MM9000 Rev-A 5-08
MM9000 Rev-A 5-08
MM9000 Rev-A 5-08
No part of this publication may be copied or reproduced in any form, including an electronic retrieval system or be
made available on the Internet, a public network, by satellite, or otherwise without the prior written permission of ZF
Marine Electronics, LLC, 12125 Harbour Reach Drive, Suite B, Mukilteo, WA 98275.
Legal Information
The information in this manual is believed to be accurate at the time of publication, but no responsibility, direct or
consequential, can be accepted for damage resulting from the use of this information. ZF Marine Electronics, LLC,
reserves the right to make changes to any of its products without notice.
Table of Contents
SW15623.OH
ClearCommand 9000 Premium (95XXX - 96XXX) Series
Operations, Installation and Troublshooting Manual
Introduction........................................................................................................................3
Manual Contents ........................................................................................................................................ 3
Basic Theory of Operation ......................................................................................................................... 3
9ZYWX Premium Processor ............................................................................................................3
System Features.......................................................................................................................................... 3
Standard Features ............................................................................................................................3
Optional Features.............................................................................................................................3
Operation ...........................................................................................................................5
DC Power On .............................................................................................................................................. 5
Taking Command....................................................................................................................................... 5
Basic Operation .......................................................................................................................................... 5
Normal Operating Mode..................................................................................................................5
Start Interlock ............................................................................................................................................ 5
Station Transfer ......................................................................................................................................... 6
Emergency Reversal Protection (Proportional Pause) ............................................................................. 6
Warm-up Mode (Throttle Only Mode) ...................................................................................................... 6
High/Low Idle............................................................................................................................................. 7
Low Idle............................................................................................................................................7
High Idle ...........................................................................................................................................7
One Lever Mode ......................................................................................................................................... 7
Turning ON One Lever Operation ..................................................................................................7
Turning OFF One Lever Operation .................................................................................................8
Engine Synchronization............................................................................................................................. 8
Criteria..............................................................................................................................................8
Types ................................................................................................................................................8
Indications........................................................................................................................................9
Turning OFF/ON when Criteria is Met...........................................................................................9
Control Systems’ Configurability .............................................................................................................. 9
Processor Functions .........................................................................................................................9
Throttle Functions..........................................................................................................................10
Clutch Functions ............................................................................................................................10
Speed Boost Functions (Optional) .................................................................................................10
Troll Functions (Optional) .............................................................................................................10
Transfer Functions .........................................................................................................................11
Troubleshooting Functions ............................................................................................................11
Audible Tones........................................................................................................................................... 11
Basic Tones.....................................................................................................................................11
Clutch Solenoid Tones...................................................................................................................12
Transfer Tones ...............................................................................................................................12
Clutch (Servo 1) Tones...................................................................................................................12
page i
Table of Contents
Installation........................................................................................................................21
Processor ...................................................................................................................................................21
Control Head(s).........................................................................................................................................21
400, MC2000, 4000 and 700 Series Control Heads...................................................................... 21
500 Series Control Heads .............................................................................................................. 21
Page ii
Table of Contents
Dock Trials........................................................................................................................47
Control Heads (Engines Stopped) ........................................................................................................... 47
Start Interlock (Engines Stopped) ........................................................................................................... 47
Basic Throttle Settings (Engines Running) ............................................................................................. 47
(E1) Throttle in Neutral..................................................................................................................47
Page iii
Table of Contents
Sea Trials..........................................................................................................................51
Full Speed Setting.....................................................................................................................................51
Proportional (Reversal) Pause Adjustments ...........................................................................................51
(C2) Reversal Pause ....................................................................................................................... 51
(C3) Proportional Pause Time ....................................................................................................... 52
Synchronization........................................................................................................................................53
Equal Throttle ................................................................................................................................ 53
Active ............................................................................................................................................. 53
Trolling Adjustments................................................................................................................................53
Basic Troll Functions..................................................................................................................... 53
Solenoid Troll ................................................................................................................................ 53
C6 & C7 ZF-Hurth [Old Type with two (2) proportional solenoids] Solenoid Trolling .......................55
Enabling ZF-Hurth Troll................................................................................................................ 55
ZF-Hurth Troll Maximum Current Adjustment............................................................................ 55
Speed Boost ...............................................................................................................................................55
Sea Trial Report........................................................................................................................................55
Vessel Information......................................................................................................................... 56
Control System Checks ................................................................................................................. 56
Record Parameters ........................................................................................................................ 58
Comments (Please use additional paper as necessary): ............................................................... 60
Page iv
Table of Contents
Appendix A
400 Series Control Head Variations..................................................................................................... A-1
MC2000 Series Standard Control Head Variations ............................................................................ A-5
4000 Series Standard Control Head Variations . ............................................................................... .A-9
700 Series Standard Control Head Variations ................................................................................... A-20
400 Series Weather Mount Enclosure................................................................................................. A-24
Deutsch Connector Assembly .............................................................................................................. A-26
Automatic Power Selector (APS) Model: 13505 ................................................................................. A-28
Grounding (Bonding) ........................................................................................................................... A-38
References and Parts Source ............................................................................................................. A-40
Engine Tachometer Sender Requirements ......................................................................................... A-42
Morse Clutch and Throttle Kit Selection ............................................................................................ A-44
Universal Mounting Kit ....................................................................................................................... A-46
43C Cable Conversion Kit .................................................................................................................... A-48
Electronic Propulsion Control Systems Three Year Limited Warranty............................................ A-50
Warranty Registration ......................................................................................................................... A-52
Appendix B
Troubleshooting General ........................................................................................................................B-1
Control System Examples .......................................................................................................................B-1
9510X-ABS (X = Zero to Four Pluggable Remote Stations) Processor ....................................... B-1
9512X-ABS (X = Zero to Four Pluggable Remote Stations) Processor ....................................... B-1
9520X-ABS (X = Zero to Four Pluggable Remote Stations) Processor ....................................... B-1
9522X-ABS (X = Zero to Four Pluggable Remote Stations) Processor ....................................... B-1
9610X-ABS (X = Zero to Four pluggable Remote Stations) Processor ....................................... B-1
9620X-ABS (X = Zero to Five pluggable Remote Stations) Processor ........................................ B-1
9622X-ABS (X = Zero to Four Pluggable Remote Stations) Processor ....................................... B-1
Typical System Main Components.........................................................................................................B-1
Control Head ................................................................................................................................ B-1
Processor ...................................................................................................................................... B-1
Power Source ............................................................................................................................... B-1
Electrical Cables and Harnesses.................................................................................................. B-2
Push-Pull Cables........................................................................................................................... B-2
Page v
Table of Contents
Page vi
Table of Contents
Appendix C
Single Screw System Drawing 13959A
Drawing 13959A-1 .................................................................................................................................. C-1
Drawing 13959A-2 ................................................................................................................................. C-2
Drawing 13959A-3 ................................................................................................................................. C-3
Drawing 13959A-4 ................................................................................................................................. C-4
Twin Screw System Drawing 13560D
Drawing 13560D-1 ................................................................................................................................. C-5
Drawing 13560D-2.................................................................................................................................. C-6
Drawing 13560D-3.................................................................................................................................. C-7
Drawing 13560D-4.................................................................................................................................. C9
Drawing 13560D-5............................................................................................................................. ...C11
Drawing 13560D-6............................................................................................................................. ...C13
Drawing 13560D-7............................................................................................................................. ...C15
Quad Screw System Drawing 14195
Drawing 14195-1 .................................................................................................................................. C-19
Drawing 14195-2................................................................................................................................... C-21
Drawing 14195-3 .................................................................................................................................. C-23
Drawing 14195-4 .................................................................................................................................. C-25
Appendix D
Service Field Test Unit Reference Manual
Revision List ........................................................................................................................................... D-1
Introduction............................................................................................................................................ D-1
Procedure: Throttle Signal Testing ....................................................................................................... D-2
DC Voltage.................................................................................................................................... D-2
Current (mA) ................................................................................................................................ D-2
Page vii
Table of Contents
Appendix E
CANtrak Display Manual
Revisions List .........................................................................................................................................E-iii
Preface..................................................................................................................................................... E-1
Conventional Symbols Used in the Manual .......................................................................................... E-1
Introduction ............................................................................................................................................ E-1
Specifications.......................................................................................................................................... E-1
Electrical ....................................................................................................................................... E-1
Environmental .............................................................................................................................. E-1
Mechanical ................................................................................................................................... E-1
Theory Of Operation .............................................................................................................................. E-1
Operation in Cruise Mode............................................................................................................ E-2
Display Configurability .......................................................................................................................... E-2
Parameter Changes....................................................................................................................... E-3
Installation .............................................................................................................................................. E-4
Required Materials ....................................................................................................................... E-4
Display (Part No. 70179) .............................................................................................................. E-4
Template ....................................................................................................................................... E-4
Wire Harnesses............................................................................................................................. E-4
System Examples .................................................................................................................................... E-5
Page viii
List of Figures
ClearCommand 9000 Premium Operation, Figure 11: Display LED A2 .......................................38
Installation and Troubleshooting Manual Figure 12: Display LED A4 .......................................38
Figure 13: Display LED A5 .......................................39
OPERATION Figure 14: Display LED E0 - Electronic....................39
Figure 1: Station taking Command............................ 5 Figure 15: Throttle Push-Pull Cable Orientation .....39
Figure 2: Control Head Detents ................................. 5 Figure 16: Display LED E0 - Servo ...........................39
Figure 3: Before Transfer of Command ....................6 Figure 17: Display LED E7 .......................................40
Figure 4: After Transfer of Command .......................6 Figure 18: Display LED C0 .......................................40
Figure 5: Control Head Warm-Up Mode ................... 6 Figure 19: Display LED C1 .......................................40
Figure 6: Control Head Normal Operating Mode ..... 6 Figure 20: Display LED C4 .......................................41
Figure 7: High/Low Idle Mode Selection .................. 7 Figure 21: Display LED C8 .......................................41
Figure 8: One Lever Operation Mode........................ 7 Figure 22: Clutch Push-Pull Cable Orientation .......41
Figure 9: One Lever Operation Mode........................ 7 Figure 23: Display LED C5 - Servo...........................41
Figure 10: Processor Pigtail Locations..................... 12 Figure 24: Clutch Push-Pull Cable Ahead Position .42
Figure 25: Display LED C6 -Servo............................42
PLAN THE INSTALLATION Figure 26: Clutch Push-Pull Cable Astern Position .42
Figure 1: Processor Dimensions .............................. 15 Figure 27: Display LED C7 - Servo...........................42
Figure 28: Display LED C5 - Solenoid......................43
INSTALLATION Figure 29: Control Head Troll Range Types ............43
Figure 1: Connector and Harness Plug Keying ....... 21 Figure 30: Display LED L0 .......................................43
Figure 2: Harness Plug Locking Mechanism........... 21 Figure 31: Display LED L1 - Solenoid ......................45
Figure 3: Start Interlock Connections...................... 22 Figure 32: Display LED F0 .......................................46
Figure 4: Twin Screw Serial Harness Figure 33: Display LED F1 .......................................46
Connections .......................................................... 22 Figure 34: Display LED F2 .......................................46
Figure 5: Liquid Tight (Watertight) Connector
Installation ............................................................ 23 DOCK TRIALS
Figure 6: Processor Hole Designations .................... 23 Figure 1: Display LED E1 .........................................47
Figure 7: Processor Circuit Board Termination Points Figure 2: Display LED E4 .........................................47
24 Figure 3: Display LED E6 .........................................48
Figure 8: Control Head Cable .................................. 25 Figure 4: Throttle Push-Pull Cable Full Throttle
Figure 9: Clamp Views ............................................. 25 Position..................................................................48
Figure 10: Terminal Strip Cable Connections......... 25 Figure 5: Display LED E3 - Servo ............................48
Figure 11: Two-Conductor Start Interlock Cable .... 25 Figure 6: Display LED E2 - Servo .............................48
Figure 12: Two-Conductor Power Cable ................. 26 Figure 7: Display LED E3 - Electronic......................49
Figure 13: AC Type Tachometer Cable ................... 26 Figure 8: Display LED E2 - Electronic......................49
Figure 14: Open Collector Tachometer Cable......... 26
Figure 15: Clutch Hard-Wired Cable ....................... 27 SEA TRIALS
Figure 16: Clutch Harness Cable ............................. 27 Figure 1: Display LED C2 .........................................52
Figure 17: Clutch/Troll Cable Heat Shrink ............. 27 Figure 2: Display LED C2 .........................................52
Figure 18: Clutch/Troll Cable Plug Connection ...... 27 Figure 3: Display LED L4 - Solenoid ........................53
Figure 19: Processor Cable Clamp Rotation............ 29 Figure 4: Display LED C6 .........................................55
Figure 20: Processor Push-Pull Cable Interior figure 5: Display LED C7 ..........................................55
Connections .......................................................... 29
Figure 21: Throttle Push-Pull Idle Orientation to CONTROL OPTIONS
Selector Lever ....................................................... 29 Figure 1: External Alarm Harness Example ............61
Figure 22: Shift Push-Pull Cable Neutral Figure 2: External Alarm Hard-Wired Example ......61
Connection............................................................ 29 Figure 3: With Processor Harness............................62
Figure 4: With Processor Hard-Wired......................62
SET UP PROCEDURES Figure 5: Speed Boost Usage Graph.........................65
Figure 1: Typical Processor Cover ........................... 31 Appendix A
Figure 2: Processor Shield Push Button and Display
LED Locations....................................................... 31 Appendix B
Figure 3: Display LED at Normal Operation ........... 31 Figure B-1: Display Function Code ........................ B-7
Figure 4: Display LED Designations ........................ 31 Figure B-2: Display Troubleshooting Function...... B-7
Figure 5: Push Buttons ............................................. 31 Figure B-3: Display Function Blinking................... B-7
Figure 6: Display Error Menu Example.................. 32 Figure B-4: Example Display of Applied Battery
Figure 7: Display Four (4) Digit Value .................... 32 Voltage ................................................................. B-7
Figure 8: Processor Circuit Board Termination Pts 33 Figure B-5: Example Display of Tach Sensor
Figure 9: Display LED A1......................................... 37 Frequency............................................................ B-7
Figure 10: Display LED A0....................................... 38 Figure B-6: Example Display Control Head Lever
Page ix
List of Figures
Page x
List Of Tables
ClearCommand 9000 Premium Operation, Table 22: Troll Functions Performed during
Installation and Troubleshooting Manual Sea Trials ...............................................................43
PREFACE Table 23: (L1) Solenoid Trolling Valve Type
Selection ................................................................43
Table 1: Premium Processor List ............................ ..1 Table 24: Troll Valve Typical Current/Pressure
Requirements for some ZF Gears .........................44
OPERATION Table 25: Solenoid Error Status Enable ...................45
Table 1: Processor Pigtail List .................................. 12
SEA TRIALS
INSTALLATION Table 1: RPM Measurement of Shaft in Normal
Table 1: Circuit Board Hard-wire Termination ...... 24 Operating Mode ....................................................54
Table 2: Processor and Control Head Hard-wiring Table 2: RPM Measurement of Shaft in Troll
Connections for Remote Stations ........................ 25 Operating Mode ....................................................54
Table 3: Processor Circuit Board Connections for Table 3: Shaft RPM Measurement of Minimum
Serial Communication Cable ............................... 26 Troll .......................................................................54
Table 4: Processor Circuit Board Connections for Table 4: Shaft RPM Measurement of Maximum
Tachometer ........................................................... 26 Troll .......................................................................54
Table 5: Processor Circuit Board Clutch Connection Table 5: Vessel Information .....................................56
and Plug Termination ........................................... 27 Table 6: Processor.....................................................56
Table 6: Processor Clutch/Troll Circuit Board and Table 7: Power Supply .............................................57
Plug Connections .................................................. 27 Table 8: Dock Trials..................................................57
Table 7: Processor Circuit Board Throttle Table 9: Sea Trials ....................................................57
Connections .......................................................... 28 Table 10: Record Processor Functions.....................58
Table 8: Engine Room/Remote Switch Circuit Board Table 11: Record Throttle Functions .......................58
Connections Points ............................................... 28 Table 12: Record Clutch Functions..........................58
Table 9: Station 2 Lockout Switch Circuit Board Table 13: Record Troll Functions ............................59
Connections Points ............................................... 28 Table 14: Record Speed Boost Functions ................59
Page 3
List Of Tables
Appendix C
Appendix D
Appendix E
CANtrak Display Manual
Table E-1: Single Station - Single Screw ................ E-5
Table E-2: Two Stations - Single Screw ................. E-5
Table E-3: Two Station - Twin Screw .................... E-6
Table E-4: Four Stations - Quad Screw .................. E-6
Page 4
REVISIONS LIST
Revision Date Revision Description
PRELIM-1 10/12/06 LDN created generic Premium Processor Book.
PRELIM - 2 12/06 SK revised per Engineering Specification
PRELIM - 3 1/11/07 LDN revising for final release.
PRELIM - 4 9-07 LG reformatting layout.
PRELIM - 5 11-07 Removed all references to Dynamic Positioning (DP) & Joystick (JS)
PRELIM - 6 02-08 Adding Terminating Resistor / Jumper Explanation and Drawing
Rev A 3-08 Engineering / Service red lines to various sections
Rev A.1 5-08 Replaced MMC-280 400 Series Standard Control Head Variation with current Rev.
Replaced MMC-329 MC2000 Standard Control Head Variation with current Rev.
PREFACE
IMPORTANT: Keep this manual in a safe place
for future reference. It contains essential WARNING: Personal injury may result if these
information about the installation and operation messages are not followed.
of the ZF Marine Electronics control system for
your vessel.
Important Information
ClearCommand Premium
WARNING: Personal Injury could occur if the
Processor List following steps are not followed exactly.
The processors for the systems listed below have
software which includes several featured options.
Information about these options is contained in this CAUTION: On Control Systems utilizing more
manual, along with all standard instructions for 9000 than one Processor, ZF Marine Electronics
series Processors. Look for details of the featured highly recommends that ALL UNITS be
options in the “Operations,” “Set Up Procedures,” upgraded to the most current Processor.
“Dock Trials,” “Sea Trials,” and (particularly)
“Control Options” sections. All vessels with CAUTION: Electro-static discharge can
Premium Processors will not necessarily use all the damage this equipment. Personnel working on
featured options. Decide on their utility based upon this equipment must be grounded to the
your application. chassis with the Anti-static Wrist Strap
provided.
Table 1: Premium Processors Covered in this Manual
Processor Part
Engine Clutch Troll
CAUTION: Disconnect the Power Harness from
Number the Power Pigtail whenever welding is being
9510X Servo 2 Servo 1 NO done on the vessel. Failure to do so can cause
9512X Servo 2 Servo 1 Solenoid permanent damage.
9520X Servo 2 Solenoid NO
CAUTION: This equipment is designed to work
9522X Servo 2 Solenoid Solenoid with other ZF Marine Electronics designed
9610X Electronic Servo 1 NO equipment. DO NOT operate this equipment
9612X Electronic Servo 1 Solenoid with any other manufacturers equipment unless
9620X Electronic Solenoid NO approved so in writing by ZF Marine Electronics
9622X Electronic Solenoid Solenoid Engineering Department.
X = 0 to 5 remote station pigtails supplied
CAUTION: Misapplication of the Speed Boost
Available Options for the Premium feature can damage the transmission or other
Processors Covered in this Manual equipment. Before using Speed Boost, the
• CANtrak Display transmission representative must be consulted
• Engine Room/Remote Switch (Station 1 only) about its use, and any limitations on clutch
• Station 2 Lockout engagement as a function of engine speed.
• Speed Boost The person(s) implementing Speed Boost have
• Fixed Neutral Delay the responsibility for ensuring it is properly
adjusted and for any damage that might occur.
1
Preface
2
INTRODUCTION
This manual is written to document every possible Throttle:
system option. Your system may not include every • mechanical engine governors
available option for single or multi-screw reverse • electronic engine governors
reduction gear applications. Only those sections that Transmissions:
apply to your specific installation are relevant to your
• mechanical activated clutches
vessel.
• solenoid activated clutches
If additional options described within this manual • solenoid controlled trolling valves
are desired, contact your dealer for availability/
Refer to PREFACE, Table 1, for list of Processors.
compatibility with your system.
3
Introduction
4
OPERATION
DC Power On NOTE: Only one Station can have command at
When DC power is turned ON to the Processor: a time.
• A short steady tone, followed by an intermittent NOTE: If Station 2 Lockout Switch is used:
tone, will sound at all Remote Stations (Refer to the "Control Options" Section for more
indicating that no station has command. info.)
• The Start Interlock relay contact will remain
Switch Closed (Station 2 only): When Station 2
open, preventing engine start.
has command, no other Remote Station can
• Throttle:
take command away. (Only Engine Room
– Electronic: The throttle signal will be
Station can take away command, if used)
commanded to Idle.
– Servo: The throttle servo will drive to Idle. Switch Open (Remote): Command can be
• Shift: taken at any Station.
– Solenoid: The Ahead and Astern shift
WARNING: An Engine STOP Switch MUST be
solenoids will be de-energized, commanding
installed at every remote operating station.
Neutral.
Refer to CFR 46, Section 62.35-5 (US Coast
– Servo: The Shift servo will drive to Neutral.
Guard) and ABYC P-24.5.8.
• Troll:
– Solenoid: The trolling valve solenoids are
commanding lock-up. Basic Operation
NOTE: If utilizing an Engine Room/Remote Normal Operating Mode
Switch ensure you have read the Engine Room/
Remote Switch explanation in the "OPTIONS" A) The Control Head has three detents: Ahead,
Chapter of Section 2 - OPERATION, before Astern and Neutral.
turning DC Power ON to the Processor(s). B) With the Control Head lever positioned in the
Neutral (vertical) detent, the Processor will
NOTE: If utilizing a Station 2 Lockout Switch
command Neutral and the throttle at Idle
ensure you have read the Station 2 Lockout revolutions per minute (RPM).
Switch explanation in the "OPTIONS" Chapter of
Section 2 - OPERATION, before turning DC C) Movement of the Control Head’s lever 15 degrees
Power ON to the Processor(s). to the Ahead or Astern detent will command
Ahead or Astern clutch engagement, while the
engine RPM remains at Idle.
Taking Command FIGURE 2: CONTROL HEAD DETENTS
To take command at any one of the Remote Stations:
A) Full Speed Astern
• Ensure all Control Head’s lever(s) at the Station B B) Astern Detent
are in the Neutral detent (vertical position).
C) Neutral Detent
• Depress the transfer button for 1/2 second.
D) Ahead Detent
FIGURE 1: STATION TAKING COMMAND E) Full Speed Ahead
A F) 80 degrees
G) 65 degrees
H) 15 degrees
D) Further movement of the Control Head lever
through the next 65 degrees, will increase the
The Slow Repetitive tone will stop at all Stations, and engine RPM in proportion to the Control Head’s
the red LED indicator light will turn ON at the lever position.
Control Head of the Station that had assumed
command of the Control System.
Start Interlock
NOTE: If Start Interlock is used: Once a Station The engine start signal is blocked unless all of the
is in command the Start Interlock relay contact following are true:
will close, allowing the engine to start. • DC power has been turned ON to the Control
NOTE: If Engine Room/Remote Switch is used: System.
(Refer to the Control Options section for more • A Remote Station is in command.
info.) • The Control System is commanding Neutral.
Switch Closed (Engine Room): Only the Engine
Room Station can take command of the
System.
Switch Open (Remote): Command can be
taken at any Station.
5
Operation
6
Operation
G) The next movement of the Control Head’s lever NOTE: The Green LED will always be lit while in
will engage the Ahead or Astern clutch (Normal One Lever Operation, no matter which position
Operation). the Master Control Head lever is in.
Selecting Between High and Low Idle Turning ON One Lever Operation
WARNING: Personal Injury could occur if the A) At the Station-in-Command, move all the Control
following steps are not followed exactly. Head levers to the Ahead detent.
FIGURE 8: ONE LEVER OPERATION MODE
Refer to the following Figure when selecting
betweenLow and High Idle (or vise versa) at the
Statin-in-Command.
A) The Control Head’s lever(s) may be in the Neutral,
Ahead or Astern detents when making a selection.
FIGURE 7: HIGH/LOW IDLE MODE SELECTION B) Depress and Hold the transfer button while
moving one of the Control Head levers forward,
out of the Ahead detent. Do Not Release the
Transfer Button until the green LED turns ON,
indicating One Lever Operation is now active.
FIGURE 9: ONE LEVER OPERATION MODE
B) Depress and hold the transfer button for 1/2
second and then release.
•If the System was in Low Idle it will toggle to
High Idle, and vice versa.
C) To return to the previous Idle setting, depress and
hold the transfer button again for 1/2 second and
then release. • The Control Head lever which the operator
chose to move out of the Ahead detent, becomes
NOTE: In Multiple Srew applications: Always the Master lever.
program all the Processors for the same amount • The Control Head lever(s) which was left in the
of High Idle. Ahead detent is now inactive.
All Processors will be in High or Low Idle at the
NOTE: The Control Head lever(s) designated by
same time.
the operator to be inactive in One Lever
Operation, may be left in the Ahead detent or
One Lever Mode
.
moved fully forward. Moving the lever fully
forward is recommended, because it moves it
out of the way and prevents accidental bumps
NOTE: This mode is not available for Single
while operating.
Screw Applications
7
Operation
8
Operation
9
Operation
A1 Number of Engines - Lets the Processor know electrically in order to eliminate "dead lever".
how many other Processors need to be Dead lever in this case can be described as a
communicated with. movement of the Control Head lever without a
•SINGLE SCREW: DO NOT ADJUST. Leave at change in the engine’s RPM.
Default Value. E3 Throttle Maximum - Adjusts the position or
•MULTI SCREW: This function must be the
amount of travel of the push-pull cable at Full
FIRST FUNCTION SET.
Throttle.
A2 One Lever Operation - Allows the installer to
disable or enable One Lever Mode capability. E4 Throttle Maximum Astern - Limits the amount
•SINGLE SCREW: DO NOT ADJUST. Leave at of the Astern Throttle Servo movement.
Default Value.
Clutch Functions
A3 THIS PARAMETER IS NOT AVAILABLE AT THIS
TIME. BASIC CLUTCH FUNCTIONS
A4 Neutral Indication Tone - When enabled, The following functions are available for all types of
produces a short 200 Hz tone to indicate Neutral. clutches.
A5 Engine Room/Remote Switch and/or Station 2 C0 Clutch Pressure Interlock - Selects the Clutch Oil
Lockout Switch - Allows the installer to enable or Pressure Interlock option. The interlock prevents
disable one or both of these features. a throttle signal above Idle from being applied
unless adequate clutch pressure is available.
Throttle Functions C1 Clutch Interlock Delay - Determines when the
BASIC THROTTLE FUNCTIONS Clutch Oil Pressure Interlock becomes active.
E1 Throttle in Neutral - Adjusts the Throttle when C2 Proportional (Reversal) Pause - Selects between
in Neutral, independent of the throttle output an In-Gear, Neutral, or Fixed Neutral delay.
when the clutch is engaged. C3 Proportional (Reversal) Pause Time - Selects the
maximum delay time during a full speed reversal.
