Mercury Outboard motor Remote Controls Service Manual

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Original Mercury Remote Controls Service Manual
Models covered:
Side Mount Control:
- 76334A10 through A40
- MerCruiser 55722A2 (215E)
- 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control
- MerCruiser 55722A2, 63063A1 Electric Remote Control
- Commander 2000 Series
- Commander 3000 Series
- Commander 4000 Series
- Commander 4500 Series
- "Hot Foot" Throttle Controls
- Chrysler and Force Remote Controls
- Jet Drive Control
- DTS (Digital Trottle and Shift
- Zero Effort Controls

Manual Part Number: 90-814705R03

Manual includes hi-resolution diagrams as well as detailed step-by-step instructions and setup procedures.

Manual chapters:
1. Special Information
- Section 1A - Throttle and Shift Cable
2. Standard Single Lever Full Gear Shift Control
- Section 2A - Standard Single Lever Full Gear Shift Remote Control
3. Side Mount Control
- Section 3A - Side Mount Control 76334A10 through A40
- Section 3B - Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control
- Section 3C - Side Mount Mercury MerCruiser 55722A2, 63063A1 Electric Remote Control Electrical Tests
4. Commander Controls
- Section 4A - Commander Panel Mount Controls
- Section 4B - Commander Side Mount Control
- Section 4C - Commander 2000 Side Mount Control
- Section 4D - Commander Console Mount Control
- Section 4E - Commander Two Lever Recessed Console Control
- Section 4F - Commander Two Lever Console Control
- Section 4G - Commander 3000 Series
5. Commander 4000/4500 Controls
- Section 5A - Commander 4000 Series Remote Control
- Section 5B - Commander 4500 Series Remote Control
6. Foot Throttle Control
- Section 6A - "Hot Foot" Throttle Controls
7. Chrysler and Force Remote Controls
- Section 7A - Chrysler Remote Controls
- Section 7B - Force Remote Control
8. Jet Drive Control
- Section 8A - Sport Jet Remote Controls
9. Digital Throttle and Shift (DTS) Electronic Remote Controls
- Section 9A - DTS Panel Mount Remote Control
- Section 9B - DTS Single Handle Console Remote Control
- Section 9C - DTS Slim Binnacle Single Handle Console Control
- Section 9D - DTS Dual Handle Console Remote Control
- Section 9E - DTS Shadow Mode Console Remote Control
- Section 9F - DTS Dual Engine Console Control with CAN Pad
- Section 9G - DTS Shadow Mode Console Control with CAN Pad
- Section 9H - DTS Dual Handle Yacht Console Remote Controls
10. Zero Effort Controls
- Section 10A - Non-DTS Quadrant Controls
- Section 10B - DTS Zero Effort Controls

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Full list of manual chapters:

Cover
    Notice to Users of This Manual
    Precautions
Manual Outline (Table of Contents)
1. Special Information
    Section 1A - Throttle and Shift Cable
        Table of Contents
        Throttle and Shift Cable End Guide Replacement
            Throttle and Shift Cable End Guide Removal
            Throttle and Shift Cable End Guide Installation
            Measuring Control Cable Length
                Measuring For Outboard Throttle/Shift Cables
                    Measuring For MerCruiser Throttle And Shift Cables
2. Standard Single Lever Full Gear Shift Control
    Section 2A - Standard Single Lever Full Gear Shift Remote Control
        Table of Contents
        Standard Single Lever Full Gear Shift Control Components
        Standard Single Lever Full Gear Shift Remote Control Disassembly and Assembly
            Standard Single Lever Full Gear Shift Remote Control Disassembly
            Wire Color Code Abbreviations
            Standard Single Lever Full Gear Shift Remote Control Assembly
                Installing Remote Control Cables
3. Side Mount Control
    Section 3A - Side Mount Control 76334A10 through A40
        Table of Contents
        Side Mount Control Mechanical Shift Components
        Side Mount Control Electric Shift Components
        Side Mount Control Disassembly
            Removing Control Cables
            Remote Control Housing Disassembly
        Remote Control Housing Components Installation
        Remote Control Wire Harness and Switches Removal
        Remote Control Wire Harness and Switches Installation
        Installing Control Cables
    Section 3B - Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control
        Table of Contents
        Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control Disassembly
