Mercury Remote Controls Service Manual – PDF DOWNLOAD
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Mercury Remote Controls Service Manual – PDF DOWNLOAD
Language : English
Pages : 659
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Mercury Remote Controls Service Manual – PDF DOWNLOAD
COVER 1
Notice to Users of This Manual 2
Precautions 3
Replacement Parts 3
Cleanliness and Care of Product 3
Manual Outline 4
1a 6
HOME 3
Section 1A – Throttle and Shift Cable 6
Table of Contents 6
Throttle and Shift Cable End Guide Replacement 7
Throttle and Shift Cable End Guide Removal 7
Throttle and Shift Cable End Guide Installation 8
Measuring Control Cable Length 8
Measuring For Outboard Throttle/Shift Cables 8
Measuring For MerCruiser Throttle And Shift Cables 9
2a 10
HOME 3
Section 2A – Standard Single Lever Full Gear Shift Remote Control 10
Table of Contents 10
Standard Single Lever Full Gear Shift Control Components 13
Standard Single Lever Full Gear Shift Remote Control Disassembly and Assembly 17
Standard Single Lever Full Gear Shift Remote Control Disassembly 17
Wire Color Code Abbreviations 20
Standard Single Lever Full Gear Shift Remote Control Assembly 21
Installing Remote Control Cables 25
3a 30
HOME 3
Section 3A – Side Mount Control 76334A10 through A40 30
Table of Contents 30
Side Mount Control Mechanical Shift Components 33
Side Mount Control Electric Shift Components 37
Side Mount Control Disassembly 39
Removing Control Cables 39
Remote Control Housing Disassembly 40
Remote Control Housing Components Installation 43
Remote Control Wire Harness and Switches Removal 49
Remote Control Wire Harness and Switches Installation 51
Installing Control Cables 53
3b 56
HOME 3
Section 3B – Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control 56
Table of Contents 56
Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control Disassembly 57
Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control Assembly 59
3c 66
HOME 3
Section 3C – Side Mount Mercury MerCruiser 55722A2, 63063A1 Electric Remote Control Electrical Tests 66
Table of Contents 66
Remote Control Electrical Test Procedure For 55722A2 67
Remote Control Electrical Test Procedure For 63063A1 68
MerControl 63064A1 (Only) 69
4a 70
HOME 3
Section 4A – Commander Panel Mount Controls 70
Table of Contents 70
Commander Classic Panel Mount Control Bezel and Handle Components 73
Control Housing Module Components 75
Commander Classic Panel Mount Control 77
Panel Mount Control Handle and Bezel Removal 77
Commander Control Module Disassembly 78
Commander Control Module Assembly 82
Panel Mount Control Handle and Bezel Installation 87
4b 92
HOME 3
Section 4B – Commander Side Mount Control 92
Table of Contents 92
Commander Side Mount Control External Components 95
Control Housing Module Components 97
Commander Side Mount Remote Control External Identification 99
Commander Side Mount Remote Control Disassembly 99
Commander Side Mount Remote Control Assembly 104
4c 114
HOME 3
Section 4C – Commander 2000 Side Mount Control 114
Table of Contents 114
Commander 2000 Side Mount Control Components 117
Commander 2000 Removal 121
Commander 2000 Side Mount Disassembly 121
Commander 2000 Side Mount Assembly 127
Shift and Throttle Cable Installation 136
Commander 2000 Installation 138
Control Handle Port Side Mounting Conversion 139
4d 142
HOME 3
Section 4D – Commander Console Mount Control 142
Table of Contents 142
Commander Console Mount Control Components 145
Control Housing Module Components 147
Commander Console Mount Control Handle and Trim Switch Removal 149
Removing Trim Switch from the Control Handle 150
Commander Control Module Disassembly 150
Commander Control Module Assembly 154
Control Module Assembly Installation 159
Commander Console Mount Control Handle and Trim Switch Installation 161
4e 164
HOME 3
Section 4E – Commander Two Lever Recessed Console Control 164
Table of Contents 164
Commander Two Lever Recessed Console Control Components 167
Commander Two Lever Console Control Disassembly 169
Commander Two Lever Console Control Assembly 169
Neutral Start Safety Switch Adjustment 173
Commander Two Lever Console Control Cable Installation 175
Attaching Control Cable Configurations 176
4f 180
HOME 3
Section 4F – Commander Two Lever Console Control 180
Table of Contents 180
Commander Two Lever Console Control Components 183
Commander Two Lever Console Control Disassembly 185
Commander Two Lever Console Control Assembly 185
