ZF MM9000 Betriebsanleitung

INSTALLATION, OPERATION

AND TROUBLESHOOTING

MM9000 - CLEAR COMMAND USER MANUAL

MARINE PROPULSION SYSTEMS

2EN 3340.758.003a - 2014-11

Released by After Sales dept.

Data subject to change without notice. We decline all responsibility for the use of non-original components or accessories wich

have not been tested and submitted for approval.

ZF reserves all rights regarding the shown technical information including the right to le industrial property right applica-

tions and the industrial property rights resulting from these in Germany and abroad.

EN 3340.758.003a - 2014-11

TABLE OF CONTENT

MM9000 Rev C.8 01/13 Page 3

MM9000 ClearCommand User Manual

Table of Contents

Installation, Operation and Troubleshooting Manual

SW15623.OE

ClearCommand User Manual.......................................................... 1

Table of Contents................................................................................. 3

List of Figures....................................................................................... 7

List of Tables ...................................................................................... 13

Revision List ....................................................................................... 15

Preface ............................................................................................... 17

1 Introduction........................................................................................ 21

1.1 Basic Theory of Operation ...............................................................................................................21

1.2 System Features ..............................................................................................................................26

2 Operation ........................................................................................... 27

2.1 DC Power On ...................................................................................................................................27

2.2 Taking Command.............................................................................................................................27

2.3 Basic Operation ...............................................................................................................................28

2.4 Start Interlock (if used)....................................................................................................................29

2.5 Station Transfer ...............................................................................................................................30

2.6 Proportional Pause ..........................................................................................................................30

2.7 Warm-up Mode................................................................................................................................31

2.8 High/Low Idle ..................................................................................................................................32

2.9 One Lever Mode (Twin Screw) ........................................................................................................33

2.10 Engine Synchronization (Twin Screw).............................................................................................35

2.11 Control System’s Configurability .....................................................................................................37

2.12 Audible Tones ..................................................................................................................................39

2.13 Push Button Set Up .........................................................................................................................41

2.14 Visual System Diagnostics, Set Up And Status Indication ..............................................................41

2.15 Pluggable Connections....................................................................................................................42

2.16 Optional Features Operation ...........................................................................................................43

3 Plan the Installation ........................................................................... 45

3.1 System Requirements......................................................................................................................45

3.2 Installer Supplied Tools And Parts...................................................................................................50

3.3 DC Power Source ............................................................................................................................51

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Table of Contents

4 Installation ......................................................................................... 53

4.1 Processor.........................................................................................................................................53

4.2 Control Head(s) ...............................................................................................................................53

4.3 Wire Harness Installation ................................................................................................................53

4.4 Hard-Wired Cable ............................................................................................................................58

4.5 Engine Stop Switches......................................................................................................................73

4.6 Push-Pull Cable Connections...........................................................................................................74

5 Set up Procedure ............................................................................... 77

5.1 Processor Components Used In Set Up ..........................................................................................77

5.2 Activating Set Up Mode...................................................................................................................80

5.3 Storing Values To Memory ..............................................................................................................80

5.4 Set Up Function Codes And Values .................................................................................................80

5.5 Field Service Test Unit (Break-out Box) and Multimeter Use..........................................................85

5.6 System Programming And Adjustments..........................................................................................86

5.7 Function Code E1 – Throttle in Neutral ...........................................................................................91

6 Dock Trials ....................................................................................... 113

6.1 Control Heads (Engines Stopped) .................................................................................................113

6.2 Start Interlock (Engines Stopped) .................................................................................................113

6.3 Engine Stop Switches....................................................................................................................113

6.4 Push-Pull Cables ............................................................................................................................113

6.5 High Idle ........................................................................................................................................113

6.6 Control Head Servo Command ......................................................................................................114

6.7 Control Head Solenoid Command .................................................................................................114

6.8 Throttle Pause Following Servo Shift ............................................................................................114

