ZF CruiseCommand 785CE Installation And Troubleshooting Manual Download Page 1

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MM14330 Rev.B 11/01

CruiseCommand 785CE Installation and

Troubleshooting Manual

SW13867.0

Table of Contents

MM14330 Rev.B 11/01................................................................................................................................................ 1

CruiseCommand 785CE Installation and Troubleshooting Manual

Table of Contents ........................................................................................................................................................ 1

Revisions List ............................................................................................................................................................... 1

1.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

1.1 This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 CruiseCommand System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

2.1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Take Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 1: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Engine Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.5 Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 2: Remote Stations before Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 3: Remote Station Transfer after Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.6 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 4: Control Head Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 5: Control Head Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.7 High / Low Idle Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.7.1 Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7.2 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 6: High/Low Idle Mode Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.7.3 Selecting Between High / Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.8 Synchronization (Multi Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.9 One Lever Operation Mode (Multi Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 7: Step A One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 8: Step B One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.10 Trolling Valve Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 9: Control Head 20 Degree Troll Range - Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 10: Control Head 35 Degree Troll Range - Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 11: Control Head 45 Degree Troll Range - Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.0 REQUIRED PARTS AND TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

3.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 12: Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Control System Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Summary of Contents for CruiseCommand 785CE

Page 1: ...l Operating Mode 5 2 7 High Low Idle Modes 6 2 7 1 Low Idle 6 2 7 2 High Idle 6 Figure 6 High Low Idle Mode Selections 6 2 7 3 Selecting Between High Low Idle 6 2 8 Synchronization Multi Screw 7 2 9 O...

Page 2: ...2 2 Start Interlock Cable 20 Figure 19 Start Interlock Connections 20 5 2 3 Control Head Harnesses 21 5 2 4 Alarm Circuit optional 21 5 2 5 Clutch Pressure optional 21 5 3 Control Heads 21 5 3 1 Mount...

Page 3: ...use Following Shift 35 Figure 38 E5 Throttle Pause Set up Activated 36 6 3 10 E6 High Idle 36 6 3 11 E7 Active Synchronization 36 Figure 39 E7 Active Synchronization Set up Activated 36 6 3 12 C0 Clut...

Page 4: ...Throttle Maximum Astern 51 Figure 53 E4 Throttle Maximum Astern Set up Activated 51 7 9 E6 High Idle 52 Figure 54 E6 High Idle Set up Activated 52 8 0 ADJUSTMENT UNDERWAY 53 8 1 Engine RPM 53 8 2 Rev...

Page 5: ...r Selector 8 Figure 3 Control Head Indicators 9 Figure 4 Processor 10 1 4 Diagnostic Menu 10 Figure 5 Display Pattern 10 Figure 6 Display Function A0 11 Figure 7 Display Function H0 11 Figure 8 Displa...

Page 6: ...ut 32 1 9 8 Clutch Power Ahead Neutral Astern 32 Figure 24 Clutch Ahead Astern and Neutral Harness Pin Out 32 1 9 9 Clutch Power Ahead Astern Troll On Off Troll Command 33 Figure 25 Clutch and Clutch...

Page 7: ...mmand Proportional Valve 47 Figure 42 Dwg 11653 N 47 3 6 Erase EEPROM H1 49 Appendix C 1 Drawing 11748 Single Screw Two Stations 3 Drawing 11746 Single Screw Two Pluggable Stations 5 Drawing 11747 Twi...

Page 8: ...ber to Table of Contents 1 Section 3 7 and 5 7 WARNING added CFR reference 2 Section 6 3 Table 1 Functions List E0 Cummins Quantum voltage revised 4 1 to 4 0 3 Section 6 3 4 Cummins Quantum voltage re...

Page 9: ...lowing boxes Appendix A 1 contains the Service Sheets created by ZF Mathers to aid in servicing set up and documenting of this vessels parameters Appendix B 1 contains Troubleshooting explanations If...

Page 10: ...Sequencing of Clutch and Engine Speed Start Interlock Station in Command Indication Warm up Mode High Low Idle Engine Synchronization Multi Screw One Lever Operation Multi Screw Audible and Visual In...

Page 11: ...ndicator light on the Control Head will light indicating the Station is in Command 2 3 BASIC OPERATION The Control Head has three detents Astern Neutral and Ahead Refer to Figure 1 With the Control He...

