SmartCraft Systems - Brunswick...

Technician Reference Manual

Printed in U.S.A. 90-881204003 1003

DigitalDiagnosticTerminal

Software Version 1.3

SmartCraft � Systems

Note:

• To take full advantage of the tool, you should be knowledgeableand well trained in the OEM system described in this manual.

• This manual contains information that will allow you to use thetool to perform diagnostic tests and find possible locations of en-gine problems. It does NOT contain information on how to correctthe problems. Once you have located a problem, consult the en-gine’s service manual for repair instructions.

• All information, illustrations and specifications contained in thistechnical manual are based on the latest information available atthe time of publication. The right is reserved to make changes atany time without notice.

SmartCraft Systems – Digital Diagnostic Terminal 90-881204003




Preface

1Reference Manual

TABLE OF CONTENTSPreface

Table of Contents 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Icons 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What’s New for Cartridge Version 1.3 – SmartCraft PCMs/ECMs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IntroductionOverview 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DDT Features 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Adaptor Cables 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keypad 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Indicators 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1 and F2 Keys 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Other Serial Printers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool Setup 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Setup 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Lock 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record/Playback 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Save Error 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . File Manager Menu 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Directory List 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Playback File 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rename 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Live Data Printing 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transferring Data to a PC 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview

1-Data Monitor 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-Fault Status 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-System Info 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-History 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-Special Functions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface

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TABLE OF CONTENTSMarine Diagnostics

Overview 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Overview 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptor Cables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Port Locations - Outboard 29. . . . . . . . . . . . . . . . . . . Diagnostic Port Locations - MerCruiser 30. . . . . . . . . . . . . . . . . Power Up 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Test 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Stroke Examples 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four Stroke Examples 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–Data Monitor 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Stroke Example Screens 35. . . . . . . . . . . . . . . . . . . . . . Four Stroke Example Screens 40. . . . . . . . . . . . . . . . . . . . . .

2–Fault Status 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–System Info 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–History 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Freeze Frame 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Seconds 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run History 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Fault History 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Run History 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master History Print 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–Special Functions 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Prime 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Misfire 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Load Test 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injector Load Test 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injector Load Test 69. . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Load Test 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Load Test 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn Load Test 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous – Idle Air Control 77. . . . . . . . . . . . . . . . . . . .

IAC Test With Engine RPM 77. . . . . . . . . . . . . . . . . . . . . IAC Test With No Engine RPM 79. . . . . . . . . . . . . . . . . . Electronic Shift Control 81. . . . . . . . . . . . . . . . . . . . . . . . . Electronic Throttle Control 83. . . . . . . . . . . . . . . . . . . . . .

Knock Output Load Test 86. . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Valve Load Test 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . Tachometer Load Test 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Load Test 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface

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Trim Relay Load Test (DTS only) 94. . . . . . . . . . . . . . . . . . . Start Relay Load Test (DTS only) 95. . . . . . . . . . . . . . . . . . . Reset Break-in 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDC Offset 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Location 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Limit (DTS only) 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailer Limit (DTS only) 103. . . . . . . . . . . . . . . . . . . . . . . . . . . Tach Link Config 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sample Printouts – Live or Recorded 107. . . . . . . . . . . . . . . . . . Glossary of Terms

SmartCraft Systems 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequently Asked Questions 120. . . . . . . . . . . . . . . . . . . . . .

AppendixEngine Location 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SAFETY PRECAUTIONS

WARNING!

• When an engine is operating, keep the service area WELLVENTILATED or attach a building exhaust removal system tothe engine exhaust. Engines produce carbon monoxide, apoisonous gas which is odorless, causes slower reactiontime, and can lead to serious injury or death.

� Fuel under pressure may escape and create a dangerouscondition if you are working with fuel lines. Make sure thereis adequate ventilation and there is no possibility of sparkspresent.

� Batteries contain sulfuric acid and produce explosive gasesthat can result in serious injury or death. To prevent ignitionof gases, keep lighted cigarettes, sparks, flames, and otherignition sources away from the battery at all times. If you areusing the battery as a power source, connect the RED (+)battery clip to the positive battery terminal and connect theBLACK (–) battery clip to a good ground away from thebattery.

� Wear an ANSI approved eye shield when testing or repairingengines. Objects can be propelled by rotating enginecomponents, and liquids escaping under pressure cancause serious injury.

� Do not operate the boat and operate the DDT at the sametime. Any distractions may cause an accident. Have oneperson operate the DDT as another person operates theboat.

Preface

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ICONSPRINT

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. TheLine Lock feature allows display lines to be lockedinto position, rather than scrolled. An underline onthe first column of a line indicates that it is locked.

Record

Available This icon indicates that RECORD is available. Pressthe RECORD key to record data being read from theEngine Control Module.

Press

To EXIT Press this key anytime when you wish to return to theprevious menu or test mode.

Press this key for extra information. (May not beavailable on all ECMs)

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WHAT’S NEW FOR CARTRIDGEVERSION 1.3 – SMARTCRAFT PCMs/ECMs

• Guardian Active Due To: – Fault Status 2004 MY and up

• Demand % – Data Monitor (DTS production models only)

• ‘Master Print All’ Function – History

• Set Maximum Trim Limit Position – Special Functions

• Set Maximum Trailer Limit Position – Special Functions

• Start/Stop Engine (DTS models only) – Output Load Test

• Shift Engine (DTS models only) – Output Load Test

• TDC Offset – Special Functions

• Glossary of terms updated

• FAQ updated

• Tach Link Config – Special Functions

• All prior PCM/ECM 555 models supported

1.0 Introduction

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OVERVIEWThe Quicksilver Digital Diagnostic Terminal (DDT) has been developedspecifically to help technicians diagnose and repair Mercury Marinetwo and four cycle engines.

The SmartCraft Engine Diagnostics Cartridge contains a diagnosticprogram for the ECM that allows the technician access to all of thediagnostic capabilities available through the engine ElectronicControl Module (ECM).

Simply hook the diagnostic cable to the ECM diagnostic connector andplug in the software cartridge. You will be able to monitor sensors andECM data values including status switches.

The ECM program can help diagnose intermittent engine problems. Itwill record the state of the engine sensors and switches for a periodof time, much like a tape recorder would, then you can play back andreview the recorded information.

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DDT FEATURES

1 SmartCraft Engine Diagnostic Cartridge – contains thememory and the software to perform diagnostic tests and otherfunctions.

2 Key Pad – allows you to enter data and reply to DDT messages.

3 Display Window – displays data and messages to the user.

4 LED Indicators – indicate faults in certain areas.

5 DDT Interface Cable – connects the DDT to the Adapter Cable.

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DDT FEATURES

1

2

3

Engine Adaptor Cables1 84-822560A 5

2001 and newer Outboard Opti/EFI/PCM or ECM 555 basedSmartCraft Systems

2 84-822560A 12Adaptor used with item 1 – for MerCruiser EFI/PCM or ECM 555based SmartCraft Systems

3 84-822560A 13MerCruiser EFI/PCM or ECM 555 based SmartCraft Systems

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DDT FEATURES

ab

cd

e

f

g

Keypada - ↑ and ↓ Keys – Move through menus and move cursor up or

downb - ← and → Keys – Move cursor left or rightc - F1/F2 Keys – Allows the user to perform special functionsd - ENTER Key – Enters your commands into the programe - MODE Key – Takes you back to the previous menu or test

modef - RECORD Key – Records data for reviewg - HELP Key – displays additional information

(available on select ECM models only).NOTE: If a screen message contains the word “ENTER”, you mustpress the ENTER key to accept the command you’ve keyed into theDDT.

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DDT FEATURES

1

2

3

4

5

6

7

8

DIGITAL

DIAGNOSTIC

TERMINAL

LED IndicatorsNOTE: The LED display consists of eight (8) LEDs arranged in twocolumns of four LEDs and located under the four line display. TheLED display shows the numbers identified in this illustration; it doesnot show descriptions.

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DDT FEATURESF1 and F2 KeysExtra functions are available using the Fl and F2 keys. All functionsare NOT active during all tests.

F Key Functions

Press Result

F1 + F1F1 Menu

Press the F1 key twice to display the available F1functions.

F1 + 1English / Metric

Toggles between English and Metric display.

F1 + 2

Tone On / Off

“Tone On” will cause an audible beep each timea key is pressed. “Tone Off” turns the beep off.Toggles between On and Off each time the 2 keyis pressed. Defaults to ON. Selection is saved inmemory.

