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ZF Marine ClearCommand Manual Download Page 87

TROUBLESHOOTING

Page 1

1.0 TROUBLESHOOTING 

The ClearCommand Control System consists of Control Heads 
located at the vessel’s Stations, connected to Control Proces-
sor(s) located in the engine room area.  

Before beginning troubleshooting, review the Appendix C Draw-
ings.  Become familiar with the component configuration on 
your vessel.

Carefully inspect the following:

• DC Power Source
• Component Location
• Component Condition
• Interconnecting Wiring
• Wire Termination’s

A key in troubleshooting the ClearCommand System is identify-
ing the problem as:

• DC Power Source
• Interconnection wiring or termination
• Component Calibration
• Component Failure

The ClearCommand System has Station-in-Command indicator 
lights on each Control Head, as well as audible tone indicators.  
These indicators will assist in troubleshooting and control system 
status.

When contacting an authorized ZF Mathers  servicing dealer, or 
the ZF Mathers Service Department, please be ready with the 
Control Processor Part Number and Serial Number.

CAUTION: Static electricity can destroy electronic components.  Any time the Control Processor 

cover is off, wear the wrist strap provided and connect it to the Processor frame.  This 
will drain any static charge you may have on your person.

Summary of Contents for ClearCommand

Page 1: ...Boost Operation 8 3 0 REQUIRED PARTS AND TOOLS 9 3 1 Processor 9 Figure 4 Control Processor 9 3 2 Control Head 9 3 3 Electric Cable 10 3 4 Tools Required For Installation 10 3 5 Push Pull Cable 11 3 6 Wire Harness 11 Figure 5 Wire Harness Connection Plug 11 3 7 Engine Stop Switch 12 3 8 Control System Power 12 4 0 PLAN THE INSTALLATION 13 4 1 Processor s Location 13 Figure 6 Control Processor Dime...

Page 2: ... Board Set up Locations 25 6 1 2 Order of Set up Adjustments 25 6 1 3 Selecting Dip Switches 25 Figure 15 Dip Switch SW1 Setting Example 25 6 1 4 Run State Normal Operating Mode 26 Figure 16 Dip Switch Run State 26 Figure 17 Jumper 2 Closed Open 26 6 1 5 Enabling Set up Mode 26 6 1 6 Storing Set up Value 27 6 2 Number of Screws Selection Single Twin etc 28 Figure 18 Dip Switch Setting Number of Sc...

Page 3: ... Boost Percentage 44 Figure 30 Dip Switch Setting Speed Boost Percentage 44 8 2 2 Speed Boost Timeout 45 Figure 31 Dip Switch Setting Speed Boost Timeout 45 8 2 3 Speed Boost Start Timeout 45 Figure 32 Dip Switch Setting Speed Boost Start Timeout 45 9 0 CONTROL OPTIONS 46 9 1 Alarm Capability 46 9 2 Clutch Oil Pressure Interlock 46 9 3 Synchronization 47 9 3 1 Serial Communication Wire Harness 47 ...

Page 4: ...er repositioning the Control Head lever 3 1 5 SYMPTOM No audible tone at a Control Head when system is first turned ON but otherwise works perfectly 4 1 6 SYMPTOM Audible steady tone from all Stations Cannot gain command at any Station 4 1 7 SYMPTOM The Control Head red indicator light does not light when in command but everything else works per fectly 5 1 8 SYMPTOM No tones or lighted indicator l...

Page 5: ...rol Head lever position 8 1 17 SYMPTOM Set up Mode is entered and the normal 3 second steady tone is heard The motor control relay clicks continuously when the Dip Switches are turned On 9 1 18 SYMPTOM The motor relay does not click once indicating values have been stored when PB1 on the Auxiliary Circuit is depressed 9 2 0 RESET ALL PARAMETERS TO FACTORY DEFAULT VALUES 10 Figure 1 Dip Switch Sett...

Page 6: ...n Gear Neutral Delay B 11 19 01 Complete manual revised to current ZF Mathers standards 1 Drawing 11202E has been revised to F Please refer to the Drawing in Appendix C for revisions 2 Section 1 2 1 Features revised from 4 Stations to 5 Stations 3 Section 3 7 Engine Stop WARNING updated with current references 4 Section 5 5 Engine Stop WARNING updated with current references ...

