ZF Marine ClearCommand 9000 Series Operating instructions

ClearCommand 9000 Series
Installation, Operation and
Troubleshooting Manual
MM9000-I Rev C.2 5/08

Copyright
Copyright American Boat and Yacht Council, Inc. Used with permission.
Copyright © 2005 ZF Marine Electronics, LLC
All Rights Reserved
No part of this publication may be copied or reproduced in any form, including an electronic retrieval system or
be made available on the Internet, a public network, by satellite, or otherwise without the prior written
permission of ZF Marine Electronics, LLC, 12125 Harbour Reach Drive, Suite B, Mukilteo, WA 98275.
Legal Information
The information in this manual is believed to be accurate at the time of publication, but no responsibility, direct
or consequential, can be accepted for damage resulting from the use of this information. ZF Marine Electronics,
LLC, reserves the right to make changes to any of its products without notice.

PREFACE
Preface-1
ClearCommand 9000 Series
This manual is for the above Processors.
Throughout this manual special attention should be paid to the following:
ATTENTION
It is important to keep this Manual in a safe place for future
reference. The manual contains answers to questions that
may arise during operation or installation of the ZF Mathers
Control System and its options.
For the purpose of this manual, the drawings illustrate pluggable systems
with two Remote Stations. The Processors described within, may in fact be
installed with anywhere from one to five Remote Stations.
ZF Mathers ENGINE CLUTCH TROLL
Processor Part No. Servo Electronic Servo Solenoid Servo Solenoid 9001 Actuator
9120 Servo 2 X Servo 3
9121 Servo 2 X Servo 1
9122 Servo 2 X X
9210 X Servo 1 Servo 3
9211 X Servo 1 Servo 2
9221 X X Servo 2
Table Preface-1: ClearCommand Processor List
NOTE: C ONTAINS HELPFUL INFORMATION .
CAUTION: Damage to the equipment may occur if these messages are not followed.
WARNING: P ERSONAL INJURY MAY RESULT IF THESE MESSAGES ARE NOT FOLLOWED .
WARNING: P
ERSONAL I NJURY COULD OCCUR IF THE FOLLOWING STEPS ARE NOT FOLLOWED
EXACTLY .
CAUTION: On Control Systems utilizing more than one Processor, ZF Mathers highly
recommends that ALL UNITS be upgraded to the most current Processor.
CAUTION: Electro-static discharge can damage this equipment. Personnel working on
this equipment must be grounded to the chassis with the Anti-static Wrist
Strap provided.
CAUTION: Disconnect the Power Harness from the Power Pigtail whenever welding is
being done on the vessel. Failure to do so can cause permanent damage.
CAUTION This equipment is designed to work with other ZF Mathers designed equip-
ment. DO NOT operate this equipment with any other manufacturers
equipment unless approved so in writing by ZF Mathers Engineering
Department.

PREFACE
Preface-2
Hard-wired installation is described in Section 4-4, with the exception
of the Tachometer Signal and Serial Communication Pigtails, which
always come from the factory pre-wired.

TABLE OF CONTENTS
TOC-1
SW15623.0
Table of Contents
Table Preface-1:ClearCommand Processor List ..........................................................................................................Preface-1
Table of Contents................................................................................................................................TOC-1
Revisions List ....................................................................................................................................TOC-14
1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
1-1 Manual Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2.1 9120 Processor (Throttle-Servo 2, Shift-Solenoid) or 9122 Processor (Throttle-Servo 2, Shift-Sole-
noid, Troll-Solenoid). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1: Basic 9120 or 9122 ClearCommand System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2.2 9121 Processor (Throttle-Servo 2, Shift-Solenoid, Troll-Servo 1) . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2: Basic 9121 ClearCommand System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2.3 9210 Processor (Throttle-Electronic, Shift-Servo 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-3: Basic 9210 ClearCommand System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2.4 9211 Processor (Throttle - Electronic, Shift - Servo 1, Troll - Servo 2) . . . . . . . . . . . . . . . . . . 1-5
Figure 1-4: Basic 9211 ClearCommand System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-2.5 9221 Processor (Throttle - Electronic, Shift - Solenoid, Troll - Servo 2) . . . . . . . . . . . . . . . . . 1-6
Figure 1-5: Basic 9221 ClearCommand System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.1 Standard Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.2 9000 Series Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3.3 Optional System Features (Section 2-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-2 Taking Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1: Station taking Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-3.1 Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-4 Trolling Valve Operationl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5 Start Interlock (if used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-3: Control Head 20 Degree Troll Range - Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4: Control Head 35 Degree Troll Range - Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-5: Control Head 45 Degree Troll Range - Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-6: Control Head 55 Degree Troll Range - Type 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-6 Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7: Remote Stations Before Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-8: Remote Station Transfer after Transfer of Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-7 Proportional Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-8 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-9: Control Head Warm-Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-10: Control Head Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9 High/Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9.1 Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9.2 High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9.3 Selecting Between High and Low Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-11: High/Low Idle Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10 One Lever Mode (Twin Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10.1 Turning ON One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-12: Step A) One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10.2 Turning OFF One Lever Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-11 Engine Synchronization (Twin Screw) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-13: Step B) One Lever Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