F2 + F2F2 Menu

Press the F2 key twice to display the available F2functions.

F2 + 0Revision Level

Displays the revision level of the cartridgesoftware.

F2 + 1Print

Prints the information you are viewing if a printeris attached.

F2 + 9File Manager

List, Playback, delete, rename or print filespreviously saved.

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PRINTER SETUPa

ba - Printer Power Plugb - DB-25 Printer Cable

NOTE: The OTC serial printer (part number 3315, which has a2400 baud rate) or OTC Hi Speed Serial printer (part number 3285,which has a 9600 baud rate) is recommended if a printer is desired.1 Connect power to the printer by using one of the following

methods:

a. Insert the printer’s power plug into the battery adapter cableand attach the battery adapter cable to the battery.

orb. Insert the printer’s power plug into a cigarette lighter

receptacle.

2 Connect the DB-25 printer cable between the DDT’s serialinterface and the printer.

3 Turn the printer power switch On.4 Set the DDT stop bit and baud rate as described in the section

of this manual titled, Tool Setup.

5 The printer will be ready to print once you have completed andsaved the setup. To begin printing, press F2, then 1 or press F2,then 9 to display the File Manager screen. While printing, theDDT ignores all commands (except the MODE key) and shows“PRINTING.”

6 To stop a printout, press the MODE key. A few more lines mayprint while the printer memory is clearing.

You can print almost any time that data from the engine is beingdisplayed. A screen that does not display data, such as the InjectorTest, does not allow printing.

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USING OTHER SERIAL PRINTERSRequirements for other printers1 The printer must have a serial data protocol with x–on/x–off

handshaking.

2 There is a tool-to-printer cable available. The cable must beconfigured as shown:

DB-25 2–TXD (Host out) 3–RCV (Host in) 7–Ground

3 The printer can have a baud rate of 300, 600, 1200, 2400, 4800,or 9600.

4 The printer must have one or two stop bit capability.(The DDT defaults to 2400 baud rate and one stop bit.)

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TOOL SETUPOverviewUse this function to select the DDT baud rate and the number of stopbits. You can also save the Tool Setup or restore the previously savedsetup.

Make sure the SELECT FUNCTION Menu screen is displayed onthe DDT.

Main Menu

SmartCraft Monitor1-Mercury Marine2-Tool Setup

Press the 2 key. The TOOL SETUP MENU screen will appear.

TOOL SETUP MENU1-General Setup2-Save Setup3-Restore Setup

General SetupTO SET THE DDT:From the TOOL SETUP MENU, press the 1 key. The GENERALSETUP screen will appear.

PRN BAUD 2400STOP BITS 1

Use the ↑ and ↓ keys to scroll the cursor. When the cursor is locatedon the line you wish to change, use the ← and → keys to change theoptions. Option choices are listed in the table below.

Parameter Options Defaults

Baud 300, 600, 1200, 2400, 4800, 9600 2400

Stop Bits 1 or 2 1

Once the selected choice is made, then press MODE to exit. From theTOOL SETUP MENU select 2 if you wish to save the setup. Follow theinstructions on the screen. When the settings are saved press MODEto return to the SMARTCRAFT MONITOR screen.

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LINE LOCKIf you want a line of data to stay in place, press key 1, 2, 3 or 4 tohold data line 1, 2, 3, or 4 in place. Pressing the number again willunlock that line. As you scroll, the lines locked will stay in place andthe next data items will appear in the unlocked lines.

ENGINE RPM 690

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RECORD/PLAYBACKThe Diagnostic Cartridge contains a Recording feature that allowsyou to capture information at certain times when data is displayedon the screen. Once data has been captured, you can play it backimmediately or save it in a file for playback and printing.

The data will be captured in “frames.” A “frame” of data is a snapshotof data read from the ECM.

Without operator action, the software continuously reads data from theECM at the rate of one frame per second. The program saves eachframe until 26 frames have been saved. The data is then continuouslyupdated.

→←

ENGINE RPM 690

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RECORD/PLAYBACKWhen all 51 frames of data have been recorded, the r displayed in thelower right hand corner of the screen will change to an upper case R(underlined).

→←

ENGINE RPM 690

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RECORD/PLAYBACKSave ErrorIf Data Capture is unable to save a file, an error screen will bedisplayed. Errors usually occur because the number in the NeededSpace 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 pressF2 + 9 to enter the File Manager and select 3 – Delete. You will needto select a file that you no longer need and delete it. This will free upspace in memory to store another file. (For further details, see thesection on deleting files under File Manager.)

File Manager MenuThe File Manager Menu allows you to manage the limited spaceavailable for saving files. It also allows you to print and play backdata that has been recorded and saved at an earlier date.

To reach the File Manager Menu, press the F2 key followed by the9 key. The screen illustrated will appear.

File Manager:1-DIRECTORY LIST2-PLAYBACK3-DELETE

4-RENAME5-PRINT

↓

Directory ListThe Directory List option of the File Manager allows scrolling throughthe list of files in memory. The top line of the display always shows theamount of available space for new files.

From the File Manager Menu, press the 1 key and the screenillustrated will appear, provided files have been saved.

>Delete File>OG123456.DMO 584>MLA2001.DMO 1364>150EFIMD.DMO 1364

The ↑ and ↓ keys can be used to scroll through the list of files. Pressthe MODE key to exit back to the File Manager Menu.

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RECORD/PLAYBACKPlayback FileThe Playback File option allows a file to be selected, then played back.

>Playback File>OG123456.DMO 584>MLA2001.DMO 1364>150EFIMD.DMO 1364

To access Playback File, press the 2 key from the File Manager Menu.

Use the ↑ and ↓ keys to scroll through the list of files. When the desiredfile is to the right of the > symbol on line 2, press the ENTER key toselect the file.

The playback displays the data as it was recorded. (Use both the ↑and ↓ keys and the ← and → keys to see information).

When you are finished playing back the data, press the MODE key toreturn to the File Manager Menu.

DeleteDelete files that are no longer needed. Otherwise, the area fills up andthere will not be room for new data.

To delete a file from the File Manager Menu, press the 3 key and theDelete File menu will appear.

Use the ↑ and ↓ keys to scroll through the list of files. When the desiredfile is to the right of the > symbol on line 2, press the ENTER key todelete it.

The file will be deleted and the File Manager Menu will appear again.

>Delete File>OG123456.DMO 584>MLA2001.DMO 1364>150EFIMD.DMO 1364

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RECORD/PLAYBACKRenameFiles may be renamed from the File Manager Menu.

To rename a file from the File Manager Menu, press the 4 key. TheRename File menu will appear.

File Manager:2-PLAYBACK3-DELETE4-RENAME

↓↑

Use the ↑ and ↓ keys to scroll through the list of files. When the desiredfile is to the right of the > symbol on line 2, press the ENTER key toselect it.

>Rename File>OG123456.DMO 584>MLA2001.DMO 1364>150EFIMD.DMO 1364

You may enter a new file name in the same way you did to originallysave the file.

New Name:__________.DMO01234567890123456789

Press the ENTER key when the new name has been entered.

Live Data PrintingLive data printing can be activated either in the Data Monitor or FaultStatus mode by pressing the F2 + 1 keys. Printing will continueindefinitely unless the MODE key is pressed. This will abort theprinting process.

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RECORD/PLAYBACKPrintOnce data has been captured and saved to a file, the data may alsobe sent to the printer. Printing of files can be done without the DDTbeing connected to an ECM. This is done using a 12 volt powersupply and printing through the File Manager function.

To print captured data from the File Manager Menu, select the PRINToption by pressing the 5 key. The Print File menu will appear.

File Manager:3-DELETE4-RENAME5-PRINT

↑

Use the ↑ and ↓ keys to scroll through the list of files. When the desiredfile is to the right of the > symbol on line 2, press the ENTER key toselect it.

>Print File>OG123456.DMO 584>MLA2001.DMO 1364>150EFIMD.DMO 1364

The selected file will then be printed.

NOTE: Files can also be transferred to a PC and printed from there.(See Personal Computer setup.)

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TRANSFERRING DATA TO A PCIt should be noted that the PRINT function can be used to transfer theformatted print data to a PC. The following example uses Windows3 , but any DEC VT-100 terminal emulation program can be used.

NOTE: You can use the existing serial printer cable, however, youmay need to use a DB25 Null Modem adaptor plug and/or a DB25 toDB9 adaptor plug if required by your PC.

