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Quicksilver SmartCraft Systems Reference Manual

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Technician Reference Manual
Digital
Diagnostic
Terminal
Software Version 1.2
SmartCraftt Systems
Printed in U.S.A.
90–881204–2 401

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Summary of Contents for Quicksilver SmartCraft Systems

  • Page 1 Technician Reference Manual Digital Diagnostic Terminal Software Version 1.2 SmartCraftt Systems Printed in U.S.A. 90–881204–2 401...
  • Page 2 Note: To take full advantage of the tool, you should be knowledgeable and well trained in the OEM system described in this manual. This manual contains information that will allow you to use the tool to perform diagnostic tests and find possible locations of en- gine problems.

  • Page 3: Table Of Contents

    Preface TABLE OF CONTENTS Preface Table of Contents ........Safety Precautions .

  • Page 4: Preface

    Preface TABLE OF CONTENTS Marine Diagnostics Overview ......... . . LED Overview .
  • Page 5 ........Glossary of Terms SmartCraft Systems ......

  • Page 6: Safety Precautions

    Preface SAFETY PRECAUTIONS WARNING When an engine is operating, keep the service area WELL VENTILATED or attach a building exhaust removal system to the engine exhaust. Engines produce carbon monoxide, a poisonous gas which is odorless, causes slower reaction time, and can lead to serious injury or death. Fuel under pressure may escape and create a dangerous condition if you are working with fuel lines.

  • Page 7: Icons

    Preface ICONS PRINT Press F2, 1 This icon indicates that the Print function is available. Press F2 and then 1 to begin printing. Line Lock Available This icon indicates that Line Lock is available. The Line Lock feature allows display lines to be locked into position, rather than scrolled.

  • Page 8: What's New For Cartridge Version

    Preface WHAT’S NEW FOR CARTRIDGE VERSION 1.2 – SMARTCRAFT PCMS/ECMS MODEL YEAR 2002 FPC Total – Data Monitor (select models) Ignition Timing – Data Monitor (select models) 30 – 60HP 4 stroke outboard with ECM555 V6 Outboard EFI with PCM555 All previous PCM555 models since 2002 MY are supported Reference Manual...
  • Page 9 Preface NOTES Reference Manual...

  • Page 10: 1.0 Introduction

    1.0 Introduction OVERVIEW The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to help technicians diagnose and repair Mercury Marine two and four cycle outboard engines. The Outboard Diagnostics Cartridge contains a diagnostic program for the ECM that allows the technician access to all of the diagnostic capabilities available through the engine Electronic Control Module (ECM).

  • Page 11: Ddt Features

    1.0 Introduction DDT FEATURES Outboard Diagnostic Cartridge – contains the memory and the software to perform diagnostic tests and other functions. Key Pad – allows you to enter data and reply to DDT messages. Display Window – displays data and messages to the user. LED Indicators –...

  • Page 12: Engine Adaptor Cables

    1.0 Introduction DDT FEATURES Engine Adaptor Cables 84–822560A 5 – 2001 Optimax/SmartCraft systems 8.1L MerCruiser/SmartCraft Systems 84–822560A 12 – Adaptor for 8.1L MerCruiser 84–822560A 13 – 8.1L MerCruiser/SmartCraft Systems Reference Manual...

  • Page 13: Keypad

    1.0 Introduction DDT FEATURES Keypad a- and Keys – Move through menus and move cursor up or down Keys – Move cursor left or right c-F1/F2 Keys – Allows the user to perform special functions d-ENTER Key – Enters your commands into the program e-MODE Key –...

  • Page 14: Led Indicators

    1.0 Introduction DDT FEATURES DIGITAL DIAGNOSTIC TERMINAL LED Indicators NOTE: The LED display consists of eight (8) LEDs arranged in two columns of four LEDs and located under the four line display. The LED display shows the numbers identified in this illustration; it does not show descriptions.

  • Page 15: F1 And F2 Keys

    1.0 Introduction DDT FEATURES F1 and F2 Keys Extra functions are available using the Fl and F2 keys. All functions are NOT active during all tests. F Key Functions Press Result F1 Menu F1 + F1 Press the F1 key twice to display the available F1 functions.

