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Mercury 30 Service Manual
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90-826148R2 MARCH 1997
2A-6 - ELECTRICAL
ELECTRICAL COMPONENTS (S/N-0G380074/
BEL-MANUAL-9928507/BEL-ELEC-9928480 & Below)
1
2
3
4
5
6
7
8
9
10
18
19
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23
24
25
26
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30
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31
33
34
35
36
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38
39
40
41
42
43
44
13
14
15
16
11
17
12
51
Liquid Neoprene (92-2571
1--2)
25
25
25
25
25
25
25
25
25
25
Loctite “222” Small Screw Threadlocker (92-809818)
51
25
Note: Apply Liquid Neoprene to all ring eyelet wiring terminals.
52
54
Table of Contents
Important Information 1 B
10
Important Information
4
General Specifications
6
Table of Contents
10
Specifications
11
Gear Case Lubricant Capacity
11
Special Tools
11
Quicksilver Lubricant/Sealant
11
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
12
Every 300 Hours of Use or Three Years 1B-2
12
Before Periods of Storage
12
After each Use
12
Before each Use
12
Inspection and Maintenance Schedule
12
Lubrication Points
13
(S/N-0G589999 & Below)
13
(S/N-0G590000 & Above)
13
Checking Power Trim Fluid
15
Gear Case Lubrication
16
Draining Gear Case
16
Checking Lubricant Level and Filling Gear Case
16
Propeller Replacement
17
Removal
17
Installation
17
Corrosion Control Anode
18
Fuel Line and Primer Bulb
19
Fuel Tank Filter
19
Maintenance
19
Fuel Tank
19
Flushing the Cooling System
20
Storage
20
Fuel System
20
Protecting External Outboard Components
21
Protecting Internal Outboard Components
21
Gear Case
21
Positioning Outboard for Storage
21
Battery Storage
21
Important Information 1 C
23
Conditions Affecting Performance
24
Serial Number Location
24
Weather
24
Boat
25
Bottom
25
Trim
25
Trimming Outboard "In" ("Down")
25
Trimming Outboard "Out" ("Up")
25
Water Absorption
25
Weight Distribution
25
Cavitation
26
Detonation
26
Engine
26
Following Complete Submersion
26
Salt Water Submersion (Special Instructions)
26
Submerged While Running (Special Instructions)
26
Propeller Selection
27
Submerged Engine (Fresh Water) (Plus Special Instructions)
27
Propeller Information Chart - 30 HP
29
Propeller Information Chart - 40 HP
30
Important Information 1 D
32
Boat Horsepower Capacity
33
Notice to Installer and Owner
33
Outboard Remote Control
33
Selecting Accessories for the Outboard
33
Lifting Outboard
34
Locate Centerline of the Outboard
34
Selecting Steering Cables and Remote Control Cables
34
Installing Outboard to Boat Transom
35
Models with Transom Bracket Thumb Screws
36
Thumb Screws
36
Fastening Outboard to the Boat Transom 1D-5
37
Installing Ride Guide Steering Cable to the Outboard
37
Single Steering Cable and Steering Link Rod Installation
37
Remote Control Installation
38
Steering Link Rod Installation
38
Boats Equipped with Panel or Console Mount Remote Control
39
Boats Equipped with Side Mount Remote Control
39
Electric Start Remote Control Model
39
Manual Start Models Using Quicksilver
39
Remote Wiring Connections
39
Required Side Mount Remote Control or Ignition Key Switch Assembly
39
Shift and Throttle Cable Installation to the Outboard
40
Shift Cable Installation
40
Throttle Cable Installation
41
Battery Connections
42
Filling the Oil Injection System
42
Set up Instructions for Oil Injection System 1D-10
42
Adjusting the Oil Injection Pump
43
Bleeding Air from the Oil Injection System
43
Propeller Installation
43
Tilt Pin Adjustment
44
Trim Tab Adjustment
45
Electrical 2
47
Special Tools
48
Specifications
48
