MM9000 Rev-A 5-08

Download as pdf or txt
Download as pdf or txt
You are on page 1of 276

ClearCommand Premium

95XXX and 96XXX


Installation, Operation and
Troubleshooting Manual
MM9000-PI RvA.1 5/08
Copyright
Copyright American Boat and Yacht Council, Inc. Used with permission.

Copyright © 2005 ZF Marine Electronics, LLC

All Rights Reserved

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

Revisions List .................................................................................................................. xiii


Preface ...............................................................................................................................1
ClearCommand Premium Processor List ................................................................................................. 1
Available Options for the Premium Processors Covered in this Manual.......................................1
Conventional Symbols Used in the Manual ............................................................................................. 1
Important Information............................................................................................................................... 1

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

Throttle (Servo 2) Tones................................................................................................................ 12


Troll Solenoid Tones ..................................................................................................................... 12
Push Button Set Up...................................................................................................................................12
Visual System Diagnostics, Set Up And Status Indication.....................................................................12
Pluggable Connections .............................................................................................................................12
Processor Pigtails........................................................................................................................... 12
Optional Features .....................................................................................................................................13
External Alarm Capability............................................................................................................. 13
Auxiliary Backup Control System................................................................................................. 13
Clutch Pressure Interlock .............................................................................................................. 13
Engine Room Only/Remote Switch .............................................................................................. 13
Fixed Neutral Delay....................................................................................................................... 13
Multiple Screw Installations ......................................................................................................... 13
Station 2 Lockout Switch .............................................................................................................. 13
Speed Boost ................................................................................................................................... 13

Plan The Installation ........................................................................................................15


System Requirements ...............................................................................................................................15
Processor(s).................................................................................................................................... 15
Control Head(s).............................................................................................................................. 15
CANtrak Display Panel(s).............................................................................................................. 16
Wire Harnesses .........................................................................................................................................16
Control Head Harnesses................................................................................................................ 16
Power, Start Interlock (optional), Clutch Pressure (optional), Alarm Harness (optional) .......... 16
Serial Communication Harness .................................................................................................... 16
Additional Harnesses .................................................................................................................... 16
Electric Cables ..........................................................................................................................................17
Control Head Cable Requirements ............................................................................................... 17
Power, Start Interlock(optional),Clutch Pressure (optional), Alarm Cable Requirements(optional)17
Serial Communication................................................................................................................... 17
Tach Sensor Cable Requirements (optional) ................................................................................ 17
Clutch or Clutch/Troll Cable Requirements................................................................................. 18
Throttle Cable Requirements ........................................................................................................ 18
Tachometer Sensors (optional) ................................................................................................................18
AC Coupled Sensors...................................................................................................................... 18
Alternator....................................................................................................................................... 18
Point side of the Coil ..................................................................................................................... 18
Active Sensors (Open Collector Output)....................................................................................... 18
Engine Room/Remote Switch (optional) .................................................................................................18
Switch Specifications .................................................................................................................... 18
Electric Cable Specifications......................................................................................................... 18
Station 2 Lockout Switch (optional) ........................................................................................................18
Switch Specifications .................................................................................................................... 18
Wire Specifications........................................................................................................................ 19
Installer Supplied Tools And Parts .........................................................................................................19
Required Tools............................................................................................................................... 19
Optional Tools ............................................................................................................................... 19
Required Parts for Servo Processors............................................................................................. 19
Engine Stop Switch ....................................................................................................................... 19
DC Power Source ......................................................................................................................................19
CANtrak Display Power ............................................................................................................... 20

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

Handheld Remote Controls ...........................................................................................................21


Display Panel(s) ........................................................................................................................................ 21
Wire Harness Installation........................................................................................................................ 21
Harness Plug Insertion and Extraction.......................................................................................... 21
Power/Start Interlock/Alarm/(optional) Clutch Pressure (optional) Harness..............................21
Serial Communication Harness (Multi Screw) .............................................................................22
Control Head Harnesses ................................................................................................................22
Tach Sensor Harness (optional)....................................................................................................22
Additional Harnesses .....................................................................................................................23
Hard-Wired Cable .................................................................................................................................... 23
Liquid Tight (Watertight) Connector .............................................................................................23
Processor Enclosure Cable Holes ..................................................................................................23
Hard-wire Installation ....................................................................................................................24
Engine Room/Remote Switch (Location M) (Optional)................................................................28
Station 2 Lockout Switch (Location N) (Optional)........................................................................28
Engine Stop Switches ............................................................................................................................... 28
Push-Pull Cable Connections................................................................................................................... 29
Processor ........................................................................................................................................29
Engine Throttle Selector Lever ......................................................................................................29
Transmission Shift Selector Lever.................................................................................................29

Set Up Procedures ...........................................................................................................31


Processor Components Used In Set Up .................................................................................................. 31
Processor Display LED...................................................................................................................31
Push Buttons...................................................................................................................................31
Activating Set Up Mode ........................................................................................................................... 32
Storing Values To Memory ...................................................................................................................... 32
Function Codes and Values ..................................................................................................................... 32
(A) Processor Function Codes .......................................................................................................32
(E) Basic Throttle Function Codes.................................................................................................33
(E) Electronic Throttle Function Codes......................................................................................... 33
(E) Servo Throttle Function Codes ................................................................................................33
(C) Basic Clutch Function Codes...................................................................................................34
(C) Solenoid Clutch Function Codes ............................................................................................. 34
(C) Servo Clutch Function Codes ..................................................................................................34
(F) Speed Boost Function Codes....................................................................................................34
(L) Basic Troll Function Codes ......................................................................................................35
(L) SolenoidTroll Function Codes .................................................................................................35
Basic Troubleshooting....................................................................................................................35
Electronic Engine/Solenoid Transmission Troubleshooting ........................................................35
Servo Troubleshooting ...................................................................................................................36
Solenoid Transmissions Troubleshooting .....................................................................................36
Field Service Test Unit (Break-out Box) and Multimeter Use ............................................................... 36
Initial System Programming and Adjustments .............................................................................36
Processor Functions .......................................................................................................................36
Throttle Functions.........................................................................................................................38
Servo Clutch Functions..................................................................................................................40
Solenoid Clutch Functions.............................................................................................................41
Troll Functions ...............................................................................................................................42
Troubleshooting Functions ............................................................................................................44
Premium Functions........................................................................................................................44

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

(E4) Throttle Maximum Astern ..................................................................................................... 47


(E6) High Idle................................................................................................................................. 47
Servo Throttle Settings (Engines Stopped)..............................................................................................48
(E3) Throttle Maximum................................................................................................................. 48
(E2) Throttle Minimum ................................................................................................................. 48
Electric Throttle Settings (Engines Stopped) ..........................................................................................48
(E3) Throttle Maximum................................................................................................................. 48
(E2) Throttle Minimum ................................................................................................................. 49
Engine Stop Switches (Engines Running) ...............................................................................................49
Servo Checks (Engines Running).............................................................................................................49
Push-Pull Cables ............................................................................................................................ 49
Control Head Command Checks (Engines Running) .............................................................................49
(E5) Throttle Pause Following Shift (Engines Running).........................................................................49
Trolling Valve............................................................................................................................................50
Troll Solenoid Adjustments........................................................................................................... 50
Engine Room/Remote Switch ..................................................................................................................50
Station 2 Lockout Switch .........................................................................................................................50

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

Control Options ................................................................................................................61


External Alarm Capability........................................................................................................................61
Installation ..................................................................................................................................... 61
Auxiliary (Backup) Control System .........................................................................................................61
CANtrak Display Panel ............................................................................................................................61
Clutch Pressure Interlock ........................................................................................................................62
(C0) Methods of Operation .......................................................................................................... 62
Installation ..................................................................................................................................... 62
Engine Room Only/Remote Switch .........................................................................................................62
Switch CLOSED on Power-up....................................................................................................... 62
Switch OPEN on Power-up ........................................................................................................... 62
Switch OPEN after Power-up........................................................................................................ 62
Fixed Neutral Delay ..................................................................................................................................62
Speed Boost ...............................................................................................................................................64
Functions ....................................................................................................................................... 64

Page iv
Table of Contents

Sea Trial Exercise...........................................................................................................................65


Station 2 Lockout Switch ......................................................................................................................... 66
Switch CLOSED on Power-up .......................................................................................................66
Switch CLOSED after Power-up ....................................................................................................66

Periodic Checks And Maintenance..................................................................................69


Control Heads........................................................................................................................................... 69
Processor................................................................................................................................................... 69
Throttle Servo Processor................................................................................................................69
Clutch Servo Processor ..................................................................................................................69
CANtrak Display Panel ............................................................................................................................ 69
DP Interface Enclosure ............................................................................................................................ 69
DP/JS Interface Enclosure ....................................................................................................................... 69
Power ........................................................................................................................................................ 69

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

Troubleshooting Questions .................................................................................................................... B-3


Troubleshooting Problem Resolution.................................................................................................... B-5
DC Power................................................................................................................................................. B-5
Component Location .............................................................................................................................. B-5
Control Heads ............................................................................................................................... B-5
Processors ..................................................................................................................................... B-5
Engine Room / Remote Switch .................................................................................................... B-5
Station Lockout Switch ................................................................................................................ B-5
DP Interface Enclosure................................................................................................................. B-5
DP/Remote Switch ....................................................................................................................... B-5
DP/JS Interface Enclosure ............................................................................................................ B-5
DP/Remote/Joystick Switch ......................................................................................................... B-5
Component Condition ............................................................................................................................ B-5
Control Heads ............................................................................................................................... B-5
Processors ..................................................................................................................................... B-5
Interface Enclosure....................................................................................................................... B-5
DP / Remote Switch ..................................................................................................................... B-5
DP / Remote / Joystick Switch .................................................................................................... B-5
Engine Room / Remote Switch .................................................................................................... B-5
Station 2 Lockout Switch ............................................................................................................. B-5
Interconnecting Wiring and Harnesses ................................................................................................ B-5
Troubleshooting Diagnostic Menu ........................................................................................................ B-7
Troubleshooting Audible Tones............................................................................................................. B-9
Basic Control System Tones................................................................................................................... B-9
Slow Repetitive Tone.................................................................................................................... B-9
One Long - Three Short Tones ..................................................................................................... B-9
Steady Tone ................................................................................................................................ B-10
Three Second Steady Tone ........................................................................................................ B-10
Three Second Steady Tone, followed by a Slow Repetitive Tone ............................................ B-11
Five Seconds On, Five Seconds Off - High Repetitive Rate Tone ............................................ B-11
Five Second Steady Tone ........................................................................................................... B-11
Clutch Solenoid Control System Tones............................................................................................... B-11
One Long - One Short Tone ....................................................................................................... B-11
Servo 2 Control System Tones ............................................................................................................. B-11
One Long - Two Short Tones ..................................................................................................... B-11
One Long, Two Short - High Repetitive Rate Tones ................................................................. B-11
Servo 1 Control System Tones ............................................................................................................. B-12
One Long - One Short Tone ....................................................................................................... B-12
One Long, One Short - High Repetitive Rate Tones.................................................................. B-12
Troubleshooting Station Transfer ....................................................................................................... B-13
Command Signal .................................................................................................................................. B-13
A to D Counts ........................................................................................................................................ B-13
Remote Station Select........................................................................................................................... B-13
Stuck Transfer Button .......................................................................................................................... B-14
Engine Room/Remote Switch .............................................................................................................. B-14
Station 2 Lockout Switch ..................................................................................................................... B-15
Troubleshooting Error Codes............................................................................................................... B-17
Problem Causes And Solutions............................................................................................................ B-21
Troubleshooting Problems Without Error Codes ............................................................................... B-29
Synchronization Troubleshooting ....................................................................................................... B-33

Page vi
Table of Contents

Equal Throttle Synchronization ...........................................................................................................B-33


Active Synchronization .........................................................................................................................B-34
Troubleshooting Wire Harnesses .........................................................................................................B-37
Basic Control System Harnesses ..........................................................................................................B-37
Clutch Harnesses..................................................................................................................................B-39
Throttle Harnesses ................................................................................................................................B-40
Processor Pigtails ..................................................................................................................................B-43
Basic Processor Pigtails ........................................................................................................................... 43
MicroCommander/ClearCommand 9000 Series Servo Throttle - Servo Clutch Qualitative Failure
Analysis & Design Verification Test Procedure...................................................................................B-47
9000 Series Electronic Throttle -- Solenoid Clutch Qualitative Failure Analysis, Design Verification
Test Procedure, and Periodic Safety Test ............................................................................................B-49
ClearCommand 9000 Series Servo Throttle -- Solenoid Clutch, Qualitative Failure Analysis & Design
Verification Test Procedure..................................................................................................................B-51
Factory Authorized Service Centers - North America.........................................................................B-53
Factory Authorized Sales & Service Centers - International ..............................................................B-61

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

PWM (Pulse Width Modulation) with DC Voltmeter ..................................................................D-3


PWM (Pulse Width Modulation) with Duty Cycle Meter............................................................D-3
Frequency (Hz.) ............................................................................................................................D-3
Procedure: Clutch Testing...................................................................................................................... D-4
Neutral Solenoid Testing..............................................................................................................D-4
Ahead Solenoid Testing ...............................................................................................................D-4
Astern Solenoid Testing ...............................................................................................................D-4
Procedures: Troll Testing....................................................................................................................... D-5
Troll On/Off Solenoid ..................................................................................................................D-5
Troll Command (Proportional Solenoid) Testing with Amp Meter ............................................D-5
Procedure: 2-Speed Testing.................................................................................................................... D-6
2nd Gear Disengaged ...................................................................................................................D-6
2nd Gear Engaged ........................................................................................................................D-6
Parts List ................................................................................................................................................. D-6

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

Current Positions................................................. B-8 Figure E-15: Trunnion Mounting ........................... E-4


Figure B-7: Example Display Control Head Transfer Figure E-16: Wire Harness (70186), Multi-drop..... E-5
Button Status View .............................................. B-8
Figure B-8: Example Display Control Head Transfer
Button Status View .............................................. B-8
Figure B-9: Example Display of Software Revision
Level View ........................................................... B-8
Figure B-1: Display Examples of Remote Stations.......
B-10
Figure B-2: Display Examples of Remote Stations A/D
Values ................................................................ B-10
Figure B-3: Display Station A/D’s No Station Transfer
Button Depressed .............................................. B-14
Figure B-4: Example Display Station A/D’s Transfer
Button Depressed for Stations 1 through 4 ...... B-14
Figure B-5: Display Station A/D/s Transfer Button
Depressed for Station 5 ..................................... B-14
Appendix C
Appendix D
Service Field Test Unit Reference Manual

Figure D-1: Service Field Test Unit


(Break-out Box).................................................... D-1
Figure D-2: CruiseCommand Connector
Locations ............................................................. D-1
Figure D-3: Example of ClearCommand Pigtail
Locations ............................................................. D-1
Figure D-4: Throttle Connection (DC Voltage) ...... D-2
Figure D-5: Throttle Connection (Current mA) ..... D-3
Figure D-6: Throttle Connection (PWM with DC
Voltmeter) ............................................................ D-3
Figure D-7: Throttle connection (PWM with Duty
Cycle Meter) ....................................................... D-3
Figure D-8: Throttle Connection (Frequency Hz) .. D-4
Figure D-9: Clutch Connections Neutral Solenoid D-4
Figure D-10: Clutch Connections Ahead Solenoid D-4
Figure D-11: Clutch Connections Astern Solenoid D-5
Figure D-12: Troll Connections Troll On/Off
Solenoid............................................................... D-5
Figure D-13: Troll Connections (Proportional
Solenoid) ............................................................. D-5
Figure D-14: 2-Speed Connections......................... D-6
Appendix E
CANtrak Display Manual
Figure E-1: Display on Power-Up ........................... E-1
Figure E-2: No Processor Power............................. E-2
Figure E-3: Processor Power On ............................ E-2
Figure E-4: Engines Started .................................... E-2
Figure E-5: Ahead Detent ....................................... E-2
Figure E-6: Full Ahead............................................ E-2
Figure E-7: Full Astern............................................ E-2
Figure E-8: Four Buttons......................................... E-3
Figure E-9: "CHNG DISP" button ........................... E-3
Figure E-10: Up and Down Arrows........................ E-3
Figure E-11: Full Ahead to Astern Detent .............. E-3
Figure E-12: "Number Screws" Selected ............... E-3
Figure E-13: On Console Mounting ....................... E-4
Figure E-14: Behind Console Mounting................. E-4

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

SET UP PROCESDURES CONTROL OPTIONS


Table 1: Processor Function Codes ......................... 33 Table 1: Descriptions and Designators for External
Table 2: Basic Throttle Function Codes .................. 33 Alarm Harness Example .......................................61
Table 3: Electric Throttle Function Codes............... 34 Table 2: Descriptions and Designators for Processor
Table 4: Throttle Servo Function Codes.................. 34 Harness..................................................................62
Table 5: Basic Clutch Function Codes..................... 34
Appendix A
Table 6: Solenoid Clutch Function Codes ............... 35
Table 7: Servo Clutch Function Codes .................... 35 Appendix B
Table 8: Speed Boost Function Codes ..................... 35 Table B-1: Examples of Components (Internal/
Table 9: Basic Trolling Function Codes................... 35 External) ..............................................................B-5
Table 10: Solenoid Troll Function Codes................ 36 Table B-2: Control Head Lever A/D Counts ........ B-13
Table 11: Basic Troubleshooting Function Code .... 36 Table B-3: Solenoid Clutch Error Codes .............. B-17
Table 12: Electronic Engine/Solenoid Transmission Table B-4: Solenoid Troll Error Codes................. B-17
Troubleshooting Function Codes ......................... 36 Table B-5: Basic Error Codes................................ B-17
Table 13: Servo Troubleshooting Function Codes .. 36 Table B-6: Solenoid Clutch Problem Causes and
Table 14: Solenoid Clutch or Clutch/Troll Solutions............................................................ B-21
Troubleshooting Function Code........................... 37 Table B-7: Solenoid Troll Problem Causes and
Table 15: Solenoid Clutch Functions requiring Field Solutions............................................................ B-21
Service Test Unit and Multimeter ........................ 37 Table B-8: Basic Control System Problem Causes and
Table 16: Electric Throttle Functions requiring Field Solutions............................................................ B-21
service Test Unit and Multimeter......................... 37 Table B-9: Servo 1 Clutch Problem Causes and
Table 17: Solenoid Trolling Functions requiring Field Solutions............................................................ B-28
Service Test Unit and Multimeter ........................ 37 Table B-10: Servo 2 Throttle Problem Causes and
Table 18: Throttle Functions Performed during Dock Solutions............................................................ B-29
Trials ..................................................................... 39 Table B-11: Basic without Error Codes ................ B-29
Table 19: Basic Clutch Functions Performed during Table B-12: Solenoid Clutch Without Error
Sea Trials............................................................... 40 Codes ................................................................. B-30
Table 20: Solenoid Clutch Functions Performed Table B-13: Servo Clutch Problems Without Error
during Sea Trials................................................... 42 Codes ................................................................. B-30
Table 21: Troll Functions that may be performed Table B-14: Electronic Throttle Without Error
during Dock Trials ................................................ 43 Codes ................................................................. B-30

Page 3
List Of Tables

Table B-15: Servo Throttle Problems Without


Error Codes........................................................ B-31
Table B-16: DP Problems Without Error Codes... B-31
Table B-17: DP/JS Problems Without Error
Codes ................................................................. B-31
Table B-18: Engine Room/Remote Switch Problems
Without Error Codes ......................................... B-33
Table B-19: Station 2 Lockout Switch Problems
Without Error Codes ......................................... B-31
Table B-20: Basic Troubleshooting....................... B-33
Table B-21: Servo Clutch Troubleshooting .......... B-33
Table B-22: Servo Throttle Troubleshooting........ B-34
Table B-23: Electronic Throttle ............................ B-34
Table B-24: Power, Start Interlock Harness
Pin-Out............................................................... B-37
Table B-25: Power, Start Interlock, Clutch Pressure
Switch Harness Pin-Out .................................... B-37
Table B-26: Power, Start Interlock, Clutch Pressure
Switch, and Alarm Harness Pin-Out ................ B-38
Table B-27: Serial Communication Harness
Pin-Out............................................................... B-38
Table B-28: Control Head Harness Pin-Out ......... B-38
Table B-29: Control Head Harness Hard-Wire .... B-39
Table B-30: Tachometer Sensor Harness Pin-Out B-39
Table B-31: Tachometer Sensor Harness with Power
Pin-Out............................................................... B-39
Table B-32: Ahead/Astern Clutch Harness
Pin-Out............................................................... B-39
Table B-33: Ahead/Neutral/Astern Clutch Harness
Pin-Out............................................................... B-40
Table B-34: Current/MAN Throttle Harness
Pin-Out............................................................... B-40
Table B-35: Frequency Throttle Harness Pin-Out B-40
Table B-36: PWM Throttle Harness Pin-Out........ B-40
Table B-37: Voltage Throttle Harness Pin-Out..... B-41
Table B-38: Power, Start Interlock, Clutch Pressure
Switch, Alarm Processor Pigtail Pin-Out.......... B-43
Table B-39: Serial Communication Processor Pigtail
Pin-Out............................................................... B-43
Table B-40: Control Head Pigtail Pin-Out (Up to 5
Stations) ............................................................. B-44
Table B-41: Throttle Pigtail Pin-Out ..................... B-44
Table B-42: Clutch Processor Pigtail Pin-Out ...... B-44
Table B-43: Tachometer Processor Pigtail
Pin-Out............................................................... B-45

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.

Conventional Symbols Used in


the Manual
Throughout this manual special attention should be
paid to the following:

NOTE: Contains helpful information

IMPORTANT: Contains helpful information.

CAUTION: Damage to the equipment may


occur if these messages are not followed.

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.

Manual Contents System Features


This manual is divided into 12 sections which cover, Standard Features
in detail, the features and operation of your system:
Further information regarding the following features
• Introduction
can be found in the "Operations" Section.
• Operation
• Plan The Installation • Sequencing of Clutch and Engine Speed.
• Installation • Station-in-Command indication.
• Set Up Procedures • Up to five Remote Stations.
• Dock Trials • Command of up to five screws.
• Sea Trials • Single Control Head lever command of speed
• Control Options and direction.
• Periodic Checks and Maintenance • Start Interlock.
• ZF Marine Electronics Service Sheets • Push Button Station Transfer.
(Appendix A) • Proportional (Reversal) Pause on through
• Troubleshooting (Appendix B) Neutral Shifts.
• System Drawings (Appendix C) • Warm-up Mode.
• High/Low Idle Selection.
• One Lever Mode.
Basic Theory of Operation • Engine Synchronization.
The ClearCommand Marine Propulsion Control Further information regarding the following features
System will hereafter be referred to as can be found in the "Operations" Section.
ClearCommand or System. • Easily configured to a vessel’s control
The System is electronic and requires a 12 or 24 VDC requirements.
power supply, one Processor per engine/gear and one • Push Button Set Up.
Control Head per remote station. • Pluggable Connections.
The ClearCommand commands the vessel’s throttle Further information regarding the following feature
and shift using a single Control Head lever. can be found in Appendix B4 - DIAGNOSTIC MENU.
The Processor is typically mounted in the • Visual system diagnostics, set up, and status
engineroom area and is connected by either electric indication.
cable harnesses or push-pull cable to the vessel’s Further information regarding the following feature
main engine throttle and transmission. can be found in Appendix B5 - AUDIBLE TONES.
One wire harness/electric cable per Control Head • Audible system diagnostics and status
lever connects the remote station(s) to the indications.
Processor(s). Only one remote station will have
command at a given time and the Station-in- Optional Features
Command is indicated by a red light located on the Further information regarding each optional feature
Control Head. Station transfer is accomplished by can be found in the "Set Up Procedures" Section.
pressing the Control Head mounted transfer button. • System failure external alarm contact.
• Auxiliary (Backup) Control System.
9ZYWX Premium Processor • Clutch pressure interlock.
• Z= 5 - Servo/6 - Electronic Throttle • Engine Room Only/Remote Switch.
• Y= 1 - Servo/2 - Solenoid Shift • Fixed Neutral Delay.
• W= 0 - No Troll/2 - Solenoid • Multiple Screw Installations.
• X= Number of Pigtail Remote Stations • Speed Boost.
• Station 2 Lockout Switch.
The System is designed for pleasure and light
commercial marine vessels that require remote
control of:

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

Station Transfer Emergency Reversal


Protection (Proportional Pause)
WARNING: Personal injury could occur if the
The proportional pause provides a means of safely
following steps are not followed exactly.
reversing the vessel’s direction. A variable pause is
introduced into the clutch command signal to allow
Command can be transferred as follows:
time for the engine RPM’s to drop to Idle and for the
A) The Station-in-Command’s lever(s) may be in any vessel’s speed through the water to slow. This pause
position. However, it is recommended that the is set during SEA TRIALS.
lever(s) are positioned to the Neutral/Idle position
whenever transferring from one station to
another. Warm-up Mode (Throttle Only Mode)
B) At the station taking command (Receiving
Station) place the Control Head’s Levers in the WARNING: Personal Injury could occur if the
Neutral/Idle Detent. following steps are not followed exactly.
FIGURE 3: BEFORE TRANSFER OF COMMAND
This feature allows the operator to increase the
engine’s RPM, while the Clutch remains in Neutral.
Warm-Up Mode is operational only when the Control
Head lever is moved in the Ahead direction.
The system is placed into Warm-Up Mode as follows:
A) At the Station-in-Command, ensure that the
Control Head’s lever is in the Neutral detent
position (refer to the following Figure).
FIGURE 5: CONTROL HEAD WARM-UP MODE

FIGURE 4: AFTER TRANSFER OF COMMAND

B) Depress and hold the transfer button.


C) While continuing to hold the transfer button,
move the Control Head’s lever to the Ahead
detent.
D) Now release the transfer button.
• The red LED indicator light will blink slowly,
indicating Warm-Up Mode is activated and the
Clutch has remained at Neutral.
C) At the station taking command (Receiving
Station) , depress and hold the receiving Station’s E) The operator now can start the engine, if
Transfer Button until the Control Head’s LED(s) is required, and increase the RPM through the
lit. entire throttle range by moving the Control Head’s
• The red LED indicator light at the receiving lever forward through the next 65 degrees.
Station’s Control Head will illuminate, F) When the Control Head’s lever is returned to the
indicating that the Sation has taken command. Neutral detent, the red LED will discontinue
• The red LED Indicator light will go OFF at the blinking and remain lit steady. After one second
transferring Station’s Control Head, indicating in Neutral, the Processor will automatically reset
that the station no longer is in command. to normal operation with full control of the
D) The commanded positons of the Throttle and clutches and engine.
Clutch will remain unchanged for one second FIGURE 6: CONTROL HEAD NORMAL OPERATING MODE
after the red LED lights. This allows the operator
time to move the Control Head’s lever(s) to a
positon approximately matching the last Station,
which will allow the vessel to maintian present
speed and direction.

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.

One Lever Mode allows the operator to control two


High/Low Idle (2) to five (5) engines and transmissions with a single
The Control System provides the input to the engine, Control Head lever. Any of the Control Head levers
so that it may run at the standard Idle speed at any Remote Station can be designated by the
(typically adjusted at the governor or carburetor), or operator as the Master lever.
it can provide a second elevated Idle speed. The designation can be changed by the operator at
any time. Most of the features (synchronization, troll,
Low Idle etc.) available in normal operation are available
• The factory default setting is for Low Idle Only. while operating in One Lever Mode.
• When the System is initially powered-up, it will
• The Processor defaults to One Lever Mode
always command Low Idle, even when High
disabled.
Idle is selected.
• One Lever Mode can be disabled or enabled in
High Idle the Set Up Procedures.
• If High Idle is desired, it may be programmed • When One Lever Mode is enabled, the
during Dock Trials. operation must be turned ON and OFF as
• High Idle is programmable up to a maximum described below.
setting of 20% of Full Throttle.
• High Idle is automatically selected when in WARNING: Personal Injury could occur if the
Warm-Up Mode. following steps are not followed exactly.