TABLE OF CONTENTS
TOC-2
2-11.1 Synchronization Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-11.1.1 E QUAL T HROTTLE S YNCHRONIZATION (T WIN S CREW ) ( DEFAULT )........................................................................... 2-8
2-11.1.2 A CTIVE S YNCHRONIZATION (T WIN S CREW )( DEFAULT D ISABLED )............................................................................ 2-8
2-11.2 Synchronization Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.3 Synchronization Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.4 Turning Synchronization OFF: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.5 Turning Synchronization ON:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-11.6 Turning Synchronization ON and OFF when Control Head Levers are not within a 10% (6 degree)
Window of One Another: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-12 Control System’s Configurability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12.2.1 B ASIC T HROTTLE F UNCTIONS ......................................................................................................................... 2-10
2-12.2.2 S ERVO T HROTTLE F UNCTIONS ........................................................................................................................ 2-11
2-12.2.3 E LECTRONIC T HROTTLE F UNCTIONS ................................................................................................................. 2-11
2-12.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12.3.1 B ASIC C LUTCH F UNCTIONS ............................................................................................................................ 2-11
2-12.3.2 C LUTCH S ERVO F UNCTIONS ........................................................................................................................... 2-12
2-12.3.3 C LUTCH S OLENOID F UNCTIONS ...................................................................................................................... 2-12
2-12.4 Troll Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-12.4.1 B ASIC T ROLL F UNCTIONS (A LL P ROCESSORS WITH T ROLL F UNCTION ).................................................................. 2-12
2-12.4.2 T ROLL S ERVO F UNCTIONS .............................................................................................................................. 2-13
2-12.4.3 I NTEGRATED T ROLL S OLENOID F UNCTIONS ....................................................................................................... 2-13
2-12.5 Troubleshooting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-12.5.1 B ASIC T ROUBLESHOOTING F UNCTIONS ............................................................................................................. 2-13
2-13 Audible Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1 Basic Processor Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.1 S LOW R EPETITIVE T ONE ................................................................................................................................2-14
Figure 2-14: Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.2 O
NE L ONG , T HREE S HORT T ONES .................................................................................................................. 2-14
Figure 2-15: One Long, Three Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.3 S
TEADY T ONE .............................................................................................................................................. 2-14
Figure 2-16: Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.4 F
IVE (5) S ECOND S TEADY T ONE ..................................................................................................................... 2-14
Figure 2-17: Five (5) Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.5 T
HREE (3) S ECOND S TEADY T ONE .................................................................................................................. 2-14
Figure 2-18: Three (3) Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-13.1.6 F
IVE S ECONDS O N , F IVE S ECONDS O FF - H IGH R EPETITIVE R ATE T ONE ................................................................ 2-15
Figure 2-19: Five Seconds On, Five Seconds Off - High Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.2 Throttle (Servo 2) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.2.1 O NE L ONG - T WO S HORT T ONES ................................................................................................................... 2-15
Figure 2-20: One Long - Two Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.2.2 O
NE L ONG , T WO S HORT - H IGH R EPETITIVE T ONE ............................................................................................ 2-15
Figure 2-21: One Long - Two Short - High Repetitive Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.3 Clutch (Servo 1) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.3.1 O NE L ONG - O NE S HORT T ONE ...................................................................................................................... 2-15
Figure 2-22: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.3.2 O
NE L ONG , O NE S HORT -H IGH R EPETITIVE R ATE T ONE ....................................................................................... 2-15
Figure 2-23: One Long, One Short - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-13.4 Clutch Solenoid Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.4.1 O NE L ONG - O NE S HORT T ONE ...................................................................................................................... 2-16
Figure 2-24: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.5 Troll Integrated Servo (Servo 1) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.5.1 O NE L ONG - O NE S HORT T ONE ...................................................................................................................... 2-16
Figure 2-25: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.5.2 O
NE L ONG , O NE S HORT -H IGH R EPETITIVE R ATE T ONE ....................................................................................... 2-16
Figure 2-26: One Long, One Short - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.6 Troll Integrated (Servo 2) Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.6.1 O NE L ONG - T WO S HORT T ONES ................................................................................................................... 2-16
Figure 2-27: One Long - Two Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.6.2 O
NE L ONG , T WO S HORT - H IGH R EPETITIVE T ONE ............................................................................................ 2-16
Figure 2-28: One Long - Two Short - High Repetitive Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-13.7 9001 Trolling Actuator Tones (Servo 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-13.7.1 O NE L ONG , F OUR S HORT T ONES .................................................................................................................... 2-17
Figure 2-29: One Long - Four Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-13.7.2 O
NE L ONG , F OUR S HORT - H IGH R EPETITIVE R ATE T ONE ................................................................................... 2-17

TABLE OF CONTENTS
TOC-3
Figure 2-30: One Long, Four Short - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-13.8 Troll Integrated Solenoid Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-13.8.3 T HREE S ECOND S TEADY T ONE ....................................................................................................................... 2-17
Figure 2-31: Three Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-14 Push Button Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-15 Visual System Diagnostics, Set Up And Status Indication . . . . . . . . . . . . . . . . . . . . . 2-17
Figure 2-32: Circuit Board Shield Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-16 Pluggable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-16.1 Standard Pluggable Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-33: Standard Processor Pluggable Connections View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-16.2 ClearCommand 9000 Series Pluggable Processors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-17 Optional Features Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-17.1 System Failure External Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-17.2 Clutch Pressure Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-17.3 Station Expander (SE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-17.4 Multiple Screw Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-17.5 9001 Mechanically Actuated Trolling Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
3 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - 3-1
3-1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-1: Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1.1 Processor(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-1.2 Control Head(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-1.3 Standard Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-1.3.1 C ONTROL H EAD H ARNESSES ............................................................................................................................ 3-3
3-1.3.2 P OWER , S TART I NTERLOCK , C LUTCH P RESSURE , A LARM H ARNESS ......................................................................... 3-3
3-1.3.3 S ERIAL C OMMUNICATION H ARNESS .................................................................................................................. 3-3
3-1.3.4 T ACH S ENSOR H ARNESS ................................................................................................................................. 3-4
3-1.4 Additional Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-1.4.1 T HROTTLE H ARNESS ....................................................................................................................................... 3-4
3-1.4.2 C LUTCH H ARNESS .......................................................................................................................................... 3-4
3-1.4.3 C LUTCH /T ROLL H ARNESS ................................................................................................................................3-4
3-1.5 Standard Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-1.5.1 C ONTROL H EAD E LECTRIC C ABLE ...................................................................................................................... 3-5
3-1.5.2 P OWER , S TART I NTERLOCK , C LUTCH P RESSURE , A LARM E LECTRIC C ABLE ............................................................... 3-5
3-1.5.2.1 Power Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
3-1.5.2.2 Start Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
3-1.5.2.3 Clutch Pressure Interlock Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-1.5.2.4 External Alarm Circuit Electric Cable Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-1.5.3 S
ERIAL C OMMUNICATION E LECTRIC C ABLE R EQUIREMENTS ................................................................................... 3-6
3-1.5.4 T ACH S ENSOR E LECTRIC C ABLE R EQUIREMENTS .................................................................................................. 3-6
3-1.5.4.1 AC Tach Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-1.5.4.2 Open Collector (Active) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6
3-1.6 Additional Electric Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-1.7 Throttle Electric Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-1.8 Clutch Electric Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-1.9 Clutch/Troll Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-1.9.5 C LUTCH S OLENOID E LECTRIC C ABLE R EQUIREMENTS ............................................................................................ 3-7
3-1.9.6 T ROLL S OLENOID E LECTRIC C ABLE R EQUIRMENTS ................................................................................................ 3-7
3-1.10 Tachometer Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-1.10.1 AC C OUPLED S ENSORS .................................................................................................................................. 3-8
3-1.10.2 A LTERNATOR ................................................................................................................................................. 3-8
3-1.10.3 P OINT SIDE OF THE C OIL .................................................................................................................................. 3-8
3-1.10.4 A CTIVE S ENSORS (O PEN C OLLECTOR O UTPUT )................................................................................................... 3-8
3-2 Installer Supplied Tools And Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-2.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-2.2 Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-2.3 Required Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-2.3.1 P ROCESSOR ’ S U TILIZING A S ERVO ..................................................................................................................... 3-9
3-2.3.2 A LL R EMOTE S TATIONS ................................................................................................................................... 3-9
3-3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-3.1 Processor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