E5 Throttle Pause following Shift - Allows the
C4 Proportional (Reversal) Pause Ratio -
adjustment of time between clutch engagement
Determines if the Ahead and Astern reversal
command and when throttle begins to increase
times are the same or if Astern is 1/2 of Ahead
above Idle.
time.
E6 High Idle - Programs a second/elevated Idle C8 Fixed Neutral Delay - Provides an adjustable
RPM. fixed Neutral delay in addition to any
E7 Synchronization - Allows the installer to select proportional delay, regardless of commanded
synchronization and select the type of speed and direction.
synchronization. SOLENOID CLUTCH FUNCTIONS
•SINGLE SCREW: DO NOT ADJUST. Leave at
This section along with the "Basic Clutch Functions"
Default Value.
Section allows the adjustment of Clutch Solenoid
ELECTRONIC THROTTLE FUNCTIONS related items:
This section along with Basic Throttle Functions
IMPORTANT: The following Functions are to be
allows the adjustment of the Electronic Throttle:
used on Hurth gears with two (2) proportional
E0 Engine Throttle Profile - Selects the throttle solenoids ONLY! Do not use on Hurth gears
signals type and range. with ON/OFF solenoids.
E2 Throttle Minimum - Allows fine tuning of the
C5 Shift Solenoid Type - Selects the approximate
throttle signal at Idle.
current levels for the 12 or 24 VDC ZF Hurth
E3 Throttle Maximum - Allows fine tuning of the Proportional Solenoids.
throttle signal at Full.
C6 ZF-Hurth Duty Cycle Ahead - Fine tunes the
E4 Throttle Maximum Astern - Allows the installer maximum current level to the Ahead
to limit the amount of throttle allowed when Full Proportional Solenoid.
Astern is commanded.
C7 ZF-Hurth Duty Cycle Astern - Fine tunes the
SERVO THROTTLE FUNCTIONS maximum current level to the Astern
This section along with "Basic Throttle Functions" Proportional Solenoid.
allows the adjustment of the Servo Throttle: SERVO CLUTCH FUNCTIONS
E0 Throttle Servo Direction - Selects whether the This section along with the "Basic Clutch Functions"
Throttle Servo pushes or pulls to increase speed. Section allows the adjustment of Clutch servo related
items:
E2 Throttle Minimum - Once set mechanically at
the Idle stop, this Function Code allows the C5 Clutch Servo Direction - Determines if the servo
position of the push-pull cable to be adjusted pushes or pulls for Ahead and Astern.
10
Operation
Troll Functions (Optional) This tone is normal when DC power is first applied to
The L0 Troll function is the only Troll function code the System. This tone indicates that system
displayed unless Troll is activated using L0. When initialization has occurred, no Remote Station has
activated, Function Codes L1 through L6 are command, the operator can accept command at any
displayed. Remote Station.
SOLENOID TROLL FUNCTIONS This tone is heard if there is a stuck transfer button,
L1 Troll Valve Function - Selects the proper current or when entering Back-up Mode, or if a Troll
range for a particular gear. If ZF Hurth Gears Solenoid error occurs. (Back-up Mode and Troll
with two (2) proportional solenoids are used, Solenoid is not available for all Processors.)
this Function must be the 3RD function set; eg, FIVE SECONDS ON, FIVE SECONDS OFF - HIGH
after A1 (first) and A0 (second). REPETITIVE RATE TONE ( NOT ENABLED)
L2 Troll Minimum Pressure - Adjusts the amount of
current at minimum Shaft rotation. This tone is not enabled for ClearCommand.
L3 Troll Maximum Pressure - Adjusts the amount of
current at maximum Shaft rotation (not
maximum pressure).
11
Operation
This tone indicates that the feedback potentiometer Table 1: Processor Pigtail List
signal from Servo 2 (Throttle) has gone out of range. FIGURE
QTY DESCRIPTION
ID
ONE LONG, TWO SHORT - HIGH REPETITIVE TONE
(JAM) A 1 Pigtail connector is provided for serial
communication between multiple
This tone indicates that Servo 2 (Throttle) cannot Processors.
reach the commanded position. This tone is also (This pigtail is also used for CANtrak Display
connection.)
referred to as Servo 2 Jam Tone.
B 1 Pigtail connector provides connection for
Troll Solenoid Tones electronic throttle.
(Pigtail [B] not supplied if Servo Throttle is used)
THREE SECOND STEADY TONE (H2 ENABLED)
C 1 Pigtail connector is provided for the
This tone indicates that the Troll Solenoid is OPEN Tachometer Sensor input used in multi
or shorted. Refer to the Error Code displayed for screw Active Synchronization.
further information. D 0 - 5 Pigtail connector provides the
connections for Remote Station Control
Heads.
Push Button Set Up 1 Pigtail connector provides the
D1
There are four (4) push buttons mounted to the connection for a Station 5.
Processor’s circuit board. These push buttons allow 1 Pigtail connector provides the
the installer/technician access to all of the Functions D2
connection for Station 4.
required for programming and troubleshooting the
G 1 Pigtail connector provides the
control system.
connections for DC Power, Start
A full description of their usage is provided in "Set Interlock, (optional) Clutch Oil Pressure
Up Procedures". Interlock (optional) and External Alarm
contact (optional).
Visual System Diagnostics, Set H 1 Pigtail connector provides the
Up And Status Indication connection to the solenoid clutch & Troll.
(Pigtail [H] not supplied if Servo Shift is used)
There are four (4), seven (7) segment LED’s
(hereafter referred to as the Display LED) mounted to
the Processor’s circuit board. The Display LED is
visible through a transparent window in the
Processor’s cover. The information displayed is used
in conjunction with the push buttons to program the
Processor. The Display LED also displays Error
Codes in the event that an anomaly is detected.
12
Operation
13
Operation
14
PLAN THE INSTALLATION
• Bulkhead mounting is the preferred method
NOTE: ZF Marine Electronics recommends that
due to ease of access for wiring and
the system be installed in accordance with ABYC,
adjustments. However, the Processor can be
E-11 and P24.
mounted in any attitude as long as the Display
LED window and push buttons are accessible.
System Requirements • Locate the Processor(s) away from sources of
The first step when installing a System is to carefully high heat, such as engine exhaust manifolds or
plan the installation. This includes finding proper turbochargers. Allow 4 feet (1,2m) of clearance
mounting locations for the Processor(s) and Control or more.
Heads. The decision must be made on where power • Do not mount the Processor on the engine,
is going to be sourced and how the power will be transmission, or in any location that will subject
routed to the Processor(s). it to excessive vibration.
• Do not mount the Processor to the transom
FIGURE 1: PROCESSOR DIMENSIONS
when the vessel is equipped with a surface
3.20 10.71
piercing drive system (due to vibration
(81,3mm) (272mm) concerns).
10.40
(264,2mm)
• Do not mount the Processor(s) in close
4.75 6.70
(120,7mm) (170,2mm) proximity to gas engine ignition systems,
2.69
(68,3mm) alternators, generators or any equipment
2.70
(68,6mm)
12256-
producing strong magnetic fields. Allow 4 feet
10.25
(260,4mm) (1,2m) clearance or more.
Once the locations have been decided, lengths of CAUTION: Strong magnetic fields can
electrical wiring, harnesses and push-pull cables influence the Processor’s electronic circuits and
must be determined. void your warranty.
• Grounding (Bonding) is required for maximum Control Head(s)
electromagnetic compatibility (EMC)
performance. Refer to Appendix A - Grounding Refer to Appendix A - Control Head Variations
(Bonding). Service Sheets for information on the various
• SERVO PROCESSORS: Locate the Processor Control Heads available and their dimensions.
such that the push-pull cables have the shortest, • Control Heads are available with pluggable
most direct path to the selector lever. The push- pigtails or may be hard-wired (no pigtails).
pull cable length should not exceed 20 feet • Retrofit applications may require an Adapter
(6,0m), the bend radius should not be less than Pad to cover the old Control Head cutout. A
18 inches (254mm) and the total degrees of variety of Adapters and Cover Pads are
bends must be less than 270 degrees. available. If an Adapter/Cover Pad is required,
please contact a ZF Marine Electronics
Only when the locations and lengths of wiring/
Representative for further information.
harnesses have been determined, should you start
• Ensure that the clearance is sufficient for the
the actual installation. The following sections
Control Head’s lever to reach full Ahead and
describe the requirements for installing the
full Astern.
components and selecting mounting locations.
• The Control Head can be mounted at any
Processor(s) location on the vessel, as long as all of the
criteria listed above are met.
Processors required per engine: • A Handheld is available to use, instead of a
• Single Screw: One (1) Processor mounted Control Head. Refer to the
• Twin Screw: Two (2) Processors Installation Manual supplied with the Handheld
Mounting Hardware is installer supplied. for additional information on the planning of
Installation/Troubleshooting Manual is included the installation.
with the Processor. • A 500 Series side mounted Control Head is
available to use, instead of a top console
The following items must be taken into account mounted Control Head. Refer to the
when selecting the location for the Processor(s): Installation Manual supplied with the 500
• The Processor is spray proof, but not water Series Control Head for additional information
proof. Therefore, an area must be selected that on the planning of the installation.
typically stays dry. • The 400 and MC2000 Series Control Heads are
• The engine room is the preferred location for spray proof from the top, but must be protected
mounting the Processor. If the engine room is from the weather on the underside.
too small, locate in any area where it is easily • When a 400 or MC2000 Series Control Head
accessible, as long as all of the criteria listed are must be mounted in a location where the
met. underside may be exposed to the weather,
15
Plan The Installation
consider using a Weather Mount Enclosure. • The Harness is available in lengths up to 30 feet
Refer to the Appendix A - Weather Mount for (9,14m) for 12 VDC systems, and up to 60 feet
specific information. (18,2m) for 24 VDC systems.
• The following minimum safe mounting distance
must be maintained between each specified Serial Communication Harness
Control Head model and any Magnetic The Serial Communication Harness is only required
Compass: in:
Control Head Model - Min. Safe Compass Distance • Multi Screw applications
MC2000 Series 250 mm (9.8 in) • When a CANtrak Display is utilized.
400 Series 100 mm (3.9 in) The Harness interconnects the Processors to each
500 Series 150 mm (5.9 in) other. A plug is attached at both ends of the Serial
Harness.
700 Series 500 mm (19.7 in)
• Multi Screw Harness required in Twin Screw
4000 Series 150 mm (5.9 in) applications with CANtrak or Triple Screw or
Handheld 500 mm (19.7 in) more applications.
• The 700 Series Control Heads are fully spray Twin Screw: One (1) Serial Harness (part no. 13316-
proof. (IP56) X)
CANtrak Display Panel(s) Additional Harnesses
Refer to Appendix D - MM70179 CANtrak Display Not all of the following harnesses may be required
Panel Manual for information on the Panel for your application. For further information
requirements and dimensions. regarding Wire Harness requirements, contact a ZF
Marine Electronics Representative. The following
Wire Harnesses lists the additional Harnesses available that plug into
the Processor:
For further information regarding Wire Harness
requirements, contact a ZF Marine Electronics CLUTCH HARNESS
Representative. The following lists the various • One Harness required per Processor.
Harnesses that plug into the Processor: • The Harness consists of 2 two-conductor cables
for Ahead and Astern Clutch Solenoids.
Control Head Harnesses CLUTCH/TROLL HARNESS
• One Control Head Harness is required for every One Harness required per Processor. The Harness
Control Head lever at every Remote Station. consists of:
• The Control Head Harnesses are available in
• 2 two-conductor cables for Ahead and Astern
various lengths.
Clutch Solenoids.
• Harnesses are available with plugs on both ends
• 2 two-conductor cables for Troll ON/OFF and
or a plug on the Processor end only.
Troll Proportional Solenoids.
• The Harness from the Port side of a Control
Head must be routed to the Port Processor. NOTE: Some transmissions only utilize one
• The Harness from the Starboard side of a solenoid for troll, therefore, the harness would
Control Head must be routed to the Starboard consist of only three cables.
Processor. • The Power for the clutches and troll are
Power, Start Interlock, Clutch Pressure supplied by the Processor’s power source.
• All of the cables in the Harness are the same
(Optional), Alarm (Optional), Backup length. Therefore, order a length that will
(Optional) Harness reach all of the previously mentioned items, if
• One Harness required per Processor Power, required.
Start Interlock, Clutch Pressure Switch, Alarm THROTTLE HARNESS
Pigtail. • One Harness required per Processor.
• The Harness is plugged at the Processor Pigtail • There are four (4) types of Throttle Harnesses:
end only. • Voltage,
• In addition to the required DC power and Start • Current,
Interlock, the Harness has options for Clutch • PWM (Pulse Width Modulation),
Oil Pressure Switch, External Alarm Circuit and • and Frequency.
Backup that are available. • Most Throttle Harnesses are plugged at the
• All of the cables in the Harness are the same Processor side only.
length, therefore, order a length that will reach • Some Throttle harness types are available with
all of the previously mentioned items, if plugs on both ends.
required. •
16
Plan The Installation
17
Plan The Installation
18
Plan The Installation
19
Plan The Installation
20
INSTALLATION
NOTE: Before starting the installation of the Harness Plug Insertion and Extraction
Control System, make sure you have the correct A) Prior to inserting the Harness plug, pay close
parts and tools on hand. Refer to "Plan The attention to the number of pins and the keying of
Installation" section. Read ALL the instructions the plug. The plug is designed to be inserted one
pertinent to each part before beginning the way only into the connector, but can be
installation of the part. incorrectly forced together in the opposite
CAUTION: Static electricity can destroy orientation.
electronic components. Connect the wrist B) When connecting the plugs, ensure that the
strap provided, to the Processor frame locking mechanisms are depressed and held until
whenever working on the Processor with the the plug is fully connected or disconnected.
enclosure cover open. This will drain any static FIGURE 1: CONNECTOR AND HARNESS PLUG KEYING
charge you may have on your person.
Pigtail Connector Harness Plug
Processor
A) Secure the Processor to the mounting surface
with three 1/4 inch or M6 fasteners, leaving the
fourth fastener unused at this time.
B) Connect the Processor to the Hull or Grounding FIGURE 2: HARNESS PLUG LOCKING MECHANISM
Bus by running a 12 AWG or larger wire between
the Processor’s fourth mounting fastener and the
Grounding Bus. (The Processor is grounded if
mounted directly to a metallic surface that is
connected to a metal hull) (Refer to Appendix A -
Grounding)
Power/Start Interlock/Alarm/(optional)
Control Head(s) Clutch Pressure (optional) Harness
400, 700, MC2000 and 4000 Series This Harness can have a minimum of two (2) cables
Control Heads (DC Power and Start Interlock) up to a maximum of
four (4) cables (Power, Start Interlock and/or Clutch
Refer to the appropriate Control Head Dimensions
Pressure Interlock and External Alarm Circuit).
and Variations Service Sheet in Appendix A for
installation. DC POWER CABLE
(Refer to Appendix A - Automatic Power Selector)
500 Series Control Heads
A) Insert the Harness’s black, twelve pin plug into
Refer to the Installation Manual supplied with the the Processor’s Power/Start Interlock Pigtail
500 Series Control Head Assembly for installation connector.
instructions. B) Run the cable to the DC Distribution Panel or the
Handheld Remote Controls optional Power Relay.
C) Strip back the appropriate amount of PVC
Refer to the Installation Manual supplied with the
jacketing and conductor insulation.
Handheld Remote for installation instructions.
D) Crimp the appropriate connectors to the
conductors.
Display Panel(s) E) Terminate the conductors to the DC Power
Refer to MM70179 CANtrak Display Manual in Source.
Appendix D for installation. Start Interlock Cable
(Refer to Figure 3)
Wire Harness Installation A) Run the cable to the Engine’s Starter Solenoid.
B) Disconnect the Starter Switch wire from the
The 9000 Premium Processor is supplied with Solenoid.
various Pigtails with connectors depending on the
C) Strip back the appropriate amount of PVC
Processor being supplied. Harnesses required will
jacketing and conductor insulation.
depend on the actual Processer used.
D) Connect one of the conductors to the Solenoid’s
Four different styles of plugs and connectors are Starter Switch terminal.
utilized but are inserted in an identical fashion as
follows: E) Butt splice the second wire to Starter Switch wire.
21
Installation
22
Installation
Hard-Wired Cable
Liquid Tight (Watertight) Connector
All cables that enter the Enclosure must go through a
Liquid Tight Connector in order to maintain the
moisture resistant integrity of the Processor. These
connectors must be assembled as shown in Figure 5:
FIGURE 5: LIQUID TIGHT (WATERTIGHT) CONNECTOR
INSTALLATION
Processor
Securing Enclosure
Nut Body
Nut
Cable
Grommet
12278
23
Installation
24
Installation
D) Place on your wrist the anti-static wrist strap Table 2: Processor and Control Head Hard-wiring
provided, attach the strap to ground, and then Connections for Remote Stations
remove the cover from the Processor.
Right Hand
Conduct Left Hand (Port)
E) Run the seven-conductor cable for each remote Circuit Board
or Control Head
(Stbd)
station through the corresponding liquid tight Termination Control Head
Color Lever
Lever
cable grip on the Processor to the appropriate
Station terminal block. Do not tighten cable grip TB1-1 thru TB5-1 Black Pin 1 Pin 1
at this time. TB1-2 thru TB5-2 Brown Pin 2 Pin 2
FIGURE 8: CONTROL HEAD CABLE
TB1-3 thru TB5-3 Red Pin 3 Pin 3
TB1-4 thru TB5-4 Orange Pin 4 Pin 4
TB1-6 thru TB5-6 Green Pin 6 Pin 6
TB1-7 thru TB5-7 Blue Pin 5 Pin 7
TB1-8 thru TB5-8 Violet Pin 8 Pin 8
Jumper Jumper
between Pins between Pins
F) Strip the PVC jacket and shielding approx. 4-1/2
3 and 7 3 and 5
inches (114,mm) on the cable.
G) Secure the seven-conductor cable to the frame START INTERLOCK CABLE (LOCATION D)
using a conductive Clamp. Ensure that the Clamp Connection at the Starter Solenoid
and Shield wire come in contact with one A) Run the length of two-conductor cable between
another. Refer to Figure 9. the Engine’s Starter Solenoid and the Processor.
H) Clip the Shield wire so that it is flush with the B) Disconnect the Starter Switch wire from the
Clamp. Strip the wire 3/8 inch (9,5mm) on each Solenoid.
lead.
C) Strip back the appropriate amount of PVC
I) Pull the Shield Wire back against the PVC jacket. jacketing and conductor insulation.
J) Slide and shrink a piece of 3/8 inch (9,5mm) D) Connect one of the conductors to the Solenoid’s
wide. X 1 inch (25,4mm) long. heat-shrink over Starter Switch terminal using an approprite
the cable. connector such as a crimp on ring terminal.
FIGURE 9: CLAMP VIEWS E) Butt splice the second wire to Starter Switch wire.
Connection at the Processor
A) Install a liquid tight connector into entry hole (No.
D). (Refer to Figure 6)
B) Run enough of the two-conductor power cable
through the liquid tight cable grip so that it can be
routed to PB2 terminal block on the Circuit Board
as shown in the ( Figure 7) Processor Circuit
Board Termination Points Figure.
C) Strip back 3 inches (76,2mm) of the PVC
jacketing. Refer to Figure 11.
FIGURE 11: TWO-CONDUCTOR START INTERLOCK CABLE
K) Connect the conductors to the appropriate
Terminal pins, as shown on Table 2:, using a small
slotted screwdriver as shown in Figure 10:
L) Connect the other station's seven-conductor
cables to the appropriate station terminal strips in
the same way.
FIGURE 10: TERMINAL STRIP CABLE CONNECTIONS D) Strip each wire 3/8-inch (9,5mm).
E) Place a 3/8 inch (9,5mm) section of shrink tubing
over the cable and heat.
F) Crimp fork or ring terminals to the wires.
G) Connect the two-conductor cable to terminal
block PB2, red lead to the terminal labeled (1) and
yellow lead to the terminal labeled (2), as
indicated on Processor Circuit board Termination
Points, Figure 7.
H) Tie wrap the start interlock cable to the
Processor’s frame.
25
Installation
Heat Shrink
G) Shrink the tubing with a heat gun.
H) Crimp fork or ring terminals to the wires.
H) Insert the cable ends through the liquid tight
I) Connect the two-conductor cable to terminal connectors and tighten the nuts.
block PB1, red lead to the terminal labeled (+) and
I) Secure the cables internally using a Clamp. Make
black lead to the terminal labeled (-), as indicated
certain that the drain wire makes contact with the
on Processor Circuit board Termination Points
Clamp’s metallic surface.
Figure 8.
J) Clip the exposed drain wires flush with the
J) Tie wrap the power cable to the processor’s
Clamps.
frame.
K) Connect the conductors to the terminal block as
Table 3: Processor Circuit Board Connections for listed in Table 4:.
Serial Communication Cable
Table 4: Processor Circuit Board Connections for
Port Processor Starboard Processor Tachometer
Conductor Color
Termination A Termination B
White TB7-6 TB7-6 Conduct Processor
or Terminatio Description Notes
Green TB7-7 TB7-7 Color n
Red TB7-8 TB7-8 Red TB9-1 Sensor Required when Open
Black TB7-9 TB7-9 Supply Collector (i.e., Hall
(+9VDC) Effect Sensors) only
Silver (Drain Wire) Clamp No Connection
Green TB9-2 AC Type The green wire
TACHOMETER CABLE (LOCATION L)
Tachometer connects here when
A) Run a two-conductor (AC Type) or three- Input AC Type Tach
conductor (Open) shielded cable from the Port Sensors (i.e.,
Processor to the Port engine’s tachometer source. Mechanical Senders,
(Refer to "Plan The Installation" section.) Magnetic Pickup,
NOTE: Three-conductor cable is required with Alternator AC, etc.)
Open Collector Type (Hall Effect) Tachometer are being used.
Senders only. TB9-3 Open The green wire
B) Run a two- or three-conductor shielded cable from Collector connects here when
the Starboard Processor to the Starboard engine’s Tachometer an Open Collector
tachometer source. Input Type Tach Sender is
used.
C) Install a 1/2 inch (12,7mm) liquid tight cable grip
into the appropriate hole of the Port and Black TB9-4 Return for Negative connection
Starboard Processors. Tachometer for both types of
Input Senders.
26
Installation
Table 4: Processor Circuit Board Connections for Table 5: Processor Circuit Board Clutch Connection
Tachometer and Plug Termination
Conduct Processor PROCESSOR PLUG
or Terminatio Description Notes
Color n Description Conducto Conducto
Terminatio Terminatio
r r
Silver Clamp Drain Wire Connection made at n n
Color Color
(Shield) Processor side only. Ahead Clutch Brown TB11-2 Pin 3 Brown
connection Solenoid ( + )
CLUTCH CABLE (LOCATION H) Ahead Clutch Green TB11-6 Pin 4 Green
A single four-conductor cable must connect the two Solenoid ( - )
Shift solenoids to the Processor through a twelve (12) Astern Clutch Black TB11-1 Pin 5 Black
pin plug. Solenoid ( + )
Processor Termination Astern Clutch Yellow TB11-5 Pin 6 Yellow
A) Install a liquid tight connector into the Solenoid ( - )
appropriate hole of the Processor. CLUTCH/TROLL CABLE (LOCATION H & I)
B) Run a 32 inch (81,28cm) piece of four-conductor A single eight-conductor cable must connect the two
cable through the liquid tight connector 16 inches Shift and two Troll solenoids to the Processor
(40,64cm) and tighten. Leave 16 inches (40,64cm) through a 12 pin plug.
outside of the Processor. Processor Termination
C) Strip back 4 inches (101,6mm) of the PVC jacket A) Install a liquid tight connector into hole no.10.
inside the Processor.
B) Run a 32 inch (81,28cm) piece of eight-conductor
D) Slide a 1 inch (24,5mm) piece of heat shrink over the end cable through the liquid tight connector 16 inches
of the cable as shown in Figure 16. (40,64cm) and tighten. Leave 16 inches (40,64cm)
FIGURE 15: CLUTCH HARD-WIRED CABLE outside of the Processor.
1 inch 4 inches C) Strip back 4 inches (101,6mm) of the PVC jacket
(25,4mm) (101,6mm)
3/8 inch inside the Processor.
(9,53mm)
D) Slide a 1 inch (24,5mm) piece of heat shrink over
the end of the cable as shown in Figure 17:.
Heat Shrink
FIGURE 17: CLUTCH/TROLL CABLE HEAT SHRINK
E) Strip back 3/8 inch (9,53mm) from the four
1 inch 4 inches
conductors and connect to the Processor as shown (25,4mm) (101,6mm)
in the following Table. 3/8 inch
(9,53mm)
Plug Termination
A) Strip back 2 1/4 inches (57,15mm) of PVC
jacketing. Heat Shrink
B) Slide the boot onto the cable.
E) Strip back 3/8 inch (9,53mm) from the eight
C) Strip back 1/4 inch (6,35mm) from the four conductors and connect to the Processor as shown
conductors. in the Table 6:.
FIGURE 16: CLUTCH HARNESS CABLE
Plug Termination
A) Strip back 2 1/4 inches (57,15mm) of PVC
jacketing.
B) Slide the boot onto the cable.
C) Strip back 1/4 inch (6,35mm) from the eight
conductors.
D) Crimp Pins onto the eight conductors.
D) Crimp Pins onto the eight conductors.
E) Insert the pins into the appropriate terminations
as shown Figure 7 in the Processor Circuit board FIGURE 18: CLUTCH/TROLL CABLE PLUG CONNECTION
Termination Points Figure.
F) Slide the boot over the connector.
G) Tie-wrap the boot in place.
27
Installation
Table 6: Processor Clutch/Troll Circuit Board and Plug E) Terminate the cable’s conductors to the
Connections appropriate points.
PROCESSOR PLUG F) Secure the cable using tie-wraps.
DESCRIPTION Conducto Terminatio Terminatio Conducto G) Repeat steps A) through E) for all Processors.
r Color n n r Color
Table 8: Engine Room/Remote Switch Circuit Board
Ahead Clutch Brown TB11-2 Pin 3 Brown Connections Points
Solenoid ( + )
Processor
Description Switch Termination
Ahead Clutch Green TB11-6 Pin 4 Green Termination
Solenoid ( - ) ER Switch ( + ) TB10-1 ER Only/Remote Switch
Astern Clutch Black TB11-1 Pin 5 Black Contact
Solenoid ( + ) ER Switch ( - ) TB10-2 ER Only/Remote Switch
Astern Clutch Yellow TB11-5 Pin 6 Yellow Contact
Solenoid ( - )
Station 2 Lockout Switch (Location N)
Troll ON/OFF Orange TB11-4 Pin 9 Orange
Solenoid ( + ) (Optional)
Troll ON/OFF White TB11-8 Pin 10 White For Switch and Operator installation guidelines,
Solenoid ( - ) refer to the installation instructions supplied with
Troll Red TB11-3 Pin 11 Red them.
Proportional • Connect the cable’s conductors to the switch’s
Solenoid ( + ) contacts per the manufacturers instructions.
