ZF MM9000 Page 176 Installation, Operation And Troubleshooting Manual Download

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176

EN 3340.758.003a - 2014-11

TROUBLESHOOTING

MM9000 Rev C.8 01/13

Page 176

MM9000 ClearCommand User Manual
Troubleshooting

10.11.1.3 Servo Throttle Equal Synchronization Troubleshooting

SYMPTOM:

The green LED is lit solid, though the Engine RPM’s differ by a significant

amount.

SYMPTOM:

One or both of the engines continually changes RPM (hunts). Will not

synchronize properly.

SYMPTOM:

Will not synchronize..

10.11.2 Active Synchronization

10.11.2.1 Basic Active Synchronization Troubleshooting

SYMPTOM:

The green LED is lit solid, though the Engine RPM’s differ by a significant

amount.

Cause

Remedy

The throttle travel from Idle to Full is set

differently on the Port and Starboard

Processors.

Scroll to Function Codes E2 and E3 on both Processors and

compare the Values.

The Values of E2 and E3 must be the same for both Processors.

The engines run at different RPM’s with

equal travel of the Governors’/

Carburetors’ selector lever.

While underway at cruising speed, decrease the Value of

Function Code E3 on the Processor running at the higher RPM

until both engine are at the same RPM.

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.

Excessive back-lash in the push-pull

cable(s) or linkage.

Remove the excessive back-lash or install Tach Senders and

enable Active Synchronization with Function Code E7.

Excessive bends in the push-pull cable(s).

Reroute the push-pull cable(s) or install Tach Sender and enable

Active Synchronization with Function Code E7.

Cause

Remedy

A Control Head’s Command Signal is

varying.

Scroll to the Diagnostic Menu Function Code H0. Go to the

appropriate Station A/D Count’s display. The Value should not

change by more than +/- 1 A/D Count.

If so, check the connections and if good, replace the Control

Head.

The push-pull cable’s travel from Idle to

Full is too short.

Lengthen the Governor or Carburetor’s selector lever and attach

the push-pull cable to a point where the travel is in excess of 2.00

inches (50,8mm).

Cause

Remedy

Excessive bends in the push-pull cable(s).

Reroute the push-pull cable(s) or install Tach Sender and enable

Active Synchronization with Function Code E7.

Cause

Remedy

The Tach Sender signal has been lost by

one or both Processors.

Scroll to Function Code H0. Go to the Value for the Tach

Sender’s input frequency. If the frequency displayed is 0000, the

signal has been lost and the system diverted to Equal Throttle

Synch. Correct the wiring or replace the Sender.

Summary of Contents for MM9000

Page 1: ...INSTALLATION OPERATION AND TROUBLESHOOTING MM9000 CLEAR COMMAND USER MANUAL MARINE PROPULSION SYSTEMS ...

Page 2: ...the use of non original components or accessories wich have not been tested and submitted for approval ZF reserves all rights regarding the shown technical information including the right to file industrial property right applica tions and the industrial property rights resulting from these in Germany and abroad ZF Friedrichshafen AG 2014 ...

Page 3: ...7 2 1 DC Power On 27 2 2 Taking Command 27 2 3 Basic Operation 28 2 4 Start Interlock if used 29 2 5 Station Transfer 30 2 6 Proportional Pause 30 2 7 Warm up Mode 31 2 8 High Low Idle 32 2 9 One Lever Mode Twin Screw 33 2 10 Engine Synchronization Twin Screw 35 2 11 Control System s Configurability 37 2 12 Audible Tones 39 2 13 Push Button Set Up 41 2 14 Visual System Diagnostics Set Up And Statu...

Page 4: ...ystem Programming And Adjustments 86 5 7 Function Code E1 Throttle in Neutral 91 6 Dock Trials 113 6 1 Control Heads Engines Stopped 113 6 2 Start Interlock Engines Stopped 113 6 3 Engine Stop Switches 113 6 4 Push Pull Cables 113 6 5 High Idle 113 6 6 Control Head Servo Command 114 6 7 Control Head Solenoid Command 114 6 8 Throttle Pause Following Servo Shift 114 6 9 Throttle Pause Following Sole...

Page 5: ...6 10 8 Error Codes 156 10 9 Basic Problem Causes And Solutions 160 10 10 Problems Without Error Codes 172 10 11 Synchronization Troubleshooting 175 10 12 Troubleshooting Wire Harnesses 179 10 13 Processor Pigtails 193 11 Appendix A System Components and Specifications 197 MMC 280 400 Series Control Head Variations 199 MMC 329 MC2000 Series Standard Control Head Variations 205 MMC 307 700 Series St...

Page 6: ... 263 ENG 144 9000 Series Electronic Throttle Servo Clutch Qualitative Failure Analysis Design Verification Test Procedure and Periodic Safety Test 267 ENG 145 9000 Series Servo Throttle Solenoid Clutch Qualitative Failure Analysis Design Verification Test Procedure 271 13 Appendix C Sales and Service Information 275 MMC 123 Factory Authorized Sales Service North America 277 MMC 151 Factory Authori...

Page 7: ...32 Figure 2 12 Step A One Lever Operation Mode 33 Figure 2 13 Step B One Lever Operation Mode 34 Figure 2 14 Circuit Board Shield Layout 41 Figure 2 15 Standard Processor Pluggable Connections View 42 Figure 3 1 Processor Dimensions 45 Figure 4 1 Harness Plug Keying 53 Figure 4 2 Start Interlock Connections 54 Figure 4 3 Twin Screw Serial Harness Connections 56 Figure 4 4 Liquid Tight Installation...

Page 8: ...cessor Test Unit and Multimeter Connections 86 Figure 5 10 L2 L3 C6 and C7 Processor Test Unit and Multimeter Connections 86 Figure 5 11 Display LED Function A0 Set Up Activated 87 Figure 5 12 Display LED Function A1 Set Up Activated 88 Figure 5 13 Display LED Function A2 Set Up Activated 88 Figure 5 14 Display LED Function A3 Set Up Activated 89 Figure 5 15 Display LED Function A4 Set Up Activate...

Page 9: ...y LED Solenoid Function L2 Set Up Activated 107 Figure 5 52 Display LED Servo Function L2 Set Up Activated 107 Figure 5 53 Display LED Solenoid Function L3 Set Up Activated 108 Figure 5 54 Display LED Servo Function L3 Set Up Activated 108 Figure 5 55 Display LED Solenoid Function L4 Set Up Activated 109 Figure 5 56 Display LED Function L6 Set Up Activated 110 Figure 5 57 Display LED Function L6 S...

Page 10: ...ead Connections 211 Figure MMC 307 5 Aft Facing Control Head 211 Figure MMC 343 1 Station Expander 244 Figure MMC 343 2 Station Expander Harness Connector Locations 246 Figure MMC 343 3 Harness Plug Connectors 246 Figure MMC 343 4 Station Expander Dimensions 247 Figure MMC 343 5 Station Expander Display LED and Arrow Push Buttons 249 Figure MMC 343 6 Display LED at Normal Operation 250 Figure MMC ...

Page 11: ...anual List of Figures Figure MM13927 10 Clutch Connections Ahead Solenoid 318 Figure MM13927 11 Clutch Connections Astern Solenoid 319 Figure MM13927 12 Troll Connections Troll On Off Solenoid 319 Figure MM13927 13 Troll Connections Proportional Solenoid 320 Figure MM13927 14 2 Speed Connections 321 ...

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Page 13: ...formation 125 Table F 226 3 Power Supply 126 Table F 226 4 Dock Trials 126 Table F 226 5 Record at Dock 126 Table F 226 6 Sea Trials 127 Table F 226 7 Record during Sea Trial 127 Table F 226 8 Processor Parameters Record 127 Table 9 1 Fully Charged Battery 136 Table 10 1 ClearCommand Processor Push Pull Reference 142 Table 10 2 Examples of Components Internal External 145 Table 10 3 Control Head L...

Page 14: ... Ahead Astern Troll Command Troll On Off p n 70390 XX 188 Table 10 29 Wire Harness Clutch Ahead Astern ZFF Transmission p n 70673 XX 189 Table 10 30 Power Start Interlock Harness Pin Out p n 13756 XX 189 Table 10 31 Wire Harness Power SI Clutch Pressure Switch p n 13552 XX 190 Table 10 32 Wire Harness Power SI Clutch Pressure Switch Alarm p n 13631 XX 190 Table 10 33 Wire Harness Power Use W exist...

Page 15: ... current revision Rev C 2 5 08 Replaced MMC 280 MMC 329 Control Head Variations current revision Rev C 3 1 09 Replaced MMC 165 Rev G 1 09 Electronic Propulsion Systems Limited Warranty Replaced MMC 123 MMC 151 MMC 172 Factory Authorized Sales Service Center Lists Rev C 4 04 09 Replaced MMC 123 MMC 151 MMC 172 Factory Authorized Sales Service Center Lists Rev C 5 09 09 Reviewed and replaced all ext...

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Page 17: ...The last number in each Processor part number is the number of stations that are being used Available Options for the Processors Covered in this Manual Dynamic Positioning Interface Station 4 Joystick Interface CANtrak Display Engine Room Remote Switch Station 1 only Station 2 Lockout Speed Boost Loaded w Software Fixed Neutral Delay Loaded w Software IMPORTANT Keep this manual in a safe place for...

Page 18: ...llowed exactly CAUTION On Control Systems with more than one Processor ZF Marine Propulsion Systems Miramar highly recommends that ALL UNITS utilize the same software revision for each Processor CAUTION Electro static discharge can damage this equipment Personnel working on this equipment must be grounded to the chassis with an Anti static Wrist Strap CAUTION Disconnect the Power from the Processo...

Page 19: ...lation operational questions prior to Sea Trials CAUTION The DP pigtail MUST NOT be used to connect any other device such as a remote station Control Head Failure to meet this requirement will nullify the Processor warranty cause an unsafe operating condition and or damage the Processor CAUTION If the DP option is being utilized with a multi screw application ALL Processors MUST HAVE the DP pigtai...

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Page 21: ... single Control Head lever One electric cable per Control Head lever connects the remote station s to the Processor s Only one remote station will have command at a given time and the Station in Command is indicated by a red light located on the Control Head Station transfer is accomplished by pressing the Control Head mounted transfer button 1 1 1 9120 Processor Throttle Servo 2 Shift Solenoid or...

Page 22: ...a electric cable Figure 1 1 Basic 9120 or 9122 ClearCommand System Diagram IDLE FULL 33C PUSH PULL CABLE IDLE FULL THROTTLE STBD STATION 2 STATION 1 PORT 12296 SERIAL COMMUNICATION 10 AMP CIRCUIT BREAKERS BY OTHERS COMMON GROUND COMMON GROUND APS CLUTCH PRES START INTERLOCK ALARM START INTERLOCK CLUTCH PRES ALARM TACH 1 TACH 1 AHEAD ASTERN TROLL COMMAND TROLL ON OFF AHEAD ASTERN TROLL COMMAND TROL...

Page 23: ...he vessel s main engine throttle selector lever and trolling valve with standard 33C type push pull cables The transmission is controlled via electrical cables connected to the Ahead and Astern Shift Solenoids Figure 1 2 Basic 9121 ClearCommand System Diagram IDLE FULL 33C PUSH PULL CABLE 33C PUSH PULL CABLE IDLE FULL THROTTLE TROLL STBD STATION 2 STATION 1 PORT 12295 SERIAL COMMUNICATION 10 AMP C...

Page 24: ...s typically mounted in the engine room area and is connected to the electronic governor with a two conductor shielded electric cable The transmission is controlled mechanically using standard 33C type push pull cable Figure 1 3 Basic 9210 ClearCommand System Diagram 33C PUSH PULL CABLE 33C PUSH PULL CABLE SHIFT F N R F R N STBD STATION 2 STATION 1 PORT 12294 SERIAL COMMUNICATION 10 AMP CIRCUIT BRE...

Page 25: ...ly mounted in the engine room area and is connected to the electronic governor with a two conductor shielded electric cable The transmission and trolling valve are controlled mechanically using a standard 33C type push pull cable Figure 1 4 Basic 9211 ClearCommand System Diagram 33C PUSH PULL CABLE 33C PUSH PULL CABLE TROLL SHIFT F N R F R N TROLL SHIFT STBD STATION 2 STATION 1 PORT 12293 SERIAL C...

Page 26: ...ead and Astern solenoids are connected via 2 two conductor cables and the trolling valve is controlled mechanically using a standard 33C type push pull cable Figure 1 5 Basic 9221 ClearCommand System Diagram 1 2 System Features 1 2 1 Standard Features Station in Command indication Section 2 2 Taking Command Up to five Remote Stations Section 2 2 Taking Command Single Control Head lever command of ...