1 Use OTC cable (p/n 212535) and connect between the DDTprinter port and the PC’s COM1 port (or an available serial port).

2 Set up the Windows terminal emulation program on the PC tocapture the print data into a file as follows:

a. Select the Accessories Icon.

b. Select the Terminal Icon.

c. From the menu bar, select Settings – Communications.Set the communications parameters as follows:

Baud Rate: 9600 Data Bits: 8 Parity: None Stop Bits: 1 Flow control: Xon/Xoff Connector: COM1

d. Select OK.

3 Make sure the DDT baud rate matches the terminal baud rate. Thiscan be done from the Tool Setup Function. Select 1 – GeneralSetup and set the following :

PRN BAUD to 9600 and PRN STOP BITS to 1.

4 From the Windows terminal menu bar, select Transfers –Receive text file. You will then be asked to assign a filename.(File name you wish to upload from the cartridge. For example,OG123456.txt) Important – the file must have a “.txt” extension.Select OK when entered.

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TRANSFERRING DATA TO A PC5 To enter the DDT File Manager menu, Press F2 and then 9 and

select choice 5 – Print. Use the ↑ and ↓ keys to scroll and selectthe file. Press ENTER. Data should now transfer to the PCscreen.

NOTE: If the data transfer to the PC screen does not look correct, thisindicates that the baud rate is not correct. The cartridge default settingis 2400. Please make sure that the tool baud rate matches what youare setting up the PC software to do.

6 Once all the data has been received, select Transfers – Stop ,from the Windows terminal menu bar. The data will be saved to thehard drive as OG123456.txt.

7 Clear the terminal screen for the next file. Select Edit – ClearBuffer. Steps 4, 5, 6, and 7 can be repeated if you need to transfermore files.

8 Once the file has been saved on the PC, it can be manipulatedin any desired manner. For example, you can;

• Print to the PC’s printer.• Edit the file.• Include the file in a report. Most PC word processors and spread

sheets can import a single text file into a document.

(Refer to your word processor manual for instructions on printing,editing and importing files.)

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25Reference Manual

OVERVIEW1-Mercury Marine

��

��

��

��

��


26 Reference Manual

OVERVIEWTesting with the DDT is easy. The software program presents a seriesof menus from which the technician selects tests or functions desired.

The software will communicate with the ECM and extract or monitordata stored or processed by the ECM. In general, the functionsprovided include; faults, events, data, data capture (recording) andfile management.

You can perform many different functions, depending on the featuresthat are available within the ECM.

a. Data Monitor – Display operating parameters that are beingreceived from the ECM.

b. Fault Status – Display the current state of engine actuatorsor sensors.

c. System Info – Display the internal ID of an ECM.

d. History – Stored history within the ECM.

e. Special Functions – Allows user to perform special testfunctions as allowed by the ECM.

All of the menu functions available for the system selected will bedisplayed. If an up or down arrow is also displayed on the screen,press the ↑ or ↓ key to see the additional screens available.

The Mainhead, Subhead, and/or Sub-subhead on the top of eachpage describes the steps needed to follow on the menu structure toarrive at the place on the DDT that is being described on that page.Select a choice by pressing the corresponding number key.

Main Menu



27Reference Manual

1-Mercury MarineLED OVERVIEW

The SmartCraft systems diagnostic cartridge contains a diagnosticprogram for the ECM that allows the technician access to all of thediagnostic capabilities available through the engine ElectronicControl Module (ECM).

Simply hook the diagnostic cable to the ECM diagnostic connectorand plug in the software cartridge. You will be able to see the currentstate of the engine, status of sensors and switches, run time historyand stored faults.

The ECM program can help diagnose intermittent engine problems.It will record the state of the engine sensors and switches for aperiod of time, much like a tape recorder would. Then you canplayback and review the recorded information.

The DDT also has LED failure indicators below the display. Theseindicators illuminate when a fault exists in the following areas:

1

2

3

4

5

6

7

8

DIGITAL

DIAGNOSTIC

TERMINAL

Ignition

Injector

Pump

Sensors

Switches

Miscellaneous

Limiter

Break In

a

a - LED Indicators


28 Reference Manual

1-Mercury MarineADAPTOR CABLES

1

2

3

1 84-822560A 52001 and newer Outboard Opti/EFI/PCM or ECM 555 basedSmartCraft Systems

2 84-822560A 12Adaptor used with item 1 – for MerCruiser EFI/PCM or ECM 555based SmartCraft Systems

3 84-822560A 13MerCruiser EFI/PCM or ECM 555 based SmartCraft Systems


29Reference Manual

1-Mercury MarineDIAGNOSTIC PORT LOCATIONS - OUTBOARD

IMPORTANT: Engine must be OFF before connecting the DDTadaptor cable to the ECM.

1 Connect the DDT adaptor cable to the ECM diagnostic port asshown. Attach the battery clips to a 12v battery.

2 Connect the DDT Interface Cable between the DDT and the DDTadaptor cable, if required.

T

T

a

b

c

a - Diagnostic Port Location 2.5L and 3.0L OptiMaxb - DDT Interface Cablec - Diagnostic Port Location 30-60 HP 4 Stroke Outboard

T Dielectric Grease (92-823506--1)

NOTE: Apply a small amount of dielectric grease to the 25 pin endsof the interface cables. This will minimize corrosion in the saltwaterenvironment.


30 Reference Manual

1-Mercury MarineDIAGNOSTIC PORT LOCATIONS - MERCRUISER

IMPORTANT: Engine must be OFF before connecting the DDTadaptor cable to the ECM.

1 Connect the DDT adaptor cable to the ECM diagnostic port asshown. Attach the battery clips to a 12v battery.

2 Connect the DDT Interface Cable between the DDT and the DDTadaptor cable, if required.

c

T

T

b

a

c

a - Diagnostic Port Location 8.1L MerCruiserb - DDT Interface Cablec - Diagnostic Port Location 4.3-5.7-6.2L MerCruiser

T Dielectric Grease (92-823506--1)

NOTE: Apply a small amount of dielectric grease to the 25 pin endsof the interface cables. This will minimize corrosion in the saltwaterenvironment.


31Reference Manual

1-Mercury MarinePOWER UP

NOTE: If the display is blank:– engine switch is off – the interface and/or adaptor cables are not properly connected

1 Insert the software cartridge into the DDT, making sure the labelis facing up. You should feel it click into place if done correctly.

2 Set the engine key to RUN or ON position.

3 A power-up screen will be displayed while the DDT performs a selftest.

After the copyright screen appears, the SmartCraft monitor screen willappear. Select 1 - Mercury Marine.


4 The DDT will attempt to communicate with the ECM. If it cannot,a NO RESPONSE screen will be displayed.

No ECM responseCheck connectorand key positionPress MODE

If the DDT can communicate with the ECM, the next screen displayedwill indicate the model year, displacement and horsepower.

THIS ENGINE IS A 01 MY DFI 2.5L 175

PRESS 1 TO CONTINUE


32 Reference Manual

1-Mercury MarineSELF TEST

The ECM diagnostic software has been enhanced to allow the user tomake use of new DDT and ECM features.

Select Function:1-AUTO SELF TEST2-MANUAL TEST

The Auto Self Test will activate all system actuators and scan allsensors to determine if they are within the expected range. It isadvisable to disable the electric fuel pump(s) during the test. Todisable the electric fuel pump remove the fuse or unplug theconnector(s) to the pump(s). Make sure the Select Function menuscreen is displayed. Press the 1 key.

USE ONLY A RESISTORTYPE SPARK PLUG TOVIEW EXTERNAL SPARKCONTINUE? 1=YES 2=NO

Press the 1 key.

DISCONNECT POWERTO HIGH PRESSUREFUEL PUMP.PRESS 1 TO CONTINUE

Press the 1 key

DO YOU WISH TO RUNTEST WITH ANY SPARKPLUGS IN CYLINDER?1=YES 2=NO

Press the 1 key

IF MOTOR IS EFI ANDPLUGS ARE IN HEAD ABACKFIRE MAY OCCUR. ↓THIS CAN CAUSE AN

Press the ↓ key.

EXTERNAL FLAME IFFLAME ARRESTOR IS REMOVED. ↓

Press the ↓ key.