Troll Blue TB11-7 Pin 12 Blue A) Processor Circuit Board Connections:
Proportional B) Run the appropriate 2-Conductor cable from the
Solenoid ( - ) location of the Station 2 Lockout Switch to the
THROTTLE CABLE (LOCATION K) Processor.
The Throttle connection is prewired at the factory. C) Run the cable through the appropriate liquid tight
Engine Shield connector at the Processor.
D) Route the cable to TB10 on the Circuit Board,
Table 7: Processor Circuit Board Throttle Connections
making sure that the cable is NOT laying on the
PROCESSOR Circuit Board.
TERMINATION
THROTTLE TYPE E) Terminate the cable’s conductors to the
Conducto Conducto
Signal Return appropriate points.
r Color r Color
DC Voltage (0 Orange TB8-5 TB8-7 Black F) Secure the cable using tie-wraps.
to 5.0 VDC) G) Repeat steps A) through E) for all Processors.
Current (4.0 to Red TB8-4 TB8-7 Black Table 9: Station 2 Lockout Switch Circuit Board
20.0 mA.) Connections Points
PWM (0 to Brown TB8-3 TB8-7 Black Processor
99%) Description Termination Switch Termination B
A
Frequency White TB8-6 TB8-7 Black
LO Switch ( + ) TB10-3 Station 2 Lockout Switch
Idle Validation Positive Negativ Contact
TB8-1 e TB8-2
LO Switch ( - ) TB10-4 Station 2 Lockout Switch
Engine Room/Remote Switch (Location Contact
M) (Optional)
For Switch and Operator installation guidelines, Engine Stop Switches
refer to the installation instruction supplied with An engine stop switch(s) must be located at all
them. Remote Stations and capable of stopping the engine
• Connect the cable’s conductors to the Switch’s at any RPM. The Installer supplies the Stop
contacts per the manufacturers instructions. Switches. Refer to the installation instruction
A) Processor Cable Installation: supplied with the switch and the engine installation
B) Run the 2-Conductor cable from the location of instructions for manufacturers recommendations.
the Engine Room Switch to the Processor.
WARNING: An Engine Stop Switch at each
C) Run the cable through the appropriate liquid tight
Remote Station is an absolute requirement.
connector at the Processor.
Refer to CFR 46, SEC. 62.35-5 and ABYC P-
D) Route the cable to TB10 on the Circuit Board, 24.5.8.
making sure that the cable is NOT laying on the
Circuit Board.
28
Installation
Anchor
Bracket 12267
Transmission Selector
Lever in Neutral Position
29
Installation
30
SET UP PROCEDURES
The Processor utilizes push buttons in conjunction Processor for the Function Code displayed to
with Display LED’s to program, adjust, calibrate and the left.
set up the various features. The push buttons also 3 A decimal point indicator is located on the
allow you to access and display information bottom right corner of each Display LED.
regarding the health of the System.
FIGURE 4: DISPLAY LED DESIGNATIONS
The following paragraphs explain how to locate and
use the push buttons and Display LEDs:
• While in the Error Menu, changes the Display B) Depress the Up or Down Push Button until the
LED back to the Function Menu. next required Function Code is reached.
FIGURE 6: DISPLAY ERROR MENU EXAMPLE C) Reactivate Set Up Mode.
NOTE:
• If no Push Buttons are pressed for five
(5) minutes, the selected Mode of
operation is automatically exited and
the System returns to Normal
RIGHT PUSH BUTTON ONLY Operating Mode.
Pressing the Right Push Button once has the • If no Push Buttons are pressed for five
following functions: (5) minutes while in Set Up Mode, it
• While in the Error Menu, clears inactive errors. will be exited without the changes
(Active errors blink, inactive do not) stored to memory
• While in Set Up Mode or Function Menu,
allows the Value of the current Function Code Function Codes and Values
to be displayed with all four Display LEDs.
The following tables list the Function Codes’ Name,
FIGURE 7: DISPLAY FOUR (4) DIGIT VALUE Default Value and Range or available Options. Each
of the Function Codes are explained in further
detail in the following sections.
NOTE:
SINGLE SCREW APPLICATIONS: The
Function Values may be entered and stored
Activating Set Up Mode in any order.
NOTE: To Escape from the Set Up procedure MULTI SCREW APPLICATIONS: The A1
at any time without saving the changed value to Function must be set FIRST, and the A0
memory, depress the Left Push Button. The Function must be set SECOND. If ZF Hurth
Function Code will stop flashing and the Gears with two (2) proportional solenoids
Function will be saved with the original Value. are used, the L1 Function must be the
THIRD function set. The rest of the
A) The Display LED is in Normal operating condition
Function Values may be entered and stored
with the red running Processor Part Number.
in any order.
B) Depressing either the Up or Down Push Button
will activate the Function Menu. Once these parameters are set, either cycle
power to the Processors or wait five (5)
C) Depressing the Up or Down Push Button will
minutes, before continuing set up.
scroll through the Function Codes one at a time.
D) Once the desired Function Code is visible on the
Display LED, press and hold down the Left and Termination of Serial
Right Push Buttons simultaneously, until the
Function Code begins to blink.
Communication Line
E) Depressing the Up Push Button will increase the
Value of the Function, while pressing the Down For Control Systems that are configured as Twin
Push Button will decrease the Value of the Screw or more, the Serial Communication Line must
Function. (Pressing and holding the Up or Down be terminated for serial communication to operate
Push Button will increase or decrease the Value properly. Each 9000 series processor comes Jumper
rapidly) 1 (JMP1) installed at the factory. Jumper 1 is located
on the left side of the LED display.
Storing Values To Memory (See Drawing in Appendix C and Figure 8)
32
Set Up Procedures
33
Set Up Procedures
34
Set Up Procedures
35
Set Up Procedures
Basic Troubleshooting
Table 11: Basic Troubleshooting Function Code
Function Default
Function Name Value Range or Options
Code Value
H1 Erase EPROM 00 Store to Return to Factory Defaults.
(FOR AUTHORIZED PERSONNEL ONLY)
Electronic Engine/Solenoid Transmission Troubleshooting
Table 12: Electronic Engine/Solenoid Transmission Troubleshooting Function Codes
Function Default
Function Name Value Range or Options
Code Value
H0 Diagnostic 00 Input Voltage (+/- 0.5VDC)
Tachometer Sensor Frequency
Lever A/D, Stations 1, 2, 3, 4, & 5
Transfer Button, Stations 1, 2, 3, 4, & 5
Software Revision Level
Servo Troubleshooting
Table 13: Servo Troubleshooting Function Codes
Function Default
Function Name Value Range or Options
Code Value
H0 Diagnostic 00 Input Voltage (+/- 0.5VDC)
Tachometer Sensor Frequency
Lever A/D, Stations 1, 2, 3, 4, & 5
Servo 1 & 2 A/D Feedback
Transfer Button, Stations 1, 2, 3, 4, & 5
Software Revision Level
36
Set Up Procedures
Field Service Test Unit (Break- NOTE: In order to prevent nuisance alarms
out Box) and Multimeter Use when first setting up a System, some Function
Codes take up to five (5) minutes to become
To aid in adjusting the following list of Processor ACTIVE. The Functions affected by this are the
signals, ZF Marine Electronics recommends the use functions that rely on Serial Communication,
of a ZF Marine Electronics Field Service Test Unit (P/ such as A0, A1, A2, A3, E7, and L0. Cycling
N 13927) (Break-out Box) and a calibrated power OFF, then ON, expedites these features
Multimeter. Refer to Appendix D - MM13927 Manual making the Functions available immediately.
for more information on the use of the Field Service
Test Unit (Break-out Box). Processor Functions
Table 15: Solenoid Clutch Functions requiring Field NUMBER OF ENGINES
Service Test Unit and Multimeter The total number of engines must be entered into the
Code Function Name memory of each of the Processors. All Processors in
C6 ZF-Hurth Duty Cycle Ahead an installation must have the SAME VALUE entered.
C7 ZF-Hurth Duty Cycle Astern The available Values for this Function are:
Table 16: Electric Throttle Functions requiring Field • 01 - Single Screw (Default Value)
Service Test Unit and Multimeter • 02 - Twin Screw
• 03 - Triple Screw (if required, contact a ZF
Code Function Name
Marine Technician.)
E1 Throttle in Neutral • 04 - Quad Screw (if required, contact a ZF
E2 Throttle Minimum Marine Technician.)
E3 Throttle Maximum • 05 - Quint Screw (if required, contact a ZF
E4 Throttle Maximum Astern Marine Technician.)
E6 High Idle NOTE: Twin screw or more applications require
Table 17: Solenoid Trolling Functions requiring Field Function Code A1 Value to be changed on ALL
Service Test Unit and Multimeter Processors prior to changing the Value of
Function Code A0.
Code Function Name
L2 Trolling Minimum Single Screw
L3 Trolling Maximum DO NOT ADJUST THIS SETTING. Contact ZF
L4 Troll Throttle Limit Marine Electronics if this Function Code is going to
be changed from the default setting.
Initial System Programming and Multi Screw
Adjustments To change the Value (Refer to Activating Set Up
Mode and Storing Values To Memory sections):
IMPORTANT: If ZF Hurth Gears are used, set A) Scroll to Function Code A1.
the L1 parameter after A1 and A0.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
NOTE: Power must be turned ON to the
Processors when programming or making any D) Store the Value to memory.
adjustments to the System. FIGURE 9: DISPLAY LED A1
38
Set Up Procedures
Throttle Functions
The following Throttle Functions are set up in
Section 6 - DOCK TRIALS:
Table 18: Throttle Functions Performed during Dock
Trials
Code Function Name
E1 Throttle in Neutral
E2 Throttle Minimum
E3 Throttle Maximum
E4 Throttle Maximum Astern FIGURE 16: DISPLAY LED E0 - SERVO
E5 Throttle Pause Following Shift
E6 High Idle
(E0) ELECTRIC ENGINE THROTTLE PROFILE
This Function, in combination with the Throttle
Harness type, configures the throttle output profile to To change the Value (Refer to Storing Values To
meet the specifications of these various engines. The Memory and Storing Values To Memory sections):
available Values for this Function are listed below: A) Ensure that the engine’s Governor or Carburetor
• 01 - Caterpillar (PWM) (8 to 92%) lever is at the Idle position.
• 02 - Cummins Centry (Voltage) (0.9 to 4.5 VDC) • If the Throttle Push-Pull cable’s ball joint is
• 03 - Cummins Quantum (Voltage) (0.9 to 1.2 - close to the Throttle lever’s position, no change
4.0 VDC) is required to this Function Code.
• 04 - Detroit Diesel (Voltage) (0.64 to 4.65 VDC) • If the Throttle Push-Pull cable’s ball joint is at
• 05 - MTU or MAN (Current) (4.0 to 20.0 mA) the opposite side of the lever’s position,
• 06 - Scania (Voltage (0.42 to 2.95 VDC) continue with the next step.
(DEFAULT) B) Scroll to Function Code E0.
• 07 - John Deere (Voltage) (0.5 to 4.5 VDC) C) Activate Set Up Mode.
• 08 - Volvo (Voltage) (0.6 to 3.6 VDC)
D) Scroll Up or Down until Value 21 is displayed.
• 09 - Detroit Diesel (Frequency) (120.64 to 360.9
Hz) E) Store the Value to memory.
• 10 - Detroit Diesel (Frequency) (120.64 to 463.5 • The Throttle Push-Pull cable’s ball joint should
Hz) drive to the Throttle lever’s Idle position.
A) Scroll to Function Code E0.
39
Set Up Procedures
Single Screw
DO NOT ADJUST THIS SETTING. Contact ZF
Marine Electronics if this Function Code is going to
be changed from the default setting.
Multi Screw (C1) CLUTCH INTERLOCK DELAY
A) Scroll to Function Code E7 IMPORTANT: This adjustment is to be set to
B) Activate Set Up Mode. Enabled only if the optional Clutch Pressure
C) Scroll Up or Down to the desired Value. Switch is being used with this application.
D) Store the Value to memory.
This Function works together with Function Code
FIGURE 17: DISPLAY LED E7 C0. Refer to the "Control Options" section for further
information.
The available Values are 00.5 to 10.0 seconds. The
Default Value is 01.0 seconds.
To change the Value (Refer to Activating Set Up
To change the Value (Refer to Activating Set Up Mode section and Storing Values To Memory
Mode and Storing Values To Memory sections): section):
BASIC CLUTCH FUNCTIONS A) Scroll to Function Code C1.
The following Clutch Functions are set up in Section B) Activate Set Up Mode.
7 - SEA TRIALS: C) Scroll Up or Down to the desired Value.
Table 19: Basic Clutch Functions Performed during D) Store the Value to memory.
Sea Trials
FIGURE 19: DISPLAY LED C1
Code Function Name
C2 Proportional (Reversal) Pause
C3 Proportional (Reversal) Pause Time
(C0) CLUTCH PRESSURE INTERLOCK
IMPORTANT: This adjustment is to be set to (C4) Proportional (Reversal) Pause Ratio
Enabled only if the optional Clutch Pressure
Switch is being used with this application. NOTE: If you have any questions about which
type of pause is best for your vessel, consult
This Function enables or disables the feature and with a ZF Marine Electronics representative.
allows for two different modes of behavior when a This Function Code selects whether the Proportional
Clutch Pressure Switch is used. Refer to the "Control (Reversal) Pause Time is the same in Ahead and
Options" Section for detailed information. Astern or whether the time in Ahead is twice that in
The available Values for this Function are: Astern.
• 00 - Not Installed (Default Value) Standard vessels with a bow and a stern typically
• 01 - Installed select a pause which is twice as much in Ahead
• 02 - Throttle Clutch Pressure Interlock Mode compared to Astern. This is because much more
speed is obtainable in Ahead, than Astern.
Consequently, more time is required to slow down
from Ahead as compared to Astern.
40
Set Up Procedures
41
Set Up Procedures
The available Values are 00.0 to 100.0% of the FIGURE 26: CLUTCH PUSH-PULL CABLE ASTERN POSITION
maximum available travel from Neutral to Ahead.
The Default Value is 80%.
FIGURE 24: CLUTCH PUSH-PULL CABLE AHEAD POSITION
43
Set Up Procedures
45
Set Up Procedures
46
DOCK TRIALS
D) Place the Control Head’s lever(s) in the Neutral/
WARNING: It is imperative that the information Idle position. Take command at a Remote Station.
provided in the previous Sections have been • Verify that the engine(s) will start in this
READ and FOLLOWED precisely, PRIOR to position.
attempting a Dock Trial. Dock Trials should be
If any of the above tests fail, verify Start Interlock
made with engines stopped unless directed
installation and connections. Refer to the
otherwise.
"Installation" section.
CAUTION: With In/Outboard or Outboard
applications, do not attempt to shift into or out
of gear with engines stopped. This may cause
Engine Stop Switches (Engines
a jam condition or damage to the linkage to Running)
some clutch configurations. Start the engine(s) and verify that the Stop switches
NOTE: On multiple screw applications, the (normally push buttons) function correctly at all
following tests must be performed on all Remote Stations. Refer to the information supplied
Processors. If any of the following tests fail, by the engine manufacturer or switch supplier for set
consult Appendix B Troubleshooting. up and adjustments.
CAUTION: An Engine Stop Switch at each
Control Heads (Engines station is an absolute requirement. Refer to
Stopped) CFR46, 62.35-5 and ABYC P-24.5.8.
A) Turn power ON to the Control System. WARNING: Do not attempt to continue tests
B) The Control Head at each Remote Station should until all Engine Stop Switches are functioning
produce an intermittent tone. correctly!
C) Take command at a Remote Station.
D) Perform each of the following steps on all Remote Basic Throttle Settings
Stations.
1 Move the Control Head’s lever(s) full Ahead and
(Engines Running)
full Astern. Ensure that there are no (E1) Throttle in Neutral
obstructions to the movement, the Processor
reacts to the lever movement, and that no tones This Function allows the engine RPM at Neutral to
are generated. be adjusted independently of the RPM at Idle Ahead
and Astern. The available Values for this Function
2 Place the Control Head’s lever(s) in the Neutral
are 00.0% to 25.0% of the Throttle Range. The
position.
Default Value is 00.0%.
3 Depress and hold the Station transfer button
To change the Value (Refer to the "Activating Set Up
while moving the Control Head’s lever(s) to the
Mode" and the "Storing Values To Memory" sections):
Ahead detent. Release the transfer button.
• The red LED on the Control Head should blink, A) Scroll to Function Code E1.
indicating Warm-up Mode has been entered. B) Activate Set Up Mode.
Warm-up Mode operates only in the Ahead C) Scroll Up or Down to the desired Value.
direction. If the red indicator light BLINKS, D) Store the Value to memory.
continue with the testing.
FIGURE 1: DISPLAY LED E1
• If the red indicator light DOES NOT BLINK,
check connections as stated in the appropriate
Appendix A - Control Head Service Sheet.
47
Dock Trials
To change the Value (the "Activating Set Up Mode" FIGURE 4: THROTTLE PUSH-PULL CABLE FULL THROTTLE
and the "Storing Values To Memory" sections): POSITION
48
Dock Trials
49
Dock Trials
Trolling Valve
Troll Solenoid Adjustments
WARNING: It is preferable to adjust the Trolling
Valve during sea trials. However, in some cases
adjustment of Troll Minimum Pressure (L2) can
be accomplished while at the dock. Do Not
attempt to make any Troll adjustments unless
the dock and the mooring lines are capable of
securing the vessel with full thrust from at least
one screw.
50
SEA TRIALS
WARNING: It is imperative that the information Proportional (Reversal) Pause
provided in the previous Sections has been read Adjustments
and followed precisely, prior to attempting a
Sea Trial. If any of the following tests fail, WARNING: Types and timing of proportional
discontinue the Sea Trial immediately and (reversal) pauses must be specifically set for
return to the dock. Consult Appendix B or a ZF each vessel during a Sea Trial. Use extreme
Facility prior to resuming the Sea Trial. caution when maneuvering your vessel before
the C2 and C3 function codes are properly set.
NOTE: MULTI SCREW APPLICATIONS: The
Any aggressive action could cause the
following tests must be performed on all
engine(s) to stall.
engines/transmissions. During the course of
the Dock Trial and Sea Trials, fill out the Trial NOTE: If you have any questions about which
Report at the end of Section 7. Retain this type of pause is best suited for your vessel,
information for future use. contact a ZF Marine Electronics representative.
The proportional pause feature provides the exact
Full Speed Setting amount of time required for engine deceleration
A) Warm-up the engine(s) and transmission(s) and during a change in vessel direction. The pause is
slowly move into open water. variable and in proportion to:
B) Gradually move the Control Head lever(s) to Full • The position of the Control Head lever before
speed. the reversal.
– SINGLE SCREW: Continue with Step 1. • The length of time the Control Head lever has
– MULTI SCREW: If synchronization is been in that position.
installed, disable synchronization as
explained in Section 2 - OPERATION. Once
(C2) Reversal Pause
disabled, continue with step 1. PAUSE TYPE SEQUENCES
1 If Throttle RPM is LOW: (If RPM is High, The sequence of events, are as follows for the three
continue with 2) (3) Pause types:
– ELECTRIC THROTTLE: Refer to Appendix In-Gear Delay [00]
B - Service Field Test Unit on how to check
electric setting. 1 The Throttle position drops to Idle.
– SERVO THROTTLE: Check whether the 2 The Transmission remains engaged in Ahead or
engine throttle lever is against the full speed Astern.
stop. 3 The Control System pauses at this position until
2 If Throttle RPM is HIGH: (If RPM was Low, skip the delay has timed out.
this step) 4 The Transmission shifts to the opposite gear
– Decrease RPM by adjusting E3 Throttle (Astern or Ahead).
Maximum, as explained in the "Dock Trials" 5 The Throttle position moves to the Control
Section. Head’s present lever position.
C) MULTI SCREW ONLY: Check that matching Idle, Neutral Delay [01]
Mid-range and Full Speed Control Head lever
1 The Throttle position drops to Idle.
positions cause equal RPM on both engines.
• ELECTRIC THROTTLE: If RPM’s do not match, 2 The Tranmission shifts to Neutral.
adjust E3 Throttle Maximum, refer to the "Dock 3 The Control System pauses at this position until
Trials" section. the delay has timed out.
• SERVO THROTTLE: If RPM’s do not match, 4 The Transmission shifts to the opposite gear
check push-pull cable travel. If travel does not (Astern or Ahead).
match when the Control Head levers are side by 5 The Throttle position moves to the Control
side, adjust Function Code E3 Throttle Head’s present lever position.
Maximum, refer to the "Dock Trials" section.
Fixed Neutral Delay [02]
CAUTION: The Fixed Neutral Delay feature was
added in order to accommodate Thruster
Control installations. Damage to the drive train
may occur when used for reverse reduction
gear applications.
1 The Throttle position drops to Idle.
2 The Tranmission shifts to Neutral.
51
Sea Trials
3 The Control System pauses at this position for setting stored during Set Up Procedures) while
the amount of time programmed (duration) with starting the stop-watch.
Function C3 Proportional Pause Time D) When the engine(s) RPM reaches Idle and the
(regardless of prior throttle setting). vessel’s speed through the water is within two (2)
4 The Transmission shifts to the opposite gear knots of the standard Idle Ahead speed, stop the
(Starboard or Port). stop-watch.
5 The Throttle position moves to the Control Record Time______________.
Head’s present lever position. E) Program Function Code C3 to the time expired on
PROGRAM C2 TYPE the stop-watch.
To change the Value (Refer to the "Activating Set Up The available Values are 00 to 99 seconds. The
Mode" and ""Storing Values To Memory" sections): default Value is 04 seconds.
A) Scroll to Function Code C2 To change the Value (Refer to the "Activating Set Up
Mode" and the " Storing Values To Memory"
B) Activate Set Up Mode.
sections):
C) Scroll Up or Down to the desired Value.
A) Scroll to Function Code C3.
D) Store the Value to memory.
B) Activate Set Up Mode.
FIGURE 1: DISPLAY LED C2 C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
FIGURE 2: DISPLAY LED C2
53
Sea Trials
NOTE: The effects of the following adjustments • If twin screw, ensure that the opposite lever is at
are not immediate. Allow enough time for the the Neutral/Idle position.
Shaft RPM to stabilize between any changes to B) Scroll to Function Code L3 and enter Setup Mode.
the L2 and L3 Values. C) Increase/decrease the Value until the Shaft RPM
NOTE: Make Troll adjustment one processor at is 70 to 80% of that measured in Table 27
a time. If more than one at time the other
Table 4: Shaft RPM Measurement of Maximum Troll
levers on the neutral detent.
Should be 70 to 80% of Table 27
(L2) TROLL MINIMUM PRESSURE ADJUSTMENT
Port Starboard
A) Ensure that the Control Head lever is at the
Neutral / Idle position.
• If the red LED is blinking rapidly, disable Troll D) Enter the new Value into memory.
by pressing the Transfer Button until the red E) If twin screw, repeat steps A) through D) on the
LED becomes lit solid. opposite side
B) Connect a Service Field Test Unit (P/N 14000) (L5) TROLL PULSE DURATION & (L6) TROLL PULSE
and Amp meter to the Troll Command Signal PERCENTAGE
output as described in Appendix B - Service Field
Whenever Troll is enabled (red LED blinking rapidly)
Test Unit Manual.
and the Control Head lever is moved from Neutral/
C) Move the Control Head lever to the Ahead detent. Idle to the Ahead or Astern detent, the current to the
D) Using a Shaft Tach, measure the RPM of the Shaft Proportional Solenoid is delivered at a value which
and record in Table 27. causes a higher clutch pressure for a set period of
Table 1: RPM Measurement of Shaft in Normal time. The period of time where the higher pressure
Operating Mode is commanded is adjustable with this Function.
Port Starboard The default Value of 00.6 seconds has been found to
be adequate with most applications. However, if the
shaft takes unreasonably long to begin rotating, or if
E) Depress and hold (approximately two [2] seconds) an excessive surge is felt when commanding Ahead
the Transfer Button until the red LED starts with Troll selected, the amount of time that the
blinking rapidly. higher pressure is commanded may be adjusted with
F) Measure the Shaft RPM and record in Table 28. the L5 Function.
Table 2: RPM Measurement of Shaft in Troll Operating The L6’s Value automatically changes to the same
Mode Value selected with Troll Maximum (Function Code
Port Starboard L3). As with L5, experience has showed us that
commanding this higher clutch pressure is adequate
in most applications. In the event that the shaft takes
G) Scroll to the L2 Function Code and enter Setup unreasonably long to begin to rotate, or an excessive
Mode. surge is produced every time Ahead is commanded
H) Adjust the Value of Function Code L2 until the with Troll, the Value can be increased or decreased.
Shaft RPM is 30 to 50% of that measured in Table
If L5 and L6 values need to be adjusted, it is
27.
recommended that small adjustments be made to
I) Enter the new Value into memory and Record in each of the functions, instead of a large adjustment
Table 29 . being made to one or the other. After each small
Table 3: Shaft RPM Measurement of Minimum Troll adjustment, test vessel response before making
Should be 30 to 50% of Table 27 further adjustments.
Port Starboard
C6 & C7 ZF-Hurth [Old Type with two (C7) ZF-HURTH DUTY CYCLE ASTERN
This function limits the amount of current delivered
(2) proportional solenoids] Solenoid to the Astern Proportional Solenoid.
Trolling Failure to limit the current may result in permanent
NOTE: It is strongly recommended that the damage to the solenoid.
Field Service Test Unit (P/N MM13927) is The available Values are 00.0% to 100.0% Duty
utilized when adjusting the ZF-Hurth Solenoid. Cycle of the applied voltage. The Default Value is
NOTE: Functions C6 & C7 limit the amount of 100%.
current to the proportional solenoids. Failure A) Ensure that Troll is not selected (no rapidly
tolimit the current in certain solenoids will blinking LED).
cause permanent damage to the soenoid. B) Connect an amp meter in series with the Astern
solenoid signal.
Enabling ZF-Hurth Troll C) Move the Control Head lever to the Astern detent.
A) Ensure Function Code C5 value is set to 01 or 02
D) Scroll to Function Code C7.
(refer to the "Set Up Procedures" sections).
E) Activate Set Up Mode.
B) Place the Control System into Troll Mode.
F) Scroll Up or Down until the appropriate minimum
C) Move the Control Head lever into the Ahead
current level is reached.
Detent.
G) Store the Value to memory.
ZF-Hurth Troll Maximum Current FIGURE 5: DISPLAY LED C7
Adjustment
A) Ensure that the current to the Ahead and Astern
Solenoids do not exceed the current rating of the
Solenoid. This is accomplished by connecting an
amp meter in series with the Ahead and then the H) Return the Control Head lever to the Neutral/Idle
Astern solenoid signal. position.
B) Place the Control Head lever into the Ahead and
the Astern detent without Troll selected (Control
Head red LED lit solid). Speed Boost
Adjust Function Code C6 for Ahead and C7 as The primary function of Speed Boost is to prevent
follows: the engines from stalling when a heavy load is
applied. This feature provides a temporary increase
(C6) ZF-HURTH DUTY CYCLE AHEAD in the speed command output signal from the
This function adjusts the maximum current available Processor. Most applications do not require Speed
to the Ahead Proportional Solenoid. Boost.
