ZF Marine ClearCommand 9000 Series Installation, Operation And Troubleshooting Manual
  1. Manuals
  2. Brands
  3. ZF Marine Manuals
  4. Control Systems
  5. ClearCommand 9000 Series
  6. Installation, operation and troubleshooting manual

ZF Marine ClearCommand 9000 Series Installation, Operation And Troubleshooting Manual

Hide thumbs
Table of Contents
  • Table of Contents
  • Table O F C O N T E N T S
  • Revisions List
  • I N T R O D U C T I O N
  • M a N U a L C O N T E N T S
  • B a S I C T H E O R y O F O P E R a T I O N
  • N O I D , T R O L L - S O L E N O I D )
  • Figure 1 - 1 : B a S I C 9 1 2 0 O R 9 1 2 2 C L E a R C O M M a N D S y S T E M D I a G R a M
  • 9 1 2 1 P R O C E S S O R ( T H R O T T L E - S E R V O 2 , S H I F T - S O L E N O I D , T R O L L - S E R V O 1 )
  • Figure 1 - 2 : B a S I C 9 1 2 1 C L E a R C O M M a N D S y S T E M D I a G R a M
  • 9 2 1 0 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 )
  • Figure 1 - 3 : B a S I C 9 2 1 0 C L E a R C O M M a N D S y S T E M D I a G R a M
  • 9 2 1 1 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 , T R O L L - S E R V O 2 )
  • Figure 1 - 4 : B a S I C 9 2 1 1 C L E a R C O M M a N D S y S T E M D I a G R a M
  • Figure 1 - 5 : B a S I C 9 2 2 1 C L E a R C O M M a N D S y S T E M D I a G R a M
  • S y S T E M F E a T U R E S
  • T a N D a R D P R O C E S S O R F E a T U R E S
  • 9 0 0 0 S E R I E S a D D I T I O N a L F E a T U R E S
  • P T I O N a L S y S T E M F E a T U R E S ( S E C T I O N 2 - 1 6 )
  • P E R a T I O N
  • D C P O W E R O N
  • T a K I N G C O M M a N D
  • Figure 2 - 1 : S T a T I O N T a K I N G C O M M a N D
  • B a S I C O P E R a T I O N
  • O R M a L O P E R a T I N G M O D E
  • Figure 2 - 2 : C O N T R O L H E a D D E T E N T S
  • T R O L L I N G V a L V E O P E R a T I O N L
  • S T a R T I N T E R L O C K ( I F U S E D )
  • Figure 2 - 3 : C O N T R O L H E a D 2 0 D E G R E E T R O L L R a N G E - T y P E 1
  • Figure 2 - 4 : C O N T R O L H E a D 3 5 D E G R E E T R O L L R a N G E - T y P E 2
  • Figure 2 - 5 : C O N T R O L H E a D 4 5 D E G R E E T R O L L R a N G E - T y P E 3
  • Figure 2 - 6 : C O N T R O L H E a D 5 5 D E G R E E T R O L L R a N G E - T y P E 4
  • S T a T I O N T R a N S F E R
  • Figure 2 - 7 : R E M O T E S T a T I O N S B E F O R E T R a N S F E R O F C O M M a N D
  • P R O P O R T I O N a L P a U S E
  • W a R M - U P M O D E
  • Figure 2 - 9 : C O N T R O L H E a D W a R M - U P M O D E
  • H I G H / L O W I D L E
  • O W I D L E
  • I G H I D L E
  • E L E C T I N G B E T W E E N H I G H a N D L O W I D L E
  • Figure 2 - 1 1 : H I G H / L O W I D L E M O D E S E L E C T I O N
  • N E L E V E R M O D E ( T W I N S C R E W )
  • T U R N I N G O N O N E L E V E R O P E R a T I O N
  • Figure 2 - 1 2 : S T E P a ) O N E L E V E R O P E R a T I O N M O D E
  • T U R N I N G O F F O N E L E V E R O P E R a T I O N
  • N G I N E S y N C H R O N I Z a T I O N ( T W I N S C R E W )
  • Figure 2 - 3 1 : T H R E E S E C O N D S T E a D y T O N
  • Figure 2 - 3 2 : C I R C U I T B O a R D S H I E L D L a y O U
  • C L U T C H P R E S S U R E I N T E R L O C
  • M U L T I P L E S C R E W I N S T a L L a T I O N
  • P L a N T H E I N S T a L L a T I O N
  • S y S T E M R E Q U I R E M E N T S
  • Figure 3 - 1 : P R O C E S S O R D I M E N S I O N S
  • R O C E S S O R ( S )
  • O N T R O L H E a D ( S )
  • T a N D a R D W I R E H a R N E S S E S
  • H a R N E S S E S
  • D D I T I O N a L H a R N E S S E S
  • L U T C H
  • L U T C H / T R O L L H a R N E S S
  • T a N D a R D E L E C T R I C C a B L E S
  • P O W E R E L E C T R I C C a B L E R E Q U I R E M E N T S
  • S T a R T I N T E R L O C K E L E C T R I C C a B L E R E Q U I R E M E N T S
  • C L U T C H P R E S S U R E I N T E R L O C K E L E C T R I C C a B L E R E Q U I R E M E N T S
  • E X T E R N a L a L a R M C I R C U I T E L E C T R I C C a B L E R E Q U I R E M E N T S
  • A C T a C H I N P U T
  • O P E N C O L L E C T O R ( a C T I V E )
  • D D I T I O N a L E L E C T R I C C a B L E S
  • H R O T T L E E L E C T R I C C a B L E R E Q U I R E M E N T S
  • L U T C H E L E C T R I C C a B L E R E Q U I R E M E N T S
  • P T I O N a L T O O L S
  • E Q U I R E D P a R T S
  • D C P O W E R S O U R C E
  • N S T a L L a T I O N
  • P R O C E S S O R
  • C O N T R O L H E a D ( S )
  • 4 0 0 , M C 2 0 0 0 a N D 7 0 0 S E R I E S C O N T R O L H E a D S
  • 5 0 0 S E R I E S C O N T R O L H E a D S
  • A N D H E L D R E M O T E C O N T R O L S
  • W I R E H a R N E S S I N S T a L L a T I O N
  • L U G I N S E R T I O N a N D E X T R a C T I O N
  • Figure 4 - 1 : H a R N E S S P L U G K E y I N G
  • T a N D a R D P O W E R / S T a R T I N T E R L O C K H a R N E S S
  • D C P O W E R C a B L E
  • Figure 4 - 3 : S T a R T I N T E R L O C K C O N N E C T I O N S
  • ( O P T I O N a L )
  • T a N D a R D C O N T R O L H E a D H a R N E S S
  • Figure 4 - 2 : H a R N E S S P L U G L O C K I N G M E C H a N I S M S
  • O N E P L U G
  • E R I a L C O M M U N I C a T I O N H a R N E S S ( T W I N S C R E W O N L y )
  • A C H S E N S O R H a R N E S S ( R E Q U I R E D F O R a C T I V E S y N C H R O N I Z a T I O N )
  • D D I T I O N a L 9 0 0 0 S E R I E S H a R N E S S E S
  • L U T C H / T R O L L H a R N E S S
  • H a R D - W I R E D C a B L E
  • I Q U I D T I G H T C O N N E C T O R
  • Figure 4 - 4 : L I Q U I D T I G H T I N S T a L L a T I O N
  • T a N D a R D P R O C E S S O R C a B L E H O L E S
  • Figure 4 - 5 : S T a N D a R D E N C L O S U R E C a B L E H O L E S
  • T a N D a R D C I R C U I T B O a R D C O N N E C T I O N S
  • 9 0 0 0 S E R I E S C I R C U I T B O a R D T E R M I N a T I O N P O I N T S
  • Figure 4 - 1 1 : 9 0 0 0 S E R I E S C I R C U I T B O a R D H a R D - W I R E D T E R M I N a T I O N P O I N T S
  • O C a T I O N S 1 - 9 I N S T a L L a T I O N
  • Figure 4 - 1 2 : S E V E N - C O N D U C T O R C O N T R O L H E a D C a B L E S H I E L D W I R E a N D H E a T - S H R I N K
  • Revision List
  • Introduction
  • Procedure: Throttle Signal Testing
  • DC Voltage
  • Current (Ma
  • PWM (Pulse Width Modulation) with DC Voltmeter
  • PWM (Pulse Width Modulation) with Duty Cycle Meter
  • Frequency (Hz
  • Procedure: Clutch Testing
  • Neutral Solenoid Testing
  • Ahead Solenoid Testing
  • Astern Solenoid Testing
  • Procedures: Troll Testing
  • Troll On/Off Solenoid
  • Troll Command (Proportional Solenoid) Testing with Amp Meter
  • Procedure: 2-Speed Testing
  • 2Nd Gear Disengaged
  • 2Nd Gear Engaged
  • Parts List

Advertisement

Quick Links

ClearCommand 9000 Series
Installation, Operation and
Troubleshooting Manual
5/08
MM9000-I Rev C.2

Advertisement

Chapters

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ClearCommand 9000 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for ZF Marine ClearCommand 9000 Series

  • Page 1 ClearCommand 9000 Series Installation, Operation and Troubleshooting Manual 5/08 MM9000-I Rev C.2...
  • Page 2 The information in this manual is believed to be accurate at the time of publication, but no responsibility, direct or consequential, can be accepted for damage resulting from the use of this information. ZF Marine Electronics, LLC, reserves the right to make changes to any of its products without notice.
  • Page 3 P R E F A C E ClearCommand 9000 Series Z F M a t h e r s E N G I N E C L U T C H T R O L L P r o c e s s o r P a r t N o . S e r v o E l e c t r o n i c S e r v o S o l e n o i d S e r v o S o l e n o i d 9 0 0 1 A c t u a t o r...
  • Page 4 P R E F A C E H a r d - w i r e d i n s t a l l a t i o n i s d e s c r i b e d i n S e c t i o n 4 - 4 , w i t h t h e e x c e p t i o n o f t h e T a c h o m e t e r S i g n a l a n d S e r i a l C o m m u n i c a t i o n P i g t a i l s , w h i c h a l w a y s c o m e f r o m t h e f a c t o r y p r e - w i r e d .

