ClearCommand 96202

Installation Manual
SM3830 Rev.A1 10/05
SYSTEM GENERAL INFORMATION

ZF Marine Electronics, LLC

ClearCommand
System Specifications
(Sept 2005 Rev.A) October 2005 Rev.A1 Quality Shipyard Hull# 1247
February 2005 (Rev.-)

Vessel Specifications

Power: Twin Screw

Caterpillar 3508
1050 HP @ 1600 RPM
Electric Selection

Transmission: Twin Disc MG5170

5.421:1 Reduction Ratio
Solenoid Selection

Stations: One Remote Station

ClearCommand Specifications:

Control Processor: 96202 (replacing 785CE)

System Serial Number: 3830
Sales Order Number: SO02471 (96202 Replacement System)
SO00549 (Original System Parts & Manual)
SO00550 (Original CruiseCommand Processor)
Drawing Number: 13068A, 4 pages

This System originally shipped with CruiseCommand 785CE Processors. These

Processors are being replaced by ClearCommand 96202 Processors.

Page 1
MATERIAL LIST

System 3830 Material List

Material List for 3830 - SO002471

Quantity No. Description
2 96202 CLEARCOMMAND-ELECT ENG,SOL GEAR,2 STA
2 15719-20 WIRE HARNESS, CLUTCH AHEAD/ASTERN 20 FT
5 SM3830 SSN 3830 INSTALLATION MANUAL

Page 1-1
PREFACE

IMPORTANT: It is important to keep this Manual in a safe place for future reference. The manual
contains answers to questions that may arise during operation or installation of the ZF Marine
Electronics Control System and its options.

Preface-1 ClearCommand 96202

ZF Marine Electronics ENGINE CLUTCH Number of
Pluggable
Processor Part No. Servo Electronic Servo Solenoid Stations

96202 X X 2

Table Preface-1: ClearCommand 96202

This manual is intended for use with the above Processors.
Preface-2 Conventional Symbols Used in the Manual
Throughout this manual special attention should be paid to the following:

NOTE: Contains helpful information

IMPORTANT: Contains helpful information.

CAUTION: Damage to the equipment may occur if these messages are not followed.

WARNING: Personal injury may result if these messages are not followed.

Preface-3 Important Information

WARNING: Personal Injury could occur if the following steps are not followed
exactly.

CAUTION: On Control Systems utilizing more than one Processor, ZF Marine

Electronics highly recommends that ALL UNITS be upgraded to the most current
Processor.

CAUTION: Electro-static discharge can damage this equipment. Personnel working

on this equipment must be grounded to the chassis with the Anti-static Wrist Strap
provided.

CAUTION: Disconnect the Power Harness from the Power Pigtail whenever welding
is being done on the vessel. Failure to do so can cause permanent damage.

CAUTION: This equipment is designed to work with other ZF Marine Electronics

designed equipment. DO NOT operate this equipment with any other manufacturers
equipment unless approved so in writing by ZF Marine Electronics Engineering
Department.
For the purpose of this manual, the drawings illustrate pluggable systems with
two Remote Stations. The Processors described within, may in fact be installed
with anywhere from one to five Remote Stations.
Page Preface-1
TABLE OF CONTENTS

SW15623.0H

Table of Contents
ClearCommand 96202
Installation Manual
System 3830 Material List .......................................................................................................................1-1
Preface-1 ClearCommand 96202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-1
Table Preface-1:ClearCommand 96202.......................................................................................................................Preface-1
Preface-2 Conventional Symbols Used in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-1
Preface-3 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-1
Table of Contents................................................................................................................................TOC-1
Revisions List ....................................................................................................................................TOC-11

1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1-1 Manual Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2.1 96202 Processor (Throttle - Electronic, Shift - Solenoid, 2 Pluggable Remote Stations) . . . . 1-1
1-3 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3.1 Standard Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3.2 Optional Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-2 Taking Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1: Station taking Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3.1 Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-4 Start Interlock (if used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5 Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5.1 Neutral Only Transfer (Mode P000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5.2 Lever Match and Neutral (Mode P002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5.3 Forward Pass Sequence [Relinquish/ Receive] (Modes P003 & P004) . . . . . . . . . . . . . . . . . . 2-2
2-5.3.1 TRANSFER REQUEST SEQUENCE [REQUEST / RELINQUISH] (MODE P003) 2-STEP .................................................... 2-3
2-5.3.2 TRANSFER REQUEST SEQUENCE [REQUEST/ RELINQUISH/ RECEIVE] (MODE P004) 3-STEP ........................................ 2-3
2-6 Proportional Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-7 Warm-up Mode (Throttle Only Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3: Control Head Warm-Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-4: Control Head Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-8 High/Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-8.1 Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-8.2 High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-8.3 Selecting Between High and Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-5: High/Low Idle Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9 One Lever Mode (Multi Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9.1 Turning ON One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-6: Step A) One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-7: Step B) One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-9.2 Turning OFF One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10 Engine Synchronization (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10.1 Synchronization Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10.2 Synchronization Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10.2.1 EQUAL THROTTLE SYNCHRONIZATION (DEFAULT ENABLED) ................................................................................... 2-7
2-10.2.2 ACTIVE SYNCHRONIZATION (DEFAULT DISABLED) ................................................................................................. 2-7

TOC-1
TABLE OF CONTENTS
2-10.3 Synchronization Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-10.4 Turning Synchronization OFF/ON when Criteria is Met. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-10.4.1 TURNING OFF: .............................................................................................................................................. 2-7
2-10.4.2 TURNING ON: ............................................................................................................................................... 2-7
2-10.5 Turning Synchronization ON/OFF when Criteria is Not Met . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-11 Control Systems’ Configurability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-11.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-11.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-11.2.1 BASIC THROTTLE FUNCTIONS ........................................................................................................................... 2-8
2-11.2.2 ELECTRONIC THROTTLE FUNCTIONS ................................................................................................................... 2-8
2-11.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.3.1 BASIC CLUTCH FUNCTIONS .............................................................................................................................. 2-9
2-11.3.2 SOLENOID CLUTCH FUNCTIONS ........................................................................................................................ 2-9
2-11.4 Speed Boost Functions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.5 Troll Functions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.6 Integrated Troll Solenoid Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-11.7 Transfer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-11.8 Troubleshooting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-11.8.1 BASIC TROUBLESHOOTING FUNCTIONS ............................................................................................................. 2-10
2-12 Audible Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12.1 Basic Processor Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12.1.1 SLOW REPETITIVE TONE ................................................................................................................................ 2-10
2-12.1.2 ONE LONG, THREE SHORT TONES .................................................................................................................. 2-10
2-12.1.3 STEADY TONE .............................................................................................................................................. 2-11
2-12.1.4 FIVE (5) SECOND STEADY TONE ..................................................................................................................... 2-11
2-12.1.5 THREE (3) SECOND STEADY TONE .................................................................................................................. 2-11
2-12.1.6 FIVE SECONDS ON, FIVE SECONDS OFF - HIGH REPETITIVE RATE TONE ................................................................ 2-11
2-12.2 Clutch Solenoid Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12.2.1 ONE LONG - ONE SHORT TONE...................................................................................................................... 2-11
2-12.3 Troll Integrated Solenoid Tones (If Troll is used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12.3.1 THREE SECOND STEADY TONE ....................................................................................................................... 2-11
2-12.4 Transfer Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12.4.1 1/2 SECOND ON, 1/2 SECOND OFF TONES .................................................................................................... 2-11
2-12.4.2 ONE SECOND STEADY TONE .......................................................................................................................... 2-11
2-13 Push Button Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-14 Visual System Diagnostics, Set Up And Status Indication . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-8: Circuit Board Shield Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-15 Pluggable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-15.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Figure 2-9: Processor Pluggable Connections View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-16 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-16.1 External Alarm Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-16.2 Clutch Pressure Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.3 Station Expander (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.4 Trolling Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.5 Engine Room Only / Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.6 Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.7 DP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-16.8 Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-16.9 Backup Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-16.10 Speed Boost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

3 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - 3-1

3-1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-1: Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1.1 Processor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1.2 Control Head(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-1.3 Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-1.3.1 CONTROL HEAD HARNESSES............................................................................................................................ 3-2
3-1.3.2 POWER, START INTERLOCK, CLUTCH PRESSURE, ALARM HARNESS ......................................................................... 3-2
3-1.3.3 SERIAL COMMUNICATION HARNESS .................................................................................................................. 3-3
3-1.4 Additional Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TOC-2
TABLE OF CONTENTS
3-1.4.4 TACH SENSOR HARNESS ................................................................................................................................. 3-3
3-1.4.5 THROTTLE HARNESS ....................................................................................................................................... 3-3
3-1.4.6 CLUTCH HARNESS .......................................................................................................................................... 3-3
3-1.5 Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-1.5.7 CONTROL HEAD ELECTRIC CABLE...................................................................................................................... 3-3
3-1.5.8 POWER, START INTERLOCK, CLUTCH PRESSURE, ALARM ELECTRIC CABLE ............................................................... 3-4
3-1.5.8.1 Power Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-1.5.8.2 Start Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-1.5.8.3 Clutch Pressure Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-1.5.8.4 External Alarm Circuit Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-1.5.9 SERIAL COMMUNICATION ................................................................................................................................ 3-4
3-1.5.10 TACH SENSOR ELECTRIC CABLE REQUIREMENTS .................................................................................................. 3-4
3-1.5.10.1 AC Tach Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3-1.5.10.2 Open Collector (Active) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
3-1.5.11 THROTTLE ELECTRIC CABLE REQUIREMENTS ........................................................................................................ 3-5
3-1.5.12 CLUTCH ELECTRIC CABLE ................................................................................................................................. 3-5
3-1.5.12.1 Clutch Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
3-1.6 Tachometer Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-1.6.13 AC COUPLED SENSORS .................................................................................................................................. 3-5
3-1.6.14 ALTERNATOR ................................................................................................................................................. 3-5
3-1.6.15 POINT SIDE OF THE COIL.................................................................................................................................. 3-5
3-1.6.16 ACTIVE SENSORS (OPEN COLLECTOR OUTPUT) ................................................................................................... 3-5
3-2 Installer Supplied Tools And Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2.2 Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2.3 Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3.1 Processor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4-1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2 Control Head(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.1 400, MC2000 and 700 Series Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.2 500 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.3 Handheld Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3 Wire Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3.1 Plug Insertion and Extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-1: Harness Plug Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-2: Harness Plug Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3.2 Standard Power/Start Interlock Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3.2.1 DC POWER CABLE ......................................................................................................................................... 4-1
4-3.2.2 START INTERLOCK CABLE ................................................................................................................................. 4-2
Figure 4-3: Start Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.2.3 EXTERNAL ALARM CIRCUIT CABLE (OPTIONAL) .................................................................................................... 4-2
4-3.2.4 CLUTCH PRESSURE SWITCH CABLE (OPTIONAL)................................................................................................... 4-2
4-3.3 Serial Communication Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.3.5 TWIN SCREW ................................................................................................................................................ 4-2
Figure 4-4: Twin Screw Serial Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.4 Standard Control Head Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.4.1 CONTROL HEAD HARNESS WITH TWO CONNECTORS ........................................................................................... 4-3
4-3.4.2 CONTROL HEAD HARNESS WITH ONE PLUG ....................................................................................................... 4-3
4-3.5 Tach Sensor Harness (required for Active Synchronization) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3.6 Additional Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3.6.1 THROTTLE HARNESS ....................................................................................................................................... 4-3
4-3.6.2 CLUTCH HARNESS .......................................................................................................................................... 4-3
4-4 Hard-Wired Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4.1 Liquid Tight Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-5: Liquid Tight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4.2 Processor Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-6: Processor Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4.3 Processor Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-7: Processor Circuit Board Hard-Wired Termination Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4.4 Hard-wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4.4.1 SEVEN-CONDUCTOR CONTROL HEAD CABLE (LOCATIONS 1, 2, 3, 6, AND 7) .......................................................... 4-5

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Figure 4-8: Seven-Conductor Control Head Cable Shield Wire and Heat-Shrink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-9: Clamp Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-10: Terminal Strip Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-1: Processor Circuit Board Connections for Remote Stations .......................................................................... 4-6
4-4.4.2 ELEVEN-CONDUCTOR DP CABLE (LOCATION 2/NO STATION 5)............................................................................. 4-6
4-4.4.3 START INTERLOCK CABLE (LOCATION 4)............................................................................................................. 4-6
4-4.4.3.1 Connection at the Starter Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
4-4.4.3.2 Connection at the Processor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Figure 4-11: Two-Conductor Start Interlock Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4.4.4 POWER CABLE (LOCATION 5)........................................................................................................................... 4-7
Figure 4-12: Two-Conductor Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4.4.5 SERIAL COMMUNICATION CABLE (LOCATION 10)................................................................................................. 4-7
Figure 4-13: Four-Conductor Serial Communication Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Table 4-2: Processor Circuit Board Connections for Serial Communication ................................................................. 4-8
4-4.4.6 TACHOMETER CABLE (LOCATION 12) ................................................................................................................ 4-8
Figure 4-14: AC Type Tachometer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-15: Open Collector Tachometer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Table 4-3: Processor Circuit Board Connections for Tachometer ................................................................................. 4-9
4-4.5 Clutch Cable (Location 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-4.5.1 PROCESSOR TERMINATION ............................................................................................................................... 4-9
Figure 4-16: Clutch Cable Heat Shrink in Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-4.5.2 PLUG TERMINATION ........................................................................................................................................ 4-9
Figure 4-17: Clutch Cable Plug Termination Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-4: Clutch Termination Table........................................................................................................................... 4-10
4-4.6 Throttle Cable (Location 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-18: Engine Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Table 4-5: Processor Circuit Board Connections for Throttle ...................................................................................... 4-10
4-5 Engine Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

5 SET UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - 5-1

5-1 Processor Components Used In Set Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-1: Typical Processor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-2: Processor Shield Push Button and Display LED Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1.1 Processor Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-3: Display LED at Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-4: Display LED Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1.2 Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-5: Circuit Board Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1.2.1 UP AND DOWN PUSH BUTTONS ....................................................................................................................... 5-2
5-1.2.2 LEFT AND RIGHT PUSH BUTTONS ...................................................................................................................... 5-2
5-1.2.3 LEFT PUSH BUTTON ONLY ............................................................................................................................... 5-2
Figure 5-6: Display LED Error Menu Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-1.2.4 RIGHT PUSH BUTTON ONLY ............................................................................................................................. 5-2
Figure 5-7: Display LED Four Digit Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Activating Set Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-3 Storing Values To Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Table 5-1: Processor Function Codes ............................................................................................................................ 5-3
Table 5-2: Throttle Function Codes................................................................................................................................ 5-3
Table 5-3: Clutch Function Codes .................................................................................................................................. 5-4
Table 5-4: Troll Function Codes ..................................................................................................................................... 5-4
5-4 Field Service Test Unit (Break-out Box) and Multimeter Use . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-8: Service Field Test Unit and Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Table 5-5: Troubleshooting Function Codes .................................................................................................................. 5-5
Table 5-6: Speed Boost Premium-Only Function Codes ................................................................................................ 5-5
Table 5-7: Station Transfer Premium-Only Function Codes........................................................................................... 5-5
Table 5-8: Clutch Functions Requiring Service Field Test Unit and Multimeter ............................................................ 5-6
Table 5-9: Throttle Functions Requiring Service Field Test Unit and Multimeter .......................................................... 5-6
5-5 System Programming And Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-5.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-5.1.1 FUNCTION CODE A0 – PROCESSOR IDENTIFICATION ............................................................................................ 5-6
Figure 5-1: Display LED Function A0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-5.1.2 FUNCTION CODE A1 – NUMBER OF ENGINES ..................................................................................................... 5-6
Figure 5-2: Display LED Function A1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-5.1.3 FUNCTION CODE A2 – ONE LEVER OPERATION .................................................................................................. 5-7
Figure 5-3: Display LED Function A2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-5.1.4 FUNCTION CODE A3 – SE (STATION EXPANDER) ................................................................................................ 5-7
Figure 5-4: Display LED Function A3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

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5-5.1.5 FUNCTION CODE A4 – NEUTRAL INDICATION TONE ............................................................................................. 5-7
Figure 5-5: Display LED Function A4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-5.1.6 FUNCTION CODE A5 – ENGINE ROOM LOCKOUT/STATION NO.2 LOCKOUT.............................................................. 5-8
5-5.1.7 FUNCTION CODE A6 – STATION NO. 5 / DP...................................................................................................... 5-8
5-5.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5.2.1 THROTTLE BASIC FUNCTIONS (E1, E4 THROUGH E7) ........................................................................................... 5-8
5-5.2.1.1 Function Code E1 – Throttle in Neutral - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Figure 5-6: Display LED Function E1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-5.2.1.2 Function Code E4 – Throttle Maximum Astern - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Figure 5-7: Display LED Function E4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-5.2.1.3 Function Code E5 – Throttle Pause Following Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Figure 5-8: Display LED Function E5 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-5.2.1.4 Function Code E6 – High Idle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Figure 5-9: Display LED Function E6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-5.2.1.5 Function Code E7 – Synchronization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Figure 5-10: Display LED Function E7 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5.2.2 THROTTLE ELECTRONIC FUNCTIONS (E0, E2, E3).............................................................................................. 5-10
5-5.2.2.1 Function Code E0 – Engine Throttle Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Figure 5-11: Display LED Function E0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5.2.2.2 Function Code E2 – Throttle Minimum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Figure 5-12: Display LED Function E2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5.2.2.3 Function Code E3 – Throttle Maximum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Figure 5-13: Display LED Function E3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5.3.1 CLUTCH BASIC FUNCTIONS (C0 THROUGH C4, C8)........................................................................................... 5-11
5-5.3.1.1 Function Code C0 – Clutch Pressure Interlock - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Figure 5-14: Display LED Function C0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5.3.1.2 Function Code C1 – Clutch Interlock Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Figure 5-15: Display LED Function C1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5.3.1.3 Function Code C2 – Proportional Pause - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Figure 5-16: Display LED Function C2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-5.3.1.4 Function Code C3 – Proportional Pause Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Figure 5-17: Display LED Function C3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-5.3.1.5 Function Code C4 – Proportional Pause Ratio - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Figure 5-18: Display LED Function C4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-5.3.1.6 Function Code C8 – Fixed Neutral Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
Figure 5-19: Display LED Function C8 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-5.3.2 CLUTCH SOLENOID FUNCTIONS (C5 THROUGH C6) ........................................................................................... 5-13
5-5.3.2.1 Function Code C5 – Shift Solenoid Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
Figure 5-20: Display LED Function C5 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-5.3.2.2 Function Code C6 – ZF-Hurth Duty Cycle Ahead - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
Figure 5-21: Display LED Function C6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-5.3.2.3 Function Code C7 – ZF-Hurth Duty Cycle Astern - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14
Figure 5-22: Display LED Function C7 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5.4 Troll Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5.4.1 TROLL BASIC FUNCTIONS (L0, L4, L5) ............................................................................................................ 5-15
5-5.4.1.1 Function Code L0 – Troll Enable and Control Head Lever Troll Range - - - - - - - - - - - - - - - - - - 5-15
5-5.5 Troubleshooting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5.5.1 BASIC PROCESSOR TROUBLESHOOTING FUNCTIONS ........................................................................................... 5-15
5-5.5.1.1 Function Code H0 - Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
5-5.5.1.2 Function Code H1 – Return to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
5-5.5.1.3 Function Code H2 - Driver Fault Detection Enable - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
Table 5-10: Solenoid Error Status Enable ...................................................................................................................... 5-15
5-5.6 Premium Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-5.6.1 SPEED BOOST FUNCTION CODES (F0 - F3)...................................................................................................... 5-16
5-5.6.1.1 Function Code F0 – Speed Boost Percent - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-5.6.1.2 Function Code F1 - Speed Boost Duration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-5.6.1.3 Function Code F2 – Speed Boost Start Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-5.6.1.4 Function Code F3 – Speed Boost Bypass Clutch Delay - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-5.6.2 TRANSFER FUNCTION CODES ( P0, P1)........................................................................................................... 5-16
5-5.6.2.1 Function Code P0 – Transfer Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16
5-5.6.2.2 Function Code P1 – Transfer Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-18

6 DOCK TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

6-1 Control Heads (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Start Interlock (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3 Engine Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-4 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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6-5 Control Head Solenoid Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-6 Throttle Pause Following Solenoid Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

7 SEA TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

7-1 Full Speed Setting - Electronic Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Proportional Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2.1 In-Gear Delay [C200] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2.2 Neutral Delay [C201] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2.3 Fixed Neutral Delay [C202] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-3 Calculating Proportional Pause Time C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3.1 Testing The Proportional Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4 Synchronization Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4.1 Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4.2 Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Sea Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-5.1 Vessel Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-5.2 Control System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Table 7-1: Sea Trial Processor Mounting....................................................................................................................... 7-4
Table 7-1: Sea Trial Power Supply ................................................................................................................................. 7-4
Table 7-1: Dock Trials .................................................................................................................................................... 7-5
Table 7-1: Sea Trials ...................................................................................................................................................... 7-5
7-5.3 Record Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Table 7-1: Record Processor Functions ......................................................................................................................... 7-6
Table 7-1: Record Throttle Functions............................................................................................................................. 7-6
Table 7-1: Record Clutch Functions ............................................................................................................................... 7-6
7-5.4 Comments (Please use additional paper as necessary): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-5.4.1 GENERAL INSTALLATION CONDITION .................................................................................................................. 7-6
7-5.4.2 ANY IRREGULARITIES:...................................................................................................................................... 7-6

8 CONTROL OPTIONS - - - - - - - - - - - - - - - - - - - - - - - - 8-1

8-1 External Alarm Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Figure 8-1: External Alarm Connections with Processor Harness Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Figure 8-2: External Alarm Connections Processor Hard-Wired Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 Clutch Pressure Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2.1 C0 Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2.1.1 01 - INSTALLED ............................................................................................................................................. 8-2
8-2.1.2 02 - THROTTLE CLUTCH PRESSURE INTERLOCK.................................................................................................... 8-2
Figure 8-3: Clutch Pressure Switch with Processor Harness Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Figure 8-4: Clutch Pressure Switch with Processor Hard-Wired Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-3 Station Expander (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-4 Trolling Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-5 Engine Room Only / Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-6 Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-7 DP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-8 Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Figure 8-5: Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-9 Backup Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-10 Speed Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Figure 8-6: Speed Boost Usage Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-10.1 Speed Boost Percent (F0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-10.2 Speed Boost Duration (F1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-10.3 Speed Boost Start Delay (F2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-10.4 Speed Boost Bypass Clutch Delay (F3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

9 PERIODIC CHECKS AND MAINTENANCE - - - - - - - - - - - - - 9-1

9-1 Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

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9-3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-3.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-3.1.1 QUARTERLY (EVERY 3 MONTHS)....................................................................................................................... 9-1
Table 9-2: Fully Charged Battery ................................................................................................................................... 9-1
9-3.1.2 SEMI-ANNUALLY (EVERY 6 MONTHS) ................................................................................................................ 9-1
9-3.1.3 ANNUALLY (EVERY 12 MONTHS) ...................................................................................................................... 9-1
9-3.2 Power Cables, Distribution Panels, etc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Appendix A
PARTS LIST.............................................................................................................................................. A-1
MMC-329 Rev.C 8/03............................................................................................................................. A-3
MC2000 Series Standard Control Head Variations
MMC-279 Rev.B 7/02............................................................................................................................. A-9
400 Series Weather Mount Enclosure
Deutsch Connector Assembly............................................................................................................... A-11
S-214 Rev.F 3/05................................................................................................................................. A-13
Automatic Power Selector (APS) Model: 13505
Drawing 11488D-1 Twin Screw Single APS Connection & Alternate Remote Switch ......................... A-15
Drawing 11488D-2 Twin Screw Dual APS Connections ....................................................................... A-17
Drawing 11488D-3 APS Notes Page..................................................................................................... A-19
MMC-287 Rev.D 8/03.......................................................................................................................... A-21
Bonding: A.B.Y.C. E-11, 46 CFR 111.05
MMC-288 Rev.E 8-03 .......................................................................................................................... A-23
References and Parts Source
SER-161 Rev.B 5/03 ............................................................................................................................. A-25
Engine Tachometer Sender Requirements
MMC-165 Rev.E 2/05 ........................................................................................................................... A-27
Electronic Propulsion Control Systems Three Year Limited Warranty
MMC-163 Rev.C 10/04......................................................................................................................... A-29
Warranty Registration

Appendix B
B1 TROUBLESHOOTING GENERAL - - - - - - - - - - - - - - - - - B1-1
B1-1 Control System Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-1.1 96202 (Throttle Electronic, Clutch Solenoid, Two Station) Processor. . . . . . . . . . . . . . . . . . B1-1
B1-2 Typical System Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-2.1 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-2.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-2.3 Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-2.4 Electrical Cables and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1

B2 TROUBLESHOOTING QUESTIONS - - - - - - - - - - - - - - - - B2-1

B3 TROUBLESHOOTING PROBLEM RESOLUTION - - - - - - - - - - B3-1

B3-1 DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1

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TABLE OF CONTENTS

B3-2 Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1

B3-2.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-2.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-3 Component Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-3.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-3.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-4 Interconnecting Wiring and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
Table B3-1: Examples of Components (Internal/External) .............................................................................................B3-1

B4 TROUBLESHOOTING DIAGNOSTIC MENU - - - - - - - - - - - - B4-1

Figure B4-1: Display Function Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-2: Display Troubleshooting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-3: Display Troubleshooting Function Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-4: Example Display of Applied Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-5: Example Display of Tach Sensor Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-6: Example Display Control Head Lever Current Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-7: Example Display Control Head Transfer Button Status View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-8: Example Display Software Revision Level View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2

B5 TROUBLESHOOTING AUDIBLE TONES - - - - - - - - - - - - - - B5-1

B5-1 Basic Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
B5-1.1 Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
Figure B5-1: Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
B5-1.2 One Long - Three Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Figure B5-2: One Long - Three Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Figure B5-3: Display Examples of Remote Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Figure B5-4: Display Examples of Remote Stations A/D Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
B5-1.3 Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Figure B5-5: Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
B5-1.4 Three Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Figure B5-6: Three Second Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
B5-1.5 Three Second Steady Tone, followed by a Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-7: Three Second Tone, followed by a Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1.6 Five Seconds On, Five Seconds Off - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-8: Five Seconds On, Five Seconds Off - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1.7 Five Second Steady Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-9: Five Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-2 Clutch Solenoid Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-2.1 One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-10: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4

B6 TROUBLESHOOTING STATION TRANSFER - - - - - - - - - - - - B6-1

B6-1 Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1
B6-2 A to D Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1
Table B6-1: Control Head Lever A/D Counts ..................................................................................................................B6-2
B6-3 Remote Station Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Figure B6-1: Display Station A/D’s No Station Transfer Button Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2
Figure B6-2: Example Display Station A/D’s Transfer Button Depressed for Stations 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . B6-2
Figure B6-3: Display Station A/D/s Transfer Button Depressed for Station 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-2

B5 TROUBLESHOOTING STUCK TRANSFER BUTTON - - - - - - - - B5-1

B8 ERROR CODES - - - - - - - - - - - - - - - - - - - - - - - - - B8-1

B8-1 Basic Control System Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-1
Table B8-1: Basic Control System Error Codes ..............................................................................................................B8-1
B8-1 Clutch Solenoid Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-2
Table B8-2: Clutch Solenoid Control System Error Codes .............................................................................................B8-2

B9 BASIC PROBLEM CAUSES AND SOLUTIONS - - - - - - - - - - - B9-1

B9-1 Basic Control System Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . B9-1
Table B9-1: Basic Control System Problem Causes and Solutions ................................................................................B9-1

TOC-8
TABLE OF CONTENTS

B10 PROBLEMS WITHOUT ERROR CODES - - - - - - - - - - - - - - B10-1

B10-1 Basic Control System Problems Without Error Codes . . . . . . . . . . . . . . . . . . . . . . B10-1
B10-2 Solenoid Clutch Control System Problems Without Error Codes . . . . . . . . . . . . . . B10-2
B10-3 Electronic Throttle Control System Problems Without Error Codes . . . . . . . . . . . . B10-2

B11 SYNCHRONIZATION TROUBLESHOOTING - - - - - - - - - - - - B11-1

B11-1 Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-1.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-1.1.1 SYMPTOM: WILL NOT SYNCHRONIZE........................................................................................................... B11-1
B11-2 Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-2.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-2.1.1 SYMPTOM: THE GREEN LED IS LIT SOLID, THOUGH THE ENGINE RPM’S DIFFER BY A SIGNIFICANT AMOUNT. ......... B11-1
B11-2.1.2 SYMPTOM: WILL NOT SYNCHRONIZE........................................................................................................... B11-1
B11-2.2 Electronic Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-2.2.1 SYMPTOM: THE GREEN LED IS LIT SOLID, THOUGH THE ENGINE RPM’S DIFFER BY A SIGNIFICANT AMOUNT. ........... B11-1
B11-2.2.2 SYMPTOM: ONE OR BOTH OF THE ENGINES CONTINUALLY CHANGES RPM (HUNTS). WILL NOT SYNCHRONIZE PROPERLY B11-1
B11-2.2.3 SYMPTOM: SYNCHRONIZATION DOES NOT FUNCTION. THE CONTROL HEAD’S GREEN LED DOES NOT LIGHT........... B11-2

B12 TROUBLESHOOTING CABLE HARNESSES - - - - - - - - - - - - B12-1

B12-1 Basic Control System Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-1
Table B12-1: Power, Start Interlock Harness Pin-Out ....................................................................................................B12-1
Table B12-2: Power, Start Interlock, and Pressure Switch Harness Pin-Out.................................................................B12-1
Table B12-3: Power, Start Interlock, Pressure Switch, and Alarm Harness Pin-Out .....................................................B12-1
Table B12-4: Serial Communication Harness Pin-Out....................................................................................................B12-1
Table B12-5: Control Head Harness Pin-Out and Hard-Wire .........................................................................................B12-2
Table B12-6: Tachometer Sensor Harness Pin-Out........................................................................................................B12-2
Table B12-7: Tachometer Sensor Harness with Power Pin-Out ....................................................................................B12-2
B12-2 Clutch Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-2
B12-2.1 Ahead/Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-2
Table B12-8: Ahead/Astern Clutch Harness Pin-Out......................................................................................................B12-2
B12-2.1 Ahead/Neutral/Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-9: Ahead/Neutral/Astern Clutch Harness Pin-Out ........................................................................................B12-3
B12-3 Throttle Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
B12-3.1 Current, MAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-10: Current, MAN, Throttle Harness Pin-Out ..................................................................................................B12-3
B12-3.1 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-11: Frequency Throttle Harness Pin-Out.........................................................................................................B12-3
B12-3.1 PWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-12: PWM Throttle Harness Pin-Out.................................................................................................................B12-3
B12-3.1 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-13: Voltage Throttle Harness Pin-Out .............................................................................................................B12-3

B13 PROCESSOR PIGTAILS - - - - - - - - - - - - - - - - - - - - - B13-1

B13-1 Basic Processor Pigtails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
Table B13-1: Power/Start Interlock/Clutch Oil Pressure Switch/Alarm Pigtail Pin-Out .................................................B13-1
Table B13-2: Serial Communication Pigtail Pin-Out.......................................................................................................B13-1
Table B13-3: Control Head Pigtail Pin-Out (Up to 5 Stations)........................................................................................B13-1
B13-2 Throttle Pigtail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
Table B13-4: Throttle Pigtail Pin-Out..............................................................................................................................B13-1
B13-3 Clutch Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-5: Clutch Pigtail Pin-Out ................................................................................................................................B13-2
B13-4 Tachometer Sensor Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-6: Tachometer Sensor Pigtail Pin-Out...........................................................................................................B13-2

ENG-143 Ver. 1 4/04 .............................................................................................................................. B-3

ClearCommand 9000 Series Electronic Throttle – Solenoid Clutch
Version: 1.0
Service Field Test Unit
Reference Manual
MM13927 Table of Contents ..............................................................................................................TOC-1

TOC-9
TABLE OF CONTENTS

Revision List .......................................................................................................................................TOC-2

1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Figure 1-1: Service Field Test Unit (Break-out Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-2: CruiseCommand Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-3: Example of ClearCommand Pigtail Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 1-1: Connector/Pigtail Descriptions ..................................................................................................................... 1-1

2 PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 Throttle Signal Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.1 DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-4: Throttle Connection (DC Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.2 Current (mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-5: Throttle Connection (Current mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1.3 PWM (Pulse Width Modulation) with DC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-6: Throttle Connection (PWM with DC Voltmeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1.4 PWM (Pulse Width Modulation) with Duty Cycle Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-7: Throttle Connection (PWM with Duty Cycle Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-1.5 Frequency (Hz.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-8: Throttle Connection (Frequency Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 CLUTCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-2.1 Neutral Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-9: Clutch Connection (Neutral Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-2.2 Ahead Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-10: Clutch Connection (Ahead Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-2.3 Astern Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-11: Clutch Connection (Astern Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 TROLL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3.1 Troll On/Off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-12: Troll Connection (ON/OFF Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3.2 Troll Command (Proportional Solenoid) Testing with Amp Meter. . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-13: Troll Connection (Proportional Solenoid with Amp Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Table 3-2: Parts List ....................................................................................................................................................... 3-1

Appendix C
Drawing 13068A-1 Notes Page............................................................................................................... C-1
Drawing 13068A-2 System Diagram....................................................................................................... C-3
Drawing 13068A-3 Processor Connections ............................................................................................ C-5
Drawing 13068A-4 Control Head Connections....................................................................................... C-7

TOC-10
REVISIONS LIST

Revisions List

Rev Date Revision Description

- 2/05 This manual is created from MM14330-I RevF 11/04 CruiseCommand Installation
Manual. Refer only to the Sections appropriate for your System.

Refer to Appendix C System Drawing for System Specific Information.

(A) A1 (9/05) 10/05 (Processor replaced with 96202 ClearCommand.) Per JimM Engine and Ratio Chg.
(Dwg 13068 revised to A.)

PageTOC-11
REVISIONS LIST

PageTOC-12
INTRODUCTION
1 INTRODUCTION
This manual is written to document every possible system option.
Your system may not include every available option for single or multi-screw
reverse reduction gear applications.
Only those sections that apply to your specific installation are relevant to your
vessel.
If additional options described within this manual are desired, contact your
dealer for availability/compatibility with your system.
1-1 Manual Contents
This manual is divided into 12 Sections which cover, in detail, the features
and operation of your system:
• Introduction (Section 1)
• Operation (Section 2)
• Plan the Installation (Section 3)
• Installation (Section 4)
• Set Up Procedures (Section 5)
• Dock Trials (Section 6)
• Sea Trials (Section 7)
• Control Options (Section 8)
• Periodic Checks and Maintenance (Section 9)
• ZF Marine Electronics Service Sheets (Appendix A)
• Troubleshooting (Appendix B)
• System Drawings (Appendix C)
1-2 Basic Theory of Operation
The ClearCommand Marine Propulsion Control System will hereafter be
referred to as ClearCommand or System.
The System is electronic and requires a 12 or 24 VDC power supply, one
Processor per engine/gear and one Control Head per remote station.
The ClearCommand commands the vessel’s throttle and shift using a
single Control Head lever.
One electric cable per Control Head lever connects the remote station(s) to
the Processor(s). Only one remote station will have command at a given
time and the Station-in-Command is indicated by a red light located on the
Control Head. Station transfer is accomplished by pressing the Control
Head mounted transfer button.
1-2.1 96202 Processor (Throttle - Electronic, Shift - Solenoid, 2 Pluggable
Remote Stations)
The System is designed for pleasure and light commercial marine
vessels that require remote control of:
• electronic engine governors
• solenoid activated clutches
1-3 System Features
1-3.1 Standard Processor Features
• Station-in-Command indication. (Section 2-2)
• Single Control Head lever command of speed and direction.
(Section 2-3)
• Start Interlock. (Section 2-4)
• Push Button Station Transfer. (Section 2-5)
• Proportional Pause on through Neutral Shifts. (Section 2-6)
• Warm-up Mode. (Section 2-7)
• High/Low Idle Selection. (Section 2-8)
• One Lever Mode. (Section 2-9)
• Engine Synchronization. (Section 2-10)
Page 1-1
INTRODUCTION
• Easily configured to a vessel’s control requirements.
(Section 2-11)
• Audible system diagnostics and status indications. (Section 2-12)
• Push Button Set Up. (Section 2-13)
• Visual system diagnostics, set up, and status indication.
(Section 2-14)
• Pluggable Connections. (Section 2-15)
1-3.2 Optional Processor Features
• System failure external alarm contact. (Section 2-16.1)
• Clutch pressure interlock. (Section 2-16.2)
• Station Expander (SE). (Sections 2-16.3)
• Integrated Solenoid Trolling Valve Control (Section 2-16.4)
• Engine Room Only/Remote Switch (Section 2-16.5)
• Lockout Switch (Section 2-16.6)
• DP Mode (Section 2-16.7)
• LCD Panel (Section 2-16.8)
• Backup Control System (Section 2-16.9)
• Speed Boost (Section 2-16.10)

Page 1-2
OPERATION
2 OPERATION
2-1 DC Power On
When DC power is turned ON to the Processor:
• A short steady tone, followed by an intermittent tone, will sound at
all Remote Stations indicating that no station has command.
• The Start Interlock relay contact will remain open, preventing
engine start.
• Throttle:
Electronic: The throttle signal will be commanded to Idle.
• Shift:
Solenoid: The Ahead and Astern shift solenoids will be de-energized,
commanding Neutral.
2-2 Taking Command
To take command at any one of the Remote Stations:
• Ensure all Control Head’s lever(s) at that Station are in
the Neutral detent (vertical position)
• Depress the transfer button for 1/2 second.
The Slow Repetitive tone will stop at all Stations, and the
red LED indicator light will turn ON at the Control Head
of the Station that had assumed command of the Control
System.
Figure 2-1: Station taking Command

NOTE: If Start Interlock is used: Once a Station is in command the Start Interlock relay contact
will close, allowing the engine to start.

NOTE: Only one Station can have command at a time.

The Operator is now in control of the vessel’s screws.

2-3 Basic Operation
2-3.1 Normal Operating Mode
A) The Control Head has three detents; Ahead, Astern and
Neutral.
B) With the Control Head lever positioned in the Neutral
(vertical) detent, the Processor will command Neutral and the
throttle at Idle revolutions per minute (RPM).