PURGE FUEL VAPORSPRIOR TO TESTPRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key

2=NO

THIS IS A KEY ON ONLY STATIC TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key


33Reference Manual

1-Mercury Marine

2 STROKE EXAMPLES 4 STROKE EXAMPLES

STATIC TEST IN PROGRESS TESTINGDIRECT INJECTORS /PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGIGNITION –PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGIGNITION –PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGFUEL INJECTORS \PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGFUEL INJECTORS \PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGIAC VALVE / PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGHORN /PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGSENSORS –PRESS MODE TO CANCEL

STATIC TEST IN PROGRESS TESTINGOIL PUMP \PRESS MODE TO CANCEL

TEST COMPLETED.PRESS 1 TO VIEWRESULTS OR PRESSMODE TO EXIT

STATIC TEST IN PROGRESS TESTINGSENSORS –PRESS MODE TO CANCEL

Press the 1 key to review results

TEST COMPLETED.PRESS 1 TO VIEWRESULTS OR PRESSMODE TO EXIT

Press the 1 key to review results

NOTE: The type of tests performed will depend on the engine typeand the system components supported by the ECM resulting indifferent screen displays.


34 Reference Manual

1-Mercury Marine��

NOTE: When starting the engine, the DDT may “lock up” due to lowbattery 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 operatingparameters available from the ECM. The screen will display “live”data such as engine speed, throttle position, battery volts, airtemperature, map psi, coolant temperature, TPI % and more. Youcan also record and/or print the data for detailed examination or foryour records.

Select Function:1-DATA MONITOR2-FAULT STATUS3-SYSTEM INFO

↓

The Data Monitor display items may vary depending on the specificengine type being serviced. Many sensors or parameters may becommon between two stroke or four stroke engines. The first sectionof the Data Monitor screens will be examples of a two stroke DFIengine. The next section will be examples of a four stroke EFIengine.

Press the 1 key. Start the engine. The DATA MONITOR screen willappear.

Line Lock

Available

Record

Available

PRINT

Press F2, 1Available


35Reference Manual


��

Use the ← or → keys to move the caret to each parameter. Thenpress the ENTER key to display the expanded data for theparameter at the caret. To exit the expanded data screens, press theMODE key to return to the Data Monitor.

ENGINE RPM 543


36 Reference Manual

1-Mercury Marine ��

��

NOTE: Pressing 0 clears the minimum/maximum values.

To view sensors on screen number 2, press the ↑ or ↓ key until thesensors for screen 2 are displayed. Press ENTER to view theexpanded screen for the sensor positioned opposite of the < caret.

COOL TMP STB °F 146


37Reference Manual


��


BLOCK PSI 2.7


38 Reference Manual


��


BLOCK PSI 2.7


39Reference Manual


��


OIL LEVEL 532


40 Reference Manual


��

Use the ← or → keys to move the caret to each parameter. Thenpress the ENTER key to display the expanded data for theparameter at the caret. To exit the expanded data screens, press theMODE key to return to the Data Monitor.

ENGINE RPM 650


41Reference Manual


��

NOTE: Pressing 0 clears the minimum/maximum values.


FUEL LEVEL 180


42 Reference Manual


��


PADDLE WHEEL 0.0


43Reference Manual


��


STB EMCT �F 138


44 Reference Manual


��


→ →←

→←

MAT �FNOW: min: max:138 38 138

R

→←

< CaretE Expanded mode available→ Moves the caret down← Moves the caret upR When data can be recorded

NOW: Current valuemin: Minimum valuemax: Maximum value

←SEA PUMP PSI

NOW: min: max:3.8 3.8 3.8

R

→←

TPS%NOW: min: max:

0.0 0.0 0.0R

TPS 1 VOLTSNOW: min: max:0.383 0.383 3.80

R

SEA PUMP PSI 3.8


45Reference Manual


You can use the Fault Status function to display the active or historystatus of ignition, injectors, pumps, sensors, switches, miscellaneousitems, limit modes or break-in status.

Make sure that the SELECT FUNCTION menu screen is displayed onthe DDT.

Select Function:1–DATA MONITOR2–FAULT STATUS3–SYSTEM INFO

↓

FAULT STATUS has been organized in a way by which all faults canbe viewed from a single display area. For example: if a sensor faultoccurs while connected to the ECM, LED 4 will light.

Press the 2 key

FAULT ACTIVEBREAK–IN YES STAR OVERHEAT NOMAP INPUT LO YES

All LED (1-8) supported faults will be displayed in the FAULTSTATUS display area. When a fault is currently active the YESmessage will appear. If the fault corrects itself while the user is stillconnected to the ECM, the message will change to NO. Themessage No would indicate that a past history event occurred withthat specific device. NO is usually an indication of an intermittentconnection problem. Faults are also stored in the Freeze Framebuffers. See the section on Freeze Frame for more details. If thereare no faults active, the message NONE will be displayed in theFAULT STATUS screen.

FAULT ACTIVENONE


46 Reference Manual


Starting with model year 2004 PCMs and ECMs can display to theDDT the exact reason that engine guardian is active. Here are a fewexamples of how engine guardian can reduce engine power:coolant temperature high, block pressure low, critical sensor faultsor battery voltage just to name a few. If there are no problemsrequiring action by guardian then ‘none’ is displayed on the ‘engineguardian active due to’ screen. The screen has been added to theend of the existing fault active screen list.

FAULT ACTIVENONE

↓General faultinformation

Press the ↓ key

ENGINE GUARDIANACTIVE DUE TO:

NONE

Guardian specificinformation ↑

PRINT

Press F2, 1

Press

To EXIT


47Reference Manual


NOTE: SYSTEM INFO includes typical ranges for sensors andoutput devices for the specific ECM.

Using the SYSTEM INFO function, you can display the ID of theengine, ECM, Calibration, Engine version as well as componentspecs which are stored in the ECM.

Make sure that the SELECT FUNCTION menu screen is displayedon the DDT.

Select Function:1-DATA MONITOR2-FAULT STATUS 3-SYSTEM INFO

↓

Press the 3 key. The SYSTEM INFO screen will appear.

Press the MODE key to return to the SELECT FUNCTION menu.The screens below are an example of how screens will appear.

01 MY DFI 175 ECM # 859610–4CODE 878086–4 ↓

IGN PRI .38-.78 ohmSEC 8.1-8.9 KohmDINJ 1.0-1.6 ohmFINJ 1.7-1.9 ohm

↓↑

TYPICAL TPI RANGE

TPI1 0.19 – 1.0v IDLE 3.45 – 4.63V WOT

↓↑

TGAP 0.025 – 0.04 in.PWR RLY 81 – 99 ohmRPM LIMIT 5850PROP RPM 5250 –5750

↓↑

AIR COMPRESSOR1 Kohm @ 77 �F/25�CAIR TEMP/COOLANT10 Kohm @ 77 �F/25�C

MORE INFO AVAILABLEMAY VARY BY MODELS

↓↑

PRINT

Press F2, 1 Available

Press

To EXIT


48 Reference Manual


Using the HISTORY function, you can display the history stored inthe ECM.

Make sure that the SELECT FUNCTION menu screen is displayedon the DDT. Use the ↓ key to display the additional screens.

Select Function:2-FAULT STATUS3-SYSTEM INFO4-HISTORY

5-SPECIAL FUNCTIONS

↓↑

The HISTORY group is split into 2 categories, FAULT and RUNHISTORY. Fault history contains Freeze Frame and Fault Secondsinformation. Run history contains a history count of actual run timesfor the entire RPM range, as well as important fault information.

Press the 4 key. The Select Function History screen will appear.

Select Function:1-FAULT HISTORY2-RUN HISTORY3-CLEAR FAULT HIST

4-CLEAR RUN HIST

↓

PRINT

Press F2, 1

Press

To EXIT


49Reference Manual


FREEZE FRAME

Fault History has been divided into two categories, Freeze Frameand Fault Seconds. Fault Seconds will record, in seconds, thelength of time an engine critical system fault occurred. All otherfaults will be stored in a 10 buffer Freeze Frame. Freeze Frameallows the technician to actually view what operating conditions theengine was under at the time the fault occured.

The freeze frame auto capture software within the ECM, will storean instantaneous snapshot of engine critical data that will give theservice technician more detailed information as to what the engineoperating conditions were like at the time a fault was logged. Thereare a total of 10 storage buffers to retain fault information. Thebuffers are labeled 0 - 9 (10 buffer total). Each buffer will store asingle fault. If frequent faults occur with the same component, ratherthan storing the same information in a new buffer, a frequencycounter will be incremented by one count and all the remaining dataitems will be updated at the time the fault reoccurred. If there are nofaults stored in freeze frame, the DDT will display the followingmessage: NO STORED FAULTS. As the freeze frame buffers arefilled, then the DDT menu choice will be updated accordingly.Example: if there are 3 buffers filled containing data, the DDT willdisplay choices 0 - 2 in the menu list.

