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COX CXO300, Installation Manual

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CXO300 

INSTALLATION MANUAL

10.0 WIRING HARNESS INSTALLATION

10.0 

WIRING HARNESS INSTALLATION

Rigging grommet

Rigging grommet housing 

(half part)

Rigging grommet half housing

Rigging grommet half housing

Rigging grommet half housing

10.19.0 

Assemble the rigging grommet housing around the rigging tube with the other half section of  

   

the rigging grommet housing (Refer to Figure 10.19). Make sure that you tighten the two screws  

   

to 8 Nm.

     

Figure 10.19. Rigging tube installation

 

  WARNING

Make sure that you use  a T25 torx driver to install the two torx screws (032511). If you do not use the 

correct Allen driver, damage can be caused to the screw heads.

Summary of Contents for CXO300

Page 1: ...INSTALLATION GUIDE CXO300 designed for purpose coxmarine com ...

Page 2: ......

Page 3: ... OUTBOARD ENGINE FROM THE CRATE MOUNTING THE OUTBOARD ONTO THE TRANSOM RIGGING INSTALLATION STEERING RIGGING TUBE INSTALLATION FUEL SYSTEM INSTALLATION POWER SUPPLY WIRING HARNESS INSTALLATION HELM CONTROL INSTALLATION OUTBOARD OIL FILL APPLYING GREASE TO THE PTT INSTALLING THE TOP COWL 4 5 6 10 16 27 31 34 38 41 48 55 57 59 ...

Page 4: ...tructions when installing a certified engine in a vessel violates federal law 40 CFR 1068 105 b subject to fines or other penalties as described in the Clean Air Act This product is EPA Tier 3 compliant and can be used on US flagged vessels To support US registered vessels to operate internationally this marine engine is also certified to IMO Annex VI Tier II standards and may therefore be limited...

Page 5: ...Make sure that the outboard is mounted safely and the Power Tilt and Trim PTT lock is on 2 5 0 Make sure that the outboard specification color leg length and gear ratio is correct 2 6 0 Make sure that you do a check for damage on the outboard cover 2 7 0 Remove the outboard cover and make sure that you do a check for damage on the outboard cover again 2 8 0 Make sure you speak to your distributor ...

Page 6: ... propeller shaft steady bar 3 5 0 Remove the two long vertical rails 3 6 0 Remove the top frame from the crate 3 7 REMOVAL OF OUTBOARD TOP COWL 3 7 1 Open the three latches that hold the top cowl to the outboard 3 7 2 Remove the outboard top cowl and stow it safely if working on multiple outboard ensure cowls are labeled 3 7 3 Close the three latches that hold the top cowl onto the outboard 3 8 0 ...

Page 7: ... No 909427 Hand tight only 3 10 1 When the centre lifting eye is tight if the eye orientation is not within 45 of the centre line of the outboard bar over the engine until it is in the correct orientation as shown 3 11 0 Install the right hand lifting eye 909441 to the starboard right cylinder head Figure3 11 and torque the two fasteners 029355 to 23Nm Figure 3 11 Lift hooks and lifting eyes posit...

Page 8: ...f the outboard Minimum strop lengths for lifting the outboard are detailed in the table below Using a longer strop length with result in a greater angle than 25 3 14 0 Remove the bolts that hold the PTT to the crate 3 15 0 Move the outboard to a safe position Minimum strop length required at 25 to the vertical mm Centre Lifting Eye 420 Left hand Lifting Eye Port 590 Right hand Lifting Eye Starboar...

Page 9: ...rate again 3 17 0 Keep or send the crate back to Cox CAUTION Do not reuse any fasteners from the shipping crate for the installation of the outboard to a vessel the fasteners are for shipping purposes only Use only components from the supplier rigging kits for installation to vessel ...

Page 10: ...thod to identify the correct center line of the outboard For example 4 5 1 Identify the center point between two chines and draw a line down the centric V of the vessel as shown on Figure 4 5 4 5 2 If you are not sure about the center line position speak to the boat builder for aid 4 6 0 Make sure that you use the center line mark as the datum the fixed starting point to measure the distance from ...