Failure to limit the current may result in permanent Use a "trial and error" exercise during sea trials to
damage to the solenoid. assess the necessity for using Speed Boost. For
The available Values are 00.0% to 100.0% Duty Cycle complete instructions about how to proceed, as well
of the applied voltage. The Default Value is 100%. as information about Speed Boost function code
A) Ensure that Troll is not selected (no rapidly values and all cautionary notes and directions, refer
blinking LED). to the "Control Options" sections.
B) Connect an amp meter in series with the Ahead
solenoid signal. Sea Trial Report
C) Move the Control Head lever to the Ahead detent. The purpose of this Sea Trial Report is to provide a
D) Scroll to Function Code C6.
. convenient checklist and record of installation, dock
E) Activate Set Up Mode. trial set up, and sea trial performance of the ZF
F) Scroll Up or Down until the appropriate Marine Electronics Propulsion Control System.
maximum current level is reached. Please enter ALL of the information. We
recommend that this form remains aboard the vessel,
G) Store the Value to memory.
and a copy is sent to ZF Marine Electronics along
FIGURE 4: DISPLAY LED C6 with the Warranty Registration which is located at
the end of Appendix A.
55
Sea Trials
Vessel Information
Table 5: Vessel Information
Vessel Name: Hull # Trial Date:
Vessel Type: Dwg No.:
Installing Yard/Project Tel:
Manager:
Owner/Owner’s Tel:
Representative:
ENGINE DATA: MAKE: MODEL: HP(KW):
RPM:
PROPELLER DATA: No. of Screws: Propeller Type: Fixed
Other
GEAR DATA: MAKE: MODEL: RATIO:
56
Sea Trials
Table 6: Processor
PORT STARBOARD
Processor Serial Number:
Is the amount of push-pull cable travel set properly for Shift? YES NO YES NO
TROLL SOLENOID
Does Trolling Valve operate in the correct direction? YES NO YES NO
Table 7: Power Supply
PORT STARBOARD
Processor Serial Number:
Are the power cables protected by 10 Ampere Circuit Breakers? YES NO YES NO
If separate power supplies are used for each Processor, do they have a YES NO YES NO
common ground?
What is the Voltage when not being charged? (VDC)
Battery___________ Battery___________
Processor_________ Processor_________
What is the Voltage when connected to Shore Power? (VDC)
Battery___________ Battery___________
Processor_________ Processor_________
What is the Voltage when the engines are running? (VDC)
Battery___________ Battery___________
Processor_________ Processor_________
Table 8: Dock Trials
Processor Serial Number: PORT: STARBOARD:
Does the engine start when the Control System is turned OFF? YES NO YES NO
Does the Engine Stop Switch function at all Stations, regardless of RPM? YES NO YES NO
Can all Remote Stations take command? YES NO YES NO
Does the Warm-up Indicator Light blink in Ahead at all Stations? YES NO YES NO
What is the Low Idle RPM? RPM RPM
Does the vessel surge forward with Control Head lever in the Ahead YES NO YES NO
Detent?
The Full Speed Reversal Delay is set for how many seconds? SECONDS SECONDS
Do the Dual Control Head levers match position and RPM throughout the YES NO YES NO
speed range?
Is Synchronization operational? YES NO YES NO
57
Sea Trials
Record Parameters
Record information onto the following Tables only
after ALL information has been recorded in the
previous section, "Control System Checks".
58
Sea Trials
59
Sea Trials
ANY IRREGULARITIES:
INSPECTOR____________________________________
_________________________
DATE_______________________
60
CONTROL OPTIONS
External Alarm Capability • and are examples of a suitable circuit, but is on
Figure 71.
CAUTION: The Processor’s Alarm circuit is • Plug the Power Wire Harness into the
limited to a maximum current of 0.5 Amperes Processor’s Power pigtail.
and a maximum voltage of 100 Volts DC. • Run the Power Wire Harnesses’s two-conductor
Exceeding these limits will permanently Alarm cable to the location of the Status
damage the Alarm circuit. Indication Circuit.
The Processor comes equipped with a normally open • Connect the black and red conductors to the
relay contact for connection to an external Status Status Indication Circuit as shown in Figure 71.
Indication or alarm circuit. The relay energizes,
closing the contact when the Circuit Board has Auxiliary Backup Control
power applied and the software program is running
normally. In the event of a power loss or processor System
failure, the relay de-energizes and the contact opens. The ZF Backup System (referred to as BU System
Table 1: Descriptions and Designators for External hereafter) provides a control system which is fully
Alarm Harness Example independent from the ZF Marine Electronics Control
System. The BU System can control the gear as well
Designator Description
as the engine.
A DC Power Source (12 or 24 VDC)
• Provides redundant throttle and clutch signals
B Fuse in the event of a failure of the Main Control
C Alarm Indication Circuit ON/OFF System.
Switch • May be selected at any time by the operator.
D Relay with a normally CLOSED Contact • A full explanation of the installation, operation
and a Diode across the Coil for Surge and adjustment of the BU System is provided in
Suppression the Installation Manual supplied with the BU
E Control System Fail Indicator Light System.
(and/or Audio Alarm.
G Maximum Current 0.5 A CANtrak Display Panel
F ZF Marine Electronics Processor The Display Panel shows various system information,
.
FIGURE 1: EXTERNAL ALARM HARNESS EXAMPLE including but not limited to: Station-in-Command,
Control Head lever position, Operating Mode (Cruise
or Troll), Throttle Command, Clutch Command, and
engine speed (if an engine speed sensor is used)
The Panel receives information via the serial
communications line.
The Panel accepts 12 or 24 VDC power supplies
A full explanation of the installation, operation, and
adjustment of the Display Panel is provided in the
MM70179 Display Manual and the manufacturers
information included with the Panel.
FIGURE 2: DISPLAY PANEL
Installation Station 1
The following items should be considered when Cruise
designing and installing the Status Indication Panel:
• The Power Wire Harness (p/n 13631-#) must be Throttle
used if an External Alarm is required.
RPM
• The Processor’s Alarm Circuit uses a “relay”
contact. Therefore, the polarity of the
conductors is not a concern.
• The External Status Indication Circuit must not
use the same power source as the Processor.
• Since the External Status Indication Circuit is ART-2007 Rev-
61
Control Options
• This feature is defaulted OFF, and therefore TAKING COMMAND WITH STATION TRANSFER
must be enabled during set up. Refer to "Set Up The Engine Room/Remote Switch is in the Remote
Procedures" section. position and any other Remote Station other than the
• When enabled, the feature is selectable with a Station 1 (Engine Room Station) is in command.
two-position selector switch, labeled Engine
A) Transfer command to the Engine Room Station as
Room Only/Remote. When switched to Engine
described in Section 2 - OPERATION.
Room Only the toggle switch is CLOSED and
command is locked to Engine Room Station. B) When command is at the Engine Room Station,
When switched to Remote the toggle switch is turn the Engine Room/Remote Switch to Engine
OPEN and any Remote Station can take Room. This will lock-out all other Remote
command away from the Engine Room Station. Stations from taking command.
• On power up, the system will go to no station on C) Command will remain locked at the Engine Room
line regardless of the switch’s position. Station until the Engine Room/Remote Switch is
returned to the Remote position. Command then
Switch CLOSED on Power-up can be transferred to another Remote Station, as
The Engine Room Station (Station No.1) will NOT described in Section 2 - OPERATION.
take command automatically on Power-up. TAKING COMMAND WITH SWITCH
• Command at the Engine Room Station is gained The Engine Room/Remote Switch is in the Remote
by moving the Control Head lever(s) into the position and any other Remote Station other than the
Neutral/Idle position and then pressing the Station 1 (Engine Room Station) is in command.
Transfer Button. A) Turn the Engine Room/Remote Switch to Engine
• ONLY the Engine Room Station (Station No.1) Room.
can take command when power is applied to
the Processor(s). B) Command will be taken away from the Station-in-
• Moving the Engine Room Only/Remote Switch Command and transferred to the Engine Room
to the Remote (OPEN) position and back to the (Station No.1) Control Head, regardless of where
Engine Room Only (CLOSED) position will take the Engine Room (Station No.1) Control Head
command. lever(s) are positioned.
• If the Control Head lever(s) ARE IN the Neutral/
Depressing a Transfer Button at any Remote Station Idle position, the Control Head is in
other than the Engine Room, will produce a tone for automatically in active command of the control
2 seconds or for the duration the Transfer Button is system.
pressed. The Remote Station’s LED will not light, • If Control Head lever(s) ARE NOT IN the Neutral/
indicating command has not been take at the Station. Idle position, the control system will enter a
NOTE: The Control Head tone will sound as "Safe Mode". The Control Head LED will flash
long as the Transfer Button is depressed at the (at the same rate as when in Warm-up Mode),
Remote Station. If it is depressed for up to tem and the control system will output Neutral/Idle.
(10) seconds the Stuck Transfer Button Alarm To gain complete command, the operator must
logic initiates. Refer to Appendix B - Stuck place the Control Head lever(s) into the Neutral
Transfer Button Section. detent for a period of one (1) to two (2) seconds
before the control system will begin to respond.
Switch OPEN on Power-up The LED will then function normally for a
Command is gained by any Remote Station that has Station-in-Command.
the Control Head lever(s) in the Neutral/Idle position C) Now, if operator presses the Transfer Button at
and the operator depresses the Transfer Button. any other Remote Station, a tone will sound for
two (2) seconds or for the duration the Transfer
Switch OPEN after Power-up Button is pressed. Other Remote Stations cannot
There are two ways of gaining command at the take command away from the Engine Room.
Engine Room Station (Station No.1) after power has
been turned ON to the control system. Fixed Neutral Delay
1 Engine Room Only/Remote Switch is in the
Remote (OPEN) position. Take command at the Fixed Neutral Delay is a feature that saves wear and
Engine Room Remote Station. Then turn the tear on clutches and transmissions, appropriate for
Engine Room/Remote Switch to Engine Room. any boat equipped with shaft brakes (for example, a
Refer to the next Section "Taking Command tugboat or commercial fishing vessel). Since the
with Station Transfer". brakes are only applied when the system is in
Neutral, this Fixed Delay ensures that the system
2 Turn the Engine Room Only/Remote Switch to
pauses in Neutral long enough for the shaft brake
Engine Room. Then move the Engine Room
application to take place, even when a Control Head
Control Head levers to the Neutral/Idle position.
lever is pushed or pulled rapidly from Ahead to
Refer to the second Section.
Astern or vice versa. The Fixed Neutral Delay
63
Control Options
function code is C8, with available values of 0 to 4 NOTE: Speed Boost has been used with some
seconds, programmable in increments of 0.1 (one- electronic engines where there is a stalling
tenth) of a second. problem due to the engine being unable to
When the Fixed Neutral Delay C8 function code is respond quickly enough to a sudden load
set, as described in Section 5 - SET UP PROCEDURE, (clutch engagement) especially with boats that
each time a change in vessel direction is have a high gear reduction (typically 4:1 or
commanded, the system will automatically pause in higher) or to reduce the droop in engine speed
Neutral for the amount of time entered as the value, (rpm) as clutches engage.
regardless of whether the operator actually stops the NOTE: Use of Speed Boost does not guarantee
Control Head lever at the Neutral detent. that an engine will not stall. Ultimately, the
The Fixed Neutral Delay time is added to any engine must be capable of producing the
Proportional (Reversal) Pauses and Proportional power required in the time frame necessary to
(Reversal) Pause Times which have been set with the handle the sudden load of clutch engagement.
function codes C2 and C3. When C8 is set in addition Functions
to C2 and C3, the vessel will respond to the
proportional pause(s) first and then pause for the There are four function codes associated with Speed
amount of time set for Fixed Neutral Delay. Boost — F0, F1, F2, and F3.
(F0) BOOST PERCENT
Speed Boost This Function is the percent of throttle to be applied
during Speed Boost. (Refer to Figure 54.)
Speed Boost is a temporary increase in the speed
command output signal from the processor during CAUTION: The range for this function is 0.0 to
clutch engagment. The primary function of Speed 20.0%. The range is provided only to allow
Boost is to prevent an engine from stalling when a enough leeway for those rare cases that might
heavy load is applied. The Speed Boost signal must need the higher value. In most cases, however,
be properly set and timed and, when used, must be using a value of 20 would very likely cause
applied responsibly and carefully. Pay particular damage to the transmission.
attention to the Cautions and Notes below.
NOTE: The value of 0 for F0 means no speed
CAUTION: Misapplication of Speed Boost can boost is used and the speed command remains
damage the transmission or other equipment. at Idle speed (0%) as the clutch is engaged.
Before applying Speed Boost, consult the The value programmed determines the amount of
transmission representative about its use, to throttle above idle, which is applied during clutch
discuss any limitations of clutch engagement as engagement. This function is the percent of the
a function of engine speed. The person throttle range. Throttle range is the difference
responsible for implementing Speed Boost is between throttle minimum (function code E2) and
the person responsible for making certain it is throttle maximum (function code E3).
implemented properly. That person is also
Boost percent example:
responsible for any damage that may occur as a
result of the use of Speed Boost. • Throttle minimum = 10.0
• Throttle maximum = 90.0
CAUTION: With a properly set and timed • Throttle range = 90.0 - 10 = 80.0
Speed Boost signal, the engine speed should
If F0 were set to 1.0, the amount of boost would be
not increase significantly (if at all) during clutch
1% of 80.0, or 0.8.
engagement. Engine speed should remain at
idle, or slightly above, as the clutch begins to The actual applied boost signal would be 10.8 (10.0 +
engage, and not rise above idle until after the 0.8 = 10.8).
clutch is fully engaged. Damage to the (F1) BOOST DURATION
transmission or other equipment may occur if
This Function controls how long the boost is applied.
the Speed Boost signal is not properly set and
This time starts when the BOOST START DELAY has
timed. Adjust the Function Codes as needed to
expired. See Figure 54: Speed Boost Usage Graph.
meet this requirement.
A F1 value of 0.0 is 0 seconds, a value of 2.5 is 2.5
NOTE: Speed Boost is NOT required for most seconds, a value of 5.0 is 5 seconds, etc.
applications. Its primary use is with engines
that have mechanical governors and where the (F2) BOOST START DELAY
engine stalls upon clutch engagement or clutch This Function controls how much time elapses after
reversal (going from Ahead to Astern or vice Ahead or Astern clutch engagement has been
versa) typically due to a high gear reduction commanded until Speed Boost is applied. This is an
ratio (4:1 or higher). open loop method of applying Speed Boost just
before the load hits the engine. (Refer to
Figure 54.) This open loop method is the only one
64
Control Options
available for the premium Processors. Because it has FIGURE 5: SPEED BOOST USAGE GRAPH
no ability to determine temperature, it is best set to a
warm gear so that the fill times are normal.
ON
CLUTCH
A F2 value of 0.0 is 0.0 seconds, a value of 0.1 is 100 COMMAND
OUTPUT
milliseconds (one tenth of a second), a value of 0.3 is OFF
TIME
300 milliseconds (0.3 seconds), etc. CLUTCH
OIL
(F3) BOOST BYPASS CLUTCH DELAY PRESSURE
0 PSI
This function controls whether Speed Boost is SPEED F1
TIME
C), repeat steps A) through C) on the opposite needs to be addressed. CORRECT THAT
side. If the same results are experienced, SPEED PROBLEM BEFORE MAKING A DECISION ABOUT
BOOST SHOULD BE ATTEMPTED. THE USE OF SPEED BOOST.
• If the droop on the second engine is • If significant droop occurred on both sides,
insignificant compared to the first, there may be SPEED BOOST MAY BE REQUIRED.
a problem with the engine or the propeller EMERGENCY REVERSALS
which needs to be addressed. SPEED BOOST
WOULD NOT BE RECOMMENDED AT THIS TIME. The REVERSAL PAUSE TIME (C3) must be properly
adjusted prior to determining the need for Speed
ASTERN CLUTCH ENGAGEMENT Boost during emergency reversals.
A) Take note of the engine RPM at Idle. A) Position both Control Head levers (twin screw
B) Move the Control Head lever to the Astern detent applications) to Ahead gear and approximately
while monitoring the engine’s tachometer. 10% of the speed range.
C) Does the engine RPM drop significantly below the B) Simultaneously move both Control Head levers to
rated Idle speed or stall? If so, Speed Boost may approximately 10% of the speed range in Astern.
be required. C) A drop of engine RPM below the rated droop
• If this is a twin screw installation and a would not be unexpected at this time. However, if
significant drop in RPM was witnessed in step any of the engines seems about to stall, speed
C), repeat steps A) through C) on the opposite boost should be considered.
side. If the same results are experienced, SPEED
D) Slowly repeat steps A) through C) in very slight
BOOST SHOULD BE ATTEMPTED.
speed increments, with the following
• If the droop on the second engine is
considerations in mind:
insignificant compared to the first, there may be
• Limit the total amount of speed applied in
a problem with the engine or the propeller
Astern to 20%.
which needs to be addressed. SPEED BOOST
• If at any time the engine stalls or almost stalls,
WOULD NOT BE RECOMMENDED AT THIS TIME.
Speed Boost may need to be applied, in
IDLE AHEAD TO IDLE ASTERN conjunction with C3 and F3.
A) Position the vessel in open water where it can be
maneuvered.
Station 2 Lockout Switch
B) Move one of the Control Head levers into the
Ahead detent. In twin screw applications, one This feature prevents any Remote Station from taking
lever must remain at Neutral. command away from Station No. 2, once Station 2
has gained command.
C) Move the Control Head lever from the Ahead to
the Astern detent. Does the engine RPM drop • This feature is defaulted OFF, and therefore
significantly below the rated Idle speed or stall? If must be enabled during set up. Refer to "Set Up
so, Speed Boost may be required. Procedures" section.
• If this is a twin screw application, repeat steps • Once enabled, the feature is selectable with a
B) and C) on the opposite side. If significant toggle switch.
droop occurs on one side only, there may be a • The Engine Room/Remote feature can override
problem with the engine or the propeller which the Lockout feature.
needs to be addressed. CORRECT THAT Switch CLOSED on Power-up
PROBLEM BEFORE MAKING A DECISION ABOUT • Any Station can take command.
THE USE OF SPEED BOOST. • Once Station No.2 has taken command, no
• If a significant droop occurred on both sides, Station can take command away from Station 2.
SPEED BOOST MAY BE REQUIRED. (If the Engine Room Only/Remote switch is
IDLE ASTERN TO IDLE AHEAD enabled and CLOSED also, Station No. 1 is the
A) Position the vessel in open water where it can be only Station permitted to take command away
maneuvered. from Station No. 2)
B) Move one of the Control Head levers into the Switch CLOSED after Power-up
Astern detent. In twin screw applications, one
• CLOSING the Lockout Switch will NOT
lever must remain at Neutral.
automatically transfer command to Station
C) Move the Control Head lever from the Astern to No.2.
the Ahead detent. Does the engine RPM droop • Any Station can take command after CLOSING
significantly below the rated Idle speed or stall? If the Lockout Switch. Once command is
so, speed boost may be required. transferred to Station No. 2, no other Remote
• If this is a twin screw application, repeat steps Station can take command away from Station
B) and C) on the opposite side. If significant No. 2. (If the Engine Room Only/Remote switch
droop occurs on one side only, there may be a is enabled and CLOSED also, Station No. 1 is
problem with the engine or the propeller which
66
Control Options
67
Control Options
68
PERIODIC CHECKS AND MAINTENANCE
The items listed below should be checked on an • Measure the voltage at the battery and at the
annual basis, or more frequently where noted: Processor while the Clutch or Throttle is
driving. There should be no more than 10%
Control Heads difference between these two points. If so,
check all devices and connections for excessive
• Check the terminal strip for signs of corrosion voltage drop
or a loose connection.
• If used, disconnect the Deutsch connector and NOTE: If an APS is used in the circuit to supply
check the pins and sockets for signs of moisture power to the Processor, account for the 0.7V
and corrosion. drop across the APS. Example: 12.6V @ battery
– 1.26V (10% drop) – 0.7V (APS drop) =
10.64V (Minimum allowable voltage)
Processor
• Check all terminal connections for signs of
corrosion or loose connections.
• Un-plug and inspect all Deutsch connectors for
signs of moisture or corrosion.
DP Interface Enclosure
The Enclosure requires no maintenance.
Power
• Check all of the connections from the battery to
the DC Distribution Panel to the APS for loose
or corroded connections.
Page 69
Periodic Checks And Maintenance
Page 82
APPENDIX A
MMC-280 Rev.N 5/08
ZF Marine Electronics, LLC
Mukilteo Plant
400 Series Control Head Variations
This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics 400 Series Control Heads.
REQUIREMENTS:
MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.
Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head lever.
CruiseCommand: one (1) Control Head Harness per Control Head lever.
Included with the Control Head:
• Gasket
• Mounting screws and washers
• Terminals (For 8-Conductor or 1-Connector Harnesses)
• Watertight cable grip for the cable entrance on the Processor (For 8-Conductor)
When the Control Head is properly mounted on a console, it is spray proof from the top only. An adhesive gasket must be
used to seal it to the mounting surface. However, below the mounting surface it needs protection from water or spray.
Consider using a Weather Mount Enclosure, which is available from ZF Marine Electronics.
MOUNTING AND INSTALLATION:
A) Select the desired mounting locations and make cutouts per template. Refer to the Dimensions Diagram.
B) Check that the four mounting screws will start into the Control Head. Remove the Control Head from the cutout.
C) Remove the backing from the adhesive gasket and apply the gasket adhesive side to the console around the cutout.
D) Run cable/harnesses between Processor and Control Head. Label both ends with the Station ID. (EXAMPLE: Port,
Center, or Starboard; Port Thrust, Port Throttle; etc.)
There are two types of Control Head connections available: Plug or Terminal Connected. Both types may be used with
MicroCommander, ClearCommand, or CruiseCommand using the appropriate cable or harness. Follow the appropriate steps
for the Control Head that has been supplied for your system.
TYPE 1 - PLUGGABLE
Plug Control Head cable into the pigtail at the Control Head. (Ensure the correct Processor Cable is being plugged into
the corresponding Control Head lever pigtail).
When connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully connected or
disconnected. Connecting or disconnecting plugs without depressing and holding the release button or buttons will damage
the plug.
TYPE 2 - HARD-WIRED
A) Strip back the PVC cover on the shielded cable approximately 2-1/2" (63,5mm) at the Control Head.
B) At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end of the PVC cover
(the drain wire at the Control Head is not connected to ground).
C) Strip 3/8" (9,5mm) insulation off each wire.
A-1
D) Twist the individual strands of the wires to minimize fraying.
E) Crimp a locking fork terminal (included with each Control Head) to each of the conductors.
F) Make connections to the Control Head as indicated in the following TERMINAL CONNECTIONS diagrams.
DIMENSIONS
CABLE/HARNESS CONNECTIONS:
DUAL CONTROL HEAD CONNECTIONS
Terminal Connections
Cable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.
MicroCommander/ClearCommand CruiseCommand/9000 Series
Port Lever: Starboard Lever: Port Lever: Starboard Lever:
Terminal 3 Red Terminal 3 Red Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER
Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER
Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue
Pluggable Connections
Pluggable Control Heads are supplied with a harness pigtail for each lever. When disconnecting/connecting the plugs, ensure that
the release button or buttons are depressed and held until plug is fully disconnected or connected. Disconnecting/connecting plugs
without depressing and holding the release button or buttons WILL damage the plug.
AFT FACING CONTROL HEADS
Handheld Control is a Station option. Contact your ZF Marine Electronics Dealer for further information on Handheld requirements
and options.
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MMC-329 Rev.E 5/08
ZF Marine Electronics, LLC
Mukilteo Plant
MC2000 Series Standard Control Head Variations
This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics MC2000 Series Control
Heads
Part Numbering Configurations Detents Available
REQUIREMENTS:
MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.
Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head lever.
CruiseCommand: one (1) Control Head Harness per Control Head lever.
Included with the Control Head:
• Mounting screws
• Terminals (For 8-Conductor or 1-Connector Harnesses)
• Watertight cable grip for the cable entrance on the Processor (For 8-Conductor)
When the Control Head is properly mounted on a console, it is spray proof from the top only. An adhesive gasket is
mounted on the bottom of the Control Head to seal it to the mounting surface. However, below the mounting
surface it needs protection from water or spray. Consider using a Weather Mount Enclosure, which is available from
ZF Marine Electronics.
MOUNTING AND INSTALLATION:
A) Select the desired mounting locations and make cutouts per template. Refer to the Dimensions Diagram.
B) Check that the two mounting screws will start into the Control Head. Remove Control Head from cutout.
C) Run cable/harnesses between Processor and Control Head. Label both ends with the Station ID. (EXAMPLE:
Port, Center, or Starboard; Port Thrust, Port Throttle; etc.)
Dimensions
There are two types of Control Head connections available: Plug or Terminal Connected. Both types may be used with
MicroCommander, ClearCommand, or CruiseCommand using the appropriate cable or harness. Follow the appropriate
steps for the Control Head that has been supplied for your system.
Pluggable
A) Plug Control Head cable into the pigtail at the Control Head. (Ensure the correct Processor Cable is being plugged into
the corresponding Control Head lever pigtail).
B) When connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully
connected or disconnected.
C) Connecting or disconnecting plugs without depressing and holding the release button or buttons will damage the plug.
A-5
Standard Cable
A) Strip back the PVC cover on the shielded cable approximately 2-1/2" (63,5mm) at the Control Head.
B) At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end of the PVC cover
(the drain wire at the Control Head is not connected to ground).
C) Strip 3/8" (9,5mm) insulation off each wire.
D) Twist the individual strands of the wires to minimize fraying.
E) Crimp a locking fork terminal (included with each Control Head) to each of the conductors.
F) Make connections to the Control Head as indicated in the following TERMINAL CONNECTIONS diagrams.
ALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM FOR ANY UNIQUE CONTROL
HEAD CONNECTIONS FOR YOUR SYSTEM.
When cable connections are complete, MOUNT Control Head to the console using the two (2) mounting screws and
washers supplied with the Control Head.
CABLE/HARNESS CONNECTIONS:
Dual Control Head Connections
Terminal Connections
Cable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.
MicroCommander/ClearCommand CruiseCommand/9000 Series
Port Lever: Starboard Lever: Port Lever: Starboard Lever:
Terminal 3 Red Terminal 3 Red Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER
Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER
Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue
Pluggable Connections
Pluggable Control Heads are supplied with a harness pigtail for each lever. When disconnecting/connecting the plugs,
ensure that the release button or buttons are depressed and held until plug is fully disconnected or connected.
Disconnecting/connecting plugs without depressing and holding the release button or buttons WILL damage the plug.
For dual lever Control Head Stations that have the user
facing aft: Reverse connections 5 and 7.
For single lever Control Head Stations that have the user
facing aft and the one Control Head lever on the user’s
right, reverse connections 5 and 7.
Handheld Control is an option. Contact your ZF Marine Electronics Dealer for further information on Handheld
requirements and options.
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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REQUIREMENTS:
Control System Wire Harness Description
MicroCommander/ ClearCommand (1) Control Head wire harness per lever. See Figure
(non-pluggable) 3, 9000 Hard Wired
Dwg #14119-2 on page #13, Figure 4, Port Processor
– Hardwiring, on page #14, and Figure 5, Starboard
Processor – Hardwiring also on page #14.
