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

CruiseCommand 785CE Installation and Troubleshooting Manual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.7.1 Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.7.2 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

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

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

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

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

2.10.1 Trolling Valve Command Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.10.2 Operation in Non-Troll Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.10.3 Operation in Troll Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.10.4 To turn Troll Mode On: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.10.5 To turn Troll Mode Off:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.10.6 Types of Trolling Valve Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

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

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

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

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

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

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

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

MM14330 Rev.B 11/01

CruiseCommand 785CE Installation and

Troubleshooting Manual

SW13867.0

Page 1

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Page 1: Table Of Contents
SW13867.0 Table of Contents MM14330 Rev.B 11/01..............................1 CruiseCommand 785CE Installation and Troubleshooting Manual Table of Contents ................................ 1 Revisions List ................................1 1.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1.1 This Manual .
Page 2 3.4 Clutch Power Supply................13 3.5 Cable Harness .
Page 3 6.1.4 Left and Right Arrow..............29 Figure 27: Left and Right Arrow Push Buttons .
Page 4 Table 3: Solenoid Error Status Enable ..........................43 7.0 ADJUSTMENTS AND TESTS (SECURED TO DOCK) - - - - - - - - - - - - - - - - - - - - - - 44 7.1 Control Head (Engines Stopped) ..............44 7.2 Start Interlock (Engines Stopped) .
Page 5 MMC-310 Rev.D 6-01 ..............................9 464-4 Control Head Sheet MMC-326 Rev.- 7/01..............................11 CH14450 Control Head Sheet MMC-279 Rev.A 11/00 ............................. 13 400 Series Watertight Enclosure Deutsch Connector Assembly ..........................15 S-214 Rev.A 6/01 ............................... 19 Automatic Power Selector (APS) Model: 13505 Figure 1: .
Page 6 Figure 16: Display with Station Transfer Button pushed ..........20 1.6.3 Stuck Transfer Button .
Page 7 3.4 Troll On/Off Solenoid ............... . . 46 Figure 41: Dwg 11654-M .
Page 8: Table Of Contents
9/01 1. SER-165 was replaced with current form. 11/01 Complete Manual revised to current ZF Mathers, LLC. standards adding Software Part Number to Table of Contents. 1. Section 3.7 and 5.7: WARNING added CFR reference. 2. Section 6.3 Table 1: Functions List E0 Cummins Quantum voltage, revised 4.1 to 4.0.
Page 9: Mm14330 Rev.b 11/01
Appendix B.1 contains Troubleshooting explanations. If you cannot find a solution within the Trouble Shooting, contact one of the companies listed on the ZF Mathers Contact list at the end of Appen- dix B.1. Appendix C.1 contains basic System Drawings.
Page 10: Cruisecommand System
INTRODUCTION 1.2 C RUISE OMMAND YSTEM The CruiseCommand System is designed for: • Engines that require either voltage, current (mA), or PWM speed command signal • Transmissions equipped with solenoid clutch or solenoid clutch/troll 1.2.1 Features • Sequencing of Clutch and Engine Speed •...
Page 11: Operation
OPERATION 2.0 OPERATION 2.1 DC P OWER When CruiseCommand control system DC power is turned ON: • Processor will command Neutral/Idle. • Intermittent tone will sound at all Stations indicating that no Station has command. (refer to Section 2.8) 2.2 T OMMAND To take command at a Station: •...
Page 12: Engine Start Interlock
OPERATION 2.4 E NGINE TART NTERLOCK The engine start signal is blocked unless the following are true: • DC power has been turned ON to the Control System. • A Station has command. • The Control System is commanding Neutral. 2.5 S TATION RANSFER...
Page 13: Warm-Up Mode
OPERATION 2.6 W This feature allows the operator to increase the engine’s RPM while the Clutch remains in Neutral. Warm-up Mode is operational only in Ahead. The system is placed into Warm-up Mode as follows: A)At the Station-in-Command, ensure that the Control Head lever is in the Neutral detent position (refer to Figure 4:): B)Depress and hold the transfer but-...
Page 14: High / Low Idle Modes
OPERATION 2.7 H ODES The CruiseCommand Control System offers two options of engine IDLE RPM settings. • Low Idle Mode (default setting) • High Idle Mode. (an adjustable elevated Idle RPM) 2.7.1 Low Idle Low Idle is the normal engine Idle RPM. When the System is initially powered up, it will always command Low Idle.
Page 15: Synchronization (Multi Screw)
OPERATION 2.8 S YNCHRONIZATION ULTI CREW The CruiseCommand System utilizes dual lever synchronization. Dual lever synchronization provides the security of both of the Control Head levers always being active. Synchronization is automatic and only operates in Ahead; conse- quently it can be left ON full time. Cruise-Command will always power-up with synchronization Enabled.
Page 16: One Lever Operation Mode (Multi Screw)