C) Movement of the
Control Head’s lever 15
degrees to the Ahead or
Astern detent will
command Ahead or
Astern clutch
engagement, while the
engine RPM remains at
Idle.
Further movement of the
Control Head lever through
the next 65 degrees, will
increase the engine RPM in
proportion to the Control
Head’s lever position.
Figure 2-2: Control Head Detents

Page 2-1
OPERATION
2-4 Start Interlock (if used)
The engine start signal is blocked unless all of the following are true:
• DC power has been turned ON to the Control System.
• A Remote Station is in command.
• The Control System is commanding Neutral.
2-5 Station Transfer

WARNING: Personal injury could occur if the following steps are not followed exactly.

These Processors offer 4 different means of Station Transfer:

• Neutral Only (Mode P000)
• Lever Match & Neutral (Mode P002)
• Relinquish/Receive or Request/Relinquish (Mode P003)
• Request/Relinquish/Receive (Mode P0004)
The transfer type is selected during initial system setup.
2-5.1 Neutral Only Transfer (Mode P000)
A) The Station-in-Command’s lever(s) may be in any position.
However, it is recommended that the lever(s) are positioned to the
Neutral/Idle position whenever transferring from one station to
another.
B) The Operator at the Remote Station taking command MUST place
the Control Head lever(s) in the Neutral/Idle position.
C) Depress and hold the receiving Station’s Transfer Button until the
Control Head’s LED(s) is lit.
• Transfer of command is now complete.
2-5.2 Lever Match and Neutral (Mode P002)
WARNING: DO NOT USE THIS MODE OF TRANSFER UNLESS ALL REMOTE
STATIONS ARE IN CLOSE PROXIMITY AND WITHIN SIGHT OF ONE ANOTHER.
Extreme care must be taken when transferring command with the receiving Station’s
Control Head lever(s) not in the Neutral/Idle position. First of all, the vessel is
moving while no person is physically at the Helm. Secondly, the engine’s RPM’s can
change by as much as 10%, resulting in a sudden increase or decrease in the
vessel’s speed.
A) The Station-in-Command’s lever(s) may be in any position.
• The Operator at the Remote Station taking command MUST
have a good view of the Station-in-Command’s lever positions.
B) Position the lever(s) of the Station taking command to Neutral or
in close proximity (within 10%) of the Station-in-Command’s
lever(s).
C) Depress and hold the receiving Station’s Transfer Button until the
Control Head’s LED(s) is lit.
• Transfer of control is now complete.
2-5.3 Forward Pass Sequence [Relinquish/ Receive] (Modes P003 & P004)
A) At the Station-in-Command, place the Control Head levers into the
Neutral/ Idle position.
B) Depress and hold the transfer button until a solid tone is heard for
one second, which indicates that transfer has been activated.
• If equipped with Indication Panels, the message “Push Transfer
Button at New Station” will be displayed at all Stations.
• A distinctive 1/2 second ON, 1/2 second OFF tone pattern will
sound at all Remote Stations for up to the time set with Function
Code P1 “Transfer Timeout”.
C) The Operator at the Remote Station taking command MUST place
the Control Head levers in the Neutral/ Idle position.
D) The Operator MUST depress and hold the transfer button within
the preset time period until a solid tone is heard, to gain command.

Page 2-2
OPERATION
• If the Operator at the Station taking command does not press the
transfer button within the preset time period, the transfer
process is aborted, the text message disappears (if so equipped)
and the tone is silenced.
• If the Operator at the Station taking command does take
command within the preset time period, the new Station-in-
Command text will appear on the Panel and the text message
will disappear.
E) The Remote Station that accepted command is now the Station-in-
Command as indicated by the lit red LED(s).
2-5.3.1 Transfer Request Sequence [Request / Relinquish] (Mode P003)
2-Step
A) At any Remote Station not in command, place the Control
Head lever into the Neutral/ Idle position.
B) Depress and hold the transfer button until a solid tone is heard
for one second. Release the transfer button to activate transfer.
• If equipped with Indication Panels, the message “Station X
Rqsts Xfer” will be displayed at all Stations.
• A distinctive 1/2 second ON, 1/2 second OFF tone pattern
will sound at all Remote Stations for up to the time set with
Function Code P1 “Transfer Timeout”.
C) The Operator at the Station-in-Command MUST place the
Control Head levers into the Neutral/ Idle position.
D) Depressing the transfer button within the preset time
relinquishes control.
• If the Operator at the Station-in-Command does not press the
transfer button within the preset time period, the transfer
process is aborted, the text message disappears (if so
equipped) and the tone is silenced.
• If the Operator at the Station-in-Command does press the
transfer button within the preset time period, control is
transferred to the new station, the new Station-in-Command
text will appear on the Panel and the text message will
disappear.
E) The Remote Station that requested control is now the Station-
in-Command as indicated by the lit red LED(s).
2-5.3.2 Transfer Request Sequence [Request/ Relinquish/ Receive] (Mode
P004) 3-Step
A) At any Remote Station not in command, place the Control
Head lever into the Neutral/ Idle position.
B) Depress and hold the transfer button until a solid tone is heard
for one second. Release the transfer button to activate transfer.
• If equipped with Indication Panels, the message “Station X
Rqsts Xfer” will be displayed at all Stations.
• A distinctive 1/2 second ON, 1/2 second OFF tone pattern
will sound at all Remote Stations for up to the time set with
Function Code P1 “Transfer Timeout”.
C) The Operator at the Station-in-Command MUST place the
Control Head levers into the Neutral/ Idle position and press
the transfer button until a solid tone is heard for one second to
allow the transfer to take place.
• A distinctive 1/2 second ON, 1/2 second OFF tone pattern
will sound at all Remote Stations for up to the time set with
Function Code P1 “Transfer Timeout”.
• If equipped with an Indication Panel, the message “Push
Transfer Button At The New Station” will be displayed at all
Stations.
D) The Remote Station that requested the transfer must depress
the transfer button for a second time.
• If the Operator at the Station requesting control does not
press the transfer button within the preset time period, the
Page 2-3
OPERATION
transfer process is aborted, the text message disappears (if so
equipped) and the tone is silenced.
• If the Operator at the Station requesting control does press
the transfer button within the preset time period, control is
transferred to the new station, the new Station-in-Command
text will appear on the Panel and the text message will
disappear.
2-6 Proportional Pause
The proportional pause provides a means of safely reversing the vessel’s
direction. A variable pause is introduced into the clutch command signal
to allow time for the engine RPM’s to drop to Idle and for the vessel’s
speed through the water to slow.
2-7 Warm-up Mode (Throttle Only Mode)
This feature allows the operator to increase the engine’s RPM, while the
Clutch remains in Neutral. Warm-Up Mode is operational only when the
Control Head lever is moved in the Ahead direction.

WARNING: Personal Injury could occur if the following steps are not followed exactly.

The system is placed into Warm-Up Mode as follows:

A) At the Station-in-Command, ensure that the
Control Head’s lever is in the Neutral detent
position (refer to Figure 2-3:).
B) Depress and hold the transfer button.
C) After one second, move the Control Head’s lever
to the Ahead detent, while continuing to hold
Figure 2-3: Control Head Warm-Up Mode the transfer button.

D) Now release the transfer button.

• The red LED indicator light will blink slowly,
indicating Warm-Up Mode is activated and the
Clutch has remained at Neutral.
E) The operator can start the engine, if required,
and increase the RPM through the entire
throttle range by moving the Control Head’s
Figure 2-4: Control Head Normal lever forward through the next 65 degrees.
Operating Mode
F) When the Control Head’s lever is returned to the Neutral detent,
the red LED will discontinue blinking and remain lit steady. After
one second in Neutral, the Processor will automatically reset to
normal operation with full control of the clutches and engine.
G) The next movement of the Control Head’s lever will engage the
Ahead or Astern clutch (Normal Operation).
2-8 High/Low Idle
The Control System provides the input to the engine, so that it may run at
the standard Idle speed (typically adjusted at the governor or carburetor),
or it can provide a second elevated Idle speed.
2-8.1 Low Idle
• The factory default setting is for Low Idle Only.
• When the System is initially powered-up, it will always
command Low Idle, even when High Idle is selected.
2-8.2 High Idle
• If High Idle is desired, it may be programmed during Dock
Trials.
Page 2-4
OPERATION
• High Idle is programmable up to a maximum setting of 20% of
Full Throttle.
• High Idle is automatically selected when in Warm-Up Mode.
2-8.3 Selecting Between High and Low Idle

WARNING: Personal Injury could occur if the following steps are not followed
exactly.

Refer to Figure 2-5: when selecting between Low and High Idle (or vice
versa) at the Station-in-Command.
A) The Control Head’s lever(s) may be in the Neutral,
Control Head Ahead or Astern detents when making a selection.
levers may be
in Neutral, Ahead, B) Depress and hold the transfer button for 1/2 second and
or Astern Detent
then release.
• If the System was in Low Idle it will toggle to High
Depress and Hold Transfer Button
Idle, and vice versa.
for ½ second to toggle between
High and Low Idle
C) To return to the previous Idle setting, depress and hold
the transfer button again for 1/2 second and then
release.
10238

Figure 2-5: High/Low Idle Mode Selection

NOTE: In Twin Screw applications, always program both Processors for the same amount of High
Idle. In Twin Screw applications, both the Port and Starboard Processors will always be in High
or Low Idle at the same time.

2-9 One Lever Mode (Multi Screw)

NOTE: The Green LED will always be lit while in One Lever Operation, no matter what position
the Master Control Head lever is in.

The system supports a mode of operation referred to as One Lever Mode.

One Lever Mode allows the operator to control two to five engines and
transmissions with a single Control Head lever. Any of the Control Head
levers at any Remote Station can be designated by the operator as the
Master lever.
The designation can be changed by the operator at any time. Most of the
features (synchronization, troll, etc.) available in normal operation are
available while operating in One Lever Mode.
• The Processor defaults to One Lever Mode disabled.
• One Lever Mode can be disabled or enabled in the Set Up
Procedures.
• When One Lever Mode is enabled, the operation must be turned
ON and OFF as described below.

WARNING: Personal Injury could occur if the following steps are not followed exactly.

2-9.1 Turning ON One Lever Operation

A) At the Station-in-Command, move all the Control Head levers to
the Ahead detent.
B) Depress and Hold the transfer button while moving one of the
Control Head levers forward, out of the Ahead detent. Do Not
Release the Transfer Button until the green LED turns ON,
indicating One Lever Operation is now active.
• The Control Head lever which the operator chose to move
out of the Ahead detent, becomes the Master lever.
• The Control Head lever which was left in the Ahead detent is
now inactive.
Page 2-5
OPERATION

Figure 2-6: Step A) One Lever Operation Mode Figure 2-7: Step B) One Lever Operation Mode

NOTE: The Control Head lever designated by the operator to be inactive in One Lever Operation,
may be left in the Ahead detent or moved fully forward. Moving the lever fully forward is
recommended, because it moves it out of the way and prevents accidental bumps while operating.

2-9.2 Turning OFF One Lever Operation

WARNING: It is strongly recommended that the Master lever is returned to the Neutral/Idle
position prior to turning OFF One Lever Operation.
• Do not attempt to transfer command from one Remote Station to another while in One
Lever Operation. Always turn One Lever Operation OFF prior to transferring.
• Failure to observe these recommendations may result in a sudden change in the vessel’s
direction.
A) Place the Master lever into the Neutral detent.
B) Place all inactive Control Head levers into the Neutral detent.
• Whenever an inactive lever is moved to the Neutral detent, One
Lever Operation is turned OFF for that lever ONLY!
• In applications with three or more screws, the green LED will
not turn OFF until all inactive Control Head levers are returned
to the Neutral detent.
NOTE:
• In Multiple Srew applications, always program all the Processors for the same amount of High
Idle.
• In Multiple Screw applications, all Processors will be in High or Low Idle at the same time.
• High Idle is not available when Transfer Mode 03 or 04 are selected or when a DP system is in
control.
2-10 Engine Synchronization (Multi Screw)
Engine Synchronization must be selected during Set Up to have automatic
synchronization.

NOTE: The Control System offers two types of synchronization, Active or Equal Throttle.

Synchronization is automatic and only operates when the Ahead clutch is

engaged, consequently it can be left ON full time. When synchronization
has been selected during set up, the Control System will always power-up
with synchronization ON.
In order for synchronization to become active (work toward synchronizing
the engines' RPM's) the Synchronization Criteria listed below must be
met.
2-10.1 Synchronization Criteria
• Both Control Heads must be commanding 5% or greater of the
throttle range.
• The Control Head levers must be within 10% of one another (+/-
approximately 6 degrees).
• Both Control Head levers are commanding Ahead clutch
engagement.

Page 2-6
OPERATION
2-10.2 Synchronization Types
The following types of synchronization use the same criteria,
indications, and are turned ON and OFF as described in following
Sections.
2-10.2.1 Equal Throttle Synchronization (default Enabled)
Equal Throttle synchronization simply commands the same
throttle to all engines. In applications where the engine governor
requires a voltage signal, the exact same voltage signal will be
applied to all governors. With Equal Throttle Synchronization the
Processors do not receive tachometer signals representative of the
engines RPM's.
CAUTION: The Control System will remain synchronized as long as the Control
Head's levers are in close proximity to one another. If a lever is moved to a point where
the 10% throttle window is exceeded, a 10% increase or decrease in engine RPM would
occur with one engine, resulting in a sudden change in the vessel's direction.
2-10.2.2 Active Synchronization (default Disabled)
Active Synchronization must be enabled during Set Up and a
Tachometer Sensor Wire Harness must be used.
The Processors each receive a tachometer signal representing
engine RPM from their respective engines. These signals are
compared with one another over a serial communication line. If
the Synchronization Criteria (Section 2-10.1, page 2-6) is met, the
throttle command signal of the engine(s) running at the higher
RPM is lowered, until the RPM's of all engines match.
2-10.3 Synchronization Indications
The green LED located on the Control Head indicates the status of
synchronization.
• In Active Synchronization the green LED blinks every time
there is a change in the commanded throttle.
• When the green LED is lit steady, the engines are synchronized.
• When the green LED is not lit, the engines are not synchronized
and the Control System is not attempting to do so.
2-10.4 Turning Synchronization OFF/ON when Criteria is Met
2-10.4.1 Turning OFF:
When the criterial listed in Section 2-10.1, page 2-6, is met,
synchronization is automatic and does not need to be turned ON.
If the operator elects to turn OFF synchronization, follow the steps
below:
A) Ensure that the Control Head's levers are positioned to a
point where Synchronization Criteria are met.
B) At the Station-in-Command, press and hold the transfer
button until the green LED blinks and then goes out
(approximately 2 seconds).
C) Synchronization is now OFF.
2-10.4.2 Turning ON:
Synchronization is automatic and does not need to be turned ON,
unless previously turned OFF, as described in Section 2-10.4.1.
A) Ensure that the Control Head's levers are positioned to a
point where Synchronization Criteria are met.
B) At the Station-in-Command, press and hold the transfer
button until the green LED lights (approximately 2
seconds).
• The green LED will blink as the system is working toward
synchronization.
• The green LED will become solid when the engines are
synchronized.
2-10.5 Turning Synchronization ON/OFF when Criteria is Not Met
The actual synchronizing of the engines occurs when the Control
Head levers are within the 10% (approximately 6 degrees) window of
Page 2-7
OPERATION
one another. However, synchronization can be turned ON or OFF
when the Control Head levers are apart more than the 10%.
A) At the Station-in-Command, press and hold the transfer
button for at least two seconds:
• If synchronization is being turned ON, the green LED
will light after two seconds and stay lighted as long as the
transfer button is depressed. When transfer button is
released the LED will go out.
• If synchronization is being turned OFF, after two
seconds, the green LED will blink twice and then stay off.
2-11 Control Systems’ Configurability
The Processor is designed in a way which allows it to be easily configured
by the installer to meet the varying needs of a wide variety of vessels.
Below you will find a list and a brief description of the groups of these
functions.
2-11.1 Processor Functions
Within this section of adjustable parameters, there are up to seven
different adjustments:
A0 Processor Identification - Assigns each Processor in multi-
screw application a unique identifying number. This
function must be the second function set during Set Up.
A1 Number of Engines - Lets the Processor know how many other
Processors need to be communicated with. This function
must be the FIRST FUNCTION SET during Set Up.
A2 One Lever Operation - Allows the installer to disable or enable
One Lever Mode capability.
A3 Station Expander (Optional) - Allows the Processor to
communicate with the Station Expander (SE), which
provides additional Remote Stations. Contact the factory if
this feature is required.
A4 Neutral Indication Tone - When enabled, produces a short 200
Hz tone to indicate Neutral.
A5 Engine Room/Remote Switch (Sta. 1)(Optional) and Lockout
(Sta. 2)(Optional) - Allows the installer to enable or disable
one or both of these features.
A6 DP (Sta. 5)(Optional) - Allows the installer to enable or disable
DP Mode with or without trolling valve operation.
Detailed information on each Function is found in Section 5-5.1,
page 5-6.
2-11.2 Throttle Functions
2-11.2.1 Basic Throttle Functions
This section applicable to both electronic and servo Throttle
adjustment:
E1 Throttle in Neutral - Adjusts the Throttle when in Neutral,
independent of the throttle output when the clutch is
engaged.
E5 Throttle Pause following Shift - Allows the adjustment of time
between clutch engagement command and when throttle
begins to increase above Idle.
E6 High Idle - Programs a second/elevated Idle RPM.
E7 Synchronization - Allows the installer to select synchronization
and select the type of synchronization.
Detail information on each function is found in Section 5-5.2.1,
page 5-8.
2-11.2.2 Electronic Throttle Functions
This section along with Basic Throttle Functions allows the
adjustment of the Electronic Throttle:
E0 Engine Throttle Profile - Selects the throttle signals type and
range.
Page 2-8
OPERATION
E2 Throttle Minimum - Allows fine tuning of the throttle signal at
Idle.
E3 Throttle Maximum - Allows fine tuning of the throttle signal at
Full.
E4 Throttle Maximum Astern - Allows the installer to limit the
amount of throttle allowed when Full Astern is
commanded.
Detail information on each function is found in Section 5-5.2.2,
page 5-10.
2-11.3 Clutch Functions
2-11.3.1 Basic Clutch Functions
The following functions are available for all types of clutches.
C0 Clutch Pressure Interlock - Selects the Clutch Oil Pressure
Interlock option. The interlock prevents a throttle signal
above Idle from being applied unless adequate clutch
pressure is available.
C1 Clutch Interlock Delay - Determines when the Clutch Oil
Pressure Interlock becomes active.
C2 Proportional Pause - Selects between an In-Gear, Neutral, or
Fixed Neutral delay.
C3 Proportional Pause Time - Selects the maximum delay time
during a full speed reversal.
C4 Proportional Pause Ratio - Determines if the Ahead and Astern
reversal times are the same or if Astern is 1/2 of Ahead
time.
C8 Fixed Neutral Delay - Provides an adjustable fixed Neutral
delay regardless of commanded speed and direction.
Detail information on each function is found in Section 5-5.3.1,
page 5-11.
2-11.3.2 Solenoid Clutch Functions
This section along with the Basic Clutch Functions Section allows
the adjustment of Clutch Solenoid related items:

IMPORTANT: The following Functions are to be used on Hurth gears with two (2) proportional
solenoids ONLY! Do not use on Hurth gears with ON/OFF solenoids.

C5 Shift Solenoid Type - Selects the approximate current levels for

the 12 or 24 VDC ZF Hurth Solenoids.
C6 ZF-Hurth Duty Cycle Ahead - Fine tunes the maximum current
level to the Ahead Proportional Solenoid.
C7 ZF-Hurth Duty Cycle Astern - Fine tunes the maximum current
level to the Astern Proportional Solenoid.
Detail information on each function is found in Section 5-5.3.2,
page 5-13.
2-11.4 Speed Boost Functions (Optional)
This section applies to electronic throttle signals:
F0 Speed Boost Percentage - Programs the amount of throttle
applied during initial clutch engagement.
F1 Speed Boost Duration - Programs how long the elevated throttle
signal will be applied after initial clutch engagement.
F2 Speed Boost Start Delay - Programs the amount of time
required after clutch engagement is commanded, until the
Speed Boost is applied.
Detail information on each function is found in Section 5-5.6.1,
page 5-16.
2-11.5 Troll Functions (Optional)
The L0 Troll function is the only Troll function code displayed unless
Troll is activated using L0. When activated, Function Codes L1
through L6 are displayed.

Page 2-9
OPERATION
L0 Troll Enable and Control Head Lever Range - Enables and
disables Troll. Selects the amount of Control Head lever
movement dedicated to Trolling Valve Control.
L4 Troll Throttle Limit - Programs the maximum throttle allowed
during trolling operation.
L5 Troll Pulse Duration - Adjusts how long a throttle boost is
applied when troll operation is initiated.
L6 Troll Pulse Percentage - Adjusts how much the throttle is
boosted when troll operation is initiated.
Detail information on each function is found in Section 5-5.4, page 5-
15
2-11.6 Integrated Troll Solenoid Functions
This section, along with the Basic Troll Functions Section, allows
the adjustment of solenoid Trolling Valve related items:
L1 Troll Valve Function - Selects the current output characteristics.
If ZF Hurth Gears with two (2) proportional solenoids are
used, this Function must be the 3RD function set.
L2 Troll Minimum Pressure - Adjusts the amount of current at
minimum Shaft rotation.
L3 Troll Maximum Pressure - Adjusts the amount of current at
maximum Shaft rotation (not maximum pressure).
Detail information on each function is found in Section 5-5.4,
page 5-15.
2-11.7 Transfer Functions
P0 Transfer Mode - Selects the various options available when
transferring from one Remote Station to another.
P1 Transfer Timeout - In certain Transfer Modes, selects the
amount of time allowed for the transfer sequence to be
completed.
Detail information on each function is found in Section 5-5.6.2,
page 5-16.
2-11.8 Troubleshooting Functions
2-11.8.1 Basic Troubleshooting Functions
H0 Diagnostics - Allows the installer/technician to look at various
inputs to the Processor.
H1 Return to Factory Defaults - Returns all settings to the factory
default values.
H2 Driver Fault Detection Enable - Allows the Processor to
monitor the clutch and/or troll solenoids.
Detail information on each function is found in Section 5-5.5,
page 5-15.
2-12 Audible Tones
Detailed information on the following tones are in Appendix B.
2-12.1 Basic Processor Tones
The Processor can produce numerous tones which inform the operator
of the status of the system or if any faults were to occur. These tones
are emitted from all Remote Stations regardless of whether they are in
command or not.
2-12.1.1 Slow Repetitive Tone

This tone is normal when DC power is first applied to the System.

This tone indicates that system initialization has occurred, no
Remote Station has command, the operator can accept command
at any Remote Station.
2-12.1.2 One Long, Three Short Tones

Page 2-10
OPERATION
This tone indicates that the command signal from the Station-in-
Command has gone out of the acceptable range.
2-12.1.3 Steady Tone

This tone indicates that the software program within the Processor
has quit running, due to low voltage or component failure.
2-12.1.4 Five (5) Second Steady Tone

This tone indicates that there has been a loss of Serial

Communication.
2-12.1.5 Three (3) Second Steady Tone

This tone is heard if there is a stuck transfer button, or when

entering Back-up Mode, or if a Troll Solenoid error occurs. (Back-
up Mode and Troll Solenoid is not available for all Processors.)
.
2-12.1.6 Five Seconds On, Five Seconds Off - High Repetitive Rate Tone

This tone indicates a loss of communication with the Station

Expander.
2-12.2 Clutch Solenoid Tones
2-12.2.1 One Long - One Short Tone

This tone indicates that a fault was detected with the Ahead,
Neutral, or Astern Clutch Solenoid.
2-12.3 Troll Integrated Solenoid Tones (If Troll is used)
2-12.3.1 Three Second Steady Tone

This tone indicates that the Troll Solenoid is OPEN or shorted.

Refer to the Error Code displayed for further information.
2-12.4 Transfer Tones
2-12.4.1 1/2 Second ON, 1/2 Second OFF Tones

This tone indicates that a Transfer Sequence has been initiated,

while in Transfer Mode 03 or Mode 04..
.
2-12.4.2 One Second Steady Tone

This tone indicates a press of the transfer button during a transfer

sequence in Transfer Mode 03 or Mode 04.
2-13 Push Button Set Up
There are four push buttons mounted to the Processor’s circuit board.
These push buttons allow the installer/technician access to all of the
Functions required for programming and troubleshooting the Processor.
A full description of their usage is provided in Section 5-1.2, page 5-2.
2-14 Visual System Diagnostics, Set Up And Status Indication
There are four, seven segment LED’s (hereafter referred to as the Display
LED) mounted to the Processor’s circuit board. The Display LED is visible
through a transparent window in the Processor’s cover. The information
displayed is used in conjunction with the push buttons to program the
Processor. The Display LED also displays Error Codes in the event that an
anomaly is detected.
For a full description of the Display LED, its capability and usage, refer to
Section 5-1.1, page 5-1.

Page 2-11
OPERATION

Push Button Location

LED Location

12255

Figure 2-8: Circuit Board Shield Layout

2-15 Pluggable Connections
2-15.1 Processor
The Processors come from the factory with enclosure mounted pigtail
connectors for easy, mistake free installations.
96202 2 Station pigtails, 5 standard pigtails
The following is a list of the pigtail connectors supplied for your
System. The figure represents all of the pigtails. Your System may not
use them all.
Refer to Figure 2-19: for pigtail locations:

Figure 2-9: Processor Pluggable Connections View

• Two pigtail connectors are provided for connection to the
Remote Station Control Heads.
• One pigtail connector provides the connections for DC Power,
Start Interlock, Clutch Oil Pressure Interlock and an External
Alarm contact.
• One pigtail connector is provided for serial communication
between multiple Processors.
• One pigtail connector is provided for the Tachometer Sensor
input used in multi-screw active synchronization.
• One pigtail connector provides connection to the throttle.
• One pigtail connector provides connection to the solenoid
clutch.
2-16 Optional Features
2-16.1 External Alarm Capability
• This optional feature is designed to provide a status signal to an
external visual or audible alarm circuit.
Page 2-12
OPERATION
• The status signal is in the form of an OPEN or CLOSED relay
contact. When the contact is CLOSED, the Processor is
functioning normally. When the contact OPENS, this indicates
the software program has quit running due to a component
failure or loss of DC power.
• A full explanation is provided in Section 8-1, page 8-1.
2-16.2 Clutch Pressure Interlock
• The purpose of the Clutch Pressure Interlock is to prevent high
engine RPM when the Clutch is not fully engaged.
• A full explanation of the Clutch Pressure Interlock is provided in
Section 8-2, page 8-2.
2-16.3 Station Expander (SE)
• The SE is a separate Processor housed in an enclosure that
allows the connection of up to five additional Remote Control
Stations.
• The SE communicates with the Processor over the serial
communication line.
• A full explanation of the installation, operation and adjustment
of the SE is provided in the Installation Manual provided with
the SE.
• If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.4 Trolling Valve Operation
• When the Control System is set up to control trolling valves, the
operation is quite different from Normal Operating Mode.
• Troll Mode is a feature that must be turned On and Off at the
Control Head.
• On initial power-up, Troll Mode is disabled.
• If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.5 Engine Room Only / Remote Switch
Station No.1 is typically designated as the Engine Room Station when
this feature is used.
• When the switch is CLOSED, Station No. 1 will take command
away from any other Remote Station, including DP. It also
prevents other Remote Stations from taking command away
from Station No.1.
• This feature is defaulted OFF, and therefore must be enabled
during set up. Refer to Section 5-5.1.6, page 5-8.
• If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.6 Lockout Switch
This feature prevents any Remote Station, other than Station No. 2
from taking command.
• This feature is defaulted OFF, and therefore must be enabled
during set up.
• Once enabled, the feature is selectable with a toggle switch.
• The Engine Room Only / Remote switch can override the
Lockout feature.
• If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.7 DP MODE
• Refer to the information supplied with the DP system for
operational guidelines.
• The ClearCommand and the DP systems cannot be in command
at the same time.

NOTE: High Idle and One Lever Mode are not available when a DP system is in command.

Page 2-13
OPERATION
If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.8 Display Panel
The Display Panel supplies various system information, including but
not limited to:
• Station-in-Command
• Control Head lever position
• Engine RPM
• Propeller shaft RPM
If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.9 Backup Control System
The Backup Control System provides a control system which is fully
independent from the ZF Marine Electronics Control System. The
Backup can control the transmission as well as the engine, but it does
not include ZF Marine Electronics control logic, safety interlock, and
timing circuits. In other words, there is no protection for operator
errors, such as shifting into gear at elevated rpm’s.
If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.
2-16.10 Speed Boost
CAUTION: Misapplication of the Speed Boost feature can damage the transmission or other
equipment. Before using Speed Boost, the transmission representative must be consulted about its use,
and any limitations on clutch engagement as a function of engine speed. The person(s) implementing
Speed Boost have the responsibility for ensuring it is properly adjusted and for any damage that might
occur.
CAUTION: With a properly set and timed Speed Boost signal, the engine speed should not increase
significantly (if at all) during clutch engagement. Engine speed should remain at or slightly above idle as
the clutch begins to engage. A certain amount of droop below idle is normal as the clutch pressure rises
and the clutch plates begin to come into contact. The idle speed should not rise until the clutch plates are
fully engaged. Transmission damage may occur if this is not followed. Adjust the Function Codes as
needed to meet this requirement.
Some vessels have the tendency to stall an engine when engaging the
clutch or during emergency reversals. In some applications this can be
minimized or eliminated by applying Speed Boost. Processors
equipped with this feature can be programmed to temporarily increase
the Speed Command Signal to the Governor at the precise time the
Clutch Plates begin to come in contact with one another.
NOTE:
1. Speed Boost is NOT required for most applications. Its primary use is with engines that have
mechanical Governors and where the engine stalls upon clutch engagement or clutch reversal
(going from Ahead to Astern or vice versa). This is typically due to a high reduction gear ratio
(4:1 or higher) or underpowered engine.
2. Speed Boost has been used in some electronic engines where there is a stalling problem due to
the engine not being able to respond quickly enough to a sudden load change (clutch
engagement). This is especially true with vessels that have a high reduction ratio (4:1 or
greater).
3. Speed Boost may also be used to reduce the droop (drop) in engine speed as the clutch
engages.
4. Use of Speed Boost does not guarantee that an engine will not stall. Ultimately the engine
must be capable of producing the power required in the time frame necessary to handle the
sudden load during clutch engagement.
If this option is going to be used, please contact a ZF Marine
Electronics Representative for further information.

Page 2-14
PLAN THE INSTALLATION
3 PLAN THE INSTALLATION

NOTE: ZF Marine Electronics recommends that the system be installed in accordance with
ABYC, E-11 and P24.

3-1 System Requirements

The first step when installing a System is to carefully plan the installation.
This includes finding proper mounting locations for the Processor(s) and
Control Heads. The decision must be made on where power is going to be
sourced and how the power will be routed to the Processor(s).
Once the locations have been decided, lengths of electrical wiring and
Harnesses and must be determined.
10.71
(272mm)

6.70
(170,2mm)

12256-

3.20
(81,3mm)

10.40
(264,2mm)
4.75
(120,7mm)

10.25
(260,4mm)
Figure 3-1: Processor Dimensions
• Grounding (Bonding) is required for maximum electromagnetic
compatibility (EMC) performance. Refer to Appendix A - Bonding.
Only when the previous items have been determined, should you start the
actual installation. The following sections describe the requirements for
installing the components and selecting mounting locations.
3-1.1 Processor(s)
Processors required per engine:
Twin Screw: Two (2) Processors
Mounting Hardware is installer supplied.
Installation/Troubleshooting Manual is included with the Processor.
The following items must be taken into account when selecting the
location for the Processor(s):
• The Processor is spray proof, but not water proof. Therefore, an
area must be selected that typically stays dry.
• The engine room is the preferred location for mounting the
Processor.
• If the engine room is too small, locate in any area where it is easily
accessible, as long as all of the criteria listed are met.

Page 3-1
PLAN THE INSTALLATION
• Bulkhead mounting is the preferred method due to ease of access
for wiring and adjustments. However, the Processor can be
mounted in any attitude as long as the Display LED window and
push buttons are accessible.
• Do not mount the Processor on the engine, transmission, or in any
location that will subject it to excessive vibration.
• Do not mount the Processor to the transom when the vessel is
equipped with a surface piercing drive system (due to vibration
concerns).
• Locate the Processor(s) away from sources of high heat, such as
engine exhaust manifolds or turbochargers. Allow 4 feet (1,2m) of
clearance or more.
• Do not mount the Processor(s) in close proximity to gas engine
ignition systems, alternators, generators or any equipment
producing strong magnetic fields. Allow 4 feet (1,2m) clearance or
more.
CAUTION: Strong magnetic fields can influence the Processor’s electronic circuits
and void your warranty.

3-1.2 Control Head(s)

Refer to Appendix A - Control Head Variations Service Sheets for
information on the various Control Heads available and their
dimensions.
• The 400 and MC2000 Series Control Heads are spray proof from
the top, but must be protected from the weather on the underside.
• The 700 Series Control Heads are fully water proof.
• Control Heads are available with pluggable pigtails or may be hard-
wired (no pigtails).
• When a 400 or MC2000 Series Control Head must be mounted in a
location where the underside may be exposed to the weather,
consider using a Weather Mount Enclosure. Refer to the Appendix
A - Weather Mount for specific information.
• Ensure that the clearance is sufficient for the Control Head’s lever
to reach full Ahead and full Astern.
• Retrofit applications may require an Adapter Pad to cover the old
Control Head cutout. A variety of Adapters and Cover Pads are
available. Refer to Appendix A - Parts List for details.
• The Control Head can be mounted at any location on the vessel, as
long as all of the criteria listed above are met.
3-1.3 Wire Harnesses
(Refer to Appendix A - Parts List)
The following lists the various Harnesses that plug into the Processor:
3-1.3.1 Control Head Harnesses
•One Control Head Harness is required for every Control Head
lever at every Remote Station.
•The Control Head Harnesses are available in various lengths.
•Harnesses are available with plugs on both ends or a plug on the
Processor side only.
•The Harness from the Port side of a Control Head is always
routed to the Port Processor.
•The Harness from the Starboard side of a Control Head is always
routed to the Starboard Processor.
3-1.3.2 Power, Start Interlock, Clutch Pressure, Alarm Harness
•One Harness required per Processor.
•The Harness is plugged at one end only.
•In addition to the DC power and Start Interlock, the Harness
options for Clutch Oil Pressure Switch and External Alarm
Circuit are available.