TABLE OF CONTENTS
TOC-4
4 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4-1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2 Control Head(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.1 400, MC2000 and 700 Series Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.2 500 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2.3 Handheld Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3 Wire Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3.1 Plug Insertion and Extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-1: Harness Plug Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3.2 Standard Power/Start Interlock Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.2.1 DC P OWER C ABLE ......................................................................................................................................... 4-2
4-3.2.2 S TART I NTERLOCK C ABLE ................................................................................................................................. 4-2
Figure 4-3: Start Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.2.3 E
XTERNAL A LARM C IRCUIT C ABLE ( OPTIONAL ).................................................................................................... 4-2
4-3.2.4 C LUTCH P RESSURE S WITCH C ABLE ( OPTIONAL )................................................................................................... 4-2
4-3.3 Standard Control Head Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2: Harness Plug Locking Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3.3.1 C
ONTROL H EAD H ARNESS WITH T WO C ONNECTORS ........................................................................................... 4-3
4-3.3.2 C ONTROL H EAD H ARNESS WITH O NE P LUG ....................................................................................................... 4-3
4-3.4 Serial Communication Harness (Twin Screw only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3.5 Tach Sensor Harness (required for Active Synchronization). . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3.6 Additional 9000 Series Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3.6.1 T HROTTLE H ARNESS ....................................................................................................................................... 4-4
4-3.6.2 C LUTCH H ARNESS .......................................................................................................................................... 4-4
4-3.6.3 C LUTCH /T ROLL H ARNESS ................................................................................................................................4-4
4-4 Hard-Wired Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4.1 Liquid Tight Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-4: Liquid Tight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4.2 Standard Processor Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-5: Standard Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4.3 Standard Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-6: Standard Circuit Board Hard-Wired Termination Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4.4 9000 Series Hard-Wired Connection Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-1: ClearCommand Processor Optional Hard-Wiring Cable List........................................................................ 4-6
4-4.4.1 9120
AND 9121 (C LUTCH S OLENOID ) C ABLE H OLE L OCATIONS .......................................................................... 4-7
Figure 4-7: 9120 and 9121 Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4.4.2 9122 (C
LUTCH /T ROLL S OLENOID ) C ABLE H OLE L OCATIONS ................................................................................. 4-7
Figure 4-8: 9122 Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4.4.3 9210
AND 9211 (T HROTTLE E LECTRONIC ) C ABLE H OLE L OCATIONS ...................................................................... 4-7
Figure 4-9: 9210 and 9211 Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4.4.4 9221 (T
HROTTLE E LECTRONIC AND C LUTCH S OLENOID ) C ABLE H OLE L OCATIONS .................................................... 4-8
Figure 4-10: 9221 Enclosure Cable Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4.5 9000 Series Circuit Board Termination Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-11: 9000 Series Circuit Board Hard-Wired Termination Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4.6 Locations 1 - 9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-4.6.1 S EVEN -C ONDUCTOR C ONTROL H EAD C ABLE (L OCATIONS 1, 2, 3, 6, AND 7).......................................................... 4-9
Figure 4-12: Seven-Conductor Control Head Cable Shield Wire and Heat-Shrink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-13: Clamp Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-14: Terminal Strip Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Table 4-2: Processor Circuit Board Terminal Strip Color Coded Connections for Remote Stations ...........................4-10
4-4.6.2 S
TART I NTERLOCK C ABLE (L OCATION 4)........................................................................................................... 4-10
4-4.6.2.1 Connection at the Starter Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-10
4-4.6.2.2 Connection at the Processor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-10
Figure 4-15: Two-Conductor Start Interlock Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-4.6.3 P
OWER C ABLE (L OCATION 5)......................................................................................................................... 4-11
Figure 4-16: Two-Conductor Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-4.6.4 S
ERIAL C OMMUNICATION C ABLE (L OCATION 8)................................................................................................. 4-12
Figure 4-17: Four-Conductor Serial Communication Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Table 4-3: Processor Circuit Board Terminal Strip Color Coded Connections for Serial Communication................... 4-12
4-4.6.5 T
ACHOMETER C ABLE (L OCATION 9) ................................................................................................................ 4-13
Figure 4-18: AC Type Tachometer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Figure 4-19: Open Collector Tachometer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Table 4-4: Processor Circuit Board Terminal Strip Color Coded Connections for Tachometer................................... 4-14
4-4.7 Locations 10 and 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-4.7.1 C LUTCH C ABLE (L OCATION 10) ...................................................................................................................... 4-14
4-4.7.1.1 Processor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-14

TABLE OF CONTENTS
TOC-5
Figure 4-20: Clutch Cable Heat Shrink in Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-4.7.1.2 Plug Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-15
Figure 4-21: Clutch Cable Plug Termination Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Table 4-5: Clutch Termination Table........................................................................................................................... 4-15
4-4.7.2 C
LUTCH /T ROLL C ABLE (L OCATION 10 & 11) .................................................................................................... 4-15
4-4.7.2.3 Processor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-15
Figure 4-22: Clutch/Troll Cable Heat Shrink in Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-4.7.2.4 Plug Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-16
Figure 4-23: Clutch Cable Plug Termination Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Table 4-6: Clutch/Troll Termination Table................................................................................................................... 4-16
4-4.8 Locations 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-4.8.1 C LUTCH C ABLE (L OCATION 10) ...................................................................................................................... 4-16
4-4.8.1.1 Processor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-16
Figure 4-24: Clutch Cable Heat Shrink in Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-4.8.1.2 Plug Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-17
Figure 4-25: Clutch Cable Plug Termination Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Table 4-7: Clutch Termination Table........................................................................................................................... 4-17
4-4.9 Location 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-4.9.1 T HROTTLE C ABLE (L OCATION 12) ................................................................................................................... 4-17
Figure 4-26: Engine Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Table 4-8: Throttle Termination Table.......................................................................................................................... 4-18
4-5 Engine Stop Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6 Push-Pull Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-27: Processor Cable Clamp Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-28: Push-Pull Cable Interior Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-6.2 Throttle Selector Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-29: Throttle Push-Pull Idle Orientation to Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-6.3 Shift Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-30: Shift Push-Pull Cable Neutral Connection at Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-6.4 Trolling Valve Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
5 SET UP PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - 5-1
5-1 Processor Components Used In Set Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-1: Typical Processor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-2: Processor Shield Push Button and Display LED Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1.1 Processor Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-3: Display LED at Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-4: Display LED Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-1.2 Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-5: Circuit Board Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-1.2.1 U
P AND D OWN P USH B UTTONS ....................................................................................................................... 5-2
5-1.2.2 L EFT AND R IGHT P USH B UTTONS ...................................................................................................................... 5-2
5-1.2.3 L EFT P USH B UTTON O NLY ............................................................................................................................... 5-3
Figure 5-6: Display LED Error Menu Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-1.2.4 R
IGHT P USH B UTTON O NLY ............................................................................................................................. 5-3
Figure 5-7: Display LED Four Digit Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2 Activating Set Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3 Storing Values To Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-4 Set Up Function Codes And Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table 5-1: Function Codes ............................................................................................................................................. 5-4
Table 5-2: Processors Function Code Defaults.............................................................................................................. 5-6
5-5 Field Service Test Unit (Break-out Box) and Multimeter Use . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-8: Service Field Test Unit and Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Table 5-3: Functions Requiring Service Field Test Unit and Multimeter ....................................................................... 5-7
5-6 System Programming And Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-6.1 Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-6.1.1 F UNCTION C ODE A0 – P ROCESSOR I DENTIFICATION ............................................................................................ 5-8
Figure 5-9: E1, E2, E3, E4, E6, L4 Processor, Test Unit, and Multimeter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Figure 5-10: L2, L3, C6, and C7 Processor, Test Unit, and Multimeter Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-6.1.2 F
UNCTION C ODE A1 – N UMBER OF E NGINES ..................................................................................................... 5-9
Figure 5-12: Display LED Function A1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-6.1.3 F
UNCTION C ODE A2 – O NE L EVER O PERATION .................................................................................................. 5-9
Figure 5-13: Display LED Function A2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-11: Display LED Function A0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-6.1.4 F
UNCTION C ODE A3 – SE (S TATION E XPANDER ).............................................................................................. 5-10