        Side Mount Mercury MerCruiser 55722A2 (215E), 63063A1 (225 ll-TR and 255 ll-TR) Electric Remote Control Assembly
    Section 3C - Side Mount Mercury MerCruiser 55722A2, 63063A1 Electric Remote Control Electrical Tests
        Table of Contents
        Remote Control Electrical Test Procedure For 55722A2
        Remote Control Electrical Test Procedure For 63063A1
            MerControl 63064A1 (Only)
4. Commander Controls
    Section 4A - Commander Panel Mount Controls
        Table of Contents
        Commander Classic Panel Mount Control Bezel and Handle Components
        Control Housing Module Components
        Commander Classic Panel Mount Control
            Panel Mount Control Handle and Bezel Removal
            Commander Control Module Disassembly
            Commander Control Module Assembly
            Panel Mount Control Handle and Bezel Installation
    Section 4B - Commander Side Mount Control
        Table of Contents
        Commander Side Mount Control External Components
        Control Housing Module Components
        Commander Side Mount Remote Control External Identification
        Commander Side Mount Remote Control Disassembly
        Commander Side Mount Remote Control Assembly
    Section 4C - Commander 2000 Side Mount Control
        Table of Contents
        Commander 2000 Side Mount Control Components
        Commander 2000 Removal
        Commander 2000 Side Mount Disassembly
        Commander 2000 Side Mount Assembly
        Shift and Throttle Cable Installation
        Commander 2000 Installation
        Control Handle Port Side Mounting Conversion
    Section 4D - Commander Console Mount Control
        Table of Contents
        Commander Console Mount Control Components
        Control Housing Module Components
        Commander Console Mount Control Handle and Trim Switch Removal
            Removing Trim Switch from the Control Handle
        Commander Control Module Disassembly
        Commander Control Module Assembly
        Control Module Assembly Installation
        Commander Console Mount Control Handle and Trim Switch Installation
    Section 4E - Commander Two Lever Recessed Console Control
        Table of Contents
        Commander Two Lever Recessed Console Control Components
        Commander Two Lever Console Control Disassembly
        Commander Two Lever Console Control Assembly
        Neutral Start Safety Switch Adjustment
        Commander Two Lever Console Control Cable Installation
            Attaching Control Cable Configurations
    Section 4F - Commander Two Lever Console Control
        Table of Contents
        Commander Two Lever Console Control Components
        Commander Two Lever Console Control Disassembly
        Commander Two Lever Console Control Assembly
        Neutral Start Safety Switch Adjustment
        Commander Two Lever Console Control Cable Installation
            Attaching Control Cable Configurations
        Commander Two Lever Console Control Electric Shift Diagrams
    Section 4G - Commander 3000 Series
        Table of Contents
        Commander 3000 Panel Mount Handle and Bezel Components
        Commander 3000 Classic Panel Mount Handle and Bezel Components
        Commander 3000 Console Mount Single Handle Components
        Commander 3000 Console Mount Dual Handle Components
        Commander 3000 Dual Handle, Three Trim Button Components
        Commander 3000 Remote Control Module Design ll Components
        Commander 3000 Remote Control Module Design lll Components
        Commander 3000 Panel Mount Remote Control
            Commander 3000 Panel Mount Handle and Bezel Disassembly
            Commander 3000 Panel Mount Handle and Bezel Assembly
        Commander 3000 Classic Panel Mount Control
            Commander 3000 Classic Panel Mount Handle and Bezel Disassembly
            Commander 3000 Classic Panel Mount Handle and Bezel Assembly
        Commander 3000 Single and Dual Handle Console Mount Controls
            Commander 3000 Single and Dual Handle Disassembly
            Commander 3000 Single and Dual Handle Assembly
            Shift and Throttle Cable Installation
                Outboard Models
                Mercury MerCruiser Models
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 3000 Remote Control Module Design ll Disassembly
            Commander 3000 Remote Control Module Design ll Assembly
            Shift and Throttle Cable Installation