Make sure the SELECT FUNCTION menu screen is displayed onthe DDT.


↓

Press the 1 key. the Select Fault History screen will appear.

Select Fault Hist:1-FREEZE FRAME2-FAULT SECONDS

Press the 1 key to view Freeze Frame data history stored in theECM.


50 Reference Manual


PLEASE WAIT READING ECM DATA.....

If there is data stored in the Freeze Frame buffer, a menu list isdisplayed which actually identifies the fault that triggered the freezeframe event.

Make sure the FREEZE FRAME menu screen is displayed on theDDT.

FREEZE FRAME BUFFERS0-BREAK-IN1-DINJ6 OPEN2-PORT OVERHEAT

FREEZE FRAME BUFFERSNO STORED FAULTS

PRESS MODE TO EXIT

or

Press the 1 key. Direct Injector 6 or its connection triggered thisevent. You will now be able to view engine system data at the exacttime the fault was recorded.

↓The barometric pressure when the fault occurred.The battery voltage when the fault occurred.The engine block pressure when the fault occurred.

←

←

DINJ 6 OPENBARO PSI 14.1BATT VOLTS 14.6BLOCK PSI 5.3

←

BOAT SPEED 0.0AIR TMP �F 78.8COOL TMP �F 127DEMAND % 0.0

↑↓

←

←←←

Boat speed when the fault occurred. 0 - 100%The engine temperature when the fault occurred.The primary (CTS) coolant temperature when the fault occurred.The Demand % (TPI%) when the fault occurred.Demand % applies to DTS models.

ENGINE RPM 0ENGINE STATE STALLFPC TOTAL 12.7FREQ COUNTER 0

↑↓

←

←←←

The engine RPM when the fault occurred.The engine state when the fault occurred.The calibrated fueling level when the fault occurred.The number of times the fault occurred. 0=1 occurrence, 1=2 occurrence

NOTE: Not all parameters are available on all engine models. Seeglossary for further descriptions of data labels.

PRINT

Press F2, 1

Press

To EXIT


51Reference Manual


FUEL LEVEL % 38.0SHIFT IN GEARLAKE/SEA TMP �F 57LOAD % 0.0

↑↓

←The main fuel tank level % when the fault occurred.The engine was in gear (or neutral) when the fault occurred.The temperature of the lake/sea water when the fault occurred.The engine load % when the fault occurred.

←←

←

MPRLY 0MAP PSI 14.1OIL LEVEL% 38.0PORT TAB POS 0.0

↑↓

←A value of zero indicates there was no request made to acti-vate the main power relay. A value greater than zero indicatesthat the main power relay was active.The MAP pressure when the fault occurred.The main oil tank level % when the fault occurred.The position of the port trim tab when the fault occurred.

←←

←

AVAILABLE PWR% 10.0RUN TIME 38.0STAR TAB POS 0.0TPI% 0.0

↑↓

← Available Engine Power % when the fault occurred.The time at which the fault occurred.(ECM run time of 38 hr.s)The position of the starboard trim tab when the fault occurred.The TPI% when the fault occurred.

←←

←

TRIM POSITION 38.0COOL TMP STB �F 140COOL TMP PRT �F 138

↑← The trim position when the fault occurred.← The starboard coolant temp when the fault occurred.← The port coolant temp when the fault occurred.


PRINT

Press F2, 1

Press

To EXIT


52 Reference Manual


FAULT SECONDS

Using the Fault Seconds function you can display the total amountof time that an engine critical fault has occurred. Fault Secondsshould be cleared once the problem has been corrected. Additionalfault problems will also be stored in the Freeze Frame buffers forfurther evaluation if required.

Make sure the Select Function menu screen is displayed. Press the4 key.


4-HISTORY

↓

The history menus will appear. Press the 1 key to view Fault History.

Select Function:1-FAULT HISTORY2-RUN HISTORY3-CLEAR FAULT HISTORY

↓

The select Fault history screen will appear.

Select Fault Hist:1-FREEZE FRAME2-FAULT SECONDS

Press the 2 key

FAULT SECONDSNONE

PRESS MODE TO EXIT

If no faults are stored in the ECM a message indicating NONE willbe displayed. If data is stored in the ECM then a fault time list willappear. Only engine critical data is recorded by the ECM. All otherfault information will be stored in the Freeze Frame buffers.


53Reference Manual


FAULT SECONDSBATT VOLT HIGH 0BATT VOLT LOW 0BLOCK PRESS LOW 0

↓

FAULT SECONDSBATT VOLT HIGH 0BATT VOLT LOW 0BLOCK PSI LOW 0

↓or

COMP OVERHEAT 0ETC MOTOR OPEN 0ETC MOTOR SHORT 0FUEL P INPUT HI 0

↓↑ COMP OVERHEAT 0ETC MOTOR OPEN 0

ETC MOTOR SHRT 0FUEL PSI IN HI 0

↓↑

FUEL P INPUT LO 0GUARDIAN 38KNOCK SENS1 0KNOCK SENS2 0

↓↑ FUEL PSI IN LO 0GUARDIAN 38

KNOCK SENS1 0KNOCK SENS2 0

↓↑

OIL PSI STR 0OIL REMOTE STR 0OIL RESERVE STR 38MAP INPUT HI 0

↓↑ OIL PSI STR 0

OIL REMOTE STR 0OIL RESERV STR 38MAP INPUT HI 0

↓↑

MAP INPUT LO 0MAP IDLE CHECK 0OIL PUMP 0OVERSPEED 38

↓

↑ MAP INPUT LO 0MAP IDLE CHECK 0OIL PUMP 0OVERSPEED 38

↓

↑

PORT OVERHEAT 0STAR OVERHEAT 0WARNING HORN 0H2O IN FUEL 0

↑PORT OVERHEAT 0STAR OVERHEAT 0WARNING HORN 0H2O IN FUEL 0

↑


PRINT

Press F2, 1

Press

To EXIT


54 Reference Manual


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 totalECM run time if the history was previously cleared. Time spent at eachpoint must be at least 1 minute to be logged in history after which thetime is updated every 6 (0.1 hour) minutes to the screen.

Press the MODE key to return to the SELECT FUNCTION menu.Make sure that the SELECT FUNCTION menu screen is displayed onthe DDT. Use the ↓ key to display the additional screens.


5-SPECIAL FUNCTIONS

↓↑

Press the 4 key. The SELECT FUNCTION screen will appear.


4-CLEAR RUN HIST

↓

Press the 2 key. The HISTORY screen will appear. Use the ↓ key todisplay the additional screens and the ↑ to return to the previousscreen.

RUN TIME HR. 16.5RPM 0-749 0.3RPM 750-1499 1.4RPM 1500-2999 10.9

↓

RPM 3000-3999 1.0RPM 4000-4499 2.5RPM 4500-4999 0.4RPM 5000-5499 0.0

↓

GRD LIMIT Sec 0ACT TEMP Sec 0BLOCK PSI Sec 0CTS TMP Sec 0

CTP TMP Sec 0LOW OIL Sec 0OIL PMP Sec 0

↑

↓↑

↑

PRINT

Press F2, 1

Press

To EXIT

RPM 5500-6249 0.0RPM 6250+ 0.0BREAK-IN LEFT 0RPM LIMIT Sec 38

↓↑

Press the MODE key to return to the Select Fault History menu.


55Reference Manual


CLEAR FAULT HISTORY

NOTE: The Clear Fault function will only work with ‘key-on’, enginenot running.

The CLEAR FAULT HISTORY function will reset all fault countersto zero. After a component is replaced the user may wish to clear thehistory fault counters.

Press the MODE key to return to the SELECT FUNCTION menu.Make sure that the SELECT FUNCTION menu screen is displayedon the DDT. Use the ↓ key to display the additional screens.


5-SPECIAL FUNCTIONS

↓↑



4-CLEAR RUN HIST

↓

Press the 3 key. The CLEAR FAULT HIST screen will appear. Usethe ↓ key to display the additional screens and the ↑ to return to theprevious screen.

Clear Fault Hist:PRESS 1 TO CLEARFAULT HISTORYPRESS MODE TO CANCEL

DO YOU WISH TO CLEARALL FAULT HISTORYCOUNTERS?1=YES 2=NO

CLEAR FAULT COUNTERSIN PROGRESS . . . .

