xX = ACCY XX
AS 5s BOW THRUSTER _____ |a/3
` ? CONVERTER (24V)
22/3 A/C UNIT F3 O 4 4% DISHWASHER 4/3
y | A (OPT)
12/3 ACCY (CKPT A/C UNIT) o | — xx ACCESSORY XX
Y Y >— ACCESSORY XX
XX ACCY
7.43
540 Sundancer: AC Wiring Diagram (220V-50hz) (Optional) 09-634
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
TO DC MAIN GROUND
SHORE POWER PLUG *1
220VAC / 32A BOAT CABLE BUSS BAR BOAT CABLE
| «+6 — GRN ===, 1 [ —— —— GRN —ch |
| HN — wr I | + : HT, BLK — |-> |
| — -- GALVANIC GALVANIC » | — N+>
ISE TB pP | ISOLATOR ISOLATOR ~ AB AMP] MT U NL
te + MAIN HORE POWER PLUG *
BREAKER | | BREAKER SHO 52 avaC/ 32A :
8 GRN
GENERATOR BOAT CABLE $ GAN 8 GRN
| me 6/3
— GRN
| 125 KW et 6 ;
220vac OT N — WHT
| 50H °T L — BLK GROUNDING BUSS
ee o — ———
POWER | POWER
г — — — — 8 GRN — тт
I о
| : ` ‘ | 8 WHT | |
TT от 8 BLK —— \ - = —
GROUNDING STUD \ \
NOTE 1 REVERSE POLARITY REVERSE POLARITY
NE NOTE 1 Е DU 71
| VW + |
| PE
GENERATOR | EVA TRANSFER | 50A 354 | | SHORE 220VAC LINE 2
PLUG 33 | |
1 [<- UNUSED 16 BLK DE —] |
2 |< UNUSED 1220) | —16 RED 8 BLK + 220
3 226-16 ВЕО/У10 — 24VDC 8 WHT
4 227-16 BLK —— , BLOCK VOLTS
LIGHTING 8 WHT VOLTS
REF DWG EI
09-603 AMPS
8 WHT =
25
]
MDP a
LINE 1 220VAC LOAD
8 BLK LINE 2 220VAC LOAD
12/3— GALLEY 715 $ d -— 20 —STOVE 12/3
14/3—— REFRIGERATOR {7.5% 4 $——30’— WASHER/ 12/3
ОНИ Zn 1 7 A/C UNIT *3 MASTER
14/3—— MICROWAVE o 7 $= 10 — STATEROOM (7,008 BTU 12/3
14/3—— PORT BLOCK HEATER 715 $ d ——10 >— WATER HEATER ————14/3
14/3——STBD BLOCK HEATER 75 $ 5 > — GENERATOR 14/3
XXX —— ACCESSORY x $ 410 — BOW THRUSTER 24v 14/3
XXX —— ACCESSORY ER $ NOTES: é——< xx > ACCESSORY XXX
AIN .
14/3— SALON 10 * $ ) DENOTES SLIDE SHUTTLE ONLY ONE SOURCE ¢——="18 > FORWARD STATEROOM — 1473
MT] A ЛО
14/3 — — MASTER STATEROOM {10° $ CAN BE ENERGIZED AT A TIME. | d ——7.8 —— COCKPIT ICEMAKER ———14/3
14/3 — A/C WATER PUMP AND RELAY ZE 4 2) ALL EQUIPMENT SAFETY GROUNDS RETURN d 15 BILCE/COCKPIT 14/3
— ах TO THE GROUNDING BUSS BAR. AN
—- s E
AC ooo MERO“ — Y 3) NEUTRAL WIRES FROM EACH LOAD BANK RETURN Xxx
12/3 ——A/C UNIT 52 SALON 20 .-—.— —ф TO THEIR RESPECTIVE NEUTRAL BUSS BARS. b—— ogy CONVERTER (24V) 12/3
12/3 —— (OPT CKPT A/C UNIT 38,000 BTU—Z 30% $ 4) VALUES LISTED FOR CAT 3406E OPT USE IO AMP b—— UK ACCY XXX
XX —— DISHEORHER 5 FOR DDEC OF xx > ACCESSORY XXX
NEUTRAL, BUSS NEUTRAL BUSS
09-634, 1 of 1, Revision 04
7.44
LINE 2
540 DA
540 Sundancer: CO Monitoring Wiring 09-699
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
REF DWG
09-604 IO RED/ VIO
| IO BLACK
O DC
R
T
GROUND BUSS
09-699, 1 of 1, Revision 00
Na
540 DA
o
premi
SALON
CO
MASTER STRM
CO MONITOR
FUSE BLOCK
= == 0 | == |]
© ©
==> | со | =_= [5]
== lu | << |f e]
= = (IS M| == [ 0]
© ©
==ЦА ео | с — | ==]
= осей =
В шее =
— 15 BEE
| =
a —
=
AFT STRM
GUEST STRM
STB
SALON
3 GUEST ST RM
5
7
CO3 16 RED/VIO — MONITOR —— C04 16 ВСК
FWD STRM =
co
NOTE
1D REF DWG 09-105 FOR INSTALLATION,
2) CO MONITOR GROUNDS TO CO MONITOR FUSE BLOCK GROUND.
MRP* 1420082
7.45
540 Sundancer: KYSOR Medallion Interface Harness Construction 09-848
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
SPLICE LOCATION PLUG 86 (A-E) LIGHTING
kde 85 INSTRUMENTS LONVERTOR
Lu KL
A|>+ 2027 16 RED :
B|>1- UNUSED YY Y Y Y VEVEVEVE
C|>+ UNUSED à to 2 Y Y Y Y Y | PLUG 87
D| >1 UNUSED =? ^ от | COMPASS/SYS MON LTS
El >+ UNUSED РО (+) (=)
F{ > UNUSED |
G | >+ UNUSED Г, Yi © |
; > po VAT 7 \ 7] © 20204 16 BLK —
>T | 7 Yi6é————120228 16 GRN 20208 16 BLK <I CAP 9l
| о 2022A 16 BLU STATION
2023 18 WHT 3 SWITCH
20255 18 WHT +< 4 PANEL
| > UNUSED 2024 18 WHT +<B
PLUG 70 2 |>1 UNUSED 2025P 18 WHT +<B
MNDE 3 |> 255 18 WHT
4 |>+ UNUSED
5 |>+ 202 18 WHT
6 |>T UNUSED
7 |>+ 200 18 WHT
8 |>1 UNUSED
9 | >} 2024 18 WHT
10 1? 2023 18 WHT -
11 |>+2025P 18 WHT
12 |>l 20255 18 WHT —
13 | >+ UNUSED 200 18 WHT +<|1
14 |>+ UNUSED UNUSED <P
202 18 WHT+4< 13 CAR 80
15 |2 UNUSED — BILGE
16 |>+ UNUSED 255 18 WHT <4 HARNESS
17 |>T UNUSED FWD DC р 25616 В|К +<B
18 |>+ UNUSED ee = UNUSED+<B
19 | > UNUSED —
20|>t 257 16/2 RED 257 16/2 RED > [1 ENGINE
21 |>+258 16/2 BLK 258 16/2 BLK 2 HARNESS
22|>+259 16/2 RED > — ST
23|>+260 16/2 BLK |
24|>+ 2030 18 BLK /2R CAP 82
> т L- 929 1672 RED TSI ENGINÉ
FWD DC 260 16/2 BLK HARNESS
GROUND
BUSS
09-848, 2 of 4, Revision 00
7.46
24VDC
MRP #1458322
540 DA
540 Sundancer: Engine Harness Construction (CAT 3406E/3196) 09-862
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
Na
CONTROL STATION
ENGINE
ENGINE CONNECTOR
IG BRN SYNC IP |
lo YEL SYNC IP2
16 ORN MAINTENANCE IND
16 YEL SECCNDARY THROTTLE
- м ев ее ее че ео == фе еее ее ст се сток еЯ == ее ее ee mer ее dm fe ee ет с нк че 0 0 ee те се тт ет wm ae ar er om == —Фо ен wn a A ED A wm ww
16 BRN PRIMARY THROTTLE
E 16 ORN/BLK SLOW VESSEL
14 BLK/RED SHUTDOWN
__ NOTE 7 IG RED ATA DATA
INSTRUMENT. / \ | J I6 BLK ATA DATA
EMS CONNECTOR A N 16 REC CAT DATA LINK(+)
— ( ] N \ 14 BLK BATTERY(-)
1>— 14 VIO 7 VER 16 ELK/YEL TROLL SW
> 14 BLK 7 | N y \
> 16 BLK US/METRIC 7 N N 14 YEL/RED STAR] — — —
4>4— 16 GRY SCROLL FWD-— N \ \
>1— 16 AWG SHIELDED TWISTED PAIR BLK NH RN 16 BLK CAT DATA LINK -
SI 16 AWC SHIELDED TWISTED PAIR RED — >< >< >IT > PA. >> >< и X NN |
> N
J N TEMP SENDER
>— 16 PNK/BLK ALARM — 2 '
19>+— 16 BLU LIGHTING = '
оо | a
or wo i = LJ
gas > °xgzxgoge „еб
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NNN NN INN LS td тоны Io
use SEC CS € © >
> OM>-DO>-5 a 6560 Za © = ‘о т т
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CONTROL STATION SW PANEL SYSTEMS PORT Cal TWIN DISC/PLEASURE LOK
REF DWG 09-601 SHEET ? MONITOR STBD P82 SYSTEM CONNECTOR
REF DWG REF DWG 09-866 OR 09-867
09-60! ATA DATA
SHEET 4
EXH TEMP
SPLICE LOCATION (h SENDER
. 60"
STBD 193
J SPLICE LOCATION (2 РЗ!
i 72 PORT 203: N. e le i
PORT 106" 6"
" " STBD 60" 12"
60 TO L— 14 BLACK TO GROUND
PORT[P5I] [P5IISTBD P82|C81| | Р9 |
CONTROL STATION TO ATA TWIN DISC/PLEASURE LOK
SWITCH PANEL — V DATA SYSTEM CONNECTOR
TO SYS MON
09-862, 1 of 2, Revision 03
540 DA
за РЗ!
