PERFECTPASS MasterCraft 2007 Operating instructions

MasterCraft 2007
Troubleshooting
(Electronic Throttle Engines)
System Not Controlling/Surging in both RPM & Speed Mode
You can quickly perform a “Control Test” to confirm whether PerfectPass has proper control of
the ECM. This test is on Page 3 and can be done on a “fake lake” or in the water.
The PerfectPass “Drive by Wire” (DBW) system for new electronic throttle engines
results in a simplified and enhanced version of PerfectPass. From the drivers seat,
PerfectPass operation is virtually identical to the present mechanical systems.
PerfectPass is now comprised of just four main parts:
1. DBW Master Control Module
2. DBW Plug & Play Engine Wiring Harness
3. Plug & Play Display Harness
4. In-Dash Display
5. ALDL Plug
On 2007 MCX and RPT, an “ALDL” ground plug is
required. On the 2006 6.0L and 8.lL, a re-flash of the
ECM is required.
Engine Display
Harness Harness
How it Operates:
The ECM of an electronic throttle engine allows an external device such as PerfectPass
to control the engine rpm using the throttle servo motor when all control signals are valid
and manual throttle lever position exceeds the rpm level request of PerfectPass.
Just three individual wires in the PerfectPass DBW wiring harness connect the speed
control to the engine ECM.
1. The Request Line from PerfectPass requests the ECM to allow PerfectPass to take
control.
2. The Status Line from the ECM indicates PerfectPass now has control of the engine.
The Status Line is the signal that confirms engagement (beeper) and system control
and must be operational for system to engage & control properly.
3. The VGOV Line establishes the engine RPM level as set by PerfectPass.
Problems with PerfectPass should be rare given the few components that now make up
the system. Most troubleshooting will simply involve voltage/continuity testing on the
PerfectPass engine harness.
PerfectPass Control Systems [phone] Page 1

Wiring Identification
Signal Color
9-Pin
MATE-
N-LOK
14-Pin
AMP
Seal
16-Pin
Connector
at Engine ECM
MEFI 5
STAT Orange 1 1 D J1-55
VGOV Blue 2 10 E J3-57
RQST Brown 3 12 C J1-30
J1-45
Ground Black 4 14 H
RPM White 5 9 B J1-24
J1-25
Speed Green 6 8
12 Volts Red 7 4
15
10 14
10 11 12 13 14
9
8
7
12 3 4 5
6
14-Pin AMPSEAL
(Black)
Back View
Connected to
PerfectPass Module
9-Pin MATE-N-LOK
(White)
Front View
Connected to
MasterCraft Harness
7
8
9
4
5
6
2
3 1
2007 MasterCraft
DBW En
g
ine Harness
Problems with PerfectPass Controlling / Not Controlling
Open circuit (bad connection/broken wire) symptoms of a DBW System
Problem #1 RQST Line Open – PerfectPass never takes control in any mode, the engine is
controlled only by the manual throttle handle.
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Problem #2 VGOV Line Open (RQST Line OK) – With the PerfectPass system
control ON, the engine will not go above idle no matter how far the manual
throttle is pushed. With PerfectPass control OFF, the engine is controlled as
normal by manual throttle handle.
Problem #3 STAT Line Open (RQST Line and VGOV Lines OK) – Engine
operates normally with PerfectPass control ON, the engine RPM’s become
limited at speed slightly above system set point, but there is no proper control
and speed remains one or two mph above setpoint. The PerfectPass does not
beep to acknowledge engagement and the underline characters never appear.
Problem #4 PerfectPass Does Not Engage The “S” (Status Line) never
appears during control test. Check “ALDL” ground plug. If not connected
properly, ECM will never give PerfectPass control. (Connects where “Diacom”
plugs into harness).
Problem #5 System Surges During Operation and During Control Test as
Described Below Reason – Poor ground. MasterCraft has had ground issues
on the ground wire for PerfectPass. Check all wires at ground bar and tighten as
required.