Pluggable Micro Commander/Clear (1) Control Head wire harness per lever. See Figure
Command 2B, Dwg #14119-1, Cable/Harness Connections –
Pluggable on page #12.
CruiseCommand (1) Control Head wire harness per lever. See Figure
2B, Dwg #14119-1, Cable/Harness Connections –
Pluggable, on page #12.
MiniCommand (1) Control Head wire harness per Control Head.
See Figure 2A, Dwg #14119-1, Cable/Harness
Connections – Pluggable, on page #12.
2. Check that the four mounting studs on the Control Head will start into the cutout
mounting holes. Remove Control Head from cutout.
3. Run cable/wire harnesses between Processor and Control Head. Label both ends
with the Station ID. (EXAMPLE: Port Bridge, Stbd Bridge or Port Wing, etc.).
CONNECTIONS
The 4000 series Control Heads are only available with pluggable connections and must not
be modified in any way. However, there are two types of Wire Harnesses available for
connecting the Control Head to the Processor (CruiseCommand, ClearCommand, etc.):
The Wire Harnesses for CruiseCommand and the MiniCommand Processors are always
pluggable at both ends. The Wire Harnesses for the 9000 Processors (MicroCommander
and ClearCommand) can be pluggable at both ends or pluggable at the Control Head end
and hardwired at the Processor end.
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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Mukilteo Plant
PLUGGABLE
1. Plug Control Head wire harness into the corresponding connector/pigtail coming from
the Processor. Ensure the correct Processor Cable is being plugged into the correct
Control Head pigtail. (Example: Port to Port, Starboard to Starboard.)
2. When making the connection, ensure that the mating connectors (plug and receptacle)
are fully inserted such that the connector latches are locked in place. (Note: To
disconnect the connectors, the release button or buttons must be depressed and held
until the plug and receptacle are fully disconnected.)
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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Mukilteo Plant
CABLE/HARNESS CONNECTIONS
PLUGGABLE
FIGURE 2A FIGURE 2B
WARNING: Pluggable Control Heads are supplied with a harness pigtail for each
lever. When disconnecting the plugs, ensure that the release button or buttons are
depressed and held until the plug is fully disconnected.
Disconnecting the plugs without depressing and holding the release button or buttons
WILL damage the plug.
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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Mukilteo Plant
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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Mukilteo Plant
PORT & STARBOARD PROCESSOR
HARD WIRING
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MMC-337 Rev- 12-07 ZF Electronics, LLC
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Figure 10: Control Head Mounting Holes and Cutout – Dwg #13293
DO NOT USE AS A TEMPLATE
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MMC-307 Rev.I 1-07
ZF Marine Electronics, LLC
Mukilteo Plant
700 Series Standard Control Head Variations
This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics 700 Series Control Heads.
Part Numbering Configurations Detents Available
REQUIREMENTS:
MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.
Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head lever.
CruiseCommand: one (1) Control Head Harness per Control Head lever.
Included with the Control Head:
• (4) Flat-washer - Stainless Steel, 1/4 inch
• (4) Screw - Stainless Steel, Philip Pan Head, 1/4 inch-20 x 1-3/4 inch
• (4) Nut - Stainless Steel, 1/4 inch-20
• (14) Terminal - Flanged For, #6
• (2) Liquid Tight Connector (in addition to those installed at the factory)
When the Control Head is properly mounted on a console, the Control Head is watertight.
Dimensions
Standard Cable
A) Remove the six screws holding the bottom cover of the Control Head housings and set aside.
B) Insert cable through the correct cable grip in the bottom cover.
C) Strip back the PVC cover on the shielded cable approximately 2-1/2" (63,5mm) at the Control Head.
D) At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end of the PVC
cover (the drain wire at the Control Head is not connected to ground).
E) Strip 3/8" (9,5mm) insulation off each wire.
F) Twist the individual strands of the wires to minimize fraying.
G) Crimp a locking fork terminal (included with each Control Head) to each of the conductors.
H) Make connections to the Control Head as indicated in the following TERMINAL CONNECTIONS diagrams.
A-20
Pluggable
A) Plug Control Head cable into the pigtail at the Control Head. (Ensure the correct Processor Cable is being plugged into
the corresponding Control Head lever pigtail).
B) When connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully
connected or disconnected. Connecting or disconnecting plugs without depressing and holding the release button or
buttons will damage the plug.
ALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM FOR ANY UNIQUE CONTROL
HEAD CONNECTIONS FOR YOUR SYSTEM.
When cable connections are complete:
A) Replace Control Head bottom cover using the six (6) mounting screws removed earlier. Ensure seal is in place.
B) Tighten watertight cable grip(s).
C) Remove front cover from the Control Head
D) Mount Control Head with supplied hardware.
E) Replace front cover when mounting is complete.
PLUGGABLE CONNECTIONS
Pluggable Control Heads are supplied with a harness pigtail for each
lever. When disconnecting/connecting the plugs, ensure that the
release button or buttons are depressed and held until plug is fully
disconnected or connected. Disconnecting/connecting plugs
without depressing and holding the release button or buttons WILL
damage the plug.
Aft Facing Control Head
For dual lever Control Head Stations that have the
user facing aft: Reverse connections 5 and 7.
For single lever Control Head Stations that have
the user facing aft and the one Control Head lever
on the user’s right, reverse connections 5 and 7.
Handheld Control is a Station option. Contact your ZF Marine Electronics Dealer for further information on Handheld
requirements and options.
TEMPLATE
A-22
MMC-279 Rev.B 7/02
ZF Marine Electronics, LLC
Mukilteo Plant
400 Series Weather Mount Enclosure
Single or Dual
Control Head
Gasket
3.54
Enclosure (89,9mm)
Watertight
Cable Grip
(two if Dual Control Head)
6.29
(159,8mm)
4.72
10241 (119,9mm)
A-26
S-214 Rev G 10-06
ZF Marine Electronics, LLC
Mukilteo Plant
Automatic Power Selector (APS) Model: 13505
ATTACHMENTS: DC POWER SOURCE DWG 11488E, 4 PAGES
A) GENERAL INFORMATION
The APS, Model 13505, provides a simple, solid state solution to the need for routing redundant DC power sources
for vital electronic equipment while maintaining isolation of the DC power sources.
Two independent batteries rated at the same nominal voltage are wired to separate terminals on the APS and
internal diodes maintain total isolation between them. A single output terminal is wired to the ZF Marine
Electronics Propulsion Control System.
The APS is rated for loads of up to 70 Amps on 12-24V systems. The unit is ruggedly constructed with heavy-duty
wiring studs and epoxy-potted components in an anodized aluminum case.
B) APS SPECIFICATIONS
Model: 13505
Maximum Load Current: 70 amps
Operating Temperature: - 40 degrees C to +80 degrees C; derate linearly from 100% @ 50 degrees C to 70% @ 80
degrees C
Voltage Drop: 0.7 VDC @ 50% load; 0.9 VDC @ full load
Dimensions: 3.25" x 4.5" x 3.1" (8,3 x 11,4 x 7,9 cm)
C) MATERIALS PROVIDED
The single APS is supplied with a hardware packet containing (6) hex nuts, (3) lock washers, (4) self-tapping
mounting screws, (1) instructions diagram.
NOTE: Not all of the hardware will be used in the installation; some spares are provided. Nut size is M-6.
The twin APS is supplied with (2) single APS hardware packets.
D) INSTALLATION
Refer to the installation Drawing 11488E.
1
Shut off all charging sources and disconnect the negative (ground) side of each battery which will be
wired to the APS.
2 Mount the APS(s) in a suitable location which will keep wire runs to a minimum length, and is
(preferably) ventilated, for cooler operation. The case of the APS is electrically isolated from the internal
diodes, so mounting on either a metal or non-metal surface is acceptable.
3 Complete the wiring as indicated on either Drawing 11488E-3 or 11488E-4.
4 Reconnect the negative battery posts.
E) IMPORTANT NOTE ABOUT BATTERY SOURCES
Whenever the load is turned on, it can be drawing power from the batteries. Therefore, if the batteries are not
simultaneously being recharged, or if charging will not be available for an extended period, it is recommended that
the load be shut off to prevent complete discharge of batteries.
Grounding (Bonding)
Grounding (Bonding) - 46 CFR 111.05 and ABYC Section E-11
Grounding (Bonding) should be done according to ABYC Section E-11 and Code of Federal Regulations 46 CFR
111.05.
Each grounded system must have only one point of connection to ground regardless of the number of power
sources operating in parallel in the system
A vessel's hull must not carry current as a conductor. A metallic hull, or the bonding and DC grounding systems,
shall not be used as a return conductor.
There are some limited exceptions: (1) Impressed current cathodic protection systems. (2) Limited and locally
grounded systems, such as a battery system for engine starting that has a one-wire system and the ground lead
connected to the engine. (3) Insulation level monitoring devices if the circulation current does not exceed 30
milliamperes under the most unfavorable conditions. (4) Welding systems with hull return except vessels subject to
46 CFR Subchapter D.
Grounding conductors should be green or green with a yellow stripe.
References:
CFR Sec. 111.05-13, Sec. 111.05-11
ABYC E-11 11.5.2.2, ABYC E-11.4, ABYC 11-18.
Groundinga
The hull of a metal hull vessel may serve as the common grounding conductor. If it is desirable for the item being
installed to be bonded to the vessel grounding system, and the installation or mounting method does not provide
the desired path, a separate grounding conductor may be required.
ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington
12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98273 Telefax (425) 493-1569
A-38
MMC-288 Rev.E 8-03
ZF Marine Electronics, LLC
Mukilteo Plant
References and Parts Source
A) REFERENCES
1. American Boat & Yacht Council (ABYC)
3069 Solomons Island Road
Edgewater, MD 21037-1416
E-3 Wiring Identification on Boats
E-11 AC and DC Electrical Systems on Boats
H-2.4e or 32.4g Ambient Temp. 50 degrees C
P-24 Electric/Electronic Propulsion Controls
2. Code of Federal Regulations
33 CFR 183 Subpart I - Electrical Systems
33 CFR 183.410 Ignition protection
33 CFR 183.415 Grounding
33 CFR 183.425 Conductors: General
33 CFR 183.430 Conductors in circuit of less than 50 Volts
33 CFR 183.445 Conductors: Protection
33 CFR 183.455 Over-current and Protection: General
46 CFR 111.01 - 15(b) Ambient Temp. Machinery Spaces 50 degrees C
46 CFR 111.05- System Grounds
3. Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096
J1171 External Ignition Protection
J1428 Marine Circuit Breakers
J378 Marine Engine Wiring
4. National Marine Manufacturers Association
401 North Michigan Avenue
Chicago, IL 60611
5. Underwriters Laboratories
B) PARTS SOURCE
Anti-Static Wrist Strap P/N 517 [Thomas & Betts (P/N AWCC)]
Automatic Power Selector P/N 13505
Circuit Breaker- UL Approved P/N 810 [E-T-A (P/N 41-2-514-LN2-10)]
Fuse P/N 1030 [Bussman (P/N. GDC-1A)]
Relay 12 VDC P/N 1114 [Potter-Brumfield (P/N KRPA5D6-12)]
Relay 24 VDC P/N 1122 [Potter-Brumfield (P/N KRPA5D6-24)]
Service Field Test Unit (Break-out Box) P/N 13927
WAGO Tool P/N 397 [WAGO (P/N 236-332)]
Field Test Control Head - Dual P/N 14000
ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington
12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-40
SER-161 Rev.B 5/03
ZF Marine Electronics, LLC
Mukilteo Plant
Engine Tachometer Sender Requirements
Engine Type Engine Model Sender Comments
Gasoline Inboard 3, 4, 6, 8 Cylinder Alternator’s N/A
Stator AC
Terminal or
Point Side of
the Coil
Gasoline Outboard 4, 6, 8, 14 Pole Alternator’s N/A
Stator AC
Terminal or
Point Side of
the Coil
Diesel Caterpillar Most Older & 3208, D336, D346, D348, D398, 8902 N/A
D399 & D334
Diesel Caterpillar 3116, 3126, 3176, 3196, 3406, 3408, 3306, 8922 Some use 8912. New engines have
3412, 3056, 3512 & 3516 Magnetic Pickup already installed on
flywheel.
Diesel Caterpillar All Electronic N/A Use ECM output. Outputs 12 PPR.
Diesel Cummins Most Older & 555 8902 N/A
Diesel Cummins B & C Series, KTA19M3, MTA855, * 8912 Most have Magnetic Pickup already
KTA1150M installed on flywheel.
Diesel Detroit DDEC Electronic System 8902 Must have Detroit data-link output module.
Diesel Detroit 53, 71, & 92 Series 8902 Engines manufactured before 1976 use
Aetna Part No. 8152 drive key with Sender.
Diesel Detroit 8.2 Liter 2 Cycle, Some 71 & 92 Series 8912 N/A
Diesel EMD Mechanical Sender Applications 8902 N/A
Diesel EMD Flywheel Applications 8912 N/A
Diesel Hino All Engines 8902 250 HP: Tach drive on front Port side of
engine.
310HP: Tach drive on rear center, just
below the head.
Diesel John Deere Older Engines 8902 Tach drive usually at rear Starboard side of
engine.
Diesel John Deere Newer Engines 8912 Magnetic Pickup usually already installed.
Diesel Lehman All Engines 8902 Engine built after 1977 require the Aetna
(Ford) Part No. 8619 tachometer drive adapter.
Diesel Lugger All Engines 8912 N/A
Diesel MAN In-line 8902 N/A
Diesel MAN V-Engines 8902 An extension tachometer cable Aetna Part
No. 9212 is usually required.
Engine Type Engine Model Sender Comments
Diesel MAN 826 8912 It may be necessary to manufacture a
mounting plate for the magnetic pickup.
Diesel MAN 2840, 2842, 2848, 2866 & 2886 8912 N/A
Diesel MTU All Engines 8902 N/A
Diesel Perkins 1980 and earlier 8902 N/A
Diesel Perkins 4-236 & 6-354 8902 Perkins Part No. 8875 drive adapter needed
on 1980 and newer engines.
Diesel Perkins 4-107, 4-108 & M-800TI 8902 N/A
A-43
MMC-289 Rev.- 6/01
Morse Clutch and Throttle Kit Selection
Pre-Engineered Throttle Connection Kits
MAKE ENGINE MODEL KIT NO.
Caterpillar 3208NA 300172
3208TA 305403
334, 3304, 3306 36680
3406 & 343 36680
3408 36680
Cummins A11 w/MVSGOV 36680
AFC Fuel Pump
V504M, V555M, V903M, VT903M, 300580
VTA903M, NT855M, VT171OM, VTA171OM, KT & KTA 1150M, KT & KTA 2300M, 1975
and later
General Motors 3, 4, & 6-71 w/var.sp.gov. 41736
6, 8, 12 V-71 & 6, 8 V-92 w/var.sp.gov. 41736
6-71 inclined 36680
2, 3, 4-53 w/left hand gov. 36680
Right hand gov. 36680
6V-53 Rear entry 36680
6V-53 Front entry 36680
6, 8V-71 Front entry 36680
12, 16V-149
Perkins 4, 236M 48931
6, 3544M; T6, 3544M; ST6, 3544M; SST6, 3544M 302026
4, 108 W/shut off 303878
1/4"
7-3/8" (6,4mm)
33C (187mm) Diameter
Cable
TYP 90
7/32" Shim
(5,8mm) Cable Clamp 31638 Selector
Diameter 31509 Lever
Jam Nut
Ball Joint
31126 2-3/4"
1" (70mm)
(25,4mm) 1/4"-28 UNF Maximum
Stud Movement
10246A
Cross-bar
Remove Lead Screw
33C Cable Remove
Connect Nut Snap Ring
Cable Retainer
Screws
11452-
CAUTION: Static electricity can destroy electronic components. Anytime the Actuator/
Processor cover is off, use an anti-static wrist strap and connect it to the Actuator/Processor
frame. This will drain any static charge you may have on your person.
Cross-bar
43C Cable Lead Screw
Connect Nut
Jam Nut
43C Cable
Retainer
10917A
Remove rubber boot
and dust cover
43C Cable
Figure 2: Actuator/Processor Cable Installation
B. Warranty Exclusions: This warranty covers only failures due to defects in materials or workmanship that
occurs during normal use. This warranty does not cover damage that occurs in shipment, failures that are
caused by products not supplied by ZF Marine Electronics, LLC, failures that result from installation that is
not in compliance with ZF Marine Electronics specifications, accident, misuse, abuse, neglect, water
damage, mishandling, misapplication, set-up adjustments, improper maintenance, alterations, modification
or service by anyone other than a ZF Marine Electronics Authorized Service Center, damage that is
attributable to acts of God or other causes unrelated to defects in materials and workmanship.
C. Warranty Period: the length of the applicable warranty period will depend on the use of your vessel. For
Commercial Craft the standard warranty period is for 24 months from the date of original shipment by
ZFME or 12 months after commissioning of the craft, whichever occurs first. A commercial craft is defined
as, any vessel used for any commercial purpose including but not limited to any use as a workboat,
passenger vessel, charter or rental fleet.
For Pleasure Craft the warranty period is 36 months from the date of original shipment by ZFME or 24
months after commissioning of the craft whichever comes first. A Pleasure Craft is any vessel that is or has
not been used for any commercial purpose including but not limited to any use as a workboat, passenger,
charter or rental fleet.
Repair or replacement parts provided under this Warranty will not be covered by the remainder of the
unexpired warranty in effect on the complete unit.
D. No Coverage Under Warranty: The exclusive remedy under this warranty is the repair or replacement of
the defective component and this warranty specifically does not provide coverage for:
1.Towing or transportation of the vessel, or travel to and from the job site or vessel.
2.Original installation charges or start-up costs.
3.Loss of use or income from the vessel and/or rental of equipment during the performance of warranty
repairs.
E. To Obtain Warranty Service: Please go to www.zf-marine.com or Call 1-425-583-1900 or (US only) 1-800-
545-5455 for the nearest ZF Marine Electronics Factory or Authorized Service Center.
4.The Service Center will contact ZF Marine Electronics Service Department for a Service Return Autho-
rization (SRA) number. Return th eproduct freight prepaid, marked clearly with the SRA number and
description of the malfunction.
5. If there are defects covered by this warranty, ZF Marine Electronics will, at its option, either repair or
replace the defective part or product. If after inspection, ZF Marine Electronicsm determines that the
product us not defective, ZF Marine Electronics will charge a atesting fee and return the product to the
sender, freight collect.
6. Repair or replacement during the warranty period will not extend the warranty period.
7.All SRA claims must be requested and submitted within 30 days from date of repair service.
8.Claims for over 3 hours labor must be pre-approved by the ZF Marine Electronics Serive Department
This Warranty is expressly in lieu of all other warranties, express or implied. Except to the extent prohibited by applicable
law, ZF Marine Electronics hereby disclaims all other implied or express warranties of any kind, including warranties of
merchantability and fitness for a particular purpose. Under no circumstrances shall ZF Marine Electronics be liable for any
incidental or consequential damages sustained in connection with the product or its use, including any costs or damages
which result from loss of use of the product or any engine or boat with which it is used. ZF Marine Electronics does not
authorize any representative or agent to assume for it any obligation or liability other than those expressly set forth above.
Some States and other jurisdictions do not allow limitations on how long an implied warranty lasts or the exclusion or
limitation of incidental or consequential damages, so above limitations may not apply to you. All implied warranties, if any,
are limited to the duration of this express warranty. This warranty gives you legal rights. and you may have other rights
which may may vary from State to State.
A-50
MMC-163 Rev.C 10/04
ZF Marine Electronics, LLC
Mukilteo Plant
Warranty Registration
A- 51
ZF Marine Electronics, LLC.
12125 Harbour Reach Drive, Suite B
Mukilteo, WA 98275
APPENDIX B
TROUBLESHOOTING GENERAL
The ZF Marine Electronics Control System consists of one
Processor per engine, typically mounted in the engine
Typical System Main
room, and one to five Control Heads located at the Components
vessel’s Remote Stations. In the event that a malfunction
occurs, review the appropriate System Diagram and Control Head
become familiar with the various components, their The primary function of the Control Head is to send out a
functions and locations on the vessel. The following variable DC voltage to the Processor. This DC voltage is
Sections are a list of the main components that make up representative of the Control Head’s present lever
a typical system, along with a brief description of their position. In addition to the primary function, the Control
functions: Head also has audible (Sound Transducer) and visual
(LED) status indications, along with a Transfer Button for
Control System Examples taking command and performing other system functions.
B-1
Push-Pull Cables
The primary function of a Push-Pull cable is to allow a
physical movement on one end to be felt at the opposite
end with a minimum of back-lash.
The Push-Pull cables are mechanically connected on one
end to the Processor’s cross-bars and the governor and/
or transmission selector levers on the other end. The
Processor uses the 33C Type push-pull cable as standard,
or 43C Type with a special adapter. (Refer to Appendix A
- 43C Cable)
There is one Push-Pull cable for Shift, per Processor.
These Push-Pull cables are mechanically connected to
the Processor’s cross-bars on one side and the
Transmission selector levers on the other.
There is one Push-Pull cable for Throttle, per Processor.
These Push-Pull cables are mechanically connected to
the Processor’s cross-bars on one side and the Throttle
selector levers on the other.
Prior to attempting to troubleshoot the System, get as
much information as possible from the owner or operator.
Inspect the System for signs of misadjustments, loose
connections, physical damage or water incursion.
Pay special attention to the following items:
• DC Power Source
• Component Location
• Component Condition
• Interconnecting Wiring and Harnesses
• Wire Terminations
• Plug and Connector Socket Pins
• Mechanical connections at the Selector Levers
Mechanical connections within the Processor
B-2
TROUBLESHOOTING QUESTIONS
Prior to lifting a tool or stepping on board the vessel, The following tones can be produced on all Systems
many problems can be resolved by asking the using Servo 1:
customer the following basic questions: • One Long, One Short - High Repetitive Rate
A) Is the System installed on a Single, Twin or Tone
Multiple Screw vessel? • One Long - One Short Tone
– If the System is installed on a Single Screw The following tones can be produced on all Systems
vessel, this question does not have much using Servo 2:
value in narrowing down the source of the • One Long - Two Short Tones
problem. • One Long, Two Short - High Repetitive Rate
– If the System is installed on a Twin or more Tones
Screw application, this question is quite
useful, if you ask the following question. The following tone can be produced on all Systems using
• Does the problem or symptom occur on the Solenoid Clutches:
Port, Starboard or both sides? • One Long - One Short Tone
– If the problem or symptom occurs on one F) Are there any Error Messages displayed on the
side only, you have effectively eliminated Processor’s Display LED?
50% of the possible causes. For example, the • In addition to generating a tone, at any time the
symptom only occurs on the Port side. All of system detects a malfunction or fault, an error
the components on the Starboard side have message will be displayed at the Processor.
been eliminated as potential causes. G) What is the status of the Control Head in
– If the problem occurs on both the Port and command’s red LED?
Starboard sides, you must ask yourself: What • The red LED(s) will be in one of the following
do both sides have in common? Most likely states:
answer to your question would be the DC – Lit Steady: When the red LED is Lit Steady,
Power source. this indicates that the Station is in command
B) What is the Part Number and Serial Number of and in Normal operative mode.
the Processor? – Not Lit: When the red LED is Not Lit, that
• Whenever the factory is called for technical Station is not in command, or there is no
assistance, the part number and serial number power to the Control System.
will be required. These numbers provide the – Blinking Slowly: A Slow Blinking red LED
Service Technician information about the indicates that the Control Head is in Throttle
operating characteristics of the Processor. The Only Mode (Warm-up Mode).
numbers are located on the Processor’s front – Blinking Rapidly: A red LED that is Blinking
cover. Rapidly indicates that the System is in Troll
C) How many Remote Stations are there? (If only Mode.
one Remote Station is present, not much will be H) Has anything on the vessel changed shortly prior
gained by asking this question. However, if more to or when the problem arose?
than one Remote Station is being used, command This question is often overlooked, but should be
should be taken from one of the other Stations to considered. Obvious changes such as additions
see if the problem occurs from another Station.) or changes to the electrical/ electronic equipment
• If the problem occurs from more than one onboard can affect the electrical load and in turn
Remote Station, the odds are that the Control the Processor’s power supply.
Heads are not the cause of the trouble. Ask the operator if any changes or maintenance
• If the problem occurs at one Remote Station to the vessel’s machinery have occurred lately.
only, there is a greater chance of the Control Items which are significant to you, the
Head or the Control Head Harness of being the technician, may not seem so to the casual owner
cause. or operator. An example would be changes to the
D) Are any tones generated when the problem engine’s fuel system.
occurs? The tones are used to bring the operator’s Ask about changes, that when initially
attention to a possible condition or problem. The considered, appear to have nothing to do with the
following basic tones can be produced on all Control System. An example where this really
Systems (refer to "Troubleshooting Audible occurred was on a vessel which had recently
Tones") been repainted. For unknown reasons, the
E) Slow Repetitive Tone painter took it upon himself to disconnect the
• One Long- Three Short Tones connections at a Control Head and then
• Steady Tone reconnected it incorrectly.
• Three Second Steady Tone In many cases, these simple questions can resolve a
• Five Seconds On, Five Seconds Off - High problem with no further action from you, the
Repetitive Rate Tone technician. Take the time to consider these
• Five Second Steady Tone
B-3
questions. In the long run, you will save yourself and
the customer a lot of time and money.
B-4
TROUBLESHOOTING PROBLEM RESOLUTION
If the problem could not be resolved by asking the
questions in the previous section, a careful
Component Condition
inspection of the Control System may be the next Control Heads
step. Even in situations where the problem was
found and corrected, it is good practice to always Inspect for any signs of corrosion due to water
perform a careful inspection of the entire Control incursion. If hard-wired, ensure that all the fork
System each and every time you are asked aboard a connectors are properly secured to the terminal.
boat. Verify all wires are fully crimped and do not pull
loose.
Always verify that the installation of the System is in
compliance with the Installation Manual by carefully Processors
inspecting the following:
Inspect the Processor for any signs of physical
damage.
DC Power Engine Room / Remote Switch
A) Ensure that the Processor(s) is connected to a
properly charged 12 or 24 VDC battery through a Inspect the switch wire terminations for loose or
10 Ampere circuit breaker. corroded connections.
B) To ensure reliable power to the Processors an APS Station 2 Lockout Switch
(Automatic Power Selector) is strongly
recommended. The APS takes inputs from two Inspect the switch wire terminations for loose or
separate power sources. Whichever power source corroded connections.
is at the higher voltage level, will be automatically
switched through. Interconnecting Wiring and
C) Refer to Automatic Power Selector information in
Appendix A.
Harnesses
A) Inspect the wire terminations for loose
connections, corrosion or wire strands.
Component Location B) Inspect the Harness’s pins and sockets for bent
pins, torn boots or any signs of corrosion.