REF DWG
3509-60!
SHEET 5
AA]
22
10
38
26
36
31
32
NANANAANANARANRAAARAXNARÁA
7.47
540 Sundancer: Twin Disc System Wiring Schematic 09-869
Note: This schematic is subject to variance due to customizing optional accessories and equipment updates.
1
STBD ENGINE MAIN DC PORT ENGINE
GROUND BUSS
CAP 73 САРТ2
MAIN DC BREAKER PANEL
STBD TROLL PLUG 37 PORT TROLL
VALVE — VALVE —
5064,5065 5056,5057
PLUG TI -САР 7|
VENDOR SUPPLIED
) <
| HELM CONTROL NN
TROLL SW
DPST J
lL NZ |
[ AR
GRN — N— WHT
RED BLK
VENDOR SUPPLIED
09-869, 1 of 1, Revision 01
Na
7.48
NOTE: ELECTRONIC SHIFT CONNECTOR SHOWN IF APPLICABLE.
540 DA
section & *
Accessories
Air Conditioning & Heating
The 540 DA air conditioning/heating system consists
of three (3) standard air conditioning/heating units,
one (1) raw water pump with a seacock and strainer
and a relay unit so the water pumps will be activated
by demand when any AC unit comes on.
The forward unit is located under the guest
stateroom bunk. The controls for the unit are located
on the forward side of the starboard hanging locker.
The air filter is located on the face of the unit.
The salon unit is located under the aft end of the
salon sofa. The controls for the unit are located above
the sofa. The air filter is located on the face of the
unit.
The 540 DA master stateroom unit is located under
the master stateroom bunk. The controls for the unit
are located on the starboard side of the bunk. The
air filter is located on the face of the unit.
The system is cooled to maintain optimal operating
temperature by the raw water pump located in the
bilge, forward of the port engine (see fig. 2.11.1).
The pump draws water through a seacock and filters
it through a sea water strainer. The water passes
through each compressor cooling the condensing
coils, then flows overboard. (The sea water strainer
should be inspected frequently and cleaned out when
plugged. To clean strainer, refer to “Section 2,
Seacocks & Strainers”).
The condensation drains for all the cabin units drain
into the shower sump located under a salon hatch.
Remove the hatch to access the sump (see fig. 5.3.1).
[
Typical Air Conditioning Component Arrangement ;
(fig. 8.1.1)
ARAN CONTROL & STATEROOM
AIR DUCT THERMOSTAT A/C UNIT
PANEL
> A/C RELAY UNIT
A
-
| > [5 17
| SALON
A/C UNIT
DM Do WATER PUMP STRAINER
MASTER
STATEROOM
- A/C UNIT
COOLING WATER
DISCHARGE SEACOCK
(THRU-HULL FITTING)
3 A/C
COMPRESSORS
AIR CONDITIONER/HEATER IN ACCESSORY
COMPRESSOR/BLOWER ROOM
ASSEMBLY
COOLING WATER INTAKE
(AC SYSTEM SEACOCK)
` J
540 DA
8.1
To start system:
1. Make sure the seacock for the cooling water
pump is open.
2. Turn ÓN the “A/C WATER PUMP & RELAY”
circuit breaker on the main AC distribution panel.
Turn ON each “A/C UNIT” circuit breaker.
3. Refer to air conditioner owner’s manual in the
owner's packet for instructions on operation of
the control panels.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
To anchor, bring the bow into the wind or current
and put the engine in neutral. When the vessel
comes to a stop, lower the anchor from the bow.
The anchor line should be 5 to 7 times the depth of
the water.
ANCHORING ARRANGEMENT I
The 540 DA is equipped with a windlass and an
anchor chute. Stow the anchor in the chute when
not in use.
NOTE: Before using the anchor, be sure the anchor
lanyard is removed from the anchor and the anchor
15 secured to the windlass chain.
Anchor Arrangement (fig. 8.2.1)
SAFETY HOOK
SEARCH LIGHT
ANCHOR CHUTE
WINDLASS FOOT SWITCHES
N D
JJ. Г) ==
57
—
DRAIN
WINDLASS
FRESH
WATER
ANCHOR HATCH WASHDOWN
Na J
Anchoring
The rode is the line connecting the anchor to the
boat.
* Nylon line is ideal because it is light, strong,
stretches, can be stowed wet and is easy to handle.
8.2
Add a short chain between the anchor and the
nylon line to prevent abrasion of the line.
The scope is technically defined as the ratio of the
rode length to the vertical distance from the bow to
the sea floor.
о Scope depends on the type of anchor, bottom,
tide, wind and sea conditions.
Rode Length
Bow Height + Water Depth
Scope =
e Minimum is 5:1 for calm conditions; norm is 7:1;
severe conditions may require 10:1.
Since you want to know how much rode to use when
anchoring, the formula is:
Rode Length = (Bow Height + Water Depth) x Scope
Example:
Rode Length = (3 feet + 10 feet) x 7*
Rode Length = 13 feet x 7*
Rode Length = 91 feet
* Scope factor may range from 5 to 10 or more.
Less than 5, the anchor breaks out too easily.
Lowering Anchor
Be sure there is adequate rode.
SINKING HAZARD — Anchor from the bow if using
one anchor. A small current can make a stern-
anchored boat unsteady; a heavy current can
drag a stern-anchored craft under water.
COLLISION HAZARD - Anchor only in areas
where your boat will not disrupt other boats. Do
not anchor in a channel or tie up to any
navigational aid. It is dangerous and illegal.
* Secure rode to both the anchor and the boat.
* Stop completely before lowering anchor.
If using windlass, refer to windlass operator’s
manual.
* Keep feet clear of coiled line.
* Turn on anchor light at night and in reduced
visibility.
Setting Anchor
* There is no best way to set an anchor.
Experiment to see how your anchor performs.
* One method is to turn the rode around a bit
and slowly pay out as the boat backs from the
540 DA
f в
Anchoring (fig. 8.3.1)
Rode Length = (Bow Height + Water Depth) x Scope \ М № хх
| о
BOW HEIGHT N
WATER DEPTH
ANCHOR
anchor site. When the proper scope has been * Attach a line to the crown or head of the anchor
reached, snub the rode quickly, causing the and the other end to a float.
anchor to dig into the bottom. * The line should be just long enough to reach
* Reverse engine slowly to drive the anchor in the surface of the water, allowing for tides.
and prevent it from dragging. * A polypropylene line is a good choice because
Secure the rode to the bitt or cleat. it is light, strong and floats.
e |fthe anchor snags, pull vertically on the tripline
Weighing Anchor to lift the anchor by the crown.
e Run the boat slowly up to the anchor, taking in
the rode as you go. A Final Word
e The anchor will usually break out when the rode An anchored boat is affected by wind and sea
becomes vertical. conditions. Because there is no headway, there is
no control. Be alert! If leaving the boat, be sure the
Be careful that trailing lines do not foul in the anchor will hold under all circumstances.
propeller.
We suggest you read this section on anchoring again
and fully understand rode and scope and their affect
on anchor performance.
Coil lines to let them dry before stowing.
Clearing a Fouled Anchor
A fouled anchor can test your patience and ingenuity.
One of the best methods of breaking free is to set a
tripline before you lower anchor.
f =
Tripline Arrangement (fig. 8.3.2) ah AS
FLOAT
a
IU,
TRIPLINE RODE
ANCHOR
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540 DA 8.3
Retractable Sun Pad
The electrically actuated retractable sun pad is
located at the aft portion of the U shaped cockpit
seating area and is mounted at the transom wall
base and extends and retracts on two sliding tracks
(see fig. 8.4.1).
Electric Sun Pad
(fig. 8.4.1)
ELECTRIC SUN PAD
SWITCH
as |
CS
A
SUN PAD TRACK
7
The electric motor actuator is located under the
retractable sun pad (see fig. 8.4.2). To extend (out)
and retract (in) the sun pad, a momentary switch is
located behind a hinged door located on the port
side of the sun pad at the transom door (see fig.
8.4.1). The switch is protected by a 5 amp breaker
located on the main DC breaker panel called
Retractable Sun Pad (see fig. 7.5.1).
f A
Electric Sun Pad
(fig. 8.4.2)
ELECTRIC SUN PAD
MOTOR/ACTUATOR
N. J
When extending or retracting the sun pad a clicking
noise will acure at the end of the extension or
retraction. Immediately release the switch allowing
the motor actuator to stop.
8.4
When the sun pad is fully retracted back to the
seating position, two (2) electrical latches lock and
secure the seating position. When the switch is
pushed to extend (out) the sun pad, a solenoid
releases the locks. The motor actuator acts as a
locking security while the sun pad is extended.
Operating instructions:
1. Clear all persons and items away from sun pad/
seat and sliding track areas.
2. Push the sun pad switch to the OUT position
until fully extended.
3. Push the sun pad switch to the IN position until
fully retracted.
* Never allow anyone to lay under or crawl under
the sun pad/seat at any time.
Before operating the sun pad/seat, clear all
persons and items in the aft cockpit away from
the sliding tracks.