  • Page 16: Printer Setup

    1.0 Introduction PRINTER SETUP a-Printer Power Plug b-DB-25 Printer Cable NOTE: The OTC serial printer (part number 3315, which has a 2400 baud rate) or OTC Hi Speed Serial printer (part number 3285, which has a 9600 baud rate) is recommended if a printer is desired. Connect power to the printer by using one of the following methods: a.

  • Page 17: Using Other Serial Printers

    1.0 Introduction USING OTHER SERIAL PRINTERS Requirements for other printers The printer must have a serial data protocol with x–on/x–off handshaking. There is a tool–to–printer cable available. The cable must be configured as shown: DB–25 2–TXD (Host out) 3–RCV (Host in) 7–Ground The printer can have a baud rate of 300, 600, 1200, 2400, 4800, or 9600.

  • Page 18: Tool Setup

    1.0 Introduction TOOL SETUP Overview Use this function to select the DDT baud rate and the number of stop bits. You can also save the Tool Setup or restore the previously saved setup. Make sure the SELECT FUNCTION Menu screen is displayed on the DDT.

  • Page 19: Line Lock

    1.0 Introduction LINE LOCK If you want a line of data to stay in place, press key 1, 2, 3 or 4 to hold data line 1, 2, 3, or 4 in place. Pressing the number again will unlock that line. As you scroll, the lines locked will stay in place and the next data items will appear in the unlocked lines.

  • Page 20: Record/Playback

    1.0 Introduction RECORD/PLAYBACK The Diagnostic Cartridge contains a Recording feature that allows you to capture information at certain times when data is displayed on the screen. Once data has been captured, you can play it back immediately or save it in a file for playback and printing. The data will be captured in “frames.”...
  • Page 21 1.0 Introduction RECORD/PLAYBACK When all 51 frames of data have been recorded, the r displayed in the lower right hand corner of the screen will change to an upper case R (underlined). ENGINE RPM 690 <E TPI 1 VOLTS 0.59 BATTERY VOLTS 13.5 PWR 1 VOLTS...

  • Page 22: Save Error

    1.0 Introduction RECORD/PLAYBACK Save Error If Data Capture is unable to save a file, an error screen will be displayed. Errors usually occur because the number in the Needed Space field will be larger than the number in the Total Free field. To free up enough space, first press the ENTER key to exit, then press F2 + 9 to enter the File Manager and select 3 –...

  • Page 23: Playback File

    1.0 Introduction RECORD/PLAYBACK Playback File The Playback File option allows a file to be selected, then played back. >Playback File >OG123456.DMO >MLA2001.DMO 1364 >150EFIMD.DMO 1364 To access Playback File, press the 2 key from the File Manager Menu. Use the keys to scroll through the list of files.

  • Page 24: Rename

    1.0 Introduction RECORD/PLAYBACK Rename Files may be renamed from the File Manager Menu. To rename a file from the File Manager Menu, press the 4 key. The Rename File menu will appear. File Manager: 2-PLAYBACK 3-DELETE 4-RENAME Use the and keys to scroll through the list of files. When the desired file is to the right of the >...

  • Page 25: Print

    1.0 Introduction RECORD/PLAYBACK Print Once data has been captured and saved to a file, the data may also be sent to the printer. Printing of files can be done without the DDT being connected to an ECM. This is done using a 12 volt power supply and printing through the File Manager function.

  • Page 26: Transferring Data To A Pc

    1.0 Introduction TRANSFERRING DATA TO A PC It should be noted that the PRINT function can be used to transfer the formatted print data to a PC. The following example uses Windows 3 , but any DEC VT–100 terminal emulation program can be used. NOTE: You can use the existing serial printer cable, however, you may need to use a DB25 Null Modem adaptor plug and/or a DB25 to DB9 adaptor plug if required by your PC.
  • Page 27 1.0 Introduction TRANSFERRING DATA TO A PC To enter the DDT File Manager menu, Press F2 and then 9 and select choice 5 – Print. Use the keys to scroll and select the file. Press ENTER. Data should now transfer to the PC screen.
  • Page 28 1.0 Introduction NOTES Reference Manual...