Page 12: ...anded positions of the Throttle and Clutch will remain unchanged for one second after the red indicator lights This allows the operator time to move the Control Head lever s to a position approximatel...

Page 13: ...in Neutral E The operator can now start and warm up the engine while mov ing the Control Head lever through the Ahead throttle ranges F When the Control Head lever is returned to the Neutral detent th...

Page 14: ...be programmed during Set up The High Idle maximum setting is 20 of full throttle 2 7 3 Selecting Between High Low Idle To select between Low and High Idle or vice versa at the Station in Command refer...

Page 15: ...r The Processor s throttle signals are compared and then matched The Processors then send the same signal to all engines The engines are now synchronized A green LED indicator light located on the Con...

Page 16: ...n the Master Control Head lever is in NOTE The Control Head lever s that are in active can now be placed out of the way in any posi tion forward of the Ahead detent Figure 7 Step A One Lever Operation...

Page 17: ...mal Operat ing Mode 2 10 3Operation in Troll Mode Troll Mode is a feature that must be turned On and Off at the Control Head A Place the Control Head lever in the Neutral Ahead or Astern Detent B Depr...

Page 18: ...ator light on the Control Head changes approximately 2 seconds then release the button When the red indicator light is blinking rapidly the control system has turned Troll Mode ON The clutch is slippi...

Page 19: ...To turn Troll Mode ON Troll Mode OFF Non Troll Mode is the same for all Troll Types NOTE When Troll Type 3 is being used maximum throttle is limited to 75 Figure 9 Control Head 20 Degree Troll Range...

Page 20: ...ontrol Head is required per Station Included with the Control Head Gasket Terminals Mounting screws Control Head Dimensions Variations Installation Sheets Figure 12 Processor The Processor receives th...

Page 21: ...sor DC Power Source cable may come from the same breaker Refer to Appendix C 1 Drawing Notes for power requirements 3 5 CABLE HARNESS Below is a general list of Wire Harnesses available to CruiseCom m...

Page 22: ...t the release but ton 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 wil...

Page 23: ...ptional Wire cutter stripper crimper Recommend Thomas Betts WT 2000 if using single terminated harnesses Service Field Test Unit Break out Box Calibrated Digital Voltmeter for CAT must read PWM 3 7 EN...

Page 24: ...e vibration Refer to Figure 15 for Processor dimensions Locate Processor s away from heat sources such as engine exhaust manifolds turbochargers Allow 4 feet 1 2m of clearance or more between the Proc...

Page 25: ...run from the Pro cessor all the way to the Remote Station in one complete cable run 4 3 DC POWER SOURCE It is important to keep the length of power cable short to reduce volt age drop It is recommend...

Page 26: ...UTCH PRESSURE OPTIONAL ALARM CIRCUIT HARNESSES Refer to Appendix A 1 Parts List for the correct Harness for this appli cation Refer only to the Sections that apply to the Harness being used in this ap...

Page 27: ...ystem is kept to a minimum ZF Mathers recommends that two power sources are utilized along with the APS Automatic Power Selector refer to Appendix A 1 S 214 as shown in Figure 17 The following wire si...

Page 28: ...with Automatic Power Selector Alternative The APS output is strictly for the CruiseCommand Proces sors only In the event that the length of the cable labeled with flag note 2 in Figure 17 exceeds 40...

Page 29: ...lling the harness support using clamps or straps not more than 18 inches 0 5m apart unless contained in a conduit Refer to ABYC Stan dard E 9 Install each harness so it is protected from physical dama...

Page 30: ...and drill the screw holes and the corner cutout holes B Saw between the corner cutout holes C Check that the two mounting screws will start into the Control Head D See Section 5 3 2 for cable connecti...

Page 31: ...nal 5 JUMPER D Place a 20 AWG Jumper Figure 20 demonstrates these modifica tions 5 3 3 Aft Facing Control Heads Refer to Figure 21 For dual lever Control Head Stations that have the user facing aft Re...

Page 32: ...ires a Tachometer Signal representative of each engines RPM s The frequency of these signals are measured and changes to the Throt tle Command Signal outputs of the Processors are made until the fre q...