Ensure sun pad is fully extended (out) or fully
retracted (in) before allowing anyone to use the
sun pad or seating position.
* Never allow anyone to lay or sit on the sun pad/
seat while operating the motor actuator.
* Do not store any items under the sun pad/seat.
The area under the sun pad/seat is not for
storage. This area allows free movement while
extending or retracting the sun pad/seat.
Use CAUTION while utilizing sun pad while yacht
Is underway at all speeds.
f A
Electric Sun Pad
(fig. 8.4.3)
540 DA
Bow Thruster
The optional Bow Thruster is electrically driven and
gives the operator more maneuverability of the bow.
The Bow Thruster battery switch and control panel
are located on the control station (see fig. 3.1.1).
The control panel has a START switch, STOP switch,
CHECK SYSTEM indicator light, STATION
ENABLED indicator light and a HAND OPERATED
joy stick or push pads for thrust direction.
f A
Bow Thruster (fig. 8.5.1)
BOW THRUSTER
\.
The Bow Thruster motor is equipped with an internal
thermally activated breaker. The thermal breaker
protects the motor from overheating. When the
thermal breaker is activated the thruster motor will
not operate and must be allowed to cool down for
normal operation. Refer to Owner’s Manual Packet
for instructions and warranty information.
The Bow Thruster will add the following equipment
to your yacht:
e Bow Thruster — Access is gained to the Bow
Thruster motor by a hatch located in salon.
Batteries — Two (2) Group 8D 12 volt batteries
connected in series to provide 24 volts DC,
located in the bilge (see fig. 2.9.1).
e Battery Switch — Located on the control station
IS a rocker with indicator light switch.
о Battery Switch Solenoid — Located on the port
bilge component board (see fig. 2.9.1). The
solenoid is equipped with two (2) automotive
style fuses, one on the line side to power the
rocker switch which energizes the solenoid and
one on the load side to power the rocker switch
indicator light.
* (Converter — Domestic-24 volt/10 amp,
International- 120/240 volt/20 amp, located on
the port bilge component board (see fig. 2.9.1).
Fuse Protection — Two (2) 500 amp in-line fuses.
One (1) located on the Bow Thruster unit and
one (1) mounted located on the port bilge
component board (see fig. 2.9.1).
Remember — if breakers or fuses fail, always replace
with the same amperage device. Never alter
overcurrent protection.
540 DA
Canvas
It is recommended that you read pages 1.12 — 1.13
and understand the effects of exhaust emissions.
CARE & MAINTENANCE
Care and maintenance instructions have been
provided by the canvas manufacturer for the canvas
used on your Sea Ray®. The information can be found
in the owner's manual packet.
By following the provided instructions, your canvas
set will give you protection from the elements and
comfort that you expect. Most of all, the instructions
provide you with installation and removal procedures
that will simplify the task.
Standard 540 DA 540 DA Hard Top
Canvas: Option:
1 Bimini Top 1 Aft Curtain
1 Sun Shade 3 Windshield Visors
1 Aft Curtain 2 Windshield Side
3 Windshield Visors Curtains
2 Windshield Side
Curtains
Components of your canvas set consist of metal tube
frames, sliding adjustable frame tubes, frame
mounts, zippers, zipper tracks, Velcro® and snaps.
These components can be found in the parts manual
located in the Owner’s Manual Packet.
Storage:
Do not fold or store any of the canvas set pieces
while wet. All canvas should be rolled or folded
when dry and stored in a clean, dry place.
Forclear vinyl pieces, rolling or laying down flat
are the recommended methods for storage. The
clear vinyl should never be folded or creased as
cracking will result. To protect the clear vinyl from
rubbing against itself while rolled or stored flat,
place a piece of very soft, nonabrasive cloth
between the pieces, or rolled up in it. If the
surface of your clear vinyl becomes scratched,
the canvas manufacturer has provided a canvas
care sheet in your Owner’s Manual Packet.
Installation Tips:
e The zippers, attached forward and aft on the
spoiler, are mounted on a zipper track. Do not
remove the zippers or zipper track on the spoiler.
8.5
When attaching any of the pieces of the canvas
set, zip the zippers only partially. This helps to
hold the piece in place and relieves tension,
helping the other side zip or snap easier. After
all of the sides of the piece are secure, then
finish zippering. This will ensure a tight fit.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
CANVAS INSTALLATION
Note: The Bimini Top and Sun Shade must be
installed first. All the other pieces are attached to
the Bimini Top and Sun Shade.
Bimini Top and Sun Shade
(540 DA with Sport Spoiler Only)
The Bimini Top and Sun Shade canvas is supported
by tubular stainless steel. Some of the frame tubes
are adjustable. When attaching the Bimini Top and
Sun Shade pieces to the spoiler, adjust the frame
tubes to relieve tension on the canvas, engage the
spoiler zippers and zip completely. By pulling down
on the front of the Bimini Top (and back of the Sun
Shade), the adjustable frame tubes will adjust to
provide tension on the canvas material and give a
tight fit.
1
540 DA Canvas (fig. 8.6.1)
WINDSHIELD VISOR
SIDE CURTAIN
AFT SIDE CURTAIN
BIMINI TOP
WINDSHIELD VISOR HARD TOP
SIDE CURTAIN |
3 PIECE AFT
CURTAIN
SPOILER
SUNSHADE
4 PIECE AFT
CURTAIN
Aft Curtain
(540 DA with Sport Spoiler or Hard Top)
The Aft Curtain attaches to the aft edge of the Sun
Shade or Hard Top. Partially attach the Aft Curtain
to the Sun Shade or Hard Top zippers, then attach
the snaps to the gunwale and transom. After
attaching the snaps, finish zipping.
Windshield Visor
(540 DA with Sport Spoiler or Hard Top)
The front Windshield Visor consists of three (3)
pieces. The Windshield Visor is best installed by
attaching all three (3) pieces to the forward edge of
the Bimini Top or Hard Top, then loosen the zipper
on the Bimini Top or Hard Top at the spoiler. Attach
the bottom of the three (3) pieces to the windshield
frame with snaps, then finish zipping.
Windshield and Sunshade Side Curtains
The Side Curtains attach in the same manner:
partially zip, snap, then finish zipping.
Coffee Maker
The drip coffee maker operates on the 120 volt
system. It is protected by the “GALLEY” breaker on
the main distribution panel which must be ON to
operate the coffee maker.
To keep the coffee maker operating efficiently, the
mineral deposits left by water must be flushed out
using the cleaning method described in the
instruction booklet.
To remove coffee maker:
1. Make sure the “GALLEY” breaker is OFF.
2. Remove the carafe and water reservoir.
3. Remove the screws going through the right and
left sides.
4. Slide out coffee maker and unplug.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Entertainment Center
SALON ENTERTAINMENT CENTER
The salon entertainment center consists of a 25"
television with remote, video cassette recorder with
remote, AM/FM stereo with compact disc player and
antenna. The 120 volt “SALON” breaker must be ON
540 DA
to operate the AM/FM stereo with compact disc
player and antenna. The 120 volt “GALLEY” breaker
must be on to operate the television and video
cassette recorder.
The system has two (2) speakers in the salon with a
subwoofer under the salon entry steps. Speakers in
the master and guest staterooms are optional.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
MASTER AND GUEST STATEROOM
ENTERTAINMENT CENTER
The stateroom entertainment centers consist of a
television and video cassette recorder with remote.
To operate, turn ON the 120 volt “MASTER or
GUEST STATEROOM” breaker on the main
distribution panel.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
TV SIGNAL SELECTOR
The antenna/cable selector panel is located inside
the mid salon upper cabinet. Push the button marked
“SHIP” for onboard TV antenna reception. Push the
button marked “SHORE” for dockside cable
reception. The dock side cable television inlet is
located aft of the transom door (see fig. 7.10.1).
REFER TO OWNER’S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
CABLE TELEVISION CONNECTION
1. Open the starboard transom hatch (see fig.
7.10.1).
2. Screw the TV coax cable into the TV cable
connector.
3. Run the cable to the dockside receptacle and
screw coax cable into receptacle.
COCKPIT ENTERTAINMENT CENTER
The system consists of a 12 volt AM/FM stereo
compact disc player with disc changer and four (4)
speakers. The CD changer is located in the salon
on the entertainment center. The unit is also
equipped with a cockpit remote located on the
starboard side. The system is wired to the fuse block
under the control station.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
8.7
Automatic Fire
Extinguisher System
Your 540 DA is equipped with an automatic fire
extinguisher system, located in the engine room bilge
(see fig. 2.11.1 and 2.11.2). The system uses fire
extinguishant and in the event of a fire, the heat
sensitive automatic head will release the
extinguishant as a vapor, totally flooding the area in
fire-killing concentrations. The system indicator light
is wired to the ignition and is turned ON when the
ignition is turned ON.
The system incorporates an engine shutdown switch
with override system.
The indicator light, located on the control station
instrument panel, indicates to the helmsman when
the unit has discharged. Under normal
circumstances, when the engines are operating, the
indicator light is lit. If the unit discharges, the light
will go out.
Automatic Fire
Extinguisher System
(fig. 8.8.1) DISCHARGE
ALARM BUZZER
CHARGE 8 DISCHARGE CA
INDICATOR LIGHTS
ENGINE SHUTDOWN
OVERRIDE SWITCH
REMOVE PIN
PULL HANDLE
UPON SYSTEM DISCHARGE, SHUTDOWN:
* ENGINE
* FORCED VENTILATION
* ELECTRICAL SYSTEMS
MANUAL FIRE
EXTINGUISHER
PULL CABLE RELEASE
STARTER
IGNITION
IGNITION
SWITCH
BATTERY
GROUND
WHEN ACTUATION OCCURS, IMMEDIATELY
SHUT DOWN ALL ENGINES, POWERED
VENTILATION, ELECTRICAL SYSTEMS AND
EXTINGUISH ALL SMOKING MATERIALS. DO
NOT IMMEDIATELY OPEN THE ENGINE
COMPARTMENT!! THIS FEEDS OXYGEN TO THE
FIRE AND FLASHBACK COULD OCCUR.