CLEAR FAULT COUNTERSSUCCESSFUL

PRESS MODE TO EXIT

YOU HAVE ABORTEDCLEARING ALLFAULT COUNTERSPRESS MODE TO EXIT

PRESSMODE KEY

PRESS 1 KEY

Press

To EXIT


56 Reference Manual


CLEAR RUN HISTORY

NOTE: The Clear Fault function will only work with ‘key-on’, enginenot running.

NOTE: The Run Time Hour and break-in left cannot be erasedduring a run history clear.

The CLEAR RUN HISTORY function will reset all run counters tozero. After engine maintenance is performed the user may wish toclear the history run counters.

Press the MODE key to return to the SELECT FUNCTION menu.Make sure that the SELECT FUNCTION menu screen is displayedon the DDT. Use the ↓ key to display the additional screens.


5-SPECIAL FUNCTIONS

↓↑



4-CLEAR RUN HIST

↓


57Reference Manual


Press the 4 key. The CLEAR RUN HIST screen will appear. Use the↓ key to display the additional screens and the ↑ to return to theprevious screen.

DO YOU WISH TO CLEARALL RUN HISTORYCOUNTERS?1=YES 2=NO

CLEAR RUN COUNTERSIN PROGRESS . . . .

RUN HISTORY CLEARSUCCESSFUL

PRESS MODE TO EXIT

YOU HAVE ABORTEDCLEARING ALLRUN COUNTERSPRESS MODE TO EXIT

PRESS2 KEY

PRESS 1 KEY

Press

To EXIT

Clear Run Hist:PRESS 1 TO CLEARRUN HISTORYPRESS MODE TO CANCEL

PRESS 1 KEY


58 Reference Manual


The MASTER HISTORY PRINT function will allow the user to print allhistory files stored in the ECM by accessing one convenient menu.

Make sure the SELECT FUNCTION menu is displayed on the DDT.Press the 5 key.


↓

4-CLEAR RUN HIST5-MASTER HIST PRINT ↑

The SELECT PRINTS screen will appear.

Select Prints, Enter1-RUN TIME HISTORY2-FREEZE FRAME3-FAULT SECONDS


59Reference Manual


To print all 3 choices requires the user to press the 1 key, followedby the 2 key and then the 3 key. The selected choices will beindicated by the number underline feature used in the linelockfunction. To deselect your choice, simply press the number of theselection you wish to not print. Once you have selected yourchoice(s) then press the ENTER key to print the file(s) you haveselected.

Select Prints, Enter1-RUN TIME HISTORY2-FREEZE FRAME3-FAULT SECONDSa

a - Linelock

NOTE: The time required to print all files will depend on the numberof files stored in the ECM history.

Line Lock

Available

Press

To EXIT


60 Reference Manual


OIL PUMP PRIME

NOTE: Priming of Oil Pump should only be needed on pre-delivery,(new engine installation) if the block has been rebuilt, essentiallyany time maintenance to the oiling system is required.

Press the MODE key to return to the SELECT FUNCTION menu.Make sure that the SELECT FUNCTION menu screen is displayed onthe DDT. Use the ↓ key to display the additional screens.


4-HISTORY5-SPECIAL FUNCTIONS

↓

Press the 5 key. The SPECIAL FUNCTIONS screen will appear.

Select Function:1-OIL PUMP PRIME2-CYLINDER MISFIRE3-OUTPUT LOAD TEST

4-RESET BREAK-IN

↓

Press the 1 key and follow the instructions on the screen to prime theelectronic oil pump.

PLEASE STOP ENGINE!PRIME PUMP: KEY ONPRESS 1 TO STARTPRESS 2 TO CANCEL

PRIME IN PROGRESSOIL INJ CNT = 16PRESS 2 TO CANCEL

OIL PUMPPRIME SUCCESSFULOIL INJ CNT = 600

Press the MODE key to return to the SELECT FUNCTION menu.Press

To EXIT


61Reference Manual


CYLINDER MISFIRE

NOTE: This test will run automatically once the user has entered acylinder number to test.

The CYLINDER MISFIRE test helps the technician isolate aproblem cylinder. Press the 2 key.


4-RESET BREAK-IN

↓

The CYLINDER MISFIRE screen will appear.

THIS TEST WILLDETERMINE IF ACYLINDER IS FIRING.CONTINUE? 1=YES 2=NO

Press the 1 key.

MISFIRE TEST CAN BE PERFORMED THROUGHOUTTHE RPM RANGEPRESS 1 TO CONTINUE

SELECT CYL TO TEST:1 2 3 4 5 6 7 8

PRESS MODE TO CANCEL

Press the 1 key to select Cylinder 1

CYLINDER 1TEST COMPLETED.

CYLINDER 1MISFIRE TEST INPROGRESS. SOUNDCHANGE IS NORMAL

Available

Press

To EXIT


62 Reference Manual


DID ENGINESOUND CHANGE ORDROP RPM?1=YES 2=NO

Press 1 key. or Press 2 key.



MISFIRE CHECK LIST:CHECK SPARK PLUG,SPARK PLUG LEAD,FUEL INJ CONNECTOR,

MISFIRE CHECK LIST:DIR INJ CONNECTOR,IGN COIL CONNECTORIGN COIL MODULE

↓↑

↓

MISFIRE CHECK LIST:CHECK ECM HARNESSFOR CONTINUITY FORSUSPECT CYLINDER

↑

Press the ↓ key.

Press the ↓ key.

NOTE: On four stroke large horsepower engines it may be difficultto detect any noticeable RPM or sound change when the misfire testis done at idle. If no obvious change is noticed try the test again atanother throttle position greater than zero percent.

Available

Press

To EXIT


63Reference Manual


IGNITION LOAD TEST

Using the OUTPUT LOAD TEST function, you can exercise the ECMand various output loads (ignition coils, injectors, pumps, horn, etc.)controlled by the ECM.

Make sure that the SELECT FUNCTION menu screen is displayed onthe DDT. Press the 3 key.


↓

The SELECT LOAD TEST screen will appear.

Select Load Test:1-IGNITION2-FUEL INJECTOR3-DIRECT INJECTOR

4-OIL PUMP5-FUEL PUMP6-HORN7-MISCELLANEOUS8-TACHOMETER9-RELAYS

↓

WARNING: When ignition load (spark) testing is required on anyconventional EFI engine (non direct fuel injection), make sure tofollow the safety precautions listed in the Preface Section of thisreference manual. If there are fuel vapors present in the engine, theignition load (spark) test could ignite the fuel vapors and cause theengine to backfire. An engine backfire condition may result ininternal engine damage. Purge fuel vapors from the system ifrequired. Do not remove flame arrestor if the engine is equipped withone, otherwise a flame from a engine backfire may ignite fuel vaporsand cause a fire or bodily harm.


64 Reference Manual


This test is run with key switch in run position only (engine off). To testthe ignition coil output press the 1 key.



DO YOU WISH TO RUN TEST WITH ANY SPARKPLUGS IN CYLINDER?1=YES 2=NO

DISCONNECT POWERTO HIGH PRESSUREFUEL PUMPPRESS 1 TO CONTINUE

Press the 1 key

THIS IS A KEY ONONLY STATIC TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key

USE ONLY A RESISTORTYPE SPARK PLUG TOVIEW EXTERNAL SPARKCONTINUE? 1=YES 2=NO

2=NO

IF MOTOR IS EFI AND PLUGS ARE IN HEAD ABACKFIRE MAY OCCUR. ↓THIS CAN CAUSE AN

EXTERNAL FLAME IFFLAME ARRESTOR ISREMOVED. ↓

PURGE FUEL VAPORSPRIOR TO TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key

Press the 1 key

THIS IS A KEY ONONLY STATIC TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCEL

IGNITION COIL 1 TESTIN PROGRESS.

ECM HAS RECEIVED APASS RESPONSE FROMTHE COIL DRIVERPRESS 1 TO CONTINUE

Press the 1 key

Press the ↓ key

Press the 1 key

Press the 1 keyPress the 1 key

Press the ↓ key

NOTE: A maximum of eight cylinders can be displayed on the testmenu screen.


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IGNITION COIL 1 TESTIN PROGRESS.OBSERVE THE SPARKACROSS THE OPEN GAP.

ECM HAS RECEIVED A FAIL RESPONSE FROMTHE COIL DRIVER.PRESS 1 TO CONTINUE



VISUAL INSPECTIONOF ALL CONNECTORS.CHECK ALL GROUNDCONNECTIONS.

