ZF MM9000 Installation, Operation And Troubleshooting Manual
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ZF MM9000 Installation, Operation And Troubleshooting Manual

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INSTALLATION, OPERATION
AND TROUBLESHOOTING
MM9000 - CLEAR COMMAND USER MANUAL
MARINE PROPULSION SYSTEMS

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Summary of Contents for ZF MM9000

  • Page 1: Clearcommand User Manual

    INSTALLATION, OPERATION AND TROUBLESHOOTING MM9000 - CLEAR COMMAND USER MANUAL MARINE PROPULSION SYSTEMS...
  • Page 2 Data subject to change without notice. We decline all responsibility for 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENT MM9000 ClearCommand User Manual Table of Contents Table of Contents Installation, Operation and Troubleshooting Manual SW15623.OE ClearCommand User Manual............1 Table of Contents................. 3 List of Figures..................7 List of Tables ..................13 Revision List ..................15 Preface ....................
  • Page 4 TABLE OF CONTENT MM9000 ClearCommand User Manual Table of Contents Installation ..................53 Processor............................53 Control Head(s) ..........................53 Wire Harness Installation ........................53 Hard-Wired Cable ..........................58 Engine Stop Switches........................73 Push-Pull Cable Connections......................74 Set up Procedure ................77 Processor Components Used In Set Up ..................77 Activating Set Up Mode........................80...
  • Page 5 TABLE OF CONTENT MM9000 ClearCommand User Manual Table of Contents Clutch Pressure Interlock ......................132 Station Expander (SE)........................133 9001 Actuator Trolling Valve Control.....................134 Periodic Checks and Maintenance ..........135 Control Heads..........................135 Processor............................135 Power Supply..........................135 Troubleshooting ................137 10.1 General ............................137 10.2 Troubleshooting Questions......................143...
  • Page 6 TABLE OF CONTENT MM9000 ClearCommand User Manual Table of Contents MMC-343 Station Expander User Instructions ..............243 Appendix B - QFA & DVTP..............257 ENG-127 9000 Series Micro/ClearCommand Servo Throttle - Servo Clutch Qualitative Failure Analysis, Design Verification Test Procedure and Periodic Safety Test ......259 ENG-143 9000 Series ClearCommand Throttle - Solenoid Clutch Qualitative Failure Analysis, Design Verification Test Procedure and Periodic Safety Test .........

  • Page 7: List Of Figures

    LIST OF FIGURES MM9000 ClearCommand User Manual List of Figures List of Figures Figure 1-1: Basic 9120 or 9122 ClearCommand System Diagram ................22 Figure 1-2: Basic 9121 ClearCommand System Diagram ..................23 Figure 1-3: Basic 9210 ClearCommand System Diagram ..................24 Figure 1-4: Basic 9211 ClearCommand System Diagram ..................

  • Page 8: List Of Figures

    LIST OF FIGURES MM9000 ClearCommand User Manual List of Figures Figure 4-20: Clutch Cable Heat Shrink in Processor ....................69 Figure 4-21: Clutch Cable Plug Termination Connections..................70 Figure 4-22: Clutch/Troll Cable Heat Shrink in Processor ..................70 Figure 4-23: Clutch Cable Plug Termination Connections..................71 Figure 4-24: Clutch Cable Heat Shrink in Processor ....................

  • Page 9: List Of Figures

    LIST OF FIGURES MM9000 ClearCommand User Manual List of Figures Figure 5-32: Display LED Function C2 Set Up Activated..................97 Figure 5-33: Display LED Function C3 Set Up Activated..................98 Figure 5-34: Display LED Function C4 Set Up Activated..................99 Figure 5-35: Clutch Push-Pull Cable Orientation ....................

  • Page 10: List Of Figures

    LIST OF FIGURES MM9000 ClearCommand User Manual List of Figures Figure 10-13: Example Display Software Revision Level View ................147 Figure 10-14: Display Examples of Remote Stations .................... 149 Figure 10-15: Display Examples of Remote Stations A/D Value................150 Figure 10-16: Display Station A/D’s No Station Transfer Button Depressed............155 Figure 10-17: Example Display Station A/D’s Transfer Button Depressed for Stations 1 - 4 ........
  • Page 11 LIST OF FIGURES MM9000 ClearCommand User Manual 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 ......................
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  • Page 13: List Of Tables

    LIST OF TABLES MM9000 ClearCommand User Manual List of Tables List of Tables Table 4-1: ClearCommand Processor Optional Hard-Wiring Cable List ..............60 Table 4-2: Processor Circuit Board Terminal Strip Color Coded Connections for Remote Stations ......66 Table 4-3: Processor Circuit Board Terminal Strip Color Coded Connections for Serial Communication ....68 Table 4-4: Processor Circuit Board Terminal Strip Color Coded Connections for Tachometer........
  • Page 14 LIST OF TABLES MM9000 ClearCommand User Manual List of Tables Table 10-17: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX)..........181 Table 10-18: Wire Harness- Throttle, Current (MAN, MTU) (p/n 13494-XX)............182 Table 10-19: Wire Harness - Throttle, Voltage (Cummins Plug), (p/n 13565-XX)..........182 Table 10-20: Voltage Throttle Harness Pin-Out (p/n 14148-XX) ................

  • Page 15: Revision List

    Revised per ELR00048 Rev C.7 09/11 Added MMC-343, changes made per ELR00144 Rev C.8 01/13 Changed name to ZF Marine Propulsion Systems Miramar, LLC MM9000 Rev C.8 01/13 Page 15 EN 3340.758.003a - 2014-11...
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  • Page 17: Preface

    Preface IMPORTANT: Keep this manual in a safe place for future reference. It contains essential information about the installation and operation of the ZF Marine Propulsion Systems Miramar control system for your vessel. ClearCommand Processor List The processors for the systems listed below have software which includes several featured options.

  • Page 18: Important Information

    WARNING: Personal Injury could occur if the following steps are not followed 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.
  • Page 19 Organization (SSO). For more information on an SSO in your area, please see Section 13: Appendix C - Sales and Service Information. NOTE: ZF Marine Propulsion Systems Miramar is not liable for any damage incurred if these notices are not followed exactly.
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  • Page 21: Introduction

    INTRODUCTION MM9000 ClearCommand User Manual Introduction Introduction This manual is written to document every possible system option. Your system may not include every available option for single or twin screw reverse reduction gear applications. Only those sections that apply to your specific installation are relevant to your vessel.

  • Page 22: Figure 1-1: Basic 9120 Or 9122 Clearcommand System Diagram

    INTRODUCTION MM9000 ClearCommand User Manual Introduction The 9122 Processor controls the electrical Transmission and Trolling Valve Solenoids for shift and trolling functions, via electric cable. STATION 1 STATION 2 SERIAL COMMUNICATION TACH 1 TACH 1 AHEAD/ASTERN AHEAD/ASTERN TROLL COMMAND TROLL COMMAND...

  • Page 23: Figure 1-2: Basic 9121 Clearcommand System Diagram

    INTRODUCTION MM9000 ClearCommand User Manual Introduction 1.1.2 9121 Processor (Throttle-Servo 2, Shift-Solenoid, Troll-Servo 1) The 9121 System is designed for pleasure and light commercial marine vessels that require remote control of: • mechanically actuated engines • solenoid activated clutches •...

  • Page 24: Figure 1-3: Basic 9210 Clearcommand System Diagram

    INTRODUCTION MM9000 ClearCommand User Manual Introduction 1.1.3 9210 Processor (Throttle-Electronic, Shift-Servo 1) The 9210 System is designed for pleasure and light commercial marine vessels that require remote control of: • electronic engine governors • mechanically actuated clutches The Processor is typically mounted in the engine room area and is connected to the electronic governor with a two-conductor, shielded, electric cable.

  • Page 25: Figure 1-4: Basic 9211 Clearcommand System Diagram

    INTRODUCTION MM9000 ClearCommand User Manual Introduction 1.1.4 9211 Processor (Throttle - Electronic, Shift - Servo 1, Troll - Servo 2) The 9211 System is designed for pleasure and light commercial marine vessels that require remote control of: • electronic engine governors •...

  • Page 26: System Features

    INTRODUCTION MM9000 ClearCommand User Manual Introduction 1.1.5 9221 Processor (Throttle - Electronic, Shift - Solenoid, Troll - Servo 2) The 9221 System is designed for pleasure and light commercial marine vessels that require remote control of: • electronic engine governors •...

  • Page 27: Operation

    OPERATION MM9000 ClearCommand User Manual Operation Operation DC Power On When DC power is turned ON to the Processor: • A short steady tone, followed by an intermittent tone, will sound at all Remote Stations indicating that no station has command.

  • Page 28: Basic Operation

    OPERATION MM9000 ClearCommand User Manual Operation Basic Operation 2.3.1 Normal Operating Mode A The Control Head has three detents; Ahead, Astern and Neutral. B With the Control Head lever positioned in the Neutral (vertical) detent, the Processor will command Neutral and the throttle at Idle revolutions per minute (RPM).

  • Page 29: Start Interlock (If Used)

    OPERATION MM9000 ClearCommand User Manual Operation D Further movement through the selectable 25, 35, 45, or 55 degrees, will increase the clutch pressure to maximum while the throttle remains at Idle. Further movement through the next 40, 30, 20, or 10 degrees will increase throttle to full, except when 45 degrees is selected (where throttle is limited to 75% of full) and 55 degrees is selected (where throttle is limited to 10% of full).

  • Page 30: Station Transfer

    OPERATION MM9000 ClearCommand User Manual Operation Station Transfer WARNING: Personal Injury may result if this message is disregarded. Command can be transferred as follows: A The Station-in-Command’s lever(s) may be left in any position. B Place the Control Head’s lever(s) of the receiving Station in the Neutral/Idle detent position (refer to...

  • Page 31: Warm-Up Mode

    OPERATION MM9000 ClearCommand User Manual Operation Warm-up Mode This feature allows the operator to increase the engine’s RPM, while the Clutch remains in Neutral. Warm-Up Mode is operational only when the Control Head lever is moved in the Ahead direction.

  • Page 32: High/Low Idle

    OPERATION MM9000 ClearCommand User Manual Operation High/Low Idle The Control System provides the input to the engine, so that it may run at the standard Idle speed (typically adjusted at the governor or carburetor), or it can provide a second elevated Idle speed.

  • Page 33: One Lever Mode (Twin Screw)

    OPERATION MM9000 ClearCommand User Manual Operation One Lever Mode (Twin Screw) NOTE: One Lever Operation may be used in Troll Mode or in Non-Troll Mode. NOTE: The Green LED will always be lit while in One Lever Operation, no matter what position the Master Control Head lever is in.

  • Page 34: Figure 2-13: Step B) One Lever Operation Mode

    OPERATION MM9000 ClearCommand User Manual Operation • The Control Head lever which was left in the Ahead detent is now inactive. Figure 2-13: Step B) One Lever Operation 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.

  • Page 35: Engine Synchronization (Twin Screw)

    OPERATION MM9000 ClearCommand User Manual Operation 2.10 Engine Synchronization (Twin Screw) Engine Synchronization must be selected during Set Up to have automatic synchronization. NOTE: The Control System offers two types of synchronization, Active or Equal Throttle. Synchronization is automatic and only operates when the Ahead clutch is engaged, consequently it can be left ON full time.
  • Page 36 OPERATION MM9000 ClearCommand User Manual Operation NOTE: In order for Equal Throttle Synchronization to work properly in Systems with mechanical Throttles, the bends in the push-pull cables must be kept to a minimum. There can be no back-lash in the linkage or cables.

  • Page 37: 2.11 Control System's Configurability

    OPERATION MM9000 ClearCommand User Manual Operation 2.11 Control System’s Configurability The Processor is designed in a way which allows it to be easily configured by the installer to meet the varying needs of a wide variety of vessels. Below you will find a list and a brief description of the groups of these functions.
  • Page 38 This section along with the Basic Clutch Functions Section allows the adjustment of Clutch Solenoid related items: • C5 Shift Solenoid Type - Selects the approximate current levels for the 12 or 24 VDC ZF Hurth Solenoids. • C6 ZF-Hurth Duty Cycle Ahead - Fine tunes the maximum current level to the Ahead Proportional Solenoid.