TABLE OF CONTENTS
TOC-6
Figure 5-14: Display LED Function A3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6.1.5 F
UNCTION C ODE A4 – N EUTRAL I NDICATION T ONE .......................................................................................... 5-10
Figure 5-15: Display LED Function A4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6.2 Throttle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6.2.1 T HROTTLE B ASIC F UNCTIONS ......................................................................................................................... 5-10
5-6.2.1.1 Function Code E5 – Throttle Pause Following Shift - - - - - - - - - - - - - - - - - - - - - - - - - - -5-10
5-6.2.1.2 Function Code E6 – High Idle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-11
Figure 5-17: Display LED Function E6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-6.2.1.3 Function Code E1 – Throttle in Neutral - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-11
Figure 5-18: Display LED Function E1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-6.2.1.4 Function Code E4 – Throttle Maximum Astern - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-11
Figure 5-16: Display LED Function E5 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-19: Display LED Function E4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6.2.1.5 Function Code E7 – Synchronization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-12
Figure 5-20: Display LED Function E7 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6.2.2 T
HROTTLE S ERVO F UNCTIONS ........................................................................................................................ 5-12
5-6.2.2.1 Function Code E0 – Throttle Servo Direction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-12
Figure 5-21: Throttle Push-Pull Cable Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6.2.2.2 Function Code E2 – Throttle Minimum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-13
Figure 5-24: Display LED Function E2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-6.2.2.3 Function Code E3 – Throttle Maximum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-13
Figure 5-25: Throttle Push-Pull Cable Full Throttle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-22: Example: Throttle Push-Pull Cable Fully Retracted Position for Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-23: Display LED Function E0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-26: Display LED Function E3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6.2.3 T
HROTTLE E LECTRONIC F UNCTIONS ................................................................................................................. 5-14
5-6.2.3.1 Function Code E0 – Engine Throttle Profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-14
Figure 5-27: Display LED Function E0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6.2.3.2 Function Code E2 – Throttle Minimum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-28: Display LED Function E2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-6.2.3.3 Function Code E3 – Throttle Maximum - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-29: Display LED Function E3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-6.3 Clutch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-6.3.1 C LUTCH B ASIC F UNCTIONS ............................................................................................................................ 5-15
5-6.3.1.1 Function Code C0 – Clutch Pressure Interlock - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-15
Figure 5-30: Display LED Function C0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-6.3.1.2 Function Code C1 – Clutch Interlock Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-16
Figure 5-31: Display LED Function C1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-6.3.1.3 Function Code C2 – Proportional Pause - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-16
5-6.3.1.4 Function Code C3 – Proportional Pause Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-17
Figure 5-33: Display LED Function C3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-6.3.1.5 Function Code C4 – Proportional Pause Ratio - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-17
Figure 5-32: Display LED Function C2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 5-34: Display LED Function C4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-6.4 Clutch Servo Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-6.4.1.1 Function Code C5 – Clutch Servo Direction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-18
Figure 5-35: Clutch Push-Pull Cable Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-6.4.1.2 Function Code C6 – Clutch Ahead Travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-19
Figure 5-37: Clutch Push-Pull Cable Ahead Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Figure 5-38: Display LED Function C6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-6.4.1.3 Function Code C7 – Clutch Astern Travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-19
Figure 5-39: Clutch Push-Pull Cable Astern Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Figure 5-36: Display LED Function C5 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-6.4.2 C
LUTCH S OLENOID F UNCTIONS ...................................................................................................................... 5-20
5-6.4.2.1 Function Code C5 – Shift Solenoid Type - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-20
Figure 5-41: Display LED Function C5 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Figure 5-40: Display LED Function C7 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-6.4.2.2 Function Code C6 – ZF-Hurth Duty Cycle Ahead - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-21
Figure 5-42: Display LED Function C6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-6.4.2.3 Function Code C7 – ZF-Hurth Duty Cycle Astern - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-21
Figure 5-43: Display LED Function C7 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-6.5 Troll Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-6.5.1 B ASIC T ROLL C OMMAND F UNCTIONS .............................................................................................................. 5-22
5-6.5.1.4 Function Code L0 – Troll Enable and Control Head Lever Troll Range - - - - - - - - - - - - - - - - - -5-22
Figure 5-44: Display LED Function L0 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-6.5.1.5 Function Code L4 – Troll Throttle Limit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-23
Figure 5-49: Display LED Function L4 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-45: Control Head 20 Degree Troll Range - Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-46: Control Head 35 Degree Troll Range - Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-47: Control Head 45 Degree Troll Range - Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