  • Page 29: Overview

    2.0 Marine Diagnostics OVERVIEW 1-Mercury Marine 1 DATA MONITOR 2 FAULT STATUS 3 SYSTEM INFO 4 HISTORY 5 SPECIAL FUNCTIONS 6-ENGINE LOCATION 7-TRIM LIMIT Reference Manual...

  • Page 30: Overview

    2.0 Marine Diagnostics OVERVIEW Testing with the DDT is easy. The software program presents a series of menus from which the technician selects tests or functions desired. The software will communicate with the ECM and extract or monitor data stored or processed by the ECM. In general, the functions provided include;...

  • Page 31: Led Overview

    2.0 Marine Diagnostics 1-Mercury Marine LED OVERVIEW The SmartCraft systems diagnostic cartridge contains a diagnostic program for the ECM that allows the technician access to all of the diagnostic capabilities available through the engine Electronic Control Module (ECM). Simply hook the diagnostic cable to the ECM diagnostic connector and plug in the software cartridge.

  • Page 32: Adaptor Cables

    2.0 Marine Diagnostics 1- Mercury Marine ADAPTOR CABLES 84–822560A 5 – 2001 Optimax/SmartCraft systems 8.1L MerCruiser/SmartCraft Systems 84–822560A 12 – Adaptor for 8.1L MerCruiser 84–822560A 13 – 2001 Optimax/SmartCraft systems 8.1L MerCruiser/SmartCraft Systems Reference Manual...

  • Page 33: Diagnostic Port Locations

    2.0 Marine Diagnostics 1- Mercury Marine DIAGNOSTIC PORT LOCATIONS IMPORTANT: Engine must be OFF before connecting the DDT adaptor cable to the ECM. Connect the DDT adaptor cable to the ECM diagnostic port as shown. Attach the battery clips to a 12v battery. Connect the DDT Interface Cable between the DDT and the DDT adaptor cable, if required.

  • Page 34: Power Up

    2.0 Marine Diagnostics 1-Mercury Marine POWER UP NOTE: If the display is blank: – engine switch is off – the interface and/or adaptor cables are not properly connected Insert the software cartridge into the DDT, making sure the label is facing up. You should feel it click into place if done correctly. Set the engine key to RUN or ON position.

  • Page 35: Self Test

    2.0 Marine Diagnostics 1-Mercury Marine SELF TEST The ECM diagnostic software has been enhanced to allow the user to make use of new DDT and ECM features. Select Function: 1-AUTO SELF TEST 2-MANUAL TEST The Auto Self Test will activate all system actuators and scan all sensors to determine if they are within the expected range.

  • Page 36: Two Stroke Examples

    2.0 Marine Diagnostics 1-Mercury Marine 2 STROKE EXAMPLES 4 STROKE EXAMPLES STATIC TEST IN STATIC TEST IN PROGRESS TESTING PROGRESS TESTING DIRECT INJECTORS / IGNITION – PRESS MODE TO CANCEL PRESS MODE TO CANCEL STATIC TEST IN STATIC TEST IN PROGRESS TESTING PROGRESS TESTING IGNITION –...

  • Page 37: 1-Data Monitor

    2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR NOTE: When starting the engine, the DDT may “lock up” due to low battery voltage. If this happens, remove the cartridge and reinsert it. This will reset the DDT and it will power up again. You can use the Data Monitor function to display engine operating parameters available from the ECM.