  • Page 39: 2.12 Audible Tones

    • L1 Troll Valve Function - Selects the proper current range for a particular gear. This Function must be the 3rd function set if ZF Hurth Gears are used. • L2 Troll Minimum Pressure - Adjusts the amount of current at minimum Shaft rotation.
  • Page 40 OPERATION MM9000 ClearCommand User Manual Operation 2.12.2 Throttle (Servo 2) Tones The following Tones are in addition to the Basic Processor Tones. 2.12.2.1 One Long - Two Short Tones Detail information on this tone is in Section 10: Troubleshooting. This tone indicates that the feedback potentiometer signal from Servo 2 (Throttle) has gone out of range.

  • Page 41: 2.13 Push Button Set Up

    OPERATION MM9000 ClearCommand User Manual Operation 2.12.7.2 One Long, Four Short - High Repetitive Rate Tone Detail information on this tone is in the Manual supplied with the 9001 Trolling Actuator. This tone indicates that Trolling Actuator Servo cannot reach the commanded position.

  • Page 42: 2.15 Pluggable Connections

    OPERATION MM9000 ClearCommand User Manual Operation 2.15 Pluggable Connections 2.15.1 Standard Pluggable Processor The standard Processor comes from the factory with five Pigtail Connectors for easy, mistake free pluggable installations. Not all Processors are supplied with all of these pigtails.

  • Page 43: 2.16 Optional Features Operation

    This Manual, as written, is intended for Single and Twin Screw applications only. The Processor has the capability of controlling Triple, Quad and Quint Screw vessels. In order to do so, contact your ZF Marine Propulsion Systems Miramar, LLC representative for the required information and materials.
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  • Page 45: Plan The Installation

    MM9000 ClearCommand User Manual Plan the Installation Plan the Installation NOTE: ZF Marine Propulsion Systems Miramar, LLC recommends that the system be installed in accordance with ABYC, E-11 and P24. System Requirements The first step when installing a System is to carefully plan the installation. This includes finding proper mounting locations for the Processor(s) and Control Heads.
  • Page 46 PLAN THE INSTALLATION MM9000 ClearCommand User Manual Plan the Installation • Do not mount the Processor on the engine, transmission, or in any location that will subject it to excessive vibration. • Do not mount the Processor to the transom when the vessel is equipped with a surface piercing drive system, due to vibration concerns.
  • Page 47 PLAN THE INSTALLATION MM9000 ClearCommand User Manual Plan the Installation 3.1.3.3 Serial Communication Harness The Serial Communication Harness is only required in Twin Screw applications or when an external trolling valve actuator (9001) is utilized. The Harness connects the Port Processor to the Starboard Processor.
  • Page 48 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.
  • Page 49 3.1.9 Clutch Electric Cable Requirements If Clutch Solenoids are hard-wired, (no plugs) to the Processor, the electric cable must meet the following specifications or may be ordered from ZF Marine Propulsion Systems Miramar, LLC: • Two-conductor, red and black, twisted.

  • Page 50: Installer Supplied Tools And Parts

    Processor’s tachometer signal requirement. If a sensor other than one supplied by ZF Marine Propulsion Systems Miramar, LLC is used, it must meet the criteria provided below for each type: 3.1.11.1 AC Coupled Sensors...

  • Page 51: Dc Power Source

    When using ZF Marine Propulsion Systems Miramar, LLC supplied 14 gauge power cable, and in accordance 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).
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  • Page 53: Installation

    INSTALLATION MM9000 ClearCommand User Manual Installation Installation NOTE: Before starting the actual installation of the Control System, make sure you have the correct parts and tools on hand. See Section Section 3: Plan the Installation. Read ALL the instructions pertinent to each part before beginning the installation of the part.

  • Page 54: Figure 4-2: Start Interlock Connections

    INSTALLATION MM9000 ClearCommand User Manual Installation • When connecting the plugs, ensure that the locking mechanisms are depressed and held until the plug is fully connected or disconnected. Refer to Figure 4-1: Harness Plug Keying 4.3.2 Standard Power/Start Interlock Harness The Power Harness has a minimum of two cables (DC Power and Start Interlock) and may have two more optional cables (Clutch Pressure Interlock and External Alarm Circuit).
  • Page 55 INSTALLATION MM9000 ClearCommand User Manual Installation 4.3.3 Standard Control Head Harness Depending on whether a pluggable or hard-wired (not pluggable) Control Head(s) is selected, will determine the procedure for terminating the Harness at the Remote Station. • The first installation procedure (Section Section 4.3.3.1: Control Head Harness with Two Connectors) below is written for the pluggable Control Head.

  • Page 56: Figure 4-3: Twin Screw Serial Harness Connections

    INSTALLATION MM9000 ClearCommand User Manual Installation Secure the Serial Harness at least every 18 in. (45,72 cm). Figure 4-3: Twin Screw Serial Harness Connections 4.3.5 Tach Sensor Harness (required for Active Synchronization) A At the Processors, remove the watertight seals from the Tach Sender pigtail plugs.
  • Page 57 INSTALLATION MM9000 ClearCommand User Manual Installation 4.3.6.2 Clutch Harness NOTE: Ensure Port Processor connects to the Port Solenoid and the Starboard Processor connects to the Starboard Processor. Plug the grey, 12 pin plug into the Clutch pigtail connector at the Processor.

  • Page 58: Hard-Wired Cable

    INSTALLATION MM9000 ClearCommand User Manual Installation Hard-Wired Cable Liquid Tight Connector All cables that enter the Enclosure must go through a Liquid Tight Connector in order to maintain the moisture resistant integrity of the Processor. These connectors must be assembled as shown in Figure 4-4: Liquid Tight Installation...

  • Page 59: Figure 4-6: Standard Circuit Board Hard-Wired Termination Points

    INSTALLATION MM9000 ClearCommand User Manual Installation Refer to Figure 4-6: Standard Circuit Board Hard-Wired Termination Points for specific termination points. (START INTERLOCK) YELLOW (START INTERLOCK) START INTERLOCK BROWN (ALARM -) BLACK (ALARM +) GREEN (CLUTCH PRESSURE -) BLUE POWER (CLUTCH PRESSURE +)

  • Page 60: Figure 4-7: 9120 And 9121 Enclosure Cable Holes

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.3 9000 Series Hard-Wired Connection Locations Table 4-1: ClearCommand Processor Optional Hard-Wiring Cable List ZF Marine Propulsion Systems Miramar, LLC ENGINE CLUTCH TROLL Processor Part No. Electronic Solenoid Solenoid 9120 (Figure 4-7: 9120 and 9121 Enclosure Cable Holes)

  • Page 61: Figure 4-8: 9122 Enclosure Cable Holes

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.3.2 9122 (Clutch/Troll Solenoid) Cable Hole Locations Station 5 Station 3 Station 1 Alarm, Clutch Pressure, and Start Interlock Power Station 4 Station 2 Serial Communication Tachometer 10. Clutch Solenoid 11. Troll Solenoid 12282.3_ART Figure 4-8: 9122 Enclosure Cable Holes MM9000 Rev C.8 01/13...

  • Page 62: Figure 4-9: 9210 And 9211 Enclosure Cable Holes

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.3.3 9210 and 9211 (Throttle Electronic) Cable Hole Locations Station 5 Station 3 Station 1 Alarm, Clutch Pressure, and Start Interlock Power Station 4 Station 2 Serial Communication Tachometer 10. Not Used 11. Not Used Throttle Signal 12282.4_ART...

  • Page 63: Figure 4-10: 9221 Enclosure Cable Holes

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.3.4 9221 (Throttle Electronic and Clutch Solenoid) Cable Hole Locations Station 5 Station 3 Station 1 Alarm, Clutch Pressure, and Start Interlock Power Station 4 Station 2 Serial Communication Tachometer 10. Clutch Solenoids 11. Not Used 12.

  • Page 64: Figure 4-11: 9000 Series Circuit Board Hard-Wired Termination Points

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.4 9000 Series Circuit Board Termination Points On the 9000 Series Processors, in lieu of using Harnesses for engine, clutch, or troll connections the Processors can be ordered with no pigtails installed or the pigtails be removed. The above connections must then be hard-wired directly to the circuit board.

  • Page 65: Figure 4-12: Seven-Conductor Control Head Cable Shield Wire And Heat-Shrink

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.5 Locations 1 - 9 Installation 4.4.5.1 Seven-Conductor Control Head Cable (Locations 1, 2, 3, 6, and 7) Run the seven-conductor cable from the Remote Station to the Processor. Support the cables using clamps or straps not more than 18 inches (0,5m) apart if not contained in a conduit.

  • Page 66: Figure 4-15: Two-Conductor Start Interlock Cable

    INSTALLATION MM9000 ClearCommand User Manual Installation Connect the other station's seven-conductor cables to the appropriate station terminal strips in the same way. Table 4-2: Processor Circuit Board Terminal Strip Color Coded Connections for Remote Stations Conductor Color Processor Termination Left Hand Control Head...

  • Page 67: Figure 4-16: Two-Conductor Power Cable

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.5.3 Power Cable (Location 5) Run the length of two-conductor power cable between the DC Power Source and the Processor. Make the connections at the vessel’s DC Power Source, but do not turn power ON.

  • Page 68: Figure 4-18: Ac Type Tachometer Cable

    INSTALLATION MM9000 ClearCommand User Manual Installation Connect the conductors to the terminal block as listed in Table 4-3: Processor Circuit Board Terminal Strip Color Coded Connections for Serial Communication Table 4-3: Processor Circuit Board Terminal Strip Color Coded Connections for Serial Communication...

  • Page 69: Figure 4-20: Clutch Cable Heat Shrink In Processor

    INSTALLATION MM9000 ClearCommand User Manual Installation Shrink the tubing with a heat gun. Insert the cable ends through the liquid tight connectors and tighten the nuts. Secure the cables internally using a Clamp as shown in Figure 4-13: Clamp Views. Make certain that the drain wire makes contact with the Clamp’s metallic surface.

  • Page 70: Figure 4-21: Clutch Cable Plug Termination Connections

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.6.1.2 Plug Termination Strip back 2 1/4 inches (57,15mm) of PVC jacketing. Figure 4-21: Clutch Cable Plug Termination Connections Slide the boot onto the cable. Strip back 1/4 inch (6,35mm) from the four conductors.

  • Page 71: Figure 4-23: Clutch Cable Plug Termination Connections

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.4.6.2.2 Plug Termination Strip back 2 1/4 inches (57,15mm) of PVC jacketing. Figure 4-23: Clutch Cable Plug Termination Connections Slide the boot onto the cable. Strip back 1/4 inch (6,35mm) from the eight conductors.

  • Page 72: Figure 4-24: Clutch Cable Heat Shrink In Processor

    INSTALLATION MM9000 ClearCommand User Manual Installation 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. 1 inch 4 inches 3/8 inch (101,6mm) (25,4mm)

  • Page 73: Engine Stop Switches

    INSTALLATION MM9000 ClearCommand User Manual Installation Pull back the shield wire and solder to a 2 1/2 inch (63,5mm), 18 AWG, green/yellow wire as shown in Figure 4-26: Engine Shield. Heat Shrink .75 inch (19,1mm) of Cable Shield Cable Solder Wire...

  • Page 74: Push-Pull Cable Connections

    INSTALLATION MM9000 ClearCommand User Manual Installation Push-Pull Cable Connections 4.6.1 Processor A Remove the #10-32 jam nut and the two rubber seals from the end of each push-pull cable that is to connect to the Processor(s) only; discard the seals, but save the nuts.