  • Page 5: Table Of Contents

    T A B L E O F C O N T E N T S S W 1 5 6 2 3 . 0 Table of Contents T a b l e P r e f a c e - 1 : C l e a r C o m m a n d P r o c e s s o r L i s t ......................P r e f a c e - 1 T a b l e o f C o n t e n t s .

  • Page 6: Table O F C O N T E N T S

    T A B L E O F C O N T E N T S 2 - 1 1 . 1 S y n c h r o n i z a t i o n T y p e s ............2 - 8 2 - 1 1 .
  • Page 7 T A B L E O F C O N T E N T S F i g u r e 2 - 3 0 : O n e L o n g , F o u r S h o r t - H i g h R e p e t i t i v e R a t e T o n e ......... . . 2 - 1 7 2 - 1 3 .
  • Page 8 T A B L E O F C O N T E N T S I N S T A L L A T I O N - - - - - - - - - - - - - - - - - - - - - - - - - - 4 - 1 4 - 1 P r o c e s s o r .
  • Page 9 T A B L E O F C O N T E N T S F i g u r e 4 - 2 0 : C l u t c h C a b l e H e a t S h r i n k i n P r o c e s s o r ........... . 4 - 1 4 4 - 4 .
  • Page 10 T A B L E O F C O N T E N T S F i g u r e 5 - 1 4 : D i s p l a y L E D F u n c t i o n A 3 S e t U p A c t i v a t e d ..........5 - 1 0 5 - 6 .
  • Page 11 T A B L E O F C O N T E N T S F i g u r e 5 - 4 8 : C o n t r o l H e a d 5 5 D e g r e e T r o l l R a n g e - T y p e 4 ..........5 - 2 3 5 - 6 .
  • Page 12 T A B L E O F C O N T E N T S T a b l e 7 - 1 : S h a f t R P M a t I d l e ............................7 - 6 7 - 1 5 .
  • Page 13 T A B L E O F C O N T E N T S M M C - 3 2 9 R e v . C 8 / 0 3 ..........................A - 9 M C 2 0 0 0 S e r i e s S t a n d a r d C o n t r o l H e a d V a r i a t i o n s M M C - 3 0 7 R e v .
  • Page 14 T A B L E O F C O N T E N T S B 1 - 2 . 5 P u s h - P u l l C a b l e s ............B 1 - 4 T a b l e B 1 - 1 : C l e a r C o m m a n d P r o c e s s o r P u s h - P u l l R e f e r e n c e .
  • Page 15 T A B L E O F C O N T E N T S T a b l e B 6 - 3 : C o n t r o l H e a d L e v e r A / D C o u n t s ........................B 6 - 2 B 6 - 3 R e m o t e S t a t i o n S e l e c t .
  • Page 16 T A B L E O F C O N T E N T S B 1 2 T R O U B L E S H O O T I N G C a b l e H a r n e s s e s - - - - - - - - - - - - - B 1 2 - 1 B 1 2 - 1 B a s i c C o n t r o l S y s t e m H a r n e s s e s .
  • Page 17 T A B L E O F C O N T E N T S E N G - 1 4 5 V e r 1 . 0 4 - 0 4 ......................... . B - 1 1 C l e a r C o m m a n d 9 0 0 0 S e r - T h r S o l - C l Q u a l i t a t i v e F a i l u r e A n a l y s i s &...

  • Page 18: Revisions List

    REVISIONS LIST Revisions List Date Revision Description Rev - 11/03 Revision - was a PRELIMINARY manual printed to support Production. Rev A 4/03 Released and Signed Off. Rev B 6/04 Updated with most current Forms and Manual Modules. Rev C 8/04 Included ELR 1167 and 1150 Rev C.1...

  • Page 19: I N T R O D U C T I O N

    I N T R O D U C T I O N I N T R O D U C T I O N T h i s m a n u a l i s w r i t t e n t o d o c u m e n t e v e r y p o s s i b l e s y s t e m o p t i o n . Y o u r s y s t e m m a y n o t i n c l u d e e v e r y a v a i l a b l e o p t i o n f o r s i n g l e o r t w i n s c r e w r e v e r s e r e d u c t i o n g e a r a p p l i c a t i o n s .

  • Page 20: Figure 1 - 1 : B A S I C 9 1 2 0 O R 9 1 2 2 C L E A R C O M M A N D S Y S T E M D I A G R A M

    I N T R O D U C T I O N 9 1 2 2 • m e c h a n i c a l l y a c t u a t e d e n g i n e s •...

  • Page 21: 9 1 2 1 P R O C E S S O R ( T H R O T T L E - S E R V O 2 , S H I F T - S O L E N O I D , T R O L L - S E R V O 1 )

    I N T R O D U C T I O N ( T h r o t t l e - S e r v o 2 , S h i f t - S o l e n o i d , T r o l l - S e r v o 1 ) 1 - 2 .

  • Page 22: 9 2 1 0 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 )

    I N T R O D U C T I O N ( T h r o t t l e - E l e c t r o n i c , S h i f t - S e r v o 1 ) 1 - 2 .

  • Page 23: 9 2 1 1 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 , T R O L L - S E R V O 2 )

    I N T R O D U C T I O N ( T h r o t t l e - E l e c t r o n i c , S h i f t - S e r v o 1 , T r o l l - 1 - 2 .

  • Page 24: Figure 1 - 5 : B A S I C 9 2 2 1 C L E A R C O M M A N D S Y S T E M D I A G R A M

    I N T R O D U C T I O N ( T h r o t t l e - E l e c t r o n i c , S h i f t - S o l e n o i d , T r o l l - 1 - 2 .

  • Page 25: S Y S T E M F E A T U R E S

    I N T R O D U C T I O N Y S T E M E A T U R E S 1 - 3 1 - 3 . 1 S t a n d a r d P r o c e s s o r F e a t u r e s •...

  • Page 26: P E R A T I O N

    O P E R A T I O N 2 O P E R A T I O N O W E R 2 - 1 D C P W h e n D C p o w e r i s t u r n e d O N t o t h e P r o c e s s o r : •...

  • Page 27: B A S I C O P E R A T I O N

    O P E R A T I O N A S I C P E R A T I O N 2 - 3 N o r m a l O p e r a t i n g M o d e 2 - 3 .

  • Page 28: S T A R T I N T E R L O C K ( I F U S E D )

    O P E R A T I O N F i g u r e 2 - 3 : C o n t r o l H e a d 2 0 D e g r e e T r o l l R a n g e - T y p e 1 F i g u r e 2 - 4 : C o n t r o l H e a d 3 5 D e g r e e T r o l l R a n g e - T y p e 2 F i g u r e 2 - 5 :...

  • Page 29: S T A T I O N T R A N S F E R

    O P E R A T I O N T A T I O N R A N S F E R 2 - 6 W A R N I N G : P E R S O N A L N J U R Y C O U L D O C C U R I F T H E F O L L O W I N G S T E P S A R E N O T F O L L O W E D E X A C T L Y C o m m a n d c a n b e t r a n s f e r r e d a s f o l l o w s :...

  • Page 30: H I G H / L O W I D L E

    O P E R A T I O N T h e s y s t e m i s p l a c e d i n t o W a r m - U p M o d e a s f o l l o w s : A ) A t t h e S t a t i o n - i n - C o m m a n d , e n s u r e t h a t t h e C o n t r o l H e a d ’...

  • Page 31: Figure 2 - 1 1 : H I G H / L O W I D L E M O D E S E L E C T I O N

    O P E R A T I O N R e f e r t o F i g u r e 2 - 1 1 : w h e n s e l e c t i n g b e t w e e n L o w a n d H i g h I d l e ( o r v i c e v e r s a ) a t t h e S t a t i o n - i n - C o m m a n d .

  • Page 32: Figure 2 - 1 2 : S T E P A ) O N E L E V E R O P E R A T I O N M O D E