Page 27: ... de energized commanding Neutral Troll Servo The trolling valve servo will drive to lock up Solenoid The trolling valve solenoids are commanding lock up 2 2 Taking Command To take command at any one of the up to five Remote Stations Ensure all Control Head s lever s at that Station are in the Neutral detent vertical position Figure 2 1 Station taking Command Depress the transfer button for 1 2 sec...

Page 28: ...Head On initial power up Troll Mode is disabled A The Control Head has three detents Ahead Astern and Neutral To turn ON Troll Mode place the Control Head lever in any of the above mentioned detents With the Control Head lever positioned in the Neutral vertical detent the Processor will command Neutral the trolling valve will be at lock up and the throttle at Idle rpm B Depress and hold the transf...

Page 29: ...ly 2 seconds then release the button When the red indicator light is a steady red Troll Mode is disabled 2 4 Start Interlock if used The engine start signal is blocked unless all of the following are true DC power has been turned ON to the Control System Reference Section 2 1 DC Power On A Remote Station is in command Reference Section 2 2 Taking Command The Control System is commanding Neutral Fi...

Page 30: ...Throttle and Clutch will remain unchanged for one second after the red LED lights This allows the operator time to move the Control Head s lever s to a position approximately matching the last Station which will allow the vessel to maintain present speed and direction 2 6 Proportional Pause The proportional pause provides a means of safely reversing the vessel s direction A variable pause is intro...

Page 31: ...tent while continuing to hold the transfer button 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 E The operator can start the engine if required and increase the RPM through the entire throttle range by moving the Control Head s lever forward through the next 65 degrees F When the Control H...

Page 32: ...o Figure 2 11 High Low Idle Mode Selection when selecting between Low and High Idle or vice versa at the Station in Command Figure 2 11 High Low Idle Mode Selection A The Control Head s lever s may be in the Neutral Ahead or Astern detents when making a selection 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 vic...

Page 33: ...ed in the Set Up Procedures When One Lever Mode is enabled the operation must be turned ON and OFF as described below 2 9 1 Turning ON One Lever Operation A At the Station in Command move the Port and Starboard Control Head levers to the Ahead detent B Depress and Hold the transfer button while moving the Port or Starboard Control Head s lever out of the Ahead detent Do Not Release the Transfer Bu...

Page 34: ...he control system is now in normal operating mode NOTE The Control Head lever designated by the operator to be inactive in One Lever Operation may be left in the Ahead detent or moved fully forward Moving the lever fully forward is recommended because it moves it out of the way and prevents accidental bumps while operating WARNING It is strongly recommended that the Master lever is returned to the...

Page 35: ... 03 for Function Code E7 should be avoided in the 9000 Series Processors with mechanical throttle control Symptom When selected Value 03 Active Synchronization no Synch if Tach signal lost for Function Code E7 Synchronization may give the operator the appearance that synchronization is not functioning This is due to the fact that the Control Head s green Synch indication LED does not light until b...

Page 36: ...urning Synchronization ON A Ensure that the Control Head s levers are positioned to a point where Synchronization Criteria are met B Press and hold the transfer button until the green LED lights approximately 2 seconds The green LED will blink as the system is working toward synchronization The green LED will become solid when the engines are synchronized 2 10 6 Turning Synchronization ON and OFF ...

Page 37: ...ows a pause prior to applying speed above Idle E6 High Idle Programs a second elevated Idle RPM E7 Synchronization Allows the installer to select synchronization and select the type of synchronization Detail information on each function is found in Section 5 6 2 1 Throttle Basic Functions 2 11 2 2 Servo Throttle Functions This section along with Section 2 11 2 1 Basic Throttle Functions allows the...

Page 38: ...4 VDC ZF Hurth Solenoids C6 ZF Hurth Duty Cycle Ahead Fine tunes the maximum current level to the Ahead Proportional Solenoid C7 ZF Hurth Duty Cycle Astern Fine tunes the maximum current lever to the Astern Proportional Solenoid Detail information on each function is found in Section 5 7 1 3 Clutch Solenoid Functions 2 11 4 Troll Functions 2 11 4 1 Basic Troll Functions All Processors with Troll F...

Page 39: ...ous tones which inform the operator of the status of the system or if any faults were to occur These tones are emitted from all Remote Stations regardless of whether they are in command or not 2 12 1 1 Slow Repetitive Tone Detail information on this tone is in Section 10 Troubleshooting This tone is normal when DC power is first applied to the System This tone indicates that system initialization ...

Page 40: ...ault was detected with either the Ahead or Astern Clutch Solenoid 2 12 5 Troll Integrated Servo Servo 1 Tones The following Tones are in addition to the Basic Tones listed in Section 2 12 1 Basic Processor Tones 2 12 5 1 One Long One Short Tone Detail information on this tone is in Section 10 Troubleshooting This tone indicates that the feedback potentiometer signal from Servo 1 Troll has gone out...

Page 41: ...d These push buttons allow the installer technician access to all of the Functions required for programming and troubleshooting the Processor A full description of their usage is provided in Section 5 1 2 Push Buttons 2 14 Visual System Diagnostics Set Up And Status Indication There are four seven segment LED s hereafter referred to as the Display LED mounted to the Processor s circuit board The D...

Page 42: ...ions View 2 15 2 ClearCommand 9000 Series Pluggable Processors The 9000 Series Processors come from the factory with standard five Pigtail Connectors listed in Section 2 15 1 Standard Pluggable Processor and additional Pigtails depending on the Processor s features Refer below to the Processor being used on this System for the list of additional pigtails 9120 and 9121 Processors One pigtail connec...

Page 43: ...arate Processor housed in an enclosure that allows the connection of up to five additional Remote Control Stations The SE communicates with the Processor over the serial communication line A full explanation of the installation operation and adjustment of the SE is provided in the Installation Manual provided with the SE Additional information can be found in Section 8 3 Station Expander SE 2 16 4...

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Page 45: ... installation The following sections describe the requirements for installing the components and selecting mounting locations 3 1 1 Processor s Processors required per engine Single Screw One 1 Processor Twin Screw Two 2 Processors Mounting Hardware is installer supplied Installation Troubleshooting Manual is included with the Processor The following items must be taken into account when selecting...

Page 46: ...earance is sufficient for the Control Head s lever to reach full Ahead and full Astern Retrofit applications may require an Adapter Pad to cover the old Control Head cutout A variety of Adapters and Cover Pads are available Refer to MMC 288 References and Parts Source for details The Control Head can be mounted at any location on the vessel as long as all of the criteria listed above are met 3 1 3...

Page 47: ...il gasoline engine or an engine s electronically produced signal Refer to SER 161 Engine Tach Sender Req 3 1 5 Additional Harnesses Refer to the Parts List in MMC 288 References and Parts Source The following lists the various Harnesses that plug into the Processor 3 1 5 1 Throttle Harness One Harness required per Processor There are 4 types of Throttle Harnesses Voltage Current PWM Pulse Width Mo...

Page 48: ...ional wire size requirements 300V 105 degrees C UL VW1 stranded tinned copper wire Maximum outside diameter 0 390 inch 9 9mm 3 1 6 2 2 Start Interlock Electric Cable Requirements If Start Interlock is hard wired no plugs the electric cable must meet the following specifications or may be ordered from ZF Marine Propulsion Systems Miramar LLC Two conductor both yellow with red stripe twisted 16 AWG ...

Page 49: ...nation of the below listed harnesses or cables Refer to Table PREFACE 1 Processor List located after the cover sheet of this manual to determine which harnesses are required The following lists the various equivalent electric cables 3 1 8 Throttle Electric Cable Requirements If Throttle is hard wired no plugs to the Processor the electric cable must meet the following specifications or may be orde...

Page 50: ...terminal may be used as the tach source The signal is inputted to the AC Coupled Sensor input The signal must meet the same criteria as any AC Coupled Sensor Signal refer to Section Section 3 1 11 1 AC Coupled Sensors 3 1 11 3 Point side of the Coil When the signal is sourced from the coil or an electronically produced tach signal used on some gasoline engines the signal is connected to the AC Cou...

Page 51: ...nce with ABYC Standard E 11 the distance from a 12 volt power source battery or DC Distribution Panel shall not exceed 15 feet 4 6m In 24 volt systems the maximum cable length is 20 feet 6 1m It is recommended by ZF Marine Propulsion Systems Miramar LLC that an Automatic Power Selector APS and a second power source battery be used Refer to S 214 Automatic Power Selector Model 13505 for examples of...

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Page 53: ...Processor has five Pigtails with plugs on the ends Two of the plugs are for Remote Stations and one each for Power Start Interlock Serial Communication and Tach Sensor Additional Harnesses required will depend on the actual installation Four different styles of plugs are utilized but are inserted in an identical fashion as follows 4 3 1 Plug Insertion and Extraction Prior to inserting the plug pay...

Page 54: ... C Strip back the appropriate amount of PVC jacketing and conductor insulation D Crimp the appropriate connectors to the conductors E Terminate the conductors to the DC Power Source 4 3 2 2 Start Interlock Cable A Run the cable to the Engine s Starter Solenoid B Disconnect the Starter Switch wire from the Solenoid C Strip back the appropriate amount of PVC jacketing and conductor insulation D Conn...

Page 55: ...rtight seal located on the Processor enclosure in the Station cable entry holes 4 3 3 2 Control Head Harness with One Plug A At the Port Processor insert the grey eight pin plug into the Station 1 pigtail plug B Run the cable to the Port side of the Control Head located at Station 1 C Connect the conductors to the Control Head as described in the appropriate Control Head Dimensions and Variations ...

Page 56: ...e red positive E Repeat steps A thru C on the Starboard side 4 3 6 Additional 9000 Series Harnesses 4 3 6 1 Throttle Harness The appropriate Throttle Harness should have been selected in Section Section 3 1 5 1 Throttle Harness The Processors 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 c...

Page 57: ... 3 6 3 Clutch Troll Harness A Plug the grey 12 pin plug into the Clutch 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 If Twin Screw repeat steps A thru D on the opposite side NOTE Ensure Port Processor conn...

Page 58: ...ht Connectors in the appropriate holes as shown in Figure 4 5 Standard Enclosure Cable HolesStation 5 2 Station 3 3 Station 1 4 Alarm Clutch Pressure and Start Interlock 5 Power 6 Station 4 7 Station 2 8 Serial Communication 9 Tachometer Figure 4 5 Standard Enclosure Cable Holes 4 4 2 Standard Circuit Board Connections On a Standard Processor in lieu of using Harnesses for Control Heads Power Seri...

Page 59: ...BLACK ALARM BROWN ALARM RED ORANGE BLUE BLACK BROWN GREEN VIOLET LEFT RIGHT UP SERIAL STATION 2 OPI ALARM TACH STATION 5 SOLENOIDS DIGITAL INPUTS START INTERLOCK ELEC THR STATION 3 CLUTCH STATION 1 STATION 4 AUTO TROLL THROTTLE POWER JMP1 P3 DS4 DS2 DS3 DS1 P4 J3 P1 TB9 TB7 TB8 TB4 TB5 TB3 PB1 TB11 TB6 PB2 TB10 TB2 TB1 1 2 3 4 2 3 5 6 8 4 7 9 10 1 1 3 4 6 7 2 5 7 6 4 3 1 8 5 2 7 6 4 3 8 5 2 1 7 6 ...

Page 60: ...ocessor being used on this application 4 4 3 1 9120 and 9121 Clutch Solenoid Cable Hole Locations 1 Station 5 2 Station 3 3 Station 1 4 Alarm Clutch Pressure and Start Interlock 5 Power 6 Station 4 7 Station 2 8 Serial Communication 9 Tachometer 10 Clutch Solenoids Figure 4 7 9120 and 9121 Enclosure Cable Holes Table 4 1 ClearCommand Processor Optional Hard Wiring Cable List ZF Marine Propulsion S...

Page 61: ... 4 4 3 2 9122 Clutch Troll Solenoid Cable Hole Locations 1 Station 5 2 Station 3 3 Station 1 4 Alarm Clutch Pressure and Start Interlock 5 Power 6 Station 4 7 Station 2 8 Serial Communication 9 Tachometer 10 Clutch Solenoid 11 Troll Solenoid Figure 4 8 9122 Enclosure Cable Holes 1 2 3 4 5 6 7 10 11 8 9 12282 3_ART ...

Page 62: ...9210 and 9211 Throttle Electronic Cable Hole Locations 1 Station 5 2 Station 3 3 Station 1 4 Alarm Clutch Pressure and Start Interlock 5 Power 6 Station 4 7 Station 2 8 Serial Communication 9 Tachometer 10 Not Used 11 Not Used 12 Throttle Signal Figure 4 9 9210 and 9211 Enclosure Cable Holes 1 2 3 4 5 6 7 8 9 12282 4_ART 12 ...