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

Turning OFF One Lever Operation SYMPTOM:


•When selected, Value 03 (Active
WARNING: It is strongly recommended that Synchronization, no Synch if Tach signal lost)
the Master lever be returned to the Neutral/Idle for Function Code E7 (Synchronization) may
position prior to turning OFF One Lever give the operator the appearance that
Operation. synchronization is not functioning. This is due
Do not attempt to transfer command from one to the fact that the Control Head’s green Synch
Remote Station to another while in One Lever indication LED does not light until the engine
Operation. Always turn One Lever Operation RPM’s are within the “Active Synch Deadband”.
OFF prior to transferring. “Active Synch Deadband” is the maximum
Failure to observe these recommendations may allowable difference in engine RPM where the
result in a sudden change in the vessel’s Processors consider the system synchronized
direction. adequately. Once the allowable difference is
obtained, the control system does not attempt to
A) Place the Master lever into the Neutral detent. match the RPM’s any closer.
B) Place all inactive Control Head levers into the •When in this Mode of Operation, there is no
Neutral detent. indication to the operator that the Control Head
• Whenever an inactive lever(s) is moved to the levers are matched close enough to start the
Neutral detent, One Lever Operation is turned synchronization process. Additionally, the green
OFF and all levers are active.
indication LED does not blink while working
• In applications with three or more screws, the
toward synchronization.
green LED will turn OFF when any inactive
Control Head lever is returned to the Neutral CAUSE:
detent. For each inactive lever that is NOT at •Function Code E7, Value 03, is operating as
Neutral detent, its red LED will be blinking. designed. Due to the imprecise positioning of
mechanical push-pull cables, the ability to
position the cables within the “Active Synch
Engine Synchronization Deadband” is severely impaired.
This Feature is not available for Single Screw SOLUTION:
Applications. •All Processors with mechanical throttle control,
where synchronization is desired, must set the
NOTE: The Control System offers two (2) types Value of Function Code E7 to Value 01 (Active
of synchronization, Active or Equal Throttle. Synchronization reverts to Equal Throttle
Synchronization if Tach Signal is lost)
Engine Synchronization must be selected during Set
Up to have automatic synchronization. Types
Synchronization is automatic and only operates The following types of synchronization use the same
when the Ahead clutch is engaged, consequently it criteria, indications, and are turned ON and OFF as
can be left ON full time. described in following Sections.
When synchronization has been selected during set
EQUAL THROTTLE ELECTRONIC SYNCHRONIZATION
up, the Control System will always power-up with
(DEFAULT ENABLED)
synchronization ON.
Equal Throttle synchronization simply commands
In order for synchronization to become active (work
the same throttle to all engines. In applications
toward synchronizing the engines' RPM's) the
where the engine governor requires a voltage signal,
Synchronization Criteria listed below must be met.
the exact same voltage signal will be applied to all
Criteria governors.
Synchronization Criteria is met when all of the With Equal Throttle Synchronization the Processors
following are true: do not receive Tachometer signals representative of
the Engine’s RPM’s.
• The Control Head Levers must be commanding
5% or greater of the throttle range. CAUTION: The Control System will remain
• The Control Head levers must be within 10% of synchronized as long as the Control Head's
one another (+/- approximately 6 degrees). levers are in close proximity to one another. If a
• All Control Head levers are commanding Ahead lever is moved to a point where the 10% throttle
clutch engagement. window is exceeded, a 10% increase or
decrease in engine RPM would occur with one
NOTE: the use of Value 03 for function Code E7 engine, resulting in a sudden change in the
should be avoided in the 9000 Series vessel's direction.
Processors with mechanical throttle control.

8
Operation

A) Ensure that the Control Head's levers are


NOTE: In order for Equal Throttle positioned to a point where Synchronization
Synchronization to work properly in Systems Criteria are met.
with electronic throttles, function codes E2 B) At the Station-in-Command, press and hold the
(Throttle Minimum) and the values of function transfer button until the green LED blinks twice
codes E3 (Throttle Maximum) must be set to and then goes out (approximately 2 seconds).
the same values on all processors. C) Synchronization is now OFF.
TURNING ON:
NOTE: In order for Equal Thorttle Synchronization is automatic and does not need to
Sychronization to work properly in systems with be turned ON, unless previously turned OFF, as
electronic throttles. Function Codes E2 (Throttle described in the previous Section.
minimum) and the values of function code E3 A) Ensure that the Control Head's levers are
(Throttle maximum) must be set to the same positioned to a point where Synchronization
values on all Processors. Criteria are met.
NOTE: In order for Equal Throttle B) At the Station-in-Command, press and hold the
Synchronization to work properly in System with transfer button until the green LED lights
mechanical Throttles, the bends in the push- (approximately 2 seconds).
pull cables must be kept to a minimum. There • The green LED will blink as the system is
can be no backlash in the linkage or cables. working toward synchronization.
Both Governors or Carburetors must provide • The green LED will become solid when the
equal engine RPM with equal movement of engines are synchronized.
their selector levers. If these conditions cannot The actual synchronizing of the engines occurs when
be met, Active Synchronization is the Control Head levers are within the 10%
recommended. (approximately 6 degrees) window of one another.
NOTE: However, synchronization can be turned ON or OFF
when the Control Head levers are apart more than
ACTIVE
the 10%.
Active Synchronization must be enabled during Set
At the Station-in-Command, press and hold the
Up and a Tachometer Sensor Wire Harness must be
transfer button for at least two seconds:
used.
• If synchronization is being turned ON, the
The Processors each receive a tachometer signal green LED will light after two seconds and stay
representing engine RPM from their respective lighted as long as the transfer button is
engines. These signals are compared with one depressed. When transfer button is released the
another over a serial communication line. If the LED will go out.
Synchronization Criteria is met, the throttle • If synchronization is being turned OFF, after
command signal of the engine(s) running at the two seconds, the green LED will blink twice and
higher RPM is lowered, until the RPM's of all engines then stay off.
match.

Indications Control Systems’


The green LED located on the Control Head Configurability
indicates the status of synchronization.
The Processor is designed in a way which allows it to
• When the green LED is lit steady, the engines
be easily configured by the installer to meet the
are synchronized.
varying needs of a wide variety of vessels. Below you
• When the green LED is not lit, the engines are
will find a list and a brief description of the groups of
not synchronized and the Control System is not
these functions. Detailed information on each
attempting to do so.
function is found in "Set Up Procedures".
• In Active Synchronization the green LED blinks
every time there is a change in the commanded Processor Functions
throttle.
A0 Processor Identification - Assigns each Processor
Turning OFF/ON when Criteria is Met in multi screw applications a unique identifying
number.
TURNING OFF: •SINGLE SCREW: DO NOT ADJUST. Leave at
When the Criteria is met, synchronization is Default Value unless a CANtrak Display is
automatic and does not need to be turned ON. If the being used. Refer to the "set Up Procedure"
operator elects to turn OFF synchronization, follow Section.
the steps below: •MULTI SCREW: This function must be the
SECOND FUNCTION SET.

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

C6 Clutch Ahead - Adjusts the amount of clutch Troubleshooting Functions


servo travel in Ahead.
BASIC TROUBLESHOOTING FUNCTIONS
C7 Clutch Astern - Adjusts the amount of clutch
servo travel in Astern. H0 Diagnostics - Allows the installer/technician to
look at various inputs to the Processor.
Speed Boost Functions (Optional) H1 Return to Factory Defaults - Returns all settings
This section applies to electronic throttle signals: to the factory default values.
F0 Boost Percentage - Programs the amount of SOLENOID TROUBLESHOOTING FUNCTION
throttle applied during initial clutch engagement. H2 Driver Fault Detection Enable - Allows the
F1 Boost Duration - Programs how long the elevated Processor to monitor the clutch and/or troll
throttle signal will be applied after initial clutch solenoids.
engagement.
F2 Boost Start Delay - Programs the amount of time Audible Tones
required after clutch engagement is commanded,
until the Speed Boost is applied. Detailed information on the following tones are in
Appendix B.
F3 Boost Bypass Clutch Delay - Controls if speed
boost is applied as a function of the reversal delay Basic Tones
time. For example if value is set to 10 (10 x 100
The Processor can produce numerous tones which
millisecond = 1 Second), then speed boost would
inform the operator of the status of the system or if
be applied only if the reversal delay is greater
any faults were to occur. These tones are emitted
than 1 second. This parameter might be useful for
from all Remote Stations regardless of whether they
boats that only need speed boost during a crash
are in command or not.
reveresal. (If C4 is set to 00 then F3 must be set to
less than 1/2 of C3). SLOW REPETITIVE TONE

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.

BASIC TROLL FUNCTIONS ONE LONG, THREE SHORT TONES


The following functions are available for all This tone indicates that the command signal from
Processors with the option of Trolling Valve Control the Station-in- Command has gone out of the
feature. acceptable range.
L0 Troll Enable and Control Head Lever Range -
STEADY TONE
Enables and disables Troll. Allows the rest of the
parameters to display when enabled. Selects the
amount of Control Head lever movement This tone indicates that the software program within
dedicated to Trolling Valve Control. the Processor has quit running, due to low voltage or
component failure.
L4 Troll Throttle Limit - Programs the maximum
throttle allowed during trolling operation. FIVE (5) SECOND STEADY TONE
L5 Troll Pulse Duration - Adjusts how long a troll
This tone indicates that there has been a loss of
boost is applied when troll operation is initiated.
Serial Communication.
L6 Troll Pulse Percentage - Adjusts how much the
troll is boosted when troll operation is initiated. THREE (3) SECOND STEADY TONE

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

For a full description of the Display LED, its


capability and usage, refer to "Set Up Procedures".
Clutch Solenoid Tones A full description of the Display LED, its capability
ONE LONG - ONE SHORT TONE (H2 ENABLED) and usage, refer to "Set Up Procedures".

This tone indicates that a fault was detected with the


Ahead, Neutral, or Astern Clutch Solenoid.
Pluggable Connections
Clutch (Servo 1) Tones Processor Pigtails
The Processors come from the factory with enclosure
ONE LONG - ONE SHORT TONE
mounted pigtail connectors for easy, mistake- free
This tone indicates that the feedback potentiometer installations.
signal from Servo 1 (Clutch) has gone out of range. FIGURE 10: PROCESSOR PIGTAIL LOCATIONS
ONE LONG, ONE SHORT -HIGH REPETITIVE RATE TONE
(JAM)

This tone indicates that Servo 1 (Clutch) cannot


reach the commanded position. This tone is also
referred to as Servo 1 Jam Tone.

Throttle (Servo 2) Tones


ONE LONG - TWO SHORT TONES

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

A full explanation is provided in "Control Options".

Multiple Screw Installations


Optional Features This Manual, as written, is intended for Single and
External Alarm Capability Twin Screw applications only. The Processor has the
capability of controlling Triple, Quad and Quint
This optional feature can provide a status signal to an Screw vessels.
external visual or audible alarm circuit. The status
signal is in the form of an OPEN or CLOSED relay If this option is going to be used, please contact a ZF
contact. When the contact is CLOSED, the Processor Marine Electronics Representative for further
is functioning normally. When the contact OPENS, information.
this indicates the processor has failed due to a Station 2 Lockout Switch
component failure or loss of DC power.
Station 2 is designated for lockout when this feature
A full explanation is provided in "Control Options".
is used.
ZF Backup Control System This feature prevents any Remote Station, other than
The optional ZF Backup Control System (ZFBU) Station 2 from taking command, except if there is an
operates independently from the ClearCommand engine room station which has priority over any
System and provides basic control of the other station.
transmission (Ahead and Astern) and engine speed. This feature is defaulted OFF, and therefore must be
It includes control logic, interlocks and timing that enabled during set up.
provide some protection for the propulsion system Once enabled, the feature is selectable with a toggle
(engine and transmission) during operation of the switch.
(ZFBU) system. If this option is going to be used,
The Engine Room/Remote switch can override the
please contact a ZF Marine Electronics
Lockout feature.
Representative for further information.
A full explanation is provided in "Control Options".
Clutch Pressure Interlock
Speed Boost
The purpose of the Clutch Pressure Interlock is to
prevent high engine RPM when the Clutch is not Speed Boost is a temporary increase in the speed
fully engaged. command output signal from the Processor. Its
purpose is to decrease the possibility of the engine
A full explanation is provided in "Control Options"’.
stalling during clutch engagement or reversal of
direction (for example, from Ahead to Astern). The
Engine Room Only/Remote Switch necessity for using Speed Boost should be assessed
Station 1 is designated as the Engine Room Station during Sea Trials, using a "trial and error" exercise.
when this feature is used. The primary function of Speed Boost is to prevent an
When the switch is CLOSED, Station 1 will take engine from stalling when a heavy load is applied.
command away from any other Remote Station. It The Speed Boost signal must be properly set and
also prevents other Remote Stations from taking timed and, when used, must be applied responsibly
command away from Station 1. and carefully.
This feature is defaulted OFF, and therefore must be
enabled during set up. Refer to the "Set Up NOTE: Under normal operating conditions,
Procedures" Section. Speed Boost is generally not required or useful.
A full explanation is provided in the "Control A full explanation is provided in "Control Options".
Options Section".

Fixed Neutral Delay


Fixed Neutral Delay is the function which provides
for a pause at Neutral whenever a change in vessel
direction is commanded, regardless of whether the
operator actually stops the Control Head lever at the
Neutral detent. This is a useful feature for boats
equipped with large propellers and shaft brakes,
because it ensures that the shaft brakes will apply on
every maneuver. This will help to prevent engine
stalls and reduce clutch wear.
Fixed Neutral Delay is independent of, and in
addition to, any proportional pause that may have
been programmed into the system.

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

TACH SENSOR HARNESS Power, Start Interlock, Clutch Pressure


One Harness per Processor is required. The Harness (optional), Alarm (optional), Backup
is plugged on one end only. There are two types of
(Optional) Cable Requirements
Tach Sensor Harnesses available:
1 An AC Coupled Sensor Harness, which is POWER CABLE
designed for inputs from items such as • Two-conductor, black and red with violet stripe,
Mechanical Senders, Magnetic Pickup Sensors, twisted.
the Alternator AC Stator Terminal or the • 14 AWG (#2,5 metric) or 12 AWG (#4 metric)
negative Coil Terminal. may be used to crimp directly to the Processor
terminals. Refer to Appendix A - Automatic
2 A Harness designed for Active (powered)
Power Selector (APS) for cable length and
Sensors with an Open Collector output, such as
additional wire size requirements.
Hall Effect Sensors.
• 300V, 105 degrees C, UL VW1, stranded tinned
This Harness is only required when Active copper wire.
Synchronization is required. • Maximum outside diameter: 0.390 inch
Determine the source of the tachometer signal, (9,9mm).
which can be provided by a mechanical tachometer
sender, magnetic pickup, alternator’s pre-rectified
output, the negative side of the coil (gasoline engine) START INTERLOCK CABLE
or an engine’s electronically produced signal. Refer • Two-conductor, both yellow with red stripe,
to Engine Tachometer Sender Requirements located twisted.
in Appendix A. • 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned
CANTRAK DISPLAY PANEL MULTI-DROP HARNESS copper wire.
• The Multi-drop Harness is required for each • Maximum outside diameter: 0.390 inch
CANTrak Panel. The Harness provides the (9,9mm).
Display Panel with power and accesses
ControlSystem data by interconnecting with the CLUTCH PRESSURE INTERLOCK CABLE (OPTIONAL)
Control System’s Serial Bus. • Two-conductor, both light blue.
• One Harness required per Display Panel. • 16 AWG (#1,5 metric).
• The Harness consists of: • 300V, 105 degrees C, UL VW1, stranded tinned
• One (1) 20 ft (6,1m) two-conductor, 14 AWG copper wire.
cable for Power. • Maximum outside diameter: 0.390 inch
• Two (2) 1 ft (30,5cm) four-conductor, 20 AWG (9,9mm).
shielded cables for connection to the Serial Bus. EXTERNAL ALARM CIRCUIT CABLE (OPTIONAL)
• The Display requies a power source of 10 - 32 • Two-conductor, red and black, twisted.
VDC, protected by a 500 mA fuse. and is • 16 AWG (#1,5 metric).
supplied by others. • 300V, 105 degrees C, UL VW1, stranded tinned
• The two (2) four-conductor cables are plugged copper wire.
to allow connection in-line with the Serial Bus. • Maximum outside diameter: 0.390 inch
(9,9mm).
Electric Cables BACKUP CABLE (OPTIONAL)
• Two-conductor
For further information regarding Electric Cable
• 16 AWG (#1, 5 metric)
requirements, contact a ZF Marine Electronics

Representative. The installation may use Harnesses,
• 300V, 105 degrees C, UL VW1, stranded tinned
Electric Cables, or a combination of both. Electric
copper wire
cable may be ordered from ZF Marine Electronics, or
• Maximum outside diameter: 0.390 inch
the cable MUST meet the following specificiations.
(9.9mm)
The following lists the various equivalent electric
cables: Serial Communication
Control Head Cable Requirements It is strongly recommended that only ZF Marine
• Seven-conductor with shield, twisted. Electronics factory manufactured Harnesses are
• Color Code – black, brown, red, orange, green, installed.
blue, and violet.
Tach Sensor Cable Requirements
• 18 AWG (nearest metric equivalent - #1).
• 300V, 105 degrees C, UL VW1, stranded tinned (optional)
copper wire. The cable selected depends on what type of Sensor is
• Maximum outside diameter: 0.390 inch being used:
(9,9mm)

17
Plan The Installation

AC TACH INPUT • The signal’s frequency may not exceed 8 KHz at


• Two-conductor, twisted, shielded. Full Throttle.
• 20 AWG (#0,5 metric)
• 300 V, 105 C, UL VW1, stranded tinned copper Alternator
• Maximum outside diameter: 0.390 inches • The pre-rectified stator AC terminal may be
(9,9mm) used as the tach source.
• The signal is inputted to the AC Coupled Sensor
OPEN COLLECTOR (ACTIVE)
input.
• Three-conductor, twisted, shielded
• The signal must meet the same criteria as any
• 20 AWG (#0,5 metric)
AC Coupled Sensor Signal (refer to “AC Coupled
• 300 V, 105 C, UL VW1, stranded tinned copper
Sensors” on page 18).
• Maximum outside diameter: 0.390 inches
(9,9mm) Point side of the Coil
• When the signal is sourced from the coil or an
Clutch or Clutch/Troll Cable
electronically produced tach signal (used on
Requirements some gasoline engines) the signal is connected
CLUTCH CABLE to the AC Coupled Sensor input.
• Two-conductor, red and black, twisted. • The signal must meet the same criteria as any
• 16 AWG (#1,5 metric). AC Coupled Sensor Signal (refer to “AC Coupled
• 300V, 105 degrees C, UL VW1, stranded tinned Sensors” on page 18).
copper wire.
• Maximum outside diameter: 0.390 inch
Active Sensors (Open Collector Output)
(9,9mm). • The sink current ability of the Sensor may be no
lower than 2 mA.
TROLL CABLE REQUIREMENTS • The operational current may not exceed 50 mA.
• Two-conductor, red with violet stripe and black, • The Sensor must have a maximum saturation
twisted. voltage of 0.8 V.
• 14 AWG (#2,5 metric). • An operational voltage requirement of 9- 10
• 300V, 105 degrees C, UL VW1, stranded tinned VDC.
copper wire. • A minimum frequency of 5 Hz at Idle.
• Maximum outside diameter: 0.390 inch • A maximum frequency of 8 KHz at Full
(9,9mm). Throttle.
Throttle Cable Requirements
• Two-conductor, red and black, twisted, Engine Room/Remote Switch
shielded.
• 16 AWG (#1,5 metric).
(optional)
• 300V, 105 degrees C, UL VW1, stranded tinned Switch and Electric Cable must meet the following
copper wire. specifications:
• Maximum outside diameter: 0.390 inch
(9,9mm). Switch Specifications
• One two position maintained Selector Switch)
• An additional normally closed (N.C.) Contact
Tachometer Sensors (optional) Block is necessary for each additional Processor
There are two types of Tachometer Sensors available • One Switch Operator per System
through ZF Marine Electronics, Mechanical (P/N • Switch Rating: switch contacts must be rated to
8902) and Magnetic Pickup (P/N 8912). Both types switch low current (2.5mA to 15mA at 12 or 24
provide two separate outputs, one for the VDC) in additon to the maximum rating of the
tachometer(s) and the second output provides the contacts.
Processor’s tachometer signal requirement. If a Electric Cable Specifications
sensor other than one supplied by ZF Marine
• Two-conductor,
Electronics is used, it must meet the criteria provided
• 16 AWG (#1,5metric) or larger
below for each type:
• 300V, 105C., UL VW1 stranded tinned copper
AC Coupled Sensors wire
• The signal must have a minimum amplitude of
+/- 1.5 V (3.0 V P-P). Station 2 Lockout Switch
• The signal’s maximum amplitude must not
exceed +/- 100 V (200 V P-P). (optional)
• The frequency of the signal must be no lower Switch and Electric Cable must meet the following
than 30 Hz at Idle. specifications:

18
Plan The Installation

Switch Specifications Engine Stop Switch


• One two position maintained Selector switch An engine STOP switch MUST be located at each
• An additional normally closed (N.C.) Contact Remote Station. The Installer supplies the switches.
Block is necessary for each additional Processor Refer to the installation instructions supplied with
• One Switch Operator per System the switch and the engine installation instructions
• Switch Rating: switch contacts must be rated to for manufacturers recommendations.
switch low current (2.5mA to 15mA at 12 or 24
VDC) in additon to the maximum rating of the WARNING: An Engine STOP Switch MUST be
contacts. installed at every remote operating station.
Refer to CFR 46, Section 62.35-5 (US Coast
Wire Specifications Guard) and ABYC P-24.5.8.
• Two-conductor,
• 16 AWG (#1,5metric) or larger
• 300V, 105C., UL VW1 stranded tinned copper DC Power Source
wire One of the most important (and often overlooked)
items for proper operation of your control system is a
Installer Supplied Tools And clean, dedicated, and reliable source of DC Power
(12 or 24 VDC).
Parts The wiring used to supply power from the power
Required Tools source (battery) through the various components
• Anti-static wrist strap (included with Processor). (fuses, distribution panel, relays, etc.) to the
• Screwdriver – medium Phillips, #2. Processors must be sized for a voltage drop of 10% or
• Wire cutter, stripper & crimper (Thomas & Betts less using 10 amps as the maximum current draw.
model WT-2000 or equivalent). Refer to ABYC Standard E-11, Table X to determine
• 7/16 inch Nut Driver or Socket with ratchet & the appropriate wire gauge for the necessary
medium extension. conductor length.
• 5/16 inch Wrench – open end. When using ZF Marine Electronics supplied 14
• Screwdriver – small straight slot. gauge power cable, and in accordance with ABYC
• Saw with blade suitable for Console Top Panel. Standard E-11, the distance from a 24 volt power
• Drill Motor with 9/32 inch and 7/32 inch drill source (battery or DC Distribution Panel) shall not
bits. exceed 20 feet (6,1m).
ZF Marine Electronics highly recommends using an
Optional Tools Automatic Power Selector (APS) and a second power
• Calibrated Digital Multimeter (Fluke 80 Series source (battery) to supply power to each Processor.
or equivalent). Refer to Appendix A - Automatic Power Selector
• Service Field Test Unit (P/N 13927, available (APS) for examples of power supplies.
through ZF Marine Electronics)
• Field Test Control Head - Dual (P/N 14000) Contact a ZF Marine Electronics representative for
the Processor’s power cable(s) maximum lengths.
Required Parts for Servo Processors Refer to Appendix A - Automatic Power Selector for
• 33C type push-pull cables. The cables are examples of the various wiring options. Ultimately,
measured from the end of the threads to the it is the boat builder or installer’s responsibility to
end of the threads. Available in 1 foot (0,3m) ensure that the vessel’s wiring meets the
increments. (If 43C type push-pull cables are requirements of American Boating & Yachting
required, a 43C Conversion Kit is available from Council standard E-11, for AC and DC Electrical
ZF Marine Electronics. Refer to Appendix A - Systems on Boats.
43C Cable Conversion Kit.)
• It is recommended that a high or premium
CANtrak Display Power
quality Push/Pull cable be used (for example, Refer to Appendix D - MM70179 CANtrak Display
Teleflex TFXTREME) for improved reliablility Manual for Electrical Specifications.
and durability.
• Many engines, transmissions and inboard/
outboard (I/O) drives are delivered with
mounting kits. If not, contact the engine/gear
dealer/manufacturer for a factory Cable
Connection Kit. Refer to Appendix A -
Universal Mounting Kit, to show other
connection options.

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

FIGURE 3: START INTERLOCK CONNECTIONS PROCEDURE 1: HARNESS WITH A PLUG ON BOTH


ENDS
A) At the Port Processor, insert the harness’s grey,
eight (8) pin plug into the Station 1 pigtail
connector.
B) Run the cable to the Port side of the Control Head
located at Station 1.
C) Insert the harness’s grey, eight (8) pin plug into
the Control Head’s Port pigtail connector.
D) Ensure that the cable has a strain relief close to
the Control Head to relieve the strain on the
connections.
E) Repeat Steps A) thru D) on all Remote Station 1
Control Head pigtails.
EXTERNAL ALARM CIRCUIT CABLE (OPTIONAL) F) Repeat Steps A) thru E) for all required Stations
Refer to the “Control Options “ section for installation (i.e. 2, 3, 4, 5).
information. • If Stations without pigtails are required to be
CLUTCH PRESSURE SWITCH CABLE (OPTIONAL) installed, follow the steps in Section 4 -
INSTALLATION "Hard-wired Cable".
Refer to the “Control Options “ section for installation
information. PROCEDURE 2: HARNESS WITH A PLUG ON
PROCESSOR END ONLY
Serial Communication Harness (Multi A) At the Port Processor, insert the harness’s grey,
Screw) eight (8) pin plug into the Station 1 pigtail
Not required for Single Screw applications. connector.
B) Run the cable to the Port side of the Control Head
TWIN SCREW APPLICATIONS
located at Station 1.
A) At the Processors, remove the watertight seals
C) Connect the conductors to the Control Head as
from the Serial pigtail connectors.
described in the appropriate Control Head
B) At the Port Processor, insert the Serial harness’s Dimensions and Variations Service Sheet in
grey, six (6) pin plug into the Serial pigtail Appendix A.
connector.
D) Provide a strain relief in close proximity to the
C) Run the harness to the Starboard Processor. Control Head’s terminal block.
D) Insert the harness’s grey, six (6) pin plug into the E) Repeat Steps A) thru D) for all Remote Station 1
Starboard Processor’s Serial pigtail connector. Control Heads.
E) Secure the Serial Harness at least every 18 in. F) Repeat Steps A) thru E) for all required Stations
(45,72 cm). (i.e. 2, 3, 4, 5).
FIGURE 4: TWIN SCREW SERIAL HARNESS CONNECTIONS • If Stations without Processor pigtails are
required to be installed, follow the steps in
Section 4 - INSTALLATION "Hard-wired
Cable".
G) Repeat all steps above for starboard side on twin
screw applications.