  • Page 75: Figure 4-29: Throttle Push-Pull Idle Orientation To Selector Lever

    INSTALLATION MM9000 ClearCommand User Manual Installation 4.6.2 Throttle Selector Lever A Ensure that the Throttle push-pull cable and the engine’s throttle lever are in close proximity to one another at Idle. If so, proceed to step C) and if not continue with step B).
  • Page 76 INSTALLATION MM9000 ClearCommand User Manual Installation 4.6.4 Trolling Valve Selector Lever CAUTION: Mis-adjusted Troll Push-Pull Cables can cause damage to the Transmission’s Clutch Pack. Ensure adjustments are made correctly and completely. A Check the trolling valve to see if the push-pull cable anchor brackets have been installed. If the bracket are not on the trolling valve, select from MMC-289 Morse Clutch and Throttle Kit or fabricate brackets as shown in MMC-290 Universal Mounting Kit - Universal Mounting Kit.

  • Page 77: Set Up Procedure

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Set up Procedure The Processor 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.

  • Page 78: Figure 5-2: Processor Shield Push Button And Display Led Locations

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure • The Push Buttons are used to scroll through Function Codes, select Function Codes and set the Values of the Function Codes. (Section 5.1.2: Push Buttons) Figure 5-2: Processor Shield Push Button and Display LED Locations 5.1.1...

  • Page 79: Figure 5-5: Circuit Board Push Buttons

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.1.2 Push Buttons The Processor has four Push Buttons located on the Circuit Board. They are identified by the words LEFT, RIGHT, UP and DOWN silk-screened on the Shield covering the Circuit Board.

  • Page 80: Activating Set Up Mode

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Activating Set Up Mode NOTE: To Escape from the Set Up procedure at any time without saving the changed value to memory, depress the Left Push Button. The Function Code will stop flashing and the Function will be saved with the original Value.
  • Page 81 SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Table 5-1: Function Codes Function Function Name Value Range or Options Code 00 – No Tone Neutral Indication Tone 01 – Tone upon engaging Neutral Detent 02 – Tone upon shifting to Neutral THROTTLE FUNCTIONS (Section 5.6.2: Throttle Functions)
  • Page 82 05 - Inverse, No Current when at Lock-up. Preset for ZF6000, 1900 or 2500, 24VDC Systems. 06 - Preset for 12VDC ZF Hurth Systems. 07 - Preset for 24VDC ZF Hurth Systems20 – Cable Fully Retracted at Lock-up. 21 – Cable Fully Extended at Lock-up. 01.0 to 80.0% Troll Minimum Pressure Will always be at least 10% below Maximum.

  • Page 83: Table 5-2: Processors Function Code Defaults

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Table 5-1: Function Codes Function Function Name Value Range or Options Code Input Voltage (+/- 0.5VDC) Tachometer Sensor Frequency Station No.1 Lever A/D Station No.2 Lever A/D Station No.3 Lever A/D Diagnostic Station No.4 Lever A/D...
  • Page 84 SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Table 5-2: Processors Function Code Defaults Default Values Function Code 9120 9121 9122 9210 9211 9221 CLUTCH FUNCTIONS 01.0 01.0 01.0 01.0 01.0 01.0 TROLL FUNCTIONS 70.0 70.0 70.0 70.0 70.0 90.0...

  • Page 85: Field Service Test Unit (Break-Out Box) And Multimeter Use

    Service Test Unit (Break-out Box). • To aid in adjusting Table 5-2: Processors Function Code Defaults list of Processor signals, ZF Marine Propulsion Systems Miramar, LLC recommends the use of ZF Marine Propulsion Systems Miramar, LLC Field Service Test Unit (P/N 13927) (Break-out Box) and a calibrated Multimeter.

  • Page 86: System Programming And Adjustments

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure • For Functions E1, E2, E3, E4, E6, and L4 connect the 8-Pin connector of the Service Field Test Unit into the Processor Throttle connector and to the Throttle Wire Harness.

  • Page 87: Figure 5-11: Display Led Function A0 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.6.1 Processor Functions 5.6.1.1 Function Code A0 – Processor Identification In applications where there is more than one screw, the system must know which Processor is where. Every Processor must have its own unique identifying number. At no time can two or more Processors be identified by the same Processor Identification Number.

  • Page 88: Figure 5-12: Display Led Function A1 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 05 Quint Screw NOTE: Twin screw or more applications require Function Code A1 Values changed on all Processors prior to changing the Value of Function Code A0. To change the Value (Refer to Sections Section 5.2: Activating Set Up Mode and Section 5.3: Storing Values To Memory): Scroll to Function Code A1.

  • Page 89: Figure 5-14: Display Led Function A3 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.6.1.4 Function Code A3 – SE (Station Expander)- Optional NOTE: This Manual does not go into detail on the Station Expander installation and adjustments. For further information on the Station Expander, see MMC-343 Station Expander User Instructions.

  • Page 90: Figure 5-16: Display Led Function E5 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.6.2 Throttle Functions 5.6.2.1 Throttle Basic Functions 5.6.2.1.1 Function Code E5 – Throttle Pause Following Shift The available Values for this Function are 00.0 seconds to 05.0 seconds. The Default Value is 00.5 seconds.

  • Page 91: Function Code E1 - Throttle In Neutral

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Function Code E1 – Throttle in Neutral This Function allows the engine RPM at Neutral to be adjusted independently of the RPM at Idle Ahead and Astern. The available Values for this Function are 00.0 to 25.0 percent of the Throttle Range.

  • Page 92: Figure 5-20: Display Led Function E7 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Activate Set Up Mode. Scroll Up or Down to the desired Value. Store the Value to memory. Figure 5-20: Display LED Function E7 Set Up Activated 5.7.0.1 Throttle Servo Functions This section along with Section 5.6.2.1: Throttle Basic Functions allows the adjustment of Throttle Servo related items: 5.7.0.1.1...

  • Page 93: Figure 5-22: Example: Throttle Push-Pull Cable Fully Retracted Position For Idle

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Scroll to Function Code E0. Activate Set Up Mode. Scroll Up or Down until the Value 21 is displayed. Figure 5-22: Example: Throttle Push-Pull Cable Fully Retracted Position for Idle Store the Value to memory. (The Throttle Push-Pull cable should drive to the fully retracted position.)

  • Page 94: Figure 5-25: Throttle Push-Pull Cable Full Throttle Position

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.0.1.3 Function Code E3 – Throttle Maximum This Function adjusts the position of the Throttle Push-Pull cable at Full Throttle. The available Values for this Function are 10.0% to 100.0%. The Default Value is 33.0%. This value will always be 10% or more above E2 Throttle Minimum.

  • Page 95: Figure 5-27: Display Led Function E0 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.0.2 Throttle Electronic Functions 5.7.0.2.1 Function Code E0 – Engine Throttle Profile This Function selects the appropriate Throttle Signal range for various engines The available Values for this Function are listed below: Caterpillar (PWM) (8 to 92%) Cummins Centry (Voltage) (0.9 to 4.5 VDC)

  • Page 96: Figure 5-29: Display Led Function E3 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.0.2.3 Function Code E3 – Throttle Maximum This Function allows the throttle signal at Full to be fine tuned from that provided by the E0 Throttle Profile. The available Values for this Function are 10.0% to 100.0%. The Value entered is the percentage of the throttle’s range from Idle to Full.

  • Page 97: Figure 5-31: Display Led Function C1 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.1.1.2 Function Code C1 – Clutch Interlock Delay NOTE: This adjustment is to be used only if the optional Clutch Pressure Switch is being used with this application. This Function works together with Function Code C0 – Clutch Pressure Interlock. Refer to Sections Section 8.2: Clutch Pressure Interlock for operational details.

  • Page 98: Figure 5-33: Display Led Function C3 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure NOTE: If C2 Proportional Pause is set to 02 Fixed Neutral Delay Enabled, Function C3 Proportional Pause Time will set the Fixed Neutral Delay duration. 5.7.1.1.4 Function Code C3 – Proportional Pause Time...

  • Page 99: Figure 5-34: Display Led Function C4 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure This is because much more speed is obtainable in Ahead, then Astern. Consequently, more time is required to slow down from Ahead as compared to Astern. NOTE: When the Controls are installed on a vessel such as a double ended Ferry or the Controls are being used to control a thruster, the proportional pause should be the same in Ahead as Astern or port and starboard in the case of a thruster.

  • Page 100: Figure 5-35: Clutch Push-Pull Cable Orientation

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Figure 5-35: Clutch Push-Pull Cable Orientation Check the Shift 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.

  • Page 101: Figure 5-37: Clutch Push-Pull Cable Ahead Position

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.1.2.2 Function Code C6 – Clutch Ahead Travel This function adjusts the amount of Clutch push-pull cable travel in both the Ahead and the Astern directions. The available Values are 00.0 to 100.0 percent of the maximum available travel from Neutral to Ahead.

  • Page 102: Figure 5-39: Clutch Push-Pull Cable Astern Position

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.1.2.3 Function Code C7 – Clutch Astern Travel This function is only required when the distance from Neutral to Astern differs from Neutral to Ahead. This Function Code allows the independent adjustment of Astern travel. Otherwise, the Value selected in Function Code C6 is automatically entered for Function Code C7.

  • Page 103: Figure 5-41: Display Led Function C5 Set Up Activated

    01 - ZF-Hurth Proportional Solenoids with 12V Power 02 - ZF-Hurth Proportional Solenoids with 24V Power The default value of 00 is used with most types of solenoids, with the exception of the ZF- Hurth Gears with proportional Ahead and Astern solenoids.

  • Page 104: Figure 5-43: Display Led Function C7 Set Up Activated

    MM9000 ClearCommand User Manual Set Up Procedure 5.7.1.3.3 Function Code C7 – ZF-Hurth Duty Cycle Astern This function limits the amount of current delivered to the Astern Proportional Solenoid. Failure to limit the current may result in permanent damage to the solenoid.

  • Page 105: Figure 5-44: Display Led Function L0 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure The available Values are: 00 No Troll (Default Value) 01 20 Degrees – Type 1 02 35 Degrees – Type 2 03 45 Degrees – Type 3 (Throttle limited to 75%).

  • Page 106: Figure 5-49: Display Led Function L1 Set Up Activated

    Systems. 05 - Inverse, No Current when at Lock-up. Preset for ZF670, 1900 or 2500, 24VDC Systems. 06 - Preset for 12VDC ZF Hurth Systems. 07 - Preset for 24VDC ZF Hurth Systems. The default value is 00. To 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):...

  • Page 107: Figure 5-50: Display Led Function L1 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Store the Value to memory Figure 5-50: Display LED Function L1 Set Up Activated 5.7.2.1.4 Function Code L2 – Solenoid Troll Minimum Pressure This Section along with the Basic Troll Command Functions allows the adjustment of the Processor’s Integrated Solenoid Troll command.

  • Page 108: Figure 5-53: Display Led Solenoid Function L3 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.2.1.6 Function Code L3 – Solenoid Troll Maximum Pressure This Section along with the Basic Troll Command Functions allows the adjustment of the Processor’s Solenoid Integrated Troll command. Function L3 fine tunes the amount of current delivered to the proportional solenoid, so that clutch pressure is at the maximum point prior to Clutch Plate lock-up.

  • Page 109: Figure 5-55: Display Led Solenoid Function L4 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.2.1.8 Function Code L4 – Solenoid Troll Throttle Limit This Section along with the Basic Troll Command Functions allows the adjustment of the Processor’s Solenoid Troll command. Function L4 allows an increase in throttle above Idle while commanding clutch slippage. The throttle increases linearly to the Value set while commanding Troll Minimum to Troll Maximum.

  • Page 110: Figure 5-56: Display Led Function L6 Set Up Activated

    SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure 5.7.2.1.10 Function Code L6 – Solenoid Troll Pulse Percentage This Section along with the Basic Troll Command Functions allows the adjustment of the Processor’s Solenoid Troll command. Function Code L6 selects the percentage of available Troll signal when first engaging the Clutch while in Troll.