6.9 Throttle Pause Following Solenoid Shift .......................................................................................114

6.10 Trolling Valve .................................................................................................................................115

7 Sea Trials.......................................................................................... 117

7.1 Full Speed Setting - Servo Throttle................................................................................................117

7.2 Full Speed Setting - Electronic Throttle.........................................................................................117

7.3 Proportional Pause ........................................................................................................................117

7.4 Synchronization Test (Twin Screw Only).......................................................................................119

7.5 Sea Trial Report .............................................................................................................................124

F-226 9000 Series Sea Trial Report ................................................................................. 125

8 Control Options................................................................................ 131

8.1 External Alarm Capability ..............................................................................................................131

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Table of Contents

8.2 Clutch Pressure Interlock ..............................................................................................................132

8.3 Station Expander (SE)....................................................................................................................133

8.4 9001 Actuator Trolling Valve Control.............................................................................................134

9 Periodic Checks and Maintenance .................................................. 135

9.1 Control Heads................................................................................................................................135

9.2 Processor.......................................................................................................................................135

9.3 Power Supply.................................................................................................................................135

10 Troubleshooting ............................................................................... 137

10.1 General ..........................................................................................................................................137

10.2 Troubleshooting Questions............................................................................................................143

10.3 Troubleshooting Problem Resolution ............................................................................................144

10.4 Troubleshooting Diagnostic Menu ................................................................................................145

10.5 Troubleshooting Audible Tones .....................................................................................................148

10.6 Troubleshooting Station Transfer ..................................................................................................154

10.7 Troubleshooting Stuck Transfer Button.........................................................................................156

10.8 Error Codes....................................................................................................................................156

10.9 Basic Problem Causes And Solutions............................................................................................160

10.10 Problems Without Error Codes......................................................................................................172

10.11 Synchronization Troubleshooting ..................................................................................................175

10.12 Troubleshooting Wire Harnesses ..................................................................................................179

10.13 Processor Pigtails ..........................................................................................................................193

11 Appendix A - System Components and Specifications.................... 197

MMC-280 400 Series Control Head Variations................................................................ 199

MMC-329 MC2000 Series Standard Control Head Variations......................................... 205

MMC-307 700 Series Standard Control Head Variations ................................................ 209

MMC-279 400 Series Weather Mount Enclosure ............................................................ 215

Deutsch Connector Assembly.......................................................................................... 217

S-214 Automatic Power Selector Model: 13505 ............................................................. 219

Drawing 11488 DC Power Source Kit .............................................................................. 221

MMC-287 Grounding (Bonding) ...................................................................................... 231

MMC-288 References and Parts Source ......................................................................... 233

SER-161 Engine Tach Sender Req. .................................................................................. 235

MMC-289 Morse Clutch and Throttle Kit......................................................................... 237

MMC-290 Universal Mounting Kit ................................................................................... 239

MMC-345 43C Cable Conversion Kit ............................................................................... 241

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Table of Contents

MMC-343 Station Expander User Instructions ................................................................ 243

12 Appendix B - QFA & DVTP................................................................ 257

ENG-127 9000 Series Micro/ClearCommand Servo Throttle - Servo Clutch Qualitative Failure

Analysis, Design Verification Test Procedure and Periodic Safety Test .......................... 259

ENG-143 9000 Series ClearCommand Throttle - Solenoid Clutch Qualitative Failure Analysis,

Design Verification Test Procedure and Periodic Safety Test ......................................... 263

ENG-144 9000 Series Electronic Throttle - Servo Clutch Qualitative Failure Analysis, Design

Verification Test Procedure and Periodic Safety Test ..................................................... 267

ENG-145 9000 Series Servo Throttle - Solenoid Clutch, Qualitative Failure Analysis & Design

Verification Test Procedure ............................................................................................. 271