                Outboard Models
                Mercury MerCruiser Models
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 3000 Remote Control Module Design lll Disassembly
            Commander 3000 Remote Control Module Design lll Assembly
            Shift and Throttle Cable Installation
                Outboard Models
                Mercury MerCruiser Models
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
5. Commander 4000/4500 Controls
    Section 5A - Commander 4000 Series Remote Control
        Table of Contents
        Commander 4000 Remote Control Side Mount Components
        Commander 4000 Panel Mount Remote Control Components
        Commander 4000 Control Module Components
        Commander 4000 Gen ll Lock Bar Panel Mount Control Components
        Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Components
        Commander 4000 Gen ll Control Module Components
        Commander 4000 Side Mount Removal, Disassembly, Assembly, and Installation
            Commander 4000 Side Mount Remote Control Removal
            Commander 4000 Side Mount Remote Control Disassembly
            Commander 4000 Side Mount Remote Control Assembly
            Shift and Throttle Cable Installation
            Commander 4000 Side Mount Installation
        Commander 4000 Pistol Grip Remote Control Removal and Installation
            Commander 4000 Pistol Grip Panel Mount Remote Control Removal
            Commander 4000 Shift and Throttle Cable Installation
                Outboard Models
                Mercury MerCruiser Models
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 4000 Pistol Grip Panel Mount Remote Control Installation
        Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Removal and Installation
            Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Removal
            Shift and Throttle Cable Installation
                Control Cable Anchor Attaching Location
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 4000 Gen ll Pistol Grip Panel Mount Remote Control Installation
        Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Removal and Installation
            Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Removal
            Shift and Throttle Cable Installation
                Control Cable Anchor Attaching Location
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 4000 Gen ll Lock Bar Panel Mount Remote Control Installation
        Pistol Grip with Finger Tip Neutral Lock Release Remote Control Removal and Installation
            Pistol Grip Remote Control with Finger Tip Lock Release Removal
            Shift and Throttle Cable Installation
                Control Cable Anchor Attaching Location
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Pistol Grip Remote Control with Finger Tip Lock Release Installation
                Throttle-only Button Removal
        Commander 4000 Series Remote Control Module Disassembly and Assembly
            Commander 4000 Remote Control Module Disassembly
            Commander 4000 Remote Control Module Assembly
            Commander 4000 Remote Control Module Gen ll Disassembly
            Commander 4000 Remote Control Module Gen ll Assembly
    Section 5B - Commander 4500 Series Remote Control
        Table of Contents
        Commander 4500 Single Handle Remote Control Components
        Commander 4500 Gen ll Single Handle Remote Control Components
        Commander 4500 Console Dual Handle Remote Control Components
        Commander 4500 Gen ll Console Dual Handle Remote Control Components
        Commander 4500 Control Module Components
        Commander 4500 Gen ll Control Module Components
        Commander 4500 Series Removal and Installation
            Commander 4500 Series Console Control Removal
            Shift and Throttle Cable Installation
                Outboard Models
                Mercury MerCruiser Models
                Typical Shift and Throttle Cable Installation, Outboard and Mercury MerCruiser
            Commander 4500 Series Console Control Installation
                Single Handle Console Control Mounting Bracket Installation
                Dual Handle Console Control Mounting Bracket Installation
                Remote Control Module Angle Adjustment
                Console Control Installation
        Commander 4500 Series Remote Control Module Disassembly and Assembly