13242-ART Tach Sensor Harness (optional)


(required for Active Synchronization)
Control Head Harnesses A) On all Processors, remove the watertight seals
The procedure for terminating the Harness at the from the Tach Sender pigtail connectors.
Remote Station depends on what Control Head is B) Insert the harness’s grey, four pin plug into the
selected (pluggable or hard-wired). Tach Sender pigtail connector at each Processor.
• Pluggable: Follow Procedure 1. C) Run the Tach Sensor Harness cables to the Tach
• Hard-wired: Follow Procedure 2. signal source for each engine.
NOTE: Multi Screw Applications: Control • Connect the conductors to the Tach source in
Heads must be connected to the same the appropriate manner, keeping in mind that
numbered Station Pigtail or Circuit Board some sources are polarity sensitive. (black wire
Station Terminal on ALL Processors. - negative, red wire - positive)

22
Installation

Additional Harnesses enclosure through Liquid Tight Connectors in the


appropriate holes.
THROTTLE HARNESS (OPTIONAL)
FIGURE 6: PROCESSOR HOLE DESIGNATIONS
The appropriate Throttle Harness should have been
selected in Section 3 - PLAN THE INSTALLATION.
The Processor’s Throttle pigtail connects directly to
the engine interface using this Throttle Wire
Harness.
A) Connect the plug end of the Harness into the
Throttle pigtail connector at the Processor.
B) Run the cable to the engine interface.
C) Refer to the engine documentation for
termination points at the engine interface. A) Station No. 5
D) If Multi Screw, repeat steps A) thru C) to all B) Station No. 3
engines. C) Station No. 1
D) Alarm, Clutch Pressure, Start Interlock
CLUTCH HARNESS (OPTIONAL) E) DC Power
A) Plug the grey, twelve (12) pin plug into the Clutch F) Station No. 4
pigtail connector at the Processor. G) Station No. 2
B) Run the cables to the transmission. H) Clutch Solenoids
C) Plug the DIN connector into the Ahead and I) Troll Solenoids
Astern Solenoids. J) Serial Communication
K) Throttle
D) Repeat steps A) thru C) for each transmission.
L) Tachometer
CLUTCH/TROLL HARNESS (OPTIONAL) M)Engine Room / Remote Switch
A) Plug the grey, twelve (12) pin plug into the Clutch N) Station 2 Lockout Switch
pigtail connector at the Processor.
B) Run the cables to the transmission.
C) Plug the DIN connector into the Ahead and
Astern Solenoids.
D) Plug the DIN connector into the Troll proportional
solenoid, and if installed the Troll ON/OFF
solenoid.
E) Repeat steps A) thru D) for each transmission.
CANTRAK MULTI-DROP HARNESS (OPTIONAL)
Refer to Appendix D - MM70179 CANtrak Display
Manual for Multi-drop Harness connections.

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

Processor Enclosure Cable Holes


When hard-wiring a Processor or installing
additional Station pigtails, the cables must enter the

23
Installation

FIGURE 7: PROCESSOR CIRCUIT BOARD TERMINATION POINTS

Table 1: Circuit Board Hard-wire Termination


Hole Name Terminal Pin Color Hole Name Terminal Pin Color
A. Station 5 TB5 2 Brown A
3 Pink
4 Orange
6 Grey
7 Blue
C. Station 1 TB1 1 Black H. Clutch TB11 1 Black
G. Station 2 TB2 2 Brown I. Troll 2 Brown
B. Station 3 TB3 3 Red 5 Yellow
4 Orange 6 Green
F. Station 4 TB4 6 Green
7 Blue
8 Violet
E. Power In PB1 Negative Black J. Serial Communication TB7 6 White
Positive Red 7 Green
D. Start Interlock PB2 1 Red 8 Red
2 Yellow 9 Black
10 Drain
Backup Input: TB6 1 White K. Throttle TB8 3 Brown
Ground 2 Orange 4 Red
Clutch Pressure 3 Blue 5 Orange
4 Green 6 White
7 Black
Alarm 5 Black M. Engine Room/Remote TB10 1 Positive
6 Brown Switch 2 Negative
L. Tachometer TB9 1 Red N. Station 2 Lockout Switch 3 Positive
2 (AC) or Green or 4 Negative
3 (Open) Green
4 Black

Hard-wire Installation in a conduit. Verify cable location protects the


cable from physical damage.
CONTROL HEAD CABLE (LOCATIONS B, C, F, & G)
C) Label each seven-conductor cable at both ends
A) Run the seven-conductor cable from the Remote with the Station Number it connects, and Port or
Station to the Processor. Starboard.
B) Support the cables using clamps or straps not
more than 18 inches (0,5m) apart if not contained

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

POWER CABLE (LOCATION E) D) Strip back 2 inches (50,8mm) of PVC jacketing


A) Run the length of two-conductor power cable from both ends of the cable.
between the DC Power Source and the Processor. E) Strip the ends of each conductor back 3/8 inch
Refer to Appendix A (9,5mm).
B) Make the connections at the vessel’s DC Power Source, • Tachometer source side only: Clip off the drain
but do not turn power ON. wire flush with the PVC jacketing.
C) Install a liquid tight connector into the DC F) Place a 1 inch (25,4mm) section of shrink tubing
POWER entry hole. over each end of the cable.
D) Run enough of the two-conductor power cable • Processor side: Bend the drain wire back and
through the liquid tight cable grip so that it can be tuck it under the shrink tubing so that the drain
routed as shown in (Figure 7) Processor Circuit wire end is exposed past the shrink tubing.
board Termination Points. (Refer to Figure 13 and Figure 14.).
E) Strip back 3 inches (76,2mm) of the PVC FIGURE 13: AC TYPE TACHOMETER CABLE
jacketing. Refer to Figure 12.
F) Strip each wire 3/8-inch (9,5mm).
G) Place a 3/8 inch (9,5mm) section of shrink tubing
over the cable and heat.
FIGURE 12: TWO-CONDUCTOR POWER CABLE FIGURE 14: OPEN COLLECTOR TACHOMETER CABLE

3/8 inch 3 inches


(9,5mm) (76,2mm) 3/8 inch
(9,5mm)

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.

E) Insert the pins into the appropriate terminations


as shown in Table 6:.
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

Push-Pull Cable Connections FIGURE 21: THROTTLE PUSH-PULL IDLE ORIENTATION TO


SELECTOR LEVER

Processor Processor Push-Pull Cable Fully Extended (Default Setting)


8 7/8 inch Maximum
A) Remove the #10-32 jam nut and the two rubber (225,3mm)
12267
seals from the end of each push-pull cable that is
to connect to the Processor(s) only; discard the
seals, but save the nuts.
Throttle Selector ORIENTATION DOES NOT MATCH
B) Remove one screw from each Cable Anchor Clip Lever at IDLE CHANGE FUNCTION E0
and loosen the other screw. Swing the two Clips
clear. Processor Push-Pull Cable Fully Extended (Default Setting)
8 7/8 inch Maximum
FIGURE 19: PROCESSOR CABLE CLAMP ROTATION (225,3mm)
12267

Throttle Selector ORIENTATION MATCHES


Lever at IDLE DO NOT CHANGE FUNCTION E0

B) If the throttle lever is at the opposite side from the


push-pull cable, change the Throttle Servo
Direction E0 as described in Section 5 - SET UP
C) Insert the appropriate push-pull cable into the PROCEDURES.
Processor according to the labels located above C) Adjust the ball joint on the Throttle cable to
the cable clips on the Processor enclosure. match the throttle lever at the Idle stop position.
D) When the push-pull cable end is visible within the D) Ensure that adequate cable threads are showing.
Processor interior, reinstall the #10-32 jam nut.
E) Tighten the jam nut.
E) Connect the push-pull cables to the hex nuts (See
Figure 20:). Use a 7/16 inch socket to turn the hex Transmission Shift Selector Lever
nut onto the cable rod end until there is CAUTION: Misadjusted Shift Push-Pull Cables
approximately 5/16 inch (7,9mm) of thread can cause damage to the Transmission’s Clutch
showing beyond the jam nut. Pack. Ensure adjustments are made correctly
FIGURE 20: PROCESSOR PUSH-PULL CABLE INTERIOR and completely.
CONNECTIONS
A) Check the engine and transmission to see if the
Lead Screw push-pull cable anchor brackets have been
Push-Pull Cable Snap Ring installed. If the brackets are not on the
Jam Nut
7/16 inch (11,11mm)
Hex Nut
transmission, select from the Appendix A - Morse
5/16 inch Clutch and Throttle Kit Selection, or fabricate
(7,9mm) Cross-bar
brackets as shown in Appendix A - Universal
Lead Screw
12280 Mounting Kit.
F) Use a 7/16 inch socket wrench and a 5/16-inch B) Turn power ON to the Control System, to ensure
open end wrench to tighten the jam nuts. that Neutral/Idle is commanded.
G) Position the Cable Anchor Clips to secure the C) With the Shift Push-Pull cable disconnected at the
cables to the Processor housing. clutch selector lever, adjust the Shift cable’s ball
joint at the transmission to align with the clutch
H) Install the screws removed in step B).
selector lever at Neutral. The push-pull cable
I) Tighten all Cable Anchor Clip screws. must form a 90 degree angle to the clutch selector
lever.
Engine Throttle Selector Lever
D) Connect the ball joint to the clutch selector lever.
A) Ensure that the Throttle push-pull cable and the
engine’s throttle lever are in close proximity to FIGURE 22: SHIFT PUSH-PULL CABLE NEUTRAL CONNECTION
one another at Idle. If so, proceed to step C) and 7 3/8 inches
if not continue with step B). 90 (187mm)

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:

Processor Components Used


In Set Up
• Each Processor has a Display LED and Push
Buttons. Push Buttons
• The Display LED can be viewed through a The Processor has four Push Buttons located on the
window on the Processor’s cover. Circuit Board. They are identified by the words
FIGURE 1: TYPICAL PROCESSOR COVER LEFT, RIGHT, UP and DOWN silk-screened on the
Shield covering the Circuit Board.
FIGURE 5: PUSH BUTTONS

UP AND DOWN PUSH BUTTONS


• The Processor enclosure cover must be
removed to access the Push Buttons. Pressing the Up or Down Push Buttons once has the
• The Display LED is used to view the Function following functions:
Codes and the Values for those Functions. • Stops Normal Operation Display (running
• The Push Buttons are used to scroll through Processor Part Number) and activates the
Function Codes, select Function Codes and set Function Menu.
the Values of the Function Codes. • While in the Function Menu, scrolls through the
Function Codes one at a time.
FIGURE 2: PROCESSOR SHIELD PUSH BUTTON AND DISPLAY
LED LOCATIONS • When an Error Code is displayed, scrolls
through the error messages one at a time. (Refer
to Section B8 - ERROR CODES)
• When in Set Up Mode, increases (Up) or
decreases (Down) the Value one digit at a time.
LEFT AND RIGHT PUSH BUTTONS
Pressing and holding the Left and Right Push Buttons
simultaneously has the following functions:
• Activates Set Up Mode as indicated by the
blinking Display LED. (must hold the buttons
Processor Display LED until the blinking begins)
• While in Set Up Mode, deactivates Set Up
FIGURE 3: DISPLAY LED AT NORMAL OPERATION
Mode, saves the displayed Value to memory and
Starts the Processor Part Number again, one number at a time. returns to the Function Menu. (must hold the
button until the blinking stops)
12309
EXAMPLE: Running Processor Part Number during Normal Operation (9210) LEFT PUSH BUTTON ONLY
• The Processor’s Display LED has four 7-segment Pressing the Left Push Button once has the following
LED’s, which light up to show either letters or functions:
numbers. • Deactivates Set Up Mode without any changes
• The Display LED will have the Processor Part to the Value being stored to memory. The Left
Number showing in a running pattern during Push Button must be held down until function
Normal operation (Figure 4) code stops blinking. The previously stored
• Parameter display: value will then be displayed.
1 The first two digit Display LED’s to the left, • While in Function Menu, changes the Display
indicate the Function Code, which is LED to the Error Menu, if any errors are
alphanumeric. present. (has no effect if there are no errors
stored)
2 The second two digit Display LED’s indicate the
numeric Value that is programmed into the
31
Set Up Procedures

• 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)

Once the desired Value has been reached in Set Up


• For a Twin Screw System, Jumper 1 must be
Mode, the Value is stored to memory as follows:
installed on both processors.
A) Depress and hold the right push button first. • For a Triple Screw System or more, Jumper 1
Then while still depressing the right button, must be installed on the Port and Starboard
depress and hold the Left push button until the processors and removed on all other processors.
Function Code stops blinking.
• The new Value is now programmed into
memory.
• Set Up Mode is exited.

32
Set Up Procedures

FIGURE 8: PROCESSOR CIRCUIT BOARD TERMINATION POINTS

(A) Processor Function Codes


Table 1: Processor Function Codes
Function Default
Function Name Value Range or Options
Code Value
A0 Processor Identification 01 01, 02, 03, 04, 05
SINGLE SCREW: DO NOT ADJUST THE ABOVE FUNCTION! Leave at default value set by the factory.
MULTI SCREW: Set Function A0 AFTER THE A1 Function Code Has Been Set.
A1 Number of Engines 01 01, 02, 03, 04, 05
SINGLE SCREW: DO NOT ADJUST THE ABOVE FUNCTION! Leave at default value set by the factory.
MULTI SCREW: The A1 Function Code is the FIRST (1ST) Parameter Set. Then set A0.
A2 One Lever Operation 00 00 - Disabled; 01 - Enabled
SINGLE SCREW: DO NOT ADJUST THE ABOVE FUNCTION! Leave at default value set by the factory.
A3 This Feature is not available at this time. DO NOT ADJUST.
A4 Neutral Indication Tone 00 00 - No Tone
01 - Tone upon Control Head engaging Neutral
02 - Tone upon Transmission shifting to Neutral
A5 Engine Room/Remote -Station 2 00 00 – Both Disabled:
Lockout 01 – Engine Room Lockout Enabled:
02 – Station 2 Lockout Enabled;
03 – Both Enabled
(E) Basic Throttle Function Codes
Table 2: Basic Throttle Function Codes
Function Default
Function Name Value Range or Options
Code Value
E1 Throttle in Neutral 00.0 00.0 to 25.0% of Throttle Range
E5 Throttle Pause Following Shift 00.5 0.0 to 05.0 Seconds
E6 High Idle 00.0 00.0 to 20.0% of Throttle Range.
[Throttle Range = Throttle Max (E3) - Throttle Min(E2)]
E7 Synchronization 02 00 - Equal Throttle (Open Loop) Synchronization
01 - Active (Closed Loop) Synchronization (reverts to Equal if
Tach Signal lost)
02 - No Synchronization
03 - Active (Closed Loop) Synchronization (no synchronization if
Tach Signal is lost)

33
Set Up Procedures

Table 2: Basic Throttle Function Codes (Continued)


Function Default
Function Name Value Range or Options
Code Value
SINGLE SCREW: DO NOT ADJUST THE ABOVE FUNCTION! Leave at default value set by the factory.
(E) Electronic Throttle Function Codes
Table 3: Electric Throttle Function Codes
Function Default
Function Name Value Range or Options
Code Value
E0 Engine Throttle Profile 06 01 - Caterpillar (PWM) (8 to 92%)
02 - Cummins Centry (Voltage)(0.9 to 4.5 VDC)
03 - Cummins Quantum (Voltage)(0.9 to 1.2- 4.0 VDC)
04 - Detroit Diesel (Voltage) (0.64 to 4.65 VDC)
05 - MTU or MAN (Current) (4.0 to 20.0 mA)
06 - Scania (Voltage) (0.42 to 2.95 VDC)
07 - John Deere (Voltage) (0.5 to 4.5 VDC)
08 - Volvo (Voltage) (0.6 to 3.6 VDC)
09 - Detroit Diesel 1800 (Frequency) (120.64 to 360.9 Hz)
10 - Detroit Diesel 2300 (Frequency) (120.64 to 463.5 Hz)
E2 Throttle Minimum 8.2 00.0 to 20.0%
Must be 10% or more below Throttle Maximum (E3).
E3 Throttle Maximum 59.2 10.0 to 100.0% of Maximum Throttle Allowable
Must be 10% or more above Throttle Minimum (E2).
E4 Throttle Maximum Astern 100.0 00.0 to 100.0% of Throttle Maximum (E3)
(E) Servo Throttle Function Codes
Table 4: Throttle Servo Function Codes
Function Default
Function Name Value Range or Options
Code Value
E0 Throttle Servo Direction 20 20 - Push (Extends) for Throttle Increase
(Fully retracted at Idle)
21 - Pull (Retracts) for Throttle Increase
(Fully retracted at Idle)
E2 Throttle Minimum 00.0 00.0 to 20.0% (00.0 to 00.6")
Must be 10% or more below Throttle Maximum (E3).
E3 Throttle Maximum 33.0 10.0 to 100.0% of Maximum Throttle Allowable.
(00.3 to 03.0)
Must be 10% or more above Throttle Minimum (E2)
E4 Throttle Maximum Astern 100.0 00.0 to 100.0% of Throttle Maximum (E3)
(C) Basic Clutch Function Codes
Table 5: Basic Clutch Function Codes
Function Default
Function Name Value Range or Options
Code Value
C0 Clutch Pressure Interlock 00 00 – Not Installed; 01 – Installed
02 – Throttle Clutch Pressure Interlock Mode
C1 Clutch Interlock Delay 1.0 00.5 to 10.0 Seconds
C2 Proportional (Reversal) Pause 00 00 – In-Gear; 01 – Neutral;
02 – Fixed Neutral Delay Enabled
(NOTE: If C2 is set to 02, the setting of C3 will set Fixed
Neutral Delay C8.)
C3 Proportional (Reversal) Pause Time 03 00 to 99 Seconds
C4 Proportional (Reversal) Pause Ratio 00 00 – 2:1 Ahead to Astern vs. Astern to Ahead
01 – 1:1 Ahead to Astern vs. Astern to Ahead
C8 Fixed Neutral Delay 00.0 00.0 to 4.0 Seconds
(In addition to any Proportional Delay)

34
Set Up Procedures

(C) Solenoid Clutch Function Codes


Table 6: Solenoid Clutch Function Codes
Function Default
Function Name Value Range or Options
Code Value
C5 Shift Solenoid Type 00 00 - All Shift Solenoids except ZF-Hurth with
proportional solenoids
01 - ZF-Hurth with two (2) Proportional Solenoids with
12V Power
02 - ZF-Hurth with two (2) Proportional Solenoids with
24V Power
C6 ZF-Hurth Duty Cycle Ahead 100.0 00 to 100% Duty Cycle
C7 ZF-Hurth Duty Cycle Astern 100.0 00 to 100% Duty Cycle
(C) Servo Clutch Function Codes
Table 7: Servo Clutch Function Codes
Function Default
Function Name Value Range or Options
Code Value
C5 Clutch Servo Direction 20 20 - Pull [Retracts] for Ahead
21 - Push [Extends] for Ahead
C6 Clutch Ahead 80 00-100% of Maximum Ahead Travel from Neutral.
(00.0 to 1.5)
C7 Clutch Astern 80 00-100% of Maximum Astern Travel from Neutral.
(00.0 to 01.5)

(F) Speed Boost Function Codes


Table 8: Speed Boost Function Codes
Function Default
Function Name Value Range or Options
Code Value
F0 Speed Boost Percent 0.0 0.0 to 50.0% of Throttle Range
F1 Speed Boost Duration 0.0 0.0 to 20.0 Seconds
F2 Speed Boost Start Delay 0.0 0.0 to 10.0 Seconds
F3 Speed Boost Bypass Clutch Delay 0.0 0.0 to 99.0 Seconds

(L) Basic Troll Function Codes


Table 9: Basic Trolling Function Codes
Function Default
Function Name Value Range or Options
Code Value
L0 Troll Enable and Control Head Troll 00 00 – No Troll
Lever Range 01 – 20 Degrees- Type 1
02 – 35 Degrees- Type 2
03 – 45 Degrees- Type 3 (Throttle limited to 75% of Throttle
Range)
04 – 55 Degrees- Type 4 (Throttle limited to 10% of Throttle
Range)
L4 Troll Throttle Limit 00 00 to 20% of Throttle Range
Throttle Range = throttle Max (E3) - Throttle Min (E2)

35
Set Up Procedures

(L) SolenoidTroll Function Codes


Table 10: Solenoid Troll Function Codes
Function Default
Function Name Value Range or Options
Code Value
L1 Troll Valve Function (solenoid) 00 00 - Normal (No Current when at Lock-up)
01 - Inverse (No Current when at Lock-up)
02 - Normal (Maximum Current when at Lock-up)
Preset for ZF220-550, 12VDC Systems.
03 - Normal (No Current when at Lock-up)
Preset for ZF220-550, 24VDC Systems.
04 - Normal (No Current when at Lock-up)
Preset for ZF2000, 24 VDC Systems.
05 - Inverse (No Current when at Lock-up)
Preset for ZF600, 1900 and 2500, 24VDC Systems.
06 - Preset for 12VDC ZF Hurth Systems with two (2)
proportional solenoids.
07 - Preset for 24VDC ZF Hurth Systems with two (2)
proportional solenoids
L2 Troll Minimum Pressure 14 01.0 to 80.0%
Must be at least 10% below Troll Maximum (L3).
L3 Troll Maximum Pressure 25 20.0 to 100.0%
Must be at least 10% above Troll Minimum. (L2)
L5 Troll Pulse Duration 00 00.0 to 09.9 Seconds.
L6 Troll Pulse Percentage 25.0 00.1 to 100.0% of available Troll Range.

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

Solenoid Transmissions Troubleshooting


Table 14: Solenoid Clutch or Clutch/Troll Troubleshooting Function Code
Function Default
Function Name Value Range or Options
Code Value
H2 Driver Fault Detection Enable none Allows the Processor to monitor the clutch or clutch/troll
solenoids.

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

NOTE: MULTIPLE SCREW APPLICATIONS


WITH NO TROLL: The A1 Function must be set
FIRST, and the A0 Function must be set
SECOND. The rest of the Function Values may
be entered and stored in any order. (A0) PROCESSOR IDENTIFICATION
In applications where there is more than one screw,
the system must know which Processor is where.
Every Processor must have its OWN UNIQUE
identifying number. At NO time can two or more
37
Set Up Procedures

Processors be identified by the same Processor FIGURE 11: DISPLAY LED A2


Identification Number.
The available Values for this Function are:
• 00 - (Default Value), 01, 02, 03, 04 and 05.
Single Screw
DO NOT ADJUST THIS SETTING. Contact ZF (A3) THIS FUNCTION IS NOT AVAILABLE AT THIS
Marine Electronics if this Function Code is going to TIME.
be changed from the default setting. (A4) NEUTRAL INDICATION TONE
Multi Screw This Function allows the installer to turn ON a 1/2
NOTE: In twin screw or more applications, the second, low frequency tone to indicate Neutral.
Value of Function Code A0 must be changed The available Values for this Function are:
AFTER the Value in Function Code A1 has • 00 - Disabled (Default Value)
been changed to 02 or higher on ALL • 01 - Tone sounds when the Control Head’s lever
Processors. reaches Neutral.
To change the Value (Refer to Activating Set Up • 02 - Tone sounds when the Processor
Mode and Storing Values To Memory sections): commands the Transmission to Neutral.
A) Scroll to Function Code A0. A) Scroll to Function Code A4.
B) Activate Set Up Mode. B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value. C) Scroll Up or Down to the desired Value.
D) Store the Value to memory. D) Store the Value to memory.
FIGURE 10: DISPLAY LED A0 FIGURE 12: DISPLAY LED A4

To change the Value (Refer to Activating Set Up


E) Repeat on all Processors BEFORE proceeding to Mode section and Storing Values To Memory
the next Function. sections):
NOTE: Before continuing set up, wait 5 (A5) ENGINE ROOM LOCKOUT/STATION NO.2
minutes or cycle power. LOCKOUT
This Function Code provides the installer with four
IMPORTANT: If ZF Hurth Gears are used, set different options. The available Values for this
the L1 parameter after A1 and A0. Function are:
00 Both Disabled (Default Value)
(A2) ONE LEVER OPERATION • When selected, all five Remote Stations behave
NOTE: If Single Screw Application, leave at in the same manner.
default value. • No Station has transfer priority or lockout
capability.
In Multi Screw applications, the System has the 01 Engine Room Lockout Enabled
ability to command all engines and transmissions to • When the Engine Room switch is CLOSED,
the same speed and direction with a single Control command is transferred to Station No.1.
Head lever. This Function allows this Feature to be • When the Engine Room switch is CLOSED, no
enabled or disabled. (Refer to the "Operations" other station can take command away from
section for operating instructions) Station No.1.
The available Values for this Function are: • When CLOSED on power-up, Station No.1 will
• 00 Disabled (Default Value) be in command without pressing the transfer
• 01 Enabled button.
To change the Value (Refer to Activating Set Up 02 Station No.2 Lockout Enabled
Mode and Storing Values To Memory sections): • When the Station No.2 switch is CLOSED (on or
A) Scroll to Function Code A2. after power-up), any Station may take
command. But once Station 2 has taken
B) Activate Set Up Mode.
command, a solid three (3) second tone is
C) Scroll Up or Down to the desired Value. sounded to alert the operator that Station 2
D) Store the Value to memory. Lockout is active and no other Station can take

38
Set Up Procedures

command away (except the Engine Room B) Activate Set Up Mode.


Station 1 if enabled). C) Scroll Up or Down until the desired Value is
03 Both Enabled displayed.
• When both switches are CLOSED, control is D) Store the Value to memory.
transferred to Station No.1. FIGURE 14: DISPLAY LED E0 - ELECTRONIC
• When both switches are CLOSED, no other
station can take command away from Station
No.1
• When both switches are CLOSED on power-up,
Station No.1 will be in command without
pressing the transfer button. To change the Value (Refer to Activating Set Up
To change the Value (Refer to Storing Values To Mode and Storing Values To Memory sections):
Memory section and Storing Values To Memory (E0) THROTTLE SERVO DIRECTION
sections):
This Function determines if the Push-Pull cable is
A) Scroll to Function Code A5. fully extended or retracted when at Idle. The
B) Activate Set Up Mode. available Values for this Function are:
C) Scroll Up or Down to the desired Value. • 20 - Fully Retracted at Idle, extends [Push] for
D) Store the Value to memory. Throttle increase (Default Value)
FIGURE 13: DISPLAY LED A5
• 21 - Fully Extended at Idle, retracts [Pull] for
Throttle increase
FIGURE 15: THROTTLE PUSH-PULL CABLE ORIENTATION

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

F) Do not connect the ball joint to the throttle lever


NOTE: The C002 value is recommended in
at this time.
Gear Boxes that take longer than 10 seconds to
(E7) SYNCHRONIZATION reach operating pressure. Refer to the
This Function Code selects the type of "Control Options" Section for more
Synchronization, if Synchronization is required. The information on the settings.
types are described in Section 2 - OPERATION . To change the Value (Refer to Activating Set Up
The available Values for this Function are: Mode section and Storing Values To Memory
• 00 - Equal Throttle (Open Loop) section):
• 01 - Active (Closed Loop) (reverts to Equal A) Scroll to Function Code C0.
Throttle if there is no Tachometer Sensor signal) B) Activate Set Up Mode.
• 02 - No Synchronization (DEFAULT VALUE) C) Scroll Up or Down to the desired Value.
• 03 - Active (Closed Loop) (reverts to no
D) Store the Value to memory.
Synchronization if there is no Tachometer
Sensor signal) FIGURE 18: DISPLAY LED C0

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

D) Store the Value to memory.


NOTE: When the Controls are installed on a
vessel such as a double ended Ferry or the FIGURE 21: DISPLAY LED C8
Controls are being used to control a thruster,
the proportional pause should be the same in
Ahead as Astern or Port and Starboard in the
case of a Thruster.
The available Values for this Function are:
00 - 2:1 Ratio (DEFAULT) Servo Clutch Functions
• This is the default setting and determines how (C5) CLUTCH SERVO DIRECTION
the value set in the Proportional (Reversal) This Function allows the Processor to be
Pause Time C3 Function is applied. programmed to retract the Push-Pull cable for Ahead
• The number of seconds selected is for an Ahead or extend for Ahead.
to Astern maneuver only. An Astern to Ahead
maneuver will be one-half of the C3 - The available Values are:
Proportional (Reversal) Pause Time selected. • 20 - Pull [Retracts] for Ahead (Default)
This is the typical selection since most vessels • 21 - Push [Extends] for Ahead
do not reach the same throttle in Astern as they FIGURE 22: CLUTCH PUSH-PULL CABLE ORIENTATION
would in Ahead.
Therefore, the time required to get to a sufficient
water speed for a safe reversal is significantly less.
01- 1:1 Ratio
• When this setting is selected, the value set in the
Proportional (Reversal) Pause Time C3 is the
SAME for both Ahead to Astern, as with Astern
to Ahead maneuvers.
• This may be selected when the vessel reaches
the same water speed in both directions, as
would be the case with a Double Ended Ferry.
Another application where this option may be
selected would be the control of a Bow or Stern
To change the Value (Refer to Activating Set Up
Thruster.
Mode and Storing Values To Memory sections):
To change the Value (Refer to Activating Set Up A) Position the Clutch Selector Lever to the Ahead
Mode and Storing Values To Memory sections): position.
A) Scroll to Function Code C4. B) Move a Control Head lever into the Ahead detent.
B) Activate Set Up Mode. C) Check the Shift Push-Pull cable to see if it drove in
C) Scroll Up or Down to the desired Value. the correct direction for Ahead.
D) Store the Value to memory. • If the cable drove in the correct direction, no
FIGURE 20: DISPLAY LED C4
change to this Function Code is required.
• If the cable drove in the opposite direction,
continue with the next step.
D) Scroll to Function Code C5.
E) Activate Set Up Mode.
F) Scroll Up to change the Value to 21.
(C8) FIXED NEUTRAL DELAY G) Store the Value to memory.
This function provides a pause at Neutral whenever a FIGURE 23: DISPLAY LED C5 - SERVO
change in direction is commanded. This pause is in
addition to any proportional delay programmed into
the system.
The available Values for this Function are 00.0 to
04.0 seconds and are programmable in one tenth of a
second intervals. (C6) SERVO CLUTCH AHEAD TRAVEL
To change the Value (Refer to Activating Set Up This function adjusts the amount of Clutch push-pull
Mode and Storing Values To Memory sections): cable travel in both the Ahead and the Astern
A) Scroll to Function Code C8 directions.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.