TESTING (CONTROL TEST)
To enter the Test Mode, press the Menu & UP Keys together and scroll down
and enter Device Test. Rope Test will first appear, press menu to enter
Servo/Control Test. This test can be performed in the shop or on water.
CONTROL 1.0
R RPM
In this test mode. Perfect
Pass requests control of the
ECM and maintains a
constant 1-volt level.
SERVO TEST
CONTROL 1.0
R RPM
SERVO TEST
CONTROL 1.0
R S
RPM
In this screen, the “S”
appears which indicates the
system is working properly.
TEST
Make sure system is in ON Mode prior to starting test. You must have an RPM
reading on PerfectPass display or it will never work properly.
With engine ON, lock the gearshift in neutral and advance the throttle
handle to 1800 RPM. When all is working correctly an “S” will appear next
to the “R” and the engine will hold at approximately 1730 RPM (it may
surge up and down by about 100 rpm). If the RPM is holding at 1730 but
the “S” is not on the display, there is a problem with the “STAT” line.
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If you lower the 1.0 volt setting by pressing Down Key to .7 volts, the engine rpm
will drop to about 1420 and hold reasonably steady.
(If you perform this test on the water on the fly, it should hold very steady at
about 1730).
If the RPM does not hold at 1730 the “RQST” line may not be connected. Either
the Request Line or the VGOV Line has lost continuity.
If the engine holds RPM at approximately 1730, but the S does not appear on
screen, then check continuity of the Status Line. Voltage Testing in Control Test
Mode. If the test fails, perform voltage checks.
Voltage Test (Control Test Mode)
These measurements are taken in Control Test Mode with system ON and R
must be on screen. This test will confirm whether PerfectPass and the ECM are
properly connected.
Locate the 14-pin engine connector on the PerfectPass Module or ideally the 9-
pin MAT N LOK connector on PerfectPass harness. You will need to apply test
tee connectors or insert small test pins beside the wires as they exit the
connector to be able to measure the voltage present on each wire. These are
taken while in Control Test, with “R” on screen.
-Measure the voltage on the RQST (request line) which should measure
less than 1 volt. (0 to 1 volt) Engine running or not running.
-Measure voltage on VGOV (vgov line) which should measure about 1 volt.
(.8 to 1.2 volts) Engine running or not running.
-Measure voltage on STAT (stat line) which will be 10 + volts when Sis not
on display. (When engaged and working properly this pin at ECM is
grounded and voltage will be less than 1 volt.) Engine must be running for any
measurement on STAT line.
-Press the OFF key and the “R” will disappear. Now measure voltage on
RQST wire again which should now measure more than 4.5 volts, this
confirms proper operation of PerfectPass Request driver and ECM
connection.
Other Measurements:
With control OFF and R not on Screen:
RQST Line – 4.5 V
VGOV Line – 4 V +
STAT Line – 10 V +
PerfectPass Control Systems [phone] Page 4

Trouble Shooting DBW
Problem – System surges in all modes, including control test.
Check – Poor ground connection for PerfectPass main ground wire.
- Perform Open circuit voltage tests on vgov, stat & rqst which may lead
you to a incorrect ECM wire location or harness issue.
Problem – Customer indicates system does not engage.
Check – Perform a CONTROL TEST. If it engages & holds properly during
control test, check the adjustable parameters (KDW, NN and Control Settings
CS/CR) If it does not engage, perform Open Circuit Tests.
Make sure there is an rpm reading on screen or PerfectPass will never operate
properly.
Problem – No speed reading on PerfectPass Display
Check – If your boat speedometer is O.K., check paddle wheel signal on green
wire coming into the Master Module on Amp Seal Connector. If paddle is spun
slowly, you should see 0 volts / 12 volts as wheel slowly turns. As wheel is spun
quickly, you will see an average of 5 volts.
(If voltage is good, perform a “System Reset”).
If MasterCraft speedometer is not reading, it must be corrected and PerfectPass
will likely then read properly.
