ZF Marine ClearCommand Manual

For ms565-13050

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MM13050 Rev.B 11/01................................................................................................................................................ 1

ClearCommand MS565-13050

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

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

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

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

1.2 ClearCommand System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

1.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

2.1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 1: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Engine Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 2: Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 3: Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5 Synchronization (Multi Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.6 Control Head Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.7 Speed Boost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.0 REQUIRED PARTS AND TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

3.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 4: Control Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Tools Required For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.5 Push-Pull Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.6 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 5: Wire Harness Connection Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.7 Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.8 Control System Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.0 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

4.1 Processor(s) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 6: Control Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Control Head Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.1 400 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.2 MC2000 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2.3 700 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.0 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

5.1 Eight-Conductor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 7: Plug Removal and Cable Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.3 Processor Connections and Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

MM13050 Rev.B 11/01

ClearCommand MS565-13050

SW13447.3

Table of Contents

Page 1

Table of Contents

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Summary of Contents for ZF Marine ClearCommand

Page 1: Table Of Contents
1.2 ClearCommand System........
Page 2 5.3.1 Processor Station Connections............. 16 Figure 8: Terminal Connection .
Page 3 7.3.1 Neutral Position ............... . 36 7.3.2 Ahead Position.
Page 4 S-214 Rev.A 6/01 ............................... 15 Automatic Power Selector (APS) Model: 13505 Figure 1: ..................16 Figure 2: .
Page 5 1.16 SYMPTOM - A slow repetitive tone is heard from all Stations when power is applied to the system. When the transfer button is depressed, the tone ceases but the red LED does not light. Further depressing of the transfer button has no effect. The transmission and engine remain at the Neutral/Idle position regardless of the Control Head lever position..
Page 6: Revisions List
Revisions List Date Revision Description 7/31/01 1. Drawing 11202D has been revised to E. Please refer to the Drawing in Appendix C for revisions. 2. Added Speed Boost and In-Gear/Neutral Delay. 11/19/01 Complete manual revised to current ZF Mathers standards. 1.
Page 7: Introduction
INTRODUCTION 1.0 INTRODUCTION 1.1 T ANUAL The purpose of the ClearCommand System manual is: • Operation (Section 2.0) • Installation (Section 5.0) • Set-up Procedure (Section 6.0) • Adjustments (Section 7.0 and 8.0) • Trouble Shooting Reference (Appendix B) Keep this Manual on the vessel for future reference.
Page 8: Clearcommand System