Page 11: ...Quad Install Twin Install Triple Install Quad Install Parallel Asymmetric Parallel Asymmetric Maximum Envelope mm in 1131 44 5276 1652 65 0394 1885 73 0315 2376 93 5433 3100 122 0472 1836 72 5276 1893 74 5276 2598 102 2835 3360 132 2835 1915 75 3937 2699 106 2598 3483 137 126 Maximum steering angle Port turn Angle A 30 17 30 17 17 26 30 26 26 30 30 30 Angle B 17 20 17 17 26 27 26 26 30 30 30 Angle...

Page 12: ...eg lengths 25 30 and 35 to make sure that the outboard operates correctly with the vessel 4 7 3 Make sure that you use the dimensions in Figure 4 8 to select the correct outboard leg length for the vessel Figure 4 7 Information about the three leg lengths of the outboard engine Units mm in 25 A 609 24 B 1997 78 6 C 141 5 6 D 1241 47 8 E R1286 50 7 F 918 36 1 G 853 33 58 30 A 732 29 B 2124 83 6 C 2...

Page 13: ...metry Figure 4 9 Different leg lengths on multiple outboard installations 4 10 0 When the positions for the center line s and height s are found 4 10 1 Make marks at the positions of the six holes for the outboard s 4 10 2 Make sure that you use the supplied template Servicing Kit No 037023 figure 4 10 to get the correct positions of the mounting holes 4 10 3 Make sure that you use two bolts on ea...

Page 14: ...t the length of the bolts are long enough to go through the PTT transom the lock nut and all washers 4 13 2 Make sure two full threads of the bolts are showing through the nyloc nuts 4 14 0 Make sure that you apply marine sealant Sikaflex 291i or equivalent to the areas around the mounting holes on the PTT and to transom face 4 15 0 Make sure that you use a gantry crane A frame to move the outboar...

Page 15: ...crane to a safe area 4 18 0 If you are doing a multiple installation repeat steps 4 15 0 through 4 18 0 for each outboard to be installed 4 19 0 Remove the lifting eyes 3 and install the crank pulley cover Torque the crank pulley cover to 9 11 Nm 4 20 0 Place the lifting eye cover on the top cover Torque the torx screws 2 to 3 Nm ...

Page 16: ...r harness 036484 1 1 2 Outboard to vessel fuel lines 031164 1 1 2 Outboard busbar nut 025599 2 2 4 Seastar Optimus EPS Core Pack Single Install 027834 1 Seastar Optimus EPS Core Pack Twin Install 027166 Seastar Steering Smart Cylinder Tournament Series Standard 027168 1 Seastar Steering Smart Cylinder Tournament Series with Starboard side Tie Bar Bracket 034385 Seastar Tie Bar Tournament Series La...

Page 17: ...nstall With Steering SK 000081 Without Steering SK 000082 With Steering SK 000078 Without Steering SK 000079 With Steering SK 000083 Without Steering SK 000084 Without Steering SK 000085 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 3 4 4 5 6 2 3 3 4 4 5 6 2 3 3 4 4 5 6 8 8 10 10 12 12 14 3 4 4 5 5 6 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 3 4 4 5 6 2 3 3 4 4 5 6 2 3 3 4 4 ...

Page 18: ...omponents with their related part numbers and schematic key Rigging Component Part Number Murphy PV450 4 Screen Kit SK 000134 Murphy PV780B 7 Screen Kit SK 000135 Murphy PV1200 12 Screen Kit SK 000136 DTM Control Head Dual 034391 STM Control Head Single 034392 CoastKey Start Panel 033979 Coastkey 2 Button Fob 033980 CoastKey Additional Fob 033980 CoastKey CECU Engine 1 033981 CoastKey CECU Engine ...

Page 19: ...ANUAL 5 0 RIGGING INSTALLATION Figure 5 2b CXO300 single installation schematic 1 Vessel Busbar 2 Fuse box 3 Fuel Level 4 Connect to Battery Breaker via a 10amp fuse 5 Victon Energy DC DC Converter 6 Vessel Battery Integration ...