8.8
Allow the extinguishant to “soak” the compartment
for at least fifteen (15) minutes and for hot metals or
fuels to cool before cautiously inspecting for cause
of damage. Have portable extinguishers at hand
and ready. Do not breathe fumes or vapors caused
by the fire.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
The dual air horn is operated and protected by a
momentary toggle switch and “HORN” breaker on
the control station switch panel. The compressor
and accumulator tank are located behind the main
distribution panel.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
The 120 volt “COCKPIT ICE MAKER?” breaker turns
ON the cockpit ice maker. The “FRESH WATER
PUMP” breaker must also be ON to supply water to
the ice maker. Do not block air flow through the
ventilation panels at the bottom of the unit.
To start unit:
1. Make sure water tank is full.
2. Turn “FRESH WATER PUMP” breaker ON.
3. Turn ON ice maker switch, located under the
ice maker door.
As a precaution, the first few cycles of ice cubes
should not be used because of possible
contamination in the line. Once the ice maker is full,
the unit will shut off automatically and cycle as ice
cubes are used.
To remove the ice maker:
1. Make sure the “FRESH WATER PUMP” and
“COCKPIT ICE MAKER” breakers are OFF.
2. Remove screws securing the unit to the
bulkhead.
3. Disconnect the ice maker water lines and
unplug.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
540 DA
Oil Change System
The oil change system, located under the port
engine, simplifies changing the oil in the engines and
transmissions. The pump is self-priming and pumps
in either direction. The reservoir jugs provided sit
behind the port engine. The oil change pump is
protected by the 24 volt “OIL CHANGE PUMP”
breaker on the DC distribution panel in the cockpit.
Operating instructions: (Service one (1) engine
at a time.)
1. Run engines or generator for several minutes
to warm the oil and mix the sludge.
2. Select the first unit to be serviced. Turn the valve
to the open position, in line with valve body.
Have only one (1) valve open at a time. Make sure
other valves are closed to prevent accidental
over filling.
3. Turn the pump on (switch position indicates the
direction of flow) and pump the old oil into
containers to be disposed of properly.
4. After oil has been pumped out of unit being
serviced, place the pump discharge hose into
a container of pre-measured fresh oil and
reverse the pump switch to pump the fresh oil
into the engine. NOTE: Fresh oil should be at
least 60° F (16° C).
5. When pumping is complete, shut the pump off
and close the valve leading to the unit being
serviced.
6. Repeat for each engine, generator or
transmission to be serviced.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Power Ventilation System
The power ventilation system removes stagnant air
from the heads and galley by means of 24 volt
exhaust fans. They are powered by the “POWER
VENTS” breaker on the DC main distribution panel
and individually turned on and off by the power vent
switch in each head and the galley.
Refrigerator/Freezer
The refrigerator/freezer units operate on the 240 volt
AC system.
The “REFRIGERATOR” breaker on the AC main
distribution panel supplies power to the unit. To
operate, connect the shore power system, turn the
“MAIN” breaker(s) ON. Then turn the
“REFRIGERATOR” breaker on the AC main
distribution panel and the switch inside the unit ON.
Oil Change Pump &
Valve Assembly
(fig. 8.9.1)
TO OIL
CONTAINER
TO PORT
ENGINE
TO PORT
TO GENERATOR
TRANSMISSION
TO STBD
TRANSMISSION
ENGINE
OIL
4707
оон 0
DOSI>IJMZMO
TRANSMISSION
4707
оон 0
540 DA
8.9
To Remove the Refrigerator/Freezer:
1. Turn the 240 volt “REFRIGERATOR” breakers
OFF.
2. Turn “REFRIGERATOR/FREEZER” icemaker
water valve OFF, located in accessory room
(see fig. 2.8.2), and disconnect water line at
refrigerator/freezer.
3. Remove screws securing unit.
4. Pull unit straight out and unplug.
Do not cover refrigerator/freezer vents.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Salon Sofa/Sleeper (Electric)
The 540 DA salon sofa center section folds out and
down electrically to convert to a bed that can
accommodate two guests. The electric switch is
located in the aft salon at the aft sofa end table.
The electric motor and switch is protected by a 12
volt fuse located on the 12 volt fuse block behind the
helm foldout door (see fig. 3.1.1).
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
* Do not sit or lay on the sofa/sleeper while oper-
ating the switch.
* Remove the salon table and anything that could
be in the way while the sofa/sleeper folds out
and down.
* Do not use the underside of the center salon
sofa/sleeper for storage. This area is for the
sofa/sleeper folding mechanical linkage andits
travel.
* Before raising the sofa/sleeper back to the sofa
position, visually inspect under and behind for
obstructions. MAKE SURE AREA IS CLEAR.
The 540 DA searchlight is mounted on the bow.
To Operate:
1. Turn ON the “SPOTLIGHT” breaker on the
control station switch panel.
8.10
2. Press the POWER button on the spotlight pad
to turn on the searchlight.
3. Press SPEED button to adjust the movement
speed of the searchlight.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Stove a Microwave
ELECTRIC STOVE
The 240 volt “STOVE” breaker on the AC main
distribution panel supplies power to the stove and
must be ON to operate the stove.
The stove has three (3) burners with control knobs
to provide a variation of heat.
A stove power safety switch is installed on the lid
recess.
When the stove lid is installed it deactivates the
switch turning off power to the stove control knobs.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
MICROWAVE/CONVECTION OVEN
The “MICROWAVE” breaker on the AC main
distribution panel supplies power to the microwave
and must be ON to operate the microwave.
Note: Turn on the galley power ventilation system
when operating the convection oven.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Telephone
The telephone option consists of a waterproof inlet
located inside the transom storage (see fig. 7.10.1),
a fifty foot shore cord and telephone outlets in
various rooms throughout the boat.
Telephone System Hookup:
1. Locate telephone shore hookup inside transom
storage.
2. Connect shore cord to dock telephone inlet and
then to the boat inlet.
3. Telephone outlets are located in the salon,
master stateroom and guest stateroom.
4. Telephone system is now operational.
540 DA
Washer & Dryer (Optional)
The washer/dryer is a single front load washing and
drying combination unit. The unit operates on the
"WASHER/DRYER" breaker on the AC main
distribution panel.
The washer/dryer is connected to hot and cold water
shutoff valves behind the unit. The shutoff valves
are located under an access panel in the bottom of
the cabinet above the unit (see fig. 5.4.1). The supply
valves should only be on when the unit is being used.
The dryer lint filter can be cleaned by opening the
access hatch located on the bottom of the cabinet
over the washer/dryer unit.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
Washer/dryer should only be used when
connected to dockside water.
Central Vacuum System
The central vacuum unit is located under the aft end
of the salon sofa. The “SALON” breaker must be
ON to operate the system. The 24 foot hose connects
to the inlets located in the master and guest
staterooms. The built in switch on the hose inlet
fitting activates the vacuum when the hose is
plugged in.
REFER TO OWNER'S MANUAL PACKET FOR
INSTRUCTIONS AND WARRANTY INFORMATION.
CENCE TR
Wall Vacuum System (fig. 8.11.1)
540 DA
The windlass is wired to the 24 volt system through
the “WINDLASS” breaker located on the cockpit DC
main breaker panel.
REFER TO WINDLASS OPERATOR'S MANUAL
FOUND IN YOUR OWNER’S PACKET FOR
DETAILED OPERATING INSTRUCTIONS.
Note: Use the fresh water washdown spigot in the
rope/chain locker to hose down the rope and/or chain
in the locker after haul-in (see fig. 8.2.1).
NOTICE
Use the safety hook supplied to ensure that the
anchor is held in place should the windlass fail.
Do not use the safety hook to support the anchor
in a stored position. The windlass should always
support the anchor and ensure that it is held in
the roller device securely.
WINDSHIELD WIPERS
There are two (2) windshield wipers, each having
its own switch to operate. The switches are located
on the control station switch panel. Each wiper is
protected by a breaker on the control station breaker
panel.
WINDSHIELD WASHER
To operate, press the “WINDSHIELD WASHER”
switch on the control station switch panel and hold
the switch. The windshield washer system is
connected to the fresh water system. There is an
electric valve that controls the water flow to the
washer ports located behind an access hatch behind
the starboard cockpit seat back.
WINDSHIELD VENT
The windshield vent is located at the center
windshield. To open and close, press the
“WINDSHIELD VENT” switch located on the control
station accessory board (see fig. 3.4.1).
8.11
ACCESSORY LOCATIONS
WASHER /DRYER
GUEST
GUEST STATEROOM STATEROOM
TV VACUUM CLEANER HOSE OUTLET
GUEST HEAD
& SHOWER
SALON TV
VACUUM CLEANER UNIT
COFFEE MAKER
MICROWAVE GALLEY SALON STEREO
BLENDER
MASTER HEAD/SHOWER
STOVE
MASTER STATEROOM TV
VACUUM CLEANER HOSE OUTLET
REFRIGERATOR FREEZER
MASTER
STATEROOM
COCKPIT ICE MAKER
OPTIONAL
REFRIGERATOR
COCKPIT
a
(fig. 8.12.1)
8.12 540 DA
Section 9 e Storage & Launching Procedures
Laying-Up Instructions
LIFTING THE BOAT
When lifting the boat always keep the bow higher
than the stern to drain the exhaust lines and to
prevent water from running forward through the
manifold and into the engine where it can become
trapped. It may seem expedient to lift only the stern
when changing a propeller, but this can result in
water entering the engine cylinders, causing
hydrostatic lock and resulting in possible internal
engine damage and quite possibly engine failure.