  • Page 111: Table 5-3: Solenoid Error Status Enable

    Function Code H1 – Return to Factory Defaults This Function may be used during troubleshooting. (Do not make any adjustments to this Function Code, unless directed to do so by ZF Marine Propulsion Systems Miramar, LLC Service or Engineering Departments).
  • Page 112 SETUP PROCEDURES MM9000 ClearCommand User Manual Set Up Procedure Table 5-3: Solenoid Error Status Enable Ahead Astern Neutral Troll Command Troll On/Off Value MM9000 Rev C.8 01/13 Page 112 EN 3340.758.003a - 2014-11...

  • Page 113: Dock Trials

    DOCK TRIALS MM9000 ClearCommand User Manual Dock Trials Dock Trials WARNING: It is imperative that the information provided in the previous Sections has been read and followed precisely, prior to attempting a Dock Trial. CAUTION: With I/O or Outboard applications, do not attempt to shift into or out of gear with engines stopped.

  • Page 114: High Idle

    DOCK TRIALS MM9000 ClearCommand User Manual Dock Trials High Idle A Place the Station in command into Warm-up Mode. B Adjust Function Code E6 to the desired engine RPM, as described in Section Section 5.6.2.1.2: Function Code E6 – High Idle.

  • Page 115: 6.10 Trolling Valve

    DOCK TRIALS MM9000 ClearCommand User Manual Dock Trials Throttle Pause Following Solenoid Shift NOTE: A Test Control Head and a stop-watch are recommended to determine the correct setting for the Throttle Pause. If a Test Control Head is not available, a second person may be needed.

  • Page 116: Table 6-2: Shaft Rpm At Idle

    DOCK TRIALS MM9000 ClearCommand User Manual Dock Trials Depress the Transfer Button until the red LED begins blinking rapidly (approximately 2 seconds). Scroll to Function Code L2 (Troll Minimum Pressure) and activate Set Up Mode. Scroll Up or Down until the Push-pull cable aligns with the troll lever.

  • Page 117: Sea Trials

    Sea Trial. If any of the following tests fail, discontinue the Sea Trial immediately and return to the dock. Consult Section Troubleshooting or a ZF Facility prior to resuming the Sea Trial. NOTE: On twin screw applications, the following tests must be performed on both sides. During the course of the Dock Trial and Sea Trials, fill out the Trial Report.
  • Page 118 SEA TRIALS MM9000 ClearCommand User Manual Sea Trial 7.3.2 Neutral Delay [C201] • The Throttle position drops to Idle. • The Transmission shifts to Neutral. • The Control System pauses at this position until the delay has timed out. •...

  • Page 119: Synchronization Test (Twin Screw Only)

    SEA TRIALS MM9000 ClearCommand User Manual Sea Trial 7.3.5 Testing The Proportional Pause CAUTION: It is critical that the Proportional Pause is tested as outlined below to ensure that it was properly programmed. Failure to do so could cause damage to the transmission.

  • Page 120: Table 7-1: Shaft Rpm At Idle

    SEA TRIALS MM9000 ClearCommand User Manual Sea Trial H Move both Control Head levers side by side to 100% of the Throttle range. Check the engine tachometers to see if they are within 1% of one another. While synchronized, if the tachometers have a greater than 1% percent difference at any engine RPM, or if they appear to be continually “hunting”...

  • Page 121: Table 7-2: Troll Valve Adjustments

    Gears. The actual amount of current required for satisfactory troll operation may differ from the preset Values. Table 7-2: Troll Valve Adjustments provides typical current requirements for some of the ZF Gears. As stated previously, the actual current required to provide satisfactory operation may differ slightly from those listed.
  • Page 122 SEA TRIALS MM9000 ClearCommand User Manual Sea Trial 7.4.4.1 Enabling Troll Press and hold the Transfer Button for two seconds with the Control Head lever in the Neutral detent • The Control Head’s red LED should begin blinking rapidly, indicating that troll is enabled.
  • Page 123 7.4.7 Integrated ZF-Hurth Solenoid Trolling NOTE: It is strongly recommended that the Field Service Test Unit (P/N 1400) is utilized when adjusting the ZF- Hurth Solenoid. 7.4.7.1 Enabling ZF-Hurth Troll Ensure Function Code C5 (Shift Solenoid Type) value is set to 01 or 02 (refer to Section Section 5.7.1.3.1: Function Code C5 –...

  • Page 124: Sea Trial Report

    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: 9000 Series Sea Trial Report

    The purpose of this Sea Trial Report is to provide a convenient checklist and record of installation, dock trial set up, and sea trial performance of the ZF Marine Propulsion Systems Miramar 9000 Series Propulsion Control System. Please enter ALL information. We recommend a copy of this completed form remain aboard the vessel, and require that you fax a copy to ZF Marine Propulsion Systems Miramar at 425-493-1569.

  • Page 126: Table F-226-3: Power Supply

    SEA TRIAL REPORT F-226 9000 Series Sea Trial Report Table F-226-2: Processor Information Processor Information Port Stbd Sta. 1 Sta. 2 Sta. 1 Sta. 2 Sta. 3 Sta. 4 Sta. 3 Sta. 4 What is the length of the Control Head Harness? Sta.

  • Page 127: Table F-226-6: Sea Trials

    SEA TRIAL REPORT F-226 9000 Series Sea Trial Report Table F-226-6: Sea Trials Processor Information Port Stbd Do the Dual Control Head levers match position and RPM throughout the speed range? Is Synchronization operational? Table F-226-7: Record during Sea Trial Processor Information Port Stbd...
  • Page 128 Clutch Pressure Interlock Clutch Interlock Delay Proportional Pause Proportional Pause Time Proportional Pause Ratio Shift Solenoid Type OR Clutch Servo Direction ZF-Hurth Duty Cycle Ahead OR Clutch Ahead ZF-Hurth Duty Cycle Astern OR Clutch Astern Fixed Neutral Delay TROLL FUNCTIONS Port Stbd...
  • Page 129 Date: Company: Contact info: MAIL COMPLETED COPY TO: ZF Marine Propulsion Systems Miramar, LLC, 12125 Harbour Reach Drive, Suite B, Mukilteo, WA 98275 OR FAX TO: 425-493-1569 ATTN: Service Department F-226 Rev A.1 02/11 Page 129 EN 3340.758.003a - 2014-11...
  • Page 130 SEA TRIAL REPORT EN 3340.758.003a - 2014-11...

  • Page 131: Control Options

    CONTROL OPTIONS MM9000 ClearCommand User Manual Control Options Control Options External Alarm Capability CAUTION: The Processor’s Alarm circuit is limited to a maximum current of 0.5 Amperes and a maximum voltage of 100 Volts DC. Exceeding these limits will permanently damage the Alarm circuit.

  • Page 132: Clutch Pressure Interlock

    CONTROL OPTIONS MM9000 ClearCommand User Manual Control Options • Since the External Status Indication Circuit is activated on a loss of power to the Processor, an On/Off Switch is strongly recommended. • Figure 8-1: External Alarm Connections Processor Hard-Wired Example and Figure 8-2: External Alarm Connections Processor Hard-Wired Example are an example of a suitable circuit, but not necessarily the only circuit acceptable.

  • Page 133: Figure 8-3: Clutch Pressure Switch With Processor Harness Diagram

    CONTROL OPTIONS MM9000 ClearCommand User Manual Control Options To External Status Indication Circuit Hydraulic Line Processor Pressure Switch Shuttle Valve Power Pigtail Power Wire To Processor Harness DC Power Source To Starter Solenoid Ahead Astern Clutch Clutch Pack Pack 15319.1_ART...

  • Page 134: Station Expander (Se)

    CONTROL OPTIONS MM9000 ClearCommand User Manual Control Options Station Expander (SE) The Processor allows up to five Remote Stations. The SE allows up to an additional four Remote Stations for a total of nine Stations. The SE and Processor communicate via the Serial Communication cable. Control Heads connected to the SE offer all of the functionality of a standard Remote Station.

  • Page 135: Periodic Checks And Maintenance

    PERIODIC CHECK AND MAINTENANCE MM9000 ClearCommand User Manual Periodic Checks & Maintenance Periodic Checks and Maintenance The items listed below should be checked on an annual basis or less, when noted: Control Heads • Check the terminal strip for signs of corrosion or a loose connection.

  • Page 136: Table 9-1: Fully Charged Battery

    PERIODIC CHECK AND MAINTENANCE MM9000 ClearCommand User Manual Periodic Checks & Maintenance • Check the voltage of the battery. The battery must have a chance to “rest” (no charging and no load for a couple of hours) prior to testing. The following table represents a fully charged...

  • Page 137: 10 Troubleshooting

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10 Troubleshooting 10.1 General The ClearCommand Control System consists of one Processor per engine, typically mounted in the engine room, and one to five Control Heads located at the vessel’s Remote Stations. In the event that a malfunction occurs, review the appropriate Processor System Diagram and the descriptions in Section 10.1.1: Control Systems Examples.

  • Page 138: Figure 10-2: 9121 Basic Twin Screw, Two Station Diagram

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.1.1.2 9121 (Throttle Servo 2, Shift Solenoid, Troll Servo 1) Processor The 9121 Processor is designed to precisely control speed, direction, and trolling valve on vessels equipped with mechanical Throttle and Trolling Valve, and Solenoid Clutch Selectors.

  • Page 139: Figure 10-3: 9210 Basic Twin Screw, Two Station Diagram

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.1.1.3 9210 (Throttle Electronic, Shift Servo 1) Processor The 9210 Processor is designed to precisely control speed and direction on vessels equipped with electronic Throttle, and mechanical Clutch Selectors. STATION 1 STATION 2 SERIAL COMMUNICATION...

  • Page 140: Figure 10-4: 9211 Basic Twin Screw, Two Station Diagram

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.1.1.4 9211 (Throttle Electronic, Shift Servo 1, Troll Servo 2) Processor The 9211 Processor is designed to precisely control speed, direction, and trolling valve on vessels equipped with electronic Throttle, and mechanical Clutch and Troll Selectors.

  • Page 141: Figure 10-5: 9221 Basic Twin Screw, Two Station Diagram

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.1.1.5 9221 (Throttle Electronic, Clutch Solenoid, Troll Servo 2) Processor The 9221 Processor is designed to precisely control speed, direction, and trolling valve on vessels equipped with electronic Throttle, solenoid Clutch selection, and mechanical Troll selector.

  • Page 142: Table 10-1: Clearcommand Processor Push-Pull Reference

    The function of the Electrical Cables and Harnesses are to move electrical information from one point to another. The ZF Marine Propulsion Systems Miramar, LLC’ System has electrical cables and/or pluggable Harnesses. These Harnesses may have plugs on one end or both, depending on its purpose.

  • Page 143: Troubleshooting Questions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.2 Troubleshooting Questions Prior to lifting a tool or stepping on board the vessel, many problems can be resolved by asking the customer the following basic questions: A Is the System installed on a Single, Twin or Multiple Screw vessel? •...

  • Page 144: Troubleshooting Problem Resolution

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting • Lit Steady: When the red LED is Lit Steady, this indicates that the Station is in command and in Normal operative mode. • Not Lit: When the red LED is Not Lit, that Station is not in command, or there is no power to the Control System.

  • Page 145: Troubleshooting Diagnostic Menu

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.3.3 Component Condition 10.3.3.1 Control Heads Inspect for any signs of corrosion due to water incursion. If hard-wired, ensure that all the fork connectors are properly secured to the terminal. Verify all wires are fully crimped and do not pull loose.

  • Page 146: Figure 10-6: Display Function Code List

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting B Depress the Up or Down Push Button to activate the Function Code List. The characters A001 will be shown on the Display like Figure 10-6: Display Function Code List Figure 10-6: Display Function Code List C Depress the Up or Down Push Button repeatedly until H000 is displayed like Figure 10-7: Display Troubleshooting Function.

