Mercury 200 Optimax Installation manual

Add to My manuals
42 Pages

advertisement

Mercury Marine OptiMax DTS 200/225 Installation Manual | Manualzz

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,

Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,

K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product

Protection logo is a registered service mark of Brunswick Corporation.

200/225 OPTIMAX DTS

INSTALLATION MANUAL

Table of Contents

Notice to Installer ................................................... 2

Installation Information .......................................... 2

Avoiding Loss of Throttle and Shift Control.......2

Before Starting the Engine................................2

Fuel Requirements............................................2

Oil Recommendation.........................................2

Avoiding Fuel Flow Restriction .............................. 2

Electric Fuel Pump ................................................ 3

Boat Horsepower Capacity .................................... 3

Selecting Accessories For Your Outboard ............ 3

Fuel Tanks ............................................................. 3

Portable Fuel Tank ........................................... 3

Permanent Fuel Tank ....................................... 3

Installation Specifications ...................................... 4

Lifting the Outboard ............................................... 4

Applying Counter Rotation Decals ........................ 5

Steering Cable - Starboard Side Routed Cable .... 5

Steering Link Rod Fasteners ................................. 6

Determining Recommended Outboard Mounting

Height .................................................................... 7

Drilling Outboard Mounting Holes ......................... 8

Front Clamp Assembly .......................................... 9

Removal ............................................................ 9

Installation ......................................................... 9

Wiring and Installation ......................................... 11

Wire Color Code Abbreviations.......................11

Installation Guidelines for DTS System

Components....................................................11

Data Harness Pulling Procedure.....................11

Junction Box (If Equipped)...............................12

Non-Mercury Marine Provided Ignition Switch.12

Wiring Accessories..........................................13

System Wiring Reference Points.....................13

Connecting 14 Pin Data Harness - Single

Engine..............................................................14

Connecting 14 Pin Data Harness - Dual Engine

.........................................................................15

Installing DTS Command Module and Harness -

Single Engine...................................................16

Installing DTS Command Module and Harness -

Dual Engine/Single Helm.................................20

Battery Cable Size For Outboard Models........21

Battery Information..........................................23

Connecting Battery Cables and DTS Power

Harness...........................................................23

Connecting Fuel Tank, Oil Tank and Speed

Sensor.............................................................26

Switched 12V Accessory Connection..............28

DTS Wiring - Single Engine.............................29

DTS Wiring - Dual Engine................................31

System Wiring Installation Checklist................32

Fuel Hose and Oil Hose Connections ................. 32

Fuel Hose Connection .................................... 32

Filling the Fuel System ........................................ 33

Filling the Oil System .......................................... 33

Priming Oil Injection Pump .................................. 34

Purging Air From the Engine Oil Tank ................. 36

Propeller Installation ............................................ 36

Trim In Pin ........................................................... 37

Paddle Wheel Speed Sensor Installation (If

Equipped) ............................................................ 38

Parts Provided ................................................ 38

Selecting Location .......................................... 38

Transom Angle Requirements ........................ 39

Installing Bracket ............................................ 39

Routing the Cable ........................................... 40

Installing and Removing the Paddle Wheel .... 41

Wiring Connections ......................................... 41

Template - Paddle Wheel Speed Sensor ....... 42

Page 1 / 42 © 2004 Mercury Marine 90-10234050 APRIL 2004

200/225 OPTIMAX DTS

Notice to Installer

This Product Requires Electronic Calibration Before Use.

Installation of this product will require electronic calibration. This calibration must not be attempted by anyone other than the Original Equipment Manufacturer (OEM) or a

Mercury technician trained in Digital Throttle and Shift systems (DTS) at an authorized

Mercury dealership. Improper installation and calibration of the DTS product will result in a system which is inoperable or unsafe for use.

Installation Information

Avoiding Loss of Throttle and Shift Control

!

WARNING

To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control.

Before Starting the Engine

!

CAUTION

Avoid engine damage. Prime the oil injection pump on new or rebuilt engines and after maintenance is performed on the oiling system.

Refer to Priming the Oil Injection Pump for instructions.

Fuel Requirements

Do not use pre-mixed gas and oil in this engine. The engine automatically receives extra oil during engine break-in. Use a fresh supply of the recommended gasoline during engine break-in and after engine break-in.

Oil Recommendation

Recommended Oil OptiMax Oil or Premium Plus 2-Cycle TC-W3 Outboard Oil

OptiMax Oil or Premium Plus TC-W3 is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or varying grades of gasoline.

IMPORTANT: Oil must be NMMA certified TC-W3 2-Cycle oil.

Periodically consult with your dealer to get the latest gasoline and oil recommendations.

If Mercury Precision or Quicksilver 2-Cycle Outboard Oil is not available, substitute another brand of 2-Cycle outboard oil that is NMMA Certified TC-W3. The use of an inferior 2-Cycle outboard oil can reduce engine durability. Damage from use of inferior oil may not be covered under the limited warranty.