Page 7: ...eated by ZF Mathers to aid in servicing set up warranty and documenting of this vessels parameters Appendix B contains a brief Trouble Shooting If you cannot find a solution within the Trouble Shooting contact ZF Mathers Service Department Appendix C contains the System Drawing and Bills of Material During Installation and Testing take special care to verify all wiring is to specifications termina...

Page 8: ... in Command Indication Section 2 3 Warm up Mode Section 2 4 ClearCommand System Fault Indication Section 2 5 Engine Synchronization optional Section 2 7 Proportional Pause on through Neutral Shifts using a Clutch Delay Sec tion 6 7 6 7 In Gear Neutral Delay Section 6 10 Speed Boost optional Section 8 2 ClearCommand Failure Alarm Contact optional Section 9 1 Clutch Oil Pressure Interlock optional S...

Page 9: ... for power connection One Two conductor electric cable for Start Interlock connection One Throttle Wire Harness for Processor engine interface connec tion One Serial Communication Wire Harness for Processor to Proces sor interconnection Multi Screw only ...

Page 10: ...ch is engaged Start Interlock will block the engine start signal if the Set up Mode Jumper is Closed on the Main Circuit Board Refer to Figure 14 page 26 for location of the Jumper The Processor is interlocked to prevent engine Start until power is ON and the transmission is in Neutral The engine Start signal will be con nected through the Processor to the starter solenoid or relay To take command...

Page 11: ...ill remain unchanged for one second after the red indicator lights to allow the operator time to move the Control Head lever s to a position approximately matching the last command setting 2 4 WARM UP MODE At the Station in Command ensure that the Control Head lever is in the Neutral vertical position refer to Figure 3 The red indicator light will blink slowly indicating Warm up Mode and the clutc...

Page 12: ...le range Commanded throttles are within 10 percent of equal RPM The Processor s throttle signals are compared and then matched The Processors then send the same signal to both engines The engines are now synchronized A green indicator light located on the Control Head of the Station in Command indicates engine synchronization When the green light is NOT LIT no synchronization When the green light ...

Page 13: ...e is steady between 12 and 24 volts DC and that there is not a momentary voltage drop If tone continues refer to the Appendix B Trouble Shooting High Repetition Rate Tone is used to signal a jam condition of the clutch push pull cable The Processor has stopped when this tone is heard Moving the Control Head lever away from the position that the tone was encountered should move the push pull cable ...

Page 14: ...ersal After the Speed Boost Start timeout has expired throttle will raise to the Speed Boost Percentage The throttle signal will remain there until the Speed Boost Timeout has expired If Speed Boost is active Speed Boost will be applied on every shift from Neutral When adjusting Speed Boost begin by leaving the Speed Boost Start Timeout at the default value of 0 seconds and work with the other two...

Page 15: ...ing Hardware is installer supplied Included with the Processor Wago Tool Anti Static Wrist Strap Spare Fuse 3 2 CONTROL HEAD Refer to Appendix A for Control Head Variations and Dimensions Sheets One Control Head required per Station Included with the Control Head Gasket 400 Series Control Head only Terminals Mounting screws Figure 4 Control Processor 11336 ...

Page 16: ...Starter Switch to Processor to Starter Sole noid 16 AWG 300 V PVC Insulated 20 degrees C to 105 degrees C UL VW 1 PVC Jacket Yellow with red stripe 3 4 TOOLS REQUIRED FOR INSTALLATION Wago Tool provided Anti static Wrist Strap provided Wire cutter stripper and crimper Recommend Thomas Betts WT 2000 Screwdriver med Phillips 2 Screwdriver med straight slot Screwdriver small straight slot Hole saw 1 ...

Page 17: ...Mathers LLC Refer to Appendix A 43C Cable Con version Kit Manual for more information Harnesses are Available from ZF Mathers LLC Select from Appendix A Parts List the correct Har ness for your System Throttle Wire Harness Processor to Engine Interface Serial Communication Wire Harness Twin Screw Proces sor to Processor The above Cable Harnesses use one or both of the plug connector types detailed...

Page 18: ... 24 volts DC A 10 ampere circuit breaker with manual reset Automatic Power Selector refer to Appendix A S 214 APS Ser vice Sheet The power for the Control System should come from the same power distribution panel as the other required engine functions Refer to Appendix C Drawing Notes WARNING An Engine Stop Switch at each Station is an absolute requirement Refer to CFR46 SEC 62 35 5 and ABYC P 24 ...