OPERATION 2.9 O EVER PERATION ULTI CREW This System utilizes One Lever Operation Mode to allow one Control Head lever (Master) to command all engines and gears. The "Master" lever can be any lever. The advantage of this is that only one Control Head lever operates all engines and gears.
Page 17: Trolling Valve Control (Optional)
OPERATION 2.10T ROLLING ALVE ONTROL PTIONAL The CruiseCommand System is able to control electric Trolling Valves that utilize single or dual solenoids. The Troll Mode option is selected during Set-up. 2.10.1Trolling Valve Command Operating Modes This system has two Modes of Operation when a Troll Valve Type of command has been set up: Troll and Non-Troll.
Page 18: To Turn Troll Mode On
OPERATION • Will increase the propeller RPM from 30 percent shaft RPM to approximately 70 percent shaft RPM; • The throttle remains at Idle or can be adjusted to increase up to 20% of maximum throttle within this Troll Range. •...
Page 19 OPERATION • 03 = Type 3 Trolling Valve Command (45 degrees Troll Range) (Refer to Section 2.10.3 for operation) NOTE: When Troll Type 3 is being used, maximum throttle is limited to 75%. To turn Troll Mode ON (Troll Mode)/OFF (Non-Troll Mode) is the same for all Troll Types.
Page 20: Required Parts And Tools
• Control Head Dimensions Variations & Installation Sheets NOTE: Retrofit applications may require planning for an adapter pad to cover the old Control Head cutout. A variety of adapter and cover pads are available from ZF Mathers, LLC. Page 12...
Page 21: Control System Power
Every connector should either have a Wire Harness or plug. Do not leave a connector empty. All Harnesses are available from ZF Mathers, LLC. Select from Appendix A.1 – Parts List the correct Harnesses for your System.
Page 22 REQUIRED PARTS AND TOOLS (1) Throttle-PWM Wire Harness (Processor to Engine Inter- face) (1) Throttle-Voltage Wire Harness (Processor to Engine Inter- face) (1) Throttle-Current Wire Harness (Processor to Engine Interface) (2) Power/Start Interlock Wire Harness (Processor to Power/Start Interlock connections) (2) Power/Start Interlock/Clutch Pressure Wire Har- ness (Processor to Power/Start Interlock/Clutch Pressure Switch con-...
Page 23: Tools For Installation
REQUIRED PARTS AND TOOLS 3.6 T OOLS NSTALLATION 3.6.1 Required • Screwdriver – med. Phillips #2 • Hole saw -- 1 inch (25,4mm) • Drills -- 9/32 inch and 7/32 inch (7,2mm) (5,6mm) • Saw (appropriate type of saw for cutting material Control Head will be mounted on) 3.6.2 Optional •...
Page 24: Plan The Installation
PLAN THE INSTALLATION 4.0 PLAN THE INSTALLATION NOTE: ZF Mathers recommends that the control system be installed in accordance with ABYC E- 9 and P24. 4.1 P ROCESSOR OCATION NOTE: Read the Warranty in Appendix A.1. Improper mounting location may cancel warranty.
Page 25: Control Head Location
3%. Refer to ABYC E-9. It is recommended by ZF Mathers that an Automatic Power Switch (APS) and a second power source be used. Refer to Appendix A.1 - APS Service Sheet and Appendix C.1 System Drawing.
Page 26: Installation
INSTALLATION 5.0 INSTALLATION Before starting the actual installation of CruiseCommand, make sure you have the correct parts and tools. See Section 3. Read ALL the instruc- tions 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 27: 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 Mathers recommends that two power sources are utilized along with the APS (Automatic Power Selector refer to Appendix A.1 S-214) as...
Page 28: Start Interlock Cable
INSTALLATION The APS output is strictly for the CruiseCommand Proces- sors only. In the event that the length of the cable labeled with flag note 2 in Figure 17: exceeds 40 feet, the alternate method shown in Figure 18: can be used.
Page 29: Control Head Harnesses
INSTALLATION CAUTION:The most common source of trouble is loose wiring connections. Verify wiring connec- tors are properly crimped and cannot be pulled out. Crimps and connections must be made to the wire, not to the wire insulation. Verify all screwed wire connections are secure.
Page 30: Mounting
INSTALLATION 5.3.1 Mounting 400 Series Control Head: A) Use the template supplied in Appendix A.1 and drill the screw holes and the corner cutout holes. B) Saw between the corner cutout holes. C) Check that the four mounting screws will start into the Control Head.
Page 31: Aft Facing Control Heads
INSTALLATION A) At the Control Head, strip back the PVC jacket on the Control Head harness cable approximately 2-1/2 inches (63,5mm) B) Strip and cut off the shielding and drain wire flush with the end of the PVC jacket. CAUTION: Do not connect the drain wire at the Control Head to ground. C) Strip 3/8-inch insulation off each wire, then install crimp ter- (9,5mm)
Page 32: Synchronization (Multi Screw Only)
INSTALLATION Figure 21: Aft Facing Control Heads 5.4 S YNCHRONIZATION ULTI CREW The Systems default method of synchronization is an Equal Throttle Synchronization. With this type of synchronization the Processors ensure that the same or an equal Throttle Command Signals are applied to both Governors when the synchronization criteria has been met.
Page 33: Tachometer Sensor Wire Harness (Active Synchronization Only) (Multi Screw)
(Multi Screw) This Harness will be plugged on both ends of the cable. The plug on the Sensor side is designed to mate with the ZF Mathers supplied Tachometer Assemblies. A) Remove from the Processor the PULSE connector cap and discard.
Page 34: Clutch And Troll Control