  • Page 38: Two Stroke Example Screens

    2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (TWO STROKE EXAMPLE SCREENS) Use the keys to move the caret to each parameter. Then press the ENTER key to display the expanded data for the parameter at the caret. To exit the expanded data screens, press the MODE key to return to the Data Monitor.
  • Page 39 2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (TWO STROKE EXAMPLE SCREENS) NOTE: Pressing 0 clears the minimum/maximum values. To view sensors on screen number 2, press the key until the sensors for screen 2 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the <...
  • Page 40 2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (TWO STROKE EXAMPLE SCREENS) To view sensors on screen number 3, press the key until the sensors for screen 3 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. BLOCK PSI COOL TMP STB F 146 <E NOW:...
  • Page 41 2.0 Marine Diagnostics 1-Mercury Marine 1 DATA MONITOR (TWO STROKE EXAMPLE SCREENS) To view sensors on screen number 4, press the key until the sensors for screen 4 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. BLOCK PSI <E OIL LEVEL...
  • Page 42 2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (TWO STROKE EXAMPLE SCREENS) To view sensors on screen number 4, press the key until the sensors for screen 4 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. TRIM OIL LEVEL <E...

  • Page 43: Four Stroke Example Screens

    2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (FOUR STROKE EXAMPLE SCREENS) Use the keys to move the caret to each parameter. Then press the ENTER key to display the expanded data for the parameter at the caret. To exit the expanded data screens, press the MODE key to return to the Data Monitor.
  • Page 44 2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (FOUR STROKE EXAMPLE SCREENS) NOTE: Pressing 0 clears the minimum/maximum values. To view sensors on screen number 2, press the key until the sensors for screen 2 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the <...
  • Page 45 2.0 Marine Diagnostics 1- Mercury Marine 1 DATA MONITOR (FOUR STROKE EXAMPLE SCREENS) To view sensors on screen number 3, press the key until the sensors for screen 3 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. PADDLE WHEEL FUEL LEVEL 180 <E...
  • Page 46 2.0 Marine Diagnostics 1-Mercury Marine 1 DATA MONITOR (FOUR STROKE EXAMPLE SCREENS) To view sensors on screen number 4, press the key until the sensors for screen 4 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. STB EMCT _F PADDLE WHEEL 0.0 <E...
  • Page 47 2.0 Marine Diagnostics 1-Mercury Marine 1 DATA MONITOR (FOUR STROKE EXAMPLE SCREENS) To view sensors on screen number 4, press the key until the sensors for screen 4 are displayed. Press ENTER to view the expanded screen for the sensor positioned opposite of the < caret. STB EMCT _F <E SEA PUMP PSI...

  • Page 48: 2-Fault Status

    2.0 Marine Diagnostics 1- Mercury Marine 2 FAULT STATUS You can use the Fault Status function to display the active or history status of ignition, injectors, pumps, sensors, switches, miscellaneous items, limit modes or break-in status. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.

  • Page 49: 3-System Info

    2.0 Marine Diagnostics 1-Mercury Marine 3 SYSTEM INFO NOTE: SYSTEM INFO includes typical ranges for sensors and output devices for the specific ECM. Using the SYSTEM INFO function, you can display the ID of the engine, ECM, Calibration, Engine version as well as component specs which are stored in the ECM.

  • Page 50: 4-History

    2.0 Marine Diagnostics 1-Mercury Marine 4 HISTORY Using the HISTORY function, you can display the history stored in the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT. Use the key to display the additional screens. Select Function: 2-FAULT STATUS 3-SYSTEM INFO...

  • Page 51: Freeze Frame

    2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY FREEZE FRAME Fault History has been divided into two categories, Freeze Frame and Fault Seconds. Fault Seconds will record, in seconds, the length of time an engine critical system fault occurred. All other faults will be stored in a 10 buffer Freeze Frame.
  • Page 52 2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY PLEASE WAIT READING ECM DATA..If there is data stored in the Freeze Frame buffer, a menu list is displayed which actually identifies the fault that triggered the freeze frame event. Make sure the FREEZE FRAME menu screen is displayed on the DDT.
  • Page 53 2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY FUEL LEVEL % 38.0 The main fuel tank level % when the fault occurred. SHIFT IN GEAR The engine was in gear (or neutral) when the fault occurred. LAKE/SEA TMP_F The temperature of the lake/sea water when the fault occurred. LOAD % The engine load % when the fault occurred.