Page 3-2
PLAN THE INSTALLATION
•All of the cables in the Harness are the same length. Therefore,
order a length that will reach all of the previously mentioned
items, if required.
•The Harness is available in lengths up to 30 feet (9,14m).
3-1.3.3 Serial Communication Harness
The Serial Communication Harness is only required in:
• Multi Screw applications,
• when an LCD Display is utilized,
• or an external trolling valve actuator (9001) is utilized.
The Harness interconnects the Processors to each other. A plug is
attached at both ends of the Serial Harness.
Twin Screw:
One (1) Serial Harness (part no. 13316-X)
3-1.4 Additional Harnesses
(Refer to Appendix A - Parts List)
The following lists the additional Harnesses that plug into the
Processor:
3-1.4.4 Tach Sensor Harness
There are two Tach Sensor Harnesses available:
1. The first is the AC Coupled Sensor Harness, which is
designed for inputs from items such as Mechanical
Senders, Magnetic Pickup Sensors, the Alternator AC
Stator Terminal or the negative Coil Terminal.
2. The second Harness is designed for Active Sensors with
an Open Collector output, such as Hall Effect Sensors.
• This Harness is only required when Active
Synchronization is required.
• One Harness per Processor is required.
• The Harness is plugged on one end only.
Determine the source of the tachometer signal, which can be
provided by a mechanical tachometer sender, magnetic pickup,
alternator’s pre-rectified output, the negative side of the coil
(gasoline engine) or an engine’s electronically produced signal.
Refer to Engine Tachometer Sender Requirements located in
Appendix A.
3-1.4.5 Throttle Harness
•One Harness required per Processor.
•There are 4 types of Throttle Harnesses: Voltage, Current, PWM
(Pulse Width Modulation), and Frequency.
•Most Throttle Harnesses are plugged at the Processor side only.
•Some Throttle harness types are available with plugs on both
ends.
3-1.4.6 Clutch Harness
•One Harness required per Processor.
•The Harness consists of 2 two-conductor cables.
•The cables supply power to the Ahead and Astern Clutch
Solenoids
•All of the cables in the Harness are the same length. Therefore,
order a length that will reach all of the previously mentioned
items, if required.
3-1.5 Electric Cables
(Refer to Appendix A - Parts List)
The installation may use Harnesses, Electric Cables or a combination
of both.
The following lists the various equivalent electric cables:
3-1.5.7 Control Head Electric Cable
If the Control Head is hard-wired (no plugs) the electric cable may
be ordered from ZF Marine Electronics, or must meet the
following specifications :
• Seven-conductor with shield, twisted.
Page 3-3
PLAN THE INSTALLATION
• Color Code – black, brown, red, orange, green, blue, and
violet.
• 18 AWG (nearest metric equivalent - #1).
• 300V, 105 degrees C, UL VW1, stranded tinned copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm)
3-1.5.8 Power, Start Interlock, Clutch Pressure, Alarm Electric Cable
3-1.5.8.1 Power Electric Cable Requirements
If Power is hard-wired, (no plugs) the electric cable may be
ordered from ZF Marine Electronics, or must meet the
following specifications:
• Two-conductor, black and red with violet stripe,
twisted.
• 14 AWG (#2,5 metric) or 12 AWG (#4 metric) may be
used to crimp directly to the Processor terminals.
Refer to Automatic Power Selector in Appendix A for
cable length and additional wire size requirements.
• 300V, 105 degrees C, UL VW1, stranded tinned
copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.5.8.2 Start Interlock Electric Cable Requirements
If Start Interlock is hard-wired (no plugs) the electric cable
may be ordered from ZF Marine Electronics, or must meet
the following specifications:
• Two-conductor, both yellow with red stripe, twisted.
• 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned
copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.5.8.3 Clutch Pressure Interlock Electric Cable Requirements
When the Clutch Pressure Interlock option is utilized, a
pressure switch with a normally open contact must be
installed on the transmission, along with a Shuttle Valve
If the Clutch Pressure Switch is hard-wired (no plugs) the
electric cable may be ordered from ZF Marine Electronics,
or must meet the following specifications:
• Two-conductor, both light blue.
• 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned
copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.5.8.4 External Alarm Circuit Electric Cable Requirements
If the External Alarm Circuit is hard-wired (no plugs) the
electric cable may be ordered from ZF Marine Electronics,
or must meet the following specifications:
• Two-conductor, red and black, twisted.
• 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned
copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.5.9 Serial Communication
Serial Communication Harnesses are required in Multiple Screw
applications. All Processors come equipped with Serial
Communication Pigtail Plugs installed.
The Serial Communication Harness mates with these plugs. It is
strongly recommended that only factory manufactured Harnesses
are installed.
Refer to Appendix A Parts List for part numbers and available
lengths.
3-1.5.10 Tach Sensor Electric Cable Requirements
The cable selected depends on what type of Sensor is being used:
3-1.5.10.1 AC Tach Input
• Two-conductor, twisted, shielded.
• 20 AWG (#0,5 metric)

Page 3-4
PLAN THE INSTALLATION
• 300 V, 165 C, UL VW1, stranded tinned copper
• Maximum outside diameter: 0.390 inches (9,9mm)
3-1.5.10.2 Open Collector (Active)
• Three-conductor, twisted, shielded
• 20 AWG (#0,5 metric)
• 300 V, 165 C, UL VW1, stranded tinned copper
• Maximum outside diameter: 0.390 inches (9,9mm)
3-1.5.11 Throttle Electric Cable Requirements
If Throttle is hard-wired, (no plugs) to the Processor, the electric
cable may be ordered from ZF Marine Electronics, or must meet
the following specifications:
• Two-conductor, red and black, twisted, shielded.
• 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.5.12 Clutch Electric Cable
3-1.5.12.1 Clutch Electric Cable Requirements
If Clutch Solenoids are hard-wired, (no plugs) to the
Processor, the electric cable may be ordered from ZF
Marine Electronics, or must meet the following
specifications:
• Two-conductor, red and black, twisted.
• 16 AWG (#1,5 metric).
• 300V, 105 degrees C, UL VW1, stranded tinned
copper wire.
• Maximum outside diameter: 0.390 inch (9,9mm).
3-1.6 Tachometer Sensors
There are two types of Tachometer Sensors available through ZF
Marine Electronics, Mechanical (p/n 8902) and Magnetic Pickup (p/n
8912). Both types provide two separate outputs, one for the
tachometer(s) and the second output provides the Processor’s
tachometer signal requirement. If a sensor other than one supplied by
ZF Marine Electronics is used, it must meet the criteria provided below
for each type:
3-1.6.13 AC Coupled Sensors
•The signal must have a minimum amplitude of +/- 1.5 V
(3.0 V P-P).
•The signal’s maximum amplitude must not exceed +/- 100 V
(200 V P-P).
•The frequency of the signal must be no lower than 30 Hz at Idle.
•The signal’s frequency may not exceed 8 KHz at Full Throttle.
3-1.6.14 Alternator
•The pre-rectified stator AC terminal may be used as the tach
source.
•The signal is inputted to the AC Coupled Sensor input.
•The signal must meet the same criteria as any AC Coupled
Sensor Signal (refer to Section 3-17.6.13).
3-1.6.15 Point side of the Coil
•When the signal is sourced from the coil or an electronically
produced tach signal (used on some gasoline engines) the signal
is connected to the AC Coupled Sensor input.
•The signal must meet the same criteria as any AC Coupled
Sensor Signal (refer to Section 3-17.6.13).
3-1.6.16 Active Sensors (Open Collector Output)
•The sink current ability of the Sensor may be no lower than
2 mA.
•The operational current may not exceed 50 mA.
•The Sensor must have a maximum saturation voltage of
0.8 V.
•An operational voltage requirement of 9- 10 VDC.
•A minimum frequency of 5 Hz at Idle.
Page 3-5
PLAN THE INSTALLATION
•A maximum frequency of 8 KHz at Full Throttle.
3-2 Installer Supplied Tools And Parts
3-2.1 Required Tools
• Screwdriver – medium Phillips, #2.
• Hole saw - 1 inch (25,4mm)
• Saw with blade suitable for Console Top Panel.
• Drill Motor with 9/32 inch and 7/32 inch drill bits.
3-2.2 Optional Tools
• Calibrated Digital Multimeter (Fluke 80 Series or equivalent).
• Service Field Test Unit (P/N 13927, available through ZF Marine
Electronics)
• Wire cutter, stripper, crimper (Recommend Thomas & Betts WT-
2000) (Required if using single terminated harnesses)
3-2.3 Engine Stop Switch
An engine STOP switch MUST be located at each Remote Station.

WARNING: An Engine STOP Switch MUST be installed at every remote operating

station. Refer to CFR 46, Section 62.35-5 (US Coast Guard) and ABYC P-24.5.8.

3-3 DC Power Source

One of the most important (and often overlooked) items for proper
operation of your control system is a clean, dedicated, and reliable source
of DC Power.
The wiring used to supply power from the power source (battery) through
the various components (fuses, distribution panel, relays, etc.) to the
Processors must be sized for a voltage drop of 10% or less using 10 amps as
the maximum current draw. Refer to ABYC Standard E-11, Table X to
determine the appropriate wire gauge for the necessary conductor length.
When using ZF Marine Electronics supplied 14 gauge power cable, and in
accordance with ABYC Standard E-11, the distance from a 12 volt power
source (battery or DC Distribution Panel) shall not exceed 15 feet (4,6m).
In 24 volt systems, the maximum cable length is 20 feet (6,1m).
ZF Marine Electronics highly recommends using an Automatic Power
Selector (APS) and a second power source (battery) to supply power to
each Processor. Refer to Appendix A - Automatic Power Selector (APS) for
examples of power supplies.
3-3.1 Processor Power
The items listed below will help ensure optimum performance from
your control system.
•The Processor requires a battery source of 12 or 24 VDC.
•Two 5 ampere (when isolated power supplies are required) or
one 10 ampere trip-free thermal circuit breaker(s) with manual
On/ Off actuation
•The use of an APS (Automatic Power Selector) is strongly
recommended.
•Power should come from the vessel’s DC Distribution Panel.
•The cables feeding power from the battery to the Processor must
be sized large enough to keep voltage drop, due to current flow,
below 10%. Reference Appendix A - Automatic Power Selector.
The Processor’s power cable(s) maximum lengths are listed in
Appendix A - Parts List, and examples of the various wiring options are
shown in Appendix A - Automatic Power Selector. Ultimately, it is the
boat builder or installer’s responsibility to ensure that the vessel’s
wiring meets the requirements of American Boating & Yachting
Councel standard E-11, for AC and DC Electrical Systems on Boats.

Page 3-6
INSTALLATION
4 INSTALLATION
NOTE: Before starting the actual installation of the Control System, make sure you have the
correct parts and tools on hand. Refer to MM9000-I Plan the Installation Section. Read ALL the
instructions pertinent to each part before beginning the installation of the part.

CAUTION: Static electricity can destroy electronic components. Connect the wrist
strap provided, to the Processor frame whenever working on the Processor with the
enclosure cover open. This will drain any static charge you may have on your person.
4-1 Processor
A) Secure the Processor to the mounting surface with three 1/4 inch or
M6 fasteners, leaving the fourth fastener unused at this time.
B) Connect the Processor to the Hull or Bonding Bus by running a 12
AWG or larger wire between the Processor’s fourth mounting fastener
and the Bonding Bus. (The Processor is bonded if mounted directly to
a metallic surface that is connected to a metal hull) (Refer to Appendix
A - Bonding)
4-2 Control Head(s)
4-2.1 400, MC2000 and 700 Series Control Heads
Refer to the appropriate Control Head Dimensions and Variations
Service Sheet in Appendix A for installation.
4-2.2 500 Series Control Heads
Refer to the Installation Manual supplied with the 500 Series Control
Head Assembly for installation instructions.
4-2.3 Handheld Remote Controls
Refer to the Installation Manual supplied with the Handheld Remote
for installation instructions.
4-3 Wire Harness Installation
The standard Off-the-Shelf Processor has five Pigtails with plugs on the
ends. Two of the plugs are for Remote Stations and one each for Power/
Start Interlock, Serial Communication, and Tach Sensor. Additional
Harnesses required will depend on the actual installation.
Four different styles of plugs are utilized but are inserted in an identical
fashion as follows:
4-3.1 Plug Insertion and Extraction
Processor Pigtail Harness Connector
A) Prior to inserting the plug, pay close attention to the
number of pins and the keying of the plug. The plug
is designed to be inserted one way only, but can be
incorrectly forced together in the opposite
orientation. Refer to Figure 4-1: to insert plug
correctly.
Figure 4-1: Harness Plug Keying

B) When connecting the plugs, ensure that the locking

mechanisms are depressed and held until the plug is
fully connected or disconnected. Refer to
Figure 4-2:

Figure 4-2: Harness Plug Locking Mechanism

4-3.2 Standard Power/Start Interlock Harness
The Power Harness has a minimum of two cables (DC Power and Start
Interlock) and may have two more optional cables (Clutch Pressure
Interlock and External Alarm Circuit).
4-3.2.1 DC Power Cable
(Refer to Appendix A - Automatic Power Selector)
A) Insert the black, twelve pin plug into the Processor’s
Power/Start Interlock Pigtail’s Socket.
Page 4-1
INSTALLATION
B) Run the cable to the DC Distribution Panel or the optional
Power Relay.
C) Strip back the appropriate amount of PVC jacketing and
conductor insulation.
D) Crimp the appropriate connectors to the conductors.
E) Terminate the conductors to the DC Power Source.
4-3.2.2 Start Interlock Cable
Start Interlock
Power N.O. Contact
Start Switch Start Interlock Pigtail Max. 5 Amps. A) Run the cable to the Engine’s Starter
Cable Solenoid.
Starter Power
Solenoid Butt Harness PROCESSOR B) Disconnect the Starter Switch wire from the
Splices Solenoid.
To DC
Power Source C) Strip back the appropriate amount of PVC
+STARTER jacketing and conductor insulation.
- D) Connect one of the conductors to the
Solenoid’s Starter Switch terminal.
+ - DC Common E) Butt splice the second wire to Starter Switch
BATTERY Ground 13248-ART
wire.
Figure 4-3: Start Interlock Connections
4-3.2.3 External Alarm Circuit Cable (optional)
Refer to Section 8-1, page 8-1, for installation information.
4-3.2.4 Clutch Pressure Switch Cable (optional)
Refer to Section 8-2, page 8-2, for installation information.
4-3.3 Serial Communication Harness
4-3.3.5 Twin Screw
(Refer to Figure 4-4:)
A) At the Processors, remove the watertight seals from the Serial
pigtail plugs.
B) At the Port Processor, insert the Serial harness’s grey, six pin
plug into the Serial pigtail plug.
C) Run the harness to the Starboard Processor.
D) Insert the harness’s grey, six pin plug into the Starboard
Processor’s Serial pigtail plug.
E) Secure the Serial Harness at least every 18 in. (457,2mm).

13242-ART

Figure 4-4: Twin Screw Serial Harness Connections

4-3.4 Standard Control Head Harness
Depending on whether a pluggable or hard-wired (not pluggable)
Control Head(s) is selected, will determine the procedure for
terminating the Harness at the Remote Station.
• The first installation procedure (Section 4-3.4.1) below is written for
the pluggable Control Head.
• If a hard-wired Control Head(s) is selected, follow the information
provided in the second procedure (Section 4-3.4.1, page 4-3):
NOTE: or Twin Screw, Dual Lever Control Heads must be connected to the same numbered
Station on both Processors.

Page 4-2
INSTALLATION
4-3.4.1 Control Head Harness with Two Connectors
A) At the Port Processor, insert the grey, eight pin plug into the
Station 1 pigtail plug.
B) Run the cable to the Control Head located at Station 1.
C) Insert the grey, eight pin plug into the Control Head’s Port
pigtail plug.
D) Ensure that the cable has a strain relief close to the Control
Head to relieve the strain on the connections.
E) Repeat Steps A) thru D) for the Starboard Processor.
F) Repeat Steps A) thru E) with Station 2.
G) When Stations 3, 4 and 5 are to be installed, they each require
the removal of the watertight seal located on the Processor
enclosure in the Station cable entry holes.
4-3.4.2 Control Head Harness with One Plug
A) At the Port Processor, insert the grey, eight pin plug into the
Station 1 pigtail plug.
B) Run the cable to the Port side of the Control Head located at
Station 1.
C) Connect the conductors to the Control Head as described in
the appropriate Control Head Dimensions and Variations
Service Sheet in Appendix A.
D) Provide a strain relief in close proximity to the Control Head’s
terminal block.
E) Repeat Steps A) thru D) for the Starboard Processor.
F) Repeat steps A) thru E) with Station 2.
G) When Stations 3, 4 and 5 are to be installed, they each require
the removal of the watertight seal located on the Processor
enclosure in the Station cable entry holes.
4-3.5 Tach Sensor Harness (required for Active Synchronization)
A) On all Processors, remove the watertight seals from the Tach
Sender pigtail plugs.
B) Insert theTach Sensor Harness’s grey, four pin plug into the Tach
Sender pigtail plug at each Processor.
C) Run the Tach Sensor Harness cables to the Tach signal source for
each engine.
D) Connect the conductors to the Tach source in the appropriate
manner, keeping in mind that some sources are polarity sensitive.
(black wire - negative, red wire - positive)
4-3.6 Additional Harnesses
4-3.6.1 Throttle Harness
The appropriate Throttle Harness should have been selected in
Section 3-1.4.5, page 3-3. The Processors Throttle pigtail connects
directly to the engine interface using this Throttle Wire Harness.
A) Connect the plug end of the Harness into the Throttle
pigtail connector at the Processor.
B) Run the cable to the engine interface.
C) Refer to the engine documentation for termination points at
the engine interface.
D) If Twin Screw, repeat steps A) thru C) on the opposite side.
4-3.6.2 Clutch Harness
A) Plug the grey, 12 pin plug into the Clutch pigtail connector at
the Processor.
B) Run the cables to the transmission.
C) Plug the DIN connector into the Ahead and Astern Solenoids.
D) Repeat steps A) thru C) for each transmission.

Page 4-3
INSTALLATION
4-4 Hard-Wired Cable
4-4.1 Liquid Tight Connector
Processor
Enclosure

All cables that enter the Enclosure must go through a Liquid

Cable
Securing Nut
Body Tight Connector in order to maintain the moisture resistant
Nut integrity of the Processor. These connectors must be
Grommet
assembled as shown in Figure 4-5:
12278

Figure 4-5: Liquid Tight Installation

4-4.2 Processor Enclosure Cable Holes
When hard-wiring a Processor or installing additional Station pigtails,
the cables must enter the enclosure through Liquid Tight Connectors
in the appropriate holes as shown in Figure 4-5:.
1. Station No.3
2. Station No.5/ (optional) DP
3. Station No.1
4. Alarm, Clutch Pressure, and Start Interlock (optional)
5. DC Power
6. Station No.4
7. Station No.2
8. Clutch Solenoids
9. Troll Solenoids (optional)
10. Serial Communication
11. Throttle
Figure 4-6: Processor Enclosure Cable Holes 12. Tachometer (optional)
4-4.3 Processor Circuit Board Connections
On a 9000 Processor, in lieu of using Harnesses for Control Heads,
Power, Serial Communication and Tachometer, the Processor can be
ordered with no pigtails installed. The above connections then must
be hard-wired directly to the circuit board Also additional Stations may
also be connected to the Processor by connecting pigtails or hard-
wiring directly to the circuit board. Refer to Figure 4-7: for specific
termination points.

Figure 4-7: Processor Circuit Board Hard-Wired Termination Points

Page 4-4
INSTALLATION

Hole # Terminal Connection Wire Cable Connections Hole # Terminal Connection Wire Cable Connections
1. Station 3: TB5 Black - 1, 8 Clutch: TB11 Black - 1
2. Station 5: TB3 (not used with DP) Brown - 2, Brown - 2
3. Station 1: TB1 Red - 3, Yellow - 5
6. Station 4: TB4 Orange - 4, Green - 6
7. Station 2: TB2 Green - 6
Blue - 7
Violet - 8
2. DP: TB3 (no Station 5 available) Brown - 2 8&9 Clutch /Troll: TB11 Black - 1
Pink - 3 Brown - 2
Orange - 4 Red - 3
Gray - 5 Orange - 4
Green - 6 Yellow - 5
Blue - 7 Green - 6
Blue - 7
DP: TB8 Violet - 1 White - 8
Tan - 2

DP: J3 Red
Black
4. Alarm: TB6 Brown - 6 10. Serial White - 6
Black - 5 Communication: TB7 Green - 7
Red - 8
Clutch Pressure: TB6 Green - 4 Black - 9
Blue - 3 Drain - 10

Start Interlock: PB2 Red - 1 11. Throttle: TB8 Brown - 3

Yellow - 2 Red - 4
Orange - 5
Ground: TB6 Orange - 2 White - 6
Black - 7
Backup Input: TB6 White - 1
5. Power In: PB1 Black - Negative 12. Tachometer: TB9 Red - 1
Red - Positive Green - 2
Black - 4
4-4.4 Hard-wire Installation
4-4.4.1 Seven-Conductor Control Head Cable (Locations 1, 2, 3, 6, and 7)
A) Run the seven-conductor cable from the Remote Station to the
Processor.
B) Support the cables using clamps or straps not more than 18
inches (0,5m) apart if not contained in a conduit. Verify cable
location protects the cable from physical damage.
C) Label each seven-conductor cable at both ends with the station
it connects, and Port or Starboard.
D) Place on your wrist the anti-static wrist strap provided, attach
the strap to ground, and then remove the cover from the
Processor.
E) Run the seven-conductor cable for each remote station through
the corresponding liquid tight cable grip on the Processor to
the appropriate Station terminal block. Do not tighten cable
grip at this time.
F) Strip the PVC jacket and shielding back approximately 4 1/2
inches (114,3mm) on the seven-conductor cable.
G) Strip the wire 3/8 inch (9,5mm) on each lead.
H) Pull the Shield wire back against the PVC jacket and slide and
shrink a piece of 3/8 inch W. X 1 inch L. heat-shrink over the
cable as shown in Figure 4-8:.

Figure 4-8: Seven-Conductor Control Head Cable Shield Wire and Heat-Shrink
I) Secure the seven-conductor cable to the frame using a
conductive Clamp. Ensure that the Clamp and Shield wire
come in contact with one another. Refer to Figure 4-9:.

Page 4-5
INSTALLATION

Top View Side View

(CLAMP) (FRAME)

(FRAME)
12266A
(CLAMP)
Figure 4-9: Clamp Views
J) Clip the Shield wire so that it is flush with the Clamp.
K) Connect the conductors to the appropriate pins as shown on
Table 4-1:, using a small slotted screwdriver as shown in
Figure 4-10:

12261

Figure 4-10: Terminal Strip Cable Connections

L) Connect the other station's seven-conductor cables to the
appropriate station terminal strips in the same way.
Table 4-1: Processor Circuit Board Connections for Remote Stations
Conductor Color Processor Termination Left Hand Control Head Right Hand Control Head
Black Station 1 thru 5, Pin 1 Pin 1 Pin 1
Brown Station 1 thru 5, Pin 2 Pin 2 Pin 2
Red Station 1 thru 5, Pin 3 Pin 3 Pin 3
Orange Station 1 thru 5, Pin 4 Pin 4 Pin 4
Green Station 1 thru 5, Pin 6 Pin 6 Pin 6
Blue Station 1 thru 5, Pin 7 Pin 5 Pin 7
Violet Station 1 thru 5, Pin 8 N/C Pin 8
Jumper between Pins 3 and 7. Jumper between Pins 3 and 5.
4-4.4.2 Eleven-Conductor DP Cable (Location 2/NO Station 5)
If this option is to be used, please contact ZF Marine Electronics.
4-4.4.3 Start Interlock Cable (Location 4)
4-4.4.3.1 Connection at the Starter Solenoid
A) Run the length of two-conductor cable between the
Engine’s Starter Solenoid and the Processor.
B) Disconnect the Starter Switch wire from the Solenoid.
C) Strip back the appropriate amount of PVC jacketing and
conductor insulation.
D) Connect one of the conductors to the Solenoid’s Starter
Switch terminal.
E) Butt splice the second wire to Starter Switch wire.
4-4.4.3.2 Connection at the Processor
A) Install a liquid tight connector into entry hole (No. 4).
(Refer to Figure 4-6:, page 4-4, for entry hole location
and Figure 4-5:, page 4-4, for cable grip installation.)
B) Run enough of the two-conductor power cable through
the liquid tight cable grip so that it can be routed to PB2
on the Circuit Board as shown in Figure 4-7:, page 4-4.
C) Strip back 2 inches (50,8mm) of the PVC jacketing.
Refer to Figure 4-11:
D) Strip each wire 3/8-inch (9,5mm).
E) Place a 3/8 inch (9,5mm) section of shrink tubing over
the cable and heat.

Figure 4-11: Two-Conductor Start Interlock Cable

Page 4-6
INSTALLATION
F) Crimp fork or ring terminals to the wires.
G) Connect the two-conductor cable to PB2, red lead to the
terminal labeled (1) and yellow lead to the terminal
labeled (2), as indicated on Figure 4-7:, page 4-4.
H) Tie wrap the start interlock cable to the Processor’s
frame.
4-4.4.4 Power Cable (Location 5)
A) Run the length of two-conductor power cable between the DC
Power Source and the Processor.
B) Make the connections at the vessel’s DC Power Source, but do
not turn power ON.
C) Install a liquid tight connector into the DC POWER entry hole
(No. 5). (Refer to Figure 4-6:, page 4-4, for entry hole location
and Figure 4-5:, page 4-4, for cable grip installation.)
D) Run enough of the two-conductor power cable through the
liquid tight cable grip so that it can be routed as shown in
Figure 4-7:, page 4-4.
E) Strip back 3 inches (76,2mm) of the PVC jacketing. Refer to
Figure 4-12:
F) Strip each wire 3/8-inch (9,5mm).
G) Place a 3/8 inch (9,5mm) section of shrink tubing over the
cable and heat.
3/8 inch
(9,5mm) 3 inches
(76,2mm)

Heat Shrink
Figure 4-12: Two-Conductor Power Cable
H) Crimp fork or ring terminals to the wires.
I) Connect the two-conductor cable to PB1, red lead to the
terminal labeled (+) and black lead to the terminal labeled (-),
as indicated on Figure 4-7:, page 4-4.
J) Tie wrap the power cable to the Processor’s frame.
4-4.4.5 Serial Communication Cable (Location 10)
A) Install 1/2 inch (12,7mm) liquid tight cable grips into hole
(No.8) of the Port and Starboard Processors. (Refer to
Figure 4-6:, page 4-4, for entry hole location and Figure 4-5:,
page 4-4, for cable grip installation.)
B) Run a four-conductor, shielded cable from the Port to the
Starboard Processors.
C) Strip back 3 inches (76,2mm) of PVC jacketing from both ends
of the cable.
D) Strip each wire 3/8 inch (9,5mm).
E) Clip the drain wire flush with the PVC jacketing on the
Starboard Processor only.
F) Place a 1 inch (25,4mm) section of shrink tubing over each end
of the cable
G) On the Port end of the cable, bend the drain wire back and
tuck it under the shrink tubing so that the drain wire end is
exposed past the shrink tubing. (Refer to Figure 4-13:)
PORT PROCESSOR STARBOARD PROCESSOR
3/8 inch 3 inches 1 inch 1 inch 3 inches 3/8 inch
(9,53mm) (76,2mm) (25,4mm) (25,4mm) (76,2mm) (9,53mm)
Drain Wire

Heat Shrink Clip Drain Wire

Figure 4-13: Four-Conductor Serial Communication Cable

Page 4-7
INSTALLATION
H) Shrink the Tubing with a heat gun.
I) Insert the four-conductor cable through the liquid tight
connectors and tighten the nuts
J) Secure the cables internally using a Clamp as shown in
Figure 4-9:, page 4-6. Make certain that the drain wire makes
contact with the Clamp’s metallic surface.
K) Clip the exposed drain wires flush with the Clamps.
L) Connect the conductors to the terminal block as listed in
Table 4-2:
Table 4-2: Processor Circuit Board Connections for Serial Communication
PORT PROCESSOR STARBOARD PROCESSOR
Conductor Color
Termination A Termination B
TB7-6 White TB7-6
TB7-7 Green TB7-7
TB7-8 Red TB7-8
TB7-9 Black TB7-9
Clamp Silver (Drain Wire) No Connection
4-4.4.6 Tachometer Cable (Location 12)
A) Run a two- or three-conductor shielded cable from the Port
Processor to the Port engine’s tachometer source. (Refer to
Section 3-1.6, page 3-5)
NOTE: Three-conductor cable is required with Open Collector Type (Hall Effect) Tachometer
Senders only.

B) Run a two- or three-conductor shielded cable from the

Starboard Processor to the Starboard engine’s tachometer
source.
C) Install a 1/2 inch (12,7mm) liquid tight cable grip into hole (No.
9) of the Port and Starboard Processors. (Refer to Figure 4-6:,
page 4-4, for entry hole location and Figure 4-5:, page 4-4, for
cable grip installation)
D) Strip back 2 inches (50,8mm) of PVC jacketing from both ends
of the cable.
E) Strip the ends of each conductor back 3/8 inch (9,5mm).
F) Clip off the drain wire flush with the PVC jacketing at the
Tachometer source side only.
G) Place a 7/8 inch (22,23mm) section of shrink tubing over each
end of the cable.
H) At the Processor side, bend the drain wire back and tuck it
under the shrink tubing so that the drain wire end is exposed
past the shrink tubing. (Refer to Figure 4-14: and Figure 4-15:)..
PROCESSOR TACHOMETER SENDER
3/8 inch 3.5 inches 1 inch 1 inch 3.5 inches 3/8 inch
(9,53mm) (88,9mm) (25,4mm) (25,4mm) (88,9mm) (9,53mm)
Wrapped Drain Wire

Heat Shrink Clip Drain Wire

Figure 4-14: AC Type Tachometer Cable
PROCESSOR TACHOMETER SENDER
3/8 inch 3.5 inches 1 inch 1 inch 3.5 inches 3/8 inch
(9,53mm) (88,9mm) (25,4mm) (25,4mm) (88,9mm) (9,53mm)
Wrapped Drain Wire

Heat Shrink Clip Drain Wire

Figure 4-15: Open Collector Tachometer Cable
Page 4-8
INSTALLATION
I) Shrink the tubing with a heat gun.
J) Insert the cable ends through the liquid tight connectors and
tighten the nuts.
K) Secure the cables internally using a Clamp as shown in
Figure 4-9:, page 4-6. Make certain that the drain wire makes
contact with the Clamp’s metallic surface.
L) Clip the exposed drain wires flush with the Clamps.
M) Connect the conductors to the terminal block as listed in
Table 4-3:.
Table 4-3: Processor Circuit Board Connections for Tachometer
Conductor
Termination Description Notes
Color
TB9-1 Red Sensor Supply (+9VDC) Required when Open Collector (i.e., Hall Effect Sensors) only
TB9-2 Green AC Type Tachometer Input The green wire connects here when AC Type Tach Sensors (i.e.,
Mechanical Senders, Magnetic Pickup, Alternator AC, etc.) are
being used.
TB9-3 Green Open Collector Tachometer Input The green wire connects here when an Open Collector Type
Tach Sender is used.
TB9-4 Black Return for Tachometer Input Negative connection for both types of Senders.
Clamp Silver Drain wire (Shield) connection. Connection made at Processor side only.
4-4.5 Clutch Cable (Location 8)
A single four-conductor cable must connect the two Shift cables to the
Processor through a 12 pin plug.
4-4.5.1 Processor Termination
A) Install a liquid tight connector into hole no.10.
B) Run a 32 inch (0,82m) piece of four-conductor cable through
the liquid tight connector and tighten, leaving 16 inches
(0,41m) outside of the Processor.
C) Strip back 4 inches (101,6mm) of the PVC jacket inside the
Processor.
D) Slide a 1 inch (24,5mm) piece of heat shrink over the end of
the cable as shown in Figure 4-16:.
1 inch 4 inches 3/8 inch
(25,4mm) (101,6mm) (9,53mm)

Heat Shrink
Figure 4-16: Clutch Cable Heat Shrink in Processor
E) Strip back 3/8 inch (9,53mm) from the four conductors and
connect to the Processor as shown in Figure 4-7:, page 4-4
4-4.5.2 Plug Termination
A) Strip back 2 1/4 inches (57,15mm) of PVC jacketing.

Figure 4-17: Clutch Cable Plug Termination Connections

B) Slide the boot onto the cable.
C) Strip back 1/4 inch (6,35mm) from the four conductors.
D) Crimp Pins onto the eight conductors.
E) Insert the pins into the appropriate terminations as shown in
Table 4-4:.
F) Slide the boot over the connector.
G) Tie-wrap the boot in place.

Page 4-9
INSTALLATION
Table 4-4: Clutch Termination Table
Description Conductor Color Processor Termination Plug Termination
Ahead Clutch Solenoid (+) Brown TB11-2 Pin 3
Ahead Clutch Solenoid (-) Green TB11-6 Pin 4
Astern Clutch Solenoid (+) Black TB11-1 Pin 5
Astern Clutch Solenoid (-) Yellow TB11-5 Pin 6
4-4.6 Throttle Cable (Location 11)
A 2-conductor shielded cable is required when hard-wiring the engine
to the Processor.
A) Install a 1/2 inch Liquid Tight Connector into hole no.12 of the
Processor.
B) Run the throttle cable through the connector so that 4 inches
(101,6mm) of the cable is pulled through.
C) Tighten the Liquid Tight Connector nut.
D) Strip back the PVC jacket to within 1/2 inch (12,7mm) of the
enclosure.
E) Clip the shield wire to 3/4 inch (19,1mm) of length.
F) Pull back the shield wire and solder to a 2 1/2 inch (63,5mm),
18 AWG, green/yellow wire as shown in Figure 4-18:.
Heat Shrink .75 inch (19,1mm)
Cable of Cable Shield

Solder Wire 12286

.38
to Shield
inch 2.5 inch (63,5mm) of
(9,65mm) 18 AWG, Green/Yellow Wire
Figure 4-18: Engine Shield
G) Slide a 1 inch (25,4mm) section of heat-shrink over the
soldered connection and shrink.
H) The termination point on TB8 depends on the type of engine to
which the Processor is interfacing. The following table lists
the termination points.
Table 4-5: Processor Circuit Board Connections for Throttle
Throttle Type Termination
DC Voltage (0 to 5.0 VDC) Signal- TB8-5, Return- TB8-7
Current (4.0 to 20.0 mA.) Signal- TB8-4, Return- TB8-7
PWM (0 to 99%) Signal- TB8-3, Return- TB8-7
Frequency ( Signal- TB8-6, Return- TB8-8
Idle Validation (+)- TB8-1, (-)- TB8-2
4-5 Engine Stop Switches
An engine stop switch(s) must be located at all Remote Stations and
capable of stopping the engine at any RPM. Refer to the installation
instruction supplied with the switch and the engine installation
instructions for manufactures recommendations.

WARNING: An Engine Stop Switch at each Remote Station is an absolute

requirement. Refer to CFR 46, SEC. 62.35-5 and ABYC P-24.5.8.

Page 4-10
SET-UP PROCEDURES

5 SET UP PROCEDURE
The Processor utilizes push buttons in conjunction with Display LED’s to
program, adjust, calibrate and set up the various features. The push buttons
also allow you to access and display information regarding the health of the
System.
The following paragraphs explain how to locate and use the push buttons and
Display LEDs:
5-1 Processor Components Used In Set Up

• Each Processor has a Display LED and

Push Buttons.
• The Display LED can be viewed through
a window on the Processor’s cover as
shown in Figure 5-1:

Figure 5-1: Typical Processor Cover

• The Processor enclosure cover must be
removed to access the Push Buttons as
Push Button Location

shown in Figure 5-2:

• The Display LED is used to view the
LED Location
Function Codes and the Values for
those Functions (Section 5-1.1, page 5-
1).
• The Push Buttons are used to scroll
through Function Codes, select
Function Codes and set the Values of
Figure 5-2: Processor Shield Push Button and Display LED the Function Codes. (Section 5-1.2,
12255

Locations page 5-1)

5-1.1 Processor Display LED
Starts the Processor Part Number again, one number at a time.

12309

EXAMPLE: Running Processor Part Number during Normal Operation (9210)

Figure 5-3: Display LED at Normal Operation
• The Processor’s Display LED has four 7-segment LED’s, which light
up to show either letters or numbers.
• The Display LED will have the Processor Part Number showing in a
running pattern during Normal operation (Figure 5-3:)
• The first two digit Display LED’s to the left, indicate the Function
Code, which is alphanumeric.
• The second two digit Display LED’s indicate the numeric Value that
is programmed into the Processor for the Function Code displayed to
Figure 5-4: Display LED the left.
Designations • A decimal point indicator is located on the bottom right corner of
each Display LED.
5-1.2 Push Buttons
The Processor has four Push Buttons located on the Circuit
Board. They are identified by the words LEFT, RIGHT, UP
and DOWN silk-screened on the Shield covering the Circuit
Figure 5-5: Circuit Board Push Buttons Board.

Page 5-1
SET-UP PROCEDURES

5-1.2.1 Up and Down Push Buttons

Pressing the Up or Down Push Buttons once has the following
functions:
• Stops Normal Operation Display (running Processor Part
Number) and activates the Function Menu.
• While in the Function Menu, scrolls through the Function
Codes one at a time.
• When an Error Code (Refer to Section B-1.9, page B-21) is
displayed, scrolls through the error messages one at a time.
• When in Set Up Mode, increases (Up) or decreases (Down)
the Value one digit at a time.
5-1.2.2 Left and Right Push Buttons
Pressing and holding the Left and Right Push Buttons
simultaneously has the following functions:
• Activates Set Up Mode as indicated by the blinking Display
LED. (must hold the buttons until the blinking begins)
• While in Set Up Mode, deactivates Set Up Mode, saves the
displayed Value to memory and returns to the Function
Menu. (must hold the button until the blinking stops)
5-1.2.3 Left Push Button Only
Pressing the Left Push Button once has the following functions:
• Deactivates Set Up Mode without any changes to the Value
being stored to memory. The Left Push Button must be held
down until function code stops blinking. The default value
will then be displayed.
• While in Function Menu, changes the Display LED to the
Error Menu, if any errors are present. (has no effect if there
are no errors stored)
Figure 5-6: Display LED Error
• While in the Error Menu, changes the Display LED back to
Menu Example the Function Menu.
5-1.2.4 Right Push Button Only
Pressing the Right Push Button once has the following functions:
• While in the Error Menu, clears inactive errors. (Active
errors blink, inactive do not)
• While in Set Up Mode or Function Menu, allows the Value of
Figure 5-7: Display LED Four Digit the current Function Code to be displayed with all four
Value Display LEDs.
5-2 Activating Set Up Mode
NOTE: To Escape from the Set Up procedure at any time without saving the changed value to
memory, depress the Left Push Button. The Function Code will stop flashing and the Function
will be saved with the original Value.
A) The Display LED is in Normal operating condition with the red
running Processor Part Number.
B) Depressing either the Up or Down Push Button will activate the
Function Menu.
C) Depressing the Up or Down Push Button will scroll through the
Function Codes one at a time.
D) Once the desired Function Code is visible on the Display LED, press
and hold down the Left and Right Push Buttons simultaneously, until
the Function Code begins to blink.
E) Depressing the Up Push Button will increase the Value of the
Function, while pressing the Down Push Button will decrease the
Value of the Function. (Pressing and holding the Up or Down Push
Button will increase or decrease the Value rapidly)

Page 5-2
SET-UP PROCEDURES

5-3 Storing Values To Memory

Once the desired Value has been reached in Set Up Mode, the Value is
stored to memory as follows:
A) Depress and hold the right push button first. Then while still
depressing the right button, depress and hold the Left push button
until the Function Code stops blinking.
• The new Value is now programmed into memory.
• Set Up Mode is exited.
B) Depress the Up or Down Push Button until the next required
Function Code is reached.
C) Reactivate Set Up Mode.
NOTE: If no Push Buttons are pressed for five minutes, the selected Mode of operation is
automatically exited and the System returns to Normal Mode. If no Push Buttons are pressed for
five minutes while in Set Up Mode, it will be exited without the changes stored to memory

The following tables list the Function Codes’ Name, Default Value and
Set Up Function Codes And Values

Range or available Options. Each of the Function Codes are explained in

further detail in the referenced sections.
NOTE:
SINGLE SCREW APPLICATIONS: The Function Values may be entered and stored in any order.
MULTI-SCREW APPLICATIONS: The A1 Function must be set FIRST, and the A0 Function must
be set SECOND. The rest of the Function Values may be
entered and stored in any order.
Table 5-1: Processor Function Codes
Function Code Function Name Default Value Value Range or Options
(Section 5-5.1, page 5-6)
A0 Processor Identification 00 01, 02, 03, 04, 05
A1 Number of Engines 01 01, 02, 03, 04, 05
A2 One Lever Operation 00 00 – Disabled
01 – Enabled
A3 SE (Station Expander) 00 00 – Disabled
01 – Enabled
A4 Neutral Indication Tone 00 00 – No Tone
01 – Tone upon engaging Neutral Detent
02 – Tone upon shifting to Neutral
A5 Engine Room Lockout/Station 00 00 – Both Disabled
2 Lockout 01 – Engine Room Lockout Enabled
02 – Station 2 Lockout Enabled
03 -- Both Enabled
A6 DP/Station 5 00 00 – DP Disabled - Station 5 Enabled
01 – DP with Troll Enabled - Station 5 Disabled
02 – DP without Troll Enabled - Station 5 Disabled
Table 5-2: Throttle Function Codes
Default
Function Code Function Name Value Range or Options
Value
(Section 5-5.2, page 5-8)
E0 Engine Throttle Profile 06 01 - Caterpillar (PWM) (8 to 92%)
02 - Cummins Centry (Voltage) (0.9 to 4.5 VDC)
03 - Cummins Quantum (Voltage) (0.9 to 1.2 - 4.0 VDC)
04 - Detroit Diesel (Voltage) (0.64 to 4.65 VDC)
05 - MTU or MAN (Current) (4.0 to 20.0 mA)
06 - Scania (Voltage (0.42 to 2.95 VDC)
07 - John Deere (Voltage) (0.5 to 4.5 VDC)
08 - Volvo (Voltage) (0.6 to 3.6 VDC)
09 - Detroit Diesel (Frequency) (120.64 to 360.9 Hz)
10 - Detroit Diesel (Frequency) (120.64 to 463.5 Hz)
E1 Throttle in Neutral 00.0 00.0 to 25.0% of Throttle Range
[Throttle Range = Throttle Maximum (E3) - Throttle
Minimum (E2)]
E2 Throttle Minimum 00.0 00.0 to 20.0%
Must be 10% or more below Throttle Maximum (E3).
E3 Throttle Maximum 59.0 10.0 to 100.0% of Maximum Throttle Allowable.
Must be 10% or more above Throttle Minimum (E2).