    O P E R A T I O N • T h e C o n t r o l H e a d l e v e r w h i c h t h e o p e r a t o r c h o s e t o m o v e o u t o f t h e A h e a d d e t e n t , M a s t e r l e v e r b e c o m e s t h e...
  • Page 33 O P E R A T I O N 9000 S HE USE OF ALUE UNCTION SHOULD BE AVOIDED IN THE ERIES ROCESSORS N O T E : WITH M E C H A N I C A L T H R O T T L E C O N T R O L Y M P T O M 03 (A HEN SELECTED...
  • Page 34 O P E R A T I O N n a l s a r e c o m p a r e d w i t h o n e a n o t h e r o v e r a s e r i a l c o m m u n i c a t i o n l i n e .
  • Page 35 O P E R A T I O N • W h e n s y n c h r o n i z a t i o n i s t u r n e d O N b y p r e s s i n g t h e t r a n s f e r b u t - t o n , t h e g r e e n L E D w i l l l i g h t a f t e r t w o s e c o n d s a n d s t a y l i g h t e d a s l o n g a s t h e t r a n s f e r b u t t o n i s d e p r e s s e d .
  • Page 36 O P E R A T I O N 2 - 1 2 . 2 . 2 S e r v o T h r o t t l e F u n c t i o n s T h i s s e c t i o n a l o n g w i t h S e c t i o n 2 - 1 2 . 2 . 1 B a s i c T h r o t t l e F u n c t i o n s , p a g e 2 - 1 0 , a l l o w s t h e a d j u s t m e n t o f t h e S e r v o T h r o t t l e : E n g i n e T h r o t t l e P r o f i l e...
  • Page 37 O P E R A T I O N D e t a i l i n f o r m a t i o n o n e a c h f u n c t i o n i s f o u n d i n S e c t i o n 5 - 5 .
  • Page 38 O P E R A T I O N 2 - 1 2 . 4 . 2 T r o l l S e r v o F u n c t i o n s N O T E : T 9 0 0 1 T H E F O L L O W I N G R O L L...
  • Page 39 O P E R A T I O N 2 - 1 3 A U D I B L E O N E S 2 - 1 3 . 1 B a s i c P r o c e s s o r T o n e s T h e P r o c e s s o r c a n p r o d u c e n u m e r o u s t o n e s w h i c h i n f o r m t h e o p e r a t o r o f t h e s t a t u s o f t h e s y s t e m o r i f a n y f a u l t s w e r e t o o c c u r .
  • Page 40 O P E R A T I O N 2 - 1 3 . 1 . 6 F i v e S e c o n d s O n , F i v e S e c o n d s O f f - H i g h R e p e t i t i v e R a t e T o n e D e t a i l i n f o r m a t i o n o n t h i s t o n e i s i n A p p e n d i x B .
  • Page 41 O P E R A T I O N 2 - 1 3 . 4 C l u t c h S o l e n o i d T o n e s 2 - 1 3 . 4 . 1 O n e L o n g - O n e S h o r t T o n e D e t a i l i n f o r m a t i o n o n t h i s t o n e i s i n A p p e n d i x B .

  • Page 42: Figure 2 - 3 1 : T H R E E S E C O N D S T E A D Y T O N

    O P E R A T I O N 2 - 1 3 . 7 9 0 0 1 T r o l l i n g A c t u a t o r T o n e s ( S e r v o 3 ) T h e f o l l o w i n g T o n e s a r e i n a d d i t i o n t o t h e B a s i c T o n e s l i s t e d i n S e c t i o n 5 - 6 .

  • Page 43: Figure 2 - 3 2 : C I R C U I T B O A R D S H I E L D L A Y O U

    O P E R A T I O N Push Button Location LED Location 12255 F i g u r e 2 - 3 2 : C i r c u i t B o a r d S h i e l d L a y o u t 2 - 1 6 P L U G G A B L E O N N E C T I O N S...

  • Page 44: C L U T C H P R E S S U R E I N T E R L O C

    O P E R A T I O N 2 - 1 6 . 2 C l e a r C o m m a n d 9 0 0 0 S e r i e s P l u g g a b l e P r o c e s s o r s T h e 9 0 0 0 S e r i e s P r o c e s s o r s c o m e f r o m t h e f a c t o r y w i t h s t a n d a r d f i v e P i g t a i l C o n n e c t o r s l i s t e d i n S e c t i o n 2 - 1 5 .

  • Page 45: M U L T I P L E S C R E W I N S T A L L A T I O N

    O P E R A T I O N 2 - 1 7 . 4 M u l t i p l e S c r e w I n s t a l l a t i o n s T h i s M a n u a l , a s w r i t t e n , i s i n t e n d e d f o r S i n g l e a n d T w i n S c r e w a p p l i c a t i o n s o n l y .

  • Page 46: P L A N T H E I N S T A L L A T I O N

    P L A N T H E I N S T A L L A T I O N 3 P L A N T H E I N S T A L L A T I O N N O T E : Z F M A B Y C , E - A T H E R S R E C O M M E N D S T H A T T H E S Y S T E M B E I N S T A L L E D I N A C C O R D A N C E W I T H P 2 4 .

  • Page 47: R O C E S S O R ( S )

    P L A N T H E I N S T A L L A T I O N 3 - 1 . 1 P r o c e s s o r ( s ) P r o c e s s o r s r e q u i r e d p e r e n g i n e : S i n g l e S c r e w : O n e ( 1 ) P r o c e s s o r T w i n S c r e w : T w o ( 2 ) P r o c e s s o r s M o u n t i n g H a r d w a r e i s i n s t a l l e r s u p p l i e d .

  • Page 48: T A N D A R D W I R E H A R N E S S E S

    P L A N T H E I N S T A L L A T I O N w e a t h e r , c o n s i d e r u s i n g a W e a t h e r M o u n t E n c l o s u r e . R e f e r t o t h e 4 0 0 S e r i e s W e a t h e r M o u n t E n c l o s u r e , p a g e A - 2 1 , f o r s p e - c i f i c i n f o r m a t i o n .

  • Page 49: D D I T I O N A L H A R N E S S E S

    P L A N T H E I N S T A L L A T I O N 3 - 1 . 3 . 4 T a c h S e n s o r H a r n e s s T h e r e a r e t w o T a c h S e n s o r H a r n e s s e s a v a i l a b l e : 1 .

  • Page 50: T A N D A R D E L E C T R I C C A B L E S

    P L A N T H E I N S T A L L A T I O N O N / O F F T W O C O N D U C T O R C A B L E S F O R R O L L A N D R O L L...

  • Page 51: C L U T C H P R E S S U R E I N T E R L O C K E L E C T R I C C A B L E R E Q U I R E M E N T S

    P L A N T H E I N S T A L L A T I O N • 3 0 0 V , 1 0 5 d e g r e e s C , U L V W 1 , s t r a n d e d t i n n e d c o p p e r w i r e .

  • Page 52: D D I T I O N A L E L E C T R I C C A B L E S

    P L A N T H E I N S T A L L A T I O N 3 - 1 . 6 A d d i t i o n a l E l e c t r i c C a b l e s ( R e f e r t o t h e P a r t s L i s t i n A p p e n d i x A ) D e p e n d i n g o n t h e r e q u i r e m e n t s o f t h e i n s t a l l e r , t h e i n s t a l l a t i o n m a y u s e H a r n e s s e s , E l e c t r i c C a b l e s o r a c o m b i n a t i o n o f b o t h .
  • Page 53 P L A N T H E I N S T A L L A T I O N T a c h o m e t e r S e n s o r s 3 - 1 . 1 0 T h e r e a r e t w o t y p e s o f T a c h o m e t e r S e n s o r s a v a i l a b l e t h r o u g h Z F M a t h e r s , M e c h a n i c a l ( p / n 8 9 0 2 ) a n d M a g n e t i c P i c k u p ( p / n 8 9 1 2 ) .

  • Page 54: P T I O N A L T O O L S

    P L A N T H E I N S T A L L A T I O N S c r e w d r i v e r – s m a l l s t r a i g h t s l o t . S a w w i t h b l a d e s u i t a b l e f o r C o n s o l e T o p P a n e l .
  • Page 55 P L A N T H E I N S T A L L A T I O N 3 - 3 . 1 P r o c e s s o r P o w e r T h e i t e m s l i s t e d b e l o w w i l l h e l p e n s u r e o p t i m u m p e r f o r m a n c e f r o m y o u r c o n t r o l s y s t e m .

  • Page 56: N S T A L L A T I O N

    I N S T A L L A T I O N 4 I N S T A L L A T I O N E F O R E S T A R T I N G T H E A C T U A L I N S T A L L A T I O N O F T H E O N T R O L Y S T E M M A K E S U R E Y O U...

  • Page 57: T A N D A R D P O W E R / S T A R T I N T E R L O C K H A R N E S S

    I N S T A L L A T I O N B ) W h e n c o n n e c t i n g t h e p l u g s , e n s u r e t h a t t h e l o c k i n g m e c h a n i s m s a r e d e p r e s s e d a n d h e l d u n t i l t h e p l u g i s f u l l y c o n n e c t e d o r d i s c o n n e c t e d .

  • Page 58: O N E P L U G

    I N S T A L L A T I O N T h e f i r s t i n s t a l l a t i o n p r o c e d u r e ( S e c t i o n 4 - 3 . 3 . 1 ) b e l o w i s w r i t t e n •...

  • Page 59: A C H S E N S O R H A R N E S S ( R E Q U I R E D F O R A C T I V E S Y N C H R O N I Z A T I O N )

    I N S T A L L A T I O N 4 - 3 . 5 T a c h S e n s o r H a r n e s s ( r e q u i r e d f o r A c t i v e S y n c h r o n i z a t i o n ) A ) A t t h e P r o c e s s o r s , r e m o v e t h e w a t e r t i g h t s e a l s f r o m t h e T a c h S e n d e r p i g t a i l p l u g s .

  • Page 60: H A R D - W I R E D C A B L E

    I N S T A L L A T I O N B ) R u n t h e c a b l e s t o t h e t r a n s m i s s i o n . C ) P l u g t h e D I N c o n n e c t o r i n t o t h e A h e a d a n d A s t e r n S o l e - n o i d s .
  • Page 61 I N S T A L L A T I O N (START INTERLOCK) YELLOW (START INTERLOCK) START INTER LO CK BROWN (ALARM -) BLACK (ALARM +) GREEN (CLU TCH PRES SURE -) BLUE POWER (CLUTCH PRES SURE +) ALARM, BLACK ORANGE (GROUND)
  • Page 62 I N S T A L L A T I O N A l l c a b l e s t h a t e n t e r t h e E n c l o s u r e m u s t g o t h r o u g h a L i q u i d T i g h t C o n n e c t o r i n o r d e r t o m a i n t a i n t h e m o i s t u r e r e s i s t a n t i n t e g - r i t y o f t h e P r o c e s s o r .

  • Page 63: 9 0 0 0 S E R I E S C I R C U I T B O A R D T E R M I N A T I O N P O I N T S

    I N S T A L L A T I O N 4 - 4 . 4 . 4 9 2 2 1 ( T h r o t t l e E l e c t r o n i c a n d C l u t c h S o l e n o i d ) C a b l e H o l e L o c a t i o n s 1 .