  • Page 54: Fault Seconds

    2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY FAULT SECONDS Using the Fault Seconds function you can display the total amount of time that an engine critical fault has occurred. Fault Seconds should be cleared once the problem has been corrected. Additional fault problems will also be stored in the Freeze Frame buffers for further evaluation if required.
  • Page 55 2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY FAULT SECONDS FAULT SECONDS BATT VOLT HIGH BATT VOLT HIGH BATT VOLT LOW BATT VOLT LOW BLOCK PRESS LOW BLOCK PSI LOW COMP OVERHEAT COMP OVERHEAT ETC MOTOR OPEN ETC MOTOR OPEN ETC MOTOR SHORT ETC MOTOR SHRT FUEL P INPUT HI...

  • Page 56: Run History

    2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY RUN HISTORY NOTE: Run Time is displayed in hours unless otherwise specified. The sum of the individual times may not always add up to the total ECM run time if the history was previously cleared. Time spent at each point must be at least 1 minute to be logged in history after which the time is updated every 6 (0.1 hour) minutes to the screen.

  • Page 57: Clear Fault History

    2.0 Marine Diagnostics 1- Mercury Marine 4 HISTORY CLEAR FAULT HISTORY NOTE: The Clear Fault function will only work with ‘key-on’, engine not running. The CLEAR FAULT HISTORY function will reset all fault counters to zero. After a component is replaced the user may wish to clear the history fault counters.

  • Page 58: Clear Run History

    2.0 Marine Diagnostics 1-Mercury Marine 4 HISTORY CLEAR RUN HISTORY NOTE: The Clear Fault function will only work with ‘key-on’, engine not running. NOTE: The Run Time Hour and break-in left cannot be erased during a run history clear. The CLEAR RUN HISTORY function will reset all run counters to zero. After engine maintenance is performed the user may wish to clear the history run counters.
  • Page 59 2.0 Marine Diagnostics 1-Mercury Marine 4 HISTORY Press the 4 key. The CLEAR RUN HIST screen will appear. Use the key to display the additional screens and the to return to the previous screen. Clear Run Hist: PRESS 1 TO CLEAR RUN HISTORY PRESS MODE TO CANCEL PRESS 1 KEY...

  • Page 60: 5-Special Functions

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS OIL PUMP PRIME NOTE: Priming of Oil Pump should only be needed on pre-delivery, (new engine installation) if the block has been rebuilt, essentially any time maintenance to the oiling system is required. Press the MODE key to return to the SELECT FUNCTION menu.

  • Page 61: Cylinder Misfire

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS CYLINDER MISFIRE NOTE: This test will run automatically once the user has entered a cylinder number to test. The CYLINDER MISFIRE test helps the technician isolate a problem cylinder. Press the 2 key. Select Function: 1-OIL PUMP PRIME 2-CYLINDER MISFIRE...
  • Page 62 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS DID ENGINE SOUND CHANGE OR DROP RPM? 1=YES 2=NO Press 1 key. Press 2 key. SELECT CYL TO TEST: MISFIRE CHECK LIST: 1 2 3 4 5 6 7 8 CHECK SPARK PLUG, SPARK PLUG LEAD, PRESS MODE TO CANCEL FUEL INJ CONNECTOR,...

  • Page 63: Ignition Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS IGNITION LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 64 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS This test is run with key switch in run position only (engine off). To test the ignition coil output press the 1 key. DISCONNECT POWER TO HIGH PRESSURE FUEL PUMP PRESS 1 TO CONTINUE Press the 1 key USE ONLY A RESISTOR DO YOU WISH TO RUN...
  • Page 65 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS SELECT CYL TO TEST: SELECT CYL TO TEST: 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 PRESS MODE TO CANCEL PRESS MODE TO CANCEL Press the 1 key NOTE: Once the test for IGNITION COIL 1 TEST...
  • Page 66 2.0 Marine Diagnostics VISUAL INSPECTION OF SPARK PLUGS. CORRECT TYPE? Press the CHECK FOR GOOD CONNECTION OF HIGH TENSION WIRE TO PLUG AND COIL Press the CHECK HARNESS CONTINUITY BETWEEN ECM AND SUSPECT COMPONENT Press the REFER TO SERVICE MANUAL WIRING SCHEMATIC FOR INFORMATION Press...

