EasyManua.ls Logo

ZF CruiseCommand 785CE User Manual

ZF CruiseCommand 785CE
160 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Page 1
MM14330 Rev.B 11/01
CruiseCommand 785CE Installation and
Troubleshooting Manual
SW13867.0
Table of Contents
MM14330 Rev.B 11/01................................................................................................................................................ 1
CruiseCommand 785CE Installation and Troubleshooting Manual
Table of Contents ........................................................................................................................................................1
Revisions List ...............................................................................................................................................................1
1.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.1 This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 CruiseCommand System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
2.1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Take Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Basic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Engine Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2: Remote Stations before Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3: Remote Station Transfer after Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4: Control Head Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 5: Control Head Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.7 High / Low Idle Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7.1 Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7.2 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6: High/Low Idle Mode Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7.3 Selecting Between High / Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.8 Synchronization (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9 One Lever Operation Mode (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 7: Step A One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8: Step B One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Trolling Valve Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10.1 Trolling Valve Command Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10.2 Operation in Non-Troll Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10.3 Operation in Troll Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10.4 To turn Troll Mode On: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.10.5 To turn Troll Mode Off:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.10.6 Types of Trolling Valve Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9: Control Head 20 Degree Troll Range - Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10: Control Head 35 Degree Troll Range - Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 11: Control Head 45 Degree Troll Range - Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.0 REQUIRED PARTS AND TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
3.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 12: Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Control System Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the ZF CruiseCommand 785CE and is the answer not in the manual?

ZF CruiseCommand 785CE Specifications

General IconGeneral
BrandZF
ModelCruiseCommand 785CE
CategoryComputer Hardware
LanguageEnglish

Summary

Introduction to CruiseCommand

About This Manual

Outlines the purpose and structure of the manual.

CruiseCommand System Overview

Describes the designed purpose and capabilities of the CruiseCommand System.

CruiseCommand System Features

Lists the key features and functionalities of the CruiseCommand System.

CruiseCommand Operation Guide

DC Power On Procedure

Details the system's behavior when DC power is initially supplied.

Taking Command at a Station

Explains the procedure for a station to gain control of the system.

Basic Control Head Operation

Describes the fundamental operation of the control head lever and detents.

CruiseCommand Operational Functions

Engine Start Interlock Conditions

Explains the safety conditions required for the engine to start.

Station Transfer Procedure

Details the step-by-step process for transferring system control between stations.

Warm-up Mode Engagement

Describes the procedure for engaging engine warm-up mode.

Advanced CruiseCommand Operations

High and Low Idle Modes

Explains the two available engine idle speed settings.

Selecting Between High and Low Idle

Details how to switch between High and Low Idle engine speed modes.

Synchronization for Multi-Screw Systems

Explains the dual lever synchronization feature for multi-engine systems.

One Lever Operation Mode

One Lever Operation for Multi-Screw

Describes the mode where a single lever controls all engines and gears.

Trolling Valve Control Features

Trolling Valve Control Options

Covers the control of electric trolling valves for slow-speed operation.

Trolling Valve Operating Modes

Details the two operational modes: Troll and Non-Troll.

Operation in Troll Mode

Explains how to engage and operate the system in Troll Mode.

Troll Mode Activation and Types

Activating Troll Mode

Step-by-step guide to activating the Troll Mode feature.

Deactivating Troll Mode

Step-by-step guide to deactivating the Troll Mode feature.

Trolling Valve Command Types

Lists the different configuration types for trolling valve commands.

Required Parts and Tools for Installation

Processor Unit Details

Describes the function and role of the central processor unit in the system.

Control Head Specifications

Details the types, connections, and requirements for control heads.

System Power and Wiring Requirements

Control System Power Supply

Specifies the power source requirements and circuit protection for the control system.

Clutch Power Supply

Outlines the dedicated power source for the clutch solenoid.

Available Cable Harnesses

Lists available wire harnesses and selection criteria based on system features.

Installation Tools and Engine Stop Switch

Tools Required for Installation

Lists the necessary and optional tools required for system installation.

Required Installation Tools

Lists the essential tools for performing the installation.

Optional Installation Tools

Lists recommended optional tools that may aid in installation.

Engine Stop Switch Requirement

Mandatory Engine Stop Switch

Mandates the installation of an engine stop switch at each remote station.

Installation Planning Guidelines

Processor Location Considerations

Provides guidance on selecting an appropriate and safe location for the processor.

Control Head Mounting Locations

Discusses considerations for mounting control heads in accessible and protected locations.