  • Page 64: O C A T I O N S 1 - 9 I N S T A L L A T I O N

    I N S T A L L A T I O N 1 2 . T h r o t t l e : T B 8 B r o w n - 3 , C l u t c h : T B 1 1 B l a c k - 1 R e d - 4 , B r o w n - 2...
  • Page 65 I N S T A L L A T I O N J ) C l i p t h e S h i e l d w i r e s o t h a t i t i s f l u s h w i t h t h e C l a m p . K ) C o n n e c t t h e c o n d u c t o r s t o t h e a p p r o p r i a t e p i n s a s s h o w n o n T a b l e 4 - 2 : , u s i n g a s m a l l s l o t t e d s c r e w d r i v e r a s s h o w n i n F i g u r e 4 - 1 4 :...
  • Page 66 I N S T A L L A T I O N b e r o u t e d t o P B 2 o n t h e C i r c u i t B o a r d a s s h o w n F i g u r e 4 - 1 1 : p a g e 4 - 1 4 C ) S t r i p b a c k 2 i n c h e s ( 5 0 , 8 m m ) o f t h e P V C j a c k e t -...
  • Page 67 I N S T A L L A T I O N I ) C o n n e c t t h e t w o - c o n d u c t o r c a b l e t o P B 1 , r e d l e a d t o t h e t e r m i n a l l a b e l e d ( + ) a n d b l a c k l e a d t o t h e t e r m i n a l l a b e l e d ( - ) , a s i n d i c a t e d o n F i g u r e 4 - 1 1 : , p a g e 4 - 1 4 .
  • Page 68 I N S T A L L A T I O N T a b l e 4 - 3 : P r o c e s s o r C i r c u i t B o a r d T e r m i n a l S t r i p C o l o r C o d e d C o n n e c t i o n s f o r S e r i a l C o m m u n i c a t i o n P O R T P R O C E S S O R S T A R B O A R D P R O C E S S O R...
  • Page 69 I N S T A L L A T I O N J ) I n s e r t t h e c a b l e e n d s t h r o u g h t h e l i q u i d t i g h t c o n n e c t o r s a n d t i g h t e n t h e n u t s .
  • Page 70 I N S T A L L A T I O N 4 - 4 . 7 . 1 . 2 P l u g T e r m i n a t i o n A ) S t r i p b a c k 2 1 / 4 i n c h e s ( 5 7 , 1 5 m m ) o f P V C j a c k e t - i n g .
  • Page 71 I N S T A L L A T I O N 4 - 4 . 7 . 2 . 4 P l u g T e r m i n a t i o n A ) S t r i p b a c k 2 1 / 4 i n c h e s ( 5 7 , 1 5 m m ) o f P V C j a c k e t - i n g .
  • Page 72 I N S T A L L A T I O N D ) S l i d e a 1 i n c h ( 2 4 , 5 m m ) p i e c e o f h e a t s h r i n k o v e r t h e e n d o f t h e c a b l e a s s h o w n i n F i g u r e 4 - 2 0 : .
  • Page 73 I N S T A L L A T I O N D ) S t r i p b a c k t h e P V C j a c k e t t o w i t h i n 1 / 2 i n c h ( 1 2 , 7 m m ) o f t h e e n c l o s u r e .
  • Page 74 I N S T A L L A T I O N B ) R e m o v e o n e s c r e w f r o m e a c h C a b l e A n c h o r C l i p a n d l o o s e n t h e o t h e r s c r e w .
  • Page 75 I N S T A L L A T I O N B ) I f t h e t h r o t t l e l e v e r i s a t t h e o p p o s i t e s i d e f r o m t h e p u s h - p u l l c a b l e , c h a n g e t h e T h r o t t l e S e r v o D i r e c t i o n E 0 a s d e s c r i b e d i n S e c t i o n 5 - 5 .
  • Page 76 I N S T A L L A T I O N • I f t h e p u s h - p u l l c a b l e e n d a n d t h e t r o l l s e l e c t o r l e v e r a r e i n c l o s e p r o x i m i t y t o o n e a n o t h e r , n o a d j u s t m e n t i s r e q u i r e d a t t h i s t i m e .
  • Page 77 S E T U P S E T U P P R O C E D U R E T h e P r o c e s s o r u t i l i z e s p u s h b u t t o n s i n c o n j u n c t i o n w i t h D i s p l a y L E D ’...
  • Page 78 S E T U P 5 - 1 . 1 P r o c e s s o r D i s p l a y L E D Starts the Processor Part Number again, one number at a time. 12309 EXAMPLE: Running Processor Part Number during Normal Operation (9210) F i g u r e 5 - 3 : D i s p l a y L E D a t N o r m a l O p e r a t i o n...
  • Page 79 S E T U P W h i l e i n S e t U p M o d e , d e a c t i v a t e s S e t U p M o d e , s a v e s t h e •...
  • Page 80 S E T U P A ) D e p r e s s a n d h o l d t h e r i g h t p u s h b u t t o n f i r s t . T h e n w h i l e s t i l l d e p r e s s i n g t h e r i g h t b u t t o n , d e p r e s s a n d h o l d t h e L e f t p u s h b u t t o n u n t i l t h e F u n c t i o n C o d e s t o p s b l i n k i n g .
  • Page 81 S E T U P T a b l e 5 - 1 : F u n c t i o n C o d e s F u n c t i o n F u n c t i o n N a m e V a l u e R a n g e o r O p t i o n s C o d e T H R O T T L E F U N C T I O N S c o n t i n u e d ( S e c t i o n 5 - 6 .
  • Page 82 S E T U P T a b l e 5 - 1 : F u n c t i o n C o d e s F u n c t i o n F u n c t i o n N a m e V a l u e R a n g e o r O p t i o n s C o d e T R O U B L E S H O O T I N G F U N C T I O N S ( S e c t i o n 5 - 6 .
  • Page 83 S E T U P T a b l e 5 - 2 : P r o c e s s o r s F u n c t i o n C o d e D e f a u l t s D e f a u l t V a l u e s F u n c t i o n C o d e...
  • Page 84 S E T U P F o r F u n c t i o n s , a n d c o n - n e c t t h e 8 - P i n c o n n e c t o r o f t h e S e r v i c e F i e l d T e s t U n i t i n t o t h e P r o c e s s o r T h r o t t l e c o n n e c t o r a n d...
  • Page 85 S E T U P T o c h a n g e t h e V a l u e ( R e f e r t o S e c t i o n s Function Code is Blinking 5 - 2 a n d 5 - 3 , p a g e 5 - 5 A ) S c r o l l t o F u n c t i o n C o d e A 0 .
  • Page 86 S E T U P 5 - 6 . 1 . 4 F u n c t i o n C o d e – S E ( S t a t i o n E x p a n d e r ) H I S A N U A L D O E S N O T G O I N T O D E T A I L O N T H E T A T I O N...
  • Page 87 S E T U P T o c h a n g e t h e V a l u e ( R e f e r t o S e c t i o n s 5 - 2 a n d 5 - 3 , p a g e 5 - 5 ) : A ) S c r o l l t o F u n c t i o n C o d e E 5 .
  • Page 88 S E T U P E x a m p l e : A V a l u e o f 5 0 . 0 w i l l a l l o w 5 0 % o f T h r o t t l e M a x i m u m w h e n c o m m a n d i n g A s t e r n .
  • Page 89 S E T U P B ) S c r o l l t o F u n c t i o n C o d e C ) A c t i v a t e S e t U p M o d e . D ) S c r o l l U p o r D o w n u n t i l t h e V a l u e d i s p l a y e d .
  • Page 90 S E T U P B ) M o v e t h e C o n t r o l H e a d l e v e r t o t h e F u l l A h e a d Function Code is Blinking p o s i t i o n .
  • Page 91 S E T U P 5 - 6 . 2 . 3 . 2 F u n c t i o n C o d e – T h r o t t l e M i n i m u m T h i s F u n c t i o n a l l o w s t h e t h r o t t l e s i g n a l a t I d l e t o b e f i n e t u n e d f r o m t h e V a l u e p r o v i d e d b y t h e E 0 T h r o t t l e P r o - f i l e .
  • Page 92 S E T U P C l u t c h P r e s s u r e S w i t c h i s u s e d . R e f e r t o S e c t i o n 8 - 2 , p a g e 8 - 2 , f o r d e t a i l e d i n f o r m a t i o n .
  • Page 93 S E T U P T o c h a n g e t h e V a l u e ( R e f e r t o S e c t i o n s 5 - 2 a n d 5 - 3 , Function Code is Blinking p a g e 5 - 5 ) : A ) S c r o l l t o F u n c t i o n C o d e...
  • Page 94 S E T U P - 1 : 1 R a t i o W h e n t h i s s e t t i n g i s s e l e c t e d , t h e v a l u e s e t i n t h e P r o p o r t i o n a l P a u s e T i m e i s t h e s a m e f o r b o t h A h e a d t o A s t e r n , a s w i t h A s t e r n t o A h e a d...
  • Page 95 S E T U P C ) C h e c k t h e S h i f t P u s h - P u l l c a b l e t o s e e i f i t d r o v e i n t h e c o r r e c t d i r e c t i o n .
  • Page 96 S E T U P A ) M o v e t h e C o n t r o l H e a d l e v e r t o t h e A s t e r n d e t e n t .
  • Page 97 S E T U P 5 - 6 . 4 . 2 . 2 F u n c t i o n C o d e – Z F - H u r t h D u t y C y c l e A h e a d T h i s f u n c t i o n a d j u s t s t h e m a x i m u m c u r r e n t a v a i l a b l e t o t h e A h e a d P r o p o r t i o n a l S o l e n o i d .
  • Page 98 S E T U P 5 - 6 . 5 T r o l l F u n c t i o n s 5 - 6 . 5 . 1 B a s i c T r o l l C o m m a n d F u n c t i o n s N O T E : I 9 0 0 1 T F T H E...
  • Page 99 S E T U P F i g u r e 5 - 4 5 : C o n t r o l H e a d 2 0 D e g r e e T r o l l R a n g e - F i g u r e 5 - 4 6 : C o n t r o l H e a d 3 5 D e g r e e T r o l l R a n g e - T y p e 1 T y p e 2...
  • Page 100 S E T U P 5 - 6 . 5 . 1 . 6 F u n c t i o n C o d e – T r o l l P u l s e D u r a t i o n T h i s F u n c t i o n d e t e r m i n e s t h e l e n g t h o f t i m e t h a t t h e V a l u e s e l e c t e d i n F u n c t i o n C o d e i s a p p l i e d .
  • Page 101 S E T U P I N G E C T I O N S W H E N M A K I N G T H E R O L L I N I M U M A N D R O L L A X I E F E R T O T H E F O L L O W...
  • Page 102 S E T U P O N O T M A K E A N Y A D J U S T M E N T S T O U N C T I O N O D E S A N D U N T I L T H E V E S S E L H A S B E E N N O T E :...
  • Page 103 S E T U P - N o r m a l , N o C u r r e n t w h e n a t L o c k - u p . P r e s e t f o r Z F 2 2 0 - 5 5 0 , 2 4 V D C S y s t e m s .
  • Page 104 S E T U P T h e a v a i l a b l e V a l u e s a r e p e r c e n t o f t h e 2 0 . 0 1 0 0 .
  • Page 105 S E T U P T h i s F u n c t i o n m a y b e u s e d d u r i n g t r o u b l e s h o o t i n g . ( D o n o t m a k e a n y a d j u s t m e n t s t o t h i s F u n c t i o n C o d e , u n l e s s d i r e c t e d t o d o s o b y Z F M a t h e r s S e r - v i c e o r E n g i n e e r i n g D e p a r t m e n t s ) .
