The provided documentation details the installation procedures and component lists for Mercury Marine side mount and binnacle mount remote controls. These instructions are intended for trained dealers, boatbuilders, and service personnel, with a strong emphasis on safety and proper installation to prevent damage or personal injury. The documentation covers component identification, mounting considerations, wiring connections, and post-installation checks. It is crucial to consult the appropriate Mercury Marine service manual for detailed component removal and installation instructions.
Components Included
Mercury Marine remote control kits contain specific components as outlined in the provided documentation. A side mount remote control kit, as detailed in the documentation, includes the following items:
- 1 Side mount remote control
- 1 Remote control spacer
- 3 Mounting screw, M6 x 120
- 3 Washer
- 3 Nut
- 3 Screw, M4 x 0.7 x 2
- 2 Screw, #8‑32 x 0.375
- 1 Cable spacer
- 1 Cable tie
- 1 Lanyard cord assembly
- 1 Lower back cover
These components are identified by reference numbers for clarity during installation. Part numbers are also provided where applicable.
Mounting Considerations
Proper mounting is critical for the reliable operation of the remote control. The documentation emphasizes the following points:
- Location: The mounting location should be a flat surface capable of providing rigid support. Strengthening the mounting surface may be necessary depending on the boat’s configuration. Suitable locations include side consoles (port side) and center consoles (port side).
- Clearance: A minimum of 2.5 inches (64 mm) of clearance must be maintained between the control handle and any part of the boat throughout the full range of throttle travel, in both forward and reverse. This clearance is essential to prevent interference during operation.
- Mounting Hole Preparation: When drilling mounting holes, a template should be used to ensure accurate placement. The documentation specifies using 1/8 inch and 1/2 inch drill bits. For controls with trim functionality, holes marked with a "T" on the template should also be drilled. A saber saw is recommended for cutting out the mounting hole, staying within the lines of the template.
Installation Procedures
The installation process involves several key steps, as detailed in the documentation:
- Cable and Wire Routing: Control cables and wires should be routed aft to the motor with no sharp bends. All bends should have a radius of at least 6 inches (15 cm).
- Electrical Connections: The documentation provides specific instructions for connecting the yellow/red neutral start switch wire to the key switch. Two wires from the remote control require connection: one to the "S" terminal and the other to a bullet connector on the key switch cable.
- Instrument Cable Connection: The instrument cable plug should be aligned with the key switch receptacle and pushed together until latched. Similarly, the three-socket plug on the instrument cable should be connected to the control receptacle until latched.
- Corrosion Protection: For installations in saltwater environments, the entire control should be sprayed with an anti-corrosion metal protectant. Electrical grease should be applied to the mating surfaces of the connectors to seal them.
- Cover Installation: The rubber boot should be placed over the shift disengage button, and the cover positioned on the control. The cover and control should then be secured with the provided screws. A manual screwdriver is recommended to avoid damaging the cover.
- Operational Check: After installation, it is essential to check that the remote control operates freely and that equal friction is felt throughout the forward and reverse throttle range. Any binding could cause the control to jam when cables are attached to the motor.
- Adjustment Screw Cover: Install the adjustment screw cover.
Wiring System Considerations
The documentation notes that for installations not utilizing the Modular Wiring System, terminal pins may need to be cut off and suitable terminals crimped on. The documentation also highlights the importance of checking the mating surfaces of connectors for dirt or contaminants before joining them.
Safety Precautions
The documentation emphasizes several safety precautions:
- Disconnect Battery: Battery cables should be disconnected from the battery before drilling or sawing near electrical wires to prevent accidental short circuits and potential injury.
- Warning Notices: The documentation includes warnings and cautions accompanied by the International Hazard Symbol to alert installers to potentially hazardous procedures. Strict compliance with these instructions and common sense operation are crucial for accident prevention.
- Qualified Personnel: Installation and servicing should be performed by trained dealers, boatbuilders, or authorized Mercury Marine dealer technicians. Improper installation or servicing could result in product damage or personal injury.
Post-Installation Checks
Following installation, a thorough operational check is required. This includes verifying:
- Free movement of the control handle throughout the entire throttle range.
- Consistent friction in both forward and reverse directions.
- Proper electrical connections and secure cable routing.
- Adequate clearance around the control handle.
Additional Notes
The documentation advises installers to familiarize themselves with the complete installation instructions before beginning the process. It also stresses the importance of testing the operation of the remote control after installation to ensure proper functionality and prevent loss of control of the boat.
Conclusion
The Mercury Marine remote control installation instructions provide a detailed guide for qualified personnel. Proper installation, adherence to safety precautions, and thorough post-installation checks are essential for ensuring reliable operation and preventing potential hazards. The documentation emphasizes the importance of using the correct components, preparing the mounting surface adequately, and making secure electrical connections. The provided information is specifically geared towards side mount and binnacle mount remote controls and should be used in conjunction with the appropriate Mercury Marine service manual for complete instructions.