INSTALLATION • One for the Astern Clutch solenoid • One for Clutch Power A) Insert the Harness plug into the CLUTCH plug-in on the Processor Cover. B) Run the two cables labeled Ahead and Astern Clutch to the transmis- sion. C) Refer to the Transmission documentation for termination points at the clutch solenoids.
Page 35: Set-Up Procedures
SET-UP PROCEDURES 6.0 SET-UP PROCEDURES The following Set-up Procedures are written with all options considered. Not all options may be used on all Processors. Read the Sections that relate to the application being used on this ves- sel. The CruiseCommand Processor has several functions that need to be set-up for each application.
Page 36: Processor Arrow Push Buttons
SET-UP PROCEDURES • The second two digit pads indicate the numeric Value that is currently programmed into the Processor for that particular Function. A decimal indicator is located on the bottom right corner of each pad. (Refer to Figure 24:) Decimal Indicators Figure 24: Display Pad Definitions 6.1.2 Processor Arrow Push Buttons...
Page 37: Left And Right Arrow
SET-UP PROCEDURES 6.1.4 Left and Right Arrow Depress and Hold simultaneously . (Refer to Figure 27:) • Activates Set-up Mode. When Display Function Code begins to blink the Push Buttons may be released. • Saves Value and deactivates Set-up Mode. When the Display Function Code stops blinking the Push Buttons may be released.
Page 38: Activating Set-Up Mode
SET-UP PROCEDURES • When in Set-up Mode, the LED’s display two digit values Refer to Figure 30: Blinking Figure 30: Display with Value more than Two Digits 6.2 A CTIVATING NOTE: To escape from the set-up procedure at any time without saving the changed value. Depress the LEFT Arrow Push Button.
Page 39 SET-UP PROCEDURES Figure 33: Display with Set-up Activated E) Depressing either the Up or Down arrow push buttons will change the Value of the Function. Holding down either the Up or Down arrow push buttons will scroll quickly through the values. F) When the value required is displayed, depress and hold the Right and Left Arrow push buttons until the Display Function Code stops blinking and becomes solid.
Page 40: Set-Up Functions & Values
SET-UP PROCEDURES 6.3 S & V UNCTIONS ALUES The following table lists the various Function Codes, the Functions Name, Default Value and Range. Each Function will be explained in one of the fol- lowing Sections. Table 1: Functions List Function Function Name Default Value Range or Options...
Page 41: A0 - Processor Identification
SET-UP PROCEDURES 6.3.1 A0 - Processor Identification In applications where there is more than one screw, the system must have some way of determining which Processor is where. Every Processor must have it’s own identifying unique number. At no time can two Pro- cessors be identified by the same Processor Identification Number.
Page 42: A2 - One Lever Operation
SET-UP PROCEDURES D) Change the Value of the Function. E) When the value required is displayed, store the value. Refer to Sec- tion 6.2. 6.3.3 A2 - One Lever Operation This System utilizes One Lever Operation Mode to allow one Control Head lever to command all engines and gears at the same speed and direc- tion.
Page 43: E1 - Throttle In Neutral
SET-UP PROCEDURES To change the value: A) Depress either the Up or Down Arrow to activate the Function Menu. B) Use the Up or Down arrow to scroll to the E0 Function Code. C) Activate Set-up Mode. Refer to Section 6.2. Figure 37: E0 - Select Engine Set-up Activated D) Change the Value of the Function.
Page 44: E6 - High Idle
SET-UP PROCEDURES Function Code is blinking Figure 38: E5 - Throttle Pause Set-up Activated D) Change the Value of the Function. E) When the value required is displayed, store the value. Refer to Sec- tion 6.2. 6.3.10E6 - High Idle This Function is accomplished during Adjustments.
Page 45: C0 - Clutch Oil Interlock Enabled/Disabled
SET-UP PROCEDURES 6.3.12C0 - Clutch Oil Interlock Enabled/Disabled This adjustment is to be set to Installed only if the optional Clutch Oil Pressure Switch is being used with this application. The function of this parameter is to let the Processor know if a Clutch Oil Pressure Switch is being used or not.
Page 46: C2 - Reversal Pause
SET-UP PROCEDURES B) Use the Up or Down arrow to scroll to the C1 Function Code. C) Activate Set-up Mode. Refer to Section 6.2. Figure 41: C1 - Clutch Oil Interlock Delay Set-up Activated D) Change the Value of the Function. E) When the value required is displayed, store the value.
Page 47: C4 - Reversal Pause Ratio
SET-UP PROCEDURES The throttle position drops to Idle and the transmission remains engaged Ahead; the pause that follows is in proportion to the prior Control Head lever position and how long the lever had been in that position before the reversal.
Page 48: L0 - Troll Lever Range
SET-UP PROCEDURES To change the value: A) Depress either the Up or Down Arrow to activate the Function Menu. B) Use the Up or Down arrow to scroll to the C4 Function Code. C) Activate Set-up Mode. Refer to Section 6.2. Figure 44: C4 - Reversal Pause Ratio Set-up Activated D) Change the Value of the Function.
Page 49: L1 - Troll Valve Function
Table 2: Trolling Valve Type Selection Troll Valve Normal (00) Troll Valve Inverse (01) Reintjes Twin Disc 6000 Series ZF 600 and higher (formerly ZF 550 and lower (formerly IRM & BW Series) HBW & HSW Series) To change the value: A) Depress either the Up or Down Arrow to activate the Function Menu.
Page 50: L2 - Troll Minimum Pressure
SET-UP PROCEDURES 6.3.19L2 - Troll Minimum Pressure This Function is accomplished during Adjustments. 6.3.20L3 - Troll Maximum Pressure This Function is accomplished during Adjustments. 6.3.21L4 - Troll Throttle Limit This Function is accomplished during Adjustments. 6.3.22L5 - Troll Pulse Duration This Function is accomplished during Adjustments.