Neutral Start Safety Switch Adjustment 189
Commander Two Lever Console Control Cable Installation 191
Attaching Control Cable Configurations 192
Commander Two Lever Console Control Electric Shift Diagrams 195
4g 198
HOME 3
Section 4G – Commander 3000 Series 198
Table of Contents 198
Commander 3000 Panel Mount Handle and Bezel Components 201
Commander 3000 Classic Panel Mount Handle and Bezel Components 203
Commander 3000 Console Mount Single Handle Components 205
Commander 3000 Console Mount Dual Handle Components 207
Commander 3000 Dual Handle, Three Trim Button Components 209
Commander 3000 Remote Control Module Design ll Components 211
Commander 3000 Remote Control Module Design lll Components 213
Commander 3000 Panel Mount Remote Control 215
Commander 3000 Panel Mount Handle and Bezel Disassembly 215
Commander 3000 Panel Mount Handle and Bezel Assembly 219
Commander 3000 Classic Panel Mount Control 225
Commander 3000 Classic Panel Mount Handle and Bezel Disassembly 225
Commander 3000 Classic Panel Mount Handle and Bezel Assembly 229
Commander 3000 Single and Dual Handle Console Mount Controls 235
Commander 3000 Single and Dual Handle Disassembly 235
Commander 3000 Single and Dual Handle Assembly 239
Shift and Throttle Cable Installation 245
Outboard Models 245
Mercury MerCruiser Models 246
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 247
Commander 3000 Remote Control Module Design ll Disassembly 248
Commander 3000 Remote Control Module Design ll Assembly 252
Shift and Throttle Cable Installation 260
Outboard Models 260
Mercury MerCruiser Models 261
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 262
Commander 3000 Remote Control Module Design lll Disassembly 263
Commander 3000 Remote Control Module Design lll Assembly 267
Shift and Throttle Cable Installation 274
Outboard Models 274
Mercury MerCruiser Models 275
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 276
5a 278
HOME 3
Section 5A – Commander 4000 Series Remote Control 278
Table of Contents 278
Commander 4000 Remote Control Side Mount Components 281
Commander 4000 Panel Mount Remote Control Components 285
Commander 4000 Control Module Components 287
Commander 4000 Gen ll Lock Bar Panel Mount Control Components 289
Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Components 291
Commander 4000 Gen ll Control Module Components 293
Commander 4000 Side Mount Removal, Disassembly, Assembly, and Installation 295
Commander 4000 Side Mount Remote Control Removal 295
Commander 4000 Side Mount Remote Control Disassembly 295
Commander 4000 Side Mount Remote Control Assembly 302
Shift and Throttle Cable Installation 311
Commander 4000 Side Mount Installation 313
Commander 4000 Pistol Grip Remote Control Removal and Installation 314
Commander 4000 Pistol Grip Panel Mount Remote Control Removal 314
Commander 4000 Shift and Throttle Cable Installation 318
Outboard Models 318
Mercury MerCruiser Models 318
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 319
Commander 4000 Pistol Grip Panel Mount Remote Control Installation 321
Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Removal and Installation 327
Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Removal 327
Shift and Throttle Cable Installation 331
Control Cable Anchor Attaching Location 331
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 332
Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Installation 334
Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Removal and Installation 339
Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Removal 339
Shift and Throttle Cable Installation 344
Control Cable Anchor Attaching Location 344
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 345
Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Installation 347
Pistol Grip with Finger Tip Neutral Lock Release Remote Control Removal and Installation 353
Pistol Grip Remote Control with Finger Tip Lock Release Removal 353
Shift and Throttle Cable Installation 358
Control Cable Anchor Attaching Location 358
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 359
Pistol Grip Remote Control with Finger Tip Lock Release Installation 361
Throttle-only Button Removal 366
Commander 4000 Series Remote Control Module Disassembly and Assembly 367
Commander 4000 Remote Control Module Disassembly 367
Commander 4000 Remote Control Module Assembly 371
Commander 4000 Remote Control Module Gen ll Disassembly 377
Commander 4000 Remote Control Module Gen ll Assembly 382
5b 388
HOME 3