Avoiding Fuel Flow Restriction

IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.

Page 2 / 42 90-10234050

200/225 OPTIMAX DTS

Electric Fuel Pump

The fuel pressure must not exceed 28 kPa (4 psi). If necessary, install a pressure regulator.

Boat Horsepower Capacity

!

WARNING

Using an outboard that exceeds the maximum horsepower limit of a boat can: 1) cause loss of boat control 2) place too much weight at the transom altering the designed flotation characteristics of the boat or 3) cause the boat to break apart particularly around the transom area. Overpowering a boat can result in serious injury, death or boat damage.

Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.

U.S. COAST GUARD CAPACITY

MAXIMUM HORSEPOWER XXX

MAXIMUM PERSON

CAPACITY (POUNDS) XXX

MAXIMUM WEIGHT

CAPACITY XXX ob00306

Selecting Accessories For Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers.

!

WARNING

Check with your dealer before installation of accessories. The misuse of acceptable accessories or the use of unacceptable accessories can result in serious injury, death, or product failure.

Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

Fuel Tanks

Portable Fuel Tank

Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place.

Permanent Fuel Tank

Permanent fuel tanks should be installed in accordance with industry and federal safety standards, which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.

90-10234050 Page 3 / 42

200/225 OPTIMAX DTS

Installation Specifications

a a b

Ob01471 a Minimum transom opening b Engine center line for dual engine - 66.0 cm (26 in.)

Minimum Transom Opening

Single engine

Dual engine

99.0 cm (39 in.)

165.0 cm (65 in.)

Lifting the Outboard

!

WARNING

Avoid possible serious injury or death. Before lifting the outboard, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting capacity for the engine weight.

1. Remove the cowl from the outboard.

2. Thread the lifting eye into the flywheel hub for a minimum of five turns.

a

Page 4 / 42 a Lifting eye or138

90-10234050

200/225 OPTIMAX DTS

3. Connect a hoist to the lifting eye.

4. Lift the outboard and place it on the boat transom.

Applying Counter Rotation Decals

IMPORTANT: For dual outboard counter rotation installation, the left- hand rotation outboard is generally placed on the port sided of the transom.

1. Apply counter rotation decal (supplied with left-hand rotation outboard) onto right-hand rotation outboard.

2. Match decal placement with left-hand rotation outboard.

Steering Cable - Starboard Side Routed Cable

1. Lubricate O-ring seal and entire cable end.

95

3724

Tube Ref. No.

95

Description

2-4-C with Teflon

2. Insert steering cable into tilt tube.

Where Used

O-ring seal and the entire cable end.

Part Number

92-802859A1

3725

3. Torque nut to specification.

3727

90-10234050 Page 5 / 42

200/225 OPTIMAX DTS

Description

Nut

Nm

47.5

lb. in.

lb. ft.

35

Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" - Part Number 10-849838) and self-locking nylon insert locknuts ("c" & "d" - Part Number 11-826709113). These locknuts must never be replaced with common nuts (non-locking) as they will work loose and vibrate off freeing the link rod to disengage.

!

WARNING

Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death.

a b c d a Special washer head bolt (10-849838) b Flat washer (2) c Nylon insert locknut (11-826709113) d Nylon insert locknut (11-826709113) ob00676

Description

Special washer head bolt

Nylon insert locknut "d"

Nylon insert locknut "c"

Nm

27

27 lb. in.

lb. ft.

20

20

Tighten until seats, then back off 1/4 turn

Assemble steering link rod to steering cable with two flat washers and self-locking nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn.

Assemble steering link rod to engine with special washer head bolt and self-locking nylon insert locknut. First torque bolt, then torque locknut to specifications.

90-10234050 Page 6 / 42

Determining Recommended Outboard Mounting Height

200/225 OPTIMAX DTS

63.5 cm

(25 in.)

60.9 cm

(24 in.) e b

58.4 cm

(23 in.) c

56.0 cm

(22 in.) e

53.3 cm

(21 in.)

50.8 cm

(20 in.) a d

48.2 cm

(19 in.)

90-10234050

10 20 30 f

40 50 60 70 80

3728 a The solid line is recommended to determine the outboard mouting height.

b The broken lines represent the extremes of known successful outboard mounting height dimensions.

c The line may be prefered to determine outboard mounting height dimesion, if maximum speed is the only objective.

d The line may be prefered to determine outboard mounting height dimesion for dual outboard installation.

e Outboard mounting height (height of outboard mounting brackets from bottom of boat transom). For heights over 56.0 cm (22 in.) a propeller, that is designed for surfacing operation is usually prefered.

f Maximum boat speed (mph) anticipated.