Problem – No rpm reading on PerfectPass display
Check – The RPM signal wire at the Amp Seal connector coming into Master
Module. With engine off you should see about 9 volts. (With engine running, you
should see a normal tach pulse signal) If no signal, check the pin at ECM. The
system will never control properly in any mode without an RPM signal.
Problem – PerfectPass in Wakeboard mode is set at 22 mph and digital
speedometer shows 22, but actual speed is 24.
Check – Use Menu Key to highlight Menu Arrow Icon and press Down Key to
reach “SPEEDOMETER ADJUST”, quickly press down key several times and
lower speed by 2 mph. All Wakeboard speeds now calibrated.
Problem – Key is on, but PerfectPass screen does not become active and
show data.
Check – PerfectPass requires 12+ volts for start up. Check voltage on red wire
(12 v) power source to Master Module. If backlight is ON, check screen contrast.
Check screen contrast – Press Menu & UP Keys together, then press UP Key a
couple of times. Does data re-appear?
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Problem – Button on PerfectPass Display does not work.
Check - If system was just installed, unplug Display from harness and inspect all
brass pins on connector to ensure they are inline. If problem occurs after much
use, the Display will require repairs by PerfectPass.
Problem – In Wakeboard/Trick mode, system sluggish or exhibits some
surging.
Check – Inspect paddle wheel. If paddle appears OK, go into adjustable
parameters by highlighting menu arrow icon, press UP and Wakeboard will
appear. Press DOWN for settings.
KDW will appear. This value represents how firm the system will control. Heavily
loaded boats may need higher settings. (Typical values 80 – 200)Press Menu to
proceed.
NNW will appear. This is the filter factor of paddle. The higher the value, the
more filtering is done prior to making a speed change.(Typical values 80 – 180)
Problem – The boat accelerates past set speed too far in Wakeboard Mode
before settling in.
Check – Go to “Control Settings” and lower the “CS” value.
Control Settings CR / CS)
These are engagement values which are adjustable to allow a customer to fine
tune engagement performance if necessary. This may be required due to a prop
change, unusual ballast loads or operating at extreme elevations.
These are found under “CTRL SETTNGS” in sub menu by pressing Menu & Up
Keys together.
CS – Control the engagement in paddle wheel speed based modes including
wakeboard.
If it is set too low, the system may not go fast enough to engage, or it will engage
& then disengage. If it is set too high, it may overshoot the set speed by several
mph before beeping and taking over. Factory setting is 750. (Range is 735 – 900)
CR – Is the same as CS except it controls engagement of the RPM Based
Modes such as slalom. Factory setting is 1940. (Range is 1900 – 2100) It would
be rare to see this value require adjustment.
Software Adjustments
System Reset – To reset the entire system back to original factory values, press
& hold ON/OFF & MENU Keys together as you turn key on to power
PerfectPass. Continue holding for a few seconds until [ System Reset ^ = Yes ]
appears. Then simply answer questions as they appear.
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Switching WakeboardPro <> DigitalPro – If you system was selected
incorrectly, perform a system reset. As you proceed through this process, you
will be asked [Wakeboard Only ^ = YES]. Answer YES for WakeboardPro, and
NO for DigitalPro
Engine Selection – On initial start up or during a system reset, PerfectPass will
ask if you have a standard 5.7 litre engine. This will appear as [ 5.7 / MPI ^ =
Yes ] This means press UP for 5.7 and DOWN for Big Block 6L or 8.1L.
To confirm if correct engine was selected, press Menu & Up Keys together to get
into back ground screen and go to “System Settings”. Following battery
voltage, etc you will see which engine was selected. If incorrect, perform a
system reset.
(An incorrectly selected engine can cause unsettled control in rpm mode only)
WakeboardPro to/ DigitalPro – The Master Module for both systems are
identical. The only difference is in the way they were initialized, i.e. as a
DigitalPro or WakeboardPro. You can change the way it was set by performing a
system reset.
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