Mercury 200 OptiMax DTS Installation Manual

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,Mercury Propellers, Mariner, Quicksilver, #1 On The W

200/225/250/275 VERADO 4-STROKEPage 10 / 51 90-10238051 Power Steering InstallationPower Steering Systemabcob01457a - Steering helmb - Steering cyli

200/225/250/275 VERADO 4-STROKE90-10238051 Page 11 / 51 • To reduce noise on aluminum or metal hulls, isolate steering hoses from hull withsuitable

200/225/250/275 VERADO 4-STROKEPage 12 / 51 90-10238051 2. Mount the power steering pump at the selected location, using appropriate fasteninghardwa

200/225/250/275 VERADO 4-STROKE90-10238051 Page 13 / 51 3. Ensure O-ring seals are in place on end of steering helm fittings.a b ob01460 a - O-ring

200/225/250/275 VERADO 4-STROKEPage 14 / 51 90-10238051 Helm Fitting ID Mark Hose ID Mark DescriptionR R-STAR Hose connects to starboard side of ste

200/225/250/275 VERADO 4-STROKE90-10238051 Page 15 / 51 4. Connect the high pressure hydraulic hose from the steering helm to the pump asshown.

200/225/250/275 VERADO 4-STROKEPage 16 / 51 90-10238051 2. Position the 90° hose fittings to the desired direction. Loosen fastening nuts in orderto

200/225/250/275 VERADO 4-STROKE90-10238051 Page 17 / 51 Electrical Connections to the Steering PumpNOTE: For single engine installation, the power s

200/225/250/275 VERADO 4-STROKEPage 18 / 51 90-10238051 NOTE: On multiple installations, the Automatic Battery Switch (ABS) (87-895091K01),must be u

200/225/250/275 VERADO 4-STROKE90-10238051 Page 19 / 51 1. Make electrical connections to the pump as shown.+ + - - R E D a b c e BLK ob01468 da - P

200/225/250/275 VERADO 4-STROKEPage 2 / 51 90-10238051 Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.94Anti-Corrosion Gre

200/225/250/275 VERADO 4-STROKEPage 20 / 51 90-10238051 4. Fill the pump tank with recommended power steering fluid.4101abca - Fill capb - Filterc -

200/225/250/275 VERADO 4-STROKE90-10238051 Page 21 / 51 9. Open bleed valve to release any remaining air in the power steering system. Allowadequate

200/225/250/275 VERADO 4-STROKEPage 22 / 51 90-10238051 5. For bleeding any air left in the steering system, start and run the engine, and turn thes

200/225/250/275 VERADO 4-STROKE90-10238051 Page 23 / 51 1. Pull out the grommet fitting from the front cowl opening. Route the wiring harnesses,batt

200/225/250/275 VERADO 4-STROKEPage 24 / 51 90-10238051 Wiring And InstallationWire Color Code AbbreviationsWire Color AbbreviationsBLK Black BLU

200/225/250/275 VERADO 4-STROKE90-10238051 Page 25 / 51 1. Inspect the routing path to make sure surfaces are free of any sharp edges or burrsthat c

200/225/250/275 VERADO 4-STROKEPage 26 / 51 90-10238051 IMPORTANT: Correct ignition key switch must be used. If a non-Mercury Marine ignitionkey sw

200/225/250/275 VERADO 4-STROKE90-10238051 Page 27 / 51 • 14 pin data harness - Connects between the command module harness and engine.a 3675bcdefa

200/225/250/275 VERADO 4-STROKEPage 28 / 51 90-10238051 Copper Battery Cable Wire Gauge SizeWire Gauge Size Number SAEModels 6-25 hp 30-115 hp (exce

200/225/250/275 VERADO 4-STROKE90-10238051 Page 29 / 51 Connecting 14 Pin Data Harness - Single EngineSINGLE HELMIMPORTANT: Avoid sharp bends in the

200/225/250/275 VERADO 4-STROKE90-10238051 Page 3 / 51 Do not overpower or overload your boat. Most boats will carry a required capacity plateindica

200/225/250/275 VERADO 4-STROKEPage 30 / 51 90-10238051 Connecting 14 Pin Data Harness - Dual EngineSINGLE HELMIMPORTANT: Avoid sharp bends in the h

200/225/250/275 VERADO 4-STROKE90-10238051 Page 31 / 51 Installing DTS Command Module and Harness - Single EngineHARNESS INSTALLATION• Locate a ro

200/225/250/275 VERADO 4-STROKEPage 32 / 51 90-10238051 NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors fromhelm 1 (he

200/225/250/275 VERADO 4-STROKE90-10238051 Page 33 / 51 • Ensure the wiring harness connected to the command module will reach all theco

200/225/250/275 VERADO 4-STROKEPage 34 / 51 90-10238051 Installing DTS Command Module and Harness - Dual Engine/Single HelmHARNESS INSTALLATION• Loc

200/225/250/275 VERADO 4-STROKE90-10238051 Page 35 / 51 • Ensure the wiring harness connected to the command module will reach all theco

200/225/250/275 VERADO 4-STROKEPage 36 / 51 90-10238051 Decal needs to be placed on or near battery box for future service reference.