NOTICE

1. The outboard should be mounted high enough on the transom so that exhaust relief hole will stay at least 25.4 mm (1 in.) above the water line when the engine is running at idle speed. Having the exhaust relief hole above the water line will prevent exhaust restrictions. Exhaust restrictions will result in poor performance at idle.

2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting heights.

3. The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models. Mounting the outboard higher may cause damage to the gearcase components.

Increasing the mounting height will usually:

• Less steering torque.

• Increase top speed.

• Increase boat stability.

• Cause propeller to break loose during planning.

Page 7 / 42

200/225 OPTIMAX DTS

Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining

Recommended Outboard Mounting Height and install outboard to the nearest recommended mounting height.

1. Use transom drilling fixture or attach (tape) engine mounting template to boat transom.

2. Mark and drill four 13.5 mm (17/32 in.) mounting holes.

ob01472

3973

3. Apply marine sealer to shanks of bolts, not the threads.

Page 8 / 42 90-10234050

4. Fasten outboard with provided mounting hardware.

200/225 OPTIMAX DTS a e b d c a Flat washer (4) b 1/2 in. diameter bolt (4) c Shank of bolt

3729 d Locknut (4) e Flat washer (4)

Front Clamp Assembly

Removal

Remove two screws with retainer and open the front clamp.

a b a c

3765 c Clamp a Screws (2) b Retainer

Installation

IMPORTANT: Sufficient slack must exist in engine wiring harness battery cables, fuel hose, and oil hoses between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.

90-10234050 Page 9 / 42

200/225 OPTIMAX DTS

1. Place the neoprene wrap around the wiring, hoses, and control cables.

3766

2. Secure both halves of clamp with cables ties.

3764

3. Secure clamp assembly into bottom cowl with retainer and two screws.

a b a a Screws (2) b Retainer c

3765 c Clamp

Page 10 / 42 90-10234050

200/225 OPTIMAX DTS

Wiring and Installation

Wire Color Code Abbreviations

BLK

BRN

GRN

PNK

RED

WHT

LT or LIT

Black

Brown

Green

Pink

Red

White

Light

Wire Color Abbreviations

BLU

GRY

ORN or ORG

PPL or PUR

TAN

YEL

DK or DRK

Blue

Gray

Orange

Purple

Tan

Yellow

Dark

Installation Guidelines for DTS System Components

!

WARNING

To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control.

DATA HARNESS

!

WARNING

To avoid the possibility of serious injury or death from loss on boat control, do not pull on cable connectors when pulling cable into boat. Observe correct pulling procedure.

Pulling on connectors can loosen terminals resulting in open or poor electrical connections. Open or poor electrical connections may result in loss of throttle and shift control.

CONNECTORS

IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that connectors are free of any lubricant or dielectric grease before installation. When the connector is properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotate the locking collar to secure the electrical connection.

NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than

12.2 m (40 ft.), contact Mercury Marine for more information.

Data Harness Pulling Procedure

IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads, and spark plugs), high power VHF coax or radios. An electrical field generated from these components could cause interference with data transmission.

IMPORTANT: Do not route data harness near sharp edges, hot surfaces or moving parts.

Fasten cables away from any sharp edges, fasteners or objects that could wear into the harness.

IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be

7.6 cm (3 in.) for the final wiring installation.

90-10234050 Page 11 / 42

200/225 OPTIMAX DTS

1. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

2. Install cable pulling tool to data harness.

3. Secure pulling tool with 2 cable ties.

IMPORTANT: The cables ties must be tight to prevent any slipping during installation.

3836

Data Cable Puller 91-888462A1

IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to data harness connector end following installation.

NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.

Junction Box (If Equipped)

• Although the junction box connections are watertight, it is recommended that the junction box be mounted in an area that stays relatively dry.

• Mount in an area where the wiring connection will not get stepped on or disturbed.

• Mount in an area that is accessible for troubleshooting and servicing the system.

• Ensure the DTS command module harness will reach all the connection points.

• Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.

• Seal all unused connections with weather caps.

b c a d e a Clamp b Weather cap (859318T 2) c Junction box ob01481 d 25.4 cm (10 in.) e DTS Command Module harness

Non-Mercury Marine Provided Ignition Switch

!

CAUTION

Prevent unexpected engine start-up. Non-Mercury Marine ignition switches may allow sufficient current leakage to cause engine to start unexpectedly.

Page 12 / 42 90-10234050

a

200/225 OPTIMAX DTS

IMPORTANT: Correct ignition key switch must be used. If a non-Mercury Marine ignition key switch is being used, make sure that the ignition switch being used meets the requirement listed.

IMPORTANT: Current leakage exceeding 5 mA at 12 volts could cause engine to start unexpectedly.

• Ignition key switch must pass ingress protection testing per IEC IP66 specification minimum. Switches that do not pass this specification could leak current.

• Switches must contain an emergency stop circuit.