Page 19: ...gure 6 for Processor dimensions Locate Processor s away from heat sources such as engine exhaust manifolds Allow 4 feet 1 2m of clearance or more between the Processor s and such heat sources Do not mount close to gas engine ignition systems alternators or electric motors Allow 4 feet 1 2m of clearance between the Pro cessor and alternators or electric motors The Processor s mounting feet must be ...

Page 20: ...DC POWER SOURCE It is important to keep the length of power cable short to reduce volt age drop The power cable should not exceed 20 feet 6m If individual wires are used for supply and return then the total wire length should not exceed 40 feet 12m It is recommended by ZF Mathers that an Automatic Power Switch APS and a second power source be used Refer to Appendix A 1 APS Service Sheet and Append...

Page 21: ...M6 fasteners B Remove the Processor cover C Connect the wrist strap to your person and the ground connector to the Processor frame D Install the watertight cable grips needed for cable entrance Refer to Figure 7 NOTE Before starting the actual installation of ClearCommand make sure you have the correct parts and tools on hand See Section 3 Read ALL the instructions pertinent to each part before be...

Page 22: ...n the sta tion terminal strip Figure 7 Plug Removal and Cable Grip Installation CAUTION Wire leads must not touch frame E Locate the WAGO Tool that is taped to the relay on the circuit board in each Processor Use this tool to depress the spring lock to release the Jumper from the Station terminal strip F Use the WAGO Tool to depress the spring lock for the individual wire connections to the termin...

Page 23: ...enoid B Strip and connect one start interlock cable wire to this lead C Strip and connect the second start interlock cable wire to the Starter Solenoid Connections at Processor A Install the start interlock grip in the Processor enclosure refer to Figure 7 NOTE Bring the other Station s eight conductor cables in the same way and connect to the appropriate station terminal strips Refer to Drawing i...

Page 24: ...trol Head A Drill the screw holes and the cable holes B Run the two conductor start interlock cable through the watertight cable grip C Strip insulation off of each wire 3 8 inch 9 5mm then install crimp terminals D Connect the two conductor cable as indi cated on the Drawing in Appendix C E Feed through a little slack cable and tighten the cable grip F Tie wrap the start interlock cable to the Pr...

Page 25: ...eight con ductor cable approximately 2 1 2 inches 63 5mm B Strip and cut off the shielding and drain wire flush with the end of the PVC jacket C Strip 3 8 inch 9 5mm insulation off each wire then install crimp ter minals Port Lever Starboard Lever Terminal 5 Blue Terminal 5 Yellow Terminal 7 Yellow Terminal 7 Blue 5 4 3 Aft Facing Control Heads For dual lever Control Head Stations that have the us...

Page 26: ...rial Communication Harness to the Serial Harness pig tail of a Processor B Run the harness cable to the next Processor Figure 10 Aft Facing Control Heads WARNING Each Station must have some method to stop the engine Refer to CFR46 SEC 62 35 5 and ABYC P 24 5 8 CAUTION When connecting the plugs ensure that the release buttons are depressed and held until plug is fully connected To disconnect the pl...

Page 27: ...ocessor Discard seals B On the Processor housing remove one screw from the cable retainer clip CAUTION Ensure all Processors are interconnected as demonstrated on the System Drawing in Appendix C Figure 11 Universal Mounting CAUTION If 43C cable is required for this application a 43C Cable Conversion Kit is required These Kits are available from ZF Mathers LLC Refer to Appendix A 43C Cable Convers...

Page 28: ...e to the Pro cessor housing I Run the push pull cable to the transmission Insure the correct push pull cable is ran to the correct selector lever Refer to the System Drawing in Appendix C and to Figure 8 page 17 J Do not connect the push pull cable at this time 5 7 MAIN ENGINE SPEED CONTROL Ensure the correct Wire Harness is selected for the Engine Selec tion required for this System Refer to the ...

Page 29: ...Circuit Board Refer to Appendix C Drawing B Select the Throttle setting for the Engine being used in this application refer to the Notes page of the System Drawing 5 7 3 Engine Signal Selection During the Set up Procedures Section an Engine Signal is selected Refer to Section 6 11 page 45 CAUTION When connecting the plugs ensure that the release buttons are depressed and held until plug is fully c...