200/225/250/275 VERADO 4-STROKE90-10238051 Page 37 / 51 SINGLE ENGINE - BATTERY AT STERNc a b d 3679 a - Batteryb - Black sleeve (negative)c - Red s

200/225/250/275 VERADO 4-STROKEPage 38 / 51 90-10238051 DUAL ENGINE - BATTERY AT STERNc b c a b a 3680d defga - Red sleeve (positive)b - Black sleev

200/225/250/275 VERADO 4-STROKE90-10238051 Page 39 / 51 DUAL ENGINE - BATTERY AT HELM3701aabbccdeffgha - Black sleeve (negative)b - Red sleeve (posi

200/225/250/275 VERADO 4-STROKEPage 4 / 51 90-10238051 Determining Recommended Outboard Mounting Height(20 in.) (21 in.) (22 in.) (23 in.) (24 in.)

200/225/250/275 VERADO 4-STROKEPage 40 / 51 90-10238051 IMPORTANT: Metal fuel tanks must be grounded to hull or battery ground in accordanceto coas

200/225/250/275 VERADO 4-STROKE90-10238051 Page 41 / 51 Switched 12V Accessory Connection+-ob01495PURREDabcdefgha - Batteryb - Fuse - 40 Ampc - Powe

200/225/250/275 VERADO 4-STROKEPage 42 / 51 90-10238051 DTS Wiring - Single EnginePANEL CONTROLabc3718WHITEBLUEBLK/ORGPUR/YELGRN/YELGRN/ORGGRN/REDBL

200/225/250/275 VERADO 4-STROKE90-10238051 Page 43 / 51 CONSOLE CONTROLabc3717WHITEBLUEBLK/ORGPUR/YELGRN/YELGRN/ORGGRN/REDBLK/YELBLK/YELBLKBLKOFFONd

200/225/250/275 VERADO 4-STROKEPage 44 / 51 90-10238051 DTS Wiring - Dual EngineCONSOLE CONTROL+3309aekiljmnocpgibdhljqidebcrsffga - To port engineb

200/225/250/275 VERADO 4-STROKE90-10238051 Page 45 / 51 System Wiring Installation ChecklistDATA CABLEVerify the data harness is not routed near sha

200/225/250/275 VERADO 4-STROKEPage 46 / 51 90-10238051 Tube Ref No. Description Where Used Part No.94Anti-Corrosion Grease Propeller shaft splines

200/225/250/275 VERADO 4-STROKE90-10238051 Page 47 / 51 Paddle Wheel Speed Sensor Installation (If Equipped)Parts ProvidedA B C D a b c d e f g h i

200/225/250/275 VERADO 4-STROKEPage 48 / 51 90-10238051 Transom Angle RequirementsStandard 13° to 20° transoms - No special adjustment required.a b

200/225/250/275 VERADO 4-STROKE90-10238051 Page 49 / 51 4. Fill any gap between the housing and the transom with a caulking material, as shown.Using

200/225/250/275 VERADO 4-STROKE90-10238051 Page 5 / 51 Increasing the mounting height will usually:• Increase top speed• Increase boat stability• Ca

200/225/250/275 VERADO 4-STROKEPage 50 / 51 90-10238051 WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL)Route the cable over the transom or through

200/225/250/275 VERADO 4-STROKE90-10238051 Page 51 / 51 NOTE: Wires can only be pushed into the connector one way. Align the wire terminal withthe t

200/225/250/275 VERADO 4-STROKEPage 6 / 51 90-10238051 MAXIMUM STATIC WATERLINEThe static waterline, with boat at rest, must be below the "MAX

200/225/250/275 VERADO 4-STROKE90-10238051 Page 7 / 51 2. Place masking tape directly onto the boat where the mounting holes will be drilled tohelp

200/225/250/275 VERADO 4-STROKEPage 8 / 51 90-10238051 5. Refer to Determining Recommended Outboard Mounting Height, and install outboardto the near

200/225/250/275 VERADO 4-STROKE90-10238051 Page 9 / 51 ! CAUTIONTo avoid loss of outboard, ensure that a minimum of two full threads of bolt extendb