TABLE OF CONTENTS
TOC-7
Figure 5-48: Control Head 55 Degree Troll Range - Type 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-6.5.1.6 Function Code L5 – Troll Pulse Duration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-24
5-6.5.2 T
ROLL S ERVO F UNCTIONS .............................................................................................................................. 5-24
5-6.5.2.1 Function Code L1 – Troll Servo Direction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-24
Figure 5-50: Display LED Function L1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-6.5.2.2 Function Code L2 – Troll Minimum Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-25
Figure 5-51: Display LED Function L2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-6.5.2.3 Function Code L3 – Troll Maximum Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-25
Figure 5-52: Display LED Function L3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-6.5.2.4 Function Code L6 – Troll Pulse Percentage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-26
Figure 5-53: Display LED Function L6 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-6.5.3 9001 T
ROLL A CTUATOR F UNCTIONS (S ERVO 3)................................................................................................ 5-26
5-6.5.4 I NTEGRATED T ROLL S OLENOID F UNCTIONS ...................................................................................................... 5-26
5-6.5.4.1 Function Code L1 – Troll Valve Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-26
Figure 5-54: Display LED Function L1 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-6.5.4.2 Function Code L2 – Troll Minimum Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-27
Figure 5-55: Display LED Function L2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-6.5.4.3 Function Code L3 – Troll Maximum Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-27
Figure 5-56: Display LED Function L3 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-6.5.4.4 Function Code L6 – Troll Pulse Percentage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-28
Figure 5-57: Display LED Function L2 Set Up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-6.5.5 T
ROUBLESHOOTING F UNCTIONS ...................................................................................................................... 5-28
5-6.5.1 B ASIC P ROCESSOR T ROUBLESHOOTING F UNCTIONS ........................................................................................... 5-28
5-6.5.1.1 Function Code H0 - Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-28
5-6.5.1.2 Function Code H1 – Return to Factory Defaults - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-28
5-6.5.2 A
DDITIONAL 9000 S ERIES T ROUBLESHOOTING F UNCTION ................................................................................... 5-29
5-6.5.2.1 Function Code H2 - Driver Fault Detection Enable - - - - - - - - - - - - - - - - - - - - - - - - - - -5-29
Table 5-1: Solenoid Error Status Enable ......................................................................................................................5-29
6 DOCK TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
6-1 Control Heads (Engines Stopped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Start Interlock (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3 Engine Stop Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-4 Push-Pull Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-5 High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-6 Control Head Servo Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-7 Control Head Solenoid Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-8 Throttle Pause Following Servo Shift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-9 Throttle Pause Following Solenoid Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-10 Trolling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-10.1 Troll Servo Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-10.1.1 T ROLL M INIMUM P RESSURE A DJUSTMENT AT THE D OCK ...................................................................................... 6-4
Table 6-1: Shaft RPM at Idle .......................................................................................................................................... 6-4
6-10.2 Troll Solenoid Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-10.2.1 T ROLL M INIMUM P RESSURE A DJUSTMENT AT THE D OCK ...................................................................................... 6-4
Table 6-2: Shaft RPM at Idle .......................................................................................................................................... 6-5
7 SEA TRIALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
7-11 Full Speed Setting - Servo Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-12 Full Speed Setting - Electronic Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-13 Proportional Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-13.1 In-Gear Delay [C200] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-13.2 Neutral Delay [C201] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-13.3 Fixed Neutral Delay [C202] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-13.4 Calculating Proportional Pause Time C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-13.5 Testing The Proportional Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-14 Synchronization Test (Twin Screw Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-14.1 Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-14.2 Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-15 Trolling Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-15.1 Integrated Servo Trolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-15.1.1 E NABLING T ROLL ............................................................................................................................................ 7-5
7-15.1.2 T ROLL M INIMUM P RESSURE A DJUSTMENTS (F UNCTION C ODE L2) ......................................................................... 7-5

TABLE OF CONTENTS
TOC-8
Table 7-1: Shaft RPM at Idle .......................................................................................................................................... 7-6
7-15.1.3 T
ROLL M AXIMUM P RESSURE A DJUSTMENTS (F UNCTION C ODE L3) ........................................................................ 7-6
7-15.2 Integrated Solenoid Trolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Table 7-2: Troll Valve Adjustments ................................................................................................................................ 7-7
7-15.2.1 E
NABLING T ROLL ............................................................................................................................................ 7-7
7-15.2.2 T ROLL M INIMUM P RESSURE A DJUSTMENT (F UNCTION C ODE L2)........................................................................... 7-8
7-15.2.3 T ROLL M AXIMUM P RESSURE A DJUSTMENT (F UNCTION C ODE L3).......................................................................... 7-8
7-15.3 Troll Throttle Limit Adjustment (Function Code L4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-15.4 Troll Pulse Duration (Function Code L5) & Troll Pulse Percentage (Function Code L6) Adjustments
7-9
7-15.5 Integrated ZF-Hurth Solenoid Trolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-15.5.1 E NABLING ZF-H URTH T ROLL .......................................................................................................................... 7-10
7-15.5.2 T ROLL M AXIMUM C URRENT A DJUSTMENT ........................................................................................................ 7-10
7-16 Sea Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16.1 Vessel Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16.2 Control System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16.3 Record Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Table 7-3: Processor Parameters Record .................................................................................................................... 7-13
7-16.4 Comments (Please use additional paper as necessary):. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-16.4.1 G ENERAL I NSTALLATION C ONDITION ................................................................................................................ 7-14
7-16.4.2 A NY I RREGULARITIES :.................................................................................................................................... 7-14
8 CONTROL OPTIONS - - - - - - - - - - - - - - - - - - - - - - - - 8-1
8-1 External Alarm Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Figure 8-1: External Alarm Connections with Processor Harness Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Figure 8-2: External Alarm Connections Processor Hard-Wired Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 Clutch Pressure Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2.1 C0 Methods of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2.1.1 01 - I NSTALLED ............................................................................................................................................. 8-2
8-2.1.2 02 - T HROTTLE C LUTCH P RESSURE I NTERLOCK .................................................................................................... 8-3
Figure 8-3: Clutch Pressure Switch with Processor Harness Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Figure 8-4: Clutch Pressure Switch with Processor Hard-Wired Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-3 Station Expander (SE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-4 9001 Actuator Trolling Valve Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
9 PERIODIC CHECKS AND MAINTENANCE - - - - - - - - - - - - - 9-1
9-1 Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2.1 Throttle Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2.2 Clutch Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2.3 Troll Integrated Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-3.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-3.1.1 Q UARTERLY (E VERY 3 M ONTHS )....................................................................................................................... 9-2
Table 9-1: Fully Charged Battery ................................................................................................................................... 9-2
9-3.1.2 S
EMI -A NNUALLY (E VERY 6 M ONTHS )................................................................................................................ 9-2
9-3.1.3 A NNUALLY (E VERY 12 M ONTHS )...................................................................................................................... 9-2
9-3.2 Power Cables, Distribution Panels, etc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Appendix A
PARTS LIST.............................................................................................................................................. A-1
MMC-280 Rev.K 8/03............................................................................................................................ A-3
400 Series Standard Control Head Variations