Page 30: ... completed System must be returned to the Run State Refer to Section 6 1 4 Run State Normal Operating Mode All of the parameters can be reset to the Factory Default Values at anytime Refer to Appendix B Troubleshooting Section Settings and adjustments are made by selecting the appropriate Dip Switches SW1 1 through SW1 7 on the Main Circuit Board and then saving the configuration by pressing PB1 o...

Page 31: ...otentiometer R7 is in the fully counter clockwise position 4 Adjustment of another parameter may be started 6 1 3 Selecting Dip Switches Figure 14 Processor Circuit Board Set up Locations When switching the Dip Switches ON select the switches in the order from Highest to Lowest EXAMPLE Refer to Figure 15 Throttle Maximum SW1 5 select ON 1st SW1 2 select ON 2nd SW1 1 select ON last Figure 15 Dip Sw...

Page 32: ...ONS ARE THE SAME Figure 16 Dip Switch Run State Figure 17 Jumper 2 Closed Open Run State is the Normal Operating Mode The System must be in Run State during the operation of ClearCommand Run State All SW1 Dip Switches are in the Off position Refer to Figure 16 Jumper 2 is in the Open State Refer to Figure 14 page 25 or the Draw ing in Appendix C 1 for location of SW1 Dip Switch and Jumper 2 NOTE W...

Page 33: ...Screw or more Systems the LED on just the side that is in Set up Mode will turn Off The other side will stay On and in Operating Mode The Run LED on the Processor Main Circuit Board will be unlit for three seconds E Set up adjustment steps can now be started A Store the value that has been set by depressing PB1 located on the Auxiliary Circuit Board Refer to Figure 15 page 28 for location of PB1 T...

Page 34: ...er 2 in the Open State A low repetitious rate tone is heard indicating that the Con trol System is out of Set up Mode and no Station is in com mand F Take command at a Station The red LED will light indicating Station is in command CAUTION The Number of Screws setting MUST be made before setting the System ID of each Processor CAUTION The settings on all Processors Main Circuit Boards MUST be set ...

Page 35: ... be commanded above Idle for 0 5 or 5 0 seconds prior to the clutch pressure switch closing If the clutch pressure switch has not closed within the Clutch Pressure Time setting throttle will command Idle Change the Clutch Pressure Time by setting the SW1 Dip Switches on the Processor Main Circuit Board using the following steps NOTE IN A MULTI PROCESSOR APPLICATION THAT USES SERIAL COMMUNICATION e...

Page 36: ... Time required Refer Figure 20 for Dip Switch set tings C Store the value that has been set by fol lowing Section 6 1 6 page 27 Figure 20 Dip Switch Setting Clutch Pressure Time CAUTION The settings on all Processors Main Circuit Boards MUST be set the same for Multi Screw applications NOTE The pause in gear on a through shift is proportional to the speed commanded and time at that speed The times...

Page 37: ...t before there is clutch plate contact Some clutches may build clutch pressure more slowly This could mean high engine RPM before clutch engagement The optional Clutch Oil Pressure Switch will ensure sufficient clutch oil pressure before allowing speed to the governor Throttle Pause is preset at the Factory for 0 5 second Figure 21 Dip Switch Setting 0 16 Seconds Clutch Delay CAUTION The setting o...

Page 38: ...ions CAUTION Ensure that the Jumper 6 setting on the Processor Auxiliary Board is the correct set ting for the Engine Signal Selection required for this vessel Refer to the Drawing in Appendix C 1 for Jumper 6 location Figure 23 Dip Switch Setting Engine Signal Selection To change use a small screwdriver 0657 600 1 2 3 4 5 6 7 OFF PUSH DOWN FOR ON PUSH DOWN FOR OFF OFF OFF OFF OFF OFF OFF ON 0 5 S...

Page 39: ...essors Main Circuit Boards MUST be set the same for Multi Screw applications A Place the System in Set up Mode by follow ing Section 6 1 5 page 26 B Place the appropriate SW1 Dip Switches ON for In Gear or Neutral Delay Refer to Figure 24 for the Dip Switch set tings C Store the value that has been set by following Section 6 1 6 page 27 Figure 24 Dip Switch Setting In Gear Neutral Delay To change ...