Page 63: ...rottle Electronic and Clutch Solenoid Cable Hole Locations 1 Station 5 2 Station 3 3 Station 1 4 Alarm Clutch Pressure and Start Interlock 5 Power 6 Station 4 7 Station 2 8 Serial Communication 9 Tachometer 10 Clutch Solenoids 11 Not Used 12 Throttle Signal Figure 4 10 9221 Enclosure Cable Holes 1 2 3 4 5 6 7 10 8 9 12282 5_ART 12 ...

Page 64: ... termination points for the engine clutch or troll connections required for the Processor being used in this application Figure 4 11 9000 Series Circuit Board Hard Wired Termination Points 12 Throttle TB8 Brown 3 Red 4 Orange 5 White 6 Black 7 10 Clutch TB11 Black 1 Brown 2 Yellow 5 Green 6 10 11 Clutch Troll TB11 Black 1 Brown 2 Red 3 Orange 4 Yellow 5 Green 6 Blue 7 White 8 LEFT RIGHT UP SERIAL ...

Page 65: ... grip at this time F Strip the PVC jacket and shielding back approximately 4 1 2 inches 114 3mm on the seven conductor cable G Strip the wire 3 8 inch 9 5mm on each lead H Pull the Shield wire back against the PVC jacket and slide and shrink a piece of 3 8 inch W X 1 inch L heat shrink over the cable as shown in Figure 4 12 Seven Conductor Control Head Cable Shield Wire and Heat Shrink Figure 4 12...

Page 66: ...be routed to PB2 on the Circuit Board as shown in Figure 4 10 9221 Enclosure Cable Holes C Strip back 2 inches 50 8mm of the PVC jacketing Refer to Figure 4 15 Two Conductor Start Interlock Cable 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 Figure 4 15 Two Conductor Start Interlock Cable F Crimp fork or ring terminals to the wires G Con...

Page 67: ...e Location 8 A Install 1 2 inch 12 7mm liquid tight cable grips into hole No 8 of the Port and Starboard Processors Refer to Figure 4 5 Standard Enclosure Cable Holes for entry hole location and Figure 4 4 Liquid Tight Installation for cable grip installation B Run a four conductor shielded cable from the Port to the Starboard Processors C Strip back 3 inches 76 2mm of PVC jacketing from both ends...

Page 68: ...the PVC jacketing at the Tachometer source side only G Place a 7 8 inch 22 23mm section of shrink tubing over each end of the cable H At the Processor side bend the drain wire back and tuck it under the shrink tubing so that the grain wire end is exposed past the shrink tubing Refer to Figure 4 18 AC Type Tachometer Cable and Figure 4 19 Open Collector Tachometer Cable Figure 4 18 AC Type Tachomet...

Page 69: ... inches 0 41m outside of the Processor C Strip back 4 inches 101 6mm of the PVC jacket inside the Processor D Slide a 1 inch 24 5mm piece of heat shrink over the end of the cable as shown in Figure 4 20 Clutch Cable Heat Shrink in Processor Figure 4 20 Clutch Cable Heat Shrink in Processor E Strip back 3 8 inch 9 53mm from the four conductors and connect to the Processor as shown in Table 4 5 Clut...

Page 70: ...sor Termination A Install a liquid tight connector into hole no 10 B Run a 32 inch 0 82m piece of eight conductor cable through the liquid tight connector and tighten leaving 16 inches 0 41m outside of the Processor C Strip back 4 inches 101 6mm of the PVC jacket inside the Processor D Slide a 1 inch 24 5mm piece of heat shrink over the end of the cable as shown in Figure X Figure 4 22 Clutch Trol...

Page 71: ...r cable must connect the two Shift cables to the Processor through a 12 pin plug 4 4 7 1 1 Processor Termination A Install a liquid tight connector into hole no 10 B Run a 32 inch 0 82m piece of four conductor cable through the liquid tight connector and tighten leaving 16 inches 0 41m outside of the Processor C Strip back 4 inches 101 6mm of the PVC jacket inside the Processor Table 4 6 Clutch Tr...

Page 72: ...hown in Table 4 5 Clutch Termination Table F Slide the boot over the connector G Tie wrap the boot in place 4 4 8 Location 12 Installation 4 4 8 1 Throttle Cable Location 12 A 2 conductor shielded cable is required when hard wiring the engine to the Processor A Install a 1 2 inch Liquid Tight Connector into hole no 12 of the Processor B Run the throttle cable through the connector so that 4 inches...

Page 73: ...must be located at all Remote Stations and capable of stopping the engine at any RPM Refer to the installation instruction supplied with the switch and the engine installation instructions for manufactures recommendations Table 4 8 Throttle Termination Table Throttle Type Termination DC Voltage 0 to 5 0 VDC Signal TB8 5 Return TB8 7 Current 4 0 to 20 0 mA Signal TB8 4 Return TB8 7 PWM 0 to 99 Sign...

Page 74: ... D When the push pull cable end is visible within the Processor interior reinstall the 10 32 jam nut E Connect the push pull cables to the hex nuts See Figure 4 28 Push Pull Cable Interior Connection Use a 7 16 inch socket to turn the hex nut onto the cable rod end until there is approximately 5 16 inch 7 9mm of thread showing beyond the jam nut Figure 4 28 Push Pull Cable Interior Connection F Us...

Page 75: ... fabricate brackets as shown in MMC 290 Universal Mounting Kit B Turn power ON to the Control System to ensure that Neutral Idle is commanded C With the Shift Push Pull cable disconnected at the clutch selector lever adjust the Shift cable s ball joint at the transmission to align with the clutch selector lever at Neutral The push pull cable must form a 90 degree angle to the clutch selector lever...

Page 76: ...the troll selector lever are in close proximity to one another no adjustment is required at this time If the push pull cable end is at the opposite side from the selector lever the cable s polarity must be changed with Function Code L1 as described in Section Section 5 7 2 1 2 Troll Solenoid L1 Function C Secure the Trolling Valve selector lever at the full pressure position with wire tie wrap etc...

Page 77: ...in how to locate and use the push buttons and Display LEDs 5 1 Processor Components Used In Set Up Each Processor has a Display LED and Push Buttons The Display LED can be viewed through a window on the Processor s cover as shown in Figure 5 1 Typical Processor Cover Figure 5 1 Typical Processor Cover The Processor enclosure cover must be removed to access the Push Buttons as shown in Figure 5 2 P...

Page 78: ...letters or numbers The Display LED will have the Processor Part Number showing in a running pattern during Normal operation Figure 5 3 Display LED at Normal Operation The first two digit Display LED s to the left indicate the Function Code which is alphanumeric The second two digit Display LED s indicate the numeric Value that is programmed into the Processor for the Function Code displayed to the...

Page 79: ...s Activates Set Up Mode as indicated by the blinking Display LED must hold the buttons until the blinking begins While in Set Up Mode deactivates Set Up Mode saves the displayed Value to memory and returns to the Function Menu must hold the button until the blinking stops 5 1 2 3 Left Push Button Only Pressing the Left Push Button once has the following functions Deactivates Set Up Mode without an...

Page 80: ...xited B Depress the Up or Down Push Button until the next required Function Code is reached C Reactivate Set Up Mode 5 4 Set Up Function Codes And Values The following tables list the Function Codes Name Default Value and Range or available Options Each of the Func tion Codes are explained in further detail in the referenced sections NOTE To Escape from the Set Up procedure at any time without sav...

Page 81: ... Throttle Minimum 00 0 to 20 0 Will always be 10 or more below Maximum E3 Throttle Maximum 10 0 to 100 0 Will always be 10 or more above Minimum E4 Throttle Maximum Astern 00 0 to 100 0 of Throttle Maximum E5 Throttle Pause Following Shift 00 0 to 05 0 Seconds E6 High Idle 00 0 to 20 0 of Throttle Maximum THROTTLE FUNCTIONS continued Section 5 6 2 Throttle Functions E7 Synchronization 00 Equal Thr...

Page 82: ...limited to 75 04 55 Degrees Type 4 Throttle limited to 10 L1 Troll Valve Function or Troll Servo Direction 0 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 ...

Page 83: ... Personnel Only H2 Driver Fault Detection Enable Allows the Processor to monitor the clutch and or troll solenoids Table 5 2 Processors Function Code Defaults Function Code Default Values 9120 9121 9122 9210 9211 9221 PROCESSOR FUNCTIONS A0 00 00 00 00 00 00 A1 01 01 01 01 01 01 A2 00 00 00 00 00 00 A3 00 00 00 00 00 00 A4 00 00 00 00 00 00 THROTTLE FUNCTIONS E0 20 20 20 06 06 06 E1 00 0 00 0 00 0...

Page 84: ...0 00 00 20 20 00 C6 100 100 100 80 80 100 C7 100 100 100 80 80 100 TROLL FUNCTIONS L0 00 00 00 00 00 00 L1 20 20 00 20 20 20 L2 70 0 70 0 100 70 0 70 0 70 0 L3 90 0 90 0 25 0 90 0 90 0 90 0 L4 00 00 00 00 00 00 L5 00 6 00 6 00 6 00 6 00 6 00 6 L6 90 0 90 0 25 0 90 0 90 0 90 0 TROUBLESHOOTING FUNCTIONS H0 00 00 00 00 00 00 H1 00 00 00 00 00 00 H2 00 00 00 00 Table 5 2 Processors Function Code Defau...

Page 85: ...Unit and Multimeter E1 E2 E3 E4 E6 L2 L3 L4 C6 C7 Throttle in Neutral Section 5 7 Function Code E1 Throttle in Neutral Throttle Minimum Section 5 7 0 1 2 Function Code E2 Throttle Minimum Throttle Maximum Section 5 7 0 1 3 Function Code E3 Throttle Maximum Throttle Maximum Astern Section 5 7 0 0 1 Function Code E4 Throttle Maximum Astern High Idle Section 5 6 2 1 2 Function Code E6 High Idle Troll...

Page 86: ... and Multimeter Connections 5 6 System Programming And Adjustments NOTE SINGLE SCREW APPLICATIONS The Function Values may be entered and stored in any order TWIN SCREW APPLICATIONS 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 NOTE Power must be turned ON to the Processors when programming or making a...

Page 87: ... the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Scroll to Function Code A0 B Activate Set Up Mode C Scroll Up or Down to the desired Value D Store the Value to memory Figure 5 11 Display LED Function A0 Set Up Activated 5 6 1 2 Function Code A1 Number of Engines The total number of engines must be entered into the memory of each of the Pro...

Page 88: ...ns to the same speed and direction with a single Control Head lever This Function allows this Feature to be enabled or disabled Refer to Section 2 9 One Lever Mode Twin Screw for operation instructions The available Values for this Function are 00 Disabled Default Value 01 Enabled To change the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Sc...

Page 89: ... the Value to memory Figure 5 14 Display LED Function A3 Set Up Activated 5 6 1 5 Function Code A4 Neutral Indication Tone This Function allows the installer to turn ON a 1 2 second low frequency tone to indicate Neutral The available Values for this Function are 00 Disabled Default Value 01 Tone sounds when the Control Head s lever reaches Neutral 02 Tone sounds when the Processor commands Neutra...

Page 90: ...e 5 16 Display LED Function E5 Set Up Activated 5 6 2 1 2 Function Code 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 Throttle Maximum The Default Value is 00 0 The Value selected is a percentage of the Value selected in Function Code E3 Throttle Maximum To change the Value Refer to Sections Section 5 2 Activ...

Page 91: ...ion Code E3 Throttle Maximum Example A Value of 50 0 will allow 50 of Throttle Maximum when commanding Astern The Value selected is a matter of personal preference To change the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory 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 F...

Page 92: ...the Throttle Push Pull cable is fully extended or retracted when at Idle The available Values for this Function are 20 Fully Retracted Pull at Idle Default Value 21 Fully Extended Push at Idle To determine and change the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Ensure that the engine s Governor or Carburetor lever is at the Idle position...

Page 93: ...e Push Pull cable s Idle position electronically The primary purpose is to adjust the Push Pull cable Throttle Selector Lever s position so that any further movement will 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 E3 Throttle Maximum To determine and change the Value R...

Page 94: ...Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory Figure 5 25 Throttle Push Pull Cable Full Throttle Position A Take command at a Remote Station B Move the Control Head lever to the Full Ahead position C Check to see if the Throttle Push Pull cable reaches the Full Throttle stop If the Throttle lever is firmly not bound against the Full Throttle stop no ...

Page 95: ...to 06 Scania Profile To determine and change the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Scroll to Function Code E0 B Activate Set Up Mode C Scroll Up or Down until the desired Value is displayed D Store the Value to memory Figure 5 27 Display LED Function E0 Set Up Activated 5 7 0 2 2 Function Code E2 Throttle Minimum This Function all...