Control Heads
The first step in troubleshooting a problem with the
There are virtually no restrictions regarding the Propulsion System is to determine if the problem is
location of the 400 Series and MC2000 Series with the Control System or something external to the
Control Heads, as long as the bottom is protected System. In all cases a Control System malfunction
from the environment. The 500 Series Control will alert the operator of the potential problem. This
Heads must be mounted to a console and the 700 is accomplished through the audible tone emitted at
Series are waterproof from top to bottom. all Remote Stations. When an audible tone is
Refer to Appendix A - Control Head Reference Sheet emitted, it will be accompanied by an Error Code at
for Installation requirements. the Processor. Also, in many cases, the Control
System will alert the operator to a problem external
Processors to the Control System.
The Processors are typically mounted in the engine The following are examples of components both
room, while maintaining a minimum distance of 4 internal and external to the Control System which
feet (1,22m) from sources of high heat and EMI could be a source of trouble:
(Electro Magnetic Interference) or RFI (Radio
Frequency Interference). Table B-1: Examples of Components (Internal/
External)
Refer to "Plan The Installation" section for
Internal External
requirements.
1 Processor 1 DC Power Source
Engine Room / Remote Switch 2 Control Head 2 Engine
This switch is mounted in close proximity to the 3 Interconnecting Wiring 3 Transmission
Engine Room’s Control Head. (Harnesses) 4 Push-Pull Cables
Refer to "Plan The Installation" section for 4 Interface Enclosure
requirements. 5 Switches
6 Push-Pull Cables
Station Lockout Switch
The following pages should give you a good guideline
The switch is mounted in close proximity to Station for making this determination. There is no need to
No. 2 Control Head. troubleshoot the system to any point further than
Refer to "Plan The Installation" section for one of the main components listed above. If the fault
requirements. is found to be with a Control System component, that
B-5
component is simply replaced. If the fault is found to
be with one of the external components, replace or
repair the defective component or contact a qualified
mechanic.
B-6
TROUBLESHOOTING DIAGNOSTIC MENU
The Processor has built in diagnostics designed to Down Push Button can also show the Tachometer
assist the technician in determining the cause of a Sender Frequency (Figure B-5):
problem. The following information is available to • The information shown is the actual frequency
view at any time: output by the Tachometer Sender. This signal is
• Applied Battery Voltage utilized in “Closed Loop” Synchronization. The
• Tachometer Sender Frequency Control Head’s lever position, and the resulting
• Stations 1- 5 A/D’s output of the Station’s Control Heads can always be
• Stations 1- 5 Transfer Button Status monitored. This is regardless of whether that
• Servo 2 Feedback A/D’s (if applicable) Station is in command or not. Note the placement
• Servo 1 Feedback A/D’s (if applicable) of the decimal points in the following examples,
• Software Revision Level which show all Stations with the lever positioned at
In order to access this information, follow the steps the Neutral/Idle position. This will be covered in
below: further detail later.
A) Locate the Display LED on the Port or Starboard FIGURE B-5: EXAMPLE DISPLAY OF TACH SENSOR
FREQUENCY
Processor. The Display LED will have the Processor
Part Number displayed in a running pattern moving
from left to right while the program is running in
Normal Operation.
B) Depress the Up or Down Push Button to activate the
Function Code List. The characters A001 will be F) The current status of all the Control Head’s Transfer
shown on the Display like Figure B-1: Buttons can be monitored within the Diagnostic
FIGURE B-1: DISPLAY FUNCTION CODE Menu. A 1 indicates a closure (depressed Transfer
Button) of the switch, while a 0 indicates an open
switch.
G) Depressing the Up or Down Push Button one more
time will show the current revision level of the
software. This feature will provide invaluable
C) Depress the Up or Down Push Button repeatedly until information in the years to come. Determining the
H000 is displayed like Figure B-2: characteristics or capabilities of a certain Processor
FIGURE B-2: DISPLAY TROUBLESHOOTING FUNCTION will be as simple as selecting this feature.
H) Pressing the Up or Down (Scroll) Push Button once
more, returns you to the Applied Battery Voltage.
I) The Diagnostic Menu can be exited two ways:
• Do not touch any Push Buttons for 5 minutes. The
system will automatically exit.
D) Depress and hold the Left and Right Push Buttons
• Depress the Left Push Button until H000 appears.
simultaneously until the H0 begins to blink (Figure B-
You may now scroll through the Set Up Menu.
3) Release the Push Buttons; the applied battery
voltage will now be displayed:
• The displayed value is in “real time” and provides a
rough estimate of the DC voltage applied to the
Processor. The reading is accurate to within 0.50
VDC. Refer to Figure B-4.
FIGURE B-3: DISPLAY FUNCTION BLINKING
Function Code is Blinking
B-7
FIGURE B-6: EXAMPLE DISPLAY CONTROL HEAD LEVER CURRENT POSITIONS
Station #1 Station #2 Station #3 Station #4 Station # 5
FIGURE B-7: EXAMPLE DISPLAY CONTROL HEAD TRANSFER BUTTON STATUS VIEW
Station #1 Station #2 Station #3 Station #4d Station # 5d
B-8
TROUBLESHOOTING AUDIBLE TONES
As mentioned previously, there are various tones D) The voltage differential between the power source
emitted from the Control Head if an error were to and the Processor should not exceed 1.2 Volts in 12
occur. VDC systems and 2.4 Volts in 24 VDC systems. If so,
there is high resistance somewhere between the
Basic Control System Tones battery and Processor.
NOTE: If an APS is being utilized in the power
These basic tones are as follows:
circuit, take into account the 0.7 VDC forward
Slow Repetitive Tone voltage drop of the diodes. This would increase
the permissible differential between power
source and Processor from 1.2 to 1.9 VDC in 12
The Slow Repetitive Tone, also referred to as the VDC circuits and 2.4 to 3.1 VDC in 24 VDC
“Initialization Tone” is the tone you hear at all circuits.
Remote Stations when power is initially applied to
the control system. When this tone is heard, you E) High resistance, resulting in a differential voltage of
know for a fact that the following are true: 1.2 Volts (12 VDC Systems) or 2.4 Volts (24 VDC
• Power has just been applied to the system. Systems) or greater, may be the result of corroded or
• The Software Program is running normally. tarnished connections, dirty or pitted relay contacts or
• The Processor is commanding the throttle to Idle. an improperly sized power cable.
• The Processor is commanding the clutch to Neutral. F) If the voltage differential is less than 1.2 Volts (12 VDC
This is a normal tone when power has first been Systems) or 2.4 Volts (24 VDC Systems), which is
applied to the Processor and no Control Head has what you would typically expect, a loose connection
taken command. However, if during normal may exist between the power source and the
operation the engine’s throttle drops to Idle, followed Processor. The vibration experienced while the vessel
by the clutch to Neutral, the Control Head’s red LED is underway may intermittently cause the circuit to
goes out and a slow repetitive tone is heard at all open. Check all the connections between the power
remote stations, the tone may be an indication of a source and the Processor for loose bolts, nuts, etc.
problem. This indicates that the voltage at the
One Long - Three Short Tones
Processor has momentarily dropped below 8 VDC
and then returned to a normal operational level.
This could be due to: This tone indicates that there is an invalid command
signal at the Station-in-Command. The Processor
• Loose battery power cable connection.
expects a DC voltage, representative of the Control
• Under-charged or defective battery.
Head’s present lever position.
• Voltage drop due to current flow.
This voltage is referred to as the “Command Signal”.
In order to pinpoint the exact cause of the low
In normally functioning Control Heads, the
voltage at the Processor, perform the following
command signal is between approximately 0.8 VDC
checks:
at Full Astern to 4.10 VDC at Full Ahead.
A) Check the Display on the Processor for Error
Messages. Error Message 57 may appear The command signal is converted by the Processor to
indicating Under Voltage. One or more of Error a digital representation, referred to as an A/D
Messages 43 through 54 may also be displayed. (Analog/Digital) Count. More on A/D Counts later.
This is due to the momentary loss of serial If the command signal drops below 0.6 VDC or
communication between the two Processors. exceeds 4.40 VDC, the tone will be generated.
Take note that the Under Voltage error is not only At the same time the tone is heard, throttle command
dependent on low voltage, it is also dependent on drops to Idle and the clutch will be commanded to
the duration of the low voltage. The possibility Neutral. The following items will cause this to occur:
exists that an error message would not be • An open or high resistance connection between the
displayed if the duration of the low voltage was Control Head and Processor.
short enough. However, the other symptoms • Out of calibration Control Head.
mentioned above still occur. • A defective Control Head.
B) In either case, follow the procedure listed under The exact cause of the malfunction can be found as
Section B4 - DIAGNOSTIC MENU until the Applied follows:
Battery Voltage is displayed. Take note of the applied A) Check the Processor’s Display for error messages.
voltage. Most likely, one of error messages 13 thru 32 will
C) Go to the battery or Main Distribution Panel which is be shown. The exact number shown depends on
feeding power to the Processor. With a DC Voltmeter, which remote station is experiencing the problem
measure the voltage at this power source. The battery and whether the command signal was too high or
voltage should be greater than 12.4 Volts in 12 VDC too low.
systems and 24.8 Volts in 24 VDC systems. If not, the B) Enter the Diagnostic Menu as outlined in Section B4 -
battery or it’s charging system needs servicing. DIAGNOSTIC MENU.
B-9
C) Depress the Up or Down (Scroll) Push Button until the – A high resistance connection exists on pin 6
appropriate Remote Station is displayed. (green wire) between the Control Head and
• The Remote Station are identified by the position of Processor.
the decimal points. • If the A/D value is less than 75:
• Station 1 has no decimal point after the first digit to – There is an open wire between pin 6 (green wire)
the far right. The remaining three digits all have of the Control Head and the Processor.
decimal points. – There is an open wire between pin 7 (blue wire)
• If the digit to the far left had no decimal point of a right hand Control Head and the Processor.
following it, but the remaining three do, this would – There is an open wire between pin 5 (blue wire)
represent Station 4. of a left hand Control Head and pin 7 (blue wire)
D) The examples above are shown with no Control of the Processor.
Heads connected to any Remote Stations. When a To gain command at the Control Head, ensure the
Control Head is connected, the appropriate A/D Control Head levers are in the Neutral/Idle position
(Analog/Digital) value for the present position of the and depress the transfer button. This will regain
Control Head’s lever will be shown, as in the command of the gear box and throttle with the
examples at the bottom of the page. ClearCommand System.
E) An A/D value of 910 or greater will generate an Error
Code. The code will be 13 to 22 (Control Head # Steady Tone
Faulted High), depending on which Station has the
high Command Signal. The Steady Tone is an indication to the operator that
• If the A/D value is greater than 910, but less than something has gone wrong within the Control
990, one of the following may be the cause: System. The Steady Tone will typically be
– The Control Head’s potentiometer is out of accompanied by an Error Message on the Processor’s
calibration. Display. If the tone is heard, the Processor’s Display
– The potentiometer is defective. must be referred to in order to further diagnosis the
problem.
In either case, it is recommended that the Control
Head is replaced. If the Transfer Button is shorted - Tone will cease
when command is taken at another Station.
• If the A/D value is 995 or higher, most likely the
potentiometer’s ground has been lost. If the Transfer Button becomes shorted for 12
• Right hand Control Heads have a jumper between seconds or more during Normal Operation, a steady
pins 3 and 5 if a Harness is used. This jumper tone will be produced at all Remote Stations as long
provides the potentiometers ground. as the Transfer Button remains shorted. Full System
• Left hand Control heads have a jumper between control remains. Transferring to another Remote
pins 3 and 7 if a Harness is used. This jumper Station silences the Steady Tone. Command cannot
provides the potentiometers ground. be regained at the (shorted) Station until the problem
• The potentiometer ground connection for Control is rectified.
Heads are hard-wired to the Processor through the
yellow wire (pin 5 on right hand and pin 7 on left
Three Second Steady Tone
hand).
This tone could indicate one of three things:
F) If the A/D value is 100 or less, one of Error Codes 23 —
32 (Control Head # Faulted Low) will be shown. • Transfer Button on the Control Head in command is
• If the A/D value is less than 100, but greater than stuck.
75, the following may be the cause: • If the Processor for this System includes the use of
– The Control Head’s potentiometer is out of Back-up Mode, this tone would indicate that there
calibration. has been a switch closure requesting Back-up
– The potentiometer is defective. Mode.
• If the Processor for this System includes Integrated
Solenoid Trolling Valve control, this tone would
B-10
indicate that there has been a Troll Solenoid error. – The green (signal) or orange (reference voltage)
Refer to the Error Code displayed. wires between the potentiometer and plug are
not making contact or have a high resistance
Three Second Steady Tone, followed by a contact.
Slow Repetitive Tone – The potentiometer is out of calibration.
– The potentiometer is defective.
This tone indicates that there has been a shorted – The Control Circuit is defective.
Transfer Button on power-up. Command can be The Servo 2 feedback signal can be viewed within
gained at any other Remote Station, which silences the Diagnostic Menu. The Value displayed depends
the Slow Repetitive Tone. on the direction and amount of push-pull cable
travel. As a general rule:
Five Seconds On, Five Seconds Off - High • When the Value displayed is 1023 or 0, the problem
Repetitive Rate Tone is with the wiring between the potentiometer and
plug.
Loss of communication with Station Expander (SE) • If the displayed Value varies, the potentiometer is
or the Troll Actuator (p/n 9001). This tone cannot be defective.
cleared unless all Error Codes (Active and In-Active) • When the Value is too high or too low when fully
have been cleared. extended, the potentiometer requires calibration.
Five Second Steady Tone One Long, Two Short - High Repetitive
Rate Tones
Loss of Serial Communication.
This tone is also referred to as a Jam Tone. When
Clutch Solenoid Control sounded, Servo 2 is unable to reach the commanded
position. In most cases when a Jam Tone is
System Tones encountered, it can be cleared by moving the Control
Head lever back to the point prior to where the tone
One Long - One Short Tone was first encountered.
The tone will be accompanied by Error Code 65 and
This tone can be produced if solenoid monitoring is is typically caused by one of the following reasons:
turned ON with Function Code H2. When this tone
• Stiff or frozen selector lever.
is sounded this tone will also be accompanied by one
• Misadjusted push-pull cable.
of the following error codes:
• Defective push-pull cable.
• 1 - Clutch Astern Shorted • Low battery voltage.
• 2 - Clutch Astern Open • Defective Processor.
• 5 - Clutch Ahead Shorted
• 6 - Clutch Ahead Open In order to isolate the cause to one of these five
items, follow the steps below:
B-12
TROUBLESHOOTING STATION TRANSFER
In order to transfer command from one Remote
NOTE: The A/D values listed for Full Ahead and
Station to another, the following must occur:
Full Astern represent the point where maximum
• There must be a valid “Command Signal” at the throttle is reached. The A/D count when the
Station being transferred to. Control Head lever is physically at it’s maximum
• The “Command Signal” must indicate that the point will be higher, but may not exceed the
Control Head’s lever(s) is at the Neutral/Idle out-of-range values listed in Table B-2 on page
position. B–13.
• The Transfer Button must be depressed which takes
the “Station Select” signal from 5.00 VDC to 0.00 • The Command Signal at Full Ahead is 82- 84% of
VDC. the Reference Voltage when measured at the
Station terminal block. The actual value read by the
If a transfer from one Remote Station to another is
Processor is 2% below that value or 80- 82% of
requested, but does not take place; the items required
1023 A/D Counts (821- 841 A/D).
for successful transfer can be tested as follows:
• The Command Signal at Full Astern is 17 - 19% of
the Reference Voltage when measured at the
Command Signal Station terminal block. The actual value read by the
• The Command Signal is a DC voltage which varies Processor is 2% below that value or 15- 17% of
in relationship to the Control Head’s lever position. 1023 A/D Counts (153- 173 A/D).
• The Processor provides each Control Head 5.00 +/- • Since the Command Signal is based on a
0.20VDC, which is referred to as the “Reference percentage of the Reference Voltage, the distance
Voltage”. of the Control Head from the Processor has no
• The Reference Voltage is applied to a 5K Ohm impact on the performance of the system.
Potentiometer in the Control Head. • The amount of voltage drop, due to current flow, is
• The potentiometer’s “Wiper” taps off a portion of the same for both the Reference and Command
the Reference Voltage and sends it back to the Voltages.
Processor. • The relationship between the Reference and
• The amount of DC voltage which is tapped off, is Command Voltages when thought of as a
dependant on the position of the Control Head’s percentage, will remain the same regardless of
lever. distance. For instance, here are two examples.
• When the lever is fully Astern, a small portion of the Example 1
Reference Voltage is tapped off by the wiper, and Reference Voltage 5.00 VDC 1023 A/D Counts
therefore, the voltage is at its lowest point Command Voltage 2.45 VDC 501 A/D Counts
(approximately 0.80 VDC).
• When the lever is positioned fully Ahead, a larger Example 2
portion is tapped off and the voltage is at its highest Reference Voltage 4.80 VDC 1023 A/D Counts
point (approximately 4.10 VDC). Command Voltage 2.35 VDC 501 A/D Counts
As you can see by the examples, even though the
A to D Counts Command Voltages are different between Examples
1 and 2, the resulting A/D counts, are the same
Since all the calculations within the control system
because of the different Reference Voltages. This
are performed digitally, these DC voltages are
would result in the Processor commanding the
expressed as and converted to a digital
identical outputs (Clutch & Throttle) in both cases.
representation.
A) The A/D count for a specific Control Head’s lever can
• The “Reference Voltage” (approximately 5.00 VDC)
be seen on the Processor’s Display by following the
by which all analog inputs are based, is represented
steps outlined in Section B4.
as 1023 A/D (Analog to Digital) Counts.
• This allows for the possibility of a 1024 possible B) Once the appropriate remote station is reached,
positions when 0 is included in the count. ensure that the displayed A/D Count represents the
• The value of the Command Voltage with the lever at Neutral/Idle position (485- 505 A/D counts).
the Neutral/Idle position is 49- 51% of the Command will not be accepted unless the Control
Reference Voltage when measured at the Station Head’s lever is at the Neutral/Idle position.
terminal block. The actual value read by the The following table shows the appropriate A/D
Processor is 2% below that value or 47% to 49% of Counts for various Control Head lever positions:
1023 A/D Counts (485- 505 A/D). Table B-2: Control Head Lever A/D Counts
Control Head Lever Position A/D Count
Lever Out of Range Low 100
Full Astern 153 - 173
Neutral / Idle 485 - 505
Ahead Shift Point 537
B-13
Table B-2: Control Head Lever A/D Counts (Continued) • A solid tone is heard from all remote stations, until
Control Head Lever Position A/D Count
the button’s contact opens or transfer to another
remote station has taken place.
Full Ahead 821 - 841
If a Control Head that is not in command has a stuck
Lever out of Range High 910
transfer button, the following will happen:
• If Control Head levers are positioned at Neutral/Idle,
Remote Station Select a solid tone is heard from all remote stations.
The second required item for taking command is • If Control Head levers are positioned other than
“Station Select” or depressing of the Transfer Button. Neutral/Idle, a three (3) second tone is heard from
The Transfer Button can be tested by entering the all remote stations.
Diagnostic Menu H0. • Error Code 33 — 42, depending on which remote
A) Depress the Up or Down (scroll) Push Button until four station, will be shown on the Processor Display.
zeroes are displayed without decimal points as shown • Command can be taken at any other operational
in Figure B-3. remote station.
• After one (1) second command can be regained at
FIGURE B-3: DISPLAY STATION A/D’S NO STATION TRANSFER the remote station with the stuck button as long as
BUTTON DEPRESSED
the problem has been corrected by depressing the
transfer button.
If a stuck Transfer Button is suspected, this can be
verified by looking at the Station Select status (1 or 0)
as outlined in Section B6-4 - "Remote Station Select".
B) For Stations 1 - 4 when the Transfer Button is • An Error Code 33 — 42 will be shown on the
depressed, the 0 which represents that remote Display, depending on which Station is
station, will change to a 1 as shown in Figure B-4. experiencing the problem.
FIGURE B-4: EXAMPLE DISPLAY STATION A/D’S TRANSFER
BUTTON DEPRESSED FOR STATIONS 1 THROUGH 4
Engine Room/Remote Switch
A defective (open) switch will prevent the transfer of
command on one side (port or starboard) only, while
command is transferred to the Engine Room Station
For Station 5 when the Transfer Button is on the other side (split control). A switch with a
depressed, all four decimal points will light as shorted contact will prevent any station, other than
shown in Figure B-5. Station 1 from taking command on one side.
FIGURE B-5: DISPLAY STATION A/D/S TRANSFER BUTTON A suspected faulty switch can be verified by
DEPRESSED FOR STATION 5 following the steps below:
A) Turn the Engine Room/ Remote ‘OFF’ (open contact).
B) Measure the DC voltage across the switch contact.
• If 5.00 ± 0.2 VDC is measured, continue with step
C).
• Whenever command cannot be gained at a • If approximately 0 VDC is measured, skip ahead to
particular remote station, the Station Select and step F).
Command Signals are the first to be investigated. If C) Turn the Engine Room/ Remote Switch ‘ON’ (closed
either the Command Signal is out of range or the contact).
Station Select is inoperable, command will not be D) Measure the DC voltage across the switch contact.
accepted at that remote station. • If 5.00 ± 0.2 VDC is measured, the switch is
defective and must be replaced.
Stuck Transfer Button • If approximately 0 VDC is measured, continue with
step E).
The Transfer Button is a normally open, momentary E) At the Processor, scroll down to Function Code A5
switch. The only time the switch should close is and ensure a value of 01 or 03 is entered.
when it is depressed to take command or when • If A5 is not set to 01 or 03, it must be changed.
entering or departing various other functions. In the • If A5 is set to 01 or 03, the Processor is defective
event that the Transfer Button became stuck in the and must be replaced.
closed position, the following will occur:
F) If 0 VDC was measured in step B), measure the DC
• The Transfer Button would have to be closed for 15
voltage at TB10, pins 1 and 2 on the Processor’s
seconds or more.
circuit board.
• The throttle and clutch are not affected.
• If 5.00 ± 0.2 VDC is measured, the cable between
the switch and the Processor has an open
conductor or is not terminated properly.
B-14
• If approximately 0 VDC is measured, continue with G) Disconnect the two conductors from TB10, pins 3 and
step G). 4.
G) Disconnect the two conductors from TB10, pins 1 and H) Measure the DC voltage across TB10, pins 3 and 4.
2. • If approximately 0 VDC is measured, the Processor
H) Measure the DC voltage across TB10, pins 1 and 2. is defective and must be replaced.
• If approximately 0 VDC is measured, the Processor • If 5.00 ± 0.2 VDC is measured, continue with step
is defective and must be replaced. I).
• If 5.00 ± 0.2 VDC is measured, continue with step I) Disconnect the two conductors from the switch
I). contact.
I) Disconnect the two conductors from the switch J) Measure the resistance across the switch contact.
contact. • If infinite resistance is measured, the switch is good
J) Measure the resistance across the switch contact. and the cable’s conductors are short circuited and
• If infinite resistance is measured, the switch is good must be replaced.
and the cable’s conductors are short circuited and • If approximately 0 Ohms is measured, the switch is
must be replaced. defective and must be replaced.
• If approximately 0 Ohms is measured, the switch is
defective and must be replaced.
B-15
TROUBLESHOOTING ERROR CODES
As stated previously, if a problem with the Control System is detected, the Processor is programmed to display
numerous Error Codes to aid in the isolation of the cause. The following tables list these Error Codes, along with
a brief description.
B-18
Table B-5: Basic Error Codes (Continued)
Error # Title Description
53 Comm. Error Time-out Communication with System 1 has been too long without a Refresh
System 4 message
54 Comm. Error Time-out Communication with System 1 has been too long without a Refresh
System 5 message
55 SE Communication Error Communication with the Station Expander has been too long without a
Refresh message.
56 High Battery Voltage Fault The applied battery voltage is 30VDC or higher for at least two seconds.
57 Low Battery Voltage Fault The applied battery voltage is 10VDC or lower for at least two seconds.
58 Reset Due to Software The system has had an unexpected Reset, due to a software problem.
Watchdog
59 Reset Due to Software Fault The system has had an unexpected Reset, due to a softwareproblem.
60 Reset Due to Hardware The system has had an unexpected Reset, due to a hardware problem.
Watchdog
61 Oscillator Watchdog The system Oscillator has experienced a malfunction.
B-19
PROBLEM CAUSES AND SOLUTIONS
The following table lists the various Error Codes and provides possible causes and solutions. Error Codes
appearing on the Port side Processor’s Display LED are port side errors and vice versa. The Causes and Solutions
provided are the most likely, but are not the only possible causes for the Errors Codes listed.
b No continuity between pin 5’s of the Control b Ensure that the red conductor is properly
Head Harness connectors. crimped to pin 5 at both connectors.
c Control Head jumper (pin 3 to 5 or 7) is missing. c Install a jumper from pin 3 to 5 on right hand
and 3 to 7 on left hand Control Heads.
23 a The Station No.1 Control Head is defective. a Replace Station No.1 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
24 a The Station No.2 Control Head is defective. a Replace Station No.2 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
B-22
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
25 a The Station No.3 Control Head is defective. a Replace Station No.3 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
26 a The Station No.4 Control Head is defective. a Replace Station No.4 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
27 a The Station No.5 Control Head is defective. a Replace Station No.5 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
28 a The Station No.6 Control Head is defective. a Replace Station No.6 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors crimped to pin 7 at both connectors and there is
continuity.
29 a The Station No.7 Control Head is defective. a Replace Station No.7 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
30 a The Station No.8 Control Head is defective. a Replace Station No.8 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
31 a The Station No.9 Control Head is defective. a Replace Station No.9 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors crimped to pin 7 at both connectors and there is
continuity.
B-23
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
32 a The Station No.10 Control Head is defective. a Replace Station No.10 Control Head.
b No continuity between pin 6’s of the Control b Ensure that the green conductor is properly
Head Harness connectors. crimped to pin 6 at both connectors and there is
continuity.
c No continuity between pin 7’s of the Control c Ensure that the blue conductor is properly
Head Harness connectors. crimped to pin 7 at both connectors and there is
continuity.
33 a The Station No.1 transfer button was held down a Clear the Error Code from memory
for 15 seconds or longer
b The Station No.1 Control Head transfer button is b Replace the Control Head
defective
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. In addition,
ensure that the red conductor is crimped to pin 5
of the connector and connected to pin 3 of the
Control Head’s terminal block.
34 a The Station No.2 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.2 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
35 a The Station No.3 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.3 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
B-24
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
36 a The Station No.4 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.4 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
37 a The Station No.5 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.5 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
38 a The Station No.6 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.6 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
39 a The Station No.7 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.7 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
B-25
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
40 a The Station No.8 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.8 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
41 a The Station No.9 transfer button was held down a Clear the Error Code from memory.
for 15 seconds or longer.
b The Station No.9 Control Head transfer button is b Replace the Control Head.
defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
42 a The Station No.10 transfer button was held a Clear the Error Code from memory.
down for 15 seconds or longer.
b The Station No.10 Control Head transfer button b Replace the Control Head.
is defective.
c The Control Head Harness is miswired. c Ensure that the orange conductor is crimped to
pin 4 at both ends and the red wire is crimped to
pin 5 at both ends of the Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to
pin 4 of the connector and connected to pin 4 of
the Control Head’s terminal block. Ensure that
the red conductor is crimped to pin 5 of the
connector and connected to pin 3 of the Control
Head’s terminal block.