13 Appendix C - Sales and Service Information ................................... 275

MMC-123 Factory Authorized Sales & Service - North America ..................................... 277

MMC-151 Factory Authorized Service Centers - North America..................................... 283

MMC-172 Factory Authorized Sales & Service Centers - International........................... 295

MMC-165 Warranty ......................................................................................................... 303

MMC-163 Warranty Registration..................................................................................... 305

MM13927 Field Service Test Unit .................................................... 307

14 Appendix D - System Drawings ....................................................... 323

Drawing 12284 ClearCommand All Configuration Twin Screw System Drawing .............. 325

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LIST OF FIGURES

MM9000 Rev C.8 01/13 Page 7

MM9000 ClearCommand User Manual

List of Figures

Figure 1-1: Basic 9120 or 9122 ClearCommand System Diagram .......................................................................... 22

Figure 1-2: Basic 9121 ClearCommand System Diagram ....................................................................................... 23

Figure 1-3: Basic 9210 ClearCommand System Diagram ....................................................................................... 24

Figure 1-4: Basic 9211 ClearCommand System Diagram ....................................................................................... 25

Figure 1-5: Basic 9221 ClearCommand System Diagram ....................................................................................... 26

Figure 2-1: Station taking Command ..................................................................................................................... 27

Figure 2-2: Control Head Detents .......................................................................................................................... 28

Figure 2-3: Control Head 20 Degree Troll Range - Type 1 ...................................................................................... 29

Figure 2-4: Control Head 35 Degree Troll Range - Type 2 ...................................................................................... 29

Figure 2-5: Control Head 45 Degree Troll Range - Type 3 ......................................................................................29

Figure 2-6: Control Head 55 Degree Troll Range - Type 4 ......................................................................................29

Figure 2-7: Remote Stations Before Transfer of Command..................................................................................... 30

Figure 2-8: Remote Station Transfer after Transfer of Command ............................................................................ 30

Figure 2-9: Control Head Warm-Up Mode ............................................................................................................. 31

Figure 2-10: Control Head Normal Operating Mode............................................................................................... 31

Figure 2-11: High/Low Idle Mode Selection........................................................................................................... 32

Figure 2-12: Step A) One Lever Operation Mode ................................................................................................... 33

Figure 2-13: Step B) One Lever Operation Mode ................................................................................................... 34

Figure 2-14: Circuit Board Shield Layout................................................................................................................ 41

Figure 2-15: Standard Processor Pluggable Connections View .............................................................................. 42

Figure 3-1: Processor Dimensions.......................................................................................................................... 45

Figure 4-1: Harness Plug Keying............................................................................................................................53

Figure 4-2: Start Interlock Connections..................................................................................................................54

Figure 4-3: Twin Screw Serial Harness Connections .............................................................................................. 56

Figure 4-4: Liquid Tight Installation........................................................................................................................ 58

Figure 4-5: Standard Enclosure Cable Holes .......................................................................................................... 58

Figure 4-6: Standard Circuit Board Hard-Wired Termination Points........................................................................ 59

Figure 4-7: 9120 and 9121 Enclosure Cable Holes ................................................................................................ 60

Figure 4-8: 9122 Enclosure Cable Holes ................................................................................................................ 61

Figure 4-9: 9210 and 9211 Enclosure Cable Holes ................................................................................................ 62

Figure 4-10: 9221 Enclosure Cable Holes .............................................................................................................. 63

Figure 4-11: 9000 Series Circuit Board Hard-Wired Termination Points ................................................................. 64

Figure 4-12: Seven-Conductor Control Head Cable Shield Wire and Heat-Shrink ................................................... 65

Figure 4-13: Clamp Views .....................................................................................................................................65

Figure 4-14: Terminal Strip Cable Connections ...................................................................................................... 65

Figure 4-15: Two-Conductor Start Interlock Cable ................................................................................................. 66

Figure 4-16: Two-Conductor Power Cable ............................................................................................................. 67