Page 51 SET-UP PROCEDURES D) Change the Value of the Function. NOTE: The “Value” should be entered which corresponds to the Solenoids which are in use and require monitoring E) When the value required is displayed, store the value.Refer to Sec- tion 6.2. Table 3: Solenoid Error Status Enable Ahead Astern...
Page 52 ADJUSTMENTS AND TESTS [AT DOCK] 7.0 ADJUSTMENTS AND TESTS (SECURED TO DOCK) 7.1 C ONTROL NGINES TOPPED A) Turn the power ON to the control system. WARNING: Turn OFF the control system power before disconnecting from the batteries. Do not disconnect battery terminals when engine is operating.
Page 53 ERVICE IELD REAK ULTI ETER To aid in adjusting Table 4: list of Processor signals, ZF Mathers recommends the use of ZF Mathers Service Field Test Unit (P/N 13927) (Break-out Box) and a cali- brated Multi Meter. Figure 48: Service Field Test Unit and Multi Meter Table 4: Functions Requiring Service Field Test Unit and Multi Meter Throttle in Neutral (Section 7.7)
Page 54 ADJUSTMENTS AND TESTS [AT DOCK] 7.4 E-2 T E-3 T HROTTLE INIMUM AND HROTTLE AXIMUM IGNAL NGINES TOPPED ADJUSTMENTS MAY NOT BE REQUIRED. Verify the existing Throttle Minimum and Maximum values prior to adjusting them. NOTE: Synchronization is dependent on the Throttle Minimum and Maximum adjustments being equal on each Processor.
Page 55 ADJUSTMENTS AND TESTS [AT DOCK] Table 5: Throttle PWM, Voltage, Current Output Adjustments PWM (Duty Cycle) Voltage (VDC) Current (mA) 3) Attach the Multi Meter Black Lead 3) Attach the Multi Meter Black Lead 3) Attach the Multi Meter Black Lead to the negative (-) and the Red to the negative (-) and the Red to the negative (-) and the Red...
Page 56 ADJUSTMENTS AND TESTS [AT DOCK] 7.5 E NGINE WITCHES NGINES UNNING A) Start engine(s). B) Verify that all Engine Stop Switches function correctly at all sta- tions. Refer to information supplied by engine manufacturer or switch sup- plier for set-up and adjustments. CAUTION: An Engine Stop Switch at each station is an absolute requirement.
Page 57 ADJUSTMENTS AND TESTS [AT DOCK] 7.7 E1 - T HROTTLE IN EUTRAL NOTE: This Function is used ONLY when the E0 Select Engine Throttle Profile is set for 03 - Cum- mins Quantum. The Cummins- Quantum Engine requires different throttle com- mand signals in Neutral than when In-Gear.
Page 58 ADJUSTMENTS AND TESTS [AT DOCK] E) Use the Up or Down arrow to scroll to the E1 Function Code. • The Multi Meter will read the output signal for Throttle in Neutral. F) Activate Set-up Mode. Refer to Section 6.2. G)Change the Value of the Function.
Page 59 ADJUSTMENTS AND TESTS [AT DOCK] 7.8 E4 - T HROTTLE AXIMUM STERN This value determines the percentage of Throttle Maximum that is allowed in Astern. This is adjustable anywhere between 1 to 100%. The values of this Function are 1.0% to 100.0%. Throttle defaults are based on Throttle Profile selected.
Page 60 ADJUSTMENTS AND TESTS [AT DOCK] 7.9 E6 - H This function allows the operator the option of having a second/ ele- vated Idle speed. This second/ elevated Idle can be adjusted from 0 to 20% of full throttle. If 0 is selected, High Idle will be the same as normal or low Idle, which is the default value.
Page 61 ADJUSTMENTS UNDERWAY 8.0 ADJUSTMENT UNDERWAY WARNING: DO NOT attempt to operate CruiseCommand away from the dock with any system abnormality. Verify that all the above tests are completed and are correct. CAUTION: Start slowly and learn to appreciate that the CruiseCom- mand System provides a light touch that is fast and accu- rate.
Page 62 ADJUSTMENTS AND TESTS UNDERWAY 8.3 L2 & L3 T ROLLING INIMUM AND AXIMUM DJUSTMENTS NGINES UNNING Troll Minimum Pressure (L2) The amount of current delivered to the Proportional Valve when Minimum Pressure is desired, is set with this function. This is adjustable anywhere between 01.0% to 99.0% of the total current output capability of the circuit.
Page 63 ADJUSTMENTS AND TESTS UNDERWAY E) Attach the Multi Meter Black (COM) and Red (mA) Leads as shown in Figure F) Turn ON power to the Clutch Power Supply. Ensure Power is On to the Processor. Figure 55: Multi Meter and Test Unit Connections G)Position the Control Head lever to the Ahead Detent and turn Troll Mode On.
Page 64 ADJUSTMENTS AND TESTS UNDERWAY Table 7: Minimum Trolling Pressure SINGLE SCREW Propeller Shaft RPM at minimum trolling pressure Approx. 30 - 50% of Table 6: Shaft RPM Current (mA) Function % TWIN SCREW Propeller Shaft RPM at minimum trolling pressure Approx.
Page 65 ADJUSTMENTS AND TESTS UNDERWAY Table 8: Maximum Trolling Pressure SINGLE SCREW Propeller Shaft RPM at maximum trolling pressure Approx. 70% of Table 6: Shaft RPM Current (mA) Function % TWIN SCREW Propeller Shaft RPM at maximum trolling pressure Approx. 70% of Table 6: Shaft RPM Current (mA) Function %...
Page 66 ADJUSTMENTS AND TESTS UNDERWAY 8.4 L4 - T ROLL HROTTLE IMIT The maximum amount of throttle command which is applied to the engine, while the Trolling Valve is actively slipping the clutch, is set with this function. This is adjustable from no increase in throttle above Idle, to an increase of 20% of full throttle.
Page 67 ADJUSTMENTS AND TESTS UNDERWAY 8.5 L5 - T ROLL ULSE URATION This function sets the time in seconds that the Proportional Valve will be commanded the current programmed in "Troll Pulse Percent- age". This function gives a pressure boost to the Clutch plate in order to get the Propeller Shaft rotating prior to dropping to the level programmed in Troll Minimum.