Page 96: ...vate Set Up Mode F Scroll Up until the throttle signal is at Full Throttle G Store the Value to memory H Return the Control Head lever to the Neutral Idle position Figure 5 29 Display LED Function E3 Set Up Activated 5 7 1 Clutch Functions 5 7 1 1 Clutch Basic Functions 5 7 1 1 1 Function Code C0 Clutch Pressure Interlock This Function enables or disables the feature and allows for two different m...

Page 97: ...tral when performing a Full Speed Reversal The In Gear Delay is most commonly used The Neutral Delay is used when a Shaft Brake is installed The amount of time is adjustable with Function Code C3 Proportional Pause Time The delay programmed is maximum and proportional when Values 00 and 01 are used The programmed delay is fixed when Value 02 is selected and Function Code C4 Proportional Pause Rati...

Page 98: ...sired Value D Store the Value to memory Figure 5 33 Display LED Function C3 Set Up Activated 5 7 1 1 5 Function Code C4 Proportional Pause Ratio 00 2 1 Ratio This is the default setting and determines how the value set in the Proportional Pause Time C3 Function is applied The number of seconds selected is for an Ahead to Astern maneuver only An Astern to Ahead maneuver will be 1 2 of the Proportio...

Page 99: ...et Up Activated 5 7 1 2 Clutch Servo Functions This section along with Section 5 7 1 1 Clutch Basic Functions allows the adjustment of Clutch Servo related items 5 7 1 2 1 Function Code C5 Clutch Servo Direction This Function allows the Processor to be programmed to retract the Push Pull cable for Ahead or extend for Ahead The available Values are 20 Pull Retracted for Ahead Default 21 Push Extend...

Page 100: ...Push Pull cable to see if it drove in the correct direction If the cable drove in the correct direction no 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 G Store the Value to memory Figure 5 36 Display LED Function C5 Set Up Activated ...

Page 101: ...Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Move the Control Head lever to the Ahead detent B Move the Clutch Selector Lever to the Ahead stop C Does the cable s ball joint and lever align If yes no further adjustment of this Function is required Figure 5 37 Clutch Push Pull Cable Ahead Position If no continue with the next step D Scroll to...

Page 102: ... determine and if required change the Value Refer to Sections Section 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory Figure 5 39 Clutch Push Pull Cable Astern Position A Move the Control Head lever to the Astern detent B Move the Clutch Selector Lever to the Astern stop C Does the cable s ball joint and lever align If yes no further adjustment of this Function is required If n...

Page 103: ... D Store the Value to memory Figure 5 41 Display LED Function C5 Set Up Activated 5 7 1 3 2 Function Code C6 ZF Hurth Duty Cycle Ahead This function adjusts the maximum current available to the Ahead Proportional Solenoid Failure to limit the current may result in permanent damage to the solenoid The available Values are 00 0 to 100 0 percent Duty Cycle of the applied voltage The Default Value is ...

Page 104: ...Enable and Control Head Lever Troll Range This Function Code tells the Processor whether or not A 9001 Trolling Actuator or integrated Troll Control exists How the trolling valve is to be controlled There are four types which can be used to control any trolling valve How these different Types function and when and where they may be applied is described in the Trolling Actuator s Installation Manua...

Page 105: ...Store the Value to memory Figure 5 44 Display LED Function L0 Set Up Activated NOTE Function Codes L1 thru L6 are not displayed on the Processor Display LED unless Function Code L0 is set to a Value other than 00 Figure 5 45 Control Head 20 Degree Troll Range Type 1 Figure 5 46 Control Head 35 Degree Troll Range Type 2 Figure 5 47 Control Head 45 Degree Troll Range Type 3 Figure 5 48 Control Head ...

Page 106: ...on 5 2 Activating Set Up Mode and Section 5 3 Storing Values To Memory A Scroll to Function Code L1 B Activate Set Up Mode C Scroll Up or Down to the appropriate Value for the Trolling Valve D Store the Value to memory Figure 5 49 Display LED Function L1 Set Up Activated 5 7 2 1 3 Troll Servo L1 Function L1 Troll Servo Direction This section along with the Basic Troll Functions allows the adjustme...

Page 107: ...play LED Solenoid Function L2 Set Up Activated A Move the Control Head lever to the Ahead detent B Scroll to the Function Code C Activate Set Up Mode D Scroll Up or Down to the appropriate Value E Store the Value to memory 5 7 2 1 5 Function Code L2 Servo Troll Minimum Pressure This Function Code along with the Basic Troll Command Functions allows the adjustment of the Processor s Integrated Servo...

Page 108: ...isplay LED Solenoid Function L3 Set Up Activated A Move the Control Head lever to the Ahead detent B Scroll to Function Code C Activate Set Up Mode D Scroll Up or Down to the appropriate Value E Store the Value to memory 5 7 2 1 7 Function Code L3 Servo Troll Maximum Pressure This Section along with the Basic Troll Command Functions allows the adjustment of the Processor s Servo Troll command This...

Page 109: ...unction L5 determines the length of time that the Value selected in Function Code L6 is applied The available Values for this Function are 00 0 to 09 9 seconds The default Value is 00 6 seconds A With Troll selected place the Control Head lever into the Ahead detent If the vessel lunges forward or the shaft takes too long to start rotating continue with the next step B Scroll to Function Code L5 C...

Page 110: ...ue with the next step B Scroll to Function Code L6 C Activate Set Up Mode D Scroll Up or Down to the desired Value E Store the Value to memory 5 7 2 1 11 Function Code L6 Servo Troll Pulse Percentage This Section along with the Basic Troll Command Functions allows the adjustment of the Processor s Servo Troll command This Function Code selects the percentage of available Troll Servo Range the Proc...

Page 111: ...Fault Detection Enable The H2 Function is available only on Processors with integrated Clutch and or Troll Solenoids i e 9120 9121 9122 and 9221 The Processor can be programmed to monitor the current flow through the clutch and or Troll solenoids When this option is selected if the current level is too high or too low an alarm is sounded and an Error Code is produced Table 5 3 Solenoid Error Statu...

Page 112: ...0 1 1 1 0 14 1 1 1 1 0 15 0 0 0 0 1 16 1 0 0 0 1 17 0 1 0 0 1 18 1 1 0 0 1 19 0 0 1 0 1 20 1 0 1 0 1 21 0 1 1 0 1 22 1 1 1 0 1 23 0 0 0 1 1 24 1 0 0 1 1 25 0 1 0 1 1 26 1 1 0 1 1 27 0 0 1 1 1 28 1 0 1 1 1 29 0 1 1 1 1 30 1 1 1 1 1 31 Table 5 3 Solenoid Error Status Enable Ahead Astern Neutral Troll Command Troll On Off Value ...

Page 113: ... engine s will not start C Take command at a Remote Station Place the Control Head s lever s to approximately 50 of the throttle range Verify that the engine s will not start D Place the Control Head s lever s in the Neutral Idle position Take command at a Remote Station Verify that the engine s will start in this position 6 3 Engine Stop Switches Start the engine s and verify that the Stop switch...

Page 114: ...trol Head lever at a time into the Ahead detent the Astern detent and then Neutral Confirm that the 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 D Run the throttle up to approximately 20 of the throttle range for at least 10 second...

Page 115: ...rn the Control Head lever to the Neutral detent If connected disconnect the push pull cable from the Trolling Valve lever E Move the Control Head lever to the Ahead detent F Manually position the Troll lever to the point where the Shaft rotation is 30 to 50 of that measured in Table 6 1 Shaft RPM at Idle above G If not previously selected enable Troll with Function Code L0 NOTE A Test Control Head...

Page 116: ...ver to the Neutral detent F Move the Control Head lever to the Ahead detent G Manually position the Troll lever to the point where the Shaft rotation is 30 to 50 of that measured in Table 6 1 Shaft RPM at Idle above H If not previously selected enable Troll with Function Code L0 I Depress the Transfer Button until the red LED begins blinking rapidly approximately 2 seconds J Scroll to Function Cod...

Page 117: ...ne RPM is high decrease by using Function Code E3 as explained in Section Section 5 7 0 1 3 Function Code E3 Throttle Maximum D For twin screw applications check that matching Idle Mid range and Full speed Control Head lever positions cause equal RPM in both engines 7 3 Proportional Pause The proportional pause feature provides engine deceleration when making a direction change The pause is variab...

Page 118: ...mum C Quickly move the Control Head lever s to Ahead Idle or Neutral depending on Function Code C4 setting while starting the stop watch D When the engine s RPM reaches Idle and the vessel s speed through the water is within two knots of the standard Idle Ahead speed stop the stop watch E Program Function Code C3 Proportional Pause Time as described in the Set Up Procedures to the time expired on ...

Page 119: ...zation by depressing the transfer button for two seconds The green LED on the Control Head should illuminate indicating synchronization C Check the engine tachometers to see if they are within 1 of one another D Move both Control Head levers side by side to approximately 50 of the Throttle range E Check the engine tachometers to see if they are within 1 of one another F Move both Control Head leve...

Page 120: ...can be adjusted so that the Shaft is rotating a 30 to 50 percent of the RPM s measured and recorded on Table 7 1 Shaft RPM at Idle F Once the desired RPM has been reached scroll to Function Code L2 Adjust the Value as described in Section Section 5 7 2 1 5 Function Code L2 Servo Troll Minimum Pressure until the Troll push pull cable aligns with the Troll selector lever G Enter the Value into memor...

Page 121: ...l Solenoid Table 7 2 Troll Valve Adjustments Model Number Troll Current Troll Pressure Comments Minimum Maximum Minimum Maximum ZF 25 80 12VDC 900 mA 24VDC 450 mA 12VDC 1260 mA 24VDC 630 mA 1 Bar 15 PSI 8 Bar 116 PSI Main shift control valve is proportional The Minimum Maximum Troll currents listed are at lock up Exceeding the Maximum current may damage the solenoid Current below the Minimum liste...

Page 122: ...h H on the opposite side 7 4 4 3 Troll Maximum Pressure Adjustment Function Code L3 A Place one Control Head lever in the Ahead detent with Troll enabled B If twin screw ensure that the opposite lever is at the Neutral Idle position C Scroll to Function Code L3 and enter Setup Mode as described in Section Section 5 7 2 1 6 Function Code L3 Solenoid Troll Maximum Pressure D Increase or decrease the...

Page 123: ... applications In the event that the shaft takes unreasonably long to begin to rotate or an excessive surge is produced every time Ahead is commanded with Troll the Value can be increased or decreased When the need to adjust these Values arises it is recommended that small adjustments to each of these Functions are made instead of one large adjustment to one or the other After each small adjustment...

Page 124: ...de a convenient checklist and record of installation dock trial set up and sea trial performance of the ZF Marine Propulsion Systems Miramar LLC Propulsion Control System Please enter ALL of the information We recommend that this form remains aboard the vessel and a copy is sent to ZF Marine Propulsion Systems Miramar LLC with the Warranty Registration located at the end of this manual ...

Page 125: ...bers 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 bonded grounded Yes No Yes No Are all Electric Cables supported every 18 inches 45 72cm Yes No Yes No Does the Shift push pull cable travel in the correct direction Yes No...

Page 126: ... Voltage when the engines are running Battery Processor Battery Processor Table F 226 4 Dock Trials Processor Information Port Stbd Does the engine start remotely 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 Y...

Page 127: ...tual The desired Troll Minimum can be calculated as follows Shaft Idle RPM x 0 3 Troll Maximum Shaft RPM RPM Actual The desired Troll Maximum can be calculated as follows Shaft Idle RPM x 0 7 Table F 226 8 Processor Parameters Record Function Code Function Name Port Stbd PROCESSOR FUNCTIONS A0 Processor Identification A1 Number of Engines A2 One Lever Operation A3 SE Station Expander A4 Neutral In...

Page 128: ...ion C6 ZF Hurth Duty Cycle Ahead OR Clutch Ahead C7 ZF Hurth Duty Cycle Astern OR Clutch Astern C8 Fixed Neutral Delay TROLL FUNCTIONS Port Stbd Only Available and Displayed When P N 9001 Troll Actuator Is Connected To The Processor OR when L0 is programmed to a value other then 0 with integrated troll L0 Troll Enable and Control Head Troll Lever Range L1 Troll Valve Function OR Troll Servo Direct...

Page 129: ...lteo WA 98275 OR FAX TO 425 493 1569 ATTN Service Department Comments Please use additional paper as necessary General Installation Condition Any Irregularities Is the Installation and Troubleshooting Manual on board Yes No If No request copy Yes No Is the Operator Card on board Yes No Is a copy of this completed Report aboard Yes No Is a copy of this completed Report Yes No Inspector Date Company...

Page 130: ...130 EN 3340 758 003a 2014 11 SEA TRIAL REPORT ...