Page 33: ...NESS The Processor s connects directly to the engine interface using a Throttle Wire Harness Refer to Appendix A 1 Parts List to select the correct Throttle Wire Harness for the engine signal required...

Page 34: ...he Troll ON OFF solenoid One for Neutral Clutch solenoid One for Ahead Clutch solenoid refer to Section 5 6 1 One for the Astern Clutch solenoid refer to Section 5 6 1 One for Clutch Power refer to Se...

Page 35: ...ay The Processor Display has four 7 segment pads which light up to show either Letters or Numbers Refer to Figure 23 This Display during Nor mal Operation has running center red dash lines The first t...

Page 36: ...sed to scroll through select and store the Functions and Values Refer to Figure 25 6 1 3 Up and Down Arrow Depress either Once Refer to Figure 26 Stops Display Normal Operating running center red dash...

Page 37: ...on Menu 6 1 5 Left Arrow Depress Once Refer to Figure 28 Escape from Set up Mode without any change being stored The Func tion Code will quit blinking and the previously saved values will be restored...

Page 38: ...the desired Function Code is visible on the Display depressing and holding the Left and Right Arrow Push Buttons at the same time will activate Set up The left two Display pads will begin to blink in...

Page 39: ...will scroll quickly through the values F When the value required is displayed depress and hold the Right and Left Arrow push buttons until the Display Function Code stops blinking and becomes solid Th...

Page 40: ...ed 01 Enabled CLUTCH FUNCTIONS C0 Clutch Oil Interlock 00 00 Not Installed 01 Installed C1 Clutch Oil Interlock Delay 05 0 00 5 to 10 0 Seconds C2 Reversal Pause 00 00 In Gear 01 Neutral C3 Reversal P...

Page 41: ...on C Activate Set up Mode Refer to Section 6 2 D Depress either the Up or Down arrows to change the Value of the Function E When the value required is displayed store the value Refer to Sec tion 6 2 6...

Page 42: ...e C Activate Set up Mode Refer to Section 6 2 D Change the Value of the Function E When the value required is displayed store the value Refer to Sec tion 6 2 6 3 4 E0 Select Engine Throttle Profile Va...

Page 43: ...E3 Throttle Maximum This Function is accomplished during Adjustments 6 3 8 E4 Throttle Maximum Astern This Function is accomplished during Adjustments 6 3 9 E5 Throttle Pause Following Shift This valu...

Page 44: ...e Synchronization would need to be selected In addition Active Synchronization requires a Tachometer Signal representative of each engines RPM s The frequency of these signals are measured and changes...

Page 45: ...wn Arrow to activate the Function Menu B Use the Up or Down arrow to scroll to the C0 Function Code C Activate Set up Mode Refer to Section 6 2 D Change the Value of the Function E When the value requ...

Page 46: ...he Up or Down Arrow to activate the Function Menu B Use the Up or Down arrow to scroll to the C2 Function Code C Activate Set up Mode Refer to Section 6 2 D Change the Value of the Function E When the...

Page 47: ...set in the Reversal Pause Time C3 Function is applied The number of sec onds selected is for an Ahead to Astern maneuver only An Astern to Ahead maneuver will be 1 2 of the Reversal Pause Time select...

Page 48: ...Command Refer to Section 2 10 3 for operation 02 Type 2 35 Degrees Trolling Command Refer to Section 2 10 3 for operation 03 Type 3 45 Degrees Trolling Command Refer to Section 2 10 3 for operation R...

Page 49: ...es When Lockup Full Pressure is selected the current drops to 0 Inverse Normal On 02 When selected the current to the Propor tional Valve decreases as Clutch pressure increases When Lockup Full Pressu...

Page 50: ...ustments or Troubleshooting For Authorized Personnel Use ONLY 6 3 26H2 High Side Driver Fault Enable The five drivers used for controlling clutch and troll solenoids can be monitored The presence of a...

Page 51: ...Enable Ahead Astern Neutral Troll Command Troll On Off Value 0 0 0 0 0 00 1 0 0 0 0 01 0 1 0 0 0 02 1 1 0 0 0 03 0 0 1 0 0 04 1 0 1 0 0 05 0 1 1 0 0 06 1 1 1 0 0 07 0 0 0 1 0 08 1 0 0 1 0 09 0 1 0 1 0...

