Name: ZF Marine ClearCommand 9000 Series
Brand: ZF Marine
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ClearCommand 9000 Series

Installation, Operation and

Troubleshooting Manual

MM9000-I Rev C.2 5/08

Table of Contents5
Table O F C O N T E N T S6
Revisions List18
I N T R O D U C T I O N19
M a N U a L C O N T E N T S19
B a S I C T H E O R y O F O P E R a T I O N19
N O I D , T R O L L - S O L E N O I D )19
Figure 1 - 1 : B a S I C 9 1 2 0 O R 9 1 2 2 C L E a R C O M M a N D S y S T E M D I a G R a M20
9 1 2 1 P R O C E S S O R ( T H R O T T L E - S E R V O 2 , S H I F T - S O L E N O I D , T R O L L - S E R V O 1 )21
Figure 1 - 2 : B a S I C 9 1 2 1 C L E a R C O M M a N D S y S T E M D I a G R a M21
9 2 1 0 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 )22
Figure 1 - 3 : B a S I C 9 2 1 0 C L E a R C O M M a N D S y S T E M D I a G R a M22
9 2 1 1 P R O C E S S O R ( T H R O T T L E - E L E C T R O N I C , S H I F T - S E R V O 1 , T R O L L - S E R V O 2 )23
Figure 1 - 4 : B a S I C 9 2 1 1 C L E a R C O M M a N D S y S T E M D I a G R a M23
Figure 1 - 5 : B a S I C 9 2 2 1 C L E a R C O M M a N D S y S T E M D I a G R a M24
S y S T E M F E a T U R E S25
T a N D a R D P R O C E S S O R F E a T U R E S25
9 0 0 0 S E R I E S a D D I T I O N a L F E a T U R E S25
P T I O N a L S y S T E M F E a T U R E S ( S E C T I O N 2 - 1 6 )25
P E R a T I O N26
D C P O W E R O N26
T a K I N G C O M M a N D26
Figure 2 - 1 : S T a T I O N T a K I N G C O M M a N D26
B a S I C O P E R a T I O N27
O R M a L O P E R a T I N G M O D E27
Figure 2 - 2 : C O N T R O L H E a D D E T E N T S27
T R O L L I N G V a L V E O P E R a T I O N L27
S T a R T I N T E R L O C K ( I F U S E D )28
Figure 2 - 3 : C O N T R O L H E a D 2 0 D E G R E E T R O L L R a N G E - T y P E 128
Figure 2 - 4 : C O N T R O L H E a D 3 5 D E G R E E T R O L L R a N G E - T y P E 228
Figure 2 - 5 : C O N T R O L H E a D 4 5 D E G R E E T R O L L R a N G E - T y P E 328
Figure 2 - 6 : C O N T R O L H E a D 5 5 D E G R E E T R O L L R a N G E - T y P E 428
S T a T I O N T R a N S F E R29
Figure 2 - 7 : R E M O T E S T a T I O N S B E F O R E T R a N S F E R O F C O M M a N D29
P R O P O R T I O N a L P a U S E29
W a R M - U P M O D E29
Figure 2 - 9 : C O N T R O L H E a D W a R M - U P M O D E29
H I G H / L O W I D L E30
O W I D L E30
I G H I D L E30
E L E C T I N G B E T W E E N H I G H a N D L O W I D L E30
Figure 2 - 1 1 : H I G H / L O W I D L E M O D E S E L E C T I O N31
N E L E V E R M O D E ( T W I N S C R E W )31
T U R N I N G O N O N E L E V E R O P E R a T I O N31
Figure 2 - 1 2 : S T E P a ) O N E L E V E R O P E R a T I O N M O D E32
T U R N I N G O F F O N E L E V E R O P E R a T I O N32
N G I N E S y N C H R O N I Z a T I O N ( T W I N S C R E W )32
Figure 2 - 3 1 : T H R E E S E C O N D S T E a D y T O N42
Figure 2 - 3 2 : C I R C U I T B O a R D S H I E L D L a y O U43
C L U T C H P R E S S U R E I N T E R L O C44
M U L T I P L E S C R E W I N S T a L L a T I O N45
P L a N T H E I N S T a L L a T I O N46
S y S T E M R E Q U I R E M E N T S46
Figure 3 - 1 : P R O C E S S O R D I M E N S I O N S46
R O C E S S O R ( S )47
O N T R O L H E a D ( S )47
T a N D a R D W I R E H a R N E S S E S48
H a R N E S S E S48
D D I T I O N a L H a R N E S S E S49
L U T C H49