Page 5-3
SET-UP PROCEDURES

Table 5-2: Throttle Function Codes

Function Code Function Name Default Value Range or Options
Value
(Section 5-5.2, page 5-8)
E4 Throttle Maximum Astern 100.0 00.0 to 100.0% of Throttle Maximum (E3)
E5 Throttle Pause Following Shift 00.5 00.0 to 05.0 Seconds
E6 High Idle 00.0 00.0 to 20.0% of Throttle Range.
[Throttle Range = Throttle Maximum (E3) - Throttle
Minimum (2)]
E7 Synchronization 00 00 – Equal Throttle (Open Loop) Synchronization
01 - Active (Closed Loop) Synchronization (reverts to
Equal if Tach Signal lost)
02 - No Synchronization
03 - Active (Closed Loop) Synchronization (no
synchronization if Tach Signal is lost)
Table 5-3: Clutch Function Codes
Default
Function Code Function Name Value Value Range or Options
(Section 5-5.3, page 5-11)
C0 Clutch Pressure Interlock 00 00 – Not Installed
01 – Installed
02 – Throttle Clutch Pressure Interlock Mode
C1 Clutch Interlock Delay 00.5 00.5 to 10.0 Seconds
C2 Proportional Pause 00 00 – In-Gear
01 – Neutral
02 – Fixed Neutral Delay Enabled (NOTE: If C2 is set to
02, the setting of C3 will set Fixed Neutral Delay
C8.)
C3 Proportional Pause Time 04 00 to 99 Seconds
C4 Proportional Pause Ratio 00 00 – 2:1 Ahead to Astern vs. Astern to Ahead
01 – 1:1 Ahead to Astern vs. Astern to Ahead
C5 Shift Solenoid Type 00 00 - All Shift Solenoids except ZF-Hurth with
proportional solenoids
01 - ZF-Hurth with two (2) Proportional Solenoids with
12V Power
02 - ZF-Hurth with two (2) Proportional Solenoids with
24V Power
C6 ZF-Hurth Duty Cycle Ahead 00 00 to 100% Duty Cycle
C7 ZF-Hurth Duty Cycle Astern 00 00 to 100% Duty Cycle
C8 Fixed Neutral Delay 00.0 00.0 to 4.0 Seconds (In addition to any Proportional
Delay)
Table 5-4: Troll Function Codes
Function Function Name Default Value Range or Options
Code Value
(Only Available and Displayed When Troll is Enabled) (Section 5-5.4, page 5-15)
L0 Troll Enable and Control Head 00 00 – No Troll
Troll Lever Range 01 – 20 Degrees- Type 1
02 – 35 Degrees- Type 2
03 – 45 Degrees- Type 3 (Throttle limited to 75% of
Throttle Range)
04 – 55 Degrees- Type 4 (Throttle limited to 10% of
Throttle Range)
L1 Troll Valve Function 00 0 - Normal, (No Current when at Lock-up)
01 - Inverse (No Current when at Lock-up)
02 - Normal (Maximum Current when at Lock-up) Preset
for ZF220-550, 12VDC Systems.
03 - Normal (No Current when at Lock-up) Preset for
ZF220-550, 24VDC Systems.
04 - Normal (No Current when at Lock-up) Preset for
ZF2000, 24 VDC Systems.
05 - Inverse (No Current when at Lock-up) Preset for
ZF6000, 1900 and 2500, 24VDC Systems.
06 - Preset for 12VDC ZF Hurth Systems with two (2)
proportional solenoids.
07 - Preset for 24VDC ZF Hurth Systems with two (2)
proportional solenoids
L2 Troll Minimum Pressure 14 01.0 to 80.0%
Must be at least 10% below Troll Maximum (L3).

Page 5-4
SET-UP PROCEDURES

Table 5-4: Troll Function Codes

Function Default
Function Name Value Range or Options
Code Value
(Only Available and Displayed When Troll is Enabled) (Section 5-5.4, page 5-15)
L3 Troll Maximum Pressure 25 20.0 to 100.0%
Must be at least 10% above Troll Minimum. (L2)
L4 Troll Throttle Limit 00 00 to 20% of Troll Range
[Troll Range = Troll Maximum (L3) - Troll Minimum (L2)]
L5 Troll Pulse Duration 00.6 00.0 to 09.9 Seconds.
L6 Troll Pulse Percentage 25.0 00.1 to 100.0% of available Troll Range.
Table 5-5: Troubleshooting Function Codes
Function Code Function Name Value Range or Options
(Section 5-5.5, page 5-15)
H0 Diagnostic Input Voltage (+/- 0.5VDC)
Tachometer Sensor Frequency
Station No.1 Lever A/D
Station No.2 Lever A/D
Station No.3 Lever A/D
Station No.4 Lever A/D
Station No.5 Lever A/D
Transfer Button, Stations 1, 2, 3, 4, & 5
Software Revision Level
H1 Return to Factory Defaults Store to Return to Factory Defaults
(For Authorized Personnel Only)
H2 Driver Fault Detection Enable Allows the Processor to monitor the clutch and/or troll
solenoids.
Table 5-6: Speed Boost Premium-Only Function Codes
Default
Function Code Function Name Value Value Range or Options
(Section 5-5.6.1, page 5-16)
F0 Speed Boost Percent 0.0 0.0 to 50.0% of Throttle Range
F1 Speed Boost Duration 0.0 0.0 to 20.0 Seconds
F2 Speed Boost Start Delay 0.0 0.0 to 10.0 Seconds
F3 Speed Boost Bypass Clutch Delay 0.0 0.0 to 99.0 Seconds
Table 5-7: Station Transfer Premium-Only Function Codes
Default
Function Code Function Name Value Range or Options
Value
(Section 5-5.6.2, page 5-16)
P0 Transfer Mode 00 00 - Neutral Only
01 - Not Used
02 - Lever Match and Neutral
03 - Request/Relinquish or Relinquish/Receive
04 - Request/Relinquish/Receive or Relinquish/
Receive
P1 Transfer Timeout 15.0 0.0 to 99.0 Seconds
5-4 Field Service Test Unit (Break-out Box) and Multimeter Use
Refer to Appendix A - MM13927 Manual for more information on the use
of the Field Service Test Unit (Break-out Box).

To aid in adjusting the list of

Processor signals in the tables
below, ZF Marine Electronics
recommends the use of ZF
Marine Electronics Field Service
Test Unit (P/N 13927) (Break-out
Box) and a calibrated Multimeter.

Figure 5-8: Service Field Test Unit and Multimeter

Page 5-5
SET-UP PROCEDURES

C6 ZF-Hurth Duty Cycle Ahead (Section 5-5.3.2.2)

C7 ZF-Hurth Duty Cycle Astern (Section 5-5.3.2.3)
Table 5-8: Clutch Functions Requiring Service Field Test Unit and Multimeter
E1 Throttle in Neutral (Section 5-5.2.1.1)
E2 Throttle Minimum (Section 5-5.2.2.2)
E3 Throttle Maximum (Section 5-5.2.2.3)
E4 Throttle Maximum Astern (Section 5-5.2.1.2)
E6 High Idle (Section 5-5.2.1.4)
Table 5-9: Throttle Functions Requiring Service Field Test Unit and Multimeter
5-5 System Programming And Adjustments
NOTE:
MULTIPLE SCREW APPLICATIONS: The A1 Function must be set FIRST, and the A0 Function
must be set SECOND. The rest of the Function Values may be entered and stored in any order.

NOTE: Power must be turned ON to the Processors when programming or making any
adjustments to the System.

NOTE: In order to prevent nuisance alarms when first setting up a System, some Function Codes
take up to 5 minutes to become ACTIVE. The Functions affected by this are the functions that rely
on the Serial Communication, such as A0, A1, A2, A3, E7, and L0. Cycling power Off, then On,
expedites these features making the Functions available immediately.
5-5.1 Processor Functions
5-5.1.1 Function Code A0 – Processor Identification
In applications where there is more than one screw, the system
must know which Processor is where. Every Processor must have
its own unique identifying number. At no time can two or more
Processors be identified by the same Processor Identification
Number.
The available Values for this Function are:
00 (Default Value), 01, 02, 03, 04 and 05.

NOTE: If Processors are not connected by a serial communication cable, leave the A0 function
code at Default Value.

NOTE: In twin screw or more applications, the Value of Function Code A0 can be changed only
after the Value in Function Code A1 has been changed to 02 or higher.

To change the Value (Refer to Sections 5-2 and 5-3, page 5-2):
Function Code is Blinking
A) Scroll to Function Code A0.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
Figure 5-1: Display LED Function A0 Set Up Activated
D) Store the Value to memory.
5-5.1.2 Function Code A1 – Number of Engines
The total number of engines must be entered into the memory of
each of the Processors. All Processors in an installation must have
the same value entered.
The available Values for this Function are:
01 Single Screw (Default Value)
02 Twin Screw
03 Triple Screw
04 Quad Screw
05 Quint Screw

NOTE: If Processors are not connected by a serial communication cable, leave the A1 function
code at Default Value.

Page 5-6
SET-UP PROCEDURES

NOTE: Twin screw or more applications require Function Code A1 Values changed on all
Processors prior to changing the Value of Function Code A0.

To change the Value (Refer to Sections 5-2 and 5-3, page 5-2):
A) Scroll to Function Code A1.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
Figure 5-2: Display LED Function A1 Set Up Activated D) Store the Value to memory.

NOTE: Before continuing set up, wait 5 minutes or cycle power.

5-5.1.3 Function Code A2 – One Lever Operation

In Twin Screw or more applications, the System has the ability to
command all engines and transmissions to the same speed and
direction with a single Control Head lever. This Function allows
this Feature to be enabled or disabled. (Refer to Section 2-9,
page 2-5, for operation instructions)
The available Values for this Function are:
00 Disabled (Default Value)
01 Enabled
To change the Value (Refer to Sections 5-2 and 5-3, page 5-2):
A) Scroll to Function Code A2.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
Figure 5-3: Display LED Function A2 Set Up Activated D) Store the Value to memory.
5-5.1.4 Function Code A3 – SE (Station Expander)
NOTE: This Manual does not go into detail on the Station Expander installation and adjustments.
For further information on the Station Expander, contact your local ZF Marine Electronics
Representative.
The SE is a separate unit, which gives the System the ability to
increase the number of Remote Stations, if more than five Remote
Stations are required. (Refer to Section 8-3, page 8-4, for further
information)
The available Values for this Function are:
00 Disabled (Default Value)
01 Enabled
To change the Value (Refer to Sections 5-2 and 5-3, page 5-2):
A) Scroll to Function Code A3.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
Figure 5-4: Display LED Function A3 Set Up Activated D) Store the Value to memory.
5-5.1.5 Function Code A4 – Neutral Indication Tone
This Function allows the installer to turn ON a 1/2 second, low
frequency tone to indicate Neutral.
The available Values for this Function are:
00 Disabled (Default Value)
01 Tone sounds when the Control Head’s lever reaches
Neutral
02 Tone sounds when the Processor commands Neutral
F
To change the Value (Refer to Sections 5-2 and 5-3, page 5-2):
A) Scroll to Function Code A4.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
Figure 5-5: Display LED Function A4 Set Up Activated D) Store the Value to memory.
Page 5-7
SET-UP PROCEDURES

5-5.1.6 Function Code A5 – Engine Room Lockout/Station No.2 Lockout

This Function Code provides the installer with four different
options.
The available Values for this Function are:
00 Both Disabled (Default Value)
1. When selected, all five Remote Stations behave in the
same manner.
2. No Station has transfer priority or lockout capability.
01 Engine Room Lockout Enabled
1. When the Engine Room switch is closed, control is
transferred to Station No.1.
2. When the Engine Room switch is closed, no other station
can take command away from Station No.1.
3. When closed on power-up, Station No.1 will be in
command without pressing the transfer button.
02 Station No.2 Lockout Enabled
1. When the Station No.2 switch is closed, control is
transferred to Station No.2.
2. When the Station No.2 switch is closed, no other station
can take command away from Station No.2.
3. When closed on power-up, Station No.2 will not be in
command unless the transfer button is pressed.
However, no other station can take command on power-
up.
03 Both Enabled
1. When both switches are closed, control is transferred to
Station No.1.
2. When both switches are closed, no other station can take
command away from Station No.1
3. When both switches are closed on power-up, Station
No.1 will be in command without pressing the transfer
button.
Contact ZF Marine Electronics if this Function Code is going to be
changed from the default setting.
5-5.1.7 Function Code A6 – Station No. 5 / DP
This Function allows Station No.5 to be set-up as a standard
Remote Station or as an interface for a Dynamic Positioning (DP)
system.
The available Values for this Function are:
00 DP Disabled (Default Value)
When disabled, Station No.5 is configured to operate with a
Standard Control Head.
01 DP Enabled with Troll
Station No.5 is configured to operate the clutch, throttle and
trolling valve in DP Mode.
02 DP Enabled without Troll
Station No.5 is configured to operate the clutch and throttle
in DP Mode.
Contact ZF Marine Electronics if this Function Code is going to be
changed from the default setting.
5-5.2 Throttle Functions
5-5.2.1 Throttle Basic Functions (E1, E4 through E7)
5-5.2.1.1 Function Code E1 – Throttle in Neutral
This Function allows the engine RPM at Neutral to be
adjusted independently of the RPM at Idle Ahead and
Astern.
The available Values for this Function are 00.0 to 25.0
percent of the Throttle Range.
The Default Value is 00.0%.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
Page 5-8
SET-UP PROCEDURES

Function Code is Blinking

A) Scroll to Function Code E1.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-6: Display LED Function E1 Set Up Activated
5-5.2.1.2 Function Code E4 – Throttle Maximum Astern
This Function limits the amount of Throttle permitted in
Astern.
The available Values for this Function are 00.0% to 100.0%.
The Default Value is 100.0% of Throttle Maximum.
The Value selected is a percentage of the Value selected in
Function Code E3 – Throttle Maximum.
Example: A Value of 50.0 will allow 50% of Throttle
Maximum when commanding Astern. The Value
selected is a matter of personal preference.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):

A) Scroll to Function Code E4.

B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-7: Display LED Function E4 Set Up Activated
5-5.2.1.3 Function Code E5 – Throttle Pause Following Shift
The available Values for this Function are 00.0 seconds to
05.0 seconds.
The Default Value is 00.5 seconds.
This Function programs the amount of delay between the
point that Clutch engagement is commanded and throttle is
allowed to increase above Idle.

NOTE: This Function is typically programmed during Dock Trials. Refer to Section 6-6, page 6-2.

To change the Value (Refer to Sections 5-2 and 5-3,

page 5-2):

A) Scroll to Function Code E5.

B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-8: Display LED Function E5 Set Up Activated
5-5.2.1.4 Function Code E6 – High Idle
This Function Code Programs the RPM of the second,
elevated Idle.
The available Values for this Function are 00.0 to 20.0% of
Throttle Maximum.
The Default Value is 00.0%.
The Value selected is a percentage of the Value selected in
Function Code E3 – Throttle Maximum.

NOTE: This Function is typically programmed during Dock Trials or Sea Trials. Refer to
Section 6-4, page 6-1

To change the Value (Refer to Sections 5-2 and 5-3,

page 5-2):
Function Code is Blinking
A) Scroll to Function Code E6.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-9: Display LED Function E6 Set Up Activated
Page 5-9
SET-UP PROCEDURES

5-5.2.1.5 Function Code E7 – Synchronization

This Function Code selects the type of Synchronization, if
Synchronization is required. The types are described in
Section 2-10, page 2-6.
The available Values for this Function are:
00 Equal Throttle (Open Loop) Synchronization
01 Active (Closed Loop) Synchronization (reverts to
Equal Throttle Synch if there is no Tachometer
Sensor signal)
02 No Synchronization (Default Value)
03 Active (Closed Loop) Synchronization (reverts to no
Synchronization if there is no Tachometer Sensor
signal)
The Default Value is 02.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):

A) Scroll to Function Code E7.

B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-10: Display LED Function E7 Set Up Activated
5-5.2.2 Throttle Electronic Functions (E0, E2, E3)
This section along with the Throttle Basic Functions Section
allows the adjustment of Throttle electronics related items:
5-5.2.2.1 Function Code E0 – Engine Throttle Profile
This Function selects the appropriate Throttle Signal range
for various engines
The available Values for this Function are listed below:
01 - Caterpillar (PWM) (8 to 92%)
02 - Cummins Centry (Voltage) (0.9 to 4.5 VDC)
03 - Cummins Quantum (Voltage) (0.9 to 1.2 - 4.0
VDC)
04 - Detroit Diesel (Voltage) (0.64 to 4.65 VDC)
05 - MTU or MAN (Current) (4.0 to 20.0 mA)
06 - Scania (Voltage (0.42 to 2.95 VDC)
07 - John Deere (Voltage) (0.5 to 4.5 VDC)
08 - Volvo (Voltage) (0.6 to 3.6 VDC)
09 - Detroit Diesel (Frequency) (120.64 to 360.9 Hz)
10 - Detroit Diesel (Frequency) (120.64 to 463.5 Hz)
The Default Value is set to 06 Scania Profile.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
A) Scroll to Function Code E0.
B) Activate Set Up Mode.
C) Scroll Up or Down until the the desired Value is
displayed.
Figure 5-11: Display LED Function E0 Set Up Activated D) Store the Value to memory.
5-5.2.2.2 Function Code E2 – Throttle Minimum
This Function allows the throttle signal at Idle to be fine
tuned from the Value provided by the E0 Throttle Profile.
The available Values for this Function are 00.0 to 20.0%.
The Default Value is 08.0%.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
Function Code is Blinking A) Scroll to Function Code E2.
B) Activate Set Up Mode.
C) Scroll Up until the engine RPM at Idle begins to
increase above Idle RPM.
D) Scroll Down until Idle RPM is reached.
Figure 5-12: Display LED Function E2 Set Up Activated E) Store the Value to memory.

Page 5-10
SET-UP PROCEDURES

5-5.2.2.3 Function Code E3 – Throttle Maximum

This Function allows the throttle signal at Full to be fine
tuned from that provided by the E0 Throttle Profile.
The available Values for this Function are 10.0% to 100.0%.
The Value entered is the percentage of the throttle’s range
from Idle to Full.
EXAMPLE: A Value of 50.0, will equal a 2.10 VDC throttle
signal when the Volvo profile is selected, which
has a throttle range of 0.6 to 3.6 VDC.
The Default Value is 59.0%.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
A) Take command at a Remote Station.
Function Code is Blinking B) Move the Control Head lever to the Full Ahead position.
C) Measure the throttle signal.
D) Scroll to Function Code E3.
E) Activate Set Up Mode.
F) Scroll Up until the throttle signal is at Full Throttle.
Figure 5-13: Display LED Function E3 Set Up G) Store the Value to memory.
Activated H) Return the Control Head lever to the Neutral/Idle
position.
5-5.3 Clutch Functions
5-5.3.1 Clutch Basic Functions (C0 through C4, C8)
5-5.3.1.1 Function Code C0 – Clutch Pressure Interlock
This adjustment is to be set to Enabled only if the optional Clutch Pressure Switch is being used with this application.
This Function enables or disables the feature and allows for
two different modes of behavior when a Clutch Pressure
Switch is used. Refer to Section 8-2, page 8-2, for detailed
information.
The available Values for this Function are:
00 Not Installed (Default Value)
01 Installed
02 Throttle Clutch Pressure Interlock Mode
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
Function Code is Blinking
A) Scroll to Function Code C0.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-14: Display LED Function C0 Set Up Activated
5-5.3.1.2 Function Code C1 – Clutch Interlock Delay
This adjustment is to be set to Enabled only if the optional Clutch Pressure Switch is being used with this application.
This Function works together with Function Code C0 –
Clutch Pressure Interlock. Refer to Sections 8-2, page 8-2,
for operational details.
The available Values are 00.5 to 10.0 seconds. The Default
Value is 01.0 seconds.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
Function Code is Blinking
A) Scroll to Function Code C1.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-15: Display LED Function C1 Set Up Activated
5-5.3.1.3 Function Code C2 – Proportional Pause
This Function selects whether the Clutch stays engaged or
at Neutral when performing a Full Speed Reversal.
The In-Gear Delay is most commonly used.
The Neutral Delay is used when a Shaft Brake is installed.

Page 5-11
SET-UP PROCEDURES

The amount of time is adjustable with Function Code C3

Proportional Pause Time.
• The delay programmed is maximum and
proportional when Values 00 and 01 are
used.
• The programmed delay is fixed when Value
02 is selected and Function Code C4
Proportional Pause
• Ratio is set to 01 (1:1 Ratio). When C4 is set
to 00, the pause from Astern through
Neutral to Ahead is 1/2 of the selected
value.
The available Values are:
00 In-Gear (Default)
01 Neutral
02 Fixed Neutral Delay Enabled
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
Function Code is Blinking
A) Scroll to Function Code C2.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-16: Display LED Function C2 Set Up Activated

NOTE: If C2 Proportional Pause is set to 02 Fixed Neutral Delay Enabled, Function C3

Proportional Pause Time will set the Fixed Neutral Delay duration.

5-5.3.1.4 Function Code C3 – Proportional Pause Time

The Proportional Pause Time feature provides engine
deceleration, followed by a pause in throttling to the
commanded speed in the new desired direction, upon a
Full-Speed Reversal. This pause time is proportional to how
much throttle is being commanded and for how long. In
order to build up to the pause value set, the vessel must be
at full throttle and Ahead six (6) times the pause set. The
default pause from Astern to Ahead is 1/2 the Proportional
Pause C2 value set.
When C2 Proportional Pause is set to 00, the throttle
position drops to Idle and the transmission remains engaged
Ahead; the pause that follows is in proportion to the prior
Control Head lever position and how long the lever had
been in that position before the reversal.
This Function selects the amount of time that the Clutch
will stay engaged or at Neutral (depending on C2 setting)
while performing a Full Speed Reversal.
The available Values are 00 to 99 seconds. The default
Value is 03 seconds.

NOTE: The Value for this Function Code should be determined during the Sea Trial.

To change the Value (Refer to Sections 5-2 and 5-3,

page 5-2):
Function Code is Blinking
A) Scroll to Function Code C3.
B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-17: Display LED Function C3 Set Up Activated
5-5.3.1.5 Function Code C4 – Proportional Pause Ratio
00 - 2:1 Ratio
This is the default setting and determines how the value
set in the Proportional Pause Time C3 Function is
Page 5-12
SET-UP PROCEDURES

applied. The number of seconds selected is for an Ahead

to Astern maneuver only. An Astern to Ahead maneuver
will be 1/2 of the Proportional Pause Time selected. This
is the typical selection since most vessels do not reach the
same throttle in Astern as they would in Ahead.
Therefore, the time required to get to a sufficient water
speed for a safe reversal is significantly less.
01- 1:1 Ratio
When this setting is selected, the value set in the
Proportional Pause Time C3 is the same for both Ahead
to Astern, as with Astern to Ahead maneuvers. This may
be selected when the vessel reaches the same water speed
in both directions, as would be the case with a Double
Ended Ferry. Another application where this option may
be selected would be the control of a Bow or Stern
Thruster.
This Function Code selects whether the Proportional Pause
Time is the same in Ahead and Astern or whether the time
in Ahead is twice that in Astern. Standard vessels with a
bow and a stern typically select a pause which is twice as
much in Ahead compared to Astern. This is because much
more speed is obtainable in Ahead, then Astern.
Consequently, more time is required to slow down from
Ahead as compared to Astern.
NOTE: When the Controls are installed on a vessel such as a double ended Ferry or the Controls
are being used to control a thruster, the proportional pause should be the same in Ahead as Astern
or port and starboard in the case of a thruster.
The available Values for this Function are:
00 2:1 Ahead to Astern vs. Astern to Ahead (Default
Value)
01 1:1 Ahead to Astern vs. Astern to Ahead
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):

A) Scroll to Function Code C4.

B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-18: Display LED Function C4 Set Up Activated
5-5.3.1.6 Function Code C8 – Fixed Neutral Delay
This function provides a pause at Neutral whenever a
change in direction is commanded. This pause is in
addition to any proportional delay programmed into the
system.
The available Values for this Function are 00.0 to 04.0
seconds and are programmable in one tenth of a second
intervals.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):

A) Scroll to Function Code C8.

B) Activate Set Up Mode.
C) Scroll Up or Down to the desired Value.
D) Store the Value to memory.
Figure 5-19: Display LED Function C8 Set Up Activated
5-5.3.2 Clutch Solenoid Functions (C5 through C6)
This section along with the Clutch Basic Functions Section allows
the adjustment of Clutch Solenoid related items:
5-5.3.2.1 Function Code C5 – Shift Solenoid Type
This Function Code must be left at the default value unless a
ZF-Hurth Gear is installed with proportional Ahead and
Astern Solenoids.

Page 5-13
SET-UP PROCEDURES

NOTE: New ZF Hurth Gears utilize standard On/Off solenoids for Clutch selection. If unsure of
your type, contact the ZF Gear Manufacturer.

When values 01 or 02 are selected, the current is limited to

the solenoids.
The available Values are:
00 - All Shift Solenoids except ZF-Hurth (DEFAULT)
01 - ZF-Hurth Proportional Solenoids with 12V Power
02 - ZF-Hurth Proportional Solenoids with 24V Power
The default value of 00 is used with most types of solenoids,
with the exception of the ZF-Hurth Gears with proportional
Ahead and Astern solenoids.
CAUTION: The maximum amount of current to ZF Hurth proportional solenoids
MUST be limited by the control system. Failure to do so can cause permanent
damage to the solenoids. Depending on the voltage applied to the solenoids, adjust
the Value to 01 for 12V power and 02 for 24V power.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):

A) Scroll to Function Code C5.

B) Activate Set Up Mode.
C) Scroll Up to change the Value.
D) Store the Value to memory.
Figure 5-20: Display LED Function C5 Set Up Activated
5-5.3.2.2 Function Code C6 – ZF-Hurth Duty Cycle Ahead
This function adjusts the maximum current available to the
Ahead Proportional Solenoid. Failure to limit the current
may result in permanent damage to the solenoid.
The available Values are 00.0 to 100.0 percent Duty Cycle of
the applied voltage.
The Default Value is 100%.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
A) Ensure that Troll is not selected (no rapidly blinking
LED).
B) Connect an amp meter in series with the Ahead
solenoid signal.
Function Code is Blinking C) Move the Control Head lever to the Ahead detent.
D) Scroll to Function Code C6.
E) Activate Set Up Mode.
F) Scroll Up or Down until the appropriate maximum
Figure 5-21: Display LED Function C6 Set Up current level is reached.
Activated G) Store the Value to memory.
H) Return the Control Head lever to the Neutral/Idle
position.
5-5.3.2.3 Function Code C7 – ZF-Hurth Duty Cycle Astern
This function limits the amount of current delivered to the
Astern Proportional Solenoid. Failure to limit the current
may result in permanent damage to the solenoid.
The available Values are 00.0 to 100.0 percent Duty Cycle of
the applied voltage.
The Default Value is 100%.
To change the Value (Refer to Sections 5-2 and 5-3,
page 5-2):
A) Ensure that Troll is not selected (no rapidly blinking
LED).
B) Connect an amp meter in series with the Astern
solenoid signal.

Page 5-14
SET-UP PROCEDURES

C) Move the Control Head lever to the Astern detent.

D) Scroll to Function Code C7.
E) Activate Set Up Mode.
F) Scroll Up or Down until the appropriate minimum
Figure 5-22: Display LED Function C7 Set Up current level is reached.
Activated G) Store the Value to memory.
H) Return the Control Head lever to the Neutral/Idle
position.
5-5.4 Troll Functions

NOTE: The only Troll function initially displayed is L0. Whe L0 is set to any Value other than 00,
the remainder of the Troll functions (L1 through L6) will be displayed.

5-5.4.1 Troll Basic Functions (L0, L4, L5)

5-5.4.1.1 Function Code L0 – Troll Enable and Control Head Lever Troll
Range
There are four types which can be used to control any
trolling valve. The available Values are:
00 No Troll (Default Value)
01 20 Degrees – Type 1
02 35 Degrees – Type 2
03 45 Degrees – Type 3 (Throttle limited to 75%).
04 55 Degrees - Type 4 (Throttle limited to 10%).
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.5 Troubleshooting Functions
5-5.5.1 Basic Processor Troubleshooting Functions
5-5.5.1.1 Function Code H0 - Diagnostics
This Function is used during troubleshooting and is
explained in detail in Appendix B - Section B4.
5-5.5.1.2 Function Code H1 – Return to Factory Defaults
This Function may be used during troubleshooting.
(Do not make any adjustments to this Function Code,
unless directed to do so by ZF Marine Electronics Service
or Engineering Departments).
5-5.5.1.3 Function Code H2 - Driver Fault Detection Enable
The H2 Function is available only on Processors with
integrated Clutch and/or Troll Solenoids (i.e. 9120, 9121,
9122, and 9221).
The Processor can be programmed to monitor the current
flow through the Clutch and/or Troll solenoids. When this
option is selected, if the current level is too high or too low,
an alarm is sounded and an Error Code is produced.
Table 5-10: lists the required value that needs to be entered
to monitor the Ahead, Astern, Neutral, Troll Command, and
Troll ON/OFF solenoids.

NOTE: Function Codes 32 through 63 are reserved for future expansion and should not be used at
this time.

Table 5-10: Solenoid Error Status Enable

Ahead Astern Neutral Troll Command Troll On/Off Value
0 0 0 0 0 00
1 0 0 0 0 01
0 1 0 0 0 02
1 1 0 0 0 03
0 0 1 0 0 04
1 0 1 0 0 05
0 1 1 0 0 06
1 1 1 0 0 07

Page 5-15
SET-UP PROCEDURES

Table 5-10: Solenoid Error Status Enable

0 0 0 1 0 08
1 0 0 1 0 09
0 1 0 1 0 10
1 1 0 1 0 11
0 0 1 1 0 12
1 0 1 1 0 13
0 1 1 1 0 14
Ahead Astern Neutral Troll Command Troll On/Off Value
1 1 1 1 0 15
0 0 0 0 1 16
1 0 0 0 1 17
0 1 0 0 1 18
1 1 0 0 1 19
0 0 1 0 1 20
1 0 1 0 1 21
0 1 1 0 1 22
1 1 1 0 1 23
0 0 0 1 1 24
1 0 0 1 1 25
0 1 0 1 1 26
1 1 0 1 1 27
0 0 1 1 1 28
1 0 1 1 1 29
0 1 1 1 1 30
1 1 1 1 1 31
5-5.6 Premium Functions
5-5.6.1 Speed Boost Function Codes (F0 - F3)
Do Not attempt to adjust any of the Speed Boost Function Codes
until you have read the descriptions of their usage and have
verified their need. Refer to Section 8-10, page 8-5.
No adjustments should be made to speed boost until Function
Codes C2 (Proportional Pause), C3 (Proportional Time), and C4
(Proportional Pause Ratio) have been properly adjusted.
5-5.6.1.1 Function Code F0 – Speed Boost Percent
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.6.1.2 Function Code F1 - Speed Boost Duration
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.6.1.3 Function Code F2 – Speed Boost Start Delay
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.6.1.4 Function Code F3 – Speed Boost Bypass Clutch Delay
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.6.2 Transfer Function Codes ( P0, P1)
5-5.6.2.1 Function Code P0 – Transfer Mode
There are four different Modes of Station Transfer available.
The Default Value is 00.
00 = Neutral Only (Default Value)
1. When selected, transfer from one Remote
Station to another can ONLY be accomplished
when the receiving Remote Station’s Control
Head lever is in the Neutral detent.
2. After the receiving Remote Station’s Control
Head LED lights, there is a 1 second delay
before the receiving Remote Station’s Control
Head lever has command. This allows the
operator time to match the position of the
previous Remote Station’s Control Head lever.

Page 5-16
SET-UP PROCEDURES

3. Once command has been taken, the engine

and gear will respond when the Control Head
levers are moved Ahead or Astern.
02 = Lever Match and Neutral
1. The operator has two options when selected:
• Option 1 requires that the receiving
Remote Station’s Control Head lever is at
the Neutral detent for a transfer to occur.
• Option 2 requires that the receiving
Remote Station’s Control Head levers to
be within 10% (+/- 10 Percent) ( +/- 33
ADs) (+/- 7.5 Degrees) of the Station-in-
Command’s Control Head levers for a
transfer to take place.
2. In both options, there is a 1 second delay after
the Control Head’s re LED is lit before the
receiving Remote Station’s Control Head
levers have command.
3. Once command has been taken, the command
to the engine and gear will respond to the
Control Head lever’s position immediately.
03 = Request / Relinquish or Relinquish / Receive
1. The operator has two options when selected.
• Option 1 requires the operator at the
receiving Remote Station request control by
pressing the transfer button on the receiving
Remote Station’s Control Head. The
Station-in-Command may now relinquish
control by pressing the transfer button on
the Station-in-Command Control Head.
• Option 2 requires that the operator at the
Station-in-Command relinquishes control by
press the Station-in-Command’s Control
Head transfer button. The receiving Remote
Station accepts command by pressing the
receiving Remote Station’s Control Head
transfer button.
2. With both options, a 1/2 second ON, followed
by a 1/2 second OFF tone wi sounded when
the transfer is initiated.
3. Once command has been taken, the command
to the engine and gear will respond to the
Control Head lever’s position immediately.
04 = Neutral Only Request - Relinquish - Receive
1. The operator has two options when selected.
• Option 1 is a three step process. This option
requires the operator at the receiving
Remote Station request control by pressing
the transfer button on the receiving Remote
Station’s Control Head. The Station-in-
Command relinquishes control by pressing
the transfer button on the Station-in-
Command Control Head. The receiving
Remote Station must press the receiving
Remote Station Control Head transfer
button a second time to receive command.
• Option 2 requires that the operator at the
Station-in-Command relinquishes control by
press the Station-in-Command’s Control
Head transfer button. The receiving Remote
Station accepts command by pressing the
receiving Remote Station’s Control Head
transfer button.
2. With both options, a 1/2 second ON, followed
by a 1/2 second OFF tone wi sounded when
the transfer is initiated.

Page 5-17
SET-UP PROCEDURES

3. Once command has been taken, the command

to the engine and gear will respond to the
Control Head lever’s position immediately.
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.
5-5.6.2.2 Function Code P1 – Transfer Timeout
The Value selected for this Function determines how much
time an opterator has to respond to a transfer request or
relinquish.
The available Values are 00 to 99 seconds. The Default
Value is 15 seconds.
Contact ZF Marine Electronics if this Function Code is
going to be changed from the default setting.

Page 5-18
DOCK TRIALS
6 DOCK TRIALS

WARNING: It is imperative that the information provided in the previous Sections

have been read and followed precisely, prior to attempting a Dock Trial.

CAUTION: With I/O or Outboard applications, do not attempt to shift into or out of gear
with engines stopped. This may cause a jam condition or damage to the linkage to some
clutch configurations.

NOTE: On multiple screw applications, the following tests must be performed on both sides. If
any of the following tests fail, consult Appendix B Troubleshooting.