Stator/Trigger (Electric Models)
49
Starter Motor Components
51
Electrical Components (S/N-0G380074/ Bel-Manual-9928507/BEL-Elec 9928480 & Below)
53
Electrical Components (S/N-USA-0G590000/ BEL-9973100 & Above)
53
Ignition Component Description
59
Principle of Operation with
59
Theory of Operation
59
Capacitor Discharge Modules (CDM)
61
Flywheel
61
Principle of Operation
61
Stator
61
Timing Protection Module (TPM)
61
Trigger Coil
61
Capacitor Charging #1 CDM
62
Theory of Operation
62
Capacitor Charging #2 CDM
63
Cylinder Trigger Circuit
64
Ignition Coil Circuit
65
Stop Circuit
66
Direct Voltage Adapter (DVA) Test for Stator
68
Ignition Test Procedures
68
Ignition Diagnostic Procedures
69
Resistance Tests
70
Stator
70
Testing Ignition Components
70
Timing Protection Module
70
Trigger (S/N-0G589999 & Below)
70
Trigger (S/N-0G590000 & Above)
70
Capacitor Discharge Module P/N822779 . 2A-24
71
Flywheel
74
Ignition Components Removal
74
Electrical 2
76
Battery
77
Operating Engine Without Battery
77
Recommended Battery
77
Special Tools
77
Specifications
77
Specific Gravity Cell Comparison Test
78
Specific Gravity Readings
78
Charging a Discharged Battery
79
Electrolyte Level
79
Winter Storage of Batteries
79
Battery Charging System (14 or 18 Ampere Alternator)
80
Battery Charging System Troubleshooting
80
Description
80
Electric Start Models
80
Manual Start Models
80
Ampere Manual Stator (S/N-0G589999 & Below)
81
Ampere Manual Stator (S/N-0G590000 & Above)
81
Ampere Stator
81
Ampere Stator (S/N-0G590000 & Above)
81
Stator Ohms Test-Alternator Coils Only
81
Alternator System Test
82
Ampere Stator
82
Ampere Stator (S/N-0G589999 & Below)
82
Ampere Stator (S/N-0G590000 & Above) 2B-6
82
Rectifier Test
84
Diode Test
85
SCR Test
85
Tachometer Circuit Test
85
Test Results
85
Test Results (1ST Reading)
85
Test Results (2ND Reading)
85
Test Results (both Test)
85
Voltage Regulator/Rectifier Test Models with (S/N-0G590000 & Above)
85
Description
86
Starter Motor Amperes Draw
86
Starter Solenoid Test
86
Starting System
86
Starting System Components
86
Troubleshooting the Starting Circuit
86
Disassembly
89
Removal
89
Starter Motor
89
Armature Test for Shorts
90
Cleaning and Inspection
90
Testing
90
Armature Test for Ground
91
Electrical 2 C
96
Tiller Handle Model (S/N-0G589999 & Below)
98
Timing Adjustments
99
Tiller Handle Model with Mechanical Spark Advance (S/N-0G590000 & Above)
100
Adjusting Idle Timing
101
Timing and Maximum Spark Advance Adjustments - Mechanical Spark Advance Models
101
Adjusting Maximum Spark Advance
102
Shift Link Rod Installation and Adjustment to Engine
102
Throttle Cable Installation
103
Oil Pump Adjustment
104
Electrical 2 D
106
30/40 Manual Start Ignition Diagram (S/N 0G380074 & Below)
107
30/40 Manual Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999)
108
30/40 Electric Start / Tiller Handle Ignition Diagram (S/N 0G380074 & Below)
109
30/40 Electric Start / Tiller Handle Ignition
110
30/40 Electric Start Ignition Diagram (S/N 0G380074 & Below)
111
30/40 Electric Start Ignition Diagram (S/N 0G380075 Thru S/N 0G589999)
112
30/40 Manual Start / Tiller Handle Ignition Diagram (S/N-0G590000 & Above)
113
Electric Start Tiller Handle Ignition Diagram
114
Electric Start Tiller Handle Ignition Diagram (S/N-0G590000 & Above)
114
30/40 Electric Start Ignition Diagram (S/N-0G590000 & Above)
115
30/40 Electric Start / Power Trim Ignition Diagram (S/N-0G590000 & Above)
116
14 Ampere Stator Charging Diagram
117
14 Ampere Stator Charging Diagram with Battery Isolator
118
Commander 2000 Side Mount Remote Control (Electric Start with Warning Horn) Wiring Diagram
119