  • Page 67: Fuel Injector Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS FUEL INJECTOR LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 68 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS FUEL INJECTOR 1 TEST IN PROGRESS. LISTEN FOR INJECTOR OPENING AND CLOSING. ECM HAS RECEIVED A ECM HAS RECEIVED A PASS RESPONSE FAIL RESPONSE FROM THE INJECTOR. FROM THE INJECTOR. PRESS 1 TO CONTINUE PRESS 1 TO CONTINUE Press 1 key.

  • Page 69: Direct Injector Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS DIRECT INJECTOR LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 70 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS DIRECT INJ 1 TEST IN PROGRESS. LISTEN FOR INJECTOR OPENING AND CLOSING. ECM HAS RECEIVED A ECM HAS RECEIVED A PASS RESPONSE FAIL RESPONSE FROM THE INJECTOR. FROM THE INJECTOR. PRESS 1 TO CONTINUE PRESS 1 TO CONTINUE Press 1 key.

  • Page 71: Oil Pump Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS OIL PUMP LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 72 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS OIL PUMP TEST IN PROGRESS ..LISTEN FOR OIL PUMP SOLENOID OPERATION. ECM HAS RECEIVED A ECM HAS RECEIVED A PASS RESPONSE FAIL RESPONSE FROM THE PUMP. FROM THE PUMP.

  • Page 73: Fuel Pump Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS FUEL PUMP LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 74 2.0 Marine Diagnostics Mercury Marine 5 SPECIAL FUNCTIONS FUEL PUMP TEST IN PROGRESS ..LISTEN FOR FUEL PUMP OPERATION. DID THE ELECTRIC FUEL PUMP RUN? 1=YES 2=NO Press 1 key. Press 2 key. Select Load Test: VISUAL INSPECTION 1-IGNITION OF ALL CONNECTORS.

  • Page 75: Horn Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS HORN LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 76 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS HORN TEST IN PROGRESS ..LISTEN FOR 5 BEEPS. ECM HAS RECEIVED A ECM HAS RECEIVED A PASS RESPONSE FAIL RESPONSE FROM THE HORN. FROM THE HORN. PRESS 1 TO CONTINUE PRESS 1 TO CONTINUE Press 1 key.

  • Page 77: Miscellaneous - Idle Air Control

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS MISCELLANEOUS – IDLE AIR CONTROL Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn etc) controlled by the ECM. Make sure the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 78 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS IAC TEST WITH ENGINE RPM – continued VISUAL INSPECTION ENGINE MUST BE OF ALL CONNECTORS. IDLING AND AT CHECK ALL GROUND OPERATING TEMP. CONNECTIONS. CONTINUE? 1=YES 2=NO Press the 1 key. Press the key.

  • Page 79: Iac Test With No Engine Rpm

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS IAC TEST WITH NO ENGINE RPM Select Test: 1–ENGINE RPM 2–NO ENGINE RPM Press the 2 key. Select Step Size: 1– 5 Percent 2– 10 Percent 3– 15 Percent 4– 20 Percent Press the 1,2,3, or 4 key for the desired step.
  • Page 80 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS IAC TEST WITH NO ENGINE RPM – continued THE IAC VALVE WILL MOVE IN THE STEPS YOU HAVE SELECTED PRESS 1 TO CONTINUE Press the 1 key. ENGINE RPM ENGINE ISN’T RUNNING DURING THIS TEST IAC DELTA % PRESS 1 TO CONTINUE...

  • Page 81: Electronic Shift Control

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS ELECTRONIC SHIFT CONTROL – ESC Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn etc.) controlled by the ECM. Make sure the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 82 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS ELECTRONIC SHIFT CONTROL – ESC – continued THEN TO REVERSE BACK Select Load : DID THE ENGINE SHIFT TO NEUTRAL. 1–IDLE AIR CONTROL GEARS? 2–ELECT SHIFT PRESS 1 TO CONTINUE 3–ELECT THROTTLE 1=YES 2=NO Press the 1 key.