6-1 Control Heads (Engines Stopped)

A) Turn power ON to the Control System.
B) The Control Head at each Remote Station should produce an
intermittent tone.
C) Perform each of the following steps on all Remote Stations.
1. Move the Control Head’s lever(s) full Ahead and full Astern.
Ensure that there are no obstructions to the movement, the
Processor reacts to the lever movement, and that no tones are
generated.
2. Place the Control Head’s lever(s) in the Neutral position.
3. Depress and hold the Station transfer button while moving the
Control Head’s lever(s) to the Ahead detent. Release the transfer
button.
• The red LED on the Control Head should blink, indicating
Warm-up Mode has been entered. Warm-up Mode only operates
in the Ahead direction.
6-2 Start Interlock (Engines Stopped)
A) Turn the Processor DC power OFF.
• Verify that the engine(s) will not start.
B) Turn Processor DC power ON. Do not take command at a Remote
Station.
• Verify that the engine(s) will not start.
C) Take command at a Remote Station. Place the Control Head’s lever(s)
to approximately 50% of the throttle range.
• Verify that the engine(s) will not start.
D) Place the Control Head’s lever(s) in the Neutral/Idle position. Take
command at a Remote Station.
• Verify that the engine(s) will start in this position.
6-3 Engine Stop Switches
Start the engine(s) and verify that the Stop switches (normally push
buttons) function correctly at all Remote Stations.
6-4 High Idle
A) Place the Station in command into Warm-up Mode.
B) Adjust Function Code E6 to the desired engine RPM, as described in
Section 5-6.2.1.2, page 5-10.
C) Return the Control Head’s lever to the Neutral/Idle position.
6-5 Control Head Solenoid Command
A) Start the engine(s) and let them run at Neutral/Idle.
B) Place one Control Head lever at a time into the Ahead detent, the
Astern detent and then Neutral. Confirm that the movement of the
vessel is in the correct direction.
Page 6-1
DOCK TRIALS
• If incorrect, reverse the electric cable connections at the shift
solenoids.
C) Place the Control System into Warm-Up Mode and confirm that there
is control of speed.
D) Run the throttle up to approximately 20% of the throttle range for at
least 10 seconds.
E) Return the lever to the Neutral/Idle position.
F) Repeat steps A) thru E) at the remaining Control Head levers.
6-6 Throttle Pause Following Solenoid Shift

NOTE: A Test Control Head and a stop-watch are recommended to determine the correct setting
for the Throttle Pause. If a Test Control Head is not available, a second person may be needed.

A) Move the Station in command’s lever to the Ahead detent, start the
stop-watch while monitoring the Shaft.
B) When the Shaft begins to rotate, stop the stop-watch.
C) Record the time expired on the stop-watch.
D) Program Function Code E5 as described in Section 5-5.2.1.3, page 5-9

NOTE: If the time recorded in Section 6-6, step C) exceeds 5.0 seconds, a Clutch Pressure
Interlock is required. Refer to Section 8-2, page 8-2.

Page 6-2
SEA TRIALS
7 SEA TRIALS
WARNING: It is imperative that the information provided in the previous Sections
has been read and followed precisely, prior to attempting a Sea Trial. If any of the
following tests fail, discontinue the Sea Trial immediately and return to the dock.
Consult Appendix B Troubleshooting Section or a ZF Facility prior to resuming the
Sea Trial.

NOTE: In multi-screw applications, the following tests must be performed on all engines. During
the course of the Dock Trial and Sea Trials, fill out the Trial Report. Retain this information for
future use.

7-1 Full Speed Setting - Electronic Throttle

A) Warm-up the engine(s) and transmission(s) and slowly move into open
water.
B) Gradually move the lever(s) to Full speed.
C) If synchronization is installed, disable synchronization as explained in
Section 5-5.2.1.5, page 5-10.
• If the engine RPM is low, refer to Appendix B - Service Field Test
Unit Manual.
• If the engine RPM is high, decrease by using Function Code E3, as
explained in Section 5-5.2.2.3, page 5-11.
D) For twin screw applications, check that matching Idle, Mid-range and
Full speed Control Head lever positions cause equal RPM in both
engines.
7-2 Proportional Pause
The proportional pause feature provides engine deceleration when making
a direction change. The pause is variable and in proportion to:
• The Control Head’s lever position prior to the reversal.
• How long the Control Head’s lever has been in that position prior to
the reversal.
The pause is In-Gear or at Neutral, depending on the Function Code C2
Proportional Pause setting. The sequence of events, are as follows for the
three different Reversal Pause types:
7-2.1 In-Gear Delay [C200]
• The Throttle position drops to Idle.
• The Transmission remains engaged in Ahead or Astern.
• The Control System pauses at this position until the delay has
timed out.
• The Transmission shifts to the opposite gear (Astern or Ahead).
• The Throttle position moves to the Control Head’s present lever
position.
7-2.2 Neutral Delay [C201]
• The Throttle position drops to Idle.
• The Transmission shifts to Neutral.
• The Control System pauses at this position until the delay has
timed out.
• The Transmission shifts to the opposite gear (Astern or Ahead).
• The Throttle position moves to the Control Head’s present lever
position.
7-2.3 Fixed Neutral Delay [C202]
CAUTION: The Fixed Neutral Delay feature was added in order to accommodate Thruster
Control installations. Damage to the drive train may occur when used for reverse
reduction gear applications.
• The Throttle drops to Idle.
• The Transmission shifts to Neutral.

Page 7-1
SEA TRIALS
• The Control System pauses at this position for the amount of
time programmed (duration) with Function C3 Proportional
Pause Time (regardless of prior throttle setting).
• The Transmission shifts to the opposite gear (Port or Starboard)
• The Throttle position moves to the Control Head’s present
commanded position.
7-3 Calculating Proportional Pause Time C3
NOTE: The pause on a through Neutral shift is proportional to the speed commanded and the
time at that speed. The Values listed for Function Code C3, Proportional Pause Time, are the
maximum possible delays. When shifting from Idle Ahead to Idle Astern or vice-versa the delay is
zero. The time required to build up to the maximum pause is six times the Value selected. In
addition, in order to build up to the maximum delay Value, the System must be commanding Full
Throttle. The Pause when shifting from Astern to Ahead is either half or the same as the Ahead to
Astern delay depending on the Value selected for Function Code C4 Proportional Pause Ratio.

NOTE: A stop-watch is required to accurately program the Proportional Pause Time.

The amount of pause required is determined as follows:

A) Place the Control Head lever(s) to the Full Ahead position.
B) Leave the Control Head lever(s) at this position for whichever
of the following two is longer:
• Sixty seconds.
• The vessel’s speed through the water reaches maximum.
C) Quickly move the Control Head lever(s) to Ahead Idle or
Neutral, (depending on Function Code C4 setting) while
starting the stop-watch.
D) When the engine(s) RPM reaches Idle and the vessel’s speed
through the water is within two knots of the standard Idle
Ahead speed, stop the stop-watch.
E) Program Function Code C3, Proportional Pause Time, as
described in the Set Up Procedures, to the time expired on the
stop-watch.
7-3.1 Testing The Proportional Pause
CAUTION: It is critical that the Proportional Pause is tested as outlined below to ensure
that it was properly programmed. Failure to do so could cause damage to the
transmission.
A) Position the boat in open water and slowly increase the Throttle to
25% of the speed range.
B) Leave the Control Head lever(s) at this position for at least 60
seconds.
C) Quickly move the Control Head lever(s) to Idle Astern.
• The engine(s) RPM should drop to Idle.
• The Clutch should stay engaged or shift to Neutral for 25% of the
time selected with Function Code C3 Proportional Pause Time.
• Once the time has expired, the Clutch should Shift to Astern.
• The engine RPM will drop slightly when the Astern load is
placed on the engine, but not to the point where it comes close
to stalling.
D) Increase the Throttle slightly until the vessel starts moving in the
opposite direction.
• If the engine stalled or came very close to stalling, increase the
Value of Function Code C3 by one second. Repeat steps A)
through C).
• If the engine does not stall or come close to stalling, proceed
with the next step.
E) Repeat steps A) through D) with the Throttle at 50%, 75%, and
100% of the speed range.
Page 7-2
SEA TRIALS
• If the engine stalls at any time, increase the Value of
Function Code C3 by one second and repeat the steps A)
through D) again.
F) Once a Full Speed Reversal is successful without coming close to
stalling, the Proportional Pause is properly adjusted.
7-4 Synchronization Test
7-4.1 Equal Throttle Synchronization
A) Move both Control Head levers side by side to approximately 25%
of the Throttle range.
B) If previously disabled, enable the synchronization by depressing
the transfer button for two seconds.
• The green LED on the Control Head should illuminate,
indicating synchronization.
C) Check the engine tachometers to see if they are within 1% of one
another.
D) Move both Control Head levers side by side to approximately 50%
of the Throttle range.
E) Check the engine tachometers to see if they are within 1% of one
another.
F) Move both Control Head levers side by side to approximately 75%
of the Throttle range.
G) Check the engine tachometers to see if they are within 1% of one
another.
H) Move both Control Head levers side by side to 100% of the
Throttle range.
I) Check the engine tachometers to see if they are within 1% of one
another.
• While synchronized, if the tachometers have a greater than 1%
difference at any engine RPM, Active Synchronization is
recommended.
7-4.2 Active Synchronization
A) Move both Control Head levers side by side to approximately 25%
of the Throttle range.
B) If previously disabled, enable the synchronization by depressing
the transfer button for two seconds.
• The green LED on the Control Head may blink while driving
toward synchronization.
• Once the engine RPM’s are within 1% of one another, the green
LED will remain solidly lit.
C) Check the engine tachometers to see if they are within 1% of one
another.
D) Move both Control Head levers side by side to approximately 50%
of the Throttle range.
E) Check the engine tachometers to see if they are within 1% of one
another.
F) Move both Control Head levers side by side to approximately 75%
of the Throttle range.
G) Check the engine tachometers to see if they are within 1% of one
another.
H) Move both Control Head levers side by side to 100% of the
Throttle range.
I) Check the engine tachometers to see if they are within 1% of one
another.
While synchronized, if the tachometers have a greater than 1% percent
difference at any engine RPM, or if they appear to be continually
“hunting” for the correct RPM, refer to the Appendix B
Troubleshooting Section.
Page 7-3
SEA TRIALS
7-5 Sea Trial Report
The purpose of this Sea Trial Report is to provide a convenient checklist
and record of installation, dock trial set up, and sea trial performance of
the ZF Marine Electronics Propulsion Control System. Please enter ALL
of the information. We recommend that this form remains aboard the
vessel, and a copy is sent to ZF Marine Electronics with the Warranty
Registration located at the end of this manual.
7-5.1 Vessel Information
Vessel Name: Hull No. Trial Date:
Vessel Type: Dwg No.:
Installing Yard/Project Manager: Tel:
Owner/Owner’s Representative: Tel::
ENGINE DATA: Make: Model: HP (KW): RPM:
PROPELLER DATA: No. of Screws: Propeller Type: Fixed Other
GEAR DATA: Make: Model: Ratio:
No. of Remote Stations: Locations: 1. 4.
2. 5.
3.
7-5.2 Control System Checks
Make the following checks prior to applying power to the Processor.
Table 7-1: Sea Trial Processor Mounting
PORT STBD
________ ________ Processor Serial Numbers
YES NO YES NO
Is the Processor subject to excessive heat? (Above 70 degrees C)
YES NO YES NO
At least 4 feet (1,2m) from strong magnetic fields?
YES NO YES NO
Accessible for checkout, adjustments, and maintenance?
YES NO YES NO
Are the Processors bonded (grounded)?
YES NO YES NO
Are all Electric Cables supported every 18 inches (45,72cm)?
YES NO YES NO
Are the electrical cable connections tight at the Processors and Control Heads?
YES NO YES NO
Is the Processor’s Start Interlock Circuit being used?
YES NO YES NO
Is there an Engine Stop Switch installed at each Remote Station?
YES NO YES NO
Does Shift operate in the correct direction?
YES NO YES NO
Does Throttle operate in the correct direction?
YES NO YES NO
Is there an Engine Room/Remote Switch installed at the Engine Room Remote Station?
YES NO YES NO
Is there an Lock-out Switch installed at Remote Station 2?

Table 7-1: Sea Trial Power Supply

PORT STBD
Outside Outside
________ ________ Processor Serial Numbers
What is the source of Processor power and how is it charged?

YES NO YES NO Is there a backup power supply? APS or other, explain.

Page 7-4
SEA TRIALS
Table 7-1: Sea Trial Power Supply
PORT STBD
Outside Outside
________ ________ Processor Serial Numbers
YES NO YES NO
Are the power cables protected by 10 Ampere Circuit Breakers?
YES NO YES NO If separate power supplies are used for each Processors do they have a common
ground?
At At At At
Battery Processor Battery Processor
What is the Voltage when not being charged?
______ _____ ______ ______
VDC VDC VDC VDC
At At At At
Battery Processor Battery Processor
What is the Voltage when connected to Shore Power?
______ _____ ______ ______
VDC VDC VDC VDC
At At At At
Battery Processor Battery Processor
What is the Voltage when the engines are running?
______ _____ ______ ______
VDC VDC VDC VDC
Table 7-1: Dock Trials
PORT STBD
Outside Outside
________ ________ Processor Serial Numbers
YES NO YES NO
Does the engine start when the Control System is turned OFF?
YES NO YES NO
Does the Engine Stop Switch function at all Stations, regardless of RPM?
YES NO YES NO
Can all Remote Stations take command?
YES NO YES NO
Does the Warm-up Indicator Light blink in Ahead?
YES NO YES NO

What is the Low Idle RPM?

RPM RPM

YES NO YES NO

High Idle RPM (optional)

RPM RPM

YES NO YES NO
Does the vessel surge forward with Control Head lever in the Ahead Detent?

Table 7-1: Sea Trials

PORT STBD
Outside Outside
________ ________ Processor Serial Numbers
RPM RPM
What is the Full Throttle RPM?
YES NO YES NO
Do the Dual Control Head levers match position and RPM throughout the speed range?
Seconds Seconds
The Full Speed Reversal Delay is set for how many seconds?
YES NO YES NO
Is Synchronization operational?
STA 1 STA 2 STA 1 STA 2

STA 3 STA 4 STA 3 STA 4

What is the length of the Control Head Harness?
STA 5 STA 5

Page 7-5
SEA TRIALS
7-5.3 Record Parameters
Record information onto the following Tables only after ALL
information has been recorded in the previous Section Control
Checks.
Table 7-1: Record Processor Functions
Function Function Name Port Stbd
Code
(Refer to Section 5-5.1, page 5-6)
A0 Processor Identification
A1 Number of Engines
A2 One Lever Operation
A3 SE (Station Expander)
A4 Neutral Indication Tone
Table 7-1: Record Throttle Functions
Function Function Name Port Stbd
Code
(Refer to Section 5-5.2, page 5-8)
E0 Engine Throttle Profile
E1 Throttle in Neutral
E2 Throttle Minimum
E3 Throttle Maximum
E4 Throttle Maximum Astern
E5 Throttle Pause Following Shift
E6 High Idle
E7 Synchronization
Table 7-1: Record Clutch Functions
Function
Function Name Port Stbd
Code
(Refer to Section 5-5.3, page 5-11)
C0 Clutch Pressure Interlock
C1 Clutch Interlock Delay
C2 Proportional Pause
C3 Proportional Pause Time
C4 Proportional Pause Ratio
C5 Shift Solenoid Type
C6 ZF-Hurth Duty Cycle Ahead
C7 ZF-Hurth Duty Cycle Astern
C8 Fixed Neutral Delay
7-5.4 Comments (Please use additional paper as necessary):
7-5.4.1 General Installation Condition

7-5.4.2 Any Irregularities:

INSPECTOR_____________________________________________________ DATE_________________

Page 7-6
CONTROL OPTIONS
8 CONTROL OPTIONS
8-1 External Alarm Capability
CAUTION: The Processor’s Alarm circuit is limited to a maximum current of 0.5
Amperes and a maximum voltage of 100 Volts DC. Exceeding these limits will
permanently damage the Alarm circuit.
The Processor comes equipped with a normally open relay contact for
connection to an external Status Indication circuit. The relay energizes,
closing the contact when the Circuit Board has power applied and the
software program is running normally. In the event of a power loss or the
software program detects an anomaly, the relay de-energizes and the
contact opens.

Figure 8-1: External Alarm Connections with Processor Harness Example

SOLENOIDS
1

PB2
2

START
INTERLOCK
2
3
8

4
7

TB6

5
6

ALARM

6
5

7
4

TB11

8
3
2

OPI
1

-
+ POWER
8

STATION1
7

J3
6

PB1
5

TB2
4

TROLL
3

AUTO-
CLUTCH

2
2

3
1

Figure 8-2: External Alarm Connections Processor Hard-Wired Example

Page 8-1
CONTROL OPTIONS
8-1.1 Installation
(Refer to Figure 8-1: or Figure 8-2:)
The following items should be considered when designing and
installing the Status Indication Panel:
• The Power Wire Harness (p/n 13631-#) must be used if an
External Alarm is required.
• The Processor’s Alarm Circuit uses a “dry” contact. Therefore,
the polarity of the conductors is not a concern.
• The External Status Indication Circuit must not use the same
power source as the Processor.
• Since the External Status Indication Circuit is activated on a loss
of power to the Processor, an On/Off Switch is strongly
recommended.
• Figure 8-1: and Figure 8-2: are an example of a suitable circuit,
but not necessarily the only circuit acceptable.
A) Plug the Power Wire Harness into the Processor’s Power pigtail.
B) Run the two-conductor Alarm cable to the location of the Status
Indication Circuit.
C) Connect the black and red conductors to the Status Indication
Circuit as shown in Figure 8-1: or Figure 8-2:.
8-2 Clutch Pressure Interlock

NOTE: The Clutch Pressure Interlock C0 must be set to be used. Refer to the Section 5-6.3.1.1,
page 5-13, for Function Code C0 – Clutch Pressure Interlock

The Clutch Pressure Interlock uses a Pressure Switch which monitors the
Ahead and Astern Clutch pressures. The Pressure Switch must have a
Normally Open (N.O.) contact that closes when adequate Clutch pressure
is reached. The primary function of the Interlock is to prevent high engine
RPM when the Clutch is not fully engaged. The Interlock option must be
selected with Function Code C0. There are two selectable methods of
operation as described below:
8-2.1 C0 Methods of Operation
8-2.1.1 01 - Installed
When selected, the Interlock will command the Throttle to Idle, if
low or a loss of pressure occurs while cruising. The Interlock is
activated when the Pressure Switch’s contact opens for the
minimum period of time selected with Function Code C1.
If adequate Clutch pressure is not reached in the time
programmed in Function Code E5, throttle will be allowed to
increase above Idle. The Throttle will remain at this commanded
speed for the time programmed in Function Code C1 and then
returned to Idle, unless adequate pressure is reached during this
time.
The Throttle will remain at Idle until the Control Head’s lever is
returned to Idle, the Pressure Switch contact closes and a speed
command above Idle is commanded.
8-2.1.2 02 - Throttle Clutch Pressure Interlock
This option is typically selected when the Clutch takes longer than
five seconds to reach full pressure. The Throttle will remain at
Idle until there is a closure of the Pressure Switch’s contact. This
prevents speeds above Idle prior to full Clutch engagement.
In the event of a loss of Clutch pressure while cruising, the
Throttle will be returned to Idle after the time selected with
Function Code C1 has expired. Once a closure of the Switch is
sensed, indicating adequate pressure, the Throttle immediately
returns to the commanded signal, without having to return the
Control Head lever to Idle first, as is the case with Value 01.
Page 8-2
CONTROL OPTIONS

To External Status Indication Circuit

Hydraulic
Line Pressure Processor
Switch
Shuttle Valve
Power
To Processor Power Wire Pigtail 12281
DC Power Harness
Source To Starter Solenoid

Ahead Astern
Clutch Clutch
Pack Pack
Figure 8-3: Clutch Pressure Switch with Processor Harness Diagram

PB 2
2
START
IN TERLO CK

8
7

TB6
6
5

A LARM
4
3
2

OPI
1
8

STATION 1
7
6
5
4
3

C LU TCH
2
1
TB 1
P2
TB3

STATI ON 3
7
6
5
J1

4
3

ELEC- THR
TB8
2
1

3 4 5 6 7
8
7

1 2
DS 1 DS 2

J MP1
6

1 2 3 4 5 6 7 8 9 10
SERIAL
5
4
3

TB7
2
1 STATI ON 5
TB5

P1

Figure 8-4: Clutch Pressure Switch with Processor Hard-Wired Diagram

8-2.2 Installation
The installation of the Clutch Pressure Switch is the same for both
methods of operation. (Refer to Figure 8-3: or Figure 8-4:)
A) Install a Shuttle Valve on or near the Transmission.
B) Connect hydraulic line from the Ahead and Astern Clutches.
C) Connect a hydraulic line that is no longer than 5 feet
(1,524m)and at approximately the same height between the
Shuttle Valve and the Pressure Switch.
D) Connect the Power Wire Harness’s Clutch Pressure Interlock
cable to the Pressure Switch’s normally open contact.
E) Calibrate the Pressure Switch to close when adequate Clutch
Pressure is reached. (Refer to the Transmission manufactures
Installation Manual)
8-3 Station Expander (SE)
The Processor allows up to five Remote Stations. The SE allows up to an
additional four Remote Stations for a total of nine Stations. The SE and
Processor communicate via the Serial Communication cable. Control
Heads connected to the SE offer all of the functionality of a standard
Remote Station.
For detailed information on the operation, installation and adjustment of
the SE, refer to the Station Expander Installation Manual supplied with
the Expander.

Page 8-3
CONTROL OPTIONS
8-4 Trolling Valve Operation
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.
8-5 Engine Room Only / Remote Switch
Station No.1 is typically designated as the Engine Room Station when this
feature is used. When the switch is CLOSED, Station No. 1 will take
command away from any other Remote Station, including DP. It also
prevents other Remote Stations from taking command away from Station
No.1.
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.
8-6 Lockout Switch
This feature prevents any Remote Station, other than Station No. 2 from
taking command.
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.
8-7 DP MODE
• Refer to the information supplied with the DP system for
operational guidelines.
• The ClearCommand and the DP systems cannot be in command at
the same time.
• When DP Mode is selected with the DP system:
1. A one second tone is heard at all Remote Stations.
2. The Station-in-Command LED’s are not lit at any Remote Station.
3. If equipped with an Indication Panel, “DP Station” will be
displayed at the top of the Panel.
• The ClearCommand system can take control away from the DP
system at any time, by taking command at a Remote Station.
• The ClearCommand system can be programmed for DP1 operation
with or without Trolling valve operation.
1. When DP operation is programmed with Trolling operation, the
system will always operate in Troll Mode Type 3 (35 degrees)
when the DP system is in control. This is regardless of the type
selected with Function Code L0.
2. When control is taken away from the DP system with a Remote
Station, the control system will remain in the same Mode (Cruise
or Troll).

NOTE: High Idle and One Lever Mode are not available when a DP system is in command or
Transfer Mode 03 or 04 is selected.

If this option is going to be used, please contact a ZF Marine Electronics

Representative for further information.
8-8 Display Panel
• The Display Panel shows various
system information, including but not DP Station
limited to: Station-in-Command, Cruise
Control Head lever position, engine Throttle
RPM, propeller shaft RPM, etc. Shaft
• The Panel provides transfer direction
for Transfer Modes 03 & 04.
• The Panel receives information via the
serial communications line. AR T-1 03 9 R e v -

Figure 8-5: Display Panel

Page 8-4
CONTROL OPTIONS
• The Panel accepts 12 or 24 VDC power supplies
• A full explanation of the installation, operation, and adjustment of
the Display Panel is provided in Appendix A MM70179 Display
Manual and the manufacturers information included with the
Panel.
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.
8-9 Backup Control System
The Backup Control System provides a control system which is fully
independent from the ZF Marine Electronics Control System. The Backup
can control the gear as well as the engine, but it does not include ZF
Marine Electronics control logic, safety interlock and timing circuits. In
other words, there is no protection for operator errors, such as shifting
into gear at elevated rpm’s.
• Provides redundant throttle and clutch signals in the event of a
failure of the Main Control System.
• May be selected at any time by the operator.
• A full explanation of the installation, operation and adjustment of
the Backup Control System is provided in the Installation Manual
supplied with the Backup System.
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.
8-10 Speed Boost
There are four different Function Codes
associated with Speed Boost (F0, F1, F2 and
F3). They all work in conjunction with each
other to apply the right amount of speed boost
at the correct time and duration.
No adjustments should be made to speed boost
until Function Codes C2 (Proportional Pause),
C3 (Proportional Time), and C4 (Proportional
Pause Ratio) have been properly adjusted.
The primary function of speed boost is to
prevent an engine from stalling when a heavy
load is applied
Do Not attempt to adjust any of the Speed
Boost Function Codes until you have read the
descriptions of their usage and have verified
their need.
Figure 8-6: Speed Boost Usage Graph
8-10.1 Speed Boost Percent (F0)
This Function programs the amount of throttle which will be applied
when the load is first being applied to the engine.
WARNING: The available range for this Function is 0.0 to 20.0%. Using a value of
20% will likely damage the transmission. This range is provided to allow as much
leeway as possible when using this Function, but is not intended to use 20%.

NOTE: A value of 0.0 for Function Code F0 means Idle Speed.

Units: Percent of Throttle Range [Throttle Range = Throttle Maximum

E3 - Throttle Minimum E2]
Default Value: 0.0
Range: 0.0 to 20.0

Page 8-5
CONTROL OPTIONS
Examples:
• A value of 0.0 results in no Speed Boost being used. The
Throttle Command Signal remains at Idle as the Clutch engages.
• A value of 5.0 results in a 5% increase in the Throttle Command
Signal during Clutch engagement. If Throttle Maximum were
set to 4.5 VDC and Throttle Minimum at 0.5 VDC, the Throttle
Range would be 4.0 VDC. 5% of 4.0 VDC equals 0.2 VDC. The
Speed Boost Throttle Command Signal would be 0.5 VDC + 0.2
VDC = 0.7 VDC.
8-10.2 Speed Boost Duration (F1)
This Function programs how long the elevated speed (Speed Boost
Signal) is applied. The duration time programmed begins when
Function Code F2 – Speed Boost Start Delay has ended.
Units: Seconds
Default: 0.0
Range: 0.0 to 20.0
Examples:
• A value of 0.0 is 0.0 seconds.
• A value of 2.5 is 2.5 seconds.
• A value of 5.0 is 5.0 seconds.
8-10.3 Speed Boost Start Delay (F2)
This Function determines the amount of time after the Ahead or
Astern clutch engagement command has been given (movement of the
Control Head lever), to the point where Speed Boost is applied.
NOTE: This is an “open loop” method of applying speed boost just prior to the load hitting the
engine. Clutch engagement timing is a function of oil viscosity and heat and these Processors
have no method of actually measuring clutch pressure. Therefore, in order to accurately adjust
the F2 Function, it is best to warm up the gear first.
Units: Seconds
Default: 0.0
Range: 0.0 to 10.0
Examples:
• A value of 0.0 is 0.0 seconds.
• A value of 0.1 is 100 milliseconds.
• A value of 2.0 is 2 seconds.
8-10.4 Speed Boost Bypass Clutch Delay (F3)
In some applications, speed boost is only required when performing an
emergency reversal. Engaging the Ahead or Astern clutch from
Neutral, or Idle Ahead to Idle Astern maneuvers do not load the engine
to the point where a stall occurs. Only when momentum is built up in
the Ahead or Astern direction, and an emergency reversal is required,
is the load on the engine significate enough to stall the engine.
In these situations, speed boost is not required every time a Clutch
engagement is commanded. This Function allows the speed boost to
be applied ONLY WHEN the time programmed is exceeded during a
reversal. The time required to perform a refersal is programmable
with Function Code C3 (Proportional Pause Time).
Units: Seconds.
Default: 0.0
Range: 0.0 to 99.0
Examples:
• A value of 0.0 is 0.0 seconds.
• A value of 1.0 is 1 second.
• A value of 99.0 is 99.0 seconds.
If this option is going to be used, please contact a ZF Marine Electronics
Representative for further information.

Page 8-6
PERIODIC CHECKS AND MAINTENANCE
9 PERIODIC CHECKS AND MAINTENANCE
The items listed below should be checked on an annual basis or less, when
noted:
9-1 Control Heads
• Check the terminal strip for signs of corrosion or a loose connection.
• If used, disconnect the Deutsch connector and check the pins and
sockets for signs of moisture and corrosion.
9-2 Processor
• Check all terminal connections for signs of corrosion or loose
connections.
• Un-plug and inspect all Deutsch connectors for signs of moisture or
corrosion.
9-3 Power Supply
9-3.1 Battery
WARNING: Batteries contain sulfuric acid and emit hydrogen gas while charging.
Therefore, specific safety precautions must be adhered to while handling and
servicing. Specific information on handling and servicing batteries can be
obtained from the Battery Council International, Battery Service Manual.
CAUTION: In many newer batteries, the vent cap is permanently attached,
preventing access to the electrolyte for water level and specific gravity tests.
Attempting to pry off these caps could result in premature battery failure.
The following tests should be performed in the intervals specified:
9-3.1.1 Quarterly (Every 3 Months)
• Check the level of the water (electrolyte) within the Lead-
Acid batteries. The plates must be covered. If not, add a
small amount of distilled water.
• Check the voltage of the battery. The battery must have a
chance to “rest” (no charging and no load for a couple of
hours) prior to testing. The following table represents a fully
charged battery:
Table 9-2: Fully Charged Battery
Lead Acid Batteries Gel Cell or AGM Batteries
12V – 12.6 to 12.8V 12V – 12.4 to 12.6V
24V – 25.2 to 25.6V 24V – 25.0 to 25.4V
• Check the battery terminals for signs of corrosion, acid
build-up or loose connections.
9-3.1.2 Semi-Annually (Every 6 Months)
• Check the specific gravity of your Lead-Acid battery(s) with a
Hydrometer. The reading for a fully charged lead acid
battery is 12.60 to 12.80.
9-3.1.3 Annually (Every 12 Months)

WARNING: The Battery Load Test should be performed by a qualified Marine

Electrician only.

The tests performed on quarterly and semi-annual basis, give a

relatively good indication of the batteries’ health. However, the
only way to accurately determine the actual health of your battery
is to perform a Battery Load Test.
• There are two types of Battery Load Tests performed in the
field, Performance and Service. In order to determine the
actual health of your battery a Performance Load Test is
recommended. The Service Load Test determines how well
your battery performs in the boat and doesn’t take into
Page 9-1
PERIODIC CHECKS AND MAINTENANCE
account the battery’s original rating, which could result in
misleading results. The Performance Load Test places an
accurate load on the battery and compares the results to the
battery manufacture’s specification. The battery should be
replaced if the results are 80% or less than the manufacture
specifications.
9-3.2 Power Cables, Distribution Panels, etc.
• Check all of the connections from the battery to the DC
Distribution Panel to the APS for loose or corroded connections.
• Measure the voltage at the battery and at the Processor while
the Clutch or Throttle is driving. There should be no more than
10% difference between these two points. If so, check all
devices and connections for excessive voltage drop.
NOTE: If an APS is used in the circuit to supply power to the Processor, account for the 0.7V drop
across the APS. Example: 12.6V @ battery – 1.26V (10% drop) – 0.7V (APS drop) = 10.64V
(Minimum allowable voltage)

Page 9-2
APPENDIX A
APPENDIX A

PARTS LIST
PART NO. DESCRIPTION

CONTROL HEADS

SINGLE SCREW
450-3L or 3RLeft or Right Control Head, 'T' Lever
453-3L or 3RLeft or Right Control Head, Chrome Knob Lever
455-3L or 3RLeft or Right Control Head, Black Low Profile Lever
456-3L or 3R Left or Right Control Head, Chrome Low Profile Lever
456-3LP or 3RPLeft or Right Control Head, Chrome Low Profile Lever, Pluggable

521-4L or 4RLeft or Right Control Head, Single Lever Tournament Style - Aluminum
521-4LB or 4RBLeft or Right Control Head, Single Lever Tournament Style - Aluminum, Junction Box
521-5L or 4RLeft or Right Control Head, Single Lever Tournament Style - Chrome
521-5LB or 4RBLeft or Right Control Head, Single Lever Tournament Style - Chrome, Junction Box

750-L or –RLeft or Right Control Head, Heavy Duty

MC2000-1L or 1RLeft or Right Black Control Head, Black Lever

MC2000-2L or 2RLeft or Right Chrome Control Head, Chrome Lever
MC2000-4L or 4RLeft or Right Black Control Head, Chrome Lever
MC2000-4LP or 4RPLeft or Right Black Control Head, Chrome Lever, Pluggable
MC2000-5L or 5RLeft or Right Black Control Head, Gold Lever

TWIN SCREW (Synchronization Indication)

460-4 Control Head, 'T' Lever
460-4P Control Head, 'T' Lever, Pluggable
463-4 Control Head, Chrome Knob Lever
463-4P Control Head, Chrome Knob Lever, Pluggable
464-4 Control Heads, Split, with Single Levers, Chrome Knobs (pair)
465-4 Control Head, Black Low Profile Lever
466-4 Control Head, Chrome Low Profile Lever

522-4 Control Head, Dual Lever Tournament Style - Aluminum

522-4B Control Head, Dual Lever Tournament Style - Aluminum, Junction Box
522-5 Control Head, Dual Lever Tournament Style - Chrome
522-5B Control Head, Dual Lever Tournament Style - Chrome, Junction Box

760 Control Head, Heavy Duty

760P Control Head, Heavy Duty, Pluggable

MC2000-1 Black Head, Black Levers

MC2000-1PBlack Head, Black Levers, Pluggable
MC2000-2 Chrome Head, Chrome Levers
MC2000-2PChrome Head, Chrome Levers, Pluggable
MC2000-3 Gold Head, Gold Levers
MC2000-4 Black Head, Chrome Levers
MC2000-4PBlack Head, Chrome Levers, Pluggable
MC2000-5 Black Head, Gold Levers

CONTROL HEAD ADAPTER PADS (400 and MC2000 Series Only)

1002 Pad Kit - white, blank
1003 Pad Kit - black, blank
1004 Pad Kit - teak, blank
1005 Pad Kit - white, machined
1006 Pad Kit -black, machined
1007 Pad Kit - teak, machined

PageA-1
APPENDIX A

CABLE (Electric)
180 8-Cond. Shielded Cable Per/ft.
350 8-Cond. Shielded Cable 500’ Spool
11811 8-Cond. Shielded Cable 1000’ Spool
212 2-Cond. Power Cable Per/ft.
349 2-Cond. Power Cable 250’ Spool
183 2-Cond. Start Interlock Cable Per/ft.
355 2-Cond. Start Interlock Cable 250’ Spool

WIRE HARNESS (Plug)

Replace the # after the Part Number with the length of harness required. EXAMPLE: 13316-10; 13316-20;
13316-30
13316-# Serial Communication (Twin Screw)

13432-# Throttle, Voltage

13494-# Throttle, Current
13533-# Throttle, PWM
14363-# Throttle, MAN
15027-# Throttle, Frequency

15719-# Clutch – Ahead/Astern/Clutch Power

15732-# Clutch – Ahead/Astern/Troll CMD
15725-# Clutch – Ahead/Astern/Troll/Troll CMD

13239-# Magnetic Pickup or Pulse Transmitter

13631-# Power/Start Interlock/Clutch Pressure/Alarm Circuit

13552-# Power/Start Interlock/Clutch Pressure
13756-# Power/Start Interlock
15023-# Power

13557-# Control Head - 1 Connector

14261-# Control Head - 2 Connectors

TEST UNIT
13927 Service Field Test Unit
14000 Field Test Control Head - Dual

PageA-2
MMC-329 Rev.C 8/03
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.
Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head
lever.
CruiseCommand: one (1) Control Head Harness per Control Head lever.
Included with the Control Head:
• Mounting screws
• Terminals (For 8-Conductor or 1-Connector Harnesses)
• Watertight cable grip for the cable entrance on the Processor (For 8-Conductor)
When the Control Head is properly mounted on a console, it is spray proof from the top only. An
adhesive gasket is mounted on the bottom of the Control Head to seal it to the mounting surface.
However, below the mounting surface it needs protection from water or spray. Consider using a
Weather Mount Enclosure, which is available from ZF Marine Electronics.

MOUNTING AND INSTALLATION:

Select the desired mounting locations and make cutouts per template. Refer to the Dimensions
Diagram.
Check that the two mounting screws will start into the Control Head. Remove Control Head
from cutout.
Run cable/harnesses between Processor and Control Head. Label both ends with Station it con-
nects (EXAMPLE: Port, Center, or Starboard; Port Thrust, Port Throttle; etc.)

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-3
 Dimensions

There are two types of Control Head connections available: Plug or Terminal
Connected. Both types may be used with MicroCommander, ClearCommand, or
CruiseCommand using the appropriate cable or harness. Follow the appropriate
steps for the Control Head that has been supplied for your system.
Standard Cable Pluggable
Strip back the PVC cover on the shielded cable approximately Plug Control Head cable into the
2-1/2" (63,5mm) at the Control Head. pigtail at the Control Head. (Ensure
At the Control Head end of the cable strip and cut off the the correct Processor Cable is being
plugged into the corresponding Control
shielding and drain wire flush with the end of the PVC cover
Head lever pigtail).
(the drain wire at the Control Head is not connected to
ground). When connecting the plugs, ensure
that the release button or buttons
Strip 3/8" (9,5mm) insulation off each wire. are depressed and held until plug is
Twist the individual strands of the wires to minimize fraying.
fully connected or disconnected.
Crimp a locking fork terminal (included with each Control Connecting or disconnecting plugs
Head) to each of the conductors. without depressing and holding the
Make connections to the Control Head as indicated in the fol-
release button or buttons will dam-
lowing TERMINAL CONNECTIONS diagrams. age the plug.
ALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM
FOR ANY UNIQUE CONTROL HEAD CONNECTIONS FOR YOUR SYSTEM.
When cable connections are complete, MOUNT Control Head to the console using the two (2)
mounting screws and washers supplied with the Control Head.

A-4
CABLE/HARNESS CONNECTIONS:
Dual Control Head Connections
TERMINAL CONNECTIONS

Cable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.
MicroCommander/ClearCommand CruiseCommand/9000 Series
Port Lever: Starboard Lever: Port Lever: Starboard Lever:
Terminal 3 Red Terminal 3 Red Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER
Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER
Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue

PLUGGABLE CONNECTIONS
Pluggable Control Heads are supplied with a harness pigtail for each lever. When
disconnecting/connecting the plugs, ensure that the release button or buttons are
depressed and held until plug is fully disconnected or connected. Disconnecting/
connecting plugs without depressing and holding the release button or buttons
WILL damage the plug.