Section 5B – Commander 4500 Series Remote Control 388
Table of Contents 388
Commander 4500 Single Handle Remote Control Components 391
Commander 4500 Gen ll Single Handle Remote Control Components 393
Commander 4500 Console Dual Handle Remote Control Components 395
Commander 4500 Gen ll Console Dual Handle Remote Control Components 397
Commander 4500 Control Module Components 399
Commander 4500 Gen ll Control Module Components 401
Commander 4500 Series Removal and Installation 403
Commander 4500 Series Console Control Removal 403
Shift and Throttle Cable Installation 407
Outboard Models 407
Mercury MerCruiser Models 408
Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser 409
Commander 4500 Series Console Control Installation 410
Single Handle Console Control Mounting Bracket Installation 410
Dual Handle Console Control Mounting Bracket Installation 410
Remote Control Module Angle Adjustment 411
Console Control Installation 411
Commander 4500 Series Remote Control Module Disassembly and Assembly 414
Commander 4500 Gen l Remote Control Module Disassembly 414
Commander 4500 Gen l Remote Control Module Assembly 418
Commander 4500 Gen ll Remote Control Module Disassembly 423
Commander 4500 Gen ll Remote Control Module Assembly 428
6a 434
HOME 3
Section 6A – “Hot Foot” Throttle Controls 434
Table of Contents 434
Components Contained in DTS Foot Throttle 437
Hot Foot Throttle 439
Wiring Diagram – Typical Installation 439
Pre-Installation 440
Foot Clearance 440
DTS Foot Throttle Component Installation 440
Adjustments 443
DTS Foot Throttle Installation 445
Optional DTS Foot Throttle Kits 445
Command Module (2006 Model Year Only) 445
Panel Mount Remote Control On/Off Switch Kit 446
DTS Foot Throttle Configuration with Hand Throttle On/Off Switch 446
System Configuration Reset 446
Hand and Foot Control Operation with Hand Throttle On/Off Switch 446
Wiring Diagram – Typical Installation 448
Inspection and Maintenance 448
7a 450
HOME 3
Section 7A – Chrysler Remote Controls 450
Table of Contents 450
Chrysler Controls 161 and 163 Components 451
161 and 163 Control Box Installation 453
Connecting the Control Cables to the Control Box 453
5901 Panel Mount Control Components 457
5901 Panel Mount Control Installation 459
865 Remote Control Components 461
7b 464
HOME 3
Section 7B – Force Remote Control 464
Table of Contents 464
Force Remote Control Installation 465
Attaching the Cable Ends to the Control Cables 465
Force Remote Control Cable Installation 467
8a 470
HOME 3
Section 8A – Sport Jet Remote Controls 470
Table of Contents 470
Sport Jet 30 Series Remote Control Components 473
Sport Jet 40 Series Remote Control 850696 Components 475
Sport Jet 40 Series Remote Control 802755 Components 477
Shift Cable Conversion Kit 850698A1 481
Shift Cable and Shift Cable Bracket Removal 481
Shift Cable and Shift Cable Bracket Installation 482
9a 486
HOME 3
Section 9A – DTS Panel Mount Remote Control 486
Table of Contents 486
Panel Mount Components 489
DTS Panel Mount Remote Control Removal, Disassembly, Assembly and Installation 491
Panel Mount Removal 491
Panel Mount Disassembly 491
Panel Mount Reassembly 492
Panel Mount Installation 492
Panel Mount Control Trim Switch Harness Test 493
9b 496
HOME 3
Section 9B – DTS Single Handle Console Remote Control 496
Table of Contents 496
Single Handle Console Mount Components 499
DTS Single Handle Console Remote Control Removal, Disassembly, Assembly and Installation 501
Single Handle Console Removal 501
Single Handle Console Disassembly 501
Single Handle Console Reassembly 502
Installing DTS Single Handle Console Control 503
Single Console Control Key Pad Harness Test 506
Single Console/Slim Binnacle Control Trim Switch Harness Test 507
9c 508
HOME 3
Section 9C – DTS Slim Binnacle Single Handle Console Control 508
Table of Contents 508
DTS Slim Binnacle Single Handle Console Mount Components 511
DTS Slim Binnacle Single Handle Console Control Removal, Disassembly, Assembly, Installation and Tests 515
DTS Slim Binnacle Single Handle Console Control Removal 515
DTS Slim Binnacle Single Handle Console Control Disassembly 516
DTS Slim Binnacle Single Handle Console Control Reassembly 518
DTS Slim Binnacle Single Handle Console Control Installation 519
Slim Binnacle Remote Control Adjustment 522
Slim Binnacle Control Start/Stop Panel Harness Test 523
Single Console/Slim Binnacle Control Trim Switch Harness Test 524
9d 526
HOME 3
Section 9D – DTS Dual Handle Console Remote Control 526