  • Page 83: Electronic Throttle Control

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS ELECTRONIC THROTTLE CONTROL – ETC Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn etc.) controlled by the ECM. Make sure the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 84 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS ELECTRONIC THROTTLE CONTROL – ETC – continued The Select Test screen is displayed on the DDT. The ETC test can be performed with the engine running or not. This test allows the technician to instruct the ECM to open or close the throttle valve (blade).
  • Page 85 2.0 Marine Diagnostics Select Test: Press the 2 key. Press the 1 key. 1–ENGINE RPM 2–NO ENGINE RPM Select Step Size: ENGINE MUST BE IN 1–5 Percent NEUTRAL AND IDLING FOR 2–10 Percent THIS TEST. 3–15 Percent CONTINUE? 1=YES 2=NO 4–...

  • Page 86: Knock Output Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS KNOCK OUTPUT LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 87 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS SENSOR WILL SHOW INCREASING OUTPUT WITH A LOAD INCREASE ENGINE RPM PRESS 1 TO CONTINUE NOW: min: max: Press the 1 key. KNOCK 1 ENGINE RPM 650 <E NOW: min: max: KNOCK 1 55038 55038 53838...

  • Page 88: Tachometer Load Test

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS TACHOMETER LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 89 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS TACH TEST IN PROGRESS ..TACH WILL DISPLAY 3000 RPM. DID THE TACH DISPLAY 3000 RPM? PRESS 1 FOR YES PRESS 2 FOR NO Press 1 key. Press 2 key.

  • Page 90: Relay Load Test

    2.0 Marine Diagnostics Mercury Marine 5 SPECIAL FUNCTIONS RELAY LOAD TEST Using the OUTPUT LOAD TEST function, you can exercise the ECM and various output loads (ignition coils, injectors, pumps, horn, etc.) controlled by the ECM. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.
  • Page 91 2.0 Marine Diagnostics 1-Mercury Marine 5 SPECIAL FUNCTIONS RELAY TEST IN PROGRESS ..RELAY WILL CYCLE ON - OFF 5 TIMES ECM HAS RECEIVED A ECM HAS RECEIVED A PASS RESPONSE FAIL RESPONSE FROM THE RELAY. FROM THE RELAY.

  • Page 92: Reset Break-In

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS RESET BREAK-IN Using the RESET BREAK-IN function, you can reprogram the ECMs factory break-in oil mode. IMPORTANT: In the event that a new powerhead is installed you must reset the oiling routine. Make sure that the SELECT FUNCTION menu screen is displayed on the DDT.

  • Page 93: 6-Engine Location

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS ENGINE LOCATION Engine location will allow the user to configure multi engine installations within the SmartCraft network. All engines shipped from the factory are ECM configured as a starboard outside engine. For example, if a dual installation is desired, then the appropriate engine ECM needs to be reprogrammed to an outside port engine.
  • Page 94 2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS The screen will appear asking you to select the number of engines installed on the boat. Press the 2 key for a twin installation. PLEASE SELECT THE NUMBER OF ENGINES INSTALLED ON THE BOAT THIS IS CURRENTLY A STARBOARD OUTSIDE ENGINE...