Y E L / R E D

Y E L / R E D

R E D c d

B L K / Y E L e

B L K

P P L

P P L / WHT f g h

3641 b

B L K / Y E L

R E D

B L K

P P L / WHT P P L

4 Position Key Switch a Connector - Packard Metripack

150 Series Sealed™ (6 pin) b Ignition switch c Crank d + 12V e Lanyard stop f Ground g Run h Accessory - 4 position key switch

Wiring Accessories

NOTE: Refer to Mercury Precision Parts Accessories Guide.

System Wiring Reference Points

FEATURES

• DTS power harness - Provides 12V power to the DTS system. Requires connection to the starting battery. If starting battery is located at the helm, DTS power harness accessory kit is required to minimize voltage drop. Use cable ties to secure power harness leads to battery cables, within 15 cm (6 in.) of battery posts.

• Battery cables - Connect to the starting battery.

• Vessel sensor harness - This harness connects to the fuel tank sensor, remote oil tank sensor and the paddle wheel speed/temperature sensor, if equipped.

• 14 pin data harness - Connects between the command module harness and engine.

Page 13 / 42 90-10234050

200/225 OPTIMAX DTS

• Control Area Network (CAN) link harness - Must be installed between command module harness for dual engine installation.

a d b c e f

3769 a 14 pin data harness b Vessel sensor harness c Battery cables d CAN link harness (dual engine application) e DTS power harness f 5 Amp fuse

Connecting 14 Pin Data Harness - Single Engine

SINGLE HELM

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm

(3 in.).

b a

Page 14 / 42 a 14 pin data harness

3619 b Clamp or cable tie

90-10234050

DUAL HELM

200/225 OPTIMAX DTS b a c d e

3682 a 14 pin data harness b Helm 2 (upper helm) - auxilary c Helm 1 (lower helm) - primary d Dual helm adapter (Y harness) e Clamp or cable tie

Connecting 14 Pin Data Harness - Dual Engine

SINGLE HELM

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm

(3 in.).

90-10234050 a b a 14 pin data harness

3977 b Clamp or cable tie

Page 15 / 42

200/225 OPTIMAX DTS

DUAL HELM a c b c d e a Helm 2 (upper helm) b Helm 1 (lower helm) c 14 pin data harness

3978 d Dual helm adapter (Y harness) e Clamp or cable tie

Installing DTS Command Module and Harness - Single Engine

HARNESS INSTALLATION

• Locate a routing path for the harness connections so they reach their installation points.

• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

• Fasten and support the harness with clamps or cable ties along the routing path.

Page 16 / 42 90-10234050

200/225 OPTIMAX DTS

• Make sure all connections are tight and seal all unused connectors with weather caps.

a b

3622

Single Helm Application a DTS command module harness b Clamp or cable tie

90-10234050 Page 17 / 42

200/225 OPTIMAX DTS

NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps.

a c e

Terminator

CAN 1

Terminator

CAN 2 f g h b c d d

3677

Dual Helm Application a Helm 2 (upper helm) b Helm 1 (lower helm) c DTS command module harness d Clamp or cable tie e CAN 1 connector f CAN 2 connector g Weather caps h Terminator resistors, blue (CAN1 &

CAN2)

MODULE INSTALLATION

• Although the Command Module connection is watertight, it is recommended that it be mounted in an area that stays relatively dry.

• Mount in an area where the wiring connection will not get stepped on or disturbed.

• Mount in an area that is accessible for troubleshooting and servicing the system.

Page 18 / 42 90-10234050

a

200/225 OPTIMAX DTS

• Ensure the wiring harness connected to the command module will reach all the connection points.

b c

Single Helm Application a DTS command module b Clamp or cable tie

3625 a d b e

90-10234050 f

3678

Dual Helm Application a Helm 2 b Helm 1 c DTS command module d Clamp or cable tie e Terminator resistors, blue (CAN1 &

CAN2) f Weather caps

Page 19 / 42

200/225 OPTIMAX DTS

Installing DTS Command Module and Harness - Dual Engine/Single Helm

HARNESS INSTALLATION

• Locate a routing path for the harness connections so they reach their installation points.

• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

• Fasten and support the harness with clamps or cable ties along the routing path.

• Make sure all connections are tight and seal all unused connectors with weather caps.

c a

Terminator

CAN 2 b

Terminator

CAN 2 c d a CAN link harness b CAN 2 Terminator resistors - do not remove c CAN 1 connectors e -

3689 d Clamp or cable tie e

DTS command module harness

MODULE INSTALLATION

• Although the Command Module connection is watertight, it is recommended that it be mounted in an area that stays relatively dry.

• Mount in an area where the wiring connection will not get stepped on or disturbed.

• Mount in an area that is accessible for troubleshooting and servicing the system.

Page 20 / 42 90-10234050

c

200/225 OPTIMAX DTS

• Ensure the wiring harness connected to the command module will reach all the connection points.

a b c a DTS command module b Clamp or cable tie

3691 c CAN link harness

Battery Cable Size For Outboard Models

IMPORTANT: Only use copper battery cables. Do not use aluminum cables for any outboard marine installations.