Aft Facing Control Heads

For dual lever Control Head Sta-

tions that have the user facing aft:
Reverse connections 5 and 7.
For single lever Control Head Sta-
tions that have the user facing aft
and the one Control Head lever on
the user’s right, reverse connec-
tions 5 and 7.

Handheld Control is an option. Contact your ZF Marine Electronics Dealer for further informa-
tion on Handheld requirements and options.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-5
ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington
12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-6
 0.25 Diameter (6,1mm) through Holes
(2 Holes)

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-7
.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-8
MMC-279 Rev.B 7/02
ZF Marine Electronics, LLC
Mukilteo Plant
400 Series Weather Mount 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
Enclosure (89,9mm)

Watertight
Cable Grip
(two if Dual Control Head)
6.29
(159,8mm)

4.72
10241 (119,9mm)

Deck Mount or Exposed Mount

Ideal for outside Weather Mount
To prevent internal condensation and moisture build up the mount is drilled to allow air circulation.
Part No. 12110

.
ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington
12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-9
A-10
 Deutsch Connector Assembly
DT Type
Step 1: Contact Removal Step 2: Wire Stripping
Solid Contacts
Contact Part Wire Gauge Strip Length
1. Remove wedgelock using
needlenose pliers or a hook Number Range (inches)
shaped wire. Pull wedge
straight out. 0460-202-20141 20 AWG .156-.218
0462-201-20141 20 AWG .156-.218

0460-202-16141 16, 18 & 20 AWG .250-.312

2. To remove the contacts, 0462-201-16141 16, 18 & 20 AWG .250-.312
gently pull wire backwards,
while at the same time 0460-215-16141 14 AWG .250-.312
releasing the locking finger 0462-209-16141 14 AWG .250-.312
by moving it away from the
contact with a screwdriver. 0460-204-12141 12 & 14 AWG .222-.284
0462-203-12141 12 & 14 AWG .222-.284

0460-204-08141 8 & 10 AWG .430-.492

3. Hold the rear seal in
0462-203-08141 8 & 10 AWG .430-.492
place, as removing the
contact may displace the
0460-204-0490 6 AWG .430-.492
seal.
0462-203-04141 6 AWG .430-.492

Step 3: Contact Crimping Step 4: Contact Insertion

Use Crimp Tool #HDT48-00
1. Strip insulation from wire.
(See Step 2). 1. Grasp crimped contact
2. Raise selector knob and approximately (25.2 mm) one
rotate until arrow is aligned with inch behind the contact barrel.
wire size to be crimped.
3. Loosen locknut, turn adjust-
ing screw in until it stops.

2. Hold connector with rear

4. Insert contact with barrel up. grommet facing you.
Turn adjusting screw counter–
clockwise until contact is flush
with indentor cover. Tighten
locknut.
3. Push contact straight into
connector grommet until a click
is felt. A slight tug will confirm
5. Insert wire into contact. that contact is properly locked
Contact must be centered in place.
between indicators. Close
handles until crimp cycle is 4. Once all contacts are in place,
completed. insert wedgelock with arrow pointing
6. Release handles and remove toward exterior locking mechanism.
crimped contact. The wedgelock will snap into place.
Rectangular wedges are not oriented.
They may go in either way.
7. Inspect terminal to ensure NOTE: The receptacle is shown –use the
that all strands are in crimp same procedure for plug.
barrel.NOTE: Tool must be
readjusted for each type/size
of contact. Use HDT04-08 for
size 8 and 4 contacts.
(800) 223-1236

A-11
A-12
S-214 Rev.F 3/05
ZF Marine Electronics, LLC
Mukilteo Plant
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 routing redundant DC power sources for vital electronic equipment while maintaining
isolation of the DC power sources.
Two independent batteries rated at the same nominal voltage are wired to separate terminals on
the APS and internal diodes maintain total isolation between them. A single output terminal is
wired to the ZF Marine Electronics Propulsion Control System.
The APS is rated for loads of up to 70 Amps on 12-24V systems. The unit is ruggedly constructed
with heavy-duty wiring studs and epoxy-potted components in an anodized aluminum case.
B) APS SPECIFICATIONS
Model: 13505
Maximum Load Current: 70 amps
Operating Temperature: -40 degrees C to +80 degrees C; derate linearly from 100% @ 50
degrees C to 70% @ 80 degrees C
Voltage Drop: 0.7 VDC @ 50% load; 0.9 VDC @ full load
Dimensions: 3.25" x 4.5" x 3.1" (8,3 x 11,4 x 7,9 cm)
C) MATERIALS PROVIDED
The single APS is supplied with a hardware packet containing (6) hex nuts, (3) lock washers, (4)
self-tapping mounting screws, (1) instructions diagram.

NOTE: Not all of the hardware will be used in the installation; some spares are provided.
Nut size is M-6.

The twin APS is supplied with (2) single APS hardware packets.
D) INSTALLATION
Refer to the installation Drawing 11488D.
1. Shut off all charging sources and disconnect the negative (ground) side of each battery
which will be wired to the APS.
2. Mount the APS(s) in a suitable location which will keep wire runs to a minimum length,
and is (preferably) ventilated, for cooler operation. The case of the APS is electrically iso-
lated from the internal diodes, so mounting on either a metal or non-metal surface is
acceptable.
3. Complete the wiring as indicated on either Drawing 11488D-1 or 11488D-2.
4. Reconnect the negative battery posts.
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.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-13 180101D 3/05
A-14 180101D 3/05
Drawing 11488D-1 Twin Screw Single APS Connection & Alternate Remote Switch

A-15 180101D 3/05

A-16 180101D 3/05
Drawing 11488D-2 Twin Screw Dual APS Connections

A-17 180101D 3/05

A-18 180101D 3/05
Drawing 11488D-3 APS Notes Page

A-19 180101D 3/05

A-20 180101D 3/05
MMC-287 Rev.D 8/03
ZF Marine Electronics, LLC
Mukilteo Plant
Bonding: A.B.Y.C. E-11, 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.
Metal - Hull Vessels
The metallic hull of the vessel may also serve as the common bonding conductor.
If it is desirable for the item being installed to be bonded to the vessel bonding system, and the
installation or mounting method does not provide the desired path, a separate bonding conductor
may be required.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-21
A-22
MMC-288 Rev.E 8-03
ZF Marine Electronics, LLC
Mukilteo Plant
References and Parts Source
A) REFERENCES
1. American Boat & Yacht Council (ABYC)
3069 Solomons Island Road
Edgewater, MD 21037-1416
E-3 Wiring Identification on Boats
E-11 AC and DC Electrical Systems on Boats
H-2.4e or 32.4g Ambient Temp. 50 degrees C
P-24 Electric/Electronic Propulsion Controls
2. Code of Federal Regulations
33 CFR 183 Subpart I - Electrical Systems
33 CFR 183.410 Ignition protection
33 CFR 183.415 Grounding
33 CFR 183.425 Conductors: General
33 CFR 183.430 Conductors in circuit of less than 50 Volts
33 CFR 183.445 Conductors: Protection
33 CFR 183.455 Over-current and Protection: General
46 CFR 111.01 - 15(b) Ambient Temp. Machinery Spaces 50 degrees C
46 CFR 111.05- System Grounds
3. Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096
J1171 External Ignition Protection
J1428 Marine Circuit Breakers
J378 Marine Engine Wiring
4. National Marine Manufacturers Association
401 North Michigan Avenue
Chicago, IL 60611
5. Underwriters Laboratories
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)]
Service Field Test Unit (Break-out Box) P/N 13927
WAGO Tool P/N 397 [WAGO (P/N 236-332)]
Field Test Control Head - Dual P/N 14000
ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington
12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-23
A-24
SER-161 Rev.B 5/03
ZF Marine Electronics, LLC
Mukilteo Plant
Engine Tachometer Sender Requirements

Engine Type Engine Model Sender Comments

Gasoline Inboard 3, 4, 6, 8 Cylinder Alternator’s N/A

Stator AC
Terminal or
Point Side of
the Coil
Gasoline Outboard 4, 6, 8, 14 Pole Alternator’s N/A
Stator AC
Terminal or
Point Side of
the Coil
Diesel Caterpil- Most Older & 3208, D336, D346, D348, 8902 N/A
lar D398, D399 & D334
Diesel Caterpil- 3116, 3126, 3176, 3196, 3406, 3408, 8922 Some use 8912. New engines have
lar 3306, 3412, 3056, 3512 & 3516 Magnetic Pickup already installed on
flywheel.
Diesel Caterpil- All Electronic N/A Use ECM output. Outputs 12 PPR.
lar
Diesel Cummins Most Older & 555 8902 N/A
Diesel Cummins B & C Series, KTA19M3, MTA855, * 8912 Most have Magnetic Pickup already
KTA1150M installed on flywheel.
Diesel Detroit DDEC Electronic System 8902 Must have Detroit data-link output
module.
Diesel Detroit 53, 71, & 92 Series 8902 Engines manufactured before 1976
use Aetna Part No. 8152 drive key
with Sender.
Diesel Detroit 8.2 Liter 2 Cycle, Some 71 & 92 Series 8912 N/A
Diesel EMD Mechanical Sender Applications 8902 N/A
Diesel EMD Flywheel Applications 8912 N/A
Diesel Hino All Engines 8902 250 HP: Tach drive on front Port side
of engine.
310HP: Tach drive on rear center, just
below the head.
Diesel John Older Engines 8902 Tach drive usually at rear Starboard
Deere side of engine.
Diesel John Newer Engines 8912 Magnetic Pickup usually already
Deere installed.
Diesel Lehman All Engines 8902 Engine built after 1977 require the
(Ford) Aetna Part No. 8619 tachometer drive
adapter.
Diesel Lugger All Engines 8912 N/A
Diesel MAN In-line 8902 N/A
Diesel MAN V-Engines 8902 An extension tachometer cable Aetna
Part No. 9212 is usually required.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
A-25
 Engine Type Engine Model Sender Comments

Diesel MAN 826 8912 It may be necessary to manufacture a

mounting plate for the magnetic
pickup.
Diesel MAN 2840, 2842, 2848, 2866 & 2886 8912 N/A
Diesel MTU All Engines 8902 N/A
Diesel Perkins 1980 and earlier 8902 N/A
Diesel Perkins 4-236 & 6-354 8902 Perkins Part No. 8875 drive adapter
needed on 1980 and newer engines.
Diesel Perkins 4-107, 4-108 & M-800TI 8902 N/A
Diesel Perkins 4-154 N/A Aetna Part No. 8709 Magnetic Sensor
must be used in lieu of SAE drive.
Diesel Perkins M-135, M225, M-300 & M30 8912 N/A
Diesel Volvo 70, 100 & 120 A or B Series 8902 N/A
Diesel Volvo 3, 6A, 17 & 30 8912 N/A
Diesel Volvo 31 & Up, 41 N/A Aetna Part No. 8709 Magnetic Sensor
must be used in lieu of SAE drive.
Diesel Volvo 40, 60, 61 & Up, 71 & Up, 100C & Up, N/A Magnetic pickup already installed on
102, 121C & Up, 122, 2010 & 2020 cam gear.
Diesel Volvo 42 & 43 N/A Connect at blower box. Black wire is
ground and grey is signal
Diesel Volvo 2030 & 2040 N/A Magnetic pickup already installed on
cam gear.
Diesel Yanmar All Engines N/A A metric Magnetic pickup is already
installed on all engines.

P/N 8902 Dual Mechanical Sender

P/N 8912 Dual Magnetic Pickup (3/4-16)
P/N 8922 Single Magnetic Pickup (5/8-18) Available through Aetna Engineering only.

A-26
MMC-165 Rev.E 2/05
ZF Marine Electronics, LLC
Mukilteo Plant
Electronic Propulsion Control Systems Three Year Limited Warranty
Your ZF Marine Electronics product has been designed and manufactured by experienced
engineers and craftsmen. ZF Marine Electronics LLC, warrants for the period indicated below, each
product to be free from defect in material and workmanship. Repair or replacement, at ZF Marine
Electronics option, will be provided if the product, upon ZF Marine Electronics inspection, is found
to be properly installed and operated in accordance with ZF Marine Electronics Manual. This
warranty does not apply to malfunction caused by damage, unreasonable use, misuse, repair or
service by unauthorized persons or normal wear and tear.
A) Coverage Under Warranty
Three years from the date of purchase by the original end user.
Year One
No charge for equipment repair, parts and labor. Up to three hours labor toward troubleshooting
and replacement of defective equipment.
Year Two and Three
There is no charge for equipment repairs performed at the factory that are covered under
warranty. No labor allowance for troubleshooting and replacement of defective equipment.
B) No Coverage Under Warranty
The following will not be covered under warranty.Travel to and from the job site.
1. Adjustment or calibration of any ZF Marine Electronics equipment.
2. Adjustment or calibration of any associated equipment which may include but not limited to push-pull
cables, engine governor or carburetor, transmission or trolling valve.
3. Damage due to accidents, improper installation or handling and or improper storage.
4. Damage due to faulty repairs performed by an unauthorized service representative.
5. Damage due to conditions, modifications or installation contrary to published specifications or
recommendations.
6. Original installation charges or start-up costs.
7. Battery service including labor charges related to battery service.
8. Rental of equipment during performance of warranty repairs.
9. Unauthorized repair shop labor, without prior approval from ZF Marine Electronics Service Department.
10. Shop supplies such as connectors, wire, cable, etc.
C) Warranty Service
Please go to www.zf-marine.com or Call 1-425-583-1900 or (U.S. only) 1-800-546-5455 for your
nearest ZF Marine Electronics Factory Authorized Dealer.
1. Prior to returning any product to the factory, you must contact ZF Marine Electronics Service Department
for a Service Return Authorization (SRA) number. Return the product freight prepaid, marked clearly with
the SRA number and a description of the malfunction.
2. If there is a defect covered by warranty, ZF Marine Electronics will, at its option, either repair or replace the
defective part or product. If after inspection, ZF Marine Electronics determines that the product is not
defective, ZF Marine Electronics will charge a testing fee and return the product to the sender, freight
collect.
3. Repair or replacement during the warranty period will not extend the warranty period.
4. All claims must be submitted within 30 days from date of service.
5. Claims for over 3 hours must be pre-approved by the ZF Marine Electronics Service Department.
This Warranty is expressly in lieu of all other Warranties, express or implied. Except to the extent prohibited by applicable law, ZF
Marine Electronics hereby disclaims all other implied or express warranties of any kind, including warranties of merchantability
and fitness for a particular purpose. Under no circumstances shall ZF Marine Electronics be liable for any consequential damages
sustained in connection with the product or its use, including any costs or damages which result from loss of use of the product or
any engine or boat with which it is used. 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. Some states do not allow limitations on how long an implied
warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
All implied warranties, if any, are limited to the duration of this express warranty. This warranty gives you legal rights, and you
may have other rights which may vary from State to State.

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
Page A-27
Page A-28
MMC-163 Rev.C 10/04
ZF Marine Electronics, LLC
Mukilteo Plant
Warranty Registration
Processor, Serial # Serial #
Number of Remote Stations
Purchase Date
Dealer's Name
Installer's Name
Phone Number ( )
Cell Number ( )
Fax Number ( )
E-Mail Address
Purchaser's Name
Street Address
City, State, Zip
Phone Number ( )
YOUR VESSEL:
Engine, Make & Model
Length
Manufacturer
ZF Marine Electronics, LLC. Product First Seen At:
Boat Show Dealer Magazine Friend

ZF MARINE ELECTRONICS, L.L.C. Mukilteo, Washington

12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Telefax (425) 493-1569
Page A-29
ZF Marine Electronics, LLC.
12125 Harbour Reach Drive, Suite B
Mukilteo, WA 98275

Page A-30
APPENDIX B
TROUBLESHOOTING
B1 TROUBLESHOOTING GENERAL
The ClearCommand Control System consists of one Processor per engine, typically
mounted in the engine room, and one to five Control Heads located at the vessel’s
Remote Stations. In the event that a malfunction occurs, review the appropriate
System Diagram and become familiar with the various components, their functions
and locations on the vessel. Section B1-2, page B1-1, is a list of the main components
that make up a typical system, along with a brief description of their functions:
B1-1 Control System Examples
B1-1.1 96202 (Throttle Electronic, Clutch Solenoid, Two Station) Processor
The 96202 is designed to precisely control speed and direction on vessels
equipped with electronic Throttle and solenoid Clutch selection.
B1-2 Typical System Main Components
B1-2.1 Control Head
The primary function of the Control Head is to send out a variable DC
voltage to the Processor. This DC voltage is representative of the Control
Head’s present lever position. In addition to the primary function, the
Control Head also has audible (Sound Transducer) and visual (LED) status
indications, along with a Transfer Button for taking command and
performing other system functions.
B1-2.2 Processor
The Processor receives the variable DC voltage from the Control Head(s) and
converts these inputs to the appropriate electronic or electric outputs at the
correct time and sequence to the Governor and Gear Box. The information
regarding throttle type, throttle/ clutch sequencing, etc., are all stored on
memory within the Processor.
B1-2.3 Power Source
All electronic equipment must have power in order to operate. Ensuring a
properly charged reliable power source is available is. The Processor
requires a 12 or 24 VDC power system. The minimum voltage at which the
Processor will continue to operate is 8.00 VDC. The maximum allowable
voltage is 30 VDC. Exceeding these limits will not damage the Processor, but
will render it unusable temporarily. The power supply must be capable of
delivering 10 amperes to each Processor on a continual basis and current
surges up to 20 amperes. All cable calculations should be based on a 10
ampere draw with no more than 10% voltage drop.
B1-2.4 Electrical Cables and Harnesses
The function of the Electrical Cables and Harnesses are to move electrical
information from one point to another. The ZF Marine Electronics’ System
has electrical cables and/or pluggable Harnesses. These Harnesses may have
plugs on one end or both, depending on its purpose. There are Harnesses
available for Control Head Interface, DC Power, Start Interlock, Clutch Oil
Pressure Interlock and External System Status Indication Circuit.
In addition, the application may require Harnesses for one or more of the
following:
• Engine Interface
• Shift Interface
• Serial Communication
• Tachometer Sensor Signal
Prior to attempting to troubleshoot the System, get as much information as possible
from the owner or operator. Inspect the System for signs of misadjustments, loose
connections, physical damage or water incursion. Pay special attention to the
following items:
• DC Power Source
• Component Location
• Component Condition
• Interconnecting Wiring and Harnesses
• Wire Terminations
• Plug and Socket Pins
Page B1-1
TROUBLESHOOTING
B2 TROUBLESHOOTING QUESTIONS
Prior to lifting a tool or stepping on board the vessel, many problems can be
resolved by asking the customer the following basic questions:
A) Is the System installed on a Single, Twin or Multiple Screw vessel?
• If the System is installed on a Single Screw vessel, this question
does not have much value in narrowing down the source of the
problem.
• If the System is installed on a Twin or more Screw application,
this question is quite useful, if you ask the following question.
1. Does the problem or symptom occur on the Port, Starboard
or both sides?
• If the problem or symptom occurs on one side only, you have
effectively eliminated 50% of the possible causes. For example,
the symptom only occurs on the Port side. All of the
components on the Starboard side have been eliminated as
potential causes.
B) What is the Part Number and Serial Number of the Processor?
Whenever the factory is called for technical assistance, the part number
and serial number will be required. These numbers provide the Service
Technician information about the operating characteristics of the
Processor. The numbers are located on the Processor’s front cover.
C) How many Remote Stations are there?
• If only one Remote Station is present, not much will be gained by
asking this question. However, if more than one Remote Station is
being used, command should be taken from one of the other
Stations to see if the problem occurs from another Station.
• If the problem occurs from more than one Remote Station, the
odds are that the Control Heads are not the cause of the trouble.
• If the problem occurs at one Remote Station only, there is a greater
chance of the Control Head or the Control Head Harness of being
the cause.
D) Are any tones generated when the problem occurs?
The tones are used to bring the operator’s attention to a possible condition
or problem.
The following basic tones can be produced on all Systems:
Slow Repetitive Tone (Refer to Section B5-1.1, page B5-1)
One Long- Three Short Tones (Refer to Section B5-1.2, page B5-2)
Steady Tone (Refer to Section B5-1.3, page B5-3)
Three Second Steady Tone (Refer to Section B5-1.4, page B5-4)
Five Seconds On, Five Seconds Off - High Repetitive Rate Tone
(Refer to Section B5-1.6, page B5-4)
Five Second Steady Tone (Refer to Section B5-1.7, page B5-4).
The following tone can be produced on all Systems using Solenoid
Clutches:
One Long - One Short Tone (Refer to Section B5-3.1, page B5-6)
E) Are there any Error Messages displayed on the Processor’s Display
LED?
In addition to generating a tone, at any time the system detects a
malfunction or fault, an error message will be displayed at the Processor.
Refer to Table B8-1:, Basic Control System Error Codes, for an explanation
of the errors.
F) What is the status of the Control Head in command’s red LED?
The red LED(s) will be in one of the following states:
Lit Steady
When the red LED is Lit Steady, this indicates that the Station is in
command and in Normal operative mode.
Not Lit
When the red LED is Not Lit, that Station is not in command, or
there is no power to the Control System.

Page B2-1
TROUBLESHOOTING
Blinking Slowly
A Slow Blinking red LED indicates that the Control Head is in
Throttle Only Mode (Warm-up Mode).
Blinking Rapidly
A red LED that is Blinking Rapidly indicates that the System is in
Troll Mode.
G) Has anything on the vessel changed shortly prior to or when the
problem arose?
This question is often overlooked, but should be considered. Obvious
changes such as additions or changes to the electrical/ electronic
equipment onboard can affect the electrical load and in turn the
Processor’s power supply.
Ask the operator if any changes or maintenance to the vessel’s machinery
have occurred lately. Items which are significant to you, the technician,
may not seem so to the casual owner or operator. An example would be
changes to the engine’s fuel system.
Ask about changes, that when initially considered, appear to have nothing
to do with the Control System. An example where this really occurred was
on a vessel which had recently been repainted. For unknown reasons, the
painter took it upon himself to disconnect the connections at a Control
Head and then reconnected it incorrectly.
In many cases, these simple questions can resolve a problem with no further
action from you, the technician. Take the time to consider these questions. In
the long run, you will save yourself and the customer a lot of time and money.

Page B2-2
TROUBLESHOOTING
B3 TROUBLESHOOTING PROBLEM RESOLUTION
If the problem could not be resolved by asking the questions in the previous section,
a careful inspection of the Control System may be the next step. Even in situations
where the problem was found and corrected, it is good practice to always perform a
careful inspection of the entire Control System each and every time you are asked
aboard a boat. Always verify that the installation of the System is in compliance with
the Installation Manual by carefully inspecting the following:
B3-1 DC Power
A) Ensure that the Processor(s) is connected to a properly charged 12 or 24
VDC battery through a 10 Ampere circuit breaker.
B) To ensure reliable power to the Processors an APS (Automatic Power
Selector) is strongly recommended. The APS take inputs from two separate
power sources. Whichever power source is at the higher voltage level, will
be automatically switched through. Refer to Automatic Power Selector
information in Appendix A.
B3-2 Component Location
B3-2.1 Control Heads
There are virtually no restrictions regarding the location of the 400 Series
and MC2000 Series Control Heads, as long as the bottom is protected from
the environment. The 500 Series Control Heads must be mounted to a
console and the 700 Series are waterproof from top to bottom.
Refer to Appendix A - Control Head Reference Sheet for Installation
requirements.
B3-2.2 Processors
The Processors are typically mounted in the engine room, while maintaining
a minimum distance of 4 feet (1,22m) from sources of high heat and EMI
(Electro Magnetic Interference) or RFI (Radio Frequency Interference).
Refer to Plan the Installation Section for requirements.
B3-3 Component Condition
B3-3.1 Control Heads
Inspect for any signs of corrosion due to water incursion. If hard-wired,
ensure that all the fork connectors are properly secured to the terminal.
Verify all wires are fully crimped and do not pull loose.
B3-3.2 Processors
Inspect the Processor for any signs of physical damage.
B3-4 Interconnecting Wiring and Harnesses
A) Inspect the wire terminations for loose connections, corrosion or wire strands.
B) Inspect the Harness’s pins and sockets for bent pins, torn boots or any signs of
corrosion.
The first step in troubleshooting a problem with the Propulsion System is to
determine if the problem is with the Control System or something external to
the System. In all cases a Control System malfunction will alert the operator
of the potential problem. This is accomplished through the audible tone
emitted at all Remote Stations. When an audible tone is emitted, it will be
accompanied by an Error Message at the Processor. Also, in many cases, the
Control System will alert the operator to a problem external to the Control
System. The following are examples of components both internal and external
to the Control System which could be a source of trouble:
Table B3-1: Examples of Components (Internal/External)
Internal External
1) Processor 1) DC Power Source
2) Control Head 2) Engine
3) Interconnecting Wiring (Harnesses) 3) Transmission
The following pages should give you a good guideline for making this determination.
There is no need to troubleshoot the system to any point further than one of the main
components listed above. If the fault is found to be with a Control System
component, that component is simply replaced. If the fault is found to be with one of
the external components, replace or repair the defective component or contact a
qualified mechanic.
Page B3-1
TROUBLESHOOTING
B4 TROUBLESHOOTING DIAGNOSTIC MENU
The Processor has built in diagnostics designed to assist the technician in
determining the cause of a problem. The following information is available to
view at any time:
• Applied Battery Voltage
• Tachometer Sender Frequency
• Stations 1- 5 A/D’s
• Stations 1- 5 Transfer Button Status
• Servo 2 Feedback A/D’s (if applicable)
• Servo 1 Feedback A/D’s (if applicable)
• Software Revision Level
In order to access this information, follow the steps below:
A) Locate the Display LED on the Port or Starboard Processor.
The Display LED will have the Processor Part Number
displayed in a running pattern moving from left to right while
the program is running in Normal Operation.
Figure B4-1: Display Function B) Depress the Up or Down Push Button to activate the Function
Code List
Code List. The characters A001 will be shown on the Display
like Figure B4-1:
C) Depress the Up or Down Push Button repeatedly until H000 is
displayed like Figure B4-2:.
D) Depress and hold the Left and Right Push Buttons
Figure B4-2: Display simultaneously until the H0 begins to blink. (Figure B4-3:)
Troubleshooting Function
Release the Push Buttons; the applied battery voltage will
Function Code is Blinking now be displayed:
• The displayed value is in “real time” and provides a rough
estimate of the DC voltage applied to the Processor. The
reading is accurate to within 0.50 DC. Refer to Figure B4-4:
Figure B4-3: Display E) In addition to the applied battery voltage, scrolling through
Troubleshooting Function Blinking the Diagnostics Menu by pressing the Up or Down Push
Button can also show the Tachometer Sender Frequency
(Figure B4-5:):
• The information shown is the actual frequency outputted
by the Tachometer Sender. This signal is utilized in “Closed
Figure B4-4: Example Display of Loop” Synchronization or “Closed Loop” Troll (future)
Applied Battery Voltage
systems
• The Control Head’s lever position, and the resulting outputs
of Stations # 1, 2, 3, 4, and 5’s Control Heads can always be
monitored. This is regardless of whether that Station is in
Figure B4-5: Example Display of command or not. Note the placement of the decimal points
Tach Sensor Frequency in the examples below, which show all five Stations with
the lever positioned at the Neutral/Idle position. This will
be covered in further detail later.
Station #1 Station #2 Station #3 Station #4 Station # 5
Lever A/D Count Lever A/D Count Lever A/D Count Lever A/D Count Lever A/D Count

Figure B4-6: Example Display Control Head Lever Current Positions

F) The current status of all the Control Head’s Transfer Buttons can be
monitored within the Diagnostic Menu. A 1 indicates a closure (depressed
Transfer Button) of the switch, while a 0 indicates an open switch.
Station #1 Station #2 Station #3 Station #4 Station # 5
Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed Transfer Button Depressed

Figure B4-7: Example Display Control Head Transfer Button Status View
Page B4-1
TROUBLESHOOTING
G) Depressing the Up or Down Push Button one more time will show the
current revision level of the software. This feature will provide invaluable
information in the years to come. Determining the characteristics or
capabilities of a certain Processor will be as simple as selecting this feature.

Figure B4-8: Example Display Software Revision Level View

H) Pressing the Up or Down (Scroll) Push Button once more, returns you to the
Applied Battery Voltage. (Figure B4-4:)
I) The Diagnostic Menu can be exited two ways:
• Do not touch any Push Buttons for 5 minutes. The system will
automatically exit.
• Depress the Left Push Button until H000 appears. You may now scroll
through the Set Up Menu.

Page B4-2
TROUBLESHOOTING
B5 TROUBLESHOOTING AUDIBLE TONES
As mentioned previously, there are various tones emitted from the Control
Head if an error were to occur.
B5-1 Basic Control System Tones
These basic tones are as follows:
B5-1.1 Slow Repetitive Tone

Figure B5-1: Slow Repetitive Tone

The Slow Repetitive Tone, also referred to as the “Initialization Tone”
is the tone you hear at all Remote Stations when power is initially
applied to the control system. When this tone is heard, you know for a
fact that the following are true:
• Power has just been applied to the system.
• The Software Program is running normally.
• The Processor is commanding the throttle to Idle.
• The Processor is commanding the clutch to Neutral.
This is a normal tone when power has first been applied to the
Processor and no Control Head has taken command. However, the
tone may also be an indication of a problem, if during normal
operation the engine’s throttle drops to Idle, followed by the clutch to
Neutral, the Control Head’s red LED goes out and a slow repetitive
tone is heard at all remote stations. This indicates that the voltage at
the Processor has momentarily dropped below 8 VDC and then
returned to a normal operational level. This could be due to:
• Loose battery power cable connection.
• Under-charged or defective battery.
• Voltage drop due to current flow.
In order to pinpoint the exact cause of the low voltage at the Processor,
perform the following checks:
A) Check the Display on the Processor for Error Messages. Error
Message 57 may appear indicating Under Voltage. One or
more of Error Messages 43 through 54 may also be displayed.
This is due to the momentary loss of serial communication
between the two Processors. Take note that the Under Voltage
error is not only dependent on low voltage, it is also dependent
on the duration of the low voltage. The possibility exists that
an error message would not be displayed if the duration of the
low voltage was short enough. However, the other symptoms
mentioned above still occur.
B) In either case, follow the procedure listed under Diagnostic
Menu (Section B4) until the Applied Battery Voltage is
displayed. Take note of the applied voltage.
C) Go to the battery or Main Distribution Panel which is feeding
power to the Processor. With a DC Voltmeter, measure the
voltage at this power source. The battery voltage should be
greater than 12.4 Volts in 12 VDC systems and 24.8 Volts in 24
VDC systems. If not, the battery or it’s charging system needs
servicing.
D) The voltage differential between the power source and the
Processor should not exceed 1.2 Volts in 12 VDC systems and
2.4 Volts in 24 VDC systems. If so, there is high resistance
somewhere between the battery and Processor.
NOTE: If an APS is being utilized in the power circuit, take into account the 0.7 VDC forward
voltage drop of the diodes. This would increase the permissible differential between power
source and Processor from 1.2 to 1.9 VDC in 12 VDC circuits and 2.4 to 3.1 VDC in 24 VDC
circuits.
E) High resistance, resulting in a differential voltage of 1.2 Volts
(12 VDC Systems) or 2.4 Volts (24 VDC Systems) or greater,
may be the result of corroded or tarnished connections, dirty
or pitted relay contacts or an improperly sized power cable.
Page B5-1
TROUBLESHOOTING
F) If the voltage differential is less than 1.2 Volts (12 VDC
Systems) or 2.4 Volts (24 VDC Systems), which is what you
would typically expect, a loose connection may exist between
the power source and the Processor. The vibration
experienced while the vessel is underway may intermittently
cause the circuit to open. Check all the connections between
the power source and the Processor for a loose bolts, nuts, etc.
B5-1.2 One Long - Three Short Tones

Figure B5-2: One Long - Three Short Tones

This tone indicates that there is an invalid command signal at the
Station-in-Command.
The Processor expects a DC voltage, representative of the Control
Head’s present lever position. This voltage is referred to as the
“Command Signal”. In normally functioning Control Heads, the
command signal is between approximately 0.8VDC at Full Astern to
4.10 VDC at Full Ahead.
The command signal is converted by the Processor to a digital
representation, referred to as an A/D Count. More on A/D Counts
later. If the command signal drops below 0.6VDC or exceeds 4.40
VDC, the tone will be generated.
At the same time the tone is heard, throttle command drops to Idle and
the clutch will be commanded to Neutral. The following items will
cause this to occur:
• An open or high resistance connection between the Control
Head and Processor.
• Out of calibration Control Head.
• A defective Control Head.
• A defective A/D Converter in the Processor.
The exact cause of the malfunction can be found as follows:
A) Check the Processor’s Display for error messages. Most likely,
one of error messages 13 thru 32 will be shown. The exact
number shown depends on which remote station is
experiencing the problem and whether the command signal
was too high or too low.
B) Enter the Diagnostic Menu as outlined in Section B4
C) Depress the Up or Down (Scroll) Push Button until the
appropriate Remote Station is displayed.
• The Remote Station are identified by the position of the
decimal points.
• Station 1 has no decimal point after the first digit to the far
right. The remaining three digits all have decimal points.
• If the digit to the far left had no decimal point following it,
but the remaining three do, this would represent Station 4.
Station 1 Station 2 Station 3 Station 4 Station 5

Figure B5-3: Display Examples of Remote Stations

D) The examples in Figure B5-3: are shown with no Control Heads
connected to any Remote Stations. When a Control Head is
connected, the appropriate A/D (Analog/Digital) value for the
present position of the Control Head’s lever will be shown, as
in the examples below:
Station 1 Station 2 Station 3 Station 4 Station 5
(Neutral Commanded) (Full Ahead Commanded) (Full Astern Commanded) (No Control Head Connected) (Neutral Commanded)

Figure B5-4: Display Examples of Remote Stations A/D Value

Page B5-2
TROUBLESHOOTING
E) An A/D value of 910 or greater will generate an Error Code.
The code will be 13 to 22 (Control Head # Faulted High),
depending on which Station has the high Command Signal.
• If the A/D value is greater than 910, but less than 990, one of
the following may be the cause:
1. The Control Head’s potentiometer is out of calibration.
2. The potentiometer is defective.
In either case, it is recommended that the Control Head is
replaced.
• If the A/D value is 995 or higher, most likely the
potentiometer’s ground has been lost.
• Right hand Control Heads have a jumper between pins 3 and
5 if a Harness is used. This jumper provides the
potentiometers ground.
• Left hand Control heads have a jumper between pins 3 and 7
is a Harness is used. This jumper provides the
potentiometers ground.
• The potentiometer ground connection for Control Heads
which are hard-wired to the Processor is through the yellow
wire (pin 5 on right hand and pin 7 on left hand).
F) If the A/D value is 100 or less, one of Error Codes 23- 32
(Control Head # Faulted Low) will be shown.
• If the A/D value is less than 100, but greater than 75, the
following may be the cause:
1. The Control Head’s potentiometer is out of calibration.
2. The potentiometer is defective.
3. A high resistance connection exists on pin 6 (green wire)
between the Control Head and Processor.
• If the A/D value is less than 75:
1. There is an open wire between pin 6 (green wire) of the
Control Head and the Processor.
2. There is an open wire between pin 7 (blue wire) of a right
hand Control Head and the Processor.
3. There is an open wire between pin 5 (blue wire) of a left
hand Control Head and pin 7 (blue wire) of the Processor.
B5-1.3 Steady Tone

Figure B5-5: Steady Tone

The Steady Tone is an indication to the operator that something has
gone wrong within the Control System. The Steady Tone will typically
be accompanied by an Error Message on the Processor’s Display. If the
tone is heard, the Processor’s Display must be referred to in order to
further diagnosis the problem.
The Transfer Button is shorted - Tone will cease when command is
taken at another Station.
If the Transfer Button becomes shorted for 12 seconds or more during
Normal Operation, a steady tone will be produced at all Remote
Stations as long as the Transfer Button remains shorted. Full System
control remains. Transferring to another Remote Station silences the
Steady Tone. Command cannot be regained at the Station until the
problem is rectified.
B5-1.4 Three Second Steady Tone

Figure B5-6: Three Second Tone

This tone could indicate one of three things:
• Transfer Button on the Control Head in command is stuck.
• If the Processor for this System includes the use of Back-up
Mode, this tone would indicate that there has been a switch
closure requesting Back-up Mode.
Page B5-3
TROUBLESHOOTING
• If the Processor for this System includes Integrated Solenoid
Trolling Valve control, this tone would indicate that there has
been a Troll Solenoid error. Refer to the Error Code
displayed.
B5-1.5 Three Second Steady Tone, followed by a Slow Repetitive Tone

Figure B5-7: Three Second Tone, followed by a Slow Repetitive Tone

This tone indicates that there has been a shorted Transfer Button on
power-up. Command can be gained at any other Remote Station,
which silences the Slow Repetitive Tone.
B5-1.6 Five Seconds On, Five Seconds Off - High Repetitive Rate Tone

Figure B5-8: Five Seconds On, Five Seconds Off - High Repetitive Rate Tone
Loss of communication with Station Expander (SE) or the Troll
Actuator (p/n 9001). This tone cannot be cleared unless all Error
Codes (Active and In-Active) have been cleared.
B5-1.7 Five Second Steady Tone

Figure B5-9: Five Second Steady Tone

Loss of Serial Communication.
B5-2 Clutch Solenoid Control System Tones
B5-2.1 One Long - One Short Tone

Figure B5-10: One Long - One Short Tone

This tone can be produced if solenoid monitoring is turned ON with
Function Code H2.
When this tone is sounded this tone will also be accompanied by one
of the following error codes:
1 - Clutch Astern Shorted
2 - Clutch Astern Open
5 - Clutch Ahead Shorted
6 - Clutch Ahead Open

Page B5-4
TROUBLESHOOTING
B6 TROUBLESHOOTING STATION TRANSFER
In order to transfer command from one Remote Station to another, the
following must occur:
• There must be a valid “Command Signal” at the Station being
transferred to.
• The “Command Signal” must indicate that the Control Head’s lever(s)
is at the Neutral/Idle position.
• The Transfer Button must be depressed which takes the “Station
Select” signal from 5.00 VDC to 0.00 VDC.
If a transfer from one Remote Station to another is requested, but does not take
place; the items required for successful transfer can be tested as follows:
B6-1 Command Signal
The Command Signal is a DC voltage which varies in relationship to the
Control Head’s lever position.
The Processor provides each Control Head 5.00 +/- 0.20VDC, which is
referred to as the “Reference Voltage”.
The Reference Voltage is applied to a 5K Ohm Potentiometer in the
Control Head.
The potentiometer’s “Wiper” taps off a portion of the Reference Voltage
and sends it back to the Processor.
The amount of DC voltage which is tapped off, is dependant on the
position of the Control Head’s lever.
When the lever is fully Astern, a small portion of the Reference Voltage is
tapped off by the wiper, and therefore, the voltage is at its
lowest point (approximately 0.80 VDC).
When the lever is positioned fully Ahead, a larger portion is tapped off and
the voltage is at its highest point (approximately 4.10 VDC).
B6-2 A to D Counts
Since all the calculations within the control system are performed
digitally, these DC voltages are expressed as and converted to a digital
representation.
• The “Reference Voltage” (approximately 5.00 VDC) by which all
analog inputs are based, is represented as 1023 A/D (Analog to
Digital) Counts.
• This allows for the possibility of a 1024 possible positions when 0 is
included in the count.
• The value of the Command Voltage with the lever at the Neutral/
Idle position is 49- 51% of the Reference Voltage when measured at
the Station terminal block. The actual value read by the Processor
is 2% below that value or 47% to 49% of 1023 A/D Counts (485- 505
A/D).
NOTE: The A/D values listed for Full Ahead and Full Astern represent the point where maximum
throttle is reached. The A/D count when the Control Head lever is physically at it’s maximum
point will be higher, but may not exceed the out-of-range values listed in Table B6-1:, page B6-2.