  • Page 95: 7-Trim Limit

    2.0 Marine Diagnostics 1- Mercury Marine 5 SPECIAL FUNCTIONS TRIM LIMIT – Note: Drive by wire models only. The trim limit function will allow the user to configure the ECM to control the maximum up trim limit function. This trim limit function is only supported if the ECM has input from the 3 wire trim sensor.
  • Page 96 2.0 Marine Diagnostics 1- Mercury Marine SAMPLE PRINTOUTS – LIVE OR RECORDED NOTE: Not all printout samples are shown. Press mode to stop printing. Output may continue until printer buffer is cleared out. Press F2 and then 1 from either the Data Monitor, Fault Status, System Info or History screens for data printout.
  • Page 97 2.0 Marine Diagnostics 1- Mercury Marine MERCURY MARINE SYSTEM INFORMATION PRINTOUT 01MY DFI 2.5L 175 ECM# 859610–4 CODE 878086–4 0310_175_002 IGN PRI .38–.78 ohm SEC 8.1–8.9 Kohm DINJ 1.0–1.6 ohm FINJ 1.7–1.9 ohm TYPICAL TPI RANGE TPI1 0.19–1.0v IDLE 3.45–4.63v WOT TGAP 0.025–0.04in PWR RLY 81–99 ohm RPM LIMIT 5850...
  • Page 98 2.0 Marine Diagnostics NOTES Reference Manual...
  • Page 99 3.0 Glossary of Terms SMARTCRAFT SYSTEMS 5 VDC PWR LO 5 Volt ECM Internal Power Supply Low (same as PWR1 Low) Air Compressor Temperature (F or C) Sensor ACT INPUT HI Air Compressor Temperature Sensor Input is High ACT INPUT LO...
  • Page 100 3.0 Glossary of Terms BUS +12 CAN Bus 12 Volt Supply for SmartCraft CALIB ID Calibration ID of ECM Controller Area Network Calibration ID of ECM CODE Coolant Temp Port (F or C) Sensor COOL TMP PRT COOL TMP STB Coolant Temp Starboard (F or C) Sensor COMP Air Compressor Temperature Sensor...
  • Page 101 3.0 Glossary of Terms ETC MOTOR OPEN Electronic Throttle Control Motor is Open (Not Available on All Models) ETC MOTOR SHORT Electronic Throttle Control Motor is Shorted (Not Available on All Models) FINJ 1 - - FINJ 8 OPEN Fuel Injector 1-8 is Open FINJ 1 - - FINJ 8 Fuel Injector 1-8 is Shorted SHORT...
  • Page 102 3.0 Glossary of Terms IDLE MAP STR Idle RPM MAP Strategy (same as MAP Idle Check) IGN 1 - - IGN 8 Ignition Coil for Cylinders One thru Eight IGN PRI Ignition Coil Primary KNOCK SENS1 Knock Sensor #1 (not available on all models) or KNK SNSR1 KNOCK SENS2 Knock Sensor #2 (not available on all models)
  • Page 103 3.0 Glossary of Terms OIL PMP Sec Time Spent with Oil Pump Fault OIL PSI Engine Oil Pressure (PSI or kPa) OIL PSI CKT HI Oil Pressure Sensor Circuit High OIL PSI CKT LO Oil Pressure Sensor Circuit Low OIL PSI STR Oil Pressure Strategy (Not Available on All Models) OIL PUMP...
  • Page 104 3.0 Glossary of Terms PRT EMCT CKT LO Port Exhaust Manifold Coolant Sensor Circuit PRT EMCT OVRHT Port Exhaust Manifold Coolant Temperature Overheat PITOT INPUT HI Pitot Pressure Sensor Input is High PITOT INPUT LO Pitot Pressure Sensor Input is Low PORT OVERHEAT Overheat on the Port Bank PWR 1 VOLTS...
  • Page 105 3.0 Glossary of Terms STEER INPUT LO Steering Wheel Sensor Input is Low (Not Available on all Models) SHIFT Neutral or In Gear Position TGAP Crank Position Sensor (Trig) Air Gap TPI % or TPS % Throttle Position Indicator (demand) Percent TPI or TPS Throttle Position Indicator or Throttle Position Sensor...
  • Page 106 3.0 Glossary of Terms Frequently Asked Questions: 1.What is a circuit (CKT) high or low fault? A circuit fault can be due to an open or short condition, which may include a damaged sensor, a connector or wiring harness problem. The ECM has detected that its sensor input has either gone to a high or low input condition.
  • Page 107 3.0 Glossary of Terms NOTES Reference Manual...
  • Page 108 4.0 Appendix ENGINE LOCATION Single engine installation Dual engine installation Reference Manual...
  • Page 109 4.0 Appendix ENGINE LOCATION STB2 Triple engine installation PRT2 STB2 Quad engine installation Reference Manual...
  • Page 110 4.0 Appendix NOTES Reference Manual...

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