Page 131: ...ple Figure 8 2 External Alarm Connections Processor Hard Wired Example 8 1 1 Installation Refer to Figure 8 1 External Alarm Connections Processor Hard Wired Example or Figure 8 2 External Alarm Connections Processor Hard Wired Example The following items should be considered when designing and installing the Status Indication Panel The Power Wire Harness p n 13631 must be used if an External Alar...

Page 132: ...f Operation 8 2 1 1 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 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 be allowed to increase a...

Page 133: ...between the Shuttle Valve and the Pressure Switch D Connect the Power Wire Harness s Clutch Pressure Interlock cable to the Pressure Switch s normally open contact E Calibrate the Pressure Switch to close when adequate Clutch Pressure is reached Refer to the Transmission manufactures Installation Manual Processor Power Pigtail Power Wire Harness To Starter Solenoid To External Status Indication Ci...

Page 134: ...onal Trolling Valve A Trolling Valve controls the amount of pressure applied to the Clutch Plate By doing so the speed of the propeller can be reduced without decreasing engine RPM The Processor allows the operator to control with a single lever the Trolling Valve Clutch and Throttle In order to do so a separate Trolling Actuator p n 9001 must be installed The Trolling Actuator and the main Proces...

Page 135: ... 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 9 2 3 Troll Integrated Servo Processor Check mechan...

Page 136: ...ded The Service Load Test determines how well your battery performs in the boat and doesn t take into account the battery s original rating which could result in misleading results The Performance Load Test places an accurate load on the battery and compares the results to the battery manufacture s specification The battery should be replaced if the results are 80 or less than the manufacture spec...

Page 137: ...ir functions 10 1 1 Control Systems Examples 10 1 1 1 9120 Throttle Servo 2 Shift Solenoid Processor and 9122 Throttle Servo 2 Shift Solenoid Troll Solenoid Processor Figure 10 1 9120 and 9122 Basic Twin Screw Two Station Diagram The 9120 Processor is designed to precisely control speed and direction on vessels equipped with mechanical Throttle and Solenoid Clutch Selectors The 9122 Processor is d...

Page 138: ...rottle and Trolling Valve and Solenoid Clutch Selectors Figure 10 2 9121 Basic Twin Screw Two Station Diagram IDLE FULL 33C PUSH PULL CABLE 33C PUSH PULL CABLE IDLE FULL THROTTLE TROLL STBD STATION 2 STATION 1 PORT 12295 SERIAL COMMUNICATION 10 AMP CIRCUIT BREAKERS BY OTHERS COMMON GROUND COMMON GROUND APS CLUTCH PRES START INTERLOCK ALARM START INTERLOCK CLUTCH PRES ALARM TACH 1 TACH 1 MAX SLIP M...

Page 139: ...peed and direction on vessels equipped with electronic Throttle and mechanical Clutch Selectors Figure 10 3 9210 Basic Twin Screw Two Station Diagram 33C PUSH PULL CABLE 33C PUSH PULL CABLE SHIFT F N R F R N STBD STATION 2 STATION 1 PORT 12294 SERIAL COMMUNICATION 10 AMP CIRCUIT BREAKERS BY OTHERS COMMON GROUND COMMON GROUND APS CLUTCH PRES START INTERLOCK ALARM START INTERLOCK CLUTCH PRES ALARM T...

Page 140: ...lve on vessels equipped with electronic Throttle and mechanical Clutch and Troll Selectors Figure 10 4 9211 Basic Twin Screw Two Station Diagram 33C PUSH PULL CABLE 33C PUSH PULL CABLE TROLL SHIFT F N R F R N TROLL SHIFT STBD STATION 2 STATION 1 PORT 12293 SERIAL COMMUNICATION 10 AMP CIRCUIT BREAKERS BY OTHERS COMMON GROUND COMMON GROUND APS CLUTCH PRES START INTERLOCK ALARM START INTERLOCK CLUTCH...

Page 141: ...nputs to the appropriate electronic or electric outputs at the correct time and sequence to the Governor and Gear Box The information regarding throttle type throttle clutch sequencing etc are all stored on memory within the Processor 10 1 2 3 Power Source All electronic equipment must have power in order to operate Ensuring a properly charged reliable power source is available is crucial The Proc...

Page 142: ...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 to the Processor s cross bars on one end and the governor and or transmission selector levers on the end The Processor uses the 33C Type push pull cable as standard or 43C Type with a special adapter Prior to attempting to troubleshoot the System get as...

Page 143: ...occurs at one Remote Station only there is a greater chance of the Control Head or the Control Head Harness of being the cause D Are any tones generated when the problem occurs The tones are used to bring the operator s attention to a possible condition or problem The following basic tones can be produced on all Systems Slow Repetitive Tone Refer to Section 10 5 1 1 Slow Repetitive Tone One Long T...

Page 144: ...the long run you will save yourself and the customer a lot of time and money 10 3 Troubleshooting Problem Resolution If the problem could not be resolved by asking the questions in the previous section a careful inspection of the Control System may be the next step Even in situations where the problem was found and corrected it is good practice to always perform a careful inspection of the entire ...

Page 145: ...ng are examples of components both internal and external to the Control System which could be a source of trouble The following pages should give you a good guideline for making this determination There is no need to troubleshoot the system to any point further than one of the main components listed above If the fault is found to be with a Control System component that component is simply replaced...

Page 146: ...e 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 DC Refer to Figure 10 9 Example Display of Applied Battery Voltage Figure 10 9 Example Display of Applied Battery Voltage E In addition to the applied battery voltage scrolling through the Diagnostics Menu by pressing the Up or Down Push Button can also ...

Page 147: ...ertain Processor will be as simple as selecting this feature Figure 10 13 Example Display Software Revision Level View H Pressing the Up or Down Scroll Push Button once more returns you to the Applied Battery Voltage Figure 10 9 Example Display of 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 Depr...

Page 148: ... Take note that the Under Voltage error is not only dependent on low voltage it is also dependent on the duration of the low voltage The possibility exists that an error message would not be displayed if the duration of the low voltage was short enough However the other symptoms mentioned above still occur B In either case follow the procedure listed under Diagnostic Menu Section 10 4 Troubleshoot...

Page 149: ... Out of calibration Control Head A defective Control Head A defective A D Converter in the Processor The exact cause of the malfunction can be found as follows A Check the Processor s Display for error messages Most likely one of error messages 13 thru 32 will be shown The exact number shown depends on which remote station is experiencing the problem and whether the command signal was too high or ...

Page 150: ...7 is a Harness is used This jumper provides the potentiometers ground The potentiometer ground connection for Control Heads which are hard wired to the Processor is through the yellow wire pin 5 on right hand and pin 7 on left hand F If the A D value is 100 or less one of Error Codes 23 32 Control Head Faulted Low will be shown If the A D value is less than 100 but greater than 75 the following ma...

Page 151: ...ences the Slow Repetitive Tone 10 5 1 6 Five Seconds On Five Seconds Off High Repetitive Rate Tone Loss of communication with Station Expander SE or the Troll Actuator p n 9001 This tone cannot be cleared unless all Error Codes Active and In Active have been cleared 10 5 1 7 Five Second Steady Tone Loss of Serial Communication 10 5 2 Servo 1 Control System Tones 10 5 2 1 One Long One Short Tone Th...

Page 152: ...nd needs to be replaced If the tone did not cease check the DC Voltage to the Processor by accessing the Diagnostic Menu H0 If the voltage is adequate replace the Processor 10 5 3 Servo 2 Control System Tones 10 5 3 1 One Long Two Short Tones This tone indicates that the feedback signal which represents the position of the Servo 2 cross bar is out of expected range This tone will be accompanied by...

Page 153: ... push pull cable from the selector lever If the tone is still present after cycling power replace the Processor If the tone is no longer present continue with step C C If disconnected reconnect the push pull cable D Depress the Transfer Button while moving the Control Head lever to the Ahead detent E Release the transfer button and continue to move the Control Head lever through the speed range If...

Page 154: ... are expressed as and converted to a digital representation The Reference Voltage approximately 5 00 VDC by which all analog inputs are based is represented as 1023 A D Analog to Digital Counts This allows for the possibility of a 1024 possible positions when 0 is included in the count The value of the Command Voltage with the lever at the Neutral Idle position is 49 51 of the Reference Voltage wh...

Page 155: ...ntering the Diagnostic Menu H0 A Depress the Up or Down scroll Push Button until four zeroes are displayed without decimal points as shown in Figure 10 16 Display Station A D s No Station Transfer Button Depressed Figure 10 16 Display Station A D s No Station Transfer Button Depressed B For Stations 1 4 when the Transfer Button is depressed the 0 which represents that remote station will change to...

Page 156: ...ransfer Button is suspected this can be verified by looking at the Station Select status 1 or 0 as outlined in Section 10 6 3 Remote Station Select An Error Code 33 42 will be shown on the Display depending on which Station is experiencing the problem 10 8 Error Codes As stated previously if a problem with the Control System is detected the Processor is programmed to display numerous Error Codes t...

Page 157: ...s 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...

Page 158: ...ontrol Head s Transfer Button has either been closed too long or has been closed since power up 41 Station No 9 Button Stuck Closed Station No 9 Control Head s Transfer Button has either been closed too long or has been closed since power up 42 Station No 10 Button Stuck Closed Station No 10 Control Head s Transfer Button has either been closed too long or has been closed since power up 43 CAN Com...

Page 159: ...10VDC or lower for at least two seconds 58 Reset Due to Software Watchdog The system has had an unexpected Reset due to a software hardware fault 59 Reset Due to Software Fault The system has had an unexpected Reset due to a software fault 60 Reset Due to Hardware Watchdog The system has had an unexpected Reset due to a software hardware fault 61 Oscillator Watchdog The system s Oscillator has had...

Page 160: ...nd 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 No continuity between pin 5 s of the Control Head Harness connectors b Ensure that the red conductor is properly 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 Contro...

Page 161: ...that the red conductor is properly 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 Head Harness connectors b Ensure that the green conductor is p...

Page 162: ...ss connectors c Ensure that the blue conductor is properly 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 Head Harness connectors b Ensure that the green conductor is properly crimped to pin 6 at both connectors and there is continuity c No continuity betw...

Page 163: ...al block 34 a The Station No 2 transfer button was held down for 15 seconds or longer a Clear the Error Code from memory b The Station No 2 Control Head transfer button is defective b Replace the Control Head 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 ...

Page 164: ...d 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 c...

Page 165: ...d 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 c...

Page 166: ...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 terminated c Ensure that the shield is terminated and the termination is at one side only 45 a The Serial Harness is not connected at one or more Processors a Ensure that the Serial Harness is properly seated...

Page 167: ...1 51 a The Serial Harness is not connected at Processor ID No 2 a Connect the Serial Harness into Processor ID 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 ID No 3 a Connect the Serial Harness into Pro...

Page 168: ...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...

Page 169: ... s feedback potentiometer is out of calibration a Replace the Processor or calibrate the potentiometer b The Clutch Servo s feedback potentiometer is unplugged from the Circuit Board b Plug the feedback potentiometer s brown plug into the Circuit Board c The Clutch Servo s feedback potentiometer is defective c Replace the Processor or the feedback potentiometer d The Processor s Circuit Board is d...

Page 170: ...e load c The Push Pull cable is defective c Replace the Push Pull cable d The Processor s Throttle Servo Servo 2 is defective d Replace the Processor 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 out of calibration a Replace the Processor or calibrate the potentiometer b The Throttle Ser...

Page 171: ...eplace the battery charging system or power distribution system 66 a The Troll Servo s feedback potentiometer is out of calibration a Replace the Processor or calibrate the potentiometer b The Troll Servo s feedback potentiometer is defective b Replace The Processor or the potentiometer c The Processor s Circuit Board is defective c Replace the Processor or the Circuit Board 67 a The Troll Servo s...

Page 172: ...and Pin 8 at the Processor b The Control Head s Sound Transducer is defective b Measure the AC voltage at pins 1 3 of the Control Head If 20 25 VAC is present replace the Control Head Cause Remedy a Incorrectly wired Station Harness Cable or Pigtail a Verify that the brown wire is properly connected to pin 2 on the Control head and pin 2 at the Processor b The Control Head s red LED or circuit is ...

Page 173: ...iagnostic Menu H0 If the frequency is not measured check the Tachometer Sensor and the wiring b Loss of Serial Communication between the Processors b If Active Synchronization is inoperative due to a lack of Serial Communications one or more Error Codes will be displayed indicating the loss of communication c The Processor s Identification number s have not been set properly c All Processors must ...

Page 174: ...n 5 6 2 1 Throttle Basic Functions c The Governor or Carburetor is incorrectly adjusted c After Causes a and b have been eliminated contact a certified engine mechanic to properly adjust Cause Remedy a The Processor is sensing that the Control Head s lever is moving in the Astern direction Depress the Transfer Button while moving the Control Head lever in the Astern direction If the LED begins to ...