• The Command Signal at Full Ahead is 82- 84% of the Reference

Voltage when measured at the Station terminal block. The actual
value read by the Processor is 2% below that value or 80- 82% of
1023 A/D Counts (821- 841 A/D).
• The Command Signal at Full Astern is 17 - 19% of the Reference
Voltage when measured at the Station terminal block. The actual
value read by the Processor is 2% below that value or 15- 17% of
1023 A/D Counts (153- 173 A/D).
• Since the Command Signal is based on a percentage of the
Reference Voltage, the distance of the Control Head from the
Processor has no impact on the performance of the system.
Page B6-1
TROUBLESHOOTING
• The amount of voltage drop, due to current flow, is the same for
both the Reference and Command Voltages.
• The relationship between the Reference and Command Voltages
when thought of as a percentage, will remain the same regardless
of distance. For instance, here are two examples.
Example 1
Reference Voltage 5.00 VDC 1023 A/D Counts
Command Voltage 2.45 VDC 501 A/D Counts
Example 2
Reference Voltage 4.80 VDC 1023 A/D Counts
Command Voltage 2.35 VDC 501 A/D Counts
As you can see by the examples, even though the Command Voltages are
different between Examples 1 and 2, the resulting A/D counts, are the
same because of the different Reference Voltages. This would result in the
Processor commanding the identical outputs (Clutch & Throttle) in both
cases.
A) The A/D count for a specific Control Head’s lever can be seen on
the Processor’s Display by following the steps outlined in
Section B4.
B) Once the appropriate remote station is reached, ensure that the
displayed A/D Count represents the Neutral/Idle position (485- 505
A/D counts). Command will not be accepted unless the Control
Head’s lever is at the Neutral/Idle position.
The following table shows the appropriate A/D Counts for various Control
Head lever positions:
Table B6-1: Control Head Lever A/D Counts
Control Head Lever Position A/D Count
Lever Out of Range Low 100
Full Astern 153 - 173
Neutral/ Idle 485 - 505
Ahead Shift Point 537
Full Ahead 821 - 841
Lever Out of Range High 910
B6-3 Remote Station Select
The second required item for taking command is “Station Select” or
depressing of the Transfer Button. The Transfer Button can be tested by
entering the Diagnostic Menu H0.
A) Depress the Up or Down (scroll) Push Button until
four zeroes are displayed without decimal points as
shown in Figure B6-1:.
Figure B6-1: Display Station A/D’s No Station B) For Stations 1 - 4 when the Transfer Button is
Transfer Button Depressed
depressed, the 0 which represents that remote
station, will change to a 1 as shown in Figure B6-2:.
For Station 5 when the Transfer Button is
depressed, all four decimal points will light as
Figure B6-2: Example Display Station A/D’s shown in Figure B6-3:
Transfer Button Depressed for Stations 1 - 4 • Whenever command cannot be gained at a
particular remote station, the Station Select and
Command Signals are the first to be investigated.
If either the Command Signal is out of range or
Figure B6-3: Display Station A/D/s Transfer Button
the Station Select is inoperable, command will
Depressed for Station 5 not be accepted at that remote station.

Page B6-2
TROUBLESHOOTING - STATION TRANSFER
B5 TROUBLESHOOTING STUCK TRANSFER BUTTON
The Transfer Button is a normally open, momentary switch. The only time the
switch should close is when it is depressed to take command or when entering
or departing various other functions. In the event that the Transfer Button
became stuck in the closed position, the following will occur:
• The Transfer Button would have to be closed for 15 seconds or more.
• The throttle and clutch are not affected.
• A solid tone is heard from all remote stations, until the button’s contact
opens or transfer to another remote station has taken place.
If a Control Head that is not in command has a stuck transfer button, the
following will happen:
• If Control Head levers are positioned at Neutral/Idle, a solid tone is
heard from all remote stations.
• If Control Head levers are positioned other than Neutral/Idle, a three
(3) second tone is heard from all remote stations.
• Error Code 33 - 42, depending on which remote station, will be shown
on the Processor Display.
• Command can be taken at any other operational remote station.
• After one (1) second command can be regained at the remote station
with the stuck button as long as the problem has been corrected by
depressing the transfer button.
If a stuck Transfer Button is suspected, this can be verified by looking at the
Station Select status (1 or 0) as outlined in Section B6-3, page B6-2.
• An Error Code 33 - 42 will be shown on the Display, depending on
which Station is experiencing the problem.

Page B5-1
TROUBLESHOOTING
B8 ERROR CODES
As stated previously, if a problem with the Control System is detected, the
Processor is programmed to display numerous Error Codes to aid in the
isolation of the cause. The following tables list these Error Codes, along with a
brief description.
B8-1 Basic Control System Error Codes
Table B8-1: Basic Control System Error Codes
Error Title Description
No.
13 Station No.1 Station No.1 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
14 Station No.2 Station No.2 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
15 Station No.3 Station No.3 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
16 Station No.4 Station No.4 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
17 Station No.5 Station No.5 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
18 Station No.6 Station No.6 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
19 Station No.7 Station No.7 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
20 Station No.8 Station No.8 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
21 Station No.9 Station No.9 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
22 Station No.10 Station No.10 Control Head’s lever position is out of range.
Faulted High The input appears to be too high.
23 Station No.1 Station No.1 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
24 Station No.2 Station No.2 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
25 Station No.3 Station No.3 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
26 Station No.4 Station No.4 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
27 Station No.5 Station No.5 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
28 Station No.6 Station No.6 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
29 Station No.7 Station No.7 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
30 Station No.8 Station No.8 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
31 Station No.9 Station No.9 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
32 Station No.10 Station No.10 Control Head’s lever position is out of range.
Faulted Low The input appears to be too low.
33 Station No.1 Station No.1 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
34 Station No.2 Station No.2 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
35 Station No.3 Station No.3 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
36 Station No.4 Station No.4 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
37 Station No.5 Station No.5 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
38 Station No.6 Station No.6 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.

Page B8-1
TROUBLESHOOTING
Table B8-1: Basic Control System Error Codes
Error
Title Description
No.
39 Station No.7 Station No.7 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
40 Station No.8 Station No.8 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
41 Station No.9 Station No.9 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
42 Station No.10 Station No.10 Control Head’s Transfer Button has either been closed too long or
Button Stuck Closed has been closed since power-up.
43 CAN Communication The Control-Area-Network protocol has detected an error in communication
Stuffing Error with other devices on the network. The error type is a stuffing error.
44 CAN Communication The Control-Area-Network protocol has detected an error in communication
Form Error with other devices on the network. The error type is a form error.
45 CAN Communication The Control-Area-Network protocol has detected an error in communication
Acknowledge Error with other devices on the network. The error type is an acknowledge error.
46 CAN Communication The Control-Area-Network protocol has detected an error in communication
Bit 1 Error with other devices on the network. The error type is a Bit 1 error.
47 CAN Communication The Control-Area-Network protocol has detected an error in communication
Bit 0 Error with other devices on the network. The error type is a Bit 0 error.
48 CAN Communication The Control-Area-Network protocol has detected an error in communication
CRC Error with other devices on the network. The error type is a CRC error.
49 CAN Communication The Control-Area-Network protocol has detected an error in communication
Bus Error with other devices on the network. The error type is a Bus failure error. The
error cannot be recovered from without cycling power to the Processor.
50 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.
System 1
51 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.
System 2
52 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.
System 3
53 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.
System 4
54 Comm. Error Time-out Communication with System 1 has been too long without a Refresh message.
System 5
55 SE Communication Error Communication with the Station Expander has been too long without a Refresh
message.
56 High Battery Voltage Fault The applied battery voltage is 30VDC or higher for at least two seconds.
57 Low Battery Voltage Fault The applied battery voltage is 10VDC or lower for at least two seconds.
58 Reset Due to Software The system has had an unexpected Reset, due to a software/ hardware fault.
Watchdog
59 Reset Due to Software Fault The system has had an unexpected Reset, due to a software fault.
60 Reset Due to Hardware The system has had an unexpected Reset, due to a software/ hardware fault.
Watchdog
61 Oscillator Watchdog The system’s Oscillator has had an unexpected fault.

B8-1 Clutch Solenoid Error Codes

Table B8-2: Clutch Solenoid Control System Error Codes
Error Title Description
No.
1 Clutch Astern Shorted The Astern Clutch Solenoid is requiring more current than expected.
2 Clutch Astern Open The Astern Clutch Solenoid should be drawing current but is not.
3 Clutch Neutral Shorted The Neutral Clutch Solenoid is requiring more current than expected.
4 Clutch Neutral Open The Neutral Clutch Solenoid should be drawing current but is not.
5 Clutch Ahead Shorted The Ahead Clutch Solenoid is requiring more current than expected.
6 Clutch Ahead Open The Ahead Clutch Solenoid should be drawing current but is not.

Page B8-2
TROUBLESHOOTING
B9 BASIC PROBLEM CAUSES AND SOLUTIONS
The following table lists the various Error Codes and provides possible causes
and solutions. Error Codes appearing on the Port side Processor’s Display LED
are port side errors and vice versa. The Causes and Solutions provided are the
most likely, but are not the only possible causes for the Errors Codes listed.
B9-1 Basic Control System Problem Causes and Solutions
Table B9-1: Basic Control System Problem Causes and Solutions
Error
No. Causes Solutions

13 a. Station No.1 Control Head is defective. a. Replace Station No.1 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
14 a. The Station No.2 Control Head is defective. a. Replace Station No.2 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
15 a. The Station No.3 Control Head is defective. a. Replace Station No.3 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
16 a. The Station No.4 Control Head is defective. a. Replace Station No.4 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
17 a. The Station No.5 Control Head is defective. a. Replace Station No.5 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
18 a. The Station No.6 Control Head is defective. a. Replace Station No.6 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
19 a. The Station No.7 Control Head is defective. a. Replace Station No.7 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
20 a. The Station No.8 Control Head is defective. a. Replace Station No.8 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
21 a. The Station No.9 Control Head is defective. a. Replace Station No.9 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
22 a. The Station No.10 Control Head is defective. a. Replace Station No.10 Control Head.
b. No continuity between pin 5’s of the Control Head Harness b. Ensure that the red conductor is properly crimped to pin 5 at
connectors. both connectors.
c. Control Head jumper (pin 3 to 5 or 7) is missing. c. Install a jumper from pin 3 to 5 on right hand and 3 to 7 on
left hand Control Heads.
23 a. The Station No.1 Control Head is defective. a. Replace Station No.1 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.

Page B9-1
TROUBLESHOOTING
Table B9-1: Basic Control System Problem Causes and Solutions
Error
Causes Solutions
No.
24 a. The Station No.2 Control Head is defective. a. Replace Station No.2 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
25 a. The Station No.3 Control Head is defective. a. Replace Station No.3 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
26 a. The Station No.4 Control Head is defective. a. Replace Station No.4 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
27 a. The Station No.5 Control Head is defective. a. Replace Station No.5 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
28 a. The Station No.6 Control Head is defective. a. Replace Station No.6 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
29 a. The Station No.7 Control Head is defective. a. Replace Station No.7 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
30 a. The Station No.8 Control Head is defective. a. Replace Station No.8 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
31 a. The Station No.9 Control Head is defective. a. Replace Station No.9 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
32 a. The Station No.10 Control Head is defective. a. Replace Station No.10 Control Head.
b. No continuity between pin 6’s of the Control Head Harness b. Ensure that the green conductor is properly crimped to pin 6
connectors. at both connectors and there is continuity.
c. No continuity between pin 7’s of the Control Head Harness c. Ensure that the blue conductor is properly crimped to pin 7
connectors. at both connectors and there is continuity.
33 a. The Station No.1 transfer button was held down for 15 a. Clear the Error Code from memory
seconds or longer
b. The Station No.1 Control Head transfer button is defective b. Replace the Control Head
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. In addition, ensure that the red conductor is
crimped to pin 5 of the connector and connected to pin 3 of
the Control Head’s terminal block.
34 a. The Station No.2 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.2 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.

Page B9-2
TROUBLESHOOTING
Table B9-1: Basic Control System Problem Causes and Solutions
Error
Causes Solutions
No.
35 a. The Station No.3 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.3 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
36 a. The Station No.4 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.4 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
37 a. The Station No.5 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.5 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
38 a. The Station No.6 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.6 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
39 a. The Station No.7 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.7 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
40 a. The Station No.8 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.8 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.

Page B9-3
TROUBLESHOOTING
Table B9-1: Basic Control System Problem Causes and Solutions
Error
Causes Solutions
No.
41 a. The Station No.9 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.9 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
42 a. The Station No.10 transfer button was held down for 15 a. Clear the Error Code from memory.
seconds or longer.
b. The Station No.10 Control Head transfer button is defective. b. Replace the Control Head.
c. The Control Head Harness is miswired. c. Ensure that the orange conductor is crimped to pin 4 at both
ends and the red wire is crimped to pin 5 at both ends of the
Harness.
d The Control Head’s Pigtail is miswired. d Ensure that the orange conductor is crimped to pin 4 of the
. . connector and connected to pin 4 of the Control Head’s
terminal block. Ensure that the red conductor is crimped to
pin 5 of the connector and connected to pin 3 of the Control
Head’s terminal block.
43 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
44 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
45 a. The Serial Harness is not connected at one or more a. Ensure that the Serial Harness is properly seated at all
Processors. Processors.
b. The Serial Harness is incorrectly wired. b. Refer to the Serial Plug pin-out in Appendix B. Correct or
replace the Harness.
c. Loss of power to one of the Processors. c. Restore Power to the Processor.
46 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
47 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
48 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
49 a. The Serial Harness is in excess of 120 feet (37m). a. Reposition the Processor(s) so that the Serial Harness is less
than 120 feet (37m).
b. The Processor is defective. b. Replace the faulty Processor.
c. The Serial Harness’s shield is not properly terminated. c. Ensure that the shield is terminated and the termination is at
one side only.
50 a. The Serial Harness is not connected at Processor ID No.1. a. Connect the Serial Harness into Processor ID No.1.
b. None of the Processors has ID No. 1 selected. b. Identify one of the Processors as ID No.1 with the A0
function.
c. Loss of power to Processor ID No.1. c. Restore power to Processor ID No.1.
51 a. The Serial Harness is not connected at Processor ID No.2. a. Connect the Serial Harness into Processor ID No.2.
b. None of the Processors has ID No.2 selected. b. Identify one of the Processors as ID No.2 with the A0
function.
c. Loss of power to Processor ID No.2 c. Restore power to Processor ID No.2.

Page B9-4
TROUBLESHOOTING
Table B9-1: Basic Control System Problem Causes and Solutions
Error
Causes Solutions
No.
52 a. The Serial Harness is not connected at Processor ID No.3. a. Connect the Serial Harness into Processor ID No.3.
b. None of the Processors has ID No.3 selected. b. Identify one of the Processors as ID No.3 with the A0
function.
c. Loss of power to Processor ID No.3. c. Restore power to Processor ID No.3.
53 a. The Serial Harness is not connected at Processor ID No.4. a. Connect the Serial Harness into Processor ID No.4.
b. None of the Processors has ID No.4 selected. b. Identify one of the Processors as ID No.4 with the A0
function.
c. Loss of power to Processor ID No.4. c. Restore power to Processor ID No.4.
54 a. The Serial Harness is not connected at Processor ID No.5. a. Connect the Serial Harness into Processor ID No.5.
b. None of the Processors has ID No.5 selected. b. Identify one of the Processors as ID No.5 with the A0
function.
c. Loss of power to Processor ID No.5. c. Restore power to Processor ID No.5.
55 a. The Serial Harness is not connected to the SE. a. Connect the Serial Harness to the SE.
b. The Serial Harness is not connected to the Processor b. Connect the Serial Harness to the Processor reporting the
reporting the fault. fault.
c. No power to the SE. c. Turn power ‘On’ to the SE.
56 a. The battery is being overcharged. a. Repair or replace the charging system.
b. There’s a loose terminal on the battery while being charged. b. Clean and tighten the battery posts and terminals.
57 a. Battery will not take a charge and is defective. a. Replace the battery.
b. The battery is not being properly charged. b. Repair or replace the charging system.
c. There’s a high resistance connection between the battery c. Locate and repair the high resistance connection.
and the Processor.
58 a. External Interference, such as a lightning strike. a. If the error message is displayed once and you are able to
clear the error, take no further actions at this time.
If the error cannot be cleared, replace the Processor.
b. Component failure. b. Replace the Processor.
59 a. External Interference, such as a lightning strike. a. If the error message is displayed once and you are able to
clear the error, take no further actions at this time.
If the error cannot be cleared, replace the Processor.
b. Component failure. b. Replace the Processor.
60 a. External Interference, such as a lightning strike. a. If the error message is displayed once and you are able to
clear the error, take no further actions at this time.
If the error cannot be cleared, replace the Processor.
b. Component failure. b. Replace the Processor.
61 a. External Interference, such as a lightning strike. a. If the error message is displayed once and you are able to
clear the error, take no further actions at this time.
If the error cannot be cleared, replace the Processor.
b. Component failure. b. Replace the Processor.

Page B9-5
TROUBLESHOOTING
B10 PROBLEMS WITHOUT ERROR CODES
In addition to the Error Codes listed above, some problems may not necessarily
generate Error Codes. The following give some examples where the Processor
may not detect a fault, though the operation may not be perfect:
B10-1 Basic Control System Problems Without Error Codes
A) SYMPTOM: No audible tones heard at one Control Station when
power is first applied to the Processor. All other features function
normally.
Cause Remedy
a. Incorrectly wired Station Harness/ Cable a. Verify that the black wire is properly
or Pigtail. connected to pin 1 on the Control Head and
Pin 8 at the Processor.
b. The Control Head’s Sound Transducer is b. Measure the AC voltage at pins 1 & 3 of the
defective. Control Head. If 20- 25 VAC is present,
replace the Control Head.
B) SYMPTOM: The Control Head’s red LED doesn’t light when in
command, but otherwise functions properly.
Cause Remedy
a. Incorrectly wired Station Harness/ Cable a. Verify that the brown wire is properly
or Pigtail. connected to pin 2 on the Control head and
pin 2 at the Processor.
b. The Control Head’s red LED or circuit is b. Measure the DC voltage at pins 2 & 3 at the
open. Control. The measurement will be
approximately 2.20 VDC when the red LED is
lit. If 4.00 VDC is measured, the red LED or
its circuit is open. Replace the Control Head.
C) SYMPTOM: When power is turned ON to the Processor, there are no
tones from any of the Remote Stations, the Control Head red LED does
not light when the Transfer Button is pressed, and the Display is not lit
at the Processor.
Cause Remedy
a. No power to the Processor. a. Disconnect the Power Harness from the
Processor. Measure the DC voltage at pins 10
(+) and 11 (-) of the Harness plug. If 12 or 24
VDC is not present, check the circuit
breakers, switches and cables feeding power
to the Processor. Correct the power source
as required.
b. The battery’s polarity is reversed at the b. Disconnect the Power Harness from the
Processor. Processor. Connect a voltmeter’s red lead to
pin 10 and the black lead to pin 11 of the
Harness’s plug. If negative voltage is
measured, reverse the wires.
c. Defective Processor. c. If Causes a. and b. were not the fault, replace
the Processor.
D) SYMPTOM: The engine begins to turn-over while starting and then
stops. A slow repetitive tone is heard from all Remote Stations.
Cause Remedy
a. The voltage available at the Processor a. Supply power to the Processor from a battery
has dropped too low, due to the starter’s other that the starting battery or supply
current requirement power from two sources through an APS
(Automatic Power Selector)
b. Battery charge is too low b. Recharge/ replace the battery or supply
battery power from two sources through an
APS.
E) SYMPTOM: Active Synchronization is inoperable.

Page B10-1
TROUBLESHOOTING

Cause Remedy
a. There is no Tachometer Sensor signal at a. The Tachometer Sensor frequency can be
the Port or Starboard Processor. seen on the Processor’s Display by accessing
the Diagnostic Menu H0. If the frequency is
not measured, check the Tachometer Sensor
and the wiring.
b. Loss of Serial Communication between b. If Active Synchronization is inoperative due
the Processors. to a lack of Serial Communications, one or
more Error Codes will be displayed
indicating the loss of communication.
c. The Processor’s Identification number(s) c. All Processors must have a unique
have not been set properly. identification number as set with Function
Code A0. Refer to Section 5-5.0.1., page 5-7.
d. The correct number of engines has not d. All Processor must have the same number of
been set. engines selected as programmed with
Function Code A1. Refer to Section 5-5.0.2.,
page 5-7.

B10-2 Solenoid Clutch Control System Problems Without Error Codes

A) SYMPTOM: Cannot obtain Warm-up Mode while moving the Control
Head lever in the Ahead direction, only in the Astern direction.
Cause Remedy
The Processor is sensing that Depress the Transfer Button while moving the Control
the Control Head’s lever is Head lever in the Astern direction. If the LED begins to
moving in the Astern direction blink, the Control Head is incorrectly wired.
• Check the colors of the wires at pins 5 and 7.
• A right hand Control Head should have yellow at pin 5
and blue at pin 7.
• A left hand Control Head should have blue at pin 5 and
yellow at pin 7.
• Ahead and Astern Solenoid Wires need to be reversed.
B10-3 Electronic Throttle Control System Problems Without Error Codes
A) SYMPTOM: The engine RPM’s vary, without moving the Control Head
lever (synchronization disabled).
Cause Remedy
a. Problem with the Governor. a. Connect the Break-out Box (p/n 13927) as shown in the
Throttle Testing Section of the Service Field Test Unit
Manual. If variations are seen, proceed to Step B). If no
variations are seen, contact a certified engine mechanic.
b. Erratic Command Signal. b. Refer to Command Signal testing. If variations of the A/D
counts occur, connect the Control Head to another Station
(if available) on the Processor. If variations persist,
replace the Control Head.
B) SYMPTOM: The engine’s Idle is too high.
Cause Remedy
a. Idle was not adjusted mechanically a. Adjust the Throttle Push-Pull cable as
correct at the Idle stop. specified in Section 5-6.2.2.1., page 5-12.
b. Function Code E2 Throttle Minimum is b. Adjust Throttle Minimum as specified in
incorrectly set. Section 5-6.2.2.2, page 5-13.
c. The Governor or Carburetor is c. After Causes a. and b. have been eliminated,
incorrectly adjusted. contact a certified engine mechanic to
properly adjust.

Page B10-2
TROUBLESHOOTING
B11 SYNCHRONIZATION TROUBLESHOOTING
If you encounter a problem with Synchronization, it will more than likely one
of the following; failure to attempt to synchronize, synchronizing at different
RPM’s or RPM variations of one or both engines while synchronized. Each
problem is distinct and the cause may differ depending on the type of Synch.
Therefore, each type is discussed individually.
B11-1 Equal Throttle Synchronization
B11-1.1 Basic Troubleshooting
B11-1.1.1 SYMPTOM: Will not synchronize.
Causes Solutions
a. Synchronization is Disabled a. At the Station-in-Command, move both Control Head levers to more than 5% of
the speed range. Press and hold the transfer button for 5 seconds.
If synch is disabled, the green LED will light as long as the button is pressed.
If synch was enabled, the green LED would have blinked twice.
b. The Serial Communication Harness is not b. Plug the Serial Communication Harness into both Processors.
plugged into both Processors.
c. The Port and Starboard Processors are not c. Scroll to Function Code A1, on the Port and Starboard Processor. Enter a Value of
set up for Twin Screw operation. 02 into both Processors.
d. The Port and Starboard Processors have d. On the Port Processor, scroll to Function Code A0 and enter a Value of 01.
the same ID number. On the Starboard Processor, scroll to Function Code A0 and enter a Value of 02.
B11-2 Active Synchronization
B11-2.1 Basic Troubleshooting
B11-2.1.1 SYMPTOM: The green LED is lit solid, though the Engine RPM’s
differ by a significant amount.
Causes Solutions
a. The Tach Sender signal has been lost by a. Scroll to Function Code H0. Go to the Value for the Tach Sender’s input frequency.
one or both Processors. If the frequency displayed is 0000, the signal has been lost and the system diverted
to Equal Throttle Synch. Correct the wiring or replace the Sender.
B11-2.1.2 SYMPTOM: Will not synchronize.
Causes Solutions
a. Synchronization is Disabled a. At the Station-in-Command, move both Control Head levers to more than 5% of
the speed range. Press and hold the transfer button for 5 seconds.
If synch is disabled, the green LED will light as long as the button is pressed.
If synch was enabled, the green LED would have blinked twice.
b. The Serial Communication Harness is not b. Plug the Serial Communication Harness into both Processors.
plugged into both Processors.
c. The Port and Starboard Processors have c. On the Port Processor, scroll to Function Code A0 and enter a Value of 01.
the same ID number. On the Starboard Processor, scroll to Function Code A0 and enter a Value of 02.
d. The Port and Starboard Processors are not d. Scroll to Function Code A1, on the Port and Starboard Processor. Enter a Value of
set up for twin screw operation. 02 into both Processors.
B11-2.2 Electronic Throttle
B11-2.2.1 SYMPTOM: The green LED is lit solid, though the Engine RPM’s differ
by a significant amount.
Causes Solutions
a. Function Code E7 is set to 00 and the a. Scroll to Function Codes E2 and E3 on both Processors and compare the Values.
Throttle Minimum and Throttle Maximum The Values of E2 and E3 must be the same for both Processors. Adjust as
Values differ between the Port and necessary.
Starboard Processors.
b. The engines run at different RPM’s with b. Active Synchronization MUST be Enabled.
the same throttle command signals.
B11-2.2.2 SYMPTOM: One or both of the engines continually changes RPM
(hunts). Will not synchronize properly
Causes Solutions
a. A Station-in-Command Control Head’s a. Scroll to the Diagnostic Menu Function Code H0. Go to the appropriate Station A/
Command Signal is varying. D Count’s display. The Value should not change by more than +/- 1 A/D Count.
If so, check the connections and if good, replace the Control Head.
b. One or both of the Tach Signals isn’t being b. Scroll to Function Code H0 on both Processors and display the frequency of the
read intermittently. Function Code E7 is Tach Signal. If variations of the signal are measured, the cause must be
set to a Value of 01 or 03. determined

Page B11-1
TROUBLESHOOTING
B11-2.2.3 SYMPTOM: Synchronization does not function. The Control Head’s
green LED does not light.
Causes Solutions
a. The Processors think Astern is being a. Place both the Port and Starboard Processor into Warm-up Mode by pressing the
commended when the Control Head lever Transfer Button while moving the Control Head levers to the Ahead detent. Both
is positioned to the Ahead Detent. Control Head’s red LEDs should be blinking. If not, the 7-conductor’s connections
at pins 5 and 7 are reversed.
b. The Serial Communication Harness is not b. Ensure the Serial Harness’ plugs are fully inserted into the Port and Starboard
properly installed. Processor’s Pigtails.
c. The Processors are not programmed for c. Scroll to Function Code A1 on both Processors and verify that the Value of both is
twin screw. set to 02.
d. Both Processors are set to the same ID d. Scroll to Function Code A0 and verify that the Port and Starboard Processors have
number. different ID numbers.
e. Function Code E7 Value is set to 02. e. Depending on the installation, change the Value of E7 to 00, 01, or 03.
f. Function Code E7 is set to 03 and no Tach f. Determine why there is no Tach Signal present.
Signal is present.

Page B11-2
TROUBLESHOOTING
B12 TROUBLESHOOTING CABLE HARNESSES
The following Sections list the various Harnesses manufactured for use with
the Processor. These tables are invaluable when troubleshooting a suspected
interface problem or when manufacturing your own Harnesses.
B12-1 Basic Control System Harnesses
Table B12-1: Power, Start Interlock Harness Pin-Out
PROCESSOR PIGTAIL ENGINE and BATTERY
Termination A Conductor Color Termination B Description
Pin 1 Yellow w/ Red Starter Solenoid Closed contact when In-command
Trace and at Neutral.
Pin 10 Red Battery (+) +12 or 24VDC.
Pin 11 Black Battery (-) - DC Return
Pin 12 Yellow w/ Red Starter Switch Closed contact when In-command
Trace Wire at the Starter and at Neutral.
Solenoid
Table B12-2: Power, Start Interlock, and Pressure Switch Harness Pin-Out
PROCESSOR PIGTAIL ENGINE and BATTERY
Termination A Conductor Color Termination B Description
Pin 1 Yellow w/ Red Starter Solenoid Closed contact when In-command
Trace and at Neutral.
Pin 6 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission
manufacturer’s minimum safe
operating pressure is reached.
Pin 7 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission
manufacturer’s minimum safe
operating pressure is reached.
Pin 10 Red Battery (+) +12 or 24VDC.
Pin 11 Black Battery (-) - DC Return
Pin 12 Yellow w/ Red Starter Switch Closed contact when In-command and at Neutral.
Trace Wire at the
Starter Solenoid
Table B12-3: Power, Start Interlock, Pressure Switch, and Alarm Harness Pin-Out
PROCESSOR PIGTAIL ENGINE and BATTERY
Termination A Conductor Color Termination B Description
Pin 1 Yellow w/ Red Starter Solenoid Closed contact when In-command
Trace and at Neutral.
Pin 2 Red External Alarm Normally Open contact opens with
Circuit fault or loss of power.
Pin 3 Black External Alarm Normally Open contact opens with
Circuit fault or loss of power.
Pin 6 Light Blue Clutch Pressure Normally Open contact that closes
Switch when transmission manufacturer’s
minimum safe operating pressure
is reached.
Pin 10 Red Battery (+) +12 or 24VDC.
Pin 11 Black Battery (-) - DC Return
Pin 12 Yellow w/ Red Starter Switch Closed contact when In-command and at Neutral.
Trace Wire at the Starter
Solenoid
Table B12-4: Serial Communication Harness Pin-Out
PROCESSOR PIGTAIL PROCESSOR
Termination A Conductor Color Termination B Description
Pin 1 Black Pin 1 CAN Low
Pin 2 Red Pin 2 CAN High
Pin 6 Yellow/ Green N/C Shield

Page B12-1
TROUBLESHOOTING

Table B12-5: Control Head Harness Pin-Out and Hard-Wire

CONTROL HEAD PIGTAIL
PROCESSOR PIGTAIL
(14261-X)
Termination A Conductor Color Termination B Description
Pin 1 Green/ Yellow Pin 1 Shield
Pin 2 Brown Pin 2 Red LED (+)
Pin 3 Violet Pin 3 Green LED (-)
Pin 4 Orange Pin 4 Transfer Button (+)
Pin 5 Red Pin 5 Ground
Pin 6 Green Pin 6 Lever Command Signal Harness Plug Pin- Out
Pin 7 Blue Pin 7 VREF (+5VDC)
Pin 8 Black Pin 8 Tone (+)

PROCESSOR PIGTAIL CONTROL HEAD TERMINAL

STRIP (13557-X)
Termination A Conductor Color Termination B Description
Pin 1 Green/ Yellow N/C Shield
Pin 2 Brown Pin 2 Red LED (+)
Pin 3 Violet Pin 8 Green LED (-)
Pin 4 Orange Pin 4 Transfer Button (+)
Port Terminal Connections
Pin 5 Red Pin 3 Ground
Pin 6 Green Pin 6 Lever Command Signal
Pin 7 Blue Pin 5- Port VREF (+5VDC)
Pin 7- Stbd
Pin 8 Black Pin 1 Tone (+)

NOTE: STARBOARD- Jumper Pins 3 to 5

PORT- Jumper Pins 3 to 7
Stbd Terminal Connections
Table B12-6: Tachometer Sensor Harness Pin-Out
PROCESSOR PIGTAIL TACHOMETER SENSOR
Termination A Conductor Color Termination B Description
Pin 2 Red Pin B Tachometer (+)
Pin 3 Black Pin C Tachometer (-)
Pin 4 Green/Yellow N/C Shield
Table B12-7: Tachometer Sensor Harness with Power Pin-Out
PROCESSOR PIGTAIL TACHOMETER SENSOR
Termination A Conductor Color Termination B Description
Pin 1 Red As Required Sensor Supply (+9VDC)
Pin 2 Green As Required Tachometer (+)
Pin 3 Black As Required Tachometer (-)
Pin 4 Green/Yellow N/C Shield
B12-2 Clutch Harnesses
B12-2.1 Ahead/Astern
Table B12-8: Ahead/Astern Clutch Harness Pin-Out
PROCESSOR GEAR BOX
PIGTAIL
Termination Conductor Termination
A Color B Description

Pin 3 Red Ahead + 24 VDC when Ahead

Solenoid Clutch Selected
Pin 4 Black Ahead - VDC Return for Ahead
Solenoid Clutch
Pin 5 Red Astern + 24 VDC when Astern
Solenoid Clutch Selected
Pin 6 Black Astern - VDC Return for Astern
Solenoid Clutch

Page B12-2
TROUBLESHOOTING
B12-2.1 Ahead/Neutral/Astern
Table B12-9: Ahead/Neutral/Astern Clutch Harness Pin-Out
PROCESSOR PIGTAIL GEAR BOX
Termination Conductor Termination
Description
A Color B
Pin 3 Red Ahead Solenoid +24 VDC when Ahead
Clutch Selected
Pin 4 Black Ahead Solenoid -VDC Return Ahead Clutch
Pin 5 Red Astern Solenoid +24 VDC when Astern
Clutch Selected
Pin 6 Black Astern Solenoid -VDC Return Astern Clutch
Pin 7 Red Neutral Solenoid +24 VDC at all times
Pin 8 Black Neutral Solenoid -VDC Return for Neutral
Solenoid
B12-3 Throttle Harnesses
B12-3.1 Current, MAN
Table B12-10: Current, MAN, Throttle Harness Pin-Out
PROCESSOR PIGTAIL ENGINE
Termination Conductor
A Color Termination B Description

Pin 1 Black Engine DC- Throttle Signal Return

Bus
Pin 3 Red ECM 0.00- 21.0 mA. Throttle Signal
Pin 8 Green/ Yellow N/C N/A

B12-3.1 Frequency
Table B12-11: Frequency Throttle Harness Pin-Out
PROCESSOR PIGTAIL ENGINE
Termination Conductor Termination Description
A Color B
Pin 1 Black Engine DC- Bus Throttle Signal Return
Pin 7 Red ECM 120.64- 463.50 Hz.
Throttle Signal
Pin 8 Green/ N/C N/A
Yellow

B12-3.1 PWM
Table B12-12: PWM Throttle Harness Pin-Out
PROCESSOR PIGTAIL ENGINE
Termination Conductor Termination
A Color B Description

Pin 1 Black Engine DC- Bus Throttle Signal Return

Pin 2 Red ECM PWM Throttle Signal - 0- 100% Duty
Cycle @ 500Hz.
Pin 8 Green / Yellow N/C N/A

B12-3.1 Voltage
Table B12-13: Voltage Throttle Harness Pin-Out
PROCESSOR PIGTAILS ENGINE
Conductor
Termination A Color Termination B Description

Pin 1 Black Engine DC- Bus Throttle Signal Return

Pin 2 Red ECM 0.00- 5.00 VDC
Throttle Signal
Pin 8 Green/ Yellow N/C N/A

Page B12-3
TROUBLESHOOTING
B13 PROCESSOR PIGTAILS
The number and types of Pigtails used varies with the different Processors and
their configurations. The basic off-the-shelf Processors are available with no
Pigtails (hard-wired) or pre-wired for for up to a total of eight Pigtails when all
five Remote Stations are being used.
The following Tables describe the pin outs and functions of the conductors
within the various Pigtails.
B13-1 Basic Processor Pigtails
Table B13-1: Power/Start Interlock/Clutch Oil Pressure Switch/Alarm Pigtail Pin-Out
CIRCUIT BOARD PLUG
Termination A Conductor Color Termination B Description
PB2-2 Yellow Pin 1 Start Interlock
TB6-6 Brown Pin 2 Alarm (N.O.) 1 - Yellow 12 - Red