INTRODUCTION 1.2 C LEAR OMMAND YSTEM The ClearCommand Control Processor (hereafter referred to as Pro- cessor) is designed for: • Engines that require either voltage, mA, or PWM speed com- mand signal • Transmissions equipped with mechanical selection During Installation and Testing, take special care to verify all wiring is to specifications, terminations are correct, and that all Notes in Appendix C Drawing Notes are followed.
Page 9 INTRODUCTION • One Two-conductor electric cable for power connection • One Two-conductor electric cable for Start Interlock connection • One Throttle Wire Harness for Processor engine interface connec- tion • One Serial Communication Wire Harness for Processor to Proces- sor interconnection (Multi Screw only) Page 3...
Page 10: Operation
OPERATION 2.0 OPERATION 2.1 DC P OWER When 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 2.6 To take command at a Station: •...
Page 11: Station Transfer
OPERATION 2.3 S TATION RANSFER When transferring command from one Station to another (refer to Fig- ure 2:) A)Leave the Control Head lever(s) of the Station-in-Command in any position. B) Place the Control Head lever(s) of the Station taking command in the Neutral (vertical) detent position.
Page 12: Synchronization (Multi Screw)
2.5 S YNCHRONIZATION ULTI CREW This ClearCommand System utilizes dual lever synchronization. The advantage of this is that the Control Head levers are active at all times, which eliminates the possibility of shifting when the engine RPM’s are not at Idle.
Page 13: Control Head Tones
ONTROL ONES Low Repetition Rate Tone is normal when DC power is first applied to ClearCommand. This tone indicates the Proces- sor is in Neutral and Idle, and the operator can take com- mand at a Station. If this tone occurs during operation, refer to Appendix B Trouble Shoot- ing Section.
Page 14: Speed Boost Operation
PEED OOST PERATION ClearCommand is capable of providing a transitory speed signal (speed boost) to the governor during clutch engagement to decrease the possibility of stalling the engine during a reversal. It is recom- mended to only use Speed Boost if required to keep the engine from stalling on a through shift, such as a reversal.
Page 15: Required Parts And Tools
REQUIRED PARTS AND TOOLS 3.0 REQUIRED PARTS AND TOOLS 3.1 P ROCESSOR One Processor required per engine (refer to the System Drawing in Appendix C) Mounting Hardware is installer supplied. Included with the Processor: • Wago Tool • Anti-Static Wrist Strap •...
Page 16: Electric Cable
REQUIRED PARTS AND TOOLS • Watertight cable grip for the cable entrance on the Processor • 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. 3.3 E LECTRIC ABLE...
Page 17: Push-Pull Cable
REQUIRED PARTS AND TOOLS 3.5 P ABLE Use Type 33C push-pull cable to the transmission clutch selector lever. NOTE: If 43C cable is required for this application, a 43C Cable Conversion Kit is required. These Kits are available from ZF Mathers, LLC. Refer to Appendix A - 43C Cable Con- version Kit Manual for more information.
Page 18: Engine Stop Switch
REQUIRED PARTS AND TOOLS 3.7 E NGINE WITCH It is mandatory for an Engine Stop Switch to be located at each Sta- tion. WARNING: An Engine Stop Switch at each Station is an absolute requirement. Refer to CFR46, SEC. 62.35-5 and ABYC P-24.5.8. 3.8 C ONTROL YSTEM...
Page 19: Plan The Installation
(1,2m) Processor(s) and such heat sources. CAUTION: Electro-magnetic fields can influence ClearCommand’s electronic circuits. Do not mount close to gas engine ignition systems, alternators, or electric motors. Allow 4 feet of clearance between the Pro- (1,2m) cessor and alternators or electric motors.
Page 20: Control Head Location
PLAN THE INSTALLATION Locate each Processor such that the push-pull cables from it to the engine governors have large radius bends, with the least total degrees of bend and moderate length. NOTE: The minimum bend radius of 10 inches for a total degree of bends of less than 270 (254mm) degrees.
Page 21: Installation
INSTALLATION 5.0 INSTALLATION NOTE: Before starting the actual installation of ClearCommand, make sure you have the correct parts and tools on hand. See Section 3. Read ALL the instructions pertinent to each part before beginning the installation of that part.