Commander 3000 Panel Mount Control
120
Commander 2000 Key Switch Test
121
Instrument Wiring Connections
122
With Light Switch
122
Without Light Switch
122
Instrument/Lanyard Stop Switch Wiring Diagram 2D-17
123
Engine Synchronizer Wiring Diagram-Commander Gauges
124
Notes
125
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
126
QSI Gauge Wiring Diagrams
128
Tachometer Wiring Diagram
128
Water Temperature Gauge
128
Wiring Diagram
128
Wiring Diagram a
128
Wiring Diagram B
128
Engine Synchronizer Wiring Diagram
129
Light Bulb Position a
129
Light Bulb Position B
129
Cleaning Gauges
130
Fuel System 3
132
Specifications
133
Fuel Pump (Manual)
134
Fuel Pump (Electric)
136
Theory of Operation
138
Troubleshooting
138
Problem: Air Bubbles in Fuel Line
139
Problem: Lack of Fuel Pump Pressure
139
Testing
139
Check Valve Assembly
140
Fuel Pump Assembly
140
Reassembly
140
Fuel System
142
Specifications
143
WME Carburetor Specifications
143
Jet Orifice Size Chart
144
Notes
145
Carburetor
146
Fuel System Fuel Flow
148
Manual Start Models
148
Electric Start Models
149
Electric Start Tiller Handle Models
150
Carburetor Adjustments
151
Carburetor Float Adjustment
151
Idle Mixture Screw Adjustment
151
Idle Speed Adjustment
151
Initial Starting Adjustment
151
Main (High Speed) Jet Adjustment
152
Rejetting Carburetors for High Altitude Operation
153
Fuel System Troubleshooting
154
General Information
154
Enrichener System Electric Start Models
157
Enrichener Valve Test
158
Fuel System 3
160
Specifications
161
Oil Injection Components
162
Oil Injection Components
163
Oil Injection System
164
Theory of Operation
164
Oil Injection Flow System(Variable Ratio Oil Pump) S/N-0G589999 & below
165
Oil Injection Flow System (Variable Ratio Oil Pump) S/N-0G590000 & above
166
Adjustments
167
Carburetor/Oil Pump Synchronization
167
Pump Drive Assembly (Variable Ratio Oil Pump)
167
Bleeding Air from Oil Injection System
168
Bleeding Air from Oil Pump Inlet Hose . 3C-8
168
Bleeding Air from Oil Pump Outlet Hose 3C-8
168
Troubleshooting
168
Powerhead
170
Specifications
171
Special Tools
172
Notes
173
Cylinder Block Components
174
Induction Manifold
176
Crankshaft/Piston/Flywheel
178
Powerhead Removal
180
Torque Sequence
180
Crankshaft Disassembly
182
Crankshaft Inspection
183
Piston and Connecting Rod Disassembly
184
Connecting Rods
185
Cleaning and Inspection
186
Cylinder Block and Crankcase Cover
186
Cylinder Bores
187
Honing Procedure
187
Cleaning Piston Ring Grooves
188
Measuring Piston Roundness
188
Pistons and Piston Rings
188
Check Valve
189
Thermostat
189
Reed Blocks
190
End Cap
191
General Information
191
Powerhead Reassembly and Installation
191
Assembling Rod to Piston
192
Piston Ring Installation
193
Crankshaft Installation
195
Installing Rods to Crankshaft
196
Connecting Rod Cap Alignment
197
Crankcase Cover to Block
197
Intake/Reed Block Manifold Installation
199
Thermostat Cover Installation
200
30/40 Bleed Hose Routing
201
Powerhead Installation
202
Break-In Procedure
203
Test Run Procedure
203
MID-Section
205
Notes
206
Clamp Bracket Components
207
Clamp Bracket Components
208
Swivel Tube Components
209
Swivel Tube Components
210
Swivel Bracket Components
211
Swivel Bracket Components
212
Drive Shaft Housing Components
213
Drive Shaft Housing Components
214
Driveshaft Housing Components
215
Driveshaft Housing Components
216
Drive Shaft Housing Disassembly/Reassembly
217
MID Section
219
Special Tools
220
Power Trim Components
221
Power Trim Mounting
223
Adjustments
225
Theory of Operation
225
Trimming Characteristics
225
Trimming Outboard "Down
225
Trimming Outboard "Up" ("Out")
225