Page 20: ...GGING INSTALLATION 5 0 RIGGING INSTALLATION Figure 5 2c CXO300 twin installation schematic 1 Vessel Busbar 2 Fuse box 3 Fuel Level 4 Connect to Battery Breaker via a 10amp fuse 5 Victon Energy DC DC Converter 6 Vessel Battery Integration ...

Page 21: ...ANUAL 5 0 RIGGING INSTALLATION Figure 5 2d CXO300 triple installation schematic 1 Vessel Busbar 2 Fuse box 3 Fuel Level 4 Connect to Battery Breaker via a 10amp fuse 5 Victon Energy DC DC Converter 6 Vessel Battery Integration ...

Page 22: ...ible to the outboard battery switch with a ground link fitted between the input and output ground cables The voltage regulator needs to be set up as a constant power source and to output a constant 12 5 12 8V This can be done by turning the adjustment screw to increase decrease the voltage or via Bluetooth using the Victron Energy App The voltage should be verified using the EST service tool Param...

Page 23: ...ltage sensing relay is used minimum 120 Amps example show is a Victron Energy 120 Amp voltage sensing battery combiner Ensure all cables are minimum 70mm for outboard supply and suitable for 120amp for other circuits Ensure all connections are correctly insulated Figure Single Vessel Battery Integration Schematic ...

Page 24: ...le purple wire on harness 033871 5 2 g On multiple outboard installs connect each of the Dometic CAN 2 purple wires to separate purple wires on harness s 033871 In the event of one system failing there is a backup whereby the system will operate with restricted performance For three and above outboard installs ensure all purple wires from outboard to vessel harnesses are connected to Dometic CAN2 ...

Page 25: ...ntrols Harness Helm Display Harness Outboard Vessel Network Power IN Power OUT Sensor Input One Marker Two Markers Three Markers CORRESPONDING CONNECTORS HAVE MATCHING COLOUR MARKERS 5 3 0 VESSEL HARNESS COLOR GUIDE Make sure that you connect related connectors as given in the instructions in the color schematic Figure 5 3a and color assignment Figure 5 3b Figure 5 3a Rigging color guide schematic...

Page 26: ...an T CAN101 001 Vessel CAN T 3 BAT001 001 002 Pump CoastKey Power Supply BATT201 001 002 GDU Power Supply BATT201 001 002 GDU Power Supply 4 FPM001 001 Fuel Pump Power CKS001 001 CoastKey Control Unit ii GDU201 B 001 GDU PORT B iii GDU201 C 001 GDU Port C GDU101 001 GDU Black Port 5 CANB001 001 Diagnostic CAN T WIF001 001 WIF Sensor PTT001 001 PTT Control Head or Trim Switch Panel FTI201 001 002 F...

Page 27: ...trols harness 033871 On a single install make sure that one of the Dometic purple wires is connected to the purple wire on the control harness 6 3 3 Make sure that you connect the other Dometic purple wire to the house battery via a separate switch it is not supplied in the rigging kit recommended rating of 20amp This connection will let the system operate with restricted performance 6 3 4 When th...

Page 28: ...the Dometic EPS tournament steering cylinder to the CXO300 PTT requires the use of SK 000100 steering cylinder spacer kit Use the following guide to ensure the correct spacer thickness is installed and record the results 6 5 1 Measure Distance A Welded nut then choose spacer from table Record the measurements in table 6 5 5 Figure 6 5a Steering actuator install guide welded end spacers CAUTION Mak...

Page 29: ... change spacers as appropriate until no gap exists Record the measurements in table 6 5 5 6 5 5 Record depth measurement for each end in four places and take an average to select the correct spacer size CXO300 Outboard Steering Actuator Install Guide Step 2 Threaded end spacers selection What is measured length B B 3 5 3 5 B 3 75 3 75 B 4 4 B 4 25 4 25 B 4 5 4 5 B 4 75 4 75 B 5 5 B 5 25 5 25 B 5 5...