Page 22: Processor Connections And Set-Up
INSTALLATION Figure 7: Plug Removal and Cable Grip Installation 5.3 P ROCESSOR ONNECTIONS AND 5.3.1 Processor Station Connections A) Insert cable through the appropriate watertight cable grip. B) Strip the PVC jacket and shielding back approximately 3 inches (75mm). C) Stagger wire lead length to match the correct Station terminal strip. CAUTION: Wire leads must not touch frame.
Page 23: Power Cable
INSTALLATION I) Feed through a little slack cable, and tighten the cable grip on the eight-conductor cable. NOTE: Bring the other Station's eight-conductor cables in the same way, and connect to the appropriate station terminal strips. (Refer to Drawing in Appendix C) J) Tie wrap the Station cable to the Processor frame.
Page 24: Control Heads
INSTALLATION B) Run the two-conductor start interlock cable through the watertight cable grip. C) Strip insulation off of each wire 3/8-inch , then install crimp terminals. (9,5mm) D) Connect the two-conductor cable as indi- cated on the Drawing in Appendix C. E) Feed through a little slack cable and tighten the cable grip F) Tie wrap the start interlock cable to the...
Page 25: Cable Connection
INSTALLATION B) Remove the six screws holding the bottom cover of the Control Head housing and set aside. (Refer to Appendix A Control Head Variations sheet) C) Run the eight-conductor cable through the correct cable grip in the bottom cover CAUTION:For Twin Screw applications, Port cable to Port side of Control Head, Starboard cable to the Starboard side of Control Head.
Page 26: Series Control Head Only
INSTALLATION Refer to Figure 10:. Lever for Side View Lever for Starboard Port Stbd Port Propulsion Propulsion Control Control 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Astern Fore Ahead Violet Violet 10987 Figure 10: Aft Facing Control Heads For single lever Control Head Stations that have the user facing aft and...
Page 27: Push-Pull Cables
INSTALLATION C) Plug the Serial Communication Harness to the Serial Harness pig- tail of the Processor. CAUTION: Ensure all Processors are interconnected as demonstrated on the System Drawing in Appendix C. 5.6 P ABLES The Processor interconnects with the transmission by push-pull cable to operate the clutch selector lever.
Page 28: Main Engine Speed Control
INSTALLATION C) Loosen the remaining screw and swing the cable retainer clip away from the entry hole. D) Insert the push-pull cables through the entry hole. E) When the push-pull cable end is visible within the Processor interior, reinstall the Number 10-32 jam nut. F) Connect the push-pull cable to the hex nut (See Figure 12:, Detail I).
Page 29: Throttle Wire Harness
INSTALLATION 5.7.1 Throttle Wire Harness The Processor(s) connects directly to the engine interface using a Throttle Wire Harness. Refer to Appendix A - Parts List to select the correct Throttle Wire Har- ness for the engine signal required. A) Connect the plug end of the Throttle Wire Harness at the Processor. CAUTION: When connecting the plugs, ensure that the release buttons are depressed and held until plug is fully connected.
Page 30: Set-Up Procedures
NOTE: Depending on the Auxiliary Board revision level, the button for storing the value selected in the ClearCommand memory may be labeled SW1 (RevC and before) or PB1 (RevD and after). The following Set-up Procedures all reflect PB1. THE USAGE OF THE BUTTON IS THE SAME, ONLY THE DESIGNATION IS DIFFERENT.
Page 31: Order Of Set-Up Adjustments
DIP SWITCH SET-UP PROCEDURES Figure 14: Processor Circuit Board Set-up Locations 6.1.2 Order of Set-up Adjustments Adjustment settings can be done one right after another or one at a time. Once a setting has been saved by depressing PB1, adjustment of another parameter may be started by: 1.
Page 32: Run State (Normal Operating Mode)
The System must be in Run State during PUSH DOWN PUSH DOWN FOR ‘ON’ FOR ‘OFF’ Setup Mode the operation of ClearCommand. (Closed) Run State: •All SW1 Dip Switches are in the Off position (Refer to Figure 16:) Normal Mode...
Page 33: Storing Set-Up Value