Even a small amount of water in the engine can
cause rust and is to be avoided.
With fiberglass boats, severe gelcoat crazing or more
serious hull damage can occur during launching and
hauling if pressure is created on the gunwales by the
slings. Flat, wide belting-type slings and spreaders
long enough to keep pressure from the gunwales are
necessary. Cable-type slings should be avoided. Do
not place the slings where they may lift on the propeller
shaft or other underwater fittings. The slings should
be in accordance with the designated areas imprinted
on the deck to assure the least amount of stress on
the hull.
Never hoist the boat with an appreciable amount
of water in the bilge. Fuel and water tanks should
preferably be empty, especially if of large capacity.
Do not use cleats for lifting.
SUPPORTING THE BOAT DURING
STORAGE
A cradle is the ideal support for the boat whenever
it is not in the water. Properly designed and
constructed, it will provide support at the proper
points, which is essential to avoid stress on the hull.
Boat placement on the cradle should line-up as
closely as possible to the sling tags on the side of
the deck. Do not rest boat on underwater fittings.
DRAINING THE BOAT
In climates where freezing occurs, it is important
that the bilge be completely drained and dried out
when the boat is laid up for the winter. Some
compartments in the bilge may not drain completely
because of the position of the boat. They should
Proper Storage on Cradle (fig. 9.1.1)
“A SLING TAG
N
“A SLING TAG
má
DS DE ES < O и
540 DA
\
RIGHT (NO GAP)
\
WRONG (GAP)
9.1
be pumped out and sponged until totally free of
water or add sufficient amount of antifreeze to
standing water to prevent freezing.
The boat’s entire fresh water system must be
drained. Open all faucets, including the shower
faucets, throughout the boat. Open a connection at
the lowest point in the fresh water lines to completely
drain them. Break the connections on each side of
the water pump. Drain the heads. Drain the water
heater. Break the lower connection if necessary.
The engine cooling system and the exhaust system
must be free of water if there is danger of freezing.
Drain plugs are provided on the engine for this
purpose. It is necessary to open a connection or
two in the exhaust system to drain the lowest
portions; these should be reassembled securely
immediately after draining is accomplished.
CONSULT YOUR ENGINE AND GENERATOR
OPERATOR'S MANUAL FOR DETAILED
INFORMATION ON PREPARING FOR STORAGE.
WINTERIZATION CHECKLIST FOR
BOATS STORED ON LAND
1. Boat Storage
* Store boat in a bow high attitude.
e Pour one (1) pint of 50% water/antifreeze
mixture in each bilge sump.
2. Water System
* Turn ON fresh water pump.
о Open all faucets, let system drain completely,
leave faucets open.
* Remove hoses from water pump.
* Remove hoses from water heater and open
drain plug.
o Blow out all lines to clean.
* Pour one (1) pint of 50% water/antifreeze
mixture in shower drain to fill shower sump.
3. Ice Maker(s)
* Shut OFF water supply.
Disconnect the water supply from the unit(s).
Allow the unit to run for one hour. Remove any
ice cubes ejected during this period.
Shut OFF the electricity and prop the door open
to allow the unit to thaw.
After it has thawed, wipe it dry.
e Refer to your Ice Maker Owner’s Manual for
detailed information on preparing the ice
maker for storage and winterization.
9.2
Engines
Flush engines with fresh water.
Remove engine drain plugs. If boat is left in the
water, close the engine seacocks. If boat is
removed from the water, open the engine
seacocks.
Remove drain plugs from mufflers and
strainers.
Refer to your Engine Operator’s Manual for
detailed information on preparing the
engines for storage and winterization.
Generator
Flush generator with fresh water.
Remove generator drain plugs. If boat is left in
the water, close the generator seacock. If boat
is removed from the water, open the generator
seacock.
Remove drain plugs from muffler and strainer.
Refer to your Generator Operator’s Manual
for detailed information on preparing the
generator for storage and winterization.
Air Conditioner
Close through-hull seacock, remove hoses from
sea water pump.
Flush with fresh water through hose from sea
water pump.
Blow out water lines with air pressure.
Loosen the screws on the pump head, allowing
water to drain from the pump.
Remove hoses from condensing unit.
Remove strainer plug.
Batteries
Remove from boat.
Remove grease and dirt from top surface.
Grease terminal bolts.
Store on wooden pallet or thick plastic in a cool
dry place. Do not store on concrete.
Keep under a trickle charge.
When replacing battery in service, remove
excess grease from terminals, recharge as
necessary and reinstall in boat.
Head System - Vacu-Flush System With
Holding Tank
Flush entire system thoroughly with fresh water.
Pump out holding tank.
Shut “FRESH WATER PUMP” breakers OFF
on the main distribution panel and remove
hoses from each side of water pump.
540 DA
* Remove water line from inlet fitting located on
back bottom half of water valve on head.
* Flush one gallon antifreeze mixed with one
gallon of water through toilet and let vacuum
pump run for one or two minutes.
* Pump out holding tank.
Use an automotive or commercial ethylene glycol
base antifreeze. Do not use alcohol base products.
9. Fuel System
Diesel:
e Diesel fuel must be treated with a biocide,
“Biobor,” which prevents bacteria and fungi from
contaminating diesel fuel that contains some
walter.
Diesel fuel should also get a petroleum distillate
additive, such as “Sta-bil” or “Racor RX1000.”
This will help assimilate water in the fuel and
prevent freezing problems.
o Fill fuel tanks with the treated fuel.
* Run engines for ten (10) minutes to ensure that
all diesel fuel in injectors and fuel lines is treated.
Do not overfill. Filling a tank until the fuel flows
from vents is dangerous. Allow room for expansion.
REFER TO INDIVIDUAL OWNERS MANUALS FOR
SPECIFIC PROCEDURES.
Fitting Out After Storage
FUEL SYSTEM
Check the entire fuel system for loose connections,
worn hoses, leaks, etc. and repair. Thisis a primary
safety precaution.
EXHAUST SYSTEM
Examine the complete exhaust system, from engine
to transom. It is imperative that the entire exhaust
system be vapor proof and water tight. If a plug or
cover was used at the exhaust port, don’t forget to
remove it. Also check the drain plugs on the bottom
of the mufflers (see fig. 2.4.1). Do not over tighten.
Recheck the system with the engines running.
540 DA
CARBON MONOXIDE HAZARD - ensure engine
exhaust system is working properly. Carbon mon-
oxide poison is extremely toxic.
BATTERIES
Before installing the batteries, clean the terminal
posts with a wire brush or steel wool and then attach
the cables. After the cable clamps are tightened, smear
the post and clamps with grease to exclude air and
acid. Do not apply grease before attaching and
tightening the terminal clamps. Examine all wiring.
Refer to Section 7, page 7.2 for battery cable removal
and replacement procedures.
SHAFT ALIGNMENT
After winter storage and launching, some engine-
to-shaft misalignment can be expected. Refer to
“Section 2, Shafts” for instructions on checking the
alignment.
MISCELLANEOUS
1. Check all through-hull fittings for unobstructed
water passage. Be alert for any deteriorated
hoses and/or fittings below the water line which
might fail in service and admit water.
2. Inspect the rudder stuffing boxes. They should
be just tight enough to prevent excessive
leaking. Overtightening will destroy the packing
and score the shaft. Check the hose clamps
for tightness.
3. Inspect the propeller shaft Strong Seals™ There
should be no leaks. Check the hose clamps for
tightness (see Section 2, page 2.7 for more
information).
4. Make sure the rudder clevis pin on each side
of the tie bars is in and safe tied.
5. Check all strut fastenings and through-hull
fastenings.
6. Test the navigation lights.
7. Check all wiring for loose connections.
8. Check all switches and equipment for proper
operation. Anchor lines and gear should be
inspected and replaced if necessary.
9. Clean bilge thoroughly if it was not done at lay-
up.
10. Check all engine and generator fluid levels.
9.3
Section 10 * Care & Refinishing
Fiberglass
The fiberglass hull, deck and some interior parts
consist of the molded shell and exterior gel coat.
The gel coat is the outer surface, often colored, that
presents the shiny smooth appearance which is
associated with fiberglass products. In some areas,
this gel coat surface is painted or taped for styling
purpose.
Wash the fiberglass regularly with clean, fresh water.
Wax gel coated surfaces to maintain the luster. In
northern climates, a semiannual waxing may suffice
for the season. In southern climates, a quarterly
application of wax will be required for adequate
protection.
Gel coat surfaces are slippery when wet. Use
extreme care when walking on wet gel coat.
Care should be utilized in waxing commonly
walked upon areas of the boat to ensure that they
are not dangerously slippery.
If the gel coated surface gloss cannot be restored
by waxing, power buff with a rubbing compound such
as 3M Super Duty #05955, followed with 3M
Finesse-It 2 #05928, then wax.
An alternate method is to use Meguiars #44 Heavy
Duty Color Restorer followed with Meguiars #50
Boat Cleaner/Polish, then wax.
Recommended waxes are; 3M Imperial Hand Glaze
#05990 or Meguiars #26 Hiteck Yellow Wax.
If gel coat is not maintained and becomes heavily
oxidized, light sanding may be required before
buffing.
If your boat is equipped with a forward deck sun
pad it should not be left on the deck when not in
use. The gel coat finish may be affected over a
prolonged period of time.
