Quicksilver SmartCraft Systems User manual

Technician Reference Manual
Printedin U.S.A. 90–881204–2 401
Digital
Diagnostic
Terminal
Software Version 1.2
SmartCraftSystems

Note:
•To take full advantage of the tool, you should be knowledgeable
and well trained in the OEM system described in this manual.
•This manual contains information that will allow you to use the
tool to perform diagnostic tests and find possible locations of en-
gine problems. It does NOT contain information on how to correct
the problems. Once you have located a problem, consult the en-
gine’s service manual for repair instructions.
•All information, illustrations and specifications contained in this
technical manual are based on the latest information available at
the time of publication. The right is reserved to make changes at
any time without notice.

Preface
1Reference Manual
TABLE OF CONTENTS
Preface
Table of Contents 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Icons 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What’s new for Cartridge Version 1.2 –
SmartCraft ECMs Model year 2002 and Prior 6. . . . . . . . . . . . .
Introduction
Overview 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DDT Features 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Adaptor Cables 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keypad 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Indicators 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F1 and F2 Keys 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using other Serial Printers 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool Setup 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Setup 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Lock 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Record/Playback 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Save Error 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File Manager Menu 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Directory List 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Playback File 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delete 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rename 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Live Data Printing 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferring Data to a PC 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview
1-Data Monitor 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-Fault Status 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-System Info 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-History 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-Special Functions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–Engine Location 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–Trim Limit 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface
2 Reference Manual
TABLE OF CONTENTS
Marine Diagnostics
Overview 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Overview 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adaptor Cables 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Port Locations 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Up 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self Test 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two Stroke Examples 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Stroke Examples 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–Data Monitor 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two Stroke Example Screens 36. . . . . . . . . . . . . . . . . . . . . .
Four Stroke Example Screens 41. . . . . . . . . . . . . . . . . . . . . .
2–Fault Status 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–System Info 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–History 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freeze Frame 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Seconds 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run History 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Fault History 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Run History 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–Special Functions 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Prime 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Misfire 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Load Test 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Load Test 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Injector Load Test 67. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Load Test 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Load Test 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn Load Test 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous – Idle Air Control 75. . . . . . . . . . . . . . . . . . . .
Iac Test With Engine Rpm 75. . . . . . . . . . . . . . . . . . . . . .
Iac Test With No Engine Rpm 77. . . . . . . . . . . . . . . . . . .
Electronic Shift Control 79. . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Throttle Control 81. . . . . . . . . . . . . . . . . . . . . .
Knock Output Load Test 84. . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Load Test 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Load Test 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Break-in 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–Engine Location 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–Trim Limit 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface
3Reference Manual
Appendix
Engine Location 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary of Terms
SmartCraft Systems 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface
4 Reference Manual
SAFETY PRECAUTIONS
WARNING
!
•When an engine is operating, keep the service area WELL
VENTILATED or attach a building exhaust removal system to
the engine exhaust. Engines produce carbon monoxide, a
poisonous gas which is odorless, causes slower reaction
time, and can lead to serious injury or death.
Fuel under pressure may escape and create a dangerous
condition if you are working with fuel lines. Make sure there
is adequate ventilation and there is no possibility of sparks
present.
Batteries contain sulfuric acid and produce explosive gases
that can result in serious injury or death. To prevent ignition
of gases, keep lighted cigarettes, sparks, flames, and other
ignition sources away from the battery at all times. If you are
using the battery as a power source, connect the RED (+) bat-
tery clip to the positive battery terminal and connect the
BLACK (–) battery clip to a good ground away from the bat-
tery.
Wear an ANSI approved eye shield when testing or repairing
engines. Objects can be propelled by rotating engine com-
ponents, and liquids escaping under pressure can cause se-
rious injury.
Do not operate the boat and operate the DDT at the same
time. Any distractions may cause an accident. Have one per-
son operate the DDT as another person operates the boat.

Preface
5Reference Manual
ICONS
PRINT
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. The
Line Lock feature allows display lines to be locked
into position, rather than scrolled. An underline on
the first column of a line indicates that it is locked.
Record
Available This icon indicates that RECORD is available. Press
the RECORD key to record data being read from the
Engine Control Module.
Press
To EXIT Press this key anytime when you wish to return to the
previous menu or test mode.
Press this key for extra information. (May not be
available on all ECMs)

Preface
6 Reference Manual
WHAT’S NEW FOR CARTRIDGE
VERSION 1.2 – SMARTCRAFT PCMS/ECMS
MODEL YEAR 2002
•FPC Total – Data Monitor (select models)
•Ignition Timing – Data Monitor (select models)
•30 – 60HP 4 stroke outboard with ECM555
•V6 Outboard EFI with PCM555
•All previous PCM555 models since 2002 MY are supported

Preface
7Reference Manual
NOTES

1.0 Introduction
8 Reference Manual
OVERVIEW
The Quicksilver Digital Diagnostic Terminal (DDT) has been developed
specifically to help technicians diagnose and repair Mercury Marine
two and four cycle outboard engines.
The Outboard Diagnostics Cartridge contains a diagnostic program
for the ECM that allows the technician access to all of the diagnostic
capabilities available through the engine Electronic Control Module
(ECM).
Simply hook the diagnostic cable to the ECM diagnostic connector and
plug in the software cartridge. You will be able to monitor sensors and
ECM data values including status switches.
The ECM program can help diagnose intermittent engine problems. It
will record the state of the engine sensors and switches for a period
of time, much like a tape recorder would, then you can play back and
review the recorded information.