400 & MC2000 Series Control Head Mounting

Specific mounting instructions and considerations for 400 and MC2000 series control heads.

DC Power Source Planning

Minimizing DC Power Cable Length

Emphasizes the importance of minimizing power cable lengths to reduce voltage drop.

Core Installation Procedures

Processor Installation Steps

Details the step-by-step procedure for physically installing the processor unit.

Harness Connections for Power and Interlocks

Guides on connecting power, start interlock, and optional circuit harnesses.

Harness Installation Details

Power Cable Installation

Instructions for wiring the main power cable to the system's processor.

Start Interlock Cable Installation

Details the correct procedure for installing the start interlock cable.

Control Head and Optional Harness Installation

Control Head Harness Installation

Explains the choices and installation process for control head wiring harnesses.

Alarm Circuit Installation (Optional)

Refers to the 'Control Options' section for alarm circuit details.

Clutch Pressure Circuit Installation (Optional)

Refers to the 'Control Options' section for clutch pressure details.

Control Head Mounting and Connections

Control Head Mounting Guidelines

Information on control head variations, dimensions, and mounting hole locations.

Mounting Specifics for Control Heads

Specific mounting instructions for different control head series (400, 700, MC2000).

Cable Connections and Aft Facing Heads

Control Head Cable Connection Details

Details on connecting wiring harnesses to the control heads and processor.

Aft Facing Control Head Installation

Specific instructions for installing control heads that face aft.

Synchronization and Throttle Harness Installation

Synchronization Setup for Multi-Screw

Instructions for setting up and enabling engine synchronization for multi-screw vessels.

Tachometer Sensor Harness for Sync

Details the tachometer harness connection for active synchronization systems.

Engine Speed and Clutch/Troll Control Wiring

Throttle Harness for Engine Speed

Connects the processor to the engine interface using the throttle harness.

Clutch and Troll Control Harnesses

Covers the harnesses required for clutch and optional troll control functions.

Specific Clutch/Troll and Stop Switch Installation

Clutch Control Only Harness

Details the clutch harness for systems with clutch control only.

Clutch and Troll Control Harness

Details the clutch and troll control harness for systems with both functions.

Engine Stop Switch Installation

Installation guidance for engine stop switches at each station.

Set-up Procedures: Processor Components

Processor Components for Set-up

Identifies the processor's display and buttons used for system configuration.

Processor Display Functionality

Describes the function and display segments of the processor unit.

Processor Controls and Navigation

Processor Arrow Push Button Functions

Explains the use of arrow push buttons for navigating functions and values.

Up and Down Arrow Button Functions

Details the function of the up and down arrow buttons for menu navigation.

Processor Navigation Buttons

Left and Right Arrow Button Functions

Explains the function of left and right arrow buttons for mode activation and saving.

Left Arrow Button Functionality

Details the function of the left arrow button for exiting set-up without saving.

Right Arrow Button Functionality

Details the function of the right arrow button for clearing error codes.

Activating System Set-up Mode

Procedure to Activate Set-up Mode

Step-by-step guide to entering the system's set-up configuration mode.

Set-up Functions and Value Configuration

Overview of Set-up Functions

Lists and explains various system set-up functions, their codes, and default values.

Table of System Functions and Values

A comprehensive table of all system functions, codes, names, and value ranges.

Processor and Engine Configuration

Processor Identification Setup

Sets a unique identification number for each processor in multi-processor systems.

Number of Engines Configuration

Configures the total number of engines connected to the system.

Throttle and Operation Mode Configuration

One Lever Operation Mode Setup

Enables or disables the one-lever control mode for engine and gear operation.

Engine Throttle Profile Selection

Selects the correct throttle profile for compatibility with different engine types.

Throttle and Idle Speed Settings

Throttle in Neutral Adjustment

Adjusts throttle signal levels for neutral/idle and when the clutch is engaged.

Throttle Minimum Signal Setting

Sets the minimum throttle output signal level.

Throttle Maximum Signal Setting

Sets the maximum throttle output signal level.

Astern Throttle, Pause, and High Idle Settings

Throttle Maximum Astern Adjustment

Sets the maximum allowed throttle percentage when operating in astern.

Throttle Pause Following Shift Setup

Defines the pause duration after clutch engagement before throttle increases.

High Idle Speed Adjustment

Allows adjustment of an elevated idle speed for the engine.

Synchronization and Clutch Interlock Settings

Active Synchronization Enable/Disable

Enables or disables the active synchronization feature between engines.