Page 52: ...indicator light does not blink check connections as stated in Section 5 3 7 2 START INTERLOCK ENGINES STOPPED A Turn the CruiseCommand DC power OFF Verify that the engine s will not start B Turn the C...

Page 53: ...nimum Section 7 4 Throttle Maximum Section 7 4 Throttle Maximum Astern Section 7 8 High Idle Section 7 9 Trolling Minimum Section 8 3 Trolling Maximum Section 8 3 Troll Throttle Limit Section 8 4 For...

Page 54: ...alue must be at least 3 greater than the Throttle Minimum setting Use the Service Field Test Unit and a Multi Meter A Disconnect the Throttle Wire Harness from the Processor B Connect the 8 Pin connec...

Page 55: ...the Processor PWM Duty Cycle Voltage VDC Current mA 3 Attach the Multi Meter Black Lead to the negative and the Red Lead to the PWM 3 Attach the Multi Meter Black Lead to the negative and the Red Lea...

Page 56: ...ad lever s to the Ahead detent position D Release the station transfer button If the red indicator light blinks Warm up Mode has been acti vated Continue with Adjustments and Tests If the indicator li...

Page 57: ...rottle output capability of the voltage circuit For example if the circuit has the ability to drive 0 to 5 00 VDC and the value entered is 10 the output at Neutral would be 0 50 VDC The values of this...

Page 58: ...Meter will read the output signal for Throttle in Neutral F Activate Set up Mode Refer to Section 6 2 G Change the Value of the Function H When the value required is displayed store the value Refer t...

Page 59: ...Har ness Refer to Figure 49 C Turn ON power to the Engine s ECM Ensure Power is On to the Processor D Depress either the Up or Down Arrow to activate the Function Menu E Use the Up or Down arrow to sc...

Page 60: ...onnect the Throttle Wire Harness from the CruiseCom mand Processor B Connect the 8 Pin connector of the Service Field Test Unit to the Processor Throttle connector and to the Throttle Wire Har ness Re...

Page 61: ...feature allows for engine deceleration and vessel speed to decrease on a High Speed Reversals The throttle setting drops to Idle and the transmission shifts to Neutral during this pause Refer to Secti...

Page 62: ...n This is adjustable anywhere between 02 0 to 100 0 of the total current output capability of the circuit The value set must be at least 1 more or less depending on whether non inverted or inverted is...

Page 63: ...Table 7 E Attach the Multi Meter Black COM and Red mA Leads as shown in Figure 55 F Turn ON power to the Clutch Power Supply Ensure Power is On to the Processor Figure 55 Multi Meter and Test Unit Con...

Page 64: ...CREW Propeller Shaft RPM at minimum trolling pressure Approx 30 50 of Table 6 Shaft RPM Current mA Function PORT STBD Figure 57 L3 Troll Maximum Set up Activated O Use the Up or Down arrow to scroll t...

Page 65: ...position U Remove the Service Field Test Unit and reconnect the Clutch Wire Harness to the Processor Table 8 Maximum Trolling Pressure SINGLE SCREW Propeller Shaft RPM at maximum trolling pressure Ap...

Page 66: ...nect the 8 Pin connector of the Service Field Test Unit to the Processor Throttle connector and to the Throttle Wire Har ness Refer to Figure 49 C Turn ON power to the Engine s ECM Ensure Power is On...

Page 67: ...Down arrow to scroll to the L5 Function Code C Activate Set up Mode Refer to Section 6 2 D Change the Value of the Function E When the value required is displayed store the value 8 6 L6 TROLL PULSE P...

Page 68: ...o scroll to the L5 Function Code C Activate Set up Mode Refer to Section 6 2 D Change the Value of the Function E When the value required is displayed store the value Refer to Section 6 2 Figure 60 L6...

Page 69: ...til the hydraulic clutch pressure has reached a value recommended by the transmission manufacturer that ensures clutch engagement The Power Harness may be ordered with a cable to be used for the Clutc...

Page 70: ...ESSOR Check all terminal connections for signs of corrosion or loose connec tions 10 2CONTROL HEAD Verify once a year that Control Head terminals are secure and free of corrosion Apply a light coating...

Page 71: ...APPENDIX A 1...

Page 72: ......