Page 40: ...rm up Mode only operates in the Ahead direction If the red indicator light blinks continue with Control Head testing If the red indicator light does not blink check connections as stated in Section 5 4 7 2 START INTERLOCK ENGINES STOPPED A Turn the ClearCommand DC power OFF WARNING Keep hands and tools clear of the Processor when power is ON Turn OFF the con trol system power before disconnecting ...

Page 41: ... push pull cable travel is adjusted by turning Potentiometer R7 while in Set up Mode The adjustment is made only to the cable travel from Neutral to Ahead Travel from Neutral to Astern will reflect the same distance as the chosen Ahead travel The Processors are set at the Factory with the default setting of 3 inches 75 4mm A Move the clutch selector lever on the transmission from the Ahead positio...

Page 42: ... R7 is in the fully counter clockwise position Figure 25 Dip Switch Setting Clutch Cable Travel D Enable Set up Mode by following Section 6 1 5 page 23 E Press the transfer button at the remote station that will be used during clutch set up Verify a tone is heard when depressing the transfer button The Control Head LED will not be lit but the Control Head will be active for set up procedures F Pla...

Page 43: ...tches function correctly at all sta tions Refer to information supplied by engine manufacturer or switch sup plier for set up and adjustments 7 5 WARM UP MODE TEST ENGINES RUNNING A Place the Control Head lever s in the Neutral position B Depress and hold the station transfer button C Move the Control Head lever s to the Ahead detent position D Release the station transfer button If the red indica...

Page 44: ...es Stopped Change the throttle minimum signal by A Take command at a Station B Leave the Control Head lever in the vertical position C Ensure that Potentiometer R7 is in the fully counter clockwise position Refer to Figure 13 page 25 or the Drawing in Appendix C for R7 location D Enable Set up Mode by following Section 6 1 5 page 23 E Press the transfer button at the remote station being used duri...

Page 45: ...ttle Wire Harness from the Throttle Pigtail at the Processor 1 Disconnect the positive throttle signal wire from the governor refer to the Drawing in Appendix A 2 Place the Control Head lever into the Ahead Detent position 2 Place the Control Head lever into the Ahead Detent position 2 Set the Multi meter up as an Amp Meter current 3 Move Jumper 6 on Auxiliary Board to Pins 2 3 voltage current set...

Page 46: ...he motor control relay will click once to confirm the value has been stored 7 Reset all of the Dip Switches to the Off position Run State 7 Store the value by depressing PB1 located on the Auxiliary Board Refer to Figure 13 page 25 for location of PB1 The motor control relay will click once to confirm the value has been stored 8 Reset all of the Dip Switches to the Off position Run State 8 Return ...

Page 47: ...urrent steps outlined in Table 2 To Measure Throttle Signals 8 Pin Throttle Connector at the Processor Pigtail PIN 1 DC Return PIN 2 PWM PIN 3 mA current PIN 4 VDC voltage PIN 8 Shield Wire Figure 29 Throttle Connector at Processor Pigtail Table 2 Throttle Maximum Output Adjustments PWM Duty Cycle Voltage VDC Current mA 1 Disconnect the Throttle Wire Harness from the Throttle Pigtail at the Proces...

Page 48: ... control relay will click once to confirm the value has been stored 6 Rotate Potentiometer R7 slowly clock wise until maximum throttle signal is achieved Refer to System Drawing for R7 location 7 Store the value by depressing PB1 located on the Auxiliary Board Refer to Figure 13 page 25 for location of PB1 The motor control relay will click once to confirm the value has been stored 7 Reset all of ...

Page 49: ...age 24 PWM Duty Cycle Voltage VDC Current mA 10 Replace Jumper 6 on Auxiliary Board to its original position 10 Reconnect the positive throttle signal wire from the governor 11 Reconnect the Throttle Wire Harness to the Throttle Pigtail at the Processor Table 2 Throttle Maximum Output Adjustments 1 2 3 ...

Page 50: ...ntage perform the following steps WARNING DO NOT attempt to operate ClearCommand away from the dock with any system abnormality Verify that all the above tests are completed and are correct CAUTION Start slowly and learn to appreciate that the ClearCommand System provides a light touch that is fast and accurate NOTE Only use Speed Boost if required to keep engines from stalling Figure 30 Dip Switc...