Page 175: ...n eliminated contact a certified engine mechanic to properly adjust Cause Remedy a Synchronization is Disabled a At the Station in Command move both Control 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 Ser...

Page 176: ...sacrificed by doing so Install Tach Senders and enable Active Synchronization with Function Code E7 c Excessive back lash in the push pull cable s or linkage c Remove the excessive back lash or install Tach Senders and enable Active Synchronization with Function Code E7 d Excessive bends in the push pull cable s d Reroute the push pull cable s or install Tach Sender and enable Active Synchronizati...

Page 177: ...e not set up for twin screw operation d Scroll to Function Code A1 on the Port and Starboard Processor Enter a Value of 02 into both Processors Cause Remedy a A Control Head s Command Signal is varying a Scroll to the Diagnostic Menu Function Code H0 Go to the appropriate Station A D Count s display The Value should not change by more than 1 A D Count If so check the connections and if good replac...

Page 178: ...d replace the Control Head b One or both of the Tach Signals isn t being read intermittently Function Code E7 is set to a Value of 01 or 03 b Scroll to Function Code H0 on both Processors and display the frequency of the Tach Signal If variations of the signal are measured the cause must be determined Cause Remedy a The Processors think Astern is being commended when the Control Head lever is posi...

Page 179: ... 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 10 12 1 Basic Control System Harnesses 10 12 1 1 Serial Wire Harnesses Table 10 14 Wire Harness Serial Communication p n 13316 XX Termination A Termination B ...

Page 180: ...0 758 003a 2014 11 TROUBLESHOOTING MM9000 Rev C 8 01 13 Page 180 MM9000 ClearCommand User Manual Troubleshooting Table 10 15 Wire Harness Serial Communication Multi Screw p n 15544 XX Termination A Termination B ...

Page 181: ...MM9000 ClearCommand User Manual Troubleshooting 10 12 1 2 Throttle Wire Harnesses Table 10 16 Wire Harness Serial Communication CANtrak p n 70422 XX Termination A Termination B Table 10 17 Wire Harness Throttle Voltage IVECO Cummins p n 13432 XX Termination A Termination B N A ...

Page 182: ...C 8 01 13 Page 182 MM9000 ClearCommand User Manual Troubleshooting Table 10 18 Wire Harness Throttle Current MAN MTU p n 13494 XX Termination A Termination B N A Table 10 19 Wire Harness Throttle Voltage Cummins Plug p n 13565 XX Termination A Termination B ...

Page 183: ...C 8 01 13 Page 183 MM9000 ClearCommand User Manual Troubleshooting Table 10 20 Voltage Throttle Harness Pin Out p n 14148 XX Termination A Termination B Table 10 21 Wire Harness Throttle Pulse width modulation PWM p n 13533 XX Termination A Termination B N A ...

Page 184: ...ING MM9000 Rev C 8 01 13 Page 184 MM9000 ClearCommand User Manual Troubleshooting Table 10 22 Voltage Throttle Harness Pin Out p n 71262 XX Termination A Termination B Table 10 23 Cable throttle MAN EDC p n 14421 XX Termination A Termination B ...

Page 185: ...3a 2014 11 TROUBLESHOOTING MM9000 Rev C 8 01 13 Page 185 MM9000 ClearCommand User Manual Troubleshooting Table 10 24 Wire Harness Throttle Current w Mag Pickup Man Non Common Rail p n 14363 XX Termination A Termination B ...

Page 186: ...6 MM9000 ClearCommand User Manual Troubleshooting 10 12 1 3 Clutch Wire Harnesses Table 10 25 Wire Harness Clutch Ahead Astern p n 15719 XX Termination A Termination B N A Table 10 26 Wire Harness Ahead Astern Troll on off Command p n 15725 XX Termination A Termination B N A ...

Page 187: ...340 758 003a 2014 11 TROUBLESHOOTING MM9000 Rev C 8 01 13 Page 187 MM9000 ClearCommand User Manual Troubleshooting Table 10 27 Wire Harness Clutch with Troll Command p n 15732 XX Termination A Termination B N A ...

Page 188: ...03a 2014 11 TROUBLESHOOTING MM9000 Rev C 8 01 13 Page 188 MM9000 ClearCommand User Manual Troubleshooting Table 10 28 Wire Harness Clutch Ahead Astern Troll Command Troll On Off p n 70390 XX Termination A Termination B ...

Page 189: ...MM9000 ClearCommand User Manual Troubleshooting 10 12 1 4 Power Wire Harnesses Table 10 29 Wire Harness Clutch Ahead Astern ZFF Transmission p n 70673 XX Termination A Termination B Table 10 30 Power Start Interlock Harness Pin Out p n 13756 XX Termination A Termination B N A ...

Page 190: ... Page 190 MM9000 ClearCommand User Manual Troubleshooting Table 10 31 Wire Harness Power SI Clutch Pressure Switch p n 13552 XX Termination A Termination B N A Table 10 32 Wire Harness Power SI Clutch Pressure Switch Alarm p n 13631 XX Termination A Termination B N A ...

Page 191: ...0 ClearCommand User Manual Troubleshooting 10 12 1 5 Control Head Wire Harnesses Table 10 33 Wire Harness Power Use W existing St Intlk Only p n 15023 XX Termination A Termination B N A Table 10 34 Wire Harness Control Head One Connector p n 13557 XX Termination A Termination B N A ...

Page 192: ... 13 Page 192 MM9000 ClearCommand User Manual Troubleshooting Table 10 35 Wire Harness Control Head Two Connectors p n 14261 XX Termination A Termination B NOTE P N 14261 Starboard Side of Control Head Jumper Pins 3 to 5 Port Side of Control Head Jumper Pins 3 to 7 ...

Page 193: ...ic off the shelf Processors are available with no Pigtails hard wired or pre wired for up to a total of eight Pigtails when all five Remote Stations are being used The following Tables describe the pin outs and functions of the conductors within the various Pigtails 10 13 1 Basic Processor Pigtails 10 13 1 1 Serial Wire Harnesses Processor Pigtails Table 10 36 Wire Harness Serial Communication Pro...

Page 194: ...bleshooting 10 13 1 2 Throttle Wire Harnesses Processor Pigtails 10 13 1 3 Clutch Wire Harnesses Processor Pigtails Table 10 37 Wire Harness Throttle Processor Lead p n 15703 XX Termination A Termination B N A Table 10 38 Wire Harness Solenoid Clutches Processor Lead p n 15701 XX Termination A Termination B N A ...

Page 195: ... Rev C 8 01 13 Page 195 MM9000 ClearCommand User Manual Troubleshooting 10 13 1 4 Power Wire Harnesses Processor Pigtails Table 10 39 Power Start Interlock Clutch Oil Pressure Switch and Alarm Pigtail Pin Out p n 15710 XX Termination A Termination B N A ...

Page 196: ...eshooting 10 13 1 5 Control Head Wire Harnesses Processor Pigtails 10 13 1 6 Mag Pickup Wire Harnesses Processor Pigtails Table 10 40 Wire Harness Control Head Processor Lead p n 15706 XX Termination A Termination B N A Table 10 41 Wire Harness Mag Pickup Processor Lead p n 15704 XX Termination A Termination B N A ...

Page 197: ...197 EN 3340 758 003a 2014 11 APPENDIX A SYSTEM COMPONENTS AND SPECIFICATIONS MMSC5000 Rev B 01 13 Page 197 MMSC5000 SmartCommand User Manual Appendix A 11 Appendix A System Components and Specifications ...

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Page 199: ...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 mounti...

Page 200: ...s 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 4 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 of...

Page 201: ...essing and holding the release button or buttons WILL damage the plug 7 AFT FACING CONTROL HEADS Figure MMC 280 5 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...

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Page 203: ...e 203 MMC 280 400 Series Standard Control Head Variations WARNING Do not mount control head less than 100mm from Compass Mounting control head too close to compass can cause the compass to malfunction WARNING Note that the dimensions are out of scale pay attention to properly size the cut out before use ...

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Page 205: ... 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 MOUNTING AND INSTALLATION A Select the desired mounting locations and make cutouts per template Refer to Figure MMC 329 2 Dimensions B Chec...

Page 206: ...hout depressing and holding the release button or buttons will damage the plug 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 insulati...

Page 207: ... 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 Figure MMC 329 4 AFT Facing Control Head Ha...

Page 208: ...08 MMC 329 MC2000 Series Standard Control Head Variations WARNING Do not mount control head less than 250mm from Compass Mounting a control head too close to compass can cause the compass to malfunction WARNING Note that the dimensions are out of scale pay attention to properly size the cut out before use ...

Page 209: ...s properly mounted on a console the Control Head is watertight Figure MMC 307 3 Dimensions 2 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 P...

Page 210: ...ams 4 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 but...

Page 211: ...ual 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 Figure MMC 307 5 Aft Facing Control Head Handheld Control is a Station option Contact your ZF Marine Electronics Dealer for further information on Handheld requir...

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Page 213: ... SPECIFICATIONS WARNING Do not mount control head less than 600mm from Compass Mounting control head too close to compass can cause the compass to malfunction WARNING Note that the dimensions are out of scale pay attention to properly size the cut out before use ...

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Page 215: ...ld up the mount is drilled to allow air circulation Part No 12110 400 Series Weather Mount Enclosure Gasket 10241 Control Head Mounting Holes 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 ZF Marine Propulsion Systems Miramar LLC 12125 Harbour Reach Dr St...

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Page 217: ...re not oriented They may go in either way NOTE The receptacle is shown use the same procedure for plug Step 1 Contact Removal Step 4 Contact Insertion Step 2 Wire Stripping 1 Remove wedgelock using needlenose pliers or a hook shaped wire Pull wedge straight out 2 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact...

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Page 219: ...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 The twin APS is supplied with 2 single APS hardware packets D INSTALLATION Refer to Drawing 11488 DC Power Source Kit 1 Shut off all charging sources and disconnect the negative ground side of each battery which will be wire...

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Page 221: ...221 EN 3340 758 003a 2014 11 APPENDIX A SYSTEM COMPONENTS AND SPECIFICATIONS Page 221 Drawing 11488 DC Power Source Kit ...

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Page 231: ...rculation 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 identified via a green or green with a yellow stripe jacket and shall not be used as a return Where grounding conductors are attached to Processors or other CE marked devices a tinned copper braid is ...

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Page 233: ... General 46 CFR 111 01 15 b Ambient Temp Machinery Spaces 50 degrees C 46 CFR 111 05 System Grounds C Society of Automotive Engineers 400 Commonwealth Drive Warrendale PA 15096 J1171 External Ignition Protection J1428 Marine Circuit Breakers J378 Marine Engine Wiring D National Marine Manufacturers Association 401 North Michigan Avenue Chicago IL 60611 E Underwriters Laboratories Parts Source Anti...

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Page 235: ...mmins Most Older 555 8902 N A Diesel Cummins B C Series KTA19M3 MTA855 KTA1150M 8912 Most have Magnetic Pickup already 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 ...

Page 236: ... 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 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 Ser...

Page 237: ...d gov Right hand gov 6V 53 Rear entry 6V 53 Front entry 6 8V 71 Front entry 12 16V 149 41736 41736 36680 36680 36680 36680 36680 36680 Perkins 4 236M 6 3544M T6 3544M ST6 3544M SST6 3544M 4 108 W shut off 48931 302026 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 2 3 4 HD HE 36680 36680 MerCruiser Inboard w o Warner...

Page 238: ...ICATIONS MMC 289 Rev A 03 11 Page 238 MMC 289 Morse Connection Kits 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 ENGINE MAKE KIT NO ...

Page 239: ...TEM COMPONENTS AND SPECIFICATIONS MMC 290 Rev A 06 09 Page 239 MMC 290 Universal Mounting Kit Universal Mounting Kit ZF Marine Propulsion Systems Miramar LLC 12125 Harbour Reach Dr Ste B Mukilteo WA 98275 P 425 583 1900 F 425 493 1569 www zf com ...

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Page 241: ...oy 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 Remove 33C Cable Connect Nut Lead Screw Remove Snap Ring Cable Retainer Screws 11452 43C Cable Connect Nut Cross bar Lead Screw Jam...

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Page 243: ...s 249 8 1 Station Expander Components Used In Set Up 249 8 2 Station Expander Display LED 250 8 3 Push Buttons 250 MMC 343 9 Activating Set Up Mode and Storing a Value 251 MMC 343 10 Set Up Functions Values 252 10 1 A0 Station Expander Identification 253 10 2 H0 Diagnostic 253 10 3 H1 Erase EPROM 253 MMC 343 11 Dock Trials 253 11 1 Control Head Engines Stopped 253 11 2 Engine Stop Switches Test En...