Page 68 ADJUSTMENTS AND TESTS UNDERWAY B) Use the Up or Down arrow to scroll to the L5 Function Code. Function Code is blinking Figure 60: L6 - Troll Pulse Percentage Set-up Activated C) Activate Set-up Mode. Refer to Section 6.2. D)Change the Value of the Function. E) When the value required is displayed, store the value.
Page 69 CONTROL OPTIONS 9.0 CONTROL OPTIONS 9.1 A LARM APABILITY ClearCommand offers a single alarm connection that OPENS with a system power failure or circuit malfunction. The Power Wire Harness may be ordered with a cable to be used for the alarm connection. The alarm circuit in the Processor operates an alarm system supplied by others.
Page 70 MAINTENANCE 10.0MAINTENANCE 10.1C ONTROL ROCESSOR Check all terminal connections for signs of corrosion or loose connec- tions. 10.2C ONTROL Verify once a year that Control Head terminals are secure and free of corrosion. Apply a light coating of Teflon grease, or corrosion block, to the contacts.
Page 71 PPENDIX...
Page 73 Appendix A 7/01 PARTS LIST PART NO. DESCRIPTION CONTROL HEADS The following Control Heads are with Terminal connections. To order pluggable connections add a P onto the Part Number. Example: 450-3LP or 460-4P 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...
Page 74 Appendix A 7/01 Page 2...
Page 75 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-280 Rev.G 6/01 400 & MC2000 Control Head Variations 11643 Page 3...
Page 76 Make connections to the Control Head as shown above for MicroCommander, ClearCom- mand, and CruiseCommand Systems. Hand Held Control is a Station option. Contact your ZF Mathers Dealer for further information on Hand Held requirements and options. Page 4...
Page 77 Page 5...
Page 78 Page 6...
Page 79 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-307 Rev.C 6-01 700 Series Control Head Sheet Standard Cable Connections A) Remove the bottom cover from the Control Head. B) Insert electrical cable through watertight cable grip(s) in Control Head bottom cover.
Page 80 E) Strip 3/8" insulation off each wire. (9,5mm) F) Twist the individual strands of the wires to minimize fraying. G) Crimp a locking fork terminal (included with each Control Head) to each of the con- ductors. H) Make connections to the Control Head as shown below for MicroCommander, ClearCommand, and CruiseCommand Systems.
Page 81 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-310 Rev.D 6-01 464-4 Control Head Sheet Standard Cable Connections Select the desired mounting locations and drill holes per template. Run cables between Actuator/ Processor and Control Head. At the Control Head, strip back the PVC cover on the shielded cable approximately 2"...
Page 82 Page 10...
Page 83 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-326 Rev.- 7/01 CH14450 Control Head Sheet Standard Cable Connections Select the desired mounting locations and drill holes per template. Run cables between Actuator/Processor and Control Head.
Page 84 Page 12...
Page 85 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-279 Rev.A 11/00 400 Series Watertight Enclosure Single or Dual Control Head Gasket Control Head .75 inch Diameter Hole Mounting Locate where required. Holes (two if Dual Control Head) 3.54...
Page 86 Page 14...
Page 87 Deutsch Connector Assembly Page 15...
Page 88 Page 16...
Page 89 Page 17...
Page 90 Page 18...
Page 91 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 Mathers Pro- pulsion Control System.
Page 92 14 AWG (#2 Metric Equiva- lent) 20’-40’ 12 AWG (#3 Metric Equiva- lent) Note: 1. APS output is strictly for ZF Mathers Controls Figure 1: 2. Power Sources may be 12 or 24 volts DC A.P.S. (Auto Power Selector) Kits...
Page 93 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-287 Rev.B 7-01 Bonding - A.B.Y.C. E-9 46 CFR 111.05 All boats equipped with a permanently installed electrical system shall also be equipped with a bonding system. The negative terminal of all batteries should be connected at only one point, the DC common, and from DC common to bond system or hull.
Page 94 Page 22...
Page 95 ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-288 Rev.C 7/01 References and Parts Source A) REFERENCES American Boat & Yacht Council (ABYC) 3069 Solomons Island Road Edgewater, MD 21037-1416 E-3 Wiring Identification on Boats E-9 DC Electrical Systems on Boats H-2.4e or 32.4g Ambient Temp.
Page 96 B)PARTS SOURCE Anti-Static Wrist Strap P/N 517 [Thomas & Betts (P/N AWCC)] Automatic Power Selector P/N 13505 Circuit Breaker- UL Approved P/N 810 [E-T-A (P/N 41-2-514-LN2-10)] Fuse P/N 1030 [Bussman (P/N. GDC-1A)] Relay 12 VDC P/N 1114 [Potter-Brumfield (P/N KRPA5D6-12)] Relay 24 VDC P/N 1122 [Potter-Brumfield (P/N KRPA5D6-24)]...
Page 97 PPENDIX...
Page 99 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.0 TROUBLESHOOTING 1.1 G ENERAL The CruiseCommand Control System consists of one Processor per engine, typically mounted in the engine room, and one to four Control Heads located at the vessel’s remote stations. The Processors are designed to precisely control electronic throttles and transmissions equipped with solenoid clutch or clutch/troll selection.
Page 100 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 are the Control Head(s), Processor(s), Electrical Wiring (Harnesses) and a Power Source. The following is a brief description of these components. As you read through this manual there are more detailed explanations of these components, their function and how this function is accomplished. 1.1.1 Control Head The primary function of the Control Head is to send out a variable DC...