Page 51: ...tches ON to activate Speed Boost Timeout Refer to Figure 31 for the Dip Switch settings C Verify engines are running D Rotate Potentiometer R7 clockwise while monitoring the engine RPM Adjust to the desired Speed Boost Timeout RPM CAUTION Turning too hard against the stop can damage Potentiometers Figure 32 Dip Switch Setting Speed Boost Start Timeout A Place the System in Set up Mode by following...

Page 52: ...aged The interlock will block a speed signal to the engine until the hydraulic clutch pressure has reached a value recommended by the transmission manufacturer that ensures clutch engagement The pressure switch is Installer supplied The requirement is a N O Normally Open pressure switch with a trip point adjustable to match the transmission manufacturers rec ommended setting The hydraulic clutch p...

Page 53: ...ocessor only DO NOT connect the violet lead in the Port Processor Refer to the Drawing in Appendix C 1 for Auxiliary Board connection 9 3 4 Control Head Test Secured to Dock A Disconnect the clutch push pull cable at the transmission B Turn On the engines C Move the Control Head levers Ahead to approximately 1500 RPM The green indicator light should start to blink and then go to a steady green whe...

Page 54: ...ify all wiring connections at the Processors Control Heads refer ence Drawing in Appendix C 1 NOTE Engines will not synchronize unless shifted to Ahead and above 10 percent of speed range The engines should synchronize If they do not make the following Operation Checks ...

Page 55: ...nnetions at the transmission Check mechanical movement of the transmission selector lever Ensure that the cable does not jam while positioning the selector lever Cycle the Processor and if lead screws are noisy apply a light coating of silicone grease to the stainless steel lead screw 10 2 CONTROL HEAD Verify once a year that Control Head terminals are secure and free of corrosion Apply a light co...

Page 56: ......

Page 57: ...APPENDIX A 1 ...

Page 58: ......

Page 59: ... Shielded Cable 1000 Spool 212 2 Cond Power Cable Per ft 349 2 Cond Power Cable 250 Spool 183 2 Cond Start Interlock Cable Per ft 355 2 Cond Start Interlock Cable 250 Spool 13062 2 Cond Start Interlock Cable Cummins Connector 10 ft 20 ft replace with the length of harness required WIRE HARNESS Plug Replace the after the Part Number with the length of harness required EXAMPLE 13316 10 13316 20 1331...

Page 60: ...Appendix A 6 20 01 Page 2 ...

Page 61: ...Page 3 ZF Mathers LLC 1415 Pacific Drive Burlington WA 98233 3103 U S A 800 546 5455 360 757 6265 Fax 360 757 2500 MMC 280 Rev G 6 01 400 MC2000 Control Head Variations 11643 ...

Page 62: ...of the PVC cover the drain wire at the Control Head is not connected to ground Strip 3 8 9 5mm insulation off each wire Twist the individual strands of the wires to minimize fraying Crimp a locking fork terminal included with each Control Head to each of the conduc tors Make connections to the Control Head as shown above for MicroCommander ClearCom mand and CruiseCommand Systems Hand Held Control ...

Page 63: ...Page 5 ...

Page 64: ...Page 6 ...

Page 65: ...the bottom cover from the Control Head B Insert electrical cable through watertight cable grip s in Control Head bottom cover C Strip back the PVC cover on the shielded cable approximately 2 50mm D 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 700 Series Control Head Sheet ...

Page 66: ...uiseCommand Systems I When connections are complete replace the bottom cover to the bottom of the Control Head housing J Tighten watertight cable grip s Mounting A Select mounting location and drill mounting holes as shown in the template on the front page B Remove front cover from the Control Head C Mount Control Head with supplied hardware D Replace front cover when mounting is complete NOTE On ...

Page 67: ... PVC cover on the shielded cable approximately 2 50mm 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 Strip 3 8 9 5mm insu lation off each wire Twist the individual strands of the wires to minimize fraying Crimp a lock ing fork terminal included with each Control Head to each of the conductors Make con...

Page 68: ...Page 10 ...

Page 69: ...PVC cover on the shielded cable approximately 2 50mm 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 Strip 3 8 9 5mm insulation off each wire Twist the individual strands of the wires to minimize fraying Crimp a locking fork terminal included with each Control Head to each of the con ductors Make conne...

Page 70: ...Page 12 ...