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

To change the Value (Refer to Activating Set Up


To change the Value (Refer to Activating Set Up Mode and Storing Values To Memory sections):
Mode and Storing Values To Memory sections): A) Move the Control Head lever to the Astern detent.
A) Move the Control Head lever to the Ahead detent. B) Move the Clutch Selector Lever to the Astern stop.
B) Move the Clutch Selector Lever to the Ahead stop. C) Does the cable’s ball joint and lever align?
C) Does the cable’s ball joint and lever align? • If yes, no further adjustment of this Function is
• If yes, no further adjustment of this Function is required.
required. • If no, continue with the next step.
• If no, continue with the next step. D) Scroll to Function Code C7.
D) Scroll to Function Code C6. E) Activate Set Up Mode.
E) Activate Set Up Mode. F) Scroll Up or Down until the ball joint and Clutch
F) Scroll Up or Down until the ball joint and lever Selector lever aligns perfectly.
align perfectly. G) Connect the ball joint to the Clutch Selector lever.
FIGURE 25: DISPLAY LED C6 -SERVO FIGURE 27: DISPLAY LED C7 - SERVO

G) Store the Value to memory. H) Store the Value to memory.


H) Return the Control Head lever to the Neutral/Idle I) Return the Control Head lever to the Neutral/Idle
position. position.
(C7) CLUTCH ASTERN TRAVEL (SERVO) Solenoid Clutch Functions
This function is only required when the distance Table 20: Solenoid Clutch Functions Performed during
from Neutral to Astern differs from Neutral to Sea Trials
Ahead.
Code Function Name
This Function Code allows the independent
C6 ZF-Hurth Duty Cycle Ahead
adjustment of Astern travel. Otherwise, the Value
selected in Function Code C6 is automatically C7 ZF-Hurth Duty Cycle Astern
entered for Function Code C7. (C5) SHIFT SOLENOID TYPE
The available Values are 00.0 to 100.0% of the This Function Code must be left at the default value
available travel from Neutral to Astern. The Default unless a ZF-Hurth Gear is installed with proportional
Value is 80%. Ahead and Astern Solenoids.
NOTE: New ZF Hurth Gears utilize standard
On/Off solenoids for Clutch selection. If unsure
of your type, contact the ZF Gear Manufacturer.
When values 01 or 02 are selected, the current is
limited to the solenoids. The available Values are:
• 00 - All Shift Solenoids except ZF-Hurth
(DEFAULT)
• 01 - ZF-Hurth Proportional Solenoids with 12V
Power
42
Set Up Procedures

• 02 - ZF-Hurth Proportional Solenoids with 24V • 00 - No Troll (Default Value)


Power • 01 - 20 Degrees – Type 1
• 02 - 35 Degrees – Type 2
CAUTION: The maximum amount of current to
• 03 - 45 Degrees – Type 3 (Throttle limited to
ZF Hurth proportional solenoids MUST be
75%).
limited by the control system. Failure to do so
• 04 - 55 Degrees – Type 4 (Throttle limited to
can cause permanent damage to the solenoids.
10%).
Depending on the voltage applied to the
solenoids, adjust the Value to 01 for 12V power FIGURE 29: CONTROL HEAD TROLL RANGE TYPES
and 02 for 24V power.
Type 1 Type 2 Type
The default value of 00 is used with most types of
solenoids, with the exception of the ZF-Hurth Gears
with proportional Ahead and Astern solenoids.
To change the Value (Refer to Activating Set Up
Mode and Storing Values To Memory sections):
A) Scroll to Function Code C5.
B) Activate Set Up Mode. Type 3 Type 4
C) Scroll Up to change the Value.
D) Store the Value to memory.
FIGURE 28: DISPLAY LED C5 - SOLENOID

A = Throttle D = Neutral Detent


Troll Functions B = Troll Range E = Ahead Detent
C = Astern Detent
The following Troll Function may be accomplished
during Dock Trials. Refer to the "Dock Trials" To change the Value (Refer to Activating Set Up
section. Mode and Storing Values To Memory sections):
Table 21: Troll Functions that may be performed A) Scroll to Function Code L0.
during Dock Trials B) Activate Set Up Mode.
Code Function Name C) Scroll Up or Down to the desired Value.
L2 Troll Minimum Pressure D) Store the Value to memory
The following Troll Functions are accomplished FIGURE 30: DISPLAY LED L0
during Sea Trials. Refer to the "Sea Trials" section:
Table 22: Troll Functions Performed during Sea Trials
Code Function Name
L2 Troll Minimum Pressure
L3 Troll Maximum Pressure (L1) SOLENOID TROLL VALVE FUNCTION
L4 Troll Throttle Limit
CAUTION: This feature MUST be entered and
L5 Troll Pulse Duration set AFTER A0 - Processor Identification, if ZF
L6 Troll Pulse Percentage Hurth Gears are used. All other features may
then be entered and set in any order.
IMPORTANT: If ZF Hurth Gears are used, set
the L1 parameter after A1 and A0. Refer to Table 24 to select the correct set up for the
trolling valve used with this application. The
(L0) TROLL ENABLE AND CONTROL HEAD LEVER manner in which the current signal to the
TROLL RANGE Proportional Valve behaves, is determined with this
There are four types which can be used to control function.
any trolling valve. The available Values are:
Table 23: (L1) Solenoid Trolling Valve Type Selection
VALUE TROLL VALVE DESCRIPTION
00 Normal Reintjes (DEFAULT) When selected, the current to the Proportional Valve increases as
ZF 550 and lower Clutch pressure increases. When Lockup (Full Pressure) is selected, the
current drops to 0.

43
Set Up Procedures

Table 23: (L1) Solenoid Trolling Valve Type Selection


VALUE TROLL VALVE DESCRIPTION
01 Inverse Twin Disc 6000 Series When selected, the current to the Proportional Valve increases as Clutch
ZF 600 and higher pressure increases. When Lockup (Full Pressure) is selected, the current
drops to 0.
02 Normal ZF 220 - 550 12 VDC When selected, the current to the Proportional Valve increases as Clutch
pressure increases. When Lockup (Full Pressure) is selected, the current
drops to 0. Preset for ZF 220 - 550 12 VDC Systems.
03 Normal ZF 220 - 550 24 VDC When selected, the current to the Proportional Valve increases as Clutch
pressure increases. When Lockup (Full Pressure) is selected, the current
drops to 0. Preset for ZF 220 - 550 24 VDC Systems.
04 Normal ZF 2000 24 VDC When selected, the current to the Proportional Valve decreases as Clutch
pressure increases. When Lockup (Full Pressure) is selected, the current
drops to 0. Preset for ZF 2000 24 VDC Series Systems.
05 Inverse ZF 600, 1900, 2500 When selected, the current to the Proportional Valve decreases as Clutch
24 VDC pressure increases. When Lockup (Full Pressure) is selected, the current
drops to 0. Preset for ZF 600, 1900, or 2500 24 VDC Series Systems.
06 ZF Hurth 12 VDC Preset for 12 VDC ZF Hurth Systems.
07 ZF Hurth 24 VDC Preset for 24 VDC ZF Hurth Systems.
Table 24: Troll Valve Typical Current/Pressure Requirements for some ZF Gears
Current Current Pressure Pressure
Model Number Comments
(Minimum) (Maximum) (Minimum) (Maximum)
ZF 25- 80 12VDC - 12VDC - 1 Bar 8 Bar Main shift control valve is proportional. The Min & Max
[Old Style with 900 mA. 1260 mA. (15 PSI) (116 PSI) Troll currents listed are at lock-up. Exceeding the Max
two (2) current may damage the solenoid. Current below the
proportional 24VDC - 24VDC - Min listed may damage the clutch pack when the
solenoids] 450 mA 630 mA. engine rpm exceeds 1000.
ZF 25- 80 12VDC - 12VDC - 1 Bar 8 Bar One variable current control valve in addition to Ahead &
[New Style with 200 mA. 300 mA. (15 PSI) (116 PSI) Astern solenoids. Increased current equals increased
two (2) On/Off pressure
and one (1) 24VDC - 24VDC -
proportional 100 mA. 150 mA.
solenoid]
ZF90- 110TS, 200 mA. 300 mA. 1 Bar 4 Bar One variable current control valve in addition to Ahead &
220- 311, 220A, (15 PSI) (58 PSI) Astern solenoids. Increased current equals increased
325, 350, 550 & pressure.
665
ZF600, 1900 350 mA. 160 mA 1 Bar 6 Bar Two Solenoids in addition to Ahead & Astern solenoids;
(15 PSI) (87 PSI) one On/ Off, one variable current control valve.
Increased current equals decreased pressure.
The ZF1900 Gear may also be ordered with Autotroll,
which is supported by System 9000 Series Processors.
Contact your ZF Representative for information.
ZF2000 150 mA 300 mA. 1 Bar 4 Bar Two Solenoids in addition to Ahead & Astern solenoids;
(15 PSI) (58 PSI) one On/ Off, one variable current control valve.
Increased current equals increased pressure
ZF2500 350 mA 175 mA 1 Bar 6 Bar Two Solenoids in addition to Ahead & Astern solenoids;
(15 PSI) (87 PSI) one On/ Off, one variable current control valve.
Increased current equals decreased pressure.
The ZF2500 Gear may also be ordered with Autotroll,
which is supported by System 9000 Series Processors.
Contact your ZF Representative for information.
ZF4500- 7500 n/a n/a n/a n/a These series of Gears are available with Autotroll only
and are supported by System 9000 Series Processors.
Contact your ZF Representative for information.
The default value is 00. To change the Value (Refer to Activating Set Up
Mode and Storing Values To Memory sections):
A) Scroll to Function Code L1.
44
Set Up Procedures

B) Activate Set Up Mode. (H1) RETURN TO FACTORY DEFAULTS


C) Scroll Up or Down to the appropriate Value for This Function may be used during troubleshooting.
the Trolling Valve.
WARNING: (Do not make any adjustments to
D) Store the Value to memory this Function Code, unless directed to do so by
FIGURE 31: DISPLAY LED L1 - SOLENOID ZF Marine Electronics Service or Engineering
Departments).

SOLENOID TROUBLESHOOTING FUNCTIONS


(H2) Driver Fault Detection Enable
Troubleshooting Functions The H2 Function is available only on Processors with
integrated Clutch and/or Troll Solenoid command.
(H0) DIAGNOSTICS
The Processor can be programmed to monitor the
This Function is used during troubleshooting and is current flow through the Clutch and/or Troll
explained in detail in Appendix B - solenoid. When this option is selected, if the current
TROUBLESHOOTING DIAGNOSTIC MENU. level is too high or too low, an alarm is sounded and
an Error Code is produced.
Table 26 lists the required value that needs to be
entered for Function Code H2, to monitor the Ahead,
Astern, Neutral clutch solenoids and the Troll
Command and Troll On/Off.
Table 25: Solenoid Error Status Enable
Neutral Troll Troll Neutral Troll Troll
Value Ahead Astern Value Ahead Astern
(optional) Command On/Off (optional) Command On/Off
00 off off off off off 16 off off off off ON
01 ON off off off off 17 ON off off off ON
02 off ON off off off 18 off ON off off ON
03 ON ON off off off 19 ON ON off off ON
04 off off ON off off 20 off off ON off ON
05 ON off ON off off 21 ON off ON off ON
06 off ON ON off off 22 off ON ON off ON
07 ON ON ON off off 23 ON ON ON off ON
08 off off off ON off 24 off off off ON ON
09 ON off off ON off 25 ON off off ON ON
10 off ON off ON off 26 off ON off ON ON
11 ON ON off ON off 27 ON ON off ON ON
12 off off ON ON off 28 off off ON ON ON
13 ON off ON ON off 29 ON off ON ON ON
14 off ON ON ON off 30 off ON ON ON ON
15 ON ON ON ON off 31 ON ON ON ON ON
When considering the use of Speed Boost, make sure
NOTE: Function Codes 32 through 63 are to read all Speed Boost information in Section 8 -
reserved for future expansion and should not be CONTROL OPTIONS, and to make no Speed Boost
used at this time. adjustments until function codes C2 (Proportional
Pause), C3 (Proportional Time), and C4
Premium Functions (Proportional Pause Ratio) have been properly set.
SPEED BOOST FUNCTION CODES (F0) Boost Percent
Speed Boost is a temporary increase in the speed To change the Value (Refer to Activating Set Up
command output signal from the Processor. Its Mode and Storing Values To Memory sections):
purpose is to decrease the possibility of the engine A) Scroll to Function Code F0.
stalling during clutch engagement or reversal of
B) Activate Set Up Mode.
direction (for example, from Ahead to Astern). The
necessity for using Speed Boost should be assessed C) Scroll Up or Down to the desired Value.
during sea trials, using a "trial and error" exercise; D) Store the Value to memory.
under normal operating conditions it is not generally
required.

45
Set Up Procedures

FIGURE 32: DISPLAY LED F0

(F1) Boost Duration


To change the Value (Refer to Activating Set Up
Mode section and Storing Values To Memory
section):
A) Scroll to Function Code F1.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
FIGURE 33: DISPLAY LED F1

(F2) Boost Start Delay


To change the Value (Refer to Activating Set Up
Mode and Storing Values To Memory sections):
A) Scroll to Function Code F2.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
FIGURE 34: DISPLAY LED F2

(F3) Boost Bypass Clutch Delay


To change the Value (Refer to Activating Set Up
Mode and Storing Values To Memory sections):
A) Scroll to Function Code F3.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
FIGURE 35: DISPLAY LED F3

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.

Start Interlock (Engines


(E4) Throttle Maximum Astern
Stopped) This Function limits the amount of Throttle
A) Turn the Processor DC power OFF. permitted in Astern. The available Values for this
• Verify that the engine(s) will not start. Function are 00.0% to 100.0%. The Default Value is
B) Turn Processor DC power ON. Do not take 100.0% of E3 Throttle Maximum setting.
command at a Remote Station.
The Value selected is a percentage of the Value
• Verify that the engine(s) will not start.
selected in Function Code E3 – Throttle Maximum.
C) Take command at a Remote Station. Place the
Example: A Value of 50.0 will allow 50% of Throttle
Control Head’s lever(s) to approximately 10% of
Maximum when commanding Astern. The Value
the throttle range.
selected is a matter of personal preference.
• Verify that the engine(s) will not start.

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

A) Scroll to Function Code E4


B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
FIGURE 2: DISPLAY LED E4

(E6) High Idle


This Function Code Programs the RPM of the
second, elevated Idle. The available Values for this
Function are 00.0% to 20.0% of E3 Throttle
Maximum. The Default Value is 00.0%. FIGURE 5: DISPLAY LED E3 - SERVO
The Value selected is a percentage of the Value
selected in Function Code E3 – Throttle Maximum.
To change the Value (the "Activating Set Up Mode"
and the "Storing Values To Memory" sections):
A) Place the Station-in-Command Control Head into
Warm-up Mode. To change the Value (the "Activating Set Up Mode"
and the "Storing Values To Memory" sections):
B) Scroll to Function Code E6.
A) Take command at a Remote Station.
C) Activate Set Up Mode.
B) Move the Control Head lever to the Full Ahead
D) Scroll Up or Down to the desired Value.
position.
E) Store the Value to memory.
C) Check to see if the Throttle Push-Pull cable
F) Return the Control Head levers to Neutral/Idle. reaches the Full Throttle stop.
FIGURE 3: DISPLAY LED E6 • If the Throttle Selector lever is firmly (not
bound) against the Full Throttle stop, no
adjustment to Function Code E3 is required.
• If the Throttle Selector lever does not reach (or
is bound against) the Full Throttle stop,
continue with the next step.
Servo Throttle Settings D) Scroll to Function Code E3.
E) Activate Set Up Mode.
(Engines Stopped) F) Scroll Up or Down until the Throttle lever is
firmly (not bound) against the Full Throttle Stop.
(E3) Throttle Maximum
G) Store the Value to memory.
This Function adjusts the position of the Throttle
H) Return the Control Head lever to the Neutral/Idle
Push-Pull cable at Full Throttle. The available Values
position.
for this Function are 10.0% to 100.0%. The Default
Value is 33.0%. This value will always be 10% or (E2) Throttle Minimum (Engines Running)
more above E2 Throttle Minimum.
This Function further adjusts the Push-Pull cable’s
The Value entered is the percentage of the servo’s Idle position electronically. The primary purpose is
maximum travel of 3.00 inches (76,2mm). to adjust the Push-Pull cable/Throttle Selector
Example: A Value of 50.0, will equal 1-1/2 inches Lever’s position is so that any further movement will
(38,1mm) of travel from Idle to Full Throttle. result in an increase in engine RPM. (No Dead-band)
The available Values for this Function are 00.0 to
20.0%. The Default Value is 00.0%. This value will
always be 10% or more below the E3 Throttle
Maximum setting.
A) Ensure that the Throttle push-pull cable is
connected to the Throttle lever.
B) Scroll to Function Code E2.

48
Dock Trials

C) Activate Set Up Mode. B) Activate Set Up Mode.


FIGURE 6: DISPLAY LED E2 - SERVO C) Scroll Up until the engine RPM at Idle begins to
increase above Idle RPM.
FIGURE 8: DISPLAY LED E2 - ELECTRONIC

To change the Value (the "Activating Set Up Mode"


and the "Storing Values To Memory" sections):
A) Scroll Up until the engine RPM begins to increase D) Scroll Down until Idle RPM is reached.
above Idle.
E) Store the Value to memory.
B) Scroll Down until Idle RPM is reached.
C) Store the Value to memory.
Servo Checks (Engines
Electric Throttle Settings Running)
(Engines Stopped)
WARNING: Must be done with the boat
(E3) Throttle Maximum secured to the dock and only for a brief period.
This Function allows the throttle signal at Full to be
fine tuned from that provided by the E0 Throttle Push-Pull Cables
Profile. The available Values for this Function are A) Check that all Push-Pull cable connection
10.0% to 100.0%. The Value entered is the fasteners are tightened securely.
percentage of the throttle’s range from Idle to Full. B) Inside of the Processor(s) check that the Push-Pull
EXAMPLE: A Value of 50.0, will equal a 2.10 VDC cable jam nuts are securely tightened. A loose hex
throttle signal when the Volvo profile is selected, nut can back off the Push-Pull cable threaded end
which has a throttle range of 0.6 to 3.6 VDC. and effectively change the cable length.
The Default Value is 59.0%.
To change the Value (the "Activating Set Up Mode" Control Head Command
and the "Storing Values To Memory" sections):
A) Take command at a Remote Station.
Checks (Engines Running)
A) Start the engine(s) and let them run at Neutral/
B) Move the Control Head lever to the Full Ahead
Idle.
position.
B) Place one Control Head lever at a time into the
C) Measure the throttle signal.
Ahead detent, the Astern detent and then Neutral.
D) Scroll to Function Code E3. • SERVO SHIFT: Confirm that the push-pull
E) Activate Set Up Mode. cable movement is in the direction commanded.
F) Scroll Up until the throttle signal is at Full If incorrect, perform the steps described in
Throttle. Section 5 - SET UP PROCEDURES "C5 Clutch
G) Store the Value to memory. Servo Direction."
• SOLENOID SHIFT: Confirm that the
FIGURE 7: DISPLAY LED E3 - ELECTRONIC
movement of the vessel is in the correct
direction. If incorrect, reverse the electric cable
connections at the shift solenoids.
C) Place the Control System into Warm-Up Mode
and confirm that there is control of speed.
H) Return the Control Head lever to the Neutral/Idle D) Run the throttle up to approximately 20% of the
position. throttle range for at least 10 seconds.
E) Return the lever to the Neutral/Idle position.
(E2) Throttle Minimum F) Repeat steps A) thru E) at the remaining Control
This Function allows the throttle signal at Idle to be Head levers.
fine tuned from the Value provided by the E0
Throttle Profile. The available Values for this
Function are 00.0% to 20.0%. The Default Value is
08.0%.
To change the Value (the "Activating Set Up Mode"
and the "Storing Values To Memory" sections):
A) Scroll to Function Code E2.

49
Dock Trials

(E5) Throttle Pause Following


Shift (Engines Running)
NOTE: A Test Control Head and a stop-watch
are recommended to determine the correct
setting for the Throttle Pause. If a Test Control
Head is not available, a second person may be
needed.
A) Move the Station-in-Command’s lever to the
Ahead detent, while monitoring the Shaft.
• SERVO THROTTLE: Start the stop-watch as
soon as the Clutch Push-Pull cable stops
moving.
• ELECTRIC THROTTLE: Start the stop-watch
while monitoring the Shaft.
B) When the Shaft begins to rotate, stop the stop-
watch.
C) Record the time expired on the stop-watch.
Record________________.
NOTE: If the time recorded in step C) exceeds
5.0 seconds, a Clutch Pressure Interlock is
required. Refer to the "Control Options" section.

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.

Refer to the steps outlined in Troll Solenoid


Adjustments in the "Sea Trials" section.

Engine Room/Remote Switch


Verify Engine Room/Remote Switch and System
operates as per the "Control Options" section.

Station 2 Lockout Switch


Verify that the Station 2 Lockout Switch function
operates correctly. For information about this
switch, refer to the "Control Options" section.

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

NOTE: If C2 is set to 02 Enabled, C3 will set


the Fixed Neutral Delay duration. If C8 code is
also used, that pause will be added to the
TESTING C3 PAUSE TIME
proportional pause time set through C3.
CAUTION: It is critical that the C3 be tested as
(C3) Proportional Pause Time outlined below, to ensure that it is correctly
programmed. Failure to test properly could
NOTE: The pause on a through Neutral shift is
cause damage to the transmission.
proportional to the speed commanded and the
duration of that speed. The Values listed for A) Position the vessel in open water and slowly
Function Code C3, are the maximum possible increase the Throttle to 25% of the speed range.
delays. When shifting from Idle Ahead to Idle B) Leave the Control Head lever(s) at this position for
Astern or vice-versa the delay is zero (0). The at least 60 seconds.
time required to build up to the maximum
C) Quickly move the Control Head lever(s) to Idle
pause is six (6) times the Value selected. In
Astern.
addition, in order to build up to the maximum
• Once the time has expired:
delay Value, the System must be commanding
Full Throttle. The Pause when shifting from 1 Clutch should Shift to Astern.
Astern to Ahead is either half or the same as 2 Engine RPM will drop slightly when the Astern
the Ahead to Astern delay, depending on the load is placed on the engine, but not to the point
Value selected for Function Code C4 in the "Set where it comes close to stalling.
Up Procedures" section. D) Increase the Throttle slightly until the vessel starts
moving in the opposite direction.
DETERMINE C3 PAUSE REQUIREMENT • If the engine stalled or came very close to
NOTE: A stop-watch is required to accurately stalling, increase the Value of C3 by following
program the Proportional (Reversal) Pause the steps in the previous Section. Then begin
Time. again with step A) of this Section.
• If the engine does not stall or come close to
The amount of pause required is determined as
stalling, proceed with the next step.
follows:
E) Repeat the previous steps with the Throttle at
A) Place the Control Head lever(s) to the Full Ahead
50%, 75%, and 100% of the speed range.
position.
• If the engine stalls at any time, increase the
B) Leave the Control Head lever(s) at this position for Value of C3 by one (1) second and begin again
whichever of the following is longer: with step A) of this Section.
• Sixty seconds.
Once a Full Speed Reversal is successful without
• The vessel’s speed through the water reaches
coming close to stalling, the Proportional Pause is
maximum.
properly adjusted.
C) Quickly move the Control Head lever(s) to Ahead
Idle or Neutral, (depending on Function Code C4
52
Sea Trials

Synchronization for the correct RPM, refer to the Appendix B


Troubleshooting Section.
NOTE: SINGLE SCREW: Skip the
Synchronization Section and continue with the
next Section. Trolling Adjustments
MULTI SCREW: Continue with this Basic Troll Functions
Section.
(L4) TROLL THROTTLE LIMIT
Equal Throttle
CAUTION: Consult the Trolling Valve’s
A) Move both Control Head levers side by side to Installation Manual prior to programming any
approximately 25% of the Throttle range. increased throttle above Idle, while slipping the
B) If previously disabled, enable the synchronization Clutch. Failure to adhere to the Transmission
• The green LED on the Control Head will light, manufacturers directives may permanently
indicating synchronization. damage the clutch pack and void the warranty.
C) Check the engine tachometers to see if they are • The Value programmed for Function Code L4 is
within 1% of one another. a percentage of the Throttle Range. The
D) Move both Control Head levers side by side to Throttle Range is the difference between
approximately 50% of the Throttle range. Throttle Maximum (E3) and Throttle Minimum
E) Check the engine tachometers to see if they are (E2).
within 1% of one another. • The maximum percentage of the Throttle Range
F) Move both Control Head levers side by side to which the Value can be set to is 20%.
approximately 75% of the Throttle range. • The adjustment of this Function Code is a
G) Check the engine tachometers to see if they are matter of personal preference. There is no set
within 1% of one another. procedure which determines when increased
throttle should be used and what percentage of
H) Move both Control Head levers side by side to
the range it should be set to.
100% of the Throttle range.
The Values available to this Function are 00 to 20%
I) Check the engine tachometers to see if they are
of Throttle Maximum. The default value is 00% of
within 1% of one another.
Throttle Maximum.
• While synchronized, if the tachometers have a
greater than 1% difference at any engine RPM, To change the Value (Refer to the "Activating Set Up
Active Synchronization is recommended. Mode" and the " Storing Values To Memory"
sections):
Active A) Scroll to Function Code.
A) Move both Control Head levers side by side to B) Activate Set Up Mode.
approximately 25% of the Throttle range. C) Scroll Up or Down to the desired Value.
B) If previously disabled, enable the D) Store the Value to memory
synchronization.
• The green LED on the Control Head may blink FIGURE 3: DISPLAY LED L4 - SOLENOID
while driving toward synchronization.
• The green LED will remain solidly lit once the
engine RPM’s are within 1% of one another.
C) Check the engine tachometers to see if they are
within 1% of one another. Solenoid Troll
D) Move both Control Head levers side by side to NOTE: It is strongly recommended that the
approximately 50% of the Throttle range. Field Service Test Unit (P/N 13927) is utilized
E) Check the engine tachometers to see if they are when adjusting the Proportional Solenoid.
within 1% of one another.
ENABLING TROLL
F) Move both Control Head levers side by side to
approximately 75% of the Throttle range. Press and hold the Transfer Button for two seconds
G) Check the engine tachometers to see if they are with the Control Head lever in the Neutral detent
within 1% of one another. • The Control Head’s red LED should begin
blinking rapidly, indicating that troll is enabled.
H) Move both Control Head levers side by side to
• If not, refer to the "Set Up Procedures" section,
100% of the Throttle range.
L0 Setting.
I) Check the engine tachometers to see if they are
within 1% of one another. NOTE: Do Not attempt the following
adjustments until the Gear oil temperature has
While synchronized, if the tachometers have a
reached a minimum of 140 degrees F (60
greater than 1% percent difference at any engine
degrees C).
RPM, or if they appear to be continually “hunting”

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

J) If twin screw application, repeat steps A) through


on the opposite side.
NOTE: Adjust the Value of L2 based on the
desired vessels water speed or shaft RPM. Do
not base the adjustment on the response time
(how quickly or slowly the shaft begins to rotate
after shifting from Neutral to Ahead or Astern).
The response time may be adjusted later with
Function Codes L5 and L6.
(L3) TROLL MAXIMUM PRESSURE ADJUSTMENT
A) Place one Control Head lever in the Ahead detent
with Troll enabled.
54
Sea Trials

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.