Page 101 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.2 T ROUBLESHOOTING UESTIONS Prior to ever lifting a tool or stepping on board the vessel, a lot of problems can be resolved by asking the customer the following basic questions: A)Is the system installed on a Single, Twin or Multiple Screw ves- sel? •...
Page 102 Write down the Error Message Number and have available for the ZF Mathers Representative. D)Are the Control Head(s) LED’s lit or not? • The LED(s) will be in one of four states 1.
Page 103 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 • When the LED in Not Lit, that Station is not in command or is experiencing an error. • A Slow Blinking LED indicates that the Control Head is in the “Warm-up Mode”. • A LED that is Blinking Rapidly or strobing indicates that the system is in “Troll Mode”.
Page 104 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 that the system is in compliance with the Installation Manual by care- fully inspecting the following: A)DC Power Source 1. Ensure that the Processor(s) and Clutch power is connected to a properly charged 12 or 24VDC battery through a 10 Ampere circuit breaker. 2.
Page 105 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 The key to troubleshooting the CruiseCommand Control System is identifying which of the categories listed below is the cause of the problem: • DC Power Source • Interconnecting Wiring (Harnesses) • Engine or Transmission • Component Calibration •...
Page 106 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Port Starboard Red LED Red LED Port Starboard Sound Sound Transducer Transducer 11580- Figure 3: Control Head Indicators In addition to the audible and visual indications provided by the Con- trol Heads, the Processor has four 7-segment pad’s (Display), which display Error Codes in addition to Set-up information described previ- ously in the Installation manual.
Page 107 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 • Stations 1- 4 Transfer Button Status • Software Revision Level A) Locate the Display on the Port or Starboard Processor. The Dis- play will have a pattern moving from left to right which looks like Figure 5: while the program is running: Figure 5: Display Pattern B) Depress the Up and Down Arrow Push-buttons simultaneously.
Page 108 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 • The displayed value is in “real time” and provides a rough estimate of the DC voltage applied to the Processor. The reading is accurate to within 0.50 DC. Figure 8: Display Applied Battery Voltage E) In addition to the applied battery voltage, scrolling through the Diagnostics Menu by pressing the Up or Down Arrow Push-but- ton can also show the Tachometer Sender Frequency: •...
Page 109 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 cates a closure (depressed Transfer Button) of the switch, while a “0” indicates an open switch. This will also be cov- ered in more detail later. Figure 11: Display Stations Control Head Transfer Button Status F) Depressing the Up or Down Arrow one more time will show the current revision level of the software.
Page 110 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.5 A UDIBLE ONES As mentioned previously, there are various tones emitted from the Control Head if an error were to occur. These tones are as follows: 1.5.1 Slow Repetitive Tone The Slow Repetitive Tone, also referred to as the “Initialization Tone” is the tone you hear at all Remote Stations when power is initially applied to the control system.
Page 111 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 B) In either case, follow the procedure listed under Diagnostic Menu (Section 1.4) until the Applied Battery Voltage is displayed. Take note of the applied voltage. C) Go to the battery or Main Distribution Panel which is feeding power to the Processor.
Page 112 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 • An open or high resistance connection between the Control Head and Processor. • Out of calibration Control Head • A defective Control Head The exact cause of the malfunction can be found as follows: A) Check the Processor’s Display for error messages. Most likely, one of error messages 13 thru 28 will be shown.
Page 113 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 priate A/D (Analog/Digital) value for the current position of the Control Head’s lever will be shown, as in the examples below: Figure 14: Display Stations A/D Value E) If the A/D value is 900 or greater, one of Error Codes 13- 20 will be shown.
Page 114 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 K) If the A/D value is less than 75, there is an open circuit on the green or blue wires. 1.5.3 Steady Tone The Steady Tone is an indication to the operator that something has gone wrong within the Control System.
Page 115 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 • The Transfer Button must be depressed which takes the “Station Select” signal from 5.00 VDC to 0.00 VDC. These items can be tested as follows: 1.6.1 Command Signal As mentioned previously, the Command Signal is a DC voltage which varies in relationship to the Control Head’s lever position.
Page 116 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 As you can see by the examples, even though the Command Voltages are different between Examples # 1 & 2, the resulting A/D counts, are the same because of the different Reference Voltages. This would result in the Processor commanding the identical outputs (Clutch &...
Page 117 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Whenever command cannot be gained at a particular remote station, the Station Select and Command Signals are the first to be investigated. If either the Command Signal is out of range or the Station Select is inop- erable, command will not be accepted at that remote station.
