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Mercruiser Commander 3000 Controls Manual



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COMMANDER 3000
CLASSIC PANEL MOUNT
REMOTE CONTROL




             74428




                      11
Table of Contents
                                                                         Page
Commander 3000 Classic Remote Control
   Maintenance and Replacement Parts . . . .                             11-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    11-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . .            11-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   11-5




11 - COMMANDER
11-0           3000
     - COMMANDER    CLASSIC
                 3000       PANEL
                      CLASSIC     MOUNT
                              PANEL     REMOTE
                                    MOUNT      CONTROL
                                          REMOTE CONTROL                        90-814705R2
Commander 3000 Classic Remote Control Maintenance and
 Replacement Parts
    Panel Mount Controls

                  1                                                                   17

                                                                         16
                      2
                                                                                                     18



                      3                                           15

                              4        12                    14
                                                   13

              7
                                                                                                          19


                                                                                       21

                                                                                                20
                                                                                 23
                                      10
                                             11
                          8
              6                                                22
                                  9
5


                                                  1 -   Handle Cover 817259
                                                  2 -   Trim Switch 87-18286A31 OB
                                                  3 -   Trailering Switch MCM Only 87-18286A33
                                                  4 -   Spring 24-16924
                                                  5 -   Throttle-Only Button 822212
                                                  6 -   Brass Locking Hex Bolt 10-822213--1
                                                  7 -   Control Handle 822211--1
                                                  8 -   Screw 10-52376
                                                  9 -   Shift Release 817259
                                                  10-   Washer (.188x.428) 12-28001
                                                  11-   Screw (10-3 x.25)
                                                  12-   Bezel Cover 37-827289
                                                  13-   Flanged Bushing 23-822980
                                                  14-   Lanyard Stop Switch (87-13398 MCM, 87-13398--1 OB)
                                                  15-   Screw (.250x20x.750) 10-53099
                                                  16-   Bezel 822216A1
                                                  17-   Retainer 12044--1
                                                  18-   Washer (.281x.734x.063) 12-69057
                                                  19-   Nut (.281x.734x.0) 11-814101
                                                  20-   Friction Screw 10-824831
                                                  21-   Screw (.250x20x1.750) 10-822214
                                                  22-   Lanyard Cord 15920A54
                                                  23-   Wood Screw (3) 10-96952




90-814705R2                            COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL - 11-1
Disassembly                                            3. Remove handle and handle bushing.

1. Remove control handle by first removing throttle-                      a
   only button. Place the control handle in the
   throttle-only position. Push "In" on button and
   place control handle forward. Throttle-only but-
   ton can now be removed. If button cannot be re-
   moved with fingers, use a small screwdriver and
   pry out gently.


Place Control in
Throttle-Only Position
Before Attempting To                                                                                           74407
Remove Button          a
                                                       a - Bushing

                    b                                  4. Feed trim wires from behind bezel and unplug at
                                                          connector.




                                                                                               b              a



                                               74410
a - Handle Assembly
b - Throttle-Only Button                                                               c
2. Remove 11/16" retainer bolt holding handle to
   module.


                                                                                                               74406
             a
                                                       a - Wiring Harness Connector
                                                       b - Trim and Trailering Switch Wiring Connector
                                                       c - Trim and Trailering Switch Wires




    b
                                               74409
a - Handle Assembly
b - Retaining Bolt




11-2 - COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL                                                 90-814705R2
5. Remove bezel cover using a small screwdriver           7. Remove bezel from boat panel by removing
   and prying on either the top or bottom of bezel to        screws and nuts as shown.
   pop tabs out of the bezel notches.
                                                                                                c
    c                              c                                                        b




                                             d

                                            b              a
b
                                                                                                              d


        b
                                                                                                             74404
                    a    b                       74405
                                                          a   -   Screw .250x20x1.750 (3)
a   -   Bezel Cover                                       b   -   Washers (3)
b   -   Cover Tab                                         c   -   Nuts .250x20 (3)
c   -   Notch in Bezel                                    d   -   Mounting Surface
d   -   Bezel
                                                          8. Remove lanyard switch by pushing up on lanyard
6. Remove module assembly by loosening three                 retainer, located on back of bezel. Locate wire
   .250x20x.750 hex screws fastening module as-              connections for switch and unplug. This will be an
   sembly to bezel assembly.                                 electrical connection or soldered connection.