TABLE OF CONTENTS
TOC-9
MMC-329 Rev.C 8/03............................................................................................................................. A-9
MC2000 Series Standard Control Head Variations
MMC-307 Rev.G 8/03 ......................................................................................................................... A-15
700 Series Standard Control Head Variations
MMC-279 Rev.B 7/02........................................................................................................................... A-21
400 Series Weather Mount Enclosure
Deutsch Connector Assembly............................................................................................................... A-23
S-214 Rev.E 5/03................................................................................................................................. A-25
Automatic Power Selector (APS) Model: 13505
Drawing 11488D-1 Twin Screw Single APS Connection & Alternate Remote Switch ......................... A-27
Drawing 11488D-2 Twin Screw Dual APS Connections ....................................................................... A-29
Drawing 11488D-3 APS Notes Page..................................................................................................... A-31
MMC-287 Rev.D 8/03.......................................................................................................................... A-33
Bonding: A.B.Y.C. E-11, 46 CFR 111.05
MMC-288 Rev.E 8-03 .......................................................................................................................... A-35
References and Parts Source
SER-161 Rev.B 5/03 ............................................................................................................................. A-37
Engine Tachometer Sender Requirements
MMC-289 Rev.- 6/01 ........................................................................................................................... A-39
Morse Clutch and Throttle Kit Selection
MMC-290 Rev.- 6/01............................................................................................................................ A-41
Universal Mounting Kit
MM13821 Rev.A 8/03 .......................................................................................................................... A-43
43C Cable Conversion Kit
Revisions List ........................................................................................................................................ A-43
MMC-165 Rev.D 3/02........................................................................................................................... A-45
Electronic Propulsion Control Systems Three Year Limited Warranty
MMC-163 Rev.B 1-01........................................................................................................................... C-47
Warranty Registration
Appendix B
B1 TROUBLESHOOTING GENERAL - - - - - - - - - - - - - - - - - B1-1
B1-1 Control Systems Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-1.1 9120 (Throttle Servo 2, Shift Solenoid) Processor and 9122 (Throttle Servo 2, Shift Solenoid, Troll
Solenoid) Processor B1-1
Figure B1-1: 9120 and 9122 Basic Single Screw, Two Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-1
B1-1.2 9121 (Throttle Servo 2, Shift Solenoid, Troll Servo 1) Processor. . . . . . . . . . . . . . . . . . . . . . B1-2
Figure B1-2: 9121 Basic Single Screw, Two Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2
B1-1.3 9210 (Throttle Electronic, Shift Servo 1) Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2
Figure B1-3: 9210 Basic Single Screw, Two Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-2
B1-1.4 9211 (Throttle Electronic, Shift Servo 1, Troll Servo 2) Processor. . . . . . . . . . . . . . . . . . . . . B1-3
Figure B1-4: 9211 Basic Single Screw, Two Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
B1-1.5 9221 (Throttle Electronic, Clutch Solenoid, Troll Servo 2) Processor . . . . . . . . . . . . . . . . . . B1-3
Figure B1-5: 9221 Basic Single Screw, Two Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-3
B1-2 Typical System Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
B1-2.1 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
B1-2.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
B1-2.3 Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
B1-2.4 Electrical Cables and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4

TABLE OF CONTENTS
TOC-10
B1-2.5 Push-Pull Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1-4
Table B1-1: ClearCommand Processor Push-Pull Reference.........................................................................................B1-5
B2 TROUBLESHOOTING QUESTIONS - - - - - - - - - - - - - - - - B2-1
B3 TROUBLESHOOTING PROBLEM RESOLUTION - - - - - - - - - - B3-1
B3-1 DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-2 Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-2.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-2.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-1
B3-3 Component Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
B3-3.1 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
B3-3.2 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
B3-4 Interconnecting Wiring and Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3-2
Table B3-2: Examples of Components (Internal/External) .............................................................................................B3-2
B4 TROUBLESHOOTING DIAGNOSTIC MENU - - - - - - - - - - - - B4-1
Figure B4-6: Display Function Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-7: Display Troubleshooting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-8: Display Troubleshooting Function Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-9: Example Display of Applied Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-1
Figure B4-10: Example Display of Tach Sensor Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Figure B4-11: Example Display Control Head Lever Current Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-2
Figure B4-12: Example Display Control Head Transfer Button Status View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
Figure B4-13: Example Display Software Revision Level View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4-3
B5 TROUBLESHOOTING AUDIBLE TONES - - - - - - - - - - - - - - B5-1
B5-1 Basic Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
B5-1.1 Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
Figure B5-14: Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-1
B5-1.2 One Long - Three Short Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Figure B5-15: One Long - Three Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-2
Figure B5-16: Display Examples of Remote Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
Figure B5-17: Display Examples of Remote Stations A/D Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-3
B5-1.3 Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-18: Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1.4 Three Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
Figure B5-19: Three Second Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-4
B5-1.5 Three Second Steady Tone, followed by a Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . B5-5
Figure B5-20: Three Second Tone, followed by a Slow Repetitive Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
B5-1.6 Five Seconds On, Five Seconds Off - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . B5-5
Figure B5-21: Five Seconds On, Five Seconds Off - High Repetitive Rate Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
B5-1.7 Five Second Steady Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
Figure B5-22: Five Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
B5-2 Servo 1 Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
B5-2.1 One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
Figure B5-23: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-5
B5-2.2 One Long, One Short - High Repetitive Rate Tones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-6
Figure B5-24: One Long, One Short - High Repetitive Rate Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-6
B5-3 Servo 2 Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
B5-3.1 One Long - Two Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
Figure B5-25: One Long - Two Short Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
B5-3.2 One Long, Two Short - High Repetitive Rate Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
Figure B5-26: One Long, Two Short - High Repetitive Rate Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-7
B5-4 Clutch Solenoid Control System Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
B5-4.1 One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
Figure B5-27: One Long - One Short Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5-8
B6 TROUBLESHOOTING STATION TRANSFER - - - - - - - - - - - - B6-1
B6-1 Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1
B6-2 A to D Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-1