Page 30: ...ing the second hole closest to the outboard and torque to 30Nm 22lb ft Figure 6 5 6a Tiller arm and steering actuator fastener Figure 6 5 6b Tiller arm and steering actuator fastener 1 Bolt 3 8 24 UNF x 1 1 2 2 Washer 3 Nyloc Nut 3 8 24 UNF Single Use Only 4 Steering Actuator 5 Tiller Arm 1 Bolt 3 8 24 UNF x 1 1 2 2 Tiller Arm 3 Steering Actuator ...

Page 31: ...ure that the length of the umbilical cable connection is sufficient to let lock to lock movement without restriction 7 4 1 Make sure that you open the service valves on the steering pumps and do a check of the outboard s rack movement from side to side 7 5 0 Remove and stow the mid to upper cowl seal Make sure that you get access to the rigging grommet and housing before running cables and fuel li...

Page 32: ...GGING TUBE INSTALLATION 7 0 RIGGING TUBE INSTALLATION Figure 7 7 Rigging tube removal Rigging grommet Rigging grommet housing half part Rigging grommet half housing Rigging grommet half housing Rigging grommet Rigging grommet half housing ...

Page 33: ...are used on this application Figure 7 8 Engineering drawing of the rigging grommet 7 9 0 Make sure that you use the lower 2 holes for the fuel feed and return lines 7 10 0 Make sure that you use the center hole for the helm control harness and the left and right center holes for the power and earth cables 7 11 0 Make sure that you use the upper holes for the Helm and CAN harnesses and 036484 ECU P...

Page 34: ... within 11 of vertical it must be installed vertically in the range of angles given Figure 8 2a Lift pump in vertical position 8 2 1 Ensure the total length of vertical horizontal pipework lies within the green area of the plot below Figure 8 2b Tank fuel pickup distance NOTE The guide for tank fuel pickup distance from the outboard rigging grommet that is the relationship between the vertical and...

Page 35: ...he necessary port and torque to 25 Nm 8 5 0 Make sure that the fuel lines have dust caps installed at each end when you receive them 8 6 0 Make sure that no unwanted materials go into the fuel system Unwanted material s are dangerous can cause damage to the fuel system components 8 7 0 Make sure the low pressure fuel system can achieve a minimum flow rate of 250 L hr with no restrictions 8 8 0 Con...

Page 36: ...afely at regular intervals 8 10 2 Clear of unwanted heat source and all structures that can possibly cause damage 8 10 3 Does not have bends tighter than the minimum allowable radius 0 1 m or hose manufacturer s specification if available 8 11 0 Look for the quick connect refer to Figure 8 10 fittings on the outboard end of each pipe and attach the quick connects 031164 into the opposite outboard ...

Page 37: ...hich are made with the materials listed below 8 16 0 Make sure that all the caps or bungs on the fuel pipe ends are removed before making connection s to the lift pump or vessel 8 17 0 If you are installing multiple outboards repeat steps 8 1 0 through 8 16 0 for each outboard Make sure that you do not join fuel hoses between outboards 8 18 0 Remove the top of the lift pump and pre fill the lift p...

Page 38: ...tive cable The breaker must maintain a minimum of 100 A continuous current flow and 400 A instantaneous current flow for short period s 9 5 0 Make sure that you install a busbar for the positive and negative power feeds in the bilge area of the vessel The busbars must keep a minimum of 100 A continuous current flow and 400 A instantaneous current flow for short periods 9 6 0 Connect the positive a...

Page 39: ... installed to prevent chafing and decrease the risk of fire Damaged cable s are dangerous and must not be used in all connections If a cable has damage s replace the cable with damage s immediately 9 11 0 Find the ECU Power Harness 036484 9 12 0 Find the large two pin harness connector located on the port side of the outboard engine wiring harness refer to figure 9 12 Figure 9 12 Large two pin har...