Figure 4-17: Four-Conductor Serial Communication Cable..................................................................................... 67

Figure 4-18: AC Type Tachometer Cable ............................................................................................................... 68

Figure 4-19: Open Collector Tachometer Cable ..................................................................................................... 69

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LIST OF FIGURES

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List of Figures

Figure 4-20: Clutch Cable Heat Shrink in Processor ............................................................................................... 69

Figure 4-21: Clutch Cable Plug Termination Connections....................................................................................... 70

Figure 4-22: Clutch/Troll Cable Heat Shrink in Processor ....................................................................................... 70

Figure 4-23: Clutch Cable Plug Termination Connections....................................................................................... 71

Figure 4-24: Clutch Cable Heat Shrink in Processor ............................................................................................... 72

Figure 4-25: Clutch Cable Plug Termination Connections....................................................................................... 72

Figure 4-26: Engine Shield ....................................................................................................................................73

Figure 4-27: Processor Cable Clamp Rotation........................................................................................................ 74

Figure 4-28: Push-Pull Cable Interior Connection ................................................................................................... 74

Figure 4-29: Throttle Push-Pull Idle Orientation to Selector Lever........................................................................... 75

Figure 4-30: Shift Push-Pull Cable Neutral Connection at Transmission.................................................................. 75

Figure 5-1: Typical Processor Cover....................................................................................................................... 77

Figure 5-2: Processor Shield Push Button and Display LED Locations .................................................................... 78

Figure 5-3: Display LED at Normal Operation......................................................................................................... 78

Figure 5-4: Display LED Designations .................................................................................................................... 78

Figure 5-5: Circuit Board Push Buttons .................................................................................................................. 79

Figure 5-6: Display LED Error Menu Example......................................................................................................... 79

Figure 5-7: Display LED Four Digit Value................................................................................................................ 79

Figure 5-8: Service Field Test Unit and Multimeter................................................................................................. 85

Figure 5-9: E1, E2, E3, E4, E6, L4 Processor, Test Unit, and Multimeter Connections ............................................86

Figure 5-10: L2, L3, C6, and C7 Processor, Test Unit, and Multimeter Connections ............................................... 86

Figure 5-11: Display LED Function A0 Set Up Activated......................................................................................... 87

Figure 5-12: Display LED Function A1 Set Up Activated......................................................................................... 88

Figure 5-13: Display LED Function A2 Set Up Activated......................................................................................... 88

Figure 5-14: Display LED Function A3 Set Up Activated......................................................................................... 89

Figure 5-15: Display LED Function A4 Set Up Activated......................................................................................... 89

Figure 5-16: Display LED Function E5 Set Up Activated......................................................................................... 90

Figure 5-17: Display LED Function E6 Set Up Activated......................................................................................... 90

Figure 5-18: Display LED Function E1 Set Up Activated......................................................................................... 91

Figure 5-19: Display LED Function E4 Set Up Activated......................................................................................... 91

Figure 5-20: Display LED Function E7 Set Up Activated......................................................................................... 92

Figure 5-21: Throttle Push-Pull Cable Orientation................................................................................................... 92

Figure 5-22: Example: Throttle Push-Pull Cable Fully Retracted Position for Idle..................................................... 93

Figure 5-23: Display LED Function E0 Set Up Activated......................................................................................... 93

Figure 5-24: Display LED Function E2 Set Up Activated......................................................................................... 93

Figure 5-25: Throttle Push-Pull Cable Full Throttle Position .................................................................................... 94

Figure 5-26: Display LED Function E3 Set Up Activated......................................................................................... 94

Figure 5-27: Display LED Function E0 Set Up Activated......................................................................................... 95

Figure 5-28: Display LED Function E2 Set Up Activated......................................................................................... 95

Figure 5-29: Display LED Function E3 Set Up Activated......................................................................................... 96