TABLE OF CONTENTS
TOC-11
Table B6-3: Control Head Lever A/D Counts..................................................................................................................B6-2
B6-3 Remote Station Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Figure B6-28: Display Station A/D’s No Station Transfer Button Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
Figure B6-29: Example Display Station A/D’s Transfer Button Depressed for Stations 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . B6-3
Figure B6-30: Display Station A/D/s Transfer Button Depressed for Station 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6-3
B7 TROUBLESHOOTING Stuck Transfer Button - - - - - - - - - - - B7-1
B8 Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - B8-1
B8-4 Clutch Solenoid Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-1
Table B8-4: Clutch Solenoid Control System Error Codes .............................................................................................B8-1
B8-5 Troll Solenoid Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-1
Table B8-5: Troll Solenoid Control System Error Codes.................................................................................................B8-1
B8-6 Basic Control System Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-1
Table B8-6: Basic Control System Error Codes..............................................................................................................B8-1
B8-7 Servo 1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-3
Table B8-7: Servo 1 Error Codes....................................................................................................................................B8-3
B8-8 Servo 2 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8-3
Table B8-8: Servo 2 Error Codes ....................................................................................................................................B8-3
B9 Basic PROBLEM CAUSES AND SOLUTIONS - - - - - - - - - - - B9-1
B9-1 Basic Control System Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . B9-1
Table B9-9: Basic Control System Problem Causes and Solutions................................................................................B9-1
B9-2 Servo 2 Throttle Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-6
Table B9-10: Servo 2 Throttle Problem Causes and Solutions.........................................................................................B9-6
B9-3 Servo 1 Clutch Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-6
Table B9-11: Servo 1 Clutch Problem Causes and Solutions...........................................................................................B9-6
B9-4 Servo 2 Throttle Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-7
Table B9-12: Servo 2 Throttle Problem Causes and Solutions.........................................................................................B9-7
B9-5 Servo 1 Troll Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-7
Table B9-13: Servo 1 Troll Problem Causes and Solutions..............................................................................................B9-7
B9-6 Servo 2 Troll Problem Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9-8
Table B9-14: Servo 2 Troll Problem Causes and Solutions..............................................................................................B9-8
B10 PROBLEMS WITHOUT ERROR CODES - - - - - - - - - - - - - - B10-1
B10-1 Basic Control System Problems Without Error Codes . . . . . . . . . . . . . . . . . . . . . . B10-1
B10-2 Servo Clutch Control System Problems Without Error Codes. . . . . . . . . . . . . . . . . B10-2
B10-3 Servo Throttle Control System Problems Without Error Codes. . . . . . . . . . . . . . . . B10-2
B10-4 Solenoid Clutch Control System Problems Without Error Codes . . . . . . . . . . . . . . B10-3
B10-5 Electronic Throttle Control System Problems Without Error Codes . . . . . . . . . . . . B10-3
B11 Synchronization Troubleshooting - - - - - - - - - - - - - - - - B11-1
B11-1 Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
B11-1.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
Table B11-15: Basic Problem Causes and Solutions........................................................................................................B11-1
B11-1.2 Servo Throttle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-1
Table B11-16: Servo Throttle Problem Causes and Solutions..........................................................................................B11-1
B11-1.3 Servo Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-2
Table B11-17: Servo Clutch Problem Causes and Solutions............................................................................................B11-2
B11-2 Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-2
B11-2.1 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-2
Table B11-18: Basic Problem Causes and Solutions........................................................................................................B11-2
B11-2.2 Servo Throttle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-3
Table B11-19: Servo Throttle Problem Causes and Solutions..........................................................................................B11-3
B11-2.3 Servo Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-3
Table B11-20: Servo Clutch Problem Causes and Solutions............................................................................................B11-3
B11-3 Electronic Equal Throttle Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11-4
Table B11-21: Electronic Throttle - Equal Throttle Synch Problem Causes and Solutions ..............................................B11-4

TABLE OF CONTENTS
TOC-12
B12 TROUBLESHOOTING Cable Harnesses - - - - - - - - - - - - - B12-1
B12-1 Basic Control System Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-1
Table B12-1: Power, Start Interlock Harness Pin-Out....................................................................................................B12-1
Figure B12-1: Power, Start Interlock Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-1
Table B12-2: Power, Start Interlock, and Pressure Switch Harness Pin-Out.................................................................B12-1
Figure B12-2: Power, Start Interlock, Pressure Switch Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-1
Table B12-3: Power, Start Interlock, Pressure Switch, and Alarm Harness Pin-Out .....................................................B12-2
Figure B12-3: Power, Start Interlock, Pressure Switch, Alarm Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-2
Table B12-4: Serial Communication Harness Pin-Out....................................................................................................B12-2
Figure B12-4: Serial Communication Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-2
Table B12-5: Control Head Harness Pin-Out and Hard-Wire.........................................................................................B12-2
Figure B12-5: Control Head Harness Plug Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-2
Table B12-6: Tachometer Sensor Harness Pin-Out........................................................................................................B12-3
Figure B12-8: Tachometer Sensor Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
B12-2 Clutch Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
B12-2.1 Ahead and Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Table B12-7: Ahead and Astern Clutch Harness Pin-Out...............................................................................................B12-3
Figure B12-9: Clutch Ahead, and Astern Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Figure B12-6: Control Head Port Terminal Strip Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
Figure B12-7: Control Head Starboard Terminal Strip Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-3
B12-2.2 Ahead, Neutral, and Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
Table B12-8: Ahead, Neutral, and Astern Clutch Harness Pin-Out................................................................................B12-4
Figure B12-10: Clutch, Ahead, Astern, and Neutral Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
B12-3 Clutch/Troll Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
B12-3.1 Ahead, Astern, Troll On/Off & Troll Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
Table B12-9: Ahead, Astern, Troll On/Off and Troll Command Clutch/Troll Harness Pin-Out .......................................B12-4
Figure B12-11: Clutch/Troll Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
B12-4 Throttle Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
B12-4.1 PWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
Table B12-10: PWM Throttle Harness Pin-Out.................................................................................................................B12-4
Figure B12-12: PWM Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-4
B12-4.2 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
Table B12-11: Voltage Throttle Harness Pin-Out .............................................................................................................B12-5
Figure B12-13: Voltage Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
B12-4.3 Current, MAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
Table B12-12: Current, MAN, Throttle Harness Pin-Out ..................................................................................................B12-5
Figure B12-14: Current Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
B12-4.4 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
Table B12-13: Frequency Throttle Harness Pin-Out.........................................................................................................B12-5
Figure B12-15: Frequency Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12-5
B13 Processor Pigtails - - - - - - - - - - - - - - - - - - - - - - - - B13-1
B13-1 Basic Processor Pigtails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
Table B13-1: Power, Start Interlock, Clutch Oil Pressure Switch, and Alarm Pigtail Pin-Out........................................B13-1
Figure B13-1: Power, Start Interlock, Clutch Oil Pressure, and Alarm Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
Table B13-2: Serial Communication Pigtail Pin-Out.......................................................................................................B13-1
Figure B13-2: Serial Communication Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
Table B13-3: Control Head Pigtail Pin-Out (Up to 5 Stations)........................................................................................B13-1
Figure B13-3: Control Head Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-1
B13-2 Clutch Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-4: Clutch Pigtail Pin-Out................................................................................................................................B13-2
Figure B13-4: Clutch Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
B13-3 Clutch/Troll Pigtail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-5: Clutch/Troll Pigtail Pin-Out........................................................................................................................B13-2
Figure B13-5: Clutch/Troll Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
B13-4 Throttle Pigtail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-6: Throttle Pigtail Pin-Out..............................................................................................................................B13-2
Figure B13-6: Throttle Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
Table B13-7: Tachometer Sensor Pigtail Pin-Out...........................................................................................................B13-2
Figure B13-7: Tachometer Sensor No.1 Pigtail Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13-2
ENG-143 Ver 1.0 4-04 ............................................................................................................................ B-3
ClearCommand 9000 Elect-Thr Sol-Shift Qualitative Failure Analysis & Design Verification Test Procedure
ENG-144 Ver 1.0 4-04 ............................................................................................................................ B-7
ClearCommand 9000 Elect-Thr Ser-Cl Qualitative Failure Analysis & Design Verification Test Procedure