H) Return the Control Head lever to the Neutral/Idle


position.

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:

NO. OF REMOTE STATIONS: Locations:


Control System Checks
Make the following checks prior to applying power to
the Processor.
Table 6: Processor
PORT STARBOARD
Processor Serial Number:

Is the Processor subject to excessive heat? (Above 70 degrees C) YES NO YES NO


At least 4 feet (1,2m) from strong magnetic fields? YES NO YES NO
Accessible for checkout, adjustments, and maintenance? YES NO YES NO
Are the Processors grounded? YES NO YES NO
Are all Electric Cables supported every 18 inches (45,72cm)? YES NO YES NO
Are the electrical cable connections tight at the Processors and Control YES NO YES NO
Heads?
Is the Processor’s Start Interlock Circuit being used? If NO, what type of YES NO YES NO
start interlock is being utilized?
Is there an Engine Stop Switch installed at each Remote Station? YES NO YES NO
Is there an Engine Room/Remote Switch installed at the Engine Room YES NO YES NO
Remote Station?
Is there a Station 2 Lockout Switch installed at Station 2? YES NO YES NO
Are Control Head Harnesses Used? YES NO YES NO
Station 1 Length:
Station 2 Length:
Station 3 Length:
Station 4 Length:
Station 5 Length:
Are all of the push-pull cable fasteners tightened? YES NO YES NO
THROTTLE ELECTRONIC
Does Throttle operate in the correct direction? YES NO YES NO
THROTTLE SERVO
Does the Throttle push-pull cable travel in the correct direction? YES NO YES NO
Is the amount of push-pull cable travel set properly for Throttle? YES NO YES NO
SHIFT SOLENOID
Does Shift operate in the correct direction? YES NO YES NO
SHIFT SERVO
Does the Shift push-pull cable travel in the correct direction? YES NO YES NO

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:

What is the source of Processor power and how is it charged?

Is there a backup power supply? YES NO YES NO


APS or other, explain

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

High Idle RPM (optional) RPM RPM

Does the vessel surge forward with Control Head lever in the Ahead YES NO YES NO
Detent?

Table 9: Sea Trials


Processor Serial Number: PORT: STARBOARD:
What is the Full Throttle RPM? RPM RPM

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".

IMPORTANT: SINGLE SCREW APPLICATIONS: DO NOT ADJUST THE FOLLOWING PARAMETERS


A0 Processor Identification; A1 Number of Engines; A2 One Lever Operation
o

Table 10: Record Processor Functions


CODE: FUNCTION NAME: PORT: STARBOARD:
A0 Processor Identification
A1 Number of Engines
A2 One Lever Operation
A3 Station Expander (SE): LEAVE AT DEFAULT.
A4 Neutral Indication Tone
A5 Engine Room Lockout / Station 2 Lockout

IMPORTANT: SINGLE SCREW APPLICATIONS: DO NOT ADJUST E7 Synchronization PARAMETER


o

Table 11: Record Throttle Functions


CODE: FUNCTION NAME: PORT: STBD:
Electronic Throttle Functions
E0 Engine Throttle Profile
Servo Throttle Functions
E0 Throttle Servo Direction
E1 Throttle in Neutral
E2 Throttle Minimum
E3 Throttle Maximum
E4 Throttle Maximum Astern
E5 Throttle Pause Following Shift
E6 High Idle
E7 Synchronization

Table 12: Record Clutch Functions


CODE: FUNCTION NAME: PORT: STBD:
Basic Clutch Functions
C0 Clutch Pressure Interlock
C1 Clutch Interlock Delay
C2 Proportional (Reversal) Pause
C3 Proportional (Reversal) Pause Time
C4 Proportional (Reversal) Pause Ratio
C8 Fixed Neutral Delay
Servo Clutch Functions
C5 Clutch Servo Direction
C6 Clutch Ahead
C7 Clutch Astern
Solenoid Clutch Functions
C5 Shift Solenoid Type
C6 ZF-Hurth Duty Cycle Ahead
C7 ZF-Hurth Duty Cycle Astern

58
Sea Trials

Table 13: Record Troll Functions


CODE: FUNCTION NAME: PORT: STBD:
Basic Troll Functions
L0 Troll Enable / Control Head Troll Lever Range
L2 Troll Minimum Pressure
L3 Troll Maximum Pressure
L4 Troll Throttle Limit
L5 Troll Pulse Duration
L6 Troll Pulse Percentage
Solenoid Troll Functions
L1 Troll Valve Function
L7 Lock Up Percentage (Hurth Only)
Only use when L106 or L107 is selected.
Table 14: Record Speed Boost Functions
CODE: FUNCTION NAME: PORT: STBD:
F0 Speed Boost Percentage
F1 Speed Boost Duration
F2 Speed Boost Start Delay
F3 Speed Boost bypass Clutch Delay

59
Sea Trials

Comments (Please use additional paper as


necessary):
GENERAL INSTALLATION CONDITION:

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-

activated on a loss of power to the Processor, an


ON/OFF Switch is strongly recommended.

61
Control Options

Clutch Pressure Interlock Table 2: Descriptions and Designators for Processor


Harness
NOTE: The Clutch Pressure Interlock C0 must Designator Description
be set to be used. Refer to the "Set Up C Pressure Switch
Procedures" section for information on setting
D ZF Marine Electronics Processor
Function Code C0.
E Ahead Clutch Pack
The Clutch Pressure Interlock uses a Pressure Switch
which monitors the Ahead and Astern Clutch F Astern Clutch Pack
pressures to prevent high engine RPM when the FIGURE 3: WITH PROCESSOR HARNESS
clutch is not fully engaged.
The Pressure Switch must have a Normally Open
(N.O.) contact that closes when adequate Clutch
pressure is reached. The primary function of the
Interlock is to prevent high engine RPM when the
Clutch is not fully engaged. The Interlock option
must be selected with Function Code C0. There are
three selectable methods of operation as described
below:

(C0) Methods of Operation FIGURE 4: WITH PROCESSOR HARD-WIRED


(00) NOT INSTALLED
This is the default value for this parameter
(01) INSTALLED
When selected, the Interlock will command the
Throttle to Idle if low or a loss of pressure occurs
while cruising. The Interlock is activated when the
Pressure Switch’s contact opens for the minimum
E F
period of time selected with Function Code C1.
If adequate Clutch pressure is not reached in the
time programmed in Function Code E5, throttle will
only be allowed to increase to this commanded speed
for the time programmed in Function Code C1 and
Installation
then returned to Idle. The installation of the Clutch Pressure Switch is the
same for both methods of operation. (Refer to the
The Throttle will remain at Idle until the Control
above Figures.)
Head’s lever is returned to Idle, the Pressure Switch
contact closes and a speed command above Idle is A) Install a Shuttle Valve on or near the
commanded. Transmission.
B) Connect hydraulic line from the Ahead and
(02) THROTTLE CLUTCH PRESSURE INTERLOCK
Astern Clutches.
This option is typically selected when the Clutch
C) Connect a hydraulic line that is no longer than 5
takes longer than five seconds to reach full pressure.
feet (1,524m) and at approximately the same
The Throttle will remain at Idle until there is a
height between the Shuttle Valve and the Pressure
closure of the Pressure Switch’s contact. This
Switch.
prevents speeds above Idle prior to full Clutch
engagement. D) Connect the Power Wire Harness’s Clutch
Pressure Interlock cable to the Pressure Switch’s
In the event of a loss of Clutch pressure while normally open contact.
cruising, the Throttle will return to Idle after the time
E) Calibrate the Pressure Switch to close when
selected with Function Code C1 has expired. Once a
adequate Clutch Pressure is reached. (Refer to
closure of the Switch is sensed, indicating adequate
the Transmission Manufacturers Installation
pressure, the Throttle immediately returns to the
Manual)
commanded signal, without having to return the
Control Head lever to Idle first, as is the case with
Value 01. Engine Room Only/Remote
Table 2: Descriptions and Designators for Processor
Harness
Switch
Station No.1 is typically designated as the Engine
Designator Description
Room Station when this feature is used. It also
A Shuttle Valve prevents other Remote Stations from taking
B Hydraulic Line command away from Station No.1.
62
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

applied as a function of the PROPORTIONAL COMMAND


OUTPUT
F2

(REVERSAL) PAUSE TIME (C3), instead of every time F0


IDLE
the clutch is engaged. With Speed Boost TIME
ENGINE Without Speed Boost
For example, if F3 is set to 01 (1 second), Speed Boost SPEED
(RPM)
IDLE

would be applied only if the PROPORTIONAL


(REVERSAL) PAUSE TIME (C3) is greater than 1 TIME

second. A useful application of this function might


be when a boat needs a speed boost during a full
speed reversal, but not when maneuvering around a Sea Trial Exercise
dock. If you believe your vessel is a candidate for Speed
A F3 value of 00 means 0 seconds, a value of 01 Boost, you can make a further determination during
means 1 second, a value of 99 means 99 seconds, etc. a Sea Trial by performing the exercises in the
Function Code C3 is PROPORTIONAL (REVERSAL) following sub-sections. Attempt slow speed reversals
PAUSE TIME and C4 is PROPORTIONAL (REVERSAL) initially without Speed Boost and then record the
PAUSE RATIO. If F3 is set at 5 seconds, C3 at 8 amount of engine droop (how far the engine speed
seconds, and C4 at the default of 2:1, then Speed drops below idle). If you determine that Speed Boost
Boost will be applied when going from Ahead to is necessary, adjust the function codes based on
Astern any time the PROPORTIONAL (REVERSAL) observations of engine response during slow speed
PAUSE TIME (C3) is greater than 5 seconds. However, reversals. Attempt a high speed reversal only after
because C4 is set to a 2:1 ratio, the PROPORTIONAL adequate testing at slow speeds.
(REVERSAL) PAUSE TIME (C3) going from Astern to Start by applying BOOST PERCENT (F0) and BOOST
Ahead can be a maximum of 4 seconds (8 seconds DURATION (F1) in small increments, record the result
divided by 2) and therefore Speed Boost will never and work upward from there. For example, for an
be applied when going from Astern to Ahead. 1800 RPM engine with Idle set at 600 RPM, try a
DETERMINING FUNCTION CODES TO BE SET starting point of 3% or 4% for BOOST PERCENT (F0)
and a BOOST DURATION (F1) of 1 second. If this is
The figure below is a graph of Speed Boost functions.
unsatisfactory, increase BOOST DURATION (F1) to 2
To determine which function codes to set (not all
seconds and evaluate those results.
need to be) and the most appropriate values for those
functions, a "trial and error" exercise must be Typically, the timing of Speed Boost is the most
performed during sea trials. Typically, the timing of critical function to set, not the amount of Speed
Speed Boost is the most critical function to set, not Boost. You may need to adjust F2 BOOST START
the amount of Speed Boost. DELAY to obtain Speed Boost just before the clutches
start to transmit significant load to the engine. Again,
The four (4) function codes associated with Speed
begin with a small initial value (for example, 200
Boost (F0, F1, F2 and F3) work in conjunction with
milliseconds, which is F2 set to 0.2 seconds).
each other to apply the right amount of Speed Boost
at the correct time and duration. Observe the engine response when engaging the
clutch at slow speed. If the engine speed increases
No adjustments should be made to Speed Boost until too much during slow speed maneuvering/clutch
function codes C2, C3, and C4 have been properly engagements, use the F3 function code to link the use
adjusted. of Speed Boost to the PROPORTIONAL [REVERSAL]
PAUSE TIME (C3) function.
The primary function of Speed Boost is to prevent an
engine from stalling when a heavy load is applied AHEAD CLUTCH ENGAGEMENT
A) Take note of the engine RPM at Idle.
DO NOT CHANGE THE VALUES OF ANY OF THE SPEED
BOOST FUNCTION CODES until you have read the B) Move the Control Head lever to the Ahead detent
descriptions of their usage and have verified their while monitoring the engine’s tachometer.
need. C) Does the engine RPM drop significantly below the
rated Idle speed or stall? If so, Speed Boost may
be required.
• If this is a twin screw installation and a
significant drop in RPM was witnessed in step
65
Control Options

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

the only Station permitted to take command


away from Station No. 2)
If this option is going to be used, please contact a ZF
Marine Electronics Representative for further
information.

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.

Throttle Servo Processor


• Check mechanical connections within the
Processor and at the Throttle selector lever.
• Check the mechanical movement of the
Throttle lever from Idle to Full. Ensure that the
cable does not bind while positioning the
Throttle at Idle or Full speed.

Clutch Servo Processor


• Check mechanical connections within the
Processor and at the Transmission selector
lever.
• Check the mechanical movement of the Clutch
selector lever from Neutral to Ahead, and
Neutral to Astern. Ensure that the cable does
not bind while positioning the Control Head
lever at Ahead or Astern. Ensure that the
Clutch selector lever and the Push-Pull cable
form a 90 degree angle at Neutral.

CANtrak Display Panel


The Panel requires no maintenance.
• While in the vicinity of the Processor, move the
Station-in-Command’s lever. If the Servo’s are
excessively noisy, apply a light coating of
silicone grease to the stainless steel lead screws.
If there are no Stations in close proximity to the
Processor(s), use a Field Service Control Head
or have someone assist.

DP Interface Enclosure
The Enclosure requires no maintenance.

DP/JS 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.

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:
• 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

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 four (4)
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.
AFT FACING CONTROL HEADS

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.
A-2
A-3
A-4
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.

Aft Facing Control Heads

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.

A-6
A-7
A-8
MMC-337 Rev- 12-07 ZF Electronics, LLC
9
Mukilteo Plant

4000 SERIES CONTROL HEAD VARIATIONS


This Service Sheet reflects all current variations of the standard 3-detent (Neutral, Forward,
Reverse) ZF Marine Electronics 4000 Series Control Heads. The 4000 Series Control Head
is for forward facing stations only. It is not currently available for aft facing stations.

Control Head # Description


4100 Control Head, 4000 Series, Single Screw. This control head has a
bridge between the levers to join them.
4100LP Control Head, 4000 Series, Single Screw, Low Profile. This control
head has a bridge between the levers to join them.
4200 Control Head, 4000 Series, Twin Screw.
4200LP Control Head, 4000 Series, Twin Screw, Low Profile.

4100LP Control Head 4200LP Control Head


4100 Control Head 4200 Control Head
(Low Profile) (Low Profile)
(Dwg 13932) (Dwg 13932)
(Dwg 13932) (Dwg 13932)

Figure 1: 4000 Control Head Variations

A-9
MMC-337 Rev- 12-07 ZF Electronics, LLC
10
Mukilteo Plant

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.

INCLUDED WITH THE CONTROL HEAD:


Mounting Studs with washers and nuts.

MOUNTING AND INSTALLATION:


1. Select the desired mounting location(s) and make cutout(s) per dimensions shown
in Figure 10: Control Head Mounting Holes and Cutout on Page #19.

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.):

• Pluggable on both ends.

• Pluggable on one end and hardwired on the other.

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.

A-10
MMC-337 Rev- 12-07 ZF Electronics, LLC
11
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.)

CAUTION: Disconnecting plugs without depressing and holding the


release button or buttons will damage the plug.

A-11
MMC-337 Rev- 12-07 ZF Electronics, LLC
12
Mukilteo Plant
CABLE/HARNESS CONNECTIONS
PLUGGABLE

ZF MARINE ELECTRONICS, LLC


P/N S/W
ZF MARINE ELECTRONICS, LLC
S/N PCA
P/N S/W
S/N PCA

FIGURE 2A FIGURE 2B

Figure 2: Dwg #14119-1, Cable/Harness Connections – Pluggable


PLUGGABLE CONNECTIONS

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.

HARD WIRED CONNECTIONS


NON-PLUGGABLE

A-12
MMC-337 Rev- 12-07 ZF Electronics, LLC
13
Mukilteo Plant

ZF MARINE ELECTRONICS, LLC


P/N S/W
S/N PCA

Figure 3: 9000 Hard Wired


Dwg #14119-2

A-13
MMC-337 Rev- 12-07 ZF Electronics, LLC
14
Mukilteo Plant
PORT & STARBOARD PROCESSOR
HARD WIRING

Figure 4: Port Processor – Hardwiring


Dwg #13932A – 15B
___________________________________________________________________________

Figure 5: Starboard Processor – Hardwiring


Dwg #13932A – 15A

A-14
MMC-337 Rev- 12-07 ZF Electronics, LLC
15
Mukilteo Plant

4200 CONTROL HEAD


FRONT VIEW

ZF MARINE ELECTRONICS, LLC


P/N S/W
S/N PCA

Figure 6: 4200 Control Head - Front View


Dwg #14132

A-15
MMC-337 Rev- 12-07 ZF Electronics, LLC
16
Mukilteo Plant

4200 CONTROL HEAD


SIDE VIEW

Figure 7: 4200 Control Head - Side View


Dwg #14133

A-16
MMC-337 Rev- 12-07 ZF Electronics, LLC
17
Mukilteo Plant

4100LP CONTROL HEAD


FRONT VIEW

ZF MARINE ELECTRONICS, LLC


P/N S/W
S/N PCA

Figure 8: 4100LP Control Head – Front View


Dwg #13932ART-8

A-17
MMC-337 Rev- 12-07 ZF Electronics, LLC
18
Mukilteo Plant

4100LP Control Head


Side View

Figure 9: 4100LP Control Head – Side View


Dwg 13932ART-9

A-18
MMC-337 Rev- 12-07 ZF Electronics, LLC
19
Mukilteo Plant

4000 SERIES CONTROL HEAD MOUNTING CUTOUT


CAUTION: NOT TO SCALE
DO NOT USE AS A TEMPLATE

Figure 10: Control Head Mounting Holes and Cutout – Dwg #13293
DO NOT USE AS A TEMPLATE

A-19
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

MOUNTING AND INSTALLATION:


Select the desired mounting locations and drill screw and cable holes as indicated on the template diagram. Refer to
the Dimensions Diagram on the next page.
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.

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.

Bottom Panel Assembly Designations


A Front Cover
B Cable Grip Nut
C Seal
D Bottom Cover
E 750-R = Plug;
750-L & 760 = Watertight Cable Grip (Cable O.D. .275 - .393 [7mm - 10mm)
F 750-L = Plug;
750-R & 760 = Watertight Cable Grip (Cable O.D. .275 - .393 [7mm - 10mm)
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.
585CE and Earlier MicroCommander and MS Series ClearCommand
Port Lever: Starboard Lever:
Terminal 3 Red Terminal 3 Red
Terminal 5 Blue Terminal 5 Yellow
Terminal 7 Yellow Terminal 7 Blue
CruiseCommand, 9000 Series, Pluggable 585CE MicroCommander
and Pluggable MS Series ClearCommand
Port Lever: Starboard Lever:
Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER
Terminal 5 Blue Terminal 5 JUMPER
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 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

Control Head .75 inch Diameter Hole


Mounting Locate where required.
Holes (two if Dual Control Head)

3.54
Enclosure (89,9mm)

Watertight
Cable Grip
(two if Dual Control Head)
6.29
(159,8mm)

4.72
10241 (119,9mm)

Deck Mount or Exposed Mount


Ideal for outside Weather Mount
To prevent internal condensation and moisture build up the mount is drilled to allow air circulation.
Part No. 12110

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-24
Deutsch Connector Assembly
DT Type
Step 1: Contact Removal Step 2: Wire Stripping
Solid Contacts
Contact Part Wire Gauge Strip Length
1. Remove wedgelock using
needlenose pliers or a hook Number Range (inches)
shaped wire. Pull wedge
straight out. 0460-202-20141 20 AWG .156-.218
0462-201-20141 20 AWG .156-.218

0460-202-16141 16, 18 & 20 AWG .250-.312


2. To remove the contacts, 0462-201-16141 16, 18 & 20 AWG .250-.312
gently pull wire backwards,
while at the same time 0460-215-16141 14 AWG .250-.312
releasing the locking finger 0462-209-16141 14 AWG .250-.312
by moving it away from the
contact with a screwdriver. 0460-204-12141 12 & 14 AWG .222-.284
0462-203-12141 12 & 14 AWG .222-.284

0460-204-08141 8 & 10 AWG .430-.492


3. Hold the rear seal in
0462-203-08141 8 & 10 AWG .430-.492
place, as removing the
contact may displace the
0460-204-0490 6 AWG .430-.492
seal.
0462-203-04141 6 AWG .430-.492

Step 3: Contact Crimping Step 4: Contact Insertion


Use Crimp Tool #HDT48-00
1. Strip insulation from wire.
(See Step 2). 1. Grasp crimped contact
2. Raise selector knob and approximately (25.2 mm) one
rotate until arrow is aligned with inch behind the contact barrel.
wire size to be crimped.
3. Loosen locknut, turn adjust-
ing screw in until it stops.

2. Hold connector with rear


4. Insert contact with barrel up. grommet facing you.
Turn adjusting screw counter–
clockwise until contact is flush
with indentor cover. Tighten
locknut.
3. Push contact straight into
connector grommet until a click
is felt. A slight tug will confirm
5. Insert wire into contact. that contact is properly locked
Contact must be centered in place.
between indicators. Close
handles until crimp cycle is 4. Once all contacts are in place,
completed. insert wedgelock with arrow pointing
6. Release handles and remove toward exterior locking mechanism.
crimped contact. The wedgelock will snap into place.
Rectangular wedges are not oriented.
They may go in either way.
7. Inspect terminal to ensure NOTE: The receptacle is shown –use the
that all strands are in crimp same procedure for plug.
barrel.NOTE: Tool must be
readjusted for each type/size
of contact. Use HDT04-08 for
size 8 and 4 contacts.
(800) 223-1236

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.

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-28
A-30
A-32
A-34
A-36
ZF Marine Electronics, LLC
Mukilteo Plant
MMC-287 Rev.F 5/06

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

a Grounding is used courtesy of American Boat and Yacht Council.


All parts of figure except processors and processor connection
2003 American Boat and Yacht Council

Metal - Hull Vessels

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

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-42
Engine Type Engine Model Sender Comments
Diesel Perkins 4-154 N/A Aetna Part No. 8709 Magnetic Sensor must
be used in lieu of SAE drive.
Diesel Perkins M-135, M225, M-300 & M30 8912 N/A
Diesel Volvo 70, 100 & 120 A or B Series 8902 N/A
Diesel Volvo 3, 6A, 17 & 30 8912 N/A
Diesel Volvo 31 & Up, 41 N/A Aetna Part No. 8709 Magnetic Sensor must
be used in lieu of SAE drive.
Diesel Volvo 40, 60, 61 & Up, 71 & Up, 100C & Up, 102, N/A Magnetic pickup already installed on cam
121C & Up, 122, 2010 & 2020 gear.
Diesel Volvo 42 & 43 N/A Connect at blower box. Black wire is
ground and grey is signal
Diesel Volvo 2030 & 2040 N/A Magnetic pickup already installed on cam
gear.
Diesel Yanmar All Engines N/A A metric Magnetic pickup is already
installed on all engines.

P/N 8902 Dual Mechanical Sender


P/N 8912 Dual Magnetic Pickup (3/4-16)
P/N 8922 Single Magnetic Pickup (5/8-18) Available through Aetna Engineering only.

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

MAKE TRANSMISSION MODEL KIT NO.


Allison M & MH 41482
Borg Worner 70, 71, 72 In line w/red gear rear entry 301474
Capital 12400 36680
2, 3, & 4 HD & HE 36680
MerCruiser Inboard w/o Warner reduction gear 62355
Paragon HF-7 36680
Twin Disc MG508, 509, 510, 510A, 512, 514C, 514CHP, 518, 521, 527, 530, 540 42577
MG502, 506, 507, W/x9994, xA7022, A7048 Valves 63696
Twin Disc MG509, 510A, 511A, 307171
Trolling Valve 514C

ENGINE MAKE KIT NO.


Chrysler 1975 & later 300465
Evinrude/Johnson 55-235 H.P. 1978 to date 301729
Mercury 40-300 H.P. 301901
Mercruiser I/O 302123
OMC Sterndrive I/O 300557
Volvo I/O Engine and out drive brackets are provided by Volvo

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-44
MMC-290 Rev.- 6/01
ZF Marine Electronics, LLC
Mukilteo Plant
Universal Mounting Kit

Fabricate Bracket to match


dimensions shown

3/16" (4,8mm) Diameter

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

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-46
43C Cable Conversion Kit
Rev Date Revision Description
A 8/03 Added 9000 Series.

Cross-bar
Remove Lead Screw
33C Cable Remove
Connect Nut Snap Ring
Cable Retainer

Screws

11452-

Figure 1: Actuator/Processor Preparation

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.

NOTE: 43C cable and jam nut are supplied by others.

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

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-48
MMC-165 Rev. F 7-07

Electronic Propulsion Control Systems Limited Warranty


A. Limited Warranty: Your ZF Marine Electronics product has designed and manufactured by experienced
engineers and craftsmen. ZF Marine Electronics, LLC, warrants for the period indicated below, each
product manufactured by ZF Marine Electronics, LLC, to be free from defects in materials and
workmanship. If during the applicable warranty period is determined by ZF Marine Electronics, LLC to be
in breach of this limited warranty, ZF Marine Electronics, LLC, at its option will repair or replace the
defective product.

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

Processor, Serial # Serial #


Number of Remote Stations
Purchase Date
Dealer's Name
Installer's Name
Phone Number ( )
Cell Number ( )
Fax Number ( )
E-Mail Address
Purchaser's Name
Street Address
City, State, Zip
Phone Number ( )
YOUR VESSEL:
Engine, Make & Model
Length
Manufacturer
ZF Marine Electronics, LLC. Product First Seen At:
Boat Show Dealer Magazine Friend

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.