Page 118 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Messages are installed into the software for future considerations, while others are surely to be added in the future. Table 1: Error Messages Title Description Clutch Astern Shorted The Astern Clutch Solenoid appears to be shorted or is requiring more current than can be supplied. Clutch Astern Open The Astern Clutch Solenoid appears to be open.
Page 119 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Table 1: Error Messages Title Description Remote Station # 7 Faulted Station # 7 Control Head’s lever position is out of range. The input appears to be too low. Remote Station # 8 Faulted Station # 8 Control Head’s lever position is out of range. The input appears to be too low. Remote Station # 1 Button Station # 1 Control Head’s Transfer Button has either been closed too long or has been closed since Stuck Closed...
Page 120 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Table 1: Error Messages Title Description Communication Error Time- Communication with the system has been too long without a Refresh message. out System 7 Communication Error Time- Communication with the system has been too long without a Refresh message. out System 8 Communication Error Time- Communication with the system has been too long without a Refresh message.
Page 121 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Table 2: Problem Scenarios Cause Solution a) The Troll On/ Off Solenoid circuit is Open. a) Properly connect the Troll On/ Off Solenoid. b) The Troll On/ Off Solenoid is defective. b) Replace the Troll On/ Off Solenoid. a) The Troll Command Solenoid is incorrectly wired at the Gear a) Properly connect the Troll Command Solenoid.
Page 122 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Table 2: Problem Scenarios Cause Solution a) The Station #8 Control Head’s Transfer Button is defective. a) Install a Transfer Button Kit or replace the Control Head. b) The Station #8 Control Head is improperly wired. b) Properly connect Station #8 Control Head.
Page 123 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 Table 2: Problem Scenarios Cause Solution a) The Serial Harness is not connected to ID #5 although it has a) Connect the Serial Harness into ID #5. been selected. b) If (5) items had been selected, ID #5 has not been identified. b) Identify one item as ID #5 with the “A0”...
Page 124 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 A) SYMPTOM The engine’s RPM varies, without moving the Con- trol Head lever (synchronization disabled). CAUSE REMEDY a. Problem with the Governor a. Connect the Break-out Box (part # 13927) as shown in Throttle Testing or Carburetor. Section.
Page 125 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 D)SYMPTOM Cannot obtain Warm-up Mode while moving the Control Head lever in the Ahead direction, only in the Astern direction. CAUSE REMEDY The Processor is sensing Con- Depress the Transfer Button while moving the Control Head lever in the trol Head lever movement in Astern direction.
Page 126 1.9 C ABLE ARNESSES The various Cable Harnesses are manufactured and tested at ZF Mathers facility in Burlington, WA. The likelihood of one being mis- wired is slim. In any case, the following tables provide the wiring information for these Harnesses: 1.9.1...
Page 127 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.9.2 Power, Start Interlock & Pressure Switch PROCESSOR ENGINE, GEAR BOX & BATTERY Termination A Conductor Termination B Description Color J11-1 Yellow w/ Starter Closed contact when In-Command and at Neutral. Red Trace Solenoid J11-6 Light Blue Clutch Oil N.O.
Page 128 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.9.4 Throttle, PWM PROCESSOR ENGINE Termination A Conductor Termination B Description Color J9-1 Black Engine Throttle Signal Return DC- Bus J9-2 PWM Throttle Signal- 0- 100% Duty Cycle @ 500Hz. J9-8 Green/ Figure 20: PWM Throttle Harness Pin Out Yellow 1.9.5 Throttle, Voltage...
Page 129 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 PROCESSOR GEAR BOX Termination A Conductor Termination B Description Color J10-4 Black Ahead - VDC Return for Ahead Clutch Solenoid J10-5 Astern + 24 VDC when Astern Clutch Selected Solenoid J10-6 Black Astern - VDC Return for Astern Clutch Solenoid 1.9.8 Clutch Power, Ahead, Neutral &...
Page 130 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 PROCESSOR GEAR BOX Termination A Conductor Termination B Description Color J10-5 Astern +24 VDC when Astern Clutch Selected Clutch Solenoid J10-6 Black Astern -VDC Return for Astern Clutch Clutch Solenoid J10-9 Troll On/ +24 VDC when Troll is selected. Solenoid J10-10 Black...
Page 131 TROUBLESHOOTING TRAIN-156 Rev.B 11/01 1.9.12 Control Head PROCESSOR CONTROL HEAD Termination A Conductor Termination B Description Color J5, 6, 7 or Green/ Chassis Yellow J5, 6, 7 or Brown Pin 2 LED Power (2.10- 4.20 VDC) J5, 6, 7 or Violet Pin 8 - DC Return for green...
Page 132 Throttle Testing TRAIN-157 Rev.B 6/01 2.0 THROTTLE SIGNAL TESTING The CruiseCommand system has the capability of sourcing throt- tle signals in the form of DC Voltage, Current or PWM (Pulse Width Modulation). The type and range of these signals are determined by the Throttle Harness and Throttle Profile selected.
Page 133 Throttle Testing TRAIN-157 Rev.B 6/01 2.1 DC V OLTAGE A) Ensure power is removed from both the Engine Electronics and the CruiseCommand Processor. B) Disconnect the Throttle Harness from the Throttle Socket on the Processor. C) Insert the Test Unit between the Throttle Socket and the Throttle Harness as shown in Figure 29:, page 35 D)Set-up a Multi meter to measure DC Volts and plug the leads into the Test Unit.