DID THE SPARK JUMPTHE GAP?

1=YES 2=NO

Press the 1 key

Press the 2 key



CHECK ALLCOMPONENTS FORCORRECT SPECS. SEESYSTEM INFO.

↓↑

Press

To EXITAvailable

↓

Press the 1 key

NOTE: Once the test forthe igniton coil is completedthe SELECT CYL TO TESTscreen will appear for thenext coil to test.

Press the ↓ key

Press the ↓ key



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CHECK FOR GOODCONNECTION OF HIGH TENSION WIRETO PLUG AND COIL

↓↑

Available

Press

To EXIT

CHECK HARNESSCONTINUITY BETWEENECM AND SUSPECTCOMPONENT

↓↑

REFER TO SERVICEMANUAL WIRINGSCHEMATIC FORINFORMATION

↑

VISUAL INSPECTIONOF SPARK PLUGS.CORRECT TYPE? ↓

↑

Press the ↓ key

Press the ↓ key

Press the ↓ key


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FUEL INJECTOR LOAD TEST

Using the OUTPUT LOAD TEST function, you can exercise the ECMand various output loads (ignition coils, injectors, pumps, horn, etc.)controlled by the ECM. Make sure that the SELECT FUNCTION menuscreen is displayed on the DDT. Press the 3 key.


4-RESET BREAK-IN OIL

↓



↓

This test is run with key switch in run position only (engine off). To testthe fuel injector for mechanical activity press the 2 key.

LISTEN FOR INJECTOROPENING AND CLOSINGDURING THIS TEST.CONTINUE? 1=YES 2=NO

ENGINE ISN’T RUNNINGDURING THIS TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press

To EXITAvailable



DISCONNECT POWERTO HIGH PRESSUREFUEL PUMPPRESS 1 TO CONTINUE

Press the1 key. Press the1 key.

Press the1 key. Press the1 key.

NOTE: This test will run automatically once the user has entered acylinder number to test. Disable fuel pump by removing fuse orunplugging fuel pump connector if so equipped.


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FUEL INJECTOR 1 TESTIN PROGRESS. LISTENFOR INJECTOR OPENINGAND CLOSING.

ECM HAS RECEIVED APASS RESPONSEFROM THE INJECTOR.PRESS 1 TO CONTINUE

ECM HAS RECEIVED AFAIL RESPONSEFROM THE INJECTOR.PRESS 1 TO CONTINUE

Press 1 key. Press 1 key.

DID YOU HEAR THEINJECTOR ACTIVATE?

1=YES 2=NO


1=YES 2=NO



↓




↓↑


↑

Press the ↓ key.

Press the ↓ key.

Available

Press

To EXIT


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DIRECT INJECTOR LOAD TEST





↓



↓

This test is run with key switch in run position only (engine off). To testthe direct injector for mechanical activity press the 3 key.

LISTEN FOR INJECTOROPENING AND CLOSINGDURING THIS TEST.CONTINUE? 1=YES 2=NO


Press

To EXITAvailable



DISONNECT POWER TO HIGH PRESSUREFUEL PUMPPRESS 1 TO CONTINUE

Press the1 key.

Press the1 key.

Press the1 key.

Press the1 key.



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DIRECT INJ 1 TESTIN PROGRESS. LISTENFOR INJECTOR OPENINGAND CLOSING.

ECM HAS RECEIVED APASS RESPONSEFROM THE INJECTOR.PRESS 1 TO CONTINUE

ECM HAS RECEIVED AFAIL RESPONSEFROM THE INJECTOR.PRESS 1 TO CONTINUE



1=YES 2=NO


1=YES 2=NO



↓

SELECT CYL TO TEST:1 2 3 4 5 6



↓↑


↑

Press the ↓ key.

Press the ↓ key.

Available

Press

To EXIT


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OIL PUMP LOAD TEST




4-RESET BREAK-IN

↓

The SELECT LOAD TEST screen will appear. Use the ↓ key to displaythe additional screens and the ↑ to return to the previous screen.

Select Load Test:4-OIL PUMP5-FUEL PUMP6-HORN

↓↑

This test is run with key switch in run position only (engine off). To testthe oil pump for mechanical activity press the 4 key.

LISTEN FOR OIL PUMPSOLENOID OPERATINGDURING THIS TEST.CONTINUE? 1=YES 2=NO

ENGINE ISN’T RUNNINGDURING THIS TEST.PRESS 1 TO CONTINUEPRESS MODE TO CANCELPress

To EXITAvailable

Press the1 key.

Press the1 key.

NOTE: This test will run automatically once the user has entered oilpump test.

NOTE: It is normal for fuel pump to run during the test since the mainpower relay controls the pump.


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OIL PUMP TEST INPROGRESS . . . . .LISTEN FOR OIL PUMPSOLENOID OPERATION.

ECM HAS RECEIVED APASS RESPONSEFROM THE PUMP.PRESS 1 TO CONTINUE

ECM HAS RECEIVED AFAIL RESPONSEFROM THE PUMP.PRESS 1 TO CONTINUE



↓


↓↑


↑



↓

Press the ↓ key.

Press the ↓ key.

Available

Press

To EXIT


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FUEL PUMP LOAD TEST





↓



↓↑

This test is run with key switch in run position only (engine off). To testthe fuel pump for mechanical activity press the 5 key.

LISTEN FOR FUEL PUMPOPERATION DURINGTHIS TEST.CONTINUE? 1=YES 2=NO


Press the1 key.

Press the1 key.

NOTE: This test will run automatically once the user has entered fuelpump test.

Press

To EXITAvailable


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FUEL PUMP TEST INPROGRESS . . . . .LISTEN FOR FUEL PUMP OPERATION.

DID THE ELECTRICFUEL PUMP RUN?

1=YES 2=NO



↓


↓↑


↑



↓

Press the ↓ key.

Press the ↓ key.

Press

To EXITAvailable


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HORN LOAD TEST




4-RESET BREAK-IN

↓



↓↑

This test is run with key switch in run position only (engine off). To testthe horn for an audible response press the 6 key.

LISTEN FOR WARNINGHORN TO BEEP 5 TIMESDURING THIS TEST.CONTINUE? 1=YES 2=NO


Press

To EXITAvailable

Press the1 key.

Press the1 key.

NOTE: This test will run automatically once the user has entered horntest. It is normal for fuel pump to run during the test since the mainpower relay controls the pump.


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HORN TEST INPROGRESS . . . . .LISTEN FOR 5 BEEPS.

ECM HAS RECEIVED APASS RESPONSEFROM THE HORN.PRESS 1 TO CONTINUE

ECM HAS RECEIVED AFAIL RESPONSEFROM THE HORN.PRESS 1 TO CONTINUE




↓↑


↑



↓

CHECK FOR +12 VOLTSAND ECM CONTROLLEDGROUND TO HORN. ↓

↓↑

Press the ↓ key.

Press the ↓ key.

Press the ↓ key.

Available

Press

To EXIT


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MISCELLANEOUS – IDLE AIR CONTROL

Using the OUTPUT LOAD TEST function, you can exercise the ECMand various output loads (ignition coils, injectors, pumps, horn etc)controlled by the ECM. Make sure the SELECT FUNCTION menuscreen is displayed on the DDT. Press the 3 key.

Select Load Test:1–OIL PUMP PRIME2–CYLINDER MISFIRE3–OUTPUT LOAD TEST

4–RESET BREAK–IN

Select Load Test:7–MISCELLANEOUS8–TACHOMETER9–RELAYS

Press the 7 key.

Select Load Test:1–IDLE AIR CONTROL2–ELECT SHIFT3–ELECT THROTTLE

Press the 1 key.

↓ ↓

The purpose of this test is to check the functionality of the Idle AirControl valve. The behavior of the test on a running engine willdepend on the engine coolant temperature and the idle controlcalibration in the ECM. Once the engine has reached it’s normaloperating temperature the running test will allow you to apply apositive or a negative offset to the base IAC setpoint. As youdecrease the offset with a negative value the engine RPM shoulddecrease. The engine idle control strategy may prevent you fromexceeding the allowable setpoints. For example a value of +60%may exhibit the same behavior as a value of +100% (no noticeablechange in RPM).

IAC TEST WITH ENGINE RPM

Select Test:1–ENGINE RPM2–NO ENGINE RPM

Press the 1 key.


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IAC TEST WITH ENGINE RPM – continued

RPMS INCREASE AS IACOPENS OR DECREASE AS IAC CLOSES.PRESS 1 TO CONTINUE

Press the 1 key.