Clutch Oil Interlock Enable/Disable

Enables or disables the clutch oil pressure interlock safety feature.

Interlock Delay and Reversal Pause Settings

Clutch Oil Interlock Delay Setup

Sets the delay time for the clutch oil pressure interlock system's response.

Reversal Pause Mode Selection

Selects whether the reversal pause occurs in-gear or in neutral during direction changes.

Reversal Pause Time and Ratio Settings

Reversal Pause Time Configuration

Sets the duration of the pause during directional reversals for engine deceleration.

Reversal Pause Ratio Configuration

Determines how the reversal pause time value is applied for different maneuvers.

Trolling Valve Functionality Settings

Troll Lever Range Setup

Configures the lever range settings for the trolling valve operation.

Troll Valve Function Configuration

Sets how the trolling valve current signal behaves based on clutch pressure.

Trolling Pressure and Throttle Limit Settings

Troll Minimum Pressure Setup

Sets the minimum pressure level for the trolling valve operation.

Troll Maximum Pressure Setup

Sets the maximum pressure level for the trolling valve operation.

Troll Throttle Limit Setup

Sets the maximum throttle limit when the trolling valve is actively engaged.

Trolling Pulse and Diagnostic Settings

Troll Pulse Duration Setup

Sets the time duration in seconds for trolling valve commands.

Troll Pulse Percentage Setup

Sets the percentage of maximum troll command for the trolling valve.

Diagnostic Function Access

Accesses diagnostic information for system troubleshooting purposes.

EEPROM Erase and Driver Fault Settings

Erase EEPROM Function

Resets all system parameters to their factory default values.

High Side Driver Fault Enable

Enables monitoring of clutch and troll solenoid circuits for faults.

Solenoid Error Status Mapping

Maps solenoid states to specific error status values for monitoring.

Adjustments and Tests (Engines Stopped)

Control Head Tests (Engines Stopped)

Tests control head functionality and lever response with engines not running.

Start Interlock Tests (Engines Stopped)

Tests the start interlock system's function with engines stopped.

Test Equipment Usage for Adjustments

Using Service Field Test Unit and Multi Meter

Explains the proper use of test equipment for system adjustments and diagnostics.

Functions Requiring Test Equipment

Lists system functions that require specific test equipment for adjustment.

Throttle Signal Adjustments (Engines Stopped)

Throttle Min/Max Signal Adjustment

Adjusts throttle minimum and maximum signals with the engine stopped.

Throttle Output Adjustment Values

Provides adjustment values and procedures for throttle signal outputs.

Tests with Engine Running

Engine Stop Switch Test (Running)

Verifies the functionality of engine stop switches while the engine is operational.

Warm-Up Mode Test (Running)

Verifies warm-up mode operation with the engine running.

Throttle Signal Adjustments (Running)

Throttle in Neutral Signal Adjustment

Adjusts throttle signal levels for neutral/idle and when the clutch is engaged.

Throttle Maximum Astern Signal Adjustment

Sets the maximum allowed throttle percentage when operating in the astern direction.

High Idle Speed Adjustment

High Idle Speed Adjustment Procedure

Adjusts the elevated idle speed setting for the engine.

Underway Adjustment Procedures

Engine RPM Adjustment

Procedures for adjusting and verifying engine RPM during underway operation.

Reversal Pause Adjustment

Details the feature for engine deceleration during high-speed directional reversals.

Trolling Adjustments and RPM Measurement

Trolling Min/Max Pressure Adjustments

Adjusts trolling minimum and maximum pressure settings with the engine running.

Propeller Shaft RPM Measurement

Records propeller shaft RPM measurements after the transmission reaches operating temperature.

Trolling Pressure and Throttle Limit Adjustments

Minimum Trolling Pressure Data

Records data related to minimum trolling pressure measurements.

Troll Throttle Limit Adjustment

Sets the maximum throttle limit when the trolling valve is actively engaged.

Trolling Pressure and Pulse Duration Adjustments

Maximum Trolling Pressure Data

Records data related to maximum trolling pressure measurements.

Troll Pulse Duration Adjustment

Sets the time duration in seconds for trolling valve commands.

Trolling Pulse Percentage Adjustment

Troll Pulse Percentage Configuration

Sets the percentage of maximum troll command for the trolling valve.

Control Options Overview

Alarm Capability Description

Describes the single alarm connection for system power failure or circuit malfunctions.

Clutch Oil Pressure Interlock Function

Explains the safety interlock to prevent high RPM when the clutch is not fully engaged.