540 DA
STAINS & SCRATCHES
Gel coat surfaces are very resistant to deep stains.
Common surface stains can be removed with diluted
household detergents, providing these detergents
do not contain ammonia or chlorine. Porcelain
cleaning powders are too abrasive and often contain
chlorine and ammonia, either of which would
permanently discolor the gel coat. Alcohol or
kerosene can be used for difficult stains but should
be washed away promptly with a mild detergent and
water. Never use acetone or any ketone solvents.
Minor scratches and deeper stains which do not
penetrate the gel coat may be removed by light
sanding and buffing.
SPECIAL CARE FOR BOATS THAT
ARE MOORED
If permanently moored in salt water or fresh water,
your boat will collect marine growth on its bottom.
This will detract from the boat's beauty and greatly
affect its performance. There are two methods of
preventing this:
Periodically haul the boat out of the water and
scrub the bottom with a bristle brush and a
solution of soap and water.
Paint the hull below the waterline with a good
grade of antifouling paint. DO NOT paint the
engine drive surfaces.
NOTE: There are EPA regulations regarding
bottom paint application. Consult your Sea Ray®
dealer for proper application methods.
Care for Bottom Paint
From time to time a slight algae or slime forms on
all vessels. The bottom painted portion of the hull
can be wiped off with a coarse turkish towel or a
piece of old rug while the boat is in the water. Do
not use a stiff or abrasive material to clean the
bottom.
The bottom paint should be inspected annually. If it
needs repainting, flush the old paint and wash with
hot water and powder laundry detergent. Rinse well
and let surface dry completely. Feather any deep
scratches with sandpaper and repaint, following the
directions on the bottom paint label. Replacement
coating can be ordered from your Sea Ray® dealer.
10.1
Fiberglass hulls should never be hauled, painted
and relaunched the same day since this does not
allow sufficient time for the moisture which has
been absorbed into the old paint film to completely
dry out. Generally, 24 to 36 hours of drying time is
required.
Bilge/Engine Compartment
1. Pump the bilges dry and remove all loose dirt.
Be sure that all limber holes are open. If there
is oil in the bilge and the source is not known,
look for leaks in engine oil lines or engine
gaskets. Qil stains can be removed by using a
bilge cleaner available from your dealer or a
marina. DO NOT use flammable solvents.
2. Check all wiring to be sure it is properly
supported, that its insulation is intact, and that
there are no loose or corroded terminals. If
there are corroded terminals, they should be
replaced or thoroughly cleaned. Tighten all
terminals securely and spray them with light
marine preservative oil.
3. Inspect the entire fuel system (including fill lines
and vents) for any evidence of leakage. Any
stains around joints could indicate a leak. Try a
wrench on all fittings to be sure they are not
loose, but do not over tighten them. Clean fuel
filters and vent screens.
4. Inspect the entire bottom for evidence of
seepage, damage or deterioration, paying
particular attention to hull fittings, hoses and
clamps. Straighten kinked hoses and replace
any that do not feel pliable. Tighten loose hose
clamps and replace those that are corroded.
Tighten any loose nuts, bolts or screws.
5. Refer to your engine operator's manual for
engine maintenance details. Wipe off engines
to remove accumulated dust and grease. If a
solvent is used, make sure it is nonflammable.
Go over the entire engine and tighten nuts,
bolts, and screws. Inspect the wiring on the
engine and clean and tighten the terminals.
Inspect the belts and tighten them if needed.
Clean and lubricate the battery terminals; fill
the battery cells with distilled water as needed.
Topside Areas
1. Check grab rails for loose screws, breaks, sharp
edges, etc., that might be hazardous in rough
weather. Inventory and inspect life jackets for
tears and deterioration. Check your first aid kit
to make sure itis complete. Check the signaling
10.2
equipment. Inspect anchor, mooring and
towing lines and repair or replace as required.
DO NOT stow wet lines or they may mildew
and rot.
2. Stainless steel and alloy fittings should be
cleaned with soap and water or household
glass cleaner. Remove rust spots as soon as
possible with a brass, silver or chrome cleaner.
Irreversible pitting will develop under rust that
remains for any period of time. Never use an
abrasive like sandpaper or steel wool on
stainless. These may actually cause rust. To
help protect the stainless we recommend the
use of a good car wax.
3. When instruments are exposed to a saltwater
environment, salt crystals may form on the
bezel and the plastic covers. These salt crystals
should be removed with a soft, damp cloth;
never use abrasives or rough, dirty cloths to
wipe plastic parts. Mild household detergents
or plastic cleaners can be used to keep the
instruments bright and clean.
Acrylic Plastic Sheeting
(Plastic Glass)
Never use a dry cloth or duster, or glass cleaning
solutions on acrylic.
To clean acrylic, first flood it with water to wash off
as much dirt as possible. Next, use your bare hand,
with plenty of water, to feel and dislodge any caked
dirt or mud. A soft, grit-free cloth may then be used
with a nonabrasive soap or detergent. A soft sponge,
kept clean for this purpose, is excellent. Blot dry
with a clean damp chamois.
Grease and oil may be removed from acrylic with
kerosene, hexane, white (not aviation or ethyl)
gasoline or aliphatic naphtha (no aromatic content).
Do not use solvents such as acetone, silicone
spray, benzine, carbon tetrachloride, fire
extinguisher fluid, dry cleaning fluid or lacquer
thinner on acrylic, since they attack the surface.
Remove fine scratches with fine automotive acrylic
rubbing and polishing compounds.
Upholsteries
Exterior fabrics should be cleaned with a sponge or
very soft scrub brush and a mild soap and warm
water solution. Rinse after scrubbing with plenty of
540 DA
cold, clean water and allow the fabric to air dry in a
well ventilated place, preferably away from direct
sunlight.
Sun pad should not be left on deck when not in
Mildew can occur if your boat does not have use. May affect gel coat finish.
adequate ventilation. Heat alone will not prevent
mildew, you must also provide for fresh air
circulation.
VITRACORE® CABINETS
To maintain the beauty of the galley cabinet surfaces and to prevent using the wrong cleaning agents, please
follow the cleaning recommendations listed below.
The following NOTICE label is placed on the fiberglass area of the galley countertop.
f ) Clean often with a soft cloth or sponge and mild
| NOTICE | soap and water. A non-ammoniated spray may
also be used. (Examples: Glass Cleaner-Vinegar
Glass Works by Miles, Inc.) Never use paper
Care and maintenance of your Vitracore® Cabinets
* Never use ammoniated window sprays or towels, abrasive pads or abrasive cleaners! Hairline
kitchen scouring components. scratches and minor abrasions can be removed or
* Never use solvents such as acetone, gasoline, minimized by using mild automobile polish, Johnson
benzene, alcohol or lacquer thinner. Paste or Mirror Glaze (M.G.M.10).
* Polish with light coat of automobile paste wax These care instructions refer specifically to the
or plastic cleaner/polish. Vitracore Cabinets surfaces. Ask your dealer about
* Failure to follow these instructions will result cleaning any hardware or trim which has been
in damage to your cabinets. incorporated in your cabinetry.
CLEANING RECOMMENDATIONS FOR MARINE FABRICS
Always clean immediately. Test an unseen area of fabric before cleaning stain.
Type of Stain Steps Cleaning Recommendations
1 2 3
Water Stain B | C | E A. White cloth - Westley's Clear Magic.
Motor Oil A B. White cloth - Westley's Clear Magic - air hose.
Spray Paint A D E С. Lendow Glass Cleaner.
Mildew A | E D. Lift Off Spot Remover,
Yellow Mustard A D E. Clothes shaver to remove lint.
Wet Leaves A F. Follow instructions of staining agent manufacturer.
Oil Base Paint A D F
Suntan Lotion” A E *Suntan lotions, wet leaves, permanent markers and some
Chewing Gum D other products contain dyes that permanently stain.
Tar D A
Lipstick A
Ketchup A
Grease A D
Ball Point Ink A
Household Soil A
Permanent Marker* A F
Coffee, Tea A
Chocolate A
Adhesive D
Teak Oil D
Latex Paint A D F
Crayon A D Cleaning recommendations provided by G&T® Industries.
540 DA 10.3
Section 11 * Service Information
Useful Service Information
OWNER
HOME PORT
BOAT NAME
REGISTRATION NUMBER STATE
HULL SERIAL NUMBER
WARRANTY REGISTRATION DATE
ENGINE MAKE & MODEL
SERIAL NUMBER PORT STARBOARD
GEAR MAKE & REDUCTION RATIO
SERIAL NUMBER PORT STARBOARD
PROPELLER SIZE PORT STARBOARD
PART NUMBER PORT STARBOARD
SHAFT SIZE (DIAMETER X LENGTH) MATERIAL
FUEL CAPACITY FWD TANK AFT
WATER CAPACITY
KEY NUMBER, IGNITION DOOR
SELLING DEALER
CITY & STATE
LENGTH BEAM DRAFT
VERTICAL CLEARANCE
ESTIMATED WEIGHT
GENERATOR SERIAL # MODEL # KILOWATTS
540 DA
NOTE: The Service Guide is based on average
operating conditions. Under severe operating
conditions, intervals should be shortened.