ENGINE RPM 738IAC DELTA % 10

PRESS MODE TO EXIT

Press the ↓ or ↑ key shouldchange the IAC valveposition resulting in someRPM change.Press MODE to exit test.

DID ENGINE RPMCHANGE?

1=YES 2=NO

Press the 1 key.


VISUAL INSPECTIONOF ALL CONNECTORS.CHECK ALL GROUND CONNECTIONS.

Press the ↓ key.

↓↑

↑

↓ENGINE MUST BE IDLING AND AT OPERATING TEMP.CONTINUE? 1=YES 2=NO

Press the 1 key.

USE THE ↑ KEY TO OPEN THE IAC VALVE.USE THE ↓ TO KEY TOCLOSE THE IAC VALVE.

Press the ↓ key.

↓

CHECK HARNESSCONTINUITY BETWEENECM AND SUSPECTCOMPONENT.

↑

CHECK ALLCOMPONENTS FOR CORRECT SPECS. SEESYSTEM INFO.

Press the ↓ key.

↓↑

Press the 2 key.

Press

To EXIT


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IAC TEST WITH NO ENGINE RPM


Press the 2 key.

Select Step Size:1– 5 Percent2– 10 Percent3– 15 Percent

4– 20 Percent

Press the 1,2,3, or 4 key forthe desired step.

ENGINE ISN’T RUNNINGDURING THIS TESTPRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key.

USE THE ↑ KEY TO OPEN THE IAC VALVE.USE THE ↓ TO KEY TOCLOSE THE IAC VALVE.

Press the ↓ key.

THE IAC VALVE WILLMOVE IN THE STEPSYOU HAVE SELECTED PRESS 1 TO CONTINUE

Press the 1 key.

↓

↓


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IAC TEST WITH NO ENGINE RPM – continued

THE IAC VALVE WILL MOVE IN THE STEPS YOU HAVE SELECTEDPRESS 1 TO CONTINUE

Press the 1 key.

ENGINE RPM 0IAC DELTA % 10

PRESS MODE TO EXIT


Press the ↓ key.


Press the ↓ key.

↓↑

Press the ↑ key. As you step in apositive direction you should hear abuzzing sound as the IAC valveopens. This sound may be difficultto hear unless the IAC is removedfrom the engine for testingpurposes only. Entering a negativestep (a value less than zero) mayhave no affect on the valve since it’salready closed. Example: a DELTA% of -20 will cause no change sincethe valve is closed.

or

ENGINE ISN’T RUNNINGDURING THIS TESTPRESS 1 TO CONTINUEPRESS MODE TO CANCEL

Press the 1 key.

↓

↓↑

↑CHECK HARNESSCONTINUITY BETWEENECM AND SUSPECTCOMPONENT.

Press

To EXIT


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ELECTRONIC SHIFT CONTROL – ESC

Using the OUTPUT LOAD TEST function, you can exercise theECM and various output loads (ignition coils, injectors, pumps, hornetc.) controlled by the ECM.

Make sure the SELECT FUNCTION menu screen is displayed onthe DDT. Press the 3 key.

Select Function:1-OIL PRIME2-CYLINDER MISFIRE3-OUTPUT LOAD TEST



Press the 7 key.

↑


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ELECTRONIC SHIFT CONTROL – ESC– continued

Select Load :1–IDLE AIR CONTROL2–ELECT SHIFT3–ELECT THROTTLE

Press the 2 key.

CAUTION: MAKE SUREBOAT IS SECURELY TIEDTO DOCK/TRAILERPRESS 1 TO CONTINUE.

Press the 1 key.

ENGINE MUST BE IN NEUTRAL AND IDLINGFOR THIS TEST.CONTINUE? 1=YES 2=NO

Press the 1 key.

↓

THE ENGINE WILL SHIFTFROM NEUTRAL TOFORWARD THEN BACKTO NEUTRAL

Press the ↓ key.

THEN TO REVERSE BACKTO NEUTRAL.

PRESS 1 TO CONTINUE

Press the 1 key.

SHIFT POSITIONNEUTRAL


↑

The shift position screen willupdate from NEUTRAL toFORWARD, to NEUTRALand then to REVERSE andfinish the test back to theNEUTRAL position.

THE ECM RECEIVED APASS RESPONSE FROMTHE ESC.PRESS 1 TO CONTINUE

Press the 1 key.

DID THE ENGINE SHIFTGEARS?

1=YES 2=NO

Press the 1 key.

OR

THE ECM RECEIVED AFAIL RESPONSE FROMTHE ESC.PRESS 1 TO CONTINUE

NOTE: This test will only function with the engine running in neutral.If the ESC (electronic shift control) on the engine does respond to thistest, then diagnose the wiring between the CHI and the ERC. Referto the electrical wiring diagram in the service manual if needed.

Press

To EXIT


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ELECTRONIC THROTTLE CONTROL – ETC

Using the OUTPUT LOAD TEST function, you can exercise the ECMand various output loads (ignition coils, injectors, pumps, horn etc.)controlled by the ECM.

Make sure the SELECT FUNCTION menu screen is displayed onthe DDT. Press the 3 key.

Select Function:1-OIL PRIME2-CYLINDER MISFIRE3-OUTPUT LOAD TEST

The SELECT LOAD TEST screen will appear. Use the ↓ key to displaythe additional screens and the ↑ to return to the previous screen. Pressthe 7 key.


The miscellaneous load test menu may consist of the Idle Air Control(IAC), the Electronic Shift Control (ESC), Electronic Throttle Control(ETC) or Knock if the engine is so equipped. To test the ETC pressthe 3 key.

Select Load Test:1-IDLE AIR CONTROL2-ELECT SHIFT3-ELECT THROTTLE

4-KNOCK

↓


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ELECTRONIC THROTTLE CONTROL – ETC– continued

The Select Test screen is displayed on the DDT. The ETC test canbe performed with the engine running or not. This test allows thetechnician to instruct the ECM to open or close the throttle valve(blade). If no engine rpm is selected the DDT is allowed to move thethrottle valve (blade) from closed to a full open postion. Testing withengine rpm the valve (blade) will not move the full range.

Select Test:1-ENGINE RPM2-NO ENGINE RPM

NOTE: If the electronic throttle control on the engine does respondto this test, then diagnose the wiring or sensors between the ECM orthe throttle control box at the helm. Refer to the electrical wiringdiagram in the service manual if needed.

Press

To EXIT


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DFI Screen

AS ETC OPENS ORCLOSES AIR INTAKESOUND WILL CHANGE.PRESS 1 TO CONTINUE

Press the 1 key.

ENGINE RPM 550ETC DELTA % 5

PRESS MODE TO EXIT

Press the ↑ key.

↓

↑


Press the 1 key. Press the 2 key.

ENGINE MUST BE IN NEUTRAL AND IDLING FORTHIS TEST.CONTINUE? 1=YES 2=NO

Press the 1 key.

USE THE ↑ KEY TO OPENTHE THROTTLE VALVE.USE THE ↓ TO KEY TOCLOSE THE VALVE.

Press the ↓ key.

DID ENGINE INTAKESOUND CHANGE?1=YES 2=NO

Select Step Size:1–5 Percent2–10 Percent3–15 Percent

4– 20 Percent

↑↓

↓

↓

↓↑

Press the 1,2,3 or 4 key.


Press the 1 key.

EFI Screen

RPMS INCREASE AS ETCOPENS OR DECREASEAS ETC CLOSES.PRESS 1 TO CONTINUE

↑USE THE ↑ KEY TO OPENTHE THROTTLE VALVE.USE THE ↓ TO KEY TOCLOSE THE VALVE.

Press the ↓ key.

THE ETC VALVE WILLMOVE IN THE STEPS YOUHAVE SELECTED.PRESS 1 TO CONTINUE

Press the 1 key.

ENGINE RPM 0ETC DELTA % 5

PRESS MODE TO EXIT

↓

NOTE: Depending on the percent incremental steps chosen, theremay not be any apparent valve movement for the first few arrow keymovements. Basically the ETC can be compared to an electronicthrottle cam. If the initial cam profile is flat for a specific engineapplication, there will be no valve position change for a given arrowkey selection.

Press

To EXIT


86 Reference Manual


KNOCK OUTPUT LOAD TEST

Using the OUTPUT LOAD TEST function, you can exercise the ECMand various output loads (ignition coils, injectors, pumps, horn, etc.)controll

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