9510X (X = Zero to Four Pluggable Processor


Remote Stations) Processor The Processor receives the variable DC voltage from the
Control Head(s) and converts these inputs to the
This Processor is designed to precisely control speed and appropriate electronic or electric outputs at the correct
direction on vessels equipped with: time and sequence to the Governor and Gear Box. The
• servo Throttle and servo Clutch selection, information regarding throttle type, throttle/ clutch
sequencing, etc., are all stored on memory within the
9512X (X = Zero to Four Pluggable Processor.
Remote Stations) Processor
This Processor is designed to precisely control speed and Power Source
direction on vessels equipped with: All electronic equipment must have power in order to
• servo Throttle, servo Clutch, and solenoid Troll operate. Ensuring a properly charged reliable power
selection, source cruicial.
• The Processor requires a 12 or 24 VDC power
9520X (X = Zero to Four Pluggable system.
Remote Stations) Processor The minimum voltage at which the Processor will
This Processor is designed to precisely control speed and continue to operate is 9.00 VDC. The maximum
direction on vessels equipped with: allowable voltage is 31 VDC. Exceeding the upper limit
• servo Throttle and solenoid Clutch selection. may damage the Processor. The power supply must be
capable of delivering 10 amperes to each Processor on a
9522X (X = Zero to Four Pluggable continual basis and current surges up to 20 amperes. All
Remote Stations) Processor cable calculations should be based on a 10 ampere draw
This Processor is designed to precisely control speed and with no more than 10% voltage drop.
direction on vessels equipped with:
• servo Throttle and solenoid Clutch/Troll selection
Electrical Cables and Harnesses
The function of the Electrical Cables and Harnesses are to
9610X (X = Zero to Four pluggable move electrical information from one point to another.
Remote Stations) Processor The ZF Marine Electronics’ System requires electrical
cables and/or pluggable Harnesses. These Harnesses
This Processor is designed to precisely control speed and
may have plugs on one end or both, depending on its
direction on vessels equipped with:
purpose.
• electronic Throttle and servo Clutch selection
There are Harnesses available for Control Head Interface,
9620X (X = Zero to Five pluggable DC Power, Start Interlock, Clutch Oil Pressure Interlock
Remote Stations) Processor and External System Status Indication Circuit.
In addition, the application may require Harnesses for
This Processor is designed to precisely control speed and
one or more of the following:
direction on vessels equipped with:
• Engine Interface
• electronic Throttle and solenoid Clutch selection,
• Serial Communication
9622X (X = Zero to Four Pluggable • Shift Interface
• Shift/Troll Interface
Remote Stations) Processor
• Tachometer Sensor Signal
This Processor is designed to precisely control speed and • Engine Room/Remote Switch
direction on vessels equipped with: • Station 2 Lockout Switch
• electronic Throttle and solenoid Clutch/Troll
selection,

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

FIGURE B-4: EXAMPLE DISPLAY OF APPLIED BATTERY


VOLTAGE

E) In addition to the applied battery voltage, scrolling


through the Diagnostics Menu by pressing the Up or

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

FIGURE B-8: EXAMPLE DISPLAY OF SOFTWARE REVISION LEVEL VIEW

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

FIGURE B-1: DISPLAY EXAMPLES OF REMOTE STATIONS


Station 1 Station 2 Station 3 Station 4 Station 5

FIGURE B-2: DISPLAY EXAMPLES OF REMOTE STATIONS A/D VALUES


Station 1 Station 2 Station 3 Station 4 Station 5
(Neutral (Full Ahead (Full Astern (No Control Head (Neutral
Commanded) Commanded) Commanded) Connected) Commanded)

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:

Servo 2 Control System Tones A) Turn the power ON to the Processor.


• If the tone is not present continue with step C)
• If the tone is present, check the DC voltage to the
One Long - Two Short Tones Processor by accessing the Diagnostic Menu H0. If
the voltage is adequate continue with step B.
This tone indicates that the feedback signal, which
represents the position of the Servo 2 cross-bar, is B) Disconnect the push-pull cable from the selector
out of expected range. lever.
• If the tone is still present after cycling power,
This tone will be accompanied by Error Code 66 or replace the Processor.
67. • If the tone is no longer present, continue with step
• If Error Code 66 is displayed, the signal received C)
from the feedback potentiometer is higher than C) If disconnected, reconnect the push-pull cable.
expected. This is due to one of the following
D) Depress the Transfer Button while moving the Control
reasons:
Head lever to the Ahead detent.
– The orange wire (ground) between the
potentiometer and plug are not making contact, E) Release the transfer button and continue to move the
or have a high resistance contact. Control Head lever through the speed range.
– The potentiometer is out of calibration. • If the tone does not sound until the Control Head
– The potentiometer is defective. lever is close to full throttle, Function Code E3
• If Error Code 67 is displayed, the signal received Throttle Maximum is misadjusted.
from the feedback potentiometer is lower than • If the tone sounds earlier than full throttle, continue
expected. This is due to one of the following with step F).
reasons:
B-11
F) Disconnect the push-pull cable from the selector The tone will be accompanied by Error Code 62 and
lever. is typically caused by one of the following reasons:
G) Manually reposition the selector lever (Idle to Full). • Stiff or frozen selector lever.
• If the selector lever is very stiff it needs to be • Misadjusted push-pull cable.
serviced. • Defective push-pull cable.
• If the selector lever moves freely, the push-pull • Low battery voltage.
cable is defective and needs replacing. • Defective Processor.
In order to isolate the cause to one of these five
Servo 1 Control System Tones items, follow the steps below:
A) Disconnect the push-pull cable from the selector
One Long - One Short Tone lever.
B) Move the Control Head lever to Ahead, Astern, and
This tone indicates that the feedback signal, which back to Neutral.
represents the position of the Servo 1 cross-bar, is • If the tone ceases continue with step C).
out of the expected range. • If the tone is still present, skip ahead to step D).
This tone will be accompanied by Error Code 63 or C) Grab a hold of the selector lever and manually
64. reposition the lever.
• If Error Code 63 is displayed, the signal received • If the selector lever is very stiff it needs servicing.
from the feedback potentiometer is higher than • If the selector lever moves freely, the push-pull
expected. This is due to one of the following cable’s travel is misadjusted and needs to be
reasons: corrected.
– The orange wire (ground) between the D) If the tone did not cease in step B), remove the push-
potentiometer and plug are not making contact, pull cable from the Processor.
or have a high resistance contact. E) Move the Control Head lever back and forth from
– The potentiometer is out of calibration. Neutral to Ahead to Astern.
– The potentiometer is defective. • If the tone ceases, the push-pull cable is defective
• If Error Code 64 is displayed, the signal received and needs to be replaced.
from the feedback potentiometer is lower than • If the tone did not cease, check the DC Voltage to
expected. This is due to one of the following the Processor by accessing the Diagnostic Menu
reasons: H0. If the voltage is adequate, replace the
– The green (signal) or orange (reference voltage) Processor.
wires between the potentiometer and plug are
not making contact or have a high resistance
contact.
– The potentiometer is out of calibration.
– The potentiometer is defective.
– The Control Circuit is defective.
The Servo 1 feedback signal can be viewed within
the Diagnostic Menu. The Value displayed depends
on the direction and amount of push-pull cable
travel. As a general rule:
• When the Value displayed is 1023 or 0, the problem
is with the wiring between the potentiometer and
plug.
• If the displayed Value varies, the potentiometer is
defective.
• When the Value is slightly too high or too low when
fully extended, the potentiometer requires
calibration.

One Long, One Short - High Repetitive


Rate Tones
This tone is also referred to as a Jam Tone. When
sounded, Servo 1 is unable to reach the commanded
position. In most cases when a Jam Tone is
encountered, it can be cleared by moving the Control
Head lever back to the point prior to where the tone
was first encountered.

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.

Station 2 Lockout Switch


If the switch itself failed, the failure would be either
and OPEN contact (will not CLOSE) or a CLOSED
contact (will not OPEN).
If the switch were to fail in a manner where the
contact will not CLOSE, the system would not
prevent a Remote Station from taking command on
one side.
If the switch were to fail in a CLOSED manner, no
station would be able to take command away from
Station 2, other than Station 1.
A suspected faulty switch can be verified as follows:
A) Turn the Station 2 Lockout Switch ‘OFF’ (OPEN
contact).
B) Measure the DC voltage across the switch contact.
• If 5.00 ± 0.2 VDC is measured, continue with step
C).
• If approximately 0 VDC is measured, skip ahead to
step F).
C) Turn the Station 2 Lockout Switch ‘On’ (closed
contact).
D) Measure the DC voltage across the switch contact.
• If 5.00 ± 0.2 VDC is measured, the switch is
defective and must be replaced.
• If approximately 0 VDC is measured, continue with
step E).
E) At the Processor, scroll down to Function Code A5
and ensure a value of 01 or 03 is entered.
• If A5 is not set to 02 or 03, it must be changed.
• If A5 is set to 02 or 03, the Processor is defective
and must be replaced.
F) If 0 VDC was measured in step B), measure the DC
voltage at TB10, pins 3 and 4 on the Processor’s
circuit board.
• 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.
• If approximately 0 VDC is measured, continue with
step G).

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.

Table B-3: Solenoid Clutch Error Codes


Error # Title Description
1 Clutch Astern Shorted The Astern Clutch Solenoid is requiring more current than expected.
2 Clutch Astern Open The Astern Clutch Solenoid should be drawing current but is not.
3 Clutch Neutral Shorted The Neutral Clutch Solenoid is requiring more current than expected.
4 Clutch Neutral Open The Neutral Clutch Solenoid should be drawing current but is not.
5 Clutch Ahead Shorted The Ahead Clutch Solenoid is requiring more current than expected.
6 Clutch Ahead Open The Ahead Clutch Solenoid should be drawing current but is not.
Table B-4: Solenoid Troll Error Codes
Error # Title Description
7 Troll ON/OFF Shorted The Troll ON/OFF Solenoid is requiring more current than expected.
8 Troll ON/OFF Open The Troll ON/OFF Solenoid should be drawing current but is not.
9 Troll Command Shorted The Troll Proportional Solenoid is requiring more current than expected.
10 Troll Command Open The Troll Proportional Solenoid should be drawing current but is not.
Table B-5: Basic Error Codes
Error # Title Description
13 Station No. 1 Faulted High Station No. 1 Control Head’s lever position is out of range. The input
appears to be too high.
14 Station No. 2 Faulted High Station No. 2 Control Head’s lever position is out of range. The input
appears to be too high.
15 Station No. 3 Faulted High Station No. 3 Control Head’s lever position is out of range. The input
appears to be too high.
16 Station No. 4 Faulted High Station No. 4 Control Head’s lever position is out of range. The input
appears to be too high.
17 Station No. 5 Faulted High Station No. 5 Control Head’s lever position is out of range. The input
appears to be too high.
18 Station No. 6 Faulted High Station No. 6 Control Head’s lever position is out of range. The input
appears to be too high.
19 Station No. 7 Faulted High Station No. 7 Control Head’s lever position is out of range. The input
appears to be too high.
20 Station No. 8 Faulted High Station No. 8 Control Head’s lever position is out of range. The input
appears to be too high.
21 Station No. 9 Faulted High Station No. 9 Control Head’s lever position is out of range. The input
appears to be too high.
22 Station No. 10 Faulted High Station No. 10 Control Head’s lever position is out of range. The input
appears to be too high.
23 Station No. 1 Faulted Low Station No. 1 Control Head’s lever position is out of range. The input
appears to be too low.
24 Station No. 2 Faulted Low Station No. 2 Control Head’s lever position is out of range. The input
appears to be too low.
25 Station No. 3 Faulted Low Station No. 3 Control Head’s lever position is out of range. The input
appears to be too low.
26 Station No. 4 Faulted Low Station No. 4 Control Head’s lever position is out of range. The input
appears to be too low.
27 Station No. 5 Faulted Low Station No. 5 Control Head’s lever position is out of range. The input
appears to be too low.
28 Station No. 6 Faulted Low Station No. 6 Control Head’s lever position is out of range. The input
appears to be too low.
29 Station No. 7 Faulted Low Station No. 7 Control Head’s lever position is out of range. The input
appears to be too low.
B-17
Table B-5: Basic Error Codes (Continued)
Error # Title Description
30 Station No. 8 Faulted Low Station No. 8 Control Head’s lever position is out of range. The input
appears to be too low.
31 Station No. 9 Faulted Low Station No. 9 Control Head’s lever position is out of range. The input
appears to be too low.
32 Station No. 10 Faulted Low Station No. 10 Control Head’s lever position is out of range. The input
appears to be too low.
33 Station No. 1 Button Stuck Station No. 1 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
34 Station No. 2 Button Stuck Station No. 2 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
35 Station No. 3 Button Stuck Station No. 3 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
36 Station No. 4 Button Stuck Station No. 4 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
37 Station No. 5 Button Stuck Station No. 5 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
38 Station No. 6 Button Stuck Station No. 6 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
39 Station No. 7 Button Stuck Station No. 7 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
40 Station No. 8 Button Stuck Station No. 8 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
41 Station No. 9 Button Stuck Station No. 9 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
42 Station No. 10 Button Stuck Station No. 10 Control Head’s Transfer Button has either been closed too
Closed long or has been closed since power-up.
43 CAN Communication The Control-Area-Network protocol has detected an error in
Stuffing Error communication with other devices on the network. The error type is a
stuffing error.
44 CAN Communication Form The Control-Area-Network protocol has detected an error in
Error communication with other devices on the network. The error type is a
form error.
45 CAN Communication The Control-Area-Network protocol has detected an error in
Acknowledge Error communication with other devices on the network. The error type is an
acknowledge error.
46 CAN Communication Bit 1 The Control-Area-Network protocol has detected an error in
Error communication with other devices on the network. The error type is a Bit
1 error.
47 CAN Communication Bit 0 The Control-Area-Network protocol has detected an error in
Error communication with other devices on the network. The error type is a Bit
0 error.
48 CAN Communication CRC The Control-Area-Network protocol has detected an error in
Error communication with other devices on the network. The error type is a
CRC error.
49 CAN Communication Bus The Control-Area-Network protocol has detected an error in
Error communication with other devices on the network. The error type is a
Bus failure error. The error cannot be recovered from without cycling
power to the Processor.
50 Comm. Error Time-out Communication with System 1 has been too long without a Refresh
System 1 message
51 Comm. Error Time-out Communication with System 1 has been too long without a Refresh
System 2 message
52 Comm. Error Time-out Communication with System 1 has been too long without a Refresh
System 3 message

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.

Table B-6: Solenoid Clutch Problem Causes and Solutions


Error
CAUSE SOLUTION
#
1 a The Astern Clutch Solenoid is defective. a Replace the Astern Clutch Solenoid.
b The Clutch Harness is incorrectly wired at the Gear b Properly connect the Clutch Harness to the Astern
Box. Solenoid.
2 a The Astern Clutch Solenoid circuit is Open. a Properly connect the Astern Clutch Solenoid.
b The Astern Clutch Solenoid is defective. b Replace the Astern Clutch Solenoid.
3 a The Neutral Solenoid is defective. a Replace the Neutral Solenoid.
b The Neutral Solenoid is incorrectly wired at the Gear b Properly connect the Neutral Solenoid.
Box.
4 a The Neutral Solenoid circuit is Open. a Properly connect the Neutral Solenoid.
b The Neutral Solenoid is defective. b Replace the Neutral Solenoid.
5 a The Ahead Clutch Solenoid Circuit is incorrectly a Properly connect the Ahead Clutch Solenoid.
wired at the Gear Box.
b The Ahead Clutch Solenoid is defective. b Replace the Ahead Clutch Solenoid.
6 a The Ahead Clutch Solenoid Circuit is Open. a Properly connect the Ahead Clutch Solenoid.
b The Ahead Clutch Solenoid is defective. b Replace the Ahead Clutch Solenoid.
Table B-7: Solenoid Troll Problem Causes and Solutions
Erro
CAUSE SOLUTION
r#
7 a The Troll On/ Off Solenoid is defective. a Properly connect the Troll On/ Off Solenoid.
b The Troll On/ Off Solenoid is incorrectly wired b Replace the Troll On/ Off Solenoid.
at the Gear Box.
8 a The Troll On/ Off Solenoid circuit is Open. a Properly connect the Troll On/ Off Solenoid.
b The Troll On/ Off Solenoid is defective. b Replace the Troll On/ Off Solenoid.
9 a The Troll Command Solenoid is defective. a Properly connect the Troll Command Solenoid.
b The Troll Command Solenoid is incorrectly b Replace the Troll Command Solenoid.
wired at the Gear Box.
10 a The Troll On/ Off Solenoid circuit is Open. a Properly connect the Troll On/ Off Solenoid.
b The Troll On/ Off Solenoid is defective. b Replace the Troll On/ Off Solenoid.
Table B-8: Basic Control System Problem Causes and Solutions
Erro
CAUSE SOLUTION
r#
13 a Station No.1 Control Head is defective. a Replace Station No.1 Control Head.
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
14 a The Station No.2 Control Head is defective. a Replace Station No.2 Control Head.
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.
15 a The Station No.3 Control Head is defective. a Replace Station No.3 Control Head.
b o continuity between pin 5’s of the Control Head b Ensure that the red conductor is properly
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.
B-21
Table B-8: Basic Control System Problem Causes and Solutions (Continued)
Erro
CAUSE SOLUTION
r#
16 a The Station No.4 Control Head is defective. a Replace Station No.4 Control Head.
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.
17 a The Station No.5 Control Head is defective. a Replace Station No.5 Control Head.
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.
18 a The Station No.6 Control Head is defective. a Replace Station No.6 Control Head.
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.
19 a The Station No.7 Control Head is defective. a Replace Station No.7 Control Head.
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.
20 a The Station No.8 Control Head is defective. a Replace Station No.8 Control Head.
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.
21 a The Station No.9 Control Head is defective. a Replace Station No.9 Control Head.
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.
22 a The Station No.10 Control Head is defective. a Replace Station No.10 Control Head.

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:

Table B-11: Basic without Error Codes


SYMPTOM: CAUSE REMEDY
No audible tones heard at a Incorrectly wired Station a Verify that the black wire is properly connected to pin 1
one Control Station when Harness/ Cable. on the Control Head and Pin 8 at the Processor.
power is first applied to the b The Control Head’s Sound b Measure the AC voltage at pins 1 & 3 of the Control
Processor. All other features Transducer is defective. Head. If 20- 25 VAC is present, replace the Control
function normally. Head.
The Control Head’s red LED a Incorrectly wired Station a Verify that the brown wire is properly connected to pin
doesn’t light when in Harness/ Cable. 2 on the Control head and pin 2 at the Processor.
command, but otherwise b The Control Head’s red b Measure the DC voltage at pins 2 & 3 at the Control
functions properly LED or circuit is open. Head. The measurement will be approximately 2.20
VDC when the red LED is lit. If 4.00 VDC is measured,
the red LED or its circuit is open. Replace the Control
Head.
The engine begins to turn- a The voltage available at the a Supply power to the Processor from a battery other
over while starting and then Processor has dropped too than the starting battery or supply power from two
stops. A slow repetitive low, due to the starter’s sources through an APS (Automatic Power Selector).
tone is heard from all current requirement
Remote Stations b Battery charge is too low b Recharge/ replace the battery or supply battery power
from two sources through an APS.
When power is turned ON a No power to the Processor. a Disconnect the Power Harness from the Processor.
to the Processor, there are Measure the DC voltage at pins 10 (+) and 11 (-) of the
no tones from any of the Harness plug. If 12 or 24 VDC is not present, check the
Remote Stations, the circuit breakers, switches and cables feeding power to
Control Head red LED does the Processor. Correct the power source as required.
not light when the Transfer b The battery’s polarity is b Disconnect the Power Harness from the Processor.
Button is pressed, and the reversed at the Processor. Connect a voltmeter’s red lead to pin 10 and the black
Display is not lit at the lead to pin 11 of the Harness’s plug. If negative voltage
Processor. is measured, reverse the wires.
c Defective Processor. c If Causes a. and b. were not the fault, replace the
Processor.
Active Synchronization is a There is no Tachometer a The Tachometer Sensor frequency can be seen on the
inoperable. Sensor signal at the Port or Processor’s Display by accessing the Diagnostic Menu
Starboard Processor. H0. If the frequency is not measured, check the
Tachometer Sensor and the wiring.
b Loss of Serial b If Active Synchronization is inoperative due to a lack of
Communication between Serial Communications, one or more Error Codes will
the Processors. be displayed indicating the loss of communication.
c The Processor’s c All Processors must have a unique identification
Identification number(s) number as set with Function Code A0. Refer to the "Set
have not been set properly. Up Procedures" section.
d The correct number of d All Processor must have the same number of engines
engines has not been set. selected as programmed with Function Code A1. Refer
to the "Set Up Procedures" section.

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.

Equal Throttle Synchronization


Table B-18: Basic Troubleshooting
SYMPTOM CAUSE SOLUTION
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 Plug the Serial Communication Harness into both
Processors are not set up Processors.
for Twin Screw
operation.
d The Port and Starboard d On the Port Processor, scroll to Function A0 and
Processors have the enter a Value of 01.
same ID number. On the Starboard Processor, scroll to Function A0
and enter a Value of 02.
Table B-19: Servo Clutch Troubleshooting
SYMPTOM CAUSE SOLUTION
Will not synchronize. a The Processor(s) think a Place both the Port and Starboard Processors into
Astern is being Warm-up Mode by pressing the transfer button
commanded. while moving the Control Head levers to the Ahead
detent. Both red LED’s on the Control Head
should be blinking.
If not, reverse the wires at pins 5 and 7 at the
Control Head. Change the Clutch direction with
Function Code C5.
Table B-20: 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 (hunts). varying. The Value should not change by more than +/- 1 A/
Will not synchronize D Count. If so, check the connections and if good,
properly. replace the Control Head.
b The push-pull cable’s b Lengthen the Governor or Carburetor’s selector
travel from Idle to Full is lever and attach the push-pull cable to a point
too short. where the travel is in excess of 2.00 inches
(50,8mm).
Will not synchronize. a Excessive bends in the a Reroute the push-pull cable(s) or install Tach
push-pull cable(s). Sender and enable Active Synchronization with
Function Code E7.

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.

Basic Control System Harnesses


Table B-24: Power, Start Interlock Harness Pin-Out
Plugs into Processor HARNESS PLUG HARNESS PLUG ENGINE & BATTERY ENGINE & 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.
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-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

Table B-28: Control Head Harness Pin-Out


Plugs into Processor Plugs into Control Head Termination Conductor
STATION Connectors Pigtail Connector A and B Color Description
Termination A and Termination B 1 Green/ Shield
Yellow
2 Brown Red LED ( + )
3 Violet Green LED ( - )
4 Orange Transfer Button ( + )
5 Red Ground
6 Green Lever Command Signal
E

7 Blue VREF + 5 VDC


8 Black Tone ( + )

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

7 Blue 5 (Port); 7 (Stbd) VREF (+5VDC)


8 Black 1 Tone ( + )

NOTE: Starboard Side of Control Head - Jumper Pins 3 to 5;


Port Side of Control Head - Jumper Pins 3 to 7

Table B-30: Tachometer Sensor Harness Pin-Out


Plugs into Processor TACH SENSOR TACH SENSOR
TACH Connector Termination A Conductor Color Termination B Description
Termination A 2 Red Pin B Tachometer ( + )
3 Black Pin C Tachometer ( - )
4 Green/ N/C N/A
Yellow

Table B-31: Tachometer Sensor Harness with Power Pin-Out


Plugs into Processor TACH SENSOR TACH SENSOR
TACH Connector Termination A Conductor Color Termination B Description
Termination A 1 Red As Required Sensor Supply (+9 VDC)
2 Green As Required Tachometer ( + )
3 Black As Required Tachometer ( - )
4 Green/ N/C N/A
Yellow

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

Table B-35: Frequency 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
7 Red ECM 120.64 - 463.50 Hz Throttle Signal
8 Green/ N/C N/A
Yellow
E

Table B-36: PWM 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
2 Red ECM PWM Throttle Signal 0 - 100% Duty
Cycle @ 500 Hz
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.

Basic Processor Pigtails


Table B-38: Power, Start Interlock, Clutch Pressure Switch, Alarm Processor Pigtail Pin-Out
Processor Pigtail
Termination A Conductor Color Description Termination B
Connector
Termination A 1 Yellow Start Interlock PB2-2
2 Brown Alarm (N.O.) TB6-6
3 Black Alarm (Common) TB6-5
4 Orange Back-up Control (Ground) TB6-2
5 White Back-up Control Input TB6-1
6 Blue Clutch Pressure Switch TB6-3
7 Green Clutch Pressure Switch (Ground) TB6-4
10 Red DC Power ( + ) PB1 (+)
11 Black DC Power ( - ) PB1 (-)
12 Red Start Interlock PB2-1
Termination B

Table B-39: Serial Communication Processor Pigtail Pin-Out


Pigtail Connector
Termination A Conductor Color Description Termination B Processor Circuit Board Connections
Serial Harness
Termination A 1 Green CAN Low TB7-7 Termination B
2 White CAN High TB7-6
4 Red CAN High TB7-8
5 Black CAN Low TB7-9 To Pigtail 13211-ART

6 Black Shield TB7-10 Termination A

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

Table B-41: Throttle Pigtail Pin-Out


Pigtail Connector Termination Processor Circuit Board
Conductor Color Description Termination B
For Throttle A Connections
Termination A 1 Black DC Return TB8-7 Termination B
2 Brown PWM ( + ) TB8-3
3 Red Current ( + ) TB8-4
4 Orange VDC ( + ) TB8-5
7 White Frequency ( + TB8-6
)
8 Green / Yellow Shield P-Clamp to
Frame

Table B-42: Clutch Processor Pigtail Pin-Out


Processor Pigtail
Termination A Conductor Color Description Termination B
Connector
Termination A 5 Black Astern Clutch ( + ) TB11-1
3 Brown Ahead Clutch ( + ) TB11-2
6 Yellow Astern Clutch ( - ) TB11-5
4 Green Ahead Clutch ( - ) TB11-6
Termination B

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

Qualitative Failure Analysis


The following qualitative failure analysis is provided to show compliance with:
• Subchapter K Small Passenger Vessels, 46 CFR 121.620
• Subchapter L Offshore Supply Vessels, 46 CFR 130.120
• Subchapter T Small Passenger Vessels, 46 CFR 184.620:

121.620 Propulsion engine control systems.


(a) A vessel must have two independent means of controlling each
propulsion engine. Control must be provided for the engine speed,
direction of shaft rotation, and engine shutdown.
(1) One of the means may be the ability to readily disconnect the
remote engine control linkage to permit local operation.
(2) A multiple engine vessel with independent remote propulsion
control for each engine need not have a second means of
controlling each engine.
(b) In addition to the requirements of paragraph (a) of this section, a vessel
must have a reliable means for shutting down a propulsion engine, at the
main pilot house control station, which is independent of the engine's
speed control.
(c) A propulsion engine control system, including pilothouse control, must
be designed so that a loss of power to the control system does not result
in an increase in shaft speed or propeller pitch.
(d) All microprocessor or computer based systems must meet the
requirements of part 62 in subchapter F of this chapter.

130.120 Propulsion control.


(a) Each vessel must have--
(1) A propulsion-control system operable from the pilothouse; and
(2) A means at each propulsion engine of readily disabling the
propulsion-control system to permit local operation.
(a) Each propulsion-control system operable from the pilothouse must
enable--
(1) Control of the speed of each propulsion engine;
(2) Control of the direction of propeller-shaft rotation;
(3) Control of propeller pitch, if a controllable-pitch propeller is
fitted; and
(4) Shutdown of each propulsion engine.
(a) The propulsion-control system operable from the pilothouse may
constitute the remote stopping-system required by Sec. 129.540 of this
subchapter.
(b) Each propulsion-control system, including one operable from the
pilothouse, must be designed so that no one complete or partial failure of
an easily replaceable component of the system allows the propulsion
engine to over-speed or the pitch of the propeller to increase.

184.620 Propulsion engine control systems.


(a) A vessel must have two independent means of controlling each
propulsion engine. Control must be provided for the engine speed,
direction of shaft rotation, and engine shutdown.
(1) One of the means may be the ability to readily disconnect the
remote engine control linkage to permit local operation.
(2) A multiple engine vessel with independent remote propulsion
control for each engine need not have a second means of
controlling each engine.
(a) In addition to the requirements of paragraph (a), a vessel must have a
reliable means for shutting down a propulsion engine, at the main
pilothouse control station, which is independent of the engine's speed
control.
(b) A propulsion engine control system, including pilothouse control, must
be designed so that a loss of power to the control system does not result
in an increase in shaft speed or propeller pitch.

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.

A requirement of the ZF Marine Electronics MicroCommander system is that there be an


engine ’STOP’ button at each remote station.
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 Marine Electronics provides audible tones at the
Control Head locations to indicate system faults.
ITEM FAILED ALARM INITIAL FINAL
NUMBER COMPONENT STATUS RESULT OUTCOME
1 ZF MARINE ELECTRONICS AUDIBLE TONE WILL SOUND AT THROTTLE RESETS TO IDLE NO INCREASE IN ENGINE
CONTROL HEAD CONTROL HEAD RPM

CLUTCH SHIFTS TO NEUTRAL NO INCREASE IN SHAFT


SPEED
2 LOSS OF POWER SUPPLY ALARM CIRCUIT WILL OPEN THROTTLE REMAINS AT LAST NO INCREASE IN ENGINE
COMMANDED POSITION RPM

CLUTCH REMAINS AT LAST NO INCREASE IN SHAFT


COMMANDED POSITION SPEED
3 ZF MARINE ELECTRONICS AUDIBLE TONE WILL SOUND AT THROTTLE RESETS TO IDLE NO INCREASE IN ENGINE
THROTTLE FEEDBACK CONTROL HEAD RPM
POTENTIOMETER
CLUTCH REMAINS AT LAST NO INCREASE IN SHAFT
COMMANDED POSITION SPEED
4 ZF MARINE ELECTRONICS CLUTCH AUDIBLE TONE WILL SOUND AT THROTTLE RESETS TO IDLE NO INCREASE IN ENGINE
FEEDBACK POTENTIOMETER CONTROL HEAD RPM
CLUTCH REMAINS AT LAST NO INCREASE IN SHAFT
COMMANDED POSITION SPEED

Design Verification Test Procedure

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.