DIP SWITCH SET-UP PROCEDURES • If a nearly solid tone is heard and the motor control relay begins clicking THE SYSTEM WAS NOT in the Run State (Normal Operating Mode). Place all Dip Switches in the Off position (Refer to Figure 16:) and place Jumper 2 in the Open State .
Page 34: Number Of Screws Selection [Single/Twin, Etc]
DIP SWITCH SET-UP PROCEDURES D)If Dip Switch R7 has been used during the Set-up, ensure R7 is in the fully counterclockwise position. E) Place Jumper 2 in the Open State • A low repetitious rate tone is heard indicating that the Con- trol System is out of Set-up Mode and no Station is in com- mand.
Page 35: System Id # Selection
DIP SWITCH SET-UP PROCEDURES 6.3 S ID # S YSTEM ELECTION NOTE: IN A MULTI-PROCESSOR APPLICATION THAT USES SERIAL COMMUNICATION, each Processor MUST HAVE ITS OWN UNIQUE SYSTEM ID #. Perform the following set-up on all Processors. CAUTION: This set-up MUST ONLY be made AFTER the Processor has been set-up for Number of Screws.
Page 36: Clutch Delay
DIP SWITCH SET-UP PROCEDURES A)Place the System in Set-up Mode by fol- lowing Section 6.1.5, page 26. B)Place the appropriate SW1 Dip Switches PUSH DOWN PUSH DOWN PUSH DOWN PUSH DOWN On for the Clutch Pressure Time FOR ‘ON’ FOR ‘OFF’ FOR ‘ON’...
Page 37: Throttle Pause
DIP SWITCH SET-UP PROCEDURES •Refer to Figure 14:, page 25, for the location of the Dip Switch. C) Store the value that has been set by following Section 6.1.6, page 27. Figure 21: Dip Switch Setting 0 - 16 Seconds Clutch Delay 6.6 T HROTTLE AUSE...
Page 38: Engine Signal Selection
DIP SWITCH SET-UP PROCEDURES Change Throttle Pause by setting the Dip Switches on the Processor Main Circuit Boards using the following steps. A)Place the System in Set-up Mode by follow- ing Section 6.1.5, page 26. B)Place the appropriate Dip Switches ON for PUSH DOWN PUSH DOWN PUSH DOWN...
Page 39: In Gear/Neutral Delay
DIP SWITCH SET-UP PROCEDURES C) Store the value that has been set by following Section 6.1.6, page 27 6.8 I EUTRAL ELAY CAUTION: The settings on all Processors Main Circuit Boards MUST be set the same for Multi- Screw applications. This feature allows the choice of having Clutch Delay begin counting down while In Gear or while in Neutral.
Page 40: Adjustments And Tests (Secured To Dock)
NOTE: If any of the following tests fail, verify Start Interlock Installation and Start Interlock con- nections as shown on the Drawing in Appendix C and in Section 5.3.3, page 25. A) Turn the ClearCommand DC power OFF. Page 34...
Page 41: Clutch Travel (Engines Stopped)
ADJUSTMENT AND TESTS [AT DOCK] • Verify that the engine(s) will not start. B) Turn the ClearCommand DC power ON. Do not take command at a Station. • Verify engine(s) will not start. C) Take command at a Station. Place the Control Head lever(s) to 50 percent throttle.
Page 42: Neutral Position
ADJUSTMENT AND TESTS [AT DOCK] 7.3.1 Neutral Position Adjust the clutch cable ball joint at the transmission to match the clutch selector lever in the Neutral position. NOTE: The push-pull cable must form a right angle (90 degrees) with the clutch selector lever in the Neutral position.
Page 43: Engine Stop Switches Test (Engines Running)
ADJUSTMENT AND TESTS [AT DOCK] • If cable travel is correct at all three positions, continue with the next step. • If cable travel is incorrect, review Sections 7.3.1 and 7.3.2, mak- ing the necessary adjustments. B) Connect the clutch cable at the transmission. C) Confirm that the Processor does not jam the clutch selector lever against its stops, and that Neutral is correct.
Page 44: Electric Throttle Signal
ADJUSTMENT AND TESTS [AT DOCK] 7.6 E LECTRIC HROTTLE IGNAL ADJUSTMENTS MAY NOT BE REQUIRED. Verify the existing Throttle Minimum and Maximum values prior to adjusting them. NOTE: Jumper 6 on the Processor Auxiliary Board must be set to either PWM output or Voltage/ Current output.
Page 45 ADJUSTMENT AND TESTS [AT DOCK] • The Control Head LED will not be lit, but the Control Head will To change, use a small screwdriver. be active for set-up procedures. PUSH DOWN PUSH DOWN FOR ‘ON’ FOR ‘OFF’ F) Place the appropriate Dip Switches On to ready the Processor for adjustment.
