COX CXO300 diesel V8 Installation Manual
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COX CXO300 diesel V8 Installation Manual

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INSTALLATION
GUIDE
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CXO300 – designed for
purpose
coxmarine.com

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  • Page 1 INSTALLATION GUIDE ––– CXO300 – designed for purpose coxmarine.com...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION INSPECTION OF OUTBOARD REMOVAL OF OUTBOARD ENGINE FROM THE CRATE MOUNTING THE OUTBOARD ONTO THE TRANSOM RIGGING INSTALLATION STEERING RIGGING TUBE INSTALLATION FUEL SYSTEM INSTALLATION POWER SUPPLY 10.0 WIRING HARNESS INSTALLATION 11.0 HELM CONTROL INSTALLATION 12.0 OUTBOARD OIL FILL 13.0 APPLYING GREASE TO THE PTT...

  • Page 4: Introduction

    1.0 INTRODUCTION 1.1 INTRODUCTION The purpose of this document is to define the procedures or steps that are required to be done in order to do a safe and correct installation of a CXO300 outboard engine(s). The different systems of the outboard(s) are designed to work together continuously to provide a safe and reliable boating experience.

  • Page 5: Inspection Of Outboard 2.0

    Remove the outboard cover and make sure that you do a check for damage on the outboard cover again. 2.8.0 Make sure you speak to your distributor or local Cox service provider for aid if: 2.8.1 Damages can be seen on the outboard, outboard cover and packaging.

  • Page 6: Removal Of Outboard Engine From The Crate

    3.0 REMOVAL OF OUTBOARD ENGINE FROM THE CRATE 3.1.0 Attach the applicable straps or chains to the correct points on the metal transportation crate (Figure 3.1a) Figure 3.1a. Points for attaching straps and steps for lifting the metal transportation crate with outboard to a vertical position.
  • Page 7 3.9.0 Remove the crank pulley cover. 3.9.2 Use 14mm hex driver or Allen key to remove the crank pully cover. 3.10.0 Install the centre lifting eye and sleeve (Kit No. 909427) . Hand tight only. 3.10.1 When the centre lifting eye is tight, if the eye orientation is not within 45° of the centre line of the outboard, bar over the engine until it is in the correct orientation as shown.
  • Page 8 3.0 REMOVAL OF OUTBOARD ENGINE FROM THE CRATE 3.12.0 Install the left hand lifting eye (909440) to the port/left cylinder head (Figure 3.11) and torque the two fasteners (029355) to 23Nm. NOTE Working load limit (WLL) for left-hand lifting eye (909440) and right-hand lifting eye (909441): Vertical outboard lift WLL = 500kg 25°...
  • Page 9 3.16.0 Assemble the crate again. 3.17.0 Keep or send the crate back to Cox. CAUTION Do not reuse any fasteners from the shipping crate for the installation of the outboard to a vessel - the fasteners are for shipping purposes only. Use only components from the supplier rigging kits for installation to vessel.

  • Page 10: Mounting The Outboard Onto The Transom

    4.0 MOUNTING THE OUTBOARD ONTO THE TRANSOM 4.1.0 Before you drill the mounting holes, make sure that: 4.1.1 The outboard is appropriate for the vessel. 4.1.2 The mounting hole positions are identified correctly. 4.2.0 Make sure that the vessel is rated for the power output of the outboard(s). 4.3.0 Make sure that the vessel transom is sufficiently strong to mount the outboard.
  • Page 11 CXO300 Outboard Install Guide (based on current Cox steering systems) Between centres 724 [28.5] 762 [30] 784 [30.9] Twin Install Twin Install Triple Quad Triple Quad Twin Triple Quad Single Install Install Install Install Install Install Install Install Parallel Parallel...
  • Page 12 4.7.2 Make sure that the anti-ventilation plate and the water line is at the correct height. Cox offer 3 outboard leg lengths (25”, 30” and 35”) to make sure that the outboard operates correctly with the vessel.
  • Page 13 4.8.0 Make sure that the water line of the vessel is between the lines which are shown on the outboard in Figure 4.9. Figure 4.8. Minimum and maximum water lines on the outboard engine. Max water line - make sure that the exhaust idle vent is out of the Min water line - make water...
  • Page 14 4.0 MOUNTING THE OUTBOARD ONTO THE TRANSOM Figure 4.10 Engineering drawing showing the PTT-Transom layout - mm (in). A 13 (0.51) B 163.5 (6.44) C 125.4 (4.94) D 95.2 (3.75) E 318.5 (12.54) F 92.5 (3.64) G 115.3 (4.54) H 18.5 (0.73) 4.11.0 Make sure that you use a 6 mm pilot drill to make initial holes in the transom.
  • Page 15 4.17.0 Remove the lifting straps or chains from the outboard and move the crane to a safe area. 4.18.0 If you are doing a multiple installation, repeat steps 4.15.0 through 4.18.0 for each outboard to be installed. 4.19.0 Remove the lifting eyes (3) and install the crank pulley cover. Torque the crank pulley cover to 9-11 Nm.