                                                                                                             b
                         a



                                                                                                         a
    b

                                                                                                     c


                                                 54587

a - .250x20x.750 Hex Screws
b - Bezel
                                                                                                             54592

                                                          a - Lanyard Retainer
                                                          b - Bezel
                                                          c - Lanyard Switch




90-814705R2                                      COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL - 11-3
9. Remove friction set screw using a 1/8" allen                    11. Remove phillip screw securing handle cover to
   wrench.                                                             control handle.

                                                                                        c


                                                                                                 b




                                                   c
                                                                            a
        a                         b
                                                                                                               54589
                                                                   a - Handle Assembly
                                                                   b - Screwdriver
a - Bezel                                                          c - Phillip Head Screw
b - Friction Set Screw
c - 1/8" Allen Wrench                                              12. Slide two components apart.
10. Disassemble handle by first removing phillip
    screw and washer holding shift release. Remove
    release lever and spring.
                                                                                                         a


                                               e
                                         d
                                                       a
                                        c                                                            c
         b

                                                                                                     b



                                                           54588

a   -   Phillip Screwdriver
b   -   Handle Assembly                                                                                        54590
c   -   Phillip Screw                                              a - Control Handle Cover
d   -   Release Lever                                              b - Control Handle
e   -   Spring (Located inside of Release Lever)                   c - Trim Switch




11-4 - COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL                                                 90-814705R2
13. Remove trim switch. If control has a trailer switch,   Assembly
    this can be removed with trim switch.
                                                           1. Install trim switch into handle grip as shown. If
                                            a                 control has a trailer switch, install both switches
                                                              into handle grip.




                                                                                                       a


          b


                                                  54591

a - Control Handle Cover
                                                                                                  c
b - Trim Switch
14. For module disassembly, refer to Section 13.

                                                                                                  b
Cleaning and Inspection
1. Clean all components thoroughly and check for
   wear or breakage.

                           CAUTION                                                                            54590
                                                           a - Control Handle Cover
Do not clean electrical, non metallic, or compo-           b - Control Handle
nents with decals or stickers with any solvent             c - Trim Switch
cleaners or damage to component may occur.
                                                               Route wires through handle as shown. Slide con-
                                                               trol handle into handle grip until grip seats against
                                                               handle completely. Install screw to secure grip to
                                                               handle.

                                                                                      CAUTION
                                                           Modules with trailer switch, be careful sliding
                                                           two parts together. Trailer wires catch on handle
                                                           very easily.




90-814705R2                                       COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL - 11-5
2. Divide trim wires over screw boss and route wires         3. Install lanyard switch by placing switch into con-
   around handle shaft as shown.                                trol bezel from the front side. Push lanyard retain-
                                                                er over switch on the rear side of bezel to hold
                                                                switch into place.

                                                                                                                    b



                                                                                                                a



                                                                                                            c




                                                                                                                    54592

                                                    55133    a - Lanyard Retainer
                                                             b - Bezel
                                                             c - Lanyard Switch
        Install spring into round boss on top of red shift
        release lever. Attach both spring and lever to       4. Install friction set screw using a 1/8" allen wrench.
        control handle by positioning shift lever spring        Do not install allen screw beyond flush with cen-
        over handle grip screw. Push "Up and In" on shift       ter bore. The friction will be adjusted after control
        lever until screw boss is located into shift lever      installation.
        slot. Install screw and washer.

                        d


                            e
                                             b                                                          c
                                                       c          a
                                         a                                                   b



                                                             a - Bezel
                                                             b - Friction Set Screw
                                                             c - 1/8" (3.1mm) Allen Wrench
                                                    54588

a   -   Phillip Head Screw
b   -   Handle Assembly
c   -   Screwdriver
d   -   Spring
e   -   (Red) Shift Release Lever




11-6 - COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL                                                90-814705R2
5. Feed lanyard switch wires through mounting                  7. Install the bezel cover. Secure the bezel cover by
   surface hole and install bezel to mounting sur-                inserting the cover tabs into the notches in the
   face using three screws, torque to 100 lb. in.                 bezel.
   (11.3 Nm).                                                     c                                   c
                                           c
                                       b