• If longer battery cables are required, the wire gauge size must increase. See chart following for correct wire gauge size.

• DTS L models are equipped with 3.7 m (12 ft.) cables. DTS XL and XXL models are not shipped with battery cables.

a a Wire gauge size b b Battery cable length or70

Page 21 / 42 90-10234050

200/225 OPTIMAX DTS

Models

2.4 m (8 ft.)

2.7 m (9 ft.)

3.0 m (10 ft.)

Cable Length

3.4 m (11 ft.)

3.7 m (12 ft.)

4.0 m (13 ft.)

4.3 m (14 ft.)

4.6 m (15 ft.)

4.9 m (16 ft.)

5.2 m (17 ft.)

5.5 m (18 ft.)

5.8 m (19 ft.)

6.1 m (20 ft)

6.4 m (21 ft.)

6.7 m (22 ft.)

7.0 m (23 ft.)

7.3 m (24 ft.)

7.6 m (25 ft.)

7.9 m (26 ft.)

8.2 m (27 ft.)

8.5 m (28 ft.)

8.8 m (29 ft.)

9.1 m (30 ft.)

9.4 m (31 ft.)

9.8 m (32 ft.)

10.1 m (33 ft.)

10.4 m (34 ft.)

10.7 m (35 ft.)

11.0 m (36 ft.)

11.3 m (37 ft.)

11.6 m (38 ft.)

11.9 m (39 ft.)

12.2 m (40 ft.)

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

2

2

1

4

4

4

6

4

4

6-25 hp

8 1.

Copper Battery Cable Wire Gauge Size

Wire Gauge Size Number SAE

30-115 hp (except OptiMax)

6 1.

125-250 hp (except OptiMax) OptiMax/Verado

-

6

6

6

6

4

4

4

4

-

6 1.

4

4

-

-

-

4 1.

2

2

4

4

2

2

2

2

2

2

2

2

1

1

4

4

4

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

1/0

1/0

1/0

1/0

1/0

1/0

1/0

2/0

2/0

2/0

2/0

2/0

2/0

2/0

2/0

2

2

2

1

1

1

1

1

1

1

1/0

1/0

1/0

1/0

1/0

1/0

1/0

1/0

2/0

2/0

2/0

2/0

2/0

2/0

2/0

2/0

1/0

1/0

1/0

1

1

1

1/0

1/0

1/0

1/0

1.

Standard (original) cable length and wire gauge size.

Page 22 / 42 90-10234050

200/225 OPTIMAX DTS

Battery Information

!

CAUTION

Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power.

• Do not use deep cycle batteries. Engines must use a marine starting battery with 1000

MCA, 800 CCA or 180 Ah.

• When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.

Description

Hex nuts

Nm

13.5

lb. in.

120 lb. ft.

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.

Decal needs to be placed on or near battery box for future service reference. One

5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied.

NOTICE - DTS & Optimax Engines

DO NOT USE DEEP CYCLE BATTERIES!

DTS (Digital Throttle and Shift) applications and

Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.

rating.

13.5Nm (120 lbs. in.)

DO NOT

USE WING

IMPORTANT:

NUTS.

Battery cable size and length is critical. Refer to engine installation manual for size requirements.

37-895387

Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

3486

Connecting Battery Cables and DTS Power Harness

!

CAUTION

To avoid the possibility of loss of electrical power due to the DTS power harness connection being pulled off battery, fasten the DTS power harness to one of the battery cables near the battery with cable tie.

• Install DTS power harness directly to the starting battery only.

• Do not extend lead length of harness.

• See accessory manual for optional lead connection kit.

3711

90-10234050 Page 23 / 42

200/225 OPTIMAX DTS

SINGLE ENGINE - BATTERY AT STERN a b d c a Battery b Black sleeve (negative)

SINGLE ENGINE - BATTERY AT HELM b c f a h

3679 c Red sleeve (positive) d DTS power harness (provided) d e g

Page 24 / 42 a 14 pin data harness b DTS command module harness c Junction box d DTS power harness (optional)

3699 e Red sleeve (Positive) f Black sleeve (Negative) g Vessel sensor harness h Weather caps

90-10234050

DUAL ENGINE - BATTERY AT STERN c g e c

200/225 OPTIMAX DTS a f a b b d a Red sleeve (positive) b Black sleeve (negative) c Battery d DTS power harness (provided) d

3680 e Ground cable f Data cable g Vessel sensor harness

Page 25 / 42 90-10234050

200/225 OPTIMAX DTS

DUAL ENGINE - BATTERY AT HELM d a b c c a b e g f f h

3701 a Black sleeve (negative) b Red sleeve (positive) c DTS power harness (optional) d DTS command module harness e Junction box weather caps f 14 pin data harness g Ground cable h Vessel sensor harness

Connecting Fuel Tank, Oil Tank and Speed Sensor

IMPORTANT: Do not connect the blk/orn wire, if equipped, to the fuel tank sensor when there is an engine battery ground strap connected to the fuel tank or sender assembly.