  • Page 106 D O C K T R I A L S 6 D O C K T R I A L S W A R N I N G : I T I S I M P E R A T I V E T H A T T H E I N F O R M A T I O N P R O V I D E D I N T H E P R E V I O U S E C T I O N S H A S B E E N R E A D A N D F O L L O W E D P R E C I S E L Y P R I O R T O A T T E M P T I N G A...
  • Page 107 D O C K T R I A L S U S H U L L A B L E S 6 - 4 A ) C h e c k t h a t a l l P u s h - P u l l c a b l e c o n n e c t i n g f a s t e n e r s a r e t i g h t - e n e d s e c u r e l y .
  • Page 108 D O C K T R I A L S H R O T T L E A U S E O L L O W I N G E R V O H I F T 6 - 8 N O T E : A T E S T O N T R O L...
  • Page 109 D O C K T R I A L S 6 - 1 0 . 1 . 1 T r o l l M i n i m u m P r e s s u r e A d j u s t m e n t a t t h e D o c k E A R O I L M U S T R E A C H N O R M A L O P E R A T I N G T E M P E R A T U R E B E F O R E T H E R O L L I N G A L V E...
  • Page 110 D O C K T R I A L S C ) W i t h t h e e n g i n e r u n n i n g , p l a c e t h e S t a t i o n - i n - C o m - m a n d ’...
  • Page 111 S E A T R I A L S 7 S E A T R I A L S W A R N I N G : I T I S I M P E R A T I V E T H A T T H E I N F O R M A T I O N P R O V I D E D I N T H E P R E V I O U S E C T I O N S H A S B E E N R E A D A N D F O L L O W E D P R E C I S E L Y P R I O R T O A T T E M P T I N G A...
  • Page 112 S E A T R I A L S R O P O R T I O N A L A U S E 7 - 1 3 P T h e p r o p o r t i o n a l p a u s e f e a t u r e p r o v i d e s e n g i n e d e c e l e r a t i o n w h e n m a k i n g a d i r e c t i o n c h a n g e .
  • Page 113 S E A T R I A L S 7 - 1 3 . 4 C a l c u l a t i n g P r o p o r t i o n a l P a u s e T i m e C 3 N O T E : T H E P A U S E O N A T H R O U G H E U T R A L S H I F T I S P R O P O R T I O N A L T O T H E S P E E D C O M M A N D E D A N D...
  • Page 114 S E A T R I A L S I f t h e e n g i n e s t a l l e d o r c a m e v e r y c l o s e t o s t a l l i n g , i n c r e a s e t h e •...
  • Page 115 S E A T R I A L S O n c e t h e e n g i n e R P M ’ s a r e w i t h i n 1 % o f o n e a n o t h e r , t h e g r e e n •...
  • Page 116 S E A T R I A L S D ) U s i n g a S h a f t T a c h , m e a s u r e t h e R P M o f t h e S h a f t a n d r e c o r d o n T a b l e 7 - 1 : .
  • Page 117 S E A T R I A L S l i s t e d . T a b l e 7 - 2 : a l s o l i s t s t h e t y p i c a l p r e s s u r e r a n g e i n b a r s d u r - i n g t r o l l o p e r a t i o n .
  • Page 118 S E A T R I A L S • I f n o t , r e f e r t o S e c t i o n 5 - 6 . 4 . 1 . 4 , p a g e 5 - 2 9 , F u n c t i o n C o d e L 0 –...
  • Page 119 S E A T R I A L S F ) I f t w i n s c r e w , r e p e a t s t e p s A ) t h r o u g h E ) o n t h e o p p o s i t e s i d e .
  • Page 120 S E A T R I A L S 7 - 1 5 . 5 I n t e g r a t e d Z F - H u r t h S o l e n o i d T r o l l i n g T I S S T R O N G L Y R E C O M M E N D E D T H A T T H E I E L D E R V I C E...
  • Page 121 S E A T R I A L S R I A L E P O R T 7 - 1 6 S T h e p u r p o s e o f t h i s S e a T r i a l R e p o r t i s t o p r o v i d e a c o n v e n i e n t c h e c k l i s t a n d r e c o r d o f i n s t a l l a t i o n , d o c k t r i a l s e t u p , a n d s e a t r i a l p e r f o r m a n c e o f t h e Z F M a t h e r s P r o p u l s i o n C o n t r o l S y s t e m .
  • Page 122 S E A T R I A L S P O R T S T A R B O A R D Y E S Y E S A r e t h e p o w e r c a b l e s p r o t e c t e d b y 1 0 A m p e r e C i r c u i t B r e a k - e r s ? Y E S Y E S...
  • Page 123 S E A T R I A L S T a b l e 7 - 3 : P r o c e s s o r P a r a m e t e r s R e c o r d F u n c t i o n F u n c t i o n N a m e P o r t...
  • Page 124 S E A T R I A L S 7 - 1 6 . 4 C o m m e n t s ( P l e a s e u s e a d d i t i o n a l p a p e r a s n e c e s s a r y ) : 7 - 1 6 .
  • Page 125 C O N T R O L O P T I O N S C O N T R O L O P T I O N S 8 - 1 E X T E R N A L L A R M A P A B I L I T Y C A U T I O N : T h e P r o c e s s o r ’...
  • Page 126 C O N T R O L O P T I O N S 8 - 1 . 1 I n s t a l l a t i o n ( R e f e r t o F i g u r e 8 - 1 : o r F i g u r e 8 - 2 : ) T h e f o l l o w i n g i t e m s s h o u l d b e c o n s i d e r e d w h e n d e s i g n i n g a n d i n s t a l l i n g t h e S t a t u s I n d i c a t i o n P a n e l : T h e P o w e r W i r e H a r n e s s ( p / n 1 3 6 3 1 - # ) m u s t b e u s e d i f a n E x t e r -...
  • Page 127 C O N T R O L O P T I O N S T h e T h r o t t l e w i l l r e m a i n a t I d l e u n t i l t h e C o n t r o l H e a d ’ s l e v e r i s r e t u r n e d t o I d l e , t h e P r e s s u r e S w i t c h c o n t a c t c l o s e s a n d a s p e e d c o m m a n d a b o v e I d l e i s c o m m a n d e d .
  • Page 128 C O N T R O L O P T I O N S A ) I n s t a l l a S h u t t l e V a l v e o n o r n e a r t h e T r a n s m i s s i o n . B ) C o n n e c t h y d r a u l i c l i n e f r o m t h e A h e a d a n d A s t e r n C l u t c h e s .
  • Page 129 P E R I O D I C C H E C K S A N D M A I N T E N A N C E 9 P E R I O D I C C H E C K S A N D M A I N T E N A N C E T h e i t e m s l i s t e d b e l o w s h o u l d b e c h e c k e d o n a n a n n u a l b a s i s o r l e s s , w h e n n o t e d : O N T R O L...
  • Page 130 P E R I O D I C C H E C K S A N D M A I N T E N A N C E C A U T I O N : I n m a n y n e w e r b a t t e r i e s , t h e v e n t c a p i s p e r m a n e n t l y a t t a c h e d , p r e v e n t i n g a c c e s s t o t h e e l e c t r o l y t e f o r w a t e r l e v e l a n d s p e c i f i c g r a v i t y t e s t s .
  • Page 131 P E R I O D I C C H E C K S A N D M A I N T E N A N C E m o r e t h a n 1 0 % d i f f e r e n c e b e t w e e n t h e s e t w o p o i n t s . I f s o , c h e c k a l l d e v i c e s a n d c o n n e c t i o n s f o r e x c e s s i v e v o l t a g e d r o p .
  • Page 133 P P E N D I X...
  • Page 135 PARTS LIST PART NO. DESCRIPTION PROCESSORS (X represents number of remote stations) 9 1 2 0 X P r o c e s s o r ( m e c h a n i c a l t h r o t t l e , s o l e n o i d s h i f t ) M u l t i - v o l t a g e 9 1 2 1 X P r o c e s s o r ( m e c h a n i c a l t h r o t t l e , s o l e n o i d s h i f t , m e c h a n i c a l t r o l l )
  • Page 136 CONTROL HEAD ADAPTER PADS (400 and MC2000 Series Only) 1 0 0 2 P a d K i t - w h i t e , b l a n k 1 0 0 3 P a d K i t - b l a c k , b l a n k 1 0 0 4 P a d K i t - t e a k , b l a n k 1 0 0 5...
  • Page 137 MMC-280 Rev.N 5/08 ZF Marine Electronics, LLC Mukilteo Plant 400 Series Control Head Variations This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics 400 Series Control Heads. PART NUMBERING CONFIGURATIONS DETENTS AVAILABLE REQUIREMENTS: MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.
  • Page 138 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 Marine Electronics Dealer for further information on Handheld requirements and options.
  • Page 140 Page A-4...
  • Page 141 MMC-329 Rev.E 5/08 ZF Marine Electronics, LLC Mukilteo Plant MC2000 Series Standard Control Head Variations This Service Sheet reflects all current variations of the standard 3-detent ZF Marine Electronics MC2000 Series Control Heads Part Numbering Configurations Detents Available REQUIREMENTS: MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.
  • Page 142 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 an option. Contact your ZF Marine Electronics Dealer for further information on Handheld requirements and options.
  • Page 145 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 146 M O U N T I N G A N D I N S T A L L A T I O N : S e l e c t t h e d e s i r e d m o u n t i n g l o c a t i o n s a n d d r i l l s c r e w a n d c a b l e h o l e s a s i n d i - c a t e d o n t h e t e m p l a t e d i a g r a m .
  • Page 147 C A B L E / H A R N E S S C O N N E C T I O N S : D u a l C o n t r o l H e a d C o n n e c t i o n s T E R M I N A L C O N N E C T I O N S C a b l e / J u m p e r c o n n e c t i o n s 5 a n d 7 a t t h e P o r t a n d S t a r b o a r d...
  • Page 148 P a g e A - 1 8...
  • Page 149 T E M P L A T E P a g e A - 1 9...
  • Page 150 P a g e A - 2 0...
  • Page 151 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 152 P a g e A - 2 2...
  • Page 153 D e u t s c h C o n n e c t o r A s s e m b l y DT Type Step 1: Contact Removal Step 2: Wire Stripping Solid Contacts Contact Part Wire Gauge Strip Length 1.
  • Page 154 P a g e A - 2 4...
