Mercury 200 OptiMax DTS Installation Manual Download

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90-10234050 APRIL 2004

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

Summary of Contents for 200 OptiMax DTS

Page 1: ...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 H...

Page 2: ...stem 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 Prem...

Page 3: ...ITY 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 acces...

Page 4: ...ual engine 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 or13...

Page 5: ... 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 3724 95 Tube Ref No Description Where Used Part Number 95 2 4 C with Teflon O ring seal and the entire cable end 92 80285...

Page 6: ... sudden sharp turn This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death ob00676 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 Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until ...

Page 7: ...f 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 wil...

Page 8: ...y 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 ob01472 2 Mark and drill four 13 5 mm 17 32 in mounting holes 3973 3 Apply marine sealer to shanks of bolts not the threads ...

Page 9: ...nut 4 e Flat washer 4 Front Clamp Assembly Removal Remove two screws with retainer and open the front clamp a a b c 3765 a Screws 2 b Retainer c Clamp 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 ...

Page 10: ...50 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 a b c 3765 a Screws 2 b Retainer c Clamp ...

Page 11: ...ONNECTORS 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 require...

Page 12: ...pped 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 junct...

Page 13: ... 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...

Page 14: ...ation a 3769 b c d e f 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 a b 3619 a 14 pin data harness b Clamp or cable tie ...

Page 15: ...lm 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 3977 a b a 14 pin data harness b Clamp or cable tie ...

Page 16: ... 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 17: ...225 OPTIMAX DTS 90 10234050 Page 17 42 Make sure all connections are tight and seal all unused connectors with weather caps 3622 a b Single Helm Application a DTS command module harness b Clamp or cable tie ...

Page 18: ...m 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 disturb...

Page 19: ... the command module will reach all the connection points a b 3625 Single Helm Application a DTS command module b Clamp or cable tie 3678 a b c d e f 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 20: ... Make sure all connections are tight and seal all unused connectors with weather caps Terminator CAN 1 Terminator CAN 1 Terminator CAN 2 Terminator CAN 2 a b d 3689 c c e a CAN link harness b CAN 2 Terminator resistors do not remove c CAN 1 connectors d Clamp or cable tie e DTS command module harness MODULE INSTALLATION Although the Command Module connection is watertight it is recommended that it...

Page 21: ...ery 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 b or70 a Wire gauge size b Ba...

Page 22: ...5 m 18 ft 4 2 2 2 5 8 m 19 ft 4 2 2 2 6 1 m 20 ft 4 2 2 2 6 4 m 21 ft 2 1 2 1 6 7 m 22 ft 2 1 2 1 7 0 m 23 ft 2 1 2 1 7 3 m 24 ft 2 1 2 1 7 6 m 25 ft 2 1 2 1 7 9 m 26 ft 2 1 0 1 1 0 8 2 m 27 ft 2 1 0 1 1 0 8 5 m 28 ft 2 1 0 1 1 0 8 8 m 29 ft 2 1 0 1 1 0 9 1 m 30 ft 2 1 0 1 1 0 9 4 m 31 ft 2 1 0 1 1 0 9 8 m 32 ft 2 1 0 1 1 0 10 1 m 33 ft 2 2 0 1 0 2 0 10 4 m 34 ft 2 2 0 1 0 2 0 10 7 m 35 ft 1 2 0 1...

Page 23: ...upplied 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 NOTICE DTS Optimax Engines 37 895387 IMPORTANT Battery cable size and length is critical Refer to engine installation manual for size requirements DO NOT USE WING NUTS DO NOT USE DEEP CYCLE BATTERIES 13 5Nm 120 lbs in DTS Digital Throttle and ...

Page 24: ...lack sleeve negative c Red sleeve positive d DTS power harness provided SINGLE ENGINE BATTERY AT HELM a b e 3699 d c f g h a 14 pin data harness b DTS command module harness c Junction box d DTS power harness optional e Red sleeve Positive f Black sleeve Negative g Vessel sensor harness h Weather caps ...

Page 25: ...TS 90 10234050 Page 25 42 DUAL ENGINE BATTERY AT STERN c b c a b a 3680 d d e f g a Red sleeve positive b Black sleeve negative c Battery d DTS power harness provided e Ground cable f Data cable g Vessel sensor harness ...

Page 26: ... 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...

Page 27: ...e grounded to hull or battery ground in accordance to coast guard regulations PNK BLK BLK ORN BLK ORN LT BLU BLK WHT YEL BLU BLK TAN ORN GRY BLU PUR YEL BLK ORN 3714 a b c d e a Fuel tank b Oil tank c Oil tank sender d Harness e Black orange wire to fuel tank sensor if equipped ...

Page 28: ...0 10234050 Switched 12V Accessory Connection ob01495 PUR RED a b c d e f g h 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 29: ...YEL GRN ORG GRN RED BLK YEL BLK YEL BLK BLK OFF O N e f g h i j d 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 ...

Page 30: ...N ORG GRN RED BLK YEL BLK YEL BLK BLK OFF O N d e f g h i j 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 ...

Page 31: ... 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 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 ...

Page 32: ...rify 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 fa...

Page 33: ... 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 ob00364 S T A R T OFF ACC ON S T A R T OFF ACC ON 3484 3 Turn the key switch back to the OFF position and squeeze the primer bulb again until it feels firm ob00360 S T A R T OFF ACC ON S T A R T OFF ACC ON 3482 4 Turn the key switch to the...

Page 34: ...ne 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 3768 b a a Oil supply hose b Oil injection pump ...

Page 35: ...conds This operates the electric fuel pump ob00364 S T A R T OFF ACC ON S T A R T OFF ACC ON 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 ob00...

Page 36: ...ler 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 ob00382 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust ...

Page 37: ...ove 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 b...

Page 38: ...m 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 accept...

Page 39: ...te 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 gelcoa...

Page 40: ...s 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 f...

Page 41: ...ble 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 ...

Page 42: ...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 A A B B C C D D A A B B C C D D a b b WHT YEL BLU BLK ob01512 a Connector b Wire retainer Template Paddle Wheel Speed Sensor a b ob01513 a Drill holes here b Align dotted line with the transom bottom edge and fold under ...

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