L U T C H / T R O L L H a R N E S S49
T a N D a R D E L E C T R I C C a B L E S50
P O W E R E L E C T R I C C a B L E R E Q U I R E M E N T S50
S T a R T I N T E R L O C K E L E C T R I C C a B L E R E Q U I R E M E N T S50
C L U T C H P R E S S U R E I N T E R L O C K E L E C T R I C C a B L E R E Q U I R E M E N T S51
E X T E R N a L a L a R M C I R C U I T E L E C T R I C C a B L E R E Q U I R E M E N T S51
A C T a C H I N P U T51
O P E N C O L L E C T O R ( a C T I V E )51
D D I T I O N a L E L E C T R I C C a B L E S52
H R O T T L E E L E C T R I C C a B L E R E Q U I R E M E N T S52
L U T C H E L E C T R I C C a B L E R E Q U I R E M E N T S52
P T I O N a L T O O L S54
E Q U I R E D P a R T S54
D C P O W E R S O U R C E54
N S T a L L a T I O N56
P R O C E S S O R56
C O N T R O L H E a D ( S )56
4 0 0 , M C 2 0 0 0 a N D 7 0 0 S E R I E S C O N T R O L H E a D S56
5 0 0 S E R I E S C O N T R O L H E a D S56
A N D H E L D R E M O T E C O N T R O L S56
W I R E H a R N E S S I N S T a L L a T I O N56
L U G I N S E R T I O N a N D E X T R a C T I O N56
Figure 4 - 1 : H a R N E S S P L U G K E y I N G56
T a N D a R D P O W E R / S T a R T I N T E R L O C K H a R N E S S57
D C P O W E R C a B L E57
Figure 4 - 3 : S T a R T I N T E R L O C K C O N N E C T I O N S57
( O P T I O N a L )57
T a N D a R D C O N T R O L H E a D H a R N E S S57
Figure 4 - 2 : H a R N E S S P L U G L O C K I N G M E C H a N I S M S57
O N E P L U G58
E R I a L C O M M U N I C a T I O N H a R N E S S ( T W I N S C R E W O N L y )58
A C H S E N S O R H a R N E S S ( R E Q U I R E D F O R a C T I V E S y N C H R O N I Z a T I O N )59
D D I T I O N a L 9 0 0 0 S E R I E S H a R N E S S E S59
L U T C H / T R O L L H a R N E S S59
H a R D - W I R E D C a B L E60
I Q U I D T I G H T C O N N E C T O R60
Figure 4 - 4 : L I Q U I D T I G H T I N S T a L L a T I O N60
T a N D a R D P R O C E S S O R C a B L E H O L E S60
Figure 4 - 5 : S T a N D a R D E N C L O S U R E C a B L E H O L E S60
T a N D a R D C I R C U I T B O a R D C O N N E C T I O N S60
9 0 0 0 S E R I E S C I R C U I T B O a R D T E R M I N a T I O N P O I N T S63
Figure 4 - 1 1 : 9 0 0 0 S E R I E S C I R C U I T B O a R D H a R D - W I R E D T E R M I N a T I O N P O I N T S63
O C a T I O N S 1 - 9 I N S T a L L a T I O N64
Figure 4 - 1 2 : S E V E N - C O N D U C T O R C O N T R O L H E a D C a B L E S H I E L D W I R E a N D H E a T - S H R I N K64
Revision List251
Introduction251
Procedure: Throttle Signal Testing252
DC Voltage252
Current (Ma252
PWM (Pulse Width Modulation) with DC Voltmeter253
PWM (Pulse Width Modulation) with Duty Cycle Meter253
Frequency (Hz253
Procedure: Clutch Testing254
Neutral Solenoid Testing254
Ahead Solenoid Testing254
Astern Solenoid Testing254
Procedures: Troll Testing255
Troll On/Off Solenoid255
Troll Command (Proportional Solenoid) Testing with Amp Meter255
Procedure: 2-Speed Testing256
2Nd Gear Disengaged256
2Nd Gear Engaged256
Parts List256

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ZF Marine ClearCommand 9000 Series Specifications

General

Brand	ZF Marine
Model	ClearCommand 9000 Series
Category	Control Systems
Language	English

ZF Marine ClearCommand 9000 Series User Manual

Table of Contents

Questions and Answers:

ZF Marine ClearCommand 9000 Series Specifications