If not used, plug the unused open bullet connector with rubber plug.

IMPORTANT: If fuel tank is plastic and fuel sensor mounting plate is not connected to battery ground, connect blk/orn wire, if equipped, to fuel sender mounting plate.

90-10234050 Page 26 / 42

200/225 OPTIMAX DTS

IMPORTANT: Metal fuel tanks must be grounded to hull or battery ground in accordance to coast guard regulations.

c a b

PNK

/BLK

BLK

/ORN e d

WHT a Fuel tank b Oil tank c Oil tank sender

3714 d Harness e Black/orange wire to fuel tank sensor, if equipped

90-10234050 Page 27 / 42

200/225 OPTIMAX DTS

Switched 12V Accessory Connection

e c d

PUR

RED b a

+ f g h ob01495

a Battery b Fuse - 40 Amp c Power harness with 40 Amp fuse d Switched 12V e Complete kit f Terminal block g Accessory power relay h DTS Command Module harness

Page 28 / 42 90-10234050

DTS Wiring - Single Engine

PANEL CONTROL

OFF ON a b

200/225 OPTIMAX DTS c j e

WHITE

+ d BLK/ORG

PUR/YEL

GRN/YEL

GRN/ORG

GRN/RED f i h

3718 a Start/stop switch (optional) b SmartCraft System View (optional) c SmartCraft Link Gauge (optional) d GPS connection e Displace harness f Cable adaptor (male to female) g Weather caps h Junction box (optional) i Accessory power relay (optional) j Foot throttle (optional) g

90-10234050 Page 29 / 42

200/225 OPTIMAX DTS

CONSOLE CONTROL

OFF ON a b c j e

WHITE

+ d BLK/ORG

PUR/YEL

GRN/YEL

GRN/ORG

GRN/RED f i h

3717 a Start/stop switch (optional) b SmartCraft System View (optional) c SmartCraft Link Gauge (optional) d GPS connection e Display harness f Cable adaptor (male to female) g Weather caps h Junction box i Accessory power relay (optional) j Foot throttle (optional) g

Page 30 / 42 90-10234050

g

DTS Wiring - Dual Engine

CONSOLE CONTROL n m l k j i c h d f e o p q l j i e f d

200/225 OPTIMAX DTS

+ – g c a

90-10234050 i s b a To port engine b Terminator resistor c DTS Command Module d Junction box connection (optional) e Connector - Zero Effort controls f Horn g Accessory power relay (optional) h DTS Command Module harness i Clamp j Connector - stop/start switch

(optional) b

3309 k Remote control connections l Key switch m Remote control n To port engine o Lanyard stop switch p To starboard engine q System View (optional) r To starboard engine s CAN link harness r

Page 31 / 42

200/225 OPTIMAX DTS

System Wiring Installation Checklist

DATA CABLE

Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.

Verify data harness is not routed near ignition components (coils, spark plug leads, and spark plugs), high power VHF coax or radios.

JUNCTION BOX (IF EQUIPPED)

Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.

Ensure the harness connections are fastened within 25.4 cm (10 in.) of the junction box.

Verify that all unused receptacles are covered with a weather cap.

NON-MERCURY MARINE SUPPLIED IGNITION KEY SWITCH

If a non-Mercury Marine ignition key is used, verify that it passes the ingress protection testing per IEC IP66 specification minimum. Ignition switches must pass this specification.

ELECTRONIC REMOTE CONTROL

Ensure Electronic Remote Control (ERC) connections are completed following ERC installation instructions prior to engine operation.

DTS COMMAND MODULE HARNESS

Verify that all connectors are properly inserted and locked in their receptacle (remote control, key switch, command module, lanyard stop switch and junction box, if equipped).

Verify that while moving the remote control handle (full forward and full reverse) the harness has unobstructed movement (moves freely).

Verify that the lanyard stop switch is wired into the system correctly.

Verify that the harness is fastened along the routing path.

Verify that all unused connectors have weather caps to prevent corrosion.

BATTERY

Verify that wing nuts have been replaced with hex nuts, provided.

Verify that all engine battery cables are connected to the correct terminals.

Verify that the DTS power harness leads are connected to the starting battery and secured with locknuts.

Ensure the 5 Amp fuse for the DTS power harness is accessible.

LANYARD STOP SWITCH

Verify that the switch is installed.

Verify that the switch is connected to the DTS command module harness.

Fuel Hose and Oil Hose Connections

Fuel Hose Connection

Fuel Hose Size - Minimum fuel line inside diameter (I.D.) is 8mm (5/16 in.), with separate fuel line/fuel tank pickup for each engine.