43 a The Serial Harness is in excess of 120 feet (37m). a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated. termination is at one side only.
44 a The Serial Harness is in excess of 120 feet (37m). a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated. termination is at one side only.
B-26
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
45 a The Serial Harness is not connected at one or a Ensure that the Serial Harness is properly seated
more Processors. at all Processors.
b The Serial Harness is incorrectly wired. b Refer to the Serial Plug pin-out in Appendix B.
Correct or replace the Harness.
c Loss of power to one of the Processorr. c Restore Power to the Processor.
46 a The Serial Harness is in excess of 120 feet (37m) a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated. termination is at one side only.
47 a The Serial Harness is in excess of 120 feet (37m). a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated termination is at one side only.
48 a The Serial Harness is in excess of 120 feet (37m). a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated. termination is at one side only.
49 a The Serial Harness is in excess of 120 feet (37m). a Reposition the Processor(s) so that the Serial
Harness is less than 120 feet (37m).
b The Processor is defective. b Replace the faulty Processor.
c The Serial Harness’s shield is not properly c Ensure that the shield is terminated and the
terminated. termination is at one side only.
50 a The Serial Harness is not connected at Processor a Connect the Serial Harness into Processor ID
ID No.1. No.1.
b None of the Processors has ID No. 1 selected. b Identify one of the Processors as ID No.1 with
the A0 function.
c Loss of power to Processor ID No.1. c Restore power to Processor ID No.1.
51 a The Serial Harness is not connected at Processor a Connect the Serial Harness into Processor ID
ID No.2. No.2.
b None of the Processors has ID No.2 selected. b Identify one of the Processors as ID No.2 with
the A0 function.
c Loss of power to Processor ID No.2 c Restore power to Processor ID No.2.
52 a The Serial Harness is not connected at Processor a Connect the Serial Harness into Processor ID
ID No.3. No.3.
b None of the Processors has ID No.3 selected. b Identify one of the Processors as ID No.3 with
the A0 function.
c Loss of power to Processor ID No.3. c Restore power to Processor ID No.3.
53 a The Serial Harness is not connected at Processor a Connect the Serial Harness into Processor ID
ID No.4. No.4.
b None of the Processors has ID No.4 selected. b Identify one of the Processors as ID No.4 with
the A0 function.
c Loss of power to Processor ID No.4. c Restore power to Processor ID No.4.
54 a The Serial Harness is not connected at Processor a Connect the Serial Harness into Processor ID
ID No.5. No.5.
b None of the Processors has ID No.5 selected. b Identify one of the Processors as ID No.5 with
the A0 function.
c Loss of power to Processor ID No.5. c Restore power to Processor ID No.5.
B-27
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
55 a The Serial Harness is not connected to the SE. a Connect the Serial Harness to the SE.
b The Serial Harness is not connected to the b Connect the Serial Harness to the Processor
Processor reporting the fault. reporting the fault.
c No power to the SE. c Turn power ‘On’ to the SE.
56 a The battery is being overcharged. a Repair or replace the charging system.
b There’s a loose terminal on the battery while b Clean and tighten the battery posts and
being charged. terminals.
57 a Battery will not take a charge and is defective. a Replace the battery.
b The battery is not being properly charged b Repair or replace the charging system.
c There’s a high resistance connection between c Locate and repair the high resistance connection
the battery and the Processor.
58 a External Interference, such as a lightning strike. a If the error message is displayed once and you
are able to clear the error, take no further
actions at this time. If the error cannot be
cleared, replace the Processor.
b Component failure. b Replace the Processor.
59 a External Interference, such as a lightning strike. a If the error message is displayed once and you
are able to clear the error, take no further
actions at this time. If the error cannot be
cleared, replace the Processor.
b Component failure. b Replace the Processor.
60 a External Interference, such as a lightning strike. a If the error message is displayed once and you
are able to clear the error, take no further
actions at this time. If the error cannot be
cleared, replace the Processor.
b Component failure. b Replace the Processor.
61 a External Interference, such as a lightning strike. a If the error message is displayed once and you
are able to clear the error, take no further
actions at this time. If the error cannot be
cleared, replace the Processor.
b Component failure. b Replace the Processor.
Table B-9: Servo 1 Clutch Problem Causes and Solutions
Erro
CAUSE SOLUTION
r#
62 a Excessive Clutch Push-Pull cable travel. a Readjust Function Code C6 and or C7.
b The load on the Push-Pull cable exceeds 40 Lbs. b Contact a certified Marine Transmission
technician to determine the cause of the
excessive load.
c The Push-Pull cable is defective. c Replace the Push-Pull cable
d The Processor’s Clutch Servo (Servo 1) is d Replace the Processor.
defective.
e Low battery voltage. e Charge, repair or replace the battery, charging
system or power distribution system.
63 a The Clutch Servo’s feedback potentiometer is a Replace the Processor or calibrate the
out of calibration. potentiometer.
b The Clutch Servo’s feedback potentiometer is b Replace the Processor or replace the
defective. potentiometer.
c The Processor’s Circuit Board is defective. c Replace the Processor or the Circuit Board.
B-28
Table B-9: Servo 1 Clutch Problem Causes and Solutions
Erro
CAUSE SOLUTION
r#
64 a The Clutch Servo’s feedback potentiometer is a Replace the Processor or calibrate the
out of calibration. potentiometer.
b The Clutch Servo’s feedback potentiometer is b Plug the feedback potentiometer’s brown plug
unplugged from the Circuit Board. into the Circuit Board.
c The Clutch Servo’s feedback potentiometer is c Replace the Processor or the feedback
defective. potentiometer
d The Processor’s Circuit Board is defective. d Replace the Processor or the Circuit Board.
Table B-10: Servo 2 Throttle Problem Causes and Solutions
Erro
CAUSE SOLUTION
r#
65 a Excessive Throttle Push-Pull cable travel. a Readjust Function Code E2 and or E3.
b The load on the Push-Pull cable exceeds 40 Lbs. b Contact a certified Marine Transmission
technician to determine the cause of the
excessive load..
c The Push-Pull cable is defective. c Replace the Push-Pull cable
d The Processor’s Throttle Servo (Servo 2) is d Replace the Processor.
defective.
e Low battery voltage. e Charge, repair or replace the battery, charging
system or power distribution system.
66 a The Throttle Servo’s feedback potentiometer is a Replace the Processor or calibrate the
out of calibration. potentiometer.
b The Throttle Servo’s feedback potentiometer is b Replace the Processor or replace the
defective. potentiometer.
c The Processor’s Circuit Board is defective. c Replace the Processor or the Circuit Board.
67 a The Throttle Servo’s feedback potentiometer is a Replace the Processor or calibrate the
out of calibration. potentiometer.
b The Throttle Servo’s feedback potentiometer is b Plug the feedback potentiometer’s brown plug
unplugged from the Circuit Board. into the Circuit Board.
c The Throttle Servo’s feedback potentiometer is c Replace the Processor or the feedback
defective. potentiometer
d The Processor’s Circuit Board is defective. d Replace the Processor or the Circuit Board.
B-29
TROUBLESHOOTING PROBLEMS
WITHOUT ERROR CODES
In addition to the Error Codes listed above, some problems may not necessarily generate Error Codes. The
following give some examples where the Processor may not detect a fault, though the operation may not be
perfect:
B-31
Table B-12: Solenoid Clutch Without Error Codes
SYMPTOM CAUSE REMEDY
Cannot obtain Warm-up a The Processor is sensing a Depress the Transfer Button while moving the
Mode while moving the that the Control Head’s Control Head lever in the Astern direction. If the
Control Head lever in the lever is moving in the LED begins to blink, the Control Head is
Ahead direction, only in Astern direction incorrectly wired. Check the colors of the wires at
the Astern direction. pins 5 and 7.
• A right hand Control Head should have yellow at
pin 5 and blue at pin 7.
• A left hand Control Head should have blue at pin
5 and yellow at pin 7.
• Ahead and Astern Solenoid Wires need to be
reversed.
Table B-13: Servo Clutch Problems Without Error Codes
SYMPTOM CAUSE REMEDY
Cannot obtain Warm-up a The Processor is sensing a Depress the Transfer Button while moving the
Mode while moving the that the Control Head’s Control Head lever in the Astern direction. If the
Control Head lever in the lever is moving in the LED begins to blink, the Control Head is
Ahead direction, only in Astern direction incorrectly wired. Check the colors of the wires at
the Astern direction. pins 5 and 7.
• A right hand Control Head should have yellow at
pin 5 and blue at pin 7.
• A left hand Control Head should have blue at pin
5 and yellow at pin 7.
• The Clutch Servo’s direction of travel must be
changed with Function Code C5 if the yellow
and blue wires are reversed.
Table B-14: Electronic Throttle Without Error Codes
SYMPTOM CAUSE REMEDY
The engine RPM’s vary, a Problem with the a Connect the Break-out Box (p/n 13927) as shown in
without moving the Governor. the Throttle Testing Section of the Service Field
Control Head lever Test Unit Manual.
(synchronization • If variations are seen, proceed to Step b).
disabled). • If no variations are seen, contact a certified
engine mechanic.
b Erratic Command Signal. b Refer to Command Signal testing in the
"Troubleshooting Station Transfer" section.
• If variations of the A/D counts occur, connect
the Control Head to another Station (if available)
on the Processor.
• If variations persist, replace the Control Head.
The engine’s Idle speed is a Function Code E2 a Adjust Throttle Minimum as specified in Section 5
too high. Throttle Minimum is - SET UP PROCEDURES.
incorrectly set.
b Function Code E6 High b Decide whether High Idle is required or not. If not
Idle is programmed to a required, set the value of E6 to 00.0. If the High
value other than 00.0. Idle feature is required, press the Transfer Button
for approximately 1/2 second to toggle to Low Idle.
c The Governor or its c After Causes a. and b. have been eliminated,
Control Module is contact a certified engine mechanic to properly
incorrectly adjusted or adjust.
faulty.
B-32
Table B-15: Servo Throttle Problems Without Error Codes
SYMPTOM CAUSE REMEDY
The engine RPM’s vary, a Problem with the a Observe the Throttle push-pull cable. If variations
without moving the Governor or Carburetor. are seen, proceed to Step b.
Control Head lever b Erratic Command Signal. b Refer to Command Signal testing in the
(synchronization "Troubleshooting Audible Tones" section. If
disabled). variations of the A/D counts occur, connect the
Control Head to another Station (if available) on
the Processor. If variations persist, replace the
Control Head.
The engine’s Idle speed is a Idle was not adjusted a Adjust the throttle Push-Pull cable as specified in
too high. mechanically correct at Section 5 - SET UP PROCEDURES.
the Idle stop.
b Function Code E2 b Adjust Throttle Minimum as specified in Section 5
Throttle Minimum is - SET UP PROCEDURES.
incorrectly set.
c The Governor or its c After Causes a. and b. have been eliminated,
Control Module is contact a certified engine mechanic to properly
incorrectly adjusted or adjust.
faulty.
Table B-16: Engine Room/Remote Switch Problems Without Error Codes
SYMPTOM CAUSE REMEDY
Command of only one a Suspected Faulty Switch a Perform the Testing Steps in the "Troubleshooting
side (Port or Starboard) is Station Transfer" section to determine remedy.
transferred to Engine
Room Station.
Table B-17: Station 2 Lockout Switch Problems Without Error Codes
SYMPTOM CAUSE SOLUTION
The Lockout Switch has a Faulty Lockout Switch a Perform the Testing Steps in the "Troubleshooting
failed to OPEN or Station Transfer" section to determine remedy.
CLOSE.
B-33
SYNCHRONIZATION TROUBLESHOOTING
If you encounter a problem with Synchronization, it will more than likely one of the following; failure to attempt
to synchronize, synchronizing at different RPM’s or RPM variations of one or both engines while synchronized.
Each problem is distinct and the cause may differ depending on the type of Synch. Therefore, each type is
discussed individually.
B-35
Table B-20: Servo Throttle Troubleshooting (Continued)
SYMPTOM CAUSE SOLUTION
The green LED is lit solid, a The throttle travel from a Scroll to Function Codes E2 and E3 on both
though the Engine RPM’s Idle to Full is set Processors and compare the Values.
differ by a significant differently on the Port The Values of E2 and E3 must be the same for both
amount. and Starboard Processors.
Processors.
b The engines run at b While underway at cruising speed, decrease the
different RPM’s with Value of Function Code E3 on the Processor
equal travel of the running at the higher RPM until both engine are at
Governors’/ Carburetors’ the same RPM.
selector lever. This is not a normal condition and is masking the
actual problem with the engine. Top speed may be
sacrificed by doing so.
Install Tach Senders and enable Active
Synchronization with Function Code E7.
c Excessive back-lash in c Remove the excessive back-lash or install Tach
the push-pull cable(s) or Senders and enable Active Synchronization with
linkage. Function Code E7.
d Excessive bends in the d Reroute the push-pull cable(s) or install Tach
push-pull cable(s). Sender and enable Active Synchronization with
Function Code E7.
Active Synchronization
Table B-21: Basic Troubleshooting
SYMPTOM CAUSE SOLUTION
The green LED is lit solid, a The Tach Sender signal a Scroll to Function Code H0. Go to the Value for
though the Engine RPM’s has been lost by one or the Tach Sender’s input frequency. If the
differ by a significant both Processors. frequency displayed is 0000, the signal has been
amount. lost and the system diverted to Equal Throttle
Synch. Correct the wiring or replace the Sender.
Will not synchronize. a Synchronization is a At the Station-in-Command, move both Control
Disabled. Head levers to more than 5% of the speed range.
Press and hold the transfer button for 5 seconds.
If synch is disabled, the green LED will light as
long as the button is pressed.
If synch was enabled, the green LED would have
blinked twice.
b The Serial b Plug the Serial Communication Harness into both
Communication Harness Processors.
is not plugged into both
Processors.
c The Port and Starboard c On the Port Processor, scroll to Function Code A0
Processors have the and enter a Value of 01.
same ID number. On the Starboard Processor, scroll to Function
Code A0 and enter a Value of 02.
d The Port and Starboard d Scroll to Function Code A1, on the Port and
Processors are not set up Starboard Processor. Enter a Value of 02 into both
for twin screw operation. Processors.
B-36
Table B-22: Servo Throttle Troubleshooting
SYMPTOM CAUSE SOLUTION
One or both of the a A Control Head’s a Scroll to the Diagnostic Menu Function Code H0.
engines continually Command Signal is Go to the appropriate Station A/D Count’s display.
changes RPM. Will not varying. The Value should not change by more than +/- 1 A/
synchronize properly. D Count. If so, check the connections and if good,
replace the Control Head.
b The engine(s) is not b Increase the engines’ RPM’s in Warm-up Mode.
running smoothly. Scroll to Function Code H0 and display the Tach
Sender’s input frequency.
• If the frequency is varying, check the push-pull
cable for movement.
• If the push-pull cable is not moving, swap the
Port and Starboard Tach Senders.
• If the frequency still varies on the same side, the
engine needs servicing.
c Defective Tach Sender. c Same procedure as b. However, if the frequency
variations move to the opposite side, replace that
Tach Sender.
Table B-23: Electronic Throttle
SYMPTOM CAUSE SOLUTION
The green LED is lit solid, a Function Code E7 is set a Scroll to Function Codes E2 and E3 on both
though the Engine RPM’s to 00 and the Throttle Processors and compare the Values.
differ by a significant Minimum and Throttle The Values of E2 and E3 must be the same for both
amount. Maximum Values differ Processors. Adjust as necessary.
between the Port and
Starboard Processors.
b The engines run at b Active Synchronization MUST be Enabled.
different RPM’s with the
same throttle command
signals.
One or both of the a A Station-in-Command a Scroll to the Diagnostic Menu Function Code H0.
engines continually Control Head’s Go to the appropriate Station A/D Count’s display.
changes RPM (hunts). Command Signal is The Value should not change by more than +/- 1 A/
Will not synchronize varying. D Count.
properly. If so, check the connections and if good, replace
the Control Head.
b One or both of the Tach b Scroll to Function Code H0 on both Processors and
Signals isn’t being read, display the frequency of the Tach Signal. If
or is being read variations of the signal are measured, the cause
intermittently. Function must be determined.
Code E7 is set to a Value
of 01 or 03.
B-37
Table B-23: Electronic Throttle (Continued)
SYMPTOM CAUSE SOLUTION
Synchronization does not a The Processors think a Place both the Port and Starboard Processor into
function. The Control Astern is being Warm-up Mode by pressing the Transfer Button
Head’s green LED does commanded when the while moving the Control Head levers to the Ahead
not light. Control Head lever is detent. Both Control Head’s red LEDs should be
positioned to the Ahead blinking. If not, the 7-conductor’s connections at
Detent. pins 5 and 7 are reversed.
b The Serial b Ensure the Serial Harness’ plugs are fully inserted
Communication Harness into the Port and Starboard Processor’s Pigtails.
is not properly installed.
c The Processors are not c Scroll to Function Code A1 on both Processors and
programmed for twin verify that the Value of both is set to 02.
screw.
d Both Processors are set d Scroll to Function Code A0 and verify that the Port
to the same ID number. and Starboard Processors have different ID
numbers.
e Function Code E7 Value e Depending on the installation, change the Value of
is set to 02. E7 to 00, 01, or 03.
f Function Code E7 is set f Determine why there is no Tach Signal present.
to 03 and no Tach Signal
is present.
B-38
TROUBLESHOOTING WIRE HARNESSES
The following Sections list the various Harnesses manufactured for use with the Processor. These tables are
invaluable when troubleshooting a suspected interface problem or when manufacturing your own Harnesses.
The Wire Harness Plug figures below indicators:
• SOLID BLACK circles wire termination
• MEDIUM GRAY circles variation in terminations (refer to Table for information)
• WHITE circles indicate no wire termination.
Table B-25: Power, Start Interlock, Clutch Pressure Switch Harness Pin-Out
Plugs into Processor HARNESS HARNESS ENGINE/GEAR/BATTERY ENGINE/GEAR/BATTERY
POWER Connector Termination A Conductor Color Termination B Description
Termination A 1 Yellow w/ Starter Solenoid Closed Contact when In-Command
Red Trace and at Neutral
6 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission manufacturer’s
minimum safe operating pressure is
reached.
7 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission manufacturer’s
minimum safe operating pressure is
reached.
10 Red Battery (+) 24 VDC
11 Black Battery ( - ) - DC Return
12 Yellow w/ Starter Switch Wire Closed contact when In-Command
Red Trace at the Starter and at Neutral
Solenoid
B-39
Table B-26: Power, Start Interlock, Clutch Pressure Switch, and Alarm Harness Pin-Out
Plugs into Processor HARNESS HARNESS ENGINE/GEAR/ALARM/ ENGINE/GEAR/ALARM/BATTERY
POWER Connector Termination A Conductor BATTERY Termination B Description
Termination A 1 Yellow w/ Start Solenoid Closed Contact when In-Command
Red Trace and at Neutral
2 Red External Alarm Normally Open contact opens with
Circuit fault or loss of power.
3 Black External Alarm Normally Open contact opens with
Circuit fault or loss of power
6 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission manufacturer’s
minimum safe operating pressure is
reached.
7 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission manufacturer’s
minimum safe operating pressure is
reached.
10 Red Battery (+) + 24 VDC
11 Black Battery ( - ) - DC Return
12 Yellow w/ Starter Switch Wire Closed contact when In-Command
Red Trace at the Starter and at Neutral
Solenoid
Table B-27: Serial Communication Harness Pin-Out
Plugs into each Processor’s HARNESS PLUG HARNESS PLUG HARNESS PLUG HARNESS PLUG
SERIAL Connector Termination End A Conductor Color Termination End B Description
Termination Termination 1 Black 1 CAN Low
A B 2 Red 2 CAN High
6 Yellow/ N/C N/A
Green
B-40
Table B-29: Control Head Harness Hard-Wire
Plugs into Processor Hard-wires to Termination Conductor Termination
Description
STATION Connectors Control Head A Color B
Termination Termination B 1 Green/ N/C Shield
A Port Yellow
2 Brown 2 Red LED ( + )
3 Violet 8 Green LED ( - )
4 Orange 4 Transfer Button ( + )
5 Red 3 Ground
Starboard 6 Green 6 Lever Command Signal
E
Clutch Harnesses
Table B-32: Ahead/Astern Clutch Harness Pin-Out
Plugs into Processor Termination Conductor GEAR BOX GEAR BOX
CLUTCH Connector A Color Termination B Description
Termination A 3 Red Ahead Solenoid + 24 VDC when Ahead Clutch
Selected
4 Black Ahead Solenoid - VDC Return for Ahead Clutch
5 Red Astern Solenoid + 24 VDC when Astern Clutch
Selected
6 Black Astern Solenoid - VDC Return for Astern Clutch
B-41
Table B-33: Ahead/Neutral/Astern Clutch Harness Pin-Out
Plugs into Processor Termination Conductor GEAR BOX GEAR BOX
CLUTCH Connector A Color Termination B Description
Termination A 3 Red Ahead Solenoid + 24 VDC when Ahead Clutch
Selected
4 Black Ahead Solenoid - VDC Return for Ahead Clutch
5 Red Astern Solenoid + 24 VDC when Astern Clutch
Selected
6 Black Astern Solenoid - VDC Return for Astern Clutch
7 Red Neutral Solenoid +24 VDC at all times
8 Black Neutral Solenoid -VDC Return for Neutral Solenoid
Throttle Harnesses
Table B-34: Current/MAN Throttle Harness Pin-Out
Plugs into Processor
Termination A Conductor Color ENGINE Termination B Description
THROTTLE Connector
Termination A 1 Black Engine DC-Bus Throttle Signal Return
3 Red ECM 0.00 - 21.0 mA Throttle Signal
8 Green/ N/C N/A
Yellow
E
B-42
Table B-37: Voltage Throttle Harness Pin-Out
Plugs into Processor
Termination A Conductor Color ENGINE Termination B Description
THROTTLE Connector
Termination A 1 Black Engine DC-Bus Throttle Signal Return
4 Red ECM 0.00 - 5.00 VDC Throttle Signal
8 Green/ N/C N/A
Yellow
E
B-43
PROCESSOR PIGTAILS
The number and types of Pigtails used varies with of eight Pigtails when all five Remote Stations are
the different Processors and their configurations. being used.
The basic off-the-shelf Processors are available with The following Tables describe the pin outs and
no Pigtails (hard-wired) or pre-wired for up to a total functions of the conductors within the various
Pigtails.
B-45
Table B-40: Control Head Pigtail Pin-Out (Up to 5 Stations)
Pigtail Connector Termination A Conductor Color Description Termination B
Termination A 1 Non-insulated to Green/ Shield Frame
Yellow
2 Brown Red LED ( + ) TB1-2 thru TB5-
2
3 Violet Green LED ( - ) TB1-8 thru TB5-
8
4 Orange Transfer Button TB1-4 thru TB5-
4
5 Red Ground TB1-3 thru TB5-
3
6 Green Lever Command TB1-6 thru TB5-
Signal 6
7 Blue VREF (+5VDC) TB1-7 thru TB5-
7
8 Black Tone ( + ) TB1-1 thru TB5-
1
Termination B (Up to 5 Stations)
To Pigtail Connector
Termination A
13211-ART
B-46
Table B-43: Tachometer Processor Pigtail Pin-Out
Termination Conductor Termination Processor Circuit Board
Pigtail Connector
A Color Description B Connections
Termination 1 Red Sensor Supply (+9 TB9-1 Termination B
A VDC)
2 Green AC Type Tach Input TB9-2
Open Collector Tach TB9-3
3 Black Return for Tach TB9-4
Input
4 Drain Shield Grounding
Screw
B-47
MicroCommander 9110 Series ZF Marine Electronics, LLC.
12125 Harbour Reach Drive,
Servo Throttle – Servo Clutch Suite B
Qualitative Failure Analysis & Design Mukilteo WA 98275
Verification Test Procedure U.S.A.
Tel: 425-583-1900
Revision A Fax: 425-493-1569
Document # AUTHOR CHECKED APPROVED DATE REVISED BY
ENG-127 Joe Case Jeff Turner Bob Anderson 4/14/05 Bob Anderson
The ZF Marine Electronics MicroCommander 9110 Series (servo throttle, servo clutch
version) marine engine controls offer single lever control of speed and direction. Each
enclosure houses an independent Control Processor and requires separate power
supplies. The system operates on 12 or 24VDC power and can have up to five remote
stations depending on the application. The system sequences the operation of speed and
shift in order to prevent an inexperienced operator from mishandling the engine or
transmission.
The MicroCommander 9110 Series (servo throttle, servo clutch version) Propulsion
Control System is compliant to the environmental design standards in 46 CFR 62.25-30.
The following test procedure covers the 4 items included in the Qualitative Failure
Analysis; 1) Control Head Potentiometer failure, 2) Loss of power supply, 3) Throttle
Feedback Potentiometer failure, and 4) Clutch Feedback Potentiometer failure.
1) Failure: Control Head Potentiometer failure.
a) Results: The Processor will shift to Neutral (if needed) and throttle will go to Idle,
(if needed).
b) Test Procedure
i) Turn power ON to both Port and Starboard Processors. Take command at a
Control Head.
ii) Move the Port and Starboard Control Head levers to approximately ½ Ahead.
iii) Locate the green wire coming from the Port Control Head in command,
connecting to pin 6 of the respective terminal block on the Processor circuit
board. Disconnect it from the Processor circuit board.
(1) The Port Processor will shift to Neutral (if needed) and throttle will go to
Idle (if needed).
(2) The Port Control Head will give an alarm tone indicating a faulty
potentiometer.
iv) Move the Port and Starboard Control Head levers back to Neutral. Reconnect
the green wire.
v) Take command at the Control Head
vi) Repeat for Starboard side.
Version: 1.0
Document # AUTHOR CHECKED APPROVED DATE
ENG-145 Tim Jones Jim D Smith Robert 4-19-04
Anderson
The ZF Mathers ClearCommand 9000 Series (servo throttle, solenoid clutch version) marine
engine controls offer single lever control of speed and direction. Each enclosure houses an
independent Control Processor and requires separate power supplies. The system operates on 12
or 24VDC power and can have up to five remote stations depending on the application. The
system sequences the operation of speed and shift in order to prevent an inexperienced operator
from mishandling the engine or transmission.
A standard feature is an alarm contact (normally open) to interface with the main alarm system of
the vessel. This switch will open and activate the alarm system with a power loss or CPU failure.
In addition, ZF Mathers provides audible tones at the Control Head locations to indicate system
faults.
CLUTCH SHIFTS TO
NEUTRAL
The ClearCommand 9000 Series (servo throttle, solenoid clutch version) Propulsion Control
System is compliant to the environmental design standards in 46 CFR 62.25-30.
The following test procedure covers the 2 items included in the Qualitative Failure Analysis; 1)
Control Head Potentiometer failure, and 2) Loss of power supply.