Page 134 Throttle Testing TRAIN-157 Rev.B 6/01 I) Return the Control Head lever to the Neutral/ Idle position and turn power ‘Off’ to the Processor. J) Remove the Test Unit and plug the Throttle Harness back into the Processor’s Throttle Socket. 2.2 C URRENT A) Ensure power is removed from both the Engine Electronics and the CruiseCommand Processor.
Page 135 Throttle Testing TRAIN-157 Rev.B 6/01 F) Plug the test leads into the Test Unit as shown in Figure 31: The appropriate Idle current for the application should be measured. If the current is off slightly, it may be adjusted using the “Throttle Minimum”...
Page 136 Throttle Testing TRAIN-157 Rev.B 6/01 2.3 PWM (P ULSE IDTH ODULATION WITH YCLE ETER A) Ensure power is removed from both the Engine Electronics and the CruiseCommand Processor. B) Disconnect the Throttle Harness from the Throttle Socket on the Processor. C) Insert the Test Unit between the Throttle Socket and the Throttle Harness as shown in Figure 33:.
Page 137 Throttle Testing TRAIN-157 Rev.B 6/01 H)The appropriate Full Throttle Duty Cycle for the application should be measured as shown in Figure 34:. If the voltage is slightly off, it may be adjusted using the Throttle Maximum "E3" function. Figure 34: Dwg 11653-F I) Return the Control Head lever to the Neutral/ Idle position and turn power ‘Off’...
Page 138 Throttle Testing TRAIN-157 Rev.B 6/01 Figure 35: Dwg 11653-G D)Set-up a Multi meter to measure DC Volts and plug the test leads into the Test Unit as shown in Figure 35:. E) Turn Power ‘On’ to the Caterpillar ECM Only. Do Not apply power to the CruiseCommand Processor at this time.
Page 139 Throttle Testing TRAIN-157 Rev.B 6/01 G)Turn power ‘On’ to the CruiseCommand Processor and take com- mand at any remote station. H)Record the DC Voltage at this time. The measurement should be 7 - 9% of the voltage recorded in step F). Refer to Figure 36:. If the DC Voltage is off slightly, it may be adjusted using the Throttle Minimum "E2"...
Page 140 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 3.0 CLUTCH AND/OR TROLL TESTING The various outputs for controlling the Clutches and Electric Trolling Valves can be monitored for Open circuits or excessive current draw by using the H2(bd) (High Side Driver Fault Detec- tion) function. However, the applied voltage or current to these devices cannot be monitored with the H2(bd) function.
Page 141 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 F) Position the Control Head lever into the Ahead detent. The mea- surement should be 12 or 24 VDC depending on the Ahead Sole- noid’s rating. G)Return the Control Head lever to the Neutral/Idle position and turn power ‘Off’...
Page 142 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 G)Return the Control Head lever to the Neutral/Idle position and turn power ‘Off’ to the Processor. H)Remove the Test Unit and plug the Clutch Harness back into the Processor’s Socket. 3.3 N EUTRAL OLENOID ESTING A) Ensure power is removed from both the CruiseCommand Proces- sor and the Clutch Power Supply.
Page 143 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 H)Return the Control Head lever to the Neutral/Idle position and turn ‘Off’ the Processor and Clutch Power Supplies. I) Remove the Test Unit and plug the Clutch Harness back into the Processor’s Socket. 3.4 T ROLL OLENOID A) Ensure power is removed from both the CruiseCommand Proces- sor and the Clutch Power Supply.
Page 144 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 I) Return the Control Head lever to the Neutral/Idle position and turn ‘Off’ the Processor and Clutch power supplies. J) Remove the Test Unit and plug the Clutch Harness back into the Processor’s Clutch Socket. 3.5 T ROLL OMMAND ROPORTIONAL...
Page 145 TROUBLESHOOTING TRAIN-158 Rev.A 5/01 G)The measurement should be approximately 150 mA when Troll is set up to operate in the “Normal” fashion and approximately 450 mA when set up “Inverse”. H)Position the Control Head lever through the selected Troll Lever Range.
Page 146 APPENDIX B - TROUBLE SHOOTING EEPROM (H1) RASE NOTE: This function is to be used only by Authorized Personnel. This function restores all of the parameters to the factory default values. Page 49...
Page 147 ZF Mathers, LLC 1415 Pacific Drive Burlington, WA 98233 USA 800-546-5455 / 360-757-6265 Fax: 360-757-2500 SER-165, Rev. B 10-01 ZF Marine Contact List AUSTRALIA FRANCE 6948 2190 ZF Australia Pty. LTD T: +61 (0) 2 9647 6222 Seimi T: 33 2 98 46 11 02 (mail) Locked Bag 13 (mail) B.P.
Page 148 ZF Marine Propulsion S.r.l. T: +39 049 8299 338 7045 Via Penghe, 48 ZF South East Asia Pte. T: +65 (0) 8 610177 I-35030 Caselle di Selvazzano (PD), 11 Tuas Drive 1 F: +39 049 8299 550 ITALY Singapore, 638678 Rep.
Page 149 Phil Organ ZF Mathers, LLC T: +1 360 757 6265 ZFI Marine - North Carolina T: +1 252 504 3700 1415 Pacific Drive c/o Jarret Bay Boat Works T: +1 252 504 3754 Burlington, WA 98233 USA 530 Sensation Weigh...
Page 151 PPENDIX...
Page 153 Drawing 11748, Single Screw, Two Stations Page 3...
Page 154 Page 4...
Page 155 Drawing 11746, Single Screw, Two Pluggable Stations Page 5...
Page 156 Page 6...
Page 157 Drawing 11747, Twin Screw, Two Stations Page 7...
Page 158 Page 8...
Page 159 Drawing 11745, Twin Screw, Two Pluggable Stations Page 9...
Page 160 Page 10...

ZF CruiseCommand 785CE Installation And Troubleshooting Manual

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