Page 244: ...essor MMC 343 2 Required Parts One Station Expander required per Processor Mounting Hardware is installer supplied System Operation Manual included with the Processor MMC 343 3 Location Expanders are spray proof but must not be immersed An engine room location of the Expanders is preferred If the engine room is too small locate in any area where it is accessible for electrical connections Bulkhead...

Page 245: ...Power Selector APS and a second power source be used Refer to S 214 Automatic Power Selector Model 13505 and Section 7 2 Power Cable MMC 343 5 Harnesses Below is a general list of Wire Harnesses available to Station Expander A complete harness list and part numbers are located in section MMC 343 13 Parts List Stations 2 4 connectors on the Station Expander are sealed with plugs at the factory Ever...

Page 246: ...ton or buttons will damage the plug Figure MMC 343 3 Harness Plug Connectors Ensure that the harness cable lengths are long enough to make one complete run from the Station Expander to the power supply the remote station the Port and Starboard Processor MMC 343 6 Tools For Installation 6 1 Required Screwdriver med Phillips 2 Hole saw 1 inch 25 4mm Drills 9 32 inch 7 2mm and 7 32 inch 5 6mm Saw app...

Page 247: ...ng 1 4 inch or M6 fasteners D Connect to the Bonding System A Insert the Wire Harness plug into the POWER connector on the Station Expander B Continue with the following Sections that apply to this application NOTE When connecting the plugs ensure that the release buttons are depressed and held until plug is fully connected To disconnect the plugs the release buttons MUST be held depressed until p...

Page 248: ... spliced A Install the Control Head Wire Harness between each Control Head and the appropriate Station Expander B Label each harness at both ends with the station it connects and Port Center or Starboard for Multi Screw applications Install each harness so it is protected from physical damage When installing the cable support using clamps or straps not more than 18 inches 0 5m apart unless contain...

Page 249: ...anual supplied with the 500 Series Control Head Assembly for installation instructions MMC 343 8 Set Up Procedures The Station Expander utilizes push buttons in conjunction with Display LED s to program adjust calibrate and set up the various features The push buttons also allow you to access and display information regarding the health of the System The following paragraphs explain how to locate ...

Page 250: ...the Functions and Values The direction of the arrow indicates Left Down Up and Right See Figure MMC 343 5 Station Expander Display LED and Arrow Push Buttons Up and Down Push Buttons Pressing the Up or Down Push Buttons once has the following functions Stops Normal Operation Display running red center dash lines and activates the Function Menu While in the Function Menu scrolls through the Functio...

Page 251: ...llowing function While in the Error Menu clears inactive errors Active errors blink inactive do not Pressing and holding the Right Push Button has the following function Figure MMC 343 9 Display LED Four Digit Value While in Set Up Mode or Function Menu allows the Function Value of the current Function Code to be displayed with all four Display LEDs MMC 343 9 Activating Set Up Mode and Storing a V...

Page 252: ...h buttons 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 The new Value is now set into memory G Depressing either the Up or Down arrow push buttons will now scroll through the Function Codes MMC 343 10 Set Up Functions Values The following table lis...

Page 253: ...a Value 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 section MMC 343 9 Activating Set Up Mode and Storing a Value 10 2 H0 Diagnostic This Function is used during Troubleshooting Refer to the 9000 Series CruiseCommand Manual supplied with the Control System for information on this Function 10 3 H1 Erase EP...

Page 254: ...ted in Section 7 5 Control Heads 11 2 Engine Stop Switches Test Engines Running A Start engine s B Verify that all Engine Stop Switches function correctly at all stations Refer to information supplied by engine manufacturer or switch supplier for set up and adjustments MMC 343 12 Periodic Checks and Maintenance 12 1 Station Expander Check all terminal connections for signs of corrosion or loose co...

Page 255: ...able MC2000 5L or 5R Left or Right Black Control Head Gold Lever B Twin Screw Synchronization Indication 460 4 Control Head T Lever 460 4P Control Head T Lever Pluggable 463 4 Control Head Chrome Knob Lever 463 4P Control Head Chrome Knob Lever Pluggable 464 4 Control Heads Split with Single Levers Chrome Knobs pair 465 4 Control Head Black Low Profile Lever 466 4 Control Head Chrome Low Profile L...

Page 256: ...Throttle MAN 15027 Throttle Frequency 13322 Clutch Ahead Astern Clutch Power 13324 Clutch Ahead Astern Neutral Clutch Power 13240 Clutch Ahead Astern Troll Troll CMD Clutch Power 14310 Clutch Ahead Astern Troll CMD Clutch Power 14925 MAN with Troll 14542 MAN without Troll 13239 Magnetic Pickup or Pulse Transmitter 13422 ZF Autotroll MS70 13231 only 15364 ZF Autotroll MS570 15382 Cannon Connector o...

Page 257: ... EN 3340 758 003a 2014 11 APPENDIX B QFA DVTP MM9000 Rev C 8 01 13 Page 257 MM9000 ClearCommand User Manual Appendix B 12 Appendix B QFA DVTP Qualitative Failure Analysis Design Verification Test Procedure ...

Page 258: ...258 EN 3340 758 003a 2014 11 APPENDIX B QFA DVTP ...

Page 259: ... 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 Propulsion control a Each vessel must have 1 A propulsion control system operable from the pilothouse and 2 A means at...

Page 260: ...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 Propulsion Systems Miramar MicroCommander ClearCommand system is that there be an engine STOP button at each remote station A standard feature is an alarm contact normally ope...

Page 261: ... if needed and throttle will go to Idle if needed The Port Control Head will give an audible tone indicating a faulty potentiometer 4 Move the Port and Starboard Control Head levers back to Neutral Reconnect the green wire 5 Take command at the Control Head 6 Repeat for Starboard side Failure Power failure to MicroCommander ClearCommand 9000 Series A power failure to the MicroCommander ClearComman...

Page 262: ...k to Neutral 5 Replace the 3 pin plug 6 Acknowledge the error by pressing the transfer button 7 Repeat test for Starboard Processor Failure Clutch Feedback Potentiometer failure a Results Clutch will remain at last commanded position 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...

Page 263: ...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 subchapte...

Page 264: ...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 st...

Page 265: ...re 2 Repeat for Starboard side 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 Star...

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Page 267: ... 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 Propulsion control A Each vessel must have A propulsion control system operable from the pilothouse and A means at each propulsion engine of readily disabling the propulsion control...

Page 268: ...m system with a power loss or CPU failure In addition ZF Marine Propulsion Systems Miramar LLC provides audible tones at the Control Head locations to indicate system faults Design Verification Test Procedure The ClearCommand 9000 Series electronic throttle servo clutch version Propulsion Control System is compliant to the environmental design standards in 46 CFR 62 25 30 The following test proced...

Page 269: ... Take command at a Control Head Move the Port and Starboard Control Head levers to approximately Ahead Turn power off to the Port side only Port side will go to Idle and clutch servo will remain at last commanded position LED on the Port side of the Control Head in command will go off The Port Control Head will no longer have command of the engine and gear The Starboard Control Head will still hav...

Page 270: ...270 EN 3340 758 003a 2014 11 APPENDIX B QFA DVTP ...

Page 271: ...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 Propulsion control A Each vessel must have A propulsion control system operable from the pilothouse and A means at each propulsion engine of readily disabling the propulsion control system t...

Page 272: ...tem with a power loss or CPU failure In addition ZF Marine Propulsion Systems Miramar provides audible tones at the Control Head locations to indicate system faults 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 ...

Page 273: ...a Control Head Move the Port and Starboard Control Head levers to approximately Ahead Turn power off to the Port side only Port side throttle will remain at last commanded position and clutch will shift to neutral LED on the Port side of the Control Head in command will go off The Port Control Head will no longer have command of the engine and gear The Starboard Control Head will still have full c...

Page 274: ...274 EN 3340 758 003a 2014 11 APPENDIX B QFA DVTP ...

Page 275: ...275 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION MM9000 Rev C 8 01 13 Page 275 MM9000 ClearCommand User Manual Appendix C 13 Appendix C Sales and Service Information ...

Page 276: ...276 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 277: ...e www tdcequipment com Company Trans Pacific Distributors Contact Henry Bramhall Address 1941 Walters Court Fairfield CA 94533 Phone 707 426 6670 Fax 707 426 0206 Email sales marinegate com Company Control Masters Contact Ed Raffaniello Address 14603 Beach Blvd Ste 600 Jacksonville FL 32250 Phone 904 260 9756 Fax 904 260 9727 Email edr controlmastersinc com Website www controlmastersinc com Compan...

Page 278: ...lf Coast Contact Mike Gauthreaux Laura Heckler Address 161 James Drive West Suite 120 St Rose LA 70087 Phone 504 443 0501 Fax 504 443 0504 Email mike gauthreaux zf com Website www zf marine com Company Marysville Marine North Contact Randy Hall John Dillon Address 1551 Michigan Ave Marysville MI 48040 Phone 810 364 7653 Phone 800 367 0987 Fax 810 364 4112 Email rhall marysvillemarine com Website w...

Page 279: ... 98103 Phone 206 632 4462 Phone 800 426 6930 Fax 206 634 4600 Email mail fisheriessupply com Website www fisheriessupply com Company Pinnacle Marine Services Company Dave Hanson Address 160 Cascade Place 229 Burlington WA 98233 Phone 360 404 2063 Fax 360 404 2064 Email pinnmar aol com Company PPC Systems Inc Contact Bill Mol Address 12147 Bayhill Road Burlington WA 98233 Phone 360 336 9698 Fax 360...

Page 280: ...cmcelectronics ca Company CMC Electronics Contact Graham Taylor Address 3600 B Laird Road Unit 12 Mississauga Ontario Canada L5L 6A7 Phone 905 607 4262 Fax 905 607 1576 Email graham taylor cmcelectronics ca Company CMC Electronics Contact Michel Roy Address 566 Duphare Street East Mantane Quebec Canada G4W 3P6 Phone 418 562 6637 Fax 418 562 5335 Email michel roy cmcelectronics ca Company CMC Elect...

Page 281: ...ed Sales Service Center North America MMC 123 Rev A 5 06 10 Page 281 Company CMC Electronics Contact Brad Funk Jim Goodfellow Address 6680 Mirah Road Saanichton British Columbia Canada V8M 1Z4 Phone 250 544 1561 Fax 250 544 2061 Email brad funk cmcelectronics ca jim goodfellow cmcelectronics ca ...

Page 282: ...282 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 283: ...23 Email debmccusker yahoo com Company Kodiak Service Contact Fred Lentz Address PO Box 1018 Kodiak AK 99615 Phone 907 486 6556 Fax 907 486 6022 Email ksci worldnethtt net Company Rainbow Glacier Company Contact Karl Johnson Address PO Box 821 Haines AK 99827 Phone 907 766 2218 Fax 907 766 2585 Company Redden Marine Supply Formerly Kachemak Gear Shed Contact John and Butch Address 3625 East End Ro...

Page 284: ...k aramark com Company Desert Recreation Inc Contact Jim Ronnie Address 315 Long Ave Bull head City AZ 86429 Phone 928 754 4391 Fax 928 754 3335 Email desrec ctaz com Company Donn s Boat Shop Inc Contact Donn DeVore Address PO box 3826 Page AZ 86040 Shipping 486 Haul Road Page AZ 86040 Phone 928 645 0313 Fax 928 645 0323 Email boatfxr donnsboatshop com Company Mobile Marine Repair Inc Contact Steve...

Page 285: ... Bayside Marine Electric Contact Mike Vihel Address PO BOX 685 Bayside CA 95524 Phone 707 498 9999 Company Fishing Boats Unlimited Contact Tony Greyshock Jason Greyshock Address 624 Terminal Way Costa Mesa CA 92627 Phone 949 642 0882 Fax 949 642 0419 Email crew fishingboatsunlimited com Website www fishingboatsunlilmited com Company Channel Coast Marine Contact Marc Hermann Address 2949 W 5th Stre...

Page 286: ...2 Phone 831 475 3383 Fax 831 475 1498 Email jhme6 cs com Company Jones Valley Shasta Lake Resorts Contact Mike Han Kip Fatout Address 22300 Jones Valley Marina Road Redding CA 96003 Phone 530 275 7950 Fax 530 275 3523 Company Outbound Yacht Service Contact Kevin Ryan Address 34241 Pacific Coast Hwy 105 Dana Point CA 92629 Phone 949 488 0652 Fax 949 489 0704 Email kevin outboundyachtservices com Co...

Page 287: ... FL 33157 Phone 305 251 7547 Cell 786 429 7068 Fax 305 926 3813 Email atmmarine1 bellsouth net Company Dave Gillen Diesel Contact Dave Gillen Address 811 N E 3RD Street Dania Beach FL 33004 Phone 954 927 6500 Fax 954 927 6090 Email Gillenda GillenDiesel net Website www Gillendiesel net Company Mega Yacht Service Contact Dave Laschomb Address 408 SE STREAMLET AVE Port St Lucy FL 34983 Phone 772 284...