Page 46: Throttle Maximum Signal
ADJUSTMENT AND TESTS [AT DOCK] Table 1: Throttle Minimum Output Adjustments PWM (Duty Cycle) Voltage (VDC) Current (mA) 5) Set Multi meter to Duty Cycle setting. 5) Rotate Potentiometer R7 slowly 5) Place the Control Head lever into the Ahead detent position. clockwise until minimum throttle signal is achieved.
Page 47 ADJUSTMENT AND TESTS [AT DOCK] C) Ensure that Potentiometer R7 is in the fully counter clockwise position. • Refer to Figure 13:, page 25, or the Drawing in Appendix C for R7 location D) Enable Set-up Mode by following Section 6.1.5, page 23. E) Press the transfer button at the remote station being used during set- •...
Page 48 ADJUSTMENT AND TESTS [AT DOCK] Table 2: Throttle Maximum Output Adjustments PWM (Duty Cycle) Voltage (VDC) Current (mA) 3) Move Jumper 6 on Auxiliary Board to 3)Connect the Multimeter to Pins 1 and 4 3)Connect one Multi-meter probe to the disconnected positive (+) throttle Pins 2-3 (voltage/current setting).
Page 49 ADJUSTMENT AND TESTS [AT DOCK] Table 2: Throttle Maximum Output Adjustments PWM (Duty Cycle) Voltage (VDC) Current (mA) 10)Replace Jumper 6 on Auxiliary Board 10)Reconnect the positive (+) throttle to its original position. signal wire from the governor 1 2 3 11)Reconnect the Throttle Wire Harness to the Throttle Pigtail at the Processor.
Page 50: Adjustment Underway
ADJUSTMENTS AND TESTS UNDERWAY 8.0 ADJUSTMENT UNDERWAY WARNING: DO NOT attempt to operate ClearCommand 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 ClearCommand System provides a light touch that is fast and accurate.
Page 51: Speed Boost Timeout
ADJUSTMENTS AND TESTS UNDERWAY E) Store the value that has been set by following Section 6.1.6, page 27 8.2.2 Speed Boost Timeout This is the amount of time boost is applied. Parameters are 0 - 5 seconds. The default value is 0 seconds. To change the Speed Boost Timeout per- form the following steps: A) Place the System in Set-up Mode by following Section 6.1.5, To change, use a...
Page 52: Control Options
9.1 A LARM APABILITY ClearCommand offers a single alarm connection that OPENS with a system power failure or circuit malfunction. The Processor's alarm connection point is a single connection block on each Processor Circuit Board. The alarm circuit in the Processor oper- ates an alarm system supplied by others.
Page 53: Synchronization
Appendix C Drawing for specific details. 9.3 S YNCHRONIZATION IMPORTANT: The installation of ClearCommand should be complete and thoroughly tested before installing synchronization. Check Control Head lever and RPM match of the engines through the speed range from IDLE to FULL speed.
Page 54: Synchronization Operation Tests
CONTROL OPTIONS 9.3.5 Synchronization Operation Tests NOTE: Engines will not synchronize unless shifted to Ahead and above 10 percent of speed range. The engines should synchronize. If they do not, make the following Operation Checks. A) Verify all wiring connections at the Processors, Control Heads (refer- ence Drawing in Appendix C.1).
Page 55: Maintenance
MAINTENANCE 10.0 MAINTENANCE 10.1 C ONTROL ROCESSOR The Processor requires the following annual checks: • Check all terminal connections for signs of corrosion or loose connections. • Check mechanical connections within the Processor. • Check mechanical connetions at the transmission. •...
Page 57: Appendix
PPENDIX...
Page 59: Parts List
Appendix A 6/20/01 PARTS LIST PART NO. DESCRIPTION CONTROL HEADS SINGLE SCREW 450-3L or 3R Left or Right Control Head, 'T' Lever 453-3L or 3R Left or Right Control Head, Chrome Knob Lever 455-3L or 3R Left or Right Control Head, Black Low Profile Lever 456-3L or 3R Left or Right Control Head, Chrome Low Profile Lever 750-L or –R...
Page 60 Appendix A 6/20/01 Page 2...
Page 61: Rev.g 6/01
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 62 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" (50mm) Strip and cut off the shielding and drain wire flush with the end of the PVC cover (the drain wire at the Control Head is not connected to ground).
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Page 65: Rev.c 6-01