  • Page 16: Rigging Installation

    SK-000136 ○/1 ○ Helm Screen Kits Part Number Victron Energy Orion-Tr 12/12-30A (360W) Isolated DC-DC Converter 038206 ●/1 ●/1 ●/1 Voltage Sensing Battery Combiner (Not Supplied by Cox) ●/1 ●/1 ●/1 KEY: STANDARD/QUANTITY ●/1 INSTALLATION-SPECIFIC/QUANTITY ○/1 MAX EXTENSIONS (m) CXO300 INSTALLATION MANUAL...
  • Page 17 If a vessel harness which is longer than 8m is necessary, make sure you speak to your Cox service provider about it. The rigging kits are as follows: Figure 5.1 Rigging Kit Contents...
  • Page 18 5.0 RIGGING INSTALLATION 5.2.0 ELECTRONIC RIGGING GUIDE 5.2.1 Make sure that you read the information in this section which contains component information, schematic keys and electronic rigging schematics. The rigging schematics (Figure 5.2a through Figure 5.2g) are as follows: Figure 5.2a. Rigging components with their related part numbers and schematic key Rigging Component Part Number Rigging Component...
  • Page 19 Figure 5.2b. CXO300 single installation schematic Vessel Busbar Fuel Level Victon Energy DC-DC Converter Fuse box Connect to Battery Breaker via a 10amp fuse Vessel Battery Integration CXO300 INSTALLATION MANUAL 5.0 RIGGING INSTALLATION...
  • Page 20 5.0 RIGGING INSTALLATION Figure 5.2c. CXO300 twin installation schematic Fuel Level Victon Energy DC-DC Vessel Busbar Converter Connect to Battery Breaker Fuse box via a 10amp fuse Vessel Battery Integration CXO300 INSTALLATION MANUAL 5.0 RIGGING INSTALLATION...
  • Page 21 Figure 5.2d. CXO300 triple installation schematic Fuel Level Victon Energy DC-DC Vessel Busbar Converter Connect to Battery Breaker Fuse box via a 10amp fuse Vessel Battery Integration CXO300 INSTALLATION MANUAL 5.0 RIGGING INSTALLATION...
  • Page 22 5.0 RIGGING INSTALLATION Figure 5.2e. CXO300 quad installation schematic Vessel Busbar Fuel Level Victon Energy DC-DC Converter Fuse box Connect to Battery Breaker via a 10amp fuse Vessel Battery Integration 5.2.2 Victron Energy DC-DC Converter Integration The voltage regulator must be integrated into the ECU power harness 036484 and as near as possible to the outboard battery switch with a ground link fitted between the input and output ground cables.
  • Page 23 Figure: Victron Energy Schematic 5.2.3 Ensure a suitable voltage sensing relay is used - minimum 120 Amps - example show is a Victron Energy 120 Amp voltage sensing battery combiner. Ensure all cables are minimum 70mm² for outboard supply and suitable for 120amp for other circuits.
  • Page 24 5.0 RIGGING INSTALLATION 5.2.f Option 1: For redundancy, connect one purple Dometic wire to purple wire on harness 033871 and the other purple wire to a separate battery via a switch (not provided). Option 2: No redundancy, if only one battery is available, splice the two Dometic purple wires into single purple wire on harness 033871.
  • Page 25 5.3.0 VESSEL HARNESS COLOR GUIDE Make sure that you connect related connectors as given in the instructions in the color schematic (Figure 5.3a) and color assignment (Figure 5.3b) Figure 5.3a. Rigging color guide schematic CORRESPONDING CONNECTORS HAVE MATCHING COLOUR MARKERS Outboard to Transom CAN Harness Outboard to Transom Controls Harness Transom to Helm Controls Harness...
  • Page 26 5.0 RIGGING INSTALLATION Figure 5.3b. Rigging color assignment guide 033876 033939 PART # 033780 033781 033877 033879 033880 033749 033878 Outboard- Outboard- Transom-Helm Helm Display Helm Display Transom Trim Switch NAME Transom CAN Controls Harness (4.5” Harness (7.8” & Controls Panels Harness Harness...