  • Page 147: Figure 10-11: Example Display Control Head Lever Current Positions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting show all five Stations with the lever positioned at the Neutral/Idle position. This will be covered in further detail later. Figure 10-11: Example Display Control Head Lever Current Positions TATION TATION TATION A/D C...

  • Page 148: Troubleshooting Audible Tones

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.5 Troubleshooting Audible Tones As mentioned previously, there are various tones emitted from the Control Head if an error were to occur. 10.5.1 Basic Control System Tones These basic tones are as follows: 10.5.1.1 Slow Repetitive Tone The Slow Repetitive Tone, also referred to as the “Initialization Tone”...

  • Page 149: Figure 10-14: Display Examples Of Remote Stations

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.5.1.2 One Long - Three Short Tones This tone indicates that there is an invalid command signal at the Station-in-Command. The Processor expects a DC voltage, representative of the Control Head’s present lever position. This voltage is referred to as the “Command Signal”.

  • Page 150: Figure 10-15: Display Examples Of Remote Stations A/D Value

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting appropriate A/D (Analog/Digital) value for the present position of the Control Head’s lever will be shown, as in the examples below: Figure 10-15: Display Examples of Remote Stations A/D Value TATION TATION TATION EUTRAL...
  • Page 151 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.5.1.3 Steady Tone The Steady Tone is an indication to the operator that something has gone wrong within the Control System. The Steady Tone will typically be accompanied by an Error Message on the Processor’s Display.
  • Page 152 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.5.2.2 One Long, One Short - High Repetitive Rate Tones This tone is also referred to as a Jam Tone. When sounded, Servo 1 is unable to reach the commanded position. In most cases when a Jam Tone is encountered, it can be cleared by moving the Control Head lever back to the point prior to where the tone was first encountered.
  • Page 153 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.5.3.2 One Long, Two Short - High Repetitive Rate Tones This tone is also referred to as a Jam Tone. When sounded, Servo 2 is unable to reach the commanded position. In most cases when a Jam Tone is encountered, it can be cleared by moving the Control Head lever back to the point prior to where the tone was first encountered.

  • Page 154: Troubleshooting Station Transfer

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.6 Troubleshooting Station Transfer In order to transfer command from one Remote Station to another, the following must occur: • There must be a valid “Command Signal” at the Station being transferred to. •...

  • Page 155: Figure 10-16: Display Station A/D's No Station Transfer Button Depressed

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Example 2 Reference Voltage4.80 VDC1023 A/D Counts Command Voltage2.35 VDC501 A/D Counts As you can see by the examples, even though the Command Voltages are different between Examples 1 and 2, the resulting A/D counts, are the same because of the different Reference Voltages.

  • Page 156: Troubleshooting Stuck Transfer Button

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.7 Troubleshooting Stuck Transfer Button The Transfer Button is a normally open, momentary switch. The only time the switch should close is when it is depressed to take command or when entering or departing various other functions. In the event that the Transfer Button became stuck in the closed position, the following will occur: •...

  • Page 157: Table 10-6: Basic Control System Error Codes

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-5: Troll Solenoid Control System Error Codes Error Title Description Troll Command Open The Troll Proportional Solenoid should be drawing current but is not. 10.8.3 Basic Control System Error Codes Table 10-6: Basic Control System Error Codes...
  • Page 158 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-6: Basic Control System Error Codes Error Title Description Station No.8 Station No.8 Control Head’s lever position is out of range. Faulted Low The input appears to be too low. Station No.9 Station No.9 Control Head’s lever position is out of range.

  • Page 159: Table 10-7: Servo 1 Error Codes

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-6: Basic Control System Error Codes Error Title Description Comm. Error Time-out Communication with System 1 has been too long without a Refresh message. System 1 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.

  • Page 160: Basic Problem Causes And Solutions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.9 Basic Problem Causes And Solutions The following table lists the various Error Codes and provides possible causes and solutions. Error Codes appearing on the Port side Processor’s Display LED are port side errors and vice versa. The Causes and Solutions provided are the most likely, but are not the only possible causes for the Errors Codes listed.
  • Page 161 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.7 Control Head is defective. Replace Station No.7 Control Head. No continuity between pin 5’s of the Control Head Ensure that the red conductor is properly crimped Harness connectors.
  • Page 162 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.4 Control Head is defective. Replace Station No.4 Control Head. Ensure that the green conductor is properly No continuity between pin 6’s of the Control Head crimped to pin 6 at both connectors and there is Harness connectors.
  • Page 163 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.10 Control Head is defective. Replace Station No.10 Control Head. Ensure that the green conductor is properly No continuity between pin 6’s of the Control Head crimped to pin 6 at both connectors and there is Harness connectors.
  • Page 164 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.4 transfer button was held down for Clear the Error Code from memory. 15 seconds or longer. The Station No.4 Control Head transfer button is Replace the Control Head.
  • Page 165 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.7 transfer button was held down for Clear the Error Code from memory. 15 seconds or longer. The Station No.7 Control Head transfer button is Replace the Control Head.
  • Page 166 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Station No.10 transfer button was held down for Clear the Error Code from memory. 15 seconds or longer. The Station No.10 Control Head transfer button is Replace the Control Head.
  • Page 167 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions Reposition the Processor(s) so that the Serial The Serial Harness is in excess of 120 feet (37m). Harness is less than 120 feet (37m).
  • Page 168 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-9: Basic Control System Problem Causes and Solutions Error Causes Solutions The Serial Harness is not connected to the SE. Connect the Serial Harness to the SE. The Serial Harness is not connected to the Processor Connect the Serial Harness to the Processor reporting the fault.

  • Page 169: Table 10-10: Servo 2 Throttle Problem Causes And Solutions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.9.2 Servo 1 Clutch Problem Causes and Solutions Table 10-10: Servo 2 Throttle Problem Causes and Solutions Error Causes Solutions Excessive Clutch Push-Pull cable travel. Readjust Function Code C6 and or C7. Contact a certified Marine Transmission The load on the Push-Pull cable exceeds 40 Lbs.

  • Page 170: Table 10-12: Servo 2 Troll Problem Causes And Solutions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-11: Servo 1 Clutch Problem Causes and Solutions Error Causes Solutions The Troll Servo’s feedback potentiometer is out of Replace the Processor or calibrate the calibration. potentiometer. The Troll Servo’s feedback potentiometer is Plug the feedback potentiometer’s brown plug...

  • Page 171: Table 10-13: Servo 2 Troll Problem Causes And Solutions

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.9.5 Servo 2 Troll Problem Causes and Solutions Table 10-13: Servo 2 Troll Problem Causes and Solutions Error Causes Solutions Excessive Troll Push-Pull cable travel. Readjust Function Code L3 or L3. Contact a certified engine technician to determine The load on the Push-Pull cable exceeds 40 Lbs.

  • Page 172: 10.10 Problems Without Error Codes

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.10 Problems Without Error Codes In addition to the Error Codes listed above, some problems may not necessarily generate Error Codes. The following give some examples where the Processor may not detect a fault, though the operation may not be perfect: 10.10.1 Basic Control System Problems Without Error Codes...
  • Page 173 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting SYMPTOM: The engine begins to turn-over while starting and then stops. A slow repetitive tone is heard from all Remote Stations. Cause Remedy The voltage available at the Processor has Supply power to the Processor from a battery other that the dropped too low, due to the starter’s...
  • Page 174 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Cause Remedy Refer to Command Signal testing in Section 10.6.1: Command Signal and Section 10.6.2: A to D Counts. If variations of the A/D Erratic Command Signal. counts occur, connect the Control Head to another Station (if available) on the Processor.

  • Page 175: 10.11 Synchronization Troubleshooting

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Cause Remedy Decide whether High Idle is required or not. If not required, set Function Code E6 High Idle is the value of E6 to 00.0. If the High Idle feature is required, press programmed to a value other than 00.0.
  • Page 176 TROUBLESHOOTING 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. Cause Remedy The throttle travel from Idle to Full is set Scroll to Function Codes E2 and E3 on both Processors and differently on the Port and Starboard compare the Values.
  • Page 177 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting SYMPTOM: Will not synchronize. Cause Remedy 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. Synchronization is Disabled If synch is disabled, the green LED will light as long as the button is pressed.
  • Page 178 TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.11.2.4 Electronic Throttle - Equal Throttle Synch Problem Causes and Solutions SYMPTOM: The green LED is lit solid, though the Engine RPM’s differ by a significant amount. Cause Remedy Function Code E7 is set to 00 and the...

  • Page 179: 10.12 Troubleshooting Wire Harnesses

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.12 Troubleshooting Wire Harnesses The following Sections list the various Harnesses manufactured for use with the Processor. These tables are invaluable when troubleshooting a suspected interface problem or when manufacturing your own Harnesses. 10.12.1 Basic Control System Harnesses 10.12.1.1 Serial Wire Harnesses...

  • Page 180: Table 10-15: Wire Harness - Serial Communication Multi-Screw (P/N 15544-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-15: Wire Harness - Serial Communication Multi-Screw (p/n 15544-XX) Termination A Termination B MM9000 Rev C.8 01/13 Page 180 EN 3340.758.003a - 2014-11...

  • Page 181: Table 10-16: Wire Harness - Serial Communication / Cantrak (P/N 70422-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-16: Wire Harness - Serial Communication / CANtrak (p/n 70422-XX) Termination A Termination B 10.12.1.2 Throttle Wire Harnesses Table 10-17: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX) Termination A Termination B MM9000 Rev C.8 01/13...

  • Page 182: Table 10-18: Wire Harness- Throttle, Current (Man, Mtu) (P/N 13494-Xx)

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

  • Page 183: Table 10-20: Voltage Throttle Harness Pin-Out (P/N 14148-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13 Page 183...

  • Page 184: Table 10-22: Voltage Throttle Harness Pin-Out (P/N 71262-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13 Page 184 EN 3340.758.003a - 2014-11...

  • Page 185: Table 10-24: Wire Harness - Throttle Current W/ Mag Pickup, Man (Non-Common Rail) (P/N 14363-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13 Page 185 EN 3340.758.003a - 2014-11...

  • Page 186: Table 10-25: Wire Harness - Clutch, Ahead, Astern (P/N 15719-Xx)

    TROUBLESHOOTING 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 Table 10-26: Wire Harness - Ahead / Astern Troll on/off Command (p/n 15725-XX) Termination A Termination B MM9000 Rev C.8 01/13...

  • Page 187: Table 10-27: Wire Harness - Clutch With Troll Command (P/N 15732-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-27: Wire Harness - Clutch with Troll Command (p/n 15732-XX) Termination A Termination B MM9000 Rev C.8 01/13 Page 187 EN 3340.758.003a - 2014-11...

  • Page 188: Table 10-28: Wire Harness- Clutch, Ahead, Astern, Troll Command, Troll On-Off (P/N 70390-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13 Page 188 EN 3340.758.003a - 2014-11...

  • Page 189: Table 10-29: Wire Harness- Clutch, Ahead, Astern, Zff Transmission (P/N 70673-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-29: Wire Harness- Clutch, Ahead, Astern, ZFF Transmission (p/n 70673-XX) Termination A Termination B 10.12.1.4 Power Wire Harnesses Table 10-30: Power, Start Interlock Harness Pin-Out (p/n 13756-XX) Termination A Termination B MM9000 Rev C.8 01/13 Page 189 EN 3340.758.003a - 2014-11...

  • Page 190: Table 10-31: Wire Harness - Power, Si & Clutch Pressure Switch (P/N 13552-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-31: Wire Harness - Power, SI & Clutch Pressure Switch (p/n 13552-XX) Termination A Termination B Table 10-32: Wire Harness - Power, SI, Clutch Pressure Switch & Alarm (p/n 13631-XX) Termination A Termination B MM9000 Rev C.8 01/13...