System Maintenance Procedures

Control Processor Maintenance

Maintenance checks for the control processor's terminal connections for corrosion or looseness.

Control Head Maintenance

Maintenance checks for control head terminals for security and corrosion.

Appendix A: Parts Information

System Parts List

Lists available system components, part numbers, and descriptions.

Appendix A: Control Head Variations

400 & MC2000 Control Head Variations

Details variations and dimensions for 400 and MC2000 series control heads.

Standard Cable Connections Guide

Instructions for making standard cable connections to various control heads.

Appendix A: Additional Control Head Information

700 Series Control Head Sheet

Technical specifications and diagrams for the 700 series control head.

700 Series Standard Cable Connections

Instructions for making standard cable connections to the 700 series control head.

Appendix A: Specific Control Head Sheets

464-4 Control Head Sheet

Technical specifications and diagrams for the 464-4 control head.

464-4 Standard Cable Connections

Instructions for making standard cable connections to the 464-4 control head.

Appendix A: CH14450 Control Head and Enclosure

CH14450 Control Head Sheet

Technical specifications and diagrams for the CH14450 control head.

CH14450 Standard Cable Connections

Instructions for making standard cable connections to the CH14450 control head.

Appendix A: Watertight Enclosure

400 Series Watertight Enclosure Details

Details and diagrams for the 400 series watertight enclosure for control heads.

Appendix A: Connector and Power Selector Information

Deutsch Connector Assembly Guide

Information on Deutsch industrial products and correct assembly of connectors.

Automatic Power Selector (APS) Installation

Specifications, installation, and wiring diagram for the Automatic Power Selector unit.

APS Installation Diagram

Wiring diagram illustrating the installation of the Automatic Power Selector.

Appendix A: Bonding and References

Bonding Requirements per ABYC Standards

Bonding requirements for electrical systems per ABYC standards for marine vessels.

References and Parts Sources

Lists relevant industry standards, regulations, and sources for system parts.

System Parts Source List

Lists specific part numbers for various components and tools required for the system.

Appendix B.1: Troubleshooting Guide

General Troubleshooting Overview

Provides an overview of the CruiseCommand Control System and its main components.

Control Head Functionality

Describes the primary function of the control head in sending voltage signals to the processor.

Processor Role in the System

Explains the role of the processor in receiving inputs and controlling outputs.

Troubleshooting: System Components and Questions

Electrical Wiring and Harness Function

Details the function of electrical wiring and the types of harnesses used.

Power Source Importance

Stresses the critical importance of a reliable and charged power source for system operation.

Initial Troubleshooting Questions

Basic questions to ask the customer to help narrow down troubleshooting issues.

Troubleshooting: System Configuration and Stations

System Configuration Identification

Identifies the system configuration (single, twin, or multiple screw) for troubleshooting.

Remote Station Count for Diagnostics

Determines the number of remote stations to help isolate potential issues.

Troubleshooting: Tones and LED Indicators

Interpreting Audible Tones

Identifies system issues by analyzing audible tones emitted by the control head.

Checking Control Head LED Status

Checks the status of control head LEDs (lit, not lit, blinking) for diagnostic purposes.

Troubleshooting: Audible Tones and Basic Faults

Audible Tones Indicating System Status

Lists and describes the various audible tones indicating system status or errors.

Slow Repetitive Tone Analysis

Explains the initialization tone and potential causes of low voltage issues.

Troubleshooting: Command Signals and Solenoid Faults

Invalid Command Signal Tone

Identifies an invalid command signal received from a control head.

Steady Tone Indicating System Fault

Indicates a general problem or malfunction within the control system.

Troubleshooting: Solenoid Malfunctions and Station Transfer

Clutch/Neutral Solenoid Malfunction Tones

Signals a malfunction in one or more of the clutch or neutral solenoid circuits.

Troll Solenoid Fault Tone

Indicates a fault detected with the troll ON/OFF or troll proportional solenoids.

Station Transfer Requirements

Outlines the requirements and conditions for transferring command between stations.

Troubleshooting: Command Signals and Station Selection

Command Signal Analysis

Explains the DC voltage signal representing the control head lever position.

Remote Station Select Functionality

Details the function and testing of the station select/transfer button.

Troubleshooting: Transfer Button and Error Messages

Stuck Transfer Button Symptoms

Identifies symptoms and verification steps for a stuck transfer button.

System Error Message Reference

Lists and provides brief descriptions of system error messages.