TABLE OF CONTENTS
TOC-13
ENG-145 Ver 1.0 4-04 .......................................................................................................................... B-11
ClearCommand 9000 Ser-Thr Sol-Cl Qualitative Failure Analysis & Design Verification Test Procedure
MMC-172 Rev.Z-O 11/03 ..................................................................................................................... B-15
Factory Authorized Sales & Service Centers - International
MM13927 Table of Contents ..............................................................................................................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: Connector/Pigtail Descriptions ..................................................................................................................... 1-2
2 PROCEDURE - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2-1 Throttle Signal Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.1 DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-4: Throttle Connection (DC Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-1.2 Current (mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-5: Throttle Connection (Current mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1.3 PWM (Pulse Width Modulation) with DC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-6: Throttle Connection (PWM with DC Voltmeter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-1.4 PWM (Pulse Width Modulation) with Duty Cycle Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7: Throttle Connection (PWM with Duty Cycle Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-1.5 Frequency (Hz.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-8: Throttle Connection (Frequency Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 CLUTCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2.1 Neutral Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-9: Clutch Connection (Neutral Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-2.2 Ahead Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-10: Clutch Connection (Ahead Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2.3 Astern Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-11: Clutch Connection (Astern Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3 TROLL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.1 Troll On/Off Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-12: Troll Connection (ON/OFF Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3.2 Troll Command (Proportional Solenoid) Testing with Amp Meter. . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-13: Troll Connection (Proportional Solenoid with Amp Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3 Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Table 3-2: Parts List ....................................................................................................................................................... 3-1
Appendix C
Drawing 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

REVISIONS LIST
Page 1-1
Revisions List
Rev Date Revision Description
Rev - 11/03 Revision - was a PRELIMINARY manual printed to support Production.
Rev A 4/03 Released and Signed Off.
Rev B 6/04 Updated with most current Forms and Manual Modules.
Rev C 8/04 Included ELR 1167 and 1150
Rev C.1 2/08 Replaced Field Service Test Unit (MM13927) manual with current revision
(reformatted). Replaced forms MMC-172 International FASSC List, MMC-165
Warranty Policy with current revision.
Rev C.2 5/08 Replaced MMC-280 & MMC-329 Control Head Variations current revision.

INTRODUCTION
Page 1-1
1 INTRODUCTION
This manual is written to document every possible system option.
Your system may not include every available option for single or
twin screw reverse reduction gear applications.
Only those sections that apply to your specific installation are rele-
vant to your vessel.
If additional options described within this manual are desired, con-
tact your dealer for availability/compatibility with your system.
1-1 M AN UAL C ONTENTS
This manual is divided into 12 Sections which cover, in detail, the
features and operation of your system:
• Introduction (Section 1)
• Operation (Section 2)
• Plan the Installation (Section 3)
• Installation (Section 4)
• Set Up Procedures (Section 5)
• Dock Trials (Section 6)
• Sea Trials (Section 7)
• Control Options (Section 8)
• Periodic Checks and Maintenance (Section 9)
• ZF Mathers Service Sheets (Appendix A)
• Troubleshooting (Appendix B)
• General System Drawings (Appendix C)
1-2 B
ASIC T HEORY OF O PERATION
The ClearCommand Marine Propulsion Control System (hereafter
referred to as ClearCommand or System) is electronic and requires
a 12 or 24 VDC power supply, one Processor per engine/clutch and
one Control Head per remote station. The ClearCommand com-
mands the vessel’s throttle and shift using a single Control Head
lever.
One electric cable per Control Head lever connects the remote sta-
tion(s) to the Processor(s). Only one remote station will have com-
mand at a given time and the Station-in-Command is indicated by a
red light located on the Control Head. Station transfer is accom-
plished by pressing the Control Head mounted transfer button
1-2.1 9120 Processor (Throttle-Servo 2, Shift-Solenoid) or 9122
Processor
(Throttle-Servo 2, Shift-Solenoid, Troll-Solenoid)
The 9120 or 9122 System is designed for pleasure and light
commercial marine vessels that require remote control of:
9120
• mechanically actuated engines
• solenoid activated clutches.

INTRODUCTION
Page 1-2
9122
• mechanically actuated engines
• solenoid activated clutches
• solenoid activated trolling valves.
The 9120 or 9122 Processor is typically mounted in the
engine room area and is connected mechanically to the ves-
sel’s main engine throttle selector lever with standard 33C
type push-pull cables.
The 9120 Processor controls the electrical Ahead and Astern
Shift Solenoids at the transmission, via electric cable.
The 9122 Processor controls the electrical Transmission and
Trolling Valve Solenoids for shift and trolling functions, via
electric cable.
Figure 1-1: Basic 9120 or 9122 ClearCommand System Diagram
IDLEFULL
33C PUSH/PULL CABLE
33C PUSH/PULL CABLE
IDLEFULL
THROTTLE
THROTTLE
STBD
STATION 2
STATION
1
PORT
12296A
SERIAL COMMUNICATION
10 AMP CIRCUIT
BREAKER
(BY OTHERS)
COMMON
GROUND COMMON
GROUND
+
-
+
-
APS
CLUTCH PRES.
START INTERLOCK
A
LARM
START INTERLOCK
CLUTCH PRES.
ALARM
TACH 1 TACH 1
AHEAD/ASTERN
TROLL COMMAND
TROLL ON/OFF
30A
FUS
E
30A
FUS
E
AHEAD/ASTERN
TROLL COMMAN
D
TROLL ON/OFF