Page 73: ...4 Control Head Black Low Profile Lever 466 4 Control Head Chrome Low Profile Lever 760 Control Head Heavy Duty MC2000 1 Black Head Black Levers MC2000 2 Chrome Head Chrome Levers MC2000 3 Gold Head G...

Page 74: ...Appendix A 7 01 Page 2...

Page 75: ...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 76: ...f 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 for...

Page 77: ...Page 5...

Page 78: ...Page 6...

Page 79: ...he 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 Str...

Page 80: ...iseCommand 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 mo...

Page 81: ...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 St...

Page 82: ...Page 10...

Page 83: ...VC 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 Str...

Page 84: ...Page 12...

Page 85: ...nt 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 Watertigh...

Page 86: ...Page 14...

Page 87: ...Page 15 Deutsch Connector Assembly...

Page 88: ...Page 16...

Page 89: ...Page 17...

Page 90: ...Page 18...

Page 91: ...urrent 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...

Page 92: ...ire 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 l...

Page 93: ...m 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 T...

Page 94: ...Page 22...

Page 95: ...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 3...

Page 96: ...or 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...

Page 97: ...APPENDIX B 1...

Page 98: ......

Page 99: ...mote stations The Processors are designed to precisely control electronic throttles and transmissions equipped with solenoid clutch or clutch troll selection Before you begin troubleshooting review th...

Page 100: ...rts these inputs to the appropriate electronic or elec tric outputs at the correct time and sequence to the Governor and Gear Box The information regarding throttle type throttle gear sequencing etc a...

Page 101: ...nly occurs on the Port side the Starboard Power Source Harnesses Processor and Control Heads have been elimi nated as potential causes If the problem occurs on both the Port and Starboard in Twin Scre...

Page 102: ...essor s Display 4 Repetitive Signal One Long One Short is used to indicate some type of malfunction with one or more of the Clutch or Neutral Solenoid Circuits This tone will be accompanied by an Erro...

Page 103: ...l you An example would be re powering of the vessel Changing from lets say a Caterpillar to a Cummins Electronic Engine would have a serious impact on delivering the correct signal from the Processor...

Page 104: ...ion of the 400 Series MC2000 Series Style Control Heads as long as the bottom is protected from the environment In the case of the 700 Series Control Heads this concern doesn t even exist 2 Processors...

Page 105: ...the vessel s current situation Are there other vessels in the area is the vessel pulling to the Port or Starboard etc The second item which will draw the attention of the operator is the Control Head...

Page 106: ...a malfunction has occurred and if so the type of malfunction Additionally the four 7 segment pad s can be used together with the arrow push buttons to display diagnostic information 1 4 DIAGNOSTIC MEN...

Page 107: ...s running B Depress the Up and Down Arrow Push buttons simultaneously The characters A0 01 will be shown on the Display C Depress the Up or Down Arrow Push button repeatedly until H0 00 is displayed D...

Page 108: ...hronization or Closed Loop Troll future sys tems The Control Head s lever position and the resulting outputs of Stations 1 2 3 4 s Control Heads can always be moni tored This is regardless of whether...

Page 109: ...ome Determining the characteristics or capabilities of a certain CruiseCommand will be as simple as selecting this feature G Pressing the Up or Down Arrow Scroll Push button once more returns you to t...

Page 110: ...ps to Idle followed by the clutch to Neutral the Control Head s rRed LED goes out and a slow repetitive tone is heard at all remote stations This indicates that the voltage at the Processor has moment...

Page 111: ...F If the voltage differential is less than 1 2 Volts 12 VDC Systems or 2 4 Volts 24 VDC Systems which is what you would typically expect a loose connection may exist between the power source and the P...

Page 112: ...oo low B To further isolate the cause enter the Diagnostic Menu as outlined in Section 1 4 C Depress the Up or Down Scroll Arrow Push button until the appropriate remote station is shown The appropria...

Page 113: ...D value is 995 or higher most likely the JUMPER between the Control Head s pins 3 5 Right Hand or 3 7 Left Hand is disconnected If in addition to the A D value being 995 or higher the LED is not lit...

Page 114: ...nt Error Messages of which one or more will be displayed in conjunction with this tone Depending on which Solenoid and whether an Open or a short is detected Error Mes sage 1 2 3 4 5 or 6 will be show...