1) Failure: Control Head Potentiometer failure.
a) Results: The Processor will shift to Neutral (if needed) and throttle will go to Idle, (if
needed).
b) Test Procedure
i) Turn power on to both Port and Starboard Processors. Take command at a Control
Head.
ii) Move the Port and Starboard Control Head levers to approximately ½ Ahead.
iii) Locate the green wire coming from the Port Control Head in command, connecting to
pin 6 of the respective terminal block on the ClearCommand 9000 Series circuit board.
Disconnect it from the ClearCommand 9000 Series circuit board.
(1) The Port Processor will shift to Neutral and throttle will go to Idle.
(2) The Port Control Head will give an alarm tone indicating a faulty potentiometer.
iv) Move the Port and Starboard Control Head levers back to Neutral. Reconnect the
green wire.
v) Repeat for Starboard side.
ALASKA ALASKA
5005 Keith Stephens 5395 Karl Johnson
Alaska Professional Marine T: 907-789-9740 Rainbow Glacier Company T: 907-766-2218
(mail) PO Box 32083 PO Box 821
Juneau, AK 99803 F: 907-789-0054 Haines, AK 99827 F: 907-766-2585
(ship) 1900 Fritz Cove Road
Juneau, AK 99803
6950 William Shattenberg 2104 Mel Holmgren, John Teas, Eric Holmgren
Anchor Electric T: 907-780-3690 Sitka Electronics Lab T: 907-747-6570
5362 Commercial Blvd. 232 Katlian Avenue
Juneau, AK 99801 F: 907-780-3692 Sitka, AK 99835 F: 907-747-6170
bill@anchoralaska.com jteas@gci.net
mnbh@ptialaska.net
Page 1 of 8
ALASKA ARIZONA
2900 Steve Ringleman
Timber & Marine T: 907-225-6644 Mobile Marine Repair, Inc. T: 928-645-1406
2547 Tongass Ave. PO Box 2988
Ketchikan, AK 99001 F: 907-225-0644 Page, AZ 86040 F: 928-645-1406
MMC
3652 John Wikan 2488 Steve Adamczyk, Steve Ringleman, Jason Giffen
Wikan Enterprises, Inc. T: 907-772-4155 Old West Marine Service T: 928-645-2705
(mail) PO Box 929 (mail) Po Box 4798
Petersburg, AK 99833 F: 907-772-4153 Page, AZ 86040 F: 928-645-2542
(ship) 103 Dock Street (ship) 1002 Vista
Petersburg, AK 99833 Page, AZ 86040
wikanent@alaska.com oldwest@oldwestmarine.com
MMC
MMC
Mike Montgomery, Glenn Carson
Skipperliner - Lake Pleasant T: 928-501-2444
ARIZONA 40202 N. 87th Avenue
Mark Suttie
Aramark/Lake Powell Resorts & Marinas T: 928-645-1186 Peoria, AZ 85382 F: 928-501-2443
PO Box 1597
Page, AZ 86040 F: 928-645-1101
phelpsjy@skipperliner.com
MMC
suttie-mark@aramark.com
MMC 2381 Tony Ferrando
Tony's Dri-Doc & Marine T: 928-645-2732
(mail) PO Box 897
7048 Jim Ronnie, Jim Prestin, Mark Munsinger
Desert Recreation, Inc. T: 928-754-4391 Page, AZ 86040 F: 928-645-5237
315 Long Avenue (ship) 902 Hemlock
Bullhead City, AZ 86429 F: 928-754-3335 Page, AZ 86040
MMC
desrec@ctaz.com
MMC CANADA - British Columbia
5139 Mike Lewis, Basil Drinnan
5935 Donn DeVore Canoe Cove Marina T: 250-656-5566
Donn's Boat Shop, Inc. T: 928-645-0313 2300 Canoe Cove Road
(mail) PO Box 3826 Sidney, BC V8L 3X9 F: 250-655-7197
Page, AZ 86040 F: 928-645-0323
(ship) 486 Haul Road
Page, AZ 86040
boatfxr@donnsboatshop.com *
MMC
5031 Don Pederson
Coast Electric T: 250-627-8531
1852 Sloan Avenue
Prince Rupert, BC V8J 4B5 F: 250-627-8531
coast@citytel.net
Page 2 of 8
CANADA - British Columbia CALIFORNIA
2949 Bill McArthur 2472 Mike Han, Kip Fatout
McArthur Enterprises Inc. T: 250-883-4640 Jones Valley & Shasta Lake Resorts T: 530-275-7950
#326 - 129 Burnett Road 22300 Jones Valley Marina Road
Victoria, BC V9B 4P6 Redding, CA 96003 F: 530-275-3523
bGmcarthur@uniserve.com
MMC, CL *
CL
MMC, CL
Robert Sherrill, Caleb Linn
2498 Marc Hermann, Dan Teske Sherrill's Marine Service T: 310-510-1610
Channel Coast Marine T: 805-985-0220 PO Box 2112
2949 W. 5th Street Avalon, CA 90704 F: 310-510-1352
Oxnard, CA 93030 F: 805-985-7707
M: 805-432-8256
MMC
MMC, CL
2456 Tony Travis
6805 Chris Schjoth Ship Shape Marine T: 510-272-9695
Chris Marine T: 530-275-3097 909 Marina Village Pkwy, #186
14265 Holiday Road Alameda, CA 94501 F: 510-419-0792
Redding, CA 96003 F: 530-275-3096 M: 510-206-0420
shipmarine@aol.com
MMC, CL
MMC
7661 Henry Bramhall
2181 Ron Easley, Roberto Reyes Trans Pacific Distributors T: 707-426-6670
Easley Marine Inc. T: 949-631-0142 1941 Walters Court
1635 Superior Avenue, Unit 9 Fairfield, CA 94533 F: 707-426-0206
Costa Mesa, CA 92627 F: 949-631-0219
easleyac@pacbell.net
MMC, CL
CONNECTICUT
2733 Joe Donatini, Mark Egon, Larry Scroggins 2131 Greg Schroder
Johnson Hicks Marine Inc. T: 831-475-3383 Mystic River Marina T: 860-536-3936
333 C Lake Avenue 36 Quarry Road
Santa Cruz, CA 95062 F: 831-475-1498 Mystic, CT 06355 F: 860-536-0713
jhme6@cs.com
MMC *
Page 3 of 8
FLORIDA GEORGIA
3387 Mike Handschmann 7587 Bill Willingham
ATM Marine, Inc. T: 305-251-7547 Maricom Electronics T: 912-354-4542
18730 Lenaire Drive 2911 River Drive
Miami, FL 33157 F: 305-238-6800 Thunderbolt, GA 31404 F: 912-356-1249
M: 305-926-3813
atmmarine@bellsouth.net
MMC, CL
sst3485@aol.com
MMC, CL MMC
6170 Shannon Neville, Nadja Dilger, David Laschomb 5946 Tim McNeil
Lost River Marine T: 772-283-1154 On Site Marine Service T: 770-614-0106
490 SW Salerno Road (mail) 2835 Still Meadows Way
Stuart, FL 34997 F: 772-283-9550 Buford, GA 30519 F: 770-271-1909
(ship) 6109 Holiday Road M: 404-867-1235
Buford, GA 30518
info@lostrivermarine.com
www.lostrivermarine.com
jmonroe@bowboat.com
MMC, CL
Page 4 of 8
LOUISIANA NORTH CAROLINA
3401 Bob Albrecht 2861 Gary Sorensen
Air Marine Radio T: 504-362-1226 Marine Control Systems T: 828-369-7572
2421 8th Street 76 May Apple Lane
Harvey, LA 70058 F: 504-368-2668 Franklin, NC 28734 F: 828-369-7572
M: 828-508-4201
MMC, CL *
MMC
NEVADA
2530 Eric R. Carl, John Weaver, Darren Weaver 7050 Jim Bell, Scott Wall
Middle River Electronics T: 410-687-6474 A & M Marine T: 702-293-1321
233C Nanticoke Road 1630 Foothill Drive
Baltimore, MD 21221 F: 410-687-3353 Boulder City, NV 89005 F: 702-293-5896
anmmarine@aol.com
MMC MMC
MMC
Page 5 of 8
NEW YORK PENNSYLVANIA
2066 Dennis McGowan 5272 Joe Loughran, James Moorhead
Den-Mac Sales T: 631-842-8967 Airline Hydraulics Corporation T: 215-638-4700
8 Ramick Drive W. Expressway 95 Business Center
Amityville, NY 11701 F: 631-842-5274 Bensalem, PA 19020 F: 215-638-1707
OREGON
6671 Jeff Dykes
Cook Engine & Co. T: 503-289-8466
503 NE Tomahawk Island Drive TENNESSEE
5391 R.S. Simpson
Portland, OR 97217 F: 503-286-2836 Simpson Marine Electronics T: 865-966-8481
(mail) PO Box 22213
Knoxville, TN 37933 F: 865-966-9707
sales@cookengine.com
(ship) 665 Chapel Point Lane
Knoxville, TN 37922
Page 6 of 8
UTAH WASHINGTON
Tami Luckesen 2410 Keith Ozby
Bullfrog Boat Shop T: 435-684-3018 Harris Electric Inc. T: 206-282-8080
PO Box 4055 4020 23rd Ave. W.
Lake Powell, UT 84533 F: 435-684-3005 Seattle, WA 98199 F: 206-284-5521
MMC *
*
MMC
6626 Skip Dassler
Marine Servicenter, Inc. - ANA T: 360-293-8200
WASHINGTON 2417 "T" Ave.
6186
Anacortes Yacht Charters T: 360-293-4555 Anacortes, WA 98221 F: 360-293-9648
2415 T Avenue, #112
Anacortes, WA 98221 F: 360-293-6683
1261
Maritime Fabrications T: 360-466-3629
(mail) PO Box 816
2967 Jim Palmer
Complete Controls T: 360-904-7525 LaConner, WA 98257 F: 360-466-3632
9306 NE 7th Street (ship) 920 West Pearle Jensen Way
Vancouver, WA 98664 F: 360-254-7846 LaConner, WA 98257
M: 360-904-7525
jpalmer1@attbi.com
MMC 3494 Dave Williams, Mike Curran
North Harbor Diesel Inc. T: 360-293-5551
720 30th Street
6662 Bill Mol
Components Unlimited T: 360-336-9698 Anacortes, WA 98221 F: 360-293-0728
17315 Olympic Place
Mt. Vernon, WA 98274 F: 360-424-8950
nharbor@fidalgo.net
M: 206-915-0712
MMC, CL
Page 7 of 8
WASHINGTON
7344 Dave Hanson
Pinnacle Marine Services T: 360-404-2063
160 Cascade Place #229
Burlington, WA 98223 F: 360-404-2064
M: 360-920-1630
pinnmar@aol.com
MMC, CL, CR, MC
psyachtservice@aol.com
*
rme@wolfenet.com
* Here from July - April (See also AK)
Page 8 of 8
ZF Marine Electronics, LLC
12125 Harbour Reach Drive
Mukilteo, WA 98275 USA
800-546-5455 / 425-583-1900
Fax: 425-493-1569
USA
ALABAMA FLORIDA (cont.)
TENNESSEE WISCONSIN
TEXAS
80 Trey Grant
Donovan Marine, Inc. T: 713-734-4171
4757 South Loop East 800-669-8392
Houston, TX 77033 F: 713-734-1674
treywalters@donovanmarine.com
CANADA
CENTRAL CANADA
Micheal Roy
CMC Electronics T: 418-562-6637
566 Duphare Street East F: 418-562-5335
Mantane, Quebec
Canada G4W 3P6
micheal.roy@cmcelectronics.com
Walter Timmerman
CMC Electronics T:514-748-3000
600 Dr Fredrik Phillips Blvd. F: 514-748-3006
Ville St Laurent, Quebec
Canada H4M 2S9
walter.timmerman@cmcelectronic.com
ZF Marine Electronics, LLC
12125 Harbour Reach Drive
Mukilteo, WA 98275 USA
800-546-5455 / 425-583-1900
Fax: 425-493-1569
ARGENTINA CHILI
7252 Ton Hekman, Rob van der Linde 157 Steven Wee
ADS/van Stigt T:31-0-183-650001 Mammoth Enterprises Pte, Ltd.
Avelingen F: 31-0-183-650001 (mail) PO Box 283 T: 65-6-44-88266
NL-422 MS Gorinchem Siglap Post Office F: 65-6-44-89800
The Netherlands Ton.Hekman@vanstigt.com Singapore 914503
(shipping) 6-A Waringin Park
NEW ZEALAND Singapore 416320
THAILAND VENEZUELA
TURKEY
U.A.E.
Page i
Table of Contents
Page ii
Revision List FIGURE D-2: CRUISECOMMAND CONNECTOR LOCATIONS
Introduction
Refer to Bulletin 02-008 for Service Field Test Unit
(Part No. 13927) recommendations. Refer to
Figure D-1 for an example of the Test Unit and a FIGURE D-3: EXAMPLE OF CLEARCOMMAND PIGTAIL
Multimeter. LOCATIONS
6
11339-Example
1
3
Designation
Description Harness Type Harness Use
#
1 Black 8 Throttle The throttle
The Service Field Test Unit, hereafter referred to as
Pin Connector/ signal is output
the “Break-out Box”, is recommended for use with
Pigtail from this
all CruiseCommand Processors (Part No. 785CE) and
connector/
with ClearCommand Processors (Part No. 9XXX
pigtail. The
Series) that have pluggable (Pigtail) Throttle, Clutch
signal may be
or Troll Connections.
in the form of
The procedures for testing the various outputs of the Pulse Width
ClearCommand and CruiseCommand Processors are Modulation
similar, with the exception of where they connect to (PWM),
the respective Processor. Figure D-2 indicates the Voltage,
location of the connectors on the CruiseCommand Current, or
Processor and Figure D-3 the typical pigtail plugs on Frequency.
a 9000 Series ClearCommand Processor.
2 Black 12 Power This connector/
NOTE: Not all ClearCommand Processors have Pin Connector/ pigtail contains
all of the pigtails shown in Figure D-3. Only the Pigtail the inputs and
pigtails that are required for a specific outputs for
application are installed in a ClearCommand Main Processor
Processor. Power, Start
Interlock,
Clutch Oil
Pressure
Interlock, and
External Alarm
Circuit.
Page D-1
Designation
Description Harness Type Harness Use
DC Voltage
#
A) Ensure that power is removed from the Engine
3 Gray 12 Clutch The external
Electronics and the Processor.
Pin Connector/ connections for
Pigtail Clutch Power, B) Disconnect the Throttle Harness from the number
Ahead, Astern, 1 Processor connector/pigtail.
and Neutral C) Insert the Break-out Box between the number 1
Solenoids, Troll Processor connector/pigtail and the Throttle
On/ Off, and Harness as shown in Figure D-4.
Proportional FIGURE D-4: THROTTLE CONNECTION (DC VOLTAGE)
Solenoids are
made at this
connector/
pigtail.
4 Gray 8 Control Head All the required
Pin Connector connections for
the Remote
Control Stations
are made at
these
connectors.
5 Gray 6 Serial The Serial
Pin Communication Communication
Connector/ connections
Pigtail between D) Set up the Multimeter to measure DC Volts and
multiple plug the black lead into the Break-out Box black
Processors in socket labeled “-” and the red lead into the socket
applications labeled “VDC”.
with more than E) Turn power ‘On’ to the Processor and take
one Processor command at any Remote Station.
at this
F) The appropriate Idle Voltage for the application
connector/
should be measured at this time.
pigtail.
G) Move the Control Head lever to the Full Throttle
6 Gray 4 Tachometer The input signal
position while depressing the Transfer Button
Pin Sensor from a
(Throttle Only Mode).
Connector/ Tachometer or
Pigtail Shaft Speed H) The appropriate Full Throttle Voltage for the
Sensor application should be measured at this time.
connects to this Current (mA)
connector/
pigtail. A) Ensure power is removed from both the Engine
Electronics and the Processor.
The actual procedures for using the Break-out Box
are the same for CruiseCommand and B) Disconnect the Throttle Harness from the number
ClearCommand Processors. However, the 1 Processor connector/pigtail.
adjustment within the Processor to obtain the correct C) Insert the Break-out Box between the number 1
output may differ. The appropriate Installation Processor connector/pigtail and the Throttle
Manual must be referred to when making the Harness as shown in Figure D-5.
adjustments. D) Set up the Multimeter to measure current (mA.)
and plug the black lead into the Break-out Box
Procedure: Throttle Signal black socket labeled “-” and the red lead into the
socket labeled “mA”.
Testing E) Turn power ‘On’ to the Processor and take
Depending on which Processor is being tested, it may command at any Remote Station.
have the capability of sourcing one or all of the F) Depress and hold the Push-button Switch labeled
following: DC Voltage, Current, PWM (Pulse Width “mA.” The appropriate Current (mA.) for the
Modulation) or Frequency. application should be measured.
NOTE: The following procedures and drawings G) Move the Control Head lever to the Full Throttle
pertain to both the CruiseCommand and position while depressing the Transfer Button
ClearCommand Processors. (Throttle Only Mode).
Page D-2
FIGURE D-5: THROTTLE CONNECTION (CURRENT MA) H) Move the Control Head lever to the Full Throttle
position while depressing the Transfer Button
(Throttle Only Mode).
I) The measurement should be 91- 93% of the
voltage measured in step F) [e.g. Idle = 8% of 12
VDC reference or 0.96 VDC; Full Throttle = 92%
of 12 VDC reference or 11.04 VDC.
PWM (Pulse Width Modulation) with DC FIGURE D-7: THROTTLE CONNECTION (PWM WITH DUTY
CYCLE METER)
Voltmeter
A) Ensure power is removed from both the Engine
Electronics and the Processor.
B) Disconnect the Throttle Harness from the number
1 Processor connector/pigtail.
C) Insert the Break-out Box between the number 1
Processor connector/pigtail and the Throttle
Harness as shown in Figure D-6 labeled “-” and
the red lead into the socket labeled “PWM”.
FIGURE D-6: THROTTLE CONNECTION (PWM WITH DC
VOLTMETER)
Page D-3
FIGURE D-8: THROTTLE CONNECTION (FREQUENCY HZ) LED should go out in CruiseCommand systems
and stay on in ClearCommand systems.
Page D-4
FIGURE D-11: CLUTCH CONNECTIONS ASTERN SOLENOID measurement should go from 12 or 24 VDC to 0
VDC at the same time the red LED on the Control
Head becomes lit solid.
Page D-6
APPENDIX E
CANtrak Display Manual
MM70179 Rev. A 8/06
SW70203.2
Table of Contents
CANtrak Display Manual
Preface .....................................................................................................................................................E-1
Conventional Symbols Used in the Manual ..........................................................................................E-1
Introduction.............................................................................................................................................E-1
Specifications ..........................................................................................................................................E-1
Electrical....................................................................................................................................... E-1
Environmental.............................................................................................................................. E-1
Mechanical ................................................................................................................................... E-1
Theory Of Operation ...............................................................................................................................E-1
Operation in Cruise Mode ........................................................................................................... E-2
Display Configurability ...........................................................................................................................E-2
Parameter Changes ...................................................................................................................... E-3
Installation...............................................................................................................................................E-4
Required Materials....................................................................................................................... E-4
Display (Part No. 70179) .............................................................................................................. E-4
Template....................................................................................................................................... E-4
Wire Harnesses ............................................................................................................................ E-4
System Examples .....................................................................................................................................E-5
Page i
Table of Contents
Page ii
Revisions List
Revision Date Revision Description
A 8/06 1 Brought Entire Manual up to current ZF Standards.
2 Software revised to SW70203.3 adding Joystick display.
3 ELR 1401:
A) Table 1, 2, 3, and 4 Item #3 changed from 13316-XX to 70422-xx
B) Made CANtrak consistent throughout manual.
C) Renamed Figures without CANtrak
Page Eiii
Page Eiv
Preface Audible alarm: 80 db @ 2.4 kHz
Wiring protection: Reverse polarity protected (fuse
IMPORTANT: It is important to keep this must be installed)
Manual in a safe place for future reference. The
manual contains answers to questions that may Environmental
arise during operation or installation of the Meets BS EN 60945 requirements
CANtrak Display.
Operating temperature: -40 to 70°C (-40 to 158°F)
This manual is intended for use in conjunction with
Humidity range: >95% RH
a ZF Marine Electronics Control Manual.
Degree of protection: Sealed to IP65/NEMA 4
Mechanical
IMPORTANT: Contains helpful information. Case material: ABS/ poly carbonate alloy
Case color: Anthracite grey
CAUTION: Damage to the equipment may Dimensions: Bezel size – 4.33" x 4.33" (110mm x
occur if these messages are not followed. 110mm)
Bezel depth: 0.95" (24mm) (including seal)
WARNING: Personal injury may result if these Panel cut-out: Front mount – 2.52" (64mm)
messages are not followed. diameter hole with (4) mounting holes 0.17"
(4.3mm) diameter
Rear mount – 4.45" x 4.45" (113mm x 113mm) with
Introduction (4) 0.17" (4.3mm) mounting holes on 2.75" x 5.5"
(70mm x 140mm) centers.
The CANtrak Display provides a visual
Overall case depth: 2.05" (52mm)
representation of various items which are beneficial
in the operation of a vessel’s propulsion system. The
information provided varies from system to system, Theory Of Operation
but may include items such as station in command,
The CANtrak Display is used in some of ZF Marine
transfer status, mode of operation, engine rpm, shaft
Electronics control systems to provide the operator
rpm, etc.
with useful information regarding the propulsion
The Display may be configured to provide and propulsion control systems. This information is
information on one to five propulsion systems and obtained from the ClearCommand/SmartCommand
may be fitted at one or all of the Propulsion Control Processors’ CAN serial bus. The display is in a
Stations. simple graphic/text format. The display presently is
FIGURE E-1: DISPLAY ON POWER-UP capable of supplying the following information:
• The name of the Station presently in control.
Marine
• The mode of operation (Warm-up, Cruise, Troll,
DP Station)
Electronics
Cetrek
914850
ID No
00644-3
E2: 82
• The percent of throttle (0- 100%) being
Testing
CAN
commanded is displayed numerically.
• The position of the Control Head’s lever(s) is
1 32 2 1- A R T R ev -
displayed graphically.
• The actual engine RPM is displayed
numerically.
Specifications • The clutch command (ahead, neutral or astern)
is displayed graphically.
Electrical • The actual shaft RPM is displayed numerically.
Display (resolution): 160 x 128 pixels • Transfer instructions in Transfer Modes 03 and
Power requirements: 10 to 32 VDC 04.
• Diagnostic Information.
Power consumption: 110 mA @ 12 VDC (backlight
off) 130 mA @ 12 VDC (backlight on)
Page E-1
Operation in Cruise Mode FIGURE E-5: AHEAD DETENT
Cruise
is first applied to the Display, it will automatically Throttle
This is the case when there is no power to the F) Moving the Control Head levers further forward
Propulsion Control System. Refer to Figure E-2. to the stops increases the throttle from Idle to
FIGURE E-2: NO PROCESSOR POWER Full. This is represented on the Display as shown
in Figure E-6.
No Station FIGURE E-6: FULL AHEAD
No Cruise No
Serial Serial
Data Throttle Data
Station 1
Cruise
Throttle
13231-ART
Station 1
Cruise Station 1
Cruise
N Throttle N
Throttle
13232-ART
13236-ART
Cruise
with the appropriate feedback information (i.e.,
N Throttle N
Shaft RPM, Engine RPM, etc.).
NOTE: All of the items listed below can be
displayed on the CANtrak screen. However, if
the appropriate feedback information is not
provided to the Processor, the value displayed
13233-ART
E) Moving the port and starboard Control Head for that item will remain at 0.
levers to the Ahead detent engages the Ahead In order to make a change, the following procedure
clutches and is displayed as shown in Figure E-5. must be followed:
.
Page E-2
FIGURE E-8: FOUR BUTTONS E) Use the Up and Down arrows until the
highlighted area is blank or the desired item is
listed.
F) Once highlighted, press the “SET” button.
• The highlighted item is programmed into
memory and will be displayed on the screen.
G) If any other changes to the items displayed are
required, repeat steps A) through F).
Parameter Changes
B) Press the button labeled “CHNG DISP” located to There are two functions performed within the
the far left. Parameter Change page. The first, “Number
FIGURE E-9: "CHNG DISP" BUTTON Screws”, programs the CANtrak Display to provide
information on one to four screws. The second,
“Number Pulses” is only required when a Tach
Sender input is being utilized. The number entered,
depending on the source, represents the number of
pulses per revolution of the engine or the output
shaft. This value is used to calculate the correct RPM
displayed on the CANtrak screen.
In order to make a change, the following procedure
must be followed:
C) Use the Up and Down arrows to enclose the A) Press any one of the four buttons to the left.
desired area of the screen in a box. B) Press the button labeled “CHNG PARM” located
FIGURE E-10: UP AND DOWN ARROWS second to the left.
C) Use the Up and Down arrows to select “Number
Screws” or “Number Pulses”.
D) Once the desired area of the screen is enclosed in
a box, press the middle “SET” button.
• The area will become highlighted as shown in
Figure E-12.
FIGURE E-12: "NUMBER SCREWS" SELECTED
13236- ART
Page E-3
D) Connect the Serial Communication Harness into
Single & Twin Screw Triple Screw
the Plug at the back of the unit.
Station 1 Station 1 E) Place the unit into position; secure it by screwing
Cruise the thumb nuts onto the studs.
N Throttle N
BEHIND CONSOLE MOUNTING
Cruise If the installation requires the mounting of the
Display to be behind the console, a Kit is available
through Teleflex Morse Electronics. The part
13232-ART 13241-ART
number is 932061.
Quad Screw Quint Screw
FIGURE E-14: BEHIND CONSOLE MOUNTING
Station 1 Station 1
Console CANTrax Display
Cruise Cruise
Thumb Nuts
RT 13241-ART
ART-13223
Gasket Molding
Installation
TRUNNION MOUNTING
Required Materials If the installation requires that the Display be
Display- LCD: Part No. 70179. Minimum of (1) for up mounted in a vertical or near vertical fashion (the
to 5 screws. angle is adjustable), a kit is available through
Wire Harness- Display. Multi-drop, 20' Power, P/N Teleflex Morse. The part number is 930293.
70186. One required per Display FIGURE E-15: TRUNNION MOUNTING
Termination Resistor, Part No. 15133. One required
per System.
13225-ART
13222-ART
System Examples
13226-ART
The following diagrams and tables provide examples of various installations and required Items.
Table E-1: Single Station - Single Screw
Item # Description Qty. Part #
1 Display- LCD 1 70179
2 Wire Harness- Display, Multi-Drop, Power 20’ (6,10m) 1 70186
3 Wire Harness- Serial Comm., Twin Screw 1 70422-XX
5 Plug- Terminating Resistor 1 15133
6 Pigtail- Serial Comm. 1 Provided with Processor
13227-ART
Page E-5
Table E-3: Two Station - Twin Screw
Item # Description Qty. Part #
1 Display- LCD 2 70179
2 Wire Harness- Display, Multi-Drop, Power 20’ (6,10m) 2 70186
3 Wire Harness- Serial Comm., Twin Screw 2 70422-XX
4 Wire Harness- Serial Comm., Multi-Screw 1 15544-XX
5 Plug- Terminating Resistor 1 15133
6 Pigtail- Serial Comm. 2 Provided with Processors
13229-ART
13230-ART
Page E-6