Figure 5-30: Display LED Function C0 Set Up Activated......................................................................................... 96

Figure 5-31: Display LED Function C1 Set Up Activated......................................................................................... 97

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LIST OF FIGURES

MM9000 Rev C.8 01/13 Page 9

MM9000 ClearCommand User Manual

List of Figures

Figure 5-32: Display LED Function C2 Set Up Activated......................................................................................... 97

Figure 5-33: Display LED Function C3 Set Up Activated......................................................................................... 98

Figure 5-34: Display LED Function C4 Set Up Activated......................................................................................... 99

Figure 5-35: Clutch Push-Pull Cable Orientation .................................................................................................. 100

Figure 5-36: Display LED Function C5 Set Up Activated....................................................................................... 100

Figure 5-37: Clutch Push-Pull Cable Ahead Position ............................................................................................ 101

Figure 5-38: Display LED Function C6 Set Up Activated....................................................................................... 101

Figure 5-39: Clutch Push-Pull Cable Astern Position ............................................................................................ 102

Figure 5-40: Display LED Function C7 Set Up Activated....................................................................................... 102

Figure 5-41: Display LED Function C5 Set Up Activated....................................................................................... 103

Figure 5-42: Display LED Function C6 Set Up Activated....................................................................................... 103

Figure 5-43: Display LED Function C7 Set Up Activated....................................................................................... 104

Figure 5-44: Display LED Function L0 Set Up Activated. ...................................................................................... 105

Figure 5-45: Control Head 20 Degree Troll Range - Type 1 ..................................................................................105

Figure 5-46: Control Head 35 Degree Troll Range - Type 2 ..................................................................................105

Figure 5-47: Control Head 45 Degree Troll Range - Type 3 .................................................................................. 105

Figure 5-48: Control Head 55 Degree Troll Range - Type 4 ..................................................................................105

Figure 5-49: Display LED Function L1 Set Up Activated ....................................................................................... 106

Figure 5-50: Display LED Function L1 Set Up Activated ....................................................................................... 107

Figure 5-51: Display LED Solenoid Function L2 Set Up Activated......................................................................... 107

Figure 5-52: Display LED Servo Function L2 Set Up Activated.............................................................................. 107

Figure 5-53: Display LED Solenoid Function L3 Set Up Activated......................................................................... 108

Figure 5-54: Display LED Servo Function L3 Set Up Activated.............................................................................. 108

Figure 5-55: Display LED Solenoid Function L4 Set Up Activated......................................................................... 109

Figure 5-56: Display LED Function L6 Set Up Activated ....................................................................................... 110

Figure 5-57: Display LED Function L6 Set Up Activated ....................................................................................... 110

Figure 8-1: External Alarm Connections Processor Hard-Wired Example ............................................................. 131

Figure 8-2: External Alarm Connections Processor Hard-Wired Example ............................................................. 131

Figure 8-3: Clutch Pressure Switch with Processor Harness Diagram...................................................................133

Figure 8-4: Clutch Pressure Switch with Processor Hard-Wired Diagram ............................................................. 133

Figure 10-1: 9120 and 9122 Basic Twin Screw, Two Station Diagram ................................................................. 137

Figure 10-2: 9121 Basic Twin Screw, Two Station Diagram................................................................................. 138

Figure 10-3: 9210 Basic Twin Screw, Two Station Diagram................................................................................. 139

Figure 10-4: 9211 Basic Twin Screw, Two Station Diagram................................................................................. 140

Figure 10-5: 9221 Basic Twin Screw, Two Station Diagram................................................................................. 141

Figure 10-6: Display Function Code List............................................................................................................... 146

Figure 10-7: Display Troubleshooting Function .................................................................................................... 146

Figure 10-8: Display Troubleshooting Function Blinking....................................................................................... 146

Figure 10-9: Example Display of Applied Battery Voltage..................................................................................... 146

Figure 10-10: Example Display of Tach Sensor Frequency ................................................................................... 146