  • Page 191: Table 10-33: Wire Harness- Power Use W/Existing St Intlk Only (P/N 15023-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting Table 10-33: Wire Harness- Power Use W/existing St Intlk Only (p/n 15023-XX) Termination A Termination B 10.12.1.5 Control Head Wire Harnesses Table 10-34: Wire Harness - Control Head One Connector (p/n 13557-XX) Termination A Termination B MM9000 Rev C.8 01/13...

  • Page 192: Table 10-35: Wire Harness - Control Head Two Connectors (P/N 14261-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13...

  • Page 193: 10.13 Processor Pigtails

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.13 Processor Pigtails The number and types of Pigtails used varies with the different Processors and their configurations. The basic 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.

  • Page 194: Table 10-37: Wire Harness - Throttle, Processor Lead (P/N 15703-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.13.1.2 Throttle Wire Harnesses Processor Pigtails Table 10-37: Wire Harness - Throttle, Processor Lead (p/n 15703-XX) Termination A Termination B 10.13.1.3 Clutch Wire Harnesses Processor Pigtails Table 10-38: Wire Harness - Solenoid Clutches, Processor Lead (p/n 15701-XX)

  • Page 195: Table 10-39: Power, Start Interlock, Clutch Oil Pressure Switch, And Alarm Pigtail Pin-Out (P/N 15710-Xx)

    TROUBLESHOOTING 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 MM9000 Rev C.8 01/13 Page 195 EN 3340.758.003a - 2014-11...

  • Page 196: Table 10-40: Wire Harness - Control Head, Processor Lead (P/N 15706-Xx)

    TROUBLESHOOTING MM9000 ClearCommand User Manual Troubleshooting 10.13.1.5 Control Head Wire Harnesses Processor Pigtails Table 10-40: Wire Harness - Control Head, Processor Lead (p/n 15706-XX) Termination A Termination B 10.13.1.6 Mag Pickup Wire Harnesses Processor Pigtails Table 10-41: Wire Harness - Mag Pickup, Processor Lead (p/n 15704-XX)

  • Page 197: 11 Appendix A - System Components And Specifications

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMSC5000 SmartCommand User Manual Appendix A 11 Appendix A - System Components and Specifications MMSC5000 Rev B 01/13 Page 197 EN 3340.758.003a - 2014-11...
  • Page 198 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 199: Mmc-280 400 Series Control Head Variations

    07/10 Previous date unavailable 02/15/12 Added compass distance note This Service Sheet reflects all current variations of the standard 3-detent ZF 400 Series Control Heads. Figure MMC-280-1: Part Numbering Configurations Figure MMC-280-2: Detents Available 1. Requirements: MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.

  • Page 200: Figure Mmc-280-3: Dimensions

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-280 400 Series Standard Control Head Variations 2. Mounting And Installation: A Select the desired mounting locations and make cutouts per template. Refer to Figure MMC-280-3: Dimensions. B Check that the four mounting screws will start into the Control Head. Remove the Control Head from the cutout.

  • Page 201: Figure Mmc-280-4: Terminal Connections

    For single lever Control Head Stations that have the user facing aft and the one Control Head lever on the user’s right, reverse connections 5 and 7. Handheld Control is a Station option. Contact your ZF Dealer for further information on Handheld requirements and options.
  • Page 202 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 203 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 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. MMC-280 Rev N.2 02/12 Page 203 WARNING: Note that the dimensions are out of scale, pay attention to properly size the cut out before use ! EN 3340.758.003a - 2014-11...
  • Page 204 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 205: Mmc-329 Mc2000 Series Standard Control Head Variations

    Previous date unavailable 02/15/12 Added compass distance note This Service Sheet reflects all current variations of the standard 3-detent ZF MC2000 Series Control Heads. Figure MMC-329-1: Part Numbering Configurations Detents Available REQUIREMENTS: MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.

  • Page 206: Figure Mmc-329-2: Dimensions

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-329 MC2000 Series Standard Control Head Variations Dimensions Figure MMC-329-2: Dimensions There are two types of Control Head connections available: Plug or Terminal Connected. Both types may be used with MicroCommander, ClearCommand, or CruiseCommand using the appropriate cable or harness. Follow the appropriate steps for the Control Head that has been supplied for your system.

  • Page 207: Figure Mmc-329-3: Terminal Connections

    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 Handheld Control is an option. Contact your ZF Dealer for further information on Handheld requirements and options. MMC-329 Rev E.2 02/12 Page 207 EN 3340.758.003a - 2014-11...
  • Page 208 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 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. MMC-329 Rev E.2 02/12 Page 208 WARNING: Note that the dimensions are out of scale, pay attention to properly size the cut out before use ! EN 3340.758.003a - 2014-11...

  • Page 209: Mmc-307 700 Series Standard Control Head Variations

    P - 425-583-1900 F - 425-493-1569 www.zf.com 700 Series Standard Control Head Variations This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics 700 Series Control Heads. Figure MMC-307-1: Part Numbering Configurations Figure MMC-307-2: Detents Available 1.
  • Page 210 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-307 700 Series Standard Control Head Variations 3. Standard Cable A Remove the six screws holding the bottom cover of the Control Head housings and set aside. B Insert cable through the correct cable grip in the bottom cover. C Strip back the PVC cover on the shielded cable approximately 2-1/2”...

  • Page 211: Figure Mmc-307-4: Dual Control Head Connections

    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 requirements and options. MMC-307 Rev I.2 03/12 Page 211 EN 3340.758.003a - 2014-11...
  • Page 212 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 213 APPENDIX A - SYSTEM COMPONENTS AND 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 ! EN 3340.758.003a - 2014-11...
  • Page 214 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 215: Mmc-279 400 Series Weather Mount Enclosure

    MMC-279 400 Series Weather Mount Enclosure ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com 400 Series Weather Mount Enclosure...
  • Page 216 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 217: Deutsch Connector Assembly

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Deutsch Connector Assembly Deutsch Connector Assembly DT Type Step 1: Contact Removal Step 2: Wire Stripping Solid Contacts Contact Part Wire Gauge Strip Length 1. Remove wedgelock using (inches) Range Number needlenose pliers or a hook shaped wire.
  • Page 218 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 219: S-214 Automatic Power Selector Model: 13505

    DC power sources. Two independent batteries rated at the same nominal voltage are wired to separate terminals on the APS and internal diodes maintain total isolation between them. A single output terminal is wired to the ZF Marine Propulsion Control System.
  • Page 220 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 221: Drawing 11488 Dc Power Source Kit

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Drawing 11488 DC Power Source Kit Page 221 EN 3340.758.003a - 2014-11...
  • Page 222 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 223 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS WARNING: Note that the dimensions are out of scale, pay attention to properly size the cut out before use ! Page 223 EN 3340.758.003a - 2014-11...
  • Page 224 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 225 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Page 225 EN 3340.758.003a - 2014-11...
  • Page 226 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 227 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Page 227 EN 3340.758.003a - 2014-11...
  • Page 228 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...
  • Page 229 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Page 229 EN 3340.758.003a - 2014-11...
  • Page 230 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 231: Grounding (Bonding)

    MMC-287 Grounding (Bonding) ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Grounding (Bonding) Grounding (Bonding) - 46 CFR 111.05 and ABYC Section E-11: July 2012 Grounding (Bonding) should be done according to ABYC Section E-11 and Code of Federal Regulations 46 CFR 111.05.
  • Page 232 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 233: Mmc-288 References And Parts Source

    MMC-288 References and Parts Source ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com References and Parts Sources References A American Boat & Yacht Council (ABYC)
  • Page 234 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 235: Ser-161 Engine Tach Sender Req

    SER-161 Engine Tach Sender Req. ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Engine Tachometer Sender Requirements Engine Type...
  • Page 236 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS SER-161 Engine Tach Sender Requirements Engine Type Engine Model Sender Comments Engine built after 1977 require the Lehman Diesel All Engines 8902 Aetna Part No. 8619 tachometer drive (Ford) adapter. Diesel Lugger All Engines 8912 Diesel In-line...

  • Page 237: Mmc-289 Morse Clutch And Throttle Kit

    MMC-289 Morse Clutch and Throttle Kit ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Morse Clutch and Throttle Kit Selection...
  • Page 238 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-289 Morse Connection Kits ENGINE MAKE KIT NO. 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 MMC-289 Rev A 03/11 Page 238 EN 3340.758.003a - 2014-11...

  • Page 239: Universal Mounting Kit

    MMC-290 Universal Mounting Kit ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Universal Mounting Kit MMC-290 Rev A 06/09 Page 239 EN 3340.758.003a - 2014-11...
  • Page 240 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 241: 43C Cable Conversion Kit

    MMC-345 43C Cable Conversion Kit ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com 43C Cable Conversion Kit Date Revision Description 8/03 Added 9000 Series.
  • Page 242 APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS EN 3340.758.003a - 2014-11...

  • Page 243: Mmc-343 Station Expander User Instructions

    MMC-343 Station Expander User Instructions ZF Marine Propulsion Systems Miramar, LLC APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Station Expander User Instructions Table of Contents MMC-343: 1 Features .....................

  • Page 244: Figure Mmc-343-1: Station Expander

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions Figure MMC-343-1: Station Expander The station expander (SE) is designed to be an addition to the 9000 Series / CruiseCommand Processors. The station expander allows the user to install more than the maximum allowed control heads (up to four). MMC-343: 1 Features •...

  • Page 245: Mmc-343: 4 Station Expander Power

    3%. Refer to ABYC E-9. It is recommended by ZF Marine Propulsion Systems Miramar that an Automatic 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.

  • Page 246: Figure Mmc-343-2: Station Expander Harness Connector Locations

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions Figure MMC-343-2: Station Expander Harness Connector Locations The Harnesses use one or both of the plug connector types detailed in Figure MMC-343-3: Harness Plug Connectors. When connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully connected or disconnected.

  • Page 247: Figure Mmc-343-4: Station Expander Dimensions

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions MMC-343: 7 Installation Before starting the actual installation of the Station Expander, make sure you have the correct parts and tools. See section MMC-343: 6 Tools For Installation. Read ALL the instructions pertinent to each part before beginning the installation of that part NOTE: When connecting the plugs, ensure that the release buttons are depressed and held until plug is fully connected.

  • Page 248: Power Cable

    It is critical to design and wire the Control System in a manner where the chance of losing power to the Control System is kept to a minimum. ZF Marine Propulsion Systems Miramar recommends that two power sources are utilized along with the APS see document S-214 Automatic Power Selector Model: 13505 for more information.

  • Page 249: Figure Mmc-343-5: Station Expander Display Led And Arrow Push Buttons

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions Check that the four mounting screws will start into the Control Head. Remove the Control Head. Strip the adhesive cover from the gasket and apply the adhesive side to the console. •...

  • Page 250: Figure Mmc-343-6: Display Led At Normal Operation

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions Station Expander Display LED Figure MMC-343-6: Display LED at Normal Operation • The Station Expander’s Display LED has four 7-segment LED’s, which light up to show either letters or numbers.

  • Page 251: Figure Mmc-343-8: Error Menu Example

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions • Deactivates Set Up Mode WITHOUT any changes to the Function Value stored in memory. (Operator must hold the button down until function code stops blinking, then release.) The previously saved Function Value will then be displayed.

  • Page 252: Figure Mmc-343-11: Display Function Menu Activated

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions B Depressing either the Up or Down Arrow Push Button will activate the Function Menu. (refer to Figure MMC-343-11: Display Function Menu Activated) C Depressing either the Up or Down Arrow Push Button will scroll through the Function Menu one at a time.

  • Page 253: Figure Mmc-343-13: Display With A0 - Station Expander Identification Set Up Activated

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions 10.1 A0 - Station Expander Identification CAUTION: This feature MUST be the SAME value as set in the 9000 Series / CruiseCommand Processor the Expander is connected to. In applications where there is more than one screw, the system must have some way of determining which Station Expander is where.