  • Page 155 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 156 P a g e A - 2 6...
  • Page 157 D r a w i n g 1 1 4 8 8 D - 1 T w i n S c r e w S i n g l e A P S C o n n e c t i o n & A l t e r n a t e R e m o t e S w i t c h P a g e A - 2 7...
  • Page 158 P a g e A - 2 8...
  • Page 159 D r a w i n g 1 1 4 8 8 D - 2 T w i n S c r e w D u a l A P S C o n n e c t i o n s P a g e A - 2 9...
  • Page 160 P a g e A - 3 0...
  • Page 161 D r a w i n g 1 1 4 8 8 D - 3 A P S N o t e s P a g e P a g e A - 3 1...
  • Page 162 P a g e A - 3 2...
  • Page 163 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 164 P a g e A - 3 4...
  • Page 165 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 166 P a g e A - 3 6...
  • Page 167 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 168 E n g i n e T y p e E n g i n e M o d e l S e n d e r C o m m e n t s D i e s e l M A N V - E n g i n e s 8 9 0 2...
  • Page 169 M M C - 2 8 9 R e v . - 6 / 0 1 M o r s e C l u t c h a n d T h r o t t l e K i t S e l e c t i o n P r e - E n g i n e e r e d T h r o t t l e C o n n e c t i o n K i t s M A K E E N G I N E M O D E L...
  • Page 170 P a g e A - 4 0...
  • Page 171 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 172 P a g e A - 4 2...
  • Page 173 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 174 I ) C a b l e I n s t a l l a t i o n [ R e f e r T o F i g u r e 2 : ] N O T E : 4 3 C C A B L E A N D J A M N U T A R E S U P P L I E D B Y O T H E R S 1 .
  • Page 175 ZF Marine Electronics does not authorize any representative or agent to assume for it any obligation or liability other than those expressly set forth above.
  • Page 176 P a g e A - 4 6...
  • Page 177 Z F M a t h e r s , L L C 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 U .
  • Page 178 Z F M a t h e r s , L L C . 1 2 1 2 5 H a r b o u r R e a c h D r i v e , S u i t e B M u k i l t e o , W A 9 8 2 7 5 P a g e C - 4 8...
  • Page 179 P P E N D I X...
  • Page 181 T R O U B L E S H O O T I N G B 1 T R O U B L E S H O O T I N G G E N E R A L T h e C l e a r C o m m a n d C o n t r o l S y s t e m c o n s i s t s o f o n e P r o c e s s o r p e r e n g i n e , t y p i c a l l y m o u n t e d i n t h e e n g i n e r o o m , a n d o n e t o f i v e C o n t r o l H e a d s l o c a t e d a t t h e v e s s e l ’...
  • Page 182 T R O U B L E S H O O T I N G B 1 - 1 . 2 9 1 2 1 ( T h r o t t l e S e r v o 2 , S h i f t S o l e n o i d , T r o l l S e r v o 1 ) P r o c e s s o r T h e P r o c e s s o r 9 1 2 1...
  • Page 183 T R O U B L E S H O O T I N G B 1 - 1 . 4 9 2 1 1 ( T h r o t t l e E l e c t r o n i c , S h i f t S e r v o 1 , T r o l l S e r v o 2 ) P r o c e s s o r T h e P r o c e s s o r 9 2 1 1...
  • Page 184 T R O U B L E S H O O T I N G Y P I C A L Y S T E M A I N O M P O N E N T S B 1 - 2 T B 1 - 2 .
  • Page 185 T R O U B L E S H O O T I N G u s e s t h e 3 3 C T y p e p u s h - p u l l c a b l e a s s t a n d a r d , o r 4 3 C T y p e w i t h a s p e c i a l a d a p t e r .
  • Page 186 T R O U B L E S H O O T I N G T R O U B L E S H O O T I N G Q U E S T I O N S P r i o r t o l i f t i n g a t o o l o r s t e p p i n g o n b o a r d t h e v e s s e l , m a n y p r o b l e m s c a n b e r e s o l v e d b y a s k i n g t h e c u s t o m e r t h e f o l l o w i n g b a s i c q u e s t i o n s : A ) I s t h e S y s t e m i n s t a l l e d o n a S i n g l e , T w i n o r M u l -...
  • Page 187 T R O U B L E S H O O T I N G ( R e f e r t o S e c t i o n B 5 - 1 . 2 , O n e L o n g - T h r e e S h o r t T o n e s p a g e B 5 - 2 ) ( R e f e r t o S e c t i o n B 5 - 1 .
  • Page 188 T R O U B L E S H O O T I N G B l i n k i n g R a p i d l y A r e d L E D t h a t i s i n d i c a t e s t h a t t h e S y s - B l i n k i n g R a p i d l y t e m i s i n T r o l l M o d e .
  • Page 189 T R O U B L E S H O O T I N G T R O U B L E S H O O T I N G P R O B L E M R E S O L U T I O N I f t h e p r o b l e m c o u l d n o t b e r e s o l v e d b y a s k i n g t h e q u e s - t i o n s i n t h e p r e v i o u s s e c t i o n , a c a r e f u l i n s p e c t i o n o f t h e C o n t r o l S y s t e m m a y b e t h e n e x t s t e p .
  • Page 190 T R O U B L E S H O O T I N G O M P O N E N T O N D I T I O N B 3 - 3 C B 3 - 3 . 1 C o n t r o l H e a d s I n s p e c t f o r a n y s i g n s o f c o r r o s i o n d u e t o w a t e r i n c u r s i o n .
  • Page 191 T R O U B L E S H O O T I N G B 4 T R O U B L E S H O O T I N G D I A G N O S T I C M E N U T h e P r o c e s s o r h a s b u i l t i n d i a g n o s t i c s d e s i g n e d t o a s s i s t t h e t e c h n i c i a n i n d e t e r m i n i n g t h e c a u s e o f a p r o b l e m .
  • Page 192 T R O U B L E S H O O T I N G E ) I n a d d i t i o n t o t h e a p p l i e d b a t t e r y v o l t - a g e , s c r o l l i n g t h r o u g h t h e D i a g n o s t i c s M e n u b y p r e s s i n g t h e U p o r D o w n P u s h B u t t o n c a n a l s o s h o w t h e T a c h o m e t e r...
  • Page 193 T R O U B L E S H O O T I N G a 0 i n d i c a t e s a n o p e n s w i t c h . T h i s w i l l a l s o b e c o v e r e d i n m o r e d e t a i l l a t e r .
  • Page 194 T R O U B L E S H O O T I N G B 5 T R O U B L E S H O O T I N G A U D I B L E T O N E S A s m e n t i o n e d p r e v i o u s l y , t h e r e a r e v a r i o u s t o n e s e m i t - t e d f r o m t h e C o n t r o l H e a d i f a n e r r o r w e r e t o o c c u r .
  • Page 195 T R O U B L E S H O O T I N G s h o u l d b e g r e a t e r t h a n 1 2 . 4 V o l t s i n 1 2 V D C s y s t e m s a n d 2 4 .
  • Page 196 T R O U B L E S H O O T I N G A ) C h e c k t h e P r o c e s s o r ’ s D i s p l a y f o r e r r o r m e s s a g e s . M o s t l i k e l y , o n e o f e r r o r m e s s a g e s t h r u w i l l b e s h o w n .
  • Page 197 T R O U B L E S H O O T I N G I f t h e A / D v a l u e i s 9 9 5 o r h i g h e r , m o s t l i k e l y t h e p o t e n t i o m e - •...
  • Page 198 T R O U B L E S H O O T I N G I f t h e P r o c e s s o r f o r t h i s S y s t e m i n c l u d e s t h e u s e o f B a c k - u p M o d e , t h i s t o n e w o u l d i n d i c a t e t h a t t h e r e h a s b e e n a s w i t c h c l o s u r e r e q u e s t i n g B a c k - u p M o d e .
  • Page 199 T R O U B L E S H O O T I N G 2 . T h e p o t e n t i o m e t e r i s o u t o f c a l i b r a t i o n . 3 .
  • Page 200 T R O U B L E S H O O T I N G • I f t h e t o n e d i d n o t c e a s e , c h e c k t h e D C V o l t a g e t o t h e P r o c e s - s o r b y a c c e s s i n g t h e D i a g n o s t i c M e n u .
  • Page 201 T R O U B L E S H O O T I N G • D e f e c t i v e p u s h - p u l l c a b l e . •...
  • Page 202 T R O U B L E S H O O T I N G B 6 T R O U B L E S H O O T I N G S T A T I O N T R A N S F E R I n o r d e r t o t r a n s f e r c o m m a n d f r o m o n e R e m o t e S t a t i o n t o a n o t h e r , t h e f o l l o w i n g m u s t o c c u r : T h e r e m u s t b e a v a l i d “...
  • Page 203 T R O U B L E S H O O T I N G N O T E : T A / D V A L U E S L I S T E D F O R U L L H E A D A N D U L L S T E R N R E P R E S E N T T H E P O I N T W H E R E...
  • Page 204 T R O U B L E S H O O T I N G T a b l e B 6 - 3 : C o n t r o l H e a d L e v e r A / D C o u n t s C o n t r o l H e a d L e v e r P o s i t i o n A / D C o u n t A h e a d S h i f t P o i n t...
  • Page 205 T R O U B L E S H O O T I N G B 7 T R O U B L E S H O O T I N G S T U C K T R A N S F E R B U T T O N T h e T r a n s f e r B u t t o n i s a n o r m a l l y o p e n , m o m e n t a r y s w i t c h .
  • Page 206 T R O U B L E S H O O T I N G E R R O R C O D E S A s s t a t e d p r e v i o u s l y , i f a p r o b l e m w i t h t h e C o n t r o l S y s - t e m i s d e t e c t e d , t h e P r o c e s s o r i s p r o g r a m m e d t o d i s p l a y n u m e r o u s E r r o r C o d e s t o a i d i n t h e i s o l a t i o n o f t h e c a u s e .
  • Page 207 T R O U B L E S H O O T I N G T a b l e B 8 - 6 : B a s i c C o n t r o l S y s t e m E r r o r C o d e s S t a t i o n N o .
  • Page 208 T R O U B L E S H O O T I N G T a b l e B 8 - 6 : B a s i c C o n t r o l S y s t e m E r r o r C o d e s R e s e t D u e t o H a r d w a r e T h e s y s t e m h a s h a d a n u n e x p e c t e d R e s e t , d u e t o a s o f t w a r e / h a r d w a r e f a u l t .
  • Page 209 T R O U B L E S H O O T I N G B A S I C P R O B L E M C A U S E S A N D S O L U T I O N S T h e f o l l o w i n g t a b l e l i s t s t h e v a r i o u s E r r o r C o d e s a n d p r o v i d e s p o s s i - b l e c a u s e s a n d s o l u t i o n s .