2) Failure: Power failure to MicroCommander 9110 Series


(A power failure to the MicroCommander 9110 Series circuit board will have the
same results as a failed microprocessor)
a) Results
i) Throttle and clutch will remain at last commanded position.
ii) LED at Control Heads will not be lit.
iii) Opposite engine still under power has full control.
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) Turn power OFF to the Port side only.
(1) Port side throttle and clutch will remain at last commanded position.
(2) LED on the Port side of the Control Head in command will go OFF.
(3) The Port Control Head will no longer have command of the engine and
gear.
(4) The Starboard Control Head will still have full command of the Starboard
engine and gear.
iv) Turn power ON to the Port Processor. Return Control Head lever to Neutral.
Take command of the Port side.
(1) The Port Control Head will operate as usual-(Non-volatile memory)
v) Repeat test for Starboard Processor.

3) Failure: Throttle Feedback Potentiometer failure


a) Results: 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) On the Port Processor, locate the 3-pin plug above the throttle servo on the
Processor’s main circuit board. Disconnect the plug from the circuit board.
(1) The Port Processor will move the throttle to Idle.
(2) The Port Control Heads will give an alarm tone indicating a faulty throttle
feedback potentiometer.
iv) Move the Port and Starboard Control Head levers back to Neutral.
v) Replace the 3-pin plug.
vi) Acknowledge the error by pressing the transfer button.
vii) Repeat test for Starboard Processor.
4) Failure: Clutch Feedback Potentiometer failure
a) Results: Clutch will remain at last commanded position. 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) On the Port Processor, locate the 3-pin plug above the clutch servo on the
Processor’s main circuit board. Disconnect the plug from the circuit board.
(1) The Port Processor clutch servo will remain at last commanded position.
Throttle servo will drive to Idle.
(2) The Port Control Heads will give an alarm tone indicating a faulty clutch
feedback potentiometer.
iv) Move the Port and Starboard Control Head levers back to Neutral.
v) Replace the 3-pin plug.
vi) Acknowledge the error by pressing the transfer button.
vii) Repeat test for Starboard Processor.
6

ZF Marine Electronics, LLC


Mukilteo Plant
9000 Series Electronic Throttle -- Solenoid Clutch Qualitative Failure Analysis,
Design Verification Test Procedure, and Periodic Safety Test
Document # AUTHOR CHECKED APPROVED DATE
ENG-143 Version: 1.0 Tim Jones Jim D Smith Robert Anderson 4/19/04

QUALITATIVE FAILURE ANALYSIS


The following qualitative failure analysis is provided to show compliance with:
• Subchapter K Small Passenger Vessels, 46 CFR 121.620
• Subchapter L Offshore Supply Vessels, 46 CFR 130.120
• Subchapter T Small Passenger Vessels, 46 CFR 184.620:
121.620 Propulsion engine control systems.
(a) A vessel must have two independent means of controlling each propulsion engine. Control must be
provided for the engine speed, direction of shaft rotation, and engine shutdown.
(b) One of the means may be the ability to readily disconnect the remote engine control linkage to permit
local operation.
(c) A multiple engine vessel with independent remote propulsion control for each engine need not have a
second means of controlling each engine.
(d) In addition to the requirements of paragraph (a) of this section, a vessel must have a reliable means for
shutting down a propulsion engine, at the main pilot house control station, which is independent of the
engine's speed control.
(e) A propulsion engine control system, including pilothouse control, must be designed so that a loss of
power to the control system does not result in an increase in shaft speed or propeller pitch.
(f) All microprocessor or computer based systems must meet the requirements of part 62 in subchapter F of
this chapter.
130.120 Propulsion control.
(a) Each vessel must have--
1) A propulsion-control system operable from the pilothouse; and
2) A means at each propulsion engine of readily disabling the propulsion-control system to permit
local operation.
(b) Each propulsion-control system operable from the pilothouse must enable--
1) Control of the speed of each propulsion engine;
2) Control of the direction of propeller-shaft rotation;
3) Control of propeller pitch, if a controllable-pitch propeller is fitted; and
4) Shutdown of each propulsion engine.
(c) The propulsion-control system operable from the pilothouse may constitute the remote stopping-system
required by Sec. 129.540 of this subchapter.
(d) Each propulsion-control system, including one operable from the pilothouse, must be designed so that no
one complete or partial failure of an easily replaceable component of the system allows the propulsion
engine to overspeed or the pitch of the propeller to increase.
184.620 Propulsion engine control systems.
(a) A vessel must have two independent means of controlling each propulsion engine. Control must be
provided for the engine speed, direction of shaft rotation, and engine shutdown.
1) One of the means may be the ability to readily disconnect the remote engine control linkage to
permit local operation.
2) A multiple engine vessel with independent remote propulsion control for each engine need not
have a second means of controlling each engine.
(b) In addition to the requirements of paragraph (a), a vessel must have a reliable means for shutting down a
propulsion engine, at the main pilothouse control station, which is independent of the engine's speed
control.

TECHNICAL DESCRIPTION Document #


Page B 31 of 32
TITLE: 9000 QFA, DVT, and PST ENG-143
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
(c) A propulsion engine control system, including pilothouse control, must be designed so that a loss of
power to the control system does not result in an increase in shaft speed or propeller pitch.
The ZF Marine Electronics ClearCommand 9000 Series (electronic 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 Marine Electronics provides
audible tones at the Control Head locations to indicate system faults.
Item No. Failed Component Alarm Status Initial Result final Outcome
1. ZF Marine Electronics Audible tone will sound Throttle resets to Idle. No increase in Engine RPM
Control Head at Control Head Clutch Shifts to Neutral. No increase in shaft speed.
2. Loss of Power Supply Alarm Circuit will OPEN. Throttle resets to Idle. No increase in Engine RPM
Clutch Shifts to Neutral No increase in shaft speed.

DESIGN VERIFICATION TEST PROCEDURE


The ClearCommand 9000 Series (electronic 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) 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:
1) Turn power on to both Port and Starboard Processors. Take command at a Control Head.
2) Move the Port and Starboard Control Head levers to approximately ½ Ahead.
3) 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.
(c) The Port Processor will shift to Neutral and throttle will go to Idle.
(d) The Port Control Head will give an alarm tone indicating a faulty potentiometer.
1) Move the Port and Starboard Control Head levers back to Neutral. Reconnect the green wire.
2) Repeat for Starboard side.
3) Failure: Power failure to ClearCommand 9000 Series
(A power failure to the ClearCommand 9000 Series circuit board will have the same results as a failed
microprocessor)
(a) Results:
1) Throttle signal to Idle and shift to Neutral.
2) LED at Control Heads will not be lit.
3) Opposite engine still under power has full control.
(b) Test Procedure:
1) Turn power on to both Port and Starboard Processors. Take command at a Control Head.
2) Move the Port and Starboard Control Head levers to approximately ½ Ahead.
3) Turn power off to the Port side only.
i) Port side will go to Neutral Idle.
ii) LED on the Port side of the Control Head in command will go off.
iii) The Port Control Head will no longer have command of the engine and gear.
iv) The Starboard Control Head will still have full command of the Starboard engine and gear.
5) Turn power on to the Port Processor. Take command of the Port side.
6) The Port Control Head will operate as usual-(Non-volatile memory)
7) Repeat test for Starboard Processor.

TECHNICAL DESCRIPTION Document #


Page B-32 of 32
TITLE: 785CE QFA, DVT, and PST ENG-122
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
ZF Mathers , LLC.
ClearCommand 9000 Series 12125 Harbour Reach Drive, Suite B
Mukilteo WA 98275
Servo Throttle – Solenoid Clutch U.S.A.
Qualitative Failure Analysis & Design Tel: 425-583-1900
Verification Test Procedure Fax: 425-493-1569

Version: 1.0
Document # AUTHOR CHECKED APPROVED DATE
ENG-145 Tim Jones Jim D Smith Robert 4-19-04
Anderson

Qualitative Failure Analysis


The following qualitative failure analysis is provided to show compliance with:
• Subchapter K Small Passenger Vessels, 46 CFR 121.620
• Subchapter L Offshore Supply Vessels, 46 CFR 130.120
• Subchapter T Small Passenger Vessels, 46 CFR 184.620:

121.620 Propulsion engine control systems.


(a) A vessel must have two independent means of controlling each propulsion
engine. Control must be provided for the engine speed, direction of shaft
rotation, and engine shutdown.
(1) One of the means may be the ability to readily disconnect the remote
engine control linkage to permit local operation.
(b) A multiple engine vessel with independent remote propulsion control for each
engine need not have a second means of controlling each engine.
(c) In addition to the requirements of paragraph (a) of this section, a vessel must
have a reliable means for shutting down a propulsion engine, at the main pilot
house control station, which is independent of the engine's speed control.
(d) A propulsion engine control system, including pilothouse control, must be
designed so that a loss of power to the control system does not result in an
increase in shaft speed or propeller pitch.
(e) All microprocessor or computer based systems must meet the requirements of
part 62 in subchapter F of this chapter.

130.120 Propulsion control.


(a) Each vessel must have--
(1) A propulsion-control system operable from the pilothouse; and
(2) A means at each propulsion engine of readily disabling the
propulsion-control system to permit local operation.
(a) Each propulsion-control system operable from the pilothouse must enable--
(1) Control of the speed of each propulsion engine;
(2) Control of the direction of propeller-shaft rotation;
(3) Control of propeller pitch, if a controllable-pitch propeller is fitted;
and
(4) Shutdown of each propulsion engine.
(a) The propulsion-control system operable from the pilothouse may constitute the
remote stopping-system required by Sec. 129.540 of this subchapter.
(b) Each propulsion-control system, including one operable from the pilothouse,
must be designed so that no one complete or partial failure of an easily replace-
able component of the system allows the propulsion engine to overspeed or the
pitch of the propeller to increase.

184.620 Propulsion engine control systems.


(a) A vessel must have two independent means of controlling each propulsion
engine. Control must be provided for the engine speed, direction of shaft
rotation, and engine shutdown.
(1) One of the means may be the ability to readily disconnect the remote
engine control linkage to permit local operation.
(2) A multiple engine vessel with independent remote propulsion control
for each engine need not have a second means of controlling each
engine.
(a) In addition to the requirements of paragraph (a), a vessel must have a reliable
means for shutting down a propulsion engine, at the main pilothouse control
station, which is independent of the engine's speed control.
(b) A propulsion engine control system, including pilothouse control, must be
designed so that a loss of power to the control system does not result in an
increase in shaft speed or propeller pitch.

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.

ITEM FAILED ALARM INITIAL FINAL


NUMBER COMPONENT STATUS RESULT OUTCOME
1 ZF MATHERS AUDIBLE TONE WILL THROTTLE RESETS NO INCREASE IN
CONTROL HEAD SOUND AT CONTROL TO IDLE ENGINE RPM
HEAD
CLUTCH SHIFTS TO NO INCREASE IN
NEUTRAL SHAFT SPEED
2 LOSS OF POWER ALARM CIRCUIT THROTTLE
SUPPLY WILL OPEN REMAINS AT LAST
COMMANDED NO INCREASE IN
POSITION SHAFT SPEED

CLUTCH SHIFTS TO
NEUTRAL

Design Verification Test Procedure

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.

2) Failure: Power failure to ClearCommand 9000 Series


(A power failure to the ClearCommand 9000 Series circuit board will have the same
results as a failed microprocessor)
a) Results
i) Throttle signal will remain at last commanded position to and clutch shifts to neutral.
ii) LED at Control Heads will not be lit.
iii) Opposite engine still under power has full control.
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) Turn power off to the Port side only.
(1) Port side throttle will remain at last commanded position and clutch will shift to
neutral.
(2) LED on the Port side of the Control Head in command will go off.
(3) The Port Control Head will no longer have command of the engine and gear.
(4) The Starboard Control Head will still have full command of the Starboard engine
and gear.
iv) Turn power on to the Port Processor. Take command of the Port side.
(1) The Port Control Head will operate as usual-(Non-volatile memory)
v) Repeat test for Starboard Processor.
ZF Marine Electronics, LLC
MMC-151, Rev. Z-Z-I 9-05 Mukilteo Plant

Factory Authorized Service Centers – North America


Factory Training Indicated by: MMC = MicroCommander,
CL = ClearCommand, MC = MasterCommand, CR = CruiseCommand.

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

399 Butch 5396 Steve Spaulding


Kachemak Gear Shed T: 907-235-7993 Spaulding Sports Supply T: 907-488-6998
3625 eAST eND rOAD 2017 Badger Road T: 907-488-5242
Homer, AK 99603 F: 907-235-7233 North Pole, AK 99708 F: 907-488-6385

5394 Ken Perry 2108 Gene Lorenson


Ketchikan Area Timber and Marine Supply T: 907-225-6644 Sutliff's Hardware Inc T: 907-486-5797
2547 Tongass Avenue PO Box 1157
Ketchikan, AK 99901 F: 907-247-0644 Kodiak, AK 99615 F: 907-486-4977

2111 Mike Luhr 3184 Chet Powell, Mike Ottesen


Piston & Rudder T: 907-772-4240 The Bay Company T: 907-874-3340
(mail) PO Box 1308 431 Front Street
Petersburg, AK 99833 F: 907-772-4239 Wrangell, AK 99929 F: 907-874-2592
(ship) 101 A Harbor Way
Petersburg, AK 99833
pisrud@gci.com

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

ARKANSAS 2331 Jay Phelps, Jerry Apalategui


6337 Tiny Joe Skipperliner T: 928-645-2444
Dreamchaser Houseboats T: 870-867-3480 (mail) PO Box 3058
(mail) PO Box 356 Page, AZ 86040 F: 928-645-5753
Mt. Ida, AR 71957 F: 870-867-2665 (ship) 550 Haul Road
(ship) 60 Marina Drive Page, AZ 86040
Mt. Ida, AR 71957

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 *

CALIFORNIA 7337 Roger Nunez, Manuel Lopez


2393 Roger Adams Reliable Marine Electronics T: 510-885-0525
A to Z Marine Services T: 619-224-1606 1925 Lafayette Street
1453 Rosecrans Street Alameda, CA 94501 F: 510-885-0526
San Diego, CA 92106 F: 619-226-0496
M: 619-921-6697
radarrog@aol.com
radams@atozmarine.net MMC, CR
MMC, CL
7084 Brian Scoles
7543 Tony Greyshock, Rick Sullivan, John Sage Scoles Marine Services T: 909-678-6171
Blue Marlin Group T: 949-642-0882 615 LeHarve Avenue
624 Terminal Way Lake Elsinore, CA 92530-5386 F: 909-678-7807
Costa Mesa, CA 92627 F: 949-642-0419

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

3259 Dave Gillen 3013 Painter Stevenson


Dave Gillen Diesel T: 954-927-6500 Mobile Marine T: 770-965-1864
811 N.E. 3rd Street PO Box 1239
Dania Beach, FL 33004 F: 954-927-6090 Buford, GA 30515 F: 770-965-8446
M: 770-480-3805

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

5742 Melody Dodamead HAWAII


Sea Wiz T: 305-289-4044 3157 Mike Rand
(mail) PO Box 501396 Mike Rand T: 808-960-1493
Marathon, FL 33050 F: 305-289-3090 75-1027 Henry Street, PMB 164
(ship) 8025 Gulf Stream Blvd. M: 305-481-0449 Kailua Kona, HI 96740 F: 808-325-1209
Marathon, FL 33050

6622 Pam Lenzion


St. Augustine Marine T: 904-824-4394
404 South Riberia Street IOWA
6863 Greg Stirn
St. Augustine, FL 32084 F: 904-824-9755 S & S Rentals, Inc. T: 563-538-4454
(mail) BOX 389 T: 563-538-4135
Lansing, IA 52151 F: 563-538-4454
(ship) 990 South Front Street
MMC
Lansing, IA 52151

5987 Enrique Giner


Yacht Electric Corporation T: 305-638-9777
7770 NW 53rd St
Miami, FL 33166 KENTUCKY
F: 305-994-7575
2270 Jamie Donahue
Pluckebaum Custom Boats, Inc. T: 502-228-0111
1231 State Road 1793
Prospect, KY 40059 F: 502-228-4767
MMC, CL

3353 Jim Monroe, Lee Moore


Yacht Equipment and Parts T: 954-463-7222
3330 SW 3rd. Avenue T: 800-349-9224
Ft. Lauderdale, FL 33315 F: 954-463-9009
M: Jim 954-868-1840

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

(owners personal e-mail)


rjaflys@aol.com MMC marinecontrolsys.com

MASSACHUSETTS NEW JERSEY


5596 Martin Niemiec 3195 Charles Hewitt
Niemiec Marine T: 508-997-7390 Martek Electronics T: 609-390-3355
173 Popes Island 47 South Shore Rd
New Bedford, MA 02740 F: 508-997-8978 Marmora, NJ 08223 F: 609-390-0849
M: 609-517-5595

MMC, CL *

MARYLAND 5597 Dave Wrigley


5906 Ben Sheets South Jersey Offshore Electric T: 609-884-6400
Hinckley Yachts Svcs T: 410-226-5113 900 Ocean Dr.
(mail) PO Box 369 Cape May, NJ 08204 F: 609-884-2995
Oxford, MD 21654 F: 410-226-5602
(ship) Bank Street
Oxford, MD 21654

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

NORTH CAROLINA 2291 Carl Ward


3601 Tom Demann Callville Bay Resort & Marina T: 702-565-4813
Demann Marine Power T: 910-791-6222 HCR 30 Box 100
107 Bryan Road Las Vegas, NV 89124 F: 702-566-9899
Wilmington, NC 28412 F: 910-791-7056

MMC

7206 Chad Ewing, Paul Chandler


5380 Don Griffin, Don Griffin Jr., Casey Carr Overton Beach Marina T: 702-394-4040
Griffin Marine Inc T: 252-473-1422 HC30 Box 7
(mail) PO Box 458 Overton, NV 89040 F: 702-394-4142
Wanchese, NC 27981 F: 252-473-4654
(ship) 898 Harbor Road M: 252-305-1173
Wanchese, NC 27981
griffinmarine@mindspring.com MMC
MMC, CL

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

"Sales Only" MMC, CL

Bob Lew PUERTO RICO


Lion Yacht Service T: 516-528-8062 5852 David Davila
P O Box 5378 Yacht Specialty T: 787-755-4406
Bay Shore, NY 11706 F: 631-666-1379 RR#2 Box 693
San Juan, PR 00926 F: 787-755-4406
M: 787-397-7518
bob@lionyacht.com
"Service Only"
MMC
2260 Mark Jarboe
Montauk Marine Basin, Inc. T: 631-668-5900
(mail) PO Box 610 SOUTH CAROLINA
3196 Tony Smircic
Montauk, NY 11954 F: 631-668-5659 MacKay Communications T: 843-766-3856
(ship) 426 Westlake Drive 1369 B Ashley River Rd
Montauk, NY 11954 Charleston, SC 29407 F: 843-571-5301

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

544 Terry Wheeler, Scott Graf, Laurie Wheeler MMC


Curry Marine T: 541-265-7955
(mail) PO Box 610
Newport, OR 97365 TEXAS
F: 541-265-4226
2266 Dennis Osborne, Danny Baldwin
(ship) 1211 SE Bay Blvd.
Lakewood Yacht Service T: 281-474-2885
Newport, OR 97365 (mail) PO Box 536
Seabrook, TX 77586 F: 281-474-2885
(ship) 2301 Nasa Road 1
Seabrook, TX 77586
6474 Bill Elderkin, Paul Kepford jjohnstone@lakewoodyachtservice.com
George's Marine Electric T: 541-888-5209
PO Box 5530
Charleston, OR 97420 F: 541-888-9557
UTAH
Mark Grahn
Aramark - Halls Crossing T: 435-684-7019
PO Box 5101
Lake Powell, UT 84533 F: 435-684-7027

6873 paul Wilson


Sells Marine T: 503-285-3838
1111 NE Marine Dr.
Portland, OR 97211

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 *

5401 Darryl Hickson, Chris Pear 2273 Ron Meng


Offshore Marina, Inc. T: 435-788-2142 Ext. 11 Islands Marine Center, Inc. T: 360-468-3377
(mail) PO Box 330330 (mail) PO Box 88
Lake Powell, UT 84533 F: 435-788-2303 Lopez Island, WA 98261 F: 360-468-2283
(ship) Hwy 276, Mile Marker 30 (ship) Fishermens Bay Road
Lake Powell, UT 84533 Lopez Island, WA 98261
offshoremarinaLP@aol.com
MMC, CL, CR, MC

VIRGINIA 2008 Chuck Knapp


3304 Craig Messick LeClerq Marine Construction T: 206-283-8555
Bluewater Yacht Sales, Inc. T: 757-723-0793 1080 W. Ewing
25 Marina Road Seattle, WA 98119 F: 206-286-1726
Hampton, VA 23669 F: 757-723-3320

*
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

* 5443 Scott Morris


Ocean Alexander Marine Center T: 206-547-1395
1115 N. Northlake Way
Seattle, WA 98103 F: 206-547-3789

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

2383 Paul Waits


Puget Sound Yacht Service T: 206-660-3630
9611 - 146th Place SE
Snohomish, WA 98296 F: 425-483-0710

psyachtservice@aol.com
*

2729 Bill Pulse


Radar Marine Electronics T: 360-733-2012
16 Squallicum Mall Blvd.
Bellingham, WA 98225 F: 360-733-2383

6669 Randy Widen


Reliance Marine Electronics T: 206-781-1105
2436 NW 61St
Seattle, WA 98107 F: 206-789-9775

rme@wolfenet.com
* Here from July - April (See also AK)

3506 Jim Brown


Yacht Care Inc. T: 206-285-2600
2601 West Marina Place, Ste. K
Seattle, WA 98199 F: 206-285-2610

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

MMC-123 Rev A 2-08

FACTORY AUTHORIZED SALES & SERVICE - NORTH AMERICA

USA
ALABAMA FLORIDA (cont.)

808 Chuck Moorhead, Mike Ellis 3353 Jim Monroe


Gulf Coast Air & Hydraulics T: 251-666-6683 Yacht Equipment & Parts T: 954-463-7222
(mail) PO Box 161134 F: 251-666-6684 3330 SW 3rd Ave. 800-349-9224
Mobile, AL 36616 Ft Lauderdale, FL 33315 F: 954-463-9099
(shipping) 3415 Halls Mills Road jmonroe@bowboat.com
Mobile, AL 33693 cmoore41984@aol.com
6427 A.J. Halavacs
CALIFORNIA ZF Marine - Headquarters T: 954-581-4040
3131 SW 42nd Street F: 954-581-4078
2462 Terry Brown Ft Lauderdale, FL 33312
TDC Equipment T: 714-373-8099 aj.halavacs@zf.com
15886 Manufacturer Lane F: 714-898-1996 www.zf-marine.com
Huntington Beach, CA 92649
tbrown@tdcequipment.com ZF Marine - Merritt Island
www.tdcequipment.com 3710 North Courtney Pkwy T: 321-449-0995
Suite 102
7661 Henry Bramhall Merritt Island, FL 32953
Trans Pacific Distributors T: 707-426-6670
1941 Walters Court F: 707-898-1996 LOUISIANA
Fairfield, CA 94533 sales@marinegate.com
80 Steve Garver, Richard McConnell
FLORIDA Donovan Marine, Inc. T: 504-488-5731
6316 Humphreys Street 800-347-4464
6265 Ed Rafaniello Harahan, LA 70123 F: 504-443-0504
Control Masters T: 904-260-9756
11623 Columbia Park Drive F: 904-260-9727 6952 Mike Gauthreaux, Laura Heckler
Jacksonville, FL 32258 ZFI Marine - Gulf Coast T: 504-443-0501
www.controlmastersinc.com 161 James Drive West F: 504-443-0504
Suite 120
3338 Steve Baum St Rose, LA 70087 www.zf-marine.com
D.S. Hull Company, Inc. T: 954-463-4307
3320 SW Third Ave. F: 954-527-4173 MARYLAND
Ft Lauderdale, FL 32258
Jeff Carter
2055 John Fox, Andy Glen ZFI- Marine - Annapolis T: 410-604-3320
H & H Marine Sales & Service T: 727-576-0923 345 Log Canoe Circle T: 410-604-3385
10220 San Martin Blvd. N. F: 727-576-9727 Stevensville, MD 21666 F: 410-604-3391
St Petersburg, FL 33702 jeff.carter@zf.com
www.zf-marine.com
MICHIGAN

3104 Randy Hall, John Dillon- VIRGINIA


Marysville Marine North T: 810-364-7653
1551 Michigan Ave. 800-367-0987 2164 Tim Walters
Marysville, MI 48040 F: 810-364-4112 Engines 1 T: 757-673-7200
www.marysvillemarine.com (mail) PO Box 7788 800-548-6252
Portsmouth, VA 23707 F: 757-673-7211
(shipping) 3504 Shipwright Street
NORTH CAROLINA Portsmouth, VA 23707
twalters@wbdiesel.com
Catherine Deegan www.engines1.com
ZFI Marine - North Carolina
1350 Sensation Way T: 252-504-3700
Beaufort, NC 28516 F: 252-504-3773 WASHINGTON
catherine.deegan@zf.com
www.zf-marine.com 2004 Mike Gibbons
Fisheries Supply Co. T: 206-632-4462
1900 N. Northlake Way 800-426-6930
NEW JERSEY Seattle, WA 98103 F: 206-634-4600
mail@fisheriessupply.com
5272 Bernie Keppel www.fisheriessupply.com
Airline Hydraulics Corp. T: 609-624-3700
428 Woodland-Ocean View Rd. F: 909-624-0863 1256 Bill Mol
Ocean View, NJ 08230 sales@airlinehyd.com PPC - Systems, Inc. T: 360-336-9698
www.airlinehyd.com 12147 Bayhill Road F: 360-757-8747
Burlington, WA 98233 Mobile: 206-915-0712

RHODE ISLAND 6957 Bud Bloom, Kevin Zwicker


12125 Harbour Reach Drive T: 425-583-1900
ZF Marine - Rhode Island T: 401-541-9014 Mukilteo, WA 98275 F: 425-493-1579
1 Mastead Drive F: 401-541-7223 bud.bloom@zf.com
Warwick, RI 02886 kevin.zwicker@zf.com
www.zf-marine.com www.zf-marine.com

TENNESSEE WISCONSIN

3070 Dan Henry 5804 Brian Hunter


Marysville Marine South T: 615-851-9456 Marysville Marine South T: 608-825-3875
127 Industrial Drive F: 615-851-9465 405 S. Thompson Road 800-992-3878
White House, TN 37188 Sun Prairies, WI 53590 F: 608-825-2790
www.marysvillemarine.com www.marysvillemarine.com

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

EASTERN CANADA WESTERN CANADA

Mark Newcomb - Commercial/Recreational 2061 Bill Falk, Alan Stovell


CMC Electronics T: 902-468-8480 Western Marine T: 604-253-7721
40 Thornhill Drive, Unit 6 F: 902-468-8484 1494 Powell Street 800-663-0600
Dartsmouth, Nova Scotia Vancouover, British Columbia F: 604-253-2656
Canada B3B 1S1 Canada V5L 5B5
mark.newcomb@cmcelectronics.ccom astovell@westernmarine.com