Page 40: ...e directly to the outboard battery Connect the positive to the breaker for the outboard battery 9 16 0 If the ECU Power harness 036484 requires to be extended to connect directly to the battery use minimum of 6mm 10AWG wire not supplied to extend the harness 9 17 0 Make sure that the positive wire of any additional harness that is required to extend the battery incorporates a 25A fuse or 25A break...

Page 41: ...n the outboard harness 10 3 0 On the vessel end of the CAN harness 033870 there are two M12 CAN connectors Connect the M12 CAN with the colour code white brown to a T piece connector 034393 10 4 0 Connect a female terminating resistor 034394 on the other end of the T piece connector Refer to Figure 10 4 10 5 0 Use the two mounting holes on the T piece to safely attach the T piece in an area that y...

Page 42: ...iple outboard installation The CAN T piece connectors in multiple outboard installation must be kept separate to make sure that the individual diagnostic network operates correctly 10 10 0 When all the outboards are installed to the CAN network add a T piece connector 034393 to the daisy chain refer to rigging schematics for detail 10 11 0 Connect the Dometic CAN2 harness to the other female port ...

Page 43: ...ssel controls harness 033871 10 15 0 Put the single ten way connector through the rigging tube and grommet 10 16 0 Connect the single ten way connector refer to Figure 10 16 to the outboard harness This step is the end of making all the connections to the outboard Figure 10 16 Single ten way connector 10 17 0 Put the rigging grommet into the half section of the rigging grommet housing of the outbo...

Page 44: ...half housing 10 19 0 Assemble the rigging grommet housing around the rigging tube with the other half section of the rigging grommet housing Refer to Figure 10 19 Make sure that you tighten the two screws to 8 Nm Figure 10 19 Rigging tube installation WARNING Make sure that you use a T25 torx driver to install the two torx screws 032511 If you do not use the correct Allen driver damage can be caus...

Page 45: ...utboard to vessel controls harness 033871 there are a Fuse box holder make sure that you attach use the two mounting holes the fuse box safely in an area where there is no water or heat source This fuse box contains refer to Figure 10 20 1b The fuel pump relay Fuse for CoastKey system 7 5A Fuse for fuel pump relay Figure 10 20 1a Fuse box for fuel pump and Coastkey system Figure 10 20 1b Fuse box ...

Page 46: ...at the bottom of the fuel lift pump unit e Fuel pump connector 2 pin Refer to Figure 10 20 1d connect it to the fuel pump of the fuel lift pump unit f Purple wire Ignition live for Dometic ECU This wire connects to the purple wires on the Dometic CAN 2 harness Refer to section 6 0 0 Steering for installation instructions 10 21 0 Make sure that you select the correct vessel helm control harness the...

Page 47: ...7 8 m vessel helm control harness 033878 10 22 0 Connect the vessel helm control harness into the outboard to vessel controls harness connector 10 23 0 Install the other applicable harnesses up the vessel and to the helm area 10 23 1 Make sure that all the harnesses are installed safely and are protected from water sharp edges and heat source damage s 10 23 2 Make sure that you put labels on the h...

Page 48: ...l operation 11 2 0 Make marks with the templates which are listed below and cut the holes for the controls Make sure that you use the correct personal protective equipment PPE 4 Display refer to Murphy PV450 7 Display refer to Murphy PV780b 12 Display refer to Murphy PV1200 CANtrak Display refer to Dometic EPS manual Book 50 1 I6800 Control head single refer to Dometic EPS manual Book 50 1 I6800 C...

Page 49: ... trim switch panels 11 4 0 Install the trim switch panels using 4 bolts and make sure that all the holes align correctly Torque to 3 Nm 11 5 0 CoastKey Control unit s Make sure that you install the correct control unit s The software that are installed in the control units are different refer to the below table 11 6 0 HELM CONTROL HARNESS CONNECTIONS 11 6 1a When you are installing three or more o...