Table of Contents 526
Dual Handle Console Mount Components 529
DTS Dual Handle Console Remote Control Removal, Disassembly, Assembly and Installation 531
Dual Handle Console Removal 531
Dual Handle Console Disassembly 531
Dual Handle Console Reassembly 532
Installing DTS Dual Handle Console Control 533
Dual Console Control Key Pad Harness Test 537
Dual Console Control Trim Switch Harness Test 538
9e 540
HOME 3
Section 9E – DTS Shadow Mode Console Remote Control 540
Table of Contents 540
Shadow Mode Console Mount Components 543
Shadow Mode Console Mount Remote Control Removal, Disassembly, Assembly and Installation 545
Shadow Mode Control Removal 545
Shadow Mode Control Disassembly 545
Shadow Mode Control Reassembly 546
Installing DTS Shadow Mode Remote Control 548
Shadow Mode Control Key Pad Harness Test 551
Shadow Mode Control Handle Trim Switch Harness Test 552
Dash Mounted Triple Trim Switch Pin-Out 552
9f 554
HOME 3
Section 9F – DTS Dual Engine Console Control with CAN Pad 554
Table of Contents 554
Dual Console Control Non-trim with CAN Pad Components 557
Dual Console Control with CAN Pad Components 559
Dual Console Control with CAN Pad Removal, Disassembly, Assembly, and Installation 561
Dual Console Control with CAN Pad Removal 561
Dual Console Control with CAN Pad Disassembly 561
Dual Console Control with CAN Pad Reassembly 562
Installing the Dual Console Control with CAN Trackpad 564
9g 568
HOME 3
Section 9G – DTS Shadow Mode Console Control with CAN Pad 568
Table of Contents 568
Shadow Mode Console Control with CAN Pad Components 571
Shadow Mode Console Mount Remote Control Removal, Disassembly, Assembly and Installation 573
Shadow Mode Control Removal 573
Shadow Mode Control Disassembly 573
Shadow Mode Control Reassembly 574
Installing the Shadow Mode Control with CAN Pad 576
Shadow Mode Control Handle Trim Switch Harness Test 579
Dash Mounted Triple Trim Switch Pin-Out 579
Dash Mounted Quad Trim Switch Pin-Out 580
9h 582
HOME 3
Section 9H – DTS Dual Handle Yacht Console Remote Controls 582
Table of Contents 582
Throttle/Throttle Dual Handle Yacht Console Remote Control Components 585
Shift/Shift Dual Handle Yacht Console Remote Control Components 587
Throttle/Shift Dual Handle Yacht Console Remote Control Components 589
Throttle/Throttle Dual Handle Yacht Console Remote Console Control with CAN Pad 591
Throttle/Shift Dual Handle Yacht Console Remote Console Control with CAN Pad 593
Dual Handle Yacht Console Remote Control with CAN Pad Removal, Disassembly, Assembly and Installation 595
Dual Handle Yacht Console Remote Control with CAN Pad Removal 595
Dual Handle Yacht Console Remote Control with CAN Pad Disassembly 595
Dual Handle Yacht Console Remote Control with CAN Pad Reassembly 597
Dual Handle Yacht Console Control with CAN Pad Assembly Installation 599
Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Removal, Disassembly, Assembly and Installation 602
Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Removal 602
Dual Handle Yacht Console Remote Control (Thottle/Throttle, Shift/Shift) Disassembly 602
Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Reassembly 604
Dual Handle Throttle/Throttle, Shift/Shift, and Throttle/Shift without CAN Pad Yacht Control Module Assembly Installation 607
Dual Handle Yacht Control Operation 611
Handle Position Adjustment 611
Removal 612
Installation 612
10a 614
HOME 4
Section 10A – Non-DTS Quadrant Controls 614
Table of Contents 614
Quadrant Control Components 617
Non-DTS Quadrant Control Installation Instructions 621
Choosing a Quadrant Control Location 621
Choosing a Quadrant Control Operation 621
Quadrant Control Clearances 622
Quadrant Controls Minimum Required Flat Surface Mounting Area 623
Quadrant Control Removal and Installation 623
Removal 623
Installation 624
Quadrant Control Cable Installation 625
Quadrant Control Neutral Start Safety Switch Replacement 627
Neutral Start Safety Switch Installation 627
Trim Harness Test 628
Quadrant Control Lever Switch Kit 848924_ _ 628
Quadrant Control Disassembly 629
Quadrant Control Reassembly 630
10b 632
HOME 4
Section 10B – DTS Zero Effort Controls 632
Table of Contents 632
Zero Effort Control Components 635
Zero Effort DTS Four Lever Control Components 639
Zero Effort DTS Six Lever Control Components 643
Zero Effort Console Removal and Installation 647
Removal 647
Assembly Guidelines 647
Assembly 650
Installation 657
Trim Harness Test 658
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