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. C) Strip back the PVC cover on the shielded cable approximately 2"...
Page 66 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. I) When connections are complete, replace the bottom cover to the bottom of the Control Head housing.
Page 67: Rev.d 6-01
Twist the individual strands of the wires to minimize fraying. Crimp a lock- ing fork terminal (included with each Control Head) to each of the conductors. Make connections to the Control Heads for MicroCommander, ClearCommand, and CruiseCommand as shown below.
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Page 69: Rev.- 7/01
Twist the individual strands of the (9,5mm) wires to minimize fraying. Crimp a locking fork terminal (included with each Control Head) to each of the con- ductors. Make connections to the Control Heads for MicroCommander, ClearCommand, and CruiseCommand as shown below. Page 11...
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Page 71: Rev.a 11/00
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 (89,9mm) Watertight...
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Page 73: Automatic Power Selector (Aps) Model: 13505
ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 S-214 Rev.A 6/01 Automatic Power Selector (APS) Model: 13505 A) GENERAL INFORMATION The APS (Automatic Power Selector), Model 13505, provides a simple, solid state solution to the need for rout- ing redundant DC power sources for vital electronic equipment while maintaining isolation of the DC power sources.
Page 74 E) IMPORTANT NOTE ABOUT BATTERY SOURCES Whenever the load is turned on, it can be drawing power from the batteries. Therefore, if the batteries are not simultaneously being recharged, or if charging will not be available for an extended period, it is recommended that the load be shut off to prevent complete discharge of batteries.
Page 75: Mm13821 Rev.- 7/00
MM13821 Rev.- 7/00 43C Cable Conversion Kit 585CE Actuator (Serial Number B06500 and up) 813CE Actuator (Serial Number C01150 and up) ClearCommand Processors (Serial Number D02100 and up) Revisions List Date Revision Description This procedure is to be used in conjunction with the technical manual supplied with the System’s Actuator / Processor.
Page 76: Cable Installation [Refer To Figure 2]
D) Remove the Snap Ring holding the Cable Connect Nut in the cross-bar using a snap ring tool or small screwdriver. E) Remove and discard Cable Connect Nut and Snap Ring. Cable Installation [Refer To Figure 2] NOTE: 43C cable and jam nut are supplied by others. A) Remove and retain the jam nut from the end of the 43C cable to be installed in the Actuator/Processor.
Page 77: Rev.b 7-01
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.
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Page 79: References And Parts Source
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 80 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 81: Electronic Propulsion Control Systems Three Year Limited Warranty
ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 MMC-165 Rev.C 10/00 Electronic Propulsion Control Systems Three Year Limited Warranty Your ZF Mathers product has been designed and manufactured by experienced engineers and craftsmen. ZF Mathers LLC., warrants for the period indicated below, each product to be free from defect in material and workmanship.
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Page 83: Rev.a 11/00
ZF Mathers, LLC 1415 Pacific Drive Burlington WA 98233-3103 U.S.A. 800-546-5455 / 360-757-6265 Fax: 360-757-2500 F-226 Rev.A 11/00 Sea Trial Report Vessel Name:_____________________________________ Trial Date:__________________ SSN:_____________ Owners Name:________________________________________________________________________________ Address:_________________________________________________________________________________ Tel/Fax/e-mail:_______________________________________________________________________________ Contact Name:_______________________________________________________________________________ APPLICATION: A:Boat Builder________________________ Model_____________________ Size_________ Year_____ Original Equipment ___ Retrofit ___ Type of Controls Replaced_______________________________ B:Single or Twin Screw_________________________________________________________________ Engine Make__________________________ Model__________________________________________ Horsepower _______________ RPM______________ Engine Hours_____________________________...