12 1110 9 8 7
2 - Brown

6 5 4 3 2 1
TB6-5 Black Pin 3 Alarm (Common)
3 - Black 11 - Black 2-Conductor
TB6-2 Orange Pin 4 Back-up Ctrl (Ground)
4 - Orange 10 - Red Cable
TB6-1 White Pin 5 Back-up Ctrl Input
5 - White
TB6-3 Blue Pin 6 Clutch Pressure Switch
6 - Blue 7- Green
TB6-4 Green Pin 7 Clutch Pressure Switch (Ground)
PB1 (+) Red Pin 10 DC Power (+)
PB1 (-) Black Pin 11 DC Power (-)
PB2-1 Red Pin 12 Start Interlock
Table B13-2: Serial Communication Pigtail Pin-Out
CIRCUIT BOARD PLUG
Termination A Conductor Color Termination B Description 3- Plug Seal
TB7-6 White Pin 2 CAN High (Not Used) 4 - Black

1 2 3

4 5 6
TB7-7 Green Pin 1 CAN Low 2- White 5 - Red
TB7-8 Black Pin 4 CAN High 1- Green 6 - Black
TB7-9 Red Pin 5 CAN Low
TB7-10 Black Pin 6 Shield

Table B13-3: Control Head Pigtail Pin-Out (Up to 5 Stations)

CIRCUIT BOARD PLUG
Termination A Conductor Color Termination B Description
8 - Black 1 2 3 4 1 - Green/Yellow
Frame Non-insulated to Green/Yellow Pin 1 Shield
5 6 7 8

7 - Blue 2 - Brown
TB1 thru 5-2 Brown Pin 2 Red LED (+)
TB1 thru 5-8 Violet Pin 3 Green LED (-) 6 - Green 3 - Violet
TB1 thru 5-4 Orange Pin 4 Transfer Button 5 - Red 4 - Orange
TB1 thru 5-3 Red Pin 5 Ground
TB1 thru 5-7 Blue Pin 7 VREF (+5VDC)
TB1 thru 5-6 Green Pin 6 Lever Command Signal
TB1 thru 5-1 Black Pin 8 Tone (+)
B13-2 Throttle Pigtail
Table B13-4: Throttle Pigtail Pin-Out
CIRCUIT BOARD PLUG
Termination A Conductor Color Termination B Description
TB8-3 Brown Pin 2 PWM (+)
TB8-4 Red Pin 3 Current (+)
TB8-5 Orange Pin 4 VDC (+)
TB8-6 White Pin 7 Frequency (+)
TB8-7 Black Pin 1 Signal Ground
P-Clamp to Frame Green/Yellow Pin 8 Shield

Page B13-1
TROUBLESHOOTING
B13-3 Clutch Pigtail
Table B13-5: Clutch Pigtail Pin-Out
CIRCUIT BOARD PLUG

121110 9 8 7
6 54 32 1
Termination A Conductor Color Termination B Description
3 - Brown
TB11-1 Black Pin 5 Astern Clutch (+) 4 - Green
TB11-2 Brown Pin 3 Ahead Clutch (+) 5 - Black
6 - Yellow
TB11-5 Yellow Pin 6 Astern clutch ( - )
TB11-6 Green Pin 4 Ahead Clutch ( - )
B13-4 Tachometer Sensor Pigtail
Table B13-6: Tachometer Sensor Pigtail Pin-Out
CIRCUIT BOARD PLUG
Termination A Conductor Color Termination B Description
TB9- 1 Red Pin 1 Sensor Supply (+9VDC) 2 - Green 3 - Black

1 2

3 4
TB9- 2 Green Pin 2 AC Type Tach Input 1 - Red 4 - Shield/
TB9- 3 N/C Open Collector Tach Input (the green wire is moved from Drain
TB9-2 to TB9-3 when an Open Collector Tach is used)
TB9- 4 Black Pin 3 Return for Tach Input
Grounding Screw Drain Pin 4 Shield

Page B13-2
ENG-143 Ver. 1 4/04
ZF Marine Electronics, LLC
Mukilteo Plant
ClearCommand 9000 Series
Electronic Throttle – Solenoid Clutch
Qualitative Failure Analysis & Design Verification
Test Procedure
Version: 1.0
Document # AUTHOR CHECKED APPROVED DATE
ENG-143 Tim Jones Jim D Smith Robert Anderson 4/19/04
Qualitative Failure Analysis
The following qualitative failure analysis is provided to show compliance with:
• Subchapter K Small Passenger Vessels, 46 CFR 121.620
• Subchapter L Offshore Supply Vessels, 46 CFR 130.120
• Subchapter T Small Passenger Vessels, 46 CFR 184.620:
121.620 Propulsion engine control systems.
a) A vessel must have two independent means of controlling each propulsion engine. Control
must be provided for the engine speed, direction of shaft rotation, and engine shutdown.
1) One of the means may be the ability to readily disconnect the remote engine control linkage
to permit local operation.
b) A multiple engine vessel with independent remote propulsion control for each engine need
not have a second means of controlling each engine.
c) In addition to the requirements of paragraph (a) of this section, a vessel must have a
reliable means for shutting down a propulsion engine, at the main pilot house control
station, which is independent of the engine's speed control.
d) A propulsion engine control system, including pilothouse control, must be designed so that
a loss of power to the control system does not result in an increase in shaft speed or
propeller pitch.
e) All microprocessor or computer based systems must meet the requirements of part 62 in
subchapter F of this chapter.
130.120 Propulsion control.
a) Each vessel must have--
1) A propulsion-control system operable from the pilothouse; and
2) A means at each propulsion engine of readily disabling the propulsion-control system to
permit local operation.
b) Each propulsion-control system operable from the pilothouse must enable--
1) Control of the speed of each propulsion engine;
2) Control of the direction of propeller-shaft rotation;
3) Control of propeller pitch, if a controllable-pitch propeller is fitted; and
4) Shutdown of each propulsion engine.
c) The propulsion-control system operable from the pilothouse may constitute the remote
stopping-system required by Sec. 129.540 of this subchapter.
d) Each propulsion-control system, including one operable from the pilothouse, must be
designed so that no one complete or partial failure of an easily replaceable component of
the system allows the propulsion engine to overspeed or the pitch of the propeller to
increase.
184.620 Propulsion engine control systems.
a) A vessel must have two independent means of controlling each propulsion engine. Control
must be provided for the engine speed, direction of shaft rotation, and engine shutdown.
1) One of the means may be the ability to readily disconnect the remote engine control linkage
to permit local operation.
2) A multiple engine vessel with independent remote propulsion control for each engine need
not have a second means of controlling each engine.
ZF MARINE ELECTRONICS, LLC 12125 Harbour Reach Drive, Suite B Telephone (425) 583-1900
Mukilteo, WA 98275 Fax (425) 493-1569
Page B-3
 b) In addition to the requirements of paragraph (a), a vessel must have a reliable means for
shutting down a propulsion engine, at the main pilothouse control station, which is
independent of the engine's speed control.
c) A propulsion engine control system, including pilothouse control, must be designed so that
a loss of power to the control system does not result in an increase in shaft speed or
propeller pitch.
The ZF Marine Electronics ClearCommand 9000 Series (electronic throttle, solenoid clutch ver-
sion) marine engine controls offer single lever control of speed and direction. Each enclosure
houses an independent Control Processor and requires separate power supplies. The system
operates on 12 or 24VDC power and can have up to five remote stations depending on the appli-
cation. The system sequences the operation of speed and shift in order to prevent an inexperi-
enced operator from mishandling the engine or transmission.
A standard feature is an alarm contact (normally open) to interface with the main alarm system
of the vessel. This switch will open and activate the alarm system with a power loss or CPU fail-
ure. In addition, ZF Marine Electronics provides audible tones at the Control Head locations to
indicate system faults.
ITEM FAILED ALARM INITIAL FINAL
# COMPONENT STATUS RESULT OUTCOME
1 ZF Marine Electronics Audible Tone Will Sound At Throttle Resets To Idle No Increase In Engine RPM
Control Head Control Head
Clutch Shifts To Neutral No Increase In Shaft Speed
2 Loss Of Power Supply Alarm Circuit Will Open Throttle Resets To Idle No Increase In Engine Rpm

Clutch Shifts To Neutral No Increase In Shaft Speed

Design Verification Test Procedure
The ClearCommand 9000 Series (electronic throttle, solenoid clutch version) Propulsion Control
System is compliant to the environmental design standards in 46 CFR 62.25-30. The following
test procedure covers the 2 items included in the Qualitative Failure Analysis.
1) Failure: Control Head Potentiometer failure.
a) Results: The Processor will shift to Neutral (if needed) and throttle will go to Idle, (if
needed).
b) Test Procedure
i) Turn power on to both Port and Starboard Processors. Take command at a Control Head.
ii) 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.
1) The Port Processor will shift to Neutral and throttle will go to Idle.
2) The Port Control Head will give an alarm tone indicating a faulty potentiometer.
iv) Move the Port and Starboard Control Head levers back to Neutral. Reconnect the green wire.
v) Repeat for Starboard side.
2) Failure: Power failure to ClearCommand 9000 Series
(A power failure to the ClearCommand 9000 Series circuit board will have the same results as a failed microprocessor)
a) Results
i) Throttle signal to Idle and shift to Neutral.
ii) LED at Control Heads will not be lit.
iii) Opposite engine still under power has full control.
b) Test Procedure.
i) Turn power on to both Port and Starboard Processors. Take command at a Control Head.
ii) Move the Port and Starboard Control Head levers to approximately ½ Ahead.
iii) Turn power off to the Port side only.
1) Port side will go to Neutral Idle.
2) LED on the Port side of the Control Head in command will go off.
3) The Port Control Head will no longer have command of the engine and gear.
4) The Starboard Control Head will still have full command of the Starboard engine and gear.
iv Turn power on to the Port Processor. Take command of the Port side.
1) The Port Control Head will operate as usual-(Non-volatile memory)
v) Repeat test for Starboard Processor.

Page B-4
 ZF Marine Electronics, LLC
MMC-172, Rev. Z-R 3-05 Mukilteo Plant

Factory Authorized Sales & Service Centers - International

ARGENTINA FINLAND
3205 Carlos Dorian Friedlander 7655 Vesa Saarinen, Ari Bragge
Trimer S.A. T: 54-11-4580-0444 Mastervolt Finland T: 358-2-433-9990
(mail) PO Box 1772 Powerduo Oy
Attn: Mariano Castroverde F: 54-11-4580-0440 Haikankatu 2 F: 358-2-435-0085
1000 Buenos Aires, ARGENTINA FIN-21200, Raisio, FINLAND
(ship) Fray J.S.M. de Oro 2030.40
1425 Buenos Aires, ARGENTINA

AUSTRALIA FRANCE
6948 Rodney Lean 2190 Mr. L. Gautier
ZF Australia Pty. Ltd. T: +61 (0)2 9679 5555 Seimi T: 33 2 98 46 11 02
(mail) Locked Bag 6305 (mail) B.P. 30307
Blacktown BC, NSW 2148 F: +61 (0)2 9679 5500 Brest Cedex, FRANCE 29603 F: 33 2 98 43 37 49
AUSTRALIA (ship) Z.I.P. Du Moulin Blanc
(ship) 14 Lidco Street Rue Alain Colas
[email protected] [email protected]
Arndell Park, NSW 2148 29200 Brest, FRANCE
www.zf.com.au www.seimi.com
AUSTRALIA

BRAZIL 3590 David Elderkin

Vidal Diffusion Marine T: 33 494 08 68 20
7000 Antonio Tucunduva (mail) B.P. 97
ZF do Brazil S.A. T: 5515-235-2301
Avenida Conda Zepplin, 1935 Toulon Cedex 9, FRANCE F: 33 494 08 26 59
CEP 18103-0000 Soroc, BRAZIL (ship) Z.I. Toulon -Est
F: 5515-235-2233
Toulon Cedex 9,
[email protected]
FRANCE

GERMANY
CHINA 7252 Jan Hogenkamp
ADS Van Stigt T: +31 (0) 183 650000
6953 Tang Zhou Qing Avelingen - West 30
ZF Shanghai Rep. Office T: 0086 21 6301 4338
Room 2504, Jiangnan Building NL-4202 MS Gorinchem, F: +31 (0) 183 650001
No. 600 Luban Rd. NETHERLANDS
F: 0086 21 6301 6449
Shanghai 200023, PR CHINA M: 13901655780 [email protected]

7636 Mathias Pein

Otto Piening GMBH T: 49 4124 916812
DENMARK Piening Propeller
7257 Elisabeth Q. Sibbern AM Altendeich 83
ZF Danmark APS T: +45 (0) 43 436243 Gluckstadt, 25348 GERMANY M: 49 171 4853376
Taastrupgaardsvej 8 - 10
DK-2630, Taastrup, DENMARK [email protected]
F: +45 (0) 43 432643

[email protected]
www.zf-marine.com

B14-5
 GREECE JAPAN
2386 Demetris Kyriazis 7253 Y. Ikeda
Amaltheia T: 30210 25 88 985 ZF Marine Japan Co. Ltd. T: +81 (0) 3 5808 4521
13 Papaflessa Str. Fujikoshi Bldg. 1-10-11 Iriya Taito-ku
143 43 N. Halkidona F: 30210 25 89 986 Tokyo, 110-0013 F: +81 (0) 3 5808 4531
Athens, GREECE JAPAN

www.zf-marine.com

ICELAND KOREA
6525 Hrafn Sigurdasson, Johann Olafur Arsaelsson 1415 M.G. Song
Merkur T: 354-568-1044 SE Jung Engineering Co. T: 82-51-415-0591
Akralind 2 #35-4 Namhangdong-1KA
201 Kopavogur, ICELAND F: 354-568-9958 Yeongdogu F: 82-51-412-6361
M: 354-863-0312 Pusan, KOREA

[email protected] [email protected]
[email protected]

IRELAND NETHERLANDS (Holland)

7326 Adi Licence 7252 Jan Hogenkamp
ZF Great Britain Ltd. T: 44-115-986-9211 ADS / Van Stigt T: +31 (0) 183 650000
Abbeyfield Road, Lenton Avelingen - West 30
Nottingham, UNITED KINGDOM F: 44-115-986-9261 NL-4202 MS Gorinchem, F: +31 (0) 183 650001
NG7 2SX NETHERLANDS
ENGLAND
[email protected]

ITALY 5446 Dick Straathof

Straathof Scheepselectra T: 31 321-382315
7093 Antonio Renzetti, Alessandro Busetto Van de Plasschelaan 4
SAIM SPA T: +39 02 488 531
Via Donizetti, 9/11 8251 PG Dronten, NETHERLANDS F: 31 321-336151
20090 Assago (MI), F: +39 02 45703070
ITALY scheepselectra.com
[email protected]
MMC, CL, CR, MC
[email protected]
www.saim-group.com NEW ZEALAND
6477 Vittorio Rasera 6948 Rodney Lean
ZF Hurth T: 011-390-464-580-555 ZF Australia Pty. LTD T: +61 (0)2 9679 5555
38062 Arco (TN) Italy (mail) Locked Bag 6305
Via S. Andrea, 16, ITALY F: 011-390-464-580-544 Blacktown BC, NSW, AUSTRALIA F: +61 (0)2 9679 5500
2148
(ship) 14 Lidco Street
[email protected]
Arndell Park, NSW, AUSTRALIA
www.zf.com.au
2148
MMC, CL, CR
7244 NORWAY
ZF Padova S.p.A. T: 39-049-8299-550
Via Panghe N. 48 7029 Karl Baumgart
KGK Norge AS T: +47 22 884 680
Selvazzano/Padova, ITALY I-35030 F: 39-049-8299-550 Casper Storms Vei 19
Oslo, N-0664 F: +47 22 720 902
[email protected] NORWAY
www.zf-marine.com [email protected]
www.zf-group.no
MMC, CL, CR

B14-6
 RUSSIA SWEDEN
7313 7234 Karl-Henry Pragsten
ZF Transmissia 000 T: 7 (812) 324 54 72 KG Knutsson AB T: +46 (0) 8 923 312
Suite 313 Transmissionsdivisionen
71, Marata Street F: 7 (812) 140 18 15 Hammarbracken 8 F: +46 (0) 8 929 599
St. Petersburg, RUSSIA 191119 S-191 81 Sollentuna, SWEDEN

[email protected] [email protected]

SCOTLAND SWITZERLAND
7326 Adi Licence 2419 Rolf Heimgartner
ZF Great Britain Ltd. T: 44-115-986-9211 Marine Parts Heimgartner T: 41 1997 4090
Abbeyfield Road, Lenton Pfaffikerstrasse 6
Nottingham, UNITED KINGDOM F: 44-115-986-9261 CH-8604 Volketswil F: 41 1997 4094
NG7 2SX Zurich, SWITZERLAND
ENGLAND
[email protected] [email protected]
www.marineparts.ch

SINGAPORE TAIWAN
157 Steven Wee 5355 Mike Ou
Mammoth Enterprises Pte. Ltd. T: 65 6 44-88266 Asia Diesel Electric Corp. T: 886 7 333 1191
(mail) PO Box 283 20th Floor
Siglap Post Office, SINGAPORE F: 65 6 44-89800 34 Min Chuan 1st Road F: 886 7 334 6808
914503 Kaohsuing, R.O.C. TAIWAN
(ship) 6-A Waringin Park
[email protected]
, SINGAPORE 416320

7045 Daniel Poone THAILAND

ZF South East Asia Pte. T: +65 (0) 8 610177
11 Tuas Drive 1 7283 Reungpoj V
ZF Thailand Co. Ltd T: +66 2 521 6520
Singapore, 638678 F: +65 (0) 6861 9173 159/33 Soi Vipawasee 64
Rep. of SINGAPORE Vipawadee-Rangsit Road F: +66 2 521 6523
[email protected] Laksi, Bangkok, Bangkok 10210
www.zf-marine.com THAILAND
[email protected]
www.zf-marine.com
SOUTH AFRICA
7261 TURKEY
ZF South Africa (Pty) Ltd T: 27 11 453 1818
(mail) PO Box 2098 7223 Mr. Georg Weinstabl
Niveko Makina Dis Ticaret Kollektif Sti T: 90 212 287 27 80
Kempton Park, 1620 SOUTH F: 27 11 453 7506 Lorenz Severin Moritz Wwinstabl ve
AFRICA Ortaklan F: 90 212 287 65 71
(ship) C/O Barlows Power Systems Hasan Yelmen Cad No.15
Cnr. Peter Barlow and Kasselss Vlei TR-34957 Tuzla -, Istanbul Deri
Rd [email protected]
Serbest Bolgesi TURKEY
SPAIN
5556 Juanma Raposa U.A.E.
ZF Espana, S.A. T: +34 (91) 4852699
Avda. Fuentermar, 11 7030 M. Narasimhan (NARSI)
ZF Middle East, LLC T: 971-6-574-7074
Coslada (Madrid), 28820 F: +34 (91) 6733931 (mail) PO Box 26093 T:
SPAIN Sharjah, U.A.E. [email protected]
(ship) #502 Golden Tower Building F: 971-6-574-7174
www.zf-marine.com Sharjah,
[email protected]
U.A.E
[email protected]
MMC, CL, MC www.zf-marine.com

B14-7
 UNITED KINGDOM (England) USA
6932 Richard Dix Cherie McAdams
Atlantis Marine Power Ltd. T: 44 1752 208810 ZF Marine LLC - Irvine Service Center T: 949-251-0140
Western Wood Way 1350 Reynolds Ave., Suite #110
Langage Science Park F: 44 1752 208811 Irvine, CA 92614 F: 949-251-0150
Plymouth, Devon,, Plymouth PL7
5BG ENGLAND
[email protected] [email protected]
www.atlantismarine.co.uk

USA Phil Organ

ZF Marine LLC - North Carolina T: 252-504-3700
1350 Sensation Weigh
ZF Marine Electronics, LLC T: 425-583-1900
12125 Harbour Reach Drive, Suite B Beaufort, NC 28516 F: 252-504-3773
Mukilteo, WA 98275 USA
F: 425-493-1569
USA
www.zf-marine.com
www.zf-marine.com
MMC, CL,CR, MC John Shea, Gil Bashaw
ZF Marine LLC - Rhode Island T: 401-541-9014
6427 Kelly Friedenberg 1 Mastead Drive
ZF Marine LLC - US Headquarters T: 954-581-4040
3131 SW 42nd Street Warwick, RI 02886 F: 401-541-7223
Fort Lauderdale, FL 33312 USA
F: 954-581-4078
USA
www.zf-marine.com
www.zf-marine.com

Randy Tredinich, Marc Kloor

ZF Marine LLC - Gulf Coast Facility T: 504-443-0501
161 James Drive West
Suite 120 F: 504-443-0504
St. Rose, LA 70087 USA

www.zf-marine.com

Kevin Zwicker, Keith Kaelberer

ZF Marine LLC - West Coast T: 425-583-1900
12125 Harbour Reach Drive, Suite B
Mukilteo, WA 98275 F: 425-493-1579
USA

www.zf-marine.com

Stafford Barringer, Jeff Carter

ZF Marine LLC - Annapolis T: 410-604-3320
301 Pier One Road
Suite 102
Stevensville, MD 21666 USA

www.zf-marine.com

Jimmy Wong, Steve Vu

ZF Marine LLC - Chicago T: 847-478-6868
777 Hickory Hill Drive
Vernon Hills, IL 60061 F: 847-478-6789
USA

www.zf-marine.com

B14-8
Service Field Test Unit
Reference Manual
MM13927 Rev.D 10/03
 MM13927 Table of Contents
MM13927 Table of Contents ..............................................................................................................TOC-1
Revision List .......................................................................................................................................TOC-2

1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - 1-1
Figure 1-1: Service Field Test Unit (Break-out Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-2: CruiseCommand Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-3: Example of ClearCommand Pigtail Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Table 1-1: Connector/Pigtail Descriptions.............................................................................................1-2

2 PROCEDURE - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 Throttle Signal Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.1 DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-4: Throttle Connection (DC Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.2 Current (mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-5: Throttle Connection (Current mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1.3 PWM (Pulse Width Modulation) with DC Voltmeter . . . . . . . . . . . . . . . . . . 2-3
Figure 2-6: Throttle Connection (PWM with DC Voltmeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-1.4 PWM (Pulse Width Modulation) with Duty Cycle Meter . . . . . . . . . . . . . . . 2-4
Figure 2-7: Throttle Connection (PWM with Duty Cycle Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-1.5 Frequency (Hz.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-8: Throttle Connection (Frequency Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 CLUTCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2.1 Neutral Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-9: Clutch Connection (Neutral Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2.2 Ahead Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-10:Clutch Connection (Ahead Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2.3 Astern Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-11:Clutch Connection (Astern Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3 TROLL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.1 Troll On/Off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-12:Troll Connection (ON/OFF Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.2 Troll Command (Proportional Solenoid) Testing with Amp Meter . . . . . . . 2-10
Figure 2-13:Troll Connection (Proportional Solenoid with Amp Meter) . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4 2-SPEED TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-4.1 2nd Gear Disengaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-14:2-Speed Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-4.2 2nd Gear Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3 Parts List - - - - - - - - - - - - - - - - - - - - - - - 3-1

Table 3-2: Parts List ...............................................................................................................................3-1

TOC-1
REVISIONS LIST

Revision List

Rev Date Revision Description

A 11/02 Revised Section 1.0 Table 1

B 2/03 Revised manual to current ZF Marine Electronics manual standards.

Revised Section 3.0

C 4/03 Deleted Section 2.1.6

D 10/03 Revising to add 9000 Series and 2-Speed information

PageTOC-2
 SERVICE FIELD TEST UNIT
1 INTRODUCTION
Refer to Bulletin 02-008 for
Service Field Test Unit (Part No.
13927) recommendations. Refer
to Figure 1-1:for an example of
the Test Unit and a Multimeter.
The Service Field Test Unit,
hereafter referred to as the
“Break-out Box”, is
recommended for use with all
CruiseCommand Processors
(Part No. 785CE) and with
ClearCommand Processors (Part
No. 9XXX Series) that have
pluggable (Pigtail) Throttle,
Clutch or Troll Connections.
Figure 1-1: Service Field Test Unit (Break-out Box)
The procedures for testing the various outputs of the ClearCommand and
CruiseCommand Processors are similar, with the exception of where they
connect to the respective Processor. Figure 1-2: indicates the location of the
connectors on the CruiseCommand Processor and Figure 1-3: the typical
pigtail plugs on a 9000 Series ClearCommand Processor.

NOTE: Not all ClearCommand Processors have all of the pigtails shown in Figure 3. Only the
pigtails that are required for a specific application are installed in a ClearCommand Processor.

6
11339-Example
1
3
Figure 1-2: CruiseCommand Connector Locations Figure 1-3: Example of ClearCommand Pigtail Locations
# Description Harness Type Harness Use
1 Black 8 Pin Throttle Connector/Pigtail The throttle signal is output from this connector/pigtail.
The signal may be in the form of Pulse Width Modulation
(PWM), Voltage, Current, or Frequency
2 Black 12 Pin Power Connector/Pigtail This connector/pigtail contains the inputs and outputs for
Main Processor Power, Start Interlock, Clutch Oil Pressure
Interlock, and External Alarm Circuit.
3 Gray 12 Pin Clutch Connector/Pigtail The external connections for Clutch Power, Ahead,
Astern, and Neutral Solenoids, Troll On/ Off, and
Proportional Solenoids are made at this connector/pigtail.
4 Gray 8 Pin Control Head Connector All the required connections for the Remote Control
Stations are made at these connectors.
5 Gray 6 Pin Serial Communication Connector/ The Serial Communication connections between multiple
Pigtail Processors in applications with more than one Processor
at this connector/pigtail
6 Gray 4 Pin Tachometer Sensor Connector/ The input signal from a Tachometer or Shaft Speed Sensor
Pigtail connects to this connector/pigtail.
Table 1-1: Connector/Pigtail Descriptions
MM13927 Page 1-1
 SERVICE FIELD TEST UNIT
2 PROCEDURE
The actual procedures for using the Break-out Box are the same for
CruiseCommand and ClearCommand Processors. However, the adjustment
within the Processor to obtain the correct output may differ. The appropriate
Installation Manual must be referred to when making the adjustments.
2-1 Throttle Signal Testing
Depending on which Processor is being tested, it may have the capability
of sourcing one or all of the following: DC Voltage, Current, PWM (Pulse
Width Modulation) or Frequency.

NOTE: The following procedures and drawings pertain to both the CruiseCommand and
ClearCommand Processors.

2-1.1 DC Voltage
A) Ensure that power is removed from the Engine Electronics and the
Processor.
B) Disconnect the Throttle Harness from the number 1 Processor
connector/pigtail.
C) Insert the Break-out Box between the
number 1 Processor connector/pigtail
and the Throttle Harness as shown in
Figure 2-4:.
D) Set up the Multimeter to measure DC
Volts and plug the black lead into the
Break-out Box black socket labeled “-”
and the red lead into the socket
labeled “VDC”.
E) Turn power ‘On’ to the Processor and
take command at any Remote Station.
F) The appropriate Idle Voltage for the
application should be measured at
this time.
G) Move the Control Head lever to the
Full Throttle position while
depressing the Transfer Button
(Throttle Only Mode).
Figure 2-4: Throttle Connection (DC Voltage)
H) The appropriate Full Throttle Voltage for the application should be
measured at this time.
2-1.2 Current (mA)
A) Ensure power is removed from both the Engine Electronics and
the Processor.
B) Disconnect the Throttle Harness from the number 1 Processor
connector/pigtail.
C) Insert the Break-out Box between the number 1 Processor
connector/pigtail and the Throttle Harness as shown in Figure 2-
5:.
D) Set up the Multimeter to measure current (mA.) and plug the black
lead into the Break-out Box black socket labeled “-“ and the red
lead into the socket labeled “mA”.
E) Turn power ‘On’ to the Processor and take command at any
Remote Station.
MM13927 Page 2-1
 SERVICE FIELD TEST UNIT

F) Depress and hold the Push-button

Switch labeled “mA.” The appropriate
Current (mA.) for the application
should be measured.
G) Move the Control Head lever to the
Full Throttle position while depressing
the Transfer Button (Throttle Only
Mode).
H) Depress and hold the “mA.” Push-
button. The appropriate Full Throttle
Current (mA.) for the application
should be measured at this time.

Figure 2-5: Throttle Connection (Current mA)

2-1.3 PWM (Pulse Width Modulation) with DC Voltmeter
A) Ensure power is removed from both the Engine Electronics and
the Processor.
B) Disconnect the Throttle Harness from the number 1 Processor
connector/pigtail.
C) Insert the Break-out Box between the
.

number 1 Processor connector/pigtail

and the Throttle Harness as shown in
Figure 2-6:
D) labeled “-“ and the red lead into the
socket labeled “PWM”.
E) Turn power ‘On’ to the Caterpillar
ECM (Electronic Control Module)
Only. Do Not apply power to the
Processor at this time.
F) Depending on the type of Caterpillar
ECM (PEEC or ADEMS), the
measurement should be
approximately 5.00 or 12.00 VDC.
Record the measurement as shown in
Drawing Figure 2-6:.
G) Set up the Multimeter to DC Volts and
plug the black lead into the Break-out
Box black socket Turn power ‘On’ to
the Processor and take command at
any Remote Station.
Figure 2-6: Throttle Connection (PWM with DC Voltmeter)
H) Record the DC Voltage at this time. The measurement should be 7-
9% of the voltage measured in step f).
I) Move the Control Head lever to the Full Throttle position while
depressing the Transfer Button (Throttle Only Mode).
J) 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; Full
Throttle = 92% of 12 VDC reference or 11.04 VDC.

MM13927 Page 2-2

 SERVICE FIELD TEST UNIT
2-1.4 PWM (Pulse Width Modulation) with Duty Cycle Meter
A) Ensure power is removed from both the Engine electronics and the
Processor.
B) Disconnect the Throttle Harness from the number 1 Processor
connector/pigtail.
C) Insert the Break-out Box between the
number 1 Processor connector/pigtail
and the Throttle Harness as shown in
Figure 2-7:
D) Set up the Multimeter to measure
Duty Cycle and plug the black lead
into the Break-out Box black socket
labeled “-“ and the red lead into the
socket labeled “PWM”.
E) Turn power ‘On’ to the Caterpillar
ECM (Electronic Control Module) and
to the Processor.
F) The measurement should be
approximately 8% duty Cycle.
G) Move the Control Head lever to the
Full Throttle position while depressing
the Transfer Button (Throttle Only
Mode).
Figure 2-7: Throttle Connection (PWM with Duty Cycle Meter)
H) The measurement will increase from 8% to 91- 93%.
2-1.5 Frequency (Hz.)
A) Ensure power is removed from both the Engine Electronics and
the Processor.
B) Disconnect the Throttle Harness from the number 1 Processor
connector/pigtail.
C) Insert the Break-out Box between the
number 1 Processor connector/pigtail
and the Throttle Harness as shown in
Figure 2-8:
D) Set up the Multimeter to measure
Frequency and plug the black lead
into the Break-out Box black socket
labeled “-“ and the red lead into the
socket labeled “FREQ”.
E) Turn power ‘On’ to the Processor and
take command at any Remote Station.
F) The appropriate Idle Frequency for
the application should be measured at
this time.
G) Move the Control Head lever to the
Full Throttle position while depressing
the Transfer Button (Throttle Only
Mode).
Figure 2-8: Throttle Connection (Frequency Hz)
H) The appropriate Full Throttle Frequency for the application should
be measured at this time.

MM13927 Page 2-3

 SERVICE FIELD TEST UNIT
2-2 CLUTCH TESTING
2-2.1 Neutral Solenoid Testing
A) Ensure power is removed from both the Processor and the Clutch
Power Supply.
B) Disconnect the Clutch Harness from the number 3 Processor
connector/pigtail.
C) Insert the Break-out Box
between the number 3
Processor connector/pigtail
and the Clutch Harness as
shown in Figure 2-9:.
D) Turn power ‘On’ to the
Processor and take
command at any Remote
Station with the Control
Head lever in the Neutral/
Idle position.
E) The measurement on the
Neutral Test Point should
be 12 or 24 VDC,
depending on the
Solenoid’s rating and the
LED adjacent to the socket
should be illuminated.
Figure 2-9: Clutch Connection (Neutral Solenoid)
F) Move the Control Head lever to the Ahead Detent position. The
voltage should drop to 0 VDC in CruiseCommand systems and
remain at 12 or 24 VDC in ClearCommand systems. The adjacent
LED should go out in CruiseCommand systems and stay on in
ClearCommand systems.
2-2.2 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.
C) Insert the Break-out Box
between the number 3
Processor connector/pigtail
and the Clutch Harness as
shown in Figure 2-10:.
D) Set up the Multimeter to
measure DC Volts and plug
the black lead into the
Break-out Box socket
labeled “CLUTCH -“ and the
red lead into the socket
labeled “AHEAD”.
E) Turn power ‘On’ to the
Processor and take
command at any Remote
Station with the lever in the
Neutral/Idle position.
Figure 2-10: Clutch Connection (Ahead Solenoid)
F) The measurement should be 0 VDC and the adjacent LED should
not be lit.
MM13927 Page 2-4
 SERVICE FIELD TEST UNIT
G) Position the Control Head lever into the Ahead detent. The
measurement should be 12 or 24 VDC depending on the Ahead
Solenoid’s rating. The LED adjacent to the Ahead plug on the
Break-out Box should be lit.
H) Return the Control Head lever to the Neutral/Idle position.
2-2.3 Astern Solenoid Testing
A) Ensure power is removed from both the Processor and the Clutch
Supply Power.
B) Disconnect the Clutch Harness from the number 3 Processor
connector/pigtail.
C) Insert the Break-out Box
between the number 3
Processor connector/pigtail
and the Clutch Harness as
shown in Figure 2-11:.
D) Set up the Multimeter to
measure DC Volts and plug
the black lead into the
Break-out Box socket
labeled “CLUTCH -“ and
the red lead into the socket
labeled “ASTERN”.
E) Turn power ‘On’ to the
Processor and take
command at any Remote
Station with the Control
Head lever in the Neutral/
Idle position.
Figure 2-11: Clutch Connection (Astern Solenoid)
F) The measurement should be 0 VDC and the adjacent LED should
not be lit.
G) Position the Control Head lever into the Astern detent. The
measurement should be 12 or 24 VDC depending on the Astern
Solenoid’s rating. The LED adjacent to the Astern plug on the
Break-out Box should be lit.
H) Return the Control Head lever to the Neutral/Idle position.

MM13927 Page 2-5

 SERVICE FIELD TEST UNIT
2-3 TROLL TESTING
2-3.1 Troll On/Off Solenoid
A) Ensure power is removed from both the Processor and the Clutch
Power Supply.
B) Disconnect the Clutch Harness from the number 3 Processor
connector/pigtail.
C) Insert the Break-out Box between
2

the number 3 Processor

connector/pigtail and the Clutch
Harness as shown in Figure 2-12:.
D) Set up the Multimeter to measure
DC Volts and connect the black
lead to the socket labeled
“CLUTCH –“ and the red lead to
the socket labeled “TROLL ON/
OFF” as shown in Figure 2-12:.
E) Turn power ‘On’ to the Processor
and the Clutch Power Supply and
take command at a Remote Station
with the Control Head lever in the
Neutral/Idle position.
Figure 2-12: Troll Connection (ON/OFF Solenoid)
F) Depress the Transfer Button again for approximately 2 seconds
until the red LED begins blinking at a fast rate (Troll Mode
Indication).
G) The measurement should be 0 VDC.
H) Position the Control Head lever to the Ahead detent. The
measurement should now be 12 or 24 VDC, depending on the
Solenoid’s rating.
I) Position the Control Head lever further forward while monitoring
the DC Voltmeter. The measurement should go from 12 or 24 VDC
to 0 VDC at the same time the red LED on the Control Head
becomes lit solid.
2-3.2 Troll Command (Proportional Solenoid) Testing with Amp Meter
A) Ensure power is removed from both the Processor and the Clutch
Power Supply.
B) Disconnect the Clutch Harness from the number 3 Processor
connector/pigtail.
C) Insert the Break-out Box between
the number 3 Processor
connector/pigtail and the Clutch
Harness as shown in Figure 2-
13:.
D) Set up the Multimeter to measure
(mA.) and connect the black lead
to black socket and the red lead
to the red socket labeled “TROLL
COMMAND” as shown in Figure
2-13:.
E) Turn power ‘On’ to the Processor
and the Clutch Power Supply and
take command at a Remote
Station with the Control Head
lever in the Neutral/Idle position.
Figure 2-13: Troll Connection (Proportional Solenoid with Amp Meter)
MM13927 Page 2-6
 SERVICE FIELD TEST UNIT
F) Depress the Transfer Button again for approximately 2 seconds
until the red LED on the Control Head begins blinking at a fast rate
(Troll Mode Indication).
G) Flip switch away from "Troll Command" to read current through
meter.
H) Move the Control Head lever to the Ahead detent. The current
measurement should be the correct value for minimum clutch
pressure (shaft rotations). This value varies depending on the type
of Marine Gear. Refer to the Literature provided with the Trolling
Valve and the Processor for specifics.
I) Slowly advance the Control Head lever while monitoring the
current. The current should increase or decrease, depending on
the Gear type, in proportion with the Control Head lever
movement. Once again, refer to the Literature provided with the
Trolling Valve and the Processor for specific values.
J) Continue to move the Control Head lever forward until the red
LED stops blinking (lit steady). The current should drop to 0 mA.

MM13927 Page 2-7

 SERVICE FIELD TEST UNIT
3 PARTS LIST
Table 3-2: Parts List
Part Name ZF Marine Electronics Part No.
Service Field Test Unit 13927
Technical Manual MM13927
Multimeter
Test Control Head - Dual 14000

MM13927 Page 3-1

APPENDIX C
Drawing 13068A-1 Notes Page

Page C-1
Page C-2
Drawing 13068A-2 System Diagram

Page C-3
Page C-4
Drawing 13068A-3 Processor Connections

Page C-5
Page C-6
Drawing 13068A-4 Control Head Connections

Page C-7
Page C-8