  • Page 210 T R O U B L E S H O O T I N G T a b l e B 9 - 9 : B a s i c C o n t r o l S y s t e m P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 211 T R O U B L E S H O O T I N G T a b l e B 9 - 9 : B a s i c C o n t r o l S y s t e m P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 212 T R O U B L E S H O O T I N G T a b l e B 9 - 9 : B a s i c C o n t r o l S y s t e m P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 213 T R O U B L E S H O O T I N G T a b l e B 9 - 9 : B a s i c C o n t r o l S y s t e m P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 214 T R O U B L E S H O O T I N G T a b l e B 9 - 9 : B a s i c C o n t r o l S y s t e m P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 215 T R O U B L E S H O O T I N G T a b l e B 9 - 1 1 : S e r v o 1 C l u t c h P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 216 T R O U B L E S H O O T I N G T a b l e B 9 - 1 3 : S e r v o 1 T r o l l P r o b l e m C a u s e s a n d S o l u t i o n s E r r o r C a u s e s S o l u t i o n s...
  • Page 217 T R O U B L E S H O O T I N G B 1 0 P R O B L E M S W I T H O U T E R R O R C O D E S I n a d d i t i o n t o t h e E r r o r C o d e s l i s t e d a b o v e , s o m e p r o b l e m s m a y n o t n e c e s s a r i l y g e n e r a t e E r r o r C o d e s .
  • Page 218 T R O U B L E S H O O T I N G A c t i v e S y n c h r o n i z a t i o n i s i n o p e r a b l e . S Y M P T O M : C a u s e R e m e d y...
  • Page 219 T R O U B L E S H O O T I N G O L E N O I D L U T C H O N T R O L Y S T E M R O B L E M S I T H O U T R R O R O D E S...
  • Page 220 T R O U B L E S H O O T I N G B 1 1 S Y N C H R O N I Z A T I O N T R O U B L E S H O O T I N G I f y o u e n c o u n t e r a p r o b l e m w i t h S y n c h r o n i z a t i o n , i t w i l l m o r e t h a n l i k e l y o n e o f t h e f o l l o w i n g ;...
  • Page 221 T R O U B L E S H O O T I N G T a b l e B 1 1 - 1 6 : S e r v o T h r o t t l e P r o b l e m C a u s e s a n d S o l u t i o n s S y m p t o m C a u s e s S o l u t i o n s...
  • Page 222 T R O U B L E S H O O T I N G B 1 1 - 2 . 2 S e r v o T h r o t t l e T r o u b l e s h o o t i n g T a b l e B 1 1 - 1 9 : S e r v o T h r o t t l e P r o b l e m C a u s e s a n d S o l u t i o n s S y s t e m C a u s e s...
  • Page 223 T R O U B L E S H O O T I N G L E C T R O N I C Q U A L H R O T T L E Y N C H R O N I Z A T I O N B 1 1 - 3 E T a b l e B 1 1 - 2 1 : E l e c t r o n i c T h r o t t l e - E q u a l T h r o t t l e S y n c h P r o b l e m C a u s e s a n d S o l u t i o n s S y s t e m...
  • Page 224 T R O U B L E S H O O T I N G B 1 2 T R O U B L E S H O O T I N G C A B L E H A R N E S S E S T h e f o l l o w i n g S e c t i o n s l i s t t h e v a r i o u s H a r n e s s e s m a n u f a c t u r e d f o r u s e w i t h t h e P r o c e s s o r .
  • Page 225 T R O U B L E S H O O T I N G T a b l e B 1 2 - 3 : P o w e r , S t a r t I n t e r l o c k , P r e s s u r e S w i t c h , a n d A l a r m H a r n e s s P i n - O u t P R O C E S S O R E N G I N E a n d B A T T E R Y T e r m i n a t i o n A...
  • Page 226 T R O U B L E S H O O T I N G T a b l e B 1 2 - 5 : C o n t r o l H e a d H a r n e s s P i n - O u t a n d H a r d - W i r e T E R M I N A L S T R I P P R O C E S S O R ( 1 3 5 5 7 - X )
  • Page 227 T R O U B L E S H O O T I N G B 1 2 - 2 . 2 A h e a d , N e u t r a l , a n d A s t e r n T a b l e B 1 2 - 8 : A h e a d , N e u t r a l , a n d A s t e r n C l u t c h H a r n e s s P i n - O u t PROCESSOR GEAR BOX...
  • Page 228 T R O U B L E S H O O T I N G P R O C E S S O R P I G T A I L S B 1 3 T h e n u m b e r a n d t y p e s o f P i g t a i l s u s e d v a r i e s w i t h t h e d i f f e r e n t P r o c e s s o r s a n d t h e i r c o n f i g u r a t i o n s .
  • Page 229 T R O U B L E S H O O T I N G L U T C H I G T A I L B 1 3 - 2 C Table B13-4: Clutch Pigtail Pin-Out C I R C U I T B O A R D P L U G T e r m i n a t i o n A C o n d u c t o r C o l o r T e r m i n a t i o n B...
  • Page 230 T R O U B L E S H O O T I N G B 1 2 - 4 . 2 V o l t a g e T a b l e B 1 2 - 1 1 : V o l t a g e T h r o t t l e H a r n e s s P i n - O u t PROCESSOR ENGINE Termination A...
  • Page 231 ENG-143 Ver 1.0 4 -04 ClearCommand 9 000 Elect-Thr Sol-Shift Qualitative Failure Ana lysis & Design Verification Tes t Procedure ZF Mathers , LLC. ClearCommand 9000 Series 12125 Harbour Reach Drive, Suite B Mukilteo WA 98275 Electronic Throttle – Solenoid Clutch U.S.A.
  • Page 232 The ZF Mathers ClearCommand 9000 Series (electronic throttle, solenoid clutch version) marine engine controls offer single lever control of speed and direction. Each enclosure houses an independent Control Processor and requires separate power supplies.
  • Page 233 Move the Port and Starboard Control Head levers to approximately ½ Ahead. iii) 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. Disconnect it from the ClearCommand 9000 Series circuit board.
  • Page 234 Appendix B-6...
  • Page 235 ENG-144 Ver 1.0 4 -04 ClearCommand 9 000 Elect-Thr Ser-Cl Qualitative Failure Analysis & Des ign Verification Tes t Procedure ZF Mathers , LLC. ClearCommand 9000 Series 12125 Harbour Reach Drive, Suite B Mukilteo WA 98275 Electronic Throttle – Servo Clutch U.S.A.
  • Page 236 The ZF Mathers ClearCommand 9000 Series (electronic throttle, servo clutch version) marine engine controls offer single lever control of speed and direction. Each enclosure houses an independent Control Processor and requires separate power supplies.
  • Page 237 Move the Port and Starboard Control Head levers to approximately ½ Ahead. iii) 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. Disconnect it from the ClearCommand 9000 Series circuit board.
  • Page 238 Appendix B-10...
  • Page 239 ENG-145 Ver 1.0 4 -04 ClearCommand 9 000 Ser-Thr Sol-Cl Qualitative Failure Analysis & Design Verification Tes t P rocedure ZF Mathers , LLC. ClearCommand 9000 Series 12125 Harbour Reach Drive, Suite B Mukilteo WA 98275 Servo Throttle – Solenoid Clutch U.S.A.
  • Page 240 The ZF Mathers ClearCommand 9000 Series (servo throttle, solenoid clutch version) marine engine controls offer single lever control of speed and direction. Each enclosure houses an independent Control Processor and requires separate power supplies.
  • Page 241 Move the Port and Starboard Control Head levers to approximately ½ Ahead. iii) 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. Disconnect it from the ClearCommand 9000 Series circuit board.
  • Page 242 Appendix B-14...
  • Page 243 ZF Marine Electronics, LLC 12125 Harbour Reach Drive Mukilteo, WA 98275 USA 800-546-5455 / 425-583-1900 Fax: 425-493-1569 MMC-172 Rev A 2-08 FACTORY AUTHORIZED SALES & SERVICE - INTERNATIONAL ARGENTINA CHILI Christian Rogers Nickelmann Carlos Dorian Freidlander Equipamiento Marino Ltda T: (56-2) 4158737 Trimer S.
  • Page 244 (shipping) Z.I. Toulon-Est www.saim-group.com Toulon Cedex 9, France d.elderkin@vidalmarine.com JAPAN www.vidalmarine.com 7253 Y. Ikeda, Nobora Kasajima GERMANY ZF Marine Japan Co. Ltd T: 81-03-5808-4521 Fujikoshi Bldg. 1-10-11 Iriya Taito-ku 7636 Mathias Pien Tokyo, 110-0013 F: 81-03-5808-4531 Otto Peining GMBH T: 49-4124-916812...
  • Page 245 THE NETHERLANDS (HOLLAND) SINGAPORE 7252 Ton Hekman, Rob van der Linde Steven Wee ADS/van Stigt T:31-0-183-650001 Mammoth Enterprises Pte, Ltd. Avelingen F: 31-0-183-650001 (mail) PO Box 283 T: 65-6-44-88266 NL-422 MS Gorinchem Siglap Post Office F: 65-6-44-89800 The Netherlands Ton.Hekman@vanstigt.com Singapore 914503 (shipping) 6-A Waringin Park NEW ZEALAND...
  • Page 246 TAIWAN 5355 Mike Ou 6427 A.J. Halavacs Asia Diesel Electric Corp. T: 886-7-333-1191 ZF Marine - US Headquarters T: 954-581-4040 20th Floor F: 886-7-334-6808 3131 SW 42nd Street F: 954-581-4078 34 Min Chuan 1st Road Ft Lauderdale, FL 33312 Kaohsuing, R.O.C.
  • Page 247 Service Field Test Unit Reference Manual MM13927 Rev.E 4-07...
  • Page 249 MM13927 Table of Contents Revision List ............................D-1 Introduction............................D-1 Procedure: Throttle Signal Testing ....................... D-2 DC Voltage............................ D-2 Current (mA) ..........................D-2 PWM (Pulse Width Modulation) with DC Voltmeter..............D-3 PWM (Pulse Width Modulation) with Duty Cycle Meter ............D-3 Frequency (Hz.)..........................
  • Page 250 Table of Contents Page ii...