  • Page 254: Engine Stop Switches Test (Engines Running)

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions • Move each Control Head lever full Ahead and full Astern. Ensure correct 9000 Series / CruiseCommand Processor and Station Expander reacts to lever movement. NOTE: This will check that the Control Head is operating. * On Twin Screw or more applications ensure the Port Control Head lever operates the Port Processor and the Starboard Control Head lever operates the Starboard Processor, etc.

  • Page 255: Mmc-343: 13 Parts List

    APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS MMC-343 Station Expander User Instructions MMC-343: 13 Parts List Part No. Description 13.1 Control Heads A Single Screw 450-3L or 3R Left or Right Control Head, 'T' Lever 453-3L or 3R Left or Right Control Head, Chrome Knob Lever 455-3L or 3R Left or Right Control Head, Black Low Profile Lever 456-3L or 3R...

  • Page 256: Wire Harness (Plug)

    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 only) 15208- ZF Autotroll (MS570-15382 Harting Connector only) 13552-# Power/Start Interlock/Clutch Pressure 13756-# Power/Start Interlock 15023-#...

  • Page 257: 12 Appendix B - Qfa & Dvtp

    APPENDIX B - QFA & DVTP MM9000 ClearCommand User Manual Appendix B 12 Appendix B - QFA & DVTP (Qualitative Failure Analysis & Design Verification Test Procedure) MM9000 Rev C.8 01/13 Page 257 EN 3340.758.003a - 2014-11...
  • Page 258 APPENDIX B - QFA & DVTP EN 3340.758.003a - 2014-11...

  • Page 259: 9000 Series Micro/Clearcommand Servo Throttle - Servo Clutch Qualitative Failure Analysis, Design Verification Test Procedure And Periodic Safety Test

    ENG-127 9000 Series Micro/ClearCommand Servo Throttle - Servo Clutch Qualitative Failure Analysis, Design Verification Test Procedure and ZF Marine Propulsion Systems Miramar, LLC 12125 Harbour Reach Dr Ste B Periodic Safety Test Mukilteo, WA 98275 APPENDIX B - QFA & DVTP...
  • Page 260 A standard feature is an alarm contact (normally open) to interface with the main alarm system of the vessel. This switch will open and activate the alarm system with a power loss or CPU failure. In addition, ZF Marine Propulsion Systems Miramar provides audible tones at the Control Head locations to indicate system faults.
  • Page 261 APPENDIX B - QFA & DVTP ENG-127 9000 Series Micro/ClearCommand Servo Throttle - Servo Clutch QFA & DVTP Design Verification Test Procedure The MicroCommander/ClearCommand 9000 Series (servo throttle, servo clutch version) Propulsion Control System is compliant to the environmental design standards in 46 CFR 62.25-30. The following test procedure covers the 4 items included in the Qualitative Failure Analysis;...
  • Page 262 APPENDIX B - QFA & DVTP ENG-127 9000 Series Micro/ClearCommand Servo Throttle - Servo Clutch QFA & DVTP Failure: Throttle Feedback Potentiometer failure Results: Throttle will go to Idle (if needed). Test Procedure. Turn power ON to both Port and Starboard Processors. Take command at a Control Head. Move the Port and Starboard Control Head levers to approximately ½...

  • Page 263: 9000 Series Clearcommand Throttle - Solenoid Clutch Qualitative Failure Analysis, Design Verification Test Procedure And Periodic Safety Test

    ENG-143 9000 Series ClearCommand Throttle - Solenoid Clutch Qualitative Failure Analysis, Design Verification Test Procedure and Periodic ZF Marine Propulsion Systems Miramar, LLC 12125 Harbour Reach Dr Ste B Safety Test APPENDIX B - QFA & DVTP Mukilteo, WA 98275...
  • Page 264 A standard feature is an alarm contact (normally open) to interface with the main alarm system of the vessel. This switch will open and activate the alarm system with a power loss or CPU failure. In addition, ZF Marine Propulsion Systems Miramar provides audible tones at the Control Head locations to indicate system faults.
  • Page 265 APPENDIX B - QFA & DVTP ENG-143 ClearCommand 9000 Series Throttle - Solenoid Clutch QFA & DVT Test Procedure Turn power on to both Port and Starboard Processors. Take command at a Control Head. Move the Port and Starboard Control Head levers to approximately ½ Ahead. Locate the green wire coming from the Port Control Head in command, connecting to pin 6 of the respective terminal block on the ClearCommand 9000 Series circuit board.
  • Page 266 APPENDIX B - QFA & DVTP EN 3340.758.003a - 2014-11...

  • Page 267: 9000 Series Electronic Throttle - Servo Clutch Qualitative Failure Analysis, Design Verification Test Procedure And Periodic Safety Test

    ENG-144 9000 Series Electronic Throttle - Servo Clutch Qualitative Failure Analysis, Design Verification Test ZF Marine Propulsion Systems Miramar, LLC 12125 Harbour Reach Dr Ste B Procedure and Periodic Safety Test APPENDIX B - QFA & DVTP Mukilteo, WA 98275...
  • Page 268 A standard feature is an alarm contact (normally open) to interface with the main alarm system of the vessel. This switch will open and activate the alarm system with a power loss or CPU failure. In addition, ZF Marine Propulsion Systems Miramar, LLC provides audible tones at the Control Head locations to indicate system faults.
  • Page 269 APPENDIX B - QFA & DVTP ENG-144 9000 Series Electronic Throttle - Servo Clutch QFA & Design Verification Test Procedure • Results: • Throttle signal to Idle and clutch servo will remain at last commanded position. • LED at Control Heads will not be lit. •...
  • Page 270 APPENDIX B - QFA & DVTP EN 3340.758.003a - 2014-11...

  • Page 271: 9000 Series Servo Throttle - Solenoid Clutch, Qualitative Failure Analysis & Design Verification Test Procedure

    ENG-145 9000 Series Servo Throttle - Solenoid Clutch, Qualitative Failure Analysis & Design Verification Test ZF Marine Propulsion Systems Miramar, LLC 12125 Harbour Reach Dr Ste B Procedure Mukilteo, WA 98275 APPENDIX B - QFA & DVTP P - 425-583-1900 F - 425-493-1569 www.zf.com...
  • Page 272 A standard feature is an alarm contact (normally open) to interface with the main alarm system of the vessel. This switch will open and activate the alarm system with a power loss or CPU failure. In addition, ZF Marine Propulsion Systems Miramar provides audible tones at the Control Head locations to indicate system faults.
  • Page 273 APPENDIX B - QFA & DVTP ENG-145 9000 Series Servo Throttle Solenoid Clutch QFA & DVTP • Results: • Throttle signal will remain at last commanded position to and clutch shifts to neutral. • LED at Control Heads will not be lit. •...
  • Page 274 APPENDIX B - QFA & DVTP EN 3340.758.003a - 2014-11...

  • Page 275: 13 Appendix C - Sales And Service Information

    APPENDIX C - SALES AND SERVICE INFORMATION MM9000 ClearCommand User Manual Appendix C 13 Appendix C - Sales and Service Information MM9000 Rev C.8 01/13 Page 275 EN 3340.758.003a - 2014-11...
  • Page 276 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 277: Factory Authorized Sales & Service - North America

    MMC-123 Factory Authorized Sales & Service - ZF Marine Propulsion Systems Miramar, LLC APPENDIX C - SALES AND SERVICE INFORMATION North America 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Factory Authorized Sales & Service - North America...
  • Page 278 Phone: 800-367-0987 Fax: 954-463-9009 Fax: 810-364-4112 Email: jmonroe@bowboat.com Email: rhall@marysvillemarine.com Website: www.marysvillemarine.com ZF Marine Propulsion Systems Miramar – US Company: Headquarters New Jersey Contact: A.J. Halavacs Company: Airline Hydraulics Corporation Address: 15351 SW 29th Street, Ste 300 Contact: Bernie Keppel...
  • Page 279 12125 Harbour Reach Dr Ste B Email: info@engines1.com Mukilteo, WA 98275 Website: www.engines1.com Phone: 425-583-1900 Fax: 425-493-1579 Washington Email: bud.bloom@zf.com; kevin.zwicker@zf.com Company: Fisheries Supply Co Website: www.zf-maine.com Contact: Mike Gibbons Wisconsin Address: 1900 N. Northlake Way Seattle, WA 98103 Company:...
  • Page 280 APPENDIX C - SALES AND SERVICE INFORMATION MMC-123 Factory Authorized Sales & Service Center - North America CANADA Eastern Canada Company: CMC Electronics Company: CMC Electronics Contact: Michel Roy Contact: Mark Newcomb Address: 566 Duphare Street East Address: 40 Thornhill Drive, Unit 6 Mantane, Quebec Dartmouth, Nova Scotia Canada G4W 3P6...
  • Page 281 APPENDIX C - SALES AND SERVICE INFORMATION MMC-123 Factory Authorized Sales & Service Center - North America 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 brad.funk@cmcelectronics.ca; Email: jim.goodfellow@cmcelectronics.ca MMC-123 Rev A.5 06/10...
  • Page 282 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 283: Factory Authorized Service Centers - North America

    Factory Authorized Service Cen- MMC-151 ZF Marine Propulsion Systems Miramar, LLC APPENDIX C - SALES AND SERVICE INFORMATION ters - North America 12125 Harbour Reach Dr Ste B Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Factory Authorized Service Centers - North America...
  • Page 284 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Company: Timber & Marine Contact: Ken Perry Company: Donn’s Boat Shop, Inc. Address: 2547 Tongass Avenue Contact: Donn DeVore Ketchikan, AK 99001 Address: PO box 3826 Phone: 907-225-6644 Page, AZ 86040...
  • Page 285 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Company: Skipperliner – Lake Pleasant Company: Fishing Boats Unlimited Contact: Mike Montgomery, Glenn Carson Contact: Tony Greyshock, Jason Greyshock Address: 40202 N. 87th Ave Address: 624 Terminal Way Peoria, AZ 85382 Costa Mesa, CA 92627...
  • Page 286 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Company: Fish Head Marine Company: Outbound Yacht Service Contact: Robert Johnson (RJ) Contact: Kevin Ryan Address: 603 Seagaze Dr Ste 162 Address: 34241 Pacific Coast Hwy #105 Oceanside, CA 92054 Dana Point, CA 92629 Phone:...
  • Page 287 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Company: Ship Shape Marine Company: Dave Gillen Diesel Contact: Tony Travis Contact: Dave Gillen Address: 909 Marina Village Pkwy, #186 Address: 811 N.E. 3RD Street Alameda, CA 94501 Dania Beach, FL 33004 Phone:...
  • Page 288 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Iowa Georgia Company: S & S Rentals, Inc. Company: J & W Marine Services Contact: Greg Stirn Contact: Jerry Sumrel Address: PO Box 389 Address: 3292 McEver Road, Suite 103 Lansing, IA 52151 Buford, GA 30518...
  • Page 289 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Louisiana Nevada Company: Total Electric Service of Arcadiana Company: A & M Marine Contact: Barry LaGrange Contact: Jim Bell, Scott Wall Address: 200 Rue Degravelle Address: 1630 Foothill Drive New Iberia, LA 70563...
  • Page 290 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Oregon Company: Montauk Marine Basin, Inc Company: Cook Engine & Co. Contact: Mark Jarboe Contact: Jeff Dykes Address: PO Box 610 Address: 503 NE Tomahawk Island Drive Montauk, NY 11954 Portland, OR 97217 Shipping:...
  • Page 291 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America South Carolina Utah Company: MacKay Communications Company: Aramark – Halls Crossing Contact: Tony Smircic Contact: Mark Grahn Address: 1369 B Ashley River Road Address: PO Box 5101 Charleston, SC 29407 Lake Powell, UT 84533 Phone:...
  • Page 292 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America Company: Complete Controls Company: North Harbor Diesel, Inc. Contact: Jim Palmer Contact: Dave Williams, Mike Curran Address: 9306 NE 7th Street Address: 720 30th Street Vancouver, WA 98664 Anacortes, WA 98221 Phone:...
  • Page 293 APPENDIX C - SALES AND SERVICE INFORMATION MMC-151 Factory Authorized Service Centers - North America 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...
  • Page 294 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 295: Factory Authorized Sales & Service Centers - International