Tilting Outboard up and down Manually
226
Trailering Outboard
226
Trim "In" Angle Adjustment
226
Power Trim Flow Diagrams
227
Trim up
227
Tilt up
229
Maximum Tilt
231
Down Mode
234
Shock Function up
235
Shock Function
237
Shock Function Return
237
Manual Tilt
239
Preliminary Checks
241
Troubleshooting
241
Hydraulic System Troubleshooting Flow Chart
242
Outboard will Not Hold Tilted Position During Reverse And/Or Trails out During High Speed Deceleration
242
Hydraulic System Troubleshooting Flow Chart
243
Hydraulic System Troubleshooting Flow Chart
244
Trim System Leaks down with Manual Release Valve Closed
244
Hydraulic System Troubleshooting Flow Chart
245
Troubleshooting the Power Trim Electrical System
246
Troubleshooting the Power Trim Electrical System
247
Power Trim System Removal
248
Disassembly
249
Shock Rod Removal
249
Shock Rod Disassembly
250
Memory Piston Removal
252
Trim Motor Removal
253
Oil Pump Removal
254
Tilt Relief Valve Removal
254
Pilot Check Valve Assembly Removal
255
Suction Seat Removal
255
Cleaning/Inspection/Repair
256
Trim Motor Electrical Tests
256
O-Ring and Seal Placement
257
Reassembly
257
O-Ring and Seal Placement
258
Power Trim Reassembly
259
Suction Seat Reassembly
259
Tilt Relief Valve Reassembly
259
Oil Pump Reassembly
260
Pilot Check Valve Reassembly
260
Shock Rod Reassembly
261
Trim Motor Reassembly
261
Bleeding Power Trim Unit
263
Manual Release Valve Installation
263
Shock Rod Installation
263
Power Trim System Installation
264
MID-Section
267
Notes
268
Clamp Bracket (Gas Assist Trim)
269
Hydraulic Assist Adjustments
271
Manual Trim System Removal
271
Manual Trim System Installation
272
Lower Unit
275
Specifications
276
Bearings
277
General Service Recommendations
277
Seals
277
Special Tools
278
Notes
280
Gear Housing Components (Drive Shaft)
281
Gear Housing Components (Propeller Shaft)
283
Draining and Inspecting Gear Lubricant
285
Propeller Removal
285
Gear Housing Removal
286
Water Pump Seals
290
Forward Gear
291
Inspection
291
Pinion Gear
291
Pinion Gear Bearing
291
Upper Drive Shaft Bearing
291
Shift Shaft
293
Cam Follower
294
Clutch Dog
294
Propeller Shaft and Carrier Inspection
294
Propeller Shaft Disassembly
294
Reverse Gear
295
Reverse Gear Bearing
295
Bearing Carrier
296
Gear Housing Reassembly
297
Shift Shaft Assembly
297
Pinion Bearing Race
298
Forward Gear
299
Pinion Gear/Drive Shaft Assembly
299
Bearing Carrier
300
Propeller Shaft
300
Water Pump
301
Filling Gear Housing with Lubricant
302
Gear Housing Installation
302
Gear Housing Pressure Test
302
Installing Gear Housing to Drive Shaft Housing
303
Trim Tab Adjustment and Replacement
304
Propeller Installation
305
Notes
308
Throttle Linkage Components (S/N-0G589999 & Below)
309
Throttle Linkage (S/N-0G590000 & Above)
312
Bottom Cowl/Shift Components
313
Bottom Cowl/Shift Components
314
Bottom Cowl/Shift Components
315
Bottom Cowl/Shift Components
316
Notes
319
Tiller Handle Components
320
Tiller Handle
321
Adjustments Tiller Handle Model (S/N-0G589999 & Below)
322
Adjustments Tiller Handle Model with Mechanical Spark Advance (S/N-0G590000 & Above)
323
Notes
326
Manual Start Components
327
Manual Start Components
328
Rewind Starter Disassembly
329
Cleaning and Inspection
330
Rewind Starter Reassembly
330
Adjusting Rewind Spring Tension
332
Starter Interlock Cable Adjustment
332
Other manuals for Mercury 30
Manual
36 pages
Operation And Maintenance Manual
110 pages
Service Bulletin
3 pages
5
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Mercury 30 Specifications
General
Brand
Mercury
Model
30
Category
Outboard Motor
Language
English
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