Table of Error Messages

A comprehensive table detailing error codes and their associated descriptions.

Troubleshooting: Problem Scenarios and Causes

Problem Scenarios Overview

Lists possible causes and solutions for identified system error messages.

Table of Problem Scenarios and Solutions

Maps specific error codes to potential causes and recommended remedies.

Troubleshooting: Problem Scenario Solutions (Part 1)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 2)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 3)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 4)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 5)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 6)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 7)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 8)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 9)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 10)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 11)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 12)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 13)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 14)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 15)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 16)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 17)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Problem Scenario Solutions (Part 18)

Problem Scenarios and Solutions (Continued)

Continues the mapping of error codes to potential causes and remedies.

Troubleshooting: Symptom Analysis

RPM Variation Symptom

Engine RPM varies without lever movement, synchronization is disabled.

No Audible Tone Symptom

No audible tone at one control head on power-up; system otherwise functions normally.

Red LED Not Lighting Symptom

Control head red LED remains off when in command, but other functions operate correctly.

Troubleshooting: Mode and Display Faults

Warm-up Mode Error Symptom

Warm-up Mode is unavailable in the Ahead direction, only functioning in Astern.

No Tone/Light/Command/Display Symptom

System shows no tone, light, or command; display remains unlit.

Starting Interruption Symptom

Engine starts turning over then stops; a slow repetitive tone is heard at all stations.

Troubleshooting: Synchronization and RPM Faults

Inoperable Active Synchronization

The active synchronization feature between engines is not functioning correctly.

Incorrect Idle/Full Throttle RPMs

Engine idle and full throttle RPMs are either excessively high or too low.

Troubleshooting: Cable Harness Information

Cable Harness Overview

Information on various cable harnesses manufactured and tested by ZF Mathers.

Power and Start Interlock Harness

Wiring information and pin-outs for power and start interlock harnesses.

Troubleshooting: Harness Wiring Details

Power, Start Interlock & Pressure Switch Harness

Wiring details for power, start interlock, and pressure switch harnesses.

Power, Start Interlock, Pressure Switch & Alarm Harness

Wiring details for power, start interlock, pressure switch, and alarm harnesses.

Troubleshooting: Throttle Harness Wiring

Throttle PWM Harness Wiring

Wiring information and pin-outs for Throttle PWM harnesses.

Throttle Voltage Harness Wiring

Wiring information and pin-outs for Throttle Voltage harnesses.

Throttle Current Harness Wiring

Wiring information and pin-outs for Throttle Current harnesses.

Troubleshooting: Clutch and Serial Harness Wiring

Clutch Power, Ahead & Astern Harness

Wiring information for clutch power, ahead, and astern harnesses.

Clutch Power, Ahead, Neutral & Astern Harness

Wiring information for clutch power, ahead, neutral, and astern harnesses.

Troubleshooting: Troll and Communication Harnesses

Clutch, Troll Control Harness Wiring

Wiring for clutch, troll on/off, and troll command harnesses.

Serial Communication Harness Wiring

Wiring information and pin-outs for serial communication harnesses between processors.

Troubleshooting: Sensor and Control Head Wiring

Tachometer Sensor Harness Wiring

Wiring details and pin-outs for tachometer sensor harnesses.

Control Head Harness Pin-Out

Wiring pin-out information for connecting control heads to the processor.

Throttle Signal Testing Procedures

DC Voltage Throttle Signal Test

Procedures for testing the throttle signal's DC voltage output.

Current (mA) Throttle Signal Test

Procedures for testing the throttle signal's current (mA) output.

PWM Throttle Signal Testing Methods

PWM Throttle Test with Duty Cycle Meter

Testing PWM throttle signals using a duty cycle meter.

PWM Throttle Test with DC Voltmeter

Testing PWM throttle signals using a DC voltmeter.

Clutch and Troll System Testing

Ahead Clutch Circuit Testing

Steps to test the voltage output of the ahead clutch circuit.

Astern Clutch Circuit Testing

Steps to test the voltage output of the astern clutch circuit.

Solenoid Circuit Testing Procedures

Neutral Solenoid Circuit Test

Steps to test the voltage output of the neutral solenoid circuit.

Troll On/Off Solenoid Circuit Test

Steps to test the voltage output of the troll on/off solenoid circuit.

Troll Command Valve Testing

Troll Command Proportional Valve Test

Steps to test the current output of the troll command proportional valve.

EEPROM Erase Functionality

Erase EEPROM Procedure

Function to restore all system parameters to factory default values.

Related product manuals