            Commander 4500 Gen l Remote Control Module Disassembly
            Commander 4500 Gen l Remote Control Module Assembly
            Commander 4500 Gen ll Remote Control Module Disassembly
            Commander 4500 Gen ll Remote Control Module Assembly
6. Foot Throttle Control
    Section 6A - "Hot Foot" Throttle Controls
        Table of Contents
        Components Contained in DTS Foot Throttle
        Hot Foot Throttle
            Wiring Diagram - Typical Installation
            Pre-Installation
                Foot Clearance
            DTS Foot Throttle Component Installation
                Adjustments
            DTS Foot Throttle Installation
            Optional DTS Foot Throttle Kits
                Command Module (2006 Model Year Only)
                Panel Mount Remote Control On/Off Switch Kit
            DTS Foot Throttle Configuration with Hand Throttle On/Off Switch
                System Configuration Reset
                Hand and Foot Control Operation with Hand Throttle On/Off Switch
            Wiring Diagram - Typical Installation
            Inspection and Maintenance
7. Chrysler and Force Remote Controls
    Section 7A - Chrysler Remote Controls
        Table of Contents
        Chrysler Controls 161 and 163 Components
        161 and 163 Control Box Installation
            Connecting the Control Cables to the Control Box
        5901 Panel Mount Control Components
        5901 Panel Mount Control Installation
        865 Remote Control Components
    Section 7B - Force Remote Control
        Table of Contents
        Force Remote Control Installation
            Attaching the Cable Ends to the Control Cables
            Force Remote Control Cable Installation
8. Jet Drive Control
    Section 8A - Sport Jet Remote Controls
        Table of Contents
        Sport Jet 30 Series Remote Control Components
        Sport Jet 40 Series Remote Control 850696 Components
        Sport Jet 40 Series Remote Control 802755 Components
        Shift Cable Conversion Kit 850698A1
            Shift Cable and Shift Cable Bracket Removal
            Shift Cable and Shift Cable Bracket Installation
9. Digital Throttle and Shift (DTS) Electronic RemoteControls
    Section 9A - DTS Panel Mount Remote Control
        Table of Contents
        Panel Mount Components
        DTS Panel Mount Remote Control Removal, Disassembly, Assembly and Installation
            Panel Mount Removal
            Panel Mount Disassembly
            Panel Mount Reassembly
            Panel Mount Installation
            Panel Mount Control Trim Switch Harness Test
    Section 9B - DTS Single Handle Console Remote Control
        Table of Contents
        Single Handle Console Mount Components
        DTS Single Handle Console Remote Control Removal, Disassembly, Assembly and Installation
            Single Handle Console Removal
            Single Handle Console Disassembly
            Single Handle Console Reassembly
            Installing DTS Single Handle Console Control
            Single Console Control Key Pad Harness Test
            Single Console/Slim Binnacle Control Trim Switch Harness Test
    Section 9C - DTS Slim Binnacle Single Handle Console Control
        Table of Contents
        DTS Slim Binnacle Single Handle Console Mount Components
        DTS Slim Binnacle Single Handle Console Control Removal, Disassembly, Assembly, Installation and Tests
            DTS Slim Binnacle Single Handle Console Control Removal
            DTS Slim Binnacle Single Handle Console Control Disassembly
            DTS Slim Binnacle Single Handle Console Control Reassembly
            DTS Slim Binnacle Single Handle Console Control Installation
            Slim Binnacle Remote Control Adjustment
            Slim Binnacle Control Start/Stop Panel Harness Test
            Single Console/Slim Binnacle Control Trim Switch Harness Test
    Section 9D - DTS Dual Handle Console Remote Control
        Table of Contents
        Dual Handle Console Mount Components
        DTS Dual Handle Console Remote Control Removal, Disassembly, Assembly and Installation
            Dual Handle Console Removal
            Dual Handle Console Disassembly
            Dual Handle Console Reassembly
            Installing DTS Dual Handle Console Control
            Dual Console Control Key Pad Harness Test
            Dual Console Control Trim Switch Harness Test
    Section 9E - DTS Shadow Mode Console Remote Control