Figure 10-11: Example Display Control Head Lever Current Positions .................................................................. 147

Figure 10-12: Example Display Control Head Transfer Button Status View ...........................................................147

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LIST OF FIGURES

MM9000 Rev C.8 01/13 Page 10

MM9000 ClearCommand User Manual

List of Figures

Figure 10-13: Example Display Software Revision Level View .............................................................................. 147

Figure 10-14: Display Examples of Remote Stations ............................................................................................ 149

Figure 10-15: Display Examples of Remote Stations A/D Value............................................................................ 150

Figure 10-16: Display Station A/D’s No Station Transfer Button Depressed.......................................................... 155

Figure 10-17: Example Display Station A/D’s Transfer Button Depressed for Stations 1 - 4 .................................. 155

Figure 10-18: Display Station A/D/s Transfer Button Depressed for Station 5....................................................... 155

Figure MMC-280-1: Part Numbering Configurations ........................................................................................... 199

Figure MMC-280-2: Detents Available ................................................................................................................. 199

Figure MMC-280-3: Dimensions .......................................................................................................................... 200

Figure MMC-280-4: Terminal Connections .......................................................................................................... 201

Figure MMC-280-5: AFT Facing Control Head ..................................................................................................... 201

Figure MMC-329-1: Part Numbering Configurations Detents Available ................................................................ 205

Figure MMC-329-2: Dimensions .......................................................................................................................... 206

Figure MMC-329-3: Terminal Connections .......................................................................................................... 207

Figure MMC-329-4: AFT Facing Control Head ..................................................................................................... 207

Figure MMC-307-1: Part Numbering Configurations ............................................................................................ 209

Figure MMC-307-2: Detents Available ................................................................................................................. 209

Figure MMC-307-3: Dimensions .......................................................................................................................... 209

Figure MMC-307-4: Dual Control Head Connections ........................................................................................... 211

Figure MMC-307-5: Aft Facing Control Head....................................................................................................... 211

Figure MMC-343-1: Station Expander.................................................................................................................. 244

Figure MMC-343-2: Station Expander Harness Connector Locations .................................................................. 246

Figure MMC-343-3: Harness Plug Connectors ..................................................................................................... 246

Figure MMC-343-4: Station Expander Dimensions............................................................................................... 247

Figure MMC-343-5: Station Expander Display LED and Arrow Push Buttons........................................................ 249

Figure MMC-343-6: Display LED at Normal Operation ......................................................................................... 250

Figure MMC-343-7: Display LED Designations..................................................................................................... 250

Figure MMC-343-8: Error Menu Example ............................................................................................................ 251

Figure MMC-343-9: Display LED Four Digit Value ................................................................................................ 251

Figure MMC-343-10: Display Normal Operating Condition .................................................................................. 251

Figure MMC-343-11: Display Function Menu Activated ....................................................................................... 252

Figure MMC-343-12: Display with Set up Activated.............................................................................................252

Figure MMC-343-13: Display with A0 - Station Expander Identification Set Up Activated .................................... 253

Figure MM13927-1: .Service Field Test Unit (Break-out Box)............................................................................... 311

Figure MM13927-2: CruiseCommand Connector Locations ................................................................................. 311

Figure MM13927-3: Example of CLEARCommand Pigtail Locations..................................................................... 312

Figure MM13927-4: Throttle Connection (DC Voltage) ........................................................................................ 313

Figure MM13927-5: Throttle Connection (Current mA)........................................................................................ 314

Figure MM13927-6: Throttle Connection (PWM with DC Voltmeter)....................................................................315

Figure MM13927-7: Throttle connection (PWM with Duty Cycle Meter) ............................................................. 316

Figure MM13927-8: Throttle Connection (Frequency Hz)..................................................................................... 317

Figure MM13927-9: Clutch Connections Neutral Solenoid................................................................................... 317

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