Page 50: ...hrough 6 to the starboard side 11 6 1d When installing 5 or 6 outboards the engines will start in pairs Make sure that you make different groups of outboards Speak to your Cox representative to make sure that the installation is correct in this condition 11 6 2 PTT SWITCH CONNECTORS 11 6 2a When you install a single outboard connect the PTT switch connector into the related connector on the i6800 ...

Page 51: ...e 11 6 3a i with the harness 033892 This harness 033892 has 4 connectors as follows 1 connector for Battery ve and ve and CAN connection 1 for fuel level gauge 2 blank connectors 11 6 3b Make sure that you connect the 2 blank connectors into port A and port D on the 4 screen Refer to Figure 11 6 3a ii 11 6 3c Make sure that you connect the battery and CAN connector into port B Refer to Figure 11 6...

Page 52: ...s follows 1 harness connector with all the connections 1 harness connector with blanking plug 11 6 3h Make sure that you connect the blanking plug into port 1 grey port on the 7 screen Figure 11 6 3g 11 6 3i Make sure that you connect the harness connector with all the connections into port 2 black port on the 7 screen Figure 11 6 3g 11 6 3j Make sure that you connect the positive and negative con...

Page 53: ...th blanking plug 11 6 3n Make sure that you connect the blanking plug into port 1 black port on the 12 screen 11 6 3o Make sure that you connect the harness connector with all the connections into port 2 grey port on the 12 screen 11 6 3p Make sure that you connect the positive and negative connections to the house battery through a 5 Amp circuit breaker 11 6 3q Make sure that you connect the fuel...

Page 54: ...nd the end of the CAN vessel harness and connect it to 3 T piece connector s 034394 11 6 4b Make sure that you install a male terminating resistor 034396 at the opposite end of the T piece connector s 034394 11 6 4c Make sure that you connect the items listed below into the three other connections on the T Piece connectors Screen M12 CAN connection CANtrak M12 CAN connection Control Head M12 CAN c...

Page 55: ...ap to let air flow 12 4 0 Attach a funnel Refer to Figure 12 4 or oil transfer pump hose safely to the mouth of the dipstick tube 12 5 0 Fill the powerhead with of 9L of engine oil check that the levels are correct if not add extra if necessary Make sure you check the oil levels after running and top up where appropriate 12 5 1 Make sure that you check for signs of leakage from the oil drain plugs...

Page 56: ...CCV separator cap and make sure that you hear a click 12 12 0 Clean all remaining oil in the area where you have been working 12 13 0 Put an oil tray with a minimum volume of 2 5 L below the transmission oil drain plug Figure 12 13 Transmission vents and drain plugs 12 14 0 Remove and stow the transmission vent plug 12 15 0 Remove and stow the transmission oil drain plug 12 16 0 Put transmission g...

Page 57: ...her torque to 15Nm 12 20 0 Remove all remaining oil on the transmission housing with a degreasing agent Make sure that you clean the degreasing agent with a paper towel 13 1 0 Turn the outboard electric circuit breaker to the ON position Refer to Figure 13 1 13 2 0 Tilt the outboard up fully and listen for smooth motor operation and movement between trim and tilt 13 3 0 Engage the tilt locks and p...

Page 58: ...acent to the grease nipple 13 6 0 Remove the outlet hose from the grease nipple 13 7 0 Apply a thin film of grease to the ends of the two trim rams Refer to Figure 13 7 13 8 0 Tilt the outboard up fully and then operate the tilt locks through their full range 3 4 times 13 9 0 Stow the tilt locks and clean the area Figure 13 4 Grease nipple in position near the PTT lever Left and 3D image right Fig...

Page 59: ...59 CXO300 INSTALLATION MANUAL 14 0 INSTALLING THE TOP COWL 14 1 0 Install the top cowl If you are installing multiple outboards make sure that you put each top cowl to their initial outboard ...

Page 60: ...WERTRAIN LIMITED The Cecil Pashley Building Unit 8 Cecil Pashley Way Brighton City Airport Lancing West Sussex BN43 5FF United Kingdom 44 0 1273 454 424 info coxpowertrain com www coxmarine com V2 30 JUL_2021 ...

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