  • Page 251: Revision List

    Revision List FIGURE D-2: CRUISECOMMAND CONNECTOR LOCATIONS Date Revision Description 11/02 Revised Section 1.0 Table 1 2/03 Revised manual to current ZF Marine Electronics manual standards. Revised Section 3.0 4/03 Deleted Section 2.1.6 10/03 Revising to add 9000 Series and 2-...

  • Page 252: Procedure: Throttle Signal Testing

    DC Voltage Designation Description Harness Type Harness Use A) Ensure that power is removed from the Engine Gray 12 Clutch The external Electronics and the Processor. Connector/ connections for B) Disconnect the Throttle Harness from the number Pigtail Clutch Power, 1 Processor connector/pigtail.

  • Page 253: Pwm (Pulse Width Modulation) With Dc Voltmeter

    FIGURE D-5: THROTTLE CONNECTION (CURRENT MA) H) Move the Control Head lever to the Full Throttle position while depressing the Transfer Button (Throttle Only Mode). I) The measurement should be 91- 93% of the voltage measured in step F) [e.g. Idle = 8% of 12 VDC reference or 0.96 VDC;...

  • Page 254: Procedure: Clutch Testing

    FIGURE D-8: THROTTLE CONNECTION (FREQUENCY HZ) LED should go out in CruiseCommand systems and stay on in ClearCommand systems. Ahead Solenoid Testing A) Ensure power is removed from both the Processor and the Clutch Power Supply. B) Disconnect the Clutch Harness from the number 3 Processor connector/pigtail.

  • Page 255: Procedures: Troll Testing

    FIGURE D-11: CLUTCH CONNECTIONS ASTERN SOLENOID 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. Troll Command (Proportional Solenoid) Testing with Amp Meter A) Ensure power is removed from both the Processor and the Clutch Power Supply.

  • Page 256: Procedure: 2-Speed Testing

    Pigtail. A) Ensure power is removed from the Processor. Parts List B) Disconnect the Clutch/2-Speed Harness from the number 3 Processor connector/pigtail. ZF Marine Electronics Part Name Part No. C) Insert the Break-out Box between the number 3 13927 Service Field Test unit (Break-out...
  • Page 257 S E R V I C E F I E L D T E S T U N I T C ) I n s e r t t h e B r e a k - o u t B o x b e t w e e n t h e n u m b e r P r o c e s s o r c o n - n e c t o r / p i g t a i l a n d t h e T h r o t t l e H a r n e s s a s s h o w n i n F i g u r e 2 - F i g u r e 2 - 8 : T h r o t t l e C o n n e c t i o n ( F r e q u e n c y H z )
  • Page 258 S E R V I C E F I E L D T E S T U N I T 2 - 2 C L U T C H T E S T I N G 2 - 2 . 1 N e u t r a l S o l e n o i d T e s t i n g A ) E n s u r e p o w e r i s r e m o v e d f r o m b o t h t h e P r o c e s s o r a n d t h e C l u t c h P o w e r S u p p l y .
  • Page 259 S E R V I C E F I E L D T E S T U N I T C ) I n s e r t t h e B r e a k - o u t B o x b e t w e e n t h e n u m b e r P r o c e s s o r c o n - n e c t o r / p i g t a i l a n d t h e C l u t c h H a r n e s s a s s h o w n i n F i g u r e 2 - 1 0 : .
  • Page 260 S E R V I C E F I E L D T E S T U N I T F i g u r e 2 - 1 1 : C l u t c h C o n n e c t i o n ( A s t e r n S o l e n o i d ) D ) S e t u p t h e M u l t i m e t e r t o m e a s u r e D C V o l t s a n d p l u g t h e b l a c k l e a d i n t o t h e B r e a k - o u t B o x s o c k e t l a b e l e d “...
  • Page 261 S E R V I C E F I E L D T E S T U N I T 2 - 3 T R O L L T E S T I N G 2 - 3 . 1 T r o l l O n / O f f S o l e n o i d A ) E n s u r e p o w e r i s r e m o v e d f r o m b o t h t h e P r o c e s s o r a n d t h e C l u t c h P o w e r S u p p l y .
  • Page 262 S E R V I C E F I E L D T E S T U N I T T r o l l C o m m a n d ( P r o p o r t i o n a l S o l e n o i d ) T e s t i n g w i t h A m p M e t e r 2 - 3 .
  • Page 263 S E R V I C E F I E L D T E S T U N I T 3 P A R T S L I S T T a b l e 3 - 2 : P a r t s L i s t P a r t N a m e Z F M a t h e r s P a r t N o .
  • Page 264 S E R V I C E F I E L D T E S T U N I T M M 1 3 9 2 7 R v D 1 0 / 0 3 P a g e 3 - 2...
  • Page 265 P P E N D I X...
  • Page 267 D r a w i n g 1 2 2 8 4 A - 1 C l e a r C o m m a n d D i a g r a m ( a l l o p t i o n s ) Appendix C-1...
  • Page 268 Appendix C-2...
  • Page 269 D r a w i n g 1 2 2 8 4 A - 2 C l e a r C o m m a n d C i r c u i t B o a r d C o n n e c t i o n s Appendix C-3...
  • Page 270 Appendix C-4...
  • Page 271 D r a w i n g 1 2 2 8 4 A - 3 C l e a r C o m m a n d D r a w i n g N o t e s P a g e Appendix C-5...
  • Page 272 Appendix C-6...

This manual is also suitable for:

Clearcommand 9120Clearcommand 9121Clearcommand 9122Clearcommand 9210Clearcommand 9211Clearcommand 9221

Table of Contents

Save PDF