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.

1.0 Introduction
9Reference Manual
DDT FEATURES
1 Outboard Diagnostic Cartridge – contains the memory and
the software to perform diagnostic tests and other functions.
2 Key Pad – allows you to enter data and reply to DDT messages.
3 Display Window – displays data and messages to the user.
4 LED Indicators – indicate faults in certain areas.
5 DDT Interface Cable – connects the DDT to the Adapter Cable.

1.0 Introduction
10 Reference Manual
DDT FEATURES
1
2
3
Engine Adaptor Cables
1 84–822560A 5 – 2001 Optimax/SmartCraft systems
8.1L MerCruiser/SmartCraft Systems
2 84–822560A 12 –
Adaptor for 8.1L MerCruiser
3 84–822560A 13 –
8.1L MerCruiser/SmartCraft Systems

1.0 Introduction
11Reference Manual
DDT FEATURES
ab
cd
e
f
g
Keypad
a-↑and ↓Keys – Move through menus and move cursor up or down
b-←and →Keys – Move cursor left or right
c-F1/F2 Keys – Allows the user to perform special functions
d-ENTER Key – Enters your commands into the program
e-MODE Key – Takes you back to the previous menu or test mode
f-RECORD Key – Records data for review
g-HELP Key – displays additional information
(available on select ECM models only).
NOTE: If a screen message contains the word “ENTER”, you must
press the ENTER key to accept the command you’ve keyed into the
DDT.

1.0 Introduction
12 Reference Manual
DDT FEATURES
1
2
3
4
5
6
7
8
DIGITAL
DIAGNOSTIC
TERMINAL
LED Indicators
NOTE: The LED display consists of eight (8) LEDs arranged in two
columns of four LEDs and located under the four line display. The LED
display shows the numbers identified in this illustration; it does not
show descriptions.

1.0 Introduction
13Reference Manual
DDT FEATURES
F1 and F2 Keys
Extra functions are available using the Fl and F2 keys. All functions
are NOT active during all tests.
F Key Functions
Press Result
F1 + F1 F1 Menu
Press the F1 key twice to display the available F1
functions.
F1 + 1 English / Metric
Toggles between English and Metric display.
F1 + 2
Tone On / Off
“Tone On” will cause an audible beep each time
a key is pressed. “Tone Off” turns the beep off.
Toggles between On and Off each time the 2 key
is pressed. Defaults to ON. Selection is saved in
memory.
F2 + F2 F2 Menu
Press the F2 key twice to display the available F2
functions.
F2 + 0 Revision Level
Displays the revision level of the cartridge soft-
ware.
F2 + 1 Print
Prints the information you are viewing if a printer
is attached.
F2 + 9 File Manager
List, Playback, delete, rename or print files pre-
viously saved.

1.0 Introduction
14 Reference Manual
PRINTER SETUP
a
b
a-Printer Power Plug
b-DB-25 Printer Cable
NOTE: The OTC serial printer (part number 3315, which has a 2400
baud rate) or OTC Hi Speed Serial printer (part number 3285, which
has a 9600 baud rate) is recommended if a printer is desired.
1Connect power to the printer by using one of the following
methods:
a. Insert the printer’s power plug into the battery adapter cable and at-
tach the battery adapter cable to the battery.
or
b. Insert the printer’s power plug into a cigarette lighter receptacle.
2Connect the DB–25 printer cable between the DDT’s serial
interface and the printer.
3Turn the printer power switch On.
4Set the DDT stop bit and baud rate as described in the section
of this manual titled, Tool Setup.
5The printer will be ready to print once you have completed and
saved the setup. To begin printing, press F2, then 1 or press F2,
then 9 to display the File Manager screen. While printing, the
DDT ignores all commands (except the MODE key) and shows
“PRINTING.”
6To stop a printout, press the MODE key. A few more lines may print
while the printer memory is clearing.
You can print almost any time that data from the engine is being
displayed. A screen that does not display data, such as the Injector
Test, does not allow printing.

1.0 Introduction
15Reference Manual
USING OTHER SERIAL PRINTERS
Requirements for other printers
1The printer must have a serial data protocol with x–on/x–off
handshaking.
2There is a tool–to–printer cable available. The cable must be
configured as shown:
DB–25
2–TXD (Host out)
3–RCV (Host in)
7–Ground
3The printer can have a baud rate of 300, 600, 1200, 2400, 4800,
or 9600.
4The printer must have one or two stop bit capability.
(The DDT defaults to 2400 baud rate and one stop bit.)

1.0 Introduction
16 Reference Manual
TOOL SETUP
Overview
Use this function to select the DDT baud rate and the number of stop
bits. You can also save the Tool Setup or restore the previously saved
setup.
Make sure the SELECT FUNCTION Menu screen is displayed on
the DDT. Main Menu
SmartCraft Monitor
1-Mercury Marine
2-Tool Setup
Press the 2 key. The TOOL SETUP MENU screen will appear.
TOOL SETUP MENU
1-General Setup
2-Save Setup
3-Restore Setup
General Setup
TO SET THE DDT:
From the TOOL SETUP MENU, press the 1 key. The GENERAL
SETUP screen will appear.
PRN BAUD 2400
STOP BITS 1
Use the ↑and ↓keys to scroll the cursor. When the cursor is located
on the line you wish to change, use the ←and →keys to change the
options. Option choices are listed in the table below.
Parameter Options Defaults
Baud 300, 600, 1200, 2400, 4800, 9600 2400
Stop Bits 1 or 2 1
Once the selected choice is made, then press MODE to exit. From the
TOOL SETUP MENU select 2 if you wish to save the setup. Follow the
instructions on the screen. When the settings are saved press MODE
to return to the SMARTCRAFT MONITOR screen.

1.0 Introduction
17Reference Manual
LINE LOCK
If you want a line of data to stay in place, press key 1, 2, 3 or 4 to
hold data line 1, 2, 3, or 4 in place. Pressing the number again will
unlock that line. As you scroll, the lines locked will stay in place and
the next data items will appear in the unlocked lines.
ENGINE RPM 690 <E
TPI 1 VOLTS 0.59
BATTERY VOLTS 13.5
PWR 1 VOLTS 5.0 r
→
←
a
a-Line Lock Example
In the example screen shown above, lines 1and 2arelocked (a locked
line will underline the first character). New data lines will appear in lines
3 and 4.

1.0 Introduction
18 Reference Manual
RECORD/PLAYBACK
The Diagnostic Cartridge contains a Recording feature that allows
you to capture information at certain times when data is displayed
on the screen. Once data has been captured, you can play it back
immediately or save it in a file for playback and printing.
The data will be captured in “frames.” A “frame” of data is a snapshot
of data read from the ECM.
Without operator action, the software continuouslyreads data from the
ECM at the rate of one frame per second. The program saves each
frame until 26 frames have been saved. The data is then continuously
updated.
→
←
ENGINE RPM 690 <E
TPI 1 VOLTS 0.59
BATTERY VOLTS 13.5
PWR 1 VOLTS 5.0 R
R = Indicates software continuously reading and updating data.
To record data, simply press the RECORD key on the DDT, but wait
until you have about 26 frames of data (approximately 26 seconds)
before you press the RECORD key. When the RECORD key is
pressed, the 26 frames of data that occurred before the key was
pressed will be captured, as well as the next 25 frames that occur
after the key is pressed (the Rdisplayed in lower right hand corner
will change to a lower case r).
→
←
ENGINE RPM 690 <E
TPI 1 VOLTS 0.59
BATTERY VOLTS 13.5
PWR 1 VOLTS 5.0 r
r = Recording in progress.