Page 288: ... 1235 Company Uhane Enterprises LLC Contact Jack Womack Address 74 425 Kealakehe Parkway 11 Kailua Kona HI 96740 Phone 808 557 9622 Fax 808 329 4157 Email kalani444 aol com Company S S Rentals Inc Contact Greg Stirn Address PO Box 389 Lansing IA 52151 Shipping 990 South Front Street Lansing IA 51251 Phone 563 538 4135 Fax 563 538 4454 Company Monticello Mobile Marine Contact Mark Tucker Pam Tucker...

Page 289: ...74 Fax 410 687 3353 Company Niemiec Marine Contact Martin Niemiec Address 173 Popes Island New Bedford MA 02740 Phone 508 997 7390 Fax 508 997 8978 Company A M Marine Contact Jim Bell Scott Wall Address 1630 Foothill Drive Boulder City NV 89005 Phone 702 293 1321 Fax 702 293 5896 Cell 609 517 5595 Email anmmarine aol com Company Callville Bay Resort Marina Contact Carl Ward Address HCR 30 Box 100 ...

Page 290: ...654 Email griffinmarine mindspring com Company Marine Control Systems Contact Gary Sorenson Address 76 May Apple Lane Franklyn NC 28734 Phone 828 508 4201 Fax 828 369 7572 Company Cook Engine Co Contact Jeff Dykes Address 503 NE Tomahawk Island Drive Portland OR 97217 Phone 503 289 8466 Fax 503 286 2836 Email sales cookengine com Company Curry Marine Contact Terry Wheeler Scot Graf Laurie Wheeler ...

Page 291: ...Service Contact Dennis Osborne Danny Baldwin Address POBox 536 Seabrook TX 37933 Shipping 2301 Nasa Road 1 Seabrook TX 77586 Phone 281 474 2885 Fax 281 474 2885 Email jjohnston lakewoodyachtservice com Company Aramark Halls Crossing Contact Mark Grahn Address PO Box 5101 Lake Powell UT 84533 Phone 435 684 7019 Fax 281 474 2885 Company Bullfrog Boat Shop Contact Tami Luckson Address PO Box 4055 Lak...

Page 292: ...6 LaConner WA 98257 Shipping 920 W Pearle Jensen Way LaConner WA 98257 Phone 360 466 3629 Fax 360 466 3632 Company North Harbor Diesel Inc Contact Dave Williams Mike Curran Address 720 30th Street Anacortes WA 98221 Phone 360 293 5551 Fax 360 293 0728 Email nharbor fidalgo net Company Ocean Alexander Marine Center Contact Scott Morris Address 1115 N Northlake Way Seattle WA 98103 Phone 206 547 139...

Page 293: ...MMC 151 Rev A 7 06 10 Page 293 Company Roberts Maritime Contact Bill Roberts Address PO BOX 1592 Coupeville WA 98239 Phone 360 678 4235 Fax 360 678 5576 Email boatzz comcast net Company Yacht Care Inc Contact Jim Brown Address 26010 West Marina Place Suite K Seattle WA 98199 Phone 206 285 2600 Fax 206 285 2610 Cell 360 914 0256 ...

Page 294: ...294 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 295: ...e 54 11 4580 0444 Fax 54 11 4580 0440 Email trimer trimer com ar Company ZF Services Australia Pty Ltd Contact Gary Bain Rodney Lean Address Locked Bag 6305 Blacktown BC NSW 2148 Australia Shipping 14 Lidco Street Arndell Park NSW 2148 Australia Phone 61 0 2 9679 5555 Fax 61 0 2 9679 5500 Email gary bain zf com au or oesales zf com Website www zf com au Company ZF do Brazil S A Contact Richard Ber...

Page 296: ...enford com Company ZF Shanghai Rep Office Contact Tang Zhou Qing Gong Lan Address Room 2504 Jiangnan Building No 600 Luban Road Shanghai 200023 PR China Phone 0086 21 6301 4338 Fax 0086 21 6301 6449 Email qiwei yao zf com Website www zf marine com Company ZF Danmark APS Contact Michael Johansson Frank Kiessling Address Taastrupgaardsvej 8 10 Taastrup DK 2630 Denmark Phone 45 7022 6243 Fax 45 7022 ...

Page 297: ... Address Gudmundur Bragasson Akralind 2 201 Kopavogur Iceland Phone 354 555 6444 Fax 354 565 7230 Email Gummi maras is Company ZF Services Great Britain Ltd Contact Adi License Address Abbeyfield Road Lenton Nottingham United Kingdom NG7 2SX England Phone 44 115 986 9211 Fax 44 115 986 9261 Email adi license zf com Website www zf marine com Company Saim SPA Contact Antonio Renzetti Alessandro Buse...

Page 298: ...NE S A DE C V Contact Ing Ernesto Cadavid Address Av Gran Via Tropical 8 Fraccionamiento Las Playas Acapulco Gro Mexico Phone 744 482 6365 Fax 744 482 6365 Email ecadavid ralline com mx Company ZF Services Australia Pty Ltd Contact Gary Bain Rodney Lean Address Locked Bag 6305 Blacktown BC NSW Australia 2148 Shipping 14 Lidco Street Arndell Park NSW Australia 2148 Phone 61 02 9679 5555 Fax 61 02 9...

Page 299: ... marine com Company Mammoth Enterprises Pte Ltd Contact Steven Wee Address PO Box 283 Siglap Post Office Singapore 914503 Shipping 6 A Waringin Park Singapore 416320 Phone 65 6 44 88266 Fax 65 6 44 89800 Email mament singnet com sg Company ZF South East Asia Contact Sharon Ho Address 11 Tuas Drive 1 Singapore Phone 6861 0177 Fax 6861 9173 Email sharon ho zf seasia Company ZF South Africa Pty Ltd C...

Page 300: ...sel electric Corp Contact Mike Ou Address 8F 1 No 34 Min Chuan 1s Road Kaohsiung Taiwan 80205 Phone 886 7 3331191 Fax 886 7 3346808 Email ade taiwan msa hinet net Website www asiadiesel com tw Company ZF Thailand Co Ltd Contact Reungpoj V Address 159 33 Soi Vipawasee 64 Vipawasee Rangsit Road Laksi Bangkok 10210 Thailand Phone 66 2 521 6520 Fax 66 2 521 6523 Email tanapath bkk loxinfo th Company A...

Page 301: ...ddress 15351 SW 29th Street Ste 300 Miramar FL 33027 Phone 954 441 4040 Fax 954 441 4140 Email aj halavacs zf com Website www zf com Company ZF Marine Propulsion Systems Miramar LLC Gulf Coast Contact Mike Gauthreaux Address 161 James Drive West Suite 120 St Rose LA 70087 Phone 504 443 0501 Fax 504 443 0504 Email mike gauthreaux zf com Website www zf com Company ZF Marine Propulsion Systems Mirama...

Page 302: ...302 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 303: ...ete unit F 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 d...

Page 304: ...304 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 305: ... At Processor Serial Serial Number of Remote Stations Purchase Date Dealer s Name Installer s Name Phone Number Cell Number E Mail Address Fax Number Purchaser s Name Street Address City State Zip Phone YOUR VESSEL Engine Make Model Length Manufacturer Boat Show Dealer Magazine Friend ZF Marine Propulsion Systems Miramar LLC 12125 Harbour Reach Dr Ste B Mukilteo WA 98275 P 425 583 1900 F 425 493 1...

Page 306: ...306 EN 3340 758 003a 2014 11 APPENDIX C SALES AND SERVICE INFORMATION ...

Page 307: ...307 EN 3340 758 003a 2014 11 REFERENCE MANUAL MM13927 FIELD SERVICE TEST UNIT MARINE PROPULSION SYSTEMS ...

Page 308: ... the use of non original components or accessories wich have not been tested and submitted for approval ZF reserves all rights regarding the shown technical information including the right to file industrial property right applica tions and the industrial property rights resulting from these in Germany and abroad ZF Friedrichshafen AG 2014 ...

Page 309: ...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 E 06 07 Brought Entire Manual up to current ZF Standards Software revised to SW70203 3 adding Joystick display ELR 1401 Table 1 2 3 and 4 Item 3 changed from 13316 XX to 70422 xx Made CANtrak consistent throughout manual Renamed Figures without CANtrak E 1 07 10 Reformatted...

Page 310: ...310 EN 3340 758 003a 2014 11 REVISION LIST ...

Page 311: ...es that have pluggable Pigtail Throttle Clutch or Troll Connections The procedures for testing the various outputs of the ClearCommand and CruiseCommand Processors are similar with the exception of where they connect to the respective Processor Figure MM13927 2 CruiseCommand Connector Locations indicates the location of the connectors on the CruiseCommand Processor and Figure MM13927 3 Example of ...

Page 312: ... Voltage Current or Frequency 2 Black 12 Pin Power Connector Pigtail This connector pigtail contains the inputs and outputs for Main Processor Power Start Interlock Clutch Oil Pressure Interlock and External Alarm Circuit 3 Gray 12 Pin Clutch Connector Pigtail The external connections for Clutch Power Ahead Astern and Neutral Solenoids Troll On Off and Proportional Solenoids are made at this conne...

Page 313: ...r to measure DC Volts and plug the black lead into the Break out Box black socket labeled and the red lead into the socket labeled VDC E Turn power On to the Processor and take command at any Remote Station F The appropriate Idle Voltage 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...

Page 314: ...urn power On to the Processor and take command at any Remote Station F Depress and hold the Push button Switch labeled mA The appropriate Current mA for the application should be measured G Move the Control Head lever to the Full Throttle position while depressing the Transfer Button Throttle Only Mode Figure MM13927 5 Throttle Connection Current mA H Depress and hold the mA Push button The approp...

Page 315: ...ype of Caterpillar ECM PEEC or ADEMS the measurement should be approximately 5 00 or 12 00 VDC Record the measurement as shown in Drawing Figure MM13927 6 Throttle Connection PWM with DC Voltmeter F Set up the Multimeter to DC Volts and plug the black lead into the Break out Box black socket Turn power On to the Processor and take command at any Remote Station G Record the DC Voltage at this time ...

Page 316: ... 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 H The measurement will increase from 8 to 91 93 2 1 5 Frequency Hz A Ensure power is removed from both th...

Page 317: ...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 2 2 Clutch Testing 2 2 1 Neutral 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 ou...

Page 318: ...lack lead into the Break out Box socket labeled CLUTCH and the red lead into the socket labeled AHEAD E Turn power On to the Processor and take command at any Remote Station with the lever in the Neutral Idle position F The measurement should be 0 VDC and the adjacent LED should not be lit G Position the Control Head lever into the Ahead detent The measurement should be 12 or 24 VDC depending on t...

Page 319: ...wer 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 MM13927 12 Troll Connections Troll On Off Solenoid Figure MM13927 12 Troll Connections Troll On Off Solenoid D Set up the Multimeter to measure DC Volts and connect the black lead to the socket...

Page 320: ...et and the red lead to the red socket labeled TROLL COMMAND as shown in Figure MM13927 13 Troll Connections Proportional 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 blinki...

Page 321: ...14 2 Speed Connections E Turn power On to the Processor and take command at any Remote Station F The voltage measurement should be approximate 0 VDC 2 4 2 2nd Gear Engaged A Leave the Break out Box and Multimeter in the same position as left in Section 2 4 1 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 blink...

Page 322: ...ev E 2 01 13 Page 322 MM13927 Field Service Test Unit Reference Manual 2 5 Parts List ZF Marine Propulsion Systems Miramar Part No Part Name 13927 Service Field Test unit Break out Box MM13927 Technical Manual Multimeter 14000 Test Control Head Dual ...

Page 323: ...323 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS MM9000 Rev C 8 01 13 Page 323 MM9000 ClearCommand User Manual Appendix D 14 Appendix D System Drawings ...

Page 324: ...324 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS ...

Page 325: ...325 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS Page 325 Drawing 12284 ClearCommand All Configuration Twin Screw System Drawing ...

Page 326: ...326 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS ...

Page 327: ...327 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS Page 327 ...

Page 328: ...328 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS ...

Page 329: ...329 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS Page 329 ...

Page 330: ...330 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS ...

Page 331: ...331 EN 3340 758 003a 2014 11 APPENDIX D SYSTEM DRAWINGS Page 331 ...

Page 332: ...5030 Caselle di Selvazzano PD ITALY Phone 39 049 8299 311 Fax 39 049 8299 550 www zf com ZF Padova S r l Via Penghe 48 I 35030 Caselle di Selvazzano PD ITALY Phone 39 049 8299 311 Fax 39 049 8299 550 www zf com EN 3340 758 003a 2014 11 ...

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