BEFORE
EVERY
USE
AFTER
FIRST
20 HRS.
EVERY
50
HOURS
EVERY
100
HOURS
ANNUALLY
CHECK SEA WATER STRAINERS & SEACOCKS
X
LUBRICATE SEACOCKS
CHECK ENGINE ALARMS
CHECK EXHAUST SYSTEM FOR LEAKS
CHECK FUEL SYSTEM LINES & CONNECTIONS
CHANGE WATER SEPARATING FUEL FILTER
CHECK STRONG SEAL™ ON PROP SHAFT
X |>X |X |X
CHECK RUDDER PACKING, TIGHTEN FOR
NO LEAKS
x
INSPECT CLEVIS PIN ON RUDDER TIE BAR
LUBRICATE RUDDER SHAFT
LUBRICATE THROTTLE & SHIFT LINKAGE
PIVOT POINTS
CHECK BATTERY ELECTROLYTE LEVEL
CHECK ALL ELECTRICAL CONNECTIONS
INSPECT PROPELLER FOR POSSIBLE DAMAGE
CHECK ENGINE TO SHAFT ALIGNMENT
CHECK WATER SYSTEM PUMP FILTERS
INSPECT FRESH WATER PUMPS
& WATER SYSTEM
CHANGE HEAD SYSTEM VENT FILTER
CHECK FLUID IN TRIM TAB PUMPS
TEST GFI OUTLETS
CHECK OIL IN STEERING SYSTEM
EVERY 3 MONTHS
540 DA
STARTING ENGINES
Quick Reference Departure
Checklist
BEFORE DEPARTING Do not run the generator or engines in an
enclosed area, such as a closed boat house, as
1. Weather Conditions - Safe To Go Out there is the possibility of inhaling exhaust fumes
2. Required Documents - All On Board and the build up of carbon monoxide.
3. Navigation Equipment - All On Board
4. Coast Guard Equipment - Required 1. Engine Seacocks - Open
Equipment On 2. Engine Compartment - Ventilated
Board
3. Blowers - Run When
5. Bilge Pumps - Working á Clean Operating Below
6. Blowers - Working Cruising Speeds
7. Navigation Lights - Workin & While
9 9 J Operating
8. Horn - Working Generator
9. Trim Tabs - Working 4. Fuel Valves - Check For Open
10. Fresh Water Tank - Full Position & Proper
, Direction Of Flow
11. Head System Holding Tank - Empty
Filled With 5. Bilge Area - Check For
12. Fuel Tanks - illed Wit Leaks, Fumes
Recommended
Fuel 6. Battery Switches - Check For ON
Position
13. Fuel System - Check For Leaks,
Fumes 7. Shift Controls - In Neutral
. Position
14. Fuel Filter - Check For
Tightness & 8. Throttle Controls - Advance Throttle
Clean Slightly As
. . Required While
15. Diesel Racor Fuel Filters - са & Water Operating Starter
ree
9. Ignition Breakers - Turn ON
16. Engine Coolant Drain Plugs - Secured
10. Alarm (Test) - Should Sound
17. Steering Fluid - Full After A Few
18. Steering System - Working Seconds
Smoothly & 11. Ignition Key - Turn ON
Properly
12. Momentary Start Switch - Hold ON Until
19. Shift & Throttle Controls - Synchronized, Engine Starts
Working Then Release
Smoothly &
Properly 13. Exhaust Port - Check To See
| That Engines Are
20. Oil - Check Level Pumping Water
21. Transmission Fluid - Check Level
Important: Do not continue to operate starter for more
22. Engine Coolant - Check Level than 10 seconds without pausing to allow starter
motor to cool for 2 minutes. This also will allow
23. Engine Seacocks - Check For Open
Position battery to recover between starting attempts.
24. Systems Monitor Panel - Test Alarm
25. Shore Power Cord - Disconnected &
Stored
540 DA 11.3
AFTER STARTING ENGINES
1. Qil Pressure Gauges - Check For
Normal Reading*
2. Water Temperature - Check For
Gauges Normal Reading*
3. Voltmeter - Check For
Normal Reading*
4. Fuel Gauges - Check For
Adequate Level
5. Fuel Lines - Check For Leaks,
Fumes
6. Engine Operation - Check Idle &
Shift
*REFER TO ENGINE OWNER'S MANUAL FOR
PROPER READINGS.
STOPPING ENGINES
1. Throttle Controls - Bring To Idle
Position
2. Gear Shift Controls - Bring To Neutral
Position
3. Mooring Lines - Secured
4. Idle Engines For 5 Minutes - To Cool Engines
5. Momentary Start Switch - Switch To OFF
Or Ignition Key Position Position
6. Battery Switches - Switch To OFF
Position
7. Fuel Shut-Off Valve - Switch To OFF
Position
11.4
OPERATING GENERATOR
Starting:
Do not run the generator or engines in an
enclosed area, such as a closed boat house, as
there is the possibility of inhaling exhaust fumes
and the build up of carbon monoxide.
1. Generator Seacock -
2. Bilge Blowers -
3. Depress And Release -
GENERATOR Switch
4. START Switch -
5. Generator Starts -
6. Load The Generator -
Stopping:
1. Breakers -
2. Generator -
3. GENERATOR Switch -
Open
Run Any Time
Generator Is
Running
Generator Goes
Into Preheat
Mode. Light
Flashes On The
Switch.
When Light
Flashes Rapidly,
Depress Until
Generator Starts
Release The
START Switch
Select
“Generator”
Power Source On
Main Distribution
Panel Main
Breaker
Switch OFF
“Generator” Main
Breakers At Main
Distribution Panel
Let Run A Few
Minutes To Cool
Depress To Stop
The Generator
Set
540 DA
A
AC Electrical System ..................eeeeneerecieccecees 7.9
Access Hatch, Engine Room .......................... 1.19
Accessory Locations esse 8.12
Accessory ROOM... eee, 2.8
Accident Report ......ccooviiiii KEG 1.9
Accommodation Plan eG 1.19
Aft Curtain ….….....…....…crrrrecsrerecsrer eee rene s anna 8.7
Air Conditioning .………….....….…….….....…errerceeesseceee 8.1
ANCHOFING eee, 8.2
Anchoring Arrangement .…….....…...........……...….…..……. 8.2
ANOAES, ZINC vrei A 7.21
Automatic Fire Extinguisher System ................. 8.8
B
Batterie ee 7.1, 7.2, 9.2, 9.3
Bilge cove, 2.1, 2.9, 2.10, 2.11, 10.2
Bilge Heat Detector ............................. 2.3
Bimini Top 8 Sun пасе... 8.6
Blower, Bilge ......ccovoiii en 2.2
Boarding .......ooooeviii en 1.6
Bow Thruster …….…....…....…...recrsereserensrcnse essences 8.5
Breakers, Electrical System 7.2
С
Cable Television Connection ........................... 8.7
Cablemaster ....................eeeeeeeeviricccecceeceeeeeeees 7.10
Canvas, Care 8 Maintenance .....................—.—..—... 8.5
Canvas Installation vn 8.6
Capacity, L08Q ee EEE EEE 1.6
Capacity, POWET ers K 1.6
Сар! то EEK KK 1.14
Carbon Monoxide ee 1.13, 1.16
Central Vacuum System ……...….…....……...….…….….… 8.11
Certifications, Manufacturer's 1.1
O1 1.13, 10.3
Cockpit Ice Maker een 8.8
Coffee Maker essen 8.7
Collision eevee eee eee, 1.14
Communication Equipment ............................. 1.16
Compass, Marine …….…..….…..…...…….sserrrccsseecnces 3.12
Construction Standards …….…....…….....…….………ecsrere 1.2
Control, Maneuvering/Maintaining .................... 1.7
Control Station Layouts 3.1, 3.2
Controls, Gear Shift & Throttle .................... 3.5-3.8
Convection Oven ..................eeevvriecireccecereeeceee. 8.10
Converters….…….....……......……rsrrrrccssence cesse rennes 7.18
Cooling System, Fresh Water ................c........... 2.5
Crossover Charging System ............................. 7.4
Crossover Fuel System ere 4.2
540 DA
Curtain, Affe ene er A 8.7
Curtains, Sunshade Side ...............................—_. 8.7
Curtains, Windshield Side ...........................—.... 8.7
D
DC System …..….....….….......rrrrerrccressareeec casser EEE 7.1
Detector, Bilge Heat …….…..……...….…...…….…..……..….……es 2.3
Detroit Diesel Electronic
Display Module (EDM) (Optional) ................. 3.11
Dimmer, Console RR RER 3.12
Distress Signals ........ccccooovviviiiii i, 1.17
DIVING conic ser en ser en ere near e eee 1.8
Draining the Boat... 9.1
DrOWNING .…..................urrcccsracc sara re sa rene near nee 1.16
E
Education .........ccoooiiii reee 1.2
ElectrolysiS .…..…...….........serserrenere sec serre senc seen ee 7.21
Emergency Procedures 1.14
Emergency Start System ……….….....….…....….…...…eeee 7.3
Engine Exhaust System …..…..…......……….....….….…….…..…. 2.4
Engine Monitoring System (EMS) (Optional) .. 3.10
Engine Room Hatch ...................222 0... 1.19
Engine Synchronizers eee 3.8
ENGINES ooo n ne 2.3
Engines, Starting... 4.3, 11.3
Engines, Stopping cree 4.4, 11.4
Entertainment Center, Cockpit ................. ==... 8.7
Entertainment Center, Guest Stateroom ........... 8.7
Entertainment Center, Master Stateroom ......... 8.7
Entertainment Center, Salon ............................. 8.7
Environmental Considerations ........................ 1.12
Equipment, Additional Recommended............ 1.10
Equipment, Minimum Required ....................... 1.11
Exhaust Emissions ...............—...r.eexeeeeeeeereee 1.12
EXplOSION …......….......…crecccercrsrensen senc senc see senese 1.14