Page 84 Sea Trials: Port Stbd Check that Twin Screw Control Head levers match position and RPM through speed range. Yes ___ No___ Yes___ No___ Set maximum engine RPM as required. ________RPM ________RPM Adjust Full Speed Reversal Delay ________SEC ________SEC Is Synchronization operational? Yes ___ No___ Yes___ No___ Is Trolling Valve operational?
Page 85: Appendix
PPENDIX...
Page 87: Troubleshooting
• DC Power Source • Component Location • Component Condition • Interconnecting Wiring • Wire Termination’s A key in troubleshooting the ClearCommand System is identify- ing the problem as: • DC Power Source • Interconnection wiring or termination • Component Calibration •...
Page 88 TROUBLESHOOTING NOTE: Always check the other Stations, to see if the symptom can be repeated. 1.1 SYMPTOM - W DC P OWER IS TURNED OPERATOR CANNOT TAKE COMMAND AT ONE TATION BOTH ORT AND TARBOARD FOR TWIN SCREW Cause: A)A corroded or loose electrical connection. B) Incorrectly wired eight-conductor cable.
Page 89 TROUBLESHOOTING B) Rewire cable connections as shown on the Appendix C Draw- ing, Appendix B Control Head Variations sheets, and the Con- trol Head Installation Section of the main manual. C) Verify the voltage between the yellow and the blue wires (Ter- minals 5 and 7) at the suspected Control.
Page 90: Symptom - No Audible Tone At A Control Head When System Is First Turned On, But Otherwise Works Perfectly
TROUBLESHOOTING Remedy: Measure the voltage at the battery without the engine or charger run- ning. The reading should be a minimum of 12.4 volts. If not, the bat- tery needs charging or possibly replacing. Measure the voltage at the Processor. This reading should be not more than 0.20 volt below the measured battery voltage.
Page 91: Symptom - The Control Head Red Indicator Light Does Not Light When In Command, But Everything Else Works Per
TROUBLESHOOTING B) If the voltage tested good, the circuit board needs repair or a Circuit Board Kit needs to be installed. 1.7 SYMPTOM - T ONTROL EAD RED INDICATOR LIGHT DOES NOT LIGHT WHEN IN COMMAND BUT EVERYTHING ELSE WORKS PERFECTLY Cause: A)Incorrectly wired eight-conductor cable.
Page 92: Circuit Board
1.10T HE ENGINE WILL NOT START Cause: A)ClearCommand does not have power turned ON. B) ClearCommand does not have a Station in command. C) The Control Head levers at the Station-in-Command are not at the Idle position. D)Low battery voltage.
Page 93 TROUBLESHOOTING E) Connect the two start interlock wires (yellow with red stripe) at the Processor to the same terminal. If the engine starts, have the Processor repaired. F) Ensure starting system is installed and works correctly. G)Take the System out of Set-up Mode (Jumper 2 Open 1.11SYMPTOM - O NE LONG NE SHORT TONES FROM ALL...
Page 94 TROUBLESHOOTING B) Install a jumper between the appropriate terminals of the Pro- cessor. Refer to the main manual for appropriate terminals. 1.14SYMPTOM - C IDLE. ANNOT GET ANY SPEED ABOVE Cause: A)Gear oil pressure switch is not closing, or is incorrectly wired. B) The gear oil pressure switch not installed.
Page 95 TROUBLESHOOTING AT THE EUTRAL DLE POSITION REGARDLESS OF THE ONTROL EAD LEVER POSITION Cause: The Processor is in the Set-up Mode and an adjustment setting is selected. Remedy: Configure the Processor into the Run State by placing Jumper 2 in the Open State and SW1-1 through SW1-7 to the Off positions.
Page 96 TROUBLESHOOTING 2.0 RESET ALL PARAMETERS TO FACTORY DEFAULT VALUES NOTE: If this procedure is used, all adjustments and tests specified in this manual MUST be repeated. Set the SW1 Dip Switches on the To change, use a small screwdriver. Processor Main Circuit Board using PUSH DOWN PUSH DOWN FOR ‘ON’...
Page 97 PPENDIX...