                                                                                                            d

                                                                                                           b
                                                                   b
    a

                                                        d


                                                                                   a
                                                      74404

a   -   Screw .250x20x1.750 (3)
                                                                                                                74405
b   -   Washers (3)
c   -   Nuts .250x20 (3)                                       a   -   Bezel Cover
d   -   Mounting Surface                                       b   -   Cover Tab
                                                               c   -   Notch in Bezel
NOTE: If mounting hole has not been installed, refer           d   -   Bezel
to Installation and Operations Guide for hole dimen-
sions and templates.                                           8. Route the trim switch and trailering switch leads
                                                                  from the handle assembly thru the bezel opening
6. Install control module assembly to bezel using                 as shown.
   three .250x20x.750 hex screws. Torque to 25 lb.
   in.
                            a




        c
                                                                   a                                       b

                                                                                    c
                                                 b

                                                      54587

a - .250x20x.750 Hex Screws
b - Control Module Assembly
c - Bezel
                                                                                                       d
        If control module is not assembled, refer to                                                           74406
        "Module Assembly" in Section 13. For shift             a   -   Bezel
        and throttle cable installation, refer to "Installa-   b   -   Trailer Switch
                                                               c   -   Trim and Trailer Switch Leads
        tion and Operator's Manual" (90-827290--1).
                                                               d   -   Handle




90-814705R2                                           COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL - 11-7
                                                          10. Install the bushing into the Commander 3000
                         CAUTION                              Classic bezel. Line up the notch in the bezel with
Verify trim/trailer wires are not pinched when                the rectangular protrusion in the bushing.
mounting remote control module to panel of
boat. Trim wires must be free to move with the
                                                          a                            c
remote control handle.

                         CAUTION
DO NOT sta-strap or otherwise secure trim leads
within 12 in. (305 mm) of panel exit. Allow suffi-
cient slack in leads to permit free movement of
trim leads through the full range of shift handle
motion.
9. Connect the trim and trailering switch wires to ap-
   propriate wiring harness.                                            b
                                                                                                                  74407

                                                          a - Notch in Bezel
                                                          b - Rectangular Protrusion
                                                          c - Bushing
                                        b         a
                                                                                    WARNING
                                                          The control handle 11/16 in. hex retaining bolt
                                                          must be torqued to 150 lb. in. (17 Nm). Failure to
                                                          torque retaining bolt as specified could allow
                                 c                        handle to disengage with subsequent loss of
                                                          throttle/shift control. If the remote control handle
                                                          is removed and reinstalled for any reason, place
                                                          Loctite 271 (obtain locally) on threads of retain-
                                                          ing bolt and torque to 150 lb. in. (17 Nm). Exces-
                                                          sive tightening torque may result in handle shaft
                                                  74406   failure.

a - Wiring Harness Connector                              11. Place handle assembly onto the remote control
b - Trim and Trailering Switch Wiring Connector               module in the neutral detent position and secure
c - Trim and Trailering Switch Wires                          with 11/16 in. brass hex bolt. Torque bolt to 150
                                                              lb. in. (17 Nm).



                                                                        a




                                                                                                                   O


                                                               b
                                                                                                                 74409
                                                          a - Handle Assembly
                                                          b - Retaining Bolt [Torque to 150 lb. in. (17 Nm)]

                                                           O         Loctite 271 (Obtain Locally)


11-8 - COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL                                                    90-814705R2
12. Install Throttle-Only button.                          15. Use an allen wrench to adjust the control handle
                                                               tension to desired tension.


                      a

              b
                                                                                                       a




                                                                                                 b
                                                                                                           74412

                                                  74410


a - Handle Assembly
b - Throttle-Only Button                                   a - 1/8" (3.1mm) Allen Wrench
                                                           b - Control Handle Tension Screw
13. Make wiring connections for neutral start safety           (Clockwise - Increase)
    switch, lanyard stop switch (if equipped) and trim         (Counterclockwise - Decrease)
    switch (if equipped). Attach power trim harness
    connector (if equipped). Refer to "Electrical
    Connections" Section 14.
14. Move the control handle forward 45 degrees to
    expose the handle tension adjusting screw.

                                a




    45_




                                              b




                                                  74411

a - Control Handle
b - Tension Adjusting Screw




90-814705R2                                       COMMANDER 3000 CLASSIC PANEL MOUNT REMOTE CONTROL - 11-9


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