  • Page 27: Steering 6.0

    EPS installation manual for outboard powered vessel – book 50.1). 6.3.0 Make sure that you use these instruction together with the Dometic manual. The instructions which Cox has given are different from those in the Dometic manual but they are put together to be used for the CXO300. 6.3.1 Make sure that you use the CAN2 connection to the private CAN network.
  • Page 28 The Dometic ECU supplies power to Cox private CAN network. CAUTION Make sure that you do not connect the Cox private CAN network to another power supply. 6.3.8 Make sure that only equipment supplied or approved by Cox is connected to the CAN network.
  • Page 29 6.5.2 Measure distance B, then choose spacer from table. Record the measurements in table 6.5.5. Figure 6.5b. Steering actuator install guide - threaded end spacers CXO300 Outboard Steering Actuator Install Guide - Step 2: Threaded end spacers selection What is measured length B? B≤3,5 3,5<B≤...
  • Page 30 6.0 STEERING 6.5.6 Install the Dometic tournament steering cylinder underneath the CXO300 tiller arm using the second hole (closest to the outboard) and torque to 30Nm (22lb-ft) Figure 6.5.6a. Tiller arm and steering actuator fastener. Bolt 3/8-24 UNF x 1-1/2 Washer Nyloc Nut 3/8-24 UNF (Single Use Only) Steering Actuator...

  • Page 31: Rigging Tube Installation 7.0

    RIGGING TUBE INSTALLATION 7.0 7.1.0 Install the rigging tube. The diameter of the tube must be 2.5” (63.6 mm) internal diameter (I.D.). I.D. 7.2.0 Move all the rigging from the servicing area (vessel bilge) and put them in an applicable location at the transom area.
  • Page 32 7.0 RIGGING TUBE INSTALLATION Figure 7.7. Rigging tube removal Rigging grommet Rigging grommet Rigging grommet half housing housing (half part) Rigging grommet half housing Rigging grommet Rigging grommet half housing CXO300 INSTALLATION MANUAL 7.0 RIGGING TUBE INSTALLATION...
  • Page 33 7.8.0 Remove the rigging grommet tube (028946) (refer to Figure 7.7) which has the cables and fuel lines holes (refer to Figure 7.8). Note: not all the holes are used on this application. Figure 7.8. Engineering drawing of the rigging grommet. 7.9.0 Make sure that you use the lower 2 holes for the fuel feed and return lines.