    MMC-172 Factory Authorized Sales & Service Centers - Inter- ZF Marine Propulsion Systems Miramar, LLC 12125 Harbour Reach Dr Ste B national APPENDIX C - SALES AND SERVICE INFORMATION Mukilteo, WA 98275 P - 425-583-1900 F - 425-493-1569 www.zf.com Factory Authorized Sales & Service Centers - International...
  • Page 296 8621-50589000 Phone: 35-8968271 Fax: 8621-505880007 Fax: 35-896827305 Email: anthony.yuen@renford.com Email: anttihiidenheimo@atoy.fi Company: ZF Shanghai Rep. Office France Contact: Tang Zhou Qing, Gong Lan Company: ZF France Address: Room 2504, Jiangnan Building Contact: Ronald Gamere No. 600 Luban Road Address: 3, rue Henri Poincare’...
  • Page 297 APPENDIX C - SALES AND SERVICE INFORMATION MMC-172 Factory Authorized Service Centers - International Ireland Germany Company: ZF Services Great Britain, Ltd Company: Otto Piening Propeller GMBH Contact: Adi License Contact: Mathias Pien Address: Abbeyfield Road, Lenton Address: AM Altendeich 83 Nottingham, United Kingdom D25348 Glückstadt...
  • Page 298 APPENDIX C - SALES AND SERVICE INFORMATION MMC-172 Factory Authorized Service Centers - International Korea New Zealand Company: SE Jung Engineering Co. Company: ZF Services Australia Pty, Ltd Contact: M.G. Song Contact: Gary Bain, Rodney Lean Address: #35-4 Namhangdong-1KA Address:...
  • Page 299 Fax: 6861-9173 Phone: 7-812-324-54-72 Email: sharon.ho@zf-seasia Fax: 7-812-140-18-15 Email: anastassia.selverstova@zf.sp.ru South Africa Company: ZF South Africa Pty, Ltd Scotland Contact: Heather Hermann Company: ZF Services Great Britain, Ltd Address: PO Box 2098 Contact: Adi License Kempton Park, 1620 South Address:...
  • Page 300 APPENDIX C - SALES AND SERVICE INFORMATION MMC-172 Factory Authorized Service Centers - International Sweden Thailand Company: KG Knutsson AB Company: ZF Thailand Co. Ltd Contact: Karl-Henry Pragsten Contact: Reungpoj V Address: Tansmissions Divisionen Address: 159/33 Soi Vipawasee 64 Hammarbracken 8...
  • Page 301 Venezuela peter@atlantismarine.com Website: www.atlantismarine.co.uk Company: Sistemas de Propulsion C.A. Address: AV 67a Entre 149By 150 2 Etapa Zona Industrial ZF Marine Propulsion Systems Miramar – US Company: Maracaibo, Venezuela Headquarters Contact: A.J. Halavacs Phone: 58-261-736-0747 Address: 15351 SW 29th Street, Ste 300...
  • Page 302 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 303: Mmc-165 Warranty

    Under no circumstances shall ZF be liable for any incidental or consequential damages sustained in connection with the product or its use, including any costs or damages that result from loss of use of the product or any engine or boat with which it is used. ZF does not authorize any representative or agent to assume for it any obligation or liability other than those expressly set forth above.
  • Page 304 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 305: Warranty Registration

    Purchaser's Name Street Address City State Phone YOUR VESSEL: Engine, Make & Model Length Manufacturer ZF Marine Propulsion Systems Miramar, LLC. Product First Seen At: Boat Show Dealer Magazine Friend MMC-163 Rev C.1 04/09 Page 305 EN 3340.758.003a - 2014-11...
  • Page 306 APPENDIX C - SALES AND SERVICE INFORMATION EN 3340.758.003a - 2014-11...

  • Page 307: Mm13927 Field Service Test Unit

    REFERENCE MANUAL MM13927 FIELD SERVICE TEST UNIT MARINE PROPULSION SYSTEMS EN 3340.758.003a - 2014-11...
  • Page 308 Data subject to change without notice. We decline all responsibility for 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.
  • Page 309 Revision List Revisions List Date Revision Description 11/02 Revised Section 1.0 Table 1 Revised manual to current ZF Marine Propulsion Systems Miramar manual standards. 2/03 Revised Section 3.0 4/03 Deleted Section 2.1.6 10/03 Revising to add 9000 Series and 2-Speed information Brought Entire Manual up to current ZF Standards.
  • Page 310 REVISION LIST EN 3340.758.003a - 2014-11...

  • Page 311: Figure Mm13927-1: .Service Field Test Unit (Break-Out Box)

    INTRODUCTION MM13927 Field Service Test Unit Reference Manual Introduction Refer to Bulletin 02-008 for Service Field Test Unit (Part No. 13927) recommendations. Refer to Figure MM13927-1: .Service Field Test Unit (Break-out Box) for an example of the Test Unit and a Multimeter Figure MM13927-1: .Service Field Test Unit (Break-out Box) The Service Field Test Unit, hereafter referred to as the “Break-out Box”, is recommended for use with all CruiseCommand Processors (Part No.

  • Page 312: Figure Mm13927-3: Example Of Clearcommand Pigtail Locations

    INTRODUCTION MM13927 Field Service Test Unit Reference Manual Figure MM13927-3: Example of CLEARCommand Pigtail Locations Designation Description Harness Type Harness Use The throttle signal is output from this connector/pigtail. The Black 8 Pin Throttle Connector/Pigtail signal may be in the form of Pulse Width Modulation (PWM), Voltage, Current, or Frequency.

  • Page 313: Figure Mm13927-4: Throttle Connection (Dc Voltage)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual Procedure Throttle Signal Testing Depending on which Processor is being tested, it may have the capability of sourcing one or all of the following: DC Voltage, Current, PWM (Pulse Width Modulation) or Frequency. NOTE: The following procedures and drawings pertain to both the CruiseCommand and ClearCommand Processors.

  • Page 314: Figure Mm13927-5: Throttle Connection (Current Ma)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual Set up the Multimeter to measure current (mA.) and plug the black lead into the Break-out Box black socket labeled “-” and the red lead into the socket labeled “mA”. Turn power ‘On’ to the Processor and take command at any Remote Station. Depress and hold the Push-button Switch labeled “mA.”...

  • Page 315: Figure Mm13927-6: Throttle Connection (Pwm With Dc Voltmeter)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual 2.1.3 PWM (Pulse Width Modulation) with DC Voltmeter Ensure power is removed from both the Engine Electronics and the Processor. Disconnect the Throttle Harness from the number 1 Processor connector/pigtail. Insert the Break-out Box between the number 1 Processor connector/pigtail and the Throttle Harness as shown in Figure MM13927-6: Throttle Connection (PWM with DC Voltmeter) labeled “-”...

  • Page 316: Figure Mm13927-7: Throttle Connection (Pwm With Duty Cycle Meter)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual Insert the Break-out Box between the number 1 Processor connector/pigtail and the Throttle Harness as shown in Figure MM13927-7: Throttle connection (PWM with Duty Cycle Meter). Figure MM13927-7: Throttle connection (PWM with Duty Cycle Meter) Set up the Multimeter to measure Duty Cycle and plug the black lead into the Break-out Box black socket labeled “-”...

  • Page 317: Figure Mm13927-8: Throttle Connection (Frequency Hz)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual Set up the Multimeter to measure Frequency and plug the black lead into the Break-out Box black socket labeled “-” and the red lead into the socket labeled “FREQ”. Figure MM13927-8: Throttle Connection (Frequency Hz) Turn power ‘On’...

  • Page 318: Figure Mm13927-10: Clutch Connections Ahead Solenoid

    PROCEDURE MM13927 Field Service Test Unit Reference Manual The measurement on the Neutral Test Point should be 12 or 24 VDC, depending on the Solenoid’s rating and the LED adjacent to the socket should be illuminated. Move the Control Head lever to the Ahead Detent position. The voltage should drop to 0 VDC in CruiseCommand systems and remain at 12 or 24 VDC in ClearCommand systems.

  • Page 319: Figure Mm13927-11: Clutch Connections Astern Solenoid

    PROCEDURE MM13927 Field Service Test Unit Reference Manual The measurement should be 0 VDC and the adjacent LED should not be lit. Figure MM13927-11: Clutch Connections Astern Solenoid Position the Control Head lever into the Astern detent. The measurement should be 12 or 24 VDC depending on the Astern Solenoid’s rating.

  • Page 320: Figure Mm13927-13: Troll Connections (Proportional Solenoid)

    PROCEDURE MM13927 Field Service Test Unit Reference Manual The measurement should be 0 VDC. Position the Control Head lever to the Ahead detent. The measurement should now be 12 or 24 VDC, depending on the Solenoid’s rating. Position the Control Head lever further forward while monitoring the DC Voltmeter. The measurement should go from 12 or 24 VDC to 0 VDC at the same time the red LED on the Control Head becomes lit solid.

  • Page 321: Figure Mm13927-14: 2-Speed Connections

    PROCEDURE MM13927 Field Service Test Unit Reference Manual 2-Speed Testing 2.4.1 2nd Gear Disengaged Ensure power is removed from the Processor. Disconnect the Clutch/2-Speed Harness from the number 3 Processor connector/pigtail. Insert the Break-out Box between the number 3 Processor connector/pigtail and the Clutch/ 2-Speed Harness as shown in Figure MM13927-14: 2-Speed Connections.1653 Figure MM13927-14: 2-Speed Connections Set up the Multimeter to measure DC Volts and connect the black lead to the socket labeled...

  • Page 322: Parts List

    PROCEDURE MM13927 Field Service Test Unit Reference Manual Parts List ZF Marine Propulsion Systems Miramar Part Name Part No. 13927 Service Field Test unit (Break-out Box) MM13927 Technical Manual Multimeter 14000 Test Control Head - Dual MM13927 Rev E.2 01/13 Page 322 EN 3340.758.003a - 2014-11...

  • Page 323: 14 Appendix D - System Drawings

    APPENDIX D - SYSTEM DRAWINGS MM9000 ClearCommand User Manual Appendix D 14 Appendix D - System Drawings MM9000 Rev C.8 01/13 Page 323 EN 3340.758.003a - 2014-11...
  • Page 324 APPENDIX D - SYSTEM DRAWINGS EN 3340.758.003a - 2014-11...

  • Page 325: Drawing 12284 Clearcommand All Configuration Twin Screw System Drawing

    APPENDIX D - SYSTEM DRAWINGS Drawing 12284 ClearCommand All Configuration Twin Screw System Drawing Page 325 EN 3340.758.003a - 2014-11...
  • Page 326 APPENDIX D - SYSTEM DRAWINGS EN 3340.758.003a - 2014-11...
  • Page 327 APPENDIX D - SYSTEM DRAWINGS Page 327 EN 3340.758.003a - 2014-11...
  • Page 328 APPENDIX D - SYSTEM DRAWINGS EN 3340.758.003a - 2014-11...
  • Page 329 APPENDIX D - SYSTEM DRAWINGS Page 329 EN 3340.758.003a - 2014-11...
  • Page 330 APPENDIX D - SYSTEM DRAWINGS EN 3340.758.003a - 2014-11...
  • Page 331 APPENDIX D - SYSTEM DRAWINGS Page 331 EN 3340.758.003a - 2014-11...
  • Page 332 ZF Padova S.r.l. ZF Padova S.r.l. Via Penghe, 48 Via Penghe, 48 I - 35030 Caselle di Selvazzano (PD) I - 35030 Caselle di Selvazzano (PD) ITALY ITALY Phone Phone +39 049 8299 311 +39 049 8299 311 +39 049 8299 550 +39 049 8299 550 www.zf.com...

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