Page 71: ...unt To prevent internal condensation and moisture build up the mount is drilled to allow air circulation Part No 12110 400 Series Watertight Enclosure Gasket 10241 Control Head Mounting Holes Watertight Enclosure 75 inch Diameter Hole Locate where required two if Dual Control Head 3 54 89 9mm 4 72 119 9mm 6 29 159 8mm Watertight Cable Grip two if Dual Control Head Single or Dual Control Head ...

Page 72: ...Page 14 ...

Page 73: ...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 APS is supplied with a hardware packet containing 8 hex nuts 4 lock washers 6 self tapping mounting screws 1 instructions diagram D INSTALLATION Refer to th...

Page 74: ...Wire Size Ref ABYC E9 15 9 10 0 15 12 AWG 3 Metric Equiva lent 15 30 10 AWG 5 Metric Equiva lent 30 60 8 AWG 8 Metric Equiva lent Flag 2 Wire Size Recommended Twisted Pair 0 20 14 AWG 2 Metric Equiva lent 20 40 12 AWG 3 Metric Equiva lent Note 1 APS output is strictly for ZF Mathers Controls 2 Power Sources may be 12 or 24 volts DC A P S Auto Power Selector Kits Twin Single Screw Screw Include the...

Page 75: ...ainer screws P N 00791 2 0 Tools Required Snap Ring Tool or Small Slotted Screwdriver Phillips Screwdriver 7 16 Nut Driver or Socket 7 16 Open End Wrench 3 0 Actuator Processor Preparation Refer to Figure 1 A Remove cover to Actuator Processor B Remove screws holding Cable Retainer in place C Remove and discard Cable Retainer 43C Cable Conversion Kit Rev Date Revision Description Figure 1 Actuator...

Page 76: ...ver the notch in the 43C cable This is intended to be a snug fit and may require some force F Install two screws through the 43C Cable Retainer and into the Actuator Processor G Tighten the two screws securely with a Phillips Screwdriver H Insert the 43C Cable Connect Nut through the cross bar I Thread the 43C Cable Connect Nut onto the end of the 43C cable J After the cable connect nut is threade...

Page 77: ...em shall also be equipped with a bonding system The negative terminal of all batteries should be connected at only one point the DC common and from DC common to bond system or hull Metal Hull Vessels The hull of a metal hull vessel may serve as the common bonding conductor Any item to be bonded not in contact with the hull requires a bonding conductor to the hull Bonding A B Y C E 9 46 CFR 111 05 ...

Page 78: ...Page 20 ...

Page 79: ...l 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 W...

Page 80: ...tor 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 ...

Page 81: ...y service 9 Rental of equipment during performance of warranty repairs 10 Unauthorized repair shop labor without prior approval from ZF Mathers Service Department 11 Shop supplies such as connectors wire cable etc C Warranty Service Call 1 800 546 5455 or 1 360 757 6265 for your nearest ZF Mathers Factory Authorized Dealer 1 Prior to returning any product to the factory you must contact ZF Mathers...

Page 82: ...Page 24 ...

Page 83: ...______________________________________ C Number of Remote Stations___________________________________________________________ Actuator Control Processor Port Model_______________________ Starboard Model_____________________ Port SN ___________________ Starboard SN _______________________ Before Running Engine Port Stbd 1 Voltage at the Battery Terminals ________VDC ________VDC 2 Voltage at the Act...

Page 84: ... ___ No___ Yes___ No___ SW1 Switch Settings PORT JMPR 3 ___ ___ STBD JMPR 3 ___ ___ PUSH PULL PUSH PULL JMPR 4 ___ ___ JMPR 4 ___ ___ PUSH PULL PUSH PULL Comments Please use additional paper as necessary General Installation Condition Any Irregularities ARE THE MANUALS ON BOARD Yes___ No___ IS THE OPERATOR CARD ON BOARD Yes___ No___ INSPECTOR__________________________________________ DATE_________...

Page 85: ...APPENDIX B 1 ...

Page 86: ......

Page 87: ...ntify ing the problem as DC Power Source Interconnection wiring or termination Component Calibration Component Failure The ClearCommand System has Station in Command indicator lights on each Control Head as well as audible tone indicators These indicators will assist in troubleshooting and control system status When contacting an authorized ZF Mathers servicing dealer or the ZF Mathers Service Dep...