Page 115: ...eCommand system are per formed digitally these DC voltages are expressed as and converted to a digital representation The Reference Voltage approx 5 00 VDC by which all analog inputs are based is repr...

Page 116: ...Neutral Idle position 491 511 A D counts Command will not be accepted unless the Control Head s lever is at the Neutral Idle position 1 6 2 Remote Station Select The second required item for taking c...

Page 117: ...pause time out A slow repetitive tone is heard from all remote stations If previously lit the red LED on the Control Head will go out Error Code 29 36 depending on which remote station will be shown...

Page 118: ...ge The input appears to be too high 14 Remote Station 2 Faulted High Station 2 Control Head s lever position is out of range The input appears to be too high 15 Remote Station 3 Faulted High Station 3...

Page 119: ...or 38 CAN Communication Form Error The Control Area Network protocol has detected an error in communication with other devices in the network The error type is a form type error 39 CAN Communication A...

Page 120: ...Reset Due to Hardware Watchdog The system has had an unexpected Reset due to a software hardware problem Table 2 Problem Scenarios Err Cause Solution 1 a The Astern Clutch Solenoid is defective b The...

Page 121: ...5 Control Head is defective a Properly connect the Station 5 Control Head b Replace the Station 5 Control Head 26 a The Station 6 Control Head is not properly connected b The Station 6 Control Head is...

Page 122: ...shield is terminated and the termination is at one side only 42 a The Serial Harness is in excess of 130 ft 40m b Processor Circuit Board fault c The Serial Harness s shield is not properly terminate...

Page 123: ...ntified c Loss of power to ID 8 a Connect the Serial Harness into ID 8 b Identify one item as ID 8 with the A0 function c Restore Power to item ID 8 52 a The Serial Harness is not connected to item ID...

Page 124: ...Section 1 6 1 If variations of the A D counts occur connect that Control Head to another Station at the Pro cessor If variations persist replace the Control Head CAUSE REMEDY a Incorrectly wired eight...

Page 125: ...need to be reversed after cor recting CAUSE REMEDY a No power to the Processor a Disconnect the Power Harness from the Processor Measure the DC voltage at pins 10 and 11 of the Harness plug If 24VDC i...

Page 126: ...played 31 thru 35 c Processor Identification has been improperly set c All Processors must have a unique identification number as set in Function Code A1 Refer to the Set up and Adjustments Section 5...

Page 127: ...d at Neutral PROCESSOR ENGINE GEAR BOX BATTERY Figure 19 Power Start Interlock Clutch Oil Pressure Switch and Alarm Harness Pin Out Termination A Conductor Color Termination B Description J11 1 Yellow...

Page 128: ...A Conductor Color Termination B Description J9 1 Black Engine DC Bus Throttle Signal Return J9 4 Red ECM 0 00 5 00 VDC Throttle Signal J9 8 Green Yellow N C N A PROCESSOR ENGINE Figure 22 Current Thr...

Page 129: ...Red DC Power Source 24 VDC J10 2 Black DC Power Source VDC Return J10 3 Red Ahead Solenoid 24 VDC when Ahead Clutch Selected J10 4 Black Ahead Solenoid VDC Return for Ahead Clutch J10 5 Red Astern So...

Page 130: ...id J10 11 Red Troll Command Solenoid 0 100 Duty Cycle 500Hz for Controlling Proportional Solenoid Valve J10 12 Black Troll Command Solenoid VDC Return for Troll Command Solenoid PROCESSOR PROCESSOR Fi...

Page 131: ...20 VDC J5 6 7 or 8 3 Violet Pin 8 Starboard side only DC Return for green LED J5 6 7 or 8 4 Orange Pin 4 Station Select Transfer Button 5 00 VDC 0 00 VDC when depressed J5 6 7 or 8 5 Red Pin 5 Right...

Page 132: ...monitoring and adjusting the actual throttle command signal In cases where the display is not avail able or the display s readings need to be verified the use of the Service Field Test Unit Part No 13...

Page 133: ...s into the Test Unit E Turn Power On to the Processor and take command at any Remote Station F The appropriate Idle Voltage for the application should be mea sured at this time If the voltage is off s...