1. Fasten remote fuel hose to fitting with hose clamp.

90-10234050 Page 32 / 42

200/225 OPTIMAX DTS

2. Connect the remote oil hoses to the engine hose connections. Fasten hose connections with cable ties.

b c e a a Hose clamp b Cable tie c Oil hose without blue stripe d

3767 d Oil hose with blue stripe e Remote fuel hose

Filling the Fuel System

When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel system.

1. Squeeze the fuel line primer bulb until it feels firm.

ob00349

2. Turn the key switch to the "ON" position for three seconds. This operates the electric fuel pump.

OF

F

ACC ON

OF

F AC

C ON

ST

A

R

ST

A

T

R ob00364 3484

3. Turn the key switch back to the "OFF" position and squeeze the primer bulb again until it feels firm.

OF

F

ACC ON

OF

F AC

C ON

ST

A

R

ST

A

T

R

3482 ob00360

4. Turn the key switch to the "ON" position again for three seconds.

5. Continue this procedure until the fuel line primer bulb stays firm.

Filling the Oil System

1. Fill the remote oil tank with the recommended oil listed in the Operation and

Maintenance Manual.

90-10234050 Page 33 / 42

200/225 OPTIMAX DTS

2. Tighten the fill cap.

a or111 a Fill cap

3. Remove the cap and fill the engine oil tank with oil.

a b a Fill cap

3763 b Engine oil tank

4. Reinstall the fill cap.

Priming Oil Injection Pump

IMPORTANT: DTS helm configuration must be completed before performing the following procedure.

Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply hose or internal passages.

a a Oil supply hose b

3768 b Oil injection pump

Page 34 / 42 90-10234050

90-10234050

200/225 OPTIMAX DTS

!

CAUTION

Avoid fuel pump damage. Always fill the engine fuel system with fuel before priming the oil injection pump. Otherwise, the fuel pump will run without fuel during the priming process.

1. Fill the fuel system.

a.

Connect fuel hose.

b.

Fill the fuel system by squeezing the primer bulb.

c.

Squeeze the fuel line primer bulb until it feels firm.

ob00349 d.

Turn the ignition key switch to the "ON" position for three seconds. This operates the electric fuel pump.

OF

F

ACC ON

OF

F AC

C ON

ST

A

R

ST

A

T

R ob00364 3484 e.

Turn the ignition key switch back to the "OFF" position, and squeeze the primer bulb again until it feels firm.

f.

Turn the ignition key switch to the "ON" position again for three seconds.

g.

Continue this procedure until the fuel primer bulb stays firm.

2. Turn the ignition key switch to the "ON" position.

OF

F

ACC ON

OF

F AC

C ON

ST

A

R

ST

A

T

R ob00364 3484

3. Within the first 10 seconds after the key switch has been turned on, move the remote control handle from neutral (N) into forward (F). This will automatically start the priming process.

N

N

F R F R

3413

3417

Page 35 / 42

200/225 OPTIMAX DTS

Purging Air From the Engine Oil Tank

IMPORTANT: DTS helm configuration must be completed before performing the following procedure.

1. Loosen the fill cap on the engine oil tank.

2. Start the engine.

3. Operate the engine until all the air has vented out and oil starts to flow out of the tank.

4. Re-tighten fill cap.

Propeller Installation

!

WARNING

If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.

1. Flo-Torq I Drive Hub Propellers - Install forward thrust hub, propeller, continuity washer, rear thrust hub, propeller nut retainer, and propeller nut onto the shaft.

a b c d a Propeller nut b Propeller nut retainer c Rear thrust hub e f ob00382 d Continuity washer e Propeller f Forward thrust hub

2. Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve, propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

a b c e f

Page 36 / 42 a Propeller nut b Propeller nut retainer c Rear thrust hub d ob00421 d Propeller e Replaceable drive sleeve f Forward thrust hub

3. Place a block of wood between gearcase and propeller and torque to specifications.

Description

Propeller nut

Nm

75 lb. in.

lb. ft.

55

90-10234050

200/225 OPTIMAX DTS

4. Secure propeller nut by bending three of the tabs into the thrust hub grooves.

ob00422

Trim In Pin

!

WARNING

Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel.

Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft live wells, given the variety of available propellers and height range of engine installations.

However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow-down planing condition called plowing. Plowing can cause bow steering or over steering and inefficiently consumes horsepower.

a or116 a Tilt pin (not included with engine)

Stainless Steel Tilt Pin 17-49930A1

The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A non-stainless steel shipping bolt should not be used in this application other than on a temporary basis.