        Table of Contents
        Shadow Mode Console Mount Components
        Shadow Mode Console Mount Remote Control Removal, Disassembly, Assembly and Installation
            Shadow Mode Control Removal
            Shadow Mode Control Disassembly
            Shadow Mode Control Reassembly
            Installing DTS Shadow Mode Remote Control
            Shadow Mode Control Key Pad Harness Test
            Shadow Mode Control Handle Trim Switch Harness Test
            Dash Mounted Triple Trim Switch Pin-Out
    Section 9F - DTS Dual Engine Console Control with CAN Pad
        Table of Contents
        Dual Console Control Non-trim with CAN Pad Components
        Dual Console Control with CAN Pad Components
        Dual Console Control with CAN Pad Removal, Disassembly, Assembly, and Installation
            Dual Console Control with CAN Pad Removal
            Dual Console Control with CAN Pad Disassembly
            Dual Console Control with CAN Pad Reassembly
            Installing the Dual Console Control with CAN Trackpad
    Section 9G - DTS Shadow Mode Console Control with CAN Pad
        Table of Contents
        Shadow Mode Console Control with CAN Pad Components
        Shadow Mode Console Mount Remote Control Removal, Disassembly, Assembly and Installation
            Shadow Mode Control Removal
            Shadow Mode Control Disassembly
            Shadow Mode Control Reassembly
            Installing the Shadow Mode Control with CAN Pad
            Shadow Mode Control Handle Trim Switch Harness Test
            Dash Mounted Triple Trim Switch Pin-Out
            Dash Mounted Quad Trim Switch Pin-Out
    Section 9H - DTS Dual Handle Yacht Console Remote Controls
        Table of Contents
        Throttle/Throttle Dual Handle Yacht Console Remote Control Components
        Shift/Shift Dual Handle Yacht Console Remote Control Components
        Throttle/Shift Dual Handle Yacht Console Remote Control Components
        Throttle/Throttle Dual Handle Yacht Console Remote Console Control with CAN Pad
        Throttle/Shift Dual Handle Yacht Console Remote Console Control with CAN Pad
        Dual Handle Yacht Console Remote Control with CAN Pad Removal, Disassembly, Assembly and Installation
            Dual Handle Yacht Console Remote Control with CAN Pad Removal
            Dual Handle Yacht Console Remote Control with CAN Pad Disassembly
            Dual Handle Yacht Console Remote Control with CAN Pad Reassembly
            Dual Handle Yacht Console Control with CAN Pad Assembly Installation
        Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Removal, Disassembly, Assembly and Installation
            Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Removal
            Dual Handle Yacht Console Remote Control (Thottle/Throttle, Shift/Shift) Disassembly
            Dual Handle Yacht Console Remote Control (Throttle/Throttle, Shift/Shift) Reassembly
            Dual Handle Throttle/Throttle, Shift/Shift, and Throttle/Shift without CAN Pad Yacht Control Module Assembly Installation
                Dual Handle Yacht Control Operation
            Handle Position Adjustment
                Removal
                Installation
10. Zero Effort Controls
    Section 10A - Non-DTS Quadrant Controls
        Table of Contents
        Quadrant Control Components
        Non-DTS Quadrant Control Installation Instructions
            Choosing a Quadrant Control Location
            Choosing a Quadrant Control Operation
            Quadrant Control Clearances
            Quadrant Controls Minimum Required Flat Surface Mounting Area
            Quadrant Control Removal and Installation
                Removal
                Installation
            Quadrant Control Cable Installation
            Quadrant Control Neutral Start Safety Switch Replacement
                Neutral Start Safety Switch Installation
            Trim Harness Test
        Quadrant Control Lever Switch Kit 848924_ _
            Quadrant Control Disassembly
            Quadrant Control Reassembly
    Section 10B - DTS Zero Effort Controls
        Table of Contents
        Zero Effort Control Components
        Zero Effort DTS Four Lever Control Components
        Zero Effort DTS Six Lever Control Components
        Zero Effort Console Removal and Installation
            Removal
            Assembly Guidelines
            Assembly
            Installation
        Trim Harness Test