Brian Sibley - Commercial Jeff Bailey - Recreational


CMC Electronics T: 902-742-3423 CMC Electronics T: 604-435-1455
59 Hawthorn F: 902-742-5593 3839 Still Creek Ave. F: 604-435-2231
PO Box 5 Burnaby, British Columbia
zyarmouth, Nova Scotia Canada V5C 4E2
Canada B5A 1N1 Jeffrey.Bailey@cmcelectronics.com
brian.sibley@cmcelectonics.com
Brad Funk - Commercial / Recreational
Bill Taafe - Commercial Jim Goodfellow - Commercial
Dave Duff - Commercial / Recreational CMC Electronics T: 250-544-1561
CMC Electronics T: 709-726-2422 6680 Mirah Road F: 250-544-2061
29 Hallett Cresent F: 709-726-2428 Saanichton, British Columbia
St. John’s Newfoundland Canada V8M 1Z4
Canada A1B 3T2 brad.funk@cmcelectronics.com
bill.taafe@cmcelectronics.com jim.goodfellow@cmcelectronics.com
dave.duff@cmcelectronics.com

CENTRAL CANADA

Paul Noack, Roy Shipley


CMC Electronics T: 905-607-4262
3600 B Laird Road, Unit 12 F: 905-607-1576
Mississauga, Ontario
Canada L5L 6A7
paul.noack@cmcelectronics.com
roy.shipley@cmcelectonics.com

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

MMC-172 Rev A 2-08

FACTORY AUTHORIZED SALES & SERVICE - INTERNATIONAL

ARGENTINA CHILI

325 Carlos Dorian Freidlander Christian Rogers Nickelmann


Trimer S. A. T: 54-11-4580-0444 Equipamiento Marino Ltda T: (56-2) 4158737
(mail) PO Box 772 F: 54-11-4580-0440 Rafael Correa 1268 Vitacura
Attn: Mariano Castroverde Santiago, Chili F: (56-2) 9-9975059
1000 Buenos Aires, Argentina equipamiento.marino@gmail.com
(shipping) Fray J.S.M. de Oro 2030-40
1425 Buenos Aires,Argentina
CHINA
Pleasure Craft Trimer@trimer.com.ar
CO0102 Paul Chow
Ing. Daniel Canoura Foilborne Engineering, Ltd. T:852-2687-2988
Unit A 7-9, 13/F Veristrong F:852-2687-1996
Transmisiones Marinas S.A. 34-36 Au Pui Wan Street / FO-Tan,
Hernandarias 3656 Tele/Fax:(54-223) 4807174 Shatin, N.T.
B7602GNH Mar Del Plata Hong Hong, China
Argentina paulchow@foilborne.biz.com.hk
TM@tmgroup.com.ar
Commercial Craft www.tmgroup.com 5224 Anthony Yuen
Renford Marine Equipment (China) Ltd.
501 Laws Commercial Plaza T:852-27427111
AUSTRALIA 788 Cheung Sha Wan Road F:852-27427171
Hong Kong, China
6948 Gary Bain anthony.yuen@renford.com
ZF Australia Pty, Ltd. T: 61-(0)2-9679-5555
(mail) Locked Bag 6305 5224 Anthony Yuen
Blacktown BC NSW 2148 F: 61-(0)2-9679-5500 Renford Marine Equipment (Shanghai) Ltd.
Australia 811 Jiaxing Building T:8621-50589000
(shipping) 14 Lidco Street 877 Dong Fang Road, Pudong
Arndell Park, NSW 2148 Shanghai, China F:8621-505880007
Australia gary.bain@zf.com.au anthony.yuen@renford.com

6953 Tang Zhou Qing, Gong Lan


BRAZIL ZF Shanghai Rep. Office T: 0086-21-6301-4338
Room 254, Jiangnan Building
7000 Richard Bergamini No. 600 Luban Road F: 0086-21-6301-6449
ZF do Brazil S.A. T: 5515-235-2301 Shanghai, 200023, PR
Avenida Conda Zepplin, 1935 F: 5515-235-2233 China qiwei.yao@zf.com
CEP 18103-0000 Sorocaba www.zf-marine.com
Brazil richard.bergamini@zf.com
www.zf-marine.com
DENMARK GREECE

7257 Michael Johansson, Frank Kiessling 2386 Demetris Kyriazis


ZF Danmark APS T: 45-7022-6243 Amaltheia Marine, Ltd. T:30210-25-88-985
Taastrupgaardsvej 8-10 F: 45-7022-2643 13 Papaflessa Str. F:30210-25-89-986
Taastrup, DK-2630 143 43 N. Halkidona
Denmark michael.johansson@zf.com Athens, Greece amalmar@otenet.gr
frank.kiessling@zf.com
www.zf-marine.com ICELAND

ECUADOR CO0133 Gudmundur Bragasson


Maras ehf T: 354-555-6444
Pedro Aspiazu Akralind 2 F: 354-565-7230
ZF Marine’s Consulting T: (593-4) 238-9306 201 Kopavogur
Urdesa Central 1A #13184 Costanera Iceland Gummi@maras.is
Guaaquil - Guayas, F: (593-4) 238-4010
Ecuador IRELAND
zfmarineconsulting@yahoo.com
7326 Adi License
FINLAND ZF Great Britain, Ltd. T: 44-115-986-9211
AbbeyfieldRoad, Lenton F: 44-115-986-9261
7487 Antti Hiidenheimo Nottingham, United Kingdom
Atoy Oy T:35-8968271 NG7 2SX, England adilicense@zf.com
PO Box 137 F: 35-8966827305 www.zf-marine.com
FIN-00101, Helsinki
Finland anttihiidenheimo@atoy.fi ITALY

FRANCE 7093 Antonio Renzetti, AlessandroBusetto


SAIM SPA T: 39-02-488-53206
2190 Laurent Gautier Via Donizetti, 9/11 F: 39-02-48825450
Seimi T: 33-2-98-46-11-02 20090 Assago (MI)
(mail) B.P. 30307 F: 33-2-98-46-11-02 Italy antonio,renzetti@saim-group.com
Toulon Cedex 9, France alessandro.busetto@saim-group.com
(shipping) Z.I. Toulon-Est www.saim-group.com
Toulon Cedex 9, France
d.elderkin@vidalmarine.com JAPAN
www.vidalmarine.com
7253 Y. Ikeda, Nobora Kasajima
GERMANY ZF Marine Japan Co. Ltd T: 81-03-5808-4521
Fujikoshi Bldg. 1-10-11 Iriya Taito-ku
7636 Mathias Pien Tokyo, 110-0013 F: 81-03-5808-4531
Otto Peining GMBH T: 49-4124-916812 Japan
AM Altendeich 83 F: 49-171-4853376
D25348 Glukstadt KOREA
Germany pein@piening-propeller.de
www.piening-propeller.de 1415 M.G. Song
Se Jung Engineering Co. T: 82-51-415-0591
#35-4 Namhangdong-1KA F: 82-51-412-6361
Yeongdogu
Pusan, Korea sjeng88@kornet.com
THE NETHERLANDS (HOLLAND) SINGAPORE

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

6948 Gary Bain 7045 Sharon Ho


ZF Australia Pty, Ltd. T: 61-(0)2-9679-5555 ZF South East Asia T:6861-0177
(mail) Locked Bag 6305 11, Tuas Drive 1 F:6861-9173
Blacktown BC NSW 2148 F: 61-(0)2-9679-5500 Singapore sharon.ho@zf-seasia
Australia
(shipping) 14 Lidco Street SOUTH AFRICA
Arndell Park, NSW 2148
Australia gary.bain@zf.com.au 7261 Heather Hermann
ZF South Africa Pty, Ltd T: 27-11-453-1818
NORWAY (mail) PO Box 2098 F: 27-11-453-7506
Kempton Park, 1620 South
7029 Bjorn Reiersen Africa
KGK Norge AS T: 47-22-884-680 (shipping) C/O Barlows Power Systems
Casper Storms Vei 19 F: 47-22-720-902 Cnr Peter Barlow and Kasselss Vlei Rd
Norway bjorn,reiersen@zf-group.com
SPAIN
PERU
5556 Maria Valladolid
7000 Pedro Gonzalez - Orbegoso ZF Espana S.A. T: 34-91-4852-699
PGO Internatinal S.A.C. T: (51-1) 421-6055 Avda. Fuentermar F: 34-91-6733931
AV.Arequipa 2450 of 1108 F: (51-1) 421-6664 Coslada (Madrid) 28820
Lima 14, Peru pgorbegoso@perusat.net.pe Spain maria.valladolid@zf.com
www.zf-marine.com
RUSSIA
SWEDEN
7313 Anastassia Selverstova
ZF Transmissia 000 T: 812-324-54-72 7234 Karl-Henry-Pragsten
Suite 313 F: 7-812-140-18-15 KGK Knutsson AB T: 46-08-923-312
71, Marata Street Tansmissons Divisionen F: 46-08-929-599
St Petersburg Hammarbracken 8,
Russia 191119 anastassia.selverstova@zf.sp.ru S-191 81 Sollentuna
Sweden zf-marine@kgk.se
SCOTLAND www.kgk.se
SWITZERLAND
7326 Adi License
ZF Great Britain, Ltd. T: 44-115-986-9211 CO0111 Fabian Kramer
AbbeyfieldRoad, Lenton F: 44-115-986-9261 Marine Parts Technic T: 41-1997-4090
Nottingham, United Kingdom Pfaffikerstrasse F: 41-1997-4094
NG7 2SX, England adilicense@zf.com CH-8604 Volketswil,
www.zf-marine.com Zurich, Switzerland
fabian.kraemer@marineparts.ch
info@marineparts.ch
www.marineparts.ch
TAIWAN USA

5355 Mike Ou 6427 A.J. Halavacs


Asia Diesel Electric Corp. T: 886-7-333-1191 ZF Marine - US Headquarters T: 954-581-4040
20th Floor F: 886-7-334-6808 3131 SW 42nd Street F: 954-581-4078
34 Min Chuan 1st Road Ft Lauderdale, FL 33312
Kaohsuing, R.O.C. Taiwan aj.halavacs@zf.com
ade.taiwan@msa.hinet.net www.zf-marine.com

THAILAND VENEZUELA

7283 Reungpoj V Sistemas de Propulsion C.A.


ZF Thailand Co. Ltd T: 66-2-521-6520 AV 67a Entre Calles 149By 150
159/33 Soi Vipawasee F: 66-2-521-6523 Municipio San Francisco T: 58-261-736-0747
Laksi, Bangkok 10210 Estado Zulia, Maracaibo, F: 58-261-736-0746
Thailand tanapath@bkk.loxinfo.th Venzuela spd@sistemaspropulsion.com

TURKEY

7223 Georg Weinstabl


Niveko Makina Dis Ticaret kollektiff Sti
Lorenz severin Moritz Weinstable ve
Ortaklan T:90-212287-27-80
Hasan Yelman cad No. 15, F:90-212-287-65-71
TR-34957 Tuzla - Instanbul Deri
Serbest Bolgesi, Turkey georg@niveko.com

U.A.E.

7030 M. Narasimhan (Narsi), A.T. Moorthy


ZF Middle East, LLC T: 971-6-574074
(mail) PO Box 26093 F: 971-6-5747174
Sharjah, U.A.E.
(shipping) #502 Golden Tower Building
Sharjah narsimhan.manian@zf-marine.com
thiru.moorthy@zf-marine.com
www.zf-marine.com

UNITED KINGDOM (ENGLAND)

6932 Peter Middleton, Paul Lakey


Atlantis Marine Power, Ltd. T: 44-1752-208810
Western Wood Way F: 44-1752-208811
Language Science Park
Plymouth, Devon, PL7 5BG
England peter@atlantismarine.com
paul.lakey@atlantismarine.com
www.atlantismarine.com
APPENDIX C
APPENDIX D
Service Field Test Unit
Reference Manual
MM13927 Rev.E 4-07
MM13927
Table of Contents
Revision List ........................................................................................................................................... D-1
Introduction............................................................................................................................................ D-1
Procedure: Throttle Signal Testing ....................................................................................................... D-2
DC Voltage.................................................................................................................................... D-2
Current (mA) ................................................................................................................................ D-2
PWM (Pulse Width Modulation) with DC Voltmeter.................................................................. D-3
PWM (Pulse Width Modulation) with Duty Cycle Meter ........................................................... D-3
Frequency (Hz.)............................................................................................................................ D-3
Procedure: Clutch Testing ..................................................................................................................... D-4
Neutral Solenoid Testing ............................................................................................................. D-4
Ahead Solenoid Testing ............................................................................................................... D-4
Astern Solenoid Testing............................................................................................................... D-4
Procedures: Troll Testing ...................................................................................................................... D-5
Troll On/Off Solenoid.................................................................................................................. D-5
Troll Command (Proportional Solenoid) Testing with Amp Meter ........................................... D-5
Procedure: 2-Speed Testing ................................................................................................................... D-6
2nd Gear Disengaged ................................................................................................................... D-6
2nd Gear Engaged ........................................................................................................................ D-6
Parts List ................................................................................................................................................. D-6

Page i
Table of Contents

Page ii
Revision List FIGURE D-2: CRUISECOMMAND CONNECTOR LOCATIONS

Rev Date Revision Description


A 11/02 Revised Section 1.0 Table 1
B 2/03 Revised manual to current ZF Marine
Electronics manual standards.
Revised Section 3.0
C 4/03 Deleted Section 2.1.6
D 10/03 Revising to add 9000 Series and 2-
Speed information

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

FIGURE D-1: SERVICE FIELD TEST UNIT (BREAK-OUT BOX)

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


Duty Cycle Meter
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.
H) Depress and hold the “mA.” Push-button. The C) Insert the Break-out Box between the number 1
appropriate Full Throttle Current (mA.) for the Processor connector/pigtail and the Throttle
application should be measured at this time. Harness as shown in Figure D-7.

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)

D) Set up the Multimeter to measure Duty Cycle and


plug the black lead into the Break-out Box black
socket labeled “-” and the red lead into the socket
labeled “PWM”.
E) Turn power ‘On’ to the Caterpillar ECM
(Electronic Control Module) and to the Processor.
F) The measurement should be approximately 8%
duty Cycle.
G) Move the Control Head lever to the Full Throttle
position while depressing the Transfer Button
(Throttle Only Mode).
D) Turn power ‘On’ to the Caterpillar ECM
H) The measurement will increase from 8% to 91-
(Electronic Control Module) Only. Do Not apply
93%.
power to the Processor at this time.
E) Depending on the type of Caterpillar ECM (PEEC Frequency (Hz.)
or ADEMS), the measurement should be A) Ensure power is removed from both the Engine
approximately 5.00 or 12.00 VDC. Record the Electronics and the Processor.
measurement as shown in Drawing Figure D-6.
B) Disconnect the Throttle Harness from the number
F) Set up the Multimeter to DC Volts and plug the 1 Processor connector/pigtail.
black lead into the Break-out Box black socket
C) Insert the Break-out Box between the number 1
Turn power ‘On’ to the Processor and take
Processor connector/pigtail and the Throttle
command at any Remote Station.
Harness as shown in Figure D-8.
G) Record the DC Voltage at this time. The
D) Set up the Multimeter to measure Frequency and
measurement should be 7- 9% of the voltage
plug the black lead into the Break-out Box black
measured in step F).
socket labeled “-” and the red lead into the socket
labeled “FREQ”.

Page D-3
FIGURE D-8: THROTTLE CONNECTION (FREQUENCY HZ) LED should go out in CruiseCommand systems
and stay on in ClearCommand systems.

Ahead Solenoid Testing


A) Ensure power is removed from both the Processor
and the Clutch Power Supply.
B) Disconnect the Clutch Harness from the number
3 Processor connector/pigtail.
C) Insert the Break-out Box between the number 3
Processor connector/pigtail and the Clutch
Harness as shown in Figure D-10.
FIGURE D-10: CLUTCH CONNECTIONS AHEAD SOLENOID

E) Turn power ‘On’ to the Processor and take


command at any Remote Station.
F) The appropriate Idle Frequency for the
application should be measured at this time.
G) Move the Control Head lever to the Full Throttle
position while depressing the Transfer Button
(Throttle Only Mode).
H) The appropriate Full Throttle Frequency for the
application should be measured at this time.

Procedure: Clutch Testing D) Set up the Multimeter to measure DC Volts and


plug the black lead into the Break-out Box socket
Neutral Solenoid Testing labeled “CLUTCH -” and the red lead into the
socket labeled “AHEAD”.
A) Ensure power is removed from both the Processor
E) Turn power ‘On’ to the Processor and take
and the Clutch Power Supply.
command at any Remote Station with the lever in
B) Disconnect the Clutch Harness from the number the Neutral/Idle position.
3 Processor connector/pigtail.
F) The measurement should be 0 VDC and the
C) Insert the Break-out Box between the number 3 adjacent LED should not be lit.
Processor connector/pigtail and the Clutch
G) Position the Control Head lever into the Ahead
Harness as shown in Figure D-9.
detent. The measurement should be 12 or 24 VDC
FIGURE D-9: CLUTCH CONNECTIONS NEUTRAL SOLENOID depending on the Ahead Solenoid’s rating. The
LED adjacent to the Ahead plug on the Break-out
Box should be lit.
H) Return the Control Head lever to the Neutral/Idle
position.

Astern Solenoid Testing


A) Ensure power is removed from both the Processor
and the Clutch Supply Power.
B) Disconnect the Clutch Harness from the number
3 Processor connector/pigtail.
C) Insert the Break-out Box between the number 3
D) Turn power ‘On’ to the Processor and take Processor connector/pigtail and the Clutch
command at any Remote Station with the Control Harness as shown in Figure D-11.
Head lever in the Neutral/Idle position. D) Set up the Multimeter to measure DC Volts and
E) The measurement on the Neutral Test Point plug the black lead into the Break-out Box socket
should be 12 or 24 VDC, depending on the labeled “CLUTCH -” and the red lead into the
Solenoid’s rating and the LED adjacent to the socket labeled “ASTERN”.
socket should be illuminated. E) Turn power ‘On’ to the Processor and take
F) Move the Control Head lever to the Ahead Detent command at any Remote Station with the Control
position. The voltage should drop to 0 VDC in Head lever in the Neutral/Idle position.
CruiseCommand systems and remain at 12 or 24 F) The measurement should be 0 VDC and the
VDC in ClearCommand systems. The adjacent adjacent LED should not be lit.

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.

Troll Command (Proportional Solenoid)


Testing with Amp Meter
A) Ensure power is removed from both the Processor
and the Clutch Power Supply.
B) Disconnect the Clutch Harness from the number
3 Processor connector/pigtail.
C) Insert the Break-out Box between the number 3
Processor connector/pigtail and the Clutch
G) Position the Control Head lever into the Astern
Harness as shown in Figure D-13.
detent. The measurement should be 12 or 24 VDC
depending on the Astern Solenoid’s rating. The FIGURE D-13: TROLL CONNECTIONS (PROPORTIONAL
LED adjacent to the Astern plug on the Break-out SOLENOID)
Box should be lit. Return the Control Head lever
to the Neutral/Idle position.

Procedures: Troll Testing


Troll On/Off Solenoid
A) Ensure power is removed from both the Processor
and the Clutch Power Supply.
B) Disconnect the Clutch Harness from the number
3 Processor connector/pigtail.
C) Insert the Break-out Box between the number 3 D) Set up the Multimeter to measure (mA.) and
Processor connector/pigtail and the Clutch connect the black lead to black socket and the red
Harness as shown in Figure D-12. lead to the red socket labeled “TROLL
FIGURE D-12: TROLL CONNECTIONS TROLL ON/OFF COMMAND” as shown in Figure D-13.
SOLENOID E) Turn power ‘On’ to the Processor and the Clutch
Power Supply and take command at a Remote
Station with the Control Head lever in the
Neutral/Idle position.
F) Depress the Transfer Button again for
approximately 2 seconds until the red LED on the
Control Head begins blinking at a fast rate (Troll
Mode Indication).
G) Flip switch away from “Troll Command” to read
current through meter.
D) Set up the Multimeter to measure DC Volts and H) Move the Control Head lever to the Ahead detent.
connect the black lead to the socket labeled The current measurement should be the correct
“CLUTCH –” and the red lead to the socket value for minimum clutch pressure (shaft
labeled “TROLL ON/OFF” as shown in Figure D- rotations). This value varies depending on the
12. type of Marine Gear. Refer to the Literature
provided with the Trolling Valve and the
E) Turn power ‘On’ to the Processor and the Clutch Processor for specifics.
Power Supply and take command at a Remote
Station with the Control Head lever in the I) Slowly advance the Control Head lever while
Neutral/Idle position. monitoring the current. The current should
increase or decrease, depending on the Gear type,
F) Depress the Transfer Button again for in proportion with the Control Head lever
approximately 2 seconds until the red LED begins movement. Once again, refer to the Literature
blinking at a fast rate (Troll Mode Indication).
provided with the Trolling Valve and the
G) The measurement should be 0 VDC. Processor for specific values.
H) Position the Control Head lever to the Ahead J) Continue to move the Control Head lever forward
detent. The measurement should now be 12 or 24 until the red LED stops blinking (lit steady). The
VDC, depending on the Solenoid’s rating. current should drop to 0 mA.
I) Position the Control Head lever further forward
while monitoring the DC Voltmeter. The
Page D-5
Procedure: 2-Speed Testing H) Unplug the Break-out Box from the Pigtail and
Harness plugs and reconnect the Harness to the
2nd Gear Disengaged Pigtail.
A) Ensure power is removed from the Processor.
B) Disconnect the Clutch/2-Speed Harness from the Parts List
number 3 Processor connector/pigtail. ZF Marine Electronics
Part Name
C) Insert the Break-out Box between the number 3 Part No.
Processor connector/pigtail and the Clutch/ 13927 Service Field Test unit (Break-out
2-Speed Harness as shown in Figure D-14. Box)
FIGURE D-14: 2-SPEED CONNECTIONS MM13927 Technical Manual
Multimeter
14000 Test Control Head - Dual

D) Set up the Multimeter to measure DC Volts and


connect the black lead to the socket labeled
“CLUTCH - “ and the red lead to the socket
labeled “TROLL ON/OFF” as shown in Figure D-
14.
E) Turn power ‘On’ to the Processor and take
command at any Remote Station.
F) The voltage measurement should be approximate
0 VDC.

2nd Gear Engaged


A) Leave the Break-out Box and Multimeter in the
same position as left in “2nd Gear Disengaged”.
B) Start the engine(s).
C) Depress the Transfer Button while moving the
lever(s) into the Ahead detent (red LED should be
blinking, indicating Warm-up Mode).
D) Continue to move both Control Head lever(s)
forward until the RPM programmed for Function
Code U1 has been reached.
E) The voltage measurement at the Multimeter
should now be 12 or 24 VDC, depending on the
Solenoid’s rating.
F) Return the Control Head levers to the Neutral/Idle
position and shut down the engines.
G) Turn power Off to the Processor(s).

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

Conventional Symbols Used in Vibration: Tested to 3.35G RMS, 5 Hz to 2 kHz in


X,Y & Z axis.
the Manual Salt-spray: Tested for 28 days, conditions 40°C
Throughout this manual special attention should be (104°F) @ 93% RH
paid to the following: EMC: Meets the requirements of European Directive
89/336/ EC, using methods and limits defined in BS
NOTE: Contains helpful information EN 60945.

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

A) The Display and Control System’s power may be


supplied from different sources. Whenever power Station 1

Cruise
is first applied to the Display, it will automatically Throttle

go through a self test and a CAN bus test. Refer to


Figure E-1.
B) If no data is present on the CAN bus, the message
“No Serial Data” will be visible on the Display.
13234-ART

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

C) Applying power to the Control System and taking


command at a Remote Station establishes 13235-A RT

communication between the Processor and the


G) Movement of the levers from Full Ahead to the
Display. The “No Serial Data” messages are no
Astern detent position, decreases throttle to Idle,
longer visible. If installed in a twin screw
after the proportional delay expires, the Astern
application, the Display will appear as shown in
Clutch is commanded On. At this point, the
Figure E-3.
Display will appear as shown in Figure E-7.
FIGURE E-3: PROCESSOR POWER ON
FIGURE E-7: FULL ASTERN

Station 1

Cruise Station 1

Cruise
N Throttle N
Throttle

13232-ART

13236-ART

D) When the engines are started, the RPM of each


engine will be displayed next to the word
“Throttle” (Tach Sender inputs must be connected
Display Configurability
to the Processors). This is shown on Figure E-4. The items displayed, including number of screws,
screen brightness and contrast can be configured by
FIGURE E-4: ENGINES STARTED
the operator. Some of the items which can be
displayed are dependent on providing the Processors
Station 1

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:
.

A) Press any one of the four buttons to the left.

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

• Up to five items may be displayed at a given


time. Number Screws
Number Pulses
2
NS

• All five can be viewed on the Display or some


may be left blank.
• The items available for viewing are: SET NEXT

Trolling (100 is Lockup) 13239-ART

Lever (100 is Full Ahead Throttle, -100 is


Full Astern Throttle) E) Press the Up or Down arrow button until the
RPM (Actual Engine RPM) desired number of screws is displayed.
Shaft (Actual Output Shaft RPM) F) Press the “SET” button.
• The desired number of screws is programmed
Shaft Cmd (Commanded Percent of Lockup)
into memory and displayed on the screen.
Blank (No Item is Displayed)
G) If a change to “Number Pulses” is required, press
D) Once the desired area of the screen is enclosed in the Down arrow once, followed by pressing the
a box, press the middle “SET” button. “SET” button to highlight.
• The area will become highlighted as shown in • The Up and Down arrows are now used to
Figure E-11. change the number of pulses required.
FIGURE E-11: FULL AHEAD TO ASTERN DETENT H) Press the “SET” button to program to memory.
I) To exit the Parameter Change page, press the
Station 1 “NEXT” button, the new standard Display screen
Cruise
will reflect the changes that you made
Throttle

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.

Display (Part No. 70179)


Trunnion
ON CONSOLE MOUNTING Mount
A) Decide on a suitable location.
• Allow adequate clearance behind the unit to CANTrax Di 13222-ART
splay
ensure cable connections are not unduly
stressed.
• Ensure that there is sufficient length of cable to Template
remove the unit for servicing purposes. NOTE: This template is not to scale and is for
• For best results, ensure there is adequate information purposes only.
ventilation behind the unit.
B) Using the template supplied as a guide, cut out the
Overall size 4.4” x 4.4” (112mm x 112mm)
hole in the console for the back of the unit and
drill (4) 0.170" (4.3mm) holes for the studs
provided.
FIGURE E-13: ON CONSOLE MOUNTING
(4) Thumb Nuts
Center Line
Cut-out for back recess
Dia. 2.5” (64mm)
Console Mount

(4) Mounting Studs Drill 4,00mm clearance


Dia. 0.17” (4,3mm)
Center Line

13225-ART
13222-ART

C) Screw the (4) studs into the rear of the Display


Wire Harnesses
Unit. If required, longer M4 studs can be used The Display ties into the Control System’s Serial
(not supplied). Communication CAN Bus. In order to do so, a
Page E-4
special Wire Harness is required. This Wire Harness Connecting this Wire Harness to the system is
(Part No. 70186) plugs into the back of the Display accomplished using standard Twin Screw and Multi-
and has three cables emerging at the other end. Two Screw Serial Communication Harnesses.
of the cables are short and are provided with plugged When an LCD Display is at the end of the Serial
ends, allowing connection to the serial bus. Communication Bus, a Termination Resistor Plug
The third cable is long (20’), is not plugged and is (Part No. 15133) is required at that Display.
provided for connection to the power supply. The following diagrams and tables provide examples
FIGURE E-16: WIRE HARNESS (70186), MULTI-DROP of various installations and required Items:

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

Table E-2: Two Stations - Single 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 1 70122-XX
5 Plug- Terminating Resistor 1 15133
6 Pigtail- Serial Comm. 1 Provided with Processor

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

Table E-4: Four Stations - Quad Screw


Item # Description Qty. Part #
1 Display- LCD 4 70179
2 Wire Harness- Display, Multi-Drop, Power 20’ (6,10m) 4 70186
3 Wire Harness- Serial Comm., Twin Screw 4 70422-XX
4 Wire Harness- Serial Comm., Multi-Screw 3 15544-XX
5 Plug- Terminating Resistor 1 15133
6 Pigtail- Serial Comm. 4 Provided with Processors

13230-ART

Page E-6

You might also like