F
Failure, Control or Steering 1.16
Fiberglass... AAA 10.1
Filters, Bilge Ventilation ............................———_—_—_— 2.2
CE 1.4, 1.14
Fire Suppression Equipment ............................. 1.5
Flame Arrestor .......cooiiii RKREKK RK EE KEG 4.1
Float Plan .................._...esreccereireeeceere reee 1.9
Flooding coor, 1.5,1.14
Fuel Crossover System .................e.eeeíevcirceneees 4.2
Fuel Gauge RER RR KR K KK R KK EEE 3.9
Fuel Recommendations ae 4.2
Fuel Spillage ......ccooovvvviiiii i, 1.12, 2.1
|
Fuel Systems ….……...........……crrreccrreeecssera casernes 4.1
Fuel Tanks ..................eeeemeiniee nenes 4.1
Fueling Precautions .................... ee... 4.3
G
Gauge, Fuel eK EEE 3.9
Gauge, Oil Pressure 3.9, 3.10
Gauge, Transmission Oil Pressure .................. 3.11
Gauge, Transmission Oil Temperature ............ 3.11
Gauge, Voltmeter ...........cooiiiiiiiii en, 3.9
Gauge, Water Temperature ...................... 3.9, 3.11
Gear Shift Control serrures 3.5-3.8
Gear, Underwater ….…..…....…......……….rrrrrccsercences 2.6
Gears, Marine eK 2.4
General Information ...................—.....eeeeeeeeie 1.1
Generator ......................eeiicicicecer e DD 7.20
Generator Power, Shifting From
Shore Power ..................veeerviecerricecee ce 7.21
Generator, Starting ...............——...— e... 7.20
Generator, Stopping eee 7.21
Glass, Plastic …........…..……..……...…..srrssrarenr en enr n rares 10.2
Ground Fault Interrupter Receptacle ............... 7.19
Grounding ....................eeeeeeeeeirer eee eee 1.15
H
Head System ….…..….….....….....…rrecccrsrerecansare cc annees 6.1
Head System Layout ….…..….....…......…...…………ereress 6.2
Head, Vacu-Flush ...................coo e 6.1
Heat Detector, Bilge ........................22......—— 2.3
Heating e AA 8.1
Holding Tank... ess ere 6.1
HOM ........eeeeeee cer e rer care are rene sen are nere nanas e nana 8.8
Hotlines, Safety ……....…….....……....…rrrrecaescrccanereee 1.9
Hourmeters .....................evierciinreerenereere eee 3.10
|
lce Maker, Cockpit.…….……..…....….....….…srneennnns 8.8
Impaired Operation ..………..……....……....……….rrccsserccuees 1.6
Inlet, Dockside Water eK 5.3
Inlet, Shore Power .......................... ee 7.12
Instruments & Controls ..................e e... 3.1-3.4
Introduction reinen DA 1.2
L
Laying-Up Instructions ................— e... 9.1
KL CE 1.15
Lifesaving Equipment ae 1.5, 1.6
Lifting Boat... AA 9.1
Lighting, Halogen ........................220 0... 7.4
Lights, Navigation essences 3.12
||
М
Macerator Discharge Pump .............................. 6.2
Main EMS Display ..................e.==.eeeemeeeeieceneee 3.10
Maneuvering .............…......…....ecesereessrrre eee 1.7
Medical Emergency... 1.16
Microwave/Convection Oven …………..…...…………..……….……. 8.10
Monitor, Systems.….….…...…….…..………………rcsrerre 3.12-3.14
N
Nautical Terms ..….…...…...…............eccrsecrecereensecnernnees 1.3
Navigation Lights... 3.12
NOISE, EXCESSIVE ceive DA 1.12
O
Oil Change System ................-..eeeme0reeireeeeeeee. 8.9
Oil Pressure Gauge...................eeeeeemeeeece 3.9,3.10
Oil Spillage .........................eeeeeeneeeeereeeeee.. 1.12, 2.1
Overboard, Person ….……….…….…….………….…………….…rssressanees 1.16
P
I reee reee. 1.13
Paint, Care for Bottom 10.1
Panel, AC Main Distribution Panel (Intl) ......... 7.16
Panel, AC Main Distribution Panel (U.S) ........ 7.13
Panel, DC Distribution 7.0
Panel, Main DC Breaker ...................—.—....... 7.4, 7.5
Panels, Control Station... 3.1-3.4
Parts a Equipment .....................eeeeeeeeerceeeceercee_ 1.3
Personal Flotation Devices (PFD) ..................... 1.5
Power Capacity .....................eeeeíeieeeecieereee e. 1.6
Power Ventilation System .....................eeexeeees 8.9
Precautions, Fueling ................—...=—...eeeee—. 4.3
Precautions, Safety ......................eeee.eereeereeee_s 1.4
Propellers ........................eermereeineerereneee e. 2.0
Propulsion Failure ................—...—...=..eeers 1.16
Pumps, Bilge... ee ss 2.1
Q
Quad Gauge....................eeeeeeeeeeereeeenreeee eee E 3.10
R
Radio Communication es 1.16
Receptacle, Ground Fault Interrupter .............. 7.19
Reference, Departure Checklist ...................... 11.3
Refrigerator/Free@ZeEl ee 8.9
Registration ..….…..…….....…......….srreseserenss see ss seen 00e 1.2
Responsibilities, Dealer ........................em..... 1.2
Responsibilities, Owner/Operator .............. 1.2, 1.3
Rudder .......cooi R RER KERKERKREK RER KERKER EEG 2.7
Видаег ЭЮ! по Вох...) 2.7
540 DA
S
Safety coo, 1.4
Safety Hotlines .........cccoovviiiiii i, 1.9
Salon Sofa/Sleeper ......................eeeeeviricccreecces 8.10
Schematics, AC & DC Electrical 7.21
Seacocks and Strainers 2.8
Searchlight ….…….......………...ccrsrrrereecesss rence creer 8.10
Service Guide o.oo A 11.2
Shaft LOG ........….….......…….rcccesessrrceceesssserc cena nee 2.7
121 RE ene rear. 2.7
Shallow Water Operation 1.8
Shore Power... 7.11, 7.12
Shore Power Breaker BOX esse 7.9
Shore Power, Cable Maintenance ................... 7.12
Shore Power, Shift to Generator Power .......... 7.21
Shower System …..…...…......…...….ccrrerecseeccenarerc eee 5.3
Side Curtains, SUNSNaAdE a 8.7
Side Curtains, Windshield er 8.7
Signal Selector, TeleViSION 2 8.7
SL Le © MEET 1.8
Slow Vessel Mode ….…..…..……..…..……..…..…...….rrrrsrenrennnen ss 3.3
Specifications and Dimensions ....................... 1.18
Specifications, Manufacturer's ....................... 1.1
Spillage, Fuel 8: Oil... 1.12, 2.1
Stability rer ee ee eee. 1.6
Stains & Scratches …….…….…….….……….….…….….…sresseenmanns 10.1
Steering System, Hydraulic Power .................... 3.5
Storage, Fitting Out After 9.3
StOVES EEE 8.10
Strainers .......................eeieeeeeree e ee 2.8
Strong Seal” EEK KR 2.7
SE 2.7
Sun Pad, Retractable ..........................._..__.__.—_.— 8.4
Sun Shade é Bimini TOp...................x.... eme... 8.6
Swambping ..................=eeeeeeeeeirernre ere. 1.14
SWIMMING «eevee eee eee, 1.8
Switches, Battery ..................—...eereeeeerierrececeeee. 7.3
SYMDOIS o.oo, IV
Synchronizers, ENGINE a 3.8
T
Tabs (Trim Tabs) ..................eeeeeseeeeveneereaeeeeece.s 3.15
Tachometer ..............e...ee.eviviriiir DAD 3.9, 3.11
Tank, Water ....................iieiiirr Ree 5.1
Tanks, FÜ eK RK RR 4.1
540 DA
Telephone... DA 8.10
TElEVISION RR R RR RR R RR R RER 8.7
Terms, Nautical eK 1.3
Throttle Controls................ eee, 3.5-3.8
Through-hull Fittings ...............— 1.20
TOWING oii K RER EKKRRERKREERKREERKEEEG 1.15
Transmission Oil Pressure Gauge................... 3.11
Transmission Oil Temperature Gauge ............. 3.11
TAM TADS eee eens 3.15
TAMMING ccc rene erre RK ERK EEE 1.8
U
Underwater Gear .............................. e A 2.6
Upholsteries .....................e2eeeereeeerereeeeces 10.2, 10.3
V
Vacuum System, Central ....................e.eeeeeeeeee. 8.11
Ventilation System, Power... 8.9
VIDration ocean 2.5
Visibility «coven, 1.7
Voltmeter vee eens 3.9
W
Wake/Wash ee eee 1.12
Warning LabelS eK 1.9
Warranty ….…...…...…....…erreecseeeeeeeeeee rare nee cena rene 1.2
Washer & Dryer.………....…....…....…..……ersrerseess 5.4, 8.11
Waste Disposal .….….…..……..…..….……………eese 1.12, 6.1, 6.2
Water Heater ….…….….….….….…..……….….…....sesesenrenanene ner eau nene 5.2
Water Level …….…..….......…...........rrsresesraneneas ananas naar ne 5.1
Water Pumps € Filters ee 5.2
Water System ….…..…....…....……..………rercrreres 5.1, 5.5, 5.6
Water System Accumulator Tank ...................... 5.2
Water Temperature Gauge ....................... 3.9, 3.11
Wear eK KK 1.8, 1.9
WIndlASS …..............rrsreresrnra rene ananas e na ananas anna nes 8.11
Windshield Vent... anne 8.11
Windshield Visor ................._.._——....eeeiere nn anne 8.7
Windshield Washer ........................... 8.11
Windshield WiperS a 8.11
Winterization Checkliste 9.2
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