Page 88: ...the red and orange wires Terminals 3 and 4 The reading should be 4 80 to 5 00 volts DC Verify the voltage at Terminals 3 and 4 while depressing the transfer button The voltage reading should be less than 0 50 volts DC If the voltage remains near 5 00 volts the Control Head needs repair 1 2 SYMPTOM ONE SIDE WILL NOT TAKE COMMAND WHEN DC POWER IS FIRST TURNED ON Cause A Port and Starboard power sour...

Page 89: ...rol Head or install a Control Head Repair Kit 1 3 SYMPTOM THE ENGINE RPM VARIES WITHOUT MOVING THE CONTROL HEAD LEVER Cause A Problem with the governor B Erratic command signal Remedy A Signal to the governor should be steady If not go on to b B At the Processor measure the DC voltage at the yellow and green wires Terminals 5 and 6 of the Station in Command The reading should be a stable voltage n...

Page 90: ...ol Head Verify connection of the red wire to Terminal 3 in the Processor and Terminal 3 at the Control Head In addition the red indicator light would not work if the red wire was loose or incorrectly wired Check for loose or corroded connections B Measure the voltage at Terminals 1 and 2 of the Control Head do not depress the transfer button The voltage should fluctu ate at a steady rate If a fluc...

Page 91: ...urement of 4 00 volts means the indicator light is OPEN Replace the Control Head or install a Control Head Repair Kit 1 8 SYMPTOM NO TONES OR LIGHTED INDICATOR LIGHTS AT THE CONTROL HEAD AND NO LIGHTED INDICATOR LIGHTS ON THE PROCESSOR CIRCUIT BOARD Cause A No power to the Processor B Polarity of the battery voltage reversed C Fuse on the Processor circuit board blown Remedy A Verify the power sou...

Page 92: ...ry B Recharge or replace the battery 1 10THE ENGINE WILL NOT START Cause A ClearCommand does not have power turned ON B ClearCommand does not have a Station in command C The Control Head levers at the Station in Command are not at the Idle position D Low battery voltage E Faulty start interlock circuit in the Processor F Faulty wire or component in the starting system G System is in Set up Mode Ju...

Page 93: ...YMPTOM THREE SHORT ONE LONG TONE FROM ALL STATIONS Cause Control Head is malfunctioning because of loose or unconnected cable connections Remedy Verify that the cable connections at the Control Head are secure and correct as shown on the System Drawing in Appendix C Control Head Sheets in Appendix A or the Control Head Installation Section of the main manual If connections are tight and correct re...

Page 94: ...R IS APPLIED TO THE SYSTEM THE SLOW REPETITIVE TONE CEASES WHEN THE TRANSFER BUTTON IS DEPRESSED SUBSEQUENTLY A STEADY TONE IS HEARD WHENEVER THE TRANSFER BUTTON IS DEPRESSED THE CONTROL HEAD LED DOES NOT LIGHT THE TRANSMISSION AND ENGINE REMAIN AT THE NEUTRAL IDLE POSITION REGARDLESS OF CONTROL HEAD LEVER POSITION Cause The Processor is in the Set up Mode Remedy Configure the Processor into the R...

Page 95: ...ORMAL 3 SECOND STEADY TONE IS HEARD THE MOTOR CONTROL RELAY CLICKS CONTINUOUSLY WHEN THE DIP SWITCHES ARE TURNED ON Cause An invalid switch combination is selected Remedy Turn SW1 1 through SW1 7 to the Off positions Refer to the Notes page of the System Drawing in Appendix C for proper switch settings 1 18SYMPTOM THE MOTOR RELAY DOES NOT CLICK ONCE INDICATING VALUES HAVE BEEN STORED WHEN PB1 ON T...

Page 96: ...indicating that the Control System is out of Set up Mode and no Station is in command G Take command at the Station The LED will light indicating Station is in command NOTE If this procedure is used all adjustments and tests specified in this manual MUST be repeated Figure 1 Dip Switch Setting Reset All Parameters to Factory Default Values Set the SW1 Dip Switches on the Processor Main Circuit Boa...

Page 97: ...APPENDIX C 1 ...

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Page 99: ...Drawing 11202F 1 ...

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Page 101: ...Drawing 11202F 2 ...

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Page 103: ...Drawing 11202F 3 Notes Page ...

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