  • Page 34: Fuel System Installation

    8.0 FUEL SYSTEM INSTALLATION 8.1.0 Make sure that you select a good location (usually in the bilge area) for the lift pump (037236) with good access to change the filter and water drain as shown in Figure 8.2a. 8.2.0 Make sure that you install the lift pump within ±11° of vertical (it must be installed vertically in the range of angles given).
  • Page 35 Figure 8.2c. Tank fuel pickup distance schematic TANK FUEL PICKUP SCHEMATIC 8.3.0 Make sure that you use three applicable fasteners to hold the lift pump in position. 8.4.0 Make sure to inspect the fuel hose spigot. If necessary, move the fuel hose spigot to the opposite side of the pump to optimize the routing of inlet and outlet hose.
  • Page 36 8.0 FUEL SYSTEM INSTALLATION If you are not sure about the correct type of hose to use, refer to your classification specifications or speak with your Cox servicing agent. 8.9.0 Attach the applicable hose clamps and torque to the manufacturer’s specification(s). It will make sure that no air can enter into the system.
  • Page 37 8.12.0 Put the two hoses through the rigging tube to the location of the fuel pump module. 8.13.0 Connect the feed hose (the male quick connect on the vessel hose) to the ‘OUT’ port on the lift pump with an applicable hose clamp. Make sure that the feed hose is supported safely. NOTE The length of the pipe can be decreased to the applicable length for the vessel(s).

  • Page 38: Power Supply

    Connect the positive and earth cables of the items listed below to the busbars: Dometic steering system. � Power connections to supply the Cox helm controls harness. � 9.7.0 Connect another pair of cables (+ve and -ve), with a minimum cross-sectional area of 70 mm²...
  • Page 39 black arrow) to the busbars on the outboard as shown in Figure 9.9. Make sure that you torque the terminal nuts to 13 Nm. WARNING Ensure that nyloc locking nuts are used to secure all power cables to the outboard busbar. Figure 9.9 Arrows showing the +ve (red) and -ve (black) cable connections to the busbars on the outboard 9.10.0...
  • Page 40 9.0 POWER SUPPLY 9.13.0 Connect the grey colored, two pin connector on the outboard end of the ECU Power harness (036484). Ensure the latch of the connector is engaged. (refer to figure 9.13). Figure 9.13. Engaged latch connector 9.14.0 Put the cables through the rigging grommet to transom area. 9.15.0 Connect the negative directly to the outboard battery.

  • Page 41: Wiring Harness Installation 10.0

    WIRING HARNESS INSTALLATION 10.0 10.1.0 Find the outboard to vessel CAN harness (033870). 10.2.0 Put the outboard to vessel CAN harness through the rigging tube and grommet. Connect it to the single 4 pin plug (Refer to Figure 10.2) on the outboard harness. Figure 10.2 Single 4 pin plug 10.3.0 On the vessel end of the CAN harness (033870), there are two M12 CAN connectors.
  • Page 42 10.0 WIRING HARNESS INSTALLATION NOTE If reloacating the diagnostic port is necessary, the harness can be extended with an applicable extension harness. 10.6.0 Install female CAN connector cover (034986) to spare port on the T-Piece. 10.7.0 Connect the connector with the colour code white/purple on the outboard transom CAN harness into a T- piece connector (034393).
  • Page 43 10.13.0 Make sure that you select the correct length of the vessel CAN harness 033873 (4 m), 033874 (6 m) and 033875 (8 m). 10.13.1 Connect the vessel CAN harness to the last port on the CAN network T-piece connector on the daisy chain.
  • Page 44 10.0 WIRING HARNESS INSTALLATION WARNING Make sure that you use a T25 torx driver to install the two torx screws (032511). If you do not use the correct Allen driver, damage can be caused to the screw heads. 10.19.0 Assemble the rigging grommet housing around the rigging tube with the other half section of the rigging grommet housing (Refer to Figure 10.19).
  • Page 45 10.20.0 Make sure that all the cables and hoses are installed safely to prevent damage. 10.20.1 In the bilge area, at the vessel’s end of the outboard to vessel controls harness (033871) there are: (a) Fuse box holder: make sure that you attach (use the two mounting holes) the fuse box safely in an area where there is no water or heat source.
  • Page 46 10.0 WIRING HARNESS INSTALLATION (b) One red wire with an M6 ring terminal: connect it to the positive (+ve) busbar of the vessel through a breaker or fuse that is rated at 10 Amps. (c) One black wire with an M6 ring terminal: connect it to the negative (-ve) busbar of the vessel.
  • Page 47 10.21.1 If it is necessary for a harness to be longer than 8 m, speak to your Cox representative: To make sure that joining the harnesses together is correct for your vessel. (ii) To make sure that the correct type of harness length which are listed below are used.

