ZF Marine ClearCommand 9000 Series User Manual

TABLE OF CONTENTS
TOC-13
EN G-145 Ver 1.0 4-04 .......................................................................................................................... B-11
ClearCommand 9000 Ser-Thr Sol-Cl Qualitative Failure Analysis & Design Verification Test Procedure
M MC-172 Rev.Z-O 11/03 ..................................................................................................................... B-15
Factory Authorized Sales & Service Centers - International
M M13927 Table of C ontents ..............................................................................................................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: C onnector/Pigtail Descriptio ns... ... ... .. ... ... ... .. ... ... ... .. ... ... ... ... .. ... ... ... .. ... ... ... .. ... ... ... .. ... ... ............................... 1-2
2 PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 Thro ttle Signal Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.1 DC Vo lta ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-4: Throttle Connection (DC Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.2 C urr e nt (mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-5: Th rottle Connection (Current mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1.3 PWM (Pul se W idth Mo dul a tio n) w ith DC V oltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-6: Throttle Connection (PWM with DC Voltmeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-1.4 PWM (Pul se W idth Mo dul a tio n) w ith Duty Cycl e Me ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7: Throttle Connection (PWM with Duty Cycle Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-1.5 Fre que ncy (Hz.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-8: Th rottle Connection (Frequency Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 CLUTCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -6
2-2.1 Neu tral S ol eno id Tes ting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-9: Clutch Co nnection (Neutral Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2.2 Ahea d So l eno id T esting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-10: Clutch Connection (Ahead Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2.3 Astern So le noi d Te sting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 7
Figure 2-11: Clutch Connection (Astern Solenoi d ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3 TROLL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.1 Tr o l l On/Off So le no id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-12: Troll Connect ion (ON/OFF Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.2 T r o l l Co mmand (Pro p o rti o nal Solenoi d) Testing w i th Amp Me ter . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-13: Troll Connection (Proportional Solenoid with Amp Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3 Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Table 3-2: Parts Li st . ...... .. ... ... ... ... .. ... ... ... .. ... ... ... .. ... ... ... .. ... ... ... .. ... ... ... ... .. ... ... ... .. ...... ... .. ... ............................................. 3-1
Appendix C
D rawing 12284A-1 ClearCommand Diagram (all options) .................................................................... C-1
Drawing 12284A-2 ClearCommand Circuit Board Connections............................................................ C-3
Drawing 12284A-3 ClearCommand Drawing Notes Page..................................................................... C-5

ZF Marine ClearCommand 9000 Series Specifications

General

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