90-10234050 Page 37 / 42

200/225 OPTIMAX DTS

Paddle Wheel Speed Sensor Installation (If Equipped)

Parts Provided

i a d e b c i h f a Spare pin yoke b Wire retainer c Connector d Bracket e Paddle wheel g j ob01505 f Flat washer (2) g #10 - 19 mm (3/4 in.) screw (4) h Cable cap i #6 - 12 mm (1/2 in.) screw (4) j Clamp (2)

Selecting Location

Single engine installation - Mount paddle wheel on the transom where the propeller blade is rotating downward. Usually the right (starboard) side to minimize cavitation. If feasible, mount at least 50 mm (2 in.) beyond the swing radius of the propeller.

Dual engine installation - Mount the paddle wheel between the engines as close to the center line (keel) of the boat as possible. On slower, heavier displacement boats, however, positioning it farther from the keel is acceptable.

NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outlets for live wells or any protrusion that may cause turbulence or cavitation.

a a 50 mm (2 in.) ob01506

Page 38 / 42 90-10234050

Transom Angle Requirements

Standard 13° to 20° transoms - No special adjustment required.

a b

200/225 OPTIMAX DTS a 13° transom angle ob01507 b 20° transom angle

Stepped or undercut transom with 3 angles - A small shim of tapered plastic, metal or wood must be fabricated and installed as shown. Mount the paddle wheel on the step for best performance.

a ob01508 a Shim

Installing Bracket

1. Cut out the template. At the location selected, tape the template to the transom. Make sure the black dotted line on the template is aligned with the transom bottom edge, as shown.

NOTE: The mounting template provided is located on the last page of this instruction sheet.

2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template. To prevent drilling too deeply, wrap masking tape around the drill bit

22 mm (7/8 in.) from the point end of drill bit.

NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about 15 mm (1/16 in.) deep to prevent surface cracks.

3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two #10 screws provided. Using the washer provided, attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the hull.

Page 39 / 42 90-10234050

200/225 OPTIMAX DTS

4. Fill any gap between the housing and the transom with a caulking material, as shown.

Using a putty knife, smooth the surface to ensure proper water flow.

a e b a Template b 50 mm (2 in.) c #10 screw c d ob01509 d Flat washer (2) e Caulking

Routing the Cable

DRILLING HOLE THROUGH TRANSOM (OPTIONAL)

1. Select a transom location for the hole above the water line that does not interfere with other cables and controls.

2. Drill a 15 mm (5/8 in.) diameter hole.

3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a comparable marine sealer after the cable has been routed through.

NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for the second clamp should be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable.

4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm

(1/2 in.) deep.

5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the cable clamps and feed the cable through cable cap.

90-10234050 Page 40 / 42

200/225 OPTIMAX DTS

WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL)

Route the cable over the transom or through a drain hole that is above the water line.

a b e d c ob01510 a Splash well drain hole b Cable cap c Cable clamp d Paddle wheel assembly e Distance between first cable clamp and top of paddle wheel - 25.4 mm

(1.0 in.)

Installing and Removing the Paddle Wheel

Installation - Slide the pins into the slots in the bracket and snap the tabs into place.

Removal - squeeze open (unlock) the tabs and pull on the paddle wheel.

a b ob01511 a Tabs b Pins

Wiring Connections

IMPORTANT: Before making wire connections, make sure wires are routed through the transom.

90-10234050 Page 41 / 42

200/225 OPTIMAX DTS

NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have the wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until they snap into place. Secure wires into connector with the wire retainer.

W H T

Y E L

B L U

B L K b a Connector

Template - Paddle Wheel Speed Sensor

a a b Wire retainer b ob01512 b ob01513 a Drill holes here b Align dotted line with the transom bottom edge and fold under

Page 42 / 42 90-10234050

advertisement

Key Features

  • Digital Throttle and Shift System
  • Fuel Efficient
  • Low Emissions
  • Powerful and Reliable
  • Electronic Throttle Control
  • Electronic Shift Control
  • Electronic Trim Control
  • Intuitive and Responsive Control

Related manuals

Frequently Answers and Questions

What type of fuel should be used for the OptiMax DTS 200/225 engine?
The engine automatically receives extra oil during engine break-in. Use a fresh supply of the recommended gasoline during engine break-in and after engine break-in.
What is the recommended oil for the OptiMax DTS 200/225 engine?
Use OptiMax Oil or Premium Plus 2-Cycle TC-W3 Outboard Oil. OptiMax Oil or Premium Plus TC-W3 is a higher grade oil that provides increased lubrication and extra resistance to carbon buildup when used with good or varying grades of gasoline.
What is the maximum horsepower capacity of the OptiMax DTS 200/225 engine?
The maximum horsepower capacity of the boat must be determined by the manufacturer following certain federal guidelines. Consult your dealer or the boat manufacturer for this information.
What is the minimum transom opening required for a single engine installation?
The minimum transom opening required for a single engine installation is 99.0 cm (39 in.).
What is the minimum bend radius for the data harness?
The minimum bend radius for the data harness should be 7.6 cm (3 in.).

advertisement

Table of contents