  • Page 48: Helm Control Installation

    Dometic EPS manual Book 50.1 � Steering helm: refer to Dometic EPS maual Book 50.1 � � Cox trim panel (2 Switch) (Refer to Figure 11.2a.). Figure 11.2a. Cox trim panel (2 switch) CXO300 INSTALLATION MANUAL 11.0 HELM CONTROLS INSTALLATION...
  • Page 49 Figure 11.2b. Cox trim panel (3 switch) 11.2.1 Print the template to the correct scale and do a check to make sure that it is accurate. Protect the vessel from dust and sparks. 11.3.0 Make sure that you use the correct template to cut the trim switch panels.
  • Page 50 11.6.1d When installing 5 or 6 outboards the engines will start in pairs. Make sure that you make different groups of outboards. Speak to your Cox representative to make sure that the installation is correct in this condition. 11.6.2 PTT SWITCH CONNECTORS 11.6.2a...
  • Page 51 11.6.2b When you install multiple outboards connect the correct PTT switch connector into the related connector in the trim switch panel. The connector labeled control head on trim switch panel loom connects into the related connector on the i6800 control head. 11.6.3 SCREEN HARNESS 11.6.3a Make sure that you connect the 4”...
  • Page 52 11.0 HELM CONTROLS INSTALLATION 11.6.3e Make sure that you connect the positive and negative connections to the house battery through a 5 Amp circuit breaker. 11.6.3f Make sure that you connect the fuel level connections to the fuel level sensor as follows: Pin 4 –...
  • Page 53 Pin 10 – Fuel gauge ground 2 (brown) � Pin 11 – Fuel gauge ground 1 (brown). � 11.6.3l Make sure that you put applicable insulation(s) on all fuel gauge inputs which are not connected and attach safely. 11.6.3m Make sure that you connect the 12” screen (Refer to Figure 11.6.3m) with the harness (033880).
  • Page 54 Make sure that you put applicable insulation(s) on all fuel gauge inputs which are not connected and attach safely. 11.6.4 COX CAN NETWORK - HELM 11.6.4a Make sure that you find the end of the CAN vessel harness and connect it to 3 T-piece connector(s) (034394).

  • Page 55: Outboard Oil Fill

    12.1.0 Make sure that you use the correct specification of oils as follows: Powerhead oil specification: Min standard - Fully Synthetic API CI-4 / SAE 10W40 or 5W40 � Transmission oil specification: API GL-5, 80W-90, Extreme Pressure (EP) classification. For �...
  • Page 56 12.0 OUTBOARD OIL FILL 12.8.1 If necessary, use a funnel to add new oil to the powerhead through the CCV oil separator until you get to the applicable oil level. WARNING Make sure the oil level in the CCV oil separator does not read the top or oil will enter the compressor intake pipes.

  • Page 57: Applying Grease To The Ptt

    12.16.1 Make sure that the transmission gear oil flows out through the transmission vent plug hole before you stop putting the transmission gear oil. 12.17.0 Install and tighten the transmission vent plug with a new Dowty washer, add torque to 15Nm. 12.18.0 Remove the gear oil filler tool.
  • Page 58 13.0 APPLYING GREASE TO THE PTT Figure 13.4. Grease nipple in position near the PTT lever (Left) and 3D image (right). 13.5.0 Attach the hose to the grease nipple. Make sure that you inject grease into the PTT until grease starts to flow out through the bleed hole that is adjacent to the grease nipple.

  • Page 59: Installing The Top Cowl

    14.1.0 Install the top cowl. If you are installing multiple outboards, make sure that you put each top cowl to their initial outboard. CXO300 INSTALLATION MANUAL 14.0 INSTALLING THE TOP COWL...
  • Page 60 COX POWERTRAIN LIMITED The Cecil Pashley Building Unit 8, Cecil Pashley Way Brighton City Airport Lancing, West Sussex BN43 5FF United Kingdom +44 (0) 1273 454 424 info@coxpowertrain.com www.coxmarine.com V2.30 JUL_2021...

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