Page 134: ...sure power is removed from both the Engine Electronics and the CruiseCommand Processor B Disconnect the Throttle Harness from the Throttle Socket on the Processor C Insert the Test Unit between the Th...

Page 135: ...l Throttle position while depressing the Transfer Button H Depress and hold the mA Jumper switch on the Test Unit while monitoring the current as shown in Figure 32 If the appropriate current for the...

Page 136: ...cket and the Throttle Harness as shown in Figure 33 D Set up a Multi meter to measure Duty Cycle and plug the test leads into the Test Unit E Turn Power On to the Processor and take command at any Rem...

Page 137: ...al Idle position and turn power Off to the Processor J Remove the Test Unit and plug the Throttle Harness back into the Processor s Throttle Socket 2 4 PWM PULSE WIDTH MODULATION WITH DC VOLTMETER A E...

Page 138: ...t Unit as shown in Figure 35 E Turn Power On to the Caterpillar ECM Only Do Not apply power to the CruiseCommand Processor at this time F Depending on the type of Caterpillar ECM the measurement shoul...

Page 139: ...Minimum E2 Function I Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode J The measurement should be 91 93 of the voltage recorded in ste...

Page 140: ...ed This is especially beneficial when setting up the amount of current delivered to the Propor tional Valve in Electric Trolling systems 3 1 AHEAD CLUTCH TESTING A Ensure power is removed from both th...

Page 141: ...A Ensure power is removed from both the CruiseCommand Proces sor and the Clutch Power Supply B Disconnect the Clutch Harness from the Processor s Clutch Socket C Insert the Test Unit between the Proc...

Page 142: ...y B Disconnect the Clutch Harness from the Processor s Clutch Socket C Insert the Test Unit between the Processor s Clutch Socket and the Clutch Harness as shown in Figure 40 D Set up the Multi meter...

Page 143: ...cessor s Clutch Socket C Insert the Test Unit between the Processor s Clutch Socket and the Clutch Harness as shown in Figure 41 D Set up the Multi meter to measure DC Volts and connect as shown in Fi...

Page 144: ...t between the Processor s Clutch Socket and the Clutch Harness as shown in Figure 42 D Set up an Amp meter to measure milliamperes as shown in Figure 42 E Turn power On to the Processor and Clutch Pow...

Page 145: ...m approximately 150 to 300 mA when set up as Normal and decrease from approxi mately 450 to 160 mA when set up Inverse I Return the Control Head lever to the Neutral Idle position and turn Off the Pro...

Page 146: ...APPENDIX B TROUBLE SHOOTING Page 49 3 6 ERASE EEPROM H1 This function restores all of the parameters to the factory default values NOTE This function is to be used only by Authorized Personnel...

Page 147: ...com T 45 0 43 436243 F 45 0 43 432643 Hesselager 21 PO Box 97 DK 2605 Broenby DENMARK FINLAND AB Marinel Oy vesa sarrinen ab marinel fi www seacompanion com fi ab marinel index htm T 358 2 444 11 F 3...

Page 148: ...gt nl T 31 0 183 650000 F 31 0 183 650001 Avelingen West 30 NL 4202 MS Gorinchem THE NETHERLANDS NORWAY ZF Norge AS www zf marine com T 47 0 22 720 575 F 47 0 22 720 902 Casper Sorms Vei 19 N 0664 Osl...

Page 149: ...rine com T 1 847 478 6868 F 1 847 478 6789 777 Hickory Hill Drive Vernon Hills IL 60061 USA Jimmy Wong ZFI Marine Maryland www zf marine com T 1 410 604 3320 F 1 410 604 3315 301 Pier Road Suite 102 S...

Page 150: ......

Page 151: ...APPENDIX C 1...

Page 152: ......

Page 153: ...Page 3 Drawing 11748 Single Screw Two Stations...

Page 154: ...Page 4...

Page 155: ...Page 5 Drawing 11746 Single Screw Two Pluggable Stations...

Page 156: ...Page 6...

Page 157: ...Page 7 Drawing 11747 Twin Screw Two Stations...

Page 158: ...Page 8...

Page 159: ...Page 9 Drawing 11745 Twin Screw Two Pluggable Stations...

Page 160: ...Page 10...

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ZF CruiseCommand 785CE, Installation And Troubleshooting Manual

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